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TRANSLATION OF THE ORIGINAL
OPERATING INSTRUCTIONS
IMPORTANT
READ CAREFULLY BEFORE USE
KEEP SAFE TO CONSULT AT A LATER DATE
KB148-ZAKC46, KB148-ZBKC46, KB149-ZAFC46, KB149-ZBFC46, KB150-ZAFC46, KB150-ZBFC46
MY21K03 - 12_1.0_22.09.2020
Familiano C-10, Familiano C-N, Familiano L-N
MY21K03 - 12_1.0_21.09.2020 2
Contents
Contents
1 About these operating instructions 6
1.1 Manufacturer 6
1.2 Language 6
1.3 Laws, standards and directives 6
1.4 For your information 6
1.4.1 Warnings 6
1.4.2 Markups 7
1.5 Nameplate 8
1.6 Type number and model 9
1.7 Identifying the operating instructions 9
2 Safety 10
2.1 Residual risks 10
2.1.1 Risk of battery fire and explosion 10
2.1.2 Risk of fire and explosion due to
short circuit in the battery 10
2.1.3 Fire hazard caused by overheated
charger 10
2.1.4 Electric shock caused by electric
drive system 10
2.1.5 Risk of a fall due to incorrectly set quick
releases 11
2.1.6 Risk of fire and burns due to hot motor 11
2.1.7 Key breaking off 11
2.2 Toxic substances 11
2.2.1 Brake fluid 11
2.2.2 Suspension oil 11
2.2.3 Defective battery 11
2.3 Requirements for the rider 11
2.4 Vulnerable groups 11
2.5 Personal protective equipment 11
2.6 Safety markings and safety instructions 12
2.7 What to do in an emergency 12
2.7.1 Dangerous situation in road traffic 12
2.7.2 Leaked brake fluid 12
2.7.3 Battery vapours emitted 13
2.7.4 Battery fire 13
2.7.5 Leaked brake fluid 13
2.7.6 Oil and lubricant leaks from the fork 13
2.7.7 Oil and lubricant leaks from the rear
frame damper 13
3Overview 14
3.1 Description 15
3.1.1 Wheel 15
3.1.1.1 Valve 15
3.1.2 Suspension 15
3.1.3 Brake 15
3.1.4 Electric drive system 16
3.1.5 Motor 16
3.1.6 Rechargeable battery 16
3.1.7 Display 18
3.1.8 Riding light 18
3.1.9 Charger 18
3.2 Proper use 19
3.3 Improper use 20
3.3.1 Maximum permitted total weight 21
3.3.2 Data privacy information 21
3.4 Technical data 22
3.4.1 Pedelec 22
3.4.2 Bicycle lighting 22
3.4.3 BOSCH Purion display 22
3.4.4 BOSCH Cargo Line Speed motor 22
3.4.5 Bosch rechargeable battery 22
3.4.5.1 PowerPack 300 22
3.4.5.2 PowerPack 400 23
3.4.5.3 PowerPack 500 23
3.5 Description of controls and screens 24
3.5.1 Handlebars 24
3.5.2 Display 24
3.5.2.1 Information display 24
3.5.2.2 Level of assistance 24
3.5.2.3 Indicator unit km/h or mph 24
3.5.2.4 Tachometer screen 25
3.5.2.5 System message 25
3.5.3 Battery level indicator 25
3.6 Environmental requirements 26
4 Transporting and storing 28
4.1 Physical transport characteristics 28
4.1.1 Designated handles/lifting points 28
4.2 Transporting 29
4.2.1 Using the brake transport securing
system 29
4.2.2 Transporting the pedelec 29
4.2.3 Shipping a pedelec 29
4.2.4 Transporting the battery 29
4.2.5 Shipping the battery 29
4.3 Storing 30
4.3.1 Break in operation 30
4.3.1.1 Preparing a break in operation 30
4.3.1.2 Carrying out a break in operation 30
5 Assembly 31
5.1 Required tools 31
5.2 Unpacking 31
5.2.1 Scope of delivery 31
5.3 Commissioning 31
5.4 Preparing the battery 32
5.4.1 Checking the battery 32
5.4.2 Checking the stem and handlebars 32
5.4.2.1 Checking the connections 32
5.4.2.2 Firm hold 32
5.4.2.3 Checking the headset backlash 32
MY21K03 - 12_1.0_21.09.2020 3
Contents
5.5 Pedelec sale 32
6 Operation 33
6.1 Risks and hazards 33
6.1.1 Personal protective equipment 34
6.2 Tips for a greater range 34
6.3 Error message 35
6.3.1 Display 35
6.3.2 Rechargeable battery 37
6.4 Instruction and customer service 38
6.5 Adjusting the pedelec 38
6.5.1 Adjusting the saddle 38
6.5.1.1 Adjusting the saddle tilt 38
6.5.1.2 Determining the seat height 38
6.5.1.3 Adjusting the seat height with quick
release 39
6.5.1.4 Adjusting the seat position 39
6.5.2 Adjusting the handlebars 40
6.5.3 Adjusting the stem 40
6.5.3.1 Adjusting the height of the handlebars 40
6.5.3.2 Adjusting the quick release clamping
force 40
6.5.4 Setting the brake 40
6.5.5 Retracting the brake linings 41
6.5.5.1 Setting the grip distance on a brake
lever 41
6.5.5.2 Setting the pressure point on a brake
lever 41
6.6 Accessories 42
6.6.1 Child seat 42
6.6.2 Trailer 43
6.6.2.1 Trailer approval for ENVIOLO hub gear 43
6.6.3 Mobile holder 44
6.6.4 Tubeless and airless 44
6.7 Check list before each ride 45
6.8 Using the kickstand 46
6.8.1 Raising the kickstand 46
6.9 Using the pannier rack 46
6.10 Using the saddle 46
6.11 Rechargeable battery 47
6.11.1 BOSCH PowerPack 47
6.11.1.1 Removing the PowerPack 47
6.11.1.2 Insert PowerPack 47
6.11.2 Charging the battery 47
6.11.3 Charging the dual battery 48
6.11.3.1 Charging process when two batteries
are used 48
6.11.3.2 Charging process when one battery
is used 48
6.11.4 Using double battery model with a
single battery only 48
6.11.5 Waking the battery 48
6.12 Electric drive system 49
6.12.1 Switching on the electric drive system 49
6.12.2 Switching off the electric drive system 49
6.13 Display 50
6.13.1 Overview of actions on the display
screen 50
6.13.2 Switching on the display 50
6.13.3 Switching off the display 50
6.14 Using the push assist system 51
6.14.1 Using the riding light 51
6.14.2 Selecting the level of assistance 51
6.14.3 Journey information 51
6.14.3.1 Switching the journey information 51
6.14.3.2 Resetting the trip distance 51
6.14.3.3 Resetting the range 52
6.14.3.4 Changing the tachometer unit 52
6.14.3.5 Displaying versions and type numbers 52
6.14.3.6 Set display screen brightness 52
6.14.4 Using the USB port 52
6.14.5 Replacing the battery 52
6.15 Brake 53
6.15.1 Using the brake lever 54
6.16 Gear shift 55
6.16.1 Using the derailleur gears 55
6.16.2 Using an ENVIOLO hub gear 55
6.16.3 Selecting automatic or manual shift 56
6.16.4 Switching gear in automatic mode 56
6.16.5 Switching gear manually 56
6.16.5.1 Changing down 56
6.16.5.2 Changing up 56
6.17 Parking the pedelec 57
7 Cleaning and servicing 58
7.1 Cleaning after each ride 58
7.1.1 Cleaning the suspension fork 58
7.1.2 Cleaning the rear frame damper 58
7.1.3 Cleaning the pedals 58
7.2 Basic cleaning 59
7.2.1 Cleaning the frame 59
7.2.2 Cleaning the stem 59
7.2.3 Cleaning the wheel 59
7.2.4 Cleaning the drive elements 59
7.2.5 Cleaning the rear frame damper 60
7.2.6 Cleaning the chain 60
7.2.7 Cleaning the battery 60
7.2.8 Cleaning the display 60
7.2.9 Cleaning the motor 60
7.2.10 Cleaning the brake 61
7.3 Servicing 61
7.3.1 Servicing the frame 61
7.3.2 Servicing the stem 61
7.3.3 Servicing the fork 61
7.3.4 Servicing the drive elements 61
7.3.5 Servicing the pedals 61
MY21K03 - 12_1.0_21.09.2020 4
Contents
7.3.6 Servicing the chain 61
7.4 Maintenance 62
7.4.1 Wheel 62
7.4.1.1 Checking the tyres 62
7.4.1.2 Checking the rims 62
7.4.1.3 Checking and adjusting the tyre
pressure – Dunlop valve 62
7.4.1.4 Checking and adjusting the tyre
pressure – Presta valve 63
7.4.1.5 Checking and adjusting the tyre
pressure – Schrader valve 63
7.4.2 Brake system 63
7.4.3 Checking the brake linings for wear 63
7.4.4 Checking the pressure point 64
7.4.5 Checking the brake discs for wear 64
7.4.6 Checking the electrical cables and
brake cables 64
7.4.7 Checking the gear shift 64
7.4.8 Checking the stem 64
7.4.9 Checking the USB port 64
7.4.10 Checking the belt and chain tension 64
8 Maintenance 65
8.1 Suspension system 66
8.1.1 Rear frame damper 66
8.1.2 Suspension fork 67
8.1.3 Suspension seat post 68
8.2 Axle with quick release 68
8.2.1 Checking the quick release 69
8.3 Maintaining the stem 69
8.4 Adjusting the gear shift 69
8.4.1 Cable-operated gear shift, single-cable 70
8.4.2 Cable-operated gear shift, dual-cable 70
8.4.3 Cable-operated twist grip, dual-cable 70
9 Troubleshooting, fault clearance
and repair 71
9.1 Troubleshooting and fault clearance 71
9.1.1 The drive system or display do not
start up 71
9.1.2 Error message 71
9.1.3 Errors in the assistance system 72
9.1.4 Battery error 73
9.1.5 On-board computer error 74
9.1.6 Lighting does not work 74
9.1.7 Other errors 74
9.2 Repair 75
9.2.1 Original parts and lubricants 75
9.2.2 Replacing the lighting 75
9.2.3 Adjusting the headlight 75
10 Recycling and disposal 76
11 Documents 77
11.1 Parts list 77
11.1.1 Familiano C-10 77
11.1.2 Familiano C-N 78
11.1.3 Familiano L-N 79
11.2 Assembly report 80
11.3 Maintenance instructions 82
11.4 Charger operating instructions 86
12 Glossary 94
12.1 Abbreviations 96
12.2 Simplified terms 96
13 Appendix 97
I. Translation of the original EC/EU
Declaration of Conformity 97
II. Declaration of conformity for
incomplete machine 98
14 Keyword index 101
MY21K03 - 12_1.0_22.09.2020 5
About these operating instructions
Thank you for your trust!
KETTLER pedelecs are premium quality bicycles.
You have made an excellent choice. Your
specialist dealer will provide you with guidance
and instruction and assemble your product. Your
specialist dealer will also be happy to assist you in
the future, whether you require maintenance,
conversion or repair.
You are receiving these operating instructions
with your new pedelec. Please take time to
become familiar with your new pedelec. Use the
tips and suggestions in the operating instructions.
They will help you to enjoy your pedelec for a long
time to come. We hope you have fun and wish you
well on all of your rides!
The operating instructions are mainly designed for
the rider or the operator. They aim to ensure that
non-professionals can use the pedelec safely.
Download the operating instructions onto your
phone at the following link, so that you can use
them when you are out riding:
https://www.kettler-alu-
rad.de/gb/en/index/
service.html.
Copyright
© KETTLER Alu-Rad GmbH
Distribution or reproduction of these operating
instructions and utilisation or communication of
their content is prohibited unless expressly
approved. Any infringement will render the
offender liable for compensation. All rights
reserved in the event that a patent, utility model or
industrial design is registered.
Editing
Text and images:
ZEG Zweirad-Einkaufs-Genossenschaft eG
Longericher Strasse 2
50739 Köln, Germany
Translation
RKT Übersetzungs- und Dokumentations-GmbH
Markenstrasse 7
40227 Düsseldorf, Germany
In case of any questions or problems
regarding these operating instructions,
please contact:
tecdoc@zeg.de
Notice
These operating instructions are not a substitute
for personal instruction by the supplying specialist
dealer.
These operating instructions are an integral part
of the pedelec. Therefore, if it is re-sold at a later
time, they must be handed over to the subsequent
owner.
Sections are also designed especially for the
specialist dealer. These sections aim to ensure
that specialist dealers complete initial assembly
and maintenance safely and reliably. The
sections for specialist dealers are highlighted in
grey and marked with a spanner symbol.
MY21K03 - 12_1.0_22.09.2020 6
About these operating instructions
1 About these operating
instructions
1.1 Manufacturer
The pedelec manufacturer is:
KETTLER Alu-Rad GmbH
Longericher Strasse 2
50739 Köln, Germany
Tel.: +49 6805 6008-0
Fax: +49 6805 6008-3098
E-mail: info@kettler-alu-rad.de
Website: www.kettler-alu-rad.de
Subject to internal changes
The information contained in these operating
instructions are the approved technical
specifications at the time of printing. Any
significant changes are included in a new
published version of the operating instructions.
You will find any modifications to these operating
instructions at:
https://www.kettler-alu-rad.de/gb/en/index/
service.html
1.2 Language
The original operating instructions are written in
German. A translation is invalid without the
original operating instructions.
1.3 Laws, standards and directives
The operating instructions comply with the
essential requirements specified in:
Machinery Directive 2006/42/EC
Electromagnetic Compatibility Directive 2014/30/
EU
ISO 20607:2018 Safety of machinery
Instruction handbook – General drafting
principles
EN 15194:2018 Cycles – Electrically power
assisted cycles – pedelec bicycles
EN 11243:2016, Cycles – Pannier racks for
bicycles – Requirements and test methods
ISO 17100:2016-05 Translation Services
Requirements for translation services.
1.4 For your information
Different markings are used in the operating
instructions to make them easier to read.
1.4.1 Warnings
Warnings indicate hazardous situations and
actions. You will find warnings in the operating
instructions:
Will lead to serious or even fatal injuries if
ignored. High-risk hazard.
May lead to serious or even fatal injuries if
ignored. Medium-risk hazard.
May lead to minor or moderate injuries if ignored.
Low-risk hazard.
Notice
May lead to material damage if ignored.
DANGER
!
WARNING
!
CAUTION
!
MY21K03 - 12_1.0_22.09.2020 7
About these operating instructions
1.4.2 Markups
You will find stylised forms of typeface in the
operating instructions:
Instructions for specialist dealers are highlighted
in grey. They are indicated by a screwdriver
symbol. Information for specialist dealers does
not require non-professionals to take any action.
Stylised form Use
Italics Glossary term
Underlined in blue Link
Underlined in grey Cross references
Check marks Requirements
Triangle Instruction for action
1Instruction for
action
Several instructions for
action in specified order
Result of the action
SPACED Indicators on the display
screen
Bulleted lists
Only applies to pedelecs
with this equipment Each type has a different
kind of equipment. A
note beneath the
heading indicates
components which can
be used as an
alternative.
Table 1: Markups
MY21K03 - 12_1.0_22.09.2020 8
About these operating instructions
1.5 Nameplate
The nameplate is situated on the frame. You can
see the exact position of the nameplate in Figure 2.
You will find thirteen pieces of information on the
nameplate.
Figure 1: Example Nameplate
KETTLER
Alu-Rad GmbH
Longericher Str. 2
50739 Köln, Germany
Typ:
KB084-NXRW
EN 15194
0,25 kW / 25 km/h
zGG 180 kg
EPAC 25 kg
BJ 2020 / MJ 2021
nach
EPAC
2
3
1
4
5
6
7
89
12
13
10
11
No. Designation Description
1CE marking The manufacturer uses the CE marking to declare that the pedelec complies with
applicable requirements.
2 Manufacturer's contact details You can contact the manufacturer at the address. You can find more information in
Section 1.
3 Type number All pedelec models have an eight-digit type number, which is used to specify the design
model year, the type of pedelec and the version. You can find more information in Section
1.
4 Maximum continuous power The maximum continuous power is the greatest possible power for the electric motor
output shaft over 30 minutes.
5 Maximum permitted total weight The maximum permitted total weight is the weight of the fully assembled pedelec with the
rider and baggage.
6 Year of manufacture The year of manufacture is the year in which the pedelec was manufactured. The
production period is from August 2020 to July 2021.
7 Pedelec type You can find more information in Section 3.2.
8 Safety markings You can find more information in Section 1.4.
9 Disposal instructions You can find more information in Section 10.
10 Area of use You can find more information in Section 3.2.
11 Model year The model year refers to the first production year that the series-manufactured pedelec
was produced in the version concerned. The year of manufacture is different to the model
year in some cases.
12 Weight of the ready-to-ride pedelec The weight of the ready-to-ride pedelec is specified as a weight of 25 kg or above and
refers to its weight at the time of purchase. You must add each additional accessory to
the weight.
13 Shut-off speed The speed that the pedelec reaches at the moment when the current has dropped to zero
or to the no-load current value.
Table 2: Nameplate details
MY21K03 - 12_1.0_21.09.2020 9
About these operating instructions
1.6 Type number and model
These operating instructions are an integral part of
pedelecs with the type numbers:
1.7 Identifying the operating
instructions
The Identification number position is located on
bottom left-hand side on each page. The
identification number is composed of the
document number, the version number and the
release date.
Type no. Model Pedelec type
KB148-ZAKC46 Familiano C-10 Cargo bike
KB148-ZBKC46 Familiano C-10 Cargo bike
KB149-ZAFC46 Familiano C-N Cargo bike
KB149-ZBFC46 Familiano C-N Cargo bike
KB150-ZAFC46 Familiano L-N Cargo bike
KB150-ZBFC46 Familiano L-N Cargo bike
Table 3: Type number, model and pedelec type
Identification number MY21K03 - 12_1.0_22.09.2020
MY21K03 - 12_1.0_21.09.2020 10
Safety
2 Safety
2.1 Residual risks
2.1.1 Risk of battery fire and explosion
The safety electronics may fail if the batteries are
damaged or faulty. The residual voltage can
cause a short circuit. The battery may self-ignite
and explode.
Only use and charge the battery and
accessories if they are in perfect condition.
Never open or repair the battery.
Batteries with external damage must be
removed from service immediately.
If a battery is dropped or struck, remove it from
service and observe it for at least 24 hours.
Faulty batteries are hazardous goods. Dispose
of faulty batteries in the correct manner. Store
battery in a dry place until disposal. Never
store in the vicinity of flammable substances.
The battery is only protected from spray water.
Penetration by water can cause a short circuit.
The battery may self-ignite and explode.
Never immerse the battery in water.
Put battery out of service if you suspect water
has penetrated it.
Temperatures over 60 °C can also cause liquid to
leak from the battery and the battery will become
damaged. The battery may self-ignite and
explode.
Protect the battery against heat.
Never store next to hot objects.
Never expose the battery to sustained direct
sunlight.
Avoid wide temperature fluctuations.
2.1.2 Risk of fire and explosion due to
short circuit in the battery
Metal objects may connect the battery's electrical
terminals. The battery may self-ignite and
explode.
Never insert paper clips, screws, coins, keys
and other small parts into the battery.
Chargers with excessive voltage damage
batteries. This may result in fire or an explosion.
Only use batteries approved for the pedelec.
Clearly label the supplied charger.
2.1.3 Fire hazard caused by overheated
charger
The charger heats up when charging the battery.
In case of insufficient cooling, this can result in fire
or burns to the hands.
Never use charger on a highly flammable
surface.
Never cover the charger during charging.
Never leave the battery unattended during
charging.
2.1.4 Electric shock caused by electric
drive system
Damaged chargers, cables and plug connectors
increase the risk of electric shock.
Check the charger, cable and plug connector
before each use. Never use a damaged
charger.
If water penetrates into the charger, there is a risk
of electric shock.
Never charge the battery outdoors.
MY21K03 - 12_1.0_21.09.2020 11
Safety
2.1.5 Risk of a fall due to incorrectly set
quick releases
Excessively high clamping force will damage the
quick release and cause it to lose its function.
Insufficient clamping force will result in
unfavourable transmission of force. This can
cause components to break. This will cause a
crash with injuries.
Never fasten a quick release using a tool (e.g.
hammer or pliers).
Only use the clamping lever with the specified
set clamping force.
2.1.6 Risk of fire and burns due to hot
motor
The motor housing becomes hot when riding.
Touching it may cause burns to the skin or other
objects.
Never touch the motor housing directly after
riding.
Never place the pedelec on a flammable
surface, such as grass or wood, directly after
use.
2.1.7 Key breaking off
If you leave a key inserted when riding or
transporting the pedelec, it may break off or the
locking system may open accidentally.
Remove the key to the battery lock.
2.2 Toxic substances
2.2.1 Brake fluid
Brake fluid may leak out after an accident or due
to material fatigue. Brake fluid can be fatal if
swallowed or inhaled.
Never dismantle the brake system.
Avoid contact with skin.
Do not inhale vapours.
2.2.2 Suspension oil
Suspension oil in the fork and the rear frame
damper is toxic to the touch, irritates respiratory
tracts and causes cancer, sterility and mutation in
germ cells.
Never dismantle the rear frame damper or the
suspension fork.
Avoid contact with skin.
