The Pedelec Drive for cargo bikes

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ERZMO® MS1
Translation of the
Original Instruction Manual
Version 1.0 Issue 04/2017
 Pedelec Drive ERZMO® MS 1

Table of contents

Introduction .................................................... 4 Assembly........................................................... 9

The Product ............................................................. 4 Recommended accessories ..................................... 9
Target Group ........................................................... 4 Mounting on the load bicycle .................................. 9
Conventions ............................................................. 4
Warranty .................................................................. 4
Manufacturer’s Address ........................................... 4 Operation........................................................ 10
Preparation and Switch-on .................................... 10
Safety instructions ..................................... 5 Operating modes ................................................... 10
Operating elements ............................................... 10
Intended use ............................................................ 5 Turn off .................................................................. 11
Improper use ........................................................... 5 Troubleshooting..................................................... 11
Hazards .................................................................... 5
Warning and Information signs ............................... 5
Personal Protective Equipment ............................... 6 Maintenance and Repairs ..................... 11
Safety Equipment .................................................... 6 Cleaning and Care.................................................. 11
Readjusting the Bowden cable .............................. 11
Technical Data .............................................. 7 Service and Repair ................................................. 12

Function principle .................................................... 8

Scope of delivery ..................................................... 8
Disassembly and Disposal ................... 12
Interfaces ................................................................. 8 Waste disposal regulations .................................... 12

Other applicable documents ............. 12

Table of contents page 3

Pedelec Drive ERZMO® MS 1

Introduction
The Product Signal word
The Pedelec Drive ERZMO® MS 1 is a powerful mid- Indicates the severity of the danger.
mounted engine with integrated 3-speed transmission.
The drive is designed for installing on load bicycles that Nature and source of danger
are used as delivery and load vehicles, works vehicles or Specifies what risk is warned and where this can occur.
for passenger transport.
Cause and Effect
Target Group
This manual is intended for individuals who are working Describes the cause of the danger or damage and its
with or handling the drive: impact
• Users of a load bicycle that is driven by the drive Remedy
• Installation and service personnel working for the Describes how to prevent the danger
manufacturer of the load bicycle or those working Handling Instructions
for traders in specialized two-wheelers. Handling instructions are numbered sequentially to
highlight the sequence of the individual steps. Results of
The target group of the documentation must possess at the actions (if present) are displayed right underneath.
least the following qualifications:
Example:
• Installation and service personnel: Specialist (Two-
wheeler mechanics, etc.). 1 This is the first step.
Technical personnel is deemed to be anyone who by 2 This is the second step.
virtue of their technical training, knowledge and
experience or knowledge of the relevant provisions ►This is the result of the second step.
are able to assess the transferred work and the pos-
sible risks. Warranty
Conventions The warranty period is 12 months, in accordance with
the manufacturer’s terms and conditions.
Warnings and other information
In the operating instructions, notes are weighted differ- The warranty shall lapse in the event of any unintended
ently and identified with a pictogram. Warnings are use or any unauthorized intervention in the drive.
structured as follows: Manufacturer’s Address
EMGR Elektromotorenwerk Grünhain GmbH
Symbol Signal word Importance Bahnhofstrasse 12 | 08344 Grünhain-Beierfeld
GERMANY
Warning
Imminent danger Death Phone: +49 (0) 3774 52-200
DANGER
or extremely severe inju- Fax: +49 (0) 3774 52-215
ries are the result.
E-Mail: [email protected]
Warning Internet: www.emgr.com
Potentially dangerous sit-
WARNING uation. Could result in
death or extremely
severe injuries.

Warning
Potentially dangerous sit-
CAUTION
uation. Could result in
slight or minor injuries.

Information
Notes for optimum
NOTE results and safe opera-
tion of the machine must
be taken into account.

