Power Assisted Bikes Owner s Manual Version 2 April 2016
Introduction Thank you for buying a PowaCycle Windsor electric bike. We hope it brings you many hours of enjoyment. For safe and compact shipping, we have despatched your PowaCycle Windsor part assembled. It therefore requires some assembly work before you can begin riding it. Please follow these instructions carefully. If you do not feel confident to assemble the bike yourself, we recommend you visit your local cycle store for professional help and advice. Some assembly details may vary due to recent product improvements. 2
Assembly Instructions Charge the Battery Before assembling your PowaCycle you should charge the battery, which will allow you to test the electrical connections during assembly. It may take up to 6 hours to fully charge. When charged, the LED changes from red to green. Please note, the battery will deteriorate if left uncharged. A lever at the base of the seat post releases the saddle, allowing it to be lifted out of the bike frame: this makes the battery accessible. Unlock the battery case lock, lift the handle on the battery and slide the battery from the base housing. Charge the battery away from water or combustible material. Connect the round-ended charger plug to the battery socket; a keyway in the socket ensures the plug will only fit the correct way round. Plug the charger into the mains supply socket and switch it on. For the first charge allow 7 hours, thereafter only around 5-6 hours is needed for a full charge. 3
Fitting the Handlebars The handlebars are already connected to the frame by cables. The handlebars and stem must be inserted into the frame as shown, at least as far as the minimum depth marker line on the stem. Align the handlebars 90 degrees to the forks. Finally, use an Allen key supplied or hexagonal tool to tighten the handlebar stem in place. NOTE: We recommend you make a final adjustment of the handlebars once the bike is fully assembled. Fitting the Pedals Pedals are marked L and R, for the left and right side of the bicycle when facing forward. Screw each pedal into the appropriate crank (pedal shaft) by hand, then tighten with a spanner to secure. NB. The left pedal has a reverse thread and therefore need to be screwed in anticlockwise. 4
The completed PowaCycle Windsor Finally Before mounting your cycle to ride, remember to check that: the battery is fully charged and locked into the battery well. the tyres are inflated to the correct pressure (as moulded into the tyre sidewalls). the brakes are operating effectively. the handlebars are correctly adjusted and secure the seat is at the correct height for the user all nuts and bolts are secure (including pre-assembled ones) and tightened to the torques shown in Safety Requirements below. 5
Safety Requirements Before use, read through this manual and ensure all riders are familiar with its contents. Always obey traffic rules. Do not carry passengers. Note that children under 14 are not allowed to ride e-bikes on the public highway. When adjusting the saddle, do not raise it so far that the Max safety line on the seat post appears above the clamp. Please note the tightening torque for the saddle rail clamping bolt and seat post clamping bolt is 16Nm. When adjusting the handlebars, do not raise the handlebar stem so far that the Max safety line appears above the headset locknut at the top of the head tube. Please note that the tightening torque for the expander bolt in the handlebar stem and the handlebar clamp bolt is 12Nm. To ensure satisfactory braking performance, regularly check the brake pads are correctly aligned, not worn out, and adjusted so maximum pressure can be applied with the levers only half way to the handlebars. The torque for brake block fixing nuts is 9Nm. Immediately replace brake cables that have frayed or have broken wire strands. The torque for the brake cable clamp bolt on the brake arm is 6Nm. The torque for front wheel axle nuts is 20Nm, and for rear wheel axle nuts is 3oNm. The torque for pedals is 40 Nm. 6
Operation of the Windsor PowaCycle Overview The PowaCycle Windsor is an electrically assisted bicycle that operates as a standard bicycle, with the assistance of a motor and battery. The power provided supports the rider s own efforts, giving increased performance with less effort. Battery Charging, Care & Safety Care of the battery is vital to maximise its long-term performance. The battery must be removed from the bike for charging. Regular Use If you are commuting significant distances, it is advisable to recharge the battery before the return journey. Occasional Use When stored out of use, recharge the battery for two hours once every two months. When the red indicator on the charger turns green, it means charging has finished. According to battery usage, charging may be complete within 2-7 hours. Recharge the battery whenever insufficient charge remains for your next journey. If power is exhausted, the battery pack shouldn't be left in a fully discharged state for more than 48 hours, but recharged as soon as convenient. Charge the battery off the bike, in a dry cool environment indoors, at a temperature above freezing. Do not use or store the battery pack near sources of high temperature s. Do not handle the charger or battery with wet hand or charge in a wet area or exposed to water splash, or in areas that can become exposed to direct sunlight. Keep the battery away from water, to prevent shocks or shorting. When attached to the bicycle, it is safe to operate in wet conditions. Wipe any dirt off the charging socket of the battery pack with dry cloth before use; otherwise it may cause poor contact and malfunction. In winter, at the end of every day of use, be sure to wash off road salt and other dirt from both battery and the battery well on the bike. Do not cover the battery or charger. 7