2.2.3 Defective battery
Liquids and vapours may leak from damaged or
faulty batteries. Excessively high temperatures
may also cause liquids and vapours to leak from
the battery. Such liquids and vapours can irritate
the airways and cause burns.
Never dismantle the battery.
Avoid contact with skin.
Do not inhale vapours.
2.3 Requirements for the rider
The rider must demonstrate adequate physical,
motor and mental abilities to ride on public roads.
A minimum age of 14 years is recommended.
2.4 Vulnerable groups
Keep batteries and charger away from children
and people with reduced physical, sensory or
mental capabilities or lacking in experience and
knowledge.
If minors use the pedelec, a legal guardian must
should provide them with comprehensive
instructions.
2.5 Personal protective equipment
Wear a suitable cycling helmet, sturdy footwear
and typical close-fitting clothing to provide
protection.
MY21K03 - 12_1.0_21.09.2020 12
Safety
2.6 Safety markings and safety
instructions
The nameplate contains these safety markings
and safety instructions:
2.7 What to do in an emergency
2.7.1 Dangerous situation in road traffic
In the event of any hazards or dangers in road
traffic, apply the brakes on the pedelec until it
comes to a halt. The brake acts as an
emergency stop system in such cases.
2.7.2 Leaked brake fluid
Remove those affected from the danger area to
fresh air.
Never leave those affected unattended.
Immediately remove any clothing items
contaminated with brake fluid.
Never inhale vapours. Ensure sufficient
ventilation.
Wear gloves and safety gloves as protective
equipment.
Keep unprotected persons away.
Take care with leaked brake fluid as it poses a
slip hazard.
Keep leaked brake fluid away from naked
flames, hot surfaces and sources of ignition.
Avoid contact with skin and eyes.
After inhalation
Take in fresh air. Immediately consult a doctor
in case of any discomfort.
After skin contact
Wash affected skin with soap and water and
rinse well. Remove contaminated clothing.
Consult doctor in the event of pain or
discomfort.
After contact with eyes
Rinse eyes under flowing water for at least ten
minutes with the lids open; also rinse under
lids. Immediately consult a doctor in case of
any pain or discomfort.
After swallowing
Rinse out mouth with water. Never induce
vomiting. Risk of aspiration!
Symbol Explanation
General warning
Adhere to the instructions for use
Table 4: Meaning of safety markings
Symbol Explanation
Read the instructions
Separate collection of electrical
and electronic devices
Separate collection of ordinary
and rechargeable batteries
Must not be thrown into fire
(burning prohibited)
It is forbidden to open any
batteries
Device of protection class II
Only suitable for use indoors
Fuse (device fuse)
EU conformity
Recyclable material
Protect from temperatures
above 50 °C and direct sunlight
Table 5: Safety instructions
max. 50°C
MY21K03 - 12_1.0_21.09.2020 13
Safety
If a person is lying on their back and vomiting,
place them in the recovery position. Seek
medical advice immediately.
Environmental protection measures
Never allow brake fluid to flow into the sewage
system, water courses or groundwater.
Notify the relevant authorities if fluid
penetrates the ground, water courses or the
sewage system.
Consult a doctor immediately in the event of
any pain or discomfort caused by combustion
gas or leaking fluids.
2.7.3 Battery vapours emitted
Vapours may be emitted if the battery is damaged
or used improperly. The vapours may cause
respiratory tract irritation.
Get into fresh air.
Consult doctor in the event of pain or
discomfort.
After contact with eyes
Carefully rinse eyes with plenty of water for at
least 15 minutes. Protect unaffected eye. Seek
medical advice immediately.
After skin contact
Remove any solid particles immediately.
Rinse the affected area with plenty of water for
at least 15 minutes. Then dab the affected skin
gently. Do not rub dry.
Remove contaminated clothing immediately.
Immediately consult a doctor if there is any
redness, pain or discomfort.
2.7.4 Battery fire
The safety electronics may fail if the battery is
damaged or faulty. The residual voltage can
cause a short circuit. The battery may self-ignite
and explode.
1Keep your distance if the battery becomes
deformed or starts to emit smoke.
2If charging, remove the plug connector from
the socket.
3Contact the fire service immediately.
Use Class fire extinguishers to put out the fire.
Never extinguish damaged batteries with water
or allow them to come into contact with water.
Inhaling vapours can cause intoxication.
Stand on the side of the fire where the wind is
blowing from.
Use breathing apparatus if possible.
2.7.5 Leaked brake fluid
The brake system must be repaired immediately if
brake fluid leaks out. Dispose of leaking brake
fluid in an environmentally responsible way in
accordance with statutory regulations.
Contact your specialist dealer.
2.7.6 Oil and lubricant leaks from the fork
Dispose of oils and lubricants which have leaked
from the rear frame damper in an environmentally
responsible way in compliance with statutory
regulations.
Contact your specialist dealer.
2.7.7 Oil and lubricant leaks from the rear
frame damper
Dispose of oils and lubricants which have leaked
from the rear frame damper in an environmentally
responsible way in accordance with statutory
regulations.
Contact your specialist dealer.
MY21K03 - 12_1.0_22.09.2020 14
Overview
3Overview
Figure 2: Kettler Familiano pedelec from right; saddle seat and cushion are not included in the basic configuration
1 Front wheel
2Fork
3 Front guard
4 Headlight
5 Handlebars
6Stem
7Frame
8 Seat post
9 Saddle
10 Pannier rack
11 Rear light and reflector
12 Rear guard
13 Rear wheel
14 Chain
15 Motor
16 Kickstand
17 Chain guard
18 Battery and nameplate
19 Pedal
1
2
3
5
6
78910
11
12
13
14 15 1617
4
18 19
MY21K03 - 12_1.0_22.09.2020 15
Overview
3.1 Description
3.1.1 Wheel
Figure 3: Visible wheel components
1Tyres
2 Rim
3 Spoke
4 Spoke nipples
5Hub
6Valve
The wheel comprises the wheel itself, an inner
tube with a valve and a tyre.
3.1.1.1 Valve
Each wheel has a valve. It is used to fill the tyre
with air. There is a valve cap on each valve. The
screw-on valve cap keeps out dust and dirt.
The pedelec either has a conventional Dunlop
valve, a Presta valve or a Schrader valve.
3.1.2 Suspension
The pedelec features a rigid fork.
Rigid forks do not feature suspension. They transfer
the used muscle and motor power to the road to
optimum effect. Pedelecs with rigid forks consume
less energy on steep roads and have a greater range
than pedelecs with adjusted suspension.
3.1.3 Brake
The pedelec features a hydraulic brake system.
The brake fluid is in a closed hose system. If the
rider pushes the brake lever, the brake fluid
activates the brake on the wheel.
The pedelec features a disc brake on the front and
rear wheels.
The mechanical brakes are used as an
emergency stop system and bring the bicycle to a
halt quickly and safely in the event of an
emergency.
Figure 4: Brake system with disc brake – example
1Brake disc
2 Brake calliper with brake linings
3 Handlebars with brake lever
4 Front wheel brake disc
5 Rear wheel brake disc
On a pedelec with a disc brake, the brake disc is
screwed permanently to the wheel hub. The brake
lever is pushed to increase brake pressure. The
brake fluid is used to transfer pressure through
the brake cables to the cylinders in the brake
calliper. The braking force is boosted by a speed
reduction and applied to the brake linings. These
apply the brake disc mechanically. If the brake
lever is pushed, the brake linings are pressed
against the brake disc and the wheel movement is
decelerated until it comes to a stop.
1
2
3
6
5
4
2
MY21K03 - 12_1.0_22.09.2020 16
Overview
3.1.4 Electric drive system
The pedelec is driven by muscle power applied to
the chain drive. The force which is applied by
pedalling in the direction of travel drives the front
chain wheel. The chain transmits the force onto
the rear chain wheel and then onto the rear wheel.
Figure 5: Diagram of mechanical drive system
1 Direction of travel
2 Chain
3 Rear chain wheel
4 Front chain wheel
5 Pedal
The pedelec also has an integrated electric drive
system in addition to its mechanical drive system.
The electric drive system is made up of
7 components:
1 Headlight
2 Display
3 PowerPack battery
4 Rear light
5 Electric gear shift (alternative)
6Motor
7 A charger which is designed for the battery.
3.1.5 Motor
As soon as the required muscle power from the
rider pedalling passes a certain level, the motor is
activated gently and assists the rider’s pedalling
motion. The pre-set level of assistance
determines the motor output.
The motor switches off automatically as soon as
the rider no longer pedals, the temperature is
outside the permitted range, there is an overload
or the shut-off speed of 25 km/h has been
reached.
A push assist system can be activated. The speed
depends on the selected gear. The motor
continues to drive the pedelec as long as the rider
presses the push assist button on the handlebars.
The speed can be a maximum of 6 km/h in this
case. The electric drive system stops when the
push assist button is released.
The pedelec does not have a separate emergency
shut-off button. In the event of an emergency, the
motor can be stopped by removing the on-board
computer. The mechanical brakes are used as an
emergency stop system and bring the bicycle to a
halt quickly and safely in the event of an
emergency.
3.1.6 Rechargeable battery
BOSCH rechargeable batteries are lithium ion
batteries which are developed and manufactured
to the latest technical standards. These batteries
meet and exceed applicable industrial safety
standards. The battery has an internal electronic
protection circuit, which is specifically designed
for the charger and the pedelec. The battery
temperature is monitored at all times. Each
individual cell in a BOSCH battery is protected by
a steel cup and cased in a plastic housing. You
must not open this housing. You must also avoid
mechanical loads or exposure to intense heat
since they may damage the battery cells and
cause flammable contents to leak out.
The battery is protected against deep discharge,
overcharging, overheating and short circuit. In the
event of a hazard, a protective circuit switches the
battery off automatically.
MY21K03 - 12_1.0_22.09.2020 17
Overview
The battery has a high energy content when
charged. The substances in lithium-ion battery
cells may become inflammable under certain
conditions. You will find codes of practice for their
safe handling in Section 2 Safety and Section 6.9
Rechargeable battery in the operating
instructions.
If the electric drive system is not used for about
10 minutes (e.g. the pedelec is stationary) and no
button has been pressed on the on-board
computer or the control panel, the electric drive
system and the battery switch off automatically to
save energy.
The type and duration of operating conditions
have a significant effect on the battery life. Just
like any other lithium-ion battery, the BOSCH
battery will age naturally, even if it is not being
used.
Its battery life can be extended if the battery is well
maintained and, more importantly, stored at the
correct temperatures. The charging capacity will
decrease with age, even if the battery is
maintained properly. If the operating time is
severely shortened after charging, this is a sign
that battery has reached the end of its useful life.
Battery performance is reduced when the
temperature drops since this increases electrical
resistance. As a result, you should expect the
range to be shorter than normal in winter. We
recommend using thermal protection sleeves
when riding longer distances in the cold.
Two BOSCH PowerPack batteries can be used at
the same time.
Figure 6: PowerPack battery in detail
1 Battery housing
2 Battery lock
3 Battery key
4 On-Off button (battery)
5 Battery level indicator (battery)
6 Charging port cover
7 Charging port
PowerPack 300 PowerPack 400 PowerPack 500
Table 6: Overview of PowerPack batteries
MY21K03 - 12_1.0_22.09.2020 18
Overview
3.1.7 Display
The model series to which these instructions
apply features the BOSCH Purion display. In
addition to the functions described here, software
changes may be introduced to rectify errors and
extend functions at any time.
The display controls the drive system with four
operating elements and shows the journey data.
The battery powers the display. The display also
has two internal non-rechargeable coin cells. This
ensures that the electric drive system can be
switched on using the display.
The pane of glass on the display may steam up
from the inside if there are abrupt fluctuations in
temperature. This is not a malfunction.
Figure 7: BOSCH Purion display
3.1.8 Riding light
When the riding light is activated, the headlight
and the rear light are switched on together.
3.1.9 Charger
Each pedelec is supplied with a charger. As a
general rule, any BOSCH charger may be used:
The 2 A compact charger
The 4 A standard charger
The 6 A fast charger
Observe the operating instructions in the
Section 11 Documents.
W
AL
W
W
W
W
W
W
A
A
L
K
K
K
K
K
W
W
W
W
W
W
W
W
WWWW
WW
W
W
W
W
W
W
W
W
W
W
WW
W
W
W
W
A
A
W
W
W
W
A
WW
W
W
W
W
W
W
W
W
W
A
WW
AAAA
AA
A
A
A
A
A
A
A
A
A
A
A
A
A
LLLL
LL
L
A
A
A
A
A
A
L
L
L
L
L
L
L
L
K
KKKK
KK
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
MY21K03 - 12_1.0_21.09.2020 19
Overview
3.2 Proper use
The pedelec must only be used in perfect, fully
functional condition. National requirements may
apply to the pedelec which the standard
equipment may not meet. For riding on public
roads, some special regulations apply in relation
to the riding light, reflectors and other components.
The general laws and the regulations for the
prevention of accidents and environmental
protection in the respective country of use must be
adhered to. All check lists and instructions for
actions in these operating instructions met.
Approved accessories can be installed by
specialist staff.
The rechargeable batteries are designed to
supply power to the pedelec motor only and must
not be used for other purposes.
Each pedelec is assigned a pedelec type, which
determines its proper use, function and area of
use.
City and trekking
bicycles
Child's bicycles/
bicycles for young
adults
Mountain bikes Racing bicycle Cargo bike Folding bicycle
City and trekking
bicycles are designed
for daily, comfortable
use. They are suit-
able for riding on
public roads.
The legal guardians
of minor riders must
read and understand
these operating
instructions before
commissioning.
The contents of these
operating instruc-
tions must be
communicated to the
riders in an age-
appropriate manner.
The cycles for chil-
dren and young
adults are suitable for
riding on public
roads. The size of the
pedelec must be
checked regularly for
orthopaedic reasons.
A check must be
made at least every
three months to make
sure that the
maximum permitted
total weight is being
observed.
Mountain bikes are
designed for sporting
use. The design char-
acteristics include a
short wheelbase, a
sitting position with
the rider inclined
towards the front, and
a brake requiring low
actuation force.
A mountain bike is a
piece of sporting
equipment. It requires
an adaptation period
and the rider must be
physically fit. Use
requires the appro-
priate training; in
particular riding in
bends and braking
should be practised.
The strain on the
rider, in particular the
hands and wrists,
arms, shoulders,
neck and back, is
accordingly high.
Inexperienced riders
tend to brake exces-
sively and lose
control as a result.
A racing bicycle is
designed for fast
rides on roads and
paths with a good,
undamaged road
surface.
A racing bicycle is a
piece of sporting
equipment and not a
means of transport. A
racing bicycle is char-
acterised by its light-
weight structure and
a design which is
stripped to the
minimum parts
required for riding.
The frame geometry
and the layout of the
operating elements
are designed in such
a way that the bicycle
can be ridden at high
speeds. The frame
design requires prac-
tice to ensure the ride
is able to ride slowly,
apply the brakes and
get on and off the
bike safely.
The sitting position is
athletic. The strain on
the rider, in particular
the hands and wrists,
arms, shoulders,
neck and back, is
accordingly high. The
sitting position there-
fore requires phys-
ical fitness.
The cargo bike is suit-
able for daily trans-
portation of loads on
public roads.
The transportation of
loads requires skill
and physical fitness
in order to balance
the additional weight.
The very varied
loading conditions
and weight distribu-
tions require special
practice and skill
when braking and
riding in bends.
A longer period is
required to adaptation
to the length, width
and turning circle.
You need to be
cautious when riding
a cargo bike. You
must pay attention to
the traffic on public
roads and the condi-
tion of the route
accordingly.
The folding bicycle is
suitable for use on
public roads.
A folding bicycle can
be folded up and is
thus suitable for
space-saving trans-
portation, for example
on public transport or
in a car.
The folding function
of the folding bicycle
makes it necessary to
use smaller wheels
and longer brake
cables and Bowden
cables. Therefore, in
case of an increased
load, a reduction in
riding stability and
braking power, dimin-
ished comfort and
reduced durability are
to be expected.
Table 7: Proper use for each pedelec type
MY21K03 - 12_1.0_21.09.2020 20
Overview
3.3 Improper use
Failure to adhere to the proper use poses a risk of
personal injury and material damage. It is
prohibited to use the pedelec in the following
ways:
when the electrical drive system has been
manipulated
riding with a damaged or incomplete pedelec
riding over steps
riding through deep water
charging with an incorrect charger
lending the pedelec to untrained riders
carrying other people
riding with excessive baggage
riding with no hands
riding on ice and snow
improper servicing
improper repair
tough areas of use, such as professional
competitions
stunt riding or acrobatics.
City and trekking
bicycles
Child's bicycles/
bicycles for young
adults
Mountain bikes Racing bicycle Cargo bike Folding bicycle
City and trekking
bicycles are not
sports bicycles. If
used for sports, the
rider can expect
reduced riding
stability and
diminished comfort
Cycles for children
and young adults are
not toys.
Mountain bikes must
be retrofitted with
lighting, a bell and
other fittings as
specified by national
laws and regulations
before they are used
on public roads.
Racing bikes must
be retrofitted with
lighting, a bell and
other fittings as
specified by national
laws and regulations
before they are used
on public roads.
A cargo bike is not a
touring bicycle or a
sports bicycle.
The folding bicycle is
not a sports bicycle.
Table 8: Information on improper use
MY21K03 - 12_1.0_21.09.2020 21
Overview
3.3.1 Maximum permitted total weight
The pedelec may only be loaded to its maximum
permitted total weight (PTW). The maximum
permitted total weight is the weight of the fully
assembled pedelec with the rider and baggage.
3.3.2 Data privacy information
When the pedelec is connected to the BOSCH
diagnosis tool, data is transferred to Bosch eBike
Systems (Robert Bosch GmbH) regarding the use
of rechargeable battery, including its temperature
and cell voltage, to help improve the product. You
will find more detailed information on the BOSCH
website:
www.bosch-ebike.com/en/.
Type no. Model PTW
KB148-
ZAKC46 Familiano C-10 t.b.a.
KB148-
ZBKC46 Familiano C-10 t.b.a.
KB149-
ZAFC46 Familiano C-N t.b.a.
KB149-
ZBFC46 Familiano C-N t.b.a.
KB150-
ZAFC46 Familiano L-N t.b.a.
KB150-
ZBFC46 Familiano L-N t.b.a.
MY21K03 - 12_1.0_21.09.2020 22
Overview
3.4 Technical data
3.4.1 Pedelec
Emissions
*The safety requirements as per Electromagnetic Compatibility
Directive 2014/30/EU have been met. The pedelec and the
charger can be used in residential areas without restriction.
Tightening torque
*if there is no other data on the component
3.4.2 Bicycle lighting
3.4.3 BOSCH Purion display
3.4.4 BOSCH Cargo Line Speed motor
3.4.5 Bosch rechargeable battery
3.4.5.1 PowerPack 300
Only applies to pedelecs with this equipment
Transportation temperature C - 2C
Ideal transportation temperature 10 °C - 15 °C
Storage temperature 10 °C - 30 °C
Ideal storage temperature 10 °C - 15 °C
Operating temperature C - 3C
Work environment temperature 15 °C - 25 °C
Charging temperature C - 4C
Power output/system 250 W (0.25 kW)
Shut-off speed 25 km/h
Table 9: Pedelec technical data
A-weighted emission sound pressure
level
<70dB(A)
Total vibration level for the hands and
arms
<2.5m/s²
Highest effective value of weighted
acceleration for the entire body
<0.5m/s²
Table 10: Emissions from the pedelec*
Axle nut tightening torque 35 Nm - 40 Nm
Handlebars clamping screw maximum
tightening torque*
5Nm - 7Nm
Table 11: Tightening torque values
Voltage about 12 V
Maximum output
Front light 17.4 W
Rear light 0.6 W
Table 12: Technical data for vehicle lighting
Batteries 2 x 3 V CHR2016
Operating temperature -5 °C - +40 °C
Storage temperature 10 °C - +40 °C
Charging temperature C - + 4C
Protection rating
(with USB cover closed)
IP54
Weight about 0.1 kg
Table 13: BOSCH Purion display technical data (BUI215)
Maximum continuous power 250 W
Max. torque 85 Nm
Nominal voltage 36 V DC
Protection class IP54
Weight 3kg
Operating temperature -5 °C - +40 °C
Storage temperature -10 °C - +40 °C
Table 14: Technical data for BOSCH Cargo Line Speed motor,
BDU490P
Nominal voltage 36 V
Nominal capacity 8.2 Ah
Energy 300 Wh
Weight 2.5/ 2.6 kg
Protection class IP54
Operating temperature -5 °C - +40 °C
Storage temperature +10 °C - +40 °C
Permitted charging temperature
range
C - + 4C
Table 15: Technical data for BOSCH PowerPack 300 battery
MY21K03 - 12_1.0_21.09.2020 23
Overview
3.4.5.2 PowerPack 400
Only applies to pedelecs with this equipment
3.4.5.3 PowerPack 500
Only applies to pedelecs with this equipment
Nominal voltage 36 V
Nominal capacity 11 Ah
Energy 400 Wh
Weight 2.5/ 2.6 kg
Protection class IP54
Operating temperature -5 °C - +40 °C
Storage temperature +10 °C - +40 °C
Permitted charging temperature
range
C - + 4C
Table 16: Technical data for BOSCH PowerPack 400 battery,
BBS265
Nominal voltage 36 V
Nominal capacity 13.4 Ah
Energy 500 Wh
Weight 2.6/ 2.7 kg
Protection class IP54
Operating temperature -5 °C - +40 °C
Storage temperature +10 °C - +40 °C
Permitted charging temperature
range
C - + 4C
Table 17: Technical data for BOSCH PowerPack 500 battery,
BBS275
MY21K03 - 12_1.0_21.09.2020 24
Overview
3.5 Description of controls and
screens
3.5.1 Handlebars
Figure 8: Detailed view of pedelec from rider position,
example
1 Rear brake lever
2Bell
3 Headlight
4 Front brake lever
5 Display
6 Suspension fork compression damper
7Shifter
3.5.2 Display
The display has nine on-screen indicators:
Figure 9: On-screen indicators overview
1 Indicator unit km/h or mph
2 Tachometer indicator
3 TRIP indicator
4 Level of assistance indicator or Function
indicator
5 Lighting indicator
6 Service indicator
7 Battery level indicator
8 RANGE indicator
9 TOTAL indicator
3.5.2.1 Information display
The display shows one of three types of
information. The displayed information can be
changed.
