Xebra Electrical Component Locations

Last updated on April 12, 2007 Copyright 2007. This document my not be reprinted, published, emailed or posted on the Internet without the approval of ZAP.

Component Locations• Sedan • PK

Components

• Battery • Battery Charger • Fusible Link • Fuses • Relays • Contactors • DC/DC Converter • Motor Controller • Motor • Motor cooling fan

Electrical Component Currents• Current Draw

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Component LocationsSD Component Locations Rear left side component locations. Motor controller. Contactors. Fuse box F5, F6 Diodes D5, D6. There may also be an in-line glass fuse or ATO fuse below the plastic fuse box.

Rear right side. Motor cooling fan. Charger Lockout JDac. Backup beeper. Battery Charger.

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Behind dash are Flasher relay on left and relays JD3-JD8, Fuses F1-F4 and Diodes D1-D4 on right. Removing the glove box allows easier access to components on right.

On the front left are the horn and DC/DC converter. On the right is the brake reservoir and cylinders.

The sedan traction pack batteries are between the front seats and under the rear seat. The accessory battery is located below here and is accessible from the bottom.

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PK Component LocationsHere is a picture of the rear of the vehicle.Accessory battery. Traction pack batteries.

Motor controller. Contactors. Fusible link. Battery charger

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Here is a picture of the front left.PCB connector harness. Horn. PCB assembly with fuses.

DC/DC converter. There is also an in-line fuse for the DC/DC converter in the PCB connector harness.

Here is a picture of the front right. PCB assembly with fuses. Brake cylinders. Brake reservoir.

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Inside on the right side is the heater and the charger lockout relay JDac. Not shown is the flasher relay above the heater and the heater control board to the right of the heater.

Inside on the left are the brake switch and the accelerator pot box.

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Component DescriptionsBatteriesThe vehicle uses six sealed lead acid batteries for the traction motor. There is also a small 12V 18Ah accessory battery. The traction batteries store about 5, 5.5 or 9 kWh (depending on if the pack is 98, 105 or 140 AH) of useful energy Some battery tips:

• Always charge your batteries whenever you can. • Never leave the vehicle in a discharged state. A discharged battery can freeze in cold weather

and sulfate at warmer temperatures. Both destroy the battery. • If you continually discharge your batteries more than 90% your batteries may only last 200

charge cycles. If you recharge after using only 25% of the energy your batteries my last for as many as 1000 charging cycles.

• Cold weather decreases energy storage significantly. Range will be severely limited below freezing.

• Charge in a heated garage during cold weather. • Consider adding 5 battery equalizers. They can be purchased at

http://www.evsource.com/tls_powercheq.php. This will also add considerable life to your batteries as well as extend range.

• If even one battery is bad, all six must be replaced.

Battery Charger Below are the two styles of charger. The Delta-Q and the BC2-7215B.

The BC2 requires a dedicated 20A circuit and the Delta-Q a dedicated 15A circuit. The charger is responsible for charging the 6 battery traction pack.

Fusible Link The final line of defense in protecting the traction battery pack is the main fusible link. It may blow because:

1. You have a short in the car wiring. 2. Your motor controller, DC/DC converter or contactor(s) are bad. 3. You switch from driving at a high speed in one direction to trying to accelerate quickly in the

other direction. Always have the vehicle come to a complete stop before you change direction.

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4. You have all your accessories on while you are driving at high speed. (If this is the case, try a fuse with a 50A higher rating (ANN-350 instead of ANN-300 for example).)

Location Under the rear seat mounted next to one of the traction batteries in the sedan. Next to the lone traction battery in the back of the PK. (Tilt the dump bed up).

Size With a 300A controller, an ANN-250 is specified. With a 450A controller, an ANN-400 is specified.

FusesThe vehicles use standard ATO blade fuses. On early SD vehicles a strange wire wound fuse was used. If your vehicle has such fuses you must replace with a Zap supplied fuse replacement kit of six fuses. These adapters allow the use of standard blade fuses which can then be inserted into the old fuse box. Refer to the “Xebra_reliability” service bulletin.

Location SDUnder the passenger side dash (4) and in the rear (2). There may be an in-line ATO or glass fuse under the dash to protect the accessory battery and another by the square plastic fuse holder in the rear.

Location PKMost ATO fuses are on the PCB module in the center front compartment under the hood. There is also an in-line fuse to the right of the PCB in the PCB connector wiring harness bundle.

There may be one in-line ATO in waterproof case protecting both the accessory battery and the 72V on the small wire.

