Bosch ZEMO SU-E FS 12 Wiring diagram

MY22Z01 - 12_1.0_25.07.2022
TURBO
SPORT
TOUR
ECO
OFF
MPH
KM/H
Reichweite
AMM
PMWH
MIN
MPH
KM /H
RESET
TURBO
SPOR T
S
TOUR
ECO
OFF
MPH
KM/H
Reichweite
AMM
P MWH
MIN
MPH
KM
/H
21-17-3234…21-17-3237, 22-15-2057…22-15-2062
SU-E FS 12, ZE 10, ZE 5F, ZE 5F Plus, ZE 5R, ZE 5R Plus
Translation of original operating instructions
for ZEMO pedelecs with BOSCH Intuvia
on-board computer
IMPORTANT
READ CAREFULLY BEFORE USE
KEEP SAFE TO CONSULT AT A LATER DATE

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Contents
Contents
1 About these operating instructions
1.1 Manufacturer 11
1.2 Laws, standards and directives 11
1.3 Language 11
1.4 For your information 11
1.4.1 Warnings 11
1.4.2 Markups 11
1.5 Aim of the operating instructions 12
1.6 Type number and model 13
1.7 Frame number 13
1.8 Identifying the operating instructions 13
2 Safety
2.1 Residual risk 14
2.1.1 Risk of fire and explosion 14
2.1.2 Electric shock 16
2.1.2.1 Damage 16
2.1.2.2 Water penetration 16
2.1.2.3 Condensation 16
2.1.3 Risk of a crash 16
2.1.3.1 Incorrect quick release setting 16
2.1.3.2 Incorrect tightening torque 16
2.1.3.3 Incorrect component 16
2.1.4 Risk of amputation 16
2.1.5 Key breaking off 16
2.2 Toxic substances 17
2.2.1 Carcinogenic substances 17
2.2.2 Toxic substances 17
2.2.3 Irritants and corrosive substances 17
2.3 Requirements for the pedelec rider 18
2.4 Vulnerable groups 18
2.5 Personal protective equipment 18
2.6 Safety guards 18
2.7 Safety markings and safety instructions 19
2.8 What to do in an emergency 19
2.8.1 Dangerous situation in road traffic 19
2.8.2 Leaked brake fluid 19
2.8.3 Battery vapour emission 20
2.8.4 Battery fire 20
2.8.5 Oil and lubricant leaks from the rear frame damper 20
2.8.6 Oil and lubricant leaks from the fork 20
3 Description
3.1 Proper use 21
3.1.1 Improper use 22
3.1.2 Permitted total weight (PTW) 23
3.1.3 Environmental requirements 24
3.2 Nameplate 26
3.3 Components 27
3.3.1 Overview 27
3.3.2 Chassis 28
3.3.2.1 Frame 28
3.3.2.2 Steering system 28
3.3.2.3 Steering headset 28
3.3.2.4 Stem 28

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Contents
3.3.2.5 Handlebars 29
3.3.2.6 Fork 29
3.3.3 Suspension 30
3.3.3.1 Rigid fork 30
3.3.3.2 Suspension fork 30
3.3.4 Wheel 34
3.3.4.1 Tyres 34
3.3.4.2 Tube-type tyre 34
3.3.5 Braking system 37
3.3.5.1 Mechanical brake 37
3.3.5.2 Hydraulic brake 37
3.3.5.3 Disc brake 38
3.3.6 Saddle 39
3.3.7 Seat post 39
3.3.7.1 Patent seat post 39
3.3.7.2 Suspension seat post 40
3.3.8 Mechanical drive system 41
3.3.8.1 Chain drive layout 41
3.3.8.2 Belt drive layout 41
3.3.9 Electric drive system 42
3.3.9.1 Motor 42
3.3.9.2 Rechargeable battery 42
3.3.9.3 Frame battery 43
3.3.9.4 Pannier rack battery 43
3.3.9.5 Integrated battery 44
3.3.9.6 Charger 44
3.3.10 Lighting 44
3.3.11 On-board computer 45
3.3.11.1 USB port 45
3.3.12 Control panel 45
3.4 Description of controls and screens 46
3.4.1 Handlebars 46
3.4.2 On-board computer 47
3.4.2.1 Riding light indicator 47
3.4.2.2 Level of assistance indicator 47
3.4.2.3 Charge level indicator (on-board computer) 48
3.4.2.4 Indicator for motor power used 48
3.4.2.5 Gear recommendation indicator 48
3.4.2.6 Tachometer indicator 48
3.4.2.7 Function display 48
3.4.2.8 Journey information 49
3.4.2.9 Additional journey information 49
3.4.2.10 System settings and data 50
3.4.2.11 Additional system settings 50
3.4.2.12 System message 51
3.4.3 Control panel 52
3.4.4 Gear shift 53
3.4.4.1 SHIMANO derailleur gears 53
3.4.5 Handbrake 54
3.4.6 Fork lock 55
3.4.6.1 SR Suntour 55
3.4.7 Battery level indicator (battery) 56
3.4.7.1 Battery level indicator (battery) 56
3.5 Technical data 57
3.5.1 Pedelec 57
3.5.2 Emissions 57
3.5.3 BOSCH Intuvia on-board computer 57
3.5.4 USB port 57
3.5.5 BOSCH Performance Line CX motor 57

