___System ___Subsystem _X_Component: 36 volt cars Model Year/Vehicle(s): 2002 / 36 VOLT SYS Core Team: Item Potential Failure

Mode Function Terminate Connections Can not handle power requirements Large Voltage drop Loss of continuity Fire, large voltage drop Loss of power and failure to start Large voltage drop Potential Effect(s) of Failure S e v C l a s s

Potential Failure Mode and Effects Analysis (Design FMEA)

Design Responsibility: Thoms J Dougherty Key Date: Jan 1, 2001

FMEA Number: AL-11 Page 1 of 1 Prepared by: Thomas J Dougherty / 414-228-2357 / Design FMEA Date (Orig.): 1999.04.19 (Rev.): 1999.04.19

Potential Cause(s)/ Mechanism(s) Failure Terminals too small. Improperly sized Too small. Corrossion. Bad contact Week or bad connection from the wire to the connector Improper connection. Unable to connect to terminal. Will not engage

O c c u r

Current Design Controls Test at max rating. Time requirement for testing. Test at max rating and pass through salt spray test. Crimp and solder the connection. Silver solder Robust, and sized for durabiility. Develop test to determine if it can withstand being run over by a car. Polarized connections with color coding. Manditory connections for all jump start terminals. New Standard needed Design contacts to be covered by plastic. Wire should have stress relieve termination. Terminal contacts to have ability to with stand many repeated make/break connections Must check out with different voltage and different state of charge batteries. Wrong voltage system will cause fues to blow, but Fuse to be sized to handle current surge from low state of charge battery. Relay to be used in place of fuse system. Indicator (buzzer or light) that tells that the unit is working.

D e t e c

A c t i o n R. P. N. Recommended Action(s) Responsibility & Target Completion Date Actions Taken

R e s u l t s S e v O c c D e t R. P. N.

Dammaged connectors Poor connection and high voltage drop

Wrong Polarity

Short circuit

Connect to wrong terminal for jump start

Contacts or wire Short Circuit making contact with opposite polarity Repeated connections Increased voltage drop leading to no start

Exposed contacts or wire

Contacts lossing connection capability.

Handle all types of voltage connections

Wrong voltage connection

Short circuit and possible fire

Unique termination and polorized connections. Fuse or solid state connection. Also, the use of relay suggested. Low state of charge battery or wrong voltage system

Short circuit and different voltage. Also reverse voltage connection

JCI now starting testing. 42-42 volts testing May 21. Short Circuit test June 15.

Large current surge Loss of fuse or solid state due to low battery device

No continutity. power

No No jump start capability

Blown fuse or bad electronic device or relay

Printed on: 1999.04.20 12:57:38 Filename: Cables to reach cars Loss of voltage No power for jump start Produced Cables to by small FMEAplus in wire for Windows size v4.1 Size and length to handle current and/or recommendation for vehicle C:\WINNT\PROFILES\ADMINI~1\DESKTOP\CONSOR~1\RU#5-C~1\C:\EUDORA\ATTACH\JUMP36V.FME wire length to long use. Should be sized for maximum size vehicle requirement.

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