3.5.2.2 Level of assistance
The higher the level of assistance, the more the
drive system assists the rider when pedalling.
eMTB mode is available for Performance Line CX
drives. In eMTB mode, the assistance factor and
the torque are dynamically adjusted depending on
the pedalling force applied to the pedals. If the
pedelec has been configured with “eMTB mode”,
“eMTB mode” appears briefly when the SPORT
level of assistance is selected.
3.5.2.3 Indicator unit km/h or mph
The speed can be displayed in km/h or mph. You
can choose between the units in the system
settings.
1
2
3
5
4
6
7
1
4
6
2
2
3
7
5
8
9
Indicator Function
TRIP Distance travelled since the last RESET
ODO total distance travelled (cannot be
changed)
RANGE Estimated range of the available battery
charge, calculated based on the most
recent manner of riding
Table 18: Information display
Level of assistance Use
OFF When the drive system is switched on,
the motor assistance is switched off.
The pedelec can be used like a normal
bicycle by simply pedalling. The push
assist system cannot be activated.
ECO Limited assistance with maximum
efficiency for maximum range
TOUR Constant assistance, for long-range
tours
SPORT/eMTB
SPORT Powerful assistance for sport rides on
mountainous routes and on urban roads
eMTB
available in
combination with
BDU250P CX,
BDU365, BDU450 CX
and BDU480 CX
motors
Optimum assistance on any terrain,
sporty start-up, improved dynamics and
maximum performance
TURBO Maximum assistance up to high
pedalling frequencies, for sport riding
Table 19: Overview of levels of assistance
MY21K03 - 12_1.0_21.09.2020 25
Overview
3.5.2.4 Tachometer screen
The tachometer indicator shows the current speed
at all times.
3.5.2.5 System message
The drive system monitors itself continuously and
if an error is detected, it is indicated by a system
message. The system may switch off
automatically depending on the type of error.
There is a table of all system messages in Section
6.2. You will find assistance for system messages
in Section 8.5 Initial help.
3.5.3 Battery level indicator
Each battery has its own level indicator:
Figure 10: Example of a battery level indicator
1 On-Off button (battery)
2 Battery level indicator
The five green LEDs on the battery level indicator
show the charge level when the battery is
switched on. Each LED represents about 20 % of
battery capacity. All five LEDs will light up when
the battery is fully charged. The charge level for
the activated battery is also shown on the display
screen.
If the battery level falls below 5 %, all the LEDs on
the battery level indicator will go out. However, the
battery level is still shown on the display screen.
MY21K03 - 12_1.0_21.09.2020 26
Overview
3.6 Environmental requirements
You can be ride the pedelec within a temperature
range between 5 °C and 35 °C. The electric drive
system is limited in its performance outside this
temperature range.
During winter use, especially at temperatures
below 0 °C, we recommend that you don't insert a
battery charged and stored at room temperature
into the pedelec until just before setting off. We
recommend using thermal protection sleeves
when riding longer distances in the cold.
Temperatures under -10 °C and over +40 °C must
be avoided.
You must also keep within the following
temperature ranges:
The nameplate contains symbols for the pedelec's
area of use. Check what roads and paths you may
use before you ride the bicycle for the first time.
Optimal operating temperature 22 °C - 26 °C
Table 20: Optimum temperatures
Transportation temperature 10 °C - 40 °C
Storage temperature 10 °C - 40 °C
Work environment temperature 15 °C - 25 °C
Charging temperature 10 °C - 40 °C
Table 21: Pedelec technical data
Area of use City and trekking
bicycles
Child's bicycles/
bicycles for young
adults
Mountain bikes Racing bicycle Cargo bike Folding bicycle
Suitable for
tarmacked and
paved roads.
Suitable for
tarmacked and
paved roads.
Suitable for
tarmacked and
paved roads.
Suitable for
tarmacked and
paved roads.
Suitable for
tarmacked and
paved roads.
Suitable for
tarmacked roads,
cycle paths and firm
gravel paths and
roads, and longer
sections with
moderate slopes and
jumps up to 15 cm.
Suitable for
tarmacked roads,
cycle paths and firm
gravel paths and
roads, and longer
sections with
moderate slopes and
jumps up to 15 cm.
Suitable for
tarmacked roads,
cycle paths and firm
gravel paths and
roads, and longer
sections with
moderate slopes
and jumps up to
15 cm.
Suitable for
tarmacked roads,
cycle paths and firm
gravel paths and
roads, and longer
sections with
moderate slopes
and jumps up to
15 cm.
Suitable for
tarmacked roads,
cycle paths and
easy to demanding
off-road riding,
sections with
moderate slopes
and jumps up to
61 cm.
Suitable for
tarmacked roads,
cycle paths and
easy to demanding
off-road riding,
limited downhill use
and jumps up to
122 cm.
Table 22: Area of use
MY21K03 - 12_1.0_21.09.2020 27
Overview
The pedelec is unsuitable for the following areas of use:
Area of use City and trekking
bicycles
Child's bicycles/
bicycles for young
adults
Mountain bikes Racing bicycle Cargo bike Folding bicycle
Never drive off-road
or perform jumps. Never drive off-road
or perform jumps. Never drive off-road
or perform jumps. Never drive off-road
or perform jumps. Never drive off-road
or perform jumps.
Never drive off-road
or perform jumps
over 15 cm.
Never drive off-road
or perform jumps
over 15 cm.
Never drive off-road
or perform jumps
over 15 cm.
Never drive off-road
or perform jumps
over 15 cm.
Never ride downhill
or perform jumps
over 61 cm.
Never traverse
extremely difficult
off-road terrain or
perform jumps over
122 cm.
MY21K03 - 12_1.0_21.09.2020 28
Transporting and storing
4 Transporting and storing
4.1 Physical transport
characteristics
Weight and dimensions during
transportation
* Vehicle weight without battery. The vehicle’s total weight
depends on the battery used.
4.1.1 Designated handles/lifting points
The box does not have any handles.
Type no.
Frame
Box dim.
[cm]
Weight**
[kg]
Shipping weight
[kg]
KB148-ZAKC46 t.b.a. t.b.a. t.b.a. t.b.a.
KB148-ZBKC46 t.b.a. t.b.a. t.b.a. t.b.a.
KB149-ZAFC46 t.b.a. t.b.a. t.b.a. t.b.a.
KB149-ZBFC46 t.b.a. t.b.a. t.b.a. t.b.a.
KB150-ZAFC46 t.b.a. t.b.a. t.b.a. t.b.a.
KB150-ZBFC46 t.b.a. t.b.a. t.b.a. t.b.a.
Table 23: Type number, model and pedelec type
Battery type Weight
PowerPack 300 battery 2.5/ 2.6 kg
PowerPack 400 battery 2.5/ 2.6 kg
PowerPack 500 battery 2.6/ 2.7 kg
MY21K03 - 12_1.0_21.09.2020 29
Transporting and storing
4.2 Transporting
4.2.1 Using the brake transport securing
system
Applicable for pedelec disc brakes only
Insert the transport securing devices between
the brake linings.
Transport securing device is squeezed
between the two linings and prevents
undesired sustained braking which can cause
brake fluid to leak out.
Figure 11: Fastening the transport securing device
4.2.2 Transporting the pedelec
Bicycle rack systems which use the handlebars or
frame to hold the pedelec in an upside-down
position exert inadmissible forces on its
components during transportation. This can cause
the supporting parts to break.
Never use bicycle rack systems which use the
pedelec's handlebars or frame to hold it in an
upside-down position. The specialist dealer will
advise you on how to select a suitable rack
system properly and how to use it safely.
Take into account the weight of the ready-to-
use pedelec when transporting it.
Protect the electrical components and
connections on the pedelec from the weather
conditions with suitable protective covers.
Transport the battery in a dry, clean position
where it is protected from direct sunlight.
4.2.3 Shipping a pedelec
When shipping the pedelec, we recommend
that you have the specialist dealer partially
dismantle the pedelec and place it in the proper
packaging.
4.2.4 Transporting the battery
Batteries are subject to hazardous goods
regulations. Undamaged batteries may be
transported by private persons in road traffic.
Commercial transport requires compliance with
regulations concerning packaging, labelling and
the transportation of hazardous goods. Open
contacts must be covered and the battery
securely packaged.
4.2.5 Shipping the battery
The battery is considered a hazardous good and
only trained persons may pack and ship a battery.
Contact your specialist dealer.
Crash caused by unintentional activation
There is a risk of injury if the drive system is
activated unintentionally.
Remove the battery.
Oil leak if no transport securing device
The brake securing device prevents the brakes
from being applied accidentally during
transportation or shipment. This could cause
irreparable damage to the brake system or an oil
leak, which will harm the environment.
Never push the brake lever when the wheel
has been dismounted.
Always use the transport securing system
when transporting or shipping.
CAUTION
!
CAUTION
!
MY21K03 - 12_1.0_21.09.2020 30
Transporting and storing
4.3 Storing
Store pedelec, battery and charger in a clean,
dry place where they are protected from
sunlight. Do not store outdoors to ensure a
long service life.
Temperatures under -10 °C or over +40 °C must
generally be avoided.
Storage at about 10 °C to 20 °C is beneficial to a
long battery life.
Store pedelec, battery and charger separately.
4.3.1 Break in operation
If the pedelec is removed from service for longer
than four weeks, you need to prepare it for a break
in operation.
4.3.1.1 Preparing a break in operation
Remove the rechargeable battery from the
pedelec.
Charge battery to around 30 % - 60 %.
The pedelec needs to be cleaned with a damp
cloth and preserved with wax spray. Never wax
the friction surfaces of the brake.
Before longer periods without use, it is
recommendable to have your specialist dealer
carry out an inspection and basic cleaning and
apply preservative agent.
4.3.1.2 Carrying out a break in operation
1Store the pedelec, battery and charger in a dry,
clean environment. We recommend storing
them in uninhabited rooms with smoke alarms.
Dry locations with an ambient temperature of
about 10 °C to 20 °C are ideal.
2Check the battery level after 6 months. If only
one LED on the battery level indicator lights up,
recharge the battery to around 30 % - 60 %.
Optimum pedelec storage temperature 10 °C - 20 °C
Table 24: Storage temperature for batteries and the pedelec
Notice
The battery discharges when not in use. This can
cause irreparable damage to the battery.
The battery must be recharged every
6 months.
The battery may become damaged if it is
connected permanently to the charger.
Never connect the battery to the charger
permanently.
MY21K03 - 12_1.0_21.09.2020 31
Assembly
5 Assembly
Assemble the pedelec in a clean, dry
environment.
The work environment temperature should be
between 15 °C and 25 °C.
The fitting stand used must be approved for a
maximum weight of at least 30 kg.
5.1 Required tools
The following tools are required to assemble the
pedelec:
5.2 Unpacking
The packaging material consists mainly of
cardboard and plastic film.
The packaging has to be disposed of in
accordance with the regulations of the
authorities.
5.2.1 Scope of delivery
Pedelecs are fully assembled in the factory for
test purposes and then dismantled for
transportation.
The pedelec is 95 - 98 % pre-assembled. The
scope of delivery includes:
the pre-assembled pedelec
the front wheel
the pedals
quick release (optional)
the charger
the operating instructions.
The battery is supplied separately from the
pedelec.
5.3 Commissioning
Only trained specialist staff may perform initial
commissioning since initial commissioning of the
pedelec requires special tools and specialist
knowledge.
Experience has shown that a pedelec which has
not yet been sold is automatically handed to
customers as soon as it appears ready to ride.
For this reason, every pedelec must be
prepared, so it is fully ready for use
immediately after being assembled.
Complete an assembly report for quality
assurance purposes. The assembly report
(see Section 11.2) describes all safety-relevant
inspections, tests and maintenance tasks. All
assembly work must be completed to ensure
the pedelec is ready to ride.
Risk of eye injury
Problems may arise if the settings are not made
to components correctly and you may sustain
serious injuries as a result.
Always wear safety glasses to protect your
eyes during assembly.
Crash and crushing hazard caused by
unintentional activation
There is a risk of injury if the drive system is
activated unintentionally.
Remove the battery.
•Knife
Hexagon socket spanner 2 (2.5 mm, 3 mm,
4 mm, 5 mm, 6 mm and 8 mm)
Torque wrench with working range between
5and 40Nm
Twelve-point square socket T25
Ring spanner (8 mm, 9 mm, 10 mm), 13 mm,
14 mm and 15 mm) and
cross recess, flat head and ordinary
screwdrivers.
WARNING
!
CAUTION
!
Burns from hot drive
The drive cooler can become extremely hot
during use. Touching it may cause burns.
Leave the drive unit to cool before assembly.
CAUTION
!
MY21K03 - 12_1.0_21.09.2020 32
Assembly
5.4 Preparing the battery
5.4.1 Checking the battery
The battery must be checked before it is charged
for the first time.
1Press the On-Off button (battery).
If none of the LEDs on the battery level
indicator light up, the battery may be damaged.
The battery may be fully charged if at least one,
but not all, of the LEDs on the battery level
indicator is lit up.
5.4.2 Checking the stem and handlebars
5.4.2.1 Checking the connections
1Stand in front of the pedelec to check whether
the handlebars, stem and fork steerer are
firmly attached to one another. Clamp the front
wheel between your legs. Grasp the handlebar
grips.
2Try to twist the handlebars towards the front
wheel.
The stem must not move or twist.
5.4.2.2 Firm hold
1Place your entire body weight on the
handlebars with the quick release lever closed
to check that the stem is firmly in place.
The handlebars shaft must not move
downwards in the fork steerer.
2If the handlebars shaft should move in the fork
steerer, increase the quick release lever
tensioning. To do so, turn the knurled nut
slightly in a clockwise direction with the quick
release lever open.
3Close the lever and check the stem is firmly in
position.
5.4.2.3 Checking the headset backlash
1To check the handlebar headset backlash,
close the quick release lever on the stem.
2Place the fingers of one hand on the upper
headset cup. Pull the front wheel brake with the
other hand and try to push the pedelec
backwards and forwards.
3The headset cup halves must not move
towards one another while you are doing this.
Note that there may be noticeable backlash
due to worn-out bearing bushes or brake lining
backlash in suspension forks and disc brakes.
4If there is headset backlash in the steering
headset, you must adjust it as soon as
possible; otherwise, the headset will become
damaged. You must make the adjustment as
described in the stem manual.
5.5 Pedelec sale
Complete Pedelec pass on the operating
instructions envelope.
Note down the manufacturer and the number of
the battery key.
Adjust the pedelec to the rider; see
Section 6.5.
Set the stand and shifter.
Instruct the operator or rider on how to use all
the pedelec's functions.
MY21K03 - 12_1.0_22.09.2020 33
Operation
6 Operation
6.1 Risks and hazards
Injuries and death caused by other road users
Other road users, trucks, cars or pedestrians often
underestimate the speed of pedelecs. Likewise,
other road users frequently do not see pedelecs.
This may cause a crash with serious injuries or
even death.
Wear a cycling helmet and high-visibility,
reflective clothing.
Always take a defensive approach to riding.
Avoid the blind spots of vehicles turning off.
Reduce speed as a precaution when other
road users turn right.
Injuries and death caused by riding
incorrectly
A pedelec is not a bicycle. Incorrect riding and
underestimated speeds soon result in hazardous
situations. This may cause a fall with serious
injuries or even death.
If you haven't ridden on a pedelec for some
time, get accustomed to the speed first before
you ride at speeds over 12 km/h. Increase the
levels of assistance gradually.
Practice braking hard on a regular basis.
Take and complete a riding safety course.
Crash caused by loose clothing
Shoe laces, scarves and other loose items may
become entangled in the spokes on the wheels
and on the chain drive. This may cause a crash
with injuries.
Wear sturdy footwear and close-fitting
clothing.
WARNING
!
CAUTION
!
Crash caused by difficult-to-spot damage
If the pedelec topples over or you have a fall or an
accident, there may be difficult-to-spot damage to
components such as the brake system, quick
releases or frame. This may cause a crash with
injuries.
Take the pedelec out of service and have a
specialist dealer carry out an inspection.
Crash caused by material fatigue
Intensive use can cause material fatigue. A
component may suddenly fail in case of material
fatigue. This may cause a crash with injuries.
Remove the pedelec from service immediately
if there are any signs of material fatigue. Have
the specialist dealer check the state.
Have the specialist dealer carry out a basic
inspection regularly. During the inspection, the
specialist dealer will inspect the pedelec for
any signs of material fatigue on the frame,
fork, suspension element mountings (if there
are any) and components made of composite
materials.
Carbon becomes brittle when exposed to heat
radiation such as heating. This can cause the
carbon part to break and result in a crash with
injuries.
Never expose carbon parts on the pedelec to
strong sources of heat.
Crash caused by soiling
Heavy soiling can impair pedelec functions, such
as braking. This may cause a crash with injuries.
Remove coarse soiling before riding.
CAUTION
!
MY21K03 - 12_1.0_22.09.2020 34
Operation
6.1.1 Personal protective equipment
It is recommended that you wear a suitable
cycling helmet, sturdy footwear and typical, close-
fitting, reflective sports clothing.
6.2 Tips for a greater range
The pedelec's range depends on many
influencing factors. A single battery charge may
only last fewer than 20 kilometres but much more
than 100 is also possible. There are a few tips
which will generally help you maximize range.
Suspension elements
Only open suspension fork and damper when
necessary on terrain or gravel paths. Block
suspension fork and damper on tarmacked
roads or on hills.
Pedalling frequency
Ride using pedalling frequencies of over
50 revolutions per minute. This optimises the
electric drive's efficiency.
Avoid pedalling very slowly.
Weight
Minimise the total weight of pedelec and
baggage.
Stopping and starting
Ride long distances at a constant speed.
Avoid stopping and starting frequently.
Gear shift
Use a low gear and a low level of assistance on
hills and when setting off.
Switch up a gear depending on the speed and
terrain.
Tyre pressure
Always use the maximum permitted tyre
pressure.
Battery and temperature
Electrical resistance increases as the temperature
drops. Battery performance is reduced. As a
result, you should expect the range to be shorter
than normal in winter.
Use a thermal protection sleeve on the battery
in winter.
Crash caused by poor road conditions
Loose objects, such as branches and twigs, may
become caught in the wheels and cause a crash
with injuries.
Be aware of the road conditions.
Ride slowly and brake in good time.
Notice
Heat or direct sunlight can cause the tyre pressure
to increase above the permitted maximum
pressure. This can destroy the tyres.
Never park the pedelec in the sun.
On hot days, regularly check the tyre pressure
and adjust it as necessary.
When riding downhill, high speeds may be
reached. The pedelec is only designed to exceed
a speed of 25 km/h for short intervals. The tyres
in particular can fail if exposed to a continuous
load.
Use the brakes to decelerate the pedelec
if you reach speeds greater than 25 km/h.
Notice
Moisture penetrating at low temperatures may
impair individual functions due to the open
structural design.
Always keep the pedelec dry and free from
frost.
If the pedelec is to be used at temperatures
below 3 °C, the specialist dealer must carry
out an inspection and prepare it for winter use.
Off-road riding subjects the joints in the arms to
severe strain.
Take a break from riding every 30 to
90 minutes, depending on the road surface
conditions.
CAUTION
!
MY21K03 - 12_1.0_21.09.2020 35
Operation
6.3 Error message
6.3.1 Display
The drive system monitors itself continuously and
displays a number as an error message if a known
error is detected. The system may switch off
automatically depending on the type of error.
Code Description Method of resolution
410 One or more display
buttons are blocked
Check whether buttons are
jammed because dirt has
accumulated between them,
for example.
Clean buttons if necessary.
414 Connection problem
control panel
Contact specialist dealer.
Have ports and connections
checked.
418 One or more buttons on
the control panel are
blocked
Check whether buttons are
jammed because dirt has
accumulated between them,
for example.
Clean buttons if necessary.
419 Configuration error 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
422 Battery connection
problem
Have ports and connections
checked.
423 Battery connection
problem
Have ports and connections
checked.
424 Communication error with
components communi-
cating with one another
Have ports and connections
checked.
426 Internal time-out error It is not possible to display or
adjust the tyre size in the basic
settings menu in this error status.
1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
430 Display battery flat Recharge display battery
(while in its mount or using
USB port).
431 Software version error 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
440 Battery internal error 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
450 Internal software error 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
Table 25: List of display screen error messages
460 Error in USB port 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
490 Internal display error Have display checked.
500 Battery internal error 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
502 Fault in the lighting 1Check the light and its
cabling.
2Re-start the system.
