AVE TH5 Operating Manual

Hybrid bike

Hide thumbs

Table Of Contents

Table of Contents

Quick Links

Original

Operating Manual

for ave. Hybrid bikes with Bosch technology

Fit for 2013

ave. TH5, TH7, TH9, TH11

ave. SH5, SH9

ave. XH3, XH5, XH7, XH9

ave. MH eTown, MH7

Version 1.0

Doc. DE2013-01-15PW

Table of Contents

Summary of Contents for AVE TH5

Page 1 Original Operating Manual for ave. Hybrid bikes with Bosch technology Fit for 2013 ave. TH5, TH7, TH9, TH11 ave. SH5, SH9 ave. XH3, XH5, XH7, XH9 ave. MH eTown, MH7 Version 1.0 Doc. DE2013-01-15PW...
Page 2 Manufacturer: deVELOpment engineering GmbH Steinhausen 20 D-85625 Glonn (Germany) +49 (0) 8093 9036-00 +49 (0) 8093 9036-20 eMail info@ave-bikes.de www.ave-bikes.de © Copyright deVELOpment engineering GmbH, Germany Printing errors, mistakes and technical changes reserved Status 1/2013 Original Operating Manual 1-2013...
Page 3: Table Of Contents
Content  Introduction …………………………………………………………………  Models, application areas ..…………………………………….  Hybrid functions, risks …………………........ Your ave. Hybrid bike …………………………………………………….  Content of package ………………………………………………………..  Assembly .……………………………………………………………………..  Commissioning and operating …………....………………  Error checking .………………….......……………………..  Instructions for driving ……………………………………………………...
Page 4: Introduction
IMPORTANT: Your Hybrid bike is equipped with a modern high-performance battery. This requires a small but regular care (see section "battery maintain"). If there are still questions open, please feel free to get in contact with your local ave. dealer or the manufacturer by eMail: info@ave-bikes.de...
Page 5: Models, Application Areas
MAN: 26 inch x 52 cm, 28 inch x 56 cm, 28 inch x 60 cm Fork Suspension fork SR Suntour NCX E/S LO Lite, 63 mm travel, air system, hydraulic speed lock Handlebar ave. Touring, aluminium Headset/ stem 1 1/8“ Ahead, semi-integrated Kalloy alu, double clamp, 33 degrees adjustable, LtSS “length to size system”...
Page 6 Schwalbe Marathon PLUS, 47 mm, flat protection 6, black reflective Hubs Front KT power dynamo, rear NuVinci Harmony advanced Saddle/ seatpost ave. ergotec comfort GEL, double density, Arctec, zonecut; Alu patent 27,2 mm Carrier/stand CAB premium edition Hebie system; comfort flex Hebie fix40 Weight...
Page 7 Schwalbe Marathon greenguard 47 mm, flat protection 5, black reflective Hubs Front Shimano dynamo with quick hub release, rear NuVinci Harmony N360 Saddle/ seatpost ave. ergotec comfort GEL, double density, Arctec, zonecut; alu patent 27,2 mm Carrier/ stand Aluminium tri tubing ave. design with spring flap; Hebie fix40 Weight...
Page 8 Suspension fork SR Suntour NEX HLO, 63 mm travel, lockout Handlebar ave. City comfort, aluminium Headset/ stem 1 1/8“ thread, semi-integrated; ave. alu, trekking adjust, LtSS “length to size system”; Gear Shimano Nexus 8g, 308 % hub gear Brakes Magura HS 11 hydraulic rim brakes...
Page 9 Carrier/ stand Aluminium Tri tubing ave. design with spring flap; Hebie fix40 Weight LOW ENTRY 27,1 kg Electric drive Bosch center drive 36 V, rated power 250 W, torque 50 Nm, sensor control Operating computer Bosch Intuvia, lighted display, remote control, USB loading, removable, mobile operations...
Page 10 Fork Suspension fork SR Suntour CR 8V, 50 mm Elastomer Handlebar ave. Touring, aluminium Headset/ stem 1 1/8“ thread, semi-integrated; ave. alu, trekking adjust, LtSS “length to size system”; Gear Shimano Nexus 7g, 246 % hub gear Brakes Shimano V-brake...
Page 11 Suspension fork SR Suntour NCX E/S LO lite, 63 mm travel, air system, hydraulic speed lock Handlebar ave. Sport rizer, aluminium (oversize) Headset/ stem 1 1/8“ Ahead, semi-integrated; ave. 3D forged, Ahead double clamp, LtSS” length to size system”; Gear SRAM Dualdrive 3x9, 27g, 576% Brakes...
Page 12 Carrier/ stand Hebie system carrier; Hebie fix40 Weight COMFORT 24,9 kg Electric drive Bosch center drive 36 V, rated power 250 W, torque 50 Nm, sensor control Operating computer Bosch Intuvia, lighted display, remote control, USB loading, removable, mobile operations Battery Bosch lithium-ion accumulator 36 V, 400 Wh, battery lock, charger 220 V~ Lighting...
