Giant MY20 Service Manual Download Page 39

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4. ASSEMBLY GUIDES

TABLE OF CONTENTS

4.1 SyncDrive - motor

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SyncDrive Pro motor

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SyncDrive Comfort / Sport / Life motor

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Battery connector spacer

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SyncDrive external speed sensor

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Integrated speed sensor replacement

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4.2 RideControl – remote & display

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Remote button & bracket

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4.3 Ridecontrol - remote & display

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Evo display & bracket (MTB type)

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Evo display & bracket (City type)

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4.4 EnergyPak-battery

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Integrated battery cover Trance-E/Intrigue E+

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Replacing RideControl one S.O.P.

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Side-release battery cover & casing

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EnergyPak fitting improvement S.O.P.

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Part 1: Replacement of cover rubbers

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Part 2: Checking and adjusting lock alignment

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Battery carrier battery casing

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4.5 Remainders

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Side-pull battery lock

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Head tube light

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Summary of Contents for MY20

Page 1: ...MY20 SERVICE MANUAL...

Page 2: ...2...

Page 3: ...3 TABLE OF CONTENTS 1 Intro 5 2 MY20 G Systems components overview 7 3 Tools 33 4 Assembly guides 39 5 Trouble shooting 81 6 Supplement 93...

Page 4: ...4...

Page 5: ...anic as a technical guide and reference work for servicing our E Bikes For information about the basic operation and functionality of e bikes please refer to the regular user manual Updated or additio...

Page 6: ...6...

Page 7: ...ideControl 17 RideControl One 17 RideControl Evo 22 RideControl Charge 25 Remote charge Evo 27 RideControl features overview 28 2 5 EnergyPak 29 Carrier EnergyPak 29 Side Release EnergyPak 29 EnergyPa...

Page 8: ...DECONTROL RIDECONTROL is the control unit on the handlebars It s the interface that gives the user control over the e bike functions The CHARGE and EVO displays are basically unchanged compared to pre...

Page 9: ...h ISIS interface SMART ASSIST Each MY20 SyncDrive Motor is equipped with PedalPlus 6 sensor tech nology Switching the assist level down to off and then one level further acti vates the Smart Assist fu...

Page 10: ...nt Service Tool software and dongle SENSORS The MY20 SyncDrive Pro motor uses PedalPlus 6 sensor technology to op erate Speed pedaling torque pedaling cadence motor rpm slope accel eration More inform...

Page 11: ...SIST Each MY20 SyncDrive Motor is equipped with PedalPlus 6 sensor tech nology Switching the assist level down to off and then one level further acti vates the Smart Assist function AUTO mode The Smar...

Page 12: ...iant Service Tool software and dongle SENSORS The SyncDrive Sport motor uses PedalPlus 6 sensor technology to operate Speed pedaling torque pedaling cadence motor rpm slope acceleration More informati...

Page 13: ...tching the assist level down to off and then one level further acti vates the Smart Assist function AUTO mode The Smart Assist will automat ically select the optimal power ratio depending on the input...

Page 14: ...about the sensors can be found in the PedalPlus chapter further on in this manual CONNECTIONS The SyncDrive motor is a central part of the G system and is connected to all the other G System parts lik...

Page 15: ...ration sensor accelerometer is mounted on the circuit board It detects whether the bicycle is accelerating or decelerating 5 MOTOR ROTATION SENSOR The motor rotation sensor is integrated into the elec...

Page 16: ...e power ratio This results in a very effi cient battery power consumption and allows the rider to set the mode once and just enjoy the ride with optimized support in all circumstances SENSOR ERRORS If...

Page 17: ...ported data fields and how to pair the e bike BUTTONS 5 PHYSICAL BUTTONS OF RIDECONTROL ONE On Off button Short press to turn on the system Long press 3 sec to turn system off Assist UP button Press t...

Page 18: ...mean that the battery is charged to about 80 100 When the charge level drops below 10 the bottom LED B1 will turn from white to orange Finally when the charge level drops below 3 the bottom LED B1 wil...

Page 19: ...SIST INDICATOR Press Assist Down button a few times down to Assist OFF and 1 press more to activate the Smart Assist function On the assist level indicator only the middle LED L3 will be on to indicat...

