Golf Cart Manual - citEcar Electric Vehicles
Contents
1. cit car citEcar Street Legal Golf Cart Owner s Manual Sold and Distributed by citEcar LLC www citEcarEV com Phone 866 542 8677 Fax 843 556 4080 Preface Thanks for purchasing a citEcar electric vehicle This manual contains information for proper operating maintaining and caring of your electric vehicle A thorough understanding of this manual will help you to obtain maximum enjoyment from this electric vehicle Please keep it properly stored for future reference Important Information Particularly important information is distinguished by the following notations WARNING Failure to follow Warning instructions could result in severe injury to the vehicle occupants bystanders or persons inspecting or repairing the vehicle CAUTION Failure to follow Caution instructions could cause damage to the vehicle Special Notices Because the seat amp backrest wrapping film may stick to the seat vinyl and cause seat vinyl to become stained please remove the seat amp backrest wrapping film when you receive the vehicle INDEX Te OVV EW ania a bbe ceusetanetencacelioatoahertoes ieee eames 4 2an CONTO Ses cnt ern aa cass neta eiead aaa ce eaten a eae E dain 6 Oe ODGANONS seii teed Seedact Atos days wanaunannadensensieemeasadded id ecaaedameous dear eate 11 A Sale ODerallOnlNSiUCniOnSs csiaiscocttestse dvese tice dacetaast aE deco testsaad cas dee ccs aa 12 Di MAING NAN O osen cumbia tut uatuacutiameie 13 52. Before using the charger please check to see if the battery charger you are getting is correctly rated as per your local AC electricity network WARNING When using a new battery make sure the new battery is per the same specifications as the original one and is appropriate in application Following are the charging steps e Turn the power key to OFF e Connect the plug to the vehicle receptacle first then connect it to your local AC power outlet WARNING Do not disconnect the cord from the battery receptacle when the charger is ON otherwise an arc could occur which may cause an explosion Always disconnect the battery receptacle first then disconnect from the AC power outlet The charger will turn off automatically when the battery is charged fully 16 WARNING The battery receptacle is combined with a security switch which can cut off the power of the vehicle when the battery is being charged so the vehicle cannot be started as long as the battery receptacle is plugged in 1 After the charger turns off disconnect the plug on the AC charging cable from the AC power outlet first and then disconnect the cord from the vehicle receptacle It is prohibited to open the housing of the charger Only a qualified technician is allowed to open the housing of the charger The charger should be stored in a safe and dry room with good ventilation The charger should be packed properly if not used for a long time Read the operation m
3. after a full charge means you will not have to worry about the water level at a different state of charge Depending on the local climate charging methods and application etc Trojan recommends that the batteries be checked once a month until you get a feeling for how thirsty your batteries are Important things to remember 1 Do not let the plates get exposed in the air This will damage corrode the plates 2 Do not fill the water to the cap This most likely will cause the battery to overflow acid consequently losing Capacity and causing a corrosive mess 3 Do not use water with a high mineral content Use distilled water only CAUTION The electrolyte is a solution of acid and water so skin contact should be avoided Step by step watering procedure Open the vent caps and look inside the filling wells Check the electrolyte level the minimum level is at the top of the plates If necessary add just enough water to cover the plates once Put batteries on a complete charge before adding water refer to the Charging section Once charging is completed open the vent caps and look inside the fill wells Add water until the electrolyte level is 1 8 below the bottom of the fill well Apiece of rubber can safely be used as a dipstick to help determine the water level Clean replace and tighten all vent caps WARNING Never add acid into the battery CONOR ON 6 TESTING Visual inspection alone is not
4. blind areas or in any dangerous conditions Always fasten the safety belt properly before the vehicle moves under the following instructions 1 Be certain the seat belts are latched securely and are free from any twists 2 Position the shoulder belt across the top of the shoulder Do not place the shoulder belt under an arm 3 Loose fitting safety belts significantly reduce protection Keep belts snug and positioned low on the hips 4 Do not exceed the recommended number of occupants for the vehicle 5 Bench seats are designed for two occupants only WHILE OPERATING THE VEHICLE Keep your entire body inside the vehicle keep seated and hold on while the vehicle is moving Do not start the vehicle until all occupants are securely seated Keep your hands on the steering wheel and your eyes on the path you are going Always back up slowly and watch the back carefully Avoid starting or stopping suddenly Avoid turning the steering wheel too sharply at high speed Always drive slowly up or down any incline Do not make any modifications or additions which may affect the capacity or safety of the vehicle Children are not allowed to play in the vehicle Children should be seated between adults and protected by them when the vehicle is moving 12 5 Maintenance Users should perform regular maintenance to ensure the vehicle is in good performance 5 1 Maintenance of the Batteries NOTE Our standard vehicles are equipped with deep cyc
5. down _ gt Step down Mechanical Brake Hydraulic Brake Parking Brake Pedal The parking brake is used for braking while parking The parking brake of the mechanical brake system is different from hydraulic brake system The parking brake of the mechanical brake system is engaged by your foot as shown in above picture refer to Mechanical Brake The parking brake of the hydraulic brake system is engaged by your hand as shown in the picture below refer to Hand Brake The parking brake should be engaged into parking position whenever the vehicle is left unattended Never drive with the parking brake engaged WARNING The foot parking brake will automatically release when the accelerator pedal is stepped down If the power key is in ON position stepping down the accelerator pedal may suddenly cause the vehicle to move How to engage and disengage the parking brake For Mechanical Brake System a Hand Brake e To engage the parking brake step down the service brake pedal to the end by lower parts of the foot and then press down the parking brake pedal by the upper parts of the foot until it s hooked NOTE If the parking brake pedal fails to be locked in the lock position please repeat above procedure until it is locked e To disengage the parking brake step down the service brake pedal to the end until the parking brake pedal is unhooked released How to engage and disengage the parking brake For Hyd
