BOSCH BDU318Y Electric Bike Owner’s Manual

BOSCH BDU318Y Electric Bike

Product Specifications:
Drive Unit: BDU318Y, BDU338Y, BDU378Y
On-board Computer: BHU3200, BHU3600, BHU3700
ConnectModule: BCM3100
Display Mount: BDS3210, BDS3250, BDS3620, BDS3630
Remote Control: BRC3100, BRC33YY, BRC3600, BRC3800
Battery: BBP324Y, BBP334Y, BBP335Y, BBP354Y, BBP355Y, BBP356Y, BBP357Y, BBP358Y, BBP362Y, BBP375Y, BBP376Y, BBP377Y
Charger: BPC3200 (NZ), BPC3210 (USA), BPC3400 (NZ), BPC3410 (USA)
Display Cable: BCH3611

Product Usage Instructions

Introduction
Thank you for purchasing a Bosch Drive System equipped bicycle. Your Bosch eBike Systems team appreciates having you as a customer and wishes you many years of safe and satisfied use of your bicycle.

About Warnings
The term DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury. Read all safety warnings and instructions to avoid any accidents.

Using Your Operator’s Manual
Follow the instructions provided in all operating manuals of the eBike system and your bicycle to ensure safe usage.

General Warnings

• Read all safety warnings and instructions carefully.
• Save all safety warnings and instructions for future reference. – Take responsibility for your own safety. – Be cautious of the added weight by the Bosch Drive System on your bicycle.

FAQ:

1. Q: Where can I find more information on safety and performance?
   A: You can refer to the online manual available at www.bosch- ebike.com for detailed safety and performance information.

2. Q: How do I recycle the eBike battery?
   A: Refer to the Battery Recycling Program section on page 13 of the manual for instructions on recycling your eBike battery.

Drive Unit
BDU318Y
BDU338Y
BDU378Y

On-board Computer
BHU3200
BHU3600
BHU3700

ConnectModule
BCM3100

Display Mount
BDS3210
BDS3250
BDS3620
BDS3630

Remote Control
BRC3100
BRC33YY
BRC3600
BRC3800

Battery
BBP324Y
BBP334Y
BBP335Y
BBP354Y
BBP355Y
BBP356Y
BBP357Y
BBP358Y
BBP362Y
BBP375Y
BBP376Y
BBP377Y

Charger
BPC3200 (NZ) BPC3210 (USA) BPC3400 (NZ) BPC3410 (USA)

Display Cable
BCH3611

Introduction
Thank You for Purchasing a Bosch Drive System Equipped Bicycle!
Your Bosch eBike Systems team appreciates having you as a customer and wishes you many years of safe and satisfied use of your bicycle.

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 eBike battery used in these operating instructions refers to all original Bosch eBike batteries from the system generation the smart system. Riders must be aware of and follow all applicable rules and regulations related to the operation or use of e-bikes in their local jurisdiction when operating or otherwise using this product. This eBike system has the capability to provide pedal assistance up to 28 mph. Riders must have the reaction, capabilities, experience, maturity, coordination and ability to control a bike at such speed, and to manage traffic, road conditions, and sudden situations, and also to respect the laws and instructions governing bicycle use. In addition, some jurisdictions may set a minimum age for the rider of this eBike. Please check your local jurisdiction for any applicable legal requirements and restrictions.

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 bi-cycle which you may not be used to lift. Avoid injury, use proper lifting techniques.

Using Your Operator’s Manual

Your operator’s manual consists of several parts:

• Operating instructions for the Bosch eBike system (this manual)
• Operating instructions for the drive unit
• Operating instructions for the display or on-board computer
• Operating instructions for the display holder or on-board computer holder
• Operating instructions for the control unit
• Operating instructions for the charger
• Operating instructions for the battery
• Operating instructions for ConnectModule

Read and observe the safety warnings and instructions in all operating instructions of the eBike system and your eBike.

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.

Bosch Drive System Overview

Bicycle View (PowerTube)

Bosch Drive System Components
All representations of bike components are schematic and can deviate from your eBike.

1. Display holder
2. Display/on-board computer
3. Control unit
4. Charger
5. Frame-mounted battery “PowerTube”/”CompactTube”
6. Drive unit
7. ConnectModule

Bicycle View (PowerPack Frame)

Bosch Drive System Components
All representations of bike components are schematic and can deviate from your eBike.

