761542

Hercules BOSCH Intuvia Pedelec Display 2021 Handleiding

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Pagina verder
TRANSLATION OF THE ORIGINAL OPERATING INSTRUCTIONS
IMPORTANT
READ CAREFULLY BEFORE USE
KEEP SAFE TO CONSULT AT A LATER DATE
Forward
Pedelecs
E-Imperial I-F8, E-Imperial I-R8, E-Imperial I-10, E-Imperial 180 S R8, E-Imperial 180 S F8, E-Imperial 180 S 9,
E-Joy F7, E-Joy R7, Futura Comp I-10, Futura Pro I-F14, Futura Pro I-F360, Futura Pro I-11, Futura Sport I-F8,
Futura Sport I-8, Futura Sport I-9, Futura Fold I-F8, Futura Fold I-R8, Montfoort F7, Montfoort Del I-F8,
Montfoort Plus F8, Rob Cargo R7, Rob Cross Sport 12.1, Rob Cross Sport 12.1 Str, Rob Fold F8, Rob Fold R8,
Rob Fold 10, Rob Fold I-F8, Rob Fold I-R8, Rob Fold Carbon, Robert/a Pro I-R8, Robert/a Deluxe I-F8,
Robert/a Deluxe I-R8, Robert/a I-F8 Belt, Robert/a I-R8 Belt, Robert/a R7 A+, Viverty E R7
20-P-0001, 20-P-0002, 20-P-0003, 20-P-0004, 20-P-0005, 20-P-0006, 20-P-0007, 20-P-0008, 20-P-0009, 20-P-0010, 20-P-0011, 20-P-0012, 20-P-0013, 20-Q-0001,
20-Q-0003, 20-Q-0004, 20-Q-0006, 20-Q-0007, 20-Q-0009, 20-Q-0010, 20-Q-0011, 20-Q-0012, 20-Q-0013, 20-Q-0014, 20-Q-0015, 20-Q-0016, 20-Q-0017, 20-Q-0018,
20-Q-0018, 20-Q-0019, 20-Q-0020, 20-Q-0021, 20-Q-0040, 20-Q-0041, 20-Q-0043, 20-Q-0044, 20-Q-0045, 20-Q-0046, 20-Q-0047, 20-Q-0048, 20-Q-0049, 20-Q-0050,
20-Q-0051, 20-Q-0052, 20-Q-0054, 20-Q-0057, 0-Q-0058, 20-Q-0059, 20-Q-0060, 20-Q-0063, 20-Q-0064, 20-Q-0066, 20-Q-0068, 20-Q-0069, 20-Q-0080, 20-Q-0081,
20-Q-0082, 20-Q-0090, 20-X-0001, 20-Y-0002, 20-Y-0003, 0-Y-0007, 20-Y-0008, 20-Y-0009, 20-Y-0010, 20-Y-0011
MY20H02-12 • 1.0 • 12. June 2019
TURBO
SPORT
TOUR
ECO
OFF
MPH
KM/H
Reichweite
AMM
PMWH
MIN
MPH
KM /H
RESET
TURBO
SPOR T
S
TOUR
ECO
OFF
MPH
Reichweite
AMM
P MWH
MIN
MPH
KM
/H
MY20H02-12_1.0_12.06.2019 2
Contents
Contents
1 About these operating instructions 6
1.1 Manufacturer 6
1.2 Type number and model 6
1.3 Identifying the operating instructions 7
1.4 Laws, standards and directives 7
1.5 Subject to change 7
1.6 Language 7
1.7 For your safety 7
1.7.1 Instruction, training and customer service 8
1.7.2 Basic safety instructions 8
1.7.3 Warnings 8
1.7.4 Safety markings 8
1.8 For your information 8
1.8.1 Instructions for actions 8
1.8.2 Language conventions 8
1.9 Nameplate 9
1.9.1 Information on the nameplate 10
2 Safety 11
2.1 General warnings 11
2.2 Toxic substances 12
2.3 Requirements for the rider 13
2.4 Protection for vulnerable groups 13
2.5 Data privacy 13
2.6 Personal protective equipment 13
2.7 Safety markings and safety instructions 13
2.8 Emergency 14
2.8.1 What to do in an emergency 14
2.8.2 First aid treatment 14
2.8.3 Fighting fire 14
2.8.4 Leaking fluids 15
2.8.4.1 Brake fluid 15
2.8.4.2 Oils and lubricants from the fork 15
2.8.4.3 Oils and lubricants from the rear frame
damper 15
3Overview 16
3.1 Description 17
3.1.1 Wheel and suspension 17
3.1.1.1 Valve 17
3.1.2 Suspension 17
3.1.2.1 Steel suspension fork structure 18
3.1.2.2 Air suspension fork structure 18
3.1.2.3 Structure of the FOX rear frame
damper 19
3.1.2.4 Structure of the Suntour rear frame
damper 19
3.1.3 Brake system 19
3.1.3.1 Rim brake 19
3.1.3.2 Disc brake 20
3.1.3.3 Back-pedal brake 20
3.1.3.4 ABS 21
3.1.4 Electric drive system 22
3.1.5 Rechargeable battery 22
3.1.5.1 Pannier rack battery 23
3.1.5.2 Integrated battery 24
3.1.6 Display 24
3.1.6.1 USB port 25
3.1.7 Riding light 25
3.1.8 Charger 25
3.2 Proper use 26
3.3 Improper use 27
3.4 Technical data 28
3.4.1 Pedelec 28
3.4.2 ActiveLine motor 28
3.4.3 ActiveLine Plus motor 28
3.4.4 Performance Line Cruise motor 28
3.4.5 Performance Line Speed motor 28
3.4.6 Performance Line CX motor 28
3.4.7 Pedelec lighting 29
3.4.8 PowerPack 300 battery 29
3.4.9 PowerPack 400 battery 29
3.4.10 PowerPack 500 battery 29
3.4.11 PowerTube battery 29
3.4.12 Intuvia display 29
3.4.13 USB port 29
3.4.14 BOSCH Pedelec ABS BAS100 30
3.4.15 Emissions 30
3.4.16 Tightening torque 30
3.5 Environmental requirements 31
3.6 Description of controls and screens 33
3.6.1 Handlebars 33
3.6.2 Battery level indicator 33
3.6.3 Control panel 33
3.6.4 On-screen indicators 33
3.6.4.1 Riding light symbol 33
3.6.4.2 Level of assistance 34
3.6.4.3 Motor power used 34
3.6.4.4 Battery level indicator 34
3.6.4.5 Gear recommendation 35
3.6.4.6 Tachometer screen 35
3.6.4.7 Function display 35
3.6.5 System message 37
3.6.6 ABS indicator lamp 37
4 Transportation and storing 38
4.1 Physical transport characteristics 38
4.1.1 Dimensions during transportation 38
4.1.2 Transport weight 38
4.1.3 Designated handles/lifting points 38
4.2 Transportation 38
4.2.1 Transporting the battery 39
4.2.2 Shipping the battery 39
4.2.3 Using the brake transport securing
system 39
MY20H02-12_1.0_12.06.2019 3
Contents
4.3 Storing 39
4.3.1 Break in operation 40
4.3.1.1 Preparing a break in operation 40
4.3.1.2 Taking out of operation 40
5 Assembly 41
5.1 Required tools 41
5.2 Unpacking 41
5.2.1 Scope of delivery 41
5.3 Commissioning 42
5.3.1 Checking the battery 42
5.3.2 Mounting the wheel in the Suntour fork 42
5.3.2.1 Mounting the wheel with screw-on axle
(15 mm) 42
5.3.2.2 Mounting the wheel with screw-on axle
(20 mm) 43
5.3.2.3 Mounting the wheel with a quick release
axle 44
5.3.3 Mounting the wheel with a quick release 45
5.3.4 Mounting the wheel in the FOX fork 46
5.3.4.1 Wheel with quick release (15 mm) 46
5.3.4.2 Adjusting the FOX quick release 47
5.3.4.3 Mounting the wheel with Kabolt axles 47
5.3.4.4 Checking the stem and handlebars 47
5.3.5 Pedelec sale 48
6Operation 49
6.1 Risks and hazards 49
6.1.1 Tips for a greater range 50
6.1.2 Personal protective equipment 50
6.2 Error messages 51
6.2.1 Error message display 51
6.2.2 Battery error message 53
6.3 Before the first ride 54
6.3.1 Adjusting the saddle 54
6.3.1.1 Adjusting the saddle tilt 54
6.3.2 Determining the seat height 54
6.3.2.1 Adjusting the seat height with quick
release 54
6.3.2.2 Height-adjustable seat post 55
6.3.2.3 Adjusting the seat position 55
6.3.3 Adjusting the handlebars 56
6.3.3.1 Adjusting the stem 56
6.3.3.2 Adjusting the height of the handlebars 56
6.3.3.3 Turning the handlebars to the side 57
6.3.3.4 Checking the clamping force in quick
releases 57
6.3.3.5 Adjusting the quick release clamping
force 57
6.3.4 Adjusting the brake lever 57
6.3.4.1 Adjusting the pressure point on a
Magura brake lever 57
6.3.4.2 Adjusting the grip distance 58
6.3.4.3 Adjusting the grip distance on a
Magura brake lever 58
6.3.5 Adjusting the suspension of the
Suntour fork 59
6.3.5.1 Adjusting the negative deflection 59
6.3.5.2 Adjusting the air suspension fork
negative deflection 59
6.3.5.3 Adjusting the steel suspension fork
negative deflection 60
6.3.5.4 Adjusting the rebound 61
6.3.6 Adjusting the suspension of the
FOX fork 61
6.3.6.1 Adjusting the negative deflection 61
6.3.6.2 Adjusting the rebound 62
6.3.7 Setting the Suntour rear frame damper 63
6.3.7.1 Adjusting the negative deflection 63
6.3.7.2 Adjusting the rebound 63
6.3.7.3 Setting the compression 64
6.3.8 Setting the FOX rear frame damper 64
6.3.8.1 Adjusting the negative deflection 64
6.3.8.2 Adjusting the rebound 65
6.3.9 Retracting the brake linings 65
6.4 Accessories 66
6.4.1 Child seat 66
6.4.2 Bicycle trailers 67
6.4.3 Pannier rack 67
6.5 Before each ride 68
6.6 Check list before each ride 68
6.7 Folding 69
6.7.1 Folding the folding bicycle 69
6.7.1.1 Folding the pedal 69
6.7.1.2 Folding the stem 1, Folding 69
6.7.1.3 Folding the stem 2, Folding 69
6.7.1.4 Pushing in the seat post 70
6.7.1.5 Folding the frame 70
6.7.2 Preparing the bicycle so that it is
ready to ride again 70
6.7.2.1 Folding out the frame 70
6.8 Using the kickstand 71
6.8.1 Raising the kickstand 71
6.8.1.1 Parking the pedelec 71
6.9 Using the pannier rack 71
6.10 Rechargeable battery 72
6.10.1 Frame battery 73
6.10.1.1 Removing the frame battery 73
6.10.1.2 Inserting the frame battery 73
6.10.2 Pannier rack battery 73
6.10.2.1 Removing the pannier rack battery 73
6.10.2.2 Inserting the pannier rack battery 73
6.10.3 Integrated battery 73
6.10.3.1 Removing the integrated battery 73
6.10.3.2 Inserting the integrated battery 74
6.10.4 Charging 74
MY20H02-12_1.0_12.06.2019 4
Contents
6.10.5 Dual charging 75
6.10.5.1 Charging process when two batteries
are used 75
6.10.5.2 Charging process when one battery is
used 76
6.10.6 Waking the battery 76
6.11 Electric drive system 77
6.11.1 Switching on the electric drive system 77
6.11.2 Switching off the drive system 77
6.12 Control panel with display 78
6.12.1 Removing and attaching the display 78
6.12.1.1 Removing the display 78
6.12.1.2 Attaching the display 78
6.12.2 Securing display against removal 78
6.12.3 Charging the internal display battery 78
6.12.3.1 Charging on the pedelec 78
6.12.3.2 Charging using the USB port 78
6.12.4 Using the USB port 79
6.12.5 Switching on the display 79
6.12.6 Switching off the display 79
6.12.7 Using the push assist system 79
6.12.8 Using the riding light 79
6.12.9 Selecting the level of assistance 80
6.12.10 Journey information 80
6.12.10.1Changing the displayed journey
information 80
6.12.10.2Resetting the journey information 80
6.12.11 Changing the system settings 80
6.13 Brake 81
6.13.1 Using the brake lever 82
6.13.2 Using the back-pedal brake 83
6.13.3 Using ABS 83
6.13.3.1 While riding 84
6.14 Suspension and damping 84
6.14.1 Adjusting the compression of the
Fox fork 84
6.14.2 Adjusting the compression of the
Fox damper 85
6.14.3 Adjusting the compression of the
Suntour fork 85
6.14.4 Adjusting the compression of a
Suntour damper 86
6.14.5 Adjusting the rebound in a Rock
Shox damper 86
6.14.6 Adjusting the compression in a
Rock Shox damper 87
6.15 Gear shift 87
6.15.1 Using the derailleur gears 87
6.15.2 Using a hub gear 88
6.15.3 Use eShift 88
6.15.3.1 eShift with Shimano DI2 automatic
hub gears 88
6.15.3.2 eShift with manual Shimano DI2 hub
gears 89
6.15.3.3 eShift with Shimano DI2 automatic
hub gears 89
6.15.3.4 eShift with NuVinci H|Sync/enviolo
with Optimized H|Sync 89
6.15.3.5 eShift with Rohloff E-14
Speedhub 500/14 89
7 Cleaning and servicing 90
7.1 Cleaning after each ride 90
7.1.1 Cleaning the suspension fork 90
7.1.2 Cleaning the rear frame damper 90
7.1.3 Cleaning the pedals 90
7.2 Basic cleaning 91
7.2.1 Cleaning the frame 91
7.2.2 Cleaning the stem 91
7.2.3 Cleaning the rear frame damper 91
7.2.4 Cleaning the wheel 91
7.2.5 Cleaning the drive elements 91
7.2.6 Cleaning the chain 92
7.2.7 Cleaning the battery 92
7.2.8 Cleaning the display 92
7.2.9 Cleaning the drive unit 92
7.2.10 Cleaning the brake 93
7.3 Servicing 93
7.3.1 Servicing the frame 93
7.3.2 Servicing the stem 93
7.3.3 Servicing the fork 93
7.3.4 Servicing the drive elements 93
7.3.5 Servicing the pedals 93
7.3.6 Servicing the chain 93
7.3.7 Servicing the drive elements 93
7.4 Maintenance 93
7.4.1 Wheel 93
7.4.2 Checking the tyres 94
7.4.3 Checking the rims 94
7.4.4 Check and correct tyre pressure 94
7.4.4.1 Dunlop valve 94
7.4.4.2 Presta valve 94
7.4.4.3 Schrader valve 95
7.4.5 Brake system 95
7.4.6 Checking the brake linings for wear 95
7.4.7 Checking the pressure point 95
7.4.8 Checking the brake discs for wear 96
7.4.9 Electrical cables and brake cables 96
7.4.10 Gear shift 96
7.4.11 Stem 96
7.4.12 USB port 96
7.4.13 Checking the chain tension 96
7.4.14 Checking the handlebar grip position 96
8 Maintenance 97
8.1 Axle with quick release 98
8.1.1 Checking the quick release 98
8.2 Adjusting the gear shift 98
MY20H02-12_1.0_12.06.2019 5
Contents
8.2.1 Cable-operated gear shift,
single-cable 99
8.2.2 Cable-operated gear shift,
dual-cable 99
8.2.3 Cable-operated twist grip,
dual-cable 99
9 Troubleshooting, fault clearance
and repair 100
9.1 Troubleshooting and fault clearance 100
9.1.1 The drive system or display do not
start up 100
9.1.2 Error messages 100
9.2 Repair 101
9.2.1 Use original parts and lubricants
only 101
9.2.2 Replacing the lighting 101
9.2.3 Setting the headlight 101
10 Recycling and disposal 102
11 Documents 103
11.1 Parts list 103
11.2 Assembly report 104
11.3 Maintenance log 106
11.4 Charger operating instructions 109
12 Keyword index 118
13 Glossary 120
I. EC declaration of conformity 123
1 About these operating instructions 9
1.1 Manufacturer 9
1.2 Type number and model 9
1.3 Identifying the operating instructions 10
1.4 Laws, standards and directives 10
1.5 Subject to change 10
1.6 Language 10
1.7 For your safety 10
1.7.1 Instruction, training and customer service
11
1.7.2 Basic safety instructions 11
1.7.3 Warnings 11
1.7.4 Safety markings 11
1.8 For your information 11
1.8.1 Instructions for actions 11
1.8.2 Language conventions 11
1.9 Nameplate 12
1.9.1 Information on the nameplate 13
2 Safety 14
2.1 General warnings 14
2.2 Toxic substances 15
2.3 Requirements for the rider 16
2.4 Protection for vulnerable groups 16
2.5 Data privacy 16
2.6 Personal protective equipment 16
2.7 Safety markings and safety instructions 16
2.8 Emergency 17
2.8.1 What to do in an emergency 17
2.8.2 First aid treatment 17
2.8.3 Fighting fire 17
2.8.4 Leaking fluids 18
2.8.4.1 Brake fluid 18
2.8.4.2 Oils and lubricants from the fork 18
2.8.4.3 Oils and lubricants from the rear frame
damper 18
3 Overview 19
3.1 Description 20
3.1.1 Wheel and suspension 20
3.1.1.1 Valve 20
3.1.2 Suspension 20
3.1.2.1 Steel suspension fork structure 21
3.1.2.2 Air suspension fork structure 21
3.1.2.3 Structure of the FOX rear frame
damper 22
3.1.2.4 Structure of the Suntour rear frame
damper 22
3.1.3 Brake system 22
3.1.3.1 Rim brake 22
3.1.3.2 Disc brake 23
3.1.3.3 Back-pedal brake 23
3.1.3.4 ABS 24
3.1.4 Electric drive system 25
3.1.5 Rechargeable battery 25
3.1.5.1 Pannier rack battery 26
3.1.5.2 Integrated battery 27
3.1.6 Display 27
3.1.6.1 USB port 28
3.1.7 Riding light 28
3.1.8 Charger 28
3.2 Proper use 29
3.3 Improper use 30
3.4 Technical data 31
3.4.1 Pedelec 31
3.4.2 ActiveLine motor 31
3.4.3 ActiveLine Plus motor 31
3.4.4 Performance Line Cruise motor 31
3.4.5 Performance Line Speed motor 31
3.4.6 Performance Line CX motor 31
3.4.7 Pedelec lighting 32
3.4.8 PowerPack 300 battery 32
3.4.9 PowerPack 400 battery 32
3.4.10 PowerPack 500 battery 32
3.4.11 PowerTube battery 32
3.4.12 Intuvia display 32
3.4.13 USB port 32
3.4.14 BOSCH Pedelec ABS BAS100 33
3.4.15 Emissions 33
3.4.16 Tightening torque 33
3.5 Environmental requirements 34
3.6 Description of controls and screens 36
3.6.1 Handlebars 36
3.6.2 Battery level indicator 36
3.6.3 Control panel 36
3.6.4 On-screen indicators 36
MY20H02-12_1.0_12.06.2019 6
Contents
3.6.4.1 Riding light symbol 36
3.6.4.2 Level of assistance 37
3.6.4.3 Motor power used 37
3.6.4.4 Battery level indicator 37
3.6.4.5 Gear recommendation 38
3.6.4.6 Tachometer screen 38
3.6.4.7 Function display 38
3.6.5 System message 40
3.6.6 ABS indicator lamp 40
4 Transportation and storing 41
4.1 Physical transport characteristics 41
4.1.1 Dimensions during transportation 41
4.1.2 Transport weight 41
4.1.3 Designated handles/lifting points 41
4.2 Transportation 41
4.2.1 Transporting the battery 42
4.2.2 Shipping the battery 42
4.2.3 Using the brake transport securing
system 42
4.3 Storing 42
4.3.1 Break in operation 43
4.3.1.1 Preparing a break in operation 43
4.3.1.2 Taking out of operation 43
5 Assembly 44
5.1 Required tools 44
5.2 Unpacking 44
5.2.1 Scope of delivery 44
5.3 Commissioning 45
5.3.1 Checking the battery 45
5.3.2 Mounting the wheel in the Suntour fork 45
5.3.2.1 Mounting the wheel with screw-on axle
(15 mm) 45
5.3.2.2 Mounting the wheel with screw-on axle
(20 mm) 46
5.3.2.3 Mounting the wheel with a quick release
axle 47
5.3.3 Mounting the wheel with a quick release 48
5.3.4 Mounting the wheel in the FOX fork 49
5.3.4.1 Wheel with quick release (15 mm) 49
5.3.4.2 Adjusting the FOX quick release 50
5.3.4.3 Mounting the wheel with Kabolt axles 50
5.3.4.4 Checking the stem and handlebars 50
5.3.5 Pedelec sale 51
6Operation 52
6.1 Risks and hazards 52
6.1.1 Tips for a greater range 53
6.1.2 Personal protective equipment 53
6.2 Error messages 54
6.2.1 Error message display 54
6.2.2 Battery error message 56
6.3 Before the first ride 57
6.3.1 Adjusting the saddle 57
6.3.1.1 Adjusting the saddle tilt 57
6.3.2 Determining the seat height 57
6.3.2.1 Adjusting the seat height with quick
release 57
6.3.2.2 Height-adjustable seat post 58
6.3.2.3 Adjusting the seat position 58
6.3.3 Adjusting the handlebars 59
6.3.3.1 Adjusting the stem 59
6.3.3.2 Adjusting the height of the handlebars 59
6.3.3.3 Turning the handlebars to the side 60
6.3.3.4 Checking the clamping force in quick
releases 60
6.3.3.5 Adjusting the quick release clamping
force 60
6.3.4 Adjusting the brake lever 60
6.3.4.1 Adjusting the pressure point on a
Magura brake lever 60
6.3.4.2 Adjusting the grip distance 61
6.3.4.3 Adjusting the grip distance on a
Magura brake lever 61
6.3.5 Adjusting the suspension of the
Suntour fork 62
6.3.5.1 Adjusting the negative deflection 62
6.3.5.2 Adjusting the air suspension fork
negative deflection 62
6.3.5.3 Adjusting the steel suspension fork
negative deflection 63
6.3.5.4 Adjusting the rebound 64
6.3.6 Adjusting the suspension of the
FOX fork 64
6.3.6.1 Adjusting the negative deflection 64
6.3.6.2 Adjusting the rebound 65
6.3.7 Setting the Suntour rear frame damper 66
6.3.7.1 Adjusting the negative deflection 66
6.3.7.2 Adjusting the rebound 66
6.3.7.3 Setting the compression 67
6.3.8 Setting the FOX rear frame damper 67
6.3.8.1 Adjusting the negative deflection 67
6.3.8.2 Adjusting the rebound 68
6.3.9 Retracting the brake linings 68
6.4 Accessories 69
6.4.1 Child seat 69
6.4.2 Bicycle trailers 70
6.4.3 Pannier rack 70
6.5 Before each ride 71
6.6 Check list before each ride 71
6.7 Folding 72
6.7.1 Folding the folding bicycle 72
6.7.1.1 Folding the pedal 72
6.7.1.2 Folding the stem 1, Folding 72
6.7.1.3 Folding the stem 2, Folding 72
6.7.1.4 Pushing in the seat post 73
6.7.1.5 Folding the frame 73
6.7.2 Preparing the bicycle so that it is
ready to ride again 73
6.7.2.1 Folding out the frame 73
6.8 Using the kickstand 74
6.8.1 Raising the kickstand 74
6.8.1.1 Parking the pedelec 74
MY20H02-12_1.0_12.06.2019 7
Contents
6.9 Using the pannier rack 74
6.10 Rechargeable battery 75
6.10.1 Frame battery 76
6.10.1.1 Removing the frame battery 76
6.10.1.2 Inserting the frame battery 76
6.10.2 Pannier rack battery 76
6.10.2.1 Removing the pannier rack battery 76
6.10.2.2 Inserting the pannier rack battery 76
6.10.3 Integrated battery 76
6.10.3.1 Removing the integrated battery 76
6.10.3.2 Inserting the integrated battery 77
6.10.4 Charging the battery 77
6.10.5 Dual charging 78
6.10.5.1 Charging process when two batteries
are used 78
6.10.5.2 Charging process when one battery is
used 79
6.10.6 Waking the battery 79
6.11 Electric drive system 80
6.11.1 Switching on the electric drive system 80
6.11.2 Switching off the drive system 80
6.12 Control panel with display 81
6.12.1 Removing and attaching the display 81
6.12.1.1 Removing the display 81
6.12.1.2 Attaching the display 81
6.12.2 Securing display against removal 81
6.12.3 Charging the internal display battery 81
6.12.3.1 Charging on the pedelec 81
6.12.3.2 Charging using the USB port 81
6.12.4 Using the USB port 82
6.12.5 Switching on the display 82
6.12.6 Switching off the display 82
6.12.7 Using the push assist system 82
6.12.8 Using the riding light 82
6.12.9 Selecting the level of assistance 83
6.12.10 Journey information 83
6.12.10.1Changing the displayed journey
information 83
6.12.10.2Resetting the journey information 83
6.12.11 Changing the system settings 83
6.13 Brake 84
6.13.1 Using the brake lever 85
6.13.2 Using the back-pedal brake 86
6.13.3 Using ABS 86
6.13.3.1 While riding 87
6.14 Suspension and damping 87
6.14.1 Adjusting the compression of the
Fox fork 87
6.14.2 Adjusting the compression of the
Fox damper 88
6.14.3 Adjusting the compression of the
Suntour fork 88
6.14.4 Adjusting the compression of a
Suntour damper 89
6.14.5 Adjusting the rebound in a Rock
Shox damper 89
6.14.6 Adjusting the compression in a
Rock Shox damper 90
6.15 Gear shift 90
6.15.1 Using the derailleur gears 90
6.15.2 Using a hub gear 91
6.15.3 Use eShift 91
6.15.3.1 eShift with Shimano DI2 automatic
hub gears 91
6.15.3.2 eShift with manual Shimano DI2 hub
gears 92
6.15.3.3 eShift with Shimano DI2 automatic
hub gears 92
6.15.3.4 eShift with NuVinci H|Sync/enviolo
with Optimized H|Sync 92
6.15.3.5 eShift with Rohloff E-14
Speedhub 500/14 92
7 Cleaning and servicing 93
7.1 Cleaning after each ride 93
7.1.1 Cleaning the suspension fork 93
7.1.2 Cleaning the rear frame damper 93
7.1.3 Cleaning the pedals 93
7.2 Basic cleaning 94
7.2.1 Cleaning the frame 94
7.2.2 Cleaning the stem 94
7.2.3 Cleaning the rear frame damper 94
7.2.4 Cleaning the wheel 94
7.2.5 Cleaning the drive elements 94
7.2.6 Cleaning the chain 95
7.2.7 Cleaning the battery 95
7.2.8 Cleaning the display 95
7.2.9 Cleaning the drive unit 95
7.2.10 Cleaning the brake 96
7.3 Servicing 96
7.3.1 Servicing the frame 96
7.3.2 Servicing the stem 96
7.3.3 Servicing the fork 96
7.3.4 Servicing the drive elements 96
7.3.5 Servicing the pedals 96
7.3.6 Servicing the chain 96
7.3.7 Servicing the drive elements 96
7.4 Maintenance 96
7.4.1 Wheel 96
7.4.2 Checking the tyres 97
7.4.3 Checking the rims 97
7.4.4 Check and correct tyre pressure 97
7.4.4.1 Dunlop valve 97
7.4.4.2 Presta valve 97
7.4.4.3 Schrader valve 98
7.4.5 Brake system 98
7.4.6 Checking the brake linings for wear 98
7.4.7 Checking the pressure point 98
7.4.8 Checking the brake discs for wear 99
7.4.9 Electrical cables and brake cables 99
MY20H02-12_1.0_12.06.2019 8
Contents
7.4.10 Gear shift 99
7.4.11 Stem 99
7.4.12 USB port 99
7.4.13 Checking the chain tension 99
7.4.14 Checking the handlebar grip position 99
8 Maintenance 100
8.1 Axle with quick release 101
8.1.1 Checking the quick release 101
8.2 Adjusting the gear shift 101
8.2.1 Cable-operated gear shift,
single-cable 102
8.2.2 Cable-operated gear shift,
dual-cable 102
8.2.3 Cable-operated twist grip,
dual-cable 102
9 Troubleshooting, fault clearance
and repair 103
9.1 Troubleshooting and fault clearance 103
9.1.1 The drive system or display do not
start up 103
9.1.2 Error messages 103
9.2 Repair 104
9.2.1 Use original parts and lubricants
only 104
9.2.2 Replacing the lighting 104
9.2.3 Setting the headlight 104
10 Recycling and disposal 105
11 Documents 106
11.1 Parts list 106
11.2 Assembly report 107
11.3 Maintenance log 109
11.4 Charger operating instructions 112
12 Keyword index 121
13 Glossary 123
I. EC declaration of conformity 126
MY20H02-12_1.0_12.06.2019 9
About these operating instructions
1 About these operating instructions
Thank you for your trust!
HERCULES pedelecs are sporting equipment of
the highest quality – you have made a good
choice. Your specialist dealer has advised you
and assembled your product. Whether
maintenance, inspection, conversion or repair,
your specialist dealer will also be happy to assist
you in the future.
You receive these operating instructions with your
new pedelec. Please take a little time to become
familiar with your new pedelec and follow the tips
and suggestions in the operating instructions.
They will help you to enjoy your HERCULES
pedelec for a long time to come. We hope you
have fun and wish you well on all of your rides!
These operating instructions are designed for the
rider and the operator of the pedelec to ensure
that non-professionals can use the pedelec safely.
