MAHLE X20 System
User Manual

Introduction

Thank you for choosing the MAHLE X20 System for your new SmartBike.
Please read this manual carefully before operating the system. Failure to do so or misunderstanding its instructions may lead to serious injuries or death.
Products and specifications are subject to change without prior notification thereof.
This Document has been drawn up in English and the content herein shall prevail in the event of any translation error or misunderstanding in its interpretation by the client of translations herein.
This manual includes instructions for the X20 Series System, including the following components:

• Drive Unit
• Head Unit
• Internal Battery Packs
• Torque and Cadence Sensor
• Active Charger

All relevant documents of the X20, including this user’s manual can be downloaded from our website: www.mahle-smartbike.com
The X20 components are certified as a complete system to guarantees full safety of the system. Any component can only be replaced with an original replacement of MAHLE SmartBike Systems to maintain the safety of the full system. Any tampering, modification, or reparation by any non-MAHLE authorized third-party shall immediately void the warranty conditions and original certification, holding MAHLE harmless with regard to any civil liability. Repairs or replacement must be performed by MAHLE SmartBike Systems, hereinafter MAHLE if applicable, certified partners only.
This manual shall not be reproduced other than in its entirety, except when prior written approval has been obtained from MAHLE SmartBike Systems.
1.1. General Warning
Please pay special attention to any warning symbol within the system highlighted with these graphics.
DANGER
WARNING
CAUTION
NOTICE
1.1.1. About Warnings
This manual contains DANGER, WARNING, and CAUTION indicators, concerning the consequences of failure to use, assemble, maintain, store, inspect and dispose of MAHLE-equipped eBikes in a safe manner. 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.
Preserve all safety warnings and instructions for the future. Do not open the Drive Unit or the Battery Pack by yourself. The system is maintenance-free. It must only be opened by qualified experts and repaired with original spare parts and specific tools. Unauthorized opening of a system would lead to voiding the warranty. All components of the Drive Unit and eBike may only be replaced with identical components or specifically approved by your eBike manufacturer. This protects your eBike system from damage. Don’t modify the Drive Unit, the battery or any other component or add any other non-approved product to improve performance or tampering. There is risk of accident in the event of accidental activation. Be careful when touching the surface of your Drive Unit. The surface may heat up considerably and cause skin burns. The walk- assistance function may only be used when pushing the eBike and require specific remotes. There is risk of injury if the wheels do not have ground contact when using this function. Use only original MAHLE batteries approved by the eBike manufacturer. Using unauthorized batteries may cause injuries or fire. Observe your regional and local regulations in reference to eBikes and pedelecs.
1.2. Maintenance, Storage & Transportation
The Drive Unit, batteries and main components are designed for long-term use and require following some simple and understandable guidelines to extend the lifespan of the MAHLE System by taking proper care during the use, cleaning and transportation thereof. 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 adjustmet of the products which are not found in the user’s manual.
• Do not disassemble or alter this product.
• These are small waterproof connectors. Do not repeat connecting and disconnecting it. It may impair the function.
• The components are designed to be fully waterproofed 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. Such substances may damage the surfaces.
• Be careful not to let water get into the terminal.

Products are not guaranteed against natural wear and tear from normal use and aging. The X20 can be installed in kid’s eBikes. For this type of use, ensure that your child is supervised and follow the eBike manufacturer’s safety instructions.
Cleaning and user maintenance shall not be executed by children without supervision.
1.2.1. Drive Unit, HMI and Accessories care
Remove any dust or mud on the surface of your Drive Unit, the HMI (displays, buttons, or remotes) and external accessories with a clean cloth. Never wash any of your eBike components using a power washer.
It is possible to clean or replace the freewheel and the bottom bracket by following the specific instructions in this manual or in manual of the bicycle manufacturer.
CAUTION
Ensure if you replace the rotor of the motor that the screws fill the follow specifications: 1.2.2. Battery Packs care
The batteries, especially the internal ones, only require removal if being replaced by an official service. They include sealed connections that protect against short circuits. Do not manipulate or connect anything in between the components. Never wash external batteries by using a power washer.
1.2.3. Charger care
Disconnect the charger and all general power supply for any cleaning operation. The charger is designed for indoor use only. Do not expose it to wet conditions, rain or snow.
1.2.4. eBike care
Keep your eBike system clean and dry for long-term or winter storage. We do recommend a charging level of at least 60-80% during long-term storage. To ensure a correct level of charge, you can either check the length of the Head Unit LED line, connect the Pulsar ONE display or the Smartphone application to the bike. The power consumption can significantly increase during use in winter, especially when the temperature drops below 0 °C. Please fully charge the eBike and external batteries before any winter use and remember that the range of your eBike could be reduced.
1.3. Transportation of your eBike system
There is a clear regulation for the transportation of the eBikes and batteries by ground, air/boat or train. There are global recommendations with regard to internal and external batteries. Remember that in all cases, the best option is to transport the battery when it is below 30% charged. For full eBike system, check the local regulations.
1.3.1. Transportation of full eBike by car
The internal battery shall not be removed from the bike for transportation. External batteries need to be removed and transported in a safe area inside the car.
1.3.2. Transportation of full eBike by air
The IATA (International Air Transportation Association) refuses to transport any eBike batteries. Please check if you can transport your eBike without the internal battery, send the battery separately and have it installed at your destination.
1.3.3. Transportation of full eBike by train
In most cases, eBikes are permitted to be transported inside trains, if the train does not provide a specific safe area for transportation. Check your local regulations or with your transportation company before setting off on your trip.
1.3.4. Transportation of batteries for repair
If, for any reason it is necessary to ship the battery, this needs to be done by an official service following the specific rules for transportation of dangerous goods, the recommendations of MAHLE and the eBike manufacturer. The battery needs to be placed in a specific, certified box and complemented with all the official documentation i.e., the MDSD report. This process cannot be performed by private persons.
1.4. Safe Charging Process
The X20 System includes a Smart Charger that establishes a direct connection with the MAHLE X20 internal and external batteries, supplying the correct charging current and the ideal balancing of the cells. Please only use MAHLE X20 original chargers for charging the MAHLE X20 Range Extenders or internal batteries and ensure the battery and charger are compatible. Charger and batteries are fully qualified for being used under the current regulations of the regions that X20 is approved to be used in.

• Connect the charger directly to a power source.
• Never use extension cords.
• Avoid reverse charging.
• Do not use for non-rechargeable batteries, as they can overheat and break.
• The Active Charger is not intended to charge automobile batteries.
• Inspect the Active Charger before every use for possible damage of the charger, the wire or and charging plug. Do not cover the charger while charging.
• Regularly inspect the battery. Never charge a battery which is potentially damaged or does have a defect.
• Make sure the charging socket and plug are not wet or humid before connecting and charging the battery.
• If the eBike or the battery are excessively cold, please wait until the warmed up before charging the system.
• Do not incinerate, disassemble or short circuit batteries.

