Page 1 W W W W W W A A 23-15-2055, 23-15-2056, 23-15-2096, 23-15-2158, 23-15-2160, 23-15-2182, 23-15-2184 M Y 2 3 P 0 1 - 2 2 _ 1 . 0 _ 2 1 . 1 0 . 2 0 2 2...
Page 2: Table Of Contents
Contents Contents About these operating instructions Manufacturer Laws, standards and directives Language For your information 1.4.1 Warnings 1.4.2 Markups Aim of the operating instructions Type number and model Frame number Identifying the operating instructions Safety Residual risk 2.1.1 Risk of fire and explosion 2.1.2 Electric shock 2.1.3...
Page 3 3.5.6 Battery level indicator (battery) 3.5.6.1 Battery level indicator (battery) Technical data 3.6.1 Pedelec 3.6.2 Emissions 3.6.3 Bicycle lighting 3.6.4 BOSCH Purion on-board computer 3.6.5 Motor 3.6.5.1 Active Line Plus 3.6.5.2 Active Line 3.6.6 Rechargeable battery 3.6.6.1 PowerPack 400 3.6.6.2 PowerPack 500 3.6.6.3...
Page 4 Checking the battery 5.3.2 Preparing the battery 5.3.2.1 Retrofitting the PowerTube adapter 5.3.2.2 Fit battery cover onto Bosch PowerTube 625 battery (horizontal) 5.3.2.3 Fit battery cover onto Bosch PowerTube 500 battery (horizontal) 5.3.3 Adjusting the suspension system to body weight 5.3.3.1 Adjusting SR Suntour suspension elements 5.3.4...
Page 5 Contents Operation Risks and hazards Tips for a greater range Error message 6.3.1 On-board computer 6.3.2 Rechargeable battery Instruction and customer service Adjusting the pedelec 6.5.1 Preparing 6.5.2 Handlebars 6.5.2.1 Replace handlebars 6.5.2.2 Adjusting the handlebar width 6.5.2.3 Adjusting the hand position 6.5.2.4 Adjusting the handlebars 6.5.3...
Page 6 Contents 6.6.2.2 Approval for trailer with ROHLOFF hub 6.6.3 Pannier rack 6.6.4 Panniers and cargo boxes 6.6.5 Front baskets 6.6.6 Bar ends 6.6.7 Kickstands 6.6.8 Additional battery headlight 6.6.9 Mobile holder 6.6.10 Suspension fork coil spring 6.6.11 Fixed weather protection systems Personal protective equipment and accessories for road safety Before each ride Use suspension and damping...
Page 7 Contents 6.20.1 Use handbrake 6.20.2 Using the back-pedal brake 6.21 Gear shift 6.21.1 Using the derailleur gears 6.21.2 Use SHIMANO hub gear 6.21.3 Using eShift 6.21.3.1 Using eShift with SHIMANO DI2 automatic hub gears 6.21.3.2 Using eShift with manual SHIMANO DI2 hub gears 6.21.3.3 Using eShift with SHIMANO DI2 automatic hub gears 6.22...
Page 8 Contents 7.3.18.1 Clean chain, including all-round chain guard Maintenance 7.4.1 Maintain frame 7.4.2 Maintain fork 7.4.3 Maintain pannier rack 7.4.4 Maintain mudguard 7.4.5 Servicing the kickstand 7.4.6 Maintaining the stem 7.4.7 Maintaining the handlebars 7.4.8 Maintaining the handles 7.4.8.1 Maintaining the rubber handles 7.4.8.2 Maintaining the leather handles 7.4.9...
Page 9 Contents 7.5.10 Checking the riding light 7.5.11 Checking the stem 7.5.12 Checking the handlebars 7.5.13 Checking the saddle 7.5.14 Checking the seat post 7.5.15 Check pedal. 7.5.15.1 Checking the derailleur gears 7.5.15.2 Checking the hub gear 7.5.16 Check gear shift 7.5.16.1 Checking the electric gear shift 7.5.16.2...
Page 10 Contents 9.2.8 Problems with back-pedal brake 9.2.9 Problems with rim brakes 9.2.10 Problem with SR SUNTOUR suspension fork 9.2.10.1 Rebound too fast 9.2.10.2 Rebounding too slowly 9.2.10.3 Suspension too soft on inclines 9.2.10.4 Excessively hard damping on bumps 9.2.11 Problems with SR SUNTOUR rear frame damper 9.2.11.1 Rebound too fast 9.2.11.2...
Page 11 About these operating instructions Thank you for your trust! Copyright Pegasus pedelecs are premium-quality vehicles. © ZEG Zweirad-Einkaufs-Genossenschaft eG You have made an excellent choice. Your specialist dealer will provide you with guidance Distribution or reproduction of these operating and instruction and assemble your product. Your instructions and utilisation or communication of specialist dealer will also be happy to assist you in their content is prohibited unless expressly...
Page 12: About These Operating Instructions
About these operating instructions About these operating instructions Manufacturer 1.4.1 Warnings Warnings indicate hazardous situations and actions. ZEG Zweirad-Einkaufs-Genossenschaft eG You will find three categories of warnings in the Longericher Strasse 2 operating instructions: 50739 Köln, Germany Tel.: +49 221 17959 0 WARNING Fax: +49 221 17959 31...
Page 13: Aim Of The Operating Instructions
About these operating instructions Aim of the operating instructions These operating instructions are not a substitute for personal instruction by the specialist dealer supplying the bike. These operating instructions Section 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.
Page 14: Type Number And Model
Type no. Model Pedelec type owner. The frame number is the most important identifier for verifying ownership. 23-15-2055 Orticello E Unisex City and trekking bicycle Identifying the operating 23-15-2056 Swing E8R Disc 20"...
Page 15: Safety
Safety Safety Residual risk Pedelecs pose the following residual risks: Never use incorrect charger • Risk of fire and explosion Chargers with excessive voltage damage • Electric shock batteries. This may cause a fire or an explosion. • Risk of a crash ...
Page 16 Safety Storing faulty batteries Your specialist dealer will dispose of faulty batteries.  Take faulty batteries to your specialist dealer.  Store the battery in a safety container in a dry place as per special regulations (ADR SV 376, P908) until you dispose of it. Figure 1: Example of a safety container ...
Page 17: Electric Shock
Safety Use correct torque 2.1.2 Electric shock 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. Never use damaged network components  Always observe the indicated tightening torque Damaged chargers, cables and plug connectors on the screw or in Section 3.5.
Page 18: Toxic Substances
Safety Toxic substances 2.2.2 Irritants and If substances are released or used which pose a corrosive risk to people and the environment, effective substances protective measures must be taken. Possible hazards, contamination and health Corrosive substances (also known as corrosives) hazards due to: destroy living tissue or attack surfaces.
Page 19: Personal Protective Equipment
Safety Personal protective equipment Safety markings and safety instructions  Wear a suitable helmet. The helmet must have a reflective strip or a light in a clearly visible Pedelec and battery nameplates contain the colour. following safety markings and safety instructions: ...
Page 20: What To Do In An Emergency
Safety What to do in an emergency After contact with eyes 1 Rinse eyes under flowing water for at least ten 2.8.1 Dangerous situation in road traffic minutes with the lids open; also rinse under lids.  If you encounter any hazards or dangers in road traffic, apply the brake on the pedelec 2 Immediately consult a doctor in case of any until it comes to a halt.
Page 21: Battery Vapour Emission
Safety 2.8.3 Battery vapour emission 2.8.4 Battery fire Vapours may be emitted if the battery is damaged The safety electronics may fail if the battery is or used improperly. The vapours may cause damaged or faulty. The residual voltage can respiratory tract irritation.
Page 22: Data Privacy Information
When the pedelec is connected to the diagnosis tool at the specialist dealer’s, data is transferred to BOSCH eBike Systems (Robert Bosch GmbH) on the use of the Bosch drive unit, including its energy consumption and temperature, to help improve the product.
Page 23: Description
Description Description Proper use All checklists and instructions for actions in these reflectors and other components when riding on operating instructions met. Approved accessories public roads. The general laws and the can be installed by specialist staff. regulations for the prevention of accidents and environmental protection in the respective country Use the pedelec when it is in perfect, proper of use must be adhered to.
Page 24: Maximum Permitted Total Weight (Ptw)
• plus body weight • plus baggage Type no. Model PTW [kg] 23-15-2055 Orticello E Unisex 23-15-2056 Swing E8R Disc 20" 23-15-2096 Ancura E7R HS11 (Wave) (NL) 23-15-2158 Ravenna EVO 7F (Gent) (NL)
Page 25: Nameplate
Description Nameplate The nameplate is situated on the frame. The The nameplate contains up to twelve pieces of precise position of the nameplate is shown in information. Figure 3. ZEG Zweirad-Einkaufs- Genossenschaft eG Longericher Str. 2 50739 Köln, Germany Typ: 23-15-2115 EPAC nach...
Page 26: Components
Description Components 3.3.1 Overview Figure 3: Pedelec viewed from the right Front wheel Frame Kickstands Front wheel hub Seat post Shifting hub Fork Saddle Chain guard Front wheel brake Pannier rack Frame number Front wheel mudguard Rechargeable battery Motor and motor cover Front light Rear light Pedal...
Page 27: Chassis
Description 3.3.2 Chassis Frame size for city and trekking bicycle, folding bicycle and cargo bike The chassis comprises two components: The tolerance for the frame height and its • Frame and associated top tube length is somewhat greater • steering system for city bicycles due to the more upright riding position.
Page 28 Description Frame size for racing bicycles and gravel Frame size for child’s bike bikes Children are growing constantly. As a result, the The different frame heights are closer together on frame size needs to be checked every six months. racing bicycles and gravel bikes. Smaller It is important that riders, especially learners, can increments in the frame heights ensure precise safely put both feet on the ground.
Page 29: Steering System
Description 3.3.2.2 Steering system The steering system components are: • Steering headset, • Stem, • Handlebars • Fork. 3.3.2.3 Steering headset The steering headset (also known as a bike headset or simply a headset) is the fork bearing system in the frame. A distinction is made between two different types: •...
Page 30: Handlebars
Description 3.3.2.5 Handlebars 3.3.2.7 Rigid forks The pedelec is steered using the handlebars. The handlebars are used to support the upper body and is the mount for operating and display components (see Section 3.5.1). Figure 7: Handlebar dimensions The main dimensions of handlebars are: Rise (measured from centre of bar to bar end) Width Backsweep...