Page 20: ...o learn more LED STATE COLOUR ERROR LT Blinking Red On all errors L5 Blinking White System overheating protection L4 none L3 Blinking White Speed sensor issue L2 Blinking White SyncDrive issue L1 Blin...

Page 21: ...low speed mode by accident MY20 bikes all have firmware with method 2 modified button sequence LOW SPEED MODE METHOD 1 OLD VERSION 1 Turn on the bike Speed must be 0 2 Push light button 5 times withi...

Page 22: ...even older G System bikes Providing it runs the latest firmware the information on the screen can adapt to almost any G System e bike it is connected to For example it will show 3 or 5 assist modes d...

Page 23: ...RVAL SETTING In the latest Service Tool software it is possible to set a service interval The de fault setting is 2000km This will start counting from every last Service Tool con nection When the set...

Page 24: ...re was an error The error message sequence displays as follows WRENCH TOOL When an error occurs turn the bike off and back on to reset the system If the error returns please use the Service Tool softw...

Page 25: ...firmware display cadence rpm set the Given ODO and connect to the RideControl app COMPATIBILITY The Charge display connects to all G system bikes just like EVO and RC One Because Charge uses a segmen...

Page 26: ...dealer for mainte nance Currently dealers can follow their own procedure for service intervals A list of advised maintenance intervals and procedures will be released in MY20 GIVEN ODO SETTING The Syn...

Page 27: ...system Syncdrive motor unit Three different mounts are available Standard grip mount on the left side of the handlebar Bracket mount city for placement integrated with toolless adjust able stem for P...

Page 28: ...e Maximum Speed On connected device Trip Time On connected device Trip Distance On connected device Total Distance On connected device User Cadence Indication On connected device Heart rate Indication...

Page 29: ...e makes them compatible with accessories like EnergyPak Plus Range extender battery The original MY19 batteries are not compatible with EnergyPak Plus The EnergyPak Smart is integrated in the downtube...

Page 30: ...RANGE TABLE SYNCDRIVE LIFE SYNCDRIVE SPORT SYNCDRIVE PRO ENERGYPAK MODE RANGE KM MODE RANGE KM MODE RANGE KM 500WH Integrated MY19 244M36500I 01V Smart MY20 244M36500I 03V Eco 75 150 Eco 75 150 Eco 65...

Page 31: ...nitor the battery cells temperature and other health indicators When cer tain cells are getting too hot or otherwise less than optimal current is reduced or diverted to other cells During the final st...

Page 32: ...These times can vary depending on various factors like ambient temperature battery health etc 110V AC 3A FAST CHARGER 220V AC 4A FAST CHARGER 100 240V AC 6A SMART CHARGER 400WH 500WH 400WH 500WH 400W...

Page 33: ...general tools 34 3 2 Service tool software USB dongle 35 3 3 Sockets and keys 35 Speed sensor and integrated battery lock 35 Spider socket 2 sprocket spider 36 Spider socket 8 notch 36 3 4 Torque tool...

Page 34: ...Any DailyTour Lock assembly jig Giant specific Battery tester discharge tool Giant specific attachments Multimeter Torque tool Mx72C lithium lead batteries capacity tester power Batteries switch setti...

Page 35: ...ise and can export the results in detailed reports Warranty on batteries are judged by Service Tool results A detailed manual for the Service Tool Software is supplied with the software package and is...

Page 36: ...hain wheel on the SyncDrive Pro motors with ISIS BB there are already sockets available in the market like Parktool BBT 18 or Truvativ TL2340 bracket tools 3 4 TORQUE TOOL For applying correct torque...

Page 37: ...hows the Voltage value of a connected battery When the display is flashing it shows the set termination Voltage at which the discharge test will stop Current LED is on The display shows the current va...

Page 38: ...ectricity and electrical circuits In addition often some kind of reference data is needed to be able to interpret the measurements made with a multimeter It is not the intention of this manual to elab...

Page 39: ...acket 52 4 3 Ridecontrol remote display 53 Evo display bracket MTB type 53 Evo display bracket City type 55 4 4 EnergyPak battery 57 Integrated battery cover Trance E Intrigue E 57 Replacing RideContr...

