SERVICE MANUAL
Contents
1. deo amp S5 50 26V EnergyPak discharge time LI ION Ambient Indication for discharge time in minutes temperature 5 ese e e amp 50 1 4 sorse lo Jo ss as o 24V EnergyPak discharge time NiMh Ambient Indication for discharge time in minutes temperature 0 6 Months 7 12 months 13 18 months 19 24 months 35 C 5 C 55 55 SOC Cd J35 25 C 5 C 55 55 dso Cd J35 15 C4 5 C 55 585 50 40 0 35 50 50 40 0 35 J30 sorse pa as 15 0 19 02 2014 HPB SERVICE MANUAL MY14 GIANT T SYNCDRIVE Be sure to detach the EnergyPak while working on a Syncdrive 7 1 SYNCDRIVE FRONT MOTOR REPLACEMENT 2 This motor can only be serviced by the manufacturer or its authorized service center Contact your Giant representative or service center to determine whether the motor should be returned for service or shall be replaced completely Step 1 Loosen the 3 screws from the cover Disconnect the motor cable and brake wires Step 2 Loosen the nuts from the axle and the fender Step 3 Take out the wheel and motor Step 4 Follow the procedure in reversed order to reassemble Make sure the anti rotation plate is correctly placed in the right side drop out Tighten the axle nuts at 40 Nm 19 02 2014 HPB SERVICE MANUAL MY14 G GIANT HYB2. 3 5 SELF TEST MODUS In self test modus several key components of the bike can be tested For example the motor torque sensor and speed sensor etcetera See Chapter 3 6 for error diagnostics Note make sure that the bike is turned off Otherwise it is not possible to get in self test mode MY14 13 Step 1 Press the light button and then the on off A button for a few seconds Step 2 One or two of indicators 2 3 and 4 will light up being the motor sensor You are in test modus Now test the various components 19 02 2014 HPB SERVICE MANUAL MY14 GIANT Step 3 Speed sensor Rotate rear wheel forwards Check if indicator 1 blinks when the magnet passes the speed sensor only when rear speed sensor is used Step 4 Motor sensor Rotate the wheel backwards Check if indicators 2 3 and 4 light up alternately applies to hub motors Step 5 Torque sensor Block the rear wheel Press the pedal with increasing force Indicators 1 2 3 4 5 should light up according to the exercised force applies to all motors Step 6 Cadence sensor Rotate the cranks forwards Indicator 5 should blink applies only to bikes with cadence sensor MY10 12 Press the on off A button and the light button B simultaneously for 5 seconds To leave the test modus press the on off A button OLDER MODELS MY 2007 2010 Switch on the bike while holding the circled 08 09 button
3. Pedalplus sensor and therefore on the range and performance of the bike To check Step 1 Remove the chain covers Step 2 Check the position and direction of the chain tensioner The chain has to run straight and clear on both sides of the flanks If it s faulty continue the steps Step 3 The chain tensioner can be slid sideways to get in line with the chain To do this the Allen bolts have to be loosened Step 4 Now the horizontal axle from the chain tensioner can be aligned Step 5 By moving the chain it can be determinated which way the chain tensioner should slide Step 6 With some pliers the wheel can be adjusted to make it run parallel with the chain 19 02 2014 HPB SERVICE MANUAL MY14 HYBRID py CYCLING TECHNOLOGY Step 7 When the chain runs smooth clear and straight the Allen bolt can be secured Step 8 Check the chain tensioner It should effectively tension the chain Step 9 Replace the covers 19 02 2014 HPB SERVICE MANUAL MY14 GIANT HYBRID By YCLING TEC e LOGY 10 TOOLS GIANT SPECIFIC Pedalplus voltage tester Gits voltage tester Part 147L HCTEST O1V Part 5481 GITS O1V Capacity tester Part 5481 test 06V E lab Part 95200000V 4pin socket for central Syncdrive MYO7 MY12 Light tester part 2520 FY06 03V Part 2520 sy06 13V 19 02 2014 HPB SERVICE MANUAL MY14 GIANT HYBRID py CYCLING TECHNOLOGY Tl CONTACT GATHERING INFORMATIO