6. sufficient to determine the overall health of the battery Both open circuit voltage and specific gravity readings can give a good indication of the battery s charge level life span and health Routine voltage and gravity checks will not only show the state of charge but also help spot signs of improper care such as undercharging and over watering and possibly even locating a bad or weak battery The following steps outline how to properly perform routine voltage and specific gravity testing on batteries I Specific Gravity Test Flooded batteries only Do not add water Fill and drain the hydrometer 2 to 4 times before pulling out a sample There should be enough sample electrolyte in the hydrometer to completely support the float Take a reading record and return the electrolyte back to the cell To check another cell repeat the 3 steps above Check all cells in the battery Replace the vent caps and wipe off any electrolyte that might have been spilled Correct the readings to 80 F Add 004 to readings for every 10 above 80 F Subtract 004 for every 10 below 80 F 9 Compare the readings 10 Check the state of charge using Table 1 shown on next page CONOR WND 14 emperature Hydrometer Reading G F fy US Trojan 43 120 L254 1 252 TESINE 4 258 1 250 a7 10S 1 262 1 256 2 0S 4 266 1 253 zm M5 1 270 1 250 el 70 i274 1 247 i5 aa 278 1244 10 TME _ 1282 iJi 05 3 1286 1238 0 39 1
7. the power key otherwise the vehicle may suddenly start moving b With the park brake applied press the Forward Reverse switch and lock it in the desired position CAUTION Do not shift from Forward f to Reverse 4 while the vehicle is moving c Make sure that your path is clear in your direction If the vehicle is equipped with mechanical brake system depress the lower section of the brake pedal to release the park brake slowly step down the accelerator pedal it will start to move If the vehicle is equipped with hydraulic brake system with hand brake release the hand brake first before you step down the accelerator pedal 11 CAUTION If the vehicle is equipped with the mechanical brake system depressing the accelerator pedal will release the parking brake if it s engaged Depressing the accelerator pedal is not the preferred method of releasing the parking brake Depressing the lower section of the brake pedal is the preferred method of releasing the parking brake to assure the longest service life of brake components If the key switch is ON and the parking brake is set depressing the accelerator will release the parking brake and cause the vehicle to move which could cause severe injury or death CAUTION If the accelerator pedal is stepped down before the power key is on the vehicle will not run In this case you should release the accelerator pedal first and then turn the power key ON then step down the accelerato
8. 290 1235 e The readings should be at or above the factory specification of 1 277 007 If any specific gravity readings register low then follow the steps below 1 Check and record voltage level s 2 Put battery s on a complete charge 3 Take specific gravity readings again e If any specific gravity readings still register low then follow the steps below 1 Check voltage level s 2 Perform equalization charge Refer to the Equalizing section for the proper procedure 3 Take specific gravity readings again e lf any specific gravity reading still registers lower than the factory specification of 1 277 007 then one or more of the following conditions may exist 1 The battery is old and approaching the end ot its life 2 The battery was left in a state of discharge too long 3 Electrolyte was lost due to spillage or overflow 4 Aweak or bad cell is developing 5 Battery was watered excessively previous to testing Batteries in conditions 1 4 should be taken to a specialist for further evaluation or retired from service ll Open Circuit Voltage Test For accurate voltage readings batteries must remain idle no charging no discharging for at least 6hrs preferably 24 hrs 1 Disconnect all loads from the batteries 2 Measure the voltage by a DC voltmeter 3 Check the state of charge with Table 1 4 Charge the battery if it registers 0 to 70 charged lf the battery value is lower than that in Table 1 the followi
9. N position Forward Reverse switch This is a three position switch pressing the upper part gets the vehicle moving forwards while pressing the lower part gets the vehicle moving backwards and the middle is neutral WARNING This switch must be fully pressed into the proper position or the electric system and motor will be damaged NOTE The buzzer will beep when the lower part of this switch is depressed to warn any people around your vehicle Accelerator pedal The accelerator pedal is used to control the speed when driving Push it down slowly to increase the speed The vehicle will soeed up with the gradual stepping down on the accelerator pedal eventually reaching the full soeed when the pedal is stepped down to the bottom The vehicle slows down with the lifting of the pedal When the pedal is fully lifted the electric brake will start to work and the vehicle will stop Service Brake pedal The service brake pedal is used for braking The shapes of the service brake pedal of the mechanical brake system and hydraulic brake system are different Please have a look at the picture of those two types of service brake pedals below refer to pictures of Mechanical Brake and Hydraulic Brake NOTE On the mechanical brake system the service brake pedal is combined with the parking brake pedal Parking Brake Pedal Service i l g Brake Service ay gt Brake m 5 s Pedal Pedal Step
