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The Brose e-Bike System
Instructions for Use
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  • Page 1

    The Brose e-Bike System
    Instructions for Use



  • Page 2

    Instructions for Use of Brose e-Bike System
    Reference number: BDA_BeBS_MY2014_en_v1.0
    2



  • Page 3

    Table of contents
    Figures.................................................................................................................. 4
    Quick Start Instructions......................................................................................... 6
    Drive unit.............................................................................................................. 7
    Display and control unit........................................................................................10
    Battery pack........................................................................................................14
    Battery charger....................................................................................................18
    Troubleshooting....................................................................................................21
    Your notes...........................................................................................................23

    3



  • Page 4

    1

    2
    FF

    1

    M

    U
    EN

    LI

    GH

    T

    ON/O

    3

    2
    A001-0

    3

    A002-0

    4
    5
    MEN

    U
    LIG

    FF

    /O

    N

    O

    HT

    6

    7

    8
    FF

    ON/O

    HT
    LIG

    4

    M

    EN

    U

    1

    3

    A003-0

    5

    A004-0

    6
    9

    18

    16

    10

    19

    11

    20

    12
    13
    FF

    ON/O

    14
    M

    E

    NU

    LIG

    HT

    15
    1
    A005-0

    Figures

    4

    17

    A006-0



  • Page 5

    7

    8

    25
    22
    21
    FF

    ON/O

    5

    -

    17

    M

    EN

    m
    m

    U

    HT
    LIG

    23

    24

    1
    A007-0

    9

    A008-0

    10
    26

    27
    28

    29

    26
    31

    30

    A010-0

    A009-0

    11

    12
    36

    32
    30

    35

    32
    33
    34
    A011-0

    A012-0

    5



  • Page 6

    Quick Start Instructions
    This section summarizes for you all the important
    information and instructions enabling you to use
    your Brose e-Bike System as quickly as possible.
    −− Fully charge the battery pack (26) (see „Charging the
    battery pack“ on page 19)
    −− Insert the battery pack (26) (see „[Fig. 10] Inserting/
    removing the battery pack“ on page 15)
    −− Lock the battery pack key (29) (see Fig. 9 sowie „Locking/unlocking the battery pack key“ on page 15)
    −− Insert the display unit  (1) (see „[Fig. 2] Inserting the
    display unit“ on page 10)
    −− Activate the Brose e-Bike System using the LED button (28) on the battery pack (26) (see Fig. 9 and also
    „Switching on the Brose e-Bike System“ on
    page 11)
    →→The display unit (1) activates automatically
    −− Select the assist level using the control unit (16) (see
    Fig. 6 and also „Setting the assist level“ on page 12)
    −− The e-Bike is now ready to use.

    6



  • Page 7

    Drive unit
    Safety directions
    −− Please follow all safety directions and instructions
    found in both these Instructions for Use and in all
    other sets of instructions supplied with the e-Bike.
    →→Not following these safety directions and instructions can lead to electric shocks, fires and/or severe injuries.
    −− Keep these Instructions for Use safe for future reference.
    −− The term “battery pack” used in these Instructions for
    Use equally relates to downtube-mounted battery
    packs, rack-mounted battery packs and frame-integrated battery packs.
    −− Never open the drive unit. It is maintenance-free and
    may only be repaired by qualified experts using only
    original spare parts.
    →→This ensures the safety of the drive unit. All warranty claims are invalidated if the drive unit has
    been opened without authorization.
    −− All components forming part of the e-Bike System
    and parts fitted to the drive unit  (e.g. chain ring,
    mounting of chain ring, pedals) may be replaced only
    by components approved by the manufacturer of the
    e-Bike.
    →→This protects the drive unit from damage (e.g. due
    to overloading).
    −− Remove the battery pack (26) from the e-Bike before
    working on it (e.g. when fitting, servicing or working
    on the chain etc.), transporting it or placing it in storage.
    →→There is a risk of injury if the e-Bike System is activated by mistake.
    −− The push-assist may only be used when the e-Bike is
    pushed.
    →→There is a risk of injury if the wheels of the e-Bike
    are not in contact with the ground when the pushassist is used.
    −− Do not make any alterations at all to your e-Bike System. On no account attempt to improve the performance of your e-Bike System.
    →→If you do so, you will shorten the service life of its
    components and run the risk of damaging both the
    e-Bike System and the e-Bike itself. Furthermore,
    the warranty and any warranty claims will be invalidated if there has been any type of manipulation of
    the e-Bike System. Incorrect handling of the e-Bike
    System also endangers both your own health and
    that of other road users. By making your own alterations to the e-Bike System, you run the risk
    of high personal liability costs or even criminal
    prosecution in the event of accidents due to
    manipulation.

    −− Please follow all national regulations relating to the
    licensing and use of e-Bikes.
    −− Please read and follow the safety directions and instructions in the Instructions for Use of the battery
    pack  (26) and in the Instructions for Use of your
    e-Bike.

    Use for the intended purpose
    The drive unit is intended solely for powering your
    e-Bike and may not be used for any other purposes.

    Key to illustrations
    All illustrations are diagrammatical and hence may differ
    in some details from your e-Bike.
    Fig.

    Explanation

    1

    Drive unit with design covers and fitted cranks

    Operation
    For information on operating the Brose e-Bike System,
    please refer to the section on the display and control
    unit (see „Display and control unit“ on page 10).
    N.B.: The Brose e-Bike System only operates when the
    display unit (1) has been inserted.

    Cycling instructions and tips
    When does the e-Bike drive operate?
    The Brose e-Bike System permits electric motor assistance of the cyclist in a Pedal Electric Cycle (PEDELEC).
    This assistance depends on the force applied to the
    pedals by the cyclist. Assistance by the e-Bike drive is
    therefore only provided when the cyclist is pedaling.
    This applies regardless of the assist level.
    The e-Bike drive switches off automatically at speeds of
    more than 25 km/h. If the speed drops below 25 km/h,
    the assist switches back on automatically.
    An exception to this is the push-assist function, in
    which the e-Bike can be pushed more comfortably at
    low speed without pedaling. When the push-assist is
    used, the pedals can also turn.
    You can also use the e-Bike at any time like a normal
    bike, without assistance, either by switching off the
    e-Bike System or setting the assist level to “OFF” (see
    „Setting the assist level“ on page  12). The same applies when the battery pack (26) is flat.
    7



  • Page 8

    Familiarization

    −− Payload.

