HDK Service Manual - Escondido Golf Car Center
Contents
1. For HDK vehicles Steering is controlled through a rack and steering assembly which is connected by steering column to a steering wheel For different steering requires the steering column of all HDK vehicles have two mounting positions as different angles and height options FIGURE P 1 P 2 The mechanical operations are passed by universal joint that connects the steering column and steering box Vehicle direction control is executed by steering gear box All the steering operations are mechanical manual adjustment to the rack pinion gear assembly is required spring loaded self adjusting mechanism is incorporated into the assembly WHEEL ALIGNMENT 1 Steering system maintenance A assure the steering system in proper function all the mounting nuts and fasten rings should be solid tight The steering wheel should be installed on the A splines of the steering shaft making sure to align the match marks placed on the wheel and steering column While operate the steering wheel one should stop turning when it comes to the dead end of the turning angle otherwise may damage the steering wheel cause the nut to strip dust cover on the universal joint or and the steering box should be kept in perfectly t2. Long connecting cable US battery flooded 6TB 170ACM 5 Nut 7 Snap washer Trojan 5 Generic 140 200Ah Washer AGM Trojan J305 Generic 200 250 Ah AGM Batteries ed on HOK vehicles according to different PE 20 5 MORENE 290 339 An configurations customers who purchase HDK vehicles fleoded 0 can choose different batteries figure the batteries Trojan 1275 Sense TG available The batteries are connected in series circuit pattern Trojan 1605 Generic 250 335 System Battery QTY PCS Single battery voltage V Toonen 3eV 6 2 1218 115AGM Generic 400Ah 40 2 5 2 s 1 4555 48V 8 6 N Battery malfunction and maintenance II Maintenance 1 the exterior of the battery the connection wires and bolts should be kept clean and dry If there is electrolyte outside the battery please clean with dry cotton cloth first then wash with water and finally wipe dry while cleaning do not allow any cleaning solution or water to get inside the battery to avoid leakage and increasing self discharge 11 The connection of the battery should always be kept in good condition please check if any battery cable terminal or nut has become loose periodically in order to prevent any sparkle or damage to terminals 111 Do not place any object on the battery and do not connect the positive pole to the negative pole This may cause a short
3. gt COVER TPO PLASTIC REAR COWL VEHICLES FEATURES CHASSISES OF GOLF CARTS ALL USE HOT GALVANIZED DIP CHASSIS HDK ASSURE YOU NO RUST IN 15 YEARS VEHICLE COLOR OPTIONS MS NAVY BLUE WHITE vELLow GREEN BLACK co HDK VEHICLE HAS DOZENS OF COLORS TO CHOOSE FROM SPECIAL COLOR REQUEST WILL ALL BE DONE BY HDK AND MAY COST EXTRA DECALS Vehicle s serial Vehicle s serial number manutactuina vear 901180678 ne Vehicles manufactured by HDK Corporation all have vehicle serial numbers are on the left side of the chassis frame behind wheel The front four numbers are the manufacturing year of the vehicle The other five numbers are the vehicle s serial number given by HDK Corporation the vehicles are documented After the vehicles are sold out of the factory HDK Corporation will track the vehicles by using the vehicle s serial number as identity Serial numbers are insurance warranty of Corporation Customers 201189678 should aware of the importance of the vehicle s Serial Numbers DON T TEAR IT DOWN while using the vehicles or in routine maintenance Steering Wheel decals OPERATING INSTRUCTIONS 1 Steering wheel Read owner s manual and dash mounted safety warnings prior to driving 2 HD K decal Study and understand controls TO OPERATE Turn wheels to desired direction and ensure path
4. 3022G DEL 3022G2Z DEL 3042G DEL 3042G2Z DEL 3062G DEL3062G2Z ix 8 Passenger capacities 2 4 4 6 6 Dimension mm LxWxH 2350X 1180 X 2610 1180 x 3100 1180 x 3360 1180 X 4900 x 1180 x 5160 X 1180 X Approximate 1780 1780 1780 1780 1780 1780 Range based on flat road at a speed of 20 km h km h 80 75 70 65 60 60 Approximate Maximum speed gear ratio of 12 49 1 gear ratio of 10 25 1 20 29 20 29 20 28 20 28 20 28 20 28 km h Approximate Maximum grade ability 30 28 25 22 20 20 Approximate Minimum turning diameter m 3 1 3 1 4 3 4 3 5 5 6 8 Approximate Brake distance V 20km h lt 3 5m lt 3 8m lt 4 0m lt 4 0 lt 4 5m lt 4 5m Approximate Minimum distance from 110 110 110 110 110 110 floor mm Approximate VEHICLE FEATURES SPEEDOMETER STEERING ur M 09 x i ARMREST E 1 E 1 SEAT f NAG CUSHION gt 4 1 i CN HEADLIGHTS AMA DRIVER SIDE HEADLIGHTS PASSENGER SIDE PLASTIC FRONT COWL y FRONT WHEEL GOLF KITS BAG STRAP BRAKE TAIL LIGHT ate PASSENGER SIDE es D SWEATER BASKET RED O4 d is mY S er BRAKE TAIL EE DRIVER SIDE TURNING LIGHT PASSENGER SIDE DRIVER SIDE TURNING LIGHT go ORANGE
5. also customer can option to upgic HDK REAR AXLE RATIO OPTIONS hydraulic brake axle as long as it is requested 10 25 1 12 49 1 customer writing i 2 TT ri occ M j J i 7 47 iff VE 3 7 n 9 6 f 4 m RO T A m r M f wre X feel y m Ne uk i ERA y UP fen 1 s a ien P AMES MIT neuf mt ri f y Cmm S ND M mme DBRAKE DRUM MOTOR A e amp FASTEN BOLT SNAP WASHERG WASHER REAR AXLE AND MOTOR Rear axle maintenance Make sure all the nuts on rear axle gear box all fastened up in case oil leaking Make sure the gear box have enough capacity of lubricate oil before use 90 of the whole capacity AN CAUTIONS THE REAR AXLE GEAR BOX SHOULD BE INJECTED WITH HEAVY DUTY AUTOMOTIVE GEAR OIL 90W AND CHANGE OIL PER 12 MONTHS Monthly customer should take off the brake drum and clean the brake shoes and backing plates One can use high velocity air to blow off the interior contamination Check the brake shoes whether the brake shoes come loose or not NCAUTIONS MONTHLY CLEARANCE ADJUSTMENTS ARE EXTREMLY NECESSARY IF NOT THE BRAKE SHOES SHED DUST MAY CAUSE DAMAGE TO THE BRAKE MECHANICAL PARTS AND WILL INCREASE THE NOISE LEVEL OF THE REAR AXLE Every three months customer should take off the brake d
