Del3022 g owner's manual

OWNER’S MANUAL

GOLF CAR SERIES

VERSION :20113001

TABLES OF CONTENTS

COLOR OPTIONS ............................................................................................... 1

VEHICLE FEATURES ........................................................................................ 2

SAFETY INFORMATION .................................................................................. 4

HDK DECLARATION ........................................................................................ 6

IMPORTANT DECALS ...................................................................................... 7

PRE-OPERATIONS ............................................................................................. 8

OPERATING INSTRUCTION ......................................................................... 11

Brake and Accelerator .................................................................................... 11

Key switch and Indicators .............................................................................. 11

Dash board ....................................................................................................... 12

Light and Horn control ................................................................................... 13

ON BOARD CHARGER .................................................................................... 14

Charger’s calibration ...................................................................................... 15

How to program charger without calibration box ....................................... 16

BATTERIES ........................................................................................................ 18

TIRES ................................................................................................................... 19

VEHICLE MODIFICATIONS ......................................................................... 20

Controller ......................................................................................................... 20

Motor and Rear axle ....................................................................................... 20

Headlights ......................................................................................................... 20

Tires .................................................................................................................. 21

Golf cart accessories option ............................................................................ 21

VEHICLE MAINTENANCE ............................................................................ 22

Tools .................................................................................................................. 22

Vehicle maintenance ........................................................................................ 23

Chassis maintenance ....................................................................................... 24

Electric components maintenance.................................................................. 26

VEHICLE STORAGE ....................................................................................... 28

SPECIFICATION ............................................................................................... 29

COLOR OPTIONS 1

HDK HAS CUSTOM COLORS AVAILABLE UPON REQUEST.

SPECIAL COLORS MAY REQUIRE ADDITIONAL COST.

VEHICLE FEATURES 2

VEHICLE FEATURES 3

EVERY HDK GOLF CART HAS THE

HOT-GALVANIZED-DIP CHASSIS. THIS

ASSURES YOU “NO RUST FOR 15

YEARS”.

SAFETY INFORMATIONS 4

CHILDREN ARE NOT ALLOWED TO PLAY WITH

THE VEHICLE.

DO NOT DRIVE THE VEHICLE OVER 25MPH/H.

DRIVING O V E R T H E S P E E D L I M I T MAY

CAUSE SEVERE INJURY.

WHEN MAKING A SHARP LEFT TURN, APPLY

THE BRAKE TO LIMIT SPEED.

WHEN MAKING A SHARP RIGHT TURN, APPLY

BRAKE TO LIMIT SPEED.

APPLY THE BRAKE TO LIMIT SPEED WHILE

DRIVING ON A STEEP HILL.

DO NOT DRIVE VEHICLES ACROSSED SLOPES

MORE THAN A 25 DEGREE ANGLE.

SAFETY INFORMATIONS 5

BATTERY POSTS, TERMINALS AND RELATED

ACCESSORIES CONTAIN LEAD AND LEAD COMPOUNDS.

THESE CHEMICALS ARE KNOWN FOR CAUSING

CANCER AND REPRODUCTIVE INJURIES.

WASH HANDS AFTER HANDLING ANY BATTERIES.

THE BATTERY WILL GENERATE HYDROGEN GAS

DURING THE CHARING PROCESS.

KEEP SMOKE, EXPLOSIVE MATERIAL AND STATIC

ELECTRICITY AWAY FROM THE BATTERY.

USE AN ISOLATED WRENCH TO OPERATE ON

THE BATTERY IN CASE THE BATTERY

SHORT CIRCUITS. SHORT CIRCUITS GENERATE

BIG CURRENTS THAT WILL CAUSE INJURY.

Grand Safety information

The owner’s manual contains important safety information. The following decals should be

noticed and followed to prevent future injuries.

Indicates the regarding situations- is very important.

Indicates the regarding situations- may cause minor injury or other

loss.

