Zap Zappy 3 Pro-Flex User manual

TableofContents
TechnicalInformation-----------------------------------1
Warning Statement--------------------------------------2
Read Before Riding-------------------------------------3
List Of Parts-----------------------------------------------4
Front Bar---------------------------------------------------6
ToolKits In The ToolBag------------------------------7
AssemblingThe Zappy3-------------------------------8
Charging The Batteries-------------------------------11
Riding The Zappy3-------------------------------------12
Folding The Zappy3------------------------------------14
Maintenance---------------------------------------------16
Wiring Diagram------------------------------------------17
Trouble Shooting Guide-------------------------------18
Warranty----------------------------------------------------20

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APPY
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PRO-FLEX
ModelNo. ZAPPY3PRO-FLEX
Product size 40 Lx27 Wx38 Hinch
(102 Lx68 Wx98 H cm)
Type of motor Permanent-magnet
brushless DC wheelmotor
Motorpower350 w Wheelmotor, 36 V
Battery type sealed lead acid battery
Battery capacity 36 Volt, 12Ah
Charger110V-240V, ULapproved
Charging time4-6 hours
Rated speedUp to 13 MPH (22 km/h)
Single charge Up to 17 MILES (28 km)
Maxcapacity 220 LBS (100 kg)
Net weight 100 LBS (46 kg)
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APPY
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APPY
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APPY
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APPY
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1Throttle
2Multi-function Instrument
3Brake lever
4Alloy handlebartub
5Quick release
6Connecting tube
7Seat
8Battery &controllercompartment
9Balancingwheel
10 Footboard
11 Rearwheel
12 Powerconnecting plug
13 Connecting tube clamp
14 Front fender
15 Front fork
16 Motor
17 Front wheel
18 Basket
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APPY
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1Brake lever
2Horn switch
3Multi-function Instrument
4Key switch
5Throttle

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APPY
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1Allen wrench (8 x10mm)
2Allen wrench (16 x18mm)
3Allen wrench (16 x18mm)
4Screwdriver
5Wrench (4mm)
6Wrench (5mm)
7charger
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APPY
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1. Unpack the ZAPPY3carefully so that you do
not misplaceany of the parts.
2. Place the ZAPPY3on a flat,levelsurface.
(You may place a cube underthe front part of
the footboard; to hold itin a balance position.)
3. Remove the bolts and nuts fromthe
connecting tube clamp (B).Place the
connecting tube into the top opening (A)and
slip back the bolt through the clamp (B).
4. Tighten the boltsand nuts using the 2 allen

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APPY
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wrenches 16 x18mm in the tools kit.
5. Extend the handle bartube to fullupright
position andslide itinto connecting with the
front fork.
6. Ensure that the handlebaris facingfront, the
brake onthe left side and the throttle on the
right, then tighten the handlebartube collar
clamp using the enclosed 5mmwrench.
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APPY
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7. Plug in the two powerconnectingplugs into
the sockets. The design ofeach plug and
socket is different. Connect the ones which
best fit eachotherto finishthe assembly.
NOTE: Handle barheight adjustment. Handle
barheight can be easily adjusted by opening the
quick release on the handlebartube to preferred
height, then firmly closing quickrelease.

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Beforeyou ridethe ZAPPY3forthe first time
you must charge the batteries for4-6hoursusing
onlythe supplied charger.
Tocharge the batteries,plugthe chargerinto
the chargersocket located on the rearside ofthe
battery/controllercompartment. Then plugthe
chargerinto a walloutlet.
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APPY
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Once you have completed the initial charge you
areready to ride. Remember,thisisnot atoy.
The ZAPPY3can reachspeedsupto12.5mph
dependingonthe terrain andtheweightofthe
rider.You must wearahelmet and protective
pads. You must also be awareof alllocallaws
and ordinances that governand/orrestrictthe
use of powered scooters. The lawsand
ordinancesvarygreatlyfrommunicipalityto
municipality.Itisyourresponsibility toknowand
abide by yourlocalrestrictions.
Toride, plug thekey into thekey switch and
turn the key in clockwise direction tillthe first click.
The batterygaugewillbe illuminated indicating
that the batteryis inoperation. If you want to turn
on thefrontlight,pleaseturnthekey tothe
second click in clockwise direction.
Hold onto the front barwith both hands. Your
left fingers willcontrolthe brakes and yourright

