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 of140°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)
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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 +23to +104 +23to +104
Storage temperature °F +50to +104 +50to +104
Protection rating IP55 IP55
Weight, approx. lbs 6,6 6,6
A) Is determined by the bicycle manufacturer
Bosch eBike Systems uses FreeRTOS (seewww.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
5
–
17 mm
(3) (4)
(1)
(2)
A
(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
2mm and at most 8mm with each rotation of the
wheel.
The correct distance between the magnet and sensor
must be maintained (see figureA) 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)
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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
20mph.
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
20/28mph, the drive switches off the assistance.
The drive is automatically re-activated as soon you
start pedaling again and the speed is below
20/28mph.
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
Este manual sirve para los siguientes modelos
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