Sport Golf Cart Manual - citEcar Electric Vehicles
Contents
1. Please contact your local dealer or a qualified 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 Main malfunction symptoms and possible causes of the controller Item Symptoms Possible Causes The controller does not have power No signal is transmitted to the controller The contacting point of the contactor is stuck The controller or the motor is damaged The Motor encoder is not programmed properly or is damaged The Motor or controller is over temperature The Electromagnetic brake locked The vehicle cannot start The vehicle can only move in one 1 The F R switch is damaged or disconnected from the harness direction The battery is going to run out The hand brake is not released or the brake shoe doesn t release The vehicle The accelerator failed cannot reach The Controller failed maximum speed Too much loading The Motor or controller is over temperature The Motor encoder failed 18 5 5 Diagnostics and Troubleshooting The 1268 controller provides diagnostics information to assist technicians in troubleshooting 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 for2. per day 1W per week 1M per month 1Q per quarter 1Y per year Item Descriptions o 1W Battery 1 Check the liquid level Please add the distilled water if necessary A 2 Charge the battery lt 3 Tighten the nut on the battery cable Y 4 Check to see if the battery is over discharged the Y battery power meter flashing when the battery is fully charged 6 Check to see if the battery is charged fully by 2 Y ways 1 Using the hydrometer 2 Checking the 5 Check the liquid density of the battery standard density should be 1 277 0 007g cm 80 F or 250 battery power meter 7 Clean the surface of the battery Charger 8 Observe the charging status check to see if the Y charger plug becomes hot 9 Clean the surface of the charger Do not get any Y water inside the charger 24 11 Clean the surface of the controller Controller 10 Check to make sure all terminals are tightened Y properly Please do this after the power is off a i 12 Check if the solenoid is in order checking its touching point 13 Check to see if any water gets in Check if it becomes too hot 14 Check to see if the carbon brush should be pi 1 MN 15 Check to see if the accelerator pedal works well Y anditcanteraeasedtecyandauomatcaly Periodic Maintenance Chart Cont d Chassis and body 16 Check to see if the brake drum and the brake Y roe toute rpicedorma A S
3. 3 Relay fuse sense line broken 5 5 MAIN DROPOUT Main contactor open 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 aaa a a ooo on ooo oan 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 20 These same fault codes will also be flashed by the external fault LED connected to Pin 22 if one is included in the system 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 inspection and cleaning as followed 1 Clean the dust and mud on the cover to keep the axle clean 2 Check to
4. citEcar citEcar Street Legal Golf Cart Owner s Manual Sport Edition 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 8 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 Ve ADE WS dd ins 4 25 ONTOS e ae 6 A e A A neem eatin 11 4 Safe Operation InStructiONS srida E E 11 ds Mamen unica dan 12 5 1Mamtenance or Ballesta ata 12 5 2 Operation and Maintenance Of Charger cccccccccssssseeeeeeceenesseeeeeeseeeesseeeeesessaasseeeeeessaes 16 5 3 Maintenance of the Traction Motor ooooccnncccccoconnncnnnncccnnannnnnnnnnnononnnennnnnonnnnnnnnnnn
5. 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 the status of the controller inputs 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 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 sho
6. Note When the grid voltage is out of range of 90 260V the charger will stop charging to protect itself in the same time the failure code light will be on to remind users When the voltage returns back to 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 maintaining a charge connection from the grid and battery after the battery is fully charged 16 Caution Charger is not allowed to be used if there is water in it Caution Use the charger when the environment temperature is between 100 to 450 Celsius Degrees WARNING Only qualified electrician 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 5 3 Maintenance of the Traction Motor WARNING There should be No explosive gas vapor 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 becomes worn out it will damage the motor badly The brush spring should also be checked when checking the car
7. ensure all the connections 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 level if not enough add some 4 Check to see if there is any link in the connection and transmission units or any unusual sound inside the axle 5 Check the brake drum the exterior temperature and smell it should be adjusted and or repaired immediately if there is any problem 6 Check if the breather valve is ventilated or not in case the oil may have 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 get first grade maintenance second grade maintenance and third grade maintenance First grade maintenance focuses on lubricate fixation and gear oil replacement Second grade maintenance focuses on check adjustment 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 shown below Period oo Period Gade 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 Malfunction and troubleshooting Symptom s Possible cause s Troubleshooting Fill with some oil or replace 1 The gear oil is insufficient or used
