E-Wheels EW-46 Service & Repair Manual Download

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EW-46

Service & Repair Manual

Summary of Contents for EW-46

Page 1: ...EW 46 Service Repair Manual...

Page 2: ...rness 8 Testing the Controller 9 Testing the Motor 11 Intermittent or Random Loss of Throttle Issue 12 Section 3 Upkeep and Maintenance 16 Daily Checks Before Riding 16 Customer Diagnosis Complete Los...

Page 3: ...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 b...

Page 4: ...ic 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 ti...

Page 5: ...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 l...

Page 6: ...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...

Page 7: ...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 an...

Page 8: ...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 h...

Page 9: ...rly 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 volt...

Page 10: ...h is approximately 4 95 5 volts Leave the scooter powered on and the connector connected This reading should be obtained at the black and red yellow and green and green and blue sensors wires while no...

Page 11: ...ld respond if the controller harness and throttle have already been tested and the brake sensors and rheostat have already been checked If not the motor needs to be replaced Going internal with the mo...

Page 12: ...knob wires 2 Brake Tension Lack of tension in the brake handle is the most likely culprit to cause random loss of throttle response while driving The brake cables can slightly stretch out during norma...

Page 13: ...ster like the one in the photo below must be used A load tester will be required to properly test the batteries under load However if the batteries are multiple years old the scooter has issues accele...

Page 14: ...the Charger To test the output voltage of the charger plug the chargers power supply directly into a wall outlet but not into the scooter Set your multimeter to DC 200 or higher and insert a multimete...

Page 15: ...or damage and injury could occur This voltage reading will vary depending on the current charge of the scooter s batteries If there is no voltage reading at all this would indicate the batteries are...

Page 16: ...e batteries become completely depleted or sit for an extended period uncharged Doing so will damage the batteries decrease the capable mileage and shorten the useable life span of the batteries Period...

Page 17: ...gauge is recommend monthly opposed to daily A tire with a loss of tire pressure will appear like the one photo to the left If the tire appears to of lost pressure testing the PSI pounds per square inc...

Page 18: ...swing arm bolts and the motor to axle bolts The front wheel is held on by a bolt that is a 19mm This can be removed with a socket and rachet or wrench The rear wheel is held on by a bolt that is a 19m...

Page 19: ...ing a 10 mm allene wrench and a 19 mm socket wrench to loosen the nut to take the axle bolt off The seat is securing by two bolts and the seat latch The seat bolts are a 5mm hex head bolt on the bolt...

Page 20: ...the scooter The bolt size is going to be Make sure the bolts are tight on each side If there is a gap between the axle bracket and the swing arm this is normal If overtightened bolts from the transax...

Page 21: ...ential assembly There is a drain and fill bolt on the top and bottom of the motor Drain old oil replace fill bolt and use 10W 30 motor oil to refill the transaxle with approximately quart Section 4 Bo...

Page 22: ...remove all screws along the Headlight Shroud You need to also remove the front big screw as shown in photo s below There will be 2 more next to the Headset Shroud The last 3 are you will see once the...

Page 23: ...23...

Page 24: ...e will be Philip screws on the front and back side of the running board There is also bolts that are a 10mm socket or screw driver Philips head Remove the 4 bolts on the floor board where your feet go...

Page 25: ...eath the seat need to be dismounted or unplugged Make sure these things are done before proceeding There is a total of twelve securing bolts three wire harness connections and one latch cable that wil...

Page 26: ...e circuit breaker before removing the storage box Once complete you will remove the storage box this is what you will see Remove the cable that goes to the truck lock You re going to want to pull up i...

Page 27: ...hat go to both taillight fob Once all these steps have been followed the main body shroud can now be lifted off Tilt the main body shroud s back end towards the front of the scooter without lifting th...

Page 28: ...ody Shroud Remove all screw that attach the bumper to the body shroud on the inside Keep in mind that there are going to be screws that go along the inside of the bumper Remove all four screw to remov...

Page 29: ...are secured by a single wheel securing nut located in the middle of the wheel The nut size is going to be a 19mm socket A jack or stand will be needed to remove the front tire The front wheel is secur...

Page 30: ...ake pads are held onto the axle s brake pad catch and to the actuating brake tension arm with spring tension Pull the two sides of the brake pads away from each other to remove and duplicate the reins...

Page 31: ...t parts are going to be a plug and play for this unit Once this done you will need to just plug it back in and its complete Batteries The batteries may need to be replaced every 2 3 years depending on...

Page 32: ...il there is only battery number four s positive terminal available without a wire connected Finish the battery wiring by connecting the remaining wire that is connected to one of the sides of the circ...

Page 33: ...saxle replacement Motor To remove the motor you must first start by removing both rear wheels The anti tip wheels will act as a jack so the body panels will not make contact with the ground Using a fl...

Page 34: ...ector Disconnect all the motor wires before proceeding Motor Oil The EW 36 uses 5W 30 motor oil synthetic or non synthetic If completely empty refill the motor with up to quart of oil The final step i...

Page 35: ...ctor to avoid confusion Once all connections have been replaced remove the old wire harness and the entirety its mounts Zip tie the new harness to the frame at the same points the old harness was moun...

Page 36: ...e handle Once lined up pull the brake cables housing away from the handle until the cable and cable housing can be slid out from the handles housing Rear Brake Pads hardware Removal Remove the rear wh...

Page 37: ...lace remove those and its out Please see the photo below for a visual Controller To remove or replace the controller the seat storage box and the main body shroud must be removed Once removed the cont...

Page 38: ...a 8mm nut and Philips Seat Latch and Seat Latch Cable Replacement Seat Latch Cable To replace the seat latch cable the seat and storage box and main body shroud must be removed Once removed dismount...

Page 39: ...h Make sure to disconnect the connecter as well Ignition Replacement Once the front big headlight shroud is removed you can now access the ignition to get it replaced There will be 2 Phillip screws th...

Page 40: ...e three securing screws that mount the speedometer to the front tiller guard Save the original speedometer s dash bulbs to save for future replacements Throttle Replacement To replace the throttle sta...

Page 41: ...nd rachet You will need to remove the top and bottom bolt to take this off Left Brake Handle Replacement To replace the left brake handle start by removing the headlight shroud Once removed take of th...

Page 42: ...r horn button start by removing the headlight shroud Once removed locate the button you intend to replace and separate the electrical connector Then dismount the original button by depressing the push...

Page 43: ...the backrest you are going to want to remove the x4 5mm allen wrench bolts as shown below The plastic mechanism covers will need to be removed to get the x2 6MM Allen bolts of each arm rest Remove th...

Page 44: ...sm covers with a Phillips screwdriver There are going to be 2 philip screws that hold the seat mechanism cover on as shown with the arrows below Lifting the seat up may make it easier to get to the sc...

Page 45: ...echanism covers on the side of the seat the armrest is being replaced Then take out the two 6mm hex head bolts and install the new armrest This is for both sides of the seat Floorboard and Horn Replac...

Page 46: ...o be removed 2 of then on the inside and 1 on the outside of it as well Update Photos and Description Will There will be 3 screws that are holing speedometer to the black tiller guard Remove all 3 wit...

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E-Wheels EW-46, Service & Repair Manual

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