Hisun HS5DUTV-2 Maintenance Handbook
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Hisun HS5DUTV-2 Maintenance Handbook

Hisun HS5DUTV-2 Maintenance Handbook

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GENERAL INFORMATION
Brief introduction to maintenance handbook of
The handbook is edited by Technical Center of Chongqing Huansong
Science And Technology Industrial Co., Ltd, and is supplied to dealers and
technicians as document of technique. Mainly, the handbook gives methods to
check, maintain and repair electric vehicles （EV）, and supplies some relevant
technique and performance data. Some techniques and method inside may be
used to check, maintain and repair other models of UTV(改成EV）, although it
is mainly for HS5DUTV-2.
Please read the handbook through and fully understand it; otherwise, any
improper repairing and amounting would bring you problems, and accident may
occur in your use.
Proper use and maintenance can guarantee EV being driven safely, reduce
its malfunction, and help the vehicle remain its best performance.
The standards, performances and specifications mentioned in interpretation
are based on the sample in design, and they are subject to changes according
to the product's improvement without prior notice.
HS5DUTV-2
-1-

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Summary of Contents for Hisun HS5DUTV-2

  • Page 1 Some techniques and method inside may be used to check, maintain and repair other models of UTV(改成EV）, although it is mainly for HS5DUTV-2. Please read the handbook through and fully understand it; otherwise, any improper repairing and amounting would bring you problems, and accident may occur in your use.
  • Page 2 GENERAL INFORMATION First version ,April 2016 Published by Chongqing Huansong Science And Technology Industrial Co., Ltd Chongqing Huansong Science And Technology Industrial Co., Ltd holds the copy right. No publishing and reprinting without permission. CONTENT CHAPTER 1 GENERAL INFORMATION INFORMATION……………………………………………………………………1 W A T N I N G S C A U T I O N S A N D...

  • Page 3: Table Of Contents

    GENERAL INFORMATION parts……………………………………………………………………………… 4 labels……………………………………………………………………………… 5 NUMBERS…………………………………………………………………………… 5 FASTENERS…………………………………………………………………………… … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … 6 fasteners………………………………………………………………………...
  • Page 4 GENERAL INFORMATION sealant…………………………………………………………………………… 8 … … … … … … … … … … … … … … … … … … … … … … … … … … … … 8 c o m p o u n d … … … … … … … … … … … … … … … … … … … … … … … … 9 …...
  • Page 5 GENERAL INFORMATION ………………………………………………………………………………… 14 P R E C I S I O N M E A S U R I N G T O O L S … … … … … … … … … … … … … … … … … … … … … … …...
  • Page 6 GENERAL INFORMATION Resistance……………………………………………………………………… … … … … Amperage……………………………………………………………………………… … M E T H O D S … … … … … … … … … … … … … … … … … … … … … … … … 2 2 f a s t e n e r s …...
  • Page 7 GENERAL INFORMATION s e le c t io n … … ……… … … … …… … … …… … … … …… … … …… … … … 2 8 P r e p a r i n g t h e f o r S t o r a g e...
  • Page 8 GENERAL INFORMATION …………………………………………………………………………………… 32 S e l f - p o w e r e d t e s t l i g h t … … … … … … … … … … … … … … … … … … … … … … … … … … 3 2 …………………………………………………………………………………...
  • Page 9 GENERAL INFORMATION H a r d b r a k e l e v e r p e d a l o p e r a t i o n … … … … … … … … … … … … … … … … … … … … Grabs………………………………………………………………………………...
  • Page 10 GENERAL INFORMATION t o r q u e s … … … … … … … … … … … … … … … … … … … … … … … … … 7 1 C h a s s i s t i g h t e n i n g t o r q u e s …...
  • Page 11 GENERAL INFORMATION p l u g … … … … … … … … … … … … … … … … … … … … … … … … … 8 5 t i m i n g … … … … … … … … … … … … … … … … … … … … … … … … 8 6 M e a s u r i n g t h e c o m p r e s s i o n...
  • Page 12 GENERAL INFORMATION C h e c k i n g t h e r e a r b r a k e p a d s … … … … … … … … … … … … … … … … … … … … … … 1 0 2 C h e c k i n g t h e...
  • Page 13 GENERAL INFORMATION C h e c k i n g a n d l u b r i c a t i n g t h e c a b l e s … … … … … … … … … … … … … … … … … … … 1 1 4 ELECTRICAL C h e c k i n g...
  • Page 14 GENERAL INFORMATION S P R I N G S … … … … … … … … … … … … … … … … … … … … … … … 1 3 6 P I S T O N … … … … … … … … … … … … … … … … … … … … … … … … … 1 4 1 E N G I N G C O O L I N G F A N...
  • Page 15 GENERAL INFORMATION TRANSMISSION……………………………………………………………………… … … … Transmission…………………………………………………………………………… a ssemb ly …………………………………………………………………… 17 3 GEAR………………………………………………………………………………177 sh a f t ………… …… … ………… ……… … …………… ……… … ………… 1 78 CHAPTER 5 CHASSIS I N S P E C T I O N … … … … … … … … … … … … … … … … … … … … … … … 1 8 3 PANEL AND CARGO BED panel…………………………………………………………………………………186 S i d e...
  • Page 16 GENERAL INFORMATION frame………………………………………………………………………… 201 DIRECTION SYSTEM p a r t … … … … … … … … … … … … … … … … … … … … … … … … … … … 2 0 3 p a r t …...
  • Page 17 GENERAL INFORMATION Front swing arm……………………………………………………………………… suspension……………………………………………………………………… 258 Rear suspension……………………………………………………………………… SYSTEM………………………………………………………………………… 269 r a d ia t o r …… … … …… … … … …… … … …… … … … …… … … …… … … 2 6 9 …………………………………………………………………………………………...
  • Page 18 GENERAL INFORMATION c o n t i n u i t y … … … … … … … … … … … … … … … … … … … … … … 2 8 3 Checking the bulbs and bulb sockets ……………………………………… 284 SYSTEM…………………………………………………………………………284 diagram……………………………………………………………………………...
  • Page 19 GENERAL INFORMATION Checking the lighting system…………………………………………………… 296 SYSTEM……………………………………………………………………… 297 diagram………………………………………………………………………… 297 Troubleshooting……………………………………………………………………… Checking the signal system……………………………………………………… SYSTEM………………………………………………………………………… 305 diagram………………………………………………………………………… 305 Troubleshooting……………………………………………………………………… 2WD/4WDSELECTINGSYSTEM…………………………………………………… … … diagram………………………………………………………………………… 308 Troubleshooting……………………………………………………………………… CHAPTER 7 ENGINE MANAGEMENT SYSTEM INTRODUCTION Ems (engine management system) …………………………………………………… 310 -19-...
  • Page 20 GENERAL INFORMATION Typical components of EMS………………………………………………………………310 c o m p o n e n t s … … … … … … … … … … … … … … … … … … … … … … … … 3 1 1 COMPONENTS OF EMS Electronic control unit ……………………………………………………………………...
  • Page 21 GENERAL INFORMATION TROUBLESHOOTING S T A R T I N G … … … … … … … … … … … … … … … … … … … 3 3 1 … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … 3 3 1 …...
  • Page 22 GENERAL INFORMATION e f f e c t … … …… … …… … … … … … … … …… … … … … … … … …… … … 3 3 4 M A L F U N C T I O N … … … … … … … … … … … … … … … … … … … 3 3 5 f u n c t i o n …...
  • Page 23 GENERAL INFORMATION The text provides complete information on maintenance，tune-up repair and overhaul，Hundreds of photographs and illustrations created during the complete disassembly of four wheel electric vehicles （EV） guide the reader through every job ，All procedures are in step-by-step format and designed for the reader who may be working on the EV for the first time.
  • Page 24 GENERAL INFORMATION DESCRIPTION 1. Headlight Assy 2. Front Shock Absorber Assembly Unit Qa(Gasbag Shock Absorber) 3. Disc brake cup 4. Steering Wheel Comp 5. Driver Seat 6. Driver Safety Belt 7. Rear Cargo 8. Rear Shock Absorber Assembly Unit Q(Gasbag Shock Absorber) 9.
  • Page 25 GENERAL INFORMATION IDENTIFICATION CODE Frame No. -25-...
  • Page 26 GENERAL INFORMATION Frame No. is carved on the right side of rear frame Electric motor No. Electric motor NO. Is behind the electric motor -26-...
  • Page 27 MAINTENANCE AND ADJUSTMENT OF THE EV SAFETY Operator Safety WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner's manual. Read this entire manual and all labels carefully. Follow the operating procedures described.
  • Page 28 MAINTENANCE AND ADJUSTMENT OF THE EV Never operate at excessive speeds. Always travel at a speed proper for the terrain, visibility and operating conditions, and your experience. Never attempt jumps or other stunts. Always inspect the vehicle before each use to make sure it's in safe operating condition.
  • Page 29 MAINTENANCE AND ADJUSTMENT OF THE EV ⚫ Do not leave children unattended on vehicle. ⚫ Turn key OFF and remove key when not in use. Place Forward/Reverse switch in NEUTRAL position. Step on the parking pedal. When repaired, the tires of the cart should be fixed by wedge-shaped objects ⚫...
  • Page 30 MAINTENANCE AND ADJUSTMENT OF THE EV 只要按下急停开关，就可以保证车子从行驶状态在短时间内完全停止。 Press the stop buttom to ensure the vehicle can stop in short time during driving.and the accelerator does not work after the electric buttom is pressed. 并且，按下急停开关后，即使再次踩下油门踏板，车子也不会行驶。 1. Spanner 2. Battery 3. Connecting cable After disconnecting the batteries, wait 90 seconds for the controller capacitors to discharge.
  • Page 31 MAINTENANCE AND ADJUSTMENT OF THE EV 本车使用铅酸蓄电池组储存能量，蓄电池组的输出电压为DC48V，使用和操作不当会造成严重伤害或 财产损失。Lead Acid Battery is used in the vehicle,with 48V voltage,incorrect usage or operation may bring damages. 如何避免危险How to avoid the risk： 严格按照本使用说明书的规定进行操作、维护保养、维修。Operate/maintain and repair it follow the instruction of user’s manual and service manual. 使用带绝缘物的工具进行维修工作。Repair it by the tools with insulated rubber tape.

  • Page 32: Parts

    MAINTENANCE AND ADJUSTMENT OF THE EV 用大量清水冲洗。Wash by water 内部处理Internal Treatment： 喝大量的牛奶和水，紧接着饮下氧化镁乳剂，打好的鸡蛋或植物油，然后迅速求医。Drink abundant water and milk and magnesium oxide liquid,and go to see the doctor. 眼睛的紧急处理Eyes Treatment： 用水冲洗15分钟，然后立即求医。Wash by water in 15 minutes and see the doctor. Cleaning Parts Cleaning parts is one of the more tedious and difficult service jobs performed in the home garage.

  • Page 33: Torque Specifications

    MAINTENANCE AND ADJUSTMENT OF THE EV Serial and identification numbers are stamped on various locations on the frame motor and controller. Record these numbers in the Quick Reference Data section in the front of the manual. Have these numbers available when ordering parts. FASTENERS Proper fastener selection and installation is important to ensure the motorcycle operates as designed and can be serviced efficiently.

  • Page 34: Washers

    MAINTENANCE AND ADJUSTMENT OF THE EV materials used to from the lock become distorted after the initial installation and removal. Discard and replace self-locking fasteners after removing them. Do not replace self-locking fasteners with standard fasteners. Washers The two basic types of washers are flat washers and lock washers. Flat washers are simple discs with a hole to fit a screw or bolt.

  • Page 35: Lubricants And Fluids

    MAINTENANCE AND ADJUSTMENT OF THE EV The two basic types of snap rings are machined and stamped snap rings. Machined snap rings (Figure 2) can be installed in either direction. Because both faces have sharp edges. Stamped snap rings (Figure 3) are manufactured with a sharp and a round edge.

  • Page 36: Greases

    MAINTENANCE AND ADJUSTMENT OF THE EV NOTE Refer to Engine Oil and Filter in Chapter Three for further information on API, SAE classifications. Always use an oil with a classification recommended by the manufacturer, Using an oil with a different classification can cause engine damage. Viscosity is an indication of the oil’s thickness.

  • Page 37: Cleaners, Degreasers And Solvents

    MAINTENANCE AND ADJUSTMENT OF THE EV WARNING Never put a mineral-based (Petroleum) oil into the brake system. Mineral oil causes rubber parts in the system to causing complete brake failure. Coolant Coolant is a mixture of water and antifreeze used to dissipate engine heat. Ethylene glycol is the most common from of antifreeze.

