Bosch PowerPack 300 User manual

Robert Bosch GmbH
Bosch eBike Systems
72703 Reutlingen
Germany
www.bosch-ebike.com
0 276 001 YYY (2012.10) T / 142
RESET
Drive Unit Cruise | Intuvia |
PowerPack 300 | PowerPack 400 | Charger
0 275 007 006 | 0 275 007 007 | 1 270 020 903 | 0 275 007 500 | 0 275 007 501 |
0 275 007 502 | 0 275 007 503 | 0 275 007 504 | 0 275 007 505 | 0 275 007 905
en Original instructions
OBJ_BUCH-1407-003.book Page 1 Friday, October 12, 2012 12:44 PM

0 276 001 YYY | (12.10.12) Bosch eBike Systems
2|
TURBO
SPORT
TOUR
MPH
KM/H
Reichweite
AMM
PMWH
MIN
MPH
KM/H
RESET
TURBO
SPORT
S
TOUR
MPH
KM/H
Reichweite
AMM
PMWH
MIN
MPH
KM
/H
TURBO
SPORT
TOUR
ECO
OFF
MPH
KM/H
Reichweite
AMM
PMWH
MIN
MPH
KM/H
3
2
1
78
9
c
b
a
e
f
d
6
5
4
OBJ_BUCH-1407-003.book Page 2 Friday, October 12, 2012 1:01 PM

| 3
BoscheBike Systems 0 276 001 YYY | (12.10.12)
ECO
KM/H
Reichweite
KM/H
RESET
ECO
KM/H
Reichweite
KM
/H
17
13
14 11
12
18
5
–
17 mm
10
4
3
15
16
BA
OBJ_BUCH-1407-003.book Page 3 Friday, October 12, 2012 1:01 PM

0 276 001 YYY | (12.10.12) BoscheBike Systems
4|
19
25
26
29
27
28
24
23
24
23
20
22 21
2221
OBJ_BUCH-1407-003.book Page 4 Friday, October 12, 2012 1:01 PM

| 5
BoscheBike Systems 0 276 001 YYY | (12.10.12)
26
23
24
26
28
27
25 24
19
20
23
25 24
23
27
D
C
OBJ_BUCH-1407-003.book Page 5 Friday, October 12, 2012 1:01 PM

0 276 001 YYY | (12.10.12) BoscheBike Systems
6|
For safe operation see manual. Risk of electric shock. Drylocation useonly. Charge onlybatteriesof
the Bosch eBike Systems. Otherbatteriesmayburst causing personal damage. Do not replace the plug
assemblyasrisk of fire or electric shock mayresult.
Para un funcionamiento con seguridad, ver el manual. Peligro de sacudida eléctrica. Utilice
solamente en lugaressecos. Cargar únicamente bateríasde sistemaseBike de Bosch.
Otrasbateríaspodrían reventar, causando lesionespersonalesydaños.Noreemplace el ensamblaje del enchufe,
ya que el resultado puede ser riesgo de incendio o sacudidaseléctricas.
Pour un fonctionnement sûr, reportez-vousau manuel. Risque de choc électrique. Utiliser en lieu sec
uniquement. A utiliser uniquement avec lesbatteriesdessystèmesd’assistance électrique
DeBike de Bosch. 'autresbatteriesrisqueraient d'éclater et de causer desblessurescorporelleset desdommages.
Ne pasremplacer la connectique car un risque d'incendie ou de choc électrique pourrait en résulter.
WARNING
ATTENTION
PRECAUCION
eBike Battery Charger 42-4/230
0 275 007 905
Made in PRC
Robert Bosch GmbH, Reutlingen
Input: 230V 50Hz 1.5A
Output: 42V 4A
30
29
31
33
32
34
OBJ_BUCH-1407-003.book Page 6 Friday, October 12, 2012 1:01 PM

| 7
BoscheBike Systems 0 276 001 YYY | (12.10.12)
21
34
35
26
35 20
31
30
F
E
OBJ_BUCH-1407-003.book Page 7 Friday, October 12, 2012 1:01 PM

English–1
0 276 001 YYY | (12.10.12) BoscheBike Systems
Drive Unit Cruise/
Drive HMI Intuvia
Safety Notes
Read all safety warnings and all instruc-
tions. Failure to followthe warnings and in-
structions may result inelectric shock, fire
and/or serious injury.
Save all safety warnings and instructions for future refer-
ence.
The term “battery pack” used inthese operating instructions
refers bothto standard battery packs (battery packs with
holder onthe bike frame) and to rack-type battery packs (bat-
tery packs withholder inthe rear rack/carrier).
Do not open the drive unit yourself. The drive unit is
maintenance-free and may be repaired only through a
qualified repair person and only using original spare
parts. This will ensure that the safety of the drive unit is
maintained. Unauthorised opening of the drive unit will
void any and all warranty claims.
All components mounted to the drive unit and all other
components of the eBike drive (e.g., the chainwheel,
chainwheel seat, pedals) may be replaced only against
identical components or components specifically ap-
provedforyoureBikebythebicyclemanufacturer.This
protects the drive unit against overload and damage.
Remove the battery pack from the eBike before work-
ingontheeBike(e.g.,assembling,maintenance,etc.),
transporting it via car or plane, or storing it. Danger of
injury whenaccidentally actuating the On/Off switch.
The push-assistance function may only be used when
pushing the eBike. Danger of injury whenthe wheels of
the eBike do nothave ground contact while using thepush-
assistance function.
Use only original Bosch battery packs approved for
your eBike by the manufacturer. Using other battery
packs canlead to injuries and pose a fire hazard. Whenus-
ing other battery packs, Boschshall not assume any liabil-
ity and warranty.
Please observe all national regulations on registering
and using eBikes.
Please read and observe the safety warnings and in-
structionsenclosedintheoperating instructionsof the
battery pack as well as in the operating instructions of
your eBike.
Product Description and
Specifications
Intended Use
The drive unit is intended exclusively for your eBike and may
not be used for other purposes.
The eBike is intended for use onpaved paths. It is not permit-
ted for use incompetition.
Product Features
(see page 2–3)
The numbering of the product features refers to the illustra-
tions onthe graphics page.
Allrepresentations ofbike components,withexceptionofthe
drive unit, drive HMI incl. operating unit, speed sensor and
corresponding holders, are schematic and candeviate from
your eBike.
1Display-functionbutton“i”
2Illuminationbutton
3Drive HMI
4Holder for drive HMI
5Drive HMI On/Off button
6“RESET” button
7USB port
8Protective cap of USB port
9Drive unit
10 Operating unit
11 Display-functionbutton“i” onthe operating unit
12 Reduce value/scroll down button“–”
13 Increase value/scroll up button“+”
14 Push-assistance button“WALK”
15 Lock latchfor drive HMI
16 Locking screwfor drive HMI
17 Speed sensor
18 Spoke magnet of the speed sensor
Indication Elements, Drive HMI
aMotor-output indicator
bAssistance-level indicator
cText indication
dValue indication
eSpeed indication
fBattery charge-control indicator
OBJ_BUCH-1407-003.book Page 1 Friday, October 12, 2012 1:01 PM

