Mahle E185 Manual

Introduction

Thank you for choosing the e185 Range Extender for your new SmartBike. The e185 Range Extender allows you to go further on your travels, helping you on long journeys that the eBike cannot complete by itself. The My SmartBike Range Extender enables fast charging. LED bar displays battery level or performance mode.

Maintenance & Storage

The e185 Range Extender and main accessories are designed for long-term use and require some simple, understandable guidelines to be followed to extend the lifespan of the MAHLE System by taking proper care during usage and cleaning.

These guidelines are as follows:

• Children must not play with the components or full eBike system.
• Contact the place of purchase or a bicycle dealer for information on installation and adjustment for products not found in the user manual.
• Do not disassemble or alter this product.
• These are small waterproof connectors. Do not repeatedly connect and disconnect. It may impair the function.
• The components are designed to be fully waterproof to withstand wet weather riding conditions; however, do not deliberately place them in water.
• Do not clean the bicycle in a high-pressure car wash. If water gets into any of the components, operating problems or rusting may occur.
• Do not use thinners or similar substances to clean the products. These substances may damage the surfaces.
• Be careful not to let water get into the terminal.
• Unsupervised children must not carry out cleaning or user maintenance.

Products are not guaranteed against natural wear and tear from normal use and ageing. The e185 Range Extender can be installed in eBikes for kids. For this type of use, ensure that your child is supervised and follow the eBike manufacturer's safety instructions.

Transporting your Product

There are specific regulations for transporting batteries:

• Transport by car: External batteries need to be removed and transported in a safe area inside the car, in their original box and properly secured with straps to prevent damage during transport, as these are hazardous goods.
• Transport by air: The IATA (International Air Transportation Association) will not transport any eBike batteries.
• Transport by train: In most cases, external eBike batteries are allowed to be transported inside trains if the train does not provide a specific safe area for transportation. Check your local regulations or ask your transportation company before setting off on your trip.
• Public transportation: Our products can be transported by public transport. There are some places where you are not permitted to take your e185 Range Extender, so ensure that you find out about the conditions of carriage in plenty of time. You should also take into account the regulations and city rules for carrying it through places you intend to travel to before you start your trip.

Remember that, in any case, the best option is to transport the battery when the battery level is under 30%.

e185 Range Extender Shipment
If, for any reason, you need to ship the battery, this must be done through an official service following the specific rules for transporting dangerous goods and the recommendations from MAHLE and the eBike manufacturer. The battery needs to be placed in a specific, certified box and all the official documentation, i.e., the MSDS (Material Safety Data Sheet) report, must be included. This process cannot be performed by individuals.

Safe Charging Process

The Active Charger, which sets up a direct connection with the MAHLE compatible system for both integrated and external SmartBike batteries, supplying the correct charging current and ideal cell balancing. Please use only the MAHLE Active Charger for charging MAHLE e185 Range Extenders. The charger and batteries are fully qualified for usage under current regulations in the regions that the X20 System (or compatible systems) is approved for use.

Before charging the e185 Range Extender, take into consideration the following:

• Connect the charger directly to a power source. Never use extension cords.
• Avoid reverse charging.
• Inspect the charger before every use for possible damage to the charger itself, the wire or the charging plug. Do not cover the charger while charging.
• Regularly inspect the battery. Never charge a battery that you suspect is damaged or that you know is broken.
• Make sure there is no moisture on the charging socket and plug before connecting and charging the battery.
• If the battery is very cold or too hot, wait for it to warm up or cool down before you start charging.
• Keep the connector clean. If any connections have been damaged, please do not use it.

Be aware of explosive gases. Prevent flames and sparks. Ensure that there is adequate ventilation during charging. The charger is designed for indoor use only. Misused other types of batteries may burst, causing personal injury and damage. Do not incinerate, disassemble, or short circuit batteries or the charger

Servicing

Servicing and replacement may only be performed by approved Service Partners. Please remember that our components may contain cells that can be damaged, or a short circuit may occur from drilling into the external case, which could result in a fire.

