E s c a r o P r o 1 0 , E s c a r o Co m p 5 B e l t , Q u a d r i g a C X 1 0 , Tr a v e l l e r E - G o l d 8 , Tra v e l l e r E - G o l d 7 ( F ) ,

Tr a v e l l e r E - Go l d 7 ( R )

K B 0 64 - ZA F D xx , K B 06 4 - ZA F Tx x, K B 06 4- Z A FW xx , K B 0 64 - ZA RWx x, K B 06 4- Z B FD 5 xx , K B 0 64 - ZB F T xx, K B 06 4- Z B F Wxx , K B 0 64 - ZB RW xx, K B 06 8- Z A F Wxx , K B 0 68 - ZA RW xx,

KB 0 68 - Z BF W xx, K B 06 8 -Z B F Wx x, KB 0 68 - Z B RW xx , K B 06 8 -Z C F Wx x, K B0 6 8-Z C RW xx , K B 0 83 - ZA RWx x, K B 08 4- Z A RW xx , K B 0 84 - ZB RWx x, K B0 8 4- Z C RW xx , K B 0 84 - ZD RW xx,

K B 111 - ZA K D xx , K B 111 - ZA K D xx , K B 111 - ZA K T xx , K B 111 -Z A K Wx x, K B 112 - ZA F D xx , K B 11 2- Z A FT xx , K B 11 2- Z A FW xx , K B 11 2- Z A R D xx, K B 112 - ZA RT xx, K B 112 - ZA RW xx,

K B11 2 -Z B F D xx, K B 112 - Z BF T xx , K B 11 2- Z B FW xx , K B 11 2- Z B RT xx , K B 11 2-Z B RW xx , K B 112 - Z C FD x x, K B11 2 -Z C F T xx, K B 112 - ZC F W xx, K B 112 - ZC R D x x, K B 112 - ZC RT xx,

K B 11 2- Z C RWx x, K B 11 6- Z A K D xx, K B 116 - Z AK T xx , K B 11 6- Z A K Wx x, KB 11 6-Z B K D xx , K B 116 - Z BK T xx , K B 11 6- Z B K Wx x, KB 11 6- Z C K D xx , K B 11 6- Z C K Tx x, KB 11 6 -Z C K W xx,

K B 116 - ZD K D x x, K B11 6 -Z D K T xx, K B 116 - Z D KW xx , K B 11 8- Z A K D xx, K B 118 - ZA K T xx , K B 11 8- Z A KW xx , K B 11 8- Z B K D xx, K B 118 - ZB K T xx , K B 11 8- Z B KW xx , K B 1 33 - ZA F W xx,

K B 1 33 - ZA RWx x, K B 13 3- Z B FW xx , K B 1 33 - ZB RWx x, K B 13 3- Z C F Wx x, K B 1 33 -Z CRW xx, K B 13 3 -Z D F Wx x, K B1 3 3- Z D RW xx , K B 1 37 - ZA K D xx , K B 1 37 - ZA K T xx , K B 1 37 - ZA K W xx,

K B 13 7 - ZB K D xx , K B 1 37 - ZB K T xx, K B 13 7 -Z B K Wx x, K B 13 7- Z C K Tx x, K B1 3 7- Z C K Wx x, KB 1 37 - Z D KT xx , K B 1 37 - ZD K W xx , K B 1 37 - ZE K D xx , K B 1 37 - ZE K T xx , K B 1 37 - ZE K W xx,

K B 1 37 - ZF K D xx , K B 1 37 - ZF K T xx, K B 13 7- Z F KW xx , K B 1 43 - ZA K D x x, KB 1 43 - Z AK T xx , K B 1 43 - ZA K W xx, K B 14 3 -Z B K D xx , K B 14 3 - ZB K T xx, K B 14 3- Z B K Wx x, K B1 4 3- Z C K D xx,

KB 1 43 - Z C KT x x, K B 1 43 - Z C KW xx , K B 1 43 - ZD K D x x, KB 1 43 - Z D KT xx , K B 1 43 - ZD K W xx , K B 1 44 - ZA F Wx x, K B 14 4- Z A RW xx , K B 1 44 - ZB F Wx x, K B 14 4- Z B RW xx , K B 1 44 - ZC F W xx,

