SERVICE MAI{UAL

L997SOLECTRIA FORCE

First Edition

NominalSystemVoitage: 156V
Batteries:LeadAcid
Charger:8C3300(3.3kW240VAC)

SOLECTRIA CORPORATION
33Industrial Way
Wilmington, MA 01887
USA
tel 508-658-2231
fax 508{58-3224
http ://wmv.solectria.co
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dra{Ber r€qufuingurly a stardardhousehold outletA Tri-Power and RegenerativeBraking,Tri-Power Selector,Seald Maintenance-Free
Selectorfacilitatesefficientdriving anduraximizes battery Batteries,Dual Airbags,Power-AssistBrakes,ElectricHeater/Defroster,
lifu,while anoptionalbatterythermalmanagement 12VDC-DCConverte&BatteryLevel Gauge(Digital Amp-.HourMebr),
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AnalogAnmeter o/ AnalogVolhneter
RearWindow Defogger

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508{5&2231/ Fax508{5&3224/ www.solechia.com OnboardBatteryChargerUpgradeto 3kW/220VAC,3.FHourFullRecharge
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 Cabin PreheatInstructions
1997SolectriaForce
Your SolecfriaForceis equippedwith a CabinPreheatsystem.This systemallowsyou to programthe vehicle's
heatto turn on automaticallybeforeyou useyour car eachmorning or eveningduring cold weather. The Cabin
Preheatsystemr$espower from the wall outlet- not the batteries- to heatyour car, so the car will be warm and
fully chargedwhen you start driving. Pleasenote the following: .

o The carmustbeplugged in to energizethe Preheatdisplayand for the PreheatSystemto operate.

o SetPreheattimer to 30 minutesmaximumoperationfor eachPreheatcycle.
o If you haveanyquestions,pleasecall SolectriaCustomerServiceat 508-658-2231.

Settingthe Clock Edittng and CheckingPreheatTimes

l. Pressandhold TIME ADJ for I secondor l. Setmodeswitchto Pl.
longer. 2. PresstheWRITE key to view the fust stepof
2. Pressthe SHIFTkey repeatedlyto movecursor your program(time to turn on is one step,time
to today'sday. to turn offis a secondstep).
3. Pressthe SETkey. The bar G) markwill turn 3. This time canbe changedusing the h andm
on. keys, andthe day canbe changedusing the
4. If thebar (-) marksfor all thedaysareblinking, SHIFT andSETkeys.
pressthe SETkey again. 4. PressWRITE to moveto eachsubsequent
5. PresstheH key to adjustthehour (notethat programmingstep.
0:00is usedinsteadof 12:00). 5. Setmodeswitchto RUN to returnto thetime
6. Pressthe m key to adjusttheminutes. ofday.
7. Pressthe WRITE key to finalizethenewtime.

Settingthe PreheatTimer Clearing all settingsand starting over

l. Turn the Modeswitchto Pl. l. Setmodeswitchto Pl.
2. Theup (on) arrowon the left sideofthe screen 2. Openthepaneldoor at thebottomof the
will be blinking. displayunit.
Selecttheday for the Preheatto turn on using 3. Presstherecessed CLR buttonwith the tip of a
theSHIFTkey. pencil.
4 . Pressset to turn on the bar O mark underthat 4. Setthemodeswitchbackto RUN.
day.
5 . The SHIFTandSET keyscanbe usedagainto
selectmoredaysif the turn on andofftimes Running the Preheatsystem
will be thesameon thoseotherdays(e.g.,to l. Plugin thevehicle.
tttrnon thePreheatfrom 8:00AM until 8:30 2. Setthe recirculate/freshair contol to
AM on Monday and TuesdayandFriday). recirculate.
6. Setthe time using the h andm keys. 3. Slidethetemperature selector(redandblue)all
7. Pressthe WRITE key to finalize the new time. the way to hot (red).
8 . The down (off) anow on the right sideof the 4. Settingthe ventselectorto defrostwill clearthe
screenwill be blinking. windshieldwhenthe Preheatcomeson, but the
9. Setthetime for the Preheatto turn offusing the vehiclemay not get as warm.
h andm kcys. 5. Setthetimer to RUN.
1 0 ,PresstheWRITE key. 6, Setbothoutputswitchesto AUTO.
l l . Repeattheprocesswith up to 12 on/offtimes. 7. The greenlight on the top right cornerofthe
t2. Setthemodeswitchto RUN. PreheatdisplaywiU turn on to showthe unit is
readyandwill now turn on at the next
programmedtime.

CopyrightI 997 SolcctriaCorporation

Rcv.3/97
. ""i '... ' .'. /: .,
''-dL.,.: '.

SOtECTRIA

SolectriaCustomerServiceProtocol

You can reach Solectria's CustomerSprviceDeparbnentat Solectria,smain number

(978{s8-223r).

Your assignedcustomer service Account Represenative

is:

JaniceDauphinais(ext 283).

If you have to return a componentfor repair call Solectia's CustomerServiceDept. and

ask for an RMA# (Returnto Manufacflrer AuthorizationNumber). Make surethe
RMA# is on thc packing slip or the box ttrat is beingreturnedto Solectria.

Rehrrnthe unit to:

SolectriaCorporation

Wilmingtoq IvIA 01887

Attn: RIvIA#

SOLECTRIACORPORATION
33 INDUSTRIAL
WAY
WILMINGTON,MA OI887.3433
USA

978-658-2231
(D** FAX978-658-3224
http://www.solectrio,com
 FORWARD
This manualhasbeenpreparedasa supplementto the serviceinformation containedin
the Geo Metro ServiceManual. Information containedin this manualis basedon the
latestproduct information availableat the time of publication. The right is reservedto
make changesat any time without notice.
 Table of Contents

Introduction page
Description/Service Guidelines .......4
AdditionalServiceInformation............... ..........9
Standard SafetyPrecautions ............... ...............9
Drive Motor/Automatic Transmission
Description/location..... ..................10
Checkingoil level ........10
Changing tansmissionoil ......... ......................10
Replacement of motor/transmission ,
................1I
Installationof motor/tansmission ...................12
Motorjunctionblockreplaoement ...................12
Battery Pack
Description/location..... ..................13
RearBatteryBox...,....... .................13
FrontBattery8ox ..........
CheckingBatterycondition(discharge testing)................. I4
Bafferyremoval.... ........16
BatteryBox Fan ..........1g
Electronic Components
(
MotorConfroller. ...........................19
DC-DCConverter ..........................19
Accelerator/Brake Contoller. ........20
Amp How Counter ......21
Battery Charger
Motor SpeedSensor ......................23
A/C Controller ........... ....................25
IgnitionBox.......... .......26
Accessories
CabinPreheating System ...............27
VacuumpurnpandReservoir.............. ............27
Range-Power Selector.... ................27
Appendix A - PartsList, Tools& TestEquipment

Appendix B - Layout and wiring Diagrams,connectorDrawings

Appendix C - TroubleshootingGuide,BatteryDischargeTestForm, Towing

Instnrctions
If additional serviceinformation is neededor to orderreplacementpds, please
call
508-658-2231or f',( 508-65g-3zz4,Monday-Friday9 AM to 5 pM Eastem
Time.
(
 r h I

FoRcE DESCRTPTTON
Ar\D SERVTCEGUTDELTNES
f
This sectioncontainsa descriptionof the 1997Solectia Forceandits major features.For
operatinginformation, refer to the 1997Solectia ForceOwner's Manual.

Pleasereadthe sectionentitledStandard PracticesFor Working On or Near High

Voltage Systemsbeforeservicingany vehicle.

All major componentsare electrically connectedto the battery pack and havehigh
voltage labels. Use due caution when servicing.

For completeservicing description,seespecificproceduresin the text.

Basic Vehicle Layout

The 1997SolectriaForceoperateson a l56V nominalDC system.The exactvoltage
level of the battery in any Forcedependson the battery'sstate-of-charge,andwhether
power is being taken from, or put back into the batteries.The batterymodulesare
divided betweena front and a rearbatterybox, locatedunderthe hood in the motor
compartnent and underthe floor of the trunk.

The Force drive systemusesa 3-phaseAC inductiondrive motor. The motor contoller,
/ locatedon top of the front batterybox underthe hood in the motor compartnent,receives
\. high current high voltage (156V) direct current@C) electicity from the batteryand
delivers variable frequencyalternatingcurrent(AC) to the motor, locatedbehindthe front
battery box.

NOTE: Each of thefottowing three electronic conEonents hashigh voltagecables

which supply them with powen

l. DC-DC Converter
The DC-DC converter(which suppliesl2V DC to powerthevehicleaccessories), power
brake system,and air conditioningcomponentsarealsolocatedunderthe hood. The
electric heateris locatedunderthe dashboard.

2.Battery Charger
The Battery Chargeris locatedon the driver's sideof the tnmk andmay be one of two
models,the standardBCl600 or the optional8C3300.

Battery Charger - BCl600

The vehicle's batterypack is rechargedfrom any 2OA,L20VAC, 60ltzoutlet
(NEMA 5-20R). This outlet shouldbe on a dedicatedGFl-protectedcircuit.

Battery Charger - 8C3300 Ontional

If your car is equippedwith an optionalBC3300charger,it is designedto be
chargedusing a standard20A,240VAC,60Hzoutlet(NEMA 6-20R). This outlet
 should be on a dedicatedGFl-protectedcircuit. In an emergencyor if 240VAC is
not available,a BC3300equippedcar may alsobe chargedwith 120VAC using
the customadaptercord provided.

3. Amp-Hour Meter
The digital Amp-Hour meterdisplay is locatedin the instrumentcluster,while the Amp-
Hour meterbox is found underthe dashnearthe steeringcolumn.

Safety
The Forcecontainsvarioussystemsfor operatorand servicepersonnelsafety:

The car will not drive if it is pluggedin.

The car will not drive if the Range-PowerSelectoris setto Forwardor Reversewhenthe
ignition key is turned on (for safety,Range-PowerSelectormustbe setto OFF position
when ignition key is turnedon).

All high voltage DC componentsexceptthe contoller andthe chargerare fusedat the

main DC fuse box. Chargersarefusedin-line in the trunk.

Battery thermal managementandthe optionalcabinpreheatsystem,which operateon

AC, arefusedat the AC junctionbox in the trunk (No1te:Carsequippedwith a BC1600
(.,' chargerdo not usean AC jwrction box asthey are intemally fusedin the charger.)

Eachbattery box is independentlyfusedto openand disablethe high voltage circuit

duing overcurrentconditions. Thesehigh-amperagefusesarelocatedinside eachof the
batteryboxes.

The batteriesin the Forcearecompletelyisolatedfrom the car chassisto preventthe

possibility of electrical shockor currentleakageto the car. However,there is still a
remotepossibility that a closedcircuit could be fomredby a subsetof batterymodulesas
a result of short circuiting to the car chassisor otherconductorsduring a severeaccident.

Extreme care must be taken when handling any high voltagecablesso as not to
short circuit the battery to the vehiclechassisor otler potentially live wires or
terminals.

Unlesstwo separateand isolatedlocationsof the high voltagesystemat different

electrical potentialsare touchedsimultaneously,thereis no hazardfor shock.
Nevertheless,exposedelectical cablesshouldbe teated with caution,and assumedto
carry high voltageregardless of the gaugeof wire.
 Battery Information
The lead acid batteriesusedin Solecftiavehiclesare sealed,starved-electrolyteleadacid.
The stawed-electolyte batterieswill not spill significantamountsof elecholyte,evenif
the modulesare broken in two. However,any clear fluid leakingfrom a Solectia vehicle
shouldbe treatedas electrolytewith the potentialfor corrosion.

Avoid contact with the skin or inhaling fumes. Wearacid/baseresistantrubbergloves,

rubber boots, and protectiveclothing and stayup-wind. Dilute the spill with large
amountsof water. Sodiumbicarbonate(baking soda)may alsobe usedcautiouslyto
neutralizeany electolyte spills.

Disabling the Vehicle

The Forceis virtually silentwhenturnedon. The absenceof noiseor motor "nmning"
soundsdoesnot indicatethat the vehicle is disabled.

Seruicing the Car - EmergencyProcedures

To secure the car. setthe parkingbrakefirmly by lifting the standardhand-operated

brake lever betweenthe front seats. Turn the Range-PowerSelector,locatedLn the floor
console,to the oFF settingto preventthe vehicle from beingdriven.

