dated on April 26, 2007
Copyright 2007. This document my not be reprinted, published, emailed or posted on the
Internet without the approval of ZAP.
Intended Readers

The purpose of this manual is to provide a mechanic, technician or savvy electric car buff with the
tools to troubleshoot and repair the vehicle. Please be sure you are familiar with the Owner's Manual
before using this guide. This troubleshooting Guide assumes a good knowledge of the Owner's
Manual, the vehicle itself and basic mechanical and electrical skills. Check with ZAP if you are
unsure who to have do the work. ZAP is not responsible for damage to your vehicle or personal
injury for work done by non-qualified personnel.

Version
This document describes the original wiring with the 12V key ignition system. Do not use this
manual for the 72V key ignition system.
Sections
Introduction

12V common

72V common
Common Problems

Tight Wire Connections

Fuse Problems

Connector Problems

Theory of operation

Troubleshooting by Vehicle Operation

Low Voltage System

High Voltage System

Troubleshooting by Problem

No 12 volts

No DC/DC converter output

Won't Drive Forward

Won't Drive in Reverse

Vehicle Won't Charge
Test Charger and Batteries

1
Inadequate Charge or Range
Alltrax Motor Controller
Appendix A Figure 1 12V electrical schematic
Appendix A Figure 2 72V electrical schematic
Appendix A Figure 3 - motor, contactor, motor controller wiring detail

Electrical Introduction
This document describes the electrical systems of the ZAP Xebra vehicles. The sedan is referred to
as "SD" and the pickup as "PK". The schematics are in appendix A. Wires are given identifying labels. Low voltage wires prefix the number with "S" (Ex. S1). High voltage wires prefix the number with "T" (Ex. T1). Low voltage power wires start with "12V" (Ex. 12VF3). High voltage power wires start with" 72V" (Ex 72VC). The low voltage common is referred to as -12V. This is also connected to the vehicle chassis. The high voltage common is referred to as -72V. Components are given identifying labels. "A" indicates a module (Ex. A1 for DC/DC converter). "JD" indicates a lower current relay (Ex. JD1). "J" indicates a high current contactor (Ex. J1). "L" indicates a light bulb (Ex. L1). "K" indicates a switch or button (Ex. K24). There is one complicated multifunction switch mounted on the steering column that controls
the head lights, blinkers, emergency flashers and windshield wipers. This is broken into K1-
1, K1-2 and K1-3 on the schematics. The electrical system is divided into: The 12V low voltage light and accessory system, running off the accessory battery. The 72V high voltage drive system, operating off the traction battery pack. The 12V system must be operational before the 72V system can be activated.
Whenever you are troubleshooting an electrical system, it is necessary to know where the
"Common" or "Ground" is located. In these vehicles the 12V system is isolated from the 72V
system. The 12V common is also tied to the metal car frame. The 72V system is completely isolated
(floating).
12V Common The 12V common is referred to as -12V in the schematics. The best place to locate the 12V common inside the cab is on the cigarette lighter. You
should get a cigarette lighter plug from an automotive store and solder a black wire to the
-12V side (the outside wall of the connector). When in the front or rear compartments of the vehicle, use any common (black wire) on a
light bulb connector. The metal frame is usually not a good place to pick up common. When using a voltmeter, set to an appropriate scale for 12V (usually the 20V range) and
connect the black voltmeter common to 12V common. Use your red voltmeter wire to probe the 12V electrical system.
2 72V Common
The 72V common is referred to as -72V in the schematics. In the SD you can remove the center traction battery cover and connect to the negative
terminal of the battery closest to the dash. In either the SD or the PK you can remove the center dashboard switch plate (two screws)
and connect to the black wire of the heater switch. When in the rear of the vehicle, use the B- post on the motor controller A21. When using a voltmeter, set to an appropriate scale for 72V (usually the 200V range). Use your red voltmeter wire to probe the 72V electrical system.
Common Electrical Problems
The most common problems include loose wire connections and fuse and connector problems. Since
the Xebra is a simple vehicle, the solution is often simple. It is important to be just like a doctor and
be a good detective.
WARNING and Safety ! Both electrical systems are capable of very high currents (means blinding light, sparks,
fire and welding are possible).
The 72V system is also capable of giving you a serious voltage shock.
When working on the vehicle, all tools and handles should be wrapped in electrical tape
or rubber coated to avoid shorting terminals; that is, never touch the positive to a
negative of any part of the system or any battery.
Positive and negative locations may not be immediately obvious, especially on the
motor controller and the printed circuit card.
Take all standard precautions for electrical systems including removing rings and
watches, wear safety glasses and gloves and proceed cautiously using common sense.
Unless necessary for troubleshooting, make sure the 12V cutoff switch and the 72V
cutoff switch are off. They must always be off whenever you are changing components
(such as the motor controller), fuses or wiring.

