pickup image missing

 Electric Mazda truck

 description, info, manuals, pix






ev album This is the truck I bought 12/1/08, described on EV Album.
safety note working on the truck can be dangerous. read this first.
controller the manual on the Kelly controller. See 'Controller' section below.
Kelly's website website for Kelly, the company which made the controller.
DC-DC converter? purchased from Cloud-9 ?
batteries the batteries used in the truck. 20 6 volt batteries. 183 AH each.
charger about the QuickCharger built into the truck.
brake assist overview of the vacuum system which assists braking.
vacuum pump vacuum performance at different pump rpms. physical dimensions.
vacuum switch acts like a relay when vacuum low. turns on pump.
spec sht specs on the vacuum pump. adjustment notes
KTA supplied many of the truck's electrical components. a good company.
insurance agent: Denny Jones, State Farm, phone: 925-356-7910

General Description

mazda. converted by Michael Mutch.
lethal amount of electric power aboard. 
# of batteries. type. placement. 
weight, balance.
5 speed manual.
clutchless. 
gauges.
on board: extension cord, log book, title, flashlight
insurance.

Driving it.

How to drive it.
'start it'. take off charger. pre-flight: ... ?
shifting.
free-wheeling.
when to shift
reverse. jerking.
range. illusive.
hills
freeway.
how to know batteries running low.
depth of discharge.
how to read the gauges.
strategies. trip planning. 
tactics. speed. braking unnecessarily.
charging in a strange place. 'charging stations'

The Controller

USA design but now company is in china. responsive company.
very capable unit. has options for regenerative braking.

configurable via RS-232 "Serial Port".
guards against hi/lo voltage/current situations.
itemFactory
value
Michael's
value
planned
value
notes
%accel  75% undecided why not increase ?
%max amps85% ? 85%/350? undecided why not increase ?
overVoltage
limit
?125(?) 130 (?) this has been a problem.
%pot box n/a 80% undecided not really a controller issue

Radio

The truck has, I'm told, a nice radio and speaker system. It worked once and was
forgotten. Now it doesn't work. It's on my list...

Heater, Defroster

I was amazed to find out how important a defroster is! To turn it on, you must do the following:

Lights

TODO: measure current draw. voltage.
these can be left on when the truck is off. 

Maintenance

Charging: can just leave it on the charger. Rain hasn't been a problem.
Battery fluid: a genuine hassle. TODO: describe technique for speeding up.
Brushes: yearly ?
pressurized lift:
windshield wipers, fluid.
tires.

Troubleshooting

clunking sound. at 60 volts.

When the batteries are getting low, you'll begin to see large swings in the voltage as you begin an acceleration. This is a warning. Not long thereafter, when the swings go all the way down to 60 volts, you'll hear a 'clunk'. If the lights are on, you'll see them flicker off. What's happened is the controller's 'minimum voltage limit', 60 volts has been reached and it has momentarily shut down!

it doesn't start

You've just taken it off the charger, you twist the key to On, step on the 'gas' pedal and nothing happens (well, maybe you can still hear a relay clicking - but the truck doesn't move). What's happened is that the freshly charged batteries are proudly announcing they have about 129 volts or so. The controller says that's too much and it refuses to pass on the battery power to the motor. If you open the hood, you'll see an LED blinking out an error number which is listed in the back of the controller manual. The sometimes-inconvenient remedy is just to wait 10 minutes; the batteries will lose a little of their glow and the controller will be again become agreeable.

it doesn't go up hills, it doesn't accelerate well

yes. all true. 0-60 in 2.5 days...

I can improve it some but, basically, this is probably the major challenge to driving it. You have to pick your routes such that you're never in an unsafe situation because of the poor acceleration. Big 'semi' trucks may have all kinds of horsepower but they're pulling very heavy loads. Their situation is much the same due to their low power-to-weight ratio. This EV will require you to emulate their thinking.

Legal

VIN
license number. 
location of docs. Registration, title.

Cost to Operate

3.6 cents per mile is my 3/5/09 calculation. It should go down when the PG&E
rate is changed. This value doesn't include the amortized cost of replacing the
batteries.

Total Cost of ownership