4. between the 1 0V and 2 0V replace the complete torque sensor assembly The E lab is a multi purpose tool for Giant E bikes Contact your Giant contact person for further information 2 Use the pedalplus voltage tester Part 5481 GITS 01V The value of the measurement has to be between 1V and 2V If the value is not between the 1 0V and 2 0V replace the complete torque sensor assembly 19 02 2014 HPB SERVICE MANUAL MY14 HYBRID py CYCLING TECHNOLOGY 3 You can also use cable assembly part 147L HCtes 01V between the connection of the torque sensor and the driver It will only fit one way The white plug is used for measurement Use a multi meter in DC setting for this measurement place the probes of the meter against the contacts of the white plug The value of the measurement has to be between 1V and 2V If the meter gives a minus in front of the numbers you have to switch the red and black probes because this is a polarity warning If the value is not between the 1 0V and 2 0V replace the complete torque sensor assembly 4 L2 REAR TORQUE SENSOR REPLACEMENT Step 1 If in order remove the cover of the torque sensor unit and the bolts of the pannier rack Step 2 Disconnect the cable of the torque sensor unit completely Step 3 Release the nut and ring of the rear axle Step 4 Unscrew the bolts of the torque sensor unit and take the unit out Place the new torque sensor unit Make sure the sens
5. blinking Step 2 Adjust with and D1 D2 Step 3 Confirm with mode C and pass on to hours Step 4 Repeat steps 2 and 3 for hours and date Step 5 Confirm all by pressing light B until all stops blinking The maximum of ODO distance shown is 9999km Please reset ODO when this distance has been reached 3 4 RESET RIDE CONTROL MY14 Reset trip data To reset the values of trip distance trip time and average speed Press and hold the M button C for 5 seconds Reset all data To reset the values of all trip data including ODD Press and hold the and buttons D1 D2 simultaneously for 5 seconds MY13 Reset trip data To reset the values of trip distance trip time and average speed Press and hold the button D1 for 5 seconds Reset all data To reset the values of all trip data including ODD Press and hold the button D2 for 5 seconds 19 02 2014 HPB SERVICE MANUAL MY14 D2 OAC P HYBRID py CYCLING TECHNOLOGY MY10 12 Step 1 Press level and light buttons simultaneously until 00 is blinking in the display Step 2 To reset trip time press level button once and light button twice Step 2a To do a complete reset press level button twice and light button twice 30V series mentioned on backside To reset the display press mode until values switch to zero
6. for 3 seconds EB 7 The bike will go into Self test mode now END RUM emer 19 02 2014 HPB SERVICE MANUAL MY14 G GIANT 3 6 ERROR DIAGNOSTICS In case of an error all battery indicators will blink three times After that the issue indicating battery indicators will continue blinking while all other battery indicators light up continuously In this chapter it s clarified what s the cause and what s the solution Be clear in the communication towards your client and Giant the bottom battery indicator is number 1 the top battery INDICATOR 5 indicator is number 5 INDICATOR 1 If there are any problems with a MY13 display be sure to work with the updated version of display RideControl bracket and buttons The updated version has a green G marked on the back of the display RideControl bracket and buttons When you work with a non updated version contact your local Giant service dealer for a replacement Quick summary EnergyPak signal problem If connections are not ok replace cable or connections If connections are ok replace battery connector male side If indicators still blink replace driver Motor signal error If indicators light up alternately replace driver If indicators do not light up alternately replace motor A Speed sensor malfunction Adjust sensor magnet position 2 1 B Cadence sensor malfunction Replace cadence sensor Torque sensor signal error Reset power Replace torque
7. sensor 1 The EnergyPak is completely empty Charge EnergyPak Comprehensive explanation Indicator 1 Cause Battery current is low Step 1 Check the remaining energy level in the EnergyPak See chapter 6 1 for help LE button Step 2 When level is low charge battery EE 19 02 2014 HPB SERVICE MANUAL MY14 GIANT Indicator 2 Cause Torque sensor signal error Step 2 Block the rear wheel Press the pedal firm and continuously 1 2 3 4 5 should light up proportionally Step 3 Check the connections between torque sensor and driver Indicator 73 Causes A Speed sensor malfunction B Cadence sensor malfunction for front and rear motors MY14 and MY13 only Step 2a Rotate rear wheel forwards Step 3a Check if 1 blinks when the magnet passes the speed sensor Step 4a If 1 does not blink adjust speed magnet m_ S E Step 5a When 1 still doesn t blink replace speed QE Next steps apply to front and rear motors MY14 and Mis erm J Step 6b Rotate crank forwards TS Step 7b If indicator 5 does not blink replace cadence sensor 19 02 2014 HPB SERVICE MANUAL MY14 GIANT Indicator 4 Cause Motor signal error Step 1 Check the cable and connections between motor and driver Step 2 Access self test mode chapter3 5 ya FN Step 3 Rotate the motor wheel backwards Step 4 Check if 2 3 and 4 light up alternately DJ Step 5 If 2 4 light up al