6. cause unrepairable damages Main fuse for 1243 1246 system Main fuse for 1268 system DC converter Input protective fuse for 1243 1246 system DC converter Input protective fuse for 1268 system Relay malfunctions When the vehicle have a break down turn on the power and whole circuitry system has no respond then the main fuse should be checked when the power is on and vehicle can be operated but all lights and horn cannot be switched on Then the DC converter Input protective fuse should be checked A To judge a broken main fuse one can judge by physical eye observation N one can tell from the revealed fuse in the middle of the fuse if it is broken then the fuse will be broken in the middle physically For other fuses one can use a multimeter to judge the resistance of the fuses are zero 1f it is broken means the inner connection be disconnected WHEN COMMIT THE FUSE CHANGING THE POWER SHOULD BE TURNED OFF BATTERIES HDK vehicle batteries connection P Batteries HDK vehicles can apply yo _ Trojan flooded Trojan 1875 LL Trojan T105 flooded Us 2000 flooded 7 j 77 4 TE eee Discover 80 150 US2200 flooded 2 Batteries connecting cable t L 3 Batteries connecting cable Discover AGM Us 250hc flooded 1 Long connecting cable _ A EN
7. circuit damage to the battery or injury to your body The battery should be recharged fully when not in use Any delay on the re charging will cause negative effect on the battery v The evaporation and electrolyzing of the water will cause the density of electrolyte of the battery increased and the liquid surface decrease especially in hot water Therefore check the distilled water or the attenuated sulfuric acid for lead acid battery with density of 1 40 to adjust the electrolyte to meet the density of the 1 28 the surface should be flat with highest level then continue to charge0 5 1 hour in order to make the internal uniform v1 Any impurities are not allowed to enter the battery Keep the apparatus clean for adding water to avoid the impurities to be fallen into the battery vii When driving the driver shall be always be aware of the drop level the battery power from the batteries capacity indicator The driver shall estimate the distance needed to be taken and recharge the battery at a proper time in case that the car can not get back to the recharging station in time for recharging vil If the golf car is going to be kept unused for a period of time the battery shall be fully charged before put away After that the battery fully recharged every month until the charger turn off automatically During charging the car shall be parked in a well ventilated area with the fill caps open Keep car far away from any frame and
8. 0 depth of the discharge The 2 left most LEDs SSS a N depth of discharge 1 _ 1 pe Batteries indicator malfunction Keyswitch on and no display Terminals not connected or improper voltage key switch not high A Stays at full Indicator voltage does not match battery voltage Will not reset Indicator does not match battery voltage or battery not fully charged Reset without terminals charging battery Not connected directly to battery A Empty too soon Indicator voltage does not match battery voltage or terminals not connected directly to battery sing environmental temperature HEAD LIGHTS HEADLIGHT BULB Y a ORANGE RULA 4 Headlight bulbs are halogen bulbs the main light bulbs rated power can range from 30 60W turning bulbs are orange color bulbs the DC DC converter provide 12V working voltage and the switch assembly control the headlights to turn on and turn off When headlights are turned on the indicator LED on the speedometer will flash as the lights are turned on Eg when turn on the main light the indicator will be flashing as well Headlights maintenance bulb changing AN HEADLIGHTS RATED POWER SHOULD ALWAYS BE KEPT WITHIN 50W OTHERWISE THE HIGHER POWER BULBS WILL CREATE MASS HEAT OVER AND DAMAGE TO THE LIGHT ASSEMBLY A THE CAP ON THE ON THE BACK OF THE HEADLIGHTS SHOULD ALWAYS STAY TIGHT TO KEEP OTHER ENT
9. 1243 controller maintenance and configurations IN CONTROLLER MAINTENANCE There are no user serviceable parts in the Curtis 1243cEN2 controller No attempt should be made to open repair or otherwise modify the controller Doing so may damage the controller and will void the warranty It is recommended that the controller be kept clean and dry and that its fault history file be checked and cleared periodically CLEANING Periodically cleaning the controller exterior will help protect it against corrosion and possible electrical control problems created by dirt grime and chemicals that are part of the operating environment and that normally exist in battery powered systems When working around any battery powered vehicle proper safety precautions should be taken These include but are not limited to proper training wearing eye protection and avoiding loose clothing and jewelry Use the following cleaning procedure for routine maintenance 1 Remove power by disconnecting the battery 2 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 3 Remove any dirt or corrosion from the connector areas The controller should be wiped clean with a 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 4 Make sure the connections are tight but do
10. ACITY OF THE BATTERY REDUCES THE ELECTRIC CONSUMPTION INDICATE SHOWS IS REDUCED THIS VALUE SHOWING IS NOT RISEN BY VOLTAGE OF THE BATTERY ONLY WHEN THE VOLTAGE OF THE BATTERY ACCORDS WITH RCV CONDITION ELECTRIC CONSUMPTION IS RESTORED TO THE FULL LEVEL INDICATE A AFTER INSERTING THE ELECTRIC INSTRUMENT PLEASE CHARGE TO BATTERY IMMEDIATELY UNTIL TO FULL LEVEL IT COULD MAKE THE ELECTRIC INSTRUMENT POINT OUT ACCURATELY VALUE A WHEN THE SPEEDOMETER PARAMETER IS SET UP DATA ARE KEPT IMMEDIATELY IF PRESENT THE FAULT OF OPERATING PROGRESS THEN PLEASE CUT OFF THE SWITCH OR CUT OFF THE INSTRUMENT POWER DIRECTLY BEFORE PARAMETER IS SET UP AND FINISHED CARRY OUT THE PARAMETER AND SET UP PROBLY WILL DESTORY INSTRUMENT THE NORMAL RUNNING OF THE SAME FUNCTIONS PLEASE MAKE SURE THE PAREMETER DATA IS CORRECTLY IF HAVE ANY FURTHER PROBLEMS PLEASE CONTACT TECHNICIAN ATTENDANT Forward Reverse switch on the body Forward Reverse switch on the dash board of the Forward Reverse are optional High speed Low speed switch Batteries capacity indicator SWITCHES High speed Low speed switch Key switch Power switch Switch assembly Switches maintenance and malfunctions solutions Mechanical switches For mechanical switches one should always keep it proper positions while operate the vehicle Such as when one choose fo drive in high speed state one should press the High speed Low speed switch make it stay at Hig
