Royal A4 User manual

INTRODUCTION
Welcome to the Royal Electric Vehicle Family. You have chosen to buy
one of the finest, safest, and most reliable golf carts on the market today.
Your Royal EV offers many safety features that most golf carts on the
market today do not offer. Please protect your investment to ensure that
your Royal EV provides years of reliable superior performance by
reading and following the instructions in this manual.
Your comfort and safety are important to us as well, so we urge you to
read and follow step by step operating instructions and safety
precautions in this manual. These instructions should be followed to
avoid the risk of severe personal injury.
Royal EV products are backed by a customer support system designed
Royal Electric Vehicles
Calhoun, Ga
888-821-9446
to offer you fast courteous service. In the event your cart needs service,
please contact your local authorized dealer who can provide technical
advice, provide warranty work, and sell parts.
We hope you consider the owner’s manual a permanent part of your golf
car. If you sell your Royal EV please include the manual so the next
owner will have the important operating, safety, and maintenance
information it contains.
Thank you and welcome to the Royal EV Family.

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General Book Info
NOTE: This manual represents the most current information at
the time of publication. Royal EV is continually working
to further improve its vehicles and other products.
These improvements may affect servicing procedures.
Any modification and/or significant change in
specifications or procedures will be forwarded to all
Royal EV dealers and will, when applicable, appear in
future editions of this manual.
Royal EV reserves the right to change specifications
and designs at any time without notice and without the
obligation of making changes to units previously sold.

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SAFETY DECAL AND FEATURE IDENTIFICATION
The following pages contain safety decal and feature identification
information. For detailed information on specific features, read the
appropriate section in this manual.
Royal EV
.

SAFETY AND FEATURE IDENTIFICATION
Page 4
Battery Charging

Page 5
GENERAL WARNINGS
The following safety statements must be adhered to whenever the vehicle is
being operated, repaired, or serviced. Vehicle feature identification information is
also included. See Safety Decal and Feature identification on page 3. Other
specific safety statements appear throughout this manual and on the vehicle.
DANGER (Carts with lead acid batteries)
• Battery – Explosive gases! Do not smoke. Keep sparks away from the
vehicle and service area. Ventilate when charging or operating vehicle in an
enclosed area.
• The vehicle will not provide protection from lightning, flying objects, or other
storm-related hazards.
WARNING
• Follow the procedures exactly as stated in this manual, and heed all
DANGER, WARNING, and CAUTION statements in this manual as well as
those on the vehicle and battery charger.
• Children requiring a child safety seat must not ride in vehicle.
• Do not leave children unattended in vehicle.
• Prior to leaving the vehicle unattended or servicing the vehicle, place the
Forward/Reverse handle or switch in the NEUTRAL position, turn the key
switch to the OFF position, and remove the key. Chock the wheels when
servicing the vehicle.
• Improper use of the vehicle or failure to properly maintain it could result in
decreased vehicle performance, severe personal injury, or death.
• Any modification or change to the vehicle that affects the electrical system,
stability or handling of the vehicle, or increases maximum vehicle speed
beyond factory specifications, could result in severe personal injury or
death.
• Check the vehicle for proper location of all vehicle safety and operation
decals and make sure they are in place and are easy to read. See Safety
Decal and Feature identification on page 3.
• Only trained technicians should service or repair the vehicle or battery
charger. Anyone doing even simple repairs or service should have
knowledge and experience in electrical and mechanical repair.
• Use insulated tools when working near batteries or electrical connections.
Use extreme caution to avoid shorting of components or wiring.

SAFETY AND FEATURE IDENTIFICATION
Page 6
DISABLING THE VEHICLE
1. Turning key off engages the parking brake.
2. Chock wheels for additional safety.
INTERNATIONAL SAFETY SYMBOLS ON BATTERIES
Anyone using, repairing, or servicing the vehicle must understand and heed the
safety symbols on the vehicle battery or batteries.
GENERAL INFORMATION
Throughout this manual, important features unique to each model are
highlighted. We urge the owner/operator to read and understand this manual,
and to pay special attention to the features specific to his/her vehicle(s).
MODEL IDENTIFICATION
The serial number of each vehicle is printed on a bar code decal mounted below
the front passenger on the bottom.

