Kettler Quadriga Translation Of The Original Operating Instructions Download Page 1

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ELECTRIC BICYCLES

877-00136 • 1.0 • 13 September 2018

TRANSLATION OF THE ORIGINAL

OPERATING INSTRUCTIONS

Comfort, Escaro Comp 8, Escaro Cross, EscaroPro,

Quadriga Cityhopper, Quadriga CX, Quadriga Cross,

Quadriga Plus, Quadriga

KB065-VAKxxx, KB065-VBKxxx, KB065-VCKxxx, KB066-VAFxxx, KB066-VBFxxx, KB066-VCFxxx,

KB068.VAFxxx, KB068-VARxxx, KB069-VAFxxx, KB070-VAKxxx, KB070-VBKxxx, KB076-VAFxxx,

IMPORTANT

READ CAREFULLY BEFORE USE

KEEP SAFE FOR LATER REFERENCE

EN_877-00136_1.0_0.01_09.18_KETTLER Suntour MY19_COVER.book Page 1 Thursday, September 13, 2018 12:56 PM

Summary of Contents for Quadriga

Page 1: ...adriga CX Quadriga Cross Quadriga Plus Quadriga KB065 VAKxxx KB065 VBKxxx KB065 VCKxxx KB066 VAFxxx KB066 VBFxxx KB066 VCFxxx KB068 VAFxxx KB068 VARxxx KB069 VAFxxx KB070 VAKxxx KB070 VBKxxx KB076 VAFxxx IMPORTANT READ CAREFULLY BEFORE USE KEEP SAFE FOR LATER REFERENCE EN_877 00136_1 0_0 01_09 18_KETTLER Suntour MY19_COVER book Page 1 Thursday September 13 2018 12 56 PM ...

Page 2: ...mmunication of their content is prohibited unless expressly approved Any infringement will render the offender liable for compensation All rights reserved in the event that a patent utility model or industrial design is registered EN_877 00136_1 0_0 01_09 18_KETTLER Suntour MY19_COVER book Page 3 Thursday September 13 2018 12 56 PM ...

Page 3: ...umber Type number Unladen weight kg Tyre size Recommended tyre pressure bar front rear Wheel circumference mm Company stamp and signature After a tyre change refer to the tyre markings for the permitted tyre pressures and make sure that they are observed The recommended tyre pressure must not be exceeded ...

Page 4: ...ctions for actions 13 1 7 2 Information on the type plate 14 1 7 3 Language conventions 15 1 8 Type plate 17 1 9 Identifying 18 1 9 1 Operating instructions 18 1 9 2 Bicycle 18 2 Safety 20 2 1 Requirements for the rider 20 2 2 Hazards for vulnerable groups 20 2 3 Personal protective equipment 20 2 4 Proper use 21 2 4 1 City and trekking bicycle 21 2 5 Improper use 22 2 5 1 City and trekking bicycl...

Page 5: ... Commissioning 46 5 3 4 1 Checking the battery 48 5 3 4 2 Checking the stem and handlebars 49 5 3 5 Sale of the bicycle 50 6 Before the first ride 51 6 1 Adjusting the saddle 51 6 1 1 Adjusting the saddle tilt 51 6 1 2 Determining the seat height 52 6 1 3 Adjusting the seat height with quick release 53 6 1 4 Setting the height adjustable seat post 55 6 1 4 1 Lowering the saddle 55 6 1 4 2 Raising ...

Page 6: ...e drive system 75 7 5 2 Switching off the drive system 75 7 6 Operating element with display 76 7 6 1 Selecting the level of assistance 76 7 7 Brakes 76 7 7 1 Using the brake 77 7 8 Gear shift 78 7 8 1 Using derailleur gears 78 7 9 Brake 79 7 9 1 Using the brake lever 83 7 9 2 Using the back pedal brake 83 8 Maintenance 84 8 1 Cleaning and servicing 86 8 1 1 After every ride 86 8 1 1 1 Cleaning th...

Page 7: ...4 8 2 2 Brake system 95 8 2 3 Electrical cables and brake cables 95 8 2 4 Gear shift 95 8 2 5 Stem 96 8 2 6 Checking the chain and belt tension 96 8 2 7 USB port 97 8 2 8 Suspension fork 97 8 3 Service 98 8 4 Adjusting and repairing 100 8 4 1 Use original parts and lubricants only 100 8 4 2 Wheel quick release 101 8 4 2 1 Clamping the quick release 102 8 4 3 Adjusting the tyre pressure 104 8 4 3 1...

Page 8: ...Table of contents 877 00136_1 0_17 09 2018 6 9 Recycling and disposal 114 10 Appendix 116 10 1 EC declaration of conformity 116 10 2 Parts list 117 10 3 Table of figures 120 10 4 Subject index 123 ...

Page 9: ...he rider and operator of the cycle In general they are technical laypersons Text passages which are expressly intended for specialist staff e g bicycle mechanics are clearly marked with a tool symbol Staff at all specialist dealers have specialist training and qualifications and are therefore capable of identifying risks and preventing hazards which may arise during maintenance servicing and repai...

Page 10: ... for bicycles EN 11243 2016 Cycles Luggage carriers for bicycles Requirements and test methods EN 82079 1 2012 Preparation of instructions for use Structuring content and presentation Part 1 General principles and detailed requirements EN ISO 17100 2016 05 Translation Services Requirements for translation service 1 3 Other valid documents These operating instructions are only complete in conjuncti...

Page 11: ...ons at the time of printing Any significant changes are included in a new issue of the operating instructions You will find any modifications to these operating instructions at www kettler alu rad de de de index service anleitung 1 5 Language The original operating instructions are written in German A translation is not valid without the original operating instructions ...

