Bosch Performance Line CX / Speed (BDU3840, BDU3880) Manual

Introduction

Some content is published under license from the PeopleForBikes Coalition, LTD.

About Warnings
This manual contains many DANGER, WARNING and CAUTION indicators concerning the consequences of failure to use, assemble, maintain, store, inspect and dispose of a Bosch-equipped eBike in a safe manner.

• The combination of the safety alert symbol and the word DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.
• The combination of the safety alert symbol and the word WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury.
• The combination of the safety alert symbol and the wordCAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.

General Warnings
Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in death, property damage or serious injury.
Save all safety warnings and instructions for future reference.
The term eBike battery used in these operating instructions refers to all original Bosch eBike batteries from the system generation the smart system.

• Read ALL accompanying manuals before riding the bike for the first time. Your Bosch Drive System comes with additional manuals and documents provided by the manufacturer of the bicycle and other components. Failure to read and understand safety information can result in death or serious injury.

• This manual contains important safety, performance and service information. Read it before you take the first ride on your new bicycle, and keep it for reference. The manual can also be found online at www.bosch-ebike.com.
• This manual is intended to be read together with the separate user manual provided with your bicycle. Be sure to read all provided documents including labels on the product before your first ride.
• Take responsibility for your own SAFETY. If you have any questions or do not understand something, consult with your dealer or the bicycle or component manufacturer.
• Some eBike accessories may present a choking hazard to small children. Keep these accessories away from children.

• The Bosch Drive System adds weight to your bicycle which you may not be used to lift. Avoid injury, use proper lifting techniques.

Using your Manual
In addition to the functions outlined here, changes to software relating to troubleshooting and functional modifications may be introduced at any time.

Graphics
The bicycle shown in this manual may differ slightly from your bicycle, but will be similar enough to help you understand our instructions.
RIGHT-HAND and LEFT-HAND sides are determined by facing in the direction the bicycle will travel when going forward. When you see a broken line (------), the item referred to is hidden from view.

Operating your Bosch Drive Unit

Safety instructions
Read and understand all safety warnings and instructions. Failure to follow the below warnings could result in death or serious injury.
Save all safety warnings and instructions for future reference.
The term eBike battery used in these operating instructions refers to all original Bosch eBike batteries from the system generation the smart system.
The terms drive and drive unit used in these operating instructions refer to all original Bosch drive units from the system generation the smart system.

• Read and observe the safety warnings and instructions in all operating instructions of the eBike components and your eBike.
• It is recommended that you periodically review this information to ensure you are following all recommendations for safe use of this product.
• Do not make any kind of modifications to the drive. Do not use any products to increase the performance and/or top speed of the eBike. Modifying an eBike to increase its performance or speed may be unlawful and can result in component failure or a loss of control, leading to a crash resulting in serious injury or death. A modified eBike may no longer be regulated as an eBike, placing the operator at risk of personal liability and criminal prosecution in the event of a crash. In addition, doing so will generally reduce the service life of the eBike components. The drive unit and eBike may be damaged and guarantee and warranty claims on the eBike you have purchased may consequently be voided.
• Do not open the drive unit. The drive unit must be repaired using only original spare parts and only by an authorized bicycle retailer. This will ensure that the eBike remains safe to use. Unauthorized opening of the drive unit may render warranty claims null and void.
• Remove the eBike battery from the eBike before beginning work (e.g. inspection, repair, assembly, maintenance, work on the chain, etc.) on the eBike. When working on permanently installed eBike batteries, take particular care to ensure that the eBike cannot be switched on. Unintentional activation of the eBike poses a risk of injury.
• The eBike can be switched on by pushing the eBike backwards or by turning the pedals backwards.
• Do not remove permanently installed eBike batteries yourself. Permanently installed eBike batteries must only be installed and removed by authorized bicycle retailers.
  Under extreme conditions, such as continuously high loads at low speed when riding up hills or carrying loads, parts of the drive unit can reach temperatures in excess of 140°F.
• u After a ride, do not allow your unprotected hands or legs to come into contact with the housing of the drive unit. Under extreme conditions, such as continuously high torques at low travel speeds, or when riding up hills or carrying loads, very high temperatures may be reached on the housing. Contact with hot components can result in burns if touched.
  The temperatures that may be reached on the drive unit housing are influenced by the following factors:
  • Ambient temperature
  • Ride profile (route/gradient)
  • Ride duration
  • Riding modes
  • User behavior (personal effort)
  • Total weight (rider, eBike, luggage)
  • Motor cover on the drive unit
  • Heat dissipation properties of the bicycle frame
  • Type of drive unit and type of gear-shiftingu
    Use only original Bosch eBike batteries from the system generation the smart system that the manufacturer has approved for your eBike. Using other eBike batteries can lead to injuries and pose a fire hazard. Bosch accepts no liability if other eBike batteries are used.

