Doohan iTank Maintenance Manual
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Doohan iTank Maintenance Manual

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Summary of Contents for Doohan iTank

  • Page 2 The employee of service provider authorized by Zhejiang Doohan Technology Co., Ltd. can provide better service to iTank users after having knowledge of this manual and the maintenance technology report which will be published afterwards.
  • Page 3 Warning: To reduce the possibility of personal and/or property damage, the following instructions must be followed: The maintenance manual provided by Zhejiang Doohan Technology Co., Ltd. is compiled for qualified professional technicians. If, any attempt to repair or maintain the vehicle without proper training and appropriate tools and equipment may lead to vehicle damage or abnormal operation of the vehicle.

  • Page 4: Table Of Contents

    Contents Chapter 1.The vehicle information Chapter 2 Standard component specification and general torque Chapter 3 Dismantle and replacement of parts of the car 3.1 Disassemble and switch the covering parts 3.1.1 Schematic diagram of the covering parts 3.1.2 Procedure of dismantling and switching the covering pieces and the tools required 3.2 Disassembling and changing of steering handle 3.2.1 Schematic diagram of the steering handle...
  • Page 5 3.4 The rear wheel and rear disc brake system 3.4.1 The rear wheel and back disc brake system map 3.4.2 Tools needed to disassemble and switch the rear wheel, rear disc brake system and the order of disassembling and switching 3.4.3 Disassemble and replace of the lower pump of the rear disc brake 3.4.4 Disassemble and switch split back splash guard 3.4.5 Disassemble and change the rear wheel and rear disc brake plate...
  • Page 6 Chapter 4 An introduction to electrical parts and their repair 4.1 Electric device 4.2 An introduction of the electrical parts 4.3Electrical principle diagram 4.4 Faulting phenomenon and repair method...

  • Page 7: Chapter 1.The Vehicleinformation

    Chapter 1.The vehicleinformation...

  • Page 9: Chapter 2 Standard Component Specification And General Torque

    Chapter 2 Standard component specification and general torque This chapter is used to inform the customers the specification of the standard components the vehicle uses and their corresponding repair tools. Specify the locking torque force for standard fixtures according to ISO standard screw thread depth.
  • Page 10 2. The car uses inner hexagon flange bolt, whose national standard number is GB/T70.1-2000. For the standard component specification, repair tools specification and general torque please refer to the following table: 3.The car uses hexagon flange bolt whose national standard number is GB/T 6177.1- 2000, and hexagon locking-nuts with flange, whose national standard number is GB/T6187.1.
  • Page 11 4.The car uses inner hexagon flange bolt, whose national standard number is GB/T70.2-2000. For the standard component specification, repair tools specification and general torque please refer to the following table: 5.The car uses cross recessed pan head tapping screws which national standard number is GB/T 845-1985, GB/T818-2000 cheese head screws with cross recess, the repair tools are uniformed as cross screwdriver There are no requirements for torque force, screwing down will be enough.

  • Page 12: Chapter 3 Dismantle And Replacement Of Parts Of The Car

    Chapter 3 Dismantle and replacement of parts of the car Preparation for dismantling and replacement ①Before the dismantling or removal, clean the dust, dirt and foreign matter on the car. ②While dismantling, the paired parts must be put together. The paired parts must be used repeatedly or switched in pairs ③While dismantling, clean all the parts, and put them on the tray in the order of dismantling sequence.

  • Page 13: Disassemble And Switch The Covering Parts

    3.1 Disassemble and switch the covering parts 3.1.1 Schematic diagram of the covering parts...

  • Page 14: Procedure Of Dismantling And Switching The Covering Pieces And The Tools

    3.1.2 Procedure of dismantling and switching the covering pieces and the tools required...
  • Page 15 Notes: ●Use appropriate support to support the car, so that the front wheel will hang in the air. ●Dismantle the parts in order. While installing, follow the sequence in an opposite direction of the dismantling process. ●If the solid wrench is not applicable, you can switch to sleeve or speed wrench of the same specification.

  • Page 16: Disassembling And Changing Of Steering Handle

    3.2 Disassembling and changing of steering handle 3.2.1 Schematic diagram of the steering handle...

  • Page 17: Tools Required To Change And Disassembling The Steering Handle Base Order

    ●If the solid wrench is not applicable, you can switch to sleeve or speed wrench of the same specification. 3.2.3 Change the steering handle base ① Place iTank on a flat platform ②Dismantling steps: ●Lower part of the front panel ●Front storage box trimming : Clutch on one end of the front storage box trimming, pull it down with great force.

