Maxon BIKEDRIVE User manual

maxon BIKEDRIVE AIR Operating Manual
mint | 2022-08 | 9473424-01 1-1
Operating Manual

Table of Contents
maxon BIKEDRIVE AIR Operating Manual
1-2 mint | 2022-08 | 9473424-01
1 CONTENT AND SYMBOLS 5
1.1 Currentness of the operating manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 DRIVE SYSTEM 7
2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 SYSTEM OVERVIEW 9
3.1 Components / scope of delivery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 System components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2.1 Drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2.2 POWERTAB / Battery SOC indicator . . . . . . . . . . . . . . . . . . . . . . . 11
3.2.3 Battery BX250I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2.4 Range Extender BX250E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2.5 Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2.6 Charging socket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2.7 Speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2.8 Remote switch for mountain bikes. . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2.9 Remote switches for racing and gravel bikes . . . . . . . . . . . . . . . . . 16
3.2.10 Light module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2.11 Installation of non BIKEDRIVE AIR accessories . . . . . . . . . . . . . . . 17
4 COMMISSIONING AND OPERATION 19
4.1 POWERTAB function overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1.1 Selecting the support level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.1.2 Individually configuring the support levels with the Connect app . . 20
4.1.3 POWERTAB energy supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.1.4 Meanings of the LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2 Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.3 Installing and removing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.4 Safety alerts and warning information for the battery . . . . . . . . . . . . . . 22
4.5 Using the charger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.5.1 Connecting the charger to the power grid . . . . . . . . . . . . . . . . . . . . 25
4.5.2 Charging process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.5.3 Maintenance and service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.6 Safety alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.7 Range Extender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.7.1 Installing the Range Extender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
TABLE OF CONTENTS

Table of Contents
maxon BIKEDRIVE AIR Operating Manual
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4.7.2 Changing the Range Extender . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.7.3 Meanings of the LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.8 Safety alerts and warning information for the Range Extender . . . . . . 28
5 MAINTENANCE 31
5.1 After an accident . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.2 Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.3 Cable routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6 CLEANING AND CARE 33
7 TRANSPORT 35
8 LIABILITY FOR MATERIAL DEFECTS 37
9 DISPOSAL 39
9.1 General information / disposal instructions . . . . . . . . . . . . . . . . . . . . . . 39
9.1.1 Recycling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
9.2 Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
9.2.1 Second use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
9.3 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
LIST OF FIGURES 41
LIST OF TABLES 43

Table of Contents
maxon BIKEDRIVE AIR Operating Manual
1-4 mint | 2022-08 | 9473424-01
• • p a g e i n t e n t i o n a l l y l e f t b l a n k • •

Content and symbols
Currentness of the operating manual
maxon BIKEDRIVE AIR Operating Manual
mint | 2022-08 | 9473424-01 2-5
1 CONTENT AND SYMBOLS
This operating manual only contains specific information about your
BIKEDRIVE AIR and should be used in combination with the operating manual of
the bike (Owner’s Manual). Please read the Owner’s Manual in its entirety before
using your BIKEDRIVE AIR. If you do not have a printed version of the Owner’s
Manual, it can be downloaded from the website of the dealer, or contact your local
dealer.
Additionally, this operating manual contains important information that increases the
safety, makes it possible to achieve a long service life for the BIKEDRIVE AIR, and
increases the enjoyment of riding with the e-bike. Disregarding the content of the
operating manual can cause damage to the vehicle and personal injuries.
Make sure that your authorized dealer provides you with all documents that belong
to the product. If certain information in this manual contradicts the product informa-
tion of a component manufacturer, please contact your local dealer.
The following symbols are used in the operating manual:
Indicates a potentially hazardous situation. Noncompliance can lead to
severe injuries.
Indicates a possibly hazardous situation or an unsafe practice.
Noncompliance can lead to injuries or damage to components.
Indicates an important aspect. Noncompliance can lead to damage to
components.
1.1 Currentness of the operating manual
The operating manual of the BIKEDDRIVE AIR is continuously checked to
ensure that it is up to date. The manual at hand reflects the knowledge
available at the time of printing. We recommend visiting our website at
maxonbikedrive.com/de/service to inform yourself about any changes. There
you can also find the current version of the operating manual as a PDF.
Safety alerts:
• Read this operating manual prior to use.
• Store the operating manual for future use.
• Closely read the operating manual for the optional components used.

Content and symbols
Currentness of the operating manual
maxon BIKEDRIVE AIR Operating Manual
2-6 mint | 2022-08 | 9473424-01
Never open the electric component of the BIKEDRIVE AIR yourself. Maintenance
must be performed by a specialist. Opening components automatically voids the
warranty.
Modifying the components or using components that are not intended for the
BIKEDRIVE AIR is not permitted and can critically affect the safety. Any
modifications or use of third-party components voids the warranty.
After a long ride, the BIKEDRIVE MX AIR drive unit can heat up significantly. This
poses risk of burns.

