make a 48V hub motor electric bike kit work at 36V

I have recently bought a DIY electric bike kit  from you, where I have bought a 36V battery and a 48V hub motor & brushless motor controller. I thought that when I ordered from your online internet shop, you would check, that the electric bike kit system would work..

On the homepage you write, that I can force the 48V hub motor controller to work with lower voltages.Also, the 48V thumb hub motor controller does not work. The twist controller works.
I have called your office and found out, that the problem is, that the 48V hub motor controller cuts off the electric bike kit system to protect the li battery. And the only solution is to manually override the system, but that is not an ideal way to operate the e-bike.

I have now ordered a new hub motor controller and thumb throttle for 36V from your homepage. What I would like you to do, is to write on the package you send me, that the package you send me is a guarantee replacement.

I do not wish to discuss guarantee and other issues with you, it is much easier for me to order new parts, but I would like to avoid to have to pay customs and VAT again for the same things. Also it takes weeks before the goods get through customs.

I also have one more suggestion for improvement:Please put 2*2 nuts on the electric bike motor wheel to be able to secure them, because my front 48V 1000w electric bike motor wheel fell off while I was starting with the e-bike. (while driven by 36V, ½ power – where I pull the break lever, push the cruise control 5 times, and use the cruise control to operate the electric bike motor) Also it would be nice if you could specify how hard I should tighten the nuts on the electric bike motor wheel.

20Nm? 60Nm?, I would like to tighten them well, but I do not wish to brake the thread. My transaction ID of electric bike kit order is 3FA78294KK410865B

Hub motor,electric bike motor,electric bike kit supplier: Leaf Motor Technology Co.,Ltd
Website:https://www.leafmotor.com

How to connect wires with leaf 1000W hub motor electric bike conversion kit

I have wired up some items to my bike, but I am unsure how to wire certain things up. Please view the pictures to see what I mean: Attachment called - Controller Wires - Which color to which color of the hub motor do I connect to ? There are three thick wires on the BLDC Motor Controller that look like connectors to they connect to the motor. Unfortunately, I do not know what color to map them to. I did connect blue to blue and green to green, but the wheel responded briefly, then the LCD screen shut off.. I would have to switch the power off and on again for it to come back. I have not gone any further as it gave me the impression I could do some damage if I continued. Attachment called - Bike Motor - Which colors connect to the colored wires of the brushless hub motor Controller This is the connectors on the hub I need you to identify for the Controller, which wire connects to what? Connecting the green to green, black to black, there is another yellowish/greenish wire on the motor that has no equivalent colored wire on the controller. The controller has a black think wire - does this yellow/green wire connect to the black? Attachment called - Light Switch & wire I do not know what this is and what it is used for - I presume a light to work from the battery. Where do I wire this to? Does it connect to the BLDC motor controller? if so, where. I found your video's quite difficult to follow as it is difficult to work out what is connected to what and how and I do not see anyone triggering anything to start the electric bike motor wheel when it starts working. Would you be able to send me some diagrams or written instructions on setting this up from scratch? See attachment ‘BLDC Motor Controller Wires’: The green and blue wires are present on your diagram, but the thick black one isn’t – where is it supposed to go? The other attachment ‘Motor Wires’: There is a Dark green wire, Dark Blue wire and a Yellowish Wire (I say yellowish as it seems to have a hint of green in it – in other words it is not too clear).. The green and blue I can match to the green and blue on the brushless hub motor controller, but what about the Yellow/green wire? I have attached these wires in various combinations, with the power coming on and empowering everything other than the wheel. The electric bike motor wheel will ‘shudder’ when I slightly twist the throttle but the whole thing will shutdown and I will have to turn off and on again to get it back. I did this a few times with the same result. I rearranged the wires again, with all items turning on, but the bike motor wheel did not respond. I eventually realised the controller wire heating up and turned everything off. I have left it for a while, but when I tried it again the power did not come on any device.

12 inch BLDC hub motor for electric bike ?

