BoschAE_HB2022_Bsp_01

Training 2022

THE
BOSCH eBIKE
MANUAL

FEEL THE FLOW

Bosch eBike Systems | EN
bosch-ebike.com

2 | Introduction

About the Bosch eBike manual

Pictograms Presentation of online information

Useful tips and supplementary  Further links to the Bosch eBike retailer portal
information (registration required) and to other sources of
information on the Internet
Necessary measures to prevent accidents,
damage, or defects  QR codes lead directly to the respective website
using a smartphone camera or a computer webcam

Necessary measures to prevent severe injury webaddress.from
to persons or major material damage → Menu item → Submenu 1
→ Submenu 2 → Target page
? Explanations of technical terms and technical
background information

Introduction | 3 Introduction

Bosch eBike Benefits

All Bosch eBike systems offer common benefits, Bosch eBike Handling
user-friendly handling, and the same high-
quality service offerings. Service
Information on all comprehensive topics
related to Bosch eBike systems can be found Overview
in this section.
eBike System 2
The eBike System 2
Diagnostics Components
The proven eBike System 2 with its wide range
of components will also be used in new eBikes Installation /
by many manufacturers in the 2022 model year. Removal
The Drive Units, displays, and batteries of the
eBike System 2 impress with the highest Overview
technical quality – and
as a perfectly The smart system
coordinated team.
Diagnostics Components
The smart system
Installation /
The new system generation will be launched in Removal
model year 2022 with the eBike Flow app,
control unit, display, battery, and Drive Unit. Working aids
The smart system
combines techno-­
logically high-quality
eBike components
with digital functions
and thus takes your
riding enjoyment
with the eBike
to the next level.

Working aids

Valuable information for workshops

4 | Introduction

A brief history of Robert Bosch GmbH

Bosch – using technology to improve quality of life

The Bosch Group is a leading global supplier of technology and
services consisting of four business sectors. The company's
mission is to develop innovative, beneficial and inspiring
products and solutions that improve the quality of life –
“Invented for life”

Around 395.000

employees
worldwide

Around 34.000

software developers

Climate-neutral worldwide since 2020

As of spring 2020, the Bosch Group has been completely
climate-neutral. More than 400 Bosch locations world-
wide – from development and production to administra-
tion – no longer have a carbon footprint. Of course, this
also includes all Bosch eBike locations.

32More than billion euros invested

in research and development in the last

five years

The Internet of Things and Artificial Intelligence

Bosch offers innovative solutions for smart homes, Industry 4.0 and
connected mobility. The company uses its expertise in sensor technology,
software and services, as well as its own IoT cloud, to offer its customers
connected, cross-domain solutions from a single source. The strategic
objective is to deliver solutions and products for a connected life that
either themselves use artificial intelligence (AI) or that are developed or
produced using AI – including for all Bosch eBike locations.

Introduction | 5 Introduction

Four business sectors Benefits

Mobility Solutions

X One of the world's largest supplier of X Vision: Multimodal and personalised Bosch eBike Handling
mobility solutions and services mobility with the lowest possible level
of emissions, stress, and accidents
X This division brings together ex-

pertise in connected mobility, automa-

ted mobility, as well as drive systems

and electrified mobility Service

Overview

Consumer goods eBike System 2

X A leading supplier of power tools, Diagnostics Components
accessories, and measuring technology

X A provider of modern, energy-efficient and
increasingly connected household appliances

94% Installation/
capital shares held by Removal

the non-profit organi-

sation Robert Bosch

Stiftung GmbH 129

development sites Overview

worldwide

Energy and building technology Industrial technology The smart system

X One of the leading manufacturers for safety and X A leader in drive and control technology Diagnostics Components
communications technology X In 2021, Bosch opened one of the world's most
Installation/
X Bosch gets stationary decentralised power plants advanced AIoT-enabled chip factories in Dresden Removal
with fuel cell technology ready for series produc-
tion X Bosch Connected Industry bundles
activities relating to Industry 4.0
X A leader in energy-efficient heating products and
hot water solutions X Robert Bosch Manufacturing Solutions GmbH is
Bosch's internal provider of assembly systems
X Smart home activities, including expertise in soft-
ware and sensor systems