Page 13 Suspension fork SR Suntour NCX D LO lite, 63 mm travel, coil spring, hydraulic speed lock Handlebar ave. Sport rizer, aluminium (oversize) Headset/ stem 1 1/8“ Ahead, semi-integrated; ave. 3D forged, Ahead double clamp, LtSS” length to size system” Gear Shimano Deore 10g, 327 % Brakes...
Page 14 Suspension fork RockShox Reba RLT, air system, travel 120 mm, thru axle 1.5" tapered Handlebar ave. Sport rizer, aluminium (oversize) Headset/ stem One.five tapered Ahead, semi-integrated; ave. 3D forged, Ahead double clamp, LtSS” length to size system” Gear Shimano Deore XT 10sp, 10g, 327 % Brakes...
Page 15 Suspension fork RockShox Recon silver TK, solo air, travel 120 mm, thru axle 1.5" tapered Handlebar ave. Sport rizer, aluminium (oversize) Headset/ stem One.five tapered Ahead, semi-integrated; ave. 3D forged, Ahead double clamp, LtSS” length to size system”; Original Operating Manual 1-2013...
Page 16 Hubs Front KT-MF 1,15 mm thru axle, Shimano Deore disc, 10 speed Saddle/ seatpost ave. ergotec SuperSport, double density, Arctec, starcut; alu patent 30,0 mm rigid race Rear suspension Damper RockShox Monarch R active single pivot, 120 mm, adjustable, lockout...
Page 17 Suspension fork RockShox Reba RTL, travel 120 mm, thru axle 1.5" tapered Handlebar ave. Sport rizer, aluminium (oversize) Headset/ stem One.five tapered Ahead, semi integrated; ave. 3D forged, Ahead double clamp, LtSS” length to size system”; Gear Shimano XT 10sp, 10g, 327 % Brakes...
Page 18 Handlebar ave. Sport rizer, aluminium (oversize) Headset/ stem One.five tapered Ahead, semi integrated; ave. 3D forged, Ahead double clamp, LtSS” length to size system” Gear Shimano SLX 10sp, 10g, 327 % Brakes Shimano SLX hydraulic disc brake, 180 mm Tires Schwalbe Rapid Rob, 2.25", black...
Page 19 Fork Aluminium wide body, gentle rigid Handlebar ave. Sport rizer, aluminium (oversize) Headset/ stem 1 1/8“ Ahead, semi-integrated; ave. compact folding, self-locking stem Gear Shimano Deore 10sp, 10g, 327 % Brakes TEKTRO Draco hydraulic disc brake, 180 mm Original Operating Manual 1-2013...
Page 20 Schwalbe Big Apple, 55 mm, black reflective Hubs Front KT power dynamo, rear Shimano Deore disc 10 speed Saddle/ seatpost ave. ergotec Sport, double density, Arctec, starcut; alu patent 34,9 mm XXL Carrier/ stand Aluminium round tubing, compact design with spring flap; Hebie Weight...
Page 21 Mobility Hybrid MH eTown (CRUISER, DELIGHT) Technical data Design CRUISER Frame Alu 6061; E-specific for Bosch center drive Frame height 26 inch x 43 cm Fork Cromo comfort Cruiser, rigid Handlebar Cruiser comfort, semi flat Headset/ stem 1 1/8“ thread, semi-integrated; aluminium trekking, double clamp Gear Shimano Nexus hub gear, 5g, 208 % Brakes...
Page 22: Hybrid Functions, Risks
Weight 22,5 kg Electric drive Bosch center drive 36 V, rated power 250 W, torque 50 Nm, sensor control Operating computer Bosch Intuvia, lighted display, remote control, USB loading, removable, mobile operations Battery Bosch lithium-ion accumulator 36 V, 300 Wh, battery lock, charger 220 V~ Lighting Shimano dynamo 6V, Busch &...
Page 23 60 km, in mountain areas of course less  ave. Hybrid bikes meet all European standards (CE EN 15194 etc.) and are compliant with international battery safety regulations (UN-T, UL, IEC, RoHS / REACH)
Page 24: Your Ave. Hybrid Bike
IMPORTANT: If hazards or risks in the use of Hybrid bike are ignored, damage of property and personal injury may occur, which can be severe esp. in public traffic situations! Your ave. Hybrid bike The following overview images with legends should help you to quickly capture & positioning components/ features on your bike.
Page 25 Example XH9 (fully) Example Original Operating Manual 1-2013...
Page 26 TH11 Example Legend Operating computer On/off button, charge Pedal/ crank (Intuvia) Gear change lever Quick release lever E-motor (Bosch) Brake lever Saddle Chain guard Stem (MH7 folding) Seatpost Battery (Bosch) Headset Carrier Bracket/ torque sensor Front light Rear light Speed sensor Fork Rear wheel Suspension/ damper...
