Hercules FAZUA Futuro 10 FA 20" 252Wh 10G S Quick guide

TRANSLATION OF THE ORIGINAL OPERATING INSTRUCTIONS
IMPORTANT
READ CAREFULLY BEFORE USE
KEEP SAFE TO CONSULT AT A LATER DATE
Pedelecs
Futuro 10 FA 20" 252Wh 10G S
20-Y-0001
MY20H06-2 • 1.0 • 26. August 2019

MY20H06-2_1.0_26.08.2019 2
Contents
Contents
1 About these operating instructions 5
1.1 Manufacturer 5
1.2 Type number and model 5
1.3 Identifying the operating instructions 5
1.4 Laws, standards and directives 5
1.5 Subject to change 6
1.6 Language 6
1.7 For your safety 6
1.7.1 Instruction, training and customer service 6
1.7.2 Basic safety instructions 6
1.7.3 Warnings 6
1.7.4 Safety markings 6
1.8 For your information 7
1.8.1 Instructions for actions 7
1.8.2 Language conventions 7
1.8.3 Information on the nameplate 7
1.9 Nameplate 8
2 Safety 9
2.1 General warnings 9
2.2 Toxic substances 10
2.3 Requirements for the rider 11
2.4 Protection for vulnerable groups 11
2.5 Data privacy 11
2.6 Personal protective equipment 11
2.7 Safety markings and safety instructions 11
2.8 Emergency 12
2.8.1 What to do in an emergency 12
2.8.2 First aid treatment 12
2.8.3 Fighting fire 12
2.8.4 Leaking fluids 13
2.8.4.1 Brake fluid 13
2.8.4.2 Oils and lubricants from the fork 13
2.8.4.3 Oils and lubricants from the rear frame
damper 13
3Overview 14
3.1 Description 15
3.1.1 Wheel and suspension 15
3.1.1.1 Valve 15
3.1.2 Suspension 15
3.1.2.1 Steel suspension fork structure 16
3.1.2.2 Air suspension fork structure 16
3.1.2.3 Structure of the FOX rear frame damper 17
3.1.2.4 Structure of the Suntour rear frame
damper 17
3.1.3 Brake system 17
3.1.3.1 Rim brake 17
3.1.3.2 Disc brake 18
3.1.3.3 Back-pedal brake 18
3.1.3.4 ABS 19
3.1.4 Electric drive system 20
3.1.5 Drive unit 20
3.1.6 Rechargeable battery 21
3.1.7 Control panel 21
3.2 Charger 22
3.3 Proper use 23
3.4 Improper use 24
3.5 Technical data 25
3.5.1 Pedelec 25
3.5.2 Emissions 26
3.5.3 Tightening torque 26
3.6 Environmental requirements 27
3.7 Description of controls and screens 29
3.7.1 Handlebars 29
3.7.2 Rechargeable battery 29
3.7.3 Control panel on-screen indicators 29
3.7.4 Control panel 29
3.7.4.1 Display bar 29
3.7.4.2 Level of assistance 30
4 Transporting and storing 31
4.1 Physical transport characteristics 31
4.1.1 Dimensions during transportation 31
4.1.2 Transport weight 31
4.1.3 Designated handles/lifting points 31
4.2 Transporting 31
4.2.1 Transporting the battery 32
4.2.2 Shipping the battery 32
4.2.3 Using the brake transport securing
system 32
4.3 Storing 32
4.3.1 Break in operation 33
4.3.1.1 Preparing a break in operation 33
4.3.1.2 Taking out of operation 33
5 Assembly 34
5.1 Required tools 34
5.2 Unpacking 34
5.2.1 Scope of delivery 34
5.3 Commissioning 35
5.3.1 Checking the battery 35
5.3.2 Installing the wheel in the Suntour fork 35
5.3.2.1 Installing the wheel with screw-on axle
(15 mm) 35
5.3.2.2 Installing the wheel with screw-on axle
(20 mm) 36
5.3.2.3 Installing the wheel with a
quick release axle 37
5.3.3 Installing the wheel with a quick release 38
5.3.4 Installing the wheel in the FOX fork 39
5.3.4.1 Wheel with quick release (15 mm) 39
5.3.4.2 Adjusting the FOX quick release 40
5.3.4.3 Installing the wheel with Kabolt axles 40