  • Page 38: Thread Locking Compound

    MAINTENANCE AND ADJUSTMENT OF THE EV caused by using a scraping tool. Most of these types of products are very caustic. Follow the gasket remover manufacturer’s instructions for use. Thread locking Compound A thread locking compound is a fluid applied to the threads of fasteners. After tightening the fastener, the fluid dries and becomes a solid filler between the threads.

  • Page 39: Screwdrivers

    MAINTENANCE AND ADJUSTMENT OF THE EV Screwdrivers Screwdrivers of various lengths and types are mandatory for the simplest tool kit. The two basic types are the slotted tip (flat blade) and the Phillips tip. These are available in sets that often include an assortment of tip size and shaft lengths. As with all tools, use a screwdriver designed for the job.

  • Page 40: A D J U S T A B L E W R E N C H E

    MAINTENANCE AND ADJUSTMENT OF THE EV The number stamped on the wrench refers to the distance of the fastener head. The box-end wrench is an excellent tool because it grips the fastener on all sides. This reduces the chance of the tool slipping. The box-end wrench is designed with either a 6 or 12-point opening.
  • Page 41 MAINTENANCE AND ADJUSTMENT OF THE EV As with wrenches. a 6-point provides superior-holding ability. While a 12-point socket needs to be moved only half as for to reposition it on the fastener Sockets are designated for either hand or impact use. Impact sockets are made of thicker material for more durability.

  • Page 42: Wrenches

    MAINTENANCE AND ADJUSTMENT OF THE EV and cause injury. Always wear eye protection when using impact or air tools Allen Wrenches Use Allen or setscrew wrenches (Figure 11) on fasteners with hexagonal recesses in the fastener head. These wrenches are available in L-shaped bar.
  • Page 43 MAINTENANCE AND ADJUSTMENT OF THE EV Torque adapters or extensions extend or reduce the reach of a torque wrench. The torque adapter shown in (Figure 13) is used to tighten a fastener that cannot be reached because of the size of the torque wrench head, drive, and socket.