440Roughly subsidiaries

and regional companies in some

60 countries Working aids

6 | Introduction

A brief profile of Bosch eBike Systems

More than 10 years of Bosch eBike.
Always one step ahead

Bosch eBike Systems was founded in 2009
and the first drive system was unveiled at
Eurobike just one year later. Since then,
eBikes have been 'ePowered by Bosch'.
Bosch has benefited from the experience
gained in the automotive and motorcycle
sectors and its great technological exper-
tise right from the start. The start-up qui-
ckly became a global player.

The pedelec as a sustainable Sustainable Bosch eBike systems
means of transport
X Long service life
X Healthy and sustainable individual X Coherent recycling strategies
mobility X Continuous development

X A key element in making successful
changes to urban traffic

X A major factor in modern mobility solutions
X Lower CO2 emissions, dust particulates,

nitrogen dioxide, etc. than other means of
transport

CO2

2009 2011 2012 2014 2015

Establishment Start of series production Inauguration of the new Establishment of Bosch Logistics centres in
within the division of in Monde­ville, France and headquarters in Reutlingen, eBike Systems Americas Hungary and Shanghai
Mobility Solutions Bühl, Germany Germany and Asia Pacific

2010 2012 2013 2014
World premiere of the Bosch Production and logistics
Presentation of the Active Introduction of the Nyon all-in-
eBike drive systems at Eurobike in Miskolc, Hungary Line and Performance Line one on-board computer

Bosch eBike landmarks

Introduction | 7Introduction

Key figures Benefits

Bosch eBike Bosch eBike Handling
Experts
Service
in 15 European countries
in 87 European cities Overview

Rund 13.000 Fachhändler
sind jährlich bei der Trainingstournee dabei

Dealer portal
Since October 2020, more than 3.300 videos played.
More than 24.000 documents accessed

Around 13.000 specialist dealers attended
the MY 2020 training course

Rund 13.000 Fachhändler
sMinodrejäthhralinch7b0ebiidkeerbTrraanindinsgwstooruldrnweiededarebleyi

on components 'ePowered by Bosch'

70 Fahrradmarken setzen we
auf Komponenten epowered

eBike System 2

Diagnostics Components

What drives Bosch eBike Systems 2021 Installation/
Removal
Bosch eBike Systems works on the future of Presentation of
a mobility, which is healthy, and economi- the smart system Overview
cally and ecologically sustainable. To achieve
this vision, Bosch eBike Systems cooperates 2020 The smart system
closely with experienced partners and utili-
ses synergies from the Bosch group. Presentation Diagnostics Components
of the new Nyon generation
Electrified, automated, and connected:
The pedelec is one of the most agile, com- 2020
fortable and smartest vehicles of our time.
With innovative products and convincing A separate business unit
services for eBike riding, Bosch eBike Sys- within the Bosch Group
tems are making the eBike world even more
fascinating. 2019

Presentation of the Performance Line CX / Speed
and Cargo Line Cruise / Speed

2016 2017 2017 Bos1c0-hy2ee0aBirk1ae9nSniyvsteresmarsy of
2018 Installation/
Presentation of DualBat- Presentation Market entry Japan Removal
tery and Purion of the PowerTube 500 Presentation of Kiox
and the Fast charger

2015 2017 2017 2017 Working aids

Presentation of the Presentation of Active Presentation of Takeover of the
Performance Line CX Line and Active Line Plus Bosch eBike ABS start-up COBI

BOSCH eBIKE

BENEFITS

This is what Bosch eBike Systems stands for 10
The benefits of Bosch eBike batteries 12
The benefits of the Bosch Drive Units 14

Working aids The smart system eBike System 2 Bosch eBike Introduction

Removal/ Diagnostics Components Overview Removal/ Diagnostics Components Overview Service Handling Benefits
Installation Installation

