Powerfly 4 Gen 3 - Bike TREK - Free user manual and instructions

Product Type	Electric Mountain Bike
Brand	Trek
Model	Powerfly 4 Gen 3
Motor	Bosch Performance Line, 250 W, 65 Nm torque
Battery	Bosch PowerTube 500 Wh, lithium-ion
Range	Up to 100 km (depending on conditions)
Maximum assisted speed	32 km/h (20 mph)
Frame	Aluminum, full suspension
Weight	Approximately 25 kg
Drivetrain	Shimano Deore, 10/11 speeds
Brakes	Shimano hydraulic disc brakes
Front suspension	Suspension fork, 120 mm travel
Tires	Bontrager XR3, 29 x 2.35"
Lighting	Powered by Bosch battery, front/rear lights
Charger	Bosch Compact Charger BCS230, 36V/2A
Operating temperature	-10 °C to +40 °C (battery)
Protection rating	IP54 (motor and display)
Maintenance	Clean with a damp cloth, no high-pressure jet
Warranty	Limited lifetime warranty on frame
Included accessories	User manual, charger, battery key

Frequently Asked Questions - Powerfly 4 Gen 3 TREK

How to start the electrical system?

Sit on the bike, insert the battery, then briefly press the On/Off button on the on-board computer. The system activates as soon as you start pedaling.

What is the battery range?

The range varies depending on the assistance level, terrain, weight, and temperature. Generally, it can reach up to 100 km with moderate use.

How to recharge the battery?

Use only the supplied Bosch charger. Plug the charger into a wall outlet, then connect it to the battery (on the bike or removed). Full charge takes about 4 to 6 hours.

Can I clean my e-bike with a pressure washer?

No, never use a pressure washer. Clean with a soft damp cloth with a little mild soap. Pressurized water can damage electrical components.

What are the different assistance levels?

The available levels are: OFF, ECO, TOUR, SPORT/eMTB, and TURBO. You can change them using the + and - buttons on the on-board computer.

How to transport the bike on a car?

Remove the battery and on-board computer before transport. Use a compatible bike rack and ensure the total weight does not exceed the indicated capacity.

What to do if an error code appears on the screen?

Stop and restart the system. If the problem persists, consult an authorized Bosch dealer. Error codes are detailed in the manual.

What is the battery lifespan?

The lithium-ion battery retains about 60-70% of its capacity after 500 charge cycles. Storing it at 60% charge and room temperature extends its lifespan.

Can I use my e-bike in the rain?

Yes, the Bosch system is waterproof (IP54). Avoid riding in deep water and dry the bike thoroughly after a ride in the rain.

How to activate walk assist?

Briefly press the WALK button, then hold the + button within 3 seconds. The motor helps push the bike up to 6 km/h. Release the button to deactivate.

USER MANUAL Powerfly 4 Gen 3 TREK

OWNER'S MANUAL LE MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO

ELECTRIC BICYCLE

epowered by

BOSCH

eBike systems (20 mph) Purion

TREK

Electra

IT IS IMPORTANT TO READ THE WARNINGS AND INSTRUCTIONS IN THIS MANUAL BEFORE RIDING YOUR NEW BICYCLE. IL EST IMPORTANT DE LIRE LES MISES EN GARDE ET INSTRUCTIONS CONTENUES DANS CE MANUEL AVANT D'UTILISER VOTRE NOUVEAU VÉLO. ES IMPORTANTE LEER ESTAS ADVERTENCIAS E INSTRUCCIONES DEL MANUAL ANTES DE USAP TU NUEVA BICICLETA.

WELCOME - BIENVENUE - BIENVENIDO

Welcome to our bike family

Thank you for purchasing your new bike.

We believe in bikes. We make high quality bikes that are built to last.

That is why each bike we make comes with a limited lifetime warranty.

We wish you many carefree and enjoyable cycling kilometers with your new bike!

However, if you experience any problems with your bike, do not hesitate to contact your local retailer. If the problem persists, please call our customer service for a solution.

Important to read before the first ride.... 3

The Bosch drive system (20 mph) 13

English, Français, Español

Purion controller....55

English, Français, Español

Drive units

- Active Line / Active Line Plus (Generation 3)....101

- Performance Line / Cargo Line (Generation 4)....141

English, Français, Español

Battery....181

English, Français, Español

Charger 239

English, Français, Español

Contact - Contacter - Contacto 283

US Customer: Supplemental Product Information

The most important points for you to do

1. Even if you have ridden a bicycle for years, it is important for every person to read the general "Bicycle Owner's manual" and the specific "Electric Bicycle Owner's manual" carefully before you ride on the new electric bicycle.

2. Both manuals contains detailed information and useful suggestions about your new bicycle.

3. Make sure that you understand the proper use, maintenance, and disposal of the components of the electrical system of your new electric bicycle.

4. Think about safety. Your safety and that of other road users is very important.

5. Do not ride the electric bicycle without the battery. The battery must be on the bicycle while riding, else the bicycle has no lights when needed.

6. Check your bicycle for normal operation, loose parts and defects before riding. If you find any problem, visit your bicycle dealer for repairs before riding.
7. Be aware that other road users (cars, trucks, motorcycles) do not expect that an electric bicycle can ride faster than a normal bicycle. Riding faster also increases the risk of accidents.

Distances will close much faster, and braking distances will become longer.

- Do not ride abusively. Only ride in the use conditions specified for your bicycle:

• Electric City/Trekking bicycles are approved for Condition 1 (paved roads with tires staying on the ground).
• Electric Mountain bicycles are approved for Condition 3 (rougher surfaces, jumps of not more than 24 in (61 cm)).
  Please refer to the general Bicycle Owner's manual for more detailed information.

- Do not overload the rear rack. The maximum allowable weight for the rear rack on electric bicycles is 44 lb (20 kg) for bicycles with a rear rack battery and 55 lb (25 kg) for bicycles with a down tube battery. On bicycles with a luggage rack at both sides of the rear fender only, without a top deck, the maximum allowed load on the rack is 33 lb (15 kg) in total.

1. The electric system of your new bicycle needs special attention.

2. Do not clean your electric bicycle with a high pressure washer. Any electrical system is sensitive to moisture. High pressure water might enter connectors or other parts of the electric system.

3. Handle your battery with care. Do not drop or impact the battery. Mishandling of the battery could lead to severe damage or over-heating. In an extremely rare case, a battery that has been severely impacted or otherwise mishandled could potentially catch fire.

If you suspect damage to your battery, visit your dealer immediately for inspection.

4. Maintain the battery as instructed in this Electric Bicycle Owner's manual.

Failure to follow these instructions may result in damage to your battery and may require battery replacement:

• Only charge the battery with the included Bosch charger.
• When not using the battery for a longer period, charge it to approximately 60% (three to four LEDs lit on the charge-control indicator). Check the charge condition after six months. When only one LED of the charge-control indicator lights up, recharge the battery again to approximately 60% .
• Once charging the battery is complete, unplug the battery from the charger and unplug the charger from the wall socket.
• A Li-Ion battery will self-discharge over time. If the battery is left uncharged, then stored without charging, it may discharge to such a low state that the battery can no longer be charged and must be replaced.
• Store the battery in a dry, well-ventilated location. Protect the battery against moisture and water.
• Under unfavorable weather conditions, it is recommended e.g. to remove the battery from the bicycle and store it in a protected location.
• The battery can be stored at temperatures between 14^ (-10°C) and 140^ (+60°C).
  For a long battery life, however, it is best to store the battery at room temperature of approximately 68^ F ( 20^ C) is of advantage.
• If the bicycle is not ridden for an extended time, do not store the battery on the bicycle.

5. Be careful when transporting an electric bicycle.

• An electric bicycle is heavier than a normal bicycle. If transporting on a vehicle, be aware of the maximum load capacity of the vehicle's roof, towing hook and/or the bicycle carrier.
  Refer to the manuals of the vehicle and bicycle carrier for details.
• Remove the controller (if removable), and battery and, if present, panniers from the bicycle and store them elsewhere in the vehicle during the drive.
• Always respect local laws about transportation of an electric bicycle.
• Because Li-Ion batteries of this size and power are considered 'Dangerous goods, class 9' when transporting, regulations may restrict the transport of separate Li-Ion batteries in some places. The restrictions apply to most airlines and some trucking companies. If you intend to ship or travel with your electric bicycle (with installed battery), check with the airline or carrier and local regulations about traveling with a Li-Ion battery.

6. Obey local regulations.

In most countries the regulations for the use of an electric bicycle are the same as those for a standard bicycle. However, there may be local differences such as where you can ride, minimum rider age, or required equipment and registration. It is the rider's responsibility to know the local regulations that apply to an electric bicycle and to obey them.

7. Mounting accessories on an e-bike.

An electric bike has hidden wiring through frame and has other critical e-bike parts like the drive unit and battery pack. When mounting accessories (e.g. a bottle cage), be sure not to impact the wiring or battery pack, e.g. by using too long or pointed bolts. This might cause a short circuit to the electric system and/or damage to the battery.

Diagram showing a battery connected to a screw with a prohibition symbol (no text or labels)

Warning. A short circuit in the electric system and/or damage to the battery might lead to over-heating. In an extremely rare case, a battery pack that has been severely impacted could potentially catch fire.

8. Visit your dealer on a regular basis for maintenance of your new bicycle.

• Your dealer has the right knowledge and equipment to maintain your e-bike and to mount accessories safely.
• If you have questions about your new electric bicycle, ask your dealer!

Limited warranty

Your bicycle is covered by a Lifetime Limited Warranty. Please visit our web site for details.

FRANÇAIS - À LIRE IMPERATIVEMENT AVANT VOTRE PREMIERE SORTIE

Diagram showing two battery components with a crossed-out circle and a diagonal line, no text or symbols present.

Owner's Manual – The Bosch Drive System Drive Unit | On-board computer | Battery | Charger (20 mph)

BDU330|BDU380|BDU385|BDU480 CX|BUI215|BUI255|BUI330|BUI350|CUI100|

BBP285|BBP286|BBP287|BBP288|BBP295|BBP296|BBS266|BBS276|BBR266|BBR276|

BCS210|BCS230

Silhouette of a bicycle with front wheel, rear wheel, and side panel (no text or symbols)

en Original operating 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.

Age:

Âge:

Edad:

16+

Table of Contents

Introduction 2

About Warnings....2

General Warnings 2

Using Your Operator's Manual....3

Bosch Drive System Overview 4

Bicycle View (Standard) 4

Bicycle View (Rack-Type)....5

Bicycle View (PowerTube) 6

Operating your Bosch Drive System ....7

Getting Ready to Ride....7

Safe Start-up Procedure 8

Notes on cycling with the eBike system....9

Transport 10

Maintenance/Cleaning....10

Battery Recycling Program....12

Introduction

Thank You for Purchasing a Bosch Drive System Equipped Bicycle!

Your Bosch eBike Systems team appreciates having you as a customer and wishes you many years of safe and satisfied use of your bicycle.

About Warnings

This manual contains many DANGER, WARNING, and CAUTION indicators concerning the consequences of failure to use, assemble, maintain, store, inspect and dispose 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 moderate injury.

General Warnings

Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in death or serious injury.

Save all safety warnings and instructions for future reference.

The term battery pack used in these operating instructions refers to all original Bosch eBike battery packs.

The Bosch Drive System is intended for use by persons 16 years of age and above. Riders must have the physical coordination, reaction and mental capabilities to control a bike and manage traffic, road conditions, and sudden situations, as well as to respect the laws and instructions governing bicycle use.

WARNING

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. Failure 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, consult with your dealer or the bicycle or component manufacturer.
▶ Some eBike accessories may present a choking hazard to small children. Keep these accessories away from children.

CAUTION

The Bosch Drive System adds weight to your bicycle which you may not be used to lift. Avoid injury, use proper lifting techniques.

Using Your Operator's Manual

Your operator's manual consists of several parts:

• Operating instructions for the Bosch eBike system (this manual)
• Operating instructions for the drive unit
• Operating instructions for the on-board computer
• Operating instructions for the charger
• Operating instructions for the battery
• Read and observe the safety warnings and instructions in all operating instructions of the eBike system and your eBike.

Graphics

The bicycle shown in this manual may differ slightly from your bicycle, but will be similar enough to help you understand our instructions.

RIGHT-HAND and LEFT-HAND sides are determined by facing in the direction the bicycle will travel when going forward. When you see a broken line (----), the item referred to is hidden from view.