  • Page 44: Pliers

    MAINTENANCE AND ADJUSTMENT OF THE EV TA=20 ft.-lb. A=3in. L=14in. TW=20×14=280=16.5 ft. - lb. 14+3 = 17 In this example, the torque wrench would be set to the recalculated torque value (TW = 16.5 ft. –lb.). When using a beam-type wrench, tighten the fastener until the pointer aligns with 16.5 ft.
  • Page 45 MAINTENANCE AND ADJUSTMENT OF THE EV Snap rings can slip and fly off when removing and installing them. Also, the snap ring pliers tips may break. Always wear eye protection when using snap ring pliers. Hammers Various types of hammers are available to fit a number of applications. Use a ball- peen hammer to strike another tool, such as a punch or chisel.
  • Page 46 MAINTENANCE AND ADJUSTMENT OF THE EV which the tool contacts the object. This feel for the equipment produces more accurate measurements and reduces the risk of damaging the tool or component. Refer to the following sections for specific measuring tools. Feeler Gauge Use feeler or thickness gauges (Figure19) for measuring the distance between two surfaces.
  • Page 47 MAINTENANCE AND ADJUSTMENT OF THE EV fixed scale. In this example, the number is 10 mm. To determine the next number, note which of the lines on the movable scale align with a mark on the fixed scale. A number of lines will seem close, but only one will align exactly.
  • Page 48 MAINTENANCE AND ADJUSTMENT OF THE EV Micrometers that cover a wider range of measurements are available. These use a large frame with interchangeable anvils of various lengths. This type of micrometer offers a cost savings, but its overall size may make it less convenient. When reading a micrometer, numbers are taken from different scales and added together.
  • Page 49 MAINTENANCE AND ADJUSTMENT OF THE EV 2. When in storage, make sure the spindle and anvil faces do not contact each other or another object. If they do, temperature changes and corrosion may damage the contact faces. 3. Do not clean a micrometer with compressed air. Dirt forced into the tool will cause wear.
  • Page 50 MAINTENANCE AND ADJUSTMENT OF THE EV Standard inch micrometer The standard inch micrometer (Figure 26) is accurate to one-thousandth of an inch or 0.001. The sleeve is marked in 0.025 in. increments. Every fourth sleeve mark is numbered 1,2,3,4,5,6,7,8,9. These numbers indicate 0.100, 0.200, 0.300, and so on.
  • Page 51 MAINTENANCE AND ADJUSTMENT OF THE EV To use a telescoping gauge, select the correct size gauge for the bore. Compress the movable post and. Care fully insert the gauge into the bore. Carefully move the gauge in the bore to make sure it is centered. Tighten the knurled end of the gauge to hold the movable post in position.
  • Page 52 MAINTENANCE AND ADJUSTMENT OF THE EV A compression gauge (Figure 33) measures combustion chamber (cylinder) pressure, usually in PSI or kg/ cm . The gauge adapter is either inserted or screwed into the spark plug hole to obtain the reading. Disable the engine so it does not start and hold the throttle in the wide-open position when performing a compression test An engine that does not have adequate compression cannot be properly tuned.
  • Page 53 MAINTENANCE AND ADJUSTMENT OF THE EV Magneto drawing (figure 36) is special tool to dismantle magneto rotor . firstly put the mandril into the inside of shaft hole ,Turn the magneto rotor accordingly, screw magnet o drawing and push-out magneto rotor ELECTRICAL SYSTEM FUNDAMENTALS A thorough study of the many types of electrical systems used in today’s motorcycles is beyond the scope of this manual.
  • Page 54 MAINTENANCE AND ADJUSTMENT OF THE EV Amperage Amperage is the unit of measurement for the amount of current within a circuit. Current is the actual flow of electricity. The higher the current, the more work can be performed up to a given point. If the current flow exceeds the circuit or component capacity, it will damage the system.
  • Page 55 MAINTENANCE AND ADJUSTMENT OF THE EV these operations performed by a shop equipped with the necessary equipment. Do not use makeshift equipment that may damage the motorcycle. 13. Repairs are much faster and easier if the EV is clean before starting work. Degrease the motorcycle with a commercial degreaser;...
  • Page 56 MAINTENANCE AND ADJUSTMENT OF THE EV For frozen screws, apply penetrating fluid as described, the insert a screwdriver in the slot and rap the top of the screwdriver with a hammer. This loosens the rust so the screw can be removed in the normal way.
  • Page 57 MAINTENANCE AND ADJUSTMENT OF THE EV Measure the height of the stud above the surface. Thread the stud removal tool onto the stud and tighten it, or thread two nuts onto the stud. Remove the stud by turning the stud remover or the lower nut.
  • Page 58 MAINTENANCE AND ADJUSTMENT OF THE EV Removal While bearing are normally removed only when damaged, there may be times when it is necessary to remove a bearing that is in good condition. However, improper bearing removal will damage the bearing and possibly the shaft or case. Note the following when removing bearings: 1.
  • Page 59 MAINTENANCE AND ADJUSTMENT OF THE EV 2. When installing a bearing as described in Step 1, some type of driver is required. Never strike the bearing directly with a hammer or it will damage the bearing. When installing a bearing, use a piece of pipe or a driver with a diameter that matches the bearing inner race.
  • Page 60 MAINTENANCE AND ADJUSTMENT OF THE EV thoroughly with detergent and water. Rinse and rewash the cases as required to remove all traces of oil and other chemical deposits a. Heat the housing to approximately 100℃ (212°F) in an oven or on a hot plate. An easy way to check that it is the proper temperature is to place tiny drops of water on the housing;...
  • Page 61 MAINTENANCE AND ADJUSTMENT OF THE EV new bearings by driving on the inner-bearing race. Install the bearing(s) until it seats completely. Seal Replacement Seals (Figure 49) contain oil, water, grease or combustion gasses in a housing or shaft. Improperly removing a seal can damage the housing or shaft.
  • Page 62 MAINTENANCE AND ADJUSTMENT OF THE EV 3、Turn the key switch to "ON" position, dash board will be lit, indicating whether the battery is fully charged, As shown below, 4. Turn the forward / reverse switch to the desired position. F： Forward. Center position：...
  • Page 63 MAINTENANCE AND ADJUSTMENT OF THE EV 5、切换模式开关M/H/L。 H：高速模式 M：节能模式 L：爬坡模式 1. 高速模式 High Speed Mod 2. 节能模式 Economical Mod 3. 爬坡模式 Climbing Mod 6、Press down the accelerator pedal, brake pedal will automatically open, EVs will start moving. 1. Parking pedal 2.
  • Page 64 MAINTENANCE AND ADJUSTMENT OF THE EV Operation Before Leaving The EV 1. Press park brake pedal until it locks and holds vehicle. 1. Parking Pedal 2. Brake pedal 2. Place F/GEAR/R switch in GEAR position. 1. Forward 2. Neutral 3. Reverse 3.
  • Page 65 MAINTENANCE AND ADJUSTMENT OF THE EV 1. OFF 2. ON Motor Braking Function Electric motor braking provides speed regulation functions. For parked vehicle, beeping alarm indicates vehicle roll away. In operation, beeping alarm indicates reduction in motor braking. Apply brakes to further reduce vehicle speed as required. DAILY SAFE CHECKING Before driving, it is necessary to make a daily safe checking of the vehicle.
  • Page 66 MAINTENANCE AND ADJUSTMENT OF THE EV ● Wheel (rim): Check whether the wheel rust or collision deformation, if there is serious corrosion or deformation, please change the wheel, otherwise, the tires may fell out from the wheel and cause the accident. ●...
  • Page 67 MAINTENANCE AND ADJUSTMENT OF THE EV ● Charger cord, plug, and socket: Visual check for cracks, looseness and abrasion of wire insulation. Hand check if cable plugs and sockets are loose. If the fault is found, please go to the dealer to conduct a comprehensive inspection on the charger. Otherwise fire may happen because of the heat or short circuit.
  • Page 68 MAINTENANCE AND ADJUSTMENT OF THE EV 11. Check if there is any abnormal noise during the driving. 12. Check if the maximum speed of the EV does not exceed 40km/h. EV is not allowed to be driven at a speed higher than 40km/h. MAINTENCE AND ADJUSTMENT OF THE EV To ensure trouble-free vehicle performance, it is very important to follow an established preventive maintenance program.
  • Page 69 MAINTENANCE AND ADJUSTMENT OF THE EV Periodic Service Schedule...
  • Page 70 MAINTENANCE AND ADJUSTMENT OF THE EV REGULAR INTERVAL SERVICE Pre-Operation and Daily Safety Checklist Daily service by owner Performance Inspection Batteries REGULAR INTERVAL SERVICE 检查电动车电量是否充足，及时对动车充电。Check the battery Weekly service by owner weekly,charge the battery in time. 检查电动车电量是否充足，及时对动车充电。及时对动车充电。 Check the battery monthy,charge the battery in time. Monthly service by owner Clean the surface of the battery or trained technician...
  • Page 71 MAINTENANCE AND ADJUSTMENT OF THE EV Check and clean the rear axle, replace the damaged parts, and add the required lubricants. Periodic Lubrication Schedules PERIODIC LUBRICATION SCHEDULE REGULAR RECOMMENDED LUBRICATION LUBRICATION PARTS POINTS INTERVAL LUBRICANT Charger receptacle WD-40 Semiannual service Lubricate the brake by trained system...
  • Page 72 MAINTENANCE AND ADJUSTMENT OF THE EV THE STORAGE AND CLEANING Cleaning 1. Use sponge or soft cloth to clean EV, the water with daily use pressure is enough. 2. Manufacturer does not recommend using any pressure cleaning or steam cleaning methods on EVs for cleaning.
  • Page 73 MAINTENANCE AND ADJUSTMENT OF THE EV Storage 1. 按下急停开关Press the stop buttom, remove the key, and leave the Forward/Reverse switch in the NEUTRAL position during storage. 按下急停开关 Press the stop buttom. This is to prevent unintentionally starting the vehicle or a fire hazard.
  • Page 74 MAINTENANCE AND ADJUSTMENT OF THE EV Adopting renowned international companies' motor and controller, this EV is with advanced performance, high reliability, strong protection, and etc. If the repair requires parts replacement, be sure to purchase the original parts to guarantee the EVs in best performance condition and providing the highest security assurance.
  • Page 75 MAINTENANCE AND ADJUSTMENT OF THE EV Battery Charger Each EV is equipped with a special battery charger. A special matching test upon battery and its charger has been done. Other types of charger will fail to charge. If other charger is used to charge, it may undercharge, overcharge and affect the usage of the battery.
  • Page 76 MAINTENANCE AND ADJUSTMENT OF THE EV element of the charger and the EV, avoid the lightning strike. ⚫ Connect the charger AC supply cord to a properly grounded, three-wire outlet of the proper voltage and frequency as shown on the charger. ⚫...
  • Page 77 MAINTENANCE AND ADJUSTMENT OF THE EV ⚫ Using the charger with any of the above symptoms could result in a fire, property damage, personal injury, or death. NOTE Before charge the vehicle, make sure to close all of the switches, including the power switch of the accessories which are installed in the vehicle.
  • Page 78 MAINTENANCE AND ADJUSTMENT OF THE EV Several months of non-use can cause a general deterioration of the EV, This is especially true in areas of extreme temperature variations. This deterioration can be minimized with careful preparation for storage. A properly stored EV is much easier to return to service.
  • Page 79 MAINTENANCE AND ADJUSTMENT OF THE EV 4. 维修/维护后，在电池端子上图“蓄电池端子导电膏”After the maintenance,to paste the “conductive paste on battery”。 TROVBLESHOOTING Diagnose electrical and mechanical problems by following an orderly procedure and remembering the basic operating requirements → Define Symptoms ↓ → Which areas could exhibit these Determine symptoms ↓...
  • Page 80 MAINTENANCE AND ADJUSTMENT OF THE EV If the problem cannot be solved. Stop and evaluate all conditions prior to the problem. If the EV must be taken to a repair facility, the mechanic will want to know as many details as possible. For removal, installation and test procedures for some components, refer to the specific chapter.
  • Page 81 MAINTENANCE AND ADJUSTMENT OF THE EV a. Perform a continuity test as described in the appropriate service procedure. Or under Continuity Test in this section b. Lightly pull or wiggle the connectors while repeating the test. Do the same when checking the wiring harness and individual components.
  • Page 82 MAINTENANCE AND ADJUSTMENT OF THE EV you purchase a new electrical component(s), install it, and then find that the system still does not work properly, you will probably be unable to return the unit for a refund. Consider any test results carefully before replacing a component that teats only slightly out of specification, especially resistance.
  • Page 83 MAINTENANCE AND ADJUSTMENT OF THE EV Ohmmeter may be analog type (needle scale) or digital type (LCD or LED readout). Both types of ohmmeter have a switch that allows the user to select different ranges of resistance for accurate readings. The analog ohmmeter also has a set-adjust control which is used to zero or calibrate the meter (digital ohmmeters do not require calibration).
