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• Page 1
  HAMMERHEAD CHARGER 48V Electric Vehicle Operator’s Manual…

• Page 2: Table Of Contents

  HAZARD LIGHT SWITCH ……………………  1 2   SPEEDOMETER  ……………………..  1 2   ACCELERATOR PEDAL ……………………  1 3   BRAKE PEDAL ……………………..  1 3   PARKING BRAKE LEVER  ……………………  1 3   BED USE …………………………  1 4   MANUAL LIFT BED OPERATION ………………….  1 5   TAIL GATE OPERATION ……………………  1 6   OPERATING THE VEHICLE ……………………  1 7   Hammerhead Charger Electric Vehicle Operator’s Manual  Page 1   …

• Page 3
  Brakes ………………………..  2 4   Rear Axle  ……………………….  2 4   Fasteners ……………………….  2 4   BATTERIES AND CHARGING ……………………  2 5   Batteries ……………………….  2 5   Charger ……………………….  2 5   GENERAL SPECIFICATIONS  ……………………  2 6   LIMITED WARRANTY POLICY …………………….  2 8         Hammerhead Charger Electric Vehicle Operator’s Manual  Page 2   …

• Page 4: Safety Information

    No warning can take place of good  common sense and prudent driving practices.  With electric powered vehicles, be sure that all electrical accessories are grounded  directly to the (‐) post.    Never uses chassis or body as a ground connection.    Never  modify the vehicle in any way that will alter the weight distribution of the vehicle,  decrease its stability or increase the speed beyond the factory specification.    Such  modifications can cause serious personal Injuries or death.    Do not make any such  modifications or changes.    The manufacturer prohibits and disclaims responsibility  for any such modifications or any other alternation which would adversely affect and  safety of the vehicle.    Once  again  thank  you  for  purchasing  Hammerhead  product,  and  we  hope  you  will  have an enjoyable experience.      Hammerhead Charger Electric Vehicle Operator’s Manual  Page 3   …

• Page 5: General Operation Instructions

  Never  charge  a  battery  in  an  area  that  is  subject  to  flame  or  spark.    Pay  ‐ particular attention to natural gas or propane gas water heaters and furnaces.   Battery  charger  must  be  operated  according  to  manufacturer’s  instructions.    ‐ Please  refer  to  battery  charger’s  separate  operator’s  manual  for  further  instructions.   Hammerhead Charger Electric Vehicle Operator’s Manual  Page 4   …

• Page 6: Display Of Warning Labels

  DISPLAY WARNING LABELS        Following are the warning labels affixed to the vehicles; read, observe and follow all  warning and operation instructions carefully.    Failure to follow these warnings can  result in series injuries or death.        Hammerhead Charger Electric Vehicle Operator’s Manual  Page 5   …

• Page 7
  DISPLAY OF WARNING LABELS ‐ 2          Hammerhead Charger Electric Vehicle Operator’s Manual  Page 6   …

• Page 8: Display Of Controls

    DISPLAY OF CONTROLS   1. Steering Wheel  2. Combination Lever  3. Digital Speedometer  4. Key Switch / Light Switch  5. Directional Selector  6. State of Charging Meter  7. Hazard Switch  8. Radio (optional)  9. Glove Compartment  10. Brake Pedal  11. Accelerator Pedal  12. Front Batteries access panel                      Hammerhead Charger Electric Vehicle Operator’s Manual  Page 7   …

• Page 9: Before Initial Use

  Five  air  exchanges per hour is considered the minimum requirements.    Never charge a battery in an area that is subject to flame or spark.    Pay particular  attention to natural gas or propane gas water heaters and furnaces.   Before a new vehicle is put into operation, the “Initial Service Check List” below must  be  performed  to  ensure  safety  operation  of  the  vehicle.    Determine  and  record  braking distance required to stop vehicle for future brake performance tests.      Initial Service Check List  Fully charge batteries  Check brake operation and adjust if necessary  Check brake hydraulic brake fluid level  Check parking brake and adjust if necessary  Check accelerator pedal and brake pedal make sure they are not sticking  Check tire pressure (see SPECIFICATION)  Check head lights, turn signals, brake lights      Hammerhead Charger Electric Vehicle Operator’s Manual  Page 8   …

