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CU800
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SPECIFICATIO
NS
CU800 Service Manua
l
57
Tire
Type
Size
Front
Rear
Pressure of
front whe
el
Pressure of
rear whee
l
Tubeless
26
×
9-14 6PR
26
×1
1-1
4
6PR
15psi (103kPa)
18psi (124kPa)
Brake
Front brake
Type
Operation
Rear brake
Type
Operation
Hydraulic d
isc brake
Foot operatio
n
Hydraulic d
isc brake
Foot operatio
n
Suspensi
on
Front suspen
sion
Rear susp
ension
Shock abs
orber
Front shock
absorber
Rear shock a
bsorber
Wheel travel
Front whee
l travel
Rear wheel t
ravel
Independent
, Dual
A-arm type
Independent
, Dual A-ar
m type
Coil spring/airb
ag dampi
ng
Coil spring/airb
ag dampi
ng
160
mm
(6.30
in)
(min)
/253
mm
(9.96
in)
(max)
180
mm
(7.09
in)
(min)
/235
mm
(9.25
in)
(max)
Headlight
type
Bulb watt
age
×
quantity
Headlight
Front Positi
on Lamp
Front direct
ion indicat
or
Rear direct
ion indicator
Rear posit
ion lamp
Brake La
mp
Neutral
Reverse
Coolant t
emperature
Parking br
ake
Four-wheel dr
ive
Differentia
l gear lock
HS1
12V
,
35W/35
W
×
2 or 55
W/
55
W×
2
12V
,
0.5W
(
L
ED
)
12V
,
0.7 W
(
LED
)
12V
,
0.75W
(
LED
)
12V
,
0.5W
(
L
ED
)
12V
,
1W
(
L
ED
)
LED
LCD screen
LCD screen
,
Code disp
lay
LED
LCD screen
LCD screen
64
66
Table of Contents
Main Page
Default Chapter
3
Table of Contents
3
Chapter 1 General Information
9
Cautions and Notes
9
Description
10
Identification Code
11
Safety
12
Operator Safety
12
Battery Safety
15
Cleaning Parts
16
Warning Labels
16
Serial Numbers
16
Fasteners
16
Torque Specifications
17
Self-Locking Fasteners
17
Washers
17
Cotter Pins
17
Snap Rings and E-Clips
18
Shop Sipplies
19
Lubricants and Fluids
19
Greases
19
Brake Fluid
19
Cleaners, Degreasers and Solvents
19
Gasket Sealant
20
Gasket Remover
20
Thread Locking Compound
20
Basic Tools
20
Screwdrivers
21
Wrenches
21
Adjustable Wrenches
22
Socket Wrenches, Ratchets and Handles
22
Impact Drivers
23
Allen Wrenches
24
Torque Wrenches
24
Torque Adapters
24
Pliers
26
Snap Ring Pliers
26
Hammers
27
Precision Measuring Tools
27
Dial Indicator
27
Insulation Tester
27
Multimeter
28
Ohmmeter (Analog) Calibration
28
Clip-On Ammeter
29
Electrical System Fundamentals
30
Voltage
30
Resistance
30
Amperage
30
Basic Service Methods
31
Removing Frozen Fasteners
32
Removing Broken Fasteners
32
Repairing Damaged Threads
33
Stud Removal/Installation
33
Removing Hoses
34
Bearings
34
Removal
34
Installation
35
Interference Fit
36
Seal Replacement
37
Basic Driving and Operating Methods
38
Proper Driving Methods
38
Operation before Leaving the EV
40
Motor Braking Function
41
Daily Safe Checking
42
Daily Safe Checking Items
42
Performance Checking Items
43
Maintence and Adjustment of the Ev
44
Periodic Service Schedule
45
Periodic Lubrication Schedules
46
Diagram of Regular Lubricant Points
46
The Storage and Cleaning
46
Cleaning
46
Storage
47
Important Electrical Components
48
Motor and Controller
48
Battery
48
Battery Charger
48
Charging Batteries
49
Charging Quantity Indicator
50
Charging Heating Strategy
51
Discharge Heating Strategy
51
Plug and Receptacle
51
Storage
52
Storage Area Selection
52
Preparing the EV for Storage
52
Returning the EV to Service
52
Troubleshooting
53
Electrical Testing
54
Preliminary Checks and Precautions
54
Intermittent Problems
54
Electrical Component Replacement
55
Test Equipment
55
Ammeter
56
Self-Powered Test Light
56
Ohmmeter
56
Insulation Tester
57
Jumper Wire
57
Test Procedures
58
Voltage Drop Test
58
Continuity Test
59
Testing for a Short with Self-Powered Test Light or Ohmmeter
59
Testing for a Short with Test Light or Voltmeter
60
Brake System
60
Soft or Spongy Brake Lever or Pedal
60
Brake Drag
61
Hard Brake Lever or Pedal Operation
61
Brake Grabs
62
Brake Squeal or Chatter
62
Leaking Brake Caliper
62
Leaking Master Cylinder
62
Chapter 2 Specifications
63
Conversion Table
63
Definition of Unit
63
Vehicle Specifications
64
Chassis Specifications
66
System Electrical Specifications
67
Lubrication Points and Lubricant Types
70
Chapter 3 Maintence and Adjustment of the Ev
71
Maintenance Schedule
71
Chassis
72
Adjusting the Brake Pedal
72
Adjusting the Parking Brake
73
Checking the Brake Fluid Level
73
Checking the Front or Rear Brake Pads
74
Checking the Brake Hoses and Brake Pipes
74
Bleeding the Hydraulic Brake System
75
Checking the Final Gear Oil Level
76
Changing the Final Gear Oil
76
Checking the Differential Gear Oil
77
Changing the Differential Gear Oil
78
Checking the Constant Velocity Joint Dust Boots
79
Checking the Steering System
79
Adjusting the Toe-In
80
Adjusting the Front and Rear Shock Absorbers
81
Checking the Tires
83
Checking the Wheels
85
Checking and Lubricating the Cables
85
Electrical
86
Checking and Charging the Battery
86
Checking the Fuses
91
Adjusting the Headlight Beam
93
Changing the Headlight Bulb
93
Changing the Tail/Brake Light Bulb
94
Chapter 4 Motor and Driving System
95
Inspection and Repairing of Motor
95
Motor Mechanical Structure
97
Motor and Controller Wiring Diagram
98
Motor Drive System Controller Error Code
103
Li-Ion Battery Pack Error Codes
108
Charger Error Codes
110
Chapter 5 Malfunction Inspection
111
Panel and Cargo Bed
114
Direction System
133
Brake System
143
Wheel and Tire Parts
155
Transmission System
160
Suspension
182
Electrical Part
192
Bumper
196
Seat
198
Chapter 6 Battery and Charger
201
Batteries
201
Battery Handling Precautions
201
Number of Battery Cycles
201
Ambient Temperature Implications on Battery
202
Charger Operation
202
Battery Operation Range
203
Maintenance
203
Chapter 7 Electrical System Malfunction Inspection
209
Electrical Components
209
Charging System
213
Lighting System
214
Signaling System
217
2Wd/4Wd Selecting System
223
Chapter 8 Troubleshooting
226
Body Parts and Protection Parts
226
Braking System
226
Electrical System
227
Running System
228
Electromotor Drive System
229
Faulty Brake
230
Shock Absorber Malfunction
230
Unstable Handling
230
Lighting System
231
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