Ezee | TORQ MK II | User manual | ezee TORQ MK II User manual

ezee TORQ MK II User manual
www.eZeebike.com
TORQ MK II
USER MANUAL
Contents
Simply moving
3
Guarantee conditions
4
Legal regulations
5
Technical data
6
Parts Identification
7
Assembly
8
Checklist
12
Battery charging
13
How eZeebike works
16
Maintenance
19
Troubleshooting
21
Afterword
23
2
Simply Moving
Congratulations on the purchase of your eZee bike. You’re
one step closer in realizing a whole new way of commuting that is
fast, fun and friendly to the environment.
The hub motor is brushless and uses a technology called
Pulse Wave Modulation control, so that its not subject to wear like
a regular DC motor. Planetary reduction gears incorporated into its
hub gives it a very strong torque, working in unison with your leg
power to flatten out those hills and to overcome headwinds.
Under normal cruising conditions (26 kmh, 16 mph), the motor draws about 5 amps at 140 watts with 5 Nm torque and has
an efficiency about 80%. Its electric consumption is about 1.0 kwH
for 100 km / 62 miles in ebike mode - even less energy than the food
you would consume riding by leg power alone. Making it by far the
most efficient vehicle ever made.
While the eZee pledge to quality means our components are
high value and reliable. Its your part to understand safety implications and the possible risks of cycling. So please take some time and
read this manual. It explains the bike in detail, how to take care of it,
so that you can enjoy using the bike for many years to come.
3
Guarantee Conditions
The following guarantee conditions complement your legal rights.
How the guarantee applies
As the makers, we guarantee against possible material or construction defects.
Provided the following conditions are satisfied :
Proof of purchase. The guarantee starts on the date of purchase.
Only the first owner is entitled to the guarantee.
The bike is guaranteed for 2 years, this comprises of the frame, fork, all mechanical and electrical parts, except normal wear and tear items.
1 year for the battery up to 70% depth of discharge from its original rated
capacity. This can be verfied by the eZee dealer you’ve purchased the bike from.
How the guarantee does not apply
When the bicycle is used negligently or results in damage due to traffic
accident.
Damage ascribed to normal wear and tear.
Poor maintenance, or modifications that no longer complies with
regulations or original technical specifications.
Damage due to external causes.
The bicycle is put up for hire.
The battery pack is used incorrectly or tempered with. This also applies during charging.
Compensatory costs arising from damages or accidents, or cost incurred by loss of the bicycle’s usage.
How the guarantee covers
Original defective parts that are sent to the manufacturer for assessment
will be replaced by the same or equal value part.
Labour and transportation charges are not included. This are borne by
the owner.
eZee exclusively makes the decision whether or not the guarantee applies.
4
Legal Regulations
EU regulations state that your vehicle is an Electric Powered
Assist Cycle (EPAC) when the following conditions are met.
[ EU directive 2002/24/EC Chapter 1 Article 1 1(h) ]
“Cycles with pedal assistance which are equipped with an
auxiliary electric motor having a maximum continuous rated power
of 0.25 kW, of which the output is progressively reduced and finally
cut off as the vehicle reaches a speed of 25 km/h or if the cyclist
stops pedaling.”
With EU compliant configuration, the power assist of an eZee
bike only functions while the rider is pedalling. The means of controlling the assistance is provided with either a dial or throttle system.
USA regulations allow a power assisted maximum speed of
20 mph. eZee bike made for the USA has a motor speed of 250 rpm
for a 20 mph top speed and a maximum rated power of 700 watts.
The power assist can function without the aid of pedalling, however
there’s nothing to stop you from doing so. Putting in some effort will
greatly increase the mileage you get from your battery.
This means you do not require a license or moped certificate,
there is no age limit and you can take cycling paths. It conforms to
regulations of normal bicycles. Legal requirements concerning insurance of your bicycle may differ, so do find out about the rules
and regulations in your country.