MY20H06-2_1.0_26.08.2019 3
Contents
5.3.4.4 Checking the stem and handlebars 40
5.3.5 Pedelec sale 41
6Operation 42
6.1 Risks and hazards 42
6.1.1 Tips for a greater range 43
6.1.2 Personal protective equipment 43
6.2 Error messages 44
6.3 Before the first ride 45
6.3.1 Adjusting the saddle 45
6.3.1.1 Adjusting the saddle tilt 45
6.3.2 Determining the seat height 45
6.3.2.1 Adjusting the seat height with
quick release 45
6.3.2.2 Height-adjustable seat post 46
6.3.2.3 Adjusting the seat position 46
6.3.3 Adjusting the handlebars 47
6.3.3.1 Adjusting the stem 47
6.3.3.2 Adjusting the height of the handlebars 47
6.3.3.3 Turning the handlebars to the side 47
6.3.3.4 Checking the clamping force in quick
releases 48
6.3.3.5 Adjusting the quick release clamping
force 48
6.3.4 Adjusting the brake lever 48
6.3.4.1 Adjusting the pressure point on a
Magura brake lever 48
6.3.4.2 Adjusting the grip distance 49
6.3.4.3 Adjusting the grip distance on a
Magura brake lever 49
6.3.5 Adjusting the suspension of the
Suntour fork 50
6.3.5.1 Adjusting the negative deflection 50
6.3.5.2 Adjusting the air suspension fork
negative deflection 50
6.3.5.3 Adjusting the steel suspension fork
negative deflection 51
6.3.5.4 Adjusting the rebound 52
6.3.6 Adjusting the suspension of the
FOX fork 52
6.3.6.1 Adjusting the negative deflection 52
6.3.6.2 Adjusting the rebound 53
6.3.7 Setting the Suntour rear frame damper 54
6.3.7.1 Adjusting the negative deflection 54
6.3.7.2 Adjusting the rebound 54
6.3.7.3 Setting the compression 55
6.3.8 Setting the FOX rear frame damper 55
6.3.8.1 Adjusting the negative deflection 55
6.3.8.2 Adjusting the rebound 56
6.3.9 Retracting the brake linings 56
6.4 Accessories 57
6.4.1 Child seat 57
6.4.2 Bicycle trailers 58
6.4.3 Pannier rack 58
6.5 Before each ride 59
6.6 Check list before each ride 59
6.7 Using the kickstand 60
6.7.1 Raising the kickstand 60
6.7.1.1 Parking the pedelec 60
6.8 Using the pannier rack 60
6.9 Charger 61
6.9.1 Connecting the charger to the mains 62
6.10 Rechargeable battery 62
6.10.1 Charging the battery 63
6.10.1.1 Charging the battery in the drive unit 64
6.10.1.2 Charging the battery on the pedelec 65
6.10.2 Inserting the battery into the drive unit 65
6.10.3 Removing the battery from the drive unit 66
6.11 Drive unit 66
6.11.1 Installing the drive unit on the pedelec 66
6.11.2 Removing the drive unit from the
pedelec 66
6.12 Electric drive system 68
6.12.1 Switching on the electric drive system 68
6.12.2 Switching off the drive system 68
6.12.3 Drive system standstill 68
6.13 Control panel 69
6.13.1 Using the push assist system 69
6.13.2 Selecting the level of assistance 69
6.14 Brake 70
6.14.1 Using the brake lever 71
6.14.2 Using the back-pedal brake 72
6.15 Suspension and damping 72
6.15.1 Adjusting the compression of the
Fox fork 72
6.15.2 Adjusting the compression of the
Fox damper 72
6.15.3 Adjusting the compression of the
Suntour fork 73
6.16 Gear shift 73
6.16.1 Selecting gears 73
6.16.2 Using the hub gear 74
7 Cleaning and servicing 75
7.1 Cleaning after each ride 75
7.1.1 Cleaning the suspension fork 75
7.1.2 Cleaning the rear frame damper 75
7.1.3 Cleaning the pedals 75
7.2 Basic cleaning 76
7.2.1 Cleaning the frame 76
7.2.2 Cleaning the stem 76
7.2.3 Cleaning the rear frame damper 76
7.2.4 Cleaning the wheel 76
7.2.5 Cleaning the drive elements 76
7.2.6 Cleaning the chain 77
7.2.7 Cleaning the battery 77

