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Hebb ELECTROGLIDE 500 Technical & Service Manual

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HEBB E-BIKES
ELECTROGLIDE 500
TECHNICAL SERVICE MANUAL

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Summary of Contents for Hebb ELECTROGLIDE 500

  • Page 1 HEBB E-BIKES ELECTROGLIDE 500 TECHNICAL SERVICE MANUAL...
  • Page 2 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...
  • Page 3 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...
  • Page 5 1. Bike Overview...
  • Page 6 1 Mudguard 15 Seat post 2 Rim 16 Saddle 3 Crank/Chain wheel 17 Seat folding mechanism 4 Pedals 18 Rear carrier 5 Chain guard 19 Rear light 6 Suspension fork 20 Left brake lever 7 Disk brake 21 Digital speedometer/odometer 8 Front LED light 22 Battery indicator 9 Head tube...
  • Page 7 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.
  • Page 8 Note! 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.
  • Page 9 2.4. System diagram...
  • Page 10 2.5. Self-diagnostic indicator Model 500 Trouble Shooting Guide (Controller version # 9923) LED blinks Problem Solution Always on Function normal 2 times No such signal a. Make sure the throttle rock switch is on at “I” 3 times Brake lever cut-off in contact meaning the bike is ready to run.
  • Page 11 5 times No motor movement when a. Make sure the throttle inside circuit is not wet. throttle is turned. Remove the throttle and let it dry. Requires several hours or up to 2 days to dry depending on how wet the throttle is.
  • Page 12 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 reduced to reduce the load and cool down controller. 11 times Thermostat failure Replace the controller.
  • Page 13 3. Motor 3.1. Motor overview EZ-DP-3 36V, nominal 350W planetary reduction gear brushless hub motor. 3.2. Motor installation / removal 3.2.1. Remove nut, spring washer, and spacer located on the right side of the bicycle. Tools required: 19mm wrench / Hex key 4. 3.2.2.
  • Page 14 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. Note: Releasing screws will detune spoke tension. Remember to recalibrate spokes on wheel after installation.
  • Page 15 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.
  • Page 16 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).
  • Page 17 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.
  • Page 18 4.2. Wiring Diagram Wiring diagram for LiMnO Battery 37V 10AH LiMnO Battery 37V 10AH 4.3. Battery Trouble Shooting 4.3.1. Problem: Battery does not fit properly into holder. Solution: 1. Remove battery and realign it along the battery grooves. 2. If fitting is too tight, apply grease on grooves for lubrication. 4.3.2.
  • Page 19 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.
  • Page 20 5. Charger 5.1. Charger overview 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 charging, charge battery in a clean, cool and dry place.

  • Page 21: Battery Indicator

    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.
  • Page 22 Unplug the left and right brake signal connectors. Cut away the nylon cable ties and shrink tube that 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 5.3.
  • Page 23 Screw 3 screws to close the battery 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.
  • Page 24 Head light 6.1. Head light overview Head light 6.2. Head light installation / removal Unscrew the head light from the frame. Tool: Allen wrench + Spanner 6.3. Head light trouble shooting 6.3.1. Head light does not work. Make sure the switch on the battery indicator is “ON”. Open up the head light and check that the wires have good connection.
  • Page 25 If there is not 36V, check the voltage between two wires in the battery indicator (as two yellow marks on Fig. 2). If the voltage between two wires is 36V, the battery indicator is damaged. Replace battery indicator. Fig. 2...

  • Page 26: Rear Light

    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 7.3. Rear light installation Screw the rear light to the frame. Tool: Spanner Solder the two wires.
  • Page 27 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 7.4.1. Rear light does not work. Checking the voltage between the two wires is 36V (refer to Fig. 1). If the voltage is 36V, the rear light is damaged.
  • Page 28 Signal wires of left and right brake lever 8.1. Brake lever 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 shooting 8.3.1. The LED on the controller blinks 3 times. Check if both left and right brake levers return to its rest position.
  • Page 29 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 removing the heat shrink but be very careful not to cut any wires. Unscrew the throttle.
  • Page 30 Tighten the 2mm Allen bolt. Tool: 2mm Allen wrench Note: Only tighten enough so the throttle does not slide off the handlebar. If over-tightened, it may prevent the throttle spring from properly working. 1. Connect the connector. 2. Wrap connection with electrical tape.
  • Page 31 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 shooting 10.3.1. The LED on the controller blinks 3 times. Check if both left and right brake levers return to its rest position.
  • Page 32 11 Front Wheel Removal for Tire Repair 1. Remove screws on torque plate using 4mm hex key. 2. Remove nut using 19mm (or adjustable) wrench on axle. 3. Remove all the small parts, nuts, washers, torque plate, etc.
  • Page 33 4. Cut nylon ties with cutter or scissor. 5. Un-screw and remove connector casing cover 6. Disconnect cable...
  • Page 34 Disconnect wire 8. Loosen nut on opposite side using a 19mm or adjustable wrench. 9. Take wheel out of the fork and proceed to change inner tube or tire.
  • Page 35 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.
  • Page 36 12 Rear Wheel Removal for Tire Repair 1. Shows gear shifting cable Grip cable with fingers or pliers. Release shifting cable and nut from hub by pulling backward and outward.
  • Page 37 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. 5. Pull back and release chain from hub sprocket. 6. Release rear wheel from frame to change tire or inner tube...
  • Page 38 7. Put rear wheel back on and chain on sprocket. 8. Put torque washer back into position 9. Tighten nuts of both sides evenly and slightly ( do not tighten yet )
  • Page 39 10. Pull wheel backward with one hand and the other holding against rear stay so that chain has slight tension is not loose. 11. Align shifting cable into groove of the hub and snap the nut back into position...