AEV 411 User manual

AEV Technologies AEV 411 Light Truck Service Manual

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AEV 411"

100% Electric Light Truck"

Service Manual

AEV Technologies AEV 411 Light Truck Service Manual

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AEV Technologies - AEV 411 Light Truck

Service Manual Introduction:

AEV Technologies produces 100% Electric Vehicles for use in Campus

Management, Facilities Service, Fast Casual Dining Delivery and the Urban

Commute. Our vehicles reﬂect our company’s commitment to advancing

sustainable light electric solutions and the passion of our leadership to deliver

clean energy transportation and a better environment."

Our service fulﬁllment processes are equally focused on sustainability, quality

and supply chain eﬃciency. "

We publish our AEV 411 Service Manual with quarterly updates to prepare our

users, dealers and service & repair partners with concise instructions to

maintain their vehicles and to manage the service life cycle of AEV equipment."

AEV Technologies AEV 411 Light Truck Service Manual

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AEV 411 Service Manual Index

Section 1: Battery & Charging System Operations"

A. Battery Maintenance"

B. Battery Charging System"

C. Battery Replacement"

Section 2: Tire Sizes and Replacements

3. Blue Tooth Communications

4. AV System Operations

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Section 1 - A: Battery Maintenance:

The AEV 411 uses VRLA (valve regulated)

“gel cell” batteries. A gel cell battery is a

variant of lead acid battery technology.

The battery uses valves to control the

normal venting of hydrogen and oxygen

generated during the recharge process.

The VRLA technology is commonly used in data centers to support uninterruptible

power supplies (UPS), mobility applications including electric service vehicles, off-

road construction equipment with large tilt angles and in the US fleet of nuclear

submarines as an energy storage media."

On a practical level, the AEV 411 batteries are sealed and do not required the

normal addition of water to the battery cell plates. Charge rates are set to limit the

rate of hydrogen gas dissipation. In addition, the AEV 411 battery box has 4 vents

to dissipate any gasses released during use or recharge."

Battery Terminals Maintenance:"

During normal operation, AEV Technologies recommends to

open the battery box annually. Lift the rubber boots on each

battery terminal and inspect the battery terminals to ensure

they are not corroded or loose."

Inspect the battery terminals to ensure they are clean and

not corroded."

"

Terminals may be inspected by lifting the rubber boot.

Corroded terminals can be removed with a 1/2” socket and

cleaned with baking soda. Cleaned and dry terminals can

be re-installed with a 1/2” socket wrench."

Caution: Do not set wrenches on the tops of the batteries where they may

short between terminals or between a positive terminal and the vehicle

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Section 1 - B: Battery Charging System

Remove the Driver’s Side Fender

The AEV 411 battery charge information

system is located on the Drivers side of the

vehicle under the rear fender. The rear

fender is secured

by 8 x #2 Phillips

head screws. "

The first 6 screws

are clearly visible

on the driver’s side

of the truck (left

side) and shown in

the picture to the

left. There a 2 more

screws on the

bottom edge of the

fender: one just

ahead of the rear

tire and the second

just behind the rear

tire. These are

shown in two pictures to the left."

With the 8 screws removed, the left rear fender may be pulled away. The fender is

ABS with a surface gel coat. Once removed we suggest to place the fender face

up on a flat surface such as the pick-up truck bed to avoid scratches. Caution:

Remove the bottom screws before the side screws to control the release of

the rear fenders / side covers. Caution: Do not short multimeter probes

together when checking battery pack voltage.

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Section 1 - B: Battery Charging System

Charge Information System

The charge information systems is just behind the fender with a picture as shown

below. The connector on the left side of the charge information system, circled in

red, reports the potential energy difference, voltage, between the positive and

negative terminals of the battery pack. An AEV 411 service technician can

reconfirm the charge level with a digital multimeter. "

1. Set the multimeter to DC voltage on the device dial. "

2. Zero the meter according to the instructions "

3. Insert the red / positive volt meter probe into the red / positive side of the

connector"

4. Insert the black / negative volt

meter probe into the black / negative

side of the connector."

The AEV 411 uses 6 VRLA gel cell

batteries, connected in series, to

create a nominal charge voltage of

72V. A new, fully charged, VRLA

battery may report up to14.4V per

battery. Accordingly the AEV 411’s

six batteries in series may report

pack voltage as high as 86.4V.

Normally, we expect in service, fully

charged, systems to report potential energy differences

of 76.2V to 82.8V."

If the battery charge level becomes too low, the AEV

411 may not directly charge the batteries. A minimum

battery voltage of 9.8V per battery and 58.8V per

pack is required to initiate charge. Below these levels,

the charge logic will act to protect the user and the

vehicle to avoid charging a defective battery or battery

pack or those with the risk of an internal short."

