Service Manual of E-scooter

Transcription

1 Service Manual of E-scooter introduction of maintenance knowledge Manufacturer: YADEA TECHNOLOGY GROUP CO.,LTD Address NO.515,XishanRoad,Xishan District, Wuxi,Jiangsu Province, China TEL/FAX: (+86) European representative: POL-PLANET E.K Marco Schuler Bahnhofstrasse 1b Lorrach Germany

2 1 LOCATION OF SERIAL NUMBERS VIN (CHASSIS NUMBER) DECRYPTING THE VEHICLE INDENTIFICATION NUMBER EXAMPLE::L5X66????????????

3 MOTOR NUMBER The motor number is stamped into motor cover. 2 SPECIFICATION

4 3.dimension of vehicle

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6 Chapter 1 Function of Electrical Parts 1. Charger Charger is the device which provides power to battery. Generally, the charging mode is divided into two types, which are 2-stage mode and 3-stage mode. 2-stage charging mode: it firstly charges with constant voltage, charging current reduces as battery voltage increases; when battery power is to a certain level, battery voltage will increase to the setting value of the charger, at this time, it switches to trickle charging mode. 3-stage charging mode: it starts with constant current charging, which provides power to battery fast; when battery voltage increases, it switches to constant voltage charging, at this time, it provides power slowly, battery voltage continues increasing; when it reaches the cut-off-charge voltage, it switches to trickle charging mode, which protects battery and provides current for self-discharging of battery. 2. Battery Battery is the power provider on the vehicle. By far, people mainly apply lead acid battery to electric scooters. Besides, lithium battery has been started to use on light e-bikes and e-scooters. 3. Controller The controller controls the rotational speed of the motor, it is also the core of the electric system of e-scooters, with protecting function of under voltage, current limit and overcurrent. Intelligent controllers also have kinds of driving mode and self-checking function for whole vehicle electric parts. Controller is the central parts for e-scooter power management and all kinds of signal dealing with. Using tips: controller CPU is e-scooter major loop with large working current and bringing large heat. Therefore, please do not stop e-scooter in the sun, and do not keep it in the rain for long time in case of controller problem.

7 COMPONENT IMAGE REQUIREMENTS ANSWER 4. Throttle, brake lever, assistant sensor Throttle, brake lever and assistant sensor and etc. are controller s signal input parts. Throttle signal is e-scooter speed control signal. Brake lever signal is a electric signal sent by brake lever inside electric circuit to controller when using brake lever on the e-scooter; After controller getting this signal, it will cut electricity supply for the motor to realize braking function and electricity-cutting function. Assistant sensor is a device to test driving pedal torque or pedal speed signal when e-scooter is under assistance situation. Controller divides different driving power to motor depending on how big assistant sensor signal is to realize automatically matching of human power and electric power and together make the motor turn. Using tips: when use speed-adjusting throttle, please turn lightly and put lightly, please do not turn vigorously 5. Motor Motor is e-scooter parts to switch battery electric power into mechanical power and make e-scooter wheel turn. For motor used on e-scooter, there are many kinds of mechanical structure, turning speed scale and electrifying type. Popular motor kinds: hub motor with brush and gear, hub motor with brush and without gear, brushless hub motor without gear, brushless hub motor with gear, side hanging motor etc. 6. Lights and speedometer Lights and speedometer are the parts which provide light and show e-scooter s situation. Generally, speedometer could show battery voltage, vehicle speed and driving situation and light situation etc. Intelligent speedometer can also show electric parts problem. 7. Others

8 Brake pads/shoes (Front) Brake pads/shoes (Rear) Brake drum (Front/Rear) Brake drum (Front/Rear) Brake cables (Front/Rear) Brake cables (Front/Rear) Brake liquid Standard measure 48*30*5 Service Limit 4000KM Standard measure 110*25*4 Service Limit Standard measure Service Limit Standard measure Service Limit Standard measure Service Limit Standard measure Service Limit Standard Quantity 6000KM Hole diameter 16*24;distance 120±2mm 3 years Hole diameter 16*24;distance 120±2mm 3 years Oil cup 75-80% Brake Disc (Front/Rear) Service Time to change Standard width measure Service width Limit Standard diameter measure 1 year Width of supporter (thickness): 6mm 1 year 180*48mm Axle alignment (Front wheel axel) Axle alignment Service diameter Limit Standard measure Service Limit Standard measure 1 year Front wheel axle M Left bushφ20 20 Right bushφ Km