Drive system
Intended use
maxon BIKEDRIVE AIR Operating Manual
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2 DRIVE SYSTEM
Congratulations on your purchase of the BIKEDRIVE AIR drive system. You have
chosen a drive system with the latest technology.
The bike equipped with the BIKEDRIVE AIR drive system has been developed for
the current electric bike market. The support is adjusted by means of a controller
that evaluates the data of three sensors (speed, cadence, and torque) and
regulates the motor depending on the selected level of support. Once a speed of 25
km/h is reached, no support is provided any more. However, you can ride faster
than 25 km/h using your own strength without electromotive support and without
additional resistance.
2.1 Intended use
Legal provisions
Inform yourself about the applicable statutory regulations in your country or at your
place of residence prior to commissioning your bike.
Your BIKEDRIVE AIR is intended for transporting one person on asphalt roads as
well as on paved and unpaved tracks. The permissible load (rider + accessories +
luggage) depends on the bike manufacturer, who is also responsible for providing
this information.
The BIKEDRIVE AIR is not intended for the following:
• Use in races / competitions
• Cleaning with a high-pressure water jet
• Transport on the outside of a car in rainy weather
• Charging the bike in an outdoor location where it is subject to moisture or
intense direct sunlight
The intended use can be limited by:
• The safety alerts in this operating manual
• The chapter “Commissioning and operation” in this operating manual
• The country-specific traffic regulations
• The country-specific regulations on registration for use in road traffic
Use of the BIKEDRIVE AIR is not recommended for the following user groups:
• Persons with restricted physical, sensory, or mental abilities
• Persons who are unable to safely operate the vehicle due to their size

Drive system
Intended use
maxon BIKEDRIVE AIR Operating Manual
3-8 mint | 2022-08 | 9473424-01
Modifications to the BIKEDRIVE AIR aimed at increasing the motor power or
the maximum support speed, pose a danger to your safety while riding. There
is risk of consequences under traffic, registration, insurance, regulatory, and
criminal law.
Rotating parts, such as wheels, crank arms, or pedals, can pull in clothing,
transported objects, and even body parts.
• Always wear close-fitting clothes, a helmet, and goggles.
• Wear shoes that have soles with good grip and that are appropriate for the ped-
als.
• Do not fasten any objects to your handlebar that could swing into the front wheel.
A bike equipped with BIKEDRIVE AIR accelerates faster than a conventional
bicycle. Always remember that other road users cannot know that you are
capable of such acceleration.
• First practice using your BIKEDRIVE AIR in a traffic-restricted zone before using
it in road traffic.
Active and passive light systems must be installed in accordance with the safety
regulations of the road traffic legislation of the corresponding country. The safety
equipment must be checked regularly and, if needed, repaired by a qualified
specialist.

System overview
Components / scope of delivery
maxon BIKEDRIVE AIR Operating Manual
mint | 2022-08 | 9473424-01 4-9
3 SYSTEM OVERVIEW
3.1 Components / scope of delivery
Figure 4-1 BIKEDRIVE AIR | Components
Read all safety alerts and instructions.
Failure to comply with the safety alerts and instructions
can cause electric shock, fire, and/or severe injuries.
1Speed sensor 2Charging socket
3Drive unit 4Range Extender BX250E
5Battery BX250I 6Light module
7POWERTAB 8Remote switch
Charger (not shown)
78 5
12346

System overview
System components
maxon BIKEDRIVE AIR Operating Manual
4-10 mint | 2022-08 | 9473424-01
Store all safety alerts and instructions for future reference.
The term “battery” used in this operating manual refers to all original
BIKEDRIVE AIR batteries.
•Do not get distracted by the display of the POWERTAB. If you do not
concentrate on the traffic only, you risk being involved in an accident.
• Read and observe the safety alerts and instructions in all operating manu-
als of the e-bike as well as in the operating manual of your
BIKEDRIVE AIR system.
3.2 System components
Depending on the configuration of your BIKEDRIVE AIR e-bike, some illustrations in
this operating manual might slightly differ from your actual bike.
3.2.1 Drive unit
• Do not remove and open the drive unit yourself. Only specialist personnel are
authorized to open it and it must be repaired with original spare parts exclusively.
Unauthorized opening of the system voids the warranty.
• Modification of the drive unit and installing other, unapproved products is not
permitted.
The drive unit consists of an efficient brushless maxon internal-rotor motor and a
low-noise performance planetary gearhead. The integrated electronics and sensors
ensure sensitive support in all riding situations. The patented, innovative freewheel
has no noticeable resistance – both when backpedaling as well as when riding
without electrical support.
Figure 4-2 BIKEDRIVE AIR | Drive unit

