Zap XEBRA D555,043 User's Manual
Contents
1. see loose or frayed wires or damage contact your local service center or dealership Do not operate the Xebra if any such damage has occurred To close the hatchback lower close and gently press at center until it clicks Do not slam it Rough handling can cause damage to the latch and or body T The following parts and components are Not intended to be serviced by the user only a ZAP trained technician Any repairs or alterations made to the vehicle WILL VOID THE WARRANTY DRIVE MOTOR The Xebra s rear wheels are powered by a 72VDC brushed series wound drive motor rated at 5 KW Located inside the rear deck lid this motor has a continuous horsepower output rating of about 5 HP with a peak power somewhat higher This is sufficient to propel the vehicle at up to 40 MPH on level terrain COOLING FAN The motor is equipped with a temperature activated cooling fan located inside the rear deck lid and above the motor A temperature sensor on the motor turns the fan on at 60 degrees C Operating the vehicle without the cooling fan working can cause the motor to overheat and could lead to serious damage If the motor gets too hot 135 degrees C a light on the dashboard voltage meter will illuminate alerting you to the problem Stop the car and allow the motor to cool before continuing Do NOT use water to cool the motor It is an electrical component and can be damaged by moisture MOTOR CONTROLLER Located in the rear deck lid a2. 1 Before you operate the Xebra for the first time you must fully charge the batteries using only the supplied internal charger This is an important step If you fail to properly condition your batteries their life and performance will suffer 2 To charge the batteries plug the extension cord into the charger socket located on the rear passenger side of the Xebra in the hatch that resembles a gas hatch Make sure the outlet is 110V and the circuit is rated for 20 amps and is a dedicated circuit 3 Be sure your batteries are FULLY charged It s best to charge them 24 hours especially the first time Your batteries are fully charged when the voltage meter on the dash reaches 79 volts or higher Remember the voltage meter will Not function until the key is on The charger will shut off automatically when charging is complete 4 Like a combustion engine the batteries will require time to properly break them in Five or more charge and discharge cycles are needed to break in the batteries for optimal range After the first full charge drive the Xebra 5 miles then charge fully The next trip drive 8 miles and charge fully The third trip drive 12 miles and charge fully On the fourth trip drive 15 miles and charge fully This procedure will maximize the capacity of the batteries On your fifth trip drive until the batteries are very low but still drivable Note how many miles this is It is recommended to discharge the batteries no more than
3. AND REGISTRATION WARRANTY CARD WILL VOID WARRANTY 4 INTERNATIONAL SALES All inclusions and exclusions of the ZAP Warranty apply except for reimbursement for shipping of parts outside the United States 5 HOW TO MAKE A WARRANTY CLAIM Customer must give ZAP or authorized ZAP XEBRA dealer notice of any claim within a reasonable period of time not to exceed thirty days ZAP will not repair any condition or replace any part if a claim is not made in a timely manner Customer must present the vehicle or defective part to an authorized ZAP XEBRA dealer Prior to the beginning of repair or replacement of defective parts a repair work order must be signed and the ZAP XEBRA Warranty Registration Card and or proof of purchase must be presented to the dealer 28 TE XEBRA 20089 Owner s Mana Dealer must have returned the PDI and a copy of the registration to ZAP All parts replaced under this warranty become the property of ZAP 6 DISCLAIMER THIS WARRANTY IS EXCLUSIVE ZAP MAKES NO OTHER WARRANTY OF ANY KIND EXPRESS OR IMPLIED ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FORA PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS OR TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY ZAPAND EXCLUDED FROM THIS WARRANTY THE PURCHASER AND ZAP EXPRESSLY AGREE THAT THE REMEDY OF REPAIR OR REPLACEMENT OF THE DEFECTIVE VEHICLE OR COMPONENT THEREOF IS THE EXCLUSIVE AND SOLE REMEDY OF THE PURCHASER ZAP MAKES NO OTHER REPRESENTATION OR WARR
4. The seat adjustment lever is below the front edge of the driver s and passenger s seats We recommend that you make the adjustments BEFORE you get in you could hit your knees on the steering wheel or dashboard if you move forward too fast or hurt someone s legs or feet in the back seat if you move back suddenly Be sure to keep fingers feet and any other objects out of the seat track Adjust the back of the seat forward or back by turning the large dial on the side of the driver s or passenger s seats This is something you can do while seated but be aware of people in the back seat Their knees and feet can be cramped or hurt while you are making the adjustments HEATER The switch for the heater is located on the mid console There are two vents both in the front one on the driver s side and one on the passenger s side The heater is a 72 volt unit It is primarily used to defog the windshield Using it will rapidly deplete the batteries shortening your range 16 ZE XEBRA 2008 ws Maa MIRRORS The rear view mirror on the windshield should be set so that you can comfortably see behind the vehicle Itis recommended that you have a point of reference behind the vehicle so that you can properly see other vehicles or obstructions such as poles fire hydrants or bicycles Since the back window is level with most truck or SUV headlights it may be necessary while driving at night or through tunnels to adjust your mirror Side view mirror
5. 50 before charging for optimal battery performance You can estimate this percentage by mileage Typical is a maximum of 15 miles for optimal performance 5 IMPORTANT If your Xebra will be exposed to FREEZING conditions your batteries MUST BE fully charged or they will be DAMAGED and the warranty will be void Keep your vehicle warm Charge it in the garage instead of outside The colder itis the less range and battery life you will have 10 TE XEBRA 2000 wner s Mana CHARGING THE BATTERIES Before charging make sure the ignition switch is in the OFF position and the key is out of the ignition It is best to charge the Xebra overnight 1 Plug the charger into a 110 volt wall outlet Any outlet to be used for charging needs to be rated at a minimum of 20 amps and needts to be a dedicated circuit to charging the Xebra 2 It can take approximately an hour to refresh your Xebra to a point where you can drive it for another three to four miles Optimal charge is achieved after eight hours longer for extended range batteries The charging system will stop the flow of current when charging is complete 3 When unplugging the power cord from the Xebra don t forcefully pull the cord from the charger jack Use caution to keep the contacts intact over time 4 Store and charge your Xebra at temperatures between 50 deg F 10 deg C and 100 deg F 38 deg C See CONDITIONING THE BATTERIES for important information on freezing condit