9 (pedal axel) Axle alignment (rear fork axel) Chain Sprocket Main gear Service Limit Standard measure Service Limit Chain clearance Standard measure Chain clearance service limit Standard length measure Service length Limit Standard measure Service Limit Standard measure Service Limit M Km Standard spring measure 3*192 Front Fork Rear suspension Front Fork liquid/grease Tires(Front/Rear) Service spring Limit Standard spring measure Service spring Limit Standard Quantity Service Time to change Standard measure (depth) Service Limit (depth) 8000KM /10 Hydraulic adjustable bold 10000Km 4 layers reinforced 15000KM Axle bearings (Front/Rear/Pedal) Service Time to change 5 years Chapter 2 Solutions and Methods for Regular Malfunction

10 1. Fault eliminating sheet Item no. fault phenomeno n possible reason solution 1 1) end of battery life time; 1.change or fix battery; 2) the fuse in the battery insurance 2.change fuse tube is broken ; Battery can t 3) bad connection between battery 3.adjust two part position to get charge or insurance tube and insurance socket good contact,or change fuse can t be 4) Charger output voltage is low or 4.change or fix charger fully without output voltage charged 5) bad connection between charger 5.reconnect power and 220v power 6) charger signal light turning 6. change or fix charger abnormal leads to fake charging 2 Speedomete r dashboard 1) Without voltage between the positive pole and negative pole 1.reconnect connectors or change cable ; signal light of speed meter dashboard,bad not working contact of connectors or lead but the wire broken circuit motor works well 2) LED breaks down; 3) there is broken circuit on the dash board circuit board 2.change or fix LED 3.change or fix speedometer s circuit board

11 3 1) Lack of capacity of battery 1.charger for the battery; The motor sometimes works sometimes not 4 Vehiclee drives hard and the speed is slow power 2 ) bad connection of battery contactor 3) bad connection between insurance tube and insurance socket inside of battery box 4) there is dirt inside of sensitive film and sensitive tube of speed-adjusting throttle 5)there is fault inside of controller 6)lead wire of speed-adjusting throttle is almost broken. 7) cutting-power switch of brake has fault 8) bad contact after power lock is burned and corroded; 9) connectors between cables have bad contact; 10) rosin joint or virtual connection between coil and carbon brush inside of the motor 1.Check if the brake stuck; 2.Check if the tire pressure is normal; 3)if battery voltage is ample 4)motor sensor damages or magnet steel demagnetizes; 5) current-limiting value of controller decreases; 2.adjust contactor position or polish contactors; 3.adjust or change to make it well 4. clean or change sensitive film, clean sensitive tube, if still cannot get rid of the fault, change speed-adjusting throttle; 5.change or recover controller ; 6.change or recover lead wire; 7.adjust or change brake power-cutting switch; 8.change or recover power lock; 9.reinsert and reconnect to get good contact; 10.change or recover motor; 1.adjust brake space; 2. charge gas for tires; 3.charge for the battery ; 4.Change or recover motor ; 5.change or recover controller

12 6) Battery damages or battery life 6.change battery; 5 Vehicle range distance becomes shorter 6 Lose control of e-scooter expires 1)check if the tire pressure is normal; 2)battery damages or use life expire; 3)Battery under voltage ; 4)charger spec decreasing leads to less charging 5)brake is used too frequently; 6)overloading of passenger or cargo on the e-scooter 1)speed-adjusting throttle damage; 2) There is fault for the controller; 3)circuit connectors short circuit or open circuit; 1.charge gas for the tire; 2.change battery 3.charge for the battery; 4.change or recover charger; 5.decrease car speed,reduce brake using rate; 6.decrease loading weight of vehicle; 1.change speed-adjusting throttle; 2.change controller; 3.check and fix 7 8 Lights and horn doesn t work Without display on e-scooter speedometer 1)bad circuit contact or broken circuit; 2)fuse of convertor damages; 3)Convertor damages; 4)Battery voltage lack, under voltage protection 5)Bulb switch or horn switch burn down; 6)bulb or horn burn down; 1)bad circuit connection or broken circuit; 2)signal light bulb broken; 3) Speed without showing, speedometer broken; 4) speed without showing,controller with fault; 1.check and fix circuit 2.change fuse; 3.change convertor; 4.charge for the battery 5.change switch; 6.change bulb or horn; 1.check and fix circuit ; 2.change bulb; 3.change speedometer; 4.change or recover controller;

