TQ-Systems TQ-HPR50 User manual

TQ-HPR50
System
Service Manual

2

3
Contents
Important notice ..............................................................................................................................4
Hazard Classification........................................................................................................................4
Ensuring safety.................................................................................................................................5
Connecting the e-bike (TQ drive system) with the PC .................................................................6
Mountain bike e-systems overview ................................................................................................ 7
Road e-systems overview ...............................................................................................................8
Overview of the tools used in the manual .....................................................................................9
Installation of the display (V01 and V02) ...................................................................................... 10
Assembly of the REMOTE V02 .......................................................................................................12
Installation of Drive Unit HPR50 .....................................................................................................14
Installation of the Battery HPRV01 ................................................................................................ 18
Installing the wiring harness..........................................................................................................20
Installation of the speed sensor....................................................................................................22
Installation of the Smart Box .........................................................................................................24
Manual Dealer Service Tool (DST) .................................................................................................26
Troubleshooting.............................................................................................................................28
Contents

4
Safety instructions
Important notice
►The service manual is geared towards professional and training bicycle mechanics.
►Be sure to also read the included operating instructions of the various products.
►Do not make any modifications to the products that are not described in the manual or that go beyond
the contained information.
►You will find all service manuals and user manuals, along with the current versions, in the TQ dealer portal:
www.tq-group.com/en/e-bike-portal/
►Please also observe the rules of the country, state or region in which you operating.
For safety reasons, read this service manuals thoroughly and follow the instructions for proper use.
Hazard Classification
DANGER
This signal word designates a hazard with a high degree of risk, which, if not averted, will result in death or
severe injury.
WARNING
This signal word designates a hazard with a moderate degree of risk, which, if not averted, will result in
death or severe injury.
CAUTION
This signal word designates a hazard with a low degree of risk, which, if not averted, could result in minor or
moderate injury.
NOTICE
A notice, as set out by this manual, is important information about the product or the respective section of
the manual requiring special attention.

5
Additional notices
Ensuring safety
DANGER
Also inform the users about the following:
Handling of the batteries and chargers
►Do not open the battery housing or charger housing under any circumstances, and never attempt to
dismantle them.
►Do not undertake any attempts to repair a damaged battery housing under any circumstances.
►Never break or perforate the battery
►Protect the battery against fire, severe heat, along with prolonged direct exposure to sunlight.
►Never immerse the battery in water.
►In case of improper use, fluid may leak out of the battery. Avoid any contact with the fluid. In case you
come into contact with the fluid, wash it off with water. Also seek the attention of a physician if your
eyes come into contact with the fluid. Fluid leaking out of the battery may lead to irritation or burns.
►In order to prevent damage to the battery, never subject the battery to mechanical impact.
►Keep the battery away from metal objects, as a danger of short-circuiting exists. Do not allow nails,
screws or other small, sharp and/or metallic objects come into contact with the battery (charging port
/ discharge socket).
►Only use the designated TQ charger for charging the battery.
►Protect the charger from moisture. Otherwise, there is the risk of electric shock.
►Only operate the charger in dry rooms.
►Keep the charger clean. Soiling could lead to an electric shock.
►Never operate the charger on an easily combustible surface (e.g. paper, textiles etc.) or in a combustible
environment. There is a fire risk due to the warming of the charger during charging.
WARNING
Strictly follow the instructions in the manuals when installing HPR products.
It is recommended to use only original TQ parts.
Wear approved eye protection when performing maintenance procedures, such as replacing components,
for example.
You will also find additional product information in the user manuals of the individual TQ
components.
Also inform the users about the following:
►When cycling, do not become distracted from the information indicated on the display, instead focus
exclusively on the traffic. Otherwise, there is the risk of accident.
►Make sure before starting out that all screws and wheels are securely fastened.
►The assistance by the drive system depends on the one hand on the selected assistance level and on
the other hand on the force that the rider is exerting on the pedals. The greater the force exerted on the
pedals, the higher the level of motor assistance. The drive assistance stops when you stop pedaling.
►Only use the original TQ charger to charge the battery and ranger extender.
►The drive unit may heat up during operation, depending on the load and other additional influencing
factors, causing the surface of the drive unit, along with adjacent components (motor covers) to
become hot. Do not come into contact with the drive unit with your hands or legs during or after a ride.
Otherwise, there is the risk of burns.