I'm in need of a simple installation electric bike motor for a special application. The subject BLDC motor look that will perfect fit our needs. I am ready to order the first to complete the prototype, but will appreciate your advice if will work properly under the following conditions: 1. Max torque 15 Kg-m 2. Speed 0 to 10 Km/ h 3. Distance between charge batteries 5 Km Important is smooth start motion (no shaking) I understand the HBL-12" 24V 250W hub motor is good for the working conditions On your internet site for this size electric bike motor there is technical performance for the 36 V model only. I need only 5 Km range between battery charges.But very important is the star movement from stop (0 Km/h) very smooth, slowly start to move otherwise possible damage of the airplane nose wheel if start move quickly and shaking. Then the question, will 36 V brushless hub motor be better than 24 V ?Since 36 V have smaller currents I have the feeling will perhaps be better starting to move more smooth and slowly... Will be great the customized low speed. But please note that this special application, not yet a commercial product, then in the last phase of development. Will you customize low speed electric bike motor at the present stage of just one unit ? Looking all your products, the choice was your Model:HBL-12" 24V 250W hub motor because so simply installation. But also, although is not our preferred solution because much more complicated installation, could be your Stepper DLDC motor, which in this case the speed can be defined by the ratio of the gears, and the diameter of the wheel (which in our case is important to be small since the device shall be below the airplane... Max 12 inches but smaller is better...) Maybe the Stepper DLDC motor have the advantage of very smooth start motion ? It is our concern to have a very slow and smooth start motion... Actually from your specifications you give for the max torque of 16000 (the point we are most interested) 243 rpm at 18 Amps, which is for a 12 inch wheel about 14 Km/h, then is very near our 10 Km/h. We believe, if we do not read wrong your performance data for the 36 V HBL 12 inch electric bike motor as it is specified is OK... Please correct me if wrong. The fact that the motor will be capable of much high speed we believe should be not a trouble, we can easily put a limitation of the speed. Still extremely important is the smooth and slow increase speed from 0 Km/h (stop) with no shacking,but we understand this is related to the BLDC motor controller, which we will test but feel should be not a problem. We need as precise as possible to control smoothly the speed from stop 0Km/h to max 10 to 15 Km/h... with slow increasing speed and keep low speed 2 to 5 Km/h .Then NOT AT ALL "on" and "off" ! Another important issue is the torque. We need minimum 15 Kg-m torque, better if 20 Kg-m... ( 147 to 196 Newton meter)- Here is a big doubt with the numbers on your performance data since indicated mN.m 16000.0 ? if lower figures could be difficult start motion when in surfaces as grass. Then I need to order not only the hub motor but also the relevant BLDC motor controller and electric bike battery. When you say 36 Volts make no difference but preferred in Europe. I choice 36 Volts... as you say... but if 24 Volts is better, off course we change to 24 Volts... we need the better solution. Normally the device speed shall be about 5 to 8 Km/h... for safety reasons... and torque between 147 to 196 Newton meter at 0 Km/h to start motion. Hub motor, BLDC motor, bike motor, electric bike motor supplier: Leaf Motor Technology Co., Ltd Website:https://www.leafmotor.com/

How to build spokes on hub motor for electric bike ?

DIY electric bike conversion kit and convert your bike is funny. Sometimes we prefer to purchase spoke hub motor , bike rim and spokes. And build spokes on electric bike motor by ourselves.
If we want to convert 26inch front wheel, we should purchase 1 set of front spokes hub motor, 26inch rim and 36pcs of spokes. We can purchase them from leaf bike motor shop online.
Received goods and check them:
1. How many spokes you received. Generally we need 36 pcs spokes to built on hub motor and 12 gauge spokes for electric bike. 13, 14 gauge spokes are too thin, just for common bike.
2. There are 36 eyelet on bike rim and hub motor.
3. Check nipple and the dia. of eyelet on rim, make sure the nipple can put into eyelet.
Calculate the length of spoke :
If you use 205 leaf front hub motor, the eyelet to eyelet of rim is 511mm that is 26inch rim, spokes should be 155mm length.
You need below tools to install spokes on hub motor.
1.iron shelf
2.slotted screwdriver
3.nipple wrench
4.magnet
5.rubber hammer
6.tape measure
7.calipers
Done check, everything is okay. But we found the dia. of nipple is 4.5mm and the rim is also 4.5mm. These eyelets are too small. See pictures.
Get an electric drill and 4.8mm aiguille. Drill 36 pcs of eyelets on bike rim first. Adjust the iron shelf so that the dia. is 100mm. Because standard front fork is 100mm. Then put the rim inside the iron shelf, hold on the hub motor. Make the first spoke wear into hub from left side, the next from right side. One by one from left side to right side. Done install all 36 pcs of spokes, please check them whether correct. See pictures.
If no problem, we should hold spokes on rim by nipples First hold one spoke on left side, then cross to fix another spoke on left side. Next step, cross two spokes on rights side and fix them. Left side, right side, a group of four spokes. See pictures.
Fix all spokes, we should use wrench to tight spokes a little, please don’t be too tight. Use hand to turn wheel, make sure there is no noise from friction of rim and nipple. Use rubber hammer to knock rim when the wheel is running so that the rim will be not jumping up and down. Still to tight spokes a little. See pictures.
Turn wheel, you will find the rim from left side to right side. In order to make the wheel running in the middle. We use calipers to measure and get the data. Then use a magnet to hold a pin. See pictures. If rim to the left, we tight right side spokes or loose left side spokes. See pictures.
It takes about 1 hour to build an wheel.

