User Manual of Challenger
Contents
1. If you find a crack please replace relevant fittings 1 Check and observe any rusty position carefully to confirm whether there s any crack Rustiness will quicken the damage of bike body or parts and large cracks 2 Clean your bike lubricate relevant fittings and make your bike away from any corrosive things such as salt 3 Do not polish drill or engrave mark on the surface of bike body Large scratches and boreholes will cause cracks Attention should be often paid to these positions or replace with new fittings A bike that s properly maintained will not produce abnormal sound while riding Some cracks Especially larger cracks will produce abnormal sound when you ride the bike Such abnormal sound is the signal of warning of danger Attention should be paid to the source of abnormal sound even if it s not caused by cracks namely eliminate the cause of abnormal sound as soon as possible Caution If bike is damaged or needs adjustment please contact seller for assistance and do not repair the bike by yourself Repair and maintenance of bike needs special knowledge and tools Non professional adjustment or repair may damage the bike or cause accident and heavy casualties If you want to master the main repair techniques 1 Ask your distributor to provide introduction data of installation and maintenance of parts of bike or contact manufacturers of parts 2 Ask your distributor to recommend the books relating to r2. can be operated flexibly Please refer to p 11 Check whether front fork moves up and down to avoid the danger caused by the clearance between steering gear and front wheel Check whether tires are inflated properly whether tread is damaged or tread patter is worn out badly Check whether wheel rim is in round shape Please replace wheel rim at once if it s out of shape Each part of bike must lock with each other to avoid the danger caused by looseness Adjust saddle height and handlebar angle properly and lock the saddle and handlebar well Please refer to p 08 Check of power system Check whether battery have sufficient power Please refer to p 05 Whether wires of power system are complete and free of damage and whether each connector is connected well It s advised to use the parts from original manufacturer in case of replacement Caution Please purchase the bike with proper size A bike which is too large or small is not only hard to control but also may cause bad effect 11 Adjustment A Saddle Height Adjustment Loose the fixed bolts of seat post adjust the saddle to proper height and then fasten the fixed bolts B Adjust saddle angle Adjustment of brake system Loosen the fixed bolts and adjust the brake lever to make tightness of brake moderate Adjust the brake lever to make tightness of brake moderate Loosen the fixed bolts 12 o ensure your
3. distance of e bike is shortened which is not due to fault Lifetime of battery is expiry due to long term use and Please contact distributor to replace battery charging discharging times Caution If fault or effect cannot be eliminated through the above instructions please send the bike to original supplier for repair as soon as possible 23 leshooting of battery and charger Condition 1 Battery cannot be charged or LED indicator is off Possible cause Fault elimination Confirm whether socket and connector between charger and mains supply is connected properly Confirm whether the LED indicator of charger turns to red lamp Indicating the standby state after connecting the power supply Charger is not connected to power supply or power line is disconnected Confirm whether charger is connected to output The output terminal of charger is terminal of battery properly disconnected from battery Confirm whether LED indicator of charger turns to orange lamp Indicating the charging state Battery have fault Please contact distributor to replace battery Condition 2 LED indicator of charger turns to red lamp indicating the standby state and doesn t turn to orange color indicating the charging state after charger is connected to output terminal of battery properly Lamp signal will change automatically several minutes later If red lamp is on constantly battery may have fault so please conta
4. instructions on the wire connector Battery is dead Use special charger to charge the battery Condition 2 There s no LED lamp signal of batteries Possible cause Fault elimination Battery supply is not turned on Press the switch of battery supply Use special charger to charge the battery Battery is dead or have fault If battery cannot be charged please contact distributor to replace battery 22 ag oubleshooting Condition 3 Battery power display flashes or is off Use special charger to charge the battery The connecting wire of controller is loose or controller has fault please check whether connector of wire is inserted properly Battery is dead Condition 4 The traveling distance of e bike is shortened Because of long distance slope climbing or motor in high load state for a long time the bike stops running very frequently Tire pressure is insufficient or Inflate the tires to achieve appropriate tire pressure flat tire occurs Repair the tire or replace the inner tube Even though the bike is not ridden for a long time The bike has not been ridden for battery will be discharged naturally thus causing a long time thus causing insufficient power so traveling distance of e bike is insufficient battery power shortened Please use special charger to charge the battery Road conditions will affect the traveling distance of e bike so it s normal that the traveling