English–2
BoscheBike Systems 0 276 001 YYY | (12.10.12)
Technical Data
Assembly
Inserting and Removing the Battery Pack
For inserting and removing the battery pack in/from the
eBike, please read and observe the battery pack operating in-
structions.
Inserting and Removing the Drive HMI
(see figure A)
To insert the drive HMI 3, slide it from the front into the
holder 4.
To remove the drive HMI 3, press the lock latch15 and slide
the drive HMI toward the front out of the holder 4.
Remove the drive HMI when parking the eBike, so that
the drive cannot be used by unauthorised persons.
Without the drive HMI, the eBike system cannot be
switched on.
The drive HMI canalso be secured inthe holder against re-
moving. For this, remove the holder 4from the handlebar. In-
sertthe drive HMI intothe holder. Screwthelocking screw16
from belowinto the corresponding thread inthe holder.
Mount the holder onto the handlebar again.
Checking the Speed Sensor (see figure B)
The speed sensor 17 and its spoke magnet 18 must be
mountedinsucha mannerthat the spoke magnet, after a turn
ofthe wheel, movespastthe speedsensorwitha clearanceof
at least 5 mm, yet no more than17 mm.
Note: If the clearance betweenspeed sensor 17 and spoke
magnet 18 is too small or too large, or if the speed sensor 17
is notproperly connected, the speed indicationewill fail, and
the eBike drive will operate inemergency mode.
Inthis case, loosenthe screwof the spoke magnet 18 and fas-
tenthe spoke magnet to the spoke insucha manner that it
runs past the mark of the speed sensor at the correct clear-
ance. Whenthe speed is still not being indicated inthe speed
indicationeafter this, please refer to anauthorised bicycle
dealer.
Operation
Initial Operation
Requirements
The eBike system canonly be activated whenthe following re-
quirements are met:
–Asufficiently charged battery pack is inserted (see operat-
ing instructions of the battery pack).
–The drive HMI is properly inserted inthe holder (see “In-
serting and Removing the Drive HMI”, page English–2).
–The drive HMI is properly connected (see “Checking the
Speed Sensor”, page English–2).
Switching the eBike System On/Off
Options for switching on the eBike system:
–Ifthe drive HMI is already switched onwheninserting it in
the holder, the eBike system is automatically switched on.
–Whenthe drive HMI and the battery pack are inserted,
briefly press the On/Off button5of the drive HMI once.
–Whenthe drive HMI is inserted, press the On/Off buttonof
the battery pack (see battery pack operating instructions).
Note: Whenswitching onthe eBike system, the pedals of the
eBikemust not be subject to load, as otherwisethemotor out-
put capacity will be limited. The error message “Release ped-
al” is displayed intext indicationc.
If the eBike system was inadvertently switched onwithload
applied to the pedals, thenswitchit off and thenonagain
without load.
The drive is activated as soonas youstep into the pedals (ex-
ceptwheninpush-assistancemode, see “Switching thePush-
assistance mode On/Off”, page English–4).The motor out-
put depends onthe settings of the drive HMI.
Drive Unit Drive Unit Cruise
Article number 0 275 007 006/
0 275 007 007
Power outputW250
Output torque, max. Nm50
Rated voltage V36
Operating temperature °C–5...+40
Storage temperature °C–10...+50
Degree of protectionIP 54 (dust and splash
water protected)
Weight, approx. kg 4
Drive HMI Intuvia
Article number 1 270 020 903
Max. charging current, USB
connection.mA 500
Charging voltage, USB con-
nectionV5
Operating temperature °C–5...+40
Storage temperature °C–10...+50
Degree of protectionIP 54 (dust and splash
water protected)
Weight, approx. kg 0.15
Lighting*
Rated voltage V6
Power output
–Front light
–Rear lightW
W2.7 0.3
*Not possible via theeBikebatterypackinall country-specificversions,
depending onthe statutory regulations
OBJ_BUCH-1407-003.book Page 2 Friday, October 12, 2012 1:01 PM