NOTICE
The battery's capacity will decrease over time. During normal use for 2 years or after 500 full charging cycles, the battery's capacity may lower to a minimum of 70% of its initial value. To obtain 100% capacity again, the battery must be replaced. Waterproofness and integrity of the battery cannot be guaranteed once the battery has been opened

Product Overview & Specifications

You have bought an e185 Range Extender, which includes:

e185 Range Extender
GTIN: 8435635802019

• Weight: 1,100 g
• Waterproofness IP67
• Capacity: 171 Wh
• Nominal voltage: 36 v
• Rated capacity: 4.73 Ah
• Max. charging current: 2.51 A
• Max. discharging current: 12 A
• Dimensions: 195 x 75 mm (Height x Diameter)
• Operational temperature: 60°C / -20°C
• Storage temperature: -10°C / 20°C

Bottle holder
GTIN: 8435635800701

• Compatible with standard water bottles
• 4 x 15 mm slotted holes (64 mm standard distance)
• Weight: 46 g

Rubber strap (to close the holder)
GTIN: 8435635800718

User Manual

Compatible Accessories

Active Charger
GTIN: 8435635800688 (Wall mount included)
GTIN: 8435635800534 (Wall mount not included)

AD RA2 30º Connector
GTIN: 8435635800725

• Total length: 193 mm (± 7 mm)
• Diameter: 6.5 mm
• Wire length: 100 mm (± 5 mm)
• Weight: 33 g
• Waterproofness IP67

DE RA2 90º Connector
GTIN: 8435635800732

• Total length: 193 mm (± 7 mm)
• Diameter: 6.5 mm
• Wire length: 110 mm (± 5 mm)
• Weight: 33 g
• Waterproofness IP67

Charging port

Operation and Use

Please read the following instructions carefully before using your new e185 Range Extender.

Installation Guide

1. Assemble the holder (Recomended torque 4 Nm)
   
2. Slide in the e185 Range Extender.
   
3. Attach the rubber strap.
   
4. Plug the connector in, first to the e185 Range Extender and then to the charging port:
   If the holder position is in the Seat Tube, use the AD RA2 30º Connector.
   If the holder position is in the Down Tube, use the DE RA2 90º Connector.
   

NOTICE
If the wire installation is not neat, please adjust the holder height installation using the slotted holes.

Operation Mode

To operate the system correctly, ensure that the eBike system (including the rear wheel) is fully connected and correctly assembled. To ensure the proper use of the e185 Range Extender, first disconnect the charging wire from the charging port of the eBike.
Ensure the e185 Range Extender is fully charged before using it for the first time. To do so, we recommend keeping the e185 Range Extender connected to the power supply and charger for at least 2 hours. For additional information on how to charge your e185 Range Extender, please go to chapter "Charging Process".
Before starting to ride, always ensure your battery is sufficiently charged.

Usage

The e185 Range Extender is designed to be used as an external battery to provide additional capacity to any MAHLE Smartbike System compatible eBike system.

Intended Usage

Our product is intended to act as a Range Extender of an Electrically Power Assisted Cycle (EPAC) (not for any other eBike application). All compatible components were designed to be incorporated into a complete eBike produced by a professional bicycle manufacturer.

The system is designed to be used under current standardised norms and certifications:

• Europe: EN15194:2017
• US / CAN (in progress): UL2849, UL 1310 (battery charger)
• Australia: EN15194

Our product is designed as per the requirements and standards established for use in EPAC applications and as per the particular environmental conditions in which these kinds of applications may be used, such as rain, salty areas, mud, etc.
The MAHLE e185 Range Extender goes beyond what the standards require, but please also pay attention to what the eBike manufacturer specifies regarding system integration and design information. In particular:

• Only clean the system as per the specific MAHLE recommendations set out in this manual. Never use a power washer to clean your eBike or the electronic components of your eBike.
• When storing your e185 Range Extender, ensure all of the batteries have been sufficiently charged.

