hebb e-bikes electroglide 500 technical service manual
Contents
1. On some bicycles the motor wires from the controller leads all the way to the front fork as shown in some cases the wires are threaded through the frame cable guides It is then necessary to cut away the connectors to continue with the dismantling of the controller 2 Release the controller unit holding screws from the battery slot 3 Release the screws and nuts of the chain guard if any and dislodge the chain to push the controller out towards the right of the bicycle Note On some bicycles the chain guard is secured using both screws and bolts use 4 mm hex key 7 SU Weep LUSISAS ex mir ee bn Tog em n 1441 A PEJ TI aial Aut EH pun i EET ny C c gate BER 7 fe A STEAM bey ani re Aa 2 4 System diagram 4 J LWWLOAHL r L Um k amp 43 1 IOS LNOO EEE z uber TF 2 5 Self diagnostic indicator Model 500 Trouble Shooting Guide Controller version 9923 Functional SSS 3 times Brake lever cut off in contact a Make sure the throttle rock switch is on at meaning the bike is ready to run When this switch is off at the LED blinks 3 times even though the brake lever is functioning Check if both brake levers are returned to their rest position No clearance is allowe2. Open up the head light and check that the wires have good connection Check the voltage between two wires 1s 36V as two yellow marks on Fig 1 If the voltage between two wires 1s 36V the head light 15 damaged Replace head light 23 5 If there is not 36V check the voltage between two wires in the battery indicator as two yellow marks on Fig 2 6 If the voltage between two wires 15 36V the battery indicator is damaged Replace battery indicator 24 7 Rear light 7 1 Rear light overview Rear light 7 2 Rear light removal Unscrew the rear light from the frame Tool Spanner De soldering the two wires Tool Soldering iron Screw the rear light to the frame Tool Spanner Solder the two wires Tool Soldering iron 25 Put the heat shrink tubes to cover two soldering points and shrink the tubes with a heat gun Or carefully wrap with electrical tape 7 4 Rear light trouble shooting 7 4 Rear light does not work Checking the voltage between the two wires 15 36V refer to Fig 1 If the voltage 15 36V the rear light is damaged Change rear light 26 8 Signal wires of left and right brake lever 8 1 Brakelever overview Brake lever 8 2 Signal wire installation removal Unscrew the screw to remove the signal wire Tool Phillips screwdriver 8 3 Signal wire trouble shootin 8 3 7 1 The LED on the controller blinks 3 times Check if both left and rig
3. Chain guard Suspension fork Disk brake Front LED light Head tube Brake wire Head stem Aluminum alloy frame Controller Battery 15 16 17 18 19 20 21 22 23 24 25 26 21 28 Seat post Saddle Seat folding mechanism Rear carrier Rear light Left brake lever Digital speedometer odometer Battery indicator Right brake lever Throttle Gear shifter Gears Chain Brushless DC motor 2 Controller 2 1 Controller Overview 1 Self diagnostic LED 2 Motor phase wires 3 Motor hall wires 4 Battery gauge Throttle Brake lever 5 Motion sensor 6 Power cables 2 2 Part Identification C1 9923 20 mile hr maximum speed Microprocessor controlled PWM output for 36V Brushless hub motor with planetary gears Ebike EPAC controller unit Overload protection 20 amps under voltage protection 31 5 V Die cast aluminum casing 2 3 Controller installation removal The controller is mounted on the bicycle in the space between the battery slot and the rear wheel Make sure that the bicycle 1s turned off and the battery taken out before proceeding with the removal of the controller Turn over the bicycle on a clean soft surface or mount it on a bicycle repair stand during the operation to prevent surface scratches and damage Disconnect all wires attached to the controller You will find these wires on the underside center of the bicycle below the battery slot base plate Note 1
