Summary of Contents for Hercules BOSCH KIOX 300 INTUVIA 100
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IMPORTANT READ CAREFULLY BEFORE USE KEEP IN SAFE PLACE READY TO CONSULT AT LATER DATE Translation of original operating instructions for HERCULES pedelecs with BOSCH Purion on-board computer L L K L K K K K K K K K...
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...
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Contents Description of controls and screens 3.3.1 Handlebars On-board computer 3.4.1 Display 3.4.2 System message 3.4.3 Handbrake 3.4.4 Gear shift 3.4.5 Suspension and damping 3.4.6 Battery level indicator (battery) Transportation 3.5.1 Using the transport securing system 3.5.2 Transporting the pedelec 3.5.3 Shipping a pedelec 3.5.4...
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Contents 6.5.12 Adjusting the suspension fork sag 6.5.13 Riding light 6.5.14 Replacing the electric drive system components 6.5.15 Adjust on-board computer 6.5.16 On-board computer Accessories 6.6.1 Child seat 6.6.2 Trailer 6.6.3 Pannier rack Using the battery 6.7.1 Frame battery 6.7.2 Pannier rack battery 6.7.3 Integrated battery...
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Contents Cleaning, maintenance and inspection Before each ride 7.1.1 Checking the guards 7.1.2 Checking the frame 7.1.3 Checking the fork 7.1.4 Checking the rear frame damper 7.1.5 Checking the pannier rack 7.1.6 Checking the mudguards 7.1.7 Check wheel concentricity 7.1.8 Checking the quick releases 7.1.9 Checking the suspension seat post...
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Contents 7.4.15 Maintaining the pedals 7.4.16 Maintaining the chain 7.4.17 Maintaining the battery 7.4.18 Maintaining the brake 7.4.19 Lubricating the Eightpins seat post tube Inspection 7.5.1 Checking the wheel 7.5.2 Checking the brake system 7.5.3 Checking the chain 7.5.4 Checking the riding light 7.5.5 Checking the stem 7.5.6...
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Contents 9.3.2 Repairing the frame 9.3.3 Repairing the suspension fork 9.3.4 Replacing the riding light 9.3.5 Adjusting the headlight 9.3.6 Checking suspension fork-tyre clearance 9.3.7 Torque Recycling and disposal 10.1 Guidelines on removal of waste Documents 11.1 Assembly report 11.2 Inspection and maintenance log 11.3 Charger operating instructions...
About these operating instructions About these operating instructions Manufacturer 1.4.1 Warnings Warnings indicate hazardous situations and actions. HERCULES GmbH You will find three categories of warnings in the Longericher Strasse 2 operating instructions: 50739 Köln, Germany Tel.: +49 4473 92617 0...
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.
About these operating instructions Frame number ype number and model Each frame has an individual frame number These operating instructions are an integral part of stamped on it (see Figure 2). The frame number pedelecs with the type numbers: can be used to link the pedelec with the owner. Type no.
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 ...
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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 ...
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.
Safety Toxic substances 2.2.2 Toxic substances If substances are released or used which pose a risk to people and the environment, effective protective measures must be taken. Toxic substances (also known as poison or toxins) refer to substances which can cause damage to Possible hazards, contamination and health living beings if they enter the organism above a hazards due to:...
Safety Personal protective equipment Defective battery Liquids and vapours may leak from damaged or Wear a suitable helmet. The helmet must have faulty batteries. Excessively high temperatures a reflective strip or a light in a clearly visible may also cause liquids and vapours to leak from colour.
Safety Safety markings and safety What to do in an emergency instructions 2.8.1 Dangerous situation in road traffic Pedelec and battery nameplates contain the following safety markings and safety instructions: If you encounter any hazards or dangers in road traffic, apply the brake until the pedelec comes to a halt.
Safety After contact with eyes After skin contact 1 Rinse eyes under flowing water for at least ten 1 Remove any solid particles immediately. minutes with the lids open; also rinse under 2 Remove contaminated clothing immediately. lids. 3 Rinse the affected area with plenty of water for 2 Immediately consult a doctor in case of any at least 15 minutes.
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.
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Description 3.1.2.1 Up to model year 2023 Area of use Unsuitable terrain Suitable for tarmacked and paved roads. Never ride off road or perform jumps. Suitable for tarmacked roads, cycle paths, firm gravel Never ride off road or perform jumps over 15 cm. tracks and longer sections with moderate slopes and jumps up to 15 cm.
Description 3.1.3 Permitted total weight (PTW) The pedelec may only be loaded to its maximum permitted total weight (PTW). The maximum permitted total weight is • the weight of the fully assembled pedelec • plus body weight • plus baggage Type no.
Description 3.1.4 Environmental requirements You can be ride the pedelec within a temperature Temperatures under -10 °C and over +60 °C must range between -5 °C and +40 °C. The electric be avoided as a general rule. Never put the drive system is limited in its performance outside battery in a car in summer or store it in direct this temperature range.
EN 15194 0,25 kW / 25 km/h zGG 150 kg EPAC 25 kg BJ 2022 / MJ 2023 Figure 2: Example HERCULES nameplate More No. Designation Description information The manufacturer uses the CE marking to declare that the pedelec...