10. OIL Missing aux brake relay FAULT ail 1 Aux coil open or not connected MAIN DRIVER Main contactor driver held 1 Main contactor coil shorted OFF high 2 Controller defective 2 MAIN WELDED Main contactor welded 1 Main contactor stuck closed 2 Main contactor driver shorted 3 3 PRECHARGE Internal voltage too low at 1 External short or leakage path to B is FAULT startup on external B connection J 2 Controller defective 4 FIELD MISSING Field winding fault 1 Motor field wiring loose 2 Motor field wiring open 5 AUX DRIVER Aux brake relay driver held 1 Aux coil shorted OFF high 2 Controller defective 1 CURRENT Armature or field current 1 Controller defective SENSE FAULT sensor fault 2 DRIVER Contactor driver or aux driver OVERCURRENT 1 Contactor or aux coil shorted M SHORTED Internal M short to B 1 Controller defective 4 4 ane RELAY Aux relay did not close 1 Aux relay missing or wire to coil open 5 WELDED AUX Welded aux relay 1 Aux relay stuck closed RELAY 2 Aux relay shorted 5 1 KEY SWITCH SRO fault 1 Key switch not off at power up SRO 2 Key switch shorted 5 2 MAIN COIL Missing the contactor 1 Main contactor coil open or not OPEN connected oF AUX DRIVER Aux EM brake or 1 Aux output short to ground ON WalkAway relay dri il h ae itd a ania C0 2 Controller defective 9 3 4 CIRCUIT BRKR Circuit breaker or fuse open in 1 Breaker fuse tripped or open OPEN WalkAwa
11. RUN switch is located under the seat on the passenger side either on the controller cover or just under the rear body as shown in the picture below Toll er Co Vi er Tow Run Switc O PEA NOTE When the TOW RUN switch is on the RUN position the vehicle will beep when you push the vehicle to remind you Pushing or towing the vehicle while in the RUN position will burn up the motor and electrical components of your vehicle This is a major fire hazard WARNING Whenever the TOW RUN switch is moved from the RUN position to the TOW position please be sure to move it back to the RUN position there will be a delay of approximately 30 seconds before the vehicle will run TURN SIGNAL HORN SWITCH Push forward This switch is used to switch the turn signal and horn on off 1 Pull back the handle lever to activate the horn 2 Push up the handle lever to activate the right turn signal lt lt 3 Pull down the handle lever to activate the left turn signal HEADLIGHT SWITCH Pull out the button on the right side to switch on the headlight Pull down 3 Operation STARTING a With the Forward Reverse switch in the Neutral position turn the power key to the ON position CAUTION The car will not run if you press down the F R switch to Forward or Reverse position before turning the power key if equipped with AC power system WARNING Do not step down the accelerator pedal when turning on
12. anual for the charger carefully follow all detailed operation instructions oe Equalizing charge Equalizing is an over charge performed on flooded lead acid batteries after they have been fully charged It reverses the buildup of negative chemical effects like stratification a condition where acid concentration is greater at the bottom of the battery than at the top Equalizing also helps to remove sulfate crystals that might have built up on the plates If left unchecked this build up which is called Sulfation will reduce the overall capacity of the battery The charger will automatically start the equalizing charge after 30 times of charging if it remains connected from the grid and battery after the battery is charged fully Equalizing is recommended when low or wide ranging specific gravity 015 is detected after fully charging a battery 5 2 Operation and Maintenance of Charger Note As standard configuration the charger is built in the vehicle in some cases it may not be built in the vehicle If it s built in the vehicle the position of the charger is either under the front seat or the bag well The procedure to use the charger when the charger is built in on the vehicle 1 Connect the cord to the receptacle on the vehicle if not already attached 2 Connect the cord to the receptacle to the outlet of household grid 3 After the charger cord is connected the red indicator on the charger will flash the charger sta
13. carefully checked Faults such as high temperature may be caused by operator habits or by overloading After a problem has been diagnosed and corrected it is a good idea to clear the fault history file This allows the controller to accumulate a new file of faults By checking the new history file at a later date you can readily determine whether the problem was in deed fixed Or checking the problems according to the flashing of the STATUS light on the top of the controller Please refer to the details mentioned in our service manual which is available separately Please contact your local dealer or a qualified technician electrician to work on the problems related to the motor controller or electrical system of the vehicle when you are not able to fix them 5 5 Diagnostics and Troubleshooting The 1268 controller provides diagnostics information to assist technicians in troubleshooting the drive system problems This information is displayed on the handheld programmer or PC Programming Station and it is also available in the form of fault codes issued by the controller s built in Status LED and the optional remote LED driven by the controller s external LED output Refer to the troubleshooting chart for suggestions covering a wide range of possible faults PROGRAMMER DIAGNOSTICS The programmer presents complete diagnostic information in plain language Faults are displayed in the Faults menu see column 2 in the Troubleshooting Chart and
14. condition Please check every week on whether any battery cable terminals or nuts have become loose in order to prevent any spark or damage to terminals Please check every week whether any battery cable is damaged or not any damaged battery cable should be replaced immediately 3 NO FOREIGN MATTER Do not place any objects on the battery and do not connect the positive pole to the negative pole This may cause a short circuit dangerous spark or may cause damage to the battery or injury to the user 4 RECHARGING a As long as you use the vehicle regardless of how long you have used it the battery should be recharged fully on the same day Any delay on the re charging will cause a negative effect on the battery Note the lead acid battery does not develop a memory so it doesn t need to be fully discharged before recharging b If the vehicle is going to be unused for a long time the battery should be fully recharged first After that the battery should be fully recharged every 2 weeks or better yet leave the charger plugged in c When driving the driver shall be always aware of the drop level of the battery power from the battery power meter any drop means the battery power is diminishing Besides the driver should estimate the distance needed to be taken and recharge the battery at a proper time in case that the vehicle cannot get back to the recharging station in time for recharging WARNING Please make sure the battery is recharged b
