SURREY Hitch Hiker 2.1 User manual

Tools suggested:
 Electric Drill
 3/8ths bit
 5/16ths bit
 Phillips screw driver
 Cung pliers
 1/2 inch socket wrench
 1/2 inch wrench or crescent wrench
 8 mm socket wrench
 Center punch
Parts included:
1. Hitch Hiker with wheel, fender, crank and
mounng apparatus
2. Baery Box (black) and controller (silver box with
electrical wires on baery box lid)
3. Baery
4. Baery Box frame (black frame in the same
shipping box as the Baery Box.
5. Throle with cord and Dashboard Adapter
6. Charger with cord
Assembly Instrucons — Read Carefully
Assembly Manual
2.1

Frame Mounng
Steps:
1. Find center of rear base frame (surrey’s base frame). You will need to drill three 3/8ths holes.
To do so, measure the overall length of the rear base frame (red doed line marking the
distance between the two red lines below). Find the center of the tube by dividing the overall
length in half (yellow line below—A). Drill the rst 3/8ths hole in the center of the tube at the
yellow mark posion. It is always advisable to rst mark where the hole should be with a
marker, and use a center punch and hammer to make an indentaon on the frame marking
where the drill bit will start the hole. Be sure bit is perpendicular to the frame!
Fig. 1
2. Measure 8 inches from the center of the hole drilled in the center of the tube (A -yellow line be-
low) in both direcons (B & C -at the green lines below). Mark the tubing at the 8 inch mark
measuring from both sides of the center hole. The two marks should match the holes in the two
legs of the baery box frame, approximately 16 inches center to center hole. Check it!
3. Use the angle iron (L shaped; see the red arrow on Fig.2) base piece of the Hitch Hiker to check
the hole paern (the center hole and the two marks 8 inches from the center of the center hole
— measure twice, drill once!) Always drill perpendicular to frame and straight!
4. Drill a 3/8ths hole in each of the posions marked below with green lines for a total of three
3/8ths holes. These three holes (two green and one yellow posions) are aachment points for
the angle iron base piece of the Hitch Hiker.
3
A
B C
1.

Fig. 2
5. Three 3.5 inch bolts are provided to secure the Hitch Hiker base piece to the base
frame of the Surrey. Entering from the boom, the bolt should pass through the black
angle iron base frame though the nylon spacer and next through the base frame. The
center bolt will secure to the frame with a washer and nylon lock nut. The bolts on
each side of the center hole will pass through the black legs for the baery box (see the
green arrow in Fig. 2 above) before applying the washer and securing with the nylon
lock nut.
6. Tighten all three nylon lock nuts so that each of the baery box legs are ush with the
frame. Do not over-ghten the nuts.
View from the front of the surrey.
View from the rear of the surrey.
Black nylon spacer
2.

7. Locate the 4 horizontal bolts on the backside of the Baery Box Frame. (Note that the rst
bolt on the driver side of the frame has the ignion keys aached)
8. The 4 horizontal bolts pass through the horizontal brace on the Hitch Hiker frame (two on
each side of the crank). Each bolt secures with a washer and a nylon lock nut. Each side
secures itself around the rear stay backrest braces that runs from each side frame down
to the base frame.
9. Securely ghten all 4 bolts alternang a complete turn on each bolt unl all are ghtened
equally. Tight so that no rale develops, but do not over-ghten. Tighten to close gaps is
not necessary.
10. Set the black Baery Box into the Baery Box Frame. Fasten the Baery Box to the
Baery Box Frame through the oor of the Baery Box with the two bolts supplied. (see
the green circles above) Do not overghten! Overghtening might damages the Baery
Box!
View from the rear of the surrey.
View from the top of the Baery Box Frame
3.

4.
Step 1. Aach the throle to the
dashboard of the Surrey. Posion the
throle to the right of the brake arm as
shown in Fig. 1. T
Carefully posion the throle so that (1)
the brake arm is unimpeded so it can be
properly operated (2) the driver can
comfortably pedal the Surrey. When the
driver’s knee is on the upswing while
pedaling, the throle grip should be clear
of the knee’s path. Tighten both nuts.
Step 2. Route Throle wire along the
boom bar of the dashboard and down
the side frame. Use the brake cable
housing as a guide down the side frame.
Use an electrical e to secure the throle
wire to the brake cable housing in
posions to keep the throle wire from
hanging loose. A loose hanging wire can
be caught on passing objects possible
causing damage to the wire. (see Fig.2)
Step 3. Route the Throle wire on top of
the base frame and over the crank boom
bracket. Use electrical zip es to secure
the slack from the Throle wire as
needed. (see Fig. 3)
Step 4. Finally, route the Throle wire
between the top and boom of the chain
(or in any other direcon) toward the
boom of the baery box, entering from
the boom. (see Fig. 4)
Fig. 1.
Fig. 2.
Fig. 3.
Fig. 4.

