Suzhou Eagle Electric Vehicles
General Maintenance Guide to Electric passenger cart
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Index: 1. Brief Introduction 2. Electric System 1.1 Power Supply 1.2 Motor 1.3 Controller 1.4 Charger 3. Chassis 1.1 Transmission System (Drive Line System) 1.2 Steering System 1.3 Brake System 1.4 Drive System 1.5 Body and Accessories 4. Using, Maintaining and Repairing 1.1 Maintaining 1.2 Repair
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1 Brief Introduction 1.1 Introduction Of Eagle Electric Vehicles Suzhou Eagle is specializing in both designing and manufacturing electric vehicles including electric passenger vehicles, electric golf vehicles, electric industrial vehicles, electric garbage vehicles and so on. 1.2 Basic component of electric vehicle Eagle electric vehicles consist of electric system, chassis, body and accessories. Electric system consists of power supply, motor, controller and charger; Chassis consists of transmission system, steering system, brake system, driving system, etc. Body and Accessories consist of bracket, chair, canopy and dashboard. The drive transfer process is as the diagram below: ---Controller 230V/110V~Charger— Batteries—
wheel Motor---transmission----rear axle ---Annex Electric equipment
wheel
1.3 The difference between Electric Passenger Vehicle and Car
Eagle Electric Passenger Car is almost the same as Mini car in Brake system, Steering system and Suspension system. And most of the parts used in Eagle vehicles are the same as mini car ’s. However, Eagle vehicle still has a big difference from car in structure and usage: (1) Power supply: the battery of the Electric passenger vehicle likes the oil box of car, and its motor like the engine of the car. The engine is running before the car moves, but the motor doesn’t need to run before the electric car moves. (2) Operation: when start the car, we should loosen the clutch slowly, at the same time, step the accelerator. But when we start electric vehicle, we can step the accelerator without step on the clutch anymore. (3) The engine can run itself when the car is still, but the electric vehicle is another case. Electric vehicle is easy to operate and control. Electric system 2.1 Power Supply (1) The Power Supply of Eagle Electric Car is either imported lead-acid battery or Chinese colloidal battery. Eagle uses imported US battery as our standard battery. Comparing to Chinese battery, US battery has higher capacity and longer lifetime. (2) Lead-acid battery consists of anode & cathode plate, clapboard, electrolyte, shell and so on. The main component is lead, lead oxide and diluent vitriol, that’s the reason why we call it lead-acid battery. Its work process is Double-sulfuration. The chemic process is like this: Pb+Pbo2+H2SO4-------2PbSO4+2H2O When discharge, the sulfur in the electrolyte is consumed and water is produced, so the electrolyte 2
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becomes thinner. When charge, water is consumed and vitriol is produced, so the electrolyte becomes thicker. (3) Technical parameter of lead-acid battery Rated capacity: refers to the amount by multiplying the discharge time and discharge current obtained during the process of discharging the battery to 1.7V of one cell at 1/5 of specified capacity. Ratio energy: refers to ratio of the output energy of the battery to the total mass of the battery, it shows the capacity of output energy of batteries based on the same mass for different battery. The bigger it is, the longer running range is. Inner resistance: battery’s inner resistance decides its discharge ability. Inner resistance has relation with electrolyte density and temperature. Both thicker and thinner electrolyte would increase inner resistance. According to experiment, in room temperature, when electrolyte density is 1.28+0.005g/m 3, internal resistance is the least. The quantity of battery used is depends on what kinds of car it is. For passenger cars, several 6v-battery is used in series, such as 8 pieces of batteries or 12 pieces of batteries. 2.2 Driving Motor When the motor drives the rear axle, the car moves. Motor has many types, such as direct current motor and alternate current motor. Direct current motor with brush consists of magnet coil, armature coil, brush and brush bracket. Armature coil is rotated in the magnetic field, which is produced when the current pay by magnet coil. Series motor means stator coil connects rotor coil in series. And shunt-wound motor means stator coil connects rotor coil parallel connection. When stator coil and rotor coil doesn’t connect together, other power supply supplies the power the stator coil needs, we call the motor separately excited motor. Eagle uses Direct Current Series Motor, Direct Current Separately Excited Motor and Alternate Current Motor. Usually, we use Direct Current Series Motor in Passenger Cars, and Separately Excited Motor in Golf Cars. Character: Series Motor has the much advantage includes: strong torque, strong overload ability, mature manufacture technics, easy speed controlling, etc. And its disadvantage includes: brush would be broken, heated, noisy and inefficient when it moves opposite to commutator. Separately excited motor can easily control and brake. Alternate Current Motor uses transducer to control the motor. It doesn’t have commutator and brush, so it has simple structure. It is maintenance-free, high efficiency, but it is expensive. 