4. HEBB E BIKES ELECTROGLIDE 500 TECHNICAL SERVICE MANUAL Index 1 Bike overview 2 Controller 2 1 Controller overview 2 2 Part identification 2 3 Controller installation removal 2 4 System diagram 2 5 Self diagnostic indicator 3 Motor 3 1 Motor overview 3 2 Motor installation removal 3 3 Motor maintenance 3 4 Motor trouble shooting 4 Battery 4 1 Battery overview 4 2 Battery removal 4 3 Battery installation 4 4 Wire diagram 4 5 Battery trouble shooting 4 6 Battery testing unit 5 Charger 5 1 Charger overview 5 2 Charging protocol 5 3 Charger trouble shooting 6 Battery indicator 6 1 Battery indicator overview 6 2 Battery indicator removal 6 3 Battery indicator installation 6 4 Battery indicator trouble shooting 7 Head light 7 1 Head light overview 7 2 Head light installation removal 7 3 Head light trouble shooting 8 Rear light 8 1 Rear light overview 8 2 Rear light removal 8 3 Rear light installation 8 4 Rear light trouble shooting 9 Throttle 9 1 Throttle overview 9 2 Throttle removal 9 3 Throttle installation 9 4 Throttle trouble shooting 10 Signal wires of left and right brake lever 10 1 Brake lever overview 10 2 Signal wire installation removal 10 3 Signal wire trouble shooting 11 Front Wheel Removal for Tire Repair 12 Rear Wheel Removal for Tire Repair 1 Bike Overview 00 Bp WO N me LH Wo NO Mudguard Rim Crank Chain wheel Pedals
5. al 2 pin black for ground 3 pin red for 5V Placing probes on 1 pin 2 pin 1 pin 3 pin 27 pin 3 pin If there is short circuit replace 5 times No motor movement when throttle 1s turned throttle Otherwise replace battery gauge 6 times Low voltage Charge the battery This is a warning signal when battery voltage drops below 30 5V Bike is functioning but user needs to charge the battery ASAP The blinks will stop once the battery is charged up to 34V If voltage is below 20V red LED light will be off and unable to activate controller 7 times Excessively high voltage The battery voltage 1s above 44V and the battery should be replaced 8 times Hall sensor in hub motor Please refer to the system diagram and disconnect the 5 breaks off pins hall sensor connector Make sure every pin is clean and mounted firmly Reconnect the connectors securely Replace the motor if the above does not work 9 times Failure of supply 3 phase a Please refer to the system diagram and disconnect the wires 3 motor phase wire connectors after the connector housings are removed as Fig 2 Fig 2 b Using a multi meter to verify if these 3 cables are broken by placing probes on A yellow green B yellow blue green blue If the ohms values among any 2 of these 3 cables are unlimited value replace motor See Fig 3 10 reduced to reduce the load and cool down controller 11 times Thermostat failure R
6. connects the EPAC interface wire to the battery indicator and unplug the connector under the BB axle Unscrew battery indicator unit clamps Tool Phillips screwdriver Screw the battery indicator unit clamps to the handle bar Tool Phillips screwdriver Unscrew 3 screws to open up the battery indicator cover Tool Phillips screwdriver Plug the left and right brake signal connectors 2 indicator cover Tool Phillips screwdriver Connect the throttle connector then cover the heat shrink tube Use the nylon cable ties and the spiral wrapping band to tie the cables together Tie and wrap the cables along the underside of frame Connect the connector from the controller and covered by the heat shrink tubes around the BB axle 5 4 Battery indicator trouble shootin 5 4 1 Battery indicator is not responding Ensure that problem is not power failure Replace the battery indicator in case of malfunction The battery indictor has no serviceable parts Insure that all wiring is intact and in working condition If the problem persists replace entire battery indicator 22 6 1 Head light Head light overview 6 2 Unscrew the head light from the frame Head light Head lieht installation removal Tool Allen wrench Spanner 6 3 Head light trouble shooting 6 3 1 Head light does not work 1 2 3 4 Make sure the switch on the battery indicator 1s
7. d on brake lever If a lever is not in rest position and the brake cable is not loose replace the brake lever Refer to the system diagram and take apart the battery gauge checking the contacts of both sides brake levers by a multi meter The contact is closed when the brake is in rest position and is open when the brake is activated Replace the brake lever if the levers do not perform as above NOTE Make sure to gently disconnect the connector as they are glued with silicone to the board Replace the battery gauge if the above processes are all good and the light still blinks 4 times Throttle does not return to The throttle should return to the rest position by Zero position twisting the throttle all the way to the end and