Zap ZAPVAN SHUTTLE 2010 Owner'S/Operator'S Manual Download Page 6

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2010

Owner and Operator’s Manual

General Information

1. Table of performance, structure and specifications for entire vehicle

1.1 Table of Dimension and Mass parameters :

Item

ZAPVAN Shuttle

Type

flat head 4×2 driving with rear wheels

4 seats

Dimension parameters

Overall size

Length

138.4”

Width

54.9”

Height

66.5”

Wheel base

79.1”

Wheel track

Front wheel

47.8”

Rear Wheel

46.9”

Mass parameters lb

Complete vehicle kerb mass

1039

Kerb axle mass

Front

496

Rear

543

Full load mass

1360

Full load axle mass

Front

636

Rear

724

carrying capacity

4 persons [150 lb ] and

108 lb (49 kg) loading

Summary of Contents for ZAPVAN SHUTTLE 2010

Page 1: ......

Page 2: ...HAT 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...

Page 3: ...esting 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 conta...

Page 4: ...suggestions 25 4 Suggestion on slippery road driving 25 5 Suggestion on parking brake 25 Chapter 5 Emergency Conditions 1 Vehicle refuses to start 26 2 Vehicle stops running 26 3 Braking trouble 26 4...

Page 5: ...2010 Owner and Operator s Manual 4 General Information 1 Overall Dimensions...

Page 6: ...Type flat head 4 2 driving with rear wheels 4 seats Dimension parameters Overall size Length 138 4 Width 54 9 Height 66 5 Wheel base 79 1 Wheel track Front wheel 47 8 Rear Wheel 46 9 Mass parameters...

Page 7: ...5 Kingpin inclination 13 Kingpin caster 3 1 Toe in 2 7 Maximum turning angle Of wheel Inside wheel 34 Outside wheel 31 Main parameters Maximum speed MPH 25 Maximum climbing capability 8 Max Travel Dis...

Page 8: ...five doors with full metal Electromotor Rated voltage v 72 Rated power kw 6 Electromotor controller Rated voltage v 72 Rated electric current A 85 Auxiliary storage battery 12V 36 Ah C20 cathode grou...

Page 9: ...peed no load 45times min 70time min Lighting system Head light 60w 55w Front position light front width indicator light 5w turn signal light 21w for front left front right rear left and rear left 5w f...

Page 10: ...oltage Use proper procedures to avoid serious injury Please disconnect the battery before performing maintenance 1 Modification WARNING Vehicle modification is absolutely prohibited as it may impair t...

Page 11: ...Pressure WARNING Improper tread depth under or over tire pressure could result in explosion and or an accident Tirepressureshouldcomplywiththespecifications contained in the following table Additional...

Page 12: ...Cabin 1 2 3 3 4 5 6 7 8 9 10 11 12 13 1 Combination switch for turn signal lights headlights and dimmer 2 Combination instrument panel 3 Wiper and washer switches 4 Odometer 5 Turn signal switch 6 Mu...

Page 13: ...never leave the key in an unattended vehicle especially when children are present 2 Combination switch Light switch Turn the handle to activate the lights There are four control positions OFF Position...

Page 14: ...aning fluid will spray on the windshield Do not use the washer continuously for over 20 seconds and it can not be used when the fluid reservoir is empty 4 Hazard warning light switch The red push butt...

Page 15: ...n turning right 7 Overload warning light This warning light turns on when the main power motor senses heavy use over a period of time indicative of potential overloading Introduction of Devices and Co...

Page 16: ...nit is volts Display of failure code When there is a vehicle malfunction the failure code display will emit three warning beeps and then display partial failure information such as E XX When there is...

Page 17: ...e multi function display will beep loudly and the charge indicator light will be turned on constantly At this time you must charge the power battery immediately NOTE When battery power is down to 01 c...

Page 18: ...The key must not be removed from the ignition switch while driving Never leave the key in an unattended vehicle Outside the door as shown in Figure 1 Unlocking Turn the key clockwise Locking Turn the...

