"user manual"
Contents
1. Product Features C1 Battery charger C2 Charger socket C3 Plug in connector C5 Charge connector 0 276 001 SPUen 23 4 14 Bosch eBike Systems English 9 On Product Warning Labels eBike Battery Charger 36 4 100 230 AWARNING For safe operation see manual Risk of electric shock Dry location use only Charge only batteries of 0275007 906 the Bosch eBike Systems Other batteries may burst causing personal damage Do not replace the plug assembly as risk of fire or electric shock may result Input 100V 230V 50 60Hz 2 2A Output 36V AA APRECAUCION Para un funcionamiento con seguridad ver el manual Peligro de sacudida el ctrica Utilice solamente en lugares secos Cargar nicamente bater as de sistemas eBike de Bosch Made in PRC Otras bater as podr an reventar causando lesiones personales y da os No reemplace el ensamblaje del enchufe Robert Bosch GmbH Reutlingen ya que el resultado puede ser riesgo de incendio o sacudidas el ctricas AATTENTION Pour un fonctionnement s r reportez vous au manuel Risque de choc lectrique Utiliser en lieu sec E uniquement A utiliser uniquement avec les batteries des systemes d assistance lectrique ah o eBike de Bosch D autres batteries risqueraient d clater et de causer des blessures corporelles et des dommages a Ne pas remplacer la connectique car un risque d incendie ou de choc lectrique pourrait en r sulter Avoid Serious Injury or Death2. Remove battery when using vehicle bike rack e Remove battery before performing bike inspection repair DANGER Explosion T e Do NOT expose above 140 F 60 C EZ a e Do NOT crush or puncture A Safety warnings charger B Safety warnings PowerPack Bosch eBike Systems 0 276 001 SPUen 23 4 14 English 10 Operating your Bosch Drive System Getting Ready to Ride gt Read and understand all safety warnings and in structions Failure to follow the warnings below could result in death or serious injury Protect others from death or serious injury Prevent unauthorized use Always remove display unit or bat tery from the bicycle when not in use and store in a se cure location Failure to secure your bicycle from unau thorized use can result in death or serious injury to others Before your first ride Check your bicycle owner s manual for important informa tion about the bike components such as brakes pedals gears shifting equipment etc 44 WARNING gt While riding do not become distracted by the dis play unit and always remain alert to all riding condi tions The display unit should only be used in a station ary and safe start up position Use the operating unit to change motor assistance levels while riding Check your bicycle manual for the maximum riding weight of your bicycle Overloading your bicycle can result in component failure which can result in death or
3. 0 276 001 SPUen 23 4 14 Bosch eBike Systems English 3 Introduction Thank You for Purchasing a Bosch Drive System Equipped Bicycle Your Bosch eBike system team appreciates having you as a customer and wishes you many years of safe and satisfied use of your bicycle General Warnings Read all safety warnings and all instructions Re Failure to follow the warnings and instructions may result in death or serious injury Save all safety warnings and instructions for future ref erence The term battery pack used in these operating instruc tions refers both to standard battery packs battery packs with holder on the bike frame and to rack type battery packs battery packs with holder in the rear rack carrier About Warnings This manual contains many DANGER WARNING and CAUTION indicators concerning the consequences of failing to use assemble maintain store inspect and dis pose of a Bosch equipped eBike in a safe manner The combination of the safety alert symbol and the word DANGER indicates a hazardous situation that if not avoided will result in death or serious injury The combination of the safety alert symbol and the word WARNING indicates a hazardous situation that if not avoided could result in death or serious injury The combination of the safety alert symbol and the word CAUTION indicates a hazardous situation that if not avoided could result in minor or
4. 550 Remove the load Restart the system If the problem persists An improper load was detected contact your Bosch eBike dealer 602 Internal battery pack error while charging Unplug the charger from the battery pack Restart the eBike system Plug the charger into the battery pack If the problem persists contact your Bosch eBike dealer 602 Internal battery pack error Restart the system If the problem persists contact your Bosch eBike dealer 603 Internal battery pack error Restart the system If the problem persists contact your Bosch eBike dealer 605 Battery pack temperature error The eBike is outside of the permissible temperature range Switch off the eBike system and allow the drive unit to either cool down or heat up to the permissible temperature Restart the system If the problem persists contact your Bosch eBike dealer 605 Battery pack temperature error while Unplug the charger from the battery pack Allow the battery pack to charging cool If the problem persists contact your Bosch eBike dealer 606 External battery pack error Check the wiring Restart the system Ifthe problem persists contact your Bosch eBike dealer 610 Battery pack voltage error Restart the system Ifthe problem persists contact your Bosch eBike dealer 620 Charging error Replace the charger Contact your Bosch eBike dealer 640 Internal battery pack error Restart the system If the problem persists contact your
5. Performance Line Robert Bosch GmbH Bosch eBike Systems 72703 Reutlingen Germany www bosch ebike com 0 276 001 SPUen 2014 04 T 34 Performance Line Owner s Manual The Bosch Drive System Drive Unit Intuvia PowerPack Charger 0 275 007 025 1 270020 909 0 275 007 524 525 0 275 007 906 en Original instructions This manual contains important safety performance and service information Read and understand it along with the information provided to you by your bicycle manufacturer before using the product and keep it for reference BOSCH Age 16 English 2 Introduction nd 3 General Warnings oooooooomoooo 3 Using your Operator s Manual 3 Bosch Drive System OvervieW ooooooooomooo 4 Bicycle Views ooooooooooocoooooooo 4 Component ViewS oooooooooooooooooo 6 On Product Warning Labels ooooooo o 9 Operating your Bosch Drive System 10 Getting Ready to Ride 10 Safe Start Up Procedure ooooooo o 10 Operation len 11 Maintenance Cleaning 15 A ne 16 Bosch Drive System Components ooooooo o 17 Drive Unit Display Unit Intuvia 17 Lithium lon Battery Pack PowerPack 21 Charger sa ne 26 Troubleshooting 2 a en 30 Battery Recycling Program oo oooooooooo 33
6. If no power is drawn from the drive unit for about 10 minutes e g because the eBike is not moving the eBike system will shut down automatically to save energy Power Supply for External Devices via USB Connection With the USB connection it is possible to operate and charge most devices whose power supply is possible via a USB port e g various mobile phones A prerequisite for the charging is that the display unit anda sufficiently charged battery pack are inserted in the eBike Open the protective cap 8 for the USB port on the display unit Connect the USB port of the external device to the USB socket 7 on the display unit using a standard compli ant Micro A Micro B USB 2 0 cable Using a USB cable that is not standard compliant or a cable adapter combination can lead to damage to the display unit 0 276 001 SPUen 23 4 14 Bosch eBike Systems Lithium lon Battery Pack PowerPack Read and understand all safety warn A Lui ings and instructions Failure to follow the warnings below could result in death or serious injury Save all safety warnings and instructions for future ref erence The term battery pack used in these operating instruc tions refers both to standard battery packs battery packs with holder on the bike frame and to rack type battery packs battery packs with holder in the rear rack carrier except when explicitly referring to the design type 4 DANGER Do not puncture