11. E gt STRICTLY CALIBRATED TO CORRECT CODE WHICH IS DESIGNED FOR SPECIFIC BATTERY RED LIES BATTERY LIES BATTERY BLACK bor bsr Trojan flooded bis bos Trojan 1875 Trojan 71105 flooded Us 2000 flooded b53 Discover 80 150AH AGM Cara US2200 flooded boa Discover AGM Us 250hc flooded b05 US battery flooded CAES 6TB 170AGM Calibration box bos b20 vo xus bss Trojan J305 jenen Generic 200 250 Ah AGM POWER LED b14 564 12TB 115AGM b28 b78 Operation illustration Inspection of the charger acquiescent charging category Entering display charge category mode Disconnect AC input wires Disconnect between the charger output and battery A when AC input is connected the display will show the program revision After around 5 seconds later it will show the charger output voltage and complete the self inspection process B Display continues to show b01 10 seconds exit the acquiescent charging mode display shows E02 Disconnect AC in put wires If there is need to change the charging category setting the positive Red negative Black terminals of the output wires should be connected to the battery positive Red negative Black terminals After connecting the grid power the charger can start charging the battery code Turn on the power of the calibration box press button to
12. ER INTO THE HEADLIGHTS THE HEAT EXHAUST TUBE ON THE BACK OF THE MAIN LIGHT SHOULD ALWAYS KEPT VENTILATED WHEN CHANGING BURNT OUT BULB ONE SHOULD WAIT UNTIL THE LIGHT BULBS IN NORMAL TEMPERATURE IN CASE MAY CAUSE BURN INJURY AFTER ONE CHANGED THE BAD BULBS ONE SHOULD BE SURE TO PUT BACK LED TAIL LIGHTS The tail lights are LED lights the brake lights are red LEDs the turning lights are orange LEDs LED light assembly have highly efficient low energy consumption and high luminance properties The LED light assembly has a diode to prevent the power polarity reverse and resister to limit the LEDs working current When turn on the front headlights the brake LED lights will be on in dim light when step the brake the brake LEDs will be on strong light The back turning lights are connected to the front turning lights in parallel circuit ALED tail lights maintenance and malfunctions THE LED LIGHTS SHOULD ALWAYS STAY AWAY FROM WATER THE WATER MAY CAUSE SHORT CIRCUTT Malfunctions AN Switch on but cannot light up Check the plug see whether it 15 tight check the input voltage with a multimeter If all check ok then the LED light assembly has a circuit break please check the diode 2 Taillight flashing too fast Change the flasher A The light too dark The resistor is defective or the voltage supply from the DC DC converter too low CONTACTOR SOLENOID Contactor solenoid is to protect th
13. OPERATION AND MAINTENANCE MANUAL HDK VEHICLES USA LLC WWW HDKEV COM CONTENTS his ul IN 1 Front WheelAhsnment u 3 Brake and Accelerator we ee a 7 Rear Axle and MOON A Ai 11 Controller oa 14 Char id be 20 DE DC OM ir 23 Specdo meli SR 24 Switches se 26 28 diui c dias 28 CO OTEACUO EET 29 aia 29 grid cT ME 30 laii niemals 30 Balteries er T 31 Electrical System Trouble Shooting and 5 0 33 Fire oae NNN 34 Warranty Appendix GENERAL INFORMATION HDK Corporation mainly deals in five types of the Electric Vehicles Electric golf car Shuttle bus people movers Utility carts Engineer and transportation cart Off Road electric cars among which DEL3022G series are electric golf cars Our golf car is environment friendly and suitable for use in golf course Hotels and many other businesses All the key components are imported from major brand name companies The whole car 16 new fashion design Offering stable performance Flexible controls and driving comfort Our golf car can be used as people movers or utility cars in vacation villages Villa areas Resort hotels and private residential areas Tourist scenic spots Commercial and Industrial Facilities Parameter DEL 3022G Series Electric Golf Cart Type DEL
14. ORN CAUSE THE SOUND TO CHANGE AND LOW SOUND THE HORN SHOULDN T BE LOADED WITH HIGH VOLTAGE BECAUSE HIGH VOLTAGE WILL EASY BREAK THE COIL IN THE HORN SAUSING DAMAGE Malfunctions AN Push the horn switch and will not respond Wrong or bad connection of horn check the horn plugs use a multimeter to check whether where is voltage loaded on horn when push the switch If all is right Then the horn is bad A Strange horn voice Push the horn change the contact position of the horn and frame Clean the surface of the horn especially dirt on it A Horn have sound on when push the switch but go off after Crank the tightness of the horn use a screwdriver to rotate the middle screw to change the tightness of the horn RELAY Relay is as a electric switch in the circuit system the relay is be placed in input side of the DC DC convertor as electric switch to control the converter power supply when vehicle power is turned on the relay will click on when the power is turned off the relay will brake attach Relay malfunctions Power switch is on relay no respond Check the connection see whether it is good connection condition if it is then the Relay 15 bad For protect the electronic circuit fuses are required The vehicle circuitry s property is low voltage and high current In case of short circuit over current working fuses are placed in the circuit for secure the electronic components in case default operation may
