Bosch 0 275 007 526, 0 275 007 534, 0 275 007 525, 0 275 007 535, 0 275 007 536 Owner's Manual
...
Robert Bosch GmbH
Bosch eBike Systems
72703 Reutlingen
GERMANY
www.bosch-ebike.com
0 275 U07 XPX (2017.05) T / 40
Active Line/Performance Line Active Line/Performance Line
This manual contains important safety,
performance and service information.
Read and understand it along with the
information provided to you by your
bicycle manufacturer before using the
product, and keep it for reference.
Este manual contiene información
importante de seguridad, rendimiento y
mantenimiento. Léalo y asegúrese de
entenderlo junto con la información que
le ha facilitado el fabricante de su
bicicleta antes de usar el producto
;
guárdelo a modo de referencia.
Cette notice contient d’importantes
informations sur la sécurité, les
performances et l’entretien. Lisez-les et
comprenez-les ainsi que les informations
fournies par le fabricant de votre vélo
avant d’utiliser le produit
, et conservez-
les pour référence ultérieure.
Owner’s Manual – The Bosch Drive System
PowerPack
BBS261: 0 275 007 538 | BBS266: 0 275 007 524 | BBS271: 0 275 007 533 | BBS276: 0 275 007 534
BBR261: 0 275 007 526 | BBR266: 0 275 007 525 | BBR271: 0 275 007 535 | BBR276: 0 275 007 536
en Original instructions
fr Notice originale
es Manual original
OBJ_BUCH-2451-004.book Page 1 Monday, May 8, 2017 9:25 AM
English–1
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Using Your Operator’s Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
On-Product Warning Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Handling the lithium-ion battery pack “PowerPack”. . . . . . . . . . . . . . . . . . . . . . . . 4
Safety warnings for Bosch eBike batteries. . . . . . . . . . . . . . . . . . . . . . . . . . 4
Product Description and Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Maintenance/Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Battery Recycling Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
0 275 U07 XPX | (8.5.17) Bosch eBike Systems
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WARNING
CAUTION
Introduction
Thank You for Purchasing a Bosch Drive System Equipped Bicycle!
Your Bosch eBike system team appreciates having you as a customer and wishes you many years of safe and satisfied use
of your bicycle.
General Warnings
Read all safety warnings and all instructions.
Failure to follow the warnings and instructions
may result in death or serious injury.
Save all safety warnings and instructions for future
reference.
The term “battery pack” used in these operating instructions refers to all original Bosch eBike battery packs.
About Warnings
This manual contains many “DANGER”, “WARNING”, and
“CAUTION” indicators concerning the consequences of
failing to use, assemble, maintain, store, inspect and dispose of a Bosch-equipped eBike in a safe manner.
The combination of the safety alert symbol and the word
“DANGER” indicates a hazardous situation that, if not
avoided, will result in death or serious injury.
The combination of the safety alert symbol and the word
“WARNING” indicates a hazardous situation that, if not
avoided, could result in death or serious injury.
The combination of the safety alert symbol and the word
“CAUTION” indicates a hazardous situation that, if not
avoided, could result in minor or moderate injury.
Read ALL accompanying manuals before riding the
bike for the first time. Your Bosch Drive System comes
with additional manuals and documents provided by the
manufacturer of the bicycle and other components. Failure to read and understand safety information can result
in death or serious injury.
Take responsibility for your own SAFETY. If you have
any questions or do not understand something, contact
your Bosch eBike dealer or the bicycle or component
manufacturer.
Some eBike accessories may present a choking
hazard to small children. Keep these accessories away
from children.
The Bosch Drive System adds weight to your bicycle
which you may not be used to lifting. Avoid injury; use
proper lifting techniques.
Using Your Operator’s Manual
In addition to the functions shown here, changes to software relating to troubleshooting and functional enhancements may be introduced at any time.
Graphics
This manual contains important safety, performance
and service information. Read it before you take the
first ride on your new bicycle, and keep it for reference.
The manual can also be found online at
www.bosch-ebike.com.
This manual is intended to be read together with the
separate user manual provided with your bicycle. Be
sure to read all provided documents including labels on
the product before your first ride.
Bosch eBike Systems 0 275 U07 XPX | (8.5.17)
The bicycle shown in this manual may differ slightly from
your bicycle, but will be similar enough to help you understand our instructions.
RIGHT-HAND and LEFT-HAND sides are determined by
facing in the direction the bicycle will travel when going forward. When you see a broken line (------), the item referred
to is hidden from view.
