Installation Guide()
Contents
1. Iden Motor eBikesDaiAVAW Sens lanu l MastUpaacer 00 072009 KOKOA Motori www goldenmotor com Contents Gel UNC Tyee ee Maen Lool Si ooo ETS oo TSG aT Preparing the Back ecl N N Installing the Handle bar Components Controller Configuration RR ee eee e eee eeee Installation of the controller and battery ee N Power Cord 1InstallatlOon ewes With sliding rack and black controller box LED Lights Circuit Diagram cece eee Solution Diagram for Regen Braking Getting started First open up the box and lay out the contents inside Check that you have 1 A motorized wheel 2 A controller set Ce a a 17 ay a Fi 3 0 gt a L 5 5 3 i H p 1 1 hy Pi ji w 0 1 EN ar j IE 5 ur Ne F 7 Se Fi d 1 E Mi i re ee ry 2 4 Ri 57 1 1 h 2 Optional items 1 Battery Pack with adapter 2 Sliding Rack 3 Cruise Horn Controller Note Check for any damage on the items Lay out the items on the floor of your garage and move on to the next pages to start building your eBike Tools needed for making your eBike Basic Tools List P Atleast 6 Zip Ties For holding wires firmly to your bicycle frame Q 3 Allen Wrench w2. Note Make sure that you secure the throttle onto the bar tightly Note The red button on the throttle is a switch for you to connect to a lamp 1f you have one on your bike or you can use it for other purposes 11 2B Installing the Twist Throttle Right Side d I 3 Slot the Twist throttle into the right side of the bar and get a feel of twisting the throttle When you feel comfortable with the position use the 3 0mm Allen Wrench and secure it into place 3 Installing the Hand Brakes Slot your hand brakes into both sides of the steering bar Place your hand on the bar and find the position you feel most comfortable with pressing the brake and then use a 5 0mm Allen Wrench and secure it into place Safety Note Make sure the brake is secured tightly as a loose brake may lead to an accident Finally push the plastic handle bars into the metal steering bar tightly and make sure it is pushed in all the way Note This Hand Brake cuts off power supply to the motor and activates the mechanical brake simultaneously You are now done with the handle bars 12 Controller MX 48C EB D_ MTT E 0 9 0 2 0 8 agrar em E Your E looks something like this Notice that the controller has 5 single connectors labeled A B C D and E and 4 pin connectors labeled W X Y and Z Usually the controller comes with wires already
3. can work brushless motors with different phase angles other than defaulted 120 degree Below are procedures to allow the controller to match the motor phases Cut off power to controller and motor Grip and hold power brake lever turn throttle to maximum speed position press and hold the cruise control button turn on the power switch using battery key Connect battery power to the system release throttle release brake lever release cruise control button Listen for two beep sounds then turn the motor wheel forward and reverse once When you hear a beep sound motor phase calibrating 15 successful If it fails swap any two of the three motor phase wires and repeat the above Steps 19 4 Installation of the Controller and Battery 1 Controller Box Place the controller into the box and secure it with tape or screws Note Controller boxes will be on sale in June 2009 on the GM website Safety Note Make sure you secure the components in the box properly 2 Sliding Rack Fix your Sliding rack onto your bicycle However do not tighten the screws as we need to put in the controller box later Note These frames are purchasable at the Golden Motor website under the category eBike D LY Note Make sure your box can fit onto the sliding rack 20 3 Wire binding Bind the wires using Zip Ties in a way such that it does not restrict the movement of the steering bar Fi
4. connected to the connectors If otherwise the following will tell you more information about the wires The following picture shows how a completely connected controller should look like MX 48C EB D TOUT TU Tas 09020018 7 f 13 Information of your Controller 1 Four Single wires Black Green Light Blue and Yellow 2 One 12 hole pin connector with the thicker Red wire connected to a Single Red Wire labeled with a Positive Sign 3 One 5 hole pin connector 4 One 2 hole dual red wire pin connector Connecting Wires Photos show connection before installing but you should make these connections after installing the components 1 The Wheel and Motor Single out the Yellow Light Blue Green Single wires and the 5 hole Pin connector of your Controller Find the 3 hole Pin connector Green Blue and Yellow Single Wires of your Motor Safety note Make sure you hear a Click sound when you connect the pin connectors 14 2 The Horn Take the Horn and connect it to the 2 hole pin connector 3 The Battery Take your controller and plug in the Black Single Wire and the Red Single Wire The outer ends of these 2 wires should have been labeled with positive or negative signs Take the Battery Pack s wires and connect them accordingly Safety note Make sure that you have connected the wires correctly before turning on the power If unsure use a Voltmeter to confirm the
