GEEKAY PMDC User manual

BICYCLE ELECTRIC CONVERSION
PMDC SIDE MOTOR KIT
(USER MANUAL)
TABLE OF CONTENT
Disclaimer
What's In the Box
Maintenance
Troubleshooting
Warranty
Warranty terms and conditions
Enhance Your Technical Knowledge
Safety of Use
Contact Us
03
04-05
06
07-11
07
08
09
10
11
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PAGE NO.

DISCLAIMER
The GEEKAY PMDC side Motor Kit is supplied as a set of do-it-yourself parts for the user
to install on their bicycle. Because this kit is installed, maintained and operated by the
purchaser, Rajesh Enterprises disclaims any responsibility for injury, damage or other
consequences arising from the use of this product. Each installation will be different and
therefore it is the responsibility of the purchaser to determine the best way to install the kit
on their particular bicycle. The following instructions should be considered as general
guidelines only – your installation will be slightly different.
If you do not have the mechanical ability to correctly and safely install this kit, you should
obtain the services of a professional bicycle shop or other qualified technician. Installation
and use of this kit will create a vehicle that has exposed moving parts, electrical
connections and high powered batteries.
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WHAT’S IN THE BOX
CONGRATULATIONS ON GETTING ONE OF THE MOST EXCITING PRODUCTS IN
THE MARKET. YOUR BOX INCLUDES THE FOLLOWING ITEMS:
24V 250W PMDC SIDE MOTOR (PIC)
1
GEEKAY has Geared PMDC Motor Systems which are the most
Trusted & Powerful E Bike Systems Currently in the Market with
all top of the Line Features & Excellent Fits.
CONTROLLER (PIC)
2
This is the Brain of the E-bike & Controls all the functions of
your Electric Bicycle. different Models of Kits & Eco Bikes have
different Controllers which are specially designed keeping In
Mind the required usage & Performance of Each Model.
WIRES
3
GEEKAY wires come with IP65 level water & Dust Protection &
are rain & Splash Proof. Wires are High Quality Copper and
ensure minimum power loss and Boost Overall Efficiency.
FULL THROTTLE GRIP
4
All GEEKAY Electric products have full Throttle which gives you
extra power & Activates the Motor Proportionally to the twist no
matter whether you pedal or not to give you a fully Electric Ride
in case you cannot Pedal or need an Instant Acceleration or
uphill push. Full Throttle is much more Convenient to use rather
than thumb or half Throttle.
LIGHT WITH INBUILT HORN AND KEY
5
GEEKAY Kits comes with High Power Led lights with built in
Horn & ON/Off Key for Rider Safety & Convenience.
POWERFUL MAGNET PEDAL ASSIST (PAS)
6
A pedal assist sensor (PAS) signals the controller to run the
motor providing a boost to your pedalling depending on the level
of assist you select while riding.
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ALLOY BRAKE LEVER WITH AUTO MOTOR CUTOFF SENSORS
7
GEEKAY Electric conversion kits come with alloy brake levers
with cut-off sensors. They cut off the power to the motor
whenever the brake levers are squeezed. It is a double safety
feature for panic stops and ensures that the motor is not
harmed while braking.
HIGH QUALITY PARTS
8
GEEKAY electric conversion kits come with 78 link chain, 18T
left thread free wheel & also 36 or 40 hole double thread hub.
BATTERY & CHARGER (OPTIONAL)
9
Geekay Battery chargers are smart CC-CV chargers and will
automatically disconnect after the battery is fully charged. You
can leave them plugged overnight with confidence and they will
cut off when the battery is fully charged.
ADDITIONAL NOTES ON THE INSTALLATION
VIBRATION
The motor and components can at times be under quite a lot of load which can result in
mild vibrations when accelerating or going up an incline. If there is a loose nut or bolt
anywhere on the bike, quite often that can increase the moderate motor vibration into an
almighty drone of a vibration, giving the rider the impression that the bike is about to come
apart. If this happens to you, you have to look for anything that could be loose. If there’s
something wrong with a component on the kit (like a motor) it won’t be that subtle
Note:-These kits are designed to be installed at home without any special tools or
expertise. However, in some cases, certain bike models require additional knowledge and
skill. You may contact us anytime if you need any guidance or assistance.
