Page 1 The eBike Manual Bosch eBike Systems 2018 | EN...
Page 3 Foreword Always one step ahead We at Bosch eBike Systems love bicycle mobility and there- fore want to support you in building long-term customer relationships founded on trust. To do this, we're offering you a diverse selection of services: Immediate support via our competently-staffed hotline...
Page 4 Management An early passion for cycling Overview of Robert Bosch GmbH From 1890 onward, Robert Bosch used a modern In 1886, Robert Bosch (1861–1942) founded the "safety bike" – a forerunner of today's bicycles – to visit "Workshop for Precision Mechanics and Electrical his customers.
Page 5 The four business sectors Mobility Solutions One of the world's largest supplier of mobility solutions. 2009 Founding of Bosch eBike Systems within the Automotive Electronics division Energy and Building Technology One of the leading manufacturers of secu- rity and communications technology,...
Page 6 Bosch eBike system Overview The on-board computer, drive unit and battery work together as a well-coordinated team. This results in a perfectly harmonized interplay of all components, maximum efficiency and comfort for the rider. Nyon Intuvia Purion Standard Charger Compact Charger...
Page 7 Videos showing installation/removal of all Bosch eBike components An overview of all recorded service events Product codes for rapid identification of main components Example: BUI275 – Bosch User Interface (type 275: Nyon) PowerPack 500/400/300 For a detailed overview, see the spare parts price list...
Page 8 PICTOGRAMS Useful tips and supplementary information Measures required to prevent accidents, damage or defects Measures required to prevent severe injury to persons or major material damage...
Page 9 2.1 Drive Units at a Glance 2.2 Advantages of the Center -mounted Range of Support for Dealers Motor Concept 5.1 Contact Points to Bosch eBike Systems 2.3 That special Bosch riding sensation 5.2 Bosch eBike Service Hotline 2.4 Active Line (BDU310) 5.3 Service Procedure...
Page 11 On-Board Computer 1.1 On-Board Computer at a glance 1.2 Initial Operation of the eBike System 1.3 Getting to Know Purion 1.4 Operating Purion 1.5 Power Supply and Technical Data 1.6 Getting to Know Intuvia 1.7 Operating Intuvia 1.8 Power Supply and Technical Data 1.9 Getting to Know Nyon 1.10 Registering Nyon 1.11 Operating Nyon...
Page 12 1.1 The On-Board Computer at a Glance...
Page 13 1.1 The On-Board Computer at a Glance 1.1 On-Board Computer at a glance 5 riding modes Walk assistance Control unit on the handlebar Splash water-proof Compatible with Classic+ Line Shift recommendation eShift compatible Off-board mode Charging function for external devices Language setting Reset of the residual range Networked with the smartphone app and the online portal...
Page 14 1.2 Initial Operation of the eBike System 1.2 Initial Operation of the eBike System The eBike system can only be activated if: If the speed 0 km/h is not shown when station- – A sufficiently charged PowerPack is inserted. ary, then check the cable connecting the –...
Page 15 1.3 Getting to Know Purion 1.3 Getting to Know Purion Clear, well arranged display with a focus on the essentials Display options: charge level of the rechargeable battery, speed, riding mode, range, trip distance, total distance Uncluttered look on the handlebar Optimal readability due to backlit display USB port for diagnostics by the dealer (not a charging unit for external devices)
Page 16 1.4 How to Operate Purion 1.4 Operating Purion: Operating controls and displays/indicators Function display/riding mode Speed Unit Bike lights Service is due Charge state of the eBike battery "On/Off" Increase support "+" Micro-USB port (for connecting to DiagnosticTool) Operating logic Operation via buttons, key combinations and duration of button pressing: –...
Page 17 1.4 How to Operate Purion Changing the display of functions Reset of the "TRIP" distance odometer Repeated, medium-duration pressing of the "–" 1. Simultaneous, long-duration pressing the buttons button sequentially displays "TRIP", (trip distance "+" and "–". odometer), "TOTAL" (total distance mileage) and 2.
Page 18 1.5 Power Supply and Technical Data 1.5 Power Supply and Technical Data Provided with power by two CR-2016 button cell 5. Replace with new batteries. batteries 6. Screw-close the battery compartment. If "LOW BAT" is shown on the display: 7. Reattach Purion on the handlebar (tightening 1.
Page 19 1.6 Getting to Know Intuvia 1.6 Getting to Know Intuvia Optimally positioned in the field of view of the Service interval display can be configured with the rider and facilitating simple and intuitive operation DiagnosticTool (see p. 107) on the on-board computer and via an operating Fine adjustment of the wheel size circumference element on the handlebar for accurate speed measurement –...
Page 20 1.7 How to Operate Intuvia 1.7 Operating Intuvia: Display screens and operating elements Shift recommendation Speed Micro-USB port Charge state of the eBike battery Motor power Riding mode used Bike lights Unit Function display Function displays Clock Trip distance: distance travelled since the last reset Maximum: maximum speed achieved since the last Odometer: total distance travelled with the eBike Cadence/Gear (with NuVinci H|Sync): see p.
Page 21 1.7 How to Operate Intuvia "Reset" Settings Switching be- Walking/start assistance "WALK" tween display of operation, see p. 57 functions Increase support "On/Off" Bike lights Decrease support Operation To reset "Trip distance", "Trip time" and "Avg. speed" To reset "Max. speed" or "Range" 1.
Page 22 1.7 How to Operate Intuvia Displaying and modifying the settings Overview of settings The "Settings" menu is no longer available during Clock Languages (German, English, Danish, Spanish, the trip. French, Italian, Dutch, Portuguese, Swedish and 1. Continuously press "RESET" and "i" at the same time Japanese) until the text display "Settings"...
Page 23 1.8 Power Supply and Technical Data 1.8 Power Supply and Technical Data Power supply of Intuvia 1. Open the protective cap. The eBike battery automatically supplies power if 2. Use a USB Micro A - Micro B charging cable to the eBike system is activated and Intuvia is inserted connect an external device with the USB port on in the mount.
Page 24 1.9 Getting to Know Nyon 1.9 Getting to Know Nyon Improved routing quality thanks to More user-friendly entry of a navigation updated map material destination thanks to a full keyboard view Display of altitude profile of the route New display values for custom views during active navigation –...
Page 25 1.9 Getting to Know Nyon The first all-in-one eBike on-board computer with Important information will be briefly overlaid over separate control unit and a wide array of options the current display screen, e.g. turn instructions and for individualisation incoming SMS on the mobile phone. Rider-friendly design: optimised ergonomics, a High resolution, transreflective 4.3"...
Page 26 1.10 Registering Nyon 1.10 Registering Nyon Online via online portal Offline via Nyon Online via the eBike Connect eBike-Connect.com smartphone app & 1. Have the eBike ready with the 1. Required: computer with an 1. Insert Nyon in the mount on the Nyon mounted and a smartphone up-to-date Internet browser eBike, select the language, then...
Page 27 1.11 How to Operate Nyon 1.11 Operating Nyon Joystick Micro- Increase support Bike lights Walking/start assistance "WALK" Light sensor port operation, see p. 57 "On/Off" " "Home" Home" (return to the return to the main screen) Status indicators main screen) (e.g.
Page 28 1.11 How to Operate Nyon "Dashboard" operating mode Connection status Total distance travelled with the eBike The maximum number of kilo- Bike lights (Bluetooth, Wi-Fi, heart meters/miles ridden within a month rate monitor, GPS) Clock Kilometers/miles ridden com- Speed Charge state of pared with the previous month the eBike battery Software version of Nyon...
Page 29 1.11 How to Operate Nyon "Ride" operating mode Own pedal power Speed Shift recommendation Average speed Clock Trip distance odometer Connection status Motor power Visualisation of Text display Charge state of the (Wi-Fi, Bluetooth, heart riding mode Riding mode eBike battery Residual range rate monitor, GPS) Functions...
