BAFANG MM G32.1000 User manual

DEALER MANUAL HD Drive SystemENSuzhou Bafang Electric Motor Science-Technology Co., LtdNo. 9 Heshun Rd Suzhou Industrial Park 215122, Suzhou [e-mail] www.szbaf.com

1DEALER MAUAL HD DRIVE SYSTEM

DEALER MANUAL HD DRIVE SYSTEM2
CONTENTImportant Notice
4For your Safety 5 61 Drive Unit (MM G32.1000) 71.1 Advantages 71.2 Scope of Application 71.3 Product Naming Protocol 7 1.4 Main Techinialc Parameters 81.5 92 System Installation 102.1 102.2 112.3 Display Installation (DP C10.UART)122.4 Auxiliary Keypad Installation132.5 Battery Rail Installation 152.6 External Speed Sensor Installation SR SD02.01
152.7 Drive Unit Installation 183 System Cabling 253.1 Connection of the Battery Cable to the Drive unit 253.2 Connection of the Speed Sensor to the Drive unit 253.3 Connection of the EB-BUS to the Drive unti
263.4 Connection of the Headlight Cable to the Drive Unit 263.5 Connection of the Headlight to the Drive Unit
274.4 Battery Health Indication
414.5 Battery Installation
425 Display (DP C10.UART) 436.1 Specifications and Parameters of the Display 436.2 Appearance and Dimensions 436.3 Function Overview and Key Definations
446.4Normal Operation
466.5 Parameter Setting 486.6 Error Code Definitions556 List of Materials567.1 Display Unit-DP C10.UART
567.2 Drive Unit -MM G32.1000
567.3 Cables587 Service and Warranty Policy 59Notes 60CONTENTNoteDrive Unit Structure and DimensionsList of Tools to be usedComponent Names4 Battery (Optional) 394.1Using the Battery Properly404.2 Charging the Battery 404.3 Battery Capacity Display
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DEALER MANUAL HD DIRVE SYSTEM
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4 DEALER MANUAL HD DRIVE SYSTEM IMPORTANT NOTICEIMPORTANT NOTICEr The Dealer Manual is to be used by professional e-bike mechanics. Dealers who have not received training on electric bicycle assembly shall not attempt to assemble parts and components by following the Dealer Manual.r
r If in doubt about any part of the manual, do not attempt to install the product. Please consult the local sales office or an electric bicycle dealer for help.r Make sure you read all of the installation manuals delivered with the product.r Do not disassemble or modify the product unless specified by the Dealer Manual.r The Dealer Manual is available on our website (www.szbaf.com). r The dealer shall observe the laws and regulations of the region, the state and the country where the product is sold. Make sure you have read this Dealer Manual carefully in order to use the product properly.To avoid any harms to riders, before assemble the HD motor you must confirm that the bike frame has high mechanical intensity.

5FOR YOUR SAFETYWhen installing this product, be sure to follow the instructions given in the manual!It is recommended that you use only genuine BAFANG parts at all times. Serious injury may result if loose or faulty bolts and nuts suddenly come off.If the product is improperly adjusted, accidents and serious injury can occur.r When performing maintenance operations (for example parts replacement), be sure to wear goggles or eye protection.r Please refer to the website www.szbaf.com or contact the dealer for information on the product not covered by this manual.r Keep this Dealer Manual in a safe place for later reference.Inform the purchaser about the following issues:r Giving too much of your attention to the e-bike display while riding can lead to an accident.r It is important to check that the wheels are properly atted to the bicycle before commencing riding. If the wheels are not securely attached fixed serious injury may result.r When riding a pedal-assisted electric bicycle, you should be fully familiar with the starting-off characteristics of the e-bike before riding it. If the e-bike starts off suddenly, accidents may result.r It is important to turn on the lights when riding in the evening and at night. Instructions on e-bike installation and maintenancer When cabling the product or installing the parts onto the e-bike, be sure to disconnect the battery. Not doing so may result in electric shock.r When installing this product, be sure to follow the instructions given in the manual. If bolts and nuts are not tightened correctly or if the product is damaged, the e-bike may suddenly fall over and serious injury may result.r The frequency of maintenance will vary depending on the usage of the e-bike. The chain should be cleaned periodically using an appropriate chain cleaner. Do not use alkaline or acidic cleaning agents to remove rust under any circumstances. If such cleaning agents are used, they may damage the chain and serious injury may result.
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NOTEImportant information for the purchaser:r Please follow instructions given in the manual for your riding safety.r Examine the battery charger regularly for damage, especially the cable, plug and housing. If the battery charger is damaged, it must not be used until it has been repaired.r Please follow the guidance given by the safety supervisor or the instructions indicated in the manual when using the product. This product is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities or persons lacking experience and knowledge in using the product.r Do not allow children to play near the product.r Please consult the nearest dealer for any errors or problems.r Do not modify the system. Doing so may lead to malfunction of the system.r For information on product installation and adjustment, please consult your dealer.r The product is designed to be fully waterproof to withstand wet weather riding conditions. Howe-ver, do not deliberately immerse it in water.r Do not clean the bicycle with a high-pressure water spray. If water gets into any of the compo-nents, operation problems or rusting may result.r When transporting the product on a car in wet weather, remove the battery and put it in a safe place to stop it from getting wet due to the rain.r Handle the product carefully and avoid subjecting it to any strong shocks.r Some important information given in this manual may also be found on the product labels.r When buying a spare key for the battery, be sure to provide the number on the battery key. Please write down the number and keep it in a safe place.r Use a wrung-out damp cloth to clean the battery and the plastic housing.r For any questions regarding the maintenance and use of the product, please contact your dealer.r Normal wear and tear due to normal use and aging is not within our scope of quality guarantee.r Please contact the seller for software updates. The newest information on software is available on the official Bafang website: www.szbaf.com.HANDLING INFORMATION'($/(5MANUAL HD DRIVE SYSTEM

