SUR-RON Light Bee Service Manual Download

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SUR-RON LIGHT BEE

QL3000DY-2

SERVICE MANUAL

Summary of Contents for Light Bee

Page 1: ... SUR RON LIGHT BEE QL3000DY 2 SERVICE MANUAL ...

Page 2: ...ket and working boots etc in case of burning cutting collision or other accidents And use protective goggle or gloves if necessary Chongqing Qiulong Technology Co Ltd Hereafter called Sur Ron has the power of interpretation for all information in the manual Sur Ron aimed to build the best electric bike in the world therefore any improvements which can make the bike have better performance and qual...

Page 3: ...ront brake assembly dismount and mount 10 8 Rear brake assembly dismount and mount 11 Bike body dissemble and assemble 11 1 Mid Bushing dismounting and mounting 11 2 Motor side cover dismounting and mounting 11 3 Motor side cover dismounting 11 4 Disassemble and assemble first level transmission belt 11 5 Disassemble and assemble left pedal assembly 11 6 Disassemble left pedal assembly 11 7 Disass...

Page 4: ...ol 13 Position adjustment 13 1 Adjust handlebar 13 2 Adjust brake handle 14 Disassembly 14 1 Dismount handlebar of accelerator 14 2 Dismount handlebar 14 3 Dismount throttle bracket 15 Transmission gear 15 1 Check chain and chain wheel 15 2 Clean and lubricate chain 15 3 Disassemble and assemble chain 16 Electric system 16 1 Electric system drawing 16 1 Check electric system 17 The use and mainten...

Page 5: ...eds different type of driving license Accidents and serious injuries Please read local provisions about electrombile and motor vehicle before using Light Bee bike According to the certification of L1e B electric moped scooter that Sur Ron Light Bee has passed its highest speed is 45km h so it is not allowed on expressway or the road segment with the minimum speed of more than 45km h If you have an...

Page 6: ... Input 110V AC or 240V DC according to local voltage Output 67 2V DC 10A c h a r g i n g t i m e standard 0 100 3 5 hours 0 95 3 hours 0 80 2 hours mileage continuation of journey ECO mode average speed 25km h 100km electromotor double stage reduction drive system bike frame hanger bracket brake bike frame Double beam cradle type lightweight aluminum alloy forge rear absorber multi link central sh...

Page 7: ... 100 Kg serial number item diameter of thread mm tightening torque N m install left and right lower controller support M6 8N m fasten front brake disk M5 8 10N m fasten rear brake disk M6 10 12N m fasten rear chainring M8 20 25N m rear absorber rear rocker arm connection rod M8 20 25N m fasten bolt of belt wheel M6 12N m fasten bolt of output shaft sprocket M6 12N m fasten nut of front belt wheel ...

Page 8: ...auxiliary frame and bike frame M8 20N m fasten nut of seat cushion M6 8N m rear absorber bike frame and back fork M8 25 30N m fasten rear wheel axle M12 55 60N m fasten rear disk brake M6 12N m fasten electrical motor M8 25N m fasten controller and controller support M6 8 10N m fasten pedal and bike frame M8 25 30N m fasten controller protector bolt M8 20N m serial numb er battery capacity speed k...

Page 9: ...frame 7 Three phase brushless DC motor 8 Ternary power lithium battery 9 Control system 10 Headlight 11 Front absorber 2 3 2 Position of head parts Fig 2 1 LCD Speedometer 2 Front brake handle 3 Rear brake handle 4 Throttle grip 5 Control switch 6 Rear view mirror 2 3 3 LCD Speedometer functions ...

Page 10: ...days we suggest you to take battery down keep its capacity not less than 50 and charge it at least once per month Only the charger and cable equipped for the bike can be used because they are specially designed for the bike Only original charger can be used in charging In order to achieve the best battery performance charge the bike immediately after use every time Full discharge may damage batter...

Page 11: ... purchased from Chongqing SUR RON Technology Co Ltd 4 1 Light Bee s special repair and maintenance tool kit 1 inner hexagonal spearhead S3 S4 S5 S6 S10 2 outer hexagonal spearhead S12 S17 3 Round nut four claw sleeve S10 4 cross screw driver 5 AVO meter 6 original special brake mineral oil LBN 7 lubricating grease 4 2 Fix Light Bee In terms of some maintenance operation of Light Bee we suggest to ...

Page 12: ...attery out see Fig 5 5 1 1 Assembly Assemble battery according to the inverse disassembly steps 6 Disassemble assemble and adjust damping system 6 1 Adjust compression damping of front absorber see Fig 6 Fig 6 The compression damping of front absorber is adjusted through the standard valve core at the lower right High pressure pump is necessary The recommended pressure is 7 10BAR 100 150 psi 6 2 A...