1. Display holder
2. Display/on-board computer
3. Control unit
4. Charger
5. Frame-mounted battery “PowerPack”
6. Drive unit
7. ConnectModule

Bicycle View (PowerPack Rack)

Bosch Drive System Components
All representations of bike components are schematic and can deviate from your eBike.

1. Display holder
2. Display/on-board computer
3. Control unit
4. Charger
5. Rack-mounted battery “PowerPack”
6. Drive unit
7. ConnectModule

Bicycle View (PowerMore)

Bosch Drive System Components
All representations of bike components are schematic and can deviate from your eBike.

1. Display holder
2. Display/on-board computer
3. Control unit
4. Charger
5. Frame-mounted battery “PowerMore”
6. Drive unit
7. ConnectModule

Operating your Bosch Drive System

Getting Ready to Ride

Read and understand all safety warnings and instructions. Failure to follow the below warnings could result in death or serious injury.

• Protect others from death or serious injury. Prevent unauthorized use. Always remove battery from the bicycle when not in use and store in a secure location. Failure to secure your bicycle from unauthorized use can result in death or serious injury to others.
• Read and understand the influences on the operating range when planning your ride (see “Influences on range”, page English – 10).

Before your first ride
Check your bicycle owner’s manual for important information about the bike components, such as the brakes, pedals, gears, gear shifting, etc.

WARNING

• If you have an impairment or disability such as a visual impairment, hearing impairment, physical impairment, cognitive/language impairment, or a seizure disorder, consult your physician before using this product.
• To reduce the risk of serious injury related to exercise, take the following precautions before use: Do not overexert yourself. Use of the Bosch Drive System requires varying amounts of physical activity.

Consult a doctor before using the device if you have any medical condition or issue that affects your ability to safely perform physical activities, or if you:

• are or may be pregnant
• have heart, respiratory, back, joint, or other orthopedic conditions
• have high blood pressure
• have difficulty with physical exercise
• have been instructed to restrict physical activity
• Wearing a helmet can prevent a severe head injury. Whenever riding, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA must meet the US Consumer Product Safety Commission standard, so look for a CPSC reference.
• Riding a Bosch drive system equipped bicycle capable of speeds up to 28 mph requires proficiency in the activity of road cycling. This product can allow you to achieve speeds greater than you may be used to achieving without the aid of motor assistance. It also may allow for riding longer periods of time at a higher speed. Higher speed results in higher forces if a crash occurs. Control your bicycle at all times. Your risk of death or serious injury increases with both speed and age.

The following are required for safe use of this product:

• Knowledge of the laws/safety guidelines/rules of road cycling (riding safely)
• Ability to operate and control a standard road bike
• Experienced rider who is actively riding
• Capable, comfortable and confident riding safely at speed up to 28 mph
• Your bike should match your riding style, be properly adapted to the dimensions of your body, and be well maintained.
• Do not use this product under the influence of drugs and/or alcohol.

WARNING

• While riding, do not become distracted by the onboard computer and always remain alert to all riding conditions. The on-board computer should only be used in a stationary and safe start-up position. Utilize the operating unit to change motor assistance levels while riding.
• Check your bicycle manual for maximum riding weight of your bicycle. Overloading your bicycle can result in component failure which can result in death or serious injury. Typically maximum riding weight is defined by the sum of the rider’s weight plus the weight of any luggage.

In addition to reading and understandings your owner’s manuals, be sure you know or refamiliarize yourself with local laws prior to using this product. Consult your bicycle dealer, local library, bookstore to choose the learning resource best for you.

Intended Use
WARNING

• Understand your bike and its intended use by consulting your bicycle owner’s manual. Using your bike in an unintended manner can result in death or serious injury.
• Using the Bosch Drive System for purposes other than what is was designed for could cause death or serious injury.

Your Bosch drive unit is not intended for towing another bicycle. For trailer towing, consult your bicycle owner’s manual and trailer owner’s manual for towing instructions and towing compatibility.

Safe Start-up Procedure

WARNING

• Follow the safe start-up procedure below. Failure to follow safe start-up procedure can result in death or serious injury.

Preparations
Before starting check the following:

• Check that you have unplugged the battery charger.
• Your battery pack is locked in place (Pull on the battery pack to ensure it is locked in place).
• Remove the battery pack key.

Start Riding

• Sit in the saddle with both feet touching the ground and two hands on the handlebars.
• Once you are in a stable position, turn on the Bosch on-board computer. The Bosch Drive System will always start up in OFF mode.
• Place both hands on the handlebars and begin pedaling.