5
Torq
Weight
Motor
Battery Pack
Controller
Charger
Interface
Fuse
6
Technical Data
22 kgs
Electric brushless hub motor
250W (EU) / 350W (US) with planetary
reduction gears
Lithium Ion with battery management circuit
37V 10Ah (370 Wh capacity)
3.1 kgs
Low voltage protection 28 V
Discharge temperature limit -15°C to +55°C
PWM
LED self diagnostic system
Overload protection 20 amps
2 amps
Smart charger
Maximum charge time 6 hrs
charging temperature +5°C +35°C
Forward magnetic motion sensor with 0 - 4.5 V VPA dial or throttle
E-bike throttle with safety ON/OFF switch
Pedelec throttle with light switch
30 amps
Torq
Parts Identifcation
25 26 27 28 29 30
31 32 33 34 35 36 37
24
23
22
1
2
3
4
5
6
7
8
9
21 20 19 18 17 16 15 14 13 12 11 10
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Brake cables
Front LED lighting
Mudguards
Disc brakes
Rims
Spokes (13g)
Hub motor
Reflectors
Tyres 26” x 1.95”
Suspension front fork
Motor wire casing
Bearing race
Frame
Pedals
Chainwheel 48T and crank
Pedal sensor
Central support stand
Chain 1/2 x 3/32
Chain stay
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
Shimano roller brakes
Shimano Nexave chain tensioner
Shimano Nexave 8 speed gears
Rear LED lighting
Al. luggage rack
Controller / Ignition
Battery
Saddle flip catch
Saddle
Seat post
Seat post clamp (quick fix)
Threadless headset
Headstem
Handle grip (Throttle)
Gear shifters
Brake levers
Battery level gauge
Handlebars
7
Torq
Assembly
If you have received your bike through mail instead of picking
it up from your local bike specialist, please read this section before
proceeding to assemble.
Unpack
Carefully remove the bicycle by lifting it straight out of the box. Becareful not to scratch yourself on the carton staples.
Remove the packing material around the bike and stand the bike on
a clean flat surface. Be sure to keep any part packages that comes
along with the bike. Discard box and packaging material only.
Dispose responsibly, recycle when possible.
Check This box should contain....the eZee Torq bicycle!
An accessory box containing.
1 Battery, Lithium Ion 37V 10Ah
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
3 Ignition keys
1 Pair of pedals
1 Battery charger
1 Power cord
2 Fuses (30 amps)
Nylon ties
Heat shrink tubes (assorted pre-cut sizes)
1 Hex Key #5
1 Hex Key #3
1 eZee Torq User manual
Shimano Nexave Gear and Brakes Manual
and check the box again for any additional purchases or variations
that should be included, according to your eZeebike dealer.
8
Torq
Assembly
Tools required
Tools are the first step to proper assembly, you will need a
Allen / Hex key metric set
Philips head screwdriver
Open-end flat wrenches metric
measurements 6mm - 17mm
Front wheel
Insert the hub motor wheel into the front fork,
ensuring that it is properly seated in the dropout slots. Tighten the
nuts alternatively on both sides till the wheel is secured.
Tightening torque 35 Nm Seat post
Insert into the seat tube of the bicycle frame
and align. Tighten clamps and ensure seat is firmly fastened.
Tigtening torque
16 Nm
Do not adjust the seat post beyond its maximum extension mark.
6
Headstem
Align headstem and handlebar so that it is
perpendicular to the frame before tightening as shown below.
9
Torq
Assembly
Pedals
Pedals are marked “L” and “R”
for left and right respectively. Screw in clockwise for the “R” pedal and counter-clockwise
for “L”. Tighten both with a wrench firmly
but not excessively as the crank threads are
made of aluminum alloy.
Front Mudguard The supports are attached to the sides and top of the front
fork, the mudguards are made of polycarbonate and should not
rattle when they’re securely fastened.