15. dify the controller Doing so may damage the controller and will void the warranty Cleaning It is recommended that the controller be kept clean and dry and that its fault history file be checked and cleared periodically Periodically cleaning the controller exterior will help protect it against corrosion and possible electrical control problems created by the dirt grime and chemicals that are part of the operating environment and that normally exist in battery powered systems Please use the following cleaning procedure for routine maintenance 1 Turn the power key to OFF position 2 Remove power by disconnecting the battery 3 Discharge the capacitors in the controller by connecting a load such as a contactor coil or a horn across the controller s B and B terminals 4 Remove any dirt or corrosion from the connector areas The controller should be wiped clean with moist rag Dry it before reconnecting the battery The controller should not be subjected to pressured water flow from either a standard hose or a power washer 5 Make sure the connections are tight but do not over tighten them Faulty History File The handheld programmer purchased separately can be used to access the controller s fault history file The programmer will read out all the faults the controller has experienced since the last time the history file was cleared Faults such as contactor faults may be the result of loose wires contactor wiring should be
16. e commutating copper and the armature coil 3 The commutating copper The central line of the commutator deviates or its surface is not turns black disorderly round and not smooth i The motor vibrates the clearance between the brush and its holder The brush wears out is too big the clearance between the brush and commutator is too changes colors and breaks big the mica between different commutators extrudes the brush is made of the wrong materials the brush is the wrong type 5 The motor is over loaded the commutators are not clean not round or not smooth mica or some of the commutator is coming out the brush is not ground properly the brush has a lot of pressure the brush is wrong type the brush is jammed in the brush holder the brush holder becomes loose or vibrating the polarity and sequence of magnetic poles become wrong Big spark The brush and its wires get Big spark from the brush poor contact between the brush and soft hot wires small section area of soft wires The brush is noisy The surface of the commutator is not smooth Maintenance of the Traction AC Motor If your vehicle is equipped with AC motor then the motor is maintenance free 18 5 4 Maintenance of the Speed Controller CAUTION Only a qualified electrician is allowed to do the maintenance for the controller WARNING There are no spare parts available inside the controller No attempt should be made to open repair or otherwise mo
17. e doing anything to the wheel and tire please make sure the power key is positioned on OFF position Please read the tire manufacturer s instructions and never exceed their recommendation Protect face and eyes from escaping air when removing the valve core Be sure the mounting demounting machine is anchored to floor Wear safety equipment when mounting demounting the wheel and tire To remove a wheel on the vehicle 1 Block the wheel then loosen the wheel lug nuts 2 Use a jack to lift the vehicle then remove the wheel lug nuts and the wheel To install a wheel on the vehicle 1 Use a jack to lift the vehicle then put the wheel onto the wheel hub with lug nuts 2 Finger tighten the lug nuts then tighten lug nuts to 50 85ft lbs 70 115Nm in 20ft lbs 83ONm increments following the cross sequence pattern Cross Sequence 3 Remove the jack If the tire is flat remove the wheel and inflate the tire to the maximum recommended pressure for the tire Immerse the tire in water to locate the leak and mark with chalk Place tire plug according to the manufacturer s specifications 23 5 8 Brake Adjustment WARNING If you have any problem with the brakes please consult with our dealers Brake failure can result in serious accident or physical danger The brakes on the vehicle are self adjusting Before you operate the vehicle please press down on the brake pedal several times to make sure the bra
18. eeded Improper charging will lower range Extension Cords We do not recommend using an extension cord to charge If you do use one it must be heavy duty 10 gauge as the extension cord will determine how many amps the charger will receive Parking Brake All vehicles have a parking brake hand or foot Driving with parking brake engaged will damage the motor and braking systems and can create a fire hazard Always disengage the parking brake before driving Storage Vehicles should NOT be left out in the elements 24 7 We recommend storing covered in a garage environment in order to preserve the integrity of the paint and fit finish of the vehicle Tires Must be inflated to proper capacity Upon delivery please check all lug nuts and tighten as they may become loose due to turbulence in shipping Additionally check lug nut tightness once a month Tow Switch Must be pointed to Run and not Tow to operate Must be in Tow position if towing This manual tries to be as sound and elaborate as possible in literal and figurative description as well as technical description on the basis of existent data At the same time our company reserves the right to alter the content of this manual and this manual is subject to change without prior notice In addition our company has the final interpretation right of this manual All rights reserved May 2015 28