Turn the key ofl as you would in a conventionalvehicle,to shutoffthe motor controller,
( therebydisconnectingthe motor, and disablingmost vehicleaccessories.(Note: When
the key is turned offand removed,the steeringwheelwill lock. To unlockttre steering
wheel, the key must be insertedandturnedto the first accessoryposition).

To isolate accessories.'To disconnectatl high voltageelecticity fiom all aruriliary

systems(such as air conditioning,Amp-Hour Meter, heat,andthe l2-volt Dc-Dc
converter),discormectthe small,red one-pinAndersonServiceDisconnectlocated
betweenthe large gray Andersonconnectorto the controllerandthe high voltagefirse
box on the passengerside,front sfirrt tower.

With this connectorunpluggedandthe motor confrollerturnedoffftey off), the electical

power of the car is isolatedto the batteryboxes,the contoller, the charger*a tf,.
connector.

All highvoltage and low voltagepower to the vehicle is thusdisabledand no systemsor

accesSorieson the vehicle will operateexceptthe charger. The charger can be disabled
by disconnectingthe small black one-pin Andersonconnectorunder the fusebox, or
simply unplugging the chargeroutput wires (2-pin red Andersonconnector).

Although turning the key to the offposition will disablethe motor controller, the
controller can also be disconnectedmanually,if necessary,by disconnectingthe large
gtay 2'pin connectorlocatedon the uppertransmissiottrupportbeam.
 WARNING!
Note that eachSolechiacomponentunderthe hood and in the tnurk may storeelecfricity
in capacitorsfor sometime evenafter being disconnectedfrom the battery. Therefore,
exposedconductorsshouldalwaysbe treatedwith caution.

To isolatebatteries: Before removing any battery interconnectwires, the red one-pin

Anderson Senice Disconnectmust be unplugged,the input to the controller must be
unplugged, and the charger outputwires must alsobe unplugged.

Oncetheseoperationsarecompleted,all high voltageand low voltagepower to the

vehicle will be disabled. Note that eachelectronicbox underthe hood and bed may hold
a chargefor sometime in capacitorsevenafter being discorurected from the battery.
Exposedconductorsfrom theseunits shouldbe treatedwith caution.

Following the procedureabovefor disablingthe vehicle shouldmakethe vehicle usafeu

while servicing it. For operatorsafety,batteryboxesshouldbe openedonly by trained
servicepersonnel. Also, electical cablesshouldneverbe cut. Cutting cablespresents
additional safetyproblems,and is not recommended by Solecnia. Failure to follow these
guidelinescould lead to seriousrnjury.

VehicleJires; Sprayvehicle fires with dry chemicalor carbondioxide foam (ABC or BC

extinguishers). In general,batteryboxesshouldnot be opened.However,if thereare
(
indicationsthat a batterymodulc is smolderingor heatingup after an accidentor ftre,
disconnectingthe smolderingbatterypack shouldeliminatethe problem. Follow the
directions in the previous paragreph for isolating the battery pack To disconnect
individual batteries,refer to the specificprocedurein the text. As statedabove,cutting
cablesand openingbatteryboxescreateadditionalhazardsthat arebestavoidedif
possible.
r- ADDITIONAL SERVICE INFORMATION

The 1997Geo Metro ServiceManual GMP/97-M (not includedwith this manualbut

availablethrough a local GEO dealemhip)shouldbe consultedfor serviceinformation on
all partsof the SolectriaForce,exceptfor the following parts:
o Electric Drive System(motor, contoller, tansmission)
o Batteries
o Solectia Electronic Components
o Heating and Air Conditioning system
o Solectria- installed wiring

SERVICE NOTES
l. The diagnosticcorurectorfor the GeoMeto is inoperativeon the SolectriaForce.
2. Replacementrear coil springsmustbe orderedfrom SolectriaCorporation. They are
not interchangeablewith the standardsprings.
3. For safety,alwaysremovethe ignition key from the steeringcolumnbefore
performing servicework on the car. Unplug the vehicle from the wall outlet when
changingout electroniccomponents.Solectriaelectroniccomponentsare not user
seniceable. Any attempt to senice componcntswill void all warranties.
4. Disconnectall Solectriacomponentswhich are connectedto the batteriesif you
attemptany fast chargingof the batteriesor if using a non-Solectia Battery Charger
unlessinstalledby Solectia. FAILIIRE TO DO SO WILL VOID ALL
WARRANTIES.
5. Liftingvehicle If using a li& usefactory recommendedlifting points (i.e. reinforced
sectionsof rocker panel). If usinga floor jack, positionjack undercenterof
reinforced sectionof sub-framejust forward of front batterybox.

WARI\INGI
Do NOT position jack directly under battery box, or aitempt to lift vehiclefrom any
point on the battery boxt

Using a floor jack at the rear,position floor jack undercenterreinforcedsectionof sub-

frame betweenlower control anrur. Positionjack standssafelyundervehicle at reinforced
sectionsof sub-frameand apply parkingbrake,or chock wheels.
6. Towing Solectriarecommendstowing the vehicle with the front wheelson a dolly or
carrying it on a flat bed vehicle. If you musttow with the front wheels(i.e., drive
wheels)on the glound, neverleavethe key in the ON position andthe regendisable
switch in the DRY position. Regenerativebreaking is enabledwith the key ON
and this could causea high towing load and the batteriesto be severely
overcharged. If you musttow in this manner,the regendisableswitch must be setto
the SLIPPERYpositionandthe key tumedOFF. SEE .TOWING
INSTRUCTIONS" IN APPENDIX C.
7. Wsshing: Solectriadoesnot recommendwashingthis vehiclein an automatic
carwash.
 I t t

STANDARD PRACTICES FORWORKING ON

OR NEAR HIGH VOLTAGE SYSTEMS

1. Always usesafetyglasses.Removeall jewelry, suchaswatches,rings,bracelets,and

necklaces.
2. No tools with exposedmetal over2" long areallowedin work area. Heat shrink metal
tools over 2" long.
3. Keep all tools away from or below high voltageareas.Keeptools in a tool caddy,
toolbox, pantspocket or floor, not on vehicle surfaces.
4. Use a fenderprotectorpad wheneverworking on the car.
5. Use only your right handwhenworking with high voltage. Put your left handin you
pocket. Never usejumper clips or touch anythingto live plugs/batteriesexcept
whenusing avoltneter.
6. Use a voltmeter to checkvoltagesandpolarity beforemakingany connectionof
components. (Make surevoltneter is not setto measurecurent, and leadsare
connectedto correctpositive andnegativejacks on meter.)
7. Unplug the red, l-pin AndersonServiceDisconnectbeforeremovinga live device. (If
the vehicle is not fully chargedwhenyou begin working on it, leavea note on the
Amp-Hour counterwith the readingbeforedisconnectingit.) Always unplug
vehicle from wall outlet while servicing.
8. Do not usefusesto connector disconnectaccessories.If you are installing an air
( conditioner controller or firse,for example,follow thesesteps:
.turn ignition key off
.check the Amp-Hour counterand put a post-it noteon the meterwith the reading
.disconnectl 10VAC or 220VAC chargingcord (gascap)or other charger
.discormectthe red l-pin AndersonServiceDisconnect
.veriff that the Amp-Hour counterhasno power (no displayshould be visible)
.install the controller or fuse
.reattachthe red connectorandcheckthat the Amp-Hour meterreads00.00
.plug chargercord into wall outlet
9. When servicing batteries,alwaysisolatethe batterypackfrom other components
beforeremoving any batteryinterconnects.Always work on only one battery
terminal at a time. Never allow anotherpersonto touchany other part of the battery
pack while you areworking on it. OIrIE PERSON OI\LYII
10. Do not use any pieceof test equipmentunlessyou havebeentrained and you fully
understandand acceptits operation. UNDER NO CIRCUMSTAI\CES SHOULD
TESTING RIGS OR USE OF THEM DISOBEY AI\TYOX'TIIE ABOVE
RULES!
 DRIVE MOTOR TRANSMISSION ASSEMBLY

MOTOR AI\D TRANSMISSION

The drive motor is a 3-phaseAC inductionmotor, locatedin the rear of the motor
compartrnentbehindthe batterybox, andcoupledto the fransmission.The motor and
transmissionare removedfrom the vehicleas a unit. Thereareno user serviceableparts
in the motor; howeverthe bearingsshouldbe checkedevery50,000miles. Pleasenotiff
Solectriawhenthis mileageis reached.

The automatictransmissionis a single-speedgearreductiondrive with an integral

differential. The hansmissionoil level shouldbe checkedat everyperiodic maintenance.

Checking TransmissionOil Level

1. Turn ignition key offand setparkingbrake. To checkoil level,look at the sightglass
locatedon the driver's sideof the tansmission forward of the hatf shaft. The oil level
should be visible in the glass. The vehicle must be level to get an accuratereading.
2. If the sight glassis not half full, it is necessary
to addtansmissionoil. To add
transmissionoil, removefiller plug. Filler plug is locatedat the top of the
transmission just belowthevent.
3. Using a clean funneladdoil until fluid level fills half the sightglass. UseDextronIII
ATF oil. Reinstallfiller plug.

(, Changing TransmissionOil
After the first 6,000miles of operationand every 12,000miles thereafter,the
transmissionoil shouldbe replaced.
It is preferableto drive the vehicle fiist to wann the gearbox. Raisethe vehicle following
the lifting instnrctionsunderAdditional service rnformation.
l. Turn ignition key offand setparking brake. The betly panmust be removedin order
to accessthe hansmissiondrain plug. Removethe two 5/16 bolts at the belly pan
bracket. Snip thg two tie-wrapsat eachforward comer. Removethe Phillips screwat
the centerbottom bracketon the front bumper. Slide the belly pan backwardand out
while putling down on the lower bumperlip.
2. Put a drain pan underthe tansmission,then removethe drain plug locatedon the
bottom of the transmission to drainthe oil.
3. Clean drain ptug. SolectriarecommendsusingLOCKTITE PneumaticHydraulic
seal 545. Then,re-installthe drainplug. Torqueto l5ft.Jbs. Do Nor
OVERTIGHTEN.
4. Allow sealerto setapproximately15minutesbeforeaddinghansmissionoil.
5 . To add transmissionoil, removefiller plug. Filler plug is locatedat the top of the
transmissionjust below the vent. Using a cleanfunnel, addapproximatelyI quart of
Dextron III ATF (AutomaticTransmissionFluid).
6. Reinstallfiller plug andcheckfor leaks. Reinstallbelly panwith new tie-wraps.

t0
 Replacementof Motor/TransmissionAssembly
r\ Note: Do NOT lower vehicle without drive axlesinstalled. If you must movethe
vehicle,eachof the front wheel bearingsmay be supportedwith a 9116"bolt and nut and.
two l3lr" washers. .
l. Turn ignition key offand applyparkingbrake.
2. Loosenthe arle nuts at the front wheels. Raisethe front of vehicle and supporton
standsso that the front suspensionhangsfree.
3. Removethe belly pan.
4. Drain the transmissionoil. SeeChangingTransmissionOil.
5. Removethe front wheelsand removeball joint-pinch bolts.
6. Loosensway bar link retainingnuts from lower control anns.
7. Pull lower ball joints from steeringknuckles.
8. Pry drive ardesout of tansmission using a largescrewdriver taking caretg avoid
damagingthe seals.
9. Pull steeringknucklesaway from a:des,andremovethe axlesfrom the vehicle.
10.Pull back the boot from the speedometer cableend whereit entersthe tansmission: it
is abovethe lower supportbeamat the bottom of the firewall. Removethe clip and
pull the cable straight out.
I l. Removethe vent tube from the hole in the framerail underthe mastercylinder.
12. Removethe controller from the vehicle as outlined in the motor controller removal
procedure.
13. Removethe gray motor speedsensorcablefrom the firewall by detachingthe hamess
( clampslocatedalong firewall. Coil the wire harnessand lay it on top of motor to
keepit out of the way- it will be removedwith the motor. A tie-wrap or rubberband
canhelp makethis procedureeasier.
14.Unplug the two l2V wire hamessconnectorsat the firewall from the motor cooling
fan andthe motor temperaturesensor.
15.To'removethe uppersupportbeam,removethe two ll4 -20 boltsholdingthe
remaininghalf of the large gray Andersonconnector.Removethe centerthroughbolt
at the rubber motor mount. Removetwo 3/8 bolts from eachendof the beam.
Removethe beamandthe motor mount as a unit. The motor/tansmissioncan leanon
the front battery box.
16. Removethe two Phillips screwsattachingthe motor cooling fan housingto the motor
and carefully tilt it up and offthe motor. The drivetain will not clearthe fusebox
with the fan on.
17. Re-insertthe through bolt at the uppermotor mount bracketandattacha suitable
lifting device to it. Put slight tensionon it. (Lifting fixtrne may be madeor
purchasedfrom Solectria.)
18.Underneath,removethe two Yz"x3/q" boltsconnectingthe lower supportbeamto flre
tansmission"bat wings." Now carefullylift the drive tain out of the vehicle.

l1
(- Motor/Transmission Installation
\ Installation is the reverseof removal. The spacerson eachlower throughbolt are 3/4
inch thick. Thesespacersmay be a stackof 6 washersor tA" round aluminumspacers.
Be sureto clean,sealandtighten the transmissiondrain plug beforeaddingfluid (l quart :
capacrty). ,

When inserting the speedometer cable,align the tab on the speedometer cableendwith
slot in the speedometerdrive gear. Pushthe speedometer cablein and insertthe securing
clip in the slot of the cableend. Do not secruethe clip over the edgeof the cableend. If
this occursit will bind andbreakthe cable.
' Be sureto cleanand greasedrive shaftsplinesand sealsurfacesbeforeinstalling.
Carefully inspectshaftsfor damageto CV boots,spindlethreads,or intemal springclips
onthe inner joint splinewhich holdsthe drive shaft into the tansmission.