Bosch Drive System Overview

Bicycle View (Standard)

Bosch Drive System Components

All representations of bike components are schematic and can deviate from your eBike.

(1) On-board computer
(2) Standard battery "PowerPack"
(3) Drive unit
(4) Charger

Bicycle View (Rack-Type)

Bosch Drive System Components

All representations of bike components are schematic and can deviate from your eBike.

(1) On-board computer
(2) Rack-mounted battery "PowerPack"
(3) Drive unit
(4) Charger

Bicycle View (PowerTube)

Bosch Drive System Components

All representations of bike components are schematic and can deviate from your eBike.

(1) On-board computer
(2) Frame-mounted battery "PowerTube"
(3) Drive unit
(4) Charger

Operating your Bosch Drive System

Getting Ready to Ride

WARNING

▶ Read and understand all safety warnings and instructions. Failure to follow the below warnings could result in death or serious injury.
▶ Protect others from death or serious injury. Prevent unauthorized use. Always remove battery from the bicycle when not in use and store in a secure location. Failure to secure your bicycle from unauthorized use can result in death or serious injury to others.
- Read and understand the influences on the operating range when planning your ride (see "Influences on range", page English – 9).

Before your first ride

Check your bicycle owner's manual for important information about the bike components, such as the brakes, pedals, gears, gear shifting, etc.

WARNING

▶ While riding, do not become distracted by the onboard computer and always remain alert to all riding conditions. The on-board computer should only be used in a stationary and safe start-up position. Utilize the operating unit to change motor assistance levels while riding.
- Check your bicycle manual for maximum riding weight of your bicycle. Overloading your bicycle can result in component failure which can result in death or serious injury. Typically maximum riding weight is defined by the sum of the rider's weight plus the weight of any luggage.
▶ Wearing a helmet can prevent a severe head injury. Whenever riding, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA must meet the US Consumer Product Safety Commission standard, so look for a CPSC reference.

Intended Use

WARNING

- Understand your bike and its intended use by consulting your bicycle owner's manual. Using your bike the wrong way and for a purpose it was not designed can result in death or serious injury.

The Bosch Drive System components are intended exclusively for your eBike and must not be used for other purposes.

Your Bosch drive unit is not intended for towing another bicycle. For trailer towing, consult your bicycle owner's manual and trailer owner's manual for towing instructions and towing compatibility.

Safe Start-up Procedure

WARNING

▶ Follow the safe startup procedure below. Failure to follow safe startup 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

• Sit in the saddle with both feet touching the ground and two hands on the handlebars.
• Once you are in a stable position, turn on the Bosch on-board computer. The Bosch Drive System will always start up in OFF mode.
• Place both hands on the handlebars and begin pedaling.

Notes on cycling with the eBike system

When does the eBike drive work?

The eBike drive assists your cycling only when you are pedaling. If you do not pedal, the assistance will not work. The motor output always depends on the pedaling force you apply.

If you apply less force, you will receive less assistance than if you apply a lot of force. This applies irrespective of the assistance level.

The eBike drive automatically switches off at speeds over 20 mph. When the speed falls below 20 mph, the drive automatically becomes available again.

An exception applies to the push assistance function, in which the eBike can be pushed at low speed without pedaling. The pedals may rotate when the push assistance is in use.

You can also use the eBike as a normal bicycle without assistance at any time, either by switching off the eBike system or by setting the assistance level to OFF. The same applies when the battery is drained.

Interaction between the eBike system and gear-shifting

The gear-shifting should be used with an eBike drive in the same way as with a normal bicycle (observe the operating instructions of your eBike on this point).

Irrespective of the type of gear-shifting, it is advisable to briefly stop pedaling when changing gear. This will facilitate the gear change and reduce wear on the powertrain.

By selecting the correct gear, you can increase your speed and range while applying the same amount of force.

Test the range of your eBike in different conditions before planning longer and more demanding trips.

Read and understand the influences on the operating range when planning your ride (see "Influences on range", page English – 9).

Influences on range

The range is affected by a number of factors, such as:

• Assistance level
• Speed
  – Gear shifting behavior
  – Tire type and tire pressure
  – Age and condition of the battery
• Route profile (gradients) and conditions (road surface)
• Headwind and ambient temperature
• Weight of eBike, rider and luggage

For this reason, it is not possible to predict the range accurately before and during a trip. However, as a general rule:

• With the same assistance level on the eBike drive: The less energy you need to exert in order to reach a certain speed (e.g. by changing gears optimally), the less energy the eBike drive will consume and the higher the range per battery charge will be.
• The higher the selected assistance level under otherwise constant conditions, the smaller the range will be.

Note: Plan your routes so that you can always reach your destination without motor assistance.

Transport

WARNING

▶ Always remove the battery pack from the bicycle before 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.
▶ Always use an approved and compatible bicycle rack when transporting your eBike. The Bosch drive system adds weight to the bicycle. Refer to your bicycle rack manual to be sure your eBike is compatible. Overloading a bike rack can result in death or serious injury.
▶ Use proper lifting techniques as electric bikes are generally heavier than bicycles.

Ship batteries only when the housing is undamaged. Tape or mask off open contacts and pack up the battery in such a manner that it cannot move around in the packaging. Inform your parcel service that the package contains dangerous goods. Please also observe possibly more detailed national regulations. Always check state and federal regulations before attempting to ship your battery.

▶ If you transport your eBike attached to the outside of your car, e.g. on a bike rack, remove the on-board computer and the eBike battery to avoid damaging them.

If you have any questions about transporting the batteries, contact an authorized bicycle dealer. You can also order suitable transport packaging from the dealer.

Maintenance/Cleaning

WARNING

• Do not open any of the components. Service should only be carried out at an authorized Bosch eBike dealer. Failure to follow above warning can cause death or serious injury. Refer to your bicycle manual or component manual for all non-Bosch drive system components.
  ▶ Always remove the battery pack before performing any bicycle inspection, maintenance or repair. Failure to remove the battery pack before performing bicycle inspection, maintenance or repair can lead to serious injury.
  ▶ 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 strip threads, stretch, deform or break. Either way, incorrect tightening

force can result in component failure, which can cause you to lose control and fall.
▶ If replacing your battery, buy only a genuine Bosch battery pack from an approved source. See your Bosch eBike dealer for original Bosch parts.
▶ 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.
- Do not charge or use your eBike in any area with a potentially 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 instructions.
- Do not submerge your eBike components in water, or wash with pressurized hose. Your Bosch drive unit is designed to be water tight to rain water or non-pressure hose washing.

▶ Note down the manufacturer and the number of the key. In case of loss of the keys, please refer to an authorised Bosch eBike dealer. Please provide the name of the manufacturer and the number of the key.
- Do not paint any components of the Bosch drive system as they may cause premature failure of the component.

Taking care of your eBike

Please observe the operating and storage temperatures of the eBike components. Protect the drive unit, on-board computer and battery against extreme temperatures (e.g. from intense sunlight without adequate ventilation). Extreme temperatures can cause the components (especially the battery) to become damaged.

Have your eBike system checked by an expert at least once a year (including mechanical parts, up-to-date-ness of system software).

Please have your eBike serviced and repaired by an authorized bicycle dealer.

After-sales service and advice on using products

If you have any questions about the eBike system and its components, contact an authorized bicycle dealer. For contact details of authorized bike dealerships, please visit www.bosch-ebike.com.

Please contact an authorized bicycle dealer if the battery is no longer working.

Cleaning

- Do not submerge your eBike components in water, or wash with pressurized hose. Your Bosch drive unit is designed to be water tight to rain water or non-pressure hose washing.

Keep all components of your eBike clean, especially the battery-pack contacts and corresponding holder contacts. All components including the drive unit may not be immersed in water or cleaned with a high-pressure cleaner. Keep all components of your eBike

clean, especially the batterypack contacts and corresponding holder contacts. Clean them carefully with a soft, damp cloth (using only mild soap and water).

Battery Recycling Program

The drive unit, on-board computer incl. operating unit, battery, speed sensor, accessories and packaging should be disposed of in an environmentally correct manner.

Do not dispose of eBikes and their components with household waste.

You may recycle your Bosch battery pack by calling 1.800.822.8837.

Table des matières

Introduction....2

Owner's Manual – The Bosch Drive System Purion

BUI215

Illustration of a walking push-button-style device with digital display and cable (no text or symbols)

en Original operating 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.

Table of Contents

Introduction....2

About Warnings....2

General Warnings 2

Using your Manual 2

Operating your Bosch on-board computer ....4

Safety instructions....4

Product description and specifications ....5

Operation....7

Speed and distance indicators....10

Troubleshooting....11

Battery Recycling Program....14

Introduction

About Warnings

This manual contains many DANGER, WARNING, and CAUTION indicators concerning the consequences of failure to use, assemble, maintain, store, inspect and dispose 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 moderate injury.

General Warnings

Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in death or serious injury.

Save all safety warnings and instructions for future reference.

The term battery pack used in these operating instructions refers to all original Bosch eBike battery packs.

WARNING

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.

In addition to the functions outlined here, changes to software relating to troubleshooting and functional modifications may be introduced at any time.

▶ 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. Failure 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, consult with your dealer or the bicycle or component manufacturer.
▶ Some eBike accessories may present a choking hazard to small children. Keep these accessories away from children.

CAUTION

The Bosch Drive System adds weight to your bicycle which you may not be used to lift. Avoid injury, use proper lifting techniques.

Using your Manual

Graphics

The bicycle shown in this manual may differ slightly from your bicycle, but will be similar enough to help you understand our instructions.

RIGHT-HAND and LEFT-HAND sides are determined by facing in the direction the bicycle will travel when going forward. When you see a broken line (----), the item referred to is hidden from view.

Operating your Bosch on-board computer

Safety instructions

Read all the safety information and instructions. Failure to observe the safety information and follow instructions may result in electric shock, fire and/or serious injury.

Save all safety warnings and instructions for future reference.

The term battery pack used in these operating instructions refers to all original Bosch eBike battery packs.

• Do not allow yourself to be distracted by the display of the on-board computer. If you do not concentrate exclusively on the traffic around you, you risk being involved in an accident. If you want to change any settings on the on-board computer other than the assistance level, always stop before entering the relevant data.
• Read and observe the safety warnings and instructions in all operating instructions of the eBike system and your eBike.
  ▶ Set the display brightness such that you can adequately see important information like speed or warning symbols. An incorrectly set display brightness can result in dangerous situations.
  ▶ Do not expose on-board computer to fire or excessive temperature. Exposure to fire or temperature above 212 °F (100 °C) may cause explosion.
  ▶ Never submerge on-board computer in fluid of any kind or allow fluid to enter them. Corrosive or conductive fluid (such as seawater or industrial chemical or bleach containing products, etc.) can cause short circuit which may result in fire, personal injury and property damage.
  ▶ Battery leakage may occur under extreme usage or temperature conditions. Avoid contact with skin and eyes. The battery liquid is caustic and

could cause chemical burns to tissues. If liquid comes in contact with skin, wash quickly with soap and water. If the liquid contacts your eyes, immediately flush eyes with water for a minimum of 15 minutes and seek medical attention.

Before each use, check the on-board computer, cable and plug. If damage is detected, do not use the on-board computer. Damaged on-board computer, charging cables and plugs increase the risk of a fire, explosion and personal injury.
- Do not disassemble on-board computer. No user serviceable part inside. Incorrect reassembly or damage may result in fire or explosion.

Product description and specifications

Product Features

(1) On/off button for on-board computer
(2) Push assistance button WALK
(3) Fastening screw for on-board computer
(4) Holder for on-board computer
(5) Decrease assistance level button -
(6) Increase assistance level button +
(7) Display
(8) Protective cap for USB port
(9) USB diagnostic port (for servicing purposes only)
(10) Battery compartment cover

On-board computer information

(a) Speedometer
(b) km/h unit indicator
(c) mph unit indicator
(d) Total distance indicator TOTAL
(e) Range indicator RANGE
(f) Service indicator
(g) Battery charge indicator
(h) Lighting indicator
(i) Assistance level indicator/value indicator
(j) Trip distance indicator TRIP

English - 6

Technical data

On-board computer Purion
Product code BUI215
BatteriesA)	2 × 3 V CR2016
Operating temperature °F +23 to +104
Storage temperature °F +50 to +104
Protection ratingB)	IP54
Weight, approx. lbs 0.22

A) We recommend using batteries offered by Bosch. You can purchase them from your bicycle dealer (article number: 1 270 016 819).
B) When the USB cover is closed The Bosch eBike system uses FreeRTOS (see http://www.freertos.org).
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, including interference that may cause undesired operation.