3Contact your specialist
dealer if the problem
persists.
503 Speed sensor error 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
504 Speed signal manipu-
lation detected
Check position of spike
magnets and re-adjust if
necessary.
Check for manipulation.
Assistance from drive has
been reduced.
503 Speed sensor error 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
510 Internal sensor error 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
511 Battery internal error 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
530 Battery error 1Switch off system.
2Remove the battery.
3Re-insert battery.
4Re-start electric drive
system.
5Contact your specialist
dealer if the problem
persists.
531 Configuration error 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
Code Description Method of resolution
Table 25: List of display screen error messages
MY21K03 - 12_1.0_21.09.2020 36
Operation
540 Temperature error
The pedelec is outside the
permitted temperature
range
1Switch off the system to cool
the motor and battery down
or warm them to the
permitted temperature
range.
2Re-start the system.
3Contact your specialist
dealer if the problem
persists.
550 An inadmissible electrical
load has been detected 1Remove consumer.
2Re-start the system.
3Contact your specialist
dealer if the problem
persists.
580 Software version error 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
591 Authentication error 1Switch off system.
2Remove the battery.
3Re-insert battery.
4Re-start the system.
5Contact your specialist
dealer if the problem
persists.
592 Incompatible component 1Insert a compatible display.
2Re-start the system.
3Contact your specialist
dealer if the problem
persists.
593 Configuration error 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
595, 596 Communication error 1Check cabling to the gears.
2Re-start the system.
3Contact your specialist
dealer if the problem
persists.
602 Internal error during
charging 1Disconnect charger from
battery.
2Re-start the system.
3Connect charger to the
battery.
4Contact your specialist
dealer if the problem
persists.
602 Internal fault 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
603 Internal fault 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
Code Description Method of resolution
Table 25: List of display screen error messages
605 Temperature error
The pedelec is outside the
permitted temperature
range
1Switch off the system to cool
the motor and battery down
or warm them to the
permitted temperature
range.
2Re-start the system.
3Contact your specialist
dealer if the problem
persists.
605 Temperature error during
the charging process 1Disconnect charger from
battery.
2Leave battery to cool down.
3Contact your specialist
dealer if the problem
persists.
606 External fault 1Check the cabling.
2Re-start the system.
3Contact your specialist
dealer if the problem
persists.
610 Voltage error 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
620 Charger error 1Replace charger.
2Contact your specialist
dealer if the problem
persists.
640 Internal fault 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
655 Multiple battery error 1Switch off system.
2Remove the battery.
3Re-insert battery.
4Re-start the system.
5Contact your specialist
dealer if the problem
persists.
656 Software version error Contact your specialist
dealer to install a software
update.
7xx Gear error Please observe the gear
manufacturer's operating
instructions.
800 Internal ABS error Contact your specialist
dealer.
810 Implausible signals from
the wheel speed sensor
Contact your specialist
dealer.
820 Error in the line to the front
wheel speed sensor
Contact your specialist
dealer.
Code Description Method of resolution
Table 25: List of display screen error messages
MY21K03 - 12_1.0_21.09.2020 37
Operation
6.3.2 Rechargeable battery
The battery is protected against deep discharge,
overcharging, overheating and short circuits by
Electronic Cell Protection (ECP). In the event of a
hazard, a protective circuit switches the battery off
automatically.
If a fault is detected in the battery, the LEDs flash
on the battery level indicator.
821 ...
826 Implausible signals from
the front wheel speed
sensor.
It is defective or incorrectly
installed; significantly
different tyre diameter
between the front wheel
and rear wheel; extreme
riding, such as riding on
the rear wheel only
1Re-start the system.
2Take a test ride of at least
two minutes. The ABS
indicator lamp must go out.
3Contact your specialist
dealer if the problem
persists.
830 Error in the line to the rear
wheel speed sensor
Contact your specialist
dealer.
831
833 ...
835
Implausible signals from
the rear wheel speed
sensor.
Sensor disc may be
missing. It is defective or
incorrectly installed; signif-
icantly different tyre
diameter between the
front wheel and rear
wheel; extreme riding,
such as riding on the rear
wheel only
1Re-start the system.
2Take a test ride of at least
two minutes. The ABS
indicator lamp must go out.
3Contact your specialist
dealer if the problem
persists.
840 Internal ABS error Contact your specialist
dealer.
850 Internal ABS error Contact your specialist
dealer.
860, 861 Error in the power supply 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
870, 871,
880
883...
885
Communication error 1Re-start the system.
2Contact your specialist
dealer if the problem
persists.
889 Internal ABS error Contact your specialist
dealer.
890 ABS indicator lamp is
defective or missing; ABS
possibly not functioning
Contact your specialist
dealer.
No
screen
display
Internal display error Re-start the drive system by
switching it on and off.
Code Description Method of resolution
Table 25: List of display screen error messages
Description Method of resolution
Code:
If the battery is outside its charging
temperature range, three LEDs will
flash on the battery level indicator.
1Disconnect charger from
battery.
2Leave battery to cool down.
3Contact your specialist
dealer if the problem
persists.
Code:
If a fault is detected in the battery,
two LEDs flash on the battery level
indicator.
Contact your specialist
dealer.
Code:
No LEDs will flash if the charger is
defective and will not charge. One or
more LEDs will light up permanently,
depending on the battery level.
Contact your specialist
dealer.
Code:
No LEDs will light up if there is no
power. 1Check all plug connections.
2Check the contacts on the
battery for dirt. Clean the
contacts carefully if needed.
3Contact your specialist
dealer if the problem
persists.
Table 26: List of battery error messages
MY21K03 - 12_1.0_21.09.2020 38
Operation
6.4 Instruction and customer service
The supplying specialist dealer will provide
customer service, whether this involves
maintenance, modification or repairs. The
specialist dealer’s contact details are provided on
the pedelec pass in the operating instructions.
The specialist dealer will explain all the pedelec
functions to the customer in person, this being
when the specialist dealer hands over the pedelec
at the latest. These operating instructions are
provided to the customer with every pedelec, so
that they can consult the instructions at a later
stage.
6.5 Adjusting the pedelec
Only a correctly adjusted pedelec will guarantee
the desired ride comfort and health-promoting
activity. Therefore adjust the saddle, the
handlebars and the suspension to your body and
your preferred riding style before the first ride.
6.5.1 Adjusting the saddle
6.5.1.1 Adjusting the saddle tilt
The saddle tilt must be adjusted to the seat height,
the saddle and handlebar position, and the saddle
shape to ensure an optimum fit. The seating
position can be optimised in this way if needed.
First adjust the handlebars, then the saddle.
Adjust the saddle tilt to horizontal.
Figure 12: Horizontal saddle tilt
6.5.1.2 Determining the seat height
To adjust the seat height safely, either
push the bike near to a wall, so that the rider can
lean on the wall to support themselves or
ask another person to hold the pedelec.
1Climb onto the bicycle.
2Place your heel on the pedal and extend your
leg, so that the pedal is at the lowest crank
rotation point.
The rider sits straight on the saddle if the seat
is at an optimum height. If this is not the case,
adjust the length of the seat post to your
needs.
Figure 13: Optimal saddle height
MY21K03 - 12_1.0_21.09.2020 39
Operation
6.5.1.3 Adjusting the seat height with quick
release
1Open the quick release on the seat post to
change the seat height (1). To do so, push the
clamping lever away from the seat post (3).
Figure 14: Opening the seat post quick release
2Set the seat post to the required height.
Figure 15: Detailed view of the seat post – examples of the
minimum insertion depth marking
3To close it, push the seat post clamping lever as
far as it will go into the seat post (2).
4Check the clamping force of quick releases.
6.5.1.4 Adjusting the seat position
The saddle can be shifted on the saddle frame.
The right horizontal position ensures an optimal
leverage position for legs. This prevents knee
pain and painful incorrect pelvis positions. If you
have displaced the saddle more than 10 mm, you
need to adjust the saddle height again since both
settings affect one another.
To adjust the seat position safely, either push the
pedelec near to a wall, so that you can lean on the
wall to support yourself or ask another person to
hold the pedelec for you.
1Climb onto the bicycle.
2Place the pedals into the vertical position with
your feet.
The rider is sitting in the optimal sitting position if
the perpendicular line from the kneecap runs
through the pedal axle.
3.1If the perpendicular line crosses behind the
pedal, bring the saddle further forward.
3.2If the perpendicular line crosses in front of the
pedal, bring the saddle further back.
4Move the saddle within its permitted
displacement range only (marked on the
saddle stay).
Figure 16: Knee cap perpendicular line
Crash caused by an excessively high seat post
setting
A seat post with is set too high will cause the seat
post or the frame to break. This will cause a crash
with injuries.
Do not pull the seat post out of the frame
beyond the minimum insertion depth marking.
3
4
5
1
2
3
CAUTION
!
The handlebar settings must only be adjusted
while the bicycle is stationary.
Unfasten and adjust the designated screw
connections, and clamp them with the
maximum tightening torque for the clamping
screws of the handlebars.
MY21K03 - 12_1.0_21.09.2020 40
Operation
6.5.2 Adjusting the handlebars
6.5.3 Adjusting the stem
6.5.3.1 Adjusting the height of the handlebars
1Open the stem clamping lever.
Figure 17: Open (2) and closed (1) stem clamping lever; All
Up used as an example
Figure 18: Pulling the locking lever upwards; All Up used
as an example
2Pull out the handlebars to the required height.
Observe minimum insertion depth.
3Close the stem clamping lever.
6.5.3.2 Adjusting the quick release clamping
force
If the handlebar clamping lever stops before
reaching its end position, unscrew the knurled
nut.
Tighten the knurled nut on the seat post if the
seat post clamping lever's clamping force is not
effective enough.
If you are unable to set the clamping force, the
specialist dealer will need to check the quick
release.
6.5.4 Setting the brake
The brake lever grip distance can be adjusted to
ensure that it can be reached more easily. The
pressure point can also be adjusted to the rider's
preferences.
Contact your specialist dealer if there is no
description of your brake below.
Crash caused by incorrectly set clamping
force
Excessively high clamping force will damage the
quick release and cause it to lose its function.
Insufficient clamping force will result in
unfavourable transmission of force. This can
cause components to break. This will cause a
crash with injuries.
Never fasten a quick release using a tool (e.g.
hammer or pliers).
Only use the clamping lever with the specified
set clamping force.
Crash caused by loose stem
Incorrectly fastened screws may come loose due
to impact. The stem may no longer be firmly fixed
in its position as a result. This will cause a crash
with injuries.
Check the handlebars and the quick release
system are firmly in position after the first two
hours of riding.
CAUTION
!
CAUTION
!
1
2
MY21K03 - 12_1.0_21.09.2020 41
Operation
6.5.5 Retracting the brake linings
Disc brakes require wearing-in time. The braking
force increases over time. You therefore need to be
aware that the braking force may increase during the
wearing-in period. The same happens after brake
pads or discs are replaced.
1Accelerate pedelec to about 25 km/h.
2Brake pedelec until it comes to a halt.
3Repeat process 30–50 times.
The disc brake is retracted and provides optimal
braking power.
6.5.5.1 Setting the grip distance on a brake
lever
You can adjust the brake lever position (grip
distance) to your requirements. Such adjustment
does not affect the pressure point or the position
of the brake linings.
Use a T25 TORX® wrench to turn the setting
screw (1) to adjust the grip distance.
Figure 19: Setting the grip distance on a Magura disc
brake lever
Turn the setting screw/twist knob (5) anti-
clockwise towards minus (–).
The brake lever moves closer to the handlebar
grip.
Turn the setting screw clockwise towards
plus (+).
The brake lever moves away from the
handlebar grip.
6.5.5.2 Setting the pressure point on a brake
lever
The pressure point setting is adjusted using the
twist knob.
Turn the twist knob towards the plus (+)
symbol.
The brake lever moves closer to the handlebar
grip. Re-adjust the grip distance as necessary.
The lever pressure point activates sooner.
Figure 20: Using the twist knob (1) to adjust the pressure
point
Crash caused by incorrectly set grip distance
If brake cylinders are set incorrectly or installed
wrongly, the braking power may be lost at any
time. This may cause a crash with injuries.
Ensure that the fully applied brake lever is at a
minimum distance of 20 mm from the
handlebars (4).
WARNING
!
Brake failure due to incorrect setting
If the pressure point is set with brakes where the
brake linings and brake disc have reached their
wear limit, the brakes may fail and cause an
accident with injury.
Before you set the pressure point, ensure that
the brake linings and brake disc have not
reached their wear limit.
WARNING
!
MY21K03 - 12_1.0_21.09.2020 42
Operation
6.6 Accessories
The following accessories are not included in the
scope of delivery and are recommended:
*System components are matched to the pannier
rack and provide sufficient stability due to special
transmission of force.
6.6.1 Child seat
Two child seats in two attachment variants are
approved for use on the pannier rack on the
Familiano. The centre of gravity of the rear child
seat must not be more than 300 mm behind the
rear wheel axle.
Attachment variant 1
Figure 21: Two child seats, suitable for 2 young children
(1–6 years old, 9–22 kg)
Attachment variant 2
Figure 22: A child seat at the rear and a saddle seat with
sideblades in front, suitable for one young child (1–6 years
old, 9–22 kg) and an older child (6–10 years old, 18–38 kg)
Description Article number
BOSCH PowerPack 500 08948-930
X Rack Rail child seat 08949-090
X Rack Rail Master Seat 08949-350
Master Seat 08949-100
Front GT Irack 08949-110
Carrier basket, small 08949-120
Carrier basket, large 08949-130
Familiano L Sideblades, short 08949-140
Familiano L Sideblades, long 08949-150
Table 27: Accessories
Crash caused by incorrect child seat
The pannier rack and down tube are unsuitable
for mounting child seats and may break. Such an
incorrect position may cause a crash with serious
injuries for the rider and the child.
Never attach a child seat to the saddle,
handlebars or down tube.
Crash caused by improper handling
When using child seats, the pedelec's handling
characteristics and stability change considerably.
This can cause a loss of control, a crash and
injuries.
You should practice how to use the child seat
safely before using the pedelec in public
spaces.
WARNING
!
CAUTION
!
Risk of crushing due to exposed springs
The child may crush his/her fingers on exposed
springs or open mechanical parts of the saddle or
the seat post.
Never install saddles with exposed springs if a
child seat is being used.
Never install seat posts with suspension with
open mechanical parts or exposed springs if a
child seat is being used.
CAUTION
!
MY21K03 - 12_1.0_21.09.2020 43
Operation
Observe the operating and safety instructions
for the child seat system.
Never exceed the maximum permitted total
weight.
The specialist dealer will advise you on choosing
a suitable child seat system for the child and the
pedelec.
The specialist dealer must install the child seat the
first time to ensure that it is safely fitted.
When installing a child seat, the specialist dealer
makes sure that the seat and the fastening
mechanism for the seat are suitable for the
pedelec and that all components are installed and
firmly fastened. They will also ensure that shift
cables, brake cables, hydraulic lines and electrical
cables are adjusted as necessary, the rider has
optimum freedom of movement and the pedelec's
maximum permitted total weight is complied with.
The specialist dealer will provide instruction on
how to handle the pedelec and the child seat.
6.6.2 Trailer
A pedelec which is approved for towing a trailer
will bear an appropriate adhesive label. You may
only use trailers with a tongue load and weight
which do not exceed the permitted values.
Figure 23: Trailer sign
The specialist dealer will advise on choosing a
suitable trailer system for the pedelec. The
specialist dealer must install the trailer the first
time to ensure that it is safely fitted.
6.6.2.1 Trailer approval for ENVIOLO hub gear
Only applies to pedelecs with this equipment
Only compatible bicycle trailers are approved for
ENVIOLO hub gears.
KETTLER
KETTLER QUADRIGA child trailer
Burley
Crash caused by brake failure
The braking distance may be longer if the trailer
is carrying excessive load. The long braking
distance can cause a crash or an accident and
injuries.
Never exceed the specified trailer load.
Notice
The operating and safety instructions for the
trailer system must be observed.
The statutory regulations on the use of bicycle
trailers must be observed.
Only use type-approved coupling systems.
CAUTION
!
Trailer Adapter
Minnow Bee
Item no. 960038
Honey Bee
Encore
solo
Cub
D’Lite
Normad
Flatbed
Tail Wagon
MY21K03 - 12_1.0_21.09.2020 44
Operation
Croozer
Thule
6.6.3 Mobile holder
Only applies to pedelecs with this equipment
A holder for SP Connect mobile case is fitted to
the stem.
Observe the operating instructions for the mobile
and the SP Connect mobile case.
Use on tarmacked roads only.
Protect mobile from theft.
To attach: insert the SP Connect mobile case
in the holder and turn 90° to the right.
To release: turn the SP Connect mobile case
90° to the left and remove.
6.6.4 Tubeless and airless
Bicycle riding without tubes reduces the risk of
tyre punctures or even avoids them completely.
The specialist dealer will advise you on choosing
a suitable tyre system for the pedelec.
The conversion to tubeless or airless tyres must
be carried out by a specialist dealer to ensure the
safety.
Trailer Adapter
Croozer Kid
Item no. 122003516,
XL: +10 mm Item no. 122003716
Item no. 12200715
Croozer axle nut adapter with Thule
coupling
Croozer Kid Plus
Croozer Cargo
Croozer Dog
Trailer Adapter
Thule Chariot Lite
Item no. 20100798
Thule Chariot Cab
Thule Chariot Cross
Thule Chariot Sport
Thule Coaster XT
MY21K03 - 12_1.0_21.09.2020 45
Operation
6.7 Check list before each ride
Check the pedelec before each ride.
Take the pedelec out of service if you spot any
anomalies.
Check that the pedelec is complete.
Check the battery is firmly in place.
Check that the lighting, reflector and brake, for instance,
are sufficiently clean.
You must check that the mudguards, the pannier rack and
the chain guard are securely installed.
Check that the front and rear wheels run true. This is
particularly important if the pedelec been transported or
secured with a lock.
Check the valves and the tyre pressure. Adjust as
necessary before each ride.
If the bicycle has a hydraulic rim brake, check whether the
locking levers are fully closed in their final positions.
Check the front and rear wheel brakes to make sure that
they are working properly. To do so, push the brake levers
while stationary to check whether resistance is generated
in the usual brake lever position. The brake must not lose
any brake fluid.
Check that the riding light is working.
Check for unusual noises, vibrations, smells, staining,
deformation, cracks, scores, abrasion and wear. This
indicates material fatigue.
Inspect suspension system for cracks, dents, bumps, parts
or leaking oil. Look at concealed sections on the pedelec's
lower surface.
If quick releases are used check them to make sure that
they are fully closed in their end position.
Be alert to any unusual operating sensations when braking,
pedalling or steering.
MY21K03 - 12_1.0_21.09.2020 46
Operation
6.8 Using the kickstand
6.8.1 Raising the kickstand
Use your foot to raise the kickstand completely
before setting off.
6.9 Using the pannier rack
Distribute the baggage as evenly as possible
between the left- and right-hand side.
We recommend the use of panniers and
baggage baskets.
The maximum load bearing capacity is indicated
on the pannier rack.
Never exceed the maximum permitted total
weight when packing the pannier.
Never exceed the maximum load bearing
capacity of the pannier rack.
Never modify the pannier rack.
6.10 Using the saddle
Do not wear studded jeans as these can
damage the saddle covering.
Wear dark clothes for your first few rides as
new leather saddles can stain clothing.
Crash caused by loaded pannier rack
The pedelec is handled differently with a loaded
pannier rack, in particular when the rider needs to
steer and brake. This can lead to a loss of control.
This may cause a crash with injuries.
You should practice how to use a loaded
pannier rack safely before using the pedelec in
public spaces.
Crushing the fingers in the spring flap
The spring flap on the pannier rack operates with
a high clamping force. There is a risk of crushing
the fingers.
Never allow the spring flap to snap shut in an
uncontrolled manner.
Be careful where you position your fingers when
closing the spring flap.
Crash caused by unsecured baggage
Loose or unsecured objects on the pannier rack,
e.g. belts, may become caught in the rear wheel.
This may cause a crash with injuries.
Objects which are fastened to the pannier rack
may cover the reflectors and the riding light. Other
users may not see the pedelec on public roads as
a result. This may cause a crash with injuries.
Secure any objects which are attached to the
pannier rack sufficiently.
Objects fastened to the pannier rack must
never cover the reflectors, the headlight or the
rear light.
CAUTION
!
CAUTION
!
MY21K03 - 12_1.0_21.09.2020 47
Operation
6.11 Rechargeable battery
Switch off the battery and the drive system before
removing or inserting the battery.
6.11.1 BOSCH PowerPack
6.11.1.1 Removing the PowerPack
Figure 24: Removing and inserting the PowerPack
1Open battery lock with battery key (1).
2Tip the battery out of the top section of the
PowerPack mount.
3Pull battery from the PowerPack mount (2).
6.11.1.2 Insert PowerPack
1Place the battery on the contacts in the lower
section of the PowerPack mount [3].
2Remove the battery key from the battery lock
(4).
3Tip the battery into the top section of the
PowerPack mount until it will go no further.
There is an audible clicking noise.
4Check the battery to make sure it is firmly in
place.
6.11.2 Charging the battery
The ambient temperature during the charging
process must be within the range from 0 °C to
40 °C.
The battery can remain on the pedelec or can be
removed for charging.
Interrupting the charging process does not
damage the battery.
1Remove the cable connection cover if
necessary.
2Connect the mains plug of the charger to a
normal domestic, grounded socket.
