Help with unknown ebike controler repair

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nitrosport_5   10 µW

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Joined: Oct 07 2020 10:56am

Help with unknown ebike controler repair

Post by nitrosport_5 » Oct 07 2020 2:25pm

I am a local atv mechanic in a small town and was asked to help fix a local disabled mans trike that has been setup with an electric front wheel.

He managed to sever the wire harness coming from the throttle assembly, so I just assumed I could repair the wires and he would be back in business, but that doesnt seem to be the case. I cant find any info on the controller at all. The throttle that is on the trike has 7 wires that have been ripped apart, but the largest connector on the controller is 6 pin. If I match colors, I'm left with a non connected blue wire and nothing works. I'm getting 41.5v out of the battery but that's it.

Any help would be ppreciated. I'm not sure where to even start. I'm not making any money off of my repairs here, I just want to help the man out. Some people in the town got together and purchased this equipment for him so idnlike to be able to help get it running again without replacing stuff.

So I had pictures of everything but they are too big to upload from my phone I guess. I can email them to someone if you can get them resized and posted.

Balmorhea   1 MW

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Location: Austin

Re: Help with unknown ebike controler repair

Post by Balmorhea » Oct 08 2020 2:54am

Are there switches on the throttle?

3 wire throttles have +5V, signal, and GND.

4 wire throttles have +5V, signal, GND, and +BATT. That’s for a state-of-charge indicator.

To this you might add a wire for the enable (“ignition”) switch. Maybe even two, but usually there’s one enable wire that is switched or jumpered to +BATT.

So to get to 7 wires, you probably have another switch or two, like lights and/or horn. Perhaps cruise lock.
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Finish Reconstruction.

nitrosport_5   10 µW

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Joined: Oct 07 2020 10:56am

Re: Help with unknown ebike controler repair

Post by nitrosport_5 » Oct 08 2020 11:54am

Thank you for the response. The throttle has 1 switch with 3 positions, and what looks to be a volt meter.

Out of the throttle I have 7 wires

Green, blue, brown, yellow, black, red, white

The controller has 5 plugs

1 6 pin with all the same colors as above minus the blue
2 2 pin with purple and black
1 3 pin with black green and red
1 4 pin with white black red yellow

Balmorhea   1 MW

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Joined: Oct 01 2019 8:30pm
Location: Austin

Re: Help with unknown ebike controler repair

Post by Balmorhea » Oct 08 2020 12:58pm

Does the three position switch have any indication what it does, or do you know what it does? The wire colors probably connect like to like (but not necessarily), and the blue wire may not do anything. You might be able to open the throttle housing and verify whether it's hooked up to a terminal inside. Be careful, because there's a return spring in there that may be ready to jump out.

If you have a multimeter, set it to DC voltage, plug the battery into the controller, and carefully probe the pins of the 6 pin controller plug to find +5V (probably red, but not necessarily), +BATT, and GND (probably black).

If the cable was severed in such a way as to connect 40+ volts from the battery to the low voltage sensor and signal wires, it may have killed the Hall sensor, logic circuits in the controller, or both. A metal blade, for instance, surely would have connected some things together electrically. But a hard yank, or getting pinched in a wooden door, might not have. In the worst case, the controller and throttle assembly both must be replaced.

You can determine whether the throttle Hall sensor is working by connecting +5V and GND to a 5 VDC source (USB power is 5V if that helps), and probing between GND and the other wires ones at a time while you work the throttle. The throttle signal will vary between about half a volt and about 4 volts when you operate the throttle.
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Finish Reconstruction.

nitrosport_5   10 µW

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Joined: Oct 07 2020 10:56am

Re: Help with unknown ebike controler repair

Post by nitrosport_5 » Nov 02 2020 7:30pm

After some more tinkering and following some of your suggestions, I think the controller and the throttle assembly need replaced. A group of us has pooled together and wants to make this right.

I've been doing some searching and just cannot come up with parts that I know will all work together. Is there a good place to buy parts? There seems to be alot of no name parts out there and I dont want junk. Any suggestions on what I may want to buy? I have a 36v battery, 750w motor with a 9pin round connector. I for sure need a twist throttle, but other than that I'm not really sure.

kcuf   100 W

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Joined: Sep 29 2018 3:21pm

Re: Help with unknown ebike controler repair

Post by kcuf » Nov 02 2020 7:53pm

pictures will be your friend
In 2013 an ad appears on Russia social networks: Интернет-операторы хотели! Работа в шикарном офисе в Ольгино !!!, зарплата 25960 рублей в месяц

nitrosport_5   10 µW

10 µW
Posts: 6
Joined: Oct 07 2020 10:56am

Re: Help with unknown ebike controler repair

Post by nitrosport_5 » Nov 10 2020 4:59pm

Hopefully the pictures will attach. Got them resized.

These are the parts I have, would like to be able to find a replacement controller and throttle and reuse the battery and motor if possible.
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IMG_10112020_135802_(1080_x_1080_pixel).jpg (369.88 KiB) Viewed 260 times
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IMG_10112020_135647_(1080_x_1080_pixel).jpg (237.72 KiB) Viewed 260 times

Voltron   1 GW

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Location: Santa Barbara CA

Re: Help with unknown ebike controler repair

Post by Voltron » Nov 11 2020 11:07am

I've got a giant bin of 36v controllers and throttles from dead bikes... I'll send you one if you pay postage. Feel free to pm me about it

nitrosport_5   10 µW

10 µW
Posts: 6
Joined: Oct 07 2020 10:56am

Re: Help with unknown ebike controler repair

Post by nitrosport_5 » Nov 11 2020 4:43pm

Pm sent! Thanks!

nitrosport_5   10 µW

10 µW
Posts: 6
Joined: Oct 07 2020 10:56am

Re: Help with unknown ebike controler repair

Post by nitrosport_5 » Nov 25 2020 2:43pm

I'm still on the hunt for the right parts. I tried to get ahold of Voltron without much luck.

There are so many options I'm not sure what to do from here other than order a complete 36v kit off of amazon and hope it's not total junk. Idnlike to get this thing back together for the guy I just dont know what the good parts are, and if ebike stuff is anything like the ATV part world, there is an awful lot of aftermarket garbage out there.

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