WARNING
Explosive gases. Prevent flames and sparks. Ensure that there is adequate ventilation during charging. 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.
1.5. Servicing
Servicing, replacement and repair may only be performed by official MAHLE Service Partners. In the event of repair, the MAHLE Service must authorize the process. Please remember that our components may contain cells (i.e., internal batteries) that can be damaged, or a short circuit could be created by drilling into the frame, which could result in a fire.
The capacity of a battery will degenerate over time. During normal use of 2 years or after 500 full charging cycles, the battery can degrade to around 70% of its initial  capacity. 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.
1.6. Recycling
It is our responsibility to ensure the correct recycling of the battery. Together, we are responsible for minimizing the CO2 footprint and environmental impact. Please ensure the correct recycling of the battery when reaching the end of its lifespan. Get in touch with your dealer or eBike manufacturer to ensure the correct recycling process. If the battery needs a replacement, please bear in mind that only official MAHLE service partners are allowed to replace the internal battery. They can also handle the recycling of your old battery.
According to the European Guideline 2012/19/EU, electrical devices / tools that are no longer usable must be collected separately and disposed of in an environmentally correct manner. This product must be disposed of at an authorized place for recycling of electrical and electronic appliances. Please also take into account the regional regulations of your country.
By collecting and recycling waste, you are doing your bit to save natural resources, and make sure the product is disposed in an environment friendly and healthy way.
1.7. Product Certificatios
MAHLE SmartBike Systems SLU hereby declares under its own responsibility that the design and construction of the product complies to the Safety requirements of application under European Standard EN 15194:2017, the follow European Directives: [MD] 2006/42/CE, [EMC] 2014/30/EU, [RED] 2014/53/CE (HMI), [BAT] 2006/66/EU (Battery Packs), [LVD] 2014/35/EU (Battery Charger) and [RoHS III] and Regulation [REACH]. The complete document about product certificatios is available at the following link: https://www.mahle-smartbike.com/conformity
1.7.1. Important information about Head Unit
Model: HUS
FCC STATEMENT
CAUTION
If any changes or modifications not expressly approved by the party responsible for compliance could void the user’s authority to operate the equipment.
This device complies with Part 15 of the FCC Rules.
Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) This device must accept any interference received, including interference that may cause undesired operation
The grantee is not responsible for any changes or modifications not expressly approved by the party responsible for compliance therewith. Such modifications could void the user’s authority to operate the equipment. The RF Exposure Compliance distance is 5 millimeters.
NOTICE
This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:

• Rotate or relocate the receiving antenna.
• Increase the separation between the equipment and receiver.
• Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.
• Consult the dealer or an experienced radio/TV technician for help.

This device contains licence-exempt transmitter(s) / receiver(s) that comply with Innovation, Science and Economic Development Canada’s licence-exempt RSS(s). Operation is subject to the following two conditions:

1. This device may not cause interference.
2. This device must accept any interference, including interference that may cause undesired operation of the device.

Class B Equipment (For Home Use Broadcasting & Communication Equipment)
This equipment is home use (Class B) electromagnetic ‘save suitability equipment and to be used mainly at home and it can be used in all arras.
WARNING
This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.
MAHLE hereby declares that the radio equipment type of this HUS is in compliance with Directive 2014/53/EU. The full text of the EU Product certifications is available at: www.mahle-smartbike.com

Head Unit Designed by MAHLE in Europe.
Head Unit Assembled in PRC.

General Overview

You have bought an eBike that includes a MAHLE X20 SmartBike System. This system is designed to support you while you are pedaling under the regional regulations of your country for this application. The X20 is composed of: 2.1 Specifications
Main Component Specifications
2.1.1. X20 Drive Unit

• R142 O.L.D. and Thru Axle (12 mm)
• 28 Straight-pull spokes
• 14G Standard
• Nominal voltage CA: 42 V
• 55Nm (Compared to Mid Drive)
• Compatible with 140mm flat mount calipers
• Max. Speed: 25km/h or 20 mph (Limited per region)
• Automatic Motor Connection System
• Standard Freewheel installation
• CAN BUS Interface
• Water ingress protection: IP66
• Weight: 1,399 grs (without freewheel)

2.1.2. X20 Torque & Cadence Sensor

• Nominal voltage CC: 6V
• Designed for press-fit BB shells
• 4 different models available (Dimensions depending on the version and standard used)
• Cadence and torque reading
• Compatible with all spindles on the market
• Mixed press-fit and threaded mechanism
• 92 mm wire to battery
• CAN BUS Interface
• Water ingress protection: IP54

2.1.3. iX250 – X20 Internal Battery

• Nominal voltage CA: 25-42 V
• Voltage & charging current CC: 42C – 2.1A / 4A
• Capacity: 236Wh / 36V
• Dimensions: 469.5 x 49.6 x 41.8 mm (LxWxH)
• CAN BUS Interface
• Water ingress protection: IP66
• 2 HMI Accessories connectors
• Light support 2A/6V (12W)/12V (24W) USB 2A/5V
• Weight: 1,500 grs

2.1.4. iX350 – X20 Internal Battery

• Nominal voltage CA: 25-42 V
• Voltage & charging CC: 42C – 2.1A / 4A
• Capacity: 350Wh / 36V
• Dimensions: 469.5 x 51 x 52 mm (LxWxH)
• Water ingress protection: IP54
• CAN BUS interface
• 2 HMI Accessories connectors
• Light support 2A/6V (12W) /12V (24W), USB 2A/5V
• Weight: 2,250 grs

2.1.5. Head Unit

• Voltage CC: 6V
• Ambient temperature: 60 C / -10C
• Dimensions: 73.1 x 28.2 x 18.9 mm (LxWxH)
• CAN BUS, ANT+ and Bluetooth® Interface
• Water ingress protection: IP54
• Weight: 32 grs

2.1.6. X20 Dropout Drive Unit Connector

• 550 mm cable length
• Water ingress protection: IP54
• Weight: 64 grs

2.1.7. Charger Port

• 6-pin connector with poka-yoke connection
• Water ingress protection: IP54
• Weight: 24 grs

2.1.8 Active Charger

• Nominal voltage AC: 90-246V, 50-60 Hz
• Nominal voltage CA: 42 V – 2.1A / 4A
• Voltage & charging CC: 42C – 2.1A / 4A
• Ambient temperature: 90 C / -15C
• Dimensions: 187 x 90 x 44.4 mm (LxWxH)
• Water ingress protection: IP20
• Weight: 690 grs

2.2 Compatible eBikes
The X20 System can only be assembled on eBikes which were designed for the integration of X20 components. An aftermarket- or retrofit application is not possible. The eBike need to pass all the certifications and homologations required by the specific regions in which the bike is going to be sold. Please check the official MAHLE SmartBike Systems website in order to access our most updated list of eBikes on the market with our X20 System:
Website: www.mahle-smartbike.com

Operation and use

Thanks for purchasing an eBike that includes the MAHLE X20 System. This system includes a lot of connectivity features as well as AI functions that will give to you the chance to entry in the era of the new SmartBikes. This chapter explains how to use the system and you must read before any operation of you eBike system.
3.1. Operation Mode
In order to operate the system in a correct way, ensure that the eBike system (including the rear wheel) is fully connected and correctly assembled. To ensure a correct use of the eBike system, first disconnect the charging wire from the charging port of the eBike. Do no ride the eBike while it is charging. Ensure that eBike is fully charged before using it for the first time. To ensure your bike is fully charged, we recommend keeping the eBike system connected to the power supply and charger for at least 2 hours. For additional information on how to charge your eBike, please check the chapter “Operations with the Charger / Charging Process”. Before starting your ride always ensure your battery is sufficiently charged. Disconnect the charger of your eBike and switch the system on by pressing the button of the Head Unit once.
3.2. Use Cases
The X20 System is designed to be used as an electronic component of a compatible full eBike.
3.2.1. Planned use
The intended use of our product is to assist the pedaling of an EPAC (not for any other eBike application). All the X20 components were designed to be integrated in a complete eBike produced by a professional bicycle manufacturer.
The system is designed to be used under the current harmonized norms and certifications:

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

Our product is designed under the requirements, which the standards established for being used in EPAC applications and certain environmental conditions in which this kind of applications may be used like rain, salty areas, mud, etc.
The MAHLE X20 System overachieves what the standards require, but please also pay attention to what the eBike manufacturer specifies regarding the system integration and design information. Pay special attention to:

• Mounting and dismounting of the rear wheel, the PAS and the torque sensor inside the bottom bracket.
• Clean the system only under the specific MAHLE recommendations inside this manual. Never use a power washer to clean your eBike or the electronic components of your eBike.
• When storing your eBike ensure a sufficient SOC of all batteries.

