MAHLE e185 User manual

e185 Range Extender
User Manual
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002

003
English
1. Introduction ................................................................................... 4
1.1 General Warnings............................................................................. 4
1.1.1 About Warnings........................................................................ 5
1.2 Maintenance & Storage ................................................................. 6
1.3 Transporting an e185 Range Extender............................................ 7
1.3.1 Transporting an e185 for repair................................................ 7
1.4 Safe Charging Process................................................................... 8
1.5 Servicing ........................................................................................ 9
1.6 Recycling........................................................................................ 9
1.7 Product Certifications ..................................................................... 10
2. Product Overview & Specications............................................... 11
2.1 Compatible Accessories................................................................. 12
3. Operation & Use ............................................................................. 14
3.1 Installation Guide ............................................................................ 14
3.2 Operating mode ............................................................................. 16
3.3 Usage............................................................................................. 16
3.3.1 Intended usage......................................................................... 16
3.3.2 Prohibited usage ..................................................................... 17
3.3.3 Operating mode (in the event of malfunction)............................ 17
3.4 Operation ...................................................................................... 19
3.4.1 System ON/OFF Standalone Switch............................................ 19
3.4.2 System ON/OFF eBike Switch..................................................... 20
3.4.3 Battery State of Charge (SOC)..................................................... 22
3.4.4 Charging Process........................................................................ 23
3.5 Update Process............................................................................. 25
3.5.1 Uploading files to the Active Charger ........................................ 25
3.5.2 Uploading the e185 Range Extender ........................................ 25
3.6 Battery Use ................................................................................... 30
4. Application & Services ................................................................. 31
4.1 My SmartBike Phone App .............................................................. 33
5. Service
5.1 Warranty......................................................................................... 33
5.2 FAQs .............................................................................................. 33
5.3 Error codes..................................................................................... 38

004
1. Introduction
Thank you for choosing the e185 Range Extender for your new SmartBike.
The e185 Range Extender allows you to go further on your travels, helping
you on long journeys that the eBike cannot complete by itself. The My
SmartBike Range Extender enables fast charging. LED bar displays battery
level or performance mode.
Please read this manual carefully before operating the system. Failure to
do so or misunderstanding of the instructions may lead to serious injury or
death.
Products and specifications are subject to change without prior notification.
This document has been drawn up in English and the content herein shall
prevail in the event of any translation error or misunderstanding in the client’s
interpretation of translations herein.
This manual includes instructions for the e185 Range Extender compatible
with the X20 System (or compatible systems).
All relevant documents for the product or any other compatible system,
including this user manual, can be downloaded from our website:
mahle-smartbike.com
MAHLE e185 Range Extender · Introduction
V.1.0.0 - 09/2022
Components must only be replaced with an original MAHLE SmartBike
Systems replacement to maintain the safety of the entire system. Any
tampering, modification or repair by a third party not authorised by MAHLE
shall immediately void the warranty conditions and original certification, and
MAHLE shall not be held responsible in regard to civil liability.
Repairs and replacements must only be performed by MAHLE SmartBike
Systems, hereinafter MAHLE, certified partners.
This manual must not be duplicated except in its entirety, unless prior written
approval has been obtained from MAHLE SmartBike Systems.
1.1. General Warnings
Please pay special attention to any warning symbols on the system, shown
with these graphics.
X
WARNING NOTICE
DANGER CAUTION

005
English
1.1.1. About Warnings
This manual contains DANGER, WARNING, and CAUTION indicators
concerning the consequences of failure to safely use, assemble, maintain,
store, inspect and dispose of MAHLE-equipped eBikes.
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.
Keep all safety warnings and instructions for future reference. Do not open
the e185 Range Extender by yourself. The system is maintenance-free. It
must only be opened by qualified experts. The unauthorised opening of a
system will void the warranty. All Drive Unit and eBike components may only
be replaced with identical components or components that are specifically
approved by your eBike manufacturer. This protects your eBike system from
damage. Do not modify the Drive Unit, the battery or any other component
or add any unapproved products to improve performance or tamper with
the product. There is a risk of injury in the event of accidental activation. Be
careful when touching the surface of your Drive Unit. The surface may heat
up considerably and cause burns to the skin. The walk-assistance function
may only be used when pushing the eBike and may require specific remotes.
There is a risk of injury if the wheels are not in contact with the ground
when using this function. Use only original MAHLE batteries approved by the
eBike manufacturer. Using unauthorised batteries may cause injuries or fire.
Observe your regional and local regulations regarding eBikes and pedelecs.