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APPY
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hand willcontrolthe throttle. As you turn the
throttle towards yourself,the speed willbe
increased. Release the throttle and applythe
brake to stop the scooter. You willcontrolthe
speed of the scooterby using both the throttle
and the brake. When the brake handle is
squeezed it cuts poweroff the throttle.
NOTE1:You may use the balancing wheel(the
smallermiddlerearwheel)tobalancethe
ZAPPY3.WARNING: Nevertrystunts beyond the
controlof yourskills. Neverride too fast foryour
skills orconditions.
NOTE2:Whenscooterisparked, please turnoff
the powerand take offthe key,thiswill avoid
anyone fromaccidentallyturningthe throttle
causing the scooterto speedforward. Failureto
do this couldlead to an accident.
NOTE3:Ifyouneedtostopin anemergencyor
killpowerquickly, you can turn thekey off
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APPY
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1. Turnoff the key switch
2. Push the clamp on the front barstemfromA
to B.
3. Pullthe clipbardown, just likefromC to D.
4. Lift the connecting tube (which is also
attached to the handlebartube).

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APPY
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5. Carefully placethe handlebartube on the
footrest frame
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APPY
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Battery: (forprofessionaluse only)
The ZAPPY3Pro-Flexis powered by three 12 volt,
rechargeablebatteries housed inasingle
compartment. Otherthanrecharging, these
batteries need no maintenance. Toprolong
batterylife,you must recharge thebatteryafter
each use. You must alsochargeyourZAPPY3
Pro-Flexif ithas not been used for30 daysor
more. If you must replace the batterypack,itis
located inside thebatterycompartment on the
footboard. Toget tothebatterypack, remove the
compartment coverby looseningthe screws.To
remove the batteries disconnect the wires from
the batteryterminals.Replace the batterypack
with anewone and reconnect the wires. Follow
the instructions oncharging batteries to charge
the newbatteries.

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APPY
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Forprofessional use only
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APPY
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Forprofessional use only
ProblemCauseSolution
Thepowerlight
on the
instrument
doesnot
illuminatewhen
the ZAPPY3
Pro-Flexison.
1. Batteryis
discharged.
2. Loose
connection
inside the
ZAPPY3
Pro-Flex.
3. Fuseisblown.
4. The
instrument is
defective
1. Rechargeyour
ZAPPY3Pro-Flex.
2. Removethe
screwsthat holdthe
batterycompartment
coverand raisethe
cover. Visually
inspect all wire
connectionsmaking
surethereareno
loosewires,
reconnectingthose
that are.
3. Replacethe fuse.
4. Replacethe
instrument.
Thepower
indicatoron the
instrument
illuminatesbut
ZAPPY3
Pro-Flexstill
doesnot work.
1. The throttle
handleisnot
operating
properly.
1. Replacethe
throttlehandle.Call
CustomerServiceto
orderanewthrottle