3Connect the charging cable to the battery's
charging port.
The charging process starts automatically.
The battery level indicator shows the charge
level during charging. When the drive system is
switched on, the display screen shows the
charging process.
The charging process is complete when the
LEDs on the battery level indicator go out.
4Once charging is complete, disconnect the
battery from the charger.
5Disconnect the charger from the mains.
(2)
(1)
(3)
(4)
Connection data 230 V, 50 Hz
Notice
Check that mains voltage! The power source
voltage must match the voltage indicated on
the charger nameplate. Chargers labelled
230 V may be operated at 220 V.
Notice
If an error occurs during the charging process, a
system message is displayed.
Remove the charger and battery from
operation immediately and follow the
instructions.
MY21K03 - 12_1.0_21.09.2020 48
Operation
6.11.3 Charging the dual battery
6.11.3.1 Charging process when two batteries
are used
If two batteries are attached to a pedelec,
charge both batteries via the non-sealed
socket.
The two batteries are charged alternately
during charging. Charging switches
automatically between the two batteries
several times. The charging time is twice as
long.
The two batteries are discharged alternately
during use.
6.11.3.2 Charging process when one battery
is used
If only one battery is inserted, only charge the
battery with an accessible charging socket.
Charge the battery with the sealed charging
socket outside its mount only.
6.11.4 Using double battery model with a
single battery only
One of the charging sockets is not accessible or is
sealed with an end cap on pedelecs with two
batteries.
If you wish to use just one battery on a pedelec
which is designed for two batteries, cover the
contacts in the free slot with the supplied cover
cap; otherwise, there is a risk of a short circuit
caused by the open contacts.
6.11.5 Waking the battery
The battery switches to sleep mode to protect
itself when not used for a longer period. The LEDs
on the battery level indicator do not light up.
Press the On-Off button (battery).
The battery level indicator shows the charge
level.
Notice
Charging via a closed charging socket can cause
irreparable damage.
Charge the battery via the accessible charging
socket only.
Never open a sealed charging socket.
MY21K03 - 12_1.0_21.09.2020 49
Operation
6.12 Electric drive system
6.12.1 Switching on the electric drive
system
A sufficiently charged battery has been inserted
into the pedelec.
The battery is firmly positioned. The battery key
has been removed.
There are three options for switching on the drive
system.
On-Off button (battery)
Press the On-Off button (battery) briefly.
On-Off button (display)
Press the On-Off button (display) briefly.
Switched-on display
If the display is already switched on when it is
inserted into its mount, the electric drive
system is switched on automatically.
After switching on, a speed of 0 KM/H is
displayed on the display. If it is not, check
whether the display screen is fully engaged into
position.
If the drive system is switched on, the drive is
activated as soon as the pedals are moved with
sufficient force (except if in push assist mode
or the level of assistance is "OFF").
The motor power is determined by the level of
assistance set on the display.
As soon as the system has been activated,
ACTIVE LINE/PERFORMANCE LINE
appears briefly on the display.
6.12.2 Switching off the electric drive
system
As soon as you stop pushing the pedals in normal
mode or reach a speed of 25 km/h, the drive
system switches off the assistance system. The
assistance system starts up again if you push the
pedals and your speed is less than 25 km/h.
The system switches off automatically ten minutes
after the last command. There are three options
for switching off the drive system manually.
On-Off button (display)
Press the On-Off button (display) briefly.
On-Off button (battery)
Press the On-Off button (battery).
Removing the display
Remove the display from the mount.
The LEDs on the operating status and battery
level indicator go out.
Crash caused by lack of readiness for braking
When it is switched on, the drive system can be
activated by the application of force on the
pedals. There is a risk of a crash if the drive is
activated unintentionally, and the brake is not
reached.
Never start the electric drive system, or switch
it off immediately, if the brake cannot be
reached safely and reliably.
CAUTION
!
MY21K03 - 12_1.0_22.09.2020 50
Operation
6.13 Display
.
Figure 25: Display overview
6.13.1 Overview of actions on the display
screen
6.13.2 Switching on the display
Press the On-Off button (display) briefly.
The electric drive system is switched on.
6.13.3 Switching off the display
Press the On-Off button (display) briefly.
The electric drive system is switched off.
Crash caused by distraction
A lack of concentration while riding increases the
risk of an accident. This may cause a crash with
serious injuries.
Never allow yourself to be distracted by the
display.
Stop bicycle if you want to make inputs on the
display other than a change in level of
assistance. Only enter data when the bicycle
is stationary.
Notice
Never use the display as a handle. The display
may become irreparably damaged if you use it
to lift the pedelec.
If you do not use your pedelec for several
weeks, remove the batteries from the display.
Adjust the display screen brightness in such a
way that you can see text and icons sufficiently
clearly.
Symbol Designation
1WALK Push assist button
2 USB port
3On-Off button (display)
4 Indicator
5+Plus button
6Minus button
Table 28: Overview of the control panel with display
CAUTION
!
WALK
WALK
WALK
W
AL
W
W
W
W
W
W
A
A
L
K
K
K
K
K
W
W
W
W
W
W
W
W
WWWW
WW
W
W
W
W
W
W
W
W
W
W
WW
W
W
W
W
A
A
WW
W
W
A
W
W
W
W
W
WW
W
W
W
W
A
WW
AAAA
AA
A
AA
A
A
A
A
A
A
A
A
A
A
LLLL
LL
L
AA
A
A
A
A
L
L
LL
L
L
L
L
K
KKKK
KK
K
K
K
K
K
KK
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
1
23
4
5
6
Action Button Duration
Switching on the display Brief
Switching off the display Brief (< 1 s)
Using the push assist system WALK
+
1. Brief (< 1 s)
2. Any
Increase assistance +Brief (< 1 s)
Reduce assistance Brief (< 1 s)
TRIP/TOTAL/RANGE screen,
assistance modes Medium (1- 2.5 s)
Switch on riding light +Medium (1- 2.5 s)
Switch off riding light +Long (> 2.5 s)
Reset journey distance – + Long (> 2.5 s)
Switch from kilometres to
miles
1. Hold
2. Brief (< 1 s)
Get versions
– + 1. Hold
2. Brief (< 1 s)
Set display screen brightness
– +
or +
1. Hold
2. Brief (< 1 s)
3. Brief (< 1 s)
Table 29: Overview of actions on the display screen
MY21K03 - 12_1.0_22.09.2020 51
Operation
6.14 Using the push assist system
The push assist helps the rider to push the
pedelec. The speed can be a maximum of 6 km/h
in this case.
The push assist cannot be activated at the OFF
assistance level.
The tractive power of the push assist and its
speed can be influenced by the selection of gear.
To spare the drive, first gear is recommended for
travelling uphill.
The level of assistance OFF must not be
selected.
1Press the push assist button briefly (< 1 s) to
activate the push assist.
2Press and hold down the plus button within
3 seconds to switch on push assist.
3Release the plus button to switch off push
assist.
The push assist system switches off
automatically as soon as the pedelec wheels
are blocked or the speed exceeds 6 km.
6.14.1 Using the riding light
The drive system needs to be already switched
on to turn on the riding light.
Push the plus button momentarily (1 to 2.5 s).
The riding light is switched on. The riding light
symbol is displayed.
Push the plus button for a long time (> 2.5 s).
The riding light is switched off. The riding light
symbol is not displayed.
6.14.2 Selecting the level of assistance
Press the plus button briefly (< 1 s) to increase
the level of assistance.
Press the minus button briefly (< 1 s) to reduce
the level of assistance.
6.14.3 Journey information
The displayed journey information can be
changed and partially reset.
6.14.3.1 Switching the journey information
Push the minus button momentarily
(1 to 2.5 s).
The journey information trip distance (TRIP),
total distance travelled (TOTAL), range
(RANGE), and support modes used are shown
on the display screen.
6.14.3.2 Resetting the trip distance
1Select the item of journey information TRIP.
2Push both the plus button and the minus
button at the same time for a long time
(> 2.5 s).
RESET is shown on the display screen.
3If you continue to jiggle the plus and minus
buttons at the same time, the trip distance will
be reset to 0.
Injury from pedals or wheels
The pedals and the drive wheel turn when the
push assist system is used. There is a risk of
injury if the pedelec wheels are not in contact with
the ground when the push assist system is used
(e.g. when carrying the pedelec up stairs or when
placing it on a bicycle rack).
Only use the push assist mode when pushing
the pedelec.
You must steer the pedelec securely with both
hands when using push assist.
Allow for enough freedom of movement for the
pedals.
CAUTION
!
MY21K03 - 12_1.0_22.09.2020 52
Operation
6.14.3.3 Resetting the range
1Select the item of journey information RANGE.
2Push both the plus button and the minus
button at the same time for a long time (>
2.5 s).
RESET is shown on the display screen.
3If you continue to jiggle the plus and minus
buttons at the same time, the range will be
reset to 0.
6.14.3.4 Changing the tachometer unit
You can change the displayed values from
kilometres to miles.
1Keep the minus button pressed down.
2Press the On-Off button (display) briefly (< 1 s).
All values are changed from kilometres to
miles.
6.14.3.5 Displaying versions and type numbers
You can retrieve the sub-system versions and
their type part numbers for maintenance purposes
if the sub-systems provide this type of information
(depends on the sub-system).
The drive system must be switched off.
1Keep the plus and minus buttons pressed
down at the same time.
2Press the On-Off button (display) briefly (< 1 s).
The version or type number will be displayed
as moving text.
6.14.3.6 Set display screen brightness
The display must be switched off.
1Keep the plus and minus buttons pressed
down at the same time.
2Press the On-Off button (display) briefly (< 1 s).
3Use the plus button or minus button to adjust
the display screen brightness in such a way
that you can see text and icons sufficiently
clearly.
6.14.4 Using the USB port
6.14.5 Replacing the battery
When the on-board computer indicates LOW BAT
on the screen, the battery is flat and must be
replaced.
Figure 26: Display with attachment screw (1) and battery
compartment cover (2)
1Remove the display from the handlebars by
unfastening the display attachment screw (1).
2Use a suitable coin to open the battery
compartment cover (2).
3Remove the used battery.
4Insert a new CR 2016 display battery. You can
obtain the batteries recommended by Bosch
from your specialist dealer. Ensure correct
polarity when inserting the display battery.
5Close the battery compartment again and
fasten the on-board computer to the
handlebars with the attachment screw (1).
Notice
The USB port is reserved to connect diagnostics
systems. The USB port must be kept completely
closed with the protective cap at all times.
Any moisture penetrating through the USB port
may cause a short circuit in the display.
Regularly check the position of the rubber
cover on the USB port and adjust it as
necessary.
WALK
WALK
WALK
W
AL
W
W
W
W
W
W
A
A
A
AL
L
L
K
K
K
K
W
W
W
W
W
W
W
W
WWWW
WW
W
WW
W
W
WW
W
W
W
W
W
W
W
W
W
WA
WA
WW
W
W
W
W
WA
W
W
W
W
W
WW
W
WA
WW
WAWAWAWA
WAWA
WA
WW
A
A
WA
A
WA
A
A
A
A
A
A
A
A
A
LLLL
ALAL
AL
W
W
A
WA
WA
WA
L
AL
AL
L
L
ALAL
AL
LK
L
L
KKKK
LKLK
LK
K
K
KK
K
K
K
K
K
K
K
K
K
K
K
K
1
2
MY21K03 - 12_1.0_21.09.2020 53
Operation
6.15 Brake
The drive force of the motor is shut off during the
ride as soon as the rider no longer pedals. The
drive system does not switch off when braking.
In order to achieve optimum braking results, do
not pedal while braking.
Crash caused by brake failure
Oil or lubricant on the brake disc in a disc brake
or on the rim of a rim brake can cause the brake
to fail completely. This may cause a crash with
serious injuries.
Never allow oil or lubricant to come into
contact with the brake disc or brake linings or
on the rim of a rim brake.
If the brake linings have come into contact with
oil or lubricant, contact a dealer or a workshop
to have the components cleaned or replaced.
If the brakes are applied continuously for a long
time (e.g. while riding downhill for a long time),
the fluid in the brake system may heat up. This
may create a vapour bubble. This will cause air
bubbles or any water contained in the brake
system to expand. This may suddenly make the
lever travel wider. This may cause a crash with
serious injuries.
Release the brake regularly when riding
downhill for a longer period of time.
Amputation due to rotating brake disc
The brake disc in disc brakes is so sharp that it
can cause serious injuries to fingers if they are
inserted into the brake disc openings.
Always keep fingers well away from the
rotating brake discs.
Burns caused by heated brake
The brakes may become very hot during
operation. There is a risk of burns or fire in case
of contact.
Never touch the components of the brake
directly after the ride.
WARNING
!
CAUTION
!
Crash caused by wet conditions
The tyres may slip on wet roads. In wet conditions
you must also expect a longer braking distance.
The braking sensation differs from the usual
sensation. This can cause loss of control or a
crash, which may result in injuries.
Ride slowly and brake in good time.
Crash caused by incorrect use
Handling the brake improperly can lead to loss of
control or crashes, which may result in injuries.
Shift your body weight backwards and down as
far as possible.
Practice braking and emergency braking
before using the pedelec in public spaces.
Never use the pedelec if you can feel no
resistance when you grip the brake handle.
Consult a specialist dealer.
Crash after cleaning or storage
The brake system is not designed for use on a
pedelec which is placed on its side or turned
upside down. The brake may not function
correctly as a result. This can cause a crash,
which may result in injuries.
If the pedelec is placed on its side or turned
upside down, apply the brake a couple of times
before setting off to ensure that it works as
normal.
Never use the pedelec if the brake does not
work properly. Consult a specialist dealer.
CAUTION
!
MY21K03 - 12_1.0_21.09.2020 54
Operation
6.15.1 Using the brake lever
Figure 27: Front (2) and rear (1) brake lever – Shimano
brake used as an example
Push the left-hand brake lever to apply the front
wheel brake.
Push the right-hand brake lever to apply the rear
wheel brake.
MY21K03 - 12_1.0_21.09.2020 55
Operation
6.16 Gear shift
The selection of the appropriate gear is a
prerequisite for a physically comfortable ride and
making sure that the electric drive system
functions properly. The ideal pedalling frequency
is between 70 and 80 revolutions per minute.
Stop pedalling briefly when changing gears.
This makes it easier to switch gears and
reduces wear on the drivetrain.
6.16.1 Using the derailleur gears
Only applies to pedelecs with this equipment
The speed and range can be increased while
applying the same force if you select the right
gear. Use the derailleur gears.
Figure 28: Down shifter (1) and up shifter (2) on the left (I)
and right (II) gear shift
Select the appropriate gear with the shifter.
The gear shift switches the gear.
The shifter returns to its original position.
Clean and lubricate the rear derailleur if gear
changes block.
6.16.2 Using an ENVIOLO hub gear
Only applies to pedelecs with this equipment
The hub cannot be switched through its entire
transmission range when stationary. As a general
rule, 50–70% of the transmission range can be
used when stationary. The remaining part of the
transmission range can be adjusted when riding.
III
1
22
1
Crash caused by incorrect use
If the rider applies too much pressure on the
pedals during a gear change and activates the
shifter or changes several gears at a time, their
feet may slip from the pedals. This may cause a
crash or flip-over with injuries.
Switching down several gears to a low gear may
cause the twist grip outer sleeve to suddenly
come off. This will not have an adverse effect on
the twist grip's correct functioning since the outer
guide returns to its original position after the gear
change is complete.
Apply little pressure on the pedals while
changing gears.
Never change more than one gear at a time.
Notice
The interior hub is not completely waterproof. If
water gets into the hub, it may rust and the gear
switch function may no longer function as a result.
Never use the pedelec in places where water
may get into the hub.
In rare cases, noises may be heard from the rear
derailleur in the hub interior after a gear change.
This is normal when gears are changed.
Never detach the hub yourself. Contact your
specialist dealer.
CAUTION
!
MY21K03 - 12_1.0_21.09.2020 56
Operation
The automatic ENVIOLO gear shift includes a
twist grip with an indicator.
Figure 29: ENVIOLO twist grip with indicator
6.16.3 Selecting automatic or manual shift
The gear shift can be used manually or in
automatic mode.
Press the mode button.
The gear shift switches between the automatic
and manual gear option.
6.16.4 Switching gear in automatic mode
In automatic mode, the system automatically
adjusts transmission to the rider's desired
pedalling frequency.
6.16.5 Switching gear manually
6.16.5.1 Changing down
Switch to a low transmission ratio for setting off or
driving uphill.
Turn the twist grip backwards.
A hill is shown on the display.
Figure 30: Hill display (1) when changing down (2)
6.16.5.2 Changing up
Switch to a high transmission ratio for higher
speeds.
Turn the twist grip forwards.
Flat terrain is shown on the display.
Figure 31: Flat terrain display (1) when changing up (2)
1 Manual gear shift indicator
2 Automatic gear shift indicator
3 Grip shifter
4 Mode button
3
4
5
12
12
12
MY21K03 - 12_1.0_22.09.2020 57
Operation
6.17 Parking the pedelec
1Switch off the drive system (see
Section 6.12.2).
2After getting off, use your foot to lower the
kickstand completely before parking. Ensure
that it is stable.
3Park the pedelec carefully and check that it is
stable.
4Cleaning the suspension fork and pedals (see
Section 7.1.)
5Protect the saddle with a saddle cover if you
park the pedelec outside.
6Secure the pedelec with a bicycle lock.
7Remove the battery (see Section 6.11.1.1 or
6.11.3.1) and, where necessary, your mobile
(see Section 6.6.3) to ensure protection
against theft.
Notice
Heat or direct sunlight can cause the tyre pressure
to increase above the permitted maximum
pressure. This can destroy the tyres.
Never park the pedelec in the sun.
On hot days, regularly check the tyre pressure
and adjust it as necessary.
Moisture penetrating at low temperatures may
impair individual functions due to the open
structural design.
Always keep the pedelec dry and free from
frost.
If the pedelec is to be used at temperatures
below 3 °C, the specialist dealer must carry
out an inspection and prepare it for winter use.
The pedelec's force of weight may cause the
kickstand to sink into soft ground, possible
causing the pedelec to topple over as a result.
Park the pedelec on firm, level ground only.
MY21K03 - 12_1.0_21.09.2020 58
Cleaning and servicing
7 Cleaning and servicing
Cleaning check list
Maintenance check list
Servicing measures must be performed regularly.
Contact your specialist dealer if you are unsure.
7.1 Cleaning after each ride
7.1.1 Cleaning the suspension fork
Remove dirt and deposits from the stanchions
and deflector seals with a damp cloth.
Check the stanchions for dents, scratches,
staining or leaking oil.
Check the air pressure.
Lubricate the dust seals and stanchions.
7.1.2 Cleaning the rear frame damper
Remove dirt and deposits from the damper
body with a damp cloth.
Check rear frame damper for dents, scratches,
staining or leaking oil.
7.1.3 Cleaning the pedals
Clean with a brush and soapy water after riding
through dirt or rain.
Service the pedals after cleaning.
Clean the pedals after each ride
Clean the suspension fork and, if
necessary, rear frame damper after each ride
Cleaning the battery once a month
Chain (mainly tarmacked road) every
250–300 km
Basic cleaning and preservation of all
components at least every six
months
Clean the charger at least every six
months
Clean and lubricate the height-adjustable
seat post every six months
Check USB rubber cover position before each ride
Check for tyre wear once a week
Check for rim wear once a week
Check tyre pressure once a week
Check brakes for wear once a month
Check electrical cables and Bowden
cables for damage and ensure they are
fully functional once a month
Check chain tension once a month
Check tension of the spokes every three
months
Check the gear shift setting every three
months
Check suspension fork and, if necessary,
rear frame damper for wear and ensure
fully functional
every three
months
Check for wear on brake discs at least every six
months
Crash and falling caused by unintentional
activation
There is a risk of injury if the drive system is
activated unintentionally.
Remove the battery before cleaning.
CAUTION
!
Required tools and cleaning agents:
Cloth
•Air pump
•Brush
Water
Dish-washing liquid
•Bucket
MY21K03 - 12_1.0_21.09.2020 59
Cleaning and servicing
7.2 Basic cleaning
Remove battery before basic cleaning.
7.2.1 Cleaning the frame
1Soak the entire frame with dish-washing
detergent if the dirt is thick and ingrained.
2After leaving it to soak for a short time, remove
the dirt and mud with a sponge, brush and
toothbrushes.
3Use a watering can or your hand to rinse the
frame.
4Service the frame after cleaning.
7.2.2 Cleaning the stem
1Clean stem with a cloth and soapy water.
2Service the stem after cleaning.
7.2.3 Cleaning the wheel
1Check the tyres, rims, spokes and spoke
nipples for any damage while cleaning the
wheel.
2Use a sponge and a brush to clean the hub and
spokes from the inside to the outside.
3Clean the rim with a sponge.
7.2.4 Cleaning the drive elements
1Spray the cassette, the chain wheels and the
front derailleur with a degreasing agent.
2Clean coarse dirt with a brush after soaking for
a short time.
3Wash down all parts with dish-washing
detergent and a toothbrush.
4Service the drive elements after cleaning.
Crash caused by brake failure
The braking effect may be unusually poor
temporarily after cleaning, servicing or repairs.
This may cause a crash with injuries.
Never apply care products or oil to the brake
discs or brake linings, or the braking surfaces
on the rims.
After cleaning, servicing or repair, carry out a
few test brake applications.