MY20H06-2_1.0_26.08.2019 4
Contents
7.2.8 Cleaning the display 77
7.2.9 Cleaning the drive unit 77
7.2.10 Cleaning the brake 78
7.3 Servicing 78
7.3.1 Servicing the frame 78
7.3.2 Servicing the stem 78
7.3.3 Servicing the fork 78
7.3.4 Servicing the drive elements 78
7.3.5 Servicing the pedals 78
7.3.6 Servicing the chain 78
7.3.7 Servicing the drive elements 78
7.4 Maintenance 78
7.4.1 Wheel 78
7.4.2 Checking the tyres 79
7.4.3 Checking the rims 79
7.4.4 Checking and adjusting the
tyre pressure 79
7.4.4.1 Dunlop valve 79
7.4.4.2 Presta valve 80
7.4.4.3 Schrader valve 80
7.4.5 Brake system 80
7.4.6 Checking the brake linings for wear 80
7.4.7 Checking the pressure point 80
7.4.8 Checking the brake discs for wear 81
7.4.9 Electrical cables and brake cables 81
7.4.10 Gear shift 81
7.4.11 Stem 81
7.4.12 USB port 81
7.4.13 Checking the belt and chain tension 81
8 Maintenance 82
8.1 Axle with quick release 83
8.1.1 Checking the quick release 83
8.2 Adjusting the gear shift 83
8.2.1 Cable-operated gear shift, single-cable 84
8.2.2 Cable-operated gear shift, dual-cable 84
8.2.3 Cable-operated twist grip, dual-cable 84
9 Troubleshooting, fault clearance
and repair 85
9.1 Troubleshooting and fault clearance 85
9.1.1 The drive system or display do not
start up 85
9.1.2 Error messages 85
9.2 Assistance function 86
9.3 Rechargeable battery 87
9.4 Lighting 88
9.5 Display 88
9.6 Miscellaneous 88
9.7 Repair 90
9.7.1 Use original parts and lubricants only 90
9.7.2 Replacing the lighting 90
9.7.3 Setting the headlight 90
10 Recycling and disposal 91
11 Documents 92
11.1 Parts list 92
11.2 Assembly report 93
11.3 Maintenance log 95
12 Keyword index 98
13 Glossary 99
I. EC declaration of conformity 102

MY20H06-2_1.0_26.08.2019 5
About these operating instructions
1 About these operating instructions
Thank you for your trust!
HERCULES pedelecs are sporting equipment of
the highest quality – you have made a good
choice. Your specialist dealer has advised you
and assembled your product. Whether
maintenance, inspection, conversion or repair,
your specialist dealer will also be happy to assist
you in the future.
You receive these operating instructions with your
new pedelec. Please take a little time to become
familiar with your new pedelec and follow the tips
and suggestions in the operating instructions.
They will help you to enjoy your HERCULES
pedelec for a long time to come. We hope you
have fun and wish you well on all of your rides!
These operating instructions are designed for the
rider and the operator of the pedelec to ensure
that non-professionals can use the pedelec safely.
You can download the operating instructions onto
your mobile phone at the following address, so
that you can use them when you are out riding:
https://www.hercules-
bikes.de/de/de/index/
downloads.html
1.1 Manufacturer
The pedelec manufacturer is:
HERCULES GMBH
Longericher Straße 2
50739 Köln, Germany
Tel.: [phone]
Fax: [phone]
E-mail: [email protected]
Internet: www.hercules-bikes.de
1.2 Type number and model
The operating instructions are an integral part of
pedelecs with the following type numbers:
1.3 Identifying the operating
instructions
You will find the operating instructions
identification number at the bottom left-hand side
of each page. The identification number consists
of the document number, the version number and
the release date.
1.4 Laws, standards and directives
The operating instructions comply with the
essential requirements specified in:
• Machinery Directive 2006/42/EC
• Electromagnetic Compatibility Directive 2014/30/
EU
• ISO/DIS 20607:2018 Safety of machinery –
Instruction handbook – General drafting
principles
• EN 15194:2017 Cycles – Electrically power
assisted cycles – pedelec bicycles
• EN 11243:2016, Cycles – Luggage carriers for
bicycles – Requirements and test methods
• EN ISO 17100:2016-05, Translation Services –
Requirements for translation service.
Notice
The operating instructions are not a substitute for
personal instruction by the supplying specialist
dealer.
The operating instructions are an integral part of
the pedelec. Therefore, if it is re-sold at a later
time, they must be handed over to the subsequent
owner.
Instructions for the specialist dealer are highlighted in grey and
marked with a symbol. Specialist dealers have specialist
training and qualifications and are thus able to identify risks and
prevent hazards which may arise during maintenance, servicing
and repairs on the pedelec. Information for specialist staff does
not require non-professionals to take any action.
Type no. Model Pedelec type
20-Y-0001 Futuro 10 FA 20" 252Wh
10G S
City and trekking
bicycle
Table 1: Type number, model and pedelec type
Identification number MY20H06-2_1.0_26.08.2019
Table 2: Identification number

