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Zap Zaptruck-XL 2009 Owner's And Operator's Manual

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May 5, 2025

im looking for a key ignition for a 2009 zap xl truck

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Summary of Contents for Zap Zaptruck-XL 2009

  • Page 2 FAILURE TO COMPLY WITH THE STANDARDS OUTLINED IN THIS MANUAL COULD RESULT IN FIRE AND/OR SERIOUS INJURY. ZAP IS NOT LIABLE FOR ANY DAMAGE OR INJURIES CAUSED BY UNSAFE OR FAULTY REPAIRS, OR ALTERATIONS. ANY REPAIRS MADE TO THIS PRODUCT BY UNAUTHORIZED SERVICE TECHNICIANS ARE THE SOLE RESPONSIBILITY OF THE OWNER.
  • Page 3 We are proactive, not perfect. If you have ideas, we want to hear from you. If you can help spread the word about ZAP, please do so. Write to: gstarr@zapworld.com As the first generation electric vehicle of its kind, we expect to learn over time how to make this vehicle better.

  • Page 4: Table Of Contents

    Introduction of Devices Chapter 6 and Control Mechanism Service and Maintenance 1. Position of switches and 1. Cleaning and maintenance ZAP Registration Card control levers in the cabin 2. Routine maintenance 2. Keys, doors and windows 3. Regular maintenance 3. Seats 4.

  • Page 5: General Information

    Owner and Operator’s Manual General Information 1. Overall Dimensions Width Length 5' 0” (1.524 mts) 13' 3” (4.038 mts) Height 6' 4” (1.841 mts)

  • Page 6: Table Of Performance, Structure

    Owner and Operator’s Manual General Information 2.Table of performance, structure and specifications for entire vehicle 2.1 Table of Dimension and Mass parameters Item ZAPTRUCK-XL Model No.WLD1200Q1P Type flatbed 4×2 driving with rear wheels Seating (Including the Driver) 2 seats Length 4115 Overall Size Width...
  • Page 7 Owner and Operator’s Manual General Information 2.2 Table of Performance Parameters Minimum Turn Radius (in meters) Radius and Clearance Ground Clearance (in milimeters) MAX. Speed (mph) Gradability % Common Statistics Best Range (in miles) 2.3 Table of Structure and Specifications Front Suspension Coil Spring McPherson Independent Suspension Suspension...
  • Page 8 Owner and Operator’s Manual General Information 2.3 Table of Structure and Specifications (cont’d) Auxiliary Storage Battery 12 V 36 Ah(C20), Cathode Ground Strap Connection Power Storage Battery 72V 115 Ah (C 5) Input Voltage (v) DC/DC Converter Output Voltage (v) 13.5 Max Output Electric Current(A) Input Voltage (v)
  • Page 9 Owner and Operator’s Manual General Information 2.3 Table of Structure and Specifications (cont’d) Brake Light/Rear Position Light 21w/5w Auxiliary Back-up Light Lighting Electrical License Plate Light System Equipment Interior Light Instrument Panel Light, Indicator Light 3.4w Turn Signal Light Flash Frequency 85±12times/min Alarming Signal Light Flash Frequency...

  • Page 10: Vehicle Marking

    3. Vehicle Maintenance 3.Branding In order to maintain the vehicle in good running Body surface has the ZAP logo in font and back. condition, please service the vehicle according ZAPTRUCK-XL and Zero Emissions are also 2.Inspection of NewVehicle to this manual.

  • Page 11: Vehicle Load

    Owner and Operator’s Manual Safety and Important Notes 4. Vehicle Load The Vehicle The maximum vehicle load is specified by the Use the lubricants and fluid for the vehicle manufacturer, the maximum vehicle load according to the specified interval and capacity is GVM (Gross Vehicle Mass).
  • Page 12 ’ Ash Tray Radio Defroster...

