Rungu Dualie 2024 Service Documentation

Hide thumbs

Table of Contents

Quick Links

Download this manual

Rungu Technical Service Documentation - Electrical Components

rungu dualie technical

service documentation -

electrical components

V2.4

Contents

Preface .......................................................................................................................................................... 3

Scope ............................................................................................................................................................. 3

Warranty Terms and Disclaimers .................................................................................................................. 3

Technician Requirements ............................................................................................................................. 4

DC Electricity ............................................................................................................................................. 4

Relays ........................................................................................................................................................ 4

Schottky diodes ......................................................................................................................................... 4

How to use a multimeter .......................................................................................................................... 4

PCBA .......................................................................................................................................................... 4

Identifying the Rungu Dualie Construction Variation ................................................................................... 5

Correspondence between model year and construction variation .......................................................... 7

System Overview .......................................................................................................................................... 8

Battery Voltages ........................................................................................................................................ 8

Connectors and Naming Conventions ...................................................................................................... 8

Variation A - Single Battery Power Diagram ........................................................................................... 10

Headlight Relay ................................................................................................................................... 10

Single Battery Cable Routing - Variation A ......................................................................................... 10

Variation A - Dual Battery Power Diagram ............................................................................................. 11

Schottky Diode Array .......................................................................................................................... 11

Variation A - Dual Battery Cable Routing ............................................................................................ 12

Variation B - Single Battery Power Diagram ........................................................................................... 13

Variation B - Single Battery Cable Routing .......................................................................................... 14

Variation B - Dual Battery Power Diagram ............................................................................................. 16

Variation B - Dual Battery Cable Routing ............................................................................................ 17

Motor Connection Diagram .................................................................................................................... 19

Gear Sensor ......................................................................................................................................... 20

v2.4

Page 1 of 82

Table of Contents

Need help?

Do you have a question about the Dualie 2024 and is the answer not in the manual?