English–3
0 276 001 YYY | (12.10.12) BoscheBike Systems
As soonas youstop pedaling wheninnormal operation, or as
soonas youhave reached a speed of 25 km/h, the assistance
fromtheeBike driveisswitchedoff.Thedriveisautomatically
re-activated as soonyoustart pedaling againand the speed is
below25 km/h.
Options for switching off the eBike system:
–Pressthe On/Off button5of the drive HMI.
–Switchthe battery pack off by its On/Off button(see bat-
tery pack operating instructions.)
–Remove the drive HMI out of its holder.
Whenno power output of the drive is requested for approx.
10minutes (e. g., becausethe eBike isparked) andno button
of the drive HMI or operating unit is pressed, the battery pack
automatically switches off to save energy.
Indications and Settings of the Drive HMI
Power Supply of the Drive HMI
Whenthe drive HMI is inserted inholder 4, a sufficiently
charged battery pack is inserted inthe eBike and the eBike
system is switched on, power is supplied to the drive HMI via
the eBike's battery pack.
Whenthe drive HMI is removed from holder 4, it is supplied
withpower via aninternal battery pack. If the internal battery
packis lowwhenswitching onthedrive HMI, “Attachtobike”
is displayed for 3 s intext indicationc. Afterwards, the drive
HMI switches off again.
To recharge the internal battery pack, insert the drive HMI in-
tothe holder 4(a battery pack must be inserted inthe eBike).
Switchthe eBike battery pack off by its On/Off button(see
battery pack operating instructions).
The drive HMI canalso be charged via USB connection. Open
protective cap 8for this. Using a matching USB cable, con-
nect the USB port 7of the drive HMI to a commercially availa-
ble USB charger or to the USB port of a computer; (5 Vcharg-
ing voltage; max. 500 mA charging current). “USB
connected” is displayed intext indicationcof the drive HMI.
Switching the drive HMI On/Off
Toswitchon thedrive HMI,briefly press the On/Offbutton5.
Whenthe internal battery pack is sufficiently charged, the
drive HMI canalso be switched onwhennot inserted inthe
holder.
To switch off the drive HMI, press the On/Off button5.
WhenthedriveHMI is notinserted intheholder and nobutton
ispressed, it automatically switches off after1 minto saveen-
ergy.
Battery Charge-control Indicator
The battery-pack charge-control indicator findicates the
charge conditionof the eBike’s battery pack, and not the
charge conditionof the drive HMI’s internal battery pack. The
charge conditionof the eBike’s battery pack canalso be read
from the battery pack’s LEDs.
On indicator f, eachbar of the battery pack symbol is equiva-
lent to a capacity of approx. 20 %:
Lessthan5 % capacity; drive assistance is no long-
er possible. The LEDs of the charge-control indica-
tor onthe battery pack go out.
Whenthe eBike lighting is powered via the battery pack
(country-specific), the capacity uponfirst indicationof the
empty battery pack symbol will be sufficient for approx.
2hours of lighting. Whenthe symbol begins to flash, the light-
ing will continue to operate only for a short period.
Whenthedrive HMI is removed fromholder 4, the last indicat-
ed battery pack charge conditionis stored.
Setting the Assistance Level
The level of assistance of the eBike drive whenpedaling can
be adjusted via the drive HMI. The assistance level canbe
changed anytime, evenduring riding.
Note: For individual versions, it is possible that the the assis-
tance level is pre-set and cannot be changed. It is also possi-
ble that less assistance levels are available for selectionthan
listed here.
The following assistance levels (max.) are available:
–“OFF”:Thedriveis switchedoff,theeBike canbeoperated
as a normal bicycle throughpedaling.
–“ECO”: Effective assistance at maximum efficiency for
maximum cruising range
–“
TOUR”: Uniform assistance, for touring withlong cruising
range
–“SPORT”: Powerful assistance for sportive riding off road
as well as for urbantraffic
–“TURBO”: Maximum assistance, supporting highest ca-
dence for sportive riding
To increase the assistance level, press the “+” button13 on
the operating unit until the desired assistance level is dis-
played inindicator b; to decrease the assistance level, press
the “ –” button12.
The requested motor output is displayed inindicator a. The
maximum motor output depends onthe selected assistance
level.
Whenthedrive HMI is removed fromholder 4, the last indicat-
ed assistance level is stored; the motor-output indicator are-
mains empty.
100 % to 80 % capacity
20 % to 5 % capacity; the battery pack should be
recharged.
Assistance Level Motor Output*
Derailleur Gear Hub
“ECO”30 % 30 %
“TOUR”100 % 90 %
“SPORT”170 % 150 %
“TURBO”250 % 200 %
*The motor output canvary for individual versions.
OBJ_BUCH-1407-003.book Page 3 Friday, October 12, 2012 1:01 PM