    Take the time to get used to your Brose e-Bike System
    before venturing into normal traffic conditions. Test the
    various assist levels until you feel confident in handling
    the system. Before setting off on long trips, gain experience of how different parameters and ambient conditions affect the range of your e-Bike.

    Careful handling of the Brose e-Bike System

    Motor setups
    The Brose e-Bike System supports various motor setups. The following tells you more about the characteristics of the different settings.
    Trekking:

    The Trekking profile ensures balanced and continual
    assistance for longer trips.
    City:

    The City profile ensures speedy movement in city
    traffic thanks to a progressive delivery of power when
    starting off.
    Mountainbike

    The Mountainbike profile provides direct and maximum
    delivery of force for trips in difficult terrain and for
    steep inclines.
    Assist level in %
    Motor Setup

    Cruise

    Tour

    Sport

    Trekking

    40

    165

    250

    City

    65

    165

    290

    MTB

    80

    240

    320

    N.B.: The motor setup or assist level can differ in the
    various models. Detailed information on the motor setup
    of your e-Bike can be obtained from the bicycle manufacturer and bicycle dealer.
    Effects on range
    The range is affected by many factors, such as:
    −− Assist level
    →→The higher the selected assist level in otherwise
    identical conditions, the shorter the range.
    −− Gear changing style
    −− Type of tire
    −− Tire pressure
    −− Age, standard of care and charge level of battery
    pack (26)
    −− Route type (slopes) and conditions (road surface)
    −− Weather conditions (e.g. head wind, ambient temperature etc.)
    −− Weight of e-Bike
    8

    Take care with the temperatures at which the e-Bike
    components are operated and stored. Protect the drive
    unit, the display unit (1) and the battery pack (26) from
    extreme temperatures  (e.g. due to intensive sunlight
    without ventilation to compensate). The components (particularly the battery pack (26)) might be damaged by extreme temperatures.

    Loss of power in drive unit
    To protect itself from overloading or overheating  (e.g.
    during uphill cycling), the drive unit has an automatic
    power reduction function.
    The drive unit first reduces its power to 50 %. If overloading persists, it switches off completely (see error code
    „44“ on page 22).

    Maintenance & cleaning
    Keep all the components of your e-Bike clean, in particular the contacts of the battery pack (26) and its mounting (31). Clean them carefully with a soft and dry cloth.
    All components including the drive unit must not be
    dipped in water or cleaned using a high-pressure cleaner.
    For servicing or repairs to the e-Bike, please contact an
    authorized bicycle dealer.

    Inspection
    For the drive unit, an inspection by a service center
    certified by Brose is mandatory after a distance covered of 15,000 km.
    Information on the service center responsible for
    you is available from your cycle dealer.

    Transport
    When transporting a complete e-Bike, please follow the
    instructions for transporting battery packs (see „Transport“ on page 17).

    Disposal
    The drive unit, display and control unit, battery pack (26),
    speed sensor  (25), accessories and packaging should
    be recycled in environment-friendly processes. Do not
    dispose of e-Bikes and their components as normal
    waste!



  • Page 9

    For EU countries only:

    In line with the European Union directive
    2012/19/EU, electrical appliances which are
    no longer serviceable must be collected separately and
    recycled in environment-friendly processes, and in line
    with directive 2006/66/EC the same applies for defective or used-up batteries.
    Please hand in battery packs (26) and display units (1)
    which are no longer serviceable to an authorized bicycle dealer.

    Specifications
    Drive unit
    Brose Material number

    C16162

    Dimensions

    213 x 150 x 128 mm

    Weight

    3.400 g

    Rated voltage

    36 V "

    Tightness

    IP56

    Torque max.

    90 Nm

    Continuous rated power

    250 W

    Assistance up to

    25 km/h

    Working temperature range

    -10 to 50°C

    9



  • Page 10

    Display and control unit
    Safety directions

    Item
    13

    5

    Display of light mode

    −− Please follow all safety directions and instructions
    found in both these Instructions for Use and in all
    other sets of instructions supplied with the e-Bike.
    →→Not following these safety directions and instructions can lead to electric shocks, fires and/or severe injuries.
    −− Keep these Instructions for Use safe for future reference.
    −− The term “battery pack” used in these Instructions for
    Use equally relates to downtube-mounted battery
    packs, rack-mounted battery packs and frame-integrated battery packs.
    −− Remove the battery pack (26) from the e-Bike before
    working on it (e.g. when fitting, servicing or working
    on the chain etc.), transporting it or placing it in storage.
    →→There is a risk of injury if the e-Bike System is activated by mistake.
    −− The push-assist may only be used when the e-Bike is
    pushed.
    →→There is a risk of injury if the wheels of the e-Bike
    are not in contact with the ground when the pushassist is used.

    14

    5

    Display of multifunctional panel

    Use for the intended purpose
    The display and control unit of the Brose e-Bike System
    is intended solely for use in the latter. It is used to display information relevant for cycling and status, and to
    control the drive unit.

    Key to illustrations
    The numbering of the components described relates to
    the illustrations on the picture pages at the beginning of
    these instructions  (see page 4-5). All illustrations
    are diagrammatical and hence may differ in some details from your e-Bike.

    10

    Item

    Fig.

    Explanation

    1

    2/4/5/7

    Display unit

    2

    2

    Mounting of display unit

    3

    2/3

    Unlocking button of mounting

    4

    3

    Fastening bolt

    5

    3

    Position of USB interface

    6

    4

    Menu button

    7

    4

    Light button

    8

    4

    On/Off button

    9

    5

    Display of assist level

    10

    5

    Display of push-assist

    11

    5

    Display of cycling speed

    12

    5

    Display of battery pack charge level

    Fig.

