Electric Car User Manual

7/25/2019 Electric Car User Manual

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1. Key switch( See Figure 1)

Open: Turn the key to right, the main circuit is through when the key hole is in ON.

Close: Turn the key to left, the main circuit is cut when the key hole is in OFF.Please pull out the key.

2. Press the forward/backward direction switch( See Figure 2)

Please choose forward/backward direction switch according to your need.

is forward direction switch. is backward direction switch. When you press

forward direction switch,the car goes forward;When you press backward direction

switch ,the car gets back.And the reversing light is on and the car makes a alarm

sound.

3. Accelerator pedal (See Figure 3)

Turn on the key ,choose the direction switch and loose the hand brake.Then put your

right foot on the accelerator pedal and start slowly. Please dont start too fast.

4. Brake pedal(See Figure 3)

Please put your right foot on the brake pedal and step it slowly when the car will stop.

How to operate and control

Notice: Please make sure your car is stopped when you change the direction switch. Please put the direction

switch to the middle and stopped 1-2 seconds ,then change the switch. Please operate it slowly otherwise the

master contactor will be damaged.


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5.Combination switch(See Figure 4)

A. Combination switch is include cornering lamp, head light ,loudspeaker, danger warning light

etc.

B .When boosting up the left switch ,the right cornering lamp turns on. The left cornerning lam

turns on when push down it.

C .When the right switch clockwise rotation, the Lo ,Hi gear of rain wipe will turn on. They wclose when the direction is opposite. The loudspeaker will turn on when boost up the switch

D .When the left switch clockwises rotation, the head light will turn on.It will close when the

direction is opposite.

E .When you press the red button ,the hazard warning lamp will turn on. On the contrary, it tur

off.

6.Parking braking( See Figure 5)

A .Parking: pull up the hand brake and make the pallet between the third and sixth ratchet ,the

rear tire will stop.B .Release the parking brake: pull up the hand brake and press the button on the top of hand

shank, push the hand shank to the bottom, then the rear tire will release.

C .You need release the parking brake completely when you driving. And you should strain the

hand shank if you parking.

7.Combination instrument(See Figure 6)

A .Combination instrument is include battery indicator, voltage indication ,mileage indicator ,to

mileage indicator, speeding indicator,temperature indicator, steering indicator, headlight

indicator etc.B . Power displays how much the power supplies and remind the user to charge. The light flick

it means it need charging

Notice: when you stop the car, please pull the parking brake, and make the direction switch in the middle


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8.Operating steps about the charger

A. Please put the charger in a dry and clean condition and make sure its well

ventilated and heat dissipated.

B. Make sure the input voltage of the charger is in normal value and the charger is well grounded.

C. Connect the output plug to battery according to polarity. When both the red

lights on, the charging get started.

D. The battery will be fully charged when the charging indicator turns green from

red.

Please notice that the charger will shutdown automatically if it works more than

12 hours, and it will restart after a power cut.

9.Lifting/stevedoring of the body

Forklift tools are essential in a standard stevedoring method. Park the forklift

steadily on the center of gravity of vehicle first, stretch the fork to the four square

tubes underneath it, and then lift the fork steadily and slowly(refer to pic. 7). When

a forklift is deficient during the stevedoring, a lift platform or similar equipment

becomes necessary. After docking the lift platform with loading device, a driver can

load or unload the vehicles on the lift platform.

For safety, the driver who works on the forklift must be professional and hold the

Forklift Driver License.


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Maintenance and service1.Checking of a new vehicle

Every new vehicle is upon strict inspection before it leaves the factory. But, the irregular usage state during the transport

might have effects on vehicles systems. For security, the following checks must be followed before its getting used.

A. Check the connecting and fastening on each part, especially on swerve, transmission, braking, suspension and wheel n

etc.B. Check that the tire pressure is proper and the tire is good.

C. Check the level and density of the accumulator and if there is a leakage.

D. Check if the braking system and the rear axle are oil leaking.

E. Check if there is damage or bonding on wire harness where it has friction with the other parts.

2.Essentials during run-in period

A refined running-in is not necessary for a new vehicle, but, the abidance by the suggestions is helpful to expand service

and improve its performance if the first distance traveled is no more than 1000 km.