Page 30 1.11 How to Operate Nyon "Map & Navigation" operating mode Speed Compass needle Shift recommendation Turn instructions and distance Clock (red = north) to next turn GPS reception Current Estimated time of arrival at location destination Radius of the surrounding area Distance to destination Prerequisites for usage Map material available (see p.
Page 31 7. Switch off Nyon and then switch it back on again. Map material can be used after GPS positioning. Installation of maps by the dealer using DiagnosticTool see chapter "Diagnostics", page 113 Bosch eBike Diagnostic Software When transferring the maps, all maps previously saved on Nyon are...
Page 32 GPX tracks imported on the online portal eBike-Connect.com. & 2. Use the joystick to select the desired destination. Addresses of Bosch eBike Experts are entered under "Points of Interest". Route selection Option 3: Route planning via the smartphone app or online portal See p.
Page 33 1.11 How to Operate Nyon "Altitude profile" Move the joystick to the right in map view during active navigation. End by pressing "Home" button. "Route course" Display of route course (2D) in the travel direction during active navigation. "Zoom Out" The level of zoom can either be changed by moving the joystick up/down or by (repeatedly) pressing the joystick.
Page 34 1.11 How to Operate Nyon "Fitness" operating mode Current performance Speed Cadence (pedalling frequency) (in Watt) or heart rate* Clock Calorie consumption Connection status Visualisation Text display Trip time Average speed (Wi-Fi, Bluetooth, GPS, of training effect of training effect heart rate monitor) Training effect analysis The training effect is calculated from pedal power,...
Page 35 1.11 How to Operate Nyon Measure heart rate The heart rate is displayed as long as a Blue- tooth-enabled heart rate monitor is connected with Nyon, including: 1. Attach a compatible heart rate monitor with slightly moistened electrodes. – e.g. Polar H7, Mio heart rate monitor, Sigma R1 BLUE COMFORTEX+, Suunto Smart Sensor (technical modifications may effect compati- bility)
Page 36 1.11 How to Operate Nyon "Settings" operating mode Connections Map & Navigation "Bluetooth": configuration of Bluetooth connections "Auto Day/Night": automatic adaptation of display "Connect Smartphone": pairs Nyon with a smart- colors and display brightness according to the time phone of day (enable/disable) "Heart Rate Monitor": configuration of heart rate "Map Manager": you can install and manage the monitors...
Page 37 1.11 How to Operate Nyon My eBike "Automatic brightness": automatic adaptation of (can only be called up when Nyon is mounted) the screen brightness depending on the ambient "Shift recommendation": switch shift recommenda- light (enable/disable) tion On/Off. "Home" button: selection of operating mode that "eShift": configuration of eShift system, see p.
Page 38 1.11 How to Operate Nyon "Settings" operating mode "System information" screen Region & Language Help "24-hour format": select whether to display clock in "FAQ": frequently asked questions about Nyon 12 or 24 hour format "Contact": detailed information sources and contact "Imperial units": displays speed, distances and information weights in country-specific units...
Page 39 All data that the user enters in the smartphone Configuration of up to four custom riding modes app eBike Connect and in the online portal (fee-based premium function) eBike-Connect.com is saved on a secure Bosch & Topo Range: graphic representation of residual server.
Page 40 1.12 Intelligently Networked with Nyon Smartphone app eBike Connect "Dashboard" menu "Activities" menu Shows the current position of the eBike on the map Documentation of trips can be displayed in three Kilometers/miles ridden in current month compared selectable views: with the previous month –...
Page 41 1.12 Intelligently Networked with Nyon "Maps" menu "Shop" menu Route planning by entering the destination via the Purchase of following fee-based premium functions: keyboard or by selecting a previously saved destina- – "Topo Range": Calculation and graphic represen- tion tation of residual range based on riding behavior The end point can be selected directly on spots in and topography the map or these can be shifted about later on...
Page 42 1.12 Intelligently Networked with Nyon Smartphone app eBike Connect Settings menu – "My Profile" Settings menu – "My eBikes" Manage personal data (name, e-mail address, Change Bike name height, fitness information) Custom screens: you can create custom display Enter the work and home address for faster route views for the "Ride"...
Page 43 1.12 Intelligently Networked with Nyon "Creating custom screens" "Configure custom riding modes" 1. Call up the menu point "Custom Ride Screens" or 1. Call up menu point "Custom riding modes" "Custom Fitness Screens" 2. There are five definable "checkpoints" or stages 2.
Page 44 1.12 Intelligently Networked with Nyon Smartphone app eBike Connect Settings menu – "Map Manager" Settings menu – "Upload using mobile data" Download map materials for many regions free-of- Synchronisation of the data between smartphone charge on your smartphone app and online portal via mobile phone network if For use of the map materials for navigation, no Wi-Fi network is available.
Page 45 1.12 Intelligently Networked with Nyon Online portal eBike-Connect.com "Dashboard" menu Once you have entered the destination, you will be Display of the current location if the position local- offered three different routes including display of ization is activated in the web browser the altitude profile: Short-cut to route planning –...
Page 46 1.12 Intelligently Networked with Nyon Online portal eBike-Connect.com Import GPX tracks and use for navigation GPX files use a sequence of spatial coordinates GPX routes can be created and processed in other (waypoints) to describe a route for navigation. suitable portals (e.g. to re-insert waypoints) and GPX files can be uploaded in the "Route planning"...
Page 47 1.12 Intelligently Networked with Nyon Factors affecting routability of GPX files Case 2: GPX file is "partially routable" Detail accuracy of Open Street Maps (OSM) maps After import of the GPX file onto Nyon, select this (the trails and side streets in remote regions may via "Use modified version": The route will be con- not be recorded) verted into a completely routable track and saved.
Page 48 1.12 Intelligently Networked with Nyon Online portal eBike-Connect.com "Activities" menu Documentation of trips can be displayed in three Saving of one's own activities as routes for navigation selectable views: – After synchronisation with Nyon, the new route – Rides: individual rides (from switch-on of the will be displayed in the operating mode "Map &...
Page 49 1.12 Intelligently Networked with Nyon "eBike system" menu "My Profile" menu Display of all components of the eBike system Configure a personal rider profile Delete or re-add components (e.g. reusage of an Configure fitness information existing Nyon with a new eBike) Delete recorded heart rate data Configure custom riding screens Language selection...
Page 50 1.13 Power Supply and Technical Data 1.13 Power Supply and Technical Data Power supply of Nyon rechargeable battery Power supply of external devices (e.g. smartphone) via the USB port The eBike battery automatically supplies power if the eBike system is activated and Nyon is inserted in Prerequisite: Nyon and a sufficiently charged recharge- the mount.
Page 51 16 million colors Lithium-ion rechargeable battery, 3.7 V; 710 mAh internal Bluetooth standard Bluetooth 4.0 Supported Wi-Fi standards 802.11b/g/n – (2.4 GHz) Bosch eBike Systems uses FreeRTOS (see & freertos.org) Compatible smartphones (updated July 19, 2017) Manufacturer Model Operating system Apple iPhone 5, 5S, 5C, iOS ≥...
Page 53 Drive Unit 2.1 Drive Units at a Glance 2.2 Advantages of the Center-mounted Motor Concept 2.3 That special Bosch riding sensation 2.4 Active Line (BDU310) 2.5 Active Line Plus (BDU350) 2.6 Active Line (BDU250C/255C) 2.7 Performance Line 2.8 Performance Line CX 2.9 Overview of riding modes...
Page 54 2.1 The Drive Units at a Glance...
Page 55 2.1 The Drive Units at a Glance 2.1 Drive Units at a Glance Active Line 270% Max. torque Maximum support Drive Unit Backpedal function Active Line (BDU310) Active Line Plus (BDU350) Active Line (BDU250C/255C) A quiet drive unit that delivers Dynamically harmonic accelera- More mobility for your everyday smooth, seamless acceleration...
