1. Introduction
This manual provides essential information for the installation, operation, and maintenance of your DYU D3F Electric Bicycle DC Brushless Controller. This controller is designed as a replacement spare part for DYU D3F electric bicycles and is available in two voltage options: 36V and 48V. Please ensure you select the correct voltage model for your e-bike.
2. Safety Information
Please read all safety instructions carefully before installation and use. Failure to follow these instructions may result in electric shock, fire, and/or serious injury.
- Always disconnect the e-bike's battery before performing any installation or maintenance.
- Ensure the controller's voltage matches your e-bike's battery and motor voltage.
- Avoid exposing the controller to water or extreme temperatures.
- Do not attempt to open or modify the controller casing.
- Professional installation is highly recommended to prevent damage to the controller or e-bike.
- Keep out of reach of children.
3. Package Contents
Your package should contain the following item:
- 1 x DYU D3F DC Brushless Controller (36V or 48V, depending on your selection)
4. Specifications
4.1. D3F 36V Controller Specifications
| Feature | Specification |
|---|---|
| Model | DQHB2.6, CD3F-6 |
| Rated Voltage | DC36V |
| Rated Current | 7A |
| Low Voltage Protection | DC31V±0.5V |
| Maximum Current | 15A±1A |
| Speed Set | 1-4.2V |
| Brake Input | High-level |
| Manufacturer | Shenzhen DYU Intelligent Mobility Technology Co., Ltd |
| Dimensions (L x W x H) | 83mm x 46mm x 30mm |
4.2. D3F 48V Controller Specifications
| Feature | Specification |
|---|---|
| Model | CD3F-1 (KugooKirin V1) |
| Rated Voltage | DC48V |
| Rated Current | 7A |
| Low Voltage Protection | DC39V±0.5V |
| Maximum Current | 20A±1A |
| Speed Set | 1-4.2V |
| Brake Input | Low-level |
| Manufacturer | Shenzhen Counterbalance Technology Co., Ltd |
| Dimensions (L x W x H) | 85mm x 52mm x 30mm |
5. Installation
Installing an e-bike controller requires technical knowledge and careful attention to wiring. If you are not confident in your ability to perform this installation, please seek assistance from a qualified e-bike technician.
5.1. Before You Begin
- Ensure the e-bike is powered off and the battery is disconnected.
- Verify that the new controller's voltage (36V or 48V) matches your e-bike's system.
- Familiarize yourself with the existing wiring of your e-bike's controller.
5.2. General Installation Steps
- Locate the Old Controller: Identify the current controller on your DYU D3F e-bike. It is typically housed in a protective casing.
- Disconnect Wiring: Carefully disconnect all wires from the old controller. Pay close attention to the color coding and connector types. It is advisable to take photos before disconnecting for reference.
- Remove Old Controller: Unmount the old controller from its position.
- Mount New Controller: Secure the new DYU D3F controller in the same location.
- Connect Wiring: Connect the wires from your e-bike to the new controller. The controller features various color-coded connectors for different functions (e.g., motor, battery, throttle, brake, display). Match the connectors and wire colors precisely.
Figure 5: 36V Controller Wiring Harness Example 
Figure 6: 48V Controller Wiring Harness Example - Secure Connections: Ensure all connections are firm and properly insulated.
- Test: Reconnect the battery and perform a functional test of the e-bike, checking throttle response, braking, and display functions.
6. Operation
The DC brushless controller is an integral part of your e-bike's electrical system, managing power delivery to the motor based on your input (throttle, pedal assist, brakes). Once correctly installed, the controller operates automatically:
- Power Management: Regulates the flow of electricity from the battery to the motor.
- Speed Control: Interprets throttle input (1-4.2V speed set) to control motor speed.
- Brake Cut-off: Activates motor cut-off when brakes are applied (High-level for 36V, Low-level for 48V).
- Low Voltage Protection: Automatically cuts off power to protect the battery when voltage drops below a safe threshold (DC31V±0.5V for 36V, DC39V±0.5V for 48V).
7. Maintenance
To ensure the longevity and optimal performance of your controller, follow these simple maintenance guidelines:
- Keep Clean: Periodically clean the exterior of the controller to prevent dust and dirt buildup. Use a dry cloth.
- Check Connections: Regularly inspect all wire connections to ensure they are secure and free from corrosion.
- Avoid Moisture: Protect the controller from heavy rain or direct water exposure.
- Temperature: Avoid operating or storing the e-bike in extreme hot or cold conditions, which can affect electronic components.
8. Troubleshooting
If you encounter issues with your e-bike after installing the controller, refer to the following common problems and solutions:
| Problem | Possible Cause | Solution |
|---|---|---|
| E-bike does not power on | Loose battery connection, faulty battery, incorrect wiring. | Check battery connection. Ensure all controller wires are correctly connected. Test battery voltage. |
| Motor not responding to throttle | Loose throttle connection, faulty throttle, motor wire issue. | Verify throttle wiring to the controller. Check motor phase wires and Hall sensor wires. |
| E-bike cuts out during operation | Low battery voltage, controller overheating, loose connections. | Charge battery fully. Ensure controller has adequate ventilation. Check all power connections. |
| Brakes not cutting motor power | Brake sensor wire disconnected or faulty. | Check brake lever sensor wiring to the controller. Ensure correct brake input level (High/Low). |
If troubleshooting steps do not resolve the issue, please contact customer support.
9. User Tips
- Verify Compatibility: Before purchasing, always confirm that the controller model (D3F 36V or D3F 48V) is compatible with your specific DYU e-bike model (e.g., DYU C3, DYU C6). Check your original controller's label for model numbers and voltage.
- Voltage Match: It is crucial to match the controller's voltage (36V or 48V) precisely with your e-bike's battery and motor voltage to avoid damage.
- Wiring Diagrams: If available, refer to your e-bike's original wiring diagram for precise connection points.
10. Warranty and Support
For warranty information, technical support, or further assistance, please contact the seller or manufacturer directly. Provide your product model and purchase details when seeking support.