Notes on cycling with the eBike system

When does the drive take effect?
The drive assists your cycling only when you are pedaling. If you do not pedal, the assistance will not work. The drive output always depends on the pedaling force and cadence that you apply.
With lower force applied or a less frequent cadence, the assistance provided will be lower than that supplied at higher force or a more frequent cadence. This applies irrespective of the assistance level.
The drive automatically switches off at speeds over 28 mph. When the speed falls below 28 mph, the drive automatically becomes available again.
An exception applies to the push assistance function, in which the eBike can be pushed at low speed with-out pedaling. The pedals may rotate when the push assistance is in use.
You can also use the eBike as a normal bicycle with-out assistance at any time, either by switching off the eBike or by setting the assistance level to OFF. The same applies when the eBike battery is drained.

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

• Read and understand the influences on the operating range when planning your ride (see “Influences on range”, page English – 10).

Influences on range
The range is affected by a number of factors, such as:

• Assistance level
• Speed
• Gear shifting behavior
• Tire type and tire pressure
• Age and condition of the eBike battery
• Route profile (gradients) and conditions (road surface)
• Headwind and ambient temperature
• Weight of eBike, rider and luggage

For this reason, it is not possible to predict the range accurately before and during a trip. However, as a general rule:

• With the same assistance level on the drive: The less energy you need to exert in order to reach a certain speed (e.g. by changing gears optimally), the less energy the drive will consume and the higher the range per battery charge will be.
• The higher the selected assistance level under otherwise constant conditions, the smaller the range will be.

Note: Plan your routes so that you can always reach your destination without drive assistance.

Transport

• Always remove the battery pack (except fixed mount 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 transport your eBike attached to the out-side of your car, e.g. on a bike rack, remove the on-board computer and the eBike battery (except fixed mount battery) to avoid damaging them.

If you have any questions about transporting the eBike 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 you suspect that something is loose, do not ride your bike. See your Bosch eBike dealer, only a qualified service provider should perform work on your Bosch Drive System. All nuts, bolts, screws require the correct tightening force. Too little force and the fastener may not hold securely. Too much force and the fastener can strip threads, stretch, deform or break. Either way, incorrect tightening force can result in component failure, which can cause you to lose control and fall.
• If replacing your battery, buy only a genuine Bosch battery pack from an approved source. See your Bosch eBike dealer for original Bosch parts.
• Always switch the battery pack off, when inserting or removing it from the holder. Never attempt to insert or remove the battery pack while riding the bike.
• Do not charge or use your eBike in any area with a potentially explosive atmosphere, such as at a fueling area, or in areas where the air contains chemicals or particles (such as grain, dust, or metal powders). Obey all signs and instructions.
• Do not submerge your eBike components in water, or wash with pressurized hose. Your Bosch drive unit is designed to be water tight to rain water or non-pressure hose washing.
• Note down the manufacturer and the number of the key. In case of loss of the keys, please refer to an authorised Bosch eBike dealer. Please provide the name of the manufacturer and the number of the key.
• Do not paint any components of the Bosch drive system as they may cause premature failure of the component.
• Remove the eBike battery from the eBike before beginning work (e.g. inspection, repair, assembly, maintenance, work on the chain, etc.) on the eBike. When working on permanently in-stalled eBike batteries, take particular care to ensure that the eBike cannot be switched on. Unintentional activation of the eBike poses a risk of injury.

Taking care of your eBike
Please observe the operating and storage temperatures of the eBike components. Protect the drive unit, on-board computer and eBike battery against extreme temperatures (e.g. from intense sunlight with-out adequate ventilation). Extreme temperatures can cause the components (especially the eBike battery) to become damaged.
Have your eBike checked by an expert at least once a year (including mechanical parts, up-to-date of system software).
Please have your eBike serviced and repaired by an authorized bicycle dealer.

After-sales service and advice on using products
If you have any questions about the eBike and its components, contact an authorized bicycle retailer. For contact details of authorized bike dealerships, please visit www.bosch-ebike.com.
Please contact an authorized bicycle dealer if the eBike 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).

Battery Recycling Program
The drive unit, on-board computer incl. operating unit, eBike 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.
You may recycle your Bosch battery pack by calling 1.800.822.8837.

Robert Bosch GmbH
72757 Reutlingen
Germany
www.bosch-ebike.com
0 275 U07 3SS (2023.03) T / 44

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