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

USER MANUAL Powerfly 4 Gen 3 TREK

• Active Line / Active Line Plus (Generation 3)

• Performance Line / Cargo Line (Generation 4)

2ENGLISH - IMPORTANT TO READ BEFORE THE FIRST RIDE 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.

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

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

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

• 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.

• 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.

• 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.

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

• 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.

• 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.

34. 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°F (-10°C) and 140°F (+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.

47. 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. 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.

• En caso de duda sobre tu nueva bicicleta eléctrica, consulta a tu distribuidor. Garantía limitada Tu bicicleta está cubierta por una garantía limitada de por vida. Para más información, visita nuestra web. 1112en Original operating instructionsfr Notice d'utilisation d'originees Instrucciones de servicio originales Ownerʼs Manual – The Bosch Drive System Drive Unit | On-board computer | Battery | Charger (20 mph) BDU330 | BDU380 | BDU385 | BDU480CX| BUI215 | BUI255 | BUI330 | BUI350 | CUI100| BBP285| BBP286| BBP287|BBP288| BBP295| BBP296| BBS266 | BBS276 | BBR266 | BBR276 | BCS210 | BCS230 Age: Âge: Edad: 16+ This manual contains important safety,performance and service information.Read and understand it along with theinformation provided to you by yourbicycle manufacturer before using theproduct, and keep it for reference. 1314English – 1 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 Bosch eBike Systems 0 275 U07 XSC | (07.04.2020) 15English – 2 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 conse- quences 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 moder- ate injury. General Warnings Read all safety warnings and all in- structions. Failure to follow the warn- ings and instructions may result in death or serious injury. Save all safety warnings and instructions for fu- ture reference. The term battery pack used in these operating in- structions refers to all original Bosch eBike battery packs. u The Bosch Drive System is intended for use by persons 16 years of age and above. Riders must have the physical coordination, reaction and men- tal capabilities to control a bike and manage traffic, road conditions, and sudden situations, as well as to respect the laws and instructions governing bicy- cle use. WARNING u This manual contains important safety, perfor- mance 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. u This manual is intended to be read together with the separate user manual provided with your bi- cycle. Be sure to read all provided documents in- cluding labels on the product before your first ride. u Read ALL accompanying manuals before riding the bike for the first time. Your Bosch Drive Sys- tem 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 in- jury. u Take responsibility for your own SAFETY. If you have any questions or do not understand some- thing, consult with your dealer or the bicycle or component manufacturer. u Some eBike accessories may present a choking hazard to small children. Keep these accessories away from children. CAUTION u The Bosch Drive System adds weight to your bi- cycle which you may not be used to lift. Avoid in- jury, use proper lifting techniques. 0 275 U07 XSC | (07.04.2020) Bosch eBike Systems 16English – 3 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 u Read and observe the safety warnings and in- structions 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 eBike Systems 0 275 U07 XSC | (07.04.2020) 17English – 4 Bosch Drive System Overview Bicycle View (Standard) (1) (2) (3) (4) 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 0 275 U07 XSC | (07.04.2020) Bosch eBike Systems 18English – 5 Bicycle View (Rack-Type) (1) (2) (3) (4) 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 Bosch eBike Systems 0 275 U07 XSC | (07.04.2020) 19English – 6 Bicycle View (PowerTube) (1) (2) (3) (4) 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 0 275 U07 XSC | (07.04.2020) Bosch eBike Systems 20English – 7 Operating your Bosch Drive System Getting Ready to Ride WARNINGu Read and understand all safety warnings and in- structions. Failure to follow the below warnings could result in death or serious injury. u Protect others from death or serious injury. Pre- vent unauthorized use. Always remove battery from the bicycle when not in use and store in a se- cure location. Failure to secure your bicycle from unauthorized use can result in death or serious in- jury to others. u Read and understand the influences on the oper- ating range when planning your ride (see "Influ- ences on range", pageEnglish – 9). Before your first ride Check your bicycle owner’s manual for important in- formation about the bike components, such as the brakes, pedals, gears, gear shifting, etc. WARNINGu 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 posi- tion. Utilize the operating unit to change motor as- sistance levels while riding. u 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. u Wearing a helmet can prevent a severe head in- jury. Whenever riding, always wear a helmet that meets or exceeds established safety stan- dards. Approved helmets in the USA must meet the US Consumer Product Safety Commission stan- dard, so look for a CPSC reference. Intended Use WARNINGu 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 an- other bicycle. For trailer towing, consult your bicycle owner’s manual and trailer owner’s manual for towing instructions and towing compatibility. Bosch eBike Systems 0 275 U07 XSC | (07.04.2020) 21English – 8 Safe Start-up Procedure WARNING u 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 bat- tery 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 ped- aling. 0 275 U07 XSC | (07.04.2020) Bosch eBike Systems 22English – 9 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 pedal- ing force you apply. If you apply less force, you will receive less assistance than if you apply a lot of force. This applies irrespec- tive of the assistance level. The eBike drive automatically switches off at speeds over 20mph. When the speed falls below 20mph, the drive automatically becomes available again. An exception applies to the push assistance function, in which the eBike can be pushed at low speed with- out pedaling. The pedals may rotate when the push assistance is in use. You can also use the eBike as a normal bicycle with- out 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. u Read and understand the influences on the oper- ating range when planning your ride (see "Influ- ences on range", pageEnglish – 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 sur- face) – 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 oth- erwise constant conditions, the smaller the range will be. Note: Plan your routes so that you can always reach your destination without motor assistance. Bosch eBike Systems 0 275 U07 XSC | (07.04.2020) 23English – 10 Transport WARNING u Always remove the battery pack from the bicy- cle 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 seri- ous injury. The battery may detach during transport and cause an accident to following vehicles. u 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. u 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 bat- tery in such a manner that it cannot move around in the packaging. Inform your parcel service that the package contains dangerous goods. Please also ob- serve possibly more detailed national regulations. Al- ways check state and federal regulations before at- tempting to ship your battery. u If you transport your eBike attached to the out- side 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 bat- teries, contact an authorized bicycle dealer. You can also order suitable transport packaging from the dealer. Maintenance/Cleaning WARNING u Do not open any of the components. Service should only be carried out at an authorized Bosch eBike dealer. Failure to follow above warn- ing can cause death or serious injury. Refer to your bicycle manual or component manual for all non- Bosch drive system components. u Always remove the battery pack before per- forming any bicycle inspection, maintenance or repair. Failure to remove the battery pack before performing bicycle inspection, maintenance or re- pair can lead to serious injury. u 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 re- quire 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. u If replacing your battery, buy only a genuine Bosch battery pack from an approved source. See your Bosch eBike dealer for original Bosch parts. u Always switch the battery pack off, when insert- ing or removing it from the holder. Never attempt to insert or remove the battery pack while riding the bike. u 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. u Do not submerge your eBike components in wa- ter, or wash with pressurized hose. Your Bosch drive unit is designed to be water tight to rain water or non-pressure hose washing. 0 275 U07 XSC | (07.04.2020) Bosch eBike Systems 24English – 11 u 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. u 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 tempera- tures of the eBike components. Protect the drive unit, on-board computer and battery against extreme tem- peratures (e.g. from intense sunlight without ade- quate 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