19. efore the battery power meter shows only 20 is left An over discharged battery will have a very short service life and will make the recharging very difficult WARNING During recharging the vehicle shall be parked in a well ventilated area with filling caps tightly secured Keep far away from any flame and sparks to avoid any explosion or fire that could cause physical injury or damage to the property WARNING In summer time when the battery is hot do not recharge the battery immediately Only charge the battery when it cools down And also do not charge the battery in the sunshine WARNING In winter time when the temperature is too low charge the battery in a warm place WARNING At the end of the battery s life its capacity will decrease dramatically When changing a new group of batteries use the batteries of same brand same model same capacity and similar voltage any difference should be less than 0 02V Equalizing charging is requested for the new group of batteries 13 5 WATERING Flooded batteries need distilled water What s more watering must be done at the right time and in the right amount or else the battery s performance and longevity suffers Distilled water should always be added after fully charging Prior to charging there should be enough water to cover the plates If the battery has been discharged partially or fully the water level should also be above the plates Keeping the water at the correct level
20. el 4 Parking Signal option A Headlight Button VETA N 2 Se ae A r ra Battery Power Mete Parking Brake Pedal ZA i pet Heg Service Brake Pedal Accelerator Pedal 08 amp 09 Style Dashboard Fuse Box y cause bodily i jury to the vehi is n motion ce of drugs or alcoho d before driving e car is parked or unat nde o iH c L v c p w c F Tow Run Switc Turn signal Right headlight and right rear position light Battery Receptacle ight Left headlight and left rear position oe and ing signa 12V accessory plug Park brake light Hand brake FUSE BOX Digital Meter Battery voltage Speedometer Mileage Left turning n 3 3 _ Right turing light light indicator indicator High beam Low beam headlight indicator Reverse indicator Parking brake indicator 2 Functions of Controls Ignition key The ignition key is used to switch on the electrical system of the vehicle To engage the motor and start the vehicle Insert the key and turn it clockwise to the ON position at the same time the 12V accessory system including the headlight turn signal taillight brake light and horns will be engaged also To switch the power off turn the key counterclockwise to OFF position CAUTION When the Key is on ON position the key cannot be pulled out Do Not try to pull out the Key when it s on O
21. ing as follows 1 Clean the dust and mud on the cover to keep the axle clean 2 Check all the connections to make sure they are in good condition in case there is any damage if any contact sticks or there is any travel in the contact 3 Check the gear oil add some if needed 4 Check if there is any link in the connection and transmission units or any unusual sound inside the axle 5 Check the brake drum check the exterior temperature and smell it should be adjusted and repaired immediately if there is any problem 6 Check if the breather valve has a hole or not in case the oil leaked 7 Check if there is any section in the parking brake cable broken or loose replace with a new one if necessary 2 Periodic maintenance The axle should be done as first grade maintenance second grade maintenance and third grade maintenance First grade maintenance focuses on lubrication fixation and gear oil replacement second grade maintenance focuses on checking adjustments and gear oil replacement Third grade maintenance focuses on the whole part cleaning assembly and gear oil replacement Maintenance in each grade should follow the requirements as noted Periodic maintenance as per below ec ee Every Month Do first grade maintenance as required above Every 2 months Do second grade maintenance as required above Every half year Do third grade maintenance as required above Main Trouble and Troubleshooting Symptom s Possible cause s Troublesh
22. kes are functioning properly 6 Lubrication 1 Use 90GL hypoid gear oil 1 liter for the rear end 2 Lubrication points a Spindle assembly driver side and passenger side b Middle shaft c Rear end Spindle Driver Side Rear End ae P T Middle Shaft 7 Running in of new vehicle In order to guarantee the performance of the vehicle and enhance its reliability and working life its parts should experience a certain period of running in before it works under peak load Each new vehicle is required to receive one month of running in time or 1000kms running in distance detail procedure per the following 1 2 3 4 Before running in please check the capacity of the oil electrolyte and brake oil if any insufficiency is found please fill it accordingly The tire pressure shall comply with the rated pressure marked on the tire Limit the speed of the vehicle to control the current of the vehicle under 40A during driving Often check and tighten regularly the fixing parts of each connecting points 24 8 Periodic Maintenance Charts Regular maintenance is required for the best performance and safe operation of the vehicle WARNING Make sure to turn off the power key and apply the parking brake when you do the maintenance unless otherwise specified If the owner is not familiar with the maintenance of this vehicle this work should be done by the dealer from whom you received your vehicle 1D per day 1W
23. le flooded lead acid batteries If your vehicle is equipped with any other types of batteries please follow the maintenance instruction by the battery manufacturer Below maintenance instruction is especially for deep cycle flooded lead acid battery WARNING Battery electrolyte is poisonous and dangerous and may cause severe burns injury and etc Always wear protective clothing gloves and goggles when handling batteries electrolyte and charging your battery KEEP OUT THE REACH OF CHILDREN 1 CLEANING a The exterior of the battery the connection wires and bolts should always be kept clean and dry When cleaning please make sure all vent caps are tightly in place Clean the battery top with a cloth or brush and solution of baking soda and water When cleaning do not allow any cleaning solution or other foreign matter to get inside of the battery This should be done every week b Clean battery terminals and the inside of cable clamps using a post and clamp cleaner Clean terminals will have a bright metallic shine This should be done when it is necessary c Reconnect the clamps to the terminals and thinly coat them with petroleum jelly Vaseline to prevent corrosion WARNING Before you disconnect any battery cable from any terminal on the battery please always remove the power by disconnecting the main battery cable from the controller 2 CHECKING THE TERMINALS AND NUTS The connection of the battery should always be kept in good