7. Maintenance Cleaning AWARNING gt Your Bosch Drive System components are mainte nance free Do not open any of the components Ser vice should only be carried out at an authorized Bosch eBike dealer Failure to follow the above warning may result in death or serious injury Refer to your bicycle manual or component manual for all non Bosch Drive System components gt Always remove the battery pack before performing any bicycle inspection maintenance or repair Fail ure to remove the battery pack before performing bicy cle inspection maintenance or repair can lead to seri Ous injury gt If you suspect that something is loose do not ride your bike See your Bosch eBike dealer only a qualified service provider should perform work on your Bosch Drive System All nuts bolts screws require the correct tightening force Too little force and the fastener may not hold securely Too much force and the fastener can stretch deform or break or the threads can be stripped Either way incorrect tightening force can re sult in component failure which can cause you to lose control and fall gt If replacing your battery only buy a genuine Bosch battery pack from an approved source See your Bosch eBike dealer for original Bosch parts gt Always switch the battery pack off when inserting or removing it from the holder Never attempt to insert or remove the battery pack while riding the bike gt Do not charge or use your eBike
8. To do this press the On Off button A4 to switch on the bat tery pack If no LED for the charge control indicator A3 lights up then the battery pack may be damaged When at least one of the LEDs but not all for the charge control indicator A3 is lit then fully charge the battery pack before using it for the first time gt Do not attempt to charge or use a damaged battery pack Please contact an authorized Bosch eBike dealer English 23 Charging the Battery Pack gt Only use the Bosch charger provided with your eBike or an identical original Bosch charger Only this char ger is matched to the lithium ion battery pack used in your eBike Notice The battery pack is supplied partially charged To ensure full battery pack capacity completely charge the battery pack in the charger before using it for the first time To charge the battery pack read and follow the operating instructions for the charger The battery pack can be recharged at any time on its own or on the bike without shortening the its service life Interrupt ing the charging process does not damage the battery pack The battery pack is equipped with a temperature control in dicator which enables charging only within a temperature range between 32 F and 104 F au pee ran When the battery pack is not within the ROKI K charging temperature range three LEDs of the charge control indicator A3 flash Disconnect the battery pack from the charger
9. battery pack used in these operating instruc tions refers both to standard battery packs battery packs with holder on the bike frame and to rack type battery packs battery packs with holder in the rear rack carrier gt Do not open the drive unit yourself The drive unit is maintenance free and must be repaired only by qual ified experts and only with original replacement parts This will ensure that the safety of the drive unit is maintained Unauthorized opening of the drive unit will void warranty claims gt All components attached to the drive unit and all oth er components of the eBike drive e g the chain wheel chainwheel seat pedals may be replaced on ly with identical components or components specifically approved for your eBike by the bicycle manufacturer This protects the drive unit against over load and damage gt Remove the battery pack from the eBike before be ginning work e g inspection repair assembly maintenance work on the chain etc on the eBike transporting it by car or plane or storing it Uninten tional activation of the eBike system poses a risk of injury gt Use only original Bosch battery packs approved for your eBike by the manufacturer Using other battery packs can lead to injuries and pose a fire hazard When using other battery packs the warranty is void and Bosch shall not assume any liability gt Donot make any modifications to your eBike system or at
10. Bosch eBike dealer 655 Multiple battery pack errors Switch off the eBike system Remove the battery pack and reinsert it Restart the system If the problem persists contact your Bosch eBike dealer 656 Software version error Contact your Bosch eBike dealer so that he can perform a software update No Internal error in the display unit Restart your eBike system by switching it off and back on display Bosch eBike Systems 0 276 001 SPUen 23 4 14 English 32 PowerPack Cause Corrective Action Two LEDs of the battery pack flashing Contact your Bosch eBike dealer Three LEDs of the battery pack flashing Battery pack too warm or too cold Disconnect the battery from the charger until the charging temperature range has been reached Do not connect the battery pack to the charger until it has reached the permissible charging temperature No charging procedure possible no indication on the battery pack Plug not inserted correctly Check all plug connections Contacts of battery pack dirty Carefully clean the battery pack contacts using a damp cloth Socket outlet cable or charger defective Check household voltage have charger checked through bicycle dealer Battery pack defective Contact your Bosch eBike dealer 0 276 001 SPUen 23 4 14 Bosch eBike Systems English 33 Battery Recycling Program General Warnings Disposal The drive unit display unit incl the
11. ONDE Oo 14 66999 l Display function button Light button Display unitIntuvia Holder for display unitIntuvia On Off button RESET button USB port Protective cap for USB port Drive unit Operating unit Display function button i on the operating unit Reduce assistance scroll down button Increase assistance scroll up button Push assistance button WALK 66999 l Not executable in some countries Display Unit Information a Drive unit assistance indicator b Assistance level indicator c Light indicator d Text indicator e Value indicator f Speed indicator g Battery charge control indicator 0 276 001 SPUen 23 4 14 Bosch eBike Systems English 7 Component View Battery Pack PowerPack Product Features Allrepresentations of bike components with the exception of the battery packs and their holders are schematic and can deviate from your eBike A1 Holder for the rack type battery pack A2 Rack type battery pack A3 Operation and charge control indicator A4 On Off button A5 Key for the battery pack lock A6 Battery pack lock A7 Upper holder for the standard battery pack A8 Standard battery pack A9 Bottom holder for the standard battery pack C1 Battery charger C6 Socket for charge connector C7 Charge socket cover Bosch eBike Systems 0 276 001 SPUen 23 4 14 English 8 Component View Charger
