Page 1 READ CAREFULLY BEFORE USE KEEP IN SAFE PLACE READY TO CONSULT AT LATER DATE Translation of original operating instructions for KETTLER cargo bikes pedelecs Quadriga Cargoline 11G KB155-xxKW Quadriga Cargoline 5G Belt KB155-xxFW M Y 2 4 K 1 0 - 6 3 _ 1 . 0 _ 0 1 . 0 2 . 2 0 2 4...
Page 2: Table Of Contents
3.5.5 Saddle 3.5.6 Seat post 3.5.7 Mechanical drive system 3.5.8 Electric drive system Description of controls and screens 3.6.1 Overview of handlebars with BOSCH LED Remote and optional Intuvia 100 display 3.6.2 BOSCH LED Remote on-board computer MY24K10 - 63_1.0_01.02.2024...
Page 3 Contents 3.6.3 BOSCH Intuvia 100 display 3.6.4 Handbrake 3.6.5 SHIMANO gear shift 3.6.6 Suspension and damping 3.6.7 Rechargeable battery Transporting and storing Transportation 4.1.1 Using the transport securing system 4.1.2 Transporting the pedelec 4.1.3 Shipping a pedelec 4.1.4 Transporting the battery 4.1.5...
Page 4 6.5.9 Fixed weather protection systems 6.5.10 Additional battery headlight 6.5.11 Kickstand Personal protective equipment and accessories for road safety Before each ride Using the BOSCH battery 6.8.1 Using the integrated battery 6.8.2 Frame battery 6.8.3 Removing the battery 6.8.4 Charging the battery Straightening the quickly adjustable stem 6.10...
Page 5 Contents 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 7.2.1 Cleaning the riding light and reflectors 7.2.2 Cleaning the suspension fork 7.2.3...
Page 6 Contents 7.5.5 Checking the riding light 7.5.6 Checking the stem 7.5.7 Checking the handlebars 7.5.8 Checking the saddle 7.5.9 Checking the seat post 7.5.10 Checking the pedal 7.5.11 Checking the gear shift Inspection and maintenance Initial inspection Major inspection Component-specific maintenance Carrying out initial inspection Perform major inspection 8.5.1...
Page 7 Contents 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 Glossary 12.1 Abbreviations 12.2 Simplified terms Appendix Translation of the original EC/EU Declaration of Conformity Keyword index MY24K10 - 63_1.0_01.02.2024...
Page 8 About these operating instructions Thank you for your trust! Copyright KETTLER pedelecs are premium quality vehicles. © KETTLER Alu-Rad GmbH You have made an excellent choice. Your specialist dealer will provide you with guidance Distribution or reproduction of these operating and instruction and assemble your product.
Page 9: About These Operating Instructions
About these operating instructions About these operating instructions Manufacturer 1.3.1 Warnings Warnings indicate hazardous situations and actions. KETTLER Alu-Rad GmbH You will find three categories of warnings in the Longericher Strasse 2 50739 Köln operating instructions: Germany WARNING Tel.: +49 6805 6008-0 Fax: +49 6805 6008-3098 May lead to serious or even fatal injuries if...
Page 10: For Your Information
About these operating instructions For your information Different icons are used to make things easier to Section read. Text for specialist dealers Über diese Betriebsanleitung   Safety   § Notice on replacing components Description   Transporting and storing ...
Page 11: Type Number And Model
Type no. Model Pedelec type The frame number is the most important identifier for verifying ownership. KB155-xxKW Quadriga Cargoline 11G Cargo bike KB155-xxFW Quadriga Cargoline 5G Cargo bike Identifying the operating Belt instructions...
Page 12: 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 13 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 14: 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 15: 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 16: Requirements For The Pedelec Rider
Safety Requirements for the pedelec Personal protective equipment rider  Wear a suitable helmet. The helmet must have a reflective strip or a light in a clearly visible The pedelec rider must have adequate physical, colour. motor and mental abilities to ride on public roads. A minimum age of 14 years is recommended.
Page 17: Safety Markings And Safety Instructions
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 on the pedelec until it comes to a halt.
Page 18: Battery Vapour Emission
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.
Page 19: Data Privacy Information
When the pedelec is connected to the diagnosis tool at the specialist dealer’s, data is transferred to BOSCH eBike Systems (Robert Bosch GmbH) on the use of the Bosch drive unit, including its energy consumption and temperature, to help improve the product.
Page 20: Description
Description Description Proper use All checklists and instructions for actions in these regulations for the prevention of accidents and operating instructions met. Approved accessories environmental protection in the respective country can be installed by specialist staff. of use must be adhered to. Use the pedelec when it is in perfect, proper The rechargeable batteries are designed to working order only.
Page 21: Area Of Use As Per En 17406, From Model Year 2024
Description 3.1.2 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 22 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.
Page 23: Technical Data
Description Technical data 3.2.1 Complete BOSCH vehicle 3.2.1.2 Environmental requirements You can be ride the pedelec within a temperature Power output/system 250 W (0.25 kW) range between -5 °C and +40 °C. The electric Shut-off speed 25 km/h drive system is limited in its performance outside...