AC Induction Motor Junction Block Replacement

1. Removethe motorjunction box cover and gasket
2. Mark the wires at eachterminal andnote their position. Removethe studnuts,
washers,and wires.
3. Removethe two M-6 screwsholdingthejunction blockto the motorplateandlift out
the block along with the two spacernuts betweenthe block andthe plate.
. 4. Install new block and spacernuts.
/ -
( 5. Install one flat washeron eachstud,then the appropriatetwo motor wires on each
stud, making surethe wire lugs seatproperly ( they shouldbe at a 45oangleto each
other). Install anotherflat washerandthe thin nut andtorqueto 90 in.-lbs. Do NOT
apply A\IY side force to the nut or stud; usea 13 mm deepsocketand supportit with
your hand. All washersandnutsmust be brassfor properelectical conductivity
6. Install the controller wires, a flat washer,and apply a small amountof 242 Locktite@
to the nut only. Install the nut andtorqueit to 120in.-lbs.,againbeing carefulto
' supportit.
7. Install the gasketand cover.

t2
 I F

BATTERY PACK
(
The batterypackconsistsof thirteen(13) l2-volt deep-cyclestarvedelecholyteleadacid
b a t t e ri e s.T h e b a tte ri e sa re locatedintwoboxes.Ther ear efivebatter ies l oc atedi nthe
front battery box, and eight batterieslocatedin the rear batterybox. SeeAppendix B for
front and rear battery box diagrams.

WARNING!
The battery electrolyteis a sulfuric acid paste. Eventhoughthe vehicle
is equippedwith sealedbatteries,you shouldalwayswear safetygoggles
or a face shield and rubbergloveswhen servicinga battery. The
batteriesmay carry acid on the surfaceof the batterywhich will damage
clothing. Solectriarecommendswearinga chemicalapron.
Do not placetools in the batterybox or in a placewherethey may fall
into the battery box. A fire or explosionhazardmay occur if a wrenchor
other metal object is placedinsidea batterybox. Wear safetyglassesor
face shield to protecteyesfrom flaming bits of molten metal. Maintain a
setof insulatedtools for batterywork.
Keep casualobserversand exha helpinghandsaway from the battery
terminals. If not wearing safetyglasses,keepobserversawayfrom the
vehicle.
**Refer to front of manualfor additionalsafetyprecautions.**
t
To Gain Accessto the Rear Battery Box
To gain accessto the batteries,lowerrear seatbackand pull carpetand foam from the
trunk floor. Removey1"-20bolts from the rearbatterybox cover and lift it off.
Make a sketchshowing the arrangementof the insulationpieces,and setthesepieces
aside.

To Gain Accessto the Front Battery Box

If vehicleis equippedwith A/C the hoseconnectionsfor the air conditioning unit
must not be disconnectedfor this procedure. Theremovalprocedueis asfollows:
l. Turn ignition key offand setparking brake. Unplug the air conditioningdrive motor.
2. Removethree W'-20 cap nuts from the air conditioningdrive unit mountingplate.
3. Lay the A/C drive unit assemblyupsidedown on the front bumper. Be sureto usea
pieceof thick foam or heavycarpet,so asnot to damagethe vehicle.
4. Disconnectthe main batteryplug (large gray2-wfueAndersonconnector)from the
motor controller. Disconnectthe 4-pin, 2-wire black Packardconnectorfor re-regen
brakelight activationthat nurs alongthe Andersonconnector.
5. If the vehicle is equippedwith metalmeshover the red, white and blue motor power
cable,removeit by cutting the two tie-wrapsand unzippingthe black zippe:.
6. Disconnectthe motor connector(largered, white andblue 3-wire connector)from the
contoller.
7. Removethe four l/4 - 20 nuts at eachcomerat the motor controller.

l3
 Undo the tie-wraps at the hamessjunction nearthe driver's sidestrut tower and
C disconnectthe 25-pin (ignition box) and 9-pin (motor speedsensor)connectors
locatedbehind the DC-DC converter. The tie-wrapon the strut tower is releasable
andreusable.
9. Removethe controller and set it in a safeplace. It shouldnot be droppedor allowed
to tip over.
10.RemovetheVc"-20bolts (andthe 4 rubberA/C mounts,if so equipped)on the
perimeterof the batterybox cover and lift it off. To remove;bendalong the long
dimension,then "roll" out from underhood by holding coverwhile it is slightly bent.
The battery box cover is fairly flexible.
I l. Make a sketchshowingthe arrangement of the insulationpieces,andsetthesepieces
aside.

Checking Battery Condition

If the rangeperformanceof the car following a full re-chargehasbeendeclining, perform
a Field Discharge Test. The following tools areneeded:
o Voltneter
o Pair of wire cutters
o Small slotted screwdriver
o 7116" socket
o Medium extension
o Ratchet
( o Tie wraps

F'IELD DISCHARGE TEST

l. Completely rechargethe batterypack. Seedefinition of Fully Chargedon next page.
2. Get from the driver the Amp-Hour readingat which the vehiclebeginsto experiencea
declinein performance.This will allow you to plan atreadandnot run out of energy
during the test. Choosea local driving loop nearyour servicefacility for this test.
When new and fully charged,the l56V car shouldbe ableto achieveat least45Ah on
the Amp-Hour Meter. The batteryperformancecanbe expectedto decreasegradually
over fime.
3. If the vehicle is equippedwith an optional ammeter,drive the car keepingthe Range-
Power selectorsetto ECONomythroughoutthis procedue. Using the optional
onboardvoltmeter asa guide,continueto drive the car until the voltagedropsto 135
volts and the maximumcurrentavailableis lessthan 50 Amps,or until the car will
not maintain 30 mph on a level road.
4. Whenthe aboveconditionsaremet, bring the car into the work are4 setthe Range-
Power Selectorto OFF, setthe parking brake,leavethe key ON, and turn on the
vehicle's high beamsandturn on the heatwith the fan on high.
5. Quickly open both the front andrear batteryboxes.
6. Feelthe batteriesin eachbox. They should be at room temperafureor slightly
aboveroom temperature. If thevehiclehasbeenparkedoutsidein cold weatherand
properly charged,yet the batteriesin one or both boxesfeel cold, the vehicle may

l4

-l
f: have low range. The batterythermalmanagementsystemmust be evaluatedat this
t, point. See"Checking ThermalManagement"in SectionII of the Troubleshooting
Guide at the end of this manual.
7. Number eachbattery accordingto the Front Battery andRearBattery diagrams.
8. Checkeachbattery'svoltagewith a reliablevoltmeterwhile keepingthe accessories
on. Recordthesenumberson a chart. (SeeBattery DischargeTest Sheet). You
should stop the test when 4 of the batteriesarebelow 10.5volts. Any batterythat
testslessthan 10.5volts beforereaching45 amphoursshouldbe replaced.

WARNING!

FAILURE TO OBSERVE THE FOLLOWING

INSTRUCTIONS MAY DAMAGE NEW BATTERIES
:
After locating the badbatteryor batteries,mark thesewith a wqrterproof
marker (to identifu the bad onesyou canwrite on the batterythe
mileage,dateandreadingon the Amp-Hotu Meter whenthe voltage
droppedbelow 10.5Volts). DO NOT REMOVE TI{E BATTERIES
AT TIIIS TIME!

Placethe insulatingfoam and coversbackon the batteryboxesto '

maintain a temperaturethat the chargerwitl recognizeasvalid.
Completely rechargethe entirebatterypack first, beforeremovingthe
bad batteries.

Oncethe whole packhasbeencompletelyrecharged,you canremove

the bad batteriesandreplacewith new FULLY CHARGED one(s).

If you are not replacingthe entirepackof batteries,tickle chargethe

new batteriesseparatelyovernight(in parallel,positive to posi{ve,
negativeto negative)usinga powersupplysetat 13.8-14.2V. t3xt{'t'zlff'ev
It is very importantto makesurethe batterypack is futly charged
before removingor installing new chargedbatteries. This ensufesthat
all batteriesareat the samelevel of chargewhenthey areusedand
preventsbatteryimbalance.

PLEASE BE SURE THAT ALL SERVICE PERSOITNEL

RECEIVE THIS NOTICE BEFORE BEGIIYNING WORK ON
BATTERIES!

Definition of "X'ully charged"

The SolectriaForce is equippedwith Sonnenschein lead acid batteriesWhichare
definedasbeingat a full stateof charge(S.O.C.)oncethe BatteryChargerhas

l5

I|
a suppliedthe batterieswith a lOohovercharge.This meansthat whenthe batteries
\ are finished re-charging,the Amp-Hour Meter shouldreada negativevalue
conespondingto l0% of the Amp-Hours obtainedin the dischargetest.
For example,if the dischargetest Amp-Hour Meter readingis about43.00Ah,
following a full recharge,the Amp-Hour Meter shouldreadingshouldbe about
-04.30Ah Calculation:43.00x(0.10) : -4.30

Note: Thesenumbersareapproximate.The actualoverchargepercentagewill

vary, but shouldbe about10%.

Thetime neededto achieveafully chargedconditionis dependent

on the typeof
Battery Charger and the age of the batterypack

Battery Removal
WARNING!

ALWAYS USE ON-BOARD CHARGER TO FULLY RECHARGE

ENTIRE BATTERY PACK BEF'ORE REMOVING AITY BATTERIES!

o Batteriesareconnectedin seriesfor a total packvoltageof l56V DC, a potentially

lethal sourceof electricity.
r To avoid shock,userubberinsulatingglovesandweareyeprotectionwhen handling
( batteryterminals.
o Always work on only oneterminalat atime.
o Never allow anotherpersonto touch a terminal at the sametime as you. This will
createa high voltagecurrentthroughthe body of the vehicleon which you are
leaning.
o Use insulatedhandtools. Thesecanbe madeinexpensivelyusing shrink wrap or
electrical tape.
o The battery pack must be completelyisolatedfrom all othercomponentsBEFORE
disconnectingany onebatteryterminal.