12. in any area with a po tentially explosive atmosphere such as at a fueling area or in areas where the air contains chemicals or particles such as grain dust or metal powders Obey all signs and follow all instructions gt Do not submerge your drive unit in water or wash with a pressurized hose Your Bosch drive unit is de signed to be water tight to rain water and non pressur ized hose washing gt Note down the manufacturer and the number of the key In case the keys are lost please contact an autho rized Bosch eBike dealer Please provide the name of the manufacturer and the number of the key gt Do not paint any components of the Bosch Drive Sys tem as this may cause premature failure of the com ponents English 15 Careful Handling of the eBike Please observe the operating and storage temperatures for the eBike components Protect the drive unit display unit and battery pack against extreme temperatures e g from intense sunlight without adequate ventilation The compo nents especially the battery pack can become damaged because of extreme temperatures After Sale Service and Customer Assistance In case of questions concerning the eBike system and its components please contact an authorized Bosch eBike dealer Contact data for authorized Bosch eBike dealers can be found at www bosch ebike com When the battery pack is no longer operative please con tact an authorized Bosch eBike dealer Cleanin
13. into the holder 4 To remove the display unit 3 press the lock latch 15 and slide the display unit toward the front out of the holder 4 Remove the display unit when you park the eBike Itis possible to secure the display unit against removal in the holder To do so remove the holder 4 from the handle bars Put the display unit in the holder Screw the locking screw 16 thread M3 8 mm long from below into the thread provided in the holder Attach the holder back onto the handlebars Bosch eBike Systems 0 276 001 SPUen 23 4 14 English 20 Checking the Speed Sensor 17 17 Speed sensor 18 Spoke magnet for the speed sensor The speed sensor 17 and its spoke magnet 18 must be at tached in such a way that the spoke magnet after a turn of the wheel moves past the speed sensor with a clearance of at least 5 mm yet no more than 17 mm Notice If the clearance between the speed sensor 17 and the spoke magnet 18 is too small or too large or if the speed sensor 17 is not properly connected the speed indi cator f will fail and the eBike drive unit will operate in the emergency mode In this case loosen the screw for the spoke magnet 18 and fasten the spoke magnet to the spoke in such a way that it runs past the mark of the speed sensor at the correct clear ance If the speed is still not being indicated on the speed indicator f after this is done please contact an authorized Bosch eBike deal
14. persists contact your Bosch eBike dealer 450 Internal software error Restart the system If the problem persists contact your Bosch eBike dealer 490 Internal error in the display unit Have the display unit checked 500 Internal error in the drive unit Restart the system If the problem persists contact your Bosch eBike dealer 502 Illumination error Check the light and the associated wiring Restartthe system Ifthe problem persists contact your Bosch eBike dealer 503 Error of the speed sensor Restart the system If the problem persists contact your Bosch eBike dealer 510 Internal sensor error Restart the system If the problem persists contact your Bosch eBike dealer 511 Internal error in the drive unit Restart the system If the problem persists contact your Bosch eBike dealer 530 Battery pack error Switch off the eBike remove the battery pack and reinsert the battery pack Restart the system If the problem persists contact your Bosch eBike dealer 531 Configuration error Restart the system If the problem persists contact your Bosch eBike dealer 0 276 001 SPUen 23 4 14 Bosch eBike Systems English 31 Code Cause Corrective Action 540 Temperature error The eBike is outside of the permissible temperature range Switch offthe eBike system and allow the drive unit to either cool down or heat up to the permissible temperature Restart the system If the problem persists contact your Bosch eBike dealer
15. serious injury Typically the maximum riding weight is defined by the sum of the rider s weight plus the weight of any luggage Intended Use 44 WARNING gt Understand your bike and its intended use by check ing your bicycle owner s manual Using your bike the wrong way and for a purpose for which it was not de signed can result in death or serious injury The Bosch Drive System components are intended exclu sively for your eBike and may not be used for other pur poses Your Bosch Drive unit is not intended for towing another bi cycle Fortrailertowing check your bicycle owner s manual and the trailer owner s manual for towing instructions and towing compatibility Safe Start Up Procedure Follow the safe start up procedure below Failure to follow the safe start up procedure can result in death or serious injury Preparations Before starting check the following Check that you have unplugged the battery charger Your battery pack is locked in place pull on the battery pack to ensure it is locked in place Remove the battery pack key Start Riding Sitin the saddle with both feet touching the ground and two hands on the handlebars Once you are in a stable position turn the Bosch Display Unit on The Bosch Drive System will always start up in the OFF mode Place both hands on the handlebars and begin pedaling 0 276 001 SPUen 23 4 14 Bosch eBike Systems Operation Initi
16. then liquid may be ejected from the battery pack Avoid contact If contact accidentally occurs flush with water If liquid contacts eyes ad ditionally seek medical help Liquid ejected from the battery pack may cause skin irritations or burns gt Battery packs must not be subjected to mechanical impacts There is a risk that the battery pack will be damaged causing vapors to escape The vapors can irri tate the respiratory system Provide for fresh air and seek medical attention in case of complaints gt Charge the battery pack only with original Bosch battery chargers When using non original Bosch char gers the risk of fire cannot be excluded gt Use the battery pack only together with eBikes that have an original Bosch eBike drive system This is the only way to protect the battery pack against dangerous overload gt Use only original Bosch battery packs approved for your eBike by the manufacturer Using other battery packs can lead to injuries and pose a fire hazard When using other battery packs the warranty is void and Bosch shall not assume any liability gt Please read and observe the safety warnings and in structions enclosed in the operating instructions for the charger and the drive unit display unit as well as in the operating instructions for your eBike gt Keep the battery pack out of reach of children Bosch eBike Systems 0 276 001 SPUen 23 4 14 English 22 Product Description and Speci
17. to lifting Avoid injury use proper lifting techniques Using Your Operator s Manual Graphics The bicycle shown in this manual may differ slightly from your bicycle but will be similar enough to help you under stand our instructions RIGHT HAND and LEFT HAND sides are determined by fac ing in the direction the bicycle will travel when going for ward When you see a broken line the item referred to is hidden from view Bosch eBike Systems 0 276 001 SPUen 23 4 14 English 4 Bosch Drive System Overview Bicycle View Standard 10 Bosch Drive System Components Allrepresentations of bike components with the exception of the eBike components are schematic and can deviate from your eBike 3 Display unitIntuvia 9 Drive unit 10 Operating unit A8 Standard battery pack PowerPack C1 Battery charger 0 276 001 SPUen 23 4 14 Bosch eBike Systems Bicycle View Rack Type English 5 Bosch Drive System Components All representations of bike components with the exception of the eBike components are schematic and can deviate from your eBike 3 Display unitIntuvia 9 Drive unit 10 Operating unit A2 Rack type battery pack PowerPack Bosch eBike Systems 0 276 001 SPUen 23 4 14 English 6 Component View Display Unit Operating Unit Drive Unit Product Features SOON OO PP ODM m m e a