6. In the event of an emergency or accident push in the large red master off button located just under the front edge of the driver s seat then immediately leave the vehicle Do NOT go back into the vehicle to retrieve items as there may be battery damage or electrical dangers See the Master off button section for more information Be aware of the battery compartment in the center console area and under the rear seat If battery fluids or wires are exposed DO NOT TOUCH Acid will burn your skin and wires may still be conducting electricity Baking soda is a good neutralizer in the event of a battery spill POLITICS There is no technical reason a full fledged electric vehicle cannot be available to everyone at a reasonable price Research and investment are the obstacles and political will to pursue this goal Write your elected officials to push for EV battery research or EV incentive legislature And to go totally green install a Solar Electric charging station on your house or garage 20 TE XEBRA 20089 Owner s Mana ADDITIONAL INFORMATION REGARDING THE XEBRA PICKUP ZAPTRUCK The ZAPTRUCK weight capacity is 500 Ibs including passengers The Gross Vehicle Weights and shipping weights can be found on page 30 Most of the components in the ZAP TRUCK are identical to those described in the Sedan Manual The locations vary somewhat PARKING BRAKE The parking brake is located to the right of the driver s seat between the driver and passenger
7. Operation is the same as for the SD BATTERY CHARGE CONTROLLER MOTOR CONTROLLER DRIVE MOTOR COOLING FAN These components are all located under the PK bed With the bed in the dump position all are easily accessible H Spare tire 5 Batteries W 2 Motor E 6 Charger 3 Cooling Fan 7 Controller 4 Horn DC TO DC CONVERTER This componentis located in the same place as on the sedan inside the front deck lid and on the left SEAT ADJUSTMENT The PK has very limited seat adjustment due to the proximity of the seats to the rear of the cab If you need a bit more room between the steering wheel and seat move the seat up so you can tilt the seat back 21 ZAPTRUCK SPARE TIRE The spare tire is located under the rear of the bed Remove it by inserting the long tool provided through the hole on the bed and into the receiver above the tire Fig 1 Rotate the handle until the tire drops far enough to release it Some spares are bolted on When replacing the spare be sure the tabs on both sides are over the tire to secure it Fig 2 Position jack as shown on Fig 3 to change the fronttire Position jack as shown on Fig 4 to change the rear tire ire lowered DUMPING AND SECURING THE BED The Xebra PK is equipped with a dumping bed Additionally all four sides of the bed can be lowered To dump the bed release the two latches on either side of the bed and underneath Hold the bed securely as shown and pull back
8. Xebra Sedan do not carry more than 4 people or more than 500 Ibs Do not place one seatbelt over two children These recommendations are for your safety while operating the Xebra The Xebra is technically a three wheel motorcycle that encloses the passengers This vehicle does not have airbags or supplemental restraint systems Because of the size and weight of the vehicle it does not have crumple zones or inner body support like other vehicles The best safety measure is to operate your Xebra carefully following the guidelines in this manual The Xebra is NOT intended for highway or freeway travel or roads where the speed limit is 45 mph or greater Higher speeds will rapidly deplete your batteries Secondly if an accident occurs at high speed the vehicle will be unsafe DRIVING CONDITIONS Wet or oily surfaces loose gravel or sand and tire and brake conditions will affect your braking Do your best to be aware of changing road conditions and adjust your speed and braking distance If you are in an emergency braking situation you may also pull up on the parking brake to help stop you Do not operate your Xebra on extremely steep inclines The suspension and braking is not engineered to handle these angles Steep hills can be dangerous and potentially unsafe so be mindful of the Xebra s capabilities The Xebra is not equipped with anti lock brakes or traction control Operate at a safe distance from other vehicles and pedestrians This is a ver
9. odometer as TT well as blinker indicators high beam indicator and reverse indicator Iere meet 3 Ammeter 4 Odometer Trip odometer The trip odometer is re settable using the small red button between the dials We recommend 5 Trip odometer reset button you use it to keep track of the distance driven since the last charge to determine your battery 7 Hardbraceenssre light Capacity or consumption 8 Low Battery indicator The Sedan is equipped with both a voltage meter to indicate battery voltage and an ammeter ee to indicate current draw With these two gages you can get a better indication of your vehicle s performance Generally speaking the harder the motor is working the more current it will draw and the lower the battery voltage will drop at least momentarily This means that starting from a stop climbing hills and driving at higher speeds will all increase power demand from the motor and reduce range Your vehicle will be operating most efficiently when the voltmeter reads higher voltages and the ammeter reads lower current draw Familiarize yourself with the interaction of these indicators to maximize range The conservative driving techniques discussed elsewhere in this manual will help you attain this result NOTE Pin point accuracy is not achieved with this voltage meter It is a relative measurement to aid you while driving Periodically check your battery voltage with a digital meter See BATTERY section Speedometer 2 V
