RAYVOLT Cruzer Page 60 Owner'S Manual Download

Page: 60 / 87

05. Elec

ical maint

enan

Owner manual

Light Kit:

Rayvolt Bikes have a front light and a rear light. Both lights
are powered directly by the battery at 48 V.

DC Converter:

It is a DC-DC voltage rectifier that allows 7 to 60 V inputs
and 3.3 to 33 V outputs. This component is connected in
parallel with the battery in order to have a 12 V output.

Wire Set:

• Main wire:

Directly connected to the controller we

have the hub, the PAS / Torque sensor and the Tank
Wire.

REAR LIGHT

FRONT LIGHT

Summary of Contents for Cruzer

Page 1: ...owner manual ...

Page 3: ...See the digital version here for easy access to all videos and links ...

Page 4: ...le adjustment Handlebar adjustment Pedal assembly Battery connection Battery installation Lubricate the chain Chain tension Covers and wheels Index 04 Accessories Light kit assembly Change mudguards Bell assembly Torque sensor installation 05 Electric maintenance Component description Wiring diagram 06 Technical specifications 07 Troubleshooting description 08 Take care of your Cruzer ...

Page 5: ...01 Introduction ...

Page 6: ...r or visit our website https www rayvoltbike com support You can also send your questions to the following email support rayvoltbike com A series of maintenance and repair work is described in detail on the digital data carrier accompanying this manual When carrying out this work always keep in mind that the instructions and indications only refer to this Rayvolt bicycle and cannot be applied to o...

Page 7: ...how to ride a bicycle or teach you the rules of the road When cycling always keep in mind that it is a potentially dangerous activity and that the rider should always maintain control over it Never use the bicycle if you are under the influence of medicines drugs alcohol or if you are tired Always drive in a way that does not endanger your own life or that of others and respect nature when driving...

Page 8: ... haven t started riding and it is essential that you carefully examine the bicycle and repair or replace faulty components 1 Maximum total weight The recommended total weight for Rayvolt bikes should not exceed 100 kg driver and luggage included 2 Check the condition of the tires Check that these aren t in bad condition scratched or worn and that they have enough pressure Higher pressure provides ...

Page 9: ...ded connections Bounce your Rayvolt bike close to the ground and try to identify the source of any noise 6 Verify that the wheels are still positioned correctly and that the tires remain centered on the frame and fork 7 Make sure chain is still in grenade on chainrings and sprockets 8 Check the position of the saddle 9 Finally finish by giving a general review of your Rayvolt Bike to confirm that ...

Page 10: ...pe of leak it can cause a short circuit damaging part or the entire system so if we want to wash our bicycle it is advisable to do it carefully and watch out for contact with water Rayvolt bikes are protected but it is recommended to wash them with non conductive distilled water or to insulate electrical components The so called quick cleaning has serious drawbacks the high pressure water jet can ...

Page 11: ... to dry and in order to protect the paint metal surfaces spokes hubs etc we apply a layer of hard wax never on the brake discs and polish the waxed surfaces with a soft cloth so that they shine and don t make direct contact with water Finally it remains to grease the chain if this is necessary Check the condition of the chain in the case of having too much friction it should be greased ...

Page 12: ...ilated area Remove the saddle and allow any moisture it may contain to dry It is recommended to apply a little oil and distribute it inside the seat tube Clean your bicycle as described in the Cleaning and care section Always charge the battery before storage and every 2 months minimum Finally it is recommended to regularly check the pressure of the wheels hang them or hang the entire bicycle The ...

Page 13: ...Owner manual The serial number of the Rayvolt Cruzer is located on the front of the frame Serial number ...

Page 14: ...Conformity This Declaration of Conformity applies only to countries following the CE marking directives Download this page if needed in the following link https www dropbox com s 0yypd1bj6ewyyai Cruzer_EC_ declaration 20of 20conformity_2021 pdf dl 0 ...