Prohibited Usage

Our system must not be integrated into a non-compatible EPAC certified under EN 15494 or into a regular bicycle. It is in breach of MAHLE standards to manipulate the legal parameters (speed or power), to repair the battery or to reuse it for any other device or EPAC. It is in breach of MAHLE regulations to tamper with our components, to change the software and firmware designed and approved by MAHLE or to add electronic components which modify the maximum assisted speed. If MAHLE terms are breached by noncompliance with the above, MAHLE shall not be held legally responsible for damages caused to individuals or materials.

The MAHLE e185 Range Extender reserves the right to include functions which can analyse and record any kind of abnormal behaviour, such as a maximum speed that is too high or abnormal data communication, which could be caused by tampering with the system. Any kind of manipulation shall immediately void all MAHLE warranty terms.

Operating Mode

(In the event of malfunction)
The system can operate in 3 different modes:

• Normal: Everything is OK.
  The system indicates the state of charge with the LED bar (Standalone, eBike) and current assist level (eBike).
• Alert: LED bar flashing ORANGE.
  Battery has a degree of malfunction, but your riding and assistance are not restricted.
• Warning: LED bar flashing RED.
  Malfunction that limits assistance. Ebike propulsion system is shut off. In this case, please contact the MAHLE SmartBike Systems Service or your local dealer. There are 2 warning (RED) levels.
  • System is ON but does not provide assistance
  • System is SWITCHED OFF

In the event of an error alert (flashing ORANGE) or warning (RED), the system sends the error or warning information through Bluetooth® and the ANT+ LEV compatible display. Please pair your smartphone to check the error using the MAHLE "My SmartBike App" or check the error using the "Pulsar ONE display" (which will display the error code number). The list of error codes is included at the end of this document.
Bear in mind that if you remove the e185 Range Extender from the compatible eBike and the Warning persists in the HMI line, the Warning might only exist in the eBike.

Operation

System ON/OFF Standalone Switch

When the e185 Range Extender is not connected to the eBike, press the button on the e185 Range Extender once to turn the system on. The LED bar will light up and the "Hello" animation will be displayed. If everything is in order, the LED bar will display the battery charging status in white (state of charge)

After the brief "Hello" animation, the e185 Range Extender light will turn CYAN and indicate the battery level status for 10 seconds (see State of Charge in the battery section).
If no connection to a compatible eBike is made during this time, the e185 Range Extender will automatically switch OFF after a brief "Goodbye" animation.

System ON/OFF eBike Switch

Switching the e185 Range Extender ON with the eBike
Press the eBike's Head Unit once to turn the system ON. The e185 Range Extender LED bar will light up and the "Hello" animation will be displayed. If everything is in order, the LED bar will display the battery level in white (state of charge).
With your e185 Range Extender connected to your eBike (follow the Installation Guide section), press the button briefly. The e185 Range Extender LED bar will display a "Hello" animation just like the Head Unit.
By default, your e185 Range Extender will be discharged first, allowing you to remove it whenever it is fully depleted.
To find out whether your e185 Range Extender is your main energy supplier (thus providing power to your eBike), a recurrent "LIGHT CHASING" animation will appear every 3 seconds on the e185 Range Extender LED bar.

Current assist level
When connected to the eBike, the e185 Range Extender will mimic the assist level shown on the ebike Head Unit.
The system includes three different assist levels, which can be customised by the user using the MAHLE My SmartBike App. Each assist level is represented by a different colour, as seen in the following table

Level	Colour
0 - No assist	White
1 - Minimum	Green
2 - Medium	Light Brown
3 - Max	Purple

Switching the e185 Range Extender OFF with the eBike
To switch the system OFF, simply press and hold the button on the eBike Head Unit for two seconds until the LED bar displays the "Goodbye" animation. The ebike Head Unit LED bar will turn OFF after the animation.
You can also switch just the e185 Range Extender OFF by directly pressing and holding the button on the battery for two seconds. In this case, only the e185 Range Extender will be switched OFF, letting you ride your compatible eBike further.