Page 12: ...t If you are unable to contact your specialist dealer you will find other specialist dealers to attend to your customer service needs on www kettler alu rad de The specialist dealer authorised to perform repairs and maintenance work receives regular training The rider or the operator of the bicycle will be instructed in person on the bicycle functions when the supplying specialist dealer hands ove...

Page 13: ...as follows SIGNAL WORD Type and source of the danger Description of the danger and the consequences Measures The following pictograms and signal words are used in the operating instructions for warnings and information notices Table 1 Meanings of the signal words GEFAHR DANGER Will lead to serious or even fatal injuries if ignored High risk hazard WARNING May lead to serious or even fatal injuries...

Page 14: ...bicycle s type plates Table 2 Safety markings on the product General warning Adhere to the instructions for use 1 7 For your information 1 7 1 Instructions for actions Instructions for actions are structured in accordance with the following pattern Requirements optional Instruction for action Result of the action optional ...

Page 15: ...itable for the road no off road riding or jumps suitable for roads off road riding and jumps of up to 15 cm suitable for rough off road riding and jumps of up to 61 cm suitable for rough off road riding and jumps of up to 122 cm suitable for the most difficult terrain Table 4 Bicycle type City and trekking bicycle Child s bicycle bicycle for young adults BMX bicycle Mountain bike Racing bicycle Ca...

Page 16: ...able material About these instructions 877 00136_1 0_17 09 2018 15 1 7 3 Language conventions The bicycle described in these operating instructions may be equipped with alternative components The equipment of the bicycle is defined by the respective type number Table 3 page 14 If applicable the notes alternative equipment and alternative version make reference to the use of alternative components ...

Page 17: ...ied terms Term Meaning Operating instructions Original operating instructions or translation of the original operating instructions Bicycle Electric motor driven cycle Motor Drive motor The following conventions are used in these operating instructions Table 7 Conventions Convention Use Italics Entry in the index SPACED Displays on the display screen Example page numbering Cross references Bullete...

Page 18: ...many Typ 19 16 0001 EN 15194 0 25 kW 25 km h zGG 180 kg EPAC 25 kg BJ 2018 MJ 2019 nach EPAC 2 3 1 4 5 6 7 8 9 12 13 10 11 Figure 1 Type plate example 1 CE marking 2 Manufacturer 3 Type number 4 Nominal continuous power 5 Permitted total weight 6 Year of manufacture 7 Bicycle type 8 Safety instructions 9 Disposal instruction 10 Area of use 11 Model year 12 Weight of the ready to ride bicycle 13 Sh...

Page 19: ...g bicycle KU117 VAFD60 2 E Beltdrive City and trekking bicycle KU117 VAFT45 2 E Beltdrive City and trekking bicycle KU117 VAFT50 2 E Beltdrive City and trekking bicycle KU118 VAFD50 2 E Street Beltdrive City and trekking bicycle KU118 VAFD55 2 E Street Beltdrive City and trekking bicycle KU118 VAFD60 2 E Street Beltdrive City and trekking bicycle KU118 VAFT45 2 E Street Beltdrive City and trekking...

Page 20: ...KU159 VAKD50 2 E Comp Street City and trekking bicycle KU159 VAKD55 2 E Comp Street City and trekking bicycle KU159 VAKD60 2 E Comp Street City and trekking bicycle KU159 VAKT45 2 E Comp Street City and trekking bicycle KU159 VAKT50 2 E Comp Street City and trekking bicycle Type number Model Bicycle type ...

Page 21: ...e battery and the charger must be kept out of the reach of children If the bicycle is used by minors comprehensive instruction should be provided by or in the presence of the legal guardians Supervised use should also be scheduled until it is certain that the bicycle is being used as per these operating instructions Legal guardians hold sole responsibility for determining whether minors are capabl...

Page 22: ...ccidents and environmental protection in the respective country of use must be adhered to All check lists and instructions for actions in these operating instructions must be met Approved accessories can be installed by specialist staff Each bicycle is assigned a bicycle type which determines its proper use and area of use 2 4 1 City and trekking bicycle City and trekking bicycles are designed for...

Page 23: ...iding through deep water lending the bicycle to untrained riders carrying other people riding with excessive luggage riding with no hands riding on ice and snow improper servicing improper repair tough areas of use such as professional competitions stunt riding or acrobatics 2 5 1 City and trekking bicycle City and trekking bicycles are not sports bicycles If used for sports the rider can expect r...

Page 24: ...erator The operator has the duty of care and responsibility for scheduling these measures and checking that they are implemented The operator makes these operating instructions available to the rider for the duration of use of the bicycle If necessary they translate the operating instructions into a language which the rider understands familiarises the rider with the functions of the bicycle befor...

Page 25: ...Overview 1 2 3 4 5 6 7 11 9 10 8 Figure 2 Bicycle viewed from the right 2 E Beltdrive used as example 1 Front wheel 2 Fork 3 Handlebars 4 Stem 5 Frame with integrated display 6 Seat post 7 Saddle 8 Reflector 9 Rear wheel 10 Chain 11 Frame number and type plate ...

Page 26: ...Description 877 00136_1 0_17 09 2018 25 3 2 Handlebars 1 2 3 4 Figure 3 Detailed view of bicycle from rider position example 1 Rear brake lever 2 Front brake lever 3 Bell 4 Integrated display ...

Page 27: ...Suspension fork head with setting wheel 4 Fork 5 Spoke 6 Quick release 7 Hub 8 Valve 9 Fork end of the suspension fork 3 3 1 Valve Each wheel has a valve It is used to fill the tyre with air There is a valve cap on each valve The screw on valve cap keeps out dust and dirt The bicycle either has a classical Dunlop valve a Presta valve or a Schrader valve ...