English–4
BoscheBike Systems 0 276 001 YYY | (12.10.12)
Switching the Push-assistance mode On/Off
The push-assistance feature makes it easier to pushthe
eBike. The speed inthis functiondepends onthe set gear and
cannot exceed6 km/h(max.).The lower theset gear, the low-
er the speed inthe push-assistance function(at full output).
The push-assistance function may only be used when
pushing the eBike. Danger of injury whenthe wheels of
the eBike do nothave ground contact while using thepush-
assistance function.
To activate the push-assistance function, press and hold the
“WALK” button14 onthe operating unit. The eBike's drive is
activated.
The push-assistance functionis switched off as soonas any
of the following incidents occur:
–Yourelease the “WALK” button 14,
–Youpedal inforward or quickly inbackward direction,
–ThewheelsoftheeBikeare blocked(e. g., throughbraking
or running against anobstruction),
–Your speed exceeds 6 km/h.
Switching the Lighting On/Off
Depending oncountry-specific regulations, two lighting ver-
sions are possible:
–The front light, rear light and display backlight canbe
switched onand off at the same time via the drive HMI.
Inthis version, “Lights on” is displayed for approx. 1 s in
textindicationcwhenswitching on, and “Lightsoff” when
switching off.
–Only the display backlight canbe switched onand off; the
front and rear light of the eBike are independent of the
drive HMI.
For bothversions, the lighting is switched on and off by
pressing button2.
Speed and Distance Indication
The speed indication ealways displays the current speed.
The following functions are available inthe function indica-
tion (combinationof text indicationcand value indicationd):
–“Range”:Estimated range of the available battery-pack
charge (for constant conditions suchas assistance level,
route profile, etc.)
–“Distance”:Distance covered since the last reset
–“Trip time”:Trip time since the last reset
–“Avg. Speed”:Average speed achieved sincethe last reset
–“Max. Speed”:Maximum speed achieved since the last re-
set
–“Clock”:Current time
To switch between the indication functions, press the “i”
button1onthedriveHMIorthe “i”button11ontheoperating
unit until the desired functionis displayed.
Toreset“Distance”,“Triptime”and “Avg.Speed”, switchto
any of the three functions and thenpress and hold the
“RESET” button6until the indicationis set to zero. This also
resets the values of the other two functions.
To reset the “Max. Speed”, switchto this functionand then
pressandholdthe “RESET”button6untilthe indicationis set
to zero.
Whenthe drive HMI is removed from the holder 4, all function
values remainstored and canbe viewed.
Displaying/Adapting Basic Settings
The basic settings canbe displayed and changed no matter if
the drive HMI is inthe holder 4or not.
To access the basic settings menu, press and hold the
“RESET” button6and the “i” button1until “Configuration”
is displayed intext indicationc.
Toswitch between the basicsettings, press the “i”button1
onthe drive HMI until the desired basic setting is displayed.
Whenthe drive HMI is inserted inholder 4, youcanalso press
the “i” button11 onthe operating unit.
Tochangethe basicsettings,press theOn/Offbutton5next
to the “ –” indicationto decrease the value or scroll down, or
theilluminationbutton2next to the “+”indicationto increase
the value or scroll up.
Whenthe drive HMI is inserted inholder 4, youcanalso
changethevalueswiththe“ –” button12orthe “+”button13
onthe operating unit.
To exit the functionand store a changed setting, press the
“RESET” button6for 3 s.
The following basic settings are available:
–“unit km/mi”:The speed and distance canbe displayed ei-
ther inkilometres or miles.
–“time format”:The time canbe displayed either inthe
12 hour or 24 hour format.
–“clock”:The current time canbe set here. Pressing and
holding the setting buttons fast-forwards the setting
speed.
–“English”:The language for text indicationcanbe
changed. The available languages are German, English,
French, Spanish, Italianand Dutch.
–“odometer”:Indicatesthe total distance travelledwiththe
eBike (not changeable).
–“power-on hours”:Indicates the total travel durationwith
the eBike (not changeable).
Error Code Indication
Thecomponents of the eBike system are continuously and au-
tomaticallymonitored. Whenanerror is detected, therespec-
tive error code is indicated intext indicationc.
To returnto the standard indication, press any buttononthe
drive HMI 3or onthe operating unit 10.
Dependingonthe typeof error,thedriveisautomatically shut
off if required. Continued travel without assistance from the
drive is possible at any time. However, have the eBike
checked before attempting newtrips.
Have all inspections and repairs carried out only by an
authorisedbicycledealer.Whenanerrorisstilldisplayed
despite corrective measures, please also refer to an
authorised bicycle dealer.
OBJ_BUCH-1407-003.book Page 4 Friday, October 12, 2012 1:01 PM

English–5
0 276 001 YYY | (12.10.12) BoscheBike Systems
Power Supply of External Devices via USB
Connection
Withthe USB connection, it is possible to operate and charge
most devices whose power supply is possible via USB (e.g.,
various mobile phones).
Prerequisite for the charging is that the drive HMI and a suffi-
ciently charged battery pack are inserted inthe eBike.
Openthe protective cap 8of the USB port onthe drive HMI.
Using a matching USB cable, connect the USB port of the ex-
ternal device to the USB port 7of the drive HMI.
Notes on Riding with the eBike System
When does the eBike Drive Operate?
The eBike drive supports youwhenriding, as long as youstep
into the pedals. Without pedaling, there is no assistance. The
motor output always depends onthe amount of your pedaling
power.
Whenapplyinglesspedalingpower,theassistanceor support
will be lower thanwhenapplying a lot of pedaling power. This
applies independent of the assistance Level.
TheeBikedriveautomaticallyswitches off at speeds inexcess
of 25 km/h. Whenthe speed falls below25 km/h, the drive is
automatically available again.
Anexceptionapplies for the push-assistance function, in
whichthe eBikecanbe pushedat lowspeed withoutpedaling.
The eBike canalso be riddenas a normal bicycle without as-
sistance at any time, by either switching off the eBike system
or setting the assistance level to “OFF”. The same applies
whenthe battery pack is empty.
Code Cause Corrective Measure
100 Internal error of the drive unit Have the drive unit checked
101 Connectionproblem of the drive unit Have connections and contacts checked
102 Error of the speed sensor Have the speed sensor checked
103* Connectionproblem of the lighting
system Have connections and contacts checked
104 Connectionproblem of the drive HMIHave connections and contacts checked
105 Temperature of the drive unit too high
(above 40 °C)Allowthe drive unit to cool down. Continued travel without assistance from the eBike drive is possible and speeds up the cooling of the drive
unit.
200 Internal electronic error of battery
pack Have battery pack checked
201 Temperature of the battery pack too
high(above 40 °C)Allowthebattery pack to cool down.Continued travel without eBike drive is possible and speeds up the cooling of the battery pack.
202 Temperature of the battery pack too
low(below–10 °C)Allowthe battery pack to warm up slowly ina warm location.
203 Connectionproblem of battery pack Have connections and contacts checked
204 Incorrect polarity of battery pack Charge the battery pack withthe original Boschcharger as described in
the operating instructions.
410 One or more buttons of the drive HMI
are blocked.
Check if any buttons are blocked, e.g. from dirt or debris. Cleanthe
buttons, if required.
414 Connectionproblem of the operating
unit Have connections and contacts checked
418 One or more buttons of the operating
unit are blocked.
Check if any buttons are blocked, e.g. from dirt or debris. Cleanthe
buttons, if required.
422 Connectionproblem of the drive unit Have connections and contacts checked
423 Connectionproblem of battery pack Have connections and contacts checked
424 Communicationerror among the com-
ponents Have connections and contacts checked
430 Internal battery pack of drive HMI
empty
Charge drive HMI (inholder or via USB port)
490 Internal error of the drive HMIHave the drive HMI checked
*only for eBike lighting via battery pack (country-specific)
OBJ_BUCH-1407-003.book Page 5 Friday, October 12, 2012 1:01 PM