• Cette notice contient d'importantes informationes sur la sécurité, les performances et l'entretien. Lisez-les et comprenez-les ainsi que les informations fournies par le fabricant de votre vélo avant d'utiliser le produit, et conservez- les pour référence ultérieure. Este manual contiene información importante de seguridad, rendimiento y mantenimiento. Léalo y asegúrese de entenderlo junto con la información que le ha facilitado el fabricante de su bicicleta antes de usar el producto; guárdelo a modo de referencia. 54en Original operating instructions fr Notice d'utilisation d'origine es Instrucciones de servicio originales Ownerʼs Manual – The Bosch Drive System Purion BUI215 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. 5556English – 1 Table of Contents Introduction p. 2
• About Warnings p. 2
• General Warnings p. 2
• Using your Manual p. 2
• Operating your Bosch on-board computer p. 4
• Safety instructions p. 4
• Product description and specifications p. 5
• Operation p. 7
• Speed and distance indicators p. 10
• Troubleshooting p. 11
• Battery Recycling Program Bosch eBike Systems 1 270 U20 XBP | (08.04.2020) 57English – 2 Introduction About Warnings This manual contains many DANGER, WARNING, and CAUTION indicators concerning the conse- quences 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 moder- ate injury. General Warnings Read all safety warnings and all in- structions. Failure to follow the warn- ings and instructions may result in death or serious injury. Save all safety warnings and instructions for fu- ture reference. The term battery pack used in these operating in- structions refers to all original Bosch eBike battery packs. WARNINGu This manual contains important safety, perfor- mance 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. u This manual is intended to be read together with the separate user manual provided with your bi- cycle. Be sure to read all provided documents in- cluding labels on the product before your first ride. u Read ALL accompanying manuals before riding the bike for the first time. Your Bosch Drive Sys- tem 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 in- jury. u Take responsibility for your own SAFETY. If you have any questions or do not understand some- thing, consult with your dealer or the bicycle or component manufacturer. u Some eBike accessories may present a choking hazard to small children. Keep these accessories away from children. CAUTIONu The Bosch Drive System adds weight to your bi- cycle which you may not be used to lift. Avoid in- jury, use proper lifting techniques. Using your Manual In addition to the functions outlined here, changes to software relating to troubleshooting and functional modifications may be introduced at any time. Graphics The bicycle shown in this manual may differ slightly from your bicycle, but will be similar enough to help you understand our instructions. 1 270 U20 XBP | (08.04.2020) Bosch eBike Systems 58English – 3 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 eBike Systems 1 270 U20 XBP | (08.04.2020) 59English – 4 Operating your Bosch on-board computer Safety instructions Read all the safety information and instructions. Failure to observe the safety information and follow instruc- tions may result in electric shock, fire and/or serious injury. Save all safety warnings and instructions for fu- ture reference. The term battery pack used in these operating in- structions refers to all original Bosch eBike battery packs. u Do not allow yourself to be distracted by the dis- play of the on-board computer. If you do not con- centrate 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. u Read and observe the safety warnings and in- structions in all operating instructions of the eBike system and your eBike. u Set the display brightness such that you can ad- equately see important information like speed or warning symbols. An incorrectly set display brightness can result in dangerous situations. u Do not expose on-board computer to fire or ex- cessive temperature. Exposure to fire or tempera- ture above 212 °F (100 °C) may cause explosion. u 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, per- sonal injury and property damage. u 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, immedi- ately flush eyes with water for a minimum of 15minutes and seek medical attention. u 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 com- puter, charging cables and plugs increase the risk of a fire, explosion and personal injury. u Do not disassemble on-board computer. No user serviceable part inside. Incorrect reassembly or damage may result in fire or explosion. 1 270 U20 XBP | (08.04.2020) Bosch eBike Systems 60English – 5 Product description and specifications WALK WALK WALK p. 14

(7) (6) (5) (j) (i) (a) (b) (c) (d) (e) (h) (g) (f)(8) (9) (1) (2) (3) (4) 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 Bosch eBike Systems 1 270 U20 XBP | (08.04.2020) 61English – 6 Technical data On-board computer Purion Product code BUI215 Batteries

IP54 Weight, approx. lbs 0.22 A) We recommend using batteries offered by Bosch. You can purchase them from your bicycle dealer (article number: 1270016819). B) When the USB cover is closed The Bosch eBike system uses FreeRTOS (seehttp://www.freertos.org

This device is in compliance with Part15 of the FCC Rules. Op- eration is subject to the following two conditions:

1. This device must not cause harmful interference, and

2. this device must accept any interference that is received, in-

cluding interference that may cause undesired operation. 1 270 U20 XBP | (08.04.2020) Bosch eBike Systems 62English – 7 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 fol- lowing requirements are met: – A sufficiently charged battery is inserted (see bat- tery 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 com- puter 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 com- puter. As soon as you stop pedaling when in normal opera- tion, or as soon as you have reached a speed of 20/28mph, the eBike drive unit switches off the as- sistance. The drive is automatically re-activated as soon you start pedaling again and the speed is below 20/28mph. The following options are available for switching off the eBike system: – Press the on/off button (1) of the on-board com- puter. – Switch off the eBike battery using its on/off button (some bicycle manufacturer-specific solutions pre- vent access to the battery on/off button; see the bi- cycle manufacturer operating instructions). The system shuts down after being switched off. This takes approximately threeseconds. It cannot be switched back on until shutdown has been com- pleted. 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. Bosch eBike Systems 1 270 U20 XBP | (08.04.2020) 63English – 8 Changing the batteries WALK WALK WALK WAL

