Conway Cairon T 5.0 User manual

E-bike components
3
1 E-bike components
The BOSCH drives consist of the components shown here. Depending on the model, the drives differ in terms of equipment, technical coordination and operation.
•Familiarise yourself with operation and functions, as well as the care and maintenance notes.
1 Control unit
2 Control computer holder
3 Control computer
4 ABS
5 Drive unit
6 Speed sensor
7 Charger
8 Battery
123
5
4
6
7
8

Table of contents
4
1 E-bike components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 In the case of an emergency . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 General protective measures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 In the event of excessive heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 In case of deformation, odour or leaking liquid . . . . . . . . . . . . . . . 7
2.4 If the battery catches fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Tuning or manipulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.1 Reading the user manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.2 Categorisation of warning notes . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.3 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.4 Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.5 Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.6 Button batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.7 Residual risks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.7.1 Risk of injury . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.7.2 Fire hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.7.3 Risk of damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5 Basic information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
5.1 Symbols on the products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.2 Symbols in this manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.3 Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.4 Written labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.5 Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6 Notes on the e-bike. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
6.1 Differences between a conventional bicycle and an e-bike . . . . 16
6.2 Functionality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.3 Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.4 Cycling with a discharged battery . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.5 Driving with ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.5.1 Privacy statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.5.2 Basic information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.5.3 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.6 Drive overheat protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7 General notes on the battery . . . . . . . . . . . . . . . . . . . . . . . . .20
7.1 Charging times. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.2 Storing the battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.3 Transporting or shipping the battery. . . . . . . . . . . . . . . . . . . . . . . 21
7.4 Temperature monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.5 Electronic cell protection (ECP) . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8 Notes on use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
8.1 Information regarding road traffic. . . . . . . . . . . . . . . . . . . . . . . . . 22
8.2 Areas of application of the battery and charger . . . . . . . . . . . . . 22
8.3 Insurance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.4 Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.5 Permissible total weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.6 Exclusion of wearable parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.7 Disclaimer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Table of contents
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9 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
9.1 By car . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
9.2 Using other forms of transportation . . . . . . . . . . . . . . . . . . . . . . . 23
9.3 Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
10 Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
10.1 Before each ride . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
10.2 Your first ride . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
10.3 Inspection instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
10.4 Preparations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
10.4.1 Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
10.4.2 Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
11 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
11.1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
11.1.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
11.1.2 Checking the battery before first use . . . . . . . . . . . . . . . . . . . . . . . 27
11.1.3 Charging the battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
11.1.4 Charge indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
11.1.5 Removing and inserting the rechargeable battery . . . . . . . . . . . . 28
11.1.6 Switching the battery on/off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
11.1.7 Tips for the optimum handling of the battery . . . . . . . . . . . . . . . . 30
11.1.8 Recharge the battery before and during storage . . . . . . . . . . . . . 30
11.2 Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
11.2.1 Connecting the charger to the power supply. . . . . . . . . . . . . . . . . 31
11.2.2 Charging the removed battery (PowerTube) . . . . . . . . . . . . . . . . . 31
11.2.3 Charging the battery on the e-bike. . . . . . . . . . . . . . . . . . . . . . . . . . 31
11.2.4 Charging process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
11.3 Kiox 300 control computer holder. . . . . . . . . . . . . . . . . . . . . . . . 32
11.3.1 Mounting positions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
11.3.2 Installation of the control computer holder . . . . . . . . . . . . . . . . . . 33
11.3.3 Mounting on the handlebar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
11.4 Control units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
11.4.1 LED Remote . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
11.4.2 Mini Remote. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
11.4.3 System Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
11.4.4 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
11.4.5 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
11.4.6 Power supply of the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
11.4.7 Switching the e-bike system on/off. . . . . . . . . . . . . . . . . . . . . . . . . 37
11.4.8 Charge indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
11.4.9 Setting the assistance level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
11.4.10 Interaction of the e-bike system with the shifting system . . . . 39
11.4.11 Switching the bicycle lights on/off . . . . . . . . . . . . . . . . . . . . . . . . 39
11.4.12 Shutting the walk assistance on/off. . . . . . . . . . . . . . . . . . . . . . . 39
11.4.13 ABS – Anti-lock braking system (optional) . . . . . . . . . . . . . . . . . 40
11.4.14 Establish a smartphone connection. . . . . . . . . . . . . . . . . . . . . . . 40
11.4.15 Activity tracking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
11.4.16 Lock function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
11.4.17 Software updates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
11.5 Kiox 300 control computer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
11.5.1 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
11.5.2 Inserting and removing the control computer. . . . . . . . . . . . . . . . 41
11.5.3 Inserting the securing plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
11.5.4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
11.5.5 Start screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
11.5.6 Status screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Table of contents
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11.6 Intuvia 100 control computer. . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
11.6.1 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
11.6.2 Inserting and removing the control computer. . . . . . . . . . . . . . . . 45
11.6.3 Inserting the locking screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
11.6.4 Changing the batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
11.6.5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
11.6.6 Display indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
11.6.7 Speed and distance indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
11.6.8 Displaying and adjusting the basic settings . . . . . . . . . . . . . . . . . 48
11.7 Drive unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
11.8 Speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
11.8.1 Speed sensor (slim) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
11.8.2 Rim magnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
12 Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
12.1 Notes on the battery lock key . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
13 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
13.1 Disposing of the e-bike and charger . . . . . . . . . . . . . . . . . . . . . . 53
13.2 Disposing of rechargeable batteries and batteries. . . . . . . . . . 53
13.3 Disposing of the packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
14 Error messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
14.1 LED Remote control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
14.1.1 Fewer critical errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
14.1.2 Critical errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
14.2 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
14.3 Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
15 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
15.1 Control computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
15.2 Control computer holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
15.3 Control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
15.4 Bicycle lighting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
15.5 Bosch eBike ABS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
15.6 Drive unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
15.7 Lithium ion rechargeable battery. . . . . . . . . . . . . . . . . . . . . . . . . 59
15.8 Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
16 Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . .60
17 Legal notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