MY2 0B01- 22 _1.0 _ 21.06.20 19

Table of Contents

Summary of Contents for Bosch BLACK BIRD KB064-ZAFT Series

Page 1 TRANSLATION OF THE ORIGINAL OPERATING INSTRUCTIONS IMPORTANT! READ CAREFULLY BEFORE USE KEEP SAFE TO CONSULT AT A LATER DATE Q u a d r i g a C o m p 5 B e l t F L , Q u a d r ig a Co m p 5 B e l t RT, Q u a d r i g a P l u s 8 , Q u a d r i g a C i t y h o p p e r, C o m f o r t 5 , Q u a d r i g a C o m p C X 1 2 , Q u a d r i g a P5 F L , Q u a d r i g a P 5 RT, Q u a d r i g a To w n &...
Page 2: Table Of Contents
Nameplate 3.4.12 Intuvia display 1.9.1 Information on the nameplate 3.4.13 USB port Safety 3.4.14 BOSCH Pedelec ABS BAS100 General warnings 3.4.15 Emissions Toxic substances 3.4.16 Tightening torque Requirements for the rider Description of controls and screens Protection for vulnerable groups 3.5.1...
Page 3 Contents 5.2.1 Scope of delivery 6.3.6.1 Adjusting the negative deflection Commissioning 6.3.6.2 Adjusting the rebound 5.3.1 Checking the battery 6.3.7 Setting the Suntour rear frame damper 5.3.2 Installing the wheel in the Suntour fork 6.3.7.1 Adjusting the negative deflection 5.3.2.1 Installing the wheel with screw-on axle 6.3.7.2 Adjusting the rebound...
Page 4 Contents information 7.3.3 Servicing the fork 6.11.10.2Resetting the journey information 7.3.4 Servicing the drive elements 6.11.11 Changing the system settings 7.3.5 Servicing the pedals 6.12 Brake 7.3.6 Servicing the chain 6.12.1 Using the brake lever 7.3.7 Servicing the drive elements 6.12.2 Using the back-pedal brake Maintenance...
Page 5 Toxic substances 3.4.12 Intuvia display Requirements for the rider 3.4.13 USB port Protection for vulnerable groups 3.4.14 BOSCH Pedelec ABS BAS100 Data privacy 3.4.15 Emissions Personal protective equipment 3.4.16 Tightening torque Safety markings and safety instructions 15 Description of controls and screens Emergency 3.5.1...
Page 6: About These Operating Instructions
Contents 5.3.1 Checking the battery 6.3.5.4 Adjusting the rebound 5.3.2 Installing the wheel in the Suntour fork 6.3.6 Adjusting the suspension of the 5.3.2.1 Installing the wheel with screw-on axle FOX fork (15 mm) 6.3.6.1 Adjusting the negative deflection 5.3.2.2 Installing the wheel with screw-on axle 6.3.6.2 Adjusting the rebound...
Page 7 Contents 6.11.6 Switching off the display 7.2.7 Cleaning the battery 6.11.7 Using the push assist system 7.2.8 Cleaning the display 6.11.8 Using the riding light 7.2.9 Cleaning the drive unit 6.11.9 Selecting the level of assistance 7.2.10 Cleaning the brake 6.11.10 Journey information Servicing 7.3.1...
Page 8: Identifying The Operating Instructions
Contents 11.4 Charger operating instructions Keyword index Glossary Appendix Translation of the original EC declaration of conformity MY20B01-22_1.0_21.06.2019...
Page 9: Subject To Change
About these operating instructions About these operating instructions Manufacturer Thank you for your trust! KETTLER pedelecs are premium quality sporting The pedelec manufacturer is: equipment – you have made an excellent choice. KETTLER Alu-Rad GmbH Your specialist dealer has advised you and Longericher Straße 2 assembled your product.
Page 10 About these operating instructions Type no. Model Pedelec type Type no. Model Pedelec type City and trekking Quadriga Town & KB084-ZBRWxx Comfort 5 KB116-ZAKWxx Mountain bike bicycle Country Comp City and trekking Quadriga Town & KB084-ZCRWxx Comfort 5 KB116-ZBKDxx Mountain bike bicycle Country Comp City and trekking...
Page 11 About these operating instructions Type no. Model Pedelec type Type no. Model Pedelec type City and trekking Traveller E-Gold 7 City and trekking KB137-ZAKWxx Quadriga CX10 KB144-ZAFWxx bicycle bicycle City and trekking Traveller E-Gold 7 City and trekking KB137-ZBKDxx Quadriga CX10 KB144-ZARWxx bicycle bicycle...
Page 12: Subject To Change
About these operating instructions Subject to change 1.7.1 Instruction, training and customer service The information contained in these operating The supplying specialist dealer will provide instructions are the approved technical customer service. Contact details can be found on specifications at the time of printing. Any the back page of these operating instructions and significant changes will be included in a new issue on the data sheet.
Page 13: Warnings
About these operating instructions 1.7.3 Warnings For your information Hazardous situations and actions are marked with 1.8.1 Instructions for actions warnings. The warnings in these operating Instructions for actions are structured in instructions are indicated as follows: accordance with the following pattern: DANGER ...
Page 14: Nameplate
About these operating instructions Nameplate The nameplate is situated on the frame. You will information on the nameplate. find the precise position of the nameplate in Figure 2. You will find thirteen pieces of ZEG Zweirad-Einkaufs- Genossenschaft eG Longericher Str. 2 50739 Köln, Germany Typ: 20-16-0001...
Page 15: Information On The Nameplate
About these operating instructions 1.9.1 Information on the nameplate Alongside the warnings, product nameplates also contain other important information about the pedelec: Read the instructions Separate collection of electrical and electronic devices Separate collection of batteries Must not be thrown into fire (burning prohibited) Battery must not be opened Device of protection class II...
Page 16: Safety
Risk of fire and explosion due to incorrect connecting cables or defective contacts. charger  Use the battery with BOSCH Systems Batteries which are recharged with an unsuitable pedelecs only. This is the only way that the charger may become damaged internally. This battery will be protected from dangerous may result in fire or an explosion.
