761786

Hercules Panasonic Pedelec 2020 Handleiding

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Panasonic Pedelecs
Intero I-R8 ZR 28" 8G, Intero I-8 ZR 28" 8G
20-Q-0055, 20-Q-0056
MY20H08-2 • 1.0 • 30. August 2019
TRANSLATION OF THE ORIGINAL OPERATING INSTRUCTIONS
IMPORTANT
READ CAREFULLY BEFORE USE
KEEP SAFE TO CONSULT AT A LATER DATE
MY20H08-2_1.0_27.08.2019 2
Contents
Contents
1 About these operating instructions 5
1.1 Manufacturer 5
1.2 Type number and model 5
1.3 Identifying the operating instructions 5
1.4 Laws, standards and directives 6
1.5 Subject to change 6
1.6 Language 6
1.7 For your safety 6
1.7.1 Instruction, training and customer service 6
1.7.2 Basic safety instructions 6
1.7.3 Warnings 6
1.7.4 Safety markings 7
1.8 For your information 7
1.8.1 Information on the nameplate 7
1.9 Nameplate 8
2 Safety 9
2.1 General warnings 9
2.2 Toxic substances 10
2.3 Requirements for the rider 11
2.4 Vulnerable groups 12
2.5 Data privacy 12
2.6 Personal protective equipment 12
2.7 Safety markings and safety instructions 12
2.8 Emergency 12
2.8.1 What to do in an emergency 12
2.8.2 First aid treatment 13
2.8.3 Fighting fire 13
2.8.4 Leaking fluids 13
2.8.4.1 Brake fluid 13
2.8.4.2 Oils and lubricants from the fork 13
2.8.4.3 Oils and lubricants from the rear frame
damper 13
3Overview 14
3.1 Description 15
3.1.1 Wheel and suspension 15
3.1.1.1 Valve 15
3.1.2 Suspension 15
3.1.2.1 Steel suspension fork structure 16
3.1.2.2 Air suspension fork structure 16
3.1.2.3 Structure of the FOX rear frame damper 17
3.1.2.4 Structure of the Suntour rear frame
damper 17
3.1.3 Brake system 17
3.1.3.1 Rim brake 17
3.1.3.2 Disc brake 18
3.1.3.3 Back-pedal brake 18
3.1.4 Electric drive system 19
3.1.5 Rechargeable battery 20
3.1.6 Riding light 20
3.1.7 Control panel 20
3.1.8 Display 21
3.2 Proper use 22
3.3 Improper use 23
3.4 Technical data 24
3.4.1 Pedelec 24
3.4.2 Panasonic GX Power Motor 24
3.4.3 Panasonic TP-PCT rechargeable
battery 24
3.4.4 USB port 24
3.4.5 Display 24
3.4.6 Control device 24
3.4.7 Emissions 24
3.4.8 Tightening torque 24
3.5 Description of controls and screens 25
3.5.1 Handlebars 25
3.5.2 Display 25
3.5.2.1 Current speed 25
3.5.2.2 Battery level indicator 25
3.5.2.3 Level of assistance 26
3.5.2.4 Function display 26
3.5.2.5 Journey information 26
3.5.2.6 System settings and data 26
3.5.2.7 System message 26
3.5.3 Control panel 26
3.6 Environmental requirements 27
4 Transporting and storing 29
4.1 Physical transport characteristics 29
4.1.1 Dimensions during transportation 29
4.1.2 Transport weight 29
4.1.3 Designated handles/lifting points 29
4.2 Transporting 29
4.2.1 Transporting the battery 30
4.2.2 Shipping the battery 30
4.2.3 Using the brake transport securing
system 30
4.3 Storing 30
4.3.1 Break in operation 31
4.3.1.1 Preparing a break in operation 31
4.3.1.2 Taking out of operation 31
5 Assembly 32
5.1 Required tools 32
5.2 Unpacking 32
5.2.1 Scope of delivery 32
5.3 Commissioning 33
5.3.1 Checking the battery 33
5.3.2 Initial use of the display 33
5.3.3 Installing the wheel in the Suntour fork 34
5.3.3.1 Installing the wheel with screw-on axle
(15 mm) 34
5.3.3.2 Installing the wheel with screw-on axle
(20 mm) 35
5.3.3.3 Installing the wheel with a quick release
axle 35
MY20H08-2_1.0_27.08.2019 3
Contents
5.3.4 Installing the wheel with a quick release 37
5.3.5 Installing the wheel in the FOX fork 38
5.3.5.1 Wheel with quick release (15 mm) 38
5.3.5.2 Adjusting the FOX quick release 38
5.3.5.3 Installing the wheel with Kabolt axles 39
5.3.5.4 Checking the stem and handlebars 39
5.3.6 Pedelec sale 39
6Operation 40
6.1 Risks and hazards 40
6.1.1 Tips for a greater range 41
6.1.2 Personal protective equipment 41
6.2 Error messages 42
6.2.1 Error message display 42
6.3 Instruction and customer service 43
6.4 Adjusting the pedelec 43
6.4.1 Adjusting the saddle 43
6.4.1.1 Adjusting the saddle tilt 43
6.4.1.2 Determining the seat height 43
6.4.1.3 Adjusting the seat height with quick
release 44
6.4.1.4 Height-adjustable seat post 44
6.4.1.5 Adjusting the seat position 45
6.4.2 Adjusting the handlebars 45
6.4.2.1 Adjusting the stem 45
6.4.2.2 Adjusting the height of the handlebars 45
6.4.2.3 Adjusting the quick release clamping
force 46
6.4.3 Adjusting the brake lever 46
6.4.3.1 Adjusting the pressure point on a
Magura brake lever 46
6.4.3.2 Adjusting the grip distance 46
6.4.3.3 Adjusting the grip distance on a
Magura brake lever 47
6.4.4 Adjusting Suntour fork 47
6.4.4.1 Adjusting the negative deflection 47
6.4.4.2 Adjusting the steel suspension fork
negative deflection 48
6.4.4.3 Adjusting the air suspension fork
negative deflection 48
6.4.4.4 Adjusting the air suspension fork
rebound 49
6.4.5 Adjusting the FOX fork 49
6.4.5.1 Adjusting the negative deflection 49
6.4.5.2 Adjusting the rebound 50
6.4.6 Setting the Suntour rear frame damper 51
6.4.6.1 Adjusting the negative deflection 51
6.4.6.2 Adjusting the rebound 51
6.4.6.3 Setting the compression 51
6.4.7 Setting the FOX rear frame damper 52
6.4.7.1 Adjusting the negative deflection 52
6.4.7.2 Adjusting the rebound 52
6.4.8 Retracting the brake linings 53
6.5 Accessories 54
6.5.1 Child seat 54
6.5.2 Bicycle trailers 55
6.5.3 Pannier rack 55
6.6 Before each ride 56
6.7 Check list before each ride 56
6.8 Using the kickstand 57
6.8.1 Raising the kickstand 57
6.8.1.1 Parking the pedelec 57
6.9 Using the pannier rack 57
6.10 Rechargeable battery 58
6.10.1 Removing the battery 59
6.10.2 Inserting the battery 59
6.10.3 Charging the battery 59
6.10.4 Waking the battery 60
6.11 Electric drive system 61
6.11.1 Switching on the electric drive system 61
6.11.2 Switching off the drive system 61
6.12 Display 62
6.12.1 Removing and attaching the display 62
6.12.1.1 Attaching the display 62
6.12.2 Securing the display against removal 62
6.12.2.1 Removing the display 63
6.12.3 Using the USB port 63
6.12.4 Using the push assist system 64
6.12.5 Using the riding light 64
6.12.6 Using night mode 64
6.12.7 Selecting the level of assistance 64
6.12.8 Journey information 65
6.12.8.1 Changing the displayed journey
information 65
6.12.8.2 Resetting the journey information 65
6.12.9 Changing the system settings 65
6.12.9.1 Changing the language 65
6.12.9.2 Changing the display contrast 65
6.12.9.3 Changing the brightness 66
6.12.9.4 Changing the unit of measure for speed 66
6.12.9.5 Setting information on the tyre size 66
6.12.9.6 Changing the distance travelled 66
6.12.9.7 Setting the clock 67
6.12.10 Replacing the battery 67
6.13 Brake 68
6.13.1 Using the brake lever 69
6.13.2 Using the back-pedal brake 70
6.14 Suspension and damping 70
6.14.1 Adjusting the compression of the
Fox fork 70
6.14.2 Adjusting the compression of the
Fox damper 70
6.14.3 Adjusting the compression of the
Suntour fork 71
MY20H08-2_1.0_27.08.2019 4
Contents
6.14.4 Adjusting the compression of a
Suntour damper 71
6.14.5 Adjusting the rebound in a Rock
Shox damper 71
6.14.6 Adjusting the compression in a
Rock Shox damper 72
6.15 Gear shift 72
6.15.1 Selecting gears 72
6.15.2 Using the hub gear 73
7 Cleaning and servicing 74
7.1 Cleaning after each ride 74
7.1.1 Cleaning the suspension fork 74
7.1.2 Cleaning the rear frame damper 74
7.1.3 Cleaning the pedals 74
7.2 Basic cleaning 75
7.2.1 Cleaning the frame 75
7.2.2 Cleaning the stem 75
7.2.3 Cleaning the wheel 75
7.2.4 Cleaning the drive elements 75
7.2.5 Cleaning the rear frame damper 76
7.2.6 Cleaning the chain 76
7.2.7 Cleaning the battery 76
7.2.8 Cleaning the display 76
7.2.9 Cleaning the drive unit 76
7.2.10 Cleaning the brake 77
7.3 Servicing 77
7.3.1 Servicing the frame 77
7.3.2 Servicing the stem 77
7.3.3 Servicing the fork 77
7.3.4 Servicing the drive elements 77
7.3.5 Servicing the pedals 77
7.3.6 Servicing the chain 77
7.3.7 Servicing the drive elements 77
7.4 Maintenance 77
7.4.1 Wheel 77
7.4.1.1 Checking the tyres 78
7.4.1.2 Checking the rims 78
7.4.1.3 Checking and adjusting the tyre
pressure – Dunlop valve 78
7.4.1.4 Checking and adjusting the tyre
pressure – presta valve 78
7.4.1.5 Checking and adjusting the tyre
pressure – Schrader valve 79
7.4.2 Brake system 79
7.4.3 Checking the brake linings for wear 79
7.4.4 Checking the pressure point 79
7.4.5 Checking the brake discs for wear 79
7.4.6 Electrical cables and brake cables 79
7.4.7 Gear shift 79
7.4.8 Stem 80
7.4.9 USB port 80
7.4.10 Checking the belt and chain tension 80
8 Maintenance 81
8.1 Axle with quick release 82
8.1.1 Checking the quick release 82
8.2 Adjusting the gear shift 82
8.2.1 Cable-operated gear shift,
single-cable 83
8.2.2 Cable-operated gear shift,
dual-cable 83
8.2.3 Cable-operated twist grip,
dual-cable 83
9 Troubleshooting, fault clearance
and repair 84
9.1 Troubleshooting and fault clearance 84
9.1.1 The drive system or display do not
start up 84
9.1.2 Error messages 84
9.2 Switching on 85
9.3 Assistance function 85
9.4 Rechargeable battery 86
9.5 Lighting 87
9.6 Display 88
9.7 Miscellaneous 88
9.8 Repair 89
9.8.1 Use original parts and lubricants only 89
9.8.2 Replacing the lighting 89
9.8.3 Adjusting the headlight 89
10 Recycling and disposal 90
11 Documents 91
11.1 Parts list 91
11.2 Assembly report 92
11.3 Maintenance log 94
12 Keyword index 97
13 Glossary 98
13.1 Abbreviations 100
13.2 Simplified terms 100
I. EC declaration of conformity 101
MY20H08-2_1.0_30.08.2019 5
About these operating instructions
1 About these operating instructions
Thank you for your trust!