18. 3 4 14 English 26 Charger Read and understand all safety warn amp Lu ings and instructions Failure to follow the warnings below could result in death or serious injury Save all safety warnings and instructions for future ref erence The term battery pack used in these operating instruc tions refers both to standard battery packs battery packs with holder on the bike frame and to rack type battery packs battery packs with holder in the rear rack carrier except when explicitly referring to the design type 4 DANGER gt Only charge eBike approved Bosch lithium ion bat tery packs The battery pack voltage must match the battery pack charging voltage of the charger Other wise there is risk of fire and explosion Keep the charger away from rain and moisture The penetration of water into a battery charger in creases the risk of an electric shock AWARNING gt Use only the original Bosch battery charger supplied with your eBike or one approved for your eBike by the manufacturer and purchased from a trusted source Bypassing the battery charger or the use of a non approved or counterfeit battery charger can lead to death or serious injury gt Keep the battery charger clean Contamination can lead to the risk of an electric shock Clean only with the use of adamp cloth mild soap water gt Check the battery charger cable and plug each time before using Do not use the battery charger when defects
19. al Operation Switching the eBike System On Off Options for switching on the eBike system Ifthe display unit is already switched on when inserted into the holder then the eBike system will be switched on automatically When the display unit and the battery pack are inserted briefly press the On Off button 5 of the display unit once When the display unit is inserted press the On Off but ton on the battery pack The motor assistance is activated as soon as you step on the pedals except when in the OFF assistance mode The motor assistance depends upon the settings of the dis play unit As soon as you stop pedaling when in normal operation or as soon as you have reached a speed of 20 mph the assis tance from the eBike drive unit is switched off The motor assistance is automatically re activated as soon you start pedaling again and the speed is below 20 mph Options for switching off the eBike system Press the On Off button 5 of the display unit Switch the battery pack off by using its On Off button see battery pack operating instructions Remove the display unit out of its holder If no power is drawn from the drive unit for about 10 minutes e g because the eBike is not moving the eBike system will shut down automatically to save energy English 11 Indications and Settings of the display unit Switching the display unit On Off To switch on the display un
20. are detected Do not open the battery char ger yourself and have it repaired only by qualified personnel using original spare parts Damaged bat tery chargers cables and plugs increase the risk of elec tric shock gt Donot operate the battery charger on easily flamma ble surfaces e g paper textiles etc or in combus tible environments There is danger of fire due to the heating of the battery charger during charging gt Battery packs must not be subjected to mechanical impacts There is arisk that the battery pack will be damaged causing vapors to escape The vapors can irri tate the respiratory system Provide for fresh air and seek medical attention in case of complaints gt Keep the battery charger away from children This will ensure that children do not play with the charger gt Persons who are not capable of safely operating the charger because of their physical sensory or mental limitations or because of their lack of experience or knowledge may only use this charger under supervi sion or after having been instructed by aresponsible person Otherwise there is a risk of operating errors and injuries gt Please read and follow the safety warnings and in structions enclosed in the operating instructions for the battery pack and drive unit display unit as well as in the operating instructions for your eBike A short version of important safety warnings in English French and Spanish with the foll
21. e charge control indicator A3 lights up recharge the battery pack again to approx 60 Notice When the battery pack is stored discharged emp ty for longer periods it can become damaged despite the low self discharging feature and the battery pack capacity may be strongly reduced It is not recommended to have the battery pack connected permanently to the charger Storage Conditions Store the battery pack in a dry well ventilated location Protect the battery pack against moisture and water Under unfavorable weather conditions it is recommended e g to remove the battery pack from the eBike and store it in an enclosed location until it is used again The battery pack can be stored at temperatures between 14 F and 140 F However storing the battery pack at the optimal temperature of 68 F will provide the longer battery life Make sure that the maximum storage temperature is not ex ceeded As an example store the battery pack out of direct sunlight and do not leave it in a vehicle during the summer Itis recommended to not store the battery pack on the bike 0 276 001 SPUen 23 4 14 Bosch eBike Systems English 17 Bosch Drive System Components Drive Unit Display Unit Intuvia Read and understand all safety warnings and amp instructions Failure to follow the warnings be low could result in death or serious injury Save all safety warnings and instructions for future ref erence The term
22. e drive unit when pedal ing can be adjusted via the operating unit The assistance level can be changed anytime even during riding Bosch eBike Systems 0 276 001 SPUen 23 4 14 English 12 Notice For individual versions it is possible that the assis tance level is preset and cannot be changed It is also pos sible that fewer assistance levels are available for selection than listed here The following assistance levels max are available OFF The motor assistance is switched off the eBike can be operated as a normal bicycle through pedaling ECO Effective assistance at maximum efficiency for maximum cruising range TOUR Uniform assistance for touring with long cruis ing range SPORT Powerful assistance for sporty off road rid ing as well as for urban traffic TURBO Maximum assistance supporting the highest speed for sporty riding To increase the assistance level press the button 13 on the operating unit until the desired assistance level is displayed in indicator b to decrease the assistance level press the button 12 The requested motor output is displayed in indicator a The maximum motor output depends on the selected assis tance level Assistance Level Assistance Factor Derailleur ECO 50 TOUR 120 SPORT 190 TURBO 275 The motor output can vary for individual version