10. 2 TE XEBRA 2008 ner s Mana QUICK GUIDE TO XEBRA DRIVING The Xebra is technically a motorcycle and should be driven in a similar manner to a motorcycle This means gradual turns and no sudden sharp turns Check with your local DMV laws to ensure compliance with license requirements To Drive 1 Make sure the batteries have sufficient charge Avoltage reading of 79 or higher is fully charged Refer to Battery Maintenance section for charging instructions 2 Fasten seat belt s and adjust mirrors See Mirror section for proper procedure 3 Place direction knob to N for neutral 4 Check that the Master off button under the driver s seat is pulled out 5 DEPRESS THE BRAKE PEDAL This is important if you are ona slope As the car has no engine or gears it will roll easily in the direction of the slope when the motor is not turning 6 Place key in ignition and turn clockwise one 72V ignition or two clicks 12V ignition You will most likely hear nothing It s electric so there s no idling you may hear the cooling fan The voltage gauge will go up 7 Release parking brake located on the lower left side of the driver s seat Sedan or to the right of driver s seat truck 8 Turn direction knob to F for forward or to R for reverse and press red reverse button If going in reverse you will hear the reverse beeper 9 Remove foot from brake and place foot on accelerator SLOWLY 10 Drive carefully with gentle turns of the steerin
11. 8 XEBRA 1 WARRANTY COVERAGE PERIOD ZAP ZAP warrants from the date of delivery to the first consumer that each ZAP XEBRA Electric Vehicle XEBRA sold as NEW and UNUSED in 2008 and pre delivered by an authorized ZAP dealer and a copy of the bill of sale and registration warranty card has been presented to ZAP will be free from any defect in material and or workmanship for a period of SIX 6 MONTHS WARRANTY NINETY 90 DAYS for rental use owners ONE 1 YEAR WARRANTY on the controller TWO 2 YEAR WARRANTY on the charger PRORATED WARRANTY on the batteries All Inclusive Coverage ZAP will repair or replace as its option all genuine ZAP parts found faulty in material and or workmanship under normal use maintenance and service with genuine ZAP parts without charge for parts and labor at any authorized ZAP XEBRA dealer during warranty coverage period Batteries covered by Battery Manufacturer Charger covered by Charger Manufacturer All genuine ZAP accessories are warranted with respect to parts and labor against defects in materials and workmanship for a period of 90 days from the date of purchase to original retail purchaser Except as otherwise provided herein 26 ZE XEBRA D008 ws Maa 2 WHAT IS NOT COVERED Normal wear and tear items such as the charger plug and receptacle seats windshield wiper blades trim pieces fuses decals except safety decals brake pads brushes bushings light
12. ANTY OF ANY KIND AND NO REPRESENTATIVE EMPLOYEE OR DEALER OF ZAP HAS THE AUTHORITY TO MAKE OR IMPLY ANY REPRESENTATION PROMISE OR AGREEMENT WHICH IN ANY WAY VARIES THE TERMS OF THIS WARRANTY ZAP RESERVES THE RIGHT TO MODIFY THIS WARRANTY AT ANY TIME BEING UNDERSTOOD THAT SUCH MODIFICAION WILL NOT ALTER WARRANTY CONDITIONS APPLICABLE TO THE XEBRA SOLD WHILE THIS WARRANTY IS INEFFECT 7 SOLE REMEDY ZAP S ONLY LIABILTIY UNDER THIS WARRANTY OR IN ANY ACTION WHETHER BASED UPON WARRANTY CONTRACT NEGLIGENCE STRICT PRODUCT LIABILITY OR OTHERWISE IS LIMITED TO THE REPAIR OR REPLACEMENT AT ZAP S OPTION OF A VEHICLE OR COMPONENT THEREOF THAT ZAP DEEMS TO BE DEFECTIVE REPLACEMENT SHALL MEAN FURNISHING DURING THE APPLICABLE WARRANTY PERIOD ANEW VEHICLE OR FACTORY RECONDITIONED VEHICLE OR COMPONENT THEREOF WHICH IS IDENTICAL OR REASONABLY EQUIVALENT TO THE WARRANTED PRODUCT OR COMPONENT AT NO COST TO THE PURCHASER REPAIR SHALL MEAN REMEDYING A DEFECT IN THE VEHICLE OR COMPONENT THEREOF AT NO COST TO THE PURCHASER DURING THE APPLICABLE WARRANTY PERIOD IF ZAP ELECTS TO REPAIR THE VEHICLE IT MAY PROVIDE FACTORY RECONDITIONED PARTS OR COMPONENTS ALL PARTS AND COMPONENTS REPLACED UNDER WARRANTY SHALL BECOME THE PROPERTY OF ZAP 8 NO CONSEQUENTIAL DAMAGES INNO EVENT SHALL ZAP BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO SHIPPING COST TO DEALER LOSS RELATED TO PROPERTY OTHER THAN THE VEHICLE LOSS OF USE LOSS O
13. C TO DC CONVERTER ZAP TRUCK this device acts like the alternator in a regular gas car It charges the 12 volt battery from the 72 volt traction pack while driving It only operates when the key is turned on HORSEPOWER VS XEBRA POWER Here are some interesting facts about your Xebra The batteries can store about 7 2 kWh of energy This translates into about 0 24 Gallons Of gasoline But only 0 15 Gallons Are actually usable about 4 75 kWh Your motor is rated at 5kW which translates to 6 71 HP Your peak horsepower is somewhat higher When the motor is running at 5 kW itis using about 70 amps from the 72V battery pack To calculate your Miles per gallon Use the following formula MPG miles traveled X 30 kWh A typical value is about 150 mpg An inexpensive watt hour meter Kill A Watt PN 9034 can be purchased from your dealer or ZAP This will give you the kWh part of the above equation To calculate the cost per mile use the following formula Cost per mile kWh X cost per kWh miles driven Atypical value is 02 per mile at 10 per kWh or about 47 per charge 9 BATTERIES The most important component of the Xebra that you can control is the batteries This section contains the procedure to follow in order to optimize the batteries performance and life If the batteries are not maintained properly the ZAP as well as the manufacturer s battery warranty may not be valid CONDITIONING THE BATTERIES
14. EBRA 100 Electric Vehicle Xebra is trademarked and patented by ZAP ZAP 2008 All Rights Reserved US Patents D550 588 Sedan D555 043 Truck 501 Fourth Street Santa Rosa CA 95401 T USA A t 707 525 8658 f 707 525 8692 e zap zapworld com www zapworld com Stock Symbol ZAAP Ride the future S XEBRA 2008 SOOO IMPORTANT BEFORE YOU OPERATE YOUR XEBRA ZAPCAR PLEASE READ THE ENTIRE MANUAL CAREFULLY Care and Feeding of Your Xebra DO NOT PLACE MORE THAN 500 POUNDS INCLUDING PASSENGERS IN THE VEHICLE BALANCE THE LOAD SINCE THIS IS A THREE WHEEL VEHICLE DO NOT TOW THE VEHICLE WITH WHEELS TOUCHING THE GROUND IF YOU HAVE QUESTIONS ABOUT THE OPERATION OF THIS VEHICLE YOU SHOULD CONSULT YOUR AUTHORIZED DEALER IT IS EXTREMELY IMPORTANT THAT YOU FOLLOW THE SAFETY GUIDELINES CONTAINED IN THIS MANUAL IN ORDER TO ENSURE MAXIMUM SAFETY FAILURE TO COMPLY WITH THE STANDARDS OUTLINED IN THIS MANUAL COULD RESULT IN FIRE AND OR SERIOUS INJURY ZAP IS NOT LIABLE FOR ANY DAMAGE OR INJURIES CAUSED BY UNSAFE OR FAULTY REPAIRS OR ALTERATIONS ANY REPAIRS MADE TO THIS PRODUCT BY UNAUTHORIZED SERVICE TECHNICIANS ARE THE SOLE RESPONSIBILITY OF THE OWNER PLEASE DISPOSE OF USED BATTERIES IN A LAWFUL MANNER ZAP 2008 All Rights Reserved US Patents D550 588 Sedan D555 043 Truck 501 Fourth Street Santa Rosa CA 95401 USA www zapworld com xebra zapworld com Stock Symbol ZAAP 1 800 251 4555 ai AUGUST 2008
