Carrera Crosscity-E User manual

Carrera Crosscity
-
E
Rear Motor Drive System
Owner’s Manual

1
Contents
Safety information
......................................................................... 2
Riding the E-Bike
............................................................................ 5
Product characteristics
............................................................... 6
Product specification ................................................................. 6
Display ............................................................................................ 7
Battery ............................................................................................. 7
Battery charger ............................................................................. 8
Charging the battery ................................................................... 9
Fitting the battery ................................................................................................................... 11
Removing the battery ............................................................................................................ 11
Assistance levels and speed .................................................. 12
Range............................................................................................. 12
Removing the rear wheel (to repair a puncture) ............... 13
EC Declaration of Conformity ................................................ 15
Halfords e-bike specific warranty conditions ................... 17
Battery pack specific warranty conditions ........................ 17

2
Safety information
WARNING
There is an increased risk of injury – even
fatal – if you do not follow instructions.
WARNING
There is a risk of serious injury – even fatal – if you do not follow instructions.
Managing the battery
 Use only batteries and chargers from Halfords
with your bike. Use of other battery packs can
cause injury and involve a risk of fire. If you use
other battery packs, Halfords will assume no
liability or warranties.
Do not throw the battery pack into a fire.
The battery must not be exposed to direct
sunlight, or charged or stored in the vicinity of
high temperatures.
 Do not use the battery for any other purpose.
Avoid contact with metal objects (paper clips,
coins, keys, nails,screws or other small
metal objects, as this may cause a
short-circuit. Shorts caused in this way will
invalidate any warranty claims.
 Do not open the battery pack. This could
cause a short circuit.Opening of the
battery package will invalidate any
warranty claims.
Do not connect, or disconnect the battery
pack / charger withwet hands.
 Keep the battery / charger out of reach of
children/animals.
How safe riding is ensured
While riding, do not focus your
attention too much on thescreen, as
this can lead to accidents.
 Ensure that the wheels are securely attached
to the bike beforeyou begin your trip. If the
wheels are not securely attached, the bike
may fall over, causing severe damage.
When riding a power-assisted bike, be sure
that you arecompletely familiar with the
starting characteristics of the bike before
riding on multi-lane roads and footpaths. If
the bike suddenly switches on, accidents
can happen.
If applicable, check that the bike lights are
working before youride at night.
How safe maintenance is ensured
 Remove the battery pack from the eBike
before you start working on it (e.g., assembly
work, maintenance, working on the chain,
etc.), before transporting it by car or plane, or
before storing it. There is a risk of injury in
case of accidental activation of the eBike
system.
 Be sure to remove the battery before you
perform wiring orinstallation work on
the bike. Otherwise there is a danger of
electric shock.
When you install this product, be sure to
follow the instructionsgiven in the user
manual. We also recommend that you use
only genuine HALFORDS parts. If nuts and
bolts are left loose or the product is damaged,
the bike may fall over suddenly and cause
serious injury.
After you have carefully read the user
manual, store it in a safeplace for later
reference.
 Ensure that unused connections are provided
with caps.
 Contact the retailer for installation and
adjustment of the product.
To allow riding in wet weather, the product is
designed to becompletely waterproof.
Nevertheless, do not expose the product
intentionally to water.
 Do not expose the bike to high-pressure
cleaning. If water should penetrate into one
of the components, operating problems or
rust may result.