A. Try to avoid a sudden starting, speeding up and keep a stable running speed.

B. Try to avoid pushing the accelerator frequently.

C. Avoid a sudden braking in the first 300 km.

D. Check the battery, controller and the cables frequently to prevent from getting loose and heated. Tighten it up if

necessary.

E. Check the temperature of the rear axle motor and the brake drum often. If there is a overheating(over 60), you should

check and carry out the troubleshooting process.

F. During or after the running-in period, an over discharging is not permitted, for that an over discharging will shorten the

service of the battery.G. Check the fastening on swerve, transmission, braking, suspension and wheel nut, etc. in the 500 km. Tighten it up if

necessary. Check if the braking systems are oil leaking, eliminate it if there is any.

F. The owner should change the rear axle housing lubricating oil after the running-in period or traveling more than 1000 km


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3.Scheduled maintenance

All the vehicles requires a scheduled maintenance that needs to be recorded which is helpful to expand the

service, lower the use-cost and bring the owners safety and happy usage experience. The owners should do

the maintenance all by themselves after three days counting from the purchasing date.(we can also providethe maintenance by our after-sale service department, which charges according to the situation.)

A. The maintaining places should be clean, safe, ventilated and fireproof.

B. Before the maintenance, the power should be off. Pull out the key and keep the parking braking on. It

suggests that a section of battery connecting line should be removed to make sure the main circuit is

disconnected before overhauling the controller and the motor from getting short.

C. While using a lifting jack, getting under the vehicle is not permitted.

D. Be careful when handling the accumulator as which contains flammable and explosive gas and caustic

sulfuric acid solution.

E. Do not smoke or even light a fire nearby the accumulator.

4.Items of the maintenance

A. Maintaining and adjusting of the steering system

B. Tightening up of the bolts of the suspension system

C. Checking and adjusting of the braking system

D. Fastening of the tire bolts, checking of the tire pressure and the abrasion of the tire tread E. Daily maintenance of the electrical part

F. Daily cleaning up of the vehicle


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Project Per week

(or 20hrs.)

Per month

(or 80hrs.)

Per season

(or 250hrs.)

Per semi-annual

(or 250hrs.)

Per ye

1000

natural oscillation momentum of the

steering wheel

A

Fastening of the ball pins and bolts of

the Steering Gear Box

A

Fastening of each parts and holders of

the steering box

A

Lubricating of rotation joints of steering

system

I

Toe-in of front wheel A

Rear axle lubrication (only for rear axle ) A

Fastening of frontmounted toolbar

suspension shock absorber

A R

Fastening of the connection beteen each

parts in front suspension

A

5.Maintaining project

Symbol description: A=check, adjust when necessary; I=identify, correct and change when necessary; R=replace;

C=cleaning and maintaining. The number of hours in the chart stands for the the cumulative working hours.


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Fastening of connecting parts in

rear axle(only for rear axle)

A

Liquid level of braking fluid A

Leakage of brake piping and joint I

Brake performance of brake lining

and drum brake

A

Tire pressure and fastening of bolts A

Abrasion of the tire tread I

Fastening of bolts of accumulator

posts

A

Connecting of wiring harness A

Working condition of each lights I

Cleaning up C

Project Per week

(or 20hrs.)

Per month

(or 80hrs.)

Per season

(or 250hrs.)

Per semi-annual

(or 250hrs.)

Per year(or

1000hrs.)


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6.Maintenance and adjustment of steering system

A. Replenish the lubricating grease of steering system semiannually, and the type is #3 lithium

grease.

B. Check and fasten the ball head bolts of steering gear box every three months to preventfrom an overmuch natural oscillation and direction hysteresis.

C. Check if that the dust cover of link connector is fractured every three month, for that a

broken dust cover is easy to fill water and dust, which will cause abrasion of ball head and

leading to a stubborn steering. The dust cover should be replaced immediately once found

fractured.

D. Check and fasten the link bolts in steering part and mounting bracket bolts every three

months.

E. Check and adjust if the steer wheel swings freely more than 25mm every three months.

F. Check and adjust if the value of toe-in of front wheel is under or beyond 31mm every

three months.

7.Check the natural oscillation of steer wheel

Park the vehicle and make sure the front wheel is dead ahead, turn the steer wheel gently, and if the

value of the natural oscillation is higher than a specified value, it need to be adjusted. Notice: turn the

steer wheel gently and forcefully.