MY20H06-2_1.0_26.08.2019 6
About these operating instructions
1.5 Subject to change
The information contained in these operating
instructions are the approved technical
specifications at the time of printing. Any
significant changes will be included in a new issue
of the operating instructions.
You will find any modifications to these operating
instructions:
https://www.hercules-bikes.de.
1.6 Language
The original operating instructions are written in
German. A translation is not valid without the
original operating instructions.
1.7 For your safety
The pedelec's safety concept comprises four
elements:
• rider and/or operator instruction, and bicycle
maintenance and repair by the specialist dealer
• the section on general safety
• the warnings in these operating instructions
• the safety markings on the nameplate and the
pedelec.
1.7.1 Instruction, training and customer
service
The supplying specialist dealer will provide
customer service. Contact details can be found on
the back page of these operating instructions and
on the data sheet. If you are unable to contact
your specialist dealer, you will find other specialist
dealers online at www.hercules-bikes.de.
The rider or the operator of the pedelec will be
instructed on the pedelec's functions in person
when the supplying specialist dealer hands over
the pedelec, if not before. In particular, this
instruction will cover the pedelec's electrical
functions and correct use of the charger.
Each rider to whom this bicycle is provided must
receive instruction on the pedelec's functions. A
printed copy of these operating instructions must
be provided to each rider, who must take note of
and observe them.
1.7.2 Basic safety instructions
These operating instructions explains all general
safety instructions in Section 2.
1.7.3 Warnings
Hazardous situations and actions are marked with
warnings. The warnings in these operating
instructions are indicated as follows:
1.7.4 Safety markings
The following safety markings are used on the
pedelec's nameplates:
Will lead to serious or even fatal injuries if
ignored. High-risk hazard.
May lead to serious or even fatal injuries if
ignored. Medium-risk hazard.
May lead to minor or moderate injuries. Low-risk
hazard.
Notice
May lead to material damage if ignored.
General warning
Adhere to the instructions for use
Table 3: Meaning of safety markings
DANGER
!
WARNING
!
CAUTION
!

MY20H06-2_1.0_26.08.2019 7
About these operating instructions
1.8 For your information
1.8.1 Instructions for actions
Instructions for actions are structured in
accordance with the following pattern:
Requirements (optional)
Instruction for action
Result of the action (optional)
1.8.2 Language conventions
The pedelec described in these operating
instructions may be equipped with alternative
equipment. The pedelec equipment is defined by
its respective type number. Where applicable, the
word Alternative beneath the heading indicates
alternatively used components. The following terms
are used for better legibility:
The following conventions are used in these
operating instructions:
1.8.3 Information on the nameplate
Besides warnings, product nameplates also
contain other important information about the
pedelec:
Term Meaning
Operating
instructions
Original operating
instructions or translation
of the original operating
instructions
Pedelec Electric motor driven cycle
Motor Drive motor
Convention Use
Italics Glossary terms
SPACED Indicators on the display
screen
[Example, page
numbering]
Cross references
• Bulleted lists
Read the instructions
Separate collection of
electrical and electronic
devices
Separate collection of
batteries
Must not be thrown into fire
(burning prohibited)
Battery must not be opened
Device of protection class II
Only suitable for use indoors
Fuse (device fuse)
EU conformity
Recyclable material
Protect from temperatures
above 50 °C and direct
sunlight
Table 4: Relevance of safety instructions
max. 50°C

MY20H06-2_1.0_26.08.2019 8
About these operating instructions
1.9 Nameplate
The nameplate is situated on the frame. You will
find the precise position of the nameplate in
Figure 2. You will find thirteen pieces of
information on the nameplate.
Figure 1: Nameplate, example
No. Designation Description
1 CE marking The manufacturer uses the CE marking to declare that the pedelec complies with
applicable requirements.
2 Manufacturer's contact details You can contact the manufacturer at this address. You can find more information in
Section 1.1.
3 Type number All pedelec models have an eight-digit type number, which is used to specify the design
model year, the type of pedelec and the version. You can find further information in
Section 1.9.1.
4 Maximum continuous power The maximum continuous power is the maximum power for the electric motor output shaft
during 30 minutes.
5 Permitted total weight The permitted total weight is the weight of the fully assembled pedelec with the rider and
baggage.
6Year of manufacture The year of manufacture is the year in which the pedelec was manufactured. The
production period is from August 2019 to July 2020.
7 Pedelec type You can find further information in Section 1.9.3.
8 Safety markings You can find more information in Section 2.6.
9 Disposal instructions You can find more information in Section 9.
10 Area of use You can find further information in Section 1.9.4.
11 Model year The model year refers to the first production year that the series-manufactured pedelec
was produced in the version and is not always identical with the year of manufacture.
The year of manufacture may be before the model year in some cases. If no technical
modifications are introduced to the series, production may continue of pedelecs from a
previous model year.
12 Weight of ready-to-ride pedelec The indicated weight for a ready-to-ride pedelec refers to the weight of a pedelec at the
time of sale. The weight of each additional accessory must be added to this weight
13 Shut-off speed Speed reached by the pedelec at the moment when the current has dropped to zero or to
the no load current value.
HERCULES GmbH
Longericher Str. 2
50739 Köln, Germany
Typ:
20-16-0001
EN 15194
0,25 kW / 25 km/h
zGG 180 kg
EPAC 25 kg
BJ 2019 / MJ 2020
nach
EPAC
2
3
1
4
5
6
7
89
12
13
10
11

