VENOM D User manual

Operating Instructions
for Model D Golf Cart
Technology Leads Life,
And Craftsmanship Creates Quality.
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Specification
Model D Golf Cart
Thank you for purchasing our products, In order to use then better,please read the operating instructions thoroughly. After reading,please keep it properly for future reference.
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Table of Contents
Ⅰ. Product introduction
1
Ⅱ. Technical parameters of complete vehicle
2
Ⅲ. Control mechanism
3
Ⅳ. Operating procedures
7
Ⅴ. Codes of safety practice
7
Ⅵ. Maintenance and repair
8
Ⅶ. Storage 20
Ⅷ. After-sales service
20
Ⅸ. Line assembly drawing 22
Ⅸ. Controller assembly drawing
24
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Ⅰ. Product introduction
1. Use and scope of application
Electric golf cart is an environment-friendly passenger vehicle specially
developed by our company for golf courses, and can also be used in resorts,
villa areas, garden hotels, tourist attractions and other places. With excellent
performance, novel appearance design, luxurious and exquisite interior
decoration, comfortable and safe driving, the complete vehicle is an ideal
electric vehicle for golf courses in China at present.
2. Executive standards
Q-321088TCD 011 202 (Whanlong Enterprise Standard)
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Ⅱ. Technical parameters of complete vehicle
Other non-standard vehicle models are partially cited. See executive standards for test methods
Model
Seat
2 Seats
450 470 470 500 530 560 550 580 610 640
80 80 70 60 80 70 60 60 70 60
25 25 25 25 25 25 25 25 20 20
3100 3100 3500 3500 4200 4200 4500 4500 5200 5200
20% 20% 20% 20% 20% 15% 20% 15% 15% 15%
120 120 200 200 120 120 200 200 120 120
4 Seats
6 Seats
Overall
dimension
(mm)
Whole machine
mass(kg)
Maximum speed
(km/h)
Minimum turning
radius of outer
wheels(mm)
Maximum
gradeability
Minimum ground
clearance(mm)
Endurance
mileage(km)
WH2020K WH2020
KSZ WH2020A WH2020 ASZ WH2040K WH2040A
WH2040
KSZ WH2040 ASZ WH2060K WH2060 KSZ
2390
1215
1880
2905
1220
1940
2440
1340
2060
2955
1340
2060
3140
1215
1880
3655
1220
1940
3190
1340
2060
3705
1340
2060
3890
1215
1880
4640
1215
1880
length
width
height
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Ⅲ. Control mechanism
1. Schematic diagram of control mechanism
Forward and backward switch
power lock
Display LCD
Brake pedal
Accelerator pedal Clock
Hazard alarm switch 12V power
USB port
(Model D dashboard)
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Power Lock
Front and rear gear switch
Accelerator pedal
1. Turn the key forward to start the
vehicle afher inserting the power lock
key vertically into the power lock hole.
2. Turn the power lock key backward
to shutdown the vehicle,and only at this
time can thekey be removed.
Operate the front and rear gear switch
according to the forward or backward
need of electric vehicle,the upward
toggle switch is the forward gear,the
downward toggle switch is the reverse
gear,and the middle is the parkinggear;
when the reverse gear is selected,a
buzzer alarm will be sent.
Select the gear,release the brake pedal
at this time,put your right foot on the
accelerator pedal,and slowly press the
accelerator pedal to start the vehicle
after opening the power lock to start
the vehicle.
Note:Do not slam on the accelerator pedal!
When switching the front and rear gears of the gear switch,the vehicle must be stopped
before switching the gears.During switching,turn the gear switch to the middle parking gear,and
then select the forward or backwardgear switch after staying for 2 seconds.Do not shift the gear
switch too quickly,so as not to affect life safety and cause vehicle damage.
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Brake pedal
When the complete vehicle needs to slow down during driving, move
your right foot to thebrake pedal and gently press the brake pedal toslow down
the vehicle until it stops.
Note: Emergency brake should be avoided!
