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Table of Contents
Summary of Contents for MadJax Storm X Series
- Page 1 Owner’s Guide ISSUED NOVEMBER 2022 PART #: 27-012...
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Page 2: Introduction
INTRODUCTION Thank you for your purchase of a MadJax XSeries electric vehicle. Prior to operation, please thoroughly read this Owner’s Manual. Please note that some items are optional accessories and may not be installed on your vehicle from the factory. -
Page 3: Table Of Contents
TABLE OF CONTENTS Introduction ............................2 Vehicle Specs ............................4-5 Identification ............................6-7 Important Notices ..........................8 Safety Precautions ......................... 9-11 Vehicle Safety Labels .........................12 Pre-Operation Checklist........................13 General Operation ........................14-16 Magnetic Brake ............................17 Lead Acid Battery Maintenance ....................18-19 Reliance Lithium Battery Operation Instructions ............20-21 Battery Charging .........................22-23 Troubleshooting / Charger Codes .................. -
Page 4: Vehicle Specs
VEHICLE SPECS POWER DIMENSIONS OVERALL LENGTH 92.7 in (235.5 cm) POWER 48-Volt Lithium or Lead Acid OVERALL WIDTH 45.5 in (115.5 cm) MOTOR TYPE Reliance AC Motor WHEEL BASE 65.7 in (167 cm) HORSEPOWER (KW) 6.7 hp (5 kW) Continuous 37.0 in (94 cm) 3 Gauge Cables Throughout FRONT WHEEL TRACK... - Page 5 VEHICLE SPECS (CONT’D) STEERING & SUSPENSION STEERING Double-Ended Rack and Pinion FRONT SUSPENSION MacPherson Strut REAR SUSPENSION Mono-Leaf Springs with Hydraulic Shocks Front/Rear Hydraulic Disc Brake SERVICE BRAKE Electromagnetic Park Brake PARKING BRAKE DRY WEIGHT 573 lb (260 kg)(without battery estimated) CURB WEIGHT 992 lb (450 kg) estimated for 4 pass VEHICLE LOAD CAPACITY...
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Page 6: Identification
IDENTIFICATION The Serial Number is located on the front of the frame, on the dashboard, and on the steering column, as shown. Example serial number shown for reference 2301ST104S******... - Page 7 IDENTIFICATION (CONT’D)
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Page 8: Important Notices
IMPORTANT NOTICES This vehicle is designed for off-highway use in compliance with the safety standards for golf cars. It is not equipped from the factory with systems required by automotive industry safety standards (including but not limited to FMVSS 571.500 low-speed vehicle or LSV standard) for use on public streets and highways. All applicable local and federal laws for on-road use must be followed by the end user, including the addition of all necessary equipment for legal street use. -
Page 9: Safety Precautions
SAFETY PRECAUTIONS • RISK OF ELECTRIC SHOCK. Ensure the charger AC cord is connected to a properly grounded outlet. Always disconnect charger AC plug before servicing vehicle. • Ensure all battery connections are tight, making good contact, and are free of corrosion. Poor electrical contact can generate heat and create a fire hazard. - Page 10 SAFETY PRECAUTIONS (CONT’D) Any modification to the vehicle that affects stability, handling, or increases speed beyond factory specifications can cause severe injury or death. Modifications may void vehicle warranty. Place run/tow switch into TOW position prior to servicing the vehicle. When servicing the vehicle, make sure the key is in OFF position and chock the wheels.
- Page 11 SAFETY PRECAUTIONS (CONT’D) DURING OPERATION: • Drivers must have a valid driver’s license. Operate only in designated areas in accordance with local, state/province, and/or national law. • Always drive at a speed consistent with terrain and weather conditions. • When going up or downhill, if possible, drive straight up or down the hill, not crossways. Never drive crossways on a grade sharper than 14%.
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Page 12: Vehicle Safety Labels
VEHICLE SAFETY LABELS... -
Page 13: Pre-Operation Checklist
PRE-OPERATION CHECKLIST With the key in the OFF position, perform the below checks prior to operation. Failure to ensure the key is OFF may lead to severe injury, death, and/or property damage. For checks requiring the key to be on, be ready to turn off and/or press the brake pedal if unexpected movement occurs. -
Page 14: General Operation
GENERAL OPERATION Knob Gear Shifter (RND Selector) Battery Gauge USB/12V Output Key Switch Steering Wheel Hazard Light Switch* Cup Holder Braking Pedal Accelerator Pedal *Some vehicles may have the switch on the dash... - Page 15 GENERAL OPERATION (CONT’D) OPERATING THE VEHICLE: After performing all pre-drive checks, ensure that the vehicle park brake is engaged and the Run/Tow switch underneath the passenger side of the front seat is in the Run position. 2. Insert the key into the ignition and turn it ON. Turn the RND knob to D for forward or R for reverse. 3.