10 | Benefits

This is what Bosch eBike Systems
stands for

More and more people are discovering the eBike for themselves. With an electric power boost, cycling is
more relaxing - enabling you to travel longer distances, more flexibly, all while protecting the environment.
Bosch eBike Systems represent the highest technical quality, innovation strength and a perfectly coordina-
ted system that offers maximum efficiency, safety and comfort. Connectivity solutions also connect eBikers
to the digital world.
But a product is only as good as its service. Bosch eBike Systems provides specialist dealers with intensive
training to make them eBike experts, as well as providing them with extensive products, services and pro-
motional materials which can be used in many ways.

Technology for the entire lifetime of the eBike

X Large product portfolio with individual combination
options

X Smooth integration of the eBike System into the
frame design of more than 70 bike brands

X Drive units for all requirements and user needs
X Different riding modes – optimum support for every

riding situation and every rider type

X Batteries with impressive mileage performance,
long service life and low weight – combined with
ergonomic design and simple handling

X Wide range of eBike displays - from the minimalist
control unit to the all-in-one on-board computer or
smartphone solution on the handlebar

X Numerous retrofit and expansion options for on-
board computers, smartphone solutions, batteries
and chargers

X eBike Protect for even greater safety on eBikes:
– Bosch eBike ABS for greater safety and stability
when braking
– Help Connect with automatic crash detection and
transmission of accident location for rapid assistance
– Lock providing electronic anti-theft protection

Benefits | 11 Introduction

Service is more than a promise Benefits

X Competent service team to provide support during Bosch eBike Handling
processing of service cases as well as answers to all
questions about Bosch eBike systems Service

X Dealer portal with comprehensive service and Overview
information for sales and workshop

X Dealer newsletter with important news on products
and service

X Team of specialist advisers with many years of industry
experience

X Provision of valuable know-how for sales and workshop
– Annual intensive training to prepare for the season
– Constantly growing range of online learning

X Wide range of sales support
– Wide range of information material for customers
– Promotional materials for store, website and advertising
– Individual profile for the Bosch eBike dealer search

X Bosch eBike B2B online store for workshop equipment,
retrofitting products, promotional material and accessories

Get the best out of your eBike – eBike System 2
with Bosch eBike diagnostic tools
Diagnostics Components
X Optimising the functionality and stability of the systems
X Software updates carried out by the eBike system and on-board computer Removal/
X Reliable identification of malfunctions Installation
X Detailed, easy to understand diagnostic reports
X Fast, straightforward creation of service cases
X Remote diagnostics option
X Also available: CapacityTester to measure the energy content of batteries

Overview

Karten © Mapbox, © OpenStreetMap The future of eBikes is connected The smart system

X Connectivity products to suit every taste and riding situation Diagnostics Components
X Apps with innovative functions and services providing practical solutions
Removal/
for navigation, fitness tracking, communication and entertainment Installation
X Can be paired with popular tour planning and fitness platforms
X Displays info about the user’s eBike along with a range of options Working aids

for customisation

12 | Benefits

The benefits of Bosch eBike
batteries

The advantage of Bosch eBike batteries X Minimum self-discharge – even after prolonged sto-
rage, e.g. storage during winter
X Highly durable, low weight and size
X Convenient charging right on eBike X The batteries are fully charged on delivery and
X Ergonomic design and easy handling do not require repeated complete charging and
X No memory effect: Can be briefly charged at any discharging cycles before usage

time regardless of its charge state; complete
discharge is not required

Benefits | 13 Introduction

Benefits

Long service life and high level of safety Bosch eBike Handling
thanks to the Battery Management System
(BMS) Service

X The battery's electronic control unit; regulates the Overview
battery and protects it from:
– Overcharging eBike System 2
– Undervoltage
– Overheating during operation Diagnostics Components
– Short circuiting
Removal/
X Monitoring of the voltage, current, temperature Installation
and state of charge of the cells
Overview
X Battery temperature is always kept within the
permitted operating range The smart system