HERCULES pedelecs are premium quality
bicycles. You have made an excellent choice.
Your specialist dealer will provide you with
guidance and assemble your product. Your
specialist dealer will also be happy to assist you in
the future whether you require maintenance,
conversion or repair.
You receive these operating instructions with your
new pedelec. Please take 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 to ensure that non-
professionals can use the pedelec safely.
Download the operating
instructions onto your phone at
the following link, 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:
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.
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. Information
for specialist staff does not require non-
professionals to take any action.
Type no. Model Pedelec type
20-Q-0055 Intero I-R8 ZR 28"
600Wh 8G
City and trekking
bicycle
20-Q-0055 Intero I-R8 ZR 28"
500Wh 8G
City and trekking
bicycle
20-Q-0055 Intero I-R8 ZR 28"
400Wh 8G
City and trekking
bicycle
20-Q-0056 Intero I-8 ZR 28"
600Wh 8G
City and trekking
bicycle
20-Q-0056 Intero I-8 ZR 28"
600Wh 8G
City and trekking
bicycle
20-Q-0056 Intero I-8 ZR 28"
600Wh 8G
City and trekking
bicycle
Table 1: Type number, model and pedelec type
Identification number MY20H08 - 1_1.0_30.08.2019
Table 2: Identification number
MY20H08-2_1.0_30.08.2019 6
About these operating instructions
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 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
• ISO 17100:2016-05 Translation Services –
Requirements for translation services.
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:
https://www.hercules-bikes.de/de/de/index/
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
maintenance and repair by the specialist dealer
• the section on general safety
• the warnings in these operating instructions
• the safety marking on the nameplate.
1.7.1 Instruction, training and customer
service
The supplying specialist dealer will provide
customer service. Contact details can be found on
the pedelec pass for these operating instructions.
If you are unable to contact your specialist dealer,
you will find other specialist dealers online at
www.hercules-bikes.de.
The rider or owner will be instructed in person on
the pedelec's functions. Instruction will be given
when the supplying specialist dealer hands over
the pedelec at the latest.
Each rider who receives this bicycle must receive
instruction on all pedelec functions. A copy of
these operating instructions must be provided to
each rider.
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:
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
!
MY20H08-2_1.0_30.08.2019 7
About these operating instructions
1.7.4 Safety markings
The following safety markings are used on the
pedelec's nameplates:
1.8 For your information
Instructions for actions are structured in
accordance with the following pattern:
Requirements (optional)
Instruction for action (individual)
1Instruction for action (in specified order)
Result of the action (optional)
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:
1.8.1 Information on the nameplate
Besides warnings, product nameplates also
contain other important information about the
pedelec:
General warning
Adhere to the instructions for use
Table 3: Meaning of safety markings
Term Meaning
Operating
instructions
Original operating
instructions
Motor Drive motor, sub-system
Convention Use
Italics Glossary term
underlined Links and cross
references in the
document
SPACED Indicators on the display
screen
• Bulleted lists
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
MY20H08-2_1.0_30.08.2019 8
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
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 10.
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 the ready-to-ride pedelec The indicated weight for a ready-to-ride pedelec refers to the weight at the time of
purchase. 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.
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
MY20H08-2_1.0_30.08.2019 9
Safety
2 Safety
2.1 General warnings
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.
If the battery becomes deformed or begins to
smoke, keep at a safe distance and disconnect
the power supply at the socket.
Contact the fire service immediately.
Never extinguish a damaged battery with
water or allow it to come into contact with
water.
If the battery is dropped or struck but shows no
signs of external damage, remove it from
service and observe it for at least 24 hours.
Batteries with external damage must be
removed from service immediately.
Faulty batteries are hazardous goods.
Dispose of faulty batteries properly and as
quickly as possible.
Store battery in a dry place until disposal.
Never store in the vicinity of flammable
substances.
Never open or repair the battery.
Only use and charge the battery and
accessories if they are in perfect condition.
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.
WARNING
!
CAUTION
!
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 use batteries approved for the pedelec.
Mark the supplied charger clearly to prevent
mix-ups – with the frame number or type
number, for example.
Risk of fire and explosion due to penetration by
water
The battery is only protected from 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
Temperatures over 60 °C can also cause liquid to
leak from the battery and the battery will become
damaged. The battery may self-ignite and
explode.
Protect the battery against heat.
Never store next to hot objects.
Never expose the battery to sustained direct
sunlight.
Avoid wide temperature fluctuations.
CAUTION
!
MY20H08-2_1.0_30.08.2019 10
Safety
2.2 Toxic substances
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.
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.
CAUTION
!
DANGER
!
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. Immediately consult a doctor in
case of any discomfort.
After skin contact
Wash affected skin with soap and water and
rinse well. Remove contaminated clothing.
Consult doctor in the event of 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.
Immediately consult a doctor in case of any pain
or discomfort.
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.
MY20H08-2_1.0_30.08.2019 11
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.
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. Excessive temperatures can also
cause liquid to leak from the battery and the
battery will become damaged. They can irritate
the airways and cause burns.
Avoid contact with leaked liquids.
Take in fresh air. Consult doctor in the event of
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.
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. Contact
your specialist dealer.
WARNING
!
CAUTION
!
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.
Dispose of leaking brake fluid in an
environmentally responsible way in
accordance with statutory regulations. Contact
your specialist dealer.
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.
Dispose of leaked oils and lubricants in an
environmentally responsible way in
accordance with statutory regulations. Contact
your specialist dealer.
CAUTION
!
MY20H08-2_1.0_30.08.2019 12
Safety
2.4 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 use the pedelec, comprehensive
instruction should be provided by or in the
presence of the legal guardians. Supervised use
should also be scheduled until 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)
regarding 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:
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.
Symbol Explanation
General warning
Adhere to the instructions for use
Table 5: Meaning of safety markings
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
max. 50°C
MY20H08-2_1.0_30.08.2019 13
Safety
2.8.2 First aid treatment
Consult a doctor immediately in the event of
any pain or discomfort caused by combustion
gas or leaking fluids.
After inhalation
Vapours may emit if the battery is damaged or
used improperly The vapours may cause
respiratory tract irritation.
Get into fresh air.
Consult doctor in the event of pain or
discomfort.
After contact with eyes
Rinse eyes with plenty of water for at least
15 minutes. Protect unaffected eye. Seek
medical advice immediately.
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, pain or discomfort.
After swallowing
Drink plenty of milk or water and induce
vomiting.
Seek medical advice immediately.
2.8.3 Fighting fire
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.
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.
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.
Dispose of leaking brake fluid in an
environmentally responsible way in
accordance with statutory regulations. Contact
your specialist dealer.
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.
Dispose of leaking brake fluid in an
environmentally responsible way in
accordance with statutory regulations. Contact
your specialist dealer.
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. Contact
your specialist dealer.
Intoxication
Inhaling vapours can cause
intoxication.
Stand on the side of the fire
where the wind is blowing from.
Use breathing apparatus if
possible.
WARNING
!
MY20H08-2_1.0_27.08.2019 14
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
hellgrün-glänzend
1
2
3
4
5
6
7
8
9
10
11
12
13 14 15 16 17
MY20H08-2_1.0_30.08.2019 15
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.
12
MY20H08-2_1.0_30.08.2019 16
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 vehicle'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
8
9
7
A
B
C
1
2
3
4
5
A
B
C
MY20H08-2_1.0_30.08.2019 17
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
MY20H08-2_1.0_30.08.2019 18
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 pushed 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 pushed, 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
MY20H08-2_1.0_27.08.2019 19
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.
You can ride the pedelec like a normal bike at any
time, either by switching off the electric drive
system or changing the level of assistance to Off.
The same applies when the battery is empty.
Figure 13: Diagram of 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 in addition to its drive system propelled by
muscle power. The electric drive system is made
up of 7 components:
Figure 14: Diagram of electric drive system
1Headlight
2Display
3Operating element
4 Rechargeable battery
5 Rear light
6Motor
7 A charger 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 assistance depends
on the force applied to the pedals by the rider.
Drive system assistance is therefore only
activated when the rider pedals. This applies
irrespective of the selected level of assistance.
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. If the speed falls below 25 km/h, the
assistance is automatically activated again.
The motor provides five levels of assistance:
HIGH, STANDARD, ECO, NO ASSIST and OFF.
The following diagram indicates the motor power
when setting off (1) on a flat road (2/5), uphill (3)
and downhill (4) when different levels of
assistance are selected.
5
2
3
4
1
B
3
1
2
4
5
Symbol Power assistance
Strong
Medium
Low
off
Table 6: On-screen indicators overview
HIGH
STANDARD
ECO
NO ASSIST
AUTO
12 3 4 5
MY20H08-2_1.0_27.08.2019 20
Overview
Power assistance may vary depending on the
weather, road conditions, condition of the pedelec
or riding style.
A push assist system can be activated. The push
assist continues to drive the pedelec as long as
the rider pushes the plus button on the handlebars.
The speed can be a maximum of 6 km/h in this
case.
3.1.5 Rechargeable battery
The lithium ion 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. 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. The battery also
switches to sleep mode for self-protection when
not used for a longer period. The battery's service
life can be extended if it is well maintained and,
above all, 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.
Three different types of pannier rack batteries can
be fitted:
Figure 15: Details of TP-SMN-01-35Su
1 Charging port
2 Port for charger plug
3 Battery level indicator
4 On/off switch
Battery level indicator
The four LEDs on the rechargeable battery
indicate the charge level. Each LED represents
25% of the charge level. The charge level for the
activated battery is also shown on the display
screen.
3.1.6 Riding light
When the riding light is activated, the headlight
and the rear light are switched on.
3.1.7 Control panel
The rider controls the drive system on the control
panel. The pedelec's battery powers the control
panel when a sufficiently charged battery is
inserted into the pedelec and the drive system is
switched on.