You can download the operating instructions onto
your mobile phone at the following address, so
that you can use them when you are out riding:
https://www.hercules-
bikes.de/de/de/index/
downloads.html
1.1 Manufacturer
The pedelec manufacturer is:
HERCULES GMBH
Longericher Straße 2
50739 Köln, Germany
Tel.: +49 4471 18735 0
Fax: +49 4471 18735 29
E-mail: info@hercules-bikes.de
Internet: www.hercules-bikes.de
1.2 Type number and model
The operating instructions are an integral part of
pedelecs with the following type numbers:
Notice
The operating instructions are not a substitute for
personal instruction by the supplying specialist
dealer.
The operating instructions are an integral part of
the pedelec. Therefore, if it is re-sold at a later
time, they must be handed over to the subsequent
owner.
Instructions for the specialist dealer are highlighted in grey and
marked with a symbol. Specialist dealers have specialist
training and qualifications and are thus able to identify risks and
prevent hazards which may arise during maintenance, servicing
and repairs on the pedelec. Information for specialist staff does
not require non-professionals to take any action.
Type no. Model Pedelec type
20-P-0001 E-Imperial I-R8 Cargo bike
20-P-0002 E-Imperial I-R8 Cargo bike
20-P-0003 E-Imperial I-F8 Cargo bike
20-P-0004 E-Imperial I-F8 Cargo bike
20-P-0005 E-Imperial I-10 Cargo bike
20-P-0006 E-Imperial I-10 Cargo bike
20-P-0007 E-Imperial 180 S R8 Cargo bike
20-P-0008 E-Imperial 180 S R8 Cargo bike
20-P-0009 E-Imperial 180 S F8 Cargo bike
20-P-0010 E-Imperial 180 S F8 Cargo bike
20-P-0011 E-Imperial 180 S9 Cargo bike
20-P-0012 E-Imperial 180 S9 Cargo bike
20-P-0013 E-Imperial 180 S9 Cargo bike
20-Q-0001 Futura Pro I-F14 City and trekking bicycle
20-Q-0003 Futura Pro I-F14 City and trekking bicycle
20-Q-0004 Futura Pro I-F360 City and trekking bicycle
20-Q-0006 Futura Pro I-F360 City and trekking bicycle
20-Q-0007 Futura Pro I-11 City and trekking bicycle
20-Q-0009 Futura Pro I-11 City and trekking bicycle
20-Q-0010 Futura Comp I-10 City and trekking bicycle
20-Q-0011 Futura Comp I-10 City and trekking bicycle
20-Q-0012 Futura Comp I-10 City and trekking bicycle
20-Q-0013 Futura Sport I-F8 City and trekking bicycle
20-Q-0014 Futura Sport I-F8 City and trekking bicycle
20-Q-0015 Futura Sport I-F8 City and trekking bicycle
20-Q-0016 Futura Sport I-9 City and trekking bicycle
20-Q-0017 Futura Sport I-9 City and trekking bicycle
Table 1: Type number, model and pedelec type
MY20H02-12_1.0_12.06.2019 10
About these operating instructions
1.3 Identifying the operating
instructions
You will find the operating instructions
identification number at the bottom left-hand side
of each page. The identification number consists
of the document number, the version number and
the release date.
1.4 Laws, standards and directives
The operating instructions comply with the
essential requirements specified in:
• Machinery Directive 2006/42/EC
• Electromagnetic Compatibility Directive
2014/30/EU
• ISO/DIS 20607:2018 Safety of machinery –
Instruction handbook – General drafting
principles
• EN 15194:2018 Cycles – Electrically power
assisted cycles – pedelec bicycles
• EN 11243:2016, Cycles – Luggage carriers for
bicycles – Requirements and test methods
• EN ISO 17100:2016-05, Translation Services –
Requirements for translation service.
1.5 Subject to change
The information contained in these operating
instructions are the approved technical
specifications at the time of printing. Any
significant changes will be included in a new issue
of the operating instructions.
You will find any modifications to these operating
instructions:
www.bulls.de/service/downloads
1.6 Language
The original operating instructions are written in
German. A translation is not valid without the
original operating instructions.
1.7 For your safety
The pedelec's safety concept comprises four
elements:
• rider and/or operator instruction, and bicycle
maintenance and repair by the specialist dealer
• the section on general safety
• the warnings in these operating instructions
• the safety markings on the nameplate and the
pedelec.
20-Q-0018 Futura Sport I-9 City and trekking bicycle
20-Q-0018 Futura Sport I-9 City and trekking bicycle
20-Q-0019 Futura Sport I-8 City and trekking bicycle
20-Q-0020 Futura Sport I-8 City and trekking bicycle
20-Q-0021 Futura Sport I-8 City and trekking bicycle
20-Q-0040 Robert/a Pro I-R8 City and trekking bicycle
20-Q-0041 Robert/a Pro I-R8 City and trekking bicycle
20-Q-0043 Robert/a Pro I-F8 City and trekking bicycle
20-Q-0044 Robert/a deLuxe I-R8 City and trekking bicycle
20-Q-0045 Robert/a deLuxe I-R8 City and trekking bicycle
20-Q-0046 Robert/a deLuxe I-F8 City and trekking bicycle
20-Q-0047 Robert/a deLuxe I-F8 City and trekking bicycle
20-Q-0048 Robert/a I-R8 Belt City and trekking bicycle
20-Q-0049 Robert/a I-R8 Belt City and trekking bicycle
20-Q-0050 Robert/a I-F8 Belt City and trekking bicycle
20-Q-0051 Robert/a I-F8 Belt City and trekking bicycle
20-Q-0052 Robert/a I-R8 City and trekking bicycle
20-Q-0054 Montfoort Del I-F8 City and trekking bicycle
20-Q-0057 Robert/a R7 A+ City and trekking bicycle
20-Q-0058 Robert/a R7 A+ City and trekking bicycle
20-Q-0059 Robert/a F7 A+ City and trekking bicycle
20-Q-0060 Robert/a F7 A+ City and trekking bicycle
20-Q-0063 Viverty E R7 City and trekking bicycle
20-Q-0064 Montfoort Plus F8 City and trekking bicycle
20-Q-0066 Montfoort F7 City and trekking bicycle
20-Q-0068 E-Joy R7 City and trekking bicycle
20-Q-0069 E-Joy F7 City and trekking bicycle
20-Q-0080 Rob Cross Sport 12.1 City and trekking bicycle
20-Q-0081 Rob Cross.Sport 12.1
Str City and trekking bicycle
20-Q-0082 Rob Cargo R7 Cargo bike
20-Q-0090 Rob Cross Sport 12.1
Str City and trekking bicycle
20-Y-0002 Futura Fold I-R8 Folding bicycle
20-Y-0003 Futura Fold I-F8 Folding bicycle
20-Y-0007 Rob Fold I-R8 Folding bicycle
20-Y-0008 Rob Fold I-F8 Folding bicycle
20-Y-0009 Rob Fold 10 Folding bicycle
20-Y-0010 Rob Fold R8 Folding bicycle
20-Y-0011 Rob Fold Carbon Folding bicycle
20-Y-0011 Rob Fold F8 Folding bicycle
Type no. Model Pedelec type
Table 1: Type number, model and pedelec type
Identification number MY20H02-12_1.0_12.06.2019
Table 2: Identification number
MY20H02-12_1.0_12.06.2019 11
About these operating instructions
1.7.1 Instruction, training and customer
service
The supplying specialist dealer will provide
customer service. Contact details can be found on
the back page of these operating instructions and
on the data sheet. If you are unable to contact
your specialist dealer, you will find other specialist
dealers online at www.hercules-bikes.de.
The rider or the operator of the pedelec will be
instructed on the pedelec's functions in person
when the supplying specialist dealer hands over
the pedelec, if not before. In particular, this
instruction will cover the pedelec's electrical
functions and correct use of the charger.
Each rider to whom this bicycle is provided must
receive instruction on the pedelec's functions. A
printed copy of these operating instructions must
be provided to each rider, who must take note of
and observe them.
1.7.2 Basic safety instructions
These operating instructions explain all general
safety instructions in Section 2 on Safety.
1.7.3 Warnings
Hazardous situations and actions are marked with
warnings. The warnings in these operating
instructions are indicated as follows:
1.7.4 Safety markings
The following safety markings are used on the
pedelec's nameplates:
1.8 For your information
1.8.1 Instructions for actions
Instructions for actions are structured in
accordance with the following pattern:
Requirements (optional)
Instruction for action
Result of the action (optional)
1.8.2 Language conventions
The pedelec described in these operating
instructions may be equipped with alternative
equipment. The pedelec equipment is defined by
its respective type number. Where applicable, the
word Alternative beneath the heading indicates
alternatively used components. The following terms
are used for better legibility:
The following conventions are used in these
operating instructions:
Will lead to serious or even fatal injuries if
ignored. High-risk hazard.
May lead to serious or even fatal injuries if
ignored. Medium-risk hazard.
May lead to minor or moderate injuries. Low-risk
hazard.
Notice
May lead to material damage if ignored.
DANGER
!
WARNING
!
CAUTION
!
General warning
Adhere to the instructions for use
Table 3: Meaning of safety markings
Term Meaning
Instruction handbook Original operating
instructions or translation
of the original operating
instructions
Pedelec Electric motor driven cycle
Motor Drive motor
Convention Use
Italics Glossary terms
SPACED Indicators on the display
screen
[Example, page
numbering]
Cross references
• Bulleted lists
MY20H02-12_1.0_12.06.2019 12
About these operating instructions
1.9 Nameplate
The nameplate is situated on the frame. You will
find the precise position of the nameplate in
Figure 2. You will find thirteen pieces of
information on the nameplate.
Figure 1: Nameplate, example
HERCULES GmbH
Longericher Str. 2
50739 Köln, Germany
Typ:
20-16-0001
EN 15194
0,25 kW / 25 km/h
zGG 180 kg
EPAC 25 kg
BJ 2019 / MJ 2020
nach
EPAC
2
3
1
4
5
6
7
89
12
13
10
11
No. Designation Description
1 CE marking The manufacturer uses the CE marking to declare that the pedelec complies with
applicable requirements.
2 Manufacturer's contact details You can contact the manufacturer at this address. You can find more information in
Section 1.1.
3 Type number All pedelec models have an eight-digit type number, which is used to specify the design
model year, the type of pedelec and the version. You can find further information in
Section 1.9.1.
4 Maximum continuous power The maximum continuous power is the maximum power for the electric motor output shaft
during 30 minutes.
5 Permitted total weight The permitted total weight is the weight of the fully assembled pedelec with the rider and
baggage.
6Year of manufacture The year of manufacture is the year in which the pedelec was manufactured. The
production period is from August 2019 to July 2020.
7 Pedelec type You can find further information in Section 1.9.3.
8 Safety markings You can find more information in Section 2.6.
9 Disposal instructions You can find more information in Section 9.
10 Area of use You can find further information in Section 1.9.4.
11 Model year The model year refers to the first production year that the series-manufactured pedelec
was produced in the version and is not always identical with the year of manufacture.
The year of manufacture may be before the model year in some cases. If no technical
modifications are introduced to the series, production may continue of pedelecs from a
previous model year.
12 Weight of ready-to-ride pedelec The indicated weight for a ready-to-ride pedelec refers to the weight of a pedelec at the
time of sale. The weight of each additional accessory must be added to this weight.
13 Shut-off speed Speed reached by the pedelec at the moment when the current has dropped to zero or to
the no load current value.
MY20H02-12_1.0_12.06.2019 13
About these operating instructions
1.9.1 Information on the nameplate
Alongside the warnings, product nameplates also
contain other important information about the
pedelec:
Read the instructions
Separate collection of
electrical and electronic
devices
Separate collection of
batteries
Must not be thrown into fire
(burning prohibited)
Battery must not be opened
Device of protection class II
Only suitable for use indoors
Fuse (device fuse)
EU conformity
Recyclable material
Protect from temperatures
above 50 °C and direct
sunlight
Table 4: Relevance of safety instructions
max. 50°C
MY20H02-12_1.0_12.06.2019 14
Safety
2 Safety
2.1 General warnings
Risk of fire and explosion due to faulty battery
The safety electronics on a damaged or faulty
battery may fail. The residual voltage can cause a
short circuit. The battery may self-ignite and
explode.
Remove batteries with external damage from
service immediately and never charge them.
Only operate the battery and accessories if
they are in perfect condition.
Only use batteries which are approved for use
on your pedelec.
Do not use the battery with defective
connecting cables or defective contacts.
Use the battery with BMZ Systems e-bikes
only. This is the only way that the battery will
be protected from dangerous overloading.
If the battery becomes deformed or begins to
smoke, keep at a safe distance, disconnect the
power supply at the socket, and notify the fire
service immediately.
Never extinguish a damaged battery with
water or allow it to come into contact with
water.
If a battery is dropped or struck but shows no
signs of external damage, remove it from
service and observe it for at least 24 hours.
Faulty batteries are hazardous goods.
Dispose of faulty batteries properly and as
quickly as possible.
Store in a dry place until disposal. Never store
in the vicinity of flammable substances.
Never open or repair the battery.
Charge the battery before use. Only use the
charger included in the scope of delivery.
WARNING
!
Avoid wide temperature fluctuations.
Do not use the battery at altitudes higher than
2,000 m.
Electric shock in case of damage
Damaged chargers, cables and plug connectors
increase the risk of electric shock.
Check the charger, cable and plug connector
before each use. Never use a damaged
charger.
Risk of fire and explosion due to short circuit
Small metal objects may jumper the electrical
connections of the battery. The battery may self-
ignite and explode.
Keep paper clips, screws, coins, keys and
other small parts away and do not insert them
into the battery.
Risk of fire and explosion due to incorrect
charger
Batteries which are recharged with an unsuitable
charger may become damaged internally. This
may result in fire or an explosion.
Only ever use the battery with the supplied
charger.
Mark the supplied charger clearly to prevent
mix-ups – with the pedelec frame number or
type number, for example.
WARNING
!
CAUTION
!
MY20H02-12_1.0_12.06.2019 15
Safety
2.2 Toxic substances
Risk of fire and explosion due to penetration by
water
The battery is only protected from simple spray
water. Penetration by water can cause a short
circuit. The battery may self-ignite and explode.
Never immerse the battery in water.
If there is reason to believe that water may
have entered into the battery, the battery must
be removed from service.
Risk of fire and explosion due to high
temperatures
Excessively high temperatures will damage the
battery. The battery may self-ignite and explode.
Protect the battery against heat.
Never expose the battery to sustained direct
sunlight.
Fire caused by overheated charger
The charger heats up when charging the battery.
In case of insufficient cooling, this can result in
fire or burns to the hands.
Never use the charger on a highly flammable
surface (e.g. paper, carpet etc.).
Never cover the charger during the charging
process.
Never leave the battery unattended during
charging.
Electric shock caused by penetration by
water
If water penetrates into the charger, there is a risk
of electric shock.
Never charge the battery outdoors.
Notice
If you leave a key inserted when riding or
transporting the pedelec, it may break off or the
locking system may open accidentally.
Remove the key from the battery lock
immediately after use.
We recommend that you attach the key to a
key ring.
CAUTION
!
Intoxication from suspension oil
Suspension oil in the rear frame damper is toxic to
the touch, irritates respiratory tracts and causes
cancer, sterility and mutation in germ cells.
Never disassemble the rear frame damper.
Never allow suspension oil to come into
contact with the skin.
Chemical burns to the skin and eyes caused by
faulty battery
Liquids and vapours may leak from damaged or
faulty batteries. They can irritate the airways and
cause burns.
Avoid contact with leaked liquids.
Ventilate with fresh air and consult a doctor if
you suffer any pain or discomfort.
Immediately consult a doctor in case of
contact with the eyes or any discomfort.
In case of contact with the skin, rinse off
immediately with water.
Ventilate the room well.
Hazard for the environment due to leaking
brake fluid
The brake system contains a toxic, environmentally
harmful brake fluid. Such fluids will contaminate if
they enter the sewers or groundwater.
The brake system must be repaired
immediately if brake fluid leaks out. Contact
your specialist dealer about repair.
Dispose of leaking brake fluid in an
environmentally responsible way in
accordance with statutory regulations. Ask a
specialist dealer for more information.
WARNING
!
CAUTION
!
MY20H02-12_1.0_12.06.2019 16
Safety
2.3 Requirements for the rider
If there are no legal requirements for riders of
electrically power-assisted cycles, we recommend
that the rider should be a minimum 15 years of
age and have experience with muscle-powered
bicycles.
The rider's physical and mental abilities must be
adequate to use a muscle-powered pedelec.
2.4 Protection for vulnerable groups
You must keep batteries and charger away from
children and people with reduced physical,
sensory or mental capabilities or lacking in
experience and knowledge.
If minors are to use the pedelec, comprehensive
instruction should be provided by or in the
presence of the legal guardians. Supervised use
should also be scheduled until it is certain that the
pedelec is being used as per these operating
instructions.
2.5 Data privacy
During maintenance, the pedelec is connected to
the diagnosis tool and data is transferred to Bosch
Pedelec Systems (Robert Bosch GmbH) about the
use of electric drive components to help improve
the product. You will find more information on the
Bosch Pedelec website
https://www.bosch-ebike.com/en/
2.6 Personal protective equipment
We recommend that you wear a suitable cycling
helmet. We also recommend that you wear sturdy
footwear and typical, close-fitting clothing for
bicycles.
2.7 Safety markings and safety
instructions
The nameplate contains the following safety
markings and safety instructions:
Environmental hazard posed by oil and
lubricants from the fork
The fork contains toxic, environmentally harmful oils
and lubricants. Such fluids will contaminate if they
enter the sewers or groundwater.
The fork must be repaired immediately if oils
and lubricants are leaking out. Contact your
specialist dealer about repair.
Dispose of leaked oils and lubricants in an
environmentally responsible way in
accordance with statutory regulations. Ask a
specialist dealer for more information.
Environmental hazard posed by oil and
lubricants from rear frame damper
The rear frame damper contains toxic and
environmentally harmful oils and lubricants. Such
fluids
will contaminate if they enter the sewers or
groundwater.
Dispose of oils and lubricants which have
leaked from the rear frame damper in an
environmentally responsible way in
accordance with statutory regulations. Ask a
specialist dealer for more information.
CAUTION
!
Symbol Explanation
General warning
Adhere to the instructions for use
Table 5: Meaning of safety markings
MY20H02-12_1.0_12.06.2019 17
Safety
2.8 Emergency
2.8.1 What to do in an emergency
In the event of a hazard or danger in road
traffic, apply the brakes on the pedelec until it
comes to a halt. The brake acts as an
emergency stop system in such cases.
2.8.2 First aid treatment
Symptoms which are caused by combustion
gases or leaking fluids require medical attention.
After inhalation
Vapours may emit if the battery is damaged or
used improperly Get into fresh air and consult a
doctor if you suffer any pain or discomfort. The
vapours may cause respiratory tract irritation.
After skin contact
Remove any solid particles immediately. Rinse
the affected area with plenty of water for at least
15 minutes. Then dab the affected skin gently. Do
not rub dry. Remove contaminated clothing
immediately. Immediately consult a doctor if there
is any redness or abnormalities.
After contact with eyes
Rinse eyes with plenty of water for at least
15 minutes. Protect unaffected eye. Seek medical
advice immediately.
After swallowing
Drink plenty of milk or water and induce vomiting.
Seek medical advice immediately.
2.8.3 Fighting fire
The safety electronics on a damaged or faulty
battery may fail. The residual voltage can cause a
short circuit. The battery may self-ignite and
explode.
Keep your distance if the battery becomes
deformed or starts to emit smoke.
Evacuate everyone from the immediate area of
the fire.
Contact the fire service immediately!
Use Class fire extinguishers to put out the fire.
Never extinguish damaged batteries with water
or allow them to come into contact with water.
Symbol Explanation
Read the instructions
Separate collection of electrical
and electronic devices
Separate collection of ordinary
and rechargeable batteries
Must not be thrown into fire
(burning prohibited)
It is forbidden to open any
batteries
Device of protection class II
Only suitable for use indoors
Fuse (device fuse)
EU conformity
Recyclable material
Protect from temperatures
above 50 °C and direct sunlight
Table 6: Relevance of safety instructions
max. 50°C
Intoxication
Inhaling vapours can cause
intoxication.
Stand on the side of the fire
where the wind is coming from.
Use breathing apparatus if
possible.
WARNING
!
MY20H02-12_1.0_12.06.2019 18
Safety
2.8.4 Leaking fluids
2.8.4.1 Brake fluid
The brake system must be repaired
immediately if brake fluid leaks out. Contact
your specialist dealer about repair.
Dispose of leaking brake fluid in an
environmentally responsible way in
accordance with statutory regulations. Ask a
specialist dealer for more information.
2.8.4.2 Oils and lubricants from the fork
The brake system must be repaired
immediately if brake fluid leaks out. Contact
your specialist dealer about repair.
Dispose of leaking brake fluid in an
environmentally responsible way in
accordance with statutory regulations. Ask a
specialist dealer for more information.
2.8.4.3 Oils and lubricants from the rear frame
damper
Dispose of oils and lubricants which have
leaked from the rear frame damper in an
environmentally responsible way in
accordance with statutory regulations. Ask a
specialist dealer for more information.
MY20H02-12_1.0_12.06.2019 19
Overview
3Overview
Figure 2: Pedelec viewed from the right, Futura Sport I F8 used as example
1Front wheel
2Fork
3 Front guard
4 Headlight
5Handlebars
6Stem
7Frame
8 Seat post
9 Saddle
10 Pannier rack
11 Rear light and reflector
12 Rear guard
13 Rear wheel
14 Chain
15 Chain guard
16 Frame number
17 Battery and nameplate
1
2
3
4
5
6
7
8
9
10
11
12
13
14 15 16 17
MY20H02-12_1.0_12.06.2019 20
Overview
3.1 Description
3.1.1 Wheel and suspension
Figure 3: Components of the wheel, example of front
wheel
1 Tyre
2 Rim
3 Suspension fork head with setting wheel
4 Shock absorber
5 Spoke
6 Quick release
7Hub
8Valve
9 Fork end of the shock absorber
3.1.1.1 Valve
Each wheel has a valve. It is used to fill the tyre
with air. There is a valve cap on each valve. The
screw-on valve cap keeps out dust and dirt.
The pedelec either has a conventional Dunlop
valve, a Presta valve or a Schrader valve.
3.1.2 Suspension
Both forks and suspension forks are fitted in this
model series. A suspension fork is based either on a
steel spring or air suspension. Unlike a rigid fork, a
suspension fork has two functions which improve
floor contact and comfort: suspension and damping.
Figure 4: Pedelec without suspension (1) and with
suspension (2) when riding over an obstacle
The suspension prevents an impact, such as one
caused by a stone lying in the bike's path, from
being channelled directly into the rider's body via
the fork. The impact is absorbed by the
suspension system instead. This causes the
suspension fork to compress. The compression
can be disabled so that a suspension fork reacts
like a rigid fork. The switch to disable the fork is
called a remote lockout.
After compressing, the suspension fork returns to
its original position. If there is a damper, it
decelerates movement, preventing the
suspension system from springing back in an
uncontrolled manner and stopping the fork from
vibrating up and down. Dampers which dampen
compressive deflection movements, i.e. a
compression load, are called compression
dampers or compression dashpots.
Dampers which dampen rebound deflection
movements, i.e. a rebound load, are called
rebound dampers or dashpots.
1
2
4
5
8
7
3
9
6
12
MY20H02-12_1.0_12.06.2019 21
Overview
3.1.2.1 Steel suspension fork structure
Figure 5: Example showing Suntour fork
The stem and handlebars are fastened to the fork
steerer (1). The wheel is fastened to the quick
release axle (6). Other elements: the compression
setting (2), crown (3), Q-Loc (5), dust seal (6),
fork end for quick release (7), stanchion (8) and
spring (9)
3.1.2.2 Air suspension fork structure
The pedelec's fork features both air suspension and
a compression damper plus a rebound damper in
some cases.
Figure 6: Example showing Yari fork
You can see the following components in the
diagram: Air valve (1), valve cap (2) fork lock (3),
quick release (4) and rebound damper
adjuster (5) and the assembly groups: Air
suspension fork (A), compression damper
assembly group (B) and rebound damper
assembly group (C)
1
1
2
3
4
5
6
7
8
7
A
B
C
1
2
3
4
5
A
B
C
MY20H02-12_1.0_12.06.2019 22
Overview
3.1.2.3 Structure of the FOX rear frame
damper
The rear frame damper features air suspension, a
compression damper and a rebound damper.
Figure 7: Example showing FOX rear frame damper
1 Guide rod eye
2Air valve
3 Setting wheel
4 Lever
5 Air chamber
6O-ring
3.1.2.4 Structure of the Suntour rear frame
damper
The rear frame damper features air suspension, a
compression damper and a rebound damper.
Figure 8: Example showing Suntour rear frame damper
1 Upper eye
2.1 Total damper length
2.2 SAG
3 Lower eye
4O-ring
5 Sleeve
6 Damper unit
7 IFP (internal floating piston)
8Air valve
9 Air chamber
10 Lockout lever
11 Rebound lever
3.1.3 Brake system
The pedelec's brake system comprises either a
hydraulic:
• rim brake on the front and rear wheels
• disc brake on the front and rear wheels or
• a rim brake on the front and rear wheels and an
additional back-pedal brake.
The mechanical brakes are used as an
emergency stop system and bring the pedelec to
a halt quickly and safely in the event of an
emergency.
3.1.3.1 Rim brake
Figure 9: Rim brake components with details; Magura
HS22 used as an example
1 Rear wheel rim brake
2 Brake booster
3 Brake lining
4Handlebars with brake lever
5 Front wheel rim brake
The rim brake stops the wheel moving when the
rider pulls the brake lever, causing two brake
linings, positioned opposite one another, to be
pressed onto the rims.
25-30%
1
2
4
3
1
2.2
3
4
5
6
78
910
11
2.1
1
2
3
4
5
MY20H02-12_1.0_12.06.2019 23
Overview
The hydraulic rim brake features a locking lever.
Figure 10: Rim brake locking lever, closed (1) and open (2)
3.1.3.2 Disc brake
Figure 11: Pedelec brake system with a disc brake –
example
1Brake disc
2 Brake calliper with brake linings
3Handlebars with brake lever
4 Front wheel brake disc
5 Rear wheel brake disc
On a pedelec with a disc brake, the brake disc is
screwed permanently to the wheel hub.
The brake lever is pulled to increase brake
pressure. The brake fluid is used to transfer
pressure through the brake lines to the cylinders
in the brake calliper. The braking force is boosted
by a speed reduction and applied to the brake
linings. These apply the brake disc mechanically.
If the brake lever is pulled, the brake linings are
pressed against the brake disc and the wheel
movement is decelerated until it comes to a stop.
3.1.3.3 Back-pedal brake
Figure 12: Pedelec brake system with a back-pedal brake
– example
1 Rear wheel rim brake
2Handlebars with brake lever
3 Front wheel rim brake
4Pedal
5 Back-pedal brake
The back-pedal brake stops the movement of the
rear wheel when the rider pedals in the opposite
direction to the direction of travel.
The rim brake locking lever is not marked with any lettering.
Only a specialist dealer may set the rim brake locking lever
1
2
3
4
5
5
2
3
4
1
MY20H02-12_1.0_12.06.2019 24
Overview
3.1.3.4 ABS
Figure 13: BOSCH ABS
1 ABS control unit with housing
2 Display screen
3 ABS indicator lamp
4 Control panel
5 Front wheel brake lever
6 Brake calliper
7 Bike speed sensor
8 Sensor disc
ABS is an added function in some pedelecs.
The rear wheel brake function does not depend on
the anti-blocking system functioning correctly.
When the brakes are applied, the ABS function
detects critical slippage thanks to the wheel speed
sensors on the front and rear wheels and limits
slippage on the front wheel by reducing brake
pressure there, thus stabilising the wheel. Once
the wheel has been stabilised, the wheel is
brought to the blocking limit again by building up
pressure selectively.
The lever moves a little more towards the
handlebars with each brake impulse during this
process. If the wheel blocks again, the pressure is
reduced again. This process is repeated to keep
the wheel at its limit of traction, thus making
optimum use of the coefficient of friction between
the tyres and the road surface.
The ABS function terminates when one of the
following events occurs:
• The buffer chamber in the ABS control unit is filled
completely.
• The pedelec has come to a halt.
• The rider releases the brake.
Besides the ABS function itself, the unit also
includes a system to detect when the rear wheel
is raised during full braking. This enables the rider
to counteract a potential flip-over caused by
extremely hard brake manoeuvres to a certain
extent.
If the battery level falls below a specified
threshold, the system deactivates the power
assistance first. The system will still remain
active, including the display, lights and ABS until
the battery reserve is also used up. The electric
drive system and, consequently, the ABS will not
switch off until the battery has almost fully
discharged.
The indicator lamp lights up for about 5 seconds
before the system switches off completely. The
ABS indicator lamp will then go out, even though
the ABS control system is not available. The ABS
is not active if there is no battery on the pedelec
or its battery is empty.
The brake system itself remains functional. It is
only the anti-blocking system control which no
longer operates.
1
1
2
(1) (2) (3) (4) (5)
(6)
(6)
(7)
(8)
MY20H02-12_1.0_12.06.2019 25
Overview
3.1.4 Electric drive system
The pedelec is driven by muscle power applied to
the chain drive. The force which is applied by
pedalling in the direction of travel drives the front
chain wheel. The chain transmits the force onto
the rear chain wheel and then onto the rear wheel.
Figure 14: Diagram of mechanical drive system
1 Direction of travel
2 Chain
3 Rear chain wheel
4 Front chain wheel
5 Pedal
The pedelec also has an integrated electric drive
system.
The electric drive system is made up of 8
components:
Figure 15: Diagram of electric drive system
1Headlight
2Display
3Control panel
4.1 Integrated rechargeable battery
4.2 Frame battery and/or
4.3 Pannier rack battery
5 Rear light
6Electric gear shift (alternative)
7Motor
• A charger which is designed for the battery.
As soon as the required muscle power from the
rider pedalling passes a certain level, the motor is
activated gently and assists the pedalling motion
of the rider. The motor force is determined by the
set level of assistance.
The pedelec does not have a separate emergency
stop or emergency shut-off button. The drive
system can be stopped in case of emergency by
removing the display.