Page 28: ...measured with this valve Presta valve The presta valve requires a smaller hole in the rim which is why it is especially suitable for the narrow rims of racing bicycles The air pressure can be measured with this valve Schrader valve The rider can fill the Schrader valve very easily at a petrol station The air pressure can be measured with this valve ...

Page 29: ...im brake components with details example Magura HS22 1 Rear wheel rim brake 2 Brake booster 3 Brake lining 4 Handlebars with brake levers 5 Front wheel rim brake The rim brake stops the wheel moving when the rider pulls the brake lever causing two brake linings positioned opposite one another to be pressed onto the rims ...

Page 30: ...018 30 The hydraulic rim brake features a locking lever 2 1 Figure 6 Rim brake locking lever closed 1 and open 2 The rim brake locking lever is not marked with any lettering Only a specialist dealer may set the rim brake locking lever ...

Page 31: ...ling in the direction of travel drives the front chain wheel The chain transmits the force onto the rear chain wheel and then onto the rear wheel 5 2 3 4 1 Figure 7 Diagram of drive system 1 Direction of travel 2 Chain 3 Rear chain wheel 4 Front chain wheel 5 Pedal The bicycle also has an integrated electric drive system The electric drive system is made up of four components ...

Page 32: ...e motor is activated gently and assists the pedalling motion of the rider The motor force is determined by the set level of assistance The bicycle does not have a separate emergency stop or emergency shut off button The drive system can be stopped in case of emergency by removing the display The motor switches off automatically as soon as the rider no longer pedals the temperature is outside the p...

Page 33: ...also switches to sleep mode for self protection when not used for a longer period The service life of the battery can be extended if it is well cared for and above all stored at the correct temperatures Even if the battery is cared for properly the charge status of the battery reduces as it ages If the operating time is severely shortened after charging this is a sign that the battery is spent Tab...

Page 34: ...6 1 1 Operating and charge status indicator The five green LEDs of the operating and charge status indicator indicate the charge status of the battery when the battery is switched on Each LED represents 20 of the charge status The charge status of the activated battery is also shown on the display If the charge status of the battery is below 5 all the LEDs of the operating and charge status indica...

Page 35: ...inserted on the bicycle and the drive system is switched on Table 10 Display technical data Storage temperature 5 C 25 C Charging ambient temperature 10 C 30 C The operating element with display has three buttons and three indicators 1 2 3 4 5 6 Figure 10 Operating element overview Table 11 Overview of operating element with indicators 1 On Off button 2 Charge status indicator 3 Level of assistanc...

Page 36: ...lling There are four levels of assistance available 3 6 2 2 Current speed The current speed is displayed in km h 3 6 2 3 System message The drive system monitors itself continuously and if an error is detected it is indicated by a system message The system may switch off automatically depending on the type of error There is a table of system messages in the Appendix ...

Page 37: ... storage temperature 10 C 15 C Operation temperature 5 C 35 C Working environment temperature 15 C 25 C Charging temperature 10 C 30 C Power output system 250 W 0 25 kW Shut off speed 25 km h Battery Table 13 Battery technical data Transportation temperature 5 C 25 C Ideal transportation temperature 10 C 15 C Storage temperature 5 C 25 C Ideal storage temperature 10 C 15 C Charging ambient tempera...

Page 38: ...he hands and arms 2 5 m s Highest effective value of weighted acceleration for the entire body 0 5 m s Tightening torque Table 16 Tightening torque values Axle nut tightening torque 35 Nm 40 Nm Handlebars clamping screw maximum tightening torque 5 Nm 7 Nm The safety requirements as per Electromagnetic Compatibility Directive 2014 30 EU have been met The bicycle and the charger can be used in resid...

Page 39: ...ustained direct sunlight CAUTION Oil leak if no transport securing device The brake securing device prevents the brakes from being applied accidentally during transport This could cause irreparable damage to the brake system or an oil leak which will harm the environment Never pull the brake lever when the wheel has been dismounted Always use the transport securing system when transporting dismoun...

Page 40: ...cle rack system The specialist dealer will advise you on how to select a suitable rack system properly and how to use it safely Transport the bicycle in a dry clean place where it is protected from direct sunlight When shipping the bicycle we recommend that you have the bicycle partially dismantled in the proper manner and packaged by the specialist dealer Bicycle rack systems which secure the bic...

Page 41: ...CAUTION Risk of fire and explosion due to high temperatures Excessively high temperatures damage the battery The battery may self ignite and explode Protect battery against heat Never expose the battery to sustained direct sunlight NOTICE If the bicycle is lying flat oil and grease may leak from the bicycle If the shipping box with a bicycle is lying flat or on one end it does not provide the fram...

Page 42: ...harger Storage temperature 5 C 25 C Ideal storage temperature 10 C 15 C 5 2 1 Break in operation NOTICE The battery discharges when it is not used This can cause damage to the battery The battery has to be recharged every 8 weeks NOTICE The battery may become damaged if it is connected permanently to the charger Do not connect the battery to the charger permanently NOTICE The internal battery in t...

Page 43: ...wax the friction surfaces of the brake Before longer periods without use it is recommendable to have your specialist dealer carry out servicing and basic cleaning and apply preservative agent 5 2 1 2 Taking out of operation Store the bicycle battery and charger in a dry and clean environment Charge the internal battery in the display every 3 months for at least 1 hour Check the charge status of th...