23. e for a battery pack charge The higher the assistance level under otherwise identi cal conditions the shorter the range will be Transport AWARNING gt Always remove the battery pack from the bicycle be fore transporting the bicycle on a vehicle bike rack Failure to remove the battery pack when using a vehicle bike rack can lead to death or serious injury The battery may detach during transport and cause an accident to following vehicles gt Always use an approved and compatible bicycle rack when transporting your eBike The Bosch Drive Sys tem adds weight to the bicycle Refer to your bicycle rack manual to be sure your eBike is compatible Over loading a bike rack can result in death or serious injury gt Use proper lifting techniques because electric bikes are generally heavier than bicycles Ship batteries only when the housings are undamaged Tape or mask off open contacts and pack up the battery in such a way that it cannot move around in the packaging No tify your parcel service that the package contains danger ous goods Please also follow possibly more detailed na tional regulations Always check the state and federal regulations before attempting to ship your battery In case of questions concerning transport of the battery packs please contact an authorized Bosch eBike dealer Bosch eBike dealers can also provide suitable transport packaging 0 276 001 SPUen 23 4 14 Bosch eBike Systems
24. e is in compliance with CAN ICES 3 B NM B 3 B Operation Initial Operation Connecting the Charger to Household Electricity gt Note the household voltage The voltage of the power supply must correspond to the specifications given on the battery charger nameplate Plug the charger plug C3 of the power cord into the charger socket C2 of the charger Connect the power supply cable country specific to the household electricity supply Charging the Removed Battery ail A4 C5 Charge connector C6 Socket for charge connector A2 Rack type battery pack A3 Battery charge control indicator A4 Battery On Off button A8 Standard battery pack Switch the battery pack off and remove it from the holder of the eBike To do this read and follow the operating instruc tions for the battery pack gt Put the battery pack down only on clean surfaces In particular avoid getting the charge socket and the con tacts dirty e g with sand or soil Insert the charger plug C5 for the battery charger into the socket C6 on the battery pack 0 276 001 SPUen 23 4 14 Bosch eBike Systems Charging the Battery on the Bike C7 In particular prevent the charge socket and the con tacts from getting dirty e g with sand or soil Lift the cover of the charge socket C7 and plug the charge connector C5 into the charge socket C6 gt Charge the ba
25. e it with the contacts facing ahead until it engages in the holder A1 of the rear rack carrier gt Always check that the battery pack is locked in place To do this pull on the battery pack handle after the key has been removed Check if the battery pack is tightly seated Always lock the battery pack with lock A6 otherwise the lock can open and the battery pack could fall out of the holder After locking always remove the key A5 from the lock A6 This prevents the key from falling out and the battery pack from being removed by unauthorized persons when the eBike is parked Toremove the standard battery pack A8 switch it off and unlock the lock with the key A5 Tilt the battery pack out of the upper holder A7 and pull it out of the lower holder A9 To remove the rack type battery pack A2 switch it off and unlock the lock with the key A5 Pull the battery pack out of the holder A1 0 276 001 SPUen 23 4 14 Bosch eBike Systems Operation Initial Operation gt Use only original Bosch battery packs approved for your eBike by the manufacturer and purchased from a trusted source Use of non approved or counterfeit battery packs can lead to death or serious injury Switching On and Off Switching the battery pack on is one of the ways of starting the eBike system Read and follow the operating instruc tions for the drive unit and the display unit Before switching on the battery pack or the eBike system check that t
26. e speed achieved since the last reset Max Speed Maximum speed achieved since the last reset Clock Current time Odometer Display of the total distance traveled with the eBike cannot be reset To switch between the indication functions press the button 1 on the display unit or the i button 11 on the op erating unit until the desired function is displayed To reset Distance Trip time and Avg Speed switch to any of the three functions and then press and hold the RESET button 6 until the indicator is set to zero This also resets the values for the other two functions To reset the Max Speed switch to this function and then press and hold the RESET button 6 until the indica tor is set to zero To reset Range switch to this function and then press the RESET 6 button until the display is reset to the value of the factory setting When the diplay unit is removed from the holder 4 all func tion values remain stored and can be viewed cc l 0 276 001 SPUen 23 4 14 Bosch eBike Systems Displaying Adapting Basic Settings The basic settings can be displayed and changed no matter if the diplay unit is in the holder 4 or not To access the basic settings menu press and hold the RESET button 6 and the i button 1 until Configura tion is displayed in text indicator d To switch between the basic settings press
27. er Operation Initial Operation Requirements The eBike system can only be activated when the following requirements are met Asufficiently charged battery pack is inserted see oper ating instructions for the battery pack The display unit is properly inserted in the holder The display unit is properly connected Switching the eBike System On Off Options for switching on the eBike system Ifthe display unit is already switched on when inserted into the holder then the eBike system will be switched on automatically When the display unit and the battery pack are inserted briefly press the On Off button 5 of the display unit once When the display unit is inserted press the On Off but ton on the battery pack The motor assistance is activated as soon as you step on the pedals except when in the OFF assistance mode The motor assistance depends upon the settings of the dis play unit As soon as you stop pedaling when in normal operation or as soon as you have reached a speed of 20 mph the assis tance from the eBike drive unit is switched off The motor assistance is automatically re activated as soon you start pedaling again and the speed is below 20 mph Options for switching off the eBike system Press the On Off button 5 of the display unit Switch the battery pack off by using its On Off button see battery pack operating instructions Remove the display unit out of its holder
28. fications AA LILTL L7L O A3 1 AT A5 BD M A3 N ETA O Product Features All representations of bike components withthe exception A7 Upper holder for the standard battery pack of the battery packs and their holders are schematicand A8 Standard battery pack can deviate from your eBike A9 Bottom holder for the standard battery pack A1 Holder for the rack type battery pack C1 Battery charger A2 Rack type battery pack C6 Socket for charge connector A3 Operation and charge control indicator C7 Charge socket cover A4 On Off button A5 Key for the battery pack lock A6 Battery pack lock 0 276 001 SPUen 23 4 14 Bosch eBike Systems Technical Data Lithium ion battery pack PowerPack 400 Article number Standard battery pack 0275007 524 Rack type battery pack 0275007 525 Rated voltage V 36 Rated capacity Ah 11 Energy Wh 400 Operating temperature uE 23 104 Storage temperature F 14 140 Permitted charging tempera ture range F 32 104 Weight appox lb 5 5 5 7 Degree of protection IP 54 dust and splash water protected Assembly gt Put the battery pack down only on clean surfaces In particular avoid getting the charge socket and the con tacts dirty e g with sand or soil Checking the Battery Pack Before Using for the First Time Check the battery pack before charging it or using it with your eBike for the first time