  • Page 18: The Front Wheel And Front Disc Brake System

    ●Right trimming of front storage compartment : Same as the above ●Front panel assembly ●Upper cover of front storage compartment ●Refer to "Disassemble the covering pieces". ●Handlebar block ●Handlebar seat ③ After changing the steering handle base, install according to the order opposite to the disassembly 3.3 The front wheel and front disc brake system 3.3.1 The front wheel and front disc brake system map...

  • Page 19: Tools Needed To Disassemble And Switch The Front Wheel, Front Disc Brake System And The Order Of Disassembling And Switching

    3.3.2 Tools needed to disassemble and switch the front wheel, front disc brake system and the order of disassembling and switching Notes: Use appropriate support to support the car, so that the front wheel will hang in the air. Dismantle the parts in order. While installing, follow the sequence in an opposite direction of the dismantling process.

  • Page 20: The Check Of Front And Back Tyres

    Exceeded the standard value (225±10KPa), please adjust the tyre pressure. Warning: ●Please check and adjust the tyre pressure when the exterior tyre temperature equals to the outdoor temperature. ●Driving an overloaded iTank will lead to the damage of the tyre or accidental injury ●Don't overload the iTank...
  • Page 21 (2) The surface of the exterior tyre is as follows I the depth of the tyre lines ⅡAbrasion indicator...
  • Page 22 If there are damages or wears, please switch. Warning: ●Better not try to revamp a pierced tyre. If this must be done, please be as carefully as possible and switch a high-quality tyre as soon as possible. ② Check the wheel rim and the disc brake plate (1) Wheel rim If there are damages or wears, please switch.
  • Page 23 (2) The plate of disc brake is as follows If the thickness of the plate of disc brake disc is beyond the standard values, please replace the disc brake disc. (3) Hydraulic braking head is as follows If the thickness of the front and back hydraulic braking head A exceeds the standard value, please switch.

  • Page 24: Disassemble And Replace The Front Disc Brake Lower Pum

    Warning: ● When the braking head on one side is worn to the usage limit, the whole braking head unit must be switched. 3.3.4 Disassemble and replace the front disc brake lower pump...

  • Page 25: Disassemble And Change The Front Wheel And Front Disc Brake Plate

    ① Put the iTank on a flat platform, then use appropriate support to support the iTank to make the front wheel be above the ground, and do not let it overset. ②Dismantling steps: ●Mud guard of left front wheel ●Front wheel axle decorating parts ●The lower pump of the front disc brake...
  • Page 26 ②Dismantling steps: ● Mud guard of right front wheel ● Front wheel axle decorating parts ● The lower pump of the front disc brake ● Front wheel ● Front disc brake plate Refer to "The front wheel and front disc brake system". ③...

  • Page 27: The Rear Wheel And Rear Disc Brake System

    3.4 The rear wheel and rear disc brake system 3.4.1 The rear wheel and back disc brake system map 3.4.2 Tools needed to disassemble and switch the rear wheel, rear disc brake system and the order of disassembling and switching...

  • Page 28: Disassemble And Replace Of The Lower Pump Of The Rear Disc Brake

    3.4.3 Disassemble and replace of the lower pump of the rear disc brake ① Put the iTank on a flat platform, then use appropriate support to support the iTank to make the front wheel be above the ground, and do not let it overset.

  • Page 29: Disassemble And Switch Split Back Splash Guard

    3.4.4 Disassemble and switch split back splash guard ① Place iTank on a flat platform ②Dismantling steps: ● Fork protective cover: use slot type screwdriver to prize the fork protective cover ● Back mud guard support ● Fork protective cover support ●...

  • Page 30: Disassemble And Change The Rear Wheel And Rear Disc Brake Plate

    3.4.5 Disassemble and change the rear wheel and rear disc brake plate ① Put the iTank on a flat platform, then use appropriate support to support the iTank to make the front wheel be above the ground, and do not let it overset.

  • Page 31: The Seat Tank And The Rear Cushion

    ③ After changing the rear wheel and rear disc brake plate, install in the order opposite to the disassembly 3.5 The seat tank and the rear cushion 3.5.1 Schematic diagram forThe seat tank and the rear cushion...

  • Page 32: Tools Needed To Disassemble And Switch The Sitting Tank And Rear Cushion And The Order Of Disassembling And Switching

    3.5.2 Tools needed to disassemble and switch the sitting tank and rear cushion and the order of disassembling and switching Notes: Dismantle the parts in order. While installing, follow the sequence in an opposite direction of the dismantling process. If the solid wrench is not applicable, you can switch to sleeve or speed wrench of the same specification.
  • Page 33 ① Place iTank on a flat platform ②Dismantling steps: ● Lower part of the front panel ● Trimming of front storage compartment ● Left trimming of front storage compartment ● Right trimming of front storage compartment ● Front panel assembly ●...
  • Page 34 ● Trim bar of right trim plate ● Rear trim plate of storage compartment ● Front battery bunker cover ● Upper cover of trim panel ● Rear battery bunker cover ● Left trim panel ● Right trim panel Refer to "Disassemble the covering pieces". ●The inner cover of the seating tank ●...

