9. TROUBLESHOOTING 9.1 MAINTENANCE 9-1 TROUBLESHOOTING 9.1 MAINTENANCE OF EV2 9.4 WARNING LIGHTS 9.2 INSPECTION
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1 9. TROUBLESHOOTING 9.1 MAINTENANCE OF EV2 9.4 WARNING LIGHTS 9.2 INSPECTION 9.5 CHARGING WARMING LIGHT 9.3 DIAGNOSIS & TROUBLESHOOTING 9.1 MAINTENANCE 1. Do not be short between the positive and negative terminals. 2. Don t let any tools cross the batteries. 3. Do not touch the 48V terminals of the batteries by hands. 4. Check the rubber covers of the batteries are positioned well. 9-1
2 The wire diagram (connect in the following numerial sequence; Pole 1 and pole 2 are the 48V terminals) 5. Turn off the power switch (the breaker) when doing a non-power inspection or removing the batteries. 6. If an electric device is damaged and has to be replaced, check all the other parts are serviceable before exchanging it. 7. Be sure to check for short circuits before turning on the power switch. 9.2 INSPECTION 1. Inspect the operation of the breaker (the power switch). 2. Check the connections of all the control wire and the power wires. Especially the terminals of the hall sensors and the batteries. The colors of the wires from the driver to the motor (U, V, W) are red, black and yellow. 9-2
3 3. Inspect the ON/OFF terminals of the power switch. 4. Inspect the total voltage of the batteries. (Keep the batteries at rest for about one hour) 100% full charged about 53V (full charging storage) 80% full charged About 51V 60% full charged About 49V 40% full charged About 47V 20% full charged About 45V 0 % full charged About43V (no charging storage) (1) Inspect the Voltage of a single battery: (11.5~13.2V) ( rest for one hour ) (2) The voltage between any two batteries should not exceed 0.15volt or the batteries should be replaced by new ones. (3) Exchange the four batteries simultaneously when any one of them is damaged. 5. Inspect the resistor of the SIDE STAND SENSOR: The resistor of the side stand sensor should be zero when the side stand is extended out and infinite when it is drawing into the side cover. 6. Inspect the resistor of the THROTTLE SENSOR: The resistor value of the throttle sensor varies from 0 to 5KΩ. Accelerator at its original position (idling) : over than 4.5KΩ. Accelerator fully opened : less than 900Ω. 7. Inspect the signals of the HALL SENSOR in motor: (1) Inspect the signal of the hall sensor. (2) Inspect the resistance between the poles and the cover of the hall sensor. 9-3
4 The insulation resistance should be higher than 500V/1MΩ. 8. Inspect the free running condition of the motor: ( about rpm / 3.5A ) 9. Inspect the wiring of the U, V, W coils of the motor: Note: Check that the resistance of the U, V, W coils is balanced and approximaldy 17m ohms, The insulation resistance should be higher than 500V/1MΩ 10. Inspect the thermal sensor of the motor: The resistance of the thermal sensor at 25 is 10K± 500Ω and the insulation resistance is 500V/1MΩ. The resistance of the thermal sensor will drop when the motor is heated. 11. Inspect the resistance of the five poles on the driver cover and their insulation resistance to the cover: Turn off the power switch before inspection. The insulation resistance should be infinitive (over 10MΩ). The relative resistance between the five poles outside the cover of the driver are as follow BLUE/RED : over 2MΩ BLUE/BLACK : over 2MΩ BLUE/YELLOW : over 2MΩ GREEN/RED : over 1.4Ω GREEN/BLACK : over 1.4Ω GREEN/YELLOW : over 1.4Ω 12. Inspect the DC/DC CONVERTER check the fuse on the main wire: Turn on the key switch before inspection. The inspection of volts should be infinitive (13.5~14MΩ). If volts value is zero change the DC/DC CONVERTER. 9-4
5 9.3 DIAGNOSIS & TROUBLESHOOTING LIGHT DOES NOT WORK TROUBLESHOOTING BLUB BROKEN POWER BREAKER (N.F.B.)TRIPPED KEY SWITCH OFF DC/DC CONVERTER FUSE BLOWN DC/DC CONVERTER BROKEN MOTOR DOES NOT WORK POWER BREAKER (N.F.B.)TRIPPED KEY SWITCH OFF THROTTLE SENSOR BROKEN DRIVER BROKEN MOTOR BROKEN SIDE STAND SWITCH BROKEN OR IS EXTENDED FLASHES CHARGING INDICATOR LIGHT CHARGING SOCKET OF THE FUSE( 7A ) BLOWN CHARGE OF THE FUSE ( 10A ) BLOWN CHARGER BROKEN BATTERY FAUILT KEY SWITCH IS ON POWER BREAKER (N.F.B.) IS NOT ON WARNING LIGHT FLASHES FOLLOW THE WARNING INDICATION LIST OF THE FREQUENCY 9-5
6 low voltage protect(42v) CONFINE VOLTAGE low voltage protect (41V) WARNING INDICATION LIST SYS(Alarm) LED: 1 every second. SYS(Alarm) LED: 1 every 4 seconds. TROUBLESHOOTING Side stand extended SYS(Alarm) LED: 1 long,1 short. long 2 seconds, short 1/4 second. HALL Error Throttle sensor broken Over Current protect (80 ) protect (90 ) protect (90 ) protect (90 ) protect broken protect short protect broken protect short SYS(Alarm) LED: 2 longs, 1 short. long 2 seconds,short 1/4 second. SYS(Alarm) LED: 2 longs, 2 shorts. long 2 seconds,short 1/4 second. SYS(Alarm) LED: 2 longs, 4 shorts. long 2 seconds,short 1/4 second. SYS(Alarm) LED: 3 longs, 1 short. long 2 seconds,short 1/4 second. SYS(Alarm) LED: 3 longs, 2 shorts. long 2 seconds,short 1/4 second. SYS(Alarm) LED: 3 longs, 3 shorts. long 2 seconds,short 1/4 second. SYS(Alarm) LED: 3 longs, 4 shorts. long 2 seconds,short 1/4 second. SYS(Alarm) LED: 4 longs, 1 short. long 2 seconds,short 1/4 second. SYS(Alarm) LED: 4 longs, 2 shorts. long 2 seconds,short 1/4 second. SYS(Alarm) LED: 4 longs, 3 shorts. long 2 seconds,short 1/4 second. SYS(Alarm) LED: 4 longs, 4 shorts. long 2 seconds,short 1/4 second. 9-6
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