Description Components 3.2.1 Overview 18 19 20 Figure 3: Pedelec viewed from right, HERCULES Futura Sport I 9 used as example Front wheel Pannier rack Fork Rear light Front guard Reflector Headlight Rear guard Handlebars Kickstand Stem Rear wheel Frame...
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3.2.1.1 Components and repair parts for ROBERT/A R7 23-Q-0085 Shape: Wave, frame size: 43 cm Shape: Wave, frame size: 45 cm Frame HERCULES, Robert/a R7 Shape: Wave, frame size: 50 cm Shape: Wave, frame size: 55 cm # Size: ETRTO 47-559 (26 × 1.75 inches), 30 Tyres CST, Supero Optima Safe (C-1880) TPI;...
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Documents Aluminium, crank set, crank length: 170 mm, for Crank set FSA, CK-220 BOSCH™ Gen3 motors Chain, 116 links; see Section # Chain/belt KMC, Z1eHX Narrow Chain, 100 links; see Section # Chain wheel/belt sprocket SAMOX, BHV03-S38T-C47 # Chain wheel, 38T; chainline: 47 mm Chain guard HORN, CATENA B18 38 Z.
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3.2.1.2 Components and repair parts for LYON R7 23-Q-0086 Shape: Wave, frame size: 45 cm Frame HERCULES, Lyon R7 Shape: Wave, frame size: 50 cm Shape: Wave, frame size: 55 cm # Size: ETRTO 47-622 (28 × 1.75 inches), 30...
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Documents Motor cable BOSCH, [BCH281] (1270.016.514) Battery motor; length: 310 mm Brake MAGURA, HS11 Rim brake Headlight FUXON, F16 EB 6-12V Rear light FUXON, R-232-EB 6...12 V Pannier rack, rear STANDWELL, Z-A23429/SW-ML001SF 700C MonkeyLoad system, with spring flap Guard, rear REINFORCE, Z-A22432/SP-60A 700C Stand...
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3.2.1.3 Components and repair parts for LYON F7 23-Q-0087 Shape: Wave, frame size: 45 cm Frame HERCULES, Lyon F7 Shape: Wave, frame size: 50 cm Shape: Wave, frame size: 55 cm # Size: ETRTO 47-622 (28 × 1.75 inches), 30...
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Documents Motor BOSCH, Active Line [BDU310] (0275.007.046) See Section 3.5.06.1 On-board computer BOSCH, Purion [BUI 215] (1270.020.917) Cable length: 1500 mm; see Section # BOSCH, Compact Charger, [BCS230] Charger Charging current (max.): 2 A; see Section # (0275.007.915) Motor cable BOSCH, [BCH281] (1270.016.514) Battery motor;...
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Documents 3.2.1.4 Components and repair parts for NIZZA F7 NL 23-Q-0091 Shape: Wave, frame size: 45 cm Frame HERCULES, Nizza F7 NL Shape: Wave, frame size: 50 cm Shape: Wave, frame size: 55 cm Tyres CST, SUPERO Optima Safe (C-1880) # Size: ETRTO 40-622 «700 ×...
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Documents 3-finger brake lever | Length: 1000 mm | Front brake SHIMANO, BL-MT200/BR-MT200 Hydraulic disc brake, 2-piston 3-finger brake lever | Length: 1700 mm | Rear brake SHIMANO, BL-MT200/BR-MT200 Hydraulic disc brake, 2-piston Front brake disc SHIMANO, SM-RT10 Ø: 180 mm Rear brake disc SHIMANO, SM-RT10 Ø: 160 mm...
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Documents 3.2.1.5 Components and repair parts for ROB FOLD R7 23-Y-0011 Frame HERCULES, Rob Fold R7 Folding frame; frame size: 46 cm # Size: ETRTO 50-406 (20 × 2.00 inches). Tyres SCHWALBE, Big Apple Version: # Valve: AV; valve length: 40 mm; size: ETRTO Tube SCHWALBE, AV7 (20")
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Documents Bell/horn NUVO ENTERPRISE, n+1 B508AP Bell, aluminium with plastic base. Ø: 42 mm Battery lock ABUS, BOSCH DT2 PLUS … not available, # information not available when document was produced MY24H01 - 22_1.0_30.01.2024...
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Documents 3.2.1.6 Components and repair parts for ROB FOLD F7 23-Q-0012 Frame HERCULES, Rob Fold F7 Folding bicycle frame; frame size: 46 cm # Size: ETRTO 50-406 (20 × 2.00 inches). Tyres SCHWALBE, Big Apple Version: # Valve: AV; valve length: 40 mm; size: ETRTO Tube SCHWALBE, AV7 (20")
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Documents Guard SKS, # EDGE AL # Stand MASSLOAD Bell/horn NUVO ENTERPRISE, n+1 B508AP Bell, aluminium with plastic base. Ø: 42 mm Battery lock ABUS, BOSCH DT2 PLUS … not available, # information not available when document was produced MY24H01 - 22_1.0_30.01.2024...
Description 3.2.2 Chassis Carbon frame The chassis comprises two components: Carbon (CFRP) is a carbon-fibre-reinforced polymer made of high-strength, rigid fibres. • Frame and Carbon frames comprise several layers of carbon • steering system with an epoxy resin matrix. The uppermost layer is known as the visible layer.