71 DRIVE UNIT (MM G32.1000)1.1 Advantagesr Use of pedal-assist speed measurement and wheel-speed measurement; the system has a dual feedback protection of the speed signals to ensure safety and reliability of the systemr High starting torque, maximum torque of more than 160 N.m, especially suitable for hill climbingr High effciency, low power consumptionr Low noise, smooth operation1.2 Scope of ApplicationThe drive unit works properly in the following environmental conditions:r Ambient temperature: -20 to + 55℃ ;r Relative humidity: 15-95 % RH; The function of the product is impaired by the presence of any major caustic gas, any medium that affects the product’s electrical insulation properties or any high-intensity magnetic field.1.3 Product Naming ProtocolThere is a badge on the housing, showing information as follows: MM G32.1000 15100001 48V
1000W A B C D
A MM G32.1000 Name of the drive unitB 1501 Date of production, January 2015 in this example; 0001 Production serial number, ran-ging from 0000 to 9999; 0001 is the production serial number of the first motorC 48V Rated voltage suitable for 36V drive systemsD 1000 W Rated motor power
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DRIVE UNIT(MM G32.1000) 1.4 Main Technical ParametersRated voltage (DCV)36 /48Rated power (W)750 /750 1000 1250Rated efficiency (%)≥ 80%Rated rotating speed (rpm) 130~150Maximum torque (N.m)≥ 160Chain wheelOptional chain guardfull chain guard / P-shaped chain guardWeight (Kg)3.9Sensorspedal assist speed sensor, and bicycle wheel speed sensor and temperature sensorNoise (dB)< 55Working environment-20°C~55°CDust-proof/ water-proof gradeIP65 CertificationFunctionsLight function: DC 500mA/6V headlight & rearlight46TCE/ UL / ROHS / EN14764DEALER MANUAL HD DRIVE SYSTEM

91.5 Drive Unit Structure and Dimensions
Dimension A 215mm
Dimension B φ210mm（46T）Dimension C 123mm
Dimension D 68 / 100 / 110 / 120mm
Dimension E 175/190/200/210mm
Dimension F 50 / 65 / 70 / 75mm
Dimension G 88 / 103 / 108 / 113mm
DEALER MANUAL HD DRIVE SYSTEM

10 2 SYSTEM INSTALLATION2.1 List of Tools to be usedComponentsUse of the ToolsToolsDisplayTo tighten M3 & M4 screws2,5mmInternal hex wrenchDrive Unit To fasten M6 & M8 & M33 bolts and nutsonto theframe adapter and the drive unit Internal hexagonalwrench and two dedicatd tools To fasten M8 screws on the crank mounting Internal hexagonal wrenchSpeed SensorTo install the iron magnetStraight slot screwdriverTo tighten M5 screws of the speed sensorPhillips screwdriverBatteryInternal hex wrench OptionalDEALER MANUAL HD DRIVE SYSTEMSYSTEM INSTALLATIONDelicated tools 1 for bottom bracket and drive unit assemblyDelicated tools 2 for bottombracket and drive unit assembly

