High Voltage 72V System
The following is the sequence of a properly operating vehicle with probable cause if there is a
failure:
1. Pull out red main disconnect switch (K21) under driver seat. This enables power from the
72V drive (traction) batteries.
2. Place direction switch in Neutral.
3. Turn on with the key.
4. The dash voltage meter should indicate voltage. This will indicate about 84V if fully
charged, between 72V and 84V if partially discharged and 72V or below if badly discharged.
See Owners Manual for battery break in and charging instructions. Possible problems to
check:
• Fuse F10 (on wire that connects to +72V if present).
• Fuse F6 in the sedan.
• Check all fuses on the PCB on the PK.
• Key switch.
• Relay JD4.
• Contactor J4.
• Associated connectors and wiring.
5. Turn direction switch to “F” position. You should here a click from the rear of the vehicle
when forward contactor J3 closes. Possible problems to check:
• Charging cord plugged into wall.
• Fuse F5.
• Relay JDac (activated by charging cord plugged into wall).
• Direction switch K24.
• Associated connectors and wiring.
6. When both the foot and emergency brakes are released you should hear a click as Main
contactor J1 closes. Possible problems to check:
• Diode D5.
• Relay JD7.
• Diode D3 and D4. (Note, these disable J1 if either the emergency or foot brakes are
applied by energizing relay JD7.) (Additional note, diode D4 is being removed,
therefore the foot brake has no effect if D4 is removed. If not already removed, ZAP
recommends removing diode D4.)
• Associated connectors and wiring.
7. The main contactor will open if the switch is placed back in “N” or the foot or emergency
brakes are engaged.
8. Pressing on the accelerator peddle will cause the vehicle to move forward. Possible problems
to check:
• Make sure the battery charging cord is unplugged from the wall (this controls relay
JDac).
• Relay JDac.
• Make sure accelerator pot wires are securely plugged onto pins 2 and 3 of motor
controller A21.
• Make sure the controller power wire is securely plugged onto pin 1 of motor
controller A21.
• Associated connectors and wiring.
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