Page 15: ...ctrically power assisted cycles EPAC bicycles EN 14764 City and trekking bicycles Safety requirements and test methods Complying with the requirements of European Parliament and Council 2006 42 EC directive Complying with the requirements of RD 339 2014 May 9th 1999 Complying with the requirements of the Electromagnetic Compatibility Directive 2004 108 EC The production control is assured by our Q...

Page 16: ...02 Bike scheme ...

Page 17: ...Bike scheme Owner manual Bike parts Tire tube Front disc brake Stem Rim Frame Handlebar Spoke Fork Grip Front hub Head parts Brake lever 1 11 12 14 16 17 18 19 20 15 5 9 2 6 10 3 7 11 4 8 12 27 28 23 24 25 ...

Page 18: ...ank cover Pedal Kickstand Saddle Quick release Charger plug Chain Motor Key switch Crankset Mudguard Saddle nut Battery case Controller Chain tensor 1 2 3 7 26 8 9 10 21 22 13 4 5 13 17 21 25 14 18 22 26 15 19 23 27 16 20 24 28 ...

Page 19: ...03 Maintenance and inspection ...

Page 20: ...set Chain Check pressure Check bearings clearance Check bearings clearance Check bearings clearance Check status Re tight Correctly lubricated Before each use Monthly Monthly Monthly Before each use Annual Before each use Check drawing and side condition Re grease Re grease Re grease Monthly Annual Annual Annual Inspection Interval ...

Page 21: ...sion Check bearings clearance Check condition and waxing Check status Disassemble and re grease Review Pads thickness Check tension Review Check location Change Wiring Pipes Monthly Monthly Monthly Monthly At most every half year At most every half year Annual Every 2 year maximum After a fall or 3 years Monthly Annual Before each use Inspection Interval ...

Page 22: ...nce and inspection Owner manual Saddle adjustment The position of the saddle is determined by pedaling A correct adjustment will allow us to have a more comfortable ride and avoid injuries M14 Wrench Tools needed ...

Page 23: ... post should be up to its insertion mark 1 Seat height Place the saddle tube on the saddle post and tighten using the quick release lever OPEN CLOSE MINIMUM EXTENSION MARK 2 Inclination To correct the inclination of the saddle you will find a nut under the saddle bars that will allow you to adjust it to your comfort Loosen it with an M14 wrench Once adjusted lock it again ...

Page 24: ...bar adjustment On your Rayvolt Cruzer the ends of the handlebar are curved Adjust the handlebar so that your wrists are relaxed and not too far out M4 Allen M5 Allen M6 Allen Visual support https www youtube com watch v OVdiQ1ZLby8 t 16s Tools needed ...

Page 25: ... will find a hex bolt on top of the stem it may be covered by a plastic cap and two bolts on the side of it Use an M5 allen key or an M6 allen key depending on your bike version to loosen them Once loosened pull the complete handlebar upwards then place each three stem spacers over or under the stem to adjust the handlebar height Retighten all the bolts The correct handlebar height can avoid disco...

Page 26: ...to your liking and retighten the bolts It is recommended to adjust the position of the hand allowing a comfortable brake application while driving 4 Adjust the position of the throttle You will find a hex bolt attaching the throttle to the handlebar Use an M2 allen key to loosen it Once loosened position it to your liking and retighten the screw It is recommended to adjust the position of it simul...

Page 27: ...03 Maintenance and inspection Owner manual Pedal assembly Visual support https www youtube com watch v OVdiQ1ZLby8 t 16s 15mm Wrench Tools needed ...

Page 28: ...Owner manual 1 Pick the appropriate pedal on each side Note that the right pedal is labeled R and the left pedal is labeled L 2 Lock each pedal with the 15mm wrench LEFT L R RIGHT ...

Page 29: ...preventive reasons Follow this steps for a proper installation before using the bike The installation may be done with the battery case attached to the bike or separated Consult the section Battery installation next in this manual to learn how to remove and install the battery case Battery connection ...

