AYRO VANISH Manuale utente

INTRO

Page 1of 48

Low

Speed Electric Vehicle

SERVICE MANUAL

CONTENTS

Page 2of 48

Table of Contents

1INTRODUCTION................................................................................................................................ 5

1.1 Applicability................................................................................................................................. 5

1.2 AYRO Service Department ........................................................................................................ 5

1.3 For Reference Only..................................................................................................................... 6

1.4 Compliance (NHTSA).................................................................................................................. 6

1.5 Applicability................................................................................................................................. 6

2GENERAL SAFETY.............................................................................................................................. 6

3CABIN .................................................................................................................................................. 7

3.1 Fascia and Trim............................................................................................................................ 7

3.1.1 Middle Front Fascia ............................................................................................................ 7

3.1.2 Upper Fascia ........................................................................................................................ 7

3.1.3 Lower Fascia ........................................................................................................................ 8

3.1.5 Interior Trim ......................................................................................................................... 9

3.1.6 Center Stack ........................................................................................................................ 9

3.1.7 Mirrors................................................................................................................................ 10

3.1.8 Wiper Arm ......................................................................................................................... 11

3.1.9 Wiper Motor assembly..................................................................................................... 11

3.1.10 Wiper Motor/Wiper Mechanism .................................................................................... 12

3.2 Upper Column Cover................................................................................................................ 12

3.2.1 Ignion switch................................................................................................................... 12

3.2.2 Lower dash panel .............................................................................................................. 12

3.3 Body ........................................................................................................................................... 13

3.3.1 Long Side Skirt................................................................................................................... 13

3.3.2 Short Side Skirt.................................................................................................................. 13

3.3.3 Rear Bumper...................................................................................................................... 13

4STEERING SYSTEM.......................................................................................................................... 15

4.1 Electric Power Steering (EPS).................................................................................................. 15

4.2 Rack and Pinion assembly........................................................................................................ 15

4.3 Steering wheel........................................................................................................................... 16

4.4 Steering Gearbox (90 degree).................................................................................................. 16

4.5 Tie Rods ..................................................................................................................................... 17

CONTENTS

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4.6 Alignment................................................................................................................................... 17

5SUSPENSION.................................................................................................................................... 18

5.1 Front ........................................................................................................................................... 18

5.1.1 Upper Control Arm ........................................................................................................... 18

5.1.2 Lower Control Arm ........................................................................................................... 18

5.1.3 Coil-Over Shock ................................................................................................................ 19

5.1.4 Wheel Hub......................................................................................................................... 19

5.2 Rear............................................................................................................................................. 20

5.2.1 Leaf Springs ....................................................................................................................... 20

5.3 Motor Speciﬁcaons ................................................................................................................ 21

6JACK POINTS.................................................................................................................................... 22

7WHEELS/TIRES ................................................................................................................................ 23

7.1 Wheel Removal ......................................................................................................................... 23

1.2 Tire rotaon............................................................................................................................... 23

8BRAKES.............................................................................................................................................. 24

8.1 Verifying Brake Fluid Levels..................................................................................................... 24

8.2 Bleeding ..................................................................................................................................... 24

8.3 Brakes & Rotors ........................................................................................................................ 26

8.3.1 Brake Pads ......................................................................................................................... 26

8.3.2 Rotors ................................................................................................................................. 26

8.3.3 Calipers .............................................................................................................................. 27

8.3.4 Tools, Equipment, Materials:............................................................................................ 27

8.3.5 Removal.............................................................................................................................. 27

9CLIMATE CONTROL SYSTEM ........................................................................................................ 29

9.1 A/C System................................................................................................................................ 29

9.1.1 Compressor ....................................................................................................................... 29

9.1.2 Refrigerant and Fluids ...................................................................................................... 29

9.1.3 Condenser.......................................................................................................................... 29

9.1.4 Manifold and Hoses.......................................................................................................... 30

9.1.5 High/Low pressure switches ........................................................................................... 30

9.2 Heater System........................................................................................................................... 30

9.2.1 Blower Unit........................................................................................................................ 30

CONTENTS

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9.2.2 Heang Element ............................................................................................................... 30

9.3 Common Issues with AC system............................................................................................. 30

10 COOLING SYSTEM ...................................................................................................................... 32

10.1 Radiator...................................................................................................................................... 32

10.1.1 Removal.............................................................................................................................. 33

10.1.2 Installaon ......................................................................................................................... 33

10.1.3 Removal.............................................................................................................................. 34

10.1.4 Installaon ......................................................................................................................... 34

11 Baery Charging & Maintenance................................................................................................ 35

