BAFANG MAX Drive System User manual

dealer Manual
MAX Drive System
EN
Suzhou Bafang Electric Motor
Science-Technology Co., Ltd
No. 9 Heshun Rd
Suzhou Industrial Park
215122, Suzhou China
[email protected]
www.szbaf.com

1DEALER MANUAL MAX DRIVE SYSTEM

2
DEALER MANUAL MAX DRIVE SYSTEM
CONTENT
Important Notice 4
For your Safety 5
Note 6
1 Drive Unit (MM G33.350) 7
1.1 Advantages 7
1.2 Scope of Application 7
1.3 Product Naming Protocol 7
1.4 Main Technical Parameters 8
1.5 Drive Unit Structure and Dimensions 9
2 System Installation 10
2.1 List of Tools to be used 10
2.2 Component Names 11
2.3 Display Installation (DP C01.RS232.7) 12
2.4 Auxiliary Keypad Installation 13
2.5 Battery Rail Installation 15
2.6 External Speed Sensor Installation SR SD02.01 15
2.7 Drive Unit Installation 18
3 System Cabling 25
3.1 Connection of the Battery Cable to the Drive Unit 25
3.2 Connection of the Speed Sensor to the Drive Unit 25
3.3 Connection of the EB-BUS to the Drive Unit 26
3.4 Connection of the Headlight Cable to the Drive Unit 26
3.5 Connection of the Headlight to the Drive Unit 27
4 Chain guard Installation 28
4.1 Installation of the Front Chainwheel 28
4.2 Chain Guard Installation (optional) 30
4.3 Crank Installation 37
5 Battery (BT C01.690) 39
5.1 Using the Battery Properly 40
5.2 Charging the Battery 40
5.3 Battery Capacity Display 41
5.4 Battery Health Indication 41
5.5 Battery Installation 42
6 Display (DP C01.RS232.7) 43
6.1 Specifications and Parameters of the Display 43
6.2 Appearance and Dimensions 43
6.3 Function Overview and Key Definitions 44
6.4 Normal Operation 46
6.5 Parameter Setting 48
6.6 Error Code Definitions 55
7 List of Materials 56
7.1 Display Unit - DP C01.RS232.7 56
7.2 Drive Unit - MM G33.350 56
7.3 Cables 58
8 Service and Warranty Policy 59
Notes 60
CONTENT

3DEALER MANUAL MAX DRIVE SYSTEM

4
DEALER MANUAL MAX DRIVE SYSTEM
IMPORTANT NOTICE
IMPORTANT NOTICE
• 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.
• 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.
• Make sure you read all of the installation manuals
delivered with the product.
• Do not disassemble or modify the product unless
specified by the Dealer Manual.
• The Dealer Manual is available on our website
(www.szbaf.com).
• 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.

5DEALER MANUAL MAX DRIVE SYSTEM
FOR YOUR SAFETY
When 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.
• When performing maintenance operations (for
example parts replacement), be sure to wear
goggles or eye protection.
• Please refer to the website www.szbaf.com or
contact the dealer for information on the product
not covered by this manual.
• Keep this Dealer Manual in a safe place for later
reference.
Inform the purchaser about the following
issues:
• Giving too much of your attention to the e-bike
display while riding can lead to an accident.
• It is important to check that the wheels are
properly fitted to the bicycle before commencing
riding. If the wheels are not securely attached
fixed serious injury may result.
• 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.
• It is important to turn on the lights when riding in
the evening and at night.
Instructions on e-bike installation and
maintenance
• 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.
• 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.
• 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.

6
DEALER MANUAL MAX DRIVE SYSTEM
HANDLING INFORMATION
NOTE
Important information for the purchaser:
• Please follow instructions given in the manual for
your riding safety.
• 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.
• 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.
• Do not allow children to play near the product.
• Please consult the nearest dealer for any errors
or problems.
• Do not modify the system. Doing so may lead to
malfunction of the system.
• For information on product installation and
adjustment, please consult your dealer.
• The product is designed to be fully waterproof to
withstand wet weather riding conditions. Howe-
ver, do not deliberately immerse it in water.
• 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.
• 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.
• Handle the product carefully and avoid subjecting
it to any strong shocks.
• Some important information given in this manual
may also be found on the product labels.
• 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.
• Use a wrung-out damp cloth to clean the battery
and the plastic housing.
• For any questions regarding the maintenance and
use of the product, please contact your dealer.
• Normal wear and tear due to normal use and
aging is not within our scope of quality guarantee.
• Please contact the seller for software updates. The
newest information on software is available on
the official Bafang website: www.szbaf.com.