Page 17: Toxic Substances
Safety Toxic substances CAUTION WARNING Risk of fire and explosion due to high temperatures Intoxication from suspension oil Excessively high temperatures will damage the Suspension oil in the rear frame damper is toxic to battery. The battery may self-ignite and explode. the touch, irritates respiratory tracts and causes ...
Page 18: Requirements For The Rider
Environmental hazard posed by oil and During maintenance, the pedelec is connected to lubricants from rear frame damper the diagnosis tool and data is transferred to Bosch Pedelec Systems (Robert Bosch GmbH) about the The rear frame damper contains toxic and use of electric drive components to help improve environmentally harmful oils and lubricants.
Page 19: Emergency
Safety After skin contact Symbol Explanation Remove any solid particles immediately. Rinse Read the instructions the affected area with plenty of water for at least 15 minutes. Then dab the affected skin gently. Do Separate collection of electrical not rub dry. Remove contaminated clothing and electronic devices immediately.
Page 20: Leaking Fluids
Safety 2.8.4 Leaking fluids 2.8.4.1 Brake fluid  The brake system must be repaired immediately if brake fluid leaks out. Contact your specialist dealer about repair.  Dispose of leaking brake fluid in an environmentally responsible way in accordance with statutory regulations. Ask a specialist dealer for more information.
Page 21: Overview
Overview Overview 14 15 Figure 2: Pedelec viewed from the right, Comfort 5 used as example Front wheel Pannier rack Fork Rear light and reflector Front guard Rear guard Headlight Rear wheel Handlebars Chain Stem Chain guard Frame Rechargeable battery Seat post Saddle MY20B01-22_1.0_21.06.2019...
Page 22: Description
Overview Description 3.1.2 Suspension Both forks and suspension forks are fitted in this 3.1.1 Wheel and suspension model series. A suspension fork is based either on a steel spring or air suspension. Unlike a rigid fork, a suspension fork has two functions which improve floor contact and comfort: suspension and damping.
Page 23: Steel Suspension Fork Structure
Overview 3.1.2.1 Steel suspension fork structure 3.1.2.2 Air suspension fork structure The pedelec's fork features both air suspension and a compression damper plus a rebound damper in some cases. Figure 5: Example showing Suntour fork The stem and handlebars are fastened to the fork steerer (1).
Page 24: Structure Of The Fox Rear Frame Damper
Overview 3.1.3 Brake system 3.1.2.3 Structure of the FOX rear frame damper The rear frame damper features air suspension, a The pedelec's brake system comprises either a compression damper and a rebound damper. hydraulic: • rim brake on the front and rear wheels •...
Page 25: Disc Brake
Overview 3.1.3.2 Disc brake 3.1.3.3 Back-pedal brake Figure 11: Pedelec brake system with a disc brake – example Figure 12: Pedelec brake system with a back-pedal brake – example Brake disc Rear wheel rim brake Brake calliper with brake linings Handlebars with brake lever Handlebars with brake lever Front wheel rim brake...
Page 26: Abs
The indicator lamp lights up for about 5 seconds Figure 13: BOSCH ABS before the system switches off completely. The ABS indicator lamp will then go out, even though ABS control unit with housing the ABS control system is not available.
Page 27: Electric Drive System
The battery temperature is monitored at all times. Each individual cell in a Bosch rechargeable battery is protected by a steel cup and cased in a plastic housing. You must not open this housing. You...
Page 28 The type and duration of operating conditions Table 7: Overview of frame batteries 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.
Page 29: Integrated Battery
Integrated rechargeable battery housing 3.1.6 Display The model series to which these instructions apply features a BOSCH Intuvia display. In addition to the functions described here, software changes may be introduced to rectify errors and extend functions at any time.
Page 30: Usb Port
When the riding light is activated, the headlight and the rear light are switched on together. 3.1.8 Charger Each pedelec is supplied with a charger. As a general rule, any BOSCH charger may be used: • The 2A compact charger • The 4A standard charger •...
Page 31: Proper Use
Overview Proper use The general laws and the regulations for the prevention of accidents and environmental The pedelec must only be used in perfect, fully protection in the respective country of use must be functional condition. National requirements may adhered to. All check lists and instructions for apply to the pedelec which the standard actions in these operating instructions met.
Page 32: Improper Use
Overview Improper use • carrying other people • riding with excessive baggage Failure to adhere to the proper use poses a risk of • riding with no hands personal injury and material damage. The pedelec • riding on ice and snow is not suitable for the following uses: •...
Page 33: Technical Data
Overview Technical data 3.4.4 Performance Line Cruise motor Continuous power rating 250 W 3.4.1 Pedelec Max. torque 63 Nm Transportation temperature 5 °C - 25 °C Nominal voltage 36 V DC Ideal transportation temperature 10 °C - 15 °C Protection class IP54 Storage temperature 10 °C - 30 °C...
Page 34: Lighting
Overview 3.4.7 Lighting 3.4.10 PowerPack 500 battery Applicable to motors: Performance Line Cruise, Nominal voltage 36 V Performance Line Speed and Performance Line CX Nominal capacity 13.4 Ah Voltage about 6/12 V Energy 500 Wh Maximum output Weight 2.6/ 2.7 kg Front light 8.4/17.4 W Protection class...
Page 35: Bosch Pedelec Abs Bas100
