Service Manual Liberty City/Kids - Camp Mobility

Service Manual Liberty City/Kids

This manual gives guidelines for maintenance service to be performed at the dealers after the sale.

Please refer to it together with the Owner´s Manual.

Service Manual Liberty City/Kids EN Revision 3 __________________________________________________________________________________

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Index 1. Maintenance........................................................................................................................................ 3

1.1 Tire and hose ................................................................................................................................. 3

1.2 Motor ............................................................................................................................................. 4

1.3 Powermodule ................................................................................................................................ 7

1.4 Brake system ............................................................................................................................... 12

1.4.1 Assemble/Reassemble of brake caliper ............................................................................... 12

1.4.2 Disc brake pad ...................................................................................................................... 14

1.4.3 Brake disc.............................................................................................................................. 17

1.4.4 Bleed and change of brake fluid ........................................................................................... 17

1.4.5 Brake lever adjustment ........................................................................................................ 27

1.5 Maintenance and recond ............................................................................................................ 28

2. Software and settings ........................................................................................................................ 29

2.1 Settings service technician .......................................................................................................... 29

Login .............................................................................................................................................. 29

Settings .......................................................................................................................................... 30

Motor calibration.......................................................................................................................... 32

Status ............................................................................................................................................. 32

Battery status ................................................................................................................................ 33

Fault messages ............................................................................................................................. 34

PIN code......................................................................................................................................... 34

Throttle .......................................................................................................................................... 34

2.2 Software update .......................................................................................................................... 35

3. Battery ............................................................................................................................................... 42

4. Fault detection chart ......................................................................................................................... 43

5. Fault codes......................................................................................................................................... 44

6. System overview................................................................................................................................ 47


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1. Maintenance

1.1 Tire and hose

To change tire or/and hose the same tools as for a regular bike are used. To be able to make the

change the complete wheel has to be removed from the Liberty unit in the following manner:

1. Loosen the screws holding the brake caliper against the

brake adaptor.

2. Loosen and remove the screws that hold the brake adaptors

against the frame so that the brake caliper together with the

adaptor can be removed from the disc brake.

3. Loosen and remove the wheel nuts and the screw that holds the

locking plates.


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4. Now remove the wheel from the frame and make sure to

disconnect the motor cable properly. Now the tire or/and hose can

be changed. Reassemble in opposite order to what has been

described.

NOTICE! When step number 4 is performed make sure that the

arrow on the cable connectors line up so that the connectors are

not damaged.

NOTICE! When step number 1 is performed when reassembling the

instructions from the manufacturer of the brake system must be

followed to make sure that the brake caliper aligns correctly to the

brake disc. These instructions can be found in chapter 3.4.1

1.2 Motor

When changing the motor, the complete laced wheel has to be replaced. This is done in the following

manner:


brake adaptor.

2. Loosen and remove the screws that holds the brake

adaptor against the frame so that the brake caliper together

with the adaptor can be removed from the disc brake.


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3. Loosen and remove the wheel nuts and the screw that holds

the locking plates.

4. Now remove the wheel from the frame and make sure to

disconnect the motor cable properly.

5. Now move the tire and hose from the faulty motor onto the new motor.

6. Reassemble the new motor and wheel into the frame and

tighten the wheel nuts and screws holding the locking plates.


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7. Reconnect the motor cable.

NOTICE! Make sure that the arrow on the cable connectors line

up so that the connectors are not damaged.

8. Before reassemble the brake calipers the new motor must be calibrated and mated together with

the powermodule. When calibrating the motor the wheel has to be able to spin completely free in

the air and the battery voltage must be a least 52V. The calibration of the motor is done in the

following steps:

8.1 Start the Liberty.

8.2 Login as Service technician (see chapter 2.1 in this service manual).

8.3 Use the down arrow on the screen until the “Calibration” menu appears on the

screen. Click on this menu and follow the instructions on the screen. After the

calibration has been performed the Liberty shall restart by itself. If for some reason

Liberty does not restart automatically, switch Liberty off manually and wait 5 seconds

before turning it on again.