15. T Microswitch o accelerator When the Vehicle is s operated the aceelerate pedal be depressed the micro switch will be in RUN position the micro switch will give out a signal To activate the vehicle s electrical circuit system into work and move car When the vehicle is stopped the micro switch will in HALT position the vehicle s The POT the accelerator use is 0 5KQ changeable resistor throttle capacity is associated to the POT 7 when the vehicle is operation the accelerate pedal is depressed the POT s value ranges from 0 5KQ accelerator as you can see from figure the POT and micro switch are fixed in specific position connected with mechanical gears when the pedal is stepped the gears will rotate with the shaft the micro switch will be triggered and POT resistance will change according to the step angle The accelerators HDK vehicles use for golf series cars are 3 accelerators accelerators are specially designed by HDK match the vehicles soeed control demands ACCELERATOR 15 EXTREMLY IMPORTANT FOR VEHICLE S SAFETY ONLY TRAINED TECHNICIAN S SHOULD BE ALLOWED TO REPAIR OR SERVICE THE ACCELERATOR TECHNICIAN S SHOULD HAVE KNOWLEDGE OR EXPERIENCES OF ELECTRICAL VEHICLE REPAIRS ANY MODIFICATION OR CHANGES TO THE ACCELERATOR MAY AFFECT THE STABILITY OR HANDLING OF THE VEHICLES MAY CAUSE SEVERE PERSONAL INJURY AND OR CAUSE DEATH BRAKE AND ACCELERATOR E
16. T DO NOT TOUCH UNINSULATED PORTION OF OUTPUT CONNECTOR OF UNINSULATED BATTERY TERMINAL DO NOT REMOVE COVER NO OPERATOR SERVICEABLE PARTS INSIDE REFER SERVICING TO QUALIFIED PERSONNEL CAUTION reso manual BEFORE CHARGING USE ONLY ON BATTERY SYSTEMS WITH AN ALGORITHM SELECTED THAT 18 APPROPRIATE TO THE SPECIFIED BATTERY AND CAPACITY SEE MANUAL CHARGING OTHER BATTERY TYPES OF VOLTAGES MAY CAUSE PERSONAL INJURY AND DAMAGE SURFACES MAY BE HOT TO AVOID RISK OF BURNS DO NOT TOUCH WARNING aiskor FXPLOSIVE BATTERY GASES ADEQUATE VENTILATION DURING CHARGING IS REQUIRED PREVENT FLAMES OR SPARKS CONSULT MANUAL DISCONNECT AC SUPPLY BEFORE MAKING OR AREAKING ONNECTIONS TO THE BATTERY ARCING AND BURNING MAY RESULT TO AVOID DAMAGE DO NOT PULL ON CHARGE CORD HAVE DEFECTIVE CORDS OR PLUGS REPLACED IMMEDIATELY BY QUALIFIED PERSONNEL BATTERY Selectable see manual g Made in China HDK ELECTRIC VEHICLES van hdkev com ALIGNMENT Front wheels camber adjustment The camber angle and toe in of both Front Wheels are done by wheel alignment Intended to equalize each of the front wheels For all HDK carts they have bolts on both side of the front wheels used to equalize the turning radius in both directions Measure the distance between the centers of the front tires at exactly the same height on front back of the front tires Loose the locking nut on the st
17. celerator adjustment and maintenance Ioo hard to unlock the parking pedal 1 Disassemble height adjusting rod in the back of the parking If if is too hard to lock unlock the parking pedal should adjust the AL j gt al brake pedal as the FIGURE shows Rotate the nut on top Change the height of the sustain rod of of the rod change the the parking pedal wil make the rod s height parking pedal easy to lock unlock If the brake of the vehicle not in proper function either too tight or too loose One can make certain things go as AT BO followed to adjust the brake into proper functional state ju QM ME Use wrenches to adjust the tightness of the brake 2 cables FIGURE Adjust the tightness of the brake shoes Remove the brake drum use a screwariver to adjust the tightness of the brake shoes Rotate the adjusting wheel in proper scale to make the space between the brake shoes and brake drum minimum brake shoes are perfect tight but don t rub the brake drum while vehicle loose the brake in running operation J FIGURE Take out the brake shoes and clean the interior Zu space Clean the brake shoes shreds and mental dust that rubbed off from brake drum the contact of brake shoes and brake drum FIGURE BRAKE AND ACCELERATOR Brake and accelerator adjustment and maintenance III Accelerator adjustment accelerator gt 9 a
18. d it should be kept firmly to prevent it from loose or falling from vehicle The wire harness that connects the speedometer to the circuitry should be fixed on the chassis with plastic fastening straps to prevent the wiring connection from breaking Speedometer should stay away from water flooding water may cause the speedometer internal short circuit stay away from fire or chemical objects High temperature or acid may cause permanent damages to the LCD screen display IN Speedometer malfunctions Speedometer has no showing Check the working power supply wire connection Speedometer stays static have no current vehicle speed numbers show on the speedometer Check the signal wiring of the speedometer the RMP terminal should have in coming signals if 1t doesn t have signal coming in one should check the connection wires conditions from the speed sensor on the DC motor to the speedometer check whether there is any torn up on wires or loose connection of plugs If the connections are all ok then one should check the speed sensor condition If it is broken a new speed sensor 15 required The speedometer LED indicating lights do not work as responds to the related operations such as when turn the turning lights but the indicating LED does not light up and flash Check the speedometer plug connection with wire harness Speedometer Setting See speedometer operation data sheets CAUTIONS A WHEN THE CAP
19. e circuitry safety and control the power on and off The current come out of the battery is extremely high for safe operation the circuit put contactor on The interior structure is basically a electronic magnet When someone steps on the accelerator the circuit will provide enough current to make the contactor to click on Then the current is allowed to enter into the controller When someone releases the accelerator the power will be cut the contactor solenoid off and will break the circuit disallowing current to controller AX Contactor Solenoid maintenance and malfunctions THE FASTENING NUTS ON THE CONTACTOR SOLENOID SHOULD BE SOLID TIGHT LOOSE CONNECTION MAY CAUSE ELECTRIC SPARKS AND CAUSE SEVERE DAMAGE Malfunctions IN Contactor Solenoid will not respond when stepping on the accelerator Bad connection or wrong connection or the contactor is broken Contactor Solenoid keeps repeating on and off Contactor Solenoid is bad or poor good from controller to Contactor solenoid A Contactor Solenoid keeps staying on when releasing the accelerator Check the micro switch in the accelerator box see if it 1s in right position check the accelerator chapter if so then the contactor Solenoid is bad internally Horn is powered by 12V voltage come out of DC DC converter controlled by switch assembly A Horn maintenance and malfunctions A THE HORN SHOULD BE KEPT SURFACE CLEAN DIRT OR OTHER OBJECT MAY AFFECT THE VIBRATION OF THE H