Questions and answers

Summary of Contents for Rungu Dualie 2024

Page 1: Table Of Contents
Relays ................................ 4 Schottky diodes ............................4 How to use a multimeter .......................... 4 PCBA ................................4 Identifying the Rungu Dualie Construction Variation ................... 5 Correspondence between model year and construction variation ............7 System Overview ............................8 Battery Voltages ............................8 Connectors and Naming Conventions ......................
Page 2 Bike Won’t Turn On – Variation B ......................24 Bike Won’t Turn On – Variation C ......................26 Battery Diagnostics: Rungu E-bike Not Getting Stated Range or Battery Not Holding Charge ....29 36W Headlight Fails to Turn On – Variation A ..................30 36W Headlight Fails to Turn On/PCBA Diagnostics –...
Page 3: Preface
This technical support guide represents Standard Bearer Machines, LLC good faith effort to help those servicing Rungu Dualie E-Bikes and it is not a guarantee of successful problem diagnosis or that all possible electrical defects/problems have been identified and documented. The diagnostic procedures,...
Page 4: Technician Requirements
Technician Requirements The team at Rungu expects technicians to know some basics about electricity and electronics to be able to understand the contents of this document and diagnose and repair the Rungu. You can learn the fundamentals from the links listed below.
Page 5: Identifying The Rungu Dualie Construction Variation
As of 2024, there are three variations of Rungu Dualie constructions in the market that have distinct differences in electronic/electrical layout. A. Rungu Dualie/MDV variation using a headlight relay.
Page 6 Rungu Technical Service Documentation – Electrical Components v2.4 The presence of certain holes and fasteners distinguish variation B from variation A. Variation B has two holes towards the top of the battery box and the exposed end of a screw. Variation A will not have these holes or the exposed end of the screw.
Page 7: Correspondence Between Model Year And Construction Variation
Correspondence between model year and construction variation If you are aware of the model year of the Rungu Dualie/MDV, this table relates model year to construction variation as described above and whether the model had a single or dual battery setup.
Page 8: System Overview
Battery Voltages Rungu uses a 52V nominal power system, which is higher than most E-Bikes. 52V gives the Rungu system 12% more power output than 48V systems using the same motor. 52V refers to the mid-point voltage of the system.
Page 9 Rungu Technical Service Documentation – Electrical Components v2.4 This next image shows the connections for the speed sensor and gear sensor, which come out of the bottom of the motor and can be found under the right chainstay. Copyright 2024 Standard Bearer Machines, LLC...
Page 10: Variation A - Single Battery Power Diagram
Rungu Technical Service Documentation – Electrical Components v2.4 Variation A - Single Battery Power Diagram The diagram below shows the power distribution for a SINGLE-BATTERY PACK Rungu Dualie with a Headlight Relay Headlight Relay Allows headlight to be powered by full battery power but is actuated by the 6V headlight output from the motor.
Page 11: Variation A - Dual Battery Power Diagram
Rungu Technical Service Documentation – Electrical Components v2.4 Variation A - Dual Battery Power Diagram The diagram below shows the power distribution for a DUAL -BATTERY Rungu Dualie with a Headlight and headlight relay. Schottky Diode Array Combines the inputs from both batteries into one and ensures that one battery does not charge the other if the two batteries are at different voltages.
Page 12: Variation A - Dual Battery Cable Routing
Rungu Technical Service Documentation – Electrical Components v2.4 Variation A - Dual Battery Cable Routing The images below show cable routing for a Dual-Battery construction with headlight viewed from underneath the bike with the battery case cover and battery removed, rear battery case with battery removed and headlight connection.
Page 13: Variation B - Single Battery Power Diagram
Variation B - Single Battery Power Diagram The diagram below shows the power distribution for a Rungu Dualie with a SINGLE BATTERY PACK and Headlight. In early 2022, Standard Bearer Machines, LLC migrated from relays and diode cables to a solid–state power distribution PCBA for Rungu Dualie Rugged + XR models.
Page 14: Variation B - Single Battery Cable Routing
Rungu Technical Service Documentation – Electrical Components v2.4 Variation B - Single Battery Cable Routing The diagram below shows the power distribution mounting plate for a SINGLE-BATTERY PACK Rungu Dualie removed from the battery case. NOTE: Refer to schematic on previous page for cable identification.
Page 15 Rungu Technical Service Documentation – Electrical Components v2.4 Copyright 2024 Standard Bearer Machines, LLC Page 15 of 82...
Page 16: Variation B - Dual Battery Power Diagram
