Mercedes Benz GL (W488AC) Customer Service Guide

Transcription

1 Mercedes Benz GL (W488AC) Customer Service Guide MMXIII Copyright Aria Child Inc.

2 Contents I) Check Battery... 3 II) Check Wiring Condition... 5 III) Check Foot Pedal IV) Gearbox Replacement.. 14 V) Door Replacement VI) Motor Control Board Replacement VII) Headlight Replacement VIII) Schematic diagram IX) Exploded View CAUTION : Disconnect the battery before proceeding. 2

3 I) Check Battery Operation: Using a Flat head screwdriver, unlock and remove the seat. Locate the battery harness, unplug the connector, and use a volt-meter to check battery condition at battery side. Step (1) Turn and unlock this plastic knob according to the icon Step (2) Unplug the battery connector (red) by holding down the small clip and pulling apart. 3

4 I) Check Battery Step (3) Voltage Reading: 6.0 V ~ 6.5 V Good condition 5.6 V ~ 5.9 V Proceed to Recharge 5.5 V Battery to be recharged if after the stipulated recharging time, voltage has not increased, the Battery needs replacement Below 5.5 V Battery needs replacement 4

5 II) Check Wiring Connection Operation: There are four positions of connections to check. A. Motor/Gearbox : Remove seat per instructions above (Point I), locate the Gearbox harness underneath Check the gearbox connector (white). Disconnect by pressing small clip and pulling apart, then push firmly back together. 5

6 II) Check Wiring Connection B. Motor Control Board : Remove seat as per instructions above (Point I), locate and access the Motor Control Board just next to the rechargeable battery. There is a WHITE plug (4-pin) on the motor control board, ensure that all four wires are properly connected. 6

7 II) Check Wiring Connection C. Dashboard : Remove the Steering Wheel and Dashboard to check the connection. Step (1) Unscrew then pull up & out to remove steering wheel Step (2) Next, unscrew these two screws to remove the dashboard 7

8 II) Check Wiring Connection Step (3) Pull up & out to remove the dashboard and windshield together as one unit. Step (4) Check the 4-Pin plug 8

9 II) Check Wiring Connection D. Shifter : Follow steps above to remove the Dashboard, then check the connection of Shifter and Main Power Switch as well. Step (1) Unplug this connector Step (2) Unscrew these four screws to remove the Windshield 9

10 II) Check Wiring Connection Step (3) Unscrew these four screws Step (4) Lift up the bottom plate to access the switch for Shifter & Power 10

11 II) Check Wiring Connection Shifter Step (5) Top Bottom Blue Pink Yellow Main Power Switch Step (6) Red wire Orange wire Empty blade (the one far away from shifter) Reverse above procedures to re-assemble the vehicle 11

12 III) Check Foot Pedal Operation: Follow below procedures to check the Foot Pedal connection. Step (1) Turn over the vehicle and push on the smaller lip to loosen the pedal Empty (front) Step (2) Pink (middle) Pink (rear) 12

13 III) Check Foot Pedal Press it down in place 2 Step (3) 1 Slide the Foot Pedal into Chassis from right side 13

14 IV) Gearbox Replacement Operation: Follow below steps to inspect the gearbox or remove for replacement. Use a flat head screwdriver to remove the hub cap (Rear right/ passenger side wheel only) Step (1) Step (2) Use the flat head screwdriver to remove the snap-pin from axle as shown 14

15 IV) Gearbox Replacement Step (3) Slide the rear wheel off of axle Follow above (Point IIB) to access the Motor harness underneath the seat, then unplug it before removing the gearbox Step (4) 15

16 IV) Gearbox Replacement Step (5) Slide the gearbox out from axle Step (6) Replace easily by sliding the new gearbox onto the axle. Fit the gray cylinder through the hold and plug in the white connectors. Reverse above procedures to re-assemble the vehicle 16

17 V) Door Replacement Operation: Follow above (Point IIC) to remove the Dashboard first and replace the Car Door by below steps. Step (1) Unscrew these two screws on hinge and release the whole door Step (2) Lift up the car door to remove 17

18 V) Door Replacement Easy steps to replace the whole Car Door Assembly completely Step (3) Reverse above procedures to re-assemble the vehicle 18

19 VI) Motor Control Board Replacement Operation: Follow above (Point I) to remove the seat first and replace the Motor Control Board (MCB) by below steps. Step (1) Unscrew these two washerscrews on MCB Step (2) Unplug these three connectors 19

20 VI) Motor Control Board Replacement Step (3) No connection needed at that 2-Pin connector Easy to replace the whole MCB by simple steps Reverse above procedures to re-assemble the vehicle 20

21 VII) Headlight Replacement Operation: Follow below steps to remove and replace the Headlight. Step (1) Turn over the vehicle to access and unscrew the headlight washerscrew Use a flat head screwdriver to release the two latch locks Step (2) Then replace the Headlight Assembly with new one Reverse above procedures to re-assemble the vehicle 21

22 VIII) Wiring Schematic 22

23 IX) Expanded View 23