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Bosch ZEMO SU-E FS 12 - User Manual

Bosch ZEMO SU-E FS 12
299 pages
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MY22Z0a - 12_1.0_25.07.2022
22-15-2061...22-15-2066
SU-E FS 12 +, ZE 12 +, ZE FS 12 +
Translation of original operating instructions for
ZEMO pedelecs with BOSCH LED Remote
on-board computer
IMPORTANT
READ CAREFULLY BEFORE USE
KEEP SAFE TO CONSULT AT A LATER DATE

Table of Contents

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Overview

The ZEMO pedelec is a premium quality electric bicycle designed for comfortable daily use and suitable for riding on public roads. It features an electric drive system that assists pedalling, a robust chassis, and various adjustable components for optimal rider comfort and safety.

Function Description

The pedelec combines muscle power with an electric drive system. When the rider applies a certain level of muscle power to the pedals, the motor activates gently to assist the pedalling motion. The motor's assistance level depends on the pedalling force applied, with more muscle power resulting in higher motor assistance, regardless of the selected assistance level. The motor automatically switches off when the rider stops pedalling, the temperature is outside the permitted range, an overload occurs, or the shut-off speed of 25 km/h is reached.

A push-assist system can be activated, allowing the motor to drive the pedelec at a maximum speed of 6 km/h as long as the push-assist button on the handlebars is pressed. This system is useful for pushing the pedelec up stairs or on a bicycle rack. The electric drive system stops when the button is released. The pedelec does not have a separate emergency shut-off button; in an emergency, the motor can be stopped by removing the on-board computer, and mechanical brakes are used to bring the bicycle to a safe halt.

The on-board computer, controlled by seven buttons on the handlebars, manages the system and displays messages. It has an internal lithium-ion battery that is charged by the pedelec battery when the drive system is switched on. The eBike Flow app, accessible via Bluetooth®, allows riders to register, change settings, analyse routes and ride data, and activate premium functions. Software updates are automatically transferred via the app. An activity tracking function records activities, provided the rider agrees to location data being saved. A lock function, when activated, deactivates the e-bike drive unit assistance by removing the on-board computer, acting as a digital key.

Important Technical Specifications

Pedelec:

  • Power output/system: 250 W (0.25 kW)
  • Shut-off speed: 25 km/h
  • Charging temperature: 0 °C…+45 °C
  • Operating temperature: -5 °C…+40 °C
  • Storage temperature: +10 °C…+50 °C
  • A-weighted emission sound pressure level: < 70 dB(A)
  • Total vibration level for the hands and arms: < 2.5 m/s²
  • Highest effective value of weighted acceleration for the entire body: < 0.5 m/s²

BOSCH LED Remote on-board computer (BRC3600):

  • Internal lithium-ion battery: 3.7 V, 75 mAh
  • Charging temperature: 0 °C…+45 °C
  • Operating temperature: -5 °C…+40 °C
  • Storage temperature: +10 °C…+50 °C
  • Protection class: IP54
  • Dimensions: 74 × 53 × 35 mm
  • Weight: 0.03 kg
  • USB charging cable: USB type C® (not included in standard scope)
  • Max. charging current for USB port: 600 mA
  • USB port charge voltage: 5 V
  • Bluetooth low energy® frequency: 2400…2480 MHz
  • Transmitting capacity: 1 mW

BOSCH Performance Line CX motor (BDU3740, BDU3741):

  • Maximum continuous power rating: 250 W
  • Max. torque: 85 Nm
  • Nominal voltage: 36 V DC
  • Protection class: IP54
  • Weight: ~3 kg
  • Operating temperature: -5 °C…+40 °C
  • Storage temperature: -10 °C…+40 °C

BOSCH PowerTube 750 battery (BBP3770 horizontal, BBP3771 vertical):

  • Nominal voltage: 36 V
  • Nominal capacity: 20.1 Ah
  • Energy: 750 Wh
  • Weight: 4.4 kg
  • Protection class: IP54
  • Operating temperature: -5 °C…+40 °C
  • Storage temperature: +10 °C…+40 °C
  • Permitted charging temperature range: 0…40 °C

Bicycle lighting:

  • Voltage: 12 V
  • Front light maximum output: 17.4 W
  • Rear light maximum output: 0.6 W

BOSCH Charger (BPC3400):

  • Input: 220-240 V ~ 50-60 Hz, 1.65 A
  • Output: 36 V, 4 A

Usage Features

Riding Positions: The pedelec offers various riding positions (roadster, city bike, trekking bike, sports bike) depending on the rider's preference, physical fitness, and desired trip distance/speed. These positions affect upper body angle, arm-to-body angle, and saddle-handlebar height difference, influencing comfort, visibility, power transmission, and muscular strain.

Saddle Adjustment: The saddle's purpose is to absorb body weight, provide support, and enable different riding positions. It can be adjusted for height, horizontal position, and angle. Retractable seat posts with remote controls allow riders to lower the seat post at traffic lights and raise it again. Saddle width can be determined using corrugated cardboard or a gel cushion to match sit bone distance. Saddle hardness can be adjusted in air cushion saddles via a pump valve.

Handlebar Adjustment: Handlebars are used for steering and supporting the upper body, and they mount most controls and displays. Handlebar width should match the rider's shoulders. Hand position is optimal when the forearm and hand are in a straight line, preventing nerve pinching. Angle-adjustable stems allow changes to handlebar height and distance from the upper body, improving ride comfort and saving space when parking. Multi-position handlebars and bar ends offer varied grip options to reduce strain on longer rides.

Suspension: Both rigid and suspension forks are available. Suspension forks improve ground contact and comfort through suspension and damping. They absorb impacts and prevent the fork from oscillating uncontrollably. Sag (negative deflection) can be adjusted to optimise ride performance on different terrains. Compression and rebound damping can be fine-tuned to adapt to terrain changes and rider preferences.

