Bosch BDU480 CX Manual de usuario

Robert Bosch GmbH

72757 Reutlingen

Germany

www.bosch-ebike.com

0 275 U07 XD4 (2023.03) T / 38

en Original operating instructions

fr Notice d'utilisation d'origine

es Instrucciones de servicio originales

Ownerʼs Manual

Drive Unit

BDU480 CX | BDU490P

Performance Line/Cargo LinePerformance Line/Cargo Line

This manual contains important safety,

performance and service information.

Read and understand it along with the

information provided to you by your

bicycle manufacturer before using the

product, and keep it for reference.

Cette notice contient d'importantes

informationes sur la sécurité, les

performances et l'entretien. Lisez-les et

comprenez-les ainsi que les informations

fournies par le fabricant de votre vélo

avant d'utiliser le produit, et conservez-

les pour référence ultérieure.

Este manual contiene información

importante de seguridad, rendimiento y

mantenimiento. Léalo y asegúrese de

entenderlo junto con la información que

le ha facilitado el fabricante de su

bicicleta antes de usar el producto;

guárdelo a modo de referencia.

0 275 U07 XD4 | (13.03.2023) Bosch eBike Systems

English – 1

Table of Contents

Introduction ..................................................................................................................................... 2

About Warnings............................................................................................................................ 2

General Warnings ......................................................................................................................... 2

Using your Manual ........................................................................................................................ 3

Operating your Bosch Drive Unit.......................................................................................................... 4

Safety instructions........................................................................................................................ 4

Product description and specifications ............................................................................................ 6

Assembly .................................................................................................................................... 7

Operation.................................................................................................................................... 8

Maintenance/Cleaning................................................................................................................. 10

Bosch eBike Systems 0 275 U07 XD4 | (13.03.2023)

English – 2

Introduction

About Warnings

This manual contains many DANGER, WARNING,

and CAUTION indicators concerning the conse-

quences of failure to use, assemble, maintain, store,

inspect and dispose of a Bosch-equipped eBike in a

safe manner.

– The combination of the safety alert symbol and the

word DANGER indicates a hazardous situation

that, if not avoided, will result in death or serious

injury.

– The combination of the safety alert symbol and the

word WARNING indicates a hazardous situation

that, if not avoided, could result in death or serious

injury.

– The combination of the safety alert symbol and the

word CAUTION indicates a hazardous situation

that, if not avoided, could result in minor or moder-

ate injury.

General Warnings

Read all safety warnings and all in-

structions. Failure to follow the warn-

ings and instructions may result in

death or serious injury.

Save all safety warnings and instructions for fu-

ture reference.

The term eBike battery used in these operating in-

structions refers to all original Bosch eBike batteries.

uRead ALL accompanying manuals before riding

the bike for the first time. Your Bosch Drive Sys-

tem comes with additional manuals and documents

provided by the manufacturer of the bicycle and

other components. Failure to read and understand

safety information can result in death or serious in-

jury.

WARNING

uThis manual contains important safety, perfor-

mance and service information. Read it before

you take the first ride on your new bicycle, and

keep it for reference. The manual can also be found

online at www.bosch-ebike.com.

uThis manual is intended to be read together with

the separate user manual provided with your bi-

cycle. Be sure to read all provided documents in-

cluding labels on the product before your first ride.

uTake responsibility for your own SAFETY. If you

have any questions or do not understand some-

thing, consult with your dealer or the bicycle or

component manufacturer.

uSome eBike accessories may present a choking

hazard to small children. Keep these accessories

away from children.

CAUTION

uThe Bosch Drive System adds weight to your bi-

cycle which you may not be used to lift. Avoid in-

jury, use proper lifting techniques.

0 275 U07 XD4 | (13.03.2023) Bosch eBike Systems

English – 3

Using your Manual

In addition to the functions outlined here, changes to

software relating to troubleshooting and functional

modifications may be introduced at any time.

Graphics

The bicycle shown in this manual may differ slightly

from your bicycle, but will be similar enough to help

you understand our instructions.

RIGHT-HAND and LEFT-HAND sides are determined

by facing in the direction the bicycle will travel when

going forward. When you see a broken line (------), the

item referred to is hidden from view.

Bosch eBike Systems 0 275 U07 XD4 | (13.03.2023)

English – 4

Operating your Bosch Drive Unit

Safety instructions

Read and understand all safety warn-

ings and instructions. Failure to follow

the below warnings could result in death

or serious injury.

Save all safety warnings and instructions for fu-

ture reference.