5. d hold the cruise control button to drive your bike at half the maximum speed The controller will automatically return to its original status when the problem 1s resolved Unknown malfunctions If your eBike fails to move and the cause 15 unknown or if your battery 15 low you can force your eBike to work While squeezing the power brakes press the cruise control button five times and if you hear the honk from your horn press and hold the cruise control button again and you can drive your bike at half speed You will need to turn off the battery power to reset the controller back to normal mode after the problem is resolved Anti theft alarm setting Cut off power supply to motor called soft switch but controller is still powered on and take out the battery key within 10 seconds press and hold the cruise control button until you hear a beep sound then release the cruise control button The vehicle is now protected from theft and the motor is electronically locked Any movement or vibration of vehicle will trigger the siren for 30 seconds and the motorized wheel will resist any pedaling movement 1 1 Pedal Assist Mode Release the throttle to its neutral position during riding press cruise speed controller button twice listen a beep sound the system enters into pedelec PAS mode Cut off power supply to the controller to reset this system Motor phase Calibrating Use it only if your motor is not from GoldenMotor The controller
6. e Pedelec function is made this way so that only intentional use 15 allowed for safety reasons Wiring Information For more detailed information please visit this website link http goldenmotor com e Bike DIY Cruise 20Controller 20Wiring 20Diagram pdf How to Enable Disable these Functions Features 1 Cruise speed control Pressing the cruise control button will make your eBike maintain the speed you are currently at Squeezing the brakes or pressing the cruise control button again will disable it 2 Motor hall sensor malfunctions When the controller detects a motor hall sensor failure 1t will beep twice before automatically entering into sensor independent control mode Twist press the throttle to run the motor and pedal your bike for a push start if the motor does not operate This malfunction seldom happens in a state of sensor independent control status 3 Throttle malfunctions When the throttle fails to function correctly the controller will beep three times In this situation press and hold the cruise control button to drive your bike at half the maximum speed The controller will automatically return to its original status when the problem is resolved 18 Power brake lever malfunction If the power brakes level malfunctions 1 e disconnected from the controller twist press the throttle repeatedly for at least four times The controller will then beep four times if this malfunction is detected Similarly press an
7. ext place one edge of the outer tire into the rim bedding Turn the wheel around and fit the inner tubing s gas valve into the opening of the wheel s rim Stuff the rest of the inner tubing in between the rim and the outer tubing and you re done assembling the wheel Important Note Please choose an inner tube with a longer valve as Golden Motor rims are double walled The rims are double walled to be able to withstand the powerful torque from the motor 5 hi 1 1 Place the wheel axles into the mount in your bike frame Push down on the bike frame to make sure that the wheel axle is locked tightly into the frame Tighten the bolts make sure it is very tight This is for safety reasons and this is a very crucial step to build a good eBike The torque of the motor is very powerful which is why you must make sure the bolts are tight enough to handle it In order for you to remember this important step we ve even made a nice little poem read it below and we hope that this will help you remember this every time you build an eBike Important GoldenMotor Poem Tighten the bolts with all your might Make sure the wheel is secured and tight The entire back wheel 15 not very light Double check both the bolts on each side If anything falls off while you ride It won t be a very pleasant sight Installing the Handle Bars Components IMPORTANT Make sure your handle bar diameter is 22mm 1 Installing the Cr
