Failure to follow the warnings and instructions may result in death or serious injury.
Save all safety warnings and instructions for future reference.
The term battery pack used in these operating instructions refers to all original Bosch eBike battery packs.

WARNING

CAUTION

Using your Manual

In addition to the functions outlined here, changes to software relating to troubleshooting and functional modifications may be introduced at any time.

Graphics
The bicycle shown in this manual may differ slightly from your bicycle, but will be similar enough to help you understand our instructions.
RIGHT-HAND and LEFT-HAND sides are determined by facing in the direction the bicycle will travel when going forward. When you see a broken line (——), the item referred to is hidden from view.

On-product warning labels

Robert Bosch GmbH
D-72757 Reutlingen
www.bosch-ebike.com

WARNING

To reduce the risk of injury, explosion, or fire, user must read instruction manual.. Do not crush, puncture, dissassemble, short terminals, or dispose in fire.. Do not use battery once it has been impacted, sustained water damage or visibly damaged. . Charge battery only with Bosch eBike chargers.

Warning labels have been placed on the Bosch eBike System for your protection. Read and follow the instructions of the labels on the product carefully. If a label becomes illegible or comes off, contact your Bosch bicycle dealer to obtain a replacement. Replacement safety labels are provided by Bosch at no charge.

Handling the lithium-ion battery pack

Safety warnings for Bosch eBike batteries

Read and understand all safety warnings and instructions. Failure to follow the below warnings could result in death or serious injury.
Save all safety warnings and instructions for future reference.
The term battery pack used in these operating instructions refers to all original Bosch eBike battery packs.

DANGER

WARNING

The safety of both our customers and our products is important to us. Our eBike batteries are lithium-ion batteries which have been developed and manufactured in accordance with the latest technology. We comply with or exceed the requirements of all relevant safety standards. When charged, these lithium-ion batteries contain a high level of energy. If a fault occurs (which may not be detectable from the outside), in very rare cases and under unfavorable conditions, lithium-ion batteries can catch fire.

Privacy notice
When you connect the eBike to the Bosch DiagnosticTool 3, data about the eBike batteries (e.g. temperature, cell voltage, etc.) is transferred to Bosch eBike Systems (Robert Bosch GmbH) for the purposes of product improvement. You can find more information about this on the Bosch eBike website at www.bosch-ebike.com.

Product description and specifications

Product features PowerTube

All representations of bike components are schematic and can deviate from your eBike.

  1. Key for the battery lock
  2. Battery lock
  3. PowerTube battery safety hook
  4. PowerTube battery (pivot)
  5. Socket for charging connector
  6. Operation/battery charge indicator
  7. On/off button
  8. PowerTube battery safety restraint

All representations of bike components are schematic and can deviate from your eBike.

  1. Key for the battery lock
  2. Battery lock
  3. PowerTube battery safety hook
  4. Socket for charging connector
  5. Operation/battery charge indicator
  6. On/off button
  7. Locking mechanism
  8. Pull strap
  9. Axial rail
  10. PowerTube battery (axial)
  11. Upper axial PowerTube holder

Intended Use
The Bosch eBike batteries are intended exclusively to provide the power supply for your eBike drive unit and must not be used for any other purpose.

Technical data

Li-ion battery                                PowerTube 750
Product code Horizontal BBP3775
Product code Vertical BBP3776
Rated voltage V= 36
Nominal capacity Ah 20.1
Li-ion battery                                PowerTube 750
Energy Wh 750 A)
Operating temperature °F 23 to 104
Storage temperature °F 50 to 104
Permitted charging tem-

perature range

°F 32 to 104
Weight, approx. lbs 9.7
Protection rating IP54

A) Advertised battery energy capacity is an approximation.
Due to manufacturing tolerances measured capacity may not always match the advertised capacity.

Fitting

The battery has a temperature monitoring function which only allows it to be charged within a temperature range of 32 °F to 104 °F.

If the temperature of the battery is outside this charging range, three of the LEDs on the battery charge indicator (6) will flash. Disconnect the battery from the charger and let it acclimatize.

CAUTION

If the battery capacity is less than 5 %, all the LEDs on the battery charge indicator (6) on the battery will go out. The display function of the on-board computer,
however, will carry on working.
Once charging is complete, disconnect the battery from the charger and the charger from the mains.

Inserting and removing the battery

  1. To remove the PowerTube battery (4), open the lock (2) using the key (1). The battery will be unlocked and fall into the safety restraint (8).
  2. Press on the safety restraint from above. The battery will be unlocked completely and fall into your hand. Pull the battery out of the frame.
    Note: As a result of varying designs, the battery may need to be inserted and removed using a different method. Read the eBike manufacturer’s operating instructions.
    Inserting the PowerTube battery (pivot) (see figure B)

In order for the battery to be inserted, the key (1) must be inserted into the lock (2) and the lock must be open.

  1. To insert the PowerTube battery (4), place it so that its contacts are in the lower holder of the frame.
  2. Push the battery upwards until it is held by the safety restraint (8).
  3. Hold the lock open with the key and press the battery upwards until you hear it click into place.
    Check that the battery is secure in all directions.
  4. Always secure the battery by closing the lock (2)
    1. otherwise the lock may open and the battery may fall out of the holder.
      Always remove the key (1) from the lock (2) after locking it. This prevents both the key from falling out and the battery from being removed by unauthorized third parties when the eBike is not in use.