Page 24: Mass
The pedelec may only be loaded to its maximum • plus body weight permitted total weight (PTW). • plus baggage Type no. Model PTW [kg] Weight [kg] KB155-xxKW Quadriga Cargoline 11G KB155-xxFW Quadriga Cargoline 5G Belt Table 11: Type number, model, PTW and weight MY24K10 - 63_1.0_01.02.2024...
Page 25: Model Year 24 Nameplate
Description Model year 24 nameplate The nameplate is situated on the frame. The exact KETTLER position of the nameplate is shown in Figure 3. Alu-Rad GmbH The nameplate contains up to twelve pieces of Longericher Str. 2 50739 Köln, Germany information.
Page 26: Nameplate
Overview Nameplate The nameplate is situated on the frame. The The nameplate contains up to twelve pieces of precise position of the nameplate is shown in information. Figure 3. KETTLER Alu-Rad GmbH Longericher Str. 2 50739 Köln, Germany Typ: KB085-xxFW EPAC nach EN 15194...
Page 27: Components
Description Components 3.5.1 Overview 21 22 16 17 18 19 20 Figure 4: Pedelec viewed from the right: KETTLER Quadriga Cargoline 11G used as example Wheel Seat post Chain Saddle Two-leg stand Suspension fork Pannier rack Guard Rear light and reflector...
Page 28 Description 3.5.1.1 Components and repair parts for Quadriga Cargoline 11G KB155-xxKW Frame KETTLER Shape: Wave; size: 48 Size: ETRTO 50-559 (26 × 2.00 inches), version: Tyres SCHWALBE, Marathon GreenGuard, see Section # Valve: AV; valve length: 40 mm; size: ETRTO 40/ Tube SCHWALBE, AV13 (26")
Page 29 SHIMANO, DEORE CS-M5100-11 (11-51T) freewheel 45-51T (11-51T); see Section # Shifter SHIMANO, DEORE SL-M5100-R Shifter with indicator, 11-speed BOSCH, Performance Line CX / Cargo [BDU3740] Motor See Section 3.5.06.1 (EB11.100.001) On-board computer BOSCH, LED Remote [BRC3600] (EB13.100.00E) See Section # Display BOSCH, Intuvia 100 [BHU3200] (EB13.100.00F)
Page 30 Description 3.5.1.2 Components and repair parts for Quadriga Cargoline 5G Belt KB155-xxFW GREAT IM, Quadriga Cargoline Nexus 5G Frame Shape: Wave; size: 48 cm (Longtail) Size: ETRTO 50-559 (26 × 2.00 inches), version: Tyres SCHWALBE, Marathon GreenGuard, see Section # Valve: AV;...
Page 31 Description BOSCH, Performance Line CX / Cargo [BDU3740] Motor See Section 3.5.06.1 (EB11.100.001) On-board computer BOSCH, LED Remote [BRC3600] (EB13.100.00E) See Section # Display BOSCH, Intuvia 100 [BHU3200] (EB13.100.00F) See Section # BOSCH, PowerTube 625 Horizontal (BBP3760) Rechargeable battery See Section # [EB12.100.011]...
Page 32: Chassis
Description 3.5.2 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.
Page 33 Description Rider’s height [cm] Frame size [cm] Rider’s height [cm] Frame size [cm] 155… 165 160… 175 43… 48 46… 48 165… 175 48… 53 165… 180 49… 51 175… 185 53… 58 170… 185 52… 54 185… 195 58… 62 175…...
Page 34 Description 3.5.2.2 Steering system The steering system components are: • Steering headset, • Stem, • Handlebars and • Suspension fork. 3.5.2.3 Steering headset The steering headset (also known as a bike headset or simply a headset) is the fork bearing system in the frame.
Page 35 Description 3.5.2.5 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 9: Without suspension (1) and with suspension (2) Damping After compressing, the suspension fork returns to its original position.
Page 36 Description Parts of a suspension fork Figure 10: 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...
Page 37 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 12: Internal structure of a steel suspension fork Sag setting wheel Damping adjuster Compression dampers...
Page 38 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.
Page 39 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).
Page 40 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.
Page 41 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.
Page 42 Description 3.5.2.7 SR SUNTOUR cartridge LOR The SR Suntour LOR cartridge features • a low-speed compression damper 2. 2. • a low-speed rebound damper Before riding, use the rebound adjuster (suspension fork) (1) to adjust the system to the surface you will ride on. The suspension system can be adjusted to the current surface during rides using the low-speed compression adjustment wheel (2).
Page 43: Wheel
Description 3.5.3 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 44 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 45 Description Bead core 3.5.3.3 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 46 Description Presta valve 3.5.3.6 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 47 Description 3.5.3.7 Hub The hub is located in the centre of the wheel. The hub is connected to the rim and tyre with the spokes. An axle runs through the hub, connecting the hub with the fork at the front and with the frame at the rear.
Page 48: Brake
Description 3.5.4 Brake 3.5.4.2 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 49 Description 3.5.4.3 Disc brake Figure 32: Brake system with disc brake – example Brake disc Brake calliper with brake linings Handlebars with brake lever Front wheel Brake disc Rear wheel brake disc On a pedelec with a disc brake, the brake disc is permanently screwed to the hub.