The motor switches off automatically as soon as
the rider no longer pedals, the temperature is
outside the permitted range, there is an overload
or the shut-off speed of 25 km/h has been
reached.
A push assist system can be activated. The speed
depends on the selected gear. The push assist
continues to drive the pedelec as long as the rider
presses the push assist button on the handlebars.
The speed can be a maximum of 6 km/h in this
case. The drive stops when the plus button is
released.
3.1.5 Rechargeable battery
Bosch rechargeable batteries are lithium ion
batteries which are developed and manufactured
to the latest technical standards. These batteries
meet and exceed applicable industrial safety
standards. The battery has an internal electronic
protection circuit, which is specifically designed
for the charger and the pedelec. The battery
temperature is monitored at all times. Each
individual cell in a Bosch rechargeable battery is
protected by a steel cup and cased in a plastic
housing. You must not open this housing. You
must also avoid mechanical loads or exposure to
intense heat since they may damage the battery
cells and cause flammable contents to leak out.
The battery is protected against deep discharge,
overcharging, overheating and short circuit. In the
event of a hazard, a protective circuit switches the
battery off automatically.
5
2
4
1
B
3
1
2
4.2
4.1
4.3
5
6
7
MY20H02-12_1.0_12.06.2019 26
Overview
The battery has a high energy content when
charged. The substances in lithium-ion battery
cells may become inflammable under certain
conditions. You will find codes of practice for their
safe handling in Section 2 on Safety and
Section 6.9 on Rechargeable battery in the
operating instructions.
If the electric drive system is not used for about
10 minutes (e.g. the pedelec is stationary) and no
button has been pressed on the display or the
control panel, the electric drive system and the
rechargeable battery are automatically switched
off to save energy.
The type and duration of operating conditions
have a significant effect on the battery life. Just
like any other lithium-ion battery, the Bosch
battery will age naturally, even if it is not being
used.
Its battery life can be extended if the battery is well
maintained and, more importantly, stored at the
correct temperatures. The charging capacity will
decrease with age, even if the battery is
maintained properly. If the operating time is
severely shortened after charging, this is a sign
that battery has reached the end of its useful life.
Battery performance is reduced when the
temperature drops since this increases electrical
resistance. As a result, you should expect the
range to be shorter than normal in winter. We
recommend using thermal protection sleeves
when riding longer distances in the cold.
The pedelec features either an integrated battery,
a pannier rack battery or a frame battery. Each
battery has its own lock.
Three different types of frame batteries can be
fitted:
Figure 16: Details of frame battery
1 Battery housing
2 Battery lock
3 Key for the battery lock
4 On-off button (battery)
5 Battery level indicator
6 Charging port cover
7 Port for charger plug
3.1.5.1 Pannier rack battery
Three different types of pannier rack batteries can
be fitted:
Figure 17: Overview of pannier rack battery
PowerPack 300 PowerPack 400 PowerPack 500
Table 7: Overview of frame batteries
PowerPack 300 PowerPack 400 PowerPack 500
Table 8: Overview of pannier rack batteries
1
2
3
4
5
678
MY20H02-12_1.0_12.06.2019 27
Overview
Figure 18: Details of pannier rack battery
1 Battery housing
2 Charging port for charger plug
3 Charging port cover
4 Battery lock
5 Key for the battery lock
6Battery level indicator
7 On-Off button (battery)
3.1.5.2 Integrated battery
Two different types of pannier rack batteries can
be fitted:
Figure 19: Details of integrated battery
1 Key for the battery lock
2 Retainer guard
3 Securing hook
4 On-Off button (battery)
5Battery level indicator
6 Integrated rechargeable battery housing
3.1.6 Display
The model series to which these instructions
apply features a BOSCH Intuvia display. In
addition to the functions described here, software
changes may be introduced to rectify errors and
extend functions at any time.
The display controls the drive system with four
operating elements and shows the journey data.
The rider can switch off the drive system by
removing the display.
The pedelec's battery powers the display if the
display is inserted in the mount, a sufficiently
charged battery is inserted into the pedelec and
the drive system is switched on.
If the rider removes the display from its mount, the
display is powered by an internal battery.
Display operating elements
The display has four buttons and a USB port.
Figure 20: Overview of the structure of the display's
operating elements
PowerTube 500
(vertical)
PowerTube 500
(horizontal)
Table 9: Overview of integrated batteries
1
2
3
4
5
6
78
1
2
3
4
5
2
6
TURBO
SPORT
TOUR
ECO
OFF
MPH
KM/H
Reichweite
AMM
PMWH
MIN
MPH
KM /H
RESET
TURB O
SPOR T
S
TOUR
ECO
OFF
MPH
KM/ H
Reichweite
AMM
PMW H
MIN
MPH
KM
/H
1
2
3
4
5
6
78
MY20H02-12_1.0_12.06.2019 28
Overview
3.1.6.1 USB port
There is a USB port beneath the rubber cover on
the right-hand edge of the display.
3.1.7 Riding light
When the riding light is activated, the headlight
and the rear light are switched on together.
3.1.8 Charger
Each pedelec is supplied with a charger. As a
general rule, any BOSCH charger may be used:
• The 2A compact charger
• The 4A standard charger
• The 6A fast charger
Observe the operating instructions in the section
on Documents.
Symbol Use
1 Display housing
2 Riding light button
3 Info button (display)
4RESET RESET button
5 On-Off button (display)
6 Display mount
7 USB port
8 USB port protective flap
Table 10: Operating elements overview
MY20H02-12_1.0_12.06.2019 29
Overview
3.2 Proper use
The pedelec must only be used in perfect, fully
functional condition. National requirements may
apply to the pedelec which the standard
equipment may not meet. For riding on public
roads, some special regulations apply in relation
to the riding light, reflectors and other components.
The general laws and the regulations for the
prevention of accidents and environmental
protection in the respective country of use must be
adhered to. All check lists and instructions for
actions in these operating instructions met.
Approved accessories can be installed by
specialist staff.
Each pedelec is assigned a pedelec type, which
determines its proper use and area of use.
City and trekking
bicycles
Child's bicycles/
bicycles for young
adults
Mountain bikes Racing bicycle Cargo bike Folding bicycle
City and trekking
bicycles are designed
for daily, comfortable
use. They are
suitable for riding on
public roads.
The legal guardians
of minor riders must
read and understand
these operating
instructions before
commissioning.
The contents of these
operating
instructions must be
communicated to the
riders in an age-
appropriate manner.
The cycles for
children and young
adults are suitable for
riding on public
roads. The size of the
pedelec must be
checked regularly for
orthopaedic reasons.
A check must be
made at least every
three months to make
sure that the
permitted total weight
is being observed.
Mountain bikes are
designed for sports
use. The design
characteristics
include a short
wheelbase, a sitting
position with the rider
inclined towards the
front, and a brake
requiring low
actuation force.
Mountain bikes are a
piece of sports
equipment. Users
require an adaptation
period and must be
physical fit to use
them. Use requires
the appropriate
training; in particular
riding in bends and
braking should be
practised.
The strain on the
rider, in particular the
hands and wrists,
arms, shoulders,
neck and back, is
accordingly high.
Inexperienced riders
tend to brake
excessively and lose
control as a result.
A racing bicycle is
designed for fast
rides on roads and
paths with a good,
undamaged road
surface.
A racing bicycle is a
piece of sporting
equipment and not a
means of transport. A
racing bicycle is
characterised by its
lightweight structure
and a design which is
stripped to the
minimum parts
required for riding.
The frame geometry
and the layout of the
operating elements
are designed in such
a way that the bicycle
can be ridden at high
speeds. The frame
design requires
practice to ensure the
ride is able to ride
slowly, apply the
brakes and get on
and off the bike
safely.
The sitting position is
athletic. The strain on
the rider, in particular
the hands and wrists,
arms, shoulders,
neck and back, is
accordingly high. The
sitting position
therefore requires
physical fitness.
The cargo bike is
suitable for daily
transportation of
loads on public roads.
The transportation of
loads requires skill
and physical fitness
in order to balance
the additional weight.
The very varied
loading conditions
and weight
distributions require
special practice and
skill when braking
and riding in bends.
A longer period is
required to adaptation
to the length, width
and turning circle.
The cargo bike
requires cautious
riding. You must pay
attention to the traffic
on public roads and
the condition of the
route accordingly.
The folding bicycle is
suitable for use on
public roads.
A folding bicycle can
be folded up and is
thus suitable for
space-saving
transportation, for
example on public
transport or in a car.
The folding function
of the folding bicycle
makes it necessary to
use smaller wheels
and longer brake
cables and Bowden
cables. Therefore, in
case of an increased
load, a reduction in
riding stability and
braking power,
diminished comfort
and reduced
durability are to be
expected.
Table 11: Proper use
MY20H02-12_1.0_12.06.2019 30
Overview
3.3 Improper use
Failure to adhere to the proper use poses a risk of
personal injury and material damage. The pedelec
is not suitable for the following uses:
• when the electrical drive has been manipulated
• riding with a damaged or incomplete pedelec
• riding over steps
• riding through deep water
• lending the pedelec to untrained riders
• carrying other people
• riding with excessive baggage
• riding with no hands
• riding on ice and snow
• improper servicing
• improper repair
• tough areas of use, such as professional
competitions
• stunt riding or acrobatics.
City and trekking
bicycles
Child's bicycles/
bicycles for young
adults
Mountain bikes Racing bicycle Cargo bike Folding bicycle
City and trekking
bicycles are not
sports bicycles. If
used for sports, the
rider can expect
reduced riding
stability and
diminished comfort
Cycles for children
and young adults are
not toys.
Mountain bikes must
be retrofitted with
lighting, a guard and
other fittings as
specified by national
laws and regulations
before they are used
on public roads.
The folding bicycle is
not a sports bicycle.
A folding bicycle is
not a touring bicycle
or a sports bicycle.
Racing bikes must be
retrofitted with
lighting, a guard and
other fittings as
specified by national
laws and regulations
before they are used
on public roads.
Table 12: Information on incorrect use
MY20H02-12_1.0_12.06.2019 31
Overview
3.4 Technical data
3.4.1 Pedelec
3.4.2 ActiveLine motor
3.4.3 ActiveLine Plus motor
3.4.4 Performance Line Cruise motor
3.4.5 Performance Line Speed motor
3.4.6 Performance Line CX motor
Transportation temperature 5 °C - 25 °C
Ideal transportation temperature 10 °C - 15 °C
Storage temperature 10 °C - 30 °C
Ideal storage temperature 10 °C - 15 °C
Operating temperature 5°C - 35°C
Work environment temperature 15 °C - 25 °C
Charging temperature 0 °C - 40 °C
Power output/system 250 W (0.25 kW)
Shut-off speed 25 km/h
Table 13: Technical data for pedelec
Continuous power rating 250 W
Max. torque 40 Nm
Nominal voltage 36 V DC
Protection class IP54
Weight about 3 kg
Operating temperature -5 °C–40 °C
Storage temperature -10 °C - +50 °C
Table 14: ActiveLine motor technical data
Continuous power rating 250 W
Max. torque 50 Nm
Nominal voltage 36 V DC
Protection class IP54
Weight about 3.3 kg
Operating temperature -5 °C–40 °C
Storage temperature -10 °C - +50 °C
Table 15: ActiveLine Plus motor technical data
Continuous power rating 250 W
Max. torque 63 Nm
Nominal voltage 36 V DC
Protection class IP54
Weight 4 kg
Operating temperature -5 - +40 °C
Storage temperature -10 - +50 °C
Table 16: Performance Line Cruise motor technical data
Continuous power rating 250 W
Max. torque 63 Nm
Nominal voltage 36 V DC
Protection class IP54
Weight 4 kg
Operating temperature -5 °C–40 °C
Storage temperature -10 °C - +50 °C
Table 17: Performance Line Speed motor technical data
Continuous power rating 250 W
Max. torque 75 Nm
Nominal voltage 36 V DC
Protection class IP54
Weight 4 kg
Operating temperature -5 °C–40 °C
Storage temperature -10 °C - +50 °C
Table 18: Performance Line CX motor technical data
MY20H02-12_1.0_12.06.2019 32
Overview
3.4.7 Pedelec lighting
3.4.8 PowerPack 300 battery
3.4.9 PowerPack 400 battery
3.4.10 PowerPack 500 battery
3.4.11 PowerTube battery
3.4.12 Intuvia display
3.4.13 USB port
Applicable to motors: Performance Line Cruise,
Performance Line Speed and Performance Line CX
Voltage about 6/12 V
Maximum output
Front light 8.4/17.4 W
Rear light 0.6/ 0.6 W
Applicable to motors: ActiveLine and ActivLine Plus
Voltage about 12 V
Maximum output
Front light 17.4 W
Rear light 0.6 W
Table 19: Pedelec lighting technical data
Nominal voltage 36 V
Nominal capacity 8.2 Ah
Energy 300 Wh
Weight 2.5/ 2.6 kg
Protection class IP54
Operating temperature -5 °C–40 °C
Storage temperature -10 °C - +60 °C
Permitted charging temperature
range
0 °C – + 40 °C
Table 20: PowerPack 300 battery technical data
Nominal voltage 36 V
Nominal capacity 11 Ah
Energy 400 Wh
Weight 2.5/ 2.6 kg
Protection class IP54
Operating temperature -5 °C–40 °C
Storage temperature -10 °C - +60 °C
Permitted charging temperature
range
0 °C – + 40 °C
Table 21: PowerPack 400 battery technical data
Nominal voltage 36 V
Nominal capacity 13.4 Ah
Energy 500 Wh
Weight 2.6/ 2.7 kg
Protection class IP54
Operating temperature -5 °C–40 °C
Storage temperature -10 °C - +60 °C
Permitted charging temperature
range
0 °C – + 40 °C
Table 22: PowerPack 500 battery technical data
Nominal voltage 36 V
Nominal capacity 13.54 Ah
Energy 500 Wh
Weight 2.8 kg
Protection class IP54
Operating temperature -5 °C–40 °C
Storage temperature -10 °C - +60 °C
Permitted charging temperature
range
0 °C – + 40 °C
Table 23: PowerTube battery technical data
Internal lithium ion battery 3.7 V, 230 mAh
Operating temperature -5 °C–40 °C
Storage temperature -10 °C - +50 °C
Charging temperature 0 °C – + 40 °C
Protection rating
(with USB cover closed)
IP54
Weight about 0.15 kg
Table 24: Intuvia display technical data
Charge voltage 5 V
Charging current Max. 500 mA
Table 25: USB port technical data
MY20H02-12_1.0_12.06.2019 33
Overview
3.4.14 BOSCH Pedelec ABS BAS100
3.4.15 Emissions
*The safety requirements as per Electromagnetic Compatibility
Directive 2014/30/EU have been met. The pedelec and the
charger can be used in residential areas without restriction.
3.4.16 Tightening torque
*if there is no other data on the component
Operating temperature -5 °C–40 °C
Storage temperature -10 °C - +60 °C
Protection class IPx7
Weight about 1 kg
Table 26: BOSCH Pedelec ABS BAS100 technical data
A-weighted emission sound pressure
level
<70dB(A)
Total vibration level for the hands and
arms
<2.5m/s²
Highest effective value of weighted
acceleration for the entire body
<0.5m/s²
Table 27: Emissions from the pedelec*
Axle nut tightening torque 35 Nm - 40 Nm
Handlebars clamping screw maximum
tightening torque*
5Nm - 7Nm
Table 28: Tightening torque values
MY20H02-12_1.0_12.06.2019 34
Overview
3.5 Environmental requirements
The pedelec is designed for outdoor use up to
altitudes of 2,000 m.
You can be ride the pedelec within a temperature
range between 5 °C and 35 °C. The drive system
is limited in its performance outside this
temperature range.
We recommend that you don’t insert a battery
charged and stored at room temperature into the
pedelec until just before setting off. We
recommend using thermal protection sleeves
when riding longer distances in the cold.
As a general rule, you should avoid temperatures
under -10 °C or over +60 °C
You must also keep within the following
temperature ranges:
The nameplate contains symbols for the pedelec's area of use. Check what roads and paths you may use
before you ride the pedelec for the first time.
Optimal operating temperature 5°C - 35°C
Transportation temperature -10 °C - 50 °C
Storage temperature -10 °C - 50 °C
Charging temperature
Work environment temperature 15 °C - 25 °C
Charging temperature 0°C - 40°C
Table 29: Technical data for pedelec
Area of use City and trekking
bicycles
Child's bicycles/
bicycles for young
adults
Mountain bikes Racing bicycle Cargo bike Folding bicycle
Suitable for
tarmacked and
paved roads.
Suitable for
tarmacked and
paved roads.
Suitable for
tarmacked and
paved roads.
Suitable for
tarmacked and
paved roads.
Suitable for
tarmacked and
paved roads.
Suitable for
tarmacked roads,
cycle paths and firm
gravel paths and
roads, and longer
sections with
moderate slopes and
jumps up to 15 cm.
Suitable for
tarmacked roads,
cycle paths and firm
gravel paths and
roads, and longer
sections with
moderate slopes and
jumps up to 15 cm.
Suitable for
tarmacked roads,
cycle paths and
easy to demanding
off-road riding,
sections with
moderate slopes
and jumps up to
61 cm.
Suitable for
tarmacked roads,
cycle paths and firm
gravel paths and
roads, and longer
sections with
moderate slopes
and jumps up to
15 cm.
Suitable for
tarmacked roads,
cycle paths and
easy to demanding
off-road riding,
limited downhill use
and jumps up to
122 cm.
Suitable for
tarmacked roads,
cycle paths and
easy to extremely
difficult off-road
riding, unlimited
downhill use and
any jumps
Table 30: Area of use
MY20H02-12_1.0_12.06.2019 35
Overview
The pedelec is unsuitable for the following areas of use:
Area of use City and trekking
bicycles
Child's bicycles/
bicycles for young
adults
Mountain bikes Racing bicycle Cargo bike Folding bicycle
Never drive off-road
or perform jumps.
Never drive off-road
or perform jumps.
Never drive off-road
or perform jumps.
Never drive off-road
or perform jumps.
Never drive off-road
or perform jumps.
Never drive off-road
or perform jumps
over 15 cm.
Never drive off-road
or perform jumps
over 15 cm.
Never drive off-
road or perform
jumps over 15 cm.
Never drive off-road
or perform jumps
over 15 cm.
Never ride downhill
or perform jumps
over 61 cm.
Never traverse
extremely difficult
off-road terrain or
perform jumps over
122 cm.
MY20H02-12_1.0_12.06.2019 36
Overview
3.6 Description of controls and
screens
3.6.1 Handlebars
Figure 21: Detailed view of pedelec from rider position,
example
1 Rear brake lever
2Bell
3 Headlight
4 Display
5 Front brake lever
6 Control panel
8 Fork lock on the suspension fork
9Shifter
3.6.2 Battery level indicator
Each battery has its own level indicator.
Figure 22: Example of a battery level indicator
1 On/off button (battery)
2 Battery level indicator
Figure 23: 7Port for charger plug
The five green LEDs on the battery level indicator
show the charge level when the battery is switched
on. Each LED represents about 20% of battery
capacity. All five LEDs will light up when the battery
is fully charged. The charge level for the activated
battery is also shown on the display screen.
If the battery level falls below 5%, all the LEDs on
the battery level indicator will go out. However, the
battery level is still shown on the display screen.
3.6.3 Control panel
The control panel has four buttons.
Figure 24: Operating elements overview
3.6.4 On-screen indicators
The display has seven on-screen indicators:
Figure 25: On-screen indicators overview
1 Riding light symbol
2 Level of assistance
3 Motor power used
4 Battery level indicator
5 Gear recommendation
6 Tachometer indicator
7 Function indicator
3.6.4.1 Riding light symbol
The riding light symbol is shown if the riding light
is active.
1
2
5
6
4
7
8
3
1
2
Symbol Designation
1 Info button (control panel)
2 Control panel
3 WAL K Push assist button
4 + Plus button
5 – Minus button
Table 31: Overview of the control panel
1
2
3
4
5
5
1
2
3
4
6
7
TURBO
SPORT
TOUR
ECO
OFF
MPH
KM/H
Reichweite
AMM
PMWH
MIN
MPH
KM/H
5
MY20H02-12_1.0_12.06.2019 37
Overview
3.6.4.2 Level of assistance
The higher the level for assistance, the more the
drive system assists the rider when pedalling. The
following levels of assistance are available:
Different levels of assistance are available for
different BOSCH motors.
eMTB mode is available for Performance Line CX
drives. In eMTB mode, the assistance factor and
the torque are dynamically adjusted depending on
the pedalling force applied to the pedals. If the
pedelec has been configured with eMTB mode,
eMTB mode appears briefly when the SPORT
level of assistance is selected.
3.6.4.3 Motor power used
The motor power used appears on the screen.
The maximum motor power depends on the
selected level for assistance. A long bar indicates
high power consumption.
3.6.4.4 Battery level indicator
The battery level indicator displays the pedelec
battery level, not the level for the display internal
battery. You can also see the charge level on the
LEDs on the battery itself.
If the display is removed from its mount, the last
displayed battery level is saved.
Each bar in the rechargeable battery symbol on
the screen represents about 20% capacity.
If a pedelec is used with two batteries, the battery
level indicator shows the charge level for both
batteries.
If both batteries are being charged on a pedelec,
the function display shows the charging progress
for both batteries. You can see which of the two
rechargeable batteries is currently being charged
by the flashing screen display on the rechargeable
battery.
Figure 26: The left battery is currently being charged
Level of assistance Use
OFF
When the drive system is switched on,
the motor assistance is switched off.
The pedelec can be used like a
normal bicycle by simply pedalling.
The push assist system cannot be
activated.
ECO Limited assistance with maximum
efficiency for maximum range
TOUR Constant assistance, for long-range
tours
SPORT
Powerful assistance, for sport rides on
mountainous rides and on urban
roads.
TURBO Maximum assistance up to high
pedalling frequencies, for sport riding
Table 32: Overview of levels of assistance, standard
Level of assistance Use
OFF
When the drive system is switched on,
the motor assistance is switched off.
The pedelec can be used like a
normal bicycle by simply pedalling.
The push assist system cannot be
activated.
ECO Limited assistance with maximum
efficiency for maximum range
TOUR Constant assistance, for long-range
tours
eMTB
Optimum assistance on all terrains,
sport
start-up, improved dynamics,
maximum perfor-
mance.
TURBO Maximum assistance up to high
pedalling frequencies, for sport riding
Table 33: Overview of levels of assistance – eMTB mode
Symbol Meaning
The battery is fully charged.
The battery needs to be recharged.
The LEDs on the battery level indicator have
gone out. The capacity for drive assistance has
been used up and assistance is gently switched
off. The remaining capacity is reserved for
lighting and the display. The screen flashes.
The pedelec battery capacity is sufficient to
provide about two hours more lighting. Other
electrical loads, such as automatic gears and
charging of external devices connected to the
USB port, are not taken into account here.
Table 34: Overview of battery level indicator
OF
MP
H
KM
/
MY20H02-12_1.0_12.06.2019 38
Overview
3.6.4.5 Gear recommendation
Pedalling frequencies higher than 50 revolutions
per minute optimise drive unit efficiency.
However, very slow pedalling uses up a great deal
of energy. You can increase the speed and range
while applying the same force by selecting the
right gear. It is therefore best to follow gear
recommendations.
The gear recommendation function reacts to
excessively slow or excessively quick pedalling
and recommends a change of gear.
The gear recommendation function has to be
switched on in the system settings.
3.6.4.6 Tachometer screen
The tachometer shows the current speed at all
times.
You can select whether the speed is displayed in
kilometres or miles in the system settings.
3.6.4.7 Function display
The function display shows texts and readings.
Three different types of information are shown:
• Journey information
• System settings and data, and
• System messages.
Journey information
Depending on the type of pedelec, the function
display may show up to seven journey information
items. The displayed journey information can be
switched.
Additional journey information
Applies only to Pedelecs with eShift with
Shimano DI2 automatic hub gears
The following additional functions are available on
the function display:
Applies only to Pedelecs with eShift with manual
Shimano DI2 automatic hub gears
The following additional functions are available on
the function display:
Applies only to Pedelecs with eShift with
Shimano DI2 automatic hub gears
The following additional functions are available on
the function display:
Applies only to Pedelecs with eShift with NuVinci
H|Sync/ enviolo with Optimized H|Sync
The following additional functions are available on
the function display:
Applies only to Pedelecs with eShift with Rohloff
E-14 Speedhub 500/14
The following additional functions are available on
the function display:
Symbol Use
Pedalling frequency is too high, a higher gear is
recommended
Pedalling frequency is too low, a lower gear is
recommended
Table 35: Symbols of the gear recommendation function
Screen display Function
CLO C K Current time
MAX. SPEED Maximum speed reached since the
last RESET
AV G . S P E E D Average speed reached since the last
RESET
TRI P TIME Journey time since last RESET
RAN G E Estimated range of the available
battery charge
OD OM E T E R Display of the total distance travelled
(cannot be changed)
TRI P D I ST ANCE Distance travelled since the last
RESET
Table 36: Journey information
Screen display Change
AUT O : O N / A UTO: OFF This menu option indicates
whether the automatic mode is
switched on or off.
Table 37: Additional journey information
Screen display Change
GE AR The current gear shift is shown on
the display screen. The new gear
is shown briefly on the screen each
time it is changed.
Table 38: Additional journey information
Screen display Change
GE A R The current gear shift is shown on
the display screen. The new gear
is shown briefly on the screen each
time it is changed.
Table 39: Additional journey information
Screen display Change
± NUVINCI CADENCE /
± NUVINCI GEAR
The current gear shift is shown
on the display screen. The new
gear is shown briefly on the
screen each time it is changed.
The standard setting is
± NuVinci cadence.
Table 40: Changing the system settings
SCREEN DISPLAY Change
GE AR The current gear shift is shown on
the display screen. The new gear
is shown briefly on the screen each
time it is changed.
Table 41: Changing the system settings
MY20H02-12_1.0_12.06.2019 39
Overview
System settings and data
In order to see the system settings and data, the
rider has to call up the system settings. The rider
can change the values of the system settings, but
not the system data.
Additional system settings
Applies only to Pedelecs with eShift with
Shimano DI2 automatic hub gears
Applies only to Pedelecs with eShift with manual
Shimano DI2 automatic hub gears.
Applies only to Pedelecs with eShift with
Shimano DI2 automatic hub gears.
Screen display Function
- C L O C K + Changing the time
- W H E E L CIRCUM + Value of the wheel circumference in
mm
- E N G L IS H + Changes the language
- U N I T K M/MI + Selects whether the speed and
distance are displayed in kilometres
or miles
- T I M E F ORMAT + Select whether the time is displayed
in 12-hour clock or 24-hour clock
format
- SHIFT RECOM.
OFF +
Switches the gear recommendation
on and off
Table 42: Changeable system settings
Screen display Function
POWER O N HOURS Display of the total journey duration
DISPL. VX.X.X.X Display software version
DU VX.X.X.X Drive system software version
DU# XXXX XXXXX Drive system serial number
SERV IC E M M /YYYY (Alternative) defined inspection
date
SERV . X X KM /MI (Alternative) defined inspection
BAT. V X . X . X . X Software version
1.B A T V X . X . X . X Software version
2.B A T V X . X . X . X Software version
Table 43: System data, not changeable
Screen display Change
– Start gear + This is where you can set the start
gear. The automatic gear switch
function is switched off in Position
– –. This menu option is only
shown when the on-board
computer is positioned in its
mount.
Gear adjustment You can use this menu option to
make a fine adjustment to the
Shimano DI2. You'll find the
specified setting range in the gear
manufacturer’s operating
instructions. Make the fine
adjustment as soon as you hear
any unusual noises from the gear
shift. This menu option is only
shown when the on-board
computer is positioned in its
mount.
Gear vx.x.x.x: this is the gear software version.
This menu option is only shown
when the on-board computer is
positioned in its mount. This menu
option is only shown if you have an
electronic control gear.
Table 44: Changing the system settings
Screen display Change
– Start gear + This is where you can set the start
gear. The automatic gear switch
function is switched off in Position
– –. This menu option is only
shown when the on-board
computer is positioned in its
mount.
Gear adjustment You can use this menu option to
make a fine adjustment to the
Shimano DI2. You'll find the
specified setting range in the gear
manufacturer’s operating
instructions. Make the fine
adjustment as soon as you hear
any unusual noises from the gear
shift. This menu option is only
shown when the on-board
computer is positioned in its
mount.
Gear vx.x.x.x: this is the gear software version.
This menu option is only shown
when the on-board computer is
positioned in its mount. This menu
option is only shown if you have an
electronic control gear.
Table 45: Changing the system settings
Screen display Change
Gear adjustment You can use this menu option to
make a fine adjustment to the
Shimano DI2. You'll find the
specified setting range in the gear
manufacturer’s operating
instructions. Make the fine
adjustment as soon as you hear
any unusual noises from the gear
shift. This menu option is only
shown when the on-board
computer is positioned in its
mount.
Gear reset You can use this menu option to
reset the rear derailleur if it has
been detached – due to a crash or
impact against the derailleur. You
will find a description of how to
reset the gear shift in the gear shift
manufacturer’s operating
instructions. This menu option is
only shown when the on-board
computer is positioned in its
mount.
Gear vx.x.x.x: this is the gear software version.
This menu option is only shown
when the on-board computer is
positioned in its mount. This menu
option is only shown if you have an
electronic control gear.
Table 46: Changing the system settings
MY20H02-12_1.0_12.06.2019 40
Overview
Applies only to Pedelecs with eShift with NuVinci
H|Sync/ enviolo with Optimized H|Sync
Applies only to Pedelecs with eShift with Rohloff
E-14 Speedhub 500/14
3.6.5 System message
The drive system monitors itself continuously and
if an error is detected, it is indicated by a system
message. The system may switch off
automatically depending on the type of error. You
will find assistance for system messages in 8.5
First aid. There is a table of system messages in
the Appendix.
3.6.6 ABS indicator lamp
The anti-blocking system indicator lamp must light
up after the system has started up and must go
out once speed has reached about 5 km/h. If the
ABS indicator lamp does not light up when the
electric drive system starts, the ABS is defective.