I . Unplug vehicle from wall outlet. DisconnectI IOVAC or 220YAC chargingcord

from gascapplug.
2. Documentthe readingon the Amp-Hour Meter (shouldbe zeroor a negative
number).
3. Unplug the l-pin red AndersonServiceDisconnectbetweenthefusebox andthe
large gray Andersonconnectorto the motor contoller. This will causethe Amp-Hour
Meter to go blank andwill also isolateall the auxiliary electricalcomponentsexcept
the charger.
4. Unplug the black one-pinAndersonconnectorhiddenunderneaththe fuse box. This
will isolate the chargeron the negativesideas it is connecteddirecfly to the battery
pack on the positive sidethroughan in-line fusenearthe rearbatterybox. Or, you
can unplug the chargeroutputwires: 2-pin red AndersonServiceDisconnect.

l6
 5. Unplug the large gray Andersonconnectorto the motor confoller (if the contoller is
" still in the vehicle).
6. For safety sakeon all batteryremovaljobs, disconnectandremovea battery
interconnectcablein rearbatterypack (preferablythe wires betweenbatteries#6 and
#7).
7. For protection in front batterybox, first disconnecttwo shortinterconnectwires
(betweenbatteries#l and#2 andbetweenit4 and #5).
8. If any cableneedsto be disconnectedin orderto removeany battery,it must be
completelyremoved. Do not disconnectoneend of a cableand leavethe otherend
connected,exceptin the caseof:
a. the interconnectcablecomingfrom the rear batterybox to battery#5 in the front.
b. the main cablefrom the firsebox to battery#l in the front.
c. the main positivecableto battery#13 in the rear.
d. the cablefrom the negativeterminal of battery#6 in the rear.
For thesewires, oncethey havebeenremovedfrom the batteryterminal, tapeup the
live endscarefully with electical insulationtape.
9. In the front batterybox, to removebattery#1, battery#2 must be removedandthe
'bad' batterymustbe slid to theposition
of #2to be removed.If battery#5 is bad,
battery#4 shouldbe removedfirst. (Ngte: If the car hasair conditioning,be careful
not to hit the condenserwhile removingbatteries.)SeeAppendix Bforfront battery
box ditgram.
/' 10.Be sureto write down the locationof the insulationpiecesinsidethe batteryboxes
V;ii beforeremoving batteries.Vacuumthe floor of the batterybox, making sureit is free
of all debris beforeinstalling batteries.
I l. Before connectingany tenninalsconfirm the physicalplacementof the positive and
negativeterminalsagreewith the batterylayout diagramandthe polarity of.each
battery is correct. Oncethe defectivebatterieshavebeenreplaced,properlytorqueall
terminalsto approximately10ft-lb. Proper torque is achiwed by using two
wrenchesclosetogetherso as not to twist or apply any load to battery terminals.
Checkthe total pack voltageat the gray Andersonconnectorto the controller.
Minimum voltage is 160-170volts. Checkalsothat the polarity is correct(the
connectoris stamped* and ). Make sureall tools havebeenremovedfrom the
battery compartnent. Securethe batterybox coversandreconnectthe contoller,
charger(black Andersonconnector),and accessories (red AndersonService
Discorurect)in that order. If the amp-hourcounterreads"100.00' insteadof "00.00",
discormectthe red Andersonconnector.Wait 10to 20 secondsandtry again.
12. Plug ttre vehicle in to top offall batteries.Cycle the batteriesgently at leasttwice by
turning on the car's high beamsandits electic heater(fan on high), and leavingthese
' on until approximately30.00amp-hourshaveregisteredonthe Amp-Hour Meter
(opencar windows so heatcanexit). Thenrechargethe vehiclecompletely.

CAUTION: Do NOT allow packto dischargeappreciablymorethan30 amp-houn

during its first few cycling. Discharginethe batteriesmorethan 30 arnp-hourswhenthev
( are new could causeoermanentharmto the pack.

l7
 NOTE
C
o For long life and optimal performance,new batteriesmust be cycled gently at first for
properconditioning. .
o Running the heatto discharge30.00 Amp-Hoursfrom the pack will take
approximately3 hours.
o It is not necessaryto monitor the vehicle continuouslyduring the batterydischarge
procedure,but rememberto checkback after 2 or 2 % hoursto seehow the batteries
aredoing.
r Servicepersonnelshouldcycle the pack twice to assureproperinitial conditioning of
the pack. However,the vehicle operatorcancompletethe batteryconditioning
processwhile driving. Pleaseadvisethe vehicleoperatorasfollows.

INSTRUCTIONS TO VEIIICLE OPERATOR

How to Condition a New Battery Pack

l. Refening to the optional dash-mountedammeteror combinationvoltneter/ammeter
as a guide, drive the car gently, ideally drawingno morethan 150Amps at any onetime
and consuminglessthan 20 Amp-Hourstotal. (f your car doesnot havean ammeteror
voltmeter/ammeter,or to avoid taking your eyesoffthe road,the sameeffect is achieved
by driving the vehicle with the power selectorswitch in *ECON' or "NORMAL" at all
timeswith few exceptions.)
2. Plug the vehicle in to completea full chargingcycle.
3. Repeatthis cycle 10times. Packis now conditionedbut you may notice an additional
improvementin performanceastime goeson.

Solectria recommendsthat new batteriesbefully cycledonce each24 hour period, if

Battery Box Fan Replacement

A battery box fan is locatedonly in the rearbatterybox. Usethe following procedureto
removeand replacethe batterybox fan.
l. Turn ignition key offand setparkingbrake. Unplugvehiclefrom wall outlet.
2. Fold down the car rear seat. Pull up the carpetand foam from the tnrnk floor.
3. Removerear batterybox cover.
4- Removethe foil tapewhich coversthe fan at the centerfront of the batterybox.
5. Removethe four Phillipsmachinescrewswhich hold the fan in place. You can
accessthesebetweenbattery#6 and#I3.
6- Lift the fan out of the hole, snip the small hamesstie, andunplugthe connector.

Battery Box Fan Installation

Installationis the reserveof removal. Be sureto aptie the harnessto the fan body.
Wiring of this fan is describedin the rearbatterybox diagram. SeeAppendix Bfor rear
battery box diagrarn

t8
 ELECTROMC COMPOIIENTS
C
MOTOR CONTROLLER
The motor controller servesasthe interfacebetweenthe batterypack andthe drive motor
in your vehicle. It doesthis by changi'ngthe DC power coming from the batterypack to
AC power to run the motor, and it regulatesthe energyflow to the motor basedon input
receivedvia the acceleratorpedalandpot-box,the motor speedsensor,and the ignition
box.

The motor controller is locatedin the motor compartmenton top of the front batterybox.
Thereare no user serviceablepartsin the motor confroller. The motor controller is air
cooled, so the cooling fans shouldbe kept free of debis. SeeAppendix Bfor diagram.

Removing Motor Controller

1. Turn ignition key offand applyparkingbrake.
2. Disconnectthe high voltageinput to motor controller (largegray Anderson
connector).
3. Disconnectregenerative brakingsignalconnector(4-pin,2-wireblackPackard
connector)
4. Snip the two tie-wrapson metalmeshover motor power connector(red, white and
blue) and unzip mesh. Removethe tie-wrapsat the three-phaseoutput connectorto
motor and disconnectmulti-coloredconnectors.
( 5. Disconnectthe 25-pin (ignition box) and 9-pin (motor speedsensor)connectors
locatedbehind the DC-DC Converter. Thetie-wrap fixed to the sideof the strut
tower is reusable.
6. Removethe l/4 - 20 nuts andwashersthat securecontoller to rubbermountsand lift
it offthe mounts.

Installing Motor Controller

Installation is the reverseof removal. Be sureto replaceanytie-wrapsthat were cut off.
Be sure the ignition key is still off and park brake is set

DC-DC COITVERTER
The DC-DC converterconverts156VDCto I2VDC for the vehicle'sl2V accessories.It
is locatedin the motor compartnenton the drivers sidebehindthe headlightassembly."
Other than the externalfusethereareno userserviceableparts. SeeAppendix Blor
diagram.

DC-DC Converter Removal

l. Tum ignition key offand setparkingbrake.
2. Disconnect 2-pingray Andersonconnector(12 volt).
3. Disconnect3-pin, 2-wire Deutschconnectorfrom the highvoltageDC input.
4- Removethe 3/8'nut holding the endattachedto the top crossmemberand the 6mm
bolt attachingthe bracketto the front hood panel.
5. Removecomponentfrom vehicle.

l9
{
\ DC-DC Converter Installation is the reverseof removal.Be surereplacementunit is
' conectvoltagefor vehicle. Note: To avoid sparkconnecthigh voltage2-pin Molex
beforethe lZY grayAndersonconnector. Be sureheadlightsand other l2V accessories
aretumed Off, andignition key is ffi

ACCELERATOR/BRAKE CONTROLLER (a.ka. " Pot-Box" and * A Rg-1 rrl

Locatedunder the hood on the driver's sidefirewall, the accelerator/brake
contoller is
, actuatedby the acceleratorcableand feedsa signalto the ignition box (urder the
dashboard)via a lO-pin cable.

ABC-I Removal
l. Turn ignition key OFF and setemergencybrake.
2. RemovethreePhillips screwsfrom the driver'ssidelower dashpanel. Pull out on the
upper left comer of the panelonly, then slide it left to clearthe small tab on the right
top corner.
' 3. Pull the white foam absorberstraightout from the kneebolsterplate (therearetwo
pushclips holding it). Undo the four Phillips screwsandremovethe plate. The
ignition box is now visible to the right of the steeringcolumn (the Amp-Horu box is
on the left).
4. Releasettre ignition box from its position (it is attachedwith Velcro) and pull it out
/. just enoughto unplugthe l0-pin cable.
( ' 5. If the cablehasbeenroutedthroughthe firewall on the driver's side,then carefully
easeit throughthe grommet. If it hasbeenroutedthroughthe passengerside of the
firewall, then do not botherto removeit.
t 6. Removethe small circlip, plastic washer,andcableendfrom the ABC arm. Remove
the secondplastic washer. Thereis no needto loosenthe cablehousingfrom the
bracket. Unscrewthe 2 cablebracketscrews,removethe secondaryretum spring,and
setthe bracketand cableassemblyaside. Removethe 4 retainingscrewsfrom the
firewall and removeunit from vehicle.
7. If the cablenrns tbroughthe firewall on the passengerside,then cut it and leavethe
cableinstalled in the vehicle.

ABC-I Installation
l. Apply a small amountof silicone sealerto the firewall aroundthe 4 retairiing screw
holes and attachthe ABC to the fuewall.
2. Install the cablebracket,cable,and secondaryreturnspring.
3. Install one washerthe ABC arm pin, thenthe cableend,anotherwasherand the
circlip. Do NoT CHANGE THE ADruSTMENT oF THE ARM oN TIIE SHAFT.
4. If the cablewas routedttuoughthe driver's sidefirewall, then easeit back throughthe
surmegrornmet. If the cablewent throughthe passengersidefirewall, then locatethe
hole in the firewall on the driver's sidewherethe clutch slavecylinder oncemounted
andpassthe 10-pincablethroughthis hole.
5. Connectcableto the ignition box. Be sureto routeandsecurethe cablein sucha way
that it doesnot interferewith the acceleratoror brakepedalconfiols.

20
AMP-HOUR COUNTER REMOVAL AI\D INSTALLATION
The Amp-Hour Meter measuresand integratesthe currentandtime when dischargingand
chargingthe battery pack. It consistsof two separatecomponentsconnectedby a 20-pin
cable. The Amp-Hour Meter displayis integralwith the instument cluster/speedometer
assembly. The Amp-Horu control box is locatedjust left of the steeringcolumn over the
lower dashpanel. The control box and displaymay be removedfrom the vehicle
individually. The Amp-Hour conhol box and display are not userserviceable.^See
Appendix Bfor diagram.

WAR}IING!

It is best to fully chargethe vehicleprior to disconnectingthe Amp-

Hour Meter.

Make a note of the Amp-Hour counter reading before disconnecting.

Before unplugging the Amp-Hour counter or the harness,disconnect

the red one-pin Anderson ServiceDisconnectwhich is locatedunder
the hood betweenthe fuse box and the large gray Anderson connector
to the controller. This will cruse the Amp-Hour counter to go blank
It will also protect it from a power surgewhen pluggrngit back in. Atl
electrical componentsare now disconnectedand will not operate
exceptfor the Battery Chareer. (ll0 or220VAC charging cord
should be disconnectedfrom the vehicle.)

Upon reconnectingthe l-pin red Anderson SeruiceDisconnect,the

Amp-Hour Meterwill resetto zero (3300.00').Pleasenote that this
doesnot indicate the actual state-of-charge.When chargingvehicle,
the Amp-Hour Meter may read negetivenumbers in excessof actual
overcharge. The Amp-Hour Meterwill resetitself as soonas it senses
a current draw after charging.

If the Amp-Hour counter reads100.00or 99.99after re-connectingthe

1-pin red Anderson Senice Disconnect,disconnectand wait at least
10 secondsbefore reconnecting.