Braking System: The pedelec uses handbrakes on the handlebars. The left lever controls the front wheel brake, and the right lever controls the rear wheel brake. Disc brakes are permanently screwed to the hub, with braking force transferred via brake fluid (hydraulic) or wire (mechanical). Grip distance and inclination angle of the handbrake levers can be adjusted for easier reach and to prevent wrist bending.

Gear Shift: The pedelec is equipped with either a chain or belt drive. Gear shift units (switch control panels or shifters) are located on the right side of the handlebars (or left for SHIMANO SW-E7000 derailleur gears). Riders can select appropriate gears to optimise speed, range, and pedalling efficiency.

Tyres: Tyres vary in design, profile, and width. Tyre pressure, indicated on the sidewall in psi or bars, must be adjusted to body weight and checked regularly. Correct tyre pressure is crucial for load bearing capacity, wear, rolling resistance, and puncture protection. Different tyre types (tube-type, tubeless, tubular, solid, mixed) are available.

Maintenance Features

Regular Checks: Before each ride, riders should check:

  • Guards (chain, belt, motor, mudguards)
  • Frame for cracks or damage
  • Fork for cracks, warping, tarnished components, or oil leaks
  • Rear frame damper for cracks, warping, tarnished components, or oil leaks
  • Pannier rack for secure connections
  • Mudguards for secure connections
  • Wheel concentricity
  • Quick releases for firm closure
  • Suspension seat post for unusual noises or resistance
  • Bell for clear sound
  • Handles for firmness
  • USB cover position
  • Riding light functionality
  • Brake functionality

Cleaning: Basic cleaning involves using a damp cloth, sponge, brush, dish-washing detergent, silicone/Teflon oil, and acid-free lubricating grease. Specific cleaning instructions are provided for:

  • On-board computer and control panel
  • Battery (electrical connections with dry cloth/paintbrush)
  • Motor (outside with soft, damp cloth)
  • Frame, fork, pannier rack, guards, and kickstand
  • Stem and handlebars
  • Handles (rubber and leather)
  • Seat post
  • Tyres, spokes, and spoke nipples
  • Hub
  • Switching elements (gear shift, shifter)
  • Cassette, chain wheels, and front derailleur
  • Brake (rim and disc)
  • Belt and chain (including all-round chain guard)

Servicing: Regular servicing includes:

  • Frame/Fork: Dry, spray with wax/care oil, wipe residue.
  • Pannier Rack: Dry, spray with wax, protect chafing points with adhesive film, care for coil springs with silicone/wax spray.
  • Mudguard: Apply hard wax polish, metal polish, or plastic care product.
  • Kickstand: Dry, spray with wax, lubricate joints with spray oil.
  • Stem/Handlebars: Spray with wax, apply silicone/Teflon oil to pivot points.
  • Handles: Apply talcum powder to rubber handles, use leather care products for leather handles.
  • Seat Post: Preserve screw connections with wax spray, replace assembly paste protective layer annually, lubricate articulated joints with spray oil.
  • Hub: Apply wax spray around spoke holes, treat rubber seals with silicone spray.
  • Spoke Nipples: Apply wax spray, treat corroded nipples with special care oil.
  • Gear Shift: Treat articulated shafts and jockey wheels with Teflon spray, lubricate mechanical parts with spray oil.
  • Pedals: Treat with spray oil, lubricate seals, remove surplus lubricant, spray metal foot rests with silicone spray.
  • Chain: Lubricate with chain oil, remove excessive oil.
  • Battery: Grease plug terminals with terminal grease or contact spray.

Inspection and Maintenance Intervals:

  • Initial Inspection (after 200 km or 4 weeks): Check quick release system, all tightening torques.
  • Major Inspection (every six months): Performed by a specialist dealer, includes checking for material fatigue on frame, fork, suspension elements, and composite components.
  • Component-specific maintenance: Intervals vary by component (e.g., suspension fork maintenance every 50-200 hours, seat post wiper cleaning every 20 hours, hub oil change every 1,000-5,000 km).

Troubleshooting: The manual provides solutions for common issues such as:

  • Sitting discomfort, pain in hips, backache, numb hands, thigh pain, knee pain, foot pain (often related to incorrect adjustments or lack of training).
  • Drive system or on-board computer not starting up.
  • Errors in assistance function (e.g., battery not charged, speed too high, lock function activated).
  • Battery errors (e.g., quick discharge, not recharging, overheating, fluid leaks).
  • Errors on the control panel (no data, power issues).
  • Lighting not working.
  • Problems with freewheel (blocked, slipping, stiff, noisy).
  • Problems with hub gear (noise, difficult engagement, stiff shifting).
  • Problems with disc brakes (noise, low braking power, spongy pressure point, incorrect torques).
  • Problems with rim brakes (noise, worn linings).
  • Problems with back-pedal brake (too sensitive, too weak, stiff rotation).
  • Other drive system errors (beeps, less effective pedal assistance).
  • Suspension fork issues (rebounding too fast/slowly, too soft/hard damping).
  • Rear frame damper issues (rebounding too fast/slowly, too soft/hard damping).

Repair: Special expertise and tools are required for most repairs, which should be carried out by a specialist dealer. This includes replacing tyres, tubes, spokes, brake linings, rims, brake discs, and tensioning the chain. Instructions are provided for removing paint damage and impact damage on the frame, suspension fork, and seat post.

Bosch ZEMO SU-E FS 12 Specifications

General IconGeneral
BrandBosch
ModelZEMO SU-E FS 12
CategoryBicycle
LanguageEnglish

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