page 4 Introduction
 Pedelec Drive ERZMO® MS 1

Safety instructions
The Pedelec Drive ERZMO® MS 1 has been designed and A load bicycle with mounted drive corresponds to a
manufactured in compliance with the mandatory legal bicycle in the sense of the German law. During use, all
provisions and in accordance with the established rules the relevant regulations and laws must be complied
concerning technical safety. with.
Yet, the persons involved, the drive or other assets Use the load bicycle only if you have been trained by the
could be exposed to hazards during operation, mainte- manufacturer of the load bicycle in the operating
nance, installation or repairs. modes of the drive and all transport related technical
regulations and safety regulations.
NOTE Use the load bicycle only with mounted cover to avoid
injuries to the sprocket of the drive.
Safe handling of the drive Note the position of the pedal when using the starting
The manufacturer assumes no liability for any personal aid to avoid injuries caused by shocks.
injury or damage to property resulting from failure to
observe the safety instructions. Do not use the drive under extreme weather conditions
For a safe handling follow the instructions in this section such as cold, heat, rain or storm.
and in other sections of this manual. When the load bicycle is not in use, do not expose the
drive consistently to sunlight to avoid heating.
Intended use Hazards during assembly, maintenance and
The drive must be used exclusively for the intended disassembly
purpose. Use for any other purposes and any modifica-
tions made subsequently are considered contrary to the The drive is heavy. To prevent personal injury or dam-
designated use. age to property caused by dropping, handle the drive
carefully during assembly and disassembly and use
Use the drive only for the designated purpose as under: appropriate personal protective equipment.
• For mounting on load bicycles for commercial oper- When mounting the drive on the load bicycle, route the
ations cable in such a way that it does not make contact with
• On load bicycles with appropriate connection any sharp edges and does not get crushed.
dimensions of the frame Allow the lithium-ion battery to cool and take it out of
• For transporting loads up to a maximum total the holder before undertaking any cleaning, mainte-
weight of 300 kg nance and repair tasks.

• Up to a maximum speed of 25 km/h The lithium-ion battery is heavy. When removing the
battery from the holder make sure you do not allow it to
fall down.
Improper use Make sure that it does not fall down when you remove
Any use other than that for the designated purpose is
considered improper use and is hence prohibited. it from the holder. The housing of the drive may be
The following also are considered contrary to the desig- opened only by the manufacturer when repairs are to
nated use: be carried out.

• Installation on systems other than load bicycles for Warning and Information signs
commercial use Points at which there is a potential danger under certain
conditions, are marked with warning and information
• Installing an additional gearshift changes to the signs.
gearbox or mounting on load cycles with existing
gearshift Warning and information signs must not be removed.
Damaged or removed signboards must be replaced
• Operation outside the technically permissible limits immediately.
(weight, speed, temperature)
The following warnings and information signboards are
• Operating during storms displayed at the relevant places of the drive.
• Operating in potentially explosive areas
Sign Importance
Hazards
Operating Hazards
The drive is operated at a low voltage (48 V). Use only
the batteries specified (see "Technical Data" on page 7). Warning for hand injuries
Non-observance may result in overheating or damage
to the drive.

Safety instructions page 5

Pedelec Drive ERZMO® MS 1

Personal Protective Equipment Safety Equipment

During assembly, maintenance and disassembly, you The following equipment form part of the safety con-
need to use various kinds of personal protective equip- cept of the drive. You should familiarize yourself with
ment to ensure safety when working with the drive. In the position and function of the safety devices before
the following list you will find information about the you deal with the drive.
necessary personal protective equipment.
Brake Sensors
• Safety shoes Both brake levers (front brake and rear brake) are
• Gloves equipped with a brake sensor. Operating a brake lever
automatically switches the drive to the idling mode.
• Safety glasses
Sprocket cover
The sprocket cover protects the user from injuries on
the sprocket. The load bicycle should not be used with-
out the sprocket cover.

page 6 Safety instructions

 Pedelec Drive ERZMO® MS 1

Technical Data
The following tables show a list of the technical data of
the drive.
Dimensions and Weight
Height 180 mm
Width 180 mm
Length 313 mm
Weight approx. 10 kg

Energy supply
Rated power 250 W
Type: Li-ion rechargeable battery
Capacity: 1.400 Wh
Voltage: 48 V
Source of energy Dimensions: 390 × 150 × 82 mm
Service life: 500 charging cycles
Range: approx. 75 km (depending on total weight,
driving style, the nature of the terrain, temperature)

Operating conditions
Maximum Total Weight 300 kg
Maximum speed 25 km/h
Ambient temperature -20° C – 40° C
Maximum humidity 95 %

Electronic Accessories
Part number 0026471 (manufacturer: MAGURA Gus-
Throttle
tav Magenwirth GmbH & Co. KG, Bad Urach)
Main switch in accordance with the drawing 240-038
Pressure switch (N/O contact) part number 0724344
Front brake sensor, rear brake sensor (manufacturer: MAGURA Gustav Magenwirth GmbH
& Co. KG, Bad Urach)
Voltage 48 V
Front light, rear light
Connection via insulation displacement terminals