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8.Check the toe-in of front wheel

Standard: 31mm when weight empty

Measure steps: A. Shake the vehicle up and down to make it hang steadily.

B. Drive about 5 meters long in a flat ground by making both the front wheels travel in

straight lines.

C. Mark the center of the back tread of the two front wheels and measure the distance

B between the left and right marks.

D. Push the vehicle forward to make the mark that in the back of the tire move to the

same height that in the front area.

E. Measure the distance A between the left and right marks after it was moved to the

front area.

F. The toe-in=B-A

If the toe-in is not in a specific range, then you can correct it by adjusting the length of

the tie-rod.

A. Loosen the locating nut between the tie-rod truss arm and the ball head.

B. Fasten the locating nut when its in a specific range.


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9.Check and replace the rear axle lubrication oil(only for the rear axle possessed vehicle) and inspect the oil leve

A. The rear axle housing oil level should be inspected semiannually.

B. The vehicle should be parking in a flat ground while inspecting the oil level.

C. Dismount the oil filler plug and check the oil level by your finger. The oil level should be no more than 5mm fromthe bottom of the oil hole. Fasten the oil filler plug if the oil level is meeting the standard.

D. After loading the oil filler plug, check whether the rear axle housing is oil leakage or broken visually.

E. Plenish moderate hypoid gear oil if the oil level is low and then fasten the oil filler plug.

10.Maintenance of the drive system(only for the rear axle attached vehicle)

The motor connects the rear axle directly, and the connecting bolts between them should be checked and tightened

up every three months.

11.Maintenance of the suspension system

Check and fasten the bolts and nuts in front and rear suspension systems if found loose every three months.

12.Maintenance of the braking system

Move the adjustment ratchet wheel that on the brake drum outward till that the tire cannot be twirled freely, then

move the ratchet wheel inward about 4 to 5 teeth, twirl the wheel drum to make sure there is no drug brake.

Notice! The lubrication oil should be GL-4 or GL-5, and the viscosity index should be SAE90.


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The use and maintenance of the motor As the only power of an electric vehicle, the correct application of power unit is essential for the normal operation of

vehicles. And here is the requirements for a normal use and relevant contents about how to proceed the maintenance.

Environmental conditions that a motor requires for a normal operation:

A. No more than 1200 meters above sea level. B. The temperature range should be in -20to 40.

C. The relative humidity should be less than 100% to prevent from condensing.

Description:

A. The power should be cut while checking

B. The motor should not be connected in a no-load condition. If it must be, the voltage should be less than 15% of the

nominal voltage.

C. The cooling air should not contain explosive and caustic gases.

D. The allowable temperature of the anti-friction bearing is 95.

E. The maximum working voltage should be 1.1 times of the nominal voltage, and the minimum should be 87.5% of the

nominal voltage.

F. The maximum permissible short-time current of the motor should be 3 times of the rated current, in which the overload

torque is 4.5 times of the nominal torque, and the working time should be less than 1 minute.

G. The motor should avoid overload and the depth of the water should be lower than the lower edge of the wheel hub.

H. Only the matching controller is available. Also, the motor and the controller should be in the same type.

I. Sweep away the dirt, stratified dust and deposited carbon semiannually in the motor for its heat dissipation and proper

function.

J. Check and fasten if the motor is in a loose condition per month.

K. If found vibrate unusually and make a strange noise, the motor should be power cut and checked immediately.


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13.Check of the oil lever of the brake fluid reservoir

A. Check and replace of the brake pipe

Check and replace if you find that the pipe is damaged, outer cover is fractured, the

pipe is oil spilling and there are bubbles in it. Check and replace if you find metal

brake pipes is damaged, fractured, impressed or corroded.

B. Maintenance of the tire

An over-high or over-low inflation pressure will cause a unusual abrasion of tire. So,

a normal pressure is required. The standard pressure is 230 kpa.

C. Check of the wheel tread

The depth of the grooves and the notches should be greater than 1.6 mm and the

tire should be replaced when its less than 1.6 mm. Also, you should check to make

sure there are no iron nails, cobblestones or other stuffs into the tire. Push the tire

inward after the nuts are loaded(the conical end should be inward) by hand, thenfasten the nuts again. Finally, tighten all the nuts by tools as picture 14 shows.


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The use and maintenance of the Maintenance Free Battery

storage battery pack is constituted by many single battery in series, which provide power for the vehicle. The right use of

the battery will expand its service and driving mileage of the vehicle.

