Veloteq 2008 Cougar XR8, Commander SHO-GT, Sorrento GT, La Tote, Osprey Owner's Manual
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Veloteq
Owner Manual
2008
Veloteq Corporation
2151 Richmond Avenue
Shepherd Square
Houston, TX 77098
www.Veloteq.com
(713 524-1175
Printed in China
Veloteq 2008 Electric Bicycle Owner Manual
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To our customers,
Thank you for choosing Veloteq as your alternate energy vehicle for recreation and local
commuting. We specialize in the design and manufacture of electric bicycles that incorporate the
most advanced motor, electrical systems, suspension, and braking systems currently available use
in the North American environment. Advanced features, available only on Veloteq ebikes include
fully automatic cruise control, anti-theft systems and extra heavy duty controllers and battery
chargers. Power-on-Demand electric bicycles by Veloteq are safe, reliable, noiseless and totally
pollution-free.
Please read this manual thoroughly before you operate your Veloteq. Always keep to
the right side of the road and use designated bike lanes whenever possible. Use the turn signals
while executing turns or changing lanes and never swerve in and out of traffic. Observe road
conditions and always allow for longer braking distances in wet or slippery conditions. Do not
permit inexperienced riders to operate the vehicle without close supervision and training. Bicycle
operators are subject to the rules of the road and safe riding practices. Observe them at all times.
Electric Bicycle Manual
Warnings (Read Features and Operation Carefully)
Veloteq electric bicycles are engineered as complete systems. Do not attempt to replace any
parts with those not supplied by your Veloteq dealer or distributor. The use of chargers, batteries and other non-Veloteq parts can result in serious damage to the electrical system and void
all product warranties. Electric bicycles should be operated on the right side of the roadway.
Allow additional braking distance when operating in wet or snowy conditions.
The optimum load capacity of Veloteq electric bicycles using Consumer Product Safety Commission standards is 170 lbs. including rider and cargo. Increased weight will lower the travel
range of the vehicle and require more frequent charging of the power supply. Do not permit
people unfamiliar with riding the vehicle to do so without proper instruction. Strictly comply
with the rules of the road and all relevant traffic laws for bicycles.
Automatic Cruise Control is activated automatically by maintaining the throttle position for
six seconds. To turn off automatic cruise control, activate either the right or left brake handle.
The power supply unit consists of four 12V Sealed Lead Acid maintenance free batteries
which generate an operating voltage of 48V. Do not under any circumstances touch the poles
of the batteries or permit them to come into contact with metal or wet objects. This may lead
to the destruction of the power supply and damage to the controller and charger.
This manual applies only to Veloteq 2008 models named below. It may be updated as required. Updates may be downloaded from the Veloteq web site at www.Veloteq.com. Manuals
for previous model years are available on the web site.
Models: Cavalier RSV-GT; Challenger RSV-GT; Commander SHO-GT, Commuter RSV-GT;
Cougar XR8, Sorrento-GT.
Veloteq Owner Manual 2008 P. 1 of 15 2/18/2008
Electric Bicycle Manual Contents
FORWARD….……………………………………………………………………………...1
FEATURES AND OPERATION ........................................................................... 3
NOTICE AND WARNING: (PAY PARTICULAR ATTENTION TO ANY TEXT
HIGHLIGHTED IN RED.) ................................................................................... 4
HOW TO CHARGE YOUR VELOTEQ ELECTRIC BICYCLE ......................... 5
ASSEMBLY AND ADJUSTMENT ....................................................................... 6
FRONT-WHEEL ASSEMBLY AND ADJUSTMENT: ....................................... 6
FRONT DRUM BRAKE ADJUSTMENT: ............................................................ 8
REAR DRUM BRAKE ADJUSTMENT: ............................................................... 7
CHAIN ADJUSTMENT: ........................................................................................ 7
OPERATIONAL CHECK: ...................................................................................... 7
PARKING YOUR ELECTRIC BICYCLE: ........................................................... 9
CIRCUIT BREAKER LOCATION AND OPERATION: ................................... 9
PEDAL INSTALLATION: ................................................................................... 10
PERIODIC ADJUSTMENTS AND MAINTENANCE: ................................... 10
TROUBLESHOOTING GUIDE ........................................................................... 11
PRODUCT WARRANTY FOR NEW VEHICLES ............................................ 12
OWNER’S RECORD OF SERVICE/REPAIR ................................................. 14
ADDENDUM I.- LUBRICATION OF GEAR REDUCTION MOTOR……….15
Veloteq Owner Manual 2008 P. 2 of 15 2/18/2008
Features and operation
Veloteq electric bicycles are equipped with a brushless DC, pulse wave modulated, 3
-phase electric motor powered by four VRSL colloided, sealed lead acid maintenance-free batteries enclosed in a heavy duty polypropolene case with associated
hardware. The core electrical system contains an extra heavy duty controller and is
equipped with a high quality automatic smart charger rated at 1.8-2A@20Ah. Mechanical parts include a motorcycle grade frame, heavy duty automotive ABS body
fairings with a high gloss enamel finish, polypropolene deck and undercarriage
parts, and advanced motorcycle cushioned drum brakes. Anti-theft systems include
an audible alarm system supplied with two remotes and a keyed digital rear wheel
lock. All models have locking handlebars. Veloteq products have been inspected
and certified for export by the Commodities Inspection Bureau of the China Ministry
of Trade and Industry and are compliant with US Consumer Product Safety and Department of Transportation regulations and Par. 2. (1) of the Canada Motor Vehicle
Safety Act.