3
Managing the battery
 Do not subject the battery or the charger to
physical shocks, e.g., by dropping.
 Fluid that leaks from the battery pack may
cause skin irritation or burns. In the event of
accidental contact, rinse with water. If fluid
gets in your eyes, seek medical advice.
 If you detect a strange odour or smoke, pull
the plug.
 Ensure that the power plug is fully inserted
into the wall outlet.
 Pull on the plug instead of the cable to
unplug the power cord from a wall outlet.
 Do not place anything on the cable. Do not
lay anything on the cable.
 Do not bend the cable. The cable must not
be rolled up while charging.
 It is dangerous to use a single outlet for
multiple devices.
 If the cable or plug is damaged, replace the
parts with new ones. Contact your
authorized dealer.
 Always keep your charging set away from
flammable gases when charging.
 The charger can be hot. Do not cover the
charger.
 The charger can be hot. Do not place the
charger on floor coverings such as carpets,
tatamis, etc.
 The charger can be hot. Avoid long skin
contact with the charger.
 Do not immerse the battery or the charger.
Do not use in rain.
 Do not charge the battery for more than 24
hours continuously.
 If the battery is not fully charged after six
hours, disconnect it immediately from the
output to stop the charging process and
contact your place of purchase. This can
lead to overheating, bursting, or ignition of
the battery.
WARNING
There is a danger of personal injury or
property damage
How safe riding is ensured
Follow the instructions in the user manual of the
bike to ensure a safe ride.
Managing the battery
 The battery comes with a 40% charge.
Discharge and charge the battery fully,
twice to reach an optimum range.
 Charge the battery before riding.
 The charger can be used with an input
voltage in the range of 100V to 240V AC.
 After charging pull the cable from the
battery and from the wall outlet.
 Keep the power plug clean and dust free.
The charger should be cleaned regularly.
 Do not rotate the pedals while the battery is
being charged and the battery is on the
battery holder.
 Provide ventilation/venting while the battery
is charging in enclosed spaces.
 During storage keep the battery at a charge
level of at least 40%.
 Charge the battery at room temperature
between 5°C and 35°C(41°F and 95°F).
Safe use of the product
 Examine the battery charger regularly for
damage, especially the cable, plug and
housing. If the battery charger is damaged,
it must only be used after it has been
repaired.
 This product must not be used by persons
(including children)with reduced physical,
sensory or mental capabilities, or who lack
experience and knowledge, unless they are
supervised by a person responsible for their
safety, or instructed in the use of the
product.
 Do not let children play near the product.

4
WARNING
 Please ensure that all carrier screws
are fastened before riding；
 Please note that the maximum load
on the carrier is 25 kg, cargo weight
must not exceed 25 kg；
 Please do not replace or modify the
carrier；
 To prevent an accident，please check
and replace the screws of carrier
periodically；
 When fitting loads on the carrier,
please ensure that the bike is
balanced to avoid accidents；
 Do not carry children on the luggage
carrier；
 Please note that the carrier is not
designed to pull a trailer;
 Please note that the bicycle may have
different performance (especially the
steering and braking) when the carrier
is loaded;
 Do not remove the reflectors;
 The tightening torque of the screws
between the carrier and the frame
should be 14N.M;
 Please note that carrier is not
designed for the attachment of a
child-seat;
 Please ensure that all the luggage
on the carrier is securely fixed and
there are no any loose straps which
could get caught in the wheels;
 Please distribute loads evenly on the
carrier.

5
Riding the E-Bike
Note:
If the battery is not used for 24 hours or
longer, it will automatically go into sleep
mode. Press the power button on the
battery for three seconds
Press 2 sec.
The handlebar display goes through a self-check routine, where
all LEDs flash. The number of permanently lit red LEDs indicates
the state of charge of the battery. The MODE defaults to ‘LOW’.

6
Product characteristics
Product specification
Operating temperature range during discharge
-
20°C
to
60°C
Operating temperature range during charge
0°C
to
45°C
Storage temperature (battery)
-
20°C
to
45°C
Humidity (storage)
up
to
80%
Charging voltage
1
0
0V
to
240
V
A
C
Charging time
approx. 6 hours
Ba
t
t
ery
type
Lithium ion ba
t
tery
Capacity
3
1
3
Wh
Nominal
v
olta
g
e
36VDC
Mo
t
or
type
Rear
-
wheel drive
Mo
t
or
type
Brushless
DC
Motor
Nominal
mo
t
or
p
o
w
er
250W
Maximum
mo
t
or
p
o
w
er
4
0
0W
T
o
r
que
32
Nm
Motor
Battery
Display

7
Display
LOW
MID ASSIST MODE BUTTON
HIGH
POWER ON/ OFF (press & hold for 2 seconds)
For WALK assistance press and hold the button
Assistance will stop as soon as you release the button
Battery
BATTERY STATUS
Charging port
Battery
release key
Battery level display and on/off ‘Power’ button
Important!
Your bike is supplied with two battery lock keys; please keep
the spare key safely. We can order you a replacement if you
can provide the key number.
Please note your key number here
-

8
 If the E-Bike not in use, remove the battery and store it at a temperature
between 0°C and 40°C in a dry environment.
 Do not store the battery with low capacity for a longer period.
 For storage, the battery should have a capacity of at least 40%.
 It is recommended to discharge the battery completely and then fully
recharge it.
Battery charger
WARNING

Use only batteries and chargers from HALFORDS with your bike. Use of other battery packs could
cause injury and involve risk of fire. If you use other battery packs, it will invalidate your warranty

The battery must not be exposed to direct sunlight, or charged or stored at high temperatures.