System overview
System components
maxon BIKEDRIVE AIR Operating Manual
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Table 4-1 Technical data | Drive unit
3.2.2 POWERTAB / Battery SOC indicator
The POWERTAB control element gives you full control over your e-bike. You can
connect it to a smartphone via Bluetooth (BLE), or to other devices from Garmin,
Sigma, or o-synce via ANT+. You can choose between three levels of support and
configure them individually. In the factory settings, there are three preset ride
modes: Level 0 - I - II - III. The SOC of the e-bike battery is displayed on the
POWERTAB. An inconspicuous and intuitive remote switch for racing bike or
mountain bike handlebars is available optionally.
Figure 4-3 BIKEDRIVE AIR | POWERTAB
Table 4-2 Technical data | POWERTAB
Technical data – BIKEDRIVE MX AIR drive unit
Nominal voltage 36 V
Power 250 W
Ambient temperature for operation -20°C to +40°C
Protection IP5K5 (in acc. with ISO 20653:2013)
Technical data – POWERTAB
Battery indicator
Support levels I - II - III
Bluetooth (BLE) and ANT+
Light switch (optional)

System overview
System components
maxon BIKEDRIVE AIR Operating Manual
4-12 mint | 2022-08 | 9473424-01
3.2.3 Battery BX250I
The lithium-ion battery is permanently mounted in the down tube and only the
specialist dealer is permitted to remove it. The battery is charged with a charger.
Depending on the bike manufacturer, the charging port for the charger can be in
different positions.
Figure 4-4 BIKEDRIVE AIR | Battery BX250I
Table 4-3 Technical data | Battery BX250I
3.2.4 Range Extender BX250E
A Range Extender is available for longer rides and adds another 250 Wh. It works
like a power bank and charges the integrated battery. The Range Extender is
screw-mounted to the frame with a holder, using the eyelets for the bottle holder.
The Range Extender is integrated into the system by means of a cable connected to
the charging socket. The cable is frame-specific and might differ from manufacturer
to manufacturer.
Technical data – Battery BX250I
Nominal voltage 36 V
Capacity 250 Wh
Weight (battery only) 1.4 kg
Charging time (0 ... 100%) 3.5 h
Charging time (0 ... 80%) 2.5 h

System overview
System components
maxon BIKEDRIVE AIR Operating Manual
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Figure 4-5 BIKEDRIVE AIR | Range Extender BX250E
Table 4-4 Technical data | Range Extender BX250E
3.2.5 Charger
Various chargers are available for the BIKEDRIVE AIR, to cover the country-
specific voltages. The customer-friendly bayonet lock can easily be connected to
the charging socket.
Figure 4-6 BIKEDRIVE AIR | Charger
Technical data – Range Extender BX250E
Nominal voltage 36 V
Capacity 250 Wh
Charging time (0 ... 100%) 3.5 h
Charging time (0 ... 80%) 2.5 h
PRELIMINARY

System overview
System components
maxon BIKEDRIVE AIR Operating Manual
4-14 mint | 2022-08 | 9473424-01
Table 4-5 Technical data | Charger
3.2.6 Charging socket
The charging socket is installed in different positions, depending on the manufac-
turer. The pin assignment of the charging socket and charging plug is specific to the
BIKEDRIVE AIR. The cover can be mounted on both sides. When not in use, the
cover should be closed.
Figure 4-7 BIKEDRIVE AIR | Charging socket
Technical data – Charger
Input voltage 220 – 240 V (also available as a 110 V
version)
Input frequency 50 – 60 Hz
Nominal output voltage 36 V
Output current 2 A ±0.2 A
Environment
Operating temperature -0°C to +40°C
Storage temperature -40°C to +55°C
Operation with humidity 20...85%
LED status display
Red turns green Battery full
Standby mode Green
Charging process Red
Full mode Green

System overview
System components
maxon BIKEDRIVE AIR Operating Manual
mint | 2022-08 | 9473424-01 4-15
3.2.7 Speed sensor
Configuring the speed sensor
• The magnet must be positioned on the spoke or brake disk.
• The sensor is positioned on the frame side and must not move.
• The permissible distance between the speed sensor and magnet is 1 mm to
8 mm.
• The magnet may only pass through one line of the sensor.
Information:
If the distance between the speed sensor and magnet is outside of the specified
range, or the speed sensor has not been connected correctly, a system error is
generated and is displayed by a red LED on the POWERTAB. When this condition
occurs, no support can be expected from the BIKEDRIVE AIR. If the problem
cannot be solved, please contact an authorized specialist dealer.
To check whether the speed sensor is functioning correctly, use the maxon Connect
app or a connected display. If the Connect app shows a plausible speed, the speed
sensor is functioning correctly. If the speed display jumps from one value to the
next, the sensor is positioned incorrectly. Check that the magnet only passes
through one line of the sensor.
Figure 4-8 BIKEDRIVE AIR | Distance between speed sensor and magnet
* The permissible distance between the sensor and magnet is 1–8 mm.
1Magnet 2Switch point marking
3Sensor
*
1
2
3