112.2 Component NamesB A
A Drive unitB Front chain wheelC External speed sensorD Battery(Optional)E Auxiliary keypadF DisplayE
F
EF
CD
DEALER MANUAL HD DRIVE SYSTEM

12 2.3 Display Installation (DP C10.UART) Rubber clamping ring Left and right display clamps for the φ22.2 handlebar: Left and right display clamps for the φ25.4 handlebar: One or two rubber clamping rings may be needed depending on the diameter of the handlebar (the applicable handlebar specicatons are φ22.2, φ25.4 and φ31.8). Open the left or right display clamp, and insert one or two clamping rings into the right position of the display clamp as shown in the picture above. Insert the clamping ring(s) to each of the two display clamps and mount them onto the handlebar. Use an interanl hex wrench to fasten the left and right clamps onto the handlebar. display clampC hex socket head cap screws M4×8
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A
A
B
B
C
C
DEALER MANUAL HD DRIVE SYSTEMSYSTEM INSTALLATION

13Adjust the angle of the display so that you can easily see the display screen when riding. After the angle has been adjusted, tighten the screws to the specified torque.Tightening torque: 1 N.m2.4 Auxiliary Keypad Installation
A keypad clampOpen the auxiliary keypad and assemble it onto a position that is easy for operation. Adjust the angle of the auxiliary keypad to ensure that the keypad is easy to see seen during riding. (Applicable to the handlebar whose external diameter is φ22.2mm) DEALER MANUAL HD DRIVE SYSTEM

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2,5mmB hex socket head cap screw M3×8Fix the keypad onto the handlebar with a screw. Then tighten the fixing screw with an internal hex wrench. H female connector at the displayh male connector at the EB-BUSMatch the female connector at the display with the male connector at the EB-BUS as shown in the picture above.
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h
HSYSTEM INSTALLATIONTightening torque:1 N.mDEALER MANUAL HD DRIVE SYSTEM

152.5 Battery Rail Installation Align the mounting holes of the carrier with the mounting holes of the battery rail. Fasten the battery rail onto the battery carrier with hex socket head screws (M5).Tightening torque: 2 N.mChoosing a corresponding battery and under the help of professional mechanics or local dealers to assemble it.2.6 External Speed Sensor Installation SR SD02.01 external speed sensor magnet unit spokecable of speed sensor chain stayBefore installing the speed sensor, please make sure the gap between the speed sensor and the magnetic unit is between 3 and 5 mm. DEALER MANUAL HD DRIVE SYSTEMD
D
A
A
E
E
B
B
C
C
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L

16 external speed sensorIf the gap is within the specified range, use the mounting bolt to fix the speed sensor.If the gap is more than 25 mm, please put spacers between the sensor and the chain stay boss to reduce this gap. Tightening torque: 1.5-2 N.m Arrange the speed sensor and the magnet unit as shown in the picture above. When installing the magnet unit, make sure its center is aligned with the center of the speed sensor’s induction zone.SYSTEM INSTALLATION A
Bcable tiesA
B
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DEALER MANUAL HD DRIVE SYSTEM

17 external speed sensor magnet unit spokeArrange the speed sensor and the magnet unit as shown by the picture above. Mount the magnet unit onto the spoke. D Mounting nut of the magnet Tighten up the mounting nut with a straight slot screwdriver. Tightening torque: 1.5-2 N.m
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C
C
B
B
A
A
D
D
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2.7 Drive Unit Installation battery cable external speed sensor cable EB-BUSCables should be arranged in advance according to the e-bike type and the cabling system before installing the drive unit. chain wheel 5-M5 screw Pay attention to the outgoing directions of the cables. Please note that the cables should not be squeezed by the drive unit.h
C
C
A
A
A
B
B
B
A
B
Assemble the drive unit from right side of bike frame into bottom bracket.DEALER MANUAL HD DRIVE SYSTEMSYSTEM INSTALLATION

19 B
Adrive unitbottom bracket B
Afixed holder2-M6 screw AA
B B
C
CM8 screw(dedicated BB)Put the fixed holder on the bottom bracket. Fasten it with M6 screw. Tightening torque: 10 N.mDedicated: fasten it with M8 screw. Tightening torque: 20 N.mDEALER MANUAL HD DRIVE SYSTEM
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Dedicated bottom bracket internal hole, machining it toΦ33.6mmAssemble the drive unit from right side of bike frame into bottom bracket.Dedicated Normal B B
AA