Storage temperature -10 °C - +60 °C Protection class IPx7 Weight about 1 kg Table 26: BOSCH Pedelec ABS BAS100 technical data 3.4.15 Emissions A-weighted emission sound pressure < 70 dB(A) level Total vibration level for the hands and < 2.5 m/s²...
Page 36: Description Of Controls And Screens
Overview Description of controls and 3.5.3 Control panel screens The control panel has four buttons. 3.5.1 Handlebars Figure 20: Detailed view of pedelec from rider position, example Rear brake lever Bell Headlight Figure 22: Control panel overview Display Symbol Designation Front brake lever Info button (control panel) Control panel...
Page 37: Level Of Assistance
You can also see the charge level on the LEDs on the battery itself. Different levels of assistance are available for different BOSCH motors. If the display is removed from its mount, the last displayed battery level is saved.
Page 38: Gear Recommendation
Overview 3.5.4.5 Gear recommendation Additional journey information Pedalling frequencies higher than 50 revolutions Applies only to Pedelecs with eShift with per minute optimise drive unit efficiency. Shimano DI2 automatic hub gears However, very slow pedalling uses up a great deal The following additional functions are available on of energy.
Page 39 Overview System settings and data Applies only to Pedelecs with eShift with manual Shimano DI2 automatic hub gears. In order to see the system settings and data, the Screen display Change rider has to call up the system settings. The rider –...
Page 40: System Message
Overview 3.5.6 ABS indicator lamp Applies only to Pedelecs with eShift with NuVinci H|Sync/ enviolo with Optimized H|Sync The anti-blocking system indicator lamp must light Screen display Change up after the system has started up and must go Gear calibration This is where you can perform a out once speed has reached about 5 km/h.
Page 41: Environmental Requirements
Overview Environmental requirements You can be ride the pedelec within a temperature As a general rule, you should avoid temperatures range between 5 °C and 35 °C. The drive system under -10 °C or over +60 °C is limited in its performance outside this You must also keep within the following temperature range.
Page 42 Overview The pedelec is unsuitable for the following areas of use: Child's bicycles/ City and trekking Area of use bicycles for young Mountain bikes Racing bicycle Cargo bike Folding bicycle bicycles adults Never drive off-road Never drive off-road Never drive off-road Never drive off-road Never drive off-road or perform jumps.
Page 43: Transporting And Storing
Transporting and storing Transporting and storing CAUTION Physical transport Oil leak if no transport securing device characteristics The brake securing device prevents the brakes from being applied accidentally during 4.1.1 Dimensions during transportation transportation. This could cause irreparable damage to the brake system or an oil leak, which There was no information relating to the box will harm the environment.
Page 44: Transporting The Battery
Transporting and storing Storing Notice The specialist dealer will advise you on how to CAUTION select a suitable rack system properly and how to use it safely. Risk of fire and explosion due to high temperatures  If you ship the pedelec, we recommend that you have it partially dismantled and packaged Temperatures over 60 °C can also cause liquid to properly by the specialist dealer.
Page 45: Break In Operation
Transporting and storing 4.3.1 Break in operation 4.3.1.1 Preparing a break in operation  Remove battery from the pedelec. Notice  Charge battery to around 30%–60% The battery discharges when not in use. This can  The pedelec needs to be cleaned with a damp cause irreparable damage to the battery.
Page 46: Assembly
Assembly Assembly Unpacking CAUTION WARNING Hand injuries caused by cardboard packaging Injury to the eyes The shipping carton is closed with metal staples. Problems may arise if the settings are not made There is a risk of puncture wounds and cuts when to components properly and you may sustain unpacking and crushing the packaging.
Page 47: Commissioning
Assembly Commissioning 5.3.1 Checking the battery WARNING CAUTION Risk of fire and explosion due to faulty battery Risk of fire and explosion due to incorrect charger The safety electronics may fail if the battery is damaged or faulty. The residual voltage can Batteries which are recharged with an unsuitable cause a short circuit.
Page 48: Installing The Wheel With Screw-On Axle
Assembly  Tighten the axle with a 5 mm hexagon socket 5.3.2.2 Installing the wheel with screw-on axle (20 mm) spanner to 8–10 Nm.  Insert the axle completely on the drive side. Figure 27: Tightening the axle  Insert the securing screw on the non-drive Figure 30: Tightening the inserted axle side.
Page 49: Installing The Wheel With A Quick Release
Assembly  Tighten the axle with the red handle. 5.3.2.3 Installing the wheel with a quick release axle CAUTION Crash caused by loose quick release axle A faulty or incorrectly installed quick release axle may become caught in the brake disc and block the wheel.
Page 50: Installing The Wheel With A Quick Release
Assembly  Check the position and clamping force of the 5.3.3 Installing the wheel with a quick quick release lever. The quick release lever release must be flush with the lower housing. You must CAUTION be able to see a slight impression on the palm of your hand when you close the quick release Crash caused by unfastened quick lever.
Page 51: Installing The Wheel In The Fox Fork
