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Motor Winding Test:
Test all motor leads from lead to lead. All readings should be .6-.7 ohms.
Controller Test:
Disconnect all the motor wires from the controller to run these test. Set the volt-meter to read
ohms. If your meter does not auto-range set meter to 20K ohms. Check between the red and black
power wires. Meter should not show low resistance. Meters that will auto-range will go up to
around 4 meg. after the capacitor has charged. Place the negative lead of the voltmeter on the
black controller wire that would go to the battery negative. Place the red lead on one of the
controller's leads going to the motor. Controller motor leads will be the yellow, blue, and green
leads that are not in the white connector. You should get close readings as you switch between the
leads Place the red lead of the voltmeter on the red lead of the controller wire that would go to the
battery positive. Place the black meter lead on one of the controller's leads going to the motor. You
should get close readings as you switch between the leads. If you get a lot of difference between
readings of the motor leads the controller is be bad.
Common Causes To Complaints:
Any customer complaints of jerky motor or motor not running have the customer check the sensor
and motor connections at the controller and at the connectors at the rear of the moped. If this
doesn't help go to steps one or two below.
1.
If the customer complains that the moped is stuttering or jerking and moving slowly the most
likely cause is that a motor sensor has failed and the motor will need to be replaced.
2.
If the customer complains the moped shuts off during hard acceleration then starts again if
the throttle is released and then turned gently. The batteries either need to be charged or one
or more of the batteries are bad. On a 48 volt system the moped has a cutoff voltage of 42
volts. If the voltage to the controller drops below 42 volts for more than a half second the
controller will stop delivering power to the motor.
3.
If the customer states the moped has power and the batteries are fully charged but will not
run. We will need both the controller and motor sent back to us so we can check them out.
Most likely one of them has failed but it could also be a bad throttle.
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