Page 30: ...open the zipper and then open the battery case 2 Place the battery inside Place the battery on the anti slipping battery base leaving the cables on the upper part of the case 4 Close the battery case If the battery case has been removed from the bike place it back Consult the section Battery installation next in this manual to learn how to do it ...

Page 31: ...03 Maintenance and inspection Owner manual Battery installation The battery case of the Rayvolt Cruzer may be extracted from the bike Follow this steps for a proper removal and installation of the case ...

Page 32: ...r remove the battery case from the left side of the bike 3 The safety lock of the case has to match the frame hole of the bike WRONG POSITION CORRECT POSITION 4 Fix the battery case with the main key Press and turn 5 Finally secure the battery with the key at the bottom lock ...

Page 33: ...03 Maintenance and inspection Owner manual Tools needed Regularly check the condition of the chain it must always be lubricated and clean Common rag Degrease Chain lubricant Lubricate the chain ...

Page 34: ...u will need a regular rag Once the degreaser is sprayed on hold the rag against the bike chain and with your free hand move the pedals back so that the chain runs through the rag and absorbs the dirt 3 Apply lubricant Shake the container well Drop the fluid from inside onto the chain while using your free hand to run the chain backward so that the lubricant sticks to its full length evenly 4 Clean...

Page 35: ... needed Regularly check the tension of the chain it must be tight enough to only allow a little movement up and down If there is no slack it is too tight If there is too much slack then a tighten is needed Chain tension 21mm Wrench M5 Allen M4 Allen ...

Page 36: ...de 2 Adjust the tension Once removed the lateral screws and nuts use an M4 allen key to adjust the tension screws from the back Tighten or loosen these screws tensioning or easing the chain and keeping the wheel in the center It is recommended to gradually tighten each side until the best result is achieved Do not over tension the chain 2 Fix the chain tensioner back Once the proper tension is obt...

Page 37: ...03 Maintenance and inspection Owner manual Covers and wheels Change front wheel Tools needed M5 Allen ...

Page 38: ... pull the axle until it comes out completely 2 Remove the front wheel Once the axle is out pull the wheel downwards to succesfully remove the front wheel 3 Fit the wheel Place the wheel back Make sure the brake disc fits properly inside the brake caliper Then put the thru axle back and lock it again ...

Page 39: ...hange rear wheel 1 Turn off the bike Make sure the bike is turned off and there is no power supply 2 Disconnect the motor wire Detach the cable from its fixation Tools needed 21mm Wrench M5 Allen M4 Allen Visual support https youtu be FZoTOesSoxA ...

Page 40: ...rward to separate the chain from the rear hub then pull the wheel backwards to remove it Keep the washers for the new wheel 6 Fit the new wheel When adding the new wheel keep the washers and the motor cable on the inner side Make sure the washers are pointing backwards and to the outside Then put the chain in the rear hub and place back the chain tensioners and flange nuts Tighten everything back ...

Page 41: ...olt Cruzer has two sizes L and M for which a different inner tube is required in each case Tube 26x3 0 Schrader for Cruzer L or 24x3 0 Schrader if it is Cruzer M Tools needed Tube 26 x 3 0 Schrader Tube 24 x 3 0 Schrader Tire lever Change bike tube ...

Page 42: ...ld have caused the puncture or that could damage the bike tube again and remove it 4 Place the new bike tube First inflate the new bike tube a little so it may take shape Insert now the inner tube by placing the air valve inside the rim first Place the rest of the bike tube inside the cover and tuck the tire back into the rim Check that the part you have already tucked back in is not coming out Us...

Page 43: ...04 Accessories ...

Page 44: ...04 Accessories Owner manual Light kit assembly Front light installation Tools needed M5 Allen ...

Page 45: ...able by its two pin red plug Consult the section 05 Electrical maintenance in this manual to identify all the cables 4 Pass the cable into the tank Pass the cable through the front side of the tank Once inside plug it with its connector 5 Close the tank and check Make sure everything is properly connected and inside the tank Start the bike and check if the lights work by pressing the light button ...