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Description 3.2.2.2 Steering system The steering system components are: • Steering headset, • Stem, • Handlebars and • Suspension fork. 3.2.2.3 Steering headset The steering headset (also known as a bike headset or simply a headset) is the fork bearing system in the frame.
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Description 3.2.2.5 Handlebars The pedelec is steered using the handlebars. The handlebars are used to support the upper body and are used to mount operating and display components (see Section 3.4.1). Figure 8: Without suspension (1) and with suspension (2) Damping After compressing, the suspension fork returns to its original position.
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Description Parts of a suspension fork Figure 9: Parts of a suspension fork Fork steerer Tyre clearance Sag adjuster Fork crown Tyre height Deflection (suspension fork) Tyre passage width Damper side Quick release Side view Pitch Installation height Fork end (suspension fork) Offset Quick release axle Air suspension side...
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Description Suspension 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 11: Internal structure of a steel suspension fork Sag setting wheel Damping adjuster Compression dampers...
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Description Lock The compression can be disabled in any A suspension system absorbs great deal of motor suspension fork. A suspension fork will then and muscle power during rides uphill or on behave like a rigid fork. optimally tarmacked roads. This increases energy consumption and reduces propulsion.
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Description The suspension fork also deflect quickly and The suspension fork responds instantly to the unhindered when hitting bumps and cushions the impact. The headset and handlebars rise slightly bump when placed at an optimum setting. when absorbing a bump (green line). Traction is retained (blue line).
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Description Compression dampers When optimally adjusted, the suspension fork counteracts deflection on hilly terrain, stays Compression dampers damp deflection higher in its deflection range and helps to maintain movements, i.e. compression loads. speed when riding on hilly terrain. The compression damper controls the The suspension fork deflects instantly unhindered compression stroke speed or the extent to which and absorbs bumps when the bike hits one.
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Description Low-speed damper A slow compression speed is generated in the suspension fork when riding over bumps. The low- The low-speed damper (also abbreviated to LSC speed damper controls the suspension fork's from low-speed compression) is a specialised behaviour positively in such riding situations. compression damper.
Description 3.2.3 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.
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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).
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Description Bead core 3.2.3.3 Rim The rim is the metal profile on a wheel which holds Tyre carcasses are wrapped around bead cores. the tyre, tube and rim band together. The rim is Wrapping the carcass around both sides creates joined to the hub with spokes.
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Description Presta valve 3.2.3.6 Spoke nipples The Presta valve, also known as the Sclaverand Spoke nipples are screw elements with an internal valve or the French valve, is the narrowest variant thread which fits onto the spoke thread. Fitted of all valves. The Presta valve requires a smaller spokes are tensioned by tightening the spoke hole in the rim, which is why it is especially nipples.
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Description 3.2.3.7 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.
Description 3.2.4 Brake 3.2.4.2 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.
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Description 3.2.4.3 Rim brake Figure 30: 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...
Description 3.2.5 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.
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Description 3.2.5.1 Ladies’ saddle 3.2.5.2 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.
Description 3.2.6 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 •...
Description 3.2.7 Mechanical drive system 3.2.7.1 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.
About these operating instructions 3.2.8 Electric drive system 3.2.8.1 Motor The pedelec has an electric drive system in addition to a mechanical one. As soon as the muscle power required for pedalling passes a certain level, the motor is activated gently and assists the pedalling motion. The pre-set level of assistance determines the motor output.
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About these operating instructions 3.2.9.1 Rechargeable battery 3.2.9.2 Frame battery BOSCH batteries are lithium ion batteries which Three different types of frame batteries can be are developed and manufactured to the latest fitted: technical standards. Each battery cell is protected by a steel cup and encased in a plastic battery housing.
Description 3.2.10 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.
Description Description of controls and screens 3.3.1 Handlebars Figure 46: Detailed view of handlebars from sitting position, example Rear wheel hand brake On-board computer Bell Lockout Headlight Shifter Front wheel handbrake MY24H01 - 22_1.0_30.01.2024...
Description On-board computer 3.4.1 Display The on-board computer is operated using four buttons on its casing. The display has nine on-screen indicators: L K K K K K L L K K K K W W A W W W W W W A A Figure 47: BOSCH Purion on-board computer layout Figure 48: Display overview Indicator for km/h or mph (see Section...
Description 3.4.1.3 Information display 3.4.1.5 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. 3.4.1.6 Maintenance indicator Display Function Indicates that maintenance is required.
Description 3.4.3 Handbrake There is a handbrake on the left and right of the handlebars. Figure 49: 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.
Description 3.4.4 Gear shift 3.4.4.1 SHIMANO NEXUS SL-C7000-5 twist grip shifter Only applies to vehicles with this equipment SHIMANO hub gears feature a NEXUS SL-C7000-5 twist grip shifter with an indicator on the right of the handlebars. Figure 50: SHIMANO NEXUS SL-C7000-5 twist grip shifter Twist grip shifter Gear indicator You change gears by turning the twist grip shifter.
Description 3.4.5 Suspension and damping 3.4.5.1 SR SUNTOUR air valve (fork) and sag setting wheel (fork) 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...