Indicates the regarding situations- may cause death or serious

injury.

HDK DECLARATION 6

HDK Vehicles USA, LLC mainly deals with five types of the electric

vehicles. Such as the electric golf car, shuttle bus, utility cart, engineer

and transportation cart, and special electric cars. Among which is the

DEL3022G series of electric golf cars. Our golf car is environmentally

friendly and suitable for use on the course, hotels and other business

places. All the key components are imported from well-known

companies. The car has been designed to take on a new fashion look for

electric carts and provides stable performance, flexible control, and

comfortable driving. Our golf car is used as people movers or utility cars

in vacation villages, villa areas, resort hotels, private residential areas,

tourist scenic spots, or any other place where this type of golf car is

allowed. The warranty papers are to standardize the after-sale service

for export vehicles, settle the claims efficiently, and improve our after-

sale service.

HDK Electric Vehicles has been dedicated in electric vehicles

manufacturing since 2006. HDK customers range from all over the

world. HDK Electric Vehicles promises any customer who buys an

HDK vehicle, HDK technicians will be always be ready to fix any

problems that may arise. We provide splendid quality of after sale

service.

For more warranty information please read the limited warranty

paperwork that customers receive with a purchase of an HDK vehicle.

IMPORTANT DECALS 7

Vehicle’s

＊Vehicle’s serial number Manufacturing year

Serial number

Vehicles manufactured by HDK Electric

Vehicles all have vehicle serial numbers on the

left side of the chassis frame. The first four

numbers are the manufacturing year of the

vehicle. The other five numbers are the vehicle’s

serial number given by HDK. All the vehicles are

recorded. After the vehicles are sold out of the

factory, HDK will track the vehicles by using the

vehicle’s serial number as identity. Serial

numbers are the insurance warranty of HDK.

Customers should be aware of the importance of

the vehicle’s serial numbers.

＊Steering wheel decals

DO NOT REMOVE while using the

vehicles or during routine maintenance.

②

①

③

①. Steering wheel

②. HDK decal

③. Vehicle operating

instructions decal

IMPORTANT DECALS 8 ＊Charger’s decals

③

② ④

①

①. Charger

②. Charger’s indicating decal

③. Charger’s stage display decal

④. HDK charger’s information

decal

⑤. Caution and warning decal

⑤

PRE-OPERATIONS 9

④

① Before using t h e vehicle, the batteries should be

fully charged. Estimated charging time should be

more than 10 hours.

② Check the accelerator pedal. When stepped on and

released it should return to its original position with full flexibility.

③ Check the brake pedal. W hen stepped o n it should be

flexible and feel firm. W h e n r e l e a s e d , i t should

return to its original position with flexibility.

Check the tires’ pressure. It should be inflated until the

pressure is around 20~23PSL (138kpa~159kpa)

Check the signal lights. T he brake lights and turning

lights should be in proper working condition.

Check the reverse beeper. When the direction selecting

switch is set at “REV”, it should beep consistently.

PRE-OPERATIONS 10

Check the tires’ surface. Remove any embedded objects you

can find. Be sure there are no cracks or other damages to

the tires. Defective tires may cause accidents while driving.

Check the level of the lubricant in the rear axle. Use a

clean stick; stick it into the rear axle and reach the

bottom. T a k e it out, check the depth, it should be

more than 13cm (1.3L).

Pull the steering wheel up and down. Check the

tightness of t h e steering wheel. Rotate the steering

wheel right and left. Be sure no excessive free play and

rattling sound occur.

Check the tightness of the battery wiring; make sure all

the nuts are solidly tight. Loose nuts and bolts on the

battery will cause big sparks while operating.

Pre-operations are extremely important, the owners of the vehicle should be aware all the required

operations needed to be executed before using the vehicle. The status of the vehicle is very

important to the safety of the passengers on board.

BE SURE TO DO THE PRE-OPERATION JOB.