Amp-Ilour Meter display removal

l. Turn the ignition key offand unplugthe vehicle from the wall.
2. Disconnectthe red one-pinAndersonServiceDisconnectunderthe hood. See
"WARI{fNG!' immediatelyabove.
3. RemovethreePhillips screwsfrom the driver'ssidelower dashpanel. Pull out on the
upper left corner of the panelonly, then slide it left to clearthe small tab on the right.

2t
 -1 4. Pull the white foam absorberstaight out from the kneebolsterplate (therearetwo
{ pushclips holding it). Undo the four Phillips screwsandremovethe plate. The
Amp-Hour control box is now visible to the teft of the steeringcolumn (the ignition
box is on the right).
5. Working from underneaththe dashboard,disconnectthe flat ribbon 20-pin connector
from the Amp-Hour box. Also disconnectthe 6-pin internationalMolex "Y'
connectorsfrom the vehicle harnessandthe Amp-Hour box.
6. Removethe (2) Torx T40 bolts holding up the steeringcolumn. Allow the steering
column to hang free but do not force it down. Removethe small left and right lower
instnrmentpanel covers,just on either sideof the steeringcolumn (one screweach).
Removethe 4 medium length screwsholding the instnrmentclusterhim panel.
7. Removethe 4 screwssecuringthe instnrmentclusterassembly.(The (2) top shorter
screwsare holding the white tabson eachside.) Reachbehindand squeezethe tab
holding the speedometercableto the speedometer head. Pull it straightoff. Remove
the 3 multi-pin electricalconnectionsalso in backof the instnrmentcluster.
8. Pull the instnrmentclusterout of the vehiclecompletewith wires to the Amp-Hour
Meter display and Ammeter/voltmeter,carefully feedingboth harnessesthroughthe
instnrmentcluster opening.
9. Squeezethe 7 black tabsholding the coveron to the clusterassemblyand pufl the
cover straight off. Undo the (2) small and(2) largePhillips screwsholding the
speedometerheadassemblyat the back of the cluster. Transferthe speedometer head
andthe ammeter/voltmeterassernblyto the new clusterassembly.
10. Installation is the reverseof removal. Pleasetake exteme carenot to pull on the
voltneter/ammeterandAmp-Hour harness.Be surethe red-Andersonconnector

wall.

Amp-Hour box removal

l. Turn the ignition key offand setparking brake. Unplug vehiclefrom the wall.
unplug the l-pin red Anderson senice DisconnJct.-seewarning obove.
2. Removethree Phillips screwsfrom the driver'ssidelower dashpanel pull out on the
upperleft cornerof the panelonly, then slide it left to clearthe small tab on the right,
3. Pull the white foam absorberstaight out from the kneebolsterplate (therearetwo
pushclips holding it). Undo the four Phillips screwsandremoie the plate. The
Amp-Hour control box is now visible to the left of the steeringcolumn (the ignition
box is on the right).
4. Releasethe Amp-Hour box from its position (it is attachedwith Velcro) and pull it
out just enoughto carefully unplug the 20-pin connectorwhich goesto the Amp-Hour
Meter display and the 6-pin Molex connectorwhich goesto the fusebox and the
voltmeter/ammetergauge.

Installation of Amp-Hour CounterBox

Installationis the reverseof removal. Be surethe redAndersonServiceDisconnect
connectorunder the hood is still unplugged,the key is off, andthe vehicle is
unplugged
from the wall.

22
 BATTERY CHARGER
The 1997SolectriaForceis equippedwith a 3.3 kW BatteryCharger(modelBC3300),
locatedin the trunk, on the driver's sideof the car. Note: Some1997SolectriaForces
useda 1.6kW BatteryCharger(modelBCl600). If your vehicleis so equipped,please
contact Solectriafor moredetailson the removaland installationof this unit.

WARI\ING!

Disconnectall Solectriacomponentswhich tre connectedto the

batteries if you attempt any fast charging of the batteries.
F'AILI.]RE TO DO SO WILL VOII) ALL WARRANTIES.
Contact Solectriaif you are unsurewhich componentsmay be
affected.

3.3 kW Battery Charger Removal

1. Turn ignition key offand setparking brake. Unplug vehicle from the wall outlet.
2. Pull back of rear seatforward.
3. Pull drivers side carpetasideand removefoam from trunk floor.
4. Unplug AC input wire at gray 3-prongconnector,locatedjust behindcarpetcloseto
the top of the inner fenderwell.
5. Remove(4)%" - 20 nylocks,gentlypull chargerup andout approximately8" to
accessconnectors
( 6. Unplug DC output corurector(red 2-pin Anderson).
7. Locate remainingconnectorsjust behindcarpet. Unplug the (2) temperaturesensors
(black 3-pin Packardconnectors).Unplug the ChargeCompleteLED wire (4-pin
Amp connector). Unplug the controller disable(a-pin Molex). Note: when
disconnectingthe Contoller disable,take carenot to unplugthe l2V fan power
supply, which is a 2-pin Amp connectoradjacentto the conholler disable.
8 . Pull the LED Box offthe carpet(it is attachedwith Velcro) andremovethe Battery
Chargerand LED Box as an assembly.

Installation of 3.3 kW Battery Charger

Note: Before installing new charger,checkinJine fuseon positivewire next to driver's
side stnrt tower on trunk floor.

Installationis the reverseof removal. Be surethevehicleis unplugeedfrom the wall

durins this procedure

Motor SpeedSensor
The motor speedsensoris locatedon the rearof the motor underthe motor end plate. It
provides the motor controllerfeedbackon the directionand speedof the motor. To
accessthe sensor,the motor cooling fan andshroudmustbe removed.

23
 TestingMotor Sensor
(
1. Turn the key offand setthe parkingbrake.
2. Jackfront of the vehicleandplaceit onjack stands.
3. Turn vehicle on, selectthe normaldriving setting,and accelerateslowly up to
maximum speed. Listen for motor vibrationsor shudders:if a motor sensoris
malfunctioning, it can shuddersharplyat a particularspeed(usually a high speed).
DO NOT CONFUSETHIS WITH OUT-OF-BALAI{CETIRES. The motormay
also turn very slowly or "growl" aswell. Do not confusothis symptomwith an out-
of-phasecontroller.
4. If the sensoris functioning properly,turn offthe key, lower the vehicle,andtest drive
for the samesymptoms. If adjustmentor replacementis requiredproceedasfollows:

Motor SpeedSensorAdjustment/Replacement
l. Turn the ignition key offand setthe parkingbrake.
2. Disconnectthe 9-pin connectorbetweenthe contoller and speedsensor. It is located
behind the DC-DC Converter.
3. Disconnectthe DC input to conholler (largegray AndersonConnector).Loosenthe
remaining half to the connectorfrom the uppercrossbeamandplaceout of the way.
4. Removethe A/C motor/compressorassembly.Do not undo compressorlines.
Simply lift motor/compressorplate out of motor comparfrnentand lay it upsidedown
on a pad on the front bumper. Disconnectthe A/C motor wires first.
5. Separatethe motor cooling fan harnessfrom the motor temperaturesensorharnessat
the firewall.
6. Removethe (2) Philips machinescrews(SAE #8-32) securingthe fan housingto the
motor and removethe fan andhousingby disengagingfrom lower sfird,then tilting it
up asiyou slide and lift it offthe motor.
7. Removethe (3) small M4 (metic) screwsfrom the motor coverplate. Carefully cut
the sealbetweenthe plate andthe motor with a razor bladewhile gently prying the
plate with a small slottedscrewdriver.Be extra carefulnearthe sensorcableexit
point from motor.
8 . Inspectencoderwheel for din andsensorwear marks. Replaceif damaged.
9. To adjust: Carefully removesiliconefrom inner slottedscrew-headat circuit board
and adjust as outlined below.
10. To replace: Cut the small zip tie securingthe gray hamessto the holder andremove
the small Phillips screw(metic M-3) securingthe holderand groundwire to the
motor.
11.Removethe siliconefrom the slottedscrewsat the circuit board. Loosenthe outer
screwalmost all the way- thereis a spacerbetweenthe boardandthe motor underthis
screw. Loosenthe inner screw(metric)all the way while reachingbehindthe board
to catchthe small spring. Now, removethe outer screwall the way being carefulto
catchthe spacer/washerbehindit. Pleasedo not loseany hardware.
12.Snipthe two black temperature sensorwirescloseto the board(l/8 - l/4 inch),then
undo the harnessclampsat the firewall andremovethe sensorfrom the vehicle.

24
(^ Motor SpeedSensorInstallation
\ 1. Install a lock washerand a flat washeron outer shorterscrew(metric M-3) and insert
throughcircuit boardand0.025spacer/washer underboard. Hold spaceron backof
. boardwhile startingscrewinto motor two tums. Placespringbehind boardandhold
it while inserting inner longerscrew(menic M-3) andflat washerthrough boardand
spring and into motor. Tighten down outer shorterscrewall the way.
2. To adjust Line up the speedsensorplate retainingscrewsparallel to the inner edge
of the circuit boardby turning the drive wheelsslightly. Using a plastic non-abrasive
feeler gaugeto avoid damagingthe sensorwheel,adjustinner screwso that the gap
betweenthe centerinneredgeof the boarditself andthe sensorplateis 0.125-0.130
inches. Insert gaugeonly l/8 inch from edgeof board. Do not lift boardwith gauge
3. Put a l/8 inch dabof siliconesealanton eachscrewheadandalongouteredgeof
board to preventmovement.
4. Re-solderthe temperaturesensorwires if they werecut uponremoval (they arenot
polarized). Be carefulnot to overheatthe terminalsor they may unsolderfrom the
board. Install small harnessholder and groundwire againstthe motor and tie-wrap
harnessto holder.
5. Run test procedureagainbeforeinstalling cover. (Temporarilyplug in gray Anderson
connectorat motor controllerand 9-pin corurector.)
6. Apply a n.urow beadof siliconesealantaroundthe motor coverplate rim and install
the cover plate. Be surehamessis seatedin its notch.
/ 7. The rest of the procedureis the reverseof removal. Be sureto install (2) tie-wrapsat
\ . the red, white and blue connectorbeforereinstallingmetalzip-on mesh. Roadtestthe
vehicle to verifr that the repairis complete.

AIR CONDITIONING CONTROLLER

The Air Conditioner (A/C) Controlleris both a switchingdeviceand a voltage converter
for the A/C compressormotor. It is locatedon the passengersideof the motor
compartmentnearthe fusebox. Otherthan the externalfuse,thereareno user
serviceableparts. Before checkingfuse,disconnectred one-pinServiceDisconnect
Andersoncorutectornearhigh voltagefusebox. Write down Amp-Horn Meter number
before disconnecting. Whenfinishedcheckingor replacingfuse,plug in red connector.

A/C Controller removal

1. Turn ignition key offand setparkingbrake. Disconnectthered AndersonService
Disconnectbetweenthe fusebox and largegray Andersonconnectorto the motor
controller. Make a note of the Amp-Hour Meter readingbeforedisconnecting(the Amp-
Hour Meter will go blank).
2. Disconnectthe high voltageinput wire (3-pin,2-wheDeutschconnectorwith black
and white wires), the outputwire (2-pin Deutschto A/C motorwith greenand white
wires), the signal wire (redwire with l-pin Packard),andblackgrourd wire with eyelet.
3. Removethe two Phillips machinescrewswhich hotd the contoller to the passenger
side upper beambracketandremoveit from the vehicle.

25
 A/C Controller installation
(
Installationis the reverseof removal. Re-connectthe red Andersonconnector.If Amp-
Hour Meter reads99.00or 100.00,disconnectthe red ServiceDisconnectAnderson
connector,wait 10 secondsandtry again.