6
Additional notices
CAUTION
Also inform the users about the following:
►Please observe the notices in the user manuals and in the operating instructions of the bike.
►Prior to each charging cycle, check to ensure that the charger, cables and plugs are not damaged.
►Do not operate the charger if cables or plugs are damaged. Otherwise, there is the risk of electric shock.
►The charger may be used by children 8 years and older and by persons with restricted physical, sensory
or mental abilities or lacking experience and knowledge if they are supervised or have been instructed
in the safe use of the equipment and the resulting dangers. Children are not allowed to play with the
equipment. Cleaning and user maintenance are not allowed to be carried out by children without super-
vision.
►Do not many any modification to the system, as this may lead to malfunctions and will also void the
warranty.
►Also observe the charging, operating and storage temperatures of the battery.
Charging temperature range: 0 °C to 40 °C / 32 °F to 104 °F
Operating temperature: -5 °C to 40 °C / 23 °F to 104 °F
Storage temperature: 10 °C to 20 °C / 50 °F to 68 °F
NOTICE
Also inform the users about the following:
►Place blind plugs on all unused connections.
►Never clean the e-bike with a high-pressure washer, as this can result in malfunctions, defects or corro-
sion of the components.
►Do not stand the bike upside down. This could possibly damage the remote or the shift levers.
►The transport of lithium batteries is subject to country-specific laws and regulations. Please become
informed about the respective regional rules, and follow them during transport.
►Do not remove the battery from the e-bike during the charging cycle.
►Never cycle with the e-bike when the charger is connected.
►Close the charge port cover if the charging cycle is completed or no service dongle is connected.
►Only use the designated TQ charger for charging the batteries.
►Use only an original HPR battery to supply the drive system with power.
►Clean the battery only with a soft, damp cloth.
Connecting the e-bike (TQ drive system) with the PC
The TQ service dongle V01 is intended for connecting the USB port of the PC with the HPR50 drive system
and is not allowed to be used for other purposes or other manufacturers. The service dongle is required for
the use of the TQ Dealer Service Tool and enables communication between the PC and the e-bike. With the
help of this interface, the software of the Dealer Service Tool can access all the components of the e-bike
drive system.
The Dealer Service Tool enables the following:
►System diagnostics of connected components
►Firmware Updates
►Service Reports
►E-bike Settings

7
E-systems overview
Mountain bike e-systems overview

8
E-systems overview
Road e-systems overview

9
Overview of the tools used
Nm
wrench
Torque wrench
caliper Caliper gauge
BB
UN55 Inner bearing tool BB-UN55
grease Ball-bearing grease
2,5
mm Hex key 2.5 mm
5
mm Hex key 5 mm
6
mm Hex key 6 mm
T
8Torx T8
10
TTorx T10
T
20 Torx T20
25
TTorx T25
45
TTorx T45
55
TTorx T55
DST Dealer Service Tool (DST)
Overview of the tools used in the manual

10
Display V01 and V02
Installation of the display (V01 and V02)
Tool required
4Nm
wrench
Torque wrench
4T
10 Torx T10
5DST Dealer Service Tool (DST)
Display installation
0
➀
➁
 M3x20 screw
 Display frame
1
Feed the connecting cable for
the display / Smart Box cleanly
through the display enclosure in
the frame.
Please make sure not to
kink the cables.
2
A
➀
➁
Version A:
Without remote and without
Smart Box
 Make the connection between
the red plug (display) and the
black socket (wiring harness).
 The protective cap needs to
be placed onto the second
display plug.
Please make sure that
plug connectors are
clean.
The pins are not allowed
to be bent.
2
B
➀
➁
Version B:
With remote and without Smart
Box
 Make the connection between
the green plug (display) and
the green socket (remote).
 Make the connection between
the red plug (display) and the
black socket (wiring harness).
Please make sure that
plug connectors are
clean.
The pins are not allowed
to be bent.
2
C
➀
➁
Version C:
Without remote and with Smart
Box
 Make the connection between
the red plug (display) and the
black socket (Smart Box).
 The protective cap needs to
be placed onto the second
display plug.
Please make sure that
plug connectors are
clean.
The pins are not allowed
to be bent.
Wiring harness
Remote
Wiring harness
Smart Box

