1. Manuals
  2. Brands
  3. Hercules Manuals
  4. Bicycle Accessories
  5. BAFANG
  6. Translation of original operating instructions

Hercules BAFANG Translation Of Original Operating Instructions

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
IMPORTANT
READ CAREFULLY BEFORE USE
KEEP IN SAFE PLACE READY TO CONSULT AT LATER DATE
Translation of original operating instructions for
HERCULES pedelecs with BAFANG DP E160.CAN
U r b a n i c o :
2 3 - Q - 0 1 0 1 ... 2 3 - Q - 0 1 0 5 , 2 3 - W - 0 0 0 3 , 2 3 - W - 0 0 0 4 , 2 4 - Q - 0 0 6 9 ... 2 4 - Q - 0 0 7 5 , 2 4 - W - 0 0 0 4 , 2 4 - W - 0 0 0 5
C o m p a c t 8 | C o m p a c t 1 0 | I - 8 | I - 1 0 | G R I - 11
M Y 2 4 H 1 5 - 1 2 _ 1 . 0 _ 2 9 . 0 1 . 2 0 2 4

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the BAFANG and is the answer not in the manual?

Questions and answers

Related Manuals for Hercules BAFANG

Summary of Contents for Hercules BAFANG

  • Page 1 KEEP IN SAFE PLACE READY TO CONSULT AT LATER DATE Translation of original operating instructions for HERCULES pedelecs with BAFANG DP E160.CAN U r b a n i c o : C o m p a c t 8 | C o m p a c t 1 0 | I - 8 | I - 1 0 | G R I - 11 2 3 - Q - 0 1 0 1 …...

  • Page 2: Table Of Contents

    3.1.1 Pedelec type 3.1.2 Improper use 3.1.3 Maximum permitted total weight (PTW) 3.1.4 Environment requirements for BAFANG 3.1.5 Area of use as per EN 17406, from model year 2024 3.1.5.1 Up to model year 2023 Model year 24 nameplate 3.2.1...
  • Page 3 3.3.8.2 Charger 3.3.8.3 Lighting 3.3.8.4 On-board computer 3.3.8.5 Rechargeable battery Description of controls and screens 3.4.1 BAFANG DP E160.CAN on-board computer 3.4.1.1 Light indicator 3.4.1.2 Battery level indicator 3.4.1.3 Speed indicator 3.4.1.4 System message 3.4.1.5 Selected level of assistance indicator 3.4.1.6...
  • Page 4 Checking stem is firmly in position 5.3.4.3 Checking the bearing clearance Selling the pedelec Operation Risks and hazards Tips for a greater range 6.2.1 BAFANG error message 6.2.1.1 On-board computer Instruction and customer service Adjusting the pedelec 6.4.1 Preparing 6.4.2 Determining the sitting position 6.4.3...
  • Page 5 Child seat 6.5.2 Trailer 6.5.3 Pannier rack Personal protective equipment and accessories for road safety Before each ride Using the Bafang battery 6.8.1 Charging the battery Straightening the quickly adjustable stem 6.10 Using the pannier rack 6.11 Raising the kickstand 6.12...
  • Page 6 Contents 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 7.1.10 Checking the bell 7.1.11 Checking the handles 7.1.12 Checking the USB cover 7.1.13 Checking the riding light 7.1.14 Checking the brake After each ride...
  • Page 7 Contents 7.4.12 Maintaining the hub 7.4.13 Maintaining the spoke nipples 7.4.14 Maintaining the gear shift 7.4.14.1 Maintaining the rear derailleur articulated shafts and jockey wheel 7.4.14.2 Maintaining the shifter 7.4.15 Maintaining the pedals 7.4.16 Maintaining the chain 7.4.16.1 Maintaining the chain and all-round chain guard 7.4.17 Maintaining the battery 7.4.18...
  • Page 8 Numb or aching hands 9.1.6 Pain in upper thigh 9.1.7 Knee pain 9.1.8 Pain in the foot BAFANG drive system 9.2.1 Drive system or on-board computer does not start up Display screen errors 9.3.1 Lighting does not work 9.3.2 Errors in assistance function 9.3.3...
  • Page 9 Contents Glossary 12.1 Abbreviations 12.2 Simplified terms Appendix Translation of the original EC/EU Declaration of Conformity Declaration of Conformity for Bafang as incomplete machine Keyword index MY24H15 - 12_1.0_29.01.2024...
  • Page 10 About these operating instructions Thank you for your trust! Copyright HERCULES pedelecs are premium quality © HERCULES GmbH bicycles. You have made an excellent choice. Your specialist dealer will provide you with Distribution or reproduction of these operating guidance and instruction and assemble your instructions and utilisation or communication of product.