20. ect the grid power until nothing shown on the display Then re connect the grid power and inspect if the charger charging category is correct After inspection confirm correct the grid power should be disconnected until nothing shown on display the charger output wire positive terminal red should be properly connected to the battery positive terminal Then connect to the grid power and start charging CAUTIONS A USE THE CHARGER ONLY WITH AN ALGORITHM SELECTED THAT IS APPROPRIATE TO THE SPECIFIC BATTERY TYPE OTHER USEAGE MAY CAUSE PERSONAL INJURY AND DAMAGE LEAD ACID BATTERIES MAY GENERATE EXPLOSIVE HYDROGEN GAS DURING NORMAL OPERATION KEEP SPARKS FLAMES AND SMOKING MATERIALS AWAY BATTERIES A PROVIDE ADEQUATE VENTLIATION DURING CHARGING NEVER CHARGE A FROZEN BATTERY BATTERY CAPS SHOULD BE REMOVED WHILE CHARGING A RISK OF THE ELECTRIC SHOCK CONNECT CHARGER POWER CORD TO AN OUTLET THAT HAS BEEN PROPERLY INSTALLED AND GROUNDED IN ACCORDANCE WITH ALL LOCAL CODES AND ORDINANCES A GROUND OUTLET IS REQUIRED TO REDUCE RISKOF THE ELECTRIC SHOCK DO NOT USE GROUND ADAPTERS OR MODIFY PLUG DO NOT TOUCH UNINSULATED PORTION OF THE OUTPUT CONNECTOR OR UNINSULATED BATTERY TERIMALS ALLWAY USE A SURGE PROTECTOR ON AC CORD TO PREVENT DAMAGE TO CHARGERS A CHILDREN SHOULD BE SUPERVISED TO ENSURE THAT THEY DO NOT PLAY WITH THE APPLIANCE DC DC CONVERTER Specifications Out cover Material Aluminum Input voltage 30 70V Input curren
21. ectly make the steering wheel light one can operate by following FIGURE 6 Use a chisel and a hammer to hit the connection spot of the joint ball of the steering box and turning knuckle multiple times until the steering wheel 15 easy to rotate in little strength Hit the joint end of the steering gear box witl a chisel and hammer Direction control not precise Check the system components see whether all the components are in functioning properly adjust the front wheel camber to equalize the front wheels make left and right wheels symmetrical check camber adjustment chapter equalize the turning angles of both side of the wheels make it parallel Check the tire pressure of both side of the front wheels make sure it 1s the same and the tire wear 1s even out of the front tires N CAUTIONS PERIODIC MAINTENANCE OF THE STEERING SYSTEM IS REQUIRED TO INSURE THE VEHICLE IN GOOD CONDITION OF DIRECTION MANIPULATION THE DIRECTION CONTROL FAIL MAY CAUSE INJURIES TO THE PASSENGERS Operating method figures Accelerator pedal operation The vehicle speed is controlled by the operation of accelerator pedal Brake pedal operation The vehicle uses the brake pedal operation to decrease the vehicle speed parking pedal operation when stopping the vehicle the parking pedal operation will keep the vehicle locked in place no matter if it is on the ramp or on flat ground BRAKE AND ACCELERATOR Brake and ac
22. eering gear box with wrench rotate tie rod with locking pliers to increase or decrease the Toe in scale Adjust the front tires front distance and back distance make the Toe in scale as follow Steering gear box on both end have adjusting ZN THE BACK DISTANCE SHOULD BE 3 8mm BIGGER THAN FRONT DISTANCE AAA aaa REAR ar FRONT While adjust the front wheels Toe in one can use measurer and framing squares to measure the physical scales of the front wheels Toe in Equal distances between tires and squares WHEEL ALIGNMENT Front Wheels Turning Angle Adjustment All HDK carts have bolts on both side of the front wheels used to equalize the turning radius in both directions ADJUSTING BOLT Loose the adjust bolts on the steering gear box with wrench rotate the bolts to equalize the turning radius in both directions All HDK carts turning angles have been calibrated HDK technicians New carts sent out of HDK factory the turning angles have been set at maximum scale For customers who want to change the turning angles Follow the instructions Figure NCAUTIONS The front wheels have to stay parallel symmetrical to keep the vehicle in the most precise operating function One can use measuring tools to measure the turning angles of the cart WHEEL ALIGNMENT Vehicle steering system CI STEERING COLUMN
23. h speed Choose to operate the vehicle forward one should make the F R switch stay at F position When mechanical switches are not easy to press and switch modes please check the whether there are objects caught in the switches if so clear the switches take out the objects When switches are in proper mechanical functions but cannot control the vehicle please check the wire harness check whether the wires come loose or not if so reconnect the wires and make it tight If after check the wire harness and is in perfect connection but the switches still cannot operate please check the switch with multimeter check whether it is connected between pins whether switch the states If the switch does not respond the switch needs to be changed locations Batteries indicator maintenance and malfunctions 1 Connecting Pin1 Battery Connects to the vehicle s main positive terminal Use as short a wire as needed Pin2 Battery Connects to the vehicle s main negative terminal use as short a wire as needed Note pins 1 2 are connected across the total battery pack Pin3 No option Pin 3 is left open Pin4 key switch to the Battery through the switched terminal of the key switch 2 Display only when the battery is properly charged is the right most LED lit As the battery s state of charge decreases successive LEDs light up only one on time The 2nd from left LED flashes indicating energy reserve 7
24. he charger has electronic protection auto reset electronic current limit Red LED amp green LED flashing Charger s calibrations and malfunction sloutions i Alert and error display Code Reason Solving method Eo No charging function Inspect if the connecting terminals are in proper connection Battery temperature is too high or too low Check if the battery temperature is in the range of 10 C 50 C Inspect if the battery voltage is in the range 48 12V to E52 No battery connection battery voltage too high or 55 2V 36V 9V to 41 4V In charging display E02 48Vbattery too low mode battery voltage is above 67 2 In 36V battery mode battery voltage is above 50 4V Ens Battery is not fully charged for long time overtime Inspect if the battery connecting terminals are loose or charging rusted Battery cannot have TRE charging charging to the Inspect if the battery is shorted or individual battery cell E04 least normal voltage that means voltage unable to damaged be charged in Ensure that surrounding temperature is not too high and E05 Charger internal temperature high HIP ventilation is good and the charger should be turned off 06 Charger internal damage Turn off the charger and send it to service dept for repairing E07 Grid power low Inspect the grid power ii Charger s calibration dero CHARGING HDK ON GRID POWER D CHARGER HAVE TO B
