AVE TH5 User manual

Version 1.0 Doc. DE2013-01-15PW
Original
Operating Manual
for ave. Hybrid bikes with Bosch technology
Fit for 2013
ave. TH5, TH7, TH9, TH11
ave. SH5, SH9
ave. XH3, XH5, XH7, XH9
ave. MH eTown, MH7

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Note: This manual is based on the requirements for technical documentation of the European
standard EN 62079, Machinery Directive 2004/108/EC and DIN 6789. Hazards and risks that
may result from improper use of the products or errors are marked separately. Please read the
sections marked by a warning triangle with particular care.
Manufacturer:
deVELOpment engineering GmbH
Steinhausen 20
D-85625 Glonn (Germany)
Tel [phone]
Fax [phone]
eMail [email protected]
URL www.ave-bikes.de
© Copyright deVELOpment engineering GmbH, Germany
Printing errors, mistakes and technical changes reserved
Status 1/2013

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Content
Introduction ………………………………………………………………… 4
Models, application areas .........……………………………………. 5
Hybrid functions, risks …………………................................... 22
Your ave. Hybrid bike ……………………………………………………. 24
Content of package ……………………………………………………….. 27
Assembly .…………………………………………………………………….. 28
Commissioning and operating …………...............……………… 31
Error checking .………………….......................…………………….. 41
Instructions for driving …………………………………………………… 42
Battery charging, maintain .…………………………………………… 45
Battery store, disposal ………….………………………………………. 50
Complete equipment, risks ………………………………………….. 52
Brakes, gear, fork /damper, wheels, lighting, protection etc.
Safety advices for battery, charger, motor ………………………….. 68
Guarantee, warranty, …………..………………………………………… 69
Final check …………………………………………………………………….. 70
Annex: Identity tag …………………………………………………………………. 71
EC declaration of conformity ………………………………………… 72
Abbreviations ……………………………………………………………….. 73
Notes ……………………………………………………………………………. 74
Source: Data and images of the Bosch mechatronic system are included in this manual with consent
from Bosch eBike Systems, Reutlingen

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Introduction
Congratulations on your purchase of an ave. Hybrid bicycle!
Your ave. Hybrid bike (pronounced ‘a-v-e’ advanced vehicle engineering) combines your own
performance with electric motor assistance - that's ‘hybrid’.
It is a pedal assisted electric cycle (Pedelec), this means power is only delivered whilst the rider
is cycling (ie pushing the pedals), up to a speed of 25 km/h or 15 mph. The extra electric power
increases your own driving force by 30 % up to 250 %. You will benefit from this ‘tailwind
support’ whenever you want, to master difficult routes, climb up the hills or run off-road.
We want to help you, to have enjoyable rides for long, therefore you should read these
operating manual carefully. When you start the first time, a few preparations have to be done.
Then follow the recommendations for riding, maintaining and keeping the safety guidelines.
And now, enjoy a ‘21th century biking’ exercise!
Your ave. team
This operating manual applies to all ave. Hybrid bikes with Bosch drives of the series Touring
(TH5, TH7, TH9, TH11), Sports (SH7, SH9), Off-Road/Xtreme (XH3, XH5, XH7, XH9) and Mobility
(MH eTown, MH7) models
IMPORTANT: Before first use, the Hybrid bike should be finally assembled and tested by an
authorized ave. dealer!
IMPORTANT: Please read the operating instructions carefully, before you start riding. Follow
the recommendations - step by step - to ensure correct operations/ functioning.
IMPORTANT: Your Hybrid bike is equipped with a modern high-performance battery. This
requires a small but regular care (see section "battery maintain").
If there are still questions open, please feel free to get in contact with your local ave. dealer or
the manufacturer by eMail: [email protected]

