Zap XEBRA ZAPCAR Series Manuel du propriétaire

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ZAP Xebra Vehicle Electrical
Repair and Troubleshooting
Manual (72V Key)
Last updated on April 26, 2007
Copyright 2007. This document my not be reprinted, published, emailed or posted on the
Internet without the approval of ZAP.
Intended Readers
The purpose of this manual is to provide a mechanic, technician or savvy electric car buff with the
tools to troubleshoot and repair the vehicle. Please be sure you are familiar with the Owner's Manual
before using this guide. This troubleshooting Guide assumes a good knowledge of the Owner's
Manual, the vehicle itself and basic mechanical and electrical skills. Check with ZAP if you are
unsure who to have do the work. ZAP is not responsible for damage to your vehicle or personal
injury for work done by non-qualified personnel.
Version
This document describes the 72V key ignition system which started shipping around March 2007.
Do not use this manual for the 12V key ignition system.
Sections
Introduction
12V common
72V common
Common Problems
Tight Wire Connections
Fuse Problems
Connector Problems
Theory of operation
Troubleshooting by Vehicle Operation
Low Voltage System
High Voltage System
Troubleshooting by Problem
No 12 volts
No DC/DC converter output
Won't Drive Forward
Won't Drive in Reverse
Vehicle Won't Charge
Test Charger and Batteries
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Résumé du contenu

Page 1 - Manual (72V Key)

ZAP Xebra Vehicle Electrical Repair and Troubleshooting Manual (72V Key)Last updated on April 26, 2007 Copyright 2007. This document my not be reprint

Page 2 - Electrical Introduction

8. Charge interlock relay JDac and associated wiring loose or faulty. Adjust or Replace.9. Switch on Chinese charger (blue and silver) turned off.10.A

Page 3 - Common Electrical Problems

2. Too cold, bring into heated garage for charging. 3. Wall socket voltage too low (must be 110VAC or greater). 4. Charging cord too long or wire gaug

Page 4

Appendix A Figure 1; 72V schematic with Alltrax Controller12

Page 5 - Low Voltage 12V System

Appendix A Figure 1; 72V schematic with Curtis Controller Detail13

Page 6

Appendix A Figure 2; 12V schematic14

Page 7 - High Voltage 72V System

Appendix A Figure 3 Motor/Motor Controller/Contactor wiring detail for both Alltrax and Curtis15

Page 8 - No 12 volts:

• Inadequate Charge or Range • Alltrax Motor Controller • Appendix A Figure 1 – 12V electrical schematic • Appendix A Figure 2 – 72V electrical sc

Page 9 - Vehicle won't charge:

72V Common • The 72V common is referred to as -72V in the schematics. • In the SD you can remove the center traction battery cover and connect to the

Page 10 - Inadequate charge or range:

• Use Zap supplied replacement fuse sockets. • In an emergency you may solder a standard blade fuse to the original fuse holder (remove all the old wi

Page 11 - Alltrax Motor Controller

16.Later models have D4 removed so that JD7 is only activated by the emergency brake. ZAP recommends you remove diode D4 to prevent the constant activ

Page 12

2. Center headlight should be on. Possible problems to check: • Fuse F4 on sedan or labeled fuse on PCB in PK. 3. Headlamp L1. 4. Center headlamp conn

Page 13

High Voltage 72V SystemThe following is the sequence of a properly operating vehicle with probable cause if there is a failure:1. Pull out red main di

Page 14

9. Turn the switch to the “R” position only when the vehicle is stopped. Then press the red “Reverse” button. 10.You will here a click as the reverse

Page 15

4. The dash voltmeter should now indicate traction battery pack voltage. 5. Check main fusible link F9 (under the rear seat in rubber boot on sedan, u

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