  • Page 11: About These Operating Instructions

    About these operating instructions About these operating instructions Manufacturer CAUTION HERCULES GmbH Longericher Strasse 2 May lead to minor or moderate injuries if ignored. 50739 Köln Low-risk hazard. Germany Notice Tel.: +49 4473 92617 0 Fax: +49 4473 92617 29 May lead to material damage if ignored.

  • Page 12: Language

    About these operating instructions Language The original operating instructions are written in Section German. A translation is invalid without the original operating instructions. About these operating instructions   Aim of the operating instructions Safety   These operating instructions are an integral part Description ...

  • Page 13: Type Number And Model

    About these operating instructions Frame number ype number and model Each frame has an individual frame number These operating instructions are an integral part stamped on it (see Figure 2). The frame number of pedelecs with the type numbers: can be used to link the pedelec with the owner. Type no.

  • Page 14: 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 15 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 16: 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 17: 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 18: 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 19: 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 20: 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 21: 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 22: Maximum Permitted Total Weight (Ptw)

    Description 3.1.3 Maximum 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.

  • Page 23: Environment Requirements For Bafang

    Description 3.1.4 Environment requirements for BAFANG 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...

  • Page 24: Area Of Use As Per En 17406, From Model Year 2024

    Description 3.1.5 Area of use as per EN 17406, from model year 2024 Average Area of use Unsuitability speed [km/h] Use on normal, paved surfaces where the tyres should maintain 15 ... 25 • Never ride off road. contact with the ground at average speed with occasional jumps. •...

  • Page 25: Up To Model Year 2023

    Description 3.1.5.1 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.

  • Page 26: Model Year 24 Nameplate

    TYP: XX-XX-XXX EPAC nach EN 15194 0,25 kW / 25 km/h zGG 150 kg / BJ 2024 EPAC XX kg Figure 2: Example HERCULES nameplate More No. Designation Description information The manufacturer uses the CE marking to declare that the pedelec...

  • Page 27: Model Year 23 Nameplate

    EN 15194 0,25 kW / 25 km/h zGG 150 kg EPAC 25 kg BJ 2022 / MJ 2023 Figure 3: Example HERCULES nameplate More No. Designation Description information The manufacturer uses the CE marking to declare that the pedelec...

  • Page 28: Components

    Description Components 3.3.1 Overview 17 18 21 22 23 24 Figure 4: Pedelec viewed from right, example Wheel Seat post Chain Saddle Stand Fork Pannier rack Chain guard Guard Rear light and reflector Pedal crank Front light Guard Pedal Steering headset Battery and nameplate Handlebars Wheel...

  • Page 29: Chassis

    Description 3.3.2 Chassis The chassis comprises two components: • Frame and • steering system 3.3.2.1 Frame The frame absorbs all forces which act on pedelec from body weight, pedalling and the ground. The frame also acts as a carrier for most components. The frame geometry determines the pedelec’s ride performance.

  • Page 30: Handlebars

    Description 3.3.2.5 Handlebars 3.3.2.6 Fork The stem and handlebars are attached to the top The pedelec is steered using the handlebars. The end of the fork steerer. The axle is fastened to the handlebars are used to support the upper body fork ends.

  • Page 31: 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 32 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 33: Rim

    Description Bead core 3.3.3.3 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.

  • Page 34: Spoke

    Description Presta valve 3.3.3.6 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.

  • Page 35: Brake

    Description 3.3.4 Brake 3.3.4.2 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.