OPERATING INSTRUCTION 11

＊Brake and Accelerator

① ② ③

① Use the accelerator pedal to control the vehicle’s speed. ② Use the brake

pedal to decrease velocity. ③ Use the parking brake to keep car stationary.

＊Key switch and indicators ⑤

④

⑥

④ Use key switch to turn on the main power. ⑤ Use direction selecting switch

to change the vehicle’s moving direction. ⑥ Use the power switch to turn on the

vehicle’s power (only 48V systems have the power switch)

OPERATING INSTRUCTION 12

＊Dashboard functions ⑧

⑨

⑦

⑩

(7) Dashboard (8) Controls and indicators panel (9) Golf ball holder

(10) Bottle holder (11) Tee holder

※NOTES

The dashboard is designed according to the usages of the vehicles that are applied

on the golf course. Owners should get familiar with the functions that the vehicle has.

OPERATING INSTRUCTION 13

＊Lights and horn control

Ⅰ Ⅲ

Switch assembly

Ⅱ Ⅳ

Ⅰ. Turn on the right turning lights Ⅱ. Turn on the left turning lights

Ⅲ. Horn button Ⅳ. Turn on the headlights

Grand information of operation

Always use the vehicle in a responsible manner and maintain the vehicle in a safe

operating condition.

Always read and observe all warnings and operation instruction labels affixed to the

vehicle.

Always follow all safety rules established in the area where the vehicle is being operated.

Always reduce speed to compensate for poor terrain or conditions.

Always apply service brake to control speed 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.

Always use extreme caution when driving over loose terrain.

Always use extreme caution in areas where pedestrians are present.

ON-BOARD CHARGER 14 ＊On-board charger

1 Red LED steady on: error occurred

2 Orange LED flashing: Low AC voltage

3 Red LED & Green LED flashing

alternately(slow):<80% Charger

4 Red LED & Green LED flashing

alternately(frequently):≥ 80% Charger

5 Green LED steady on : battery fully

charged

Ⅰ. Charger’s Specifications

ⅰ. Charging display process

TRE BUL CONSTANT

VOLTAGE

ⅱ. LED display

HDK Charger is highly intellective; charger can be

calibrated to be 36V or 48V. The chargers have

electronic protection, auto-reset, and electronic

current limit.

FLOAT

CHARGE

FULLY

CHARGED

Charger’s calibrations and malfunction solutions

ⅰ. Alert and error display

Code

Reason

Solving method

E01 No charging function. Inspect if the connecting terminals are in proper connection

Battery temperature is too high or too low. Check if the battery temperature is in the range of-10℃-50℃

E02

No battery connection; battery voltage too high or

too low.

Inspect if the battery voltage is in the range (48:12V to

55.2V/36V:9V to 41.4V).In-charging display E02, 48V battery

mode, battery voltage is above 67.2;In 36V battery mode,

battery voltage is above 50.4V.

E03 Battery is not fully charged for long time (overtime

charging)

Inspect if the battery connecting terminals are loose or rusted

E04

Battery cannot have TRE charging, charging to

the least normal voltage. That means voltage unable

to be

charged in.

Inspect if the battery is shorted or individual battery cell

damaged

E05

Charger internal temperature high Ensure that surrounding temperature is not too high , and

ventilation is good , and the charger should be turned off .

E06

Charger internal damage

Turn off the charger and send it to service dept. for repairing

E07 Grid power low Inspect the grid power

RL1 Grid power alert Inspect the grid power

ON-BOARD CHARGER 15 ＊On-board charger

ⅱ. Charger’s calibration

BEFORE CHARGING, THE HDK

ON BOARD CHARGER HAS TO BE

STRICTLY CALIBRATED TO THE

CORRECT CODE WHICH IS DESIGNED

FOR A SPECIFIC BATTERY TYPE.

