BAFANG MM G510.500 18 027 User manual

1
DEALER MANUAL MM G510.1000
CONTENT
1 Introduction 
1.1 Advantages 2
1.2 Scope of Application 2
1.3 Product Naming Protocol 2
1.4 Drive Unit Appearance 3
1.5 Drive Unit Structure and Dimensions 4
1.6 Main Technical Parameters 5
2 Installation 6
2.1 List of Tools to be used 6
2.2 Welding Frame Adapter 7
2.3 Mounting Drive Unit 7
2.4 Cable Connection 9
2.5 Mounting Drive Unit Cover 9
2.6 Chain Wheel Parts Installation 10
2.7 Crank Installation 10
2.8 External Speed Sensor Installation SR SD02.01 11
3 Cabling 14
3.1 Connection of the Battery Cable to the Drive Unit 14
3.2 Connection of the Speed Sensor to the Drive Unit 14
3.3 Connection of the EB-BUS to the Drive Unit 15
3.4 Connection of the Headlight Cable to the Drive Unit 15
3.5 Connection of the Headlight to the Drive Unit 16
4 List of Materials 17
4.1 Drive Unit - MM G510.1000 17
4.2 Cables 18
5 Service and Warranty Policy 19
Notes 20
CONTENT
MM G510.1000

2DEALER MANUAL MM G510.1000
1 INTRODUCTION
1.1 Advantages
• Use of torque measurement, pedal-assist
speed measurement and wheel-speed mea-
surement; the system has a dual feedback
protection of the speed signals to ensure
safety and reliability of the system
• High starting torque, maximum torque of
more than 160 N.m, especially suitable for
hill climbing
• High efficiency, low power consumption,
longer range
• Low noise, smooth operation
1.2 Scope of Application
The drive unit works properly in the following
environmental conditions:
• Ambient temperature: -20 to + 55°C ;
• 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
Protocol
There is a badge on the housing, showing infor-
mation as follows:
MM G510. 500 18 027 F3 R320 0001
A B C D
AMM: Mid motor
BG510: Motor model
C500: Rated motor power
D18: Stator turns
E027: Connection combination sort
FF3: Measurement and control equipment
number
GR320: Production date, 20th March,2017
H0001: Production serial number, ranging
from 0000 to 9999; 0001 is the production
serial number of the first motor
Labelling part : QR code+48V
E F G H

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INTRODUCTION
DEALER MANUAL MM G510.1000
1.4 Drive Unit Appearance

4DEALER MANUAL MM G510.1000
1.5 Drive Unit Structure and Dimensions

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INTRODUCTION
DEALER MANUAL MM G510.1000
1.6 Main Technical Parameters
Drive unit model MM G510.500 18 027 MM G510.750 12 027 MM G510.1000 12 027
Rated voltage (V) 48 48 48
Rated power (W) 500 750 1000
Rated efficiency (%) ≥82% ≥82% ≥82%
Rated rotating speed
(rpm) 150±10 150±10 150±10
Maximum torque (Nm) ≥100 ≥140 ≥160
Chain wheel 44T/40T 44T/40T 44T/40T
Noise (dB) ≤55 ≤55 ≤55
Water-proof grade IP66 IP66 IP66
Certification CE ROHS/EN14766/
EN14764/REACH
CE ROHS/EN14766/
EN14764/REACH
CE ROHS/EN14766/
EN14764/REACH
Operating environment -20℃~55℃-20℃~55℃-20℃~55℃

6DEALER MANUAL MM G510.1000
2 INSTALLATION
2.1 List of Tools to be used
Use of the Tools Tools
To fasten screw onto the frame adapter and the
drive unit Internal hexagonal wrench
To fasten nuts onto the frame adapter and the
drive unit Socket spanner
To install chain cover Cross screwdriver
To fix and remove the chain wheel lock nut Dedicated tool
To fasten M15 bolt on the crank mounting Internal hexagonal wrench

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INSTALLATION
DEALER MANUAL MM G510.1000
2.2 Welding Frame Adapter
IQC inspection specification for the frame adapter is 53.0 (+0.3/ 0). After
welding, the frame adapter need to heat treat together with bicycle frame to
ensure the dimension of drive unit installation, the concentricity and the
location of mounting hole. It is not allowable to there is paint on the six
mounting surfaces and in the six mounting holes and M4 threaded hole of the
frame adapter. The three M4 screw holes in the frame adapter shall not be
deformed which are used to mount plastic cover.
2.3 Mounting Drive Unit
Align the three mounting holes of the drive unit with the mounting holes in the bike frame and mount
the drive unit onto the bicycle frame.
Pay attention to the outgoing directions of the cables. Please note that the cables should not be squee-
zed by the drive unit.

