Cannondale E-BIKE User Manual

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CONTENTS

Safety Information ..................................... 2

Intended Use ............................................................... 2

Battery & Charger ....................................................... 3

Rack & Kickstand ......................................................... 3

Parts of the E-Series Bike .............................. 4

Frame ......................................................................... 4

BOSCH Drive Unit ........................................................ 5

BOSCH Handlebar

Mounted Interface (HMI) ............................................6

BOSCH Speed Sensor ................................................... 6

BOSCH Battery Pack .................................................... 8

BOSCH Charger ............................................................ 9

Operation Instructions ............................... 10

Turning the System ON/O .......................................10

Lighting ....................................................................10

Trip Information ........................................................ 10

Selecting Assistance Mode/Support Level ................. 11

Factors Aect Assistance Range ................................12

Error Codes ................................................................ 12

Keys ..........................................................................13

Headshok Suspension Fork ......................... 14

Maintenance ............................................ 16

Cleaning.................................................................... 17

Tightening Torques ................................................... 17

Geometry .................................................. 18

About This Supplement

Cannondale Owner’s Manual Supplements provide important model specic safety, maintenance, and technical information. They are not replacements for your Cannondale Bicycle Owner’s Manual.

This supplement may be one of several for your bike. Be sure to obtain and read all of them.

If you need a manual or supplement, or have a question about your bike, please contact your Cannondale Dealer immediately, or call us at one of the telephone numbers listed on the back cover of this manual.

You can download Adobe Acrobat PDF versions of any Cannondale Owner’s Manuals or Supplements from our website: http://www.cannondale.com/.

Online E-Series Product Support

You may download a copy of this supplement and other manuals and instructions available for your bike at : http://www.cannondale.com/support-ebike

Your Cannondale Dealer

To make sure your bike is serviced and maintained correctly, and that you protect applicable warranties, please coordinate all service and maintenance through your authorized Cannondale Dealer.

NOTICE

Unauthorized service, maintenance, or repair parts can result in serious damage and void your warranty.

Specications ............................................ 19

Replacement Parts .................................... 20

This bike complies with EN 15194 Electrically Power Assisted Cycles (EPAC).

02/11

SAFETY INFORMATION

Intended Use

ASTM F2043

ASTM CONDITION 2, General Purpose Riding.

For o-road

riding and

jumps less than

12” (30cm)

Your E-Series bike has an electric pedal assist drive system. It is not a moped or motorcycle. In EU contries, it is known legally as an “EPAC” cycle or Electrically Powered Assisted Cycle.

The drive assist system consists of a drive unit, a battery, a computer control, and various electronic components (harness wires, sensors, and switches). Your E-Series bike does share components common with pedal-only bikes. See Figure 1.

It is important to know that when the assist system is turned ON, the drive unit enages to provide power only while you are pedaling. The amount of power provided by the drive unit depends on your pedaling force and the assistance mode/level you set with the handlebar control unit. At anytime, if you stop pedaling, the drive assist will dis-engage. In all modes/ levels, the drive assist system power reduces progressively and cuts o as the bike reaches a speed of 25 km/h, (15.5 mph) , or sooner if you stop pedaling. The drive assist re-enages when speed drops below 25 km/h, (15.5 mph) as long as the pedals are turning.

Whenever the drive assist system is turned OFF, You can pedal the bike normally. The drive system will not engage.

WARNING

INTENDED USE: This bicycle is intended to be used

as a commuter bicycle. This bike complies with the requirements of European Standard EN 15194, Electrically Power Assisted Cycles. The drive assist system is limited to a maximum continuous power rating of 0,25 kW (250 W) and a maximum speed of 25Km/h, (15.5 mph).

NOT INTENDED: You must not ride this bike in automobile trac lanes. This vehicle must only be operated on paved surfaces that are legally open to commuter pedal bicycles. This bike is not for mountain biking use, jumping, or racing.