    Explanation

    15

    6

    Control unit

    16

    6

    Cable routing of control unit

    17

    6

    “Raise assist level” button

    18

    6

    multifunctional panel button

    19

    6

    “Lower assist level” button

    20

    7

    Cover cap of USB interface

    21

    7

    USB interface

    22

    8

    Spoke magnet

    23

    8

    Fastening bolt of spoke magnet

    24

    8

    Speed sensor

    Assembly
    [Fig. 2] Inserting the display unit
    −− Insert the display unit (1) with the guide groove on the
    rear face into the guide opening of the mounting (2).
    −− Slide the display unit  (1) all the way down until you
    hear it snap into place.
    [Fig. 3] Removal preventer

    The mounting (2) has an optional removal preventer.
    −− Where applicable, screw the fastening bolt (4) lightly
    from underneath into the mounting (2) once the display unit (1) is in place.
    Removing the display unit
    −− Deactivate the display unit (1) before removing it from
    the mounting (2).
    −− Undo the fastening bolt (4), where applicable.
    −− Keep the unlocking button  (3) pressed down and
    push the display unit  (1) upwards inside its guide
    opening until it can be removed from the mounting  (2).
    N.B.: An integrated memory ensures that your data (e.g.
    clock time, kilometers per day, cycling time etc.) are
    saved when the display unit (1) is removed.

    Putting into service
    Putting the display and control unit into service does
    not require any further steps after assembly. The display
    and control unit is ready to operate as soon as it has
    been correctly inserted into the mounting (2).
    N.B.: Full functioning is only possible when the speed
    sensor  (25) and the cables have been correctly fitted
    and the battery pack (26) sufficiently charged.



  • Page 11

    Operation
    Once the display unit  (1) is in place inside the mounting  (2), a battery pack  (26) with sufficient charge has
    been inserted into the e-Bike and the e-Bike System
    has been switched on, the display unit  (1) is supplied
    with power by the battery pack (26).
    N.B.: The display unit (1) does not have its own battery
    and so cannot be used or operated outside of its mounting (2).

    OR
    −− Press the LED button (28) on the battery pack (26) for
    a long time (< 3 seconds).
    →→This display unit (1), the drive unit and the battery
    pack (26) are completely switched off.
    N.B.: For reactivation after complete switch-off, the
    system must be restarted using the LED button (28) on
    the battery pack  (26)  (see „Switching battery pack on
    and off“ on page 16).
    [Fig. 5] Displays and settings

    N.B.: As soon as the battery pack  (26) is in “Active
    Mode”, the display unit (1) always remains switched on
    during cycling, even if the motor assist has been deactivated.
    Switching on the Brose e-Bike System
    −− Press the LED button (28) on the battery pack (26).
    →→The display unit (1) activates automatically.
    →→The e-Bike is now ready to use.
    N.B.: Directly after switch-on, the software version number of the display unit  (1) briefly appears in the multifunctional panel (15).

    The display unit (1) shows various useful information:
    −− selected assist level (9)
    −− activity of push-assist (11)
    −− current cycling speed (12)
    −− current charge level of battery pack  (13) in 10-percent increments
    −− light mode (14)
    −− multifunctional panel (15)
    Background lighting

    The background lighting is activated for 2 seconds
    whenever a button is pressed. The brightness here is
    100 %.

    Switching off the Brose e-Bike System
    Standby mode

    If the e-Bike is not moving, the display unit (1) and the
    drive unit switch to a standby mode. This can however
    also be activated manually.
    If you want to park your e-Bike only for a short period,
    this is how you switch to the standby mode:
    −− Press the On/Off button (8) briefly (< 2 seconds).
    →→This switches off the display unit (1) and the drive
    unit.
    →→The battery pack (26) remains in the “Active Mode”
    for two hours  (see „Operating modes of battery
    pack“ on page 16).
    −− As soon as you move your e-Bike again, the display
    and the drive unit are re-activated and the Brose eBike System is ready to use again.
    −− After 2 hours in the “Active Mode”, the battery
    pack  (26) goes into the “Deep Sleep Mode”  (see
    „Operating modes of battery pack“ on page 16).

    At night, the background lighting is active all the time.
    The brightness is much lower here so that the cyclist is
    not dazzled. Brightness is regulated depending on the
    ambient light.
    Battery charge and remaining range

    The charge level (13) of the battery pack is shown in the
    display of the display unit  (1) with 10 segments. One
    segment here corresponds to about 10 % of the battery
    capacity (see „Charge level display“ on page 15).
    Display change in multifunctional panel (15)

    −− Press the menu button  (6) on the display unit to
    switch between the functions of the multifunctional
    panel (15).

    Complete switch-off

    There are two ways to switch off the Brose e-Bike System completely:
    −− Press the On/Off button  (8) for a long time  (< 2 seconds).

    11



  • Page 12

    The multifunctional panel  (15) presents the following
    information:
    →→Clock time
    →→Trip distance
    →→Trip calories
    →→Trip time
    →→Trip average speed
    →→Total kilometers
    →→Total time
    →→Pedal resistance

    Your Brose e-Bike System has three assist levels  (9).
    Their characteristics are set out in the following table:
    Description
    Off
    Cruise

    Changing over the measurement units

    Tour

    −− Switch off the display unit  (1) using the On/Off button (8) (press it briefly for < 2 s).
    −− Press the On/Off button (8) and the menu button (6)
    simultaneously for > 3 s until the software version of
    the display unit (1) appears in the multifunctional panel (15).
    →→All displayed units are changed over between “km”
    and “mi” and “km/h” and “mph” respectively.

    Sport

    Setting the clock time

    −− In the multifunctional panel  (15), change to the display of the clock time by pressing the menu button (6).
    −− Press the menu button (6) for > 2 s.
    →→The hour display flashes.
    −− Set the hour display using the buttons “Raise assist
    level” (18) and “Lower assist level” (20).
    −− Confirm your entry using the menu button (6) or the
    multifunctional panel button (19).
    →→The minute display flashes.
    −− Set the minute display using the buttons “Raise assist level” (18) and “Lower assist level” (20).
    −− Confirm your entry and leave the menu using the
    menu button  (6) or the multifunctional panel button (19).
    Reset trip functions

    To reset the displayed values of the trip functions in the
    multifunctional panel (15), proceed as follows:
    −− Select any trip function by pressing the menu button (6).
    −− Press the menu button (6) for > 2 seconds.
    →→All displayed values of the trip functions are reset
    to 0.
    Reset total time

    To reset the displayed value of the “Total time” function
    in the multifunctional panel (15), proceed as follows:
    −− Select the “Total time” function by pressing the menu
    button (6).
    −− Press the menu button (6) for > 2 seconds.
    →→The displayed value of the “Total time“ function is
    reset to 0.