Avoid contact with metal objects (paper clips, coins, keys, nails, screws, or other small metal
objects) as these may cause a short- circuit. Short circuits caused in this way will invalidate any
warranty claims.

Do not open the battery pack. This could cause a short circuit.

Opening of the battery package will invalidate any warranty claims.

Do not connect, or disconnect the battery pack/charger with wet hands.

Keep the battery/charger out of reach of children and animals.
CONNECTION DISPLAY PLUG

9
Charging the battery
WARNING

Do not subject the battery or the charger to physical shocks, e.g., by dropping. Rinse in
the event of accidental contact with water. If fluid gets in your eyes, seek medical
advice. Fluid that leaks from the battery pack may cause skin irritation or burns.

Do not bend the cable. The cable must not coiled up while charging.

The charger can get warm. Do not wrap or cover the charger or place it on soft floor
coverings such as carpets, etc.

If the battery is not fully charged after six hours, disconnect it immediately from the
mains to stop the charging process and contact your place of purchase. This can lead
to overheating, bursting, or ignition of the battery.
Note – If you store your e bike in an unheated shed or garage, low temperatures in winter
can affect charging efficiency and the range during discharge.
For best charging performance, remove the battery from the bike and bring it indoors to
charge. Once charged the electrochemical reactions inside the battery will also be more
efficient with the battery at room temperature, so fitting the battery at room temperature
will improve the range of the e-bike.
The charger LED changes from red to
green when the
battery is fully charged

10
Battery power remaining indication
Press the ‘Power’ button for 2 seconds; the LED will indicate the amount of charge remaining in the battery
Remaining total capacity
< 20%
>20% & <40%
>40% & <60%
>80%

11
Fitting the battery
1. Push the battery into the end of the frame with the charging port on the left side
2. Turn the key 180°
Removing the battery
Unlock with the key & slide out the ba
t
t
ery

12
Assistance levels and speed
Range
Factors which affect the range
The above figures are based on a speed of 20 km/h on a level road at 15°C–20°C. The
range is influenced by many factors:
15.5
12.5
9.3
Miles per
hour

Weight of the rider
 Weight of the luggage
 Selection of path
 Experience and
concentration of the rider
 State of maintenance of
the E
-
Bike

Type, condition and air
pressure in the tires
 Nature of the route
 Speed, average speed and
changes in speed
 Traffic flow, for example,
stop and go
 Wind direction and wind
speed

13
Battery contact protection
When the Crosscity-e is folded there are two
bladed battery contacts exposed at the front of
the rear section of the main frame tube.
Stored inside the
central frame folding
catch is a plastic
battery contact
protector.
When the bike is folded always slide
this protector over the two bladed
contacts.
This will prevent the contact blades
getting bent by accidental pressure
during transport or storage.

14
Removing the rear wheel (to repair a puncture)
 Unplug the two parts of the cable connector.
You will need to ‘wiggle’ these parts to
overcome the grip of the waterproof seal of
this connector.
 Release the two ‘arms’ of the rear V brake by
pulling on the rear brake cable ‘noodle’ &
releasing it from the ‘cage’ on the top of the
arm
 Remove the rubber caps from both rear wheel nuts & loosen the nuts (19 mm
spanner). You may need to remove the nuts to release the wheel.

