TukTuk Factory E-TUK LIMO-GT User Manual & Maintenance Manual

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Keep this booklet with your vehicle

USER MANUAL &
MAINTENANCE GUIDE

E-TUK LIMO-GT

Version number: LGT01
Version release date: August 2017

21

You probably cannot wait to start driving! However, please read this
manual carefully before you get started. This will enable you to be fully

informed about how to fully take advantage of the capabilities of the
vehicle.

Reading and understanding this manual is essential for both your
own safety and the safety of your passengers. It also provides useful
information for troubleshooting any errors that the vehcile may have.

If you take good care of your vehicle, it will always be in the upmost
condition. Keep track of your maintenance in this booklet and follow
the maintenance schedule.

Please check our website www.tuktukfactory.com for an electronic
copy of all versions of this manual including the latest version.

Thank you and enjoy your e-Tuk!

Congratulations on purchasing your new e-Tuk!

- The Tuk Tuk Factory team

Getting

familiar

DrivingBatteryMaintenance

Quick start guide 3

Getting familiar 5

Dashboard & handlebars 5
Controls 7
BDI (Battery Display Indicator) 8
Maximum load 9
Safety 10

Driving conditions 11

Temperatures 11
Ways to extend your range 12

Battery information 13

Battery health 13

Battery specications 15

Watering the battery 15

Charging 19

Charging procedure 19
The charger display 21
Dashboard charging LED 22

Electronics 23

The fuse box 23
12V Battery 25
Tail lights 25
Headlights 26

Fluids 27

Oil 27

Relling the washer reservoir 28

Raincovers and roof canopy 28

Troubleshooting 29

Jacking 29
Changing tires 29

Vibrating front wheel 30
Towing 30

Troubleshooting 31

Handheld programmer 1313 31

It’s not working! 33
It’s still not working! 34

BDI error messages 35

Vehicle information 37

Maintenance schedule 39

Your e-Tuk’s DNA 41

Service & maintenance history 42

Battery analysis tools 47

Battery analysis table 47
Drive logging form 48
Battery logging form 49

CONTENTS

43

Key Display turns on Parking brakeUnplug Direction switch

Put in of (Drive or Reverse)

Before driving o, 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.

Turn the key clockwise. The display will switch

on and you will hear two
*clicks*, one louder than

the other.

Check the state of charge
and Ub or system voltage. If
it is around 76V your battery
is full.

Make sure the parking brake
is released.

Do not forget to put on your
seatbelt before you start
driving.

Put the direction switch in D
to drive forwards and R to
drive backwards.

Gently twist the throttle
and enjoy your ride!

QUICK START GUIDE

Getting

familiar

L

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11

1 Windscreen washer
2 Windscreen wiper
3 Hazard light switch
4 Windscreen washer uid

5 Tell-tales display
6 Speedo- & Odometer
7 Battery Display Indicator
8 Charger LED

9 Key switch

10 Throttle

11 Direction Switch

12 Outlet 12V

A

B

C

D

E

A Direction indicator

B Driving lights on/o

C Driving beam / passing beam
D Directions left / right
E Horn

12

GETTING FAMILIAR

Dashboard & handlebars

Getting

familiar

of

on

L

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87

By pressing the brake pedal with your right foot you will engage the
friction brakes. Slowing down and stopping your vehicle can also be
done by braking with the motor alone. You can slow down without even

using the brake pedal. This process also recharges the battery and
therefore extends the driving range.

GETTING FAMILIAR

Turn the throttle to accelerate. By releasing the gas handle the vehicle

will automatically use the motor to slow down and stop. 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 steer switch before you

start driving.

Please note that for safety reasons, the position lights are always on.
You’ll notice that the centre headlight cannot be switched on. EU­regulation states that you are not allowed to drive on public roads with

three head lights.

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

shows the estimated battery level, not an exact calculation.

The display alternates between 4-6 dierent screens. The display button

can be used to scroll through these manually:

The BDI also displays codes in case of an error. To know what these error
codes mean, please refer to the troubleshoot section on page 35.

Ub The amount of volts drawn from the battery
R RPM (Rotations Per Minute) of the electic motor
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 km (on some models)

There is a 12V outlet on the dashboard that is compatible with any 12V car
appliance (max 10A). Be careful with any wires that might get entangled
in the steering wheel. Please note that the range of your vehicle may be
inuenced by the type of device that is being used. A phone charger will
hardly aect the range, but a heater will be a bigger drain the battery.

There is also a 12V outlet in the back of the vehicle next to the rear bench.

Controls BDI

Getting

familiar

on

o

109

It is a legal requirment that the driver and any passengers use the

seatbelts as provided on the e-Tuk. If you want to use a child seat

check the relevant instructions for the child seat to ensure it can be
secured using a 3-point seat belt.

Maximum load

e-Tuk Limo GT

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 e-Tuk’s driving behaviour and range change when driving around with

more passengers or higher loads.

• Driver plus passenger seats for 4 adults/
children

Please note the emergency switch connected to the throttle (on the
righthand side of handlebar). Pressing the o button will disable the

battery and motor which will make the e-Tuk shut down immediately.
Keep in mind that the pedal brake will need to be used to bring the

vehicle to a stand still if the vehicle is moving.