Brakes
One of the most important safety features on
the bicycle. To minimise the risk of injury, its vital to ensure they are
corrected adjusted. Ensure that the V-brake blocks are parellel to
the rim, and that the distance between them do not exceed 2mm,
then tighten the brake mounting bolts. Fine tune with a philips head
screwdriver. Squeeze brakes to test its responsiveness.
For more information about the rear Shimano Roller brake, please
read the Shimano manual that comes along with your purchase.
Models that come with disc brake options, check that the wheels
rotate freely without touching the pads.
<
If you have little experience with bicycle maintenance. We
recommend you get this done with your local bike shop.
Accessories
Install any optional accessories you have purchaed with your bike. Read the manufacturer’s manual provided.
10
Torq
Assembly
Battery Insert key into keyhole located by the controller box and turn key counter clockwise while pressing it in, so
that it arrives in the open position. Release the catch located at the
underside of the saddle to flip it over. Locate the battery flanges in
their slots in the battery holder; then push the battery firmly into the
holder until the connecting pins are firmly in the battery sockets.
The fit can be tight when new, so it may be required to apply gentle
pressure. Once the battery is in position, lock into place by turning
the key one click clockwise to the “OFF” position. Ensure that the
key is in “OFF” position until you are ready to ride.
6
Do not use excessive force to fit the battery, which could result in damaging the connection sockets or pins.
If there is an A/C outlet near to where your bicycle is parked. It may
not be necessary to remove the battery from the bicycle to charge.
Tyres
Ensure that the tyres are inflated to the correct
pressure of 60 psi. Well inflated tyres enhances the comfort, safety
and efficiency of your ride.
11
Torq
Checklist
Usage
The eZee Torq is designed for your daily commute and for long treks. Understand your bike well and be well
equipped before venturing far out onto traffic. It is your responsbility
to be attentive of your environment and traffic rules, as this concerns
the safety of all who share the paths, especially you.
a.
b.
c.
d.
e.
f.
g.
wear shoes that stay on your feet and grip firmly to the pedals. No barefoot or sandles.
dress to be visible on the road and avoid loose clothes that will tangle with moving parts of the bicycle.
keep your speed at levels appropriate to road conditions
be aware of wet weather conditions, as these affect braking distance. Brake earlier than you normally would on dry roads.
familiarise with the traffic rules in the country you are riding in.
avoid cycling in poor weather and visibility conditions such as fog, night, heavy rain and snow. keep your lights on in such conditions.
familiarise yourself with the usage of the bike and how to maintain it.
Inspect
Before every ride, make a quick inspection of your bike’s mechanical and electronic features. Be safe, not sorry.
frame & fork
Visually check for damage, do not ride if bent or fractured.
wheels and tyres
Check for missing or damage spokes. Feel spokes to ensure
tightness. wheels should be true (straight) and tyres inflated to its correct pressure.
handlebar and stem
Tightened firmly in the ‘face forward’ positions, the handlebars
will rotate the front fork and wheel, ensure that the grips are also firmly seated.
Brakes
Squeeze brake levers to test .Brake cables should remain unobstructed by other cables or accessories.
Chain
Turn crank arms to ensure chain runs smoothly. Keep the chain
lubricated and clean. Chain tension is adjusted by the tensioning bolt located at the end of
the frame.
Electronics
Red light from the controller unit should be illuminated when
the electric bike is ‘ON’. All wires to be fastened securely in place
12
Battery Charging
Before your first ride, the battery needs charging. Bring it to a
wall socket. (220V - 230V AC EU other countries or 115V AC US)
1
2
1
2
3
4
5
6
3
4
5
6
Fuse / Fuse holder (30 amps)
Battery grip
Charging socket
Battery slot guides
Batter lock slot
Serial number, battery information
Insert charging plug into socket on battery and connect charger power
cord to A/C outlet. Turn on A/C outlet.