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Models, application areas
Touring bikes
The T-series is designed for use on trips and tours. The bicycles with electric support are fully
equipped according to the Highway Code and travel on land, in urban environment and the city
on paved roads, squares and streets, where allowed.
Touring Hybrid TH11 (MAN)
Technical data
Design MAN COMFORT LOW ENTRY
Frame
Alu 6061T6; COMFORT: 3D forged BOSCH motor mount; MAN: EMI motor mount
Frame height
LOW ENTRY: 26 inch x 46 cm, 28 inch x 52 cm/ x 58 cm; COMFORT: 26 inch x 46 cm, 28 inch x 52 cm;
MAN: 26 inch x 52 cm, 28 inch x 56 cm, 28 inch x 60 cm
Fork
Suspension fork SR Suntour NCX E/S LO Lite, 63 mm travel, air system, hydraulic speed lock
Handlebar
ave. Touring, aluminium
Headset/ stem
1 1/8“ Ahead, semi-integrated
Kalloy alu, double clamp, 33 degrees adjustable, LtSS “length to size system”

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Gear
Automatic 360 % NuVinci N360 Harmony (electronic hub gear)
Brakes
Shimano Alfine hydraulic disc brake, 180mm
Tires
Schwalbe Marathon PLUS, 47 mm, flat protection 6, black reflective
Hubs
Front KT power dynamo, rear NuVinci Harmony advanced
Saddle/ seatpost
ave. ergotec comfort GEL, double density, Arctec, zonecut; Alu patent 27,2 mm
Carrier/stand
CAB premium edition Hebie system; comfort flex Hebie fix40
Weight
MAN 26,5 kg
Electric drive
Bosch center drive 36 V, rated power 250 W, torque 50 Nm, sensor control
Operating computer
Bosch Intuvia, lighted display, remote control, USB loading, removable, mobile operations
Battery
Bosch lithium-ion accumulator 36 V, 400 Wh, battery lock,charger 220 V~
Lighting
KT Power hub dynamo 6V, Busch & Müller LED front light Lumotec Lyt T senso plus 30 lux, LED rear light Linetec,
daylight and parking light function
Specials
Push assistance by drive unit up to 5,5 km/h, automatic drive stop
Touring Hybrid TH9 (LOW ENTRY)

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Technical data
Design LOW ENTRY MAN COMFORT
Frame
Alu 6061T6; COMFORT: 3D forged BOSCH motor mount; MAN: EMI motor mount
Frame height
LOW ENTRY: 26 inch x 46 cm, 28 inch x 52 cm/ x 58 cm; COMFORT: 26 inch x 46 cm, 28 inch x 52 cm;
MAN: 26 inch x 52 cm, 28 inch x 56 cm, 28 inch x 60 cm
Fork
Suspension fork SR Suntour NCX E/S LO Lite, 63 mm travel, air system, hydraulic speed lock
Handlebar
ave. Touring, aluminium
Headset/ stem
1 1/8“ Ahead, semi-integrated
Kalloy alu, double clamp, 33 degrees adjustable, LtSS „length to size system”
Gear
Automatic 360 % NuVinci N360 Harmony (electronic hub gear)
Brakes
Shimano Alfine hydraulic disk brake, 180mm
Tires
Schwalbe Marathon greenguard 47 mm, flat protection 5, black reflective
Hubs
Front Shimano dynamo with quick hub release, rear NuVinci Harmony N360
Saddle/ seatpost
ave. ergotec comfort GEL, double density, Arctec, zonecut; alu patent 27,2 mm
Carrier/ stand
Aluminium tri tubing ave. design with spring flap; Hebie fix40
Weight
LOW ENTRY 26,2 kg
Electric drive
Bosch center drive 36 V, rated power 250 W, torque 50 Nm, sensor control
Operating computer
Bosch Intuvia, lighted display, remote control, USB loading, removable, mobile operations
Battery
Bosch lithium-ion accumulator 36 V, 400 Wh, battery lock,charger 220 V~
Lighting
Shimano hub dynamo 6V, Busch & Müller LED front light Lumotec Lyt T senso plus 30 lux, LED rear light Linetec
plus, daylight and parking light function
Specials
Push assistance by drive unit up to 5,5 km/h, automatic drive stop