  • Page 36: Disc Brake

    Description 3.3.4.3 Disc brake Figure 19: 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 37: Saddle

    Description 3.3.5 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.

  • Page 38: Ladies' Saddle

    Description 3.3.5.1 Ladies’ saddle 3.3.5.2 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.

  • Page 39: Seat Post

    Description 3.3.6 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 •...

  • Page 40: 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 41: Electric Drive System

    3.3.8.2 Charger Each pedelec is supplied with a charger. The following BAFANG charger may be used: • C01.2A. 3.3.8.3 Lighting Figure 30: Diagram of an electric drive system with...

  • Page 42: Rechargeable Battery

    Description 3.3.8.5 Rechargeable battery BAFANG batteries are lithium ion batteries which are developed and manufactured to the latest technical standards. Each battery cell is protected by a steel cup and encased in a plastic battery housing. Applicable safety regulations are met.

  • Page 43: Description Of Controls And Screens

    The on-board computer on the handlebars is used as a control panel. The on-board computer has a display. It controls the system and all indicators on the display screen using three buttons. Figure 32: Overview of BAFANG DP E160.CAN on-board computer Selected level of assistance indicator Light indicator...

  • Page 44: Light Indicator

    Description 3.4.1.1 Light indicator 3.4.1.6 Push assist indicator The on-board computer displays the light symbol The on-board computer displays the push assist when the light is activated. symbol when the push assist is activated. 3.4.1.2 Battery level indicator The battery level indicator shows the battery charge level.

  • Page 45: Handbrake

    Description 3.4.2 Handbrake There is a handbrake on the left and right of the handlebars. Figure 33: 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 46: Shimano, Deore Sl-M4100-R

    Description 3.4.2.1 SHIMANO, DEORE SL-M4100-R Only applies to vehicles with this equipment On the right of the handlebars, you will find the SHIMANO DEORE SL-M4100-R gear shift unit. The gear shift unit features two shifters. Figure 34: SHIMANO DEORE SL-M5130-R10 Down button (gear shift) Up button (gear shift) Gear indicator...

  • Page 47: Technical Data

    Technical data Technical data 3.5.1 Bafang pedelec Power output/system 250 W (0.25 kW) Shut-off speed 25 km/h Charging temperature 0 °C … +45 °C Operating temperature -20 °C … +45 °C Storage temperature +10 °C … +50 °C Work environment temperature +15 °C …...

  • Page 48: Bafang H600 Motor

    36H x 16G Cassette 8 ... 10 Throttle Table 16: Technical data for Bafang H600 Details on noise emissions from the drive unit The A-weighted emission sound pressure level of the drive unit is < 70 dB(A) in normal mode.

  • Page 49: Bafang Dp E160.Can On-Board Computer

    230/850 Connector type G5.4.2 Operating temperature -20 ... +45 Storage temperature -20 ... +50 Air humidity during storage 30% ... 70% Display Display type Nominal voltage [V] 36/43/48 DC Table 17: Technical data for BAFANG DP E160.CAN MY24H15 - 12_1.0_29.01.2024...

  • Page 50: Battery, Bafang Bt F014.410.C

    Voltage range [V] 32.4 ... 49.2 Charging time [h] 6 (2 A)/4.5 (3 A) Max. permanent discharge current [A] Charging temperature [°C] 0 ... 45 Operating temperature [°C] -20 ... 50 Table 18: Technical data for BAFANG DP E160.CAN MY24H15 - 12_1.0_29.01.2024...

  • Page 51: Tyres

    Description 3.5.5 Tyres 3.5.5.1 SCHWALBE puncture protection level V-GUARD Inserts The V-Guard puncture protection Webbing Rubber insert belt comprises of lightweight, cut- insert Combination resistant fibres. Its webbing ensures highly effective puncture resistance SmartGuard® for lightweight race and tour tyres. DualGuard Tubeless Easy Double Defense®...

