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Bosch BULLS Twenty 6 EVO, Translation Of The Original Operating Instructions, Page: 102 / 116

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Bosch BULLS Twenty 6 EVO Translation Of The Original Operating Instructions Download Page 102

MY20B01 - 52_1.0_02.10.2019

102

Documents

Technical inspection, checking safety, test ride 

Components

Description

Criteria

Measures if rejected

Assembly/inspection

Tests

Accept-

ance

Rejection

Brake system

Functional check

O.K.

No full braking; braking 

distance too long

Locate defective part in brake 

system and correct

Gear shift under operat-

ing load

Functional check

O.K.

Problems when shifting 

gear

Readjust gear shift

Suspension compo-

nents (fork, shock 

absorber, seat post)

Functional check

O.K.

Suspension too deep or no 

longer exists

Locate defective component and 

correct

Electric drive

Functional check

O.K.

Loose connection, 

problems when riding, 

accelerate

Locate defective part in electric 

drive and correct

Light system

Functional check

O.K.

No continuous light, too 

bright

Locate defective part in light 

system and correct

Test ride

No strange 

noises.

Strange noises.

Locate source of noise and 

correct

Date

Fitter's name:

Final inspection by workshop

manager

Summary of Contents for BULLS Twenty 6 EVO

Page 1: ... MY20B01 52_1 0_02 10 2019 BULLS Twenty 6 EVO BULLS Twenty 6 EVO Team W ALK W ALK W ALK W AL W W W W W W A A LK K K K K W W W W W W W W W W W W W W W W W W W W W W W W W W W W W A A W W W A W W W W W W W W W W A W W A A A A A A A A A A A A A A A A A A L L L L L L L A A A A A A L L L L L L LK K K K K K K K K K K K K K K K K K K K K K K K K K K K ...

Page 2: ...2 3 1 6 Display 22 3 1 7 Riding light 22 3 1 8 Charger 22 3 2 Proper use 23 3 3 Improper use 24 3 4 Technical data 25 3 4 1 Pedelec 25 3 4 2 ActiveLine motor 25 3 4 3 ActiveLine Plus motor 25 3 4 4 Performance Line Cruise motor 25 3 4 5 Performance Line Speed motor 25 3 4 6 Performance Line CX motor 25 3 4 7 Pedelec lighting 26 3 4 8 PowerPack 300 battery 26 3 4 9 PowerPack 400 battery 26 3 4 10 P...

Page 3: ...egative deflection 55 6 5 6 3 Adjusting the air suspension fork negative deflection 55 6 5 6 4 Adjusting the air suspension fork rebound 56 6 5 7 Adjusting the FOX fork 56 6 5 7 1 Adjusting the negative deflection 56 6 5 7 2 Adjusting the rebound 57 6 5 8 Setting the Suntour rear frame damper 58 6 5 8 1 Adjusting the negative deflection 58 6 5 8 2 Adjusting the rebound 58 6 5 8 3 Setting the compr...

Page 4: ... 81 7 2 4 Cleaning the drive elements 81 7 2 5 Cleaning the rear frame damper 81 7 2 6 Cleaning the chain 82 7 2 7 Cleaning the battery 82 7 2 8 Cleaning the display 82 7 2 9 Cleaning the drive unit 82 7 2 10 Cleaning the brake 83 7 3 Servicing 83 7 3 1 Servicing the frame 83 7 3 2 Servicing the stem 83 7 3 3 Servicing the fork 83 7 3 4 Servicing the drive elements 83 7 3 5 Servicing the pedals 83...

Page 5: ...ycling and disposal 96 11 Documents 97 11 1 Parts list 97 11 2 Assembly report 98 11 3 Maintenance log 100 11 4 Charger operating instructions 103 13 Glossary 113 13 1 Abbreviations 115 13 2 Simplified terms 115 I Translation of the original EU Declaration of Conformity 116 ...

Page 6: ...ng instructions are an integral part of pedelecs with the following type numbers The type number was not available when we went to press 1 3 Identifying the operating instructions You will find the operating instructions identification number at the bottom left hand side of each page The identification number consists of the document number the version number and the release date 1 4 Subject to ch...

Page 7: ...rnings The warnings in these operating instructions are indicated as follows 1 7 2 Markups The following conventions are used in these operating instructions Will lead to serious or even fatal injuries if ignored High risk hazard May lead to serious or even fatal injuries if ignored Medium risk hazard May lead to minor or moderate injuries Low risk hazard Notice May lead to material damage if igno...

Page 8: ...5 Permitted total weight The permitted total weight is the weight of the fully assembled pedelec with the rider and baggage 6 Year of manufacture The year of manufacture is the year in which the pedelec was manufactured The production period is from August 2019 to July 2020 7 Pedelec type You can find more information in Section 3 2 8 Safety markings You can find more information in Section 1 7 9 ...

Page 9: ...er cable and plug connector before each use Never use a damaged charger WARNING CAUTION Risk of fire and explosion due to short circuit Small metal objects may connect the battery s electrical terminals The battery may self ignite and explode Keep paper clips keys and other small item away from the battery Do not insert into the battery Risk of fire and explosion due to incorrect charger Batteries...

