TTF Limo-GT Service Work Instructions Download | Manualshive

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TTF Limo-GT

Service work instructions

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Summary of Contents for Limo-GT

Page 1: ...TTF Limo GT Service work instructions 1...

Page 2: ...Jacks and lifts Vehicle Jack point locations Special cases apply for Vendo and pre 2017 vehicles 2 Workshop guidelines Lifting 2 Column lift Jack Scissor lift...

Page 3: ...Handbrake mechanical cables Disc Brake front Brake Pedal assembly hydraulic incl Brake Fluid res and Brake Master Cylinder Brake system layout Drum brake rear 3...

Page 4: ...here are similar but different versions with different length and diameter Check free wheel movement after installing differential components and or motor Always re torque wheel bolts after 100km Rear...

Page 5: ...iew A Springs B Dampers C Arms D Swaybar E Rubber stop F Brackets and spacers Springs and arms connected to the frame Dampers connected with brackets and spacers spacers Stabilizing rod also connected...

Page 6: ...ontaminated oil will lead to differential failure make sure there are no loose metal parts in the oil When replacing the differential it is advised to also replace the drive shafts Old and new compone...

Page 7: ...e main battery B from the motor controller see safety instruction section b Open the motor cable enclosure and disconnect all cables and connectors Remove the motor cable enclosure c Unbolt 6 M6 hex b...

Page 8: ...ed in place it needs to be cut away and reinstalled using a retrofit flange kit Installation 1 Thoroughly clean the inside of the axle and all parts to remove all debris and dirt 2 Clean the contact s...

Page 9: ...pe of e tuk before ordering spare parts older Tuk Tuks have different body parts than the Limo GT Body replacement 9 Old Tuk Tuk has a small step in and a continuous body around the passenger section...

Page 10: ...10 Electrical hardware...

Page 11: ...k Factory first Dashboard 1 Remove rear bench 2 Open controller box 3 Remove blue relay Back 1 Put the vehicle in neutral 2 Use the parking brake 3 Turn the vehicle off 4 Mark the spot Dashboard Batte...

Page 12: ...controller turns on but does not respond as expected check the input signals with the 1313 handheld controller 1 KSI 2 DNR switch 3 Throttle 4 Kill switch 5 Brake switch 6 Charger inhibit 7 BDI 8 Mot...

Page 13: ...turn on Lights are not bright enough Several devices do not work How to identify power supply issues Measure 12V battery voltage Should be higher than 12V when vehicle is off should be over 13 2V whe...

Page 14: ...APTER DCDC FUSE COMPONENTS MOTOR CONTROL CONTROLLER 35P MAIN CONTACTOR MAIN FUSE POWER ON KEY FUSE Controller KEY RELAY DC DC FUSE POWER DC DC converter Charger connection COMMUNICATION CANbus connect...

Page 15: ...d circuit Whenever a fuse is blown the reason for failure should be verified Possible causes Wrong fuse value The right values can be found in the wiring diagrams Short circuit in a wire caused by wir...

Page 16: ...5P connector 3 Disconnect B and isolate B battery cable with tape 4 Disconnect all motor cables 5 Disconnect B bus bar 6 Unbolt controller 4xm6 hex bolts 7 Remove controller Placement Please follow th...

Page 17: ...conductive paste 3 Position controller on alu plate and bolt down 4 Connect all cables Fasten bolts with 14Nm 5 Connect 35pin connector Place controller and thermal paste on clean desk Flip controller...

Page 18: ...stop driving and let the controller cool down If the C_hot error occurs regularly there might be another problem 1 Dirt The controller and heat sink need to be cleaned of dirt 2 Terminals These termin...

Page 19: ..._tuktuk135_123x_20170623 1234SE 1236SE 1236E Folder 123xse Lithium_tuktuk150_123XSE_20180110 Lead Acid_tuktuk141_123XSE_20170623 3 Run exe file with latest software from PC 4 Select correct COM port P...

Page 20: ...id_20170623 New motor 1236_OS12_KDS_Lead Acid_20170623 8 1234SE 1236SE 1236E Folder 123xse 1236SE_OS26_KDS_Lithium_20171204 1236SE_OS26_KDS_Lead Acid_20171026 9 Select connect in PC programming statio...

Page 21: ...lp verify inputs next slide Error 23 Usually an empty battery Recharge If this does not help check battery health Error 12 36 73 Encoder fault Clean encoder and check encoder connection Error 38 Main...

Page 22: ...witch 7 Only on when D DNR Reverse Switch 8 Only on when R Handheld programmer 22 Troubleshooting All controller inputs can be read in the 1313 menu MONITOR INPUTS You should verify if all controls re...

Page 23: ...puter go to Control Panel Device Manager Universal Serial Bus USB Controller ZLG USBCAN 2 Right click Update Driver Software Browse my Computer Go to Dynavolt Drivers folder 3 Install driver Lithium b...

Page 24: ...d PC 2 Open GDTS folder on provided USB stick 3 Start GTDS Car Monitor exe Lithium battery Software 24 1 2 Interface 1 Homescreen Click GTDS logo to connect 2 Battery Cell voltage temperature 3 BMS Fa...

Page 25: ...e of the motor to help direct the debris out of the motor There could be a problem with the encoder when you receive errors 12 13 25 36 or 37 To check encoder function check MOTOR SPEED A and MOTOR SP...

Page 26: ...BATTERIES 26...

Page 27: ...ery tray constructed What kind of service and maintenance is required What kind of errors can be expected Content Lead acid vs lithium Lead acid battery Installation Maintenance Troubleshooting Lithiu...

Page 28: ...nt procedure Single modules from top Possible with all tuks B1 Remove middle seating arrangement B2 Remove middle plate with key B3 Detach controller charger terminals with isolated wrench Next slide...

Page 29: ...1 Cable routing 2 Remove controller cable and charger connections 3 Tray Frame mounting points Lead acid battery replacement procedure 29...

Page 30: ...ble installation follow the next steps 1 The cable needs to be installed on the outer side of the terminal The inner side is smaller and suitable for the squared nut 2 Install the battery cable on the...

Page 31: ...Correct installation order Use prescribed torque Terminal corrosion protection Inspection Cleanliness Cables Water level Water color Voltage Maintenance Cleaning Watering Equalizing Charging Never cha...

Page 32: ...If voltage varies an equalization charge should be performed 2 Water weight needs to be the same per cell If weight varies 0 030 an equalization charge should be performed 3 If water is brown the lead...

Page 33: ...tch charger 5 Open controller box 6 Unscrew battery terminal cables and isolate 7 Remove cables from chassis 8 Lift vehicle put lifting table underneath battery 9 Remove bolt securing battery 10 Remov...

Page 34: ...found in the Error Handbook Lithium battery Troubleshooting Common lithium battery errors Controller shows CANbus error controller error 58 59 Canbus communication issue the controller cannot read th...

Page 35: ...er gives error code count red blinking light Check the error handbook Battery voltage is too low Use a special service charger Algorithm 1 V1 13 to raise pack voltage above 60V Charger stops after som...

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