  • Page 52: Torque

    Technical data 3.5.6 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...
  • Page 53 Technical data BOSCH System Controller Attachment screw 0.5 Nm Torx® T10 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...
  • Page 54 Technical data 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 …...
  • Page 55 Technical data Suspension 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 56 Technical data 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 57 Technical data Chainring FIT, Brose FIT Crank start spider lockring 28 Nm ISIS bottom bracket axle tool FIT, Panasonic FIT Crank star screws 13 Nm Hex key, 5 mm FIT, Panasonic FIT Crank start spider lockring 40 Nm ISIS bottom bracket axle tool FIT, Panasonic FIT Crank star screws 13 Nm...
  • Page 58 Technical data SHIMANO, HOLLOWTECH Ii/two-part crank set 0.7 … 1.5 Nm TL-FC16 / TL-FC18 SHIMANO, HOLLOWTECH Ii/two-part crank set Screw for left-hand crank arm 12 … 14 Nm Hex key, 5 mm SHIMANO, OCTALINK type Linker for adapter and main body 50 …...
  • Page 59 Technical data ENVIOLO Interface lock nut 10 ... 15 Nm ENVIOLO Tapered nut 9 .. 10 Nm ENVIOLO Initial speed ring 1.0 Nm ENVIOLO Screw for control cable cover 0.2 ... 0.3 Nm (hand-tight) ROHLOFF, 14/500 Bayonet lock/cable drum screws 1.5 Nm 2 mm hex bit ROHLOFF, 14/500...
  • Page 60 Technical data 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, 40 Nm Adjustable spanner and special tool TL-LR15 FH-MT200-B, FH-MT400, (SHIMANO) FH-MT400-B, FH-MT500, FH-MT500-B, FH-MT510, FH-MT510-B, FH-RM33, FH-RM35,...
  • Page 61 Technical data 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 … 24 Nm M5 fixing grub screws 3 Nm 2.5 mm hex bit BY.SCHULZ G2...
  • Page 62 Technical data SHIMANO XTR SL-M9100 Attachment screw 3 Nm 4 mm hex bit SRAM AXS controller Collar attachment screw 2 Nm Torx® T25 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...
  • Page 63 Technical data SHIMANO for racing bicycles Hex key, 5 mm/ Attachment screw 5 … 7 Nm Screw wrench, 9 mm 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...

  • Page 64: Transporting And Storing

    About these operating instructions Transporting and storing Weight and dimensions for transportation # Not yet available when the instructions were produced Designated handles, lifting points The box does not have any handles. MY24H15 - 12_1.0_29.01.2024...

  • Page 65: Transportation

    Transporting and storing Transportation 4.3.2 Transporting the pedelec 4.3.2.1 By car CAUTION Bicycle rack systems which use the handlebars or frame to hold the pedelec in an upside-down Crash caused by unintentional activation position exert inadmissible forces on its There is a risk of injury if the drive system is components during transportation.

  • Page 66: 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 67: Storing

    Transporting and storing Storing  Always store pedelec, battery, on-board New battery computer, display and charger separately. Inspect battery for damage after delivery.  Storage temperature +10 °C …+50 °C  If batteries are faulty, observe instructions in Humidity 30% … 85% Handling a damaged or faulty battery during storage and disposal (see Section 2.1.1).

  • Page 68: Break In Operation

    Transporting and storing 4.4.4 Break in operation 4.4.4.1 Preparing a break in operation 1 The pedelec needs to be cleaned with a damp Notice cloth and preserved with wax spray. Never wax the friction surfaces of the brake. Batteries discharge if they are not used. If the 2 Have the specialist dealer carry out battery is stored for a longer period of time when maintenance and basic cleaning and apply...

  • Page 69: 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 70: 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. It makes sense to prepare each pedelec so that it is fully ready for use immediately after being assembled.

  • Page 71: Preparing The Wheel

    Assembly 5.3.2 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 72: Fitting The Pedals

    Assembly 5.3.3 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 73: Checking The Stem And Handlebars

    Assembly 5.3.4 Checking the stem and handlebars 5.3.4.1 Checking the connections 5.3.4.3 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 74: 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 75 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 ...