3.2.2. Prohibited Use
You are not allowed to integrate our system in a non-compatible EPAC that was certified under EN 15494 or in a regular bicycle. It is a 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 a breach of MAHLE regulations to tamper our components, to change the software and firmware designed and approved by MAHLE, or to add electronics components which modify the maximum assist speed. If MAHLE terms are breached by non-compliance with the foregoing, MAHLE does not carry any legal responsibilities for damage caused to people or material.
The MAHLE system reserves the right to include functions which can analyze and record any kind of abnormal behavior such as too high a maximum speed or abnormal data communication, which could be caused by tampering the system. Any kind of manipulation shall immediately void all MAHLE warranty terms.
3.2.3. Operative mode (In the event of malfunction)
The system can operate in 3 different modes:

• Normal: Everything is OK.
  Systems shows SOC and current assist level

• Alert: Head Unit line flashing ORANGE.
  System does carry a level of malfunction, but your riding and assistance are not restricted.

• Warning: Head Unit line flashing RED.
  Malfunction that limits the assistance. Ebike propulsion system is shut off. In this case, please reach out to the MAHLE SmartBike Systems Service or your local dealer

In case of any errors alerts (flashing ORANGE) or warnings (RED), the system sends the error or warning information through the Bluetooth® and ANT+ LEV compatible display. Please pair your smartphone and to check the error using the MAHLE APP My SmartBike or check the error using the Pulsar ONE display (will display the error code number).
There are 2 warning (RED) levels.

• System is ON but does not give assistance
• System starts automatically to SWITCH OFF

The list of error codes is attached at the end of this document.
3.3. Operation
3.3.1 Switching the system ON / OFF
Switching the system ON
Press the button of the Head Unit onceto turn the system on. The LED of the Head Unit will light up and ‘’hello’’ will be displayed. If everything is in order, the LED will display the battery charging status in white (SOC).
Switching the system OFF
To switch the system OFF, simply press and hold for 2 seconds the button of the Head Unit until the LED shows a Goodbye animation. The LED will turn OFF after the animation. 3.3.2 Automatic System Switching OFF
To save battery, when there is no speed and the smartphone with the APP is not connected, after 5 min, the system will switch OFF automatically by activation of the Power Safe Mode. At any time, the system can be switched ON again by following the normal procedure. This auto OFF process also occurs while charging process when the inner battery reaches 100% of SOC
3.3.3 Change the assist level
The assist levels can be changed through different methods:
Control the assist level using the Head Unit To increase the assist level, briefly press the button on the Head Unit. The assist level of the eBike will increase.
Once you reached the highest assist level, by pressing the button, the system will start the cycle again assist-free.
NOTICE
The system does remember the last selected assist level before the bike was switched off. If an error occurred before the bike was switched off, the assist level will be 0.
Control the assist level using e-Shifters
The system will allow to optionally add electronic shifters. The e-Shifters are based on 2 small micro buttons that can be installed on your handlebar. If these 2 remote buttons are connected to the Head Unit, you can also control the assistance of the eBike using the micro buttons when the eBike system is switched ON.Operation| Action
---|---
Left Short| Assist Down
Right Short| Assist Up
Left Hold| Reset Data
Right Hold| Turn ON/OFF Lights

NOTICE
The eBike manufacturer can configure or change the functionality of the Left and Right remote buttons. The functionality is set by default during the manufacturing process. For more information on this product, check the manual included in the e-Shifters or download it from the website: www.mahle- smartbike.com
Control the assist level using Pulsar ONE display Your system can be used with the wireless Pulsar ONE display. The display has all information such as speed, current assist level, batteries SOC, time, distance, power, etc. The Pulsar ONE and your eBike communicates automatically through ANT+. The Pulsar ONE display comes with 3 buttons – a small one in the middle and two big ones on each side. With this accessory, you can also control the assistance of your eBike, by using the left and right buttons on your Pulsar ONE display, when the eBike is switched ON.

3.4. Switching the lights ON/OFF
If the lights on your eBike are connected to the X20 System you can control them using the Head Unit. Please ensure that the used lights are compatible and a MAHLE compatible remote is used to activate or deactivate the light system too.
There are two main modes to control the lights:

• Automatic Mode: with the Ambient Light Sensor and according to environmental conditions the Head Unit will activate/deactivate the lights accordingly.
• Manual Mode: user can take control of activating the lights at any time, either via ANT+ LEV display or via e-Shifters when installed.

NOTICE
The eBike manufacturer could establish an additional automatic mode based on the switching ON/OFF of the eBike.
Switching the lights ON
Press the LEFT button of the e-Shifter long to switch the lights on. A “switching lights on” animation can be seen on the LED bar. If everything is ok the LED bar will turn
back to the battery status.
Yellow color outer animation when switching ON the lights
Switching the lights OFF
Press the LEFT button of the e-Shifter long to switch the lights off again A “switching lights off” animation can be seen on the LED bar. If everything is ok the LED bar will turn back to the battery status.
Yellow color inner animation when switching OFF the lights
NOTICE
The functionality of the LEFT and RIGHT button can be changed by the manufacturer. Please check the manual of your specific model for detailed information. Pressing the button for longer can control both walk assist and the lights. In accordance with particular regulations, the OEM can setup the status lights of the eBike upon system start.
3.5. Walk-assist Mode
To use the walk-assist mode, an additional remote e-Shifter accessory is required.
To activate the walk assist you need to hold the right button of the e-Shifter pressed down. Be aware that the bicycle manufacturer can always customize the functionality of the e-Shifters. The maximum speed during walk-assist is 6 km/h (Approximately 10 miles). If exceeded the walk assist will automatically shut off. The walk-assist will also shut off when you release the button.
The color of the current assist level will be displayed at 50% of the LED bar, when the walk mode is active. This will be visible while the mode is active.
NOTICE
Remember than the walk assist mode should only be used when walking the bike. The wheels need to be in contact with the ground to prevent injuries.
3.6. Information of the Head Unit LED
The Head Unit permanently will inform you about the two most important parameters:

• SOC, State of Charge of the battery
• Active Assist Level

1. Control Button
2. Ambient light sensor
3. RGB Dynamic Line
4. Set screw

3.6.1. (SOC), State of Charge of the battery
The Head Unit will display the current battery status (SOC) through the visible length of the LED bar. 100% capacity, are represented through the full length of the line. As the battery is slowly draining, the illuminated length of the LED bar will decrease representing the decrease in capacity. The LED bar will always keep a minimum of one LED illuminated to be able to display the assist level used.
The LED line is generated by 7 LEDs that can create visual effects and animations. For the charging status and the length of the illuminated LED bar the relation is the following: Iluminated LEDs| SOC
---|---

7| 94 – 100%

6| 82 – 93%

5| 70 – 81%

4| 56 – 69 %

3| 36 – 55%

2| 16 – 35%

1| 0 – 15%

1 (Blink slow)| 0 – 10 %

1 (Blink fast)| 0 – 5 %

5-10% SOC – The system is limited to a maximum of 70% of its maximum nominal power output.
0-5% SOC – The system is limited to a maximum of 40% of its maximum nominal power output.
3.6.2. Current Assist Level
The system includes three different assist levels, which can be customize by the user, using the MAHLE APP My SmartBike. Each Assist level is represented by a different color as seen in the following table:

3.6.3. Set the intensity of the LEDs
The main Head Unit button has a light sensor integrated.
Using this sensor, the Head Unit automatically will increase or decrease the intensity of the LED line, to improve the visibility of the information.
3.6.4. Other Information displayed by the Head Unit
The battery status and the assist level are displayed through the color and the length of the LED bar.
Depending on the status of the eBike system, additional information can be communicated
Switching the bike OFF
A white color appears after briefly pressing the button down.
Switching the bike ON
A white color appears after briefly pressing the button down.
Charging Status while charge
Cyan color appears with a pulsating effect.
Battery Charged
Permanent green LED bar.
BLE connected or disconnected
Blue color appears.
Lights switched ON or OFF
Yellow outer color appears when lights are switched ON Lights ON
Yellow inner color appears when lights are switched OFF Lights OFF
Error
Flashing red light when the system is having an active error. Please switch off the system and ensure the error is solved.
Error Warning
WARNING
Flashing orange light when the system is having an active warning alert. The use of the system is not restricted but attention should be paid to the warning.
Updating in progress
Flashing pink light when software update is performed on the system.
Walk assist mode activated
The color of the current assist level will be displayed at 50% of the LED bar, when the walk mode is active. This will be visible while the mode is active.
3.7. Operation with the Charger
3.7.1. X20 My SmartBike Active Charger
X20 My SmartBike Active Charger includes CAN BUS communication and a Micro-USB interface to perform updates on full eBike System. This charger is compatible with all X20 MAHLE inner batteries and Range Extenders.
The Active Charger allows fast charging with up to 4A, using the CAN Communication port to identify the battery model and current charging status, supplying the appropriated charging current depending on the current SOC.
It does include 2 LED bars to inform about the charging mode and status, projecting a retro-illumination against any surface i.e., the wall or the floor.
As an optional component there is a wall mount available to place the Active Charger on the wall, keeping the wiring organized when not connected to the eBike or while charging.
3.7.2. Charging Process
To ensure that it is being charged correctly, please follow these instructions

1. Connect the charger to the power outlet. LED of the charger 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 eBike
   LED of the charger and the Head Unit of the bike will turn CYAN. Breathing effect: From high to low frequency by increasing level of charge.

3. Charge process finished
   Once charging is completed, the LED of the Head Unit will be a steady GREEN light.
   Disconnect the charger from the power source before disconnecting from the eBike.
   Error during charging process
   If a critical error occurs while charging, the LED of the charger will flash in RED.

3.8. Updating Process
It is possible to update the system by using the micro-USB port of the smart charger. To perform an update, you need to connect the charger to your computer and transfer the updating files to the charger. Please follow this process:
3.8.1. Uploading files to the Active Charger

1. Disconnect the charger of the Power outlet
   No LED will be operating.

2. Connect the charger to your computer using micro-USB port
   LED of the charger and the HMI will turn to a PURE BLUE light.
   Copy the unzipped update files (update_MUT.bin) to the new Drive Unit (MAHLE_UTOOL) which will appear on your computer and safety remove the new drive on your computer.
   

3. Disconnect the charger of your computer
   No LED will be operating.
   Error while uploading
   If an error occurred during the uploading process, the LED of the charger will turn to a steady RED light for 10 seconds. After that, the charger goes back to normal operation.

3.8.2. Updating eBike system
Once the files are into the Active Charger you can update your system. For updating a second eBike you will need to repeat the full updating process.

1. Connect the charger of the Power outlet
   LED of the charger will display a steady WHITE light.

2. Connect the Charger to the eBike
   Connect the charger to the eBike as you would connect it for a normal charging process. The LED of the charger will constantly flash in PURPLE while the update is being performed.

3. Update Completed
   Once the update process is finished the LED of the charger will turn to a steady GREEN light for 10 seconds. After that, the charger goes back to normal operation.
   Error while uploading
   If an error occurred during the updating process, the LED of the charger will turn to a steady RED light for 10 seconds. After that, the charger goes back to normal operation.

3.9. Battery Use
MAHLE SmartBike Systems does use high quality cells for both, inner- and external batteries. We do this to get the most out of our minimalistic battery following our LIGHT, SPORT, SMART premise. To ensure a long battery life, please follow the guidelines below:

• One important factor is the number of charging cycles – every time you charge the battery it will degrade.
• If you store the battery, try to keep the battery status between 30% and 60%.
• Don’t leave your bike exposed to the sun for extended periods
• Don’t expose the battery to cold temperatures for extended periods of time.
• When starting an activity, do not use the maximum assist right away – your battery needs to reach its operating temperature first
• Do not store your battery 100% charged for long periods and remember to drain it frequently
• When storing your bike for longer periods of time ensure the temperature stays within 10-20 degrees.

NOTICE
Remember a battery is considered as a consumable good.

Accessories

Your X20 System is compatible with various accessories. Your eBike might already be initially equipped with some additional accessories from brand side. If your eBike is not equipped yet with additional components, the following accessories can always be added to the X20 System:

• Pulsar ONE display
• e-Shifters
• Range Extender

4.1. Pulsar ONE display
Pulsar ONE is an ANT+ eBike computer developed by MAHLE specially designed to be used with ANT+ compatible MAHLE systems (X35+ or X20). The Pulsar ONE connects wireless to the eBike system using the ANT+ LEV communication protocol (Light Electronic Vehicle – all new MAHLE systems are fully compatible).
The 2.1” wide screen lets you see vital information about your eBike system such as battery level, assistance level, light system status, range and errors, as well as basic riding information such as speed or time. This information is complemented by additional essential data for any rider, such as average speed, maximum speed, ride time, ride distance, eBike odometer, heart rate, cadence, etc.
Pulsar ONE display
SKU: 330 100 000 00 000
Includes display, Screen protector, battery CR2032 and user manual.

• 2.1” black & white LCD with 3 buttons
• Wireless connectivity by ANT+
• Waterproofness IP67
• Battery type CR2032 (Included)
• Certifications (CE, FCC, IC, KCC, Telec and RCM) ANT+ LEV, HR, CAD, PWR, CTF
• Dimensions (57.7 mm x 41.1 mm)
• Weight 28 grs (with CR2032)

NOTICE
You can use the buttons of the display to control the assist levels and the lights. Further information on this product can be found in the user manual.
4.1.1. Pulsar ONE holders
There are two different optional holders to place the display in 4 different positions. It is also possible to use other GARMIN compatible device holders. To ensure a safe installation, please ensure you are using a compatible holder with your Pulsar ONE display:
Pulsar ONE Sport holder
SKU: 330 100 000 01 000 Pulsar ONE Urban holder
SKU: 330 100 000 02 000 4.2. e-Shifters
e-Shifters is a set of 2 small optional buttons connected to the Head Unit which allow to control the functions of the MAHLE SmartBike System directly form the handlebar (assist level, lights, etc.). The minimalist design allows them to be installed independently from the handlebar used (drop- or flat bar).
**By pressing the e-Shifters, whether briefly or for longer, different commands are sent to the system. A maximum of 2 e-Shifters per eBike can be installed (left and right). The e-Shifters give haptic feedback to the rider by vibrating (under patent) whenever the status of the system is changed to not draw the attention away from riding.
Using the e-Shifters can help to increase the safety while riding by avoiding removing the hand from the handlebar. Additionally, the vibration of e-Shifter buttons deliver additional information to the rider when the APP or the eBike system changes the status or reports an alert.
To upgrade e-Shifters to your X20 equipped bike, please get in touch with your local dealer to ensure a correct installation and connection to the X20 System. The following configurations are available:
e-Shifter 720
SKU: 350 100 000 00 200
Giftbox + Y-Joint + 2 e-Shifters with 720mm length wire + 2 Silicon Bands + Manual e-Shifter 970
SKU: 350 100 000 00 300
Giftbox + Y-Joint + 2 e-Shifter with 970mm length wire + 2 Silicon Bands + Manual 4.2.1. e-Shifters Installation
The e-Shifters allow to be installed in various ways and areas of the handlebars. The included e-Shifter rubber hoods can be used to install the e-Shifters in every possible area of the handlebar. Without the rubber hoods, the e-Shifters can be installed under the bar tape on drop bars.
Curved – Road and Gravel The ergonomic design of e-Shifters and rubber hoods allows the installation in various areas of the handlebar.
Flat – Mtb and Commuter
The ergonomic design of the e-Shifter and rubber hoods allows them to be placed in a perfect, easy to reach position.
4.3. e185 – Range Extender
The e185 Range Extender is our latest generation of external batteries and can always be added to the X20 System. The e185 is working as an independent battery supplying its power directly to the motor without any interference of the main battery. With the new My SmartBike APP, it is now possible to customize the power consumption of your eBike betwenn the main and the external battery.The Range Extender carries 171Wh in addition and  allows you to increase your range drastically, while only adding 1Kg of extra weight to the system. This will upgrade your total capacity by 77% when added to the iX250 battery and 53% when added to the iX350 battery. The new designed holder for the e185 Range Extender follows the design, size and mounting points of a regular bottle cage and can therefore also be used to carry a regular bottle when the Range Extender is not used.
4.3.1. Range Extender Pack Components
The Range Extender e185 pack includes:
Battery Pack e185
SKU: 41010400000000**

