User Manual & Maintenance guide Keep this booklet with your vehicle 1
Congratulations on purchasing your e-Tuk! You probably cannot wait to start driving. But, before you get started, read this manual carefully. We have put together this booklet so you can take full advantage of the capabilities of the vehicle. For your safety and the safety of your passengers, please read the instructions carefully. It provides you with helpful information, what to do in case of an error and how to get the most out of your e-Tuk.
6 ELECTRICS 24 Dashboard & handlebars 6 The Fusebox 24 Controls 8 12V Battery 26 BDI 9 FLUIDS 28 Maximum load 10 Oil 28 Safety 11 Troubleshooting 30 DRIVING CONDITIONS It’s not working! 32 Temperatures 12 BDI error messages 34 Tips to extend your range 13 VEHICLE INFO 36 BATTERY INFORMATION 14 MAINTENACE SCHEDULE 38 Battery health 14 Your eTuk’s DNA 40 Battery specs 16 Service & maintenance history 42 CHARGING Standard Charger 20 Standard charging sequ
QUICK START GUIDE Direction switch Make sure the vehicle is not being charged, the e-Tuk should not be able to drive while you are charging. Place the charging cable securely under the rear seats. Put the direction switch in neutral N , and make sure the throttle is not engaged. Ignition LO Unplug CK 4 Turn the key clockwise.
Parking brake The display will switch on and you will hear two *clicks*, one louder than the other. Make sure the park brake is released. The e-Tuk will not drive when it is engaged. Put the direction switch in D to drive forwards and R to drive backwards. Check the state of charge and if possible the Ub or system voltage. If it is around 76V your battery is full.
GETIING FAMILIAR Dashboard & handlebars A B 1 2 3 C 30 60 50 20 40 20 10 ON E OFF 6 4 5 6 5 002 0 0 mph 0 0 kmph D A Signal light B Driving lights on/off C Main beam / dip beam D Directions left / right E Horn 10 30 10 40 20 30 20 10 8 70 4
40 80 50 90 100 kmph 50 60 mph 30 2036 60 40 70 50 80 Getting familiar 1 Windscreen washer 2 Windscreen wiper 3 Taxi sign light 4 Windscreen washer fluid 5 Tell-tales display 6 Speedo- & Odometer 7 Battery Display Indicator 8 Charger LED 9 Key switch 10 Throttle 11 Direction Switch 12 Hazard light switch 13 Outlet 12volt CK LO 7 8 9 10 11 12 13 *2011 model.
Getting familiar Controls By pressing the brake pedal by your right foot you can apply mechanical stopping force on all three tyres and the motor. Braking can also be done by only the motor. You can slow down and stop without using the brake pedal too much. This will also regain energy and safe kilometers. Turn the gas handle to accelerate. By releasing the gas handle the vehicle will automatically use the motor to slow down and stop.
This is the Battery Display Indicator (BDI). It shows you the battery level and up to date driving information. The number of bars on the display is an estimation of the battery level, not an exact calculation. Getting familiar BDI The display alternates between 4 values: Ub, r, A and H.
GETTING FAMILIAR Maximum load Please do not exceed the indicated load capacity of the e-Tuk. Doing so may cause damage to the vehicle and could be dangerous to you and your fellow passengers. Please be aware that your eTuks driving behaviour and range change when driving around with more passengers or higher loads.
Please note there is a emergency switch located left of the driver seat. Pressing it will disable all electrical systems and will make the e-Tuk shut down immediately. Keep in mind that this will not stop the vehicle. You will still have to use the manual brake for that. Getting familiar Safety This Vehicle Identification Number Plate can be found above the brake pedal. This plate contains the e-Tuk’s serial number and other manufactoring information.
DRIVING CONDITIONS Temperatures Weather conditions may have affect on performance and vehicle range. High temperatures (35+ °C) combined with high payloads may cause the motor and controller to get very warm. Drive calmly and at a steady pace and give the motor time to cool down every now and again. Very cold weather may reduce the range of your vehicle slightly, as cold batteries hold less energy. Your vehicle will drive normally but keep in mind that you may get a few kilometers less on a single charge.