System overview
System components
maxon BIKEDRIVE AIR Operating Manual
4-16 mint | 2022-08 | 9473424-01
3.2.8 Remote switch for mountain bikes
The mountain bike remote switch can be used universally and is suitable for instal-
lation on straight handlebars. Using the switch, the support level can be increased
or decreased.
Figure 4-9 BIKEDRIVE AIR | Remote switch for mountain bikes
3.2.9 Remote switches for racing and gravel bikes
The remote switches consist of two buttons that can be mounted on the handlebars
of racing bikes and gravel bikes. The support level can be decreased at any time
using the left switch or increased using the right switch.
Figure 4-10 BIKEDRIVE AIR | Remote switches for racing and gravel bikes
3.2.10 Light module
The light module is optional and, depending on the manufacturer, has possibly
already been installed in series, or it can be retrofitted. Have the installation
performed by an authorized dealer.
Table 4-6 Technical data | Light module
Technical data – Light module
Nominal voltage 12 V
Maximum power 18 W

System overview
System components
maxon BIKEDRIVE AIR Operating Manual
mint | 2022-08 | 9473424-01 4-17
3.2.11 Installation of non BIKEDRIVE AIR accessories
When accessories, such as a child seat or bike trailer, are installed, the accessory
manufacturer or a specialist dealer must verify that the accessory is compatible with
the BIKEDRIVE AIR.

System overview
System components
maxon BIKEDRIVE AIR Operating Manual
4-18 mint | 2022-08 | 9473424-01
• • p a g e i n t e n t i o n a l l y l e f t b l a n k • •

Commissioning and operation
POWERTAB function overview
maxon BIKEDRIVE AIR Operating Manual
mint | 2022-08 | 9473424-01 5-19
4 COMMISSIONING AND OPERATION
This chapter describes how to get your BIKEDRIVE AIR ready for riding.
In the standard delivery, the BIKEDRIVE AIR is shipped fully mounted by the
specialist dealer. If the delivery was nonstandard, contact your specialist
dealer.
4.1 POWERTAB function overview
To switch on the e-bike, press the On/Off button on the POWERTAB.
A short press of the button switches on the bike. When it starts up, no support level
is active.
To switch off the e-bike, you have to press the button for around 5 seconds.
Note:
• If the bike is not used, it switches off automatically after 15 minutes.
• Always switch off the e-bike if you are not using it.
If a light has been permanently mounted on the bike, the On/Off button of the
POWERTAB has to be pressed once again.
Figure 5-11 BIKEDRIVE AIR | POWERTAB
1Button for decreasing the support 2Support levels: 0 - I - II - III
3Error LED 4Service LED
5Status LED 6Active additional battery (Range
Extender)
1
2
3
4
5
6
9
8
7

Commissioning and operation
POWERTAB function overview
maxon BIKEDRIVE AIR Operating Manual
5-20 mint | 2022-08 | 9473424-01
4.1.1 Selecting the support level
The selected support level is displayed as bars.
• If no bar is lit, support level Zero has been selected and the bike does not
provide any support.
• One lit bar symbolizes level I.
• Two lit bars symbolize level II.
• Three lit bars symbolize level III.
Zero The motor support has been switched off. The e-bike behaves like a normal bicycle.
You can switch to level Zero at any time for “normal” cycling. The BIKEDRIVE AIR
e-bike behaves as if it is completely switched off. It freewheels internally, and you
will not notice its presence at all.
Level I, II &
III
When you pedal, the motor supports you. The levels have been predefined by the
manufacturer. Three sensors (torque, velocity, and cadence) continuously provide
data that is used to give the rider the best possible support. With the Connect app,
each level can be configured individually.
4.1.2 Individually configuring the support levels with the Connect app
maxon offers end users a Connect app, which is available for iOS and Android. With
the Connect app, the rider can individually configure the support levels and use the
cell phone as a display on the handlebar.
4.1.3 POWERTAB energy supply
The POWERTAB is supplied with voltage by the main battery.
7State of charge (SOC) 8On/Off button and light switch
9Button for increasing the support
Google Play
Store iOS App Store
Connect app