    12

    Basic functions

    No motor assist. At the same time, cycling without any
    resistance.
    Cyclist dominates, with perceptible assistance by the
    motor.
    Motor enhances the strength of the cyclist over-proportionally (and yet sustainably).
    Full delivery of the motor force with little effort by the
    cyclist.

    Setting the assist level

    −− Press the button “Raise assist level” (18) on the control unit (16) to increase the assist level from OFF to
    SPORT.
    −− Press the button “Lower assist level” (20) on the control unit (16) to reduce the assist level from SPORT to
    OFF.
    N.B.: If the control unit (16) on your e-Bike has been installed reversed by 180°, then the button functions of
    items 18 and 20 are reversed. It is always the button
    with the arrow pointing in the cycling direction that raises the assist level.
    Activating/deactivating the push-assist

    The push-assist  (11) is used for assistance when
    pushing the e-Bike. It is activated as follows:
    −− Switch the assist level to “OFF” to activate the pushassist (11).
    →→The arrow  (10) is activated in the display of the
    display unit (1) and signals that the push-assist (11)
    is ready to operate.
    −− Press the button “Lower assist level” (20) down for >
    1 second to activate the push-assist (11).
    →→This activates the symbol for the push-assist (11)
    in the display unit (1).
    →→The e-Bike accelerates without pedal assist to a
    manufacturer-specified speed of between 3 and 6
    km/h
    −− Release the button “Lower assist level” (20) to deactivate the push-assist (11).
    Expanded functions
    Light mode (14)

    You can switch the lighting on or off manually, or select
    the Automatic mode that automatically activates and
    deactivates the lighting depending on the ambient
    brightness.
    −− Press the light button (7) to switch the light on or off.
    −− Press the light button  (7) for > 2 seconds to switch
    the Automatic mode on or off.



  • Page 13

    → An “A” inside the light symbol  (14) comes on or
    goes out.
    [Fig. 7] Power supply via USB interface

    External devices can be supplied with power and charged using the Type A USB interface (22) integrated into
    the mounting (2).
    − Insert the display unit (1) into the mounting (2).
    − Open the cover cap (21) of the USB interface (22).
    − Use a suitable USB cable to make the connection
    between the USB interface (22) and the required end
    device.
    → If the connection is successful, the display
    “CHArG” briefly appears in the display unit (1).

    Maintenance & cleaning
    Keep all the components of your e-Bike clean, in particular the contacts of the battery pack (26) and its mounting (31). Clean them carefully with a soft and dry cloth.
    All components including the drive unit must not be
    dipped in water or cleaned using a high-pressure cleaner.
    For servicing or repairs to the e-Bike, please contact an
    authorized bicycle dealer.

    Specifications
    Display and control unit
    Brose Material No. Display unit

    C54764

    Brose Material No. Control unit

    C54760

    Dimensions of display unit

    44,0 x 62,5 x 8,0 mm

    Dimensions of display area

    38,0 x 50,0 mm

    Dimensions of control unit

    18,0 x 46,0 x 19,75 mm

    Weight of display unit

    67 g

    Tightness

    IP65

    Working temperature range

    -10 to 60°C

    Storage temperature range

    -20 to 85°C

    USB charge voltage

    5 V "

    USB charge current max.

    500 mA

    Lights
    Rated voltage

    6 V "

    Rated output*
    − Front light

    2,6 W

    − Rear light

    0,6 W

    * The rated power of the lights can differ depending on
    the battery pack model used. Detailed information can
    be obtained from the bicycle manufacturer and your
    bicycle dealer.

    Disposal
    The drive unit, display and control unit, battery pack (26),
    speed sensor  (25), accessories and packaging should
    be recycled in environment-friendly processes. Do not
    dispose of e-Bikes and their components as normal
    waste!
    For EU countries only:
    In line with the European Union directive
    2012/19/EU, electrical appliances which are
    no longer serviceable must be collected separately and recycled in environmentfriendly processes, and in line with directive 2006/66/
    EC the same applies for defective or used-up batteries.
    Please hand in battery packs (26) and display units (1)
    which are no longer serviceable to an authorized bicycle dealer.

    13



  • Page 14

    Battery pack
    Safety directions
    −− Please follow all safety directions and instructions
    found in both these Instructions for Use and in all
    other sets of instructions supplied with the e-Bike.
    →→Not following these safety directions and instructions can lead to electric shocks, fires and/or severe injuries. Injury and/or damage are also possible
    as a result of dangerous reactions of chemical
    substances leaking out of the battery pack (26) due
    to a failure to follow the safety directions.
    −− Keep these Instructions for Use safe for future reference.
    −− The term “battery pack” used in these Instructions for
    Use equally relates to downtube-mounted battery
    packs, rack-mounted battery packs and frame-integrated battery packs.
    −− Remove the battery pack (26) from the e-bike before
    working on the latter  (e.g. when fitting, servicing or
    working on the chain etc.), transporting it, placing it in
    storage or not using it for a lengthy period.
    →→There is a risk of injury if the e-Bike System is activated by mistake.
    −− Do not open, take apart or break up the battery
    pack (26).
    →→There is a risk of a short-circuit. If the battery
    pack  (26) is opened, this invalidates all warranty
    claims.
    −− Protect the battery pack (26) from heat (e.g. also from
    continual sunlight), fire and immersion in water.
    →→This creates an explosion risk.
    −− Keep all metal objects (e.g. paper clips, nails, screws,
    keys etc.) well clear of the stored battery pack  (26):
    they could cause bridging of the contacts.
    →→A short-circuit can lead to burns or fires. If shortcircuit damage results in this context, any claim for
    warranty by Brose is invalidated.
    −− Fluid can leak out of the battery pack (26) if the latter
    is not used correctly. Avoid any contact with this fluid. If contact does occur, rinse off the affected parts
    of the body with water. If the fluid contacts any sensitive membranes  (e.g. eye), please also consult a
    doctor without delay.
    →→Leaking battery fluid can cause skin irritation or
    burns.
    −− Battery packs (26) must not be subjected to any mechanical impacts.
    →→There is a risk of the battery pack (26) being damaged.
    −− On no account continue to use any battery packs (26)
    which are defective or damaged.
    →→There is an increased risk of short-circuits, fires or
    electric shocks.