Page 44: ...orking environment temperature Working environment temperature 15 C 25 C If a fitting stand is used it must be approved for a maximum weight of 30 kg To reduce the weight we recommend that you always disconnect the battery from the bicycle for the duration of use of the fitting stand 5 3 1 Required tools The following tools are required to assemble the bicycle Knife Hexagon socket spanner 2 2 5 mm...

Page 45: ...ipping carton is opened The packaging material consists mainly of cardboard and plastic film The packaging has to be disposed of in accordance with the regulations of the authorities 5 3 3 Scope of delivery The bicycle was completely assembled in the factory for test purposes and then dismantled for transportation The bicycle is 95 98 pre assembled The scope of delivery includes the pre assembled ...

Page 46: ...vent mix ups with the bicycle frame number or type number for example Since initial commissioning of the bicycle requires special tools and specialist knowledge only trained specialist staff may perform initial commissioning Experience has shown that a bicycle which has not yet been sold is spontaneously handed to consumers as soon as it appears ready to ride For this reason every bicycle must be ...

Page 47: ...hat they are firmly in place Check all the settings and the tightening torque on the axle nuts Check the entire cable harness to make sure that it is routed properly You must prevent the cable harness from coming into contact with moving parts The cable routes must be smooth and free from sharp edges Moving parts must not apply any pressure or tension to the cable harness Check the drive system th...

Page 48: ...may self ignite and explode Never charge a defective battery The battery needs to be checked before it is charged for the first time Press the On Off button battery If none of the LEDs on the operating and charge status indicator light up the battery may be damaged The battery can be charged if at least one of the LEDs on the operating and charge status indicator is fully lit up but not if all of ...

Page 49: ... the handlebars towards the front wheel The stem must not move or twist Firm hold Place your entire body weight on the handlebars with the quick release lever closed to check that the stem is firmly in place The handlebars shaft must not move downwards in the fork shaft If the handlebars shaft should move in the fork shaft increase the quick release lever tensioning To do so turn the knurled nut s...

Page 50: ... this Note that there may be noticeable backlash due to worn out bearing bushes or brake lining backlash in suspension forks and disc brakes If there is headset backlash in the steering headset you must adjust it as soon as possible otherwise the headset will become damaged You must make the adjustment as described in the stem manual 5 3 5 Sale of the bicycle Fill out the data sheet on the first p...

Page 51: ...correctly adjusted bicycle will guarantee you the desired ride comfort and health promoting activity Therefore adjust the saddle the handlebars and the suspension to your body and your preferred riding style before the first ride 6 1 Adjusting the saddle 6 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 ens...

Page 52: ...at height safely either push the bicycle near to a wall so that you can lean on the wall to support yourself or ask another person to hold the bicycle for you Climb onto the bicycle Place your heel on the pedal and extend your leg so that the pedal is at the lowest crank rotation point The rider sits straight on the saddle if the seat is at an optimum height If this is not the case you can adjust ...

Page 53: ... height with quick release Open the quick release on the seat post to change the seat height To do so pull the clamping lever away from the seat post 3 4 5 1 2 3 Figure 14 Seat post quick release 3 with clamping lever 5 and setting bolt 4 in the open position 1 and in the direction of the closed position 2 ...

Page 54: ...se the seat post or the frame to break This will result in a crash and injuries Do not pull the seat post out of the frame beyond the minimum insertion depth marking 3 4 2 1 Figure 15 Detailed view of the seat post examples of the minimum insertion depth marking To close it push the seat post clamping lever as far as it will go into the seat post Check the clamping force of the quick releases ...

Page 55: ... n e m s p ä t e r e n c h m a l s m o n t i e r e n i e d e n m i t g e l i e f e r t e n W i n k e l m i t d e r i n r r i c h t u n g u n d s t e c k e n S i e d i e H ü l l e i n d i e v o r r i c h t u n g e r R e m o t e h e b e l 5 O d e r 2 8 1 2 Figure 16 The seat post activation lever can be mounted either on the left 1 or the right 2 side of the handlebars 6 1 4 1 Lowering the saddle To...

Page 56: ... either push the bicycle near to a wall so that you can lean on the wall to support yourself or ask another person to hold the bicycle for you Climb onto the bicycle Place the pedals into the vertical position 3 o clock position with your feet The rider is sitting in the optimal sitting position if the knee cap perpendicular line runs through the pedal axle If the perpendicular line crosses behind...

Page 57: ... Handlebars clamping screw maximum tightening torque Maximum tightening torque for the clamping screws of the handlebars if there is no other data on the component 5 Nm 7 Nm Adjusting the stem CAUTION Crash caused by loose stem Incorrectly fastened screws may come loose due to impact The stem may no longer be firmly fixed in its position as a result This will result in a crash and injuries Check t...

Page 58: ...se components to break This will result in a crash and injuries Never fasten a quick release using a tool e g hammer or pliers Only use the clamping lever with the specified set clamping force Open the clamping lever Pull the locking lever on the stem up and simultaneously pivot the handlebars into the desired position You feel the locking lever click into place Pull out the handlebars to the requ...

Page 59: ...l transmission of force This will result in a crash and injuries Never fasten a quick release using a tool e g hammer or pliers Only use the clamping lever with the specified set clamping force Open the clamping lever Pull the locking lever on the stem up and simultaneously pivot the handlebars into the desired position You feel the locking lever click into place Pull out the handlebars to the req...

Page 60: ...knurled nut Tighten the knurled nut on the seat post if the clamping lever s clamping force is not sufficient If you are unable to set the clamping force the specialist dealer will need to check the quick release 6 3 Adjusting the brake lever 6 3 1 Adjusting the pressure point on a Magura brake lever WARNING Brake failure due to incorrect setting If the pressure point is set with brakes where the ...