  • Page 76: 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 77: Bafang Error Message

    Troubleshooting, fault clearance and repair 6.2.1 BAFANG error message 6.2.1.1 On-board computer The on-board computer indicates whether a Code Description Method of resolution critical or less critical error has arisen in the drive Temperature sensor in  Contact specialist system.
  • Page 78 Troubleshooting, fault clearance and repair Code Description Method of resolution Code Description Method of resolution Torque signal error. Contact specialist Total battery voltage is  Replace battery. too high. dealer. Check that all connections are properly Total battery voltage is Charge the battery.

  • Page 79: Instruction And Customer Service

    Operation Instruction and customer service 6.4.1 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 80: Determining The Sitting Position

    Operation 6.4.2 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.

  • Page 81: Seat Post

    Operation 6.4.3 Seat post 6.4.4 Saddle 6.4.3.1 Adjusting the seat post to body weight 6.4.4.1 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 §...

  • Page 82: Determining The Saddle Shape

    Operation 6.4.4.2 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 47: Pressure points on a saddle, male anatomy To distribute the pressure on the male bone structure in the seat area optimally, the saddle...

  • Page 83: Determining The Minimum Saddle Width

    Operation 6.4.4.3 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.

  • Page 84: Selecting The Saddle Hardness

    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...

  • Page 85: Straightening The Saddle

    Operation 6.4.4.6 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. •...

  • Page 86: Setting The Saddle Height With The Remote Control

    Operation 6.4.4.9 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.

  • Page 87: Adjusting The Saddle Tilt

    Operation 6.4.4.10 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.

  • Page 88: Handlebars

    Operation 6.4.5 Handlebars 6.4.5.1 Replacing the handlebars 6.4.5.3 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 §...

  • Page 89: Adjusting The Handlebars

    Operation 6.4.5.4 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.

  • Page 90: Stem

    Operation 6.4.6 Stem 6.4.6.1 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.

  • Page 91: Setting The Quill Stem

    Operation 6.4.6.5 Setting the quill stem 6.4.6.6 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.

  • Page 92: Handles

    Operation 6.4.7 Handles 6.4.7.1 Replacing the handles 6.4.7.2 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.

  • Page 93: Tyres

    Operation 6.4.8 Tyres 6.4.8.1 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 §...
  • Page 94 Operation 2 Perform a visual check on tyres. Figure 68: Correct tyre pressure. The tyre is barely deformed under the load of the body weight Figure 69: Far too little tyre pressure MY24H15 - 12_1.0_29.01.2024...

  • Page 95: Brake

    Operation 6.4.9 Brake 6.4.9.3 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.

  • Page 96: Changing The Handbrake Inclination Angle

    Operation 6.4.9.4 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 –...

  • Page 97: Control Panel And Gear Shift

    Operation 6.4.10 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.

  • Page 98: Riding Light

    Operation 6.4.11 Riding light 6.4.11.1 Replacing the headlight 6.4.11.2 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 99: Adjusting The Headlight

    Operation 6.4.11.4 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 100: Accessories

    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.

  • Page 101: Trailer

    Operation 6.5.3 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 6.5.2 Trailer suitable pannier rack. The specialist dealer must install the pannier rack the first time to ensure that it is safely fitted.

  • Page 102: 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 103: Using The Bafang Battery

    Operation Using the Bafang battery Switching off the electric drive system (see  Section 6.13.2). 6.8.1 Charging the battery The battery can remain on the pedelec when charging. Interrupting the charging process does not damage the battery. The battery is fitted with...

  • Page 104: Straightening The Quickly Adjustable Stem

    Operation Straightening the quickly 6.10 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 105: Raising The Kickstand

    Operation 6.12.1 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 106: Setting The Saddle Height With The Remote Control

    Operation 6.14 Setting the saddle height with the 6.16 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. 6.14.1 Lowering the saddle ...

  • Page 107: Using Bar Ends

    Operation 6.16.2 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.

  • Page 108: Using The Electric Drive System

    Operation 6.17 Using the electric drive system 6.17.1 Switching on the electric drive 6.17.2 Switching off the electric drive system system As soon as the rider stops pushing the pedals in normal mode or reaches a speed of 25 km/h, the CAUTION drive system switches off the assistance system.