PROGRAM CODE CONTRAST TABLE

48V 36V BATTERY 48V 36V BATTERY

b01 b51 Trojan flooded b15 b65 Trojan T875

b02 b52 Trojan T105 flooded b16 b66 Us 2000 flooded

b03 b53 Discover 80-150AH AGM b17 b67 US2200 flooded

b04 b54 Discover AGM b18 b68 Us 250hc flooded

b05 b55 US battery flooded b19 b69 6TB-170AGM

b06 b56 Trojan 30XHS b20 b70 Generic 140-200Ah AGM

b08 b58 Trojan J305 b21 b71 Generic 200-250 Ah AGM

b09 b59 Generic 200-255 Ah flooded b22 b72 Generic 250-335 Ah AGM

b11 b61 Trojan 1275 b26 b76 Generic 140-200Ah flooded

① b13

b63 Trojan T605 b27 b77 Generic 250-335Ah flooded

b14 b64 12TB-115AGM b28 b78 Generic 400Ah flooded

Operation illustration

Ⅰ. Inspection of the charger acquiescent charging category

Entering display charge category mode:

ⅰ. Disconnect AC input wires.

ⅱ. Disconnect between the charger output and battery.

ⅲ. A. When AC input is connected the display will show the program revision. After around 5 seconds later, it will show the charger

output voltage and complete the self-inspection process.

B. Display continues to show b01 10 seconds, exit the acquiescent charging mode, display shows E02.

ⅳ. Disconnect AC in put wires. If there is need to change the charging category setting, the

positive (Red)/negative (Black) terminals of the output wires should be connected to the battery

positive (Red)/negative (Black) terminals. After connecting the grid power, the charger can start charging the battery code.

ⅴ. Turn on the power of the calibration box ,press button “+ “to increase code number , press “-“ to decrease the code number

;until to the right code of the battery .

Press “SAVE” button to save the setting, the code display will flash after save the setting.

① ② Connect the negative output

①Plug the charger to the

grid power, t h e c h a r g e r

② will display “E02.

terminal to the batteries terminal

pole.

Use the positive terminal to

touch the batteries’ positive to

change the charger’s code.

BE SURE THE OUTPUT

TERMINALS DO NOT HAVE

ANY CONTACT BEFORE

PLUGGING THE CHARGER TO

GRID POWER.

Operation illustration

Ⅰ. Enter the battery selection mode (batteries are not connected to charger);

Ⅱ. When the display shows the default charging category, charger output wire negative terminal (black/white

wire) c o n n e c t s to battery negative terminal. Use the charger output wire positive ring terminal to touch the battery

positive terminal for 3 seconds (+/-0.5 second).Remove the ring terminal. The display shows addition of the battery category

(eg. b01 adding to b02.Remark: If the charger output wire positive ring terminal is removed, the display shows the battery

charging category without addition. this illustrate that the touching time is not suff icient for 3 seconds. Please repeat the

operation);

Ⅲ. If this continues to increase, steps 2 should be repeated (remark: if the operation stop time exceeds 30 seconds during the

operation process, the display will show E02. Please did connect the grid power until nothing shown on display .then connect to

grid power again and repeat the setting);

Ⅳ. If the current setting needs to be stored, the charger output wire positive ring terminal should be used to touch the battery

positive terminal for more than 10 seconds. When the replay activation sound is heard and the display flashes ,then the

new setting is successfully stored;

Ⅴ. Disconnect the grid power until nothing shown on the display. Then, re-connect the grid power, and inspect if the charger

charging category is correct.

Ⅵ. After inspection confirms correct, the grid power should be disconnected until nothing shown on display. The charger

output wire positive terminal (red) should be properly connected to the battery positive terminal. Then connect to the grid

power, and start charging.

ON-BOARD CHARGER 17

ONLY PROFESSIONAL PERSONS ARE ALLOWED TO CONDUCT THE ADJUSTING OR REPAIRS ON CHARGER.