Discharging for the battery:

A. Avoid discharging more than 80% of the rated capacity to expand the service and the discharging should be stopped

when the last light in the indicator gauge blinks. The single batterys voltage should be 12V and the voltage of thebatteries ending should be no less than 10V after the discharging finished, and then the battery should be charged

immediately.

B. If the accumulator discharges too much, then it will need more time to recharge. And the battery will discharge in a low

voltage in the next discharge process. If the circulation continues, the battery will get invalid.

C. After a deep discharging, the battery should get charged as soon as possible and should not be leaved uncharged mor

than one day. In addition, an discharging which is more than 80% of the rated capacity will shorten the service.

Charging for the battery:

A. The battery should not be in a working condition and should get cool down before charging.

B. Only the matching charger is available. Also, the charger and the battery pack should be in the same type.

C. The parking braking should be pulled up and the direction switch should be in the neutral position before and during the

charging, switch it off and pull out the key.

D. Connect the output plug and the charging jack first, then connect an A.C. power

E. When the charging indicator off, the battery gets fully charged.

F. Pull out the Charger plug, then pull out the battery connector when the charging finished.

Charging for the batteries long-stalled and occasionally used: A. A self discharge happens when the battery is not in use and which will lower the charging capacity, cause the

vulcanization and reduce the service of a battery as time goes by.

B. Get the battery fully charged per month and put it in a dry and cool place if the battery is not used frequently.

C. A long-stalled battery should be recharged, the density and the level of the bath solution should be checked when its

get in use again.


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The use and maintenance of the charger:

A. Charger should be placed on ventilation, no dust, no corrosive gas, dry and the temperature is not higher

than 40 degrees area.B. Charger input electric is single-phase AC 220V 50Hz, socket should be 16A.

C. When charging, do not open the case.

D. When charging , where there is voltage is too high or too low, that is over 180V-260V , you should stop

charging, and other electrical,when the voltage returned to normal range, you can go on the charging.

E. Forbid to lengthen or replace the output cable.

F. Do not block the air inlet and outlet of the charger.

G. When moving the charger , disconnect the electric and charging plug first.

H. When there are abnormal sound or smell, unplug the power cord.

Vehicle cleaning

when cleaning ,Special attention to the vehicle electrical parts, especially drive motors, controllers, etc., they

are can not be wet otherwise it will result in damage to electrical parts.


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Trouble Reason analysis Solution

Instrument panel do not show anything Key switch short circuit Maintenance or replacement

Circuit connection loose or turnoff Tightening the connection

Battery connection loose Tightening the connection

Controlling circuit burned out Replacement

Instrument panel worked well, but the car

can nor drive

Operating procedure error Use right operating procedure

Accelerator breakdown Maintenance or replace the spare parts

Direction switch breakdown Maintenance or replacement

Master contactor or reversing contactor

breakdown

Maintenance or replace the spare parts

Controller breakdown Maintenance or replacement

Control circuit breakdown Examine the circuit and the plug

Motor fault Check and maintain the motor, replacewhen necessary

The whole car 12v accessory equipment

do not work

The converter is working or not Check the converter or replace it.

Some accessory equipment do not work

Protective tube burn out or the switch

failure

Replace the protective tube , and

maintain the switch

Electrical equipment fault Maintain or replace it

The battery do not work

The charger break down or the wire

loose contact

Replace the charger

The charger socket break down Maintenance or replacement

The input voltage is too high or too low Pause charging or use AC voltage

stabilizer

The battery is break out Replace the battery

Common trouble shooting


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Trouble Reason analysis Solution

The wear of tire is not even

The air pressure of tire is too high or too

low

Adjust the tire pressure to specified valu

Toe-in of front tire is not right Adjust the toe-in to specified value

The turn system is inflexible

The grease of turn system is solidified After clean, add suitable quantity grease

and replace the dust cover

Turn system is lacking of adjustment or

been wear

Add grease

Low air pressure in front tire Adjust the pressure to normal value

The of steering wheel is too muh Steering linkages bulb wear orloose Adjustment or replacement

Need adjustment Adjustment or replacement

Braking deviation

The tire pressure is not even Adjust the tire pressure value to normal

one

The brake force of tire is not even Adjust brake clearance


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Documents

Electric Car User Manual