9. Reassemble the adaptors holding the brake calipers and

tighten the screws.


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10. Tighten the screws holding the brake caliper.

NOTICE! When reassembling the calipers, the instructions

from the manufacturer of the brake system must be

followed to make sure that the brake caliper aligns

correctly to the brake disc. These instructions can be found

in chapter 3.4.1

1.3 Powermodule

The powermodule on Liberty is located in the bottom of the front part. If there is a problem with the

powermodule or the cables connected to the powemodule the hole unit incl. cables have to be

replaced. This is done in following steps:

1. Start by taking out the cable for the front light that is

located inside the steering column. Disconnect the M8

connector between the front light and the powermodule.


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2. Now loosen and remove the 4 lower screws

holding on each side that holds the lower front

profile. Remove the lower front profile including

the front light and put aside.

3. Loosen and remove the cable clip that holds the cable

that connects the front and middle part of Liberty. Pull the

connector apart and then pull the cable that connects to

the powermodule back down the cable pipe so that it

comes out above the fender.


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4. Loosen the right hand M8 cable in the display

that connects to the powermodule. Pull this cable

down through the cable pipe so that it comes out

above the fender.

5. Gently pull the motor cable so that the connector that sits

inside the fork leg is exposed. Pull the connector apart.

6. The powermodule including its cables are now

loose. Gently push it upward and outwards at the

same time. Make sure that no cables are damaged

during this operation.


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7. Perform step 1-6 in opposite order, start with step 6. Make sure to be careful so that no cables

are damaged or loosen from its seats in the powermodule.


brake adaptor.

9. Loosen and remove the screws that holds the brake

adaptor against the frame so that the brake caliper

together with the adaptor can be removed from the disc

brake.

10. The motor must be calibrated and mated together with the new powermodule. When calibrating

the motor the wheel has to be able to spin completely free in the air and the battery voltage must

be a least 52V. The calibration of the motor is done in the following steps:

8.1 Start the Liberty.

8.2 Login as Service technician (see chapter 2.1 in this service manual).

8.3 Use the down arrow on the screen until the “Calibration” menu appears on the

screen. Click on this menu and follow the instructions on the screen. After the

calibration has been performed the Liberty shall restart by itself. If for some reason

Liberty does not restart automatically, switch Liberty off manually and wait 5 seconds

before turning it on again.


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11. Reassemble the adaptors holding the brake calipers and

tighten the screws.

12. Tighten the screws holding the brake caliper.

NOTICE! When reassembling the calipers, the instructions

from the manufacturer of the brake system must be

followed to make sure that the brake caliper aligns

correctly to the brake disc. These instructions can be found

in chapter 3.4.1


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1.4 Brake system

Liberty City/Kids is equipped with a hydraulic brake system from SRAM called Level T. In this brake

system DOT brake fluid is used. The manufacturer of the brake system recommends that the brake

fluid is changed once a year.

Below instructions show the most common service actions.

Also visit SRAM´s homepage for more information about the brake system:

https://www.sram.com/sram/mountain/products/level-t

1.4.1 Assemble/Reassemble of brake caliper Assemble/reassemble of brake calipers is shown in the next couple of pictures:

Assemble the caliper bracket (1) and

tighten the screws (2). The screws that

hold the brake caliper (3) are loosely

tightened so that the brake caliper still

can move in the bracket.

Pull the brake lever (4) so that the

brake caliper adjusts itself onto the

brake disc.


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Tighten the screws (5) that hold the brake

caliper at the same that the brake lever is

pulled.

Release the brake lever (6).


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1.4.2 Disc brake pad Change of the disc brake pads is done in the following steps:

Remove the safety clip on the screw that holds the

brake pads.

Loosen and remove the screw that holds the brake

pads.

Insert a flat blade screwdriver between the brake pads and push the pads towards the pistons to push the pistons into the piston bores so that they are flush within the caliper (no picture is shown for this).


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Remove the brake pads from the caliper.

Assemble the new brake pads together with the new

holder for the brake pads.