15. F TIME INCONVENIENCE ORANY OTHER ECONOMIC LOSS 29 9 CUSTOMER ASSISTANCE In the event of a controversy or a dispute arising in connection with this ZAP Warranty ZAP suggests that you try to resolve the issue at the dealership level We recommend discussing the issue with your authorized dealer s service manager or owner If further assistance is required please submit your complaint in writing to ZAP Customer Service Department 501 Fourth Street Santa Rosa CA95401 USA Xebra zapworld com 707 525 8658 XEBRA MODELS amp SPECIFICATIONS Xebra ZAPCAR Steel Sedan Xebra ZAPTRUCK Pick up Length 10 3 feet Length 11 2 feet Width 5 3 feet Width 4 8 feet Height 5 3 feet Height 5 3 feet Weight 1441 Ibs without fuel Weight 1481 Ibs without fuel Gross Vehicle Weight 2805 Ibs Gross Vehicle Weight 2805 Ibs Charger Universal Changer on board Charger Universal Changer on board Classification Zero Emission Vehicle Classification Zero Emission Vehicleo 30 Ze XEBRA 2008 ws Maa The HERD ZAP 2008 Xebra ZAPCAR Sedan Xebra Xero Sedan With Solar Panels Vehicles in Development ZAPTRUCK XL Xebra Xero Pickup With Solar Panels ZAP ALIAS Visit your local dealership or www zapworld com For shareholder information ask your broker about ZAP stock symbol ZAAP 31 XEBRA 2009 ners Manual August 2008 Dear Electric Xebra Enthusiast Thank you and congratulations on purchasing the
16. V or higher Repeat for all six batteries USE CAUTION Avoid shorting terminals together with tools or your body Add the six readings together and compare with analog meter reading Alternately make one reading across the entire pack by placing one lead of your meter on the beginning and one lead on the end of the string This requires long leads for the sedan The digital meter will give you a very accurate reading whereas the dashboard meter is a relative measurement to aid you while driving Another perhaps more accurate way to determine the state of the batteries and charger function is to buy a Kill A Watt hour meter It will record how much energy is going into the batteries during charging A fully discharged pack should take 4 75kWh or higher The ZAP warehouse in Santa Rosa California will accept old battery packs Or you can drop them off at your local hazardous waste disposal facility most Interstate Battery distributors or any other battery recycler see Recycling Batteries EXTENDING THE RANGE The main limitation of any electric vehicle EV is its limited range between charges The duration of an average charge at an even speed of 30 mph on level terrain will yield approximately 20 miles of travel on one charge Lower speeds will yield more miles higher speeds less miles per charge Factors such as prolonged high speed excessive stop and go traffic inclined or uneven roads and weight will play a role in the distance you can driv
17. al knob This is a three position turn switch that controls the forward neutral and reverse functions Simply turn the knob to F for forward N for neutral and R for reverse To drive in reverse you must also press the red Reverse button which will activate the reverse safety beeper The purpose of this extra step is to prevent the rapid change of direction while the motor is still turning Changing direction while the motor is turning can damage the motor controller and shorten its life Make sure the car is completely stopped before changing directions POWER CORD The Xebra comes standard with a 10 foot power cord for charging stowed to the right of the front passenger s seat If you choose to use an extension cord a heavy duty 12 AWG or known as 1 2 3 extension cord is necessary Ideal length is no longer than 25 feet If a cord is longer than 25 feet use 10 AWG 10 3 cord Be sure the charging cord is disconnected before driving Be responsible with your cord Position it to avoid tripping over it driving over it dropping things on it or otherwise damaging it 6 XE B RA Owner s Manual FRONT amp REAR DECK LIDS The Xebra Sedan is a hatchback with storage capacity in the rear but no storage space inside the front deck lid Do not attempt to stow create storage or strap anything in this area It allows no safe place for foreign objects It s very important not to this open while the Xebra is turned on This could result in unex
18. bulbs mats and pads cosmetic deterioration and items which deteriorate or fail due to exposure Damage caused by failure to provide proper service maintenance and or storage as described in the ZAP Owner s Manual Damages resulting from improper repairs modifications or use of non approved parts or repairs done by a non authorized ZAP dealer Damage resulting from continued use of the vehicle after a defect is or should have been discovered Damage resulting from accident fire explosion theft vandalism riot or any act of God Damages to batteries resulting from lack of maintenance too deep of discharge or from freezing condition Misusing the ZAP vehicle such as driving over curbs overloading or racing Tampering with the ZAP vehicle Altering or modifying the ZAP vehicle including the body chassis mechanical or electrical Customer applied chemicals or accidental spills Using contaminated or improper fluids Non ZAP parts installed after the vehicle leaves the ZAP factory or control Transportation expenses for warranty services Damages related to plastic and finish on plastic and dashboard including but not limited to scratches cracks and discoloration Driving through water deep enough to cause electrical system damage This warranty does not cover such tires that have failed as a result from normal wear road hazards such as cuts bruises impacts punctures etc overloadin
