Hammerhead Charger 48V User manual

HAMMERHEAD
CHARGER 48V
Electric Vehicle Operator’s Manual

HammerheadChargerElectricVehicleOperator’sManual Page1
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TABLEOFCONTENTS
SAFETYINFORMATION.............................................................................................................................3
GENERALOPERATIONINSTRUCTIONS..............................................................................................4
MAINTENANCESAFETYINSTRUCTIONS............................................................................................4
VENTILATION....................................................................................................................................4
DISPLAYOFWARNINGLABELS.................................................................................................................5
DISPLAYOFCONTROLS.............................................................................................................................7
BEFOREINITIALUSE..................................................................................................................................8
BATTERIES.........................................................................................................................................9
ON‐BOARDCHARGER.......................................................................................................................9
CONTROLSANDINDICATORS.................................................................................................................10
KEY/LIGHTSWITCH.......................................................................................................................10
DIRECTIONSELECTOR.....................................................................................................................11
STATEOFCHARGINGMETER..........................................................................................................11
COMBINATIONLEVER(TurningSignals,HighBeamLights,Horn)..................................................11
HAZARDLIGHTSWITCH..................................................................................................................12
SPEEDOMETER................................................................................................................................12
ACCELERATORPEDAL.....................................................................................................................13
BRAKEPEDAL..................................................................................................................................13
PARKINGBRAKELEVER...................................................................................................................13
BEDUSE..................................................................................................................................................14
MANUALLIFTBEDOPERATION......................................................................................................15
TAILGATEOPERATION...................................................................................................................16
OPERATINGTHEVEHICLE.......................................................................................................................17

HammerheadChargerElectricVehicleOperator’sManual Page2
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STARTINGANDDRIVING.................................................................................................................17
STARINGVEHICLEONAHILL..........................................................................................................18
VEHICLECLEARNINGANDCARE.............................................................................................................19
REPAIR....................................................................................................................................................20
WHEELSANDTIRES.........................................................................................................................20
FUSEREPLACEMENT.......................................................................................................................20
SERVICEANDMAINTENANCE.................................................................................................................22
VehicleIdentificationPlateLocation..............................................................................................22
PeriodicMaintenanceSchedule.....................................................................................................23
TireInspection................................................................................................................................24
Brakes.............................................................................................................................................24
RearAxle.........................................................................................................................................24
Fasteners........................................................................................................................................24
BATTERIESANDCHARGING....................................................................................................................25
Batteries.........................................................................................................................................25
Charger...........................................................................................................................................25
GENERALSPECIFICATIONS......................................................................................................................26
LIMITEDWARRANTYPOLICY.................................................................................................................28
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HammerheadChargerElectricVehicleOperator’sManual Page3
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SAFETYINFORMATION
ThankyouforpurchasingHammerheadelectricalvehicle.Forsafeandenjoyable
operationofyourelectricvehicle,besuretofollowtheinstructionsand
recommendationsinthisowner’smanual.Thismanualhasbeendesignedtoassist
theowner‐operatorinoperatingandmaintainingthevehicleinaccordancewith
proceduresdevelopedbythemanufacturer.Yourmanualincludesinstructions
forminormaintenance,butmajorrepairsshouldbeperformedonlybyaCertified
DealerTechnician.Duetoconstantimprovementsinthedesignandqualityof
productioncomponents,someminordiscrepanciesmayresultbetweentheactual
vehicleandtheinformationpresentedinthispublication.Proceduresinthis
publicationareintendedforreferenceuseonly.Noliabilitycanbeacceptedfor
omissionsorinaccuracies.
Manyvehiclesareusedforavarietyofdifferenttasksbeyondtheoriginalintended
useofthevehicle;thereforeitisimpossibletowarnagainsteverypossible
combinationofcircumstancesthatmayoccur.Nowarningcantakeplaceofgood
commonsenseandprudentdrivingpractices.