(3) (4) (10) If the on-board computer shows LOW BAT on the dis- play, remove the on-board computer from the handle- bars by unscrewing the fastening screw(3) of the on- board computer. Open the battery compartment cover(10) using a suitable coin, remove the used batteries and insert new CR2016batteries. 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 se- lected gear and can reach a maximum of 3.7mph. The lower the selected gear, the lower the speed of the push assistance function (at full power). u 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 acti- vation, press the + button within 3s and keep it pressed. The eBike drive is switched on. Note: The push assistance cannot be activated at as- sistance 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 3.7mph. The push assistance function is subject to local regu- lations; 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 as- sistance 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 max- imum: – OFF: Motor assistance is switched off. The eBike can just be moved by pedaling, as with a normal bi- cycle. The push assistance cannot be activated at this assistance level. – ECO: Effective assistance with maximum effi- ciency, for maximum range – TOUR: Steady assistance, long range for touring 1 270 U20 XBP | (08.04.2020) Bosch eBike Systems 64English – 9 – 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 BDU480CX. 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 in- dicator (i). To decrease the assistance level briefly press the button– (5). If the display is set to TRIP, TOTAL or RANGE, the se- lected 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 but- ton+ will switch on the front and rear lights simulta- neously. 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 ac- tivates this saved status accordingly after a restart. Switching the bike lights on and off has no effect on the backlighting of the display. Bosch eBike Systems 1 270 U20 XBP | (08.04.2020) 65English – 10 Speed and distance indicators (j) (i) (a) (b) (c) (d) (e) (h) (g) (f) 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 distanceTRIP, the total distanceTOTAL and the battery rangeRANGE one af- ter the other. (Briefly pressing the button– will de- crease the assistance level.) To reset the trip distanceTRIP, select the trip dis- tanceTRIP and simultaneously press and hold the buttons+ and –. The display will initially showRE- SET. If you continue to press both buttons, the trip distanceTRIP will be set to 0. To reset the battery rangeRANGE, select the battery rangeRANGE and simultaneously press and hold the buttons+ and –. The display will initially showRE- SET. If you continue to press both buttons, the trip distanceTRIP 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 func- tion. u 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

Display TRIP, TOTAL, RANGE, assistance modes

Switch on bike lights

Switch off bike lights

Activate push assistance Implement push assistance WALK

quired Switch from kilometers to miles

• Active Line/Active Line Plus/Performance Line This manual contains important safety,performance and service information.Read and understand it along with theinformation provided to you by yourbicycle manufacturer before using theproduct, and keep it for reference. 101102English – 1 Table of Contents Introduction p. 2
• About Warnings p. 2
• General Warnings p. 2
• Using your Manual p. 2
• Operating your Bosch drive unit p. 4
• Safety instructions p. 4
• Product description and specifications p. 6
• Assembly p. 7
• Operation p. 8
• Maintenance/Cleaning Bosch eBike Systems 0 275 U07 XD3 | (08.04.2020) 103English – 2 Introduction About Warnings This manual contains many DANGER, WARNING, and CAUTION indicators concerning the conse- quences 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 moder- ate injury. General Warnings Read all safety warnings and all in- structions. Failure to follow the warn- ings and instructions may result in death or serious injury. Save all safety warnings and instructions for fu- ture reference. The term battery pack used in these operating in- structions refers to all original Bosch eBike battery packs. WARNINGu This manual contains important safety, perfor- mance 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. u This manual is intended to be read together with the separate user manual provided with your bi- cycle. Be sure to read all provided documents in- cluding labels on the product before your first ride. u Read ALL accompanying manuals before riding the bike for the first time. Your Bosch Drive Sys- tem 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 in- jury. u Take responsibility for your own SAFETY. If you have any questions or do not understand some- thing, consult with your dealer or the bicycle or component manufacturer. u Some eBike accessories may present a choking hazard to small children. Keep these accessories away from children. CAUTIONu The Bosch Drive System adds weight to your bi- cycle which you may not be used to lift. Avoid in- jury, use proper lifting techniques. Using your Manual In addition to the functions outlined here, changes to software relating to troubleshooting and functional modifications may be introduced at any time. Graphics The bicycle shown in this manual may differ slightly from your bicycle, but will be similar enough to help you understand our instructions. 0 275 U07 XD3 | (08.04.2020) Bosch eBike Systems 104English – 3 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 eBike Systems 0 275 U07 XD3 | (08.04.2020) 105English – 4 Operating your Bosch drive unit Safety instructions Read and understand all safety warn- ings and instructions. Failure to follow the below warnings could result in death or serious injury. Save all safety warnings and instructions for fu- ture reference. The term battery pack used in these operating in- structions refers to all original Bosch eBike battery packs. u Do not attempt to change – in particular, to in- crease – the power of your drive or the maxi- mum speed that it supports. Doing this may put yourself and others at risk, and you could also breach statutory regulations. u Do not open the drive unit yourself. The drive unit must only be repaired by qualified person- nel using only original spare parts. This will en- sure that the safety of the drive unit is maintained. Unauthorized opening of the drive unit will render warranty claims null and void. u 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 compo- nents that have been specifically approved by the manufacturer for your eBike. This will protect the drive unit from overloading and becoming dam- aged. u Remove the battery from the eBike before be- ginning 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. u The eBike system can be activated by pushing the eBike backwards or by turning the pedals backwards. u 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. u When the push assistance is activated, the ped- als may turn at the same time. When the push as- sistance function is activated, make sure that there is enough space between your legs and the turning pedals to avoid the risk of injury. u After a ride, do not allow your unprotected hands or legs to come into contact with the housing of the drive unit. Under extreme condi- tions, 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 u Use only original Bosch batteries that the manu- facturer 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. u Do not make any modifications to your eBike system or fit any other products that might in- 0 275 U07 XD3 | (08.04.2020) Bosch eBike Systems 106English – 5 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 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 manip- ulation of the bicycle. Under extreme conditions, such as con- tinuously 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. u Please observe all local, state and federal regu- lations when registering and using eBikes. u Read and observe the safety warnings and in- structions 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 con- sumption, temperature, etc.) is transferred to Bosch eBike Systems (Robert Bosch GmbH) for the pur- poses of product improvement. You can find more in- formation about this on the Bosch eBike website at www.bosch-ebike.com p. 10