Assemble the new brake pads and holder into the

caliper.


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Reassemble the screw that holds the brake pads and its

security clip.


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1.4.3 Brake disc To change the brake disc the complete wheel must be removed from Liberty. The disc is then

changed and the screws are tightened in the order and to the torque instructed in the picture below.

Also check the rotation direction of the disc, there is a mark on the disc.

1.4.4 Bleed and change of brake fluid The brake fluid in the system is recommended to be changed once a year. When performing this is

recommended to buy a ”SRAM Brake Bleed Kit”.

NOTICE! Use safety glasses and safety gloves when handling the brake fluid.

NOTICE! Make sure that no brake fluid come in contact with the brake disc or brake pads. This can

cause failure in brake capability.

Change of the brake fluid is done in the following steps:

Assemble the two

syringes.


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Now fill the syringes with brake DOT4 or

DOT5.1 never use mineral oil.

The syringe for the caliper is filled 3/4 with

brake fluid.

The syringe for the brake lever is filled to

1/4 with brake fluid.

Hold the syringes upright, cover the tip with a rag, and depress the plunger just enough to remove any air bubbles.

Remove the brake pads

and install the plastic block

instead that comes with

the SRAM Brake Bleeding

Kit.

Read chapter 1.4.2 to learn

more about how to

remove the brake pads.

Brake Caliper Brake Lever


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Remove the screw on the caliper that protects the bleed port (looks and position of the bleed port can differ from the picture). Clean any DOT fluid that drips from the bleed port with a rag and water.

Insert the syringe into the bleed valve.

NOTICE! The syringe that holds 3/4 of

brake fluid that is used.


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Adjust the brake lever until the lever blade is 75-80 mm from the centerline of the handlebar.

Remove the screw on the brake lever that protects the bleed port (looks and position of the bleed port can differ from the picture). Clean any DOT fluid that drips from the bleed port with a rag and water.

Insert the syringe into the bleed valve of the brake

lever. NOTICE! The syringe that holds 1/4 of brake fluid

that is used.


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Hold the caliper syringe vertically. Gently push the caliper plunger down, stopping when the caliper syringe is 1/4 full and the lever syringe is 3/4 full.

Close the clamp on the syringe at the brake lever.

Use a toe strap or your hand to hold the lever blade to the bar. Do not release the lever until instructed to do so.


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Hold the syringe at the caliper vertically. Firmly pull on the plunger to create a vacuum, then compress the plunger to pressurize the system. Repeat this process several times or until only a small amount of bubbles exit the system.

While holding the lever blade to the bar, compress the plunger at the caliper and let the pressure move the lever blade to the fully extended position.


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Close the clamp on the syringe at the caliper.

Remove the syringe at the caliper from the bleed port. Clean any DOT fluid that drips from the bleed port with a rag.

Reinstall the screw in the bleed port. Clean any DOT fluid

that drips from the bleed port with a rag.


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Open the clamp on the syringe at the brake lever.

Hold the syringe at the lever vertically. Firmly pull on the plunger to create a vacuum, then compress the plunger to pressurize the system.

Squeeze and release the brake lever ten times,

allowing the lever to snap back to its starting

position.

Repeat above several times or until only a small amount of bubbles exit the system.


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Compress and release the plunger at the lever to

equalize the system.

Close the clamp on the syringe at the lever.


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Remove the syringe at the lever from the bleed port. Clean any DOT fluid that drips from the bleed port with a rag.

Reinstall the screw in the bleed port. Clean any

DOT fluid that drips from the bleed port with

water and a rag.


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Reinstall the brake

pads inside the

calipers.

Read chapter 1.4.2 to

learn more about

how to remove the

brake pads.

Turn the reach adjust counter-clockwise to move the lever blade closer to the handlebar.

1.4.5 Brake lever adjustment

In each brake lever

there is an adjustment

screw for the lever

blade.

Turn the adjustment

screw counter-

clockwise to move the

lever blade closer to

the handlebar.


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1.5 Maintenance and recond

Cleaning

Clean the product when necessary

• Shut off the unit and disconnect from wheelchair.

