Maintenance Support

Comprehensive Guide to Periodic Maintenance: Essential Tips and Best Practices

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.

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.

Before servicing vehicle, read complete section(s) and any referenced information that may be relevant to the service or repair to be performed.
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. Anyone doing even simple repairs or service should have knowledge and experience
in electrical and mechanical repair.
The appropriate instructions must be used when performing maintenance, service, or accessory installation.
Do not attempt to service hot motor. Attempting to do so could cause severe burns.
To avoid unintentionally starting the vehicle, disconnect the batteries and discharge the controller.
Do not allow tools or other metal objects to contact frame when disconnecting batteries or other electrical wiring. Never allow a positive wire to touch the vehicle frame, engine, or other metal component.
Service, repairs, and adjustments must be made per instructions in the maintenance and service manual.
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.

PERIODIC MAINTENANCE CHART

Regular maintenance is required for the best performance and safe operation of the electric vehicle . Periodic maintenance need to perform accordingly .
1D-per day 1W-per week 1M-per month 1Q-per quarter 1Y-per year
Item	Descriptions	1D	1W	1M	1Q	1Y
Battery	1.Check the damages may occur on battery surface .		v
	2.Charge the battery .	v
	3.Tighten the nut on the battery cable .	v
	4. Fasten the nut of the battery terminal .		v
	5.Check whether the battery is over-charged .	v
	6.Check the SOH state of health of the battery .（）		v
	7.Check whether the battery is fully charged .	v
	8.Clean the surface of battery .		v
Charger	9.Observe the charging status, check if the charger plug becomes hot.	v
Charger	10.Clean the surface of charger . Do not let water enter into charger .		v
Motor and controller	11.Check whether all terminals are tightened properly(Turn off the power).			v
	12.Clean the surface of the controller.				v
	13.Check whether the solenoid is in order, checking the touching point.					v
	14.Check whether there is water get into motor.	v
	15.Check whether all the connectors of motor & controller are tightened		v
	16. Check whether the accelerator pedal works well .	v
Chassis and body	17.Check whether the brake pedal is firm and can be released freely .			v
	18.Check whether the brake drum and brake shoe need to be replaced or not				v
	19.Check the hand break function.			v
	20.Check the break liquid tank liquid level .			v
	21.Check tire pressure and tire surface .		v
	22.Check Whether the shock is leaking or not .			v
	23.Fasten the bolt of shaft .			v
	24.Check whether there is sufficient oil inside of rear axle gear box .				v
	25.Add grease to front hub and steering gear box .				v
	26. Adjust the front and rear suspension .				v
	27.Clean the body and seat .	v

DAILY PRE-OPERATION INSPECTION

Before every customer gets behind the wheel of a golf car, ask yourself the following questions. In addition, review the EVOLUTION-CARE guidelines, listed here, to ensure superior golf cart performance:

Have you performed a daily inspection ?
Is the golf cart fully charged ?
Is the steering responding properly ?
Are the brakes activating properly ?
Is the accelerator pedal free from obstruction ? Does it return to it’s upright position ?
Are all the nuts, bolts and screws tight ?
Do the tires have proper pressure ?
Have the batteries been filled to proper level(lead-acid battery only)?
Are the wires tightly connected the battery post and free of corrosion ?
Does any of the wiring show cracks or fraying ?
Are the brake fluid (hydraulic brake system) at right levels ?
Are the lubricant of rear axle at right levels ?
Are the joints/knobs being properly greased
Have you checked for leaks of oil/water, etc ?

TIRE PRESSURE

Maintaining proper tire pressure in your personal golf cars is as important as it is with your family car. If tire pressure is too low, your car will use more gas or electrical energy. Check your tire pressure monthly, because dramatic fluctuations in daytime and nighttime temperatures can cause tire pressure to fluctuate. Tire pressure varies from tires to tires.
Maintain tire pressure within 1-2 psi of the recommended pressure marked on tires at all times.

BATTERIES

(LEAD ACID BATTERY) Like most things, batteries need clean water to survive. Improper fluid levels can cause batteries to fail prematurely. While insufficient water can adversely affect battery life and performance, overfilling can be just as harmful.Proper battery watering is always performed after the batteries are charged, not before the charging .To maintain proper fluid levels, a single-point watering system is essential and it is a standard feature on new electric vehicles. These systems eliminate the time-consuming process of removing battery caps to add water. After the proper amount of water is dispensed through a valve system,the flow of water to individual cells shuts off automatically. Make sure to use a deionizer water purifier and replace the filter cartridges regularly. This will ensure your batteries are getting the best quality water.Have a trained technician wash battery tops and clean terminals with baking soda/water solution monthly. Also apply authorized battery terminal protector spray to battery terminals.
(LITHIUM BATTERY) Attach the battery to a 2-phase charger, ensuring that the charger’s positive lead is attached to the battery’s red or positive pole and negative lead is joined with the negative pole. It’s also prudent to charge the battery after every time the golf cart is used.

CHARGING

Properly charged batteries are one of the most important factors in the performance of your golf cars. By the same token, improperly charged batteries can shorten the lifespan and adversely affect your cart’s performance.
Batteries should be fully charged before a new vehicle is first used; after vehicles have been stored; and before vehicles are released for use each day. All cars should be plugged into chargers overnight for storage, even if the car has only been used for a short time during the day. To charge batteries, insert the charger’s AC plug into the vehicle receptacle.
However, if you have lead-acid batteries in your golf cart before you charge any vehicles, be sure to adhere to important precautions:
Since lead-acid batteries contain explosive gases, always keep sparks and flames away from vehicles and the service area.
Never allow staff to smoke while batteries are charging.
Everyone who works around batteries should wear protective clothing, including rubber gloves, safety glasses, and a face shield.
Some people might not realize it, but new batteries require a break-in period. They must be significantly recharged at least 50 times before they can deliver their full capabilities. To be significantly discharged, batteries must be discharged, and not merely unplugged and plugged back in to perform one cycle.

