Troubleshooting Tongsheng Motors: How To Fix Common Errors

Disclaimer: This site may contain affiliate links, meaning we may earn a commission if you make a purchase through them, at no extra cost to you. Thank you for your support!

Tongsheng motors, particularly the TSDZ2, TSDZ2B, and TSDZ8 models, are a popular choice in the e-bike conversion community, celebrated for their reliable performance and torque-sensing capabilities, which deliver a smooth and natural riding experience.

However, like any sophisticated system, they can occasionally encounter hiccups that trigger error codes and momentarily disrupt the riding experience. Understanding these error codes and their underlying causes is essential for swift troubleshooting and maintenance, ensuring you spend more time enjoying the open road and less time tinkering with your e-bike.

Table of Contents

Decoding the Language of Your Tongsheng Motor

Rear wheel of an e-bike with a Tongsheng rear hub motor and disc brake — *Rear wheel of an e-bike equipped with a Tongsheng rear hub motor and disc brake*

Error codes are your e-bike’s way of communicating that something isn’t quite right. These diagnostic messages, displayed on the LCD screen, pinpoint specific issues within the drive system, whether it’s a mid-drive motor integrated into the bike frame or a hub motor located within the wheel hub, as well as the battery, or other components, allowing for targeted troubleshooting and repairs.

Both Tongsheng and Bafang motors use these error codes to assist users in maintaining their e-bikes. By decoding these codes, you gain valuable insights into the problem at hand, empowering you to take the necessary steps to resolve it and get back on track quickly.

How to Recognize Tongsheng Error Codes

Error codes are typically displayed on the Tongsheng display unit, such as the VLCD5 or VLCD6, in the format “ERR-XX.” Each code corresponds to a specific fault within the system, such as a motor hall fault, throttle failure, or low battery alarm. The appearance of an error code typically coincides with a loss of motor assistance or other operational disruptions.

Tonghseng vlcd13 display unit — *The Tongsheng VLCD13 display, showing essential metrics and error codes to help troubleshoot and optimize e-bike performance.*

Common Triggers for Tongsheng Motor Errors

Tongsheng error codes can be triggered by a variety of factors. Recognizing these potential causes can help you quickly diagnose and resolve the issue efficiently.

Electrical Issues: Loose connections, damaged wires, or malfunctioning sensors can disrupt the communication between the motor and the controller, leading to error codes.
Mechanical Problems: Worn-out gears, improper installation, or physical obstructions in the motor’s moving parts can cause the system to detect a fault and display an error code.
Environmental Factors: Extreme temperatures, moisture ingress, or excessive vibrations can affect the sensitive electronic components within the motor, leading to errors.
User Errors: Incorrect start-up procedures, such as applying pressure to the pedals while turning on the system, can sometimes trigger error codes.

Common Tongsheng Motor Error Codes & Troubleshooting Tips

Tongsheng motors, especially the TSDZ Series, are equipped with diagnostic systems that display error codes to help users identify and troubleshoot issues. These error codes appear on the display unit and correspond to specific faults within the motor or its components.

Below is a chart detailing common Tongsheng motor error codes, their descriptions, potential causes, and troubleshooting steps.

Error Code	Description	Potential Causes	Troubleshooting Steps
ERR-02	Motor Hall Fault or Motor Short Circuit	Faulty motor hall sensor Short circuit in motor wiring Loose or damaged motor connectors	Check and secure motor hall sensor connections Inspect motor wiring for damage or short circuits Replace motor hall sensor if necessary
ERR-03	Controller Failure	Internal failure in controller Overheating of controller Electrical faults in controller circuitry	Allow controller to cool down if overheated Inspect for visible damage or burnt components Ensure all connections to controller are secure Replace controller if necessary
ERR-04	Throttle Failure	Damaged or faulty throttle sensor Loose or disconnected throttle wiring Throttle blockage or physical damage	Inspect throttle for damage or obstructions Check throttle wiring for secure connections Test throttle sensor Replace throttle if defective
ERR-06	Turn on Motor with Cyclist\u2019s Feet on Pedal (Coaster Brake Version)	Cyclist\u2019s feet on pedals during power-on Sensor misreading pedal position	Ensure feet are off pedals when turning on motor Check pedal position sensor for proper operation Restart system ensuring proper procedure
ERR-08	Low Battery Alarm	Battery charge too low Faulty battery Connection issues	Charge battery to full capacity Inspect battery connections for security and corrosion Test battery with voltmeter Replace battery if it fails to charge
ERR-10	Motor Blocked	Motor is physically blocked or jammed Hall effect sensor failure	Check for physical obstructions in the motor Replace faulty hall effect sensors
ERR-30	Communication Reception Failure	Loose or damaged connections Faulty controller or display unit	Check and secure all connections between the controller and display Replace the controller or display unit if necessary

Common Problems with Tongsheng Motors & How to Fix Them

Tongsheng motors are widely used in e-bike conversions due to their reliability and performance. However, like any complex mechanical system, they can experience various issues over time.

Below is a chart detailing some of the frequent problems encountered with Tongsheng motors, their causes, and troubleshooting steps.

Problem	Description	Potential Causes	Troubleshooting Steps
Overheating	The motor tends to overheat during prolonged or intensive use.	Insufficient cooling High ambient temperatures Continuous high-power usage	Install additional heat sink or cooling fins Avoid continuous high-power usage Allow motor to cool periodically
Blue Nylon Gear Wear	The blue nylon gear inside the motor wears out prematurely.	High torque Frequent gear changes Inadequate lubrication	Replace nylon gear with a steel gear Ensure proper lubrication Avoid harsh riding conditions
Torque Sensor Issues	Torque sensor failure or erratic readings affecting motor responsiveness.	Poor solder connections Cracked sensor rings Misalignment	Resolder poor connections Replace damaged torque sensor Ensure proper alignment and calibration
Motor Powering Down Randomly	The motor powers down suddenly, causing loss of assistance.	Battery management system (BMS) issues Loose connections Controller faults	Secure all battery and motor connections Test and replace BMS if necessary Inspect and replace controller if needed
Controller Settings Corruption	Corruption of controller settings if powered on with pedal pressure.	Improper start-up procedure Software glitches	Discharge capacitors by shorting motor connections after removing battery Reflash controller with updated firmware
Creaking and Play in Crank Arm	Small play in the crank arm and occasional creaking noises.	Movement of ball bearings held by circlips Dry headset bearings	Re-grease headset bearings Check ball bearings and circlips for secure fitting

Share Your Tongsheng Motor Troubleshooting Triumphs & Challenges

The insights provided above offer a detailed guide to help you navigate and resolve these problems efficiently. However, experiences can vary, and often, the community can provide valuable insights and solutions.

We would love to hear about your experiences with Tongsheng motors. Have you encountered any of these error codes or issues? How did you handle them? Your stories and solutions could help others facing similar challenges. Please leave a comment below and share your tips, tricks, and advice. Together, we can build a more informed and supportive e-bike community.