Exceptional quality, extensive testing Diagnostics Components

X High-quality, technically advanced high quality
lithium-ion cells from leading cell manufacturers

X Each cell is protected by a rugged steel cup and all
cells are contained in a robust plastic or alumi-
nium housing

X In addition to the legally required tests, internal
testing regarding the safety, function, service life
and industrial health & safety

Test protocols for UN transportation test:
bosch-ebike.net → Service → Hazardous
goods transport → Documents for downloading

Cost-effective charging

X Commuting by eBike: The pure energy costs for
25 km in a car are around 2.75 euros and about
0.06 euros with an eBike (average petrol price
1.35 euros/l; green energy 0.30 euros/kWh). Thus,
it only costs 15 cent to charge a battery with
500 Wh (sources: ADAC battery test; Federal Envi-
ronment Agency; Lithium-ion battery handbook)

How a lithium-ion battery works Cathode Anode

X While riding (energy output), the electrodes Lithium-ions Removal/
move from the negative anode via the Drive Unit Electron Installation
to the positive cathode Graphite
Lithium-ion flow Working aids
X The lithium ions provide balance and therefore Electrical current
allow current to flow

X The reverse process takes place when the bat-
tery is charged

14 | Benefits

The benefits of the Bosch Drive Units

Superior centre-mounted motor concept X Robust sensors thanks to protected torque and
cadence regulation in the drive
X Precise motor control enables optimum support,
depending on your model and type of application X Faster wheel dismounting during transportation or
repairs compared to a bicycle
X A natural riding sensation due to direct power
transmission to the chain X A very compact constructional design of the
motor is thereby possible
X The low centre of gravity exploits ideal weight
distribution for straight-line directional stability X Universal Drive Units
and stable handling – A back pedal brake is available on many models
– Can be used with a hub gear system or derailleur
X The drive power via the chainring / drive pinion system
enables motor control within the optimal RPM
speed range and therefore high efficiency and
lower energy consumption

Benefits | 15 Introduction

Benefits

Bosch eBike Handling

Service

Overview

eBike System 2

Diagnostics Components

Removal/
Installation

That special Bosch riding sensation X Optimal interaction with the shifting system Overview
– Motor support can be adjusted to a variety of
X A demanding multi-sensor concept for optimal gear shifting system types The smart system
balancing of motor support: More than 1,000 – The Drive Unit detects a gear shifting operation
sensor measurements per second record the and automatically adjusts the torque Diagnostics Components
torque (pedal power), cadence (pedalling – This ensures smooth and gentle gear shifting
frequency) and speed – Protects the eBike components
– No unintended, premature initiation of support
– No unwanted "after-run" operation when pedal- X Compact construction and low weight enable:
ling is discontinued – Seamless integration into the frame design
– The feeling that you are riding a bike using your – Wide range of designs and frame geometries
own bodily force remains – More ground clearance and a smaller Q factor
(pedal distance) for ergonomic power transmission
X Precise motor control
– When the maximum legally permissible speed is
reached, the motor support powers down
– Efficient and reliable temperature monitoring