Page 10: ...mper The rear frame damper contains toxic and environmentally harmful oils and lubricants Such fluids will contaminate if they enter the sewers or groundwater Dispose of oils and lubricants which have leaked from the rear frame damper in an environmentally responsible way in accordance with statutory regulations Contact your specialist dealer Environmental hazard posed by oil and lubricants from t...

Page 11: ...ery heavy for children Children must not carry the pedelec e g up or down stairs Children must get used to the heavy weight of the pedelec Before a child or adolescent can ride a pedelec they must be able to ride a bicycle safely in traffic The child s individual learning development must be taken into account The attention span of children 8 years and older is about 30 minutes The driving distanc...

Page 12: ...s with plenty of water for at least 15 minutes Protect unaffected eye Seek medical advice immediately After skin contact Remove any solid particles immediately Rinse the affected area with plenty of water for at least 15 minutes Then dab the affected skin gently Do not rub dry Remove contaminated clothing immediately Immediately consult a doctor if there is any redness pain or discomfort After swa...

Page 13: ...hem to come into contact with water 2 8 4 Leaking fluids 2 8 4 1 Oils and lubricants from the fork Dispose of oils and lubricants which have leaked from the rear frame damper in an environmentally responsible way in compliance with statutory regulations Contact your specialist dealer 2 8 4 2 Oils and lubricants from the rear frame damper Dispose of oils and lubricants which have leaked from the re...

Page 14: ...view 3 Overview Figure 2 Pedelec viewed from the right Bulls Twenty 6 used as example 1 Front wheel 2 Fork 3 Handlebars 4 Stem 5 Frame 6 Seat post 7 Saddle 8 Rear wheel 9 Chain 10 Damper 11 Battery and nameplate 1 2 3 4 5 6 7 8 9 10 11 ...

Page 15: ...n fork is based either on a steel spring or air suspension Unlike a rigid fork a suspension fork has two functions which improve floor contact and comfort suspension and damping The suspension prevents an impact such as one caused by a stone lying in the pedelec s path from being channelled directly into the rider s body via the fork The impact is absorbed by the suspension system instead This cau...

Page 16: ...st seal 4 fork end 7 and stanchion 8 3 1 2 4 Air suspension fork The air suspension fork features air suspension and a compression damper plus a rebound damper in some cases Figure 6 Example showing Yari fork You can see these components in the diagram Air valve 1 valve cap 2 fork lock 3 quick release 4 and rebound damper adjuster 5 and the assembly groups Air suspension fork A compression damper ...

Page 17: ...ever the brake fluid activates the brake on the wheel The pedelec has either a rim brake on the front and rear wheels a disc brake on the front and rear wheels or a rim brake on the front and rear wheels and an additional back pedal brake The mechanical brakes are used as an emergency stop system and bring the pedelec to a halt quickly and safely in the event of an emergency 3 1 3 1 Rim brake Figu...

Page 18: ...back pedal brake example 1 Rear wheel rim brake 2 Handlebars with brake lever 3 Front wheel rim brake 4 Pedal 5 Back pedal brake The back pedal brake stops the movement of the rear wheel when the rider pedals in the opposite direction to the direction of travel 3 1 3 4 ABS Figure 13 BOSCH ABS 1 ABS control unit with housing 2 Display screen 3 ABS indicator lamp 4 Control panel 5 Front wheel brake ...

Page 19: ... wheel is raised during full braking The ABS thus counteracts a flip over during extremely hard braking manoeuvres If the battery is low the ABS deactivates the power assistance first However the electric drive system including the display lighting and ABS will remain active until the battery is empty The electric drive system the ABS will not switch off until the battery has almost fully discharg...

Page 20: ...tically as soon as the rider no longer pedals the temperature is outside the permitted range there is an overload or the shut off speed of 25 km h has been reached A push assist system can be activated The speed depends on the selected gear The push assist continues to drive the pedelec as long as the rider presses the push assist button The speed can be a maximum of 6 km h in this case The drive ...

Page 21: ...ng thermal protection sleeves when riding longer distances in the cold The pedelec features either an integrated battery a pannier rack battery or a frame battery Each battery has its own lock 3 1 5 1 Frame battery Three different types of frame batteries can be fitted Figure 16 Details of frame battery 1 Battery housing 2 Battery lock 3 Battery key 4 On Off button battery 5 Battery level indicato...

Page 22: ...e rear light are switched on together 3 1 8 Charger Each pedelec is supplied with a charger As a general rule any BOSCH charger may be used The 2A compact charger The 4A standard charger The 6A fast charger Observe the operating instructions in the section on Documents PowerTube 500 vertical PowerTube 500 horizontal Table 8 Overview of frame batteries Internal button cell batteries type CR2016 3 V...

Page 23: ...braking should be practised The strain on the rider in particular the hands and wrists arms shoulders neck and back is accordingly high Inexperienced riders tend to brake exces sively and lose con trol as a result A racing bicycle is designed for fast rides on roads and paths with a good undamaged road sur face A racing bicycle is a piece of sporting equipment and not a means of transport A racing...

Page 24: ...acrobatics City and trekking bicycles Child s bicycles bicycles for young adults Mountain bikes Racing bicycle Cargo bike Folding bicycle City and trekking bicy cles are not sports bicycles If used for sports the rider can expect reduced riding stability and dimin ished comfort Cycles for children and young adults are not toys Mountain bikes must be retrofitted with lighting a guard and other fitt...