Assembly  Push in the quick release until you hear a 5.3.4 Installing the wheel in the FOX fork clicking sound. Make sure that the flange is Only applies to pedelecs with this equipment extended. 5.3.4.1 Wheel with quick release (15 mm) The procedure for installing the 15 x 100 mm and 15 x 110 mm quick releases is the same.
Page 52: Adjusting The Fox Quick Release
Assembly 5.3.4.2 Adjusting the FOX quick release 5.3.4.3 Installing the wheel with Kabolt axles The procedure for installing the 15 x 100 mm and 15 x 110 mm Kabolt axles is the same.  Place the front wheel in the fork ends of the fork.
Page 53: Pedelec Sale
Assembly Checking the headset backlash  To check the handlebar headset backlash, close the quick release lever on the stem. Place 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.
Page 54: Operation
Operation Operation CAUTION Risks and hazards Risk of fire and burning due to hot motor The motor housing becomes hot when riding. WARNING Touching it may cause burns to the skin or other objects. Injuries and death caused by other road users ...
Page 55: Tips For A Greater Range
Operation Gear shift Moisture penetrating at low temperatures may impair individual pedelec functions due to the Shifting gears correctly also makes pedelecs open structural design. more efficient: It is best to set off and ride up hills using a low gear and switch up a gear depending ...
Page 56: Error Messages
Operation Error messages Code Description Method of resolution 6.2.1 Error message display  Internal display error Have display checked. The drive system monitors itself continuously and  Internal drive unit error Re-start the system.  Contact your specialist displays a number as an error message if a known dealer if the problem error is detected.
Page 57 Operation Code Description Method of resolution Code Description Method of resolution   Authentication error Turn off the drive system. Charger error Replace the charger.   Remove the battery. Contact your specialist  Insert the battery again. dealer if the problem ...
Page 58: Battery Error Message
Operation 6.2.2 Battery error message Code Description Method of resolution The battery is protected against deep discharge,  870, Communication error Re-start the system.  overcharging, overheating and short circuits by 871, Contact your specialist dealer if the problem Electronic Cell Protection (ECP). In the event of a 883 ...
Page 59: Before The First Ride
Operation Before the first ride 6.3.2 Determining the seat height  To determine the seat height safely, either push CAUTION the pedelec near to a wall, so that you can lean on the wall to support yourself or ask another person Crash caused by incorrectly adjusted torques to hold the pedelec for you.
Page 60: Height-Adjustable Seat Post
Operation  Set the seat post at the required height. Lowering the saddle  To lower the saddle, press your hand down on the CAUTION saddle or sit on the saddle. Press the seat post activation lever and hold it down. Crash caused by an excessively high seat post ...
Page 61: Adjusting The Handlebars
Operation  The handlebar settings must only be adjusted while the pedelec is stationary.  Unfasten and adjust the designated screw connections, and clamp them with the maximum tightening torque for the clamping screws of the handlebars. 6.3.3 Adjusting the handlebars Figure 52: Open (2) and closed (1) clamping lever on the stem;...
Page 62: Checking The Clamping Force In Quick
Operation 6.3.3.4 Checking the clamping force in quick releases  Open and close the quick releases on the stem or the seat post.  The clamping force is sufficient if the clamping lever can be moved easily from the open final position into the middle and has to be pressed with the fingers or base of the thumb from the middle point onwards.
Page 63: Adjusting The Grip Distance On A
Operation 6.3.4.3 Adjusting the grip distance on a CAUTION Magura brake lever Only applies to pedelecs with this equipment Crash caused by incorrectly set suspension If the suspension is adjusted incorrectly, the fork Use a T25 TORX® wrench to turn the setting may become damaged, so that problems may screw to adjust the grip distance.
Page 64: Adjusting The Air Suspension Fork
Operation  Get off the pedelec without allowing it to 6.3.5.2 Adjusting the air suspension fork negative deflection deflect. Only applies to pedelecs with this equipment  Measure the distance between the dust wiper and the cable tie. This dimension is the sag. ...
Page 65: Adjusting The Rebound
Operation  The ideal setting in relation to the weight of the 6.3.6 Adjusting the suspension of the rider has been achieved when the shock FOX fork absorber deflects 3 mm under the stationary Only applies to pedelecs with this equipment load of the rider.
Page 66: Adjusting The Rebound
Operation  Pump the suspension fork up to the desired  Increase or reduce the air pressure until you pressure. Never exceed the recommended have reached the desired sag. maximum air pressure. Comply with the values  Once the sag is correct, re-tighten the blue air of the filling pressure table.
Page 67: Setting The Suntour Rear Frame Damper
Operation 6.3.7 Setting the Suntour rear frame 6.3.7.2 Adjusting the rebound damper The rebound defines the speed at which the rear frame damper rebounds after being loaded. The Only applies to pedelecs with this equipment rebound setting depends on the air pressure setting. Higher sag settings require lower rebound settings.
Page 68: Setting The Fox Rear Frame Damper
Operation 6.3.8 Setting the FOX rear frame damper The negative deflection (2) is the distance between the O-ring (4) and the rubber air Only applies to pedelecs with this equipment chamber seal (1). The total deflection of the rear frame damper (5) is the distance between the end 6.3.8.1 Adjusting the negative deflection of the rear frame damper (3) and the rubber air chamber seal (1)