    14

    −− If the battery pack (26) is damaged or used incorrectly, vapors may be emitted. Let in plenty of fresh air,
    and consult a doctor if you suffer from any complaint.
    →→These vapors can irritate the airways.
    −− Charge the battery pack  (26) using only the battery
    charger (33) supplied with your Brose e-Bike System.
    →→If other chargers are used, a risk of fire cannot be
    ruled out.
    −− Use the battery pack (26) only in conjunction with eBikes using the original Brose e-Bike System.
    →→This is the only way to protect the battery pack (26)
    from dangerous overloading.
    −− Only use battery packs  (26) approved by the cycle
    manufacturer for your e-Bike.
    →→Using other battery packs can lead to injury and/or
    fire risk. If other battery packs are used, Brose shall
    not assume any liability or warranty.
    −− Please read and follow the safety directions and instructions found in both these instructions for use of all
    components of the e-bike systems and the instructions for use of your e-bike.
    −− Keep the battery pack (26) away from children.
    −− Always keep the battery pack (26) clean and dry.
    −− Always ensure that the contacts of the battery
    pack (26) are clean. If they are fouled, clean them with
    a dry cloth.
    −− Avoid unnecessary charging. Do not charge the battery pack (26) over a long period if you do not use it.
    −− Never leave the battery pack  (26) and battery charger (33) unattended during charging.

    Use for the intended purpose
    The battery pack (26) is designed and intended only for
    use in a Brose e-Bike System.

    Key to illustrations
    The numbering of the components described relates to
    the illustrations on the picture pages at the beginning of
    the instructions.
    N.B.: All illustrations are diagrammatical and serve as
    examples. They may differ in some details from your eBike, since the Brose e-Bike System can be combined
    with a large number of different battery pack variants.
    Detailed information on the battery pack  (26) used in
    your e-Bike can be obtained from your bicycle dealer
    and the cycle manufacturer.



  • Page 15

    Item

    Fig.

    Explanation

    25

    9/10

    Battery pack

    26

    9

    Charge level display

    27

    9

    LED button

    28

    9

    Integrated lock

    29

    9/11

    Charging socket

    30

    10

    Mounting rail

    Assembly
    [Fig. 10] Inserting/removing the battery pack
    The Brose e-Bike System can be combined with a large
    number of different battery pack variants. Fitting and
    removal of the battery pack (26) depend on the battery
    pack model used. Detailed information on this can be
    obtained from your bicycle dealer and the bicycle manufacturer.
    N.B.: Always switch off the battery pack (26) before inserting it into the mounting (31) or removing it from the
    latter.
    Locking/unlocking the battery pack key
    The different assembly variants of the battery pack (26)
    also entail different variants of the battery pack key (29).
    Detailed information on locking/unlocking the battery
    pack (26) can be obtained from your bicycle dealer and
    the bicycle manufacturer.

    Putting into service
    Testing the battery pack before its first use
    The battery pack (26) is supplied partially charged. For
    that reason, test the battery pack (26) before charging it
    for the first time or using it with your e-Bike.
    −− Press the LED button  (28) to switch on the battery
    pack (26).
    →→The charge level display  (27) should now light up
    between “empty” and “full” and then display the
    current charge level for about 4 seconds.
    →→If no LED in the charge level display (27) comes on
    and the battery pack  (26) cannot be activated, it
    may be that the cell voltage is too low and the
    battery pack (26) needs to be charged.
    →→If at least one but not all LEDs of the charge level
    display (27) comes on, the battery pack (26) should
    be fully charged before it is first used.

    [Fig. 11] Charging the battery pack
    Use only the battery charger (33) supplied with your eBike. Only this charger is matched to the lithium-ion
    battery pack (26) used in your e-Bike.
    N.B.: The battery pack (26) is supplied partially charged
    (approx. 30-50 %). To ensure full power from the battery
    pack  (26), fully charge it before its first use using the
    battery charger  (33) (see also „Battery charger“ on
    page 18).
    The battery pack (26) can be charged at any time, either
    separately or on the e-Bike, without shortening its service life.
    −− Connect the battery charger (33) to the mains.
    →→The LED status display  (34) of the battery charger  (33) should now be active (see „LED status
    displays“ on page 19).
    Battery pack not on e-Bike:

    −− Connect the charging plug  (32) of the battery charger  (33) to the charging socket  (30) of the battery
    pack (26).
    →→The charging operation begins.
    N.B.: Some battery packs (26) can be provided with two
    charging sockets  (30). It is not important which of the
    two sockets (30) you use for charging.
    Battery pack on e-Bike:

    −− Connect the charging plug  (32) of the battery charger  (33) to the vacant charging socket  (30) of the
    battery pack (26).
    →→The charging operation begins.
    N.B.: Interrupting the charging operation does not damage the battery pack (26).
    N.B.: If the battery pack (26) does not recharge, then the
    cell voltage has fallen below the critical value of 2 V per
    cell and the battery pack (26) is defective.
    N.B.: Do not charge a damaged battery pack (26) and do
    not use it. Please contact an authorized bicycle dealer.
    N.B.: The battery pack (26) attains its maximum service
    life when it is charged at ambient temperatures between
    10 and 30 °C.
    Charge level display
    The five LEDs of the charge level display (27) show the
    charge level of the battery pack  (26) when the LED
    15



  • Page 16

    button  (28) is pressed. Each LED here corresponds to
    about 20 % of capacity. When the battery pack (26) is
    fully charged, all five LEDs light up. The charge level of
    the switched-on battery pack (26) is also shown on the
    display in the display unit (1) (see „Battery charge and
    remaining range“ on page  11). If the capacity of the
    battery pack  (26) is below 10 %, the first LED of the
    charge level display (27) flashes.
    The battery pack (26) can be charged with and without
    the display unit  (1). Without the display unit  (1), the
    charging operation can only be tracked at the charge
    level display  (27) of the battery pack  (26). The display
    unit  (1) can be removed during charging or fitted only
    after the charging operation has started. The charge
    level is indicated by the charge level display (27) on the
    battery pack (26) and by the bar (13) on the display unit.
    During charging, the LEDs of the charge level display (27) on the battery pack (26) light up. Each steady
    LED corresponds to about 20 % of capacity. The flashing LED shows the charging of the next 20 %.
    During charging, the charge level display (27) is as follows:
    LED steady

    LED flashing

    Charge level

    -

    1

    0-19 %

    1

    2

    20-39 %

    1, 2

    3

    40-59 %

    1, 2, 3

    4

    60-79 %

    1, 2, 3, 4

    5

    80-99 %

    1, 2, 3, 4, 5

    -

    End of charging, battery
    pack 100 % charged

    Operation
    Switching battery pack on and off
    Switching on the battery pack (26) is one of the options
    for switching on the Brose e-Bike System.
    −− Press the LED button (28) on the battery pack (26).
    →→The LEDs of the charge level display (27) come on
    briefly and then show the current charge level for
    about 4 seconds.
    N.B.: If the capacity of the battery pack  (26) is below
    10  %, only the first LED of the charge level display (27)
    flashes.
    −− To switch off the battery pack  (26), press the LED
    button (28) for > 3 seconds.
    →→The LEDs of the charge level display (27) go out.
    →→The e-Bike System too is also switched off.