Turn the ‘1’ switch on the charger.
<
It’s important that to follow this
sequence of actions everytime you
charge the battery.
6
Do not remove the plug by
pulling the cord, always grip the charging port by its metal body.
a
b
c
d
e
f
g
h
13
Battery Charging
Check the indicator lights on the front of the charger.
RED
YELLOW
light indicates that the charger is connected and
running from an A/C outlet.
light indicates that the battery is charging
GREEN
light indicates that the battery is fully charged
It will take a maximum of 6 hours to fully charge your battery. You
may interrupt the charging at any time.
As Li Ion batteries do not suffer from memory effect, it is not required for the battery to be empty to commence a recharge. Top-up charging everytime you’ve completed your cycle ride is
recommended.
Kept in good condition Li Ion battery will perform at least 350 full
charge cycles, with a retention of 70% from its original capacity.
Please use only the Li ion charger as provided.
a.
d.
g.
j.
Male charging plug
Charger serial no.
Charger ‘ON’ LED
Power switch b,
e.
h.
k.
Charging cord
Cooling fan
Charging status LED
A/C voltage switch c.
f.
i.
l.
Charger specifications
Fuse 10 Amps
Warning label
Power cord socket
A new battery might take 2 - 3 charges before it performs at its
stated capacity.
<
i
14
j
k
l
Dispose your battery responsibly, refer to your town council or eZee dealer.
Battery Charging
Sometimes after temporary disconnection, the charging status light may give a false green reading. To verify that your battery is fully charged, switch the charger off, wait for the charger
lights to go out and switch it back on again. The charging status
light should quickly return from amber to green, when the battery is
fully charged.
The battery may be also charged on the bicycle, do make
sure that the bicycle is switched off so as to not waste electricity.
If the battery refuses to accept a charge, refer your eZee
dealer for more information.
Battery charging is automatically regulated, there is no danger of overcharging. We advised that you disconnect the battery and switch the charger off when the charging process is
completed.
6
6
6
Do not charge the battery in wet conditions.
Never allow children to play with the battery or charger.
Do not leave your battery in a fully discharge state for long periods of time. The battery will continue to self-discharge, resulting in damage.
15
How eZeebike works
Your first ride
Before you wheel your bike out into the world,
we recommend you practice handling the bike in a safe area away
from obstructions and traffic. The motor may look small, but it’s
powerful! You’ll be riding faster than you think.
Turn the key to the ‘ON’ position. A red LED will illuminate below the key socket. If the light flashes, read the Troubleshooting section of this manual. If it shines steadily, you’re ready for the next step.
EPAC / Pedelec As you pedal, rotation on the crank is picked
up by a sensor in the bottom bracket. This allows the drive system
to be engaged. A twist of the throttle then provides power-on-
demand, reducing the pedalling effort required.
E-Bike
The motor runs as soon as you turn the throttle. Ensure that you are seated and ready to ride off before
you use the throttle. You may toggle the throttle on and off with the
switch located on it.
In E-bike mode, the range of your bike will be approximately 40
kms (25 miles). The hillier the terrain, the less you pedal, shortens
your range. While EPAC, judicious use of gears, power assistance
all contributes to increasing the mileage you can get out of your
ride. 40 - 60 kms (25 - 40 miles).
16
How eZeebike works
Variable Power Assist (VPA)
In lieu of a throttle, you may
have received or chosen a potentiometer dial. This set-up is only
compatible with EPAC mode eZeebikes.
The dial settings from 0 - 8 correspond accordingly to the level of
continous power assistance acheived by the motor during pedalling. The level of assistance remains the same throughout
regardless of road conditions until you re-set the dial to another
position. This is especially useful for long treks or when you do not
wish to fuss about with a more sensitive throttle.
You can always choose to ride your bicycle as an ordinary bicycle.