• Weight: 1.100 grs.
• Waterproofness IP67
• Capacity: 177Wh

Holder
SKU: 24010414300000

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

Rubber (to lock the holder)
SKU: 24010414301000 4.3.2. Range Extender Wires
Due to different frame designs the Range Extender is sold without connection wires. Two versions of the connection wire are available, which allow two different installation positions for each cable. When purchasing the connection cable, please consult your bike manufacturer to ensure that you choose the correct cable so it does not interfere with your cranks while pedaling.
Connector AD RA2 30º
SKU: 24010411000000

• Total length: 193 mm (± 7mm)
• Diameter: 6,5 mm
• Wire length: 100 mm (± 5mm)
• Weight: 33 grs.
• Waterproofness IP67

Connector DE RA2 90º
SKU: 240 104 110 01 000

• Total length: 193 mm (± 7mm)
• Diameter: 6,5 mm
• Wire length: 110 mm (± 5 mm)
• Weight: 35 grs.
• Waterproofness IP67

Application and Services

The MAHLE My SmartBike application allows you to connect your smart device to your X20 System. The My SmartBike application will not only display all critical ride data and let you track and record your activities, it also lets you customize the assist levels to your own expectations.
MAHLE will continue to add new features and functions to the system, to ensure your bike will always be fully compatible with new software applications and added smart solution added in the future.
Your X20 System is compatible with the full family of MAHLE SmartBike Systems APPs that provide the following features:

• My SmartBike iOS version for iPhones
• My SmartBike for Android phones
• www.my-smartbike.com Browser applications To diagnose the system in a professional workshop environment we also offer a dealer-only application:
• Smarbike Lab (iOS and Android)

NOTICE
To ensure your X20 System is always up-to-date, we highly recommend downloading the My SmartBike APP and regularly connecting your system to your smart device. Doing so will ensure your bike will always feature the newest updates.
5.1. My-SmartBike phone APP
The MAHLE My SmartBike APP is compatible with smart devices using iOS or Android systems. The APP lets you track and record your activities. With the available features, your smart device becomes your all-in-one smart bike display when placed on the handlebar.
CAUTION
For your own safety, we do not recommend using your smart device while riding if is not firmly connected to your handlebar.
Use the following links to download the APPs|
---|---
https://apps.apple.com/es/app/my-smartbike/id1566348476| https://play.google.com/store/apps/details?id=com.mahle.sbs&gl=ES

5.1.1. Smartphone APP. Main Functions
If you connect your eBike to the MAHLE My SmartBike APP you will benefit from the following features:

• Motor performance definition. Control the power, acceleration and reactivity of each assist level.
• Record and track your activities and automatically synchronize with STRAVA. You can always also view your completed activities online.
• Use your smartphone as your main display to see your main parameters such as batteries status, hearth rate, range, etc.
• Automatic assist level control.
• Get access to extra information and tutorials.
• Keep track of the status of your eBike.
• Keep your system updated.
• Localize your eBike (last position connected to your smart device).
• Additional features will be added in the future.

5.1.2. Smartphone APP. Motor settings
The X20 System includes 3 PRESET modes. Each preset mode is a full system setup of which will modify the peak power, acceleration, and reactiveness of each assist level (1 to 3).The system also features a CUSTOM mode. The CUSTOM mode will allow you to customize each of the assist levels (1 to 3) by adjusting peak power, acceleration, and reactiveness.
PEAK-System The system also features a CUSTOM mode. The CUSTOM mode will allow you to customize each of the assist levels (1 to 3) by adjusting peak power, acceleration, and reactiveness.

• Power:
  Peak power defines the maximum power the motor can provide for a short period of time (Watts).

• Acceleration:
  Acceleration defines the time it takes to reach the full level of assistance you selected. Less % will result in a smoother change while more % will make it change faster.

• Reactiveness to applied torque:
  Reactiveness defins the effort you need to apply to reach the designated power outlet. Less % will result in more effort while more % will make it easier to reach the selected power outlet.

5.1.3. Smartphone APP Account creation
To enjoy all functions of the My SmartBike APP, please ensure you create your personal account:

1. Access www.my-smartbike.com/user/login through your web browser and create a user account.
2. Download the My SmartBike APP to your smart device and create a user account directly on your device.

https://my-smartbike.com/user/register

Once you have created your personal account, open the MAHLE My SmartBike APP, switch your eBike on and simply follow the process of the APP to connect your device and eBike by Bluetooth.
If you need support connecting your device to your eBike, please use the tutorials provided in the APP.

NOTICE
Open the APP and click on SETTINGS. Once you choose SETTINGS go to TUTORIALS 5.2. My Smarbike Web APP
You can also view all your eBike details online through your web browser (on any smart device or computer). The Web APP is designed to give you more details about your activities and a higher level of trackability about your general usage of the system. To access the website please go to www.my- smartbike.com
5.2.1. Web APP. Main Functions
The following features are available through the web application:

• Timeline of all your activities
• Complete overview of all your achievement
• Detailed visualization of your general usage including the use of the different assist levels
• Locate your eBike (last position connected to your smart device)
• Status of your eBike (Serial number, errors, reports, trouble shooting, components, …)
• Full trackability of your activities incl. map overview and power mapping
• Segmentation of your ride by elevation, speed, slope, altitude, HR or assist level used or power consumed
• Access to all public activities
• Synchronization with STRAVA
• Share your tracks on Social Media
• Documentation of your system
• Support

5.2.2. Web APP. Account creation
Use the same username and password as you are using for the smart device applications to access the web application.

Servicing

All components of the X20 System are fully replaceable. Please be aware that some parts can only be changed or handled by an authorized MAHLE service partner or dealer. Components such as the rear wheel can be changed or replaced by the end user directly. To ensure that you will not injure yourself or damage the components please follow some basic guidelines.
WARNING
If servicing is required, please remember at all times that this can only be performed by a professional mechanic. eBike components include electronic components and connections that need to be installed correctly . Misuse of batteries or other components may cause serious injuries or damage to the components.
6.1. Rear wheel removal and installation
Should you need to remove the rear wheel for servicing or replacement, please read the following paragraph carefully.
The rear wheel includes the X20 Drive which does not have direct wire connection. It features an automatic connection which needs to be taken care of when installing or removing the rear wheel. Please follow the steps below.
6.1.1. Rear wheel removal

1. If you run a single speed setup, please continue with step 3.

2. If you run a cassette, downshift to the smallest sprocket.
   

3. Loosen your axle and disassemble it.

4. Slide the wheel out of the frame. Ensure you give room to the wheel by pressing the rear derailleur away from the cassette.
   