Safety instructions for the rim magnet
The following safety instructions must be observed when handling the rim magnet:

• Warning of very strong magnetic fields: The rim magnet generates a very strong magnetic field that may influence the magnetic storage media (e.g. credit card) and electronic devices (e.g. clock). There is a risk of data loss and damage to devices. Do not move any media or devices sensitive to magnetic fields into the immediate vicinity of the rim magnet.
• Warning of hand injuries caused by parts attracted to the magnet: There is a risk of injury if your fingers or hands get caught between the magnet and the objects attracted to it. This may cause skin injuries (e.g. if metal chips are attracted), crushing injuries, contusions or fractures. You can avoid these by being vigilant and wearing suitable protective clothing.
• Danger to persons with implants and other medical devices, e.g. pacemakers, defribrillators or insulin pumps:
  Keep these away from the immediate vicinity of the rim magnet.
  • The magnet creates a field which can impair the function of implants and medical devices.
  • To avoid impairments, the rim magnet should not be held directly in front of the chest.
  • A minimum distance of 30 cm to the chest should be maintained.
• Observe all national regulations which set out the approved use of eBikes.
• Please observe all local, state and federal regulations when registering and using eBikes.

Privacy notice
When connecting the eBike to the Bosch DiagnosticTool 3 or when exchanging eBike components, technical information about your eBike (e.g. manufacturer, model, bike ID, configuration data) as well as regarding the use of the eBike (e.g. total travel time, energy consumption, temperature) is transmitted to Bosch eBike Systems (Robert Bosch GmbH) for processing your request, in service cases and for the purposes of product improvement. More information on data processing can be found at www.bosch-ebike.com/privacy-full.

Product description and specifications

Intended use
The Bosch drive unit from the system generation the smart system is intended exclusively for driving your eBike and must not be used for any other purpose.
In addition to the functions outlined here, changes to software relating to troubleshooting and functional modifications may be introduced at any time.

Technical data

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

^A) Depends on legal regulations, not possible in all countryspecific models via the eBike battery
Inserting a bulb incorrectly can cause it to blow.

Details on noise emissions on the drive unit
The A-rated emission sound pressure level for the drive unit is < 70 dB(A) in standard operating mode. If the eBike is moved without authorization, the drive unit generates an alarm tone as a key feature of the <eBike Alarm> service. This alarm tone may exceed the emission sound pressure level of 70 dB(A) and is 80 dB(A) two meters away from the drive unit. The alarm tone is only available after activating the <eBike Alarm> service and can be deactivated again via the eBike Flow app.

Assembly

Checking the speed sensor (see figure A)

1. Speed sensor
2. Spoke magnet
3. CenterLock magnet
4. Rim magnet

^a Different sensor shape and installation position possible
^b a different installation position is possible

Speed Sensor (slim)
The speed sensor (1) and its CenterLock magnet (3) or spoke magnet (2) are mounted ex works in such a manner that the magnet, after a turn of the wheel, moves past the speed sensor with a clearance of at least 2 mm, yet no more than 15 mm. The correct distance between the magnet and sensor must be maintained (see figure A) if design changes are made.
Note: The rim magnet's alignment with the rim must not be changed (see figure A).
If a rim magnet is installed, no sensor is required to detect a wheel turn. The drive unit itself detects when the magnet is close to it and calculates the speed and any other data required from the frequency of the emergence of the magnetic field.
Since the drive unit is sensitive to magnetic fields, avoid other magnetic fields in the vicinity of the drive unit (e.g. magnetic clipless pedals, magnetic cadence sensors, magnetic or magnetized tools, etc.) in order to prevent disruption to the drive unit.

Rim magnet
Note: The rim magnet's alignment with the rim must not be changed (see figure A). If a rim magnet is installed, no sensor is required to detect a wheel turn. The drive unit itself detects when the magnet is close to it and calculates the speed and any other data required from the frequency of the emergence of the magnetic field. Since the drive unit is sensitive to magnetic fields, avoid other magnetic fields in the vicinity of the drive unit (e.g. magnetic clipless pedals, magnetic cadence sensors, magnetic or magnetized tools, etc.) in order to prevent disruption to the drive unit.

Operation

An operating unit from the system generation the smart system is required for starting operation of the eBike. Observe the operating instructions for the operating unit and additional components from the system generation the smart system where necessary.

Notes on cycling with your eBike
Note: The eBike system always starts in OFF mode for drive units with a maximum speed of more than 20 mph.