The term eBike battery used in these operating in-

structions refers to all original Bosch eBike batteries.

uRead and observe the safety warnings and in-

structions in all operating instructions of the

eBike system and your eBike.

uDo not make any kind of modifications to the

drive. Do not use any products to increase the

performance of the drive. This will result in you

using an illegal mode of transport in public areas.

Moreover, in doing so, you may endanger yourself

and others; accidents that can be attributed to ma-

nipulation run the risk of high personal liability

costs and possibly even criminal prosecution. In ad-

dition, doing so will generally reduce the service life

of the eBike components. The drive unit and eBike

may be damaged and guarantee and warranty

claims on the eBike you have purchased may con-

sequently be voided.

uDo not open the drive unit. The drive unit must

be repaired using only original spare parts and

only by an authorized bicycle retailer. This will

ensure that the eBike remains safe to use. Unautho-

rized opening of the drive unit will render warranty

claims null and void.

uRemove the eBike battery from the eBike before

beginning work (e.g. inspection, repair, assem-

bly, maintenance, work on the chain, etc.) on

the eBike, transporting it by car or airplane, or

storing it. Unintentional activation of the eBike

poses a risk of injury.

uThe push assistance function must only be used

when pushing the eBike. There is a risk of injury if

the wheels of the eBike are not in contact with the

ground while using the push assistance.

uWhen the push assistance is activated, the ped-

als may turn at the same time. When the push as-

sistance function is activated, make sure that there

is enough space between your legs and the turning

pedals to avoid the risk of injury.

uWhen using the push assistance, ensure that

you can always control the eBike and hold it se-

curely. The push assistance can be suspended un-

der certain conditions (e.g. obstacle on the pedal

or accidentally slipping off the button of the operat-

ing unit). The eBike can suddenly move backwards

towards you or start to tip. This poses a particular

risk for the user if there is an additional load. When

using the push assistance on the eBike, do not

place the eBike in situations in which you cannot

hold the eBike by yourself.

uAfter a ride, do not allow your unprotected

hands or legs to come into contact with the

housing of the drive unit. Under extreme condi-

tions, such as continuously high torques at low

travel speeds, or when riding up hills or carrying

loads, very high temperatures may be reached on

the housing.

The temperatures that may be reached on the drive

unit housing are influenced by the following factors:

– Ambient temperature

– Ride profile (route/gradient)

– Ride duration

– Assistance modes

– User behavior (personal effort)

– Total weight (rider, eBike, luggage)

– Motor cover on the drive unit

– Heat dissipation properties of the bicycle frame

– Type of drive unit and type of gear-shifting

0 275 U07 XD4 | (13.03.2023) Bosch eBike Systems

English – 5

uUse only original Bosch eBike batteries that the

manufacturer has approved for your eBike. Us-

ing other eBike batteries can lead to injuries and

pose a fire hazard. Bosch accepts no liability or

warranty claims if other eBike batteries are used.

Under extreme conditions, such as con-

tinuously high loads at low speed when

riding up hills or carrying loads, parts of

the drive unit can reach temperatures

in excess of140°F.

uPlease observe all local, state and federal regu-

lations when registering and using eBikes.

Privacy notice

When connecting the eBike to the Bosch Diagnostic-

Tool or when exchanging eBike components, techni-

cal information about your eBike (e.g. manufacturer,

model, bike ID, configuration data) as well as regard-

ing the use of the eBike (e.g. total travel time, energy

consumption, temperature) is transmitted to Bosch

eBike Systems (Robert Bosch GmbH) for processing

your request, in service cases and for the purposes of

product improvement. More information on data pro-

cessing can be found at

www.bosch-ebike.com/privacy-full.

Bosch eBike Systems 0 275 U07 XD4 | (13.03.2023)

English – 6

Product description and specifications

Intended use

The drive unit is intended exclusively for driving your

eBike and must not be used for any other purpose.

In addition to the functions outlined here, changes to

software relating to troubleshooting and functional

modifications may be introduced at any time.

Technical data

Drive unit Performance Line CX/

Cargo Line

Performance Line Speed/

Cargo Line Speed

Product code BDU480 CX BDU490P

Continuous rated power W 250 250

Torque at drive, max. Nm 85 75/85A)

Rated voltage V= 36 36

Operating temperature °F +23to +104 +23to +104

Storage temperature °F +50to +104 +50to +104

Protection rating IP55 IP55

Weight, approx. lbs 6,6 6,6

A) Is determined by the bicycle manufacturer

Bosch eBike Systems uses FreeRTOS (seewww.freertos.org).

Bicycle lightsA)

Voltage approx. V= 12

Maximum power

– Front light W 17.4

– Rear light W 0.6

A) Depends on legal regulations, not possible in all country-specific models via the eBike battery

Inserting a bulb incorrectly can cause it to blow.