Page 27: Content Of Package
Content of package The Hybrid bike is supplied by the factory 95% pre-assembled and in a re-usable cardboard box. The box can be used for storage or safe transportation, such as return or repair. If the box is no longer needed, it should be disposed of properly. The package for the final assembly consists of the following items: (examples) handlebar/stem, operating computer...
Page 28: Assembly
Assembly Unpacking Remove the packing materials carefully from the Pedelec base. Check whether all parts and documents are enclosed and nothing was lost or damaged during transit. IMPORTANT: The initial installation should be performed or tested by a dealer/ specialist. The manufacturer is only liable for the delivery status of the bike.
Page 29 IMPORTANT: Incorrectly assembled stems or damaged handlebars can lead to dangerous driving situations and downfalls! Therefore check whether the handlebar is tight (by jerk for- ward & through pressure at fully pulled brake levers), while the headset must not have a slack or cracking noise, but the steering system must go easy, without lock.
Page 30 Example fig. 1 fig. 2 fig. 3 IMPORTANT: A loose saddle or shifting saddle positions can lead to dangerous driving situations and downfalls. Do not drive with a faulty or loose saddle. Always fix the saddle first, before you are going to ride or step-off the bike. Installing the battery If you had removed the battery before assembling the bike, you should now check the charge status of the battery, before mounting it again.
Page 31: Commissioning And Operating
For inserting the carrier battery case, slide it on the carrier bar with the contacts first, until it clicks into the holder (see below). Check, that the battery is firmly seated. carrier battery battery lock/key IMPORTANT: The lock secures the battery in the holder and protects it against misuse by third parties.
Page 32 Commissioning  Insert and release battery (frame and carrier versions) Turn off the battery, if you put it in the holder, or out of the holder (27). The key (23) should be in the lock (24) and the lock must be unlocked, to insert or release the battery. Keep the frame battery (26) with the contacts facing down and insert it into the battery holder (27) on the frame tube.
Page 33 Turn the battery off and unclose the lock with the key (23), before you remove it. Then, pull the battery out of the holder (19). Note: The grip and the housing of the carrier battery should not be used to lift the whole bike. In case of an incorrect battery adjustment on the bar or a misfit of the plug contacts, the rear battery lifting of the bike could cause damages.
Page 34 The best magnet position is near the B or H of the BOSCH sensor label (points of higher sensitivity). If there is still no speed displayed on Intuvia, please get in contact with your ave. dealer. ...
Page 35 To switch on the e-drive unit (9), you have the following options: - pushing the operating computer (3) onto the bracket (4), starts the drive automatically - switching on the Intuvia power button (5), provided the operting computer is attached - pressing the power button at battery side, provided the battery is installed Note: The pedals of the Hybrid bike should not be burdened during switch-on of the system.
Page 36 Indications, buttons, plugs of the operating computer/unit : (see pictures above and below) a motor output (power level) b assistance level c text indication d value indication e speedometer f battery charging status 1 function indication (i = information) 2 lighting on/off ( 5 e-drive/system on/off ( ) 6 re-set button (values to zero/default) 7 USB-port (incl.
Page 37 (e.g. display request ‘connect with bicycle’) by the bike battery or via USB-port by a computer or USB-charger (display indication ‘USB connected’). Intuvia stores the last displayed drive data, including battery level, support level, trip distance and time, remaining range, and can help to evaluate and plan trips at home or during a break. →...