DC Relays JD1-JD8 and AC Relay JDacThere are two types of DC relays in the car. One has a 12V coil and the other has a 72V coil. All coils:

• are physically the same size • have a JD reference in the schematics

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• can switch 12V or 72V signals. • are single pole single throw. • have two connections for the coil voltage, pin 85 and pin 86. • have three connections for the relay contact, common is pin 30, normally open is pin 87 and

normally closed is pin 87a.

DC Relay Location

In the SD, six of the relays are under the dash on the passenger side and two are in the rear of the car behind the four large contactors. In the PK all the relays are on the PCB module in the center front compartment under the hood.

12V Coil DC Relay 72V Coil Relay (tab usually cutoff) 110VAC Coil Charger Lockout Relay

The 12V DC coil relay has writing on the top indicating that is a 12V coil. The 72V relay has no writing on it.

ContactorsAll four contactors are grouped together in the rear of the vehicle next to the motor controller and have 72V coils. All coils are protected with fly back diodes.

Schematic designation Function Contact

Current Description

J4 Control contactor

DC/DC and heater current

Energized when the 12V cutoff switch is on and the key is turned to the 1st position. This provides power to the DC/DC converter, dash volt meter and the heater.

J1 Main contactor

Full motor current

Energized when the 12V cutoff switch is on, the key is turned to the 2nd position, the car is in forward or reverse and both the emergency and foot brakes are released. This provides power to the motor, motor controller and the forward and reverse contactors.

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J2 Reverse Contactor

Full motor current

Energized when the 12V cutoff switch is on, the key is turned to the 2nd position and the car is in reverse. This configures the motor wiring to run the motor in reverse.

J3 Forward Contactor

Full motor current

Energized when the 12V cutoff switch is on, the key is turned to the 2nd position and the car is in forward. This configures the motor wiring to run the motor in the forward direction..

All contactors are identical except the forward and reverse contactors have these two extra tabs.

DC/DC Converter The DC/DC converter takes the 72V from the traction battery pack and derives a 14V power signal to power the 12V electrical accessories (lights, radio, horn, etc.) and charge the 12V accessory battery. The input power is supplied through control contactor J1 and a fuse. The output is fed to the 12V system through a second fuse.

There are two versions, the 20A model (has screws on top) and the 30/25A model (no screws on top).

The 20A DC/DC has a different connector pair than the 30/25A unit. If you receive a replacement 30A unit that is to be installed in a vehicle with a 20A you will be supplied the mating connectors to solder

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to the wiring harness in place of the old connectors.

Motor ControllerThe motor controller is controlled by the potentiometer connected to the foot throttle and varies the current from the traction battery pack to the motor with pulse width modulation electronics driving high current FET transistors.

There are three models, the 300A and 450A Alltrax and the Curtis controller.

Motor The traction motor is a series wound, brushed, DC 5 kW motor connected to the rear two wheels through single speed gearing, a differential, CV joints and drive shafts.

• Only maintenance is to replace brushes when they become worn (every 2-4 years). • Driving in dirty and/or wet conditions shortens the brush life. • Dusty gravel or dirt roads will shorten brush life.

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The specifications of the motor are:

• Model: 192 ZC52• POWER: 5kW• Volts: 72 volts• Amps: 84 amps• RPM: 2,800 rpm• RPM Max.: 3,600 rpm• Ambient Temperature: No greater than 40-degrees Celsius• Insulation Class: F

The motor is located here.

Motor Cooling FanThere is a thermostatically controlled motor cooling fan. Also, if the motor gets too hot, a dashboard light illuminates to indicate this serious condition. Be sure and pull over and let the motor cool. To verify that these items are function use the following tests:

1. Unscrew or unsnap the four conductor connector from the motor A22. 2. Jumper between pins 3 and 4 (both green wires) and the cooling fan should run. 3. Jumper between pin 1 (brown) which is +12V and pin 2 (blue) and the dash voltmeter high

temperature light should light.

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Current DrawCurrent DrawThe following table shows current draw for various components.

Component Current Draw in amps

Brake lights incandescent (Two) 4.2

Blinkers incandescent (Two) 4.2

Flashers incandescent (Four Blinkers) 8.3

Windshield wiper 2.9

Radio 0.4

Backup lights and beeper 1.4

Side Headlights (high beam) 5.3

Dome light 0.3

Center headlight 5.1

Center headlight high beam 5.7

Motor cooling fan 1.7

Heater 6.0A

Basic contactors 0.7A

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