Bosch BBP3775 Drive System PowerTube 750 Owner’s Manual

BOSCH BBP3775 Drive System PowerTube 750

Introduction

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 word CAUTION 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 or serious injury.
Save all safety warnings and instructions for future reference.
The term battery pack used in these operating instructions refers to all original Bosch eBike battery packs.

WARNING

• 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.
• 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.
• 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.

CAUTION

• 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.

On-product warning labels

Robert Bosch GmbH
D-72757 Reutlingen
www.bosch-ebike.com

WARNING

To reduce the risk of injury, explosion, or fire, user must read instruction manual.. Do not crush, puncture, dissassemble, short terminals, or dispose in fire.. Do not use battery once it has been impacted, sustained water damage or visibly damaged. . Charge battery only with Bosch eBike chargers.

Warning labels have been placed on the Bosch eBike System for your protection. Read and follow the instructions of the labels on the product carefully. If a label becomes illegible or comes off, contact your Bosch bicycle dealer to obtain a replacement. Replacement safety labels are provided by Bosch at no charge.

Handling the lithium-ion battery pack

Safety warnings for Bosch eBike batteries

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 battery pack used in these operating instructions refers to all original Bosch eBike battery packs.

DANGER

• Do not puncture or crush the battery pack. Do not impact the battery pack or modify it in any way. Do not use the battery pack if it shows visible damage. Danger of fire or explosion which can cause death or serious injury.
  Protect the battery pack against heat (e.g., temperature > 140 °F), fire and immersing into water. Danger of explosion.

WARNING

• Use only original Bosch battery packs approved for your eBike by the manufacturer and purchased from a credible source. Use of non-approved or counterfeit battery packs can lead to death or serious injury.
• Remove the battery from the eBike before beginning work (e.g. inspection, repair, assembly, maintenance, work on the chain, etc.) on the eBike, transporting it with a car or airplane, or storing it. Unintentional activation of the eBike system poses a risk of injury.
• Do not open the battery. There is a risk of shortcircuiting.
  Opening the battery voids any and all warranty claims.
• When the battery is not in use, keep it away from paper clips, coins, keys, nails, screws or other small metal objects that could make a connection from one terminal to another. A short circuit between the battery terminals may cause burns or a fire. Short circuit damage which occurs in this instance voids any and all warranty claims against Bosch.
• Avoid mechanical loads and exposure to high temperatures. These can damage the battery cells and cause the flammable contents to leak out.
• Do not place the charger or the battery near flammable materials. Ensure the battery is completely dry and placed on a fireproof surface before charging. There is a risk of fire due to the heat generated during charging.
• The eBike battery must not be left unattended while charging.
• If used incorrectly, liquid may leak from the battery.
  Contact with this liquid should be avoided.
  If contact occurs, rinse off with water. If the liquid comes into contact with your eyes, seek additional medical attention. Liquid leaking from the battery may cause irritation or scalding.
• Batteries must not be subjected to mechanical shock. There is a risk of the battery being damaged.
• The battery may give off fumes if it becomes damaged or is used incorrectly. Ensure the area is well ventilated and seek medical attention should you experience any adverse effects. The fumes may irritate the respiratory system.
• Only charge the battery using original Bosch chargers. When using chargers that are not made by Bosch, the risk of fire cannot be excluded.
• Use the battery only in conjunction with eBikes that have original Bosch eBike drive systems.
  This is the only way in which you can protect the battery against dangerous overload.
• Use only original Bosch batteries that the manufacturer has approved for your eBike. Using other batteries can lead to injuries and pose a fire hazard. Bosch accepts no liability or warranty claims if other batteries are used.
• Read and observe the safety warnings and instructions in all operating instructions of the eBike system and your eBike.
• Keep the battery away from children.

The safety of both our customers and our products is important to us. Our eBike batteries are lithium-ion batteries which have been developed and manufactured in accordance with the latest technology. We comply with or exceed the requirements of all relevant safety standards. When charged, these lithium-ion batteries contain a high level of energy. If a fault occurs (which may not be detectable from the outside), in very rare cases and under unfavorable conditions, lithium-ion batteries can catch fire.

Privacy notice
When you connect the eBike to the Bosch DiagnosticTool 3, data about the eBike batteries (e.g. temperature, cell voltage, etc.) is transferred to Bosch eBike Systems (Robert Bosch GmbH) for the purposes of product improvement. You can find more information about this on the Bosch eBike website at www.bosch-ebike.com.

Product description and specifications

Product features PowerTube

All representations of bike components are schematic and can deviate from your eBike.

1. Key for the battery lock
2. Battery lock
3. PowerTube battery safety hook
4. PowerTube battery (pivot)
5. Socket for charging connector
6. Operation/battery charge indicator
7. On/off button
8. PowerTube battery safety restraint

All representations of bike components are schematic and can deviate from your eBike.

1. Key for the battery lock
2. Battery lock
3. PowerTube battery safety hook
4. Socket for charging connector
5. Operation/battery charge indicator
6. On/off button
7. Locking mechanism
8. Pull strap
9. Axial rail
10. PowerTube battery (axial)
11. Upper axial PowerTube holder

Intended Use
The Bosch eBike batteries are intended exclusively to provide the power supply for your eBike drive unit and must not be used for any other purpose.

