• 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 wire).
• Or purchase and wire blade fuse holders with wire pigtails (available at any automotive
store).
• There are six of these "bad" wire fuses, F1-F4 are under the front passenger side dashboard
and F5-F6 are in the rear motor compartment above the contactors. Removing the glove box
makes working on the fuse block much easier.
Connector problems, solutions and tips
• The connectors sometimes become loose or disconnected.
• Simply reconnect making sure the connector latching mechanism seats properly.
• Be sure no pins or lugs have become unseated. If so, press them back into the connector until
they snap or catch in place.
• If you suspect a bad connection between the wire and the pin, remove pin, uncrimp to
remove wire, cut out bad section, strip, re-crimp and solder connection.
Theory of Electrical Operation
This section gives a step by step description of how the ZAP Xebra vehicle's electrical systems
operate:
1. Enable the 72V electrical system by pulling out (turning on) the red "Main Disconnect"
switch (K21) in front of the driver's seat.
2. Turn the key ignition switch (K26) to position 1 (1st click). It does not matter if you go to
key position 2 since only key position 1 is used.
3. This energizes relay JD4 which activates main contactor J4. On even newer vehicles the key
activates J4 directly and relay JD4 is missing.
4. The key also activates relay JD8 which connects the 12V accessory battery to the 12V
system.
5. Also 72V is placed onto the input of the DC/DC converter through contactor J4 and outputs
about 14.0 VDC which powers the 12V electrical system and charges the 12V battery
through relay JD8.
6. The dash voltmeter should indicate the voltage of the 72 volt system and all the lights and
accessories will operate.
7. Voltage 72VC is also connected from contactor J4 onto battery charger lockout relay JDac.
8. As long as the battery charger is unplugged, JDac is not energized so 72VC is passed to the
forward/neutral/reverse switch K23 over wire T1 and T4.
9. If the battery charger is plugged in, the charger disable relay energizes, removing the voltage
to wire T1 and T4.
10.As long as direction switch K23 is in "N" (Neutral), the 72V goes no further but vehicle is
armed for motion.
11.To drive forward, place the directional switch K23 in position "F".
12.This energizes the forward contactor J3 over T6.
13.Power is then routed to relay JD7 through diode D5 over T8.
14.When either or both the foot and emergency brakes are activated, relay JD7 is energized,
removing coil power to the main contactor J1.
15.When both the foot and emergency brakes are released, relay JD7 is de-energized which puts
power on the main contactor coil J1 over T9.
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