5. is abnormal and controller is abnormal 21 Motor speed is reduced and returns to normal automatically Recover the maximum Special output power of motor function Prevent motor from exceeding the temperature by re startup Turn down controller and controller will return to normal automatically after cooling down Send back to original manufacturer for check Color YS 7626 1 ORANGE or YS 9189 1 BLUE Dimension 26 17 Frame 7071 ALU ALLOY Front fork 28 6X25 4X 185MM SUSPENSION FORK BK GEAR 42T 1 2 X3 32 Chain wheel CRANK 170MM ALU ALLOY Rear derailleur SHIMANO RD M310 BK Shifter Chain 1 2 x3 32 116EYES SHIMANO ASLR S43R 7A Brake system F R DISC BRAKE Handlebar Handlebar stem 25 4X8S5MMX180MM ALU ALLOY L 620MM H 20MM ALU ALLOY Seat post 030 4x300mm ALU ALLOY Wheel rim BX 32 26 X36H AV BK CNC 14G STAINLESS BRASS NIPPLE Spoke Tire K841 26 X1 75 A V BK Motor 36V500W DC BRUSHLESS HUB MOTOR Battery 36V14AH LITHIUM BATTERY Charger 36V4A CHARGER Display LED CONSOLE Sensor device SPEED SENSOR 28 2011 10 31 V1 2 SA ore
6. power output While riding accelerate the bike slowly to maintain riding safety It s advised that all power supply is shut sj down if you stop the bike to prevent from operating the throttle improperly and micro power consumption of battery Te To press the bell downward to make sound Pre load system A Suspension A fork Mee Ed y N Lock out system By using lever to adjust the fork s compression from fast to slow gradually then till lock out position in the end Pre load system Adjustment by preload adjuster to improve the forks performance which vary from respective rider s weight Turning the adjuster clock wise to make the spring stiffer if soring too soft Turning the adjuster counter clock wise to reduce the spring tension and make it softer 1 Lower control system It s the message transmission hub of central processing unit speed sensor and battery pack The overall wires are dustproof and waterproof with IP 65 protection class E LTR POWER p HT irv riii 1 3 Lithium battery pack It has 36V 14AH high capacity and is ultra light only 4 5 kg It can be used for multiple modes and installed on bike frame Power consumption under full charge lt 0 7 degree Endurance on the flat ground can achieve 100kg ction of pedelec system 2 Speed sensor set amp power off lever It can automatically sense t
7. riding safety please make sure to read in detail and observ following instructions and obey traffic rules Otherwise it may give rise to product damage and endanger your own or others life Do not load other persons to avoid accident While riding the bike please wear the helmet with the mark of conformity and buckle the belt of helmet Make sure to carry out routine check and scheduled maintenance to reduce the fault of bike Please refer to p 18 Do not ride the bike under the influence of alcohol Please keep good mental conditions while riding Do not modify bike frame body or remove parts illegally Structure of bike interacts with function Modification without permission will affect the operation and riding safety of bike and shorten the lifetime of bike Do not disassemble bike body panel battery or other parts without instructions indicated in this manual Do not let hands free or conduct other dangerous actions such as stunt show while riding Do not ride the bike on the too rough pavement to avoid the danger caused by damage of e bike Do not brake the bike abruptly at high speed to avoid crash Do not ride the bike on the water logged ground to avoid damp and fault of battery Please refer to p 17 Continuous slope climbing will cause too high temperature of motor which will stop power supply automatically Slope angle should be less than 13 degrees While riding at night please use special bike lamp o