2.3 Speed controller At present, the controller Eagle used includes Series Controller and Separately Excited Controller, which are manufactured by US Cutis Company. Customers can choose different Controller according to different environment. Below is the circuit diagram of Cutis Series Controller( Page 12): Main circuit working route: Anode of Battery—250A Fuse—Main Contactor---Motor A1A2---Motor S1S2—M---Cathode of Battery Control Circuit: Anode of Battery---10A Fuse---Diode---Electric Lock---Accelerator—Main Contactor Coil—Cathode of Battery ADD Coil — Cathode of Battery Page 4, Total: 11
Assistant Circuit: Anode of 24V Power Supply—add Coil—F3—Various Electric Equipment---Cathode of Battery 2.4 Charger. The main method of battery charge includes constant voltage charge, constant current charge and quick charge, etc. The charge process is as follow: (1) Check Electrolyte Level, if less, add some. (2) Check and Fix Battery Connecting Cables. (3) Check if the battery voltage and charger battery is the same. (4) Connect charger and battery group. First connect the jack on the car, and then connect the jack on the power supply. The input power supply is single-phase 220V/110V±5% dynamical power supply. For single group batteries (8 pieces), the section area of input lead shouldn’t be less than 2.5 mm2, the capacity of the power supply switch should be bigger than 16A. For double group batteries (16pieces), the section area of the input lead shouldn’t be less than 5mm2, the capacity of the power supply switch should be bigger than 32A. We suggest customers select dynamical power supply switch. The fixation circuit is as follow: N pole + pole + pole + pole 220V
Air switch
outlet
outlet
220V
Air switch
outlet
outlet
220V
Air switch
outlet
outlet
(5) Check the density of the electrolytes. When bleb comes from electrolytes, check the density once an hour. Battery is full charge when electrolytes density stops increasing. (6) Turn off the power supply, take out the Plug。 (7) Read the manual carefully before use the Charger. Chassis 3.1 Transmission parts: Transmission is used to transfer the torque generated by motor to wheels. Transmission system mainly consists of flywheel, clutch, transmission case, transmission shaft, drive axle. As electric car can start with load, so clutch, transmission case can be taken away, that makes the structure of car simple and maintenance easy. The detailed structure of the transmission system of the mini car can be reference to that’s of electric car. For Eagle Electric Cars, there are two types of transmission systems. One type is similar to the car’s, which include clutch, transmission case, universal transmission (mechanical transmission); in another transmission system, motor connects with drive axle directly (non-stage transmission), for example, EG6042 and EG6062. Both Mechanical transmission and 3
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stepless transmission have their own merit. As far as mechanical transmission concerned, it has abundance gear ratio, high range drive distribution, quicker rate, high adaptability to different gradient, less power consumption and longer drive range. As far as stepless transmission concerned, as clutch, transmission case and universal transmission are taken away, the structure becomes simple, controlling and maintenance become easy. But non-stage transmission doesn’t have enough drive distribution, if it is used in 8+ seats car, the adaptability to the gradient is not so good. 3.2 The body bracket is anti-corrosive as it is dealt with sandblast and gavilanizing . The structure of the body bracket is welding frame structure, which is designed based on the structure of bus and car. That structure provides bigger load and better anti-deforming, and also facilitates the layout of parts and wiring on the chassis. Suspension is independent suspension, which absorbs shock very well and makes running stable. The front axle Eagle used is CH1018 divided front axle which has used in mini car long time. The rear axle Eagle used has many types according to different types of vehicles. Usually, Eagle Koala Series, such as EG6042 and EG6062 use TongChuan rear axle whose final gear ratio is 10.25, and Free Series, such as EG6082, EG6112, EG6152 and Theory Series such as EG6083, EG6113, EG6153 use undivided mini car axle whose loading capacity is 1500kgs and final gear ratio is 5.125. 3.3 Steering system includes: 1) Steering operation system: steering wheel, steering shaft, universal joint 2) Redirector: rack and pinion, simple structure, high transfer efficiency, stable controlling. 3) Steering transmission system consists of horizontal puller and longitudinal puller, central lever. It is easy to maintain as it uses ball-joint. 3.4 Brake system includes: 1) Brake system includes two sets of system: running brake system and park brake system. 2) Running brake system uses double hydraulic brake lines, i.e. two independent brake line, which enhances the reliability and security because if one line is broken, the other line is still working. 3) Brake line consists of oil tank, master Cylinder, Vitta, Wheel Cylinder, arrester, brake drum. 3.5 Body, dashboard and accessories The material of the body Eagle used is fibre glass which is light, strong and anti-rust. As the body is light, the drive range is enhanced. Accessories consist of windshield wiper, light assembly, electric horn, reversing alarm, radio, sunshade, etc. Eagle vehicles can be used in various conditions, such as night, raining day, foggy day, etc. 4