English–3
A
On-Product Warning Labels
A Safety warnings,“PowerPack”
Warning labels have been placed on the Bosch eBike
System for your protection. Read and follow the
instructions of the labels on the product carefully. If
a label becomes illegible or comes off, contact your
Bosch bicycle dealer to obtain a replacement.
Replacement safety labels are provided by Bosch at no
charge.
0 275 U07 XPX | (8.5.17) Bosch eBike Systems
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DANGER
max.140°F
WARNING
Handling the lithium-ion battery pack “PowerPack”
Safety warnings for Bosch eBike
batteries
Read and understand all safety
warnings and instructions. Failure to
follow the warnings below could result
in death or serious injury.
Save all safety warnings and instructions for future
reference.
The term “battery pack” used in these operating instructions refers to all original Bosch eBike battery packs.
Do not puncture or crush the battery pack. Do sub-
ject the battery pack to mechanical impacts or modify it in any way. Do not use the battery pack if it shows
visible damage. Otherwise, there is the risk of a fire or an
explosion, which can cause death or serious injury.
Protect the battery pack against heat (e.g., temperature > 140 °F), fire and immersing into
water. Otherwise, there is the risk of an explosion.
Use only original Bosch battery packs approved for
your eBike by the manufacturer and purchased from
a trusted source. Use of non-approved or counterfeit
battery packs can lead to death or serious injury.
Remove the battery pack from the eBike before
beginning work (e.g. inspection, repair, assembly,
maintenance, work on the chain, etc.) on the eBike,
transporting it by car or plane, or storing it. Uninten-
tional activation of the eBike system poses a risk of injury.
Do not open the battery pack. There is a risk of a short
circuit. Opening the battery pack voids any and all
warranty claims.
If it is not being used, keep the battery pack away
from paper clips, coins, keys, nails, screws or other
small metal objects that can make a connection from
one terminal to another. Shorting the battery pack
terminals together may cause burns or a fire. For any
damage caused by shorting the terminals in this way,
any and all warranty claims through Bosch shall be
invalid.
Avoid mechanical loads and exposure to high tem-
peratures. These can damage the battery cells and
cause the flammable contents to leak out.
Do not place the charger or battery pack near flam-
mable materials. Charge battery packs only when
dry and in a fireproof area. There is a risk of fire due to
the heat generated during charging.
The eBike battery must not be left unattended while
charging.
If it is abused, then liquid may be ejected from the
battery pack. Avoid contact. If contact accidentally
occurs, flush with water. If liquid contacts eyes,
additionally seek medical help. Liquid ejected from
the battery pack may cause skin irritations or burns.
Battery packs must not be subjected to mechanical
impacts. There is a risk that the battery pack will be
damaged causing vapors to escape. The vapors can
irritate the respiratory system. Provide for fresh air and
seek medical attention in case of complaints.
The battery may give off fumes if it becomes dam-
aged or is used incorrectly. Provide a fresh air supply
and seek medical advice in the event of pain or discomfort of being exposed to these fumes. These
fumes may irritate the respiratory tract.
Charge the battery pack only with original Bosch
battery chargers. When using non-original Bosch
chargers, the risk of fire cannot be excluded.
Bosch eBike Systems 0 275 U07 XPX | (8.5.17)
English–5
Use the battery pack only together with eBikes that
have an original Bosch eBike drive system. This is the
only way to protect the battery pack against dangerous
overload.
Use only original Bosch battery packs approved for
your eBike by the manufacturer. Using other battery
packs can lead to injuries and pose a fire hazard. When
using other battery packs, the warranty is void and
Bosch shall not assume any liability.
Do not use the rack-type battery pack as a handle.
Lifting the eBike up by the battery pack can cause
damage to the battery pack.
Read and observe the safety warnings and instruc-
tions in all operating instructions of the eBike
system and your eBike.
Keep the battery pack out of reach of children.
The safety of both our products and customers is
important to us. Our PowerPacks are lithium-ion batteries which have been developed and manufactured in accordance with the latest technology. We comply with or
exceed the requirements of all relevant safety standards. When charged, these lithium-ion batteries contain a high level of energy. In the case of a fault (which
may not be detectable from the outside), lithium-ion
batteries can, in very rare cases and under unfavourable
conditions, catch fire.
0 275 U07 XPX | (8.5.17) Bosch eBike Systems
Product Description and Specifications
1
11
9
12
13
8
6
5
5
7
2
13
12
4
3
3
4
6
10
English–6
Product Features
All representations of bike components, with the exception
of the battery packs and their holders, are schematic and
can deviate from your eBike.