Page 13: ...crease preload force turn nut anticlockwise to reduce preload force 6 3 Damping and lubrication Warning Light Bee QL3000DY absorber is designed for non detachable don t attempt to open or disassemble absorber Don t disassemble Light Bee QL3000DY s absorber Please lubricate absorber according to the following steps and keep its best state dismount protective cover see Fig 9 unscrew dustproof ring s...

Page 14: ... 10 12N m Fig 10 6 4 2 Disassemble headlight and front turning light see Fig 11 Dismount turning light install nuts and take down turning light dismount bolts of support of front case and separate headlight and front case dismount bolts of headlight and separate headlight and front case 6 4 2 1 Assembly Assemble headlight and turning light according to reverse disassembly steps and fasten them wit...

Page 15: ... Fig 13 14 place front wheel assembly flatwise with disk upwards Clean and protect it Dismount bolts of front brake disk take down front brake disk and avoid contaminating brake disk 6 4 4 1 Assembly Assemble front brake disk according to the inverse disassembly steps use thread locking glue Loctite 243 on bolt fasten it with the torque force of 8 10N m Pay attention to rotation and install direct...

Page 16: ...EE QL3000DY on platform or support plat at bottom bracket area Loosen the bolts of connector at the upper part of absorber fix rear wheel make sure it not falls off and dismount bolts Put the bike on floor Loosen the bolts of connector at the lower part of absorber dismount absorber Dismount bolts of rocker arm and take down connecting rod of rocker arm and rocker arm 6 5 1 Assembly Assemble rear ...

Page 17: ...ng gap or overhigh resistance after the recommended torque is achieved by tightening some parts on bearing may be damaged In the case you must use new head parts 7 2 Disassemble head parts Disassemble the head parts of Light Bee QL3000DY according to the following steps Put Light Bee QL3000DY on support at bracket area Dismount front case and instrument see 6 4 1 disassemble front case and instrum...

Page 18: ...f it is at a deeper position than the designed depth locking bolts are not long enough to achieve proper fastening Fig 20 8 Disassemble and assemble handlebar assembly Fig 21 Disassemble head parts of Light Bee QL3000DY according to the following steps Put Light Bee QL3000DY on support at bracket area Dismount left and right rearview mirror Dismount handle grips throttle and switch Do not damage s...

Page 19: ...tance reduce service time clamping and piercing 9 2 Check wheel rim Deformation examination for wheel rim should be conducted according to the following steps Put Light Bee QL3000DY on support at bracket area Confirm wheels rotate properly Check whether wheels swing transversely see Fig 22 If swing transversely occurred measure their transverse motion through indicator If transverse motion exceeds...

Page 20: ...s not found at the starting point of stroke of brake handle deflate brake system see 10 2 1 deflate brake 10 1 2 Check the status of flexible brake pipe Check the length of all flexible brake pipes and accessories connect with brake handle and callipers to find any potential damage or fluid leakage 10 1 3 Check brake pad As shown in Fig 24 the thickness of brake pad is 2 5mm at least including met...

Page 21: ... it is used to fix the shock insulator of brake pad fix piston on brake caliper in case that brake caliper bounces after pressing brake handle Use rubber band to fix shock insulator Fix brake caliper above brake pump brake handle When there is no oil in long needle cylinder lift brake caliper above brake pump and remove long needle cylinder from adapter Dismount head bolts of brake caliper Then us...

Page 22: ...e caliper to obtain the maximum braking force if necessary Fig 26 10 3 Dismount brake handle see Fig 27 Install brake handle on pump by pressing pull rod Dismount brake handle according to the following steps Fix pump firmly press handle dismount positioning bolts and screens gasket from pin axle Push rod A down with the cylindrical tool with the diameter of less than that of pull rod Pull rod may...

Page 23: ...ng glue Loctite 243 on bolts Pinch brake handle slightly and rotate wheel Target brake caliper with brake disk aligns correctly Keep brake pressure handle still and fasten the bolts on brake caliper with the torque force of 8 10Nm Fig 29 10 6 Dismount the adapter of brake caliper only suitable for front brake caliper see Fig 30 Dismount the adapter of brake caliper according to the following steps...

Page 24: ... out of flexible brake pipe during operation The brake fluid in LIGHT BEE QL3000DY is mineral oil and nor corrosive Brake fluid can be wiped with clean cloth Contacts machine oil may permanent damages brake pad 10 8 1 Assembly Put flexible brake pipe near brake caliper on bike frame Install pipe clamps Place parts according to the following steps rubber guard plate nut insertion piece and lubricat...