Page 31: Suspension Fork
Description 3.3.2.8 Suspension fork The stem and handlebars are attached to the top end of the fork steerer. The axle is fastened to the fork ends. The wheel is fastened to the axle. Unlike rigid forks, suspension forks improve contact with the ground and thus enhance comfort using two functions: •...
Page 32 Description Suspension fork structure Figure 10: Suspension fork structure Fork steerer Tyre clearance Sag adjuster Fork crown Tyre height Fork deflection Tyre passage width Damper side Quick release Side view Pitch Installation height Fork end Offset Quick release axle Air suspension side Lower Fork bridge (also known as arch) Stanchion...
Page 33 Description Fork assembly groups A suspension fork can feature up to three different assembly groups: • Compression damper (blue) • Rebound damper (red) • Air suspension or steel spring (orange) Figure 12: Internal structure of a steel spring fork Deflection adjustment ring Sag setting wheel Compression dampers Suspension fork structure...
Page 34 Description Negative deflection (sag) The negative deflection (sag) is the percentage of The pedelec rebounds at a controlled speed if it is entire deflection that is compressed by the rider’s optimally adjusted. The wheel stays in contact body weight, including equipment (such as a with the ground when passing over bumps (blue backpack), the seating position and frame line).
Page 35 Description Rebound dampers increases, the extension and rebound speeds also increase. Rebound damping needs to be Rebound dampers damp rebound movements, i.e. increased to achieve an optimal setting if the air rebound stress loads. Rebound damping pressure or spring stiffness is increased. The determines the speed at which the suspension damper rebounds at a controlled speed if the fork rebounds after being exposed to load.
Page 36 Description High-speed damper A high speed is generated in the suspension fork, The settings on the high-speed damper control e.g. on a mogul slope or during landing after a the suspension behaviour of the fork during jump. • stronger impacts •...
Page 37: Sr Suntour Lo
Description 3.3.2.9 SR SUNTOUR LO The SR Suntour LO cartridge features a • a compression damper 2. 2. • a rebound damper Before riding, the rebound adjuster (1) is used to adjust the system to the surface concerned. The compression adjuster (2.2) remote control can be used to open and close damping.
Page 38: Sr Suntour Hlo
Description 3.3.2.10 SR SUNTOUR HLO The SR Suntour HLO cartridge features a • a compression damper 2. 2. • a rebound damper Before riding, the rebound adjuster (1) is used to adjust the system to the surface concerned. The compression adjuster (2.2) remote control can be used to open and close damping.
Page 39: Wheel
Description 3.3.3 Wheel Tyre pressure The permitted pressure range is indicated on the side of the tyre. It is indicated in psi or bars. The tyre is only able to support the pedelec if there is adequate tyre pressure. The tyre pressure must be adjusted to the body weight and then checked on a regular basis.
Page 40 Description Carcass Tread with profile The carcass is the tyre’s supporting structure. A rubber tread is attached to the exterior of the There are usually three carcass plies beneath the carcass. tread. The carcass comprises a webbing with The tread has little influence on riding characteristics threads, usually made of polyamide (nylon).
Page 41 Description Bead core Puncture protection belt (optional) Tyre carcasses are wrapped around bead cores. There may be a puncture protection belt between Wrapping the carcass around both sides creates the carcass and the tread. three carcass plies. To ensure that tyres do not slip when inflated on the rim and have an effective grip, the bead cores are stabilised in two different ways: Figure 26: Effect of puncture protection belt...
Page 42: Rim
Description 3.3.3.3 Rim The rim is the metal profile on a wheel which holds the tyre, tube and rim band together. The rim is joined to the hub with spokes. In rim brakes, the outer surface of the rim is used to brake.
Page 43: Hub
Description 3.3.3.7 Hub The hub is located in the centre of the wheel. The hub is connected to the rim and tyre with the spokes. An axle runs through the hub, connecting the hub with the fork at the front and with the frame at the rear.
Page 44: Saddle
Description 3.3.4 Saddle The purpose of the saddle is to absorb body When riding, the rider's body weight is distributed weight, provide support and enable different riding between the pedals, the saddle and the positions. The shape of the saddle thus depends handlebars.
Page 45: Ladies' Saddle
Description 3.3.4.1 Ladies’ saddle 3.3.4.2 Men’s saddle The distance between the ischial tuberosities and In contrast to the female anatomy, men's pubic the pubic symphysis is on average a quarter less bones are at a much steeper angle to one another. in women than in men.
Page 46: Seat Post
Description 3.3.5 Seat post Seat posts are not designed to fasten the saddle but also to adjust exactly to the optimum sitting position. The seat post can: • adjust the seat height in the seat tube • adjust the saddle horizontally with a clamping mechanism and •...
Page 47 Description SATORI, Harmony LT2 The Satori Harmony LT2 is a suspension seat post which is immune to side play thanks to a patented, square stanchion forged in a single piece. It contains a coil spring which can be replaced to adjust to the rider’s body weight.
Page 48: Brake
Description 3.3.6 Brake 3.3.6.2 Hydraulic brake A pedelec’s brake system is primarily operated using the brake lever on the handlebars. The brake fluid is in a closed hose system. If the brake lever is pulled, the brake fluid transfers • If the left brake lever is pulled, the brake on the front wheel is applied.
Page 49: Disc Brake
Description 3.3.6.3 Disc brake Figure 41: Brake system with disc brake – example Brake disc Brake calliper with brake linings Handlebars with brake lever Front wheel Brake disc Rear wheel brake disc On a pedelec with a disc brake, the brake disc is permanently screwed to the hub.
Page 50: Rim Brake
Description 3.3.6.4 Rim brake Figure 42: Brake system with rim brake in detail – MAGURA HS22 used as an example Rear wheel rim brake The rim brake stops the wheel moving when the Brake lining rider pulls the brake lever, causing two brake Brake booster linings, positioned opposite one another, to press Handlebars with brake lever...
Page 51: Backpedal Brake
Description 3.3.6.5 Back-pedal brake Figure 44: Brake system with a back-pedal brake – example Rear wheel rim brake Handlebars with brake lever Front wheel rim brake Pedal Backpedal brake The back-pedal brake is an extra brake. The back- pedal brake stops the rear wheel from moving by pushing the pedals in the opposite direction to the direction of travel.
Page 52: Mechanical Drive System
Description 3.3.7 Mechanical drive system 3.3.7.1 Chain drive layout The pedelec is driven by muscle power, just like a bicycle. The force which is applied by pedalling in the direction of travel drives the front chain wheel. The chain or belt transmits the force onto the rear chain wheel and then onto the rear wheel.
Page 53: Electric Drive System
(not shown). emergency. 3.3.8.2 Charger Each pedelec is supplied with a charger. As a general rule, any BOSCH charger may be used: • The 2A compact charger • The 4A standard charger •...
Page 54: On-Board Computer
Description 3.3.10 On-board computer The pedelec has a BOSCH Purion on-board computer. The on-board computer controls the drive system and shows the journey data on the display screen. The battery powers the on-board computer. The on-board computer also has two internal non- rechargeable coin cells.
Page 55: Description Of Controls And Screens
Description Description of controls and screens 3.4.1 Handlebars Figure 50: Detailed view of handlebars from sitting position, example Rear wheel hand brake On-board computer Bell Lockout Headlight Shifter Front wheel handbrake MY23P01 - 22_1.0_21.10.2022...
Page 56: On-Board Computer
L K K K K K L L K K K K W W A W W W W W W A A Figure 51: BOSCH Purion on-board computer layout Figure 52: Display overview Indicator for km/h or mph (see Section Symbol 3.8.1.1)
Page 57: Information Display
Description 3.5.1.3 Information display 3.5.1.5 Riding light symbol The display shows one of three types of The riding light symbol is shown when the information. The displayed information can be riding light is on. changed. 3.5.1.6 Maintenance indicator Display Function Indicates that maintenance is required.
Page 58: Gear Shift
Description 3.5.3 Gear shift 3.5.3.1 SHIMANO SL-T6000 derailleur gears Only applies to vehicles with this equipment The gear shift unit is on the left of the handlebars. The gear shift unit features two switches and an indicator. Figure 53: SHIMANO SL-T6000 gear shift 1 Gear indicator 2 Lever A (gear shift) 3 Lever B (gear shift)
Page 59: Shimano Hub Gear
Description 3.5.3.2 SHIMANO hub gear Only applies to vehicles with this equipment SHIMANO hub gears feature a twist grip with a display on the right-hand side of the handlebars. Figure 54: SHIMANO SL-C30000-7 twist grip, top view Twist grip Gear indicator The Gear indicator shows the selected gear.
Page 60: Handbrake
Description 3.5.4 Handbrake There is a handbrake on the left and right of the handlebars. Figure 55: Front wheel (2) and rear (1) brake levers – Shimano brake used as an example The left handbrake (2) controls the front wheel The right handbrake (1) controls the rear wheel brake.
Page 61: Suspension And Damping
Description 3.5.5 Suspension and damping 3.5.5.1 Air valve and sag setting wheel SR SUNTOUR Model AIR EQ COIL Adjustable COIL Air valve (fork) Air valve (fork) Sag setting wheel Sag setting wheel Suspension Air suspension Air suspension Steel spring Steel spring Durolux Auron ZERON35...
Page 62: Battery Level Indicator (Battery)
Description 3.5.6 Battery level indicator (battery) 3.5.6.1 Battery level indicator (battery) Each battery has its own level indicator: The five green LEDs on the battery level indicator show the charge level when the battery is switched on. Each LED represents 20% of battery capacity. LED 1,2,3,4,5 Battery level 100…80%...
Page 63: Technical Data
Table 28: Technical data for Active Line Plus BDU310 Charging temperature 0 °C - + 40 °C motor Protection class IPx7 (with USB cover closed) Weight about 0.1 kg Table 26: Technical data for BOSCH Purion on-board computer (BUI215) MY23P01 - 22_1.0_21.10.2022...
Page 64: Rechargeable Battery
Description 3.6.6 Rechargeable battery 3.6.6.3 PowerTube 400 Internal battery, horizontal 3.6.6.1 PowerPack 400 Nominal voltage 36 V Standard battery, seat tube Max. voltage 42 V Nominal voltage 36 V Nominal capacity 11 Ah Nominal capacity 11 Ah Rated current 10 A Energy 400 Wh Max.