ANYONE WHO HAS NO EXPERIENCE ON ELECTRONIC COMPONENTS MAINTENANCE IS NOT ALLOWED TO

OPERATE ON THE CHARGER. UNREQUIED OPERATIONS ON THE CHARGER MAY CAUSE ELECTRIC SHOCK,

MAY LEAD TO DEATH.

DO NOT OPEN UP THE CHARGER. ANY ATTEMPTIONS TO TRY TO REPAIR THE DEFECT CHARGER SHOULD BE

UNDER THE GUIDANCE OF A DEALER OR MANUFACTURER’S TECHNICIAN.

USE THE CHARGER ONLY WITH AN ALGORITHM SELECTED THAT IS APPROPRIATE TO THE SPECIFIC

BATTERY TYPE. OTHER USAGE MAY CAUSE PERSONAL INJURY AND DAMAGE. LEAD ACID BATTERIES MAY

GENERATE EXPLOSIVE HYDROGEN GAS DURING NORMAL OPERATION. KEEP SPARKS, FLAMES, AND

SMOKING MATERIALS AWAY FROM THE BATTERIES.

PROVIDE ADEQUATE VENTLIATION DURING CHARGING. NEVER CHARGE A FROZEN BATTERY. BATTERIES’

CAPS SHOULD BE REMOVED WHILE CHARGING.

RISK OF THE ELECTRIC SHOCK: CONNECT CHARGER POWER CORD TO AN OUTLET THAT HAS BEEN

PROPERLY ISTALLED AND GROUNDED IN ACCORDANCE WITH ALL LOCAL CODES AND ORDINANCES. A GROUND

OUTLET IS REQUIRED TO REDUCE RISK OF THE ELECTRIC SHOCK. DO NOT USE GROUND ADAPTERS OR MODIFY

PLUG. DO NOT TOUCH UNINSULATED PORTION OF THE OUTPUT CONNECTOR OR UNINSULATED BATTERY

TERIMALS

CHILDREN SHOULD BE SUPERVISED TO ENSURE THAT THEY DO NOT PLAY WITH THE APPLIANCE.

※NOTES

HDK on-board charger is specially designed for HDK vehicles. The charger’s working voltage

range from 85V~265V, working frequency range from 45HZ ~65HZ. Customers from all over the

world can use HDK on-board without any changes.

HDK on-board charger can be operated in the temperature -30℃~+50℃ (-22℉~122℉), which allows HDK on-board chargers to be used in most circumstances.

BATTERIES 18

Trojan flooded Trojan T875

Us 2000 flooded

Discover 80-150AH AGM US2200 flooded

Discover AGM Us 250hc flooded

US battery flooded 6TB-170AGM

Trojan 30XHS Generic 140-200Ah

AGM

Trojan J305 Generic 200-250 Ah

AGM

Generic 200-255 Ah

flooded

Generic 250-335 Ah

AGM

Trojan 1275 Generic 140-200Ah

flooded

Trojan T605 Generic 250-335Ah

flooded

12TB-115AGM Generic 400Ah flooded

System Battery QTY(PCS) Single battery voltage(V)

36V 6 6

48V 6 8

48V 8 6

ⅰ. The exterior of the battery, the connection wires and bolts should be kept clean and dry. If there is electrolyte outside the battery, please clean with dry

cotton cloth first, then wash with water and finally wipe up. (while cleaning, do not allow any cleaning solution or water to get inside the battery, to avoid

leakage and increasing self-discharge, clean with baking soda and water only).

ⅱ. The connection of the battery should always be kept in good condition. Please check if any battery cable terminal or nut has become loose periodically

in order to prevent any sparking or damage to terminals .

ⅲ. Do not place any object on the battery and do not connect the positive pole to the negative pole. This may cause a short circuit, damage to the battery or

injury to your body.

ⅳ. The battery should be recharged fully when not in use. Any delay on the re-charging will cause negative effect on the battery.

