SEA ISUZU FSR User manual

OWNER’S MANUAL (SEA ISUZU FSR/FSD EV)
SEA Electric Pty Ltd. 13 Advantage Drive Dandenong South, Victoria, Australia 3175.
T/ [phone]. ABN 42 618 821 346.

OWNER’S MANUAL (SEA ISUZU FSR/FSD EV)
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Contents
1. Introduction ........................................................................................................................................3
2. Safety Notices and Safety Instructions ...............................................................................................4
3. Vehicle Layout –Components and Specifications ..............................................................................6
SEA-Drive® layout and components ...................................................................................................7
HV Li-Ion Battery Pods ........................................................................................................................8
4. Controls and Display .........................................................................................................................12
Drive Selector....................................................................................................................................12
Display...............................................................................................................................................13
5- Charging the Traction Batteries........................................................................................................16
Vehicle Charger Connection Socket..................................................................................................18
Disconnecting the Charge Cable .......................................................................................................21
Kwik Portable Charger ......................................................................................................................22
6- Pre-Start Checks................................................................................................................................26
7- Driving the Vehicle............................................................................................................................27
Starting the SEA-Drive® Vehicle........................................................................................................27
Driving the SEA-Drive® Vehicle .........................................................................................................28
Regenerative Braking........................................................................................................................29
8- Parking the Vehicle ...........................................................................................................................30
9- Maintenance.....................................................................................................................................31
Maintenance-free 24V Battery .........................................................................................................33
Fuse Box (FB01).................................................................................................................................35
Relay Box (FB02) ...............................................................................................................................36
10- Inspection and Service Scheduling .................................................................................................37
11- Trouble Shooting Guide..................................................................................................................39
12- Towing Procedure...........................................................................................................................41
Appendix A: Charging Procedure..........................................................................................................42
Charging Procedure (Two-LED Function)..........................................................................................46
Charging Procedure (Alternate Mounting).......................................................................................50
Appendix B: Wall Charger Specs...........................................................................................................54
Appendix C: Emergency Quick Response..............................................................................................55

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1. Introduction
To ensure you are fully aware of safety and operational information, the following symbols are used
throughout this manual;
All information contained in this manual is based on the latest product information available at the
time of printing. We reserve the right to make changes at any time without notice. No part of this
publication may be reproduced or transmitted, in any form by any means; electronic, mechanical,
photocopying, recording or otherwise, without the prior written permission of the publisher. This
includes text, pictures and tables.
To become familiar with the vehicle, it is necessary to read and understand the Owner’s Handbook
and all additional literature that is part of your vehicle’s documentation pack.
It is your responsibility to ensure that all the documentation stays with the vehicle.
This type of box contains points of operation to NOTE
Assumes that incorrect handling may cause hazardous conditions,
resulting in medium or slight injury, or may cause physical damage only.
Assumes that incorrect handling may cause hazardous conditions,
resulting in death or severe injury, or major physical damage.

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2. Safety Notices and Safety Instructions
See Appendix C at the end of manual as Emergency Quick Response Reference.
Electrical Isolation
The SEA-Drive® vehicle is fitted with an automated High Voltage Isolator. The High Voltage Isolator
ensures that high voltage power circuits to the drive motor, inverters and battery management system
are only enabled when the SEA-Drive® vehicle’s ignition switch is in the ON position and EV control
system start-ups checks have been completed successfully.
High Voltage Isolation
As an override to the automated High Voltage Isolation system in the SEA-Drive® vehicle, isolating the
SEA-Drive® vehicle’s low voltage battery system will prevent the EV control system from powering up
and ensuring the High Voltage system remains isolated (refer below).
Low Voltage Isolation
The Low Voltage Isolation switch is located next to the low voltage batteries (Position of the
batteries is based on the truck chassis).
Never attempt to open a battery pack. This vehicle uses a battery pack
that operates at 450 volts DC.
Never attempt to remove, unplug or cut any of the ORANGE marked
cables or conduit. Orange marked cable carry high voltage.
Only authorised personnel are allowed to work on electrical power
and/or control systems.
DO NOT carry out any welding or other dirty works like grinding, etc. on the
vehicle without permission from SEA-Electric. Otherwise serious damage can be
caused to the drive train and the electronic control systems.

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The power from the traction batteries can be isolated by following this procedure:
1. Remove the ignition key.
2. Turn the 24V isolator switch to its vertical position.
24V Battery System Isolation Switch
Loss of Electrical Power during Operation
If the SEA-Drive® vehicle was to lose electrical power while the vehicle is in motion, the steering will
become stiff and the vehicle will continue to roll. The regenerative braking system will not assist
braking. Use of the park brake will affect braking on the rear wheels only.
IMPORTANT!! The traction battery pods will remain charged, even when switched off!
The battery pods will remain charged, even when switched off.
The leads and connectors on the pods will not be live if the pods are switched off.