11
Display V01 and V02
2
D
➀
➁
Version D:
With remote and with smart
box
 Make the connection between
the green plug (display) and
the green socket (remote).
 Make the connection between
the red plug (display) and the
black socket (Smart Box).
Please make sure that
plug connectors are
clean.
The pins are not allowed
to be bent.
3
➀
➁
 Insert the display enclosure
down into the frame.
 The screw hole in the display
needs to be above the screw
hole in the frame.
4
Tighten the included M3×20
display screw with a torque of
0.5 Nm. 10
T
Nm
wrench
0.5 Nm
5
Launch the TQ Dealer Service
Tool and connect the dongle
with the PC and the bike. DST
6
Perform available software
updates in order to keep the
system up to date.
Remote

12
Remote
Assembly of the REMOTE V02
Tool required
3Nm
wrench
Torque wrench
32,5
mm Hex key 2.5 mm
Remote assembly
0
➀
➁
 Remote control unit
 Remote cable
1
Plug the remote control unit into
the left handlebars.
Makes sure it is properly
aligned.
2
Insert the oval plug of the remote
cable properly aligned and all
the way into the remote control
unit. Feed the cable within the
handlebars in the direction of the
display.
Pay attention to the oval
coding of the plug.
Please make sure that
the plug connectors are
clean, the pins are not
allowed to be bent.
3
Tighten the pre-assembled M3
remote screw using a torque of
1 Nm.
2,5
mm
Nm
wrench
1 Nm
Make sure the remote is
in the proper position,
the handlebar grip and
brake must be mounted
beforehand.
4
Make the connection between
the green socket (remote) and
the green plug (display).
Please make sure that
the plug connectors are
clean, the pins are not
allowed to be bent.
Remote cable socket
Remote cable plug
Remote

13
Remote

14
Installation of Drive Unit HPR50
Tool required
2caliper Caliper gauge
2T
55 Torx T55
4
6Nm
wrench
Torque wrench
46
mm Hex key 6 mm
5grease Multi-purpose grease
6BB
UN55 BB-UN55 inner bearing tool
8DST Dealer Service Tool (DST)
Motor installation
0
➁➂
➀
 Rear motor bolt
62 mm
 Front motor bolt
73 mm or 76.5 mm
(depending on manufacturer)
 Lockring
1
➀
➁
 Insert the plug of the
speed sensor into the socket
of the drive unit.
 Then connect the drive unit to
the wiring harness.
Pay attention to the cod-
ing of the plug.
Please make sure that
the plug connectors are
clean, the pins are not
allowed to be bent.
2
Adjust the two motor compensa-
tion screws to the correct frame
width at the mounting points.
Maximum axial frame tolerances
of ± 1 mm can be compensated.
55
T
The two screws have a
left-hand thread!
Incorrectly adjusted
screws may cause dam-
age to the frame or drive
unit!
Drives without compen-
sation screws have a fixed
installation dimension
and may only be used for
corresponding models.
Drive Unit Speed Sensor
Drive Unit Wiring harness
Compensation
screws
Drive Unit

15
Drive Unit
2
A
➀ ➁
 Use a caliper gauge to mea-
sure the distance between the
two mounting points in the
frame.
 Then set this value on the
motor compensation screws
and thus adjust them to the
required frame width.
caliper
The maximum motor
compensation width is
not allowed to exceed or
fall below a maximum of
± 1 mm.
3
Insert the drive unit into the
e-bike frame – matching the
mounting points.
Make sure that no cables
or plugs are crushed or
kinked.
4
➁
➀
Tighten the motor bolts  and
 according to the respec-
tive e-bike manufacturer with
a tightening torque of 20 Nm.
Use new motor bolts (using a
medium-strength threadlocker if
necessary)
6
mm
Nm
wrench
20 Nm
Ensure that the contact
surfaces are clean.
5
➁➀
Prior to assembly
of the lockring, grease the O ring