Page 61: ...ers are set incorrectly or installed wrongly the braking power may be lost at any time Such damage may cause you to fall from the bicycle and injure yourself Once the grip distance has been set check the position of the brake cylinder and adjust it as necessary Never correct the brake cylinder position without special tools Have a specialist dealer correct it The brake lever grip distance can be a...

Page 62: ...a T25 TORX wrench to turn the setting screw to adjust the grip distance Turn the setting screw in the minus direction The brake lever moves closer to the handlebar grip Turn the setting screw in the plus direction The brake lever moves away from the handlebar grip 1 2 Figure 22 Using the setting screw 2 to adjust the distance from the brake lever to the handlebar grip 1 ...

Page 63: ...inings New brake linings take time to break in and adjust to their final braking force Accelerate bicycle to about 25 km h Brake bicycle until it comes to a halt Repeat process 30 50 times The brake linings and brake discs are now broken in and provide optimal braking power ...

Page 64: ... riding CAUTION Crash caused by poor road conditions Loose objects such as branches and twigs may become caught in the wheels and cause a crash with injuries Be aware of the road conditions Ride slowly and brake in good time NOTICE When riding downhill high speeds may be reached The bicycle is only engineered for exceeding a speed of 25 km h briefly In particular the tyres can fail if exposed to a...

Page 65: ...ng at low temperatures may impair individual bicycle functions due to the open structural design Always keep the bicycle dry and free from frost If the bicycle is to be used at temperatures below 3 C the specialist dealer must carry out an inspection and prepare the bicycle for winter usage first Off road riding subjects the joints in the arms to severe strain Take a break from riding every 30 to ...

Page 66: ...onent may suddenly fail in case of material fatigue Such damage may cause you to fall from the bicycle and injure yourself Remove the bicycle from service immediately in case of any signs of material fatigue Have the specialist dealer check the state Have the specialist dealer carry out a basic inspection regularly During the inspection the specialist dealer inspects the bicycle for any signs of m...

Page 67: ...wheel brakes to make sure that they are working properly To do so operate the brake levers while stationary in order to check whether resistance is generated in the usual brake lever position The brake must not lose any brake fluid Check that the driving light is working Check for unusual noises vibrations smells staining deformation cracks scores abrasion and wear This indicates material fatigue ...

Page 68: ... bicycle may cause the kickstand to sink into soft ground and the bicycle may topple and crash over The bicycle must be parked on firm level ground only It is particularly important to check that the bicycle is stable if it is equipped with accessories or loaded with luggage Raising the kickstand Before the ride raise the kickstand completely with your foot Parking the bicycle Before parking lower...

Page 69: ...re service immediately Never extinguish damaged batteries with water or allow them to come into contact with water If a battery is dropped or struck but shows no signs of external damage remove the battery from service and observe it for at least 24 hours Faulty batteries are hazardous goods Dispose of faulty batteries properly and as quickly as possible Store in a dry place until disposal Never s...

Page 70: ...rom damaged or faulty batteries They can irritate the airways and cause burns Avoid contact with leaked liquids Immediately consult a doctor in case of contact with the eyes or any discomfort In case of contact with the skin rinse off immediately with water Ventilate the room well CAUTION Fire and explosion caused by penetration by water The battery is only protected from simple spray water Penetr...

Page 71: ...the lock 7 4 1 2 Inserting the integrated battery Place the battery with the contacts first into the mount above Push the integrated battery downwards so that it audibly clicks into place Use the key to fasten the battery lock Remove the key Check the inserted battery to make sure it is firmly in place If a key is left inserted when transporting the bicycle or when riding it may break off or the l...

Page 72: ...ic shock Never charge the battery outdoors CAUTION Electric shock in case of damage Damaged chargers cables and plug connectors increase the risk of electric shock Check the charger cable and plug connector before each use Never use a damaged charger The ambient temperature during the charging process must be within the range from 10 C to 30 C Charging temperature 10 C 30 C The battery can remain ...

Page 73: ...ing and charge status indicator go out CAUTION Risk of fire and explosion caused by damaged batteries The safety electronics on damaged or faulty batteries may fail The residual voltage can cause a short circuit The batteries may self ignite and explode If the battery becomes deformed or begins to smoke keep at a safe distance disconnect the power supply at the socket and notify the fire service i...

Page 74: ...n not used for a longer period the battery switches to sleep mode for self protection The LEDs of the operating and charge status indicator do not light up Press the On Off button battery The battery s operating and charge status indicator indicates the charge status ...

Page 75: ...diately if the brake cannot be reached safely and reliably A sufficiently charged battery has been inserted on the bicycle The battery is firmly in place The key has been removed Press and hold the On Off button for 2 seconds 00 is shown on the display If the drive system is switched on the drive is activated as soon as the pedals are moved with sufficient force 7 5 2 Switching off the drive syste...

Page 76: ...spaces Shift your weight back and down as far as possible CAUTION Crash caused by wet conditions The tyres may slip on wet roads In wet conditions you must also expect a longer braking distance The braking sensation differs from the usual sensation This can cause loss of control or a crash which may result in injuries Ride slowly and brake in good time CAUTION Crash after cleaning servicing or rep...

Page 77: ...t switch off when braking In order to achieve optimum braking results do not pedal while braking 7 7 1 Using the brake Pull the brake levers until the desired speed has been reached Burns caused by heated brake The brakes may become very hot during operation There is a risk of burns in case of contact Never touch the components of the brake directly after the ride ...

Page 78: ...and 80 revolutions per minute It is advisable to stop pedalling briefly when changing gears This makes it easier to switch gears and reduces wear on the drivetrain 7 8 1 Using derailleur gears Figure 23 Down shifter 1 and up shifter 2 on the left I and right II shift Select the appropriate gear with the shifter The gear shift switches the gear The shifter returns to its original position Clean the...