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Contents
3.5.6 Battery BOSCH PowerTube 625 57
3.5.7 Bicycle lighting 57
3.5.8 Torque 58
4 Transporting and storing
4.1 Weight and dimensions for transportation 65
4.2 Designated handles, lifting points 65
4.3 Transportation 66
4.3.1 Using the transport securing system 66
4.3.2 Transporting the pedelec 66
4.3.3 Shipping a pedelec 66
4.3.4 Transporting the battery 66
4.3.5 Shipping the battery 66
4.4 Storing 67
4.4.1 Storage mode 67
4.4.2 Break in operation 67
4.4.2.1 Preparing a break in operation 67
4.4.2.2 Carrying out a break in operation 67
5 Assembly
5.1 Unpacking 68
5.2 Required tools 68
5.3 Commissioning 69
5.3.1 Checking the battery 69
5.3.2 Preparing the battery 70
5.3.2.1 Retrofitting the PowerTube adapter 70
5.3.2.2 Fit battery cover onto Bosch PowerTube 625 battery (horizontal) 71
5.3.2.3 Fit battery cover onto Bosch PowerTube 500 battery (horizontal) 72
5.3.2.4 Securing the PowerTube BS2 battery mount 73
5.3.3 Preparing the wheel 78
5.3.4 Installing the wheel in the SUNTOUR fork 79
5.3.4.1 Screw-on axle (12AH2 and 15AH2) 79
5.3.4.2 20 mm cross axle 80
5.3.4.3 Q-LOC quick release 82
5.3.5 Preparing the LIMOTEC seat post 83
5.3.6 Fitting the pedals 84
5.3.7 Checking the stem and handlebars 85
5.3.7.1 Checking the connections 85
5.3.7.2 Checking stem is firmly in position 85
5.3.7.3 Checking the bearing clearance 85
5.4 Selling the pedelec 85
6 Operation
6.1 Risks and hazards 86
6.2 Tips for a greater range 88
6.3 Error message 89
6.3.1 On-board computer 89
6.3.2 Rechargeable battery 91
6.4 Instruction and customer service 92
6.5 Adjusting the pedelec 92
6.5.1 Preparing 92
6.5.2 Pedelec adjustment procedure 93
6.5.3 Determining the sitting position 94
6.5.3.1 Straighten saddle 95
6.5.3.2 Positioning the saddle with eightpins suspension seat post 95
6.5.3.3 Adjusting the saddle height 96
6.5.3.4 Setting the saddle height with the remote control 97
6.5.3.5 Adjusting the saddle position 98