Transportation temperature 5°C - 25°C
Ideal transportation temperature 10 °C - 15 °C
Storage temperature 5°C - 25°C
Ideal storage temperature 10 °C - 15 °C
Charging ambient temperature 10 °C - 30 °C
Table 7: Rechargeable battery technical data
TP-PCT 417 TP-PCT 504 TP-PCT 600
Table 8: Overview of frame batteries
Storage temperature 5°C - 25°C
Charging ambient temperature -10 °C - +60 °C
Table 9: Control panel technical data
1
2
3
4
MY20H08-2_1.0_27.08.2019 21
Overview
The control panel features 5 buttons.
Figure 16: Details of control panel
3.1.8 Display
The display screen shows all ride data. The
display has one button and a USB port.
Figure 17: On-Off button (1) and USB port (2) on the
display
Figure 18: Display rear with battery compartment (1) and
reset button (2)
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. The display also
features a battery, so that it can also be operated
separately from the drive system.
1
2
3
4
5
1
2
MY20H08-2_1.0_27.08.2019 22
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 usage 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 suita-
ble 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 instruc-
tions must be com-
municated to the
riders in an age-
appropriate manner.
The cycles for chil-
dren 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 maxi-
mum permitted total
weight is being
observed.
Mountain bikes are
designed for sporting
use. The design char-
acteristics include a
short wheelbase, a
sitting position with
the rider inclined
towards the front, and
a brake requiring low
actuation force.
A mountain bike is a
piece of sporting
equipment. It requires
an adaptation period
as well as physical fit-
ness. Use requires
the appropriate train-
ing; in particular rid-
ing 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 exces-
sively and lose con-
trol as a result.
A racing bicycle is
designed for fast
rides on roads and
paths with a good,
undamaged road sur-
face.
A racing bicycle is a
piece of sporting
equipment and not a
means of transport. A
racing bicycle is char-
acterised by its light-
weight structure and
a design which is
stripped to the mini-
mum parts required
for riding.
The frame geometry
and the layout of the
operating elements
are designed in such
a way that the bicy-
cle 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 there-
fore requires physi-
cal fitness.
The cargo bike is suit-
able for daily trans-
portation of loads on
public roads.
The transportation of
loads requires skill
and physical fitness
in order to balance
the additional weight.
The very varied load-
ing conditions and
weight distributions
require special prac-
tice and skill when
braking and riding in
bends.
A longer period is
required to adaptation
to the length, width
and turning circle .
You need to be cau-
tious when riding a
cargo bike. 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 trans-
portation, 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, dimin-
ished comfort and
reduced durability are
to be expected.
Table 10: Proper use
MY20H08-2_1.0_27.08.2019 23
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 bicy-
cles are not sports
bicycles. If used for
sports, the rider can
expect reduced riding
stability and dimin-
ished 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.
Racing bikes must be
retrofitted with light-
ing, a guard and other
fittings as specified
by national laws and
regulations before
they are used on pub-
lic roads.
A cargo bike is not a
touring bicycle or a
sports bicycle.
The folding bicycle is
not a sports bicycle.
Table 11: Information on incorrect use
MY20H08-2_1.0_30.08.2019 24
Overview
3.4 Technical data
3.4.1 Pedelec
3.4.2 Panasonic GX Power Motor
3.4.3 Panasonic TP-PCT rechargeable
battery
3.4.4 USB port
3.4.5 Display
The display has a 3 V coin cell.
3.4.6 Control device
3.4.7 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.
3.4.8 Tightening torque
*if there is no other data on the component
Transportation temperature 5°C - 25°C
Ideal transportation temperature 10 °C - 15 °C
Storage temperature 5°C - 25°C
Ideal storage temperature 10 °C - 15 °C
Operation temperature 5°C - 35°C
Work environment temperature 15 °C - 25 °C
Charging temperature 10 °C - 30 °C
Power output/system 250 W (0.25 kW)
Shut-off speed 25 km/h
Table 12: Pedelec technical data
Weight 3200g
Nominal voltage 36 V DC
Max. torque 60 Nm
Continuous power rating 250 W
Assistance up to 25 km/h
Table 13: Panasonic GX Power Motor technical data
Voltage 36 V
Capacity 11.6 Ah
Energy content 417 Wh
Weight About 3.3 kg
Capacity 14 Ah
Energy content 504 Wh
Weight About 3.3 kg
Capacity 17.5 Ah
Energy content 630 Wh
Weight About 3.8 kg
Table 14: Panasonic TP-PCT rechargeable battery
technical data
Charge voltage 5 V
Charging current Max. 1000 mA
Table 15: USB port technical data
Weight (g) About 0.4 kg
Nominal voltage 36 V DC
Protection class IPX5
Operating temperature -10 - +40 °C
Storage temperature -20 - +50 °C
Table 16: Control device technical data
A-weighted emission sound pressure
level
< 70 dB(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 17: Emissions from the pedelec*
Axle nut tightening torque 35 Nm - 40 Nm
Handlebars clamping screw maximum
tightening torque*
5Nm - 7Nm
Table 18: Tightening torque values
MY20H08-2_1.0_27.08.2019 25
Overview
3.5 Description of controls and
screens
3.5.1 Handlebars
Figure 19: Detailed view of pedelec from rider position,
example
1 Rear brake lever
2 Headlight
3 Display
4 Front brake lever
5 Control panel
6 Gear shift
3.5.2 Display
Figure 20: Display front
Figure 21: Display back
The operating element display has seven on-
screen indicators:
Figure 22: On-screen indicators overview
3.5.2.1 Current speed
You can select whether the speed is displayed in
kilometres or miles in the system settings.
3.5.2.2 Battery level indicator
The battery level indicator does not display the
charge level for the coin cell inside the control
device indicator unit; it indicates the pedelec's
rechargeable battery charge level.
You can also check the LEDs on the pedelec's
rechargeable battery to verify its charge level.
Use
1Front: On-Off button
2USB port front
1Battery compartment rear
2 Reset button rear
1
2
4
6
5
7
8
3
1
2
3
4
56
1
2
Use
1Power assistance indicator
2Light indicator
3Clock
4 Battery level indicator
5 Speed indicator
6Journey information indicator
7 On-Off indicator
8USB indicator
9 System messages indicator
Table 19: On-screen indicators overview
Symbol Lit Charge level
581 - 100%
461 - 80%
341 - 60%
2 21 - 40%
1 11 - 20%
1 flashes 1 - 10%
1
2
3
4
5
6
78
9
MY20H08-2_1.0_27.08.2019 26
Overview
3.5.2.3 Level of assistance
The rider can select from five levels of assistance
by pressing on the levels of assistance button.
The higher the level of assistance, the more the
drive system assists the rider when pedalling. The
following levels of assistance are available:
3.5.2.4 Function display
The function display shows two different items of
information:
• journey information and
• System messages.
3.5.2.5 Journey information
The pedelec provides six types of journey
information on the function display. The displayed
journey information can be switched.
3.5.2.6 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.
3.5.2.7 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.
There is a table with all the system messages at
the end of the chapter Maintenance.
3.5.3 Control panel
The control panel features 5 buttons.
Figure 23: Display details
Level of assistance Use
HIGH Powerful assistance
STANDARD Normal assistance
ECO Low assistance
NO ASSIST
When the drive system is
switched on, the motor
assistance is switched off.
AUTO
In the automatic level of
assistance, the system
automatically chooses the
appropriate assistance for the
riding conditions.
Table 20: Overview of levels of assistance
Screen display Function
TRIP Distance travelled
AVG Average speed
MAX Maximum speed of a journey
ODO Total distance travelled
RANGE Estimated range of the available battery
charge, calculated based on the most recent
riding mode. The range is an estimated value
since the remaining battery capacity is
calculated based on consumption.
REMAINING
BATTERY
CAPACITY
Battery level as a percentage.
Table 21: Journey information
Screen display Symbol with
2 indicators
Symbol with 4
indicators
TRIP
AVG
MAX
ODO
RANGE
REMAINING
BATTERY
CAPACITY
Table 22: Journey information
Screen display Function
LANGUAGE Changing the language
CONTRAST Changing the display contrast
BRIGHTNESS Change display screen brightness
UNIT Changing the unit of measure for speed
WHEEL Adjusting the tyre size
ODO INPUT Changing the distance travelled
CLOCK Setting the clock
Table 23: Changeable system settings
Designation Use
1Push assist
button
Movement can be assisted up to 6 km/h if
the electric bicycle is being pushed with a
heavy load.
2
Night mode
button
Backlights the indicator unit.
Whenever the headlight is powered via
the electric bicycle battery, the rear light
will also light up and vice versa. This
depends on local regulations.
3Info button Switches between indicator elements,
such as the distance travelled.
4
Up button
Selects the assistance mode between
[HIGH], [STANDARD], [ECO],
[NO ASSIST] and [AUTO]
5
Down button
Selects the assistance mode between
[HIGH], [STANDARD], [ECO],
[NO ASSIST] and [AUTO]
Table 24: Display overview
1
2
3
4
5
MY20H08-2_1.0_27.08.2019 27
Overview
3.6 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.
During winter use, especially at temperatures
below 0 °C, 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
Work environment temperature 15 °C - 25 °C
Charging temperature 0°C - 40°C
Table 25: Pedelec technical data
Area of use City and trekking
bicycles
Child's bicycles/
bicycles for young
adults
Mountain bikes Racing bicycle Cargo bike Folding bicycle
Suitable for tar-
macked and paved
roads.
Suitable for tar-
macked and paved
roads.
Suitable for tar-
macked and paved
roads.
Suitable for tar-
macked and paved
roads.
Suitable for tar-
macked and paved
roads.
Suitable for tar-
macked roads, cycle
paths and firm gravel
paths and roads, and
longer sections with
moderate slopes and
jumps up to 15 cm.
Suitable for tar-
macked roads, cycle
paths and firm gravel
paths and roads, and
longer sections with
moderate slopes and
jumps up to 15 cm.
Suitable for tar-
macked roads,
cycle paths and
easy to demanding
off-road riding, sec-
tions with moderate
slopes and jumps
up to 61 cm.
Suitable for tar-
macked roads, cycle
paths and firm
gravel paths and
roads, and longer
sections with moder-
ate slopes and
jumps up to 15 cm.
Suitable for tar-
macked roads,
cycle paths and
easy to demanding
off-road riding, lim-
ited downhill use
and jumps up to
122 cm.
Suitable for tar-
macked roads,
cycle paths and
easy to extremely
difficult off-road rid-
ing, unlimited
downhill use and
any jumps
Table 26: Area of use
MY20H08-2_1.0_27.08.2019 28
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.
MY20H08-2_1.0_30.08.2019 29
Transporting and storing
4 Transporting and storing
4.2 Transporting
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 push 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
!
MY20H08-2_1.0_30.08.2019 30
Transporting 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 24: 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.
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.
Storage temperature 5 °C - 25 °C
Optimum pedelec storage temperature 10 °C - 15 °C
Optimum battery storage temperature 22 °C - 26 °C
Table 27: Storage temperature for batteries, the pedelec and
charger
CAUTION
!
MY20H08-2_1.0_30.08.2019 31
Transporting 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 an inspection 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 8 weeks. If only
one LED on the battery level indicator lights up,
recharge the battery to around 60%.