CLEANING

When you clean cars, be sure to use the products recommended in the owner’s manual. Refrain from using silicone- based products on floor mats, pedals, and seats; silicone-based products can leave surfaces slippery and lead to accidents.
Although a pressure washer is undoubtedly the fastest way to remove dirt and debris from golf cars, it can sometimes do as much harm as good. We find that a garden hose at normal pressure is adequate for most clean-up jobs while stopping short of damaging the car’s paint and clear coat.

STORAGE

A EVOLUTION ELECTRIC VEHICLE gives you years of trouble-free service when properly maintained. Please follow the recommended long-term storage checklist. For more information on overall vehicle maintenance, consult the owner’s manual.
TWO WEEKS PRIOR TO THE STORAGE
Perform the following procedure at least two weeks prior to long-term storage to ensure proper mixing of water and electrolyte. It takes approximately five charge cycles with a minimum of 10 EUs removed to properly mix the water with electrolyte . DO NOT water batteries immediately prior to storage. This will not provide sufficient charge time to mix the water with the electrolyte. Freezing can occur when batteries are stored in this condition.
(For Lead-acid Battery) Make sure the vehicle is plugged in and that the proper electrolyte level is maintained throughout the entire storage period. Perform the following procedure at least two weeks prior to long-term storage to ensure proper mixing of water and electrolyte. It takes approximately five charge cycles with a minimum of 10 Eus removed to properly mix the water with electrolyte. DO NOT water batteries immediately prior to storage. This will not provide sufficient charge time to mix the water with the electrolyte. Freezing can occur when batteries are stored in this condition.
Check the water levels in each battery cell. If water is required, fill the cells to cover the plates, charge the set and use distilled water to top off each cell. Electrolyte levels should be from 1/2-inch (13 mm) above plates to 1/4-inch (6 mm) below the level indicator. (See illustration.)

(For Lithium Battery) Make sure the vehicle battery is plugged in for charging throughout the entire storage period.
JOBS TO BE DONE PRIOR TO THE STORAGE
Put golf cart under shelter, keep the golf cart in dry and ventilated space .Optimal temperature 14°F to 95°F (-10°C to 35°C) . Maximum storage temperature should not be higher than 122 °F (50°C).
Turn the key switch to the OFF position, remove the key and leave the forward/reverse switch in the NEUTRAL position during storage.
Power down all accessories.
Clean the battery packs, tops and terminals using a battery acid neutralizer (1 cup baking soda per 1 gallon water).Check, clean and treat battery terminal connections with a battery terminal protector spray.
If your vehicle is equipped with a Single Point Watering System(for golf carts with lead-acid battery), place the fill tube on top of the battery. This allows any water in the tube to drain back into the batteries.
Disconnect batteries per owner manual ensuring that the cables do not come into contact with a terminal (Disconnect the 48V Main power outlet cables from battery pack ,insulate the cable)
Connect Battery cables back to system , charge the battery to full state every 1-3 months to keep battery alive without damages caused by self discharge/over-discharge , etc.
Check Tire pressure and infate the tires to standard pressure level as values presented on tires.
Perform all semi-Annual Lubrications
Thoroughly clean the front and rear body ,seats ,battery compartment and underside of the vehicle.
DO NOT engage the park brakes , but secure the golf cart from rolling. Chock the wheels with wheel stopper or something similar .

Always:

Maintain the vehicle in accordance with the manufacturer’s periodic service schedule.
Ensure that repairs are performed by those that are trained and qualified to do so.
Follow the manufacturer’s maintenance procedures for the vehicle. Be sure to disable the vehicle before performing any maintenance. Disabling includes removing the key from the key switch and removal of a battery wire.
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 an insulating material.
Check the polarity of each battery terminal and be sure to rewire the batteries correctly.
Use specified replacement parts. Never use replacement parts of lesser quality.
Use recommended tools.
Determine that tools and procedures not specifically recommended by the manufacturer will not compromise the safety of personnel nor jeopardize the safe operation of the vehicle.
Support the vehicle using wheel chocks and jack stands. Never get under a vehicle that is supported by a jack. Lift the vehicle in accordance with themanufacturers instructions.
Maintain the vehicle in an area away from exposed flame or persons who are smoking.
Be aware that a vehicle that is not performing as designed is a potential hazard and must not be operated.
Test drive the vehicle after any repairs or maintenance. All tests must be conducted in a safe area that is free of both vehicular and pedestrian traffic.
Replace damaged or missing warning, caution or information labels.
Keep complete records of the maintenance history of the vehicle.

The manufacturer can not anticipate all situations, therefore people attempting to maintain or repair the vehicle must have the skill and experience to recognize and protect themselves from potential situations that could result in severe personal injury or death and damage to the vehicle. Use extreme caution and, if unsure as to the potential for injury, refer the repair or maintenance to a qualified mechanic.

L48100 LI-ION

L48105 LI-ION

L48105-A LI-ION

L48110 LI-ION

L48160 LI-ION

L48160-A LI-ION

L48205 LI-ION

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