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Summary of Contents for Woosh HL30
- Page 1 Fitting Guide for HL/G30 Hub Kits Important: For your own safety you must read this manual before attempting to fit this kit. You must also ensure that you fit the kit in strict accordance with the instructions in this manual. Tel: 01702 435566 —...
- Page 2 You will of course need to pay for the technician to install your kit, these costs are not covered by Woosh Bikes. Warranty Terms:...
- Page 3 What’s in the Box Ensure that you have all the parts listed below before going any further, if there are any missing parts, contact us on 01702 435566. The motor kit comprises of a motor wheel with hub motor, a battery cradle with integral controller, a battery, a charger, modular cable/loom, pedal-assist sensor, a thumb throttle, brake sensors and a King- Meter KM529 LCD.
- Page 4 Installation of the various Pedelec Assist Sensor (PAS) types There are three types of PAS that can be used, two that fit on the right side of the bike between the chain -ring and frame, and the left-side sensor, which slots into the end of the bottom bracket. The right-side PAS kit consists of two parts, these are the sensor itself and the PAS disc.
- Page 5 Seat-post mounted PAS: The seat-post mounted sensor is shown below and is simply cable-tied to the lower part of the seat tube. If the sensor isn’t sitting back far enough, it is possible to remove one of the plastic spacers on the rear of the mounting buy simply undoing the bolt and then removing the lower of the two spacers.
- Page 6 HL Battery/Controller The HL battery-cradle/controller included with this kit mounts on your down-tube, where your bottle holder would normally be. If the bike does not have these fixings or they are not in a suitable position, you will need to fit riv-nuts (supplied) to allow you to mount the battery cradle. Ensure that you mount the cradle high enough along the down-tube so that the cradle doesn’t foul on the chain-ring.
- Page 7 G30 Battery/Controller The G30 battery-cradle/controller included with this kit mounts on your down-tube, where your bottle holder would normally be. If the bike does not have these fixings or they are not in a suitable position, you will need to fit riv-nuts (supplied) to allow you to mount the battery cradle. Ensure that you mount the cradle high enough along the down-tube so that the cradle doesn’t foul on the chain-ring.
- Page 8 85SX Important note for purchasers of the 85SX motor wheel You must NOT use rotor bolts longer than 10mm. Longer bolts will protrude too far into the motor housing and will damage the motor.
- Page 9 Motor Wheel Swap the tyre, tube and freewheel/cassette (in the case of a rear wheel) from your original wheel over to the motor wheel. The wheel comes with the nuts and washers that you will need, they should normally be fitted in the or- der shown below, but sometimes it is necessary to re-arrange them, or to fit additional washers to ensure the wheel is correctly aligned.
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Page 10: Cable Orientation
Motor Wheel cont… To complete the installation of the wheel, fit the nut covers. The left side cover simply pushes on, the drive side cover should be slid down the cable and fitted as shown below-right. arrow on the diagram above-right shows the typical route for the motor cable (in the case of a rear hub conversion), with the quick-release connector (in the cable) indicated by the solid box. - Page 11 Handlebar Components: The display would normally be mounted on the left side. If you decide not to fit the throttle (a lot of peo- ple don’t), then it is not necessary to fit brake cut-outs. If you are using throttle, you will need to fit one of the three types of brake cut-outs: Levers (for cabled brakes), inline sensors (for cabled brakes), hydraulic sensors which can also be used for cabled brakes in situations where the gear shifter and brake levers are a single unit.
- Page 12 The next step is to run the modular cable (for the LCD, throttle and brake cut-outs) from the front of the bike, to the controller . Ensure that there is enough play in the cables so that they do not get stretched or pulled as the handle- bars are rotated.
- Page 13 Speed Sensor: Note: Most of the kits we supply now do not require an external speed sensor, it is built into the hub. In these cases, you will not receive a speed sensor with your kit, and you can skip to the next page. The speed sensor consists of two parts, the sensor itself and a magnet that is attached to one of the spokes.
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Page 14: Motor Cable
Controller Connections: Exiting from the bottom of the battery cradle are three or four cables, these are for the speed sensor, the motor wheel, the pedelec sensor and the modular cable. The modular cable runs up to the handlebars and connects to the display unit, the thumb-throttle and the brake levers. All of the connectors have ar- rows on them that need to be correctly aligned before pushing the connectors firmly together. -
Page 15: Lcd Control Panel
LCD—Control Panel The display has many advanced features and modes, these include back-lit display (for night riding), indi- cator options for max speed, average speed and current speed and a battery power indicator. It also fea- tures a walking mode which is used when you want to wheel/push the bike, this is basically a very low speed mode which is activated by pressing and holding the minus (-) button, this can also be used as a start-aid. - Page 16 Battery care: Some care is needed to ensure that the battery performs at its best and lasts as long as possible. All batteries age over time, and the way that they age is that the range you can achieve will gradually de- crease.
- Page 17 Battery operation: The HL and G30 batteries are effectively always on, and when the button at the top is pressed, it shows the current state of the battery—the more lights illuminated, the more full the battery is. Troubleshooting (HL Battery): Bike cutting out, display switching itself off whilst riding: If you find after some months that the display/motor cuts out when riding, it is likely that the contacts on the underside of the battery need some cleaning/adjustment.
- Page 18 Rack battery: The rack batteries (unlike the downtube batteries) have a switch towards the rear left of the unit which is used to turn the battery on/off—a master-switch effectively. At the very end (the rear-most part) of the battery), there is small button in the middle, pressing this button firmly and holding it will illuminate the LED’s either side of the button.
- Page 19 Troubleshooting cont. If the kit seems to function but does not seem to have much power, or the kit functions but no speed is indicated on the display. It is likely that the connection where the cable from the controller meets the cable coming from the controller is not fully mated.
- Page 20 ASAP, normally later the same day. Support staff are not available at the weekends, emails received over the weekend will be read and replied to on the following working day. Email: support@wooshbikes.co.uk © 2021 Woosh Bikes Limited...
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