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MAINTENNANCE
Just like any regular bicycle, your electric bike is going to need routine maintenance.
However, don’t be put off by the bike’s electrical components as they actually don't require
any maintenance – it’s the tires, the brakes, and the wheels that need to be maintained by
an Experienced Bike or E-Bike Mechanic.
Geekay Dealerships will ensure that before you buy, your bike is in tip-top shape from the
moment you take it out of the store. This is especially important for E bikes as they need
to be set up correctly to function properly. To get the longest life possible out of your
E-bike you can take some simple steps to maintain it yourself or you can take it to an
experienced dealer.
KEEP YOUR E-BIKE CLEAN IF POSSIBLE
Ideally, clean your ebike after each ride, especially after riding it through mud or dirt. You
should use a sponge with bike specific cleaners to gently wipe the parts down. Do not use
a hose or any kind of pressure washing as this can wash out grease lubricating the
bearings. It will also force water into the internal components which in turn will corrode
and destroy the electric parts.
KEEP THE TIRES PROPERLY INFLATED
It’s important to check your tire pressure at least once a week. You can use a tire pressure
gauge or the manual method of pushing down on the tire with your thumb. If the tire is
underinflated, it can lead to uneven tire wear and burn the battery too quickly. It will also
make your life easier as the bike will be easier and more fun to handle with less resistance.
Of course, you want to ensure that you don’t over inflate your tires as they will pop/ burst.
Be sure to check the correct pressure which is usually printed on the side of the tire.
CHECK THE BRAKE PADS
Keep an eye on the brake pads about once a month to see how much worn they are. If you
realize there is a lot of wear and tear then it is probably time to replace them. When you
start to ride, you always want to test out e-bike brakes to make sure they are in good
working order, especially if you haven’t ridden for a while. It’s essential that you have
effective brakes or else you could end up in a serious accident. Brake pads can be easy
and cheap to replace whenever needed so you don’t need to worry about spending money.
(06)

THE TABLE BELOW IS BY NO MEANS A COMPREHENSIVE TROUBLESHOOTING GUIDE,
BUT RATHER A GENERAL GUIDE FOR THE MOST COMMON ISSUES. EACH PROBLEM
MUST BE LOOKED AT ON A CASE BY CASE BASIS
TROUBLESHOOTING
Fully charge battery
The battery performs best
with a payload less than 80Kg.
Make sure you combine
throttle power with manual
pedaling.
Ensure motor hall wires are
connected properly to the
controller.
Ask your dealer to fit another
motor and test the speed.
Low battery capacity
Battery overloaded
Hall wires loose
Damage to motor
Speed is too slow
(less than 6Km/Hr)
PROBLEMS POSSIBLE REASONS CORRECTIVE ACTION
11
2 2
33
4
4
Check battery connection
Open controller plastic box
and check connection.
Check if you get a drive using
pedal assist. If there is a drive,
check the throttle connection
to the controller. Contact your
dealer for replacement of the
throttle if damaged.
If none of the above worked,
ask your dealer to fit a new
controller and check the
difference.
As a last resort, ask your
dealer to fit a new motor to
verify whether your old motor
is damaged.
Battery unplugged
Motor unplugged from
controller
Throttle damaged or
unplugged from controller
Controller damaged
Motor damaged
No drive from motor 1 1
2 2
33
4
44
5
5
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Pump air in the tires.
Recondition the battery by
charging it for 12 hours and
using it until completely
drained. Repeat 3 times.
Try to avoid running on
throttle only as the battery
power is meant to be
combined with manual
pedaling to avoid overloading
Ask your dealer to charge your
battery with a new charger to
verify if there is any
difference.
Replace battery.
Tyre pressure too low
Undercharged battery
Hill climbing, frequent stops,
head wind, overloading
Fault with charger
Battery capacity loss
Driving range is very low.
I.e. less than 10km
11
2 2
33
4
4
5
5
Do a thorough check from
battery power lines to the
controller and all other
connectors.
Turn battery on using the
on/off switch on the battery
(some models)
See if battery charge indicator
LEDs light up.
Try charging the battery.
Try turning on the system
when charger is plugged in.
Try turning off the battery hold
5 seconds then turn on.
Check out battery fuse (only in
Li ion battery).
Inspect battery for any sign of
impact, moisture penetration,
etc.