8DEALER MANUAL MM G510.1000
M8 dedicated screw stem
1401280000003
M8 flat washer-A level
1401060000196
M8 lock nut
1401080000127
dedicated socket spanner
A
B
C
D
1) Align the three mounting holes of the drive unit with the mounting holes in the bike frame.
From the right of the bike frame, insert the three dedicated M8 screw stem into the three mounting holes
in the bike frame and the drive unit, and out from the left.
2) From the left side, fasten the three M8 lock nuts and washers onto the screw stem, tighten torque is
35N.m

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INSTALLATION
DEALER MANUAL MM G510.1000
2.4 Cable Connection
Connect the connectors of all cables to the connectors of the cables of drive unit (the method of cable
arrangement shall be suit for frame adapter. The power bus, which is made up of a positive battery cable,
a negative battery cable and battery communication cables (optional), is connected to the battery cables
at the drive unit). After cables connection, place the cables neatly.
2.5 Mounting Drive Unit Cover
Use the three M4*8 bolts to fasten drive unit cover into the frame adapter. Tighten torque: 1.5 N.m
Motor cover
1333000000008
cross recess pan head
screw M4*8
1401020000167
A
B

10 DEALER MANUAL MM G510.1000
2.6 Chain Wheel Parts Installation
chain wheel parts
(depend on customer’s
requirement)
spline nut
1401080000131
dedicated tool
A
B
C
Chain wheel installation: align spline teeth of the drive unit with spline teeth on the chain wheel parts
and insert chain wheel, use dedicated tool to fasten anticlockwise the spline nut onto the drive unit,
tighten torque is 35N.m
2.7 Crank Installation
Fasten the right crank onto the bottom bracket on the right with a M15 inner hexagonal bolt, tighten
torque is 35-40N.m (350-400kgf.cm), Install the left crank in the same way.
Awater-proof M15 in-
ternal hexagonal screw
1401020000224
Bright crank (depending
on the customer’s requi-
rement)
Cleft crank (depending on
the customer’s require-
ment)

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INSTALLATION
DEALER MANUAL MM G510.1000
2.8 External Speed Sensor Installation SR SD02.01
Aexternal speed sensor
Bmagnet unit
Cspoke
Dchain stay
Before installing the speed sensor, please make sure the gap between the speed sensor and the magnetic
unit is between 5 and 25 mm.
ADust cap
2301030000003
Bmounting bolt M5×12
Cexternal speed sensor
Dsensor bracket (chain
stay boss)
If the gap is within the specified range, use the mounting bolt to fix the speed sensor.
If the gap is more than 25mm, please put spacers between the sensor and the chain stay boss to reduce
this gap.
Tightening torque: 1.5 – 2 Nm

12 DEALER MANUAL MM G510.1000
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.
Aexternal speed sensor
Bmagnet unit
PS01010702/
2308040000001
Cspoke
Arrange the speed sensor and the magnet unit as shown by the picture above. Mount the magnet unit
onto the spoke.

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INSTALLATION
DEALER MANUAL MM G510.1000
DMounting nut of the
magnet
PS01010701/
2327000000003
Tighten up the mounting nut with a straight slot screwdriver. Tightening torque: 1.5– 2 Nm

14 DEALER MANUAL MM G510.1000
3 CABLING
3.1 Connection of the Battery Cable to the Drive Unit
Afemale connector for the
communication cables
at the battery
amale connector for the
communication cables
at the drive unit
Bfemale connector for
the positive cable at the
battery
bmale connector for the
negative cable at the
drive unit
Cmale connector for the
negative cable at the
battery
cfemale connector for
the negative cable at the
drive unit
The power bus, which is made up of a positive battery cable, a negative
battery cable and battery communication cables, is connected to the
battery cables at the drive unit.
3.2 Connection of the Speed Sensor to the Drive Unit
Emale connector at the
speed sensor
efemale connector at the
drive unit for connection
to the speed sensor
Link the male connector at the external speed-detecting sensor to the female connector for the external
speed-detecting sensor cable at the drive unit.

