My ebike has died. Need help please !!

[andy300z]

I have a 48v 1000W direct geared hub motor conversion kit, fitted to standard mountain bike, kit supplied by BMSbattery a few years ago.

I have used it for a couple of years no problems at all.

Today, for the first time, I went up a very very steep hill. As I got near the top of the hill, it slowed right down, then cut out. Error code 03 came up on the display. I recharged battery, but error code 03 comes up when I turn throttle. No sounds from the motor at all.

I'm assuming the heavy load has burnt something out, although I didn't smell anything burning.

Can anyone tell me how I can work out which component has gone wrong (motor, controller or cables ??)

Are all the components interchangeable with the many components seen on ebay, or perhaps you know of someone who can supply ?

I'd really appreciate any help or advice people can give.

Thanks.

Andy

 

[andy300z]

photos attached of the kit

 

[vfr400]

Error 03 is motor hall signal.
Causes: 1. Motor connector not all the way in or corroded; 2. Motor cable damaged; 3. Blown hall sensor; 4. Wire rubbed through inside motor.

You can check the hall signals at the white block connector on the controller. Measure between ground and each of blue, yellow and green while you turn the wheel. You should see each switching 5v on and off. Do that test first to confirm, then start on the motor itself. It's not too difficult to repair whatever is wrong.

 

[Andy-Mat]

If the infos already posted do not help, first check (if possible) that your battery voltage is fully correct with a volt meter.
If OK, then maybe a fuse has blown say in the controller, though I am told, not all e-bike electronics/motors have fuses.
Not all makes of e-bike motors actually allow such voltage checks apparently, Bosch being one that prevents that, I am told!
Yours is not a Bosch I would guess, as you did not mention a make...
Mine (standard Chinese e-bike) does no have a fuse, or I should say, at least "outside" of the battery itself none is shown.
But I am loath to go inside any of my batteries without a specific battery type of problem first becoming apparent! Sorry!
Best wishes for a quick and cheap fix for you.
Andy

 

[andy300z]

A slight update.
I noticed the blue connector block near the hub show signs of slight melting. So I stripped all the wires, reconnected all the wires loosely (no soldering iron available at this point). I rested the wheel on the floor (not mounted on bike). Switched it all back on. Turned the throttle and this time the motor made a sound for 1 second then threw the 03 code again. Previously the motor made no sound. Does it sound like I'm on the right lines ?

 

[andy300z]

So I now know I just need to change one hall sensor. The writing printed on the old sensor is so small I can't read it (I must be getting old !!)
Does it matter which make/model of sensor I get ? The other two sensors output exactly 5v

 

[Nealh]

Try a mag glass to read it.
SS41 bipolar halls.