IGNITION BOX
The ignition box is an electonic devicewhich givesthe motor controller input signals
from the vehicle operatorandprovidesother safetyinterlocks suchasneutal interlock
"on" with Range-
and charginginterlock (i.e., vehicle cannotbe driven if key is turned
Power Selectorsetto a forward or reversesetting,or if vehicle is charging). The ignition
box is locatedjust right of the steeringcolumn over the lower dashpanel. SeeAppendix
Bfor diagratn

Ignition Box removal

l. Turn ignition key off and setparkingbrake. Unplug vehicle from the wall. Be sure
parking brakeis set.
2. RemovethreePhillips screwsfrom the driver'sside lower dashpanel. Pull out on the
upper left cornerof the panelonly, then slide it left to clearthe small tab on the right
top corner.
3. Pull the white foam absorberstraightout from the kneebolsterplate (therearetwo
push clips hotding it). Undo the four Phillips screwsandremovethe plate. The
ignition box is now visible to the right of the steeringcolumn (the Amp-Hour box is
on the left).
4. Releasethe ignition box from its position (it i$attachedwitlt Velcro) andpull it out
just enoughto unplugthe following connections:
No particular order required
a. RegenerativeDisable: 2-pin femaleAmp connector(2 yellow wires)
b. ChargeInterlock: 4-pin femaleMolex connector(2 wires, white andblue)
c. Range-PowerSelector: 3-pin femaleAmp connector(3 wires, red, greenand black)
d. Forward.Reversesignalfrom Power-RangeSelector: 3-pin maleIntemationalMolex
connector(3 wires, red, greenandblack)
Neutral Interlock to Range-PowerSelector: 2-pin femaleinternationalMolex (orange
and purple wires)
f. 12V ignition supply: roundsingle-pinmaleconnector(white wire)
g. Groundwire: male spadeconnector(gray wire)
h. Controllercable: 25-pinmaleD-subcorurector
i. Pot box: lO-pin maleheaderconnector

Ignition Box Installation

Installationis the reverseof removal.

26
( ACCESSORIES

CABIN PREHEAT
The Preheatsystemis programmedto heatthe cabin beforethe driver startsa tip.
The Preheatsystemusespower from the batterypack,howeverit only works when the
vehicle is pluggedinto wall outlet. The chargeris typicalty ableto replenishor supply
enoughenergyusedby the preheatsystemto keepthe batteriesfully chargedduring the
preheatcycle. SeeOwnersmanualfor operation andprogramming.

Cabin Preheat removal

l. Turn ignition key offand setparkingbrake. Unplugvehiclefrom wall outlet.
RemovethreePhillips screwsfrom the driver'ssidelower dashpanel. Pull out on the
upper left cornerof the panelonly, then slide it left to clearthe small tab on the right.
2. Pull the white foam absorberstraightout from the kneebolsterplate (thereare two
push clips holding it). Undo the four Phillips screwsandremovethe plate.
3. Reachup and unscrewthe (2) plastic thumb screwsfrom the back of the cabinpreheat
computer.
4. Pull out the computerjust enoughto unplugthe two connectors:
a. I I0VAC or 220YAC supply: 2-pin maleinternationalMolex (blackandwhite wires).
b. Signatto heaterrelay: 2-pin male amp corurector(purpleandred/whitewires).

Cabin Preheat installation

Installationis the reverseof removal.

VACUI.]M PUMP AI\D RESERVOIR

Becausethere is no vacuumcreatedby the electic motor, a l2Y vacuumpump is utilized
to supply vacuumto the brakebooster. It is locatedbesidethe drivers sideheadlight. A
vacuumreservoiris alsousedin the system. It is locatedunderthe hood at the pasisenger
side irurer fender.

Vacuum Pump Removal

The vacuumpump is removedcompletewith the bracket. To removethe vacuumpump
assembly, separatethe l/4 - 20 bolt attachedto the headlighthousingand the 6 mm nut
on the top of the assembly.Unplug the l2V wires andthe vacuumhose,and slide it out
over the front bumper.

Vacuum Pump Installation

Installationis the reverseof removal.

RANGE-POWER SELECTOR
The Range-PowerSelector,usedto selectforwardor reversemotionor OFF, is located
on the centerconsole.

Range-PowerSelectorRemoval
l. Turn key offand setparkingbrake.

27
(- 2. Unscrewthe 6 screwssecuringthe console.Lift out the console.
\ 3. Removethe four l/4" nutsholdingthe Range-Power Selectorbracketto the floor and
move it out in orderto give yourselfspaceto disconnectthe following:
a. 2-pin malemini-Molex (blackwires)to Regen.relay(reverselights)
b. 3-pin female internationalMolex (red,black, andwhite with red stripe wires)
to ignition box (forward/reversesignal)
c. 2-wire, 3-pin male Amp connector(black and orangewires) to ignition box
(power saversignal)
d. 2-pin male internationalMolex (purplewires) to ignition box (neutal
interlock)
4. Unplug the 2-wire connectorfrom the regendisableswitch (yellow wires).
5. Follow the wires from the heatswitchanddisconnect;
a. orangewire to heaterrelay
b. gray groundwire
c. red wire to heaterfan *To'tapbehindglovebox
6. Removeunit from vehicle.

Range-PowerSelectorInstallation
Installation is the reverseof removal. Be surethe key is off. Also be sureto include all
the wires that were underthe samegroundscrewasthe heaterswitch.

28
I

Appendix A

Parts List

Tools & Test Equipment

(=

REPAIRPART SOLECTRIACORPORATION
ASSEMBLIES1997

Itemgroup: assy lD: descriP.:

BC3300 l6lb. batterycharger,20&240VAC input,33d)W output,120'4
latterysyst€ms 3TMcontrol box Thermal
3attery Manegem€nt Front
SystemSensor,
lan€rysystsms = rcar BB cover =orcsPbrearbatteryboxcover(plastlc)
Srakes y'ham6ss BrakeVacuumHamess
Bnkes y'reservoir eservoir14078506
lrek€s Uswitchassem vliqoswitcfiassembly
)hassis oellypan front lelly panfiont for 1995-97brce
lhassis lelly pan rear rclly pan rearbr 1995-97force
lontrollers \c325 :ontrollerfor 156-i 80vDC,45kW@180q/
lontrollcrs )c30 VC controller,non-legsn,20A battcrycunentmax.,144,156,18
DGDC Conveiler )c,Dc575 i75Woutput12VouFut up to 46A, 10G200VInput
)rive System \T1200 ieatuox ior standad Forceto be usedwithACgux20,ACge2O
DdvcSystcm shieldingkit ;hieldingkit, EMI
)rivs System ipeetl SensorShort lpeed sensorbr any motorpt# MSSElO
{VAC l34A Compressor \lr Condltionlng Comprcssor
il/AC l34A F Condensor \lr Condltloning Condrnscr
{vAc l34A F Evaporator \k CondltlonlngEvaporetol
{vAc l3'lA F Hamcss \lr Conditloning Wring Hamess
{vAc VC Motorassembly 1 HP Alr Condltionlng motorwlredwlthconneclors.
FIVAC Flslcment fleetsr element$rlthtsmp. cilt ofr
{vAc Hrulay {eaterrelaywlthtimcr
{VAC Hswftcfr patcr switcltwith out timer, 1995and newer
tlotor \Cgbeo notorfor 34kW.12kWnomlnel,p€akToquc 70Nm
lensor : tempsensorFrcnt 3stterychaErr tcmpsratur€semor, Front
lcn30r =tcmpSensod(t 3rontandRearTcmperatun sensoraKlt br a Force
Sensor =tgmpsonsoflear lettgrychergertempsraturs Roar
Sssnsor,
Shuntr SHlOO l00Ashunt,60mV,used Inthc ForceFusebox
hcmal system Fftont themd pad asse hermalpadwlpd w/ PP15coneclors
hcrmal systcm : rearthermalpadasse hermalpadwiredW PP15conedon
Jscr interfacc \BG1 nt box=accelerator/bnkecontroller
Jser interface \H10Odisplay \H100Display
(-
\ PARTS1997
REPAIR CORPORATION
SOLECTRIA
FORCE
SOLECTRIA

Itemgroup: SoleclriapartlD: descrip.:

:conn )825 shell ;hellfor DB25housed
'conn DB25Fhoused )825 hmale oimp plugwith metalhousing(sh
i@nn DB25Fstraightplastic lB25 femalestraightboardmount
;oonn )825M crimp )B25 mde oimp plug
iconn tackard2F torer iretertite,fits femalepins
rconn rackard2M shroud vatertite,fits malepins
iconn rackard4M shroud vateftit€,lits maleplns
lconn PackardF pin bmalepin for towers
rad<ad M pin nalepin for shrouds
-iquititagrommetlaqe l/2" NPT.23 -.47'cerd
lEstock -huititesromm€tmediu 12"NPT.19"-.35'cod
-hultitegrommetsmall Y8' NPT .15'-.32'cord
|8OLETseml l80A250Vtuse140VDC
max
lfuse useholderinlinesmall nlinefuseholderfor standad 3AGglass/cerami
€lay egen relay {ella relayt2v
'erm -ug 1/4'4awg )ne holecest compressionlug,greycolorkeye
 6
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(

Appendix B

Layout and \iliring Diagrams

(
ConnectorDrawings

I|
( Wiring Diagramsfor 1997SolectriaForce

Under Hood Layout

AC JunctionBox (for vehiclesequippedwith 8C3300charger)

Air Conditioning

Amp-Hour Meter

Battery - Front BatteryBox

Battery - RearBatteryBox

DC-DC Converter

Fuse Box
( ,
Heater

Ignition

RegenBrake Light
 L997SOLECTRIAFORCE
(
DIAGRAM OF EQUIPMENT I]NDER
THEHOOD

(ttpoc Boxft)
AcceleraEor/Brake ConErol
High Integrated Half- Throttle Control
Voltage Gearbox/ Shaft
Fuse \ Service Differential
Box Disconnect
Air
Conditioner
Motor
Contoller

Air
Conditioner
Compressor

Power Brake
Vacuum
\*r.-

DC-DC
Converter

Windshield
WasherFluid

Air PowerBrake
Condenserand Fan BatteryBox Motor Contoller Horn VacuumPump
(

g,
-g
e
Y
L
o
g
3
H RE

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(d$
(E
ltJ - F 9B
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trI cv:t
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(
1997LEAD ACID FORCE AIR-CONDITIONING WIRING

Air-conditioner Metro A/C

compressorclutch
signal

A/C motor
controller

Metro
A/C compressor
clutchwire

I
rra Qp.t
Deutch l pin
3-pin Packanl
2wfte

to fuse to shunt

Fuse Box car

chassle
(l2v ground)

ll4" ring
 1997LBAD ACID FORCE AMP.HOUR METBR WIRING

RcdAtrdcru
snaald

Fuses

Amp-hour
display Ncjrdw
dirlr
Tonc3.dn
on dashboard rlE
lmildld&
l^" \*;**'
- -ttblrnda
na!rdw
xlG

To Volt meter

Caution: Pins 1 and 2 havefull

battery pack voltare

(
C 1997LEAD ACID FORCE FRONTBATTERY BOX

Red
Anderson
Dgf\Il-Ce LrtctreyArdcmn
^ qrKtor lo
ULSCOnneCE orrdtc
BlmLAtd.m
Mrln podtn crbh frc lcrE

A./Ccontroller

C Removethcsebefore if #ii mustbe rcplaced.

removc and tapc up thc
beginningany work on
front battery removal. cablcon thepositive
terminal of #5 batary.
*t4 will havc to bc removed
in order to replace#5.

WARNING:ALWAYSU NPLAGTHE
VEHICLE FROM1IO.Z2OVAC
- cHARcrNc SaPPLY4aASCAP).
DISCONNECT THE RED
ANDERSONACCESSORY
c o NNECTO& BLACK ANDERSON
CHARGERCONNECTO&AND THE
GREYANDERSONCONNECTORTO
CONTROLIfrRBEFORE
REPIA,CI NG AT,IY
BATTERY!

I|
-l

C
€F
$3
6p
EE $

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c
f
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€E$ E fi
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e

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o

e8 {EH
fE
 1997LEAD ACID FORCEDC.DC WIRING
156V INPU
(
CABLE 5A,250V
Grn#YelG)
fast-blow
wht (+) 1.1/4"glass

I
Red12V(+) Grey(small)
sB-50
Anderson
/. coilector,
To Geo MeEro
Fuse Box aE
driverIe sLde
lnner fender

grey
s8.50
Anderson
connector

DC.DC
converter
156Vinput
12Vouptut
(575Watts)

ttNerrV
 1997LEAD ACID FORCEFUSEBOX
(

Main positive cable Batteryconnector

from rear battery box for motor controller

Red Anderson
Servicedisconnect\

To negative
terminal inside
front battery
box.Thisis
main negative
wire.
Negative Heater power
charger wire 3 pin,2 wire
Deutch
DC-DCpower

Air-conditioner
power

Amp-hour
meter plug
4 pin
Deutch

!.) DC-DC converterfuse(6A, 250V)

2.) Heaterfuse(20A slow blow, 250V)
3.) Air conditioningfuse(20A, 250V)'
4.) Amp hour counterfuse(2A, 250V)

Il
 1997LBAD ACID FORCEHEATER WIRING

Internadonal
molex

Heater activation switch

lleater (on console)
Heater
Element relay, timer
(within dash) (underdash)

EItGry Corctor
ld mts onarollq

n.d Ardmn
srEtor

Fuses

To nr3.dw ttnn|[l
l- ltrld. {tont brttrn ba
rrrttrunrtrdw
!