YOU MUST FOLLOW ALL LOCAL LAWS: It is your responsibility to identify and follow all local laws and regulations (including tting your bike with additional equipment) necessary to comply with local laws. Ask your Cannondale Dealer for more information about operating an electrically assited pedal bicycle in your area.

DO NOT MODIFY THIS BICYCLE/FORK IN ANY WAY FOR ANY REASON. Doing so can result in severe damage,

faulty or dangerous operating conditions, or violation of local laws.

IMPORTANCE OF PRACTICE & RIDER TRAINING -

Before you ride this bike, practice riding in a safe area free from hazards. Take time to learn to bike’s controls and performance. Practice the controls and gain the experience necessary to avoid the many hazards you will encounter while riding.

UNDERSTAND YOUR BIKE AND ITS INTENDED USE. USING YOUR BIKE THE WRONG WAY IS DANGEROUS.

Please read your Cannondale Bicycle Owner’s Manual for more information about Intended Use and Conditions 1-5

YOU CAN BE YOU SERIOUSLY INJURED, PARALYZED OR KILLED IF YOU IGNORE THESE WARNINGS.

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Battery & Charger

WARNING

BOSCH INSTRUCTIONS - In addition to this supplement,

you must read and follow the BOSCH battery and charger. instructions. Go to : http://www.cannondale.com/ support-ebike

REPLACEMENT - Only use the battery pack and charger indicated in the Specications section of this supplement. Do not use other batteries or chargers. Do not use the charger to charge other batteries.

PREVENT DAMAGE - Do not drop the battery or charger. Do not open or modify the battery or charger. No user servicable parts inside.

Keep the battery out of intense sunlight. Keep away from heat. Heat will damage the battery.

Keep battery away from paper clips, coins, keys, nails, screws or other small metal items, to prevent shorting exposed battery contacts. Shorting battery contacts can cause severe burns, re, or explosion.

ACCIDENTAL ACTIVIATION - Always remove battery from bike rack before working on the bicycle or if you transport the bike by car or plane. Accidentalactivation of the bicycle drive system can result in serious injury.

STORAGE & TRANSPORTATION - When the battery is not in use in the bicycle, its transportation is subject to hazardous materials regulation. Special packaging and labeling requirements may exist. Contact local authorities for specic requirements. Never transport a damaged battery. Insulate battery contacts before packaging. Package battery inside shipping container to prevent damage.

CHARGING - Remove battery from bike before charging. Bring indoors and allow to reach room temperature before charging. Make sure charger and A/C outlet are the same voltage.

Locate both charger and battery indoors, in a clean, dry area with good ventilation to charge. Make sure the area is free from combustibles to avoid re from sparks or overheating. Keep charger ventilation openings unobstructed. Do not cover the charger.

Disconnect the battery from the charger unit when fully charged. Do not leave a fully charged battery connected to the charger. Unplug the charger from the wall outlet when not in use.

DISPOSAL- Battery pack/charger contain regulated materials and must be disposed/discarded in accordance with national and/or local laws. Do not discard the battery/ charger into re, water or ordinary household waste/ garbage. Take to a waste facility/recycler.

Failure to observe these warnings can result in electrical res, explosion, or severe burns or electrocution.

YOU CAN BE YOU SERIOUSLY INJURED, PARALYZED OR KILLED IF YOU IGNORE THESE WARNINGS.

Rear Rack & Kickstand

WARNING

Do not sit on the bicycle with the kickstand down. Kickstand is not designed to support the weight of a person. Make sure kickstand is up before riding.

Do not overload the rear rack. Make sure the cargo is secured properly.

YOU CAN BE YOU SERIOUSLY INJURED, PARALYZED OR KILLED IF YOU IGNORE THESE WARNINGS.

PARTS OF THE ESERIES BIKE

Frame

Figure 1.