Page 40: ...s Take all necessary precautions Reaching into an active system can cause serious injury Pull connectors do not pull wires 1 Remove EnergyPak Remove crank bolts left and right 2 Remove cranks left and...

Page 41: ...te more room 7 Slightly loosen all 4 motor bolts 2x M6 2x M8 a few turns 8 First take out the 2 motor bolts on the front side starting with the smaller M6 bolt right side Lightly tap the head of the M...

Page 42: ...que using a calibrated torque wrench Left side M8 bolts tightening torque 22 Nm Right side M6 bolts tightening torque 11 Nm M8 22Nm M6 11Nm 2 Mount the left crank first Mount the chain wheel locknut u...

Page 43: ...reduce strain inside the motor This is a feature not a flaw 1 First remove EnergyPak Remove the cranks Cranks can be removed with a regular pulley 2 Remove the big chain wheel nut Usage of the special...

Page 44: ...not fall out 7 Disconnect all the wires Remove the third motor bolt and remove the motor ASSEMBLE 1 To reassemble follow the complete procedure in reversed order The frame bolts should be tightened w...

Page 45: ...ard on the connector as this might damage the wires On some occasions it could be that the power wires are clamped or stuck between the motor and the frame Then it will be necessary to partly disassem...

Page 46: ...er should fit in the recess easily and all the holes should line up nicely 7 Insert all screws and engage the threads a few turns 8 Tighten the 4 screws to 1Nm 9 Place the battery 10 The bike is now r...

Page 47: ...CDRIVE MOTOR SYNCDRIVE EXTERNAL SPEED SENSOR Follow illustration for proper speed sensor and spoke magnet assembly To prevent unneeded replacements start by making sure the speed sensor is positioned...

Page 48: ...t Switch the system on display will fade out Reaching into an active system can cause serious injury Pull connectors do not pull wires 2 Loosen the bolt in the frame which secures the EnergyPak using...

Page 49: ...tor cover using a Allen key size 2 5 8 Remove the bolt of the motor cover using a Allen key size 4 9 Remove the left cranck arm using a Allen key size 8 10 Remove the 4 bolts from the side cover using...

Page 50: ...sing a Torx 30 tool 14 Remove the bolt at the front left side of the motor using a Torx 30 tool 15 Loosen the bolt at the rear left side of the motor using a Torx 30 tool do not remove the bolt 16 Wit...

Page 51: ...evious steps in reversed order Use Loctite 263 thread locker on M8 and M6 motor bolts to prevent bolts from loosening over time due to vibrations Be sure to tighten the motor bolts to the specified to...

Page 52: ...or Loosen the grip remote mounting bracket clamping screw 2 Remove the handlebar endcap Remove the grip and bracket from the handlebar Remove the grip from the remote mounting bracket 3 Remove the 3 s...

Page 53: ...nnectors Please note that other cables can obstruct the exit hole Try to avoid using too much force while pulling out the connector to pre vent damage to the cable When the connector is pulled complet...

Page 54: ...Remove the 4 screws on the bottom of the display bracket 8 Remove the display from the bracket ASSEMBLE 1 Repeat steps in reverse for re assembly When placing the bracket back on the handlebar make su...

Page 55: ...n obstruct the exit hole Try to avoid using too much force while pulling out the connector to prevent damage to the cable 2 When the connector is pulled completely out of the frame disconnect the disp...

Page 56: ...e display bracket clamps 7 Remove the display bracket ASSEMBLE 1 Repeat steps in reverse for re assembly When placing the bracket back on the handlebar make sure that the wires exit on the front side...

Page 57: ...LE 1 Remove side rubber between battery and battery cover 2 Remove cover screw 3 Slide cover over battery ASSEMBLE 1 Make sure all surfaces are clean and degreased Make sure 4 rubbers and 1 screw are...

Page 58: ...battery 5 The ridges on both sides of the inside of the cover should go into the grooves in both sides of the battery Slide in one side first snap the other side in by hand Push the ridges of the bot...

Page 59: ...ber onto the battery Make sure everything is properly aligned Make any necessary adjustments before continuing to the next step 10 Carefully peel away the film while guiding and securing the rubber in...