Withelectricpoweredvehicles,besurethatallelectricalaccessoriesaregrounded
directlytothe(‐)post.Neveruseschassisorbodyasagroundconnection.Never
modifythevehicleinanywaythatwillaltertheweightdistributionofthevehicle,
decreaseitsstabilityorincreasethespeedbeyondthefactoryspecification.Such
modificationscancauseseriouspersonalInjuriesordeath.Donotmakeanysuch
modificationsorchanges.Themanufacturerprohibitsanddisclaimsresponsibility
foranysuchmodificationsoranyotheralternationwhichwouldadverselyaffectand
safetyofthevehicle.
OnceagainthankyouforpurchasingHammerheadproduct,andwehopeyouwill
haveanenjoyableexperience.
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GENERALOPERATIONINSTRUCTIONS
‐Alwaysusethevehicleinresponsiblemannerandmaintainthevehicleinsafe
operationcondition.
‐Alwaysreadandobserveallwarningandoperationinstructionslabelsaffixedto
thevehicle.
‐Alwaysfollowallsafetyrulesestablishedinareawherethevehicleisbeing
operated.
‐Alwaysreducespeedforbadterrainorroadconditions.
‐Alwaysapplybraketocontrolspeedonsteepgrades.
‐Alwaysmaintainadequatedistancebetweenvehicles.
‐Alwaysreducespeedinwetareas.
‐Alwaysuseextremecautionwhenapproachingsharporblindturns.
MAINTENANCESAFETYINSTRUCTIONS
‐Alwaysmaintainyourvehicleinaccordancewithmanufacturer’speriodicservice
schedule.
‐Alwaysfollowthemanufacturer’sdirectionsifyoudoanymaintenanceonyour
vehicle.
‐Alwaysinsulateanytoolsusedwithinthebatteryareainordertopreventsparks
orbatteryexplosioncausedbyshortingthebatteryterminalsorassociated
wiring.Removethebatteriesorcoverexposedterminalswithinsulating
materials.
‐Alwaysusespecifiedreplacementparts.
‐Alwaystestdrivethevehicleafteranyrepairsormaintenance.Alltestsmust
beconductedinasafeareathatisfreeofbothvehiclesandpedestriantraffic.
VENTILATION
‐Hydrogengasisgeneratedinchargingcycleofbatteriesandisexplosivein
concentrationsaslowas4%.Becausehydrogengasislighterthanair,itwill
collectintheceilingorbuildingsnecessitatingproperventilation.Fiveair
exchangesperhourisconsideredtheminimumrequirements.
‐Neverchargeabatteryinanareathatissubjecttoflameorspark.Pay
particularattentiontonaturalgasorpropanegaswaterheatersandfurnaces.
‐Batterychargermustbeoperatedaccordingtomanufacturer’sinstructions.
Pleaserefertobatterycharger’sseparateoperator’smanualforfurther
instructions.

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DISPLAYOFWARNINGLABELS
Followingarethewarninglabelsaffixedtothevehicles;read,observeandfollowall
warningandoperationinstructionscarefully.Failuretofollowthesewarningscan
resultinseriesinjuriesordeath.
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HammerheadChargerElectricVehicleOperator’sManual Page6
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DISPLAYOFWARNINGLABELS‐2
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DISPLAYOFCONTROLS
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1. SteeringWheel2. CombinationLever
3. DigitalSpeedometer4. KeySwitch/LightSwitch
5. DirectionalSelector6. StateofChargingMeter
7. HazardSwitch8. Radio(optional)
9. GloveCompartment10. BrakePedal
11. AcceleratorPedal12. FrontBatteriesaccesspanel
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HammerheadChargerElectricVehicleOperator’sManual Page8
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BEFOREINITIALUSE
Read,understandandfollowthesafetylabelontheinstrumentpanel.Besureyou
understandhowtooperatethevehicle,itsequipmentandhowtouseitsafely.
