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Prodeco Technologies G Plus Mariner 36V User Manual

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You have purchased one of the highest
quality electric bicycles available today. It is
important
you
read
understand your new electric bicycle. All
riders
including
bicycle riders should read this manual. This
manual explains the functions of your new
electric bicycle and details on performing
basic maintenance. All riders must read the
section on throttling due to the nature of how
to power the bicycle forward. Please take the
time to register your new G Plus Mariner
electric bicycle for the warranty to take effect.
this
manual
experienced
traditional
to
USER GUIDE
Some of the content of this manual may differ from
your bicycle depending on the options of the bicycle
and what your dealer provided.
© 2012 PRODECO TECHNOLOGIES. All rights
reserved.
PRODECO
PRODECO TECHNOLOGIES logo are trademarks of
PRODECO TECHNOLOGIES. Printed in USA.
36V
TECHNOLOGIES
and
the

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Summary of Contents for Prodeco Technologies G Plus Mariner 36V

  • Page 1 Please take the © 2012 PRODECO TECHNOLOGIES. All rights time to register your new G Plus Mariner reserved. PRODECO...

  • Page 2: Table Of Contents

    Table of Contents Chapter 1: Introduction ……………………………………………………………………………………………… 4 About this manual ………………………………………………………………………………………………… 4 Important notices …………………………………………………………………………………………………. 4 General warning ………………………………………………………………………………………………….. 5 A special note to parents ………………………………………………………………………………………… 5 Chapter 2: Getting Started ………………………………………………………………………………………….. 6 Unpacking your box ………………………………………………………………………………………………. 6 Folding and unfolding …………………………………………………………………………………………….. 6 Familiarize yourself with your bicycle’s parts …………………………………………………………………...
  • Page 3 Registering your bike ………………………………………………………………………………………………. 43 Serial Numbers and where to find them ………………………………...……………………………...……….. 43 Registration card …………………………………………………………………………………………………… 43 Part replacement procedure ………………………………………………………………………………………. 44 Contacting Prodeco Technologies ……………………………………………………………………………….. 44 11) Chapter 11: Parts and Components List …………………………………………….………………………..…… 45   12) Chapter 12: Specifications …………………………………………………………………………………………… 47...

  • Page 4: Chapter 1: Introduction

    1) Chapter 1: Introduction Prodeco Technologies thanks you for your purchase of your new G Plus Mariner. Your bicycle is a high quality and environmentally friendly light electric vehicle. This manual will serve to provide you with the information needed to operate, maintain and enjoy it safely.

  • Page 5: General Warning

    As a parent or guardian, you should read and understand this manual. Before letting any child ride the G Plus Mariner or any of Prodeco Technologies electric bicycles, review with them all warnings and cautions;...

  • Page 6: Chapter 2: Getting Started

    2) Chapter 2: Getting Started CAUTION: If you have purchased the bicycle by mail order or through a sales channel whereas your new G Plus Mariner is still in the box, it is recommended you read Chapter 3 “Basic Instructions” section g “Before your first ride”...

  • Page 8: Familiarize Yourself With Your Bicycle's Parts

    Check the contents of your box. Your new G Plus Mariner should include the following items in the box or your dealer should have included these items with your purchase:  G Plus Mariner electric bicycle  Prodeco G Plus saddle (attached to alloy suspension seat post)  Prodeco Technologies 38.4V 9Ah LiFEPO4 removable battery  43.8V LiFEPO4 charger ...

  • Page 9: A Guideline Of Your G Plus Mariner Tool Set

    e. A guideline of your G Plus Mariner tool set The G Plus Mariner includes a multi-use tool set. This tool set includes all the tools necessary to make adjustments and service your new bicycle. The only additional tool you will ever need is an 18mm wrench to remove the front wheel.