25. he assembly box FIGURE 1 4 The springs that attached to the brake or the accelerator should always have good and flexible to pull back the brake or accelerator One should check the springs one time flexibility per month to prevent cart operating hazards Low flexibility of the accelerator spring may cause the car still running when the accelerator pedal is in the HALT position It may cause severe injuries or death to persons BE SURE TO TURN OFF THE VEHICLE POWER WHILE CONDUCTING ANY OPERATIONS TO THE ACCELERATOR BE SURE TO KEEP ON FLAT GROUND WHILE CONDUCTING THE BRAKE ASSEMBLY MAINTENANCE ANY OF THESE MISOPERATIONS MAY CAUSE THE CAR TO RUN UNINTENTIONLY AND MAY CAUSE INJURIES TO PERSONS AND PEOPERT Y DO NOT TRY TO DRIVE THE VEHICLE TO MAINTENANCE SPOT WHEN THE CAR HAS A BRAKE OR ACCELERATOR MALFUNCTION ANY INTENTIONS TO TRY TO DRIVE THE VEHICLE MAY CAUSE CAR LOSE CONTROL AND MAY CAUSE INJURIES OR DEATH TO PERSONS OR PROPERT Y REAR AXLE AND MOTOR MOTOR OPTIONS 3KW AKW 5KW HDK vehicles use ADC motors as a standard configuration ADC motors are a first class motor on the market today Excellent performance highly dependable low energy consumption Customers can choose different rated voltage DC motors We have 3KW AKW SKW motors available as customer options vehicle s maximum speed customer can different rear axles as options ihe standard configuration is mechanical E axles But
26. ight to keep dust or other foreign objects and water to enter inside of the mechanical parts FIGUREO joint parts of the steering system or the connection spot should add lubricant per month to keep the joint part shaft perfectly smooth FIGURE The front tire pressure should be the same tires should be at the same worn out situation and the wheel nuts should be retighten periodically to reduce the shake of all the steering system components Fasten ring A Steering system malfunctions e Steering wheel too heavy to operate To eliminate the heavy steering wheel malfunction one can do as followed Check the connection of the steering system and be sure all the bolts and nuts are tight Add lubricant to the joints FIGURE Lift up the front wheels with a jack FIGURE Loose the bolts that connect the universal joint to steering column and steering box FIGURE Loose the jack put down back the vehicle shake the vehicle for multiple times to make the connection of the universal joints and steering column steering gear box perfect Fasten back the bolts make it solid tight Follow the steps above will make the steering wheel getting light s me 9 t I ae A Lift the front wheels up u NC E with a jack Loose the boltson gt f E A PE universal joint VEL 2 P N both end the AN If still can not perf
27. increase code number press to decrease the code number until to the right code of the battery Press SAVE button to save the setting the code display will flash after save the setting i Charger s default setting Enter the battery selection mode when the display shows the default charging category charger output wire negative terminal black white wire connects to battery negative terminal Use the charger output wire positive ring terminal to touch the battery positive terminal for 3 seconds 0 5 second Remove the ring terminal The display shows addition of the battery category eg b01 adding to b02 Remark If the charger output wire positive ring terminal is removed the display shows the battery charging category without addition this illustrate that the touching time is not sufficient for 3 seconds Please repeat the operation Jf this continues to increase steps 2 should be repeated remark if the operation stop time exceeds 30 seconds during the operation process the display will show E02 Please disconnect the grid power until nothing shown on display then connect to grid power again and repeat the setting Jf the current setting needs to be stored the charger output wire positive ring terminal should be used to touch the battery positive terminal for more than 10 seconds When the replay activation sound is heard and the display flashes then the new setting is successfully stored disconn
28. is clear Turn key to ON position 3 hi While roger place Forward Reverse switch in desired position Ve operating F Forward N Neutral R Reverse Buzzer will sound Park brake will release will start moving when accelerator pedal is pressed Slowly press accelerator pedal to increase speed Instructions decal To stop release accelerator pedal and press brake pedal BEFORE LEAVING Press park brake pedal until it locks and holds vehicle Place Forward Reverse switch in NEUTRAL position Turn key OFF and remove key when not in use MOTOR BRAKING _ Electric motor braking provides speed regulation functions For parked vehicle beeping alarm indicates vehicle roll away In operation beeping alarm indicates reduction in motor braking Apply brakes to further reduce vehicle as required System is activated only when tow switch is in the RUN position When towing this vehicle tow switch must be in the TOW position 102518001 DECALS _ x 5 decals Charger Charger s indicating decal Charger s stage display decal HDK charger s information decal Caution and warning decal Charging Stage Display Charging Progr Failure Code Displa Charging Stag SE OCS YES AA le A beris AME TG LIL STD 072 OR FORMS TO UL STL Tits ete ert Us ai intertek DANGER ask or eLECTRIC shock connect ONLY PROPERLY GROUNDED AC OUTLE