Page 79: ...ove those affected from the danger area to fresh air Never leave those affected unattended Ensure sufficient ventilation Immediately remove clothing items contaminated with hydraulic fluid Serious slip hazard due to hydraulic fluid leakage Keep away from naked flames hot surfaces and sources of ignition Avoid contact with skin and eyes Do not inhale vapours or aerosols After inhalation Take in fre...

Page 80: ...n a stable recovery position on their side Seek medical advice immediately Environmental protection measures Never allow hydraulic fluid to flow into the sewage system surface water or groundwater Notify the relevant authorities if fluid penetrates the ground or pollutes water bodies or the sewage system WARNING Amputation due to rotating brake disc The brake disc in disc brakes is so sharp that i...

Page 81: ...f the brakes are applied continuously for a long time e g while riding downhill for a long time the fluid in the brake system may heat up This may create a vapour bubble This will cause air bubbles or any water contained in the brake system to expand This may suddenly make the lever travel wider This may cause a crash with serious injuries Release the brake regularly when riding downhill for a lon...

Page 82: ...an feel no resistance when pulling on the brake handle Consult a specialist dealer CAUTION Crash after cleaning or storage The brake system is not designed for use on a bicycle which is placed on its side or turned upside down The brake may not function correctly as a result This can cause a crash which may result in injuries If the bicycle is placed on its side or turned upside down apply the bra...

Page 83: ...ack pedal brake Alternative The best braking effect is achieved if the pedals are in the 3 o clock and 9 o clock position when braking To bridge the free travel between the riding movement and the braking movement it is recommendable to pedal a little beyond the 3 o clock and 9 o clock position before you pedal in the opposite direction to the direction of travel and start braking Pedal in the opp...

Page 84: ...six months Maintenance check list Check USB rubber cover position before each ride Check for tyre wear once a week Check for rim wear once a week Check the tyre pressure once a week Check brakes for wear once a month Check electrical cables and Bowden cables for damage and ensure they are fully functional once a month Check the chain tension once a month Check the tension of the spokes every three...

Page 85: ...k on the suspension fork Every 50 hours Suspension fork maintenance and dismantling Every 100 hours or at least every year Complete maintenance of the rear frame damper Every 125 hours Inspection by the specialist dealer every six months Inspection of the drive unit 15 000 km ...

Page 86: ...pecialist dealer 8 1 1 After every ride 8 1 1 1 Cleaning the suspension fork Remove dirt and deposits on the stanchions and deflector seals with a damp cloth Check the stanchions for dents scratches staining or leaking oil Check the air pressure Lubricate the dust seals and stanchions 8 1 1 2 Cleaning the rear frame damper Remove dirt and deposits from the damper body with a damp cloth Check rear ...

Page 87: ...he braking surfaces on the rims After cleaning servicing or repair carry out a few test brake applications NOTICE Water may enter into the inside of the bearings if you use a steam jet The lubricant inside is diluted the friction increases and as a result the bearings are destroyed in the long term Never clean the bicycle with a steam jet NOTICE Greased parts e g the seat post the handlebars or th...

Page 88: ...g the stem Clean stem with a cloth and washing water Service the stem after cleaning 8 1 2 3 Cleaning the rear frame damper Clean rear frame damper with a cloth and washing water 8 1 2 4 Cleaning the wheel WARNING Crash due to braking hard on rim A rim can break and block the wheel if you brake hard It may cause a crash with serious injuries Check rim wear on a regular basis Check the tyres rims s...

Page 89: ...ing 8 1 2 6 Cleaning the chain NOTICE Never use aggressive acid based cleaners rust removers or degreasers when cleaning the chain Do not use chain cleaning devices or chain cleaning baths Slightly dampen a brush with dish washing liquid Brush both sides of the chain Dampen a cloth with dish washing liquid Place the cloth on the chain Hold with slight pressure while slowly turning the rear wheel s...

Page 90: ...ed air Never immerse the battery in water Never use cleaning agent Remove the battery from the bicycle before cleaning Only clean the electrical connections of the battery with a dry cloth or brush Wipe off the decorative sides with a damp cloth 8 1 2 8 Cleaning the drive unit NOTICE If water enters into the drive unit the unit will be permanently damaged Never immerse the drive unit in water Neve...

Page 91: ...lly clean the display with a damp soft cloth 8 1 2 10 Cleaning the brake WARNING Brake failure due to water penetration The brake seals are unable to withstand high pressures Damaged brakes can fail and cause an accident with injury Never clean the bicycle with a high pressure water device or compressed air Take great care when using a hosepipe Never point the water jet directly at the seal sectio...

Page 92: ...ly a little acid free lubricant grease between the stem quick release lever and the sliding piece to reduce the quick release lever operating force 8 1 3 3 Servicing the fork Treat the dust seals with fork oil 8 1 3 4 Servicing the drive elements Spray the cassette the chain wheels and the front derailleur with a degreasing agent Clean coarse dirt with a brush after soaking for a short time Wash d...

Page 93: ...877 00136_1 0_17 09 2018 93 Maintenance 8 1 3 7 Servicing the drive elements Service Maintain front and rear derailleur articulated shafts and jockey wheels with Teflon spray ...

Page 94: ...ard on rim A rim can break and block the wheel if you brake hard It may cause a crash with serious injuries Check rim wear on a regular basis NOTICE If the pressure is too low in the tyre the tyre does not achieve its load bearing capacity The tyre is not stable and may come off the rim If the pressure in the tyre is too high the tyre may burst Check the tyre pressure against the specifications Da...