Notice
The battery discharges when not in use. This can
cause irreparable damage to the battery.
The battery must be recharged every
3 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.
MY20H08-2_1.0_30.08.2019 32
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 28: 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
!
MY20H08-2_1.0_30.08.2019 33
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 battery level
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 Initial use of the display
The display features an integrated coin cell (3 V)
for the time display memory. When the display is
delivered, there is plastic protective shield in the
battery compartment to ensure the coin cell does
not discharge. Remove this plastic shield before
you use the display for the first time.
Figure 25: Open battery compartment with a coin on the
display rear
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
!
MY20H08-2_1.0_30.08.2019 34
Assembly
Use a coin to turn the battery compartment
latching cover on the display rear in a anti-
clockwise direction.
The coin cell compartment will open.
Remove the coin cell.
Remove the plastic shield from the minus pole
side.
Dispose of the plastic shield in the correct
manner.
Insert the coin cell into the battery
compartment.
Turn the latching cover clockwise.
The battery compartment is now locked.
5.3.3 Installing the wheel in the Suntour
fork
Only applies to pedelecs with this equipment
5.3.3.1 Installing the wheel with screw-on axle
(15 mm)
Insert the axle completely on the drive side.
Figure 26: Fully inserting the axle
Tighten the axle to 8-10 Nm with a 5 mm
hexagon socket spanner.
Figure 27: Tightening the axle
Insert the securing screw on the non-drive
side.
Figure 28: 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 29: Tightening the securing screw
Notice
If the cover does not firmly latch into position, the
indicator unit will not work properly since it will
cause a malfunction caused by water penetrating
the compartment, for example.
MY20H08-2_1.0_30.08.2019 35
Assembly
5.3.3.2 Installing the wheel with screw-on axle
(20 mm)
Insert the axle completely on the drive side.
Figure 30: Tightening the inserted axle
Tighten the securing clip with a 4 mm hexagon
socket spanner to 7 Nm.
Figure 31: Tightening the axle
5.3.3.3 Installing the wheel with a quick release
axle
Insert the axle into the hub on the drive side.
Clamping version II.
Figure 32: Pushing the axle into the hub
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
!
MY20H08-2_1.0_30.08.2019 36
Assembly
Tighten the axle with the red handle.
Figure 33: Tightening the axle
Push the quick release lever into the axle.
Figure 34: Pushing the quick release lever into the axle
Reverse the quick release lever.
The lever is secured.
Figure 35: Securing the lever
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 36: 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 37: Adjusting the quick release clamping force
MY20H08-2_1.0_30.08.2019 37
Assembly
5.3.4 Installing the wheel with a quick
release
Before installing, ensure that the quick release
flange is extended. Open the lever completely.
Figure 38: Closed and opened flange
Push in the quick release until you hear a
clicking sound. Make sure that the flange is
extended.
Figure 39: Pushing the quick release in
Adjust the clamping with a half-open clamping
lever until the flange reaches the fork end.
Figure 40: 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 41: Closing the quick release
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
!
MY20H08-2_1.0_30.08.2019 38
Assembly
5.3.5 Installing the wheel in the FOX fork
Only applies to pedelecs with this equipment
5.3.5.1 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 42: 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 lever. 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 43: 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 in front of the fork), the quick release
must be adjusted.
5.3.5.2 Adjusting the FOX quick release
Figure 44: 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.
1-20 mm
1
2
3
45
MY20H08-2_1.0_30.08.2019 39
Assembly
5.3.5.3 Installing 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 45: Pushing the Kabolt axle in
Tighten the Kabolt axle screw to 17 Nm (150
in-lb) with a 6 mm hex key.
5.3.5.4 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.
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.
5.3.6 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.
MY20H08-2_1.0_30.08.2019 40
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 pedelecs.
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.
Reduce 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 first before
you ride at speeds over 12 km/h. Increase the
level of assistance gradually.
Practice braking hard 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 intervals. The tyres in
particular can fail if exposed to a continuous load.
Use the brakes to decelerate the pedelec
if you reach speeds greater than 25 km/h.
CAUTION
!
MY20H08-2_1.0_30.08.2019 41
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.
Pedalling frequency
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 increases efficiency. 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 display screen 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 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 it for winter use.
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
MY20H08-2_1.0_30.08.2019 42
Operation
6.2 Error messages
6.2.1 Error message display
Parts of the electronic drive system are
permanently monitored during use and charging.
If an error is detected, the error code detected
appears on the display screen. Press any button
on the control panel to switch the display screen
back to the default screen.
Power assistance is automatically stopped in the
case of specific error codes. There is no longer
power assistance, but you can still use the
pedelec in a conventional manner without the
drive.
If an error is shown, correct it using the measures
described in the following table and/or contact
your specialist dealer.
Symptom Cause Remedy
A torque sensor error is
displayed on starting up.
Are you applying pressure to the pedals
when switching on?
Press the On-Off button again and avoid applying pressure to the
pedals.
The pedelec has only a little
power assistance after
starting up.
An error is displayed on
starting up.
Are you pressing other buttons while
pushing the On-Off button?
Press the On-Off button again and avoid pushing other buttons at the
same time.
Table 29: Error solution when switching on
MY20H08-2_1.0_30.08.2019 43
Operation
6.3 Instruction and customer service
Your supplying specialist dealer will provide
customer service. Contact details can be found on
the pedelec pass for these operating instructions.
If you are unable to contact your specialist dealer,
you will find other specialist dealers online at
www.hercules-bikes.de. The specialist dealer will
explain all the pedelec functions to you in person,
this being when the specialist dealer hands over
the pedelec at the latest. These operating
instructions are provided to you with every
pedelec, so that you can consult them at a later
stage.
Your specialist dealer will also be happy to assist
you in the future whether you require
maintenance, conversion or repair.
6.4 Adjusting the pedelec
Only a correctly adjusted pedelec will guarantee
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.
6.4.1 Adjusting the saddle
6.4.1.1 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 46: Horizontal saddle tilt
6.4.1.2 Determining the seat height
To determine 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.
1Climb onto the bicycle.
2Place 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 47: Optimal saddle height
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
!
MY20H08-2_1.0_30.08.2019 44
Operation
6.4.1.3 Adjusting the seat height with quick
release
1Open the quick release on the seat post (1) to
change the seat height. To do so, push the
clamping lever away from the seat post (3).
Figure 48: Opening the seat post quick release
2Set the seat post at the required height.
Figure 49: Detailed view of the seat post – examples of the
minimum insertion depth marking
3To close it, push the seat post clamping lever as
far as it will go into the seat post (2).
4Check the clamping force of quick releases.
6.4.1.4 Height-adjustable seat post
Only applies to pedelecs with this equipment
Preparing
1When 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.
Lowering the saddle
Figure 50: The seat post lever can be installed either on
the left (1) or right (2) side of the handlebars
1Press your hand down on the saddle or sit on
the saddle to lower the saddle.
2Press the seat post lever and hold it down.
3Release the seat post lever once you have
reached the required height.
Raising the saddle
1Press the seat post lever and hold it down.
2Remove any pressure from the saddle.
3Release the seat post lever once you have
reached the required height.
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.
3
4
5
1
2
3
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
MY20H08-2_1.0_30.08.2019 45
Operation
6.4.1.5 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
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.
1Climb onto the bicycle.
2Place the pedals into the vertical position with
your feet.
The rider is sitting in the optimal sitting position if
the knee cap perpendicular line runs through the
pedal axle.
3.1If the perpendicular line crosses behind the
pedal, bring the saddle forward.
3.2If the perpendicular line crosses in front of the
pedal, bring the saddle back.
4Move the saddle within its permitted
displacement range only (marked on the
saddle stay).
Figure 51: Knee cap perpendicular line
6.4.2 Adjusting the handlebars
6.4.2.1 Adjusting the stem
6.4.2.2 Adjusting the height of the handlebars
1Open the stem clamping lever.
Figure 52: Open (2) and closed (1) stem clamping lever;
by.schulz speedlifter used as an example
2Pull the locking lever on the stem up, and
simultaneously pivot the handlebars into the
desired position.
The handlebar settings 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.
90°
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.
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.
CAUTION
!
CAUTION
!
1
2
MY20H08-2_1.0_30.08.2019 46
Operation
You feel the locking lever click into place.
Figure 53: Pulling locking lever upwards – by.schulz
speedlifter used as an example
3Pull out the handlebars to the required height.
4Close the stem clamping lever.
6.4.2.3 Adjusting the quick release clamping
force
If the clamping lever on the handlebars cannot
be moved into its final position, unscrew the
knurled nut.
Tighten the knurled nut on the seat post if the
seat post 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.
6.4.3 Adjusting the brake lever
6.4.3.1 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.
Figure 54: Using the twist knob (1) to adjust the pressure
point
6.4.3.2 Adjusting the grip distance
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
!
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
!
MY20H08-2_1.0_30.08.2019 47
Operation
6.4.3.3 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.
Brake lever 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 55: Using the setting screw (2) to adjust the
distance from the brake lever to the handlebar grip (1)
6.4.4 Adjusting Suntour 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.
6.4.4.1 Adjusting the negative deflection
Negative deflection depends on the rider's weight
and sitting position. The recommended negative
deflection is between 15% (hard) and 30% (soft)
of the total fork deflection.
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
!
MY20H08-2_1.0_30.08.2019 48
Operation
6.4.4.2 Adjusting the steel suspension fork
negative deflection
Only applies to pedelecs with this equipment
You can adjust the tensioning in the fork spring to
the rider's weight and their preferred riding style.
This reduces the negative deflection in the fork.
Figure 56: Negative deflection setting wheel on the
suspension fork crown
1You will find the negative deflection setting
wheel beneath the plastic cover on the crown.
Remove the plastic cover.
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 decrease the
spring pre-tensioning.
You will have made the ideal setting when the
shock absorber deflects 3 mm when subject to
the rider's weight.
3Replace the plastic cover on the crown after
making the setting.
6.4.4.3 Adjusting the air suspension fork
negative deflection
Only applies to pedelecs with this equipment
The air valve is located beneath the valve cap
on the crown of the left-hand shock absorber.
Unscrew the valve cap.
Figure 57: Screw caps in different designs
1Attach a high pressure damper pump to the air
valve.
2Pump air suspension fork to the required
pressure. Observe the levels in the Suntour
filling pressure table. Never exceed the
recommended maximum air pressure.
3Detach high-pressure damper pump.
4Measure the distance between the crown and
the dust seal. This distance is total deflection
of the fork.
5Push a temporarily attached cable tie
downward against the dust seal.
6Put on your normal cycling clothing, including
luggage.
7Sit on the pedelec in your usual riding position
and support yourself against an object, such as
a wall or tree.
8Get off the pedelec without allowing it to
deflect.
9Measure distance between the dust seal and
the cable tie.
This measurement is the negative deflection.
The recommended value is between 15%
(hard) and 30% (soft) of the total fork
deflection.