GETTING FAMILIAR

The Vehicle Identication Number Plate can be found above the

brake pedal. This plate contains the e-Tuk’s serial number and other
manufacturing information. The serial number is the number that is

stamped into the plate. When contacting your service engineer, make

sure you have the serial number ready.

Your e-Tuk is equipped with a steering column lock. To engage the
lock, turn the handlebars all the way to the right, then turn the key all
the way to the left (counter clock wise). Now remove the key and the

handlebars are locked into position.

Safety

Getting

familiar

on

o

L

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e-Tuk Limo

• Driver plus passenger seats for 4 adults

• or 3 adults & 3 children

• or 6 children

1211

DRIVING CONDITIONS

Weather conditions may aect the performance and the vehicle’s range.
High temperatures (35+ °C) combined with high payloads may cause

the motor and controller to get very hot. Drive calmly at a steady pace

and give the motor time to cool down every now and then.

Driving uphill drains more energy from the batteries and requires more

power from the motor. As such driving in a hilly area will reduce the
range. Your vehicle will be able to drive up a inclination of 20%.

When the vehicle is stationary on a hill, do not use the throttle to
prevent the vehicle from rolling down the hill as this will cause the
controller to overheat. Instead always use the brake pedal.

When driving from stand still on a hill, apply throttle and release the
foot brake. Your vehicle may roll back slightly before taking o.

Temperatures

Driving on slopes

Cold weather reduces the range of your vehicle. Your vehicle will

drive normally but keep in mind that you may not be able to drive
so many kilometres on a single charge. It is recommended that you

park your vehicle inside, preferably in a warm environment. The ideal

temperature for your battery is 27 °C.

Ways to extend your range

KG

By anticipating trac you can make the ride more comfortable. If you
release the throttle you slow down quite rapidly. You’ll regain energy
and your brakes will last longer.

More weight means more power from the batteries. For maximum

range leave unnecessary belongings at home.

Properly inated tires reduce friction. The recommended tire pressure
is 3bar / 40psi. Check your e-Tuk’s tire pressure at least every month.

Lower your maximum speed and acceleration, the batteries will last

longer if you take it easy on the throttle.

Driving to a place with electricity? Charge on the spot!

The range of the vehicle can be extended by taking breaks in driving.

This allows the batteries to settle and recover some energy.

takes you
further

Driving

1413

BATTERY INFORMATION - LEAD ACID

Your e-Tuk’s battery is one of the most
important components of the 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.

These rules have been set up by the battery

manufacturer*. Not following them will void
battery warranty. Additional information can
be found on the next few pages.

• All battery maintenance, except for
cleaning and watering, should be done

by an authorised service mechanic. This
should be done at least

•

Battery health

Safety

Inspection & Cleaning

Storage

Watering

Charging

• once every year. Always wear protective
clothing, gloves and goggles when

handling batteries

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

• Neutralize acid spills with baking soda
immediately

• Charge with vent caps or lling system
securely in place

• Provide proper ventilation during charging

• Keep batteries clean and dry

• Check that all vent caps are tight

• Check if all connections are tight (fastening
torque is 11 Nm)

• Use a mixture of baking soda and water
to clean if there is acid residue on the
batteries or corrosion on the terminals

• 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.
Let the batteries cool down after charging
before adding water

• 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 eect (they do not need to be

fully discharged prior to charging)

• The charging cycle should always be

nished completely to ensure battery life

• If charging cycles have been cut o,
equalization should be done. See
“Equalization” on page 20.

• 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

• 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 overll the batteries

* Source: Trojan batteries

Battery

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

1615

BATTERY INFORMATION - LEAD ACID

Battery specications

Watering the battery

Your e-Tuk has been tted with 12 Lead-Acid Deep Cycle batteries. Each battery produces 6
Volt and around 185Ah. The total battery pack gives your vehicle 72V to power the motor and
electronics. There are various batteries available. They all work the same and should be serviced
in the same manner. However, they cannot be used simultaneously. One broken battery should
be replaced with the same type, brand and health/age.

Watering the battery manually

!

!

!

Always use distilled or de-ionized

water to rell the battery.

• Make sure your vehicle is turned o

• Make sure that your batteries are fully

charged and have cooled down

• Remove the rubber mat and oor plate in
the passenger compartment

• For the GT model the front passenger

bench must also be removed.

• Open the vent caps and look inside the

lling wells

• Check the liquid level; the lead plates in
the battery should be submerged.

• If necessary, add water until the liquid

level is 0.3cm below the bottom of the ll
well

• A piece of rubber can be used safely as a

• Only add water to fully charged batteries, except when the battery plates are

above the water.

• Let the batteries cool down after charging before adding water.

Not enough

Too much

Just right!

• Never add acid to a battery.

• Battery uid is hazardous!
Always protect your clothes,

skin and eyes.

Your e-Tuk’s battery needs regular watering. The water is an essential part that makes the
battery work. During heavy use the batteries heat up and the water evaporates. TTF recommends
regular lling (see “Maintenance schedule” on page 39 for more info). Monitoring the amount
of water which is used during the relling process will give you a good indication of your water

use. Watering can be done per battery cell or in one go for the entire pack if you have a battery

lling system.

Battery

• We recommend to replace the entire battery pack if only one battery is broken.

!