I just found this forum, and was cleared to participate. I guess that means I'm not a robot. Yea!
I am a tinkerer by hobby, and a retired electronics tech/Technical Manager by trade. My main hobby is repairing pinball machines, both electromechanical and solid state. I also ride my road bicycle about 1000 miles per year. (I'm a fair weather rider - nothing below 55 degrees, winds higher than 18MPH, and no wet surfaces.)
During one of my rides, I was talking with an elderly gentleman who became very excited about my ability to solder and troubleshoot electronics. Well, I offered to help him fix his Global Ebike, and now I'm stuck with this challenge. So far, I have found and repaired three things - A broken wire off of the battery strength indicator circuit board (Which also serves as a junction point), a pinched/open wire from the throttle potentiometer to the controller, and a bad pin on the connector from the throttle assembly to the controller.
After repairing those, it still did not work. More troubleshooting has led me to figuring out the controller assembly is bad. I've checked the fuses and the capacitors, all check good. The FETS seem to check good on an ohmeter. Now, the rookie mistake: I plugged in the logic module into the wrong plug on the controller, and got some arcing. So, I'm sure I cooked the logic module. Now, there are no beeps indicating the bike is ready to go, and there are no battery indications. Giant step backwards.
So, I guess I am asking for help in troubleshooting, or at least a sympathetic shoulder. Does anyone have the programming for the IC (KS86P4004N) and a good chip that they can program for me? Does anyone have the schematic for the logic board? (Searching for the only identifiers on the board turn up nothing.) Has anyone successfully repaired these controllers? Did I just turn his Ebike into a boat anchor? Are there working controllers out in the wild?
I appreciate all responses.