Description 3.4.6 Battery level indicator (battery) Each battery has its own level indicator. All five LEDs will light up when the battery is fully charged. The charge level for the activated battery is also shown on the on-board computer. If the battery level falls below 5%, all the LEDs on the operating status and battery level indicator will go out.
Transporting and storing Transportation 3.5.2 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.
Transporting and storing 3.5.4 Transporting the battery 3.5.2.3 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.
Transporting and storing Storing Store pedelec, on-board computer, battery and 3.6.3.1 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.
Transporting and storing 3.6.4 Break in operation 3.6.4.1 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 ...
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) ...
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. It makes sense to prepare each pedelec so that it is fully ready for use immediately after being assembled.
Assembly 5.3.2 Adjusting the suspension system to body weight Not included in price 5.3.2.1 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.
Assembly 5.3.3 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.
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 equipment Before installing the wheel, ensure that the O-ring 4 Insert the securing screw on the non-drive ...
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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.
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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 65: Perfect position for the clamping lever 6 Use 4 mm hexagon socket spanner to adjust the clamping lever clamping force if required.
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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.
Assembly 5.3.5 Checking the stem and handlebars 5.3.5.1 Checking the connections 5.3.5.3 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.
Assembly Assembly instructions for online sales 5.0.2 Preparing Your specialist dealer will complete assembly and commissioning for this pedelec. The pedals were unscrewed and the handlebars repositioned Assemble the pedelec in a clean, dry environ- before transportation. You need these instructions ment.
Assembly 5.0.4 Straightening the handlebars 5.0.4.2 Stem with clamping lever version II Only applies to pedelecs with this equipment The handlebars must be turned so that they are parallel to the frame and tyres for transportation. 1 Open the clamping lever on the stem quick 1 Turn handlebars clockwise until they are release.
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Assembly 5.1.1 Checking the stem and handlebars are in correct position 5.1.1.1 Checking the connections 5.1.1.3 Checking the bearing clearance 1 Place the fingers of one hand on the upper 1 Stand in front of the pedelec. Clamp the front headset cup.
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Assembly 5.1.2 Fitting the pedals 3 Turn the pedal marked R anti-clockwise by The pedals have two different threads to ensure 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.
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.
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Operation Notice CAUTION Heat or direct sunlight can cause the tyre pressure Crash caused by material fatigue to increase above the permitted maximum pres- Intensive use can cause material fatigue. A com- sure. This can destroy the tyres. ponent may suddenly fail in case of material ...
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.
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.
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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.
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.
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...
Operation 6.5.2 Determining the sitting position The starting point for a comfortable posture is the Position on roadster Position on city bike correct position of the pelvis. If the pelvis is in the wrong position, it can cause different types of pain, e.g.
Operation 6.5.3 Seat post 6.5.4 Saddle 6.5.3.1 Adjusting the seat post to body weight 6.5.4.1 Replacing the saddle Not included in price Not included in price Seat post are components that may be replaced Saddles are components that may be replaced §...
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Operation 6.5.4.2 Determining the saddle shape Ladies’ saddle To distribute the pressure optimally over the female bone structure in the seat area, a ladies’ saddle should: • have a relief opening far to the front • have a wide V-shaped saddle edge. Figure 78: Pressure points on a saddle, male anatomy To distribute the pressure on the male bone structure in the seat area optimally, the saddle...
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Operation 6.5.4.3 Determining the minimum saddle width With corrugated cardboard With a gel cushion 1 Place corrugated cardboard on a flat, hard, 1 Smooth gel cushion. unpadded seat. 2 Place gel cushion on a flat, hard, unpadded 2 Sit in the middle of the corrugated board. seat.
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Operation Using calculation Depending on the position, the following value is added to the minimum saddle width. Position on roadster + 4 cm Position on city bike + 3 cm Position on trekking bike + 2 cm Position on sports bike + 1 cm Triathlon/time trials + 0 cm...
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Operation 6.5.4.6 Straightening the saddle 4 Take a test ride. Pedelec riders sit straight on the saddle at an Position saddle in direction of travel. In doing optimal saddle height. so, align the tip of the saddle with the top tube. •...
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Operation 6.5.4.9 Adjusting the saddle position The saddle can be shifted on the saddle frame. The right horizontal position ensures an optimal leverage position for legs. This prevents knee pain and painful incorrect pelvis positions. If you have displaced the saddle more than 10 mm, you need to adjust the saddle height again since both settings affect one another.
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Operation 6.5.4.10 Adjusting the saddle tilt The saddle tilt must be adjusted to the seat height, the saddle and handlebar position, and the saddle shape to ensure an optimum fit. The seating position can be optimised in this way if needed. The saddle prevents pedelec riders from slipping backwards or forwards when placed in a horizontal position.
Operation 6.5.5 Handlebars 6.5.5.1 Replacing the handlebars 6.5.5.3 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 §...
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Operation 6.5.5.4 Adjusting the handlebars The handlebars and their position determine the posture that the pedelec rider adopts on the pedelec. 1 After selecting the seating position (see Section 6.5.2), determine the angle of the upper body and the upper arm. 2 Tension the back muscles when adjusting the handlebars.