An error code on the display also tells the rider
that it is defective.
If the indicator lamp does not go out after you set
off or it lights up while you are riding, this means
there is an error in the anti-blocking system. The
anti-blocking system is then no longer active. The
brake system itself remains functional. It is only
the anti-blocking system control which no longer
operates.
If the ABS indicator lamp is lit, the ABS function is
not active.
Note: You need to stop and restart the pedelec
(switch off and on again) to reactivate the anti-
blocking system.
Screen display Change
Gear calibration This is where you can perform a
calibration on the stepless gear.
Press on the Lighting button to
confirm calibration. Then follow the
instructions. You also might need
to perform a calibration while riding
in the event of a fault. In such
cases, you also press on the
Lighting button to confirm
calibration and then follow the
instructions on the display. This
menu option is only shown when
the on-board computer is
positioned in its mount
Gear vx.x.x.x: this is the gear software version.
This menu option is only shown
when the on-board computer is
positioned in its mount. This menu
option is only shown if you have an
electronic control gear.
Table 47: Changing the system settings
Screen display Change
Start gear This is where you can set the start
gear.
The automatic reset function is
switched off in Position – –. This
menu option is only shown when
the on-board computer is
positioned in its mount.
Gear vx.x.x.x: this is the gear software version.
This menu option is only shown
when the on-board computer is
positioned in its mount. This menu
option is only shown if you have an
electronic control gear.
Table 48: Changing the system settings
Notice
The anti-blocking system indicator lamp may light
up if the front and rear wheels are rotating at
widely different speeds from one another – for
example, if the rider cycles on the rear wheel only
or if a wheel is rotating for a unusually long time
without making contact with the ground (fitting
stand). The anti-blocking system switches off in
such cases.
MY20H02-12_1.0_12.06.2019 41
Transportation and storing
4 Transportation and storing
4.2 Transportation
Take into account the weight of the ready-to-
use pedelec when transporting it.
Remove the display screen and the batteries
before transporting the pedelec.
Protect the electrical components and
connections on the pedelec from the weather
conditions with suitable protective covers.
Remove accessories such as drinking bottles
before transporting the pedelec.
You must use a suitable bicycle rack system
when transporting by car.
4.1 Physical transport
characteristics
4.1.1 Dimensions during transportation
There was no information relating to the box
dimensions at the time of going to press. You'll
find the information in the latest operating
instructions on the retailer portal.
4.1.2 Transport weight
There was no information relating to the box
dimensions at the time of going to press. You'll
find the information in the latest operating
instructions on the retailer portal.
4.1.3 Designated handles/lifting points
There was no information relating to the box
dimensions at the time of going to press. You'll
find the information in the latest operating
instructions on the retailer portal.
Crash caused by unintentional activation
There is a risk of injury if the drive system is
activated unintentionally.
Remove the battery before the pedelec is
transported.
Risk of fire and explosion due to high
temperatures
Excessively high temperatures will damage the
battery. Batteries may self-ignite and explode.
Never expose batteries to sustained direct
sunlight.
CAUTION
!
Oil leak if no transport securing device
The brake securing device prevents the brakes
from being applied accidentally during
transportation. This could cause irreparable
damage to the brake system or an oil leak, which
will harm the environment.
Never pull the brake lever when the wheel has
been dismounted.
Always use the transport securing system
when transporting dismounted wheels.
Notice
Oil and grease may leak from the pedelec if it is
lying flat.
If the shipping box with a pedelec is lying flat or
standing on one end, it does not provide the frame
and wheels with adequate protection against
damage.
Transport the pedelec in an upright position
only.
Bicycle rack systems which use the handlebars or
frame to hold the pedelec in an upside-down
position exert inadmissible forces on its
components during transportation. This can
cause the supporting parts to break.
Never use bicycle rack systems which use the
pedelec's handlebars or frame to hold it in an
upside-down position.
CAUTION
!
MY20H02-12_1.0_12.06.2019 42
Transportation and storing
Transport the pedelec in a dry, clean position
where it is protected from direct sunlight.
4.2.1 Transporting the battery
Batteries are subject to hazardous goods
regulations. Undamaged batteries may be
transported by private persons in road traffic.
Commercial transport requires compliance with
regulations concerning packaging, labelling and
the transportation of hazardous goods. Open
contacts must be covered and the battery
securely packaged.
4.2.2 Shipping the battery
The battery is considered a hazardous good and
only trained persons may pack and ship a battery.
Contact your specialist dealer regarding any
battery shipment.
4.2.3 Using the brake transport securing
system
Insert the transport securing devices between
the brake linings.
The transport securing device is squeezed
between the two linings.
Figure 27: Fastening the transport securing device
4.3 Storing
If the pedelec features a hydraulic seat post, fix
only the lower seat post or the frame into a fitting
stand to prevent damage to the upper seat post
and the seat post lever.
Never place a pedelec with a hydraulic seat post
upside down on the floor; otherwise you, will
damage the seat post lever.
Store the pedelec, battery and charger in a dry,
clean location.
Temperatures under -10 °C or over +60 °C
Storage at about 20 °C is beneficial to a long
service life.
Notice
The specialist dealer will advise you on how to
select a suitable rack system properly and how to
use it safely.
If you ship the pedelec, we recommend that
you have it partially dismantled and packaged
properly by the specialist dealer.
Risk of fire and explosion due to high
temperatures
Temperatures over 60 °C can also cause liquid to
leak from the battery and the battery will become
damaged. Batteries may self-ignite and explode.
Protect batteries against heat.
Never store in proximity to hot or flammable
objects.
Never expose batteries to continuous direct
sunlight and never store near heaters.
Notice
Oil and grease may leak from the pedelec if it is
lying flat.
If the shipping box with a pedelec is lying flat or
standing on one end, it does not provide the frame
and wheels with adequate protection against
damage.
Store the pedelec in an upright position only.
Optimum pedelec storage temperature 20 °C
Optimum battery storage temperature 22 °C - 26 °C
Table 49: Storage temperature for batteries, the pedelec and
charger
CAUTION
!
MY20H02-12_1.0_12.06.2019 43
Transportation and storing
4.3.1 Break in operation
If the pedelec is to be removed from service for
longer than four weeks, for the winter, for
example, you need to prepare it for a break in
operation.
4.3.1.1 Preparing a break in operation
Remove battery from the pedelec.
Charge battery to around 30%–60%
The pedelec needs to be cleaned with a damp
cloth and preserved with wax spray. Never wax
the friction surfaces of the brake.
Before longer periods without use, it is
recommendable to have your specialist dealer
carry out servicing and basic cleaning and apply
preservative agent.
4.3.1.2 Taking out of operation
Store the pedelec, battery and charger in a dry,
clean environment. We recommend storing
them in uninhabited rooms with smoke alarms.
Dry locations with an ambient temperature of
about 20 °C are ideal.
Recharge the display battery for at least 1 hour
every 3 months.
Check the battery level after 6 months. If only
one LED on the battery level indicator lights up,
recharge the battery to around 30% - 60%.
Notice
The battery discharges when not in use. This can
cause irreparable damage to the battery.
The battery must be recharged every
6 months.
The battery may become damaged if it is
connected permanently to the charger.
Never connect the battery to the charger
permanently.
The display battery discharges when it is not in
use. This can cause it to be irreparably damaged.
Recharge the display battery for at least
1 hour every 3 months.
MY20H02-12_1.0_12.06.2019 44
Assembly
5 Assembly
Assemble the pedelec in a clean, dry
environment.
The work environment temperature should be
between 15 °C and 25 °C.
If a fitting stand is used, it must be approved for a
maximum weight of 30 kg.
We recommend that you always disconnect the
battery from the pedelec when using the fitting
stand to reduce weight.
5.1 Required tools
The following tools are required to assemble the
pedelec:
5.2 Unpacking
The packaging material consists mainly of
cardboard and plastic film.
The packaging has to be disposed of in
accordance with the regulations of the
authorities.
5.2.1 Scope of delivery
The pedelec was completely assembled in the
factory for test purposes and then dismantled for
transportation.
The pedelec is 95–98% pre-assembled. The
scope of delivery includes:
• the pre-assembled pedelec
• the front wheel
• the pedals
• quick release (optional)
• the charger
• the operating instructions.
The battery is supplied separately from the
pedelec.
Injury to the eyes
Problems may arise if the settings are not made
to components properly and you may sustain
serious injuries as a result.
Always wear safety glasses to protect your
eyes during assembly.
Crushing caused by unintentional activation
There is a risk of injury if the drive system is
activated unintentionally.
Remove the battery if it is not absolutely
necessary for assembly
Work environment temperature 15 °C - 25 °C
Table 50: Work environment temperature
•Knife
• Hexagon socket spanner 2 (2.5 mm, 3, mm
4 mm, 5 mm, 6 mm and 8 mm)
• Torque wrench with working range between
5and 40Nm
• Twelve-point square socket T25
• Ring spanner (8 mm, 9 mm, 10 mm, 13 mm,
14 mm and 15 mm) and
• Cross, flat head and ordinary screwdriver.
WARNING
!
CAUTION
!
Hand injuries caused by cardboard packaging
The shipping carton is closed with metal staples.
There is a risk of puncture wounds and cuts when
unpacking and crushing the packaging.
Wear suitable hand protection.
Remove the metal staples with pliers before
the shipping carton is opened.
CAUTION
!
MY20H02-12_1.0_12.06.2019 45
Assembly
5.3 Commissioning
Only trained specialist staff may perform initial
commissioning since initial commissioning of the
pedelec requires special tools and specialist
knowledge.
Experience has shown that a pedelec which has
not yet been sold is automatically handed to end
users as soon as it appears ready to ride.
For this reason, every pedelec must be
prepared, so that it is fully ready for use
immediately after being assembled.
All assembly work described in the assembly
report (see appendix) must be performed to
ensure the pedelec is ready to ride. It
describes all safety-relevant inspections, tests
and maintenance tasks for the pedelec in a
separate list.
Complete an assembly report for quality
assurance purposes.
5.3.1 Checking the battery
The battery must be checked before it is charged
for the first time.
Press the On-Off button (battery).
If none of the LEDs on the charge status
indicator light up, the battery may be damaged.
The battery may be fully charged if at least one,
but not all, of the LEDs on the battery level
indicator is lit up.
Once the battery has been charged, insert it
into the pedelec.
5.3.2 Mounting the wheel in the Suntour
fork
Only applies to pedelecs with this equipment
5.3.2.1 Mounting the wheel with screw-on axle
(15 mm)
Insert the axle completely on the drive side.
Figure 28: Fully inserting the axle
Risk of fire and explosion due to incorrect
charger
Batteries which are recharged with an unsuitable
charger may become damaged internally. This
may result in fire or an explosion.
Only ever use the battery with the supplied
charger.
Mark the supplied charger clearly to prevent
mix-ups – with the pedelec frame number or
type number, for example.
Burns from hot drive
The drive cooler can become extremely hot
during use. Contact may cause burns.
Leave the drive unit to cool before cleaning.
CAUTION
!
Risk of fire and explosion due to faulty battery
The safety electronics may fail if the battery is
damaged or faulty. The residual voltage can
cause a short circuit. The battery may self-ignite
and explode.
Never charge a faulty battery.
WARNING
!
MY20H02-12_1.0_12.06.2019 46
Assembly
Tighten the axle with a 5 mm hexagon socket
spanner to 8–10 Nm.
Figure 29: Tightening the axle
Insert the securing screw on the non-drive
side.
Figure 30: Pushing the quick release lever into the axle
Tighten the securing screw with a 5 mm
hexagon socket spanner to 5–6 Nm.
The lever is mounted.
Figure 31: Tightening the securing screw
5.3.2.2 Mounting the wheel with screw-on axle
(20 mm)
Insert the axle completely on the drive side.
Figure 32: Tightening the inserted axle
Tighten the securing clip with a 4 mm hexagon
socket spanner to 7 Nm.
Figure 33: Tightening the axle
MY20H02-12_1.0_12.06.2019 47
Assembly
5.3.2.3 Mounting the wheel with a quick release
axle
Insert the axle into the hub on the drive side.
Clamping version II.
Figure 34: Pushing the axle into the hub
Tighten the axle with the red handle.
Figure 35: Tightening the axle
Push the quick release lever into the axle.
Figure 36: Pushing the quick release lever into the axle
Reverse the quick release lever.
The lever is secured.
Figure 37: Securing the lever
Crash caused by loose quick release axle
A faulty or incorrectly installed quick release axle
may become caught in the brake disc and block
the wheel. This will cause a crash.
Never fit a defective quick release axle.
Crash caused by faulty or incorrectly
installed quick release axle
The brake disc becomes very hot during
operation. Parts of the quick release axle may
become damaged as a result. The quick release
axle becomes loose. This will cause a crash with
injuries.
The quick release axle and the brake disc
must be opposite one another.
Crash caused by incorrectly set quick release
axle
Insufficient clamping force will cause a
detrimental transmission of force. The
suspension fork or the quick release axle may
break. This will cause a crash with injuries.
Never fasten a quick release axle with a tool,
such as a hammer or pliers.
CAUTION
!
CAUTION
!
MY20H02-12_1.0_12.06.2019 48
Assembly
Check the position and clamping force of the
quick release lever. The quick release lever
must be flush with the lower housing. You must
be able to see a slight impression on the palm
of your hand when you close the quick release
lever.
Figure 38: Perfect position for the clamping lever
Use a 4 mm hexagon socket spanner to adjust
the clamping lever clamping force if required.
Afterwards, check the quick release lever
position and clamping force.
Figure 39: Adjusting the quick release clamping force
5.3.3 Mounting the wheel with a quick
release
Before mounting, ensure that the quick release
flange is extended. Open the lever completely.
Figure 40: Open and closed flange
Crash caused by unfastened quick
release
A faulty or incorrectly installed quick release may
become caught in the brake disc and block the
wheel. This will cause a crash.
Never fit a defective quick release.
Crash caused by faulty or incorrectly
installed quick release
The brake disc becomes very hot during
operation. Parts of the quick release may become
damaged as a result. The quick release comes
loose. This will cause a crash with injuries.
The front wheel quick release lever and the
brake disc must be situated on opposite sides.
Crash caused by incorrectly set clamping
force
Excessively high clamping force will damage the
quick release and cause it to lose its function.
Insufficient clamping force will cause a
detrimental transmission of force. The
suspension fork or the quick release may break.
This will cause a crash with injuries.
Never fasten a quick release using a tool (e.g.
hammer or pliers).
Only use the clamping lever with the specified
set clamping force.
CAUTION
!
MY20H02-12_1.0_12.06.2019 49
Assembly
Push in the quick release until you hear a
clicking sound. Make sure that the flange is
extended.
Figure 41: Pushing the quick release in
Adjust the clamping with a half-open clamping
lever until the flange reaches the fork end.
Figure 42: Adjusting the clamping
Fully close the quick release. Check the quick
release to ensure it is firmly in place and adjust
on the flange if necessary.
The lever is secured.
Figure 43: Closing the quick release
5.3.4 Mounting the wheel in the FOX fork
Only applies to pedelecs with this equipment
5.3.4.1 Wheel with quick release (15 mm)
The procedure for installing the 15 x 100 mm and
15 x 110 mm quick releases is the same.
Place the front wheel in the fork ends of the
fork. Push the axle through the fork end on the
non-drive side and hub.
Figure 44: Pushing the quick release in
Open the axle lever.
Turn the axle five to six complete revolutions
clockwise into the axle nut.
Close the quick release. The lever must be
tensioned to the point that it leaves a mark on
your hand.
The lever must be 1 to 20 mm ahead of the fork
leg in the closed position.
Figure 45: Spacing between lever and fork leg
If the lever is tensioned too little or too much
when closed in the recommended position (1 to
20 mm ahead of the fork), the quick release
must be adjusted.
1-20 mm
MY20H02-12_1.0_12.06.2019 50
Assembly
5.3.4.2 Adjusting the FOX quick release
Figure 46: Structure of quick release from rear with (1)
axle nut lock, (2) axle nut securing screw, (3) directional
arrow, (4) axle setting value and (5) axle nut
Record the axle setting value (4) indicated by
the directional arrow (3).
Loosen the axle nut securing screw (2) with a
2.5 mm hex key by approx. four revolutions,
but do not remove the screw completely.
Turn the quick release lever to the open
position and loosen the axle by approx. four
revolutions.
Press the axle inward from the side of the open
lever. This pushes out the axle nut securing
screw so that you can turn it out of the way.
Push the axle further forward and turn the axle
nut clockwise to increase the lever tension or
anti-clockwise to reduce the lever tension.
Reinsert the axle nut lock and tighten the screw
to 0.9 Nm (8 in-lb).
Repeat the steps for installing the axle to check
proper installation and correct adjustment.
5.3.4.3 Mounting the wheel with Kabolt axles
The procedure for installing the 15 x 100 mm and
15 x 110 mm Kabolt axles is the same.
Place the front wheel in the fork ends of the
fork. Push the Kabolt axle through the fork end
on the non-drive side and hub.
Figure 47: Pushing the Kabolt axle in
Tighten the Kabolt axle screw to 17 Nm
(150 in-lb) with a 6 mm hex key.
5.3.4.4 Checking the stem and handlebars
Checking connections
Stand in front of the pedelec to check whether
the handlebars, stem and fork steerer are
firmly attached to one another. Clamp the front
wheel between your legs. Grasp the handlebar
grips. Try to twist the handlebars towards the
front wheel.
The stem must not move or twist.
Firm hold
Place your entire body weight on the
handlebars with the quick release lever closed
to check that the stem is firmly in place.
The handlebars shaft must not move
downwards in the fork steerer.
If the handlebars shaft should move in the fork
steerer, increase the quick release lever
tensioning. To do so, turn the knurled nut
slightly in a clockwise direction with the quick
release lever open.
Close the lever and check the stem is firmly in
position.
1
2
3
45
MY20H02-12_1.0_12.06.2019 51
Assembly
Checking the headset backlash
To check the handlebar headset backlash,
close the quick release lever on the stem.
Place the fingers of one hand on the upper
headset cup, pull the front wheel brake with the
other hand and try to push the pedelec
backwards and forwards.
The headset cup halves must not move
towards one another while you are doing this.
Note that there may be noticeable backlash
due to worn-out bearing bushes or brake lining
backlash in suspension forks and disc brakes.
If there is headset backlash in the steering
headset, you must adjust it as soon as
possible; otherwise, the headset will become
damaged. You must make the adjustment as
described in the stem manual.
5.3.5 Pedelec sale
Complete the data sheet on the operating
instructions envelope.
Note down the key manufacturer and its
number.
Adjust the pedelec to the rider.
Set the stand and the shifter, and show the
purchaser the settings.
Instruct the operator or rider on how to use all
the pedelec's functions.
MY20H02-12_1.0_12.06.2019 52
Operation
6 Operation
6.1 Risks and hazards
Injuries and death caused by other road users
Other road users, trucks, cars or pedestrians often
underestimate the speed of pedelecs. Likewise,
other road users frequently do not see pedelec
riders. This may cause a crash with serious injuries
or even death.
Wear a cycling helmet and high-visibility,
reflective clothing.
Always take a defensive approach to riding.
Avoid the blind spots of vehicles turning off
and reduce your speed as a precaution when
other road users turn right.
Injuries and death caused by riding
incorrectly
A pedelec is not a bicycle. Incorrect riding and
underestimated speeds soon result in hazardous
situations. This may cause a fall with serious
injuries or even death.
If you haven't ridden on a pedelec for some
time, get accustomed to the speed before you
ride at speeds over 12 km/h. Increase the level
of assistance on your pedelec gradually.
Practice hard braking on a regular basis.
Take and complete a riding safety course.
Crash caused by loose clothing
Shoe laces, scarves and other loose items may
become entangled in the spokes on the wheels
and on the chain drive. This may cause a crash
with injuries.
Wear sturdy footwear and close-fitting
clothing.
WARNING
!
CAUTION
!
Risk of fire and burning due to hot motor
The motor housing becomes hot when riding.
Touching it may cause burns to the skin or other
objects.
Never touch the motor housing directly after
riding.
Never place the pedelec on a flammable
surface, such as grass or wood, directly after
use.
Crash caused by soiling
Heavy soiling can impair pedelec functions, such
as braking. This may cause a crash with injuries.
Remove coarse soiling before riding.
Crash caused by poor road conditions
Loose objects, such as branches and twigs, may
become caught in the wheels and cause a crash
with injuries.
Be aware of the road conditions.
Ride slowly and brake in good time.
Notice
Heat or direct sunlight can cause the tyre pressure
to increase above the permitted maximum
pressure. This can destroy the tyres.
Never park the pedelec in the sun.
On hot days, regularly check the tyre pressure
and adjust it as necessary.
When riding downhill, high speeds may be
reached.
The pedelec is only designed to exceed a speed
of 25 km/h for short periods. The tyres in
particular can fail if exposed to a continuous load.
Decelerate the pedelec with the brakes if you
reach speeds greater than 25 km/h.
CAUTION
!
MY20H02-12_1.0_12.06.2019 53
Operation
6.1.1 Tips for a greater range
How far can a pedelec actually travel? There is no
simple answer to this question as range depends
on many influencing factors. A single battery
charge may only last fewer than 20 kilometres but
much more than 100 is also possible. There are a
few tips which will help you maximize the range.
Cadence
Pedalling frequencies higher than 50 revolutions
per minute optimise drive unit efficiency.
However, very slow pedalling uses up a great deal
of energy.
Weight
Weight should be minimised. The total weight of
the pedelec and baggage should not be
unnecessarily high.
Stopping & starting
Stopping and starting all the time is less
economical than long stretches at the same
speed, just like with a car.
Gear shift
Shifting gears correctly also makes pedelecs
more efficient: It is best to set off and ride up hills
using a low gear and switch up a gear depending
on the speed and terrain. The on-board computer
provides gear shift recommendations.
Tyre pressure
Rolling resistance can be minimised if tyres are
inflated to the right pressure. Tip: Use the
maximum permitted tyre pressure to optimize your
range.
Motor power indicator
Keep an eye on the motor power indicator on the
display screen and adjust your riding accordingly.
A long bar indicates high power consumption.
Battery & temperature
Battery performance is reduced as the
temperature drops since this increases electrical
resistance. As a result, you should expect the
range to be shorter than normal in winter.
6.1.2 Personal protective equipment
We recommend that you wear a suitable cycling
helmet. We also recommend that you wear sturdy
footwear and typical, close-fitting, reflective
cycling clothing.
Notice
Moisture penetrating at low temperatures may
impair individual pedelec functions due to the
open structural design.
Always keep the pedelec dry and free from
frost.
If the pedelec is to be used at temperatures
below 3 °C, the specialist dealer must carry
out an inspection and prepare the pedelec for
winter usage first.
If you leave a key inserted when riding or
transporting the pedelec, it may break off or the
locking system may open accidentally.
Remove the key from the battery lock
immediately after use.
We recommend that you attach the key to a
key ring.
Off-road riding subjects the joints in the arms to
severe strain.
Take a break from riding every 30 to
90 minutes, depending on the road surface
conditions
MY20H02-12_1.0_12.06.2019 54
Operation
6.2 Error messages
6.2.1 Error message display
The drive system monitors itself continuously and
displays a number as an error message if a known
error is detected. The system may switch off
automatically depending on the type of error.
Code Description Method of resolution
410
One or more display
buttons are blocked
Check whether buttons are
jammed because dirt has got
into them, for example.
Clean the buttons if they
need it.
414 Connection problem with
the control panel
Have ports and connections
checked
418
One or more buttons on
the control panel are
blocked.
Check whether buttons are
jammed because dirt has got
into them, for example.
Clean the buttons if they
need it.
419
Configuration error Re-start the system.
Contact your specialist
dealer if the problem
persists.
422 Connection problem with
the Drive unit
Have ports and connections
checked
423 Connection problem Have ports and connections
checked
424 Communication error with
components communicat-
ing with one another
Have ports and connections
checked
426
Internal time-out error Re-start the system.
Contact your specialist
dealer if the problem
persists.
It is not possible to display or
adjust the tyre size in the
basic settings menu in this
error status.
430
Internal display battery flat Recharge internal display
battery (while in its bracket or
using USB port).
431
Software version error Re-start the system.
Contact your specialist
dealer if the problem
persists.
440
Internal drive unit error Re-start the system.
If the problem persists,
contact your specialist
dealer.
450
Internal software error Re-start the system.
Contact your specialist
dealer if the problem
persists.
460
Error in USB port Re-start the system.
Contact your specialist
dealer if the problem
persists.
490 Internal display error Have display checked.
Table 51: List of error messages
500
Internal drive unit error Re-start the system.
Contact your specialist
dealer if the problem
persists.
502
Fault in the lighting Check the light and its
cabling.
Re-start the system.
Contact your specialist
dealer if the problem
persists.
503
Speed sensor error Re-start the system.
Contact your specialist
dealer if the problem
persists.
510
Internal sensor error Re-start the system.
Contact your specialist
dealer if the problem
persists.
511
Internal drive unit error Re-start the system.
Contact your specialist
dealer if the problem
persists.
530
Battery error Turn off the drive system.
Remove the battery.
Insert the battery again.
Re-start the system.
Contact your specialist
dealer if the problem
persists.
531
Configuration error Re-start the system.
Contact your specialist
dealer if the problem
persists.
540
Temperature error The pedelec is outside the
permitted temperature
range.
Switch the pedelec off to cool
the drive unit down or warm it
up to the permitted
temperature range.
Re-start the system.
Contact your specialist
dealer if the problem
persists.
550
An inadmissible electrical
load has been detected
Remove the electrical load.
Re-start the system.
Contact your specialist
dealer if the problem
persists.
580
Software version error Re-start the system.
Contact your specialist
dealer if the problem
persists.
591
Authentication error Turn off the drive system.
Remove the battery.
Insert the battery again.
Re-start the system.
Contact your specialist
dealer if the problem
persists.
592
Incompatible component Insert a compatible display.
Re-start the system.
Contact your specialist
dealer if the problem
persists.
Code Description Method of resolution
Table 51: List of error messages
MY20H02-12_1.0_12.06.2019 55
Operation
593
Configuration error Re-start the system.
Contact your specialist
dealer if the problem
persists.
595,
596
Communication error Check the cabling to the
gears.
Re-start the system.
Contact your specialist
dealer if the problem
persists.
602
Internal error during the
charging process
Disconnect the charger from
the battery.
Re-start the system.
Plug the charger into the
battery.
Contact your specialist
dealer if the problem
persists.
602
Internal fault Re-start the system.
Contact your specialist
dealer if the problem
persists.
603
Internal fault Re-start the system.
Contact your specialist
dealer if the problem
persists.
605
Temperature error The pedelec is outside the
permitted temperature
range.
Switch the system off to cool
the drive unit down or warm it
up to the permitted
temperature range.
Re-start the system.
Contact your specialist
dealer if the problem
persists.
605
Temperature error during
the charging process
Disconnect the charger from
the battery.
Leave the battery to cool.
Contact your specialist
dealer if the problem
persists.
606
External fault Check the cabling.
Re-start the system.
Contact your specialist
dealer if the problem
persists.
610
Voltage error Re-start the system.
Contact your specialist
dealer if the problem
persists.
620
Charger error Replace the charger.
Contact your specialist
dealer if the problem
persists.
640
Internal fault Re-start the system.
Contact your specialist
dealer if the problem
persists.
655
Multiple battery error Turn off the system.
Remove the battery.
Insert the battery again.
Re-start the system.
Contact your specialist
dealer if the problem
persists.
Code Description Method of resolution
Table 51: List of error messages
656
Software version error Contact your specialist
dealer to install a software
update.
7xx
Gear error Please observe the
manufacturer's operating
instructions.
800 Internal ABS error Contact your specialist
dealer.
810 Implausible signals from
the wheel speed sensor
Contact your specialist
dealer.
820 Error in the line to the front
wheel speed sensor
Contact your specialist
dealer.
821 ...
826
Implausible signals from
the front wheel speed
sensor.
Sensor disc possibly
missing, defective or
incorrectly installed;
significantly different tyre
diameter between the
front wheel and rear
wheel; extreme riding
situation, such as riding on
the rear wheel only
Re-start the system.
Take a test ride of at least
two minutes. The ABS
indicator lamp must go out.
Contact your specialist
dealer if the problem
persists.
830 Error in the line to the rear
wheel speed sensor
Contact your specialist
dealer.
831
833 ...
835
Implausible signals from
the rear wheel speed
sensor.
Sensor disc possibly
missing, defective or
incorrectly installed;
significantly different tyre
diameter between the
front wheel and rear
wheel; extreme riding
situation, such as riding on
the rear wheel only
Re-start the system.
Take a test ride of at least
two minutes. The ABS
indicator lamp must go out.
Contact your specialist
dealer if the problem
persists.
840 Internal ABS error Contact your specialist
dealer.
850 Internal ABS error Contact your specialist
dealer.
860,
861
Error in the power supply Re-start the system.
Contact your specialist
dealer if the problem
persists.
870,
871,
880
883 ...
885
Communication error Re-start the system.
Contact your specialist
dealer if the problem
persists.
889 Internal ABS error Contact your specialist
dealer.
890 ABS indicator lamp is
defective or missing; ABS
possibly not functioning
Contact your specialist
dealer.
No
screen
display
Internal display error Re-start your drive system by
switching it on and off.
Code Description Method of resolution
Table 51: List of error messages
MY20H02-12_1.0_12.06.2019 56
Operation
6.2.2 Battery error message
The battery is protected against deep discharge,
overcharging, overheating and short circuits by
Electronic Cell Protection (ECP). In the event of a
hazard, a protective circuit switches the battery off
automatically.
If a fault is detected in the battery, two LEDs flash
on the battery level indicator. Contact an
authorised specialist dealer in such a case.
Code Description Method of resolution
If the battery is outside its
charging temperature
range, three LEDs will
flash on the battery level
indicator
Disconnect the battery from
its charger until it comes
within the charging
temperature range. Do not
connect the rechargeable
battery to the charger again
until the permitted charging
temperature has been
reached.
If a fault is detected in the
battery, two LEDs flash on
the battery level indicator
Contact your specialist
dealer.
