Volto CROSS5 Series User manual

VOLTO ELECTRIC BICYCLE
USER MANUAL
CROSS5 Series
PLEASE READ CAREFULLY
NZ EBIKES 2016 Ltd
19 Esk Street
Parkvale
Tauranga
www.volto.co.nz

Safety Precautions
1) Don’t break traffic rules, follow the road rules
carefully.
2) Always wear a suitable helmet.
3) Always use your lights at night - be visible!
4) Don’t use your e-bike before reading the user
manual, or lend it to others who don’t know how to
operate it properly.
5) When you don’t use your e-bike, assure that the
power switch is off.
6) When raising the saddle don’t extend the seat post beyond the safety line.
7) Regularly check the performance of the brake pads and leave more time for
stopping by increasing the braking distance on rainy or
snowy days.
8) Make sure that the front hub is secured and the quick
release is properly tightened.
9) The tightening torques of the rear hub nuts are 30Nm.
Operation Guide and Precautions
RIDING THE ELECTRIC BYCYCLE:
To secure the battery box on the e-bike body, insert the key into the box lock,
press down on the upper cover of the battery box, turn the key clockwise for
about 180 degrees, and then remove the key after lockup.
Before riding, turn the battery on, a blue indicator in the button shows that the
power is on.
Please make yourself familiar with the display:
Safety line
Insert
Insert
Safety line

Turn the controller on by pressing the power button on the display for 1 second.
There are two riding modes:
1. PAS (pedal assist) and pedal only.
2. If you are using PAS mode, the motor will only operate while the pedals are
turning, and the motor will start after several turns of the pedals. When
using PAS level 0 the motor will not start and you can ride the bicycle as a
normal push bike.
While riding and using the motor, the battery indicator will change as power is
consumed. When the indicator shows that the battery is out of charge, use the
pedals instead. The battery can be used again once it has been re-charged.
Note: The battery level is best judged by the display status of the
indicator during the steady running at full speed.
The riding distance after each battery charge will vary according to factors like
road type, hills, user weight, and wind direction. When starting the e-bike uphill,
tackling repeated steep hills or riding upwind, it is better to assist the motor by
pedalling in order to save power, and extend the lifetime of the motor and
battery.
After use, turn off the power switch.
Human powered riding
Keep the PAS level on 0 (default when powered on). No motor support will be
engaged.
USING YOUR BATTERY CHARGER
Before using the charger, please read the manual, including the warning label on
the charger and battery pack.
Do not expose the charger to rainy, snowy or wet weather, or to low
temperatures (below 0℃) or high temperatures (above 35℃). These conditions
may destroy the inner parts of the charger and battery pack.

The charger can only be used with VOLTO rechargeable Lithium batteries and
rechargeable polymer batteries. Use with other types of batteries may cause
burns or fires.
When not charging, pull out the jack plug to prevent the plug and power wire
from being damaged.
Do not lengthen the power wire. Never undo the charger and battery pack wiring.
Incorrect wiring may cause electric shock or fire.
Using the charger with other accessories may cause fire, short circuit or injury.
If the battery or charger is damaged, don’t use it any longer. Take it to your
service centre to have it checked or repaired.
Make sure that the power plug is pulled out when cleaning and maintaining the
e-bike or battery to prevent electric shock.
Keep the power wire tidy so people do not trip over it or it is damaged by other
objects.
The charger and battery pack are designed to work together. Never use the
charger for batteries of power tools or other different types of battery pack. And
don’t use other chargers for the e-bike battery.
Do not store the battery in an environment which is above 50℃(eg in a metal
shed or in a car in summer). Exposure to high temperatures will reduce battery
life and performance.
Don’t throw the battery pack into the fire, it may cause an explosion. Please
always recycle old battery.
The INPUT and OUTPUT voltage details are marked on the rating label on the
charger. Please operate according to these specifications. Don’t insert the plug
into wrong voltage power point as this may destroy the charger.
Take care of the power lead. Don’t pull the power wire when holding the charger
or when pulling out the power point. Keep hot, oily, sharp objects away from
power wire.
Always charge the battery in a well ventilated location. Don’t cover the charger
with cloth or other objects.
Don’t make the battery pack short circuit, as this would create a high current
surge which may cause the battery pack to overheat or explode.
Don’t let inexperienced people use the charger without guidance or supervision.
Don’t let children play with the charger. Place the charger on a platform which is
at least 150cm high.
If the charger is not used for a long time, please put the charger and battery
together with the manual in the packing box, and store in a dry environment.
Charge the battery regularly every three month to prevent damage to
the battery during periods of none use.
WARNING: To ensure your safety, do not use your VOLTO charger for any
other battery pack or it may cause the battery to be destroyed or even
explode.

