A41 Electric Car Maintenance Manual

A41 Electric Car Maintenance Manual
1.Scope

This manual applies to the A41 model, whose main features include, but are not limited to:

  • Four-wheel mini cargo pickup vehicle.
  • With 72V 106AH lithium battery.
  • With 2900/3000W motor.
  • With Digital instrument panel (battery level/speed/mileage/lights/rearview camera).
  • With Front disc brake, rear disc brake.
  • Speed: 25/40km/h.

This manual is for routine maintenance, troubleshooting, and basic repair reference only and does not cover high-voltage modifications or performance upgrades.

1.1 Model



 
1.2 Vehicle Identification Number
The Vehicle Identification Number (VIN) is engraved on the left side of the chassis.

The motor number is engraved on the motor.

1.3 Specifications

Standard specifications

Project Specification
Size Length 2995mm
Width 1369mm
Height 1709mm
Wheelbase 1965mm
Maximum payload 829kg
Chassis Front suspension Helical spring type
Rear suspension Leaf spring type
Front tire size 4.50-12
Rear tire size 4.50-12
Front brake Disc brake
Rear brake Disc brake

Suspension specifications

Project Min Max
Front Spring length 260mm 320mm
Rear Spring length / /

1.4 Main parts position

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
2.Circuit diagram
3.Precautions
  • Power must be turned off and battery connector disconnected before maintenance.
  • No maintenance operations are allowed while the battery is charging.
  • Avoid short circuits, squeezing, and dropping when handling the battery.
  • If severe aging or burning is found in the wiring, stop using the device immediately.
  • Non-professionals should not disassemble the controller or motor's internal structure.
  • Do not perform maintenance while the power is on in rainy or humid conditions.
4.Commonly used tools
  • Phillips/flathead screwdrivers.
  • Hex wrenches (4mm / 5mm / 6mm).
  • Adjustable wrenches/socket wrenches.
  • Multimeter (voltage, resistance testing).
  • Needle-nose pliers/diagonal pliers.
  • Cable ties, insulating tape.
5.Main component structure description
5.1 Battery
  • Common Specifications: 72V106AH.
  • Type: Lithium battery.
  • Location: Under the cargo box.

5.2 Electric motor

  • Type: Brushless motor..
  • Power: 2900W/3000W
  • Driven by a controller.
5.3 Controller
  • Function: Controls motor speed and current output.
  • Common problems: Water ingress, loose connectors, aging components.
5.4 Brake system
  • Front wheel brake type: disc brake.
  • Rear wheel brake: disc brake.

6.Routine maintenance items
6.1Weekly check
  • Check tire pressure.
  • Check brake sensitivity.
  • Check battery securely mounted.
  • Check battery wiring is correct.
6.2 Monthly check
  • Check the wiring harness for wear and aging.
  • Check the front and rear wheel axle nuts for looseness.
  • Check the lights and horn for proper functioning.
6.3 Quarterly check
  • Check if the battery voltage is normal.
  • Check if the controller shows signs of water ingress or overheating.
  • Check the brake pad wear.
  • Check the vehicle's wiring and bolts for proper functioning.
7.Common problems and troubleshooting methods
7.1 The vehicle has no power or can not started

Possible causes:

  1. Battery depleted or aged.
  2. Circuit breaker tripped.
  3. Loose or oxidized battery connections.
  4. Damaged key switch.

Solutions:

  1. Check battery voltage, fully charge and try again.
  2. Reset or replace the circuit breaker.
  3. Re-tighten and clean battery connections.
  4. Replace the key switch.

7.2 Battery life is significantly shorter

Possible causes:

  1. Battery aging (common after 1.5–2 years).
  2. Insufficient tire pressure.
  3. Prolonged overloading and frequent hill climbing.
  4. Decreased controller efficiency.

Solutions:

  1. Replace with a battery of the same specification.
  2. Inflate the tires properly.
  3. Control the load and avoid prolonged high current operation.
  4. Inspect or replace the controller.

7.3 the vehicle cannot charge / charger not working

Possible causes:

  1. Charger damaged.
  2. Loose or burned charging port.
  3. Failed battery cell.

Solutions:

  1. Replace the charger and try again.
  2. Inspect or replace the charging port.
  3. Inspect the battery and replace any faulty cells.

7.4 No movement when accelerating/ Intermittent movement

Possible causes:

  1. Poor contact in the motor Hall sensor wire.
  2. Controller malfunction.
  3. Brake power-off switch stuck.

Solutions:

  1. Check if the Hall sensor connector is loose.
  2. Replace the controller.
  3. Check the brake return mechanism; replace the brake switch if necessary.

7.5 Abnormal noise during driving

Possible causes:

  1. Worn motor bearing.
  2. Insufficient lubrication in the rear axle gears.
  3. Loose wheel nuts.

Solutions:

  1. Replace the motor bearing.
  2. Lubricate the rear axle gears.
  3. Tighten all wheel bolts.

7.6 Weak Start / Difficulty Climbing Hills

Possible Causes:

  1. Low battery voltage.
  2. Insufficient controller power.
  3. Insufficient or aged motor wiring.

Solutions:

  1. Replace or upgrade the battery.
  2. Upgrade the controller with matching power.
  3. Inspect or replace the motor wiring harness.

7.7 Unsuccessful brakes / Uneven braking

Possible Causes:

  1. Brake cable stretched.
  2. Worn brake pads.
  3. Uneven left and right brake adjustment.

Solutions:

  1. Adjust or replace the brake cable.
  2. Replace the brake pads.
  3. Readjust the left and right brake clearance.

7.8 The car doesn't move after releasing the brake

Possible causes:

  1. Brake power cut-off switch not reset.
  2. Brake cable stuck.

Solutions:

  1. Replace the brake power cut-off switch.
  2. Add lubricant to the brake cable or replace it.

7.9 Lights doesn’t work/ Instrument panel not displaying

Possible causes:

  1. Blown fuse.
  2. Poor wiring connection.
  3. Damaged DC converter.

Solutions:

  1. Replace the fuse.
  2. Check the wiring connectors.
  3. Replace the DC converter

7.10 Turn signals not flashing or constantly on

Possible causes:

  1. Damaged flasher unit.
  2. Incompatible bulb wattage.

Solutions:

  1. Replace the flasher unit.
  2. Use a bulb with the correct wattage.
8.Battery usage and maintenance instructions
  1. It is recommended to fully charge the battery before using the new car for the first three times.
  2. If the car is not used for a long period of time, it should be charged once a month.
  3. Avoid completely depleting the battery.
  4. Reduced range in low-temperature winter environments is normal.
9.Disclaimer
       This manual is a general repair reference document. Due to differences between brands and models, actual repair operations should be based on the specific vehicle structure. The manufacturer and publisher shall not be liable for any losses caused by improper repairs.

HANGZHOU HORECA TECHNOLOGY CO., LTD

Add: Room 2603, Lvdu Jiarui Building, Beigan Street, Xiaoshan District, Hangzhou, Zhejiang, China.

Web: //www.amoto.group/

Phone: +86 136 5666 4161

Email: lucia@horeca-pos.cn

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