  • Page 10: Adjusting The Saddle

    Can you comfortably operate the brakes? If not, you are able to adjust their angle and reach. See Chapter 5 “Perfect Fit and Ride” section e “Brake lever height adjustments” for details. Do you fully understand how to operate your new bicycle? If not, before your first ride, have your dealer or contact us to explain any functions or features that you do not understand after fully reading this manual.
  • Page 11 CAUTION: The saddle mounting clamp front and rear barrel nut and bolt must remain tight at all times. Test saddle for looseness or play in the rotation of the nose. If saddle is loose, tighten the clamp bolts to ensure the saddle will not accidentally rotate up or down when riding.

  • Page 12: Adjusting The Handlebar

    Prodeco Technologies will continue to follow new rules and guidance set forth by these agencies, always welcoming and adhering to the guidelines they feel are required to assure safety for the electric bicycle rider.
  • Page 13 Prodeco Technologies only offers electric bicycles that fall under the category of “weighing under 100 pounds and a top speed of less than 20 miles per hour”. According to the DOT and NHSTA, Prodeco electric bicycles meet the exception of Motorized Vehicles and therefore can be ridden on non-motorized trails and bike paths permitting state and local laws.

  • Page 14: Safety First

    e. Safety first It is important you follow your local bicycle laws but also it is important you ride safely. Below are examples of understanding how to ride your new G Plus Mariner safely.  Always wear an approved helmet when riding your bike, and follow the helmet manufacturer’s instructions for fit, use and care of your helmet.

  • Page 15: Before Your First Motorized Ride

    g. Before your first motorized ride Before your first ride study this manual in its entirety. Make sure you are comfortable and confident when sitting on the bicycle. If an adjustment does not feel right or something feels loose, check to ensure you are properly fitted to the bike and do a mechanical safety check as explained in the previous section.

  • Page 16: Using Your Brakes

    k. Using your brakes Your G Plus Mariner includes a high performance Promax braking system. Promax’s top of the line XL-86 levers were chosen for their ability to offer quick stopping power with little pull effort. When matched to Promax’s DSK-400 front disc brake and rear TX-120 V-brake, your Mariner will have the ability to stop quickly and accurately.

  • Page 17: Chapter 4: Safety

     Grab the handle at the back of battery and pull towards the back of the bicycle to slide off.  The battery is now transportable and can be charged away from the bicycle. For charging, please review the following instructions. ...

  • Page 18: Riding Safety

     Avoid loose clothing or long coats that can catch in pedals or wheels. Leg clips or bands keep pants legs from tangling in the chain.  Avoid crossing raised sewer grates.  Regular maintenance is essential for safe riding. Refer to the maintenance recommendations. If you do not have basic mechanical skills, an authorized dealer should perform repairs and maintenance.

  • Page 19: Wet Weather Riding

    CPSC (US Consumer Product Safety Commission) requires front, rear, wheel and pedal reflectors. Your G Plus Mariner includes federal regulated reflectors and they should not be removed. If needing to be replaced, replace them with authorized Prodeco reflectors or reflectors approved by the CPSC. Night riding Almost anywhere in the world today, bicycle night riding requires front and rear lights on your bicycle.

  • Page 20: Adding Accessories

    Prodeco Technologies G Plus Mariner’s frame measurement will differ from traditional bicycle frames due to the seat tube being longer than a traditional bicycle and the stem being at centerline with the steering tube.

  • Page 21: Recommended Sizing

    The G Plus Mariner’s crank is forward of the seat tube and the G Plus Mariner also has a higher than normal seat tube angle. A crank being mounted in front of the seat tube produces a sit up riding position and allows for the seat tube distance to steering tube to be enhanced while maintaining a compact folded dimension.

  • Page 22: Brake Lever Height Adjustments

    you cannot view the LED battery indicator properly, you can loosen the throttle clamp and move the throttle into a preferred position. As stated above, you may have to loosen the brake assemble to move the throttle to your desired position. Please see section e “Brake lever height adjustments” following this section to loosen and adjust the brake lever assembly and maintain correct brake lever height adjustments.