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CONTROLS AND INDICATORS – ELECTRIC VEHICLES
WARNING
• Make sure the driver is familiar with all controls and operating procedures
before allowing the vehicle to be driven.
• Do not shift the Forward/Reverse switch while the vehicle is moving. To
avoid injury to an unsuspecting passenger or damage to the vehicle, always
bring the vehicle to a full stop before shifting the Forward/Reverse switch.
• Release the accelerator pedal and then press the brake pedal firmly until
the vehicle stops. To avoid unintentionally starting or rolling the vehicle,
place the Forward/Reverse switch in the NEUTRAL position, turn the key
switch to the OFF position, and remove the key when leaving the vehicle.
KEY SWITCH
The key switch is mounted on the dash to the right of the steering column. It has
two positions, OFF and ON
See following NOTE.
NOTE: When the key is turned to the OFF position, the main vehicle
systems are disabled. The key switch may be used as an emergency
stop.
The key can be removed only when the key switch is in the OFF position
FORWARD/REVERSE CONTROL
The D (DRIVE FORWARD) and R (REVERSE) are clearly marked on the
dashboard. Push down the “D” Top side of the switch to operate the vehicle in
the forward direction, or push down the ”R” bottom side of the switch to operate
the vehicle in reverse. When the rocker switch is positioned in the NEUTRAL
position, with neither side down, the vehicle will not operate if the accelerator
pedal is pressed. The reverse buzzer will sound as a warning when the
Forward/Reverse switch is in the REVERSE position.

CONTROLS AND INDICATORS
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ACCELERATOR PEDAL
The accelerator pedal is the pedal on the right. When the key switch is in the ON
position, and the Forward/Reverse switch is in either the FORWARD or
REVERSE position, pressing the accelerator pedal will automatically release
the park brake and start the vehicle moving in the direction selected (forward or
reverse). As the accelerator pedal is pressed, speed will increase until full speed
is reached. When the accelerator is released, power will be cut off and the motor
will stop running.
Walk Away Braking: This vehicle is equipped with a magnetic parking brake.
Turning the ignition key to off position engages the brake. Do not try to push cart
when magnetic brake is engaged. Lift seat and flip tow-run silver toggle switch
located on the passenger side of the vehicle under the seat. Then turn the key to
the on position to disengage the park brake. This will put the cart in tow mode so
it can be pushed safely. When the batteries are recharged remember to flip the
switch back to the run position or the cart won't run.
BRAKE PEDAL
The brake pedal is the large pedal on the left. To slow or stop the vehicle, press
the brake pedal with your foot
The park brake will release automatically
when the key is turned to the on position
and the accelerator pedal is pressed.

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PRE-OPERATION AND DAILY SAFETY CHECKLIST
Each Royal EV has been thoroughly inspected and adjusted at the factory;
however, upon receiving your new vehicle(s), you should become familiar with its
controls, indicators, and operation.
Use the following checklist as a guide to inspect the vehicle. This checklist
should be used daily to ensure that the vehicle is in proper working condition.
Any problems should be corrected by an authorized Royal EV dealer.
Any vehicle not functioning correctly should be removed from use until it is
properly repaired. This will prevent further damage to the vehicle and avoid the
possibility of injury due to unsafe conditions.
Pre-Operation and Daily Safety Checklist
Use the following checklist in conjunction with the Daily Pre-Operation and Safety
Checklist as a guide to inspect the vehicle and check daily for proper operation.
Any problems should be corrected by an authorized Royal EV dealer.
All Vehicles
• Forward/Reverse switch: Check for proper operation.
• Brakes: Be sure the brakes function properly. When brake pedal is pressed
using moderate pressure, the vehicle should come to a smooth, straight
stop. If the vehicle swerves or fails to stop, stops abruptly, or makes a
grinding or squeaking noise, have the brake system checked and adjusted
as required. Continued, moderate brake pedal pressure should be able to
lock the wheels, but using lesser pressure should also permit a slow,
gradual deceleration.
• Reverse buzzer: The reverse buzzer will sound as a warning when the
Forward/Reverse handle or switch is in the REVERSE position.
• Steering: The vehicle should be easy to steer and should not have any play
in the steering wheel.
• General: Listen for any unusual noises such as squeaks or rattles. Check
the vehicle’s ride and performance. Have a Royal EV dealer investigate
anything unusual.
• Accelerator: With the key switch in the ON position and the
Forward/Reverse switch in the FORWARD position, as the accelerator pedal
is pressed, the motor should start, and the vehicle should accelerate
smoothly to full speed. When the pedal is released it should return to the
original position. All Royal EV vehicles operate at reduced speed in
reverse.