No LEDs will flash if the
charger is defective. One
or more LEDs will light up
permanently depending on
the battery level
Contact your specialist
dealer.
No LEDs will light up if
there is no power
Check all plug connections.
Check the contacts on the
battery for dirt. Clean the
contacts carefully if they
need it.
Contact your specialist
dealer if the problem
persists.
MY20H02-12_1.0_12.06.2019 57
Operation
6.3 Before the first ride
Only a correctly adjusted pedelec will guarantee
you the desired ride comfort and health-promoting
activity. Therefore adjust the saddle, the
handlebars and the suspension to your body and
your preferred riding style before the first ride.
6.3.1 Adjusting the saddle
6.3.1.1 Adjusting the saddle tilt
The saddle tilt must be adjusted to the seat height,
the saddle and handlebar position, and the saddle
shape to ensure an optimum fit. The seating
position can be optimised in this way if needed.
First, readjust the saddle after finding the
handlebar position you prefer.
Place the saddle tilt in the horizontal position to
adjust the pedelec to your needs for initial use.
Figure 48: Horizontal saddle tilt
6.3.2 Determining the seat height
To adjust the seat height safely, either push the
pedelec near to a wall, so that you can lean on the
wall to support yourself or ask another person to
hold the pedelec for you.
Climb onto the pedelec.
Place your heel on the pedal and extend your
leg, so that the pedal is at the lowest crank
rotation point.
The rider sits straight on the saddle if the seat
is at an optimum height. If this is not the case,
you can adjust the length of the seat post to
your needs.
Figure 49: Optimal saddle height
6.3.2.1 Adjusting the seat height with quick
release
Open the quick release on the seat post to
change the seat height. To do so, push the
clamping lever away from the seat post.
Figure 50: Seat post quick release (3)
Crash caused by incorrectly adjusted torques
If a screw is fastened too tightly, it may break. If a
screw is not fastened enough, it may loosen. This
will cause a crash with injuries.
Always observe the indicated torques on the
screw or in the operating instructions.
CAUTION
!
3
4
5
1
2
3
MY20H02-12_1.0_12.06.2019 58
Operation
The seat post quick release with clamping
lever (5) and setting bolt (4) in the open
position (1) and in the direction of the closed
position (2)
Set the seat post at the required height.
.
Figure 51: Detailed view of the seat post – examples of the
minimum insertion depth marking
To close it, push the seat post clamping lever as
far as it will go into the seat post.
Check the clamping force of quick releases.
6.3.2.2 Height-adjustable seat post
Only applies to pedelecs with this equipment
When using your seat post for the first time, you
must give it a firm push downwards to set it in
motion. This is due to the natural tendency of the
seal to repel oil from the seal surface. You only
need to do this before the first use or after a
longer period of non-use. Once you have
displaced the post through its deflection, the oil
spreads on the seal and the post begins to
function normally.
Figure 52: The seat post activation lever can be mounted
either on the left (1) or the right (2) side of the handlebars
Lowering the saddle
To lower the saddle, press your hand down on the
saddle or sit on the saddle. Press the seat post
activation lever and hold it down.
Release the lever once you have reached the
required height.
Raising the saddle
Pull the seat post activation level.
Remove any pressure on the saddle and
release the lever once you have reached the
required height.
6.3.2.3 Adjusting the seat position
The saddle can be shifted on the saddle frame.
The right horizontal position ensures an optimal
leverage position for legs. This prevents knee
pain and painful incorrect pelvis positions. If you
have displaced the saddle more than 10 mm, you
then need to adjust the saddle height again since
both settings affect one another.
To adjust the seat position safely, either push the
pedelec near to a wall, so that you can lean on the
wall to support yourself or ask another person to
hold the pedelec for you.
Climb onto the pedelec.
Place the pedals into the vertical position (3
o'clock position) with your feet.
The rider is sitting in the optimal sitting position
if the knee cap perpendicular line runs through
the pedal axle. If the perpendicular line crosses
behind the pedal, bring the saddle forward. If
the perpendicular line crosses in front of the
pedal, bring the saddle back. Move the saddle
Crash caused by an excessively high seat post
setting
A seat post with is set too high will cause the seat
post or the frame to break. This will cause a crash
with injuries.
Do not pull the seat post out of the frame
beyond the minimum insertion depth marking.
CAUTION
!
3
4
2
1
e
tiert w
se Position zur Be
aber in einem spätere
ochmals montieren.
Sie den mitgelieferten Winkel mit de
orrichtung und stecken Sie die Hülle in die
nvorrichtung.
der
Remotehebel
5
Oder
28
12
MY20H02-12_1.0_12.06.2019 59
Operation
within its permitted displacement range only
(marked on the saddle stay).
Figure 53: Knee cap perpendicular line
6.3.3 Adjusting the handlebars
6.3.3.1 Adjusting the stem
6.3.3.2 Adjusting the height of the handlebars
Open the clamping lever.
Pull the locking lever on the stem up, and
simultaneously pivot the handlebars into the
desired position.
You feel the locking lever click into place.
Pull out the handlebars to the required height.
Lock the quick release.
Figure 54: Open (2) and closed (1) clamping lever on the
stem; by.schulz speedlifter used as an example
The handlebars must only be adjusted while the
pedelec is stationary.
Unfasten and adjust the designated screw
connections, and clamp them with the
maximum tightening torque for the clamping
screws of the handlebars.
Crash caused by loose stem
Incorrectly fastened screws may come loose due
to impact. The stem may no longer be firmly fixed
in its position as a result. This will cause a crash
with injuries.
Check the handlebars and the quick release
system are firmly in position after the first two
hours of riding.
90°
CAUTION
!
Crash caused by incorrectly set clamping
force
Excessively high clamping force will damage the
quick release and cause it to lose its function.
Insufficient clamping force will cause a
detrimental transmission of force. This can cause
components to break. This will cause a crash with
injuries.
Never fasten a quick release using a tool (e.g.
hammer or pliers).
Only use the clamping lever with the specified
set clamping force.
CAUTION
!
1
2
MY20H02-12_1.0_12.06.2019 60
Operation
6.3.3.3 Turning the handlebars to the side
Only applies to pedelecs with this equipment
Open the clamping lever.
Pull the locking lever on the stem up, and
simultaneously pivot the handlebars into the
desired position.
You feel the locking lever click into place.
Pull out the handlebars to the required height.
Lock the quick release.
Figure 55: Pushing locking lever upwards – by.schulz
speedlifter used as an example
6.3.3.4 Checking the clamping force in quick
releases
Open and close the quick releases on the stem
or the seat post.
The clamping force is sufficient if the clamping
lever can be moved easily from the open final
position into the middle and has to be pressed
with the fingers or base of the thumb from the
middle point onwards.
6.3.3.5 Adjusting the quick release clamping
force
If the clamping lever on the handlebars cannot
be moved into its final position, screw out the
knurled nut.
Tighten the knurled nut on the seat post if the
clamping lever's clamping force is not sufficient.
If you are unable to set the clamping force, the
specialist dealer will need to check the quick
release.
6.3.4 Adjusting the brake lever
6.3.4.1 Adjusting the pressure point on a
Magura brake lever
The pressure point setting is adjusted using the
twist knob.
Turn the twist knob towards the plus (+)
symbol.
The brake lever moves closer to the handlebar
grip. Re-adjust the grip distance as necessary.
The lever pressure point activates sooner.
Crash caused by incorrectly set clamping
force
Excessively high clamping force will damage the
quick release and cause it to lose its function.
Insufficient clamping force will cause a
detrimental transmission of force. This will cause
a crash with injuries.
Never fasten a quick release using a tool (e.g.
hammer or pliers).
Only use the clamping lever with the specified
set clamping force.
CAUTION
!
Brake failure due to incorrect setting
If the pressure point is set with brakes where the
brake linings and brake disc have reached their
wear limit, the brakes may fail and cause an
accident with injury.
Before you set the pressure point, ensure that the
brake linings and brake disc have not reached
their wear limit.
WARNING
!
MY20H02-12_1.0_12.06.2019 61
Operation
Figure 56: Using the twist knob (1) to adjust the pressure
point
6.3.4.2 Adjusting the grip distance
Figure 57: Brake lever grip distance
6.3.4.3 Adjusting the grip distance on a
Magura brake lever
Only applies to pedelecs with this equipment
Use a T25 TORX® wrench to turn the setting
screw to adjust the grip distance.
Turn the setting screw in the minus
(–) direction.
The brake lever moves closer to the
handlebar grip.
Turn the setting screw in the plus (+) direction.
The brake lever moves away from the
handlebar grip.
Figure 58: Using the setting screw (2) to adjust the
distance from the brake lever to the handlebar grip (1)
Crash caused by incorrectly set grip distance
If brake cylinders are set incorrectly or installed
wrongly, the braking power may be lost at any
time. This may cause a crash with injuries.
Once the grip distance has been set, check the
position of the brake cylinder and adjust it as
necessary.
Never correct the brake cylinder position without
special tools. Have a specialist dealer correct it.
The brake lever grip distance can be adjusted
to ensure that it can be reached more easily.
Contact your specialist dealer if the brake
handle is too far from the handlebars or is
hard to use.
1
WARNING
!
1
2
MY20H02-12_1.0_12.06.2019 62
Operation
6.3.5 Adjusting the suspension of the
Suntour fork
Only applies to pedelecs with this equipment
The following Suntour forks can be installed in this
series of models:
The adjustment shown here represents a basic
setting. The rider should change the basic setting
to suit the surface and his/her preferences.
It is advisable to make a note of the basic
setting. This way, it can be used as the starting
point for subsequent, optimised settings and to
safeguard against unintentional changes.
6.3.5.1 Adjusting the negative deflection
Negative deflection (sag) is compression of the
fork caused by the weight of the rider and their
gear (e.g. a backpack), the sitting position and the
frame geometry. This sag is not caused by riding.
Each rider has a different weight and sitting
position. The sag depends on the rider's position
and weight and should be between 15% and 30%
of the maximum fork deflection, depending on
pedelec usage and preferences.
6.3.5.2 Adjusting the air suspension fork
negative deflection
Only applies to pedelecs with this equipment
The air valve is located under a cover on the
head of the left shock absorber. Screw off the
cover.
Figure 60: Screw caps in different designs
Screw a high-pressure pump onto the valve.
Pump the suspension fork up to the desired
pressure. Never exceed the recommended
maximum air pressure. Comply with the values
of the filling pressure table.
Remove the high-pressure pump.
Aion-35 Boost Air suspension fork
NCX Air suspension fork
NEX Steel suspension fork
XCM-ATB Steel suspension fork
XCM Steel suspension fork
XCR32 Air suspension fork
XCR34 Air suspension fork
Figure 59: Overview of Suntour forks
Crash caused by incorrectly set suspension
If the suspension is adjusted incorrectly, the fork
may become damaged, so that problems may
occur when steering. This will cause a crash with
injuries.
Never ride the pedelec without air in the air
suspension fork.
Never use the pedelec without adjusting the
suspension fork to the rider's weight.
Notice
Settings on the chassis change riding
performance significantly. You need to get used
to the pedelec and break it in to prevent
accidents.
CAUTION
!
MY20H02-12_1.0_12.06.2019 63
Operation
.
Measure the distance between the crown and
the dust wiper of the fork. This distance is the
total deflection of the fork.
Push a temporarily attached cable tie
downward against the dust wiper of the fork.
Put on your usual bicycling clothing, including
luggage.
Sit on the pedelec in your usual riding position
and support yourself (e.g. against a wall or
tree).
Get off the pedelec without allowing it to
deflect.
Measure the distance between the dust wiper
and the cable tie. This dimension is the sag.
The sag value should be between 15% (hard)
and 30% (soft) of the total fork deflection.
Increase or reduce the air pressure until you
have reached the desired sag.
Once the sag is correct, re-tighten the blue air
cover cap clockwise.
If you cannot achieve the desired sag, you may
need to make an internal adjustment. For this
purpose, contact your specialist dealer.
6.3.5.3 Adjusting the steel suspension fork
negative deflection
Only applies to pedelecs with this equipment
You can adjust the fork by tensioning the spring to
the rider's weight and their preferred riding style.
It is not the coil spring hardness which is adjusted;
it is its pre-tensioning. This reduces the fork's
negative deflection when the rider sits on the
pedelec.
Figure 61: Negative deflection setting wheel on the
suspension fork crown
The setting wheel may be located under a
plastic cover on the suspension fork crown.
Remove the plastic cover by pulling it off
upwards.
Turn the negative deflection setting wheel in a
clockwise direction to increase the spring pre-
tensioning. Turn the negative deflection setting
wheel in an anti-clockwise direction to reduce
it.
The ideal setting in relation to the weight of the
rider has been achieved when the shock
absorber deflects 3 mm under the stationary
load of the rider. Reattach the cover after the
adjustment.
Rider weight AION, NEX XCR 32, XCR 34
< 55 kg 35 - 50 psi 40 - 55 psi
55 - 65 kg 50 - 60 psi 55 - 65 psi
65 - 75 g 60 - 70 psi 65 - 75 psi
75 - 85 kg 70 - 85 psi 75 - 85 psi
85 - 95 kg 85 - 100 psi 85 - 95 psi
< 100 kg + 105 psi + 100 psi
Max. pressure 150 psi 180 psi
Table 52: Filling pressure table for Suntour air forks
MY20H02-12_1.0_12.06.2019 64
Operation
6.3.5.4 Adjusting the rebound
Only applies to pedelecs with this equipment
The rebound defines the speed at which the fork
rebounds after being loaded. The rebound setting
depends on the air pressure setting. Higher sag
settings require lower rebound settings.
Turn the rebound adjuster clockwise to the
closed position until it stops.
Figure 62: Suntour rebound adjuster (2) on the fork (1)
Turn the rebound adjuster anti-clockwise.
Adjust the rebound in such a way that the fork
rebounds quickly, but without bottoming out
upward during testing. Bottoming out is where
the fork rebounds too quickly and stops moving
abruptly once it has reached the full rebound
distance. You will hear and feel a slight knock
when this occurs.
6.3.6 Adjusting the suspension of the
FOX fork
Only applies to pedelecs with this equipment
The adjustment shown here represents a basic
setting. The rider should change the basic setting
to suit the surface and his/her preferences.
It is advisable to make a note of the basic
setting. This way, it can be used as the starting
point for subsequent, optimised settings and to
safeguard against unintentional changes.
6.3.6.1 Adjusting the negative deflection
Negative deflection (sag) is compression of the
fork caused by the weight of the rider and their
gear (e.g. a backpack), the sitting position and the
frame geometry. This sag is not caused by riding.
Each rider has a different weight and sitting
position. The sag depends on the rider's position
and weight and should be between 15% and 20%
of the maximum fork deflection, depending on
pedelec usage and preferences.
When adjusting the sag, ensure that each
compression adjuster is in the open position, i.e.
turned clockwise until it stops.
The pressure is to be measured at an ambient
temperature of 21 to 24 °C.
1
2
Crash caused by incorrectly set suspension
If the suspension is adjusted incorrectly, the fork
may become damaged, so that problems may
occur when steering. This will cause a crash with
injuries.
Never ride the pedelec without air in the air
suspension fork.
Never use the pedelec without adjusting the
suspension fork to the rider's weight.
Notice
Settings on the chassis change riding
performance significantly. You need to get used
to the pedelec and break it in to prevent
accidents.
CAUTION
!
MY20H02-12_1.0_12.06.2019 65
Operation
The air valve is located under a blue cover on
the head of the left shock absorber. Screw off
the cover anti-clockwise.
Place a high-pressure pump on the valve.
Pump the suspension fork up to the desired
pressure. Never exceed the recommended
maximum air pressure. Comply with the values
of the filling pressure table.
Remove the high-pressure pump.
Measure the distance between the crown and
the dust wiper of the fork. This distance is the
"total deflection of the fork."
Push the O-ring downward against the dust
wiper of the fork. If an O-ring is not available,
attach a cable tie to the stanchion temporarily.
Put on your usual bicycling clothing, including
luggage.
Sit on the pedelec in your usual riding position
and support yourself (e.g. against a wall or
tree).
Get off the pedelec without allowing it to
deflect.
Measure the distance between the dust wiper
and the O-ring or cable tie. This dimension is
the sag. The recommended sag value is
between 15% (hard) and 20% (soft) of the
"total fork deflection."
Increase or reduce the air pressure until you
have reached the desired sag.
Once the sag is correct, re-tighten the blue air
cover cap clockwise.
6.3.6.2 Adjusting the rebound
The rebound defines the speed at which the fork
rebounds after being loaded. The rebound setting
depends on the air pressure setting. Higher sag
settings require lower rebound settings.
Turn the rebound adjuster clockwise to the
closed position until it stops.
Figure 63: FOX rebound adjuster (1) on the fork
Turn the rebound adjuster anti-clockwise.
Adjust the rebound in such a way that the fork
rebounds quickly, but without bottoming out
upward during testing. Bottoming out is where
the fork rebounds too quickly and stops moving
abruptly once it has reached the full rebound
distance. You will hear and feel a slight knock
when this occurs.
Rider weight Rhythm 34 Rhythm 36
Minimum air
pressure
40 psi (2.8 bar) 40 psi (2.8 bar)
54 - 59 kg 58 psi 55 psi
59 - 64 kg 63 psi 59 psi
64 - 68 kg 68 psi 63 psi
68 - 73 kg 72 psi 67 psi
73 - 77 kg 77 psi 72 psi
77 - 82 kg 82 psi 76 psi
82 - 86 kg 86 psi 80 psi
86 - 91 kg 91 psi 85 psi
91 - 95 kg 96 psi 89 psi
95 - 100 kg 100 psi 93 psi
100 - 104 kg 105 psi 97 psi
104 - 109 kg 110 psi 102 psi
109 - 113 kg 114 psi 106 psi
Max. pressure 120 psi (8.3 bar) 120 psi (8.3 bar)
Table 53: Filling pressure table for the FOX air fork
If you cannot achieve the desired sag, you may
need to make an internal adjustment. For this
purpose, contact your specialist dealer.
1
MY20H02-12_1.0_12.06.2019 66
Operation
6.3.7 Setting the Suntour rear frame
damper
Only applies to pedelecs with this equipment
6.3.7.1 Adjusting the negative deflection
Negative deflection (sag) is compression of the
rear frame damper caused by the weight of the
rider and their gear (e.g. a backpack), the sitting
position and the frame geometry. This sag is not
caused by riding. Each rider has a different weight
and sitting position. The sag depends on the
rider's position and weight and should be between
25% and 30% of the maximum Rear frame
damper, depending on pedelec usage and
preferences.
Set the compression adjuster to the OPEN
position so that the sag setting is not affected.
Remove the cap on the air valve.
Attach a high-pressure damper pump to the
valve.
Adjust the air pressure of the damper so that it
corresponds to your weight.
Remove the high-pressure pump.
Measure the distance between the rubber air
chamber seal and the end of the damper. This
distance is the "total damper deflection".
Put on your usual bicycling clothing, including
luggage. Sit on the pedelec in your usual riding
position and support yourself against an object
such as a wall or tree.
Push the O-ring downward against the rubber
air chamber seal.
Get off the pedelec without allowing it to
deflect.
Measure the distance between the rubber air
chamber seal and the O-ring. This dimension is
the sag. The recommended sag value is
between 15% (hard) and 25% (soft) of the
"total damper deflection."
Increase or reduce the air pressure until you
have reached the desired sag.
6.3.7.2 Adjusting the rebound
The rebound defines the speed at which the rear
frame damper rebounds after being loaded. The
rebound setting depends on the air pressure
setting. Higher sag settings require lower rebound
settings.
Figure 64: Suntour rebound adjuster wheel (1) on the rear
frame damper
Turn the rebound adjuster wheel towards the
– symbol to increase rebounding.
Turn the rebound adjuster wheel towards the
+ symbol to reduce compressive deflection
movement.
Notice
If the air pressure in the rear frame damper is
exceeded or undershot, the damper can be
permanently damaged.
Do not exceed the maximum air pressure of
300 psi (20 bar).
1
MY20H02-12_1.0_12.06.2019 67
Operation
6.3.7.3 Setting the compression
The compression damper setting of the rear frame
damper makes it possible to set the damper
according to the conditions of the ground. The
compression damper setting specifies the speed
at which the rear frame damper deflects after
being loaded.
Figure 65: Suntour compression adjuster on the rear
frame damper
Turn the compression adjuster towards the
– symbol to increase rebounding.
Turn the compression adjuster towards the
+ symbol to reduce compressive deflection
movement.
6.3.8 Setting the FOX rear frame damper
Only applies to pedelecs with this equipment
6.3.8.1 Adjusting the negative deflection
Negative deflection (sag) is compression of the rear
frame damper caused by the weight of the rider and
their gear (e.g. a backpack), the sitting position and
the frame geometry. This sag is not caused by riding.
Each rider has a different weight and sitting position.
The sag depends on the rider's position and weight
and should be between 25% and 30% of the
maximum Rear frame damper, depending on
pedelec usage and preferences.
Set the compression adjuster to the OPEN
position.
Adjust the air pressure of the damper so that it
corresponds to your weight.
Attach the high-pressure pump to the damper.
Slowly compress the damper over 25% of the
deflection 10 times until you have reached the
desired pressure. This equalises the air
pressure between the positive and negative air
chambers, and the pressure indication on the
pump manometer changes accordingly.
Remove the high-pressure pump.
Figure 66: FOX rear frame damper
The negative deflection (2) is the distance between
the O-ring (4) and the rubber air chamber seal (1).
The total deflection of the rear frame damper (5) is
the distance between the end of the rear frame
damper (3) and the rubber air chamber seal (1)
Measure the distance between the rubber air
chamber seal (1) and the end of the damper (3).
This distance is the "total damper deflection" (5).
Put on your usual bicycling clothing, including
luggage. Sit on the pedelec in your usual riding
position and support yourself against an object
such as a wall or tree.
Push the O-ring (4) downward against the rubber
air chamber seal (1).
Get off the pedelec without allowing it to deflect.
Measure the distance between the rubber air
chamber seal and the O-ring. This dimension is
the sag. The recommended sag value is between
25% (hard) and 30% (soft) of the "total damper
deflection" (5).
Increase or reduce the air pressure until you have
reached the desired sag.
Notice
If the air pressure in the rear frame damper is
exceeded or undershot, the damper can be
permanently damaged.
Do not exceed the maximum air pressure of
350 psi (24.1 bar). The minimum air suspension
pressure of 50 psi (3.4 bar) must be complied
with.
1
25-30%
2
1
3
4
5
MY20H02-12_1.0_12.06.2019 68
Operation
6.3.8.2 Adjusting the rebound
The rebound defines the speed at which the rear
frame damper rebounds after being loaded. The
rebound setting depends on the air pressure
setting. Higher sag settings require lower rebound
settings.
Figure 67: FOX rebound adjuster wheel (1) on the rear
frame damper
Turn the rebound adjuster clockwise to the
closed position until it stops.
Determine your rebound setting based on the
air pressure. Turn the rebound adjuster back
anti-clockwise by the number of clicks
specified in the table below:
6.3.9 Retracting the brake linings
Disc brakes require wearing-in time. The braking
force increases over time. You therefore need to
be aware that the braking force may increase
during the wearing-in period. The same happens
after brake pads or discs are replaced.
Accelerate pedelec to about 25 km/h.
Brake pedelec until it comes to a halt.
Repeat process 30–50 times.
The brake linings and brake discs are now
retracted and provide optimal braking power.
Air pressure (psi) Recommended rebound setting
< 100 Open (anti-clockwise)
100 - 120 11
120 - 140 10
140 - 160 9
160 - 180 8
180 - 200 7
200 - 220 6
220 - 240 5
240 - 260 4
260 - 280 3
280 - 300 2
Table 54: Filling pressure table for the FOX air fork
1
MY20H02-12_1.0_12.06.2019 69
Operation
6.4 Accessories
We recommend a parking stand into which either
the front or rear wheel can be inserted securely for
pedelecs which do not have a kickstand. The
following accessories are recommended:
*System components are matched to the pannier
rack and provide sufficient stability due to special
transmission of force.
**System components are matched to the drive
system.
6.4.1 Child seat The specialist dealer will advise you on choosing
a suitable child seat system for the child and the
pedelec.
The specialist dealer must mount the child seat
the first time to ensure that it is safely fitted.
When installing a child seat, the specialist dealer
makes sure that the seat and the fastening
mechanism for the seat are suitable for the
pedelec and that all components are installed and
firmly fastened. They will also ensure that shift
cables, brake cables, hydraulic and electrical
cables are adjusted as necessary, the rider's
freedom of movement is not restricted and the
pedelec's permitted total weight is not exceeded.
The specialist dealer will provide instruction on
how to handle the pedelec and the child seat.
The specialist dealer will advise you on choosing
a suitable child seat system for the child and the
pedelec.
The specialist dealer must mount the child seat
the first time to ensure that it is safely fitted.
Description Article number
Protective cover for electrical
components 080-41000 ff
Panniers,
system component* 080-40946
Rear wheel basket,
system component* 051-20603
Bicycle box,
system component* 080-40947
Parking stand
universal stand XX-TWO14B
Table 55: Accessories
Crash caused by incorrect child seat
Neither the pannier rack nor the pedelec down
tube are suitable for child seats and may break.
Such an incorrect position may cause a crash
with serious injuries for the rider and the child.
Never attach a child seat to the saddle,
handlebars or down tube.
Crash caused by improper handling
When using child seats, the pedelec's handling
characteristics and stability change considerably.
This can cause a loss of control, a crash and
injuries.
You should practice how to use the child seat
safely before using the pedelec in public
spaces.
WARNING
!
CAUTION
!
Risk of crushing due to exposed springs
The child may crush his/her fingers on exposed
springs or open mechanical parts of the saddle or
the seat post.
Never install saddles with exposed springs if a
child seat is being used.
Never install seat posts with suspension with
open mechanical parts or exposed springs if a
child seat is being used.
Notice
Observe the legal regulations on the use of
child seats.
Observe the operating and safety notes for the
child seat system.
Never exceed the total weight of the pedelec.
CAUTION
!
MY20H02-12_1.0_12.06.2019 70
Operation
When installing a child seat, the specialist dealer
makes sure that the seat and the fastening
mechanism for the seat are suitable for the
pedelec and that all components are installed and
firmly fastened. They will also ensure that shift
cables, brake cables, hydraulic and electrical
cables are adjusted as necessary, the rider's
freedom of movement is not restricted and the
pedelec's permitted total weight is not exceeded.
The specialist dealer will provide instruction on
how to handle the pedelec and the child seat.
6.4.2 Bicycle trailers
A pedelec which is approved for towing a trailer
will bear an appropriate adhesive label. Only
bicycle trailers with a support load and total mass
which do not exceed the permitted values may be
used.
Figure 68: Trailer sign
The specialist dealer will advise on choosing a
suitable trailer system for the pedelec. The
specialist dealer must install the trailer the first
time to ensure that it is safely fitted.
6.4.3 Pannier rack
The specialist dealer will advise on choosing a
suitable pannier rack.
The specialist dealer must mount the pannier rack
the first time to ensure that it is safely fitted.
When installing a pannier rack, the specialist
dealer will make sure that the fastening
mechanism for the rack is suitable for the pedelec
and that all components are installed and firmly
fastened. They will also ensure that shift cables,
brake cables and hydraulic and electrical lines are
adjusted as necessary, the rider's freedom of
movement is not restricted and the permitted total
weight of the pedelec is not exceeded.
The specialist dealer will provide instruction on
how to handle the pedelec and the pannier rack.
Crash caused by brake failure
The brake may not work sufficiently if there is an
excessive trailer load. The long braking distance
can cause a crash or an accident and injuries.
Never exceed the specified trailer load.
Notice
The operating and safety notes for the trailer
system must be observed.
The statutory regulations on the use of bicycle
trailers must be observed.
Only use type-approved coupling systems.
CAUTION
!
MY20H02-12_1.0_12.06.2019 71
Operation
6.5 Before each ride 6.6 Check list before each ride
Check the pedelec before each ride.
Do not use the pedelec if there is evidently
something wrong with it.
Crash caused by difficult-to-spot damage
If the pedelec topples over or you have a fall or an
accident, there may be difficult-to-spot damage to
components such as the brake system, quick
releases or frame. This may cause a crash with
injuries.
Take the pedelec out of service and have a
specialist dealer carry out an inspection.
Crash caused by material fatigue
Intensive use can cause material fatigue. A
component may suddenly fail in case of material
fatigue. This may cause a crash with injuries.
Remove the pedelec from service immediately
if there are any signs of material fatigue. Have
the specialist dealer check the state.
Have the specialist dealer carry out a basic
inspection regularly. During the inspection, the
specialist dealer will inspect the pedelec for
any signs of material fatigue on the frame,
fork, suspension element mountings (if there
are any) and components made of composite
materials.
Carbon becomes brittle when exposed to heat
radiation such as heating. This can cause the
carbon part to break and result in a crash with
injuries.
Never expose carbon parts on the pedelec to
strong sources of heat.
CAUTION
!
Check that the pedelec is complete.
Check the battery is firmly in place.
Check that the lighting, reflector and brake, for instance,
are sufficiently clean.
You must check that the mudguards, the pannier rack and
the chain guard are securely installed.
Check that the front and rear wheels run true. This is
particularly important if the pedelec been transported or
secured with a lock.
Check the valves and the tyre pressure. Adjust as
necessary before each ride.
If the pedelec has a hydraulic rim brake, check whether the
locking levers are fully closed in their final positions.
Check the front and rear wheel brakes to make sure that
they are working properly. To do so, push the brake levers
while stationary to check whether resistance is generated
in the usual brake lever position. The brake must not lose
any brake fluid.
Check that the riding light is working.
Check for unusual noises, vibrations, smells, staining,
deformation, cracks, scores, abrasion and wear. This
indicates material fatigue.
Inspect suspension system for cracks, dents, bumps, parts
or leaking oil. Look at concealed sections on the pedelec's
lower surface.
Use body weight to compress suspension system. Adjust to
the optimum sag value if suspension is too soft.