Operation

Symbols and their meaning

Symbol Explanation
	Short button press(less than 1 second)
	Medium button press(between 1 second and 2.5 seconds)
	Long button press(longer than 2.5 seconds)

Start-up

Requirements

The eBike system can only be activated when the following requirements are met:

– A sufficiently charged battery is inserted (see battery operating instructions).
- The speed sensor is connected properly (see drive unit operating instructions).

Switching the eBike system on/off

The following options are available for switching on the eBike system:

• Press the on/off button (1) of the on-board computer with the eBike battery inserted.
• Press the on/off button of the eBike battery (see battery operating instructions).

The drive is activated as soon as you start pedaling (except for in the push assistance function or with the assistance level OFF). The motor output depends on which assistance level is set on the on-board computer.

As soon as you stop pedaling when in normal operation, or as soon as you have reached a speed of 20/28 mph, the eBike drive unit switches off the assistance. The drive is automatically re-activated as soon you start pedaling again and the speed is below 20/28 mph.

The following options are available for switching off the eBike system:

• Press the on/off button (1) of the on-board computer.
• Switch off the eBike battery using its on/off button (some bicycle manufacturer-specific solutions prevent access to the battery on/off button; see the bicycle manufacturer operating instructions).

The system shuts down after being switched off. This takes approximately three seconds. It cannot be switched back on until shutdown has been completed.

If the eBike is not moved for approx. ten minutes and no button is pressed on the on-board computer, the eBike system switches off automatically in order to save energy.

Note: Always switch off the eBike system when you park the eBike.

Note: If the batteries of the on-board computer are drained, you can still switch on your eBike using the bike's battery. It is, however, recommended that you replace the internal batteries as soon as possible in order to avoid damage.

Energy supply of the on-board computer

The on-board computer is supplied with voltage by two CR2016 button cells.

Changing the batteries

If the on-board computer shows LOW BAT on the display, remove the on-board computer from the handlebars by unscrewing the fastening screw (3) of the onboard computer. Open the battery compartment cover (10) using a suitable coin, remove the used batteries and insert new CR2016 batteries. You can obtain batteries recommended by Bosch from your bicycle dealer.

When inserting the batteries, ensure that the polarity is correct.

Close the battery compartment again and fasten the on-board computer to your eBike's handlebars using the fastening screw (3).

Switching the push assistance on/off

The push assistance aids you when pushing your eBike. The speed of this function depends on the selected gear and can reach a maximum of 3.7 mph.

The lower the selected gear, the lower the speed of the push assistance function (at full power).

The push assistance function must only be used when pushing the eBike. There is a risk of injury if the wheels of the eBike are not in contact with the ground while using the push assistance.

To activate the push assistance, briefly press the WALK button on your on-board computer. After activation, press the + button within 3 s and keep it pressed. The eBike drive is switched on.

Note: The push assistance cannot be activated at assistance level OFF.

The push assistance is switched off as soon as one of the following occurs:

• You release the + button;
  – the wheels of the eBike are locked (e.g. by applying the brakes or hitting an obstacle);
• the speed exceeds 3.7 mph.

The push assistance function is subject to local regulations; the way it works may therefore differ from the description above. It can also be deactivated.

Setting the assistance level

You can set the level at which the eBike drive assists you while pedaling on the on-board computer. The assistance level can be changed at any time, even while cycling.

Note: In some models, the assistance level may be preset and cannot be changed. There may also be fewer assistance levels available than stated here.

The following assistance levels are available as a maximum:

• OFF: Motor assistance is switched off. The eBike can just be moved by pedaling, as with a normal bicycle. The push assistance cannot be activated at this assistance level.
• ECO: Effective assistance with maximum efficiency, for maximum range
• TOUR: Steady assistance, long range for touring

- SPORT/eMTB:

SPORT: Powerful assistance, for mountain biking and for cycling in urban traffic

eMTB: Optimum assistance whatever the terrain, rapid acceleration when starting from a standstill, improved dynamics, top performance (eMTB is only available in combination with drive units BDU250P CX, BDU365, BDU450 CX and BDU480 CX. This also requires a software update.)

- TURBO: Maximum assistance even at high pedaling speeds, for biking sports

To increase the assistance level, briefly press the button + (6) on the on-board computer repeatedly until the required assistance level appears on the indicator (i). To decrease the assistance level briefly press the button - (5).

If the display is set to TRIP, TOTAL or RANGE, the selected assistance level will only be shown briefly (for approx. one second) on the display when switching over.

Switching bike lights on/off

For the model which has the bike lights powered by the eBike system, a medium-length press ⬆ of the button + will switch on the front and rear lights simultaneously. To switch off the bike lights, press and hold ⬆ the button +.

The lighting symbol (h) is displayed when the light is on.

Before starting each journey, check that your bike lights are working correctly.

The on-board computer saves the light status and activates this saved status accordingly after a restart.

Switching the bike lights on and off has no effect on the backlighting of the display.

Speed and distance indicators

The speedometer (a) always displays the current speed.

The indicator (i) always displays the last setting as standard. Repeated medium-length presses of the button – will display the trip distance TRIP, the total distance TOTAL and the battery range RANGE one after the other. (Briefly pressing the button – will decrease the assistance level.)

To reset the trip distance TRIP, select the trip distance TRIP and simultaneously press and hold ● the buttons + and - . The display will initially show RESET. If you continue to press both buttons, the trip distance TRIP will be set to 0.

To reset the battery range RANGE, select the battery range RANGE and simultaneously press and hold the buttons + and -. The display will initially show RESET. If you continue to press both buttons, the trip distance TRIP will be set to 0.

You can switch the displayed values from kilometers to miles by holding down ⬆ the button – and briefly pressing the on/off button (1).

The versions of the subsystems and their model part numbers can be displayed for servicing purposes, provided the subsystems divulge this information (dependent on the subsystem). With the system switched off, simultaneously press the buttons - and + and then press the on/off button (1).

The USB port is reserved for connecting diagnostic systems. The USB port does not have any other function.

The USB port must always be completely sealed with the protective cap (8).

Action Buttons Duration
Switch on on-board computer
Switch off on-board computer
Increase assistance	+
Decrease assistance	-
DisplayTRIP, TOTAL,RANGE, assistance modes	-
Switch on bike lights	+
Switch off bike lights	+
Reset trip distance	- +
Activate push assistanceImplement push assistance	WALK+	1. 2. As re-quired
Switch from kilometers to miles	-	1. Keeppressed2.
Display the versionsA)B)	- +	1. Keeppressed2.
Adjust display brightnessC)	- + - or +	1. Keeppressed2.

A) The eBike system must be switched off.

B) The information is shown as scrolling text.

C) The display must be switched off.

Troubleshooting

The components of the eBike system are continuously monitored automatically. If a fault is detected, the corresponding fault code will appear on the onboard computer.

The drive may also be switched off automatically depending on what type of fault has occurred. You can

continue riding at any time without assistance from the drive, but you should have your eBike checked before completing any more journeys.

▶ Only have repairs performed by a certified bicycle dealer.

Code Cause Corrective measures

410 One or more buttons of the on-board computer are disabled.	Check whether any buttons are stuck, e.g. as a result of dirt finding its way in. Clean the buttons if need be.
414 Operating unit connection problem Have the connections checked
418 One or more buttons on the operating unit are disabled.	Check whether any buttons are stuck, e.g. as a result of dirt finding its way in. Clean the buttons if need be.
419 Configuration error Restart the system. If the problem persists, contact your Bosch eBike dealer.
422 Drive unit connection problem Have the connections checked
423 eBike battery connection problem Have the connections checked
424 Communication problem between components	Have the connections checked
426 Internal time-out error Restart the system. If the problem persists, contact your Bosch eBike dealer. With this error, it is not possible to bring up the wheel circumference in the basic settings menu or to adjust it.
430 Internal battery of the on-board computer is flat (does not apply to BUI350)	Charge the on-board computer (in the holder or via the USB port)
431 Software version error Restart the system. If the problem persists, contact your Bosch eBike dealer.
440 Internal drive unit fault Restart the system. If the problem persists, contact your Bosch eBike dealer.
450 Internal software error Restart the system. If the problem persists, contact your Bosch eBike dealer.
460 Error at USB port Remove the cable from the USB port of the on-board computer. If the problem persists, contact your Bosch eBike dealer.
490 Internal fault of the on-board computer	Have the on-board computer checked

English - 12

Code Cause Corrective measures

500 Internal drive unit fault Restart the system. If the problem persists, contact your Bosch eBike dealer.

502 Bike light fault Check the light and the associated wiring. Restart the sys-tem. If the problem persists, contact your Bosch eBike dealer.

503 Speed sensor fault Restart the system. If the problem persists, contact your Bosch eBike dealer.

504 Speed signal distortion detected. Check that the spoke magnet is positioned correctly, and adjust it if necessary. Check that nothing has been tam-pered with (tuning). Drive assistance is reduced.

510 Internal sensor fault Restart the system. If the problem persists, contact your Bosch eBike dealer.

511 Internal drive unit fault Restart the system. If the problem persists, contact your Bosch eBike dealer.

530 Battery fault Switch off the eBike, remove the eBike battery and rein-sert the eBike battery. 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.

540 Temperature error The eBike is outside of the permissible temperature range.Switch off the eBike system and allow the drive unit to ei-ther cool down or heat up to the permissible temperature range. Restart the system. If the problem persists, contact your Bosch eBike dealer.

550 An impermissible load has been de-tected. Remove the load. Restart the system. If the problem per-sists, contact your Bosch eBike dealer.

580 Software version error Restart the system. If the problem persists, contact your Bosch eBike dealer.

591 Authentication error Switch off the eBike system. Remove the battery pack and reinsert it. Restart the system. If the problem persists, contact your Bosch eBike dealer.

592 Incompatible component Use a compatible display. If the problem persists, contact your Bosch eBike dealer.

593 Configuration error Restart the system. If the problem persists, contact your Bosch eBike dealer.

595, 596 Communication error Check the wiring to the drive and restart the system. If the problem persists, contact your Bosch eBike dealer.

Code Cause Corrective measures

602 Internal battery fault Restart the system. If the problem persists, contact your Bosch eBike dealer.
603 Internal battery fault Restart the system. If the problem persists, contact your Bosch eBike dealer.
605 Battery temperature error The battery is outside of the permissible temperature range. Switch off the eBike system and allow the battery to either cool down or heat up to the permissible temperature range. Restart the system. If the problem persists, contact your Bosch eBike dealer.
606 External battery fault Check the wiring. Restart the system. If the problem persists, contact your Bosch eBike dealer.
610 Battery voltage error Restart the system. If the problem persists, contact your Bosch eBike dealer.
620 Charger fault Replace the charger. Contact your Bosch eBike dealer.
640 Internal battery fault Restart the system. If the problem persists, contact your Bosch eBike dealer.
655 Multiple battery faults 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 they can perform a software update.
7xx Error relating to third-party components	Observe the information in the operating instructions of the respective component manufacturer.
Display is blank	Internal fault of the on-board computer Restart your eBike system by switching it off and back on.

Battery Recycling Program

The drive unit, on-board computer incl. operating unit, battery, speed sensor, accessories and packaging should be disposed of in an environmentally correct manner.

Do not dispose of eBikes and their components with household waste.

You may recycle your Bosch battery pack by calling 1.800.822.8837.

Table des matières

Introduction....2

Owner's Manual – The Bosch Drive System Drive Unit

BDU330 | BDU380 | BDU385 | BDU386

Three identical Bosch Maxi processor units shown from different angles (no visible text or labels)

en Original operating 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.

Active Line/Active Line Plus/Performance Line

Table of Contents

Introduction....2

About Warnings....2

General Warnings 2

Using your Manual 2

Operating your Bosch drive unit....4

Safety instructions....4

Product description and specifications ....6

Assembly 7

Operation....8

Maintenance/Cleaning....10

Introduction

About Warnings

This manual contains many DANGER, WARNING, and CAUTION indicators concerning the consequences of failure to use, assemble, maintain, store, inspect and dispose 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 moderate injury.

General Warnings

Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in death or serious injury.

Save all safety warnings and instructions for future reference.

The term battery pack used in these operating instructions refers to all original Bosch eBike battery packs.