Page 46: ...04 Accessories Owner manual Rear light installation Tools needed 10mm Wrench SPRING NUTS AND SPACERS ...

Page 47: ...the saddle and the metal bars to the front 4 Place the saddle back Place back the saddle and adjust it to your height 5 Open the tank and locate the rear light wire Identify the rear light cable by its six pin black plug Consult the section 05 Electrical maintenance in this manual to identify all the cables 6 Pass the cable into the tank Pass the cable through the left back side of the tank Once i...

Page 48: ...04 Accessories Owner manual Change mudguards Tools needed 21mm Wrench M5 Allen M4 Allen M3 Allen ...

Page 49: ...manual to correctly remove the rear wheel 3 Remove the rear mudguard Once the wheel is removed use an M3 allen key to remove both screws attaching the bracket to the sides and the screws holding the mudguard to the bottom of the frame 4 Place the new mudguards If needed first assembly the brackets to the mudguards Then put the new mudguards in place and lock them in position with all the screws ba...

Page 50: ...04 Accessories Owner manual Bell assembly Tools needed Phillips screwdriver ...

Page 51: ...he bottom part for better placement on the handlebar 2 Place the bell on the handlebar Place it in such a way that it is comfortable to use We recommend the left side next to the brake 3 Tight the bolt again Place the bottom part and fix the bell in the desired position with the bell screw ...

Page 52: ...04 Accessories Owner manual Torque sensor installation Visual support https www youtube com watch v yi2DoA4TNaI Tools needed M8 Allen Bottom bracket tools 15mm Wrench Cassette extractor ...

Page 53: ... tool to remove the crank arm 3 Take out the PAS Once removed the left crank arm the Pedal Assisted Sensor is next Disconnect the PAS cable and remove it by pulling 4 Go to the opposite side and repeat the process 5 Remove the BB set Use the Bottom bracket head and an adjustable spanner to untighten the BB set Remove both sides 6 Now take the new Torque Sensor ...

Page 54: ... with the bottom bracket tool 9 Connect the Torque sensor Using the cable extension from the Torque sensor kit connect the Torque sensor cable to the plug where the PAS was connected before 10 Install the new chainring from the Torque sensor kit Attach the chain to the plate and place the lock nut use the Bottom bracket head to tighten it 11 Place both crank arms Lock them with the crank arm nuts ...

Page 55: ...05 Electrical maintenance ...

Page 56: ...ical components of the Rayvolt Cruzer will help identify and understand each part and its wire in the following wiring diagram Motor Responsible for transmitting movement to the chain in order to move the wheel It is directly connected to the controller 250 W and 50 Nm or 100 Nm POWER HUB SMART HUB ...

Page 57: ... entire system alive To provide long battery life ALWAYS charge the battery after using the bike Controller The brain of the entire electronic system Inside it is loaded the firmware in charge of managing the input and output signals of the controller itself DUAL BATTERY STD BATTERY ...

Page 58: ...cient to activate the motor We can also regulate the power transmitted to the motor It should not be hit or opened It must be in the correct position without moving It must not be bent or cut Brake sensor It consists of an inductive sensor capable of recognizing when the braking hand is actuated The sensor sends a signal to the controller capable of activating the RBS Regenerative Brake System a s...

Page 59: ... on the front lights and rear lights The 3 LEDs indicate the battery level with 3 LEDs on full and 1 LED on low battery Torque sensor Sensor capable of detecting the force exerted on the pedal It transforms the applied force into an electrical signal and sends it to the controller TORQUE SENSOR KIT ...

Page 60: ...e battery at 48 V DC Converter It is a DC DC voltage rectifier that allows 7 to 60 V inputs and 3 3 to 33 V outputs This component is connected in parallel with the battery in order to have a 12 V output Wire Set Main wire Directly connected to the controller we have the hub the PAS Torque sensor and the Tank Wire REAR LIGHT FRONT LIGHT ...

Page 61: ...data bus It shares bidirectional signals between controller throttle controller brake sensors It is used to power both the throttle LEDs and the front and rear lights and all sensors actuators Light wire Splitter used to power both the front and rear lights In addition to receiving signals from the switch ...