10 Increase or reduce air pressure until you have
reached the desired negative deflection.
If the negative deflection is correct, turn the
valve cap in a clockwise direction.
If you are unable to achieve the desired
negative deflection, an internal adjustment
may be needed. Contact your specialist dealer.
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
Maximum air
pressure
150 psi 180 psi
Table 30: Suntour filling pressure table for air forks
MY20H08-2_1.0_30.08.2019 49
Operation
6.4.4.4 Adjusting the air suspension fork
rebound
Only applies to pedelecs with this equipment
The rebound setting depends on the negative
deflection setting: A higher negative deflection
requires a lower rebound setting.
1Turn the Suntour rebound screw in a
clockwise direction to the closed position until
it stops.
Figure 58: Suntour rebound screw (2), fork (1)
2Turn the Suntour rebound screw slightly in an
anti-clockwise direction.
3Adjust the rebound in such a way that the fork
rebounds quickly, but without bottoming out
upward. Bottoming out refers to when the fork
rebounds too quickly and stops moving
abruptly once it has reached the full rebound
distance. You can hear and feel a slight impact
when this happens.
6.4.5 Adjusting the FOX fork
Only applies to pedelecs with this equipment
The adjustment shown here represents a basic
setting. The basic setting can be adjusted to the
riding surface and personal preferences.
6.4.5.1 Adjusting the negative deflection
Negative deflection depends on the rider's weight
and sitting position. The recommended negative
deflection is between 15% (hard) and 20% (soft)
of the total fork deflection depending on
preferences and pedelec use.
When adjusting the negative deflection, ensure
that each pressure level adjuster is in an open
position, i.e. each pressure level adjuster has
been turned in an anti-clockwise direction until it
goes no further.
The pressure is to be measured at an ambient
temperature of 21 to 24 °C.
1The air valve is located beneath a blue valve
cap on the crown of the left-hand shock
absorber. Unscrew the valve cap in an anti-
clockwise direction.
2Attach a high pressure damper pump to the air
valve.
3Pump the suspension fork to the required
pressure. Observe the levels in the FOX filling
pressure table. Never exceed the maximum
air pressure or fall below the minimum air
pressure recommended in the table.
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.
1
2
CAUTION
!
Notice
Settings on the chassis change riding
performance significantly. You need to get used
to the pedelec and break it in to prevent
accidents.
It is recommended to note down the determined
negative deflection and rebound levels. This way,
the levels can be used as a starting point for
subsequent, optimised settings and as a
safeguard against unintentional changes.
MY20H08-2_1.0_30.08.2019 50
Operation
4Detach high-pressure damper pump.
5Measure the distance between the crown and
the fork's dust wiper. This distance is total
deflection of the fork.
6Push the O-ring downwards against the fork's
dust wiper. If there is no O-ring, attach a cable
tie to the stanchion temporarily.
7Put on your normal cycling clothing, including
luggage.
8Sit on the pedelec in your usual riding position
and support yourself against an object, such as
a wall or tree.
9Get off the pedelec without the suspension fork
deflecting.
10 Measure the distance between the dust wiper
and the O-ring or cable tie.
This measurement is the negative deflection.
The recommended value is between 15%
(hard) and 20% (soft) of the total fork
deflection.
11 Increase or reduce the air pressure until you
have reached the desired negative deflection.
If the negative deflection is correct, turn the
blue valve cap in a clockwise direction.
6.4.5.2 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. A higher
negative deflection requires a lower rebound
setting.
1Turn the FOX rebound adjuster in a clockwise
direction to the closed position until it stops.
Figure 59: FOX rebound adjuster (1) on the fork end
2Turn the FOX rebound adjuster slightly in an
anti-clockwise direction.
3Adjust the rebound in such a way that the fork
rebounds quickly, but without bottoming out
upward. Bottoming out refers to when the fork
rebounds too quickly and stops moving
abruptly once it has reached the full rebound
distance. You can hear and feel a slight impact
when this happens.
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
Maximum air
pressure
120 psi (8.3 bar) 120 psi (8.3 bar)
Table 31: FOX filling pressure table for air fork
If you are unable to achieve the desired negative
deflection, internal settings may need to be
changed. Contact your specialist dealer.
1
MY20H08-2_1.0_30.08.2019 51
Operation
6.4.6 Setting the Suntour rear frame
damper
Only applies to pedelecs with this equipment
6.4.6.1 Adjusting the negative deflection
Negative deflection depends on the rider's weight
and sitting position. The recommended negative
deflection should be between 25% and 30% of the
total rear frame damper deflection, depending on
preferences and pedelec use.
When adjusting the negative deflection, ensure
that the pressure level adjuster is in an open
position, i.e. the lockout lever is in the OPEN
position.
1Remove the valve cap from the air valve.
2Attach a high-pressure damper pump.
3Adjust the rear frame damper air pressure to
the rider's weight.
4Detach high-pressure damper pump.
5Measure the distance between the air chamber
seal and the end of the rear frame damper.
This gap is the total rear frame damper
deflection.
6Put on your normal cycling clothing, including
luggage.
7Sit on the pedelec in your usual riding position
and support yourself against an object, such as
a wall or tree.
8Push the O-ring downwards against the air
chamber seal.
9Get off the pedelec without the suspension fork
deflecting.
Measure the distance between the air chamber
seal and the O-ring. This measurement is the
negative deflection. The recommended value
is between 25% (hard) and 30% (soft) of the
total rear frame damper deflection.
10 Increase or reduce the air pressure until you
have reached the desired negative deflection.
If the negative deflection is correct, fasten the
valve cap onto the valve.
6.4.6.2 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 60: Suntour rebound adjuster wheel (1) on the rear
frame damper
Turn the rebound adjuster wheel in the
– direction to increase rebounding.
Turn the rebound adjuster wheel in the
+ direction to reduce compressive deflection
movements.
6.4.6.3 Setting the compression
You can use the pressure damper setting to adjust
the rear frame damper to the ground conditions.
The pressure damper setting defines the speed at
which the rear frame damper rebounds after being
subjected to load or impact.
Figure 61: Suntour pressure level adjuster on the rear
frame damper
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
1
MY20H08-2_1.0_30.08.2019 52
Operation
Turn the pressure level adjuster towards the
– symbol to increase rebounding.
Turn the pressure level adjuster towards the
+ symbol to reduce compressive deflection
movement.
6.4.7 Setting the FOX rear frame damper
Only applies to pedelecs with this equipment
6.4.7.1 Adjusting the negative deflection
Negative deflection depends on the rider's
weight and sitting position. The recommended
value is between 25% (hard) and 30% (soft) of
the total rear frame damper deflection.
1Turn the pressure level adjuster to the OPEN
position.
2Attach a high-pressure damper pump to the air
valve.
3Adjust the rear frame damper air pressure to
the rider's weight.
4Slowly compress the damper to 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. The high-
pressure damper pump pressure gauge
changes.
5Remove the high-pressure damper pump.
Figure 62: FOX rear frame damper
6Measure the distance between the air chamber
seal (1) and the end of rear frame damper (3).
This gap is the total deflection for the rear
frame damper (5).
7Sit on the pedelec in your usual riding position
and support yourself against an object, such as
a wall or tree.
8Push the O-ring (4) downwards against the air
chamber seal (1).
9Get off the pedelec without the suspension fork
deflecting.
Measure the distance between the air chamber
seal (1) and the O-ring (4). This measurement
is the negative deflection (2). The
recommended value is between 25% (hard)
and 30% (soft) of the total deflection for the
rear frame damper (5).
10 Increase or reduce the air pressure until you
have reached the desired negative deflection.
6.4.7.2 Adjusting the rebound
The rebound adjuster defines the speed at which
the rear frame damper rebounds after being
subjected to load or impact. The rebound setting
depends on the air pressure setting. A higher
negative deflection requires a lower rebound
setting.
1Attach a high-pressure damper pump to the air
valve.
2Read the air pressure.
3Remove the high-pressure damper pump.
Figure 63: FOX rebound adjuster wheel (1) on the rear
frame damper
4Turn the rebound adjuster clockwise to the
closed position until it stops.
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.
25-30%
2
1
3
4
5
1
MY20H08-2_1.0_30.08.2019 53
Operation
5Adjust the rebound setting based on the air
pressure reading. Turn the rebound adjuster
back anti-clockwise by the number of clicks
specified in the table below.
6.4.8 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 disk is retracted and provides
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 32: Filling pressure table for the FOX air fork
MY20H08-2_1.0_30.08.2019 54
Operation
6.5 Accessories
We recommend a parking stand into which either
the front wheel 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.
6.5.1 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 install 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 maximum
permitted total weight is not exceeded.
The specialist dealer will provide instruction on
how to handle the pedelec and the child seat.
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 33: Accessories
Crash caused by incorrect child seat
The pannier rack and down tube are unsuitable
for mounting 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 instructions
for the child seat system.
Never exceed the maximum permitted total
weight.
CAUTION
!
MY20H08-2_1.0_30.08.2019 55
Operation
6.5.2 Bicycle trailers
A pedelec which is approved for towing a trailer
will bear an appropriate adhesive label. You may
only use bicycle trailers with a support load and
weight which do not exceed the permitted values.
Figure 64: 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
6.5.3 Pannier rack
The specialist dealer will advise on choosing a
suitable pannier rack.
The specialist dealer must install 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 maximum
permitted total weight 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 instructions 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
!
MY20H08-2_1.0_27.08.2019 56
Operation
6.6 Before each ride 6.7 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.
MY20H08-2_1.0_30.08.2019 57
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
between the left- and right-hand side.
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, possible
causing the pedelec to topple over as a result.
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 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 maximum permitted total
weight when packing the pannier.
Never exceed the maximum load bearing
capacity of the pannier rack.
Never modify the pannier rack.
CAUTION
!
MY20H08-2_1.0_30.08.2019 58
Operation
6.10 Rechargeable battery
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.
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 e-bike.
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 a 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
!
MY20H08-2_1.0_30.08.2019 59
Operation
Switch off the battery and the drive system before
removing or inserting the battery.
6.10.1 Removing the battery
Use your right hand to push the battery up into
the frame.
The lock hook is disengaged in the frame.
Hold underneath the battery with your right
hand. Press key towards the down tube.
The lock hook releases the battery.
The battery will now fall out of the frame or can
be pulled out of the down tube, depending on
how much space there is between the battery
and down tube.
Remove the key from the lock.
6.10.2 Inserting the battery
Place the battery into the lower mount with the
contacts facing the front.
Open the lock with the key.
Press the key towards the down tube and hold.
The lock hook in the frame clears the way for
the battery.
Swivel the battery into the down tube. Apply a
little pressure to push the battery into the
frame.
Release the key.
The lock hook moves into the secure position
and holds the battery.
Close the lock. Remove the key.
Check the battery is firmly in position.
6.10.3 Charging the 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.
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 a battery charging unattended.
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.
Risk of fire and explosion caused by damaged
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.
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.
CAUTION
!