  • Page 13: Introduction Of Devices And Control Mechanism

    Owner and Operator’s Manual Introduction of Devices and Control Mechanism 1. Ignition Switch and Steering Lock START Turn Signal Lamp Switch The ignition switch has four positions: When the key is turned to this position, the As shown in the picture, when pushing up the LOCK motor starts.
  • Page 14 Owner and Operator’s Manual Introduction of Devices and Control Mechanism 3. Windshield Wiper Switch operation,the wiper motor could be burned When the ignition switch is in “ON” or “ACC” 5.Direction Choice Switch out even though the windshield wiper is position, turn the switch to “INT”,“LO” or “HI” There are three shifts of the direction choice switched off.
  • Page 15 Owner and Operator’s Manual Introduction of Devices and Control Mechanism 6. Combination Instrument 8.Assistant battery charge indicator light- When the ignition switch is at “ON” position and the voltage of the assistant battery is below 11.8V,the light will turn on. 1.Warning light of low brake fluid level When activating the right turn signal, this light When brake fluid is low, the warning light will...
  • Page 16 Owner and Operator’s Manual Introduction of Devices and Control Mechanism Idiographic Failure Code and Information: 7. Multi-Functional Display (A) will light up on the Choice Button. When the discharging current module is working, it shows Code Definition E-01 over voltage protection current power (ampere) main battery E-02...
  • Page 17 Owner and Operator’s Manual Introduction of Devices and Control Mechanism valid signals at the same time for there is 9.Radio something wrong with the direction selector switch. The electric controller system will output nothing and emit the failure code to multifunction display.Turn the ignition switch to “OFF”...

  • Page 18: Keys, Doors And Windows

    Owner and Operator’s Manual Introduction of Devices and Control Mechanism 2. Keys, Doors and Windows WARNING CAUTION 1 KEYS Every vehicle has two Before opening the door be sure that it is Never leave you keys in the vehicle. safe around the vehicle. identical keys;...

  • Page 19: Seats

    Owner and Operator’s Manual Introduction of Devices and Control Mechanism 3. Seats 4. Back Gate and Side Gates of Truck Bed 1.FRONT SEATS 1.BACK GATE Fold up and lift seats by adjusting the handle to Lowering the direction as shown in the figure to fold Undo clasp of the gate hook, seatback forwards lower the rear gate.

  • Page 20: Safety Belts

    Owner and Operator’s Manual Introduction of Devices and Control Mechanism 5. Safety Belt 2.SIDE GATE Safety BeltAdjustment Opening This truck uses a three-point ELR Adjust the seat and sitting posture to a (Emergency Locking Retractor) type Open handhold of the plate hook and support of comfortable position, and fasten the waist belt safety belt .
  • Page 21 Owner and Operator’s Manual Introduction of Devices and Control Mechanism It is illegal to change the safety belt Additional Safety Belt equipment or additional mechanism with WARNINGS a ny o t h e r t h a n s p e c i f i e d by t h e The shoulder belt should be fastened across manufacturer.

  • Page 22: Other Devices

    Owner and Operator’s Manual Introduction of Devices and Control Mechanism 6. Other Devices 1) External Rearview Mirror 3) SunVisor NOTE Adjustment: Adjustment: For added safety, passengers can hold safety The position of external rearview mirror can be Rotate the sun visor so that the driver's vision handles during driving.
  • Page 23 Owner and Operator’s Manual Introduction of Devices and Control Mechanism WARNING Turn the direction choice switch to“N”. Parking brake must be released during driving or the braking system may be permanently impaired and other parts may be damaged. WARNING If parking brake cannot be completely To avoid potential fire, the ashtray should The jack is located underneath the passenger released do not operate the vehicle and have...

  • Page 25: Driving Suggestions

    Owner and Operator’s Manual Driving Suggestions 3) Running mode,and you will feel faint braking. I. Driving Operation § § Adjust the driving direction by controlling the When the vehicle is moving, release the 1) Before starting the vehicle steering wheel. accelerator completely and press the brake §...