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Hydrogengasisgeneratedinchargingcycleofbatteriesandisexplosivein
concentrationsaslowas4%.Becausehydrogengasislighterthanair,itwill
collectintheceilingorbuildingsnecessitatingproperventilation.Fiveair
exchangesperhourisconsideredtheminimumrequirements.
Neverchargeabatteryinanareathatissubjecttoflameorspark.Payparticular
attentiontonaturalgasorpropanegaswaterheatersandfurnaces.
Beforeanewvehicleisputintooperation,the“InitialServiceCheckList”belowmust
beperformedtoensuresafetyoperationofthevehicle.Determineandrecord
brakingdistancerequiredtostopvehicleforfuturebrakeperformancetests.
InitialServiceCheckList
9Fullychargebatteries
9Checkbrakeoperationandadjustifnecessary
9Checkbrakehydraulicbrakefluidlevel
9Checkparkingbrakeandadjustifnecessary
9Checkacceleratorpedalandbrakepedalmakesuretheyarenotsticking
9Checktirepressure(seeSPECIFICATION)
9Checkheadlights,turnsignals,brakelights
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HammerheadChargerElectricVehicleOperator’sManual Page9
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BATTERIES
Thiselectricvehiclerunsona48‐Voltssystem.Itusessix8‐Voltsbatteriesconnected
inseries.Therearetwobatterieslocatedunderthefronthoodthatcanbeaccess
throughanaccesspanelbelowthedash.Thereareanotherfourbatterieslocated
underneaththebenchseat.(Seelocationimagebelow)
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ON‐BOARDCHARGER
The110‐VoltsDelta‐Qonboardchargerislocatedundertheseatonthedriver’sside
ofthevehicle(seeimagebelow).Itiswireddirectlytothebatteries.Thereisalsoa
chargingportbelowthedriver’sseatthatcanbepluggeddirectlyintoany110Volt
walloutlets.(Seelocationimagebelow).FormoreinformationaboutDelta‐Q
Charger,pleasereferenceincludedcopyofDelta‐Qcharger’soperatorsmanual.
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HammerheadChargerElectricVehicleOperator’sManual Page10
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TheDelta‐QchargerisprogrammedtorunTrojanbatteries.Ifbatteriesneedto
bechanged,pleasecontactyourauthorizeddealerforcompatibilityquestions.
CONTROLSANDINDICATORS
Vehiclecontrolsandindicatorsconsistofthefollowings:
zKey/Lightsswitches
zDirectionselector
zStateofchargemeter
zCombinationlever(Lights/Horn/TurnSignals)
zHazardlightswitch
zSpeedometer
zAcceleratorpedal
zBrakepedal
zParkingbrakelever
KEY/LIGHTSWITCH
Locatedonthedashpanel,thisswitchenablesthebasicelectricsystemofthe
vehicletobeturnedonandoffbyturningthekey.Topreventinadvertent
operationofthevehiclewhenleftunattended,thekeyshouldbeturnedtothe‘OFF’
positionandremoved.Thekeyswitchalsohasapositionforturnonthehead
lights.(Seeimagebelow)
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HammerheadChargerElectricVehicleOperator’sManual Page11
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DIRECTIONSELECTOR
Locatedonthecontrolpanel,thisswitchpermitstheselectofeither“FWD”for
forwardmoving,“REV”forreverse,orNeutral(thepositionbetweenforwardand
reverse).Vehicleshouldbeleftinneutralwhenunattended.(SeeImageBelow)
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Toreducethepossibilityofcomponentdamage,thevehiclemustbecompletely
stoppedbeforemovingthedirectionselector.