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Operation
The ambient temperature during the charging
process must be within the range from 10 °C to
30 °C.
The battery can remain on the pedelec or can be
removed for charging.
Interrupting the charging process does not
damage the 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. Only use the charger supplied in
the scope of delivery.
The charging process starts automatically.
The battery level indicator indicates the charge
level during charging. The charging process is
complete when the LEDs on the battery level
indicator go out.
6.10.4 Waking the battery
When not used for a longer period, the battery
switches to sleep mode for self-protection. The
LEDs on the battery level indicator do not light
up.
Press the On-Off button (battery).
The battery level indicator shows the charge
level.
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.
Charging temperature 10 °C - 30 °C
Connection data 230 V, 50 Hz
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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.
Press the On-Off button (display).
The indicator will switch on after a few
seconds.
If the drive system is switched on, the drive is
activated as soon as the pedals are moved with
sufficient force.
6.11.2 Switching off the drive system
The system switches off automatically ten minutes
after the last command.
Press the On-Off button (display) while
stationary to actively switch off the drive
system.
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.
Notice
Do not apply any pressure to the pedelec's
pedals when switching on the electric bicycle
system. If you do, this may cause a torque
sensor error or reduced assistance
performance.
Do not press any other buttons when pushing
the On-Off button; if you do, an error will be
displayed.
CAUTION
!
Notice
Never use the On-Off button while riding.
When you don't need power assistance, press
on the up or down button to select the level of
assistance [NO ASSIST].
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Operation
6.12 Display
6.12.1 Removing and attaching the display
The system is switched off by removing the
display.
6.12.1.1 Attaching the display
Align the display screen ▼ arrow and the
mount▲ arrow with one another.
Slide the display in the direction of the arrow in
the diagram until the display ▼ is pointing to
the O position on the mount.
Figure 65: Attaching the display (2) to the mount (1)
Press the On-Off button (display).
The LCD display lights up. The display is
connected to the power.
6.12.2 Securing the display against
removal
Detach the mount from the handlebars.
Insert the display in its mount.
Use the setting screw (M4 x L10) to attach the
display rear to the mount.
Figure 66: Using the setting screw (1) to fasten mount to
display
Crash caused by distraction
A lack of concentration while riding increases the
risk of an accident. This may cause a crash with
serious injuries.
Never allow yourself to be distracted by the
display.
Stop pedelec if you want to make inputs on the
display other than a change in level of
assistance. Only enter data when the bicycle
is stationary.
Notice
Do not use the display as a handle. You may
irreparably damage the display if you use it to
lift the pedelec.
If you do not use your pedelec for several
weeks, remove the display from its mount.
Store the display safely at room temperature in
a dry environment.
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.
CAUTION
!
1
2
1
MY20H08-2_1.0_30.08.2019 63
Operation
Fasten the mount to the handlebars.
Figure 67: Screwing the mount to handlebars
6.12.2.1 Removing the display
Detach the indicator unit from the mount after you
have switched off the electric bicycle system.
Figure 68: Pressing the catch (2) on the display (1) and
removing from mount (3)
The electric drive system is switched off.
Slide the display forwards while pressing the
mount catch bolt down at the same time.
6.12.3 Using the USB port
You may recharge external devices such as
mobile telephones, which can be connected to the
control device via the USB cable. Connect the
exclusive USB cable to recharge for more than
three hours.
External devices can only be recharged if the
control device indicator unit and a charged
battery are inserted into the pedelec.
Notice
Never detach the display if it has been fastened
to the mount with the setting screw.
Never remove the display while riding.
3
2
1
Notice
Never recharge external devices while riding.
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.
The device being charged may fall off, possibly
causing a malfunction.
Place the external device on a flat, stable
surface only while it is charging.
Notice
The port function has only be tested with a few
external devices and the exclusive USB cable.
There is no guarantee that an external device will
function correctly.
Contact the external device manufacturer to
find out whether it can be recharged with the
Panasonic display.
Back-up the internal data on the external
device since there is a risk that they could be
deleted.
Do not connect the exclusive USB cable
(optional) to any devices other than the control
device. Devices could become damaged.
Never recharge external devices in the rain.
Never connect a damp or wet USB cable. The
system may malfunction as a result.
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Operation
A USB cable compatible with the external device
(available from retailers) is required.
Figure 69: Pressing the catch (2) on the display (1) and
removing from mount (3)
Open the protective flap on the USB port.
Connect the USB cable (optional; micro USB
side: Type B; USB side: male) to the
corresponding Micro-USB port on the control
device indicator unit.
Connect the USB cable (available from
retailers) which is compatible with the external
device to the external device and the exclusive
USB cable (optional).
Replace the protective flap after using the USB
port.
6.12.4 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.
Hold down the push assist button to activate the
push assist function.
Release the push assist button to deactivate the
push assist function.
6.12.5 Using the riding light
To switch on the riding light, the drive system
needs to be switched on first.
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).
6.12.6 Using night mode
Night mode changes the brightness of the
indicator unit backlight. The backlight settings
feature a normal mode and a night mode. Five
brightness levels can be used in each mode.
Brightness is reduced in night mode compared to
normal mode to ensure any glare is reduced while
riding at night.
The electric drive system is switched on.
Press the night mode button.
The night mode indicator is displayed on the
indicator unit and the backlight changes to
night mode. Press the night mode button again
to return to normal mode.
6.12.7 Selecting the level of assistance
To switch on the level of assistance, the drive
system has to be switched on already.
Press the up button to increase the level of
assistance.
Press the down button to reduce the level of
assistance.
Notice
The pedals turn when using the push assist due
to the system design.
You must steer the pedelec securely with both
hands when using push assist.
Allow for enough freedom of movement for the
pedals.
1
2
3
Notice
If the pedals strike against the kerb or another
object and push assist stops working, hold
down the push assist button (walk assist)
again.
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Operation
6.12.8 Journey information
The displayed journey information can be changed
and partially reset.
6.12.8.1 Changing the displayed journey
information
The pedelec provides six types of journey
information on the function display. The displayed
journey information can be switched.
Press on the info button repeatedly until the
required journey information is displayed.
6.12.8.2 Resetting the journey information
The journey information TRIP, AVG and MAX
can be reset.
Press the info button repeatedly until the
required journey information is displayed.
Press the info button for a long time.
The value 0 is displayed.
The journey information TRIP, AVG or MAX is
reset.
6.12.9 Changing the system settings
The system settings can be changed.
6.12.9.1 Changing the language
The language can be chosen from a selection of
ten: English, German, Dutch, French, Italian,
Spanish, Finnish, Swedish, Norwegian and
Danish.
Press the info button and the down button
together for three seconds.
The display screen indicates LANGUAGE and
the language currently selected.
Press the info button.
The language currently selected starts to flash.
Press the up button or down button repeatedly
until the desired language is displayed.
Press the night mode button.
The language has been changed.
6.12.9.2 Changing the display contrast
The contrast can be set in ten levels from level 1
to level 10.
Press the info button and the down button
together for three seconds.
Press the up button or down button repeatedly
until CONTRAST and the currently set value
are shown on the display screen
The value currently selected starts to flash.
Press the up button or down button repeatedly
until the desired Contrast is displayed.
Press the night mode button.
The contrast has been changed.
Screen display Function
TRIP Distance travelled
AVG Average speed
MAX Maximum speed of a journey
ODO Total distance travelled
RA NGE Expected range of the available battery
charge, calculated based on the most
recent riding mode (estimate).
BATTERY
CAPACITY
Battery level as a percentage.
Table 34: Journey information
Screen display Symbol with 2
indicators
Symbol with 4
indicators
TRIP
AVG
MAX
ODO
RANGE
REMAINING
BATTERY
CAPACITY
Table 35: Journey information
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Operation
6.12.9.3 Changing the brightness
The backlight settings feature a normal mode and
a night mode. The backlight setting is changed
depending on whether the light is switched on or
off. The brightness can be set in five levels from
OFF (no backlight) to level 4 (brightest level).
Set the normal mode brightness when the night
mode indicator is not displayed. Set the night
mode brightness when the night mode indicator is
displayed.
If you set the same brightness for normal and
night mode, the brightness will not change even if
you switch modes.
Press the info button and the down button
together for three seconds.
Press the up button or down button repeatedly
until BRIGHTNESS and the currently set value
are shown on the display screen.
Press the info button.
The value currently selected starts to flash.
Press the up button or down button repeatedly
until the desired brightness is displayed.
Press the night mode button.
The brightness has been changed.
6.12.9.4 Changing the unit of measure for speed
The unit of measure for speed can be set in km/h
or mph.
Press the info button and the down button
together for three seconds.
Press the up button or down button repeatedly
until UNIT and the currently set value are
shown on the display screen.
Press the info button.
The value currently selected starts to flash.
Press the up button or down button repeatedly
until the desired unit of measure is displayed.
Press the night mode button.
The brightness has been changed.
6.12.9.5 Setting information on the tyre size
Press the info button and the down button
together for three seconds.
Press the up button or down button
repeatedly until WHEEL appears on the display
screen
Press the info button.
The value currently selected starts to flash.
Press the up button or down button repeatedly
until the desired Size is displayed.
Press the night mode button.
The tyre size information has been changed.
6.12.9.6 Changing the distance travelled
Press the info button and the down button
together for three seconds.
Press the up button or down button repeatedly
until ODO INPUT and the currently set value
are shown on the display screen.
Press the info button.
The value currently selected starts to flash.
Press the up button or down button repeatedly
until the desired distance travelled is
displayed.
Press the night mode button.
The distance travelled has been changed.
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Operation
6.12.9.7 Setting the clock
Press the info button and the down button
together for three seconds.
Press the up button or down button repeatedly
until CLOCK and the currently set time are
shown on the display screen.
Press the info button.
The time currently selected starts to flash.
Press the info button.
The time is displayed in 24-hour format.
Pressing the button changes between hours
and minutes.
Press the up button or down button repeatedly
until the desired time is displayed.
Press the night mode button.
If the night mode button is pressed, the time will
run starting from the changed time.
6.12.10 Replacing the battery
The display features an integrated coin cell (3 V)
for the time display memory. If the "0:00" time
indicator flashes on the display screen, the coin
cell has come to the end of its useful life. The
clock functions are stopped if the coin cell has
fully discharged.
Figure 70: Open battery compartment with a coin on the
display rear
Use a coin to turn the battery compartment
latching cover on the display rear in a anti-
clockwise direction.
The coin cell compartment will open.
Remove the coin cell.
Remove the plastic shield from the minus pole
side.
Dispose of the plastic shield in the correct
manner.
Insert the coin cell into the battery
compartment.
Turn the latching cover clockwise. The battery
compartment is now locked.
Notice
Battery fluid leaks can cause a malfunction on the
display.
Replace a used coin cell with a new one
immediately in the display.
Dispose of coin cells which can no longer be
used in accordance with local recycling
regulations.
Notice
If the cover does not firmly latch into position, the
indicator unit will not work properly since it will
cause a malfunction caused by water penetrating
the compartment, for example.