ⅴ The evaporation and electrolyzing of the water will cause the density of electrolyte of the battery increased and the liquid surface decrease, especially in

hot weather. Therefore check the distilled water or the attenuated sulfuric acid for lead-acid battery with density of 1.40 to adjust the electrolyte to meet the

density of the 1.28, the surface should be flat with highest level then continue to charge0.5-1 hour in order to make the internal uniform.

ⅵ. Any impurities are not allowed to enter the battery. Keep the apparatus clean for adding water to avoid the impurities to be fallen into the battery.

ⅶ. When driving, the driver shall be always be aware of the drop level the battery power from the batteries’ capacity indicator .the driver shall estimate the

distance needed to be taken, and recharge the battery at a proper time in case that the car cannot get back to the recharging station in time for recharging .

ⅷ. If the golf car is going to be kept unused for a period of time, the battery shall be fully charged before put away. After that ,the battery fully recharged

every month ,until the charger turn off automatically

ⅸ. During charging, the car shall be parked in a well-ventilated area with the fill caps open. Keep car far away from any frame and sparks and avoid any

explosion or fire that could cause physical injury or damage to the property.

ⅹ. Once charged the cap should be kept tightly covered.

＊HDK vehicle battery connection

Batteries HDK vehicles can apply

② Trojan T105 flooded

①

Batteries loaded on HDK vehicles, according to different

configurations, customers who purchase HDK vehicles can

choose different batteries (figure② Are the batteries

available). The batteries are connected in ser i e s

c ircui t pattern:

TIRES 19

①

②

③

＊Vehicle Tires’ tread

For different circumstances the vehicle being used, different tire treads are optional,

t h e standard tires HDK vehicles have are turf tires.

FIGURE ① STANDARD TREAD

FIGURE ② PREMIUM TREAD

FIGURE ③ EXTRA TRACTION

FOR ATTACHING THE MAXIUM PEFORMANCE THE TIRES SHOULD ALWAYS

BE CHOOSEN ACCORDING TO THE CIRCUMSTANCES THE VEHICLE MOSTLY BEEN

USED.

① Front hub

② Brake drum

CROSS-SEQUENCE

③ Dust cover ①

③ ④ Dust cover seal

While fastening the wheel nuts, one should always

keep it in a cross-sequence .To attach the perfect tight situation.

④ ②

Tubeless tire cautions

1. Clean both tire beads to remove dirt or other object.

2. Where the tire beads seat, clean the wheel rim with a wire brush

3. Apply plenty of tire mounting lubricant (soap and solution) to both beads

and rim flanges

4. Install the tire on the rim from the valve stem side .if there is no tire

machine available, use a rubber mallet and tire iron

5. Remove the valve core and position tire so that both beads are on the rim

flange narrow bead seats

6. Quickly remove the air nozzle and install the valve core

7. Adjust the tire, ke e p the air pressure between 3.5-4.0MP, immerse the

tire into water to make sure there are no leaks

VEHICLE MODIFICATIONS 20

1.

＊VEHICLE PERFORMANCE REMODIFICATION

Ⅰ. Controller adjustment

For attaching different speed performance or regenerative brake effect; The ramp climbing

ability or low speed cruising pattern performance re-modification all can be done by changing the

controller’s parameter settings.

Ask dealer or manufacturer for specific information about remodify the controller parameters.

ONLY TRAINED PERSON ARE ALLOWED TO REMODIFY CONTROLLER PARAMETER SETTINGS. ANY INPROPER

SETTING CHANGES MAY CAUSE SEVERE DAMAGES TO THE VEHICLE OR JEOPARDISE PASSENGERS SAFTY.

Ⅱ. Motor and Rear axle

The motor and rear axle’s performance are fixed when the customer buys it from dealer. The

rated power and torque capability are limited due to the vehicle’s configuration.

