Help with Tongsheng TSDz2 motor

[Baseline]

Greetings from Ocala FL

I have TSDz2 mid drive on my HP Velotechnik recumbent trike. It's worked fine for a year but something wrong now. Motor is still turning but making noises. Made a couple of videos to see if anyone here might know what's wrong.

First one is in walk assist mode

Second one is level 4 throttle

Please let me know what you think. In fact, anyone with experience with these motors that lives in central Florida who could help me fix it or knows someone I'm definitely willing to pay. None of the bike shops I have talked to will touch it.

Need to get this fixed cuz the boss likes to ride.

 

[amberwolf]

Take the chain off of the output chainring and retest. It sounds like the links are catching on the guide tube (or something else), though I couldn' tell for certain from the video if the sound is really synced with the chain link positions.

 

[Baseline]

Thanks for reply, here it is without the chain, definitely something in the motor, motor still turns ok but something is not working

Let me know what you think it is

 

[amberwolf]

Sounds very very loud; most of the time noises inside the casing are muffled by the casing, so this sounds like something on the outside that the chainrings/etc might be hitting?

If it's not that, then since the repetition rate of the sound seems to sync up with that of the chainrings, it is probably one of the output-side parts of the internal gearing or bearings. If a bearing race has cracked, it could sound like that, or if a bit of something broke off inside and is being mashed in a gear (broken tooth on a plastic gear, for instance).

 

[bikes4two]

• My goodness me, that is one heck of a noise and to me it is definitely something inside the motor.
• I'm guessing mechanics isn't your thing but just taking the outer cover off as though you were looking to change the infamous 'blue gear' (lots of YT vids on this) may give a clue to the problem.
• I also would not be riding/using the motor anymore in case of further damage.
• Worst case of course is to buy another motor which at the end of the day are less than half the price of those poor souls needing another Bosch battery .

 

[Baseline]

• My goodness me, that is one heck of a noise and to me it is definitely something inside the motor.
• I'm guessing mechanics isn't your thing but just taking the outer cover off as though you were looking to change the infamous 'blue gear' (lots of YT vids on this) may give a clue to the problem.
• I also would not be riding/using the motor anymore in case of further damage.
• Worst case of course is to buy another motor which at the end of the day are less than half the price of those poor souls needing another Bosch battery .

Thanks for reply. I watched a video on blue gear replacement, doesn't look too hard. Can I do that with just Allen wrenches and screwdrivers or do I need special bike tools?

 

[hemo]

No special tools are needed to open the motor or to replace the Blue gear.

 

[Baseline]

Sounds very very loud; most of the time noises inside the casing are muffled by the casing, so this sounds like something on the outside that the chainrings/etc might be hitting?

If it's not that, then since the repetition rate of the sound seems to sync up with that of the chainrings, it is probably one of the output-side parts of the internal gearing or bearings. If a bearing race has cracked, it could sound like that, or if a bit of something broke off inside and is being mashed in a gear (broken tooth on a plastic gear, for instance).

UPDATE: I bought a small tool kit for bikes and opened motor up, blue gear was damaged so replaced with brass gear. Motor worked perfectly for 3 days and then during a short ride the motor just stopped working. No pedal assist, no throttle assist, no walking assist. My 860C display still working, shows mph when I pedal so I assume speed sensor still working. No error codes displayed. Briefly looked at cable connections as this is a recumbent trike so various extensions used. Did not see any loose connections. Not sure what the problem is???

 

[amberwolf]

If the display is showing you everything it normally would, and changing assist levels and whatnot, then the controller is probably not dead or disconnected. However, it could have an internal connection issue or failed MOSFETs, or other problem preventing current flow from controller to motor.

If the motor does not run at all, and power usage (if monitored) does not increase from zero regardless of control inputs, but everything behaves normally, connection of motor phases to controller would be my first suspect as I don't think that kind of failure would generate an error message.

Disassembly of motor housing for parts replacement has more chance to affect internal connections than electronics, so I'd check those first.