13 5)speed without showing, motor 5.change or recover motor; sensor broken; 6)remaining power without 6.change speedometer; showing,speedometer is broken 9 1.plastic parts not 1.adjust Turning not new assemble well with friction 2.adjust and oil adding working vehicle each other 3.change short screws 2.fixing screw nut are too 4.adjust,change tight 5. adjust,change 3.screw of windshield is too long 4.fixing screw nut does not match with windshield 5.braking cable,mileage cable and head cover leading cable are too short Unexpe 1.front fork not work well 1.change cted with unknown thing friction 2. check and air adding event 2.front wheel air pressure 3. shape-adjusting or change not plenty 3.basket support shape changes Normal 1. steel bearing lacking of 1.sugget to change whole set aging oil steel bowls, adjust,add oil 2.steel bearing lacking oil 2.removing rust and adding oil and getting rust Adjust, add oil 3.fixing screws loosens 3.adjust, add oil

14 4.front wheel bearing 4. change, add oil broken Chapter 3 Analysis on Regular Problems 1. Speedometer shows power, but motor doesn t work (Pic.1) (Pic.2) (Pic.3) (Pic.4) Reasons which cause the motor not work: (1) Check if there is voltage in the throttle (Pic.1); (2) Check if there is resistance value in hall (Pic.2); (3) Check if there is voltage in controller (Pic.3); (4) Check if there is resistance while the rear wheel is turning (Pic.4). 2. No power in whole vehicle (Pic.5) (Pic.6) (Pic.7) (Pic.8) Reasons which cause no power in the whole vehicle: (1) Check if the 5A fuse is burnt (Pic.5); (2) Check if the plugs of electric power switch is loosen (Pic.6);

15 (3) Check if air switch is loosen (Pic.7); (4) Check if there is 12V output voltage from converter (Pic.8). 3. The vehicle sometimes stops while running (Pic.9) (Pic.10) (Pic.11) Reasons which cause stop of the vehicle: (1) Check if the plugs of the hall are loosen (Pic.9); (2) Check if there is bad connection in throttle (Pic.10); (3) Check if there is bad connection in 5A fuse (Pic.11); 4. No power in main cable (Pic.12) (Pic.13) (Pic.14) Reasons which cause no power in main cable: (1) Check if air switch has tripped (Pic.12); (2) Check if the fuse of battery is burnt out (Pic.13); (3) Check if 5A fuse is burnt out (Pic.14);

16 5. The speed can t change (Pic.17) ( Pic.15 ) ( Pic.16 ) (Pic.18) (Pic.19) Reasons which cause the speed can t be changed: (1) Check if the electric lock power is turned on (Pic.15); (2) Check if 5A fuse is burnt out (Pic.16); (3) Check if air switch is turned on (Pic.17); (4) Check if the plugs of hall are loosen (Pic.18); (5) Check if brake lever is turned back to the original position (pic.19). 6. Vehicle lack of power while running

17 (Pic.20) (Pic.21) (Pic.22) Reasons which cause the lack of power: (1) Check if the battery power is regular (Pic.20); (2) Check if there is air in the tire (Pic.21); (3) Check if the speed limit is not canceled (Pic.22); 7. Distance range is short (Pic.25) ( Pic.23 ) ( Pic.24 ) Reasons which cause the short range: (1) Check if there is air in the tire (Pic.23); (2) Check if the battery power is regular (Pic.24); (3) Check if the tire turns flexibly (Pic.25); 8. Vehicle loses control

18 (Pic.28) ( Pic.26 ) ( Pic.27 ) Reasons which cause the loss of control: (1) Check if the cables of throttle fall down (Pic.26); (2) Check if the battery power is regular (Pic.27); (3) Check if the throttle turns flexibly (Pic.28); 9. Vehicle can t be charged (Pic.29) (Pic.30) (Pic.31) (Pic.32) Reasons which cause the loss of control: (1) Check if there is voltage in charging socket (Pic.29); (2) Check if the charging plug is loosen (Pic.30); (3) Check if the air switch is turned on (Pic.31); (4) Check if there is failure in the charger (Pic. 32) 10. The lights and horns don t work

19 (Pic.35) ( Pic.33 ) ( Pic.34 ) Reasons which cause the not working of lights and horns: (1) Check if there is short circuit in taillight (Pic.33); (2) Check if there is 12V output voltage from converter (Pic.34); (3) Check if the horn is broken (Pic.35); 11. No indicator on speedometer (Pic.38) ( Pic.36 ) ( Pic.37 ) Reasons which cause the no indicator: (1) Check if the speedometer shows the voltage of electric power lock (Pic.36); (2) Check if there is failure of the component inside the speedometer (Pic.37); (3) Check if there is voltage in turning lights (Pic.38);