Battery State of Charge

The light line will display the current battery level (State of the Charge - SOC) along the visible length of the LED bar. 100% capacity is indicated with the full length. As the battery drains, the illuminated length of the LED bar will decrease, representing the reduction in capacity. The LED bar will always keep a minimum of one LED illuminated in order to display the assist level used.
The LED bar consists of 6 LEDs that can create visual effects and animations. For state of charge, the LED bar will be illuminated as shown in the following image:

Charging Process

To ensure correct charging, please follow these instructions:

1. Connect the charger to the power outlet.
   The charger LED will display a steady WHITE light.
   Make sure there is no cable connected to the micro-USB port before charging.
   
2. Connect the charger to the charging port on the e185 Range Extender.
   The charger LED and the e185 Range Extender light line will turn CYAN and a breathing effect will be displayed, with the frequency of the flashing changing from fast to slow as the level of charge increases.
   
3. Charge process finished
   Once charging is complete, the e185 Range Extender LED will turn steady GREEN.
   Disconnect the charger from the power source before disconnecting it from the battery.
   
4. Error during charging process
   If a critical error occurs while charging, the charger LED will flash RED.
   

3. Disconnect the charger from your computer. There should be no LEDs lit up.
   

Error while uploading
If an error occurred during the upload process, the charger LED will turn a steady RED for 10 seconds. After that, the charger will return to normal operation.

Updating Process

The system can be updated using the micro-USB port on the active charger. To perform an update, you need to connect the charger to your computer and transfer the update files to the charger. Please follow this process.

Uploading files to the Active Charger

1. Disconnect the charger from the power outlet. There should be no LEDs lit up.
   
2. Connect the charger to your computer using the micro-USB port
   The charger LED and the HMI will turn BLUE.
   Copy the extracted update files (update_MUT.bin) to the new Drive Unit (MAHLE_UTOOL), which will appear on your computer, and safely eject the new drive unit from your computer.
   

Updating the Device

1. Connect the charger to the power outlet. The charger LED will display a steady WHITE light.
   
2. Connect the Charger to the Range Extender.
   Connect the charger to the e185 Range Extender as you would connect it for a normal charging process. The charger LED will flash continuously in PURPLE while the update is being performed.
   
3. Update Completed
   Once the update process is complete, the charger LED will turn a steady GREEN for 10 seconds. After that, the charger will return to normal operation.
   
4. Error while uploading
   If an error occurred during the update process, the charger LED will turn a steady RED for 10 seconds. After that, the charger will return to normal operation.
   

NOTICE
The use of any other update device or tool will be considered in breach of the MAHLE warranty.
MAHLE shall not be held legally responsible for damages caused to individuals or materials as a result of incorrectly updating the unit

Application and Services

The MAHLE My SmartBike App enables you to connect your mobile device to your e185 Range Extender compatible system. This App not only displays all essential journey details and allows you to track and record your activity, it also allows you to customise your assist levels according to your own criteria and access relevant functionalities and data on your e185 Range Extender.

MAHLE will continue to add new features and functions to the system for the purpose of ensuring that your bicycle is always fully compatible with new software Apps and smart solutions added in the future.
This component is compatible with the full series of MAHLE SmartBike Systems Apps offered in the following versions:

• iOS My SmartBike version for iPhones
• My SmartBike for Android phones
• www.my-smartbike.com App for browsers

For system diagnostics by professionals (for example, in a workshop), we also offer an exclusive App for dealers:

• SmartBike Lab (iOS and Android)

My SmartBike Phone App
The MAHLE My SmartBike App is compatible with mobile devices that use iOS or Android systems. This App will enable you to track and record your activity, and with the functions available, your mobile device will become the screen for your smart bike if you set it on the handlebars.

For your own safety, we do not recommend that you use your mobile device while cycling if it is not fixed to your handlebars. Use the following links to download the App.

Service

As mentioned above in previous sections, the e185 Range Extender and its compatible elements cannot be repaired. Please follow the instructions provided here in this chapter to answer any questions or resolve any issues.
If the problem persists, please do not hesitate to contact the MAHLE technical service or your closest dealer.

