GreenWorks OVB916 Service Manual
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GreenWorks OVB916 Service Manual

GreenWorks OVB916 Service Manual

80v e-bike 26inches
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80V E-BIKE 26INCHES
SERVICE MANUAL
OVB916
www.greenworkstools.com
REV1.0
1

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Summary of Contents for GreenWorks OVB916

  • Page 1 80V E-BIKE 26INCHES SERVICE MANUAL OVB916 www.greenworkstools.com REV1.0...

  • Page 2: Table Of Contents

    Table of contents 1. Component location ........................ 4 2. Warning ............................ 6 3. Electrical system ........................7 3.1 Schematic diagram of electrical components connection for the entire vehicle ......7 3.2 Description of instrument display ..................... 7 3.3 Error codes ............................8 4.
  • Page 3 6.2 Drive Motor and Transmission Parts ....................26 6.2.1 Motor wheel .......................... 26 6.2.2 Chainset ..........................27 6.2.3 Free wheel ..........................28 7. Operator System ........................29 7.1 Seat Assembly ..........................29 7.1.1 Saddle ..........................29 7.2 Braking System ..........................30 7.2.1 Brake disc ..........................

  • Page 4: Component Location

    Component location 1. Handlebar 8. Kickstand 2. Headlight 9. 7-speed derailleur 3. Front fork 10. Rear-hub motor 4. Front disc brake 11. Tire 5. Brake caliper 12. Seat post clamp 6. Pedal 13. Saddle 7. Battery box 21 20 14. Front brake lever 18.
  • Page 5 22. On/off button 25. Walk-assist button 23. Parameter setting button 26. Headlight button 24. PAS (Pedal-assist sensor) 27. PAS (Pedal-assist decrease button sensor) increase button REV1.0...

  • Page 6: Warning

    Warning 2.1. All disassembly, replacement, repair, and maintenance operations must be performed by professional operators who have read this manual. 2.2. For the ease of quick disassembly and maintenance, you are advised to: before disassembly, put the machine in a suitable work area; prepare the necessary disassembly tools beforehand; remove the bolts in an appropriate order;...

  • Page 7: Electrical System

    Electrical system 3.1 Schematic diagram of electrical components connection for the entire vehicle 1. Headlight 4. Right brake lever 7. Controller 2. Left brake lever 5. Speed regulation switch 8. Motor 3. LCD display 6. Battery pack 3.2 Description of instrument display 1 10 1.

  • Page 8: Error Codes

    3.3 Error codes Error Codes Error Contents Possible Solution Controller fault 1. Check if the fault is eliminated after replacing the controller. E001 2. If the fault persists, contact the after-sales service team. Communication fault 1. Unplug and plug the connector between the instrument and the main line, and check whether the fault is eliminated.

  • Page 9: Body And Structures System

    Body and Structures System 4.1 Frame Assembly 4.1.1 Bell Fig.1 1. Screw M4*20 2. Bell Disassembly: 1. Remove the fixing screws (1) that hold the bell to the handle bar with a cross screwdriver to take out the old bell (2). Assembly: 1.

  • Page 10: Pedal

    4.1.2 Pedal Fig.2 1. Pedal Disassembly: 1. Loosen the fixed connection between the pedal (1) and the crank with a wrench to the pedal (1). Assembly: 1. Install the new pedal (1) on the crank and tighten it with a wrench. Note: Remove the left pedal clockwise;...

  • Page 11: Chain

    4.1.3 Chain Fig.3 Chain Disassembly: 1. Locate the interface of the chain (1) (first find the place marked with a symbol, which is the interface); 2. Align the opening of the chain cutter with the pin (2) at the interface of the chain (1) and press down to remove the pin (2);...

  • Page 12: Kickstand

    4.1.4 Kickstand Fig.4 1. Kickstand 2. Hexagon socket head cap screws M6*25 3. Spacer ø6*1.5T 4. Lock nut M6 Disassembly: 1. Remove the two fixing screws (2), two spacers (3) and two nuts (4) of the kickstand (1) with a 5mm Allen wrench to remove the kickstand (1).

  • Page 13: Wheel Reflectors

    4.1.5 Wheel reflectors Fig.5 Buckle Wheel reflectors Disassembly: 1. Pull out the two buckles (1) at both ends of the wheel reflector to remove the wheel reflector (2). Assembly: 1. Install the wheel reflector (2) onto the spokes of the wheel hub and secure it with the buckle (1). REV1.0...