Tips to extend your range takes you Take a break every once in a while. Your battery pack is just like the human body. You can go further if you rest every now and then. Give further Properly inflated tires reduce road friction. The recommended tire pressure is 3bar / 44psi. Check your eTuks tire pressure every month. KG Driving the battery some time to recover. More weight means more power from the batteries. For maximum range, leave stuff you do not need at home.
BATTERY INFORMATION Battery health Your eTuk’s battery is one of the major components of the vehicle. It gives you the energy to get wehere you need to go. If you can rely on your battery, you can rely on your vehicle. To keep your battery in the best condition you need to take good care of it. Following some basic maintenance rules keeps your battery in good shape and increases its lifetime. These rules have been set up by the battery manufacturer*.
• 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 Watering • Add distilled water to cells • Never add acid to cells this is dangerous and will alter the chemistry • Only add water to fully charged batteries.
BATTERY INFORMATION Battery specs Your e-Tuk has been fitted with 12 Lead-Acid Deep Cycle batteries. Each battery produces 6Volt and around 185Ah. The total battery pack gives your vehicle 72V to power the motor and electronics.
• Make sure your vehicle is turned off • Make sure that your batteries are fully charged and cooled down • Remove the rubber mat and floorplate in the passenger compartment • Open the vent caps and look inside the fill wells • Check the liquid level; the lead plates in the battery should be submerged. • If necessary, add water until the liquid level is 0.
BATTERY INFORMATION Refilling the battery using the water filling system If your e-Tuk is fitted with a water filling system. This system lets you fills all batteries at once through a single hose. with a de-ionizing unit you can make your own pure water directly from the water from your tap.
The de-Ionizing unit can be used directly with battery watering guns. Connect the watering gun the the hose of the de-ionizing unit. Put the nozzle of the watering gun in the battery fill wells and squize the trigger. It stops automatically when the battery liquid has reached the correct level. 3P-051-103 lower battery capacity and prolong battery life. Cooler temperatures will slow selfdischarge.
CHARGING Standard Charger Standard charging sequence Turn off Parking brake Plug in LO CK Remove the key from the keylock. Apply the parking brake to make sure your vehicle does not roll away. Insert the plug into your home socket. The electrical plug that is needed to charge your e-Tuk can be found underneath the rear seats. It is connected to the yellow/black charger box. Wait at least 15 minutes before driving off after charging, your batteries need to cool down.
Time to charge The Delta Q 72V @ 12Amp is standard equipment on every e-Tuk. You can find it underneath the rear bench. The charge your e-Tuk from 0 to 100% takes about 14 hours. That long? Yes, it takes a while to charge such a huge battery. Tuk Tuk factory offers faster chargers, which are listed below.
CHARGING Standard Charger The Charger display The eTuk’s standard charger is located underneath the rear bench. It has a display on which you can check the progress of the charging sequence. Cutting off an unfinished charging sequence wil lower your battery lifetime. So, waiting for the 100% green light to turn on is the best thing to do. Ampère meter Solid: Displays approximate scale of charge during the first 80%. Flashing: High internal charger temperature.
Dashboard charging LED LO CK Constant: Flashing: Yellow Flashing: Red Flashing: LO Green CK LO CK Fully charged Short: <80% Charge Long: >80% Charge Not constant: Contact your service supplier Reduced Power Mode: Low AC Voltage or High internal charger temperature. Use a shorter extension cord Charging error.
ELECTRICS The Fusebox The e-Tuk several fuses. contains All of the 12V fuses are located in the fusebox underneath the driver seat. To reach the fusebox you will have to remove the driver seat and the cover below it. relay front plug unswitched taxi sign unassigned The illustration shows the location and function of the fuses.
