Zap ZAPVAN SHUTTLE 2010 Manual del propietario
2010 Owner and Operator’s Manual
1
IMPORTANT!
BEFORE YOU OPERATE YOUR ZAPVAN SHUTTLETM PLEASE READ THE
ENTIRE MANUAL CAREFULLY
DO NOT PLACE MORETHAN 708 POUNDS -INCLUDING PASSENGERS- IN THE VEHICLE.
DO NOTTOWTHE VEHICLE WITH WHEELS TOUCHING THE GROUND.
IF YOU HAVE QUESTIONSABOUTTHE OPERATION OF THIS VEHICLE, YOU SHOULD CONSULTYOURAUTHORIZED DEALER.
IT IS EXTREMELY IMPORTANTTHATYOU FOLLOW THE SAFETY GUIDELINES CONTAINED IN THIS MANUAL
IN ORDER TO ENSURE MAXIMUM SAFETY.
FAILURE TO COMPLY WITHTHE STANDARDS OUTLINED INTHIS MANUALCOULD RESULT IN FIREAND/OR SERIOUS INJURY.
ZAP IS NOTLIABLE FORANY DAMAGE OR INJURIES CAUSED BY UNSAFE OR FAULTY REPAIRS, ORALTERATIONS.
ANY REPAIRS MADE TO THIS PRODUCT BY UNAUTHORIZED SERVICE TECHNICIANSARE THE SOLE RESPONSIBILITY OF THE OWNER.
PLEASE DISPOSE OF USED BATTERIES INALAWFULMANNER.
© ZAP 2009All Rights Reserved
501 Fourth Street, Santa Rosa, CA95401 USA
www.zapworld.com
Stock Symbol: ZAAP
1(800)251-4555
2010 Owner and Operator’s Manual
2
July 2010
Dear ZAPVAN Enthusiast,
Thank you and congratulations on purchasing the ultimate clean air vehicle! The ZAPVAN SHUTTLE is the rst of its
kind. To our knowledge it is the world’s only affordable electric vehicle that meets federal standards and goes up to 25
miles an hour.
In these days of higher 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: [email protected]
As the rst 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 ZAPVAN SHUTTLE not only a practical electric
vehicle, but the best in its class.
Thank You Again!
1(800)251-4555
2010 Owner and Operator’s Manual
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TABLE OF CONTENTS
Chapter 1
General Information
1. Overall dimensions............................................4
2.Table of performance, structure
and specication for entire truck..................5
3. Vehicle marking..................................................9
Chapter 2
Safety and Important Notes
1. Non-permissible to ret..................................9
2. Inspection of new vehicle................................9
3. Vehicle maintenance..........................................9
4. Vehicle load......................................................10
5. Inspection of tire and tire pressure............10
6. Usage of lubricants and uid for
vehicle................................................................10
7. Proper usage of safety belt...........................10
Chapter 3
Introduction of Devices
and Control Mechanism
1. Position of switches and
control levers in the cabin.............................11
2. Keys, doors and windows..............................17
3. Seats...................................................................18
4. Back gate and side gates of truck bed ........18
5. Safety belts........................................................19
6. Other Devices.................................................21
Chapter 4
Driving Suggestions
1. Driving operation...................................................24
2. Normal driving suggestions .................................24
3. Economical driving 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. Steering trouble......................................................26
5. Light changing..........................................................26
6. Deated tires..........................................................27
7. Emergency towing..................................................29
8. Anchoring.................................................................29
Chapter 6
Service and Maintenance
1. Cleaning and maintenance....................................30
2. Routine maintenance.............................................31
3. Regular maintenance..............................................31
4. Requirement for regular maintenance..............34
Chapter 7
Solutions for Malfunctions
1. Rear axle malfunction..............................................38
2. Steering, suspension, wheel and tire....................39
3. Braking malfunctions...............................................44
4. Malfunctions of power system..............................46
5. Malfunctions of on-board charger........................46
6. Malfunctions of electric controlling system.......47
7.Malfunctions of lights, instruments,
switches and indicating lights.................................48
Chapter 8
Oil Fluid forVehicle
And Electric Theory Fig
of Complete Vehicle
1. Specication and capacity of lubricant,
lubricant grease and braking uid.........................54
2. Electric Theory Fig of Complete Vehicle............54
ZAP Registration Card...................................55
2010 Owner and Operator’s Manual
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General Information
1. Overall Dimensions
2010 Owner and Operator’s Manual
5
General Information
1. Table of performance, structure and specications for entire vehicle
1.1 Table of Dimension and Mass parameters :
Item ZAPVAN Shuttle
Type at 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
2010 Owner and Operator’s Manual
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General Information
1.2 Table of performance parameters
1.3 Table of Structure and Specications
Item ZAPVAN Shuttle
Trafcability
parameters
Minimum turn radius 177.2”
Ground clearance 6”
Approach angle°30
Departure angle° 25
Front overhang 30.7”
Rear overhang 28”
Steering parameter
(what is the
measurement?)