Page 50: Saddle
Description 3.5.5 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 51 Description 3.5.5.1 Ladies’ saddle 3.5.5.2 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 52: Seat Post
Description 3.5.6 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 53 Description 3.5.6.3 Structure of LIMOTEC A3 dropper post The LIMOTEC Alpha 3 suspension seat post is a The suspension in the seat post ensures sitting continuously height-adjustable seat post, which comfort when riding over rough terrain (e.g. in can be lowered using a remote control on the woodland or on farm tracks).
Page 54: Mechanical Drive System
Description 3.5.7 Mechanical drive system 3.5.7.1 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 55: Electric Drive System
3.5.8.2 Charger Each pedelec is supplied with a charger. The following BOSCH charger may be used: • the 4 A Charger BPC3400. Observe the operating instructions in the Section 11.4 Documents.
Page 56 Description 3.5.8.4 Rechargeable battery The following battery can be built into the pedelec: BOSCH 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.
Page 57 The display shows the main drive system functions and the ride data. Figure 47: BOSCH LED Remote on-board computer The eBike Flow app can be accessed via Bluetooth®. The on-board computer has an internal lithium ion battery.
Page 58: Description Of Controls And Screens
Description Description of controls and screens 3.6.1 Overview of handlebars with BOSCH LED Remote and optional Intuvia 100 display Figure 50: Detailed view of handlebars with BOSCH LED Remote, example 1, 6 Handle BOSCH LED Remote on-board computer Rear wheel handbrake (behind handlebars)
Page 59: Bosch Led Remote On-Board Computer
BOSCH LED Remote on-board computer The on-board computer on the handlebars is used as a control panel. It controls the system and all indicators on the display screen using six buttons. Figure 52: Overview of BOSCH LED Remote on-board computer Decrease brightness button/ <...
Page 60 Description 3.6.2.1 Selected level of assistance indicator 3.6.2.3 Battery level indicator (on-board com- puter) The higher the selected level of assistance, the The battery level indicator (on-board computer) more the drive system assists with pedalling. shows the battery charge level. You can also see eMTB mode is available for Performance Line CX the battery charge level on the LEDs on the drives.
Page 61 Description Flash sequence Capacity Flash sequence Capacity 60 … 69% 10 … 19% 50 … 59% 0 … 9% Red LED is 40 … 49% flashing: The uppermost bar will flash if the battery is charging. 3.6.2.4 System message 30 … 39% The on-board computer indicates whether a critical or less critical error has arisen in the drive system.
Page 62 Software updates are automatically transferred to smartphone to record activities. the on-board computer in the background of the BOSCH eBike Flow smartphone app as soon as The rider needs to agree to location data being the app is connected to the on-board computer.
Page 63 Description 3.6.2.7 Lock function When the lock function is used, the on-board computer acts in a similar way to a key for the drive system. Once the lock function is switched on, the e-bike drive unit assistance is deactivated by removing the on-board computer. The rider can continue to use the mechanical drive system.
Page 64: Bosch Intuvia 100 Display
Description 3.6.3 BOSCH Intuvia 100 display 2 Selected level of assistance indicator The display is controlled on the LED Remote on- board computer. The higher the selected level of assistance, the more the drive system assists with pedalling. Figure 53: Intuvia 100 display...
Page 65 Menu Submenu → <Wheel circum.> → <Range reset> → <Auto trip reset> → <Hours of operation> → <BOSCH components used> Table 25: Adjustable and viewable values for the Intuvia 100 display in the eBike Flow app MY24K10 - 63_1.0_01.02.2024...
Page 66: Handbrake
Description 3.6.4 Handbrake There is a handbrake on the left and right of the handlebars. Figure 56: 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 67: Shimano Gear Shift
Description 3.6.5 SHIMANO gear shift 3.6.5.3 MTB switch control panel There is either a switch control panel or a shifter on the right side of the handlebars. There can be three different switches, depending on the model: • 3-switch control panel •...
Page 68 Description 3.6.5.6 Shifter SL-M8100 Figure 61: Shifter SL-M8100 Shifter Attachment screw for shifter MY24K10 - 63_1.0_01.02.2024...
Page 69 Description 3.6.5.7 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 62: SHIMANO NEXUS SL-C7000-5 twist grip shifter Twist grip shifter Gear indicator You change gears by turning the twist grip shifter.
Page 70: Suspension And Damping
Description 3.6.6 Suspension and damping 3.6.6.1 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...
Page 71 Description 3.6.6.2 SR SUNTOUR adjuster damper Only applies to vehicles with this equipment R2C2-PCS 3CR-PCS 2CR-PCS RC-PCS Model RC2-PCS Suspension fork Aion Durolux Mobie34 Mobie35 Raidon Zeron35 x = fitted O = fitted in PCS piston Explanation Rebound damper with high-speed and low-speed setting options and high-/low-speed compression damper in the R2C2-PCS piston compensator system Rebound damper with low-speed setting option and high-/low-speed compression damper in the piston...