5 amp 5 amp When you are replacing fuses, only use blade fuses with amps according to the schedule below. 5 amp 10 amp 5 amp 5 amp 5 amp 5 amp 5 amp unassigned 5 amp 10 amp In order to check if a fuse is broken, carefully remove it from the fusebox. If the metal wire between the 2 poles is broken, it means the fuse is blown.
ELECTRICS WARNING 12V Battery The 12V battery can be found underneath the driver’s seat, in front of the fusebox. The battery should give at least 11Volt. When measuring the voltage, make sure the vehicle is switched off. If the battery voltage is 10V or less, it is time to replace the battery. !NEVER CONNECT THE 12V BATTERY TO THE CHASSIS (B-)! The 12Volt battery and the 72V battery have common ground. Tail lights The tail lights and are highly durable LED light units.
Changing front light bulbs If one of your lights is not working, first check if the wiring is properly connected and that the fuse is not broken. To replace the light bulb in the headlights, first remove the entire headlight assembly: Use a BA20D 12V 35/35W bulb. Maintenance 54mm 36mm 17 mm • Unscrew the two screws inside the dashboard that holds the headlight in place. • Slide the black rubber protection cap back to seveal the white fitting.
FLUIDS Oil Your e-Tuk uses different types of oil for different parts of the vehicle. Regularly check the ground underneath your vehicle for any traces of fluid that may have leaked. Communicate any leakage to your local service provider immidiately. Differential oil Brake fluid Check the state of your differential oil every 3 years and replace if necessary. Use about 750ml of 85W90 oil to fill the differential. Check the level of brake fluid every year.
Refill the washer reservoir Maintenance PUSH LIFT Your windscreen washer can easily befilled with washer fluid. Best way to do it is to lift it out of its holder. This way the opening cap is easy to reach and you won’t spill a drop.
Troubleshooting Jacking To change one of the rear tires, first jack up your vehicle. Remove the screw of the plastic wheel cover. Then, remove the 4 nuts that hold the wheel in place. Take off the wheel. Make sure you put the new wheel in place and secure the bolts while the vehicle is still jacked up. Jack up the vehicle only underneath the rear suspension spring or rear axle. Only jack up the vehicle on the allocated jacking points. These are the cylindrical blocks underneath the frame.
Vibrating front wheel Towing Try to adjust the steering damper if your front wheel is vibrating while driving. The steering damper is located on the right side of the front fork underneath the front fender. In case your vehicle needs to be towed, only use the towing ring at the front of the vehicle. Switch on the vehicle and press the red emergency switch located left of the driver’s seat to disable motor resistance. Make sure your hazard lights are turned on while being towed.
Troubleshooting It’s not working! Check the charger cable. Whenever it is plugged in the eTuk will not drive. Make sure that the red emergency button is not pressed. Rotate the botton clockwise to release. LO CK Do a re-run of the starting sequence. Check if the direction switch is in N Check the battery display for the battery level. Remember that the indication bars are an estimation, not an exact representation of your battery’s charge.
Most common errors are shown on page 34 Lights, horn, display, wiper, washer do not work Display does not function Vehicle does not start, no lights, no click X Vehicle starts moving by itself Vehicle rear axle makes a lot of noise Battery does not charge X Motor stops while driving (bump) X Vehicle turns on & clicks but does not drive Vehicle turns on, but no click and does not drive X X X X X Vehicle drives jolty at slow and fast speed X Vehicle does not go up to high speed X Vehicle turns on
Troubleshooting BDI error messages Error What does it mean? 16 Extreme overheating of the controller. Vehicle will not drive. 17 Battery indicates that it is almost empty. Driving speed is reduced. 22 The controller is overheated. Heat sink temperature Drive slowly. Accelarate & Driving speed is reduced. reached +85°C. deccelarate little by little. The controller will slowly cool down. 23 Battery power is getting low. Driving speed is reduced. The motor is too hot. Driving speed is reduced.