• Page 10: Batteries

  There  are  another  four  batteries  located  underneath the bench seat.    (See location image below)      ON‐BOARD CHARGER    The 110‐Volts Delta‐Q onboard charger is located under the seat on the driver’s side  of the vehicle (see image below).    It is wired directly to the batteries. There is also a  charging port below the driver’s seat that can be plugged directly into any 110 Volt  wall  outlets.    (See  location  image  below).    For  more  information  about  Delta‐Q  Charger, please reference included copy of Delta‐Q charger’s operators manual.          Hammerhead Charger Electric Vehicle Operator’s Manual  Page 9   …

• Page 11: Controls And Indicators

    To  prevent  inadvertent  operation of the vehicle when left unattended, the key should be turned to the ‘OFF’  position  and  removed.    The  key  switch  also  has  a  position  for  turn  on  the  head  lights.    (See image below)          Hammerhead Charger Electric Vehicle Operator’s Manual  Page 10   …

• Page 12: Direction Selector

  )      URNING  IGNALS   IGH  EAM  IGHTS   Much  like  a  car’s  turning  signal  lever,  this  combination  lever  is  located  below  the  steering wheel on the steering column operates turning signals, high/low beam lights  and horn.    Push down on the combination lever to signal turning left, push up the  lever to signal turning right.    Push in on the lever to turn on high beam, pull back on  the lever to turn on the high beam.    Push in on the end of the lever to horn.    (See  image below)  Hammerhead Charger Electric Vehicle Operator’s Manual  Page 11   …

• Page 13: Hazard Light Switch

  Digital  speedometer  is  located  in  the  middle  of  the  console.    It  displays  current  speed  information  in  MPH,  as  well  as  odometer  in  Miles.    At  the  bottom  of  the  speedometer  are  turning  signal  indicators,  parking  brake  indicator  and  high  beam  indicator. (See image below)      Hammerhead Charger Electric Vehicle Operator’s Manual  Page 12   …

• Page 14: Accelerator Pedal

  With  the  key  switch  “ON”,  release  the  parking  brake,  depressing  the  accelerator  starts the motor.    When pedal is released, the motor will stop.    To stop the vehicle  more quickly, depress the brake pedal. (See image below)    BRAKE PEDAL    This vehicle is equipped with hydraulic brake system that controls a set of four brake  discs; one on each wheel.    To slow down the vehicle or to stop the vehicle, depress  the brake pedal. Depressing the brake pedal further will increase the effectiveness of  braking.    (See Image Below)      PARKING BRAKE LEVER      This vehicle is equipped with parking brake lever.    Push the release button and then  pull the parking brake lever up to active parking brake.    When parking the vehicle,  pull up the parking brake and then turn the key to “OFF” position. (See image below)    To release the parking brake, push the release button in and then push the parking  brake lever down.  Hammerhead Charger Electric Vehicle Operator’s Manual  Page 13   …

• Page 15: Bed Use

  Never  fill  a  gas  can  in  bed  of  a  vehicle.    Static  discharge  could  ignite  gasoline  vapor and cause an explosion.  Always place a gas can on the ground before filling.    NEVER fill a gas can in the bed  of  the  vehicle.    Static  electricity  is  build  up  during  the  fueling  process  and  could  discharge causing the gasoline vapor to ignite.    Hammerhead Charger Electric Vehicle Operator’s Manual  Page 14   …

• Page 16: Manual Lift Bed Operation

  Raise  the  bed  using  handle  on  the  side  of  the  bed.    The  gas  struts  will  assist  in  raising the empty load bed and will keep the bed raised.      To  lower  the  manual  lift  bed,  grasp  the  bed  handle  and  lower  the  bed  to  the  rest  position.    Be sure fingers are not trapped by the bed.        Hammerhead Charger Electric Vehicle Operator’s Manual  Page 15   …