If quick releases are used check them to make sure that
they are fully closed in their end position. If quick release
axle systems are used, make sure that all attachment
screws are tightened to the correct torque.
Be alert to any unusual operating sensations when braking,
pedalling or steering.
Check that the ABS indicator lamp lights up correctly on
pedelecs with an ABS system.
MY20H02-12_1.0_12.06.2019 72
Operation
6.7 Folding
Only applies to pedelecs with this equipment
6.7.1 Folding the folding bicycle
The pedelec is folded in eight steps.
Switch off the electric drive system.
Use the kickstand.
Remove the display.
Remove the battery if necessary.
Fold the pedal.
Fold the stem.
Push in the seat post.
Fold the frame.
6.7.1.1 Folding the pedal
Push the pedal against the pedal crank with the
foot.
Figure 69: Pushing the pedal against the pedal crank (1)
Fold the pedal against the pedal crank.
Figure 70: Folding the pedal up (I) or down (II)
6.7.1.2 Folding the stem 1, Folding
Only applies to pedelecs with this equipment
Open the clamping lever on the stem quick
release.
Pull the locking lever on the stem upwards and
simultaneously pivot it 90° to the right or the left.
You feel the handlebars click into place.
Push in the handlebars.
Close the clamping lever on the stem quick
release.
Figure 71: Opened clamping lever on the stem quick
release (3) on the stem (2), version I, with locking lever on
the stem (1)
6.7.1.3 Folding the stem 2, Folding
Only applies to pedelecs with this equipment
Open the clamping lever on the stem quick
release.
Push the unlocking knob.
Pivot the handlebars 90° to the right or left.
You feel the handlebars click into place.
Close the clamping lever on the stem quick
release.
Figure 72: Stem, version II with clamping lever on the stem
quick release (1) and unlocking knob (2)
Notice
Never crush or bend cables, electric cables or
brake cables when folding.
1
III
1
2
3
1
2
MY20H02-12_1.0_12.06.2019 73
Operation
6.7.1.4 Pushing in the seat post
Open the clamping lever for the quick release on
the seat post.
Push in the saddle to the minimum position.
Close the clamping lever for the quick release on
the seat post.
6.7.1.5 Folding the frame
Pivot the frame locking lever upwards.
The frame clamping lever can be opened freely.
Open the frame clamping lever.
Pivot in the frame as far as it will go.
Figure 73: Frame, with closed frame clamping lever (1) and
open frame locking lever (2)
6.7.2 Preparing the bicycle so that it is
ready to ride again
The specialist dealer will show the operator or
rider how the pedelec is folded, how it is prepared,
so that it is ready to ride again, and how the quick
releases are used.
The bicycle is prepared so that it is ready to ride
again in eight steps.
Switching off the electric drive system.
Use the kickstand.
Fold out the frame.
Adjust the stem.
Adjust the saddle.
Fold out the pedal.
Insert the battery.
Attach the display.
6.7.2.1 Folding out the frame
Completely fold out the frame.
Close the frame clamping lever.
The frame clamping lever rests on the limit stop.
The frame locking lever holds the frame clamping
lever. The frame clamping lever is closed.
Figure 74: Frame, with closed frame clamping lever (1) and
closed frame locking lever (2). Folding out the pedal
Push the pedal against the pedal crank with the
foot from the front.
Figure 75: Pushing the pedal against the pedal crank (1)
Use the foot to fold the pedal up or down.
Figure 76: Folding up the pedal
Risk of fire and explosion due to faulty battery
If the bicycle is not prepared correctly ready for
use, this may result in the rider falling and
sustaining serious injury.
Only use pedelec when it is correctly prepared
ready for use with the locking lever closed.
1
2
WARNING
!
1
2
MY20H02-12_1.0_12.06.2019 74
Operation
6.8 Using the kickstand
6.8.1 Raising the kickstand
Before the ride, raise the kickstand completely
with your foot.
6.8.1.1 Parking the pedelec
Use your foot to lower the kickstand completely
before parking.
Park the pedelec carefully and check that it is
stable.
6.9 Using the pannier rack
Distribute the baggage as evenly as possible
on the left- and right-hand side of the pedelec.
We recommend the use of panniers and
baggage baskets.
Crash caused by a lowered kickstand
The kickstand does not fold up automatically.
There is a risk of crashing if riding with the
kickstand lowered.
Raise the kickstand completely before setting
off.
Notice
The pedelec's force of weight may cause the
kickstand to sink into soft ground and the pedelec
may topple over.
The pedelec must be parked on firm, level
ground only.
It is particularly important to check that the
pedelec is stable if it is equipped with
accessories or loaded with baggage.
Crash caused by loaded pannier rack
The pedelec is handled differently with a loaded
pannier rack, in particular when the rider needs to
steer and brake. This can lead to a loss of control.
This may cause a crash with injuries.
You should practice how to use a loaded
pannier rack safely before using the pedelec in
public spaces.
CAUTION
!
CAUTION
!
Crash caused by unsecured baggage
Loose or unsecured objects on the pannier rack,
e.g. belts, may become caught in the rear wheel.
This may cause a crash with injuries.
Objects which are fastened to the pannier rack
may cover the pedelec's reflectors and the riding
light. Other users may not see the pedelec on
public roads as a result. This may cause a crash
with injuries.
Secure any objects which are attached to the
pannier rack sufficiently.
Objects fastened to the pannier rack must
never cover the reflectors, the headlight or the
rear light.
Crushing the fingers in the spring flap
The spring flap on the pannier rack operates with
a high clamping force. There is a risk of crushing
the fingers.
Never allow the spring flap to snap shut in an
uncontrolled manner.
Be careful where you position your fingers
when closing the spring flap.
Notice
The maximum load bearing capacity is indicated
on the pannier rack.
Never exceed the permitted total weight when
packing the pedelec.
Never exceed the maximum load bearing
capacity of the pannier rack.
Never modify the pannier rack.
CAUTION
!
MY20H02-12_1.0_12.06.2019 75
Operation
6.10 Rechargeable battery
Risk of fire and explosion due to faulty battery
The safety electronics on a damaged or faulty
battery may fail. The residual voltage can cause a
short circuit. The battery may self-ignite and
explode.
Remove batteries with external damage from
service immediately and never charge them.
Only operate the battery and accessories if
they are in perfect condition.
Only use batteries which are approved for use
on your pedelec.
Do not use the battery with defective
connecting cables or defective contacts.
Use the battery with BMZ Systems e-bikes
only. This is the only way that the battery will
be protected from dangerous overloading.
If the battery becomes deformed or begins to
smoke, keep at a safe distance, disconnect the
power supply at the socket, and notify the fire
service immediately.
Never extinguish a damaged battery with
water or allow it to come into contact with
water.
If a battery is dropped or struck but shows no
signs of external damage, remove it from
service and observe it for at least 24 hours.
Faulty batteries are hazardous goods.
Dispose of faulty batteries properly and as
quickly as possible.
Store in a dry place until disposal. Never store
in the vicinity of flammable substances.
Never open or repair the battery.
Charge the battery before use. Only use the
charger included in the scope of delivery.
Avoid wide temperature fluctuations.
WARNING
!
Do not use the battery at altitudes higher than
2,000 m.
Chemical burns to the skin and eyes caused by
faulty battery
Liquids and vapours may leak from a damaged or
faulty battery. Excessive temperatures can also
cause liquid to leak from the battery and the
battery will become damaged. Such liquids can
irritate the airways and cause burns.
Avoid contact with leaked liquids.
Immediately consult a doctor in case of
contact with the eyes or any discomfort.
In case of contact with the skin, rinse off
immediately with water.
Ventilate the room well.
Protect the battery against heat over 60 °C,
e.g. against permanent direct sunlight.
Risk of fire and explosion due to short circuit
Small metal objects may jumper the electrical
connections of the battery. The battery may self-
ignite and explode.
Keep paper clips, screws, coins, keys and
other small parts away and do not insert them
into the battery.
Risk of fire and explosion due to penetration by
water
The battery is only protected from simple spray
water. Penetration by water can cause a short
circuit. The battery may self-ignite and explode.
Never immerse the battery in water.
Never clean the battery with pressure washer
If there is reason to believe that water may
have entered into the battery, the battery must
be removed from service.
WARNING
!
CAUTION
!
MY20H02-12_1.0_12.06.2019 76
Operation
Switch off the battery and the drive system before
removing or inserting the battery.
6.10.1 Frame battery
Only applies to pedelecs with this equipment
6.10.1.1 Removing the frame battery
Figure 77: Removing and inserting the frame battery
(1) Open the lock with the key.
Tip the battery out of the top mount.
(2) Pull the battery out of the mount.
6.10.1.2 Inserting the frame battery
(3) Place the battery on the contacts in its
lower mount.
(4) Remove the key from the lock.
Tilt into the top mount as far as it will go.
There is an audible clicking noise.
Check inserted battery to ensure it is firmly in
place.
6.10.2 Pannier rack battery
Only applies to pedelecs with this equipment
6.10.2.1 Removing the pannier rack battery
Figure 78: Removing (2) and inserting (3) the pannier rack
battery
(1) Open the lock with the key.
(2) Pull the pannier rack battery backwards and
out of its mount.
Remove the key from the lock.
6.10.2.2 Inserting the pannier rack battery
(3) Insert the pannier rack battery into its mount
with the contacts facing the front until it clicks
into place.
Check inserted battery to ensure it is firmly in
place.
6.10.3 Integrated battery
Only applies to pedelecs with this equipment
6.10.3.1 Removing the integrated battery
Figure 79: Removing the integrated battery
Notice
If you leave a key inserted when riding or
transporting the pedelec, it may break off or the
locking system may open accidentally.
Remove the key from the battery lock
immediately after use.
We recommend that you attach the key to a
key ring.
(1)
(2)
(3)
(4)
(1) (2)
(3)
(1)
(2)
(3)
(4)
MY20H02-12_1.0_12.06.2019 77
Operation
(1) Open the lock with the key.
(2) The battery is released and falls into the
retainer guard.
(3) Hold the battery in your hand from beneath.
Use the other hand to push on the retainer
guard from above.
(4) The battery is released and falls into the
hand.
Remove the battery from the frame.
Remove the key from the lock.
6.10.3.2 Inserting the integrated battery
Figure 80: Inserting the integrated battery
(1) Place the battery into the lower mount with
the contacts facing the front.
(2) Flip the battery upwards, so that it is held by
the retainer guard.
(3) Push the battery upwards, so that it audibly
clicks into place.
Check battery to ensure it is firmly in place.
(4) Lock the battery with the key; otherwise, the
battery may fall out of the mount when you
open the lock.
Remove the key from the lock.
Check the battery to ensure it is firmly in place.
6.10.4 Charging the battery
The ambient temperature during the charging
process must be within the range from 0 °C to
40 °C.
The battery can remain on the pedelec or can be
removed for charging.
(1)
(2) (3)
(4)
Fire and explosion due to faulty battery
The safety electronics on damaged or faulty
batteries may fail. The residual voltage can cause a
short circuit. Batteries may self-ignite and explode.
Never charge a faulty battery
Fire caused by overheated charger
The charger heats up when charging the battery.
In case of insufficient cooling, this can result in
fire or burns to the hands.
Never use the charger on a highly flammable
surface (e.g. paper, carpet etc.).
Never cover the charger during the charging
process.
Never leave battery unattended during
charging.
Electric shock caused by penetration by water
If water penetrates into the charger, there is a risk
of electric shock.
Never charge the battery outdoors.
Electric shock in case of damage
Damaged chargers, cables and plug connectors
increase the risk of electric shock.
Check the charger, cable and plug connector
before each use. Never use a damaged
charger.
Notice
If an error occurs during the charging process,
a system message is displayed. Remove the
charger and battery from operation
immediately and follow the instructions.
WARNING
!
CAUTION
!
MY20H02-12_1.0_12.06.2019 78
Operation
Interrupting the charging process does not
damage the battery.
If pedelec features two batteries, charging for
both batteries is started via pannier rack battery.
Remove the rubber cover from the battery.
Connect the mains plug of the charger to a
normal domestic, grounded socket.
Connect the charging cable to the battery's
charging port.
The charging process starts automatically.
The battery level indicator shows the charge
level during charging. When the drive system is
switched on, the display screen shows the
charging process.
Disconnect the battery from the charger and allow
it to cool down. Do not connect the rechargeable
battery to the charger again until the permitted
charging temperature has been reached.
The charging process is complete when the
LEDs on the operating status and battery level
indicator go out.
Once charging is complete, disconnect the
battery from the charger and the charger from
the mains.
6.10.5 Dual charging
Only applies to pedelecs with this equipment
One of the charging sockets is not accessible or is
closed with an end cap on Pedelecs with two
batteries.
Figure 81: Covering open contacts with cover cap –
example: pannier rack battery
(1) If you wish to use just one battery on a
pedelec which is designed for two batteries,
cover the contacts on the free slot with the
supplied cover cap; otherwise, there is a risk of
a short circuit caused by the open contacts.
6.10.5.1 Charging process when two batteries
are used
If two batteries are attached to a pedelec,
charge the two batteries via the non-closed
socket.
The two batteries are charged alternately
during the charging process. Charging
switches automatically between the two
batteries several times. The charging time is
twice as long.
The two batteries are discharged alternately
during use.
Connection data 230 V, 50 Hz
Notice
Check that mains voltage is correct. The
power source voltage must match the voltage
indicated on the charger nameplate. Chargers
labelled 230 V may also be operated at 220 V.
If the battery is outside
its charging
temperature range,
three LEDs will flash on
the battery level
indicator.
Notice
Charge the battery via the accessible charging
socket only.
Never open a closed charging socket.
Charging via a pre-closed charging socket can
cause irreparable damage
(1)
MY20H02-12_1.0_12.06.2019 79
Operation
6.10.5.2 Charging process when one battery is
used
You can charge each battery individually if you
remove them from their mounts.
If only one battery is used, you will only be able to
charge the battery on the pedelec which has an
accessible charging socket. You can only charge
battery with the closed charging socket if you
remove it from its mount.
6.10.6 Waking the battery
The battery switches to sleep mode to protect
itself when not used for a longer period. The LEDs
on the operating status and battery level indicator
do not light up.
Press the On-Off button (battery).
The operating status and battery level indicator
shows the battery level.
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Operation
6.11 Electric drive system
6.11.1 Switching on the electric drive
system
A sufficiently charged battery has been inserted
into the pedelec.
The battery is firmly positioned. The key has been
removed.
There are three options for switching on the drive
system.
1 On-Off button
Press the On-Off button (battery) briefly.
2 Display On-Off button
Press the On-Off button (display) once.
3 Switched-on display
If the display is already switched on when it is
inserted into its mount, the electric drive
system is switched on automatically.
After switching on, a speed of 0 KM/H is
displayed on the display. If this is not the case,
you must check whether the display has been
engaged properly in place.
If the drive system is switched on, the drive is
activated as soon as the pedals are moved with
sufficient force (except if in push assist mode
or the level of assistance is "OFF").
The motor power is determined by the level of
assistance set on the display.
As soon as the system has been activated,
ACTIVE LINE/PERFORMANCE LINE
appears briefly on the display.
6.11.2 Switching off the drive system
As soon as you stop pushing the pedals in normal
mode or reach a speed of 25 km/h, the drive
system switches off the assistance system. The
assistance system starts up again if you push the
pedals and your speed is less than 25 km/h.
The system switches off automatically ten minutes
after the last command. There are three options
for switching off the drive system manually.
1 Display On-Off key
Press the On-Off button (display) once.
2 On-off button
Press the On-Off button (battery).
3 Removing the display
Remove the display from the mount.
The LEDs on the operating status and battery
level indicator go out.
Crash caused by lack of readiness for braking
When it is switched on, the drive system can be
activated by the application of force on the
pedals. There is a risk of a crash if the drive is
activated unintentionally, and the brake is not
reached.
Never start the electric drive system, or switch
it off immediately, if the brake cannot be
reached safely and reliably.
CAUTION
!
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Operation
6.12 Control panel with display
6.12.1 Removing and attaching the display
The system is switched off by removing the
display.
6.12.1.1 Removing the display
Push the display catch down and
simultaneously push the display forwards and
out of the mount.
6.12.1.2 Attaching the display
Place the display on the mount.
Push the display back as far as it will go.
Figure 82: Push display (2) over the display catch (1) until
it locks into the mount (3)
6.12.2 Securing display against removal
Detach the display mount from the handlebars.
Position the on-board computer in its mount.
Fasten the blocking screw (M3 thread, 8 mm in
length) into the designated thread in the mount
from below
Fit the mount to the handlebars.
6.12.3 Charging the internal display battery
If the internal display battery is low when you
switch on the display, ATTA CH T O
PE DEL EC appears on the text display for three
seconds. The display then switches back off.
There are two options for charging the battery.
6.12.3.1 Charging on the pedelec
Once a battery has been inserted into the
pedelec, place the display in the mount for the
display.
Press the On-Off button (battery).
Using the pedelec
6.12.3.2 Charging using the USB port
Open the protective flap on the USB port.
Connect the USB port to a commercially
available USB charger or the USB port on a
computer (5 V charge voltage; max. 500 mA
charge current), using a suitable USB cable.
US B CONN EC T ED is displayed on the
display.
Notice
If the rider is not present, the display can be used
without authorisation, e.g. it may be stolen, the
system settings may be changed or journey
information may be read.
Remove the display when the pedelec is
parked.
Notice
The blocking screw does not offer protection
against theft.
ECO
MPH
KM/H
Reichweite
KM /H
RESET
EC O
MPH
KM/H
Reichweite
KM
/H
1
2
3
Notice
The internal display battery discharges when it is
not in use. This can cause damage to the internal
display battery.
Charge the internal display battery for at least
one hour every three months.
MY20H02-12_1.0_12.06.2019 82
Operation
6.12.4 Using the USB port
The USB port can be used to operate external
devices which can be connected using a standard
micro A/micro B USB 2.0 cable.
Open the protective flap on the USB port.
Replace the protective flap after using the USB
port.
6.12.5 Switching on the display
Press the On-Off button (display) once.
The electric drive system is switched on.
6.12.6 Switching off the display
If the display is not inserted into the bracket, it will
switch off automatically after one minute to save
energy if no button is pressed.
Press the On-Off button (display) once.
The electric drive system is switched off.
6.12.7 Using the push assist system
The push assist helps the rider to push the
pedelec. The speed can be a maximum of 6 km/h
in this case.
The tractive power of the push assist and its
speed can be influenced by the selection of gear.
To spare the drive, first gear is recommended for
travelling uphill.
The level of assistance OF F must not be
selected.
Press the push assist button once to activate
the push assist.
Press and hold the plus button within 3
seconds to switch on the push assist.
Release the plus button to shut off the push
assist. The push assist system switches off
automatically as soon as the pedelec wheels
are blocked or the speed exceeds 6 km.
6.12.8 Using the riding light
The drive system needs to be already switched
on to turn on the riding light.
Press the riding light button.
The riding light is switched on (riding light
symbol is displayed) or switched off (riding
light symbol is not displayed).
Notice
Any moisture which enters through the USB port
may trigger a short circuit in the display.
Regularly check the position of the rubber
cover on the USB port and adjust it as
necessary.
Injury from pedals or wheels
The pedals and the drive wheel turn when the
push assist system is used. There is a risk of
injury if the pedelec wheels are not in contact with
the ground when the push assist system is used
(e.g. when carrying the pedelec up stairs or when
placing it on a bicycle rack).
Only use the push assist mode when pushing
the pedelec.
You must steer the pedelec securely with both
hands when using push assist.
Allow for enough freedom of movement for the
pedals
CAUTION
!
MY20H02-12_1.0_12.06.2019 83
Operation
6.12.9 Selecting the level of assistance
Press the plus button to increase the level of
assistance.
Press the minus button to reduce the level of
assistance.
6.12.10 Journey information
The displayed journey information can be
changed and partially reset.
If the on-board computer is removed from its
mount, all function values are saved and can still
be displayed.
6.12.10.1 Changing the displayed journey
information
Press the info button (display) or info button
(operating element) repeatedly until the
required journey information is displayed.
6.12.10.2 Resetting the journey information
If you wish to reset the Trip Distance, Trip Time
and Avg Speed in journey information, switch
to one of these three functions and then press
the RESET button until the indicator is reset to
zero. This will also reset the readings for the
other two functions.
If you wish to reset the maximum journey
information, switch to this function and then
press the RESET button until the indicator is
reset to zero.
If you wish to reset the Range journey
information, switch to this function and then
press the RESET button until the indicator is
reset to factory setting.
6.12.11 Changing the system settings
System settings screen displays and changes are
possible regardless of whether the display is
inserted into the mount or not. A few settings are
only visible and changeable if the display is
inserted. A few menu options may be missing,
depending on the Pedelec's features.
The System settings can be changed.
Press the info button (display) and the RESET
button together.
CONFIGURATION is displayed on the
display. The System settings is opened.
Press the info button (display) repeatedly until
the system setting which you wish to change is
displayed.
Press the plus button or the minus button to
change the displayed setting.
Press and hold the RESET button for
3 seconds to save the changed system
settings and return to the journey information.
Screen display Change
- C L O C K + You can set the current time. If you
press on the setting buttons for a
longer period of time, the time will
be changed faster.
- W H E E L CI RCUM. + You can change the value that the
manufacturer pre-set by ± 5%.
This menu option is only shown if
the display is in its mount.
- E N G L I S H + You can change the language for
on-screen messages. You can
choose between English, German,
French, Spanish, Italian,
Portuguese, Swedish, Dutch and
Danish.
- U N I T K M /M I + You can display the speed and
distance in kilometres or miles.
- T I M E F O RM AT + You can display the time in
12-hour or 24-hour format.
- SHIFT RECOM.
OFF +
You can turn the gear
recommendation screen display on
or off.
Table 56: Changing the system settings
MY20H02-12_1.0_12.06.2019 84
Operation
6.13 Brake
Hydraulic fluid can be fatal if it is swallowed
and penetrates into the respiratory system
Hydraulic fluid may leak out after an accident or
due to material fatigue. Hydraulic fluid can be
fatal if swallowed and inhaled.
First aid treatment
Wear gloves and safety goggles as protective
equipment. Keep unprotected persons away.
Remove those affected from the danger area to
fresh air. Never leave those affected unattended.
Ensure sufficient ventilation.
Immediately remove clothing items contaminated
with hydraulic fluid.
Serious slip hazard due to hydraulic fluid
leakage.
Keep away from naked flames, hot surfaces and
sources of ignition.
Avoid contact with skin and eyes.
Do not inhale vapours or aerosols.
After inhalation
Take in fresh air; consult doctor if any pain or
discomfort.
After skin contact
Wash affected skin with soap and water and
rinse well. Remove contaminated clothing.
Consult doctor if any pain or discomfort.
After contact with eyes
Rinse eyes under flowing water for at least ten
minutes with the lids open; also rinse under lids.
Consult eye doctor if pain or discomfort
continues.
DANGER
!
After swallowing
Rinse out mouth with water. Never induce
vomiting! Risk of aspiration!
Place a person lying on their back who is
vomiting in a stable recovery position on their
side. Seek medical advice immediately.
Environmental protection measures
Never allow hydraulic fluid to flow into the
sewage system, surface water or groundwater.
Notify the relevant authorities if fluid penetrates
the ground or pollutes water bodies or the
sewage system.
Crash caused by brake failure
Oil or lubricant on the brake disc in a disc brake
or on the rim of a rim brake can cause the brake
to fail completely. This may cause a crash with
serious injuries.
Never allow oil or lubricant to come into contact
with the brake disc or brake linings or on the rim
of a rim brake.
If the brake linings have come into contact with oil
or lubricant, contact a dealer or a workshop to
have the components cleaned or replaced.
If the brakes are applied continuously for a long
time (e.g. while riding downhill for a long time),
the fluid in the brake system may heat up. This
may create a vapour bubble. This will cause air
bubbles or any water contained in the brake
system to expand. This may suddenly make the
lever travel wider. This may cause a crash with
serious injuries.
Release the brake regularly when riding downhill
for a longer period of time.
DANGER
!
WARNING
!
MY20H02-12_1.0_12.06.2019 85
Operation
The drive force of the motor is shut off during the
ride as soon as the rider no longer pedals. The
drive system does not switch off when braking.
In order to achieve optimum braking results, do
not pedal while braking.
6.13.1 Using the brake lever
Figure 83: Front (2) and rear (1) brake lever; Shimano
brake used as an example
Push the left brake lever for the front wheel brake
and the right lever for the rear wheel brake until
the desired speed is reached.
Amputation due to rotating brake disc
The brake disc in disc brakes is so sharp that it
can cause serious injuries to fingers if they are
inserted into the disc brake openings.
Always keep fingers well away from the rotating
brake disc.
Crash caused by wet conditions
The tyres may slip on wet roads. In wet conditions
you must also expect a longer braking distance.
The braking sensation differs from the usual
sensation. This can cause loss of control or a
crash, which may result in injuries.
Ride slowly and brake in good time.
Crash caused by incorrect use
Handling the brake improperly can lead to loss of
control or crashes, which may result in injuries.
Shift your body weight backwards and down as
far as possible.
Practice braking and emergency braking before
using the pedelec in public spaces.
Never use the pedelec if you can feel no
resistance when you grip the brake handle.
Consult a specialist dealer.
Burns caused by heated brake
The brakes may become very hot during
operation. There is a risk of burns or fire in case
of contact.
Never touch the components of the brake directly
after the ride.
WARNING
!
CAUTION
!
Crash after cleaning or storage
The brake system is not designed for use on a
pedelec which is placed on its side or turned
upside down. The brake may not function
correctly as a result. This can cause a crash,
which may result in injuries.
If the pedelec is placed on its side or turned
upside down, apply the brake a couple of times
before setting off to ensure that it works as
normal.
Never use the pedelec if it no longer brakes as
normal. Consult a specialist dealer.
CAUTION
!
1
2
MY20H02-12_1.0_12.06.2019 86
Operation
6.13.2 Using the back-pedal brake
Only applies to pedelecs with this equipment
The best braking effect is achieved if the pedals
are in the 3 o'clock and 9 o'clock position when
braking. To bridge the free travel between the
riding movement and the braking movement, it is
recommendable to pedal a little beyond the
3 o'clock and 9 o'clock position before you pedal
in the opposite direction to the direction of travel
and start braking.
Pedal in the opposite direction to the direction of
travel until the desired speed has been reached.
6.13.3 Using ABS
Only applies to pedelecs with this equipment
Accident due to ABS failure
If the ABS indicator lamp is lit, the ABS function is
not active.
Adapt riding to the circumstances.
In extreme riding situations, the ABS may not be
able to regulate until the pedelec comes to a halt.
This may cause a crash with serious injuries.
Release the front wheel brake briefly. This allows
you to brake with the ABS function again.
Adjust your riding to the current environmental
conditions and your personal riding skills.
An ABS malfunction cannot be displayed if the
ABS indicator lamp is faulty.
Ensure that the ABS indicator lamp lights up
when you start up the electric drive system; if it
doesn’t, the indicator lamp is faulty.
WARNING
!
Accidents on bends and slippery ground
You are at greater risk of falling off if you use ABS
braking manoeuvres on bends. It is easier for
tyres to skid on slippery ground, meaning there is
a greater risk of falling off. This may cause a
crash with serious injuries.
Adjust your riding to the current environmental
conditions and your personal riding skills
Accidents due to extended braking distance
The ABS suppresses blocking on the front wheel.
This may cause the braking distance to be longer
in some situations. This may cause an accident
with serious injuries.
Adjust your riding to the current environmental
conditions and your personal riding skills
Never fool about when riding.
Accidents due to air in the hydraulic system
Air in the brake system can mean less brake
pressure builds up, particularly when the ABS has
activated causing the brake lever to move closer
to the handlebars. This may cause an accident
with serious injuries.
It’s therefore important to pull on the brake before
each ride to check whether you can reach a
clearly noticeable pressure point and whether the
gap between the brake lever and handlebar grip
is still sufficient. The pressure point should arise
at about third of the brake lever path.
If in doubt, place the lever path adjuster in the
maximum possible position.
If any air has entered the brake system, contact
your specialist dealer.
Adjust your riding to the current environmental
conditions and your personal riding skills
WARNING
!
MY20H02-12_1.0_12.06.2019 87
Operation
6.13.3.1 While riding
The anti-blocking system indicator lamp must light
up after the system has started up and must go
out once speed has reached about 5 km/h. If the
ABS indicator lamp does not light up when the
electric drive system starts, the ABS is defective.
An error code on the display also tells the rider
that it is defective. If the indicator lamp does not
go out after you set off or it lights up while you are
riding, this means there is an error in the anti-
blocking system. The anti-blocking system is then
no longer active. The brake system itself remains
functional. It is only the anti-blocking system
control which no longer operates. If the ABS
indicator lamp is lit, the ABS function is not active
Adjust your riding to the current environmental
conditions and your personal riding skills
Remember that the anti-blocking system can
make your braking distance longer.
Reduce your speed on slippery ground. Brake in
bursts and in good time.
You need to stop and restart the pedelec (switch
off and on again) to reactivate the anti-blocking
system.
6.14 Suspension and damping
6.14.1 Adjusting the compression of the
Fox fork
Only applies to pedelecs with this equipment
The compression adjuster makes it possible to
make quick adjustments to the suspension
behaviour of the fork to suit changes in terrain. It
is intended for adjustments made during the ride.
Figure 84: FOX compression adjuster with the OPEN (1)
and HARD (2) positions
Compression damping is lowest in the OPEN po-
sition, making the fork feel softer. Use the HARD
position if you want to the fork feel stiffer and you
are riding on soft ground. The lever positions be-
tween the OPEN and HARD positions enable fine
adjustment of compression damping.
We recommend setting the lever of the compres-
sion adjuster to the OPEN mode position first.
Accidents due to manipulation
Modified or manipulated ABS components or use
of non-authorised replacement components will
have an adverse effect on the ABS function. This
may cause a crash with serious injuries.
Always carry out maintenance work and repairs
correctly.
Replace defective components with original parts
only.
Damage to components or risk of crushing
There is a gap between the ABS control unit and
the frame. Components or body parts can be
crushed if the handlebars are turned completely.