Page 25: ...ee Fig 32 Dismount side cover of DC motor from LIGHT BEE QL3000DY according to the following steps Dismount fastening bolts of side cover of DC motor and put them on workbench 11 2 1 Assembly Assemble side cover of DC motor according to the inverse disassembly steps Fasten bolt with torque force 4 5N m Fig 32 11 3 Disassemble side cover of DC motor see Fig 33 Dismount side cover of DC motor accord...

Page 26: ... damaging switching line Dismount bolts of left pedal assembly and left pedal assembly from bike 11 5 1 Assembly Assemble left pedal assembly according to the inverse disassembly steps Tighten bolts with torque force 25 30N m Fig 34 11 6 Disassemble left pedal assembly see Fig 35 Disassemble left pedal assembly according to the following steps Use tools to disassemble spring of side stand on platf...

Page 27: ...ching sensor on left pedal support Dismount hanging hook of spring from left pedal support 11 8 1 Assembly Assemble pedal assembly according to the inverse disassembly steps Tighten adapter bracket of pedal with torque force 40 45N m Fig 37 11 9 Dismount guard plate of DC motor see Fig 38 Dismount guard plate under DC motor according to the following steps Put side stand down on floor to support b...

Page 28: ...ombination according to the inverse disassembly steps Tighten M6 bolts with torque force 10N m Fig 40 11 12 Disassemble air circuit breaker combination see Fig 41 Disassemble air circuit breaker combination according to the following steps Dismount fall detection sensor support and take down fall detection sensor Avoid damaging the sensor wire Dismount air circuit breaker fixing bolts cut the cabl...

Page 29: ...ontrol lock combination according to the inverse disassembly steps Tighten M6 bolts with torque force 5N m Fig 42 11 14 Disassemble USB and electric control lock see Fig 32 Dismount USB and electric control lock combination according to the following steps Use tools to press limitation support of electric control lock pull it upwards and take electric control lock out Dismount plastic nuts of USB ...

Page 30: ...s In assembly the height of bolts should be kept consistent in order to make first level belt wheels parallel Otherwise belt may have abnormal sound Fig 44 11 16 Dismount tailstock assembly see Fig 45 Dismount tail stock assembly according to the following steps Put LIGHT BEE QL3000DY on support Dismount rear fender inner plate see dismount rear fender inner plate disconnect taillight and GPS if h...

Page 31: ...he following steps Dismount power battery see dismount battery Dismount bolts of left and right limited blocks of battery and take left and right limited blocks down 11 18 1 Assembly Assemble left and right limited blocks of battery according to the inverse disassembly steps Fig 47 11 19 Dismount horn see Fig 48 Dismount horn according to the following steps Dismount USB and electric control lock ...

Page 32: ...ear disk brake take brake caliper of rear disk brake and put shock insulator plastic piece with the thickness of 2mm between brake pads adjust adjustment bolts of rear wheel shorten bolts to take chains down loosen shaft of rear wheel take chains down if adjustment bolt of rear wheel is not short enough use tools to dismount clip of chain connector and disconnect chain then take shaft of rear whee...

Page 33: ...disassembly steps and fasten bolts with torque wrench Bolts of rear brake disk 12N m Bolts of chain wheel of rear wheel 20 25N m Fig 51 11 23Dismount rear fork see Fig 52 Dismount rear fork according to the following steps Dismount rear absorber rocker arm belt and chain of DC motor refer to the disassembly method of rear absorber rocker arm belt and chain of DC motor Dismount bolts of protect cov...

Page 34: ...illight wire take out cable tie of rear fender taillight wire and disconnect wire with rear fender Dismount bolts of rear fender and remove rear fender assembly put it rear fender assembly on platform dismount bolts of seat of taillight and take seat of taillight down Dismount taillight turning light support and rear license plate successively Dismount turning light from turning light support 11 2...

Page 35: ...ount lower battery plate according to the following steps Dismount power battery see dismount battery Dismount back shield of battery see dismount back shield of battery Dismount DC motor see dismount DC motor assembly Dismount bolts of lower battery plate take throttle cable down disconnect speed control device and power converter port Take lower battery plate down 11 28 1 Assembly Assemble lower...

Page 36: ...or and electrical connection of brake 12 2 Check handle of accelerator throttle Accelerator only can be checked on bike The operation conditions and rider s operation speed and lean angle must response immediately with accelerator and power supply must proportional to accelerator position If fail to response according to the operation check electrical connection and perform diagnosis refer to elec...