15
 Having repaired puncture, refit the rear wheel. Take care to ensure the motor cable
is pointing directly downwards to align the anti-rotation toothed washers on the
wheel axle with the dropout slots.
 Firmly tighten both wheel nuts to 40 +/-5 Nm
 Push the two parts of the motor cable connector together, making sure that the
moulded arrows are aligned
 Replace the rubber wheel nut caps & clip the motor cable back under the chainstay.
 Reconnect the rear V brake.
EC Declaration of Conformity

16
The equipment which accompanies this declaration is in conformity with
the following EU Directives:-
83/37/EC Machinery Directive
2006/95/EC Low Voltage Directive
2004/108/EEC Electromagnetic Compatibility Directive
2001/95/EC General Product Safety Directive
2012/19/EU Waste Electrical and Electronic Equipment Directive
2006/66/EC Batteries Directive
Manufacturer:- TIANJIN FUJI-TA BICYCLE CO.,LTD. Dongjin Road,
Junliangcheng Town, Dongli District, Tianjin, China
Represented in the EU by:- Halfords Plc, Redditch, B98 0DE.
A copy of the Technical file for this equipment is available from:- the EU
address above.
Description of Equipment
Battle E-Bike Halfords Carrera Crosscity 250 W Rear Motor Drive System,
8.7Ah Li-Ion Battery & Battery Charger
The following harmonized standards have been used:-
EN 15194:2009 + A1:2011 Cycles – Electrically power assisted cycles –
EPAC Bicycles
EN ISO 4210-2:2014 Safety requirements for bicycles. Requirements for city
and trekking, young adult, mountain and racing bicycles
Other key standards used:-
UN/DOT 38.3 UN Manual of Tests and Criteria Transportation Testing of
Lithium Batteries.
Authorised signatures of manufacturer and EU representative
Manufacturer
EU representative
Signature:
Name of signatory:
Billd Lee
Chris Hall
Position in company
:
QC Manager
Head of
Quality
Place and Date:
Tianjin China Dec 2016
Redditch UK
Dec
2016

17
Halfords e-bike specific warranty conditions
Your Carrera Crosscity e-bike is guaranteed against manufacturing defects arising from
faulty workmanship or materials for 2 years from the original date of sale.
Providing that the cycle:
 Has been properly cared for, regularly serviced and maintained.
 Has not been ridden as part of a commercial use (e.g. hire, courier or delivery service,
etc.).
 Has only been fitted with parts recommended by Halfords.
 Has not been modified or altered in any way, in particular no modifications to the motor
 Has not been damaged by accident or misuse.
Any failure caused by normal wear and tear or a lack of servicing and maintenance is
excluded.
Under the terms of this guarantee Halfords will bear the cost of the replacement parts and
labour to carry out the repair.
Important: This guarantee applies only to cycles used under normal riding conditions.
This guarantee does not affect your statutory rights.
Battery pack specific warranty conditions
The battery pack is guaranteed over the warranty period to provide a minimum of 500
charging cycles and to hold at least 60% of its nominal battery capacity.
This is dependent upon the correct use, regular re-charging, correct preparation for storage
and storage (as detailed in the HALFORDS Owner’s Manual).
Halfords will be able to confirm the exact number of charge cycles and whether the battery
has been correctly charged / stored from the information that is recorded in the battery
pack monitoring and control electronic circuit.
Information on Waste Disposal for Consumers of Electrical & Electronic Equipment
This mark on a product and/or accompanying documents indicates that when it is to be
disposed of, it must be treated as Waste Electrical & Electronic Equipment (WEEE).
Any WEEE marked waste products must not be mixed with general household waste, but
kept separate for the treatment, recovery and recycling of the materials used.
For proper treatment, recovery and recycling; please take all WEEE marked waste to
your Local Authority Civic waste site, where it will be accepted free of charge.
If all consumers dispose of Waste Electrical & Electronic Equipment correctly, they will be
helping to save valuable resources and preventing any potential negative effects upon
human health and the environment, of any hazardous materials that the waste may contain.

18
Please recycle your spent batteries.
Batteries should not be disposed of in unsorted municipal waste, but separately
collected to facilitate the correct treatment and recycling of the substances they
contain. The recycling of batteries ensures the recovery of these valuable materials and
prevents any potentially harmful effects upon both the environment and human health.
Please contribute to battery recycling by segregating all spent batteries and actively
participating in their collection and recycling. Various battery collection schemes will be in
operation in different areas of the country. However, battery collection bins will be available
at retail stores that sell batteries as well as at schools, libraries and other public buildings.