In the case of an emergency
7
2 In the case of an emergency
You can find notes on handling the battery in this user manual. Despite compliance
with all safety measures, the battery poses a risk e.g. if it catches fire.
•In an emergency, behave in such a way that you do not at any time endanger
yourself or other persons.
•In an emergency, follow the instructions on this page.
•Immediately read these instructions so that you can concentrate and respond in
a calculated manner in the event of an emergency.
•We recommend keeping a suitable fire extinguisher on hand at all times.
2.1 General protective measures
If you identify defects or damage to the battery:
•Do not use the battery.
•Wear protective gloves when you touch the battery.
•Do not inhale any gases or vapours that are emitted.
•Avoid contact between your skin and any liquid that has leaked.
2.2 In the event of excessive heat
If you notice that excessive heat is being generated by the battery:
•Have the battery checked by your specialist dealer immediately. Inform your
specialist dealer about the charge level before transport.
•For short-term temporary storage, select an outdoor location and, if possible,
place the battery in a fire-proof container or on the soil.
•If you store the battery outdoors, clearly secure the area with ample space around
the storage location and protect the battery from unauthorised access.
2.3 In case of deformation, odour or leaking liquid
If you identify any deformation, odour or liquid leaked on the battery:
•Place the battery in a fire and acid-proof container, e.g. made of rock or clay, and
cover the battery with sand.
•Have your specialist dealer dispose of the battery immediately.
•For short-term temporary storage, choose an outdoor location.
•If you store the battery outdoors, clearly secure the area with ample space around
the storage location and protect the battery from unauthorised access.
2.4 If the battery catches fire
If the battery catches fire, carcinogenic gases may be produced. Protect your
respiratory system and avoid inhaling gases and smoke emitted during the fire.
•Call the fire brigade immediately.
•If there is no danger to you and you are physically able, use a suitable fire
extinguisher to put out the fire.
•If there is no danger to you and you are physically able, cool the battery by placing
it in fireproof container filled with water. The water must completely surround the
battery.
•If there is no danger to you and you are physically able, cover the battery completely
with sand.