Electrical Connecons
The box will mount under the boom seat at the rear of the
surrey.
Steps:
Install Baery in Baery Box-
1. Remove green Baery from shipping box. The
Baery will include a white foam pad on the boom
of the Baery in the shipping box. Do not remove
that pad. Use that foam pad on the boom of the
Baery inside the black Baery Box.
2. Aach the three red wires with loops inside the
Baery Box to the + terminal on the Baery.
3. Aach the two black wires with loops inside the
Baery Box to the - terminal on the Baery.
4. Inside the Baery Box, locate the three connecon
points not connected already including a (i) yellow
plasc block, (ii) rectangular connector with a white,
black and red wire and (iii) a square connector with
mulple colored wires aached.
5. From the Hitch Hiker Wheel, there are a total of 4
wires that exit from the driver side of the wheel.
Those four wires should enter the Baery Box
through the hole on the boom side of the Baery
Box, which is easily idenable near the edge of the
Controller.
6. Aer removing the cover from the yellow box with a
Phillips screwdriver, use a 8 mm wrench to remove
the nut of the yellow wire. Aach the yellow wire
from the motor and replace the 8 mm nut and
ghten it securely. Repeat this step for both the
green and blue wire. Make sure the colors are
matched, yellow to yellow, blue to blue and green to
green. Securely ght all nuts. (Use the color of the tape
on the controller side of the phase wires to match colors)
7. Replace the yellow block cover and secure it with
the two Phillips screws. If oponal speedometer/
voltmeter was purchased, skip to the aached
addendum at the back of these instrucons.
Baery Pad Controller
(Mounted
on the Lid)
Key Switch
(Mounted
on the Lid)
(i) Wires inside yellow
(ii) Throle
Connector (iii) Motor
Connector
5.
Please note—A spark may occur
when connecng the baery
wires. It is a normal occurrence.

8. Locate the red, black and green Throle wire from
the controller (marked). Plug the male end with
the red, black and blue wires into the controller
side connector matching red to red.
9. Locate the mul-colored wire from the Motor
wheel. Locate the mul-colored wire from
Controller. Match the colors and securely plug the
wire connector in unl it clicks into place.
10. Replace the Baery Box cover and secure the
Baery Box cover to the base with the Phillips head
screws provided with one at each corner.
11. Aer installaon is complete and all components
are ght, check the operang instrucon for
charging procedures.
12. Aer the Hitch Hiker is fully charged, next rotate
the crank clockwise to li the Hitch Hiker wheel o
the ground, insert the key and turn the ignion all
the way to the right unl you feel spring loaded
resistance, remove your hand from the key and
gently twist the throle. The wheel should spin.
The Hitch Hiker is ready to ride!
13. If the wheel does not spin, check all connecons,
including baery terminal connecons, and bu
end connecons. Again, test the throle.
14. Test the baery with a volt meter to conrm that
the baery is providing at least 53 volts. Again, test
the throle.
15. Please check to make sure you have proper re
pressure in the Hitch Hiker re and all res on your
Surrey. Recommended re pressure is noted on
the side of each re. Do this before each ride
during the like of the Hitch Hiker.
16. Check proper brake adjustment on your Surrey
wheels before each ride also!
17. If you have quesons, call 1.800.765.7370.
6.

Speedometer/ Voltmeter>
> Oponal Equipment

1. Using the bracket that was purchased
with the speedometer/voltmeter, aach
the unit on the driver side awning post at
the desired height for the user.
2. Run the electrical wires encased in the
housing along the same route along the
frame as the brake cables. Before geng
to the front of the driver side rear wheel,
run the wires under the Hitch Hiker’s
black box and enter the access hole
under the box.
3. As shown by the wire diagram in these direcons, the speedometer/voltmeter
properly connects by:
A. Aach the red power wire to the side of the ignion switch where the
controller’s thin red switch wire is connected (opposite side of the
ignion switch that is connected to the thicker red wire that is
connected to the posive(+) side of the baery.
B. Aach the green wire to the negave (-) post of the baery.
C. Connect the single wire from the speedometer/voltmeter with the
single wire from the controller. We advise using a small but of
electrical tape to sure up the connecon and to ensure it will not
vibrate loose.
Speedometer / Voltmeter Installaon Addendum
Proceed with the remainder of the installaon in the instrucons!

THIS CERTIFICATE OF WARRANTY offered by International Surrey Company Ltd.
(“Company”) is a non-transferable, limited warranty on the electric product (“Product”). The limited, non-transferable warranty is a 180 day warranty from the date of delivery on all me- chanical frame components and 90 day warranty on all electrical components against all mate- rial and manufacturing defects. All other warranties, express or implied, statutory and other- wise, including but not limited to fitness for a particular purpose and merchantability, are spe- cifically disclaimed. Damage or component failure from normal wear and tear and/or misuse, casualty or other damage is specifically excluded from this Certificate of Warranty. This war- ranty does not include any labor cost in connection with repairing, replacing and maintaining the Product. All warranty claims must be made to Company in writing and all parts on which warranty is claimed must be returned to Company for its determination, in its sole and abso- lute discretion, on whether this warranty applies. Claimant is responsible for all shipping, handling and/or freight costs associated with making a claim on this warranty.