How-to-build-a-hub-electric-bike-motor

These days hub electric bike motor wheels are used for e-bikes widely. Nearly all of hub bike motor are brushless gearless. Because of low noise, high efficiency, long life are popular with riders.
Order 1 set 12" 14" 16" 18" 20" 24" 26" 700c 28" inch hub motor kit, convert your common bike to e-bike is so easy. Directly front or rear drive your bike.
The important part is an engine -hub motor. How to build this electric bike motor?

Step 1: winding
Calculate motor power, speed RPM and confirm what type of copper wire would you use. Next is fix a rotor on the steel shelf, wind copper wires by handwork or machine. It takes about 1 hour to done it by handwork. And should use rubberized fabric to wrap your fingers. Nipping copper wires will break your fingers.
Step 2:soak paint
After winding should soak paint in order to be insulated. Use brush to put the insulated paint on the winding and make sure be soaked everywhere. It takes about 24 hours.
Step 3:press axis into rotor
Put axis into rotor winding and use a key to fix axis. Use A-B glue to paste three hall sensors on hub motor rotor, put 9-pin (three pin/each hall) into PCB and use insulated wire to fix it. Put 8-pin cable inside the axis and heavy yellow, blue, green wires to connect the three copper wires(Phase A,B,C) separately. Thin red, black wires are be weld to PCB + and - .
Step 4:paste magnet
Paste magnet inside hub, one N pole, next S pole ..one by one. More magnet, higher torque, more power. The height of our magnet is 30mm,6mm higher than other hub motor. In market,24mm high magnet only build max 500w electric bike motor. So our bike motor works at 36V can reach 750w.
Put the rotor winding inside the magnet hub, be careful hand. It has powerful magnetism.
Step 6:install two covers
Before installing both covers, we should press bearing into cover. Use hexagon wrench to tight screw nuts. When you hear "poop" from electric bike motor. That means install correctly. Done it.
Power on battery and use bldc motor controller to drive this hub motor. If no any strange noise. It's okay.
Hub motor, electric bike motor, bike motor supplier: Leaf Motor Technology Co., Ltd
Website:https://www.leafmotor.com

Hub motor was very sluggish

Question:While trying to get the hub motor up and running here we have run in to some problems. After installing the hub motor wheel in the fork it was very sluggish to turn and took quite a bit of effort, not freewheeling at all. The first time we plugged the battery (fully charged 48V 12AH LiFePo4 at 52.9V) in to hub motor (without the throttle connected to the controller cable) the hub motor beeped three times. When we hooked up the controller cable black and yellow pin connectors to the corresponding ones on the throttle there was no response from the electric bike motor , but the battery level lights did light up. We tried both throttles sent with the same results.
As it was the weekend I went to the forum and looked there for assistance. I received some good feedback that the 3 beeps we heard were a signal that the throttle was not functionable which is what we found as soon as we hooked up the throttle. We have checked all the leads for correct amperage as per his instructions with positive results.
I am assuming that electric bike kit is bench tested before it leave there? The packaging was undamaged upon delivery and all seemed in good order upon receipt. If you could please advise us on what to do to get this resolved we would appreciate it as we want to get on with our trials here to be able to get out product to market by summer.
I have checked my throttle and hub motor controller wires against your PDF diagram and there seems to be some discrepancy? I wish my camera was working but I will describe my findings. Diagram Throttle Black 3 pin shows: Red? perhaps Orange?/White/Blue Our Throttle Black 3 pin has:
Orange/White/Black from core with black jump to yellow 2 pin Diagram Controller Black 3 pin has: Red? perhaps Orange?/black/Yellow Hub Motor Controller Black 3 pin has: Rust from Core with Red Jumper to PAS White three pin/White/Black from core with Black jumper to yellow 2 pin
I checked the 8 pin connector again and can’t see that it isn’t making good contact. No bent pins or obstructions.Electric Bike Motor still beeps three times upon connecting to full battery as described with and without full connections of cables.
Yes jumping the two holes as indicated does make the electric bike kit run. It seemed like at first that by moving the controller wire that the electric bike motor would stop and start as if there was a short right at the junction and we thought that might be the problem. We hooked up the cable but I still am not getting any response from either throttle when hooked up to the black two pin connector even if I move the cable at the junction and now using the jumper the short method that issues seems to have gone away?
We are trying hard to make this electric bike kit work here but I have to admit we are getting a bit frustrated. The throttle cable while hooked up shows 5.0 amps on the red wire and from .8 amps at rest and 3.8 amps on the white wire when at full throttle like it should? Without the black pin connector together there are 5.0 amps at the red wire and .1 amps at the white wire if that is any useful information.
Hub motor,electric bike motor,electric bike kit supplier: Leaf Motor Technology Co.,Ltd
Source:https://www.leafmotor.com

The issue about 250W hub motor electric bike kit

Bought 1 set of electric bike kit from one supplier in China two months ago. Sent more than 10 emails, haven’t gotten any reply. I met below issue, hope solve it.