MY20H06-2_1.0_26.08.2019 9
Safety
2 Safety
2.1 General warnings
Risk of fire and explosion due to faulty battery
The safety electronics may fail if the battery is
damaged or faulty. The residual voltage can
cause a short circuit. The battery may self-ignite
and explode.
Remove batteries with external damage from
service immediately and never charge them.
Only operate the battery and accessories if
they are in perfect condition.
Only use batteries which are approved for use
on your pedelec.
Do not use the battery with defective
connecting cables or defective contacts.
Use the battery with BOSCH Systems
pedelecs only. This is the only way that the
battery will be protected from dangerous
overloading.
If the battery becomes deformed or begins to
smoke, keep at a safe distance, disconnect the
power supply at the socket, and notify the fire
service immediately.
Never extinguish a damaged battery with
water or allow it to come into contact with
water.
If a battery is dropped or struck but shows no
signs of external damage, remove it from
service and observe it for at least 24 hours.
Faulty batteries are hazardous goods.
Dispose of faulty batteries properly and as
quickly as possible.
Store in a dry place until disposal. Never store
in the vicinity of flammable substances.
Never open or repair the battery.
Charge the battery before use. Only use the
charger included in the scope of delivery.
WARNING
!
Electric shock in case of damage
Damaged chargers, cables and plug connectors
increase the risk of electric shock.
Check the charger, cable and plug connector
before each use. Never use a damaged
charger.
Risk of fire and explosion due to short circuit
Small metal objects may jumper the electrical
connections of the battery. The battery may self-
ignite and explode.
Keep paper clips, screws, coins, keys and
other small parts away and do not insert them
into the battery.
Risk of fire and explosion due to incorrect
charger
Batteries which are recharged with an unsuitable
charger may become damaged internally. This
may result in fire or an explosion.
Only ever use the battery with the supplied
charger.
Mark the supplied charger clearly to prevent
mix-ups – with the pedelec frame number or
type number, for example.
Risk of fire and explosion due to penetration by
water
The battery is only protected from simple spray
water. Penetration by water can cause a short
circuit. The battery may self-ignite and explode.
Never immerse the battery in water.
If there is reason to believe that water may
have entered into the battery, the battery must
be removed from service.
CAUTION
!

MY20H06-2_1.0_26.08.2019 10
Safety
2.2 Toxic substances
Risk of fire and explosion due to high
temperatures
Excessively high temperatures will damage the
battery. The battery may self-ignite and explode.
Protect the battery against heat.
Never expose the battery to sustained direct
sunlight.
Fire caused by overheated charger
The charger heats up when charging the battery.
In case of insufficient cooling, this can result in
fire or burns to the hands.
Never use the charger on a highly flammable
surface (e.g. paper, carpet etc.).
Never cover the charger during the charging
process.
Never leave the battery unattended during
charging.
Electric shock caused by penetration by
water
If water penetrates into the charger, there is a risk
of electric shock.
Never charge the battery outdoors.
Notice
If you leave a key inserted when riding or
transporting the pedelec, it may break off or the
locking system may open accidentally.
Remove the key from the battery lock
immediately after use.
We recommend that you attach the key to a
key ring.
CAUTION
!
Intoxication from suspension oil
Suspension oil in the rear frame damper is toxic to
the touch, irritates respiratory tracts and causes
cancer, sterility and mutation in germ cells.
Never disassemble the rear frame damper.
Never allow suspension oil to come into
contact with the skin.
Chemical burns to the skin and eyes caused by
faulty battery
Liquids and vapours may leak from damaged or
faulty batteries. They can irritate the airways and
cause burns.
Avoid contact with leaked liquids.
Ventilate with fresh air and consult a doctor if
you suffer any pain or discomfort.
Immediately consult a doctor in case of
contact with the eyes or any discomfort.
In case of contact with the skin, rinse off
immediately with water.
Ventilate the room well.
Hazard for the environment due to leaking
brake fluid
The brake system contains a toxic, environmentally
harmful brake fluid. Such fluids will contaminate if
they enter the sewers or groundwater.
The brake system must be repaired
immediately if brake fluid leaks out. Contact
your specialist dealer about repair.
Dispose of leaking brake fluid in an
environmentally responsible way in
accordance with statutory regulations. Ask a
specialist dealer for more information.
WARNING
!
CAUTION
!