Use, Maintenance and Repair
4.1 Use and Maintain
Electric car has no pollution and less noise. Before drive electric car, read and master the operation manual. Details please read 《Suzhou Eagle Electric Vehicle Operation Manual》. Especially, please pay attention to follow item: (1) Often check the acid level and density, make sure car is used in normal condition. (2) Try to avoid operating vehicle at full throttle long time. After the vehicle is started and accelerated, stabilize the accelerator pedal. (3) When decelerating, loosen the accelerator pedal, step on the brake pedal lightly. Try to avoid stopping suddenly and starting suddenly. (4) Charge the battery as soon as possible once the battery capacity is not enough—before less than 20%. Do not use the vehicle when the battery is overcharged. Page 6, Total: 11
(5) Customers should use the car in accordance with the Manual strictly. Especially, change lubricating oil, brake fluid and battery acid timely in accordance with the stipulation on the Manual. (6) No after service will be provided to shattery parts, such as glass, gasket, bulb, plastic parts, lubricating oil, electrolyte, brake fluid, shoes, windshield wiper cushion, brake drum, clutch cushion. But if those shattery parts have quality problem, they will be guaranteed.
Eagle Electric Vehicle Maintenance Item And Period Items
Maintain Content
Check per day
1、Check the liquid level, if less, add distilled water
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2、Charge to full state (Every day)
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3、Open the battery cover when charge
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Battery Maintenance
4、Tighten the battery terminals 5、Measure overdischarge (Drive the car when the voltage meter indicate yellow area)
Check per season
6 、 Measure the electrolyte’s specific gravity, normally, it should be 1.28±0.005g/cm3 7 、 Check if battery is charge full, method: a: measure density; b check voltage meter; check bleb in the battery.
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9、Check the charger when it is working, check the heating of the jock.
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11、Fix joints( note: power supply should be off)
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12、Clean up outer dust.
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13、Contactor( check the contact point ) 14、Check if water enter into, heat.
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15、Motor Carbon(Abrasion)
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16 、 Check if accelerating pedal is agility and returnable. 17、Check free travel of clutch pedal Chassis And Body
Check per half year
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10 、Clean up the dust on the cover, avoid water entering into. Controller And Motor
Check per month
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8、Clean the battery surface Charger
Check per week
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18 、 Check the abrasion of the brake drum and friction slice。
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19、Brake cable and pipe(oil leakage, shatter)
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20、Brake fluid(fluid level, oil leakage)
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21 、 Check the abrasion and air pressure of the tires, fix the nuts of the tires.
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22、Shock absorber(oil leakage, spring, abnormal sound)
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23、Tighten the bolt of transmission shaft.
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24、Change oil in transmission case and rear axle gear (run-in time).
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25 、 Inject lube into redirector and wheel hub bearing.
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26 、 Check Front suspension and rear suspension(degree of tightness, abnormal sound, cracking)
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Out of run-in time
27、Clean up the surface of the body and chair.
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28、Take trial on road.。
Each time, drive on road after maintain, and check the maintained parts.
2. Diagnose and Eliminate Malfunction There is no settled mode to diagnose and eliminate the malfunction of electric vehicles. During maintaining and checking, we suggest you first listen, then look and feel. Below is the diagnoses and maintenance of some familiar malfunctions.