Page 95: ...mage may cause you to fall from the bicycle and injure yourself Check the brake disc brake linings and the hydraulic brake system on a regular basis and replace if necessary Replace the brake linings on the disc brake when the pad thickness has reached 0 5 mm 8 2 3 Electrical cables and brake cables Check all visible electrical cables and cables for damage If for example the sheathing is compresse...

Page 96: ...ICE Excessive chain or belt tension increases wear If the chain or belt tension is too low there is a risk that the chain or belt will slip off the chain wheels Check the chain and belt tension once a month Check the chain or belt tension in three or four positions turning the crank a full revolution If the chain or the belt can be pushed more than 2 cm you need to have the chain or belt tensioned...

Page 97: ...y moisture which enters through the USB port may trigger a short circuit in the display Regularly check the position of the cover on the USB port and adjust it as necessary 8 2 8 Suspension fork The specialist dealer will check the suspension fork function and the torques of attachment screws and nuts on the lower surfaces steel 10 Nm alloy 4 Nm They will check the suspension fork for scratches de...

Page 98: ...erform an inspection at least every six months This is the only way to ensure that the bicycle remains safe and fully functional The specialist dealer will inspect the bicycle for any signs of material fatigue during basic cleaning The specialist dealer will check the software version of the drive system and update it The electrical connections are checked cleaned and preservative agent is applied...

Page 99: ...als of air forks overhaul the air suspension change the oil and replace the dust wipers The further servicing measures correspond to those which are recommended for a bicycle as per EN 4210 Particular attention is paid to the rim and brake wear The spokes are re tightened in accordance with the findings 877 00136_1 0_17 09 2018 99 Maintenance ...

Page 100: ...s activated unintentionally Remove the battery before the service 8 4 1 Use original parts and lubricants only The individual parts of the bicycle have been selected carefully and to matched to each other Only original parts and lubricants must be used for maintenance and repair The constantly updated lists of approved accessories and parts are available to specialist dealers ...

Page 101: ... of the quick release may become damaged as a result The quick release comes loose This will result in a crash and injuries The front wheel quick release lever and the brake disc must be situated on opposite sides CAUTION Crash caused by incorrectly set clamping force Excessively high clamping force will damage the quick release and cause it to lose its function Insufficient clamping force will ca...

Page 102: ...ing lever can be moved easily from the open final position into the middle and has to be pressed with the fingers or base of the thumb from the middle point onwards 8 4 2 1 Clamping the quick release Hold the open clamping lever Fasten the setting nut on the opposite side Clamp the clamping lever The final position of the clamping lever is at a right angle to the fork or frame 3 1 2 Figure 26 Whee...

Page 103: ...o its proper final position by pushing it with the hand or if it is too loose its clamping force will need to be readjusted Open the clamping lever completely Unfasten the setting nut a little Clamp the clamping lever If the clamping lever is not yet in the proper final position repeat the steps until the proper final position has been achieved ...

Page 104: ...ing instructions for the bicycle pump must be adhered to Unscrew and remove the valve cap Connect the bicycle pump Pump up the tyre slowly and pay attention to the tyre pressure in the process The tyre pressure has been adjusted as per the data Data sheet page 1 If the tyre pressure is too high unfasten the union nut let off air and tighten the union nut again Remove the bicycle pump Screw the val...

Page 105: ...turns Carefully apply the bicycle pump so that the valve insert is not bent Pump up the tyre slowly and pay attention to the tyre pressure in the process The tyre pressure has been adjusted as per the data Data sheet page 1 Remove the bicycle pump Tighten the knurled nut with your finger tips Screw the valve cap tight Screw the rim nut gently against the rim with the tips of your fingers Figure 28...

Page 106: ... be adhered to Unscrew and remove the valve cap Connect the bicycle pump Pump up the tyre slowly and pay attention to the tyre pressure in the process The tyre pressure has been adjusted as per the data Data sheet page 1 Remove the bicycle pump Screw the valve cap tight Screw the rim nut gently against the rim with the tips of your fingers Figure 29 Schrader valve with rim nut 1 ...

Page 107: ...e and observe it for at least 24 hours Faulty batteries are hazardous goods Dispose of faulty batteries properly and as quickly as possible Store in a dry place until disposal Never store in the vicinity of flammable substances Never open or repair the battery The components of the drive system are checked constantly and automatically If an error is detected the respective error code appears on th...

Page 108: ... a note of the system message Table 20 Error eradication using the code Error Remedy 10 12 24 Incorrect charger 40 41 44 Overcurrent detected and motor overheating Relieve the motor with reduced pedalling or a lower assistance level If the system message is still displayed contact the KETTLER specialist dealer Charge the battery Charge the battery Use the supplied charger for charging ...

Page 109: ...947 660 Fitting stand 08981 880 Wall mount 08959 000 Ceiling mount 08959 500 Parking stand 08982 500 Messenger bag 08987 742 Layana shopping bag 08987 741 Pannier rack basket 08985 500 Smart bag 08987 745 Single bag 08987 746 Handlebar bag 08987 747 Smart Bag Waterproof 08987 748 Single Bag Waterproof 08987 749 Business bag 08987 744 Ladies bag 08987 743 System components are matched to the pannie...

Page 110: ...rably This can cause a loss of control a crash and injuries You should practice how to use the child seat safely and reliably before using the bicycle in public spaces CAUTION Risk of crushing due to exposed springs The child may crush his her fingers on exposed springs or open mechanical parts of the saddle or the seat post Never install saddles with exposed springs if a child seat is being used ...