For attaching different torque and power performances, customer can choose different motors or

rear axles as options to remodify the vehicle configurations.

MOTOR OPTIONS; 3kw/4kw/5kw

REAR AXLE OPTIONS (SORTED BY RATIOS): 10.25:1 / 12.49:1

ONLY PERSONS WHO HAVE E X P E R I E N C E W I T H REAR AXLE AND MOTOR MAINTENANCES ARE

ALLOWED TO CONDUCT MODIFICATIONS.

Ⅲ. Headlights’ bulbs

For change the luminance of headlights, customer can

choose different rated power bulbs as options.

The maximum rated power for headlights bulbs are 60 W.

The maximum rated power for turning light bulbs is

15W.

VEHICLE MODIFICATIONS 21

c

Ⅰ Ⅱ Ⅲ

I. Turf tire Ⅱ. Off road tire Ⅲ. Extra traction

1. Clean both tire beads to remove dirt or other object.

2. Where the tire beads seat, clean the wheel rim with a wire brush.

3. Apply plenty of tire mounting lubricant (soap and solution) to both beads and rim flanges.

4. Install the tire on the rim from the valve stem side. If there is no tire machine available ,use a rubber mallet and

tire iron

5. Remove the valve core and position tire so that both beads are on the rim flange narrow bead seats

6. Quickly remove the air nozzle and install the valve core

7. Adjust the tire ,keep the air pressure between 3.5-4.0MP,immerse the tire into water to make sure there are no

leaks

Ⅲ. Vehicle tires

Ⅲ. Golf cart accessories option

Ⅳ Ⅴ Ⅵ

Ⅳ. Cool box Ⅱ. Golf ball washer Ⅲ. Aluminum box

VEHICLE MAINTENANCE 22

Ⅰ. Tools

① ② ③ ④

⑤ ⑥ ⑦ ⑧ ⑨

⑩

① Wrenches ② Retaining ring pliers’ ③ Battery fluid injection tool faucet

④ Tire air inflating tool ⑤ Hydrometer ⑥ Lubricant can

⑦ Charger’s calibration box ⑧ Multimeter ⑨ Tape measure ⑩ Jack

※NOTES All the maintenance tools are available from hardware stores.

VEHICLE MAINTENANCE 23

.

Ⅱ. Vehicle maintenance

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 the manufacturer’s 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 cannot 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.

VEHICLE MAINTENANCE 24

ⅰ. Chassis maintenance

Check the dust-proof caps on steering gear box, the

caps are supposed to be tight on the two terminal

ends.

Loose caps will let water and dust into the gear

box, cause the gears rusting.

Add lubricant to mechanical joint parts, the vehicle

should be kept in good turning and operating

functions. To attach that one should add lubricant

to needed parts every one month.

Check the tires every time use the vehicle. The tires

should be inflated with enough air. The air

pressure should with normal level.

Check the tire chapter for more specific

information of tire inflation.

FLAT TIRE MAY CAUSE UNSTABLE

STEERING FUNCTION WHILE DRIVING.

Check the tires every use of the vehicle; remove

embedded objects or metal items away from tire

surface.

If the tire has embedded objects on the surface, it

will lead to excessive noises from tire while driving

or tire internal air leaking.

VEHICLE MAINTENANCE 25

Check the lubricant capacity of rear axle. Low lubricant capacity may cause damages to rear

axle cams or make excessive noises.

Maintenance period: change the lubricant of rear axle

every 6 month.

Clear the brake shoes surface, all the brake shoes shed

dust and should be cleaned out in periodic time. Shred

dust may cause mechanical malfunctions of brake.

Use a compressed air to blow the dust out.

Maintenance period: one time per month.

Check the brake shoes worn out conditions, if it is

extremely worn out (1/3 left), then the brake shoes

need to be replaced with a new one

DO N O T D R I V E T H E V E H I C L E W I T H

P O O R BRAKES.