Page 69: Retracting The Brake Linings
Operation  Determine your rebound setting based on the air pressure. Turn the rebound adjuster back anti-clockwise by the number of clicks specified in the table below: Air pressure (psi) Recommended rebound setting < 100 Open (anti-clockwise) 100 - 120 120 - 140 140 - 160 160 - 180...
Page 70: Accessories
Operation Accessories CAUTION We recommend a parking stand into which either Risk of crushing due to exposed springs the front or rear wheel can be inserted securely for pedelecs which do not have a kickstand. The The child may crush his/her fingers on exposed following accessories are recommended: springs or open mechanical parts of the saddle or Description...
Page 71: Bicycle Trailers
Operation 6.4.3 Pannier rack cables, brake cables, hydraulic and electrical cables are adjusted as necessary, the rider's The specialist dealer will advise on choosing a freedom of movement is not restricted and the suitable pannier rack. pedelec's permitted total weight is not exceeded. The specialist dealer must install the pannier rack The specialist dealer will provide instruction on the first time to ensure that it is safely fitted.
Page 72: Before Each Ride
Operation Before each ride Check list before each ride  Check the pedelec before each ride. CAUTION  Do not use the pedelec if there is evidently something wrong with it. Crash caused by difficult-to-spot damage If the pedelec topples over or you have a fall or an ...
Page 73: Using The Kickstand
Operation Using the kickstand CAUTION CAUTION Crash caused by unsecured baggage Crash caused by a lowered kickstand Loose or unsecured objects on the pannier rack, e.g. belts, may become caught in the rear wheel. The kickstand does not fold up automatically. This may cause a crash with injuries.
Page 74: Rechargeable Battery
 Protect the battery against heat over 60 °C, connecting cables or defective contacts. e.g. against permanent direct sunlight.  Use the battery with BOSCH Systems Risk of fire and explosion due to short circuit pedelecs only. This is the only way that the...
Page 75: Frame Battery
Operation 6.9.2 Pannier rack battery Notice Only applies to pedelecs with this equipment If you leave a key inserted when riding or transporting the pedelec, it may break off or the 6.9.2.1 Removing the pannier rack battery locking system may open accidentally. ...
Page 76: Inserting The Integrated Battery
Operation  (1) Open the battery lock with the key. 6.9.4 Charging the battery  (2) The battery is released and falls into the WARNING retainer guard.  (3) Hold the battery in your hand from beneath. Risk of fire and explosion due to faulty battery Use the other hand to push on the retainer The safety electronics on damaged or faulty guard from above.
Page 77: Charging The Dual Battery
Operation  6.9.5 Charging the dual battery The ambient temperature during the charging process must be within the range from 0 °C to Only applies to pedelecs with this equipment 40 °C.  The battery can remain on the pedelec or can be One of the charging sockets is not accessible or is removed for charging.
Page 78: Charging Process When One Battery Is Used
Operation 6.9.5.2 Charging process when one battery is used You can charge each battery individually if you remove them from their mounts. If only one battery is used, you will only be able to charge the battery on the pedelec which has an accessible charging socket.
Page 79: Electric Drive System
Operation 6.10 Electric drive system 6.10.2 Switching off the drive system As soon as you stop pushing the pedals in normal 6.10.1 Switching on the electric drive mode or reach a speed of 25 km/h, the drive system system switches off the assistance system. The assistance system starts up again if you push the CAUTION pedals and your speed is less than 25 km/h.
Page 80: Control Panel With Display
Operation 6.11 Control panel with display 6.11.1.2 Attaching the display  Place the display on the mount. CAUTION  Push the display back as far as it will go. Crash caused by distraction A lack of concentration while riding increases the risk of an accident.
Page 81: Charging On The Pedelec
Operation 6.11.5 Switching on the display 6.11.3.1 Charging on the pedelec  Once a battery has been inserted into the  Press the On-Off button (display) once. pedelec, place the display in the display mount.  The electric drive system is switched on. ...
Page 82: Using The Riding Light
Operation 6.11.8 Using the riding light 6.11.11 Changing the system settings  The drive system needs to be already switched System settings screen displays and changes are on to turn on the riding light. possible regardless of whether the display is inserted into the mount or not.
Page 83: Brake
Operation 6.12 Brake DANGER DANGER After swallowing Hydraulic fluid can be fatal if it is swallowed  Rinse out mouth with water. Never induce and penetrates into the respiratory system vomiting! Risk of aspiration!  Place a person lying on their back who is Hydraulic fluid may leak out after an accident or due to material fatigue.
Page 84: Using The Brake Lever
Operation WARNING CAUTION Amputation due to rotating brake disc Crash after cleaning or storage The brake disc in disc brakes is so sharp that it The brake system is not designed for use on a can cause serious injuries to fingers if they are pedelec which is placed on its side or turned inserted into the disc brake openings.
Page 85: Using The Back-Pedal Brake
Operation 6.12.2 Using the back-pedal brake WARNING Only applies to pedelecs with this equipment Accidents on bends and slippery ground  The best braking effect is achieved if the pedals You are at greater risk of falling off if you use ABS are in the 3 o'clock and 9 o'clock position when braking manoeuvres on bends.