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APPY
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Noisecoming
frommotor1The motor sensoris
defective.
1. Replacemotor
sensor. Call
CustomerServiceto
orderanewsensor
When the brake
leveris
squeezed the
ZAPPY3
Pro-Flexdoes
not stop.
1. The brakes
arenotadjusted
properly.
1. Adjustthe brake
bylooseningthebolt
on therearbrake
wheel, pull the cable
and retighten the
bolt.
Scooteris
losingspeed.1. Lowbattery 2. Batteryis
defective
1. Rechargeyour
batteryfor4~6hours.
2. Replacebattery.
Call Customer
Servicetoordera
newbattery.
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Wa ar rr ra an nt ty y ZAPPY3
PRO-FLEX
ZAPwarrants each newZAPproduct forthree(3)
months according tothefollowingterms.
Batteries arealso warranted forthree (3)months.
Thiswarranty extends tothe originalretail
purchaseronlyand commences on the dateof
the original retailpurchase. Any partof the ZAP
product manufactured orsuppliedby ZAPand
found inthe reasonablejudgment of ZAPtobe
defective inmaterialorworkmanshipwill be
repaired orreplacedby an authorized ZAP
servicedealerwithout charge forpartsorlabor.
The product including any defective parmust be
returned to an authorized service dealerwithin
the warranty period.Theexpense ofdelivering
the ZAPproduct to the factoryorauthorized
servicedealerforwarranty workorthe expense
of returningitbacktotheownerafterrepairor
replacement will be paid forbytheowner.
ZAP’sresponsibility inrespectto claimsislimited
to making the required repairsorreplacements
and no claimof breach of warranty shall be
cause forcancellation orrescission ofthe
contract of saleofany ZAPproduct. Proofof
date of purchase willbe required by the dealerto
substantiateany warranty claim.Anauthorized
ZAPservicedealermust performall warranty

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APPY
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work. The warranty islimited to thirty (30)days
fromthe date of purchase forany ZAPproduct
that isusedforrentaldemonstration or
commercial purposesorany otherincome
producingpurpose.Thiswarranty doesnot
coverand ZAPproduct that has been subjectto
misuse, neglect, negligence oraccident, orhas
been operated inany way contrarytothe
operatinginstructions as specifiedinthe ZAP
owner’smanual.Thiswarrantydoes not apply
any damage to the ZAPproduct that isthe result
of impropermaintenance orto any ZAPproduct
that has been altered ormodifiedso asto
adverselyaffect the productsoperation,
performance ordurabilityorthathasbeen altered
ormodified tochange itsintendeduse.This
warranty does not extend to repairsmade
necessaryby normalwearand orby use of parts
that areincompatiblewithZAPproducts.In
addition thiswarrantydoesnotcoveritemsthat
experiencenormal wearandtear.ZAPreserves
the right to improve the design of theproduct
without assuming anyobligations to modify any
product previouslymanufactured. Allwarranties
arelimited indurationtothethree(3)months
warranty period. Any such implied warranties
including merchantability, fitness fora particular
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APPY
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purposeorotherwisearedisclaimed intheir
entirety aftertheexpiration ofthe appropriate
thirty day warranty period. ZAP’sobligationunder
thiswarranty isstrictlyand exclusivelylimited to
the repairandreplacement of defective partsand
ZAPdoes not assumeforthemany obligation.
Somestates do not allowlimitationson howlong
an implied warranty last, sothe above limitation
may not applyto you. ZAPassumes no
responsibility forincidental consequential orother
damages including but not limited to expenseof
returning theZAPproductto anauthorized
servicedealerandexpense of delivering it back
to the owner.Mechanic’stravel,timetelephone
charges, rentalof alike productduringthe time
the warrantyserviceisbeingperformed travel
lossordamage topersonalproperty,lossof
revenue, loss of time, orinconvenience. Some
states donoallowthe exclusion orlimitationof
incidentalorconsequentialdamages sothe
above limitationsmay not applyto you.
WHATZAPWILL DO:
ZAP will, at its sole option, eitherrepair,replace
orrefund the purchase price of any unit that does
not conformto thislimited warranty. ZAP may
choose at its option to use functionallyequivalent

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APPY
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reconditioned, refurbished ornewunits orparts
orany units. You are responsible to get the unit
back to ZAP.
HOW TOGETWARRANTYSERVICE:
To obtain warranty service, please callorfaxto
the following telephone numbers fromanywhere
in the continentalUnited States:
Tel. [phone]
orFax.1-707-636-0177
Correspondencemay also be mailed to:
Email: [e-mail]
ZAP CustomerService -WarrantyRepair
501 Fourth Street, Santa Rosa, CA95401
DO NOTRETURN YOUR PRODUCTTOTHE
ABOVEADDRESS.
Please callorwrite forthe location of the ZAP
authorized service centernearest youand forthe
procedures forobtaining warranty claims.