A41 Analysis Of Common Faults And Repair Methods For Four-Wheeled Electric Pickup Truck
A41 Analysis Of Common Faults And Repair Methods For
Four-Wheeled Electric Pickup Truck
With the increasing demand for short-distance urban logistics and rural transportation, four-wheeled electric vehicles are being used by more and more users due to their advantages such as low cost, environmental friendliness, and ease of operation. However, during long-term use, core components such as batteries, motors, and controllers are bound to malfunction, making it crucial to master basicmaintenance and fault diagnosis methods.
Chapter 1: Basic information
Main technical data parameters of the electric truck
The A41 model whose main features include, but are not limited to the following:
|
Motor power
|
3000W |
|
Drive type
|
electric motor RDW
|
|
Battery capacity/type
|
72V 106AH lithium battery
|
|
Mileage
|
80—120km
|
|
Maximum speed
|
25/40km/h
|
|
Cargo bed size
|
1374*1267*674mm
|
|
Rated load
|
829kg
|
|
Maximum hill-starting ability
|
≤18°
|
Main parts of the electric truck
|
NO
|
Name
|
Material
|
Rangle
|
|
1
|
Left rear-view mirror outer edge
|
PP | 2.5 |
| 2 |
Right rear-view mirror outer edge
|
PP | 2.5 |
| 3 |
Left hand outer edge
|
Metal
|
2.5 |
| 4 |
Right hand outer edge
|
Metal
|
2.5 |
| 5 |
Head lamp
|
PC | 2.5 |
| 6 |
Rear grouped lamp
|
AS | 2.5 |
| 7 |
Rim
|
Aluminum
|
2.5 |
| 8 |
Windscreen wiper
|
Rubber
|
2.5 |
Circuit diagram for the electric truck
Chapter 2: Safe operating
Before driving the A41 electric pickup truck, please be sure to read the following safety guidelines:
To ensure safety, please never exceed the electric vehicle’s rated load capacity. Overloading will increase braking distance, cause motor overheating, and drastically reduce battery life and also affect driving safety.
- Driving Environment: Avoid driving the vehicle into deep water to prevent water from entering the electric motor and cause damage.
- Slope Safety: When starting on a slope, please use the handbrake to prevent the vehicle from rolling backward.
- Charging: Never charge the vehicles outdoors in the rain, do not use inferior power strips or non-standard power outlets.
Chapter 3: Driving and instruction
Start the vehicle and driving
Starting procedure: Depress the brake pedal -> Insert the key and turn it to the "ON" position -> Confirm that the instrument panel lights up READY-> Turn the knob/lever to "D" (forward) or "R" (reverse) -> Slowly release the handbrake and press the accelerator pedal.
Instrument Panel description
- Battery Level display: When the battery level drops below 20%, please charge the vehicle or replace the battery immediately.
- Speed display: The speed will be displayed while driving. Mileage display: Indicates the total distance which the vehicles driving.
- Turn signals display: Indicated by two arrows on the speedometer, the corresponding arrow will illuminate when the turn signal is activated.
- Lights: When the corresponding light is activated, the corresponding icon on theinstrument panel will illuminate as a notification.
- Screen: The screen on the right side displays the information from the reversing camera.
Chapter 4: Battery charging
It is recommended to connect the battery plug to the vehicle's charging port first, then connect the power cable to the power outlet. After the light on the charger changes from red to green, indicating that the battery is fully charged. If the light doesn't turn on or stays on only one color, the charger may be faulty. Please change a new charger to charge your electric truck.
Charging environment: Keep away from flammable materials and keep the surrounding area well-ventilated and dry when charging the vehicle to avoid possible accidents.
Battery maintenance tips
This electric vehicle is equipped with a lithium battery, therefore, avoid charging it after it has been completely discharged. It is recommended to charge the electric vehicle when the battery level shows below 20%. In summer, charge in a shaded area. in winter, it is recommended to charge indoors or immediately after driving (utilizing the residual heat of the battery to improve charging efficiency).
Electric vehicle battery fault quick diagnosis
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Fault Symptom
|
Quick Inspection Method
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Possible Cause
|
Solution
|
|
Battery cannot be charged
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Check if the charger indicator turns green
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Battery aging, damaged cell, or charger failure
|
Check battery voltage and replace battery or charger if necessary
|
|
Charging finishes too quickly
|
Charging takes only 1–2 hours before turning green
|
Battery capacity degradation
|
Replace the battery pac
|
|
Battery voltage
normal but vehicle does not move
|
Measure battery output voltage
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Loose battery connection or blown fuse
|
Check wiring and replace fuse
|
|
Voltage drops
sharply when accelerating
|
Measure voltage during riding
|
High internal resistance due to battery aging
|
Replace battery
|
|
Driving range becomes much shorter
|
Fully charge and perform riding test
|
Battery capacity decreased
|
Replace battery
|
|
Battery overheats
|
Touch battery during charging or operation
|
Internal short circuit or battery aging
|
Stop using immediately and replace battery
|
|
Voltage fluctuates (unstable)
|
Test with a multimeter
|
Loose wiring or BMS protection
|
Check connectors or replace BMS
|
|
Battery swelling (lithium battery)
|
Visual inspection
|
Overcharging or internal damag
|
Stop using and replace battery immediately
|
|
Battery leakage (lead-acid battery)
|
Visual inspection |
Battery casing damage or aging
|
Replace battery
|
|
Cannot charge after long storage
|
Measure battery voltage below protection level
|
Over-discharge
|
Try battery activation charging or replace battery
|
Chapter 5: Regular maintenance
To ensure safe and long-term vehicle use and to promptly identify any problems, please regularly inspect and maintain the vehicle as needed to ensure it is in good condition. This will guarantee safety and longevity.