Removal/
Installation

Working aids

250 | Tools and tips

The smart system
Tightening torques
and tools

Component Tools Tightening torque
On-board computer and control unit
LED remote Allen key size 3 1 Nm
Mount on the handlebar Allen key size 3 1 Nm
Control unit on the mount Torx 6 Loosely tighten by hand
Battery compartment cover on the control
unit Allen key size 3 1 Nm
Kiox 300 Allen key size 3 As specified for the 1-arm socket
Display mount on 1-arm socket Allen key size 3 As specified for the 1-arm socket
1-arm socket on the handlebar
Angle adjustment screw Torx T20 3 Nm
Rechargeable battery Torx T20 3 Nm
PowerTube 750 (Pivot) Torx T20 3 Nm
Locking unit on the frame base Torx T25 4.5 Nm
Lock on threaded flange Torx T25 4.5 Nm
Frame base on mounting plate Torx T15 1.2 Nm
Mount on rail
Rail / mount on frame Torx T20 3 Nm
Mounting plate on PowerTube 750 Torx T25 4.5 Nm
PowerTube 750 (Axial) Torx T15 1.2 Nm
Frame base on mounting plate Torx T15 1.5 Nm
Rail on frame According to the specifications of the
Locking unit on PowerTube 750 Depending on the lock key manufacturer
Cover on the locking unit
Torx Plus 40 20 Nm ± 2 Nm
Lock on the locking unit Torx T30 Initial assembly: 10 Nm ± 0.5 N
Subsequent assembly: 9.5 Nm ± 0.5
Drive Unit BDU3740 / 3741 Depending on the Nm
Drive Unit with mounting plates on frame type of screw According to manufacturer's specifica-
tions, Bosch recommendation for
Mounting plates on the Drive Unit Torx T20 initial assembly: 10 Nm ± 0.5 N,
Spider Tool Subsequent assembly: 9.5 Nm ± 0.5
Directly mounted Drive Unit on the frame Allen key size 8 Nm
Initial assembly (self-tapping):
Design cover Torx T20 3 Nm ± 0.5 Nm;
Subsequent assembly: 2 Nm ± 0.5 Nm
Lock ring on the Drive Unit Torx T20 30 Nm
Phillips screwdriver According to manufacturer's specifica-
Crank arms on bottom bracket shaft size PH02 tions
Torx T20
ConnectModule Initial assembly: 5 Nm,
Mounting plate (BCM) on mounting plate Subsequent assembly: 4 Nm
(BDU374y) of the Drive Unit
Slim speed sensor 3 Nm
Chain stay adapter on chain / seat stay
Spoke Magnet 1 Nm
Sensor clip on the open end or frame
Wheel rim magnet 0.8 Nm
Valve nut on the wheel rim magnet
Tighten by hand

Product codes | 251 Introduction

Bosch mounting plates for Benefits
Drive Unit BDU3740 / 3741
Scale 1 : 1 Bosch eBike Handling

793080T08/20=

Service

Mounting plate, long left Mounting plate, long right Overview
EB11.200.00T EB11.200.00R

00R The eBike System 2
7938 08/20=
Diagnostics Components
00U =0709S38 06/20
7938 06/20-

Mounting plate, short left  For assembly, use M6 x 16 Mounting plate, short right Removal /
EB11.200.00U screws (see p. 229) EB11.200.00S Installation

Product codes Overview

 To better identify and separate our products, Abbreviation Component The smart system
product codes have been introduced for all main
components BAS Bosch Anti-lock Breaking System Diagnostics Components
BBP Bosch Battery PowerTube
 The first three letters define the product group, BBR Bosch Battery Rack Removal /
the following character combination the specific BBS Bosch Battery Standard Installation
component BCC Bosch Component Connector
BCH Bosch Cable Harness
 Examples: BCM Bosch ConnectModule
– BDU250P CX – Bosch Drive Unit Performance CX BCS Bosch Charger Station
25 km/h BCT Bosch Capacity Tester
– BUI330 – Bosch User Interface Kiox BDS Bosch Display Socket
– BBP291 – Bosch Battery PowerTube 625 Wh BDU Bosch Drive Unit
vertical BHU Bosch Head Unit
BPC Bosch Power Charger
BRC Bosch Remote Control Working Aids
BUI Bosch User Interface

Robert Bosch GmbH Please note that you are receiving this manual exclusively in your capacity as a
Bosch eBike Systems retailer of eBikes with Bosch brand systems. Its purpose is to help you in handling
Postfach 1342 our products. All contents of the manual (in particular, text and images) as well as
72703 Reutlingen their layout within the manual are subject to copyright protection and other
Germany protective legislation. The content of this manual may not be copied, distributed,
bosch-ebike.net modified or made available to third parties for commercial purposes without the
consent of the respective rights holder. Transferring this manual to third parties is
boschebikesystems not permitted.

September 2021/EN Subject to modifications