  • Page 84 MAINTENANCE AND ADJUSTMENT OF THE EV 3. Jumper wires are temporary test measures only. Do not leave a jumper wire installed as a permanent solution. This creates a severe fire hazard that could easily lead to complete loss off the motorcycle 4.
  • Page 85 MAINTENANCE AND ADJUSTMENT OF THE EV 1. Connect the positive meter test lead to the electrical source (where electricity is coming from). 2. Connect the voltmeter negative test lead to the electrical load (where the electricity is going). 3. If necessary, activate the component(s) in the circuit. For example. If checking the voltage in the starter circuit, it would be necessary to push the starter button.
  • Page 86 MAINTENANCE AND ADJUSTMENT OF THE EV 4. The self-powered test lead comes on if there is continuity. An ohmmeter reads 0 or very low resistance if there is continuity. A reading of infinite resistance if there is continuity. A reading of infinite resistance indicates no continuity, the circuit is open.
  • Page 87 MAINTENANCE AND ADJUSTMENT OF THE EV Operate the front brake lever or rear brake pedal and check to see if the lever travel distance increases. If the lever travel does increase while being operated, or feels soft or spongy, there may be air in the brake line. In this condition, the brake system is not capable of producing sufficient brake force.
  • Page 88 MAINTENANCE AND ADJUSTMENT OF THE EV WARNING A leaking fork seal can allow oil to contaminate the brake pads and disc. 10. Worn or damaged master cylinder cups and/or cylinder bore. 11. Worn or damaged brake caliper piston seals. 12. Contaminated master cylinder assembly. 13.
  • Page 89 MAINTENANCE AND ADJUSTMENT OF THE EV 3. Sticking master cylinder piston. 4. Glazed or worn brake pads. 5. Mismatched brake pads. 6. Damaged front brake lever. 7. Damaged rear brake pedal. 8. Brake caliper not sliding correctly on slide pins. 9.
  • Page 90 MAINTENANCE AND ADJUSTMENT OF THE EV 6. Damaged banjo bolt threads in caliper body. Leaking Master Cylinder 1. Damaged piston secondary seal. 2. Damaged piston snap ring/ snap ring groove. 3. Worn or damaged master cylinder bore. 4. Loose banjo bolt washers. 5.
  • Page 91 MAINTENANCE AND ADJUSTMENT OF THE EV 0.6214 3.281 1.094 0.3937 0.03937 ） cc（cm 0.03527 oz（IMP liq.） Volume/capacit ） cc（cm 0.06102 cu·in lit（liter） 0.8799 qt（IMP liq.） lit（liter） 0.2199 gal（IMP liq.） kg/mm 55.997 Ib/in ） Others kg/cm 14.2234 psi（lb/in Centigrade 9/5（℃）+32 Fahrenheit（°F） （2）Definition of unit Unit Read...
  • Page 92 MAINTENANCE AND ADJUSTMENT OF THE EV Dimensions: Overall length 2,800mm (110.23 in) Overall width 1,615mm（63.58 in） Overall height 1,850mm（72.83 in） Seat height 860mm（33.85 in） Wheelbase 1,850mm（72.83 in） Minimum ground clearance 260mm（10.24 in） Minimum turning radius 3,420mm (134.64 in) Basic weight: 824kg (1816.6 lbs) Max.
  • Page 93 MAINTENANCE AND ADJUSTMENT OF THE EV On-board charger: Model Delta Q 120-volt AC input; 48-volt DC output Transmission: Main gear case Direct drive with low-noise gears 电子档位选择Electronic Gear Select 档位变换Gear Shift H/M/L 变速箱传动比Gearbox Transmission Ratio 14.14 后桥传动比Rear Bridge Transmission Ratio 前桥传动比Front Bridge Transmission Ratio Gear shift system F, N, R gears driven by direction of...
  • Page 94 MAINTENANCE AND ADJUSTMENT OF THE EV Suspension Front suspension Independent, Dual A-arm type Rear suspension Independent, Dual A-arm type Shock absorber Front shock absorber Coil spring/airbag damping Rear shock absorber Coil spring/airbag damping Wheel travel Front wheel travel 160mm (6.30 in) (min) /235mm (9.25 in) (max) Rear wheel travel 180mm (7.09 in) (min) /235mm (9.25 in)
  • Page 95 MAINTENANCE AND ADJUSTMENT OF THE EV Item Standard Limit Steering system Type Rack and pinion ---- Front suspension Shock absorber travel 140 mm (5.51 in) ---- Spring free length 294 mm (11.57 in) ---- Spring rate 19.04N/mm(1.94kg/mm) ---- Stroke 30-140 mm (1.18 ~ 5.51in) ---- Rear suspension Shock absorber travel...
  • Page 96 MAINTENANCE AND ADJUSTMENT OF THE EV Rear wheel Type Aluminum Alloy wheel ---- Rim size 12×8 AT(min) /14×9 AT (max) ---- Rim material A356 ---- Rim runout limit radial ---- 2.0 mm (0.08 in) lateral ---- 2.0 mm (0.08 in) Brake lever and brake pedal Accelerator pedal free play 2 ~ 3mm (0.079 ~ 0.118 in)
  • Page 97 MAINTENANCE AND ADJUSTMENT OF THE EV Rear disc brake Type Dual ---- Disc outside diameter × thickness 183×4 mm (7.20× 0.16in) ---- Pad thickness inner 6.0 mm (0.24 in) ---- Pad thickness outer 6.0 mm (0.24 in) ---- Master cylinder inside diameter 19.0mm (0.75in) ---- 22.6mm （0.89in）...
  • Page 98 MAINTENANCE AND ADJUSTMENT OF THE EV Signaling system fuse ---- Backup fuse(odometer) 10 A×1 5 A×1 10 A×1 15 A×1 48V SYSTEM ELECTRICAL SPECIFICATIONS Item Standard Limit Controller parameter3 ---- Working voltage 48 VDC Voltage range 36V-48VDC PWM frequency 15KHz Overvoltage protective voltage 69.6V low-voltage protective voltage...
  • Page 99 MAINTENANCE AND ADJUSTMENT OF THE EV Maximum power 7250rpm Rated torque 11N.m Maximum torque 125N.m Rated frequency 125.6Hz Protection class IP55 Duty S2 60min Charger parameter Model HK-H-48-25 Rated input voltage AC90V-AC265V Rated frequency 45-65Hz Rated Power 1.8KW ≥93％ Full load efficiency Working temperature -35℃~+85℃...
  • Page 100 MAINTENANCE AND ADJUSTMENT OF THE EV Protection function Input Over-voltage Protection,Input Under-voltage Protection,Output Over- voltage Protection, Output Over-current Protection,Over-temperature Protection,Short-circuit Protection. Standard Protection Item Limit Structure non-output opposing connection All-closed, no fan, natural air cooling Circuit breaker Type Fuse ---- Controller’s main fuse 425A Cable’s main fuse...
  • Page 101 MAINTENANCE AND ADJUSTMENT OF THE EV Rear shock absorber and frame Rear shock absorber and rear lower arm Rear Balancing pole and frame ball head of Rear Balancing pole and Rear Balancing pole ball head of Rear Balancing pole and rear lower Differential gear case and frame Differential gear case filler plug Differential gear case drain plug...
  • Page 102 MAINTENANCE AND ADJUSTMENT OF THE EV Steering wheel and steering shaft assembly Steering knuckle and front upper arm Steering knuckle and front lower arm Tie-rod locknut Steering knuckle and tie-rod Front lower arm protector board and front lower Seat belt and frame Tightening torque Thread Part to be tightened...
  • Page 103 MAINTENANCE AND ADJUSTMENT OF THE EV Brake master cylinder and pedal holder assembly Secondary brake master cylinder kit stopper bolt Brake rod locknut Rear brake disc and brake disc Install seat Rear brake pad holding bolt Rear brake caliper and Install seat Rear brake hose union bolt Parking brake case and rear brake caliper Parking brake lever assembly and frame...
  • Page 104 MAINTENANCE AND ADJUSTMENT OF THE EV A: Distance between flats B: Outside thread diameter General tightening torques (nut) (bolt) m · kg ft · lb 10 mm 6 mm 12 mm 8 mm 14 mm 10 mm 17 mm 12 mm 19 mm 14 mm 22 mm...
  • Page 105 MAINTENANCE AND ADJUSTMENT OF THE EV Lubrication points Lubricant Lip of oil seal (full) Light lithium-base grease o-ring(full) Light lithium-base grease Steering shaft (upper end ,lower end) Light lithium-base grease Ball connection of steering pushing rod Light lithium-base grease Front wheel fork(ball-shaped joint) Light lithium-base grease Front wheel bearing Grease used for bearing...
  • Page 106 MAINTENANCE AND ADJUSTMENT OF THE EV MAINTENANCE AND ADJUSTMENT OF THE EV NOTE: The correct maintenance and adjustment are necessary to ensure vehicle and normal driving The repair personnel should be familiar with the contents of this article. MAINTENANCE SCHEDULE EVERY INITAL month...
  • Page 107 MAINTENANCE AND ADJUSTMENT OF THE EV ·Check bearing assemblies for looseness /damage. ○ ○ ○ ○ Wheel bearing* ·Replace if necessary. ·Check operation./Replace if damaged ○ ○ ○ ○ ○ Steering system* ·check toe-in./Adjust if necessary. ·Lubricate with lithium–soap–based Drive shaft universal ○...
  • Page 108 MAINTENANCE AND ADJUSTMENT OF THE EV...
  • Page 109 MAINTENANCE AND ADJUSTMENT OF THE EV ADJUSTING THE BRAKE PEDAL 1. Check: ·brake pedal free play a Out of specification adjust. NOTE: The end of the brake rod ① should lightly contact the brake master cylinder. Brake pedal free play 0 mm (0.0 in) 2.
  • Page 110 MAINTENANCE AND ADJUSTMENT OF THE EV ·lift the hood up Refer to “SEATS” in chapter5 3. Check: ·parking brake cable free play Out of specification Adjust.。 Parking brake cable free play 2 ~ 3 mm (0.079 ~ 0.118 in) 4. Adjust: ·parking brake cable free play a.
  • Page 111 MAINTENANCE AND ADJUSTMENT OF THE EV 3. Check: brake fluid level Fluid level is under “MIN” · level line ① Fill up. NOTE: Brake fluid may erode painted surfaces or plastic parts. Always clean up spilled fluid immediately. WARNING · Use only the designed quality brake fluid: otherwise, the rubber seals may deteriorate, causing leakage and poor...
  • Page 112 MAINTENANCE AND ADJUSTMENT OF THE EV Brake pad wear limit ○,a 1.5 mm (0.06 in) 3. Operate the brake pedal. 4. Install: ·front wheels CHECKING THE REAR BRAKE PADS 1. Check: ·brake pads Wear indicator groove ○, almost disappeared Replace the brake pads as a set.
  • Page 113 MAINTENANCE AND ADJUSTMENT OF THE EV Fluid leakage Replace all damaged parts. NOTE: Hold the vehicle in an upright position and apply the brake pedal. 5. Install: ·console ·seat BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING Bleed the brake system if: ·...
  • Page 114 MAINTENANCE AND ADJUSTMENT OF THE EV □, Front □, Rear d. Place the other end of the hose into a container. e. Slowly apply the brake pedal several times. f. Push down on the pedal and hold it. g. Loosen the bleed screw and allow the pedal to travel towards its limit.
  • Page 115 MAINTENANCE AND ADJUSTMENT OF THE EV CHECKING THE FINAL GEAR OIL LEVEL 1. Place the vehicle on a level surface. 2. Remove: ·oil filler plug ① 3. Check: ·oil level Oil level should be up to the brim of the hole.
  • Page 116 MAINTENANCE AND ADJUSTMENT OF THE EV Recommended oil SAE 80 API “GL-4” Hypoid gear oil WARNING Take care not allow foreign material to enter the final gear case. 4. Install: ·oil filler plug Tightening torque 23 Nm (2.3 m·kgf, 16.3 ft·lbs) CHANGING THE FINAL GEAR OIL 1.
  • Page 117 MAINTENANCE AND ADJUSTMENT OF THE EV ·Final gear oil drain bolt ② ·Fill: final gear case Periodic oil change 0.25 L (0.22 Imp qt) Total amount 0.28 L (0.25 Imp qt) WARNING Take care not to allow foreign material to enter the final gear case.
  • Page 118 MAINTENANCE AND ADJUSTMENT OF THE EV Oil level should be up to the brim of hole. Oil level low Add oil to proper level. WARNING Take care not allow foreign material to enter the differential gear case. 4. Install: ·oil filler plug 23 Nm (2.3 m ·...
  • Page 119 MAINTENANCE AND ADJUSTMENT OF THE EV 0.28L (0.25 lmp qt, 0.3 US qt) NOTE: If gear oil is filled to the brim of the oil filler hole, oil may start leaking from the differential gear case breather hose. Therefore, check the quantity of the oil, not its level.
  • Page 120 MAINTENANCE AND ADJUSTMENT OF THE EV Damage Replace. Refer to “FRONT CONSTANT VELOCITY JOINTS,” in chapter 5. □, Front □, Rear CHECKING THE STEERING SYSTEM 1. Check: Place the vehicle on a level surface. • steering assembly bearings Try to the steering wheel up and down, and back and forth.
  • Page 121 MAINTENANCE AND ADJUSTMENT OF THE EV Excessive play Replace the steering shaft assembly. • tie-rod ends Turn the steering wheel to the left and right until it stops completely, and then move the steering wheel slightly in the opposite direction. Tie-rod end (s) have vertical play Replace the tie-rod end(s).
  • Page 122 MAINTENANCE AND ADJUSTMENT OF THE EV a. Mark both front tire tread centers. b. Face the steering wheel straight ahead. c. Measure distance □, between the marks. d. Rotate the front tires 180° until the marks are exactly opposite one another. e.
  • Page 123 MAINTENANCE AND ADJUSTMENT OF THE EV d. Tighten the rod end locknut on each tie-rod. Locknut (rod end) 40 Nm (4.0 m · kg, 29 ft · lb) ADJUSTING THE FRONT AND REAR SHOCK ABSORBERS WARNING These shock absorber assemblies contain highly pressurized nitrogen gas, read and understand the following information before handling the shock absorber...
  • Page 124 MAINTENANCE AND ADJUSTMENT OF THE EV Spring preload 1. Loosen the locknut. 2. Turn the spring preload adjusting nut in direction ⓐ to increase the spring preload and thereby harden the suspension, and in direction ⓑ to decrease the spring preload and thereby soften the suspension.
  • Page 125 MAINTENANCE AND ADJUSTMENT OF THE EV Rebound damping force Turn the rebound damping force adjusting screw ① in direction S to increase the rebound damping force and thereby harden the damping, and in direction F to decrease the rebound damping force and thereby soften the damping.