  • Page 35: Disassemble And Changing Rear Cushion

    ③ After changing the sitting tank , install according to the order opposite to the disassembly 3.5.4 Disassemble and changing rear cushion ① Place iTank on a flat platform ②Dismantling steps: ⚫ Refer to "Disassemble and changing sitting tank ⚫ Rear cushion ③...

  • Page 36: Procedure Of Dismantling And Switching The Front Mechanism And The Tools

    3.6.2 Procedure of dismantling and switching the front mechanism and the tools required...

  • Page 37: Disassemble And Switch The Front Mechanism (The Whole Machine)

    3.6.3 Disassemble and switch the front mechanism (the whole machine) ① Put the iTank on a flat platform, then use appropriate support to support the iTank to make the front wheel be above the ground, and do not let it overset.
  • Page 38 ● Left trimming of front storage compartment ● Right trimming of front storage compartment ● Front panel assembly ● Upper cover of the front storage compartment ● Hook for the safety helmet ● Front storage compartment ● Left mud guard of bicycle frame ●...

  • Page 39: Front Mechanism Exploded Views (Components)

    ● Left trim panel Refer to "Disassemble the covering pieces". ● Mud guard of front wheel ● Front wheel axle decorating parts ● The lower pump of the front disc brake ● Front wheel Refer to "Disassemble and changing of front wheel" ●...

  • Page 40: Disassemble And Change Steering Linkage Assembly

    3.6.5 Disassemble and change steering linkage assembly ① Put the iTank on a flat platform, then use appropriate support to support the iTank to make the front wheel be above the ground, and do not let it overset. ②Dismantling steps:...

  • Page 41: Disassembly And Change The Steering Base

    ● Rubber sleeve seal cartridge cut off the ribbon that binds the bearing rubber case ● Steering linkage assembly Pull the bearing dust prevention rubber case on in the circle of the picture below to the inside to display the knuckle bearing at the end of the rod, Then take off the left steering base, connecting rod of the steering column and the cotter of the right steering base separately, and use a 16# wrench to unscrew the three M10 open slot nuts, take out the steering linkage assembly and use a 16#...
  • Page 42 ① Put the iTank on a flat platform, then use appropriate support to support the iTank to make the front wheel be above the ground, and do not let it overset.