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3. Vehicle Layout –Components and Specifications
Motor
SEA-Drive® 120b, 150kW Continuous, AC Permanent Magnet Motor.
Controller
Torque control system providing variable speed drive with regenerative braking.
Batteries
136kWh, Lithium Ion NMC
Charger
Fully automatic, on-board 415V, 3-phase, 32A, 22kW maximum charge,
approximately 6 hours (IEC 62196 Charging Protocol).
Ancillary
Electrics
3kW 24V DCDC Converter
Range
Up to 300km between charges (unladen)
The location and layout of the SEA-Drive® vehicle and its SEA-Drive® components are shown as below.

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SEA-Drive® layout and components
Components shown on below figure, may have been modified and improved in position on the chassis
based on different variations.
Overall Chassis Layout
WARNING:
The EV Component Box contains many of the HV Electrical components
and wiring for the SEA-Drive® system.
It should only be opened by SEA-Drive® technicians or qualified Electrical
tradespersons.
•Drive motor
•Cooling Box
•Air compressor
& Power Steering unit
•EV Component box
•Drive Motor Controller
•
SEA Power Li-Ion Batteries
•Cab Heater

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HV Li-Ion Battery Pods
Notice
At the end of their useful life, the high voltage batteries will be traded/exchanged with new high
voltage batteries, resulting in the depleted high voltage batteries being returned to the manufacturer
for secondary use. This process may incur shipping, handling and tax costs, and will be facilitated by
SEA Electric at the time of replacement.

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EV Component Box
•AC Compressor
•HV Distribution Box
•On-board Charger
•Charger Cable Connector
•Fuse Box
•Inverter

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Air Compressor and Power Steering Systems
Drive Motor Controller

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Cooling System

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4. Controls and Display
Drive Selector
The vehicle drive mode control in one of the two variations below is located next to the driver's seat
in the middle console.
Drive Mode Selector (1)
•3 position Lever to select Drive mode
•NEUTRAL –Middle Position
•Select when Parking/Stopping
•Vehicle must be in this position to start
•DRIVE –Push Lever forward to select DRIVE
•Select for Forward operating motion
•REVERSE –Pull Lever back to select REVERSE
•Select for Reversing operating motion
Drive Mode Selector
Drive Mode Selector (2)
•3 position Lever to select Drive mode
•NEUTRAL –Middle Position
•Select when Parking/Stopping
•Vehicle must be in this position to start
•DRIVE –Push Lever back to select DRIVE
•Select for Forward operating motion
•REVERSE –Pull Lever forward to select REVERSE
•Select for Reversing operating motion
Drive Mode Selector

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Display
Drive Mode
Battery State of Charge (%SOC)
Indicated by the bar & numerical
percentage. Battery percentage is
indicative only. Drivers should return to a
charge port when vehicle is near 5%
Speedometer
Vehicle speed is shown as a digital
read out
ECO Meter
Meter shows the amount of power
being drawn or added back into the
High Voltage battery. Acceleration will
cause meter to ascend in RED.
Regenerative Braking will cause the
meter to descend in GREEN
Estimated Range
Figure shows estimated travel distance until
vehicle is needing to be recharged. Figure is
indicative only and driver should not plan trip
based on figure. Estimated range remaining will
vary depending on many factors such as driving
style, geography (hills), temperature and more

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Drive Mode
Vehicle State
Indicates if the vehicle is drive
ready. Other states are ACC
(accessory) and OFF
Selected Gear
Shows if the park brake is active and will turn red
if the park brake is on when trying to drive. States
shown are D (Drive), N (Neutral), R (Reverse)
Regen Active
Shows when regenerative braking is
available (White) and when Regenerative
braking is being applied (Green)
Vehicle Fault Indicators
Various Symbols will appear in the event
of a system fault/failure. A reference of
each fault can be found by tapping the
centre of the screen. SEA 24/7 Support is
also listed in this menu

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Charging Mode
32A
Charge Speed
Charge current supplied by the
in-cord charger
Battery State of Charge (%SOC)
Indicated by the bar & numerical
percentage. Battery percentage is indicative
only. Drivers should return to a charge port
when vehicle is near 5%

