MAHLE X20 User manual

MAHLE X20 System
User Manual
V 1.0.2

003
Index
1. Introduction
1.1 General Warning ............................................ 4
1.1.1 About Warnings........................................ 4
1.2 Maintenance, Storage & Transportation .......... 4
1.2.1 Drive Unit, Head Unit & Accessories care.. 5
1.2.2 Battery Packs care ................................... 5
1.2.3 Charger care ............................................ 5
1.2.4 Ebike care ................................................ 5
1.3 Transportation of your eBike system ............... 5
1.3.1 Transportation full eBike by car ............... 5
1.3.2 Transportation full eBike by air ................ 5
1.3.3 Transportation full eBike by train .............. 5
1.3.4 Transportation of batteries for repair ....... 5
1.4 Safe Charging Process...................................6
1.5 Servicing ........................................................ 6
1.6 Recycling........................................................ 6
1.7 Product Certifications ..................................... 6
1.7.1Important information about Head Unit ...... 6
2. General overview
2.1 Specifications ................................................. 9
2.1.1 X20 Drive Unit........................................... 9
2.1.2 X20 Torque & Cadence Sensor ................ 9
2.1.3 iX250 – X20 Internal Battery ..................... 9
2.1.4 iX350 - X20 Internal Battery ..................... 9
2.1.5 Head Unit ............................................... 10
2.1.6 X20 Dropout Drive Unit Connector ......... 10
2.1.7 Charger Port........................................... 10
2.1.8 Active Charger ....................................... 10
2.2 Compatible eBikes .......................................10
3. Operation and use
3.1 Operation Mode ........................................... 11
3.2 Use Cases.................................................... 11
3.2.1 Planned use ...........................................11
3.2.2 Prohibited Use........................................ 11
3.2.3 Operative mode (In the event of malfunction) 11
3.3 Operation ..................................................... 12
3.3.1 Switching the system ON / OFF ............. 12
3.3.2 Automatic System Switching OFF .......... 12
3.3.3 Change the assist level ........................... 12
Control the assist level using the Head Unit .. 12
Control the assist level using e-Shifters......... 12
Control the assist level using Pulsar ONE
display ......................................................... 12
3.4 Switching the lights ON/OFF ........................ 13
3.5 Walk-assist Mode ......................................... 13
3.6 Information of the Head Unit LED .................13
3.6.1 (SOC), State of Charge of the battery .... 14
3.6.2 Current Assist Level................................ 14
3.6.3 Set the intensity of the LEDs................... 14
3.6.4 Other Information displayed by the Head
Unit ................................................................. 14
EnglishEnglish
003
3.7 Operation with the Charger ............................15
3.7.1 X20 SmartBike Active Charger .................15
3.7.2 Charging Process ....................................15
Error while charging process...........................15
3.8 Updating Process...........................................15
3.8.1 Uploading files to the Active Charger........15
3.8.2 Updating eBike system.............................16
3.9 Battery Use ....................................................16
4. Accessories
4.1 Pulsar ONE display.........................................16
4.1.1 Pulsar ONE holders ..................................17
4.2 e-Shifters........................................................17
4.2.1 e-Shifters Installation ................................17
4.3 e185 - Range Extender ..................................18
4.3.1 Range Extender Pack Components..........18
4.3.2 Range Extender Wires ..............................19
5. Application and Services
5.1 My SmartBike phone APP .............................20
5.1.1 Smartphone APP. Main Functions...........20
5.1.2 Smartphone APP. Motor settings............20
5.1.3 Smartphone APP Account creation ........21
5.2 My Smarbike Web APP .................................21
5.2.1 Web APP. Main Functions......................21
5.2.2 Web APP. Account creation...................22
6. Service
6.1 Rear wheel removal and installation ................22
6.1.1 Rear wheel removal ..................................22
6.1.2 Rear wheel installation ..............................23
6.2 Other Services ...............................................23
6.2.1 Freewheel and bottom bracket servicing ..23
6.2.2 Battery, Motor, Head Unit Servicing ..........23
6.2.3 Replacing Automatic Dropout
Connection.............................................. 24
6.3 Warranty ........................................................24
6.4 FAQs ..............................................................24
6.5 Error Codes....................................................25

1. 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.
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.
WARNING
CAUTION
NOTICE
DANGER
X
004
MAHLE X20 System · Introduction
V.1.0.2 - 06/2022

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, Head Unit 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.
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.
CAUTION
Max. 2,8 mm
Min. 8 mm
Max. 10 mm
English
005