2 rln 3 oln
Dardr 6md.

(
 1997FORCE AUTOMATIC IGNITION WIRING

SOLECTR,A

SeeFigure 1
for de_tailwiring
4.PIN BIL
MoLEx ,f\,
Hf:'o"\/
(tSrldo! bqdd.

Chargcr
Interloclc/Controller

Figure I
n.ta rbrbh
Lpla I

Range-Power Molqlilmt&fu|
Selector nd.

se*eg-
<---#'
Ndrrd lntldocl
€
t2V dndc Dln
*tt**--
l.patrAnp
ddc k tcrl l2V
 1997FORCE REGEN BRAKE LIGHT WIRING

r: Relay contacts
are connected
to metre
stop-light
switch
leads(both the
metro switch
so[ECTR|A and the regen
rclay can
activate the
brake lights)

RegenBrake-light
Motor Controller Relay

Regen
Brake-light
relay
terminals

Wht (hot+12V)

Grn (switched+)

HOTATAIITTMES
(|h6IrC.DC|mGt d)

(
in, 2-wLre Ipackara
Motor Controller
view: rear "T" t"p
grey wire I
 SolectriaConnectors

C Female

6-pin International Molex

o Amp-Hour CounterHarnessunder dash

3-pin International Molex

o Range-Power(Forward-Reverse)Selector

2-pin International Molex

o Neutral Interlock
o I I0VAC or 220VACto Battery Thermal
Management

4-pin Molex
o Charger Interlock

2-pin Molex
. High-Voltage Heater under dash

2-pin Amp
c RegenDisable
4-pin Amp
o ChargeCompleteLED

*Note: Connectornomenclatureis definedby Solectia. Connectorgendermay not be

consistentwith other industries.Pleasenotewhetherthe pins areexposedor setinto the
connector.
SolectriaConnectors

SBI7SLargeGreyAnderson
oBatter!to MotorController

PowerPole120
c Re4 WhiteandBlue
Motor PowerLeads

SB50Ander.son
o Red-8C3300Chargeroulputto Baneries,
oGre!_DC_DCI2V Ouput

Powerpote50
o Red- AccessoryPositive_Serttice
Disconnect
o Black - ChargerNegativeDisconnect
 SolectriaConnectors

25-pinD sub
Ignition Boxto Motor Controller

(
cMotorSpeed
Sensor
toM"r:Zn::;:

t
 SolectriaConnectors

(3-pin model depicted)

3-pin Packard
c Batter! TemperatureSensors

4-pin Packard
. RegenBrake Light Activation

(3-pin model depicted)

2-pin Deutsch
o ,UC Controllerto,4/C motor

3-pin Deutsch
o DC-DC, Heat and,4/C out offuse box

( 4-pin Deutsch
. Amp-hourmeterharnessunderhood
C

Appendix C

TroubleshootingGuide

Battery DischargeTest Form

Towing Instructions
(

TroubleshootingGuide

1997SolectriaForce

NominalSystemVoltage: 156V

Batteries:LeadAcid

BatteryCharger: Solectria8C3300
(

SectionI: ProblemSolving

SectionII: SystemsDiagnosis
(- SectionI: ProblemSolving

icle doesnot drive.

Range-Powerselectoris setto Setthe Range-Power selectorto the "OFF'

one of the forward or rev€rse settingandturn the igrition key offthen on
settingswhen the igrition key is againp clicks). Now setthe Range-Power
turned on. selectorto one of the forward settings,or to the
reveniesetting,andtry driving the vehicleagain.
Be sureto pushacceleratorpedaldown at least
half way beforecar will startto move. (When
the ignition key is turned on, the vehiclewill
power up only if the Range-Powersclectoris at
the OFF setting.)

l2V systemis not working. Are "

See I2V accessories
don't work" below.
lights out? Horn not working?

Ifthe vehicledoesnot Main fuse in front or rear battery Leavingthe key on, checkmain batteryvoltage
move or stopsabruptly box may haveblown or one or at the gray Andersonconnectorto the motor
while driving more batterymodulesare open. contoller. If lower than 156V,tirm ttre key off,
openthe rearbatterybox and checkthe main
( interconnectfuse (voltageacrossthe fuse
indicatesa blown fuse).If fuse is okay, check
the firse in the front batterybox. (Call Solectria
for replacementfuses)Also, checkfor open
modulesand faulty interconnects.If a moduleis
openor partially open,follow the procedurein
the text for batteryreplacement.

Ignition circuit. Doesignition See "Checkingignition circuit" in SectionIL

circuit underdash"click" when
kcy is turned?(Click soundis
normal.)

Motor Contoller, Doesmotor "Checking

See Motor and Controller" in
controller "clunk" on? Section II..
(Clunk soundis normal.)

Motor speedsensorout of "Checking

See Motor and Controller" in
adjustnent or failed. Section II tirst, then see "Motor Speed Sensor
Adjustment" in tqt.
(t'

carmaynotdriveif amp-hourmeterreads
40.00-50.00Ah? If so,batleries over40.00-50.00Ah. The batterypackshould
arenrnning low on energyand be fully rechargedat this time (until the "Charge
needto be recharged. Complete"LED on the dashcomeson). If
necessary,the vehicle may bc driven following a
partial recharge,but it shouldbe fully recharged
at the earliestopportunity for maximum battery
performanceand life.

Is Range-Powerselectoris setto Selectto NORMAL or POWERsettingfor more

ECON? power (and lessrange).

Is vehiclein 'limp home'mode SettheRange-Power selectorto'NORMAL"

due to low, weak, or damaged and pushthe acceleratorpedalall the way down.
batterypack, or faulty battery Using the optional dashmountedvoltneter (or a
interconnects. separatevoltneter - See "How to Measure
Voltage"sectionin tut), checkto seethat the
voltagedoesnot drop under l40V at any time
when the amp-hourmeter is between00.00and
35.00amp-houn. If it doesfall under 140V,
perform abattery dischargetest.,See"Battery
DischargeTest" sectionin tut. It is necessary
to fully chargethe batterypack at this time.

If vehiclehasbeenleft unpluggedin the cold for

sometime, thcn plug it in rmtil the battcrieshave
reached60oFbeforedriving. Ifthe vehicle has
beenpluggedin, then cheokthat the thermal
managementsystemis functioning properly.
See "CheckingThermalManagement" in
SectionII..

Vehiclc is jerking on Faulty controller or faulty 25-pin "ClecHng

See Motor andController" in
cable. SectionII..

Motor speedsensorout of See"Motor SpeedSensor" in tst.

adjustnent.

Faultypot-boxsignal. If hesitationoccurcat a particularpoint in the

acceleratorpedaltravel, or seemsto be affected
by bumps,thenthe problemmay be in the pot-
box. Call Solectriafor detailson checkingpot
box resistance.
(

l2-volt accessories Ignition key is not in "ON' T[rn igrition key on (2 clicks).
don't work position.

Inertial kill-switch is open. Turn key offand resetthe Inertialkill-switch

locatedunderhood at the fnewall on the driver's
side. To resetthis switch, push down on the red
rubber cap of the switch.

DC-DC Converteris in brown- Tum off ignition key and disconnectinput wires
out mode. to the DC-DC Converter(small gray Deutsch
connectorwith greenand white wires), then
reconnectinput wires to DC-DC; checkoutput
on 2-pin gray Andersonconnectorfor l2V (red
and black wires), or ntm key on and tum on the
headlights.

BlownfuseatDC fuseboxor at Checkfusesat DC fusebox and at the DC-DC

DC-DCconverter. converteras follows.
l. TUmigrition keyto offposition.
2. Disconnectthe small gray Deutsch
connectorwith greenand white wires.
3. Take out the fuse from on top of the DC-DC
Converter,and test it with a continuity
meter.
4. Replacethe fuse if it is blown with the same
value andtlpe of fuse,or re-install the
original if it is not blown.
5. Takeout the DC-DC Converterfuse from
the High-VoltageDC fuse box and test it
with a continuity meter.
6. Sameasstep4.
7. Re-connectthe small gray Deutsch
connector.
8. Try tuming headlightson.
9. See"Clecking DC -DC Converter" in
SectionII.

Main fusein frontor rearbattery Checkfor approximatelyl56V at contoller.

box is blownor batterymoduleis See"Vehicledoesnot drive" in SectionI of this
open. Tl oubleshooting Guide.
 CONDITION ING MOTOR WIIEN
DIAGNOSING.
l. Unplugsingleredwire fiomA/C
confroller.Turn on igrition, fan, and A"/C,and
checkfor +l2V betweenharnesswire and
chassisground.
2. If no +l2V is present,reconnectthe wire
and unplugthe moldedconnectorat the
pressureswitch mountedon the receiver/drier.
Connectthe wires with a jumper or pliers to
temporarilyblpass the switch and if the A/C
motor starts,then the systemrefrigerant is low.
Have it tested evacuatedand rechargedwith 24
oz. Rl34a refrigerant.
3. If the compressordoesnot run with the
pressureswitch bypassedthen checkthe relays
at the 12V fusebox, locatedunder the hood
behindthe gloveboxon the evaporator.

Blown fusesand/orblown A/C l. Turn ignitionkey offand unplug l56V

controller input to A./Ccontroller. Check for l56V (
betweenthe white and greenwiros). If no
156V,checkA/Cfuseatmain DC fusebox.
2. If thereis 156V,tun ignition key ofi, re-
connectl56V input and disconnestthe
connectorconnectingthe A/C motor contoller
to the A/C motor. Tirm ignition key on and
checkcontoller outputto A./Cmotor for
minimumof 40-50VDC.
3. Ifthere is no voltagepresentat the
confrolleroutput,unplug the l56V input wire
againandcheck the fuse in the controller. If
t[is fuseis fme, the A/C contoller must be
replaced.
Note: Do not plug in t56V supplyor the motor
unlessthe red +l2V wire is disconnecrcdor the
ignition key is off. Doing so will causesparla
that will damagethe connectors.

Burnt brushesand/orA"/Cmotor. Turn ignition key offand disconnectA/C motor

to controllerwires. Tum ignition key baokon
andcheckforminimum 48V DC at outputof
A"/Ccontrollerto motor. If voltage is present,
turn key off. Removemotor brushesand inspect
commutiatorfor wear and discoloration. Clean
commutatorwith cotton swaband alcohol, and
replace. Replacebrushif carbonsectionis less
thanW'in leneth. Othenpise.reolacemotor.
(
Brakesnot working acuumpump not working or To checkif pumpis working,turnkeyon anJ
adequately vacuumswitch not working. listen for pump after applying brakesseveral :
times. If pumpdoesn'trun, checkif +l2V DC
is presentat pumpterminal. tf +l2V is presen!
checkfor +l2V at switch(at reservoir).Also,
checkswitchground.

Vacuumleak or vacuumlow. Let the pump stoprunning, apply brakesthree

times and note the feel of the pedal. If you get
lessthan threepumpson the brake pedalbeforeit
feels stiffor if the vacuumpump doesn't stop
running within 60 seconds,you may havea
vacuumleak. Checkfor leak or low vacuumwith
vacuumgauge. Vacuumswitch shouldshut offat
19" of Hg.

Vehicletips GFI (Ground Water and salt in AC plug or

Fault Intemrpt) Circuit washthe two endsin hot soapywater. Rinseand
dry. WashoffAC plug at chargeport (gascap)
on vehiclewith distilled water and an old tooth
brush.

Bypassthe chargeport by plugging the extension

cord directly into the charger. If the GFI still
( trips, then call Solectriafor a replacementcharger.

Have GFI circuit checkedby licensedelectrician.

Altcrnate modelsor makesmay work more
reliably with Solectriachargers. Call Solectia for
moredetails.