• Page 17: Tail Gate Operation

  TAIL GATE OPERATION      There  are  two  tailgate  switches  located  on  the  top  side  of  the  bed.  To  open  the  tailgate, push the small tab forward on the switch, and pull back the locking plate.    (See image below)    To close the tailgate, hook the tailgate latch and push down on  the locking plate.          Hammerhead Charger Electric Vehicle Operator’s Manual  Page 16   …

• Page 18: Operating The Vehicle

  Never drive vehicle up, down or across an incline that exceeds 14 degrees.  STARTING DRIVING        To  avoid  the  possible  of  roll  back  which  could  result  in  severe  injury  or  vehicle  damage, do not release the brake until motor has started.  Remove  charger  plug  from  vehicle  receptacle  and  properly  store  the  cables  before  moving the vehicle.  To operate vehicle:  Hammerhead Charger Electric Vehicle Operator’s Manual  Page 17   …

• Page 19: Staring Vehicle On Ahill

  Note:  When  the  direction  selector  is  in  the  reserve  position,  a  warning  signal  will  sound to indicate that the vehicle is ready to run in reverse.  STARING VEHICLE HILL            To reduce the possibility of roll‐back which could result in severe injury or vehicle  damage, do not release the parking brake lever until motor has started.    Do not hold the vehicle on a hill by using accelerator and motor.    Leaving motor in  a stalled condition for more than 3‐4 seconds will cause permanent damage to the  motor.  To reduce the possibility of permanent damage to the drive system, it is important to  prevent excessive roll‐back when starting the vehicle on a hill.  Place left foot on foot brake and release the parking brake.    Depress the accelerator  with right foot and release the foot brake by lifting the left foot.      Hammerhead Charger Electric Vehicle Operator’s Manual  Page 18   …

• Page 20: Vehicle Clearning And Care

  VEHICLE CLEARNING CARE        When cleaning the exterior of the vehicle, do not use pressure in excess of 700 psi.    To  reduce  the  possibility  of  cosmetic  damage,  do  not  use  any  abrasive  or  reactive  solvents to clean plastic parts.  Normal cleaning of vinyl seats and plastic or rubber trim requires the use of a mild  soap solution applied with a sponge or soft brush and wipe with damp cloth.    Rinse  with clear water.            Hammerhead Charger Electric Vehicle Operator’s Manual  Page 19   …

• Page 21: Repair

  The  vehicle  is  fitted  with  low  pressure  tubeless  tires  mounted  on  one  piece  rims;  therefore, the most cost effective way to repair a puncture in the thread is to use a  commercial tire plug.  FUSE REPLACEMENT    To replace fuses, locate the fuse block under the bench seat.    Pull out old fuse and  replace  with  new  fuse.    Fuses  are  available  from  local  authorized  repair  center.      Hammerhead Charger Electric Vehicle Operator’s Manual  Page 20   …

• Page 22
  (See images below).    There are three types of fuses used on this vehicle, see wiring  diagram for details.        Do not attempt any type of repairs beyond your technical skills; contact your local  authorized repair center for help.    Unauthorized repairs can cause serious safety  hazard to the operator, as well as permanent damage to the vehicle.      Hammerhead Charger Electric Vehicle Operator’s Manual  Page 21   …

• Page 23: Service And Maintenance

  EHICLE  DENTIFICATION  LATE  OCATION The  vehicle  Identification  plate  is  on  the  vehicle  behind  the  driver’s  seat.    (See  image below).    Design changes take place on an ongoing basis.    In order to obtain  the  correct  components  for  the  vehicle,  the  VIN  number  must  be  provided  when  ordering service parts.  Hammerhead Charger Electric Vehicle Operator’s Manual  Page 22   …