8. ith diameters 2 5mm 3 0mm 6 0mm R Adjustable wrench S Philip Screwdriver Optional List 1 Gear removing tools 2 Washers 3 Wire binders 4 Hammer Preparing the Back Wheel includes Gear and Disc Brake 1 Remove the gear cluster from your old back wheel Use a Gear Removing Tool to remove the Gear from your back wheel Note The gear removing tool can be found in your local Bike Shops 2 Installing the Disc Brake Note Please confirm your Disc Brake diameter 140mm or 160mm In most cases 140mm Disc Brakes are for the back wheel whilst 160mm are for the front wheel Twist the Disc Brake Plate into position Make sure you insert a Disc Brake Plate Tube into the axle Safety Note The Disc Brake Plate Tube holds the disc brake in position It is a very important component in the Disc Brake System Important Note Usually the position of the Disc Brake is to the left of the direction your wheel is travelling 1 e The disc brake should be installed on the side where the Motor Wiring protrudes Note Use Washers to adjust the vertical alignment of the disc brake 3 Installing the Gear Cluster Take your preferred Gear Cluster and twist it onto the other side of the Motor TA f gt 72 Note Golden Motor Wheels supports most of 3 to 6 speed gear clusters 4 Installing the Tires First confirm the direction of the thread pattern of your tire N
9. nd ways to lock all the wires onto your bicycle frame such that they are not very visible Also secure the brake threads to your front and back brakes accordingly Note As a suggestion after you bind your wires rotate your bike handles to see if the movement is smooth 4 Connecting the wires to your controller Refer to the guide on the Controller and connect your wires to the controller accordingly 21 Use Zip Ties or anything else you prefer to secure the controller box onto the sliding 5 M Note You can place the controller box wherever you feel like as long as the wires are long enough to connect to it 5 Battery placement Slide the battery pack onto the sliding rack with the battery s handle bar facing backwards Plug the cable in but do not twist the key Proceed to the final 7 checklist before testing your bike iy Safety note Make sure the battery is turned off before you even plug in the power cable 22 6 Finishing the fight Checklist Turn off the battery 1 Wheel is secured in place 2 Back wheel is vertically aligned with front wheel 3 Wheel has no loose parts 4 All components on the handle bar have been secured tightly 5 You are comfortable with the throttle brakes etc 6 The handle bar is able to rotate freely 7 The mechanical brakes work properly 8 The battery cannot slide off without unlocking it 9 Check that the battery pole
10. poles are correct It is IMPORTANT to connect them correctly as a short circuit may occur Disclaimer GoldenMotor will not be responsible for any damage caused to the controller if a short circuit occurs 15 4 The Throttle My me l 5 l 3 4 gt Take the throttle wire and single out the 3 hole pin connector Take the 3 hole pin connector Blue Black Red from the controller area Z and plug them together Colder Safety Note Make sure you hear a Click sound when you connect them If not your motor would not work 16 5 The Brakes Find the 2 pin connector Black and White wires from area Z and plug it into the Brake wire a 5855 tee AM 9 8 a2 53 5 55 Note This brake does not control the disc brakes on your wheel it only cuts out the power supply to the motor You would have to connect this brake to your disc brake manually By squeezing the brake the controller enters regenerative braking mode for smooth stopping 6 Cruise Speed Control Find the 2 hole pin connector Beige and Black wires and plug it into your Cruise Control system 17 7 PAS Pedal Assistance System For customers who opted for PAS plug your PAS 2 hole pin connector into area Y i i TH BTM INI EEEFBE I Note Power ON the pedelec by pressing the Cruise Control Button twice Power it OFF by cutting off the power supply to the controller Th
11. s are connected correctly Congratulations You have completed your own custom made Electric Bicycle Important Note While using regenerative braking DO NOT turn off the battery 23 PAS Installation PAS Pedal Assistance System also known as pedelec system is a compulsory component of an electric vehicle in European countries The system controls the amount of electricity supplied to the motor proportional to the angular velocity of the pedal 1 e the faster you pedal the faster the motor turns After removing the the pedal crank arm place the receiver ring into the axle and secure it in position using washers or superglue Place the outer magnetic ring next to the inner ring Make sure they do not have any contact in between using washers Screw back the pedal into place connect the PAS wire with the controller and you are ready to ride legally in Europe 24 Power cable installation guide If you purchased our sliding rack and controller box To make sure our power cord is connected securely to the battery we have made extra measures to ensure this however the procedure is also made more difficult Hence follow this guide to beat this tricky installation part You should have 1 The sliding rack 2 The Black Controller box 3 Black connector 4 Plastic connector protector 5 Power cord The point is to get the wires through one of these two holes Therefore we sent