BATTERY CHARGING
Note: when the battery pack is first being charged, keep charging for ten hours until
the battery pack is fully charged.
To charge first firmly insert the charging jack into the battery pack.
Then insert the charger’s power plug into AC outlet. Then the red indicator light
on the charger will illuminate, showing that charging is in process. When the
plug is firstly inserted into the socket, a spark will sometimes occur if the power
point was not first switched off. This is normal and not dangerous.
During the charging process, the light on the charger will be red. It will turn
green when the battery pack is fully charged. Once the charging light is green
the charger will supply the battery with a small current.
The green light will remain illuminated when charging is over.
If a fully-charged battery pack is inserted into the charger again, the green light
will illuminate to indicate charging is complete.
CAUTION: When the battery pack is moved from a location where the
temperature is low (below 5℃)to a warmer location it is better to leave it for at
least one hour until the temperature of the battery pack is similar to room
temperature. Then charging can commence.
When holding the charger, never put your finger into the output hole of the
charger.
WARNING: * Never connect the charger directly to an unregulated
generator.
* Don’t open holes on the charger or battery pack.
* Keep away from explosive gas, flame or spark during the
charging process.
The Indicator Light (LED):
RED LED: A red light indicates that the charger is working to charge the battery
pack, and the current is on.
GREEN LED:A green light indicates that the battery pack is fully charged.
CAUTION
If the light is green, it means the battery is fully charged. Then the charger
will turn to constant low voltage charging status. Normally it takes about
5-10 hours to get the battery pack fully charged, with the actual time
varying depending on current supplied.
ATTENTION: The charging time should not be over 10 hours. If the battery
seems to take more than 10 hours to charge, have it and the charger
inspected.
Under the constant voltage charging state (when the light is green), the
battery will not be damaged even if it left connected to the charger, but it is
preferable to switch off the charger and disconnect it from the battery pack
once the battery pack is fully charged.
After charging is complete, please first pull out the power plug, and then pull
out the charger’s jack from the battery pack.

No matter how much or how little power was consumed during a trip, please
re-charge the battery promptly to preserve battery life. If the battery is not
used for a long time, store it when it’s full and charge it once a month.
During the charging process, the charger and battery box should be in a
stable position to prevent the falling over. Don’t cover the charger or battery
box or restrict ventilation.
When the life span of the battery is exhausted, return it to NZEBIKES for
replacement and recycling. Do not dispose of in domestic rubbish collection.
The old battery must be recycled.
Care and Maintenance
Before using your e-bike always check that the battery box is locked up, and the
battery level meter shows normal status.
Ensure the bike is clean and that there is no dirt or moisture in the plug
connecting the battery pack to the bicycle.
Regularly check tyre pressure so extend riding range and avoid punctures. We
recommend a pressure of 40 psi or 3 kPa for both tyres.
Regularly check that the brakes are working properly.
As with non-electric bikes, regular mechanical driving and safety checks are
required.
Your e-bike can work normally on a flooded road if the water depth is lower than
the lowest part of wheel hub. Do not immerse your e-bike in water above the
hub or above the level of the battery or these units will be damaged.
Keep the bicycle body away from the moisture, high temperature and toxic
gases to avoid chemical corrosion on the electroplated surfaces of metal parts.
Avoid prolonged exposure to direct sunshine or rain so as to avoid damage to
the parts inside the control unit or cause accidents due to other component
malfunctions.
Don’t try to reassemble or repair a complex structure in the electrical control
unit by yourself.
It is normal that the bicycle feels much heavier when pushed backwards. It is
also normal for the wheel hub to make a slight friction sound as it runs forward.
To avoid damage to the battery or electric motor do not overload the e-bike
(including by carrying objects or people of excess weight).
Lubrication is an important item in the maintenance of the electrical bicycle.
According to your pattern of usage, scrub and lubricate (preferably with
specialised bicycle lubricant) once or twice a year all moving parts such as the
front, back and middle axles, chain ring, and front fork. Special lubricating oil
has been smeared on the driving components inside electrical wheel hub, so it
is unnecessary to do scrubbing and lubricating yourself. Take your e-bike to
your service centre if you find an unusual situation.