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5- Charging the Traction Batteries
Specification of Charge Facility:
•IEC 62196 Mode 2/3 Charging
•32A, 400VAC
•3-phase with neutral and earth
•22kW
Warning
➢Portable charger should not be left somewhere exposed to moisture due to no completely sealing cap
on the connector part.
➢If moisture remains on the connector of EVSE (Electric Vehicle Supply Equipment), it may cause fuse
trip as well as charger damage.
➢Charger equipment should be kept into the isolated box or in the CAB.
The SEA-Drive® vehicle is recharged by connecting the approved wall or portable charger to the truck
charging point.
See Appendix B at the end of manual as SEA-Drive® wall charger requirements.
•Park the vehicle safely within reach of a wall socket with the above specification.
•Turn the ignition key to the OFF position.
•Connect the charge cable between the vehicle and the EVSE.
•EVSE will switch on automatically and the charger cable will be locked in the charge socket.
Connector of EVSE

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➢EVSE IEC 62196 equipment maintains a safety circuit between the mains (3-phase) supply
and the vehicle.
➢If this circuit is broken, the mains supply is automatically isolated at the mains for the
protection of all.
EV Charger Connection on Component Box
•Charger Cable Connector

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Vehicle Charger Connection Socket
Vehicle Charger Connection Socket
(Type1)
Type1 –Version1 (One LED Status Light)
The SEA-Drive®Electric Vehicle On-Board Charging socket has anLED status light that illuminates when
the charge cable is connected. See the following descriptions of the LED Status light for correct
operation:
LED Colour
Description
Red
Cable is connected but no mains power supply detected
Check Mains Power Supply availability and circuits
Yellow or
Light green
Cable is connected
SEA-Drive® vehicle is charging
Green
Cable is connected
Batteries are fully charged
Note:
1. Once full charge is reached, the SEA-Drive® system automatically shuts
down to stop any residual load on the battery systems.
2. Green LED is extinguished.
3. SEA-Drive® system periodically checks that battery system charge
remains at 100%. If remaining charge is detected as less than 100%,
charging system restarts to charge SEA-Drive® batteries to 100%.
Unlit
Cable is not properly connected
Check Cable connector is fully engaged in socket

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Type1 –Version2 (Two LED Status Lights)
The SEA-Drive® Electric Vehicle On-Board Charging socket has two LED status lights that illuminate
when the vehicle is plugged in to charge.
The two LED’s show different functions of the vehicle:
Left LED: White LED, indicates if the charger is locked in place (Illuminated White when locked).
NOTE: The charger will not activate until the charge inlet is locked. If the charger does not lock
properly, check the position and status of the in-cord charger.
Right LED: Multicolour LED, shows the state of the charger.
See the following descriptions of the right LED for correct operation:
Right LED Colour
Description
SOLID Red
Cable is connected but no mains power supply detected.
Check Mains Power Supply availability and circuits.
FLASHING Green
Cable is connected.
SEA-Drive® vehicle is charging.
SOLID Green
Cable is connected.
Batteries are fully charged.
Note:
1. Once full charge is reached, the SEA-Drive® system automatically shuts
down to stop any residual load on the battery systems.
2. Green LED is extinguished.
3. SEA-Drive® system periodically checks that battery system charge remains
at 100%. If remaining charge is detected as less than 100%, charging system
restarts to charge SEA-Drive® batteries to 100%.
Unlit
(When plugging in)
Cable is not properly connected.
Check Cable connector is fully engaged in socket.
Charge Cable is not turned on that the wall.
Unlit
(After Charge Complete)
Vehicle will deactivate the LED’s some time after charge has been
completed. This is to prevent any power drain of the low voltage batteries.

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Vehicle Charger Connection Socket (Type2)
LED Colour
Description
Red - Solid
Fault Detected –Charge system has detected a fault. Disconnect the
charger from vehicle using the correct procedure. Contact SEA Electric
24/7 Support
Red - Flashing
Standby Mode - Charge cable is detected but no mains power is being
supplied. Vehicle is setting up charge mode in this state and may take up
to 5 seconds to engage
Green - Flashing
Charge Mode –Vehicle has engaged the charging circuits. Vehicle is using
power from the wall to charge the high voltage batteries.
Green - Solid
Charge Complete –Vehicle charge cycle has been complete. The charge
inlet LED will extinguish after some time
Note:
4. Once full charge is reached, the SEA Drive system automatically shuts
down to stop any residual load on the battery systems.
5. Green LED is extinguished.
6. If SEA-Drive® system remains plugged in after completing charge, the
SEA-Drive® charge circuits will periodically energize to battery cells
further.
Unlit –Directly
after plugging in
Cable is not detected, check the charge cord is properly connected to
wall and power is switched on. Check the vehicle is not isolated by
inspecting the RED Isolator Switch
NOTE: When the charging cable is plugged into the vehicle, the SEA-Drive® Electric vehicle will be
unable to drive. Before attempting to drive, please disconnect the charging cable according to the
following procedure.