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DRIVING INSTRUCTIONS
WARNING
• Make sure the driver is familiar with all controls and operating procedures
before allowing the vehicle to be driven.
• No more than two persons per bench seat should be on the vehicle at one
time.
• The vehicle is not specially equipped for handicapped persons. Be sure all
persons can properly operate the vehicle prior to allowing them to drive the
vehicle.
• Be sure all passengers are capable of securing themselves in a vehicle
before allowing them to ride.
• For night use, the vehicle is equipped with headlight, taillights,blinkers, and
brake lights.
• Stop the vehicle before shifting the Forward/Reverse switch. Failure to do so
may result in injury to an unsuspecting passenger and (or) damage to the
vehicle.
• To help avoid being struck, do not stand in front of or behind the vehicle.
• Operate the vehicle from the driver seat only.
• To help prevent falls from the vehicle, remain seated in a moving vehicle
and hold on to hand holds or handrails at all times. Driver should keep both
hands on the steering wheel when the vehicle is in motion.
• To help prevent the possibility of serious injury, keep your entire body inside
the vehicle.
• Do not leave children unattended on vehicle.
• To help prevent overturning the vehicle, drive slowly straight up and down
slopes. Avoid driving the vehicle on slopes exceeding 30% incline.
• To help avoid the possibility of losing control of or overturning the vehicle,
reduce speed for adverse driving conditions such as wet grass, rough
terrain, or when turning.
• Obey all local rules concerning golf cars.
• The vehicle should be driven in only specified areas by trained drivers.
• Do not drive while under the influence of alcohol, drugs, or medications.
• To prevent overturning the vehicle, drive slowly in turns.
• Use brakes to reduce speed when coasting downhill.
• Do not drive the vehicle under tree limbs, bridges, tunnels, or other objects
that are less than 84 inches (203 cm) from the ground.
No one should drive the vehicle without first being instructed in the proper
operation and use of the vehicle’s controls. An experienced operator should
accompany each first-time driver on a test drive before allowing him/her to
operate the vehicle alone.
To ensure safe operation of the vehicle, follow exactly and in order, all the
following procedures. Read and understand all instructions prior to driving the
vehicle.

DRIVING INSTRUCTIONS
Page 11
STARTING THE VEHICLE
1. Study and understand controls.
2. Make sure everyone is seated and holding onto seat handles or
handrails.
3. Read safety and information decals located on the vehicle.
4. Make sure wheels are turned in desired direction.
5. Place Forward/Reverse switch in neutral, then turn key to the on
switch. Select direction by placing Forward/Reverse handle or
switch in desired position (F = forward or R = reverse). A buzzer
will sound as a warning when the Forward/Reverse handle or
switch is in the REVERSE position.
6. Slowly press accelerator pedal. The park brake will release
automatically, and the vehicle will start to move. As the
accelerator pedal is pressed, speed will increase until full speed is
reached. See following WARNING.
WARNING
NOTE: If the Forward/Reverse switch is shifted into the NEUTRAL position,
power will be cut off and the engine will stop running.
See General Warnings.
WARNING
• Turn the key switch to the OFF position, remove the key, and leave the
Forward/Reverse switch in the NEUTRAL position during storage.
• For lead acid batteries: Do not attempt to charge frozen batteries or
batteries with bulged cases. Discard the battery. Frozen batteries can
explode.
• For lithum batteries: Never charge batteries under 36 F. This will cause
permanent damage to the battery.
CAUTION
• Batteries in a low state of charge will freeze at low temperatures
(lead acid batteries only).
To avoid exposing electrical components to moisture and subsequent damages,
do not use any type of pressure washing or steam cleaning equipment to wash
the cart.
PREPARING THE ELECTRIC VEHICLE FOR EXTENDED STORAGE
To keep batteries fully charged during storage:
• Plug the battery charger into the car. Leave battery chargers plugged in
during storage. The charger will automatically activate when necessary.
(see page 20, lithium battery warranty-battery tips)

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MAINTENANCE
To ensure trouble-free vehicle performance, it is very important to follow an
established preventive maintenance program. Regular and consistent vehicle
maintenance can prevent vehicle downtime and expensive repairs that can result
from neglect. Use the Pre-Operation and Daily Safety Checklist beginning on
page 16, the Performance Inspection, and the following Periodic Service
Schedules and Periodic Lubrication Schedules to keep the vehicle in proper
working condition.
Any vehicle not functioning correctly should be removed from use until it is
properly repaired. This will prevent further damage to the vehicle and avoid the
possibility of injury due to unsafe conditions.
Contact your local Royal EV dealer to perform all repairs and semiannual and
annual periodic service.
WARNING
• If any problems are found during scheduled inspection or service, do not
operate the vehicle until repairs are made. Failure to make necessary
repairs could result in fire, property damage, severe personal injury, or
death.
• Only trained technicians should service or repair the vehicle or battery
charger. The appropriate instructions must be used when performing
maintenance, service, or accessory installation.
PERIODIC SERVICE SCHEDULES
WARNING
• Service, repairs, and adjustments must be made per instructions in the
maintenance and service manual.
NOTE: If the vehicle is constantly subjected to heavy use or severe operating
conditions, the preventive maintenance procedure should be performed more
often than recommended in the periodic service and lubrication schedules.
Both the Periodic Service Schedule and Periodic Lubrication Schedule must be
followed to keep vehicle in optimum operating condition.

