Wisper 705eco Manuel de service

1 Dealer Service Manual Maintenance and repair Instructions Wisper Electric Bicycles March 2011 1st edition ©Copyright 2010 Wisper Ltd

10 extreme weather conditions. The brown wire pin insert has been pushed back out of the connector body resulting in no power to the bike. 12. Extr

11 2.2 Handlebar display types and functions: Wisper bikes use five types of handlebar display: 2.2.1 Battery charge indicator status lights house

12 2.2.3 Hi Lo selector switch fitted to late 2008 and 2009 model bikes to control level of power assistance (20% and 80%). Early bikes default to

13 NB: The light switch incorporated in this unit controls the display backlight and not the main bike lists LCD display fitted to Alpino models No

14 2. The green button works as follows: 3. When the button is pushed and latched ”in” the bike is restricted to the statutory maximum speed of 15

15 2.4 Brake cut outs 1. These switches are installed within the brake levers on all Wisper bikes to comply with legal requirements and to protec

16 No (off bike) testing of the 3 wire type apart from checking connections as described in the throttle section above is practical without more s

17 2.5 Pedelec sensors 1. These sensors are fitted to the bottom bracket (axle and frame) and control the operation in pedelec mode by detecting th

18 As this disc is a friction fit on the bottom bracket axle it can be easily moved along the axle to achieve the correct air g

19 2.6 Controllers 1. All Wisper bikes utilise a controller, which incorporates all of the inputs from the above devices and the battery and pro

2 Contents 1 Section 2: Overview of Wisper models and key features / differences ... 5 2 Section 3: D

20 2. The controller is located behind the triangular plate located underneath the battery cradle. It is also accessible from beneath the bike by r

21 3 Motors: 1. Wisper bikes currently use two types of motor fitted in either the front or rear wheel referred to as the Bafang or Dapu motor typ

22 8. Take off the left hand nut that keeps the entire inner assembly in the hub. 9. Give a sharp tap to the end of the spindle

23 12. Due to the need to ensure correct axial alignment of the motor internal components it is not recommended that the motor hub is replaced separ

24 16. Always ensure the colour codes on the 8 motor cables match the corresponding colours on the controller connector and that the power con

25 Visual inspection and electrical tests: The following inspection and tests can be undertaken on wheels fitted with the Bafang motor if a wheel is

26 21. With the bike suitably supported of the ground and the power off rotate the wheel in a forward and backward direction by hand. In the forward

27 4 Batteries 1. Wisper bikes use a variety of battery sizes and capacities the details of which are shown in Annexe 1. A selection of battery t

28 Current 705 and 905 model battery 2. All batteries use Lithium Ion technology and incorporate a battery management system and LED charge status

29 protect the battery from excessive discharge will be activated and cut the power to the bike. 6. The battery capacity is specified in terms of A

3 9 Removing and replacing motor wheels from the bike for servicing ... 48 9.1 Non Alpino/XC models ...

30 4.1 Battery fuses 1. Most Wisper batteries contain two fuses. One of these is shown in the image below: 2. The fuse fitted at the top of the b

31 7. For older style Aluminium case batteries fitted to early 705 models the fuse fitted to the top of the battery is the charging fuse and the bo

32 4.2 Battery change procedure 1. On later 700 and 900 series bikes the 8Ah and 14 Ah batteries can be interchanged following the procedure shown

33 4.3 Battery fault finding procedure Obtain a description of the problem from the customer and depending on this information and any observations

34 Step 6; Measure voltage again. If still 0 volts or < 30 volts then return battery to Wisper Step 7: If between 30-40

35 Step 3: If a charger of known performance is not available then test customer’s charger as described in the main manual to ensure it is not the c

36 Step 2: Check external factors affecting range from the annexe of this manual and discuss with the customer if these are likely to be the cause

37 Step 8; If greater than 41 volts then road test the bike / battery and discuss performance and other findings with cus

38 5 Battery Chargers 1. Most Wisper bikes utilise a fan-cooled charger rated at 24 or 36 volts and 2, 3 or 4 amp output. 2. General instruction

39 obtained for a 36 volt charger. Great care is needed when doing this not to short out the charger when connecting the test lead probes. 10. If

4 Section 1: Scope 1. This manual covers the fault finding procedures, maintenance and repair of all variants of Wisper bikes produced during the pe

40 6 Logical Fault finding procedures on bikes fitted with Bafang motor system (flow chart based) The flow charts below cover a generic logical fau

41 6.1 Top level fault finding: The general order of fault finding should be as shown in the flow chart below: Step 1: Establish what if any operati

42 Step 9: Check pedelec sensor Step 10: Check controller Step 11; Check Motor

43 6.2 Detailed fault finding procedure: Ensure the bike is secured in a suitable stand. An ideal arrangement to do this and for most service activ

44 Step 9: If no apparent faults are found with the brake switches and the bike is still not working then disconnect the two switches again. Th