MY20H06-2_1.0_26.08.2019 11
Safety
2.3 Requirements for the rider
If there are no legal requirements for riders of
electrically power-assisted cycles, we recommend
that the rider should be a minimum 15 years of
age and have experience with muscle-powered
bicycles.
The rider's physical and mental abilities must be
adequate to use a muscle-powered pedelec.
2.4 Protection for vulnerable groups
You must keep batteries and charger away from
children and people with reduced physical,
sensory or mental capabilities or lacking in
experience and knowledge.
If minors are to use the pedelec, comprehensive
instruction should be provided by or in the
presence of the legal guardians. Supervised use
should also be scheduled until it is certain that the
pedelec is being used as per these operating
instructions.
2.5 Data privacy
During maintenance, the pedelec is connected to
the diagnosis tool and data is transferred to Bosch
Pedelec Systems (Robert Bosch GmbH) about the
use of electric drive components to help improve
the product. You will find more information on the
Bosch Pedelec website
https://www.bosch-ebike.com/en/
2.6 Personal protective equipment
We recommend that you wear a suitable cycling
helmet. We also recommend that you wear sturdy
footwear and typical, close-fitting clothing for
bicycles.
2.7 Safety markings and safety
instructions
The nameplate contains the following safety
markings and safety instructions:
Environmental hazard posed by oil and
lubricants from the fork
The fork contains toxic, environmentally harmful oils
and lubricants. Such fluids will contaminate if they
enter the sewers or groundwater.
The fork must be repaired immediately if oils
and lubricants are leaking out. Contact your
specialist dealer about repair.
Dispose of leaked oils and lubricants in an
environmentally responsible way in
accordance with statutory regulations. Ask a
specialist dealer for more information.
Environmental hazard posed by oil and
lubricants from rear frame damper
The rear frame damper contains toxic and
environmentally harmful oils and lubricants. Such
fluids
will contaminate if they enter the sewers or
groundwater.
Dispose of oils and lubricants which have
leaked from the rear frame damper in an
environmentally responsible way in
accordance with statutory regulations. Ask a
specialist dealer for more information.
CAUTION
!
Symbol Explanation
General warning
Adhere to the instructions for use
Table 5: Meaning of safety markings

MY20H06-2_1.0_26.08.2019 12
Safety
2.8 Emergency
2.8.1 What to do in an emergency
In the event of a hazard or danger in road
traffic, apply the brakes on the pedelec until it
comes to a halt. The brake acts as an
emergency stop system in such cases.
2.8.2 First aid treatment
Symptoms which are caused by combustion
gases or leaking fluids require medical attention.
After inhalation
Vapours may emit if the battery is damaged or
used improperly Get into fresh air and consult a
doctor if you suffer any pain or discomfort. The
vapours may cause respiratory tract irritation.
After skin contact
Remove any solid particles immediately. Rinse
the affected area with plenty of water for at least
15 minutes. Then dab the affected skin gently. Do
not rub dry. Remove contaminated clothing
immediately. Immediately consult a doctor if there
is any redness or abnormalities.
After contact with eyes
Rinse eyes with plenty of water for at least
15 minutes. Protect unaffected eye. Seek medical
advice immediately.
After swallowing
Drink plenty of milk or water and induce vomiting.
Seek medical advice immediately.
2.8.3 Fighting fire
The safety electronics may fail if the battery is
damaged or faulty. The residual voltage can
cause a short circuit. The battery may self-ignite
and explode.
Keep your distance if the battery becomes
deformed or starts to emit smoke.
Evacuate everyone from the immediate area of
the fire.
Contact the fire service immediately!
Use Class fire extinguishers to put out the fire.
Never extinguish damaged batteries with water
or allow them to come into contact with water.
Symbol Explanation
Read the instructions
Separate collection of electrical
and electronic devices
Separate collection of ordinary
and rechargeable batteries
Must not be thrown into fire
(burning prohibited)
It is forbidden to open any
batteries
Device of protection class II
Only suitable for use indoors
Fuse (device fuse)
EU conformity
Recyclable material
Protect from temperatures
above 50 °C and direct sunlight
Table 6: Relevance of safety instructions
max. 50°C
Intoxication
Inhaling vapours can cause
intoxication.
Stand on the side of the fire
where the wind is blowing from.
Use breathing apparatus if
possible.
WARNING
!

MY20H06-2_1.0_26.08.2019 13
Safety
2.8.4 Leaking fluids
2.8.4.1 Brake fluid
The brake system must be repaired
immediately if brake fluid leaks out. Contact
your specialist dealer about repair.
Dispose of leaking brake fluid in an
environmentally responsible way in
accordance with statutory regulations. Ask a
specialist dealer for more information.
2.8.4.2 Oils and lubricants from the fork
The brake system must be repaired
immediately if brake fluid leaks out. Contact
your specialist dealer about repair.
Dispose of leaking brake fluid in an
environmentally responsible way in
accordance with statutory regulations. Ask a
specialist dealer for more information.
2.8.4.3 Oils and lubricants from the rear frame
damper
Dispose of oils and lubricants which have
leaked from the rear frame damper in an
environmentally responsible way in
accordance with statutory regulations. Ask a
specialist dealer for more information.