8. 14 ction to the charging operations ing procedures 1 Remove battery from the original equipment 2 Confirm whether all power lines battery lines and battery connectors are in the normal and usable state 3 Confirm whether output voltage of charger is compatible with the voltage of the connected battery 4 Make clear the positive and negative polarity and then connect battery to charger connector 5 Confirm whether AC voltage of socket is consistent with the voltage of the selected charger connect charger to power supply and turn on I O switch and then power indicator Red lamp will light up which shows startup 6 When the charging begins the indicator of the charging state will show the charging lamp signal and will turn to green lamp after the charging is finished Lamp signal instructions Power indicator If red lamp is on constantly it means that charger starts up normally and is standby Indicator instructions Green lamp is on constantly Standby Orange lamp flashes Pre charging under low voltage Orange lamp is on constantly Pre charging Orange lamp is on constantly In the charging process under rated current Orange lamp is on constantly In the charging process under rated voltage Green lamp is on constantly The charging 1s finished Orange lamp flashes Pre charging for 1 5 hours and in the charging process under rated current or rated voltage for 10 hours State has not yet been changed when t
9. User Manual of Challenger oS Z Dro New Mobility Solution With Powerful Driving System RIDE TO YOUR OUUU BEAT anual of Challenger Table of Conte Forward 03 II About Challenger bike Name of each part and operation introduction 04 Introduction to pedelec system 07 III Information on riding safety Prior riding check and routine check 09 Simple adjustment 12 Precautions 13 IV Introduction to battery Introduction to the charging operations 14 Instructions for use of battery 18 V Maintenance and care Safekeeping and care 19 Scheduled maintenance 21 VI Simple troubleshooting Troubleshooting of bike 22 Troubleshooting of battery and charger 24 Abnormal display of controller and fault elimination form 26 VII Specification form 28 No matter how high place you want to go EZW5000 is definitely your best p for all kinds of challenge Irreplaceable and incomparable Upgraded 36V system EZW5000 offers longer continuance of battery power and improves the loading capacity Strong 500W brushless hub motor outputs higher horse power providing speed and explosiveness Equipped with large volume of 14Ah Lithium battery EZW5000 is easy to extend your journey up to 100km Three pedaling modes cater to different demands Throttle acceleration 100 electric power pedelec I P T S and normal bike Front suspension fork and front rear disc brakes system match perfectly riding safet
10. and the second scheduled maintenance within six months and then check and maintenance should be conducted once every six months Check items and time Symbol definition Adjustment Check m Tighten A Lubricate e Replace I height and angle Upright height oA Front fork revolving if parts are loose or not A mA mA If pedals and BB principal axis are loose or not If front wheel motor axes and rear wheel inner shift hub are loose or not If front and rear brakes are flexible or not If brake handle grip distance 1s proper or not If brake block is abraded or not a n If big and small Crankset are abraded or distorted If wheel rim leaves the center or distorted If spokes are loose or broken o E If frame and front fork are damaged or not If attachment or other screws are x loose or not ple troubleshooting Jleshooting of bike Condition 1 Ride the bike with great effort or there s no power Possible cause Fault elimination Insert battery key and turn on battery supply Switch of battery is not turned on Press the power supply of LCD control system Select pedelec setting Output terminal of battery disconnects from the input terminal of battery holder Confirm whether output terminal of battery is connected to input terminal of battery holder well Connector of the wire that connects battery to other parts is disconnected Connect the wire well according to arrow
11. ct distributor to replace battery Charge the battery for the first time or after battereis have not used for a long time Condition 3 LED inciator of charger is off or doesn t turn to orange lamp indicating the charging state after charger is connected to output terminal of battery Please stop charging and pull out the plug Charger or battery have fault immediately Contact distributor to replace the charger or battery 24 eshooting of battery and charger Condition 4 After charging for 3 4 hours LED indicator of charger is off or doesn t turn to green lamp indicating that the charging has been finished Possible cause Fault elimination Please stop charging and pull out the plug Charger or battery have fault immediately Contact distributor to replace the charger or battery Condition 5 LED indicator of charger red lamp and green lamp flash alternately Please stop charging and pull out the plug Charger or battery have fault immediately Contact distributor to replace the charger or battery Condition 6 The charger indicates that the charging has been finished But battery power indicates that all 9 grids are not full Please contact distributor to replace battery charger or controller Battery charger or controller has fault Condition 7 Abnormal sound odour or smook occur in the charing process Please stop charging and pull out the plug Charger has fault immediately Contact distributor