  • Page 14: Battery Cover Assembly

    4.2 Battery Cover Assembly 4.2.1 Upper cover assembly Fig.1 1. Upper cover assembly Disassembly: 1. Remove the upper cover assembly (1) from the battery slide by turning the key clockwise. Assembly: 1. Install the new upper cover assembly (1) in place by turning the key clockwise. REV 1.0...

  • Page 15: Electrical System

    5. Electrical System 5.1 Controllers Parts 5.1.1 Controller Fig.1 1. Upper cover assembly 4.Countersunk head cross screw M5*45 2. Hexagon socket head cap screw M5*45 5. Semicircular head cross tapping screw ST4*13 3. Spacer ø6 6.Controller Disassembly: 1. Turn the key clockwise to remove the upper cover assembly from the battery slide (1); 2.
  • Page 16 4. Unplug the connector between the battery compartment and the controller to remove the components of the battery compartment and slide; 5. Use a cross screwdriver to remove the four fixing screws (5) from the upper cover of the controller,and then remove the upper cover of the controller box.

  • Page 17: Wire Harness Assembly

    5.2 Wire Harness Assembly 5.2.1 Waterproof wire Fig.1 1. Waterproof wire 2. Wire clamp 3. Countersunk hexagon socket screws M8*12 Disassembly: 1. Remove the winding pipe of the waterproof wire (1), and unplug the connector between the front end component of the frame and the waterproof wire (1);...

  • Page 18: Meter Parts

    5.3 Meter Parts 5.3.1 Instrument Fig.1 1. Hexagon socket head cap screw M4*8 3. Hexagon socket head cap screw M3*10 2. Instrument display 4. Instrument switch Disassembly: 1. Take out the battery pack in the battery compartment; 2. Unplug the instrument display (2) and the connector of the waterproof wire main line; 3.

  • Page 19: Lights Parts

    5.4 Lights Parts 5.4.1 Head light Fig.1 1. Head light 3. Spacer ø6 2. Hexagon socket head cap 4. M6 waterproof nut screw M6*35 Disassembly: 1. Take out the battery pack in the battery compartment; 2. Unplug the head light (1) and the connector of the waterproof wire main line; 3.

  • Page 20: Others

    5.5 Others 5.5.1 Speed regulation handle Fig.1 1. Hexagon socket head cap screw M5*8 2. Speed regulation handle 3. Handle sleeve Disassembly: 1. Take out the battery pack in the battery compartment; 2. Remove the handle sleeve (3); 3. Remove the fixing screw (1) of the speed regulation handle (2) with a 2.5mm Allen wrench; 4.

  • Page 21: Drive System

    Drive System 6.1 Wheel Assembly 6.1.1 External tire Fig.1 1. M10 lock nut 2. Inner tube cap 3. External tire Front external tire Disassembly: 1. Remove the two fixing nuts (1) of the wheel hub assembly with a wrench to remove the wheel hub assembly; 2.
  • Page 22 Fig.2 1. Lock nut M13 2. Inner tube cap 3. External tire Rear external tire Disassembly: 1. Remove the two fixing nuts (1) of the wheel hub assembly with a wrench; 2. Disconnect the connector between the motor wheel and the controller and remove the motor wheel assembly; 3.

  • Page 23: Inner Tube

    6.1.2 Inner tube Fig.3 1. Lock nut M10 3. External tire 2. Inner tube cap 4. Inner tube Front inner tube Disassembly: 1. Remove the two fixing nuts (1) of the wheel hub assembly with a wrench to remove the wheel hub assembly; 2.
  • Page 24 Fig.4 1. Lock nut M13 3. External tire 2. Inner tube cap 4. Inner tube Rear inner tube Disassembly: 1. Remove the two fixing nuts (1) of the motor wheel assembly with a wrench; 2. Disconnect the connector between the motor wheel and the controller and remove the motor wheel assembly; 3.

  • Page 25: Wheel Hub

    6.1.3 Wheel hub Fig.5 1. Lock M10 3. Heaxgon socket mushroom 4 External tire 6. Wheel hub 2. Brake disc head screw M6*10 5 Inner tube 7. Wheel reflector Disassembly: 1. Remove the two fixing nuts (1) of the wheel hub assembly with a wrench to remove the wheel hub assembly; 2.

  • Page 26: Drive Motor And Transmission Parts

    6.2 Drive Motor and Transmission Parts 6.2.1 Motor wheel Fig.1 1. Lock nut M13 4. Heaxgon socket mushroom 6. Inner tube 2. Free wheel head screw M6*10 7. Wheel reflector 3. Brake disc 5. External tire 8. Motor wheel Disassembly: 1.

