Giant GLI270 6A EnergyPak 5 pin charger tear down / repair / fuse replace

[offroad]

Case secured with 4 x Torx screws underside. Double tab fasteners along both sides centre need leverage to unclick.

White rubber gasket occupies surrounding groove. Unclip aluminium covers, 2 clips each side ends. Unclip LED daughterboard / switch. Bottom aluminium heat sink is stuck to case with glue or tape, prise upwards.

Top aluminium cover has soldered earth wire. (Remove temporarily for convenience).

If no LED's light, check input fuse F1 adjacent IEC AC input socket.

If LED's light, but less than 40v DC output and no flashing GREEN LED, check output stage fuse F2 adjacent red and black output wires. Both fuses wrapped in black heat shrink. Output fuse is common issue. Replace with slow blow T15A 250V ceramic fuse with leads pre-attached.

Why does this last image keep duplicating itself and won't delete ? I give up.

 

[JurijB]

Hello.

I have the following problem with the original Giant GLI180a 4Ah charger: when you plug it in, first the red and then the green LED flash briefly, after which the charger turns off and does not charge the battery, regardless of whether it is on the bike or disconnected and charging directly.
By experimenting, I found that the charger connected to the bike is partially "activated" if I then try to turn on the bike's drive - the on/off button, which is otherwise "forbidden". In such a case, the red LED on the charger is constantly lit, which otherwise signals that there is no battery. If I then charge the battery directly, the charging LEDs flash on the battery, but it charges extremely slowly.
Does anyone know a similar case and/or solution?

The Giant seller says that the charger is defective and needs to be replaced.

PS: the battery are OK and normally charge on other charger.

 

[offroad]

Measure the output voltage and if not 42v it's cactus. Cut the 5 pin cable off the charger and connect the +/- red black wires to any 42v / 4A charger. You don't need the Canbus communications to charge the battery.

 

[JurijB]

Thank you; Giant already change charger for new one. Unofficial is the issue with one series made in corona times with chipsets from another supplier.