Check out battery voltage
right at the battery output
port.
Connections are not
completed
Battery is turned off
Battery is dead
System does not turn on 1 1
22
33
PROBLEMS POSSIBLE REASONS CORRECTIVE ACTION
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Check out battery voltage at
controller power input plugs.
Contact your local dealer or
Geekay customer service with
the report of the above tests
for battery repair or
replacement.
Check out related cables and
connectors at handlebar.
Check out related cables and
connectors at controller side.
Visual inspection of the
display and motor controller
for visible sign of damage.
Contact Geekay customer
service for service/solution.
Check out battery connections
to controller.
Check out battery voltage at
controller input plugs.
Visual check of all
connections and parts.
Contact Geekay customer
service for service/solution.
Front Light or keypad issues
Motor controller issues
Driving range is very low.
I.e. less than 10km
PROBLEMS POSSIBLE REASONS CORRECTIVE ACTION
4
4
5
5
Battery indicator delays
updating the recent charge
status. Above 41V for 36V
nominal systems is
considered full
Green LED may turn on when
the charger is plugged to the
battery only without being
connected to the wall. Try
different wall plugs.
Try different charger cable
cords.
Unplug charger from electric
socket, connect charger to
battery first then plug the
charger to the electric socket.
Battery is already full
Charger does not function
Battery does not charge
up with standard charger
11
2
2
(09)

The brake levers are not
properly installed or adjusted.
To let the system rub, unplug
the brake sensors from the
main controller. Test the
motor, then try re-installing or
re-adjusting the brake sensors
one connected at a time.
The brake cut-off might have
problem
The system is on, but
motor is not running
using both throttle or
pedal assist
PROBLEMS POSSIBLE REASONS CORRECTIVE ACTION
Throttle has connection or
other issues
When using throttle nothing
changes
The system is on, motor
is not running using
throttle but works with
pedal assist
11
11
Check wires and connections.
Check magnet disk working
surface.
Make sure magnet disk is
spinning together with crank
and not loose.
Check gap and spacing
between little magnets and
PAS sensor head.
Sensor should be aligned
radial to the magnet disk (not
angled or tangential to disk).
In case of water or salt water
penetration clean and dry the
sensor. Sensor might be
broken and needs
replacement.
PAS sensor disconnected
PAS sensor does not work
when spinning the crank
forward
The system is on, motor
is not running using pedal
assist but with Throttle
1
1
22
Fix it in place using epoxy or
flexible heat or silicon glue.
Align the disk with the sensor.
PAS magnet disk on the crank
is loose or wobbling.
Motor works on and off
while pedaling, but fine
when using throttle
11
Needs parts replacement.Keypad or display issue.System works but cannot
change anything on the
display
11
Needs parts replacement.Display LCD issue (some
models)
System works but cannot
read anything on the
display.
11
(10)

No action.
Try adjusting and fixing loose
parts which cause vibration
Normal when motor is loaded
on hills.
Motor normal vibration is
causing resonance on other
bicycle components such as
disk brake rotor, fenders, etc
Motor making extra noise
PROBLEMS POSSIBLE REASONS CORRECTIVE ACTION
If more, try making some
ventilation or wait to cool
down. Check if any parts
makes friction and puts extra
load on controller
Normal up to 70 Degree
Celsius.
Controller getting too hot
when riding long on hills.
11
11
22
Replace the bullet connector.
Crimp properly and make sure
the connector will stay fully
connected.
Loose connectivity cause
sparks which fries and melt
the connector.
Controller power bullet
connectors are melted.
11
Give the charger space to
dissipate heat.
NormalCharger gets hot. 11
(11)

WARRANTY
All Geekay components are made of the highest quality parameters. Our motor &
controller are covered by a 6 month free warranty against the manufacturer's defect only.
All our components are tested under rigorous environments to provide you with the
highest quality products. If the problem is caused by an accident, wrong or careless
installation by the customer, careless actions, wire stretch, bad storage or not following
the instruction manual, the customer will pay the cost of the part and replacement. The
cause of the failure will be recognized by our experts. Please read our warranty
terms and conditions.
Geekay Dealerships will ensure that before you buy, your bike is in tip-top shape from the
moment you take it out of the store. This is especially important for E bikes as they need
to be set up correctly to function properly. To get the longest life possible out of your
E-bike you can take some simple steps to maintain it yourself or you can take it to an
experienced dealer.