Page 65: Saddle
Description 3.6.7 Saddle 3.6.7.1 BROOKS ENGLAND saddle width 3.6.7.3 SELLE ROYAL saddle width Riding position Riding position Athletic Position on trekking bike Narrow saddle Position on trekking bike Sharply inclined upper body, Sharply inclined upper body, back at an angle of 30°…60°. back at an angle of 30°…60°.
Page 66: Satori Suspension Seat Post, Harmony Lt2
Description 3.6.7.4 SATORI suspension seat post, Harmony LT2 Figure 60: Satori seat post dimensions, SATORI, Harmony-LT2 Numbering in drawing Maximum Mounting body- Offset Angle Length Ø Deflection Variable type fixture [mm] weight [mm] [°] [mm] [mm] [mm] [mm] [kg] 27.2 Ø 300 43 ×...
Page 67: Fork
Description 3.6.8 Fork 3.6.8.1 Maximum rider weight for SR SUNTOUR steel suspension fork SR SUNTOUR steel suspension forks are available in three different hardness types for different body weights: Medium Coil spring model Soft Hard/rigid Fitted as standard Max. bodyweight [kg] 50 - 75 70-95 90-120...
Page 68: Tyres
Description 3.6.9 Tyres V-GUARD The V-Guard puncture protection 3.6.9.1 SCHWALBE puncture protection level belt comprises of lightweight, cut- resistant fibres. Its webbing ensures highly effective puncture resistance Inserts Webbing for lightweight race and tour tyres. Rubber insert insert Combination SmartGuard® DualGuard Tubeless Easy Double Defense®...
Page 69: Tyres, Supero Puncture Protection Level
Description 3.6.9.2 Tyres, SUPERO puncture protection level Level 7 Rubber Combination of Webbing insert inserts insert An EPS webbing layer is located beneath a 3-mm LPD layer. Level 7 Level 6 Level 6 EPS 2 EPS BtB An EPS webbing layer is combined with a 1-mm layer of rubber.
Page 70: Torque
Mounting bracket 0.8 Nm Torx® T20 FIT Remote Display Mounting bracket 0.8 Nm Torx® T20 BOSCH Intuvia 100 bracket Attachment screw 1, M3 × 22 1 Nm 3 mm hex bit Attachment screw 2, M3× 14 1 Nm 3 mm hex bit...
Page 71 Description BOSCH Mini Remote Attachment screw 0.4 Nm (not 0.6 Nm, as written on mini-remote) 3 mm hex bit SHIMANO SC-E5003 0.8 Nm 3 mm hex bit Attachment screw Brake linings SHIMANO Hex key, 3 mm Circlip 2–4 Nm Slotted-head screwdriver...
Page 72 Description Brake disc SHIMANO for centre lock type TL-LR15 Attachment screw, quick TL-FC36/TL-LR11 release 40–50 Nm Adjustable spanner SHIMANO for centre lock type Attachment screw, nut TL-LR10 version 40–50 Nm Screw wrench SHIMANO for 5-hole version Attachment screws 2–4 Nm Star bit [no.
Page 73 Description Fork Intend Edge Double bridge screw 12 Nm SR SUNTOUR Suspension side, top, plastic 5 Nm SR SUNTOUR Suspension side, top, aluminium 20 Nm SR SUNTOUR Suspension side, bottom 10 Nm Hex bit (torque) SR SUNTOUR Suspension side, bottom 8 Nm Aluminium nut (torque) SR SUNTOUR...
Page 74 Description SRAM RockShox, Lyrik, ButterCup housing guide rod end plate - end plate to guide rod - air suspension and damper 3.3 Nm Torx® T25 SRAM RockShox, Lyrik, ButterCup housing (top) to ButterCup housing (bottom) – air suspension and damper 3.3 Nm 23 mm spanner head SRAM RockShox...
Page 75 Description Handbrake SHIMANO Hex key, 4 mm Attachment screw 6–8 Nm Hex key, 5 mm SHIMANO Attachment screw, BL-M987/ BL-M9000/BL-M9020 4–6 Nm Hex key, 4 mm SHIMANO, lever for disc brake Bleed nipple 4–6 Nm Socket wrench, 7 mm SHIMANO, lever for disc brake Bleed screw 0.3–0.5 Nm...
Page 76 Chain guard Brose chain guard bash guard Hex key, 3 mm Attachment screws 6 Nm Chain guard for BOSCH Motor BDU37xx Attachment screws max. 10 Nm M6 × 10; head: max. 5 mm; length: max. 8.5-mm Crank bearing/crank set Conventional cartridge crank …...
Page 77 Description Motor cover BOSCH motor cover BDU37xx Initial fitting: 3 ± 0.5 Nm Torx® TX 20 Attachment screws for lower Retrofit: 2 ± 0.5 Nm motor cover Initial fitting: 3 ± 0.5 Nm Torx® TX 20, 4 × 8 mm Attachment screws for motor Retrofit: 2 ±...
Page 78 Description ROHLOFF, 14/500 Attachment screw for shift handle on handlebars 1 Nm 2.5 mm hex bit ROHLOFF, 14/500 End stop 3 Nm Torx® TX 20 ROHLOFF, 14/500 Cable guide 6 Nm 4 mm hex bit SHIMANO quick release version FH-M3050, FH-M4050, FH- 40 Nm Adjustable spanner and special tool TL-LR15 MT200-B, FH-MT400, FH-...
Page 79 Description SHIMANO hub dynamo J2 model 20 Nm Screw wrench SHIMANO hub dynamo J2-A model 20 Nm Screw wrench Pedal Pedal, conventional 33 … 35 Nm Screw wrench, 15 mm SHIMANO Attachment screw 35–55 Nm Screw wrench, 15 mm Seat post by.schulz, G1 M8 seat clamp screw 20 …...
Page 80 Description Rear derailleur SHIMANO for MTB/trekking Attachment screw, standard type 8–10 Nm Hex key, 5 mm SHIMANO for MTB/trekking Attachment screw with bracket 3–4 Nm Hex key, 5 mm SHIMANO for BMX bicycles Attachment screw 3–4 Nm Adjustable spanner SHIMANO for MTB/trekking Hex key, 4 mm/ Attachment screw for inner 6–7 Nm...
Page 81 Description SHIMANO for racing bicycles Attachment screw, Bowden Hex key, 5 mm/ cable 6–7 Nm Underride guard Socket wrench, 8 mm FIT, Brose Hex key, 4 mm Attachment screws 6 Nm Hex key, 3 mm V-Brake brake SHIMANO Attachment screw for Hex key, 5 mm connecting cable 6–8 Nm...
Page 82: Transporting And Storing
Transporting and storing Transporting and storing Weight and dimensions for transportation Weight and dimensions during transportation 23-15-2055 23-15-2056 23-15-2096 23-15-2158 23-15-2160 23-15-2182 23-15-2184 Table 37: Type number, model and pedelec type * Vehicle weight without battery # Not yet available when the instructions were produced Designated handles, lifting points The box does not have any handles.
Page 83: Transportation
Transporting and storing Transportation 4.3.2 Transporting the pedelec Lithium-ion batteries store great amounts of energy. You must comply with a few precautionary CAUTION measures when transporting gas cylinders.  Discharge battery to about 30% before placing Crash caused by unintentional activation pedelec in a vehicle to transport or take it on a There is a risk of injury if the drive system is trip.
Page 84: By Local Transport
Transporting and storing 4.3.4 Transporting the battery 4.3.2.3 By local transport You can normally take pedelecs on local public Batteries are subject to hazardous goods transport, e.g. by bus or suburban rail, if you regulations. Undamaged batteries may be purchase a bike ticket. There may be times when transported by private persons in road traffic.
Page 85: Storing
Transporting and storing Storing  Store pedelec, on-board computer, battery and 4.4.3.1 Storage mode charger in a clean, dry place where they are The battery features a power-saving storage protected from sunlight. Do not store outdoors mode status, which minimises discharge from the to ensure a long service life.
Page 86: Break In Operation
Transporting and storing 4.4.4 Break in operation 4.4.4.1 Preparing a break in operation Remove the rechargeable battery from the  Notice pedelec. Charge battery to 30%–60%.  The battery discharges when not in use. This can The pedelec needs to be cleaned with a damp ...
Page 87: Assembly 5.1 Unpacking
Assembly Assembly Scope of delivery WARNING 1 × pre-assembled pedelec  Risk of eye injury 1 × front wheel  Problems may arise if components are set 2 × pedals  incorrectly. They may cause serious injuries to 2 × quick releases (optional) ...
Page 88: Commissioning
Assembly 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 customers as soon as it appears ready to ride. ...
Page 89: Preparing The Battery
Only applies to pedelecs with this equipment 4 Remove the PowerTube adapter. The PowerTube Adapter 400 or 500 needs to be altered to use the BOSCH PowerTube 625 battery mount. 1 Use a TORX® T25 wrench to undo the screws in the battery mount.
Page 90: Fit Battery Cover Onto Bosch Powertube 625 Battery (Horizontal)
Assembly 5.3.2.2 Fit battery cover onto Bosch PowerTube 625 battery (horizontal) Only applies to pedelecs with this equipment 1 Detach upper interface (lock side) from the BOSCH PowerTube 625 battery with a TORX® T20 wrench. Figure 71: Pushing the battery cover onto battery ...
Page 91: Fit Battery Cover Onto Bosch Powertube 500 Battery (Horizontal)
Assembly 5.3.2.3 Fit battery cover onto Bosch PowerTube 500 battery (horizontal) Only applies to pedelecs with this equipment 1 Detach upper interface (lock side) from the 3 Screw the battery mounting plate onto BOSCH PowerTube 625 battery with a TORX®...
Page 92: Adjusting The Suspension System To Body Weight
Assembly 5.3.3 Adjusting the suspension system to body weight Not included in price 5.3.3.1 Adjusting SR Suntour suspension elements Seat post and forks are components that may be § Not included in price replaced after approval by the vehicle or parts manufacturer.
Page 93: Installing The Wheel In The Suntour Fork
Assembly 5.3.4 Installing the wheel in the SUNTOUR fork Only applies to Suntour forks with this equipment 5.3.4.1 Screw-on axle (12AH2 and 15AH2) Only applies to Suntour forks with this 4 Insert the securing screw on the non-drive equipment side. Before installing the wheel, ensure that the O-ring ...
Page 94: Mm Cross Axle
Assembly 5.3.4.2 20 mm cross axle Only applies to Suntour forks with this 2 Tighten the cross axle with the red handle. equipment CAUTION Crash caused by loose cross axle A faulty or incorrectly installed cross axle may become caught in the brake disc and block the wheel.