releasing Turn off the bike and turn on power again If the LED still blinks replace throttle Note You may be able to get the throttle to return to the rest position by slightly loosening the 2 mm bolt holding the throttle to the handlebar a Make sure the throttle inside circuit 1s not wet Remove the throttle and let it dry Requires several hours or up to 2 days to dry depending on how wet the throttle is 90 error lies at throttle very few fail at battery gauge Please refer to the system diagram and disconnect connectors between throttle and battery gauge Use a multi meter to verify if there 1s a short circuit at the throttle connector among first 3 pins The 1 pin green for sign
8. eplace the controller The thermostat 15 to protect the controller from high temperature The controller can still drive the motor but it may be burned if temperature increases too high Controller failure Replace controller Motor cannot be activated Controller failure Replace controller Motor cannot be activated 10 times Controller temperature high Cool down the controller ASAP The controller thermostat activated temperature protection is activated Motor is able to continue to work but the current will be automatically 3 4 times Motor stalled Make sure there isn t any obstacle to prevent the motor from turning Switch key off and on again to reboot the bike An extremely high load will stall the motor Power will be cut off if overload protection is activated 3 5 times Supply 3 phase wires broken a Please refer to the system diagram and disconnect the This symptom will show 3 motor phase wire connectors after the connector only when the power is on housing is removed as Fig 2 and throttle 1s twisted b Using a multi meter to verify 1f these 3 cables are broken by placing probes on A yellow green yellow blue green blue If the ohms values among any 2 of these 3 cables are an unlimited value replace motor See Fig 3 11 3 Motor 3 1 Motor overview EZ DP 3 si lt 36V nominal 350W planetary reduction gear brushless hub motor 3 2 Motor installation removal 3 2 1 Remove n
9. harging charge battery in a clean cool and dry place Ensure voltage on charger is set correctly and fuse is working and secure Plug power cord into wall socket Plug charger to battery and then turn on charger Red light indicates charger is on Yellow light indicates battery is charging Green light indicates charging has stopped 5 3 Charger Trouble shooting 5 3 1 Charger does not light up Ensure that voltage has been set correctly Ensure that the 10 fuse has not blown replace if necessary Ensure that power cord is fitted in properly and in good condition 5 3 2 Charger yellow light is blinking The charger 15 sensitive to movement temperature and voltage drop Switch off charger and retry using the protocol described above 5 3 3 After retrying charging protocol problem persists Inspect battery fuse There are no distributor serviceable parts on the Lithium Ion battery Replace battery 1f necessary 19 5 Battery Indicator 5 1 Battery Indicator overview Battery indicator unit Two step switch available in following arrangements according to wiring settings LED on off Bi model arrangement Secondary on off Ebike safety precaution 5 2 Battery indicator removal Take off the heat shrink tube and disconnect the throttle connector indicator cover Tool Phillips screwdriver 20 Unplug the left and right brake signal connectors Cut away the nylon cable ties and shrink tube that
10. hooting 9 4 1 The motor does not move when the throttle 1s twisted Check the voltage of pin 1 throttle on the throttle connector refer to Fig 1 The voltage should change when the throttle 1s twisted If the voltage does not change the throttle is defective Replace with a new throttle 9 4 2 The motor moves slightly when the throttle 1s n the off position Check the voltage of pin 1 throttle on the throttle connector refer to Fig 1 The nominal voltage should be 0 9V If the voltage 1s over 1 2V the function of throttle is abnormal Replace with a new throttle 9w Switch LED FO Satih Throttle Indicator N Side Ground 3 Side Throttle hrottle Connector Throttle Pinout Fig 1 29 10 Signal wires of left and right brake lever 10 1 Brake lever overview Brake lever 10 2 Signal wire installation removal Unscrew the screw to remove the signal wire Tool Phillips screwdriver 10 3 Signal wire trouble shootin 10 3 1 The LED on the controller blinks 3 times 9 Check if both left and right brake levers return to its rest position No clearance 1s allowed on brake lever If it is not in rest position and the brake cable is not loose replace the signal wire of brake lever 10 Refer to the system diagram and take apart the battery gauge checking the contacts of both sides brake levers by multimeter The contact is closed