20 Part 4 Battery knowledge (1)Inner structure of battery The main battery used on e-vehicle so far is lead-acid battery. Some e-vehicles may use NI-MH battery, lithium battery, or fuel battery. Overall, lead acid battery is cheap with abundant source, mature technology. Component of lead acid battery: + pole;- pole; septum; battery cover; battery container; electrolyte; terminal; relief valve, etc. (2)Battery fundamental theory, performance, and maintenance. 1 Fundamental theory of lead acid battery For lead-acid battery, + pole is Pb02, - pole is Pb. When discharging, Pb02 and Pb create PbSO4, consumes H2SO4, create electricity; When charging, Pb04 on + pole creates Pb02, Pb04 on pole creates Pb, together creates H2SO4, which make electricity in the battery. 2 Performance of lead acid battery (1)lead acid battery capacity: We call amount of electricity in battery as capacity. For example 6-DZM-10, data 10 means 10Ah, which means that the battery can discharge for 2 hours under 5A current. (2)relations between charging voltage and temperature: Low temperature causes low charging efficiency; it needs higher voltage to make full charge. High temperature causes high charging efficiency, the charging voltage can be low accordingly. 3 Maintenance of lead acid battery: (1)The vehicle must be charged before 80-90% electricity are used, 100% use of electricity will damage the battery. (2)Avoid charging after a short distance driving. Normally the effective charging time is times (life time). (3)Make 100% discharge every one month, then fully charge for hours, which can prolong the battery lifetime. (4)In terms of good after sales service, it s suggested to require users come back after 90 days to test the vehicles(main parts screws, brake, light, battery cable). After this, every 90 days invite users come back to test vehicle, ensure the vehicle in good condition. (3)Connection procedure of battery

21 1 Requirement& Attention during battery connection& welding: (1)Battery must be put in order; (2)Cable connected must be correct; (3)The +&- pole must be connected correctly; (4)It should put rubber pad under battery; (5)Battery cable connected shall be welded; (6)Battery box should put in right place, screw tightly 2 Attention during welding: (1)220V,50W Choose electric iron 220V, 50W; ( 2 ) Welding should be quick and tight. If takes long time, the battery will be damaged by high temperature and have leak risk; (3)No cold joint or lack of weld is allowed. Screw; spring shim; flat washer; battery cable (diagram above) (2)Requirement: 1) Don t mix the positive pole and negative pole; connect battery cells according to above guidance; separate battery cells with rubber blocks; 2) Strictly follow the manuals to assemble battery, screws should be turned tightly. 3) Battery connected cable, battery box, battery layer, should be separate to avoid damage of bolt or nut. Notice: For the e-scooter vehicles without plastic battery box, the battery is assembled directly to battery box in the frame. It must use rubber plate to cover the battery pole to avoid the risk the short circuit during driving. 5 Yadea E-vehicle battery assembly standard (1)There s danger if the battery is not assembled correctly. For example: the battery connected cable will be loose or damaged by the battery layer, which finally lead to self-ignition.

22 (2)Therefore, Yadea have certain requirement for battery assembly: if the battery is not assembled according to Yadea instruction, any problem caused from battery connection issue will be borne by the dealers. (4)Inspection of battery 1 Connect the battery, ampere meter, and resistance wire after full charge of battery. 2 Test the voltage of each battery cell with multi meter; record the voltage data and discharging time; adjust the resistance wire to make current 5A. 3 Battery internal disconnection: For this problem, it shows: battery has voltage, but no current; the whole vehicle has electricity, but motor don t work; If change a new battery set, the vehicle works, then it s surely the battery problem. 4 Charger always show green light during charging: Charger always show green light during charging, the charger also shows green light during no-load, then it s problem of lack of water or H2SO4 in battery. Open the battery upper cover, and add proper quantity of special battery liquid (5ml~8ml), the signal light will turn to red after 6-10 hours charging. Chapter 5 steps of disassembling and assembling motor Steps of assembling motor: 1. Take off the split pin of the motor lever 2. Using air gun with No.13 sleeve to take of the motor lever nut, then take off the screw of the lever

23 3. Using air gun with No.22 sleeve to loose the motor nuts. 4. Using air gun with No.10 sleeve to disassemble the positioning screws on the motor. 5. Hold rear fork axle with both hands to take off the motor from the rear fork. Steps of disassembling motor:

24 1. Hold rear fork axle with both hands and adjust the motor nuts to the proper position, then separate the positioning piece from the motor, lift the motor and jam it on the rear fork. ( hub cap facing the right side) 2. Using air gun with No.10 sleeve to tighten the bolt M6* Align the hole of motor lever and the hole of hub cap, put bolt M8*30 from inside to outside, add M13 nut, then tighten with air gun and No.13 sleeve.