and the shaft seal  at the
marked points with ball-bearing
grease.
grease
6
➁
➀
Place the chain ring (manufac-
turer-dependent) on the output
shaft.
Attach the lockring  with the
help of an mounting tool 
and tighten it with a tightening
torque of 50 Nm.
Then remove the mounting tool
 .
BB
UN55
Nm
wrench
50 Nm
Mounting without a
mounting tool can lead to
damage of the shaft seal
and thus to motor dam-
age, e.g. due to water
ingress!
7
UP
Mount both cranks, taking into
account the index markings.
After initial start-up, fail-
ure to observe the index
marking may result in out-
of-center assistance for
the first 300 m or 984 ft.
Marking

16
Drive Unit
8
Launch the TQ Dealer Service
Tool and connect the dongle
with the PC and the bike. DST
9
The Dealer Service Tool connects
to the TQ database and identifies
the e-system.
Confirm the bike serial number;
if identification is not possible,
enter the serial/frame number.
10
Perform available software
updates in order to keep the
system up to date.

17
Drive Unit

18
Installation of the Battery HPRV01
Tool required
2
4Nm
wrench
Torque wrench
2T
10 Torx T10
4T
25 Torx T25
additional tools may be required
to remove the skid plate.
Battery installation
0
Battery installed in the frame and
connected.
1
A
Select the manufacturer-depen-
dent battery brackets and the
recommended screws:
The figure on the left shows the
horizontal layout of the brackets.
Please note the manufac-
turer-dependent horizon-
tal or vertical design of
the brackets.
1
B
The figure on the left shows the
vertical layout of the brackets.
2
Screw the two brackets to the
battery with the ISO14580 M3×6
screws (with threadlockers) with
a torque of 1 Nm.
10
T
Nm
wrench
1 Nm
During
installation, pay attention
to the connector coding.
(see Fig. left)
Connector
side
Connector
side
Torx T10
Battery

19
Battery
3
Carefully slide the Battery V01
into the battery compartment up
to the specified screw-on points.
The wiring harness should al-
ready be pre-mounted See also
“Installing the wiring harness” on
Page 20.
Be careful not to crush
any cables.
Please observe the
manufacturer-dependent
instructions for the wiring
harness.
4
Fasten the Battery V01 to the
frame with the TQ screws (M5)
provided for this purpose and
tighten them with a tightening
torque of 3 Nm.
25
T
Nm
wrench
3 Nm
Note other manufactur-
er-dependent bracket/
screw solutions, where
applicable.
5
Connect the battery plug from
the wiring harness to the battery.
Ensure that the plug is
properly locked.
The plug snaps into place
with a clicking sound.
6
Where appropriate, mount the
drive unit see “Installation of
Drive Unit HPR50” on Page 14
and/or the manufacturer-depen-
dent skid plate.
Observe the
manufacturer's instruc-
tions for skid plate instal-
lation.
Screw-on points
Torx T25
TQ screw

20
Wiring harness
Installing the wiring harness
Tool required
3Nm
wrench
Torque wrench
3T
8Torx T8
XT
10 Torx T10
6T
25 Torx T25
additional manufacturer-depen-
dent tools may be required
Wiring harness installation
0
➀
➁➂
➃
Interfaces of the wiring harness
as seen on the "Road" version:
 Charge port
 Splitter
 Battery connection
 Display connector
1
Select the appropriate wiring
harness:
CAB01 for MTB (position of
charge port above the battery).
CAB02 for Road (position of
charge port below the battery).
2
Use of the "charge port gripper"
mounting tool:
To guide the charge port at the
MTB to the desired position, the
charge port can be picked up
via the two lugs and thus guided
more easily to the appropriate
position.
The charge port gripper
is available separately in
the TQ online store.
3
Position the charge port in the
correct position in the frame
using the charge port gripper
(MTB) or by hand (Road).
Then screw it on with the three
M2.5×10 screws provided with a
tightening torque of 0.8 Nm.
T
8
Nm
wrench
0.8 Nm
Pay attention to the
manufacturer-dependent
coding of the charging
plug!
This can be checked
with the charging plug of
the TQ charger prior to
mounting.
MTB
Charge port
Road
Charge port Gripper