    16

    Operating modes of battery pack
    Active Mode

    After switch-on, the battery pack  (26) is in the “Active
    Mode”. It remains in the “Active Mode” for 2 hours without any further action (operation or movement of the
    e-Bike).
    The “Active Mode” is activated by operating the LED
    button (28), by charging the battery pack (26), or by inserting the battery pack (26) into the e-Bike.
    Deep Sleep Mode

    To minimize the power consumed by the system itself,
    the battery pack  (26) switches automatically to the
    “Deep Sleep Mode” after 2 hours in the “Active Mode”
    without any activity and with the display unit  (1) switched off. The “Deep Sleep Mode” is also activated
    when the LED button (28) or the On/Off button (8) of the
    display unit (1) is pressed for > 3 seconds or when the
    battery pack (26) is not inserted into the e-Bike for longer than 30 seconds.

    Power reduction of battery pack
    For self-protection against overloading or overheating,
    the battery pack (26) has a function for automatic power
    reduction depending on the charge level and temperature.
    Above a cell temperature of 70°C, and between 0 and
    10°C, the motor power is reduced in 4 stages (25  %
    each) until the drive is switched off.
    With a charge level of < 5 %, the drive assist is switched
    off, so that the display unit  (1) and the lights can be
    operated for at least 4 more hours before the battery
    pack (26) deactivates for self-protection.

    Maintenance, cleaning and storage
    Keep the battery pack (26) clean. Clean it carefully with
    a soft and dry cloth. The battery pack (26) must not be
    immersed in water or cleaned using a water jet. If the
    battery pack  (26) is no longer working, please contact
    an authorized bicycle dealer. Set down the battery
    pack (26) only on clean surfaces. Avoid in particular any
    fouling of the charging sockets (30) and of the contacts.
    The service life of the battery pack (26) can be extended
    if it is looked after well and above all stored in the right
    conditions:
    Temperature

    18-23°C

    Humidity

    0-80 %

    Charge level

    70 %



  • Page 17

    As the battery pack (26) gets older, its capacity will diminish even when it is looked after well. A considerably
    shorter operating time after charging indicates that the
    battery pack (26) is used up. You should then replace it.
    Recharging the battery pack during storage
    Check the charge level of the battery pack (26) after it
    has been in storage for around 3 months, and recharge
    it to about 60-79 % if necessary.

    Transport
    The battery pack  (26) may only be dispatched in packaging suitable for hazardous goods and provided
    with the necessary warning notices.
    If you have any questions about transport, please contact an authorized bicycle dealer. The dealer can also
    provide you with suitable transport packaging.

    Disposal
    The drive unit, display and control unit, battery pack (26),
    speed sensor  (25), accessories and packaging should
    be recycled in environment-friendly processes. Do not
    dispose of e-Bikes and their components as normal
    waste!
    For EU countries only:
    In line with the European Union directive
    2012/19/EU electrical appliances which are
    no longer serviceable must be collected separately and recycled in environmentfriendly processes, and in line with directive 2006/66/
    EC the same applies for defective or used-up batteries.
    Please hand in battery packs (26) and display units (1)
    which are no longer serviceable to an authorized bicycle dealer.

    Specifications
    You will find detailed information on the specifications
    of the battery pack (26) used in your e-Bike in the data
    sheet supplied by the bicycle manufacturer.
    Battery pack
    Battery technology

    Lithium ions

    Rated output voltage

    36 V "

    Cell configuration

    10S4P (40 cells) or
    10S5P (50 cells)

    Capacity

    Variable

    17



  • Page 18

    Battery charger
    Safety directions
    −− Please follow all safety directions and instructions
    found in both these Instructions for Use and in all
    other sets of instructions supplied with the e-Bike.
    →→Not following these safety directions and instructions can lead to electric shocks, fires and/or severe injuries.
    −− Keep these Instructions for Use safe for future reference.
    −− The term “battery pack“ used in these Instructions for
    Use equally relates to downtube-mounted battery
    packs, rack-mounted battery packs and frame-integrated battery packs.
    −− Never expose the battery charger (33) to heavy moisture (e.g. rain, snow etc.).
    →→If water gets into the battery charger (33), there is
    a risk of electric shock.
    −− Only charge the lithium-ion battery pack (26) supplied
    for your Brose e-Bike System. Battery voltage and
    charge voltage of the battery charger  (33) must
    match.
    →→Otherwise there is a risk of fire and explosion.
    −− Always keep the battery charger (33) clean.
    →→Fouling leads to a risk of electric shock.
    −− Check the battery charger (33), cables and plugs every time before using them. If you discover any damage, on no account use the battery charger  (33). Do
    not open the battery charger (33), and have it repaired
    only by qualified experts using only original spare
    parts.
    →→Damaged battery chargers (33), cables and plugs
    increase the risk of an electric shock.
    −− Do not operate the battery charger (33) on easily inflammable surfaces (e.g. paper, textiles etc.) or in inflammable surroundings.
    →→The heating up of the battery charger  (33) during
    charging creates a fire risk.
    −− Children and persons unable to safely operate the
    battery charger (33) due to lower physical, sensory or
    mental capacities or their inexperience or their lack of
    knowledge, may not use the charger without supervision or instruction by a responsible adult.
    →→Failing that, there is a risk of incorrect operation
    and injury.
    −− Please read and follow the safety directions and instructions found in both the Instructions for Use of the
    battery pack (26) and of the drive unit/display unit and
    in the Instructions for Use of your e-Bike.
    −− The underside of the battery charger (33) is provided
    with a brief version of important safety directions in
    English, French and Spanish stating the following:
    →→For safe use please follow the Instructions for Use.
    Risk of electric shock.
    18

    →→Only use in dry surroundings.
    →→Only charge battery packs (26) of the Brose e-Bike
    System. Other battery packs  (26) might explode
    and cause injury.
    →→Do not replace the mains cable. There is a risk of
    fire and explosion.
    −− Never leave the battery pack  (26) and battery charger (33) unattended during charging.