Page 25: ... 10 C 50 C Table 14 ActiveLine motor technical data Continuous power rating 250 W Max torque 50 Nm Nominal voltage 36 V DC Protection class IP54 Weight about 3 3 kg Operating temperature 5 C 40 C Storage temperature 10 C 50 C Table 15 ActiveLine Plus motor technical data Continuous power rating 250 W Max torque 63 Nm Nominal voltage 36 V DC Protection class IP54 Weight 4 kg Operating temperature 5...

Page 26: ...ity 11 Ah Energy 400 Wh Weight 2 5 2 6 kg Protection class IP54 Operating temperature 5 C 40 C Storage temperature 10 C 60 C Permitted charging temperature range 0 C 40 C Table 21 PowerPack 400 battery technical data Nominal voltage 36 V Nominal capacity 13 4 Ah Energy 500 Wh Weight 2 6 2 7 kg Protection class IP54 Operating temperature 5 C 40 C Storage temperature 10 C 60 C Permitted charging tem...

Page 27: ...on the component Operating temperature 5 C 40 C Storage temperature 10 C 60 C Protection class IPx7 Weight about 1 kg Table 26 BOSCH pedelec ABS BAS100 technical data A weighted emission sound pressure level 70 dB A Total vibration level for the hands and arms 2 5 m s Highest effective value of weighted acceleration for the entire body 0 5 m s Table 27 Emissions from the pedelec Axle nut tightenin...

Page 28: ...nical data Area of use City and trekking bicycles Child s bicycles bicycles for young adults Mountain bikes Racing bicycle Cargo bike Folding bicycle Suitable for tarmacked and paved roads Suitable for tarmacked and paved roads Suitable for tarmacked and paved roads Suitable for tarmacked and paved roads Suitable for tarmacked and paved roads Suitable for tar macked roads cycle paths and firm grav...

Page 29: ...ever drive off road or perform jumps Never drive off road or perform jumps Never drive off road or perform jumps Never drive off road or perform jumps Never drive off road or perform jumps over 15 cm Never drive off road or perform jumps over 15 cm Never drive off road or perform jumps over 15 cm Never drive off road or perform jumps over 15 cm Never ride downhill or perform jumps over 61 cm Never...

Page 30: ...ully charged The charge level for the activated battery is also shown on the display screen If the battery level falls below 5 all the LEDs on the battery level indicator will go out However the battery level is still shown on the display screen 3 6 3 Control panel on screen indicators The control panel with display has seven on screen indicators Figure 23 On screen indicators overview 3 6 3 1 Uni...

Page 31: ...ively slow or excessively quick pedalling and recommends a change of gear The gear recommendation function has to be switched on in the system settings 3 6 3 5 Tachometer screen The tachometer shows the current speed at all times You can select whether the speed is displayed in kilometres or miles in the system settings 3 6 3 6 Function display The function display shows texts and readings Three d...

Page 32: ...lay Change AUTO ON AUTO OFF This menu option indicates whether the automatic mode is switched on or off Table 36 Additional journey information Screen display Change GEAR The current gear shift is shown on the display screen The new gear is shown briefly on the screen each time it is changed Table 37 Additional journey information Screen display Change GEAR The current gear shift is shown on the d...

Page 33: ...is positioned in its mount Gear vx x x x this is the gear software version This menu option is only shown when the on board computer is positioned in its mount This menu option is only shown if you have an electronic control gear Table 44 Changing the system settings Screen display Change Gear adjustment You can use this menu option to make a fine adjustment to the Shimano DI2 You ll find the spec...

Page 34: ...stem is then no longer active The brake system itself remains functional It is only the anti blocking system control which no longer operates If the ABS indicator lamp is lit the ABS function is not active Note You need to stop and restart the pedelec switch off and on again to reactivate the anti blocking system Screen display Change Start gear This is where you can set the start gear The automat...

Page 35: ... the pedelec is lying flat If the shipping box with a pedelec is lying flat or standing on one end it does not provide the frame and wheels with adequate protection against damage Transport the pedelec in an upright position only Crash caused by unintentional activation There is a risk of injury if the drive system is activated unintentionally Remove the battery CAUTION Oil leak if no transport se...

Page 36: ... service life 4 3 1 Break in operation If the pedelec is removed from service for longer than four weeks you need to prepare it for a break in operation 4 3 1 1 Preparing a break in operation Remove battery from the pedelec Charge battery to around 30 60 The pedelec needs to be cleaned with a damp cloth and preserved with wax spray Never wax the friction surfaces of the brake Before longer periods...

Page 37: ...ructions The battery is supplied separately from the pedelec Injury to the eyes Problems may arise if the settings are not made to components correctly and you may sustain serious injuries as a result Always wear safety glasses to protect your eyes during assembly Crushing caused by unintentional activation There is a risk of injury if the drive system is activated unintentionally Remove the batte...

Page 38: ...5 3 1 Checking the battery The battery must be checked before it is charged for the first time 1 Press the On Off button battery If none of the LEDs on the battery level indicator light up the battery may be damaged The battery may be fully charged if at least one but not all of the LEDs on the battery level indicator is lit up 2 Insert charged battery into the pedelec 5 3 2 Installing the wheel i...