29. le run time maximum 999 hours Total running time maximum 9999 hours Zero clearing after exceeding precision of mileage value 0 1 Single run 1 Total running Display mode of running time Hour Minute Hour Mileage value inaccuracy 1 The voltage of signal of the indicator lamp 10 15V 2 All functions show at switch on show time 3 seconds A o E The signal of the switch input voltage 10V min 15V max DC LCD type TN concrete parameter is omitted Functions opeed display by digital are precise as to 0 1 Km H anti shake he bar code shows the RPM Speed Electric consumption display 6 shelves have two kinds of alarm Single course distance TRIP Total mileage ODO The electric car operates once riding time RT The electric car operates total time RTT Kilometer Mileage switching 9 The inside parameter adjusting 10 Turn left turn right high light parks trouble low light LED indicator lamp 11 Light green back light always lighting Speedometer maintenance The speedometer 16 highly integrated instrument to keep 1t in good working conditions one should keep in usage under the specifications limits of the speedometer eg the working environment should be between 30 C 80 C the working voltage should be between 6 15 The speedometer should be installed properly on the front of the vehicle an
30. liminate accelerator maltunctions and accelerator maintenance Accelerator no respond Be sure power key is on ON position F R switch in F or R position Remove the accelerator assembly part s plastic lid Check the micro switch s position When the pedal is loosed the micro switch should stay at HALT position and when the accelerator pedal is depressed the micro switch should stay at RUN position depress the accelerator pedal see if the cams rotate as the shaft rotates if not see which cam can not rotate If all the accelerator s mechanical functions in good condition check the POT s resistance value with a multimeter see figure If the POT values are not right replace it with a new POT Switch If all the accelerator s mechanical functions in good condition check the micro switch see if it is connected while it is on RUN position if not change it with a new one vehicle still running when loose the accelerator pedal Turn off the vehicle s power Remove the accelerator assembly s cover lid 3 Keep the accelerator pedal in loose position state and check the micro switch position see if while it is in the HALT position PAGE 9 the accelerator micro switch still in the RUN position if so Then adjust the accelerator height restraint bolt FIGURE to adjust the height Make the accelerator s micro switch stay at HALT position while loose the accelerator pedal 4 If the micro switch is i
31. mal Measure the resistance of the NO 1 post and NO 2 post as the figure shows if either of the two have no respond value then we can be sure the motor has a internal coil break Disassemble the motor and find out the break spot and repair broken or break in the coil Disassemble the outside cover of the motor and check the carbon brushes whether it is in proper condition If it is extremely worn out then the motor may not have good contact conditions Change the brushes with new pair ii Motor creates too much noises Check the bolts that fasten the motor to the rear axle the bolts should be solid tight and if they come loose may create much more noise and will cause the shaft of the motor to get damaged The mechanical parts of the motor may become lack of lubricate grease after certain time s usage Add grease to the rotor of the motor bearings Be sure all the bolts and nuts are fasten up inside of the motor CONTROLLER 1243 controller 1 FEATURES a user DUnparalleled Driving and Braking Feel Regenerative braking allows shorter stopping distances increases usable battery energy and reduces motor heating The half bridge armature drive topology allows regenerative braking down to zero vehicle speed e Ramp Restraint feature provides automatic electronic braking that restricts vehicle movement while in neutral e Vehicle speed is controlled by the throttle at all times including d
32. n good working condition then one should check the solenoid contactor gt Use the multimeter to mesurer the resistance value of the left and right pins see the if the value is 5 Do Use the multimeter measure the resistance value of the left right and middle pins step the pedal as well see if the value is range from 0 5 KO MAC A TAM Use a measurer to measure the height of the accelerator pedal HEIGHT _ ADJUSTING BOLT a MU TM n 2 u 1 ps C ge a bgi EON Eu Y x Bee 3 a Pon e apt Ew N inm P ic a 222 a 7 PJ Na FE Adjust the height of the accelerator pedal by rotate the height adjusting bolt BRAKE AND ACCELERATOR IV Brake and accelerator maintenance 1 The strength to press down the brake pedal is about 30kgf Pay attention to the distance between the brake pedal and the front of the cart 2 The brakes on golf carts are self adjusting The strength for parking brake is about 30kgf Of parking limits should be accurate reliable and fully brake Otherwise please readjust it 3 The accelerator assembly box should be kept water proof water will cause short circuit of the electronic components inside of the accelerator assembly box When one removes the cover lid and assembles it back one should put silicone gel on the fringe of the assembly box then put back the lid fasten the screws tight to keep water from leaking into t
33. not over tighten them maximum tightening torque specifications for the battery and motor connections are limited FAULT HISTORY A programming device 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 carefully checked Faults such as over temperature may be caused by operator habits or by over loading After a problem has been diagnosed and corrected it is a good idea to clear the 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 indeed fixed IN Controller configurations See 1243 controller parameter data sheets AN cautions CUSTOMER SHOULD NOT TRY TO OPEN THE CONTROLLER BOX IN ANY CIRCUMSTANCES CONTROLLER 1266 controller I Charger s specifications u 1 Charging display process BUL CONSTANT FLOAT FULLY VOLTAGE CHARGE CHARGED ii display 1 Red LED steady on error occurred 2 Orange LED flashing Low AC voltage v 3 Red LED amp green LED flashing alternately slow lt 80 Charger 4 _ alternately frequent lt 80 Charger 5 Green LED steady on battery fully Charged can be calibrated to be 36V or 48V t