This can cause injuries or damage to
components.
Ensure you do not pinch any components such
as brake cables, wiring or parts of your body
between the frame and the ABS control unit.
If you wish to fasten accessories to the
handlebars, ensure that handlebars can move
freely to each side by at least 60° from their
central position. You can prevent fingers
becoming trapped with a clearance of 25 mm.
Steering limiters should be used if necessary.
WARNING
!
CAUTION
!
Notice
The anti-blocking system indicator lamp may light up
if the front and rear wheels are rotating at widely
different speeds from one another – for example, if
the rider cycles on the rear wheel only or if a wheel
is rotating for a unusually long time without making
contact with the ground (fitting stand). The anti-
blocking system switches off in such cases.
1
1
2
MY20H02-12_1.0_12.06.2019 88
Operation
6.14.2 Adjusting the compression of the
Fox damper
Only applies to pedelecs with this equipment
The compression adjuster makes it possible to make
quick adjustments to the suspension behaviour of
the damper to suit changes in terrain. It is intended
for adjustments made during the ride.
Figure 85: FOX compression adjuster on the rear frame
damper with the OPEN (1), MEDIUM (2) and HARD (3)
positions
Use the OPEN position for rough descents, the
MEDIUM position for rough terrain and the HARD
position for efficient climbing. First set the
compression adjuster to the OPEN position.
Figure 86: Fine adjustment of the OPEN position is made
using the adjuster (4)
The FOX rear frame damper features fine
adjustment for the OPEN position.
We recommend that fine adjustments be made
when the compression adjuster is in the MEDIUM
or HARD position.
Pull out the adjuster.
Turn the adjuster to position 1, 2 or 3. Setting 1 is
for the softest riding performance, whereas 3 is
for the hardest.
Press the adjuster in to lock in the setting.
6.14.3 Adjusting the compression of the
Suntour fork
Only applies to pedelecs with this equipment
The compression adjuster makes it possible to
make quick adjustments to the suspension
behaviour of the fork to suit changes in terrain. It
is intended for adjustments made during the ride.
Figure 87: Suntour compression adjuster with the
OPEN (1) and LOCK (2) positions
Compression damping is lowest in the OPEN
position, making the fork feel softer. Use the
LOCK position if you want the fork to feel stiffer
and you are riding on soft ground. The lever
positions between the OPEN and LOCK positions
enable fine adjustment of compression damping.
We recommend setting the lever of the
compression adjuster to the OPEN position first.
1
2
3
4
3
2
1
1
2
MY20H02-12_1.0_12.06.2019 89
Operation
6.14.4 Adjusting the compression of a
Suntour damper
Only applies to pedelecs with this equipment
The compression adjuster makes it possible to
make quick adjustments to the suspension
behaviour of the damper to suit changes in terrain.
It should never be used while riding on rough
terrain.
Figure 88: Suntour compression adjuster open (1)
Use the OPEN position for rough descents and
the LOCK position for efficient climbing. First set
the compression adjuster to the OPEN position.
Figure 89: Suntour compression adjuster closed (2)
6.14.5 Adjusting the rebound in a Rock
Shox damper
Only applies to pedelecs with this equipment
The rebound damper determines the speed at
which the fork rebounds to full length after
deflection. This speed affects the wheel's contact
with the ground and thus has an influence on
control and efficiency. The rear frame damper
should rebound fast enough to sustain traction
without producing an erratic or bumpy sensation.
If rebound damping is too tight, the rear frame
damper is unable to rebound fast enough before
the next impact. The rebound damper for the rear
wheel is located in the rear frame damper.
Figure 90: Setting the rebound damper strength on the
rear frame damper setting wheel (1)
Turn the setting wheel to the middle position.
Ride the pedelec over a small obstacle.
The ideal setting for the rebound damper has
been achieved when the rebound movement of
the rear wheel feels comparable to that of the
front wheel.
If the rear wheel bounces back much more
quickly or slowly than the front wheel, change the
setting by turning the setting wheel.
• Turn the setting wheel in an anti-clockwise
direction to increase the rebound speed.
• Turn the setting wheel in a clockwise direction to
decrease the rebound speed.
1
2
2
2
3
1
MY20H02-12_1.0_12.06.2019 90
Operation
6.14.6 Adjusting the compression in a
Rock Shox damper
Only applies to pedelecs with this equipment
The compression damper controls the speed at
which the rear frame damper deflects during slow
impact, such as smaller impacts or when the rider
goes round a corner or shifts their weight. The
damper improves control and efficiency.
If the compression damper is set too high, the
suspension is too hard during impacts. The lever
is used to set the compression damper.
• Turn the setting wheel in a clockwise direction (+)
to decrease the deflection speed.
Turn the setting wheel in an anti-clockwise
direction (–) to increase the deflection speed.
Figure 91: Setting the compression damper strength using
the rear frame damper setting lever (1)
6.15 Gear shift
The selection of the appropriate gear is a
prerequisite for a physically comfortable ride and
making sure that the electric drive system
functions properly. The ideal pedalling frequency
is between 70 and 80 revolutions per minute.
It is advisable to stop pedalling briefly when
changing gears. This makes it easier to switch
gears and reduces wear on the drivetrain.
6.15.1 Using the derailleur gears
Only applies to pedelecs with this equipment
The speed and range can be increased while
applying the same force if you select the right
gear. Use the derailleur gears.
Figure 92: Down shifter (1) and up shifter (2) on the left (I)
and right (II) gear shift
Select the appropriate gear with the shifter.
The gear shift switches the gear.
The shifter returns to its original position.
Clean the rear derailleur if the gear change
blocks.
1
III
1
22
1
MY20H02-12_1.0_12.06.2019 91
Operation
6.15.2 Using a hub gear
Only applies to pedelecs with this equipment
.
Figure 93: Example; Shimano Nexus gear shift: twist
grip (1) for the hub gear with its screen (3), the direction of
rotation to switch up a gear (2) and the direction of
rotation to switch down a gear (4)
Turn the twist grip.
The gear shift switches the gear.
The number on the screen display shows the
changed gear.
6.15.3 Use eShift
eShift refers to the integration of electronic gear
shift systems into the pedelec system.
6.15.3.1 eShift with Shimano DI2 automatic
hub gears
Only applies to pedelecs with this equipment
You can operate the automatic Shimano DI2 hub
gears in manual mode or automatic mode. You
used the gear shift to change gears in manual
mode. In automatic mode, the shift system
changes gear automatically depending on the
speed, pedalling power and pedalling frequency.
You will find how to switch from automatic to
manual mode, depending on the shifter used,
described in your operating instructions for your
gear shift.
If you use the shifter when in automatic mode, the
gear system will change to the next gear, but it will
remain in automatic mode.
Manual gear changes in automatic mode
influence shift behaviour in your gear system and
adjust gear changes to your riding performance
since it is a self-learning system.
If the system is switched on for the first time when
a new, unused wheel is used, the system will learn
the gears first. To do so, the automatic system
changes to the highest/most difficult gear and
then switches through all gears during the first
ride. The new gear is shown briefly on the screen
each time it is changed.
Since the drive unit detects the gear shift and
consequently reduces motor assistance briefly, it
is also possible to switch gears under load or on
hills.
If the pedelec is brought to a halt from a speed
greater than 10 km, the system can automatically
switch back to a pre-set START GEAR.
You can set the START GEAR in the system
settings.
Crash caused by incorrect use
If the rider applies too much pressure on the pedals
during a gear change and activates the shifter or
changes several gears at a time, their feet may slip
from the pedals. As a result, the pedelec may flip
over or fall, which may cause injury.
Switching down several gears to a low gear may
cause the twist grip outer sleeve to suddenly come
off. This will not have an adverse effect on the twist
grip's correct functioning since the outer guide
returns to its original position after the gear change
is complete.
Apply little pressure on the pedals while changing
gears.
Never change more than one gear at a time.
Notice
The interior hub is not completely waterproof. If
water gets into the hub, it may rust and the gear
switch function may no longer function as a result.
Never use the pedelec in places where water
may get into the hub.
In rare cases, noises may be heard from the rear
derailleur in the hub interior after a gear change.
This is normal when gears are changed.
Do not detach the hub. If you need to detach it,
contact your dealer.
CAUTION
!
1
2
3
4
MY20H02-12_1.0_12.06.2019 92
Operation
6.15.3.2 eShift with manual Shimano DI2 hub
gears
Only applies to pedelecs with this equipment
The new gear is shown briefly on the screen each
time it is changed.
Since the drive unit detects the gear shift and
consequently reduces motor assistance briefly, it
is also possible to switch gears under load or on
hills.
If the pedelec is brought to a halt from a speed
greater than 10 km, the system can automatically
switch back to a pre-set START GEAR.
You can set the START GEAR in the system
settings.
6.15.3.3 eShift with Shimano DI2 automatic
hub gears
Only applies to pedelecs with this equipment
The new gear is shown briefly on the screen each
time it is changed. Since the drive unit detects the
gear shift and consequently reduces motor
assistance briefly, it is also possible to switch
gears under load or on hills.
6.15.3.4 eShift with NuVinci H|Sync/enviolo
with Optimized H|Sync
Only applies to pedelecs with this equipment
NUVINCI CADENCE mode allows you to
reduce or increase the desired pedalling
frequency using the plus button or minus button
on the operating unit.
If you hold the plus button or minus button down,
you can increase or reduce the pedalling
frequency in increments of five. The desired
pedalling frequency is displayed on the screen.
NUVINCI GEAR mode allows you to switch
between several specified transmissions using
the plus button or minus button on the operating
unit. The selected transmission (gear) is
displayed on the screen.
6.15.3.5 eShift with Rohloff E-14
Speedhub 500/14
Only applies to pedelecs with this equipment
The new gear is shown briefly on the screen each
time it is changed.
Since the drive unit detects the gear shift and
consequently reduces motor assistance briefly, it
is also possible to switch gears under load or on
hills.
If the pedelec is brought to a halt from a speed
greater than 10 km/h, the system can
automatically switch back to a pre-set START
GEAR.
You can set the START GEAR in the system
settings.
MY20H02-12_1.0_12.06.2019 93
Cleaning and servicing
7 Cleaning and servicing
Cleaning check list
Maintenance check list
The following servicing measures must be
performed regularly. Servicing can be performed
by the operator and rider. In case of any doubt,
consult the specialist dealer.
7.1 Cleaning after each ride
7.1.1 Cleaning the suspension fork
Remove dirt and deposits on the stanchions
and deflector seals with a damp cloth.
Check the stanchions for dents, scratches,
staining or leaking oil.
Check the air pressure.
Lubricate the dust seals and stanchions.
7.1.2 Cleaning the rear frame damper
Remove dirt and deposits from the damper
body with a damp cloth.
Check rear frame damper for dents, scratches,
staining or leaking oil.
7.1.3 Cleaning the pedals
Clean with a brush and soapy water after riding
through dirt or rain.
Service the pedals after cleaning.
Clean the pedals after each ride
Clean the suspension fork and, if
necessary, rear frame damper after each ride
Cleaning the battery once a month
Chain (mainly tarmacked road) every 250–
300 km
Basic cleaning and preservation of all
components
at least every six
months
Clean the charger at least every six
months
Clean and lubricate the height-adjustable
seat post every six months
Check USB rubber cover position before each ride
Check for tyre wear once a week
Check for rim wear once a week
Check tyre pressure once a week
Check brakes for wear once a month
Check electrical cables and Bowden
cables for damage and ensure they are
fully functional
once a month
Check chain tension once a month
Check tension of the spokes every three
months
Check the gear shift setting every three
months
Check suspension fork and, if necessary,
rear frame damper for wear and ensure
fully functional
every three
months
Check for wear on brake discs at least every six
months
Crash and falling caused by unintentional
activation
There is a risk of injury if the drive system is
activated unintentionally.
Remove the battery before inspection.
CAUTION
!
Required tools and cleaning agents:
• Cloth
•Air pump
•Brush
• Water
• Dish-washing liquid
•Bucket
MY20H02-12_1.0_12.06.2019 94
Cleaning and servicing
7.2 Basic cleaning
Remove battery and display before basic
cleaning.
7.2.1 Cleaning the frame
Soak dirt stains on the frame with dish-washing
detergent if the dirt is thick and ingrained.
After leaving it to soak for a time, remove the
dirt and mud with a sponge, brush and
toothbrush.
Use a watering can or your hand to rinse the
frame to finish off.
Service the frame after cleaning.
7.2.2 Cleaning the stem
Clean stem with a cloth and soapy water.
Service the stem after cleaning.
7.2.3 Cleaning the rear frame damper
Clean rear frame damper with a cloth and
soapy water.
7.2.4 Cleaning the wheel
Check the tyres, rims, spokes and spoke
nipples for any damage when cleaning the
wheel.
Use a sponge and a brush to clean the hub and
spokes from the inside to the outside.
Clean the rim with a sponge.
7.2.5 Cleaning the drive elements
Spray the cassette, the chain wheels and the
front derailleur with a degreasing agent.
Clean coarse dirt with a brush after soaking for
a short time.
Wash down all parts with dish-washing
detergent and a toothbrush.
Service the drive elements after cleaning.
Crash caused by brake failure
The braking effect may be unusually poor
temporarily after cleaning, servicing or repairing
the pedelec. This may cause a crash with injuries.
Never apply care products or oil to the brake
discs or brake linings, or the braking surfaces
on the rims.
After cleaning, servicing or repair, carry out a
few test brake applications.
Notice
Water may enter into the inside of the bearings if
you use a steam jet. This dilutes the lubricant
inside, the friction increases and, as a result, the
bearings are permanently damaged in the long
term.
Never clean the pedelec with a steam jet.
Greased parts, such as the seat post, the
handlebars or the stem, may no longer be safely
and reliably clamped.
Never apply grease or oil to clamping sections.
Required tools and cleaning agents:
•Cloths
• Sponge
•Air pump
•Brush
• Toothbrush
• Paintbrush
• Watering can
•Bucket
•Water
• Dish-washing liquid
• Degreaser
• Lubricant
• Brake cleaner or spirit
CAUTION
!
Crash caused by braking hard on rims
A rim can break and block the wheel if you brake
hard. This may cause a crash with serious
injuries.
Check rim wear on a regular basis.
WARNING
!
MY20H02-12_1.0_12.06.2019 95
Cleaning and servicing
7.2.6 Cleaning the chain
Slightly dampen a brush with dish-washing
liquid. Brush both sides of the chain.
Dampen a cloth with soapy water. Place the
cloth on the chain.
Hold and apply slight pressure while slowly
turning the rear wheel, so the chain passes
through the cloth.
If the chain is still dirty afterwards, clean it with
lubricant.
Service the chain after cleaning.
7.2.7 Cleaning the battery
Clean the battery electrical connections with a
dry cloth or brush only.
Wipe off the decorative sides with a damp
cloth.
7.2.8 Cleaning the display
Carefully clean the display with a damp, soft
cloth.
7.2.9 Cleaning the drive unit
Carefully clean the drive unit with a damp, soft
cloth.
Notice
Never use aggressive (acid-based) cleaners,
rust removers or degreasers when cleaning
the chain.
Do not use chain cleaning devices or chain
cleaning baths.
Risk of fire and explosion due to penetration by
water
The battery is only protected from simple spray
water. Penetration by water can cause a short
circuit. The battery may self-ignite and explode.
Never clean the battery with a high-pressure
water device, water jet or compressed air.
Keep the contacts clean and dry.
Never immerse the battery in water.
Never use cleaning agents.
Remove the battery from the pedelec before
cleaning.
Notice
Do not clean the battery with solvents, such as
thinners, alcohol, oil and corrosion protection,
or with cleaning agents.
CAUTION
!
Notice
If water enters into the display screen, it will be
permanently damaged.
Never immerse the display in water.
Never clean with a high-pressure water
device, water jet or compressed air.
Never use cleaning agents.
Remove the display from the pedelec before
cleaning.
Burns from hot drive
The drive cooler can become extremely hot
during use. Contact may cause burns.
Leave the drive unit to cool before cleaning.
Notice
If water enters into the drive unit, the unit will be
permanently damaged.
Never immerse the drive unit in water.
Never clean with a high-pressure water
device, water jet or compressed air.
Never use cleaning agents.
Never open.
CAUTION
!
MY20H02-12_1.0_12.06.2019 96
Cleaning and servicing
7.2.10 Cleaning the brake
Clean brake and brake discs with a brush,
water and dish-washing detergent.
Clean brake discs thoroughly with brake
cleaner or spirit.
7.3 Servicing
7.3.1 Servicing the frame
Dry frame after cleaning.
Spray with care oil. Clean off the care oil again
after a short time.
7.3.2 Servicing the stem
Apply silicone or Teflon oil to the stem shaft
tube and the quick release lever pivot point.
If you have speedlifter Twist, also apply oil to
the unlocking bolt using the groove in the
speedlifter body.
Apply a little acid-free lubricant grease
between the stem quick release lever and the
sliding piece to reduce the quick release lever
operating force.
7.3.3 Servicing the fork
Treat the dust seals with fork oil.
7.3.4 Servicing the drive elements
Spray the cassette, the chain wheels and the
front derailleur with a degreasing agent.
Clean coarse dirt with a brush after soaking for
a short time.
Wash down all parts with dish-washing
detergent and a toothbrush.
7.3.5 Servicing the pedals
Treat with spray oil after cleaning.
7.3.6 Servicing the chain
Grease the chain thoroughly with chain oil after
cleaning.
7.3.7 Servicing the drive elements
Service front and rear derailleur articulated
shafts and jockey wheels with Teflon spray.
7.4 Maintenance
The following maintenance measures must be
performed on a regular basis. They can be carried
out by the operator and rider. In case of any doubt,
consult the specialist dealer.
7.4.1 Wheel
Brake failure due to water penetration
The brake seals are unable to withstand high
pressures. Damaged brakes can fail and cause
an accident with injury.
Never clean the pedelec with compressed air
or a high-pressure water device.
Take great care when using a hosepipe. Never
point the water jet directly at the seal section.
Required tools and cleaning agents:
•Cloths
• Toothbrushes
• Dish-washing liquid
• Care oil for frames
• Silicone or Teflon oil
• Acid-free lubricating grease
• Fork oil
• Chain oil
• Degreaser
• Spray oil
• Teflon spray
WARNING
!
Crash and falling caused by unintentional
activation
There is a risk of injury if the drive system is
activated unintentionally.
Remove the battery before maintenance.
Crash caused by braking hard on rims
A rim can break and block the wheel if you brake
hard. This may cause a crash with serious
injuries.
Check rim wear on a regular basis.
CAUTION
!
WARNING
!
MY20H02-12_1.0_12.06.2019 97
Cleaning and servicing
Check tyre wear.
Check the tyre pressure.
Check the rims for wear.
• The rims of a rim brake with invisible wear
indicator are worn as soon as the wear indicator
becomes visible in the area of the rim joint.
• The rims with visible wear indicator are worn as
soon as the black, all-round groove on the pad
friction surface is no longer visible. We
recommend that you also replace the rims with
every second brake lining replacement.
Check the tension of the spokes.
7.4.2 Checking the tyres
Check the tyre wear. The tyre is worn if the
anti-puncture protection or the carcass cords
are visible.
A specialist dealer will need to change the tyre
if it is worn.
7.4.3 Checking the rims
Check the rims for wear. The rims are worn as
soon as the black, all-round groove on the pad
friction surface becomes invisible.
Worn rims must be replaced by a specialist
dealer.
We recommend that you also replace the rims
at the same time as every second brake lining
replacement.
7.4.4 Check and correct tyre pressure
7.4.4.1 Dunlop valve
The tyre pressure cannot be
measured on the simple
Dunlop valve. The tyre
pressure is therefore measured
in the filling hose when
pumping slowly with the bicycle
pump.
It is recommendable to use a
bicycle pump with a pressure
gauge. The operating
instructions for the bicycle
pump must be adhered to.
Unscrew and remove the
valve cap.
Connect the bicycle pump.
Pump up the tyre slowly and
pay attention to the tyre pressure in the
process.
Correct the tyre pressure according to
specifications in the Pedelec pass.
If the tyre pressure is too high, unfasten the
union nut, let out air and tighten the union nut
again.
Remove the bicycle pump.
Screw the valve cap tight.
Screw the rim nut gently against the rim with
the tips of your fingers.
7.4.4.2 Presta valve
It is recommendable to use a
bicycle pump with a pressure
gauge. The operating
instructions for the bicycle pump
must be adhered to.
Unscrew and remove the
valve cap.
Open the knurled nut around
four turns.
Carefully apply the bicycle
pump so that the valve insert is
not bent.
Notice
If the tyre pressure is too low in the tyre, the tyre
does not achieve its load bearing capacity. The
tyre is not stable and may come off the rim.
If the tyre pressure is too high, the tyre may burst.
Check the tyre pressure as per specifications
Adjust the tyre pressure as necessary.
MY20H02-12_1.0_12.06.2019 98
Cleaning and servicing
Pump up the tyre slowly and pay attention to
the tyre pressure in the process.
The tyre pressure has been adjusted as per the
specifications.
Remove the bicycle pump.
Tighten the knurled nut with your fingers.
Screw the valve cap tight.
Screw the rim nut gently against the rim with the
tips of your fingers.
7.4.4.3 Schrader valve
It is recommendable to use a
bicycle pump with a pressure
gauge. The operating
instructions for the bicycle pump
must be adhered to.
Unscrew and remove the
valve cap.
Connect the bicycle pump.
Pump up the tyre slowly and
pay attention to the tyre
pressure in the process.
The tyre pressure has been adjusted as per the
specifications.
Remove the bicycle pump.
Screw the valve cap tight.
Screw the rim nut gently against the rim with
the tips of your fingers.
7.4.5 Brake system
The maintenance interval for the brake depends on
the weather conditions and how frequent the
pedelec is used. If the pedelec is used under
extreme conditions such as rain, dirt or high
mileage, maintenance must be performed more
frequently.
7.4.6 Checking the brake linings for wear
Check brake linings after brake has been fully
applied 1,000 times.
Check that the brake linings are no less than
1.8 mm wide at any point and no less than
2.5 mm between the brake lining and
supporting plate.
Push brake lever and hold. In doing so, check
the transport safety wear gauge can fit
between the brake lining supporting plates.
The brake linings have not reached their wear
limit. If they have, a specialist dealer will need
to replace the brake linings.
7.4.7 Checking the pressure point
Push brake lever and hold several times.
If you are unable to clearly detect the pressure
point and it changes, a ZEG specialist dealer
needs to vent the brake.
1
Crash caused by brake failure
Worn brake discs and brake linings, as well as a
lack of hydraulic fluid in the brake cable, reduce
the braking power. This may cause a crash with
injuries.
Check the brake disc, brake linings and the
hydraulic brake system on a regular basis and
replace if necessary.
CAUTION
!
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Cleaning and servicing
7.4.8 Checking the brake discs for wear
Check that the brake disc is no less than 1.8
mm at any point.
The brake discs have not reached the wear
limit. If they have, a specialist dealer will need
to replace brake discs.
7.4.9 Electrical cables and brake cables
Check all visible electrical cables and cables
for damage. If the sheathing is compressed, for
example, the pedelec will need to be removed
from service until the cables have been
replaced.
Check all electrical cables and cables to make
sure they are fully functional.
7.4.10 Gear shift
Check the gear shift and the shifter or the twist
grip setting and adjust it as necessary.
7.4.11 Stem
The stem and quick release system should be
inspected at regular intervals. The specialist
dealer should adjust them if necessary.
If the hexagon socket head screw is also
loosened, the headset backlash also needs to
be adjusted. Medium-strength thread locker,
such as Loctite blue, then needs to be applied
to the loosened screws and the screws
tightened as per specifications.
Check for wear and signs of corrosion
(maintain with an oily cloth) and for oil leaks.
7.4.12 USB port
7.4.13 Checking the chain tension
Check the chain tension in three or four
positions, turning the crank a full revolution.
If the chain can be pushed more than 2 cm, the
chain or drive belt will need to be tensioned
again by the specialist dealer.
If the chain or the drive belt can only be pushed
up and down less than 1 cm, you will need to
slacken the chain or the drive belt.
The optimum chain tension is achieved if the
chain or the drive belt can be pushed a
maximum of 2 cm in the middle between the
pinion and the toothed wheel. The crank must
also turn without resistance.
If a hub gear is featured, the rear wheel must
be pushed backwards or forwards to tighten
the chain. This should be done by a specialist
only.
Figure 94: Checking the chain tension
7.4.14 Checking the handlebar grip
position
Check the handlebar grip is firmly in position.
Notice
Any moisture which enters through the USB port
may trigger a short circuit in the display.
Regularly check the position of the cover on the
USB port and adjust it as necessary.
Notice
Excessive chain tension increases wear.
If the chain tension is too low, there is a risk that
the chain or the drive belt will slip off the chain
wheels.
Check the chain tension once a month.
2 cm
MY20H02-12_1.0_12.06.2019 100
Maintenance
8 Maintenance
You must have the specialist dealer perform
maintenance every six months as a minimum.
This is the only way to ensure that the pedelec
remains safe and fully functional.
Special tools, special lubricants and knowledge of
suspension components are required to maintain
and repair brake discs as well as vent brakes or
replace brake discs. The pedelec may become
damaged if the stipulated maintenance intervals
and procedures are not carried out. That is why
only specialist dealers may carry out
maintenance.
The retailer will check the pedelec based on
the maintenance table in the appendix.
The specialist dealer will inspect the pedelec
for any signs of material fatigue during basic
cleaning.
The specialist dealer will check the software
version of the drive system and update it. The
electrical connections are checked, cleaned
and preservative agent is applied. The
electrical cables are inspected for damage.
The specialist dealer will dismantle and clean
the entire suspension fork interior and exterior.
They will clean and lubricate the dust seals and
slide bushings, check the torques and adjust
the fork to the rider's preferred position. They
will also replace the sliding collar if the
clearance is too great (more than 1 mm on the
fork bridge).
Injury due to damaged brakes
Special tools and specialist knowledge are
required to repair the brakes. Incorrect or
unauthorised assembly can damage the brakes.
This may lead to an accident with injuries.
Only specialist dealers may carry out repairs
on brakes.
Never carry out work or changes (such as
dismantling, sanding or painting) which are not
explicitly allowed and described in the brake user
manual.
Injury to the eyes
Problems may arise if the settings are not made
properly and you may sustain serious injuries as
a result.
Always wear safety glasses to protect your eyes
when carrying out maintenance work such as
replacing components.
Crash and falling caused by unintentional
activation
There is a risk of injury if the drive system is
activated unintentionally.
Remove the battery before inspection.
Crash caused by material fatigue
If the service life of a component has expired, the
component may suddenly fail. This may cause a
crash with injuries.
Have the specialist dealer carry out basic
cleaning of the pedelec every six months,
preferably at the same time as the required
servicing work.
WARNING
!
CAUTION
!
Hazard for the environment due to toxic
substances
The brake system contains toxic and
environmentally harmful oils and lubricants. Such
fluids will contaminate if they enter the sewers or
groundwater.
Dispose of lubricants and oils left over after
repairs in an environmentally responsible way
in accordance with statutory regulations.
Notice
The motor is maintenance-free and may only be
opened by qualified specialist personnel.
Never open the motor.
CAUTION
!
MY20H02-12_1.0_12.06.2019 101
Maintenance
The specialist dealer will fully inspect the
interior and exterior of the rear frame damper,
overhaul the rear frame damper, replace all air
seals on air forks, overhaul the air suspension,
change the oil and replace the dust wipers.
They will pay particular attention to rim and
brake wear. The spokes are re-tightened in
accordance with the findings.
8.1 Axle with quick release
8.1.1 Checking the quick release
Check the position and clamping force of the
quick release lever. The quick release lever
must be flush with the lower housing. You must
be able to see a slight impression on the palm
of your hand when you close the quick release
lever.
Figure 95: Adjusting the quick release clamping force
Use a 4 mm hexagon socket spanner to adjust
the clamping lever clamping force if required.
Afterwards, check the quick release lever
position and clamping force.
Figure 96: Adjusting the quick release clamping force
8.2 Adjusting the gear shift
If you cannot select the gears effortlessly, you will
need to adjust the setting for the shift cable
tension.
Carefully pull the adjusting sleeve away from
the shifter housing, turning it as you do so.
Check the gear shift function after each
adjustment.
Crash caused by unfastened quick
release
A faulty or incorrectly installed quick release may
become caught in the brake disc and block the
wheel. This will cause a crash.
Install the front wheel quick release lever on
the opposite side to the brake disc.
Crash caused by faulty or incorrectly
installed quick release
The brake disc becomes very hot during
operation. Parts of the quick release may become
damaged as a result. The quick release comes
loose. This will cause a crash with injuries.
The front wheel quick release lever and the
brake disc must be situated on opposite sides.
Crash caused by incorrectly set clamping
force
Excessively high clamping force will damage the
quick release and cause it to lose its function.
Insufficient clamping force will cause a
detrimental transmission of force. The
suspension fork or the frame may break. This will
cause a crash with injuries.
Never fasten a quick release using a tool (e.g.
hammer or pliers).
Only use the clamping lever with the specified
set clamping force.
CAUTION
!
MY20H02-12_1.0_12.06.2019 102
Maintenance
8.2.1 Cable-operated gear shift,
single-cable
Only applies to pedelecs with this equipment
For a smooth gear shift, adjust the adjusting
sleeves on the shifter housing.
Figure 97: Adjusting sleeve (1) for the single-cable, cable-
operated gear shift with shifter housing (2), example
8.2.2 Cable-operated gear shift,
dual-cable
Only applies to pedelecs with this equipment
For a smooth gear shift, set the adjusting
sleeves underneath the chain stay on the
frame.
The shift cable has around 1 mm play when it
is pulled out gently.
Figure 98: Adjusting sleeves (2) on two alternative
versions (A and B) of a dual-cable, cable-operated gear
shift on the chain stay (1)
8.2.3 Cable-operated twist grip,
dual-cable
Only applies to pedelecs with this equipment
For a smooth gear shift, set the adjusting
sleeves on the shifter housing.
There is noticeable play of around 2–5 mm
(1/2 gear) when twisting the twist grip.