Page 86: While Riding
Operation  Remember that the anti-blocking system can WARNING make your braking distance longer.  Reduce your speed on slippery ground. Brake in Accidents due to manipulation bursts and in good time. Modified or manipulated ABS components or use of non-authorised replacement components will Notice have an adverse effect on the ABS function.
Page 87: Adjusting The Compression Of The
Operation 6.13.2 Adjusting the compression of the 6.13.3 Adjusting the compression of the Fox damper Suntour fork Only applies to pedelecs with this equipment Only applies to pedelecs with this equipment The compression adjuster makes it possible to The compression adjuster makes it possible to make quick adjustments to the suspension make quick adjustments to the suspension behaviour of the damper to suit changes in terrain.
Page 88: Adjusting The Rebound In A Rock
Operation  Use the OPEN position for rough descents and  If the rear wheel bounces back much more the LOCK position for efficient climbing. First set quickly or slowly than the front wheel, change the the compression adjuster to the OPEN position. setting by turning the setting wheel.
Page 89: Using The Derailleur Gears
Operation 6.14.1 Using the derailleur gears Notice The interior hub is not completely waterproof. If Only applies to pedelecs with this equipment water gets into the hub, it may rust and the gear The speed and range can be increased while switch function may no longer function as a result.
Page 90: Eshift With Manual Shimano Di2
Operation You will find how to switch from automatic to 6.14.3.3 eShift with Shimano DI2 automatic hub gears manual mode, depending on the shifter used, described in your operating instructions for your Only applies to pedelecs with this equipment gear shift. The new gear is shown briefly on the screen each If you use the shifter when in automatic mode, the time it is changed.
Page 91: Cleaning And Servicing
Cleaning and servicing Cleaning and servicing Cleaning check list The following servicing measures must be performed regularly. Servicing can be performed  Clean the pedals after each ride by the operator and rider. In case of any doubt, consult the specialist dealer. Clean the suspension fork and, if ...
Page 92: Basic Cleaning
Cleaning and servicing Basic cleaning 7.2.1 Cleaning the frame  Soak dirt stains on the frame with dish-washing CAUTION detergent if the dirt is thick and ingrained.  After leaving it to soak for a time, remove the Crash caused by brake failure dirt and mud with a sponge, brush and The braking effect may be unusually poor toothbrush.
Page 93: Cleaning The Chain
Cleaning and servicing 7.2.6 Cleaning the chain Notice Notice  Do not clean the battery with solvents, such as thinners, alcohol, oil and corrosion protection,  Never use aggressive (acid-based) cleaners, or with cleaning agents. rust removers or degreasers when cleaning the chain.
Page 94: Cleaning The Brake
Cleaning and servicing 7.3.1 Servicing the frame Notice  Dry frame after cleaning. If water enters into the drive unit, the unit will be  Spray with care oil. Clean off the care oil again permanently damaged. after a short time. ...
Page 95: Maintenance
Cleaning and servicing Maintenance 7.4.2 Checking the tyres  Check the tyre wear. The tyre is worn if the anti- CAUTION puncture protection or the carcass cords are visible. Crash and falling caused by unintentional  A specialist dealer will need to change the tyre if activation it is worn.
Page 96: Presta Valve
Cleaning and servicing 7.4.4.2 Presta valve 7.4.5 Brake system  It is recommendable to use CAUTION a bicycle pump with a pressure gauge. The Crash caused by brake failure operating instructions for the bicycle pump must be Worn brake discs and brake linings, as well as a adhered to.
Page 97: Checking The Brake Discs For Wear
Cleaning and servicing 7.4.8 Checking the brake discs for wear 7.4.13 Checking the belt and chain tension  Check that the brake disc is no less than 1.8 Notice mm at any point. Excessive chain tension increases wear.  The brake discs have not reached the wear limit.
Page 98: Maintenance
Maintenance Maintenance CAUTION Hazard for the environment due to toxic WARNING substances Injury due to damaged brakes The brake system contains toxic and Special tools and specialist knowledge are environmentally harmful oils and lubricants. Such required to repair the brakes. Incorrect or fluids will contaminate if they enter the sewers or unauthorised assembly can damage the brakes.
Page 99: Axle With Quick Release
Maintenance 8.1.1 Checking the quick release clearance is too great (more than 1 mm on the fork bridge).  Check the position and clamping force of the  The specialist dealer will fully inspect the quick release lever. The quick release lever interior and exterior of the rear frame damper, must be flush with the lower housing.
Page 100: Cable-Operated Gear Shift, Single-Cable
Maintenance 8.2.1 Cable-operated gear shift, single- 8.2.3 Cable-operated twist grip, dual- cable cable Only applies to pedelecs with this equipment Only applies to pedelecs with this equipment  For a smooth gear shift, adjust the adjusting  For a smooth gear shift, set the adjusting sleeves on the shifter housing.
Page 101: Troubleshooting, Fault Clearance And Repair
Troubleshooting, fault clearance and repair Troubleshooting, fault clearance and repair Troubleshooting and fault  Insert the battery. clearance  Start the drive system.  If the drive system does not start up, remove WARNING the battery. Risk of fire and explosion due to faulty battery ...