11.1Baery Handling Precauons.................................................................................................. 35

11.2 CHARGING WARNING ........................................................................................................... 35

12 PAYLOAD CONFIGURATIONS................................................................................................... 38

13 DIAGRAMS/LAYOUTS (FUSES, WIRING)................................................................................. 39

13.1 Fuse Box..................................................................................................................................... 39

13.2 Wiring......................................................................................................................................... 40

14 SPARE PARTS LIST ............................................................................................................................ 41

14.1 Baeries and Charging System ............................................................................................... 41

14.2 Body ........................................................................................................................................... 42

14.3 Brakes, Disc ............................................................................................................................... 42

14.4 Coolant System ......................................................................................................................... 44

14.5 Suspension, Front & Rear......................................................................................................... 44

14.7 Wheel End Components.......................................................................................................... 46

14.8 Windshield................................................................................................................................. 46

14.9 Windshield Wiper & Washer system...................................................................................... 46

INTRODUCTION

Page 5of 48

1INTRODUCTION

AYRO designs and produces all-electric vehicles and e-delivery systems that redeﬁne the very

nature of sustainability. We deﬁne sustainability as a ubiquitous construct. From re tread, fuel

cells, sound, and even discordant visuals, we apply engineering and arstry to every element of

our product mix.

Your vehicle(s) reﬂect our company’s commitment to advancing sustainable light electric

soluons, the passion of our leadership to deliver clean energy transportaon, and a beer

environment. These purpose-built and innovave EVs support a plurality of last-mile delivery,

micro distribuon, and campus / facility mobility needs.

The purpose of this Service Manual is to present informaon you require as an authorized

AYRO service representave. This Manual provides the instrucons and guidance needed for

the maintenance or repair of the AYRO Vanish Low Speed Electric Vehicle models (LSV and

Non-LSV).

Once you have read this Service Manual, you will:

•Be able to perform roune maintenance on the vehicle.

•Be able to ﬁnd the informaon needed to service and support the vehicle.

•If so qualiﬁed, be able to perform service and maintenance on the vehicle’s electrical and

baery systems.

1.1 Applicability

This service manual applies to the following Model Years: 2023-2024

Baery Module Conﬁguraon A applies to the following vehicle idenﬁcaon numbers:

4A9AA11U1RR050006

4A9AA11U2RR050001

4A9AA11U3RR050007

4A9AA11U4RR050002

4A9AA11U5RR050008

4A9AA11U6RR050003

4A9AA11U8RR050004

4A9AA11UXRR050005

Baery Module Conﬁguraon B applies to the following vehicle serial numbers and higher:

4A9AA11U7RR050009

1.2 AYRO Service Department

AYRO Service Department

Te l : +1 512.994.4917 Press 1 for Service Department (USA and Internaonal)

Email: su[email protected]

Web: www.AYRO.com

INTRODUCTION

Page 6of 48

1.3 For Reference Only

All informaon contained in this publicaon is based on the latest product informaon available

at the me of publicaon. Product improvements or changes may result in diﬀerences between

this Manual and the vehicle. Descripons, depicons, and/or procedures in this document are

intended for reference only.

No liability can be accepted for omissions or inaccuracies. AYRO, Inc. reserves the right to make

changes at any me, without noce and without incurring any obligaon to make the same or

similar changes to vehicles previously manufactured. Any reprinng or reuse of these

descripons, depicons, and/or procedures, whether in whole or in part, is expressly prohibited.

1.4 Compliance (NHTSA)

This vehicle complies with the U.S. Department of Transportaon Naonal Highway Traﬃc Safety

Administraon (NHTSA) low-speed vehicle regulaons and can be operated on many streets

posted with lower speed limits. Please familiarize yourself with all laws and regulaons

concerning the operaon of the vehicle in your area.

1.5 Applicability

This Manual applies to the following AYRO low-speed electric vehicles:

•AYRO Vanish LSV •AYRO Vanish Non-LSV

2GENERAL SAFETY

•Read your Owner’s Manual before operang this vehicle.

•Do not operate this vehicle under the inﬂuence of alcohol, drugs, or medicaon.

•This vehicle is not intended to be driven at speeds exceeding 25 MPH (40 km/h).

•Never exceed the passenger and cargo limits of this vehicle.

•Avoid sharp turns on inclines and at high speeds (may cause rollover).

•Reduce speed on wet and slippery surfaces and in turns.

•Set the park brake before performing maintenance, service, or leaving the vehicle.

•Remove key when leaving vehicle unaended.

•Stop vehicle before reversing direcon.

•Be aware of small children and objects behind you before reversing direcon.