WARNING

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. Failure 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, consult with your dealer or the bicycle or component manufacturer.
▶ Some eBike accessories may present a choking hazard to small children. Keep these accessories away from children.

CAUTION

The Bosch Drive System adds weight to your bicycle which you may not be used to lift. Avoid injury, use proper lifting techniques.

Using your Manual

Graphics

The bicycle shown in this manual may differ slightly from your bicycle, but will be similar enough to help you understand our instructions.

In addition to the functions outlined here, changes to software relating to troubleshooting and functional modifications may be introduced at any time.

RIGHT-HAND and LEFT-HAND sides are determined by facing in the direction the bicycle will travel when going forward. When you see a broken line (----), the item referred to is hidden from view.

Operating your Bosch drive unit

Safety instructions

Read and understand all safety warnings and instructions. Failure to follow the below warnings could result in death or serious injury.

Save all safety warnings and instructions for future reference.

The term battery pack used in these operating instructions refers to all original Bosch eBike battery packs.

• Do not attempt to change – in particular, to increase – the power of your drive or the maximum speed that it supports. Doing this may put yourself and others at risk, and you could also breach statutory regulations.
• Do not open the drive unit yourself. The drive unit must only be repaired by qualified personnel using only original spare parts. This will ensure that the safety of the drive unit is maintained. Unauthorized opening of the drive unit will render warranty claims null and void.

• All components fitted to the drive unit and all other components of the eBike drive (e.g. chainring, chainring receptacle, pedals) must only be replaced with identical components or components that have been specifically approved by the manufacturer for your eBike. This will protect the drive unit from overloading and becoming damaged.
  ▶ Remove the battery from the eBike before beginning work (e.g. inspection, repair, assembly, maintenance, work on the chain, etc.) on the eBike, transporting it with a car or airplane, or storing it. Unintentional activation of the eBike system poses a risk of injury.

• The eBike system can be activated by pushing the eBike backwards or by turning the pedals backwards.
  The push assistance function must only be used when pushing the eBike. There is a risk of injury if the wheels of the eBike are not in contact with the ground while using the push assistance.

• When the push assistance is activated, the pedals may turn at the same time. When the push assistance function is activated, make sure that there is enough space between your legs and the turning pedals to avoid the risk of injury.
  ▶ After a ride, do not allow your unprotected hands or legs to come into contact with the housing of the drive unit. Under extreme conditions, such as continuously high torques at low travel speeds, or when riding up hills or carrying loads, very high temperatures may be reached on the housing.
  The temperatures that may be reached on the drive unit housing are influenced by the following factors:
• Ambient temperature
• Ride profile (route/gradient)
• Ride duration
• Assistance modes
• User behavior (personal effort)
• Total weight (rider, eBike, luggage)
• Motor cover on the drive unit
• Heat dissipation properties of the bicycle frame
• Type of drive unit and type of gear-shifting
  ▶ Use only original Bosch batteries that the manufacturer has approved for your eBike. Using other batteries can lead to injuries and pose a fire hazard. Bosch accepts no liability or warranty claims if other batteries are used.
• Do not make any modifications to your eBike system or fit any other products that might in-

crease the performance of your eBike system.

Doing so will generally reduce the service life of the system and risks damaging the drive unit and the bike. You also run the risk of losing the guarantee and warranty claims on the bicycle you have purchased. By handling the system improperly you are also endangering your safety and that of other road users, thus running the risk of high personal liability costs and possibly even criminal prosecution in the event of accidents that can be attributed to manipulation of the bicycle.

Under extreme conditions, such as continuously high loads at low speed when riding up hills or carrying loads, parts of the drive unit can reach temperatures in excess of 60 °C.

▶ Please observe all local, state and federal regulations when registering and using eBikes.
- Read and observe the safety warnings and instructions in all operating instructions of the eBike system and your eBike.

Privacy notice

When you connect the eBike to the Bosch Diagnostic-Tool, data about the eBike drive unit (e.g. energy consumption, temperature, etc.) is transferred to Bosch eBike Systems (Robert Bosch GmbH) for the purposes of product improvement. You can find more information about this on the Bosch eBike website at www.bosch-ebike.com.

Product description and specifications

Intended use

The drive unit is intended exclusively for driving your eBike and must not be used for any other purpose.

In addition to the functions outlined here, changes to software relating to troubleshooting and functional modifications may be introduced at any time.

Technical data

Drive unit Active Line Active Line Plus Performance Line Performance Line Sport
Product code BDU330 BDU380 BDU385 BDU386
Continuous rated power W 250 250 250 250
Torque at drive, max. Nm 40 50 65 65
Rated voltage V= 36 36 36 36
Operating temperature °F +23 to +104 +23 to +104 +23 to +104 +23 to +104
Storage temperature °F +50 to +104 +50 to +104 +50 to +104 +50 to +104
Protection rating IP 54 IP 54 IP 54 IP 54
Weight, approx. kg 2.9 3.2	3.2 3.2

The Bosch eBike system uses FreeRTOS (see http://www.freertos.org).

Bicycle lightsA)
Voltage approx.B)	V=	12
Maximum power
- Front light	W	17.4
- Rear light	W	0.6

A) Depends on legal regulations, not possible in all country-specific models via the eBike battery

B) When changing the bulbs, ensure that they are compatible with the Bosch eBike system (ask your bicycle dealer) and are suitable for the specified voltage. Bulbs must only be replaced with bulbs of the same voltage.

Inserting a bulb incorrectly can cause it to blow.

Assembly

Inserting and removing the battery

For inserting and removing the eBike battery in/from the eBike, please read and observe the battery operating instructions.

Check speed sensor

(1) Speed sensor (standard)
(2) Spoke magnet
(4) Speed sensor (slim) ^A)
(5) Magnet

A) Different sensor shape and installation position possible

Speed Sensor (standard)

The speed sensor (1) and its spoke magnet (2) must be fitted such that the spoke magnet moves past the speed sensor at a distance of at least 5 mm and at most 17 mm with each rotation of the wheel.

Note: If the distance between the speed sensor (1) and the spoke magnet (2) is too small or too large, or if the speed sensor (1) is not properly connected, the speedometer display will fail and the eBike drive unit will operate in emergency mode.

Should this occur, loosen the screw of the spoke magnet (2) and fasten the spoke magnet to the spoke such that it runs past the marking on the speed sensor at the correct clearance. If the speed is still not

being indicated on the speedometer display after doing this, please contact an authorized bicycle dealer.

Speed Sensor (slim)

The speed sensor (slim) (4) and its spoke magnet (5) must be fitted ex works such that the spoke magnet moves past the speed sensor at a distance of at least 2 mm and at most 8 mm with each rotation of the wheel.

The correct distance between the magnet and sensor must be maintained (see figure A) if design changes are made.

Notes: Ensure that you do not damage the sensor or sensor bracket when fitting or removing the rear wheel.

Operation

Start-up

Requirements

The eBike system can only be activated when the following requirements are met:

• A sufficiently charged battery is inserted (see battery operating instructions).
• The on-board computer is properly inserted in the holder (see on-board computer operating instructions).
• The speed sensor is correctly connected.

Switching the eBike system on/off

The following options are available for switching on the eBike system:

• If the on-board computer is already switched on when you insert it into the holder, the eBike system will be automatically activated.
• When the on-board computer and the eBike battery are inserted, briefly press the on/off button of the on-board computer.
• With the on-board computer inserted, press the on/off button on the eBike battery (some bicycle manufacturer-specific solutions prevent access to the battery on/off button; see the battery operating instructions).

The drive is activated as soon as you start pedaling (except for in the push assistance function, Switching the push assistance on/off). The motor output depends on which assistance level is set on the onboard computer.

As soon as you stop pedaling when in normal operation, or as soon as you have reached a speed of 20 mph, the eBike drive unit switches off the assistance. The drive is automatically re-activated as soon you start pedaling again and the speed is below 20 mph.

The following options are available for switching off the eBike system:

- Press the on/off button of the on-board computer.

• Switch off the eBike battery using its on/off button (some bicycle manufacturer-specific solutions prevent access to the battery on/off button; see the bicycle manufacturer operating instructions).
• Remove the on-board computer from its holder. If the eBike is not moved for approx. ten minutes and no button is pressed on the on-board computer, the eBike system switches off automatically in order to save energy.

eShift (optional)

eShift is the integration of electronic gear-shifting systems into the eBike system. The eShift components are electrically connected to the drive unit by the manufacturer. The separate operating instructions describe how to operate the electronic gear-shifting systems.

Setting the assistance level

You can set the level at which the eBike drive assists you while pedaling on the on-board computer. The assistance level can be changed at any time, even while cycling.

Note: In some models, the assistance level may be preset and cannot be changed. There may also be fewer assistance levels available than stated here.

The following assistance levels are available as a maximum:

• OFF: Motor assistance is switched off. The eBike can just be moved by pedaling, as with a normal bicycle. The push assistance cannot be activated at this assistance level.
• ECO: Effective assistance with maximum efficiency, for maximum range
• TOUR: Steady assistance, long range for touring

- SPORT/eMTB:

SPORT: Powerful assistance, for mountain biking and for cycling in urban traffic

eMTB: Optimum assistance whatever the terrain, rapid acceleration when starting from a standstill, improved dynamics, top performance (eMTB is only available in combination with drive units BDU250P CX, BDU365, BDU450 CX and BDU480 CX. This also requires a software update.)

- TURBO: Maximum assistance even at high pedaling speeds, for biking sports

The requested motor output appears on the display of the on-board computer. The maximum motor output depends on which assistance level is selected.

Assistance level	Assistance factor A)
	Active Line (BDU330)	Active Line Plus (BDU380)	Performance Line (BDU385)	Performance Line Sport (BDU386)
ECO	40 % 40 % 55 % 55 %			B)
TOUR	100 % 100 % 120 % 120 %			B)
SPORT/eMTB	150 % 180 % 200/120-300 %	C)		200 % B)
TURBO	250 % 270 % 300 % 300 %			B)

A) The assistance factor may vary in some models.
B) Dynamic-progressive assistance level
C) Dynamic-progressive assistance level between TOUR and TURBO modes

Switching the push assistance on/off

The push assistance aids you when pushing your eBike. The speed of this function depends on the selected gear and can reach a maximum of 3.7 mph. The lower the selected gear, the lower the speed of the push assistance function (at full power).

The push assistance function must only be used when pushing the eBike. There is a risk of injury if the wheels of the eBike are not in contact with the ground while using the push assistance.

To activate the push assistance, briefly press the WALK button on your on-board computer. After activation, press the + button within 3 s and keep it pressed. The eBike drive is switched on.

Note: The push assistance cannot be activated at assistance level OFF.

The push assistance is switched off as soon as one of the following occurs:

• You release the + button;
• the wheels of the eBike are locked (e.g. by applying the brakes or hitting an obstacle);
• the speed exceeds 3.7 mph.

The push assistance function is subject to local regulations; the way it works may therefore differ from the description above. It can also be deactivated.

Switching bicycle lights on/off

On the model where the bike lights are powered by the eBike system, the front light and taillight can be switched on and off at the same time via the on-board computer.

Before starting each journey, check that your bike lights are working correctly.

Maintenance/Cleaning

WARNING

• Do not open any of the components. Service should only be carried out at an authorized Bosch eBike dealer. Failure to follow above warning can cause death or serious injury. Refer to your bicycle manual or component manual for all non-Bosch drive system components.
  ▶ Always remove the battery pack before performing any bicycle inspection, maintenance or repair. Failure to remove the battery pack before performing bicycle inspection, maintenance or repair can lead to serious injury.
  ▶ 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 strip threads, stretch, deform or break. Either way, incorrect tightening force can result in component failure, which can cause you to lose control and fall.
  ▶ If replacing your battery, buy only a genuine Bosch battery pack from an approved source. See your Bosch eBike dealer for original Bosch parts.
  ▶ 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.
• Do not charge or use your eBike in any area with a potentially 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 instructions.
• Do not submerge your eBike components in water, or wash with pressurized hose. Your Bosch

drive unit is designed to be water tight to rain water or non-pressure hose washing.

▶ Note down the manufacturer and the number of the key. In case of loss of the keys, please refer to an authorised Bosch eBike dealer. Please provide the name of the manufacturer and the number of the key.
- Do not paint any components of the Bosch drive system as they may cause premature failure of the component.

When changing the bulbs, ensure that they are compatible with the Bosch eBike system (ask your bicycle dealer) and are suitable for the specified voltage.

Bulbs must only be replaced with bulbs of the same voltage.