- Page 16 GENERAL OPERATION (CONT’D) ROTARY SWITCH RUN/TOW SWITCH The three letters stand for Turn the key to “OFF” position. Drive, Neutral and Reverse. 2. Flip open the seat and switch the controller to “TOW” position. Now it is safe to tow the vehicle. The motor and rotating parts will be free from damage.
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Page 17: Magnetic Brake
MAGNETIC BRAKE Never put the car in TOW or manually disengage the e-brake on a sloped surface. If it is necessary, one person MUST be in position to hold the service brake pedal and steer the vehicle before releasing park brake. Failure to do so can lead to injury and/or vehicle/ property damage. -
Page 18: Lead Acid Battery Maintenance
LEAD ACID BATTERY MAINTENANCE (Lead-Acid Deep Cycle Batteries Only) ALWAYS wear safety goggles and rubber gloves when performing battery maintenance. Battery acid may burn the skin and/or clothing. Keep sparks away and never smoke while working near batteries. • Water levels should be checked at least monthly (time can vary by individual use or climate; it is recommended to check more often) by visual inspection through the caps on each battery. - Page 19 LEAD ACID BATTERY MAINTENANCE (CONT'D) (Lead-Acid Deep Cycle Batteries Only)
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Page 20: Reliance Lithium Battery Operation Instructions
RELIANCE 105 Ah LITHIUM BATTERY OPERATION INSTRUCTIONS SAFETY WARNING Please read the operating instructions carefully before use, and follow detailed safety instructions to reduce any risk: To reduce the risk of a fire, install the battery system while the vehicle is on the surface of non-flammable materials, such as brick, concrete or metal. - Page 21 RELIANCE 105 Ah LITHIUM BATTERY OPERATION INSTRUCTIONS (CONT’D) Please read and follow the instructions carefully to ensure the long-term safe and reliable operation of your battery system: In order to ensure the safety of the battery and guarantee the battery life, please only use the charger which is provided or recommended by the supplier to charge the battery.
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Page 22: Battery Charging
BATTERY CHARGING SG-720 LEAD ACID CHARGER & SG-1200 LITHIUM BATTERY CHARGER Lithium Battery Charger Lead Acid Charger Charger Receptacle Charger Plug... - Page 23 BATTERY CHARGING (CONT’D) OPERATING INSTRUCTIONS: First, tightly connect the charger output plug or ring terminals to the battery pack, then firmly connect the AC plug with the AC outlet. Once connected, the red charger light will begin to flash. The green light turns on after it finishes charging.
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Page 24: Troubleshooting / Charger Codes
CHARGER CODES/MEANING (FLASHING LED) TROUBLESHOOTING LED INDICATOR STATUS Note: The charger indicator LED CHARGE LEVEL INDICATIONS may be under the seat connected to the charger and can be installed to the Lead Acid Charger / Lithium Charger customer's location of choice using a 7/8" bit to drill a mounting hole. - Page 25 CHARGER CODES/MEANING (FLASHING LED, CONT'D) LED INDICATOR STATUS / FAULTS AND SOLUTIONS Note: If any fault repeats after troubleshooting, contact tech support. Status or Fault Description LED Indication (Lead Acid & Solution Dash “ ” = 1 Sec Pause Lithium Charger) Check connection between battery and charger, and confirm polarity No Load is hooked up correctly.
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Page 26: Vehicle Maintenance
VEHICLE MAINTENANCE Frequency Items Checked Lead Acid Batteries Check water level and terminal cleanliness If the vehicle is disabled and towing is necessary, ALWAYS ensure that the Weekly Battery Wires Check torque on connections parking brake is released and that the Accessories Check any accessory mounts Run/Tow switch is switched to TOW. -
Page 27: Vehicle Storage Procedure
VEHICLE STORAGE PROCEDURE This vehicle will give you years of trouble-free service when properly maintained. Please follow the recommended electric vehicle long-term storage checklist. For more information on the overall vehicle maintenance, consult page 26. If any of the following conditions exist, use these electric vehicle long-term storage methods: •... - Page 28 VEHICLE STORAGE PROCEDURE (CONT’D) Two weeks prior to storage: Check the water levels in each battery cell. If water is required, fill the cells to cover the plates, charge the set and then use distilled water to top off each cell. The electrolyte level should be from 1/2-inch (13 mm) above plates to 1/4-inch (6 mm) below the level indicator.