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Section 1 - B: Battery Charging System

Charge Information System (continued)

The AEV 411 Charge Information system communicates with the motor controller

to define a ready operations status. The

charge level is shown on the 4’ display on the

upper dashboard as shown below. The

attached pictures communicates the following

information to the AEV 411 driver:"

1. Charge Status: The Red Car with an

electrical plug at the bottom of the display

shows that the vehicle is plugged in and

charging. "

2. Gear Selector: The “N” immediately to the

right of the 0 MPH indicator shows that the vehicle is in Neutral. "

3. Battery Icon: The green battery icon shows the vehicle battery systems

discharge rate is currently able to meet the energy demands of the system. "

4. Ready: The READY indicator is communicated from the motor controller to

show the battery charge levels are between the High and Low thresholds and

the motor controller will support normal operation."

5. Red Exclamation Point: This signal shows that the parking brake, located

between the seats, is engaged"

If the battery charge level is too low, the motor control level with not provide a

“READY” icon to the Charge Information Systems display. An example is shown

below. In this case, we have simulated the charge protection logic used to disable

battery discharge from a battery pack that is (1) below the minimum charge

threshold or (2) showing unbalance charge levels

across the battery pack. Please contact the AEV

Service Center for help with diagnostics and

specialized firmware to update battery

management from a fully discharged battery

pack. AEV Service can be reached at (512)

994-4917

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Section 1 - C: Battery Replacement

Flat Bed, Pick-Up Bed and Van Box Removal Process

The AEV 411 batteries are housed in a steel battery box mounted between the frame

rails, ahead of the motor and transaxle, and immediately below the truck bed."

To access the batteries and battery box we have

3 steps to complete in sequence: Step 1 -

Remove the Fenders by removing 8 screws on

each fender. This step is outlined in Section 1-

B. Step 2 is to remove the truck bed to allow

access to the battery box. The AEV 411 Beds,

whether Flat Bed, Pick-Up or Van Box, are

secured by 6 carriage bolts. The bolts have a

rounded head and square collar extending

through the floor of the truck. Each bolt attaches

to a steel mounting plate on the top of the truck’s ladder frame. The bolts can be

removed with a 18mm socket wrench. Once removed, the beds can be lifted off."

The flat and the pick-up beds are

aluminum. The Flat Bed weighs

approximately 80 lbs. The Pick-Up

Bed weighs approximately 100 lbs.

Generally 2 people are sufficient to

lift off these light weight beds. The

Van Box is heavier at about 260 lbs

depending on the accessories. We

recommend to raise the van box up

on each of the four corners and to

lift it off with a fork lift. If no fork lift is available, removing the van box is a four person

operation.

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Section 1 - C: Battery Replacement

Battery Disconnect Process

The batteries are held in a steel battery box located

between the frame rails and covered by box lid and a

cross brace with 3 x 13mm

bolts. The lid of the battery

box is secured by 8 x #2

Phillips head screws. "

Caution: Make sure the

vehicle is turned off, the

charge cable is disconnected, and the wheels are chocked

before removing the cross brace and the battery box lid.

The box contains 6 batteries in series to create 72V and 120

Ah of current. Do not rest tools, fasteners, the box lid or

the battery box brace across the battery box once as the

removal tasks are completed.

The battery box cross brace is

held by 3 x 13mm bolts: 1 on

the exposed end of the brace

and 2 just under the cab. The

battery box lid screws can be

removed with a screw driver

or a screw tip in an electric

torque driver. Once the box

lid has been removed, the

battery connection cables are

visible. The AEV 411 batteries

are connected as 6 batteries in series. The battery

terminals are daisy chained together, positive to negative, in the same way that

batteries are stacked into a flash light. The left rear battery has 1 positive cable

Front of Vehicle

Rear of Vehicle

Front of Vehicle

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Section 1 - C: Battery Replacement

Battery Disconnect Process (continued):

The left rear battery has 1 red termination on the positive cable connected to the

power out connection on the passenger side of the battery box. The left front battery

has 1 black termination on the negative cable connected to

the power out connection on the passenger side. 1st

Disconnect: Disconnect the black negative cable circled

below at the front of the battery box. 2nd Disconnect:

Remove the red positive cable shown in the picture below

at the rear of the battery box. Once these two cables are

removed the battery box is no longer connected to the

vehicle operating systems. However, each battery may still

by fully charged. Caution: Please remove each of the

remaining battery cables and place them outside of the

battery box and outside of the vehicle work area.

Once the battery serial cables are removed, the battery

cross braces may also be

removed. The cross braces

are used inside the battery

box to hold the batteries in

place during normal vehicle

operations. These are

secured with 15mm nuts on

the brace posts. "

With the battery braces

removed, the 120 Ah batteries may be lifted out of the

battery box. Each battery is heavy: approximately 35

Kg / 77 lbs. Our suggestion is to use a lift strap and a

fork lift to raise the batteries in groups of 3 from the

Rear of Vehicle

Front of Vehicle

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AEV 411 User manual

AEV 411 User manual

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