8. voltage of the battery The voltage LED lights up for a 36V battery the ideal voltage is 41 5 V 0 2V for a 26V battery the ideal voltage is 29 5V 0 2V Step 4 Press one of the yellow buttons until time LED lights up during testing you can switch at any time between Voltage Current and Time Step 5 Now press the green start button The tester will start with the discharge of the battery The discharge LED lights up Step 6 The finish LED will light up when the test is completed Compare this value with the correct table on the next page 19 02 2014 HPB SERVICE MANUAL MY14 GIANT 6 2 2 DISCHARGE TIME TABLE If the discharge is below given values for given time and temperature contact your Giant representative for possible warranty claim regarding the applicable conditions for warranty 36V EnergyPak discharge time LI ION 10AH Ambient Indication for discharge time in minutes temperature 113 uo ton 90 79 sesse us Jno iu 9 17 asese ie Ps Je Je m 5 C4 5 C 100 99 90 8 0 72 5 C 5s C 95 Jo dee 76e 68 36V EnergyPak discharge time LI ION 8AH Ambient Indication for discharge time in minutes temperature 35 C4 5 C 90 8 SSO 25C 5 C 90 8e amp 75 0 65 60 15 C4 5 C 85 des SSO S cs s c 8 feo 65 fo 85 S CW 5 C 735 75
9. E RMS MULTIMETER 19 02 2014 HPB SERVICE MANUAL MY14 GIANT HYBRID py CYCLING TECHNOLOGY 4 4 MOTOR ROTATION SENSOR Every motor has 3 sensors for rotation detection The position of the sensors regulates the current that is sent to the coils of the motor to make it run smoothly If the speed sensor is malfunctioning the motor rotation sensor will generate a speed signal until approximately 12 Km h This means that despite a malfunctioning speed sensor a speed indication will still show Above approximately 12km h OL will appear in the screen If only a LED screen is used LED 4 will blink 19 02 2014 HPB SERVICE MANUAL MY14 GIANT HYBRID py CYCLING TECHNOLOGY 5 DRIVER The driver collects all info and controls the motor It s the brain of the bike Driver failures should be solved by the dealer by replacement of the complete driver Malfunctioning drivers should be returned to your Giant representative Different sorts of bikes and EnergyPaks use different drivers 5 1 VOLTAGE DIFFERENCE Different voltage drivers have been used From MY11 on 36V drivers have been in use There is an obvious visual distinction between the 26V and 36V versions being the connectors and the color of the Voltage decal 36V MALE CONNECTOR 5 2 REPLACING DRIVER When replacing a driver unplug the EnergyPak first Loosening cables of drivers Note Do not damage the plug and cable Never pull the cable direc
10. ERVICE MANUAL MY14 GIANT HYBRID By CYCLING TECHNOLOGY 8 WIRING SCHEMES FRONT SYNCDRIVE CENTRAL SYNCDRIVE REAR SYNCDRIVE 19 02 2014 HPB SERVICE MANUAL MY14 GIANT HYBRID By CYCLING TECHNOLOGY 9 VARIOUS ISSUES 9 1 LIGHTS Step 1 Check for faulty connectors on the lightning wiring Step 2 Check with the special tool part 2520 SY06 13V if the front or tail light is OK The tool can be connected to the lights directly Make sure the AA batteries are full Step 3 Replace the light if not functioning If the light is working correctly with the battery set attached reconnect the lights to the system to see if the problem is solved If not follow the next steps Step 4 Switch on the bike then switch on the lights The backlight of the RideControl should switch on If the backlight does not function replace the RideControl display Step 5 Use the multi meter in DC mode If the voltage on the light plugs near the headlight is not approximately 6V check at the driver directly Step 6 Use the multi meter in DC mode If the voltage on the light plugs near driver is approximately 6V replace the cable assembly 19 02 2014 HPB SERVICE MANUAL MY14 7 GLANT 9 2 CHAIN TENSIONER Front wheel hub motored bikes are equipped with a chain tensioner If mounted the derailleur is being used as such Otherwise a separate chain tensioner is mounted Its running smooth is of big influence on the