FAQs

I have not used my e185 Range Extender for a long time and now it does not turn on when I press the button
If you have not used the external battery for more than 60 days, it automatically goes into suspension mode. Connect it to the charger to activate it. The battery may have gone into ultra suspension mode, in which case you will need to leave it connected to the charger for at least one hour.

Can I use my e185 Range Extender on other MAHLE Smartbike Systems?
The e185 Range Extender is currently not compatible with X35 systems. This system has a Range Extender that is specific to X35 systems.

How long does my e185 Range Extender take to charge?
An 80% charge level can be reached after two hours of charging. The final part will take longer to charge, depending on the internal battery version installed, but the maximum charging time is around 4 hours. The battery will automatically switch off 20 minutes after reaching 100% charge.

Will the internal battery of MySmartbike discharge when I connect my e185 Range Extender?
By default, it will be your external battery that will discharge first (see relevant section), which allows you to have the remaining capacity of your internal battery when you remove (or do not remove) the e185 Range Extender, giving you the best experience and making your ride quicker. Using the MySmart App, you can, however, choose which battery will be used first (Main Energy Supplier) and select the % charge at which it will switch to the other.

My e185 Range Extender is displaying an Alert. Can I continue with my route?
Yes. The e185 Range Extender has been designed so that if the charge is too low or the power needed by the compatible eBike cannot be supplied, it gives priority to the internal battery as the Main Energy Supplier, allowing you to enjoy the full experience. It will revert to normal when the error in your e185 Range Extender is solved.

What is the duration of my e185 Range Extender? By how much does it increase my range?
The system's general range will increase by around 60 km, although this distance can vary depending on the cyclist's weight, the gradient of the route and the type of terrain.

Can my e185 Range Extender be updated?
Yes, we recommend that you keep your system updated with the latest version. The update process and firmware instructions needed are on our website: mahle-smartbikes.com/activecharger/

Can my e185 Range Extender be repaired?
No. If there is an issue with your e185 Range Extender, please contact our customer service.

I have lost or broken all my fixing straps and bottle holders. What can I do?
These parts can be replaced. Please contact your closest dealer or visit our website:
https://mahle-smartbike.com/

How do I know whether it is my e185 Range Extender that has an issue or my eBike?
To find out which unit (compatible eBike or e185 Range Extender) has an Alert or an Error, contact a current dealer. If the error only appears on the external battery, only your external battery is affected. If the error appears on both, the problem will be with your compatible eBike. If you are unsure, check the error code in the relevant section of the user manual for your compatible eBike and your e185 Range Extender and check which one matches.

My eBike's power goes down in certain circumstances. Why might this be?
MAHLE has designed the product with passive protection measures to protect the integrity and durability of the battery (Li-ion cells). Two recurring situations are:

• Under exposure to high temperatures (see corresponding error codes).
• When the state of charge is <5%

If this behaviour occurs under different circumstances, please check the error codes or errors that appear on the system, as well as the rest of the FAQ section. If the error persists, please do not hesitate to contact your nearest dealer.

After completing a route, my battery will not start to charge. Why is this?
As a protective measure against the accelerated degradation of the battery cells, the e185 Range Extender includes charging protection against extreme climate exposure (very high or very low temperatures). Leave your Active charger connected to your e185 Range Extender. When the temperature of the cells comes into an acceptable range for charging, it will begin to do so as normal.

Can I use a third-party charger?
No. The charger is a device that establishes digital communication with the batteries and if you use non-MAHLE devices, you run the risk of damaging the elements and breaching the terms of the warranty

Quick Error Guide

Warning Light	Cause	Solution
No light when pressing button	Battery low	Charge the e185 Range Extender for an extended period of time.
Flashing red light when connected to charger	Temperature too high for charging	Disconnect Range Extender from charging device. If it is too hot or too cold, wait until the temperature is restored to normal levels and try again. If the error persists, please check the error code using the My Smartbike App.
Flashing red light	Range Extender or eBike error	Simple troubleshooting: Disconnect the e185 Range Extender form your eBike. It the error persists (flashing red light on the e185 Range Extender), the error is in the external battery. If not, the error is in the eBike. When the error persists, please connect the e185 Range Extender to your eBike and check the error code using the My Smartbike App.
Steady white while connected to charger	Communication error	Connect Active charger to eBike. If the light on the Active charger is still steady white, replace the Active charger. If the charger is working normally, take the Range Extender to your dealer.
Unit is switched off when connected to the eBike	Damaged wire	Please check whether the External wire and Connectors (eBike, e185 Range Extender) are in good condition. If the error persists, please go to your dealer.