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Touring Hybrid TH7 (LOW ENTRY)
Technical data
Design LOW ENTRY
Frame
Alu 6061T6, 3D forged BOSCH motor mount
Frame height
LOW ENTRY: 26 inch x 46 cm, 28 inch x 52 cm/ x 58 cm
Fork
Suspension fork SR Suntour NEX HLO, 63 mm travel, lockout
Handlebar
ave. City comfort, aluminium
Headset/ stem
1 1/8“ thread, semi-integrated; ave. alu, trekking adjust, LtSS “length to size system”;
Gear
Shimano Nexus 8g, 308 % hub gear
Brakes
Magura HS 11 hydraulic rim brakes
Tires
Schwalbe Marathon greenguard 47 mm, flat protection 5, black reflective
Hubs
Front Shimano hub dynamo, rear Shimano Nexus 8
Saddel/ seatpost
ave. ergotec comfort, double density, Arctec, zonecut; alu patent 27,2 mm

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Carrier/ stand
Aluminium Tri tubing ave. design with spring flap; Hebie fix40
Weight
LOW ENTRY 27,1 kg
Electric drive
Bosch center drive 36 V, rated power 250 W, torque 50 Nm, sensor control
Operating computer
Bosch Intuvia, lighted display, remote control, USB loading, removable, mobile operations
Battery
Bosch lithium-ion accumulator 36 V, 300 Wh, battery lock,charger 220 V~
Lighting
Shimano hub dynamo 6V, Busch & Müller LED front light Lumotec Lyt N plus 25 lux, LED rear light Toplight Flat S
plus, with parking light function
Specials
Push assistance by drive unit up to 5,5 km/h, automatic drive stop
Touring Hybrid TH5 (LOW ENTRY)
Technical data
Design LOW ENTRY
Frame
Alu 6061 T6, ave. enforced BOSCH motor mount

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Frame height
LOW ENTRY: 26 inch x 46 cm, 28 inch x 52 cm/ x 58 cm
Fork
Suspension fork SR Suntour CR 8V, 50 mm Elastomer
Handlebar
ave. Touring, aluminium
Headset/ stem
1 1/8“ thread, semi-integrated; ave. alu, trekking adjust, LtSS “length to size system”;
Gear
Shimano Nexus 7g, 246 % hub gear
Brakes
Shimano V-brake
Tires
Schwalbe Energizer PLUS, 47 mm, flat protection 4, black reflective
Hubs
Front Shimano hub dynamo, rear Shimano Nexus 7
Saddle/ seatpost
ave. ergotec comfort, double density, Arctec, zonecut; alu patent 27,2 mm
Carrier/ stand
Aluminium tri tubing ave. design with spring flap; Hebie fix40
Weight
LOW ENTRY 27 kg
Electric drive
Bosch center drive 36 V, rated power 250 W, torque 50 Nm, sensor control
Operating computer
Bosch Intuvia, lighted display, remote control, USB loading, removable, mobile operations
Battery
Bosch lithium-ion accumulator 36 V, 300 Wh, battery lock,charger 220 V~
Lighting
Shimano hub dynamo 6V, Busch & Müller LED front light Lumotec Lyt BN plus 15 lux, LED rear light Toplight Flat
plus with parking light function
Specials
Push assistance by drive unit up to 5,5 km/h, automatic drive stop
Sports bikes
The S-series is reduced in weight by applying lightweight material. Therefore it is especially
suitable for sports use. One model is fully equipped according to the Highway Code and usable
for trips and speed travel on land, in urban environment and city areas, on all paved roads,
squares, streets, where allowed.
The lighter model without Highway Code equipment is meant for driving off-road, on private
land, sports and leisure facilities.