BATTERY CHARGER
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BATTERY CHARGER
WARNING
• Only trained technicians should repair or service the charger. Contact your
nearest authorized Royal EV dealer.
• Have worn, cut, or damaged power cords or wires replaced immediately.
• Do not use near fuels, grain dust, solvents, thinners, or other flammables.
Chargers can ignite flammable materials and vapors.
• Do not expose to rain or any liquid. Keep the charger dry.
• Do not connect a stationary charger to the receptacle if the charger cord,
plug, or the vehicle receptacle is broken, damaged, or does not make a
good electrical connection. Fire or personal injury can result. Have a
qualified technician replace the parts.
• When the charger is on, the charger DC cord may be disconnected from the
vehicle receptacle slowly. Jerking or pulling the DC cord out quickly could
cause arcing and burning that could damage the plug and receptacle and
could cause batteries to explode.
CAUTION
• The battery charger provided with this vehicle is approved for use only with
the battery type originally installed in the vehicle. Using a different battery
type (different brand, different capacity, etc.) can cause under or
overcharging and subsequent battery damage unless the charger is first
reprogrammed with a new charging algorithm. Royal EV only recommends
OEM replacement batteries. Contact your authorized Royal EV dealer with
any questions about battery and charger compatibility or algorithm updates.

BATTERY CHARGER
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WARNING
• Two chargers can share a circuit, which should be a dedicated 15 or 20
amperes separately protected (circuit breaker or fuse) single-phase branch
circuit that complies with all applicable electrical codes for the location.
• Connect the charger AC supply cord to a properly grounded, three-wire
outlet within the voltage and frequency range shown on the charger.
• Do not use an adapter to plug the charger with a three-prong plug into a
two-prong outlet. Improper connection of the equipment-grounding
conductor can result in a fire or an electrical shock.
• Place all cords so they will not be stepped on, tripped over, or otherwise
subjected to damage or stress.
To reduce the risk of electric shock, the battery charger must be grounded. The
charger is equipped with an AC electric cord having an equipment-grounding
conductor and a grounding type plug. The AC plug must be connected to an
appropriate receptacle that is properly installed and grounded in accordance with
the National Electrical Code and all local codes and ordinances.
The use of an extension cord with the charger should be avoided.
PLUG AND RECEPTACLE
The charger cord and plug are wear items and should be inspected daily.
Visually inspect them for cracks, loose connections, and frayed wiring; they must
be replaced when worn or damaged.
WARNING
• If pins are bent, the plug must be replaced immediately. The plug is not
serviceable. Do not attempt to repair the plug or straighten bent pins.
Contact your local authorized Royal EV dealer for repairs.
• Disconnect the AC cord prior to lubricating the plug and receptacle.
NOTE: If the warning tag has been damaged or removed from the DC
cord, have it replaced immediately.

BATTERY CHARGER
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F
WARNING
• Place all cords so they will not be stepped on, tripped over, or otherwise
subjected to damage or stress.
Charger Mounting Holes
Examples of Charger Mounting Orientation
CHARGER POWER CONNECTION FUSE
The vehicle charger power circuit has an in-line 30-amp fuse located near the
solenoid.
AC INPUT VOLTAGE DETECTION
The charger automatically detects the AC input voltage and will operate at full
power if the voltage is within the 100 to 240 VAC range. The charger also will
function outside of that range down to 85 VAC and up to 270 VAC although
charging times will be longer. Outside of the 85 to 270 VAC range, the charger
will not operate.
LONG-TERM STORAGE
Royal EV chargers are designed to be left connected with AC power to the
charger during off-season or long-term storage. (for lead acid batteries)
For lithium batteries, see page 21, lithium battery warranty-battery tips.