Page 39: ... by loose quick release axle A faulty or incorrectly installed quick release axle may become caught in the brake disc and block the wheel This will cause a crash Never fit a defective quick release axle Crash caused by faulty or incorrectly installed quick release axle The brake disc becomes very hot during operation Parts of the quick release axle may become damaged as a result The quick release ...

Page 40: ... 5 Check the position and clamping force of the quick release lever The quick release lever must be flush with the lower housing You must be able to see a slight impression on the palm of your hand when you close the quick release lever Figure 36 Perfect position for the clamping lever 6 Use 4 mm hexagon socket spanner to adjust the clamping lever clamping force if required 7 Check the quick relea...

Page 41: ...rrectly installed quick release may become caught in the brake disc and block the wheel This will cause a crash Never fit a defective quick release Crash caused by faulty or incorrectly installed quick release The brake disc becomes very hot during operation Parts of the quick release may become damaged as a result The quick release comes loose This will cause a crash with injuries The front wheel...

Page 42: ... is tensioned inadequately or too strongly when closed in the recommended position 1 to 20 mm in front of the fork Setting the quick releases Figure 44 Structure of quick release from rear with 1 axle nut lock and 5 axle nut 1 Record the axle setting value 4 indicated by the directional arrow 3 2 Loosen the axle nut securing screw 2 with a 2 5 mm hex key by approx four revolutions but do not remov...

Page 43: ...ould move in the fork steerer increase the quick release lever tensioning To do so turn the knurled nut slightly in a clockwise direction with the quick release lever open 3 Close the lever and check the stem is firmly in position 5 3 4 3 Checking the headset backlash 1 To check the handlebar headset backlash close the quick release lever on the stem 2 Place the fingers of one hand on the upper he...

Page 44: ... the wheels and on the chain drive This may cause a crash with injuries Wear sturdy footwear and close fitting clothing WARNING CAUTION Risk of fire and burning due to hot motor The motor housing becomes hot when riding Touching it may cause burns to the skin or other objects Never touch the motor housing directly after riding Never place the pedelec on a flammable surface such as grass or wood di...

Page 45: ...hen setting off and on hills Switch up a gear depending on the speed and terrain Follow the gear recommendations on the display screen Tyre pressure Always use the maximum permitted tyre pressure Motor power indicator Adjust your riding to the displayed motor power A long bar indicates high power consumption Battery temperature Electrical resistance increases as the temperature drops Battery perfo...

Page 46: ...ntact your specialist dealer if the problem persists 450 Internal software error 1 Re start the system 2 Contact your specialist dealer if the problem persists Table 49 List of display screen error messages 460 Error in USB port 1 Re start the system 2 Contact your specialist dealer if the problem persists 490 Internal display error Have display checked 500 Internal drive unit error 1 Re start the...

Page 47: ...creen error messages 605 Temperature error during the charging process 1 Disconnect charger from battery 2 Leave battery to cool down 3 Contact your specialist dealer if the problem persists 606 External fault 1 Check the cabling 2 Re start the system 3 Contact your specialist dealer if the problem persists 610 Voltage error 1 Re start the system 2 Contact your specialist dealer if the problem per...

Page 48: ...ation error 1 Re start the system 2 Contact your specialist dealer if the problem persists 889 Internal ABS error Contact your specialist dealer 890 ABS indicator lamp is defective or missing ABS may not be functioning Contact your specialist dealer No screen display Internal display error Re start the drive system by switching it on and off Code Description Method of resolution Table 49 List of d...

Page 49: ... 1 1 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 First readjust the saddle after finding the handlebar position you prefer Place the saddle tilt in the horizontal position to adjust the pedelec to your needs for initial use Fi...

Page 50: ...oil spreads on the seal and the post begins to function normally Lowering the saddle Figure 50 The seat post lever can be installed either on the left 1 or right 2 side of the handlebars 1 Press your hand down on the saddle or sit on the saddle to lower the saddle 2 Press the seat post lever and hold it down 3 Release the seat post lever once you have reached the required height Raising the saddle...

Page 51: ...Adjusting the stem 6 5 3 1 Adjusting the height of the handlebars 1 Open the stem clamping lever Figure 52 Open 2 and closed 1 stem clamping lever by schulz speedlifter used as an example 2 Pull the stem clamping lever upwards while swivelling the handlebars into the required position You feel the locking lever click into place The handlebar settings must only be adjusted while the pedelec is stat...

Page 52: ...can be adjusted to ensure that it can be reached more easily The pressure point can also be adjusted to the rider s preferences Contact your specialist dealer if there is no description of your brake below 6 5 4 1 Setting the grip distance on a Magura HS33 brake lever Only applies to pedelecs with this equipment You can adjust the brake lever position grip distance to your requirements Such adjust...

Page 53: ...ver position grip distance to your requirements Such adjustment does not affect the pressure point or the position of the brake linings Use a T25 TORX wrench to turn the setting screw 1 to adjust the grip distance Figure 56 Setting the grip distance on a Magura disc brake lever Turn the setting screw twist knob 5 anti clockwise towards minus The brake lever moves closer to the handlebar grip Turn ...

Page 54: ...and his her preferences It is advisable to make a note of the basic setting This way it can be used as the starting point for subsequent optimised settings and to safeguard against unintentional changes 6 5 6 1 Adjusting the negative deflection Negative deflection depends on the rider s weight and sitting position The recommended negative deflection is between 15 hard and 30 soft of the total fork...