8. part of this switch is depressed to warn people around the vehicle Emergency brake switch Optional available with vehicle with Curtis 1243 Curtis 1266 and Curtis 1268 controller and EM brake this switch is a two position switch two way interlock Push down the red button to the end and depress the upper part to 8 release EM brake then the vehicle can run Push down the red button to the end and depress the lower parts to engage the EM brake to park the vehicle during this time the P light will be on Most vehicles come with an upgraded hand brake instead Emergency light switch whenever you need to stop the vehicle aside the road in case of an emergency switch on the emergency light button Tow Run Switch available for Curtis 1266 and 1268 controller Before operating the vehicle make sure the TOW RUN switch is on RUN position Make sure the TOW RUN switch is in the TOW position if towing or pushing the vehicle The TOW RUN switch is under the rear body as shown in picture to the right Note When the TOW RUN switch is on the RUN position the vehicle will beep when pushed to remind you to stop WARNING Whenever the TOW RUN switch is moved from the RUN position to the TOW position please move it back to the RUN position there is a delay of approximately 30 seconds before the vehicle will run Note When the TOW RUN switch is on the RUN position the vehicle will
9. power key is positioned to 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 Blocking the wheel then loosen the lug nuts 2 Use a jack to lift the vehicle and then remove the lug nuts and the wheel To install a wheel on the vehicle 1 Use a jack to lift the vehicle and then put the wheel onto the wheel hub with lug nuts 2 Finger tighten the lug nuts then tighten lug nuts to 50 85ft Ibs 70 115Nm in 20ft Ibs 30Nm increments following the cross sequence pattern Cross Sequence Wis 22 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 5 8 Brake Adjustment WARNING If you have any problem with the brakes please consult our dealers Brake failure can result in serious accident or physical danger The brakes on the vehicle can be self adjusted Before you operate the vehicle please press down on the brake pedal several times to make sure the brakes are functioning properly Check and replace the br
10. sure 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 of the same specifications as the original one and is appropriate in application Following are the 9 charging steps 1 Turn the ignition key to OFF position and pull it out 2 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 3 The charger will turn off automatically when the battery is charged fully 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 4 After the charger turns off disconnect the plug on the AC charging cable from the AC power outlet first and then disconnect the DC output plug from the vehicle receptacle It is prohibited to open the housing of the charger Only a qualified electrician 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 carefully the operation man
11. the contactor should be checked any defective parts should be replaced immediately Clean any dust with low pressure air 5 The electric contactors easily become hot if their mutual contact is not in good condition so special attention should be paid regularly to the electric contactors 6 When changing the fuse make sure that the new fuse is the correct rated current For the sake of safety disconnect the positive pole from the battery when maintenance is done 8 Never step the accelerator hard and frequently which may shorten the life of the controller It is prohibited to fill any other liquids such as battery additives mineral water and tap water into the battery ONLY the distilled water is allowed to fill in the battery 10 Do not drive at high speed when going downhill slow down the vehicle when turning and remind the passengers to hold on when turning and going downhill 11 Children are not allowed to play in the vehicle Children should be seated between adults and the vehicle driven by adults when the vehicle is running 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 vehicle maintenance it should be done by the dealer from whom you get your vehicle Periodic Maintenance Chart 1D