1. BOSCH Drive Unit

2. BOSCH Battery

3. BOSCH HMI Unit

4. Headshok Fork

5. Headlight

6. Taillight

7. Rack

8. Chainguard

9. Headshok Stem

10. Lockout Lever

11. Bell

12. Kickstand

13. Rear Wheel Lock

14. Front Brake Lever

15. Rear Brake Lever

16. Rear Shift Control

17. Pedal

18. BOSCH Speed Sensor

19. Rear Cassette

20. Front Chainring

21. Drive chain

22. Crankarm (drive side)

23. Seat Binder

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BOSCH Drive Unit

See Figure 2. The BOSCH drive unit (1) is mounted to the frame bottom bracket node (5). Control cables from the HMI unit,

battery, and speed sensor are routed to the unit inside the frame.

Figure 2.

1. BOSCH Drive Unit (removed)

2. Front Chainring

3. Frame Mounting Bolts

4. ISIS Axle end (non-drive side)

5. Frame BB Node

6. Pedal

7. ISIS Crankarm (drive side)

8. ISIS Crankarm Bolt

NOTICE

Drive unit is maintenance-free and must only be serviced at an authorized service center. This will ensure the quality and safety of the driving unit. Never attempt to open, remove it from the frame, or work on it yourself.

Other components of the eBike drive (e.g. drive chain, front chain ring, rear cassette, rear derailleur, crankarm) must be serviced by your Cannondale Dealer. Replacement parts must be identical to the original Cannondale specication for the bike. See Specications. Failure to replace components with original specication can result in serious overload or other damage to the drive unit.

Unauthorized opening or service of the drive unit will void the warranty.

Please note: The drive unit utilizes an ISIS standard drive axle. While the ISIS crankarms can be removed a reinstalled following crankarm manufacturer’s instructions, the ISIS axle itself can not be removed from the BOSCH drive unit. It must be serviced at an authorized service center.

See also BOSCH Instructions 0 275 007 X00 http://www.cannondale.com/support-ebike

BOSCH Handlebar Mounted Interface (HMI)

See Figure 4. The handlebar mounted interface (HMI) is a cycling computer (1) that enables you to both control the bicycle’s

drive assistance functions as well as turn lighting on and o, and display speed, distance, and display trip several functions. The buttons and display functions/features of the (HMI) are described on the next several pages.

The HMI unit attaches to the handlebar mounting base (2). The base unit should be positioned on the handlebar for convenient use without interference with other bicycle controls. The handlebar position can be changed, however, to avoid damage, this is somethingyour Cannondale Dealer should do for you.

To remove the computer:

When the bicycle is not in use, remove the computer unit (1) from the base (2) to prevent theft. To remove the unit, carefully twist the computer unit counter-clockwise and detach.

To re-install the computer:

Align and mate the tabs on the back of the computer with the corresponding slots in the base unit. Rotate the computer unit clockwise until it clicks into place on the base unit.

NOTICE

The drive system will not function without the computer unit attached to the base properly. If the computer disconnects from the base during operation, the drive system will shut o. If this happens you will have to stop the bike, turn the system o , re-attach the computer to the base, and then turn the system back on to resume.

Remove the computer when not operating the bike to prevent theft or unauthorized use.

The HMI displays the battery charge level (13) continuously as long as the computer is turned ON.

Displayed/ Battery Level (for reference only)

100 - 80% 39-20%

79 - 60% 20 - 5%

59 - 40% 5 - 0%

Figure 3.

BOSCH Speed Sensor

See Figure 4. The BOSCH speed sensor (14) is mounted on the rear chainstay (15). This device must be attached and

functioning properly in order for system to work. If it is damaged, set-up incorrectly, or the magnet (16) is not present on the wheel spoke (17) the drive system and speedometer will not function.

To adjust it’s position, loosen the screw (18 ) on the magnet. Slide the magnet along the spoke to adjust the distance between the magnet and speed sensor. Spin the wheel to check the speed registers on the HMI to ensure the distance is set correctly. Ensure the magnet is facing the speed sensor or it will not function. The maximum working distance (a) is 17mm.

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