Page 56 2.2 Advantages of the Center-mounted Motor Concept 2.2 Advantages of the Center-mounted Motor Concept 2.2 Advantages of the Center - mounted Motor Concept Highest efficiency and less energy consumption Low centre of gravity and ideal weight distribution due to motor control within the optimal RPM speed result in stable handling and straight-line direc- range and therefore with higher efficiency tional stability...
Page 57 2.3 That special Bosch riding sensation 2.3 That special Bosch riding sensation 2.3 That special Bosch riding sensation A demanding multi-sensor concept for optimal Optimal interaction with the bicycle gear system balancing of motor support: 1000 sensor readings – Motor is always operating in the optimal RPM per second record the torque (pedalling force), speed range.
Page 58 2.4 Active Line (BDU310) 2.4 Active Line (BDU310) Discover the city! Relaxed and safe bicycle riding sensation A quiet drive unit that delivers smooth, seamless acceleration No increased pedalling resistance at over 25 km/h Available for both derailleur and hub gear applica- or in Off mode compared to a conventional bicycle tions Max.
Page 59 2.5 Active Line Plus (BDU350) 2.5 Active Line Plus (BDU350) Experience the freedom Versatile: eBike forays beyond the city limits Dynamically harmonic acceleration with quiet drive operation No increased pedalling resistance at over 25 km/h Available for both derailleur and hub gear applica- or in Off mode compared to a conventional bicycle tions Perfectly metered-out support, ideal for city trips...
Page 60 2.6 Active Line (BDU250C/255C) 2.6 Active Line (BDU250C/255C) Experience the mobility Perfectly metered-out support for more mobility during your daily routing – up to a max. 25 km/h – ideal for city trips or tours Smooth, harmonic delivery of performance from Available with derailleur gear and hub gear sys- the drive unit conveys a relaxed and safe bicycle tems, the latter with an optional backpedal func-...
Page 61 2.7 Performance Line 2.7 Performance Line 2.7 Performance Line Feel the tingle of adventure Sports-oriented drive unit for more ambitious riders (trekking, mountainous terrain, commuting) Max. torque: 63 Nm Max. support factor: 275% Dynamic support of up to max. 25 km/h (Perfor- mance Line Cruise), respectively, max.
Page 62 2.8 Performance Line CX 2.8 Performance Line CX Ready for the trail The superlative under drive units – Powerful drive unit for ambitious, more athletic riders and demanding eBikers – ideal for off-roading – Sporty acceleration for the ultimate "uphill flow" eMTB mode –...
Page 63 2.8 Performance Line CX Your notes:...
Page 64 2.9 Overview of Riding Modes 2.9 Overview of riding modes Support factor Riding mode Active Line Active Line Plus Active Line Performance Performance (BDU310) (BDU350) (BDU250C/255C) Line Line CX – – – – – K: 40 % K: 40 % K: 40 % K: 50 % K: 50 % N: 40 %...
Page 65 2.10 Walk Assistance 2.10 Walk assistance "Walk" function Operation Speed-regulated walk assistance 1. Press "WALK" button on the control panel (min. 3 km/h, max. 6 km/h), or start assistance 2. Starting with model year 2017, first press the up to 18 km/h for Performance Line Speed "WALK"...
Page 66 2.11 Background Information about Control Technology 2.11 Background Information about Control Technology Adapted motor support with hub gear Gear shift detection during derailleur gear system shifting Motor support acts directly on the chain wheel and During gear shifting, the motor torque is reduced at is not constant, but rather modulates up and down exactly the right moment and then increased again.
Page 67 2.11 Background Information about Control Technology Applications for the eBike system Examples of current applications for the Bosch eBike system: Software that bike manufacturer installs on eBike Determines the ride handling of the eBike and may Cruise derailleur system (can also be used with...
Page 68 – More safety due to complete concentration on ation instructions in the dealer portal riding & bosch-ebike.net under → Service → Technical – Reduced stress on the components, less wear Information Optimal utilization of battery capacity – Shifting reacts proactively to the riding behavior of the eBiker –...
Page 69 2.12 eShift – Integrated Gear Shift Function 2.12 eShift – Integrated Gear Shift Function Manual gear shift Automatic gear shift (gear control) Nexus Di2 + Alfine Di2 XTR Di2 + Deore XT Di2 Hub gear system Defined gears Cruise Derailleur system Defined gears Cruise Automatic gear shifting based on cadence and pedal...
Page 70 2.12 eShift – Integrated Gear Shift Function 2.12 eShift H|Sync NuVinci H|Sync Electronically actuated shifting system with continuously variable gear ratio based on the desired cadence predefined by you – Active Line (BDU350, BDU310 and BDU250C/255C): 30–100 RPM – Performance Line: 30–120 RPM Ride with uniform loading and always with the optimal gear ratio –...
Page 71 2.12 eShift – Integrated Gear Shift Function Display of gear or cadence (A) eShift operation with Nyon Gear calibration Selection and configuration of the modes "Cadence Operating mode "Settings" → "My eBike" Control" and "Gear Control" (manual gear shift) in Follow the further instructions on the display.
Page 72 2.12 eShift – Integrated Gear Shift Function 2.12 eShift Shimano Di2 Automatic hub gear systems Nexus Di2 (8-gear) and Alfine Di2 (8-gear or 11-gear) based on cadence/torque – for usage in the city or on trekking tours, manual operation can be selected –...
Page 73 2.12 eShift – Integrated Gear Shift Function Operation with Nyon Display of the gear (A) Gear change Gear calibration Actuate the Shimano gear lever on the handlebar Operating mode "Settings" → "My eBike" Follow the further instructions on the display. For derailleur system: if the gearing has been May also be required during the trip moved out of position (e.g.
Page 74 2.12 eShift – Integrated Gear Shift Function 2.12 eShift E-14 Speedhub 500/14 Rohloff E-14 Speedhub 500/14 A dependable hub gear system for the highest demands and long mileage High degree of shifting convenience for fast and precise gear shifts 14 gears and 527% spread of gear ratios with integrated multishift function for fast gear change – even for sport eBikes Operation with Intuvia TURBO...
Page 75 2.12 eShift – Integrated Gear Shift Function Operation with Nyon Display of the gear (A) Gear change Gear calibration Actuate the Rohloff Speedhub gear lever on the Operating mode "Settings" → "My eBike" handlebar Follow the further instructions on the display. May also be required during the trip Setting the starting gear Operating mode "Settings"...
Page 76 2.13 Technical Data 2.13 Technical Data Active Line (BDU310) Active Line (BDU310) Cruise Gear system type Hub gear system Derailleur system Nominal continuous power 250 W 250 W Turbo: Turbo: Sport: Sport: Support Tour: Tour: Eco: Eco: Turbo: Turbo: Maximum possible drive torque (con- Sport: Sport: verted to a gear ratio of 1: 1 crankset to...
Page 77 2.13 Technical Data 2.13 Technical Data for Active Line Plus (BDU350) Active Line Plus (BDU350) Cruise Gear system type Hub gear system Derailleur system Nominal continuous power 250 W 250 W Turbo: Turbo: Sport: Sport: Support Tour: Tour: Eco: Eco: Turbo: Turbo: Maximum possible drive torque (con-...
Page 78 2.13 Technical Data 2.13 Technical Data for Active Line (BDU250C/255C) Active Line (BDU250/255C) Cruise Gear system type Hub gear system Derailleur system Nominal continuous power 250 W 250 W Turbo: Turbo: Sport: Sport: Support Tour: Tour: Eco: Eco: Turbo: Turbo: Maximum possible drive torque (con- Sport: Sport:...