19. cerning the operation of and equipment requirements of electric vehicles Make sure that your equipment and operation of your electric vehicle meets these standards Failure to obey these laws may result in severe injury or death 3 AVOID UNINTENTIONAL STARTING Do not leave the Xebra with the key in the ignition when notin use 4 DO NOT disassemble the motor controller Return the Xebra to your authorized service dealer for service or repair 5 DO NOT wash the exterior of the car with the center headlight on The light gets very hot and immersion with cold water can crack the glass 23 BATTERY WARNINGS 1 To reduce the risk of injury use only batteries provided or recommended by ZAP Other batteries may explode causing personal injury and damage 2 DO NOT PLACE THE BATTERY NEAR FIRE OR HEAT It could explode 3 Batteries can emit explosive gases while being charged Read the instructions supplied before attempting to charge your battery 4 PERIODICALLY BE SURE ALL BATTERY CONNECTORS ARE TIGHT CHARGER WARNINGS 1 Before charging read the applicable sections including BAT TERY Charger Battery Maintenance and Power Cord 2 USE ONLY THE APPROVED GAUGE POWER CORD with your Xebra Use of any other cord could cause the battery to explode Causing serious injury 3 Do not expose the charger to moisture or water 4 To reduce the risk of damage to the charger and cord disconnect the charger by taking the plug in hand and pulling i
20. e However if you re like most Americans and your household owns more than one car then at least one of these cars probably doesn t go more than 30 miles in any given day which is within the range of your Xebra Note If you plug in twice a day you can double your daily range Stay aware of the voltage meter If your level drops below 60V while you are driving at a steady speed you will not be able to operate the vehicle If you find you are low on power stop at a location where you can plug in your Xebra In the event of an outage we ask that you are responsible with your charging methods The use of business power outlets without express permission is prohibited Please be aware of your charging location Look for public charging locations Allowing the batteries to rest for 30 minutes may give you a mile or two more Te XEBRA 2000 wner s Maral Until the better battery arrives here are some things you can do to extend your range IMPORTANT Charge your batteries ALL THE WAY If you are plugging into a 110 volt 20 amp circuit it can take f up to 12 hours to charge batteries that are 100 discharged Take off slowly avoiding jack rabbit starts Pretend an egg is between your foot and the accelerator pedal Add solar panels this will increase your Xebra s range and battery lifetime a Keep your speed slow and steady A constant 30 mph is better than going 20 30 40 30 etc f A b Anticipate stops and coast into them Sinc
21. e there is no idle in an EV you can save quite a bit of energy here Correct tire pressure is critical to maintain good performance and range It is generally recommended that the tire pressure be kept at the tire manufacturer s maximum rated pressure of 51 psi However if the ride is a little too rough the pressure in either the front tire alone or all three tires may be reduced slightly This will increase the rolling resistance and reduce the range somewhat but depending upon your driving requirements you may decide that the smoother ride is worth the trade off Avoid steep hills Take a more level route if possible even if itis longer Limit the use of all other electrical items especially your heater Eliminate excess weight from your EV 100 Ibs 2 increase in range Keep your Xebra garaged during cold weather Trickle charging with solar panels will help keep the batteries warm permitting them to hold their charge longer Be sure your batteries are fully charged before leaving on your trip Use the correct gauge extension cord and not longer than needed 12 AWG 12 3 or 1OAWG 10 3 must be used for charging See Power Cord section for more information Opportunity charge that is charge wherever and whenever you can even 30 minutes of charging will give you more miles than the mathematics suggest However remember that for optimal battery life charge before the battery is 50 discharged as described in the Conditioning t
22. event injury to yourself and to others do not operate your Xebra if you are fatigued or on medication 4 Do not operate your Xebra while under the influence of drugs alcohol or any other controlled substance 5 Be sure all wire connections especially all battery connections are clean and tight 6 Follow all federal state and local laws regarding electric three wheeled motorcycles vehicles OTHER SAFETY WARNINGS 1 Keep your Xebra in good working condition Call your authorized service dealer for repairs or maintenance procedures that are not described in this manual Visit www zapworld com for the name of a dealer near you 2 Use only original equipment manufacturer s replacement parts when servicing this Xebra These parts are available from your authorized service dealer The use of non standard parts or other accessories or attachments not designed for the Xebra could result in serious injury to the user and damage to the Xebra IT IS EXTREMELY IMPORTANT THAT YOU FOLLOW THE SAFETY GUIDELINES CONTAINED IN THIS MANUAL IN ORDER TO ENSURE MAXIMUM SAFETY FAILURE TO COMPLY WITH THE STANDARDS OUTLINED IN THIS MANUAL COULD RESULT IN FIRE AND OR SERIOUS INJURY 25 ZAP IS NOT LIABLE FOR ANY DAMAGE OR INJURIES CAUSED BY UNSAFE OR FAULTY REPAIRS ANY REPAIRS MADE TO THIS PRODUCT BY UNAUTHORIZED SERVICE TECHNICIANS ARE THE SOLE RESPONSIBILITY OF THE OWNER ANY ALTERATIONS WILL VOID THE FOLLOWING WARRANTY _ gio WARRANTY A August 200
23. g excessive speed spinning on slippery surfaces improper inflation tire chains wheel misalignment improper application damage caused by abuse collision accident fire or vandalism Any damage caused by a puncture or tire repair also is not covered Parts and labor needed to maintain the ZAP vehicle and the replacement of parts due to normal wear and tear 27 Surface rust and deterioration of paint trim upholstery and other appearance items that result from use and or exposure to the elements including sun damage Using the ZAP to tow other vehicles trailers etc may void warranty 2 a SEPARATE MANUFACTURER S WARRANTY Batteries Controller and Charger are covered under separate manufacturer s warranty 3 VOIDING OF WARRANTY THIS AND ANY OTHER WARRANTY SHALL BE VOID IF THE VEHICLE IS ABUSED OR USED IN AN UNINTENDED MANNER OR SHOWS INDICATIONS THAT IT HAS BEEN ALTERED IN ANYWAY INCLUDING BUT NOT LIMITED TO USE OF NON GENUINE ZAP PARTS INCLUDING BATTERIES MODIFICATION OF THE SPEED GOVERNOR BRAKING SYSTEM STEERING TRANSAXLE OR OTHER OPERATING SYSTEMS OF THE VEHICLE TO CAUSE IT TO PERFORM OUTSIDE ZAP SPECIFICATIONS THE WARRANTY IS LIKE WISE VOID IF THE VEHICLE SHOWS INDICATIONS THAT REASONABLE OR NECESSARY MAINTENANCE AS OUTLINED IN THE OPERATION AND MAINTENANCE SECTION OF THE OWNER S MANUAL WAS NOT PERFORMED AT THE TIME AND IN THE MANNER SPECIFIED IN SUCH MANUALS FAILURE OF DEALER TO PROVIDE A PDI BILL OF SALE