BATTERY CHARGER
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CHARGING BATTERIES
WARNING
• Do not rock or bend the plug. To connect the charger plug to the vehicle
receptacle, grasp the plug handle and push the plug straight into the
receptacle.
• Do not pull on the DC cord. Do not twist, rock or bend the plug. To
disconnect the charger plug from the vehicle receptacle, grasp the plug by
the handle and pull the plug straight out of the receptacle.
• Do not attempt to charge frozen batteries or batteries with bulged cases.
Discard the battery in accordance with all environmental laws or return to an
authorized Royal EV dealer. Frozen batteries can explode.
• Do not use a charger if any of the following conditions exist:
− The plug is too loose or does not make a good connection.
− The plug and receptacle feel hotter than normal during charge.
− The plug pins or receptacle contacts are bent or corroded.
− The plug, receptacle, or cords are cut, worn, have any exposed wires
or are damaged in any way.
• Using the charger with any of the above symptoms could result in a fire,
property damage, personal injury, or death.
CAUTION
• On all vehicles, turn off all accessories before charging batteries.
• The battery charger provided with this vehicle is approved for use only with
the battery type originally shipped with the vehicle. Using a different battery
type (different brand, different capacity, etc.) can cause under or
overcharging and subsequent battery damage unless the charger is first
reprogrammed with a new charging algorithm. Royal EV recommends only
OEM replacement batteries. Contact your authorized Royal EV dealer with
any questions about battery and charger compatibility or algorithm updates.
NOTE: When temperatures fall below 65 °F (18.3 °C), batteries charged
in unheated areas should be placed on charge as soon as possible after
use. Batteries are warmest immediately after use, and cold batteries
require more time to fully charge (lead batteries only).
Because the charger has a storage charge feature that automatically
checks and recharges the batteries as necessary, the charger can
remain plugged to the vehicle throughout the storage period.(lead acid
battery)
For lithium batteries, it is recommended that after the battery is fully
charged, disconnect charge cord and turn off battery when not in use.
(see page 21, lithium battery warranty- battery tips)

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CLEANING THE VEHICLE
The Royal EV is equipped with hand-washable front and rear bodies. Use only
commercially available automotive cleaners with a sponge or soft cloth for normal
cleaning. A garden hose at normal residential water pressure is adequate.
Royal EV does not recommend any type of pressure washing or steam cleaning.
Such a process will expose electrical components to moisture. Moisture entering
electrical components can result in water damage and subsequent component
failure.
Use non-abrasive wax products. Battery acid, fertilizers, tars, asphalt, creosote,
paint, or chewing gum should be removed immediately to prevent possible
stains. See following CAUTION.
CAUTION
• Use of leveling or rubbing compounds will permanently dull finish of vehicle.
• Do not apply wax products to the black plastic material of the front and rear
under-body, the front bumper, or the textured area of the rear beauty panel
marked.
• Do not spray water or liquids directly on digital dash or batteries.

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Royal EV FOUR PASSENGER/ SIX-PASSENGER
VEHICLE
The Royal EV four-passenger/six-passenger vehicle is designed to provide a
smooth and comfortable ride for four/six passengers and is offered in electric
power configuration. This owner’s manual should be read thoroughly prior to
operating the vehicle.
The Royal EV four-passenger/six-passenger vehicle should be driven and
maintained as stated in this owner’s manual with the following additions:
WARNING
• Vehicle should be driven at slower speeds when four persons are in the
vehicle.
• Passengers should hold on to hand holds or hand rails at all times. Driver
should keep both hands on the steering wheel while vehicle is moving.
• Do not leave children unattended on the rear seaT.
• No more than four persons should be on the four passenger vehicle at one
time and six persons on a six passenger at one time.
MAINTENANCE
NOTE: If the vehicle is constantly hauling heavy loads, the preventive
maintenance procedures should be performed more often than
recommended in the service and lubrication schedules.

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VEHICLE SPECIFICATIONS
Drive Motor: 5 KW 48 volts AC (4 Passenger and 6 Passenger))
Electrical system: 48 Volts AC
Batteries: 100 amp lithium
Battery Warranty: 5 year lithium
Charger: automatic 48 volt on board
Brakes: 4 wheel hydraulic brakes (front disc, rear drum)
Front Suspension: coil over strut with A arm
rear suspension leaf spring
Controller: 400 amp
Max Speed: 29 mph
Braking Distance: 7 to 9 feet
Windshield: Acrylic fold down
Charge Ports: USB
Tire Pressure: Between 15 and 18 psi
Frame: powder coated steel
Deck Height: A4 and A6 - 12 inch deck height
A4L and A6L – 18 inch deck height
Instrument: Digital Dash showing mph, odometer, and
battery charge
Max Climb: 25% grade