Page 79 2.13 Technical Data 2.13 Technical Data for Performance Line Performance Line Cruise Speed Gear system type Hub gear system Derailleur system Derailleur system Nominal continuous power 250 W 250 W 250 W Turbo: Turbo: Turbo: Sport: Sport: Sport: Support Tour: Tour: Tour: Eco:...
Page 80 2.13 Technical Data 2.13 Technical Data Performance Line CX Performance Line CX Gear system type Derailleur system Nominal continuous power 250 W Turbo: 300 % eMTB: dynamic, max. 300% Support Tour: 120 % Eco: Turbo: 75 Maximum possible drive torque (con- eMTB: dynamic, max.
Page 81 2.13 Technical Data Your notes:...
Page 83 Batteries and Charger 3.1 Batteries and Charger at a Glance 3.2 Getting to Know Bosch eBike Batteries 3.3 Getting to Know the DualBattery System 3.4 Getting to Know the Chargers 3.5 Inserting and Removing the PowerPack 3.6 Inserting and Removing the PowerTube 3.7 Charging of the Battery...
Page 84 3.1 Batteries and Charger at a Glance...
Page 85 Glance Batteries – energy customized High mileage, long service life, low weight Ergonomic design, easy and simple handling Intelligent electronic Bosch Battery Management System (BMS) prevents overcharging, undervoltage, overheating and short circuiting. PowerPack 300/400/500 DualBattery The right battery for every requirement Doubles the range by combining two –...
Page 86 Test protocol: bosch-ebike.net → → Service → – Minimum self-discharge – even after prolonged Hazardous goods (& Recycling) storage In addition to the legally required tests, Bosch When delivered, Bosch batteries are fully undertakes internal testing regarding the safety, charged and do not require repeated complete function, service life and industrial health &...
Page 87 3.2 Getting to Know Bosch eBike Batteries 3.2 Getting to Know Bosch eBike Batteries PowerTube 500 A lithium-ion battery that can be entirely integrated in the bicycle frame High energy capacity of approx. 500 Wh Compact dimensions and minimalistic design open...
Page 88 3.3 Getting to Know the DualBattery System 3.3 Getting to Know the DualBattery System Double the range Compatibility Combination of: Cannot be retrofitted – 2 PowerPacks Both batteries must have up-to-date software ver- – 1 PowerTube and 1 PowerPack sions. –...
Page 89 3.4 Getting to Know the Chargers 3.4 Getting to Know the Chargers 3.4 Getting to Know the Chargers Standard Charger Charger Adapter Compact, light and robust – ideal for carrying along Used to connect PowerPacks for the Classic+ Line Cable Velcro binder for compact packing to the Standard Charger or Compact Charger Silent operation during charging Only one charger needed when taking tours with...
Page 90 Rack battery pushed with battery contacts toward 4. Remove the key. rack contacts until they click into the mount. Battery locks are not Bosch spare parts and 4. Make sure it is securely mounted. PowerPack must must be purchased from ABUS, AXA-BASTA or latch firmly in place, otherwise it may fall out of the TRELOCK or their respective dealer partners.
Page 91 See documentation of 5. Lock the lock, if required. respective bike manufacturer. Battery locks are not Bosch spare parts and must be purchased from ABUS, AXA-BASTA or TRELOCK or their respective dealer partners.
Page 92 Disconnect battery from charger and unplug charger. tions regarding battery and charger in the oper- A full charge of a PowerPack 300 costs less than ating manual! See bosch-ebike.net → Service → 10 cents (assumption: green electricity rate of Technical Informations 25 cents/kWh).
Page 93 3.7 Charging of the Battery > 40 °C < 0 °C °C LED display on PowerTube underside Electronic defect LED display on the battery Each LED corresponds to 20 % of the capacity. Energy capacity is used up; support is switched A flashing LED indicates charging of the next 20 %. off.
Page 94 – Insert battery just before starting the ride The eBike Battery Guide – Use protective thermal cover Order free of charge from the Bosch Dealer web- – Battery-charging inside the home is preferable shop (see p. 138) – Allow battery to warm up at least 1 hour before...
Page 95 4. As the temperature sinks, the performance of – Starting up frequency (stop & go) batteries also sinks: – Therefore, you can expect reduced range in – Range Assistant online: bosch-ebike.com winter. → Service → Range Assistant – To integrate on your own website: The remaining range is calculated on the last 4 bosch-ebike.net →...
Page 96 3.10 Range Tables...
Page 97 Type of bike and Touring bike / MTB sport bike posture Bosch eBike system Drive unit, battery and Intuvia * The ranges are typical values of the new batteries and may decrease if one of the conditions listed above deteriorates.
Page 98 & 3.10 Range Tables Range of Active Line (BDU310) PowerTube 500 and PowerPack 500 Turbo Sport Tour Mix* 220 km PowerPack 400 Turbo Sport Tour Mix* 220 km PowerPack 300 Turbo Sport Tour Mix* 220 km DualBattery 1000 Turbo...
Page 99 & Range of Active Line Plus (BDU350) PowerTube 500 and PowerPack 500 Turbo Sport Tour Mix* 180 km PowerPack 400 Turbo Sport Tour Mix* 180 km PowerPack 300 Turbo Sport Tour Mix* 180 km DualBattery 1000 Turbo Sport Tour Mix* Average of equal, combined use of all 4 modes.
Page 100 & Range of Active Line (BDU250C/255C) PowerTube 500 and PowerPack 500 Turbo Sport Tour Mix* 220 km PowerPack 400 Turbo Sport Tour Mix* 220 km PowerPack 300 Turbo Sport Tour Mix* 220 km DualBattery 1000 Turbo Sport Tour Mix* 440 km Average of equal, combined use of all 4 modes.
Page 101 & 3.10 Range Tables Range of Performance Line Cruise PowerTube 500 and PowerPack 500 Turbo Sport Tour Mix* 180 km PowerPack 400 Turbo Sport Tour Mix* 180 km PowerPack 300 Turbo Sport Tour Mix* 180 km DualBattery 1000 Turbo...
Page 102 & 3.10 Range Tables Range of Performance Line Speed PowerTube 500 and PowerPack 500 Turbo Sport Tour Mix* 100 km PowerPack 400 Turbo Sport Tour Mix* 100 km PowerPack 300 Turbo Sport Tour Mix* 100 km DualBattery 1000 Turbo...
Page 103 & 3.10 Range Tables Range of Performance Line CX PowerTube 500 and PowerPack 500 Turbo Sport Tour Mix* 160 km PowerPack 400 Turbo Sport Tour Mix* 160 km PowerPack 300 Turbo Sport Tour Mix* 160 km DualBattery 1000 Turbo...
Page 104 3.11 Technical Data 3.11 Technical Data Energy Battery Charging Weight (+/– Battery name Voltage capacity Cell pack ** type * temperature 100 g) (min.) F: 40 cells F: 2.5 kg (10s4p) 8.2 Ah / PowerPack 300 36 V 300 Wh R: 2.6 kg R: 40 cells (10s4p)
Page 105 3.11 Technical Data Standard Charger Compact Charger Voltage 220 – 240 V AC 100 – 240 V AC Output power max. 198 W max. 100 W Maximum charging current Weight < 800 g < 600 g Charging times *** Battery name Standard Charger Compact Charger 100 %: 100 %:...
Page 107 Diagnostic Tools 4.1 Getting to Know the DiagnosticTool 4.2 Prerequisites for use 4.3 Preparation for eBike diagnostics 4.4 Operation of DiagnosticTool 4.5 "Configuration" menu 4.6 "Service" menu 4.7 "Maps" menu 4.8 "Settings" Menu 4.9 "Support" menu 4.10 Troubleshooting 4.11 Remote diagnostics 4.12 Error Analysis on the eBike by Component Cross-Swap 4.13 Getting to Know the CapacityTester...