  • Page 26: Economical Driving Suggestions

    Owner and Operator’s Manual Driving Suggestions 3. Economical Driving Suggestion To achieve economical driving, always service, WARNING! 4. Suggestion on maintain the vehicle periodically to keep it in Pull manual brake tight when parking. Slippery Road Driving optimum running. § §...

  • Page 27: Emergency Conditions

    Owner and Operator’s Manual Emergency Conditions I. Vehicle Starting Failure 1) Check Charging NEVER touch the radiator on the motor roadside and consult your ser vice immediately after the vehicle stops. technician. The vehicle has a charging check function.Check the charge connect from theAC to source. If the steering system is completely out of NOTE control, make arrangements...

  • Page 28: Deflated Tires

    Owner and Operator’s Manual Emergency Conditions 6. Deflated Tires Lower Arm Retainer Wheel nut wrench If the wheel is equipped with an ornamental WARNING! cover, pry off the cover with a straight Jack up the vehicle with care until the wheel is In case of a flat tire while running, do not screwdriver.
  • Page 29 Owner and Operator’s Manual Emergency Conditions WARNING! NOTE To avoid vehicle damage and personal Do not apply machine oil or grease on wheel injury: nut, otherwise it may become loose during driving. Do not place the hoisting jack in positions other than those specified.

  • Page 30: Emergency Towing

    Owner and Operator’s Manual Emergency Conditions 7. Emergency Towing Towing trailing Precautions for using the draw ring: It is suggested to schedule vehicle towing only If it is impossible to start the vehicle, attach a · Make sure the draw ring is secure. by a qualified towing service organization.

  • Page 31: Service And Maintenance

    Owner and Operator’s Manual Service and Maintenance I. Cleaning and Maintenance gently with wet cloth. WARNING! 1. External Cleaning and Maintenance for Vehicle Wet brakes may lead to an accident. Wet MAINTENANCE OF SAFETY BELT brakes cannot perform the braking function. CLEAN §...

  • Page 32: Routine Maintenance

    Owner and Operator’s Manual Service and Maintenance § SAFETY CHECK When cleaning the inside of the vehicle door, NOTE § Check that lights, instruments, wipers, hand door sill, sole bar and other parts, the drain hole Before repairing electrical equipment, should be unobstructed.
  • Page 33 2010 Service and Maintenance...
  • Page 34 2010 Service and Maintenance...

  • Page 35: Requirement For Regular Maintenance

    Owner and Operator’s Manual Service and Maintenance 4. Requirement for Regular Maintenance Power Battery (Main Pack) ACAsynchronous Motor and Controller To avoid short circuit,do not allow any metal Power batteries provide energy to move the The AC asynchronous motor (Fig.1) and object to touch the battery anytime.
  • Page 36 Owner and Operator’s Manual Service and Maintenance Reference value of electrolyte density is 1.28 NOTE (when 20 ), and density declining indicates that If the controller stops due to various the battery is at low power and shall be charged protection conditions, such as over-loading, in time.
  • Page 37 Owner and Operator’s Manual Service and Maintenance FreeTravel of SteeringWheel Adjustment of Brake Pedal Wiper andWasher Fluid WIPER Keep steering wheel in a position that makes the ADJUSTMENT If the wiper blade has become brittle,cracked or vehicle drive straight, then turn steering wheel Reference value is 153 to 158mm.
  • Page 38 Owner and Operator’s Manual Service and Maintenance Checking Range of Parking Brake the piston of brake master cylinder), the travel If the distance is smaller than the reference Pull up the handle of parking brake by force of of pedal at this point is the free travel, the value, possibly it is because of the following 400N (about 40Kg), if the pulling travel is within causes,and repair or adjust:...

  • Page 39: Solutions For Malfunctions

    Owner and Operator’s Manual Solutions for Malfunctions 1. Rear Axle Malfunctions TROUBLE DESIGNATION DESCRIPTION REMEDY Oil seal is damaged or worn Replace There is too much oil Adjust oil level Oil leaks Air plugs are blocked Clean (Constant noise) gear oil deteriorates or is with water content Change oil and refill (Constant noise) gear oil is insufficient or of the wrong type Change oil or add oil...