24. leaking fluid Applicable for vehicle with hydraulic brake 19 Check to see if the brake fluid inside the brake fluid reservoir is enough Applicable for vehicle with hydraulic brake 20 Check the air pressure of the tires check if the tires are worn and check to see if the lug nuts are tightened properly 21 Check if the shock absorber has any oil leaking flat or abnormal noise 22 Check if there is oil leaking on the gear box and the rear end 23 Add the lubricant inside the wheel hub steering system 24 Adjust the toe in of the front end 25 Clean the body and seat After above maintenance drive the vehicle to check if the vehicle works properly 9 Storage Please follow the steps as below when the vehicle is stored 1 Check the liquid level inside the battery Refill it fully before storing the vehicle WARNING Please charge the battery once a month if your vehicle will be stored more than one month 2 Turn the power key to OFF remove the key and store the key in a safe place 3 Move the tow switch into TOW position on the controller cover 4 Check the tire pressure to make sure its pressure is set to recommended pressure 5 Clean the exterior of the vehicle and apply the rust inhibitor 6 Cover the vehicle with a breathable cover and store it in a dry safe and well ventilated place 7 lf the vehicle is planned to be stored for a long time then please check the liquid level inside the ba
25. ng conditions may exist 1 The Battery was left in a state of discharge too long 2 The Battery has a bad cell Batteries in these conditions should be taken to a specialist for further evaluation or retired from service 15 TABLE 1 State of charge as related to specific gravity and open circuit voltage Specific Gravity Open Circuit Voltage Percentage of Charge Corrected to 80 F 7 BATTERY INSTALLATION WARNING When working with the battery DO NOT put wrenches or any other metal objects across the battery terminals otherwise an arc can occur and it may cause explosion of the battery and physical injury Battery is to be installed or replaced only by a qualified technician 8 BATTERY CHARGING NOTE The Standard charger on the vehicle is an onboard one It s either installed in the rear bag well or under the seat or under the front body Sometimes based upon a dealer s special request the charger may not be installed on the vehicle Please always consult with the seller regarding the position of the charger When it s an onboard charger a separate charging cord will be provided with the vehicle for connecting the charger and AC electricity Charge the vehicle fully before your first use WARNING Before you use the charger please read the operation manual provided with the charger WARNING Explosive hydrogen gas is produced while the battery is charging Only charge the battery in well ventilated areas WARNING
26. ooting 1 The gear oil is insufficient or used improperly ew n oe mie 2 The bearing is assembled incorrectly Assembly correctly The axle housing 3 The brake shoe pin shim or the interval needs Adjust or replace gear and bearing adjusting or replacing are damaged and here stoa much an gear between axle 1 and 2 is not touching Adjust correctly noise on the final oun drive 5 The final drive is too noisy 1 Check if there is Remove the impurity replace the any impurity 2 check the if the gear is damaged gear 6 Axle 1 strikes heavily Adjust or replace a new one 7 The rear axle is out of shape check if it is Replace the rear axle over loaded 22 1 There is interval between the brake shoes Adjust the interval and drum 2 There is oil dirt on the brake shoes or drum Remove the impurity adeo beating 3 There is air in the brake line Dispel the air force A tebdkeire keie Repair the leakage or change the brake line 5 The brake shoes are over rubbed Replace with a new one 6 The brake cable is too long or is blocked Adjust the brake cable 1 The brake pedal cannot bounce back Replace with a new one aa smoothly The brake is difficult to release 2 he brake shoe is out of shape Refit or replace completely 3 There is some blockage on the transmission Refit or replace 1 The Oil Seal is damaged Replace with a new one The oil leaks 2 T00 much Oil Adjust the oil level 5 7 Wheel Replacement WARNING Befor
27. per week 1M per month 1Q per quarter 1Y per year Descriptions Battery 1 Check the liquid level Please add the distilled water if necessary 2 Charge the battery 3 Tighten the nut on the battery cable 4 Check to see if the battery is over discharged the battery power Y meter flashing 5 Check the liquid density of the battery standard density should be 2 lt 1 277 0 007g cm 80 F or 25 C when the battery is fully charged 6 Check if the battery is charged fully by 2 ways a using the hydrometer b checking the battery power meter 7 Clean the surface of battery Charger 8 Observe the charging status check if the charger plug becomes hot 9 Clean the surface of the charger Do not get any water inside the E omer Controller 10 Check to see if all terminals are tightened properly Please do this after the power is off 11 Clean the surface of the controller 12 Check to see if the solenoid is in order checking its touching point 13 Check if any water gets in Check if it becomes too hot 14 Check to see if the carbon brush should be replaced 15 Check to see if the accelerator pedal works well and if it can be released freely and automatically Chassis 16 Check to see if the brake drum and the brake shoe should be and body replaced or not 17 Check to see if the hand brake functions Applicable for vehicle with hand brake 18 Check to see if the hose and tube for the brake may be
28. programmer shows the forward switch closing and the vehicle now drives normally the problem has been corrected TROUBLESHOOTING CHART PROGRAMMER LED CODE LCD DISPLAY EXPLANATION POSSIBLE CAUSE HW FAILSAFE Self test or watchdog fault 1 Controller defective THROTTLE Wiper signal out of range 1 Throttle input wire open FAULT 1 2 Throttle input wire shorted to B or B 3 Throttle pot defective SPEED No pulses from sensor 1 Speed sensor not connected SENSOR FAULT 2 Speed sensor defective throttle inputs MOTOR STALL Motor stall at current 1 Slope too steep for vehicle weight 1 Mechanically locked motor 2 EM brake wiring failure 3 Speed sensor defective a LOW BATTERY Low battery voltage 1 Battery voltage lt under voltage cutback VOLTAGE threshold 2 Corroded battery terminal 3 Loose battery or controller terminal OVERVOLTAGE Overvoltage 1 Battery voltage lt under voltage cutback threshold 2 Vehicle operating with charger attached 3 Battery was disconnected during regen braking THERMAL Over under temperature 1 Temperature gt 85 C or lt 25 CUTBACK 2 Excessive load on vehicle 3 Improper mounting of controller 4 Operation in extreme environments 2 MAIN DRIVER Main contactor coil held low 1 Main contactor missing or wire to coil is ON open 2 Controller defective 20 1 1 1 2 1 3 1 4 1 5 2 1 2 2 2 3 4 Troubleshooting Chart Cont d 2 5 AUX C