Check the bearings inside of front hub, the hubs

should have enough lubricated grease.

Maintenance period: one per 6 month.

VEHICLE MAINTENANCE 26

ⅱ. Electric components maintenance

Check the headlight backing rubber caps, the caps

should always be kept on tightly. Otherwise water or

dust may enter into the headlight chambers.

It will cause halogen bulbs to burn down easily and

vague vision of headlights.

Maintenance period: One time per week

Keep LED rear lights waterproof, keep the cover lid

tight, keep dust and water out of LED light assembly.

Dense humidity or water may cause LED diodes to

burn down.

DO NOT LOAD LED LIGHTS WITH HIGH

VOLTAGES.

Keep the controller from water, water may cause

short circuit. If water enters into controller, the vehicle

may run unintentionally after turning on the power

switch.

DO NOT SPLASH WATER ON THE CONTROLLER

INTENTIONALLY WHILE WASHING THE

VEHICLE.

Check fluid level before and after charging ,

electrolyte should be at least 1/2”(13mm)above the

plates and 1/4” tp3/8”(6 to 10mm) below bottom of the

vent .

NEVER CHARGE BATTERY WITH LITTLE

ELECTROLYTES, IT MAY CAUSE OVERHEATED

OR EVEN EXPLOSION!

VEHICLE MAINTENANCE 27

Use a hydrometer to check the specific gravity of the battery

fluid in each cell.

Fluid density ranges from different values in different

periods of battery usage.

Maintenance period: One time per 10 months

Use a injection faucet to inject distilled water

into the battery when the battery doesn’t have

enough capacity of battery fluid.

Maintenance period: One time per 6 months

Always remember to take

precautions while conducting

any operations on batteries or

handling batteries.

Wear gloves to protect person

from acid corrosion.

Wear glasses to protect person

from acid splash.

Always remember to wash

hands after handling batteries

or touch battery’s cap and

battery terminals.

VEHICLE STORAGE 28

If the vehicle is put away for storage for long time; certain things need to be done to

prevent vehicle from malfunctions or other loss.

Please always follow the methods shown below.

Ⅰ

Ⅱ

Ⅲ

Ⅰ. Keep vehicle in dry and ventilated place, keep it out of the rain.

Ⅱ. Remember to charge the batteries fully before putting away the vehicle.

Ⅲ. Disassemble the connection cables between batteries and controller.

SPECIFICATION 29

Parameter

Type

DEL 3022G Series Electric Golf Cart

DEL 3022G DEL 3022G2Z DEL 3042G DEL 3042G2Z DEL 3062G DEL3062G2Z

Passenger capacities

2

4

4

6

6 8

Dimension (mm) (L×W×H)

2350×1180×

1780 2610×1180×

1780 3100×1180×

1780 3360×1180×

1780 4900×1180×

1780 5160×1180×

1780

Range (based on flat road at a

speed of 20 km/h) (km/h)

80

75

70

65

60

60

Maximum speed (gear ratio of

12.49:1/gear ratio of 10.25;1)

(km/h)

20/29

20/29

20/28

20/28

20/28

20/28

Maximum grade ability

30%

28%

25%

22%

20%

20%

Minimum turning diameter (m)

3.1

3.1

4.3

4.3

5.5

6.8

Brake distance (V=20km/h)

≤ 3.5m

≤ 3.8m

≤ 4.0m

≤ 4.0

≤ 4.5m

≤ 4.5m

Minimum distance from

floor(mm)

110

110

110

110

110

110

Noise (db)

63

63

63

63

63

63

All specs and parameters are approximate only and may vary

SPECIFICATION 30

Max slope accessing angle Max ramp angle

NOTE

NOTE

NOTE

HDK Vehicles USA, LLC.

2112 First Street

Rosenberg TEXAS 77471

Tel: 281-342-1040 Fax: 281-342-6432

Email:

[email protected]

Website: www.hdkusa.com