ezee TORQ MK II User manual

www.eZeebike.com
TORQ MK II
USER MANUAL

Contents
Simply moving
Guarantee conditions
Legal regulations
Technical data
Parts Identication
Assembly
Checklist
Battery charging
How eZeebike works
Maintenance
Troubleshooting
Afterword
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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 atten 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 efciency 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 efcient vehicle ever made.
While the eZee pledge to quality means our components are
high value and reliable. Its your part to understand safety implica-
tions 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.
Simply Moving

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 satised :
Proof of purchase. The guarantee starts on the date of purchase.
Only the rst 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 vered 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 trafc
accident.
Damage ascribed to normal wear and tear.
Poor maintenance, or modications that no longer complies with
regulations or original technical specications.
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.
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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 nally
cut off as the vehicle reaches a speed of 25 km/h or if the cyclist
stops pedaling.”
With EU compliant conguration, the power assist of an eZee
bike only functions while the rider is pedalling. The means of control-
ling 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 certicate,
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 nd out about the rules
and regulations in your country.

Technical Data
Weight
Motor
Battery Pack
Controller
Charger
Interface
Fuse
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
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Parts Identifcation
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Torq
1 Brake cables
2 Front LED lighting
3 Mudguards
4 Disc brakes
5 Rims
6 Spokes (13g)
7 Hub motor
8 Reectors
9 Tyres 26” x 1.95”
10 Suspension front fork
11 Motor wire casing
12 Bearing race
13 Frame
14 Pedals
15 Chainwheel 48T and crank
16 Pedal sensor
17 Central support stand
18 Chain 1/2 x 3/32
19 Chain stay
20 Shimano roller brakes
21 Shimano Nexave chain tensioner
22 Shimano Nexave 8 speed gears
23 Rear LED lighting
24 Al. luggage rack
25 Controller / Ignition
26 Battery
27 Saddle ip catch
28 Saddle
29 Seat post
30 Seat post clamp (quick x)
31 Threadless headset
32 Headstem
33 Handle grip (Throttle)
34 Gear shifters
35 Brake levers
36 Battery level gauge
37 Handlebars
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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 at 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.
a. 3 Ignition keys
b. 1 Pair of pedals
c. 1 Battery charger
d. 1 Power cord
e. 2 Fuses (30 amps)
f. Nylon ties
g. Heat shrink tubes (assorted pre-cut sizes)
h. 1 Hex Key #5
i. 1 Hex Key #3
j. 1 eZee Torq User manual
k. Shimano Nexave Gear and Brakes Manual
1 Battery, Lithium Ion 37V 10Ah
and check the box again for any additional purchases or variations
that should be included, according to your eZeebike dealer.
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Tools required Tools are the rst step to proper assembly,
you will need a
Allen / Hex key metric set
Philips head screwdriver
Open-end at 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 rmly fastened.
Tigtening torque 16 Nm
Do not adjust the seat post beyond its maximum extension
mark.
Headstem Align headstem and handlebar so that it is
perpendicular to the frame before tightening as shown below.
Torq Assembly
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Torq Assembly
Pedals Pedals are marked “L” and “R”
for left and right respectively. Screw in clock-
wise for the “R” pedal and counter-clockwise
for “L”. Tighten both with a wrench rmly
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.
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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 ip it over. Locate the battery anges in
their slots in the battery holder; then push the battery rmly into the
holder until the connecting pins are rmly in the battery sockets.
The t 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.
Do not use excessive force to t 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 inated to the correct
pressure of 60 psi. Well inated tyres enhances the comfort, safety
and efciency of your ride.
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Torq Checklist
Usage The eZee Torq is designed for your daily com-
mute and for long treks. Understand your bike well and be well
equipped before venturing far out onto trafc. It is your responsbility
to be attentive of your environment and trafc rules, as this concerns
the safety of all who share the paths, especially you.
a. wear shoes that stay on your feet and grip rmly to the pedals. No barefoot or
sandles.
b. dress to be visible on the road and avoid loose clothes that will tangle with
moving parts of the bicycle.
c. keep your speed at levels appropriate to road conditions
d. be aware of wet weather conditions, as these affect braking distance. Brake
earlier than you normally would on dry roads.
e. familiarise with the trafc rules in the country you are riding in.
f. avoid cycling in poor weather and visibility conditions such as fog, night, heavy
rain and snow. keep your lights on in such conditions.
g. 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 inated to its correct pressure.
handlebar and stem Tightened rmly in the ‘face forward’ positions, the handlebars
will rotate the front fork and wheel, ensure that the grips are also rmly seated.
Brakes Squeeze brake levers to test .Brake cables should remain un-
obstructed 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
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Battery Charging
Before your rst ride, the battery needs charging. Bring it to a
wall socket. (220V - 230V AC EU other countries or 115V AC US)
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1 Fuse / Fuse holder (30 amps)
2 Battery grip
3 Charging socket
4 Battery slot guides
5 Batter lock slot
6 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.
Do not remove the plug by
pulling the cord, always grip the
charging port by its metal body.
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a b c d e f g h

Battery Charging
Check the indicator lights on the front of the charger.
RED light indicates that the charger is connected and
running from an A/C outlet.
YELLOW 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. Male charging plug b, Charging cord c. Charger specications
d. Charger serial no. e. Cooling fan f. Fuse 10 Amps
g. Charger ‘ON’ LED h. Charging status LED i. Warning label
j. Power switch k. A/C voltage switch l. Power cord socket
i j k l
A new battery might take 2 - 3
charges before it performs at its
stated capacity.
Dispose your battery
responsibly, refer to your town
council or eZee dealer.
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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.
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.
Battery Charging
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How eZeebike works
Your rst 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 trafc. 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
ashes, 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).
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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,
‘Pulsing’, or straining any capacity left in the battery will
deteoriate its quality fairly quickly. Charge often!
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How eZeebike works
Lighting system eZee bikes features wide angle high
performance reectors 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 eZee-
bike. Use your feet to depress the stand downwards, ensure the
stand is rmly rested on the ground before leaving the bike.
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 tted on the rear rack, from panniers to child seats. Do
however, take note that the load limit is 25 kgs.
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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
nger. 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.
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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.
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.
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 rst
unplug the wires than run from the motor to
controller. There should be 1 x 6 pin
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