25 4. Using air gun with No.22 sleeve to tighten the motor nuts. 5. Put M2*20 split pin through the nut of motor lever, then brake the end into 90 angle. Chapter 6 steps of disassembling and assembling wheels Steps of disassembling front wheel: 1. Using air gun with No.14 sleeve to disassemble the fixing screw of front disc brake, then take out the bolt and disc plate.

26 2. Using air gun with No.19 sleeve to disassemble the nut of front wheel, take off the spring pad and flat washer 3. Using right hand to hold the front fork, using left hand to take out the front fork axle front right to left, keep the axle bushes well. Steps of assembling front wheel: 1. Assemble the front fork axle to the assembling hole on the side without disc brake pad, put the axle through the assembling hole of left front fork 2. Put right hand on the side with disc brake pad, lift the front wheel, put it between the front forks, put the axle through the bush and the holes on front wheel

27 3. D Chapter 10 About switch steps for internal speed limit 1. Temporary switch steps for internal speed limit If the customer requires to test-ride when they buy e-bikes, it is suggested to use temporary relieving method, then it can make sure it s in the condition of speed limit for whole vehicles in shop, avoiding any incidentally random inspection. Steps for switching from the condition of speed limit to temporary full-speed: (Controller must be valid under the condition of speed limit.) No Temporary switch steps of internal speed limit 1 Under the condition of shutdown of power lock, middle kickstand or rear double kickstand works, and the motor is allowed to have micro switch(speed no more than 5km/h) 2 Hold brake(left or right one all is OK) 3 Open power lock 4 Keep brake condition for more than 3 seconds 5 Loosen brake handlebar completely 6 Done with the switch 7 After finishing test-riding and shutdown of the power lock, restart the e-bike then it s still the condition of speed limit 2. Steps for permanent relieving of speed limit If the user requires relieving of speed limit after transaction, the seller can permanently relieve the condition of speed limit by the way below. No Steps for permanent relieving of speed limit 1 Under condition of shutdown of power lock, middle kickstand or rear double kickstand works, and motor hub stay still. (If motor hub moves, then the following steps are invalid, that is preventing misoperation during riding ) 2 Keep throttle to the maximum (to maximum signal more than 3V), while hold brake (left or right

28 brake all is OK) 3 Open power lock 4 Hold brake and throttle to the maximum at the same time for more than 3 seconds 5 Loosen brake and throttle completely 6 It is permanent relieving after done with switch 3. Switch from the condition of permanent relief to speed limit If there is dispute about user returning e-bike or issues relate to speed limit, please set whole e-bike in condition of speed limit by setting steps for permanent speed limit. Steps for switching into condition of speed limit: (regardless of former condition) No Switching from the condition of permanent relief to speed limit 1 Under condition of shutdown of power lock, middle kickstand or rear double kickstand works, and motor hub stay still. (If motor hub moves, then the following steps are invalid, that is preventing misoperation during riding ) 2 Keep throttle to the maximum (to maximum signal more than 3V), while hold brake (left or right brake all is OK) 3 Open power lock 4 Keep the brake, and after completely loosen throttle twice continuously, then put throttle to the maximum 5 Hold brake and throttle to the maximum at the same time for more than 3 seconds 6 Loosen brake and throttle completely 7 Done with the switch Chapter 11 Testing and solving the throttle problem

29 (Pic.39) (Pic.40) (Pic.41) (Pic.42) Chapter 12 torques of fixture standard parts and circuit diagram of whole vehicle Table 1 torques of fixture standard parts Torque(N m) No. Designation Specs Performance grade Remarks M4 2~3 2~3 M5 3.5~6 4~7 M6 6~9 8~15 M8 16~21 15~30 1 Bolt, nut M10 28~36 M ~40 39~48 M12 42~52 M ~56 50~60 M ~65 55~65 M14 60~70 M ~75 70~80 M ~85 80~90 M4 1.0~ ~2.5 M5 3~5 3.5~5.5 2 Screw M6 5~8 6~10 M8 15~20 15~30 M10 22~25 39~48 Remarks: The torques of screws is fit for covers, if it is for connection of iron parts, please refer to torques of bolts Table 2 torques of tapping screws No. Specs Torque(N m) Remarks 1 ST ~3

30 2 ST ~5 3 ST ~6.5 Electric diagrams Electric diagram of brushless controller

31 Chapter 13 failure diagnosis FAILURE DIAGNOSIS PROCEDURE WHEN THE HYDRAULIC DISC BRAKE FAILS

32 MAINTENANCE PROCEDURE WHEN MOTOR WON T STOPRUNNING

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