  • Page 27: Chainset

    6.2.2 Chainset Fig.2 1. Hexagon socket head cap screw M8*13 2. Crank assembly 3. Chainset Disassembly: 1. Use a 8mm Allen wrench to remove the fixing screws (1) of the crank assembly (2); 2. Remove the crank assembly (2) with a sprocket remover; 3.

  • Page 28: Free Wheel

    6.2.3 Free wheel Fig.3 1. Lock nut M13 2. Free wheel Disassembly: 1. Remove the two fixing nuts (1) of the motor wheel assembly with a wrench; 2. Disconnect the connector between the motor wheel and the controller and remove the motor wheel assembly; 3.

  • Page 29: Operator System

    Operator System 7.1 Seat Assembly 7.1.1 Saddle Fig.1 1. Saddle 3. Lower pipe clamp 2. Hexagon socket head cap 4. Upper pipe clamp screw M8 * 43 5. Pressure block Disassembly: 1. Use a 6mm Allen wrench to remove the fixed screw (2) from the saddle (1), and take down the lower pipe clamp (3), upper pipe clamp (4), pressure block (5), and saddle (1).

  • Page 30: Braking System

    7.2 Braking System 7.2.1 Brake disc Fig.1 1. Lock nut M10 2. Brake disc 3. Heaxgon socket mushroom head screw M6*10 Front brake disc Disassembly: 1. Remove the two fixing nuts (1) of the wheel hub assembly with a wrench to remove the wheel hub assembly; 2.
  • Page 31 Fig.2 1. Lock nut M13 2. Brake disc 3. Heaxgon socket mushroom head screw M6*10 Rear brake disc Disassembly: 1. Remove the two fixing nuts (1) of the wheel hub assembly with a wrench; 2. Disconnect the connector between the motor wheel and the controller and remove the motor wheel assembly; 3.

  • Page 32: Brake Lever

    7.2.2 Brake lever Fig.3 1. Handle sleeve 3. Brake lever 2. Speed regulation handle 4. Hexalobular socket head cap screw M6*16 Right brake lever Disassembly: 1. Take out the battery pack in the battery compartment; 2. Remove the lever sleeve (1) and the speed regulation handle (2) (refer to 5.5.1); 3.
  • Page 33 Fig.4 1. Lever sleeve 2. Brake lever 3. Hexalobular socket head cap screw M6*16 Left brake lever Disassembly: 1. Take out the battery pack in the battery compartment; 2. Remove the lever sleeve (1); 3. Remove the core wire from the brake lever (2); 4.

  • Page 34: Torque Specifications

    Torque Specifications Torque Specification Chart (General Standard Parts) Tighten Torque Spec (Mechanical Property of Grade 8.8 for Fasteners components) Diameter of Pitch value of Thread (mm) Thread (mm) Standard Value Max Value Min Value N•m Ft-lbs N•m N•m N•m Ft-lbs 12.0 1.25 23.0 17.0 26.0 19.2 16.0 11.8 25.0 18.5 28.0 20.7 17.0 12.5 59.0 43.5 75.0 55.4...
  • Page 35 Torque Specification Chart (General Standard Parts) Tighten Torque Spec (Mechanical Property of Grade 10.9 for Fasteners components) Diameter of Pitch value of Thread (mm) Thread (mm) Standard Value Max Value Min Value N•m Ft-lbs N•m N•m N•m Ft-lbs 74.0 54.6 90.0 66.4 52.0 38.4 1.25 78.0 57.6 93.0 68.6 63.0 46.5 80.0 59.0 95.0 70.1 65.0 48.0...
  • Page 36 Torque Specification Chart (General Standard Parts) Tighten Torque Spec (Mechanical Property of Grade 4.6 for Fasteners components) Diameter of Pitch value of Thread (mm) Thread (mm) Standard Value Max Value Min Value N•m Ft-lbs N•m N•m N•m Ft-lbs 1.25 11.0 11.5 19.7 14.5 29.7 21.9 14.3 10.6 1.25 20.8 15.4 25.8 19.0 16.7 12.3 21.8 16.1 26.5...
  • Page 37 Torque Specification Chart (General Standard Parts) Tighten Torque Spec (Mechanical Property of Grade 5.6 for Fasteners components) Diameter of Pitch value of Thread (mm) Thread (mm) Standard Value Max Value Min Value N•m Ft-lbs N•m N•m N•m Ft-lbs 1.25 10.6 14.0 10.3 11.0 15.0 11.1 26.0 19.2 33.0 24.4 19.0 14.0 1.25 28.0 20.7 34.0 25.1 22.0...

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