  • Page 23: Suspension Fork Adjustment

    Suspension fork adjustment The G Plus Mariner uses a dual pre-load adjustable suspension fork. The fork’s dual adjustment offers either a softer of firmer ride for smoothing out the bumps in your path. The pre-load can be adjusted according to your weight and liking.
  • Page 24  Each axle side has 2 washers and a nut. Slide the washers into the fork dropout safety flange and tighten nuts by hand.  Using an 18mm wrench, fully tighten axle nuts. Axle nuts should be tightened to 250 lb*in. ...

  • Page 25: Removing And Installing The Rear Wheel

    c. Removing and installing the rear wheel The rear wheel on the G Plus Mariner can be removed or installed without tools. A quick release skewer through a hollow axle is utilized for easy and quick wheel removal. A quick release skewer is a rod that has a threaded acorn nut on one end and a cam lever assembly on the other end.

  • Page 26: Replacing A Tube Or Tire

     Pull the wheel back towards the back of the bicycle and align the tire with the center of the frame. Do not apply to much pressure backwards to cause the chain to be too tight. The chain should also not be hanging and run in a straight line.
  • Page 27 WARNING: There is a safety risk in using gas station air hoses or other air compressors. They are not made for bicycle tires. They move a large volume of air very rapidly, and will raise the pressure in your tire very rapidly, which could cause the tube to explode. Tire pressure is given either as maximum pressure or as a pressure range.
  • Page 28 side of the wheel between the tire bead and rim edge while lifting the tire bead and sidewall over the rim edge.  If removing only the tube, you can now pull the tube outside the side of the tire wall. If replacing the tube, you can now install the new tube.

  • Page 29: Chapter 7: Maintenance And Replacement

     Fill the tube with 50% air and then check the tire bead and rim edge again to see if the tube is protruding anywhere. Once you confirm the tube is not protruding, you can fill the tire to your desired air pressure.

  • Page 30: Brake Adjustments

    Both front and rear brake systems are easy to adjust with multiple adjusting points. Please follow the instructions below on how to adjust your brakes. If you are unsure as to a component or installation procedure, please contact your local Prodeco Technologies authorized dealer. CAUTION: The braking performance may be less than 100% at first until the pads are broken-in and can achieve their normal braking performance.
  • Page 31 CAUTION: Do not use the brake lever and caliper adjusting barrel bolts to tension the cables permanently. This will cause the brake modulation to change, resulting in decreased braking action.  Now that the cable is tight, check to make sure the pad clearance is properly set to the disc rotor. For example at the front brakes, look through the front of the fork to the caliper and pay attention to the area where the center of the caliper over laps the disc rotor.
  • Page 32 The V Brake should now be properly adjusted. Test for braking, the brake pads should lock the wheel at full pressure applied. If wheel does not lock, check for oil or grease on the rim surface or pads and clean. If brakes continue not to perform, bring your bicycle to an Authorized Prodeco Technologies dealer.

  • Page 33: Brake Pad Replacement

    Avid BB5 disc brakes and can be found or ordered from almost any neighborhood bicycle shop or you can contact your Authorized Prodeco Technologies dealer. The pads are always available at no charge through Prodeco Technologies directly.

  • Page 34: Wheel Check

    Your bicycle now has new brake pads installed and your brakes should perform as new. If your brakes are not performing as new, re-read section c “Brake adjustments” of this chapter and re-adjust your brakes. If your brakes still do not perform properly, bring your bicycle in to an Authorized Prodeco Technologies dealer.

  • Page 35: Lubricating

    Folding Mechanisms: The folding hinge components on the frame and handlebar stem should each be lubricated with a drop of lubricant. Any other type of lubrication or greasing of bearings should be performed by an authorized Prodeco Technologies dealer. h. Crankset The crankset of your G Plus Mariner is a multi-piece system which includes a bottom bracket, crank arms, chainring, chainring bolts, chain guard and chain.