Bosch eBike Systems 0 275 U07 XD3 | (08.04.2020) 107English – 6 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 ActiveLine ActiveLinePlus PerformanceLine PerformanceLine 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 +23to +104 +23to +104 +23to +104 +23to +104 Storage temperature °F +50to +104 +50to +104 +50to +104 +50to +104 Protection rating IP54 IP54 IP54 IP54 Weight, approx. kg 2.9 3.2 3.2 3.2 The Bosch eBike system uses FreeRTOS (seehttp://www.freertos.org

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 suit- able for the specified voltage. Bulbs must only be replaced with bulbs of the same voltage. Inserting a bulb incorrectly can cause it to blow. 0 275 U07 XD3 | (08.04.2020) Bosch eBike Systems 108English – 7 Assembly Inserting and removing the battery For inserting and removing the eBike battery in/from the eBike, please read and observe the battery oper- ating instructions. Check speed sensor

(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 mag- net (2) and fasten the spoke magnet to the spoke such that it runs past the marking on the speed sen- sor at the correct clearance. If the speed is still not being indicated on the speedometer display after do- ing 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 2mm and at most 8mm with each rotation of the wheel. The correct distance between the magnet and sensor must be maintained (see figureA) if design changes are made. Notes: Ensure that you do not damage the sensor or sensor bracket when fitting or removing the rear wheel. Bosch eBike Systems 0 275 U07 XD3 | (08.04.2020) 109English – 8 Operation Start-up Requirements The eBike system can only be activated when the fol- lowing requirements are met: – A sufficiently charged battery is inserted (see bat- tery operating instructions). – The on-board computer is properly inserted in the holder (see on-board computer operating instruc- tions). – 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 de- pends on which assistance level is set on the on- board computer. As soon as you stop pedaling when in normal opera- tion, or as soon as you have reached a speed of 20mph, the eBike drive unit switches off the assis- tance. The drive is automatically re-activated as soon you start pedaling again and the speed is below 20mph. 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 pre- vent access to the battery on/off button; see the bi- cycle 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 compo- nents are electrically connected to the drive unit by the manufacturer. The separate operating instruc- tions 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 as- sistance 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 max- imum: – OFF: Motor assistance is switched off. The eBike can just be moved by pedaling, as with a normal bi- cycle. The push assistance cannot be activated at this assistance level. – ECO: Effective assistance with maximum effi- ciency, for maximum range – TOUR: Steady assistance, long range for touring 0 275 U07 XD3 | (08.04.2020) Bosch eBike Systems 110English – 9 – 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 BDU480CX. 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

The assistance factor may vary in some models.

Dynamic-progressive assistance level

Dynamic-progressive assistance level betweenTOUR andTURBO modes Switching the push assistance on/off The push assistance aids you when pushing your eBike. The speed of this function depends on the se- lected gear and can reach a maximum of 3.7mph. The lower the selected gear, the lower the speed of the push assistance function (at full power). u 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 acti- vation, press the + button within 3s and keep it pressed. The eBike drive is switched on. Note: The push assistance cannot be activated at as- sistance 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 3.7mph. The push assistance function is subject to local regu- lations; 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. Bosch eBike Systems 0 275 U07 XD3 | (08.04.2020) 111English – 10 Maintenance/Cleaning WARNING u Do not open any of the components. Service should only be carried out at an authorized Bosch eBike dealer. Failure to follow above warn- ing can cause death or serious injury. Refer to your bicycle manual or component manual for all non- Bosch drive system components. u Always remove the battery pack before per- forming any bicycle inspection, maintenance or repair. Failure to remove the battery pack before performing bicycle inspection, maintenance or re- pair can lead to serious injury. u 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 re- quire 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. u If replacing your battery, buy only a genuine Bosch battery pack from an approved source. See your Bosch eBike dealer for original Bosch parts. u Always switch the battery pack off, when insert- ing or removing it from the holder. Never attempt to insert or remove the battery pack while riding the bike. u 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. u Do not submerge your eBike components in wa- ter, or wash with pressurized hose. Your Bosch drive unit is designed to be water tight to rain water or non-pressure hose washing. u 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. u 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 com- patible 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 tempera- tures of the eBike components. Protect the drive unit, on-board computer and battery against extreme tem- peratures (e.g. from intense sunlight without ade- quate 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