Page 55: ...n after making the setting 6 5 6 3 Adjusting the air suspension fork negative deflection Only applies to pedelecs with this equipment The air valve is located beneath the valve cap on the crown of the left hand shock absorber Unscrew the valve cap Figure 59 Screw caps in different designs 1 Attach a high pressure damper pump to the air valve 2 Pump air suspension fork to the required pressure Obse...

Page 56: ... the full rebound distance You can hear and feel a slight impact when this happens 6 5 7 Adjusting the FOX fork Only applies to pedelecs with this equipment The adjustment shown here represents a basic setting The basic setting can be adjusted to the riding surface and personal preferences 6 5 7 1 Adjusting the negative deflection Negative deflection depends on the rider s weight and sitting posit...

Page 57: ...ion If the negative deflection is correct turn the blue valve cap in a clockwise direction 6 5 7 2 Adjusting the rebound The rebound defines the speed at which the fork rebounds after being loaded The rebound setting depends on the air pressure setting A higher negative deflection requires a lower rebound setting 1 Turn the FOX rebound adjuster in a clockwise direction to the closed position until...

Page 58: ...ement is the negative deflection The recommended value is between 25 hard and 30 soft of the total rear frame damper deflection 10 Increase or reduce the air pressure until you have reached the desired negative deflection If the negative deflection is correct fasten the valve cap onto the valve 6 5 8 2 Adjusting the rebound The rebound defines the speed at which the rear frame damper rebounds afte...

Page 59: ...ition and support yourself against an object such as a wall or tree 8 Push the O ring 4 downwards against the air chamber seal 1 9 Get off the pedelec without the suspension fork deflecting Measure the distance between the air chamber seal 1 and the O ring 4 This measurement is the negative deflection 2 The recommended value is between 25 hard and 30 soft of the total deflection for the rear frame...

Page 60: ... on the air pressure reading Turn the rebound adjuster back anti clockwise by the number of clicks specified in the table below Air pressure psi Recommended rebound setting 100 Open anti clockwise 100 120 11 120 140 10 140 160 9 160 180 8 180 200 7 200 220 6 220 240 5 240 260 4 260 280 3 280 300 2 Table 53 Filling pressure table for the FOX air fork ...

Page 61: ...on Article number Protective cover for electrical components 080 41000 ff Panniers system component 080 40946 Rear wheel basket system component 051 20603 Bicycle box system component 080 40947 Parking stand universal stand XX TWO14B Table 54 Accessories Crash caused by incorrect child seat The pannier rack and down tube are unsuitable for mounting child seats and may break Such an incorrect posit...

Page 62: ...annier rack the specialist dealer makes sure that the fastening mechanism is suitable for the pedelec and that all components are installed and firmly fastened They will also ensure that shift cables brake cables hydraulic cables and electrical cables are adjusted as necessary the rider has optimum freedom of movement and the pedelec s maximum permitted total weight is adjusted The specialist deal...

Page 63: ...the battery is firmly in place Check that the lighting reflector and brake for instance are sufficiently clean You must check that the mudguards the pannier rack and the chain guard are securely installed Check that the front and rear wheels run true This is particularly important if the pedelec been transported or secured with a lock Check the valves and the tyre pressure Adjust as necessary befo...

Page 64: ...eer and brake This can lead to a loss of control This may cause a crash with injuries You should practice how to use a loaded pannier rack safely before using the pedelec in public spaces CAUTION CAUTION Crash caused by unsecured baggage Loose or unsecured objects on the pannier rack e g belts may become caught in the rear wheel This may cause a crash with injuries Objects which are fastened to th...

Page 65: ...n of the frame battery mount until it will go no further There is an audible clicking noise 4 Check the battery to make sure it is firmly in place 6 11 2 Pannier rack battery Only applies to pedelecs with this equipment 6 11 2 1 Removing the pannier rack battery Figure 68 Removing 2 and inserting 3 the pannier rack battery 1 Open battery lock with battery key see 1 2 Pull the pannier rack battery ...

Page 66: ...during the charging process must be within the range from 0 C to 40 C The battery can remain on the pedelec or can be removed for charging Interrupting the charging process does not damage the battery 1 Remove the cable connection cover if necessary 2 Connect the mains plug of the charger to a normal domestic grounded socket 1 2 3 4 Fire caused by overheated charger The charger heats up when charg...

Page 67: ...only one battery is inserted only charge the battery with an accessible charging socket The battery with the sealed charging socket can only be charged outside its mount 6 11 6 Using double battery model with a single battery only One of the charging sockets is not accessible or is sealed with an end cap on pedelecs with two batteries Figure 71 Covering open contacts with cover cap example pannier...

Page 68: ...stance set on the display As soon as the system has been activated ACTIVE LINE PERFORMANCE LINE appears briefly on the display 6 12 2 Switching off the drive system As soon as you stop pushing the pedals in normal mode or reach a speed of 25 km h the drive system switches off the assistance system The assistance system starts up again if you push the pedals and your speed is less than 25 km h The ...

Page 69: ... the display as a handle The display may become irreparably damaged if you use it to lift the pedelec If you do not use your pedelec for several weeks remove the display from its mount Store the display safely at room temperature in a dry environment The internal display battery discharges when it is not in use This can cause damage to the internal display battery Charge the internal display batte...