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Contents
6.5.3.6 Adjusting the saddle tilt 98
6.5.3.7 Checking saddle stability 98
6.5.4 Handlebars 99
6.5.4.1 Replace handlebars 99
6.5.4.2 Adjusting the handlebar width 99
6.5.4.3 Adjusting the hand position 99
6.5.4.4 Adjusting the handlebars 100
6.5.5 Stem 101
6.5.5.1 Replacing the handlebars 101
6.5.5.2 Adjusting the handlebar height with quick release 101
6.5.5.3 Checking the stem stability 101
6.5.5.4 Adjusting the quick release clamping force 101
6.5.5.5 Setting the quill stem 102
6.5.5.6 Adjusting the Ahead stem 102
6.5.5.7 Adjusting the angle-adjustable stem 103
6.5.6 Handles 104
6.5.6.1 Replacing the handles 104
6.5.6.2 Adjusting ergonomic handles 104
6.5.6.3 Checking handlebar stability 104
6.5.7 Tyres 105
6.5.7.1 Adjust tyre pressure 105
6.5.7.2 Replacing tyres 106
6.5.8 Brake 107
6.5.8.1 Change handbrake position 107
6.5.8.2 Change handbrake inclination angle 107
6.5.8.3 Determining the grip distance 108
6.5.8.4 Grip distance on a MAGURA disc brake lever 109
6.5.8.5 Pressure point on a MAGURA brake lever 110
6.5.8.6 Replacing brakes 111
6.5.8.7 Retracting the brake linings 111
6.5.9 Gear shift 112
6.5.9.1 Replacing the gear shift 112
6.5.9.2 Adjusting the SHIMANO shifter 112
6.5.10 Suspension 113
6.5.11 Fork sag 113
6.5.11.1 Adjusting the SR SUNTOUR fork steel suspension 114
6.5.11.2 Adjusting the SR SUNTOUR fork air suspension 115
6.5.12 Fork rebound damping 116
6.5.12.1 Adjusting the SR SUNTOUR fork rebound damping 117
6.5.13 Riding light 118
6.5.13.1 Adjusting the headlight 119
6.5.14 Adjust on-board computer 120
6.5.14.1 Attaching the on-board computer 120
6.5.14.2 Removing the on-board computer 120
6.5.14.3 Attaching the on-board computer 120
6.5.14.4 Securing the on-board computer against removal 120
6.5.14.5 Charging the on-board computer battery 121
6.5.14.6 Changing the system settings 121
6.6 Accessories 122
6.6.1 Child seat 122
6.6.2 Trailer 123
6.6.2.1 Approval for trailer with Enviolo hub 123
6.6.2.2 Approval for trailer with ROHLOFF hub 124
6.6.3 Mobile holder 124
6.6.4 Tubeless and airless tyres 124
6.6.5 Suspension fork coil spring 124
6.6.6 Pannier rack 125
6.6.7 Panniers and cargo boxes 125
6.7 Personal protective equipment and accessories for road safety 126

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Contents
6.8 Before each ride 126
6.9 Straightening the quickly adjustable stem 127
6.10 Using the pannier rack 127
6.11 Raising the kickstand 128
6.12 Using the saddle 128
6.12.1 Using the leather saddle 128
6.13 Using the pedals 128
6.14 Using the bell 128
6.15 Using the handlebars 129
6.15.1 Using multi-position handlebars 129
6.15.2 Using bar ends 129
6.15.3 Using leather handles 129
6.16 Using the battery 130
6.16.1 Frame battery 130
6.16.1.1 Removing the frame battery 130
6.16.1.2 Inserting the frame battery 130
6.16.2 Pannier rack battery 130
6.16.2.1 Removing the pannier rack battery 130
6.16.2.2 Inserting the pannier rack battery 130
6.16.3 Integrated battery 131
6.16.3.1 Removing the integrated battery 131
6.16.3.2 Inserting the integrated battery 131
6.16.4 Charging the battery 132
6.16.5 Charging the dual battery 132
6.16.5.1 Charging process when two batteries are used 132
6.16.5.2 Charging process when one battery is used 132
6.16.6 Using double battery model with a single battery only 133
6.16.7 Waking the battery 133
6.17 Using pedelec with the electric drive system 134
6.17.1 Switching on the electric drive system 134
6.17.2 Switching off the electric drive system 134
6.18 Using the on-board computer 135
6.18.1 Using the USB port 135
6.18.2 Switching on the on-board computer 135
6.18.3 Switching off the on-board computer 135
6.18.4 Using the push assist system 136
6.18.5 Using the riding light 136
6.18.6 Selecting the level of assistance 136
6.18.7 Journey information 136
6.18.7.1 Switching the displayed journey information 136
6.18.7.2 Resetting the journey information 136
6.19 Using the brake 137
6.19.1 Use handbrake 137
6.19.2 Using the back-pedal brake 137
6.20 Use suspension and damping 138
6.20.1 Adjusting the SR SUNTOUR compression adjuster 139
6.21 Gear shift 140
6.21.1 Using the derailleur gears 140
6.21.2 Use SHIMANO hub gear 141
6.21.3 Using eShift 142
6.21.3.1 Using eShift with SHIMANO DI2 automatic hub gears 142
6.21.3.2 Using eShift with manual SHIMANO DI2 hub gears 142
6.21.3.3 Using eShift with SHIMANO DI2 automatic hub gears 142
6.22 Parking 143
6.22.1 Screwing in the quickly adjustable stem 144
7 Cleaning, servicing and inspection
7.1 Before each ride 149
7.1.1 Checking the guards 149

