vehicles that run on fun! | etuk usa - owners …...some basic maintenance procedures. these...

Owners Manual

eTuk USA, LLC

© eTuk USA

Table of Contents

• Quick Start Guide p. 3-4 • Vehicle Controls & Equipment p. 5-7 • Battery Display Indicator p. 8 • Maximum Load p. 9 • Safety p. 10 • Driving Conditions p. 11 • Tips On Extending Vehicle Range p. 12 • Battery Information p. 13-18 • Charging The Vehicle p. 19-22 • Electrical p. 23-25 • Fluids p. 26-27 • Jacking & Changing Tires p. 28 • Eliminating Vibration & Towing p. 29 • Trouble Shooting p. 30-33 • Preventative Maintenance p. 34-35 • Your eTuk Info p. 36 • Service & Maintenance History p. 37-44

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© eTuk USA

Quick Start Guide

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© eTuk USA

Quick Start Guide

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The display will switch on and you will hear two clicking sounds. One louder than the other. Check the state of charge and if possible the Ub or System voltage. If it is around 76V your battery is full

Make sure the parking brake is released.

First ensure the driver and all passengers are wearing their seatbelts. Put the direction switch in D to drive forwards and R to drive backwards. Gently twist the throttle to engage the motor

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Vehicle Controls & Equipment

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1) Windscreen Washer 2) Windscreen Wiper 3) Taxi Light (if Equipped) 4) Windscreen Washer Fluid 5) Indicator Display 6) Speedometer & Odometer 7) Battery Display Indicator

(BDI) 8) Charger LED Indicator (If

activated) 9) Ignition Switch 10) Throttle 11) Direction Switch 12) Hazard Light Switch 13) 12V Outlet 14) Kill Switch

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• By pressing the brake pedal with your right foot you will engage the friction brakes.

• Turn the throttle to accelerate. By releasing the throttle handle the vehicle will automatically use the motor to slow down and stop (and in the act also recharge the batteries). The easier you are on the throttle and brakes, the further one single battery charge will take you.

• Familiarize yourself with the controls on the steering bar switch before you start driving

• Your Tuk Tuk comes with a working Hi/Lo center headlight. The two auxiliary lights are not functional upon delivery.

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Battery Display Indicator (BDI)

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This is the Battery Display Indicator (BDI). It displays the battery level and up to date driving information. The indicator is an approximation of remaining charge and not an exact calculation. At times, you may not see all bars illuminated even though you have a full 76 volt charge. This is not a major concern and usually resetting the ignition will correct the problem. The vehicle will enter limp-home mode soon after the vehicle displays 3-4 Bars.

The display alternates between 4 values: Ub, r, A, h, T and O. You can push the display button to manually select display parameters.

Ub The voltage being drawn from the battery

r RPM (Rotations Per Minute) of the engine

A Total number of Amperes drawn from the battery

h Total driving time of the vehicle in hours

T Temperature of the controller (on some models)

O Total mileage of the vehicle in miles (on some models)

There are two 12V outlets compatible with any 12V car appliance (rated up to a max of 10A). Be sure not to get any wires entangled with the steering mechanism. Note the range of the vehicle will be directly impacted by the load placed on the vehicle though these outlets.

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Maximum Load

• Each eTuk USA Tuk Tuk is rated and marked with a maximum Gross Vehicle Weight Rating (GVWR) in order to maintain compliance with all applicable Federal Motor Vehicle Safety Standards (FMVSS) for the stock tires installed on the vehicle. In addition, each vehicle is rated and marked with a maximum Gross Axel Weight Rating (GAWR) and tire inflation pressure on the VIN Label attached to the vehicle. Those maximum ratings are as follows:

• Short Body Classic, Cargo and Vendor

– GVWR = 2622 lbs (1189 kg)

– Front GAWR = 805 lbs (365 kg)

– Rear GAWR = 1817 lbs (824 kg)

• Long Body Limo, Cargo XL and Vendor XL

– GVWR = 2908 lbs (1319 kg)

– Front GAWR = 789 lbs (358 kg)

– Rear GAWR = 2119 lbs (961 kg)

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http://upload.wikimedia.org/wikipedia/commons/d/dc/400x400px-pounds_weight.svg

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Safety

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There is a Kill Switch located on the right handle bar accessible in the normal driving position. Setting the switch to the “OFF” position will disable the motor. Keep in mind that this will not stop the vehicle. You will still have to apply pressure to the foot brake for that. The motor will not function again until the Kill Switch is set back to the “On” Position

Your eTuk is equipped with a steering column lock. To engage the lock, turn the handlebars all the way to the right, then turn the key counter-clockwise all the way to the left. Now remove the key and the handlebars are locked in position.