English–6
BoscheBike Systems 0 276 001 YYY | (12.10.12)
Interaction of the eBike System with the Bicycle Gears
The bicycle gears should be used as witha normal bicycle,
evenwitheBike drive (please observe the operating instruc-
tions of your eBike).
Independent of the type of gearing, it is recommended to
briefly interrupt the pedaling while changing gears. This
makes changing gears easier and reduces the wear of the
drive train.
By selecting the right gear, youcanincrease the speed and
range withthe same pedaling effort.
Gathering First Experience
It is recommended to gather first experience withthe eBike
away from roads withheavy traffic.
Try out the different assistance levels. As soonas youfeel
safe, youcanparticipate intraffic withthe eBike as withany
other bicycle.
Test the operating range of your eBike under different condi-
tions before planning longer and more challenging rides.
Influences on the Operating Range
The operating range depends onmany factors, suchas:
– Assistance level,
–Gear-switching behaviour,
–Bicycletyresand tyre pressure,
–Ageand conditionof the battery pack,
–Route profile (inclines) and road or pathconditions (road
or pathsurface),
– Head wind and ambient temperature,
–Weight of the eBike, rider and equipment/luggage
For these reasons, it is not possible to predict anaccurate op-
erating range before starting your ride. General rules:
–Forthe same motor output of the eBike drive: The less
power or force that youhave to bring about to reacha cer-
tainspeed (e.g. throughoptimaluse of the gears), theless
energy the eBike drive will consume, and the greater the
range for a battery-pack charge.
–Thehigherthe assistance level under otherwise same con-
ditions, the lower the range.
Careful Handling of the eBike
Pleaseobservetheoperatingandstoragetemperaturesofthe
eBike components. Protect the drive unit, drive HMI and bat-
tery pack against extreme temperatures (e.g. from intense
sunlight without adequate ventilation). The components (es-
pecially the battery pack) canbecome damaged throughex-
treme temperatures.
Maintenance and Service
Maintenance and Cleaning
Keep all components of your eBike clean, especially the bat-
tery-packcontacts and correspondingholder contacts. Clean
them carefully witha soft, damp cloth.
All components including the drive unit may not be immersed
inwater or cleaned witha high-pressure cleaner.
For service or repairs onthe eBike, please refer to anauthor-
ised bicycle dealer.
After-sales Service and Customer Assistance
Incaseofquestions concerning the eBike system and its com-
ponents, please refer to anauthorised bicycle dealer.
Forcontactdataofauthorised bicycle dealers, please refer to
www.bosch-ebike.com
Transport
The battery packs are subject to the Dangerous Goods Legis-
lationrequirements. Private users cantransport battery
packs by road without further requirements.
Whenbeing transported by commercial users or third parties
(e.g. via air transport or forwarding agency), special require-
mentsonpackagingandlabellingmustbeobserved(e.g.ADR
Regulations). For preparationof the item being shipped, an
expert for hazardous material canbe consulted as required.
Dispatchbattery packs only whenthe housing is undamaged.
Tape or mask off opencontacts and pack up the battery pack
insuchamanner thatit cannotmove aroundinthepackaging.
Please also observe possibly more detailed national regula-
tions.
Incase of questions concerning transport of the battery
packs, please refer to anauthorised bicycle dealer. Bicycle
dealers canalso provide suitable transport packaging.
Disposal
The drive unit, drive HMI (incl. operating unit), bat-
tery pack, speed sensor, accessories and packaging
should be sorted for environmental-friendly recy-
cling.
Do not dispose of eBikes and their components into house-
hold waste!
OBJ_BUCH-1407-003.book Page 6 Friday, October 12, 2012 1:01 PM

English–7
0 276 001 YYY | (12.10.12) Bosch eBike Systems
Only for EC countries:
According to the European Guideline
2002/96/EC, electrical devices/tools that
are no longer usable, and according to the
European Guideline 2006/66/EC, defec-
tive or used battery packs/batteries, must
be collected separately and disposed of in
an environmentally correct manner.
The integrated battery pack in the drive HMI may only be re-
moved for disposal. Opening the housing shell can damage or
destroy the drive HMI.
Please return battery packs that are no longer usable to an au-
thorised bicycle dealer.
Li-ion:
Please observe the instructions in sec-
tion “Transport”, page English–6.
Subject to change without notice.
OBJ_DOKU-25177-003.fm Page 7 Friday, October 12, 2012 3:16 PM

English–8
BoscheBike Systems 0 276 001 YYY | (12.10.12)
Lithium ion battery pack PowerPack
Safety Notes
Readallsafetywarningsand
all instructions. Failure to fol-
lowthe warnings and instruc-
tions may result inelectric
shock, fire and/or serious in-
jury.
Save all safety warnings and instructions for future refer-
ence.
The term “battery pack” used inthese operating instructions
refers bothto standard battery packs (battery packs with
holder onthe bike frame) and to rack-type battery packs (bat-
tery packs withholder inthe rear rack/carrier), except when
explicitly referring to the designtype.
Remove the battery pack from the eBike before work-
ingontheeBike(e.g.,assembling,maintenance,etc.),
transporting it via car or plane, or storing it. Danger of
injury whenaccidentally actuating the On/Off switch.
Donot open the battery pack. Dangerofshort-circuiting.
Opening the battery pack voids any and all warranty
claims.
Protect the battery pack against heat (e. g., al-
so against continuous intense sunlight), fire
and immersing into water. Danger of explosion.
Keep the battery pack not being used away from paper
clips, coins, keys, nails, screws or other small metal ob-
jects, that can make a connection from one terminal to
another. Shorting the battery-pack terminals together
may cause burns or a fire. For short-circuiting damage
causedinthismanner,any and all warrantyclaims through
Boschshall be invalid.
Under abusive conditions, liquid may be ejected from
thebattery pack. Avoidcontact.If contact accidentally
occurs, flush with water. If liquid contacts eyes, addi-
tionally seek medical help. Liquid ejected from the bat-
tery pack may cause skinirritations or burns.
Vapours can escape in case of damage and improper
use of the battery pack. Provide for fresh air and seek
medical attention in case of complaints. The vapours
canirritate the respiratory system.
Charge the battery pack only with original Bosch bat-
tery chargers. Whenusing non-original Boschchargers,
the danger of fire cannot be excluded.
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 canlead to injuries and pose a fire hazard. Whenus-
ing other battery packs, Boschshall not assume any liabil-
ity and warranty.
Please read and observe the safety warnings and in-
structionsenclosedintheoperating instructionsof the
charger and drive unit/drive HMI (Human Machine In-
terface),aswellas intheoperatinginstructionsofyour
eBike.
Product Description and
Specifications
Product Features
(see page 4–5)
The numbering of the product features refers to the illustra-
tions onthe graphics pages.
Allrepresentations ofbike components,withexceptionofthe
battery packs and their holders, are schematic and candevi-
ate from your eBike.
19 Holder of the rack-type battery pack
20 Rack-type battery pack
21 Operationand charge-control indicator
22 On/Off button
23 Key of the battery pack lock
24 Battery-pack lock
25 Upper holder of the standard battery pack
26 Standard battery pack
27 Bottom holder of the standard battery pack
28 Carrying strap
29 Battery charger
OBJ_BUCH-1407-003.book Page 8 Friday, October 12, 2012 1:01 PM

