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2.2 

Safety instructions 

These safety instructions are designed for your protection and to prevent damage to the product or individual compo- 

nents. Please read them thoroughly before working on the product: 

Please retain all safety instructions and information for future reference. 

Make sure you read and understand the assembly instructions to ensure safe product handling. 

Please observe the safety instructions. Failure to follow these instructions could put you and others at risk. 

All components of this product and its safety devices must be properly assembled to ensure correct operation. 

Alterations and unauthorized modifications to the product and use of unapproved parts are not permitted. 

Always observe applicable national and international safety, health and operating instructions. 

Keep the immediate area clear of highly flammable and other combustible materials. 

Protect the product against unintended activation. 

Disconnect the power supply before starting to assemble the product. 

Keep the work area clear of any tools, objects or cables. 

Always wear suitable personal protective equipment during assembly work. 

Ensure that insulated tools are used at all times for assembly. 

Use only the power supply lines designed for this product. 

Carefully inspect the fully assembled product and check component performance after assembly. Inadequate product 
assembly or inspection may result in serious injury. 

Never change the component design or state without prior agreement with Brose Drives e-Bike GmbH & Co. KG. 
Faulty modifications may significantly impair product performance and cause serious injury. 

Make sure only skilled staff can access components that have not been fully mounted. 

Always use suitable tools for pulling connectors out of their sockets. 

Never grab the cables to pull the connectors out of their connection sockets 

Always use a torque tool for the assembly of bolted joints to prevent damaging aluminum or carbon parts 

Summary of Contents for TRB1

Page 1: ...BESV TRB1 Technical Manual...

Page 2: ...nsor and spoke magnet 15 3 7 1 Fitting the speed sensor and spoke magnet 15 3 7 2 Front and rear light 15 3 8 Fitting the motor design covers 16 3 8 1 Right hand motor design cover 16 3 8 2 Left hand...

Page 3: ...n 1 1 Electronic components connection The following figure shows the connection of all bike s electronic components Battery F M F M HMI Docking Handlebar Switch HMI Display Speed Sensor F M Battery K...

Page 4: ...icates the personal protective equipment that must be worn in the following steps Brose scope of delivery Indicates the parts or materials from Brose s scope of delivery that are to be used in the fol...

Page 5: ...isk of serious injury Failure to observe this safety information will result in serious injury WARNING Risk of serious injury Failure to observe this warning may result in serious injury WARNING Risk...

Page 6: ...rials Protect the product against unintended activation Disconnect the power supply before starting to assemble the product Keep the work area clear of any tools objects or cables Always wear suitable...

Page 7: ...protective equipment The following protective equipment must be worn to ensure safe operation and assembly WARNING Risk of serious injury Component handling and commissioning may cause crush injuries...

Page 8: ...g harness display unit holder remote control unit B002 0 B003 0 C16162 3 x C34175 M8 hex serrated flange nut C54764 C54760 with assembly material Speed sensor Spoke magnet Motor design cover right Mot...

Page 9: ...ngthemountingrails Please refer to the manufacturer s instructions for assembling the relevant components These instructions do not provide any information about their assembly 3 2 2 Fitting the batte...

Page 10: ...ing or pinching any existing cables during assembly Place drive unit 1 into the drive mount 2 from the right in direction of travel Make sure that the through holes A are lined up Check that the drive...

Page 11: ...t 6 e Bike Insert connectors into the sockets in the drive unit Observe shape coding Insert connector without applying force until it clicks into place Use dummy plugs for non assigned sockets Dummy p...

Page 12: ...et around the handlebar and secure lightly with hexagon socket screws 3 Align holder and tighten hexagon socket screw 3 Check the distance between the clam ping brackets is as specified Make sure that...

Page 13: ...13 The figure on the right hand side shows the dimensions of the holder for the display unit B019 0 66 50 11 45 45 5 71 93...

Page 14: ...positioned on the left or right side of the handlebar Run the cable 2 from the remote control unit 1 according to the required handle bar position Right handlebar position Run the cable 2 from the le...

Page 15: ...protective cap 1 Line spoke magnet up with slot 5 on spoke The flat side of the spoke magnet 5 should be facing the speed sensor 2 Center spoke magnet 5 along the line marking and secure with cross re...

Page 16: ...ght are from the rider s perspective Position the motor design cover 2 so that the screw holes line up Use M4x8 1a and M4x6 1b hexagon socket screws to attach the motor design cover to the drive unit...

Page 17: ...dingtomanufacturer sspecifications 3 9 2 Fitting the spider and chain ring unit Make sure that you apply the specified torque Mount pre assembled unit consisting of spider and chair ring 1 on drive sh...

Page 18: ...pply a small quantity of grease to the ISIS connection 1 Place crank arm 2 on drive shaft Secure crank arm 2 with hexagon socket screw 3 Make sure that you apply the specified torque Repeat these step...

Page 19: ...nly relate to specified tools and work steps and are intended for guidance only 4 1 Crank arms and pedals SW 8 hexagon socket wrench Standard puller if necessary 4 1 1 Removingthepedals Remove pedals...

Page 20: ...ormation see Fitting the spi der and chain ring unit on page 17 4 3 Motor design covers Right hand motor design cover with 3 x M4x8 hexagon socket screws and 2 x M4x6 hexagon socket screws C60330 Left...

Page 21: ...emoving the drive unit For more information see General information on cable routing on page 11 Ensure drive unit is protected from falling before loosening the hex nuts Loosen and remove hex nuts SW...

Page 22: ...ch 1 x M4x10 hexagon socket screw 0 1 0 3 Nm 2 x M6x12 hexagon socket screw truss head 7 9 Nm 2 x M6x12 5 x M6x12 hexagon socket screw cap head 7 9 Nm 4 6 1 Removing theBattery bracket Loosen and lift...

Page 23: ...further disassembly Remove crank motor cover and motor unit according to above CH 4 1 4 3 4 5 Disconnect the lock cable and power cable and remove cable out of the frame carefully Remove the battery...

Page 24: ...Remove the battery from the bike system Wait one minute and insert the battery and power on again Display unit 1 not supplying cycling data even though the e Bike is in motion Spoke magnet 23 not cor...

Page 25: ...ug connections of all components of the e Bike Sys tem 70 Force applied to pedal not in valid range Switch off the system completely and then back on using the LED button 28 on the battery pack 26 If...

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