29. r pedal again the vehicle will start moving STOPPING To stop the vehicle gradually press down the brake pedal When the vehicle has come to a stop apply the parking brake pedal and turn the power key to OFF and press the F R switch on Neutral position CAUTION Do not hold the vehicle on an incline with the accelerator please use the brake 4 SAFE OPERATION INSTRUCTIONS Our electric vehicle is designed for simple operation However please make sure to observe the following safe operation instructions BEFORE OPERATING THE VEHICLE ALWAYS read these instructions first before you start driving the vehicle ONLY authorized people should drive this vehicle and from the driver s side ONLY Do not drive this vehicle on any public road before it is registered and has the license place attached ONLY drive the vehicle in areas where allowed to be used by law or local regulations and the conditions are safe to do so DO NOT allow more than the designated amount of people on the vehicle DO NOT overload the vehicle in any case otherwise the motor may be damaged The vehicle may also lose control and or the driver and passengers will be put in danger DO NOT operate the vehicle while under the influence of alcohol or drugs otherwise their effect on vision and judgment will put the driver and passenger s in danger DO NOT make the vehicle climb any slope beyond its grade ability DO NOT overtake other vehicles at crossroads in
30. raulic brake system Press down this button when you pull up the hand lever with the button being pressed down Engage the hand park brake __ _ Disengage the hand park brake e To engage the hand parking brake pull up the hand brake lever to the end e To disengage the hand parking brake pull up the hand brake lever to the end and then press down the button on the top of the brake lever with the button being pressed down push down the brake lever to the bottom WARNING Please always release the brake handle completely before you drive the vehicle WARNING Do not step down on both the brake pedal and the accelerator pedal at the same time this will badly damage the motor Steering wheel The steering wheel is used to control the driving direction Please avoid any sudden and wild turns Battery Power Meter There are 10 divisions on the meter from 0 to 1 The meter will decline from the top to the bottom as the battery discharges When the battery is too low the red indicator light will flash reminding you to recharge the battery T NOTE please refer to your Battery Chargers Owner Manual for information on how to recharge the batteries 3 n 10 TOW RUN SWITCH available for Curtis 1266 and 1268 controller Before operating the vehicle make sure the TOW RUN switch is in the RUN position Make sure the TOW RUN switch is on the TOW position if towing or pushing the vehicle The TOW
31. refully and understand the contents on the safety label attached on the vehicle SAFETY and OPERATING INSTRUCTIONS WARNING Failure to comply with all safety warnings may cause bodily injury to the vehicle operator and or passengers Keep entire body in vehicle and hold on when vehicle is in motion Only qualified people should operate this vehicle Do not operate this vehicle while under the influence of drugs or alcohol Make sure all passengers are securely seated before driving Apply park brake inte the locked position when the car is parked or unattended Label Above is attached on the dash panel as below SAFETY and OPERATING INSTRUCTIONS WARNING Failure to comply with all safety warnings may cause bodily injury to the vehicle operator and or passengers KCep cnt ody in vehicle and hold on when vehicle is in motii Vehicle Information Name Plate The name plate is either at the lower part of the dashboard as below Fig 2 shows or at the back of the front seat as below Fig 1 shows ELECTRIC VEHICLE ELECTRIC VEHICLI Fig 1 Fig 2 Chassis number of the vehicle The position where the chassis number is located as per the picture below PP To the front of the vehicle There is where the chassis number located 2 Controls 1 Schematic Figure of controls Please see the general overview of your dashboard below Fuse Box Forward Reverse Switch Turn Signal and Horn Switch Ignition Key Steering Whe
32. rts the procedure of self inspection after self inspection the green indicator flashes and the charger starts to charge the batteries 4 When battery capacity is less than 80 the green indicator flashes slowly when battery capacity is more than 80 the green indicator flashes fast when the battery is fully charged the green indicator will stop flash and always be on and the charger will stop charging automatically Note This charger has the function of over discharging protection to protect the battery from over discharging When the battery is close to the charging point it will reduce the discharging current from the battery to reduce the speed of the vehicle if it fails to charge the battery it will cut the current from the battery and stop the vehicle to force the user to charge the battery Note When the grid voltage is out of range of 90 260V the charger will stop charging to protect itself at the same time the failure code light will be on to remind users When the voltage returns back the requested voltage range of 90 260V it will automatically start to charge Note The charger will automatically start equalizing charge after 30 times of charging if it remains connected from the grid and battery after the battery is charged fully CAUTION Charger is not allowed to be used if it gets wet CAUTION Use the charger when the environment temperature is between 10 C to 45 C Celsius Degree WARNING Only a qualified