  • Page 126 MAINTENANCE AND ADJUSTMENT OF THE EV • TIRE CHARACTERISTICS a. Tire characteristics influence the handling of vehicle’s. If other tire combinations are used, they can adversely affect your vehicle’s handling characteristics and are therefore not recommended. Size Type Front 26 × 9-12 Rear 26×...
  • Page 127 MAINTENANCE AND ADJUSTMENT OF THE EV • Tire pressure (cold tire pressure) Out of specification Adjust. NOTE: • The tire pressure gauge ① is included as standard equipment. • If dust or the like is stuck to this gauge, it will not provide the correct readings.
  • Page 128 MAINTENANCE AND ADJUSTMENT OF THE EV CHECKING THE WHEELS 1. Check: • Wheels ① Damage/bends Replace. NOTE: Always balance the wheel when a tire or wheel has been changed or replaced. WARNING • Never attempt even small repairs to the wheel.
  • Page 129 MAINTENANCE AND ADJUSTMENT OF THE EV 2. Apply: • lithium-soap-based grease (onto end of the cable) lithium-soap-based. - 129 -...
  • Page 130 MAINTENANCE AND ADJUSTMENT OF THE EV - 130 -...
  • Page 131 ENGINE ELECTRICAL CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling working near batteries. •...
  • Page 132 ENGINE or vegetable oil. Get immediate medical attention. WARNING • This is a sealed battery. Never remove the sealing caps because the balance between cells will not be maintained and battery performance will deteriorate. • Charging time, charging amperage and charging voltage for an MF battery are different from those of conventional batteries.
  • Page 133 ENGINE NOTE: First, disconnect the negative battery lead ①, and then the positive battery lead ②. • Remove: battery • Check: battery charge a. Connect a pocket tester to the battery terminals. Positive tester probe positive battery terminal Negative tester probe negative battery terminal NOTE: •...
  • Page 134 ENGINE NOTE: • Never remove the MF battery sealing caps. • Do not use a high-rate battery charger since it forces a high-amperage current into the battery quickly and can cause battery overheating and battery plate damage. • If it is impossible to regulate the charging current on the battery charger, be careful to overcharge the battery.
  • Page 135 ENGINE stabilizes about 30 minutes after charging has been completed. Therefore, wait 30 minutes after charging is completed before measuring the open-circuit voltage. Charging method using a variable-current (voltage) charger NOTE: • Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage.
  • Page 136 ENGINE Measure the open-circuit voltage Prior to charging. Connect a charger and ammeter to the battery and start charging. Is the amperage higher than the standard charging amperage written on the battery? Charge the battery until the This type of battery charger charging voltage reaches 15 cannot charge an MF battery.
  • Page 137 ENGINE -137-...
  • Page 138 ENGINE NOTE: Constant amperage chargers are not suitable for charging MF batteries. 3. Install: • battery • Connect: battery leads NOTE: First, connect the positive battery lead ①, and then the negative battery lead ②. • Check: Battery terminals Dirt Clean with a wire brush.
  • Page 139 ENGINE • fuses a. Connect the pocket tester to the fuse and check it for continuity. 。 NOTE: Set the tester to the “Ω × 1” position. b. If the tester indicates“∞”, replace the fuse. 3. Replace: • blown fuse a.
  • Page 140 ENGINE Reserve WARNING ever use a fuse with a rating other than that specified. Never use other materials in place of a fuse. An improper fuse may cause extensive damage to the electrical system, a malfunction of the lighting and ignition systems and could possibly cause a fire.
  • Page 141 ENGINE CHANGING THE HEADLIGHT BULBⅠ Remove: • Lift the hood up. • headlight bulb holder cover ② • headlight bulb holder (with bulb) ③ • bulb NOTE: Remove the defective bulb by unhooking the headlight bulb holder tabs ④. WARNING Keep flammable products and your hands away from the bulb while it is on, since it will be hot.
  • Page 142 ENGINE Keep it free from oil; otherwise, the transparency of the glass, life of the bulb, and luminous flux will be adversely affected. If oil gets on the bulb, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner.
  • Page 143 ENGINE Keep it free from oil; otherwise, the transparency of the glass, life of the bulb, and luminous flux will be adversely affected. If oil gets on the bulb, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner.
  • Page 144 ENGINE 5. Check the functionality of Change the damaged rotate output of the rotate speed speed sensor. sensor. 6. Check the sensor between the motor and the controller, Repair or change the whether the socket is open damaged plug or socket. circuit or not.
  • Page 145 ENGINE 6. Check the motor's field winding for Change the damaged motor. turnoff. 7. Check the controller for Change the damaged damage. controller. 8. Check the sensor of Change the damaged throttle acceleration. sensor. 9. Check whether the carbon Change the new carbon brushes are excessive brushes.
  • Page 146 ENGINE Part Name Remarks Binding post Output shaft Socket connector Bearing -146-...
  • Page 147 ENGINE SPEED SENSOR DIAGRAM ： Test methods For each rotation of the motor, output four pulseson the V-out .Need to use the oscilloscope when testing. MOTOR AND CONTROLLER WIRING DIAGRAM -147-...
  • Page 148 ENGINE -148-...
  • Page 149 ENGINE Part Name Remarks 前轮胎Front Tire 后轮胎Rear Tire 前轮毂安装座Front hub assembly base 前桥部件Front Bridge 前桥中间传动轴组合Mid transmission Alex front bridge 驱动电机部件Drive motor assy 减速箱Decelerate Box 后桥Rear Bridge 后半轴Rear half axle 后轮毂安装座Rear hub assembly base 前半轴Front half axle -149-...
  • Page 150 ENGINE Part Name Remarks 控制器Motor Controller 主接触器组合Main Connector Assy 铝板Aluminum Plate 驱动电机部件Drive Motor Assy 减速箱Decelerate Box 后桥Rear Bridge 温度传感器Temperature Sensor 相位传感器Phase Sensor -150-...
  • Page 151 ENGINE Part Name Remarks 充电器Charger 蓄电池部件Battery Assy -151-...
  • Page 152 CHASSIS FAULT CODE failure code Message Description 4481 Handbrake Fault Handbrake is active when direction selected. 4541 Fan Fault No speed feedback from external heatsink fans 4542 Low Oil Low Oil 4543 Hydraulic filter Hydraulic Filter 4544 Pump Current Low Pump motor is not drawing sufficient current Isolation fault detected between logic and power 4545...
  • Page 153 CHASSIS BDI remaining charge (0x2790,1) is less than BDI Warning level (0x2C30,5) 45C1 BDI Warning BDI remaining charge (0x2790,1) is less than 45C2 BDI Cutout BDI Cutout level (0x2C30,4) Battery voltage (0x5100,1) is less than Under 45C3 Low Battery Cut Voltage limit (0x2C02,2) for longer than the protection delay (0x2C03,0) Battery voltage (0x5100,1) is greater than Over...
  • Page 154 CHASSIS SinCos Encoder Min Max Values are heading 46C2 SinCos Tracking Warning towards a voltage rail or converging together. A fault ride through event has been encountered, 46C3 Fault Ride Through but operation is allowed to continue although the system may be derated The open loop VF induction motor software has 46C4 Motor Pull-Out Warning...
  • Page 155 CHASSIS Traction function inhibited using traction inhibit 488A Traction Inhibit Fault switch (0x2137) Vehicle changed from traction mode to pump 488B Illegal Mode Change Fault mode (or vice versa) when direction selected 488C Tilt Sensor Fault Aichi error code (0x3802,0) set to 0x02 488D Belly fault Belly function has activated.
  • Page 156 CHASSIS One or more configured RPDOs not received 4E81 RPDO Timeout (severe) with 3s at start up or 500ms during normal operation. Controller is unable to control a current in the 4EC1 Cant Establish Fld Curr field winding The motor control protection subsystem 4EC2 Pulsing Disabled unexpectedly disabled the PWM...
  • Page 157 CHASSIS EMCY message received from non-Sevcon node 4F81 CANopen anon EMCY level 3 and anonymous EMCY level (0x2830,0) is set to EEPROM or flash configuration data corrupted 5041 Bad NVM Data and data can not be recovered. 5042 VPDO Out of Range VPDO mapped to non-existent or invalid object 5043 Static Range Error...
  • Page 158 CHASSIS Motor current exceeded controller rated 52C2 Motor Overcurrent Fault maximum Motor controller unable to maintain control of 52C3 Current Control Fault motor currents 52C4 Motor Overspeed Fault Motor control tripped due to motor overspeed 52C5 Encoder Alignment Severe Encoder is not aligned properly. Large rate of change of current detected multiple 52C6 di/dt fault (suspected s/c)
  • Page 159 CHASSIS 5315 SDO Send Error Internal CANbus fault 5316 SDO unknown event Internal CANbus fault 5317 SDO Bad SRC Internal CANbus fault 5318 SDO bad error number Internal CANbus fault 5319 Motor slave in wrong state Motor slave in wrong state 531A Ren Protocol CAN device on Renault Twizy not responding...
  • Page 160 CHASSIS 54CC IGBT M2 Low Driver Fail IGBT driver failure 54CD IGBT M2 High Driver Fail IGBT driver failure 54CE IGBT M3 Low Driver Fail IGBT driver failure 54CF IGBT M3 High Driver Fail IGBT driver failure 5741 Invalid Powerframe Rating Unable to identify hardware EMCY message received from non-Sevcon node and anonymous EMCY level (0x2830,0) is set to...
  • Page 161 CHASSIS 1. Check whether disc plates abrasion exceeded limits. 2. Check whether brake shoe of clamp abrasion Brake performance degressive exceeded limits or polluted by friction material such as oil. 3、Check whether the oil cup of brake fluid lack oil. Grinding noises emerged from 1.
  • Page 162 CHASSIS 3. Check whether steering column bottom end inner bearing damaged. 1. Check whether tie-rod and steering column locknut loosen or damaged, or steering knuckle and steering Front wheel steering column locknut loosen or damaged. clearance excessive 2. Check whether tie-rod two ball joint damaged. 1.
  • Page 163 CHASSIS Phenomenon Measure 1. Check whether front and rear axles splines damaged. 2. Check whether gears of front gearbox and differential over worn. Front and rear axles arise abnormal sound during drive 3. Check whether rear gearbox gears over worn. 4.
  • Page 164 CHASSIS PANEL AND CARGO BED Front Panel - 164-...
  • Page 165 CHASSIS Part Name Remarks Removing the front panel Instrument mask Instrument panel Right back plate I ,cabin outside Left back plate I ,cabin outside Front fender Front left wheel regula I Headlight mounting plate - 165-...
  • Page 166 CHASSIS Part Name Remarks Sundry box cover Lock of sundry box Big pan head screw with cross recess M5×16 Plastic hinge, sundry box Socket hexagon plain head screw M6×16,green Nut clamp M6×2 Cross small plate head tapping screw ST4.8×13 Water cup cover Bright white front panel - 166-...
  • Page 167 CHASSIS Knob switch Part Name Remarks Washer Φ15×Φ22×1 Rubber sleeve, knob switch Hexagon flange nut M5 Socket hexagon plain head screws M6×12 Front left reflector Front right side reflector Cup cover circlip - 167-...
  • Page 168 CHASSIS - 168-...
  • Page 169 CHASSIS DIASSEMBLING THE HOOD Remove: ① Switch ② Hood ② ③ Release ③ To open the hood, pull up the switch to release the latch and open the hood . CAUTION: ⚫ Never open operator’s seat while the engine is running. ⚫...
  • Page 170 CHASSIS Side Cover, Footrest part Part Name Remarks Removing the side cover footrest part Left footrest Middle protective plate, footrest Right footrest Right backplate Ⅱ,cabin outside Lower backplate I, seat cushion Lower backplate Ⅱ, seat cushion - 170-...
  • Page 171 CHASSIS Left backplate Ⅱ,cabin outside Rear left wheel regula Ⅰ Tank Opening Decorative Cover - 171-...
  • Page 172 CHASSIS Part Name Remarks View window plate Right Cover, seat sundry box Rear right wheel regula Ⅰ Rear fender Ⅱ Rear fender Ⅰ Cross Plate Head Screw M6×16 Rear Protective Plate Ⅰ Rear Protective Plate Ⅱ Nut clamp M6×2 Knob switch Washer Φ15×Φ22×1 - 172-...
  • Page 173 CHASSIS Part Name Remarks Rubber Sleeve, Knob Switch Socket Hexagon Screw M6×16 Decorative sheet, front left backplate Decorative sheet, front right backplate Rearview mirror rubber pad - 173-...
  • Page 174 CHASSIS CHECKING THE BRAKE PEDAL ① Brake pedal ② Free travel ③ Pedal stroke Inspect the brake pedals for free clearance and smooth operation. Adjust if incorrect measurement is found. - 174-...
  • Page 175 CHASSIS - 175-...
  • Page 176 CHASSIS Cargo Rack Part Name Remarks Removing the cargo rack Hexagon flange bolt M6×16 Cargo bed door cable Big pan head screw with cross recess M6×20 Bolt, bed cable M6×12 Bed gas spring Flat rubber washer Φ13×10 Tension spring H Mounting cap, cushion rubber - 176-...
  • Page 177 CHASSIS Part Name Remarks Damping cover, balancing lever Φ14×29 Handle gum cover Invert bracket assy, carrier R-pin B Cargo bed plate assy Container shaft assy Turn up plastic liner Φ12×Φ18 Spring washer 6 Cargo bed door mounting assy - 177-...
  • Page 178 CHASSIS Part Name Remarks Door panel lock assy Hexagon flange nut M6 Bolt, bed cable M6×12 Hexagon flange bolt M8×12 Container hinge plate Cargo gas spring assy Step cotter pin Φ12×47 - 178-...