Operation 6.5.6 Stem 6.5.6.1 Replacing the stem 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.
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Operation 6.5.6.5 Setting the quill stem 6.5.6.6 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.
Operation 6.5.7 Handles 6.5.7.1 Replacing the handles 6.5.7.2 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.
Operation 6.5.8 Tyres 6.5.8.1 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 §...
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Operation 2 Perform a visual check on tyres. Figure 99: Correct tyre pressure. The tyre is barely deformed under the load of the body weight Figure 100: Far too little tyre pressure MY24H01 - 22_1.0_30.01.2024...
Operation 6.5.9 Brake 6.5.9.3 Changing the 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.
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Operation 6.5.9.4 Changing the handbrake inclination 2 Set the brake lever angle as indicated in the angle table. The nerves that pass through the carpal tunnel are connected to the thumb and the index and middle fingers. An excessively steep or 20 –...
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Operation 6.5.9.6 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.
Operation 6.5.10 Control panel and gear shift The control panel and gear shift must be adjusted to the rider's needs. 1 Undo attachment screw. 2 Place control panel or gear shift into the position where the rider can use the control panel or the shifter with their thumb and/or index finger.
Operation 6.5.11 Suspension and damping Suspension and damping can be adjusted to the Follow the correct order for adjustment. rider's weight in up to six increments, depending on the suspension system. For pedelecs with components only Sequence Adjustment Section Suspension fork Rear frame damper...
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Operation 6.5.12.1 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;...
Operation 6.5.13 Riding light 6.5.13.1 Replacing the headlight 6.5.13.2 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 §...
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Operation 6.5.13.4 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.
Operation 6.5.14 Replacing the electric drive system 6.5.15.1 Attaching the on-board computer components Notice All the components in the electric drive system § (motor, sensor, electric control, electrical cables, If the rider is not present, the on-board computer on-board computer, control panel, display can be used without authorisation, e.g.
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Operation 6.5.15.5 Charging the on-board computer 6.5.15.6 Changing the system settings battery The System settings can be displayed and changed no matter whether the on-board Notice computer is inserted in the mount or not. A few settings are only visible and changeable if the on- The on-board computer battery discharges when board computer is inserted.
Operation 6.5.16 On-board computer 6.5.16.1 Changing the tachometer unit The on-board computer is operated using four buttons on its casing. The displayed values can be changed from kilometres to miles. 1 Keep minus button pressed down. 2 Press On-Off button (on-board computer) briefly.
Operation Accessories CAUTION We recommend a parking stand into which either the front wheel or rear wheel can be inserted Crash caused by improper handling securely for pedelecs which do not have a kickstand. The following accessories are When using child seats, the pedelec's handling recommended: characteristics and stability change considerably.
Operation 6.6.3 Pannier rack The specialist dealer will provide instruction on how to handle the pedelec and the child seat. The specialist dealer will advise on choosing a 6.6.2 Trailer suitable pannier rack. The specialist dealer must install the pannier rack the first time to ensure that it is safely fitted.
Operation Using the battery 6.7.2 Pannier rack battery Switch off the battery and the drive system before removing or inserting the battery. Only applies to pedelecs with this equipment 6.7.1 Frame battery 6.7.2.1 Removing the pannier rack battery Only applies to pedelecs with this equipment 6.7.1.1 Removing the frame battery Figure 115: Removing (2) and inserting (3) the pannier rack battery...
Operation 6.7.3 Integrated battery Only applies to pedelecs with this equipment 6.7.3.1 Removing the integrated battery 6.7.3.2 Inserting the integrated battery Figure 117: Inserting the integrated battery Figure 116: Removing the integrated battery 1 Place the battery into the integrated battery 1 Open battery lock with battery key (1).
Operation 6.7.4 Charging the battery 6.7.5 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 ...
Operation 6.7.6 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 118: Covering open contacts with cover cap – example: pannier rack ...
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.
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.
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.
Operation 6.15 Setting the saddle height with the 6.17 Using the handlebars remote control Wear heavily padded cycling gloves. Only applies to pedelecs with this equipment This helps protect sensitive areas of your palms. 6.15.1 Lowering the saddle ...
Operation 6.17.2 Using bar ends Only applies to pedelecs with this equipment Bar ends can be added to normal handlebars. Adjustable bar ends feature a ball joint which you can use to choose the optimum position as required. Adjust bar ends correctly. To do so, your hand, elbow and shoulder must be in line with one another when the hand takes hold of the bar ends.
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.
Operation 6.19 On-board computer 6.19.1 Actions on the on-board computer Notice Action Button Duration Never use the display as a handle. The display Switching on the on-board Brief computer may become irreparably damaged if you use it to lift the pedelec. Switching off the on-board Brief (<...
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.
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 ...
Operation 6.20 Using the brake 6.20.1 Using the 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.
Operation 6.20.3 Using a 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.
Operation 6.20.4 Using eShift 6.20.4.2 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 6.20.4.1 Using eShift with SHIMANO DI2 computer each time it is changed.
Operation 6.21 Use suspension and damping 6.21.1 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 crown or a remote lockout activated on the the user is riding on bumpy cycle paths, dirt roads handlebars.