• Page 24: Periodic Maintenance Schedule

  To  perform  service  that  is  in  this  schedule  but  not  described  in  this  manual,  contact  a  local  authorized service center for this vehicle.  Daily Service  Before Use:  Check brake operation  Check parking brake operation  Check warning device function in reverse  Check Lights, turning Signals, Horns  Check tire condition  Check overall vehicle condition  Recharge battery to full state of charge after each day’s use  Weekly Service  Tires: Exam for cuts, excessive war and pressure  Wheels: Check for bent rims, missing or loose lug nuts  Monthly Service or Every 20 Hours (includes list in weekly service above)  Front Axle: Check for damage to axle and loose or missing hardware  Shock Absorbers: Check front and rear shock absorbers for oil leakage and loose fasteners  Front Wheel Alignment: Check for unusual tire wear, align if required  Parking Brake: Check for bent/binding linkage rod.  Hardware and fasteners: Check for loose or missing hardware and components.  Semi‐Annual or Every 125 Hours (includes list in previous service above)  Direction Selector: Check for wear and smooth movements  Steering Assembly: Check for rack and pinion seal or damage or grease leakage  Rod End ball Joints: Check for excessive play, Lubricate.  Rear Axle: check for unusual noise and loose or missing mounting hardware  Annual or Every 250 Hours (includes list in previous service above)  Front wheel bearings: Check and adjust as required.  Rear Axle: Check lubricant, add lubricant (SAE 30 oil) as required  Brake: Clean and adjust.    Check for brake pads linings.    Check brake fluid.  Hammerhead Charger Electric Vehicle Operator’s Manual  Page 23   …

• Page 25: Tire Inspection

  To  reduce  the  possibility  of  severe  injury  or  death,  always  evaluate  pedal  travel  before operating a vehicle to verify some braking function is present.  Check master cylinder fluid annually or if there is a decrease in braking effectiveness.    Inspect components for damage or wear.        EAR  The rear axle is provided with a lubricant level check/fill plug located on the bottom  of  the  differential.    Unless  leakage is  evident,  the  lubricant  need  only be  replaced  after five years.      ASTENERS Periodically, the vehicle should be inspected for loose fasteners.      Hammerhead Charger Electric Vehicle Operator’s Manual  Page 24   …

• Page 26: Batteries And Charging

  If  the  electrolyte  level  is  barely  covering  the  plates,  add  distilled  or  de‐ionized  water to a level 1/8” (3mm) below the vent well (this is the plastic shield inside  the vent hole) for standard batteries and to the maximum (MAX) level indicator  for PLUS Series batteries.  After adding water, secure vent cap back on batteries.  This  vehicle  uses  Deep  Cycle  Deep  Acid  battery  from  Trojan.    Please  read  “Trojan  Battery Users Guide” for more information.      HARGER   The Delta‐Q charger is programmed to run Trojan batteries.    If batteries need to  be changed, please contact your authorized dealer for compatibility questions.    This vehicle uses a 48 Volt Delta‐Q Charger.    Please read included “Delta‐Q Charger  Owner’s Manual” for more information.  Hammerhead Charger Electric Vehicle Operator’s Manual  Page 25   …

• Page 27: General Specifications

  Six 8 Volts Deep Cycle Battery  Charger  220 Volt Delta‐Q On Board Charger  Top Speed  25 MPH  Front Tire  Tubeless 21 x 8 ‐10  Front Tire Pressure  Maximum 36 PSI  Rear Tire  Tubeless 23 x 8.5 ‐ 12  Rear Tire Pressure  Maximum 36 PSI  Weight  990 lbs (450 KG)  Length  85” (2330 mm)  Width    49” (1300 mm)  Height  71” (1750 mm)  Wheelbase  63” (1600 mm)  Ground Clearance  8.6” (220 mm)  Cargo Bed Capacity  39” x 23” x 11” (970 x 590 x 280 mm)  Vehicle Payload  1200 Lbs (550 KG)    *Specification subject to change without notice           Hammerhead Charger Electric Vehicle Operator’s Manual  Page 26   …

• Page 28
                Hammerhead Charger Electric Vehicle Operator’s Manual  Page 27   …

• Page 29: Limited Warranty Policy

  This  warranty  does  not  cover  damage  or  faults  caused  by  misuse,  negligence,  alternation, accidents or any abnormal use including the use of none genuine replace  parts, renting or leasing, competition or racing.    This warranty does not cover loss  of  use  of  the  vehicle  or  loss  of  time,  inconvenience.    This  warranty  also  does  not  cover  normal  wear  and  deterioration  of  consumable  items  such  as  tires,  brakes,    suspension parts, light bulbs, tires, batteries and etc.   Hammerhead Charger Electric Vehicle Operator’s Manual  Page 28   …

• Page 30
  TROJAN BATTERY USER’S GUIDE Congratulations on your purchase from Trojan Battery Company, the manufacturer of the world’s most trusted deep cycle batteries. The battery you purchased was engineered by Trojan to deliver superior power, performance, durability and reliability for use in a broad range of demanding applications.
• Page 32
  TROJAN BATTERY USER’S GUIDE Table of Contents Equipment Needed …………4 Battery Installation .