11. N If this manual doesn t help out you can contact your Giant service manager Make sure to have at hand Energypak charged completely A clear explanation of the customer s complaint Frame number Model and version of the bike Any measurement data List of actions taken parts replaced Other relevant data 19 02 2014 HPB SERVICE MANUAL MY14 7 GIANT
12. PB SERVICE MANUAL MY14 GIANT CYCLING TECHNOLOGY HYBRID By Installing the drive unit Step 1 Lightly grease the attachment points on the bicycle frame the threads of the stub bolts 4 not visible in the drawing must be kept free of grease Step 2 Install the motor on the right of the frame in the direction of motion Step 3 Insert the fixing screws First all the M6 screws 1 then screw on the expansion sleeves 2 together with the mounting plate 3 Always use new expansion sleeves and install them free of grease Step 4 Tighten the M6 bolts 1 first Use a torque wrench and tighten them with 8 10 Nm Step 5 Tighten the expansion sleeves 2 Use a torque wrench and tighten them with 25 30 Nm For further details regarding the Bosch system use the Bosch training 19 02 2014 HPB SERVICE MANUAL MY14 GIANT 7 4 SYNCDRIVE REAR MOTOR REPLACEMENT This motor can only be serviced by the manufacturer or its authorized service center Contact your Giant representative or service center to determine whether the motor should be returned for service or shall be replaced completely Step 1 Disconnect the motor cable Step 2 Loosen the axle nuts or quick release Step 3 Remove the rear wheel Step 4 Follow the procedure in reversed order to remount the Syncdrive Make sure the anti rotation plate is correctly placed Make sure the wire outlet faces downwards Tighten the axle nuts at 40 Nm 19 02 2014 HPB S
13. RID By CYCLING TECHNOLOGY 7 2 YAMAHA MOTOR REPLACEMENT This motor can only be serviced by the manufacturer or its authorized service center Contact your Giant representative or service center to determine whether the motor should be returned for service or shall be replaced completely Step 1 Remove the cover and the i crank bolt Both cranks can be removed with a regular pulley Step 2 Remove the big nut at the chain ringside Beware opens clockwise Blocking the rear wheel can be useful The chain ring can be taken of the axle together with the chain now Remove the motor covers now Step 3 Untighten the three frame bolts The rear bolt should remain in the frame The two front bolts can be removed The motor now can twist but will not fall out Step 4 Disconnect all the wires and take out the motor Step 5 Follow the procedure in reversed order to reassemble The frame bolts should be tightened with 40Nm The big nut for the chain ring tightens with 40Nm 19 02 2014 HPB SERVICE MANUAL MY14 GIANT 7 3 BOSCH MOTOR REPLACEMENT p M This motor can only be serviced by the manufacturer or its authorized service center Motor failures should be solved by the dealer by replacement of the complete motor unit Malfunctioning motors should be returned to a Bosch authorized Service Center Removing the chain wheel Step 1 Remove the crank arms allen key size 8 ISIS crank puller Step 2 Block the
14. dYBHRID CYCLING TECHNOLOGY GIANT HYBRID By CYCLING TECHNOLOGY 19 02 2014 HPB SERVICE MANUAL MY14 amp GIANT HYBRID py CYCLING TECHNOLOGY 1 2 INTRODUCTION UPDATES LATEST UPDATE 19 02 2014 RIDE CONTROL 3 1 DISPLAY AND CONTROLLERS 3 2 DISPLAY IN WORKING ORDER 3 3 SET RIDECONTROL 3 4 RESET RIDE CONTROL 3 5 SELF TEST MODUS 3 6 ERROR DIAGNOSTICS PEDALPLUS 4 1 TORQUE SENSOR 4 1 1 Zero value torque sensor test 4 1 2 Rear torque sensor replacement 4 1 3 Chain wheel torque sensor replacement 4 2 SPEED SENSOR 4 3 CADENCE SENSOR 4 4 MOTOR ROTATION SENSOR DRIVER 5 1 VOLTAGE DIFFERENCE 5 2 REPLACING DRIVER ENERGYPAK 6 1 TEST FUNCTION ON ENERGYPAK 6 2 CAPACITY TESTER 6 2 1 Guidance 6 2 2 Discharge time table SYNCDRIVE 7 1 SYNCDRIVE FRONT MOTOR REPLACEMENT 7 2 YAMAHA MOTOR REPLACEMENT 7 3 BOSCH MOTOR REPLACEMENT 7 4 SYNCDRIVE REAR MOTOR REPLACEMENT WIRING SCHEMES FRONT SYNCDRIVE CENTRAL SYNCDRIVE REAR SYNCDRIVE VARIOUS ISSUES 9 1 LIGHTS 9 2 CHAIN TENSIONER 10 TOOLS GIANT SPECIFIC 11 CONTACT 19 02 2014 HPB SERVICE MANUAL MY14 1 INTRODUCTION This manual is about Giant hybrid bikes Along with explaining the parts problem solving is being handled Specific tools are pointed out along with their Giant part codes In case of an update this will be mentioned Steps I DRIVER RIDE CONTROL Step 1 Select the power mo