The diagram below shows the power distribution for DUAL BATTERY PACK variations with a Headlight using a PCBA to distribute power and control the headlight. In early 2022, Standard Bearer Machines, LLC migrated from relays and diode cables to a solid–state power distribution PCBA for Rungu Dualie Rugged + XR models.
Page 17: Variation B - Dual Battery Cable Routing
Rungu Technical Service Documentation – Electrical Components v2.4 Variation B - Dual Battery Cable Routing The images below show cable routing for the DUAL BATTERY PACK systems on the PCBA mounting panel removed from the battery case cover, cable routing above the PCBA mounting panel with the panel and battery removed, rear battery case with battery removed, and the external headlight connector.
Page 18 Rungu Technical Service Documentation – Electrical Components v2.4 Copyright 2024 Standard Bearer Machines, LLC Page 18 of 82...
Page 19: Motor Connection Diagram
Motor Connection Diagram Rungu Dualie uses the BBSHD motor from Bafang. Bafang modifies the motor for Rungu to accommodate Rungu’s 52V standard so that the nominal output is 1,120 W. The image below explains the input/output cables to the motor its embedded controller. Refer to the connector images shown earlier to associate connector type to connection.
Page 20: Gear Sensor
Rungu Technical Service Documentation – Electrical Components v2.4 Gear Sensor The gear sensor is a device that detects movement of the derailleur cable during up and down shifts. When detecting movement, the gear sensor cuts motor power for approximately one second to allow the rider to complete the gear change on pedal power alone.
Page 21: Electrical Measurement Tools Requirements And Usage
Electrical Measurement Tools Requirements and Usage Multimeter with probes – must be able to measure voltages up to 60VDC 5.5x2.1 connector measurement adapters (Male and Female) – supplied by Rungu 5.5x2.1 connector measurement adapters give probe points for you to measure voltage at 5.5x2.1...
Page 22: Accessing Rungu Cabling And Electronics
Rungu recommends suspending the front end of the Rungu. We do not recommend using standard bicycle stands due to the weight of the Rungu unless they are rated to support up to 150 lbs. In the absence of an adequate bike stand, there are two methods we recommend using tie- down straps to suspend the front end –...
Page 23: Troubleshooting Procedures By Construction Variation
Inspect the wiring to look for severed wires and make sure that the connections are intact. a. If your Rungu has one battery, reconnect the battery. Then press and hold the on/off key. If that fails to turn on the display, continue to step 4.
Page 24: Bike Won't Turn On - Variation B
Inspect the wiring to look for severed wires and make sure that the connections are intact. a. If your Rungu has one battery, reconnect the battery. Then press and hold the on/off key. If that fails to turn on the display, continue to step 4.
Page 25 4. Check that each battery is fully charged with a multimeter as shown below. If the voltage is at or below 44V, the battery is fully discharged. a. If the battery or batteries are fully charged and this Rungu uses a two-battery system, check the PCBA. Refer to the...
Page 26: Bike Won't Turn On - Variation C
Rungu Technical Service Documentation – Electrical Components v2.4 Bike Won’t Turn On – Variation C After pressing and holding the on/off key, the display fails to light up; no power is coming to the motor. Procedure: 1. Press and hold the on/off key for at least two seconds. If that fails to turn on the display, 2.
Page 27 Rungu Technical Service Documentation – Electrical Components v2.4 5. Grasp the battery and rotate it sideways away from the frame. Reconnect the battery then press and hold the on/off key. If that fails to turn on the display, continue to the next step.
Page 28 9. Repeat steps 4-5 to unlock and remove the battery. Use the multimeter to test the signal from the battery. e. If the voltage is within operating range (58-60 VDC), note the voltage and contact Rungu support. a. If no voltage is present contact Rungu support.
Page 29: Battery Diagnostics: Rungu E-Bike Not Getting Stated Range Or Battery Not Holding Charge
2. If under warranty, return the old battery to Rungu. Upon return of the old battery, Rungu will test the battery to evaluate if it has at least 85% capacity. If it has 85% or more capacity, and there is a battery fault, Rungu will refund the purchase of the replacement battery.
Page 30: 36W Headlight Fails To Turn On - Variation A
Continue to the next step if the display shows the icon. 2. Follow the earlier instructions to suspend the front end of the Rungu to access the main battery case.
Page 31 If the headlight fails to turn on; contact Rungu to order a replacement 6V Relay replace the relay according to the procedure described below. If no voltage is present at the connector, check the wiring/contact Rungu to order a Relay Cable Harness and replace damaged cabling.
Page 32: 36W Headlight Fails To Turn On/Pcba Diagnostics - Variation B