Page 62: ...nfiguring parameters such as pedalling assistance or turning on the lights MicroEIVA works as an accessory to the EIVA 2 0 App For more information see the MicroEIVA manual End Plug Rayvolt Cruzer wiring is designed to work with a MicroEIVA device therefore when it is not installed on the bike an End plug is needed to close the electrical circuit It works as a closed switch ...

Page 63: ...05 Electrical maintenance Owner manual Wiring Diagram This is the wiring diagram of the Rayvolt Cruzer for the Controller V4 ...

Page 64: ... 1 Blue 4 pin connector XII Front light wire 1 Red 2 pin connector VI Main bike wire 1 Black 8 pin connector III IV V VI VII VIII IX X XI XII XIII XIV Controller Cruzer V4 CONTROLLER V4 I Power wire 1 Red V 2 Black ground II Controller wire 1 1 White connector III Controller wire 2 1 Yellow 3 pin connector IV Motor wire 1 Black 9 pin connector V Pedal Assist Sensor wire 1 Orange 3 pin connector BR...

Page 65: ...06 Technical Specifications ...

Page 66: ...lt Two Pieces Crankset Pedals Flat Rayvolt Pedals Chain KMC Silver Chain Rims Double wall 40 mm Rear Rim Tires M 24 x 3 0 L 26 x 3 0 Speed Control PAS Pedal Assist System Thumb throttle Torque sensor optional E Drive System Rayvolt EIVA Drive Motor Smart Hub 50 Nm 250 W Power Hub 100 Nm 250 W Battery Life of 1000 cycles Smart Battery Samsung Li ion Removable 48 V 10 5 Ah Range of 60 km Charge time...

Page 67: ...General Weight 29 kg 33 kg D G A D C F J H I B Dimensions M 1890 x 990 x 720 mm L 2165 x 1030 x 720 mm A L M B C D E F G H I J 1890 2165 1240 1470 175 152 268 327 990 1030 636 690 846 884 150 150 720 720 28º mm 25º ...

Page 68: ...07 Troubleshooting description ...

Page 69: ...sn t turn on and three lights on the throttle are off no microEIVA installed 1 Battery not connected First of all take out the battery case of its position Open it and check that inside is everything connected and there are not loose connections After that close again the case and place it correctly ensuring that there is a full contact between the battery case and the lower pins on the frame Lock...

Page 70: ...king the next step is to open the tank case of your Cruzer Inside you will find some of the wiring system of the bike There may be a black plastic cover hiding some of the connections If needed remove the two bolts from the medal and you will be able to remove the plastic cover Otherwise the wiring system may be also pulled through the hole Search for the wire End plug consult the section 05 Elect...

Page 71: ...4 DC Converter issue In the event all is well connected and the problem is not solved it is needed to unplug the DC Converter Disconnect it and test if the bike works now 5 Brake sensors issue If it still has the same behaviour disconnect the brake sensors from the tank case These are the two red plugs on the tank wire 6 Controller issue In the case it doesn t solve the problem open the controller...

Page 72: ...re off microEIVA installed 1 Battery not connected First of all take out the battery case of its position Open it and check that inside is everything connected and there aren t loose connections After that close again the case and place it correctly ensuring that there is a full contact between the battery case and the lower pins on the frame Lock the battery in the correct position 2 A blown fuse...

Page 73: ...ons If needed remove the two bolts from the medal and you will be able to remove the plastic cover Otherwise the wiring system may be also pulled through the hole Search for the MicroEIVA wire consult the section 05 Electrical maintenance in this manual to identify it and check that it is well connected to the 6 pins green connector A common issue is due to connecting the MicroEIVA to the 6 pins b...

Page 74: ...re 5 Controller issue In the case it doesn t solve the problem open the controller case and check if it has the red led on To open the controller case it is needed to remove the three screws under the frame just below the battery case Contact your nearest distributor or shop and explain the process done and if the red led was on the controller they will give you further instructions Scenario 3 Thr...