Page 38 Support level in % (share of e-power to medium body power) Level e-power @ derailleur e-power @ hub gear TOUR 100% SPORT 170% 150% TURBO 250% 200% If the operating computer is removed from the holder (4), the previously indicated support level (b) is stored, only the motor power indication (a) remains empty.
Page 39 → Speed and distance indications The speed indication (e) always shows the actual speed of the Hybrid bike. The function indication (= text in c and value in d) comprise the following options: ‘range‘: range being estimated on actual battery charge, provided that all other con- ditions like support level, route profile etc.
Page 40 ‚odometer’ indicates the total distance travelled with the eBike (not changeable) ‚power-on time’ indicates the total eBike travel time (not changeable) → Power supply of the operating computer When the operating computer is attached to the holder (4) and a sufficiently charged battery is in place and switched on, then the power for the operating computer is supplied by the bike.
Page 41: Error Checking
Error checking Error code indication The components of the eBike system are continuously and automatically monitored. When an error is detected, the respective error code is shown in the text indication (c). To return to the standard indication, press any button on the operating computer (3) or the operating unit (10). Depending on the type of error, the drive is automatically shut off, if required.
Page 42: Instructions For Driving
→ Repair If an error persists despite several remedy attempts, please contact your local ave. dealer or an auhtorized Bosch eBike Service. The service personnel will check and do a diagnosis based on the error code, the drive data stored in the system and your information about the circumstances of the failure. Thus will give you fast Service response.
Page 43 fasten luggage bags, baskets or seats only after expert advice. The models are not prepared for trailers. Drive carefully with any load, because it affects driver’s functions considerably, including maneuvering, maintaining balance and braking Electrical system  The electric drive of the pedelec is only available when you move the pedals and it will stop immediately, if you use the brakes (EPAC standard).
Page 44 Combined drives operation (man-machine hybrid)  The pedelec gear is to be used as on normal cycles (see original gear instructions, attached). It serves primarily to adapt to individual requirements and driving needs of the track. During the switching process of a hub gear you may shortly withdraw from pedaling (this makes gear changes easier), with a derailleur gear it is the opposite, you should pedaling to support the shifting ...
Page 45: Battery Charging, Maintain
- Weight of the bike, rider and luggage  Hybrid bike models with Bosch technology indicate the residual range on the operating computer display, where you can orient yourself while driving. The range for e-power support is estimated, based on actual battery charge and load average of the drive Care ...
Page 46 A fully loaded and functional battery will have all 5 LED’s lit permanently Note: If the battery cannot be charged any longer or appears to be damaged, please contact your ave. dealer or an authorized Bosch eBike Service → Charger operations Safety advices ...
Page 47  Keep the charger away from rain or moisture. The penetration of water into a battery charger increases the risk of an electric shock  Before each use, check the battery charger, cable and plug. If damage is detected, do not use the battery charger, there is a risk of electric shocks.
Page 48 (34) with respect to the contacts into the socket (35) of the battery. Do not use force if you have contact problems with your charger. Check the plugs and contacts and try it again; otherwise bring in the charger (incl. cables) to an ave. Bosch eBike Sevice. → Battery charging Once the charger is connected with both, the battery and the power supply, the charging starts automatically.
Page 49 If the battery is faulty while charging or can not be loaded, check the system by the trouble- shooting list below. If a bug can not be fixed, please contact your ave. dealer or an authorized Bosch eBike Service.