Page 60: ...hile unlocking support the battery to prevent damage due to falling out 3 Remove the two tamper proof bolts of the locking mechanism using the pin in torx tool part number 2520 T25 01V 4 Disassemble t...

Page 61: ...f the RC One fur ther in to the frame 7 Take the connectors out of the frame and disconnect them 8 Pull the connector of the RC One out of the frame 9 Pull the connector of the RC One through the rubb...

Page 62: ...Place the RC One onto the handlebar 14 Tighten the screw of the RC One at 1 Nm 15 Push the connector of the RC One trough the rubber 16 Put the connector back in to the frame 17 Make sure you have eno...

Page 63: ...rect into the frame If the cables are not aligned correctly the battery won t fit and the locking mechanism won t function properly 21 Mount the locking mechanism back in to the frame Make sure the ca...

Page 64: ...the battery Tighten the screws at 4 to 5 Nm 25 Check if the battery can smoothly move in and out of the frame when locking and unlocking Check if the secondary lock functions properly so the battery...

Page 65: ...n the battery around to the front end Lift up the corner of the cover and snap the first hook on this side out of its groove Continue all the way down the length of the battery until the topside of th...

Page 66: ...ttery with the charging plug facing up Use a small and thin flathead screwdriver as a lever between the connector and the casing to create a small gap Place a tire lever upside down next to the chargi...

Page 67: ...sing Position battery charge connector Slide over top side housing pay attention of no cables getting stuck inside Gently increase pressure for the hooks to engage Be careful not to damage the waterpr...

Page 68: ...lock and remove the battery from the bike Place the battery on a non scratching surface 2 Remove the small screw from the cover attachment plate on the bottom of the Battery 3 Slide the battery cover...

Page 69: ...battery until the cover attachment plate sits against the bottom of the battery 9 Place the small screw from the cover attachment plate on the bottom of the battery and tighten it Do not over tighten...

Page 70: ...and remove the EnergyPak from the bike Place the Ener gyPak on a non scratching surface 2 Loosen and take out the upper bolt of the lock assembly 3 Place the battery positioning tool in to the frame a...

Page 71: ...se as possible towards the bottom of the tube 9 Tighten the bolt on the bottom of the down tube 10 Loosen the single bolt that fixes the battery positioning tool onto the lock assembly and take it out...

Page 72: ...t moisture 13 Place the battery back into the tube Make sure the EnergyPak is locked Only if the lock assembly makes a clear click sound the battery is locked properly It is unsafe to ride with a batt...

Page 73: ...e the 4 screws on the corners on the bottom of the battery 2 Use a small and thin flathead screwdriver as a lever between the con nector and the casing to create a small gap 3 Place a tire lever in th...

Page 74: ...SSEMBLE 1 For battery casing Gently slide in cell pack in bottom side housing Posi tion battery charge connector Slide over top side housing pay atten tion of no cables getting stuck inside Tighten th...

Page 75: ...the bottom Use a tire lever to lift it out without damage Gently pull out the inner cover If necessary use the tire lever to create some room around the edges 3 Take out the two screws on the most le...

Page 76: ...k isn t properly adjusted Adjust the lock assembly base plate when the battery doesn t fit well in the frame 3 If the lock assembly base plate needs to be replaced copy the distance from the original...

Page 77: ...d tape measure and or pencil marking as a refer ence for mounting the new base plate 5 Repeat steps in reverse for re assembly Make sure all bolts are tightened properly Double check if the battery fi...

Page 78: ...andlebar hang down alongside the frame 3 Lift the bike up as much as just the top of the fork stem is still inside the headtube and the complete light becomes accessible from inside the headtube 4 Dep...

Page 79: ...79 6 Disconnect the light and replace it ASSEMBLE 1 Reverse the previous steps for re assembly...

Page 80: ...80...

Page 81: ...error 83 5 3 RideControl charge error 84 5 4 Error codes 85 5 5 System malfunction 86 Response 1 switching on impossible 87 Response 2 switching off impossible walk assistance 88 Response 3 button fu...

Page 82: ...ge error What do the error codes stand for See chapter 4 4 Error Codes My system can t switch on or off What to do See chapter 4 5 System Malfunction How come Giant Syncdrive Central motor makes a dif...