  • Page 179 CHASSIS Cargo Bed Part Name Remarks Removing the cargo bed Nut clamp M6×2 Screw M6×16 Hexagon flange bolt M8×20 Inner hexagon bolt with pan M6×16 Front bed guardrail Rear right wheel regula Ⅱ Front panel, R - 179-...
  • Page 180 CHASSIS Plastic bed Part Name Remarks Front bed plate Front panel, l Rear left wheel regula Ⅱ Hex tapping screws ST5.3×16 Liner panel, cargo bed Tube Supporting plate, cargo bed Bed door lock axis Bed door sheet - 180-...
  • Page 181 CHASSIS Rotating liner plate Part Name Remarks Cross big plate head tapping screw ST4.8×13 Screw M6×12 Side bed guardrail assy Nylon flange bushing Φ10×Φ18×Φ22.5×13 Split pin 2×25 Rear reflector assy Screws ST4.2×13 Back door panel switch assy Rear left side reflector - 181-...
  • Page 182 CHASSIS Rear right side reflector Washer Φ6×Φ18×1.6 - 182-...
  • Page 183 CHASSIS Raising and Lowering the Cargo Bed To raise the cargo bed • Apply the parking brake with the engine off. • Pull up the cargo bed handle. To lower the cargo bed Press down the cargo bed hard to make the gas spring contractive till it is locked.
  • Page 184 CHASSIS - 184-...
  • Page 185 CHASSIS Head Shed Frame Part Name Remarks Removing the head shed frame Shed bar assy Ⅴ Hexagon flange bolt M6×25 Swivel bolt M8×22-Φ10×16 Curved washer Swivel nut M8×25 Cap nut M6×14 - 185-...
  • Page 186 CHASSIS Bolt M10×1.25×20 Shed bar assy Ⅳ Part Name Remarks Shed bar assy Ⅲ Shed bar assy Ⅱ Shed bar assy Ⅰ Hexagon socket head screw M10×1.25×45 Cap nut M10×1.25 Spring washer -10 Roof shed joint rubber boot C - 186-...
  • Page 187 CHASSIS DIRECTION SYSTEM Steering Wheel part Part Name Remarks Removing the steering wheel Steering wheel comp - 187-...
  • Page 188 CHASSIS Fixed cap, steering wheel Screw M5×20 Horn insulation pad 1 Horn switch Steering column cover Ⅰ circlip for shaft d0=17 Deep groove ball bearing 6003-2RZ Adjustable steering wheel swivel seat Deep groove ball bearing 6805 - 188-...
  • Page 189 CHASSIS Part Name Remarks Ignition switch assy. Horn earth wire Direction gas spring assembly Step slotting pin Φ8×34 Cotter pin Φ5×1 Direction of the seat Hexagon flange bolt M10×1.25×16 Bolts M6×Φ10×2.5×30.5 Metal insert hexagon lock nut with flange M6×1.25 Step slotting pin Φ8×45 Steering column cover Ⅲ...
  • Page 190 CHASSIS Part Name Remarks Cross small plate head tapping screw ST3.9×13 Direction drive shaft assembly Hexagon bolt with flange M8×30 Metal insert hexagon locknut with flange M12×1.25 Round head screw with cross M4×8 Horn spring Connection strap for horn Washer Φ10×Φ20×2 - 190-...
  • Page 191 CHASSIS Spring washer Φ10 Split washer Φ8 Washer Φ8 Insulation spacer for horn 2 Adapter sleeve , steering wheel Steering mechanism part Part Name Remarks Removing the steering mechanism Steering comp Diverter bulb assembly Hexagon nut M12 Split pin 2×30 Hexagon bolt with flange M10×1.25×35 Elasticity anchor ear H...
  • Page 192 CHASSIS Dustproof cover1 Hex nut M14×1.25 Steering ball head components - 192-...
  • Page 193 CHASSIS THE STRUCTURE OF STEERING WHEEL PART DIASSEMBLING THE PARTS OF THE STEERING WHEEL Remove: • screw M5×20 ① • Decoration cover for steering wheel ② • Horn assembly ③ a. Takes down the screw ① b. Takes down the decoration cover for steering wheel ②...
  • Page 194 CHASSIS The reverse running clearance whether does surpass the limited stipulation Adjust NOTE: The reverse running clearance is less than 30mm. The grip part which is covered by the foam whether has damaged, if it is, must replace a new steering wheel. - 194-...
  • Page 195 CHASSIS Inspect fastens nut of the steering wheel whether does have flaw and fissure , if it is, must replace. Check the internal spline between the steering wheel and steering column whether have damaged, if the attrition is serious, must replace the steering wheel.
  • Page 196 CHASSIS • steering shaft c. Loose the bolt which is on the steering drive axle, the top of spline, draws out the cross gimbal. d. Loose the fastening two pieces M8×13.5 bolt on the steering shaft, take down the steering shaft from the frame.
  • Page 197 CHASSIS CHECKING AND SERVICE THE STEERING COLUMN PARTS 1. Check: • steering column tube ① • bearing ② • central axis of the steering shaft ③ • spline ④ • loosening ⑤ The central axis of the steering shaft whether flexible and moves.
  • Page 198 CHASSIS steering drive axle, pull out the top of the steering drive axle. 2. Loose the clamp one piece flange bolt in the cross gimbal, spline on the bottom of the steering drive axle, pull out the lower of the steering drive axle.
  • Page 199 CHASSIS STEERING MACHINE PARTS THE STRUCTURE OF THE STEERING 1. Check: • pressure pad ① • Rubber dust cover ② Wear/damage Replace. Damage/degradation Replace NOTE: When replace the dust boots of the ball , must enter 1/2 volume in lithium grease in to the dust boots.
  • Page 200 CHASSIS 4. Check: ·steering joint Crack/distortion Replace. BRAKE SYSTEM - 200-...
  • Page 201 CHASSIS PREPARATION FOR CHECKING BEFORE MAINTENANCE OF THE BRAKE SYSTEM. Brake system is crucial to the life safety of the operator and therefore must be periodically inspected and maintained. This vehicle uses the single return route hydraulic pressure disc brake system. Please follow the tips of inspection as below.
  • Page 202 CHASSIS ·rear disk brake plate ① ·thickness ② Periodical inspection of the wear condition of rear disk brake plate is also necessary. Disk brake plate must be replaced depending on its wear condition. 3. Disk brake plate uses hydraulic pressure of brake fluid.
  • Page 203 CHASSIS Part Name Remarks Removing brake components Hydraulic brake subassembly Ⅰ Right front hydraulic tubing Left front hydraulic tubing Front right disc brake clamp combination Front left disc brake clamp combination Front Left Brake Pad Brake rod combination Hexagon flange bolt M10×1.25×22 Hydraulic tubing gasket - 203-...
  • Page 204 CHASSIS Part Name Remarks Strainer bolt Ⅰ Hydraulic tubing retaining clip Hexagon flange bolt M6×16 Main Brake Pump Right rear hydraulic tubing Hexagon flange bolt M10×1.25×25 Left rear hydraulic tubing Hexagon Flange Bolt M12×1.25×155 Strainer bolt Ⅱ Middle hydraulic tubing Left rear brake sheet - 204-...
  • Page 205 CHASSIS Right rear brake sheet Part Name Remarks Middle brake assy Hexagon flange bolt M6×30 Rear right disc brake clamp combination Rear left disc brake clamp combination Hydraulic line three Brake pad assy Rear brake disc Parking disc brake plate Hexagon Bolt M8×1×20 Front Right Brake Pad Front disc brake plate...
  • Page 206 CHASSIS Hexagon Flange Bolt M12×1.25 Cylindrical Bushφ12.5×φ22×55 - 206-...
  • Page 207 CHASSIS CHECKING THE FRONT BRAKE DISC 1. Check: • brake disc Galling/damage Replace. 2. Measure: • brake disc deflection Out of specification Check the wheel runout. If wheel runout is within the limits, replace the brake disc. Brake disc maximum deflection 0.10 mm (0.004 in) •...
  • Page 208 CHASSIS - 208-...
  • Page 209 CHASSIS REPLACING THE FRONT BRAKE PADS NOTE: It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads. 1.Check: • brake pad ① Damage/wear Replace 2.Measure: • brake pad thickness ⓐ Out of specification Replace the brake pads as a set.
  • Page 210 CHASSIS c. Tighten the brake caliper bleed screw. Brake caliper bleed screw 6 Nm (0.6 m · kg, 4.3 ft · lb) d. Install the retaining bolts and brake caliper. Brake pad holding bolt 18Nm (1.8 m · kg, 13 ft · lb) - 210-...
  • Page 211 CHASSIS 4. Check: • brake fluid level • minimum level mark ① Must use DOT4 Brake Fluid 5. Check: •brake pedal operation Soft or spongy feeling Bleed the brake system. DISASSEMBLING THE FRONT BRAKE CALIPERS WARNING: • Brake caliper is one of the most important security components.
  • Page 212 CHASSIS • dust seals ① • caliper piston seals ② a. Blow compressed air into the hose joint opening to force out the caliper piston from the brake caliper body. WARNING: • Never try to pry out a caliper piston. •...
  • Page 213 CHASSIS b. Remove the dust seals and caliper piston seals. WARNING: All internal brake components should be cleaned in new brake fluid only. Do not use solvents as they will cause seals to swell and distort. 2. Check: • brake caliper pistons ① Scratches/rust/wear Replace the brake caliper assembly.
  • Page 214 CHASSIS - 214-...
  • Page 215 CHASSIS ASSEMBLING THE FRONT BRAKE CALIPERS WARNING: • All internal brake components should be cleaned and lubricated with new brake fluid only before installation. Must use DOT4 Brake Fluid • Replace the caliper piston seals and dust seal whenever a brake caliper is disassembled.
  • Page 216 CHASSIS INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the front brake calipers. 1. Install: • brake caliper assembly • bolt flange 48Nm (4.8m · kg,35 ft · lb) • brake hose ① • copper washers ② •...
  • Page 217 CHASSIS NOTE: When installing the brake hose on the brake caliper, make sure that the brake pipe touches the projection a on the brake caliper. WARNING: Proper brake hose routing is essential to insure safe vehicle operation. 2. Fill: • brake reservoir Must use DOT4 Brake Fluid NOTE:...
  • Page 218 CHASSIS - 218-...
  • Page 219 CHASSIS The service method of the rear brake caliper is as the same as the front brake caliper, please refer to the before-mentioned to operate.) - 219-...
  • Page 220 CHASSIS - 220-...
  • Page 221 CHASSIS CHECKING THE PARKING BRAKE DISC 1. Check: • parking disc ① Galling/damage Replace. 2. Measure: • parking disc deflection Out of specification Replace. Parking disc maximum deflection 0.10 mm (0.004 in) • parking disc thickness ② Out of specification Replace.
  • Page 222 CHASSIS - 222-...
  • Page 223 CHASSIS REPLACING THE PARKING BRAKE PADS 1. Check: • brake pad • brake pad plate Damage/wear Replace 2. Measure: • brake pad thickness Out of specification Replace the brake pads as a set. Brake pad wear limit 1.0 mm (0.04 in) 3.
  • Page 224 CHASSIS • minimum level mark ① Should the fluid level falls under the minimum mark, please refill the box with the same type of fluid as was recommended by the manufacturer to ensure the fluid level is higher than the minimum mark.
  • Page 225 CHASSIS DISASSEMBLING THE PARKING BRAKE 1. Install: • parking brake case ① • parking brake case bolts ② 22Nm (2.2 m · kg,16 ft · lb) 2. Install: • parking brake arm shaft ① • parking brake arm ② • set bolt ③ •...
  • Page 226 CHASSIS - 226-...
  • Page 227 CHASSIS 3. Install: • brake pad ① NOTE: 将开口销ⓐ和销子ⓑ拆下,在把机械驻车制动片组 合重新装配。 4. Install: • brake pad holding bolts 17Nm (1.7 m · kg,12 ft · lb) - 227-...
  • Page 228 CHASSIS - 228-...
  • Page 229 CHASSIS CHECKING THE MASTER CYLINDER 1. Check: • brake master cylinder Wear/scratches Replace the brake master cylinder assembly. • brake master cylinder body Cracks/damage Replace. • brake fluid delivery passage (brake master cylinder body) Blockage Blow out with compressed air. 2.
  • Page 230 CHASSIS - 230-...
  • Page 231 CHASSIS INSTALLING THE BRAKE MASTER CYLINDER 1. Install: • brake master cylinder 16Nm (1.6 m · kg,11 ft · 2. Install: • brake pipe 19Nm (1.9 m · kg,13 ft · • washer plate • brake hose • union bolt 27Nm (2.7 m ·...
  • Page 232 CHASSIS • brake system 5. Check: • brake fluid level Brake fluid level is under the “MIN” level line Fill up. - 232-...
  • Page 233 CHASSIS WHEEL AND TYRE PARTS FRONT WHEELS Part Name Remarks Removing the front wheel Front wheel rim Front tyre Cycle valve Nut M10×1.25 Wheel decoration cover Ⅳ Nut M24×1.5 WARNING: Front hub Securely support the vehicle so - 233-...
  • Page 234 CHASSIS Valve spool cap There is no danger of it falling over. Bolt M8 Cotter 3.2×50 REAR WHEELS Part Name Remarks Removing the rear wheel Rear wheel rim - 234-...
  • Page 235 CHASSIS Rear tyre Cycle valve Nut M10×1.25 Wheel decoration cover Ⅳ WARNING: Nut M24×1.5 Securely support the vehicle so There is no danger of it falling Rear hub over. Valve spool cap Bolt M8 Cotter 3.2×50 - 235-...
  • Page 236 CHASSIS CHECKING THE WHEEL TYRE 1. Check: • wheel tyre 2. Measure: • wheel runout Over the specified limit Replace the wheel or check the wheel bearing play ①. 3. Check: • wheel balance Out of balance Adjust. Wheel runout limit Radial ②: 2.0 mm (0.08 in) Lateral ③: 2.0 mm (0.08 in) WARNING:...
  • Page 237 CHASSIS CHECKING THE WHEEL HUB 1. Check: • wheel hub ① Cracks/damage Replace. • splines (wheel hub) ② Wear/damage Replace. ·nuts (wheel hub) loosen or distorted Replace or tighten - 237-...
  • Page 238 CHASSIS INSTALLING THE WHEEL HUB 1. Install: • axle nut 260 Nm (26.0 m · kg, 190 ft · lb) INSTALLING THE WHEEL TYRE 1. Install: • wheel NOTE: The arrow mark ① on the tyre must point in the direction of rotation □, of the wheel.
  • Page 239 CHASSIS - 239-...
  • Page 240 CHASSIS SPECIFICATION OF WHEEL AND TYRE Tyre Wheel Pressure Tyre Dimension (Kpa Dimension /psi) Front 12×6(min) 25×8-12(min) Whee 138/20 14×7(max 26×9-14(max) Rear 12×8(min) 25×10-12(min) Whee 138/20 14×9(max 26×11- 14(max) • Since wheels and tyres are crucial to the vehicle operation, inspection for tyre pressure and profile depth is necessary.
  • Page 241 CHASSIS TRANSMISSION SYSTEM - 241-...