Seatbelts are available in all positions. Seatbelts must be worn at all times.

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Driving Conditions

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Weather conditions may affect the performance and range of the vehicle. High Temperatures (Over 95 Degrees F) combined with high payloads may cause the motor and/or the controller to overheat. Drive calmly and at a steady pace and give the motor time to cool down occasionally.

Cold weather reduces the range of the vehicle, as cold batteries hold less energy. We recommend storing vehicles indoors in a warm environment should outdoor temperatures drop. The ideal ambient temperature for eTuk batteries is 80 Degrees Fahrenheit.

Driving uphill requires more power from the motor and draws more energy from the batteries. In turn the range of the eTuk may be degraded in hilly environments.

eTuks are rated to climb hills up to 20 Percent (11.3 degrees).

When on a hill in a stationary position do not use the throttle to prevent the vehicle from rolling down the hill. This will cause the controller to overheat. Instead use the brake pedal as you would in a normal vehicle. When starting from a stop on a hill, apply the throttle then release the foot-brake. Your vehicle may roll back slightly before taking off.

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Tips on extending vehicle range

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Properly inflated tires reduce road friction. The recommended tire pressure is 44 PSI (3 Bars). Check/adjust your tire pressure on a regular basis (at-least once a month)

The heavier the weight the more power required to drive the vehicle. For maximum range leave unnecessary items behind.

Driving to a place with electricity? Take the opportunity to charge on the spot.

Aggressive driving (Fast acceleration and high speeds) draws more power from the batteries. Take it easy on the throttle to extend your range.

Anticipating stop lights can make your ride more comfortable. Releasing the throttle engages the engine brake, and recharges your battery. Using the engine brake has the dual benefit of charging your battery and reducing ware on the disc-brakes

http://upload.wikimedia.org/wikipedia/commons/d/dc/400x400px-pounds_weight.svg

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Battery Information

Health:

Your eTuk’s battery system is one of the major components of the vehicle. It gives you the energy to get where you need to go. To maintain battery system health requires some basic maintenance procedures. These procedures are based on Trojan’s (the manufacturer) recommendations. Not following the maintenance procedures may invalidate your battery warranty and result in shortened life. Additional information can be found on the next few pages.

Safety:

• All battery maintenance, except for cleaning and watering, should be done by an authorized service mechanic. Always wear protective clothing, gloves and goggles when handling batteries.

• Keep flames, sparks or metal objects away from batteries (use insulated tools)

• Neutralize acid spills with baking soda immediately

• Charge with vent caps securely in place

• Ensure proper ventilation while charging to prevent explosive gas build up

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Battery Information

Inspection and cleaning:

• Keep batteries clean and dry

• Check that all vent caps are tight

• Check that all connections are tight (fastening torque is 8.1 ft-lbs)

• In the event of acid residue buildup or battery corrosion use a solution of baking soda and water to clean the batteries.

• Terminal protectors or protective spray can be applied to reduce corrosion

Storage:

• Batteries should be fully charged prior to and during storage

• Never store discharged batteries

• Store batteries in a cool, dry place to minimize self-discharge

• Recharge batteries prior to putting them back into service to ensure they are fully charged

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Battery Information

Watering:

• Add distilled water only to cells

• Never add acid to cells this is dangerous and will alter the chemistry

• Only add distilled water to fully charged batteries. Let the batteries cool down after charging before adding water

• If the plates are exposed in discharged batteries, add water to a level just above the lead plates

• Add water to the maximum level indicator

• Do not overfill the batteries

Charging:

• Batteries should be charged after every use to ensure they are never stored in a discharged condition

• If batteries are stored for extended periods of time they should be charged approximately every 6 weeks

• Lead-acid batteries DO NOT have a memory effect (they do not need to be fully discharged prior to charging)

• The charging cycle should always be finished completely to ensure battery life

• If charging cycles have been cut off, equalization should be done. See “Equalization” section

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Battery Information

Battery Specs:

Standard eTuks have been fitted with 12 Lead-Acid Deep Cycle batteries. Each battery produces 6 Volts and around 185Ah. The total battery pack gives your vehicle 72V to power the motor and electronics.

eTuks can be fitted with a variety of battery models. Many function in a similar manner and should be serviced with the same procedures. However, different models cannot be used simultaneously. Any damaged battery should be replaced with the same brand and model.

Watering Systems:

Your eTuk’s battery needs regular watering. Watered batteries are critical to battery functionality. During heavy use the batteries heat up and the water evaporates. Regular filling (see “Maintenance schedule”) is recommended. Monitoring the amount of water that goes in during filling will give you a good indication of your water use. Experience will teach you if you can extend the filling schedule.

Watering can be done per battery cell or, if you have a filling system, in one action for the entire pack.

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• Only add distilled water to fully charged batteries, with the exception of when battery plates are exposed (visible above the water). If plates are exposed, add distilled water prior to charging

• Never add batteries while still hot from use/charging • Never overwater your batteries. Watering while using a filling system

should only take 20-30 seconds. Overwatering can cause acid leaks that will corrode the batteries and surrounding structure.

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Watering the battery manually

• Ensure the vehicle is off and the keys removed

• Ensure that the vehicle is fully charged and the charger is un-plugged

• Access the batteries through the floor hatch

• Open the vent caps and inspect the water level.

• The lead plates should be submerged, in the event they are visible add distilled water to submerge the plates per the diagram on the right.

• A clean piece of rubber can be safely used as a dipstick to help visualize the water level

• Clean, refit, and tighten all the vent caps.

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• Always wear appropriate Personal Protective Equipment (PPE) prior to conducting any work on eTuks

• Never add acid to the batteries • Battery fluid is extremely hazardous • Only use distilled or de-ionized water to refill the battery system

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Using Battery Filling Systems

If your eTuk is fitted with a Battery Filling System (BFS) you will be able to fill all batteries through a single hose. To fill the batteries:

• Ensure the vehicle is off and the keys removed

• Ensure that the vehicle is fully charged and the charger is un-plugged

• Locate the filling hose

• Connect the hose to the filling apparatus (hand pump or filling tank)

• Initiate the filling process (either via manual pumping or by placing the tank high above the batteries allowing the water to flow)

• When the liquid stops flowing the batteries are full.

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Charging

• Allow batteries to cool down for 15 minutes after charging before driving. Driving immediately after charging may damage your batteries and affect range.

• Always finish the charging sequence. Cutting off a sequence may damage your batteries and affect your range

• When using an extension cord, ensure that it is uncoiled so that it does not generate excessive heat.

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Charging Time and Equalization

Charging Time: The DeltaQ 72 V @ 12 AMP (5A nominal) is the standard charging equipment on each e-Tuk. Charging your e-Tuk with the standard equipment can take up to 14 hours to charge from 0% to 100%, with the final 5-10% taking up a significant amount of that time. WARNING: In the event you own multiple e-Tuks Only connect one eTuk to a 15A circuit at a time. Equalization: If your battery performance feels reduced or you have been unable to complete full cycle charges you may need to equalize your batteries. In order to equalize your batteries: • Charge the batteries until the charger indicates a full charge • Unplug the charger and wait 5-10 minutes • Plug the charger back in • Equalization may take up to 6 hours to perform.

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Charger Display

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Dashboard Charging LED (If Activated)

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Electrical

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Fuses

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Electrical

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Fluids

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Windshield Washer Fluid

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Jacking and Changing Tires

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Eliminating Vibration and Towing

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Troubleshooting

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Make sure the kill switch is Set to On

vehicles that run on fun! | etuk usa - owners …...some basic maintenance procedures. these...

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