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Contents
7.1.2 Checking the frame 149
7.1.3 Checking the fork 149
7.1.4 Checking the rear frame damper 149
7.1.5 Checking the pannier rack 149
7.1.6 Checking the mudguards 149
7.1.7 Check wheel concentricity 149
7.1.8 Checking the quick releases 149
7.1.9 Checking the suspension seat post 150
7.1.10 Checking the bell 150
7.1.11 Checking the handles 150
7.1.12 Checking the USB cover 150
7.1.13 Checking the riding light 150
7.1.14 Checking the brake 150
7.2 After each ride 151
7.2.1 Cleaning the riding light and reflectors 151
7.2.2 Cleaning the suspension fork 151
7.2.3 Caring for the suspension fork 151
7.2.4 Cleaning the pedals 151
7.2.5 Cleaning the brake 151
7.2.6 Cleaning the suspension seat post 151
7.2.7 Cleaning the rear frame damper 151
7.3 Basic cleaning 152
7.3.1 Clean on-board computer and control panel 152
7.3.2 Cleaning the battery 152
7.3.3 Cleaning the motor 152
7.3.4 Clean Frame, fork, pannier rack, guards and kickstand 153
7.3.5 Cleaning the stem 153
7.3.6 Cleaning the handlebars 153
7.3.7 Clean handles 153
7.3.7.1 Cleaning leather handles 153
7.3.8 Clean seat post 153
7.3.9 Cleaning the saddle 154
7.3.9.1 Cleaning the leather saddle 154
7.3.10 Cleaning the tyres 154
7.3.11 Cleaning the spokes and spoke nipples 154
7.3.12 Clean hub 154
7.3.13 Cleaning the switching elements 154
7.3.13.1 Cleaning the shifter 154
7.3.14 Clean cassette, chain wheels and front derailleur 154
7.3.15 Clean brake 155
7.3.15.1 Clean handbrake 155
7.3.16 Cleaning the brake disc 155
7.3.17 Cleaning the belt 155
7.3.18 Cleaning the chain 155
7.3.18.1 Clean chain, including all-round chain guard 155
7.4 Servicing 156
7.4.1 Frame 156
7.4.2 Fork 156
7.4.3 Pannier rack 157
7.4.4 Mudguard 157
7.4.5 Servicing the kickstand 157
7.4.6 Stem 157
7.4.7 Handlebars 157
7.4.8 Handle 157
7.4.8.1 Rubber handles 157
7.4.8.2 Leather handle 157
7.4.9 Seat post 158
7.4.9.1 Suspension seat post 158
7.4.9.2 Carbon seat post 158

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Contents
7.4.10 Rim 158
7.4.11 Leather saddle 158
7.4.12 Hub 158
7.4.13 Spoke nipples 158
7.4.14 Gear shift 159
7.4.14.1 Rear derailleur articulated shafts and jockey wheels 159
7.4.14.2 Shifter 159
7.4.15 Pedal 159
7.4.16 Caring for the chain 159
7.4.16.1 Caring for the chain and all-round chain guard 160
7.4.17 Caring for the battery 160
7.4.18 Caring for the brake 160
7.4.18.1 Caring for handbrake 160
7.4.19 Lubricating the Eightpins seat post tube 160
7.5 Inspection 161
7.5.1 Checking the wheel 161
7.5.1.1 Checking tyre pressure 161
7.5.1.2 Checking the tyres 163
7.5.1.3 Checking the rims 164
7.5.1.4 Checking the nipple holes 164
7.5.1.5 Checking the nipple well 164
7.5.1.6 Checking the rim hooks 164
7.5.1.7 Checking the spokes 164
7.5.2 Checking the brake system 165
7.5.2.1 Checking the handbrake 165
7.5.2.2 Checking the hydraulic brake system 165
7.5.2.3 Checking the Bowden cables 165
7.5.2.4 Checking the disc brake 166
7.5.2.5 Checking the back-pedal brake 167
7.5.2.6 Checking the rim brake 168
7.5.3 Checking the chain 169
7.5.4 Checking the chain tension 169
7.5.4.1 Check tension in derailleur gears 169
7.5.4.2 Check tension in hub gear 169
7.5.5 Checking the belt for wear 169
7.5.5.1 Rough check 169
7.5.5.2 Check 170
7.5.6 Checking the belt 171
7.5.7 Checking the belt for wear 171
7.5.8 Checking the belt sprockets for wear 171
7.5.9 Check belt tension 171
7.5.9.1 Gates Carbon Drive mobile app 172
7.5.9.2 Gates Krikit tension meter 172
7.5.9.3 ECO tension tester 173
7.5.10 Checking the riding light 174
7.5.11 Checking the stem 175
7.5.12 Checking the handlebars 175
7.5.13 Checking the saddle 175
7.5.14 Checking the seat post 175
7.5.14.1 Checking the derailleur gears 175
7.5.14.2 Checking the hub gear 176
7.5.15 Check gear shift 176
7.5.15.1 Electric gear shift 176
7.5.15.2 Mechanical gear shift 176
7.5.15.3 Checking the derailleur gears 177
7.5.16 Adjusting gear shift 177
7.5.16.1 Adjusting the ROHLOFF hub 177
7.5.17 Adjusting cable-operated gear shift, dual-cable 177
7.5.18 Adjusting Bowden-cable-operated twist grip, dual-cable 178