1 Holder for the rack-type battery pack
2 Rack-type battery pack
3 Operation and charge-control indicator
4 On/Off button
5 Key for the battery pack lock
6 Battery pack lock
7 Upper holder for the standard battery pack
8 Standard battery pack
9 Bottom holder for the standard battery pack
10 Cover lid (supplied only on eBikes with
2 battery packs)
11 Battery charger
12 Socket for charge connector
13 Charge socket cover
Bosch eBike Systems 0 275 U07 XPX | (8.5.17)
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Technical Data
Lithium-ion battery pack PowerPack 400 PowerPack 500
Article number
– Standard battery pack
– Rack-type battery pack
Rated voltage V= 36 36
Rated capacity Ah 11 13.4
Energy
Operating temperature
Storage temperature °F +14...+140 +14...+140
Permitted charging temperature range °F +32...+104 +32...+104
Weight, approx. lb 5.5/5.7 5.7/6.0
Degree of protection IP 54 (dust and splash water
This device is in compliance with Part 15 of the FCC Rules. Operation is subject to the following two conditions:
(1) This device must not cause harmful interference, and
(2) this device must accept any interference that is received, including interference that may cause undesired operation.
This device is in compliance with CAN ICES-3(B)/NM B-3(B).
Wh 400 500
°F +23...+104 +23...+104
0 275 007 524/538
0 275 007 525/526
IP 54 (dust and splash water
protected)
0 275 007 533/534
0 275 007 535/536
protected)
Assembly
Put the battery pack down only on clean surfaces. In
particular, avoid getting the charge socket and the contacts dirty, e.g., with sand or soil.
Checking the Battery Pack Before Using for the
First Time
Check the battery pack before charging it or using it with
your eBike for the first time.
To do this, press the On/Off button 4 to switch on the battery pack. If no LED for the charge-control indicator 3 lights
up, then the battery pack may be damaged.
When at least one of the LEDs, but not all, for the chargecontrol indicator 3 is lit, then fully charge the battery pack
before using it for the first time.
Do not attempt to charge or use a damaged battery
pack. Please contact an authorized Bosch eBike dealer.
Charging the Battery Pack
Only use the Bosch charger provided with your eBike
or an identical original Bosch charger. Only this
charger is matched to the lithium-ion battery pack used
in your eBike.
Note: The battery pack is supplied partially charged. To
ensure full battery pack capacity, completely charge the
battery pack in the charger before using it for the first time.
To charge the battery pack, read and follow the operating
instructions for the charger.
The battery can be charged at any level of charge. Interrupting the charging process does not damage the battery pack.
The battery pack is equipped with a temperature control indicator, which enables charging only within a temperature
range between 32 °F and 104 °F.
When the battery pack is not within the
charging temperature range, three
LEDs of the charge-control indicator 3
flash. Disconnect the battery pack from
the charger until its temperature has adjusted.
CAUTION: Do not connect the battery pack to the
charger until it has reached the permissible charging
temperature.
Charge-control Indicator
When the battery pack is switched on, the five green LEDs
for the charge-control indicator 3 indicate the charge condition of the battery pack.
Here, each LED indicates approx. 20 % capacity. When the
battery pack is completely charged, all five LEDs light up.
The charge-control for the switched on battery pack is also
indicated on the display for the on-board computer. Read
and follow the operating instructions for the drive unit and
the on-board computer.
0 275 U07 XPX | (8.5.17) Bosch eBike Systems
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8
5
6
9
1
2
5
6
7
7°
10
10
When the capacity of the battery pack is below 5 %, all LEDs
for the charge-control indicator 3 on the battery pack turn
off; however, the on-board computer does provide an additional indicator function.
After charging, disconnect the battery from the charger and
the charger from the network.
Using Two Battery Packs for One eBike
(optional)
An eBike can also be equipped with two battery packs by
the manufacturer. In this case, one of the charge sockets is
not accessible or is sealed by the eBike manufacturer with
a sealing cap. Charge the battery packs only at the
accessible charge socket.
Never open charge sockets that have been sealed by
the manufacturer. Charging at a previously sealed
charge socket can lead to irreparable damage.
If you have an eBike that is designed for two battery packs
and you want to use it with only one battery pack, cover off
the contacts of the unused socket using the cover lid 10
provided because otherwise the open contacts pose a risk
of short-circuiting.
Inserting and removing the battery pack
Charging with Two Battery Packs Inserted
If two battery packs are mounted on one eBike, both battery packs can be charged using the unsealed connection.
The charging process will charge both battery packs alternately, automatically switching between both battery
packs numerous times. The charging times add up.
Both battery packs are also discharged alternately during
operation.