When does the drive take effect?
The drive assists your cycling only when you are pedaling. If you do not pedal, the assistance will not work. The drive output always depends on the pedaling force and cadence that you apply.
With a lower force applied or a less frequent cadence, the assistance provided will be lower than that supplied at a higher force or a more frequent cadence. This applies irrespective of the riding mode.
The drive automatically switches off at speeds over 20/28 mph. When the speed falls below 20/28 mph, the drive automatically becomes available again.
An exception applies to the push assistance function, in which the eBike can be pushed at low speed without pedaling. The pedals may rotate when the push assistance is in use.
You can also use the eBike as a normal bicycle without assistance at any time, either by switching off the eBike or by setting the riding mode to OFF. The same applies when the eBike battery is drained.

Interaction of the drive unit with the gear-shifting
You should shift through gears on an eBike in the same manner as when using a normal bicycle (observe the operating instructions of your eBike with regard to this point).
Irrespective of the type of gear shifting, it is advisable that you briefly reduce the pressure on the pedals when changing gear. This will aid gear shifting and reduce wear on the powertrain.
By selecting the correct gear, you can increase your speed and range while applying the same amount of force.

Gaining initial experience
We recommend that you gain initial experience with the eBike away from busy roads.
Test the various riding modes. Start in a riding mode with a small amount of assistance. As soon as you feel confident, you can ride your eBike in traffic like any other bicycle.
Test the range of your eBike in different conditions before planning longer and more demanding trips.

Influences on range
It is not possible to calculate the range accurately before and during a trip because the range is affected by a number of factors.
Enter the factors in the Range Assistant in order to better assess the effects on the range.

Scan the code provided to open the Range Assistant.

Maintenance/Cleaning

• Do not open any of the components. Service should only be carried out at an authorized Bosch eBike dealer. Failure to follow above warning can cause death or serious injury. Refer to your bicycle manual or component manual for all nonBosch drive system components.
• Always remove the battery pack before performing any bicycle inspection, maintenance or repair. Failure to remove the battery pack before performing bicycle inspection, maintenance or repair can lead to serious injury.
• If you suspect that something is loose, do not ride your bike. See your Bosch eBike dealer, only a qualified service provider should perform work on your Bosch Drive System. All nuts, bolts, screws require the correct tightening force. Too little force and the fastener may not hold securely. Too much force and the fastener can strip threads, stretch, deform or break. Either way, incorrect tightening force can result in component failure, which can cause you to lose control and fall.
• If replacing your battery, buy only a genuine Bosch battery pack from an approved source. See your Bosch eBike dealer for original Bosch parts.
• Always switch the battery pack off, when inserting or removing it from the holder. Never attempt to insert or remove the battery pack while riding the bike.
• Do not charge or use your eBike in any area with a potentially explosive atmosphere, such as at a fueling area, or in areas where the air contains chemicals or particles (such as grain, dust, or metal powders). Obey all signs and instructions.
• Do not submerge your eBike components in water, or wash with pressurized hose. Your Bosch drive unit is designed to be water tight to rain water or non-pressure hose washing.
• Note down the manufacturer and the number of the key. In case of loss of the keys, please refer to an authorised Bosch eBike dealer. Please provide the name of the manufacturer and the number of the key.
• Do not apply any cleaning agents, paint or chemicals to any components of the Bosch drive system as they may cause premature failure of the component.

When changing the bulbs, ensure that they are compatible with the Bosch eBike system of the generation the smart system (ask your bicycle retailer) and are suitable for the specified voltage. Bulbs must only be replaced with bulbs of the same voltage.
All components fitted to the drive unit and all other components of the drive (e.g. chainring, chainring receptacle, pedals, cranks) must only be replaced with identical components or components that have been specifically approved by the manufacturer for your eBike. This will protect the drive unit from overloading and becoming damaged.
Keep the drive unit clean and avoid contact with aggressive substances and fuels, e.g. diesel. Take care when cleaning the drive unit.

Cleaning

• Do not submerge your eBike components in water, or wash with pressurized hose. Your Bosch drive unit is designed to be water tight to rain water or non-pressure hose washing.

Keep all components of your eBike clean, especially the battery pack contacts and corresponding holder contacts. All components including the drive unit may not be immersed in water or cleaned with a high-pressure cleaner. Clean them carefully with a soft, damp cloth (using only mild soap and water).

Taking care of your eBike

Please observe the operating and storage temperatures of the eBike components. Protect the drive unit, on-board computer and eBike battery against extreme temperatures (e.g. from intense sunlight without adequate ventilation). Extreme temperatures can cause the components (especially the eBike battery) to become damaged.
Have your eBike checked by an expert at least once a year (including mechanical parts, up-to-dateness of system software).
Please have your eBike serviced and repaired by an authorized bicycle dealer.

After-sales service and advice on using products