11. ht brake levers return to its rest position No clearance is allowed on brake lever If it is not in rest position and the brake cable is not loose replace the signal wire of brake lever Refer to the system diagram and take apart the battery gauge checking the contacts of both sides brake levers by a multi meter The contact is closed when the brake 1s in rest position and is open when the brake is activated Replace the signal wire of brake lever if 1t does not respond correctly Note Make sure to gently disconnect the connectors as they are glued with silicone to the board 27 9 Throttle 9 1 Throttle overview Throttle 9 2 Throttle removal Take of the wire and the heat shrink tube and disconnect the throttle Using a very sharp knife is helpful in E removing the heat shrink but be very BS careful not to cut any wires Unscrew the throttle Tool 2 mm Allen wrench Slide off the throttle Note the J routing of the throttle wires X Slide on the replacement throttle Route the throttle wire the same as the original throttle 28 Tighten the 2mm Allen bolt Tool 2mm Allen wrench Note Only tighten enough so the gt throttle does not slide off the handlebar Ifover tightened it may prevent the throttle spring from properly working 1 Connect the connector 2 Wrap connection with electrical tape i 3 Replace the wire ties to secure the wires 9 4 Throttle trouble s
12. icator flashes 8 times Check wires and ensure that all are in order Open up motor to inspect for short circuitry 3 4 6 LED does not blink motor does not operate Check to insure throttle 1s working 15 4 Battery 4 1 Battery overview 1 Charging port 2 Housing screws 3 Fuse 4 Battery sliding groove 5 Locking pin socket 6 Bottom plate screws Li Lithium Manganese Oxide LiMnO Battery 37V 10AH E2 002 30A Fuse and fuse cover Note There are no distributor serviceable parts in the Li battery Removal of the warranty sticker will void warranty 16 4 2 Wiring Diagram Wiring diagram for LiMnO Battery 37V 10AH Charging port Battery bottom plate 4 3 Battery Trouble Shooting 4 3 Problem Battery does not fit properly into holder Solution 1 Remove battery and realign it along the battery grooves 2 If fitting 1s too tight apply grease on grooves for lubrication 4 3 2 Problem Battery 1s in holder but the key does not turn Solution 1 Push battery firmly down and ensure that it is securely in place 2 Check the alignment of battery locking socket and the pin 3 Ensure that the correct key 15 used for the bicycle 4 3 3 Problem Battery is in holder key 1s at on position but there is no power Solution 1 Ensure that the battery is charged battery pins are not damaged and fuse is not blown 2 Check integrity of power cables Refer to the system diagram 4 3 4 P
13. mited to re greasing the gears or replacement of gears Any modification or reparation work done without explicit consent of Hebb will immediately void warranty 3 3 2 Apply silicone grease on gears and gear ring with a soft brush as shown on the pictures above 3 3 3 Removal of planetary gears Remove washer Tools required Snap ring pliers 3 3 4 Use Snap ring pliers to remove snap ring Apply the 2 pointed ends of the snap ring pliers into the holes located in the snap ring Gently and firmly press the plier s handles to enlarge the ring out of its groove Remove the snap ring out and over the axle 3 3 5 To prevent water from leaking into the motor core apply silicone as shown 14 3 3 6 Silicone should completely cover up the cable entry point in the axle Refit motor wheel when the silicone is dry 3 4 Motor trouble shooting 3 4 1 Motor is not working Check LED self diagnostic indicator Ensure that all cables are properly attached see wiring diagram 3 4 2 Motor makes grinding noise but refuses to spin Check that the phase wires of motor are connected in correct order 3 4 3 Motor runs but cuts immediately or during riding Check wires and ensure that all are in order Open up motor to inspect for short circuitry 3 4 4 Motor makes grinding noises throughout ride Open up motor to examine planetary gears for any damage or misalignment 3 4 5 LED self diagnostic ind