Check for Tight Wiring Connections wires on fuse and diode blocks wires to and between batteries wires to main traction battery fusible link F9 wires to contactors wires to motor controller wires to drive (traction) motor Make sure the small wires on the motor controller (A21) are tight; crimp as necessary
Fuse problems, solutions and tips The PK uses standard blade fuses and do not have the following problems. The SDs originally used wire wound fuses. These fuses can discolor (oxidize) over time
(which causes the resistance to increase). Refer to the waterproofing and reliability guide for
information on replacing these fuses. If you find such fuses they must be removed and changed to standard
automotive blade fuses.

3
Use Zap supplied replacement fuse sockets. In an emergency you may solder a standard blade fuse to the original fuse holder (remove all
the old wire). Or purchase and wire blade fuse holders with wire pigtails (available at any automotive
store). There are six of these "bad" wire fuses, F1-F4 are under the front passenger side dashboard
and F5-F6 are in the rear motor compartment above the contactors. Removing the glove box
makes working on the fuse block much easier.
Connector problems, solutions and tips The connectors sometimes become loose or disconnected. Simply reconnect making sure the connector latching mechanism seats properly. Be sure no pins or lugs have become unseated. If so, press them back into the connector until
they snap or catch in place. If you suspect a bad connection between the wire and the pin, remove pin, uncrimp to
remove wire, cut out bad section, strip, recrimp and solder connection.
Theory of Electrical Operation
This section gives a step by step description of how the ZAP Xebra vehicle's electrical systems
operate:
1. Enable the 72V electrical system by pulling out (turning on) the red "Main Disconnect"
switch (K21) in front of the driver's seat.
2. Turn on the 12V electrical system by turning on the power (cutoff) switch (K25) on the
dashboard.
3. Turn the key ignition switch (K26) to position 1 (1st click).
4. This energizes relay JD8 which turns the 12V electrical system on through fuse F2.
5. The ignition switch also energizes relay JD4 which activates contactor J4 which connects
72VC through fuse F6 to 72VF6 and the DC/DC converter.
6. The DC/DC converter outputs about 14.0 VDC which takes over the operation of the 12V
electrical system and charges the 12V battery through fuse F1, relay JD8, ignition switch
K26, cutoff switch K25 and battery protection fuse F7.
7. Note, if the 12V battery is badly discharged, relay JD4 will not turn on, which in turn
prevents starting the DC/DC converter.
8. On cars so equipped, press the green emergency start button K20. This forces +72V to start
the DC/DC converter.
9. Otherwise, most vehicles have been modified so you can charge the 12V battery through one
of the cigarette lighters.
10. On very early models you must connect your battery charger directly to the 12V battery.
11. You may use any standard 12V car battery charger but select a low current range (15A or
lower).
12. The dash voltmeter should indicate the voltage of the 72 volt system.
13. Now all the lights and accessories will operate except the reverse lights and beeper which
require the traction drive system to be enabled.
14. Voltage 72VC is also connected from contactor J4 onto battery charger lockout relay JDac.
15. As long as the battery charger is unplugged, JDac is not energized so 72VC is passed to
relay JD5 over wire T1.
4 16. If the battery charger is plugged in, the charger disable relay energizes, removing the voltage
to JD5.
17. Turning the key to position 2 (2nd click) energizes relay JD5.
18. The 72V is now passed from JD5 over T2 through fuse F5 through T4 to the direction switch
K23. As long as this switch is in "N" (Neutral), the 72V goes no further.
1