  • Page 109: Using The On-Board Computer

    Operation 6.18 Using the on-board computer 6.18.2 Using the push assist system Notice CAUTION Injury from pedals or wheels  Never use on-board computer as a handle. The components may become irreparably The pedals and the drive wheel turn when the damaged if you use the on-board computer to push assist system is used.

  • Page 110: Selecting The Level Of Assistance

    Operation 6.18.3 Selecting the level of assistance 3 Push the push assist button within 10 seconds to reactivate motor assistance. The control panel is used to set how much the 4 If motor assistance deactivates within electric drive should assist the rider when 5 seconds, the push assist function switches pedalling.

  • Page 111: Brake

    Operation 6.19 Brake CAUTION WARNING Crash caused by wet conditions Crash caused by brake failure The tyres may slip on wet roads. In wet conditions you must also expect a longer braking distance. Oil or lubricant on the brake disc in a disc brake The braking sensation differs from the usual sen- or on the rim of a rim brake can cause the brake sation.

  • Page 112: Using The Brake Lever

    Operation 6.19.1 Using the brake lever Figure 92: Front (2) and rear (1) brake lever – Shimano brake used as an example  Push the left brake lever to apply the front wheel brake.  Pull the right-hand brake lever to apply the rear wheel brake.

  • Page 113: Gear Shift

    Operation 6.20 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 114: Parking

    Operation 6.21 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 115: Screwing In The All Up Handlebars

    Operation 6.21.1 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 95: All Up with open stem clamping lever 2 Pull handlebars into highest possible position.

  • Page 116: Cleaning, Maintenance And Inspection

    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...
  • Page 117 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 118 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 7.5.11.2 shift...
  • Page 119 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 120: 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 121: 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 122: 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 123: 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 124: Cleaning The Frame, Fork, Pannier Rack, Guards And Kickstand

    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.

  • Page 125: Cleaning The Saddle

    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.

  • Page 126: Cleaning The Shifter

    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...

  • Page 127: Cleaning The Chain

    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.

  • Page 128: 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 129: Maintain Pannier Rack

    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.

  • Page 130: Maintaining The Handles

    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.

  • Page 131: Maintaining The Hub

    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.

  • Page 132: Maintaining The Chain

    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.

  • Page 133: Maintaining The Brake

    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.

  • Page 134: 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 135 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 ...

  • Page 136: 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 137: 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 138: 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 139: 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 140: Checking The Chain

    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. ...
  • Page 141 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 111: Gauge is inserted 2 Lower gauge down to the left-hand side. Figure 106: Example of a KMC gauge Figure 112: Lower gauge to the left Figure 107: Example of a SHIMANO gauge...

  • Page 142: Checking The Belt

    Cleaning, maintenance and inspection 7.5.4 Checking the belt  The tooth profile is pointed and teeth have worn thinner. Contact specialist dealer. The belt sprocket does need to be replaced. 7.5.4.1 Checking the belt for wear  Check belt for indications of wear: Figure 115: Indications of wear on a belt Figure 117: Worn tooth profile 1 Carbon tensile fibres are exposed...
  • Page 143 Cleaning, maintenance and inspection There are three common methods of measuring 1 Open app. belt tension: 2 Click on the voltage symbol. • Gates Carbon Drive mobile app for iPhone® and 3 Click on MEASURE. Android®, • Gates Krikit tension meter and 4 Point phone microphone towards the belt.
  • Page 144 Cleaning, maintenance and inspection 3 Press the check gauge down with just one ECO tension tester finger until it clicks into place. Not included in price 1 Attach the measuring stick on the belt. Figure 121: Pressing the check gauge down with one finger 4 Take reading where line A meets line B.

  • Page 145: Checking The Riding Light

    Cleaning, maintenance and inspection 7.5.5 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 146: Checking The Stem

    Cleaning, maintenance and inspection 7.5.6 Checking the stem 7.5.9 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 147: Checking The Gear Shift

    Cleaning, maintenance and inspection 7.5.11 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.

  • Page 148: Adjusting The Rohloff Hub

    Cleaning, maintenance and inspection 7.5.11.5 Adjusting the ROHLOFF hub 7.5.11.6 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 ...