Brushless DC (BLDC) Electromotor: The BLDC motor incorporates high-performance
rare earth nickel-dymium boron (NiB) permanent magnet, outer-rotor direct drive
wheel, and an ECVT transmission featuring efficiency, energy economy, long life,
and no maintenance noise-free operation. Maximum output is fixed at 750W in the
U.S. and 500W in Canada.
Drive controller: The central controller performs the functions of electric motor
drive, battery under-voltage protection, cross current protection and speed limiting,
automatic braking power kill, power storage display, speed governor and ECVT
(electronic cont continuously variable transmission) control. The system is integrated with the gearless accelerator to regulate the ECVT. These fully integrated
functions insure safe and reliable operation under all road conditions.
VRSL (Voltage Regulated Sealed Lead Acid) Power Supply: The batteries contained
in the power supply are VRSL-type sealed and maintenance-free. A colloiding agent
renders the electrolyte spill-proof even in the event that the cases are cracked.
They are specifically designed and matched to the Veloteq deep cycle, deep discharge requirements and have a very high power density, long life-time (greater
than 400 recycles at an 80% discharge rate), and are easily recycled using current
widespread disposal technology. The models 500A-GT, 500C-GT, 500D-GT SHO,
and 500ZX-GT use 20Ah batteries. The models 500B-GT and 500XR8 use 14Ah
batteries.
Automatic Smart Charger: The power supply chargers supplied with Veloteq electric
bicycles are specifically matched to the 14Ah and 20Ah rated battery systems. The
power supply may be recharged either while installed in the electric bicycle or while
removed for long term storage or transportation. Operation is fully automatic to
Veloteq Owner Manual 2008 P. 3 of 15 2/18/2008
protect both the charger and the power supply unit against overcharging and does not require
supervision. It may be used over an input range of 110V/60HZ to 220V/50Hz. and carry CCC,
CE, and cUL or cTUV safety certification. The charger, power supply, motor and electrical systems are protected by a high power circuit breaker.
Notice and Warning: (Pay particular attention to any text highlighted in red.)
The PSU (Power Supply Unit) is a key component of the electric bicycle power system. We use
only UL Recognized premium quality batteries designed for long life. Fully discharged batteries
can be recharged up to 400 times. To prolong the life of the batteries always recharge after
use. Conserving the use of your power supply to no more than 80% discharged as indicated on
the instrument power meter will greatly extend the life of the batteries and under normal circumstances will exceed 400 recycles.
Do not store the charger or power supply or charge the battery in ambient temperature envi-
o
ronments below 14
F (-10oC). Prolonged exposure to below freezing temperatures will change
the electrical characteristics of the charging unit causing possible serious malfunction.
Application and Use Practices:
Do not fully discharge the battery supply. Recharge after each use to prolong battery life. Extensive long term in-plant testing has revealed that frequent recharging, avoiding full discharge, will prolong battery life to approximately 9,500 miles (15,000km) of regular use.
The efficiency of the batteries is influenced by temperature. The power supply will function better in warmer to hot temperatures. At temperatures below 32F (0℃) battery performance may
decrease more than 1/3. Full functionality and power density will be restored when the surrounding temperature rises to 68F (20℃).
Frequent stopping and starting, riding uphill, riding against the wind, on muddy roads continuous
use of lights and accessories while not riding, or carrying an additional passenger or extra cargo
are all factors that will reduce the travel distance per charge of your Veloteq.
If the electric bicycle or PSU is stored for a prolonged period it should be fully charged prior to
storage. We recommend that the PSU be removed and recharged at intervals of 20 days during
the storage period to prolong battery life and prevent sulphication of the battery cells. Sulphication of the battery plates can be compared to the rusting of metal parts. It occurs when a
discharged battery is left in an uncharged state. The batteries used in your electric bicycle do not
have “memory” however all batteries self-discharge while not in use.
Use or storage at temperatures higher than 140F (60℃) such as unventilated storage in high
summer temperatures, will adversely effect the normal working functions of the electric bicycle.
Sudden relocation of the electric bicycle from a cold outside area to a warm interior may result in
crystallization of electric components. Before moving from a cold exterior to a heated interior,
remove the PSU and permit natural cooling and dissipation of any crystals.
The electric bicycle may be ridden in both rain and snow, however under no circumstances allow
it to be immersed in water. Immersion in water such as deep puddles may cause the controller
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