Page 108 4.1 Getting to Know the DiagnosticTool 4.1 Getting to Know the DiagnosticTool...
Page 109 Modification of configuration data or diagnostic reports, etc.) make it possible for Create eBike Service Report (for customers) or Bosch eBike Service team to rapidly come to the aid eBike Diagnostic Report (for dealers) Configure the eBike according to customer's wishes...
Page 110 4.2 Prerequisites for use Prerequisites for purchase System requirements for Windows Attendance of a Bosch eBike training program or Prozessor: min. CPU: Intel® Core™ i3-3217U participation in online training (see below) to pur- (3 MB cache, 1.80 GHz) or better chase a certificate Free hard disk space: minimum of 2 GB.
Page 111 4.3 Preparation for eBike Diagnostics 4.3 Preparation for eBike diagnostics 1. Make sure that the battery is sufficiently charged (at The DiagnosticTool opens with the start screen least one LED lit, respectively, 20% energy capacity). depicted above. 2. Connect the DiagnosticDongle to a USB port on the Use of the original diagnostics cable prevents computer.
Page 112 4.4 Operation of DiagnosticTool 4.4 Operation of DiagnosticTool Identification of the Software version of DiagnosticTool Connection status Language settings connected eBike system Menus Status of action currently executing Client ID for remote diagnostics Menus Explanations of display elements Configuration Header: Product line, bike manufacturer-specific Service identification number and software version of the Maps (or Capacity test)
Page 113 4.5 "Configuration" menu 4.5 "Configuration" menu Read out the configuration data Enable power supply to the bike lights (permanently The configuration data of the eBike are read out enabled on speed pedelecs). automatically. Switch power supply output (D) between 6 V/12 V To start the process manually, click on the "Bicycle"...
Page 114 4.5 "Configuration" menu 4.5 "Configuration" menu Manual update of the eBike software 1. Make sure an active Internet connection exists If automatic updates is activated (see p. 114), 2. Activate the check box "Perform software and appli- then a message about available new software cation parameter update".
Page 115 4.5 "Configuration" menu Individual updates for Intuvia/Nyon Service interval configuration A single update is especially useful if the last update 1. Set next service according to date and/or mileage of the eBike/on-board computer was a long time ago. (message appears on display when service is due) 1.
Page 116 4.6 "Service" menu 4.6 "Service" menu Reading out parameters and error messages Examples with battery 1. To select the desired system component, select the corresponding tab (A). Number of complete charging cycles Max./min. battery temperature in relation to total On eBikes with DualBattery, a second PowerPack power-on hours tab is displayed.
Page 117 4.6 "Service" menu Creation of reports Delete error messages 1. Click "Dealer" or "Customer" (D) button to generate 1. First either print out or save the diagnostics or the desired report type. Create service report. eBike Diagnostic Report (for dealers) or 2.
Page 118 Distance in Tour mode 10.9 mi 223.3 Ah lifetime Bosch eBike Diagnostic Software Version 4.3.5.0 eBike service report Report for customers in new, attractive layout. Editable fields in programs such as Acrobat Print out by means of any PDF display program.
Page 119 Energy consumed by motor (classified according to assistance mode) eBike diagnostic report, 29. July 2017, 10:59 PM Page 3 User-defined assistance mode Bosch eBike Diagnostic Software Version 4.3.5.0 eBike diagnostic report, 29. July 2017, 10:59 PM Page 3 eBike diagnostic report, 29. July 2017, 10:59 PM Page 3 eBike diagnostic report, 29.
Page 120 Design parts Screws OK = okay, not OK = not okay, corr. = corrected, n.a. = not applicable Bosch eBike Diagnostic Software Version 4.3.5.0 Service log Checklist for testing of eBike components during a service performance. Fields can be be checked...
Page 121 4.7 "Maps" menu 4.7 "Maps" menu Download maps onto the computer and then install on Nyon 1. In the "Settings" menu, select the storage location The download may take considerable time for the maps (see p. 114). depending on the size of the map selected 2.
Page 122 4.8 "Settings" menu 4.8 "Settings" Menu 1 Internet address for Bosch update server 6 Map material for Nyon: specify storage location on computer Only make changes according to the instructions of Bosch eBike Service. 7 Option for storing business address and dealer logo...
Page 123 3 Contact for Bosch eBike Service team 4 Option to save a service log or flight recorder file (only required after request by Bosch eBike Service team) 5 Link to the DiagnosticTool User Manual...
Page 124 4.10 Troubleshooting 4.10 Troubleshooting Problem description Measures One or more components indicate malfunctions and The software of the respective component(s) may are continuously displayed in "FBL mode". not be functional. 1. Make sure that the DiagnosticTool is updated to the most recent version (if required, perform update).
Page 125 4.10 Troubleshooting Problem description Measures Components are again in FBL mode after a com- 1. Connect eBike or on-board computer with Diag- pleted update. nosticTool (display in status line: "Connected" or Function disruptions without any apparent dam- "Connected FBL"). age to the eBike components 2.
Page 126 4.11 Remote Diagnostics 4.11 Remote Diagnostics Bike manu- Dealer facturer workshop Why remote diagnostics? System requirements For a brief period, the bike manufacturer's technical Windows operating system support team can access the bicycle dealer's com- Bandwidth of Internet connection: puter. –...
Page 127 4.11 Remote Diagnostics Starting a remote diagnostics session 1. Ensure that the Internet connection is active. 6. If the "Yes" button is clicked, then the remote diag- 2. Check whether the personal Client ID (A) is dis- nostics session can start. The Service employee can played in the lower right of the DiagnosticTool.
Page 128 Cross-swap procedure Disconnect the eBike with malfunctions from Diag- Reconnect the eBike to DiagnosticTool. Check nosticTool; swap out components. whether the problem persists. Preparation for contact with Bosch eBike Service On-board Battery Mounts/ Cable set (see p. 131). computer...
Page 129 Purchase procedure same as with DiagnosticTool, – DiagnosticDongle see p. 102 Completely charge the PowerPack so that Order through a Bosch eBike service partner measurement can start. (Magura or Fuchs-Movesa) Begin the measurement procedure within 5 min. Price of CapacityTester: 299 € net...
Page 130 4.14 Operation of CapacityTester 4.14 Operation of CapacityTester Menu in DiagnosticTool Serial number, hardware and software version Connection status Status bar To start the CapacityTester 1. Connect plug-in power adaptor to the Capacity- 1. The energy capacity of batteries can be Tester and plug in mains power socket.
Page 131 4.14 Operation of CapacityTester Perform capacity test 1. Connect battery to the CapacityTester. 7. Measurement can be cancelled by pressing the 2. Click on the "Capacity Test" tab. "Stop" button in the DiagnosticTool. 3. Select battery type. 8. If the battery is completely discharged, then the 4.
Page 132 4.14 Operation of CapacityTester 4.14 Operation of CapacityTester Software update for CapacityTester 1. Click on the "Configuration" menu. Before operating, please pay attention to the 2. Click the button with the green arrow. safety instructions in the Capacity Tester operat- 3.
Page 133 4.14 Operation of CapacityTester...
Page 135 Range of Support for Dealers 5.1 Contact Points to Bosch eBike Systems 5.2 Bosch eBike Service Hotline 5.3 Service Procedure 5.4 Expert Advisor Team 5.5 Bosch eBike dealer portal and newsletter 5.6 Dealer Webshops 5.7 Sales Support 5.8 Checklist for Checking New eBikes 5.9 Proper Handling of eBike Components...
Page 136 5.1 Contact points to Bosch eBike 5.1 Contact points to Bosch eBike...
Page 137 Range Assistant, downloads, news and stories industries Bosch eBike Service Hotline Support during processing of service cases as well as answers to questions about Bosch eBike systems Expert team Bosch eBike experts with many years of expertise and comprehensive know-how in the branch...