Page 95 Assembly 5 Check the position and clamping force of the quick release lever. The quick release lever must be flush with the shock absorber. Figure 85: Perfect position for the clamping lever 6 Use 4 mm hexagon socket spanner to adjust the clamping lever clamping force if required.
Page 96: Q-Loc Quick Release
Assembly 5.3.4.3 Q-LOC quick release Only applies to Suntour forks with this equipment 1 Push in the quick release until you can hear a click. Make sure that the flange is extended. CAUTION Crash caused by unfastened quick release A faulty or incorrectly installed quick release may become caught in the brake disc and block the wheel.
Page 97: Preparing The Wheel
Assembly 5.3.5 Preparing the wheel There is an arrow on the sides of the tyres with the • The FRONT rotation direction arrow indicates the recommended direction of rotation for the front inscription ROTATION to show the direction of wheel. rotation.
Page 98: Fitting The Pedals
Assembly 5.3.6 Fitting the pedals The pedals have two different threads to ensure 3 Turn the pedal marked R anti-clockwise by they don’t come loose while the rider is pedalling. hand into the crank arm on the right as seen when facing the direction of travel.
Page 99: Checking The Stem And Handlebars
Assembly 5.3.7 Checking the stem and handlebars 5.3.7.1 Checking the connections 5.3.7.3 Checking the bearing clearance 1 Stand in front of the pedelec. Clamp the front 1 Place the fingers of one hand on the upper wheel between your legs. Grasp the handlebar headset cup.
Page 100: Operation
Operation Operation Risks and hazards WARNING WARNING Injuries and death caused by distraction Injuries and death caused by blind spots A lack of concentration while riding increases the Other road users, trucks, cars and pedestrians risk of an accident. This may cause a crash with often underestimate the speed of pedelecs.
Page 101 Operation Notice CAUTION Heat or direct sunlight can cause the tyre pressure Crash caused by material fatigue to increase above the permitted maximum Intensive use can cause material fatigue. A pressure. This can destroy the tyres. component may suddenly fail in case of material ...
Page 102: Tips For A Greater Range
Operation Tips for a greater range The pedelec’s range depends on many Gear switching habits influencing factors. A single battery charge may only last fewer than 20 kilometres but much more  Use a low gear and a low level of assistance on than 100 is also possible.
Page 103: Error Message
Operation Error message 6.3.1 On-board computer The drive system monitors itself continuously and Code Description Method of resolution displays a number as an error message if a known Battery internal error Re-start the system. error is detected. The system may switch off Contact your specialist automatically depending on the type of error.
Page 104 Operation Code Description Method of resolution Code Description Method of resolution Configuration error Re-start the system. Temperature error Switch off the system to cool The pedelec is outside the motor and battery down Contact your specialist the permitted temper- or warm them to the dealer if the problem ature range.
Page 105: Rechargeable Battery
Operation 6.3.2 Rechargeable battery Code Description Method of resolution The battery is protected against deep discharge, Error in the line to the  Contact specialist rear wheel speed dealer. overcharging, overheating and short circuits by sensor Electronic Cell Protection (ECP). In the event of a Implausible signals Re-start the system.
Page 106: Instruction And Customer Service
Operation Instruction and customer service 6.5.1 Preparing The supplying specialist dealer will provide customer service. Contact details can be found on the pedelec pass for these operating instructions. The following tools are required to adjust the pedelec: The specialist dealer will explain all the pedelec functions to the new owner in person, this being when the specialist dealer hands over the pedelec Tape measure...
Page 107: Handlebars
Operation 6.5.2 Handlebars 6.5.2.1 Replace handlebars 6.5.2.3 Adjusting the hand position The hand is an optimal position on the handlebars Not included in price when the forearm and hand are in a straight line, i.e. the wrist is not bent. In this way, the nerves are Handlebars are components that may be §...
Page 108: Adjusting The Handlebars
Operation 6.5.2.4 Adjusting the handlebars The handlebars and their position determine the posture that the pedelec rider adopts on the pedelec. 1 After selecting the riding position (see Section 6.6.2.1), determine the angle of the upper body and upper arm. 2 Pre-tension the back muscles when adjusting the handlebars.
Page 109: Stem
Operation 6.5.3 Stem 6.5.3.1 Replacing the handlebars 2 Pull out the handlebars to the required height. Observe minimum insertion depth. Not included in price Handlebar-stem units are components that may § be replaced after approval by the vehicle or parts manufacturer.
Page 110: Setting The Quill Stem
Operation 6.5.3.5 Setting the quill stem 6.5.3.6 Adjusting the Ahead stem Only applies to pedelecs with this equipment Only applies to pedelecs with this equipment In the case of a quill stem, the stem and fork In the case of an Ahead stem, the stem is placed steerer form a permanently interconnected directly on the fork steerer, which protrudes over component, which is clamped in the fork steerer.
Page 111: Adjusting The Angle-Adjustable Stem
Operation 6.5.3.7 Adjusting the angle-adjustable stem Only applies to pedelecs with this equipment Angle-adjustable stems are available in different lengths for quill and Ahead stems. Figure 102: Different versions of angle-adjustable stems Adjusting the stem angle (c) changes both the distance from the upper body to the handlebars (b) and the handlebar height (a).
Page 112: Handles
Operation 6.5.4 Handles 6.5.4.1 Replacing the handles 6.5.4.2 Adjusting ergonomic handles Only applies to pedelecs with this equipment Not included in price Handles with bolt clamps are components which § may be replaced without approval. Only handles that are approved for use on e-bikes may be used to replace the existing ones.
Page 113: Tyres
Operation 6.5.5 Tyres 6.5.5.1 Replacing tyres As a general rule, wide tyres are operated at a lower tyre pressure. They provide the option of Not included in price exploiting the advantages of the lower tyre pressure without the serious disadvantages it Different tyres need to be used when the area of causes with regard to wear, rolling resistance and §...
Page 114 Operation 2 Perform a visual check on tyres. Figure 105: Correct tyre pressure. The tyre is barely deformed under the load of the body weight Figure 106: Far too little tyre pressure MY23P01 - 22_1.0_21.10.2022...
Page 115: Brake
Operation 6.5.6 Brake 6.5.6.3 Change handbrake position The handbrake grip distance can be adjusted to ensure that it can be reached more easily. The Having the handbrake in the correct position pressure point can also be adjusted to the pedelec prevents the rider from stretching their wrist too rider’s preferences.
Page 116: Change Handbrake Inclination Angle
Operation 6.5.6.4 Change handbrake inclination angle 2 Set the brake lever angle as indicated in the table. The nerves that pass through the carpal tunnel are connected to the thumb and the index and middle fingers. An excessively steep or excessively flat brake angle will cause the wrist to 20 –...
Page 117: Setting The Grip Distance For A Magura Handbrake Disc Brake
Operation 6.5.6.6 Setting the grip distance for a MAGURA handbrake disc brake Only applies to pedelecs with this equipment The handbrake position can be adjusted to the rider’s requirements. Such adjustment does not WARNING affect the pressure point or the position of the Crash caused by incorrectly set grip distance brake linings.
Page 118: Grip Distance On Magura Hs11 Handbrake
Operation 6.5.6.7 Grip distance on Magura HS11 handbrake Only applies to pedelecs with this equipment The handbrake position can be adjusted to the Use a 2.5 mm wrench to turn the setting screw (1)  to adjust the grip distance. rider’s requirements.
Page 119: Grip Distance On Shimano St-Ef41 Handbrake
Operation 6.5.6.8 Grip distance on SHIMANO ST-EF41 handbrake Only applies to pedelecs with this equipment The handbrake position can be adjusted to the Notice rider’s requirements.  Undo 2 mm setting screw anti-clockwise. If the setting screw is fully removed, components inside the handbrake will also be permanently ...
Page 120: Gear Shift
Operation 6.5.7 Gear shift 6.5.7.1 Replacing the gear shift Adjust the position of the gear shift to the pedelec riders’ needs. Not included in price 1 Undo attachment screw. All gear shift components (rear derailleur, shifter, 2 Place control panel or shifter into the position §...
Page 121: Suspension
Operation 6.5.8 Suspension Suspension and damping can be adjusted to the  Follow the correct order for adjustment. rider’s weight in up to three increments, depending on the suspension system. Sequence Adjustment Section Adjust the suspension fork sag Section 6.5.9 Adjust the suspension fork rebound damper (optional) Section 6.5.10...
Page 122 Operation When optimally adjusted, the fork counteracts This allows the rider to maintain the same speed deflection on hilly terrain and stays higher in its more easily on hilly terrain. deflection range. Figure 116: Optimum fork ride performance on hilly terrain When optimally adjusted, the fork deflects quickly The fork responds quickly to the bump.
Page 123: Adjusting The Sag For The Sr Suntour Steel Suspension Fork
Operation 6.5.9.1 Adjusting the sag for the SR SUNTOUR steel suspension fork Only applies to pedelecs with this equipment You can pre-tension the steel suspension to riding style. It is not the coil spring hardness which adjust to the rider's weight and their preferred is adjusted;...
Page 124: Fork Rebound Damping
Operation 6.5.10 Fork rebound damping Only applies to pedelecs with this equipment Rebound damping in the suspension fork and the Rebound damping needs to be increased to rear frame damper determines the speed at which achieve an optimal setting if the air pressure or the rear frame damper rebounds after being spring stiffness is increased.
Page 125: Adjusting The Sr Suntour Fork Rebound Damping
Operation 6.5.10.1 Adjusting the SR SUNTOUR fork rebound damping Only applies to pedelecs with this equipment Figure 120: Example of SR SUNTOUR rebound screw (1) The fork sag is adjusted.  1 Turn the rebound screw in a clockwise direction towards the closed position until it stops.
Page 126: Riding Light
Operation 6.5.11 Riding light 6.5.11.1 Replacing the headlight 6.5.11.2 Replacing the rear light and (spoke) reflector Not included in price Not included in price Headlights may only be replaced after approval § The rear light and (spoke) reflector may be §...
Page 127: Adjusting The Headlight
Operation 6.5.11.4 Adjusting the headlight 1 Position the pedelec so that its front is facing a wall. 2 Mark the height of the headlight (1) on the wall with chalk. 3 Mark half the height of the headlight (2) on the wall with chalk.
Page 128: On-Board Computer
The display must be switched off.  1 Keep the plus and minus buttons pressed down at the same time. Figure 124: BOSCH Purion on-board computer layout 2 Press On-Off button (display) briefly. Symbol 3 Use the plus button or minus button to adjust...