If you need more information about system errors, download the MAHLE "My SmartBike" App available for iOS and Android. By connecting your bike to this App, you will have more information about the issue and how to solve it.

Error Codes

Here you can find a short list of potential error codes that may appear on the HMI. For more information, check with your local dealer or the MAHLE technical service:
-> Flashing Red (ERROR)
-> Flashing Orange (WARNING)

Code	Head Unit	Description / Action
210		Power output limited The temperature is too high, so the power output will be limited until normal operating conditions are restored. To do so: Please lower the assistance level or take a break while the temperature drops Or Switch off the e185 Range Extender and continue your ride with the main battery.
211		Battery Imbalance Please fully charge your e185 Range Extender. If the error persists or happens again, please contact your dealer.
220		External battery charging current is too high for charging. Please check whether the Range Extender and Charger are in good condition. If you need help or if everything is correct but the error persists, take the Charger and Range Extender to your bike shop or dealer.
221		External battery discharging current is higher than normal. Check that the wiring and the Range Extender are in good condition. If the error persists with the Range Extender connected, try without it. If the error persists without the Range Extender, take the bike and the Range Extender to a Dealer If the error does not persist without the Range Extender, take only the Range Extender to a Dealer
222 224 229 237 238		Critical battery error. Please take the Range Extender to your dealer.
225 226 227 228 236		Abnormal battery temperature (high, low) The temperature of the external battery is either too high or too low. Please bring the battery to room temperature. If the problem persists, take the external battery to a bike shop or dealer.
231		Overvoltage The external battery voltage exceeds the level permitted. Please unplug the charger and try to use it on your eBike. If the problem persists, take the external battery to a bike shop or dealer.
232		Undervoltage The external battery voltage is below the level permitted. Please charge the battery. If the problem persists, please take the external battery to your dealer

General Warnings

Please pay special attention to any warning symbols on the system, shown with these graphics.

NOTICE

About Warnings
This manual contains DANGER, WARNING, and CAUTION indicators concerning the consequences of failure to safely use, assemble, maintain, store, inspect and dispose of MAHLE-equipped eBikes.
The combination of the safety alert symbol and the word DANGER indicates a hazardous situation that, if not prevented, could lead to death or serious injury.
Keep all safety warnings and instructions for future reference. Do not open the e185 Range Extender by yourself. The system is maintenance-free. It must only be opened by qualified experts. The unauthorised opening of a system will void the warranty. All Drive Unit and eBike components may only be replaced with identical components or components that are specifically approved by your eBike manufacturer. This protects your eBike system from damage. Do not modify the Drive Unit, the battery or any other component or add any unapproved products to improve performance or tamper with the product. There is a risk of injury in the event of accidental activation. Be careful when touching the surface of your Drive Unit. The surface may heat up considerably and cause burns to the skin. The walk-assistance function may only be used when pushing the eBike and may require specific remotes. There is a risk of injury if the wheels are not in contact with the ground when using this function. Use only original MAHLE batteries approved by the eBike manufacturer. Using unauthorised batteries may cause injuries or fire.
Observe your regional and local regulations regarding eBikes and pedelecs.

Documents / Resources

References

• My SmartBike Website
• MAHLE SmartBike Systems - Light. Sport. Smart.
• ‎My SmartBike en App Store
• Google Play

Download manual

Here you can download full pdf version of manual, it may contain additional safety instructions, warranty information, FCC rules, etc.

Download Mahle E185 Manual