12. 17 Check to make sure the hand brake functions Y appia torvento minana mratak S 18 Check the hose and tube for the brake to see if Y any liquid is leaking Applicable for vehicle with hydraulic brake 19 Check the brake fluid level to make sure it is enough Applicable for vehicle with hydraulic brake see if the tire surface is worn and check to see if the lug nuts are tightened properly 21 Check to see if the shock absorber has any oil leaking is flat or makes any abnormal noise 22 Check to see if there is oil leaking on the gear box and the rear end 20 Check the air pressure inside the tires check to Y steering system 24 Adjust the toe in of the front end 25 Clean the body and seat 23 Add the lubricant inside the wheel hub and B Y After above maintenance drive the vehicle to check if the vehicle works properly 9 Location of Fuses 1 Blade fuses amp fuse box All the accessory fuses 8 pieces for DC system 9 pcs for AC system are installed in the fuse box which is located in the left side of the seat pod 25 Rear body o Headlight high beam els Position light ght hig Brake light amp Acclerator power _ _ Fuse box Control circuit fuse ae i Cl 4 Ty a a A Controller i fuse AC system Horn amp P light Headlight low beam Reverse indicator Turning light 2 Main fuse Main fuse is located on the controller mounting b
13. ARNING If the accelerator pedal is stepped down before the power key is switched on the car will not run In this case you should release the accelerator pedal first then turn the power key to ON position then step down the accelerator pedal again the vehicle will start moving CAUTION Slow down the speed of the vehicle to less than 10mph before turning the vehicle Stopping To stop the vehicle gradually press down on the brake pedal When the vehicle stops apply the parking brake and turn the power key to OFF position and pull out the key press the F R switch to the 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 e ALWAYS read this first before you start driving the vehicle e ONLY authorized people should drive this vehicle from the driver s side ONLY e Do not drive this vehicle on a public road before it s registered and the license plate is attached e Drive the vehicle ONLY in areas where it is allowed to be used by law or local regulations and the conditions are safe to do so DO NOT allow more than the recommended number of people on the vehicle 1 person per seatbelt DO NOT overload the vehicle in any case otherwise the motor may be damaged the vehicle may also l
14. ake shoe periodically 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 Right of the vehicle j Rear End i 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 give one month of running in time or 1000kms running in distance detail procedure is as per the following 1 Before running in please check the capacity of oil electrolyte and brake oil if any one of these are low please fill it accordingly 2 The tire pressure should be inflated to the rated pressure marked on the tire 3 Limit the speed of the vehicle to maintain the current of the vehicle at under 40A during driving 4 Check often and tighten regularly the fixing parts of each of the connecting points WARNING 1 To avoid any damage on the brake shoe the handbrake should be released to its bottom before starting the vehicle 23 2 The lubricant for the rear power assembly must be applied and changed as per user s manual 3 The brake system must be adjusted once every 3 months 4 The electric system must be checked once every 3 months especially main circuit for its fastening parts and wiring connections Meanwhile
15. battery power meter shows 20 power left inside the battery An over discharged battery will have a very short service life and will make the recharging very difficult WARNING During recharging the car should be parked in a well ventilated area with the fill 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 don t recharge the battery immediately Only charge the battery when it cools down And also don t 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 new group of batteries you should use the same brand batteries same model same capacity and similar voltage difference be less than 0 02V Equalizing charging is requested for the new group of batteries CAUTION Equalizing charge is requested every month for the batteries when they are used Sj O 5 CHECKING THE LIQUID LEVEL During the use of the battery the water inside the electrolyte will be consumed because of electrolysis and volatilization which causes the liquid level to drop Therefore you must to check the liquid level frequently we recommend checking it every week Add distilled water if the liquid level is under the standard 6 WATERING Flo
16. beep when pushed to remind you Combination switch This combination switch is for standard configuration The combination switch includes two paris left part is the switch for activating the turn signals and horn right part is the switch for the headlight Left Part Turning light switch and horn switch This switch is used to operate the turn signals and horn 1 Pull left lever forward towards you to activate the horn Pull out 2 Push left handle lever upwards to activate the gt right turn signal y m 3 Pull left handle lever down to activate the left turn signal Push forward Right Part Headlight switch Pull down Pull out the button on right to switch on the headlight Lighting Switch and Horn amp wiper switch Optional This lighting switch and horn amp wiper switch is for higher level configuration The lighting switch includes turning light switch and headlight switch The horn amp wiper switch includes horn switch and wiper switch optional Turning light switch Horn amp Wiper swtich Head light hight low beam switch Left lever Lighting switch 1 The top button of the lever is used to control the headlight turn to the first position the position light will be on turn to the second position the low beam will be on 2 Push the lever to the top to engage the right turning light when planning to turn the vehicle to the right 3 Push the lever to the down to engage the left turning
