1. Introduction
This manual provides essential information for the installation, operation, and maintenance of your Kugoo ES2 Microgo M5 Electric Scooter Controller. This controller is designed to manage the motor functions of compatible electric scooters, ensuring optimal performance and a maximum speed of 30 km/h. Please read this manual thoroughly before attempting any installation or use.
2. Safety Information
- Always disconnect the scooter's power source (battery) before installing or replacing the controller.
- Ensure all connections are secure and correctly matched to prevent electrical damage.
- If you are unsure about any step, seek professional assistance.
- Keep the controller dry and away from extreme temperatures.
3. Installation and Setup
The controller is an internal component of the electric scooter. Installation typically involves replacing an existing controller. Refer to your scooter's specific service manual for exact location and removal procedures. The following images illustrate the controller and its various wire connectors.
Figure 3.1: Kugoo ES2/M5 Electric Scooter Controller with various wire connectors. Note the different colored wires and connector types for various scooter functions.
Figure 3.2: Close-up view of the controller, showing the product label with specifications and the arrangement of wire harnesses.
Figure 3.3: Example of a compatible electric scooter (Kugoo ES2 or Microgo M5) for which this controller is designed.
Connection Overview:
The controller features multiple wire harnesses, each designed for a specific connection:
- Motor Wires: Typically thicker wires (often three phases) connecting directly to the scooter's motor.
- Battery Wires: Thicker red and black wires for power input from the battery.
- Hall Sensor Wires: Smaller wires (usually five) for motor position sensing.
- Throttle/Accelerator Wires: Connect to the handlebar throttle for speed control.
- Brake Wires: Connect to the brake levers for motor cut-off during braking.
- Display/Dashboard Wires: For communication with the scooter's display unit.
- Light Wires: For connecting headlights or taillights (if applicable).
Ensure each connector is securely plugged into its corresponding port. Incorrect wiring can lead to malfunction or damage.
4. Operating Instructions
Once the controller is correctly installed and the scooter's battery is connected, the controller will manage the scooter's electrical functions. Operation is performed via the scooter's standard controls (throttle, brakes, display).
- Power On/Off: Use the scooter's main power button to activate or deactivate the system.
- Speed Control: The controller regulates motor speed based on throttle input. This controller supports a maximum speed of 30 km/h.
- Braking: When brakes are applied, the controller cuts power to the motor and may activate regenerative braking (if supported by the scooter model).
- Display Feedback: The controller sends data to the scooter's display, showing speed, battery level, and other relevant information.
Figure 4.1: Scooter handlebar showing the display and controls that interact with the installed controller.
5. Maintenance
The electric scooter controller is a robust electronic component, but proper care ensures its longevity:
- Keep Dry: Protect the controller from water and excessive moisture. While some scooters have water resistance, direct exposure can cause damage.
- Clean Connections: Periodically check and clean electrical connections to ensure good contact and prevent corrosion.
- Avoid Physical Damage: Protect the controller from impacts or vibrations that could damage internal components.
- Temperature: Operate the scooter within recommended temperature ranges to prevent overheating of the controller.
6. Troubleshooting
If you experience issues with your scooter after controller installation, consider the following common troubleshooting steps:
| Problem | Possible Cause | Solution |
|---|---|---|
| Scooter does not power on. | Loose battery connection, faulty battery, controller not receiving power. | Check battery connections. Ensure battery is charged. Verify controller power input. |
| Motor not responding to throttle. | Loose throttle connection, faulty throttle, motor wires disconnected. | Check throttle and motor wire connections. |
| Inconsistent speed or power. | Loose motor phase wires, Hall sensor issues, low battery voltage. | Inspect motor and Hall sensor connections. Charge battery fully. |
| Error code on display. | Specific component malfunction. | Consult your scooter's user manual for error code definitions and solutions. |
If problems persist after basic troubleshooting, contact customer support.
7. Specifications
| Feature | Detail |
|---|---|
| Product Type | Electric Scooter Controller |
| Brand | Kugoo |
| Model Compatibility | Kugoo ES2, Microgo M5 |
| Max Speed Control | 30 km/h |
| Origin | Mainland China (Zhejiang) |
| Usage | Electric Scooters, Self-balancing Electric Scooters |
| High-concerned chemical | None |
8. User Tips
- Professional Installation: If you lack experience with scooter electronics, consider having the controller installed by a qualified technician to avoid damage.
- Firm Connections: Always double-check that all connectors are fully seated and locked into place. Loose connections are a common cause of intermittent issues.
- Cable Management: After installation, ensure all cables are neatly routed and secured to prevent them from being pinched or damaged during scooter operation.
9. Support
For technical assistance or further inquiries, please contact our support team:
- Whatsapp/WeChat: +86 19350856924
- Email: zlinshow001@163.com
Please have your product details ready when contacting support.
Video 9.1: A general welcome video from the store. For product-specific support, please use the contact information provided above.