Page 70: ...nce Press the minus button for less than one second to decrease the level of assistance 6 14 3 Journey information The displayed journey information can be changed and partially reset 6 14 3 1 Switching the journey information Press the minus button for 1to 2 5 seconds to change the displayed journey information The journey information trip distance TRIP total distance travelled TOTAL range RANGE ...

Page 71: ...LOW BAT on the screen the battery is flat and must be replaced Figure 72 Display with attachment screw 1 and battery compartment cover 2 1 Remove the display from the handlebars by unfastening the display attachment screw 1 2 Use a suitable coin to open the battery compartment cover 2 3 Remove the used battery 4 Insert a new CR 2016 display battery You can obtain the batteries recommended by Bosch...

Page 72: ...f they are inserted into the brake disc openings Always keep fingers well away from the rotating brake discs Burns caused by heated brake The brakes may become very hot during operation There is a risk of burns or fire in case of contact Never touch the components of the brake directly after the ride WARNING CAUTION Crash caused by wet conditions The tyres may slip on wet roads In wet conditions y...

Page 73: ...s Never fool about when riding 1 2 WARNING Accident due to ABS failure If the ABS indicator lamp is lit the ABS function is not active Adapt riding to the circumstances In extreme riding situations the ABS may not be able to regulate until the pedelec comes to a halt This may cause a crash with serious injuries Release the front wheel brake briefly This allows you to brake with the ABS function ag...

Page 74: ... positions Compression damping is lowest in the OPEN position making the fork feel softer Use the lock position if you want the fork to feel stiffer and you are riding on soft ground The positions between OPEN and LOCK provide fine adjustment of compression damping We recommend setting the compression adjuster to the OPEN position first Accidents due to manipulation Modified or manipulated ABS com...

Page 75: ...mpression adjuster closed 2 6 16 3 Adjusting the compression in the Fox fork Only applies to pedelecs with this equipment The compression adjuster makes it possible to make quick adjustments to the suspension behaviour of the fork to suit changes in terrain It is intended for adjustments made during the ride Figure 77 FOX compression adjuster with OPEN 1 and HARD 2 positions Compression damping is...

Page 76: ...ne adjuster to lock 6 16 5 Adjusting the rebound in the RockShox rear frame damper Only applies to pedelecs with this equipment The rebound damper determines the speed at which the fork rebounds to full length after deflection This speed affects the wheel s contact with the ground and thus has an influence on control and efficiency The rear frame damper should rebound fast enough to sustain tracti...

Page 77: ...changing gears This makes it easier to switch gears and reduces wear on the drivetrain 6 17 1 Using the derailleur gears Only applies to pedelecs with this equipment The speed and range can be increased while applying the same force if you select the right gear Use the derailleur gears Figure 82 Down shifter 1 and up shifter 2 on the left I and right II gear shift Select the appropriate gear with ...

Page 78: ...xt gear and it will remain in automatic mode Manual gear changes in automatic mode influence shift behaviour in the gear system and adjust gear changes to riding performance If the system is switched on for the first time when a new unused wheel is used the system will learn the gears first To do so the automatic system changes to the highest most difficult gear and then switches through all gears...

Page 79: ...h NuVinci H Sync enviolo with Optimized H Sync Only applies to pedelecs with this equipment Setting the desired pedalling frequency 1 Open NUVINCI CADENCE operating mode 2 Keep the plus or minus button pressed to increase or reduce the pedalling frequency in increments of five The desired pedalling frequency will be shown on the display screen Changing transmission 1 Select the NUVINCI GEAR operat...

Page 80: ...aning the battery once a month Chain mainly tarmacked road every 250 300 km Basic cleaning and preservation of all components at least every six months Clean the charger at least every six months Clean and lubricate the height adjustable seat post every six months Check USB rubber cover position before each ride Check for tyre wear once a week Check for rim wear once a week Check tyre pressure onc...

Page 81: ... drive elements after cleaning 7 2 5 Cleaning the rear frame damper Clean rear frame damper with a cloth and soapy water Crash caused by brake failure The braking effect may be unusually poor temporarily after cleaning servicing or repairs This may cause a crash with injuries Never apply care products or oil to the brake discs or brake linings or the braking surfaces on the rims After cleaning ser...

Page 82: ...e chain cleaning devices or chain cleaning baths Risk of fire and explosion due to penetration by water The battery is only protected from simple spray water Penetration by water can cause a short circuit The battery may self ignite and explode Never clean the battery with a pressure washer water jet or compressed air Keep contacts dry and clean Never immerse the battery in water Never use cleanin...

Page 83: ...asing agent 2 Clean coarse dirt with a brush after soaking for a short time 3 Wash down all parts with dish washing detergent and a toothbrush 7 3 5 Servicing the pedals Treat pedals with spray oil 7 3 6 Servicing the chain Grease the chain thoroughly with chain oil 7 3 7 Servicing the drive elements Service front and rear derailleur articulated shafts and jockey wheels with Teflon spray Notice If...

Page 84: ...edelecs with this equipment The tyre pressure cannot be measured on the simple Dunlop valve The tyre pressure is therefore measured in the filling hose when pumping slowly with the bicycle pump It is recommendable to use a bicycle pump with a pressure gauge The operating instructions for the bicycle pump must be adhered to 1Unscrew and remove the valve cap 2 Connect the bicycle pump 3 Pump up the ...

