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[SuperDave42]

Hello Everyone ,
My Name is David,  and this is my first E-Bike.  I just recently acquired a 2009/2010 DS with 1,600 miles on it.  The problem it had was motor cables were falling off and the motor bolts were falling out..  Has a PERM PMG-132 in it.

Battery pack achieves full Green light  ( 100% charge )   I have not actually measured the voltage yet

When applying throttle it would move the motor and cause a lot of arcing etc  ( since the power cables were super loose )  also the motor made crazy clunk sounds as it slid in the adjustable motor mounts...  ok   I solved both problems and installed new brushes while I had the motor out.  Simple,  also broke in the motor brushes slowly on the bench using a 400 watt battery charger in NiMH mode and 4 amps  ( this just slowly ran the motor up and down for a while)


I re-assembled everything,  and now the throttle will not enable.   Power-on beep and self check appear to be working fine.  the display does show an "  R1  "  while it is doing the self test.  I cannot find any info on it yet.  possibly it's a clue ?.

I am new to all this,  but I am a Mechanical Engineer that also designs and builds my own Aerial drones.. I work for XP-Power designing custom AC/DC and DC/DC power conversion products, so I am knowledgeable in the realm of mechanics and electrical/power,  So I can understand the lingo that you guys are speaking  ;-).


I do not mind doing the legwork at all,  I just was not able to find a Wiring diagram or even a service manual for this bike  :-(.

after reading what I have so far  it seems there are various reasons for the throttle to be disabled.

one thing to note.  the temp sensor was hacked and twisted back on to the harness.  I did remove it and solder it back and heatshrink it nicely.   it does turn the fan on when I hit it with hot air.


the warning LED on the stand-alone bracket on the dash,  seems to blink when the kickstand is down and or when the kill switch is in the off position.   pushing the switch to the ON position and raising the kickstand causes the warning LED to stop flashing.  so it appears both switches are operational.

I am not getting ANY LED action on the Alltrax controller.  I guess at first I want to verify that the controller is actually ok.

I just find it weird that it allowed the throttle before I took it apart, maybe I missed a wire somewhere ?

I just joined this forum today, and Plan to read mostly through the Zero related posts.  it has to be a simple problem,  not like the tranny or clutch is bad lol.

Thanks for taking the time to read my long post.

I'm in Morgan hill California.


Dave




in researching I found the Alltrax AXE is programmable ! cool.   my computer does not see it as being connected.  :-(

[protomech]

Double-check connections to the controller? If it was working before you took it apart then it's probably not just dead.

http://www.alltraxinc.com/Products_AXE.html

You should be able to connect to the controller with RS232 and the Alltrax software. I think this is the AXE4855.

[Harlan]

Check for pack voltage (~56V) across the B+ and B- Alltrax terminals. If pack voltage is present, then check for pack voltage bross B- to pin 1. Let us know what you find.

[SuperDave42]

Thanks guys !,  I will check that tonight when I get home from work.

I am also pondering what the "R1" means on the display when I boot it up.  I took a short video



It's soo close ! I can't wait to ride it

[protomech]

I think that is probably a version stamp for the Koso display, not a diagnostic code.

[rollandelliott]

good luck and welcome to the forum.
I wish someone would make a video on how to change out the brushes on these 200-2010 bikes. it seems like I have read 2 or 3 of them failing because of bad brushes, so it is a fairly common issue.

[SuperDave42]

Thanks for the welcome 

Darn,,,   I should have made a video when I did my brushes.   it was tricky to get all 8 springs compressed properly.

I took a lot of photos,  I can probably share a Google + album     Where would be the best spot to post something like that ?

[scZero]

I wish someone would make a video on how to change out the brushes on these 200-2010 bikes. it seems like I have read 2 or 3 of them failing because of bad brushes, so it is a fairly common issue.

Workshop manual in pdf on the Agni motor:

http://www.agnimotors.com/workshop_manual_v1.pdf

Videos on the Agni motor, cleaning, brush resistance, setup, etc...:

https://www.youtube.com/user/Jozztek/videos

[SuperDave42]

ok  I measured the goods...

56V across battery terminal inputs
56V from batt - to  Pin 1 :-(

I just noticed that the battery is making a high frequency noise  no matter if the master switch is armed or not..  seems weird that the battery would be energizing "something" with the master switch disconnected..   is this normal ? 

I pulled the quick-connects that go to pin 2 and 3  ( throttle input ? )  and I measured 60 ohms at the terminals at zero throttle,  then I twisted the throttle and my autoranging DMM went out of range and never came back to 60 ohms.

I understand these connections are a pass-thru from the main bike board ?   

I'm thinking next I should just pull the AXE out and try to power it up on the bench and use a 5K POT connected to pins 2 & 3 and simulate the throttle like that.

I work at a company that designs power supplies.. kinda of pissed that this AXE is fully potted lol.  I could fix it if it wasn't   ( but also glad they fully potted it... double edged sword I suppose lol)

So that's the update for tonight.

[kensiko]

There is a board on Li-Ion batteries managing the battery. It is true for any Li-Ion battery I think, or most of them.

[oobflyer]

Welcome and congrats on the new toy. I hope you get it running soon. Will you be using it for your commute?

[SuperDave42]

Welcome and congrats on the new toy. I hope you get it running soon. Will you be using it for your commute?

Thank you 

I wish I could use it for my commute,  but I am 36 miles away of 65-70mph freeway down 101.  from what I've read I don't think this model has the ability to reach that.   This just may be a segway into a newer model though  :-)

[rollandelliott]

you could commute that far if you did one of two things
1. got some aerodynamic fairings
http://www.schultzengineering.us/
2. I've been told you can buy the leaf batteries for $800 and that will give you double the range

I think the first choice would be easiser, and allow you to ride in colder weather as well since the wind doesn't hit you as much.
aerotech sells the dustbin fearings for about $600

[SuperDave42]

Well  the Alltrax is dead  :-(   time for a new one.

[nigezero]

Super dave; Bugger on the altrax! I have a 2010DS and had a brush meltdown very early. Long story short, with new motor I couldnt get her working and it turned out the throttle was fried and a replacement was called for. I'm not a tech head but have a suspicion that when the motor fried, it may have spiked the throttle. Just a thought.

Beware the fuses on these models too; separate (long) thread on that one too. They can't hack the pace and are impossible to get too, so when you have a chance and the packs out, replace and move them.