EV TECHNICIAN TRAINING

Step-by-Step Fault Diagnosis

Gaadi ON na hona, motor na chalna, jhatka, charging problem, kam range aur baar-baar aane wali kharabi ki jaanch.

What You Will Learn

Achha mechanic andaaze se parts nahi badalta. Wo pehle customer ki shikayat samajhta hai, phir sambhavit karanon ko ek-ek karke test karta hai aur result ke aadhaar par agla kadam tay karta hai.

1

Display ON hai lekin Motor nahi Chal Rahi

Sabse zaroori diagnosis flow

Step 1: Brake cut-off signal jaanchein.

Step 2: Throttle supply aur signal jaanchein.

Step 3: Motor hall supply aur signal jaanchein.

Step 4: Motor phase connector jaanchein.

Step 5: Battery voltage ko load ke samay dekhein.

Step 6: Controller ke input aur output ko vehicle specification ke anusaar jaanchein.

Practical Tip: Ek saath controller, throttle aur motor badalne ke bajay ek-ek karan ko hatate jayein.

2

Gaadi ON hi nahi ho Rahi

Battery se display tak power flow dekhein

Step 1: Battery voltage jaanchein.

Step 2: Main fuse/MCB jaanchein.

Step 3: Main power connector jaanchein.

Step 4: Key switch/key signal jaanchein.

Step 5: Controller input aur enable signal jaanchein.

Step 6: Display ya low-voltage supply tak power pahunch rahi hai ya nahi dekhein.

Practical Tip: Battery voltage maujood hona aur vehicle ka ON hona do alag baatein hain.

3

Motor Jhatka Lekar Rukti hai

Phase aur hall ki jaanch

Phase connector me loose ya jala hua pin dekhein.

Hall connector aur chhote signal wire jaanchein.

Wheel ghumane par hall signal badal raha hai ya nahi dekhein.

Teeno phase ki sthiti compare karein.

Wheel, brake aur bearing ki mechanical condition bhi dekhein.

Baaki test sahi hone ke baad hi controller fault par jayein.

Practical Tip: Phase aur hall wire ka colour har vehicle me ek jaisa nahi hota.

4

Battery Jaldi Khatam ho Rahi hai

Kam range ki sahi jaanch

Tyre pressure jaanchein.

Brake drag aur wheel bearing jaanchein.

Battery full charge ho rahi hai ya nahi dekhein.

Load par battery voltage ka behaviour dekhein.

Customer se load aur riding style ke baare me poochhein.

Zaroorat padne par battery health/capacity ki uchit test karein.

Practical Tip: Kam range ka matlab hamesha kharab battery nahi hota.

5

Charging nahi ho Rahi

Charger se battery tak poora rasta dekhein

AC supply jaanchein.

Charger indicator aur output dekhein.

Charging socket aur connector jaanchein.

Charging fuse aur wiring jaanchein.

Battery voltage aur BMS protection jaanchein.

Battery aur charger ki compatibility jaanchein.

Practical Tip: Charger, wiring, BMS aur battery me fault ko alag-alag pehchanein.

6

Kabhi Chalta hai, Kabhi Band ho Jata hai

Intermittent fault ki jaanch

Loose connector aur terminal sabse pehle dekhein.

Corrosion aur paani jaane ke nishan dekhein.

Vibration ke baad fault aata hai to wiring aur connector ki sthiti dekhein.

Customer se poochhein ki fault kab aata hai.

Fault garam hone par aata hai ya thandi gaadi me, ye bhi poochhein.

Ek baar me ek hi karan ko test karke fault ko pakdein.

Practical Tip: Intermittent fault me customer ki poori jaankari bahut kaam aati hai.

7

Customer se Sahi Sawaal Poochhein

Diagnosis customer ki baat se shuru hoti hai

Problem kab shuru hui?

Achanak hui ya dheere-dheere?

Kya baarish ya paani ke baad problem aayi?

Kya gaadi gaddhe ya accident me lagi?

Kya battery, charger ya controller haal me badla gaya?

Kya charging ke samay spark, heat ya smell aayi?

Kya display par koi error code aata hai?

Kya problem garam hone ke baad ya load par aati hai?

Practical Tip: Customer ki baat ko dhyan se sunein aur use diagnosis me use karein.

8

Repair ke Baad Final Check

Customer ko gaadi dene se pehle

Saare connectors aur covers sahi jagah lage hain ya nahi dekhein.

Battery terminals safe hain ya nahi dekhein.

Brake sahi kaam kar raha hai ya nahi jaanchein.

Throttle response jaanchein.

Horn, light aur indicator jaanchein.

Vehicle ko safe tarike se test ride karein.

Original complaint theek hui hai ya nahi sunishchit karein.

Practical Tip: Repair tabhi poora mana jaye jab fault theek hone ke saath safety check bhi poora ho.

Practical Checklist

Customer ki shikayat likhein.

Visual inspection karein.

Battery aur protection check karein.

Power flow follow karein.

Signal aur component test karein.

Ek samay me ek sambhavit karan jaanchein.

Repair ke baad poora functional test karein.

Safety First

Diagnosis ke dauraan vehicle ko safe rakhein. High-current battery, live wiring aur ghumte wheel se uchit doori rakhein.

Module Complete?

Checklist complete karne ke baad next module par move karein.