17. bon brush 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 frequenily to distribute the heat radiation 4 Periodically use the 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 r malfunction ha ala and a causes of the DC motor tiem Symptoms Possible Possible Causes ss uN All copper plates turn The pressure of the brush is incorrect black The commutating Short circuit happens between the commutating copper or among copper turns black in a the armature coil poor welding or disconnection happens between certain order and in the commutating copper and the armature coil groups The commutating The central line of the commutator deviates or its surface is not copper turns black round and not smooth disorderly The motor vibrates the clearance between the brush and its holder is too big the clearance between the brush and commutator is too big the mica between different commutators comes out the brush is made of wrong materials the brush is wrong in type The motor is over loaded the commutators are not clean not round or not smooth mica or some commutator are coming out the brush is not ground properly the brush is under a lot of pressure the brush is wrong in type the brush is jammed in th
18. charge before adding water refer to the Charging section 13 5 Once charging is completed open the vent caps and look inside the fill wells 6 Add water until the electrolyte level is 1 8 below the bottom of the fill well 7 A piece of rubber can be used safely as a dipstick to help determine this level 8 Clean replace and tighten all vent caps WARNING Never add acid into the battery 7 TESTING Visual inspection alone is not 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 readi
19. cle Children are not allowed to play in the vehicle Children should be seated between adults and protected by them when the vehicle is moving 5 MAINTENANCE Users should perform regular maintenance to insure the vehicle provides good performance 5 1 MAINTENANCE OF BATTERY WARNING Battery electrolyte is poisonous and dangerous and it may cause sever burns injury etc Always wear protective clothing gloves and goggles when handling batteries electrolyte and charging your battery KEEP OUT OF 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 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 batt
20. e brush holder the brush holder becomes loose or vibrating the polarity and sequence of the magnetic poles becomes wrong The brush and its wires Big sparks from the brush poor contact between brush and soft get hot wires only a small section area of soft wires The brush is noisy The surface of the commutator is not smooth CAUTION Only a qualified technician is allowed to perform the maintenance on the motor The brush wears out changes colors and breaks Big sparks Main malfunction symptoms and possible causes of the AC motor Symptoms Possible Causes The motor is noisy The bearing is damaged 17 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 user serviceable parts inside the 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 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
21. ery should always be kept in good condition Please check every week to see if any battery cable terminal or nut has become loose in order to prevent any sparks or damage to terminals Please check every week to see whether any battery cable is damaged or not any damaged battery cable should be replaced immediately 12 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 your body 4 RECHARGING a As long as you use the vehicle regardless of how long you have used it the battery shall be recharged fully on the same day Any delay in re charging will cause a negative effect on the battery Notes The lead acid battery does not develop a memory so there is no need to be fully discharged before recharging If the vehicle is going to be kept unused for a long period the battery should be fully recharged first After that the battery shall be fully recharged every_2 weeks 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 Also the driver should estimate the distance needed to be taken and recharge the battery at a proper time in case the car cannot get back to the recharging station in time for recharging WARNING Please make sure the battery is recharged before the
22. 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 6 hrs 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 following 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 TABLE 1 State of charge as related to specific gravity and open circuit voltage Specific Gravity Open Circuit Voltage Percentage of Corrected to Charge 800 F 8 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 electrician 15 9 BATTERY CHARGING WARNING Before you use the charger please read the operation manual provided with the charger WARNING Explosive hydrogen gas is produced while battery is charging Only charge the battery in well ventilated areas WARNING Before using the charger please check to make