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Contents
7.5.19 Checking kickstand stability 178
8 Inspection and maintenance
8.1 Initial inspection 179
8.2 Major inspection 179
8.3 Component-specific maintenance 179
8.4 Carry out initial inspection 182
8.5 Inspection and maintenance instructions 183
8.5.1 Inspecting the frame 190
8.5.1.1 Inspect the carbon frame 190
8.5.2 Inspecting the pannier rack 190
8.5.3 Inspect and maintain rear frame damper 190
8.5.4 Inspect gear hub 191
8.5.4.1 Adjusting the hub with cone bearing 191
8.5.5 Inspecting the stem 191
8.5.6 Inspect and grease steering headset 191
8.5.7 Inspecting axle with quick release 192
8.5.8 Inspecting the fork 193
8.5.8.1 Inspect the carbon suspension fork 193
8.5.8.2 Inspect the suspension fork 193
8.5.9 Inspecting the seat post 194
8.5.9.1 Inspect carbon seat post 194
8.5.9.2 Inspecting and greasing BY.SCHULZ suspension seat post 195
8.5.9.3 Inspecting and greasing RS SUNTOUR suspension seat post 195
9 Troubleshooting, fault clearance and repair
9.1 Preventing pain 196
9.1.1 Sitting discomfort 197
9.1.2 Pain in hips 197
9.1.3 Backache 197
9.1.4 Pain in shoulders and nape of neck 198
9.1.5 Numb or aching hands 198
9.1.6 Pain in upper thigh 198
9.1.7 Knee pain 199
9.1.8 Pain in the foot 199
9 Troubleshooting, fault clearance and repair
9.1 Troubleshooting and fault clearance 200
9.1.1 Drive system or on-board computer does not start up 200
9.1.2 Error message 200
9.1.3 Assistance function errors 201
9.1.4 Battery error 202
9.1.5 On-board computer error 203
9.1.6 Lighting does not work 203
9.1.7 SR SUNTOUR suspension fork 204
9.1.7.1 Rebound too fast 204
9.1.7.2 Rebounding too slowly 205
9.1.7.3 Suspension too soft on inclines 206
9.1.7.4 Excessively hard damping on bumps 207
9.1.8 Problems with freewheel 208
9.1.9 Problems with hub gear 209
9.1.10 Problems with disc brakes 211
9.1.11 Problems with rim brakes 212
9.1.12 Problems with back-pedal brake 213
9.1.13 RockShox suspension fork 214
9.1.13.1 Rebound too fast 214
9.1.13.2 Rebounding too slowly 215
9.1.13.3 Suspension too soft on inclines 216

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Contents
9.1.13.4 Excessively hard damping on bumps 217
9.1.14 Other errors 218
9.2 Repair 219
9.2.1 Original parts and lubricants 219
9.2.2 Repairing the frame 219
9.2.2.1 Removing paint damage on frame 219
9.2.2.2 Removing damage from impact on the carbon frame 219
9.2.3 Repairing the suspension fork 219
9.2.3.1 Removing paint damage on the fork 219
9.2.3.2 Removing damage from impact on the carbon frame 219
9.2.3.3 Repairing the seat post 219
9.2.3.4 Repairing damage from impact on the carbon post seat post 219
9.2.4 Replacing the riding light 220
9.2.5 Adjusting the headlight 220
9.2.6 Checking suspension fork-tyre clearance 220
10 Recycling and disposal
10.1 Guidelines on removal of waste 221
11 Documents
11.1 Assembly report 223
11.2 Inspection and maintenance log 225
11.3 Parts list 229
11.3.1 SU-E FS 12 229
11.3.2 ZE 10 231
11.3.3 ZE 5F 233
11.3.4 ZE 5F Plus 235
11.3.5 ZE 5R 237
11.3.6 ZE 5F Plus 239
11.4 Charger operating instructions 241
12 Glossary
12.1 Abbreviations 253
12.2 Simplified terms 253
13 Appendix
I. Translation of the original EC/EU Declaration of Conformity 254
II. Declaration of conformity for incomplete machine 255
14 Keyword index