If you take the battery packs out of the holders, you can
charge each battery pack individually.
Always switch off the battery pack and the eBike
system when you insert the battery pack into the
holder or when you take it out of the holder.
In order for the battery pack to be inserted, the key 5 must
Charging with One Battery Pack Inserted
If only one battery pack is inserted, then you can charge
only the battery pack that has the accessible charge socket
on the bike. You can charge the battery pack with the
sealed charge socket only when you take the battery pack
out of the holder.
be inserted into the lock 6 and the lock must be unlocked.
To insert the standard battery pack 8, place it with the
contacts on the lower holder 9 on the eBike (the battery
pack can be inclined up to 7° to the frame). Tilt it into the
upper holder 7 until it engages.
To insert the rack-type battery pack 2, slide it with the
contacts facing ahead until it engages in the holder 1 of the
rear rack/carrier.
Always check that the battery pack is locked in
place. To do this, pull on the battery pack handle (after
the key has been removed).
Check if the battery pack is tightly seated. Always lock the
battery pack with lock 6; otherwise the lock can open and
the battery pack could fall out of the holder.
Bosch eBike Systems 0 275 U07 XPX | (8.5.17)
English–9
WARNING
WARNING
After locking, always remove the key 5 from the lock 6. This
prevents the key from falling out and the battery pack from
being removed by unauthorized persons when the eBike is
parked.
To remove the standard battery pack 8, switch it off and
unlock the lock with the key 5. Tilt the battery pack out of
the upper holder 7 and pull it out of the lower holder 9.
To remove the rack-type battery pack 2, switch it off and
unlock the lock with the key 5. Pull the battery pack out of
the holder 1.
Operation
Initial Operation
Use only original Bosch battery packs approved for
your eBike by the manufacturer and purchased from
a trusted source. Use of non-approved or counterfeit
battery packs can lead to death or serious injury.
Switching On and Off
Switching the battery pack on is one of the ways of starting
the eBike system. Read and follow the operating instructions for the drive unit and the on-board computer.
Before switching on the battery pack or the eBike system,
check that the lock 6 is locked.
To switch on the battery pack, press the On/Off button 4.
The LEDs for indicator 3 light up and, at the same time,
indicate the charge condition.
Always check that the battery pack is locked in
place. To do this, pull on the battery pack handle (after
the key has been removed).
Note: When the battery pack capacity is below 5 %, none of
the LEDs for charge-control indicator 3 will light up. Only
the on-board computer will indicate if the eBike system is
switched on.
To switch off the battery pack, press the On/Off button 4
again. The LEDs for indicator 3 go out. This also switches
off the eBike system.
When no power output from the eBike drive unit is requested for approx. 10 minutes (e. g., because the eBike is
parked) and no button for the drive on-board computer or
operating unit is pressed, then the eBike system, and thus
the battery pack, automatically switches off to save energy.
The battery pack is protected against deep discharging,
overcharging, overheating and short-circuiting by the
“Electronic Cell Protection (ECP)”. In case of hazardous
situations, a protective circuit automatically switches off
the battery pack.
When a defect in the battery pack is detected, two LEDs for the charge-control
indicator 3 flash. In this case, please
contact an authorized Bosch eBike
dealer.
Transport
Always remove the battery pack from the bicycle be-
fore transporting the bicycle on a vehicle bike rack.
Failure to remove the battery pack when using a vehicle
bike rack can lead to death or serious injury. The battery
may detach during transport and cause an accident to
following vehicles.
Always use an approved and compatible bicycle rack
when transporting your eBike. The Bosch Drive System adds weight to the bicycle. Refer to your bicycle
rack manual to be sure your eBike is compatible. Overloading a bike rack can result in death or serious injury.
Use proper lifting techniques because electric bikes
are generally heavier than bicycles.
Ship batteries only when the housings are undamaged.
Tape or mask off open contacts and pack up the battery in
such a way that it cannot move around in the packaging.
Notify your parcel service that the package contains
dangerous goods. Please also follow possibly more detailed national regulations. Always check the state and
federal regulations before attempting to ship your battery.
In case of questions concerning transport of the battery
packs, please contact an authorized Bosch eBike dealer.
Bosch eBike dealers can also provide suitable transport
packaging.
Maintenance/Cleaning
Do not open any of the components. Service should
only be carried out at an authorized Bosch eBike
dealer. Failure to follow the above warning may result in
death or serious injury. Refer to your bicycle manual or
component manual for all non-Bosch Drive System components.
Always remove the battery pack before performing
any bicycle inspection, maintenance or repair.