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Operation 6.21.2 Adjusting the suspension fork compression damper The compression damper allows the rider to make When placed at an optimum setting, the quick adjustments to the suspension behaviour of suspension fork counteracts deflection on hilly the suspension fork to adapt to changes in terrain. terrain, remains higher in its deflection range and It is intended for adjustments made during the helps maintain speed when riding on terrain hilly...
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Operation 6.21.2.1 Using SR Suntour high-speed compression damping 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.
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Operation 6.21.2.2 Using the SR Suntour low-speed compression damping Low-speed movement in the suspension fork is The settings on the high-speed damper control caused, for example, by riding over bumps. the suspension behaviour of the fork • during staggered jumps •...
Operation 6.21.3 Adjusting the SR Suntour compression damper Figure 135: SR SUNTOUR compression adjuster in open (1) and closed (2) position Place compression adjuster in the OPEN position. The compression adjuster is open. Place compression adjuster in the LOCK position.
Operation 6.22 Folding 2 Fold the pedal against the pedal crank. Notice Never crush or bend Bowden cables, electric cables or brake cables when folding. 6.22.1 Folding the pedelec Only applies to pedelecs with this equipment The pedelec is folded in eight steps. 1 Switch off electric drive system (see Figure 137: Folding the pedal up (I) or down (II) Section...
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Operation 6.22.1.3 Folding up the stem, version II Only applies to pedelecs with this equipment CAUTION 1 Open the clamping lever on the stem quick Crash caused by using the opened locking release. lever incorrectly 2 Push the unlocking knob. The frame will suddenly fold together while the 3 Pivot the handlebars 90°...
Operation 6.22.2 Preparing the bicycle so that it is 6.22.2.2 Folding out the pedal ready to ride again 1 Push the pedal against the pedal crank with the foot from the front. The bicycle is prepared so that it is ready to ride again in eight steps.
Operation 6.23 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 ...
Operation 6.23.1 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 144: All Up with open stem clamping lever 2 Pull handlebars into highest possible position.
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Cleaning, maintenance and inspection Cleaning, maintenance 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...
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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 ...
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Cleaning, maintenance and inspection Checklist: Tasks performed at least every six months Checklist: Tasks performed at least every six months (or every 1,000 km) (or every 1,000 km) Check Bowden cables gear Servicing the stem See Section 7.4.6 See Section 7.5.10.2 shift...
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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.
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.
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.
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: ...
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...
Cleaning, maintenance and inspection 7.3.4 Cleaning the frame, fork, pannier 7.3.7 Cleaning the handles rack, 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.
Cleaning, maintenance and inspection 7.3.9 Cleaning the saddle 7.3.12 Cleaning the 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.
Cleaning, maintenance and inspection 7.3.16 Cleaning the brake 7.3.14.1 Cleaning the shifter 7.3.16.1 Cleaning the handbrake Carefully clean shifter with a damp, soft cloth. Carefully clean the handbrake with a damp, 7.3.15 Cleaning the cassette, chain wheels soft cloth. and front derailleur 7.3.17 Cleaning the brake disc...
Cleaning, maintenance and inspection 7.3.19 Cleaning the chain Notice Never use aggressive (acid-based) cleaners, rust removers or degreasers when cleaning the chain. Never use gun oil or rust remover spray. Never use chain cleaning devices or chain cleaning baths.
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.
Cleaning, maintenance and inspection 7.4.3 Maintain pannier rack 7.4.6 Maintaining the stem 1 Dry pannier rack with a cloth. 1 Spray painted and polished metal surfaces 2 Spray pannier rack with spray wax and leave to with wax spray and leave to dry. dry.
Cleaning, maintenance and inspection 7.4.8 Maintaining the handles Maintaining the 7.4.9.2 carbon seat post Maintaining 7.4.8.1 rubber handles 1 Apply talcum powder to sticky rubber handles. Notice Notice Rain and puddle water can cause contact Never apply talcum powder to leather or foam corrosion if carbon seat posts are used in an handles.
Cleaning, maintenance and inspection 7.4.12 Maintaining the hub 7.4.14 Maintaining the gear shift Maintaining 7.4.14.1 the rear derailleur articu- lated shafts and jockey wheel 1 Apply wax spray especially around the spoke holes. In doing so, ensure that no wax is applied to brake parts.
Cleaning, maintenance and inspection 7.4.16 Maintaining the chain 7.4.16.1 Maintaining the chain and all-round chain guard Place newspaper or paper towels underneath to Place newspaper or paper towels underneath to collect chain oil. collect chain oil. 1 Lift rear wheel. 1 Lift rear wheel.
Cleaning, maintenance and inspection 7.4.18 Maintaining the brake 7.4.18.1 Maintaining the handbrake Notice Never treat brake handbrake with degreaser or penetrating oil spray. Lubricate articulated joints and mechanical parts which are accessible from outside with a few drops of spray oil or precision mechanics oil.
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.
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Cleaning, maintenance and inspection Dunlop valve Schrader valve Only applies to pedelecs with this equipment Only applies to pedelecs with this equipment The tyre pressure cannot be measured on the It is recommended to use an air pump at a filling ...
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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.
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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 ...
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...
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Cleaning, maintenance and inspection 7.5.2.4 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.