English–9
0 276 001 YYY | (12.10.12) BoscheBike Systems
Technical Data
Assembly
Place down the battery pack only on clean surfaces. In
particular, avoid soiling the charge socket and the con-
tacts, e. g. by means of sand or ground.
Checking the Battery Pack Before Using for the
First Time
Check the battery pack before charging it or using it withyour
eBike for the first time.
For this, press the On/Off button22 to switchonthe battery
pack. Whenno LED of the charge-control indicator 21 lights
up, the battery pack may be damaged.
Whenat least one, but not all LEDs of the charge-control indi-
cator 21 is lit, thenfully charge the battery pack before using
for the first time.
Do not charge a damaged battery pack and do not use
it. Please refer to anauthorised bicycle dealer.
Charging the Battery Pack
Use only the charger provided with your eBike or an
identical original Bosch charger. Only this charger is
matchedto the lithium-ionbatterypack usedinyoureBike.
Note: The battery pack is supplied partially charged. To en-
sure full battery pack capacity, completely charge the battery
pack inthe charger before using for the first time.
The battery pack must be removed from the eBike for charg-
ing.
Forchargingthebatterypack,readandobservetheoperating
instructions of the charger.
The battery pack canbe charged any time without reducing
the service life. Interrupting the charging procedure does not
cause damage to the battery pack.
The battery pack is equipped witha temperature control indi-
cator, whichenables charging only withina temperature
range between0°Cand 40 °C.
Whenthe battery pack is not
withinthe charging-tempera-
ture range, three LEDs of the
charge-control indicator 21
flash. Disconnect the battery pack from the charger until its
temperature has adjusted.
Do not connect the battery pack to the charger until it has
reachthe allowable charging temperature.
Charge-control Indicator
Whenthe battery pack is switched on, the five greenLEDs of
the charge-control indicator 21indicate the charge condition
of the battery pack.
Inthis, eachLED indicates approx. 20 % capacity. Whenthe
battery pack is completely charged, all five LEDs light up.
Additionally, the charge conditionof the switched onbattery
pack is indicated onthe drive HMI. Read and observe the op-
erating instructions of the drive unit and the drive HMI.
Whenthe capacity of the battery pack is below5 %, all LEDs
of charge-control indicator 21 onthe battery pack go out;
however, the drive HMI does provide anadditional indication
function.
Inserting and Removing the Battery Pack
(see figures C–D)
Always switch the battery pack off when inserting or
removing it from the holder.
Inorder for the battery pack to be inserted, the key 23 must
be inserted into the lock 24 and the lock must be unlocked.
To insert the standard battery pack 26, place it via the con-
tacts onto the bottom holder 27 onthe eBike. Pivot the bat-
tery pack to the stop into the upper holder 25.
Lithium ion battery pack PowerPack 300 PowerPack 400
Article number
–Standard battery pack, black
–Standard battery pack, white
–Rack-type battery pack
0 275 007 500
0 275 007 501
0 275 007 502
0 275 007 503
0 275 007 504
0 275 007 505
Rated voltage V=3636
Rated capacity Ah8.2 11
Energy Wh300 400
Operating temperature °C–10...+40 –10...+40
Storage temperature °C–10...+60 –10...+60
Allowable charging temperature range °C0...+40 0...+40
Weight, approx. kg 2.5 2.5
Degree of protectionIP 54 (dust and splashwater
protected) IP 54 (dust and splashwater protected)
OBJ_BUCH-1407-003.book Page 9 Friday, October 12, 2012 1:01 PM

