• Inadequate Charge or Range
• Alltrax Motor Controller
• Appendix A Figure 1 – 12V electrical schematic
• Appendix A Figure 2 – 72V electrical schematic
• Appendix A Figure 3 - motor, contactor, motor controller wiring detail
Electrical Introduction
This document describes the electrical systems of the ZAP Xebra vehicles. The sedan is referred to
as "SD" and the pickup as "PK".
• The schematics are in appendix A.
• Wires are given identifying labels.
• Low voltage wires prefix the number with "S" (Ex. S1).
• High voltage wires prefix the number with "T" (Ex. T1).
• Low voltage power wires start with "12V" (Ex. 12VF3).
• High voltage power wires start with" 72V" (Ex 72VC).
• The low voltage common is referred to as -12V. This is also connected to the vehicle chassis.
• The high voltage common is referred to as -72V.
• Components are given identifying labels.
• "A" indicates a module (Ex. A1 for DC/DC converter).
• "JD" indicates a lower current relay (Ex. JD1).
• "J" indicates a high current contactor (Ex. J1).
• "L" indicates a light bulb (Ex. L1).
• "K" indicates a switch or button (Ex. K24).
• There is one complicated multifunction switch mounted on the steering column that controls
the head lights, blinkers, emergency flashers and windshield wipers. This is broken into K1-
1, K1-2 and K1-3 on the schematics.
• The electrical system is divided into:
• The 12V low voltage light and accessory system, running off the accessory battery.
• The 72V high voltage drive system, operating off the traction battery pack.
• The 12V system must be operational before the 72V system can be activated.
Whenever you are troubleshooting an electrical system, it is necessary to know where the
"Common" or "Ground" is located. In these vehicles the 12V system is isolated from the 72V
system. The 12V common is also tied to the metal car frame. The 72V system is completely isolated
(floating).
12V Common
• The 12V common is referred to as -12V in the schematics.
• The best place to locate the 12V common inside the cab is on the cigarette lighter. You
should get a cigarette lighter plug from an automotive store and solder a black wire to the
-12V side (the outside wall of the connector).
• When in the front or rear compartments of the vehicle, use any common (black wire) on a
light bulb connector.
• The metal frame is usually not a good place to pick up common.
• When using a voltmeter, set to an appropriate scale for 12V (usually the 20V range) and
connect the black voltmeter common to 12V common.
• Use your red voltmeter wire to probe the 12V electrical system.
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