23. gnition key The Ignition key is used to power up or switch on the electrical system of the vehicle This ignition has two positions Insert the key and turn it clockwise to the first 1 position to engage the 12V accessory system including the headlight turn signal taillight brake light horn wiper and digital meter turn it clockwise further to the second II position to engage the motor and to drive the vehicle To switch the power off turn the key counterclockwise to B position and pull out the key to turn it off Note Only when you pull out the key the 12V accessory system will be powered off completely CAUTION When the Key is on the Il and Il position the key cannot be pulled out Don t try to pull out the key when it is on I and II position y Accelerator pedal It is used to control the speed Push it down gradually to increase the speed The vehicle will speed up with the gradual stepping down of the accelerator pedal eventually reaching the full speed when the pedal is stepped down to Step down the bottom The vehicle slows down with the releasing of the pedal Ref photo to right 7 Brake Pedal It is used to decelerate the METAS vehicle Push the brake pedal to decelerate AS the vehicle and stop the vehicle if needed x g sono Hand brake for parking the hand brake is used for parking The hand brake should be engaged into the parking posit
24. he car is parked or unattended Label above is attached on the dash panel as shown below SAFETY and OPERATING INSTRUCTIONS n an A lo Be vence ope Vehicle Information Name Plate The name plate is located at the lower part of the steering column cover as shown below ELECTRIC VEHICLE Chassis number of the vehicle The chassis number of the vehicle is printed on the right side of the right beam and above the rear right wheel as picture below shows The chassis Number VIN and ID number The VIN and ID number of the vehicle are printed on the left side of the left beam and above the rear left wheel as the picture below shows VIN ID No LH of the vehicle Rear 2 Controls 1 Schematic Figure of controls Horn and Wiper switch Digital meter Ignition key Steering wheel a q y y WE F R switch Lighting switch Si Steering column Battery power meter adjusting handle Service brake pedal EM brake switch Accelerator pedal Emergency light switch Fig 1 Lighting switch Digital meter DR A P og Steering column adjusting handle Fig 2 Fig 3 Horn amp wiper Switch Digital Meter Battery voltage Speedometer Mileage Left turning 5 z a i e Right turing light light indicator indicator High beam Low beam headlight indicator High Low Speed Switch Forward 12v Power Reverse Outlet Battery Meter Fig 5 2 Function of the controls I
25. improperly 2 The bearing is not assembled correctly Assemble correctly 3 Adjust the brake shoe pin shim or the interval Adjust or replace The axle housing gear and bearing are damaged and there 4 The gear between axle 1 and 2 is not touched Adjust correctly is too much noise on tightly the final drive 5 The final drive is too noisy 1 Check if there is Remove the impurity any impurity 2 check if the gear is damaged clean replace the gear l Adjust or replace with a 6 Axle 1 strikes heavily 7 The rear axle is out of shape check to see if it is Replace overloaded Lack of breaking 1 There is an interval between the brake shoes Adjust the interval force and drum 21 4 The brake line leaks Repair the pipe 5 The brake shoes are over worn Replace with a new one 6 The brake cable is too long or is blocked Adjust the brake cable 2 There is oil or dirt on the brake shoes or drum ne Wom PONY clean 3 There is air in brake line Dispel the air Troubleshooting Chart Cont d 1 The brake pedal does not bounce back smoothly Replace with a new one The brake is difficult to release 2 The 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 Too much Oil Adjust the oil lever 5 7 Wheel Replacement WARNING Before doing anything on the wheel and tire please make sure the
26. ion whenever the vehicle is left unattended pull up the hand brake to the end position in order to park the vehicle completely This operation will make the vehicle stay in parking position when the vehicle is unattended WARNING Do not drive the vehicle when the hand brake is engaged Always check and release the hand brake before driving Failure to do this will cause the motor to burn How to engage and disengage the parking brake e To engage the parking brake pull up the hand brake lever to the end e To disengage the 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 Press down this button when you pull up the hand lever gt with the button being pressed o down push down the hand lever Engage the hand park brake Engage Disengage the hand park brake Disengage Steering wheel the steering wheel is used to control the driving direction Please avoid any sudden and big turning Forward reverse switch this switch is a three position switch depressing the upper part gets the vehicle to move forwards while depressing the lower part gets the vehicle to move backwards and the middle position is neutral WARNING This switch must be fully depressed into the proper position or the electric system and motor will be damaged Note The buzzer will beep when the lower