Failure to remove the battery pack before performing
bicycle inspection, maintenance or repair can lead to
serious injury.
0 275 U07 XPX | (8.5.17) Bosch eBike Systems
English–10
If replacing your battery, only buy a genuine Bosch
battery pack from an approved source. See your
Bosch eBike dealer for original Bosch parts.
Always switch the battery pack off when inserting or
removing it from the holder. Never attempt to insert or
remove the battery pack while riding the bike.
Do not charge or use your eBike in any area with a
potentially explosive atmosphere, such as at a fueling area, or in areas where the air contains chemicals
or particles (such as grain, dust, or metal powders).
Obey all signs and follow all instructions.
Do not submerge your eBike components in water,
or wash with pressurized hose. Your Bosch battery is
designed to be water tight to rain water or non-pressure
hose washing.
Note down the manufacturer and the number of the
key. In case the keys are lost, please contact an autho-
rized Bosch eBike dealer. Please provide the name of
the manufacturer and the number of the key.
Do not paint any components of the Bosch Drive
System as this may cause premature failure of the
components.
After Sale Service and Customer Assistance
In case of questions concerning the eBike system and its
components, please contact an authorized Bosch eBike
dealer.
Contact data for authorized Bosch eBike dealers can be
found at www.bosch-ebike.com
When the battery pack is no longer operative, please
contact an authorized Bosch eBike dealer.
Cleaning
Do not submerge your eBike components in water,
or wash with pressurized hose. Your Bosch battery is
designed to be water tight to rain water or non-pressure
hose washing.
Keep all components of your eBike clean, especially the
battery pack contacts and the corresponding holder
contacts.
All components including the drive unit may not be
immersed in water or cleaned with a high-pressure cleaner.
Clean them carefully with a soft, damp cloth (using only
mild soap and water).
Storing
Notes for Optimum Handling of the
Battery Pack
The battery pack life can be extended if properly maintained and especially if operated and stored at the right
temperatures.
With increasing age, however, the battery pack capacity
will diminish, even if properly maintained.
A significantly reduced operating period after charging
indicates that the battery pack is worn out and must be replaced. You can replace it yourself by purchasing a genuine
Bosch PowerPack from an authorized Bosch eBike dealer.
Recharging the Battery Pack Before and During Storage
When not using the battery pack for a longer period, charge
it to approx. 60 % (3 to 4 LEDs lit on the charge-control
indicator 3).
Check the charge condition after 6 months. When only one
LED on the charge-control indicator 3 lights up, recharge
the battery pack again to approx. 60 %.
Note: When the battery pack is stored discharged (empty)
for longer periods, it can become damaged despite the low
self-discharging feature, and the battery pack capacity may
be strongly reduced.
It is not recommended to have the battery pack connected
permanently to the charger.
Storage Conditions
Store the battery pack in a dry, well-ventilated location.
Protect the battery pack against moisture and water. Under
unfavorable weather conditions, it is recommended e. g.,
to remove the battery pack from the eBike and store it in an
enclosed location until it is used again.
Store the eBike batteries in the following locations:
– in a room with a smoke alarm
– away from combustible or easily flammable objects
– away from heat sources
Store the batteries at temperatures between 0 °C and
20 °C. Never store them at temperatures below – 10 ° C or
above +60 °C. To ensure that the lifetime is as long as
possible, storage at approx. 20 °C (room temperature) is
recommended.
Make sure that the maximum storage temperature is not exceeded. As an example, store the battery pack out of direct
sunlight and do not leave it in a vehicle during the summer.
It is recommended to not store the battery pack on the bike.
Bosch eBike Systems 0 275 U07 XPX | (8.5.17)
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Troubleshooting
Cause Corrective Action
Two LEDs of the battery pack flashing
Battery pack defective Contact an authorized bicycle dealer.
Three LEDs of the battery pack flashing
Battery pack too warm or too cold Disconnect the battery from the charger until the charging
temperature range has been reached.
Do not connect the battery pack to the charger until it has reached
the permissible charging temperature.
No LED flashes (one or more LEDs light up continuously
depending on the charging state of the eBike battery pack).
The charger is not charging. Contact an authorized bicycle dealer.
No charging procedure possible (no indication on the battery pack)
Plug not inserted correctly Check all plug connections
Contacts of battery pack dirty Carefully clean the contacts on the battery pack.
Socket outlet, cable or charger defective Check household voltage; have charger checked through bicycle
dealer
Battery pack defective Contact an authorized bicycle dealer.
0 275 U07 XPX | (8.5.17) Bosch eBike Systems
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