ewheels EW-72 Operating instructions
EW-72
Service & Repair Manual
2
Table of Contents
Contents
Customer Diagnosis................................................................................................................. 3
Complete Loss of Power:.................................................................................................................. 3
Loss of Throttle Response: ............................................................................................................... 3
Section 2 –Technician Diagnosis Guide ................................................................................... 4
All Possible Tools Needed: ........................................................................................................... 4
Complete Loss of Throttle Response:.......................................................................................... 6
Checking Connections................................................................................................................... 6
Testing the Throttle: .............................................................................................................................7
Testing the Rheostat (Speed Knob/Potentiometer): ............................................................................8
Testing the Wire Harness:.....................................................................................................................9
Testing the Controller: ........................................................................................................................10
Testing the Motor .......................................................................................................................... 12
Intermittent or Random Loss of Throttle Issue ............................................................................... 13
Section 3- Upkeep and Maintenance ..................................................................................... 16
Daily Checks Before Riding ............................................................................................................. 17
www.ewheelsdealers.com
(888) 571-2845 - Service
(888) 305-0881 - Sales
(888) 571-2845 Service
3
Customer Diagnosis
Complete Loss of Power:
1.) If the scooter has no power when turned on, the first thing to check is that the circuit breaker
underneath the seat* is flipped to the on position. If the circuit breaker is labeled with an “I’ and
an “O”, the “I’ is the on position.
2.) Check that the light on the charger turns from green while plugged just into the wall outlet,
to red when plugged into the scooter and wall outlet.
If neither of these steps returns power or the charger light is staying green, please contact
EWheels service department directly for assistance.
Loss of Throttle Response:
1.) If the throttle does not respond when turned, the first thing to check is the current battery
charge. Look at the battery indicator when the scooter power it turned on. If the scooter is not
displaying a full charge, please fully charge the machine
4
2.) The only feature of the EW-72 that can cut off power to the motor is the brake sensors that
are within the brake handles. To check the brake sensors, pull the brake handle while looking at
the taillights with the scooter’s power turned on. If the sensors are working correctly, the brake
lights will illuminate when the brake handle is pulled and turn back off when the brake handle is
released.
3.) If the above steps have been followed and the machine is still not driving, the next step is to
reset the controller (brain) for the scooter. Turn the circuit breaker to the off (“O”) position, and
let it sit in the off position for a minimum of three hours to allow for the controller (brain) to
restart.
Loss of All Lights:
1. If all lights will not come on at all even the power light on the dash, it’s more than likely
going be a voltage regulator int the rear of the scooter, under the seat, under the storage
box. It’s a small metal box with 1 connection going to it.
If following these steps still do not allow the scooter to drive, please contact Ewheels service
department directly for assistance.
*If unsure on how to open the seat, please check page 8 of the owner’s manual.
Section 2 –Technician Diagnosis Guide
All Possible Tools Needed:
1.) Metric wrench set
2.) Metric socket wrench set
3.) Metric hex wrench set
4.) Phillips head screwdriver set (#1, #2, #3)
5.) Multimeter or voltage tester
6.) Floor jack (optional, not needed)
7.) Solder pen and solder
8.) Shrink wrap tubing
9.) Zip ties (any length or color)
5
10.) Box cutter
11.) Wire stripper
12.) 3/8th Rachet ( Extensions If Needed )
6
Complete Loss of Throttle Response:
Checking Connections
Start by checking all connections on both ends of the wire harness, focusing specifically on the
three-wire throttle connector and motor wires. Make sure no pins are pulling out of the backside
of any connectors, and that the pin s on the female side of connectors are not folded over to the
side of the connectors.
There are very rare instances where a short in the accessory wiring can cause the machine not to
drive. To ensure this is not the issue, please leave lights, turn signals, and all other accessories
turned off.
A continuity test can be run on each side of connectors to ensure there is not an issue with the
connector pins making proper contact. Connections can be checked by separating the connecting
pins, one separated the pins can be folded or pulled out of the connectors.