• Use a lightly damp cloth or compressed air when cleaning the unit.

• Do not clean with solvent such as gasoline or paint thinner. This may damage the painting and plastic parts.

• Use a neutral detergent when cleaning the unit.

• When disinfecting the unit use a towel and alcohol.

• After cleaning some part may have to be lubricated.

Recommended Maintenance

Period Check Point User Technician Daily/Weekly Charge the battery after each use X Once a week Tire pressure X Once a month Tire wear (if damaged get in contact with a technician) X Once a year Drive wheel (screws and nuts) X Once a year Screws and nuts in general X Once a year Function check docking mechanism X Once a year Brake system (wear and function check) X Once a year Brake system (bleed and change of brake fluid) X Once a year Battery status (cell information, charge cycles) X Once a year Cables, connectors and peripheral X Once a year Lubrication of the support leg holder X Once a year Function check

- Throttle - Front light - Rear light - Locking handle - Release handle

X

• NOTICE!

Do not wash by directly hosing it down with water. Also, do not wash using steam.

The electronic devices can get damaged, which may lead to malfunction.


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2. Software and settings

2.1 Settings service technician

Logging in as service technician makes it possible to change parameters, calibrating the motor,

updating software etc.

Login Login in as service technician is

made under the menu ”Unit

Information” and then the

Technician button.

The code for login as a service

technician can be obtained

when contacting the

manufacturer.

NOTICE! Never give the code

away to an end user of the

product.


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Settings

Max speed: Sets the maximum

speed that the end user can set in

their personal profile. This is also

the default maximum speed for

the standard profile.

Max acceleration: Sets the

maximum acceleration that the

end user car set in their personal

profile. This is also the default

acceleration for the standard

profile.

Engine brake (max): Sets the

maximum engine brake that the

end user can set in their personal

profile. This is also the default

acceleration for the standard

profile.

Engine brake min: Sets the

minimum engine brake that the

end user can set in their

personal profile.

Units: Sets in which units the

speed and trip are shown;

Metric or miles.

Firmware: Menu for updating

the software of the Liberty. This

is described i a separate chapter

in this document.


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Calibration: Menu for

calibrating the motor.

Calibration needs to be

performed when powermodule

or motor is replaced.

Sound test: Tests the built-in

speakers.

Status: General status showing

temperatures in the power

module, hook signal etc.

Battery status: Status menu for

the battery where

temperatures, voltages, capacity

etc. is shown.

Fault messages: History of fault

messages.

Pin code: Meny for setting the

PIN-code access control of the

Liberty

Throttle: Menu for different

settings related to the throttle


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Motor calibration

If the motor or the powermodule

is changed a calibration needs to

be performed.

Before starting the calibration the

following needs to be performed

and checked:

- The brakes are removed and

the wheel is free hanging so it

can be rotated freely in the air.

- The voltage in the battery

should be at least 52V (this can

be checked on the battery status

menu).

Start the calibration and wait for

the Liberty to finish and restart

itself.

Status

This menu shows the following:

- Information about the power

module regarding temperature

and speed.

- Hook signal indicating if Liberty

is connected correctly to the

wheelchair.

- Odometer showing both the

total mileage for the power

module and the user mileage

that can be reset.


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Battery status

Here the status of the battery

system of Liberty is presented.

- Current capacity of the battery

- Maximum capacity of the

battery.

- Battery health

- Number of cycles that the

battery has been charged.

- Temperatures for different part

of the battery.

- The level of voltage in all the

cells of the battery. If the battery

becomes unbalanced the

difference between the highest

and lowest reading of cell

voltages will increase..


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Fault messages

Here the history of faults that

have occurred is presented. This

could be useful information when

contacting the manufacturer of

the product.

PIN code

Here the service technician can

set how and if the PIN code

should be used at startup.

- Always of means that the user

can not choose to have a PIN

code at startup.

- User can set on/off means that

the user can choose if the PIN

code is used at startup.