WARRANTY TERMS AND CONDITIONS
All Geekay components are tested under rigorous environments to provide you with the
highest quality products. Geekay Motor, controller, battery and charger are covered by 6
month free warranty against manufacturer's defects only. The cause of the failure will be
recognized by our experts.
THE GEEKAY WARRANTY COVERS THE FULL WARRANTY PERIOD FOR ALL PARTS OF THE
ELECTRIC CONVERSION SYSTEMS TO THE FIRST OWNER, WITHIN THE FRAMEWORK OF
THE FOLLOWING CONDITIONS:
This warranty exclusively covers Geekay Electric conversion kit components provided by
Rajesh Enterprises or its registered dealers and there is a proof of purchase of the product
This warranty covers the repair and/or the replacement of components.
This warranty only covers material and manufacturing defects.
Costs for repair work performed in advance by persons who have not been authorized by
Rajesh Enterprises will not be reimbursed. In such a case, any warranty claim will cease.
The warranty period starts with the date of purchase. Warranty claims must be reported
immediately.
If the battery pack does not provide full capacity in the course of normal use or for
batteries going through a normal aging process or reduction of performance, Geekay
warranty covers that within the warranty period if the capacity proved to be less than 70%
of Initial condition.
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No warranty claims are accepted in the case of damages due to the following:
External influences, particularly falling rocks, collision, accident and other external events
with an immediate external effect due to mechanical powers.
Purposeful and/or malevolent acts, theft and robbery as well as natural hazard events and/or
acts of mischief.
Inappropriate use, e.g. the product was exposed to liquids, chemicals of any type and/or
extreme temperatures, wetness and humidity and/or if the battery suffers damages due to
non-compliance with instructions.
Overcharging the battery or not adhering to the instructions of battery handling.
a)
b)
c)
d)
No warranty claims are accepted
In the case of test, maintenance, repair and replacement work due to normal use.
If the model, serial or product number on Geekay product has been changed, deleted, blurred
or removed
In the case of use of the battery in systems that are not approved for such use with this
particular product.
In the case of the operation of the Geekay electric systems with batteries other than the
batteries designed for the Geekay system (refer to user manual).
a)
b)
c)
d)
If one or more than one Geekay component has been opened, altered or repaintede)
This warranty only covers the mentioned repair work and/or the replacement of defective
or compromised components. It excludes any claims as to the reimbursement of property
damages, downtimes and expenses for renting or leasing equipment, travel expenses, lost
profit or any other claims. Rajesh Enterprises liability in connection with this warranty is
limited to the respective acquisition value of the product. This warranty only covers
original Geekay components. The use of spare parts from unknown sources, for example,
replacement parts from third parties, is strictly prohibited. Warranty will be voided on any
system on which it will be concluded that there has been any case of modification or
tampering with firmware.
RETURN & EXCHANGE
There are terms and conditions applied to return or exchange of products. All parts shall
be unused, undamaged, un-scratched, clean and resell-able to be eligible for a
return and full refund.
Packing and shipping expenses including any labor involved in the customized order are
not refundable. You need to inform us prior to any shipment. Customers will take shipping
costs for both directions; unless the buyer makes a good case with proof of Geekay’s
mistakes. Note that the colour of parts may be different than in pictures, e.g. silver or
black motor, rack, battery, etc.
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REPAIRS
Contact us and explain the problem with our experts. It might be resolved through a
telephone discussion or email instructions provided to you. Sometimes something as
simple as a loose connection or bad adjustment can cause failure.
If there is a broken part that you have recognized yourself or with the help of our
technician, we will simply send you the right part and you can replace it yourself.
Our experts will help you find the fastest and most cost-efficient way to have your ebike
working again. This is done through our service strategy:
Fast reply to your inquiry and question.
Probing deep into the causes and reasons and fault diagnosis on call or online.
Educating you about the problem.
a)
b)
c)
Replacing only the defective parts, not the whole pack.
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ENHANCE YOUR
TECHNICAL KNOWLEDGE
COST OF POWER
The average power consumption is about 1KWh/100km. taking 1KWh Rs 8 then the power
cost of 100km will be about Rs 8.