Continue to the next step if the display shows the icon. 2. Follow the earlier instructions to suspend the front end of the Rungu to access the main battery case. Copyright 2024 Standard Bearer Machines, LLC...
Page 33 Rungu Technical Service Documentation – Electrical Components v2.4 3. Open the Front battery case lid and unplug the battery power (Connector #2) and charging (Connector #1) cables, remove the front battery and mounting screws, and check all connections are plugged in correctly according to diagrams and images in this document.
Page 34 PCBA. If there is any sign of this, disconnect the batteries and contact Rungu support immediately. ii. if there are no burn marks or residue contact Rungu support to order a replacement headlight power output extension cable.
Page 35 PCBA circled in red. With the headlight toggled on, use the multimeter to test the signal from the XT30 end of the headlight power input extension cable (Connector #13). If the voltage is within operating range (6 VDC), contact Rungu support. If no voltage is present continue to the next step.
Page 36: 3W Headlight Fails To Turn On - Model C
A headlight icon appears at the top of the screen as shown below. If this does not occur, the display does not recognize the input and may require a replacement keypad/display that you can order from Rungu Support. Continue to the next step if the display shows the icon.
Page 37 Rungu Technical Service Documentation – Electrical Components v2.4 2. Cut the zip ties circled below. Lift and remove the wiring cover. 3. Check that the headlight power output extension cable is connected to the Headlight Control Signal Output, circled below. NOTE: If there is tape or heat shrink holding the two connectors together, remove it.
Page 38 [the outside of the pin is negative (-) and the inside is positive (+)]. a. If the voltage is within operating range (6 VDC), continue to the next step. b. If no voltage present, contact Rungu to order a replacement motor controller. Copyright 2024 Standard Bearer Machines, LLC...
Page 39 Rungu Technical Service Documentation – Electrical Components v2.4 5. Using a small Phillips screwdriver, loosen the screw circled below. 6. Cut the zip ties that are tied to the downtube finish cover. Copyright 2024 Standard Bearer Machines, LLC Page 39 of 82...
Page 40 Rungu Technical Service Documentation – Electrical Components v2.4 7. Using an adjustable wrench and a M4 hex wrench, loosen and remove the M5 screw and nylock nut. 8. Remove the downtube finish cover and the headlight from the downtube by spreading apart the two halves and pulling them out.
Page 41: Replacing Defective Headlight Power Output Extension Cable - Variation C
If there is tape or heat shrink holding the two connectors together, remove it. a. If the voltage is within operating range (6 VDC), contact Rungu support to receive a new headlight.
Page 42 Rungu Technical Service Documentation – Electrical Components v2.4 3. Remove the ST2.6 x 16 screw circled below using a Phillips head screwdriver. Copyright 2024 Standard Bearer Machines, LLC Page 42 of 82...
Page 43 Rungu Technical Service Documentation – Electrical Components v2.4 4. Remove the rear battery mount. 5. IF THE UNIT YOU HAVE HAS A BASH GUARD/SKID PLATE, Remove the four M6 x 18 screws holding the skid plate in place using a 5mm hex wrench. Otherwise skip to step 7 6.
Page 44 Rungu Technical Service Documentation – Electrical Components v2.4 7. Remove the cable tip from the end of the shifter cable. Loosen the respective cable fixing bolt circled below using a 4mm hex wrench and remove the shifter cable from the derailleur.
Page 45 Rungu Technical Service Documentation – Electrical Components v2.4 10. Pull the shifter cable housing out of shifter as shown. Pull the shifter cable completely out of the housing. 11. Pull the shifter cable housing out of the gear sensor. Copyright 2024 Standard Bearer Machines, LLC...
Page 46 Rungu Technical Service Documentation – Electrical Components v2.4 12. Pull the shifter cable housing completely out from the top of the downtube. 13. Pull the male end of the headlight power output extension cable out from the part of downtube where the rear battery mount was removed.
Page 47 Rungu Technical Service Documentation – Electrical Components v2.4 15. Insert the female end of the new headlight power output extension cable through the top of the downtube until it can be seen through the part of downtube where the rear battery mount was removed.
Page 48 Rungu Technical Service Documentation – Electrical Components v2.4 17. Insert the female end of the new headlight power output extension cable in between the seat tube and the side of the downtube as shown below. DO NOT feed the connector through yet, this will be done in a later step.
Page 49 Rungu Technical Service Documentation – Electrical Components v2.4 20. Insert the shifter cable housing through the same gap that was described in step 17, but start from the bottom of the downtube as shown. Feed the housing until it can be seen through the part of downtube where the rear battery mount was removed.