29. g gt Do not submerge your drive unit in water or wash with a pressurized hose Your Bosch drive unit is de signed to be water tight to rain water and non pressur ized hose washing Keep all components of your eBike clean especially the battery pack contacts and the corresponding holder con tacts All components including the drive unit may not be im mersed in water or cleaned with a high pressure cleaner Keep all components of your eBike clean especially the battery pack contacts and the corresponding holder con tacts Clean them carefully with a soft damp cloth using only mild soap and water Bosch eBike Systems 0 276 001 SPUen 23 4 14 English 16 Storing Notes for Optimum Handling of the Battery Pack The battery pack life can be extended if properly main tained and especially if operated and stored at the right temperatures With increasing age however the battery pack capacity will diminish even if properly maintained A significantly reduced operating period after charging in dicates that the battery pack is worn out and must be re placed You can replace it yourself by purchasing a genuine Bosch PowerPack from an authorized Bosch eBike dealer Recharging the Battery Pack Before and During Storage When not using the battery pack for a longer period charge it to approx 60 3 to 4 LEDs lit on the charge control in dicator A3 Check the charge condition after 6 months When only one LED on th
30. he lock A6 is locked To switch on the battery pack press the On Off button A4 The LEDs for indicator A3 light up and at the same time in dicate the charge condition gt Always check that the battery pack is locked in place To do this pull on the battery pack handle after the key has been removed Notice When the battery pack capacity is below 5 none of the LEDs for charge control indicator A3 will light up On ly the display unit will indicate if the eBike system is switched on To switch off the battery pack press the On Off button A4 again The LEDs for indicator A3 go out This also switches off the eBike system When no power output from the eBike drive unit is request ed for approx 10 minutes e g because the eBike is parked and no button for the drive display unit or operat ing unit is pressed then the eBike system and thus the bat tery pack automatically switches off to save energy The battery pack is protected against deep discharging overcharging overheating and short circuiting by the Electronic Cell Protection ECP In case of hazardous sit uations a protective circuit automatically switches off the battery pack nen gt When a defect in the battery pack is de OLE TET tected two LEDs for the charge control indicator A3 flash In this case please contact an authorized Bosch eBike dealer English 25 Bosch eBike Systems 0 276 001 SPUen 2
31. it briefly press the On Off but ton 5 When the internal battery pack is sufficiently charged the display unit can also be switched on when not inserted in the holder To switch off the display unit press the On Off button 5 When the display unit is not inserted in the holder and no button is pressed it automatically switches off after 1 min to save energy Battery charge control indicator The battery pack charge control indicator g indicates the charge condition of the eBike s battery pack and not the charge condition of the display unit s internal battery The charge condition of the eBike s battery pack can also be read from the battery pack s LEDs On indicator g each bar of the battery pack symbol is equivalent to a capacity of approx 20 in The battery is fully charged T 1 The battery should be recharged h Once there are no remaining LED bars illuminated on the charge control indicator the motor support is gently switched off and the charge control indica tor begins to flash The flashing charge control indi cator means there is only enough battery power re maining to power the eBike lights for approximately 2 more hours This does not account for other con sumers e g automatic gearbox charging external devices at the USB port When the display unit is removed from holder 4 the last in dicated battery pack charge condition is stored Setting the Assistance Level The level of assistance of the eBik
32. l indicator A3 on the battery pack light up Each continuous ly lit LED is equivalent to a charge capacity of approx 20 The flashing LED indicates the charging of the next 20 gt Use caution when touching the charger during the charging procedure Wear protective gloves Espe cially in high ambient temperatures the charger can heat up considerably Once the battery is fully charged the LEDs extinguish im mediately and the display unit is switched off The charging procedure is terminated The charging state can be dis played for 3 seconds by pressing the On Off button A4 Disconnect the charger from the main power supply and the battery pack from the charger When disconnecting the battery pack from the charger the battery pack is automatically switched off Notice If you have charged on the bike carefully close the charge socket C6 with the cover C7 after the charging pro cedure so that no dirt or water can get in If the charger is not disconnected from the battery after charging after a few hours the charger will switch itself back on check the charging state of the battery and begin the charging procedure again if necessary Bosch eBike Systems 0 276 001 SPUen 23 4 14 English 30 Troubleshooting Display unit Intuvia Error Code Indicator The components of the eBike system are continuously and Depending on the type of error the drive unit is automati cally shut off if required Co
33. moderate injury 44 WARNING The Bosch Drive System is intended for use by per sons 16 years of age and older Riders must have the physical coordination reaction and mental capabilities to control a bike and manage traffic road conditions and sudden situations and also to respect the laws and instructions governing bicycle use This manual contains important safety performance and service information Read it before you take the first ride on your new bicycle and keep it for reference The manual can also be found online at www bosch ebike com This manual is intended to be read together with the separate user manual provided with your bicycle Be sure to read all provided documents including labels on the product before your first ride Read ALL accompanying manuals before riding the bike for the first time Your Bosch Drive System comes with additional manuals and documents provided by the manufacturer of the bicycle and other components Fail ure to read and understand safety information can result in death or serious injury Take responsibility for your own SAFETY If you have any questions or do not understand something contact your Bosch eBike dealer or the bicycle or component manufacturer gt Some eBike accessories may present a choking haz ard to small children Keep these accessories away from children 4 CAUTION gt The Bosch Drive System adds weight to your bicycle which you may not be used