Page 50: Battery Store, Disposal
Your local ave. dealer can help you to determine the actual battery status by reading out its operating parameters and clarify your warranty status for substitution.
Page 51 If your battery once have faults (e. g. severe loss of power after short use, permanently low voltage, not rechargeable), then please get in touch with your local ave. dealer. The battery will be returned to the manufacturer (e. g. for checking) or properly disposed.
Page 52: Complete Equipment, Risks
Please follow these instructions and recommended values such as pressure, tightening torques, settings etc. For maintenance please get in contact with your local ave. dealer. Warranty claims of compo- nents may be processed directly with the manufacturer of the original equipment.
Page 53 Hydraulicdisk brakes → Example: Tektro Draco 180 mm Most models are equipped with two disc brake systems (front brake lever is left, rear brake lever right) or with two rim or V-brakes. As brakes are a key safety element, their functioning should be checked before each ride by tightening both brake levers.
Page 54 Gear shift Depending on the model, your ave. Hybrid bike has a quality chain or hub gear shift or a continuously variable transmission (CVT) with automatic  NuVinci N360 Harmony  NuVinci N360  SRAM Dualdrive 27g  Shimano Deore 10g ...
Page 55 part (human) largely is kept constant and the engine support is controlled electronically. This results in a perfect harmony between the two hybrid drives. The translation is adjusted at the throttle (1, see fig. above). The indication (3) shows a hill curve (orange) and the current translation ratio state (bicycle symbol).
Page 56 For details on handling and maintenance, refer to the attached Shimano manual and actual information on the manufacturer's website http://bike.shimano.com/ Example: SRAM Dualdrive at rear hub Note: The Bosch drive is not intended for transmissions with multiple chain rings. Therefore do not change the Hybrid bike in contrary to the specification.
Page 57 For details on handling and maintenance see the enclosed Shimano manual and the manufac- turer's homepage http://bike.shimano.com/ Fork, damper ave. Hybrid bikes are well equipped with suspension forks and dampers  Rock Shox Reba RLT  Rock Shox Recon silver TK ...
Page 58 The hydraulic forks (air, oil) are high-tech units which contribute much to the comfort and safety of ave. Hybrid bikes. The off-road XHybrid has 120mm suspension forks and double chamber air dampers, which help you to move safely and smoothly in the terrain.
Page 59 Wheels, tires → Wheels 20“, 26“, 28“, 29“ ave. Hybrid bikes have premium wheels (aluminum, carbon), spokes and tires, matching the higher demands of an e-driven bike in weight, acceleration and braking deceleration. Most models have a quick-release axle for wheel change, which facilitates the removal and installation of the wheels fast and easy.
Page 60  Before working, remove the battery from the bike, to prevent unintentional driving  Loosen the wheel out of suspension by flipping the quick-release lever (180 °)  Turn the lever of the shaft counter-clockwise, until the wheel loosens enough, that it can be removed from its holder (if necessary remove the axle, keep nut holding screws, and remember position for re-installation) ...
Page 61 Otherwise, get in contact with a professional bicycle repair shop or your ave. dealer. → Tires (Marathon) ave. Hybrid bikes are equipped with impervious tires (Kevlar protection) of high quality  Schwalbe Marathon PLUS (flat-less)  Schwalbe Marathon Greenguard (puncture protection 5) ...
Page 62 When a puncture or wheel clamping occurs, contact your ave. dealer or the next bicycle work- shop, to benefit from their tools, spare parts (tubing, casing, valve, rims, spokes, etc.) and expertise. If you fix the glitch by yourself, adhere to the code of tire mounting and consider the recommendations of the tire manufacturer, as well as proceed for removal and installation in accordance with the steps, described above.