Page 50 Rungu Technical Service Documentation – Electrical Components v2.4 23. Once the shifter cable is completely inserted, insert the shifter cable housing into the shifter as shown. Ensure that the sealed end cap is installed. 24. Feed the shifter cable through the gear sensor until the end of the cable comes out of the housing connected to the derailleur.
Page 51 Rungu Technical Service Documentation – Electrical Components v2.4 26. Spread apart both sides then slide the downtube finish covers into place as shown below. 27. Before clamping the downtube finish covers sides together make sure: a. The headlight mount hole is aligned with the holes on either side of the downtube finish cover.
Page 52 Rungu Technical Service Documentation – Electrical Components v2.4 29. Use a small Phillips head screwdriver to screw in the M2.9 x 19 FHS Type C to retain the downtube finish covers in the downtube slot. 30. Use a 4mm hex wrench and M5 x 35 screw to fasten the downtube finish covers sides together and secure the headlight as shown below.
Page 53 Rungu Technical Service Documentation – Electrical Components v2.4 31. Using the 4mm hex wrench and an adjustable wrench, tighten the M5 x 35 screw and M5 Nylock nut. Tighten so the headlight can still be moved, but with resistance. 32. Zip tie the Front Brake bifurcation to the downtube finish cover.
Page 54 Rungu Technical Service Documentation – Electrical Components v2.4 34. The zip ties will be tied together and fed through the 3D printed cover as shown below. 35. Once the cables are in the correct position, slide the 3D printed cover into position and use 2 zip ties for each tiedown.
Page 55 Rungu Technical Service Documentation – Electrical Components v2.4 37. IF YOU REMOVED A SKID PLATE/BASH GUARD IN STEP 5, Replace the skid plate mount and tighten both M5 x 14 screws by three full turns using a 4mm hex wrench.
Page 56 Rungu Technical Service Documentation – Electrical Components v2.4 40. Fasten the ST2.6 x 16 screw circled below using a Phillips head screwdriver. 41. Fasten the M3 x 12 screw circled below using a 2.5mm hex wrench. 42. Ziptie the brake line, brake pigtail and derailleur cable housing together as shown.
Page 57 Rungu Technical Service Documentation – Electrical Components v2.4 43. Route the shifter cable housing along the bottom of the chainstay. Zip tie the shifter cable housing to the first tie down as shown 44. Take up the slack in the gear sensor cable by making an “S” shape with the connected cabling.
Page 58 Rungu Technical Service Documentation – Electrical Components v2.4 46. With the shifter in the highest gear and tension on the shifter cable, attach the cable to the derailleur and tighten the cable fixing bolt using a 4mm hex wrench. Re-tune the derailleur as necessary.
Page 59: Display Error 21
2. Check that the sensor is in place. It is found inside the left chain stay. Check the image below and verify the same sensor is on your Dualie. If not contact Rungu or go online to obtain a replacement sensor.
Page 60 4. Check the picture below and verify your rear wheel has a magnet attached to one spoke. If you cannot find the magnet on one of the spokes, reorder one from Rungu or other sources online before proceeding. If you are replacing a magnet, place the magnet so that the face of the magnet faces the sensor and algins with the oblong recess on the sensor –...
Page 61 7. Check that the sensor is in place. It is found under the right side chain stay. Check the image below and verify the same sensor is on your Dualie. If not contact Rungu or go online to obtain a replacement sensor.
Page 62 9. Check the picture below and verify your rear wheel has a magnet attached to one spoke. If you cannot find the magnet on one of the spokes, reorder one from Rungu or other sources online before proceeding. 10. If you are replacing a magnet place the magnet up to an inch in front of where the spokes cross on the rear wheel with the magnetic surface facing out to the right side of the bike.
Page 63 Rungu Technical Service Documentation – Electrical Components v2.4 11. To realign the speed sensor, us wire cutters to clip the zip ties supporting the speed sensor mount and remove them from the speed sensor mount. 12. Thread new zip ties into the speed sensor mount.
Page 64 1/8” or 3 mm. 18. Retest the sensor to make sure you’ve resolved Error 21, otherwise 19. Contact Rungu Support to order a replacement Speed Sensor Cable and Magnet – indicate whether right or left chainstay. Copyright 2024 Standard Bearer Machines, LLC...
Page 65: Display Error 8
1. Turn off the motor and disconnect one (or both batteries) and reconnect the batteries to the motor. 2. Turn on the motor, and ride the Dualie 100-200 yards. If the error reappears contact Rungu to investigate other measures. Excessive Noise from Motor Grinding metal noises may occur when the motor is running.
Page 66: Power Component Replacement
Tools needed: 7mm socket with appropriate wrench and extension, multimeter, 5.5x2.1 measurement adapter 1. Lift the front of the Rungu into the air and remove the front wheels for easier access to the front battery case and its contents. 2. To access the headlight relay, first remove the battery case cover, unplug the main power (S#1 D#2) and charging cable (S#0 D#5) and remove the battery.