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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
!
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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 71: 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 brake disc 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
MY20H08-2_1.0_30.08.2019 70
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.
6.14 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 72: FOX compression adjuster with the OPEN (1)
and HARD (2) positions
Compression damping is lowest in the OPEN
position, 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 between the OPEN and HARD
positions enable fine adjustment of compression
damping.
We recommend setting the lever of the
compression adjuster to the OPEN mode position
first.
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 73: 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 74: 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.
1
1
2
1
2
3
4
3
2
1
MY20H08-2_1.0_30.08.2019 71
Operation
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 75: 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.
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 76: 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 77: 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 78: Setting the rebound damper strength on the
rear frame damper setting wheel (1)
Turn the setting wheel to the middle position.
Ride the vehicle 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.
1
2
1
2
2
2
3
1
MY20H08-2_1.0_30.08.2019 72
Operation
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.
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 79: 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 Selecting 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 80: 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
MY20H08-2_1.0_30.08.2019 73
Operation
6.15.2 Using the hub gear
Only applies to pedelecs with this equipment
.
Figure 81: 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.
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
MY20H08-2_1.0_30.08.2019 74
Cleaning and servicing
7 Cleaning and servicing
Cleaning check list
Maintenance check list
Servicing measures must be performed regularly.
Contact your specialist dealer if you are unsure.
7.1 Cleaning after each ride
7.1.1 Cleaning the suspension fork
Remove dirt and deposits from 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 cleaning.
CAUTION
!
Required tools and cleaning agents:
• Cloth
•Air pump
•Brush
• Water
• Dish-washing liquid
•Bucket
MY20H08-2_1.0_30.08.2019 75
Cleaning and servicing
7.2 Basic cleaning
Remove battery and display before basic
cleaning.
7.2.1 Cleaning the frame
1Soak the entire frame with dish-washing
detergent if the dirt is thick and ingrained.
2After leaving it to soak for a short time, remove
the dirt and mud with a sponge, brush and
toothbrushes.
3Use a watering can or your hand to rinse the
frame.
4Service the frame after cleaning.
7.2.2 Cleaning the stem
1Clean stem with a cloth and soapy water.
2Service the stem after cleaning.
7.2.3 Cleaning the wheel
1Check the tyres, rims, spokes and spoke
nipples for any damage when cleaning the
wheel.
2Use a sponge and a brush to clean the hub and
spokes from the inside to the outside.
3Clean the rim with a sponge.
7.2.4 Cleaning the drive elements
1Spray the cassette, the chain wheels and the
front derailleur with a degreasing agent.
2Clean coarse dirt with a brush after soaking for
a short time.
3Wash down all parts with dish-washing
detergent and a toothbrush.
4Service the drive elements after cleaning.
Crash caused by brake failure
The braking effect may be unusually poor
temporarily after cleaning, servicing or repairs.
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 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 pressure
washer.
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
!
MY20H08-2_1.0_30.08.2019 76
Cleaning and servicing
7.2.5 Cleaning the rear frame damper
Clean rear frame damper with a cloth and
soapy water.
7.2.6 Cleaning the chain
1Slightly dampen a brush with dish-washing
liquid. Brush both sides of the chain.
2Dampen a cloth with soapy water. Place the
cloth on the chain.
3Hold and apply slight pressure while slowly
turning the rear wheel, so the chain passes
through the cloth.
4If the chain is still dirty afterwards, clean with
lubricant.
5Service the chain after cleaning.
7.2.7 Cleaning the battery
Clean the battery electrical connections with a
dry cloth or paintbrush 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.
Never 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 pressure
washer, water jet or compressed air.
Keep contacts dry and clean.
Never immerse the battery in water.
Never use cleaning agents.
Remove the battery from the pedelec before
cleaning.
CAUTION
!
Notice
Never clean the battery with solvents, such as
oil, thinners, alcohol or corrosion protection, or
with cleaning agents.
Notice
If water enters into the display screen, it will be
permanently damaged.
Never immerse the display in water.
Never clean with a pressure washer, 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 pressure washer, water jet
or compressed air.
Never use cleaning agents.
Never open battery.
CAUTION
!
MY20H08-2_1.0_30.08.2019 77
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 the frame.
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
1Spray the cassette, the chain wheels and the
front derailleur with a degreasing agent.
2Clean coarse dirt with a brush after soaking for
a short time.
3Wash down all parts with dish-washing
detergent and a toothbrush.
7.3.5 Servicing the pedals
Treat pedals with spray oil.
7.3.6 Servicing the chain
Grease the chain thoroughly with chain oil.
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.
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 a pressure
washer or compressed air.
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
!
MY20H08-2_1.0_30.08.2019 78
Cleaning and servicing
1Check the tyres for wear.
2Check the tyre pressure.
3Check 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.
4Check the tension of the spokes.
7.4.1.1 Checking the tyres
Check the tyres for 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.
7.4.1.2 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.
Contact your specialist dealer to have the rims
replaced. We recommend that you also replace
the rims at the same time as every second
brake lining replacement.
7.4.1.3 Checking and adjusting the tyre
pressure – Dunlop valve
Only applies to pedelecs with this equipment
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.
1Unscrew and remove the
valve cap.
2Connect the bicycle pump.
3Pump up the tyre slowly and
pay attention to the tyre pressure in the
process.
4Correct the tyre pressure according to
specifications in the Pedelec pass.
5If the tyre pressure is too high, unfasten the
union nut, let air out and re-tighten the union
nut.
6Remove the bicycle pump.
7Screw the valve cap tight.
8Screw the rim nut gently against the rim with
the tips of your fingers.
7.4.1.4 Checking and adjusting the tyre
pressure – presta valve
Only applies to pedelecs with this equipment
It is recommendable to use a
bicycle pump with a pressure
gauge. The operating
instructions for the bicycle pump
must be adhered to.
1Unscrew and remove the
valve cap.
2Open the knurled nut around
four turns.
3Carefully 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 against the
specifications
Adjust the tyre pressure as necessary.
MY20H08-2_1.0_30.08.2019 79
Cleaning and servicing
4Pump up the tyre slowly and pay attention to
the tyre pressure in the process.
5Correct the tyre pressure as per the
specifications on the tyre.
6Remove the bicycle pump.
7Tighten the knurled nut with your fingers.
8Screw the valve cap tight.
9Screw the rim nut gently against the rim with
the tips of your fingers.
7.4.1.5 Checking and adjusting the tyre
pressure – Schrader valve
Only applies to pedelecs with this equipment
It is recommended to use a
bicycle pump with a pressure
gauge. The operating
instructions for the bicycle pump
must be adhered to.
1Unscrew and remove the
valve cap.
2Attach the bicycle pump.
3Pump up the tyre slowly and
pay attention to the tyre
pressure in the process.
The tyre pressure has been adjusted as per the
specifications.
4Remove the bicycle pump.
5Screw the valve cap tight.
6Screw the rim nut (1) gently against the rim
with the tips of your fingers.
7.4.2 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.
7.4.3 Checking the brake linings for wear
Check brake linings after brake has been fully
applied 1,000 times.
1Check 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.
2Push 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. Contact your specialist dealer if any of
these components are worn.
7.4.4 Checking the pressure point
Push brake lever and hold several times.
If you are unable to clearly detect the pressure
point and it changes, the brake needs to be
vented. Contact your specialist dealer.
7.4.5 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 their wear
limit yet; brake discs need to be replaced if
they have. Contact your specialist dealer.
7.4.6 Electrical cables and brake cables
Check all visible electrical cables and cables
for damage. If the sheathing is compressed, a
brake defective or a light does not work, the
pedelec will need to be removed from service
until the lines or cables have been repaired.
Contact your specialist dealer.
7.4.7 Gear shift
Check the gear shift and the shifter or the twist
grip setting and adjust it as necessary.
Crash caused by brake failure
Worn brake discs and brake linings and 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
hydraulic brake system on a regular basis.
Contact your specialist dealer if any of these
components are worn.
1
CAUTION
!
MY20H08-2_1.0_30.08.2019 80
Cleaning and servicing
7.4.8 Stem
The stem and quick release system must 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.
Contact your specialist dealer if there is any
wear or signs of corrosion.
7.4.9 USB port
7.4.10 Checking the belt and chain tension
1Check the chain tension in three or four
positions, turning the crank a full revolution.
Figure 82: Checking the chain tension
2If the chain can be pushed more than 2 cm, the
chain or drive belt will need to be tensioned
again by the specialist dealer.
3If 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. Contact your specialist dealer.
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
MY20H08-2_1.0_30.08.2019 81
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.
Technical expertise, special tools and special
lubricants are required no matter whether disc
brakes need replacing, brakes venting or wheels
changing. The pedelec may become damaged if
the stipulated maintenance intervals and proce-
dures are not carried out. That is why only special-
ist 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.
Only carry out work or changes, such as
dismantling, sanding or painting, which are
permitted and described in the brake operating
instructions.
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
!
MY20H08-2_1.0_30.08.2019 82
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 83: 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 84: 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
!
MY20H08-2_1.0_30.08.2019 83
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 85: 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 86: 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 87: Twist grip with adjusting sleeves (1) and play of
the gear shift (2)
2
1
1
A
B
1
2
2
1
2
MY20H08-2_1.0_30.08.2019 84
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 respective error code appears on
the display. The drive may be shut off
automatically, depending on the type of error.
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
!
MY20H08-2_1.0_30.08.2019 85
Troubleshooting, fault clearance and repair
9.2 Switching on
9.3 Assistance function
Symptom Cause Remedy
A torque sensor error is dis-
played on starting up.
Are you applying pressure to the pedals
when switching on?
Press the On-Off button again and avoid applying pressure to the
pedals.The pedelec has only a little
power assistance after start-
ing up.
An error is displayed on
starting up.
Are you pressing other buttons while
pushing the On-Off button?
Press the On-Off button again and avoid pushing other buttons at the
same time.
Table 36: Error solution when switching on
Symptom Cause Remedy
Assistance is not available.
Is the battery charged sufficiently? Check the battery level.
If the battery is almost flat, recharge it.
Are you riding up long inclines in summer
weather or have you been carrying a heavy
load for a long time?
The battery may be too hot.
Turn off the drive system.
Wait a while and then check again.
The drive unit (DU-E8000), the bicycle
computer (SC-E8000/SC-E6010) or the
assistance switch (SW-E8000-L/SW-
E6000/SW-E6010) may be connected
incorrectly or one or more of them may
have a problem.
Contact your specialist dealer.
Is the speed too high?
Check the on-screen indicators.
The electronic gear assistance only works up to a maximum speed
of 25 km/h.
Assistance is not available.
Are you pedalling? The pedelec is not a motorbike. You also need to pedal.
Is the assistance mode set to [OFF]?
Set the assistance mode to a different level of assistance than
[OFF].
Contact your specialist dealer if you still feel that the pedelec does
not provide assistance.
Is the system switched on? Press the battery on-off button to switch it on again.
The assisted journey dis-
tance is too short.