Cleaning, maintenance and inspection 7.5.3 Checking the chain 3 Check the chain tension at three to four points. If the deviation is greater than 20 mm, tighten Check chain for rust, damage and chain links chain. that are difficult to move. ...
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Cleaning, maintenance and inspection 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 160: Gauge is inserted 2 Lower gauge down to the left-hand side. Figure 155: Example of a KMC gauge Figure 161: Lower gauge to the left Figure 156: Example of a SHIMANO gauge...
Cleaning, maintenance and inspection 7.5.4 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.
Cleaning, maintenance and inspection 7.5.5 Checking the stem 7.5.8 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.
Cleaning, maintenance and inspection 7.5.10 Checking the gear shift 4 Check that there is clearance between the chain tensioner and spokes. 1 Check that all gear shift components are free of If there is no clearance or the chain scrapes damage.
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Cleaning, maintenance and inspection 7.5.10.5 Adjusting the ROHLOFF hub 7.5.10.6 Adjusting the cable-operated gear shift, dual-cable Only applies to pedelecs with this equipment Only applies to pedelecs with this equipment 1 Check whether shift cable tension is set in such ...
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Cleaning, maintenance and inspection 7.5.10.8 Checking kickstand stability 1 Place the pedelec on a slight elevation of 5 cm. 2 Extend kickstand. 3 Jolt pedelec to check stability. If pedelec topples over, tighten screws or change height of the kickstand. MY24H01 - 22_1.0_30.01.2024...
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. Tasks require technical expertise, Vibrations produced while riding can cause special tools and special lubricants. The pedelec screws and springs that were tightened during may become damaged if the stipulated pedelec manufacture to settle or come loose.
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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 ...
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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 ...
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.
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 Fre- Components Description Criteria Measures if rejected quency Accept- Inspection...
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Inspection and maintenance Fre- Components Description Criteria Measures if rejected quency Accept- Inspection Tests Maintenance Rejection ance Once a Cleaning … Section 7.3.5 O.K. Dirt Cleaning month 6 months … Section 7.4.6 O.K. Untreated Stem 6 months Check mount fas- Section 7.5.5 …...
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Inspection and maintenance Fre- Components Description Criteria Measures if rejected quency Accept- Inspection Tests Maintenance Rejection ance Wheel Before Concentricity Section 7.1.7 … O.K. Not straight Re-mount wheel each ride Wheel 6 months Assembly Section 7.5.1 … O.K. Loose Adjust quick release Once a Cleaning Section...
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Inspection and maintenance Fre- Components Description Criteria Measures if rejected quency Accept- Inspection Tests Maintenance Rejection ance Once a Cleaning … Section 7.3.12 O.K. Dirt Cleaning month Once a Care … Section 7.4.12 O.K. Untreated Treat month Hub gear 6 months Check mount fas- …...
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Inspection and maintenance Fre- Components Description Criteria Measures if rejected quency Accept- Inspection Tests Maintenance Rejection ance Back-pedal 6 months Attachment Check mount … O.K. Loose Retighten screws brake braking fastening armature 6 months Attachment Check mount … O.K. Loose Retighten screws Brake system fastening...
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Inspection and maintenance Fre- Components Description Criteria Measures if rejected quency Accept- Inspection Tests Maintenance Rejection ance 6 months First examination See Section on … O.K. Error message Contact battery manu- Rechargeable Assembly facturer; take out of battery service, new battery 6 months Firmly in position, Check mount...
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.
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.
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.
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...
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.
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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.
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.
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 6.5.2). • Pain in the lower back •...
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.
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).
Troubleshooting, fault clearance and repair Troubleshooting and fault 9.2.2 Error message clearance If an error message is displayed, run through the following actions: The components of the drive system are 1 Make a note of the system message. There is constantly checked automatically.
Troubleshooting, fault clearance and repair 9.2.3 Errors in assistance function Symptom Cause Remedy Check battery is charged. Is the battery charged sufficiently? Recharge the battery if it is almost flat. Press On-Off button (battery). Is the system switched on? ...
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. Disconnect the charger mains plug and plug it in again. Start charging.
Troubleshooting, fault clearance and repair Symptom Cause Remedy Remove from the battery immediately. There is an unusual Contact the fire service immediately. smell. Observe all the warnings in Section 2 Safety. Remove from the battery immediately. Fumes are emitted from Contact the fire service immediately.
Troubleshooting, fault clearance and repair 9.2.7 Correcting disc brake faults Symptom Cause Remedy Ringing and unusual Contact specialist dealer. Fit a city or trekking tyre. sounds from disc brakes. Riding on asphalt with off-road tyres. Dirty or greasy brake disc. ...
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.
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.
Troubleshooting, fault clearance and repair 9.2.10 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.
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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.
Troubleshooting, fault clearance and repair 9.2.11 Correcting faults in the SR SUNTOUR suspension fork 9.2.11.1 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.
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Troubleshooting, fault clearance and repair 9.2.11.2 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.
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Troubleshooting, fault clearance and repair 9.2.11.3 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 178: Excessively soft suspension in the suspension fork on hilly terrain Solution ...
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Troubleshooting, fault clearance and repair 9.2.11.4 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.