Page 102: Repair
Troubleshooting, fault clearance and repair 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 brake pads and brake linings • Replacing and tensioning the chain.
Page 103: Recycling And Disposal
Recycling and disposal Recycling and disposal CAUTION Hazard for the environment WARNING The fork, rear frame damper and hydraulic brake Risk of fire and explosion system contain toxic and environmentally harmful The safety electronics on a damaged or faulty oils and lubricants. Such fluids will contaminate if battery may fail.
Page 104: Documents
Documents Documents 11.1 Parts list There was no information relating to a parts list yet at the time of going to press. You'll find the information in the latest operating instructions. MY20B01-22_1.0_21.06.2019...
Page 105: Assembly Report
Documents 11.2 Assembly report Date: Frame number: Components Description Criteria Measures if rejected Accept- Assembly/inspection Tests Rejection ance Front wheel Assembly O.K. Loose Adjust quick release Kickstand Check mount fastening Functional check O.K. Loose Retighten screws Tyre pressure too low/too Tyres Tyre pressure check O.K.
Page 106 Documents Components Description Criteria Measures if rejected Drive/gear shift Chain/cassette/ Refasten if necessary or replace Check for damage O.K. Damage pinion/chainring as specified in parts list Chain guard/spoke Check for damage O.K. Damage Replace as specified in parts list guard Bottom bracket axle/ Check mount fastening O.K.
Page 107: Maintenance Log
Documents 11.3 Maintenance log Diagnosis and documentation of current status Date: Frame number: Components Frequency Description Criteria Measures if rejected Inspection Tests Maintenance Accept- Rejection ance Front wheel 6 months Assembly O.K. Loose Adjust quick release Kickstand 6 months Check mount fastening Functional check O.K.
Page 108 Documents Components Frequency Description Criteria Measures if rejected Inspection Tests Maintenance Accept- Rejection ance Light system First examination O.K. Error message Contact battery Rechargeable manufacturer; take out of battery service, new battery Connections, correct O.K. Cable defective, New cabling Light cabling wiring no light Side light...
Page 109 Documents Technical inspection, checking safety, test ride Components Description Criteria Measures if rejected Assembly/inspection Tests Accept- Rejection ance Functional check O.K. No full braking; braking Locate defective part in brake Brake system distance too long system and correct Gear shift under operat- Functional check O.K.
Page 110: Charger Operating Instructions
Documents 11.4 Charger operating instructions MY20B01-22_1.0_21.06.2019...
Page 111 Standard Charger BCS220 0 275 007 907 Input: 230V 50Hz 1.5A Li-Ion Output: 36V Use ONLY with BOSCH Li-Ion batteries Made in PRC Robert Bosch GmbH, Reutlingen eBike Battery Charger 36-6/230 Fast Charger BCS250 0 275 007 918 Input: 230V 50Hz 2.15A...
Page 112 Documents Compact Charger %&6 MY20B01-22_1.0_21.06.2019...
Page 113 Documents MY20B01-22_1.0_21.06.2019...
Page 114 Documents MY20B01-22_1.0_21.06.2019...
Page 115 Documents MY20B01-22_1.0_21.06.2019...
Page 116 Documents MY20B01-22_1.0_21.06.2019...
Page 117 Documents MY20B01-22_1.0_21.06.2019...
Page 118 Documents MY20B01-22_1.0_21.06.2019...
Page 119: Keyword Index
Keyword index Keyword index Drive system, 27 - switching off, 79 On-Off button, Air chamber, 24 Battery, 29 Air valve - switching on, 79 Fork, 23 Display, 30 Rear frame damper, 24 On-screen indicator, 36, 71 Fork lock, Alternative, 13 Operating status indicator, 36 Position, 23 O-ring, 24...
Page 120 Keyword index Transporting, see Transportation Type number, 14 Tyres, 22 - checking, 95 USB port, 30 - using, 81 Using 89 Valve cap, 23 Valve, 22 Dunlop valve, 22 Presta valve, 22 Schrader valve, 22 Weight, permitted total weight, 14 Wheel, - maintaining, 95 Winter break, see Break in operation...
Page 121: Glossary
Glossary Glossary and associated wiring for the motor electrical power assistance. Brake lever Electrically power assisted cycle, pedelec Source: EN 15194:2017: lever used to apply the Source: EN 15194:2017: electrically power brake. assisted cycle, equipped with pedals and an auxiliary electric motor, which cannot be propelled Braking distance exclusively by means of the auxiliary electric motor, except in start-up assistance mode.
Page 122 Glossary Maximum continuous power Permitted total weight Source: ZEG: the maximum continuous power is Source: EN 15194:2017: weight of the fully the maximum power for the electric motor output assembled pedelec plus the rider and baggage, shaft during 30 minutes. as specified by the manufacturer.
Page 123 Glossary Wear Source: DIN 31051: reduction in useful life (4.3.4), caused by chemical and/or physical processes. 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.
Page 124: Appendix
Appendix Translation of the original EC declaration of conformity The manufacturer: KETTLER Alu-Rad GmbH Longericher Straße 2 50739 Köln, Germany hereby declares that the electrically power assisted cycles of types: KB064-ZAFDxx, KB064-ZAFTxx, KB064-ZAFWxx, KB064-ZARWxx, KB064-ZBFD5xx, KB064-ZBFTxx, KB064-ZBFWxx, KB064-ZBRWxx, KB068-ZAFWxx, KB068-ZARWxx, KB068-ZBFWxx, KB068-ZBFWxx, KB068-ZBRWxx, KB068-ZCFWxx, KB068-ZCRWxx, KB083-ZARWxx, KB084-ZARWxx, KB084-ZBRWxx, KB084-ZCRWxx, KB084-ZDRWxx, KB111-ZAKDxx, KB111-ZAKDxx, KB111-ZAKTxx, KB111-ZAKWxx, KB112-ZAFDxx, KB112-ZAFTxx, KB112-ZAFWxx, KB112-ZARDxx, KB112-ZARTxx, KB112-ZARWxx,...

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Bosch BLACK BIRD KB064-ZAFT Series Translation Of The Original Operating Instructions

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