Removing the PowerTube battery (axial) (see figure C)

  1. To remove the PowerTube battery (12), open the lock (2) using the key (1), remove the key (1) and fold the locking mechanism (9) to the side.
  2. Use the pull strap (10) to pull the battery (12) out of the frame.
    Note: As a result of varying designs, the battery may need to be inserted and removed using a different method. Read the eBike manufacturer’s operating instructions.

Inserting the PowerTube battery (axial) (see figure D)

In order for the battery to be inserted, the locking mechanism (9) must be folded to the side. At this point, the key (1) must not be inserted in the battery lock (2).

  1. To insert the PowerTube battery, insert it into the frame with the socket for the charging connector (5) facing upwards until the battery clicks into place.
  2. Close the locking mechanism (9), insert the key (1) into the battery lock (2) and secure the battery. Make sure that the safety hook (3) is hooked in at the opening of the axial rail (11).
  3. Check that the battery is secure in all directions.
    Always remove the key (1) from the lock (2) after locking it. This prevents both the key from falling out and the battery from being removed by unauthorized third parties when the eBike is not in use.

Operation

Start-up

If no power is drawn from the eBike drive for about 10 minutes (e.g. because the eBike is not moving) and no button is pressed on the on-board computer or the control unit of the eBike, the eBike system will switch off automatically.
The battery is protected against deep discharge, overloading, overheating and short-circuiting by the “Electronic Cell Protection (ECP)”. In the event of danger, a protective circuit switches the battery off automatically.

If a fault is detected in the battery, two of the LEDs on the battery charge indicator (6) will flash. Contact an authorized bicycle dealer if this happens.
Behavior in the event of a fault
The Bosch eBike battery must not be opened, even for repairs. There is a risk that the Bosch eBike batterycould catch fire, e.g. due to a short circuit. This risk arises if a Bosch eBike battery which has already  been opened is reused at a later point in time.
Therefore, do not repair the Bosch eBike battery in  the event of a fault, but have it replaced with an original Bosch eBike battery by your specialist retailer.

Transport

WARNING

Maintenance/cleaning

WARNING

Cleaning

Storing

The service life of the battery can be extended if it is looked after well and especially if it is stored at the correct temperature.

As it ages, however, the capacity of the battery will diminish, even with good care.
A significantly reduced operating period after charging indicates that the battery pack is worn out and must be replaced. You can replace it yourself by purchasing
a genuine Bosch PowerPack from an authorized Bosch eBike dealer.
Recharging the battery before and during storage
When you are not going to use the battery for an extended period (longer than three months), store it at a state of charge of around 30 % to 60 % (when two to three of the LEDs on the battery charge indicator (6) are lit).
Check the state of charge after six months. If only one of the LEDs on the battery charge indicator (6) is lit, charge the battery back up to around 30 % to 60 %.

Note: If the battery is stored with no charge for an extended period of time, it may become damaged despite the low self-discharge and the battery capacity
could be significantly reduced.
Leaving the battery permanently connected to the charger is not recommended.

Storage conditions
If possible, store the battery in a dry, well-ventilated place. Protect it against moisture and water. When the weather conditions are bad, it is advisable to remove the battery from the eBike and store it in a closed room until you use it next, for example.

Store the eBike batteries in the following locations:

For an optimum service life, store the eBike battery at temperatures between 50 °F and 68 °F. Never store it at temperatures below 14 °F or above 140 °F.
Make sure that the maximum storage temperature is not exceeded. Do not leave the battery in your car in the summer, for example, and store it away from direct sunlight.
Leaving the battery on the bicycle for storage is not recommended.

Troubleshooting

Cause                                                                         Corrective measures

Battery defective

Two LEDs flash on the battery.

Contact an authorized bike dealership.

Battery too warm or too cold

Three LEDs flash on the battery.

Disconnect the battery from the charger until the charging temperature range has been reached.

Do not reconnect the battery to the charger until it has

reached the correct charging temperature.

The charger is not charging.

No LEDs flashing (one or more LEDs will remain permanently lit depending on the state of charge of the eBike battery).

Contact an authorized bike dealership.

Charging not possible (no indicator on battery)
Connector not attached properly Check all connections.
Battery contacts dirty Carefully clean the battery contacts.
Socket outlet, cable or charger defective Check the mains voltage, have the charger checked

over by a bike dealership.

Battery defective Contact an authorized bike dealership.

Battery Recycling Program

The drive unit, on-board computer incl. operating unit, battery, speed sensor, accessories and packaging should be disposed of in an environmentally correct manner.
Do not dispose of eBikes and their components with household waste.
Tape or mask off the contact surfaces of the battery pack’s terminals with adhesive tape before disposing of battery packs.
Do not touch severely damaged eBike batteries with your bare hands – electrolytes may escape and cause skin irritation. Store the defective battery in a safe location outdoors. Cover the terminals if necessary and inform your dealer. They will help you to dispose of it properly.

You may recycle your Bosch battery pack by calling 1.800.822.8837.

Documents / Resources

BOSCH BBP3775 Drive System PowerTube 750 [pdf] Owner's Manual
BBP3775, BBP3776, Drive System PowerTube 750
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