14. n shifting cable into groove of the hub and snap the nut back into position 38
15. roblem Battery pin is damaged Solution Refer to battery wiring diagram Remove fuse before attempting any repair of the pins Refer to battery bottom plate for positive and negative wires 4 3 5 Problem Li battery cannot be charged Solution 1 Ensure that the fuse is intact 2 Use a different charger 17 CAUTION Do not attempt to open Li to trouble shoot Record battery details and keep aside for future inspection by Hebb 4 3 6 Problem Battery is not giving enough mileage has lower capacity than specification Solution Be sure the battery has been properly charged several times Warranty for battery is 80 of DOD for 1 year from the date of purchase The battery must be tested to determine the amount of discharge NOTE 1 Use the correct battery charger to charge battery 2 Charge the battery for 30 minutes after 3 months without using hour after 6 months without using 3 Do not fully discharge the battery 4 Keep batteries in a cool and dry storage area 18 5 Charger 5 1 Charger overview MODEL HP 204C 1 INPUT tyeesovac gt 107 i RED su LED YELLOW CHARGING 60 SOMz 1 5 0 9 GREEN FULL CHANG OUTPUT NORTON E ioco O Lithium Ion battery charger 2 Amps smart charge maximum charge time 4 5 hours Do not attempt to use Li charger with other battery types Always ensure voltage is set correctly to your country s specification 5 2 Charging protocol For optimum and safe c
16. ut spring washer and spacer located on the right side of the bicycle Tools required 19mm wrench Hex key 4 3 2 2 Release nut torque plate screwed onto fork and spacer on the left side of bicycle The motor wires are threaded through these parts These parts may not be removed without first cutting off the connection plugs from the motor wires The protection bracket may be removed 3 2 3 If it is necessary to remove front hub wheel completely away from the bicycle remove connections located by the front fork as shown The front wheel may now be removed from the bicycle 12 Note When reinstalling the bicycle remember to fit front hub motor wheel in the correct direction 3 2 4 Release all 6 screws on hub motor cover Tools required Philips head screwdriver 7 KINN 3 Note Releasing screws will detune spoke tension Remember to recalibrate spokes on wheel after installation 3 2 5 Knock axle as shown on the picture to release hub motor from casing Tools required Rubber mallet Remove hub motor Note 1 Hub motor should be worked on in a clean environment to avoid particles from entering sensitive electronic equipment 2 Ensure while working or when placing away the hub motor not to put weight or pressure on the axle to prevent damage of the axle 13 3 3 Motor maintenance 3 3 All motor parts are not serviceable by dealers with the exception of gears Gears servicing is li
17. when the brake 15 in rest position and is open when the brake is activated Replace the signal wire of brake lever if 1t does not respond correctly PS Make sure gently disconnect the connectors as they are glued with silicone to the board 30 11 Front Wheel Removal for Tire Repair Eu 87 ON LLLA P 1 Remove screws on torque plate using 4mm hex key 3 Remove all the small parts nuts washers torque plate etc 3 6 Disconnect cable 9 Take wheel out of the fork and proceed to change inner tube or tire 29 10 Put wheel back in place and tighten both sides evenly a little on each side at a time Reconnect the cables and wires Check alignment of the disc brakes 34 12 Rear Wheel Removal for Tire Repair A Ar 4 A _ ar Fi 1 Shows gear shifting cable 2 Grip cable with fingers or pliers 3 Release shifting cable and nut from hub by pulling backward and outward 35 E au ii 4 Release nut and bolt assembly from brake assembly using 10mm wrench and nut driver At this point you should also remove the axle nuts and torque washer 6 Release rear wheel from frame to change tire or inner tube 36 9 Tighten nuts of both sides evenly and slightly do not tighten yet 37 10 Pull wheel backward with one hand and the other holding against rear stay so that chain has slight tension is not loose 11 Alig
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