  • Page 40: Steering, Suspension, Wheel And Tire

    Owner and Operator’s Manual Solutions for Malfunctions 2. Steering, Suspension,Wheel and Tire Malfunctions TROUBLE DESIGNATION DESCRIPTION REMEDY Tires are unmatched Replace Tire pressure is improper Adjust tire pressure to specified value Wheel runs with misalignment Front spring is damaged or shortened due to plastic deformation Replace spring Evenness of radial tire (referring to lateral oscillating quantity) exceeds limit value Replace tire...
  • Page 41 Owner and Operator’s Manual Solutions for Malfunctions 2. Steering, Suspension,Wheel and Tire Malfunctions (cont’d) TROUBLE DESIGNATION DESCRIPTION REMEDY Tire has a bulge or damaged Replace tire Evenness of radial tire (referring to change in radial rigidity) exceeds limit value Replace tire Wheel bounces Radial run out of wheel or tire exceeds limit value Replace tire...
  • Page 42 Owner and Operator’s Manual Solutions for Malfunctions 2. Steering, Suspension,Wheel and Tire Malfunctions (cont’d) TROUBLE DESIGNATION DESCRIPTION REMEDY Tire is under inflated Charge the tire to specified pressure Replace ball pin of steering linkage or Ball pin of steering linkage or ball pin of lower left and right trailing arm jams Steering is difficult lower trailing arm Tightness of steering gear is not adjusted...
  • Page 43 Owner and Operator’s Manual Solutions for Malfunctions 2. Steering, Suspension,Wheel and Tire Malfunctions (cont’d) TROUBLE DESIGNATION DESCRIPTION REMEDY Replace tire or charge the tire to Tires are unmatched or inflation pressure is uneven specified pressure Replace suspension arm or ball pin of Ball joint of lower trailing arm or tie rod of steering linkage has been loose Oscillating occurs during steering linkage...
  • Page 44 Owner and Operator’s Manual Solutions for Malfunctions 2. Steering, Suspension,Wheel and Tire Malfunctions (cont’d) TROUBLE DESIGNATION DESCRIPTION REMEDY Vehicle is overloaded or load is uneven Check load and spread weight more evenly Suspension is pressed Spring holder of front shock absorber is sealed off Replace front shock absorber to the bottom Spring is damaged or shortened due to plastic deformation...

  • Page 45: Braking Malfunctions

    Owner and Operator’s Manual Solutions for Malfunctions 3. Braking Malfunctions TROUBLE DESIGNATION DESCRIPTION REMEDY Friction lining is damaged Replace brake shoe or brake pad Braking system is leaking oil Find leaky parts and repair Malfunctions of brake master cylinder Repair or replace brake master cylinder Brake height of brake pedal is too low (soft brake) Air is intermingled in brake hydraulic system...
  • Page 46 Owner and Operator’s Manual Solutions for Malfunctions 3. Braking Malfunctions (cont’d) TROUBLE DESIGNATION DESCRIPTION REMEDY Friction lining has oil stains or grease Replace brake shoe Brake force is uneven Malfunctions of self adjustment mechanism of rear wheel brake Repair or replace self adjustment mechanism Brake drum or brake disc is out of round Replace brake drum or brake disc Tire pressure is uneven...

  • Page 47: Malfunctions Of Power System

    2010 Solutions for Maintenance Checking flow of power system and control system...
  • Page 48 2010 Service and Maintenance Checking flow of power system and control system...
  • Page 49 2010 Service and Maintenance Checking flow of power system and control system...

  • Page 50: Malfunctions Of Electric Controlling System

    Owner and Operator’s Manual Solutions for Malfunctions 6. Malfunctions of Electric Controlling System REMEDY TROUBLE CODE DESCRIPTION Turn the ignition switch to the “OFF” position, restart the vehicle after the system initializes Over voltage protection E-01 If the problem repeats, check the controller and repair Turn the ignition switch to the “OFF”...