Technical data

A) Advertised battery energy capacity is an approximation.
Due to manufacturing tolerances measured capacity may not always match the advertised capacity.

Fitting

• Ensure the battery is placed on clean surfaces only. Avoid getting dirt, e.g. sand or soil, in the charging socket and contacts in particular.
  Testing the battery before using it for the first time
  Test the battery before charging it for the first time or using it in your eBike.
  To do this, press the on/off button (7) to switch the battery on. If none of the LEDs on the battery charge indicator (6) light up, the battery may be damaged.
  If at least one (but not all) of the LEDs on the battery charge indicator (6) lights up, the battery will need to be fully charged before using it for the first time.
• Do not charge or use batteries if they are damaged.
  Contact an authorized bicycle dealer.
  Charging the battery
• A Bosch eBike battery must only be charged using an original Bosch eBike charger.
  Note: The battery is supplied partially charged. To ensure full battery capacity, fully charge the battery in the charger before using it for the first time.
  To charge the battery, read and follow the instructions in the operating manual for the charger.
  The battery can be charged at any state of charge. Interrupting the charging process does not damage the battery.

The battery has a temperature monitoring function which only allows it to be charged within a temperature range of 32 °F to 104 °F.

If the temperature of the battery is outside this charging range, three of the LEDs on the battery charge indicator (6) will flash. Disconnect the battery from the charger and let it acclimatize.

CAUTION

• Do not connect the battery pack to the charger until it has reached the allowable charging temperature.
  Battery charge indicator
  The five green LEDs on the battery charge indicator (6) indicate the battery’s state of charge of when the battery is switched on.
  Each LED represents approximately 20 % of the charging capacity. When the battery is fully charged, all five LEDs will be lit.
  The battery’s state of charge when switched on is also shown on the display of the on-board computer. Read and follow the instructions in the operating manuals for the drive unit and on-board computer.

If the battery capacity is less than 5 %, all the LEDs on the battery charge indicator (6) on the battery will go out. The display function of the on-board computer,
however, will carry on working.
Once charging is complete, disconnect the battery from the charger and the charger from the mains.

Inserting and removing the battery

• Always switch off the battery and the eBike system when inserting the battery into the holder or removing it from the holder.
  Removing the PowerTube battery (pivot) (see figure A)

1. To remove the PowerTube battery (4), open the lock (2) using the key (1). The battery will be unlocked and fall into the safety restraint (8).
2. Press on the safety restraint from above. The battery will be unlocked completely and fall into your hand. Pull the battery out of the frame.
   Note: As a result of varying designs, the battery may need to be inserted and removed using a different method. Read the eBike manufacturer’s operating instructions.
   Inserting the PowerTube battery (pivot) (see figure B)

In order for the battery to be inserted, the key (1) must be inserted into the lock (2) and the lock must be open.

1. To insert the PowerTube battery (4), place it so that its contacts are in the lower holder of the frame.
2. Push the battery upwards until it is held by the safety restraint (8).
3. Hold the lock open with the key and press the battery upwards until you hear it click into place.
   Check that the battery is secure in all directions.
4. Always secure the battery by closing the lock (2)
   1. otherwise the lock may open and the battery may fall out of the holder.
      Always remove the key (1) from the lock (2) after locking it. This prevents both the key from falling out and the battery from being removed by unauthorized third parties when the eBike is not in use.

Removing the PowerTube battery (axial) (see figure C)

1. To remove the PowerTube battery (12), open the lock (2) using the key (1), remove the key (1) and fold the locking mechanism (9) to the side.
2. Use the pull strap (10) to pull the battery (12) out of the frame.
   Note: As a result of varying designs, the battery may need to be inserted and removed using a different method. Read the eBike manufacturer’s operating instructions.

Inserting the PowerTube battery (axial) (see figure D)

In order for the battery to be inserted, the locking mechanism (9) must be folded to the side. At this point, the key (1) must not be inserted in the battery lock (2).

1. To insert the PowerTube battery, insert it into the frame with the socket for the charging connector (5) facing upwards until the battery clicks into place.
2. Close the locking mechanism (9), insert the key (1) into the battery lock (2) and secure the battery. Make sure that the safety hook (3) is hooked in at the opening of the axial rail (11).
3. Check that the battery is secure in all directions.
   Always remove the key (1) from the lock (2) after locking it. This prevents both the key from falling out and the battery from being removed by unauthorized third parties when the eBike is not in use.