12. epair of bike 3 Consult your distributor on the courses relating to repair of bike 19 nance and care Maintenance and care instructions Do not clean the bike by strong spraying to avoid damp and damage of battery system Dry cloth can be used for cleaning Please use neutral or soft detergent for cleaning to avoid damage of bike body Do not use seawater or water source containing salt for cleaning Cold water should be used so as to avoid accelerated corrosion After bike has been cleaned or when you store the bike please keep the bike and surroundings as dry as possible to avoid rustiness If long term storage is required please remove battery from bike Please avoid exposing the bike to the sun and rain and you should place the bike in buildings as much as possible If bike is out of use for a long time please lubricate the gears or screws properly Caution Correct maintenance and care can not only make you bike keep brand new appearance but also maintain the best performance 20 e maintenance While bike is used many factors will cause the wear and tear consumption dama and looseness of parts If check and maintenance is not conducted regularly at ordinary times lifetime of your bike will be shortened except the danger that s easy to occur while riding Generally the first scheduled maintenance should be conducted within two months as from the purchase date of bike
13. ffect on battery module and then we will not be responsible for warranty Do not insert metals e g wires copper coin and clip etc into any terminal Do not conduct fire resistant test and waterproof test for lithium battery module and charger Do not apply solvent or other chemical agent to battery module Dry cloth can be used for cleaning The lithium battery module is developed specially for e bike and do not use it for other products Do not touch power line and socket with wet hands Do not place the charger within children s reach to avoid accident Do not ride the bike when battery on the bike is charging to avoid danger caused by drawing the power line or bike damage If battery is damaged or immersed in water do not continue to use the battery and you should send them for repair Do not stack heavy objects on battery to avoid battery damage CATION To safeguard your own rights and interests pleasure make sure to observe the above precautions which can reduce accidents and extend the lifetime of batteries 18 ntenance and care Emphasis of safekeeping and care Check whether bike body is cracked Any crack means potential danger and will give rise to accident If repair is not conducted or relevant fittings are not replaced in time there will be severer danger Once bike body 1s cracked the crack will become larger in a short time Rustiness or discoloration may hint the occurring of cracks
14. he force applied by rider on the pedal provide assistance with linear acceleration and make the riding smoothly and fast like automatic transmission system Manual power off system will ensure more safety 4 500W DC brushless motor With high energy efficiency low wear out and high durability prmation on riding safety riding check and routine check 1 Check of saddle Height position of saddle If you sit on the saddle and you can straighten your leg slightly at the bottom of the pedal stroke the saddle height is most appropriate If you can only step on pedal with tiptoe or you cannot straighten your leg it s easy to cause fatigue or injury and saddle height must be adjusted When you adjust the height of saddle attention should be paid to safety line A indicated on seat post that should not be exceeded to avoid danger See the following picture for details 2 Check of handlebars To make rider safer and more comfortable please adjust handlebar to appropriate angle See the following Fig B and confirm that you can rotate handlebar to each direction To make rider safer and more comfortable please adjust handlebar height to appropriate angle See the following Fig C 3 Check of tires Tire specification 26 X1 75 Tire pressure 45 60 PSI Check of the worn out situation of tires If groove of tread pattern is worn out please replace tire with new one It s better to replace tires
15. he time set by Timer is up In case of burnout of fuse Fuse 10A 250V 1 Rotate the fuse 2 Take out the fuse a a 2 ae ke 3 Replace the fuse Remove the power line of batteries that connects bike body Remove the quick release at the front end of batteries Remove the batteries from the left of bike body Caution Assembly disassembly must be conducted from the left of bike bodv to ensure correct installation of batteries Warning If the bike is used as general bicycle by removing the batteries the wire that connects motor to controller must be disconnected to avoid burnout of controller 16 1 Electrical specification of lithium battery Nominal voltage DC36V Nominal capacity 14Ah Range of operating voltage DC30V 42V 2 Accessories of lithium battery Power line One Charger One Charger specification Input 100 240VAC 50 60Hz 3A Output 42V 4 0A Caution l Please read this user manual and safety code in detail before you use lithium battery module so as to understand the specifications and precautions of product According to provisions of transportation regulations capacity of lithium battery module must be lower than 50 in transit So user must charge the bike with the attached charger for 12 hours before the initial use and then use the bike after it s fully charged Please use the attached charger for charging and do not u