33. s Maintenance OF Baley ecsenisan a A T O T te tenet 13 5 2 Operation and Maintenance of Charger cccccccsececeeceeeeeceeeeseeeeeeeesseeeseeesaeeeseeeeaes 17 3 3 Maintenance ot the Traction Motol esien cawtal unre E aetna tetas 18 5 4 Maintenance of the Speed Controller ccccccccceecccseeeeceeeeseeeeeseeeeseeeesseeeeseeeesaeeeas 19 5 Diagnostics and Troubleshooting jevtnncssscensunsetosansiseves unas eee eE ESE Eoo R dE 19 360 Maintenance ol Rear AXE eseni a E a a amare 13 5 7 Wheel REDIACCINGM wistenancariomincnstonancs vicuasanin eid cmreaeridarnia edn hemeaaicanaeda diem heaatieareede diem tease 23 5 8 Brake AGIUSIMGENL 2 tezatctetsaicdetessecttie tector e N 24 6 WUWDIIG ATION aar Gata ark Gate ope E E a a E Neti ace 24 7 Running in of New Venicle cccccccecccecececccecccececececseecseeceeecaeeceesaeeseeecueecaeseseeceeseaesnass 24 8 Penodic Maintenance Gai S tecicct xt ee iceetacdicd e enedlomeaa diel Aeasiee e 25 SESLE rc 6 pee nee aE A E ee E A AE A AE NA AN AA N A AE A A ee 26 TO WINO Dag aM a Ean EEEN aN 26 1 OVERVIEW Our vehicle is environmental friendly and it can be used as a people mover or utility car at a golf course resort hotels private residential areas tourist scenic spots or any other places where allowed Please always be sure of any restrictions in the area where you intend to use the vehicle to avoid any unpleasant experiences IMPORTANT LABELS SAFETY LABEL Please read ca
34. technician is allowed to open the housing of the charger WARNING When charging the batteries hydrogen will be generated so it s important to keep the charging area in a safe and dry room with good ventilation and also to avoid any fire and spark 17 5 3 Maintenance of the Traction DC Motor WARNING Be sure there are NO explosive gas vapors in the air otherwise it may cause serve injury and damage to your body and property if the explosive gas vapor contacts the sparks generated from the motor 1 For DC motor the carbon brush should be checked every 3 months to see if it is worn or not as it is an easily worn part If it is not replaced in time before it wears out it will badly damage the motor 2 Do not keep the motor running idly for long periods of time Any idle running of the motor should be avoided 3 Removal of mud sand and other clinging objects shall be done frequently to help keep it from overheating 4 Periodically use low pressure air to remove the dust from the carbon brush and the commutator Periodically check the connection of the carbon brush and the commutator Main malfunction and possible reason of DC motor Symptoms Possible Causes All copper plates turn black The pressure of the brush is incorrect 2 The commutating copper Short circuit happens between the commutating copper or among turns black in a certain order the armature coil poor welding or disconnection happens between and in groups th
35. the status of the controller inouts outputs is displayed in the Monitor Menu Accessing the Fault History menu provides a list of the faults that have occurred since the fault history file was last cleared Checking and clearing the fault history file is recommended each time the vehicle is brought in for maintenance The following 4 step process is recommended for diagnosing and troubleshooting an inoperative vehicle 1 visually inspect the vehicle for obvious problems 2 diagnose the problem using the programmer 3 test the circuitry with the programmer and 4 correct the problem Repeat the last three steps as necessary until the vehicle is operational 19 Example A vehicle that does not operate in forward is brought in for repair Step 1 Examine the vehicle and its wiring for any obvious problems such as broken wires or loose connections Step 2 Connect the programmer select the Faults menu and read the displayed fault information In this example the display shows No Known Faults indicating that the controller has not detected any problems Step 3 Select the Monitor menu and observe the status of the inputs and outputs in the forward direction In this example the display shows that the forward switch did not close when forward was selected which means the problem is either in the forward switch or the switch wiring Step 4 Check or replace the forward switch and wiring and repeat the test If the
36. ttery once a month recharge the battery 10 Wiring Diagram 1 Wiring diagram for vehicle 48V with Curtis Controller 1268 see next page 26 204 Say F3 Chargin Eaa SMN tow run switch key switch i hager Main connet light switch Accelerator edirection swite E B waming alarm A fle al he tuming signal switch L 9 rR Ua MTL 171615 3131 left left tail head head light light light speed sensor ae ay o U A electric current meter 27 Client Responsibilities Maintenance Issues Batteries Battery fluid must be checked at least once monthly Use distilled water only Do no overfill Battery Cables Tighten battery cables per battery manufacturer instructions located on batteries Failure to tighten once a month could result in damage to the batteries BEFORE placing the vehicle into service please check all battery cables and tighten as they may become loose due to turbulence in shipping Battery Lock Washers Make sure a qualified technician maintains lock washers on all battery posts when replacement batteries are needed Charger Power Cord Do not remove the manufacture tag on the power cord as doing so will void the warranty Always unplug the charger before turning the vehicle on Charging Each charger must have a dedicated circuit with 20 amps Vehicle should be left plugged in when not in use Charger will trickle charge at 80 only when n
37. y circuit Q3 Q3 D A gt A 6 oO 2 Breaker fuse defective 3 Relay fuse sense line broken 5 9 MAIN Main contactor open La DROPOUT a 1 Main contactor defective A built in Status LED is visible through a window in the label on top of the controller When the controller detects a fault the Status LED flashes the 2 digit fault code The code is flashed continuously until the fault is corrected For example code 3 2 welded main contactor appears as noon an ana an anana an etc 3 2 3 2 3 2 The codes are listed in the Troubleshooting Chart Only one fault is indicated at a time and faults are not queued up If multiple faults are active simultaneously the code of the highest priority fault is flashed After all faults have been cleared the code of the last active fault will continue to flash for one minute This feature is designed to help service personnel identify intermittent faults when no programmer is available These same fault codes will also be flashed by the external fault LED connected to Pin 22 if one is included in the system 21 5 6 Maintenance of Rear Axle While using your vehicle the rear axle should be maintained daily periodically and randomly 1 Periodic maintenance means the driver should do some daily maintenance before during or after driving to prevent something unexpected from happening The maintenance is focused on examining cleaning and repair
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