Owing to a small risk of fire when charging a battery that has become faulty, do not leave the battery permanently charging from the mains supply or charging unsupervised, especially overnight. Only use the charger provided to charge the battery. The charger's supply voltage must match local voltage. During charging, the battery pack should be located in a stable position on its side to prevent damage by toppling over. If during charging, storage, or use the battery pack should overheat or exhibit other abnormality this indicates a fault with either battery pack or charger. In that case, cut the power supply immediately and return battery and charger to your vendor's aftersales-service centre for repair. Do not use the battery to power anything other than the Powacycle for which it was purchased. Do not disassemble or modify the battery. Do not expose the battery to fire or extreme temperatures. Do not short circuit the battery. Do not drop, and take care to avoid violent impacts. Do not pierce the battery case with sharp tools. At end of life always dispose of a defunct battery by returning it to your dealer, or otherwise at a dedicated waste facility. Keep battery pack and charger out of the reach of children. Tyres Check the tyres regularly to ensure that the correct pressures are maintained (pressure range is shown on the sides of the tyres). Do not over-inflate the tyres. There are different types of pumps available for cycles. Ask your local cycle shop for the one best suited to your needs (do not use a garage forecourt air hose to inflate your tyres). Brakes Make sure your brakes are adjusted correctly at all times. Major adjustment (needs tools) can be made at the cable clamp bolt on the brake arms. Fine tuning the brakes can be done by twisting the barrel adjusters located where the cables enter the brake levers. Replace brake blocks when worn. 8
Power Switch on the power by turning on the key switch on the battery. The Windsor can be operated as a pedelec. This means that, as soon as the rider begins to pedal, the motor supplies energy to support the cyclist s efforts. If the rider prefers to cycle without the assistance of the motor, they should turn the battery off. Throttle In order to use throttle power, operate the red rocker switch by the left hand grip, then the throttle (combined with the right hand grip) can be twisted to obtain motor power. Note the throttle will only operate while pedalling. Gears and Bicycle Chain Change through the gears one at a time and only when the bicycle is being pedalled. To maintain performance, ensure all mechanical parts of the gears are lightly oiled; the chain must be lubricated with bicycle chain oil once a week in wet weather, or once a month when dry; avoid getting oil deposits on the wheel rims. If the chain mechanism becomes dislodged, turn the pedals forward gently to reengage it. If the chain becomes completely dislodged, lift it back onto the smallest gear cog (top gear). Saddle For maximum comfort ensure that the saddle is both correctly adjusted and secure. Once set up correctly, the height of the saddle can be adjusted without tools. Loosen the lever at the top of the frame below the saddle to raise or lower the saddle. Once the saddle is at the required height, secure it by tightening the lever. Tighten or loosen the nut on the lever if required. Professional Maintenance We recommend you have your cycle serviced by a professional cycle engineer at least once a year to ensure ongoing safe performance. If you are unsure as to how to carry out an assembly procedure or adjustment, we recommend that you consult your local cycle shop. 9
Troubleshooting 1 Brakes not working effectively Check for excessive distance between brake blocks and wheel rims. Check the blocks are parallel with the wheel rims. Check for any wear on the brake blocks. See operating instructions: Brakes. 2 Motor not working Check that the ignition has been switched on. Check that the battery is properly inserted in its housing. Check that the battery is charged. Check that both brake lever blades snap back into their brackets when released: stiff brake cables or bent brake levers can prevent this and cause the brake cutout switches to stay On, thereby preventing the motor from working. Check that none of the electrical cables or connections has become dislodged. Warranty Information 1 The frame Has a warranty of two years. 2 Other main parts Have a warranty of one year. 3 The battery Is covered by a 6 month warranty, as battery life will be determined by user care. 4 Bulbs, brake blocks, tyres etc Are regarded as consumables, therefore when replacements are required, these need to be purchased from your local cycle store. 10
PowaCycle, Ultima Networks PLC, Akhter House, Perry Road, Harlow, Essex, CM18 7PN Tel: 01279-821243 www.powacycle.co.uk 11 E&OE Ultima Networks plc