Page 138 5.2 Bosch eBike Systems 5.2 Bosch eBike Service Hotline Support during processing of service cases as well Availability: as answers to questions about Bosch eBike systems – Telephone call billed at country-specific For inquiries regarding a previously recorded service local call rate case, please have your service case form available –...
Page 139 Perform a test ride Carry out a new diagnostics test. Save the new report (see p. 108) Preparing to speak to Bosch eBike Service Team Exact problem description – Does just an error message appear or does the eBike system exhibit malfunctions? –...
Page 140 Bosch eBike Service checks guarantee claim Available – Bosch eBike Service is responsible for free replacement and return shipping. – For reimbursement of working hours, send informal request by email to Bosch eBike Service with reference to the service case number. Not available –...
Page 141 Observe the following with return shipments This form is created when a service case is reported Never ship defective component before recording of to Bosch eBike Service Team. This is then sent to the service request the dealer by email.
Page 142 Contact partner: Contact partner: Contact partner: Transport company eBike manufacturer Bosch eBike Systems Service Legally regulated liability for material defects Liability of the commercial seller (bicycle dealer) Limitation period in the EU: 24 months starting from the transfer of the product to the consumer (regard- with respect to the consumer is legally regulated.
Page 143 5.4 Expert Advisor Team 5.4 Expert Advisor Team Bosch eBike experts with many years of expertise Name and contact information of the bicycle and comprehensive know-how in the branch dealer responsible for the region under Bosch eBike trainers, for example, coaching at the bosch-ebike.net →...
Page 144 5.5 Bosch eBike dealer portal bosch-ebike.net and newsletter The dealer portal offers An overview of all recorded service cases Access to the Bosch eBike Webshops and for train- Case number ing session registration Product, status, and logistics information prior information for the next training course tour Product information for all components Online Training e.
Page 145 5.5 Dealer Portal and Newsletter Bosch eBike Systems Dealers Newsletter Regular updates for Bosch eBike dealers with all important information Registration to the newsletter 1. After login to the dealer portal click on 2. Select “Profile” 3. Subscribe to the profiles newsletter in the area...
Page 146 5.6 Dealer Webshops 5.6 Dealer Webshops Ordering spare parts, tools, accessories, advertising Registration for Bosch eBike training sessions is and communication material only possible in the Webshops Bosch eBike-Webshop powered by Magura Bosch eBike Webshop powered by Fuchs- Movesa bosch-ebike.com/webshop bosch-ebike.ch/webshop...
Page 147 – Nyon Interactive Journey lettering and clothing for Service personnel – Animation of a drive unit – Range assistant Order from the Bosch eBike Webshop – Brochures, logos, photo and video material (see p. 138) Download under bosch-ebike.net → → Sales Support →...
Page 148 Handover of an optimally prepared eBike to the customer Download the Checklist under bosch-ebike.net → Service → Technical Information Procedure In the presence of the transportation company, check- 8.
Page 149 5.8 Checklist for Checking New eBikes Notes...
Page 150 Additional service information at bosch-eBike.com → Service → Cleaning and transporting On-Board Computer Bosch eBike Service with tips and informa- Always keep the on-board computer screen clean. Soiling may result in the incorrect detection of tion for eBike riders (e. g. travelling with brightness.
Page 151 5.9 Proper Handling of eBike Components 5.9 Proper Handling of eBike Components Transport with an automobile Protective covers for the drive unit, battery and on-board computer Always remove the battery and on-board computer and stow them safely inside the car Intended to protect from Protect electrical contacts of eBike components –...
Page 152 Therefore all lithium-ion batteries must be tested Once the battery is inserted in the eBike, the according to UN model regulations: bike becomes a "Battery-powered vehicle or bosch-ebike.net → Service Battery-powered equipment" (UN number 3171). →Technical Information If the goods are not dangerous, ADR regula-...
Page 153 Packer and Shipper (Distributor), Carrier, Driver, The dealer receives this completed in advance from Unloader, Receiver must be instructed based on Bosch eBike Service team: their work and areas of responsibility in accordance – (A) Complete address of the sender and recipient with chapter 1.3.
Page 154 Classification: Lithium ion batteries with more than Shipping in type-approved packaging with correct 100 Wh labelling Class 9: Miscellaneous dangerous substances and – Available from the Bosch eBike Webshop (see p. objects 138) Dangerous goods description: Lithium-ion batteries – Undamaged used packaging can be used again.
Page 155 (contents must remain intact when dropped from a materials; please provide advance notice if the height of 1.2 m) package is not picked up by Bosch. (Transport Outer packaging sufficiently sturdy and undamaged possible with e.g. FedEx, TNT, DHL, GLS) Outer packaging must be marked with the words "outer box"...
Page 156 Only use original Bosch batteries, otherwise – Risk of injury and fire Building insurance expansion, if required – Liability/warranty by Bosch in case of con- Report to business insurance: Storage of eBikes and sequential damage lithium-ion batteries > 100 Wh...
Page 157 Never transport it yourself or hand it over to a par- Capability problems, superficial scratches, broken handle, cel service/freight forwarder LEDs 2 and 4 flashing Establish contact with the Bosch eBike service Battery can usually be switched on and, if required, Keep in a safe place diagnosed...
Page 158 5.12 Legal Status of a S-Pedelec 5.12 Legal Status of a S-Pedelec 5.12 Legal Status of a S-Pedelec On vehicles with a technically permissible total This chapter explains the EU-wide legal mass of up to 150 kg, tyres without type status of newly equipped S-pedelecs from approval may be used with a cross-section width MY 2018 onward.
Page 159 5.12 Legal Status of a S-Pedelec 5.12 Legal Status of a S-Pedelec Trailers Country specific regulations: Children's trailers/bicycles are not allowed (excep- tion: Switzerland) Load/dog trailer allowed, if type-tested bicycle trailer coupling available Only trailer with max. 50% of the mass of the vehi- cle in running condition (= unloaded, without driver and without battery) Conversion and replacement of bicycle...
Page 160 5.13 Error Codes Basic approach Print the diagnostic report Delete the error code If needed, perform a software update Restart the system If the problem persists, contact Bosch Service Hotline. Classic+ Line Error description, repair error code error code in DiagnosticTool in display Internal error in the drive unit.
Page 161 5.13 Error Codes PerformanceLine CX, PerformanceLine, ActiveLinePlus (BDU350), ActiveLine (BDU310), ActiveLine (BDU250C / 255C) Error description, repair error code error code in DiagnosticTool in display Speed sensor error, limited motor support, speed indication on the display is 0. Check the position of the magnet (distance to sensor 5 mm to 17 0x503001 mm).
Page 162 Print the diagnostic report Delete the error code If needed, perform a software update Restart the system If the problem persists, contact Bosch Service Hotline. PerformanceLine CX, PerformanceLine, ActiveLinePlus (BDU350), ActiveLine (BDU310), ActiveLine (BDU250C / 255C) Error description, repair error code...
Page 163 Battery authentication error: Battery could not be correctly identified. 0x530001 Motor support off or delayed in the starting phase. Walk Assist or Drive- Off-Mode not available. Be sure to use only original Bosch batteries. 0x530002 Switch off eBike, remove and reinstall the batteries, restart eBike.
Page 164 Print the diagnostic report Delete the error code If needed, perform a software update Restart the system If the problem persists, contact Bosch Service Hotline. PerformanceLine CX, PerformanceLine, ActiveLinePlus (BDU350), ActiveLine (BDU310), ActiveLine (BDU250C / 255C) Error description, repair error code...
Page 165 5.13 Error Codes PerformanceLine CX, PerformanceLine, ActiveLinePlus (BDU350), ActiveLine (BDU310), ActiveLine (BDU250C / 255C) Error description, repair error code error code in DiagnosticTool in display Tail light is defective, overloaded or interrupted. Light functionality is not available. Cross inspection by replacing the front/backlights and connec- 0x550351 tor.