Parking brake handle - Used for parking brake.
Steering wheel - Control the driving direction of the vehicle.
Combination instrument
Display current vehicle status information, capacity, speed, mileage, light
signals, etc. During driving, you can know whether the operation is correct
according to the lighting of the indicator light in the dashboard.
Combination switch
1. Turn signal lamp: When turning the lever forward, the left turn signal
lamp flickers, and the left turn signal indicator lamp lights up on the dashboard
at this time. When turning the lever backward, the right turn signal indicator
lamp lights up.
2. Low beam: The front half end of the lever can be turned. After the
vehicle starts, turn the lever forward for two gears to turn on the low beam.
Turn the lever backward to turn off the low beam.
3. High beam: Lift the lever (steering wheel surface) to turn on the high
beam. After releasing the lever, the lever will be automatically reset, and the
high beam turns off at this time. Turn on the low beam first, and then lift the
lever. At this time, the lever will not be automatically reset, thus realizing the
permanent lighting of the high beam.
4. Horn: The head end of the lever is a horn button, which can be pressed
lightly.
Please be familiar with all operations before driving, strictly abide by
the operation process and avoid illegal operation!
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Graphical representation of dashboard lighting icons:
Setting
Radio
Switch
Home
Clock
Clock
Clock
F-CAM Phone
USB BT Music
Home
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Ⅰ
Ⅳ. Operating procedures
1. Switch on the power lock;
2. Press the forward and backward rocker switch, lock it in forward or
backward state, and check whether it is in place;
3. Release the parking brake;
4. Press the accelerator pedal at a constant speed and the vehicle starts.
When opening the power lock, the forward and backward switch must
be in neutral position, otherwise the vehicle will not be driven; if you step on
the accelerator pedal first and then open the power lock, the vehicle will not
be driven. At this time, you must release the pedal and then step on the pedal
again before the vehicle is driven.
Ⅴ. Codes of safety practice
The driver must fully understand the technical performance, control
mechanism and operating procedures ofthe vehicle, and abide by the following
codes of safety practice:
The vehicle is off-road vehicle, please don’t drive on the highway!
Do not overload while driving, so as to avoid potential safety
hazards like reduced brake performance.
Unqualified personnel are not allowed to drive the vehicle.
Please drive within the approved slope range.
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Ⅵ. Maintenance and repair
Maintenance of electric vehicles is very important, which is directly
related to the driving performance and service life of electric vehicles.
Therefore, users have to abide by the following maintenance rules.
（Assembly diagram of a lead-acid battery）
Batteries are very important, because they provide the overall power
source for the complete vehicle, just like the heart of electric vehicles.
6.1 Overview
1.1Scope of Use
This instruction manual applies to the lithium ion power battery
produced by Ganfeng,including the necessary tasks and steps of the power
battery.Please contact ganfeng after-sale service personnel directly for matters
not covered.
This instruction manual is suitable for customers,professionals and
qualified personnel.Personnel performing the following tasks must read and
use this manual,and carefully check the battery nameplate information(in-
cluding model,weight,etc.):
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1.2Target Personnel
Do customers
people who use products or require services.
☆ Professional personnel
Trained and qualified,with electrical related and professional knowledge
and electri cian qualification certificate,authorized by customers.Understand
the product or knowledge of relevant laws and regulations,able to complete
product related work independently or with the assistance of after-sales staff.
☆Qualified personnel
Trained and qualified personnel,able to use the product independent-
ly,based on their practiacl experience and understanding of relevant
standards and regulations,able to identify the potential risks in the use od yhe
product,able to prevebt these potential risks.
☆After-sale personnel
Engineers who provide after-sales service for products.
1.3 Emergency handling
Step 1:Leave the vehicle quickly and call the police according to the
situation on the scene.
Step 2:Under the condition of ensuring the safety of personnel,condi-
tionally carry out the following operations:if the battery wiring harness is on
fire, use carbon dioxide or dry powder fire extinguisher to extinguish the
fire;If the battery is on fire, use a highpressure water gun to extinguish the
fire from a distance. If smoke is inhaled,transfer the battery to a doctor as
soon as possible.
