Citycoco engine: cable replacement and temperature sensor installation

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In the conditions of modern Russian reality, the development of new vehicles is a rather non-trivial task.

Even with the design and implementation of the ATV’s supporting structure, you cannot just go to the store and buy a powerful but not too heavy electric motor, a suitable controller, display, throttle stick and wires.

To do this, in addition to studying technical literature, you will have to dig up many sites, read countless reviews, order a copy of equipment from different suppliers and choose the most suitable one.

The problem is exacerbated by the fact that most large manufacturers selling products in thousands of pieces will not ship a single item.

In our case, a Citycoco engine was used for the all-terrain vehicle. The challenge is to replace (rewire) the cable in this engine and install the temperature sensor.

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The photo shows that to connect the motor from Citycoco, three terminals for the power wires and a 5-pin connector for connecting Hall sensors were originally to be used.

The new wire will have one connector at the end, which combines all power wires, wires from Hall sensors and a wire from a temperature sensor, which is not provided in the current version.

The factory-made power wires are connected by welding — this is immediately visible after removing the protective glass-reinforced tubes.

We remember the location of the wires by color. If you mix them up and put everything together, you will have to swap the power wires inside the controller to start the engine. Otherwise, the engine will not start.

We clean each copper strand separately. The procedure is tedious, but necessary. I always prioritize quality, even if the work takes longer.

The power wires are prepared, the old wire has been removed from the motor shaft. It is necessary to clean the fixing sealant and push through a new wire.

The wire is stretched, we begin to unsolder the power wires. I decided to take the glass-reinforced tubes of a smaller diameter so that they would sit more tightly on the wire and would not be able to move.

The power wires are wired according to the original color scheme. Now you need to unsolder the wires of the Hall sensors. In the new cable, in addition to the wires we need, there are two more — we just insulate them.

An NTC10K temperature sensor is essentially a resistor whose resistance changes as the temperature changes. At 25 degrees, it has a resistance of 10 kΩ. We solder it between the black and white wires.

After soldering, bend the temperature sensor down so that it is as close to the windings as possible. Due to the fact that during operation various vibrations will affect the structural elements, we fix the wires and the thermal sensor with epoxy resin.

In place of the old sealant at the cable entry into the motor axis, we apply a new one and assemble the motor.

Now let’s summarize the work done.

The engine from Citycoco received a cable of the required length (not too long), which to a certain extent will affect the efficiency of its operation.

A temperature sensor is installed in it, which, in combination with thermal protection in the controller, will increase the reliability of the system as a whole.

And of course, the new connector is much more convenient to use when assembling the structure of the all-terrain vehicle.

Thank you for reading the article to the end!

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