Page 72 Description LORC-PCS Model LORC Suspension fork Aion Axon Mobie25 Raidon Zeron35 x = fitted O = fitted in PCS piston Explanation Rebound damper with low-speed setting option and low-speed compression damper with lockout in the piston LORC-PCS compensator system LORC Rebound damper with low-speed setting option and low-speed compression damper with lockout Rebound damper with low-speed setting option with lockout MY24K10 - 63_1.0_01.02.2024...
Page 73 Description 3.6.6.3 SR SUNTOUR adjuster damper with remote control Only applies to vehicles with this equipment There is a remote control to open and close the damper on the handlebars. R-3CR-PCS RLRC-PCS RLRC Model R-2CR-PCS Suspension fork Aion Axon Mobie25 Mobie34 Raidon Zeron35...
Page 74: Rechargeable Battery
LED 1,2,3,4,5 Battery level 100 … 80% 79 … 60% 59 … 40% 39 … 20% 19 … 15% Figure 63: BOSCH PowerPack battery indicator and operating element 5 … 0% Figure 65: Battery level indicator Symbols: LED on LED off All five LEDs will light up when the battery is fully charged.
Page 75: Transporting And Storing
Transporting and storing Transporting and storing Transportation 4.1.2 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 the battery to about 30% before Crash caused by unintentional activation placing pedelec in a vehicle to transport or take There is a risk of injury if the electric drive system it on a trip.
Page 76: Shipping A Pedelec
Transporting and storing 4.1.3 Shipping a pedelec 4.1.2.3 By local transport You can normally take pedelecs on local public  Private users are not permitted to ship transport, e.g. by bus or suburban rail, if you rechargeable batteries, neither by road not by purchase a bike ticket.
Page 77: Storing
Transporting and storing Storing  Remove the on-board computer from its mount  Store pedelec, on-board computer, battery and if the pedelec is not going to be used for up to charger in a clean, dry place where they are four weeks.
Page 78: 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 79: 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 80: Adjusting The Suspension System To Body Weight
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.
Page 81: Adjusting The Limotec Seat Post
Assembly 5.3.3 Adjusting the LIMOTEC seat post Only applies to pedelecs with this equipment The rider’s body weight exceeds or falls below the  seat post’s functional weight. 1 Order new Limotec seat post with suitable functional weight. 2 Remove existing seat post. Replacing Limotec A1 and A5 3 Use the seat height formula to calculate the optimum seat post height for leg length:...
Page 82: Preparing The Wheel
Assembly 5.3.4 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 83: Installing The Wheel In The Suntour Fork
Assembly 5.3.5 Installing the wheel in the SUNTOUR fork Only applies to Suntour forks with this equipment 5.3.5.1 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 ...
Page 84 Assembly 5.3.5.2 20 mm cross axle Only applies to Suntour forks with this 2 Tighten the cross axle with the red handle. equipment CAUTION Crash caused by loose cross axle A faulty or incorrectly installed cross axle may become caught in the brake disc and block the wheel.
Page 85 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 78: Perfect position for the clamping lever 6 Use 4 mm hexagon socket spanner to adjust the clamping lever clamping force if required.
Page 86 Assembly 5.3.5.3 Q-LOC quick release Only applies to Suntour forks with this equipment 1 Push in the quick release until you can hear a click. Make sure that the flange is extended. CAUTION Crash caused by unfastened quick release A faulty or incorrectly installed quick release may become caught in the brake disc and block the wheel.
Page 87: Fitting The Pedals
Assembly 5.3.6 Fitting the pedals The pedals have two different threads to ensure 3 Turn the pedal marked R anti-clockwise by they don’t come loose while the rider is pedalling. hand into the crank arm on the right as seen when facing the direction of travel.
Page 88: Checking The Stem And Handlebars
Assembly 5.3.7 Checking the stem and handlebars 5.3.7.1 Checking the connections 5.3.7.3 Checking the bearing clearance 1 Stand in front of the pedelec. Clamp the front 1 Place the fingers of one hand on the upper wheel between your legs. Grasp the handlebar headset cup.
Page 89: 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 90 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 91: 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 92: 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 93: 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 94: 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 95 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 89: Pressure points on a saddle, male anatomy To distribute the pressure on the male bone structure in the seat area optimally, the saddle...
Page 96 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 97 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 98 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 99 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 100 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 101: 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 102 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 103: 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 104 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 105: 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 106: 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 107 Operation 2 Perform a visual check on tyres. Figure 110: Correct tyre pressure. The tyre is barely deformed under the load of the body weight Figure 111: Far too little tyre pressure MY24K10 - 63_1.0_01.02.2024...
Page 108: 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 109 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 110 Operation 6.4.9.6 MAGURA handbrake pressure point Only applies to pedelecs with this equipment The pressure point setting is adjusted using the twist knob. WARNING  Turn the twist knob towards the plus (+) Brake failure due to incorrect setting symbol. If the pressure point is set with brakes where the ...
Page 111 Operation 6.4.9.7 Setting the grip distance for a MAGURA handbrake disc brake Only applies to pedelecs with this equipment The handbrake position can be adjusted to the rider’s requirements. Such adjustment does not WARNING affect the pressure point or the position of the Crash caused by incorrectly set grip distance brake linings.
Page 112: 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 113: Suspension And Damping
Operation 6.4.11 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...