•ALWAYS DRIVE SAFELY. FAILURE TO FOLLOW THESE WARNINGS COULD RESULT IN

SERIOUS OR FATAL INJURY.

WARNING: The voltage in the battery pack is enough to cause death by

electrocution. Never attempt to perform service on the

electric drive system, including the battery pack, unless you

are properly trained to work on electrical systems.

CABIN

Page 7of 48

3CABIN

3.1 Fascia and Trim

Tools, Equipment, Materials:

•Metric Allen hex wrench

•Metric wrench (typically 10 mm)

3.1.1 Middle Front Fascia

Tools, Equipment, Materials:

•Metric Allen hex wrench (typically 2.5 mm)

•Metric wrench (typically 10 mm)

Removal

1. Remove the two (2) screws from the driver side trim panel using a metric Allen wrench

and remove the panel. Repeat the step on the passenger side.

2. Remove the three (3) bolts that secure the driver side of the fascia to the cab frame using

a wrench. The middle fascia side bracket will come oﬀ as well. Repeat the step on the

passenger side.

3. Pop out the white front fascia.

Installaon

1. Align the middle front fascia with the proper slots for the tabs on the top and boom and

pop the fascia into posion.

2. Using the middle fascia side bracket and three (3) bolts, secure the middle fascia to the

cab frame with a wrench. Repeat the step on the passenger side.

3. Install the driver side trim panel by aligning the tabs on the trim piece with the proper

slots and secure with two (2) screws using a metric Allen wrench.

3.1.2 Upper Fascia

Tools, Equipment, Materials:

•Metric wrench (typically 10 mm)

Removal

1. Remove the middle front fascia (Ref. 3.1.1)

2. Remove the wiper arm (Ref. 3.1.8)

3. Remove the three (3) bolts that secure the upper fascia to the ﬁrewall bracket using a

wrench.

CABIN

Page 8of 48

4. Pop out the upper fascia and remove the windshield sprayer hose from the ﬁng on the

inside of the fascia panel.

Installaon

1. Aach the windshield sprayer hose to the ﬁng on the inside of the panel then insert the

upper fascia into posion by pung the top lip of the fascia under the windshield.

2. Secure the upper fascia to the ﬁrewall bracket with three (3) bolts using a wrench.

3.1.3 Lower Fascia

Tools, Equipment, Materials:

•Metric wrench (typically 10 mm)

Removal

1. Remove the middle front fascia (Ref. 3.1.1)

2. Remove the ﬁve (5) bolts that secure the lower fascia to the ﬁre wall using a wrench.

3. Remove the lower fascia panel.

Installaon

1. Hold the lower fascia in place and secure it to the ﬁrewall using ﬁve (5) bolts and a

wrench.

Figure 1: Firewall locaon of Lower Fascia

CABIN

Page 9of 48

3.1.5 Interior Trim

Removal

1. Remove middle front fascia (Ref. 3.1.1).

2. Remove steering wheel (Ref. 4.3)

3. Remove upper column cover (Ref 3.2)

4. Remove Ignion switch. (Ref. 3.2.1)

5. Remove the four (4) nuts that secure the trim panel to the dash using a wrench; the outer

two (2) nuts have a trim retaining bracket that will need to be removed as well. Secure the

trim retaining brackets while removing the nuts so they do not get lost in the dash.

6. Remove the trim panel and trim insert.

***Process is the same for driver and passenger side interior trim panels***

3.1.6 Center Stack

Tools, Equipment, Materials:

•Metric Allen hex wrench (typically 2.5 mm)

•Metric wrench (typically 10 mm)

Removal

1. Remove the lower dash panel (Ref. 3.2.2).

2. Remove the pop-in cover behind the center stack.

3. Remove the two (2) boom center stack bracket bolts using a metric Allen hex wrench.

(Boom bolts are in the middle of the center stack, behind it, threaded in up towards the

roof of the cab)

4. Remove the top center stack bolts that secure the center stack to the upper dash frame

using a wrench. (The top bolts are visible once the pop-in cover is removed from the back

of the Center stack)

5. Remove the Center stack.

Installaon

1. Hold the center stack in posion and use two (2) bolts to mount the center stack to the

upper dash frame using a wrench.

2. Using a metric Allen wrench install the two (2) boom center stack bolts.

3. Install the pop-in cover behind the center stack.

CABIN

Page 10 of 48

3.1.7 Mirrors

Figure 2: Mirrors with 2 Bolts

Tools, Equipment, Materials:

•Metric Allen hex wrench (typically 6 mm)

Removal

1. Remove magnec cover from the mirror hinge.

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