1. Introduction
This manual provides essential information for the safe and correct installation and operation of the KUGOO M2 Pro Electric Scooter Dashboard and Controller. This controller serves as the central electronic processing unit of your electric scooter. It regulates power delivery from the battery to the motor based on input from the throttle, brake sensors, and other components, controlling speed, acceleration, and braking regeneration.
2. Safety Information
- ATTENTION: Protective equipment should be worn when operating the scooter. Not to be used in traffic.
- ATTENTION: This product is only for domestic use.
- ATTENTION: Not suitable for children under 36 months.
- Always ensure the scooter is powered off and the battery disconnected before performing any installation or maintenance.
- Incorrect wiring can cause severe damage to the controller, battery, and motor, and poses a fire risk.
3. Usage Limitations
- Voltage & Current Rating: This controller is designed for a specific voltage (e.g., 36V, 48V) and current rating. Never connect it to a battery with a different voltage, as this can cause immediate and catastrophic failure, fire, or explosion. Refer to the specifications section for details.
- Motor Compatibility: It must be used only with a brushless DC (BLDC) hub motor whose specifications (phase, hall sensor configuration) are compatible with the controller.
- Thermal Limits: The controller has operational temperature limits. Avoid continuous high-load operation (e.g., climbing long, steep hills) which may cause overheating and automatic shutdown or permanent damage. Ensure it is installed in a location with adequate ventilation.
- Moisture & Environment: This component is not waterproof unless specified with a certified IP rating. It must be protected from direct exposure to water, rain, snow, and high humidity. Do not install it in areas prone to splashing or submersion.
- Modification Prohibited: Do not attempt to modify, reprogram ("tune"), or bypass any safety limits of the controller. Doing so voids any warranty, can damage the motor and battery, and significantly increases the risk of accident or fire.
4. Setup and Installation
- Preparation (Safety First): Ensure the scooter is completely powered off and the battery is disconnected. Wait at least 5 minutes after disconnection to allow any residual current to dissipate.
- Mounting: Securely mount the controller inside the scooter's deck or designated compartment using the provided screws or mounting brackets. Ensure it does not contact sharp edges, moving parts, or the battery. The metal heat sink (if present) should face an open area for airflow.
Figure 2: Controller unit with wiring harness. - Wiring Connection: Connect all cables in the following order, ensuring each connector is fully seated and locked.
- Battery: Connect the main power cables from the battery to the controller's battery input terminals, observing correct polarity (RED to Positive (+), BLACK to Negative (-)). Incorrect connection will destroy the controller.
- Motor: Connect the three thick phase wires (usually Yellow, Green, Blue) and the thinner hall sensor wires (5-pin connector) from the motor to the corresponding ports on the controller.
- Throttle, Brake Levers, Display: Connect the throttle, brake sensor, and dashboard/display unit cables to their designated ports.
Figure 3: Dashboard unit.
- Final Check & Power-On: Double-check all connections for correctness and security. Ensure no wires are pinched. Reconnect the battery. Power on the scooter. Do not apply throttle yet. Listen for any unusual sounds from the controller or motor.
- Initial Test: With the scooter lifted off the ground, gently apply the throttle. Observe if the motor spins smoothly and in the correct direction. If the wheel spins backward, power off and swap any two of the three motor phase wire connections on the controller. Test again. Confirm that the brake levers cut motor power as intended.
5. Operating the Scooter (Post-Installation)
Once the Dashboard and Controller are correctly installed and tested, the electric scooter should operate as intended. Refer to your scooter's main user manual for specific operating instructions, including power on/off procedures, speed modes, and display functions.
- Power On/Off: Use the power button on the dashboard to turn the scooter on or off.
- Display Functions: The dashboard displays speed, battery level, and other relevant information. Consult your scooter's manual for detailed explanations of all display indicators.
- Throttle Control: Gently apply the throttle to accelerate.
- Braking: Use the brake levers to slow down or stop. Ensure the motor cuts power when brakes are applied.
6. Maintenance
- Regular Inspection: Periodically check all wiring connections to ensure they are secure and free from damage.
- Cleanliness: Keep the controller and dashboard free from dust, dirt, and moisture. Use a dry, soft cloth for cleaning. Do not use liquids or harsh chemicals.
- Ventilation: Ensure the controller's heat sink area remains unobstructed for proper airflow.
- Avoid Overheating: Do not operate the scooter under conditions that cause the controller to overheat consistently.
7. Troubleshooting
| Problem | Possible Cause | Solution |
|---|---|---|
| Scooter does not power on. | Loose battery connection, faulty battery, dashboard issue. | Check battery connections. Ensure battery is charged. Inspect dashboard wiring. |
| Motor does not spin or spins incorrectly. | Incorrect motor wiring, faulty motor, controller issue. | Re-check motor phase and hall sensor wiring. Perform initial test steps (Section 4.5). |
| Dashboard display is blank or erratic. | Loose display connection, faulty display unit. | Check dashboard cable connection to the controller. |
| Scooter accelerates without throttle input or brakes don't work. | Faulty throttle/brake sensor, incorrect wiring. | Immediately power off the scooter. Check throttle and brake sensor wiring. Replace faulty components if necessary. |
For complex issues, it is recommended to consult a qualified technician or refer to the detailed user manual PDF.
8. Specifications
| Feature | Detail |
|---|---|
| Product Type | Electric Scooter Dashboard & Controller |
| Model (Controller) | KZ_KGCG-M2002-3-KH |
| Voltage | DC-36V |
| Lowest Voltage | 29 ± 0.5V |
| Rated Power | 350W |
| Max Current | 15.5 ± 1A |
| Serial Number (Example) | QZFT-ZG-ZG240704-2226 |
| Package Dimensions | 20 cm (L) x 15 cm (W) x 10 cm (H) |
| Package Weight | 0.4 kg |
9. User Tips
- Before installation, take photos of your existing wiring to serve as a reference.
- When connecting wires, ensure a snug fit to prevent intermittent connections.
- Always double-check polarity for battery connections to avoid irreversible damage.
- After installation, test the scooter in a safe, open area before riding.
10. Warranty and Support
For detailed warranty information, technical support, or further documentation, please refer to the official KUGOO support channels or the seller. A comprehensive user manual in PDF format is available for download, which may contain additional diagrams and instructions:
