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MY22P01 - 22_1.0_22.08.2021

157

Maintenance

8.5

Maintenance instructions

Complying with these maintenance instructions is the only way to reduce wear on components, increase
the operating hours and guarantee safety.

Diagnosis and documentation of current status

Components

Fre-

quency

Description

Criteria

Measures if rejected

Inspection

Tests

Maintenance

Accept-

ance

Rejection

Chassis

Frame

Once a

month

Dirt

…

Section 7.3.4

O.K.

Dirt

Cleaning

6 months

Servicing

…

Section 7.4.1

O.K.

Untreated

Wax

6 months

Check for damage –

fracture, scratches

Section 8.6.1

…

O.K.

Damage

detected

Take pedelec out of

service, new frame as

specified in parts list

Carbon frame

(optional)

Once a

month

Dirt

Section 7.3.4

…

O.K.

Dirt

Cleaning

6 months

Servicing

…

Section 7.4.1

O.K.

No wax

Wax

6 months

Damage to paint-

work

Section 8.6.1.1 ...

O.K.

Damage to

paintwork

Apply paint

6 months

Damage from

impact

Section 8.6.1.1 ...

O.K.

Damage from

impact

Take pedelec out of

service, new frame as

specified in parts list

RockShox

Rear frame

damper

(optional)

6 months

Check for damage,

corrosion, fracture

See Rock-

Shox compo-

nent

maintenance

instructions

Maintenance as

specified by

manufacturer

Air chamber

assembly group,

damper and

spring.

O.K.

Damage

detected

New rear frame

damper as specified

in parts list

FOX

Rear frame

damper

(optional)

6 months

Check for damage,

corrosion, fracture

...

Send to FOX

O.K.

Damage

detected

New rear frame

damper as specified

in parts list

Suntour

Rear frame

damper

(optional)

6 months

Check for damage,

corrosion, fracture

See Suntour

component

maintenance

instructions

Maintenance as

specified by

manufacturer

Complete shock

absorber service

including

damper reas-

sembly and air

seal replace-

O.K.

Damage

detected

New rear frame

damper as specified

in parts list

Steering system

Handlebars

Once a

month

Cleaning

...

Section 7.3.6

O.K.

Dirt

Cleaning

6 months

Wax

...

Section 7.4.7

O.K.

Untreated

Wax

6 months

Check mount

fastening

Section 7.5.5

...

O.K.

Loose, rust

Retighten screws;

new handlebars as

specified in parts list if

necessary

Stem

Once a

month

Cleaning

…

Section 7.3.5

O.K.

Dirt

Cleaning

6 months

Wax

…

Section 7.4.6

O.K.

Untreated

Wax

6 months

Check mount

fastening

Section 7.5.4

and Section

8.6.4

…

O.K.

Loose, rust

Retighten screws;

new stem as specified

in parts list if neces-

sary

Содержание 22-15-2094

Страница 1: ...tions for PEGASUS Pedelecs with BOSCH Purion on board computer 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 W A A W W W A W W W W W W W W...

Страница 2: ...2 1 3 2 Incorrect tightening torque 14 2 1 3 3 Incorrect component 14 2 1 4 Risk of amputation 14 2 1 5 Key breaking off 14 2 2 Toxic substances 15 2 2 1 Brake fluid 15 2 2 2 Suspension oil 15 2 2 3...

Страница 3: ...3 8 Electric drive system 39 3 3 8 1 Motor 39 3 3 8 2 Rechargeable battery 39 3 3 8 3 Frame battery 40 3 3 8 4 Pannier rack battery 40 3 3 8 5 Integrated battery 41 3 3 8 6 Charger 41 3 3 9 Lighting 4...

Страница 4: ...battery 58 5 3 2 Preparing the battery 59 5 3 2 1 Retrofitting the PowerTube adapter 59 5 3 2 2 Fit battery cover onto Bosch PowerTube 625 battery horizontal 61 5 3 2 3 Fit battery cover onto Bosch Po...

Страница 5: ...6 5 11 1 Adjusting the Suntour fork steel suspension 95 6 5 11 2 Adjusting the Suntour fork air suspension 96 6 5 12 Fork rebound damping 97 6 5 12 1 Adjusting the Suntour fork rebound damping 98 6 5...

Страница 6: ...ssist system 114 6 18 6 Selecting the level of assistance 114 6 18 7 Using the journey information 114 6 18 7 1 Switching the journey information 114 6 18 7 2 Resetting the trip distance 114 6 18 7 3...

Страница 7: ...dle 133 7 3 10 Tyres 133 7 3 11 Spokes and spoke nipples 133 7 3 12 Hub 133 7 3 13 Switching elements 133 7 3 13 1 Shifter 133 7 3 14 Cassette chain wheels and front derailleur 133 7 3 15 Brake 134 7...

Страница 8: ...s 150 7 5 9 2 Checking the hub gear 150 7 5 10 Checking the gear shift 150 7 5 10 1 Electric gear shift 150 7 5 10 2 Mechanical gear shift 150 7 5 10 3 Checking the derailleur gears 150 7 5 11 Adjusti...

Страница 9: ...1 6 Lighting does not work 185 9 1 7 Other errors 186 9 2 Repair 187 9 2 1 Original parts and lubricants 187 9 2 2 Replacing the lighting 187 9 2 3 Setting the front light 187 9 2 4 Checking tyre cle...

Страница 10: ...G Distribution or reproduction of these operating instructions and utilisation or communication of their content is prohibited unless expressly approved Any infringement will render the offender liabl...

Страница 11: ...n A translation is invalid without the original operating instructions 1 4 For your information Different markings are used in the operating instructions to make them easier to read 1 4 1 Warnings War...

Страница 12: ...operating instructions identification number is located in bottom left hand corner of each page The identification number is composed of the document number the version number and the release date Typ...

Страница 13: ...staff are highlighted in blue and marked with a spanner symbol These paragraphs aim to allow trained technical staff bicycle mechatronics engineers bicycle mechanics or similar to carry out initial a...

Страница 14: ...ures over 60 C can also cause liquid to leak from the battery and the battery will become damaged The battery may self ignite and explode Protect the battery against heat Never store next to hot objec...

Страница 15: ...break This will cause a crash with 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 2 1 3 2 Incorrect tightenin...

Страница 16: ...ns Never dismantle the battery Avoid contact with skin Do not inhale vapours 2 3 Requirements for riders The rider must have the required mental capacity and physical and motor skills to ride on publi...

Страница 17: ...faces and sources of ignition Avoid contact with skin and eyes After inhalation Take in fresh air Immediately consult a doctor in case of any discomfort After skin contact Wash affected skin with soap...

Страница 18: ...d 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 consu...

Страница 19: ...iod in addition to physical fitness Learning how to ride a mountain bike takes practice especially braking and riding around bends The strain on hands wrists arms shoul ders the neck and back is consi...

Страница 20: ...tions stunt riding or 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 spor...

Страница 21: ...The maximum permitted total weight is the weight of the fully assembled pedelec plus body weight plus baggage Type no Model PTW kg 22 15 2164 Ancura E7R HS 135 22 15 2165 Ancura E8R Disc Wave 135 22...

Страница 22: ...s 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 a...

Страница 23: ...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 over 15 cm Never drive off road or perform jumps...

Страница 24: ...permitted total weight is the weight of the fully assembled pedelec with the rider plus baggage 6 Year of manufacture The year of manufacture is the year in which the pedelec was manufactured The pro...

Страница 25: ...el mudguard 6 Front light 7 Steering headset 8 Handlebars 9 Stem 10 Frame 11 Seat post 12 Saddle 13 Pannier rack 14 Rechargeable battery 15 Rear light 16 Rear wheel brake 17 Rear wheel mudguard 18 Rea...

Страница 26: ...g headsets for threadless fork steerers what are known as headsets 3 3 2 4 Stem The stem is the connecting component between the handlebars and the fork steerer tube The stem is used to adjust the han...

Страница 27: ...lays see Section 3 4 1 Figure 5 Handlebar dimensions The main structural dimensions of handlebars are 1 Rise height 2 Width 3 Backsweep 3 3 2 6 Fork The stem and handlebars are attached to the top end...

Страница 28: ...from being channelled directly into the body via the fork The impact is absorbed by the suspension system instead This causes the suspension fork to compress After compressing the suspension fork ret...

Страница 29: ...ne when riding over bumps The suspension motion is predictable and controlled Figure 8 Optimum fork riding performance When optimally adjusted the fork counteracts deflection on hilly terrain and stay...

Страница 30: ...llow terrain green line when riding over bumps The suspension motion is predictable and controlled Figure 11 Optimum fork riding performance Suspension fork compression adjustment Only applies to pede...

Страница 31: ...n 4 Dust seal 5 Q Loc 6 Axle 7 Fork end 8 Stanchion 9 Compression damper Air suspension fork structure Depending on the model the air suspension fork has either an air suspension assembly group orange...

Страница 32: ...smit the driving braking and steering forces The tread can also help improve control on dirty road surfaces If a tyre with a deep tread is used on asphalt this may make an unpleasant noise when the br...

Страница 33: ...lve Figure 19 Schrader valve 3 3 4 4 Spoke A spoke is a rod that connects the hub to the rim The bent end of the spoke which is hooked into the hub is called the spoke head A thread between 10 mm and...

Страница 34: ...gency The brake is applied using the brake lever either with the brake lever and shift cable mechanical brake or with the brake lever and hydraulic brake cable hydraulic brake 3 3 5 1 Mechanical brake...

Страница 35: ...is screwed permanently to the wheel hub You increase brake pressure by pulling the brake lever The brake fluid is used to transfer pressure through the brake cables to the cylinders in the brake calli...

Страница 36: ...ever 5 Front wheel rim brake Figure 24 Rim brake locking lever closed 1 and open 2 The rim brake stops the wheel moving when the rider pulls the brake lever causing two brake linings positioned opposi...

Страница 37: ...system with a 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 rear wheel from moving by...

Страница 38: ...to ensure sufficient tension when tightening the screw Patent saddle posts are fastened into the seat tube with either a quick release or a screwable clamp Figure 27 Example of a quick release 3 3 6...

Страница 39: ...ravel 2 Chain or belt 3 Rear chain wheel or belt pulley 4 Front chain wheel or belt pulley 5 Pedal The pedelec is equipped with either a chain or belt drive 3 3 7 1 Chain drive layout Figure 29 Chain...

Страница 40: ...f an emergency 3 3 8 2 Rechargeable battery BOSCH batteries are lithium ion batteries which are developed and manufactured to the latest technical standards Each individual cell is protected by a stee...

Страница 41: ...of frame battery Figure 33 Details of frame battery 1 Battery housing 2 Battery lock 3 Battery key 4 On off button battery 5 Battery level indicator battery 6 Charging port cover 7 Charging port 3 3...

Страница 42: ...ry level indicator battery 6 Battery housing 3 3 8 6 Charger Each pedelec is supplied with a charger As a general rule any BOSCH charger may be used The 2 A compact charger The 4 A standard charger Th...

Страница 43: ...also has two internal non rechargeable coin cells This ensures that the electric drive system can be switched on using the on board computer Figure 38 BOSCH Purion on board computer W ALK W ALK W ALK...

Страница 44: ...Description of controls and screens 3 4 1 Handlebars Figure 39 Detailed view of handlebars from sitting position example 1 Rear wheel hand brake 2 Bell 3 Headlight 4 Front wheel hand brake 5 On board...

Страница 45: ...mputer see Section 3 8 1 7 8 RANGE indicator see Section 3 8 1 3 9 TOTAL indicator see Section 3 8 1 3 3 5 1 1 Indicator unit km h or mph The speed can be displayed in km h or mph You can choose betwe...

Страница 46: ...in Section 6 2 Display Function TRIP Distance travelled since the last RESET TOTAL Total distance travelled cannot be changed RANGE Estimated range of the available battery charge calculated based on...

Страница 47: ...hicles with this equipment The gear shift is on the right of the handlebars The gear shift has one or two shifters SHIMANO SL M315 gear shift Figure 42 Example of SHIMANO SL M315 1 Shifter A 2 Shifter...

Страница 48: ...ist grip with a display on the right hand side of the handlebars Figure 44 SHIMANO SL C30000 7 gear shift top view 1 Twist grip 2 Gear indicator The Gear indicator shows the selected gear The gear is...

Страница 49: ...rake There is a hand brake on the left and right of the handlebars Figure 46 Front wheel 2 and rear 1 brake levers Shimano brake used as an example The left hand brake controls the front wheel brake T...

Страница 50: ...ator battery The five green LEDs on the battery level indicator show the charge level when the battery is switched on Each LED represents 20 of battery capacity Symbols All five LEDs will light up whe...

Страница 51: ...ting Batteries 2 x 3 V CHR2016 Operating temperature 5 C 40 C Storage temperature 10 C 40 C Charging temperature 0 C 40 C Protection class with USB cover closed IP54 Weight about 0 1 kg Table 19 Techn...

Страница 52: ...ature 10 40 C Permitted charging temperature range 0 40 C Table 23 Technical data for PowerTube 400 BBP282 and BBP283 vertical batteries Nominal voltage 36 V Nominal capacity 13 4 Ah Energy 500 Wh Wei...

Страница 53: ...nt screw Bowden cable fastener 2 5 Nm 5 Nm 4 mm hex bit 3 mm hex bit Axle Conventional axle nut 35 40 Nm SUNTOUR screw on axle 12AH2 Axle Securing screw 8 10 Nm 5 6 Nm 6 mm hex bit 5 mm hex bit SUNTOU...

Страница 54: ...er sleeve 8 Nm 18 Nm 0 5 Nm 8 Nm 8 Nm 0 5 Nm 6 mm hex bit 3 mm hex bit 5 mm hex bit 5 mm hex bit 3 mm hex bit 3 mm hex bit LIMOTEC LimoDP Seat post clamping screw Saddle clamping screw 6 7 Nm 7 9 Nm S...

Страница 55: ...ns during transport Vehicle weight without battery Not yet available when the instructions were produced 4 2 Designated handles lifting points The box does not have any handles Type no Frame Box dim c...

Страница 56: ...covers Transport the battery in a dry clean position where it is protected from direct sunlight 4 3 3 Shipping a pedelec When shipping the pedelec we recommend that you have the specialist dealer pla...

Страница 57: ...e brake Before longer periods without use it is recommended to have the specialist dealer carry out an inspection and basic cleaning and apply preservative agent 4 4 1 2 Carrying out a break in operat...

Страница 58: ...Problems may arise if components are set incorrectly They may cause serious injuries to the face Always wear safety glasses to protect eyes when assembling pedelecs Crash and crushing hazard caused by...

Страница 59: ...immediately after being assembled The assembly report see Section 11 2 describes all safety relevant inspections tests and maintenance tasks All assembly work must be completed to ensure the pedelec...

Страница 60: ...e 52 Undoing screws on battery mount 2 Use a ratchet to remove the two 4 mm hexagon screws in the PowerTube adapter If you don t have a ratchet you can use a hexagonal key to remove the screws Figure...

Страница 61: ...MY22P01 22_1 0_22 08 2021 60 Assembly 6 Use a TORX T25 wrench to fasten the screws into the battery mount Figure 57 Fastening the battery mount...

Страница 62: ...y mounting plate to the BOSCH the PowerTube 625 battery with original BOSCH screws M4 8 T20 In doing so ensure that the removal tab faces the front of the battery Figure 59 Fitting the mounting plate...

Страница 63: ...he PowerTube extension must face upwards away from the battery Figure 62 Fitting the PowerTube extension 3 Screw the battery mounting plate onto the PowerTube extension with original BOSCH screws M4 8...

Страница 64: ...nt wheel into the fork ends 2 Insert the axle into the hub on the drive side Figure 65 Inserting the axle in the direction of the arrow 3 Use a 6 mm hex key to tighten the axle using between 8 and 10...

Страница 65: ...h caused by loose quick release axle A faulty or incorrectly installed cross axle may become caught in the brake disc and block the wheel This will cause a crash Never fit a defective cross axle Crash...

Страница 66: ...lever must be flush with the shock absorber Figure 73 Perfect position for the clamping lever 6 Use 4 mm hexagon socket spanner to adjust the clamping lever clamping force if required Figure 74 Adjus...

Страница 67: ...lty or incorrectly 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 ins...

Страница 68: ...ds to transmit the drive forces the front wheel is responsible for transmitting braking and steering forces Drive and braking forces have different directions of action This is why some tyres are moun...

Страница 69: ...calculate the optimum seat post height for the length of rider s leg Seat height SH inner leg length I 0 9 2 Lower the seat post further into the seat tube 3 The seat post Bowden cable must be tighten...

Страница 70: ...81 Example of markings on pedals 1 Coat threads in both pedals with waterproof grease 2 Turn the pedal marked L anti clockwise by hand into the crank arm on the left as seen when facing the direction...

Страница 71: ...the handlebars cannot be fastened contact your specialist dealer Stem with clamping lever version II and stem with screw If the handlebars cannot be fastened contact your specialist dealer 5 3 7 3 Che...

Страница 72: ...sed to road traffic and speed before riding at speeds over 12 km h especially if you have not ridden a bike for some time Increase the levels of assistance gradually Practice braking hard on a regular...

Страница 73: ...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 when it is raining CAU...

Страница 74: ...er the range is Gear shift Use a low gear and a low level of assistance on hills and when setting off Switch up a gear depending on the speed and terrain 50 80 crank rotations are optimal Avoid high s...

Страница 75: ...r battery flat Recharge on board computer battery while in its mount or using USB port 431 Software version error 1 Re start the system 2 Contact your specialist dealer if the problem persists Table 2...

Страница 76: ...persists Code Description Method of resolution Table 29 List of on board computer error messages 595 596 Communication error 1 Check cabling to the gears 2 Re start the system 3 Contact your specialis...

Страница 77: ...problem persists 830 Error in the line to the rear wheel speed sensor Contact your specialist dealer 831 833 835 Implausible signals from the rear wheel speed sensor Sensor disc may be missing It is...

Страница 78: ...ry level indicator 1 Disconnect charger from battery 2 Leave battery to cool down 3 Contact your specialist dealer if the problem persists Code If a fault is detected in the battery two LEDs flash on...

Страница 79: ...usting the pedelec Only a correctly adjusted pedelec will guarantee the desired ride comfort and health promoting activity All settings must be re configured if the body weight or maximum baggage weig...

Страница 80: ...1 6 5 4 3 6 5 4 5 6 5 4 6 2 Handlebars 6 5 5 3 Stem 6 5 6 4 Handles 6 5 7 5 Tyres 6 5 8 6 1 6 2 6 3 6 4 Brake Position of the brake handles Brake handle tilt angle Determine grip distance Adjust the g...

Страница 81: ...60 70 Angle between upper arm upper body red line Extremely acute angle at around 20 The upper arms are almost parallel to the upper body The hands are simply placed loosely on the handlebars An angle...

Страница 82: ...r Push the pedelec near to a wall so that the rider can lean on the wall to support themselves or Ask another person to hold the pedelec 1 Use the seat height formula to roughly set the saddle height...

Страница 83: ...r 3 Release the remote control operating lever when you have reached the desired height Figure 90 Remote control operating lever 1 Raising the saddle 1 Remove any pressure from the saddle 2 Press the...

Страница 84: ...Figure 91 Knee cap perpendicular line 3 Unfasten and adjust the designated screw connections and clamp them with the maximum tightening torque for the saddle clamping screws 6 5 4 6 Adjusting the sadd...

Страница 85: ...andlebars are advisable for sports bikes e g MTB They support direct steering behaviour but lead to peaks in pressure and greater muscular strain on the arm and shoulder muscles 6 5 5 3 Adjusting the...

Страница 86: ...sting the quick release clamping force If the handlebar clamping lever stops before reaching its end position unscrew the knurled nut Tighten the knurled nut on the seat post if the seat post clamping...

Страница 87: ...Adjusting the quill stem height 1 Undo screw 2 Pull quill stem out 3 Tighten screw 6 5 6 3 Adjusting the Ahead stem Only applies to pedelecs with this equipment In the case of an Ahead stem the stem i...

Страница 88: ...table stems are available in different lengths for quill and Ahead stems Figure 99 Different versions of angle adjustable stems Adjusting the stem angle c changes both the distance from the upper body...

Страница 89: ...andle A greater contact surface means that the pressure is more evenly distributed Nerves and vessels are no longer squeezed in the carpal tunnel Figure 101 Correct 1 and incorrect 2 position of the h...

Страница 90: ...ow tyre pressure often leads to premature wear in the tyre Cracking in the side wall is a typical consequence of very low tyre pressure Abrasion is also unnecessarily high On the other hand a tyre can...

Страница 91: ...lebar 2 Extend the index finger about 15 Figure 104 Brake handle position 3 Push brake lever outwards until the third finger phalanx sits in the brake lever recessed grip 6 5 9 2 Brake handle tilt ang...

Страница 92: ...tance 1 Measure hand size using the grip distance gauge 2 Adjust the grip distance at the pressure point based on the hand size Figure 107 Brake lever position Saddle handlebar height difference mm Br...

Страница 93: ...kwise towards minus The brake lever moves closer to the handlebar grip Turn the setting screw twist knob 5 clockwise towards plus The brake lever moves away from the handlebar grip Figure 108 Adjustin...

Страница 94: ...ing force increases over time The braking force is increased during break in time This is also the case when the brake pads or brake discs are replaced 1 Accelerate pedelec to 25 km h 2 Brake pedelec...

Страница 95: ...a firmer more efficient ride and is generally used on pedelecs with a shorter deflection The adjustment shown here represents a basic setting The rider should change the basic setting to suit the surf...

Страница 96: ...wn Remove the plastic cover Figure 109 Sag setting wheel 1 on the suspension fork crown Turn the sag setting wheel clockwise to increase the spring pre tensioning Turn the sag setting wheel anti clock...

Страница 97: ...ge 7 Sit on the pedelec in your usual riding position and support yourself against an object such as a wall or tree 8 Get off the pedelec without allowing it to deflect 9 Measure distance between the...

Страница 98: ...ody weight spring stiffness deflection the terrain and the rider s preferences If the air pressure or spring stiffness increases the extension and rebound speeds also increase Rebound damping needs to...

Страница 99: ...crew in a clockwise direction to the closed position until it stops 2 Turn the rebound screw slightly in an anti clockwise direction Adjust the rebound damping in such a way that the fork rebounds qui...

Страница 100: ...k Example 3 If the front light is positioned too low the space ahead is not illuminated to an optimum extent and the rider s vision is reduced in the dark Figure 113 Light positioned too high 1 correc...

Страница 101: ...igh 1 correctly 2 and too low 3 7 Check the position of the light beam I if the upper edge of the light beam is above the front light height mark 1 the light will dazzle The front light must be positi...

Страница 102: ...and their type part numbers for maintenance purposes if the sub systems provide this type of information depends on the sub system The drive system must be switched off 1 Keep the plus and minus butt...

Страница 103: ...iers system component 080 40946 Rear wheel basket system component 051 20603 Bicycle box system component 080 40947 Parking stand universal stand XX TWO14B Table 39 Accessories Crash caused by incorre...

Страница 104: ...RLY CROOZER THULE Crash caused by brake failure The braking distance may be longer if the trailer is carrying excessive load The long braking distance can cause a crash or an accident and injuries Nev...

Страница 105: ...easons 6 6 5 Suspension fork coil spring If the desired suspension fork sag cannot be achieved after adjustment the coil spring assembly must be replaced with a softer or harder spring Fit a softer co...

Страница 106: ...ed so that it does not dazzle other road users If the white reflector is not integrated into the front light it must be clean at all times 7 The two separate brakes on the pedelec must work at all tim...

Страница 107: ...er 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 Crushing the...

Страница 108: ...from material beneath and mould can form If the leather handles get wet dry handles completely 6 13 Using the pedals The ball of the foot is placed on the pedal when riding and pedalling Figure 123 Co...

Страница 109: ...battery key from the battery lock 4 3 Tip the battery into the top section 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...

Страница 110: ...the frame 4 Remove the battery key from the battery lock 6 16 3 2 Inserting the integrated battery Figure 127 Inserting the integrated battery 1 Place the battery into the integrated battery lower mou...

Страница 111: ...ith this equipment 6 16 5 1 Charging process when two batteries are used If two batteries are attached to a pedelec charge both batteries via the non sealed socket The two batteries are charged altern...

Страница 112: ...If you wish to use just one battery on a pedelec which is designed for two batteries cover the contacts in the free slot with the supplied cover cap 1 otherwise there is a risk of a short circuit caus...

Страница 113: ...stance is OFF The motor power is determined by the level of assistance set on the on board computer 6 17 2 Switching off the electric drive system As soon as you stop pushing the pedals in normal mode...

Страница 114: ...se the display as a handle The display may become irreparably damaged if you use it to lift the pedelec Remove the batteries from the display if the pedelec is not going to be used for several weeks S...

Страница 115: ...Press minus button medium length of time The journey information trip distance TRIP total distance travelled TOTAL range RANGE and support modes used are shown on the display screen 6 18 7 2 Resettin...

Страница 116: ...battery compartment 6 Fasten on board computer onto the handlebars with attachment screw 1 The battery has been changed 6 18 9 Using the USB port W ALK W ALK W ALK W AL W W W W W W A A A A L L LK K K...

Страница 117: ...ond the 3 o clock and 9 o clock position 2 Pedal in the opposite direction to the direction of travel until the desired speed has been reached Crash caused by brake failure Oil or lubricant on the bra...

Страница 118: ...n absorbing a bump green line Threshold The damping threshold prevents deflection until a medium impact or downward force occurs Threshold mode increases drive efficiency over level terrain The thresh...

Страница 119: ...on Place compression adjuster in the OPEN position The compression adjuster is open Place compression adjuster in the LOCK position The compression adjuster is locked Position compression adjuster bet...

Страница 120: ...s This makes it easier to switch gears and reduces wear on the drivetrain However keep the crank moving while switching gears Figure 134 Switching gears with lever A using gear shift SL M315 as an exa...

Страница 121: ...s Switching down several gears to a low gear may cause the twist grip outer sleeve to suddenly come off This will not have an adverse effect on the twist grip s correct functioning since the outer gui...

Страница 122: ...and then switches through all gears during the first ride The new gear is shown briefly on the on board computer each time it is changed Since the motor detects the gear shift and consequently reduces...

Страница 123: ...h open stem clamping lever Notice Heat or direct sunlight can cause the tyre pressure to increase above the permitted maximum pressure This can destroy the tyres Never park the pedelec in the sun On h...

Страница 124: ...ull handlebars into highest possible position Figure 138 All Up pulled into highest possible position 3 Turn handlebars 90 in a clockwise direction Figure 139 All Up screwed in 4 Place handlebars at r...

Страница 125: ...2 1 Clean brake see Section 7 2 5 Clean suspension fork see Section 7 2 2 Care for suspension fork see Section 3 Clean suspension seat post see Section 7 2 6 Clean rear frame damper see Section 7 2 7...

Страница 126: ...Section 7 3 7 1 Care for leather handles see Section 7 4 8 2 Clean the leather saddle see Section 7 3 9 1 Care for leather saddle see Section 7 4 10 Clean handlebars see Section 7 3 6 Cleaning the mot...

Страница 127: ...1 Care for handlebars see Section 7 4 7 Check handlebars see Section 7 5 5 Check light see Section 7 5 3 Care for hub see Section 7 4 11 Check hub gear see Section 7 5 9 2 Check nipple holes see Secti...

Страница 128: ...high pressures Damaged brakes can fail and cause an accident with injury Never clean the pedelec with a pressure washer or compressed air Take great care when using a hosepipe Never point the water j...

Страница 129: ...from service Contact specialist dealer 7 1 5 Checking the pannier rack 1 Hold onto pedelec by its frame Hold onto pannier rack with the other hand 2 Move the pannier rack backwards and forwards to che...

Страница 130: ...ed check the position of the cover on the USB port on a regular basis and adjust if necessary 7 1 13 Checking the lighting 1 Switch light on 2 Check that the front and rear lights come on If the front...

Страница 131: ...r leaking oil 2 Lubricate the dust seals and stanchions with a few drops of silicone spray 3 Care for the suspension fork after cleaning 7 2 3 Caring for the suspension fork Treat dust seals with fork...

Страница 132: ...side with a soft damp cloth Tool Cleaning agent Gloves Toothbrush Water Lubricant Cloth Paintbrush Dish washing liquid Brake cleaner Sponge Watering can Degreaser Leather cleaner Brushes Bucket Table...

Страница 133: ...g can 7 3 7 Handles 1 Clean handles with sponge water and soapy water 2 Rinse off component with water from a watering can 3 Care for rubber handles after cleaning see Section 7 4 8 7 3 7 1 Leather ha...

Страница 134: ...e 3 Rinse off component with water from a watering can 4 Care for spoke nipples after cleaning see Section 7 4 12 7 3 12 Hub 1 Put on protective gloves 2 Remove dirt from hub with a sponge and soapy w...

Страница 135: ...y slight pressure while slowly turning the rear wheel so the chain passes through the cloth 4 Wipe off oily dirty chains thoroughly with a cloth and degreaser 5 Care for chain after cleaning see Secti...

Страница 136: ...idue with a cloth 7 4 2 Fork 1 Dry frame with a cloth 2 Spray care oil on frame and leave to dry 3 Wipe away any wax residue with a cloth Tool Cleaning agent Cloth Toothbrush Frame wax spray Silicone...

Страница 137: ...m 1 Spray painted and polished metal surfaces with wax spray and leave to dry 2 Wipe away any wax residue with a cloth 3 Apply silicone or Teflon oil to the stem shaft tube and the quick release lever...

Страница 138: ...eep leather smooth and resistant brighten its appearance and improve or replace stain protection 1 Try leather care product out on a less visible spot before use 2 Care for leather saddle from below w...

Страница 139: ...pply a wafer thin thread of oil to the chain links The faster the crank is turned the thinner the threads of oil will be Figure 141 Lubricating the chain 4 Remove excessive chain oil with a cloth If y...

Страница 140: ...or precision mechanics oil 7 4 18 Lubricating the eightpins seat post tube Use a 2 5 ml syringe to carefully fill eightpins Fluid V3 very slowly into the lubricating nipple on the outer tube Figure 14...

Страница 141: ...se pressure on a continuous basis since the air pressures in a pedelec tyre are significantly higher and the wall thicknesses significantly finer than in a car tyre Pressure loss of 1 bar per month ca...

Страница 142: ...easy bicycle pumps are unsuitable for filling tyres via a Schrader valve 1 Unscrew and remove the valve cap 1 Undo the rim nuts 2 Attach the bicycle pump 3 Pump up the tyre slowly and pay attention to...

Страница 143: ...re visible Since resistance to punctures also depends on the thickness of the tread it may make sense to change the tyre at an earlier stage Figure 144 Tyre without tread which can still be used 1 and...

Страница 144: ...le If there are cracks on the edge of the nipple hole contact your specialist dealer 7 5 1 5 Checking the nipple well The nipple holes can weaken the tyre bed Check to see if cracks are emerging from...

Страница 145: ...5 10 7 Contact your specialist dealer if the pressure point cannot be reached 7 5 2 2 Checking the hydraulic system 1 Push the brake lever and check whether any brake fluid leaks out of the lines conn...

Страница 146: ...e brake lining supporting plates If the transport safety wear gauge fits between the supporting plates the brake linings have not reached their wear limit Contact your specialist dealer if they are wo...

Страница 147: ...here are sharp corners and edges on the back pedal brake Wear gloves 1 Hold and check counter support to ensure it is firmly attached to rear frame down tube Tighten screw into the counter support if...

Страница 148: ...twisted If the brake linings twist the brake lining bracket is defective and must be replaced Contact specialist dealer 5 Check that the brake linings move uniformly and symmetrically towards the rim...

Страница 149: ...alist dealer 2 Switch light on 3 Check that the front and rear lights come on If the front or rear lights do not come on take pedelec out of service Contact specialist dealer 4 Place pedelec 5 m from...

Страница 150: ...wists tilts or can be pushed in one direction or other If the saddle twists tilts or can be pushed in one direction or other adjust the saddle see Section xxx Contact your specialist dealer if the sad...

Страница 151: ...n has been achieved if the chain can be pushed between a maximum of 10 and 15 mm in the middle between the pinion and the toothed wheel The crank must also turn without resistance 7 5 10 Checking the...

Страница 152: ...on the left hand side 3 If the marking and numbers on the shift handle to no longer coincide after the gear shift is adjusted tighten one of the tension adjusters and screw out the other tension adjus...

Страница 153: ...s on the shifter housing There is noticeable play of 2 to 5 mm 1 2 gear when you turn the twist grip Figure 153 Twist grip with adjusting sleeves 1 and play in the gear shift 2 7 5 15 Checking kicksta...

Страница 154: ...aintenance book 8 3 Component specific maintenance tasks High quality components require extra maintenance Maintenance tasks require technical expertise special tools and special lubricants The pedele...

Страница 155: ...ension seat post Maintenance After the first 250 km every 1 500 km after that Suntour suspension seat post Maintenance Every 100 hours or once a year Eightpins suspension seat post Clean wiper 20 hour...

Страница 156: ...ls for hub SHIMANO 11 speed hub Internal oil change and maintenance 1 000 km after start of use then every 2 years or every 2 000 km All other SHIMANO gear hubs Lubricate internal components Once a ye...

Страница 157: ...d and described in the brake operating instructions Injury to the eyes Problems may arise if the settings are not made properly and you may sustain serious injuries as a result Always wear safety glas...

Страница 158: ...for damage corrosion fracture See Rock Shox compo nent maintenance instructions Maintenance as specified by manufacturer Air chamber assembly group damper and spring O K Damage detected New rear frame...

Страница 159: ...oil change as speci fied by manufac turer O K Damage detected New fork as specified in the parts list FOX suspen sion fork optional 6 months Check for damage corrosion fracture Send to FOX O K Damage...

Страница 160: ...e a month Cleaning Section 7 3 12 O K Dirt Cleaning Once a month Care for Section 7 4 11 O K Untreated Treat Hub with cone bearing optional Once a month Cleaning Section 7 3 12 O K Dirt Cleaning Once...

Страница 161: ...ter that Complete clean check fastening and paint protection film lubricate Section 8 6 8 2 O K Loose Tighten screws new paint protection film new seat post as specified in parts list if damaged Sunto...

Страница 162: ...e Retighten screws Brake fluid 6 months Check fluid level Depending on time of year O K Too little Top up brake fluid take Pedelec out of service if damaged new brake hoses Brake linings 6 months Brak...

Страница 163: ...n board computer 6 months Check for damage Check for damage O K No screen defective screen display Restart test battery new software or new on board computer decommissioning Electric drive control pan...

Страница 164: ...onal 6 months Attachment Check mount fastening O K Loose Retighten screws Components Fre quency Description Criteria Measures if rejected Components Description Criteria Measures if rejected Assembly...

Страница 165: ...ks and breaks Replace damaged pannier racks If the paint protection film is missing or has worn away affix a new paint protection film 8 5 3 Servicing axle with quick release 1 Undo quick release 2 Fa...

Страница 166: ...m may no longer be firmly fixed in its position as a result This will cause a crash with injuries Check the handlebars and the stem s quick release are firmly in position 8 5 5 Servicing the gear hub...

Страница 167: ...intwork remove the pedelec from service New fork as specified in the parts list 3 Clean inside and exterior 4 Grease fork 5 Install fork Injury due to explosion The air chamber is pressurised If the a...

Страница 168: ...e from impact There may be damage to the laminate beneath the paintwork in the case of impact damage The fork may break even under light stress Take pedelec out of service New fork as specified in the...

Страница 169: ...ass to see if fibres are permanently damaged Damage to paintwork 1 Gently sand paintwork damage with 600 grit sandpaper 2 Smooth edges 3 Apply one or two coats of repair paint Damage from impact There...

Страница 170: ...move safety and protective cover 3 Examine seat post rack for scratches cracks and breaks Replaced damaged seat post as specified in the parts list If the paint protection film is missing or has worn...

Страница 171: ...emove outer sleeve from the seat post remote control Figure 159 Removing the cartridge 4 Use a 5 mm to undo Postpin axle and pull out Figure 160 Undoing the Postpin axle 5 Pull cartridge from the pist...

Страница 172: ...Pull slide bushing tube out of the seat tube Figure 165 Removing the outer sleeve and slide bushing Caring for the outer sleeve 1 Detach spring washer or outer sealing ring Figure 166 Removed spring w...

Страница 173: ...nserting and fastening the wiper Cleaning the slide bushing 1 Clean the slide bushing tube with a damp cloth Figure 172 Cleaning the slide bushing tube Increasing the air pressure 1 Use 3 mm hex spann...

Страница 174: ...interface against twisting with a 24 mm open end spanner Figure 178 Securing against twisting 3 Set the torque to 18 Nm with a torque wrench and a 6 mm hex bit with a shaft length of at least 25 mm Ro...

Страница 175: ...rect Bowden cable 4 Carefully push cartridge into the seat tube Pull the Bowden cable out of the frame to help Figure 185 Fastening the cartridge valve lid 5 Look at the frame interface through the ho...

Страница 176: ...nting hole in the outer sleeve Turn outer sleeve into the right position Figure 190 Fastening the outer sleeve 14 Feed height adjustment clamp into the seat tube The two height adjustment clamp guides...

Страница 177: ...97 Removing the seat post 3 Pull out the special end cap for the outer sleeve from the bracket 4 Detach the Bowden cable head from the hydraulic activation lever bracket 5 If necessary operate the lev...

Страница 178: ...sleeve with a cloth Figure 204 Cleaning the outer sleeve 10 Carefully re insert dry felt ring with one end in the designated groove 11 Unfurl felt ring within the outer sleeve so that it lies on the...

Страница 179: ...our hand until it will go no further Figure 209 Pulling the seat post out 3 Clean the seat post longitudinal grooves with a damp cloth Figure 210 Cleaning the longitudinal groove 4 Apply grease into t...

Страница 180: ...ome damaged Figure 215 Attaching and pushing in the seat post 4 Hold the Bowden cable firmly on the handlebars while feeding it in Carefully pull the end of the Bowden cable from the frame so that the...

Страница 181: ...tion in germ cells Always wear safety goggles and nitrile gloves when carrying suspension oil Never perform maintenance when you are pregnant Use an oil catchment tray under the section where the rear...

Страница 182: ...n forks rear frame dampers and suspension seat posts Maintenance includes a complete inspection of interiors exteriors All dampers are reconditioned The airtight seals are replaced in air suspension f...

Страница 183: ...level indicator light up but the drive system does not start up remove the battery 3 Insert the battery 4 Start the drive system 5 If the drive system won t start remove the battery 6 Clean all the c...

Страница 184: ...load for a long time 1 Switch off the drive system 2 Leave pedelec to cool down 3 Start the drive system The assisted journey distance is too short Is the battery fully charged 1 Check charge level 2...

Страница 185: ...arging when the charger is connected The battery may be at the end of its useful life Replace old battery with new one The battery and charger become hot Has the battery or charger temperature exceede...

Страница 186: ...been disconnected 2 Contact your specialist dealer if this is not the case A component may be connected which the system is unable to recognise Contact your specialist dealer The gear level is not sho...

Страница 187: ...used 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 switchin...

Страница 188: ...new components 9 2 2 Replacing the lighting Only use components of the respective power class for replacement 9 2 3 Setting the front light The front light must be set so that its light beam shines on...

Страница 189: ...ay be available depending on the region Store the individual parts of the decommissioned pedelec in a dry place free from frost where they are protected from direct sunlight 10 1 Removal of waste guid...

Страница 190: ...Hydraulic fluid Brake fluid Never mix different oil fluids Store in original container Small quantities usually 30 kg Take to municipal collection points for hazardous waste e g mobile toxic waste col...

Страница 191: ...ing 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...

Страница 192: ...d measurement O K Pedelec travelling 10 too fast slow Take pedelec out of service until the source of the error is found Cabling Visual inspection O K Failure in system damage kinked cables New cablin...

Страница 193: ...e Retighten screws Saddle 6 months Check mount fastening O K Loose Retighten screws Seat post 6 months Check mount fastening O K Loose Retighten screws Guard 6 months Check mount fastening O K Loose R...

Страница 194: ...s list replace if necessary Front lamp 6 months Side light daytime riding light Functional check O K No constant light New front light as specified in parts list replace if necessary Reflectors 6 mont...