Page 129: Accessories
Operation Accessories Notice Not included in price  Observe the legal regulations on the use of child seats. 6.6.1 Child seat  Observe the operating and safety instructions Child seats may only be used with the vehicle for the child seat system. §...
Page 130: Trailer
Operation 6.6.2 Trailer 6.6.2.1 Approval for trailer with Enviolo hub Trailers may only be used with the vehicle Only applies to pedelecs with this equipment § manufacturer’s approval and only if they are approved for use on e-bikes. Only compatible bicycle trailers are approved for ENVIOLO hub gears.
Page 131: Approval For Trailer With Rohloff Hub
Operation 6.6.2.2 Approval for trailer with ROHLOFF hub 6.6.3 Pannier rack Only applies to pedelecs with this equipment Front and rear pannier racks are only permitted § with the vehicle manufacturer’s approval and ROHLOFF Speedhub 500/14 only if they are approved for use on e-bikes. As a basic rule, it is permitted to use a trailer The specialist dealer will advise on choosing a in combination with the ROHLOFF...
Page 132: Front Baskets
Operation 6.6.10 Suspension fork coil spring 6.6.5 Front baskets If the desired suspension fork sag cannot be Take care with front baskets because their load § achieved after adjustment, the coil spring distribution is not fixed. They are only permitted assembly must be replaced with a softer or harder with the vehicle manufacturer’s approval and spring.
Page 133: Personal Protective Equipment And Accessories For Road Safety
Operation Personal protective equipment and accessories for road safety Seeing and being seen is crucial in road traffic. 7 The two separate brakes on the pedelec must The following requirements must be met for riding work at all times. a pedelec safely on public roads. 8 The clear sounding bell must be fitted and must work.
Page 134: Use Suspension And Damping
Operation Use suspension and damping 6.9.1 Locking the suspension A suspension system is designed to cushion and Some suspension forks thus feature a lockout on compensate for unevenness on a surface whether the fork crown or a remote lockout on the the user is riding on bumpy cycle paths, dirt roads handlebars.
Page 135: Straightening The Quickly Adjustable Stem
Operation 6.10 Straightening the quickly 6.11 Using the pannier rack adjustable stem CAUTION Only applies to pedelecs with this equipment 1 Open stem clamping lever. 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.
Page 136: Raising The Kickstand
Operation 6.13.1 Using the leather saddle Sunlight and UV light tarnish the colour and cause the leather to dry out and fade.  Park pedelec in the shade.  Always use a saddle cover. Moisture may cause the leather to detach from material beneath and mould may form.
Page 137: Using The Handlebars
Operation 6.16 Using the handlebars 6.16.2 Using bar ends Only applies to pedelecs with this equipment  Wear heavily padded cycling gloves.  This helps protect sensitive areas of your Bar ends can be added to normal handlebars. palms. Adjustable bar ends feature a ball joint which you ...
Page 138: Using The Battery
Operation 6.17 Using the battery 6.17.2 Pannier rack battery Switch off the battery and the drive system before  removing or inserting the battery. Only applies to pedelecs with this equipment 6.17.1 Frame battery 6.17.2.1 Removing the pannier rack battery Only applies to pedelecs with this equipment 6.17.1.1 Removing the frame battery Figure 135: Removing (2) and inserting (3) the pannier...
Page 139: Integrated Battery
Operation 6.17.3 Integrated battery Only applies to pedelecs with this equipment 6.17.3.1 Removing the integrated battery 6.17.3.2 Inserting the integrated battery Figure 137: Inserting the integrated battery Figure 136: Removing the integrated battery 1 Place the battery into the integrated battery 1 Open battery lock with battery key (1).
Page 140: Charging The Battery
Operation 6.17.4 Charging the battery 6.17.5 Charging the dual battery Only applies to pedelecs with this equipment  The ambient temperature during the charging process must be within the range from 0 °C to 40 °C. Notice The battery can remain on the pedelec or can be ...
Page 141: Using Double Battery Model With A Single Battery Only
Operation 6.17.6 Using double battery model with a single battery only One of the charging sockets is not accessible or is sealed with an end cap on pedelecs with two batteries. Figure 138: Covering open contacts with cover cap – example: pannier rack ...
Page 142: Using Pedelec With The Electric Drive System
Operation 6.18 Using pedelec with the electric drive system 6.18.1 Switching on the electric drive 6.18.2 Switching off the electric drive system system As soon as the rider stops pushing the pedals in CAUTION normal mode or reaches a speed of 25 km/h, the drive system switches off the assistance system.
Page 143: On-Board Computer
W W A W W W W W W A A  Press On-Off button (on-board computer) briefly.  The electric drive system is switched on. Figure 139: BOSCH Purion on-board computer layout 6.19.3 Switching off the on-board Symbol computer WALK Push assist button ...
Page 144: Using The Push Assist System
Operation 6.19.5 Using the push assist system 6.19.6 Selecting the level of assistance  Press plus button briefly.  The level of assistance is increased. CAUTION  Press minus button briefly. Injury from pedals or wheels  The level of assistance is reduced. The pedals and the drive wheel turn when the push assist system is used.
Page 145: Replacing The Battery
Operation 6.19.8 Replacing the battery 6.19.9 Using the USB port  If the on-board computer shows LOW BAT on the Notice display screen, the battery is flat and must be replaced. The USB port is reserved to connect diagnostics The recommended CR 2016 battery can be ...
Page 146: Using The Brake
Operation 6.20 Using the brake 6.20.1 Use handbrake Only applies to pedelecs with this equipment WARNING 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.
Page 147: Gear Shift
Operation 6.21 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. ...
Page 148: Use Shimano Hub Gear
Operation 6.21.2 Use SHIMANO hub gear Only applies to pedelecs with this equipment CAUTION 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.
Page 149: Using Eshift
Operation 6.21.3 Using eShift 6.21.3.2 Using eShift with manual SHIMANO DI2 hub gears eShift refers to the integration of electronic gear Only applies to pedelecs with this equipment shift systems into the electric drive system. The new gear is shown briefly on the on-board 6.21.3.1 Using eShift with SHIMANO DI2 auto- computer each time it is changed.
Page 150: Parking
Operation 6.22 Parking Checklist after each ride Notice Cleaning Heat or direct sunlight can cause the tyre pressure 7.2.5  Lights and reflectors See Section to increase above the permitted maximum 7.2.5  Brake See Section pressure. This can destroy the tyres. 7.2.1 ...
Page 151: Screwing In The All Up Handlebars
Operation 6.22.1 Screwing in the All Up handlebars Only applies to pedelecs with this equipment Screw in the All Up stem to save space when 3 Turn handlebars 90° in a clockwise direction. parking 1 Open stem clamping lever. Figure 145: All Up with open stem clamping lever 2 Pull handlebars into highest possible position.
Page 152: Cleaning, Servicing And Inspection
Cleaning, maintenance and inspection Cleaning, servicing and inspection  Clean, maintain and inspect pedelec as indicated on checklists. Complying with these cleaning instructions can increase operational reliability, reduce wear on components, extend the service life of components and ensure safety. Checklist: Before each ride Checklist: weekly tasks Check everything is sufficiently...
Page 153 Cleaning, maintenance and inspection Checklist: monthly tasks Checklist: monthly tasks Cleaning the battery See Section 7.3.2 Cleaning the motor See Section 7.3.3    Clean on-board computer See Section 7.3.1  Clean hub See Section 7.3.12  Clean on-board computer See Section 7.3.1 ...
Page 154 Cleaning, maintenance and inspection Checklist: Tasks performed at least every six months (or Checklist: Tasks performed at least every six months (or every 1,000 km) every 1,000 km) Check Bowden cables gear Check steering headset See Section 8.5.6   See Section 7.5.16.2 shift...
Page 155 Cleaning, maintenance and inspection CAUTION WARNING Crash and falling caused by unintentional Crash caused by brake failure activation Oil or lubricant on the brake disc in a disc brake There is a risk of injury if the electric drive system or on the rim of a rim brake can cause the brake is activated unintentionally.
Page 156: Before Each Ride
Cleaning, maintenance and inspection Before each ride 7.1.5 Checking the pannier rack Complying with these cleaning instructions is the only way to reduce wear on components, increase 1 Hold onto pedelec by its frame. Hold onto the operating hours and guarantee safety. pannier rack with the other hand.
Page 157: Checking The Suspension Seat Post
Cleaning, maintenance and inspection 7.1.9 Checking the suspension seat post  Deflect and let the suspension seat post rebound.  If you hear unusual noises when the suspension seat post deflects and rebounds, or it yields without any resistance, take pedelec out of service.
Page 158: After Each Ride
Cleaning, maintenance and inspection After each ride 7.2.4 Cleaning the pedals Complying with these cleaning instructions is the only way to reduce wear on components, increase the operating hours and guarantee safety. The following items should be ready for use to clean the pedelec after each ride: ...
Page 159: Basic Cleaning
Cleaning, maintenance and inspection Basic cleaning 7.3.2 Cleaning the battery Complying with these basic cleaning instructions is the only way to reduce wear on components, increase the operating hours and guarantee safety. The following are required for basic cleaning: CAUTION Tool Cleaning agent Risk of fire and explosion due to penetration by...
Page 160: Clean Frame, Fork, Pannier Rack, Guards And Kickstand
Cleaning, maintenance and inspection 7.3.4 Clean Frame, fork, pannier rack, 7.3.7 Clean handles guards and kickstand 1 Clean handles with sponge, water and soapy water. 1 Soak the components with dish-washing 2 Rinse off component with water from a detergent if the dirt is thick and ingrained. watering can.
Page 161: Cleaning The Saddle
Cleaning, maintenance and inspection 7.3.9 Cleaning the saddle 7.3.12 Clean hub 1 Clean the saddle with lukewarm water and a 1 Put on protective gloves. cloth dampened with soapy water. 2 Remove dirt from hub with a sponge and soapy 2 Rinse off component with water from a water.
Page 162: Clean Brake
Cleaning, maintenance and inspection 7.3.15 Clean brake 7.3.18 Cleaning the chain 7.3.15.1 Clean handbrake Notice  Carefully clean the handbrake with a damp,  Never use aggressive (acid-based) cleaners, soft cloth. rust removers or degreasers when cleaning the chain. 7.3.16 Cleaning the brake disc ...