• Page 34: Equipment Needed

  TROJAN BATTERY USER’S GUIDE This User’s Guide was created by Trojan’s applications engineers and contains vital information regarding proper care and maintenance of your new battery. Please read through this user’s guide carefully and completely before using your battery. It will help you achieve optimum performance and long life from your new investment.

• Page 35: Battery Connections

  TROJAN BATTERY USER’S GUIDE Battery Connections 2.2. Battery cables provide the link between the batteries, equipment and charging system. Faulty connections can lead to poor performance and terminal damage, meltdown or fire. To ensure proper connections, please use the following guidelines for cable size, torque values and terminal protection.

• Page 36: Torque Values

  Torque Values 2.2.2. Tighten all cable connections to the proper specification to make sure there is good contact with the terminals. Over-tightening the connection to the terminal can result in terminal breakage and loose connections which can result in meltdown or fire. Refer to Table 2 for the proper torque values based on the type of terminal on your battery.

• Page 37: Connecting Batteries To Increase System Power

  TROJAN BATTERY USER’S GUIDE Connecting Batteries to Increase System Power 2.4. Series Connections 2.4.1. To increase voltage, connect batteries in series. This will not increase the system capacity. Refer to Diagram 1 for series connections. Diagram 1 Example : Two T-105, 6V Batteries rated at 225AH Connected in Series System Voltage: 6V + 6V = 12V System Capacity = 225AH…

• Page 38: Series/Parallel Connections

  Series/Parallel Connections 2.4.3. To increase both voltage and capacity, connect additional batteries in series and parallel. Refer to Diagram 3 for series/parallel connections. Diagram 3 Example : Four T-105, 6V Batteries rated at 225AH Connected in Series/Parallel System Voltage: 6V + 6V = 12V System Capacity = 225AH + 225AH = 450AH Battery Orientation 2.5.

• Page 39: Preventative Maintenance

  TROJAN BATTERY USER’S GUIDE Preventative Maintenance Inspection 3.1. • Examine the outside appearance of the battery. The tops of the batteries and terminal connections should be clean, free of dirt and corrosion, and dry. Refer to section 3.2 Cleaning • If fluids are on the top of a flooded/wet battery this may mean that the battery is being over-watered.

• Page 40: Watering (Flooded/Wet Batteries Only)

  Watering (flooded/wet batteries ONLY) 3.3. Water should never be added to gel or AGM batteries as they do not lose water during use. Flooded/wet batteries need to be watered periodically. The frequency depends upon battery usage and operating temperatures. Check new batteries every few weeks to determine the watering frequency for your application.

• Page 41
  TROJAN BATTERY USER’S GUIDE Table 3 Recommended Maximum Allowable Impurities In Water for Battery Use Impurity Parts Per Million Effects of Impurity Color Clear and “White” Suspended Matter Trace Total Solids 100.00 Organic and Volatile 50.0 Corrosion of positive plate Matter Ammonia Slight self-discharge of both plates…

• Page 42: Charging And Equalizing

  Charging and Equalizing 3.4. Charging 3.4.1. Proper charging is imperative to maximize battery performance. Both under- or over-charging batteries can significantly reduce the life of the battery. For proper charging, refer to the instructions that came with your equipment. Most chargers are automatic and pre-programmed.