Mechanical interfaces
Pedal insertion point ISO 6885 M8 × 1
Sprocket ISO 81 1/2 × 1/8“; z=16; d=65.1 mm
Simple roller chain to be mounted DIN ISO 606-061 1/2 × 1/8“

Technical Data page 7

Pedelec Drive ERZMO® MS 1

Function principle Interfaces

The Pedelec Drive ERZMO® MS 1 is an electric engine The drive has the following interfaces for assembly and
with integrated 3-gear transmission. The drive is installation on the load cycle:
designed to be mounted on load bicycles that are to
used as delivery and load vehicles, works vehicles or for
passenger transport. A B CD B
The drive propels the rear axle via simple roller chain
when the pedals are actuated. As the integrated 3-gear 148

1
transmission is not connected to the power flow of the
drive, the pedal force has no effect on the engine per-
formance. The operator specifies the required torque

66,5
with the handle and supports the drive by pedalling. The
engine controller monitors the rotational and linear
speeds.
Scope of delivery
The drive is supplied ex-works as follows: 74,37

C
Image 1-2: The interfaces to the drive
A (B)
A Sprocket
B Pedal insertion point
C Mounting holes
D Connector for cable harness

D
C

Image 1-1: The scope of delivery of the drive

A Mid-mounted engine and gear transmission

B Cable harness with main fuse and electronic inter-
faces (not in the image)
C Shift lever cluster (see Image 1-5:)
D Bowden cable
E Pinion Cover (not in the image)

page 8 Technical Data

 Pedelec Drive ERZMO® MS 1

Assembly
Recommended accessories 5 Connect all of the accessories with the electrical
During assembly the drive is fitted with the following interfaces of the cable harness and attach the
accessories (For specifications please see "Technical accessories according to the information provided
Data" on page 7): by the manufacturer.
• Li-ion rechargeable battery 6 Lay a simple roller chain that is appropriate for the
sprocket and tighten the simple roller chain.
• Simple roller chain
7 Install the sprocket cover.
• Pedals
8 Install the appropriate pedals in accordance with the
• Included cable harness with electrical interfaces for
specifications of the manufacturer.
the following accessories:
– Main switch
– Throttle
– Front brake lever and brake sensor
– Rear brake lever and brake sensor A+D
– Front light
– Rear light
B
Mounting on the load bicycle
To mount the drive on the load bicycle proceed as fol-
lows: C+E
1 Secure the drive with 3 cylinder screws (DIN 912
M8 x 70 8.8, tightening torque 30 Nm) on the bike
frame. A

NOTE
B
The connection dimensions can be found in E C
the figure "The interfaces to the drive" on page 8.
D

2 Secure the shift lever cluster to the steering rod and

route the Bowden cable in the frame or very close to
the frame.
3 Connect the main connector of the supplied cable Image 1-3: Accessories and interfaces, top view
harness to the connection plug of the drive.
A Front light
4 Route the individual strands of the cable harness in B Main switch
the frame or very close to the frame.
C Rear brake lever
D Throttle
NOTE
E Front brake lever
The figures "Accessories and interfaces, top
view" on page 9 and "Accessories and interfaces, side
view" on page 10 show the type of interfaces of the ac-
cessories to the cable harness and the indicative figures
for the items.

Assembly page 9
Pedelec Drive ERZMO® MS 1

A B C
A

B F E D
Image 1-4: Accessories and interfaces, side view

A Main connector for cable harness D Rear light

B Pedals E Simple roller chain
C Li-ion rechargeable battery F Cable harness

Operation
Preparation and Switch-on To use the drive support turn the throttle when you
To use a load bicycle with the drive, proceed as follows: start operating the pedals. The engine output is regu-
lated using the throttle. You can also use the pedal force
1 Charge the lithium-ion battery in accordance with to relieve the load on the engine.
the specifications of the manufacturer.
2 Insert the lithium-ion battery in the battery holder NOTE
on the load bicycle.
3 Check cables and plugs for correct position and Automatic idling
damages. The drive automatically switches to the idling mode
when the permissible speed of 25 km/h is attained or
4 Use the main switch to turn on the drive. when a brake is operated.
►The load bicycle with the drive is ready for use.
Operating elements
Operating modes In the drive support operating mode the drive is oper-
The drive supports you when cycling in different oper- ated with the following elements:
ating modes:
Shift lever
Manoeuvring aid Using the shift levers you can choose between the 3
Up to a speed of 6 km/h, the engine can be used as a gears of the drive.
manoeuvring aid.
Use the lowest gear to reach the charging point if for
To use the manoeuvring aid, turn the throttle if the ped- instance the battery is discharged. In the highest gear,
als are dormant. you can switch the engine up to the maximum speed of
25 km/h.
Drive support
Between speeds of 6 km/h and 25 km/h, the engine can
be used as a drive support.

page 10 Operation
 Pedelec Drive ERZMO® MS 1

Throttle
The speed is regulated using the throttle.