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Sport Hybrid SH9 (COMFORT)
Technical data
Design COMFORT MAN
Frame
Alu 6061T6; COMFORT: 3D forged BOSCH motor mount; MAN: EMI motor mount
Frame height
COMFORT: 26 inch x 46 cm, 28 inch x 52 cm; MAN: 26 inch x 52 cm, 28 inch x 56 cm, 28 inch x 60 cm
Fork
Suspension fork SR Suntour NCX E/S LO lite, 63 mm travel, air system, hydraulic speed lock
Handlebar
ave. Sport rizer, aluminium (oversize)
Headset/ stem
1 1/8“ Ahead, semi-integrated; ave. 3D forged, Ahead double clamp, LtSS” length to size system”;
Gear
SRAM Dualdrive 3x9, 27g, 576%
Brakes
TEKTRO Draco hydraulic disk brake, 180 mm
Tires
Schwalbe Smart Sam, 42 mm, black reflective
Hubs
Front KT power dynamo, rear SRAM Dualdrive 3 x 9
Saddle/ seatpost
ave. ergotec SuperSport, double density, Arctec, zone cut; alu patent 27,2 mm

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Carrier/ stand
Hebie system carrier; Hebie fix40
Weight
COMFORT 24,9 kg
Electric drive
Bosch center drive 36 V, rated power 250 W, torque 50 Nm, sensor control
Operating computer
Bosch Intuvia, lighted display, remote control, USB loading, removable, mobile operations
Battery
Bosch lithium-ion accumulator 36 V, 400 Wh, battery lock,charger 220 V~
Lighting
KT power dynamo 6V, Busch & Müller LED front light Lumotec Lyt T senso plus 30 lux, LED rear light Linetec Plus,
daylight and parking light function
Specials
Push assistance by drive unit up to 5,5 km/h, automatic drive stop
Sport Hybrid SH5 (MAN)
Technical data
Design MAN
Frame
Alu 6061T6; MAN: EMI motor mount

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Frame height
MAN: 26 inch x 52 cm, 28 inch x 56 cm, 28 inch x 60 cm
Fork
Suspension fork SR Suntour NCX D LO lite, 63 mm travel, coil spring, hydraulic speed lock
Handlebar
ave. Sport rizer, aluminium (oversize)
Headset/ stem
1 1/8“ Ahead, semi-integrated; ave. 3D forged, Ahead double clamp, LtSS” length to size system”
Gear
Shimano Deore 10g, 327 %
Brakes
TEKTRO Draco hydraulic disc brake, 180 mm
Tires
Schwalbe Energizer PLUS, 47 mm, black reflective
Hubs
Front Shimano, rear Shimano Deore Disc 10 speed
Saddle/ seatpost
ave. ergotec Sport, double density, Arctec, starcut; alu patent 27,2 mm
Stand
Hebie fix40
Weight
MAN 21,7 kg
Electric drive
Bosch center drive 36 V, rated power 250 W, torque 50 Nm, sensor control
Operating computer
Bosch Intuvia, lighted display, remote control, USB loading, removable, mobile operations
Battery
Bosch lithium-ion accumulator 36 V, 300 Wh, battery lock,charger 220 V~
Specials
Push assistance by drive unit up to 5,5 km/h, automatic drive stop
Offroad/ Xtreme ‘all terrain bikes’
The X-series is designed for off-road, all-terrain use. An optimized ground clearance, highly
stable frames and suspension systems allow effective sports riding.
Hiking trails in fields, forests, meadows, marchland, hills or mountains are typical application
areas - if permitted.
Not intended are jumps, free-riding, down-hill races, dirt jumping and similar applications.