Taking care of your eBike

Please observe the operating and storage temperatures of the eBike components. Protect the drive unit, on-board computer and battery against extreme temperatures (e.g. from intense sunlight without adequate ventilation). Extreme temperatures can cause the components (especially the battery) to become damaged.

Have your eBike system checked by an expert at least once a year (including mechanical parts, up-to-date-ness of system software).

Please have your eBike serviced and repaired by an authorized bicycle dealer.

After-sales service and advice on using products

If you have any questions about the eBike system and its components, contact an authorized bicycle dealer.

For contact details of authorized bike dealerships, please visit www.bosch-ebike.com.

Please contact an authorized bicycle dealer if the battery is no longer working.

Cleaning

- Do not submerge your eBike components in water, or wash with pressurized hose. Your Bosch drive unit is designed to be water tight to rain water or non-pressure hose washing.

Keep all components of your eBike clean, especially the battery-pack contacts and corresponding holder contacts. All components including the drive unit may not be immersed in water or cleaned with a high-pressure cleaner. Keep all components of your eBike clean, especially the batterypack contacts and corresponding holder contacts. Clean them carefully with a soft, damp cloth (using only mild soap and water).

English - 12

Table des matières

Introduction....2

Active Line/Active Line Plus/Performance Line

Owner's Manual – The Bosch Drive System Drive Unit

BDU480 CX | BDU490P

Close-up of a Bosch carabiner with visible brand logo (no text or symbols beyond branding)

en Original operating 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.

Performance Line/Cargo Line

Table of Contents

Introduction....2

About Warnings....2

General Warnings 2

Using your Manual 2

Operating your Bosch Drive Unit ....4

Safety instructions....4

Product description and specifications ....6

Assembly 7

Operation....8

Maintenance/Cleaning....10

Introduction

About Warnings

This manual contains many DANGER, WARNING, and CAUTION indicators concerning the consequences of failure to use, assemble, maintain, store, inspect and dispose 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 moderate injury.

General Warnings

Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in death or serious injury.

Save all safety warnings and instructions for future reference.

The term battery pack used in these operating instructions refers to all original Bosch eBike battery packs.

WARNING

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. Failure 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, consult with your dealer or the bicycle or component manufacturer.
▶ Some eBike accessories may present a choking hazard to small children. Keep these accessories away from children.

CAUTION

The Bosch Drive System adds weight to your bicycle which you may not be used to lift. Avoid injury, use proper lifting techniques.

Using your Manual

Graphics

The bicycle shown in this manual may differ slightly from your bicycle, but will be similar enough to help you understand our instructions.

In addition to the functions outlined here, changes to software relating to troubleshooting and functional modifications may be introduced at any time.

RIGHT-HAND and LEFT-HAND sides are determined by facing in the direction the bicycle will travel when going forward. When you see a broken line (----), the item referred to is hidden from view.

Operating your Bosch Drive Unit Safety instructions

Read and understand all safety warnings and instructions. Failure to follow the below warnings could result in death or serious injury.

Save all safety warnings and instructions for future reference.

The term battery pack used in these operating instructions refers to all original Bosch eBike battery packs.

• Do not attempt to change – in particular, to increase – the power of your drive or the maximum speed that it supports. Doing this may put yourself and others at risk, and you could also breach statutory regulations.
• Do not open the drive unit yourself. The drive unit must only be repaired by qualified personnel using only original spare parts. This will ensure that the safety of the drive unit is maintained. Unauthorized opening of the drive unit will render warranty claims null and void.
• All components fitted to the drive unit and all other components of the eBike drive (e.g. chain-ring, chainring receptacle, pedals) must only be replaced with identical components or components that have been specifically approved by the manufacturer for your eBike. This will protect the drive unit from overloading and becoming damaged.
  ▶ Remove the battery from the eBike before beginning work (e.g. inspection, repair, assembly, maintenance, work on the chain, etc.) on the eBike, transporting it with a car or airplane, or storing it. Unintentional activation of the eBike system poses a risk of injury.
  The push assistance function must only be used when pushing the eBike. There is a risk of injury if

the wheels of the eBike are not in contact with the ground while using the push assistance.

• When the push assistance is activated, the pedals may turn at the same time. When the push assistance function is activated, make sure that there is enough space between your legs and the turning pedals to avoid the risk of injury.
  ▶ After a ride, do not allow your unprotected hands or legs to come into contact with the housing of the drive unit. Under extreme conditions, such as continuously high torques at low travel speeds, or when riding up hills or carrying loads, very high temperatures may be reached on the housing.

The temperatures that may be reached on the drive unit housing are influenced by the following factors:

• Ambient temperature
• Ride profile (route/gradient)
• Ride duration
• Assistance modes
• User behavior (personal effort)
• Total weight (rider, eBike, luggage)
• Motor cover on the drive unit
• Heat dissipation properties of the bicycle frame
• Type of drive unit and type of gear-shifting

▶ Use only original Bosch batteries that the manufacturer has approved for your eBike. Using other batteries can lead to injuries and pose a fire hazard. Bosch accepts no liability or warranty claims if other batteries are used.
- Do not make any modifications to your eBike system or fit any other products that might increase the performance of your eBike system.

Doing so will generally reduce the service life of the system and risks damaging the drive unit and the bike. You also run the risk of losing the guarantee and warranty claims on the bicycle you have pur-

chased. By handling the system improperly you are also endangering your safety and that of other road users, thus running the risk of high personal liability costs and possibly even criminal prosecution in the event of accidents that can be attributed to manipulation of the bicycle.

Under extreme conditions, such as continuously high loads at low speed when riding up hills or carrying loads, parts of the drive unit can reach temperatures in excess of 60 °C.

▶ Please observe all local, state and federal regulations when registering and using eBikes.
- Read and observe the safety warnings and instructions in all operating instructions of the eBike system and your eBike.

Privacy notice

When you connect the eBike to the Bosch Diagnostic-Tool, data about the eBike drive unit (e.g. energy consumption, temperature, etc.) is transferred to Bosch eBike Systems (Robert Bosch GmbH) for the purposes of product improvement. You can find more information about this on the Bosch eBike website at www.bosch-ebike.com.

Product description and specifications

Intended use

The drive unit is intended exclusively for driving your eBike and must not be used for any other purpose.

In addition to the functions outlined here, changes to software relating to troubleshooting and functional modifications may be introduced at any time.

Technical data

Drive unit Performance Line CX/	Cargo Line	Performance Line Speed/ Cargo Line Speed
Product code BDU480 CX BDU490P
Continuous rated power W 250 250
Torque at drive, max. Nm 85 75/85		A)
Rated voltage V= 36 36
Operating temperature °F +23 to +104 +23 to +104
Storage temperature °F +50 to +104 +50 to +104
Protection rating IP 54 IP 54
Weight, approx. kg 3 3

A) Is determined by the bicycle manufacturer The Bosch eBike system uses FreeRTOS (see http://www.freertos.org).

Bicycle lights ^A)

Voltage approx. ^B)	V=12
Maximum power
- Front light	W	17.4
- Rear light	W	0.6

A) Depends on legal regulations, not possible in all country-specific models via the eBike battery

B) When changing the bulbs, ensure that they are compatible with the Bosch eBike system (ask your bicycle dealer) and are suitable for the specified voltage. Bulbs must only be replaced with bulbs of the same voltage.

Inserting a bulb incorrectly can cause it to blow.

Assembly

Inserting and removing the battery

For inserting and removing the eBike battery in/from the eBike, please read and observe the battery operating instructions.

Check speed sensor

(1) Speed sensor (standard)
(2) Spoke magnet
(3) Speed sensor (slim) ^4
(4) Magnet

A) Different sensor shape and installation position possible

Speed Sensor (standard)

The speed sensor (1) and its spoke magnet (2) must be fitted such that the spoke magnet moves past the speed sensor at a distance of at least 5 mm and at most 17 mm with each rotation of the wheel.

Note: If the distance between the speed sensor (1) and the spoke magnet (2) is too small or too large, or if the speed sensor (1) is not properly connected, the speedometer display will fail and the eBike drive unit will operate in emergency mode.

Should this occur, loosen the screw of the spoke magnet (2) and fasten the spoke magnet to the spoke such that it runs past the marking on the speed sensor at the correct clearance. If the speed is still not

being indicated on the speedometer display after doing this, please contact an authorized bicycle dealer.

Speed Sensor (slim)

The speed sensor (slim) (3) and its spoke magnet (4) must be fitted ex works such that the spoke magnet moves past the speed sensor at a distance of at least 2 mm and at most 8 mm with each rotation of the wheel.

The correct distance between the magnet and sensor must be maintained (see figure A) if design changes are made.

Notes: Ensure that you do not damage the sensor or sensor bracket when fitting or removing the rear wheel.

Operation

Start-up

Requirements

The eBike system can only be activated when the following requirements are met:

• A sufficiently charged battery is inserted (see battery operating instructions).
• The on-board computer is properly inserted in the holder (see on-board computer operating instructions).
• The speed sensor is correctly connected.

Switching the eBike system on/off

The following options are available for switching on the eBike system:

• If the on-board computer is already switched on when you insert it into the holder, the eBike system will be automatically activated.
• When the on-board computer and the eBike battery are inserted, briefly press the on/off button of the on-board computer.
• With the on-board computer inserted, press the on/off button on the eBike battery (some bicycle manufacturer-specific solutions prevent access to the battery on/off button; see the battery operating instructions).

Note: The eBike system always starts in OFF mode for drive units with a maximum speed of more than 20 mph.

The drive is activated as soon as you start pedaling (except for in the push assistance function, Switching the push assistance on/off). The motor output depends on which assistance level is set on the onboard computer.

As soon as you stop pedaling when in normal operation, or as soon as you have reached a speed of 20/28 mph, the eBike drive unit switches off the assistance. The drive is automatically re-activated as soon you start pedaling again and the speed is below 20/28 mph.

The following options are available for switching off the eBike system:

• Press the on/off button of the on-board computer.
• Switch off the eBike battery using its on/off button (some bicycle manufacturer-specific solutions prevent access to the battery on/off button; see the bicycle manufacturer operating instructions).

- Remove the on-board computer from its holder. If the eBike is not moved for approx. ten minutes and no button is pressed on the on-board computer, the eBike system switches off automatically in order to save energy.

eShift (optional)

eShift is the integration of electronic gear-shifting systems into the eBike system. The eShift components are electrically connected to the drive unit by the manufacturer. The separate operating instructions describe how to operate the electronic gear-shifting systems.

Setting the assistance level

You can set the level at which the eBike drive assists you while pedaling on the on-board computer. The assistance level can be changed at any time, even while cycling.

Note: In some models, the assistance level may be preset and cannot be changed. There may also be fewer assistance levels available than stated here.

The following assistance levels are available as a maximum:

• OFF: Motor assistance is switched off. The eBike can just be moved by pedaling, as with a normal bicycle. The push assistance cannot be activated at this assistance level.
• ECO: Effective assistance with maximum efficiency, for maximum range
• TOUR: Steady assistance, long range for touring

- SPORT/eMTB:

SPORT: Powerful assistance, for mountain biking and for cycling in urban traffic

eMTB: Optimum assistance whatever the terrain, rapid acceleration when starting from a standstill, improved dynamics, top performance (eMTB is only available in combination with drive units BDU250P CX, BDU365, BDU450 CX and BDU480 CX. This also requires a software update.)

- TURBO: Maximum assistance even at high pedaling speeds, for biking sports

The requested motor output appears on the display of the on-board computer. The maximum motor output depends on which assistance level is selected.

Assistance level Assistance factor
	Performance Line (BDU490P)	Performance Line CX (BDU480 CX)	Cargo Line
ECO	60 % 60 % 60 %
TOUR	140 % 140 % 140 %
SPORT/eMTB	240 % 240/140–340 %	B)	240 %
TURBO	340 % 340 % 400 %

A) The assistance factor may vary in some models.
B) Dynamic-progressive assistance level between TOUR and TURBO modes

Switching the push assistance on/off

The push assistance aids you when pushing your eBike. The speed of this function depends on the selected gear and can reach a maximum of 3.7 mph. The lower the selected gear, the lower the speed of the push assistance function (at full power).

The push assistance function must only be used when pushing the eBike. There is a risk of injury if the wheels of the eBike are not in contact with the ground while using the push assistance.

To activate the push assistance, briefly press the

WALK button on your on-board computer. After activation, press the + button within 3 s and keep it pressed. The eBike drive is switched on.