Battery level gauge When riding a fully charged
bicycle, the battery level gauge shows ‘green’. Powerful acceleration or uphill riding causes the battery voltage to drop and
may bring the level gauge to ‘amber’ or even ‘red’ (in the cases of
very steep hills).
As you continue to cycle and the battery power drops, the level
gauge will correspond to the state of charge remaining. When it
remains in ‘amber’ and dips into ‘red’, you have approximately a
1/3 of the charge left. Best to recharge the battery soon.
To prevent the battery from deep discharge, the controller has a
low voltage protection cut-off set at 30.0 V. You may reboot the
bicycle if it cuts off however,
6
‘Pulsing’, or straining any capacity left in the battery will deteoriate its quality fairly quickly. Charge often!
17
How eZeebike works
Lighting system eZee bikes features wide angle high performance reflectors at the front, sides and rear. Front and rear
LED lights are powered by the main battery, electrical consumption
is negligible, be safe, use them often.
Lock
When parking your bicycle, turning the key to
the ‘OFF’ position and removing it will shut the system off and lock
the battery in place. Use a chain lock to further secure your bicycle
when necessary. We also recommend you insure your bike against
theft. Consult your eZee dealer or LBS for more information.
Kick stand
This spring loaded stand supports your eZeebike. Use your feet to depress the stand downwards, ensure the
stand is firmly rested on the ground before leaving the bike.
6
Do not sit on the bike with the stand parked. The kick side
stand is made of aluminum alloy and meant to only take the weight
of the bicycle and not with the rider on it.
Luggage rack
The luggage rack provided comes equipped
with a spring loaded catch and elastic strap. If you plan to carry
luggage on the rear, make sure everything is securely fastened
and clear from the rear wheel. There are many useful accessories
that can be fitted on the rear rack, from panniers to child seats. Do
however, take note that the load limit is 25 kgs.
18
Maintenance
<
Maintaining your bicycle ensures you’ll get the most out of
every ride and out of the entire life of your eZee bike. How much of
your bike’s maintenance you can do yourself will depend on your
knowledge, skill, experience and whether you have the necessary
tools for the job.
Learning from available cycling literature and joining cycling
communities can be an enjoyable way of improving your skill and
knowledge about maintaining bicycles. Beyond this manual, it is
good to consult your LBS and eZee dealer for advice regularly.
Before every ride Mechanical safety checks, use a fully charged
battery, visual inspection for damages.
Every 150kms (100 miles) Clean the bike, incl. chain rings and
sprocket. Clean and lightly oil the chain and gears.
Every 20 - 30 hours of riding Squeeze the brakes and rock the
bike to check for any looseness with each forward of backward
movement. If the headset is loose, have your dealer check it.
Lift the front wheel and rotate handlebars to check for tightness of
steering, it may be necessary to lubricate ball bearings.
Check and recalibrate the brakes, replace if worn out.
Squeeze spokes in adjoining pairs between your thumb and index
finger. They all should have the same tension. Have your dealer
respoke or true the wheel if necessary.
Check cables for rust, kinks and fraying, have your dealer replace
them if necessary.
19
Maintenance
Repairing a punctured tyre
If you have a punctured tyre, we
recommend that you get a specialist to carry out the repairs. You
can always of course consult a specialist and carry out the repairs on your own.
As there are no electronic components on the rear wheel, its removal follow standard proceedures as with normal bicycles with internal gears. Read the Shimano gear manual provided for more
instructions.
As the front wheel contains the hub motor,
there are additional steps in the case you require the entire wheel to be removed from
the bike.
A philips head screwdriver will be required to
open the cable housing (shown on left) to first
unplug the wires than run from the motor to
controller. There should be 1 x 6 pin
connection and 3 colour coded wire connections (Blue, Yellow,
Green). Unplug these before proceeding to remove the front wheel.
Be mindful of the tightening assembly sequence of washers, nuts
and spacers.