34. ntinued travel without assis tance from the drive unit is possible at any time However have the eBike checked before attempting new trips automatically monitored When an error is detected there Troubleshooting actions may be performed by the spective error code is indicated in text indicator d To return to the standard indicator press any button on the display unit or on the operating unit 10 Code Cause 410 owner except those explicitly noted as Contact your Bosch eBike dealer Corrective Action One or more buttons of the display unit are Check if any buttons are blocked e g by dirt or debris Clean the blocked buttons if required 414 Operating unit connection problem Have connections and contacts checked 418 Oneor more buttons of the operating unit Check if any buttons are blocked e g by dirt or debris Clean the are blocked buttons if required 422 Drive unit connection problem Have connections and contacts checked 423 Battery pack connection problem Have connections and contacts checked 424 Communications error amongthe Have connections and contacts checked components 426 Internal time out error Restart the system If the problem persists contact your Bosch eBike dealer 430 Internal battery pack of display unitempty Charge display unit in holder or via USB port 440 Internal error in the drive unit Restart the system If the problem
35. operating unit battery pack speed sensor accessories SN and packaging should be sorted for environmen tally friendly recycling Do not dispose of eBikes and their components with the household waste You may recycle your Bosch battery pack by calling 1 800 822 8837 Bosch eBike Systems 0 276 001 SPUen 23 4 14
36. or crush the battery pack Do sub ject the battery pack to mechanical impacts or modi fy it in any way Do not use the battery pack if it shows visible damage Otherwise there is the risk of afire oran explosion which can cause death or serious injury Protect the battery pack against heat e g tem ar perature gt 140 F fire and immersing into wa ter Otherwise there is the risk of an explosion 44 WARNING Use only original Bosch battery packs approved for your eBike by the manufacturer and purchased from a trusted source Use of non approved or counterfeit battery packs can lead to death or serious injury Remove the battery pack from the eBike before be ginning work e g inspection repair assembly maintenance work on the chain etc on the eBike transporting it by car or plane or storing it Uninten tional activation of the eBike system poses a risk of injury gt Do not open the battery pack There is a risk of a short circuit Opening the battery pack voids any and all war ranty claims English 21 gt If itis not being used keep the battery pack away from paper clips coins keys nails screws or other small metal objects that can make a connection from one terminal to another Shorting the battery pack ter minals together may cause burns or a fire For any dam age caused by shorting the terminals in this way any and all warranty claims through Bosch shall be invalid gt If itis abused
37. owing content can be found on the bottom side of the charger marked with num ber C4 in the representation on the graphics page For safe operation see the manual Risk of electric shock Dry location use only Only charge batteries for the Bosch eBike System Other batteries may burst causing personal damage Donotreplace the plug assembly as a risk of fire or elec tric shock may result 0 276 001 SPUen 23 4 14 Bosch eBike Systems English 27 Product Description and Specifications e Product Features C1 Battery charger C2 Charger socket C3 Plug in connector C5 Charge connector Bosch eBike Systems 0 276 001 SPUen 23 4 14 English 28 Technical Data Battery Charger Charger Article number 0275007 906 Rated voltage V 100 230 Frequency Hz 50 60 Output voltage V 36 Charging current A 4 Permitted charging temperature range AE 32 104 Charging time h 3 5 Number of battery cells 30 40 Operating temperature F 32 104 Storage temperature oF 14 122 Weight according to EPTA Procedure 01 2003 Ib 1 8 Degree of protection IP 40 This device is in compliance with Part 15 of the FCC Rules Operation is subject to the following two conditions 1 This device must not cause harmful interference and 2 this device must accept any interference that is received in cluding interference that may cause undesired operation This devic
38. r is detected the re spective error code is indicated in text indicator d To return to the standard indicator press any button on the display unit or on the operating unit 10 Depending on the type of error the drive unit is automati cally shut off if required Continued travel without assis tance from the drive unit is possible at any time However have the eBike checked before attempting new trips WARNING Have all checks and repairs performed only by an authorized Bosch eBike dealer English 13 Notes on Riding with the eBike System When does the eBike Drive Unit Operate The eBike drive unit assists you when riding as long as you step on the pedals Without pedaling there is no assis tance The motor output always depends on the amount of your pedaling power When applying less pedaling power the assistance or sup port will be lower than when applying a lot of pedaling pow er This applies independent of the assistance level The eBike motor assistance automatically switches off at speeds in excess of 20 mph When the speed falls below 20 mph the motor assistance is automatically available again The eBike can also be ridden as a normal bicycle without as sistance at any time by either switching off the eBike sys tem or setting the assistance level to OFF The same ap plies when the battery pack is empty Interaction of the eBike System with the Bicycle Gears The bicycle gears should be used a
39. s If you switch the eBike system on or place the display unit when it is switched off into the holder then the assistance level is reset to OFF WARNING If you remove the display unit when it is switched on from the holder and again put it back without turning it off then the last set assistance level remains and is not reset to OFF Switching the Lighting On Off If your lights are set up to be powered by the eBike system then you can use the 2 button on the display unit to simulta neously switch the front light and rear light on and off When the lighting is switched on Lights on appears and when the lighting is switched off Lights off appears for approx 1 s in the text indicator d The light symbol cis dis played when the light is on Switching the driving light on and off has no effect on the backlighting for the display The backlighting for the display is active as soon as the system or the display is switched on Speed and Distance Indicator The speed indicator f always displays the current speed The following functions are available in the function indi cator combination of text indicator d and value indicator e Range Estimated range of the available battery pack charge for constant conditions such as assistance lev el route profile etc Distance Distance covered since the last reset Trip time Trip time since the last reset Avg Speed Averag