7
Testing the Throttle:
The throttle responds via a hall effect positioning sensor. The sensor increases its output voltage
the more the throttle is pulled. To test this sensor, start by turning the scooter on. Next, set your
multimeter to DC 20 volts (or closest setting). While leaving the scooter powered on, and
ensuring the throttle to harness, harness to controller, and controller to motor connections are
plugged in, insert the multimeter red lead into the throttle connections red wire, and the black
multimeter lead into the throttle connections black wire. The voltage reading should be around
.82 volts when the throttle is not being pulled
(no load).
If you are getting the correct voltage with
the power turned on, without pulling the
throttle (no load), then the next step is to
check the throttle voltage under load
(while pulling the throttle). The voltage
should increase to around 3.51 volts under
full load (while fully rotated). The scooter
should engage forward when the voltage
rating hits approximately 1.54 volts. If all
steps above are followed, and the scooter
is not driving, the throttle is not the
component causing the problem.
If the throttle is not working properly,
please contact EWheels service
department directly for a replacement.
8
Testing the Rheostat (Speed Knob/Potentiometer):
To test that the rheostat (speed knob/potentiometer) is working properly, you can disconnect it
from its wire harness connection, and try to see if a throttle response returns. This removes all
the limitation and ohm resistance from the positioning sensor in the throttle.
The rheostat can also be tested with a
multimeter. The rheostat will have an
OHM rating of 100k if it is a sport EW-
36, which is marked on the rheostat
itself. Set your multimeter to OHM
100K (or closest setting above 100K)
and use the two ports with the wires
soldered on to obtain an OHM reading.
Twist the knob with your leads attached,
and check that the rheostat varies from
approximately 0, to the 100k OHM's it is
rated for.
If the rheostat (speed
knob/potentiometer) is not working
properly, please contact EWheels
service department directly for a
replacement.
9
Testing the Wire Harness:
To test that the wire harness is working properly, visually inspecting and running continuity
checks will be necessary. Touch your leads together to see if your specific multimeter beeps
when there is continuity.
If your leads are long enough, you can run test of both ends of each wire on the wire harness. If
your leads are not long enough to reach both ends of the harness, you can find something
conductive to cross the pins of two wires in a connector that are located right by each other
(screwdriver tip, paperclip, or any other conductive
item you have available to you). Doing this will allow
for one multimeter lead to receive the voltage being
sent from the other multimeter lead, which helps to
verify there are no breaks in the wires being tested. If
crossing connections, ensure that the power is turned
off, and that both ends of the wire harness are not
plugged in.
Focus on testing the throttle wires, rheostat (speed
knob/potentiometer), and brake sensors, which all
pertain to drivability issues. Testing accessory wiring
is not needed when diagnosing drivability issues.
If the wire harness has breaks that are not able to be repaired, please contact EWheels service
department directly for a replacement.
10
Testing the Controller:
To test that the controller is working properly,
checking the output voltage for the throttles
positioning sensor will be necessary. Leave the
scooter power turned on while testing, but Do Not
cross the throttle wires or a short may occur
which can cause damage, personal injury, or
death.
Use the two outside wires of the three prong
throttle wires on the harness, shown in the picture,
to obtain a voltage reading. Set the multimeter to
DC 20 (or closest setting higher than 20). If the
controller is working properly, it should be
emitting approximately 3.48 volts while plugged
into the harness with the scooter power turned on,
or approximately 4.99 volts with the harness
connection unplugged. If there is no voltage under
load, this means the controller has failed and needs
to be replaced.
To test that the controller is emitting the proper voltage to the motor, connect your multimeter to
any color combination on the motor phase wires where they connect at the yellow junction box.
Set your meter at DC 50 or higher, and test under load (with the scooter power turned on, while
pulling the throttle). The voltage should start at 0 and increase between 2.5-3.6 volts while under
full load (holding the throttle pulled at the way).
*Continued next page*
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