  • Page 51: Malfunctions Of Lights, Instruments, Switches And Indicating Lights

    Owner and Operator’s Manual Solutions for Malfunctions 6. Malfunctions of Electric Controlling System REMEDY TROUBLE CODE DESCRIPTION Voltage sensor failure E-16 Check the circuitry; replace the voltage sensor Phase fault E-17 Exchange two phase line arbitrarily Start the vehicle with pressing the accelerator, and then the failure appears. Release the accelerator Accelerator over high E-18 and restart the vehicle, the failure disappears...
  • Page 52 Owner and Operator’s Manual Solutions for Malfunctions 7. Malfunctions of Lights, Instruments, Switches and Indicating Lights (cont’d) 1) MALFUNCTIONS OF FRONT HEAD LIGHTS (cont’d) TROUBLE DESIGNATION DESCRIPTION REMEDY Lights are damaged Check lights Malfunctions of front head light switch Check front head light switch Only one front head light Check left and right fuses;...
  • Page 53 Owner and Operator’s Manual Solutions for Malfunctions 3) MALFUNCTIONS OF TURN SIGNAL LIGHTS AND EMERGENCY ALARM LIGHTS TROUBLE DESIGNATION DESCRIPTION REMEDY Lights on the side with high flashing frequent are damaged Check lights Lamp arrangement is incorrect Check lights Flashing occurs too frequently or exists Malfunctions of turn signal/emergency alarm relay Check flashing relay...
  • Page 54 Owner and Operator’s Manual Solutions for Malfunctions 4) MALFUNCTIONS OF BACKUP LIGHT TROUBLE DESIGNATION DESCRIPTION REMEDY Lights are damaged Check lights Check fuse; replace if necessary Fuse (F11) of backup light blows out (In case of replacement, check for short circuit) Backup light is off Malfunctions of backup light switch Check switch...
  • Page 55 Owner and Operator’s Manual Solutions for Malfunctions 6) MALFUNCTIONS OF ALARM LIGHTS FOR BRAKING FLUID LEVEL AND PARKING BRAKE TROUBLE DESIGNATION DESCRIPTION REMEDY Light for combination instrument is damaged Check light Check fuse; replace if necessary Fuse (F11) blows out (In case of replacement, check for short circuit) When braking fluid level is low, brake alarm light is off...

  • Page 56: Zap Registration Card

    Owner and Operator’s Manual Solutions for Malfunctions 7) WIPER AND WASHER MALFUNCTIONS TROUBLE DESIGNATION DESCRIPTION REMEDY Check fuse; replace if necessary Fuse (F6) for wiper (washer) blows out (In case of replacement, check for short circuit) Malfunctions of wiper motor Check wiper motor Wiper fails or can't return to its original position...

  • Page 57: Oil Fluid For Vehicle

    Owner and Operator’s Manual Oil, Fluid for Vehicle and Electrical Values of Complete Vehicle 1. Specification and Capacity of Lubricant, Lubricant Grease and Braking Fluid ITEM STANDARD (Recommended) CAPACITY (liters) REMARK GL-4 85W90 0 C-50 C Gear-box GL-4 85W90 -35-0 C Lubricant oil GL-4 75W90...
  • Page 58 REGISTRATION CARD (Not returning this card will not void the original 6-months limited warranty.) 1. Name & Address: 8. What most influenced your decision to purchase a ZAPTRUCK? * Title Mrs. Miss Factors (check all that apply): Received as a gift Advertisement Brand name Friend's/relative's recommendation...
  • Page 59 Own a CD-ROM Drive Thank you for filling in this registration card. Please tear off along the doted line and fax, mail or e-mail to the following address ZAP 501 Fourth Street, Santa Rosa, CA 95403 USA. , mrickard@zapworld.com, fax: 707-526-6464...

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