15. de and you re ready to ride Monitor riding information from the screen and adjust the tempo Giant designed all its controls so that you can operate them with your hands firmly on the grip This gives you safe and intuitive control to your bicycle repapws Step 2 The Pedalplus sensor system precisely registers the amount of force you re putting into the pedals and your moving speed This information is sent directly to the I driver unit Giant combines 4 sensors human torque motor speed cadence and bicycle speed A 1 DRIVER Step 3 The I driver unit receives the information from the PedalPlus sensors Via its proprietary software it is able to send a smoothed out power curve demand to the EnergyPak power source Accurate computing allows to maintain an ideal cadence and makes power consumption more efficient ag ENERGYPAK Step 4 The high capacity Lithium ion battery pack produces more power and a longer riding range The EnergyPak communicates with the I driver to deliver just the right amount of power to the SyncDrive motor A SYNCDRIVE Step 5 Thanks to Giants proprietary Sine Wave software and integrated motor sensors Giant offers you a smooth and quietly on your ride Because of the wide range of motors you can choose the most suitable version 19 02 2014 HPB SERVICE MANUAL MY14 G GIANT HYBRID py CYCLING TECHNOLOGY 2 UPDATES In case of an update of this manual you will receive pages to replace th
16. e expired ones in this manual An overview will be visible down here This way this manual will always be up to date Be sure to always remove old pages LATEST UPDATE 19 02 2014 19 02 2014 HPB service manual release date 19 02 2014 HPB SERVICE MANUAL MY14 GIANT 3 RIDE CONTROL The Ride Control is the interface between user and driver With these display and buttons functions can be selected and information can be shown 3 1 DISPLAY AND CONTROLLERS LED MY14 13 A On off button B Light D1 Power assist selector up D2 Power assist selector down E Power Assist indication L Indicator energy level In case of a double EnergyPak a double line of LED s L is visible representing the second EnergyPak A on off EnergyPak selector B Lighting B1 Lighting indication C Mode D Power assist button D1 up D2 down E Power assist indication F Speed G Average speed Odo total distance J Trip time K Time MY14 no info L EnergyPak indicator L1 battery 1 L2 battery 2 M Energy select indicator Left or Right N No info O Ridecontrol plug socket P Ridecontrol communication cable plug Q Motion assist R Power assist level indication bar 19 02 2014 HPB SERVICE MANUAL MY14 GIANT LCD MY10 12 A On off EnergyPak selector B Lighting C Mode D Power assist button E Power assist indication F Speed G Average speed H Trip distance Total distance J Trip time K Time L EnergyPak charge indicat
17. or M EnergyPak select indicator left right 3 2 DISPLAY IN WORKING ORDER When you see no figures displayed on the Ride Control Step 1 Make sure the battery is charged and not in an idle state Step 2 Make sure the display is connected correctly and the bike is switched on Step 3 Check the connections between RideControl bracket and buttons Sometimes the connector is not connected firmly Step 4 Check the contact points on the RideControl bracket They sometimes are crooked by misuse MY13 and older Step 5 Check the connections between the driver and RideControl Do not use contact spray A degreaser spray is advised Step 6 If previous steps are OK replace RideControl display Step 7 If RideControl display still does not switch on replace the driver 3 3 SET RIDECONTROL Q D20AC P Display settings Press button C to select the following display Speed trip distance Average speed ODO total distance amp trip time Power assist setting Press button D1 to choose a higher Power assist level E Press button D2 to choose a lower Power assist level E SPORT High power assist Gives the smallest range NORMAL Normal power assist ECO Low power assist Gives the maximum range OFF For riding without power assist but with cycle computer and light functions 19 02 2014 HPB SERVICE MANUAL MY14 GIANT Time setting not available for MY14 Step 1 Press light B until minutes J start