- Always on means that the user

is forced to use a PIN code at

startup. Default PIN code is: 0000

Throttle

Here you can set how much the

throttle handle must be twisted

before full throttle is reached.

When set to 4250mV the throttle

has to be twisted all the way to

reach full throttle. If this value i

set lower full throttle will be

reached sooner.

Use extra switch is a future

function. This function is

normally inactive.


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2.2 Software update

To update the software of the Liberty a computer with Bluetooth and Windows 8 or later is

necessary. The update is done in two steps. In the first step the files are transferred to Liberty using

LibertyUpdater software. In the second step these files are installed on the Liberty, this is done in the

service technician menu.

2.2.1 Transferring files, Liberty APP

To be able to transfer the files you need a computer with Bluetooth and Windows 8 or later.

LibertyUpdater must be installed and the update file downloaded to the computer.

For the most stable transfer it is recommended that the computer should be within 1m from the

Liberty unit.

Step 1.1 Start the LibertyUpdater and press the ”Update Firmware”. Choose the update file, a

text will now appear with an explanation about the update. Then press “Next”.

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Step 1.2 Turn on the Liberty unit

Step 1.3 Choose the Liberty unit that shows in the list (make sure only one unit is powered on).

Press “XX” to start the file transfer.





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Step 1.4 Files are now transferring onto the Liberty unit. When all files are transferred a

message will appear that you have to login on Liberty as a service technician to

complete the software update. The transfer takes about 5-6 minutes.


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2.2.2 Install the software update on Liberty unit

Now that the files are transferred onto the Liberty unit the new software can be installed. This is

done in the following steps:

Step 2.1 Login as Technician in the “Unit Information” menu.

Step 2.2 Scroll down and choose ”Firmware”




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Step 2.3 Choose ”Select firmware” to select which version that should be installed. Normally

you will have two choices, the one that is already installed on the Liberty unit and the new one that

have been transferred in the step 1 in this chapter of the manual.



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Step 2.4 When you have chosen the firmware version you like to install, choose ”Install

firmware”. A message with information about the update procedure will appear.

Press the green check mark to start the installation of the new firmware.




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Step 2.5 The automatic update that starts is done in different steps. It updates the software in

all electrical parts of the Liberty in the following order:

1. PM (Powermodul)

2. BMS (Battery)

3. JUNC (Middlepart)

4. DISPLAY

It takes 5-10 seconds for the update to start on the PM. If the percent counter doesn’t change after

one minute, restart Liberty and try again from step 2.1. The complete update will take about 3-4

minutes.

After the update of the JUNC electronics the Liberty unit will restart automatically. When Liberty

starts up again the firmware for the DISPLAY will be automatically installed.

When the home screen appears the Liberty is ready.


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3. Battery

The battery in Liberty is of Li-ion type and will normally not need any maintenance.

The battery shall be stored in a cool and dry space (a place with a temperature of 10-25 °C ).

If you are planning to not use the Liberty for a longer period of time (one month or

longer) charge the battery to 60-70% before you store it. If the battery is not used for

3 weeks or longer the battery will go into storage mode if the voltage in the battery

is not to high. If the battery has gone into storage mode you have to activate it by

using the charger. Control every 3rd month that the charge level is not to low and

charge to 70-80% if so.

There is no battery indicator on the battery itself. To check the battery status, you have to use the

display of the Liberty. In the status menu for service technician’s information about each cell in the

battery pack, total amount of charge cycles etc. can be obtained.


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4. Fault detection chart

Status Light Mainswitch

Rear Light Sound Check point Action

Screen does not light up when

pressing the main switch.

Off

- No Is the battery charged?

Charge the battery

Off - No Is the battery properly installed in Liberty?

Check that the battery is properly installed.

Off - No Electrical connection between front and middle part of Liberty.

Connect cable connectors with the arrows lined up.

One flash One flash No Control that he cables are properly attached on the backside of the display.

Connect the cables properly on the backside of the display.

Does not respond

when engaging throttle

even though

Liberty is connected

to wheelchair and docked in its upper

position.

On - No Is the locking handle in its lower position?