Operation

Start-up

• Use only original Bosch batteries that the manufacturer mhas approved for your eBike. Using other batteries can lead to injuries and pose a fire hazard. Bosch accepts no liability or warranty claims if other batteries are used. Switching on/off Switching on the battery is one way to switch on the eBike system. Read and follow the instructions in the operating manuals for the drive unit and on-board computer.
  Before switching on the battery, i.e. the eBike system, make sure that the lock (2) is closed.
  To switch on the battery, press the on/off button (7).
  Do not use sharp or pointed objects to press the button.
  The LEDs on the indicator (6) will light up, indicating the battery’s state of charge at the same time.
• Always check that the battery pack is locked in place. To do this, pull on the battery pack (after the key has been removed).
  Note: If the battery capacity is less than 5 %, none of the LEDs on the battery charge indicator (6) will light up. Whether the eBike system is switched on is only visible on the on-board computer/control unit.
  To switch off the battery, press the on/off button (7) again. The LEDs on the indicator (6) go out. This will also switch the eBike system off.

If no power is drawn from the eBike drive for about 10 minutes (e.g. because the eBike is not moving) and no button is pressed on the on-board computer or the control unit of the eBike, the eBike system will switch off automatically.
The battery is protected against deep discharge, overloading, overheating and short-circuiting by the “Electronic Cell Protection (ECP)”. In the event of danger, a protective circuit switches the battery off automatically.

If a fault is detected in the battery, two of the LEDs on the battery charge indicator (6) will flash. Contact an authorized bicycle dealer if this happens.
Behavior in the event of a fault
The Bosch eBike battery must not be opened, even for repairs. There is a risk that the Bosch eBike batterycould catch fire, e.g. due to a short circuit. This risk arises if a Bosch eBike battery which has already  been opened is reused at a later point in time.
Therefore, do not repair the Bosch eBike battery in  the event of a fault, but have it replaced with an original Bosch eBike battery by your specialist retailer.

Transport

WARNING

• Always remove the battery pack from the bicycle before transporting the bicycle on a vehicle bike rack. Failure to remove the battery pack when using a vehicle bike rack can lead to death or serious injury. The battery may detach during transport and cause an accident to following vehicles.
• Always use an approved and compatible bicycle rack when transporting your eBike. The Bosch drive system adds weight to the bicycle. Refer to your bicycle rack manual to be sure your eBike is compatible. Overloading a bike rack can result in death or serious injury.
• Use proper lifting techniques as electric bikes are generally heavier than bicycles.
  Ship batteries only when the housing is undamaged.
  Tape or mask off open contacts and pack up the battery in such a manner that it cannot move around in the packaging. Inform your parcel service that the package contains dangerous goods. Please also observe possibly more detailed national regulations. Always check state and federal regulations before attempting to ship your battery.
  If you have any questions about transporting the batteries, contact an authorized bicycle dealer. You can also order suitable transport packaging from the dealer.

Maintenance/cleaning

WARNING

• 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 non-Bosch 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 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 paint any components of the Bosch drive system as they may cause premature failure of the component.
  After-sales service and advice on using products
  If you have any questions about the eBike system and its components, contact an authorized bicycle dealer.
  For contact details of authorized bike dealerships, please visit www.bosch-ebike.com.
  Please contact an authorized bicycle dealer if the battery is no longer working.

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).

Storing

The service life of the battery can be extended if it is looked after well and especially if it is stored at the correct temperature.

As it ages, however, the capacity of the battery will diminish, even with good care.
A significantly reduced operating period after charging indicates that the battery pack is worn out and must be replaced. You can replace it yourself by purchasing
a genuine Bosch PowerPack from an authorized Bosch eBike dealer.
Recharging the battery before and during storage
When you are not going to use the battery for an extended period (longer than three months), store it at a state of charge of around 30 % to 60 % (when two to three of the LEDs on the battery charge indicator (6) are lit).
Check the state of charge after six months. If only one of the LEDs on the battery charge indicator (6) is lit, charge the battery back up to around 30 % to 60 %.

Note: If the battery is stored with no charge for an extended period of time, it may become damaged despite the low self-discharge and the battery capacity
could be significantly reduced.
Leaving the battery permanently connected to the charger is not recommended.

Storage conditions
If possible, store the battery in a dry, well-ventilated place. Protect it against moisture and water. When the weather conditions are bad, it is advisable to remove the battery from the eBike and store it in a closed room until you use it next, for example.

Store the eBike batteries in the following locations:

• In a room with a smoke alarm
• Away from combustible or easily flammable objects
• Away from heat sources

For an optimum service life, store the eBike battery at temperatures between 50 °F and 68 °F. Never store it at temperatures below 14 °F or above 140 °F.
Make sure that the maximum storage temperature is not exceeded. Do not leave the battery in your car in the summer, for example, and store it away from direct sunlight.
Leaving the battery on the bicycle for storage is not recommended.

Troubleshooting

Battery Recycling Program

The drive unit, on-board computer incl. operating unit, battery, speed sensor, accessories and packaging should be disposed of in an environmentally correct manner.
Do not dispose of eBikes and their components with household waste.
Tape or mask off the contact surfaces of the battery pack’s terminals with adhesive tape before disposing of battery packs.
Do not touch severely damaged eBike batteries with your bare hands – electrolytes may escape and cause skin irritation. Store the defective battery in a safe location outdoors. Cover the terminals if necessary and inform your dealer. They will help you to dispose of it properly.

You may recycle your Bosch battery pack by calling 1.800.822.8837.