Page 114 Operation 6.4.12.1 Adjusting the sag for SR SUNTOUR air suspension fork Only applies to pedelecs with this equipment 1 Turn the air valve cap (see Section 3.6.6.1) 3 Pump air suspension to the required pressure anti-clockwise away from the air valve level.
Page 115 Operation Recommended air pressure [psi] < 55 40… 55 40… 55 40… 55 40… 55 40… 55 40… 55 55… 65 … … 55… 65 55… 65 55… 65 55… 65 65… 75 … … 65… 75 65… 75 65… 75 65…...
Page 116 Operation Adjusting preload internally  Only your specialist dealer may make an internal adjustment to the preload. The air volume spacers can be replaced on some fork models. This changes the value for the centre stroke and the bottom-out (bounce) resistance. ...
Page 117 Operation Aion35 Zeron35 Axon32 Mobie34-air Mobie45-air Rubber volume 4.3cc 4.3cc space Deflection [mm] … … … … … … … … … … … … … … … … … … … … … … … … … … … …...
Page 118: Adjusting The Suspension Fork Rebound Damper
Operation 6.4.13 Adjusting the suspension fork rebound damper Only applies to pedelecs with this equipment Rebound damping is adjusted to the rider’s body weight, spring stiffness, deflection, the terrain and the pedelec rider's preferences. If the air pressure or spring stiffness increases, the extension and rebound speeds also increase.
Page 119 Operation 6.4.13.1 Adjusting the SR Suntour rebound damper suspension fork Only applies to pedelecs with this equipment Figure 119: Example of SR SUNTOUR rebound adjuster (suspension fork) (1) Adjusting the suspension fork sag (see  Section 6.4.12). 1 Turn the rebound adjuster (suspension fork) clockwise to the closed position until it stops.
Page 120: Riding Light
Operation 6.4.14 Riding light 6.4.14.1 Replacing the headlight 6.4.14.2 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 121 Operation 6.4.14.4 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 122: Adjusting The On-Board Computer
Updating the software user account first. Software updates are managed by the Bosch Registering on a PC eBike Flow smartphone app. 1 Create the user account on the BOSCH The on-board computer is now connected to the  website. smartphone.
Page 123 Operation 6.4.15.5 Setting up the lock function (optional) 6.4.15.6 Inserting the battery The user account can be used to activate the lock 1 Use a slotted-head screwdriver to pry open the function. This will create a digital key on the battery compartment lid on the display rear.
Page 124 Operation 6.4.15.7 Inserting the display 6.4.15.9 Securing the on-board display (optional) 1 Insert the battery compartment nub (1) into the It is possible to secure the on-board computer so bracket mount recess (2). that it cannot be removed. Inserting the blocking 2 Gently press display downwards.
Page 125 Increase brightness button/ > Forward button (scroll left) Decrease brightness button/ < Back button (scroll right) Select button Plus button/ light button Minus button/ – push assist button Table 37: Description of BOSCH LED Remote operating elements MY24K10 - 63_1.0_01.02.2024...
Page 126 Operation 6.4.15.11 Adjust on-board computer 6.4.15.12 Selecting the language The pedelec is stationary. You cannot open and 1 Open the <Language> submenu.  adjust the settings while riding. 2 Press the select button briefly until the Inserting the display.  required language is displayed.
Page 127 Operation 6.4.15.17 Adjusting the backlight 1 Open <Backlight> submenu. 2 Press the Select button briefly to select the duration of the backlight after pressing a button. 3 Press the Back button.  You now exit the submenu. The backlight has been set.
Page 128: Accessories
Operation Accessories Not included in price 6.5.1.1 Approval for trailer with SHIMANO hub Only applies to pedelecs with this equipment 6.5.1 Trailer As a basic rule, it is permitted to use a trailer in Trailers may only be used with the vehicle §...
Page 129 Operation 6.5.1.4 Quadriga Child Trailer THULE trailers Trailer Adapter Thule Chariot Lite Thule Chariot Cab Thule Chariot Cross Item no. 20100798 Thule Chariot Sport Thule Coaster XT 6.5.1.3 Approval for trailer with ROHLOFF hub Only applies to pedelecs with this equipment ROHLOFF Speedhub 500/14 Figure 130: Quadriga Child Trailer As a basic rule, it is permitted to use a trailer...
Page 130 Operation 6.5.1.5 Quadriga Cargo Trailer 6.5.1.6 Doggy Top Figure 131: Quadriga Cargo Trailer The Quadriga Cargo transport trailer has been developed to carry goods. The trailer is fitted with the K-Link system. This means the trailer can be connected to the Quadriga and Escaro series. The Quadriga Cargo transport trailer has a Figure 132: Doggy Top maximum load of 40 kg.
Page 131: Child Seat
Operation 6.5.2 Child seat 6.5.1.7 Quadriga Big Dog Trailer Child seats may only be used with the vehicle § manufacturer’s approval and only if they are approved for use on e- bikes. WARNING Crash caused by incorrect child seat Pannier racks with a maximum load capacity under 27 kg and the down tube are unsuitable for mounting child seats and may break.
Page 132 Operation 6.5.2.1 Quadriga child seat Notice  Observe the legal regulations on the use of child seats.  Observe the operating and safety instructions for the child seat system.  Never exceed the maximum permitted total weight. The Quadriga child seat has been developed for pedelecs.