Page 63 Service personnel (warranty). The sensors for measurement inside the housing are adjusted, so that any change to the electronics could make the whole drive unit unusable. If the drive unit fails, due to sensor errors and lack of e-drive support, then bring the Hybrid bike to your ave. dealer.
Page 64 Hybrid bikes of the Touring, Sports and Mobility series have the top line of lighting equipment on board, with super bright LED light (30 lux), daylight function, dimmed and parking lights as well as light bars at the rear for safety.
Page 65 Toplight Line plus Toplight Flat S The rear lights of ave. Hybrid bikes have a bar-shaped beam (Linetec design) and therefore are better to recognize from far distances, than ususal spot lights. In addition, your bike is equipped with the required reflectors, integrated in the front head-lamp and another device at the rear, as well as reflective tire strips, depending on the model.
Page 66 The carrier on ave. Hybrid bikes are stable and designed for smaller loads up to 20 kg (weight w/o battery) and are not intended for the carriage of passengers or heavy loads. If you want to use a bike trailer (max. load 30 resp. 40 kg), you should seek expert advice first, because the bike is not prepared for trailers by factory.
Page 67 Your ave. Hybrid bike has a range of protection and safety equipment on board, some of which are to be discussed here: The chain ring bears on the outside a chain guard, that is designed to prevent pinch of fabric or even body parts, between the gear and the chain and being injured (see fig.
Page 68: Safety Advices For Battery, Charger, Motor
To secure the bike against misuse and simple theft, all Touring and some Sports models have an integrated frame lock on the rear side (see fig. above). This allows you to prevent an unwanted use of the bike. The key corresponds to both, frame and battery lock, so that you only need one key to be on the save side! NOTE: In order to secure your Hybrid bike for parking or a longer stand it is recommended to lock it at the frame or by a chain and to take the operating computer with you and if necessary...
Page 69: Guarantee, Warranty
 Charge the Li-ion battery only with the specified (Bosch) charger  Before each use, check the charger, cables and connectors for visible defects  Do not open the charger itself and let it only repair by qualified personnel  Keep the charger clean and make sure that the vents of the charger are free and clear ...
Page 70: Final Check
1. Do you have read the operating manual carefully before the first ride and be sure, that you are fully familiar with the operations of your ave. Hybrid bike 2. Are all Hybrid bike functions checked before using, are all missing or damaged parts replaced and necessary adjustments or repairs carried out 3.
Page 71: Annex: Identity Tag
Annex: Identity tag Your ave. Hybrid bike has an identity tag (label) whose data you should provide in complaints, warranty processing or for repair. See the label at the lower seat tube end of your Hybrid bike frame. In case of a loss, it is important to identify the bike quickly. Therefore it is recommended that you or your dealer note the model’s name and the stamped frame ID number (at the bottom of...
Page 72: Ec Declaration Of Conformity
EG-Konformitätserklärung Original Operating Manual 1-2013...
Page 73: Abbreviations
Abbreviations Ampere hours (measure of the current flow per hour) Accu/batt. Accumulator/ battery (rechargeable power cells) ave. advanced vehicle engineering (Hybrid bike/eBike brand name of deVELOpment engineering GmbH, Germany) measurement unit for pressure BATSO Battery Safety Organization (industry consortium for battery safety) Certified for Europe (product label to declare conformity with EC rules/laws) Controller Area Network (esp.
Page 74: Notes
Notes deVELOpment engineering GmbH Steinhausen 20 D-85625 Glonn +49 (0) 8093 9036-00 +49 (0) 8093 9036-20 eMail info@ave-bikes.de www.ave-bikes.de Original Operating Manual 1-2013...

This manual is also suitable for:

Th7 Th9 Th11 Sh5 Sh9 Xh3 ... Show all