• Performance Line/Cargo Line This manual contains important safety,performance and service information.Read and understand it along with theinformation provided to you by yourbicycle manufacturer before using theproduct, and keep it for reference. 141142English – 1 Table of Contents Introduction p. 2
• About Warnings p. 2
• General Warnings p. 2
• Using your Manual p. 2
• Operating your Bosch Drive Unit p. 4
• Safety instructions p. 4
• Product description and specifications p. 6
• Assembly p. 7
• Operation p. 8
• Maintenance/Cleaning Bosch eBike Systems 0 275 U07 XD4 | (09.04.2020) 143English – 2 Introduction About Warnings This manual contains many DANGER, WARNING, and CAUTION indicators concerning the conse- quences 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 moder- ate injury. General Warnings Read all safety warnings and all in- structions. Failure to follow the warn- ings and instructions may result in death or serious injury. Save all safety warnings and instructions for fu- ture reference. The term battery pack used in these operating in- structions refers to all original Bosch eBike battery packs. WARNINGu This manual contains important safety, perfor- mance 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. u This manual is intended to be read together with the separate user manual provided with your bi- cycle. Be sure to read all provided documents in- cluding labels on the product before your first ride. u Read ALL accompanying manuals before riding the bike for the first time. Your Bosch Drive Sys- tem 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 in- jury. u Take responsibility for your own SAFETY. If you have any questions or do not understand some- thing, consult with your dealer or the bicycle or component manufacturer. u Some eBike accessories may present a choking hazard to small children. Keep these accessories away from children. CAUTIONu The Bosch Drive System adds weight to your bi- cycle which you may not be used to lift. Avoid in- jury, use proper lifting techniques. Using your Manual In addition to the functions outlined here, changes to software relating to troubleshooting and functional modifications may be introduced at any time. Graphics The bicycle shown in this manual may differ slightly from your bicycle, but will be similar enough to help you understand our instructions. 0 275 U07 XD4 | (09.04.2020) Bosch eBike Systems 144English – 3 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 eBike Systems 0 275 U07 XD4 | (09.04.2020) 145English – 4 Operating your Bosch Drive Unit Safety instructions Read and understand all safety warn- ings and instructions. Failure to follow the below warnings could result in death or serious injury. Save all safety warnings and instructions for fu- ture reference. The term battery pack used in these operating in- structions refers to all original Bosch eBike battery packs. u Do not attempt to change – in particular, to in- crease – the power of your drive or the maxi- mum speed that it supports. Doing this may put yourself and others at risk, and you could also breach statutory regulations. u Do not open the drive unit yourself. The drive unit must only be repaired by qualified person- nel using only original spare parts. This will en- sure that the safety of the drive unit is maintained. Unauthorized opening of the drive unit will render warranty claims null and void. u 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 compo- nents that have been specifically approved by the manufacturer for your eBike. This will protect the drive unit from overloading and becoming dam- aged. u Remove the battery from the eBike before be- ginning 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. u 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. u When the push assistance is activated, the ped- als may turn at the same time. When the push as- sistance function is activated, make sure that there is enough space between your legs and the turning pedals to avoid the risk of injury. u After a ride, do not allow your unprotected hands or legs to come into contact with the housing of the drive unit. Under extreme condi- tions, 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 u Use only original Bosch batteries that the manu- facturer 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. u 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 pur- 0 275 U07 XD4 | (09.04.2020) Bosch eBike Systems 146English – 5 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 manip- ulation of the bicycle. Under extreme conditions, such as con- tinuously 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. u Please observe all local, state and federal regu- lations when registering and using eBikes. u Read and observe the safety warnings and in- structions 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 con- sumption, temperature, etc.) is transferred to Bosch eBike Systems (Robert Bosch GmbH) for the pur- poses of product improvement. You can find more in- formation about this on the Bosch eBike website at www.bosch-ebike.com p. 10

Bosch eBike Systems 0 275 U07 XD4 | (09.04.2020) 147English – 6 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

Rated voltage V= 36 36 Operating temperature °F +23to +104 +23to +104 Storage temperature °F +50to +104 +50to +104 Protection rating IP54 IP54 Weight, approx. kg 3 3 A) Is determined by the bicycle manufacturer The Bosch eBike system uses FreeRTOS (seehttp://www.freertos.org

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 suit- able for the specified voltage. Bulbs must only be replaced with bulbs of the same voltage. Inserting a bulb incorrectly can cause it to blow. 0 275 U07 XD4 | (09.04.2020) Bosch eBike Systems 148English – 7 Assembly Inserting and removing the battery For inserting and removing the eBike battery in/from the eBike, please read and observe the battery oper- ating instructions. Check speed sensor

(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 mag- net (2) and fasten the spoke magnet to the spoke such that it runs past the marking on the speed sen- sor at the correct clearance. If the speed is still not being indicated on the speedometer display after do- ing 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 2mm and at most 8mm with each rotation of the wheel. The correct distance between the magnet and sensor must be maintained (see figureA) if design changes are made. Notes: Ensure that you do not damage the sensor or sensor bracket when fitting or removing the rear wheel. Bosch eBike Systems 0 275 U07 XD4 | (09.04.2020) 149English – 8 Operation Start-up Requirements The eBike system can only be activated when the fol- lowing requirements are met: – A sufficiently charged battery is inserted (see bat- tery operating instructions). – The on-board computer is properly inserted in the holder (see on-board computer operating instruc- tions). – 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 20mph. 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 de- pends on which assistance level is set on the on- board computer. As soon as you stop pedaling when in normal opera- tion, or as soon as you have reached a speed of 20/28mph, the eBike drive unit switches off the as- sistance. The drive is automatically re-activated as soon you start pedaling again and the speed is below 20/28mph. 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 pre- vent access to the battery on/off button; see the bi- cycle 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 compo- nents are electrically connected to the drive unit by the manufacturer. The separate operating instruc- tions 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 as- sistance 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 max- imum: – OFF: Motor assistance is switched off. The eBike can just be moved by pedaling, as with a normal bi- cycle. The push assistance cannot be activated at this assistance level. – ECO: Effective assistance with maximum effi- ciency, for maximum range – TOUR: Steady assistance, long range for touring 0 275 U07 XD4 | (09.04.2020) Bosch eBike Systems 150English – 9 – 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 BDU480CX. 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

The assistance factor may vary in some models.

Dynamic-progressive assistance level betweenTOUR andTURBO modes Switching the push assistance on/off The push assistance aids you when pushing your eBike. The speed of this function depends on the se- lected gear and can reach a maximum of 3.7mph. The lower the selected gear, the lower the speed of the push assistance function (at full power). u 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 acti- vation, press the + button within 3s and keep it pressed. The eBike drive is switched on. Note: The push assistance cannot be activated at as- sistance 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 3.7mph. The push assistance function is subject to local regu- lations; 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. Bosch eBike Systems 0 275 U07 XD4 | (09.04.2020) 151English – 10 Maintenance/Cleaning WARNING u Do not open any of the components. Service should only be carried out at an authorized Bosch eBike dealer. Failure to follow above warn- ing can cause death or serious injury. Refer to your bicycle manual or component manual for all non- Bosch drive system components. u Always remove the battery pack before per- forming any bicycle inspection, maintenance or repair. Failure to remove the battery pack before performing bicycle inspection, maintenance or re- pair can lead to serious injury. u 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 re- quire 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. u If replacing your battery, buy only a genuine Bosch battery pack from an approved source. See your Bosch eBike dealer for original Bosch parts. u Always switch the battery pack off, when insert- ing or removing it from the holder. Never attempt to insert or remove the battery pack while riding the bike. u 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. u Do not submerge your eBike components in wa- ter, or wash with pressurized hose. Your Bosch drive unit is designed to be water tight to rain water or non-pressure hose washing. u 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. u 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 com- patible 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 tempera- tures of the eBike components. Protect the drive unit, on-board computer and battery against extreme tem- peratures (e.g. from intense sunlight without ade- quate 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