Page 67 Rungu Technical Service Documentation – Electrical Components v2.4 4. Locate and unplug the three connectors of the relay, two will be inside the box, and one will be on the outside connecting to the headlight. (S#2,3,4 D#4,7,8) 5. Unbolt the M4 nylock nut with the 7mm socket that is holding the relay in and remove the relay and wiring.
Page 68: Schottky Diode Array Diagnostic Procedure - Variation A
Tools needed: 5.5mm (or 7/32) socket with wrench and extension 1. Lift the front of the Rungu into the air and remove the front wheels for easier access to the front battery case and its contents.
Page 69 Rungu Technical Service Documentation – Electrical Components v2.4 < close up of Schottky diode Array location and orientation Copyright 2024 Standard Bearer Machines, LLC Page 69 of 82...
Page 70: Upgrading Rungu Dualie From Construction Variation A To Variation B - Replacing The Headlight Relay And Schottky Diode Array With Pcba (Dual Battery Only) - Variation A
Upgrading Rungu Dualie from Construction Variation A to Variation B - Replacing the Headlight Relay and Schottky Diode Array with PCBA (Dual Battery only) – Variation A When the Headlight Relay and Schottky diode array are replaced with a PCBA, Rungu will send a pre- tested PCBA with the mounting plate.
Page 71 Rungu Technical Service Documentation – Electrical Components v2.4 2. Loosen the M3 locknut, circled below, using a 7/32 socket and remove the Schottky diode. 3. Loosen the M4 locknut, circled below, using a 7mm socket and remove the relay. Copyright 2024 Standard Bearer Machines, LLC...
Page 72 5. Connect the headlight power input cable that goes from the motor cable harness to the PCBA for the headlight into the appropriate connector. NOTE: Refer to schematic in the “Dual Battery Power diagram – PCBA – Rungu Dualie XR Built After 2021” section for cable identification. Copyright 2024 Standard Bearer Machines, LLC...
Page 73 Rungu Technical Service Documentation – Electrical Components v2.4 6. Connect the headlight power output cable that goes from the PCBA to the headlight into the appropriate connector. 7. Connect the extension cable that goes from the motor cable harness to the PCBA into the appropriate connector.
Page 74 Rungu Technical Service Documentation – Electrical Components v2.4 8. Insert the motor data cable through the slot shown in the first image. Then loop the cable and zip tie it to the battery case as shown below. 9. Plug in the motor data cable to the connector on the motor cable harness.
Page 75 Rungu Technical Service Documentation – Electrical Components v2.4 10. Hold the PCBA battery case mount in the position shown below. Connect the 5.5x2.1 F connector to the 5.5x2.1 M connector that comes from the motor cable harness as shown below.
Page 76 Rungu Technical Service Documentation – Electrical Components v2.4 12. Connect the charging extension cable to the PCBA (this is the smaller yellow connector that is in spiral wrap the leads to the cargo rack). NOTE: This step is for dual battery units only.
Page 77 Rungu Technical Service Documentation – Electrical Components v2.4 14. Connect the power extension cable to the PCBA (this is the larger yellow connector that is in spiral wrap the leads to the cargo rack). 15. Route the power extension cable and charging cable as shown below.
Page 78 Rungu Technical Service Documentation – Electrical Components v2.4 16. Zip tie the motor cable harness (the one with the pigtail) to the black cable of the power extension cable. 17. The final result for the cables is displayed below. motor...
Page 79 Rungu Technical Service Documentation – Electrical Components v2.4 18. Ensure that no cables interfere with the PCBA mounting. If any cables are caught under the mount, use a 2.5mm hex wrench to push them out of the way as shown in the second image.
Page 80 Rungu Technical Service Documentation – Electrical Components v2.4 20. Use a 2.5mm hex wrench to screw in a M4x10 screw into the bottom hole. 21. Use a 2.5mm hex wrench to screw in a M4x10 screw into the top hole.
Page 81 Rungu Technical Service Documentation – Electrical Components v2.4 22. Zip tie the power extension cable and the motor data cable as shown below. 23. The final result is displayed below. 24. Trim zip tie leads. Copyright 2024 Standard Bearer Machines, LLC...
Page 82: Contacting Rungu Support
This document does not address repair or diagnosis of internal battery or motor components. If you believe that there is a problem internal to a battery or the mid-drive motor, or if you are experiencing other electrical problems that are not covered in this document contact Rungu Support at: •...

This manual is also suitable for:

Mdv 2024

Rungu Dualie 2024 Service Documentation

Quick Links

Need help?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Rungu Dualie 2024

Summary of Contents for Rungu Dualie 2024

This manual is also suitable for:

Table of Contents