34. own hills e Load Compensation provides improved loaded versus unloaded speed regulation by compensating for losses in the armature 2 Fully Programmable Fully compatible with the Curtis Models 1311 and 1314 programmers for programming test and diagnostic information MultiMode feature allows four user selectable vehicle operating profiles Each profile has separate drive current limits brake current limits acceleration rates brake rates and maximum speeds e specifications 16 Molex low current connector the controller A 4 pin low power connector is provided for the low current logic control connections the handheld programmer A complete 1311 programmer kit including the appropriate LG connecting cable can be ordered from company Pin load sensor input opfionall Pin 2 Fault 1 output pump input Fault 2 output Pin 3 Fault 2 output Pin 4 main contactor driver output Pin 5 throttle 3 wire pot high Pin 6 throttle 0 5V pot wiper Pin 7 throttle pot low Pin 8 auxiliary driver output typically Pin 9Mode Select 2 input Pin 10 emerg reverse check output optional Pin 11 reverse input Pin 12 forward input Pin 13 emergency reverse input Pin 14 Mode Select 1 input Pin 15 interlock input Pin 16 keyswitch input KSI Pin 1 receive data 5V Pin 2 ground B Pin 3 transmit data 5V Pin 4 15V supply 100mA Hanheld Programer CONTROLLER 1
35. rum and add lubricate oil to the mechanical parts in the brake drum to the cams and shafts For the shed dust of the brake shoes cause the mechanical parts malfunctions NCAUTIONS CUSTOMERS SHOULD BE CAREFUL ABOUT THE OIL SPRAY WHILE ADD OIL TO MECHANICAL PARTS DO NOT GET THE BRAKE SHOES SURFACE CONTAMINATED WITH OIL IF SO PLEASE CLEAN THE BRAKE SHOES SURFACE WITH RAG AND BRAKE CLEANER THEN RUB THE SURGFACE WITH ROUGH SAND PAPER MULTIPLE TIMES REAR AXLE AND MOTOR IL Motor maintenance The electric cables connected to the motors should be big enough Standard cables should 40mm2 or more Because the cables have tremendous current burden if the cables not big enough it will generate lots of heat and the big current will brake the cables cause brake circuit The nuts fastened to the motors should be solid tight loose nuts will cause big electric sparks and may cause severe motor damage or explosion Motor s malfunctions Motor is extremely hot and cannot operate DCheck the fasten nuts on the top of the DC motor be sure they are tight The DC motor may have internal coils break up Turn off the vehicle power disconnect the cables attached to the motor Use a multimeter and set it to resistance function Measure the four brass post on the motor as the figure shows the motor has two coils and if either one has a break in the circuit the motor won t operate and the motor will generate more heat than nor
36. sparks and avoid any explosion or fire that could cause physical injury or damage to the property x Once charged the cap should be kept tightly covered A I malfunctions and solutions ELECTRICAL CIRCUITR Y MALFUNCTIONS AND SOLUTIONS N Y N Y N Y N X VEHICLES TREAD For different circumstances the vehicle being used different tire treads are optional the standard tires HDK vehicles have are turf tires FIGURE 1 STANDARD TREAD FIGURE 2 PREMIUM TREAD FIGURE 3 EXTRA TRACTION FOR ATTACHING THE MAXIUM PEFORMANCE THE TIRES SHOULD ALWAYS BE CHOOSEN ACCORDING TO THE CIRCUSTANCES THE VEHICLE MOSTLY BEEN USED Front hub brake drum Dust cover Dust cover seal Tire wheel fasten nut ho fasten wheel nuts one should always keep fas en it on in cross sequence To attach the perfect tight situation Tubeless tire cautions 1 Clean both tire beads to remove dirt or other object Where the tire beads seat clean the wheel rim with a wire HII THE TIRE brush CONSTANTLY WHILE INTLATE THE TIRE Apply plenty of tire mounting lubricant soap and solution to both beads and rim flanges Install the tire on the rim from the valve stem side if thre is no tire machine available use a rubber mallet and tire iron Remove the valve core and position tire so that both OF THE TIRE 15 BETWEEN 3 5 4 0MP beads are on the rim flange narrow bead seats Y Q
37. t 5A Working frequency 100KHZ Output voltage 12 0 1V Max output current 18A 12V continuing work for 12 hours Water proof level 21 54 Working temperature 401 85 Lifetime 10000 hours Insulating strength 1000VDC DC DC converter maintenance HDK vehicles use DC DC converters special designed for vehicle s control circuit diagram HDK DC DC converter have automatic over current over heated short circuit over current protection and recover functions AN The burden of the vehicle system should not be over 150W total power of all the lights If so the DC converter will shut A DC DC converter malfunctions All the lights and horn can not switched on Check the Input I Light get dark when turn all the lights and horn be used DC converter extremely hot while working IV All the lights shut off automatically after short time turn on the lights OUTPUT SPEEDOMETER Specifications Working voltage 6 15V DC It does not allow to higher than 15V The reverse geostatic gt 200V Working temperature 30 80 suitable for the cold area gt Store temperature 35 85 speed shows the maximum 199 9 Km H The speed show value measured values RPM shows the maximum Self defining Acquiescence 6000RPM The electric consumption restored way OCR HVR Single course distance maximum 999 9 Km Total mileage maximum 300 000 kilometers Sing
38. uickly remove the air nozzle and install the valve core d Adjust the tire pressure between BAROMETER 3 5 4 0MP immerse the tire into water to make sure there are no leaks WARRANTY The warranty is to standardize the after sale service for export vehicles Settle the claims efficiently and improve our after sale service Experience HDK Electric Vehicle Corporation is dedicate in the electric vehicle manufacturing since 2006 HDK customers are all over the world HDK Electric Vehicle Corporation promises any client who buys HDK vehicles HDK technician s will be always be ready to help fix the problems with you We provide superior quality for after sales service For more warranty information please see limited warranty form that customers receive when purchasing HDK vehicles Appendix 1 www hdkusa com
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