Page 166 Basic approach Print the diagnostic report Delete the error code If needed, perform a software update Restart the system If the problem persists, contact Bosch Service Hotline. PowerPack 300/400/500, PowerTube 500 Error description, repair error code error code in DiagnosticTool...
Page 167 5.13 Error Codes PowerPack 300/400/500, PowerTube 500 Error description, repair error code error code in DiagnosticTool in display Configuration error. External voltage off, pre-charge out, charger out. 0x656005 Run the software update. More than one battery was detected on the eBike system. Remove a bat- 0x658001 tery from the eBike system..
Page 168 Basic approach Print the diagnostic report Delete the error code If needed, perform a software update Restart the system If the problem persists, contact Bosch Service Hotline. PowerPack 300/400/500, PowerTube 500 Error description, repair error code error code in DiagnosticTool...
Page 169 0x02 00 02 Error in battery: Excess current (... 13), electronics (... 02) or short circuit 0x02 00 13 (... 0F). Contact Bosch Service Hotline. 0x02 00 0F 0x02 00 05 CAN-Communication problem between battery and other system compo- nents.
Page 170 5.13 Error Codes Basic approach Print the diagnostic report Delete the error code If needed, perform a software update Restart the system If the problem persists, contact Bosch Service Hotline. Nyon, Intuvia, Purion Error description, repair error code error code in DiagnosticTool in display Software version error.
Page 171 5.13 Error Codes Nyon, Intuvia, Purion Error description, repair error code error code in DiagnosticTool in display 0x4C002B 0x4C002C Internal memory error. Print diagnostic report, clear error code, update – 0x4C002D software, restart system. If the error persists, replace on-board computer. 0x4C002E Internal pressure sensor error.
Page 172 5.13 Error Codes 5.13 Error Codes Please note: The following error messages are not caused by the Bosch eBike system, but by the switch system. In the event of a service case, contact the gear system manufacturer. eShift – all systems...
Page 173 Let the ClickBox cool down. Surrounding temperature too low. Turn the system off and then on again, – allow the system to slowly heat to room temperature. SRAM-DD3-ClickBox software version does not support the connected – Bosch eBike system.
Page 174 5.13 Error Codes 5.13 Error Codes Please note: The following error messages are not caused by the Bosch eBike system, but by the switch system. In the event of a service case, contact the gear system manufacturer. eShift – Shimano DI2...
Page 175 5.13 Error Codes CapacityTester Error description, repair error code error code in DiagnosticTool in display Internal temperature sensor error. Print the diagnostic report, clear the 0xA21000 – error, and restart the device. Perform software update. The temperature at sensor 1 is too high. Allow the device to cool for 30 0xA22100 –...
Page 176 5.13 Error Codes 5.13 Error Codes CapacityTester Error description, repair error code error code in DiagnosticTool in display Internal discharge error. Print the diagnostic report, clear the error, and 0xA43000 – restart the device. Perform software update. Internal hardware error. Print the diagnostic report, clear the error, and 0xA44000 –...
Page 177 5.13 Error Codes CapacityTester Error description, repair error code error code in DiagnosticTool in display 0xAA1001 0xAA3001 0xAA3002 0xAA4000 0xAA5000 Internal software error. Print the diagnostic report, clear the error, and 0xAC0105 – restart the device. Perform software update. 0xAC0106 0xAC0107 0xAC0108 0xAC0109...
Page 178 5.13 Error Codes 5.13 Error Codes CapacityTester Error description, repair error code error code in DiagnosticTool in display The temperature of the connected battery is too low to start the measure- PC_TOOL FAULT – ment. Allow the battery to warm slowly to room temperature, restart the No.
Page 179 5.13 Error Codes Notes...
Page 181 Installing/Removing eBike Components 6.1 Safety Instructions 6.2 CE Marking 6.3 On-Board Computer and Control Unit 6.4 PowerTube 6.5 Frame Battery 6.6 Rack battery 6.7 Removing Drive Unit (BDU310/350) 6.8 Installing Drive Unit (BDU310/350) 6.9 Removing Drive Unit (BDU250C/255C) 6.10 Installing Drive Unit (BDU250C/255C) 6.11 Electrical Connections 6.12 Speed sensor 6.13 Tightening Torques and Tool...
Page 182 When replacing components mounted on the drive on the eBike. unit and all other components of the eBike (e.g. It is not permissible to open Bosch eBike compo- chainring, chainring spider, pedals): Only install nents. The warranty is voided and components may...
Page 183 6.2 CE Marking 6.2 CE Marking 6.2 CE Marking Mandatory CE marking in the EU Risks from tuning CE marking = manufacturer's declaration that his prod- Do not modify the eBike system or attach uct satisfies the respective legal requirements of the EU: products to increase performance.
Page 184 6.3 On-Board Computer and Control Unit 6.3 On-Board Computer and Control Unit Work steps (identical for both the Intuvia and Nyon) Tool Secure the on-board com- Ø 22.2 mm, 25.4 mm or 31.8 Allen key size 3 puter in the mount (if mm –...
Page 185 6.3 On-Board Computer and Control Unit Work steps (identical for both the Intuvia and Nyon) Tool Replace the cable Phillips screwdriver size PH00 on the mount Torque wrench 1. Remove the on-board computer When replacing the mount, from the mount. it is not necessary to 2.
Page 186 6.3 On-Board Computer and Control Unit 6.3 On-Board Computer and Control Unit Work steps Tool Information about installa- Important spare parts Allen key size 3 tion of Purion Purion Button Cell Battery Torque wrench Assembly on the left side of the Order number: 1.270.016.819 handlebar Battery Cover incl.
Page 187 6.4 PowerTube 6.4 PowerTube Work steps Tool Installation of the charging Alternative procedure: Torx wrench T10 socket 1. Guide the rubber cap (E) into the 1. Hold the charging socket base (A) cut-out provided for this in the onto the frame's inner side at the charging socket base.
Page 188 6.4 PowerTube 6.4 PowerTube Work steps Tool Torx wrench Preparing mount system for installation T20/T25 Lock side: Attachment of mounting aid: Allen key 1. Press the bar to backside of 5. Lightly attach the L -angle (G) on size 2 / size 4 mount plate (A), place lock (B) the lock side of the mounting Torque wrench...
Page 189 6.4 PowerTube Work steps Tool Attaching the battery hous- Insertion of the mounting Torx wrench T10 ing sections to the mount- aid into the frame cut-out Torx wrench T25 ing aid 1. Lay in the cables, tilt the Allen key size 2 Battery housing sections can be mounting aid (B) and guide into Torque wrench...
Page 190 (D); horizontal: use necessary, make adjustments. lower tapped holes (E) in the aluminum angle (A). Spare parts for PowerTube available from Bosch (see spare parts list), for example: – Cables, various lengths – Charging Socket Kit – Threaded Flange Kit...
Page 191 6.5 Frame Battery 6.5 Frame Battery Work steps Tool Preinstalling the lock Installing the lower mount Torx wrench T25 adapter 1. Clip in the lock into the (A) Torque wrench lower housing section (B). Place the mount adapter (C) 2. Make sure that all five clips over the thread inserts in the have snapped into place.
Page 192 6.5 Frame Battery 6.5 Frame Battery Work steps Tool Installing the PowerPack Torx wrench T15 cable and mount casing Torque wrench 1. Thread the PowerPack cable (A) through the adapter (B) and insert the plug (C) in the adapter. Tightening 2.
Page 193 6.5 Frame Battery 6.5 Frame Battery Work steps Tool Installing the lock Allen key size 4 1. Place the lock with the lower 4. Tighten the two screws (B). Blue PowerPack assembly jig housing section (A) onto the 5. Remove the assembly jig. (Order number: top mount section (welded 0.275.009.004)
Page 194 6.6 Rack Battery 6.6 Rack battery 8 mm 4 mm Work steps Tool Pre-installation of the PowerPack mount Torx wrench T15 1. Slide the rail (A) fully into the Key cylinders (incl. lock Torque wrench key cylinder (B) and clip it on. cylinders) are available from 2.