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.
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.
WARNING
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
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
006
MAHLE X20 System · Introduction
V.1.0.2 - 06/2022
CAUTION

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.
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.
L’émetteur/récepteur exempt de licence contenu dans le
présent appareil est conforme aux CNR d’Innovation,
Sciences et Développement économique Canada
applicables aux appareils radio exempts de licence.
L’exploitation est autorisée aux deux conditions
suivantes:
1. L’appareil ne doit pas produire de brouillage;
2. L’appareil doit accepter tout brouillage radioélectrique
subi, même si le brouillage est susceptible d’en
compromettre le fonctionnement.
NOTICE
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.
WARNING
English
007
CAN ICES-3(B)/NMB-3(B)
Le présent appareil est conforme aux CNR Innovation,
Sciences et Développement économique Canada
applicables aux appareils radio exempts de licence.
L’exploitation est autorisée aux deux conditions
suivantes:
(1) il ne doit pas produire de brouillage et (2) l’ utilisateur
du dispositif doit étre prêt à accepter tout brouillage
radioélectrique reçu, même si ce brouillage est
susceptible de compromettre le fomctionnement du
dispositif.
CAN ICES-3(B)/NMB-3(B)
The device meets the exemption from the routine
evaluation limits in section 2.5 of RSS 102 and
compliance with RSS-102 RF exposure, users can obtain
Canadian information on RF exposure and compliance.
Le dispositif rencontre l’exemption des limites courantes
d’évaluation dans la section 2.5 de RSS 102 et la
conformité à l’exposition de RSS-102 rf, utilisateurs peut
obtenir l’information canadienne sur l’exposition et la
conformité de rf.
This transmitter must not be co-located or operating in
conjunction with any other antenna or transmitter. This
equipment should be installed and operated with a
minimum distance of 5 millimeters between the radiator
and your body.
Cet émetteur ne doit pas être Co-placé ou ne
fonctionnant en même temps qu’aucune autre antenne
ou émetteur. Cet équipement devrait être installé et
actionné avec une distance minimum de 5 millimètres
entre le radiateur et votre corps.

008
MAHLE X20 System · General Overview
V.1.0.2 - 06/2022
2. 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:
Accessories
Pulsar ONE display e-Shifters
X20 Drive Unit X20 Internal Battery
(iX250 or iX350)
X20 Head Unit
(Button & LED line display)
Wires & adapters
X20 Charging port X20 Torque &
Cadence Sensor
Range Extender

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
English
009

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
010
MAHLE X20 System · General Overview
V.1.0.2 - 06/2022
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

3. 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.
English
011

012
MAHLE X20 System · Operation and Use
V.1.0.2 - 06/2022
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.
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.
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.
NOTICE
NOTICE
Operation
Left Short
Right Short
Left Hold
Right Hold
Assist Down
Assist Up
Reset Data
Turn ON/OFF Lights
Action
Operation
Left Short
Right Short
Left Hold
Right Hold
Assist Down
Assist Up
Lights ON/OFF
Walk Assist
Action

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.
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
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.
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
NOTICE NOTICE
English
013
Control Button Ambient light sensor
RGB Dynamic Line Set screw
NOTICE

014
MAHLE X20 System · Operation and Use
V.1.0.2 - 06/2022
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:
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.
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.
Iluminated LEDs
#7
#6
#5
#4
94 - 100%
82 - 93%
70 - 81%
56 - 69 %
36 - 55%
16 - 35%
0 - 15%
0 - 10 %
0 - 5 %
SOC
#3
#2
#1
#1 (Blink fast)
#1 (Blink slow)
Blink
Slow Blink
Fast
90% 80% 65% 50% 35% 15% 10% 5%
100%
Level
0 - No assist
1 - Minimum
2 - Medium
3 - Max
White
Green
Clear Brown
Purple
Color
#585858
#00710F
#EE420F
#9416FF
RGB
WARNING
Error Warning

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
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. 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
3. Charge process finished
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.
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.
1. Disconnect the charger of the Power outlet
No LED will be operating.
3. Disconnect the charger of your computer
No LED will be operating.
2. Connect the charger to your computer using
micro-USB port
LED of the charger and the Head Unit
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.
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.
English
015
100%
Updating...

016
MAHLE X20 System · Accessories
V.1.0.2 - 06/2022
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.
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.
4. 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.
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)
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.
Remember a battery is considered as a consumable
good.
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
3. Update Completed
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.
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.
NOTICE
Pulsar ONE display
SKU: 330 100 000 00 000
NOTICE