  • Page 36: Pedals

    Headset Cartridge bearing headsets are only utilized on all Prodeco Technologies bicycles. These are maintenance free systems and should not be serviced by anyone other than a knowledgeable bicycle repair person. The headset on your bicycle is a double nut threaded system with an alloy cover.

  • Page 37: Torque Specifications For Common Parts

    Torque specifications for common parts Nuts and bolts for your bicycle are set to standard torque settings at the factory. Over time of use and shipping, settings could change and nut or bolt could become loose. Below is a chart on the torque settings in Lb per Inch for the common parts of the G Plus Mariner.

  • Page 38: Installing And Locking The Battery

    To remove the battery, follow these instructions:  Locate the key ignition on the battery base and turn the key in a counter clockwise rotation to the “UNLOCK” position. You must push the key in to turn from the “OFF” position to the “UNLOCK” position.

  • Page 39: Storing The Battery

     The battery includes a battery indicator also to check for charging. The indicator can be found under the left side battery handle. Press the indicator button to display the battery’s energy storage  Once the battery is charged, you should discontinue charging and remove the charger. ...

  • Page 40: Battery Replacement

    If the motor fails, simply remove the motor as explained in Chapter 6 and send the motor to Prodeco Technologies or the closest Authorized service center for a replacement. This motor can also be purchased separately. Check Chapter 11: Parts and Components List for the part number and cost.

  • Page 41: Wiring Harness

    off of the battery base, the controller can be disconnected. If removing the controller, you must first remove the battery completely from the bicycle. There is only one way to connect and disconnect the controller from the bicycle. No two connections are the same. c.

  • Page 42: Chapter 10: Warranty Service And Repair

    Since the bicycle is a mechanical item, there is the possibility of an issue arising. Prodeco Technologies includes one of the best warranties in the industry if there is an issue and this is a 2 year Front to Back warranty with no pro-rating.

  • Page 43: Registering Your Bike

    It is required you register your bicycle within 2 weeks from the date of purchase. You must save your receipt of purchase. To register your bicycle, you can fill out the form on the Prodeco Technologies website at www.prodecotech.com or you can fill out the registration card in the next section below and scan it to service@prodecotech.com, or fax it to 954.974.6729 or mail it to:...

  • Page 44: Part Replacement Procedure

    Part replacement procedure Prodeco Technologies tries to make part replacement as painless as possible. Simply contact Prodeco Technologies service department and explain the problem. A representative will assist you with getting the part at issue replaced. You could also bring your bicycle to a local authorized dealer and they can assist you with the problem.

  • Page 45: Chapter 11: Parts And Components List

    Fork - Suspension Aluminum - V190 - 20" Rim Size - Zoom - 121mm 1 1/8" Threaded Steerer - Silver Gloss PT.FO.20.V190.121.SG $49.95 Frame - Folding Aluminum - V12 - 20" Rim Size - Prodeco Technologies Mariner - Brushed Aluminum PT.FR.MAR.V12.BA $119.95 Freewheel - 16T 3/32"...
  • Page 46 Fork - Suspension Aluminum - V190 - 20" Rim Size - Zoom - 121mm 1 1/8" Threaded Steerer - Black Gloss PT.FO.20.V190.121.BG $49.95 Frame - Folding Aluminum - V12 - 20" Rim Size - Prodeco Technologies Mariner S - Pearl Black PT.FR.MARS.V12.PB $119.95 Freewheel - 16T 3/32"...

  • Page 47: Chapter 12: Specifications

    Fork: Zoom Aluminum Alloy w/ Pre-Load Adjust Zoom Aluminum Alloy w/ Pre-Load Adjust Motor: Prodeco 250W HO Brushless Mini w/ Disc Mount Prodeco 250W HO Brushless Mini w/ Disc Mount Battery: Prodeco LiFEPO4 38.4V 9Ah EZ Remove Prodeco LiFEPO4 38.4V 9Ah EZ Remove...

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