Step 3:Notify the brand dealer of the vehicle to obtain further treatment
opinions.
Tip:If the fire is caused by abnormal charging,be sure to cut off the
power supply at the first time before performing the next fire extinguishing
action.
1.4 Glossary
☆ SOC:ratio of battery remaining power.
☆ Operating vehicle:a vehicle that is used and recharged every day.
☆Unused vehicles:vehicles that have not been used for more than 15
consecutive days.
☆Motor operation vehicles:vehiclea with fixed use frequency.
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1.5 Safety in struction
Do not flush or close to a heat source
Disassembly whithout training or
authorization is strictly prohibited
keep away from inflammable
and explosive objects
It is forbidden to short-circuit the
positive and negativepoles
Recycling,no littering
Beware of high voltage electric shock
1.6 Environmental protection
Customers should comply with the following requirements when
recycling products:It should comply with the specific environmental protec-
tion regulations of the country or region where the product is used.
The waste parts and components should be turned over to a local
business which has a state-approved business to recycle and dispose of them.
The classification and collection of this product.
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6.2 Instructions
To ensure the long-term and effective operation of your battery
system,please observe the following rules;
Battery system temperature requirements
Operating temperature:-20℃-50℃
Storage ambient temperature:-30℃to 60℃
Optimum charge and discharge temperature:25℃-50℃
2.1 Battery Installation Procedure
Check the battery status and ensure that the power switch is off.
The installation personnel wear insulation gloves and lift/lift the battery into
the battery compartment.
Ensure that the discharge port and communication port are properly
connected and securely connected,turn on the battery power switch.
After the above steps and ststus are confirmed,the battery can be used
normally.
2.2 Check before driving
Please first confirm whether the emergency stop switch of vehicle is in
the closed state(avoid damaging the relay when the battery is on).
Observe the instrument panel and make sure that the battery is normal
and there is no alarm message.
When the SOC is greater than 50% and the state is good,it is recom-
mended to start with full battery.
When SOC is less than 30%,battery system power is low,charge at least
50%bafore running;
2.3 Requirements for Normal operation vehicles
If the battery level is lower than 30%,charge it immediately.It is recom-
mended that you use it after it is fully charged.
Do full power work at least once every two weeks.
Battery maintenance should be performed every two manths to prevent
damage to the battery system.See section 1.8 for specific maintenance
methods;
2.4 System Transportation and use Requirements
During loading,unloading and transportation,violent shaking and large
external impact should be avoided,and throwing,rolling,inverted and extru
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sion are prohibited.to prevent rain in the transport process;
Before transportation,ensure that the battery or battery pack is not
loaded,the charging device is disconnected,and there is no charge or
discharge in any form;
2.5 System power-on and power-off procedure
Discharge power on procedure
Turn the vehicle key to ON,power on BMS,wake up,battery system
self-check,no fault,then the discharge relay is closed;When the self-test fails
or there is a serious fault,the discharge relay is disconnected and the fault is
reported.
Discharge power off procedure
Turn the vehicle key to off gear,BMS power off,or discharge serious
fault,the discharge relay will be disconnected.
2.6 User charging steps and precautions
The charging step
·Ensure that the key switch of the vehicle to be charged is closed,that
is,the vehicle is not charged;
·Please use lithium charging equipment matching the model;
·Remove the head of the charging gun from the charging device,check
the charging gun and the charging socket of the battery end to ensure that
there is no foreign matter in the port and whether the terminals inside the
plug-in are damaged;
·There is a power switch at the back of the char ging device.Push on the
power switch,and the power indicator lights up.At this time,the charging gun
is not connected to the battery,and the charging device is in standby or
shutdown state.