Page 133: Monkeyload System
Operation 6.5.3 MonkeyLoad system 6.5.3.2 Detaching MonkeyLoad system components The pannier rack is MonkeyLoad-ready, i.e. all 1 Open locked MonkeyLoad system with the key. MonkeyLoad system components can be used on the pannier rack. Other systems such as I-Rack, 2 Pull on the pull knob gently. racktime or MIK are not compatible.
Page 134: Panniers And Cargo Boxes
Operation 6.5.6 Mobile holder 6.5.5 Panniers and cargo boxes This phone case, used as the base for the SP Panniers and cargo boxes are permitted if they § Connect system, is mounted on the stem. are approved for use on e-bikes. Depending on the holder model, a mobile can either be fitted directly on the handlebars or on the 6.5.5.1 Bags...
Page 135: Suspension Fork Coil Spring
Operation 6.5.6.2 Releasing the mobile 6.5.11 Kickstand 1 Turn the mobile 90° to the left Kickstands are permitted if they are able to bear § the weight of the pedelec.  The fastener is released. 2 Remove mobile We recommend a parking stand into which either the front wheel or rear wheel can be inserted 6.5.7 Suspension fork coil spring...
Page 136: 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 137: Using The Bosch Battery
Operation Using the BOSCH battery Switch off the electric drive system. 6.8.1.2 Inserting the integrated battery  The key is inserted in the lock.  6.8.1 Using the integrated battery The lock is unlocked.  Only applies to pedelecs with this equipment 6.8.1.1 Removing the integrated battery...
Page 138: Frame Battery
Operation 6.8.2 Frame battery 3 Keep the lock open with the key. 4 Push the battery upwards (3). Only applies to pedelecs with this equipment  The battery can be heard locking into place. 6.8.2.1 Inserting the battery 5 Check battery to ensure it is firmly in place on The key is inserted in the lock.
Page 139: Charging The Battery
Operation 6.8.4 Charging the battery  Charging is complete when the LEDs on the battery level indicator go out. The battery can remain on the pedelec or can be 4 Once charging is complete, disconnect the removed for charging. Interrupting the charging battery from the charger.
Page 140: 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 141: 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 142: 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 143: 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 144: Using The Electric Drive System
 Press the On-Off button (battery).  The battery level indicator (on-board computer) and the indicator for the selected level of assistance go out. Figure 151: Position of the On-Off button on the BOSCH LED Remote  The pedelec is switched off. MY24K10 - 63_1.0_01.02.2024...
Page 145: Using The On-Board Computer
 Keep the diagnosis port flap closed at all times to ensure no dust or moisture can penetrate through the port. Figure 152: Overview of BOSCH LED Remote on-board computer 6.18.2 Charging the on-board computer battery Symbol...
Page 146: Using The Riding Light
Operation 6.18.3 Using the riding light 6.18.5 Using the push assist system  The drive system needs to be already switched on to turn on the riding light. CAUTION Injury from pedals or wheels The pedals and the drive wheel turn when the push assist system is used.
Page 147: Selecting The Level Of Assistance
Operation 6.18.6 Selecting the level of assistance 1 Press Push assist button for longer than 1 seconds. Hold down the button. The on-board computer is used to configure to  The battery level indicator goes out and a white what extent the electric drive should assist the running light in the direction of travel indicates rider when pedalling.
Page 148: Using The Brake
Operation 6.19 Using the brake 6.19.1 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.
Page 149: 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 150: Using A Shimano Hub Gear
Operation 6.20.2 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.
Page 151: Using Eshift
Operation 6.20.3 Using eShift 6.20.3.2 Using eShift with manual SHIMANO DI2 hub gears eShift refers to the integration of electronic gear Only applies to pedelecs with this equipment shift systems into the electric drive system. The new gear is shown briefly on the on-board 6.20.3.1 Using eShift with SHIMANO DI2 computer each time it is changed.
Page 152: Use Suspension And Damping
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.
Page 153: Adjusting The Suspension Fork Compression Damper
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...
Page 154 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.
Page 155 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 •...
Page 156: Parking
Operation 6.22 Parking 6 Remove battery to protect against theft (see Notice Section 6.7.1.1). 7 Clean and service pedelec after every ride; see Heat or direct sunlight can cause the tyre pressure Section 7.2. to increase above the permitted maximum pressure.
Page 157: Screwing In The Quickly Adjustable Stem
Operation 6.22.1 Screwing in the quickly adjustable 6.22.2 Folding up the pedal stem  Clean the pedal (see Section 7.2.4). Only applies to pedelecs with this equipment 1 Use two fingers to pull the pedal folding latch (1) Screw in the quickly adjustable stem to save downwards and hold in position.
Page 158: Activating The Lock Function
Operation 6.22.3 Activating the lock function Only applies to pedelecs with this equipment  Remove the on-board computer used during set-up.  The lock function is activated. The drive system now provides no assistance However, the rider can continue to use the pedelec without assistance.