  • Page 43: Dismantling And Change Knuckle

    ● There are right and left knuckles, if you want to change knuckle on one side, you only need to dismantle parts connected to it. ① Put the iTank on a flat platform, then use appropriate support to support the iTank to make the front wheel be above the ground, and do not let it overset.
  • Page 44 ● Mud guard of front wheel ● Front wheel axle decorating parts ● The lower pump of the front disc brake ● Front wheel Refer to "Front wheel and front disc brake system". ● Lower part of the front panel ●...
  • Page 45 ③ Change the elevation in the order opposite to the disassembly...
  • Page 46 Chapter 4An introduction to electrical parts and their repair 4.1 Electric device (1) Buzzer (2) Flasher (3) VCU (4) Accelerator (5) Burglar alarm (6)Horn (7)DC-DC converters (8) Left switch (9) Right switch (10) Controller (11) Kick stand shut-down switch...
  • Page 47 4.2 An introduction of the electrical parts Cell: Cell is the on-mobile power providing energy to the electrombile. The batteries of the electro mobiles produced by our company all uses 18650 ternary battery of the Japanese and Korean system. The total capacity of the battery pack is improved by series connection.
  • Page 48 Controller is the part which controls the electric machine's speed, it is also the core of the electrombile's electrical system. It uses FOC vector control technology. The starting noise is small. And the vehicle has undervoltage, current limit and overcurrent protection functions. Applying the brake during the driving process can recover the energy by using electrical machine as the generator.
  • Page 49 connecting the input end of the charger to the, or else the charger will not be launched into charging state; the charge has precharge function. When the pressure of the battery is lower than 4.45V and higher than 35V, it will enter into precharge state. When the batter pressure is higher than 46.4V, it will enter into normal charging state.
  • Page 50 VCU is the vehicle's central control system. It is used as the part of the vehicle for receiving and sending data. SIM card, GPS orientation module and gyroscope is set within it. For example, when a vehicle's location changes, check the location via GPS module, send the location to the server via SIM card's network, after processing by the server, the location will be updated to the map on the interface of the APP, at this time, the location of the vehicle can be read by people And the data and status of the vehicle...
  • Page 51 Burglar alarm: The burglar alarm has the functions of searching for the car, burglar alarming and locking the electrical machine. 4.3Electrical principle diagram...
  • Page 54 4. 4 Faulting phenomenon and repair method 4.4.1 Complete vehicle is out of electricity ① The battery is out of electricity: a.Press the button of indicator light; observe whether the indicator light is turned on, if the red light is always on than the electricity is at its lowest, if the red light flickers than the battery is out of electricity.
  • Page 55 c. If after the battery is fully charged, the battery pressure is still very low after being tested according to the “a” and “b” step, then the battery is faulty, it needs to be vamped and switched. ② The battery has electricity, when it is connected to the vehicle, the vehicle has no electricity If the battery has electricity, after connecting it to the vehicle's battery plug, opening the electrical door lock, the vehicle has no electricity, check whether the battery plug...
  • Page 56 If the pressure is over low or there is no pressure, it means that the battery has no normal output, check whether the fuse 70A and 5A of the vehicle are fused(disconnect the battery first), the fuse of 5A is in the cover of the controller under the cushion, it can only be seen when it cover is uncovered, if the 70A fuse is fused, check whether the controller has been burned out, if 5A's fuse is fused, then check whether DC converter has been burned out...
  • Page 57 Similar to the methods of measuring the controller, dismantle the big light part of the vehicle, unplug the converter plug, measure whether the red line of the converter are conducted with the green line or black line. If they are conducted, then the converter has been burned out and needs to be changed d.
  • Page 58 The battery output is normal, the instruments, lights and the horn all do not work, the vehicle has no forward gear, and can only back off, at this time the DC converter has burned out, and needs to be switched or repaired b.
  • Page 59 control, press lock, open or search key, to see if they function properly, if they do then the power supply is normal, take the second step ② Disconnect the battery for over 2 minutes, then connect the battery, open the electrical door lock and observe whether the instrument displays normally, connect working personnel to update VCU software remotely;...
  • Page 61 4.4.2 Faults phenomenon: Open the electrical door lock, turn the speed regulating handle, the electrical machine doesn't rotate Failure reason and maintenance program ① The battery voltage is too low, the controller enters into undervoltage protection; Charge the battery ② Whether the accelerator pull box has been reset Check whether the accelerator bracing wire has been took off from the accelerator pull box, install properly ③The accelerator pull box is broken: Change the accelerator pull box;...
  • Page 62 ⑥The electrical machine HALL plug is not well connected to the controller: Unplug the electrical machine HALL connector, re-plug it; ⑦The electrical machine HALL is burned out: Repair the electrical machine HALL or change the electrical machine ⑧The controller is burned out: Repair or change the controller 4.4.3 Faults phenomenon: After the battery is fully charged, the driving distance is short Failure reason and maintenance program...
  • Page 63 Failure reason and maintenance program ① The charger is faulty, so the battery is not fully charged: Change or revamp the charger. ② The battery socket is aging, the connection is not good: Repair or change the battery. 4.4.5 Faults phenomenon: When the charger is charging the vehicle or battery, after plugging the plug, the charger green light is always on or no light is on and the fan doesn't move, cause of the faulty and methods to repair: ①Notice the order of connection between the charger and the battery: Firstly connect...
  • Page 64 ④ When the charger and the battery are connected, the indicator light is not on: Change or repair the charger; ⑤The charger is charging the battery, the fan is not moving: Change or revamp the charger. 4.4.6 Faults phenomenon: The battery electricity quantity display is not accurate, it is not displayed as 100% when the battery is fully charged, the display difference is great, cause of the fault and repairing method: ①Conduct full charge and full discharge learning calibration to the battery：...
  • Page 69 If you find any errors or if you have any advice to manual produced by Zhejiang Doohan Technology, Co., Ltd., we would like to listen. You can report the error and advice to Zhejiang Doohan Technology Co., Ltd. through mail or email, our contacting info. is as follows: After-Sales Department of Zhejiang Doohan Technology Co., Ltd.
  • Page 70 ● Necessary relevant info.(such as a sample or marked page) Zhejiang Doohan Technology Co., Ltd. will reply to your problem in the following methods: ● Present your problem to relevant repair engineers ● Ask relevant repair engineers to reply ● Provide the answer to your problem in 10 working days We welcome Doohan customers to send their concerned issue to After Sale Department of Zhejiang Doohan Technology Co., Ltd., Tel:...

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