Camber angle°2±15´
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 Distance 40 (miles)
Max. slope-parking capacity° (No-load)20
Item ZAPVAN Shuttle
Suspension Front suspension Coil spring Macpherson independent suspension
Rear suspension Leaf spring non-independent suspension
Steering type Pinion & rack
Braking Service brake Dual-circuit hydraulic braking system front disc and rear drum
brakes
Parking brake Mechanical cable type
2010 Owner and Operator’s Manual
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General Information
1.3 Table of Structure and Specications (cont’d)
Item ZAPVAN Shuttle
Wheel
Type of tires Meridian tire
Tire specication 155 R12 LT 6PR
wheel rim 4.5B×12
Tire pressure
(COLD)
Front Kpa(PSI) No-load: 200 Kpa (31 PSI)
Full-load: 200 Kpa (31 PSI)
Rear Kpa(PSI) No-load: 200 Kpa (31 PSI)
Full-load: 270Kpa (39.1 PSI)
body ve 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 12 V 36 Ah(C20), cathode ground strap connection
Power storage battery 72V 115Ah(C5)
DC/DC Converter
Input voltage (v) 72
Output voltage (v) 13.5
Max output electric current(A) 25
Charger (AC/DC)
input voltage (v) 90-260 (AC)
Max input electric current (A) 12
Max charging time (h) 12
Safety control system the rated electric current of fuse cutout( A) 300
the rated electric current of contactor( A) 100
2010 Owner and Operator’s Manual
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Item ZAPVAN Shuttle
Low pressure electrical
equipment
The connection type of wire cathode ground strap connection
Rated voltage of circuit 12V
Battery 12V/36 Ah
Hoot ≥93dB (the position of 2m distance)
Washer intermittent washing and wiping with motor
Wiper Motor auto-return, intermittent and two-speed (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 for side
front fog light 55w
brake lamp/ rear position
light 21w/5w
backup light 21w
license plate light 10w
interior light 5w
instrument panel light,
indicator light 3.4w
turn signal light ashing frequency 85±12times/min
alarming signal light ashing frequency
General Information
1.3 Table of Structure and Specications (cont’d)
2010 Owner and Operator’s Manual
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General Information
3.Vehicle Marking
Safety and Important Notes
1. (VIN) Vehicle
Identication
Number
VIN is printed on
the lower frame of
driver’s seat in the cab,
the upper left of the
instrument panel and
on the nameplate.
2.Vehicle Nameplate
The nameplate, which is marked with Vehicle
Identication Number (VIN) is riveted on the left
B-pillar inside cab . See gure below.
3. Branding
Body surface has the ZAP logo in font and back.
ZAPVAN and Zero Emissions are also branded
on the sides.
Safety and Important Notes
WARNING!
Avoid any dangerous operation such as sudden
start and acceleration, sudden steering as the
vehicle could go out of control, roll over or
become damaged.
Avoid driving on extremely rough roads.
All passengers must wear safety belts when
the vehicle is in operation.
Do not overload the vehicle.
Vehicle circuit runs on high voltage. Use
proper procedures to avoid serious injury.
Please disconnect the battery before
performing maintenance.
1. Modication
WARNING!
Vehicle modication is absolutely prohibited
as it may impair the vehicle’s performance,
life, safety provisions and may even be
illegal by state law. Vehicle damage and
personal injury and death caused by vehicle
modication is not within the scope of the
limited warranty.
2. Inspection of New Vehicle
Owners should inspect the following items after
taking delivery of the new vehicle in order to
ensure its safety provisions and reliability:
•Check all xings of the vehicle,
especially safety parts such as steering
nut, braking and wheel nuts, etc.
•Check to see if there is any air or water leaks.
•Check oil level of gear box and rear
axle.
•Check uid level of battery.
•Check tire pressure.
•After turning on, check to see if all
instruments are functioning properly.
•When performing service, make sure
the foot and parking brakes are working
properly.
•Check that steering mechanism is
functioning normally.
•Check the driveline for abnormal noise.
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