Maintenance on the brake system
The hydraulic brakes usually do not need any maintenance.
When brake pads are worn they can be easily replaced.
Check both brake levers as shown in Fig1. It should reach
full braking when its stroke reaches 1/2X. If the lever goes
further the brake needs a hydraulic bleeding. Please ask your local bike shop to do
this work for you if you are not familiar with the process.
For further adjustments and maintenance please refer to the Shimano Maintenance
Manual.
Maintenance on the gear system
The Cross5 has a Shimano Alivio 8 gear system at
the rear wheel and a 3 gear Alivio system at the
crank. It can happen after a while that gears do not
perfectly change anymore or you experience a
rattling noise while peddling. This is normal due to
the nature of the used control wire which gets stretched over time. To re-adjust it
usually enough to slight tighten the gear wires. Turn (A) clockwise while turning the
pedal till the rattle goes away –otherwise turn counter-clockwise.
Troubleshooting
Problem
Trouble Description
Causes
Solution
The power indicator is
not on and the bicycle
doesn’t start when the
switch is turned on.
Poor contact of the
electrodes of the battery
box or battery seat.
Check for dirt on the electrodes
of the battery box or seat, and
remove it.
After the switch has
been turned on, the
power indicator is on
but the bicycle doesn’t
start
Check whether the plug at
the outlet of the battery is
properly inserted or in
poor contact.
1. Press the plug tightly to
ensure it is locked in places.
2. If the above solution has no
effect, check whether the
conductive core inside the
cable is loose. If it is replace
it.
The motor immediately
starts running once the
switch is on. (Note:
immediately turn off the
switch to avoid
accident.)
The throttle is not
reset.
The controller is
damaged.
Check whether the throttle
is jammed. If so, release it.
Replace the controller.
Slow speed, and the
riding distance after
each charge is short.
The tyres are not
inflated enough.
Frequent uphill
starting, or climbing,
or riding against the
wind
Battery capacity is in
Inflate the tyres.
Pedal at the start or while
climbing.
Replace the old battery with
a new one.
X

reduced.
The green power
indicator is not on after
the charger is
connected to a power
supply
AC outlet has no
power.
Input 2A fuse inside
the charger is fused.
Check another appliance to
test if the outlet has power;
or connect the charger to
another outlet.
Undo the 4 screws at the
bottom of the charger, open
the upper cover, and replace
the 2A fuse which lies close
to the transformer
If the above steps are not
effective take the charger to
your service centre.
Green power indicator
on the charger is on,
and the red one is
always on, but
unrelated with charging
status.
5A output fuse inside
the charger is fused.
The charging plug seat
inside the battery box
is in poor contact.
The fuse of the box
(15A) is fused.
Open the upper cover of the
charger, and replace the 5A
fuse which lies away from
the transformer.
Repeatedly insert and pull
out the charging plug to
ensure good contact.
Replace the fuse of the
battery box.
If the above steps are not
effective take the charger to
your service centre.
IMPORTANT!
●The figures in this manual are used only for the purpose of explanation and
showing the operation, not as criteria to examine the products.
●Our company has the right to change some modifications for higher performance
without further notice.
"WARNING - In the interests of safety it is recommended that you have
this cycle assembled and serviced by a skilled mechanic."
Declaration of Conformity:
This bicycle meets the AS/NZS 1927:2010 Standard for Pedal Bicycles
For further information visit
www.volto.co.nz