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6V VW Type 2 Bus (W487)
Customer Service Guide
MMXV © Copyright RollPlay
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Customer Service Guide
Contents
I) Check Battery …………………………............................................. 3
II) Check Wiring Condition ……………………………..………………………. 6
III) Check Foot Pedal ………………………………………………………..….… 9
…………………………………………..………… 11
…………………………………….. 16
IV) Gearbox Replacement
V) Control Board Replacement
VI) Schematic diagram …………..…………………………………….………..… 18
21 VII) Exploded View .......................................................................
CAUTION : Disconnect the battery before checking
and/or replacing processes
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Customer Service Guide
I) Battery Troubleshooting
Operation: Use a flat head screwdriver, then unlock and remove the seat. Locate thebattery harness, unplug the connector then use a volt-meter to check the red connector on the battery.
Step (1)
Turn and unlock the seat lock
Unlock position
Step (2)
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Customer Service Guide
I) Battery Troubleshooting
Unplug the battery connector (RED) underneath seat
Step (3)
Step (4)
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Customer Service Guide
I) Battery Troubleshooting
Step (5)
Volt Meter Reads: 6.0 V ~ 6.6 V – Good condition
5.6 V ~ 5.9 V – Recharge the battery
5.5 V – Recharge the battery. If after the stipulatedrecharging time voltage has not increased, then the battery needs to be replaced.
Below 5.5 V – Battery needs to be replaced
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Customer Service Guide
II) Check Wiring Connection: Gearbox Troubleshooting
Operation: There are three positions where wiring connections should be checked.
A. Motor/Gearbox : Follow above steps to remove the seat, then locate the gearbox
harness underneath. Disconnect the white connectors, blow air into the connectors, then firmly reconnect them to ensure a complete connection.
Check the white connector of gearbox underneath the seat
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Customer Service Guide
II) Check Wiring Connection: Steering Wheel/Sound Troubleshooting
B. Steering Wheel : Access the steering wheel connector per below procedures.
Step (1)
Use a Phillips screwdriver to remove the steering wheel
Step (2)
Slide the wheel out from steering column, and check the connection
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Customer Service Guide
II) Check Wiring Connection: Dashboard Troubleshooting
C. Dashboard : Access the connectors of the dashboard underneath the vehicle.
Three sets of connectors located underneath the right front wheel
Step (3)
Step (4)
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Check any loose connections of these three plugs
Customer Service Guide
III) Check Foot Pedal
Operation: Follow below procedures to check the foot pedal connection.
Step (1)
Turn over the vehicle and remove the foot pedal
cover by using a flat head screwdriver.
Empty (front)
Step (2)
Brown
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Customer Service Guide
III) Check Foot Pedal
Step (3)
Slide in the foot pedal into chassis from right side
2
Snap back in place
1
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Customer Service Guide
IV) Gearbox Replacement
Operation: Remove the seat first, and then follow below steps to take apart the whole gearbox subassembly and replace.
Step (1)
Unscrew the wiring clip as shown
Unscrew the locking screw for gearbox as shown below
Step (2)
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Customer Service Guide
IV) Gearbox Replacement
Step (3)
Unplug the gearbox connector (white color)
Step (4)
Use a flat head screwdriver to detach the rim cover latches
Right rear wheel only
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Customer Service Guide
IV) Gearbox Replacement
Step (5)
There are four latches as shown
Step (6)
Use a flat head screwdriver to remove the snap pin from axle
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Customer Service Guide
IV) Gearbox Replacement
Step (7)
Slide the rear axle away from the right wheel
Step (8)
Take the rear wheel off from axle
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Customer Service Guide
IV) Gearbox Replacement
Step (9)
Slide the gearbox out from axle
Step (10)
Replace the whole gearbox
sub-assembly with a new one
Reverse the above procedures to re-assemble the vehicle
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Customer Service Guide
V) Control Board Replacement
Operation: Remove the seat, and access the control board underneath.
Step (1)
Unscrew the two screws as shown above to release the control board
Step (2)
Unplug these two white connectors
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Customer Service Guide
V) Control Board Replacement
Step (3)
Unplug the gearbox connector
Step (4)
Replace the control board with
a new one
Reverse the above procedures to re-assemble the vehicle
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Customer Service Guide
VII) Wiring Schematic
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Customer Service Guide
VIII) Exploded View