    Use for the intended purpose
    The battery charger  (33) must be used exclusively for
    charging the battery pack (26) supplied with the Brose
    e-Bike System.

    Key to illustrations
    The numbering of the components described relates to
    the illustrations on the picture pages at the beginning of
    the instructions.
    N.B.: All illustrations are diagrammatical and serve as
    examples. They may differ in some details from your eBike, since the Brose e-Bike System can be combined
    with various battery chargers (33). Detailed information
    on the battery charger  (33) supplied with your e-Bike
    can be obtained from your bicycle dealer and the bicycle manufacturer.
    Item

    Fig.

    Explanation

    31

    11/12

    Charge plug

    32

    12

    Battery charger

    33

    12

    LED status display

    34

    12

    Mains connection plug

    35

    12

    Mains connection

    Putting into service
    [Fig. 12] Connecting the battery charger to the mains
    N.B.: Ensure the correct mains voltage! The voltage of
    the power source must match the specifications on the
    rating plate of the battery charger (33)
    −− Connect the mains connection plug (35) to the battery charger (33).
    −− Connect the battery charger  (33) to the mains by
    plugging the mains cable into a suitable socket.
    →→The LED status display  (34) of the battery charger (33) should now be active.
    →→The battery charger (33) is now ready to operate.



  • Page 19

    Operation
    Charging the battery pack
    − Charge the battery pack (26) only when all safety directions are followed.
    Charging the removed battery pack

    − Switch off the battery pack (26) (see „Switching battery pack on and off“ on page 16).
    − Remove the battery pack (26) from the mounting (31)
    on the e-Bike (see „[Fig. 10] Inserting/removing the
    battery pack“ on page 15).
    N.B.: Set down the battery pack (26) only on clean surfaces. Avoid in particular any fouling of the charging
    sockets (30) and of the contacts.
    − Insert the charging plug  (32) of the battery charger (33) into one of the two charging sockets (30) on
    the battery pack (26).
    → The charging operation begins.
    [Fig. 11] Charging the battery packs on the e-Bike

    − Disconnect the battery charger (33) from the mains.
    − Disconnect the battery pack  (26) from the battery
    charger (33).
    → This switches off the battery pack  (26) automatically.
    If the battery pack  (26) is not disconnected from the
    battery charger (33) after charging and the battery charger (33) remains connected to the mains, it will switch
    back on after a few hours, check the charge state of the
    battery pack (26), and if necessary begin another charging operation.
    LED status displays
    Battery charger 2 A
    Standby

    green LED steady

    Pre-charge

    green and red LEDs flashing

    Charging in progress

    red LED steady

    battery pack full / trickle charge

    green LED steady

    Battery test

    green LED steady

    Battery charger 4 A
    Standby

    Green LED flashing

    Charging in progress

    red LED steady

    battery pack full / trickle charge

    green LED steady

    Error

    green and red LEDs flashing

    − Switch off the battery pack (26).
    − Insert the charging plug (32) into the vacant charging
    socket (30) on the battery pack (26).
    → The charging operation begins.

    Maintenance & cleaning

    N.B.: Avoid any fouling of the charging sockets (30) and
    of the contacts.

    If the battery charger (33) is no longer serviceable, please contact an authorized bicycle dealer.

    Charging in progress

    Use a soft and dry cloth to clean the battery charger. Do
    not use water or any other cleaning fluids!

    Charging begins automatically as soon as the battery
    charger (33) has been connected to the battery pack (26)
    and the mains.
    The battery pack (26) can be charged with and without
    the display unit  (1). Without the display unit  (1), the
    charging operation can only be tracked at the charge
    level display  (27) of the battery pack  (26). The display
    unit  (1) can be removed during charging or fitted only
    after the charging operation has started. The charge
    level is indicated by the charge level display (27) on the
    battery pack  (26) and by the bar  (13) on the display
    unit  (1). During charging, the LEDs of the charge level
    display  (27) on the battery pack  (26) come on (see
    „Charge level display“ on page 15).
    N.B.: Be careful when you touch the battery charger (33)
    during charging. It can become very hot, particularly in
    high ambient temperatures.

    Disposal
    Battery chargers  (33), accessories and packaging
    should be recycled in environment-friendly processes.
    Do not dispose of battery chargers (33) as normal waste!
    For EU countries only:
    In line with European Directive 2012/19/ EU
    on waste electrical and electronic equipment and its implementation in national law,
    chargers which are no longer usable must
    be collected separately and recycled in environmentfriendly processes.

    Once the battery pack (26) is fully charged, the LEDs go
    out immediately. The charging operation is terminated.
    19



  • Page 20

    Specifications
    The Brose e-Bike System can be combined with a large
    number of battery chargers (33). Detailed information on
    your model can be obtained from your bicycle dealer
    and the bicycle manufacturer.
    Battery charger 2 A
    Dimensions

    140,0 x 70,0 x 40,0 mm

    Weight

    475 g

    End-of-charge voltage

    42 V "

    Rated output current

    2 A

    Working temperature range

    -10 to 40°C

    Storage temperature range

    -20 to 70°C

    Battery charger 4 A

    20

    Dimensions

    206,0 x 94,0 x 61,0 mm

    Weight

    770 g

    End-of-charge voltage

    42 V "

    Rated output current

    4 A

    Working temperature range

    0 to 45°C

    Storage temperature range

    -25 to 70°C



  • Page 21

    Troubleshooting
    If any problems occur during use of your Brose e-Bike System, first of all check them off against those listed in the
    table. This will enable you to solve the problem yourself in many cases.
    Symptom

    Possible cause

    Solution approach

    Display unit (1) and/or Brose e-Bike System

    Malfunction of battery pack  (26) despite full

    Press the LED button (28) to check whether

    cannot be activated.

    charge

    the battery pack can be switched on. The
    LEDs of the charge level display (27) on the
    battery pack (26) should come on. If this is
    not the case, there may be a defect in the
    battery pack (26).