Page 19: ...1 Lift up the angle adjuster handle as per below picture to fold seats forward 2 Draw the seat buckle up as the arrow in the above picture to unfasten the shackle from hook 3 Turn the seat over Mid ro...

Page 20: ...the pelvis Do not fasten it around the abdomen Fasten the shoulder belt to the shoulder but do not let it slide to arm The tightness of the shoulder belt may be adjusted automatically as needed When s...

Page 21: ...s and under the pelvis never fasten it around the abdomen Belt fit should be proper as over tightness could be uincomforttable and too loose can greatly diminish protective performance Lying down is p...

Page 22: ...or use them for other purposes 5 Glove box Open the box cover by pulling the handle Push back to fasten WARNING While driving the glove box door should be closed to minimize injury should an accident...

Page 23: ...shtray should not be used as a junk receptacle Extinguish all smoking materials before closing the tray 1 Attached tooling assembly 2 Tool kit assembly 3 G type double offset ring spanner 16 17 4 Cros...

Page 24: ...and have the parking brake repaired immediately Internal rearview mirror 9 Pedals 1 Brake Pedal 2 Accelerator Pedal NOTE Do not depress the brake pedal concurrently with the accelerator pedal 10 Onboa...

Page 25: ...will start to accelerate NOTE Depressing the brake pedal after the vehicle starts will prevent the vehicle from moving 4 Starting on a slope When the vehicle is stopped on a slope by using the hand b...

Page 26: ...or brake is an assistant To prevent brake fade as a result of overheated brake do not press brake pedal for a long time or for many times during ascending and descending driving When the vehicle is mo...

Page 27: ...ely after the vehicle stops NOTE You should routinely brush off dirt and dust from the radiator of the on board charger the motor and the controller Do so only when these devices are cool to the touch...

Page 28: ...Cover the wheel nut wrench on the bolt then loosen the bolt to dismantle spare wheel Jack up positions of the hoisting jack Front axle Jack up the underside of lower trailing arm with hoisting jack a...

Page 29: ...ing Completely lower the vehicle and then screw down wheel nuts tightly According to the sequences in the above figure gradually tighten to the regulated torque 88N m 108N m Install wheel cover if any...

Page 30: ...sides or vertically Use the Hazzard Signals when towing the vehicle Remark While towing if necessary softly depress the brake so as to ensure that towing cable is tense all the time If the towing cab...

Page 31: ...s surface 4 Rust Prevention A Following factors can cause rust Roads and air borne salt ingredients Dirt and moisture Defects of all exposed metals such as nicks and scratches Chemicals and industrial...

Page 32: ...ark the vehicle in poorly ventilated place Keep the finish coat and coverings in good condition If there is any scratch or notch on the finish coat re coat as soon as possible Keep the vehicle s inter...

Page 33: ...icant G J B G Bolts for connecting Fastening N N Wheels Wheel nuts tightening as per specified torque and completed amount J N N Inspect and lubricate the bearing preload of front wheel hub J T Q T To...

Page 34: ...spect the friction plate J T G Bolts for connecting fastening N N Suspensions Inspect the working function of front rear shock absorber J Wear and rubber aging and cracking inspections to the sleeve o...

Page 35: ...water directly 3 AC Asynchronous Motor and Controller TheAC asynchronous motor Fig 1 and controller Fig 2 are the power equipment of the vehicle controlled by the accelerator and brake Please clean du...

Page 36: ...ort circuit 5 Fuse Master fuse Check with the multimeter if there is any fuse blow out If any circuit may be the problem Find our the causes and repair them before replacing master fuse WARNING Please...

Page 37: ...ng wheel is the free travel Too much free travel will cause manipulating response sluggish or front wheel swinging 8 Axial Clearance of Steering Column There should not be clearance when pulling or pu...

Page 38: ...brake meets the requirement but the vehicle can not stop absolutely when parking or parking can not be released completely when releasing the handle of parking brake the vehicle brake system must be...