Page 163: Maintenance
Cleaning, maintenance and inspection Maintenance 7.4.1 Maintain frame Complying with these servicing instructions is the only way to reduce wear on components, increase the operating hours and guarantee safety. Notice  Hard wax polish and protection wax are particularly resistant on gloss paintwork. These car accessory retail products are unsuitable for matt paint finishes.
Page 164: Maintain Pannier Rack
Cleaning, maintenance and inspection 7.4.3 Maintain pannier rack 4 If you have a Speedlifter Twist, also apply oil to the unlocking bolt groove in the Speedlifter body. 5 Apply a little acid-free lubricant grease 1 Dry pannier rack with a cloth. between the stem quick release lever and the sliding piece to reduce the quick release lever 2 Spray pannier rack with spray wax and leave to...
Page 165: Maintaining The Seat Post
Cleaning, maintenance and inspection 7.4.9 Maintaining the seat post 7.4.11 Maintaining the leather saddle 1 Carefully preserve screw connections with wax spray. In doing so, ensure that no wax is applied to the metal contact surfaces. Standard leather care products keep leather 2 Replace the assembly paste protective layer smooth and resistant, brighten its appearance and on the metal contact surfaces on the seat post...
Page 166: Maintaining The Gear Shift
Cleaning, maintenance and inspection 7.4.14 Maintaining the gear shift 7.4.16 Maintaining the chain Maintaining 7.4.14.1 the rear derailleur articu- lated shafts and jockey wheel Place newspaper or paper towels underneath to  collect chain oil. 1 Lift rear wheel.  Treat front and rear derailleur articulated 2 Turn the crank briskly in an anti-clockwise shafts and jockey wheels with Teflon spray.
Page 167: Maintaining The Chain And All-Round Chain Guard
Cleaning, maintenance and inspection 7.4.18 Maintaining the brake 7.4.16.1 Maintaining the chain and all-round chain guard 7.4.18.1 Maintaining the handbrake Place newspaper or paper towels underneath to  collect chain oil. Notice 1 Lift rear wheel. 2 Turn the crank briskly in an anti-clockwise ...
Page 168: Inspection
Cleaning, maintenance and inspection Inspection The following tools are required for an inspection: 7.5.1.1 Checking tyre pressure Notice Gloves If the tyre pressure is too low in the tyre, the tyre does not achieve its load bearing capacity. The Ring spanners 8 mm, 9 mm, 10 mm, 13 mm, 14 mm and 15 mm tyre is not stable and may come off the rim.
Page 169 Cleaning, maintenance and inspection Dunlop valve 5 Remove the bicycle air pump. Only applies to pedelecs with this equipment 6 Screw the valve cap tight. 7 Screw the rim nut gently against the rim with The tyre pressure cannot be measured on the the tips of your fingers.
Page 170: Checking The Tyres
Cleaning, maintenance and inspection 7.5.1.2 Checking the tyres 2 Check the side walls for wear. If there are any cracks or tears, the tyre must be replaced. The tread is far less important for bicycle tyres than it is for car tyres, for example. Consequently, tyres can still be used with a worn tread with the exception of tyres on mountain bikes.
Page 171: Checking The Rims
Cleaning, maintenance and inspection 7.5.1.3 Checking the rims 7.5.1.5 Checking the nipple well The nipple holes can weaken the tyre bed. WARNING  Check to see if cracks are emerging from the nipple holes. Crash caused by a worn rim ...
Page 172: Checking The Brake System
Cleaning, maintenance and inspection 7.5.2 Checking the brake system 7.5.2.2 Checking the hydraulic brake system CAUTION 1 Pull on the handbrake and check whether any brake fluid leaks out of the lines, connections or on the brake linings. Crash caused by brake failure Worn brake discs and brake linings and a lack of 2 If any brake fluid leaks from anywhere, take hydraulic fluid in the brake cable reduce the...
Page 173: Checking The Disc Brake
Cleaning, maintenance and inspection 7.5.2.4 Checking the disc brake Only applies to pedelecs with this equipment Checking the brake linings Checking the brake discs  Check that the brake linings are no less than Put on gloves as the brake disc is very sharp. ...
Page 174: Checking The Back-Pedal Brake
Cleaning, maintenance and inspection 7.5.2.5 Checking the back-pedal brake Only applies to pedelecs with this equipment There are sharp corners and edges on the back-  pedal brake. Wear gloves. 1 Hold and check counter support to ensure it is firmly attached to rear frame down tube.
Page 175: Checking The Rim Brake
Cleaning, maintenance and inspection 7.5.2.6 Checking the rim brake Only applies to pedelecs with this equipment Checking the brake linings Adjusting the V-brake  We recommend that you also replace the rims  Check that the braking effect initiates after one at the same time as every second brake lining third of the handbrake distance is reached.
Page 176: Checking The Chain
Cleaning, maintenance and inspection 7.5.3 Checking the chain 1 Lift chain upwards. Measure the distance to the centre. Press chain downwards. Measure the  Check chain for rust, damage and chain links distance to the centre. that are difficult to move. 2 Add the two values together to calculate the ...
Page 177: Check
Cleaning, maintenance and inspection 7.5.5.2 Check 1 Insert gauge between two chain links on the right-hand side. There is a different wear gauge for each chain, depending on the manufacturer: Figure 162: Gauge is inserted Figure 157: Example of a KMC gauge 2 Lower gauge down to the left-hand side.
Page 178: Checking The Belt
Cleaning, maintenance and inspection 7.5.6 Checking the belt  The tooth profile is pointed and teeth have worn thinner. Contact specialist dealer. The belt sprocket does need to be replaced. 7.5.7 Checking the belt for wear  Check belt for indications of wear: Figure 166: Indications of wear on a belt Figure 168: Worn tooth profile 1 Carbon tensile fibres are exposed...
Page 179: Gates Carbon Drive Mobile App
Cleaning, maintenance and inspection With any of these methods, the tension along the 1 Open app. belt may vary slightly, so you should repeat the 2 Click on the voltage symbol. process several times. Turn the pedal a quarter 3 Click on MEASURE. after each measurement.
Page 180: Eco Tension Tester
Cleaning, maintenance and inspection 3 Press the check gauge down with just one 7.5.9.3 ECO tension tester finger until it clicks into place. Not included in price 1 Attach the measuring stick on the belt. Figure 172: Pressing the check gauge down with one finger 4 Take reading where line A meets line B.
Page 181 Cleaning, maintenance and inspection 7.5.10 Checking the riding light 1 Check the cable connections on the headlight  If the headlight or rear lights do not come on, take pedelec out of service. Contact specialist and rear light for damage and corrosion and dealer.
Page 182 Cleaning, maintenance and inspection 7.5.11 Checking the stem 7.5.14 Checking the seat post 1 Take seat post out of the frame.  The stem and quick release system must be 2 Check seat post for cracks and corrosion. inspected at regular intervals. The specialist dealer should adjust them if they require 3 Reinsert seat post.
Page 183 Cleaning, maintenance and inspection 7.5.16 Check gear shift 7.5.15.2 Checking the hub gear In the case of pedelecs with a hub gear or back- 1 Check that all gear shift components are free of pedal brake, the chain or the belt is tensioned by damage.
Page 184 Cleaning, maintenance and inspection 7.5.16.3 Checking the derailleur gears 1 Check that there is clearance between the chain tensioner and spokes.  If there is no clearance or the chain scrapes against the spokes or tyres, contact your specialist dealer. 2 Check that there is clearance between the chain or rear derailleur and spokes.
Page 185 Cleaning, maintenance and inspection 7.5.19 Adjusting Bowden-cable-operated twist grip, dual-cable Only applies to pedelecs with this equipment  For a smooth gear shift, adjust the adjusting sleeves on the shifter housing.  There is noticeable play of 2 to 5 mm (1/2 gear) when you turn the twist grip.
Page 186 Inspection and maintenance Inspection and maintenance Initial inspection Component-specific maintenance After 200 km or 4 weeks after purchase High-quality components require extra maintenance. The tasks require technical Vibrations produced while riding can cause expertise, special tools and special lubricants. screws and springs that were tightened during The pedelec may become damaged if the pedelec manufacture to settle or come loose.
Page 187 Inspection and maintenance Inspection and maintenance intervals for suspension fork Inspection and maintenance intervals for seat post SR SUNTOUR suspension fork by.schulz suspension seat post Maintenance 1 Every 50 hours Maintenance After the first  250 km; every  1500 km after Maintenance 2 Every 100 hours ...
Page 188 Inspection and maintenance Inspection and maintenance intervals for rear frame Inspection and maintenance intervals for hub damper SHIMANO 11-speed hub RockShox rear frame damper Internal oil change and maintenance 1,000 km after Service air chamber assembly Every 50 hours start of use, then ...
Page 189 Inspection and maintenance CAUTION WARNING Hazard for the environment due to toxic Injury due to damaged brakes substances Special tools and specialist knowledge are The brake system contains toxic and required to repair the brakes. Incorrect or environmentally harmful oils and lubricants. Such unauthorised assembly can damage the brakes.
Page 190 Inspection and maintenance Perform major inspection Complying with these inspection and maintenance instructions is the only way to reduce wear on components, increase the operating hours and guarantee safety. Diagnosis and documentation of current status Components Frequency Description Criteria Measures if rejected Inspection/ Accept- Inspection...
Page 191 Inspection and maintenance Components Frequency Description Criteria Measures if rejected Inspection Tests Maintenance Acceptance Rejection Once a Cleaning … Section 7.3.7 O.K. Dirt Cleaning month Once a Care Section 7.4.8 … O.K. Untreated Talcum powder month Handles before Wear; check if fas- Section 7.1.11 …...
Page 192 Inspection and maintenance Components Frequency Description Criteria Measures if rejected Inspection Tests Maintenance Acceptance Rejection 6 months … Section 7.4.10 O.K. Untreated 6 months Wear Section 7.5.1.3 … O.K. Defective rim New rim as specified Rims in the parts list Once a Wear on brake Section...
Page 193 Inspection and maintenance Components Frequency Description Criteria Measures if rejected Inspection Tests Maintenance Acceptance Rejection Once a Cleaning … Section 7.3.8 O.K. Dirt Cleaning month 6 months Care … Section 7.4.9.2 O.K. Untreated Assembly paste Carbon seat post 6 months Complete clean, …...
Page 194 Inspection and maintenance Components Frequency Description Criteria Measures if rejected Inspection Tests Maintenance Acceptance Rejection Venting … See manufac- O.K. 50 hours turer Cleaning … See manufac- O.K. 50 hours turer Venting … See manufac- O.K. 200 hours turer RockShox dropper post Complete …...