27. light when planning to turn the vehicle to the left 4 Pull the towards you to engage the high beam light The lever will be back to the middle automatically when you let go 5 Press down the lever to engage the high beam light Right lever Horn amp wiper switch Note Wiper switch only functions when the vehicle comes with wiper and or water spray 1 Lift the lever to engage the horn 2 Turn the top button to the ON position to engage the wiper motor push the lever to the front to the LO and HI position to start the wiper Note There are three speed position signals on the right lever INT LO and HI but the wiper motor only has one speed in either LO or HI positions They are the same speed Battery Power Meter Indicates the battery power There are 10 divisions on the meter from O to 1 The meter will decline from the top to the bottom as the battery discharges When the battery is too low the ES indicator light will flash reminding you to recharge the battery Note please refer to your Battery Chargers Owners Manual for how to recharge the batteries Steering column adjusting handle This is used to adjust the steering column If the driver space is not enough for you pull down this handle and lift the steering column up or down accordingly Digital Meter 1 Speedometer shows the speed when the vehicle is running 2 Mileage shows the accumulated distance that the vehicle has run 3 Ba
28. ngs to 80 F Add 004 to readings for every 10 above 800 F Subtract 004 for every 10 below 80 F 9 Compare the readings 10 Check the state of charge using Table 1 on next page CONOR ON emperature Hydrometer Reading G F icy US Trojan 43 120 1 254 1 302 49 110 1 258 1 259 37 100_ 1 262 1 256 32 m3 1 266 1 253 76 1 270 1 250 el TO 1 274 1247 15 603 1278 1244 10 TME 1282 861241 4 05 1 386 1 238 o ES 1 290 1 235 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 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 If 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 14 1 The battery is old and approaching the end of its life 2 The battery was left in a state of discharge too long 3 Electrolyte was lost due to spillage or overflow 4 A weak or bad cell is developing 5 Battery was watered excessively prior to testing Batteries in conditions 1 4 should be taken to a specialist
29. nnnnanancennnnss 17 5 4 Maintenance of the Speed Controller oooonnncccncnnncccccnconcononncncnnnnononononononanannnencnnnnnncnnnos 18 5 5 Diagnostics Aand MroUnleSAOO Ia il 19 5 6 Maintenance of Rear Ade iia 19 a REDA CEM A A o o E Ea 22 9 0 Brake AG JUSTMC tia ia a 23 SN A A E E E ineactuccadaloumeal 23 7 RUNNING INOF NeW Ven unica lic 23 8 Periodic Maintenance Chant ici a Able dadntecreauelaetaieers 244 LOCO RUSOS ia AO a 25 a A 26 E WnG DIAG aN e aa A 26 1 OVERVIEW Our vehicle is environmentally friendly and it can be used as people mover or utility car at a golf course vacation villages villa areas resort hotels private residential areas tourist scenic spots or any other places where it is allowed Please always be sure as to whether there is any restriction in the area where you intend to use the vehicle to avoid any unpleasant experience IMPORTANT LABELS SAFETY LABEL Read carefully 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 into the locked position when t
30. oard under the front seat 10 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 If the vehicle is planned to be stored for a long time then please check the liquid level inside the battery once a month recharge the battery 11 Wiring Diagram 1 Wiring diagram for vehicle 48V with Curtis Controller 1268 see next page 26 204 Sn 3 Chargin biutecden mith tow run switch key switch i charger y Ae F5 SA FS Main connet light Accelerator switch edirection swite E B waming alarm A f fh G R turning signat switch L PR fe left left loft tall head head light light light speed sensor SY Y YY YY Y Y Y electric current meter 27 Client Responsibilities Maintenance Issues Batteries Battery fluid must be checked at least once monthly Use distilled water onl
31. oded batteries need 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 distilled 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 after a full charge you should 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 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 or deionized water only CAUTION The electrolyte is a solution of acid and water so skin contact should be avoided Step by step watering procedure 1 Open the vent caps and look inside the filling wells 2 Check the electrolyte level the minimum level is at the top of the plates 3 If necessary add just enough distilled water to cover the plates once 4 Put batteries on a complete
32. ose control and or the driver and passengers will be in danger 11 O DO NOT operate the vehicle while under the influence of alcohol or drugs their effect on vision and judgment will put the driver and passenger s in danger O DO NOT make the vehicle climb any slope beyond its grade ability DO NOT overtake other vehicles at crossroads in blind areas or in any dangerous areas O Always fasten the safety belt properly before the vehicle moves adhering to the following instructions 1 Be certain the seat belts are latched securely and are free from 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 on the incline Do not make any modification or addition which may affect the capacity or safety of the vehi