5. Ensure to not damage the frame with the disc rotor when sliding the wheel out of the frame
   

6.1.2. Rear wheel installation
To install the rear wheel, please follow the steps below:

1. Ensure the upper chain is lying on the cassette, while the lower part of the chain is running underneath the cassette and is not blocking the dropouts.
   

2. Ensure that both the disc rotor and the brake caliper are perfectly aligned to avoid any damage to the frame or brake caliper.
   

3. Carefully slide the rear wheel into the dropouts. Please ensure that the motor connector is facing upwards and is aligned with the dropout. Once the wheel sits smoothly in the dropouts, guide the axle through the motor and tighten it to the frame manufacturers recommendations. Once the axle is tight, the motor is automatically connected to the rest of the system.

WARNING
Always ensure that both, the motor and the frame side of the automatic connector are clean before installing the rear wheel. Check the connector before installing the rear wheel – all pins should be straight. Should you need support installing your rear wheel, please reach out to your local dealer.
6.2. Other Services
Your X20 System does require regular servicing and some components are suspect to wear. To always ensure your eBike is working as intended please ensure regular service. If any of the components needs to be replaced, please get in touch with your local dealer for further support.
6.2.1. Freewheel and bottom bracket service
The X20 System does feature a fully replaceable freewheel and bottom bracket which both require regular servicing.
For both freewheel and bottom bracket installation, there are guidelines that explain the process step by step in detail.
Any kind of replacement or service needs to be performed by a professional mechanic. Always ensure that no wires or connectors are damaged in the process of installing or removing system components. Before you perform any kind of replacement, please read the recommendations of both MAHLE and the bike manufacturer, including all additional information about bicycle maintenance and care. Pay special attention to the guidelines of the bottom bracket removal and installation.
6.2.2. Battery, Motor, Head Unit Service
Should a new battery be required, please be aware that the replacement can only be performed by a professional mechanic. We therefore recommend getting in touch with your dealer prior to the replacement. Additional steps such as the activation of the battery may occur for various components which can only be performed by an authorized MAHLE service partner. Please be aware that MAHLE only warrants the X20 Drive Unit which is the rear hub of your eBike wheel. Should you face any issues with your spokes or rim or other parts of your rear wheel, please get in touch with your bike manufacturer directly.

NOTICE
MAHLE SmartBike Systems components require a specific software activation. Pay special attention when replacing the BB, the Drive Unit, the battery or HMI. In any case, replacements must only be performed by professional mechanics.
6.2.3. Replacing Automatic Dropout Connection
If the motor connector is damaged a replacement is possible. Please get in touch with your local dealer if a replacement is required.
6.3. Warranty
Warranty terms and periods are based in our end user final policy and into the end user warranty regulation and laws of each region. Please get in touch with your dealer should you have any problem with the system. MAHLE has a global distribution and service network for the regions where the sale of the X20 System is authorized.

FAQs

I was long time without using My SmartBike and it doesn’t switch ON when I press the button?****

– If you were more than 60 days without using your eBike it can automatically enter in sleep mode. To wake up just connect your charger. Even battery can goes to ultra-sleep mode, in that situation you will need to keep connected at least one hour.

Is it possible to change the inner battery?****

– Changing the battery also requires an additional process that only a dealer with the proper tools can carry out. It is possible to change the inner batteries but only through the official network.

Is it possible to install a MAHLE display on your SmartBike?****

– The X20 Systems supports ANT+ LEV profile; therefore using the Pulsar ONE as a display grants full compatibility with your X20.

Is the bike compatible with other displays?****

– Other compatible displays can be found here: https://www.thisisant.com/directory/

Is it possible to install or retrofit the eBike e-Shifters?

– Commercial Answer. Technically it can be done; but wiring routing on some OEM integrations might become tricky from end user point of view.

By how much does the Range Extender increase my range?****

– Range Extender e185 offers you an additional 171Wh. As well as with the inner batteries, the increase depends on the way you use your eBike. What we can say is that it increases the range of the eBike with iX350 batteries by 50% and the eBike with iX250 batteries by 75%. (from 30 km to 70 km).

Is It possible to upgrade the eBike from the iX250 to iX350 battery?****

– Check with your dealer. Change batteries will change the specifications of your eBike. Anyway, iX250 and iX350 have different sizes but share same fitting points. Any battery replacing also requires the activation of the new battery by the dealer.

In case of malfunction what do I have to do?****

– A malfunction shall be shown as an error or warning on the head unit. Please, connect the My SmartBike APP from MAHLE to check the code number that identifies the malfunction and share with an authorized Dealer or Customer Service.

Is it possible to repair the battery?****

– The battery is considered a dangerous good. Therefore, MAHLE recommends that the battery should only be handled by MAHLE specialists and replaced with a new one in the official dealer network.

Is it possible to update the system?****

– Sure. It is possible. Use the micro-USB port included in the Active Charger. Review the specific section of this manual for that.

Why is the Head Unit flashing when the battery is close to being drained?****

– The head unit LED bar will light up in the color of the engaged assist level and show the actual state of your battery charge. When battery charge goes below 10%, the Head Unit LED bar starts flashing to warn you about this status, when charge goes below 5%, flashing becomes faster to warn about an eventual ordered shutdown of the system at any time.

The X20 System is too aggressive or not powerful enough, how can I reduce or increase the power?****

– Sure. X20 System includes the capability to adjust the power, acceleration, and reactiveness. For a proper adjustment, install the My-SmartBike APP, pair your eBike and go to Motor Settings. Custom setup gives to you the opportunity to set up your own power definition.

What is the range with the iX250 and iX350 batteries?****

– Range depends on your weight and cargo carried, elevation of terrain, wheel size, assist used, motor setup defined, speed and type of battery installed. As reference we can use this table:
– Remember that you can always add the External Range e185 extender that will close to double your iX250 inner battery.

How long does it take to charge the inner battery?****

– It is possible to get 80% of SOC after the first 2 hours of charging. The last part of the charge will take more time depending on the inner battery version installed. Maximum charging time is around 4 hours. Five minutes after reaching the max SOC the eBike is automatically switched OFF.

My display or Head Unit Control shows an error, what do I have to do?****

– A malfunction shall be shown as an error or warning on the head unit. Please connect the My SmartBike APP from MAHLE to check the code number that identifies the malfunction and share it with an authorized Dealer or Customer Service.

Your Head Unit Control flashes orange.?****

– X20 functionality is limited and therefore the Head Unit shows you a warning. A malfunction will be shown as an error or warning on the Head Unit. Please, connect the My SmartBike APP from MAHLE to check the code number that identifies the malfunction and share it with an authorized Dealer or Customer Service.

My Head Unit Control flashes red?****

– X20 functionality is compromised and therefore the head unit shows you an error. A malfunction will be shown as an error or warning on the head unit. Please connect the My SmartBike APP from MAHLE to check the code number that identifies the malfunction and share with an authorized Dealer or Customer Service.

Can I use a third-party charger?****

– NO. The Active Charger is a device that establishes a digital communication with the batteries. If you do use NON-MAHLE original equipment, you run the risk of destroying components and voiding the warranty terms.

Is it possible to use third-party Range Extenders?****

– NO. The Range Extender is a device that establishes a digital communication with the batteries. If you do use NON-MAHLE original equipment, you run the risk of destroying components and voiding the warranty terms.

What is the consequence of tampering with the eBike system?****

– Tampering will cause a direct security and safety issue that will affect the normal operation mode designed, running a high risk of suffering personal injuries and losing the normal warranty terms. Only use MAHLE official components to avoid that.