Note: The push assistance cannot be activated at assistance level OFF.

The push assistance is switched off as soon as one of the following occurs:

- You release the + button;

• the wheels of the eBike are locked (e.g. by applying the brakes or hitting an obstacle);
• the speed exceeds 3.7 mph.

The push assistance function is subject to local regulations; the way it works may therefore differ from the description above. It can also be deactivated.

Switching bicycle lights on/off

On the model where the bike lights are powered by the eBike system, the front light and taillight can be switched on and off at the same time via the on-board computer.

Before starting each journey, check that your bike lights are working correctly.

Maintenance/Cleaning

WARNING

• Do not open any of the components. Service should only be carried out at an authorized Bosch eBike dealer. Failure to follow above warning can cause death or serious injury. Refer to your bicycle manual or component manual for all non-Bosch drive system components.
  ▶ Always remove the battery pack before performing any bicycle inspection, maintenance or repair. Failure to remove the battery pack before performing bicycle inspection, maintenance or repair can lead to serious injury.
  ▶ 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 strip threads, stretch, deform or break. Either way, incorrect tightening force can result in component failure, which can cause you to lose control and fall.
  ▶ If replacing your battery, buy only a genuine Bosch battery pack from an approved source. See your Bosch eBike dealer for original Bosch parts.
  ▶ 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.
• Do not charge or use your eBike in any area with a potentially 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 instructions.
• Do not submerge your eBike components in water, or wash with pressurized hose. Your Bosch

drive unit is designed to be water tight to rain water or non-pressure hose washing.

▶ Note down the manufacturer and the number of the key. In case of loss of the keys, please refer to an authorised Bosch eBike dealer. Please provide the name of the manufacturer and the number of the key.
- Do not paint any components of the Bosch drive system as they may cause premature failure of the component.

When changing the bulbs, ensure that they are compatible with the Bosch eBike system (ask your bicycle dealer) and are suitable for the specified voltage.

Bulbs must only be replaced with bulbs of the same voltage.

Taking care of your eBike

Please observe the operating and storage temperatures of the eBike components. Protect the drive unit, on-board computer and battery against extreme temperatures (e.g. from intense sunlight without adequate ventilation). Extreme temperatures can cause the components (especially the battery) to become damaged.

Have your eBike system checked by an expert at least once a year (including mechanical parts, up-to-date-ness of system software).

Please have your eBike serviced and repaired by an authorized bicycle dealer.

After-sales service and advice on using products

If you have any questions about the eBike system and its components, contact an authorized bicycle dealer.

For contact details of authorized bike dealerships, please visit www.bosch-ebike.com.

Please contact an authorized bicycle dealer if the battery is no longer working.

Cleaning

- Do not submerge your eBike components in water, or wash with pressurized hose. Your Bosch drive unit is designed to be water tight to rain water or non-pressure hose washing.

Keep all components of your eBike clean, especially the battery-pack contacts and corresponding holder contacts. All components including the drive unit may not be immersed in water or cleaned with a high-pressure cleaner. Keep all components of your eBike clean, especially the batterypack contacts and corresponding holder contacts. Clean them carefully with a soft, damp cloth (using only mild soap and water).

English - 12

Table des matières

Introduction....2

Performance Line/Cargo Line

Owner's Manual – The Bosch Drive System Battery

BBS266|BBS276|BBR266|BBR276|

BBP285|BBP286|BBP287|BBP288|BBP295|BBP296

Three electronic devices with visible internal components and connectors, shown from different angles (no text or symbols)

en Original operating 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.

Table of Contents

Introduction....2

About Warnings....2

General Warnings 2

Using your Manual 2

On-product warning labels ....4

Handling the lithium-ion battery pack ....5

Safety warnings for Bosch eBike batteries....5

Product description and specifications ....7

Fitting....10

Operation....14

Transport 14

Maintenance/cleaning....15

Storing....15

Troubleshooting....17

Battery Recycling Program....18

Introduction

About Warnings

This manual contains many DANGER, WARNING, and CAUTION indicators concerning the consequences of failure to use, assemble, maintain, store, inspect and dispose 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 moderate injury.

General Warnings

Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in death or serious injury.

Save all safety warnings and instructions for future reference.

The term battery pack used in these operating instructions refers to all original Bosch eBike battery packs.

WARNING

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. Failure 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, consult with your dealer or the bicycle or component manufacturer.
▶ Some eBike accessories may present a choking hazard to small children. Keep these accessories away from children.

CAUTION

The Bosch Drive System adds weight to your bicycle which you may not be used to lift. Avoid injury, use proper lifting techniques.

Using your Manual

Graphics

The bicycle shown in this manual may differ slightly from your bicycle, but will be similar enough to help you understand our instructions.

In addition to the functions outlined here, changes to software relating to troubleshooting and functional modifications may be introduced at any time.

RIGHT-HAND and LEFT-HAND sides are determined by facing in the direction the bicycle will travel when going forward. When you see a broken line (----), the item referred to is hidden from view.

On-product warning labels

A

B

A Safety instructions for PowerPack
B Safety instructions for PowerTube

▶ Warning labels have been placed on the Bosch eBike System for your protection. Read and follow the instructions of the labels on the product carefully. If a label becomes illegible or comes off, contact your Bosch bicycle dealer to obtain a replacement. Replacement safety labels are provided by Bosch at no charge.

Handling the lithium-ion battery pack

Safety warnings for Bosch eBike batteries

Read and understand all safety warnings and instructions. Failure to follow

the below warnings could result in death or serious injury.

Save all safety warnings and instructions for future reference.

The term battery pack used in these operating instructions refers to all original Bosch eBike battery packs.

DANGER

▶ Do not puncture or crush the battery pack. Do not impact the battery pack or modify it in any way. Do not use the battery pack if it shows visible damage. Danger of fire or explosion which can cause death or serious injury.

Protect the battery pack against heat (e.g., temperature >140 °F), fire and immersing into water. Danger of explosion.

WARNING

▶ Use only original Bosch battery packs approved for your eBike by the manufacturer and purchased from a credible source. Use of non-approved or counterfeit battery packs can lead to death or serious injury.
▶ Remove the battery from the eBike before beginning work (e.g. inspection, repair, assembly, maintenance, work on the chain, etc.) on the eBike, transporting it with a car or airplane, or storing it. Unintentional activation of the eBike system poses a risk of injury.
- Do not open the battery. There is a risk of short-circuiting. Opening the battery voids any and all warranty claims.

• When the battery is not in use, keep it away from paper clips, coins, keys, nails, screws or other small metal objects that could make a connection from one terminal to another. A short circuit between the battery terminals may cause burns or a fire. Short circuit damage which occurs in this instance voids any and all warranty claims against Bosch.
• Avoid mechanical loads and exposure to high temperatures. These can damage the battery cells and cause the flammable contents to leak out.
  ▶ Do not place the charger or the battery near flammable materials. Ensure the battery is completely dry and placed on a fireproof surface before charging. There is a risk of fire due to the heat generated during charging.
• The eBike battery must not be left unattended while charging.
  If used incorrectly, liquid may leak from the battery. Contact with this liquid should be avoided. If contact occurs, rinse off with water. If the liquid comes into contact with your eyes, seek additional medical attention. Liquid leaking from the battery may cause irritation or scalding.
  ▶ Batteries must not be subjected to mechanical shock. There is a risk of the battery being damaged.
  The battery may give off fumes if it becomes damaged or is used incorrectly. Ensure the area is well ventilated and seek medical attention should you experience any adverse effects. The fumes may irritate the respiratory system.
  ▶ Only charge the battery using original Bosch chargers. When using chargers that are not made by Bosch, the risk of fire cannot be excluded.

English - 6

▶ Use the battery only in conjunction with eBikes that have original Bosch eBike drive systems.
This is the only way in which you can protect the battery against dangerous overload.
▶ Use only original Bosch batteries that the manufacturer has approved for your eBike. Using other batteries can lead to injuries and pose a fire hazard. Bosch accepts no liability or warranty claims if other batteries are used.
- Do not use the rack-mounted battery as a handle. Lifting the eBike up by the battery can damage the battery.
- Read and observe the safety warnings and instructions in all operating instructions of the eBike system and your eBike.
▶ Keep the battery away from children.

The safety of both our customers and our products is important to us. Our eBike batteries are lithium-ion batteries which have been developed and manufactured in accordance with the latest technology. We comply with or exceed the requirements of all relevant safety standards. When charged, these lithium-ion batteries contain a high level of energy. If a fault occurs (which may not be detectable from the outside), in very rare cases and under unfavorable conditions, lithium-ion batteries can catch fire.

Privacy notice

When you connect the eBike to the Bosch diagnostic tool, data about the eBike batteries (e.g. temperature, cell voltage, etc.) is transferred to Bosch eBike Systems (Robert Bosch GmbH) for the purposes of product improvement. You can find more information about this on the Bosch eBike website at www.bosch-ebike.com.

Product description and specifications

Product features PowerPack

All representations of bike components are schematic and can deviate from your eBike.

(1) Rack-mounted battery holder
(2) Rack-mounted battery
(3) Operation/state of charge indicator
(4) On/off button
(5) Key for the battery lock
(6) Battery lock
(7) Upper holder for standard battery
(8) Standard battery

(9) Lower holder for standard battery
(10) Cover (supplied only on eBikes with two battery packs)
(11) Charger
(12) Socket for charging connector
(13) Charging socket cover

Product features PowerTube

All representations of bike components are schematic and can deviate from your eBike.

(3) Operation/state of charge indicator
(4) On/off button
(5) Key for the battery lock
(6) Battery lock

(11) Charger

(12) Socket for charging connector

(13) Charging socket cover
(14) PowerTube safety restraint
(15) PowerTube battery
(16) PowerTube safety hook

Intended Use

The Bosch eBike batteries are intended exclusively to provide the power supply for your eBike drive unit and must not be used for any other purpose.

Technical data

Li-ion battery PowerPack 400 PowerPack 500
Product code BBS266	A)	BBS276A)
	BBR266B)	BBR276B)
-Rack-mounted battery 0 275 007 525/526 0 275 007 535/536
Rated voltage V= 36 36
Nominal capacity Ah 11 13.4
Energy Wh 400 500
Operating temperature °F +23 to +104 +23 to +104
Storage temperature °F +50 to +104 +50 to +104
Permitted charging temperature range	°F +32 to +104 +32 to +104
Weight, approx. lb 5.5	A)/5.7B)	5.7A)/6.0B)
Protection rating	IP 54	IP 54

A) Standard battery
B) Rack-mounted battery

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, including interference that may cause undesired operation.

This device is in compliance with CAN ICES-3(B)/NM B-3(B).

English - 10

Li-ion battery PowerTube 400 PowerTube 500 PowerTube 625

Product code BBP287 horizontal	BBP288 vertical	BBP285 horizontalBBP286 vertical	BBP295 horizontalBBP296 vertical
Rated voltage V= 36 36 36
Nominal capacity Ah 11 13.4			16.7
Energy Wh 400 500 625
Operating temperature °F +23 to +104 +23 to +104 +23 to +104
Storage temperature °F +50 to +104 +50 to +104 +50 to +104
Permitted charging temperature range	°F +32 to +104 +32 to +104 +32 to +104
Weight, approx. lb 6.4 6.4 7.7
Protection rating IP 54 IP 54 IP 54

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, including interference that may cause undesired operation.
This device is in compliance with CAN ICES-3(B)/NM B-3(B).

Fitting

▶ Ensure the battery is placed on clean surfaces only. Avoid getting dirt, e.g. sand or soil, in the charging socket and contacts in particular.

Testing the battery before using it for the first time

Test the battery before charging it for the first time or using it in your eBike.

To do this, press the on/off button (4) to switch the battery on. If none of the LEDs on the battery charge indicator (3) light up, the battery may be damaged. If at least one (but not all) of the LEDs on the battery charge indicator (3) lights up, the battery will need to be fully charged before using it for the first time.

▶ Do not charge or use batteries if they are damaged. Contact an authorized bicycle dealer.

Charging the battery

▶ A Bosch eBike battery must only be charged using an original Bosch eBike charger.

Note: The battery is supplied partially charged. To ensure full battery capacity, fully charge the battery in the charger before using it for the first time.

To charge the battery, read and follow the instructions in the operating manual for the charger.

The battery can be charged at any state of charge. Interrupting the charging process does not damage the battery.

The battery has a temperature monitoring function which only allows it to be charged within a temperature range of 32^ F to 104^ F.