• 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. 181182English – 1 Table of Contents Introduction p. 2
• About Warnings p. 2
• General Warnings p. 2
• Using your Manual p. 2
• On-product warning labels p. 4
• Handling the lithium-ion battery pack p. 5
• Safety warnings for Bosch eBike batteries p. 5
• Product description and specifications p. 7
• Fitting p. 10
• Operation p. 14
• Transport p. 14
• Maintenance/cleaning p. 15
• Storing p. 15
• Troubleshooting p. 17
• Battery Recycling Program Bosch eBike Systems 0 275 U07 XPX | (09.04.2020) 183English – 2 Introduction About Warnings This manual contains many DANGER, WARNING, and CAUTION indicators concerning the conse- quences 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 moder- ate injury. General Warnings Read all safety warnings and all in- structions. Failure to follow the warn- ings and instructions may result in death or serious injury. Save all safety warnings and instructions for fu- ture reference. The term battery pack used in these operating in- structions refers to all original Bosch eBike battery packs. WARNINGu This manual contains important safety, perfor- mance 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. u This manual is intended to be read together with the separate user manual provided with your bi- cycle. Be sure to read all provided documents in- cluding labels on the product before your first ride. u Read ALL accompanying manuals before riding the bike for the first time. Your Bosch Drive Sys- tem 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 in- jury. u Take responsibility for your own SAFETY. If you have any questions or do not understand some- thing, consult with your dealer or the bicycle or component manufacturer. u Some eBike accessories may present a choking hazard to small children. Keep these accessories away from children. CAUTIONu The Bosch Drive System adds weight to your bi- cycle which you may not be used to lift. Avoid in- jury, use proper lifting techniques. Using your Manual In addition to the functions outlined here, changes to software relating to troubleshooting and functional modifications may be introduced at any time. Graphics The bicycle shown in this manual may differ slightly from your bicycle, but will be similar enough to help you understand our instructions. 0 275 U07 XPX | (09.04.2020) Bosch eBike Systems 184English – 3 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 eBike Systems 0 275 U07 XPX | (09.04.2020) 185English – 4 On-product warning labels To reduce the risk of injury, explosion, or fire, user must read instruction manual. Do not crush, puncture,disassemble, short terminals, or dispose in fire. Do not usebattery once it has been impacted, sustained water damage orvisibly damaged. Charge battery only with Bosch eBike chargers. Remove battery when using vehicle bike rack! L'utilisateur doit lire le mode d`emploi pour réduire le risque de blessure, explosion ou d'incendie. Ne pas écraser, perforer, démonter, court-circuiter les bornes ou jeter dans un feu. Ne pas réutiliser lapile si elle a subi una choc, des dégâ ts causés par l'eau ou d'autres dommages visibles. Ne chargerla pile qu'avec un chargeur Bosch eBike. Retirez la batterie avant letransport sur le porte-vélos.AVERTISSEMENTWARNING使用前に取扱説明書を読むこと分解、改造、端子の短絡、火気への投入禁止故障が疑われる時は使用を停止する専用充電器を使用すること車で運搬時はバッテリーを取り外すこと p. 18

To reduce the risk of injury, explosion, or fire, user must read instruction manual.

Do not crush, puncture, dissassemble, short terminals, or dispose in fire.

Do not use battery once it has been impacted, sustained water damage or visibly damaged.

Safety instructions for PowerPack Safety instructions for PowerTube u Warning labels have been placed on the Bosch eBike System for your protection. Read and fol-low the instructions of the labels on the productcarefully. If a label becomes illegible or comesoff, contact your Bosch bicycle dealer to obtaina replacement. Replacement safety labels are pro-vided by Bosch at no charge. 0 275 U07 XPX | (09.04.2020) Bosch eBike Systems 186English – 5 Handling the lithium-ion battery pack Safety warnings for Bosch eBike batteries Read and understand all safety warn- ings and instructions. Failure to follow the below warnings could result in death or serious in- jury. Save all safety warnings and instructions for fu- ture reference. The term battery pack used in these operating in- structions refers to all original Bosch eBike battery packs. DANGER u 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. max.140°F Protect the battery pack against heat (e.g., temperature >140°F), fire and immersing into water. Danger of ex- plosion. WARNING u Use only original Bosch battery packs approved for your eBike by the manufacturer and pur- chased from a credible source. Use of non-ap- proved or counterfeit battery packs can lead to death or serious injury. u Remove the battery from the eBike before be- ginning 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. u Do not open the battery. There is a risk of short- circuiting. Opening the battery voids any and all warranty claims. u 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 con- nection from one terminal to another. A short cir- cuit 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. u Avoid mechanical loads and exposure to high temperatures. These can damage the battery cells and cause the flammable contents to leak out. u Do not place the charger or the battery near flammable materials. Ensure the battery is com- pletely dry and placed on a fireproof surface be- fore charging. There is a risk of fire due to the heat generated during charging. u The eBike battery must not be left unattended while charging. u If used incorrectly, liquid may leak from the bat- tery. Contact with this liquid should be avoided. If contact occurs, rinse off with water. If the liq- uid comes into contact with your eyes, seek ad- ditional medical attention. Liquid leaking from the battery may cause irritation or scalding. u Batteries must not be subjected to mechanical shock. There is a risk of the battery being dam- aged. u 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. u Only charge the battery using original Bosch chargers. When using chargers that are not made by Bosch, the risk of fire cannot be excluded. Bosch eBike Systems 0 275 U07 XPX | (09.04.2020) 187English – 6 u 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. u Use only original Bosch batteries that the manu- facturer 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. u Do not use the rack-mounted battery as a han- dle. Lifting the eBike up by the battery can damage the battery. u Read and observe the safety warnings and in- structions in all operating instructions of the eBike system and your eBike. u 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 manufac- tured in accordance with the latest technology. We comply with or exceed the requirements of all rele- vant 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 out- side), in very rare cases and under unfavorable condi- tions, 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. tempera- ture, 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

0 275 U07 XPX | (09.04.2020) Bosch eBike Systems 188English – 7 Product description and specifications Product features PowerPack (6) (5) (1) (13) (12) (2) (3) (4) (11) (10) (3)(4) (5) (6) (7) (8) (9) (12) (13) 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 bat- tery packs) (11) Charger (12) Socket for charging connector (13) Charging socket cover Bosch eBike Systems 0 275 U07 XPX | (09.04.2020) 189English – 8 Product features PowerTube (16) (14) (5) (6) (12) (13) (14) (15) (11) (4) (3) (4) 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 0 275 U07 XPX | (09.04.2020) Bosch eBike Systems 190English – 9 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

– Rack-mounted battery 0275007525/526 0275007535/536 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

Protection rating IP 54 IP 54 A) Standard battery B) Rack-mounted battery This device is in compliance with Part15 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.