16. r appropriate bike lamp for safety purpose While riding on public road please equip the bike with bike lamp and reflector complying with regulations While riding attention should be paid to the vehicles that are driven into or out of the lane in front of you While riding attention should be paid to whether the door of the vehicle stopped in front of you is opened suddenly While riding attention should be paid to any pedestrian who rushes out suddenly While riding attention should be paid to obstacles such as pits stones and rails which may make you deviate the riding direction at any time Ifthe riding safety is affected by damaged parts while riding please stop riding It s advised that parts of the original manufacturer are used in case of replacement The bike is originally designed for urban commuting purpose Do not use it for cross country competition or on too rough pavement etc which will injure you or damage the bike frame duction to use of battery uction to the charging operation Charger a E connector of LITHIUM POWER batteries SOORT 36V 14an ae Se Fuse Charger Indicator Lamp signal I O switch Voltage115 230 Power plug Pullup or pulldown is possible to switch the correct voltage for socket Warning Please confirm whether AC voltage of socket is consistent with voltage of charger before charging to avoid burnout of fuse
17. se the charger of other manufacturers After lithium battery is fully charged do not connect charger to lithium battery for a long time The lithium battery are specially used for e bike and do not use them for other products Before use please ensure that lithium battery is fixed to the bike and confirm whether output terminal of battery is connected to the terminal of battery holder properly If battery is not used for a long time please charge the battery fully and then turn off switch and put battery in a cool ventilated place indoors Battery should be charged once a month at least to ensure lifetime While charging heating of charger and battery belongs to normal phenomenon tions for use of battery Please ensure that battery module is dray Do not put battery module into water Do not charge the lithium battery module near fire source or in high temperature environment because high temperature will affect the lifetime of battery Do not discard the old battery module that has been replaced to fire source or high temperature environment Please send them to distributor for recycling Do not throw or knock battery module because strong external force will damage the casing and internal circuit and protective circuit of battery which is hardly to ensure safety of user Do not use other chargers than the attached special one for charging Using the chargers of other manufacturers will have bad e
18. t us by email or phone and we will serve you with heart and soul 3 ut Challenger Applicable Terrain ground and h Handlebar Refer to the following Battery supply detailed picture or p 06 Controller signal Saddle Seat post Lower control system Quick release Switch for 100 electric power mode La Freewheel Front fork Motor Tire Rim yj P ih i Battery Tire nd og A Rear K T derailleur Chain Pedal Valve Kickstand Rim Spoke Chainwheel Power off Brake Power off lever Handlebar Handlebar Handlebar Stem Bell Shifter Controller signal Attachment 1 Charger 2 User Manual 3 Warranty Card 4 Battery of each part and operation introduction Battery Voltage meter It represents low Red signal to high Green signal power from left to right Torque segments One lamp signal represents one segment The more lamp signals are the stronger torque is ra Mie M To press Plus to increase torque level 5 segments LEVEL Torque regulator at most To press Minus to decrease segments If yellow signal and red signal are on it means battery should be charged Ifred signal blink it means under voltage and charging is urgently needed Power output should be stopped to avoid overdischarging With memory function it is needless to re set again when startup each time Bat