Hub motor and general inspection
After 5,000 kms (3,000 miles) of cycling. We recommend you arrange to have a thorough inspection of your bicycle by an eZee
dealer. This includes opening up the hub motor to inspect and
lubricate the gears.
20
Troubleshooting
Electronic self-diagnostic system
When the bicycle is functioning normally, the red LED that is
situated by the controller is lit continually.
In the case of an electronic malfunction, the controller comes programmed with diagnostic capabilities to determine where the
fault lies. The red LED will emit a series of blinks, count them and
refer to the table below for its explanation and solutions.
No. of
blinks
Explanation
Solution
No response on motor
lost connection on 5V wire to motor, check
connectors at front fork
2
Brake lever cut off in
contact
check brake lever spring, brake levers should
return to position (applicable with electric cut-off
levers)
3
Brake lever cut off in
contact
check wiring connection, inspect for damage to
the battery level gauge
4
Throttle not in position
check if throttle spring is faulty
5
Throttle failure
Ground + signal wire to throttle shorted
5V+ signal wire to throttle shorted
Moisture penetration / leave it to dry
Check throttle connections and cable, or replace
6
low voltage
Activated when voltage drops below 30.5 V .This
continue to blink and will stop when voltage
recovers to 34V, Or when the main switch is powered off. Battery charging
7
excessively high voltage
Battery voltage is above 44 V./ do not use battery
that is not supplied by eZee, contact your eZee
dealer
ON
21
Troubleshooting
No. of
blinks
Explanation
Solution
8
Hall sensor in motor
faulty
One or more hall sensor disconnected or faulty.
Check connector at the front fork. If connector
is OK, contact your eZee dealer
9
Supply 3 phase wire
Check phase wires at the front fork. Contact your
eZee dealer
10
Controller overheating
Motor continue to function but the amps directed
will be lessened to reduce the load and cool
controller
11
Thermostat faulty
the motor will continue to work, but extreme
temp. arise without thermostat protection may
damage controller - Replace controller
12
Controller failure
Motor does not work - Replace controller
2+3
Controller failure
Motor does not work - Replace controller
3+4
Stalled motor
Extremely overload stalling motor, switch off and
on – reboot
3+5
Supply 3 phase wires
Inspect cable and connector for dislocation or
damage. Diagnostic appears during throttle usage.
No Light Power supply faulty /
Controller failure
Inspect battery and power connections for damage / Replace controller
The faults listed may not cover every possible failure. In the
event of moisture or water entering the controller, haphazard signals might appear. We’ve designed the eZeebike to repel water
as much as possible, encapsulating circuit boards with silicone
resins and connections with silicone grease.
Since this manual simply cannot cover every detail that
might occur during the lifetime of your product. Check our websites
and dealers website routinely for updates, or contact us directly for
more detailed questions you might have.
22
Troubleshooting
Serial Numbers Record the serial numbers found on your motor, frame, controller, charger and battery here for reference.
This are important datas for us to understand and troubleshoot
your eZeebike.
Proof of purchase Keep your proof of purchase handily, with the
date of purchase clearly marked.
Afterword
As people all around the world have begun to realize how
easy and beneficial it is to ride our electric bike. At eZee, our
mission is simple - to continue to make the best electric bike out
there. We’re on the constant lookout for ways to evolve our bikes,
to find methods and adapt solutions for our bikes to enrich lives
everywhere.
We also want to get to know and thank everyone of you.
If you have anything to ask, to comment or suggest; perhaps you
have an idea, a project to discuss, or simply would like share your
stories and photos with us. Contact us directly, we want to hear
from you!
eZee kinetics technology co. ltd.
No. 233 Feng Yong Road
Feng Xian, Shanghai, China 201414
Tel: +86 (0)21 5756 6097
Fax: +86 (0)21 5756 2566
www.eZeebike.com
info@ezeebike.com
All rights reserved. eZee kinetics technology co. ltd 2008
23
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