Press the locking handle to its lower position.

On - No No indication on the display that Liberty is locked against the wheelchair.

Press the locking handle to its lower position.

On - No No indication on the display that Liberty is locked against the wheelchair even though the locking handle is in its lower position.

Repeat pressing the locking handle to its lower position multiple times in a resolute action.

On - No Check that the throttle is properly attached to the backside of the display.

Connect the cable properly on the backside of the display.

On - No Check the connector between the powermodule and motor.

Connect cable connectors with the arrows lined up.


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Status Light Mainswitch

Rear Light Sound Check point Action

Unable to dock

Liberty onto the

wheelchair

- - - Uneven ground. Move Liberty to a more even ground.

- - - The height adjustment of Liberty has changed.

Adjust Liberty and the support leg so that it fits the wheelchair that Liberty will be docked onto.

- - - The lower docking mechanism has been pushed into its locked position.

Press the release handle all the way to release the lower docking mechanism.

Unable to push down the locking handle.

- - - Liberty is not docked and connected to the lower docking mechanism. The front wheels/castors of the wheelchair are still on the ground.

Dock the Liberty properly to the wheelchair so that the front wheels/castor of the wheelchair rises from the ground.

Unable to disconnect Liberty from wheelchair.

- - - Unable to press the release handle.

Move the locking handle to its upper position.

- - - Liberty does not disconnect even though the release handle is pressed to end position.

Adjust/strain the wire at the release handle.

5. Fault codes

Fault code Explanation Action

C6CB N:O1 Communication error powermodule

Control cable between display and powermodule

Restart Liberty on the main switch

If the fault remains, contact the distributor

C6CB N:O2 Communication error BMS/Battery

Control that the battery is properly installed



C6CB N:O3 Communication error Middle part/JUNC

Check the cable connector between front part and middle part of Liberty.




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Fault code Explanation Action

ABBE N:03 Over voltage protection Powermodule



ABBE N:04 General fault Restart Liberty on the main switch.


ABBE N:05 Communication with display was lost but recovered automatically



ABBE N:06 Powermodule overheated Shut of Liberty and wait for 2 minutes

Start Liberty


ABBE N:07 Faulty signals from motor Check that motorcable is not damaged and correctly connected



ABBE N:08 Possible short circuit inside motor detected

Check that motorcable is not damaged



7F42 N:01 Internal fault BMS Restart Liberty on the main switch









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Felkod Felförklaring Åtgärd

2DF1 N:01 Internal fault BMS Restart Liberty on the main switch


2DF1 N:02 Internal fault BMS Restart Liberty on the main switch


2DF1 N:03 Battery hot Liberty can still be used but the motor brake is disabled. Avoid excessive stress to the motor since this can rise the temperature even further

2DF1 N:04 Battery cold Liberty can still be used but the motor brake is disabled

2DF1 N:05 Over voltage protection BMS Restart Liberty on the main switch


2DF1 N:06 Short circuit protection BMS Restart Liberty on the main switch


2DF1 N:07 Battery overvoltage If possible, drive Liberty to lower voltage in battery

2DF1 N:08 Battery undervoltage Charge the battery

2DF1 N:09 BMS unable to activate main voltage. Possible short circuit in Powermodule

Contact the distributor

2DF1 N:10 Battery overheated Move the battery to a cooler location if possible

Wait for 10minutes


2DF1 N:11 Battery to cold Move the battery to a warmer location if possible

Wait for 30minutes


2DF1 N:12 Battery is unbalanced Contact the distributor

1337 N:01 Throttle fault, short circuit potentiometer



1337 N:02 Throttle fault, short circuit in microswitch or faulty throttle settings

Check the throttle settings

Restart Liberty on the main switch.


1337 N:03 Throttle fault, short circuit in microswitch or faulty throttle settings

Check the throttle settings

Restart Liberty on the main switch.



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6. System overview


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Mejl: [email protected]

Service Manual Liberty City/Kids - Camp Mobility

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Transcript of Service Manual Liberty City/Kids - Camp Mobility