45 If no status lights are visible on the handlebar controls then follow the procedure below: Step 16: Check the battery output voltage at t

46 7 Fault finding procedures on Alpino model bikes fitted with Dapush motor system and LCD diagnostics display A table containing simple fault fin

47 8 LED Front lights 1. Some models are fitted with LED headlamps wired to the bike electrical system. 2. On Alpino models the lights are autom

48 9 Removing and replacing motor wheels from the bike for servicing 9.1 Non Alpino models; 1. To remove the rear wheel turn the bike over and e

49 4. Unplug the eight-pin motor cable plug or the 3 separate motor connectors and one 5-pin connector. 5. Note: depress the

5 1 Section 2: Overview of Wisper models and key features / differences 1. The key model identifying features are listed in annexe 1 to this man

50 the wheel complete with motor cable clear of the drop-outs and derailleur gear changer. Ensure the motor cable is not snagged and lif

51 9.2 Alpino models 1. Turn the bike upside down and secure it in a safe working position as per the first step in the above procedure. 2. Unpl

52 10 Servicing of electrical connections 10.1 Maintenance of motor Connections: 1. Check the high current plug/socket connections for your moto

53 6. Spray a little of contact improver (WD-40, CRC 2-26, etc) into both sockets. Check the 8 pins of the motor cable plug are well aligned a

54 10.2 Removing 8 pin connectors 1. To remove the connector first remove the yellow insert by carefully pulling it out of the connector using long

55 11 The green de restrict button 1. To install the green button remove the left hand handlebar grip and slide the green button onto the handleba

56 12 Braking system components 1. Wisper bikes have used a variety of brake system components and care must be taken when replacing these compon

57 13 Pre delivery inspection (PDI) and 300 mile service procedures The PDI is a critical part of the overall QA process and must be completed by

58 14 Check smoothness and running clearance of bottom bracket 15 Check seat post clamp quick release clamp is properly in place and secure and sadd

59 7 Check functionality of LED display on Non Alpino bikes Ensure 3 levels of assistance can be selected and all functions are correct as described

6 2 Section 3: Description of main electrical system control components 1. This section describes the main electrical system control components

60 14 Identifying and ordering spare parts If spare parts are required use the charts located in Annexe 1 to identify the model year, variant and t

61 15 Frequently asked questions (FAQs) The following section covers frequently asked questions. In many cases the detailed answers to these quest

62 Q. How can I extend battery life? A. By following the instructions above. Q. My customer is reporting a low battery range A. See section 5.3 and A

63 Q. Where do I find the ECN number on the controller? A. This number will be on the controller label as shown in section 3.6 Q. The LED headlamp is

64 Q. How do I remove the rear wheel on bikes fitted with rear motors? A. Full details are described in section 10.1 of the manual. Q. The pedals ar

65 16 Glossary A glossary of electric bike specific terms is included below to assist with providing standardised descriptions of components when d

66 Pedelec sensor – a sensor fitted to the bottom bracket of the bike to detect rotation of the pedal cranks. Controller – an electronic control unit

67 17 Training Wisper is working in partnership with the British Electrical Bike Association (BEBA) and the Cycle industry training organisation Cy

68 18 Annexe 1: Chart of Model variations and identifying features 2008 model bikes with older style batteries (see pictures for illustration belo

69 Mid 2008 Voltage (volt) 24 36 24 24 36 36 Capacity (Ah) 8 9 8 10 10 14 Battery case type Aluminium Aluminium Aluminium Aluminium Plastic – k

7 2.1 Throttle 1. Wisper throttles are all of the Hall effect type with an output (control) voltage ranging from 0 to 5 volts. 2. Depending on

70 2009 model bikes with new style batteries (see pictures for illustration below table) Year /Model 705se 806fe 905eco 905se (3 variants Mid 2009

71 2010 model bikes with new style batteries (see pictures for illustration below table) Year /Model 705se 706 Alpino 805fe 806 Alpino 905 (all varia

72 LED display fitted to non Alpino bikes LCD display fitted to Alpino models

73 19 Annexe 2: Wiring diagrams (Large files are available on request from Wisper Support 19.1 2009 model 705Se, 905Se Sport, City and City S

74 19.2 2009 model 705 and 905 eco

75 19.3 2009 Model 705 and 905 Front Connector Box

76 19.4 2010 model 805fe

77 19.5 2010 model 806 Alpino

78 19.6 2010 model 905eco

79 19.7 2010 Model 706 Alpino and 906 Alpino

8 8. Typical throttles are shown below: Early type throttle Used on late 2008 model bikes

80 20 Annexe 3: Torque settings. The following torque settings should be used on Wisper bikes: (A) Front axle nuts. 70Nm (Alpino), 46Nm

81 21 Annexe 4: Factors affecting Range The range of an electric bike can vary massively depending on the following factors: Weight: Not just the

9 Alpino models with L.H. throttle 9. Testing (throttle taken off the bike) is limited to the red on / off switch