If the temperature of the battery is outside this charging range, three of the LEDs on the battery charge indicator (3) will flash. Disconnect the battery from the charger and let it acclimatize.

CAUTION

- Do not connect the battery pack to the charger until it has reached the allowable charging temperature.

Battery charge indicator

The five green LEDs on the battery charge indicator (3) indicate the battery's state of charge of when the battery is switched on.

Each LED represents approximately 20 % of the charging capacity. When the battery is fully charged, all five LEDs will be lit.

The battery's state of charge when switched on is also shown on the display of the on-board computer. Read and follow the instructions in the operating manuals for the drive unit and on-board computer.

If the battery capacity is less than 5 %, all the LEDs on the battery charge indicator (3) on the battery will go out. The display function of the on-board computer, however, will carry on working.

Once charging is complete, disconnect the battery from the charger and the charger from the mains.

Using two batteries for one eBike (optional)

The manufacturer can also equip an eBike with two batteries. In this case, one of the charging sockets will not be accessible or it will have been sealed with a sealing cap by the bicycle manufacturer. Only charge the batteries via the charging socket that is accessible.

▶ Never open charging sockets that have been sealed by the manufacturer. Charging batteries via a charging socket that used to be sealed may cause irreparable damage.

If you want to use an eBike that is designed for two batteries with only one battery, cover the contacts of the unused socket using the cover (10) provided. Otherwise there is a risk that the exposed contacts will cause a short circuit (see figures A and B).

Charging with Two Battery Packs Inserted

If two battery packs are mounted on one eBike, both battery packs can be charged using the unsealed connection. To begin with, both batteries are charged one after the other until they reach approx. 80–90 % capacity, then they are both charged at the same time until full (the LEDs on both batteries flash).

When the bike is in operation, power is drawn from both batteries on an alternating basis.

If you take the battery packs out of the holders, you can charge each battery pack individually.

Charging with one battery fitted

If only one battery is fitted, you can only charge the battery that has the accessible charging socket on the bike. You can only charge the battery with the sealed charging socket if you take the battery out of the holder.

Inserting and Removing the battery

▶ Always switch off the battery and the eBike system when inserting the battery into the holder or removing it from the holder.

Inserting and Removing the Standard Battery

In order for the battery to be inserted, the key (5) must be inserted into the lock (6) and the lock must be open.

To insert the standard battery (8), place it onto the contacts on the lower holder (9) on the eBike (the battery can be tilted towards the frame by up to 7°). Tilt it into the upper holder (7) as far as possible.

▶ Always check that the battery pack is locked in place. To do this, pull on the battery pack (after the key has been removed).

Check that the battery is secure. Always secure the battery by closing the lock (6) – otherwise the lock may open and the battery may fall out of the holder. Always remove the key (5) from the lock (6) after closing it. This prevents both the key from falling out and the battery from being removed by unauthorized third parties when the eBike is not in use.

To remove the standard battery (8), switch it off and open the lock using the key (5). Tilt the battery out of the upper holder (7) and pull it out of the lower holder (9).

Inserting and removing the rack-mounted battery

In order for the battery to be inserted, the key (5) must be inserted into the lock (6) and the lock must be open.

To insert the rack-mounted battery (2), slide it contacts-first into the holder (1) on the rack until it clicks into place.

▶ Always check that the battery pack is locked in place. To do this, pull on the battery pack (after the key has been removed).

Check that the battery is secure. Always secure the battery by closing the lock (6) – otherwise the lock may open and the battery may fall out of the holder. Always remove the key (5) from the lock (6) after closing it. This prevents both the key from falling out and the battery from being removed by unauthorized third parties when the eBike is not in use.

To remove the rack-mounted battery (2), switch it off and open the lock using the key (5). Pull the battery out of the holder (1).

Removing the PowerTube battery

① To remove the PowerTube battery (15), open the lock (6) using the key (5). The battery will be unlocked and fall into the safety restraint (14).
② Press on the safety restraint from above. The battery will be unlocked completely and fall into your hand. Pull the battery out of the frame.

Note: As a result of varying designs, the PowerTube battery may need to be inserted and removed using a different method. In this case, consult the bicycle documentation provided by your bicycle manufacturer.

Inserting the PowerTube battery

In order for the battery to be inserted, the key (5) must be inserted into the lock (6) and the lock must be open.

To insert the PowerTube battery (15), place it so that its contacts are in the lower holder of the frame.
② Push the battery upwards until it is held by the safety restraint (14).
③ Hold the lock open with the key and press the battery upwards until you hear it click into place. Check that the battery is secure in all directions.
④ Always secure the battery by closing the lock (6) – otherwise the lock may open and the battery may fall out of the holder.

▶ Always check that the battery pack is locked in place. To do this, pull on the battery pack (after the key has been removed).

Always remove the key (5) from the lock (6) after locking it. This prevents both the key from falling out and the battery from being removed by unauthorized third parties when the eBike is not in use.

Operation

Start-up

▶ Use only original Bosch batteries that the manufacturer has approved for your eBike. Using other batteries can lead to injuries and pose a fire hazard. Bosch accepts no liability or warranty claims if other batteries are used.

Switching on/off

Switching on the battery is one way to switch on the eBike system. Read and follow the instructions in the operating manuals for the drive unit and on-board computer.

Before switching on the battery, i.e. the eBike system, make sure that the lock (6) is closed.

To switch on the battery, press the on/off button (4). Do not use sharp or pointed objects to press the button. The LEDs on the indicator (3) will light up, indicating the battery's state of charge at the same time.

▶ Always check that the battery pack is locked in place. To do this, pull on the battery pack (after the key has been removed).

Note: If the battery capacity is less than 5 %, none of the LEDs on the battery charge indicator (3) will light up. The only way to see if the eBike system is switched on is via the on-board computer.

To switch off the battery, press the on/off button (4) again. The LEDs on the indicator (3) go out. This will also switch the eBike system off.

If no power is drawn from the eBike drive for about 10 minutes (e.g. because the eBike is not moving) and no button is pressed on the on-board computer or the operating unit of the eBike, the eBike system, and therefore also the battery, will switch off automatically to save energy.

The battery is protected against deep discharge, overloading, overheating and short-circuiting by the "Electronic Cell Protection (ECP)". In the event of danger, a protective circuit switches the battery off automatically.

If a fault is detected in the battery, two of the LEDs on the battery charge indicator (3) will flash. Contact an authorized bicycle dealer if this happens.

Behavior in the event of a fault

The Bosch eBike battery must not be opened, even for repairs. There is a risk that the Bosch eBike battery could catch fire, e.g. due to a short circuit. This risk arises if a Bosch eBike battery which has already been opened is reused at a later point in time.

Therefore, do not repair the Bosch eBike battery in the event of a fault, but have it replaced with an original Bosch eBike battery by your specialist retailer.

Transport

▶ Always remove the battery pack from the bicycle before 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.
▶ Always use an approved and compatible bicycle rack when transporting your eBike. The Bosch drive system adds weight to the bicycle. Refer to

your bicycle rack manual to be sure your eBike is compatible. Overloading a bike rack can result in death or serious injury.

▶ Use proper lifting techniques as electric bikes are generally heavier than bicycles.

Ship batteries only when the housing is undamaged. Tape or mask off open contacts and pack up the battery in such a manner that it cannot move around in the packaging. Inform your parcel service that the

package contains dangerous goods. Please also observe possibly more detailed national regulations. Always check state and federal regulations before attempting to ship your battery.

If you have any questions about transporting the batteries, contact an authorized bicycle dealer. You can also order suitable transport packaging from the dealer.

Maintenance/cleaning

• Do not open any of the components. Service should only be carried out at an authorized Bosch eBike dealer. Failure to follow above warning can cause death or serious injury. Refer to your bicycle manual or component manual for all non-Bosch drive system components.
  ▶ Always remove the battery pack before performing any bicycle inspection, maintenance or repair. Failure to remove the battery pack before performing bicycle inspection, maintenance or repair can lead to serious injury.
  ▶ If replacing your battery, buy only a genuine Bosch battery pack from an approved source. See your Bosch eBike dealer for original Bosch parts.
  ▶ 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.
• Do not charge or use your eBike in any area with a potentially 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 instructions.
• Do not submerge your eBike components in water, or wash with pressurized hose. Your Bosch drive unit is designed to be water tight to rain water or non-pressure hose washing.

▶ Note down the manufacturer and the number of the key. In case of loss of the keys, please refer to an authorised Bosch eBike dealer. Please provide the name of the manufacturer and the number of the key.
- Do not paint any components of the Bosch drive system as they may cause premature failure of the component.

After-sales service and advice on using products

If you have any questions about the eBike system and its components, contact an authorized bicycle dealer.

For contact details of authorized bike dealerships, please visit www.bosch-ebike.com.

Please contact an authorized bicycle dealer if the battery is no longer working.

Cleaning

- Do not submerge your eBike components in water, or wash with pressurized hose. Your Bosch drive unit is designed to be water tight to rain water or non-pressure hose washing.

Keep all components of your eBike clean, especially the battery-pack contacts and corresponding holder contacts. All components including the drive unit may not be immersed in water or cleaned with a high-pressure cleaner. Keep all components of your eBike clean, especially the batterypack contacts and corresponding holder contacts. Clean them carefully with a soft, damp cloth (using only mild soap and water).

Storing

The service life of the battery can be extended if it is looked after well and especially if it is stored at the correct temperature.

As it ages, however, the capacity of the battery will diminish, even with good care.

A significantly reduced operating period after charging indicates that the battery pack is worn out and must be replaced. You can replace it yourself by purchasing a genuine Bosch PowerPack from an authorized Bosch eBike dealer.

Recharging the battery before and during storage

When you are not going to use the battery for an extended period (longer than three months), store it at a state of charge of around 30 % to 60 % (when two to three of the LEDs on the battery charge indicator (3) are lit).

Check the state of charge after six months. If only one of the LEDs on the battery charge indicator (3) is lit, charge the battery back up to around 30 % to 60 %.

Note: If the battery is stored with no charge for an extended period of time, it may become damaged despite the low self-discharge and the battery capacity could be significantly reduced.

Leaving the battery permanently connected to the charger is not recommended.

Storage conditions

If possible, store the battery in a dry, well-ventilated place. Protect it against moisture and water. When the weather conditions are bad, it is advisable to remove the battery from the eBike and store it in a closed room until you use it next, for example.

Store the eBike batteries in the following locations:

– In a room with a smoke alarm
– Away from combustible or easily flammable objects
– Away from heat sources

For an optimum service life, store the eBike battery at temperatures between 50°F and 68°F. Never store it at temperatures below 14°F or above 140°F.

Make sure that the maximum storage temperature is not exceeded. Do not leave the battery in your car in the summer, for example, and store it away from direct sunlight.

Leaving the battery on the bicycle for storage is not recommended.

Troubleshooting

Cause Corrective measures

Battery defective		Two LEDs flash on the battery.Contact an authorized bike dealership.
Battery too warm or too cold		Three LEDs flash on the battery.Disconnect the battery from the charger until the charging temperature range has been reached.Do not reconnect the battery to the charger until it has reached the correct charging temperature.
The charger is not charging.		No LEDs flashing (one or more LEDs will remain permanently lit depending on the state of charge of the eBike battery).Contact an authorized bike dealership.
Charging not possible (no indicator on battery)
Connector not attached properly Check all connections.
Battery contacts dirty Carefully clean the battery contacts.
Socket outlet, cable or charger defective Check the mains voltage, have the charger checked over by a bike dealership.
Battery defective Contact an authorized bike dealership.

Battery Recycling Program

The drive unit, on-board computer incl. operating unit, battery, speed sensor, accessories and packaging should be disposed of in an environmentally correct manner.

Do not dispose of eBikes and their components with household waste.

Tape or mask off the contact surfaces of the battery pack's terminals with adhesive tape before disposing of battery packs.

Do not touch severely damaged eBike batteries with your bare hands – electrolyte may escape and cause skin irritation. Store the defective battery in a safe location outdoors. Cover the terminals if necessary and inform your dealer. They will help you to dispose of it properly.

You may recycle your Bosch battery pack by calling 1.800.822.8837.

Table des matières

Introduction....2

Maintenance/nettoyage....15

Stockage....16

Owner's Manual – The Bosch Drive System Charger

BCS 210 | BCS230

Illustration of two connected electronic devices with power leads, no text or symbols present

en Original operating 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.