Notice
Water may enter the inside of the bearings if you
use a steam jet. This dilutes the lubricant inside,
the friction increases and, as a result, the
bearings are permanently damaged in the long
term.
Never clean the pedelec with a pressure
washer.
Greased parts, such as the seat post, the
handlebars or the stem, may no longer be safely
and reliably clamped.
Never apply grease or oil to clamping sections.
Required tools and cleaning agents:
•Cloths
Sponge
•Air pump
•Brush
Toothbrush
Paintbrush
Watering can
•Bucket
•Water
Dish-washing liquid
Degreaser
Lubricant
Brake cleaner or spirit
CAUTION
!
Crash caused by braking hard on rims
A rim can break and block the wheel if you brake
hard. This may cause a crash with serious
injuries.
Check rim wear on a regular basis.
WARNING
!
MY21K03 - 12_1.0_21.09.2020 60
Cleaning and servicing
7.2.5 Cleaning the rear frame damper
Only applies to pedelecs with this equipment
Clean rear frame damper with a cloth and
soapy water.
7.2.6 Cleaning the chain
1Slightly dampen a brush with dish-washing
liquid. Brush both sides of the chain.
2Dampen a cloth with soapy water. Place the
cloth on the chain.
3Hold and apply slight pressure while slowly
turning the rear wheel, so the chain passes
through the cloth.
4If the chain is still dirty afterwards, clean with
lubricant.
5Service the chain after cleaning.
7.2.7 Cleaning the battery
Clean the battery electrical connections with a
dry cloth or paintbrush only.
Wipe off the decorative sides with a damp
cloth.
7.2.8 Cleaning the display
Carefully clean the display with a soft, damp
cloth.
7.2.9 Cleaning the motor
Carefully clean the motor with a soft, damp
cloth.
Notice
Never use aggressive (acid-based) cleaners,
rust removers or degreasers when cleaning
the chain.
Never use chain cleaning devices or chain
cleaning baths.
Risk of fire and explosion due to penetration by
water
The battery is only protected from simple spray
water. Penetration by water can cause a short
circuit. The battery may self-ignite and explode.
Never clean the battery with a pressure
washer, water jet or compressed air.
Keep contacts dry and clean.
Never immerse the battery in water.
Never use cleaning agents.
Remove the battery from the pedelec before
cleaning.
CAUTION
!
Notice
Never clean the battery with solvents, such as
oil, thinners, alcohol or corrosion protection, or
with cleaning agents.
Notice
If water enters into the display screen, it will be
permanently damaged.
Never immerse the display in water.
Never clean with a pressure washer, water jet
or compressed air.
Never use cleaning agents.
Remove the display from the pedelec before
cleaning.
Burns from hot motor
The motor cooler can become extremely hot
during use. Touching it may cause burns.
Leave the motor to cool before cleaning.
Notice
If water penetrates the motor, it will be
permanently damaged.
Never immerse the motor in water.
Never clean with a pressure washer, water jet
or compressed air.
Never use cleaning agents.
CAUTION
!
MY21K03 - 12_1.0_21.09.2020 61
Cleaning and servicing
7.2.10 Cleaning the brake
Clean brake and brake discs with a brush,
water and dish-washing detergent.
Clean brake discs thoroughly with brake
cleaner or spirit.
7.3 Servicing
7.3.1 Servicing the frame
Dry the frame.
Spray with care oil.
Clean off the care oil again after a short time.
7.3.2 Servicing the stem
Apply silicone or Teflon oil to the stem shaft
tube and the quick release lever pivot point.
If you have speedlifter Twist, also apply oil to
the unlocking bolt using the groove in the
speedlifter body.
Apply a little acid-free lubricant grease
between the stem quick release lever and the
sliding piece to reduce the quick release lever
operating force.
7.3.3 Servicing the fork
Treat the dust seals with fork oil.
7.3.4 Servicing the drive elements
1Spray the cassette, the chain wheels and the
front derailleur with a degreasing agent.
2Clean coarse dirt with a brush after soaking for
a short time.
3Wash down all parts with dish-washing
detergent and a toothbrush.
4Treat front and rear derailleur articulated
shafts and jockey wheels with Teflon spray.
7.3.5 Servicing the pedals
Treat pedals with spray oil.
7.3.6 Servicing the chain
Lubricate the chain thoroughly with chain oil.
Brake failure due to water penetration
The brake seals are unable to withstand high
pressures. Damaged brakes can fail and cause
an accident with injury.
Never clean the pedelec with a pressure
washer or compressed air.
Take great care when using a hosepipe. Never
point the water jet directly at the seal section.
Required tools and cleaning agents:
•Cloths
Toothbrushes
Dish-washing liquid
Care oil for frames
Silicone or Teflon oil
Acid-free lubricating grease
Fork oil
Chain oil
Degreaser
Spray oil
Teflon spray
WARNING
!
MY21K03 - 12_1.0_21.09.2020 62
Cleaning and servicing
7.4 Maintenance
The following maintenance measures must be
performed on a regular basis.
7.4.1 Wheel
1Check the tyres for wear.
2Check the tyre pressure.
3Check the rims for wear.
The rims of a rim brake with invisible wear
indicator are worn as soon as the wear
indicator becomes visible in the area of the rim
joint.
The rims with visible wear indicator are worn as
soon as the black, all-round groove on the pad
friction surface is no longer visible. We
recommend that you also replace the rims with
every second brake lining replacement.
4Check the tension of the spokes.
7.4.1.1 Checking the tyres
Check the tyre wear. The tyre is worn if the
anti-puncture protection or the carcass cords
are visible.
A specialist dealer will need to change the tyre
if it is worn.
7.4.1.2 Checking the rims
Check the rims for wear. The rims are worn as
soon as the black, all-round groove on the pad
friction surface becomes invisible.
Contact your specialist dealer to have the rims
replaced. We recommend that you also replace
the rims at the same time as every second
brake lining replacement.
7.4.1.3 Checking and adjusting the tyre
pressure – Dunlop valve
Only applies to pedelecs with this equipment
The tyre pressure cannot be
measured on the simple Dunlop
valve. The tyre pressure is
therefore measured in the filling
hose when pumping slowly with
the bicycle pump.
It is recommendable to use a
bicycle pump with a pressure
gauge. The operating
instructions for the bicycle pump
must be adhered to.
1Unscrew and remove the
valve cap.
2Connect the bicycle pump.
3Pump up the tyre slowly and pay attention to
the tyre pressure in the process.
4Correct the tyre pressure according to
specifications in the Pedelec pass.
5If the tyre pressure is too high, unfasten the
union nut, let air out and re-tighten the union
nut.
6Remove the bicycle pump.
7Screw the valve cap tight.
8Screw the rim nut gently against the rim with
the tips of your fingers.
Crash and falling caused by unintentional
activation
There is a risk of injury if the drive system is
activated unintentionally.
Remove the battery before maintenance.
Crash caused by braking hard on rims
A rim can break and block the wheel if you brake
hard. This may cause a crash with serious
injuries.
Check rim wear on a regular basis.
Notice
If the tyre pressure is too low in the tyre, the tyre
does not achieve its load bearing capacity. The
tyre is not stable and may come off the rim.
If the tyre pressure is too high, the tyre may burst.
Check the tyre pressure as per specifications
Adjust the tyre pressure as necessary.
CAUTION
!
WARNING
!
MY21K03 - 12_1.0_21.09.2020 63
Cleaning and servicing
7.4.1.4 Checking and adjusting the tyre
pressure – Presta valve
Only applies to pedelecs with this equipment
It is recommendable to use
a bicycle pump with a
pressure gauge. The
operating instructions for
the bicycle pump must be
adhered to.
1Unscrew and remove the
valve cap.
2Open the knurled nut
around four turns.
3Carefully apply the bicycle
pump so that the valve
insert is not bent.
4Pump up the tyre slowly and pay attention to
the tyre pressure in the process.
5Correct the tyre pressure as per the
specifications on the tyre.
6Remove the bicycle pump.
7Tighten the knurled nut with your fingers.
8Screw the valve cap tight.
9Screw the rim nut gently against the rim with
the tips of your fingers.
7.4.1.5 Checking and adjusting the tyre
pressure – Schrader valve
Only applies to pedelecs with this equipment
It is recommendable to use a
bicycle pump with a pressure
gauge. The operating
instructions for the bicycle
pump must be adhered to.
1Unscrew and remove the
valve cap.
2Attach the bicycle pump.
3Pump up the tyre slowly
and pay attention to the tyre pressure in the
process.
The tyre pressure has been adjusted as per the
specifications.
4Remove the bicycle pump.
5Screw the valve cap tight.
6Screw the rim nut (1) gently against the rim
with the tips of your fingers.
7.4.2 Brake system
The maintenance interval for the brake depends
on the weather conditions and how frequent the
bicycle is used. If the pedelec is used under
extreme conditions such as rain, dirt or high
mileage, maintenance must be performed more
frequently.
7.4.3 Checking the brake linings for wear
Check brake linings after brake has been fully
applied 1,000 times.
1Check that the brake linings are no less than
1.8 mm wide at any point and no less than
2.5 mm between the brake lining and
supporting plate.
2Push brake lever and hold. In doing so, check
the transport safety wear gauge can fit
between the brake lining supporting plates.
The brake linings have not reached their wear
limit. Contact your specialist dealer if any of
these components have become worn.
Crash caused by brake failure
Worn brake discs and brake linings, as well as a
lack of hydraulic fluid in the brake cable, reduce
the braking power. This may cause a crash with
injuries.
Check the brake disc, brake linings and
hydraulic brake system on a regular basis.
Contact your specialist dealer if any of these
components have become worn.
CAUTION
!
1
MY21K03 - 12_1.0_21.09.2020 64
Cleaning and servicing
7.4.4 Checking the pressure point
Pull brake lever and hold repeatedly several
times.
If you are unable to clearly detect the pressure
point and it changes, the brake needs to be
vented. Contact your specialist dealer.
7.4.5 Checking the brake discs for wear
Check that the brake disc measures no less
than 1.8 mm in depth at any point.
The brake discs have not reached their wear
limit yet; brake discs need to be replaced if
they have. Contact your specialist dealer.
7.4.6 Checking the electrical cables and
brake cables
Check all visible electrical cables and Bowden
cables for damage. If the sheathing is
compressed, a brake is defective or a light
does not work, the pedelec must be removed
from service until the lines or cables have been
repaired. Contact your specialist dealer.
7.4.7 Checking the gear shift
Check the gear shift and the shifter or the gear
twist grip setting and adjust as necessary.
7.4.8 Checking the stem
The stem and quick release system must be
inspected at regular intervals. The specialist
dealer should adjust them if necessary.
If the hexagon socket head screw is also
loosened, the headset backlash also needs to
be adjusted. Medium-strength thread locker,
such as Loctite blue, then needs to be applied
to the loosened screws and the screws
tightened as per specifications.
Contact your specialist dealer if there is any
wear or signs of corrosion.
7.4.9 Checking the USB port
7.4.10 Checking the belt and chain tension
1Check the chain tension in three or four
positions, turning the crank a full revolution.
Figure 32: Checking the chain tension
2If the chain can be pushed more than 2 cm, the
chain or drive belt will need to be tensioned
again by the specialist dealer.
3If the chain or the drive belt can only be pushed
up and down less than 1 cm, you will need to
slacken the chain or the drive belt.
The optimum chain tension is achieved if the
chain or the drive belt can be pushed a
maximum of 2 cm in the middle between the
pinion and the toothed wheel. The crank must
also turn without resistance.
4If a hub gear is fitted, the rear wheel must be
pushed backwards or forwards to tighten the
chain. Contact your specialist dealer.
5Check the handlebar grip is firmly in position.
Notice
Any moisture penetrating through the USB port
may cause a short circuit in the display.
Regularly check the position of the cover on the
USB port and adjust it as necessary.
Notice
Excessive chain tension increases wear.
If the chain tension is too low, there is a risk that
the chain or the drive belt will slip off the chain
wheels.
Check the chain tension once a month.
2 cm
MY21K03 - 12_1.0_22.09.2020 65
Maintenance
8 Maintenance
You must have the specialist dealer perform main-
tenance every six months as a minimum. This is
the only way to ensure that the pedelec remains
safe and fully functional. No matter whether disc
brakes need replacing, brakes venting or wheels
changing, many maintenance tasks require tech-
nical expertise, special tools and special lubri-
cants. The pedelec may become damaged if the
stipulated maintenance intervals and procedures
are not carried out. That is why only specialist
dealers may carry out maintenance.
The retailer will check the pedelec based on
the maintenance instructions in Section 11.3.
The specialist dealer will inspect the pedelec
for any signs of material fatigue during basic
cleaning.
The specialist dealer will check the software
version of the drive system and update it. The
electrical connections are checked, cleaned
and preservative agent is applied. The
electrical cables are inspected for damage.
The specialist dealer will dismantle and clean
the entire suspension fork interior and exterior.
They will clean and lubricate the dust seals and
slide bushings, check the torques and adjust
the fork to the rider's preferred position. They
will also replace the sliding collar if the clear-
ance is too great (more than 1mm on the fork
bridge).
Injury due to damaged brakes
Special tools and specialist knowledge are
required to repair the brakes. Incorrect or
unauthorised assembly can damage the brakes.
This may lead to an accident with injuries.
Only specialist dealers may carry out repairs
on brakes.
Only carry out work or changes, such as
dismantling, sanding or painting, which are
permitted and described in the brake operating
instructions.
Injury to the eyes
Problems may arise if the settings are not made
properly and you may sustain serious injuries as
a result.
Always wear safety glasses during
maintenance work.
Crash and falling caused by unintentional
activation
There is a risk of injury if the drive system is
activated unintentionally.
Remove the battery before inspection.
Crash caused by material fatigue
If the service life of a component has expired, the
component may suddenly fail. This may cause a
crash with injuries.
Have the specialist dealer carry out basic
cleaning of the pedelec every six months,
preferably at the same time as the required
servicing work.
WARNING
!
CAUTION
!
Hazard for the environment due to toxic
substances
The brake system contains toxic and
environmentally harmful oils and lubricants. Such
fluids will contaminate if they enter the sewers or
groundwater.
Dispose of lubricants and oils left over after
repairs in an environmentally responsible way.
in accordance with statutory regulations.
Notice
The motor is maintenance-free and only qualified
specialist personnel may open it.
Never open the motor.
CAUTION
!
MY21K03 - 12_1.0_22.09.2020 66
Maintenance
The specialist dealer will fully inspect the
interior and exterior of the rear frame damper,
overhaul the rear frame damper, replace all air
seals on air forks, overhaul the air suspension,
change the oil and replace the dust wipers.
They will pay particular attention to rim and
brake wear. The spokes are re-tightened in
accordance with the findings.
8.1 Suspension system
The correct execution of maintenance on the
suspension system not only guarantees a long
service life, but also ensures optimal
performance. Each maintenance interval shows
the maximum cycling hours for the corresponding
type of recommended maintenance. Depending
on terrain and environmental conditions, the
performance can be optimised through shorter
maintenance intervals.
8.1.1 Rear frame damper
Only applies to pedelecs with this equipment
Maintenance intervals
Special tools, special lubricants and knowledge of
suspension components are required to maintain
and repair the rear frame damper.
The rear frame damper may become damaged if
the procedure is not followed as described. Only
specialist dealers may carry out maintenance on
rear frame damper.
RockShox rear frame damper
Service air chamber assembly Every 50 hours
Service damper and spring Every 200 hours
FOX rear frame damper
Complete maintenance (full interior and
exterior inspection, damper overhaul, air
spring overhaul, oil change and dust
wiper replacement)
Every 125 hours
or once a year
Suntour rear frame damper
Complete shock absorber service
including damper reassembly and air seal
replacement Every 100 hours
Injury due to explosion
The air chamber is pressurised. If the air system is
serviced in a rear frame damper, it can explode and
cause serious injury.
Wear safety goggles, protective gloves and
safety clothing when assembling or servicing
the vehicle.
Release the air for the air chambers. Detach
all air insert fitments.
Never service or dismantle a rear frame
damper if it has not completely rebounded.
Intoxication from suspension oil
Suspension oil irritates the respiratory tract, leads to
germ cell mutations and sterility, causes cancer and
is toxic to touch.
Always wear safety goggles and nitrile gloves
when working with suspension oil.
Never perform maintenance when you are
pregnant.
Use an oil catchment tray under the section
where the rear frame damper is serviced.
Hazard for the environment due to toxic
substances
The rear frame damper contains toxic and
environmentally harmful oils and lubricants. Such
fluids will contaminate if they enter the sewers or
groundwater.
Dispose of lubricants and oils left over after
repairs in an environmentally responsible way
in accordance with statutory regulations.
WARNING
!
WARNING
!
CAUTION
!
MY21K03 - 12_1.0_22.09.2020 67
Maintenance
8.1.2 Suspension fork
Only applies to pedelecs with this equipment
Maintenance intervals
Special tools, special lubricants and knowledge of
suspension components are required to service
and repair suspension forks.
The suspension fork may be damaged if
procedures are not followed as described. Only
specialist dealers may carry out maintenance on
the suspension fork.
Suntour suspension fork
Maintenance 1
Functional check, fastening and wear test Every 50 hours
Maintenance 2
Maintenance 1 + cleaning entire fork
interior and exterior / cleaning and
lubrication of dust seals and guides/
plastic bushings / check torques
Every 100 hours
FOX suspension fork
Full maintenance (complete interior/
exterior inspection, damper overhaul,
replacement of air seals on air forks, air
suspension overhaul, oil change and dust
wiper replacement).
Every 125 hours
or once a year
RockShox suspension fork
Maintenance of stanchions for:
Paragon™, XC™ 28, XC 30, 30™, Judy®,
Recon™, Sektor™, 35™*, Bluto™, REBA®,
SID®, RS-1™, Revelation™, PIKE®, Lyrik™,
Yari™, BoXXer
Every 50 hours
Maintenance of spring and damper unit
for:
Paragon, XC 28, XC 30,30 (2015 and earlier),
Recon (2015 and earlier), Sektor (2015 and
earlier), Bluto (2016 and earlier), Revelation
(2017 and earlier), REBA (2016 and earlier),
SID (2016 and earlier), RS-1 (2017 and earlier),
BoXXer (2018 and earlier)
Every 100 hours
Maintenance of spring and damper unit
for:
30 (2016+), Judy (2018+), Recon (2016+),
Sektor (2016+), 35 (2020+)*, Revelation
(2018+), Bluto (2017+), REBA (2017+), SID
(2017+), RS-1 (2018+), PIKE (2014+), Lyrik
(2016+), Yari (2016+), BoXXer (2019+)
Every 200 hours
Injury due to explosion
The air chamber is pressurised. If the air system is
serviced in a faulty suspension fork, it can explode
and cause serious injury.
Wear safety goggles, protective gloves and
safety clothing when assembling or servicing
the vehicle.
Release the air for the air chambers. Detach
all air insert fitments.
Never service or dismantle a suspension fork
if it has not completely rebounded.
Hazard for the environment due to toxic
substances
The suspension fork contains toxic and
environmentally harmful oils and lubricants. Such
fluids will contaminate if they enter the sewers or
groundwater.
Dispose of lubricants and oils left over after
repairs in an environmentally responsible way
in accordance with statutory regulations.
WARNING
!
CAUTION
!
MY21K03 - 12_1.0_22.09.2020 68
Maintenance
8.1.3 Suspension seat post
Only applies to pedelecs with this equipment
Maintenance intervals
Special tools, special lubricants and knowledge of
suspension components are required to service
and repair suspension seat posts.
The suspension seat post may be damaged if
procedures are not followed as described. Only
specialist dealers may carry out maintenance on
the suspension seat post.
8.2 Axle with quick release
by.schulz seat post
Check all screws for correct tightening
torques for:
G1 and G2
After 250 km and
every 1,500 km
Suntour suspension seat post
Maintenance 1 Every 100 hours
RockShox suspension seat post
Venting of remote control lever and/or
maintenance of lower seat post unit for:
Reverb™ A1/A2/B1, Reverb Stealth A1/A2/B1/
C1*, Reverb AXS™ A1*
Every 50 hours
Venting of remote control lever and/or
maintenance of lower seat post unit for:
Reverb B1, Reverb Stealth B1/C1*, Reverb
AXS A1*
Every 200 hours
Complete maintenance of seat post for:
Reverb A1/A2, Reverb Stealth A1/A2 Every 200 hours
Complete maintenance of seat post for:
Reverb B1, Reverb Stealth B1 Every 400 hours
Complete maintenance of seat post for:
Reverb AXS A1*, Reverb Stealth C1* Every 600 hours
All other suspension seat posts
Maintenance Every 100 hours
Crash caused by unfastened quick
release
A faulty or incorrectly installed quick release may
become caught in the brake disc and block the
wheel. This will cause a crash.
Install the front wheel quick release lever on
the opposite side to the brake disc.
Crash caused by faulty or incorrectly
installed quick release
The brake disc becomes very hot during
operation. Parts of the quick release may become
damaged as a result. The quick release comes
loose. This will cause a crash with injuries.
The front wheel quick release lever and the
brake disc must be situated on opposite sides.
Crash caused by incorrectly set clamping
force
Excessively high clamping force will damage the
quick release and cause it to lose its function.
Insufficient clamping force will cause a
detrimental transmission of force. The
suspension fork or the frame may break. This will
cause a crash with injuries.
Never fasten a quick release using a tool (e.g.
hammer or pliers).
Only use the clamping lever with the specified
set clamping force.