Page 195 Inspection and maintenance Components Frequency Description Criteria Measures if rejected Inspection Tests Maintenance Acceptance Rejection Drive/gear shift 6 months Check for damage Check for … O.K. Damage Refasten if necessary Chain/cassette/ damage or replace as speci- pinion/chainring fied in parts list Chain guard/ 6 months Check for damage...
Page 196 Inspection and maintenance Components Frequency Description Criteria Measures if rejected Inspection Tests Maintenance Acceptance Rejection Miscellaneous before Stability Section 7.1.5 … O.K. Loose Firm each ride Once a Dirt … Section 7.3.4 O.K. Dirt Cleaning month Pannier rack 6 months Maintenance …...
Page 197 Inspection and maintenance 8.5.1 Inspect frame 8.5.3 Inspecting and maintaining the rear frame damper 1 Check frame for cracks, warping and damage Only applies to pedelecs with this equipment to the paintwork.  If there are any cracks, warping or damage to the paintwork, remove the pedelec from WARNING service.
Page 198 Inspection and maintenance 8.5.5 Inspecting the stem CAUTION Incorrectly fastened screws may come loose due to impact. The stem may no longer be firmly fixed Hazard for the environment due to toxic in its position as a result. This will cause a crash substances with injuries.
Page 199 Inspection and maintenance 8.5.7 Inspecting the axle with quick  The quick release lever is flush with the lower release housing.  You should be able to see slight impression on the palm of your hand when you close the quick CAUTION release lever.
Page 200 Inspection and maintenance 8.5.8 Inspecting the fork 8.5.8.1 Inspecting the carbon suspension fork Only applies to pedelecs with this equipment WARNING 1 Remove fork. 2 Check fork for cracks, warping and damage to Injury due to explosion the paintwork. The air chamber is pressurised. When the air 3 You need to distinguish between scratches on system in a faulty suspension fork is maintained, the paintwork and impacts if the carbon...
Page 201 Inspection and maintenance 8.5.9 Inspecting the seat post 8.5.9.2 Inspecting and greasing BY.SCHULZ suspension seat post Only applies to pedelecs with this equipment WARNING 1 Remove seat post from the frame. Intoxication from lubrication oil 2 Remove safety and protective cover. The lubrication oil for Eightpins seat posts is toxic 3 Clean seat post on the inside and outside.
Page 202 Inspection and maintenance 8.5.9.3 Inspecting and greasing RS SUNTOUR suspension seat post Only applies to pedelecs with this equipment 1 Remove seat post from the frame. 2 Remove safety and protective cover. 3 Examine seat post rack for scratches, cracks and fractures.
Page 203 Troubleshooting, fault clearance and repair Troubleshooting, fault clearance and repair Preventing pain The pedelec is both a means of transport and a piece of sports equipment that promotes health. After the first few rides, you may experience sore muscles the next day. However, permanent pain should never occur during or after a ride.
Page 204 Troubleshooting, fault clearance and repair 9.1.1 Sitting discomfort Around 50% of all pedelec riders experience Solution sitting discomfort: • Adopt an optimal riding position (see • Pressure pain in the sitting bones Section 6.5.3). • Pain in the lower back •...
Page 205 Troubleshooting, fault clearance and repair 9.1.4 Pain in shoulders and nape of neck The weight of the upper body places a strain on Solution the shoulders due to the bent-forward posture. • A more upright riding position will The more stretched the position is, the more strain immediately reduce pain.
Page 206 Troubleshooting, fault clearance and repair 9.1.7 Knee pain Pedelec riding is a sport that is easy on the knee Solution joints and is recommended for beginners. Very • Contact specialist dealer. Have the powerful forces are transmitted from the thigh to pedelec adjusted (see Section 6.5).
Page 207 Troubleshooting, fault clearance and repair Drive system 9.2.2 Error message The components of the drive system are constantly checked automatically. If an error is If an error message is displayed, run through the detected, an error message appears on the on- following actions: board computer.
Page 208 Troubleshooting, fault clearance and repair 9.2.3 Errors in assistance function Symptom Cause Remedy Assistance is not Is the battery charged sufficiently? Check battery is charged. available. Recharge the battery if it is almost flat. Is the system switched on?  Press On-Off button (battery). ...
Page 209 Troubleshooting, fault clearance and repair 9.2.4 Battery errors Symptom Cause Remedy The battery discharges The battery may be at the end of its  Replace old battery with new one. quickly. useful life. The battery cannot be Is the charger mains plug firmly Disconnect the charger mains plug and plug it in again.
Page 210 Troubleshooting, fault clearance and repair Symptom Cause Remedy Fluid is leaking from the  Observe all the warnings in Section 2 Safety. battery. There is an unusual Remove from the battery immediately. smell. Contact the fire service immediately. Observe all the warnings in Section 2 Safety. Fumes are emitted from Remove from the battery immediately.
Page 211 Troubleshooting, fault clearance and repair 9.2.7 Problems with disc brakes Symptom Cause Remedy Ringing and unusual  Contact specialist dealer. Fit a city or trekking tyre. sounds from the disc Riding on tarmac with off-road tyres. brake. Dirty or greasy brake disc. ...
Page 212 Troubleshooting, fault clearance and repair 9.2.8 Problems with back-pedal brake Symptom Cause Remedy Contact specialist dealer. Lubricate brake hub. Brake is too sensitive Replace brake shoe unit. Contact specialist dealer. Replace brake shoe unit. Brake is too weak If the problem should persist, replace the internal hub unit. The rider needs to push Contact specialist dealer.
Page 213 Troubleshooting, fault clearance and repair 9.2.9 Problems with rim brakes Symptom Cause Remedy  This is not a malfunction. During the first 50 km or so after Break in brakes. A rim brake’s full braking power is not produced until the replacing the brake linings, check the rims and brake linings rider has cycled several kilometres.
Page 214 Troubleshooting, fault clearance and repair 9.2.10 Problem with SR SUNTOUR suspension fork 9.2.10.1 Rebound too fast The suspension fork rebounds too quickly, Fork head and handlebars are deflected upwards producing a "pogo stick" effect, where the wheel if the wheel bounces back from the ground. Body lifts from the ground in an uncontrolled way.
Page 215 Troubleshooting, fault clearance and repair 9.2.10.2 Rebounding too slowly The fork does not rebound quickly enough after The fork remains in a deflected state, causing the absorbing a bump. The fork also remains headset and handlebars to move to a lower deflected over subsequent bumps, which reduces position.
Page 216 Troubleshooting, fault clearance and repair 9.2.10.3 Suspension too soft on inclines The fork deflects at a low point in the terrain. The deflection is quickly used up, body weight shifts forward and the pedelec loses some momentum. Figure 191: Excessively soft suspension in the suspension fork on hilly terrain Solution ...
Page 217 Troubleshooting, fault clearance and repair 9.2.10.4 Excessively hard damping on bumps When the bike hits a bump, the fork deflects too The headset and handlebars are deflected slowly and the wheel lifts up from the bump. upwards significantly, which can impair control. Traction decreases when the wheel no longer touches the ground.
Page 218 Troubleshooting, fault clearance and repair 9.2.11 Problems with SR SUNTOUR rear frame damper 9.2.11.1 Rebound too fast The rear frame damper rebounds too quickly, Saddle and handlebars are deflected upwards producing a "pogo stick" effect or causing the bike when the wheel bounces back from the ground. to bounce after the wheel hits a bump and lands The rider's body weight may be shifted upwards on the ground again.
Page 219 Troubleshooting, fault clearance and repair 9.2.11.2 Rebounding too slowly The rear frame damper does not rebound quickly The rear frame damper remains in a deflected enough after a bump has been compensated and state after contact with the first bump. When the is not in the required initial position when the rear wheel hits the second bump, the saddle wheel hits the next bump.
Page 220 Troubleshooting, fault clearance and repair 9.2.11.3 Suspension too soft on inclines The rear frame damper deflects deeply through used up, body weight shifts downwards and the the deflection range. The deflection is quickly pedelec loses some momentum. Figure 197: Excessively soft suspension in the rear frame damper on hilly terrain Solution ...
Page 221 Troubleshooting, fault clearance and repair 9.2.11.4 Excessively hard damping on bumps When the bike hits a bump, the damper deflects Saddle and pedelec rider are deflected upwards too slowly and the rear wheel lifts up from the and forwards, the rear wheel loses contact with bump.
Page 222 Troubleshooting, fault clearance and repair 9.2.12 Problems with hub gear Symptom Cause Remedy A noise is heard when the All gear speeds except 1. pedals are turning. A noise is heard when the pedelec is pushed All gear speeds except 1. backwards.
Page 223 Troubleshooting, fault clearance and repair Symptom Cause Remedy Strange noises occur  when the brakes are Contact specialist dealer. applied. Rotation feels stiff during  Contact specialist dealer. free rotation. Chain jumps between the  gearwheels when gear is Gearwheels and/or chain worn. Contact specialist dealer.
Page 224 Troubleshooting, fault clearance and repair 9.2.13 Problems with freewheel Symptom Cause Remedy Cover forgotten after fitting.  Contact specialist dealer. Check installation correct. Freewheel blocked.  Contact specialist dealer. Measure the length of the socket. If After fitting, socket was compressed by over-tightening the quick-release axle.
Page 225 Troubleshooting, fault clearance and repair 9.2.14 Lighting does not work Symptom Cause Remedy The front light or rear light The default settings in the electric drive Take pedelec out of service immediately. does not go on, even system have probably been configured when the switch is Contact specialist dealer.
Page 226 Troubleshooting, fault clearance and repair Other errors Symptom Cause Remedy Two beeps will sound if a Pressed switch mode has been  This is not a malfunction. switch is pressed but the deactivated. switch cannot be operated. Three beeps are A fault or warning has occurred.
Page 227 Troubleshooting, fault clearance and repair Repair 9.4.3 Repairing the suspension fork Special expertise and tools are required for many repairs. For this reason, repairs may only be carried out at a specialist dealer. These include: 9.4.3.1 Removing paint damage on the fork •...
Page 228 Troubleshooting, fault clearance and repair 9.4.4 Replacing the riding light  Only use components in the corresponding power class for replacement. 9.4.5 Adjusting the headlight  The headlight must be positioned so that its light beam shines on the road 10 m in front of the pedelec (see Section 6.4).