40. s with a normal bicycle even with eBike motor assistance please follow the operat ing instructions for your eBike Independent of the type of gearing it is recommended to briefly interrupt the pedaling while changing gears This makes changing gears easier and reduces the wear on the drive train By selecting the right gear you can increase the speed and range with the same pedaling effort Test the operating range of your eBike under different con ditions before planning longer and more challenging rides gt Read and understand the Influences on the Operat ing Range section below before planning your ride Influences on the Operating Range The operating range depends on many factors such as the following Assistance level Gear switching behavior Bicycle tires and tire pressure Age and condition of the battery pack Route profile inclines and road or path conditions road or path surface Headwind and ambient temperature Weight of the eBike rider and equipment luggage Bosch eBike Systems 0 276 001 SPUen 23 4 14 English 14 For this reason it is not possible to precisely predict the range before starting a trip General rules For the same motor output of the eBike drive unit the less power or force that you have to bring about to reach acertain speed e g through optimal use of the gears the less energy the eBike drive unit will consume and the greater the range will b
41. tach any other products which would be suitable for increasing the performance of your eBike sys tem Unauthorized modification of the system could re sult in death or serious injury gt Please follow all local state and federal regulations when registering and using eBikes gt Please read and follow the safety warnings and in structions provided in the operating instructions for the battery pack as well as in the operating instruc tions for your eBike Bosch eBike Systems 0 276 001 SPUen 23 4 14 English 18 Product Description and Specifications Product Features Display Unit Information 1 Display function button i a Drive unit assistance indicator 2 Light button b Assistance level indicator 3 Display unitIntuvia c Light indicator 4 Holder for display unitIntuvia d Text indicator 5 On Off button e Value indicator 6 RESET button f Speed indicator 7 USB port g Battery charge control indicator 8 Protective cap for USB port 9 Drive unit 10 Operating unit 11 Display function button i on the operating unit 12 Reduce assistance scroll down button 13 Increase assistance scroll up button 14 Push assistance button WALK Not executable in some countries 0 276 001 SPUen 23 4 14 Bosch eBike Systems Technical Data Article number 0275007025 Power W 350 Torque at drive max Nm 60 Rated voltage V 36 Opera
42. the i but ton 1 on the display unit until the desired basic setting is displayed When the display unit is inserted in holder 4 you can also press the i button 11 on the operating unit To change the basic settings press the On Off button 5 next to the indicator to decrease the value or scroll down or the light button 2 next to the indicator to in crease the value or scroll up When the display unit is inserted in holder 4 you can also change the values with the button 12 or the button 13 on the operating unit To exit the function and store a changed setting press the RESET button 6 for 3s The following basic settings are available unit km mi The speed and distance can be displayed either in kilometers or miles time format The time can be displayed either in a 12 hour or 24 hour format clock The current time can be set here Pressing and holding the setting buttons fast forwards the setting speed English The language for the text indicator can be changed The available languages are German English French Spanish Italian and Dutch power on hours Indicates the total travel time with the eBike can not be changed wheel circum You can change this value pre set by the manufacturer by 5 Error Code Indicator The components of the eBike system are continuously and automatically monitored When an erro
43. ting temperature al 23 FIDA Storage temperature F 14 122 Degree of protection IP 54 dust and splash water protected Weight appox Ib 8 8 Article number 1270020 909 Max charging current USB connection mA 500 Charging voltage USB connection V 5 Operating temperature E 23 104 Storage temperature SE 14 122 Charging temperature F 32 104 Degree of protection IP 54 dust and splash water protected Weight appox Ib 0 3 This device is in compliance with Part 15 of the FCC Rules Operation is subject to the following two conditions 1 This device must not cause harmful interference and 2 this device must accept any interference that is received in cluding interference that may cause undesired operation This device is in compliance with CAN ICES 3 B NM B 3 B Lighting Rated voltage V 6 Power output Front light W 6 6 Rear light W 0 6 Not possible via the eBike battery pack in all country specific ver sions depending on the statutory regulations English 19 Assembly Inserting and Removing the Battery Pack To insert or remove the battery pack in from the eBike please read and follow the battery pack operating instruc tions Inserting and Removing the Display Unit 3 Display unit 4 Holder for display unit 15 Lock latch for display unit 16 Locking screw for display unit To insert the display unit 3 slide it from the front
44. ttery only in accordance with all safety instructions If this is not possible remove the battery from the holder and charge itin a more suitable location When doing so read and follow the operating instruc tions for the battery Switch the battery off Clean the cover of the charge socket English 29 Charging Procedure The charging procedure begins as soon as the charger is connected to the battery or the charge socket on the bike and the main power supply Notice The charging procedure is only possible when the temperature of the battery pack is within the permissible charging temperature range Notice The drive unitis deactivated during the charging procedure The battery can be charged with or withoutthe display unit When charging without the display unit the charging pro cedure can only be observed on the battery charge control indicator When the display unit is connected the backlighting for the display is switched on at low intensity and Charging ap pears in the text display The display unit can be removed during the charging proce dure or it can also be attached after the charging proce dure has begun The charging state is displayed by the battery charge con trol indicator A3 on the battery and by the bars on the dis play unit When charging the main battery on the bike the battery for the display unit can also be charged During the charging procedure the LEDs for charge contro
45. until its temperature has adjusted gt CAUTION Do not connect the battery pack to the charger until it has reached the permissible charging temperature Charge control Indicator When the battery pack is switched on the five green LEDs for the charge control indicator A3 indicate the charge con dition of the battery pack Here each LED indicates approx 20 capacity When the battery pack is completely charged all five LEDs light up The charge control for the switched on battery pack is also indicated on the display for the display unit Read and fol low the operating instructions for the drive unit and the dis play unit When the capacity of the battery pack is below 5 all LEDs for the charge control indicator A3 on the battery pack turn off however the display unit does provide an additional in dicator function Bosch eBike Systems 0 276 001 SPUen 23 4 14 English 24 Inserting and Removing the Battery Pack gt Always switch the battery pack off when inserting or removing it from the holder In order for the battery pack to be inserted the key A5 must be inserted into the lock A6 and the lock must be unlocked To insert the standard battery pack A8 place it with the contacts on the lower holder A9 on the eBike the battery pack can be inclined up to 7 to the frame Tilt it into the upper holder A7 until it engages To insert the rack type battery pack A2 slid
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