Page 85: ...le pump 5 Screw the valve cap tight 6 Screw the rim nut 1 gently against the rim with the tips of your fingers 7 4 2 Brake system The maintenance interval for the brake depends on the weather conditions and how frequent the pedelec is used If the pedelec is used under extreme conditions such as rain dirt or high mileage maintenance must be performed more frequently 7 4 3 Checking the brake linings...

Page 86: ...ct your specialist dealer if there is any wear or signs of corrosion 7 4 9 USB port 7 4 10 Checking the belt and chain tension 1 Check the chain tension in three or four positions turning the crank a full revolution Figure 84 Checking the chain tension 2 If the chain can be pushed more than 2 cm the chain or drive belt will need to be tensioned again by the specialist dealer 3 If the chain or the ...

Page 87: ...cial tools and specialist knowledge are required to repair the brakes Incorrect or unauthorised assembly can damage the brakes This may lead to an accident with injuries Only specialist dealers may carry out repairs on brakes Only carry out work or changes such as dismantling sanding or painting which are permitted and described in the brake operating instructions Injury to the eyes Problems may a...

Page 88: ... you will need to adjust the setting for the shift cable tension Carefully pull the adjusting sleeve away from the shifter housing turning it as you do so Check the gear shift function after each adjustment Crash caused by unfastened quick release A faulty or incorrectly installed quick release may become caught in the brake disc and block the wheel This will cause a crash Install the front wheel ...

Page 89: ...mooth gear shift set the adjusting sleeves underneath the chain stay on the frame The shift cable has around 1 mm play when it is pulled out gently Figure 88 Adjusting sleeves 2 on two alternative versions A and B of a dual cable cable operated gear shift on the chain stay 1 8 2 3 Cable operated twist grip dual cable Only applies to pedelecs with this equipment For a smooth gear shift set the adju...

Page 90: ...ove the battery 3 Insert the battery 4 Start the drive system 5 If the drive system does not start up remove the battery 6 Clean all the contacts with a soft cloth 7 Insert the battery 8 Start the drive system 9 If the drive system does not start up remove the battery 10 Fully charge the battery 11 Insert the battery 12 Start the drive system 13 If the drive system does not start up remove the dis...

Page 91: ... journey distance is too short The journey distance can be shorter depending on the road conditions the gear level and the entire light usage time 1 Check the battery level 2 If the battery is almost flat recharge it The battery does not perform as well in winter weather This does not indicate a problem The battery is a consumable Repeated charging and long periods of use cause the battery to degr...

Page 92: ... t recharge contact your specialist dealer The battery does not start charging when the charger is connected The battery may be at the end of its useful life Replace the battery with a new one The battery and charger become hot The temperature of the battery or the charger may have exceeded the operating temperature range 1 Stop the charging process 2 Wait a while and then start charging again 3 I...

Page 93: ... down to switch on the power again Is the battery charged If the battery is fitted to the pedelec and is being charged it cannot be switched on Stop the charging process Is the connector fitted to the power cable correctly Check whether the power cable connector connecting the motor unit to the drive unit has not disconnected If you are not sure contact your specialist dealer A component may be co...

Page 94: ...s occurs when a warning or an error is shown on the display screen Follow the instructions for the code indicated on screen in Section 6 2 System Messages When you use an electronic gear shift you can feel that pedal assistance becomes weaker when the gear is changed This is because the computer sets the pedal assistance to the optimum level This is not a malfunction A noise can be heard after swi...

Page 95: ...ts 9 2 2 Replacing the lighting Only use components of the respective power class for replacement 9 2 3 Adjusting the headlight The headlight must be set so that its light beam shines on the road 10 m in front of the pedelec 9 2 4 Tyre clearance check The tyre needs to be checked each time a suspension fork tyre is changed to another size 1 Release pressure from the fork 2 Press fork together full...

Page 96: ...s and help to protect the environment The pedelec battery motor display screen and charger are recyclable materials You must dispose of and recycle them separately from the domestic waste in compliance with applicable statutory regulations Sorted waste collection and recycling saves on raw material reserves and ensures that all the regulations for health and environmental protection are met when t...

Page 97: ... 52_1 0_02 10 2019 97 Documents 11 Documents 11 1 Parts list There was no information relating to a parts list yet at the time of going to press You ll find the information in the latest operating instructions ...

Page 98: ...ng New bell as specified in the parts list Suspension elements Fork suspension fork Check for damage O K Damage detected New fork as specified in the parts list Rear frame damper Check for damage O K Damage detected New fork as specified in the parts list Suspension seat post Check for damage O K Damage detected New fork as specified in the parts list Brake system Brake lever Check mount fastening...

Page 99: ...delec travelling 10 too fast slow Shut off pedelec until source of fault is found Cabling Visual inspection O K Failure in system damage kinked cables New cabling Battery mount Firmly in position lock contacts Functional check O K Loose lock doesn t close no contacts New battery mount Motor Visual inspection and mount O K Damage loose Refasten motor contact motor manufacturer new motor Software Ch...

Page 100: ...Loose Retighten screws Attachments 6 months Check mount fastening O K Loose Retighten screws Bell 6 months Functional check O K No ring too quiet missing New bell as specified in the parts list Suspension elements Fork suspension fork To manu facturer s specifica tions Check for damage corrosion fracture Maintenance as specified by manufacturer Lubrication oil change as specified by manufacturer O...