18. or cable does not get stuck Step 5 Replace the bolts Tighten them with a torque wrench 10Nm Use the correct sequence being center right left 1 2 3 Step 6 Replace the axle nut and ring and tighten them with a torque wrench 40Nm Step 7 Realign the cable and do the Zero value torque sensor test as previously described If the test is ok replace the covers and rear rack The bike is ready for use 4 1 3 CHAIN WHEEL TORQUE SENSOR REPLACEMENT In older model years MYO7 MY12 bottom bracket torque sensors were used Step 1 Remove the crank with a regular extractor The Pedalplus chain wheel unit stays on the axle 19 02 2014 HPB SERVICE MANUAL MY14 GIANT CYCLING TECHNOLOGY HYBRID py Step 2 Remove the lock ring with 4 pin socket turn clockwise part 2520 FY06 03V Step 3 Remove the chain wheel unit The torque sensor can be removed by loosening the 3 screws and disconnecting the connector i Step 4 Follow the procedure in reversed order with a new sensor to reassemble 4 2 SPEED SENSOR As of MY14 front hub motors have an internal speed sensor In case of an external speed sensor actions as written below should be followed Step 1 For proper function the center of the magnet must be aligned with one of the ends of the speed sensor S Marks and point in the direction of the sensor If you listen very close you can hear the relais click inside the speed sensor If
19. rear wheel Step 3 Unscrew the lock ring 2 with the spider tool 1 Be aware left hand thread Step 4 Remove the chain Step 5 Remove the chain wheel crank spider3 together with the chain wheel take the chain wheel with both hands and pull it out by moving back and forth Prise off the spider with a long lever from the housing DO NOT use a hammer the torque sensor can be destroyed Removing the stone chip protection Step 1 Remove 3 screws 1 Torx T20 Ensure that you do not inadvertently remove the screws of the motor casing Step 2 Pull the stone chip protection 2 forwards 19 02 2014 HPB SERVICE MANUAL MY14 GIANT CYCLING TEC ae NOCH HYBRID py wm Disconnecting the cable connections on the drive unit Step 1 Unplug all cables the connector to the battery has a locking hook 1 Prize it off by 1 2 mm with a screwdriver Damage is possible if the locking hook is not disengaged before oe Do not damage the plug and cable always remove the plugs using your fingers or long nose pliers Never pull the cable directly Remove the drive unit Step 1 Loosen and remove the fixing screws 1 Torx T30 2 Torx T40 and mounting plate 3 Step 2 Pull the drive in the direction of motion to the right from the frame Step 3 Dispose of the 3 expansion sleeves 2 The expansion sleeves cannot be reused new expansion sleeves are supplied with each new motor Step 4 Retain all the rest of the components 19 02 2014 H
20. s to release the driver S Older models MY 07 MY10 Step 1 Loosen the three screws Step 2 Remove the cover Step 3 Loosen the screws to release the driver Step 4 Follow the procedure in reversed order with a new sensor to reassemble 19 02 2014 HPB SERVICE MANUAL MY14 GIANT HYBRID py CYCLING TECHNOLOGY 6 ENERGYPAK Giant hybrid powered bikes use various Energypaks They vary in voltage capacity and shape The type of Energypak can always be found on the Energypak itself usually on the backside 6 1 TEST FUNCTION ON ENERGYPAK The 36V EnergyPaks are equipped with an internal test function If you push the push button on the EnergyPak battery pack for a few seconds it will show the remaining amount of energy left in the battery pack If you encounter issues with charging an EnergyPak check all connectors on both EnergyPak and charger 19 02 2014 HPB SERVICE MANUAL MY14 7 GIANT HYBRID By CYCLING TECHNOLOGY 6 2 CAPACITY TESTER 6 2 1 GUIDANCE The capacity tester is used to determine the discharge time of the EnergyPak Important This measurement is only reliable when started with a fully charged EnergyPak Usage Step 1 Use the correct position of the Volts indicator depending on the type of battery Step 2 Connect a fully charged EnergyPak to the tester check polarity Step 3 Switch on the tester at the back of the machine The display indicates the