  • Page 242 CHASSIS C.V Axle, Front Axle Part Name Remarks Removing the C.V axle, front axle (L.&R.) Front left axle shaft component C Front right axle shaft component B Rubber dust-p boot F Rubber dust-p boot clamp A Rubber dust-p boot clamp B Rubber dust-p boot B - 242-...
  • Page 243 CHASSIS Front Bridge - 243-...
  • Page 244 CHASSIS Part Name Remarks Removing the front bridge Front bridge assy Front Axle Gear Box Cover O-type ring Φ140×Φ2.65 Bearing Φ35×Φ62×9 Cir clip d0=62 Shaft connector Shaft connecting sleeve Adjustment washer Φ71×Φ83×0.1 Bearing 61912 Transfer gear wheel - 244-...
  • Page 245 CHASSIS - 245-...
  • Page 246 CHASSIS Part Name Remarks Front bridge bevel gear Washer Adjustment washer Φ40×Φ57×0.1 Drive gear wheel Bearing 6007 Adjustment washer Φ50×Φ61.5×0.1 Front axle body assy Hexagon screw M10×1.25×16 Flat washer 10 Oil seal, output shaft, front bridge Φ24×Φ38×8 Oil seal, output shaft, front bridge Φ24×Φ38×8 - 246-...
  • Page 247 CHASSIS - 247-...
  • Page 248 CHASSIS Part Name Remarks Bearing Φ15×Φ21×12 Spring Washer Φ10 Bearing 6007 Circlip d0=62 Oil seal, drive gear, front bridge Φ48×Φ65×9 O-Ring Φ14×Φ7 , Driving Tooth Hexagon flange self-lock nuts M14×1.5 Screw M14×1.5×10 O-type seal ring, rubber Φ12.5×Φ1.5 Hexagon flange bolt M10×1.25×16 O-type ring Φ1.5×Φ9 - 248-...
  • Page 249 CHASSIS - 249-...
  • Page 250 CHASSIS Part Name Remarks Hexagon flange bolt M8×25 Air bag nozzle, rear bridge Inner Hexagon Screw With Flat Head M8×10 Pin Φ5×75 Fork Rack O-type seal ring, transfer Φ81×Φ2 Transfer assy Inner hexagon screw with columniform-head M8×20 Washer 8 Connection Fork H - 250-...
  • Page 251 CHASSIS - 251-...
  • Page 252 CHASSIS Part Name Remarks Connection Fork D Cross joint assy C-type Washer(φ20) Circlip C Gas pipe A Spring clamp Φ10 Front bridge mounting plate(L) Front bridge mounting plate(R) Bushing Φ10.5×Φ22×36.5 Hexagon flange bolt M10×1.25×142 Hexagon flange nut M10×1.25 - 252-...
  • Page 253 CHASSIS - 253-...
  • Page 254 CHASSIS Part Name Remarks Hexagon flange bolt M10×1.25×20 Hexagon flange bolt M10×20 Flat washer Φ10 - 254-...
  • Page 255 CHASSIS 前传动轴部件Front Transmission Axle Assy - 255-...
  • Page 256 CHASSIS Part Name Remarks 拆卸前传动轴Transmission Axle knock down Front Bridge Drive Shaft Assy Transmission Shaft Dust Cover Pain Washer A Cir clip D0=25 Front Transmission Shaft R Pressure Spring B,Drive Shaft Transmission Shaft Dust Cover B Connection Fork C Cross-Shaped Component C-type Washer(φ20) - 256-...
  • Page 257 ELECTRICAL COMPONENTS - 257 -...
  • Page 258 ELECTRICAL COMPONENTS Part Name Remarks Cir clip D0=24 Cir clip D0=25 Oil Seal φ25×φ42×7 Ball Bearing 6205-2Rs Transmission Bearing Seat Hexagon Flange Bolt M6×20 Hexagon Flange Bolt M8×25 Front Drive Shaft T Rear Drive Shaft S Connection Fork L Front Bridge Middle Drive Shaft Assy Front Bridge Rear Drive Shaft Assy Front Bridge - 258 -...
  • Page 259 ELECTRICAL COMPONENTS DISASSEMBLING THE UNIVERSAL JOINT Remove: • universal joint a. Remove the circlips ①. b. Place the universal joint in a press. c. With a suitable diameter pipe ② ben- eath the yoke ③, press the bearing ④ into the pipe as shown.
  • Page 260 ELECTRICAL COMPONENTS - 260 -...
  • Page 261 ELECTRICAL COMPONENTS CHECKING THE AXLE, FRONT AXLE 1.Check: • Rubber dust-P cover Cracks/damage Replace 2.Check: • double off-set assembly • ball joint spline • shaft spline Wear/damage Replace. • balls and ball races • inner surface of double off-set Pitting/wear/damage Replace.
  • Page 262 ELECTRICAL COMPONENTS 2. The dustproof rubber wrap does not allow to be scratched, a slight scratches can damage the dustproof rubber wrap very quickly. 3. When reassembles the left and right transmission shaft, in the ball cage must sufficiently enter 2/3 volume with the Lithium lubricating.
  • Page 263 ELECTRICAL COMPONENTS ASSEMBLING THE UNIVERSAL JOINT Install: • universal joint a. Install the opposite yoke into the universal joint. b. Apply wheel bearing grease to the bearings. c. Install the bearing ① onto the yoke. d. Press each bearing into the universal joint using a suitable socket.
  • Page 264 ELECTRICAL COMPONENTS C.V Axle, Rear Axle - 264 -...
  • Page 265 ELECTRICAL COMPONENTS Part Name Remarks Removing the rear axle(L.&R.) Rear right axle shaft component B Rear right axle shaft component B Rubber dust-p boot F Rubber dust-p boot E Rubber dust-p boot clamp A Rubber dust-p boot clamp B Rear Bridge - 265 -...
  • Page 266 ELECTRICAL COMPONENTS - 266 -...
  • Page 267 ELECTRICAL COMPONENTS Part Name Remarks Removing the rear bridge reducer Idler Gear Driving Bevel Wheel Idler Gear Shaft Flat Key M10×25 6205 Bearing 25×52×15 6206 Bearing 30×62×16 Transfer Case Air Tap, Rear Axle Cir clip D0=52 Cir clip D0=62 - 267 -...
  • Page 268 ELECTRICAL COMPONENTS - 268 -...
  • Page 269 ELECTRICAL COMPONENTS Part Name Remarks Dust Cover Oil Seal 30×55×8 Oil Seal Sleeve I Locking Block Oil Seal 30×55×8 Rear Axle Gear Box Cover 6208 Bearing 40×80×18 Transfer Gear Rear Axle Gear Box 6008 Bearing 40×68×15 Drive&Driven Gears Assy, Rear Axle - 269 -...
  • Page 270 ELECTRICAL COMPONENTS - 270 -...
  • Page 271 ELECTRICAL COMPONENTS Part Name Remarks 30207 Bearing 35×72×18.25 Locating Sleeve O-Ring 75×1.8 O-Ring 58×1.8 Adjust Gasket Press Plate Watch Oil Mirror Oil Standard Paper Pad Driven Bevel Wheel Paper Pad Oil Pan - 271 -...
  • Page 272 ELECTRICAL COMPONENTS - 272 -...
  • Page 273 ELECTRICAL COMPONENTS Part Name Remarks Rear Bridge Oil Outer Bolt Oil Preventor Cover Gasket I Cushion Cover II Gasket II O-Ring 26.5×2.65 Oil Seal Sleeve II O-Ring 45×62×8 Anti-Rotation Gasket Wood ruff Key 6×9×22 Washer Φ15×Φ22×1.5 Hexagon Flange Locked Nut M14×1.5 - 273 -...
  • Page 274 ELECTRICAL COMPONENTS - 274 -...
  • Page 275 ELECTRICAL COMPONENTS Part Name Remarks Joint Plate Dash Cover Round Nut Small Dash Cap End Cap Cushion Cover II Drive Motot Part Hexagon Flange Bolt M8×30 Motor Fixed Support Rear Bridge Mounting Plate II Rear Bridge Mounting Plate I Rear Axle Assy 驱动电机护板...
  • Page 276 ELECTRICAL COMPONENTS Rear Bridge The service method of the rear bridge parts is as the same as the front bridge parts, please refer to the before-mentioned to operate.) NOTE: Apply lithium-soap-based grease to the bearing assembly and o-ring and bearing and driven gear and oil seal and drive shaft coupling and final drive pinion gear bearing housing.
  • Page 277 ELECTRICAL COMPONENTS Shift Operating System - 277 -...
  • Page 278 ELECTRICAL COMPONENTS Part Name Remarks Removing the shift operating system Accelerator Accelerator Pedal Hexagon Flange Bolt M8×20 Hexagon Socket Cap Screw M6×25 Accelerator Mounting Plate Plain Washer 6 Cotter Pin 2×30 Parking Brake Cable C Washer Φ15×Φ22×1.5 - 278 -...
  • Page 279 ELECTRICAL COMPONENTS Part Name Remarks Brake Pedal Mounting Seat Gearshift Decoration Cover Hexagon Flange Bolt M6×16 Footrest Park Assy Hexagon Flange Bolt M8×20 Park Dust-Proof Pad F Hexagon Flange Locked Nut M6 Hexagon Flange Bolt M8×25 Parking Pedal Cross Plate Head Tapping Screw M2×14 Micros witch - 279 -...
  • Page 280 ELECTRICAL COMPONENTS Part Name Remarks Torsional Spring J Brake Pedal Throttle Cable Y Oil Pipe Clip I Hexagon Flange Bolt M6×16 Cir clip Φ12 Micros witch - 280 -...
  • Page 281 ELECTRICAL COMPONENTS Reverse mechanism parts - 281 -...
  • Page 282 ELECTRICAL COMPONENTS ADJUSTING REVERSE MECHANISM PARTS F:Forward GEAR R:Revers M:Middle H:High range L:Low range NOTE: Before shifting, you must stop the vehicle and take your foot off the accelerator pedal. Otherwise, the transmission may be damaged. - 282 -...
  • Page 283 ELECTRICAL COMPONENTS Reverse mechanism parts - 283 -...
  • Page 284 ELECTRICAL COMPONENTS CHECKING AND SERVICE OF REVERSE MECHANISM 1. Check the mobility of gear shift handle. If it is not working properly, remove the gear shift Mechanism to check if the fork , ball and spring is stuck.,in which case replace the defective component and try again.The last way is to turn to the professional repairman.
  • Page 285 ELECTRICAL COMPONENTS SUSPENSION - 285 -...
  • Page 286 ELECTRICAL COMPONENTS Front Swing Arm Part Name Remarks Removing the front swing arm Hexagon bolt with flange M10×1.25×55 Hexagon bolt with flange M10×1.25×55 Metal insert hexagon locknut with flange M10×1.25 Front shock absorber assembly unit QA(gasbag shock absorber) Front Suspension - 286 -...
  • Page 287 ELECTRICAL COMPONENTS Part Name Remarks Removing the front suspension Front left lower rocker arm Front right lower rocker arm Hexagon bolt with flange M10×1.25×78 Columniform bush Φ10.3×Φ23×50 Turn up liner for rocker arm Φ23×Φ28 Metal insert hexagon locknut with flange M10×1.25 Rocker arm backplate Ⅰ...
  • Page 288 ELECTRICAL COMPONENTS Part Name Remarks CirclipD0=30 Spring washer Φ12 Hexagon nut M12×1.25 Cotter pin 2.5×30 Front left upper rocker arm Front right upper rocker arm Hexagon flange bolt M10×1.25×230 Turnup bush Φ15.5×Φ19 Columniform bush Φ10.2×Φ15×211 Front right lower frame member Front right upper frame member Left front sway frame member Front left bottom frame member...
  • Page 289 ELECTRICAL COMPONENTS Front Suspension and arm DISASSEMBLING, SERVICE AND ASSEMBLY THE SUPPORTING ROCKER PARTS 1. Disassembling and Service In the suspension, there is easy to appear the problem with bushing, cotter pin and shock absorber. ·If the left and right rocker rocks fiercely, check the few aspect, whether the bushing of the rocker is crushed, the middle rubber separate is aging and chapped.
  • Page 290 ELECTRICAL COMPONENTS ·These components should be greased with butter before assembly. ·The surface of components can not be cracked. Front Suspension and arm - 290 -...
  • Page 291 ELECTRICAL COMPONENTS ·Check whether these components are greased with butter and then tighten the up-and-down rocker arm assembly and L/R fore dampers and ther components. Fix the L/R tension rods into hole by way of the trough of open-groove nut with cotter pin (4 pcs), and make these tension rods bisection on feet.
  • Page 292 ELECTRICAL COMPONENTS Bends/damage Replace the shock absorber assembly. • shock absorber assembly Oil leaks Replace the shock absorber assembly. • spring Fatigue Replace the shock absorber assembly. Move the spring up and down. Front Suspension and arm - 292 -...
  • Page 293 ELECTRICAL COMPONENTS INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER 1. Install: • front arms • front shock absorber a. Install the front upper arm ①and front lower arm ②. NOTE: • Lubricate the bolts ③ with lithium-soap- based grease. •...
  • Page 294 ELECTRICAL COMPONENTS Rear Suspension - 294 -...
  • Page 295 ELECTRICAL COMPONENTS Part Name Remarks rear suspension Removing the Rear right lower rocker arm Rear left lower rocker arm Hexagon bolt with flange M10×1.25×78 Turnup liner for rocker arm Φ23×Φ28 Columniform bush Φ10.3×Φ23×50 Metal insert hexagon locknut with flange M10×1.25 Welding assembly, rear balancing lever Cushion pad Φ20×45 Mounting cap, cushion rubber...
  • Page 296 ELECTRICAL COMPONENTS Part Name Remarks Hexagon bolt with flange M8×16 Rod assembly, rear balancing lever Hexagon flange bolt M10×1.25×40 Hexagon flange nut M10×1.25 Hexagon flange bolt M10×1.25×40 Hexagon flange nut M10×1.25 Rear shock absorber assembly unit Q(gasbag shock absorber) Hexagon flange bolt M6×16 Hexagon bolt M10×1.25×55 Hexagon flange nut M12×1.25 Hexagon bolt M10×1.25×55...
  • Page 297 ELECTRICAL COMPONENTS Part Name Remarks Rear right upper rocker arm Rear left upper rocker arm Hexagon bolt with flange M10×1.25×78 Rocker arm backplate Ⅰ Rocker arm backplate Ⅱ Hexagon flange bolt M12×1.25×110 Spring washer Φ8 Round plastic plug Φ38 Rear left bottom frame parts Rear right shelf parts After the left sway frame Rear right upper frame parts...
  • Page 298 ELECTRICAL COMPONENTS Rear Suspension and arm CHECKING AND SERVICE OF REAR SUSPENSION 1. It is similar to the front suspension ,Check if there exists any distortion or crack on the install axis of the shock absorber in which case it must be replaced.
  • Page 299 ELECTRICAL COMPONENTS Rear Suspension and arm CHECKING THE STABILIZER 1. Check: • bar, stabilizer Bends/cracks/damage Replace. CHECKING THE STEERING KNUCKLES 1. Check: • steering knuckles Damage/pitting Replace CHECKING THE REAR ARMS 1. Check: • rear arms Bends/damage Replace. 2. Check: •...
  • Page 300 ELECTRICAL COMPONENTS 1. Check: • shock absorber rod Bends/damage Replace the shock absorber assembly. • shock absorber assembly Oil leaks Replace the shock absorber assembly. • spring Move the spring up and down. Fatigue Replace the shock absorber assembly. - 300 -...
  • Page 301 ELECTRICAL COMPONENTS INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBER 1. Install: • rear arms • rear shock absorber a. Install the rear upper arm ① and rear lower arm ②. NOTE: • Lubricate the bolts ③with lithium-soap- based grease. •...
  • Page 302 ELECTRICAL COMPONENTS Nut ④ 45 Nm (4.5 m · kg, 32 ft · lb) - 302 -...