Tuning or manipulation
8
3 Tuning or manipulation
WARNING
Risk of accident and injury!
Tuning or manipulating the speed settings of your e-bike may have a
negative impact on your bicycle’s braking or riding performance and may
lead to accidents and injury.
• Do not make any structural modifications to the e-bike.
WARNING
Risk of accident and injury!
Tampering with the anti-lock braking system (ABS) can lead to brake failure.
• Do not make any structural modifications to the anti-lock braking system.
CAUTION
Risk of injury!
The e-bike may respond in a manner other than that which you expect if the
e-bike system has been manipulated.
• Do not make any structural changes to the e-bike system.
NOTICE
Risk of damage!
You can cause irreparable damage to your e-bike by tuning it.
• Do not make any structural changes to the e-bike system.
-You can cause irreparable damage to your e-bike by tuning it.
-The frame, wheels and brakes are not designed for higher speeds.
-Any modification of the e-wheel system or the anti-lock braking system leads to
the exclusion of the warranty or other claims.
-Tuning your e-bike has legal consequences.
-Operating an e-bike at speeds of over 25 km/h require a driving licence and an
insurance policy as well as a registration plate.
-Riders of e-bikes at a speed above 25 km/h are subject to compulsory helmet
use.
-Any modification of the e-bike system will result in the loss of your driving
licence.
-Any modification of the e-bike system will result in the loss of insurance cover
(personal liability).
-In the event of a repeat offence, an entry may be made in the police clearance
certificate (criminal record).
-Any modification of the e-bike system will result in the loss of the Declaration of
Conformity (CE).
-Any modification of the e-bike system precludes participation in road traffic.
-Any change to the anti-lock braking system can lead to brake failure.

Safety
9
4 Safety
4.1 Reading the user manual
Read all warnings and notes in this user manual with care before you
operate the e-bike for the first time.
This user manual consists of supplementary instructions and applies in
addition to the user manual of your e-bike. The complete scope of the
original operating manual for your e-bike includes the bicycle user manual, this user
manual and, if applicable, other included user manuals for the components installed
on your e-bike.
Keep all user manuals so that they are handy and available at all times. Include the user
manual when passing the e-bike on to third parties.
4.2 Categorisation of warning notes
The warning notes are intended to draw your attention to potential hazards. Your
complete attention is required when reading the warning notes; the statements must
be understood completely. Failure to follow a warning note may result in injury to
yourself or other persons. The warning notes alone cannot prevent dangers.
•Follow all warning notes to avoid a risk when using the e-bike.
There are warning notes in the following categories:
DANGER
This key word designates a hazard with a moderate degree of risk
which may lead to death or severe injury if unheeded.
WARNING
This key word designates a hazard with a moderate degree of risk
which may lead to death or severe injury if unheeded.
CAUTION
This key word designates hazard with a low degree of risk, which may
result in minor or moderate injury if unheeded.
NOTICE
This key word warns of possible damage to property.

Safety
10
4.3 Use
WARNING
Risks for children and persons with impaired physical, sensory or
mental capacities or lack of experience and knowledge, e.g. children
or persons with impaired mental and physical capacities!
The e-bike, battery and the charger may only be used by persons, who are
able to act without restriction with respect to their mental and physical
abilities. There is a high risk of injury for persons with restricted mental and
physical capacities!
• Only allow the e-bike, battery and the charger to be used by persons briefed
on safe and proper use and who understand the risks arising in connection
with it.
• Do not let children play or ride the e-bike.
WARNING
Risk of accident and injury!
There is an increased risk of accident and injury if the e-bike is used in an
improper manner or with disregard for regulations.
• Do not repair the e-bike yourself.
• Have repairs performed by your specialist dealer.
NOTICE
Risk of damage!
High or low temperatures could restrict the functioning of the e-bike or
damage it.
• Take note of the temperature limits.
• Do not park the e-bike near heat sources.
4.4 Battery
WARNING
Risk of fire and explosion!
Batteries that have caught fire are very difficult to extinguish; the cells
affected must burn down in a controlled manner. Responding properly may
prevent severe damages.
• Read the section “2 In the case of an emergency” on page 7so that you are
prepared.
WARNING
Risk of fire and explosion!
Internal damage to the battery may cause the battery to overheat, emit
gases or leak liquids even a significant amount of time after the damage
has occurred.
• Have your specialist dealer inspect the battery after falls or severe impacts.
• Do not open, dismantle, drill through or deform the battery.
WARNING
Risk of fire and explosion!
Heat (e.g. strong sunlight), fire and other heat sources can damage the
battery.
• Keep the battery away from fire and other heat sources; protect it against
exposure to intense sunlight.
• Never leave the e-bike with the battery inserted in the blazing sun or expose
it to strong heat.