  • Page 149: Checking Kickstand Stability

    Cleaning, maintenance and inspection 7.5.11.8 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. MY24H15 - 12_1.0_29.01.2024...

  • Page 150: Inspection And Maintenance

    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.
  • Page 151 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 152 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 153: Carry Out Initial Inspection

    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 154: Perform Major Inspection

    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...
  • Page 155 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 7.5.6 …...
  • Page 156 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...
  • Page 157 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- …...
  • Page 158 Inspection and maintenance Fre- Components Description Criteria Measures if rejected quency Accept- Inspection Tests Maintenance Rejection ance 20 hours Refill oil … Section 7.4.19 O.K. No oil Refill oil 20 hours Clean wiper O.K. Dirt Cleaning EIGHTPINS 40 hours Clean slide bushing O.K.
  • Page 159 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...
  • Page 160 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...

  • Page 161: Inspect Frame

    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 162: Inspecting The Gear Hub

    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 163: Inspecting The Axle With Quick Release

    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 164: Inspecting The Fork

    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 165: Inspecting The Seat Post

    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 166: Inspecting And Greasing Rs Suntour Suspension Seat Post

    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 167: Troubleshooting, Fault Clearance And Repair

    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 168: Sitting Discomfort

    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 •...

  • Page 169: Pain In Shoulders And Nape Of Neck

    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 170: Knee 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).

  • Page 171: Bafang Drive System

    Troubleshooting, fault clearance and repair BAFANG drive system The on-board computer indicates whether a 1 Check whether the battery is switched on. If critical or less critical error has arisen in the drive not, start the battery. system.  Contact your specialist dealer if the battery level indicator LEDs do not light up.

  • Page 172: Lighting Does Not Work

    Troubleshooting, fault clearance and repair 9.3.1 Lighting does not work Symptom Cause Remedy Front lamp or rear lamp The default settings in the electric drive Take pedelec out of service immediately. does not go on, even system have probably been configured Contact specialist dealer.

  • Page 173: Battery Errors

    Troubleshooting, fault clearance and repair Symptom Cause Remedy It is difficult to pedal. Are the tyres pumped to an adequate Pump up tyres. pressure? Is the level of assistance set to [0]? Set level of assistance to [1], [2], [3], [4] or [5]. Contact your specialist dealer if the pedals are still stiff.
  • Page 174 Troubleshooting, fault clearance and repair Symptom Cause Remedy There is an unusual Contact the fire service immediately. smell. Observe all the warnings in Section 2 Safety. Fumes are emitted from Contact the fire service immediately. the battery. Observe all the warnings in Section 2 Safety. Table 38: Error solution for battery MY24H15 - 12_1.0_29.01.2024...

  • Page 175: Correcting Disc Brake Faults

    Troubleshooting, fault clearance and repair 9.3.4 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. ...

  • Page 176: Correcting Freewheel Faults

    Troubleshooting, fault clearance and repair 9.3.5 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.

  • Page 177: Correcting Lighting Faults

    Troubleshooting, fault clearance and repair 9.3.6 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.

  • Page 178: Correcting Other Faults And Errors

    Troubleshooting, fault clearance and repair 9.3.9 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.

  • Page 179: Repairs At The Specialist Dealer

    Troubleshooting, fault clearance and repair Repairs at the specialist dealer 9.4.3 Repairing the suspension fork Expert knowledge and special tools are required for many repairs. For this reason, repairs may only 9.4.3.1 Removing paint damage on the fork be carried out at a specialist dealer. These include: 1 Gently sand paintwork damage with 600-grit •...

  • Page 180: Replacing The Riding Light

    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 181: Recycling And Disposal

    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 182 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 183: Documents

    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.
  • Page 184 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...

  • Page 185: Inspection And Maintenance Log

    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 186 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.
  • Page 187 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...
  • Page 188 Documents Notes MY24H15 - 12_1.0_29.01.2024...