Page 159: 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 160 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 161 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 162 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 163: 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 164: 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 165: 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 166: 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 167: 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 168: 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 169: Cleaning The Cassette, Chain Wheels And Front Derailleur
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 170: 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 171: 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 172: 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 173: 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 174: 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 175: 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 176: 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 177: 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 178 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 179 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 180 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 181: 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 182 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 183: 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 184 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 181: Gauge is inserted 2 Lower gauge down to the left-hand side. Figure 176: Example of a KMC gauge Figure 182: Lower gauge to the left Figure 177: Example of a SHIMANO gauge...
Page 185: 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 185: Indications of wear on a belt Figure 187: Worn tooth profile 1 Carbon tensile fibres are exposed...
Page 186 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 187 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 191: Pressing the check gauge down with one finger 4 Take reading where line A meets line B.
Page 188: 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 189: 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 190: 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 191 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 192 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. MY24K10 - 63_1.0_01.02.2024...
Page 193: 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. The tasks require technical Vibrations produced while riding can cause expertise, special tools and special lubricants. screws and springs that were tightened during The pedelec may become damaged if the pedelec manufacture to settle or come loose.
Page 194 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 195 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 196: Carrying 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 197: 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 198 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 199 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 200 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 201 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 202 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 203 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 204: 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 205: 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 206: 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 207: 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 208: 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 209 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 210: Torque
Mounting bracket 0.8 Nm Torx® T20 FIT Remote Display Mounting bracket 0.8 Nm Torx® T20 BOSCH Intuvia 100 bracket Attachment screw 1, M3 × 22 1 Nm 3 mm hex bit Attachment screw 2, M3× 14 1 Nm 3 mm hex bit...
Page 211 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...
Page 212 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®...
Page 213 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...
Page 214 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 –...
Page 215 Chain guard Brose chain guard bash guard Attachment screws 6 Nm Hex key, 3 mm Chain guard for BOSCH Motor BDU37xx Attachment screws max. 10 Nm M6 × 10; head: max. 5 mm; length: max. 8.5-mm Crank bearing/crank set Conventional cartridge crank bearing 35 …...
Page 216 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®...
Page 217 Description ROHLOFF, 14/500 Chain tensioner attachment screw 8 Nm 5 mm hex bit ROHLOFF, 14/500 Chain guide attachment screw 3 Nm Torx® TX 20 ROHLOFF, 14/500 Rear spacer sleeve attachment screw 3 Nm Torx® TX 20 ROHLOFF, 14/500 Attachment screw for shift handle on handlebars 1 Nm 2.5 mm hex bit...
Page 218 Description SHIMANO, HB-M7000, HB-M6000 HB-M4050 Lock nut 10 … 15 Nm Hub spanner, 13 mm and 17 mm SHIMANO, HB-M7010, HB-M7010-B HB-M6010, HB-M6010-B, HB-M618, HB-M618-B, HB-MT400, HB-MT400-B Lock nut 21 … 26 Nm Hub spanner, 22 mm SHIMANO hub dynamo E2 model 20 - 25 Nm Screw wrench...
Page 219 Description SHIMANO DEORE XT SL-M8100 Attachment screw 3 Nm 4 mm hex bit SHIMANO DEORE XT SL-M8130 Attachment screw 3 Nm 4 mm hex bit SHIMANO, SLX SL-M7100 Attachment screw 3 Nm 4 mm hex bit SHIMANO XTR SL-M9100 Attachment screw 3 Nm 4 mm hex bit SRAM AXS Controller...
Page 220 Description SHIMANO for MTB/trekking Inner bearing adapter 35 … 50 Nm … SHIMANO for MTB/trekking Top swing screw, clip type 5 … 7 Nm Hex key, 5 mm/ and e-type Screw wrench, 9 mm SHIMANO for MTB/trekking Down swing screw, clip type, 5 …...
Page 221: 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 222: 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 223: 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 224: 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 225: Troubleshooting And Fault Clearance
Troubleshooting, fault clearance and repair Troubleshooting and fault clearance The on-board computer indicates whether a 11 Insert the battery. critical or less critical error has arisen in the drive 12 Start the drive system. system. 13 If the drive system does not start, press the On- The error messages generated by the drive Off button (on-board computer) for at least system can be read in the eBike Flow app and by...
Page 226: Errors In Assistance Function
Troubleshooting, fault clearance and repair 9.2.2 Errors in assistance function Symptom Cause Remedy Assistance is not Is the battery charged sufficiently? Check battery is charged. available. Recharge the battery if it is almost flat. Is the system switched on?  Press On-Off button (battery). ...
Page 227: Battery Errors
Troubleshooting, fault clearance and repair 9.2.3 Battery errors Symptom Cause Remedy The battery discharges The battery may be at the end of its  Replace old battery with new one. very quickly. useful life. The battery cannot be Is the charger mains plug firmly Disconnect the charger mains plug and plug it in again.
Page 228: Display Screen Errors
Troubleshooting, fault clearance and repair Symptom Cause Remedy There is an unusual Remove from the battery immediately. smell. Contact the fire service immediately. Observe all the warnings in Section 2 Safety. Fumes are emitted from Remove from the battery immediately. the battery.