    Battery pack  (26) not correctly snapped into

    Remove the battery pack  (26) again and

    mounting (31)

    then re-insert it. Ensure that it is seated
    correctly.

    Battery pack (26) not charged

    Complete a charging operation using the
    supplied battery charger (33).

    Contacts of battery pack (26) and/or of moun-

    Check that all contacts are clean. If neces-

    ting (31) fouled

    sary clean them with a soft and dry cloth.

    Display unit  (1) not correctly snapped into

    Remove the display unit (1) again and then

    mounting (2)

    re-insert it. Ensure that it is seated correctly.

    Contacts of display unit  (1) and/or of moun-

    Check that all contacts are clean. If neces-

    ting (2) fouled

    sary clean them with a soft and dry cloth.

    Plug connections at the drive unit not correct-

    Check the cables and plug connections,

    ly inserted

    and connect them properly where necessa-

    Display unit  (1) not supplying cycling data

    Spoke magnet  (23) not correctly fitted  (dis-

    Check the fitting of the spoke magnet (23),

    even though the e-Bike is in motion.

    tance from speed sensor (25))

    particularly its distance from the speed

    ry.

    sensor (25) on the chain stay. This distance
    must be between 5 and 17 mm (see Fig. 8).
    Correct the distance where necessary.
    Bike lights cannot be activated.

    Cable for lights incorrectly connected

    Check the cables and plug connections,
    and connect them properly where necessary.

    Display unit (1) displays an error code in the

    There is an active error in the system.

    Please refer to the following table

    multifunctional panel (15).

    Error codes
    You can see from the following table which error is present in the system and what can be done when your display
    unit (1) displays an error code.
    Error code

    Description

    Solution approach

    10

    The battery voltage is too low.

    Charge the battery pack (26) using the battery charger (33).

    11

    The battery voltage is too high.

    Switch off the system completely and then back on using the LED button (28)

    12

    The battery is almost/completely dis-

    on the battery pack (26). If the problem persists, contact your e-Bike dealer.
    Charge the battery pack (26) using the battery charger (33).

    charged
    20

    Electrical measurements are faulty.

    21

    Thermo sensor defective

    23

    Thermo sensor defective

    24

    The internal voltage is outside the wor-

    Switch off the system completely and then back on using the LED button (28)
    on the battery pack (26). If the problem persists, contact your e-Bike dealer.
    Switch off the system completely and then back on using the LED button (28)
    on the battery pack (26). If the problem persists, contact your e-Bike dealer.
    Switch off the system completely and then back on using the LED button (28)
    on the battery pack (26). If the problem persists, contact your e-Bike dealer.
    Charge the battery pack (26) using the battery charger (33).

    king range.
    25

    Error in motor current measurement

    26

    A software reset has been performed

    Switch off the system completely and then back on using the LED button (28)
    on the battery pack (26). If the problem persists, contact your e-Bike dealer.
    Switch off the system completely and then back on using the LED button (28)
    on the battery pack (26). If the problem persists, contact your e-Bike dealer.

    21



  • Page 22

    Error code

    Description

    Solution approach

    30

    Error in push-assist

    Switch off the system completely and then back on using the LED button (28)

    40

    Over-current detected in motor

    Reduce the load on the motor by pedaling less or by reducing the assist level.

    41

    Over-current detected in motor

    Reduce the load on the motor by pedaling less.

    42

    Fault in motor turning

    Switch off the system completely and then back on using the LED button (28)

    on the battery pack (26). If the problem persists, contact your e-Bike dealer.

    on the battery pack (26). If the problem persists, contact your e-Bike dealer.
    43

    Short-circuit in motor

    Switch off the system completely and then back on using the LED button (28)
    on the battery pack (26). If the problem persists, contact your e-Bike dealer.

    44

    Overheating of motor

    Reduce the load on the motor by pedaling less or by reducing the assist level.

    45

    The software has corrected an error du-

    Switch off the system completely and then back on using the LED button (28)

    ring turning of the motor

    on the battery pack (26). If the problem persists, contact your e-Bike dealer.

    No motor movement detected although

    Switch off the system completely and then back on using the LED button (28)

    a current of > 2 A was measured

    on the battery pack (26). If the problem persists, contact your e-Bike dealer.

    Interruption of data exchange on the

    Check the cables and plug connections of all components of the e-Bike Sys-

    CAN BUS

    tem.

    70

    Force applied to pedal not in valid range

    Switch off the system completely and then back on using the LED button (28)

    71

    Turning of pedals not detected

    72

    Force applied to pedal not detected

    73

    Fault in link to pedal force sensor

    80

    Incorrect motor parameter

    81

    An error was detected in the data

    82

    The program has been manipulated

    83

    Error in program sequence

    84

    Incorrect motor parameter

    46
    60

    on the battery pack (26). If the problem persists, contact your e-Bike dealer.
    Switch off the system completely and then back on using the LED button (28)
    on the battery pack (26). If the problem persists, contact your e-Bike dealer.
    Switch off the system completely and then back on using the LED button (28)
    on the battery pack (26). If the problem persists, contact your e-Bike dealer.
    Switch off the system completely and then back on using the LED button (28)
    on the battery pack (26). If the problem persists, contact your e-Bike dealer.
    Switch off the system completely and then back on using the LED button (28)
    on the battery pack (26). If the problem persists, contact your e-Bike dealer.
    Switch off the system completely and then back on using the LED button (28)
    on the battery pack (26). If the problem persists, contact your e-Bike dealer.
    Switch off the system completely and then back on using the LED button (28)
    on the battery pack (26). If the problem persists, contact your e-Bike dealer.
    Switch off the system completely and then back on using the LED button (28)
    on the battery pack (26). If the problem persists, contact your e-Bike dealer.
    Switch off the system completely and then back on using the LED button (28)
    on the battery pack (26). If the problem persists, contact your e-Bike dealer.

    22



  • Page 23

    Your notes

    23



  • Page 24

    Brose Antriebstechnik GmbH & Co. KG, Berlin
    Sickingenstr. 29-38
    10553 Berlin
    +49 30 343498 100
    +49 30 343498 122
    ebike.berlin@brose.com
    www.brose-ebike.com






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