English–10
BoscheBike Systems 0 276 001 YYY | (12.10.12)
To insert the rack-type battery pack 20, slide it withthe
contacts facing ahead until it engages inthe holder 19 of the
rear rack/carrier.
Check if the battery pack is tightly seated. Always lock the
batterypack withlock 24, as otherwisethelock canopenand
the battery pack could fall out of the holder.
After locking, always remove the key 23 from the lock 24.
This prevents the key from falling out and the battery pack
from being removed from unauthorised persons whenthe
eBike is parked.
To remove the standard battery pack 26, switchit off and
unlock the lock withthe key 23. Pivot the battery pack out of
the upper holder 25 and pull it by the carrying strap 28 out of
the bottom holder 27.
To remove the rack-type battery pack 20, switchit off and
unlock the lock withthe key 23. Pull the battery pack out of
the holder 19.
Operation
Initial Operation
Use only original Bosch battery packs approved for
your eBike by the manufacturer. Using other battery
packs canlead to injuries and pose a fire hazard. Whenus-
ing other battery packs, Boschshall not assume any liabil-
ity and warranty.
Switching On and Off
Switching the battery pack onis one of the possibilities to
start the eBike system. Read and observe the operating in-
structions of the drive unit and the drive HMI.
Before switching onthe battery pack or the eBike system,
check that the lock 24 is locked.
Note: Whenswitching onthe eBike system, the pedals of the
eBike may not be subject to load, as otherwise the output ca-
pacity of the drive will be limited.
To switch on the battery pack, press the On/Off button22.
The LEDs of indicator 21 light up and at the same time indi-
cate the charge condition.
Note: Whenthe battery-pack capacity is below5%,none of
the LEDs of charge-control indicator 21 will light up. Only the
drive HMI will indicate if the eBike system is switched on.
To switch off the battery pack, press the On/Off button22
again. The LEDs of indicator 21 go out. This also switches off
the eBike system.
Whenno power output of the eBike drive is requested for ap-
prox. 10 minutes (e. g., because the eBike is parked) and no
buttonof thedrive HMI or operating unit is pressed, the eBike
system and thus the battery pack automatically switchoff to
save energy.
The battery pack is protected against deep discharging, over-
charging, overheating and short-circuiting throughthe “Elec-
tronicCell Protection(ECP)”. Incase of hazardous situations,
a protective circuit automatically switches off the battery
pack.
Whena defect of the battery
pack is detected, two LEDs of
thecharge-control indicator 21
flash. Inthis case, please refer
to anauthorised bicycle dealer.
Notes for Optimum Handling of the Battery Pack
The battery-pack life canbe prolonged whenbeing properly
maintainedand especiallywhenbeing operatedand stored at
the right temperatures.
Withincreasing age, however, the battery-pack capacity will
diminish, evenwhenproperly maintained.
A significantly reduced operating period after charging indi-
cates that the battery pack is wornout and must be replaced.
Youcanreplace the battery pack yourself.
Incase the carrying strap 28 of the standard battery pack
should be defective, please have it replaced by a bicycle deal-
er.
Recharging the Battery Pack prior to and during Storage
Whennot using the battery pack for a longer period, charge it
to approx. 60 % (3 to 4 LEDs lit onthe charge-control indica-
tor 21).
Check the charge conditionafter 6 months. Whenonly one
LEDof the charge-control indicator21lightsup, recharge the
battery pack againapprox. 60 %.
Note:Whenthebattery packisstoreddischarged(empty)for
longer periods, it canbecome damaged despite the lowself-
discharging and the battery-pack capacity may be strongly re-
duced.
It is not recommended to have the battery pack connected
permanently to the charger.
Storage Conditions
Store the battery pack ina dry, well-ventilated location. Pro-
tect the battery pack against moisture and water. Under unfa-
vourable weather conditions, it is recommended e. g. to re-
move the battery pack from the eBike and store it inan
enclosed locationuntil being used again.
The battery pack canbe stored at temperatures between
–10 °Cand +60 °C. For a long battery-pack life, however,
storing the battery pack at a room temperature of approx.
20 °Cis of advantage.
Take care that the maximal storage temperature is not ex-
ceeded. As anexample, do not leave the battery pack ina ve-
hicle insummer and store it out of direct sunlight.
OBJ_BUCH-1407-003.book Page 10 Friday, October 12, 2012 1:01 PM

English–11
0 276 001 YYY | (12.10.12) BoscheBike Systems
Maintenance and Service
Maintenance and Cleaning
Keep the battery pack clean. Cleanthe battery pack carefully
witha soft, damp cloth. The battery pack may not be im-
mersed inwater or cleaned witha water jet.
Whenthe battery pack is no longer operative, please refer to
anauthorised bicycle dealer.
After-sales Service and Customer Assistance
Incase of questions concerning the battery packs, please re-
fer to anauthorised bicycle dealer.
Notedownthemanufacturerandthenumberofthekey
23.Incaseof lossofthekeys,pleasereferto anauthorised
bicycledealer. Please provide the name ofthe manufactur-
er and the number of the key.
Forcontact data of authorisedbicycle dealers, pleaserefer to
www.bosch-ebike.com
Transport
The battery packs are subject to the Dangerous Goods Legis-
lationrequirements. Private users cantransport battery
packs by road without further requirements.
Whenbeing transported by commercial users or third parties
(e.g. via air transport or forwarding agency), special require-
mentsonpackagingandlabellingmustbeobserved(e.g.ADR
Regulations). For preparationof the item being shipped, an
expert for hazardous material canbe consulted as required.
Dispatchbattery packs only whenthe housing is undamaged.
Tape or mask off opencontacts and pack up the battery pack
insuchamanner that itcannot movearound inthepackaging.
Please also observe possibly more detailed national regula-
tions.
Incase of questions concerning transport of the battery
packs, please refer to anauthorised bicycle dealer. Bicycle
dealers canalso provide suitable transport packaging.
Disposal
Battery packs, accessories and packaging should be
sorted for environmental-friendly recycling.
Do not dispose of the battery packs into household waste!
Only for EC countries:
According to the EuropeanGuideline
2002/96/EC, electrical devices/tools that
are no longer usable, and according to the
EuropeanGuideline 2006/66/EC, defec-
tive or used battery packs/batteries, must
be collected separately and disposed of in
anenvironmentally correct manner.
Please returnbattery packs that are no longer usable to anau-
thorised bicycle dealer.
Li-ion:
Please observe the instructions insec-
tion“Transport”, page English–11.
Subject to change without notice.
OBJ_BUCH-1407-003.book Page 11 Friday, October 12, 2012 1:01 PM