19. tery capacity 90 t Remark Reference PE value setting 130W 200W 250W 380W 500W Battery supply Switch for 100 electric power mode ry Supply It s in the Off state Power assisted speed sensor may be used It s in the Off state No power is supplied o Activate battery supply Activate 100 electric power mode Throttle grip may be used Activate pedelec mode When battery supply is on Caution 1 It s advised that all power supply is shut down if you will not ride the bike to prevent from operating throttle improperly and micro power consumption of battery 2 If battery will not be used for a long time all power supply must be shut down Take out battery holder and put it in a cool ventilated place indoors Battery should be charged once within six months as from shipping date to ensure lifetime It is charged with 70 of power before shipment 5 Grasp the brake power off lever inward to exert good brake effect Do not brake the bike strongly and abruptly but to slow down the bike gradually Form of Shifter Rotary 7 segments While riding rotate the shifter to change speed Rotate the shifter downward to reach a higher segment and upward to a lower segment Left handlebar Rotate the left grip of throttle downward to make bike go forward and loose the grip to slow In the 100 electric power mode down the bike If your loose the grip completely x P the bike will stop
20. to replace the charger 25 O display of controller and fault elimination fo Power off of brake system is abnormal Power on accelerator is abnormal Cancel pedelec mode and electric mode G Y R LED flash 0 5S 0 5S Y_LED flash 0 3S 0 3S Y_LED flash 1S 1S Battery voltage is too low Lithium battery 36V system Less than 32V Lead acid battery 36V system Less than 30V Brake gets stuck or short circuit occurs Accelerator gets stuck or short circuit occurs Battery power indicates that output of torque is set to be zero Non pedelec mode 26 Check battery supply Replace or charge the battery Check whether brake has been pressed and remove brake wire Check whether accelerator turns to original point and returns to normal automatically The setting device of power display and output torque within 5 segments of output torque Startup detection Startup detection Special function al display of controller and fault elimination D LED abnormal display Accelerating Japan 24km EU 25km USA 32km Motor is overloaded Temperature of controller is too high Controller motor is abnormal G LED flash 0 3S 0 3S Y R LED flash 0 5S 0 5S Motor speed exceeds the limit speed Motor has been overloaded for four minutes reducing output power of motor Temperature of controller exceeds 70 C Motor
21. when the bike has been running for about 5 000 km to ensure safety iding check and routine check 4 Check of wheel rims Rim specification Double layer rims made of aluminum alloy Check of the worn out situation of rims All rims have safe line If the safe line is unclear due to abrasive wear please replace rim 5 Check of brake system Brakes will have weak clamping force if you ride the bike at rainy day please brake the bike safely at longer distance and slow down If you ride the bike at too high speed do not brake the bike strongly and abruptly and you should slow down the bike gradually Brake inner wire Cable wire The outlet of inner wire Cable wire of brake should avoid bifurcation Please mount aluminum sheath As shown in Fig 1 at the end of cable wire Inner wire Cable wire of brake should be lubricated Stitching machine oil on a regular basis to avoid rustiness or unsmooth actuation 6 Check of chain Lubricating time and position of chain If chain produces abnormal sound please add a little lubricating oil to the chain Special chain lubricant should be used 10 iding check and routine check Please carry out the following items to guarantee your own safety Check of bike frame body Please confirm whether bike stand can be raised or lowered normally Please refer to p 11 Hold the left and right levers to check whether brake system is efficient and levers
22. y is guaranteed All in one hybrid technology integrated with safe riding concept EZW5000 not only presents comfortable and powerful performance but also represents the new lifestyle of health and sustainability LOHAS To improve riding enjoyment and pedelec efficiency the intelligent pedal speed sensor 1s used which responds to power take off control of pedal speed sensor synchronously by a central processing unit with artificial intelligence It means that depending on change of terrain and riding gear pedelec system will output relevant auxiliary power automatically and synchronously achieving the riding enjoyment of the rider integrating into E bike So it s not only a 100 special bike but also an eco hybrid two wheel drive bike by activating pedelec system People can not only regard it as a general recreational bike simply but also use pedelec system to make the challenging long distance riding or slope terrain become much easier and more comfortable One bike e Many roles Thank you again for purchasing our product and welcome you to ride the new generation of bike To ensure that your bike is in the best riding state please read this manual in detail before using this product This manual will help you understand the key use and maintenances of bike more as well as various precautions for riding safety so as to create more riding enjoyment and value If you have any question about EZpro e bike please visit our website or contac
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