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Xtreme Hybrid XH9 (FULLY)
Technical data
Design MAN
Frame
Alu 6061T6; EMI motor mount (3D forged BOSCH)
Frame height
26 inch x 45 cm, 26 inch x 50 cm
Fork
Suspension fork RockShox Reba RLT, air system, travel 120 mm, thru axle 1.5" tapered
Handlebar
ave. Sport rizer, aluminium (oversize)
Headset/ stem
One.five tapered Ahead, semi-integrated; ave. 3D forged, Ahead double clamp, LtSS” length to size system”
Gear
Shimano Deore XT 10sp, 10g, 327 %
Brakes
Shimano XT hydraulic disc brake, 180 mm
Tires
Schwalbe Racing Ralph 2.25", black
Hubs
Front Shimano SLX disc thru axle, rear Shimano SLX disc 10 speed
Saddle/ seatpost
ave. ergotec SuperSport, double density, Arctec, zone cut; alu patent 30,0 mm rigid race
Rear suspension
Damper RockShox Monarch RT3 active single pivot, 120 mm, adjustable, lockout

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Weight
21,8 kg
Electric drive
Bosch center drive 36 V, rated power 250 W, torque 50 Nm, sensor control
Operating computer
Bosch Intuvia, lighted display, remote control, USB loading, removable, mobile operations
Battery
Bosch lithium-ion accumulator 36 V, 400 Wh, battery lock,charger 220 V~
Specials
Push assistance by drive unit up to 5,5 km/h, automatic drive stop
Xtreme Hybrid XH7 (FULLY)
Technical data
Design MAN
Frame
Alu 6061T6; EMI motor mount (3D forged BOSCH)
Frame height
26 inch x 45 cm, 26 inch x 50 cm
Fork
Suspension fork RockShox Recon silver TK, solo air, travel 120 mm, thru axle 1.5" tapered
Handlebar
ave. Sport rizer, aluminium (oversize)
Headset/ stem
One.five tapered Ahead, semi-integrated; ave. 3D forged, Ahead double clamp, LtSS” length to size system”;

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Gear
Shimano SLX 10sp, 10g, 327 %
Brakes
Shimano SLX hydraulic disc brake, 180 mm
Tires
Schwalbe Rapid Rob 2.25", black
Hubs
Front KT-MF 1,15 mm thru axle, Shimano Deore disc, 10 speed
Saddle/ seatpost
ave. ergotec SuperSport, double density, Arctec, starcut; alu patent 30,0 mm rigid race
Rear suspension
Damper RockShox Monarch R active single pivot, 120 mm, adjustable, lockout
Weight
20,7 kg
Electric drive
Bosch center drive 36 V, rated power 250 W, torque 50 Nm, sensor control
Operating computer
Bosch Intuvia, lighted display, remote control, USB loading, removable, mobile operations
Battery
Bosch lithium-ion accumulator 36 V, 300 Wh, battery lock,charger 220 V~
Specials
Push assistance by drive unit up to 5,5 km/h, automatic drive stop
Xtreme Hybrid XH5 (HARDTAIL 29”)

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Technical data
Design MAN
Frame
Alu 6061T6; EMI motor mount (3D forged BOSCH)
Frame height
26 inch x 40 cm, 26 inch x 45 cm, 26 inch x 50 cm; 29 inch x 50 cm, 29 inch x 55 cm
Fork
Suspension fork RockShox Reba RTL, travel 120 mm, thru axle 1.5" tapered
Handlebar
ave. Sport rizer, aluminium (oversize)
Headset/ stem
One.five tapered Ahead, semi integrated; ave. 3D forged, Ahead double clamp, LtSS” length to size system”;
Gear
Shimano XT 10sp, 10g, 327 %
Brakes
Shimano XT hydraulic disc brake, 180 mm
Tires
Schwalbe Racing Ralph, 2.25”, black
Hubs
Front Shimano SLX disc thru axle, Shimano rear SLX disc 10 speed
Saddle/ seatpost
ave. ergotec SuperSport, double density, Arctec, zonecut; alu patent 30,0 mm rigid race
Weight
20,4 kg
Electric drive
Bosch center drive 36 V, rated power 250 W, torque 50 Nm, sensor control
Operating computer
Bosch Intuvia, lighted display, remote control, USB loading, removable, mobile operations
Battery
Bosch lithium-ion accumulator 36 V, 400 Wh, battery lock,charger 220 V~
Specials
Push assistance by drive unit up to 5,5 km/h, automatic drive stop
Xtreme Hybrid XH3 (HARDTAIL)
Technical data
Design MAN
Frame
Alu 6061T6; EMI motor mount (3D forged BOSCH)
Frame height
26 inch x 40 cm, 26 inch x 45 cm, 26 inch x 50 cm; 29 inch x 50 cm, 29 inch x 55 cm
Fork
Suspension fork RockShox Recon silver TK, solo air, travel 120 mm, thru axle 1.5" tapered