Page 195 6.6 Rack Battery 6.6 Rack Battery Work steps Tool Installing the PowerPack mount Tool dependent 1. Insert the PowerPack mount Matching luggage rack can on the screws used into the rack. Make sure that be purchased from e.g. Torque wrench the centring pin (A) on the bike Curana, Hebie, Pletscher, rack engages in the cut-out on...
Page 196 5. Remove the O-ring (B) and Spider Tool trained specialist using the carefully check it for damage. (e.g. X-Tool rev. 1) original Bosch Spider Tool. Only reuse O-rings if they are intact. 1. Dismount the crank arms (Allen 6. Remove spider (C) together...
Page 197 6.7 Removing Drive Unit (BDU310/350) 6.7 Removing Drive Unit (BDU310/350) Active Line (BDU310) Active Line Plus (BDU350) Work steps Tool Removing the design cover Disconnect the cables Torx T20 Active Line (BDU310): Remove the cable ties. Side cutters 1. Remove the two screws (A). Small screwdriver Disconnecting the cable 2.
Page 198 6.7 Removing Drive Unit (BDU310/350) 6.7 Removing Drive Unit (BDU310/350) Work steps Tool Removing the drive unit Torx screwdriver (T30) 1. Check that all cables (A) are The drive unit is secured to Open end wrench size 13 disconnected (see page 189). the frame by only three Pull out all cables as far as hexagon bolts.
Page 199 6.8 Installing Drive Unit (BDU310/350) 6.8 Installing Drive Unit (BDU310/350) Work steps Inserting the drive unit 1. Thread all cables into the frame interface. 2. Insert the drive unit including all three hexagon bolts (A) (M8 x 60) into the frame interface. Make sure that no cables are pinched.
Page 200 6.8 Installing Drive Unit (BDU310/350) 6.8 Installing Drive Unit (BDU310/350) Work steps Tool Fastening the drive Cable routing Torx wrench T30 unit with screws Fix excessive cable lengths Socket wrench insert size 13 1. Insert the mounting plate (A) in using cable ties. Use the holes Torque wrench such a way that the cable are in the adapter plate for this...
Page 201 Tool Installing the Active Line (BDU310) design cover Torx wrench T20 1. Place the front piece (A) on the 4. Only glue on the Bosch logo Torque wrench drive unit and screw onto the cover (F) if absolutely neces- housing using two M4 x 10 sary.
Page 202 6.8 Installing Drive Unit (BDU310/350) 6.8 Installing Drive Unit (BDU310/350) Work steps Tool Installing the Active Line (BDU350) design cover Torx wrench T20 1. Place the right-side lower design 3. Place on the right-side upper Torque wrench cover (A) on the drive unit and design cover (E) and clip into screw onto the housing using two the lower design cover (A).
Page 203 6.8 Installing Drive Unit (BDU310/350) Work steps Tool Mounting a chain guard 1. Screw on the adapter (A) to the Torx wrench T20 adapter (optional) screw-on points provided (up Torque wrench A chain guard adapter is to five screws). required to mount a chain 2.
Page 204 6.8 Installing Drive Unit (BDU310/350) 6.8 Installing Drive Unit (BDU310/350) Work steps Tool Mounting chainring on the 5. Pull the slightly greased spider Allen key size 8 spider locknut (E) with the Spider Torque wrench The chainring (A) must be Tool. The lettering must be Spider Tool mounted on the bike side on which visible.
Page 205 Lock ring made of plastic up to with an O-ring with chainring size 14. model year 2014 Prevents damage resulting from Can be used for all Bosch eBike Tightening torque: 20–25 Nm on incorrect installation and use of and chainring sizes. non-greased threads improper tools.
Page 206 6.9 Removing the Drive Unit (BDU250C/255C) 6.9 Removing Drive Unit (BDU250C/255C) Work steps Tool Removing the Remove the cable guard (D) Torx wrench T20 design cover (A) for Performance Line CX 1. Remove the three screws (B). Remove screws (E, F) and take 2.
Page 207 6.9 Removing the Drive Unit (BDU250C/255C) Work steps Tool Disconnect the cables Do not damage the plug and Side cutters Remove the cable ties (A). cable! Always remove the Small screwdriver plugs using your fingers or a Long nose pliers Disconnecting the cable long nose pliers.
Page 208 6.9 Removing the Drive Unit (BDU250C/255C) 6.9 Removing Drive Unit (BDU250C/255C) Work steps Tool Removing the drive unit Torx screwdriver (T30) 1. Pull out all cables (A) as far as The drive unit is secured to Socket wrench insert size 13 possible from the frame inter- the frame by only three face (B).
Page 209 6.10 Installing Drive Unit (BDU250C/255C) 6.10 Installing Drive Unit (BDU250C/255C) Work steps Inserting the drive unit 1. Thread all cables (A) into the frame interface (B). 2. Place the drive unit on the frame interface. Do not pinch cables! Drive unit with damping foil glued in place 3.
Page 210 6.10 Installing Drive Unit (BDU250C/255C) 6.10 Installing Drive Unit (BDU250C/255C) Work steps Tool Fastening the drive Torx wrench T30 unit with screws Socket wrench insert size 13 1. Insert the mounting plate (A). Torque wrench 2. Lightly screw in the three nuts (B) with washers (C), but do not tighten.
Page 211 6.10 Installing Drive Unit (BDU250C/255C) Work steps Tool Retrofitting with a chain 1. Screw on the chain protection Torx wrench T20 guard adapter (optional) adapter (A) to the screw-on Torque wrench Installing a chain guard will also points provided (self-tapping require: screws). Chain guard adapter (A) 2.
Page 212 2. Glue on the logo cover (G). plate, a spacer sleeve (C) is 3. Pay attention to the installation required for the installation of position: The BOSCH lettering the design cover. (is delivered must be positioned horizon- pre-assembled; also as a spare tally.
Page 213 Installing the chainring and crankshaft Bearing grease Torque wrench The chainring spider may only 2. Lightly grease the gear profile Original Bosch Lock Ring Tool be loosened and tightened by and fine threads on the motor (Order number: a trained specialist using the shaft.
Page 214 6.11 Electrical Connections 6.11 Electrical Connections Active Line (BDU310), Active Line Plus (BDU350) Pos. Connection Color Voltage Battery Black 36 V Display Black 12 V Speed sensor Grey 3.3 V / min. 3.1 V Rear light Black 12 V 12 V Front lamp Blue Active Line (BDU250C/255C),...
Page 215 – Output power for lighting: 9 W at 6 V, Lupine, Spanninga, Supernova and Trelock. 18 W at 12 V, max. 1500 mA ▶ Original Bosch eBike lighting cables are avail- – Distribution of the output current to the front able from Bosch eBike service partners.
Page 216 3. If required, align the sensor with additional spacers When replacing the spoke magnets: Use only an original Bosch spare part (Order number: 1.270.015.931). Conventional bicycle computer magnets do not have a sufficiently strong mag- netic field strength.
Page 217 Mount adapter on frame Torx T25 4 Nm Mount casing Torx T15 2 Nm Lock (not a Bosch spare part) on the frame Allen key size 4 4–5 Nm Lock cover on the lock Torx T15 2 Nm On-Board Computer and Control Unit...
Page 218 6.13 Tightening Torques and Tool Your notes:...
Page 220 Robert Bosch GmbH Bosch eBike Systems Postfach 1342 72703 Reutlingen Dealer portal: bosch-ebike.net Website: bosch-ebike.com...

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Bosch eBike Active Line BDU310 Manual

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