006
1.2. Maintenance & Storage
The e185 Range Extender and main accessories are designed for long-term
use and require some simple, understandable guidelines to be followed to
extend the lifespan of the MAHLE System by taking proper care during us-
age and cleaning.
These guidelines are as follows:
• 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 adjustment for products not found in the user manual.
• Do not disassemble or alter this product.
• These are small waterproof connectors. Do not repeatedly connect and
disconnect. It may impair the function.
• The components are designed to be fully waterproof 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. These
substances may damage the surfaces.
• Be careful not to let water get into the terminal.
• Unsupervised children must not carry out cleaning or user maintenance.
Products are not guaranteed against natural wear and tear from normal use
and ageing. The e185 Range Extender can be installed in eBikes for kids.
For this type of use, ensure that your child is supervised and follow the eBike
manufacturer’s safety instructions.
MAHLE e185 Range Extender · Introduction
V.1.0.0 - 09/2022

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English
3.5. Updating Process
The system can be updated using the micro-USB port on the active charger.
To perform an update, you need to connect the charger to your computer
and transfer the update files to the charger. Please follow this process.
3.5.1 Uploading files to the Active Charger
1. Disconnect the charger from the power outlet. There should be no LEDs
lit up.
2. Connect the charger to your computer using the micro-USB port
The charger LED and the HMI will turn BLUE.
Copy the extracted update files (update_MUT.bin) to the new Drive Unit
(MAHLE_UTOOL), which will appear on your computer, and safely eject the
new drive unit from your computer.
100%
Updating...

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1.3. Transporting your e185 Range Extender
There are specific regulations for transporting batteries:
• Transport by car: External batteries need to be removed and transported
in a safe area inside the car, in their original box and properly secured with
straps to prevent damage during transport, as these are hazardous goods.
• Transport by air:
The IATA (International Air Transportation Association) will
not transport any eBike batteries.
• Transport by train: In most cases, external eBike batteries are allowed to
be transported inside trains if the train does not provide a specific safe area
for transportation. Check your local regulations or ask your transportation
company before setting off on your trip.
• Public transportation: Our products can be transported by public
transport. There are some places where you are not permitted to take your
e185 Range Extender, so ensure that you find out about the conditions of
carriage in plenty of time. You should also take into account the regulations
and city rules for carrying it through places you intend to travel to before you
start your trip.
Remember that, in any case, the best option is to transport the battery when
the battery level is under 30%.
1.3.1. e185 Range Extender Shipment
If, for any reason, you need to ship the battery, this must be done through an
official service following the specific rules for transporting dangerous goods
and the recommendations from MAHLE and the eBike manufacturer. The
battery needs to be placed in a specific, certified box and all the official
documentation, i.e., the MSDS (Material Safety Data Sheet) report, must be
included. This process cannot be performed by individuals.
MAHLE e185 Range Extender · Introduction
V.1.0.0 - 09/2022

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English
1.4. Safe Charging Process
The Active Charger, which sets up a direct connection with the MAHLE
compatible system for both integrated and external SmartBike batteries,
supplying the correct charging current and ideal cell balancing. Please
use only the MAHLE Active Charger for charging MAHLE e185 Range
Extenders. The charger and batteries are fully qualified for usage under
current regulations in the regions that the X20 System (or compatible
systems) is approved for use.
Before charging the e185 Range Extender, take into consideration the
following:
• Connect the charger directly to a power source. Never use extension
cords.
• Avoid reverse charging.
• Inspect the charger before every use for possible damage to the charger
itself, the wire or the charging plug. Do not cover the charger while charging.
• Regularly inspect the battery. Never charge a battery that you suspect is
damaged or that you know is broken.
• Make sure there is no moisture on the charging socket and plug before
connecting and charging the battery.
• If the battery is very cold or too hot, wait for it to warm up or cool down
before you start charging.
• Keep the connector clean. If any connections have been damaged,
please do not use it.
Be aware of explosive gases. Prevent flames and sparks. Ensure that there
is adequate ventilation during charging. The 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.
WARNING

010
NOTICE
1.5. Servicing
Servicing and replacement may only be performed by approved Service
Partners. Please remember that our components may contain cells that can
be damaged, or a short circuit may occur from drilling into the external case,
which could result in a fire.
The battery’s capacity will decrease over time. During normal use for 2
years or after 500 full charging cycles, the battery’s capacity may lower
to a minimum of 70% of its initial value. 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.
1.6. Recycling
It is our responsibility to ensure the correct recycling of the e185 Range
Extender. Together, we are responsible for minimising the CO2 footprint and
environmental impact. Please ensure the battery is properly recycled when
it reaches the end of its lifespan. Get in touch with your dealer or eBike
manufacturer to find out about the correct recycling process. If the battery
needs to be replaced, please bear in mind that only approved Service
Partners are allowed to replace the internal battery. They can also handle the
recycling of your old battery.
According to European Guideline 2012/19/EU, electrical devices/tools that
are no longer usable must be collected separately and disposed of in an
environmentally-appropriate manner. Do not dispose of your e185 Range
Extender in the normal household rubbish. It must be disposed of according
to local battery disposal regulations. Dealers must provide used battery
collection and appropriate disposal services. If not, contact your MAHLE
dealer.
By collecting and recycling waste, you are doing your bit to save natural
resources and making sure the product is disposed of in an environmentally-
friendly, healthy way.
MAHLE e185 Range Extender · Introduction
V.1.0.0 - 09/2022