7DEALER MANUAL MAX DRIVE SYSTEM
1 DRIVE UNIT (MM G33.350)
1.1 Advantages
• Use of torque measurement, 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 system
• High starting torque, maximum torque of more
than 80Nm, 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 environ-
mental 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 information
as follows:
MM G33.350 14010001 36V 250W
A B C D
AMM G33.350 Name of the drive unit
B1401 Date of production, January 2014 in this
example; 0001 Production serial number, ran-
ging from 0000 to 9999; 0001 is the production
serial number of the first motor
C36V Rated voltage suitable for 36V
drive systems
D250W Rated motor power

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DRIVE UNIT (MM G33.350)
DEALER MANUAL MAX DRIVE SYSTEM
1.4 Main Technical Parameters
Rated voltage (DCV) 36 / 43
Rated power (W) 250 350 / 250 350
Rated efficiency (%) ≥80%
Rated rotating speed (rpm) 100± 5
Maximum torque (Nm) ≥80
Chain wheel 36T (recommended), 38T (optional), 42T (optional)
Optional chain guard full chain guard / P-shaped chain guard
Weight (Kg) 3.9
Sensors pedal assist speed sensor, pedal assist torque sensor and bicycle wheel
speed sensor and temperature sensor
Noise (dB) <55
Working environment -20°C~55°C
Dust-proof/ water-proof grade IP66
Certification CE ROHS/ EN14766/ EN14764/ REACH
Functions Light function: DC 500mA/6V headlight & rearlight
Optional functions: Bluetooth module, gear sensor, reprogramming function

9DEALER MANUAL MAX DRIVE SYSTEM
1.5 Drive Unit Structure and Dimensions

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SYSTEM INSTALLATION
DEALER MANUAL MAX DRIVE SYSTEM
2 SYSTEM INSTALLATION
2.1 List of Tools to be used
Components Use of the Tools Tools
Display To tighten M3 & M4 screws 2,5mm Internal hex wrench
Drive Unit
To fix the chain
wheel retaining
ring
Special tool
To remove the chain wheel retaining
ring
Plier for the
retaining ring
To tighten M4 screws on the chain
guard Cross screwdriver
To fasten M6 bolts and nuts onto the
frame adapter and the drive unit
Internal hexagonal
wrench
To fasten M8 screws on the crank
mounting
Internal hexagonal
wrench
Speed Sensor
To install the iron magnet Straight slot
screwdriver
To tighten M5 screws of the speed
sensor Phillips screwdriver
Battery To fasten the battery plate onto the
carrier using M5 screws Internal hex wrench
The tool used to install the retaining ring onto the hub
Tool code (GZ-MM G31-5025)

11 DEALER MANUAL MAX DRIVE SYSTEM
2.2 Component Names
B ACD
E F
B
A
C
D
ADrive unit
BFront chain wheel
CExternal speed sensor
DBattery
EAuxiliary keypad
FDisplay

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SYSTEM INSTALLATION
DEALER MANUAL MAX DRIVE SYSTEM
2.3 Display Installation (DP C01.RS232.7)
ARubber clamping ring
(whose inner diameter is
Ø22.2 or Ø 25.4)
2316020400007
2316020400008
Left and right display
clamps for the Ø22.2
handlebar:
Left clamp
-2316020400017
Right clamp
-2316020400018
Left and right display
clamps for the Ø25.4
handlebar:
Left clamp
-2316020400007
Right clamp
-2316020400008
One or two rubber clamping rings may be needed depending on the diameter of the
handlebar (the applicable handlebar specifications are Ø22.2, Ø 25.4 and Ø31.8).
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 internal hex
wrench to fasten the left and right clamps onto the handlebar.
Bdisplay clamp
Chex socket head cap
screws M4×8

13 DEALER MANUAL MAX DRIVE SYSTEM
Adjust 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: 1Nm
2.4 Auxiliary Keypad Installation
Akeypad clamp
Open 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 Ø22.2mm)

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SYSTEM INSTALLATION
DEALER MANUAL MAX DRIVE SYSTEM
2,5mm
Bhex socket head cap
screw M3×8
Fix the keypad onto the handlebar with a screw. Then tighten the fixing screw with an internal hex wrench.
Tightening torque: 1Nm
Hfemale connector at the
display
hmale connector at the
EB-BUS
Match the female connector at the display with the male connector at the EB-BUS as shown in the picture above.

15 DEALER MANUAL MAX DRIVE SYSTEM
2.5 Battery Rail Installation
Ahex socket head cap
screw (M5)
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: 2Nm
2.6 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 25mm.

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SYSTEM INSTALLATION
DEALER MANUAL MAX DRIVE SYSTEM
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– 2Nm
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.

17 DEALER MANUAL MAX DRIVE SYSTEM
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.
DMounting nut of the
magnet
PS01010701/
2327000000003
Tighten up the mounting nut with a straight slot screwdriver. Tightening torque: 1.5– 2Nm

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SYSTEM INSTALLATION
DEALER MANUAL MAX DRIVE SYSTEM
2.7 Drive Unit Installation
Abattery cable
Btaillight cable
Cexternal speed sensor
cable
Dheadlight cable
EEB-BUS
Cables should be arranged in advance according to the e-bike type and the cabling system before installing the drive
unit.
Amounting holes
Bdrive unit
MM G33.350
Align the three mounting holes of the drive unit with the mounting holes in the bike frame.
Pay attention to the outgoing directions of the cables. Please note that the cables should not be squeezed by the drive unit.

19 DEALER MANUAL MAX DRIVE SYSTEM
CM6 nuts
1401080000101
Insert, from the right, special M6 nuts into the mounting holes in the bike frame and the drive unit.
DM6 bolts
1401080000099
Insert, from the left, the M6 bolts into the bike frame so that they will come to contact with the nuts. Tighten bolts
onto nuts to the specified torque.
Tightening torque: 18– 20Nm