0 275 U07 XD4 | (13.03.2023) Bosch eBike Systems

English – 7

Assembly

Check speed sensor

2– 8 mm

–

17 mm

(3) (4)

(1)

(2)

(1) Speed sensor (standard)

(2) Spoke magnet

(3) Speed sensor (slim)a)

(4) Magnet

a) Different sensor shape and installation position possible

Speed Sensor (standard)

The speed sensor (1) and its spoke magnet (2) must

be fitted such that the spoke magnet moves past the

speed sensor at a distance of at least 5 mm and at

most 17 mm with each rotation of the wheel.

Note: If the distance between the speed sensor(1)

and the spoke magnet(2) is too small or too large, or

if the speed sensor(1) is not properly connected, the

speedometer display will fail and the drive unit will

operate in emergency mode.

Should this occur, loosen the screw of the spoke mag-

net (2) and fasten the spoke magnet to the spoke

such that it runs past the marking on the speed sen-

sor at the correct clearance. If the speed is still not

being indicated on the speedometer display after do-

ing this, please contact an authorized bicycle dealer.

When changing a wheel, make sure that the sensor

cable is routed so that it is not under tension and has

no kinks.

Speed Sensor (slim)

The speed sensor (slim)(3) and its spoke magnet(4)

must be fitted ex works such that the spoke magnet

moves past the speed sensor at a distance of at least

2mm and at most 8mm with each rotation of the

wheel.

The correct distance between the magnet and sensor

must be maintained (see figureA) if design changes

are made.

Notes: Ensure that you do not damage the sensor or

sensor bracket when fitting or removing the rear

wheel.

When changing a wheel, make sure that the sensor

cable is routed so that it is not under tension and has

no kinks.

The CenterLock magnet(4) can only be removed and

reinserted up to five times.

Bosch eBike Systems 0 275 U07 XD4 | (13.03.2023)

English – 8

Operation

Start-up

Requirements

The eBike can only be activated when the following

requirements are met:

– A sufficiently charged eBike battery is inserted (see

operating instructions for the eBike battery).

– The on-board computer is properly inserted in the

holder (see on-board computer operating instruc-

tions).

– The speed sensor is correctly connected Checking

the speed sensor (see figure A).

Switching the eBike system on/off

The following options are available for switching on

the eBike:

– If the on-board computer is already switched on

when you insert it into the holder, the eBike will be

activated automatically.

– When the on-board computer and the eBike battery

are inserted, briefly press the on/off button of the

on-board computer.

– With the on-board computer inserted, push the on/

off button on the eBike battery (bicycle manufac-

turer-specific solutions are possible when there is

no access to the eBike battery on/off button; see

the eBike battery operating instructions).

Note: The eBike system always starts in OFF mode

for drive units with a maximum speed of more than

20mph.

The drive is activated as soon as you start pedaling

(except for in the push assistance function, Switching

the push assistance on/off). The drive power de-

pends on the settings of the assistance level on the

on-board computer.

As soon as you stop pedaling when in normal opera-

tion, or as soon as you have reached a speed of

20/28mph, the drive switches off the assistance.

The drive is automatically re-activated as soon you

start pedaling again and the speed is below

20/28mph.

The following options are available for switching off

the eBike:

– Press the on/off button of the on-board computer.

– Switch off the eBike battery using its on/off button

(bicycle manufacturer-specific solutions are possi-

ble when there is no access to the eBike battery on/

off button; see the bicycle manufacturer operating

instructions).

– Remove the on-board computer from its holder.

If the eBike is not moved for approx. 10 min and no

button is pressed on the on-board computer, the

eBike switches off automatically in order to save en-

ergy.

eShift (optional)

eShift is the integration of electronic gear-shifting

systems into the eBike. The eShift components are

electrically connected to the drive unit by the manu-

facturer. The separate operating instructions de-

scribe how to operate the electronic gear-shifting sys-

tems.

Setting the assistance level

You can set the level at which the drive assists you

while pedaling on the on-board computer. The assis-

tance level can be changed at any time, even while cy-

cling.

Note: In some models, the assistance level may be

preset and cannot be changed. There may also be

fewer assistance levels available than stated here.

The following assistance levels are available as a max-

imum:

–OFF: Drive assistance is switched off. The eBike

can only be moved by pedaling, as with a normal bi-

cycle. The push assistance cannot be activated at

this assistance level.

–ECO: Effective assistance with maximum effi-

ciency, for maximum range

0 275 U07 XD4 | (13.03.2023) Bosch eBike Systems

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