24. g wheel 11 Anticipate stops your Xebra does Not have power brakes 12 The most common reason the Xebra won t drive is the MASTER OFF BUTTON is pushed in The second reason is the parking brake is engaged 13 Finally do not forget to disconnect the charging cord RECYCLING THE BATTERIES oe XEBRA Owner s Manual TABLE OF CONTENTS Maintenance GEAR BOX FLUID Unique Features BRAKE FLUID INSTRUMENT PANEL ZERK GREASE FITTING SPEEDOMETERAND VOLTAGE METER IGNITION MASTER OFF BUTTON Additional Equipment and Information DIRECTION KNOB SEAT ADJUSTMENT POWER CORD HEATER FRONT AND REAR DECK LIDS MIRRORS DRIVE MOTOR HORN COOLING FAN TURN SIGNALS MOTOR CONTROLLER LIGHTS BATTERY CHARGER LOCKS DC TO DC CONVERTER SPARE TIRE HORSEPOWER VS XEBRA POWER DRIVING SAFELY DRIVING CONDITIONS ENVIRONMENTAL CONDITIONS Batteries WEIGHT LIMIT CONDITIONING INCASE OF ANACCIDENT CHARGING POLITICS CHECKING BATTERY VOLTAGE EXTENDING THE RANGE Safety Warnings Warranty Information ALLABOUT YOUR WARRANTY TE XEBRA 20089 Owner s Manta UNIQUE FEATURES Xebra Sedan Panel INSTRUMENT PANEL 2 P There are three main components of the instrument panel the speedometer the voltage meter 3g gt ee and the ammeter speedometer and voltage meter only on the ZAPTRUCK The inner dial of the soeedometer indicates speed in MILES per hour the outer in KILOMETERS per hour Also on the speedometer you will find the overall odometer and the trip
25. he Batteries section Be sure your brakes are properly adjusted and are not rubbing when not engaged RECYCLING BATTERIES Do not attempt to destroy or disassemble the battery pack or remove any of its components Also never touch both terminals with metal objects or body parts as a short circuit may result Keep the battery away from children Failure to comply with these warnings could result in fire or serious injury Old batteries must be recycled Lead mercury cadmium and a host of other toxic heavy metals contained in most consumer electronics and batteries pose a real threat to public health and the environment Recycle your batteries properly keeping in compliance with current environmental laws Do Not dispose of lead acid batteries in ordinary trash Consult your local waste authority for information regarding available recycling and or disposal options CALIFORNIA According to The California Department of Toxic Substances Control DTSC it is mandatory to recycle your batteries As of February 9 2006 according to California State Law disposing of batteries with regular garbage is against the law If you believe that your vehicle has a defect which could cause a crash or could cause injury or death you should immediately inform the National Highway Traffic safety Administration NHTSA in addition to notifying Qinggi Group Motorcycle Co LTD If NHTSA receives similar complaints it may open an investigation and if it finds that a
26. ions 5 Keep your batteries charged Batteries stored for long periods of time will self discharge The higher the temperature the greater the rate of self discharge 6 Keep the terminals on the batteries contactors motor controller and motor CLEAN AND TIGHT Loose or dirty wires and connectors can lead to unnecessary battery drain or diminished performance from your vehicle 7 Recharge your batteries when you have discharged a maximum of 50 as described in the CONDITIONING THE BATTERIES section for optimal performance Greater depth of discharge on a continual basis will diminish the overall life of the battery Unlike other rechargeable batteries itis not possible to damage the batteries by charging them frequently 8 Recharge your batteries at least once every 30 days Hint Using a cord with a lighted plug end will let you see immediately if there is power to the outlet you are using Make sure you have the proper gauge cord for the distance from the outlet as discussed above ZAP ASSUMES NO RESPONSIBILITY FOR DAMAGE OR LOSS OF RESOURCES IN CONJUNCTION WITH IRRESPONSIBLE CHARGING PRACTICES CHECKING BATTERY VOLTAGE As noted in the Instrument Panel section periodic checks of the battery voltage with a digital meter are recommended To manually check voltage first turn the heater on for 2 to 3 minutes to remove surface charge Leave heater on Place a lead on each terminal of the first battery Record the reading It should be 12 6
27. nd inside the High Voltage Electrical Components Box large cables connect the battery pack to the motor controller through the power contactors Its function is to take the input from the accelerator and adjust the speed of the motor accordingly It is programmed by ZAP with a general purpose power curve and is not user serviceable BATTERY CHARGER Located inside the rear deck lid the battery charger regulates the power going into the traction battery pack 72 volt from the 110VAC charging cord It will shut off automatically when charging is complete To determine proper function of charger refer to the Checking Battery Voltage section 8 Owner s Manual The charger has a group of 6 graduated lights indicating the relative charging current When initially plugged in to a depleted pack the top light will illuminate indicating a relatively high charging current As the pack is charged the lights will illuminate sequentially At some point in this process the top light in the next group of 4 will illuminate indicating an 80 charge has been achieved When all of the graduated lights are off the second light in the group of 4 will illuminate indicating a full charge The third light indicates that AC power is applied to the unit The last light is red and indicates a fault condition Refer to Charger Instructions to determine possible problem If fault is indicated the charger must be unplugged for 20 seconds to be reset D
28. oil weighted at 80 90 will be suitable too BRAKE FLUID Inside the front deck lid and to the right is the brake fluid reservoir Check the level regularly Gently twist the cap and lift off You will see directly into the brake fluid reservoir If the fluid level is low fill with DOT Type 4 brake fluid using a funnel Do not spill fluid on tires brakes or paint Also the brake light on the voltage meter will illuminate if the master brake cylinder needs attention or if the brake fluid is low WINDSHIELD WIPER FLUID TANK The Xebra steel Sedan comes with a windshield wiper fluid tank inside the front deck lid to the left Check the level regularly As with the brake fluid reservoir gently twist the cap and lift off You will see directly into the wiper fluid tank and fill appropriately when needed 15 ZERK FITTING Periodically lube the Zerk fitting with a high quality marine grade waterproof lubricant It is located just above the fronttire It is recommended to have regular maintenance performed on your Xebra by a trained technician At 1000 miles your dealer should change the gear oil Also the batteries should be checked with a digital volt meter This will catch a failed charger early For maintenance schedules please refer to your Service Intervals Sheet After that your dealer will recommend a maintenance schedule based upon your driving conditions ADDITIONAL EQUIPMENT AND INFORMATION mri SEAT ADJUSTMENT