33. power key to OFF position 2 Cut off 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 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 5 Make sure the connections are tight but do not over tighten them Faulty History File The handheld programmer ordered 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 carefully checked Faults such as over 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
34. 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
35. troller 4 Operation in extreme environments 2 4 MAIN DRIVER ON Main contactor coil held 1 Main contactor missing or wire to coil is low open 2 Controller is defective AUX COIL FAULT Missing aux brake relay 1 Aux coil open or not connected coil 3 1 MAIN DRIVER Main contactor driver 1 Main contactor coil shorted IC A 3 2 MAIN WELDED Main contactor welded 1 Main contactor stuck closed S ANED IPPO ean conactoraver shored Troubleshooting Chart Cont d PRECHARGE Internal voltage too low at 1 External short or leakage path to B is on FAULT startup external B connection 2 Controller defective 3 FIELD MISSING Field winding fault 1 Motor field wiring loose S EVS POSM 3 Motor hot wimg opon 3 5 AUX DRIVER OFF Aux brake relay driver 1 Aux coil shorted ee feaman IO a anlar aeree FAULT sensor fault OVERCURRENT driver overcurrent 4 3 4 4 4 5 WELDED AUX Welded aux relay 1 Aux relay stuck closed RELAY 2 Aux relay shorted 5 1 5 2 E MAIN COILOPEN Missing the main contactor 1 Main contactor coil open or not connected 5 3 AUX DRIVER ON Aux EM brake or 1 Aux output short to ground WalkAway relay driver 2 Controller defective coil held low 5 4 CIRCUIT BRKR Circuit breaker or fuse open 1 Breaker fuse tripped or open OPEN in WalkAway circuit 2 Breaker fuse defective EY SWITCH SRO SRO fault 1 Key switch not off at power up 2 Key switch shorted
36. ttery voltage shows the voltage of the battery group 4 Left turning light indicator indicates the left turning light is on 5 Right turning light indicator indicates the right turning light is on 10 6 High beam headlight indicator indicates the high beam headlight is on 7 Low beam headlight indicator indicates the low beam headlight is on 8 Reverse indicator indicates F R switch is on Reverse position and vehicle is in reverse 9 Parking brake indicator indicates that the parking brake is engaged you must release the parking brake when ready to drive the vehicle 3 OPERATION Starting 1 Press the F R to the neutral if it s not already there Insert the ignition key and turn it to the second position Press the F R switch and lock it to the desired position Release the parking brake a If it s equipped with hand park brake release the hand parking brake as instructed above b If it s equipped with EM brake and the system of the vehicle is DC system press the brake switch to upper part c If it s equipped with EM brake and the system of the vehicle is AC system when step on the accelerator pedal the EM brake will release automatically 5 Step down the accelerator pedal slowly and smoothly the vehicle will start to move BE W MN WARNING Do not step down the accelerator pedal when turning on the power key otherwise the vehicle may suddenly start moving W
37. ual for the charger for detailed operation instructions A el ad 5 2 The 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 seat or the bag well or front body The procedure to use the charger when the charger is built in the vehicle 1 Connect the cord to the receptacle on the vehicle 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 starts the procedure of self inspection after self inspection green indicator flashes and 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 user does not recharge the battery it will cut the current from the battery and stop the vehicle to force the user to charge the battery
38. ws 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 programmer shows the forward switch closing and the vehicle now drives normally the problem has been corrected TROUBLESHOOTING CHART LED PROGRAMMER HW FAILSAFE self test or watchdog 1 Controller is defective fault i FAULT Wiper signal out of range 1 Throttle input wire is open 2 Throttle input wire is shorted to B or B 3 Throttle pot is defective SPEED SENSOR No pulses from sensor 1 Speed sensor is not connected FAULT 2 Speed sensor is defective Pedal Disable fault 1 Improper sequence of direction and throttle inputs Md STALL Motor stall at current 1 Slope is too steep for the vehicle weight 1 Mechanically locked motor 2 EM brake wiring failure 3 Speed sensor defective 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 braking 2 1 LOW BATTERY Low battery voltage 1 Battery voltage lt under voltage cutback VOLTAGE threshold 2 3 THERMAL Over under temperature 1 Temperature gt 85 C or lt 25 CUTBACK 2 Excessive load on vehicle 3 Improper mounting of con
39. y 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 needed 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
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