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 Part15 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 u 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. u Do not charge or use batteries if they are dam- aged. Contact an authorized bicycle dealer. Charging the battery u A Bosch eBike battery must only be charged us- ing an original Bosch eBike charger. Note: The battery is supplied partially charged. To en- sure 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 instruc- tions in the operating manual for the charger. The battery can be charged at any state of charge. In- terrupting the charging process does not damage the battery. The battery has a temperature monitoring function which only allows it to be charged within a tempera- ture 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 bat- tery from the charger and let it acclimatize. 0 275 U07 XPX | (09.04.2020) Bosch eBike Systems 192English – 11 CAUTION u Do not connect the battery pack to the charger until it has reached the allowable charging tem- perature. 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 accessi- ble. u 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 con- nection. 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. Bosch eBike Systems 0 275 U07 XPX | (09.04.2020) 193English – 12 Inserting and Removing the battery u Always switch off the battery and the eBike sys- tem when inserting the battery into the holder or removing it from the holder. Inserting and Removing the Standard Battery

(8) (9) (10) (5) (6) (7) 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. u 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 (6) (5) (1) (10) (2) 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 con- tacts-first into the holder (1) on the rack until it clicks into place. u 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 bat- tery out of the holder (1). 0 275 U07 XPX | (09.04.2020) Bosch eBike Systems 194English – 13 Removing the PowerTube battery

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). ❷ 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 manufac- turer. Inserting the PowerTube battery

(14) (15) (6) (5) 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. ❷ Push the battery upwards until it is held by the safety restraint (14). ❸ 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.

Always secure the battery by closing the lock (6) – otherwise the lock may open and the battery may fall out of the holder. u 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. Bosch eBike Systems 0 275 U07 XPX | (09.04.2020) 195English – 14 Operation Start-up u Use only original Bosch batteries that the manu- facturer 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 sys- tem, 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 but- ton. The LEDs on the indicator (3) will light up, indi- cating the battery's state of charge at the same time. u 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 auto- matically 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 in- dicator (3) will flash. Con- tact 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 bat- tery 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 origi- nal Bosch eBike battery by your specialist retailer. Transport u Always remove the battery pack from the bicy- cle 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 seri- ous injury. The battery may detach during transport and cause an accident to following vehicles. u 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. u 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 bat- tery in such a manner that it cannot move around in the packaging. Inform your parcel service that the 0 275 U07 XPX | (09.04.2020) Bosch eBike Systems 196English – 15 package contains dangerous goods. Please also ob- serve possibly more detailed national regulations. Al- ways check state and federal regulations before at- tempting to ship your battery. If you have any questions about transporting the bat- teries, contact an authorized bicycle dealer. You can also order suitable transport packaging from the dealer. Maintenance/cleaning u Do not open any of the components. Service should only be carried out at an authorized Bosch eBike dealer. Failure to follow above warn- ing can cause death or serious injury. Refer to your bicycle manual or component manual for all non- Bosch drive system components. u Always remove the battery pack before per- forming any bicycle inspection, maintenance or repair. Failure to remove the battery pack before performing bicycle inspection, maintenance or re- pair can lead to serious injury. u If replacing your battery, buy only a genuine Bosch battery pack from an approved source. See your Bosch eBike dealer for original Bosch parts. u Always switch the battery pack off, when insert- ing or removing it from the holder. Never attempt to insert or remove the battery pack while riding the bike. u 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. u Do not submerge your eBike components in wa- ter, or wash with pressurized hose. Your Bosch drive unit is designed to be water tight to rain water or non-pressure hose washing. u 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. u 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

To reduce the risk of injury, explosion, or fire, user must read instruction manual.

Do not crush, puncture, dissassemble, short terminals, or dispose in fire.

Do not use battery once it has been impacted, sustained water damage or visibly damaged.

To reduce the risk of injury, explosion, or fire, user must read instruction manual.

Do not crush, puncture, dissassemble, short terminals, or dispose in fire.

Do not use battery once it has been impacted, sustained water damage or visibly damaged.