When I was riding my electric bike three weeks ago, the 250w mini front hub motor suddenly started to make a strange and strong noise. If I try to turn the twist throttle on when the e-bike doesn’t have any load, I keep the hub motor wheel in the air. The electric bike motor works fine and electric bike kit does not make any noise.

However, if I try riding my electric bike and turning the throttle on, the electric bike motor starts making a strong and continuous noise. I tried to riding my bike keeping the brakes continuously pressed and any noise appears so it seems to be some electric problem. It is very strange and I am so much worried.

I took off electric bike kit wheel and used screwdriver to disconnect six screw nuts, took apart hub motor cover and found there was a rotor-winding, two bearings, three sets of 42-gear, 1 set of 21-gear on the axis, 1 set of 81-gear on the hub. There wasn’t any impurity inside the hub motor. Re-install and test electric bike motor wheel, still have the same problem. Don’t know what’s the problem.

Contact my supplier many times and can’t get any reply. I looked for answers by google, yahoo and bike forums, still can’t find the correct answer. Yesterday I got a message from my US friend about there was a company, leaf motor can help me. So I sent an email to leaf motor.

Surprisingly just half an hour past, leafmotor replied me and asked me to check the bearings. How to check hub motor bearing? Take off two bearings from axis, and use little finger to hold inside of bearing, the other hand to turn bearing, faster, better. If you can hear some noise from bearing that can confirm the problem comes from electric bike motor ‘s bearing. At last, I found there was a bearing was broken. According as the bearing model, I bought two new ones in market and replaced them.

Test electric bike kit wheel in the air, no noise. Brake hub motor wheel, still no noise. Nice, Have sloved it.

I should thank leaf motor that help me and I found fun throught repairing electric bike motor. Now I decide to buy leaf ‘s electric bike kit if I have need and will recommend my friends to order leafmotor’s electric bike motor, bike kit…

Though I haven’t ordered any goods from leafmotor by now. But they are very professional, has best service and believe they have high quality products.

Hub motor, electric bike motor, electric bike kit supplier: Leaf Motor Technology Co.,Ltd

Website:https://www.leafmotor.com

power on the electric bike hub motor was gone

Electric bike hub motor kit was gone, how to solve it?

Received my electric bike kit .Product list:

1.26” 36V 250W front brushless geared hub motor wheel

2.36V 6-MOSFET brushless motor controller working with LCD(display speed,mileage,battery gauge..)

3.standard black twist throttle with battery gauge

4.brake lever with low voltage to brake

5.three button-ON/OFF switches that are used for control front&rear lights,cruise,horn…

Check rim whether in the middle of fork and the direction of hub motor runs.Then I have installed everything on my bicycle according as instruction manual and the electric bike kit worked fine.

I was running e-bike about 25km and then I stopped the electric bike motor . Charged the electric bike battery because I was staying there for some hours. Started on the way home and after some heavy hills (about 3 km)it was completely dead. The electric bike kit system was running like normal up to this, but suddenly all power on the electric bike motor wheel was gone.

Those three led lights on twist throttle for electric bike battery were still lit. I tried to turn e-bike off and on again, but same result.

Today the electric bike kit is still dead.

Do you have any idea? Measured 0,1 Ohm between the electric bike motor(hub motor phase wire: yellow, green, blue).Infinity between hub motor cable and hub motor cover. So it does not look like it is burned. The electric bike motor controller has 41,8 Volt input.

Measure the hub motor hall sensor:

Red, black, yellow, blue, green wires.

1.The voltage between red and black is 4.5V;

2.The voltage between yellow and black is 4.2V or 0V,(When use hand to turn hub motor, the voltage will change from 0~4.5V~0~4.5V)

3.The voltage between blue and black is 0.2V; (When use hand to turn hub motor, the voltage could not change)

4.The voltage between green and black is 0.1V. (When use hand to turn hub motor, the voltage could not change)

From above test data, I doubt there were two hall sensor inside the electric bike motor that were broken.

Electric bike hub motor kit was gone, how to solve it?

Hub motor, electric bike motor, electric bike kit supplier: Leaf Motor Technology Co., Ltd

Website:https://www.leafmotor.com