GEEKAY ELECTRIC CONVERSION PMDC SIDE MOTOR KIT MAINTENANCE
No maintenance is required for Geekay electric Conversion PMDC side Motor Kits other than
simple physical protections and keeping batteries fully charged after each use.
USING ECO BIKE OR GEEKAY CONVERSION KITS IN RAIN
Our products have a water protection rating of IP65. The system is rain proof, good to go in
rain, however no water jet and no parking or storing uncovered in rain.
HELMET USAGE
Always wear an approved helmet and ensure it fits according to the manufacturers’
instructions. Most serious bicycle injuries involve head injuries, which might have been
avoided if the rider had worn an appropriate helmet. FAILURE to wear a helmet when riding
may result in serious injury or death.
WEIGHT CAPACITY
Geekay Electric Bike systems are designed with a maximum weight capacity of 150Kgs on
the motor.
axle when evenly distributed between two-wheel axles. Exceeding the maximum weight
capacity can result in damage to the bike, which can lead to serious injury or death.
However, the bicycle's weight carrying load capacity ranges from 80 kgs to 200 kgs.
Choose Geekay Bikes to get most from your electric conversion kits.
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SAFETY OF USE
Once again we thank-you for choosing Geekay quality products. Our number one focus is
to make you aware of the dangers of riding a bicycle and especially an electric bicycle so
you can ensure you have safe and enjoyable riding experiences for years to come.
Please read this manual in its entirety before riding your bike or allowing anyone else to
ride your bike. All others should read this manual before you allow them to ride your bike
without your supervision. If you have any concerns, questions or suggestions about your
electric bike, please contact us at [e-mail].
IMPORTANT:
THIS MANUAL IS NOT INTENDED AS A DETAILED USER, SERVICE, REPAIR OR
MAINTENANCE MANUAL. PLEASE SEEK ASSISTANCE FROM A QUALIFIED TECHNICIAN
FOR SERVICE, REPAIRS OR MAINTENANCE. YOUR INSURANCE POLICIES MAY NOT
PROVIDE COVERAGE FOR ACCIDENTS INVOLVING THE USE OF THIS BICYCLE. TO
DETERMINE IF COVERAGE IS PROVIDED YOU SHOULD CONTACT YOUR INSURANCE
COMPANY OR AGENT. DO NOT DISASSEMBLE, MODIFY OR REPLACE ELECTRICAL PARTS.
PLEASE NOTE:
This manual contains many “Warnings” and “Cautions” concerning the consequences of
failure to maintain or inspect your bicycle and of failure to follow safe cycling practices.
The Caution symbol can be seen throughout this Manual, and indicates a potentially
hazardous situation which, if not avoided, could result in serious injury or death, or is an
alert against unsafe practices.
Many of the Warnings and Cautions say, “You may lose control and fall.” Because any fall
can result in serious injury or even death, we do not always repeat the warning of possible
injury or death, and if we do not, please assume this is the case, as all bicycles, including
electric bikes, are dangerous and their safe use requires constant and consistent
maintenance and care.
Please ensure that prior to each and every ride (without exception), each electric bike rider
reviews the safety requirements enumerated throughout this Manual, and if any problems
are observed, they should be resolved prior to use. Because it is impossible to anticipate
every situation or condition which can occur while riding, this Manual makes no
representation about the safe use of this Electric Bike under all conditions.
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There are risks associated with the use of any bicycle which cannot be predicted or
avoided, and which may be caused and/or prevented through the actions of the rider, and
which are the sole responsibility of the rider. You should save this Manual along with any
other documents that were included with your bicycle purchase for future reference. All
content in this Manual is subject to change or withdrawal without notice. Visit
https://www.geekaybikes.com to download the latest version. Rajesh Enterprises assumes
no responsibility or liability for any errors or inaccuracies that may inadvertently appear
herein.
In India, electric bikes are defined as “a two- or three wheeled vehicle with fully operable
pedals and an electric motor of less than 250 watts with maximum speed of 25Km/hr."
LEGALITY
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CONTACT US
Customer Care :- [phone]
Email:- [email protected]
Rajesh Enterprises
B XXIX 92/1C/4, BMS Nagar, St no 2.5, Daba Road
Ludhiana 141003, PB, India
www.geekaybikes.com
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Since 1961