MY20H06-2_1.0_26.08.2019 14
Overview
3Overview
Figure 2: Pedelec viewed from the right, example
1Front wheel
2Fork
3 Front guard
4 Headlight
5Handlebars
6Stem
7Frame
8 Seat post
9 Saddle
10 Pannier rack
11 Pannier rack battery
12 Rear light and reflector
13 Rear guard
14 Kickstand
15 Rear wheel
16 Chain guard casing
17 Frame number and nameplate
1
2
3
4
5
6
7
8
9
10
11
13
15 16
17
14
12

MY20H06-2_1.0_26.08.2019 15
Overview
3.1 Description
3.1.1 Wheel and suspension
Figure 3: Components of the wheel, example of front wheel
1 Tyre
2 Rim
3 Suspension fork head with setting wheel
4 Shock absorber
5 Spoke
6 Quick release
7Hub
8Valve
9 Fork end of the shock absorber
3.1.1.1 Valve
Each wheel has a valve. It is used to fill the tyre
with air. There is a valve cap on each valve. The
screw-on valve cap keeps out dust and dirt.
The pedelec either has a conventional Dunlop
valve, a Presta valve or a Schrader valve.
3.1.2 Suspension
Both forks and suspension forks are fitted in this
model series. A suspension fork is based either on a
steel spring or air suspension. Unlike a rigid fork, a
suspension fork has two functions which improve
floor contact and comfort: suspension and damping.
Figure 4: Pedelec without suspension (1) and with
suspension (2) when riding over an obstacle
The suspension prevents an impact, such as one
caused by a stone lying in the bike's path, from
being channelled directly into the rider's body via
the fork. The impact is absorbed by the
suspension system instead. This causes the
suspension fork to compress. The compression
can be disabled so that a suspension fork reacts
like a rigid fork. The switch to disable the fork is
called a remote lockout.
After compressing, the suspension fork returns to
its original position. If there is a damper, it
decelerates movement, preventing the
suspension system from springing back in an
uncontrolled manner and stopping the fork from
vibrating up and down. Dampers which dampen
compressive deflection movements, i.e. a
compression load, are called compression
dampers or compression dashpots.
Dampers which dampen rebound deflection
movements, i.e. a rebound load, are called
rebound dampers or dashpots.
1
2
4
5
8
7
3
9
6
12

MY20H06-2_1.0_26.08.2019 16
Overview
3.1.2.1 Steel suspension fork structure
Figure 5: Example showing Suntour fork
The stem and handlebars are fastened to the fork
steerer (1). The wheel is fastened to the quick
release axle (6). Other elements: the compression
setting (2), crown (3), Q-Loc (5), dust seal (6),
fork end for quick release (7), stanchion (8) and
spring (9)
3.1.2.2 Air suspension fork structure
The pedelec's fork features both air suspension and
a compression damper plus a rebound damper in
some cases.
Figure 6: Example showing Yari fork
You can see the following components in the
diagram: Air valve (1), valve cap (2) fork lock (3),
quick release (4) and rebound damper
adjuster (5) and the assembly groups: Air
suspension fork (A), compression damper
assembly group (B) and rebound damper
assembly group (C)
1
1
2
3
4
5
6
8
9
7
A
B
C
1
2
3
4
5
A
B
C

MY20H06-2_1.0_26.08.2019 17
Overview
3.1.2.3 Structure of the FOX rear frame damper
The rear frame damper features air suspension, a
compression damper and a rebound damper.
Figure 7: Example showing FOX rear frame damper
1 Guide rod eye
2Air valve
3 Setting wheel
4 Lever
5 Air chamber
6O-ring
3.1.2.4 Structure of the Suntour rear frame
damper
The rear frame damper features air suspension, a
compression damper and a rebound damper.
Figure 8: Example showing Suntour rear frame damper
1 Upper eye
2.1 Total damper length
2.2 SAG
3 Lower eye
4O-ring
5 Sleeve
6 Damper unit
7 IFP (internal floating piston)
8Air valve
9 Air chamber
10 Lockout lever
11 Rebound lever
3.1.3 Brake system
The pedelec's brake system comprises either a
hydraulic:
• rim brake on the front and rear wheels
• disc brake on the front and rear wheels or
• a rim brake on the front and rear wheels and an
additional back-pedal brake.
The mechanical brakes are used as an
emergency stop system and bring the pedelec to
a halt quickly and safely in the event of an
emergency.
3.1.3.1 Rim brake
Figure 9: Rim brake components with details; Magura HS22
used as an example
1 Rear wheel rim brake
Brake booster
3 Brake lining
4Handlebars with brake lever
5 Front wheel rim brake
The rim brake stops the wheel moving when the
rider pulls the brake lever, causing two brake
linings, positioned opposite one another, to be
pressed onto the rims.
The hydraulic rim brake features a locking lever.
Figure 10: Rim brake locking lever, closed (1) and open (2)
25-30%
1
2
4
3
1
2.2
3
4
5
6
78
910
11
2.1
The rim brake locking lever is not marked with any lettering.
Only a specialist dealer may set the rim brake locking lever
1
2
3
4
5