CAUTION
!
MY21K03 - 12_1.0_22.09.2020 69
Maintenance
8.2.1 Checking the quick release
Check the position and clamping force of the
quick release lever. The quick release lever
must be flush with the lower housing. You must
be able to see a slight impression on the palm
of your hand when you close the quick release
lever.
Figure 33: Adjusting the quick release clamping force
Use a 4 mm hexagon socket spanner to adjust
the clamping lever clamping force if required.
Check the quick release lever position and
clamping force.
Figure 34: Adjusting the quick release clamping force
8.3 Maintaining the stem
Incorrectly fastened screws may come loose due
to impact. The stem may no longer be firmly fixed
in its position as a result. This will cause a crash
with injuries.
Check the handlebars and the stem's quick
release system are firmly in position after the
first two hours of riding.
8.4 Adjusting the gear shift
If you cannot select the gears effortlessly, you will
need to adjust the setting for the shift cable
tension.
Carefully pull the adjusting sleeve away from
the shifter housing, turning it as you do so.
Check the gear shift function after each
adjustment.
MY21K03 - 12_1.0_22.09.2020 70
Maintenance
8.4.1 Cable-operated gear shift, single-
cable
Only applies to pedelecs with this equipment
For a smooth gear shift, adjust the adjusting
sleeves on the shifter housing.
Figure 35: Adjusting sleeve (1) for the single-cable, cable-
operated gear shift with shifter housing (2), example
8.4.2 Cable-operated gear shift, dual-
cable
Only applies to pedelecs with this equipment
For a smooth gear shift, set the adjusting
sleeves underneath the chain stay on the
frame.
The shift cable has around 1 mm play when it
is pulled out gently.
Figure 36: Adjusting sleeves (2) on two alternative
versions (A and B) of a dual-cable, cable-operated gear
shift on the chain stay (1)
8.4.3 Cable-operated twist grip, dual-
cable
Only applies to pedelecs with this equipment
For a smooth gear shift, set the adjusting
sleeves on the shifter housing.
There is noticeable play of around 2–5 mm
(1/2 gear) when twisting the twist grip.
Figure 37: Twist grip with adjusting sleeves (1) and play of
the gear shift (2)
2
2
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Troubleshooting, fault clearance and repair
9 Troubleshooting, fault clearance
and repair
9.1 Troubleshooting and fault
clearance
The components of the drive system are checked
constantly and automatically. If an error is
detected, an error message appears on the
display. The drive may be shut off automatically,
depending on the type of error.
9.1.1 The drive system or display do not
start up
If the display and/or the drive system do not start up,
proceed as follows:
1Check whether the battery is switched on. If
not, start the battery.
Contact specialist dealer if the battery level
indicator LEDs do not light up.
2If the LEDs on the battery level indicator light
up, but the drive system does not start up,
remove the battery.
3Insert the battery.
4Start the drive system.
5If the drive system does not start up, remove
the battery.
6Clean all the contacts with a soft cloth.
7Insert the battery.
8Start the drive system.
9If the drive system does not start up, remove
the battery.
10 Fully charge the battery.
11 Insert the battery.
12 Start the drive system.
13 Contact your specialist dealer if the drive
system does not start up.
9.1.2 Error message
If an error message is displayed, run through the
following actions:
1Make a note of the system message. There is
a table containing all system messages in
Section 6.3.
2Shut off and re-start the drive system.
3If the system message is still displayed,
remove the battery and then re-insert.
4Re-start the drive system.
5If the system message is still displayed,
contact your specialist dealer.
MY21K03 - 12_1.0_22.09.2020 72
Troubleshooting, fault clearance and repair
9.1.3 Errors in the assistance system
Symptom Cause Remedy
Assistance is not
available.
Is the speed too high? 1 Check on-screen indicators. Electronic gear assistance is only
active up to a maximum speed of 25 km/h.
Is the battery charged sufficiently? 2 Check battery is charged.
3 Recharge the battery if it is almost flat.
The battery may become too hot when
you ride at high temperatures, up long
inclines or with a heavy load for a long
time.
4 Switch off the drive system.
5 Wait a moment and then check again.
The rechargeable battery, the on-board
computer or the assistance switch may
be connected incorrectly, or one or
more of them may have a problem.
6 Contact your specialist dealer.
Assistance is not
available.
Are the pedals being pushed? 1 The pedelec is not a motorbike. Push the pedals.
Is the system switched on? 2 Press the battery on-off button to switch it on.
Is the assistance mode set to [OFF]?
3 Set the assistance mode to a different level of assistance than
[OFF].
4 Contact your specialist dealer if you still feel that the no
assistance is being supplied.
The assisted journey
distance is too short.
The battery does not perform as well in
winter weather. This does not indicate a problem.
The journey distance can be shorter
depending on the road conditions, the
gear level and the entire light usage
time.
1 Check battery is charged.
2 Recharge the battery if it is almost flat.
Is the battery fully charged?
3 If the distance covered with a fully charged battery has
become shorter, the battery may be affected. Replace the
battery with a new one.
The battery is a consumable. Repeated
charging and long periods of use cause
the battery to degrade (loss of power).
4 If the distance you can cover with one single charge is very
short, replace the battery with a new one.
It is difficult to pedal.
Are the tyres pumped to an adequate
pressure? 1 Pump up tyres.
Is the assistance mode set to [OFF]? 2 Set level of assistance to [BOOST].
The battery charge might be low. 3 Check battery is charged.
4 Recharge the battery if it is almost flat.
Have you switched on the system with
your foot on the pedal?
5 Switch on the system again without applying pressure to the
pedals.
6 Contact your specialist dealer if assistance is still not being
provided.
Table 30: Error solution for assistance system
MY21K03 - 12_1.0_22.09.2020 73
Troubleshooting, fault clearance and repair
9.1.4 Battery error
Symptom Cause Remedy
The battery discharges
quickly. The battery may be at the end of its
useful life.
Replace old battery with new one.
The battery cannot be
recharged.
Is the charger mains plug firmly
connected to the socket?
1 Disconnect the charger mains plug.
2 Insert the mains plug.
3 Start charging.
Is the charger plug firmly connected to
battery?
4 If the battery still won't recharge, disconnect the charger plug.
5 Insert charger plug.
6 Start charging.
Is the adapter firmly connected to the
charger plug or the battery's charging
port?
7 If you are still unable to recharge the battery, connect the
adapter with the charger plug or the battery’s charger
connection.
8 Start charging.
Is the connection terminal for the
charger, charger adapter or battery
dirty?
9 If you are still unable to recharge the battery, wipe the
connection terminals with a dry cloth to clean them.
10 Start charging.
11 If the battery still won't recharge, contact your specialist
dealer.
The battery does not start
charging when the
charger is connected.
The battery may be at the end of its
useful life.
Replace old battery with new one.
The battery and charger
become hot.
The temperature of the battery or the
charger may have exceeded the
operating temperature range.
1 Interrupt charging process.
2 Wait a moment.
3 Start charging.
4 If the battery is too hot to touch, there might be a problem with
the battery. Contact your specialist dealer.
The charger is hot. If the charger is used continuously to
charge batteries, it may become hot.
1 Wait a moment.
2 Start charging.
The LED on the charger
does not light up.
The LED on the charger will go out
when the battery is fully charged. This is not a malfunction.
Is the charger plug firmly connected to
battery?
1 Check the connection for any contaminants.
2 Insert charger plug.
3 Contact your specialist dealer if there is no change.
Is the battery fully charged?
4 Disconnect the charger mains plug if there is no change.
5 Insert the mains plug.
6 Start charging.
7 Contact your specialist dealer if the LED on the charger still
doesn’t light up.
The battery cannot be
removed.
Contact your specialist dealer.
The battery cannot
be inserted.
Contact your specialist dealer.
Fluid is leaking from the
battery.
Observe all the warnings in Section 2 Safety.
Table 31: Error solution for battery
MY21K03 - 12_1.0_22.09.2020 74
Troubleshooting, fault clearance and repair
9.1.5 On-board computer error
9.1.6 Lighting does not work
9.1.7 Other errors
There is an unusual smell.
1 Remove the battery from the pedelec immediately.
2 Contact the fire service.
3 Observe all the warnings in Section 2 Safety.
Fumes are emitted from
the battery. 1 Remove the battery from the pedelec immediately.
2 Contact the fire service.
3 Observe all the warnings in Section 2 Safety.
Symptom Cause Remedy
Table 31: Error solution for battery
Symptom Cause Remedy
No data are shown on the
monitor if you press the
on-off button (battery).
The battery charge level may be
insufficient. 1 Charge the battery.
Is the power switched on? 2 Press the on-off button (battery) to switch the power on.
Is the battery charged? 3 If the battery is fitted to the pedelec and is being charged, it
cannot be switched on. Interrupt charging process.
Is the connector fitted to the power
cable correctly?
4 Check that the power cable connector has not been
disconnected.
5 Contact your specialist dealer if this is not the case.
A component may be connected which
the system is unable to recognise. 6 Contact your specialist dealer.
The gear level is not
shown on the display
screen.
The gear level is only shown if the
electronic gear shift is used.
1 Check whether the power cable plug has been disconnected.
2 Contact your specialist dealer if this is not the case.
The settings menu cannot
be opened while you are
riding.
The product is designed in such a way
that the settings menu cannot be
opened if the system detects that
someone is riding the pedelec. This is
not a malfunction.
1 Stop the pedelec.
2 Change settings when stationary only.
The time display is
flashing "0:00". The battery in the on-board computer
has come to the end of its service life.
Replace the on-board computer battery.
Table 32: Display error solution
Symptom Cause Remedy
The front light or rear light
does not go on, even
when the switch is
pressed.
The basic settings in the electric drive
system have probably been configured
incorrectly. The light is defective.
1 Take pedelec out of service immediately.
2 Contact your specialist dealer.
Table 33: Error solution for battery
Symptom Cause Remedy
Two beeps will sound if a switch is
pressed but the switch cannot be
operated.
Pressed switch mode has been
deactivated.
This is not a malfunction.
Table 34: Error solution for battery
MY21K03 - 12_1.0_22.09.2020 75
Troubleshooting, fault clearance and repair
9.2 Repair
Special knowledge and tools are required for
many repairs. That is why only a specialist dealer
may perform repairs such as:
Replacing tyres and rims
Replacing rims and brake linings or brake discs
Replacing and tensioning the chain
9.2.1 Original parts and lubricants
The individual pedelec parts have been carefully
selected and matched to one other.
Only original parts and lubricants must be used
for maintenance and repair.
The constantly updated accessory approval
and parts lists are in Section 11, Documents
and Drawings.
Follow the operating instructions for the new
components.
9.2.2 Replacing the lighting
Only use components of the respective power
class for replacement.
9.2.3 Adjusting the headlight
The headlight must be set, so that its light beam
shines on the road 10 m in front of the pedelec.
Three beeps are sounded. A fault or warning has occurred. This
occurs when an error message is
displayed.
Follow the instructions for the code indicated on
the display screen in Section 6.2 System
Messages.
When you use an electronic gear shift,
you can feel that pedal assistance
becomes weaker when the gear is
changed.
This is because the on-board computer
sets the pedal assistance to the
optimum level.
This is not a malfunction.
A noise can be heard after switching. Contact your specialist dealer.
It is normal to hear a noise coming from
the rear wheel when cycling as normal. The gear shift setting may not have
been made properly.
Contact your specialist dealer.
If the pedelec stops, gear transmission
does not switch to the position pre-
configured in the functional feature.
You may have applied too much
pressure on the pedals.
It is easier to change gears if you press onto the
pedals gently.
Symptom Cause Remedy
Table 34: Error solution for battery
MY21P01 - 42_1.0_21.09.2020 76
Recycling and disposal
10 Recycling and disposal
This device is marked according to the
European Directive 2012/19/EU on
waste electrical and electronic
equipment – WEEE and the European
Directive 2006/66/EC on accumulators.
The directive provides the framework for
the return and recycling of used devices
across the EU. As a consumer, you are legally
required to return all used batteries of any type. It
is forbidden to dispose of batteries in domestic
waste. The manufacturer is obliged to take back
used and old batteries free of charge as per
Section 9 German Batteries Act. You thus meet
statutory obligations and help to protect the
environment. The pedelec, battery, motor, display
screen and charger are recyclable materials. You
must dispose of and recycle them separately from
the domestic waste in compliance with applicable
statutory regulations. Separate collection and
recycling saves reserves of raw materials and
ensures that all the regulations for protection of
health and the environment are adhered to when
recycling the product and/or the battery.
Never dismantle the pedelec, batteries or
charger for disposal.
The pedelec, display screen, the unopened
and undamaged battery and the charger can
be returned to any specialist dealer free of
charge. Depending on the region, further
disposal options may be available.
Store the individual parts of the
decommissioned pedelec in a dry place, free
from frost, where they are protected from direct
sunlight.
MY21K03 - 12_1.0_21.09.2020 77
Documents
11 Documents
11.1 Parts list
11.1.1 Familiano C-10
KB148-ZAKC46, KB148-ZBKC46
Model name Familiano C-10
Fork RIGID aluminium
Headset FSA NO.55
Handlebars Humpert Ergotec
Handles Velo VLG-1879
Stem Kalloy Alu, adjustable
Saddle Selle Royal
Seat post Patent seat post, rigid
Saddle clamp Quick release
Crank set FSA CK220
Pedals VP658
Rear derailleur Shimano Deore RD-M6000
Shifter Shimano SL-T6000 shifter
Cassette/cassette sprocket Shimano CS-HG500-10 11-42Z cassette
Chain KMC chain
Front brake Shimano BR-MT420/4 piston
Front brake lever Shimano MT402
Disc, front Shimano SR-MT30/180mm
Rear brake Shimano BR-MT420/4 piston
Rear brake lever Shimano MT402
Disc, rear Shimano RT-EM300/180mm
Front rim RYDE Andra 40 double wall
Rim, rear RYDE Andra 40 double wall
Hub, front Formula CL-51QR hub
Hub, rear Formula ECT-148S hub
Spokes Spoke 2.0 Mach1
Tyres Schwalbe Super Moto-X
Hose Schwalbe DV7
Front lamp Fuxon F130K, 30 Lux
Rear lamp Fuxon RL Mini rear light
Pannier rack IRack 2 system pannier rack
Guards SKS CAB
Chain guard Hebie
Lock AXA Victory
Stand URSUS Jumbo
Motor BOSCH Cargo Line, BDU450 CX
Rechargeable battery BOSCH PowerTube 500, BBP280 horizontal and BBP281 vertical
Display BOSCH Purion
Charger BOSCH Compact Charger BCS230, 2 A
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Documents
11.1.2 Familiano C-N
KB149-ZAFC46, KB149-ZBFC46
Model name Familiano C-N
Fork RIGID aluminium
Headset FSA NO.55
Handlebars Humpert Ergotec
Handles Velo VLG-1879
Stem Kalloy Alu, adjustable
Saddle Selle Royal
Seat post Patent seat post, rigid
Saddle clamp Quick release
Crank set FSA CK220
Pedals VP658
Shifter ENVIOLO SP Manual Controller shifter
Chain KMC chain
Front brake Magura MT5/4 piston
Front brake lever Magura MT5
Disc, front Magura Storm HC/180mm
Rear brake Magura MT4/2 piston
Rear brake lever Magura MT4
Disc, rear Magura Storm HC/180mm
Front rim RYDE Andra 40 double wall
Rim, rear RYDE Andra 40 double wall
Hub, front Formula DC-91QR hub
Hub, rear ENVIOLO SP
Spokes Spoke 2.0 Mach1
Tyres Schwalbe Super Moto-X
Hose Schwalbe DV7
Front lamp Comus F15 Pro
Rear lamp Fuxon RL Mini rear light
Pannier rack IRack 2 system pannier rack
Guards SKS CAB
Chain guard Hebie
Lock AXA Victory
Stand URSUS Jumbo
Motor BOSCH Cargo Line, BDU450 CX
Rechargeable battery BOSCH PowerTube 500, BBP280 horizontal and BBP281 vertical
Display BOSCH Purion
Charger BOSCH Compact Charger BCS230, 2 A
MY21K03 - 12_1.0_21.09.2020 79
Documents
11.1.3 Familiano L-N
KB150-ZAFC46, KB150-ZBFC46
Model name Familiano L-N
Fork RIGID aluminium
Headset FSA NO.55
Handlebars Humpert Ergotec
Handles Velo VLG-1879
Stem Kalloy Alu, adjustable
Saddle Selle Royal
Seat post Patent seat post, rigid
Saddle clamp Quick release
Crank set FSA CK220
Pedals VP658
Gear shift type Hub gear
Shifter ENVIOLO SP Manual Controller shifter
Chain KMC chain
Front brake Magura MT5/4 piston
Front brake lever Magura MT5
Disc, front Magura Storm HC/180mm
Rear brake Magura MT4/2 piston
Rear brake lever Magura MT4
Disc, rear Magura Storm HC/180mm
Front rim RYDE Andra 40 double wall
Rim, rear RYDE Andra 40 double wall
Hub, front Formula DC-91QR hub
Hub, rear ENVIOLO SP
Spokes Spoke 2.0 Mach1
Tyres Schwalbe Super Moto-X
Hose Schwalbe DV7
Front lamp Fuxon F170/70 lux
Rear lamp Fuxon RL Mini rear light
Pannier rack IRack 2 system pannier rack
Guards SKS CAB
Chain guard Hebie
Lock AXA Victory
Stand URSUS Jumbo
Motor BOSCH Cargo Line, BDU450 CX
Rechargeable battery BOSCH PowerTube 500, BBP280 horizontal and BBP281 vertical
Display BOSCH Purion
Charger BOSCH Compact Charger BCS230, 2 A
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Documents
11.2 Assembly report
Date: Frame number:
Components Description Criteria Measures if rejected
Assembly/inspection Tests Accept-
ance Rejection
Front wheel Assembly O.K. Loose Adjust quick release
Kickstand Check mount fastening Functional check O.K. Loose Retighten screws
Tyres Tyre pressure check O.K. Tyre pressure too low/
too high Adjust tyre pressure
Frame Check for damage –
fracture, scratches O.K. Damage detected Take out of operation, new frame
Handles, coverings Check mount fastening O.K. Not provided Retighten screws, new handles or
coverings as specified in parts list
Handlebars, stem Check mount fastening O.K. Loose Retighten screws; new stem as
specified in parts list if necessary
Steering headset Check for damage Functional check O.K. Loose Retighten screws
Saddle Check mount fastening O.K. Loose Retighten screws
Seat post Check mount fastening O.K. Loose Retighten screws
Protective plate Check mount fastening O.K. Loose Retighten screws
Pannier rack Check mount fastening O.K. Loose Retighten screws
Attachments Check mount fastening O.K. Loose Retighten screws
Bell Functional check O.K. No ring, too quiet, missing New bell as specified in the parts
list
Suspension elements
Fork, suspension
fork Check for damage O.K. Damage detected New fork as specified in the parts
list
Rear frame damper Check for damage O.K. Damage detected New fork as specified in the parts
list
Suspension seat post Check for damage O.K. Damage detected New fork as specified in the parts
list
Brake system
Brake lever Check mount fastening O.K. Loose Retighten screws
Brake fluid Check fluid level O.K. Too little Refill with brake fluid; new brake
hoses if damaged
Brake linings
Check brake linings,
brake discs or rims for
damage O.K. Damage detected New brake linings, brake discs or
rims
Back-pedal brake
braking armature Check mount fastening O.K. Loose Retighten screws
Light system
Rechargeable battery First examination O.K. Error message Take out of service; contact
battery manufacturer, new battery
Light cabling Connections, correct
wiring O.K. Cable defective, no light New cabling
Rear light Side light Functional check O.K. No constant light Take out of service; new rear
light as specified in parts list;
replace if necessary
Front light Side light, daytime riding
light Functional check O.K. No constant light Take out of service; new front
light as specified in parts list;
replace if necessary
Reflectors All complete, state,
fastening O.K. Damaged or not all
complete New reflectors
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Documents
Technical inspection, checking safety, test ride
Drive/gear shift
Chain/cassette/
pinion/chainring Check for damage O.K. Damage Refasten if necessary or replace
as specified in parts list
Chain guard/spoke
guard Check for damage O.K. Damage Replace as specified in parts list
Bottom bracket axle/
crank Check mount fastening O.K. Loose Retighten screws
Pedals Check mount fastening O.K. Loose Retighten screws
Shifter Check mount fastening Functional check O.K. Loose Retighten screws
Shift cables Check for damage Functional check O.K. Loose or defective Adjust shift cables; new shift
cables if necessary
Front derailleur Check for damage Functional check O.K. Gear shift difficult or not
possible Adjust
Rear derailleur Check for damage Functional check O.K. Gear shift difficult or not
possible Adjust
Electric drive
Display Check for damage Functional check O.K. No screen, defective
screen display
Restart, test battery, new
software, or new display – take
out of service,
Electric drive control
panel DriveCheck for damage Functional check O.K. No response Restart; contact control panel
manufacturer, new control panel
Tachometer Speed measurement O.K. Pedelec travelling 10% too
fast/slow Take pedelec out of service until
the source of the error is found
Cabling Visual inspection O.K. Failure in system, damage,
kinked cables New cabling
Battery mount Firmly in position, lock,