English–12
BoscheBike Systems 0 276 001 YYY | (12.10.12)
Charger
Safety Notes
Readallsafetywarningsand
all instructions. Failure to fol-
lowthe warnings and instruc-
tions may result inelectric
shock, fire and/or serious in-
jury.
Save all safety warnings and instructions for future refer-
ence.
The term “battery pack” used inthese operating instructions
refers bothto standard battery packs (battery packs with
holder onthe bike frame) and to rack-type battery packs (bat-
tery packs withholder inthe rear rack/carrier).
Keep the charger away from rain or moisture. The
penetrationof water into a battery charger increases
the risk of anelectric shock.
Only charge eBike-approved Bosch lithium-ion battery
packs. The battery-pack voltage must match the bat-
tery-pack charging voltage of the charger. Otherwise
there is danger of fire and explosion.
Keep the battery charger clean. Contaminationcanlead
to danger of anelectric shock.
Before each use, check the battery charger, cable and
plug. If damage is detected, do not use the battery
charger. Never open the battery charger yourself.
Have repairs performed only by a qualified technician
and only using original spare parts. Damaged battery
chargers, cables and plugs increase the risk of anelectric
shock.
Do not operate the battery charger on easily inflamma-
ble surfaces (e. g., paper, textiles, etc.) or surround-
ings. The heating of the battery charger during the charg-
ing process canpose a fire hazard.
Vapours can escape in case of damage and improper
use of the battery pack. Provide for fresh air and seek
medical attention in case of complaints. The vapours
canirritate the respiratory system.
Supervise children. This will ensure that childrendo not
play withthe charger.
Childrenorpersonsthat owing to their physical, senso-
ryor mentallimitationsor totheir lack ofexperience or
knowledge, are not capable of securely operating the
charger, may only use this charger under supervision
or after having been instructed by a responsible per-
son. Otherwise, there is danger of operating errors and in-
juries.
Please read and observe the safety warnings and in-
structionsenclosedintheoperating instructionsof the
battery pack and drive unit/drive HMI, as well as in the
operating instructions of your eBike.
A short versionof important safety warnings inEnglish,
Frenchand Spanishwiththe following content canbe
foundonthe bottom sideof the charger(marked withnum-
ber 33 inthe representationonthe graphics page):
–Forsafeoperationsee manual. Risk of electric shock.
–Drylocationuse only.
–Charge only batteries of the BoscheBike Systems. Oth-
er batteries may burst causing personal damage.
–Donot replace the plug assembly as risk of fire or elec-
tric shock may result.
Product Description and
Specifications
Product Features
(see page 6–7)
The numbering of the product features refers to the illustra-
tionof the battery charger onthe graphics page.
20 Rack-type battery pack
21 Battery charge-control indicator
26 Standard battery pack
29 Battery charger
30 Charger socket
31 Plug-inconnector
32 Ventilationopenings
33 Safety warnings, charger
34 Charge connector
35 Socket for charge connector
Technical Data
Battery Charger Charger
Article number 0 275 007 905
Rated voltage V~207–264
Frequency Hz 47 –63
Output voltage V42
Charging currentA4
Allowable charging temperature
range °C0...+40
The values givenare valid for a nominal voltage [U] of 230 V. For differ-
ent voltages and models for specific countries, these values canvary.
OBJ_BUCH-1407-003.book Page 12 Friday, October 12, 2012 1:01 PM

English–13
0 276 001 YYY | (12.10.12) BoscheBike Systems
Operation
Place down the battery pack only on clean surfaces. In
particular, avoid soiling the charge socket and the con-
tacts, e. g. by means of sand or ground.
Initial Operation
Connecting the Charger (see figures E–F)
Observe the mains voltage! The voltage of the power
supply must correspond withthe data givenonthe name-
plate of the battery charger. Battery chargers marked with
230 Vcanalso be operated with220 V.
Plug the charger plug 31 of the power cord into the charger
socket 30 of the charger.
Connect the mains cable (country-specific) to the mains sup-
ply.
Switchthe battery pack off and remove it from the holder of
the eBike. For this, read and observe the operating instruc-
tions of the battery pack.
Insertthe chargerplug 34ofthe batterychargerintothe sock-
et 35 onthe battery pack.
Charging Procedure
The charging procedure begins as soonas the charger is con-
nected withthe battery pack and the mains supply.
Note: The charging procedure is only possible whenthe tem-
perature of the battery pack is withinthe allowable charging-
temperature range.
During the charging procedure, the LEDs of charge-control in-
dicator 21 onthe battery pack light up. Eachcontinuously lit
LED is equivalent to a charge capacity of approx. 20 %. The
flashing LED indicates the charging of the next 20 %.
Use caution when touching the charger during the
chargingprocedure.Wear protectivegloves.Especially
inhighambient temperatures, the charger canheat up
considerably.
Note: Pay attentionthat the charger is well ventilated during
the charging procedure and that the ventilationopenings 32
onbothsides are not clogged or contaminated.
The battery pack is completely charged whenall five LEDs of
indicator 21 light up continuously. The charge procedure is
automatically ended.
Disconnectthechargerfrom themainssupplyand thebattery
pack from the charger.
Whendisconnecting the battery pack from the charger, the
battery pack is automatically switched off.
The battery pack cannowbe inserted into the eBike.
Troubleshooting –Causes and Corrective
Measures
Charging time
–PowerPack 300
–PowerPack 400
h
h
2.5
3.5
Number of battery cells 10 –80
Operating temperature °C–10...+75
Storage temperature °C–20...+70
Weight according to
EPTA-Procedure 01/2003 kg 0.8
Degree of protectionIP 40
Battery Charger Charger
The values givenare valid for a nominal voltage [U] of 230 V. For differ-
ent voltages and models for specific countries, these values canvary. Cause Corrective Measure
Two LEDs of the battery
pack flashing
Battery pack defectiveRefertoanauthorisedbicycle
dealer
Three LEDs of the battery
pack flashing
Battery pack too warm or too
cold Disconnect the battery pack from the charger and allowto
adjustto the ambient temper-
ature until the charging-tem-
perature range is reached.
Do not connect the battery
packtothechargeruntilithas
reachthe allowable charging
temperature.
Nochargingprocedurepossible(noindicationonbattery
pack)
Plug not inserted correctly Check all plug connections
Contacts of battery pack
soiled
Carefully cleanthe contacts
of the battery pack
Ventilationopenings 32 of
the charger clogged or con-
taminated
Cleanventilationopenings
32 and set up charger well
ventilated
Socket outlet, cable or charg-
er defective
Check mains voltage, have
charger checked through
bicycle dealer
Battery pack defectiveRefertoanauthorisedbicycle
dealer
OBJ_BUCH-1407-003.book Page 13 Friday, October 12, 2012 1:01 PM