Page 229: Error Message
Operation Error message 9.3.1 On-board computer The on-board computer indicates whether a  Press selection button. critical or less critical error has arisen in the drive  The error is acknowledged and the indicator for system. the selected level of assistance displays the colour for the configured level of assistance The error messages generated by the drive permanently.
Page 230 Operation Description Method of resolution If a battery fault is detected, two  Contact specialist LEDs will flash on the battery dealer. level indicator. Code: No LEDs will light up if there is Check all plug connections. no power. Check contacts on the battery for dirt.
Page 231: Correcting Disc Brake Faults
Troubleshooting, fault clearance and repair 9.3.3 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 232: Correcting Faults In The Sr Suntour Suspension Fork
Troubleshooting, fault clearance and repair 9.3.4 Correcting faults in the SR SUNTOUR suspension fork 9.3.4.1 Rebound too fast The suspension fork rebounds too quickly, Fork head and handlebars are deflected upwards producing a "pogo stick" effect, where the wheel if the wheel bounces back from the ground. Body lifts from the ground in an uncontrolled way.
Page 233 Troubleshooting, fault clearance and repair 9.3.4.2 Rebounding too slowly The fork does not rebound quickly enough after The fork remains in a deflected state, causing the absorbing a bump. The fork also remains headset and handlebars to move to a lower deflected over subsequent bumps, which reduces position.
Page 234 Troubleshooting, fault clearance and repair 9.3.4.3 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 210: Excessively soft suspension in the suspension fork on hilly terrain Solution ...
Page 235 Troubleshooting, fault clearance and repair 9.3.4.4 Excessively hard damping on bumps When the bike hits a bump, the fork deflects too The headset and handlebars are deflected slowly and the wheel lifts up from the bump. upwards significantly, which can impair control. Traction decreases when the wheel no longer touches the ground.
Page 236: Problems With Hub Gear
Troubleshooting, fault clearance and repair 9.3.5 Problems with hub gear Symptom Cause Remedy A noise is heard when the All gear speeds except 1. pedals are turning. A noise is heard when the pedelec is pushed All gear speeds except 1. backwards.
Page 237 Troubleshooting, fault clearance and repair Symptom Cause Remedy Strange noises occur  when the brakes are Contact specialist dealer. applied. Rotation feels stiff during  Contact specialist dealer. free rotation. Chain jumps between the  gearwheels when gear is Gearwheels and/or chain worn. Contact specialist dealer.
Page 238: 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 239: 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 240: 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 241: 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 242: Replacing Pedelec Components If Lock Function Is Installed
9.4.7 Replacing pedelec components if lock function is installed 9.4.7.1 Replacing a smartphone 1 Install Bosch eBike connect app on the new smartphone. 2 Log on using the same account which was used to activate the lock function. 3 Connect on-board computer with the smartphone while the on-board computer is in use.
Page 243: 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 244 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 245: 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 246 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 247: 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 248 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 249 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 250 Documents Notes MY24K10 - 63_1.0_01.02.2024...
Page 251: Charger Operating Instructions
Documents 11.3 Charger operating instructions MY24K10 - 63_1.0_01.02.2024...
Page 252 Documents 4A Charger MY24K10 - 63_1.0_01.02.2024...
Page 253 Documents MY24K10 - 63_1.0_01.02.2024...
Page 254 Documents MY24K10 - 63_1.0_01.02.2024...
Page 255 Documents MY24K10 - 63_1.0_01.02.2024...
Page 256 Documents MY24K10 - 63_1.0_01.02.2024...
Page 257 Documents MY24K10 - 63_1.0_01.02.2024...
Page 258: 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 259 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 260 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 261: 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 262: Appendix
Longericher Strasse 2 Germany 50739 Köln Germany The machine, pedelec types: KB155-xxKW Quadriga Cargoline 11G Cargo bike KB155-xxFW Quadriga Cargoline 5G Belt Cargo bike Year of manufacture 2023 to year of manufacture 2025, complies with the following applicable EU provisions: •...
Page 263: Keyword Index
Keyword index Keyword index Brake cable, Cargo bike, torque, Cassette, Activity tracking, Brake calliper, - clean, - activate position, CE marking, Air valve, 16, 27 torque, Chain guard position, Brake disc, Chain guard, Articulated shaft, - check, - clean, - maintain - clean torques Axle,...
Page 264 Keyword index Disc brake, Hub, torque, - adjust ROHLOFF Gear hub, Display, - clean, - inspect, - insert, - maintain Gear shift, Down tube, - service - adjust dual-cable, Bowden- Drive belt, hub, cable-operated twist Drive system, position, grip shifter - switch on, torque, - check...
Page 265 Keyword index Minimum insertion depth mark- Patent seat post, Rear frame fork end, ing, Pedal, Rear frame seat stay, Minimum insertion depth, - clean, Rear light, 59, 145 Minus button, - fit - clean Model year, - maintain, position, Motor cover torque, Rear wheel brake, Motor cover,...
Page 266 Keyword index 27, 52, 260 Seat post, Suspension seat post, 164, 189 - check - clean, Wear, - clean, - maintain, 27, 43, 261 Wheel, - inspect, Switching element, - check concentricity - maintain, - clean, - check, - patent seat post 80, 82, 83, 86 - fit - suspension seat post...

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