• Page 43
  TROJAN BATTERY USER’S GUIDE Diagram 5 Recommended Trojan Deep-Cycle Gel™ Charging Profile Voltage Current (per cell) (Amps) Charge Current 2.35V to 2.40V Total Charge Input is (@ 25 C , 77 105 to 109% of Amp Hours of Capacity Removed Charge Voltage Approximately C /200…

• Page 44: Equalizing (Flooded/Wet Batteries Only)

  Equalizing (flooded/wet batteries ONLY) 3.4.2. Equalizing is an overcharge performed on flooded/wet batteries after they have been fully charged. Trojan recommends equalizing only when batteries have low specific gravity, below 1.250 or wide ranging specific gravity, 0.030, after fully charging a battery. Gel or AGM batteries should never be equalized. •…

• Page 45
  TROJAN BATTERY USER’S GUIDE Table 4 State of Charge as a measure of Specific Gravity and Open- Circuit Voltage Open Circuit Voltage Percentage Specific Charge Gravity Cell 6 Volt 8 Volt 12 Volt 1.277 2.122 6.37 8.49 12.73 1.258 2.103 6.31 8.41 12.62…

• Page 46: Storage In Hot Environments (Greater Than 90°F Or 32°C)

  Storage in Hot Environments (greater than 90°F or 32°C) 4.1. Avoid direct exposure to heat sources, if possible, during storage. Batteries self- discharge faster in high temperatures. If batteries are stored during hot, summer months, monitor the specific gravity or voltage more frequently (approximately every 2-4 weeks).

• Page 47: Trouble-Shooting

  TROJAN BATTERY USER’S GUIDE Trouble-Shooting These battery testing procedures are guidelines only for identifying a battery that may need to be replaced. Unique situations may be observed that are not identified within this procedure. Please contact Trojan Battery Company’s technical support engineers at 800-423-6569 or +1-562-236-3000 for help interpreting the test data.

• Page 48: Specific Gravity Testing

  Specific Gravity Testing (flooded/wet batteries ONLY) 7.3. • Fill and drain the hydrometer 2-3 times before drawing a sample from the battery • Measure specific gravity readings for all battery cells • Correct specific gravity readings for temperature by adding 0.004 for every 10°F (5°C) above 80°F (27°C) and subtract 0.004 for every 10°F (5°C) below 80°F (27°C) •…

• Page 49: Discharge Testing

  TROJAN BATTERY USER’S GUIDE Discharge Testing 7.5. • Connect and start discharger • Record the runtime (minutes) when discharge is complete • Correct runtime minutes for temperature using the following formula (valid between 24°C (75°F) and 32°C (90°F): o Mc = Mr [1 – 0.009 (T — 27)] where Mc is the corrected minutes, Mr is the minutes recorded and T is the temperature at the end of discharge in °C •…

• Page 50: Battery Recycling

  TROJAN BATTERY USER’S GUIDE Battery Recycling Lead-acid batteries are the environmental success story of our time because more than 97 percent of all battery lead is recycled. In fact, lead-acid batteries top the list of the most highly recycled consumer products and Trojan Battery supports proper recycling of your battery to keep the environment clean.

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  TROJAN BATTERY USER’S GUIDE Trojan Battery Company would like to thank you for selecting our battery. With over 80 years of experience, Trojan Battery is the world’s most trusted name in deep cycle battery technology backed by our outstanding technical support. We look forward to serving your battery needs.
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  Notes…
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  For more information call 800-423-6569 or +1-562-236-3000 www.trojanbattery.com…

• Page 54: Safety Instructions

  User’s Guide SAVE THESE IMPORTANT INFORMATIONS IMPORTANTES DE SÉCURITÉ SAFETY INSTRUCTIONS Ce manuel contient des instructions importantes This manual contains important safety and operating concernant la sécurité et le fonctionnement. instructions – read before using charger. Attention: Utiliser le chargeur seulement avec un algorithme Warning: Use charger only with an algorithm selected that is approprié…

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  4. Optional Charger Single-LED Display (internal or external) LED Colour Indication (following “Power-On Self Test”) Green Solid: Charging complete. Charger in Maintenance Mode. Flashing: Short: <80% Charge. Long: >80% Charge. When battery is not connected: Algorithm Number display. Amber Flashing: Reduced Power Mode: Low AC Voltage or High internal charger temperature.