·The manufacture’s designated charger must be used
Precautions for Charging
·Turn off the key switch to charge
·Charge in a relatively safe environment(such as avoiding liquid and
fire)
·The charging equipment should be equipped with necessary fire
extinguishing devices around it,so that emergency fire extinguishing
treatment can be carried out in extreme circumstances
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6.3 Maintenance and repair of traction motor
Common faults and causes of DC motor:
·Befor charging,it is necessary to confirm that there is no no dust,water
and other foreign matters in the charging gun and charging soket,If there are
foreign matters,it is necessary to clean them up before charging, otherwise it
will lead to poor
1.The motor of the vehicle can work normally within the nominal
working voltage range of the battery pack.
2.The motor is not allowed to idle, and the terminals cannot be short-
circuited externally.
3. The air should not contain explosive gas.
4. Frequently remove the sediment and other adhesions on the motor shell
so as not to affect the heat dissipation.
5. Check the carbon brushes of DC system motors every three months,
and replace the severely worn carbon brushes and invalid carbon brush
compression springs in time. AC system motors are maintenance-free.
Short circuit between commutator
segment or armature coil, poor
welding or open circuit between
commutator segment and armature coil
S/N
1
2
3
4
Fault
All copper sheets are
blackened
Brushes are worn,
discolored and broken
The motor vibrates;the gap between
brush and brush box is too large;the
distance between brush box and
commutator working surface is too
large;the mica is protruding between
upper commutator segments;the brush
material is poor;the brush grade is wrong
Commutator segments
are blackened and there
is no certain rule
Commutator segments
are blackened in sets in
certain order
Incorrect brush pressure
Cause
The commutator center line is
displaced,and the commutator surface
is not round or even
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Note: The adjustment and replacement of motor carbon brushes and
the trimming of motor commutators need to be operated by professionals.
Common faults and causes ofAC motor:
S/N Fault
Cause
1 Abnormal noise of motor
Motor bearing damage
6.4 Maintenance and repair of electroni c control gear
The electronic control gear used in the vehicle is an original imported
product, and high-frequency MOS technology is adopted to realize smooth,
silent, efficient and energy-saving vehicle speed, torque and brake control.
To prevent runaway upon starting, when the vehicle starts, if the
controller detects that the pedal input signal is greater than 20%, it will
trigger the controller protection function (HPD) and the controller will
prohibit the output.
The microprocessor is powered on for self-inspection and subject to
continuous diagnosis during operation. In case of any fault, the controller
will stop output immediately, thus protecting the operator and the vehicle
5 Big spark
6Brushes and brush
discrimination lines are
heated
7 Brushes have noise The commutator surface is not smooth
The brush spark is large,the contact
between the brush and the soft wire is
poor,and the cross-sectional area of the
soft wier is too small
The motor is overloaded;the commutator
is unclean;the commutator is not smooth
or round;the mica plate or part of
commutator segment is protruding;the
brush grinding is not good;the brush
pressure is not high enough;the brush
grade is wrong;the brush is stuck in the
brush box; the brush holder is loose or
vibrates;the polarity and arrangement
sequence of magnetic poles are incorrect.
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comprehensively.
The AC controller also has temperature monitoring and protection
functions to effectively prevent the motor from high temperature and
avoid damaging the motor.
1. Regular maintenance
a. Check whether the contact between contactor contacts is good, whether
there is adhesion or open circuit, whether there are sundries and ablation
between contacts, and whether the moving contact is mechanically stuck.
b. Check whether the microswitch in the accelerator has good on-off
performance.
c. Check whether the on-off performance of the direction switch is good.
(CVT vehicle).
d. Check whether the connection between the motor, battery pack and
controller unit is good. Note: Check in case of power failure.
e. Check and keep the electric control, motor and battery pack clean.
The above checks shall be conducted at least once every three months.
After turning off the power, the filter capacitor in the controller unit should be
kept discharging for several minutes. Do not flush the electrical components
with water! Clean brush or high-pressure gas can be used to remove dust.
2. Fault characteristics and possible causes:
Fault characteristic
Possible cause
The vehicle cannot
start
(I) The controller has no power supply
(II) The signal is not transmitted to the controller
(III) The contactor contact is bonded.