The journey distance can be shorter
depending on the road conditions, the gear
level and the entire light usage time.
Check the battery level.
If the battery is almost flat, recharge it.
The battery does not perform as well in
winter weather.
This does not indicate a problem.
The battery is a consumable. Repeated
charging and long periods of use cause the
battery to degrade (loss of power).
If the distance you can cover with one single charge is very short,
replace the battery with a new one.
Is the battery fully charged?
If the distance covered with a fully charged battery has become
shorter, the battery may be affected. Replace the battery with a new
one.
Table 37: Level of assistance error solution
MY20H08-2_1.0_30.08.2019 86
Troubleshooting, fault clearance and repair
9.4 Rechargeable battery
It is difficult to pedal.
Are the tyres pumped to an adequate
pressure?
Pump up the tyres.
Is the assistance mode set to OFF?
Select the level of assistance [BOOST].
Contact your specialist dealer if you still feel that the pedelec does
not provide assistance.
The battery charge might be low.
Check how powerful assistance is again after charging the battery.
Contact your specialist dealer if you still feel that the pedelec does
not provide assistance.
Have you switched on the system with your
foot on the pedal?
Switch the system on again without applying pressure to the pedal.
Contact your specialist dealer if you still feel that the pedelec does
not provide assistance.
Symptom Cause Remedy
The battery discharges
quickly.
The battery may be at the end of its service
life.
Replace the old battery with a new one.
The battery cannot be
recharged.
Is the charger mains plug firmly connected
to the socket?
Pull out the charger mains plug and reconnect it again.
Try charging again.
If the battery still won't recharge, contact your specialist dealer.
Is the charger plug firmly connected to
battery?
Pull out the charger mains plug and reconnect it again.
Try charging again.
If the battery still won't recharge, contact your specialist dealer.
Is the adapter firmly connected to the
charger plug or the battery's charging port?
Connect the adapter firmly to the charger plug or the battery's
charging port.
Re-start the charging process.
Contact your specialist dealer if the battery still does not charge.
Is the battery, the connection terminal for
the battery charger or the charger adapter
dirty?
Wipe the connection terminal with a dry cloth to clean it.
Try charging again.
If the battery still won't recharge, contact your specialist dealer.
The battery does not start
charging when the charger
is connected.
The battery may be at the end of its service
life.
Replace the old battery with a new one.
The battery and charger
become hot.
The temperature of the battery or the
charger may have exceeded the operating
temperature range.
Stop the charging process.
Wait a while and then start charging again.
If the battery is too hot to touch, there might be a problem with the
battery. Contact your specialist dealer.
The charger is hot. If the charger is used continuously to
charge batteries, it may become hot.
Wait a while before using the charger again.
The LED on the charger
does not light up.
Is the charger plug firmly connected to
battery?
Check the connection to the external body before inserting the
charger plug again.
If nothing changes, contact your specialist dealer.
Is the battery fully charged?
The LED on the battery charger will go out when the battery is fully
charged. This is not a malfunction.
Pull out the charger mains plug and reconnect it again.
Then try charging again.
If the LED on the charger still does not light up, contact your
specialist dealer.
Table 38: Error solution for battery
Symptom Cause Remedy
Table 37: Level of assistance error solution
MY20H08-2_1.0_30.08.2019 87
Troubleshooting, fault clearance and repair
9.5 Lighting
The battery cannot be
removed.
Contact your specialist dealer.
The battery cannot be
inserted.
Contact your specialist dealer.
Fluid is leaking from the bat-
tery. Move away from the battery immediately.
Contact the fire service immediately.
Observe all the safety instructions in Section 2 Safety.
There is an unusual smell. Move away from the battery immediately.
Contact the fire service immediately.
Observe all the safety instructions in Section 2 Safety.
Fumes are emitted from the
battery. Move away from the battery immediately.
Contact the fire service immediately.
Observe all the safety instructions in Section 2 Safety.
Symptom Cause Remedy
The front light or rear light
does not go on, even when
the switch is pressed.
The basic settings in the electric drive
system have probably been configured
incorrectly.
The light is defective.
Take the pedelec out of service immediately.
Contact your specialist dealer.
Table 39: Error solution for battery
Symptom Cause Remedy
Table 38: Error solution for battery
WARNING
!
WARNING
!
WARNING
!
MY20H08-2_1.0_30.08.2019 88
Troubleshooting, fault clearance and repair
9.6 Display
9.7 Miscellaneous
Symptom Cause Remedy
No data are shown on the
monitor if you press the on-
off button on the battery.
The battery charge level may be
insufficient.
Charge the battery.
Switch the power on.
Is the power switched on? Keep the battery on-off button pressed down to switch on the power
again.
Is the battery charged? If the battery is fitted to the pedelec and is being charged, it cannot
be switched on. Stop the charging process.
Is the connector fitted to the power cable
correctly?
Check whether the power cable connector connecting the motor unit
to the drive unit has not disconnected. If you are not sure, contact
your specialist dealer.
A component may be connected which the
system is unable to recognise.
Contact your specialist dealer.
The gear level is not shown
on the display.
The gear level is only shown if the
electronic gear shift is used.
Check whether the power cable pug has been disconnected. If you
are not sure, contact your specialist dealer.
The settings menu cannot
be opened while you are
riding.
The product is designed in such a way that
the settings menu cannot be opened if the
system detects that someone is riding the
pedelec. This is not a malfunction.
Stop the pedelec and then adjust the settings.
The time display is flashing
"0:00".
The coin cell in the display has come to the
end of its service life.
Replace the coin cell in the display.
Table 40: Error solution for the display
Symptom Cause Remedy
Two beeps will sound if a
switch is pressed but the
switch cannot be operated.
Pressed switch mode has been
deactivated.
This is not a malfunction.
Three beeps are sounded. A fault or warning has occurred. This occurs when a warning or an error is shown on the display
screen. Follow the instructions for the code indicated on screen in
Section 6.2 System Messages.
When you use an electronic
gear shift, you can feel that
pedal assistance becomes
weaker when the gear is
changed.
This is because the computer sets the
pedal assistance to the optimum level.
This is not a malfunction.
You hear a noise after
shifting gears.
Contact your specialist dealer.
It is normal to hear a noise
coming from the rear wheel
when cycling as normal.
The gear shift setting may not have been
made properly.
Contact your specialist dealer.
If you stop the pedelec, gear
transmission does not switch
to the position pre-
configured in the functional
feature.
You may have applied too much pressure
onto the pedals.
It is easier to change gears if you press onto the pedals gently.
Table 41: Error solution for battery
MY20H08-2_1.0_30.08.2019 89
Troubleshooting, fault clearance and repair
9.8 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.
9.8.1 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.
9.8.2 Replacing the lighting
Only use components of the respective power
class for replacement.
9.8.3 Adjusting the headlight
The headlight must be set, so that i ts light beam
shines on the road 10 m in front of the pedelec.
MY20H08-2_1.0_30.08.2019 90
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. This means you 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 may fail if the battery is
damaged or faulty. 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
!
MY20H08-2_1.0_27.08.2019 91
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.
MY20H08-2_1.0_27.08.2019 92
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
MY20H08-2_1.0_27.08.2019 93
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
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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
MY20H08-2_1.0_27.08.2019 95
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
MY20H08-2_1.0_27.08.2019 96
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
MY20H08-2_1.0_27.08.2019 97
Keyword index
12 Keyword index
A
Air chamber, 17
Air valve
Fork, 16
Rear frame damper, 17
Alternative equipment, 7, 100
B
Back-pedal brake,
-braking, 70
Battery level indicator, 20
Battery, 20
- charging, 59
- checking, 33
- disposing of, 90
- waking, 60
Belt tension, 80
Brake arm, 17
Brake calliper, 18
Brake disc, 18
Brake lever, 25
- adjusting the pressure point 46
Brake lining, 17
- maintaining, 79
Brake,
- using the transport securing
system, 30
Break in operation, 31, 34, 67
- carrying out, 31
- preparing, 31
C
Chain drive, 19
Chain guard,
- checking, 56
Chain tension, 80
Chain wheel, 19
Chain, 14, 19
- maintaining, 80
Charger,
- disposing of, 90
Clamping force,
- Checking the quick releases, 35
- Setting the quick releases, 35
D
Direction of travel, 19
Display, 20, 21, 26
- attaching, 62
- charging the battery, 61, 62, 63, 64,
67
- removing, 63
Drive system, 19
- switching on, 61, 62
E
EC Declaration of Conformity, 101
F
Fork, 15
- setting the compression damper,
72
Fork end, 15
Setting the rebound damper, 71
structure, 16
Frame, 14
Front wheel brake, 17, 18
- braking, 69
Front wheel, see Wheel
G
Gear shift twist grip,
- checking, 79
Gear shift,
- maintaining, 79
- switching, 72
H
Handlebars, 14, 25
Headlight, 19
Hub, 15
I
Initial commissioning 33
J
Journey information, 26
- resetting, 65
- switching, 65
L
Level of assistance, 26
- selecting, 64
ECO, 26
SPORT, 26
TOUR, 26
TURBO, 26
Lever, 17
M
Minimum insertion depth marking, 44
Model year, 8
Motor, 19
Mudguards,
- checking, 56
O
On-screen indicator, 19, 25, 55
Operating status indicator, 20
O-ring, 17
P
Packaging, 32
Pannier rack, 14
- changing, 57
- checking, 56
- using, 57
Pedal, 18, 19
Q
Quick release, 15
R
Rear frame damper,
structure, 17
Rear light, 19
Rear wheel brake, 18
Riding light, 20, 26
- checking function, 56
Rim brake locking lever 18
Rim, 15
- checking, 78
Roller brake,
-braking, 70
S
Saddle, 14
- changing the saddle tilt, 43
- changing the seat length, 45
- determining the saddle height, 43,
45
Seat post, 14
Setting wheel, 17
Shifter,
- checking, 79
- setting, 82
Spoke, 15
Suspension head, 15
System message, 26
System setting, 26
- changing, 65
changeable, 26
T
Transportation, 29
Transporting, see Transportation
Type number, 8
Tyres, 15
- checking, 78
U
Using 73
V
Valve, 15
Dunlop valve, 15
W
Weight,
permitted total weight, 8
Wheel,
- maintaining, 78
Winter break, see Break in operation
MY20H08-2_1.0_30.08.2019 98
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.
MY20H08-2_1.0_30.08.2019 99
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.
MY20H08-2_1.0_30.08.2019 100
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).
13.1 Abbreviations
ABS anti-blocking system
ECP electronic cell protection
13.2 Simplified terms
The following terms are used for better legibility:
Term Meaning
Operating
instructions
Original operating
instructions
Motor Drive motor, sub-system
Table 42: Simplified terms
MY20H08-2_1.0_27.08.2019 101
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 bicycles of types:
20-Q-0055, 20-Q-0056,
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 bicycles 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, 07/08/2019
…………………………………………………………………………………………………
Place, date and signature
Georg Honkomp
-Managing Director-
… 98 …

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