36 37 38 39 44 47 73 The motor temperature The motor temperature Check the 2 pin connection by sensor is not connected. The sensor is loose. the motor. vehicle will not drive. Encoder error. The encoder is loose. Check the 4 pin connection by the motor. The motor face is open. There was a short circuit in Check the wiring of the motor. Vehicle shuts down. the wiring of the motor. The main contactor is welded The main contactor does Replace the main contactor. shut. Vehicle shuts down. not open anymore.
VEHICLE INFO Vehicle Driver comfort seat Passenger seats Cargo space (ltr) Maximum payload (kg) Maximum speed (km/h) Range** (km) EU vehicle category Battery Deep cycle Lead-Acid Capacity (kWh) Charging time 0-100% (hrs) Lifetime (years / km) Charger type Delta Q Cargo & Vendo XL ● 3000 300 45 60-70 L5 ● 15 14 14 14 Stretched ● 3 300 45 70-80 L5 ● 15 14 3/100.000 3/100.000 3/100.000 3/100.
Size and weight ● 7 10 Cargo & Vendo XL ● 7 10 ● ● ● ● Track (mm) Wheelbase (mm) Kerb weight (kg) Tyre size rear wheels 2980 1410 1850 1255 2270 700 3980 1410 1850 1255 2700 850 2980 1410 1850 850 1400 1200* 1255 2270 700 3980 1410 1850 1850 1400 1200* 1255 2700 850 155/80R13 155/80R13 155/80R13 155/80R13 Tyre size front wheel 145/70R12 145/70R12 145/70R12 145/70R12 Motor type AC Motor power (kW) Reverse speed (km/h) Controller type Curtis AC Size Cargo space Length (mm) Width (mm) He
U x x x x x x x x x x x x x x x Flush brake fluid U Clean motor U Fully charge batteries after full discharge Lights check*** U Brake pads and shoes check Tyre profile check U Water batteries* Apply silicone lubricant on rain cover zippers Mainenance done by Weekly or 200km Monthly or every 800km Yearly or every 12.500km Every 2 years or 25.000km Clean steer damper Proper maintenance is an important factor of your vehicle.
x x x x x x x M M M M M M x x x x x *The battery manufacturer recommends that batteries be checked once a month. Check the water level of the batteries monthly until you get a feel for how thirsty your batteries are. Also, check all battery pole connections for corrosion. Only fill batteries one hour after charging them. **The optimal tire pressure is 3bar / 44 psi. ***Check to see if all the lights (front, rear, direction indicators) work every week.
Your eTuk’s DNA VIN Type Color Licence plate nr.
Service & maintenance history In this section we have reserved space for your servce and maintenance provider to keep track of service and repairs on your eTuk. Please keep in mind that your vehicle needs regular maintenance. Regular checks need to be done on your battey. You can find the maintenance schedule on page 38. We advice you to keep all invoices you receive for these repairs. They will give additional insight in your vehicle’s history.
Service & maintenance history Date / km Date / / Comments Comments Service stamp: Service stamp: Next service km/date Next service km/date Date 42 / / / km Date / / Comments Comments Service stamp: Service stamp: Next service km/date Next service km/date km km
/ / km Date / / Comments Comments Service stamp: Service stamp: Next service km/date Next service km/date Date / / km Date / / Comments Comments Service stamp: Service stamp: Next service km/date Next service km/date km km Maintenance Date 43
Service & maintenance history Date / km Date / / Comments Comments Service stamp: Service stamp: Next service km/date Next service km/date Date 44 / / / km Date / / Comments Comments Service stamp: Service stamp: Next service km/date Next service km/date km km
/ / km Date / / Comments Comments Service stamp: Service stamp: Next service km/date Next service km/date Date / / km Date / / Comments Comments Service stamp: Service stamp: Next service km/date Next service km/date km km Maintenance Date 45
Notes 46
Maintenance Notes 47
If you are having issues with you vehicle, please contact your local service provider. Before you do, please make sure you have read this manual carefully.
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