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CABLING
DEALER MANUAL MM G510.1000
3.3 Connection of the EB-BUS to the Drive Unit
Dmale connector at the
EB-BUS
2105020000099
dfemale connector at the
drive unit for connection
to the EB-BUS
Link the EB-BUS cable to the EB-BUS connector at the drive unit.
3.4 Connection of the Headlight Cable to the Drive Unit
Ffemale connector at the
headlight cable
fmale connector for the
headlight at the drive unit
Link the headlight cable to the connector for the headlight at the drive unit.

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3.5 Connection of the Headlight to the Drive Unit
Gfemale connector at
the headlight cable
gmale connector for
the headlight at the
drive unit
Link the headlight cable to the connector at the drive unit.

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LIST OF MATERIALS
DEALER MANUAL MM G510.1000
4 LIST OF MATERIALS
4.1 Drive Unit - MM G510.1000
4.1.1 Drive Unit Accessories
Name Material No. Quantity Specification
M8 nut 1401080000127 3 M8
M8 bolt 1401280000003 3 M8
M8 spacer 1401060000196 3 M8
4.1.2 Motor Cover Accessories
Name Material No. Quantity Specification
Motor cover 1333000000008 1
cross pan head screw M4×8 1401020000167 3
4.1.3 Chain Wheel Module
Name Material No. Quantity Specification
Spline nut 1401080000131 1
4.1.4 Crank Components
Name Material No. Quantity Specification
Crank mounting screws 1401020000224 2 M15

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4.2 Cables
Name Material No. Quantity Specification
Integrated cables 1 according to order
Speed sensor components 1 according to order
Battery cable 1 according to order
Headlight cable 1 according to order
Taillight cable 1 according to order

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SERVICE AND WARRANTY POLICY
DEALER MANUAL MM G510.1000
5 SERVICE AND WARRANTY POLICY
Suzhou Bafang Motor Science-Technology Co., Ltd (hereinafter referred to as the BAFANG) guarantees:
During the warranty period, BAFANG gives warranty for products bought from BAFANG or dealers, as
long as the reclamation concerns quality defects caused by the material or manufacture. (This only applies
to BAFANG complete drive systems; BAFANG component parts are not covered by the warranty.)
Warranty Period and Scope
The warranty period starts from the date of leaving factory. It is 30 months for motors, and 18 months
for controllers, displays, sensors and other electrical components.
The following faults are not covered by the warranty:
• Damage, failure and/or loss caused by refitting, neglect or improper maintenance, use for competiti-
on or commercial purposes; incorrect or improper use or accidents
• Damage, failure and/or loss due to transport by the purchaser
• Damage, failure and/or loss on/of the product caused by improper installation, adjustment or repair
• Damage, failure and/or loss not caused by the material or manufacture, but by incorrect use by the
purchaser
• Damage, failure and/or loss to the exterior of the product that dooes not affect its function
• Damage, failure and/or loss caused by repair or installation undertaken by repair bases or dealers
unauthorized by BAFANG
• Damage, failure or loss caused by normal wear and tear
BAFANG reserves the right to repair or replace faulty components, and is only obliged to repair or replace
them.
If bike manufacturers or dealers encounter quality issues when using or selling BAFANG products, they
can report the purchase order number and serial number of the product to BAFANG service department.
who will check whether the products are under warranty or not. For products under warranty, BAFANG
will provide free repair or give a replacement. If a repair is necessary after the expiry of the warranty
period, BAFANG will invoice component parts, labor cost and shipping. If the BAFANG system needs
repairing on a bike, please contact the bike manufacturer or dealer directly.
If this warranty statement is against a current law at the place of business of the dealer, the legislation
currently in force shall prevail. BAFANG reserves the right to modify the terms without prior announce-
ment.
For more information, please visit the company website: www.szbaf.com

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NOTES
NOTES