Page 83: ...layed as well For most errors the motor assist will remain func tional Motor assist will only stop in case of a SyncDrive error The wrench tool will show on the screen for as long as the problem persi...

Page 84: ...ill remain functional Motor assist will only stop in case of a A1 SyncDrive error The error code will show on the screen for as long as the problem persists Hardly ever there is reason for immediate c...

Page 85: ...nsor locked at low speed 38 Auto running without crank rotating 39 Crank rev sensor failure 61 Current sensor offset 62 Motor over current 63 EEPROM failure 64 Thermistor failure 65 Circuit board over...

Page 86: ...Switch on impossible Switching system on is impossible Response 1 Immediate switch off After switching on system switches off immediately Response 1 Switching off impossible Switching off the system...

Page 87: ...Can the system be influenced by bending the display wire at the connector to the remote button Replace display YES NO Is corrosion visible on the USB port Replace display YES NO Is corrosion visible o...

Page 88: ...CE Can the system be influenced by bending the display wire at the connector to the remote button Replace display YES NO Are the issues solved YES NO Replace remote button YES NO Are the issues solved...

Page 89: ...89 RESPONSE 3 BUTTON FUNCTION LOSS Do some buttons occasionally loose functionality Replace display YES NO Are the issues solved YES NO Contact Giant Service Center Done...

Page 90: ...range can vary The range strongly depends on several circumstances such as but not only Weather conditions such as ambient temperature and wind Road conditions such as elevation and road surface Bike...

Page 91: ...eries Connect the wire attachment to the output discharge connector of the battery and connect the multimeter probes to either number 4 1 or 3 2 terminals on the round connector of the wire attachment...

Page 92: ...92...

Page 93: ...CHAPTER CONTENTS 6 1 EnergyPak LED indicator 94 6 2 EnergyPak LED indicator Charging 95 6 3 Led indication EnergyPak 96 6 4 Led indication Count of cycle 97 6 5 Service mode EnergyPak 99 6 6 MY19 Qui...

Page 94: ...INDICATOR FOR BATTERIES WITH 4 LED INDICATION State of charge not charging Push and release the button on the EnergyPak to read out the current state of charge LED Indication State of charge 0 25 26 5...

Page 95: ...ARGING FOR BATTERIES WITH 4 LED INDICATION State of charge while charging When the charger is connected the LED board will display the current state of charge LED Indication State of charge 0 25 26 50...

Page 96: ...arging When the charger is connected the LED board will display the current state of charge State of charge not charging Push and release the button on the EnergyPak to read out the current state of c...

Page 97: ...RIES WITH 5 LED INDICATION To read out the count of cycle number of times the battery has been fully charged press the button twice in a row LED Indication Count of Cycle 0 50 51 100 101 150 151 200 2...

Page 98: ...98 LED Indication Count of Cycle 501 550 551 600 601 650 651 or more Led On Led Blinking...

Page 99: ...ton pressed in after 7 to 8 seconds the LED will indicate the 1st service stage After entering the 1st service stage the error code will be displayed on the LED board To enter the next stage release t...

Page 100: ...CATION The service mode is displaying 5 stages in these stages you can read out error codes and the condition of the battery STAGE 1 ERR1 1 LED Indication Error No error Over charge Over discharge Ove...

Page 101: ...ATION The service mode is displaying 5 stages in these stages you can read out error codes and the condition of the battery STAGE 2 ERR1 2 LED Indication Error No error Cell over temp Cell thermistor...

Page 102: ...is connected the LED board will display the current state of charge The service mode is displaying 5 stages in these stages you can read out error codes and the condition of the battery STAGE 3 ERR2 1...

Page 103: ...cted the LED board will display the current state of charge The service mode is displaying 5 stages in these stages you can read out error codes and the condition of the battery STAGE 4 ERR2 2 LED Ind...

Page 104: ...is connected the LED board will display the current state of charge The service mode is displaying 5 stages in these stages you can read out error codes and the condition of the battery STAGE 3 ERR2 1...

Page 105: ...105 6 6 MY19 QUICK E 45 EU G SYSTEM WIRING SCHEME...

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