Page 39: ...sufficient or wrong gear oil Change oil or add oil Makes noise while sliding main drive gear conical bearing is damaged Replace Sounds during rotation axle shaft bearing or rear axle bearing of the di...

Page 40: ...s or parts Tire suffers from abnormal wearing Front spring is damaged or shortened due to plastic deformation Replace Dynamic unbalance of tire exceeds limit value Adjust Side slip of front wheel is o...

Page 41: ...t of steering linkage is overworn Replace steering balljoint assembly or replace steering linkage Balljoint of left and right lower trailing arm or sleeve of trailing arm is worn Replace lower trailin...

Page 42: ...mpletely Ball pin of steering linkage jams Replace ball pin assembly of steering linkage Ball pin of lower trailing arm jams Replace lower trailing arm Steering column jams Repair or replace Steering...

Page 43: ...ush Spring is damaged or shortened due to plastic deformation Replace spring Tightness of steering gear is adjusted improperly Check and adjust torque of rack and pinion Connecting globe joint of stee...

Page 44: ...lder of front shock absorber is sealed off Replace front shock absorber Spring is damaged or shortened due to plastic deformation Replace spring Heeling angle is over large during steering Anti roll b...

Page 45: ...replace self adjustment mechanism Brake is Sluggish Parking brake is maladjusted Adjust parking brake Return spring of rear brake fails Replace return spring Brake hydraulic pipe is obstructed so that...

Page 46: ...rake effect is poor due to stiff brake pedal Friction lining is contaminated with oil stains or grease Repair or Replace brake shoe Brake shoe plate distorts or friction lining becomes glossy due to a...

Page 47: ...ent is working The DC DC convertor does not work Handle it according to stated method above The energy of the auxiliary battery is insufficient Have the auxiliary battery charged separately The auxili...

Page 48: ...Turn the ignition switch back to position OFF and restart the vehicle after the system resting If the problem o ccurs repeatedly please have the controller checked and repaired E 04 Undervoltage of c...

Page 49: ...lease have the controller checked and repaired E 10 Warning of pedal brake Release the brake and then press the accelerator pedal to start the vehicle Check the pedal brake switch E 11 Contactor congl...

Page 50: ...cuit Only one front head lamp is off Lamps are damaged Check lamps Malfunctions of front head lamp switch Check front head lamp switch Both left and right fuses F9 F10 of front head lamps blow out Che...

Page 51: ...relay There is open circuit or excessive resistance between turn signal emergency alarm switches and lamps Repair the circuit Malfunctions of wires or ground Repair the circuit No flashing Fuse of sma...

Page 52: ...switch Check switch Malfunctions of wires or ground Repair the circuit Turning off backup light can not be turned off Malfunctions of backup light switch Check or replace switch 5 MALFUNCTIONS OF STOP...

Page 53: ...t circuit Check combination instrument circuit Malfunctions of switch for braking fluid level Check switch for braking fluid level Malfunctions of wires or it is grounded Repair the circuit Alarm ligh...

Page 54: ...rcuit Malfunctions of wiper motor Check wiper motor Malfunctions of wiper switch multi function switch Check wiper switch Malfunctions of wires or is grounded Repair the circuit Washer will not work R...

Page 55: ...35 GL 4 80W90 35 0 1 0 Rear axle lubricating oil GL 4 90 0 50 GL 4 75W90 under 35 GL 4 80W90 35 0 1 1 Chassis lubricating grease ChongqingYi Ping 7022 NO 2 consistency Q SHYPO2 017Z 2000 Brake cylinde...

Page 56: ...plan to use your ZAPVAN 11 Not including yourself what is the GENDER and AGE in years of children and other adults living in your household 12 Occupation check all that apply You Spouse Received as a...

Page 57: ...gular basis 20 Using the numbers in the above list please indicate your 3 most important activities ____ _____ _____ 01 Bicycling 02 Golf 03 Physical Fitness Exercise 04 Running Jogging 05 Snow Skiing...

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