Daily maintenance advice
|
frequency
|
items
|
|
weekly check
|
Check tire pressure
|
|
Check brake sensitivity.
|
|
|
Check battery wiring is correct.
|
|
|
Check battery securely mounted.
|
|
|
month check
|
Check the wiring harness for wear and aging.
|
|
Check the front and rear wheel axle nuts for looseness.
|
|
|
Check the lights for proper functioning.
|
|
|
Check the horn for proper functioning.
|
|
|
quarterly check
|
Check if the battery voltage is normal.
|
|
Check if the controller shows signs of water ingress or overheating.
|
|
|
Check the brake pad/ brake disc wear.
|
|
|
Check the vehicle's wiring and bolts for proper functioning.
|
|
|
every 1000km
|
Inspect and tighten all vehicle bolts and replace rear axle gear oil.
|
|
every 3000km
|
Check the brake system sensitivity and brake pad thickness, replace severely worn brake pads,
and top up brake fluid as needed.
|
|
every 5000km
|
Check if the tires are steerable and avoid rotating them to prevent wear.
|
|
every10000km
|
Check the insulation of the high-voltage wiring harness for damage and replace it promptly.
Clean the dust accumulated on the outside of the motor.
|
Chapter 6: Other precautions
For this type electric vehicle, in addition to the common charging safety, avoiding overloading, and regularly inspecting basic components, there are some easily overlooked but very important things which often have a great impact on the vehicle's lifespan and safety. Please also need to pay attention to them.
- Avoid prolonged deep discharge
Many users have a habit of letting the battery drain to almost 0% before recharging, which is actually not good for the battery. We recommend that to charge battery when the battery level is 20%–30%. Prolonged deep discharge could easily lead to a decrease in battery capacity and affect the battery lifespan.Turn off the circuit
If the electric truck will not be used for an extended period, please turn off the circuit. To prevent the vehicle from failing to start due to slow battery depletion.
- Avoid prolonged full-load uphill driving
Although this mini four-wheeled electric trucks have the capacity to carry cargo, climbing hills fully loaded for extended periods would probably cause the motor to overheat, the controller to be overloaded, and the battery to experience excessive instantaneous current, which will damage the vehicles.
- Do not drive through deep water in rainy days
While electric delivery trucks offer some water resistance, they are not completely waterproof. Please ensure the water depth does not exceed the wheel well height and prevent water from entering the controller, motor, and wiring connections. Otherwise, it may cause short circuits or damage to the controller and other components.
- Do not arbitrarily replace high-power controllers
Do not perform any high-voltage modifications or performance upgrades on the electric picuk trucks. If necessary, it is recommended to consult a professional for assistance.
Chapter 7: Common problems and troubleshooting methods
|
items
|
possible causes
|
solutions
|
|
The vehicle has
no power
or can not started
|
Battery depleted or aged
|
Check battery voltage, fully charge and try again
|
|
Circuit breaker tripped
|
Reset or replace the circuit breaker
|
|
|
Loose or oxidized battery connections
|
Re-tighten and clean battery connections
|
|
|
Damaged key switch
|
Replace the key switch
|
|
|
Battery life is
significantly shorter
|
Battery aging (common after 1.5–2 years)
|
Replace with a battery of the same specification
|
|
Insufficient tire pressure
|
Inflate the tires properly
|
|
|
3)Prolonged overloading and
frequent hill climbing
|
Control the load and avoid prolonged high current operation
|
|
|
Decreased controller efficiency
|
Inspect or replace the controller
|
|
|
the vehicle cannot
charge / charger
not working
|
Charger damaged
|
Replace the charger and try again
|
|
Loose or burned charging port
|
Inspect or replace the charging port
|
|
|
Failed battery cell
|
Inspect the battery and replace any faulty cells
|
|
|
No movement
when accelerating/
Intermittent movement
|
Poor contact in the motor Hall sensor wire
|
Check if the Hall sensor connector is loose
|
|
Controller malfunction
|
Replace the controller
|
|
|
Brake power-off switch stuck
|
Check the brake return mechanism;
replace the brake switch if necessary
|
|
|
Abnormal noise
during driving
|
Worn motor bearing
|
Replace the motor bearing
|
|
Insufficient lubrication in the rear axle gears
|
Lubricate the rear axle gears
|
|
|
Loose wheel nuts
|
Tighten all wheel bolts
|
|
|
Weak start /
difficulty climbing hills
|
Low battery voltage
|
Replace or upgrade the battery
|
|
Insufficient controller power
|
Upgrade the controller with matching power
|
|
|
Insufficient or aged motor wiring
|
Inspect or replace the motor wiring harness
|
|
|
Unsuccessful
brakes / Uneven
braking
|
Brake cable stretched
|
Adjust or replace the brake cable
|
|
Worn brake pads
|
Replace the brake pads
|
|
|
Uneven left and right brake adjustment
|
Readjust the left and right brake clearance
|
|
|
The car doesn't move after
releasing the brake
|
Brake power cut-off switch not reset
|
Replace the brake power cut-off switch
|
|
Brake cable stuck
|
Add lubricant to the brake cable or replace it
|
|
|
Lights doesn’t
work/ Instrument
panel not displaying
|
Blown fuse
|
Replace the fuse
|
|
Poor wiring connection
|
Check the wiring connectors
|
|
|
Damaged DC converter
|
Replace the DC converter
|
|
|
Turn signals not
flashing or constantly on
|
Damaged flasher unit
|
Replace the flasher unit
|
|
Incompatible bulb wattage
|
Use a bulb with the correct wattage
|
A41 User Manual for Electric Four-Wheeler
Maintenance Manual for Model A31