Page 101: ...g Functional check O K Loose Retighten screws Shift cables Check for damage Functional check O K Loose or defective Adjust shift cables new shift cables if necessary Front derailleur Check for damage Functional check O K Gear shift difficult or not possible Adjust Rear derailleur Check for damage Functional check O K Gear shift difficult or not possible Adjust Electric drive Display Check for dama...

Page 102: ... when shifting gear Readjust gear shift Suspension compo nents fork shock absorber seat post Functional check O K Suspension too deep or no longer exists Locate defective component and correct Electric drive Functional check O K Loose connection problems when riding accelerate Locate defective part in electric drive and correct Light system Functional check O K No continuous light too bright Locat...

Page 103: ...MY20B01 52_1 0_02 10 2019 103 Documents 11 4 Charger operating instructions H I H I H ...

Page 104: ...eries Input 230V 50Hz 2 15A Output 36V 6A Made in Vietnam Robert Bosch GmbH Reutlingen Fast Charger BCS250 eBike Battery Charger 36 4 230 0 275 007 907 Li Ion Use ONLY with BOSCH Li Ion batteries Input 230V 50Hz 1 5A Output 36V 4A Made in PRC Robert Bosch GmbH Reutlingen Standard Charger BCS220 Standard Charger Fast Charger ...

Page 105: ...MY20B01 52_1 0_02 10 2019 105 Documents Compact Charger ...

Page 106: ...MY20B01 52_1 0_02 10 2019 106 Documents ...

Page 107: ...MY20B01 52_1 0_02 10 2019 107 Documents ...

Page 108: ...MY20B01 52_1 0_02 10 2019 108 Documents ...

Page 109: ... M O 3 D 1 1 1 D O 4 M O D 1 1 D 1 D 4 O O R N O D 1 1 1 D 1 D N M O D 1 O O D 1 1 M 4 D D 1 1 D 1 1 D 1 D O D 1 D D D 1 O O D 1 1 1 1 1 4 4 D D D D D 1 1 1 1 D 4 M O 3 D D 1 1 D 1 O L W T Q 4 HV L 1 O 4 M O 4 O 1 1 O 4 O L O OO O O H N N H O H O H L O OO ...

Page 110: ... M M M Z 4 M R M M cH d d d cH Z d Z d Z d P M R M M M O 4 O H d Q O eTf O K O OO L O K 1 1 D O 4 O O H K K O 4 H 4 L O D 1 4 OO O P M L O 1 D 1 D M M O D 1 H 4 OO H O M M L Q O O D D D 1 O M O P M L O O 4 O M 4 M O R i Z_ ij M O Q N O P M 4 4 O L O O M L 5 I 4 L O 4 L 5 I L 4 4 L P 4 L M P L M L O ...

Page 111: ...R ij O O Q N R ij O M Q N R L 4 OO O O OO N O O P O M L 4 OO 5 I O M O 4 O L M 4 O O O M 4 4 O O O 4 M O O O E 1 1 1 1 O 0 D H 4 0 D N O N 5 0 0 D D H D H H H O 1 1 M L O H M O H C C O O M L 1 1 O M L U O M 444 L H M O N O 4 4 K D 1 I N _ T P L 4M L O L O 1 9 1 ...

Page 112: ...15 I Initial commissioning 38 Integrated battery removing 65 J Journey information 31 32 switching 70 Avg speed 32 Clock 32 Maximum 32 Range 32 Trip distance 32 Trip Time 32 L Level of assistance selecting 70 Lever 17 M Minimum insertion depth marking 50 Minus button 22 Model year 8 Motor 20 Mudguards checking 63 O On Off button Battery 21 22 Display 22 On screen indicator 30 62 Operating status i...

Page 113: ...for the motor electrical power assistance Electrically power assisted cycle pedelec Source EN 15194 2017 electrically power assisted cycle equipped with pedals and an auxiliary electric motor which cannot be propelled exclusively by means of the auxiliary electric motor except in start up assistance mode Fault Source EN 13306 2018 02 6 1 state of an item 4 2 1 characterized by inability to perform...

Page 114: ...ion tyres with coarse tread patterns and a wide range of transmission gears Off road rough terrain Source EN 15194 2017 coarse pebble tracks forest trails and other general off road tracks where tree roots and rocks are likely to be encountered Permitted total weight Source EN 15194 2017 weight of the fully assembled pedelec plus the rider and baggage as specified by the manufacturer Quick release...

Page 115: ...t of conditions under which work is performed Year of manufacture Source ZEG the year of manufacture is the year in which the Pedelec was manufactured The production period is always from August to July of the following year Young adult bicycle Source EN ISO 4210 2 bicycle designed for use on public roads by a young adult whose weight is less than 40 kg with maximum saddle height of 635 mm or more...

Page 116: ... Directive 2014 30 EU The safety objectives in the Low Voltage Directive 2014 35 EU have been met in compliance with Appendix I No 1 5 1 of the Machinery Directive 2006 42 EC The following harmonised standards have been applied ISO 20607 2018 Safety machinery Instruction handbook General drafting principles EN 15194 2017 Cycles Electrically power assisted cycles EPAC Bicycles The following other t...

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