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STATEOFCHARGINGMETER
Locatedinthedash,thestateofchargingmeterindicatestheamountofusable
powerremaininginthebatteries.(Seeimagebelow)
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COMBINATIONLEVER(TURNINGSIGNALS,HIGHBEAMLIGHTS,HORN)
Muchlikeacar’sturningsignallever,thiscombinationleverislocatedbelowthe
steeringwheelonthesteeringcolumnoperatesturningsignals,high/lowbeamlights
andhorn.Pushdownonthecombinationlevertosignalturningleft,pushupthe
levertosignalturningright.Pushinonthelevertoturnonhighbeam,pullbackon
thelevertoturnonthehighbeam.Pushinontheendofthelevertohorn.(See
imagebelow)

HammerheadChargerElectricVehicleOperator’sManual Page12
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HAZARDLIGHTSWITCH
Hazardlightswitchislocatedonthedashcontrolcluster.Turnonthisswitchto
activatehazardouslights.
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SPEEDOMETER
Digitalspeedometerislocatedinthemiddleoftheconsole.Itdisplayscurrent
speedinformationinMPH,aswellasodometerinMiles.Atthebottomofthe
speedometerareturningsignalindicators,parkingbrakeindicatorandhighbeam
indicator.(Seeimagebelow)
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HammerheadChargerElectricVehicleOperator’sManual Page13
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ACCELERATORPEDAL
Withthekeyswitch“ON”,releasetheparkingbrake,depressingtheaccelerator
startsthemotor.Whenpedalisreleased,themotorwillstop.Tostopthevehicle
morequickly,depressthebrakepedal.(Seeimagebelow)
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BRAKEPEDAL
Thisvehicleisequippedwithhydraulicbrakesystemthatcontrolsasetoffourbrake
discs;oneoneachwheel.Toslowdownthevehicleortostopthevehicle,depress
thebrakepedal.Depressingthebrakepedalfurtherwillincreasetheeffectivenessof
braking.(SeeImageBelow)
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PARKINGBRAKELEVER
Thisvehicleisequippedwithparkingbrakelever.Pushthereleasebuttonandthen
pulltheparkingbrakeleveruptoactiveparkingbrake.Whenparkingthevehicle,
pulluptheparkingbrakeandthenturnthekeyto“OFF”position.(Seeimagebelow)
Toreleasetheparkingbrake,pushthereleasebuttoninandthenpushtheparking
brakeleverdown.

HammerheadChargerElectricVehicleOperator’sManual Page14
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BEDUSE
Amanualliftbedisstandardforthevehicle.
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Failuretofollowtheseinstructionsmayresultinpersonalinjury,damagethe
vehicleand/orcausethevehicletotipover.Operatethevehiclewithawareness
oftheload.Read,understandandfollowthewarninginstructionsonthefrontof
theloadbed.
DONOTPERMITANYONETORIDEINTHEBED.Beforeoperating,ensurenoone
isbehindthevehicle.
Aloadbedwarninglabelisaffixedtotheinsidefrontofthebed.Thisvehiclebedis
ratedat250Lbs.Thislabelmustbeunderstoodandobservedatalltimesfor
safetyoperationofthevehicle.Seetheloadbedwarninglabelformaximumload
capacity.Theloadmustbepositionedinthebedasfarforwardaspossibleand
securelyfasteneddown.
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Neverfillagascaninbedofavehicle.Staticdischargecouldignitegasoline
vaporandcauseanexplosion.
Alwaysplaceagascanonthegroundbeforefilling.NEVERfillagascaninthebed
ofthevehicle.Staticelectricityisbuildupduringthefuelingprocessandcould
dischargecausingthegasolinevaportoignite.
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HammerheadChargerElectricVehicleOperator’sManual Page15
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MANUALLIFTBEDOPERATION
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Exercisecautionwhileoperatingthemanualliftbedtoensurethebedisnot
releasedduringliftingorloweringprocedure.Severeinjurycouldresultifbedis
releasedandtrapsfingerorotherbodyparts.
Toliftthemanualliftbed,pushdownonthelatchreleasehandlebehindtheseat.
Raisethebedusinghandleonthesideofthebed.Thegasstrutswillassistin
raisingtheemptyloadbedandwillkeepthebedraised.
Tolowerthemanualliftbed,graspthebedhandleandlowerthebedtotherest
position.Besurefingersarenottrappedbythebed.