(IV) The motor or controller is damaged.
(V) The phase sequence of the motor encoder is wrong or
damaged
(VI) The motor or controller is in temperature protection
state
(VII) The electromagnetic brake is locked
The vehicle only
moves forward and
cannot move backward
or only moves
backward and cannot
move forward
(I) The direction switch is damaged or the line is
disconnected (CVT vehicle)
(II) The insert on reverse contactor is loose (CVT vehicle)
(III) The reverse contactor is damaged (CVT vehicle)
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The maximum speed
slows down
(I) The battery is about to run out
(II) The hand brake is forgot to release or the brake shoes
are not reset
(III) The accelerator pedal is faulty
(IV) The controller is faulty
(V) Excessive load
(VI) The motor or controller is in temperature protection
state
(VII) Abnormal motor encoder
6.5 Brake part
1. Press the brake pedal with a force of about 30kgf, and the pedal stroke
shall not exceed 2/3 of the total stroke.
2. The brake pad clearance is automatically adjusted. Under the action of
20kgf pull, parking brake handle should be stuck in certain tooth between 5-
10 ratchets, and the wheel should be effectively locked. When the handle is
fully released and reset, the parking brake is released.
3. Regularly check and replace brake shoes and fill lubricating oil in brake
hub bearing.
6.6 Lubrication and maintenance of complete vehicle
1. The brake fluid used for ex-factory is Like 901 automobile brake fluid,
and it is forbidden to mix and use different brands of brake fluid.
2. 85W/90GLhypoid gear oil is used for gearbox and rear axle, and the
filling amount is 0.8L.
3. Main lubricating points: Fill butter in steering gear box, tie rod, steering
knuckle and bearing parts.
6.7 Running-in of new vehicle
To ensure the use performance of the vehicle, improve the reliability of
the complete vehicle and prolong the service life of the complete vehicle, the
parts should be subject to running-in before the vehicle works at the maximum
load. It is stipulated that the running-in period of new vehicle is one month or
1000 kilometers, which should be carried out according to the following
specifications:
1. Before the running-in of new vehicle, it is required to carefully check
the capacity of oil, electrolyte and brake fluid. If it is insufficient, it should be
filled according to regulations; tyres should meet 205/50-10, and the air
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pressure should be 200-250kPa.
2. Try not to drive on the ring road.
3. Always check the fastening of connecting parts, and tighten them if
they are loose.
4. During the running-in period of new vehicle, the speed is controlled
within 15km/h.
Precautions:
1. Before driving, the parking brake must be put to the bottom to avoid
burning the brake pad.
2. Check the rear powertrain everythree months and fill or replace grease.
3. Check the wear of brake shoes every three months, and adjust and
replace them in time in case of any problem.
4. Check the fastening of electrical system once a month, especially the
connection between large current circuits, such as battery, motor and electric
control, and keep it in good condition. At the same time, the contact state of
the contact parts should be checked, any defect found should be corrected in
time, and deposited dust should be removed in time.
5. As the electrical contact is not in good contact, it will heat up, so we
should usually pay attention to the heating state at the contact point.
6. When changing the fuse, check whether the rated current of the new
fuse is correct.
7. During maintenance and repair of the vehicle, in order to ensure safety,
the positive and negative power cables of the battery pack should be removed.
8. It is strictly forbidden to slam on the accelerator or inching the
accelerator frequently, so as not to damage the accelerator and shorten the
service life of the electronic control gear.
9. It is strictly forbidden to add other liquids to the battery, such as battery
additives, mineral water, tap water, etc., and distilled water must be added.
10. Drive safely. It is forbidden to drive at high speed when going
downhill. Slow down when turning, and remind passengers to pull handrails
when turning and going downhill to avoid safety accidents.
11. Children are strictly forbidden to play in the vehicle. Children should
sit in the middle position and be cared for by adults to avoid children falling
from the vehicle.
12. Please conduct regular maintenance according to the table below:
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