6.5. Error Codes
This is a short list of the potential error codes that might occur in the HMI. For further information, get in touch with your local dealer or the MAHLE technical service:
-> Flashing Red (ERROR)
-> Flashing Orange (WARNING)

Check the connections. If there is no recovery go to your dealer.
30| | OVER_CURRENT_PROTECTION
Restart the system. If there is no recovery go the dealer.
32| | COMM_HMI_ECU_ERROR
Error in the HMI – ECU Communication. Check the connections. Needs to go to assistance 0 to assist again. If there is no
recovery, go to your dealer.
33| | NO_SPEED_SENSOR_INFO
Speed Sensor error. If there is no recovery, go to your dealer.
43| | TORQUE_FAULT
Torque sensor error. Review the connections. If there is no recovery, go to your dealer.
44| | LOW_VOLTAGE_PROTECTION
Battery voltage too low. Charge the battery.
45| | OVER_VOLTAGE_PROTECTION
Battery voltage too high. Discharge the battery.
46| | HALL_SENSORS_FAULT
Motor sensor error. If there is no recovery, go to your dealer.
47| | ECU_OVER_TEMPERATURE_PROTECTION
Motor controller temperature too high. Let the system cool down.
49| | BATTERY_CURRENT_ERROR
Battery current too high, reduce the assistance. If there is no recovery, go to your dealer.
50| | BMS_COMMUNICATION_FAULT
Error in the BMS – ECU Communication. If there is no recovery, go to your dealer.
51| | COMMUNICATION_FAULT_LOST_FRAME_JOB_1
Warning, communication problem. If there is no recovery, go to your dealer.
52| | DRIVER_ERROR_VG_UNDERVOLTAGE
Motor controller voltage too low, charge the battery. If there is no recovery, go to your dealer.
53| | DRIVER_ERROR_VG_UNDERVOLTAGE
Motor controller voltage too low, charge the battery. If there is no recovery, go to your dealer.
54| | DRIVER_ERROR_OVERCURRENT
Motor controller current too high, reduce the assistance. If there is no recovery, go to your dealer.
55| | DRIVER_ERROR_VDD_UNDERVOLTAGE
Motor controller voltage too low, charge the battery. If there is no recovery, go to your dealer.
56| | CADENCE_INVALID
Cadence sensor error. If there is no recovery, go to your dealer.
57| | SPEED_PLAUSABILITY
Speed sensor error. If there is no recovery, go to your dealer.
59| | SPEEDS_PLAUSABILITY
Speed sensor error. If there is no recovery, go to your dealer.
61| | HARD_MOTOR_BLOCK
Motor error. If there is no recovery, go to your dealer.
62| | EXCEED_TICK_SHIFT
Motor controller FW error. Re-start the eBike. If there is no recovery, go to your dealer.
67| | CAN_UDS_DLC
Communication problem. Restart the system and review connections. If there is no recovery, go to your dealer.
69| | PHASE_ZEROING_ERROR
Power system error. If there is no recovery, go to your dealer.
70| | DU_UNDER_TEMP
Motor under temperature. Please go to a warmer place.
71| | DU_OVER_TEMP
Motor over temperature. Please go to a cooler place.
72| | DU_SNS_UNDER_TEMP
Motor sensors under temperature. Please go to a warmer place.
73| | DU_SNS_OVER_TEMP
Motor sensors over temperature. Please go to a cooler place.
74| | G EARSET_OVERSPEED
Motor over speed. Please reduce the speed of the eBike. If there is no recovery, go to your dealer.
77| | UNBALANCE_PHASE_CURRENT
Power system error. If there is no recovery, go to your dealer.
79| | CAN_OFF_LONG
Communication error. If there is no recovery, go to your dealer.
80| | POWER_STAGE_ERROR
Power system error. If there is no recovery, go to your dealer.
84| | ANALOG_INPUT_ERROR
Motor controller sensors error. If there is no recovery go to your dealer.
85| | MC_UNDER_TEMP
Motor controller under temperature. Please go to a warmer place.
86| | MC_LIB_ERROR
Motor controller internal error. Re-start the system. If there is no recovery go to your dealer.
87| | TCS_POWER_SUPPLY_ERROR
Torque and cadence sensors power supply error. Re-start the eBike. If there is no recovery, go to your dealer.
88| | MOTOR_CONNECTION_ERROR
Motor error. Restart the eBike. If it doesn’t reset, contact your dealer

HMI demo mode. Assistance goes to 0. If there is no recovery, go to your dealer.
130| | HMI_CONFIGURATION_FAIL
HMI configuration fail. Assistance goes to 0. If there is no recovery, go to your dealer.
132| | CAN_TX_ERROR
HMI Communication error. If there is no recovery, go to your dealer.
133| | CAN_RX_BMS
HMI – BMS communication error. Assistance goes to 0. If there is no recovery, go to your dealer.
134| | CAN_RX_ECU
HMI – ECU communication error. Assistance goes to 0. If there is no recovery, go to your dealer.
136| | MAIN_BUTTON_DIAGNOSIS
Main button error. Assistance goes to 0. If there is no recovery, go to your dealer.
137| | LEFT_BUTTON_DIAGNOSIS
e-Shifter left button error. Assistance goes to 0. If there is no recovery, go to your dealer.
138| | RIGHT_BUTTON_DIAGNOSIS
e-Shifter right button error. Assistance goes to 0. If there is no recovery, go to your dealer.
139| | NOT_CALIBRATED
HMI not calibrated. Assistance goes to 0. If there is no recovery, go to your dealer.
140| | LIMITED_FUNCTIONALITY_IMU
HMI limited functionality. Assistance goes to 0. If there is no recovery, go to your dealer.
144| | ALS_LIMITED
ALS limited functionality. If there is no recovery, go to your dealer.
145| | LIMITED_FUNCTIONALITY_LED
LEDs limited functionality. If there is no recovery, go to the dealer.
160| | ANTITHIETF ACTIVE
Antitheft mode active.

