Falco e-motors Intelligent energy management system User manual

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Welcome to the exciting world of e-bikes. Thank you for Purchasing the Falco e-
motors intelligent energy management system. The Falco e-motor system is
adaptable, powerful, light, and allows regenerative energy capture to enhance your
riding experience with unparalleled control. Prepare for the ultimate e-motor
sensation.
Before installation, or your first ride, please spend a few minutes to read through
this manual to get acquainted with the features and functions of your new e-bike kit.
We are convinced this product will bring immense satisfaction and riding pleasure
for many years to come.
Welcome to the Falco family.
Sincerely,
Rakesh K Dhawan
President & CEO Falco e-Motors
North American Region:
Falco eMotors Inc
Washington DC
USA
Email:
[e-mail]
Phone: Toll Free USA [phone]
Fax: Toll Free USA [phone]
Asian Region:
Falco eMotors Pvt. Ltd
Pune, Maharashtra
India
Email:
[e-mail]
Phone: [phone]
Phone: [phone]
Phone: [phone]
European Region:
Falco eMotors
Fareham
Hampshire
UK
Email:
[e-mail]
Phone: [phone]

3
CONTENTS:
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Read all safety warnings and all instructions. Failure to follow the warnings and
instructions may result in electric shock, fire and/or serious injury. Save all safety
warnings and instructions for future reference. The term “battery pack” used in
these operating instructions refers both to standard battery packs (battery packs with
holder on the bike frame) and to rack-type battery packs (battery packs with holder
in the rear rack/carrier).
$
 Do not open the Hx e-motor/drive unit yourself. The Hx e-motor/drive unit is
maintenance-free and may be repaired only through a qualified repair person and
only using original spare parts. This will ensure that the safety of the drive unit is
maintained. Unauthorised opening of the Hx e-motor/drive unit will void any and
all warranty claims.
$
 All components mounted to the drive unit and all other components of the eBike
drive (e.g., the chainwheel, chainwheel seat, pedals) may be replaced only against
identical components or components specifically approved for your eBike by the
bicycle manufacturer. This protects the drive unit against overload and damage.
$
 Remove the battery pack from the eBike before working on the eBike (e.g.,
assembling, maintenance, etc.), transporting it via car or plane, or storing it. There
is a serious danger of injury when accidentally actuating the On/Off switch.
$
 Use only original Falco battery packs approved for your eBike by the
manufacturer. Using other battery packs can lead to injuries and pose a fire hazard.
When using other battery packs, Falco shall not assume any liability and warranty.
 Please observe all federal and state regulations on registering and using eBikes.
$
 Please read and observe the safety warnings and instructions enclosed in the
operating instructions of the battery pack as well as in the operating instructions of
your eBike.
$
 Do not open the battery pack. Danger of short-circuiting. Opening the battery
pack voids any and all warranty claims. Protect the battery pack against heat (e. g.,
also against continuous intense sunlight), fire and immersing into water. There is a
serious danger of explosion.

8
 Keep the battery pack not being used away from paper clips, coins, keys, nails,
screws or other small metal objects, that can make a connection from one terminal
to another. Shorting the battery-pack terminals together may cause burns or a fire.
For short-circuiting damage caused in this manner, any and all warranty claims
through Falco shall be invalid.
$
 Under abusive conditions, liquid may be ejected from the battery pack. Avoid
contact. If contact accidentally occurs, flush with water. If liquid contacts eyes,
additionally seek medical help. Liquid ejected from the battery pack may cause skin
irritations or burns.
$
 Vapours can escape in case of damage and improper use of the battery pack.
Provide for fresh air and seek medical attention in case of complaints. The vapours
can irritate the respiratory system.
$
 Charge the battery pack only with original Falco battery chargers. When using
non-original Falco chargers, the danger of fire cannot be excluded.
$
 Use the battery pack only together with eBikes that have an original Falco eBike
drive system. This is the only way to protect the battery pack against dangerous
overload.
$
 Use only original Falco battery packs approved for your eBike by the
manufacturer. Using other battery packs can lead to injuries and pose a fire hazard.
When using other battery packs, Falco shall not assume any liability and warranty.
$
 Please read and observe the safety warnings and instructions enclosed in the
operating instructions of the charger and drive unit/Console, as well as in the
operating instructions of your eBike.

9
5 MOTOR INSTALLATION
5.1 Included Components List
Wheel: Falco Hx Motor built into double skinned dimpled rim.
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+S/+83+&'+*$B@++($D)3(*+8"$O+$108-&<(I$8+'-..+&*$)13&<$;$*3./(+*$83.X$0@31$
;((-B1$b-8$;$108;3<@0$1/-M+$(3&+$;&*$.;S3.3d+1$1/-M+$(3b+"(
Battery Pack: Power supply for the Hx motor. Capacity will vary depending on
options taken.
Battery Carrier: Attaches to the frame of the bike. Holds battery in place and
transfers electrical energy between the battery and the motor.
Battery Charger: Mains charger for battery pack.
Wireless Transmitter (Dongle):
Z/03-&;($'-./-&+&0$b-8$)1+$B30@$B38+(+11$
'-&1-(+"$$
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Power Assist Sensor (PAS): PAS
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10
5.2 Tools Required
Spanners: 17mm, 10mm, 8mm
File
Allen Keys: 2,3,4,5,6mm
Pump
Torx Key: T25
Heat Gun/Hair Dryer
Side Cutters/Snips
>(;0$L(;*+$C'8+B*83F+$
C0;&(+I$V&3b+$
5.4 Installing the Motor
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1/8-'M+01$;&*$*31'$D8;M+$8-0-8"$
$

11
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12
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!
Tip:!If!the!axle!starts!to!
turn!in!drop4out!while!
tightening!axle!nuts,!it!can!
help!to!hold!the!axle!still!
with!a!10mm!spanner!on!
the!opposite!side!to!the!one!
you!are!tightening.!
]-0+c$C-.+$*8-/e-)01$@;F+$
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b)((I"

13
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!
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$
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'-&&+'0-8"$$O@+&$1+')8+*$083.$+S'+11$d3/$03+$.;0+83;("$
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Tip:!It!is!usually!best!to!attach!the!torque!“arm”!to!either!a!disc!brake!mount!or!
pannier!mount!hole.!

14
5 PAS & MAGNET RING INSTALLATION
5@+8+$;8+$.;&I$*3bb+8+&0$D-00-.$D8;'M+0$;&*$'8;&M$*+13<&1$-)0$0@+8+$1-$0@31$
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$
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1+&1-8$.-)&0+*$-&$0@+$LL$1@+(("$$
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15
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