MY20H06-2_1.0_26.08.2019 18
Overview
3.1.3.2 Disc brake
Figure 11: Pedelec brake system with a disc brake – example
1Brake disc
2 Brake calliper with brake linings
3Handlebars with brake lever
4 Front wheel brake disc
5 Rear wheel brake disc
On a pedelec with a disc brake, the brake disc is
screwed permanently to the wheel hub.
The brake lever is pushed to increase brake
pressure. The brake fluid is used to transfer
pressure through the brake lines to the cylinders
in the brake calliper. The braking force is boosted
by a speed reduction and applied to the brake
linings. These apply the brake disc mechanically.
If the brake lever is pushed, the brake linings are
pressed against the brake disc and the wheel
movement is decelerated until it comes to a stop.
3.1.3.3 Back-pedal brake
Figure 12: Pedelec brake system with a back-pedal brake –
example
1 Rear wheel rim brake
2Handlebars with brake lever
3 Front wheel rim brake
4Pedal
5 Back-pedal brake
The back-pedal brake stops the movement of the
rear wheel when the rider pedals in the opposite
direction to the direction of travel.
1
2
3
4
5
5
2
3
4
1

MY20H06-2_1.0_26.08.2019 19
Overview
3.1.3.4 ABS
Figure 13: BOSCH ABS
1 ABS control unit with housing
2 Display screen
3 ABS indicator lamp
4 Control panel
5 Front wheel brake lever
6 Brake calliper
7 Bike speed sensor
8 Sensor disc
ABS is an added function in some pedelecs.
The rear wheel brake function does not depend on
the anti-blocking system functioning correctly.
When the brakes are applied, the ABS function
detects critical slippage thanks to the wheel speed
sensors on the front and rear wheels and limits
slippage on the front wheel by reducing brake
pressure there, thus stabilising the wheel. Once
the wheel has been stabilised, the wheel is
brought to the blocking limit again by building up
pressure selectively.
The lever moves a little more towards the
handlebars with each brake impulse during this
process. If the wheel blocks again, the pressure is
reduced again. This process is repeated to keep
the wheel at its limit of traction, thus making
optimum use of the coefficient of friction between
the tyres and the road surface.
The ABS function terminates when one of the
following events occurs:
• The buffer chamber in the ABS control unit is filled
completely.
• The pedelec has come to a halt.
• The rider releases the brake.
Besides the ABS function itself, the unit also
includes a system to detect when the rear wheel
is raised during full braking. This enables the rider
to counteract a potential flip-over caused by
extremely hard brake manoeuvres to a certain
extent.
If the battery level falls below a specified
threshold, the system deactivates the power
assistance first. The system will still remain
active, including the display, lights and ABS, until
the battery reserve is also used up. The electric
drive system and, consequently, the ABS will not
switch off until the battery has almost fully
discharged.
The indicator lamp lights up for about 5 seconds
before the system switches off completely. The
ABS indicator lamp will then go out, even though
the ABS control system is not available. The ABS
is not active if there is no battery on the pedelec
or its battery is empty.
The brake system itself remains functional. It is
only the anti-blocking system control which no
longer operates.
1
1
2
(1) (2) (3) (4) (5)
(6)
(6)
(7)
(8)

MY20H06-2_1.0_26.08.2019 20
Overview
3.1.4 Electric drive system
The pedelec is driven by muscle power applied to
the chain drive. The force which is applied by
pedalling in the direction of travel drives the front
chain wheel. The chain transmits the force onto
the rear chain wheel and then onto the rear wheel.
Figure 14: Diagram of mechanical drive system
1 Direction of travel
2 Chain
3 Rear chain wheel
4 Front chain wheel
5 Pedal
The pedelec also has an integrated electric drive
system. The electric drive system is made up of
5 components:
Figure 15: Diagram of electric drive system
1 Control panel
2 Bottom-bracket gears
3Drive unit
4Rechargeable battery
5 A charger designed for the battery.
3.1.5 Drive unit
Figure 16: Drive unit
As soon as the required muscle power from the
rider pedalling passes a certain level, the motor is
activated gently and assists the pedalling motion
of the rider. The motor force is determined by the
set level of assistance. The system performance
is determined using the pedal assistance settings
on the control panel.
The pedelec does not have a separate emergency
stop or emergency shut-off button. The motor
switches off automatically as soon as the rider no
longer pedals, the temperature is outside the
permitted range, there is an overload or the shut-
off speed of 25 km/h has been reached.
When you step on the pedals again and the speed
drops below 25 km/h, the system starts again
A push assist system can be activated. The speed
depends on the selected gear. The rider slows the
pedelec down to their own pace by holding the
pedelec firmly while pushing.
5
2
4
1
1
234
1
2