16.Later models have D4 removed so that JD7 is only activated by the emergency brake. ZAP
recommends you remove diode D4 to prevent the constant activation of main contactor J1
every time the driver steps on the foot brake.
17.T9 also places power on the speed controller. The controller green LED should light.
18.Pressing the accelerator pedal causes the 5K pot (A25) to vary the control signal to the
controller which causes the speed of the motor to vary.
19.Placing the direction switch in reverse (R) arms the vehicle for reverse.
20.Press the "Reverse Button" to latch relay JD2 in the energized position.
21.This energizes the reverse contactor J2 and also relay JD1 over T7.
22.Relay JD1 energizes the backup lights and beeper.
23.Power is then routed to relay JD7 through diode D6 over T8.
24.The main contactor J1 and controller A21 are activated as described above.
25.Pressing the accelerator pedal causes the 5K pot to vary the control signal to the controller
which causes the speed of the motor to vary in the reverse direction.
26.Placing the direction switch in neutral or forward causes relay JD2 to turn off, taking the
vehicle out of reverse.
Electrical Troubleshooting by Vehicle Operation
Low Voltage 12V System
The following is the sequence of a properly operating system with probable cause if there is a
failure:
1. Measure the voltage of the 12V accessory battery through the cigarette lighter. It should be
in the 12 to 13V range.
2. If all voltage is absent, make sure fuse F7 is not blown.
3. If the voltage is below 10V you may have a bad 12V accessory battery. Remove and charge
outside the vehicle. If the battery won't take a charge, replace.
4. Turn key on one click to position 1.
5. Relay JD8 is activated connecting the accessory battery to the 12V electrical system.
6. Also, the DC/DC converter is activated which should start charging the 12V accessory
battery.
7. Now measure the voltage through the cigarette lighter. It should be higher than before you
turned the key (in the 13V range) indicating that charging is taking place.
8. If the voltage does not go up suspect fuses F1 and F6 in the sedan.
9. In the PK there are also two fuses, one is on the PCB in the front of the PK. The second is in
a plastic fuse box to the left of the PCB where the PCB wiring harness connectors are
located. You may have to cut the tie wraps to get to this fuse.
10.If the fuses are good, check the input and output voltages on the connectors to the DC\DC
converter. If you have a 72V input and no output, suspect a failed DC/DC converter.
11. Now test all your lights, backup lights and beeper and windshield wiper.
12.If some or none of this works, check fuses F2 to F3 in the sedan.
13.Check the fuses on the PCB in the front of the PK.
If there are problems proceed as follows:
1. Test Dome (rear view mirror) light. Possible problems to check:
• Dome light L14 or switch.
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