Page 37: ...ndlebar grip out Before dismounting right handlebar grip cut right handlebar grip open longitudinally carefully until it can be opened and dismounted Before installing a new handlebar grip clean handlebar left or handle of accelerator right apply polyurethane adhesive on its surface and plug handlebar grip into its end 14 3 Dismount throttle holder Dismount throttle holder according to the followi...

Page 38: ...the tension degree of chain timely If the adjustment limit of rear wheel of bottom fork is exceeded suggest to replace chain see dismount chain Fig 61 Fig 62 15 2 Clean and lubricate chain Clean chains after use every time It is very important to apply special chain oil to keep chains lubricated 15 2 1 Lubrication of chain Lubricate LIGHT BEE according to the following steps see Fig 63 Arrange the...

Page 39: ...minimum wheel axel fork distance rear wheel axel is closest to bottom fork and loose chain reaches minimum tension Look for chain connector and rotate rear wheel until chain connector is below rear fork A Push chain lock up clip with tools as shown in the following figure Take lock up clip and connecting plate down successively And push connector out from one side You may need some long flat nose ...

Page 40: ...ctors of battery controller and other port of bike especially the largely exposed or frequently operated parts Before any operation on the electrical system of LIGHT BEE QL3000DY cut off power or stop other operations in case of damaging electrical elements 17 Use and maintenance of battery 17 1 Disassembly and assembly of battery see Fig 67 17 1 1 Plug key into battery compartment then turn key a...

Page 41: ...ember that many factors will influence the service life of battery These factors will change greatly with service conditions and intensity 17 3 Charging of battery The battery can only be charged with special lithium battery charger in order to avoid damaging battery or dangers Check whether the input voltage of charger is same with the voltage of power grid AC110V 220V Plug the power source into ...

Page 42: ...se stop charging immediately and take it to check and repair 18 Checking and maintenance of controller 18 1 Disassembly of controller see Fig 70 Take controller down from LIGHT BEE according to the following steps Turn off and disconnect air circuit breaker Disconnect battery Dismount guard plate of DC motor see guard plate under DC motor Dismount guard plate under controller see dismount guard pl...

Page 43: ...and power source or take battery down 18 2Checking of controller Check the wire of controller regularly make sure the wire is not loose and still insulating 19 Electrical failure diagnosis and troubleshooting Refer to the following table or failure diagnosis content for electrical failure checking and troubleshooting of bike fault possible reason method solution bike has battery is not installed i...

Page 44: ... Replace controller battery is damaged turn off air circuit breaker use multimeter to check the output voltage is DC45V 67 2V if the above problem can t be solved by charging with charger that means battery is damaged repair or replace battery at the designated shop switch protection of side stand lift side stand up lift side stand up brake to cut off power system disconnect plug of brake to cut o...

Page 45: ...oller black and white line green and white line changes between 0 8V and 3 4V replace speed controller plug of controller has bad connection pull and plug again to check whether terminal is normal insert and pull the controller plug Plug of Hoare line of DC motor has bad connection pull and plug again to check whether terminal is normal insert and pull Hoare plug of DC motor fault of controller or...

Page 46: ...tion check plug of charger insert and pull of charging plug charger is damaged if bike still can t be charged after the above troubleshooting that means charger is malfunction replace charger battery is damaged if bike still can t be charged after replacing charger that means battery is malfunction replace battery power mode is invalid or lack of power battery is too low check electric capacity of...

Page 47: ...her terminal is functional replace plug or terminal inside plug speed signal of controller doesn t have output check speed signal of controller output voltage with multimeter replace controller instrument is damaged check whether the input signal of instrument is functional with multimeter replace instrument Display instrumen t not working after turn on the power key plug of display instrument has...

Page 48: ... the voltage on plug of horn is 12V with multimeter replace horn failure code definition solution Er 102 battery MOS temperature sensor malfunction repair or replace battery at designated after sale shop Er 103 battery soft start failure repair or replace battery at designated after sale shop Er 105 battery primary over discharge protection charge battery Er 106 battery charge MOS damaged repair o...

Page 49: ...on check connection of controller or replace controller Er 208 power tube failure of controller replace controller Er 209 controller current sampling failure replace controller Er 211 Throttle to controller signal wire short circuit check wire of speed controller or replace speed controller Er 212 controller rush out protection check free stroke of throttle cable Er 213 controller low voltage prot...

Page 50: ...Er 223 Fall detection protection turn off key and turn on key after righting bike Er 224 power off protection of side stand lift side stand or disconnect switch plug of side stand ...

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