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Page 29: Tire Pressure/Wear Condition
TIRE PRESSURE/WEAR CONDITION Check Tire Pressure Use a tire pressure gauge to make sure your tires are properly inflated and then fill your tires with air as needed. To check your pressure, remove the valve stem cap, press the gauge head evenly onto the valve stem, use firm pressure so that the hissing sound stops. -
Page 30: Vehicle And Battery Storage
VEHICLE AND BATTERY STORAGE If this vehicle must be stored for a long period, please follow the long-term storage recommendations below and review the recommendations for lead-acid or lithium batteries as applicable. Following these recommendations will help reduce the chance of major maintenance being required when coming out of storage. -
Page 31: Lead Acid Battery Storage
LEAD ACID BATTERY STORAGE If stored incorrectly, long periods of inactivity can be harmful to the longevity of lead-acid batteries, reducing runtime and usable cycles. Two weeks prior to long-term storage, follow the below recommendations: • Inspect battery cables for loose crimps or damage. Check all connections and torque to 95-105 in-lb (10.7-11.9 Nm). -
Page 32: Reliance Lithium Battery Storage
LITHIUM ION BATTERY STORAGE • It is recommended to fully charge the battery pack before storage. o If storing for less than one month, State of Charge should be at least 60% when storing. For a period up to 6 months, State of Charge must be at least 80% when storing. •... -
Page 33: Reliance Lithium Battery Tips
LITHIUM ION BATTERY TIPS • Download the Reliance Battery app. QR codes are located on page 21 or on top of the battery for iOS and Android apps. • When the switch on the battery and the key are both on, the system will enter sleep mode after 5 minutes at idle. -
Page 34: Controller Fault Codes
CONTROLLER FAULT CODES If the controller experiences a fault, the LED on the controller will flash the number of times in the “Flash” column below. To view the LED, remove the Phillips head screws on the controller cover (where the Run/Tow switch is located). - Page 35 CONTROLLER FAULT CODES (CONT’D) Flash LCD Display Fault Solution Battery pack Check battery pack for errors. undervoltage Battery pack Check battery pack for errors. overvoltage Shutdown vehicle. Wait several minutes before restarting. If error continues, check Motor overheated motor temperature sensor and/or replace motor. Restart controller.
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Page 36: Warranty
Nivel Parts and Manufacturing Co., Vehicle Frame (Workmanship) Lifetime LLC, (“Company”) provides that any Suspension and Steering (Shocks, Leaf Springs, MadJax XSeries vehicle (“Vehicle”) - 3 Years Steering Rack, Steering Column) and/or accessory purchased from the Major Electronic Components (Electric Motor,... - Page 37 WARRANTY INFORMATION (CONT’D) The Warranty Period for all parts and components of the Vehicle shall commence on the date the vehicle is purchased. Purchaser must confirm that Dealer has warranty registered the vehicle. This Limited Warranty applies only to the Purchaser and not to any subsequent purchaser without the prior written approval of the Company Customer Service Department.
- Page 38 WARRANTY INFORMATION (CONT’D) This limited warranty may be voided or limited at the sole discretion of the Company if the vehicle and/or battery charger: • Shows indications that routine maintenance was not performed per the Owner’s Guide, including but not limited to rotation of fleet, proper tire inflation, lack of charging, loose battery hold downs, corroded battery cables and loose battery terminals;...
- Page 39 WARRANTY INFORMATION (CONT’D) Liability limitations: in no case shall the Company be liable for indirect, incidental, special, punitive or consequential damages, including but not limited to death, personal injury or property damage arising from or related to any alleged failure in a vehicle or battery charger, or any damage or loss to the purchaser or any third party for lost time, inconvenience or any economic loss, whether or not the Company was apprised of the foreseeability of such damages or losses.
- Page 40 WARRANTY WARRANTY CERTIFICATE TERMS 3510-1 Port Jacksonville Pkwy, Jacksonville, FL 32226 Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of Nivel Parts & Manufacturing Co., LLC.