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Summary of Contents for TQ-Systems TQ-HPR50
- Page 1 TQ-HPR50 System Service Manual...
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Page 3: Table Of Contents
Contents 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) .................. -
Page 4: Important Notice
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. -
Page 5: Ensuring Safety
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. ►... -
Page 6: Connecting The E-Bike (Tq Drive System) With The Pc
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. ►... -
Page 7: Mountain Bike E-Systems Overview
E-systems overview Mountain bike e-systems overview... -
Page 8: Road E-Systems Overview
E-systems overview Road e-systems overview... -
Page 9: Overview Of The Tools Used In The Manual
Overview of the tools used Overview of the tools used in the manual Torque wrench wrench Caliper gauge caliper Inner bearing tool BB-UN55 UN55 Ball-bearing grease grease Hex key 2.5 mm Hex key 5 mm Hex key 6 mm Torx T8 Torx T10 Torx T20 Torx T25... -
Page 10: Installation Of The Display (V01 And V02)
Display V01 and V02 Installation of the display (V01 and V02) Tool required Torque wrench wrench Torx T10 Dealer Service Tool (DST) Display installation ➀ M3x20 screw ➁ Display frame Feed the connecting cable for Please make sure not to the display / Smart Box cleanly kink the cables. - Page 11 Display V01 and V02 Version D: Please make sure that With remote and with smart plug connectors are Remote clean. ➀ Make the connection between The pins are not allowed the green plug (display) and to be bent. the green socket (remote). ➁...
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Page 12: Assembly Of The Remote V02
Remote Assembly of the REMOTE V02 Tool required Torque wrench wrench Hex key 2.5 mm Remote assembly ➀ Remote control unit ➁ Remote cable Plug the remote control unit into Makes sure it is properly the left handlebars. aligned. Remote cable socket Insert the oval plug of the remote Pay attention to the oval cable properly aligned and all... - Page 13 Remote...
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Page 14: Installation Of Drive Unit Hpr50
Drive Unit Installation of Drive Unit HPR50 Tool required Caliper gauge caliper Torx T55 Torque wrench wrench Hex key 6 mm Multi-purpose grease grease BB-UN55 inner bearing tool UN55 Dealer Service Tool (DST) Motor installation ➀ Rear motor bolt 62 mm ➁... - Page 15 Drive Unit ➀ Use a caliper gauge to mea- sure the distance between the caliper two mounting points in the frame. The maximum motor compensation width is ➁ Then set this value on the not allowed to exceed or motor compensation screws fall below a maximum of and thus adjust them to the ±...
- Page 16 Drive Unit Launch the TQ Dealer Service Tool and connect the dongle with the PC and the bike. 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.
- Page 17 Drive Unit...
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Page 18: Installation Of The Battery Hprv01
Battery Installation of the Battery HPRV01 Tool required Torque wrench wrench Torx T10 Torx T25 additional tools may be required to remove the skid plate. Battery installation Battery installed in the frame and connected. Select the manufacturer-depen- Please note the manufac- Connector dent battery brackets and the turer-dependent horizon-... - Page 19 Battery Carefully slide the Battery V01 Be careful not to crush into the battery compartment up any cables. to the specified screw-on points. Please observe the The wiring harness should al- manufacturer-dependent ready be pre-mounted See also instructions for the wiring “Installing the wiring harness”...
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Page 20: Installing The Wiring Harness
Wiring harness Installing the wiring harness Tool required Torque wrench wrench Torx T8 Torx T10 Torx T25 additional manufacturer-depen- dent tools may be required Wiring harness installation Interfaces of the wiring harness as seen on the "Road" version: ➀ Charge port ➁... - Page 21 Wiring harness Feed the connecting cable for Please make sure not to the display / Smart Box cleanly kink the cables. through the display enclosure in the frame. Version A: Please make sure that Without remote and with Smart plug connectors are Smart Box clean.
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Page 22: Installation Of The Speed Sensor
Speed Sensor Installation of the speed sensor Tool required Torque wrench wrench Torx T20 Torx T25 for 6-hole magnet where applicable additional manufacturer-depen- dent tools may be required Mounting the speed sensor Speed sensor installed and con- nected to drive unit. Speed Sensor Feed the plug- Be careful not to crush... - Page 23 Speed Sensor Check the air gap between the 1-8 mm speed sensor and magnet. This must be 1-8 mm.
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Page 24: Installation Of The Smart Box
Smart Box Installation of the Smart Box Tool required Torx T10 Dealer Service Tool (DST) Installation of the Smart Box Smart Box installed and connect- ed between the display and the wiring harness. Smart Feed the connecting cable for Please make sure not to the display / Smart Box cleanly kink the cables. - Page 25 Smart Box Connect the lighting for example Please make sure that Smart Box Micro B to “Output 1, Output 2 or Output plug connectors are Output (Light plug) 3” on the Smart Box via compati- clean. ble Higo Micro B connectors. The pins are not allowed to be bent.
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Page 26: Manual Dealer Service Tool (Dst)
Dealer Service Tool Manual Dealer Service Tool (DST) Connect the Dealer Service Tool to the PC via USB port and to the Connect bike via the charging port. to PC Connect to bike Now establish the connection in the DST software. After the system has been suc- cessfully connected, you can ac- cess the "Diagnostics", "Software... - Page 27 Dealer Service Tool If updates are available, they are automatically uploaded to the components. After calling up the diagnostics, various functions are checked and the result of the test is then clearly displayed. The following things can be con- figured under "Bike Settings": General Settings •...
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Page 28: Troubleshooting
Troubleshooting Troubleshooting Connect service tool and launch diagnostics. Important notice: A software update must be performed after each component swap. Error code Cause Remedy ERR 401 DRV SW General software error 1. Reboot the system 2. In case of outdated firmware, please perform a software update ERR 403 DRV COMM Peripheral... - Page 29 Troubleshooting Error code Cause Remedy ERR 42B DRV SW General software error Outdated firmware. 1. Please perform a software update. ERR 42E DRV SW 2. Replace motor ERR 440 DRV HW Electronics fault in drive unit 1. Reboot the system 2.
- Page 30 Troubleshooting Error code Cause Remedy ERR 480 DRV SENS Drive unit assistance fault Unintended use! Avoid extraordinary cycling situation to the extent possible. 1. Reboot the system 2. In case of outdated firmware, please perform a software update 3. Replace motor if error occurs during start ERR 481 BATT COMM Battery communication error 1.
- Page 31 Troubleshooting Error code Cause Remedy ERR 49C DRV SENS Torque sensor error Unintended use! Avoid extraordinary cycling situation to the extent possible. ERR 49D DRV SENS 1. Reboot the system ERR 49E DRV SENS 2. Replace motor if error occurs during start ERR 49F DRV SENS ERR 4A0 DRV COMM CAN bus communication error...
- Page 32 Troubleshooting Error code Cause Remedy ERR 4C8 DRV SW General software error Outdated motor firmware 1. Reboot the system ERR 4C9 DRV SW 2. Please perform a software update ERR 4CA DRV SW ERR 4CB DRV SW WRN 601 SPD SENS Speed sensor Missing or defective speed sensor.
- Page 34 The information in this publication is reviewed periodically and necessary corrections are included in subsequent editions. All trademarks mentioned in this manual are the property of their respective owners. Copyright © TQ-Systems GmbH TQ-Systems GmbH | TQ-Drives Item No.: HPR50-SM Gut Delling l Mühlstraße 2 l 82229 Seefeld l Germany...
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