NOTE
Start-up assistance for dormant pedals
If the pedals are dormant, turning the throttle activates
the starting aid.

Turn off
To turn off the drive, proceed as follows:
1 Ensure that the pedals remain stationary.
2 Press the main switch to turn off the drive.

Troubleshooting
A B C For troubleshooting take note of the FAQs of the man-
ufacturer by visiting www.emgr.de.
Image 1-5: The shift lever cluster of the drive

A Shift lever “Lower gear”

B Shift lever “Higher gear”
C Adjusting screw

Maintenance and Repairs

The components in the interior of the drive are lubri- Readjusting the Bowden cable
cated for life and are therefore maintenance-free. To When in use the Bowden cable can expand and lose its
maintain the drive in a functional state, it is important to tension as a result of multiple gear changes or wide var-
handle the drive carefully. At the same time regular iations in temperature. Switching gears becomes diffi-
cleaning and maintenance are also important. cult or all the gears can no longer be engaged. To adjust
the Bowden cable, proceed as follows:
CAUTION Readjusting at the shift lever cluster
Turn the adjusting screw on the shift lever cluster to
Risk of burning tighten the Bowden cable.
The drive can get heated during operation or if ex-
Readjusting at the drive
posed to sunlight.
If readjusting of the shift lever cluster does not deliver
– Allow the drive to cool adequately before begin- the desired effect, the Bowden cable in the interior of
ning work. the drive must be readjusted using the adjusting screw.
– Remove the battery to disconnect the power
supply. NOTE
The drive must be opened only by qualified
Cleaning and Care personnel appointed by a specialist dealer or by the
The drive components must be kept clean and func- manufacturer of the load bicycle.
tional.
Protect the contacts, plugs and moving parts from To readjust the Bowden cable with the adjusting screw
moisture and dirt and make sure that no liquids get into in the interior of the drive, proceed as follows:
the drive.
1 Remove the pedals using the relevant extraction
Clean the components with a lightly moist lint-free device.
cloth. Do not use any aggressive cleaning agents or
high-pressure cleaners. 2 Loosen the fastening screws and remove the hous-
ing cover.

Maintenance and Repairs page 11

Pedelec Drive ERZMO® MS 1

3 Turn the adjusting screw counter-clockwise.

4 Tighten the lock nut to the stop.
5 Mount the housing cover and secure it using the fas-
tening screws.
6 Install the pedals.

►The Bowden cable is readjusted and the load byci-

cle is again ready for operation.

E Service and Repair

All tasks in the interior of the drive apart from readjust-
D ment of the Bowden cable must be undertaken exclu-
sively by the manufacturer. These include opening the
two halves of the drive housing, replacement of elec-
tronic components and repairs to the transmission or
similar tasks.

A B C
Image 1-6: Bowden cable in the open engine

A Fastening screws (13 pcs.)

B Housing cover
C Adjusting screw
D Seal
E Locknut

Disassembly and Disposal

Switch off the drive, as described in the section "Turn
CAUTION off".
Remove the lithium-ion battery from the holder before
Risk of injury the starting work.
There could be mechanical and electrical hazards
Wear suitable personal protective equipment.
during the disassembly of the drive. To avoid this,
observe the following instructions. Waste disposal regulations
Discard the drive in a professional and environmentally
friendly manner.
The drive must be disassembled only by authorized and Observe all statutory, municipal and corporate regula-
qualified personnel. tions.

Other applicable documents

This operating instructions manual together with the • FAQ ERZMO® MS1 (see www.emgr.de)
following documents is applicable:
• Drawing HT11308/2: Cable harness (see
• EC Declaration of Conformity for Pedelec Drive www.emgr.de)
ERZMO® MS1 (see www.emgr.de)
• Drawing 240-038 Main switch (see www.emgr.de)

page 12 Disassembly and Disposal

EMGR Elektromotorenwerk Grünhain GmbH
Bahnhofstrasse 12
08344 Grünhain-Beierfeld
GERMANY

Phone: +49 (0)3774 52-200

Fax: +49 (0)3774 52-215
Internet: www.emgr.de
E-Mail: [email protected]