  • Page 303 ELECTRICAL COMPONENTS SEAT Part Name Remarks Removing the seat Seat cushion Ⅰ Rubber socket, seat latch Backrest assy Pan head screw with cross recess M6×25 Lock catch for the safety belt Ⅰ Hexagon flange nut M10×1.25 Hexagon flange step bolt M10×1.25×20-φ14×5 Hexagon flange bolt M10×1.25×20 Hexagon flange nut M10×1.25...
  • Page 304 ELECTRICAL COMPONENTS Operator’s Seat ① Seat To open the seat, raise the seat to the forward position. ① CAUTION: ·These components should be greased with butter before assembly. ·The surface of components can not be cracked. - 304 -...
  • Page 305 ELECTRICAL COMPONENTS FEATURES AND CONTROLS Batteries This vehicle is equipped with eight 6-volt batteries that supply the power needed to operate the vehicle. The batteries are located under the seat. See page 69 for battery access instructions. Always observe all battery safety warnings and safe handling procedures as outlined on vehicle safety labels and in this manual.
  • Page 306 ELECTRICAL COMPONENTS New batteries cannot initially hold all of their capacity. The approximate capacity of the battery pack increases as the number of charge cycles increases. # of Charge Cycles: Percent of Full 95% 100% Capacity: Ambient Temperature Implications on Batteries 1.
  • Page 307 ELECTRICAL COMPONENTS MAINTENANCE Batteries WARNING Battery posts, terminals and related components contain lead and lead compounds, chemicals known to cause cancer and reproductive harm. Always wash your hands after touching or handling the batteries. WARNING Charging a damaged battery can result in serious injury.
  • Page 308 ELECTRICAL COMPONENTS Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away. Ventilate when charging or using in an enclosed space. Always shield eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN. Battery Charging - 308 -...
  • Page 309 ELECTRICAL COMPONENTS When not in use, park the vehicle and connect the battery charger. The vehicle’s charging cord is located inside the right Storage box. WARNING Failure to provide adequate ventilation while charging batteries can result in an explosion. Hydrogen gas is emitted during charging and will rise and accumulate at the ceiling.
  • Page 310 ELECTRICAL COMPONENTS Always follow these precautions when charging the batteries: 1. Position the vehicle on a level surface. 2. Make sure the charging area is well ventilated. 3. Make sure the key is off. 4. Open the hood and any door enclosures or zippers. 5.
  • Page 311 ELECTRICAL COMPONENTS batteries, make sure any wire or metal items (including seat belt latches) remain clear of the battery compartment to avoid causing a short circuit to the electrical system. Battery Inspections Inspect battery terminal connections monthly. Clean batteries as recommended. Using an insulated wrench, torque bolts to 8 ft.
  • Page 312 ELECTRICAL COMPONENTS ELECTRICAL SYSTEM MALFUNCTION INSPECTION Failure Inspection Solution 1. Check the functionality of Repair or change the headlight switch. damaged switches. Headlight does not 头灯不正 work properly. 2. Check the cable for damage. Repair. 常工作 3. Check the light or lamps for Change the damaged damage.
  • Page 313 ELECTRICAL COMPONENTS 1. Check the functionality of key Change the damaged key switch. switch. Turn the "key switch "to "ON" position, the 2. Check the DC/DC convertor for Change the damaged odometer does not damage. DC/DC convertor. display, electric golf cars does not work.
  • Page 314 ELECTRICAL COMPONENTS 1. Check the functionality of Change the damaged combination switch. taillight switch. Repair. 2. Check the cable for damage. Tail light doesn’t work properly. 尾灯不正 3. Check the light or lamp for Change the damaged light 常工作 or lamp. damage.
  • Page 315 ELECTRICAL COMPONENTS Speed become slow 1. Whether the socket is open or power become circuit or not. weak. 1. Check the switch Change the damaged “Forward/Revers switch. Can not reverse. 不能 e”. 逆转 Change the damaged 2. Check the controller. controller.
  • Page 316 ELECTRICAL COMPONENTS 2. Check the parameter of Reset the controller with Maximum speed controller for incorrect settings. portable programmer. exceeded 24km/h 最大 速度超过24公里/小时 Change the damaged 3. Check the motor. motor. ELECTRICAL ELECTRICAL COMPONENTS 1. 喇叭 Horn 2. 卷扬机继电器组合 Windlass controller 3.
  • Page 317 ELECTRICAL COMPONENTS 6. 驱动开关组合 Driven switch assy. 7. 前桥差速转换开关 Front bridge differential convert switch 8. 应急灯开关 Emergency lamp switch 9. 转向灯转换开关 10. 换挡控制开关 11. 模式转换开关 12. 卷扬机控制开关 Windlass controller switch 13. DC插座组合 DC socket 14. 组合点火开关部件 Ignition switch parts 15. 充电器部件 1.
  • Page 318 ELECTRICAL COMPONENTS 7. 驱动电机部件 8. 卷扬机组合 9. 动力蓄电池部件 10. 加速器 Checking the switch continuity Refer to “CHECKING THE SWITCH” and check for continuity between lead terminals. Poor connection, no continuity Correct or replace. * The coupler locations are circled. - 291 -...
  • Page 319 ELECTRICAL COMPONENTS 1. 照明开关组合 2. 远近光转换开关 3. 驱动开关组合 Driven switch assy 4. 前桥差速转换开关 The front axle differential switch 5. 应急灯开关 6. 转向灯转换开关 7. 换挡控制开关 8. 模式转换开关 9. 组合点火开关部件 - 292 -...
  • Page 320 ELECTRICAL COMPONENTS CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals Damage/wear Repair or replace the bulb, bulb socket or both. Improperly connected Properly connect. Incorrect continuity reading Repair or replace the bulb, bulb socket or both.
  • Page 321 ELECTRICAL COMPONENTS CHARGING SYSTEM CIRCUIT DIAGRAM（ see 337 page ） - 294 -...
  • Page 322 ELECTRICAL COMPONENTS TROUBLESHOOTING IF THE BATTERY IS NOT CHARGED: IF THE BATTERY IS NOT CHARGED: 1. Fuse (main) 4. DC/DC转换器 2. Battery 5. Wiring connections(the entire charging system) 3. Charging voltage 充电电压 NOTE: Remove some parts before maintenance 1. Cushion Repair with following special toolings 1.
  • Page 323 ELECTRICAL COMPONENTS 测试电压为13.8V，则正常 NOTE: Use a fully charged battery. OUT OF SPECIFICATION MEETS SPECIFICATION The charging circuit is not faulty. 4. DC/DC转换器 检测蓄电池组对DC/DC的输入端电压是否为 33V-52V 检测DC/DC转换器的输出端电压是否为 OUT OF SPECIFICATION 不 符合规范 13.8V MEETS 更换DC/DC转换器 SPECIFICATION 符合规范 5. Wiring connections POOR CONNECTION - 296 -...
  • Page 324 ELECTRICAL COMPONENTS • Check the connections of the entire charging system. Refer to “CIRCUIT Properly connect the charging system. DIAGRAM”. CORRECT Replace the rectifier/regulator. LIGHTING SYSTEM 照明系统 CIRCUIT DIAGRAM（ see 337 page ） - 297 -...
  • Page 325 ELECTRICAL COMPONENTS TROUBLESHOOTING IF THE HEADLIGHT AND/OR TAILLIGHT FAIL TO COME ON: - 298 -...
  • Page 326 ELECTRICAL COMPONENTS Procedure Check 4. Light switch 1. Fuses (main, lighting system) 5. Wiring connections(the entire lighting system) 2. Battery 3. Main switch NOTE: • Remove the following part(s) before troubleshooting: 1. Console 2. Front luggage carrir 3. Front covering parts •...
  • Page 327 ELECTRICAL COMPONENTS • Check the connections of the entire lighting system. Refer to “CIRCUIT Replace the light switch. DIAGRAM”. POOR CONNECTION CORRECT Check the condition of each of the lighting system’s circuits. Refer to “CHECKING Properly connect the lighting system. THE LIGHTING SYSTEM”.
  • Page 328 ELECTRICAL COMPONENTS 检查 CHECKING THE LIGHTING SYSTEM 照明 1. If the headlights fail to come on: 系统 (1). Bulb and bulb socket • Check the bulb and bulb socket for NO CONTINUITY continuity. CONTINUITY (2). Voltage Replace the bulb and/or bulb socket. •...
  • Page 329 ELECTRICAL COMPONENTS 2. If the taillights fail to come on: (1). Bulb and bulb socket • Check the bulb and bulb socket for continuity. NO CONTINUITY CONTINUITY (2) . Voltage Replace the bulb and/or bulb socket. • Connect the pocket tester (DC 20 V) to the tail/brake light couplers.
  • Page 330 ELECTRICAL COMPONENTS SIGNALING SYSTEM 信号系统 CIRCUIT DIAGRAM（ see 337 page ） - 303 -...
  • Page 331 FOREWORD TROUBLESHOOTING IF A BRAKE LIGHT, AN INDICATOR LIGHT, OR THE WARNING LIGHT FAILS TO COME - 304 -...
  • Page 332 FOREWORD Procedure 3. Main switch Check: 4. Wiring connections (the entire signal system) 1. Fuses (main, signaling system) NOTE: 2. Battery • Remove the following part(s) before troubleshooting: 1. Console 2. Front frame 3. Front pedal • Use special tool(s) for troubleshooting. NO CONTINUITY 1.
  • Page 333 FOREWORD Check the condition of each of the signal system’s circuits. Refer to “CHECKING Properly connect the signal system. THE SIGNAL SYSTEM”. 检查信 CHECKING THE SIGNAL SYSTEM 号系统 1. If the brake lights fail to come on: (1). Bulb and bulb socket •...
  • Page 334 FOREWORD MEETS SPECIFICATION The wiring circuit from the main switch to bulb socket connector is faulty, repair it. This circuit is not faulty. - 307 -...
  • Page 335 FOREWORD 2. If F,N,R light is not bright (1). 检测档位开关 Refer to “CHECKING THE SWITCH”. NO CONTINUITY CONTINUITY 更换档位开关 (2). Wire connection Check the main beam connected to the NO CONTINUITY gear switch connector is strong CONNECTION IS FIRM Repair the main beam connection with gear switch connector This circuit is not faulty.
  • Page 336 FOREWORD - 309 -...
  • Page 337 FOREWORD 3. If the parking brake indicator light fails to come on: 制动指示灯 (1). Brake switch NO CONTINUITY Refer to “CHECKING THE SWITCH”. CONTINUITY (2). Voltage Replace the parking brake switch Set the multimeter to DC12V, test the brake lamp voltage at both ends ①...
  • Page 338 FOREWORD - 311 -...
  • Page 339 FOREWORD 4. If the reverse indicator light fails to come (1). Directional signal switch NO CONTINUITY Refer to “CHECKING THE SWITCH”. CONTINUITY Replace the Reverse switch (2). Voltage Set the multimeter to DC12V, test the direction lamp voltage at both ends ①...
  • Page 340 FOREWORD - 313 -...
  • Page 341 FOREWORD 7. If the four-wheel drive indicator light fails to come on： - 314 -...
  • Page 342 FOREWORD (1). 2WD/4WD switch detection Refer to “CHECKING THE SWITCH”. NO CONTINUITY CONTINUITY (2). Voltage Replace the 2WD/4WD switch. Set the multimeter to DC12V, test the 2WD /4WD switch voltage at both ends. ① Red power meter pens NO VOLATGE DISPLAY ②...
  • Page 343 FOREWORD 2WD/4WD SELECTING SYSTEM CIRCUIT DIAGRAM（ see 337 page ） TROUBLESHOOTING 1. Check if the 2/4WD switch is working. - 316 -...
  • Page 344 FOREWORD a. Turn on the switch, put the gear to position N; keep front and rear wheel off the ground , and then roll the front wheel to see if the rear wheel is moving together with it or if it is rotatable. b.
  • Page 345 FOREWORD SCHECKING THE SWITCH - 318 -...
  • Page 346 FOREWORD - 319 -...
  • Page 347 FOREWORD - 320 -...
  • Page 348 FOREWORD Present section clarifies the ordinary malfunction maintenance and countermeasure for the electric vehicle. It is useful for your using on the electric vehicle. The maintenance of the electric vehicle requires the expertise. For the problems which can not be solved by you, please contact the dealers. NOTE: The following trouble, not including all possible troubles, is a help for trouble guide.
  • Page 349 FOREWORD BODY PARTS AND PROTECTION PARTS malfunction phenomena countermeasure 1、Check the hole of frame and lug mounted to panel, whether it is distortion or dilapidation. And then repair and lacquer it. Panel cracked up 2、Change new plastic pancel. 3、Re-paste the sticker and warning plate. 1、Check the rear speed reducer box, whether it is disrepair or oil leakage.
  • Page 350 FOREWORD ELECTRICAL SYSTEM malfunction phenomena countermeasure 1、Check the function of the big light switch. Lights working abnormally 2、Check cables. 3、Check lights and bulbs. 1、Check the switch. When the haul/run switch is 2、Check the controller. at “ON” position, on skid- proof function 3、Check the cables.
  • Page 351 FOREWORD malfunction phenomena countermeasure 1、Check the lock nuts of shift straight rod, turning joint and steering stem. 2、Check the two ball joints at the each end of the shift straight rod. Steering wheel turning clearance is too much big 3、Check the cross gimbals of turning transmission shaft, whether the clearance is large or not.
  • Page 352 FOREWORD malfunction phenomena countermeasure 1、Check the sensor of acceleration. 2、Check the cables. Speed can not be changed 3、Check the connect cable of the motor sensor. 4、Check the controller. 5、Check the motor. 1、Check the battery, whether the voltage of battery is less than standard value or the battery is broken.
  • Page 353 FOREWORD FAULTY BRAKE POOR BRAKING EFFECT 1、Worn brake pads 2、Worn disc 3、Air in brake fluid 4、Leaking brake fluid Disc brake 5、Faulty master cylinder kit cup 6、Faulty caliper kit sea 7、Loose union bolt 8、Broken brake hose and pipe 9、Oily or greasy disc/brake pads 10、Improper brake fluid level SHOCK ABSORBER MALFUNCTION Loss of damping function...
  • Page 354 FOREWORD 5、Bent tie-rods 1、Uneven tire pressures on both sides Tires 2、Incorrect tire pressure 3、Uneven tire wear 1、Deformed wheel 2、Loose bearing 3、Bent or loose wheel axle 1、Bent Frame 2、Damaged frame 1、 Over worn or loosen main knuckle ball stud 2、 Bent rocker Suspension 3、...
  • Page 355 FOREWORD ERROR DISPLAY OF METER 1、 Then sensor on rear axle is damaged or polluted by iron powder Wrong Speed 2、 The connection between sensor to meter is wrong. 3、 Broken meter - 328 -...

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