Table of Contents

Introduction....2

About Warnings....2

General Warnings 2

Using your Manual 2

On-product warning labels ....4

Operating the Charger 5

Safety Instructions....5

Product Description and Specifications ....7

Operation....9

Maintenance/cleaning....11

Troubleshooting....12

Battery Recycling Program....13

Introduction

About Warnings

This manual contains many DANGER, WARNING, and CAUTION indicators concerning the consequences of failure to use, assemble, maintain, store, inspect and dispose 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 moderate injury.

General Warnings

Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in death or serious injury.

Save all safety warnings and instructions for future reference.

The term battery pack used in these operating instructions refers to all original Bosch eBike battery packs.

WARNING

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. Failure 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, consult with your dealer or the bicycle or component manufacturer.
▶ Some eBike accessories may present a choking hazard to small children. Keep these accessories away from children.

CAUTION

The Bosch Drive System adds weight to your bicycle which you may not be used to lift. Avoid injury, use proper lifting techniques.

Using your Manual

Graphics

The bicycle shown in this manual may differ slightly from your bicycle, but will be similar enough to help you understand our instructions.

In addition to the functions outlined here, changes to software relating to troubleshooting and functional modifications may be introduced at any time.

RIGHT-HAND and LEFT-HAND sides are determined by facing in the direction the bicycle will travel when going forward. When you see a broken line (----), the item referred to is hidden from view.

On-product warning labels

A

B

A Wide range charger

B Compact charger

A short version of important safety warnings in English, French and Spanish with the following content can be found on the bottom side of the charger (marked with number (4) in the representation on the graphics page):

• For safe operation, see manual.
  – Risk of electric shock
• Indoor use only
• Charge only batteries for 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.

Operating the Charger

Safety Instructions

IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS -

This manual contains important safety and operating instructions for this battery charger.

▶ Before using battery charger, read all instructions and cautionary markings on battery charger, battery, and product using battery.

CAUTION

▶ To reduce risk of injury, charge only batteries of the Bosch eBike Systems. Other types of batteries may burst causing personal injury and damage.

Save all safety warnings and instructions for future reference.

The term battery pack used in these operating instructions refers to all original Bosch eBike battery packs.

DANGER

▶ Only charge eBike-approved Bosch lithium-ion battery packs. The battery pack voltage must match the battery pack charging voltage of the charger. Otherwise, there is risk of fire and explosion.

Do not expose the charger to rain or wet conditions. If water enters a charger, there is a risk of electric shock.

WARNING

▶ 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.
- Keep the battery charger clean. Contamination can lead to the risk of an electric shock. Clean only with the use of a damp cloth (mild soap/water).

▶ Always check the charger, cable and plug before use. Stop using the charger if you discover any damage. Do not open the charger. Damaged chargers, cables and plugs increase the risk of electric shock.
- Do not operate the charger on an easily ignited surface (e.g. paper, textiles, etc.) or in a flammable environment. There is a risk of fire due to the charger heating up during operation.
▶ Take care if you touch the charger while it is charging. Wear protective gloves. The charger can get very hot, especially when the ambient temperature is high.
The battery may give off fumes if it becomes damaged or is used incorrectly. Ensure the area is well ventilated and seek medical attention should you experience any adverse effects. These fumes may irritate the respiratory tract.
- The eBike battery must not be left unattended while charging.
▶ Batteries must not be subjected to mechanical shock. There is a risk of the battery being damaged.
- Keep the battery charger away from children. This will ensure that children do not play with the charger.
▶ 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 supervision or after having been instructed by a responsible person. Otherwise, there is a risk of operating errors and injuries.
- Read and observe the safety warnings and instructions in all operating instructions of the eBike system and your eBike.

English - 6

NOTICE: This equipment complies with FCC radiation exposure limits set forth for an uncontrolled environment. This equipment should be installed and operated with minimum distance of 20 cm between the radiator and your body. This transmitter must not be co-located or operating in conjunction with any other antenna or transmitter:

1. This device must not cause harmful interference, and
2. this device must accept any interference that is received, including interference that may cause undesired operation.

NOTICE: Changes or modifications made to this equipment not expressly approved by the Robert Bosch GmbH may void the FCC authorization to operate this equipment.

NOTE: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:

– Reorient or relocate the receiving antenna.
- Increase the separation between the equipment and receiver.
- Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.
- Consult the dealer or an experienced radio/TV technician for help.

Responsible party:

Bosch eBike Systems Americas

Robert Bosch LLC

27211 Burbank, Foothill Ranch, CA 92610, USA, www.bosch-ebike.com/us/

Product Description and Specifications

Product Features

(1) Charger
(2) Device socket
(3) Device connector
(4) Charger safety instructions
(5) Charging connector

English - 8

Technical data

Charger Wide Range Charger	(36-4/100-230)	Compact Charger (36-2/100-240)
Product code BCS210 BCS230
Rated voltage V~ 90-264 90-264
Frequency Hz 47-63 47-63
Battery charging voltage V= 36 36
Charging current (max.) A 4 2
Charging time
– PowerPack 400, approx. hrs 3.5 6.5
– PowerPack 500, approx. hrs 4.5 7.5
Operating temperature °F +32 to +104 +32 to +104
Storage temperature	°F +50 to +104 +50 to +104
Weight, approx.	lb 1.8 1.3
Protection rating	IP 40	IP 40
Power cable
Article number		1 270 020 343
Rated voltage – cables	V~	300
Rated voltage – connectors/plug-in connectors	V~	125
Rated current – connectors/plug-in connectors	A	10
Material – cables		PVC
Safety standard – cables		UL 62
Safety standard – connectors/plug-in connectors		UL 817
Length, approx.	m	1.8

Operation

Start-up

Connecting the charger to the mains

▶ Note the household voltage! The voltage of the power supply must correspond to the specifications given on the battery charger nameplate.

Plug the device connector (3) of the power cable into the device socket (2) on the charger.

Connect the power cable (country-specific) to the mains.

Use only the supplied input connection: standard AC power cord ((3) in the diagram) when connecting to the household electrical supply.

Charging the battery when removed

(5) Charging connector
(6) Socket for charging connector

(8) Rack-mounted battery
(9) Operation/state of charge indicator
(10) On/off button for battery
(11) Standard battery

Switch the battery off and remove it from its holder on the eBike. When doing so, read and observe the operating instructions of the battery.

▶ Ensure the battery is placed on clean surfaces only. Avoid getting dirt, e.g. sand or soil, in the charging socket and contacts in particular.

Plug the charging connector (5) of the charger into the socket (6) on the battery.

Charging the battery when inserted in the bicycle

(5) Charging connector
(6) Socket for charging connector
(7) Charging socket cover
(11) Standard battery

(5) Charging connector
(6) Socket for charging connector
(7) Charging socket cover
(8) Rack-mounted battery

(5) Charging connector
(6) Socket for charging connector
(7) Charging socket cover

Switch the battery off. Clean the cover of the charging socket (7). Avoid getting dirt, e.g. sand or soil, in the charging socket and contacts in particular. Lift the cover of the charging socket (7) and plug the charging connector (5) into the charging socket (6).

There is a risk of fire due to the charger heating up during charging. Ensure the battery on the bike is completely dry and placed on a fireproof

surface before charging. If this is not possible, remove the battery from the holder and charge it in a more suitable location. When doing so, read and observe the operating instructions of the battery.

Charging with Two Battery Packs Inserted

If two battery packs are mounted on one eBike, both battery packs can be charged using the unsealed connection. To begin with, both batteries are charged one after the other until they reach approx. 80–90% capacity, then they are both charged at the same time until full (the LEDs on both batteries flash).

When the bike is in operation, power is drawn from both batteries on an alternating basis.

If you take the battery packs out of the holders, you can charge each battery pack individually.

Charging process

The charging process begins as soon as the charger is connected to the battery or charging socket on the bike and to the mains.

Note: The charging process is only possible when the temperature of the eBike battery is within the permitted charging temperature range.

Note: The drive unit is deactivated during the charging process.

The battery can be charged with or without the on-board computer. When charging without the on-board computer, the charging progress can be observed via the battery charge indicator.

When the on-board computer is connected, a charging notification appears on the display.

The state of charge is displayed by the battery charge indicator (9) on the battery and by the bars on the onboard computer.

The LEDs on the battery charge indicator (9) will flash during the charging process. Each solid illuminated LED represents approximately 20 % of the charging capacity. The flashing LED indicates the next 20 % currently charging.

Once the eBike battery is fully charged, the LEDs extinguish immediately and the on-board computer is

switched off. The charging process is terminated. The state of charge can be displayed for three seconds by pressing the on/off button (10) on the eBike battery. Disconnect the charger from the mains and the battery from the charger. When the battery is disconnected from the charger, the battery is automatically switched off.

Note: If you have charged the battery on the bike, carefully close the charging socket (6) with the cover (7) after charging, so that no dirt or water can get in. If the charger is not disconnected from the battery after charging, the charger will switch itself back on after a few hours, check the state of charge of the battery and begin the charging process again if necessary.

Maintenance/cleaning

WARNING

• Do not open any of the components. Service should only be carried out at an authorized Bosch eBike dealer. Failure to follow above warning can cause death or serious injury. Refer to your bicycle manual or component manual for all non-Bosch drive system components.
• Do not charge or use your eBike in any area with a potentially 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 instructions.
• Do not submerge your eBike components in water, or wash with pressurized hose. Your Bosch drive unit is designed to be water tight to rain water or non-pressure hose washing.
• Do not paint any components of the Bosch drive system as they may cause premature failure of the component.

After-sales service and advice on using products

If you have any questions about the eBike system and its components, contact an authorized bicycle dealer. For contact details of authorized bike dealerships, please visit www.bosch-ebike.com. Please contact an authorized bicycle dealer if the battery is no longer working.

Troubleshooting

Cause Corrective measures

Battery defective		Two LEDs flash on the battery.Contact an authorized bike dealership.
Battery too warm or too cold		Three LEDs flash on the battery.Disconnect the battery from the charger until the charging temperature range has been reached.Do not reconnect the battery to the charger until it has reached the correct charging temperature.
The charger is not charging.		No LEDs flashing (one or more LEDs will remain permanently lit depending on the state of charge of the eBike battery).Contact an authorized bike dealership.
Charging not possible (no indicator on battery)
Connector not attached properly Check all connections.
Battery contacts dirty Carefully clean the battery contacts.
Socket outlet, cable or charger defective Check the mains voltage, have the charger checked over by a bike dealership.
Battery defective Contact an authorized bike dealership.

Battery Recycling Program

The drive unit, on-board computer incl. operating unit, battery, speed sensor, accessories and packaging should be disposed of in an environmentally correct manner.

Do not dispose of eBikes and their components with household waste.

You may recycle your Bosch battery pack by calling 1.800.822.8837.

English - 14

Table des matières

Introduction....2

Maintenance/nettoyage....11

A Wide range charger

B Compact charger

Bosch eBike Systems Americas

Robert Bosch LLC

27211 Burbank, Foothill Ranch, CA 92610, USA, www.bosch-ebike.com/us/

Bosch eBike Systems Americas

Robert Bosch LLC

27211 Burbank, Foothill Ranch, CA 92610, USA,

www.bosch-ebike.com/us/

Addres and telephone number:

Trek US

Customer Service

801 W Madison street,

Waterloo, Wisconsin 53594

USA

Telephone: [phone]

Internet: www.trekbikes.com

Electra Bicycle Company

364 2nd Street

Encinitas, CA 92024

USA

Telephone: [phone]

Internet: www.electrabike.com

Limited warranty

Your bicycle is covered by a Lifetime Limited Warranty. Please visit our web site for details. For Service and Warranty, please contact your local dealer.

Please refer to the website (Menu/Support) for the latest revision of this manual.

New features, as described in the latest manual, may not be applicable on your electric bike.

801 W Madison street,

Waterloo, Wisconsin 53594

USA

Téléphone: 920.478.4678

Internet: www.trekbikes.com

Electra

Bicycle

Company

364 2nd Street

Encinitas, CA 92024

USA

Téléphone: 1.800.585.8737

Internet: www.electrabike.com

Garantie limitée

801 W Madison street,

Waterloo, Wisconsin 53594

USA

Electra Bicycle Company

364 2nd Street

Encinitas, CA 92024

USA

P/N 5253892 - 5253893 Rev.2 - US, October 2020

© 2020 Trek Bicycle Corporation. All rights reserved.

Part nr. 5253892 - 5253893 - Us Rev. 2