Страница 195: ...ufacturer new motor take out of service Software 6 months Check version In latest version Not latest version Import update Components Frequency Description Criteria Measures if rejected Components Des...

Страница 196: ...MY22P01 22_1 0_22 08 2021 195 Notes...

Страница 197: ...io RD M3100 SGS 9 gear Shifter SHIMANO Alivio SL M3100 Shifter Shift motor Cassette cassette sprocket SHIMANO CS HG200 11 36T Chain KMC X9E Belt Front brake TEKTRO HD T280 Hydraulic disc brake Rear br...

Страница 198: ...mation not available when document was produced Stand Motor BOSCH Active Line Plus 250 W 50 Nm Battery 1 BOSCH PowerTube 400 Horizontal 400 Wh or battery 2 BOSCH PowerTube 500 Horizontal 500 Wh On boa...

Страница 199: ...shift lever Shift motor Cassette cassette sprocket SHIMANO SM 7R45N 18T Chain KMC Z1EHX Narrow Belt Front brake Magura HS 11 Hydraulic rim brake Rear brake Magura HS 11 Hydraulic rim brake Brake lever...

Страница 200: ...not available when document was produced Motor BOSCH Active Line Plus 250 W 40 Nm Battery 1 BOSCH PowerPack 400 Pannier rack battery 400 Wh or battery 2 BOSCH PowerPack 500 Pannier rack battery 500 Wh...

Страница 201: ...ft motor Cassette cassette sprocket SHIMANO SM 7C25 18T Chain KMC Z1EHX Narrow Belt Front brake Magura HS 11 Hydraulic rim brake Rear brake Magura HS 11 Hydraulic rim brake Brake lever front rear Magu...

Страница 202: ...rmation not available when document was produced Motor BOSCH Active Line Plus 250 W 40 Nm Battery 1 BOSCH PowerPack 400 Frame battery 400 Wh or battery 2 BOSCH PowerPack 500 Frame battery 500 Wh On bo...

Страница 203: ...ette sprocket SHIMANO CS HG31 8 11 34T Chain KMC X8 Belt Front brake Tektro HD T280 Hydraulic disc brake Rear brake Tektro HD T280 Hydraulic disc brake Brake lever front rear Tektro HD T280 Disc front...

Страница 204: ...s not available Information not available when document was produced Battery 1 BOSCH PowerPack 400 Frame battery 400 Wh or battery 2 BOSCH PowerPack 500 Frame battery 500 Wh On board computer BOSCH Pu...

Страница 205: ...MY22P01 22_1 0_22 08 2021 204 Documents 11 4 Charger operating instructions 0123435678 9 78 7 3951 8 ABC D ABC D ABC...

Страница 206: ...2 15A Output 36V 6A Made in Vietnam 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 B...

Страница 207: ...MY22P01 22_1 0_22 08 2021 206 Documents D Compact Charger A G A C EBE D F...

Страница 208: ...MY22P01 22_1 0_22 08 2021 207 Documents D EBE D F A G A C...

Страница 209: ...MY22P01 22_1 0_22 08 2021 208 Documents D A G A C EBE D F...

Страница 210: ...MY22P01 22_1 0_22 08 2021 209 Documents D EBE D F A G A C...

Страница 211: ...C 0 C H G M G N G C 0 G N N G G G C 0 0 G G G M G G G G C C 0 0 C 0 0 C 0 C G N G C 0 0 0 0 0 G G G G G G C C C C C 0 0 0 0 C G M G N C C 0 0 C 0 K G G G N G G L G G G G V S Pk G A CBU G L 0 7 G N G G...

Страница 212: ...J G N G G G G B G L N G C 0 C G G NN N G G A OG M G L N G 0 C 0 C M M G G G G N G G G G C 0 G C G G NN B G N G G M M G G L P N G N G G G G G G 0 0 0 0 C C C 0 N G M G N G G G OG M G L N G N N A M G G...

Страница 213: ...NN 5 H N G G G G M N G G G G N G L M G N G G N G N G M N N G G G G N M G G N G N G G G N D 0 0 0 0 A N C B G G A C H G N G G G G G G H G G G G G G G G G G 5 C C B G G C B G BG A B N G M G N BG G M G G...

Страница 214: ...eamless ring belt which is used as a means of transmitting drive force Electrical control system Source EN 15194 2017 electronic and or electrical component or an assembly of components provided for i...

Страница 215: ...recommended by the tyre or rim manufacturer for a safe and efficient performance If the rim and tyre both indicate a maximum tyre pressure the maximum inflation pressure is the lower of the two press...

Страница 216: ...erial number Source ZEG each pedelec has an eight digit type number which is used to specify the design model year the type and the version Shut off speed Source EN 15194 2017 speed reached by the ped...

Страница 217: ...year in which the pedelec was manufactured The production period is always from August to July of the following year 12 1 Abbreviations ABS anti blocking system ECP electronic cell protection 12 2 Si...

Страница 218: ...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...

Страница 219: ...MY22P01 22_1 0_22 08 2021 218 Appendix II Declaration of conformity for incomplete machine...

Страница 220: ...MY22P01 22_1 0_22 08 2021 219 Appendix...

Страница 221: ...MY22P01 22_1 0_22 08 2021 220 Appendix...

Страница 222: ...peration 56 carrying out 56 preparing 56 Button Minus 44 101 113 On Off battery 40 41 On Off display 44 101 113 Plus 44 101 113 Push assist 44 101 113 C Carbon seat post caring for 137 Cassette cleani...

Страница 223: ...ry remove 113 removing 108 109 110 Pannier rack caring for 136 changing 107 cleaning 132 using 106 Patent seat post 37 Pedal 36 38 caring for 138 cleaning 130 Pedelec shipping 55 transporting 55 Plus...

Страница 224: ...MY22P01 22_1 0_22 08 2021 3 Keyword index Vehicle Technical data 50 W Weight Shipping weight 54 Weight 54 Wheel 31 installing 63 66 Winter break see Break in ope ration...

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