Short in batterythermal LocateAC junction box in tunk. One at a tinre,

managementsystem. unplugthe two (2) wire connectorsmarkedfront
and rear(black and clear wires). If GFI trips with
*front'or "real"
connccted,then openthe
conespondingbatterybox and inspectthe
integrity of the circuit. See "Checfing Thernal
Management' in SectionlI Note: The batteries
must be below 60oFor the thermal sensorswill be
"open" and
this testwill be invalid.
(-

BC3300equippedvehicleis No power from wall outlet.

not charging - GreenLED at vehicle end. Resetcircuit breakeror GFI.
amp-hourmeter is not
flashing and numbersare not No LED light comeon at trunk- With vehiclepluggedin: checkfor the AC voltage
counting down mountedchargerinterfacebox. No at the end ofthe chargerinput extensioncord
AC voltage rnputto charger. insidethe tnrnk. Ifno voltagepresent checkfor
** Note: If your vehlcle ls voltageat the AC junction box. tf voltage is
equlppedwttha BCI600 presentto the chargerandthe charger doesn't
charge4 please call Solectrla operate,contactSolectriaCorporation. The
for more detalls. chargermay haveto be replaced.

BC3300equippedvehicleis is in fault mode: Problem With vehicleunnluseed.disconnecttwo-pin red

not charging - Yellow LED with batterypack voltageto Andersonchargeroutput connectorand checkfor
is lit on tnrnk-mounted charger. DC voltageat vehicleharness.If no voltagcor
chargerinterfacebox very low voltageis present checkthe inline fuse
betweenthe Andersonoonnectorand tho positive
terminal of #13 battery. (This fusc is locatedncar
the left rearstnrt tower.) Sometimesthe fuse can
be blown in sucha way that full pack voltagecan
be measuredat tho output. In this case,leavethe
chargeroutputhookedup to ffre car harness.
Carefully backprobethe connector. Make sure
the car is unpluggedfiom the wall. If no or low
voltageis present then disconnectthe 2-pin red
( Andersonconnectorand replacethe fuse.

Chargeris in fault mode:Bad Unnlue vehicle. Disconnecttemperaturesensonr

signal from temperaturesensor. from chargerinterfacebox andmeasurethe
resistanceat the vehicle side of the harness@lack
Packard3-pin, 2-wire conn@torswith clear and
black wires). Resistanceshouldme,asure
anpvhercfrom l5k to 45k depcndingon battcry
temperature.If no resistanceis measuredor if out
of specificatiorUcall Solecria for a chart which
showscorrcctrasistanocvalucsat various
temperatures.(It's possiblethe batteriesmay be
too hot or too cold.) Othenrise, call Solecniafor
a replacementsensor.

Chargeris in fault mode: Batteries Unplue vehicle.Disconnectthe temperature

aretoohot(overl30F) sensonfrom the interfacebox. Check for
resistanceon both front and back temperature
sensorconnectors. Ifresistanceis lower than lOk
ohms,plug the temperaturesensotsback in and
park the car in shadeto let batteriescool. The
chargerwill re'start on its own whe,nthe batteries
havecooledif the yellow LED was not on when
the car waspluggedin. If the batterieswere
VERY hot andthe yellow fault LED was on, then
re-setthe chargerby unpluggingthe vehicle,wait
five (5) seconds,andplug it back in agai
 8C3300equipoedvehicleis Batteriesaretoo cold (under32F) vehicle unpluggedandtemperaturesensors
not charging - Yellow LED unpluggedfrom the interfacebox, measure
is lit on tmnk-mounted resistanceat temp€raturesensorharness.Ifthe
chargerinterfacebox batteriesare cold the resistancewill be higherthan
(cont'd) 50k ohms. If car is equrppedwith automatic
batterythermalmanagementsystem,leavethe
vehicle pluggedin for at leasteight (8) houn. The
chargershouldre-starton its own. If the batteries
arestill below32T the following day,thenmove
vehicle indoon and checkthermalmanagement
systemoperation. See" CheckingThermal

(
( SectionII: Systems
Diagnosis

CheckingDC-DC With key offand car unpluesedfrom wall. useavo

Converter voltagesideof the DC-DC converter(grayAndersonconnectorwith red and black
wires).

o rf full 12v is present,disconnectone-by-oneeachof the main fuseslocated

next to the DC-DC converter and measuringthe voltageat the gray Anderson
connectorto find what circuit of the car is shorted.

o rf voltage is considerablylower than l2v, checkcar harnessfor a short.

o rf no voltage is present,unplugthe l56V input to the DC-DC converter(gray

Deutschconnectorwith greenandwhite wires) and checkthe fuse in the DC-
DC converter.

If the fuseis blown try replacingit with the samecurrentrating(5A). Re-install

goodfuse,re-connect156v input (be certainthe key is offor l2v output is
disconnected) andcheckfor l2V at Wy Andersonconnector.

If therestill is no l2v, unplugthe l56v input andcheckthe car harnessfor l56V

( input to the DC-DC converter. If full voltageis presentandthe fusein the DC-DC
is goodandtherestill is no l2v output,thenthe Dc-Dc convertermust be
replaced.

If thereis no voltageor very low voltagepresentat the DC-DC inpu! checkthe

Dc-Dc fuse in the main DC fusebox with the DC-DC input still unplugged.

If the DC-DC fusein the main fusebox hascontinuity,checkthe main batterypack

voltage at the gray Andersonconnectorto the controller. See"Vehicle doesnot
drive" section.
(.

the windowsrolled up (it mustbe quietto

Setthe Range-Powerselectorto any forward setting. Make surethe car is

unplugeedfrom wall outletandthe PaxkineBrakeis set.

Turn the ignition key ON. Wait until the reminderchimestops. Put seatbelt on.

Slowly turn the Range-Power selectorbacktowardsthe OFFsetting. @on't let the

spring detentin the Range-Powerselectoraffect turning the handle). Listen for the
relay in the ignition box to 'click' (the relay is locatedunderthe steeringcolumn)
beingcarefulnot to confusethe ignition relay click with the mechanicaldetentin
the Range-Powerselectorthat 'clicks' first. The ignition click indicatesthat the
ignition circuit, the Range-Powerselector,and the neutral interlock circuit are all
working properly.

If no 'click' is heard,checkfor keyed+l2v DC to the ignition box (white wire).

see "Ignition Box" sectionin text to access.unplug the singlepin white wire to
the ignition box andplug it backin with key on to checkif the relay inside'clicks'.
Make sureit is alsogrounded(graywire). If l2v is presentandgroundis in good
condition, checkthe Range-Powerselectorfor continuity in Forward or Reverse
(call Solectriaat 508-658-2231fordetails). If okay,replacethe ignition box.
r
and Controller
Make surethat the ignition circuit is working by listeningfor
ignition relay .click,
under dash. Refer to "checking lgnition circuit" in preiiotu
iection.
Turn the ignition switchoffand on with the Range-power
selectorin the *oFF,
setting' Listenand/orfeel for the contoller to 'clunk' when
the key is turnedon. If
the controller doesnot clunk, checkbatterypackvortage gray
at Anderson
connector' If approximatelyl56V is presen-!checktrri
inteE iiv of the 25-pincable
both at the controller and at the ignition box. If it appears
of"y, tt "n call solecbia
for furthertestingof the 25 pin "abl" ot a repracemint
contotier.
If the controller'clunks', but the motor doesnot turn,
checkthe 9-pin cablefrom
the motor speedsensor. It may also be necessaryto perform
a pot-box resistance
test (call solectriafor details),or a motor speedsensor
adjusnnlnvreplacement.
IF INSTALLING A NEw CONTROLLER: Sometimes
the new controlleris out of
phasewith the motor. swap the red andwhite cables
"orning torn the motorat the
red, white, andblue connector.

(
('

CheckingThermal 't'he
tunctionof thermalmanagement is to maintainthe batt@
Management at least68T duringmostconditionsand at a temperaturenot lessthan301 above
ambientat extremelylow temperatures.To test the operationof the thermal
management system,fully chargethe vehicleandthen leaveit pluggedin outsideat
leasteight (8) hours(preferablyovernight) when the ambienttemperatureis less
than60F.

Using a non-conductivetemperatureprobe,checktemperatureof both the front and

rear boxesby insertingthe probe into them. The rear box can be probedthrough
the vent holeson the sidesofthe box cover. The front box canbJ probedttuougtr
the grommetfor the main interconnectlocatedat the top rearof the driver's side.
Both boxesshouldbe approximately68T.

If the temperaturereadingsdo not matchthis, the rearAC junction box wires must
be accessed.First ensurethat properAC currentis reachingthe plug of the car. If
so,gentlypull the three(3) grayjacketedwires out from behindthe carpeton the
driver's sideof the trunk.

Ifyou havenot alreadydoneso,plug in the car andbackprobethe 2-pin

InternationalMolex pins,onesetfor the front andone s"ifor the rear. If no voltage
is present,unplugcar from the wall andcheckfusesin AC junction box, replaceai
( necessary.If still no voltageis found,replacerearAC junJtion box.

If voltageis presentat2-pinMorex connector,unplugit andcheckresistanceof

ThermalManagement circuits. The resistanceshouldbe approximately320 ohms
each. If circuit is openand the batteriesare below 60 F, or differ significantly
(more than2O%)in resistance,the batterybox must be openedand another
resistancecheckmadeat the mini red and black Andersohconnector. If there is no
continuity here,the thermalpad must be replaced. If there is continuity here,but
nonethroughto the temperafuresensor,and batteriesare definitely below 60 F, call
Solectriafor a replacement temperafuresensorbox.
C'

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 Towing Instructionsfor 1997SolectriaForce
(

Do not attachwinch cablesor "J"-hooksto

suspension components whentowing.

Alwaysuse"T"-hooksinsertedinto the .,T,'-

hookslots. Seediagrams.

u
Attachr-hook chainson bothsides,in the slottedholes
in thebrackets,
just aheadof thefront wheels.
(' Addendum#1

1997SolectriaForceServiceManual
NewJersey Proiect:PowerGommute

SpecialOptions
The SolectriaForcesmanufactured
for the NewJerseyProject PowerCommute
programare equippedwith severalspecialoptions.
We encourageyou to takea
momentto learnabouttheiroperation.

Inertia Disconnect Switch

Locatedunderthe hood,this deviceshutsoff powerto the drivesystemwhen
the vehiclehas experienceda sharpbumpor impact. Seetext in Owner's
Manualfor moredetails.

Back-UpAlarm
\M,tenyou select"REVERSE",a back-upbeepingtonewill automatically sound.
The beepingwill be louderwhenmorebackgroundnoiseis present,and will stop
when you set the Range-PowerControlbackto "OFF"or one of the forward
settings.

Parking Brake Alarm

An reminderalarmhas beenaddedto the parkingbrake,whichmustbe used
everytime the vehicleis parkedto preventunintentional
rollingof the vehicle.
Whenparkingthe vehicle,pullup the parkingbrakeuntilthealarmdiscontinues
to securebrakefirmly. (Note: Parkingbrakealarmwill soundonlywhen key is
off.)

lf you haveany questions,pleasecall SolectriaCustomerServiceat 508€58-

2231.

April 1997
(- Addendum#2

1997SolectriaForceSeruiceManual
New Jersey Project:PowerGommute

InertiaDisconnectSwitch
Due to a designand manufacturing change,use of the InertiaDisconnectSwitch
has been discontinued.lf an InertiaDisconnectSwitchis stillpresentin your
vehicle,this switcheitherhas beenor shouldbe disconnected so that it is no
longeroperational.lf you haveany questions,plbasecall SolectriaCustomer
Serviceat 508-658-2231

June1997

(
 Attacha separate
safetychainaroundtheoutboardencl
of eachlowercontrolarrn.
Do not lvrap chain aroundhack rods,sway
(., bars,tie rods,or brakelines.

7,
A
{.., -
AttachT-hookchainsto theTlhookslotsin the
bottomof thefloor panjust aheadof therearwheels
on bothsides.
 SpareTire Policy

Solectria recommendsthat you keep this sparetire in a convenientand accessible

off-board location. Doing so will maximize the performance,range,and carrying
capacity(payload)of your vehicle.

In the unlikely event that your vehicle experiencesa flat tire, a can of tire sealant
has beenprovided to restorethe flat tire sufficiently to get to a gas station or other
automotive service center for proper repair of the tire.

If you usethe sealant,please...

. follow directionson cancarefully
o havetire repairedproperlyat earliestconvenience
(it is impofiant to inform
repairpersonnelthot tire sealantwasused)
. replaceit andkeepa freshcanwith the vehicleat all times

Pleaserefer to your Owner's Manual for more information,or call us at 50g-65g-

2231if you needfunher assistance.

Nov. 1995