Battery level too low for correct motor operation. The user is recommended to change the battery quickly. Assistance goes to 0.
168| | LOW_VOLTAGE_PACK
Battery level too low for correct motor operation. The user is recommended to change the battery quickly. Assistance goes to 0.
169| | LOW_VOLTAGE_PACK
Battery level too low for correct motor operation. The user is recommended to change the battery quickly. Assistance goes to 0.
170| | DERRATING_ACTIVE_DISCHARGING
High battery temperature. To ensure safety, the engine power will be reduced. Please deactivate the electric assistance or take a break while the battery temperature is decreasing.
171| | IMBALANCE_LIGHT_PACK
Imbalance between cells. The capacity of the battery may be limited. Perform a full charge of the battery as soon as possible.
172| | USB_OVERLOAD_OR_SHORTCIRCUIT
An overcurrent or short-circuit has occurred in the USB charger line. The bike can work properly except for the USB line.
If there is no recovery, go to your dealer to check the conditions of the battery and auxiliary wiring.
173| | LIGHTS_OVERLOAD_OR_SHORTCIRCUIT
An overcurrent or short-circuit has occurred in the lights line. Check the condition of the bike lights and the wiring to the battery. If there is no recovery, go to your dealer.
174| | BACKUP_OVERLOAD_OR_SHORTCIRCUIT
An overcurrent or short circuit has occurred in the lights line. Check the condition of the bike lights and wiring to the battery. If there is no recovery, go to your dealer. Bike can work properly except for the lights (Power OFF).
180| | CHARGE_OVERCURRENT
An overcurrent occurred during the charging process. Check that the charger is in good condition. If the problem persists, go to your dealer.
181| | DISCHARGE_OVERCURRENT
Battery has suffered an overcurrent. This may be due to the motor demanding more peak power than the battery can deliver. Assistance level goes to 0. Reduce the assistance level and check the wiring. If the problem persists, go to your dealer.
182| | SHORTCIRCUIT
Critical error of the BMS. If the problem persists, go to your dealer.
183| | OPEN_CELL_WIRE
Failure in the internal wiring of the battery. Assistance level goes to 0. If the problem persists, go to you dealer.
184| | IMBALANCE_SEVERAL_CELL
Severe imbalance between cells. Assistance level goes to 0. Please perform a full charge of the battery as soon as possible.
185| | PACK_OVERTEMPERATURE
High battery temperature. The battery cells are suffering severe degradation from high temperature. Assistance level goes to 0. Please go to a cooler place.
186| | PACK_UNDERTEMPERATURE
Low battery temperature. The battery cells are suffering and degradation from low temperature. Assistance level goes to 0.
Please go to a warmer place for better cell life.
187| | PACK_OVERTEMPERATURE_CHARGING
The temperature is too high to charge the battery. Assistance goes to 0. Please goes to a cooler place for better cell life.
188| | PACK_UNDERTEMPERATURE_CHARGING
The temperature is too low to charge the battery. Assistance goes to 0. Please go to warmer place for better cell life.
189| | OVERVOLTAGE_PROTECTION_PACK
Battery pack voltage is more than the max allowed. Please stop the charging process and try to discharge it.
190| | UNDERVOLGATE_PROTECTION_PACK
Battery pack voltage is less than the minimum allowed. Assistance level goes 0. It is recommended to charge the battery as soon as possible.
191| | OVERVOLTAGE_PROTECTION_CELL
Cell voltage is more than the max allowed. Please stop the charging process and try to discharge it.
192| | UNERVOLTAGE_PROTECTION_CELL
Battery pack voltage is higher than the maximum allowed. Assistance level goes to 0. It is recommended to charge the battery as soon as possible.
193| | FET_OVERTEMPERATURE
BMS MOSFET temperature failure. If the problem persists, go to your dealer.
194| | HMI_1_OVERLOAD_OR_SHORTCIRCUIT
There is an overcurrent fault on the HMI 1 line. Assistance goes to 0 and power OFF. Disconnect HMI 1 and connect the remote to HMI 2 line.
195| | HMI_2_OVERLOAD_OR_SHORTCIRCUIT
There is an overcurrent fault on the HMI 2 line. Assistance goes to 0 and power OFF. Disconnect HMI 2 and connect the remote to HMI 1 line.
196| | MCON_OVERLOAD_OR_SHORTCIRCUIT
There is an overcurrent fault on the MCON line. Assistance level goes to cero. If the problem persists, go to your dealer.
197| | FATAL_SOFTWARE_ERROR
Critical error of the BMS. Assistance goes to 0. If the problem persists, go to your dealer.
198| | CAN_COMMUNICATION_ERROR
There are security errors in the BMS communications. Assistance level goes to 0. Avoid using NON MAHLE original equipment.
200| | CRITICAL_ERROR
Critical communication in the BMS. Assistance goes to 0. If the problem persists, go to your dealer.
201| | REVERSE_CURRENT
Reverse current error. Please check that the motor is not breaking the eBike. If the problem persists, go to your dealer.

RE battery level too low for correct motor operation. It is recommended to charge the RE quickly. Assistance goes to 0.
209| | LOW_BATTERY_PACK
RE battery level too low for correct motor operation. It is recommended to charge the RE quickly. Assistance goes to 0.
210| | DERRATING_ACTIVE_CHARGING
High charging temperature. Please place RE in cool environment for charging. To avoid damage to the RE charging speed
has been slowed down.
211| | DERATING_ACTIVE_DISCHARGING
High RE temperature. The RE cells are suffering from high temperature. To ensure safety, the motor power will be reduced.
Please switch off the RE or decrease assist level to recover operation temperature.
212| | IMBALANCE_LIGHT_PACK
Imbalance between RE cells. The capacity of the range extender may be limited. Please perform a full charge of the RD as
soon as possible.
221| | CHARGE_OVERCURRENT
An overcurrent occurred while charging process. Assistance goes to 0. Please check that the charger and range extender are in good condition. If error persist replaces the hardware.
222| | DISCHARGE_OVERCURRENT
The RE has suffered an overcurrent. They may be due motor has demanded more power than the RE can deliver. Assistance goes to 0. Check the status of wiring or decrease assist level.
223| | SHORTCIRCUIT
Critical error of the RD. If the problem persists, go to your dealer.
224| | OPEN_CELL_WIRE
Failure in the internal wiring of the RE. Assistance level goes to 0. If the problem persists, go to your dealer.
225| | IMBALANCE_SEVERAL_CELLS
Imbalance between RE cells. The capacity of the RE may be limited. Perform a full charge of the battery as soon as possible.
226| | PACK_OVERTEMPERATURE
The temperature of the RE is too high. Assistance goes to 0. Please cold down the RE for better cell life.
227| | PACK_UNDERTEMPERATURE
The temperature of the RE is too low. Assistance goes to 0. The RD cells are suffering a degradation from low temperature. Please warm the RE for better cell life.
228| | PACKOVERTEMPERATURE CHARGING
The temperature is too high to charge the RE. Please go to a cooler place to charge.
229| | PACK_UNDERTEMPERATURE_CHARGING
The temperature is too low to charge the RE. Please go to a warmer place to charge.
230| | OVERVOLTAGE_PROTECTION PACK
RE pack voltage is more than the max allowed. Please stop charging the RE and try to discharge it.
231| | UNDERVOLGATE_PROTECTION_PACK
RE pack voltage is less than the minimum allowed. It is recommended to charge the battery as soon as possible.
232| | OVERVOLTAGE_PROTECTION_PACK
Cell voltage of the RE is more than the max allowed. Please stop the charging process and try to discharge it.
233| | UNERVOLTAGE_PROTECTION_CELL
RE pack voltage is higher than the maximum allowed. It is recommended to charge the battery as soon as possible.
234| | FET_OVERTEMPERATURE
RE BMS MOSFET temperature failure. If the problem persists, go to your dealer with the RE.
238| | FATAL_SOFTWARE_ERROR
Critical error of the RE. Assistance goes to 0. If the problem persists, replace the RE.
239| | CAN_COMMUNICATION_ERROR
There are security errors in the RE communications. Assistance goes to 0. Avoid using NON MAHLE original accessories.
240| | POWER_OFF
241| | BMS_COMM_ERROR
Internal error in the communication of internal components of the BMS. Assistance level goes to 0. If the problem persists, replace the battery.
242| | REVERSE_CURRENT
Reverse current error. Assistance goes to 0. Check the motor is not breaking the eBike. If the problem persists, go to your dealer.

Charger overtemperature. Please go to a cooler place to lower the temperature of the charger.
249| | CHARGER_SHORTCIRCUIT
Charger power error. Review the wiring. Unplug and plug again the charger. If the problem persists, please go to your dealer.
250| | CHARGER_OVERVOLTAGE
Charger overvoltage. Unplug and plug again the charger. If the problem persists, go to your dealer.
251| | CHARGER_OVERCURRENT
Charger overcurrent. Unplug and plug again the charger. If the problem persists, please go to your dealer.
252| | CHARGER_TIMEOUT
Charger communication error. Unplug and plug again the charger. If the problem persists, go to your dealer.
253| | CHARGER_CAN_COMMUNICATION
Charger communication error. Review the connectors. Unplug and plug the charger. If the problem persists, please go to your
dealer.

MAHLE X20 System
V.1.0.1 – 04/2022

References

• Home - MAHLE SmartBike Systems
• MAHLE X20 Conformity Declaration

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