contacts Functional check O.K. Loose; lock doesn't close,
no contacts New battery mount
Motor Visual inspection and
mount O.K. Damage, loose Refasten motor, contact motor
manufacturer, new motor
Software Check version In latest
version Not latest version Import update
Components Description Criteria Measures if rejected
Components Description Criteria Measures if rejected
Assembly/inspection Tests Accept-
ance
Rejection
Brake system Functional check O.K. No full braking; braking
distance too long Locate defective part in brake
system and correct
Gear shift under
operating load
Functional check O.K. Problems when shifting
gear Readjust gear shift
Suspension
components (fork,
shock absorber, seat
post)
Functional check O.K. Suspension too deep or no
longer exists Locate defective component and
correct
Electric drive
Functional check O.K. Loose connection,
problems when riding,
accelerate
Locate defective part in electric
drive and correct
Light system Functional check O.K. No continuous light, too
bright Locate defective part in light
system and correct
Test ride No strange
noises Strange noises Locate source of noise and
correct
Date:
Fitter's name:
Final inspection by workshop manager
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Documents
11.3 Maintenance instructions
Diagnosis and documentation of current status
Date: Frame number:
Components Frequency Description Criteria Measures if rejected
Inspection Tests Maintenance Accept-
ance
Rejection
Front wheel 6 months Assembly O.K. Loose Adjust quick release
Kickstand 6 months Check mount fastening Functional check O.K. Loose Retighten screws
Tyres 6 months Tyre pressure check O.K. Tyre pressure
too low/too high Adjust tyre pressure
Frame 6 months Check for damage –
fracture, scratches O.K. Damage
detected Take pedelec out of service,
new frame
Handles,
coverings 6 months Wear; check if
fastened securely O.K. Not provided Retighten screws, new
handles or coverings as
specified in parts list
Handlebars,
stem 6 months Check mount fastening O.K. Loose Retighten screws; new stem
as specified in parts list if
necessary
Steering
headset 6 months Check for damage Functional check Lubricating and
adjustment O.K. Loose Retighten screws
Saddle 6 months Check mount fastening O.K. Loose Retighten screws
Seat post 6 months Check mount fastening O.K. Loose Retighten screws
Protective plate 6 months Check mount fastening O.K. Loose Retighten screws
Pannier rack 6 months Check mount fastening O.K. Loose Retighten screws
Attachments 6 months Check mount fastening O.K. Loose Retighten screws
Bell 6 months Functional check O.K. No ring, too
quiet, missing New bell as specified in the
parts list
Suspension elements
Fork,
suspension fork
To manu-
facturer's
specifica-
tions*
Check for damage –
corrosion, fracture
Maintenance as
specified by
manufacturer
Lubrication, oil change
as specified by
manufacturer
O.K. Damage
detected New fork as specified in the
parts list
Rear frame
damper
To manu-
facturer's
specifica-
tions*
Check for damage –
corrosion, fracture
Maintenance as
specified by
manufacturer
Lubrication, oil change
as specified by
manufacturer
O.K. Damage
detected New fork as specified in the
parts list
Suspension
seat post
To manu-
facturer's
specifica-
tions*
Check for damage Maintenance as
specified by
manufacturer O.K. Damage
detected New fork as specified in the
parts list
Brake system
Brake lever 6 months Check mount fastening O.K. Loose Retighten screws
Brake fluid 6 months Check fluid level Depending on time of
year O.K. Too little Top up brake fluid; take
Pedelec out of service if
damaged; new brake hoses
Brake linings 6 months Check brake linings,
brake discs or rims for
damage O.K. Damage
detected New brake linings, brake
discs or rims
Back-pedal
brake braking
armature
6 months Check mount fastening O.K. Loose Retighten screws
Brake system 6 months Check mount fastening Functional check O.K. Loose Retighten screws
* see Section 8.1
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Inspection Tests Maintenance Accept-
ance
Rejection
Light system
Rechargeable
battery 6 months First examination O.K. Error message Contact battery
manufacturer; take out of
service, new battery
Light cabling 6 months Connections, correct
wiring O.K. Cable defective,
no light New cabling
Rear light 6 months Side light Functional check O.K. No constant light New rear light as specified in
parts list; replace if
necessary
Front light 6 months Side light, daytime
riding light Functional check O.K. No constant light New front light as specified
in parts list; replace if
necessary
Reflectors 6 months All complete, state,
fastening O.K. Damaged or not
all complete New reflectors
Drive/gear shift
Chain/cassette/
pinion/
chainring
6 months Check for damage O.K. Damage Refasten if necessary or
replace as specified in parts
list
Chain guard/
spoke guard 6 months Check for damage O.K. Damage Replace as specified in parts
list
Bottom bracket
axle/crank 6 months Check mount fastening O.K. Loose Retighten screws
Pedals 6 months Check mount fastening O.K. Loose Retighten screws
Shifter 6 months Check mount fastening Functional check O.K. Loose Retighten screws
Shift cables 6 months Check for damage Functional check O.K. Loose or
defective Adjust shift cables; new shift
cables if necessary
Front derailleur 6 months Check for damage Functional check O.K. Gear shift difficult
or not possible Adjust
Rear derailleur 6 months Check for damage Functional check O.K. Gear shift difficult
or not possible Adjust
Electric drive
Display 6 months Check for damage Functional check O.K. No screen,
defective screen
display
Restart, test battery, new
software, or new display –
take out of service,
Electric drive
control panel 6 months DriveCheck for
damage Functional check O.K. No response Restart; contact control
panel manufacturer, new
control panel
Tachometer 6 months Speed measurement O.K. Pedelec
travelling 10%
too fast/slow
Take pedelec out of service
until the source of the error is
found
Cabling 6 months Visual inspection O.K. Failure in
system, damage,
kinked cables
New cabling
Battery mount 6 months Firmly in position, lock,
contacts Functional check O.K. Loose; lock
doesn't close, no
contacts
New battery mount
Motor 6 months Visual inspection and
mount O.K. Damage, loose Refasten motor, contact
motor manufacturer, new
motor; take out of service
Software 6 months Check version In latest
version Not latest version Import update
Components Frequency Description Criteria Measures if rejected
MY21K03 - 12_1.0_21.09.2020 84
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Technical inspection, checking safety, test ride
Components Description Criteria Measures if rejected
Assembly/inspection Tests Accept-
ance
Rejection
Brake system 6 months Functional check O.K. No full braking; braking
distance too long Locate defective part in brake
system and correct
Gear shift under
operating load 6 months Functional check O.K. Problems when shifting
gear Readjust gear shift
Suspension
components (fork,
shock absorber, seat
post)
6 months Functional check O.K. Suspension too deep or no
longer exists Locate defective component and
correct
Electric drive 6 months Functional check O.K. Loose connection,
problems when riding,
accelerate
Locate defective part in electric
drive and correct
Light system 6 months Functional check O.K. No continuous light, too
bright Locate defective part in light
system and correct
Test ride 6 months Functional check No strange
noises Strange noises Locate source of noise and
correct
Date:
Fitter's name:
Final inspection by workshop
manager
Notes
MY21K03 - 12_1.0_21.09.2020 85
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Notes
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11.4 Charger operating instructions
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MY21K03 - 12_1.0_21.09.2020 87
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D
eBike Battery Charger 36-6/230
0 275 007 918
Li-Ion
Use ONLY with BOSCH Li-Ion batteries
Input: 230V 50Hz 2.15A
Output: 36V 6A
Made in Vietnam
Fast Charger BCS250
eBike Battery Charger 36-4/230
0 275 007 907
Li-Ion
Use ONLY with BOSCH Li-Ion batteries
Input: 230V 50Hz 1.5A
Output: 36V 4A
Made in PRC
Robert Bosch GmbH
72757 Reutlingen
Germany
Standard Charger BCS220
Robert Bosch GmbH
72757 Reutlingen
Germany
Standard Charger
Fast Charger
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MY21K03 - 12_1.0_21.09.2020 88
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MY21K03 - 12_1.0_21.09.2020 92
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0"C !"!"0"!C
-$!!M!MGG*
!
[GG%&NGGG
*%,&G
"$$"C%$0"G-&
C,GGNNBG$NGG
*%&-$!!M!MGGL
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 !!CC" !"" 0"
"$$#NGM$G
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NG
"$$ "
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
#N*GNGG!MG
G!$!
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GG!$!G
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OGGL!!MGL
NG!
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%*&G!GGL!L

GPKHGG!%*&NG!G
GKG!!PKHL
EBEDF AGA*C
MY21K03 - 12_1.0_21.09.2020 93
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KGI'
Q]iNGGGNGPKH
!GQ]iG
GA*NG!MGPKHL
!!GL!,G!NNG
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!!NG!GNNL
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HGGNG!GN
GG
OGG!!NGGMGL
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MY21K03 - 12_1.0_21.09.2020 94
Glossary
12 Glossary
Brake lever
Source: EN 15194:2017: lever used to apply the
brake.
Braking distance
Source: EN 15194:2017: distance travelled by a
pedelec between the commencement of braking
and the point at which the pedelec comes to rest.
Cargo bike
Source: DIN 79010: bicycle mainly designed to
carry goods.
CE marking
Source: Directive 2006/42/EC on Machinery: the
manufacturer uses the CE marking to declare that
the Pedelec complies with the applicable
requirements.
City and trekking bicycles
Source: EN-ISO 4210 - 2: pedelec designed for
use on public roads primarily for means of
transportation or leisure.
Consumables
Source: EN 82079-1: any part or material that is
necessary for continued use or maintenance of
the product.
Decommissioning
Source: DIN 31051: intentional, unlimited
interruption in an object's functional capability.
Disc brake
Source: EN 15194:2017: brake in which brake
pads are used to grip the lateral faces of a thin
disc attached to or incorporated in the wheel hub.
Drive belt
Source: EN 15194:2017: seamless ring belt which
is used as a means of transmitting motive force.
Electrical control system
Source: EN 15194:2017: electronic and/or
electrical component, or an assembly of
components provided for installation into a
vehicle, together with all electrical connections
and associated wiring for the motor electrical
power assistance.
Electrically power assisted cycle, pedelec
Source: EN 15194:2017: electrically power
assisted cycle, equipped with pedals and an
auxiliary electric motor, which cannot be propelled
exclusively by means of the auxiliary electric
motor, except in start-up assistance mode.
Fault
Source: EN 13306:2018-02, 6.1: state of an item
(4.2.1) characterized by inability to perform a
required function (4.5.1), excluding the inability
during preventive maintenance or other planned
actions, or due to lack of external resources.
Folding bicycle
Source: EN-ISO 4210-2: bicycle designed to fold
into a compact form, facilitating transport and
storage.
Fork steerer
Source: EN 15194:2017: part of a fork that rotates
about the steering axis of a bicycle frame head
tube. It is normally connected to the fork crown or
directly to the fork legs, and is normally the point
of connection between the fork and the handlebar
stem.
Fracture
Source: EN 15194:2017: unintentional separation
into two or more parts.
Instruction handbook
Source: ISO/FDIS 20607:2018: part of the user
information that machine manufacturers provide
to machine operators; it contains guidance,
instructions and tips related to the use of the
machine in all its life cycle phases.
Maintenance
Source: DIN 31051: maintenance is generally
performed at regular intervals and often carried
out by trained technical staff. This ensures a
maximum service life and low wear and tear for
the maintained items. Proper maintenance is
often also a pre-requisite for providing a warranty.
Maximum continuous power
Source: ZEG: the maximum continuous power is
the maximum power for the electric motor output
shaft during 30 minutes.
MY21K03 - 12_1.0_21.09.2020 95
Glossary
Maximum saddle height
Source: EN 15194:2017: vertical distance from
the ground to the point where the top of the seat
surface is intersected by the seat-post axis,
measured with the saddle in a horizontal position
and with the seat-post set to the minimum
insertion-depth mark.
Maximum tyre pressure
Source: EN 15194:2017: maximum tyre pressure
recommended by the tyre or rim manufacturer for
a safe and efficient performance. If the rim and
tyre both indicate a maximum tyre pressure, the
maximum inflation pressure is the lower of the two
pressures indicated.
Minimum insertion depth mark
Source: EN 15194:2017: mark indicating the
minimum insertion-depth of handlebar stem into
fork steerer (fork stem) or seat post into frame.
Model year
Source: ZEG: the model year refers to the first
production year that the series-manufactured
pedelec was manufactured in the version in
question and is not always identical with the year
of manufacture. The year of manufacture may be
before the model year in some cases. If no
technical modifications are introduced to the
series, production may continue of pedelecs from
a previous model year.
Mountain bike
Source: EN-ISO 4210-2: bicycle designed for use
off-road on rough terrain, on public roads, and on
public pathways, equipped with a suitably
strengthened frame and other components, and,
typically, with wide-section tyres with coarse tread
patterns and a wide range of transmission gears.
Off-road rough terrain
Source: EN 15194:2017: coarse pebble tracks,
forest trails, and other general off-road tracks
where tree roots and rocks are likely to be
encountered.
Permitted total weight
Source: EN 15194:2017: weight of the fully
assembled pedelec plus the rider and baggage,
as specified by the manufacturer.
Quick-release device, quick release
Source: EN 15194:2017: lever actuated
mechanism that connects, retains or secures a
wheel or any other component.
Racing bicycle
Source: EN-ISO 4210-2: bicycle intended for high-
speed amateur use on public roads having a
steering assembly with multiple grip positions
allowing for an aerodynamic posture, a multi-
speed transmission system, tyre width not greater
than 28 mm and a maximum mass of 12 kg for the
fully assembled bicycle.
Seat post
Source: EN 15194:2017: component that clamps
the saddle (with a bolt or assembly) and connects
it with the frame.
Shut-off speed
Source: EN 15194:2017: speed reached, by the
pedelec, at the moment the current has dropped
to zero or to the no load current value.
Spare part
Source: EN 13306:2018-02, 3.5: item intended to
replace a corresponding item in order to retain or
maintain the original required function of the item.
Suspension fork
Source: EN 15194:2017: front fork incorporating
controlled, axial flexibility to reduce the
transmission of road-shocks to the rider.
Suspension frame
Source: EN 15194:2017: frame incorporating
controlled, vertical flexibility to reduce the
transmission of road-shocks to the rider.
Type number
Source: ZEG: all pedelec models have an eight-
digit type number which is used to specify the
design model year, the type of pedelec and the
version.
Wear
Source: DIN 31051: reduction in useful life (4.3.4),
caused by chemical and/or physical processes.
MY21K03 - 12_1.0_21.09.2020 96
Glossary
Weight of ready-to-ride bicycle
Source: ZEG: the indicated weight for a ready-to-
ride bicycle refers to the weight of a pedelec at the
time of sale. The weight of each additional
accessory must be added to this weight.
Wheel
Source: EN 15194:2017: assembly or
combination of hub, spokes or disc, and rim, but
excluding tyre assembly.
Work environment
Source: EN ISO 9000:2015: set of conditions
under which work is performed.
Year of manufacture
Source: ZEG: the year of manufacture is the year
in which the Pedelec was manufactured. The
production period is always from August to July of
the following year.
Young adult bicycle
Source: EN-ISO 4210-2: bicycle designed for use
on public roads by a young adult whose weight is
less than 40 kg, with maximum saddle height of
635 mm or more and less than 750 mm. (see
ISO 4210).
12.1 Abbreviations
ABS anti-blocking system
ECP electronic cell protection
12.2 Simplified terms
The following terms are used for better legibility:
Term Meaning
Operating
instructions
Original operating
instructions
Motor Drive motor, sub-system
Table 35: Simplified terms
13 Appendix
I. Translation of the original EC/EU Declaration of Conformity
The machine, pedelec types:
KB148-ZAKC46 Familiano C-10 Cargo bike
KB148-ZBKC46 Familiano C-10 Cargo bike
KB149-ZAFC46 Familiano C-N Cargo bike
KB149-ZBFC46 Familiano C-N Cargo bike
KB150-ZAFC46 Familiano L-N Cargo bike
KB150-ZBFC46 Familiano L-N Cargo bike
Year of manufacture 2020 and year of manufacture 2021, complies with the following applicable EU
provisions:
Machinery Directive 2006/42/EC
Directive 2011/65/EU RoHS
Electromagnetic Compatibility Directive 2014/30/EU.
The safety objectives in the Low Voltage Directive 2014/35/EU have been met in compliance with Appendix
I, No. 1.5.1 of the Machinery Directive 2006/42/EC.
The following harmonised standards have been applied:
ISO 20607:2018 Safety machinery – Instruction handbook – General drafting principles
EN 15194:2017, Cycles – Electrically power assisted cycles – EPAC Bicycles
The following other technical standards have been applied:
EN 11243:2016, Cycles – Luggage carriers for bicycles – Requirements and test methods
Cologne, 26/08/2020
………………………………………………………………………………………………………………
Egbert Hageböck, managing director of the KETTLER Alu-Rad GmbH
* Community member who is authorised to compile the technical documentation
Manufacturer
KETTLER Alu-Rad GmbH
Longericher Str. 2
50739 Köln
Authorised representative for documentation*
Janine Otto
c/o ZEG Zweirad-Einkaufs-Genossenschaft eG
Longericher Strasse 2
50739 Köln, Germany
MY21K03 - 12_1.0_21.09.2020 98
Appendix
II. Declaration of conformity for incomplete machine
MY21K03 - 12_1.0_21.09.2020 99
Appendix
MY21K03 - 12_1.0_21.09.2020 100
Appendix
MY21K03 - 12_1.0_21.09.2020 101
Keyword index
14 Keyword index
A
Alternative equipment, 96
Articulated shaft,
– care 61
B
Basic cleaning 59
Battery housing, 17
Battery key, 17
Battery level indicator (battery), 17
Battery lock, 17
Battery, 17
- checking, 32
- cleaning, 60
- disposing of, 76
- inserting, 47
- remove, 43, 44
- shipping 29
- transporting 29
- waking, 48
Technical data 22, 23
Bell,
position 24
Belt tension, 64
Brake calliper, 15
Brake disc, 15
- check 64
Brake lever,
- adjusting the pressure point, 41
position 24
Brake lining, 15
- check 63
- maintaining, 63
Brake,
- check brake cables 64
- check brake disc 64
- check brake linings 63
- check pressure point 64
- securing during transport 29
Break in operation, 30
- carrying out 30
- preparing 30
Button,
Minus, 50
On-Off (display), 50
Plus, 50
Push assist, 50
C
Cassette,
– care 61
Chain drive, 16
Chain guard,
- checking, 45
Chain tension, 64
Chain wheel, 16
Chain wheels,
– care 61
Chain, 14, 16
– care, 61
- maintaining, 64
Charger,
- disposing of, 76
Charging port cover, 17
Charging port, 17
Child seat, 42
Compression damper,
position 24
D
Dimensions, 28
Direction of travel, 16
Display,
- charging the battery, 50
- cleaning, 60
position 24
Drive system,
- switching off, 49
- switching on, 49
E
Electrical cable,
- check 64
Emergency stop system 12
F
Fork,
– care, 61
Frame battery,
- inserting, 47
- remove, 43, 44
Frame, 14
– care, 61
- cleaning, 59
Front derailleur,
– care, 61
Front wheel brake, 15
- braking, 54
Front wheel, see Wheel
G
Gear shift twist grip,
- checking, 64
Gear shift,
- check 64
- maintaining, 64
- switching, 55, 57
H
Handlebars, 14, 24
- check 32
Headlight, 16
position 24
Hub, 15
I
Initial commissioning, 31
J
Jockey wheel,
– care 61
Journey information, 24
- switching, 51
L
Level of assistance, 24
- selecting, 51
ECO, 24
eMTB 24
OFF, 24
SPORT 24
SPORT, 24
TOUR, 24
TURBO, 24
M
Minimum insertion depth marking, 39
Minus button, 50
Model year, 8
Motor, 16
- cleaning, 60
Technical data 22
Mudguards,
- checking, 45
O
On-Off button (battery), 17
On-Off button,
Display, 50
On-screen indicator, 43
P
Pannier rack, 14
- changing, 46
- checking, 45
- using, 46
Pedal, 16
– care, 61
- cleaning, 58
Pedelec,
- shipping 29
- transporting 29
Plus button, 50
Push assist button, 50
Push assist,
- using, 51
R
Rear frame damper,
- cleaning, 58, 60
Rear light, 16
Rear wheel brake, 15
Riding light, 18
- checking function, 45
Rim, 15
- checking, 62
S
Saddle, 14, 46
- changing the saddle tilt, 38
- changing the seat length, 39
- determining the saddle height, 38,
39
- using, 46
MY21K03 - 12_1.0_21.09.2020 102
Keyword index
Screen display,
Battery level 25
Battery level, position 24
Function 24
Level of assistance 24
Level of assistance, position 24
Lighting, position 24
RANGE, position 24
Service, position 24
Tachometer 25
Tachometer, position 24
TOTAL, position 24
TRIP 24
TRIP, position 24
Unit 24
Unit, position 24
Seat post, 14
Shifter,
- checking, 64
- setting, 69
position 24
Spoke, 15
Stem,
– care, 61
- check 32, 64
- cleaning, 59
Suspension fork,
- cleaning, 58
System message, 25, 35
T
Trailer, 43
Transportation, 28
Transporting, see Transportation
Type number, 8
Tyre rim,
- check 62
Tyres, 15
- check 62
- check tyre pressure 62
- checking, 62
- converting 44
Airless 44
Tubeless 44
U
USB port, 50
- check 64
V
Valve, 15
Dunlop valve, 15
W
Weight,
– shipping weight, 28
– Weight, 28
permitted total weight, 8
Wheel,
- cleaning, 59
- maintaining, 62
Winter break, see Break in operation
79

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