12. uise Control and Horn Switch 2 5mm Allen Wrench Slot the switch into the handle bar Note You can slot it into the side you feel comfortable with pressing the buttons The red button activates the cruise control and the green button activates the horn However you can also use these buttons for other purposes you wish for Place your hand on the handle bar and find the ideal position of the switch where your thumb is able to press the two buttons comfortably Then use the 2 5mm Allen Wrench to tighten it Safety Note Make sure that when your hand is on the handle bar your thumb is able to reach both buttons Pick a type of speed throttle you wish to install A Thumb throttle B Twist throttle Note If you already have a gear shift then we suggest you use the thumb throttle 10 Take the mini tripod and place it in the thumb throttle as shown Note This tripod comes useful if you are installing the thumb throttle on the right side of the steering bar The tripod prevents the edge of the movable ring from getting stuck when it comes into contact with the exterior handle bars Slot the thumb throttle into either side of the steering bar that you feel comfortable with Place your hand on the bar and find the position where your thumb feels most comfortable pressing down on the throttle 7 Use the 3 0mm Allen Wrench and tighten the q VK bolt beneath the throttle SS A S Safety
13. with hills or slopes steeper than 10degrees For riders who live in places with flat terrains this is not a necessity For your own safety and for the controller s safety please ensure that your battery is always turned on unless you have installed this diode GoldenMotor batteries will all be equipped with this diode from July 6 2009 onwards Hence for users who are using batteries from other sellers or have bought GoldenMotor batteries before the 6 of J uly please take note of this issue 29 30 Written and editied by GM Yao Yuan Tom Update contributors Duane Smeckert Gregory McIntire
14. y regenerative braking Solution Diagram Regenerative Braking down a steep slope burns controller if battery is turned off Diode 100V 20Amps 4 Motor zA Keys itch z Controller a owe Internal Battery Pack Battery Casing Original concept Gregory McIntire Reworked edited Yao Yuan Verified GoldenMotor Engineering department www goldenmotor com When you turn off the battery and continue riding by pedaling using the regenerative braking may burn out your controller The current generated from the regenerative braking flows into the battery under normal circumstances However if you turn off the battery the current gets trapped inside the controller and if the current 1s too large it will burn the controller Hence GoldenMotor engineers will place a diode inside as shown in the circuit diagram above as of July 6 2009 Users who ride our bike in terrains that contain steep slopes please ensure that your battery is always turned on If you have experience in engineering please install a diode of rating 100V 20A inside the battery pack according to the diagram above When the battery switch is turned off the current generated by the regenerative braking will still flow into the positive terminal charging the battery However the electrical energy from inside the battery itself cannot flow out due to the diode This basically solves most issues for riders who live in mountainous regions
15. you items 3 4 and 5 separately as item 5 must be thin enough to go through this hole First slide the power cable through the controller box s hole as shown on the right 25 Next take one of the two power cables and bend it as shown Slide in the unbent cable into the protector After the wire has been pushed through push the bent wire in as well this is because the neck of the protector is not big enough to fit both at the same time When both power cords go through push the protector all the way back 26 2 Look closely at the ends of the power cord it looks like a talon Keep in mind that this is designed to be a talon like a giant ass eagle that wants to claw and grip onto the connector Watch out for the signs on the connector make sure Red goes into and black goes into Push all the way in until you hear a click sound Make sure the Nails of the Talon has reached the end and clipped onto the metal plate If this is done correctly it is nearly impossible to pull out the power cord without tools Slide back the protector and Voila You re done grab a beer to congratulate yourself Or if you are a minor get some Pepsi instead LED Light Connection Diagram Yellow Brown Lamp Throttle i A N Black Red Both front and rear have the exact same connection Resolved Case Burnt out Controller b
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