mercedes benz gl (w488ac) customer service...

Mercedes Benz GL (W488AC)Customer Service Guide

MMXIII © Copyright Aria Child Inc.

2

Customer Service Guide

Contents

I) Check Battery …………………………............................................. 3

II) Check Wiring Condition ……………………………..………………………. 5

III) Check Foot Pedal ………………………………………………………….….... 12

IV) Gearbox Replacement …………………………………………..…………… 14

V) Door Replacement .…………………………………..…….……..….………. 17

VI) Motor Control Board Replacement .….………..…….……..….………. 19

VII) Headlight Replacement .….……………………...…….……..….………. 21

VIII) Schematic diagram ……………..…………….…..….………..……………. 22

IX) Exploded View …………..………………..…....….……….……..…….…… 23

CAUTION : Disconnect the battery before proceeding.

3


I) Check Battery

Operation: Using a Flat head screwdriver, unlock and remove the seat. Locate the batteryharness, unplug the connector, and use a volt-meter to check battery condition

at battery side.

Step (1)

Turn and unlock this plastic knob according to the icon

Step (2)

Unplug the battery connector (red) by holding down the small clip and pulling apart.

4


I) Check Battery

Step (3)

Voltage Reading: 6.0 V ~ 6.5 V – Good condition

5.6 V ~ 5.9 V – Proceed to Recharge

5.5 V – Battery to be recharged if after the stipulated recharging time, voltage has not increased, the Battery needs replacement

Below 5.5 V – Battery needs replacement

5


II) Check Wiring Connection

Operation: There are four positions of connections to check.

A. Motor/Gearbox : Remove seat per instructions above (Point I), locate the Gearbox harness underneath

Check the gearbox connector (white). Disconnect by pressing small clip and pulling apart, then push firmly back together.

6



B. Motor Control Board : Remove seat as per instructions above (Point I), locate andaccess the Motor Control Board just next to the rechargeable battery.

There is a WHITE plug (4-pin) on the motor control

board, ensure that all four wires are properly connected.

7



C. Dashboard : Remove the Steering Wheel and Dashboard to check the connection.

Step (1)

Unscrew then pull up & out to remove steering wheel

Step (2)

Next, unscrew these two screws to remove the dashboard

8



Step (3)

Pull up & out to remove the dashboard and windshield together as one unit.

Step (4)

Check the 4-Pin plug

9



D. Shifter : Follow steps above to remove the Dashboard, then check the connectionof Shifter and Main Power Switch as well.

Step (1)

Unplug this connector

Step (2)

Unscrew these four screws to remove the Windshield

10



Step (3)

Unscrew these four screws

Step (4)

Lift up the bottom plate to access the switch for Shifter & Power

11



Shifter

Step (5)

Main Power Switch

Step (6)

Empty blade

(the one far away from shifter)

Red wire

Orange wire

Blue Pink Yellow

Top Bottom

Reverse above procedures to re-assemble the vehicle

12


III) Check Foot Pedal

Operation: Follow below procedures to check the Foot Pedal connection.

Step (1)

Turn over the vehicle and push on the smaller lip to loosen the pedal

Empty (front)

Step (2)

Pink (middle)

Pink (rear)

13


III) Check Foot Pedal

Step (3)

Slide the Foot Pedal into Chassis from right side

①

②

Press it down in place

14


IV) Gearbox Replacement

Operation: Follow below steps to inspect the gearbox or remove for replacement.

Use a flat head screwdriver to remove the hub cap

(Rear right/ passenger side wheel only)

Step (1)

Step (2)

Use the flat head screwdriver to remove

the snap-pin from axle as shown

15



Step (3)

Slide the rear wheel off of axle

Follow above (Point IIB) to access the Motor harness underneath

the seat, then unplug it before removing the gearbox

Step (4)

16



Step (5)

Slide the gearbox out from axle

Step (6) Replace easily by sliding the new gearbox onto the axle. Fit the gray cylinder through the hold and plug in the white connectors.


17


V) Door Replacement

Operation: Follow above (Point IIC) to remove the Dashboard first and replace the Car Door by below steps.

Step (1)

Unscrew these two screws on hinge and release the whole door

Step (2)

Lift up the car door to remove

18


V) Door Replacement

Easy steps to replace the whole Car Door Assembly completely

Step (3)


19


VI) Motor Control Board Replacement

Operation: Follow above (Point I) to remove the seat first and replace the Motor Control Board (MCB) by below steps.

Unscrew these two washerscrews on MCB

Step (1)

Step (2)

Unplug these three connectors

20


VI) Motor Control Board Replacement

Step (3)

Easy to replace the whole MCB by simple steps


No connection needed at that 2-Pin connector

21


VII) Headlight Replacement

Operation: Follow below steps to remove and replace the Headlight.

Turn over the vehicle to access and unscrew the headlight washerscrew

Step (1)

Use a flat head screwdriver to release the two latch locks

Step (2)

Then replace the Headlight Assembly with new one


22


VIII) Wiring Schematic

23


IX) Expanded View

mercedes benz gl (w488ac) customer service...

Documents