Page 75: ...e bike Consult the EIVA 2 0 manual to see how to do this After the parameter reset on the main screen increase the assist level Otherwise if the Connected message appears and the battery indicator is red there is a communication error Turn off the bike and the application and try again to connect If the problem is not solved try another phone If the problem persists contact your nearest distributo...

Page 76: ... that turn off the bike and ride it if the noise is still there it is a mechanical noise Otherwise it will be an electrical noise 1 Mechanical noise Check that there is nothing touching the wheel while turning wires stones mudguard rear rack If there is nothing touching the wheel the tension of the spokes needs to be adjusted It is a procedure that needs to be done periodically since the torque of...

Page 77: ...there is an error on the main screen If there is an error click on it and a pop up will show the error description Follow the instructions on EIVA 2 0 manual to solve it Otherwise if there is not an error do a Reset Parameters If the noise persists disconnect the motor wire and check that all pins are in a good condition Reconnect it and make sure it makes full contact If the noise has not disappe...

Page 78: ...l there If it is not solved repeat the process If the noise persists adjust the brake calipers To do that first loose the caliper screws Then press the left brake lever and tighten the screws while pressing the lever If you have used your bike a lot the brake pads may need to be changed consult the section Braking system in this manual to learn how to do it Scenario 7 Battery doesn t charge If you...

Page 79: ...nd if you have another charger use it to charge the battery If the battery charges there is a problem with the charger Otherwise if the battery doesn t charge there is a problem with the battery or with the charge plug In the case you don t have another battery nor charger first check battery problem and then charger problem 1 Battery problem If the problem is in the battery remove both fuses of t...

Page 80: ...ld have a small wire crossing all the fuse If the wire is broken or it is not in the fuse it needs to be replaced Otherwise return the fuse to its position and contact your nearest dealer 3 Charge plug problem If there is a problem with the charge plug Introduce the battery that charges if you have one inside the battery case of the one that doesn t work If it doesn t charge contact your nearest d...

Page 81: ...08 Take care of your ...

Page 82: ...100 kg You are warned that you assume the risk for personal injury damage or losses if you breach the above conditions and the warranty will be void automatically Keep your e bike away from damp high temperature or corrosive environment You must ride with your helmet and follow the local laws and regulations Keep your e bike away from sun scorched and raindrenched areas It is not recommended for K...

Page 83: ...frequently or stored for quite a long time it must be fully charged every 2 months The battery life may be reduced after long storage without regular charging as instructed above due natural discharge Never use any metals directly to connect the two poles of the battery otherwise the battery will be damaged due to short circuit Never put the battery near to fire or heat source Never strongly shake...

Page 84: ... you can finish charging the battery 4 To finish charging you must disconnect the charger input plug first from the AC outlet and after that disconnect the charger output plug from the battery pack Finally close the cover on the charging socket of the battery pack and check the socket is covered Do not use this charger in an environment of explosive gas and corrosive substances Never shake punch o...

Page 85: ...ing guideline 1 Pay attention to protect from ingress of water and immersion in water which may damage the controller Note If you think water may have got into the control box please switch off the power immediately and pedal without electric assistance You can pedal with electric assistance as soon as the controller has dried out 2 Pay attention to protect from any strong shaking and punching whi...

Page 86: ...inium cover and body may break 4 Make regular checks on the screws on both sides of the hub motor fasten them even if they are just a little bit loose 5 It is necessary to check the cable connection to the motor This is a very important component for riding with safety First you should pay attention to protect it from impact and avoid any damage Second make regular check on all bots and nuts and f...

Page 87: ...www rayvoltbike com ...

Search results

Summary of Contents for Cruzer

Reviews:

Related manuals for Cruzer

Brands by name

Popular brands

RAYVOLT Cruzer, Owner'S Manual

Search results

Summary of Contents for Cruzer

Reviews:

Related manuals for Cruzer

Brands by name

Popular brands