Figure 99: Twist grip with adjusting sleeves (1) and play of
the gear shift (2)
2
1
1
A
B
1
2
2
1
2
MY20H02-12_1.0_12.06.2019 103
Troubleshooting, fault clearance and repair
9 Troubleshooting, fault clearance
and repair
9.1 Troubleshooting and fault
clearance
The components of the drive system are checked
constantly and automatically. If an error is
detected the corresponding error code will appear
on the display screen. Depending on the type of
error, the drive will also be automatically switched
off.
9.1.1 The drive system or display do not
start up
If the display and/or the drive system do not start up,
proceed as follows:
Check whether the battery is switched on. If
not, start the battery.
Contact specialist dealer if the battery level
indicator LEDs do not light up.
If the LEDs on the battery level indicator light
up, but the drive system does not start up,
remove the battery.
Insert the battery.
Start the drive system.
If the drive system does not start up, remove
the battery.
Clean all the contacts with a soft cloth.
Insert the battery.
Start the drive system.
If the drive system does not start up, remove
the battery.
Fully charge the battery.
Insert the battery.
Start the drive system.
If the drive system does not start up, remove
the display.
Fasten the display.
Start the drive system.
Contact your specialist dealer if the drive
system does not start up.
9.1.2 Error messages
If an error message is displayed, run through the
following actions:
Make a note of the system message.
Shut off and re-start the drive system.
If the system message is still displayed,
remove and then re-insert the battery.
Re-start the drive system.
If the system message is still displayed,
contact your specialist dealer.
Risk of fire and explosion due to faulty battery
The safety electronics may fail if the battery is
damaged or faulty. The residual voltage can
cause a short circuit. Batteries may self-ignite and
explode.
Batteries with external damage must be
removed from service immediately.
Never allow damaged batteries to come into
contact with water.
If a battery is dropped or struck but shows no
signs of external damage, remove it from
service and observe it for at least 24 hours.
Faulty batteries are hazardous goods.
Dispose of faulty batteries properly and as
quickly as possible.
Store in a dry place until disposal. Never store
in the vicinity of flammable substances.
Never open or repair the battery.
WARNING
!
MY20H02-12_1.0_12.06.2019 104
Troubleshooting, fault clearance and repair
9.2 Repair
Special knowledge and tools are required for
many repairs. That is why only a specialist dealer
may perform repairs such as:
• Replacing tyres and rims
• Replacing brake pads and brake linings
• Replacing and tensioning the chain.
9.2.1 Use original parts and lubricants
only
The individual pedelec parts have been carefully
selected and matched to one other.
Only original parts and lubricants must be used for
maintenance and repair.
The constantly updated accessory approval and
parts list are Section 11, Documents and
Drawings.
9.2.2 Replacing the lighting
Only use components of the respective power
class for replacement.
9.2.3 Setting the headlight
The headlight must be set, so that its light be am
shines on the road 10 m in front of the pedelec.
MY20H02-12_1.0_12.06.2019 105
Recycling and disposal
10 Recycling and disposal
This device is marked according to the
European Directive 2012/19/EU on
waste electrical and electronic
equipment – WEEE and the European
Directive 2006/66/EC on accumulators.
The directive provides the framework for
the return and recycling of used devices
across the EU. As a consumer, you are legally
required to return all used batteries of any type. It
is forbidden to dispose of batteries in domestic
waste. The manufacturer is obliged to take back
used and old batteries free of charge as per
Section 9 German Batteries Act. You thus meet
statutory obligations and help to protect the
environment. The pedelec, battery, motor, display
screen and charger are recyclable materials. You
must dispose of and recycle them separately from
the domestic waste in compliance with applicable
statutory regulations. Sorted waste collection and
recycling saves on raw material reserves and
ensures that all the regulations for health and
environmental protection are met when the
product and/or the battery are recycled.
Never dismantle the pedelec, batteries or
charger for disposal.
The pedelec, display screen, the unopened
and undamaged battery and the charger can
be returned to any specialist dealer free of
charge. Depending on the region, further
disposal options may be available.
Store the individual parts of the decommissioned
pedelec in a dry place, free from frost, where they
are protected from direct sunlight.
Risk of fire and explosion
The safety electronics on a damaged or faulty
battery may fail. The residual voltage can cause a
short circuit. The battery may self-ignite and
explode.
Remove battery with any external damage
from service immediately and never recharge
it.
If the battery becomes deformed or begins to
smoke, keep at a safe distance, disconnect the
power supply at the socket, and notify the fire
service immediately.
Never extinguish damaged batteries with
water or allow them to come into contact with
water.
Faulty batteries are hazardous goods.
Dispose of faulty batteries properly as quickly
as possible.
Store in a dry place until disposal. Never store
in the vicinity of flammable substances.
Never open or repair the battery.
Chemical burns to the skin and eyes
Liquids and vapours may leak from a damaged or
faulty battery. They can irritate the airways and
cause burns.
Avoid contact with leaked liquids.
Immediately consult a doctor in case of
contact with the eyes or any discomfort.
In case of contact with the skin, rinse off
immediately with water.
Ventilate the room well.
WARNING
!
CAUTION
!
Hazard for the environment
The fork, rear frame damper and hydraulic brake
system contain toxic and environmentally harmful
oils and lubricants. Such fluids will contaminate if
they enter the sewers or groundwater.
Dispose of lubricants and oils in an
environmentally responsible way in
accordance with statutory regulations.
CAUTION
!
MY20H02-12_1.0_12.06.2019 106
Documents
11 Documents
11.1 Parts list
There was no information relating to a parts list
yet at the time of going to press. You'll find the
information in the latest operating instructions.
MY20H02-12_1.0_12.06.2019 107
Documents
11.2 Assembly report
Date: Frame number:
Components Description Criteria Measures if rejected
Assembly/inspection Tests Accept-
ance Rejection
Front wheel Assembly O.K. Loose Adjust quick release
Kickstand Check mount fastening Functional check O.K. Loose Retighten screws
Tyres Tyre pressure check O.K. Tyre pressure too low/too
high Adjust tyre pressure
Frame Check for damage –
fracture, scratches O.K. Damage detected Take out of operation, new frame
Handles, coverings Check mount fastening O.K. Not provided Retighten screws, new handles or
coverings as specified in parts list
Handlebars, stem Check mount fastening O.K. Loose Retighten screws; new stem as
specified in parts list if necessary
Steering headset Check for damage Functional check O.K. Loose Retighten screws
Saddle Check mount fastening O.K. Loose Retighten screws
Seat post Check mount fastening O.K. Loose Retighten screws
Protective plate Check mount fastening O.K. Loose Retighten screws
Pannier rack Check mount fastening O.K. Loose Retighten screws
Attachments Check mount fastening O.K. Loose Retighten screws
Bell Functional check O.K. No ring, too quiet, missing New bell as specified in the parts
list
Suspension elements
Fork, suspension
fork Check for damage O.K. Damage detected New fork as specified in the parts
list
Rear frame damper Check for damage O.K. Damage detected New fork as specified in the parts
list
Suspension seat post Check for damage O.K. Damage detected New fork as specified in the parts
list
Brake system
Brake lever Check mount fastening O.K. Loose Retighten screws
Brake fluid Check fluid level O.K. Too little Refill with brake fluid; new brake
hoses if damaged
Brake linings
Check brake linings,
brake discs or rims for
damage
O.K. Damage detected New brake linings, brake discs or
rims
Back-pedal brake
braking armature Check mount fastening O.K. Loose Retighten screws
Light system
Rechargeable battery First examination O.K. Error message Take out of service; contact
battery manufacturer, new battery
Light cabling Connections, correct
wiring O.K. Cable defective, no light New cabling
Rear light Side light Functional check O.K. No constant light
Take out of service; new rear
light as specified in parts list;
replace battery if necessary
Front light Side light, daytime riding
light Functional check O.K. No constant light
Take out of service; new front
light as specified in parts list;
replace battery if necessary
Reflectors All complete, state,
fastening O.K. Damaged or not all
complete
New reflectors
MY20H02-12_1.0_12.06.2019 108
Documents
Technical inspection, checking safety, test ride
Drive/gear shift
Chain/cassette/
pinion/chainring Check for damage O.K. Damage Refasten if necessary or replace
as specified in parts list
Chain guard/spoke
guard Check for damage O.K. Damage Replace as specified in parts list
Bottom bracket axle/
crank Check mount fastening O.K. Loose Retighten screws
Pedals Check mount fastening O.K. Loose Retighten screws
Shifter Check mount fastening Functional check O.K. Loose Retighten screws
Shift cables Check for damage Functional check O.K. Loose or defective Adjust shift cables; new shift
cables if necessary
Front derailleur Check for damage Functional check O.K. Gear shift difficult or not
possible Adjust
Rear derailleur Check for damage Functional check O.K. Gear shift difficult or not
possible Adjust
Electric drive
Display Check for damage Functional check O.K. No screen display,
defective screen display
Restart, test battery, new
software, or new display; take out
of service,
Electric drive control
panel Check for damage Functional check O.K. No response Restart; contact control panel
manufacturer, new control panel
Tachometer Speed measurement O.K. Pedelec travelling 10% too
fast/slow
Shut off pedelec until source of
fault is found
Cabling Visual inspection O.K. Failure in system, damage,
kinked cables New cabling
Battery mount Firmly in position, lock,
contacts Functional check O.K. Loose; lock doesn't close,
no contacts New battery mount
Motor Visual inspection and
mount O.K. Damage, loose Refasten motor, contact motor
manufacturer, new motor
Software Check version In latest
version Not latest version Import update
Components Description Criteria Measures if rejected
Assembly/inspection Tests Accept-
ance
Rejection
Brake system Functional check O.K. No full braking; braking
distance too long
Locate defective part in brake
system and correct
Gear shift under
operating load
Functional check O.K. Problems when shifting
gear
Readjust gear shift
Suspension
components (fork,
shock absorber, seat
post)
Functional check O.K. Suspension too deep or no
longer exists
Locate defective component and
correct
Electric drive
Functional check O.K. Loose connection,
problems when riding,
accelerate
Locate defective part in electric
drive and correct
Light system Functional check O.K. No continuous light, too
bright
Locate defective part in light
system and correct
Test ride No strange
noises.
Strange noises. Locate source of noise and
correct
Date
Fitter's name:
Final inspection by workshop manager
Components Description Criteria Measures if rejected
MY20H02-12_1.0_12.06.2019 109
Documents
11.3 Maintenance log
Diagnosis and documentation of current status
Date: Frame number:
Components Frequency Description Criteria Measures if rejected
Inspection Tests Maintenance Accept-
ance
Rejection
Front wheel 6 months Assembly O.K. Loose Adjust quick release
Kickstand 6 months Check mount fastening Functional check O.K. Loose Retighten screws
Tyres 6 months Tyre pressure check O.K. Tyre pressure
too low/too high
Adjust tyre pressure
Frame 6 months Check for damage –
fracture, scratches
O.K. Damage
detected
Shut off pedelec; new frame
Handles, cover-
ings
6 months Wear; check if
fastened securely
O.K. Not provided Retighten screws, new
handles or coverings as
specified in parts list
Handlebars, stem 6 months
Check mount fastening O.K. Loose Retighten screws; new stem
as specified in parts list if
necessary
Steering headset 6 months Check for damage Functional check Lubricating and
adjustment
O.K. Loose Retighten screws
Saddle 6 months Check mount fastening O.K. Loose Retighten screws
Seat post 6 months Check mount fastening O.K. Loose Retighten screws
Protective plate 6 months Check mount fastening O.K. Loose Retighten screws
Pannier rack 6 months Check mount fastening O.K. Loose Retighten screws
Attachments 6 months Check mount fastening O.K. Loose Retighten screws
Bell 6 months Functional check O.K. No ring, too
quiet, missing
New bell as specified in the
parts list
Suspension elements
Fork, suspension
fork
To manu-
facturer`s
specifica-
tions
Check for damage –
corrosion, fracture
Maintenance as
specified by
manufacturer
Lubrication, oil change
as specified by
manufacturer
O.K. Damage
detected
New fork as specified in the
parts list
Rear frame
damper
To manu-
facturer`s
specifica-
tions
Check for damage –
corrosion, fracture
Maintenance as
specified by
manufacturer
Lubrication, oil change
as specified by
manufacturer
O.K. Damage
detected
New fork as specified in the
parts list
Suspension seat
post
To manu-
facturer`s
specifica-
tions
Check for damage Maintenance as
specified by
manufacturer
O.K. Damage
detected
New fork as specified in the
parts list
Brake system
Brake lever 6 months Check mount fastening O.K. Loose Retighten screws
Brake fluid 6 months
Check fluid level Depending on time of
year
O.K. Too little Top up brake fluid; take out
of service if damaged; new
brake hoses
Brake linings 6 months
Check brake linings,
brake discs or rims for
damage
O.K. Damage
detected
New brake linings, brake
discs or rims
Back-pedal brake
braking armature 6 months Check mount fastening O.K. Loose Retighten screws
Brake system 6 months Check mount fastening Functional check O.K. Loose Retighten screws
MY20H02-12_1.0_12.06.2019 110
Documents
Inspection Tests Maintenance Accept-
ance
Rejection
Light system
Rechargeable
battery
First examination O.K. Error message Contact battery
manufacturer; take out of
service, new battery
Light cabling Connections, correct
wiring
O.K. Cable defective,
no light
New cabling
Rear light
Side light Functional check O.K. No constant light New rear light as specified in
parts list; replace battery if
necessary
Front light
Side light, daytime
riding light
Functional check O.K. No constant light New front light as specified
in parts list; replace battery if
necessary
Reflectors All complete, state,
fastening
O.K. Damaged or not
all complete
New reflectors
Drive/gear shift
Chain/cassette/
pinion/chainring
Check for damage O.K. Damage Refasten if necessary or
replace as specified in parts
list
Chain guard/
spoke guard
Check for damage O.K. Damage Replace as specified in parts
list
Bottom bracket
axle/crank
Check mount fastening O.K. Loose Retighten screws
Pedals Check mount fastening O.K. Loose Retighten screws
Shifter Check mount fastening Functional check O.K. Loose Retighten screws
Shift cables Check for damage Functional check O.K. Loose or
defective
Adjust shift cables; new shift
cables if necessary
Front derailleur Check for damage Functional check O.K. Gear shift difficult
or not possible
Adjust
Rear derailleur Check for damage Functional check O.K. Gear shift difficult
or not possible
Adjust
Electric drive
Display
Check for damage Functional check O.K. No screen
display, defective
screen display
Restart, test battery, new
software, or new display;
take out of service,
Electric drive con-
trol panel
Check drive for
damage
Functional check O.K. No response Restart; contact control
panel manufacturer, new
control panel
Tachometer
Speed measurement O.K. Pedelec
travelling 10%
too fast/slow
Shut off pedelec until source
of fault is found
Cabling
Visual inspection O.K. Failure in
system, damage,
kinked cables
New cabling
Battery mount
Firmly in position, lock,
contacts
Functional check O.K. Loose; lock
doesn't close, no
contacts
New battery mount
Motor
Visual inspection and
mount
O.K. Damage, loose Refasten motor, contact
motor manufacturer, new
motor; take out of service
Software Check version In latest
version
Not latest version Import update
Components Frequency Description Criteria Measures if rejected
MY20H02-12_1.0_12.06.2019 111
Documents
Technical inspection, checking safety, test ride
Components Description Criteria Measures if rejected
Assembly/inspection Tests Accept-
ance
Rejection
Brake system Functional check O.K. No full braking; braking
distance too long
Locate defective part in brake
system and correct
Gear shift under operat-
ing load
Functional check O.K. Problems when shifting
gear
Readjust gear shift
Suspension compo-
nents (fork, shock
absorber, seat post)
Functional check O.K. Suspension too deep or no
longer exists
Locate defective component and
correct
Electric drive
Functional check O.K. Loose connection,
problems when riding,
accelerate
Locate defective part in electric
drive and correct
Light system Functional check O.K. No continuous light, too
bright
Locate defective part in light
system and correct
Test ride No strange
noises.
Strange noises. Locate source of noise and
correct
Date
Fitter's name:
Final inspection by workshop
manager
MY20H02-12_1.0_12.06.2019 112
Documents
11.4 Charger operating instructions
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Documents
eBike Battery Charger 36-6/230
0 275 007 918
Li-Ion
Use ONLY with BOSCH Li-Ion batteries
Input: 230V 50Hz 2.15A
Output: 36V 6A
Made in Vietnam
Robert Bosch GmbH, Reutlingen
Fast Charger BCS250
eBike Battery Charger 36-4/230
0 275 007 907
Li-Ion
Use ONLY with BOSCH Li-Ion batteries
Input: 230V 50Hz 1.5A
Output: 36V 4A
Made in PRC
Robert Bosch GmbH, Reutlingen
Standard Charger BCS220
Standard Charger
Fast Charger
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"""!"1!D1? 
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"#4'(+'+*(4
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D"!!"!"? 
!$:"" "!"!D "
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#""#$1D" !
&'4M'(+('O*'('''
(+3'
""#"D"$"
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MY20H02-12_1.0_12.06.2019 119
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MY20H02-12_1.0_12.06.2019 120
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MY20H02-12_1.0_12.06.2019 121
Keyword index
12 Keyword index
A
Air chamber, 22
Air valve
Fork, 21
Rear frame damper, 22
Alternative, 11
B
Back-pedal brake,
-braking, 86
Battery level indicator, 36
Battery, 26
- charging, 77
- checking, 45
- disposing of, 105
- removing, 76, 78
- waking, 79
Belt tension, 99
Brake arm, 22
Brake calliper, 23
Brake disc, 23
Brake lever, 36
- adjusting the pressure point 60
Brake lining, 22, 23
- maintaining, 98
Brake,
- using the transport securing
system, 42
Break in operation, 43
- carrying out, 43
- preparing, 43
Button,
Info (control panel), 36
Info (display), 28
Minus, 36
On-Off (battery), 27
On-Off (display), 28
Plus, 36
Push assist, 36
RESET, 28
Riding light, 28
C
Chain drive, 25
Chain guard,
- checking, 71
Chain tension, 99
Chain wheel, 25
Chain, 19, 25
- maintaining, 99
Charger,
- disposing of, 105
Clamping force,
- Checking the quick releases, 47
- Setting the quick releases, 47
Control panel, 36
D
Direction of travel, 25
Display, 27
- attaching, 81
- removing, 81
Down tube battery,
- removing, 76, 78
Drive system, 25
- switching off, 80
- switching on, 80
E
EC declaration of conformity, 126
F
Fork lock,
Position, 21
Fork, 20
- setting the compression damper,
90
Fork end, 20
Setting the rebound damper, 89
structure, 21
Frame, 19
Front wheel brake, 22, 23
- braking, 85
Front wheel, see Wheel
G
Gear recommendation, 38
Gear shift twist grip, 36
- checking, 99
Gear shift,
- maintaining, 99
- switching, 90
H
Handlebars, 19, 36
Headlight, 25
Hub, 20
I
Info button (display), 28
Info button, 36
Initial commissioning 45
J
Journey information, 38
- resetting, 83
- switching, 83
Avg. speed, 38
Clock, 38
Max. speed, 38
Odometer, 38
Range, 38
Trip distance, 38
Trip Time, 38
L
Level of assistance, 36, 37
- selecting, 83
ECO, 37
OFF, 37
SPORT, 37
TOUR, 37
TURBO, 37
Lever, 22
M
Minimum insertion depth marking, 58
Minus button, 36
Model year, 12
Motor, 25
Mudguards,
- checking, 71
O
On-Off button,
Battery, 27
Display, 28
On-screen indicator, 36, 70
Operating status indicator, 36
O-ring, 22
P
Packaging, 44
Pannier rack, 19
- changing, 74
- checking, 71
- using, 74
Parts list, 126
Pedal, 23, 25
Plus button, 36
Push assist button, 36
Push assist,
- using, 82
Q
Quick release, 20
Position, 21
R
Rear frame damper,
structure, 22
Rear light, 25
Rear wheel brake, 23
Rebound damper adjuster,
Position, 21
RESET button, 28
Retainer guard, 27
Riding light button, 28
Riding light, 28
- checking function, 71
Rim brake locking lever 23
Rim, 20
- checking, 97
Roller brake,
-braking, 86
S
Saddle, 19
- changing the saddle tilt, 57
- changing the seat length, 58
- determining the saddle height, 57,
58
Seat post, 19
Securing hook, 27
Setting wheel, 22
Shifter,
- checking, 99
- setting, 101
Spoke, 20
Storage, 42
Storing, see Storage
Suspension head, 20
System message, 40, 54
System setting, 39
- changing, 83
changeable, 38, 39, 40, 83
System data, 39
T
Total journey duration, 39
Transportation, 41
Transporting, see Transportation
Type number, 12
Tyres, 20
- checking, 97
MY20H02-12_1.0_12.06.2019 122
Keyword index
U
USB port, 28
- using, 82
Using 91
V
Valve cap, 21
Valve, 20
Dunlop valve, 20
Presta valve, 20
Schrader valve, 20
W
Weight,
permitted total weight, 12
Wheel,
- maintaining, 97
Winter break, see Break in operation
MY20H02-12_1.0_12.06.2019 123
Glossary
13 Glossary
Brake lever
Source: EN 15194:2017: lever used to apply the
brake
Braking distance
Source: EN 15194:2017: distance travelled by a
pedelec between the commencement of braking
and the point at which the pedelec comes to rest
Cargo bike
Source: DIN 79010: bicycle mainly designed to
carry goods.
CE marking
Source: Directive 2006/42/EC on Machinery: the
manufacturer uses the CE marking to declare that
the Pedelec complies with the applicable
requirements.
City and trekking bicycles
Source: EN-ISO 4210 - 2: pedelec designed for
use on public roads primarily for means of
transportation or leisure.
Consumables
Source: EN 82079-1: any part or material that is
necessary for continued use or maintenance of
the product
Decommissioning
Source: DIN 31051: intentional, unlimited
interruption in an object's functional capability.
Disc brake
Source: EN 15194:2017: brake in which brake
pads are used to grip the lateral faces of a thin
disc attached to or incorporated in the wheel hub
Drive belt
Source: EN 15194:2017: seamless ring belt which
is used as a means of transmitting motive force.
Electrical control system
Source: EN 15194:2017: electronic and/or
electrical component, or an assembly of
components provided for installation into a
vehicle, together with all electrical connections
and associated wiring for the motor electrical
power assistance
Electrically power assisted cycle, pedelec
Source: EN 15194:2017: electrically power
assisted cycle, equipped with pedals and an
auxiliary electric motor, which cannot be propelled
exclusively by means of the auxiliary electric
motor, except in start-up assistance mode
Fault
Source: EN 13306:2018-02, 6.1: state of an item
(4.2.1) characterized by inability to perform a
required function (4.5.1), excluding the inability
during preventive maintenance or other planned
actions, or due to lack of external resources
Folding bicycle
Source: EN-ISO 4210-2: bicycle designed to fold
into a compact form, facilitating transport and
storage.
Fork steerer
Source: EN 15194:2017: part of a fork that rotates
about the steering axis of a bicycle frame head
tube. It is normally connected to the fork crown or
directly to the fork legs, and is normally the point
of connection between the fork and the handlebar
stem.
Fracture
Source: EN 15194:2017: unintentional separation
into two or more parts
Instruction handbook
Source: ISO/FDIS 20607:2018: part of the user
information that machine manufacturers provide
to machine operators; it contains guidance,
instructions and tips related to the use of the
machine in all its life cycle phases
Maintenance
Source: DIN 31051: maintenance is generally
performed at regular intervals and often carried
out by trained technical staff. This ensures a
maximum service life and low wear and tear for
the maintained items. Proper maintenance is
often also a pre-requisite for providing a warranty.
MY20H02-12_1.0_12.06.2019 124
Glossary
Maximum continuous power
Source: ZEG: the maximum continuous power is
the maximum power for the electric motor output
shaft during 30 minutes.
Maximum saddle height
Source: EN 15194:2017: vertical distance from
the ground to the point where the top of the seat
surface is intersected by the seat-post axis,
measured with the saddle in a horizontal position
and with the seat-post set to the minimum
insertion-depth mark
Maximum tyre pressure
Source: EN 15194:2017: maximum tyre pressure
recommended by the tyre or rim manufacturer for
a safe and efficient performance. If the rim and
tyre both indicate a maximum tyre pressure, the
maximum inflation pressure is the lower of the two
pressures indicated.
Minimum insertion depth mark
Source: EN 15194:2017: mark indicating the
minimum insertion-depth of handlebar stem into
fork steerer (fork stem) or seat post into frame
Model year
Source: ZEG: the model year refers to the first
production year that the series-manufactured
pedelec was manufactured in the version in
question and is not always identical with the year
of manufacture. The year of manufacture may be
before the model year in some cases. If no
technical modifications are introduced to the
series, production may continue of pedelecs from
a previous model year.
Mountain bike
Source: EN-ISO 4210-2: bicycle designed for use
off-road on rough terrain, on public roads, and on
public pathways, equipped with a suitably
strengthened frame and other components, and,
typically, with wide-section tyres with coarse tread
patterns and a wide range of transmission gears.
Off-road rough terrain
Source: EN 15194:2017: coarse pebble tracks,
forest trails, and other general off-road tracks
where tree roots and rocks are likely to be
encountered
Permitted total weight
Source: EN 15194:2017: weight of the fully
assembled pedelec plus the rider and baggage,
as specified by the manufacturer
Quick-release device, quick release
Source: EN 15194:2017: lever actuated
mechanism that connects, retains or secures a
wheel or any other component
Racing bicycle
Source: EN-ISO 4210-2: bicycle intended for high-
speed amateur use on public roads having a
steering assembly with multiple grip positions
allowing for an aerodynamic posture, a multi-
speed transmission system, tyre width not greater
than 28 mm and a maximum mass of 12 kg for the
fully assembled bicycle.
Seat post
Source: EN 15194:2017: component that clamps
the saddle (with a bolt or assembly) and connects
it with the frame
Shut-off speed
Source: EN 15194:2017: speed reached, by the
pedelec, at the moment the current has dropped
to zero or to the no load current value.
Spare part
Source: EN 13306:2018-02, 3.5: item intended to
replace a corresponding item in order to retain or
maintain the original required function of the item
Suspension fork
Source: EN 15194:2017: front fork incorporating
controlled, axial flexibility to reduce the
transmission of road-shocks to the rider
Suspension frame
Source: EN 15194:2017: frame incorporating
controlled, vertical flexibility to reduce the
transmission of road-shocks to the rider
Type number
Source: ZEG: all pedelec models have an eight-
digit type number which is used to specify the
design model year, the type of pedelec and the
version.
MY20H02-12_1.0_12.06.2019 125
Glossary
Wear
Source: DIN 31051: reduction in useful life (4.3.4),
caused by chemical and/or physical processes.
Weight of ready-to-ride bicycle
Source: ZEG: the indicated weight for a ready-to-
ride bicycle refers to the weight of a pedelec at the
time of sale. The weight of each additional
accessory must be added to this weight.
Wheel
Source: EN 15194:2017: assembly or
combination of hub, spokes or disc, and rim, but
excluding tyre assembly
Work environment
Source: EN ISO 9000:2015: set of conditions
under which work is performed.
Year of manufacture
Source: ZEG: the year of manufacture is the year
in which the Pedelec was manufactured. The
production period is always from August to July of
the following year.
Young adult bicycle
Source: EN-ISO 4210-2: bicycle designed for use
on public roads by a young adult whose weight is
less than 40 kg, with maximum saddle height of
635 mm or more and less than 750 mm. (see
ISO 4210)
MY20H02-12_1.0_12.06.2019 126
Appendix
I. EC declaration of conformity
Translation of the original EC declaration of conformity
The manufacturer:
HERCULES GMBH
Longericher Straße 2
50739 Köln, Germany
hereby declares that the electrically power assisted cycles of types:
20-P-0001, 20-P-0002, 20-P-0003, 20-P-0004, 20-P-0005, 20-P-0006, 20-P-0007,
20-P-0008, 20-P-0009, 20-P-0010, 20-P-0011, 20-P-0012, 20-P-0013, 20-Q-0001,
20-Q-0003, 20-Q-0004, 20-Q-0006, 20-Q-0007, 20-Q-0009, 20-Q-0010, 20-Q-0011,
20-Q-0012, 20-Q-0013, 20-Q-0014, 20-Q-0015, 20-Q-0016, 20-Q-0017, 20-Q-0018,
20-Q-0018, 20-Q-0019, 20-Q-0020, 20-Q-0021, 20-Q-0040, 20-Q-0041, 20-Q-0043,
20-Q-0044, 20-Q-0045, 20-Q-0046, 20-Q-0047, 20-Q-0048, 20-Q-0049, 20-Q-0050,
20-Q-0051, 20-Q-0052, 20-Q-0054, 20-Q-0057, 0-Q-0058, 20-Q-0059, 20-Q-0060,
20-Q-0063, 20-Q-0064, 20-Q-0066, 20-Q-0068, 20-Q-0069, 20-Q-0080, 20-Q-0081,
20-Q-0082, 20-Q-0090, 20-X-0001, 20-Y-0002, 20-Y-0003, 0-Y-0007, 20-Y-0008,
20-Y-0009, 20-Y-0010, 20-Y-0011
Year of manufacture 2019 and year of manufacture 2020
comply with all applicable requirements of Machinery Directive 2006/42/EC.
Furthermore, the electrically power assisted cycles comply with all applicable basic
requirements of Electromagnetic Compatibility Directive 2014/30/EU.
The following standards were applied: ISO/DIS 20607:2018 Safety of machinery –
Instruction handbook – General drafting principle; EN 15194:2018 Cycles –
Electrically power assisted cycles – EPAC bicycles and EN 11243:2016 Cycles –
Luggage carriers for bicycles – Requirements and test methods.
Ms. Janine Otto (Technical Editor), c/o HERCULES GMBH, Longericher Straße 2,
50739 Köln, Germany, is authorised to compile the technical documentation.
Cologne, 06/05/2019
…………………………………………………………………………………………………
Place, date and signature
Georg Honkomp
-Managing Director-
1 …

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