  • Page 189: Parts List

    Ø: 34.9 mm Pedal MARWI, SP828 Aluminium, with reflector, 9/16" Crank set SAMOX, EC40-F13-JIS Pedal crank length: 170 mm Chain/belt KMC, Z82 Chain, 114 links; see Section # Chain wheel/belt sprocket BAFANG, CW B1.11 # Chain wheel, 38T MY24H15 - 12_1.0_29.01.2024...
  • Page 190 Section # Shifter SHIMANO, SL-M315-8R Shifter with indicator, 8-speed Motor BAFANG, H600 See Section 3.5.06.1 On-board computer BAFANG, Controller CR S105.250 See Section # Display BAFANG, DP E160/161.CAN See Section # Rechargeable battery BAFANG, BT F014.410.C Charger BAFANG, C01.2A...
  • Page 191 Assembly 11.3.2 Urbanico I-10 23-Q-0101...23-Q-0103, 24-Q-0069...24-Q-0071 HE, TR, ZR Shape: HE; size: 48 cm Shape: HE; size: 53 cm Shape: HE; size: 58 cm Shape: TR; size: 48 cm Frames (variants) HAOJE, Frame R25/23 Shape: TR; size: 53 cm Shape: TR; size: 58 cm Shape: ZR;...
  • Page 192 Shifter SHIMANO, DEORE SL-M4100-R Shifter with indicator, 10-speed Motor BAFANG, H600 See Section 3.5.06.1 On-board computer BAFANG, Controller CR S105.250 See Section # Display BAFANG, DP E160/161.CAN See Section # Charger BAFANG, C01.2A See Section # # 3-finger brake lever | Hydraulic disc brake, 2-...

  • Page 193: Urbanico Gr

    Crank set SAMOX, EC40-F13-JIS Pedal crank length: 170 mm Chain/belt KMC, X11e Chain, # links; see Section # Chain wheel/belt sprocket BAFANG, CW B1.11 # Chain wheel, 38T Rear derailleur SHIMANO, GRX RD-RX812 See Section # Sprocket/belt sprocket/ SUNRACES, CSMX8 EAY...
  • Page 194 Assembly Motor BAFANG, H600 See Section 3.5.06.1 On-board computer BAFANG, Controller CR S105.250 See Section # Display BAFANG, DP E160/161.CAN See Section # Charger BAFANG, C01.2A See Section # DUAL CONTROL LEVER | Length: 1700 mm | Rear brake Hydraulic disc brake, 2-piston...

  • Page 195: Glossary

    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.
  • Page 196 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 197 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.

  • Page 198: Abbreviations

    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...

  • Page 199: Appendix

    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-0101...
  • Page 200 – Part 2: Lithium. Cologne, 21.09.2023 ……………………………………………………………………………………………… Georg Honkomp, Managing Director, HERCULES GmbH * Community member who is authorised to compile the technical documentation MY24H15 - 12_1.0_29.01.2024...

  • Page 201: Declaration Of Conformity For Bafang As Incomplete Machine

    Appendix Declaration of Conformity for Bafang as incomplete machine MY24H15 - 12_1.0_29.01.2024...

  • Page 202: Keyword Index

    Keyword index Keyword index torque, 53 Chainring brake, Brake, torque, 57 Articulated shaft, - check brake disc, 139 Charger, 41 - maintain 131 - check brake linings, 139 - dispose, 181 Axle, - check pressure point, 138 Chassis, 29 torque, 52 - check, 121, 138 Child seat, 100 - clean, 122...
  • Page 203 Keyword index position 28 torque, 62 Mountain bike, 196 suspended, 197 Headset, see steering headset Mountain bike, see MTB Fracture, 196 Hub gear, MTB, see mountain bike Frame, 29 - check 147 Mudguard 18 - check 120 Hub, Mudguard, - clean, 124 - adjust ROHLOFF 148 - clean, 124 - inspect, 161...
  • Page 204 Keyword index - service 128 Road tyres, 32 Suspension seat post 39 - ship, 66 Suspension seat post, - unpacking 69 - clean, 122 Saddle, 105 - use 104 - maintain, 130 - adjust hardness 84 Placing on the market, 197 Switching element, - change the seat length, 86 Plus button, 43...

Table of Contents