1) The vehicle doesn’t move, which means when the power is on, step on the accelerator pedal, the vehicle doesn’t move. Below are the reasons and troubleshooting of such malfunction when the controller is Curtis Controller. Malfunction Key switch is on, voltmeter has no signal
Possible reason 1.Circuit Joints loosen or open 2.Fuse of controller and main circuit open 3.Connecting wire of battery loosen or disconnect
Tighten or connect Change fuse Tighten or change
4.Key switch is broken
Change
5.Voltmeter is broken
Change
6.Battery terminals connect improperly Key switch is on, Voltage meter has signal.
Troubleshooting
1.Switch or Plug of pedal open
Adjust Repair and connect
2.Turn Switch is broken
Change or repair
3.Improper operating procedure
Operate properly
4.Controller is broken
Check or Change
5.Solenoid is broken
Check, repair, change
6.Accelerator pedal is broken
Repair or Change
7.Motor is broken
Repair or change
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8.Parking brake doesn’t loosen
Loosen parking brake
9.Over-heat protection
Check, eliminate
2) Lose control when vehicle is runningďźšspeed cannot be adjusted Malfunction
Possible reason
Vehicle runs at full speed when it just starts
1.Terminals together
of
Normal at low speed Little power at full step on accelerator pedal
stick
Check, repair
2.Controller is broken 3.Potentiometer Pedal is broken
Stop once start
Solenoid
Troubleshooting
of
Change Accelerator
Repair, change
1. Motor is short-cut internal
Repair, change
2.Motor assembling is too tight or blocked
Repair, change
3.Controller is broken
Repair, change
4.Accelerator Pedal is broken
Repair, change
1. Controller is broken
Check, change
2. Motor is broken
Check, change
3. Accelerator Pedal is broken
Check, change
3) Vehicle cannot change direction: vehicle can only run in the one direction Malfunction Only run directing
in
one
Possible reason
Troubleshooting
1.Contact point of front contactor is damaged/burnt
Check, repair, change
2.Contact point of back contactor is damaged/burnt 3.Circuitry disconnect or heading contactor coil open 4.Controller is broken
Check, repair, change Check, change Check, change
4) Possible reason and troubleshooting of the malfunction of electric vehicle mechanic system System Transmissio n System
Malfunction Abnormal sound When Run
Possible reason
Troubleshooting
1.Clearance of rear axle decelerating gear is too big, or the decelerating gear is broken
Adjust, change
2.Transmission cross shaft wear out
Change
3.Gear of transmission wear out or break
Change
4. Flange bearing is broken
Change
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5.Bearing of Motor is broken 6.Gear liquid is deficient or empty
Add Gear liquid
Hard to change
1.Clutch cannot separate smoothly
Adjust
the gear shift
2.The lead of gear is broken
Change
3.Gear of transmission case wear out
Change
4.Orientation pin loosen
Change
Gear, and gear shift jumping in different shifts
Steering System
Change
Hard to turn
1.Pressure of front wheel tire is deficient.
Check the pressure and Inflate
2. Screw plug of Redirector is too tight
Adjust
3.Lack of lube in redirector
Maintain，add lube
4. Toe-in abnormal
Adjust
5.Clearance of puller ball is too big
Steer unsteadily （wheels flirt）
Change
6. Steering knuckle and master pin is not lubricating 7.Steering shaft or its plastic cover wear out
Add Lube
1.Rack of redirector wear out
Change Redirector
Change
2.Screw plug of Redirector is too tight
Adjust
3.Toe-in adjust improperly [9QnkE`rektEblI] 4.Shaft of front wheel drum wear out
Adjust Change
5.Horizontal puller ball and joint wear out 6.Redirector loosen
Change puller Fix
System
Malfunction
Possible reason
Eliminate Method
Driving System
Deflected Running
1.The pressure of the two front wheels is different
Inflate
2.Toe-in is too big or too small
Adjust
3. Tightness of the left and right drum bearing of front wheels is different
Adjust
4.Single wheel’s brake drags 5.Screw Spring abnormal
shock
absorber
6.Parts of front suspension loosen
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Adjust or Change is
Change Change
Abnormal Tire Fray
1.Tire pressure is abnormal or left and right tire doesn’t exchange for a long time
Inflate or exchange
2.Toe-in is improper
Adjust
3.Drum shaft loosen
Change
4. U type Bolt of Leaf Spring loosen
Tighten
5. hubcap distort, body bracket distort
Tighten
6.Brake force of each wheel is different
Adjust
7. Overexert accelerate or brake
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Alter operation