29. oltage meter 3 Odometer Trip odometer Also on the voltage meter are red indicator lights for high motor temperature low battery voltage 4 Trip odometer reset button and hand brake engaged The brake light will also illuminate if the master brake cylinder needs y yj bie onssse light attention or if the brake fluid is low See MAINTENANCE section 7 Low Battery indicator 8 High motor temperature light 5 IGNITION Put the key into the ignition and turn it clockwise one or two clicks Unlike a traditional engine you will Not hear a loud 9 noise or revving You may hear the sound of the motor cooling fan The cooling fan is operated by a temperature SS sensor on the motor If the motor gets hot 60 degrees C the cooling fan turns on If you open the window the sound will be louder See DRIVE MOTOR section for more information As you select forward or reverse on the console you will hear clicks as relays are activated see Direction Knob below MASTER OFF BUTTON Under the driver s seat is a large red button It is operated by pushing in for off and pulling out for on This button disables the entire 72 volt electrical system You may want to push it in if you plan on leaving the car idle for many days for safety during repairs in the event the car is damaged in an accident etc This button MUST BE PULLED OUT for normal operation and charging the vehicle DIRECTION KNOB Located on the console is the direction
30. on the left side of the steering column Turn the dial counter clockwise to turn on the lights The first position is off Second position causes the headlights to turn on similar to running lights Third causes each headlight s main bulb to be lit as a low beam light Fourth position is the same as second position LOCKS The Steel Xebra Sedan comes with Central Electronic Door locks and Key Fob On the Xebra ZAPTRUCK all locks are manual Additionally there are no child safety locks Please keep your children in their seat belts at all times and be alert Unlock the Xebra from the driver s side Always lock and unlock with the key to avoid locking the keys inside If you do lock yourself out of the Xebra contact your roadside assistance provider to open it Do not attempt to open with a coat hanger as you may damage the interior of the door or window mechanism etc SPARE TIRE JACK The Steel Xebra Sedan does NOT come with a spare tire Optional spare tire can be purchased for 50 Read the ADDITIONAL INFORMATION REGARDING THE XEBRAZAPT RUCK for information the pickup s spare tire TE XEBRA 2008 wner s Mana DRIVING SAFELY There are four seat belts installed in your Xebra It is both unsafe and illegal to place more than one person in a single seat belt It is very important to wear them at all times even for a drive down the block Follow seatbelt laws as with any other vehicle Note that the rear seats do not have lap belts For the
31. pected injuries To open the front deck lid pull the release handle located on the front passenger s side Pull gently andthe ais lid latch will release There is a bar that is intended to hold the deck lid open Do not force the deck lid upward this will result in damage to the windshield and put stress on the hinges Inside the front deck lid you will find the brake fluid reservoir the horn and the windshield fluid tank Inthe ES y center you will see the access to the front tire and suspension It is not recommended that you make any adjustments to braking or suspension systems aside from checking brake and windshield fluids regularly To close the front deck lid remove the support bar and place it into its clip Close and press the lid down towards the back gently until it clicks Do not slam the front deck lid Slamming could damage the deck lid clamp Check to ensure the deck lid closed firmly and properly If not release the lid as before and close it again Pressing down hard on it with a hand or knee may leave an indentation in the deck lid To open the hatchback press the release button in the rear of the vehicle and open upwards me beneath the rear storage area you will find a rear deck lid To open you must push the rear seats forward and lift the lid Fig 1 Inside you will find the motor the contactors the battery charger and the motor controller These are often very hot even during charging DO NOT TOUCH them If you
32. s are adjusted by pressing gently on the bottom corners of the right and left side of the mirror itself Have someone help you set the passenger s side mirror for optimal rear view You may install a blind spot mirror on the side mirror to give you a better peripheral view These can be purchased at any auto parts store IMPORTANT If you press too hard on the side mirror glass while making the adjustments you may crack the mirror so be gentle Never clean the mirrors with an abrasive or dry paper towels this will scratch them HORN The horn is located in the center of the steering wheel It is powered by electricity The key must be on for the horn to operate ot d fa l TURN SIGNALS a a The right and left blinker lever is on the left side of the steering column You should always signal 10 15 i seconds before you intend to make your turn Given the size of your Xebra be aware that you may be in other vehicles blind spots Cok ie a ay hk ae 5 The turn signals are self centering so they will return to neutral after the turn However if the turn is too gradual manual re setting may be required LIGHTS The Xebra has three lights in the front The center is the running light It is always on when the key is on Ithas two settings high and low The center light high low switch is located on the console Toggle the switch for high and low _ The control for the two headlights is found on the same lever as the turn signal
33. safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Qingqi Group Motorcycle Co LTD To contact NHTSA you may call the Vehicle Safety Hotline toll free at 1 888 327 4236 TTY 1 800 424 9153 go to http www safercar gov or write to Administrator NHTSA 400 Seventh Street SW Washington DC 20590 You can also obtain other information about motor vehicle safety from http www safercar gov ZE XEBRA 2008 ws Maa MAINTENANCE GEAR BOX OIL After 500 miles you will want to change the oil in the gear box 1 Remove the square head drain plug at the bottom of the gear box and drain the oil into a pan Be careful how much torque you put on the bolts the plug bolts are made of a semi soft metal and you don t want to strip them 2 Replace the bottom drain plug bolt and remove the square head side overflow plug Take your time and go easy 3 Remove the white oil spout plug at the top of the gear box and SLOWLY pour the oil into the spout area until it begins to come out the side overflow hole It will take about 6 8 oz of lubricant 4 Replace the overflow plug and the oil spout plug 5 Look in the phone book for a place that recycles oil or disposes of oil 6 After the break in period check periodically with a dipstick and change when dirty It is recommended to use Lucas Heavy Duty Oil Stabilizer at 100 A gear
34. t out of the wall Don t disconnect it by pulling on the cord 5 Make sure the cord is located so that it will not be stepped on tripped over or otherwise be subject to damage or stress 6 Animproper extension cord could result in fire or electric shock If you must use an extension cord ensure that a The pins on the plug of the extension cord are the same number as the charger It must be grounded b The extension cord is the proper size for the amperage and in good electrical condition 7 Ifthe cord or plug is damaged replace the cord completely 8 Do not operate the Xebra if it has received a sharp blow been struck or been damaged in any way 9 Do not disassemble the charger The charger is not serviceable Disassembly may result in electric shock or fire 10 To reduce the risk of electric shock unplug the charger from the outlet before cleaning the Xebra 11 Itis ideal to charge in dry or sheltered conditions Charging in heavy rain or precipitation may lead to mechanical or personal harm 12 Charge in a well ventilated area away from sparks flames and smoking areas 13 For optimum performance your Xebra should be charged in a location where the temperature is more than 50 deg F 10 deg C butless than 100 deg F 37 deg C See BATTERY MAINTENANCE 24 OPERATIONAL SAFETY WARNINGS 1 Keep hands face feet and long hair away from all moving parts 2 Do not touch the wheels while they are rotating 3 Be alert To pr
35. ultimate clean air vehicle The Xebra is the first of its kind To our Knowledge it is the world s only affordable electric vehicle that meets federal standards and goes over 25 miles an hour Itis also the first Chinese manufactured vehicle to come to the USA In these days of record high gas prices daily discussions of global warming and dependence on foreign oil we appreciate your commitment to change Investing in an electric vehicle company and or buying an electric vehicle are two of the best things you can possibly do for the environment We are looking for dealers If you are interested please contact us We are proactive not perfect If you have ideas we want to hear from you If you can help spread the word about ZAP please do so Write to gstarr zapworld com As the first generation electric vehicle of its kind we expect to learn over time how to make this vehicle better We appreciate your pioneering spirit and value your input to help make the Xebra not only the first practical electric vehicle but the bestin its class Thank You Again 32
36. ward The vehicle will not tip over with the bed in the fully dumped position To fold down the sides release the latches holding the side you wish to fold down There are a total of four latches Remember each side is held by two latches Dumping combined with the ability to transform it into a flat bed makes the PK a very versatile animal 22 SAFETY WARNINGS THE PURPOSE OF SAFETY SYMBOLS IS TO ATTRACT YOUR ATTENTION TO POSSIBLE DANGERS THE SAFETY SYMBOLS AND THE EXPLANATIONS WITH THEM DESERVE YOUR CAREFUL ATTENTION AND UNDERSTANDING THE SAFETY WARNINGS BY THEMSELVES DO NOT ELIMINATE ANY DANGER THE INSTRUCTIONS OR WARNINGS THEY GIVEARE NOT SUBSTITUTES FOR PROPERACCIDENT PREVENTION MEASURES Failure to obey a safety warning can result in injury to yourself or others Always follow the safety precautions to reduce the risk of fire electric shock and personal injury PRE OPERATIONAL SAFETY WARNINGS 1 Read and understand this owner s manual before using this unit Be thoroughly familiar with the proper use of your Xebra 2 Thoroughly inspect your Xebra for loose or damaged parts before each use If there are any loose or damaged parts have a technician perform the needed adjustments or repairs before starting your Xebra GENERAL WARNINGS 1 You should not smoke while operating a Xebra Keep the Xebra away from open flames such as lighters etc Never smoke while charging 2 The operator must know and obey all local laws con
37. y light and maneuverable vehicle but like any vehicle it must be operated within its limits ENVIRONMENTAL CONDITIONS A major factor affecting your batteries is temperature Extreme heat or cold will drastically alter the batteries capacity and will require longer charging or give less range if very cold See the BATTERY MAINTENANCE section for important information on how temperature affects the batteries In cold climates your Xebra should be kept warm in a garage or enclosure In hot climates park in the shade or keep in a cool garage or enclosure 19 DO NOT POUR WATER ON THE MOTOR MOTOR CONTROLLER DC TO DC CONVERTER OR BATTERY CHARGER TO COOL or HEAT THEM They are electrical devices and this will void your warranty cause severe damage to your vehicle and result in physical harm WEIGHT LIMIT The TOTAL payload is 500lbs Speed and weight will change your battery consumption The more the batteries have to work the quicker they will need recharging The same rule applies to cargo Passengers plus cargo should not exceed 500 Ibs If you are unsure about the exact weight of your passengers or the materials you intend to transport please use common sense and do not put too much strain on your Xebra s motor batteries suspension or tires More weight will also require more stopping distance Your Xebra is Not equipped with power brakes Exercise caution and do not follow too closely Be aware of road obstructions INCASE OFAN ACCIDENT
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