21. ternately replace driver Step 6 If 2 4 do not light up alternately replace motor MEN Indicator 5 Cause Battery signal error Step 2 If head and rear lights glow the wires are connected in the wrong way Energypak and lighting system have the same connectors Reconnect them the right way Step 3 If connections are ok replace battery connector male side Step 4 If 5 still blinks replace driver a See various issues for further problem solving 19 02 2014 HPB SERVICE MANUAL MY14 G GIANT HYBRID py CYCLING TECHNOLOGY wy 4 PEDALPLUS Giant is using a 4 sensor technology for torque cadence motor rotation and speed sensor These sensors give information to the driver With this info the driver can decide what support is necessary 4 1 TORQUE SENSOR The Pedalplus is a torque sensor that generates the signal of power given by the rider The amount of power assistance from the motor depends partially on how much signal is generated by the torque sensor Central motor systems have this sensor built in If there are problems with inconsistent assistance and insufficient range it is advised to test the torque sensor 4 11 ZERO VALUE TORQUE SENSOR TEST To make sure the torque sensor is ok a test can be done It can be done with three different tools 1 The E lab Part 9500000V is a Giant multi usable device The value of the measurement has to be between 1V and 2V If the value is not
22. this doesn t work try step2 Step 2 Switch the multi meter in O position Measure at the plug of the speed sensor Turn NN the wheel Every time the magnet passes the uf al I oue sensor the indication on the multi meter p 117 TRUE RMS MULTMETER should jump from OL to a value If this doesn t work try step 3 MIN MAX RANGE Step 3 Switch the multi meter in DC position Switch on the bike Measure at the plug of the speed sensor from the driver The voltage should be approx 5 Volt If this doesn t work replace speed sensor 19 02 2014 HPB SERVICE MANUAL MY14 G GIANT 4 3 CADENCE SENSOR As of MY14 a cadence sensor is mounted in all bikes The response of this sensor smoothens the ride especially after every stop This sensor is inside the motor of central Syncdrives Yamaha and Bosch In all front and rear Syncdrives this sensor is mounted under a cover at the bottom bracket MY14 13 Step 1 Remove the cover of the driver Step 2 The cadence sensor is mounted on the bottom bracket Step 3 Remove the sensor To measure the cadence sensor you can also use cable assembly partt 147L HCtes 01V between the connection of the cadence sensor and the driver It will only fit one way The white plug is used for measurement Use a multi meter in DC setting for this measurement place the probes of the meter against the contacts of the white plug The value of the measurement has to be 5V 117 TRU
23. tly Always remove the plugs using your fingers or long nose pliers Step 1 Unplug the battery cables first The connector to the battery has a locking hook Press it off by a small screwdriver Step 2 Unplug bus connectors Green and blue cables can be hard to distinguish in dark areas Step 3 Unplug the other cables The connectors have a locking hook Unlock this S Note Avoid stressing the connectors when mounting the driver back into the driver compartment MY 14 models with driver in down tube 19 02 2014 HPB SERVICE MANUAL MY14 GIANT NY BR MP y CYCLING EOE M Step 1 Loosen the 3 Philips screws Step 2 Remove the cover Step 3 Remove the screws that fixes the cadence sensor Step 4 Pull the driver out of the tube Disconnect all cables MY 13 models with driver in down tube Step 1 Loosen the 3 Philips screws 19 02 2014 HPB SERVICE MANUAL MY14 GIANT Step 2 Remove the cover Step 3 Remove the screw that fixes the driver Pull the driver out of the tube MY 13 models with horizontal EnergyPak Step 1 Loosen the two hex bolts Step 2 Slide the cover backwards in between pannier rack and driver housing Step 3 Loosen the screws of the driver 19 02 2014 HPB SERVICE MANUAL MY14 GIANT CYCLING TECHNOLOGY HYBRID py MY10 and later models with vertical EnergyPaks Step 1 Loosen the two hex bolts Step 2 Pull the cover up and pull of forward Loosen the screw
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