Page 111: ...d the bicycle s permitted total weight is not exceeded The specialist dealer will provide instruction on how to handle the bicycle and the child seat 877 00136_1 0_17 09 2018 111 Maintenance 8 5 2 Bicycle trailer CAUTION Crash caused by brake failure The brake may not work sufficiently if there is an excessive trailer load The long braking distance can cause a crash or an accident and injuries Nev...

Page 112: ...st dealer must mount the pannier rack the first time to ensure that it is safely fitted When installing a pannier rack the specialist dealer makes sure that the rack and the fastening mechanism for the rack are suitable for the bicycle and that all components are installed and firmly fastened They will also ensure that shift cables brake cables hydraulic and electrical cables are adjusted as neces...

Page 113: ...ervice immediately Never extinguish damaged batteries with water or allow them to come into contact with water Faulty batteries are hazardous goods Dispose of faulty batteries properly and as quickly as possible Store in a dry place until disposal Never store in the vicinity of flammable substances Never open or repair the battery CAUTION Chemical burns to the skin and eyes Liquids and vapours may...

Page 114: ...nd recycling saves reserves of raw materials and ensures that all the regulations for protection of health and the environment are adhered to when recycling the product and or the battery Never dismantle the bicycle battery or charger for disposal The bicycle display the unopened and undamaged battery and the charger can be returned to any specialist dealer free of charge Depending on the region f...

Page 115: ...es comply with all applicable basic requirements of Electromagnetic Compatibility Directive 2014 30 EU The following standards were used EN ISO 12100 2010 Safety of machinery General principles of design Risk assessment and reduction EN 15194 2015 Cycles Electrically power assisted cycles EPAC bicycles EN ISO 4210 Cycles Safety requirements for bicycles EN 11243 2016 Cycles Luggage carriers for bi...

Page 116: ...ube Stem Kalloy ML 2 monkeylink ready Fork Rigid fork alloy Seat post Kalloy SP 368 patented post Tyres Schwalbe G One 40 622 Table 23 2 E Street Beltdrive parts list Model 2 E Street Beltdrive Type number KU118 VAFD50 KU118 VAFD55 KU118 VAFD60 KU118 VAFT45 KU118 VAFT50 Wheel size 28 Drive Belt drive Motor Suntour EBHM17 rear wheel hub motor Gears Single gear Rechargeable battery Shimano BR MT200 ...

Page 117: ...be Fork Kalloy ML 2 monkeylink ready Seat post Rigid fork alloy Tyres Kalloy SP 368 patented post Table 25 2 E Carbon parts list Model 2 E Carbon Type number KU120 VAFD50 KU120 VAFD55 KU120 VAFD60 KU120 VAFT45 KU120 VAFT50 Wheel size 28 Drive Belt drive Motor Suntour EBHM17 rear wheel hub motor Gears Single gear Rechargeable battery Shimano BR MT200 hydraulic disc brake Stem BMZ Evo Intube Fork Ka...

Page 118: ...k alloy Tyres Kalloy SP 368 patented post Table 27 2 E Comp Street parts list Model 2 E Comp Street Type number KU159 VAKD50 KU159 VAKD55 KU159 VAKD60 KU159 VAKT45 KU159 VAKT50 Wheel size 28 Drive Chain drive Motor Suntour EBHM17 rear wheel hub motor Gears Shimano Deore 9 gear derailleur Rechargeable battery Shimano BR MT200 hydraulic disc brake Stem BMZ Evo Intube Fork Kalloy ML 2 monkeylink read...

Page 119: ...the open position 1 and in the direction of the closed position 2 53 Figure 15 Detailed view of the seat post examples of the minimum insertion depth marking 54 Figure 16 The seat post activation lever can be mounted either on the left 1 or the right 2 side of the handlebars 55 Figure 17 Knee cap perpendicular line 56 Figure 18 Open 2 and closed 1 clamping lever on the stem example by schulz speed...

Page 120: ... 0_17 09 2018 121 Figure 27 Dunlop valve with union nut 1 and rim nut 2 104 Figure 28 Presta valve with valve insert 1 knurled nut 2 and rim nut 3 105 Figure 29 Schrader valve with rim nut 1 106 Figure 30 Trailer sign 112 ...

Page 121: ...ration of conformity 116 Error message see System message F Fork 27 Fork end 27 Frame number 1 Frame 24 Front wheel brake 29 braking 77 83 Front wheel see Wheel G Gear shift twist grip checking 95 Gear shift maintaining 95 switching 78 H Handlebars 24 25 Headlight 24 Hub 27 I Initial commissioning 46 L Level of assistance 36 selecting 76 M Mass see Weight Minimum insertion depth marking 54 Model y...

Page 122: ... 09 2018 124 V Valve 27 Dunlop valve 27 Presta valve 27 Schrader valve 27 W Weight permitted total weight 17 Unladen weight 1 Wheel circumference 1 Wheel maintaining 94 Winter break see break in operation Working environment 44 ...

Page 123: ...her Straße 2 50739 Köln Germany Translation Tanner Translations GmbH Co Markenstraße 7 40227 Düsseldorf Germany Operating instructions 877 00136 1 0 13 09 2018 EN_877 00136_1 0_0 01_09 18_KETTLER Suntour MY19_COVER book Page 135 Thursday September 13 2018 12 56 PM ...

Page 124: ...lu rad de KETTLER Alu Rad GmbH Longericher Straße 2 50739 Köln Germany Tel 49 6805 6008 0 Fax 49 6805 6008 3098 E mail info kettler alu rad de EN_877 00136_1 0_0 01_09 18_KETTLER Suntour MY19_COVER book Page 1 Thursday September 13 2018 12 56 PM ...

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Kettler Quadriga, Translation Of The Original Operating Instructions

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