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HammerheadChargerElectricVehicleOperator’sManual Page16
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TAILGATEOPERATION
Therearetwotailgateswitcheslocatedonthetopsideofthebed.Toopenthe
tailgate,pushthesmalltabforwardontheswitch,andpullbackthelockingplate.
(Seeimagebelow)Toclosethetailgate,hookthetailgatelatchandpushdownon
thelockingplate.
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HammerheadChargerElectricVehicleOperator’sManual Page17
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OPERATINGTHEVEHICLE
Readandunderstandthefollowingwarningsbeforeattemptingtooperatethe
vehicle.
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Toreducethepossibilityofsevereinjuryordeathresultingfromlossofvehicle
control,thefollowingwarningsmustbeobserved:
Whendrivingvehicle,considertheterrain,trafficconditionsandenvironmental
factorswhicheffecttheterrainandtheabilitytocontrolthevehicle.
Useextracareandreducedspeedwhendrivingonpoorsurfaces,suchasloosedirt,
wetgrass,gravel,etc.
Stayindesignatedareasandavoidextremelyroughterrains.
Maintainasafespeedwhendrivingdownhill.Usebraketocontrolspeedwhen
travelingdownanincline.Asuddenstoporchangeofdirectionmayresultinloss
ofcontrol.
Topreventlossofcontrol,donotmovethedirectionselectorofavehiclewhilethe
vehicleisinmotion.Movingtheselectorwillresultinasuddenslowingofthe
vehicleandbeepingofawarningdevice.
Slowdownbeforeandduringturns.Allturnsshouldbeproceedwithreduced
speed.
Neverdrivevehicleup,downoracrossaninclinethatexceeds14degrees.
STARTINGANDDRIVING
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Toavoidthepossibleofrollbackwhichcouldresultinsevereinjuryorvehicle
damage,donotreleasethebrakeuntilmotorhasstarted.
Removechargerplugfromvehiclereceptacleandproperlystorethecablesbefore
movingthevehicle.
Tooperatevehicle:

HammerheadChargerElectricVehicleOperator’sManual Page18
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zApplythefootbrake,placethekeyinthekeyswitchandturnittothe“ON”
position.
zMovethedirectionselectortothedirectiondesired.
zReleasetheparkingbrakebypushingdowntheparkingbrakereleasebutton
andpushdowntheparkingbrakelever.
zSlowlydepresstheacceleratorpedaltostartthemotor.
zWhentheacceleratorpedalisreleased,themotorstops.Tostopthevehicle
morequickly,depressthefootbrakepedal.
Note:Whenthedirectionselectorisinthereserveposition,awarningsignalwill
soundtoindicatethatthevehicleisreadytoruninreverse.
STARINGVEHICLEONAHILL
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Toreducethepossibilityofroll‐backwhichcouldresultinsevereinjuryorvehicle
damage,donotreleasetheparkingbrakeleveruntilmotorhasstarted.
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Donotholdthevehicleonahillbyusingacceleratorandmotor.Leavingmotorin
astalledconditionformorethan3‐4secondswillcausepermanentdamagetothe
motor.
Toreducethepossibilityofpermanentdamagetothedrivesystem,itisimportantto
preventexcessiveroll‐backwhenstartingthevehicleonahill.
Placeleftfootonfootbrakeandreleasetheparkingbrake.Depresstheaccelerator
withrightfootandreleasethefootbrakebyliftingtheleftfoot.
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HammerheadChargerElectricVehicleOperator’sManual Page19
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VEHICLECLEARNINGANDCARE
Whencleaningtheexteriorofthevehicle,donotusepressureinexcessof700psi.
Toreducethepossibilityofcosmeticdamage,donotuseanyabrasiveorreactive
solventstocleanplasticparts.
Normalcleaningofvinylseatsandplasticorrubbertrimrequirestheuseofamild
soapsolutionappliedwithaspongeorsoftbrushandwipewithdampcloth.Rinse
withclearwater.
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