• Cette notice contient d'importantes informationes sur la sécurité, les performances et l'entretien. Lisez-les et comprenez-les ainsi que les informations fournies par le fabricant de votre vélo avant d'utiliser le produit, et conservez- les pour référence ultérieure. Este manual contiene información importante de seguridad, rendimiento y mantenimiento. Léalo y asegúrese de entenderlo junto con la información que le ha facilitado el fabricante de su bicicleta antes de usar el producto; guárdelo a modo de referencia. 238en Original operating instructions fr Notice d'utilisation d'origine es Instrucciones de servicio originales Ownerʼs Manual – The Bosch Drive System Charger BCS 210 | BCS230 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. 239240English – 1 Table of Contents Introduction p. 2
• About Warnings p. 2
• General Warnings p. 2
• Using your Manual p. 2
• On-product warning labels p. 4
• Operating the Charger p. 5
• Safety Instructions p. 5
• Product Description and Specifications p. 7
• Operation p. 9
• Maintenance/cleaning p. 11
• Troubleshooting p. 12
• Battery Recycling Program Bosch eBike Systems 0 275 U07 XCX | (08.04.2020) 241English – 2 Introduction About Warnings This manual contains many DANGER, WARNING, and CAUTION indicators concerning the conse- quences 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 moder- ate injury. General Warnings Read all safety warnings and all in- structions. Failure to follow the warn- ings and instructions may result in death or serious injury. Save all safety warnings and instructions for fu- ture reference. The term battery pack used in these operating in- structions refers to all original Bosch eBike battery packs. WARNINGu This manual contains important safety, perfor- mance 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. u This manual is intended to be read together with the separate user manual provided with your bi- cycle. Be sure to read all provided documents in- cluding labels on the product before your first ride. u Read ALL accompanying manuals before riding the bike for the first time. Your Bosch Drive Sys- tem 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 in- jury. u Take responsibility for your own SAFETY. If you have any questions or do not understand some- thing, consult with your dealer or the bicycle or component manufacturer. u Some eBike accessories may present a choking hazard to small children. Keep these accessories away from children. CAUTIONu The Bosch Drive System adds weight to your bi- cycle which you may not be used to lift. Avoid in- jury, use proper lifting techniques. Using your Manual In addition to the functions outlined here, changes to software relating to troubleshooting and functional modifications may be introduced at any time. Graphics The bicycle shown in this manual may differ slightly from your bicycle, but will be similar enough to help you understand our instructions. 0 275 U07 XCX | (08.04.2020) Bosch eBike Systems 242English – 3 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 eBike Systems 0 275 U07 XCX | (08.04.2020) 243English – 4 On-product warning labels p. 13

Compact charger A short version of important safety warnings in Eng- lish, 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 dam- age. – Do not replace the plug assembly as risk of fire or electric shock may result. 0 275 U07 XCX | (08.04.2020) Bosch eBike Systems 244English – 5 Operating the Charger Safety Instructions

IMPORTANT SAFETY INSTRUCTIONS SAVE THESE

INSTRUCTIONS – This manual contains important safety and operat- ing instructions for this battery charger. u Before using battery charger, read all instructions and cautionary markings on battery charger, bat- tery, and product using battery. CAUTION u To reduce risk of injury, charge only batteries of the Bosch eBike Systems. Other types of batter- ies may burst causing personal injury and damage. Save all safety warnings and instruc- tions for future reference. The term battery pack used in these operating in- structions refers to all original Bosch eBike battery packs. DANGER u 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 explo- sion. Do not expose the charger to rain or wet conditions. If water enters a charger, there is a risk of electric shock. WARNING u Use only the original Bosch battery charger sup- plied 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. u 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). u 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 elec- tric shock. u 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. u Take care if you touch the charger while it is charging. Wear protective gloves. The charger can get very hot, especially when the ambient tem- perature is high. u 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. u The eBike battery must not be left unattended while charging. u Batteries must not be subjected to mechanical shock. There is a risk of the battery being dam- aged. u Keep the battery charger away from children. This will ensure that children do not play with the charger. u 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. u Read and observe the safety warnings and in- structions in all operating instructions of the eBike system and your eBike. Bosch eBike Systems 0 275 U07 XCX | (08.04.2020) 245English – 6 NOTICE: This equipment complies with FCC radiation exposure limits set forth for an uncontrolled environ- ment. This equipment should be installed and oper- ated 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,

2. this device must accept any interference that is re-

ceived, including interference that may cause un- desired operation. NOTICE: Changes or modifications made to this equipment not expressly approved by the Robert Bosch GmbH may void the FCC authorization to oper- ate this equipment. NOTE: This equipment has been tested and found to comply with the limits for a Class B digital device, pur- suant to Part 15 of the FCC Rules. These limits are de- signed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio fre- quency energy and, if not installed and used in accor- dance with the instructions, may cause harmful inter- ference to radio communications. However, there is no guarantee that interference will not occur in a par- ticular 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 mea- sures: – 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 con- nected. – Consult the dealer or an experienced radio/TV tech- nician for help. Responsible party: Bosch eBike Systems Americas Robert Bosch LLC 27211 Burbank, Foothill Ranch, CA 92610, USA, www.bosch-ebike.com/us/ 0 275 U07 XCX | (08.04.2020) Bosch eBike Systems 246English – 7 Product Description and Specifications (5) (1) (4) (3) (2) (2) Product Features (1) Charger (2) Device socket (3) Device connector (4) Charger safety instructions (5) Charging connector Bosch eBike Systems 0 275 U07 XCX | (08.04.2020) 247English – 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 +32to +104 +32to +104 Storage temperature °F +50to +104 +50to +104 Weight, approx. lb 1.8 1.3 Protection rating IP40 IP40 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 0 275 U07 XCX | (08.04.2020) Bosch eBike Systems 248English – 9 Operation Start-up Connecting the charger to the mains (2) (2) (3) u Note the household voltage! The voltage of the power supply must correspond to the specifica- tions 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 (11) (6) (5) (9) (10) (8) (6) (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. u 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 (11) (6) (7) (5) (5) Charging connector (6) Socket for charging connector (7) Charging socket cover (11) Standard battery Bosch eBike Systems 0 275 U07 XCX | (08.04.2020) 249English – 10 (8) (6) (7) (5) (5) Charging connector (6) Socket for charging connector (7) Charging socket cover (8) Rack-mounted battery (5) (6) (7) (5) Charging connector (6) Socket for charging connector (7) Charging socket cover Switch the battery off. Clean the cover of the charg- ing 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 charg- ing connector (5) into the charging socket (6). u 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, re- move 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 con- nection. 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 permit- ted charging temperature range. Note: The drive unit is deactivated during the charg- ing 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 ob- served via the battery charge indicator. When the on-board computer is connected, a charg- ing 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 on- board 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 ex- tinguish immediately and the on-board computer is 0 275 U07 XCX | (08.04.2020) Bosch eBike Systems 250English – 11 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 bat- tery 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 af- ter charging, the charger will switch itself back on af- ter a few hours, check the state of charge of the bat- tery and begin the charging process again if neces- sary. Maintenance/cleaning WARNING u Do not open any of the components. Service should only be carried out at an authorized Bosch eBike dealer. Failure to follow above warn- ing can cause death or serious injury. Refer to your bicycle manual or component manual for all non- Bosch drive system components. u 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. u Do not submerge your eBike components in wa- ter, or wash with pressurized hose. Your Bosch drive unit is designed to be water tight to rain water or non-pressure hose washing. u 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