Page 229 Recycling and disposal Recycling and disposal This device is marked according to the recycling saves reserves of raw materials and European Directive 2012/19/EU on ensures that all the regulations for protection of waste electrical and electronic health and the environment are adhered to when equipment –...
Page 230 Recycling and disposal Waste type Disposal Dispose of Residual waste Residual waste bin (grey bin) Biodegradable lubricants Residual waste bin (grey bin) Biodegradable oils Cleaning cloths covered in biodegradable oil Filament lamps, halogen lamps Residual waste bin (grey bin) Hazardous waste Recycling Batteries, rechargeable batteries Return to the battery manufacturer.
Page 231 Documents Documents 11.1 Assembly report Date: Frame number: Components Description Criteria Measures if rejected Assembly/ Acceptan Tests Rejection inspection Front wheel Assembly O.K. Loose Adjust quick release Kickstands Check mount fastening Functional check O.K. Loose Retighten screws Tyre pressure too low/ Tyres Tyre pressure check O.K.
Page 232 Documents All complete, state, Damaged or not all Reflectors O.K. New reflectors fastening complete Drive/gear shift Chain/cassette/ Refasten if necessary or replace Check for damage O.K. Damage sprocket/chainring as specified in parts list Chain guard/ Check for damage O.K. Damage Replace as specified in parts list spoke guard Bottom bracket axle/...
Page 233 Documents 11.2 Inspection and maintenance log Diagnosis and documentation of current status Date: Frame number: Measures if Component Frequency Description Criteria rejected Accept- Inspection Test Rejection ance Front wheel 6 months Assembly O.K. Loose Adjust quick release Check mount Kickstands 6 months Functional check O.K.
Page 234 Documents Acceptan Inspection Test Rejection Brake system Check mount Handbrake 6 months O.K. Loose Retighten screws fastening Top up brake fluid; Depending on time of take Pedelec out of Brake fluid 6 months Check fluid level O.K. Too little year service if damaged;...
Page 235 Documents Acceptan Inspection Test Rejection Electric drive system Check for damage Functional check O.K. No screen, Restart; test battery; On-board defective new software or new 6 months computer screen display on-board computer; take out of service Control panel Check Functional check O.K.
Page 236 Documents Notes MY23P01 - 22_1.0_21.10.2022...
Page 237 Aluminium, crank set, crank length: Length: 170 mm, for BOSCH™ Gen3 motors Chain/belt Chain wheel/belt sprocket SAMOX, EMS05-BHV03 Steel, chain wheel, teeth: 44 T, 3/32" × 38T, for BOSCH™ GEN 3 motors, plastic chain guard Chain guard SAMOX, EMS05-BHV04 SAMOX, EMS05-BHV04 Chain guide …...
Page 238 Battery lock ABUS, BLO ZEG IT4 “EVO IV” X-PLUS with digital key card for ABUS lock Chain lock # VELO, #CO-Z-P2202-2 (#VLD-I-1155), BOSCH™ 750W BATTERY COVER, PC INJECTION TC-621 70% MATT BLACK (NOT PAINTED), W/ DECAL Bottle holder FIDLOCK, BOTTLE CAGE …...
Page 239 Aluminium, crank set, crank length: Length: 170 mm, for BOSCH™ Gen3 motors Chain/belt Chain wheel/belt sprocket Steel, chain wheel, teeth: 38 T, 3/32" × 38T, for BOSCH™ GEN 3 motors Chain guard SAMOX, EMS05-BHV03 Plastic, 38T for BOSCH™ GEN3 motors Chain guide … … MY23P01 - 22_1.0_21.10.2022...
Page 240 Documents Motor BOSCH™, Active Line Plus (BDU350) See Section 3.6.5 On-board computer BOSCH™, Purion (BUI215) See Section 3.6.4 Display … … Control panel … … Rechargeable battery BOSCH™, See Section 3.6.6 PowerPack 400 (BBS265) or PowerPack 500 (BBS275) Charger BOSCH™, Compact Charger, BCS230 Charger, charging current (max.): 2 A...
Page 241 Documents 11.3.3 Ancura E7R HS11 (Wave) (NL) 23-15-2096 ...not available # Information not available when document was produced MY23P01 - 22_1.0_21.10.2022...
Page 242 Documents 11.3.4 Ravenna EVO 7F (Gent) (NL) 23-15-2158, 23-15-2160 PEGASUS, FM-Z-70A23355 Aluminium, welded, frame shape and size: Frame Hydro Wave: 45/50/55/60 cm Rear frame damper … … SUPERO, C3031, OPTIMA SAFE Clincher Tyres Size: 700 × 50C Front | Rear Pressure: max.
Page 243 Documents FSA, CK-220 Aluminium, crank set, crank length: Length: 170 mm, Crank set for BOSCH™ Gen3 motors Chain/belt SAMOX, EMS05-BHV03 Steel, chain wheel, teeth: 38 T, 3/32" × 38T, for Chain wheel/belt sprocket BOSCH™ GEN 3 motors Chain guard HESLING, Fluente 38T for e-bikes...
Page 244 Aluminium/plastic, basic pedal with anti-slip surface, Pedal W/9/16", with reflector Crank set FSA, CK-220 Aluminium, crank set, for BOSCH™ Gen3 motors Chain/belt SAMOX, EMS05-BHV03 Steel, chain wheel, teeth: 38 T, 3/32" × 38T, for Chain wheel/belt sprocket BOSCH™ GEN 3 motors...
Page 245 Documents Chain guide … … Motor BOSCH™, Active Line (BDU310) See Section 3.6.5 On-board computer BOSCH™, Purion (BUI215) See Section 3.6.4 Display … … Control panel … … BOSCH™, See Section 3.6.6 Rechargeable battery PowerPack 400 (BBS265) or PowerPack 500 (BBS275) BOSCH™, Compact Charger, BCS230...
Page 246 Documents 11.4 Charger operating instructions MY23P01 - 22_1.0_21.10.2022...
Page 247 Battery Charger 36-4/230 Standard Charger BCS220 0 275 007 907 Li-Ion Input: 230V 50Hz 1.5A Output: 36V Use ONLY with BOSCH Li-Ion batteries Made in PRC Robert Bosch GmbH 72757 Reutlingen Germany eBike Battery Charger 36-6/230 Fast Charger BCS250...
Page 248 Documents Compact Charger %&6 MY23P01 - 22_1.0_21.10.2022...
Page 249 Documents MY23P01 - 22_1.0_21.10.2022...
Page 250 Documents MY23P01 - 22_1.0_21.10.2022...
Page 251 Documents MY23P01 - 22_1.0_21.10.2022...
Page 252 Documents MY23P01 - 22_1.0_21.10.2022...
Page 253 Documents MY23P01 - 22_1.0_21.10.2022...
Page 254 Documents MY23P01 - 22_1.0_21.10.2022...
Page 255 Glossary Glossary Bicycle for young adults Disc brake Source: ISO 4210-2: pedelec designed for use on Source: EN 15194:2017: brake in which brake public roads by a young adult whose weight is less pads are used to grip the lateral faces of a thin than 40 kg, with maximum saddle height of disc attached to or incorporated into the wheel 635 mm or more and less than 750 mm...
Page 256 Glossary Fork steerer Maximum tyre pressure Source: EN 15194:2017: part of a fork that rotates Source: EN 15194:2017: maximum tyre pressure around the steering axis of a pedelec frame head recommended by the tyre or rim manufacturer for tube. It is normally connected to the fork crown or a safe and efficient performance.
Page 257 Glossary Placing on the market Slippage Source: Directive 2006/42/EC on Machinery, Source: DIN 75204-1:1992-05: the difference in 17.05.2006, Making available for the first time in relation to vehicle speed between the vehicle the Community machinery or partly completed speed and the speed of its wheels at their machinery with a view to distribution or use, circumference.
Page 258 Glossary 12.1 Abbreviations Work environment Source: ISO 9000:2015: set of conditions under Abbreviation Meaning/derivation which work is performed. Anti-blocking system Year of manufacture EPAC Electric power assisted cycle Source: ZEG: the year of manufacture is the year Permitted total weight in which the pedelec was manufactured.
Page 259 ZEG Zweirad-Einkaufs-Genossenschaft eG c/o ZEG Zweirad-Einkaufs-Genossenschaft eG Longericher Str. 2 Longericher Str. 2 50739 Köln, Germany 50739 Köln, Germany The machine, pedelec types: 23-15-2055 Orticello E Unisex City and trekking bicycle 23-15-2056 Swing E8R Disc 20" City and trekking bicycle 23-15-2096...
Page 260 Appendix Declaration of conformity for incomplete machine MY23P01 - 22_1.0_21.10.2022...
Page 261 Appendix MY23P01 - 22_1.0_21.10.2022...
Page 262 Appendix MY23P01 - 22_1.0_21.10.2022...
Page 263 Keyword index Keyword index Brake calliper, 48 Cargo bike, 254 position, 48 Cassette, Air valve, 32 torque, 70 - clean, 160 position, 32 Brake disc, 48 CE marking, 254 Articulated shaft, - check, 172 Chain guard 18 - maintain 165 - clean 161 Chain guard, Axle,...
Page 264 Keyword index Drive belt, 254 Gear shift, function 55 Drive system, 51 - adjust Bowden-cable- level of assistance 56 - switch off, 141 operated twist grip, dual- level of assistance, position - switch on, 141 cable 184 electric, 52 - check 182 lighting, position 55 Dual pivot rim brake, - check electric gear shift,...
Page 265 Keyword index Minimum insertion depth, 255 Pedelec, 254 Rebound damping, 31 Minus button, 55, 127, 142 - adjust 105 Rebound, 256 Model year, 255 - after each ride, 157 Rechargeable battery, 256 Motor cover 18 - assemble 86 Rechargeable battery, see Motor cover, - before each ride 132, 155 battery...
Page 266 Keyword index Spokes, 41 USB port, 55, 127, 142 - check, 170 - replace 226 Valve, 38 position, 38 Dunlop valve, 41 Steering headset 28 position, 38 Steering headset, V-Brake brake, - grease, 197 torque, 80 - inspect, 197 V-brake, Stem, 28 - adjust 174 - adjust 134...

This manual is also suitable for:

23-15-2056 23-15-2096 23-15-2158 23-15-2160 23-15-2182 23-15-2184

Bosch 23-15-2055 Manual

Quick Links

Related Manuals for Bosch 23-15-2055

Summary of Contents for Bosch 23-15-2055

This manual is also suitable for:

Table of Contents