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Handlebar
ave. Sport rizer, aluminium (oversize)
Headset/ stem
One.five tapered Ahead, semi integrated; ave. 3D forged, Ahead double clamp, LtSS” length to size system”
Gear
Shimano SLX 10sp, 10g, 327 %
Brakes
Shimano SLX hydraulic disc brake, 180 mm
Tires
Schwalbe Rapid Rob, 2.25", black
Hubs
Front KT-MF 1,15 mm thru axle, rear Shimano Deore disc 10 speed
Saddle/ seatpost
ave. ergotec Sport, double density, Arctec, starcut; alu patent 30 mm, rigid race
Stand
Hebie fix40
Weight
MAN 21,2 kg
Electric drive
Bosch center drive 36 V, rated power 250 W, torque 50 Nm, sensor control
Operating computer
Bosch Intuvia, lighted display, remote control, USB loading, removable, mobile operations
Battery
Bosch lithium-ion accumulator 36 V, 300 Wh, battery lock,charger 220 V~
Specials
Push assistance by drive unit up to 5,5 km/h, automatic drive stop

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E-Mobility
The E-series is designed compact, lightweight and portable. The bikes are fully equipped
according to the Highway Code and ready for use in cities and urban areas on streets, squares
and solid paths, where permitted.
Mobility Hybrid MH7 (COMPACT, DELIGHT)
Technical data
Design COMPACT
Frame
Alu 6061; E-specific for Bosch center drive
Frame height
20 inch x 40 cm
Fork
Aluminium wide body, gentle rigid
Handlebar
ave. Sport rizer, aluminium (oversize)
Headset/ stem
1 1/8“ Ahead, semi-integrated; ave. compact folding, self-locking stem
Gear
Shimano Deore 10sp, 10g, 327 %
Brakes
TEKTRO Draco hydraulic disc brake, 180 mm

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Tires
Schwalbe Big Apple, 55 mm, black reflective
Hubs
Front KT power dynamo, rear Shimano Deore disc 10 speed
Saddle/ seatpost
ave. ergotec Sport, double density, Arctec, starcut; alu patent 34,9 mm XXL
Carrier/ stand
Aluminium round tubing, compact design with spring flap; Hebie
Weight
23,9 kg
Electric drive
Bosch center drive 36 V, rated power 250 W, torque 50 Nm, sensor control
Operating computer
Bosch Intuvia, lighted display, remote control, USB loading, removable, mobile operations
Battery
Bosch lithium-ion accumulator 36 V, 300 Wh, battery lock,charger 220 V~
Lighting
KT power dynamo 6V, Busch & Müller LED front light Lumotec Lyt N plus 25 lux, LED rear light Toplight Mini, with
parking light function
Specials
Push assistance by drive unit up to 5,5 km/h, automatic drive stop
Compact design
The MH7 model, with its compact design and low weight, is ideal for use in combination with
other means of transportation (e-mobility). The folding handlebar stem (semi-folder) and a
widely adjustable saddle allow small a package size of approx. L 160 x H 95 x D 40 cm.
Thus, MH7 can easily be transported in a car trunk, caravan, train compartment or to be carried
down and parked in the basement.