B
50
Repair and Service Manual
ELECTRICAL
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
10002660
Controller Replacement
Tool List
Qty.
Socket, 7/16................................................................. 1
Socket, 13mm.............................................................. 1
Ratchet ........................................................................ 1
Extension, 6" ............................................................... 1
Wrench, 7/16” .............................................................. 1
Wrench, 13mm ............................................................ 1
Insulated Wrench, 9/16” .............................................. 1
Torque Wrench, ft. lbs. ................................................ 1
To prevent electrical shock, the neg-
ative (B-) wire must be removed
before discharging the controller.
Use a large screwdriver to cause a short-circuit in
the positive (B+) and negative (B-) terminals of the
controller. Be sure to hold screwdriver by the insu-
lated handle.
NOTICE: Record the location of the wiring on the
controller before disconnecting it.
NOTICE: Always test the motors for a shorted condi-
tion before installing a new converter. An electrical
motor short may be the cause of the controller fail-
ure and will damage the new controller (See AC
Motor Bench Test on page 122).
1.
Use an insulated wrench to remove the negative (B-)
wire from the battery.
2.
Remove the bolts (21) and flat washers (22)(Ref.
Fig. 10).
3.
Remove the connectors from the controller (24) (Ref.
Fig. 10).
4.
Disconnect the cables connecting the controller to
the motor.
5.
Remove bolts (23) and lock nuts (25)(Ref. Fig. 10).
6.
Remove the controller (24) from the controller
bracket(Ref. Fig. 10).
7.
Mount new controller (24) and connect wiring(Ref.
Fig. 10).
8.
Tighten the hardware to the torque values specified
below.
9.
Connect the negative (B-) battery cable.
Fig. 10 Controller Removal
Item
Torque Specification
21
80 - 90 in. lbs. (9 - 10.1 Nm)
25
92 - 100 in. lbs. (10.3 - 11.2 Nm)
BLUE (W)
Front of Vehicle
CONTROLLER with REAR MOTOR CONNECTIONS
YELLOW (V)
GREEN (U)
GREEN (U)
Connect Control
Harness to Controller
by Connecting the Short
Lead Controller Connector
to Passenger Side Controller
Rear Motor
Grease Connection
Connect Control
Harness to Controller
by Connecting the Long
Lead Controller Connector
to Driver Side Controller
for Front Motor
Grease Connection
BLUE (W)
YELLOW (V)
GREEN (U)
YELLOW (V)
BLUE (W)
BLACK (B-)
RED (B+)
Front of Vehicle
RED (B+)
23
22
21
25
24