Troubleshooting, fault clearance and repair 9.2.12 Correcting freewheel faults 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.
Troubleshooting, fault clearance and repair 9.2.13 Correcting lighting faults 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.
Troubleshooting, fault clearance and repair 9.2.16 Correcting other faults and 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.
Troubleshooting, fault clearance and repair Repairs at the specialist dealer 9.3.3 Repairing the suspension fork Expert knowledge and special tools are required for many repairs. For this reason, repairs may only 9.3.3.1 Removing paint damage on the fork be carried out at a specialist dealer. These include: 1 Gently sand paintwork damage with 600-grit •...
Troubleshooting, fault clearance and repair 9.3.4 Replacing the riding light Only use components in the corresponding power class for replacement. 9.3.5 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).
Description 9.3.7 Torque Model Torque Tool Axle Conventional axle nut 35 … 40 Nm* 15 mm spanner SR SUNTOUR screw-on axle 12AH2 Axle 8 … 10 Nm 6 mm hex bit Securing screw 5 … 6 Nm 5 mm hex bit SR SUNTOUR screw-on axle 15AH2 Axle...
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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 TEKTRO for hydraulic disc brake system...
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Description SHIMANO for 5-hole version Attachment screws 2 … 4 Nm Star bit [no. 25] SHIMANO for 6-hole version Attachment screws 2 … 4 Nm Star bit [no. 25] TEKTRO for hydraulic disc brake system Attachment screws 4 … 6 Nm Torx®...
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Description SR SUNTOUR Damping side, top, aluminium 20 Nm SR SUNTOUR Damping side, bottom, without adjuster 10 Nm SR SUNTOUR Damping side, bottom, with adjuster 7 Nm SR SUNTOUR Fork head clamps 7 Nm SRAM RockShox, 35 Cover cap 28 Nm socket nut, 24 mm SRAM RockShox, Lyrik, Compression damper cover...
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Description SRAM RockShox Locking screw – remote control stop ring Hand-tight or 0.1 … 0.3 Nm 2 mm hex bit SRAM RockShox, Lyrik, Clamping screw – rebound adjuster ring 0.84 Nm 2.5 mm hex bit SRAM RockShox, Lyrik, Air suspension guide rod insert (Select+, Select, Base –...
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Description SHIMANO, FC-M8000, single version Attachment screw for crank/ chainring 12 … 14 Nm Star bit [no. 30] SHIMANO, FC-M8000, dual version Largest chainring 12 … 14 Nm Star bit [no. 30] Smallest chainring 16 … 17 Nm Star bit [no. 30] SHIMANO, FC-M8000, triple version Largest chainring...
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Description BOSCH motor BDU37xx 20 ± 2 Nm Torx Plus® P40, M8 × 16 6 x attachment screws for motor BOSCH Intuvia 100 bracket Torx ® Torx Plus ® Motor cover BOSCH motor cover BDU37xx Attachment screws for lower Initial fitting: 3 ± 0.5 Nm Torx®...
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 –...
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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.
Documents Documents 11.1 Assembly report Frame number: Date: Components Description Criteria Measures if rejected Assembly Accept- Tests Rejection /inspection ance 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.
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Documents Components Description Criteria Measures if rejected Assembly Accept- Tests Rejection /inspection ance 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/spoke Check for damage O.K. Damage Replace as specified in parts list guard Bottom bracket axle/ Check mount fastening...
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.
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Documents Measures if Component Frequency Description Criteria rejected Accept- Inspection Test Rejection ance 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.
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Documents Measures if Component Frequency Description Criteria rejected Accept- Inspection Test Rejection ance 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 Check control panel Functional check...
Glossary Glossary Bicycle for young adults Disc brake Source: ISO 4210-2: bicycle 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.
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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.
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Glossary Operating instructions Seat post Source: ISO/DIS 20607:2018: part of the user Source: EN 15194:2017: component that clamps information that machine manufacturers provide the saddle (with a bolt or assembly) and connects to machine operators; it contains guidance, it to the frame. instructions and tips related to the use of the Shut-off speed machine in all its life cycle phases.
Glossary 12.1 Abbreviations Weight of the ready-to-ride pedelec Source: ZEG: the indicated weight for a ready-to- Abbreviation Meaning/derivation ride pedelec refers to the weight of a pedelec at the time of sale. The weight of each additional Anti-blocking system accessory must be added to this weight Bluetooth Low Energy EPAC Electric power-assisted cycle...
Appendix Appendix Translation of the original EC/EU Declaration of Conformity Manufacturer Authorised representative for documentation* HERCULES GmbH Janine Otto Longericher Strasse 2 c/o ZEG Zweirad-Einkaufs-Genossenschaft eG 50739 Köln Longericher Strasse 2 Germany 50739 Köln Germany The machine, pedelec types: 23-Q-0078...
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EN 62133-2:2017-11 Secondary cells and batteries containing alkaline or other non-acid electrolytes. Safety requirements for portable sealed secondary cells, and for batteries made from them, for use in portable applications – Part 2: Lithium systems. Cologne, 21.09.2023 ……………………………………………………………………………………………… Georg Honkomp, Managing Director, HERCULES GmbH MY24H01 - 22_1.0_30.01.2024...
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