Non-Specific Scooter Components

From The Currie Tech Dealer Wiki

Battery packs

Testing equipment required:

• DMM
• Probes

Battery voltage check

When fully charged, a 24V SLA battery pack should measure at about 25-26 volts. A 36V SLA battery pack should measure at about 38-39 volts. Immediately after charging, the voltage reading may be higher; let the battery sit off the charger for about 15 minutes before taking a voltage reading. Failure of the battery to charge to the expected maximum voltage may indicate that the pack has reached the end of its useful life.

To test the voltage of a scooter battery pack, simply set your DMM to Voltage, then insert probes into the battery connector.

Alternately, if the battery is plugged into the scooter, you can test the voltage through the charger port by measuring at pins 1 and 2.

Do not use probes to test XLR-4 charger ports (1000 scooter)! The diameter of most probes is too large, and they will damage the charger port. Use TL-WR-009 instead.

Voltage test of a 24V pack. The battery does not need to be out of its protective case to be tested.

Battery wiring inspection

The cells in scooter battery packs are connected in series. 24V packs use two 24V cells, 36V packs use three 12V cells.

When inspecting the wiring in a battery pack, make sure each metal clip is fully contacting its battery terminal, and check for loose or broken wiring. Usually the terminal clips are soldered to the battery, so there is little chance for a bad connection.

Scooter battery pack wiring for 24V (top) and 36V (bottom).

Brake inhibitors

Same procedure as bicycle brake inhibitor testing. See Non-Specific_Bicycle_Components#Brake_inhibitors

Fuses

Scooter fuses are found in different locations, depending on model. The easiest way to find the fuse is to simply follow the wiring harness connected to the controller. Follow the wiring up into the body of the scooter from the connections at the controller.

Fuse testing

For testing of ceramic and glass style (tube-shaped) fuses, see RMB:Service#Battery_fuse_check.

For testing of blade-style (automotive) fuses, see Non-Specific Bicycle Components#Fuse_testing

Scooter fuse specifications

40 Amp blade fuse

• Currie Part # AU-062
• Alternate replacement fuse: ATO series (Blade 30A/32V)
• Littelfuse part # 257040 (Fast-Acting Automotive Blade Fuse) - 257 Series

(same as 40A fuse in bicycle fuses)

Motors

Basic motor test

Required tools:

• Phillips-head screwdriver
• Penny

1. Remove the deck plate of the scooter
2. Disconnect and remove the battery pack
3. Using the Phillips screwdriver, remove the access panel in the front of the battery compartment and expose the controller
4. Disconnect the motor connector (blue and green wire with white plug)
5. Hold the rear wheel of the scooter and turn it up toward the ceiling. Get a feel for the resistance given by the wheel as you turn it.
6. Hold the half of the disconnected connector that comes from the motor
7. Insert a penny into the connector so that it touches both brass contacts
8. Once again, turn the rear wheel up toward the ceiling. Compare the resistance given by the rear wheel now with the resistance given when the penny was not in the plug

If the resistance is the same or less, the motor needs to be replaced

Motor replacement, 400 scooter

See Media:400 motor replacement rev1.pdf

Throttles

Same procedure as bicycle throttle testing. See Non-Specific_Bicycle_Components#Throttles

See also Scooter:Service#Throttle