BAFANG M510 Mid Motor User Manual

Introduction

Product Model: MM G522.250.C

Scope of Application: This motor is designed for electric-powered bicycles, specifically for pedelec use, and is suitable for mountain bikes. It is not intended for competition or other commercial purposes.

Identification: The product features unique identification marks on its housing. These include a 'Labeling part' and a 'Laser part'. It is important to keep this information for software updates or after-sales service.

[Diagram: Motor housing showing identification labels marked as 'Labeling part' and 'Laser part'.]

Specifications

Outline and geometric size: The motor has specific dimensions and a chain line (CL) of 53mm. The shaft standard is BAFANG.

[Diagram: A detailed technical drawing of the BAFANG M510 Mid Motor showing its overall dimensions, including lengths like 127mm, 128mm, 197mm, and angles such as 35°, 45.8°, 47.7°. It also illustrates a central circular cutout with a diameter of 3+0.06/-0.02 mm and the main shaft. The diagram indicates the motor's placement relative to a bicycle's center.]

Surface: The motor features a shockproof black coating.

Storage Information: The pedelec unit should be stored in a ventilated, humid, and dry room. Avoid storing it near strong magnetic objects.

Drive Unit Installation

List of Tools to be used

Note: Do not use impact wrenches. ?

Install Drive Unit to Connection Interface

Components:

• A: M8 bolt
• B: M8 flat washer
• C: M8 lock nut
• D: Tool-socket spanner

Steps:

1. Align Hole 1 on the frame interface with the mounting hole on the motor.
2. Rotate the motor anticlockwise around Hole 1, and align Hole 2 and Hole 3.
3. Fasten 3 M8 bolts into Hole 1, 2, 3 from the right side to the left side.
4. Fasten the 3 M8 lock nuts with flat washers on the left of the frame, with a tightening torque of 35 N.m.

[Diagram: Illustrates the process of installing the drive unit. It shows the motor being aligned with the frame interface using specific holes (1, 2, 3) and components like M8 bolts (A), M8 flat washers (B), and M8 lock nuts (C). A tool-socket spanner (D) is also depicted.]

Cabling

Connectors:

• A: Male connector (8 pin) at the drive unit
• a: Female connector (8 pin) for the front BUS cable
• B: Male connector (6 pin) at the drive unit
• b: Female connector (6 pin) for other devices
• C: Female connector (8 pin) at the drive unit
• c: Male connector (8 pin) for the rear BUS cable
• D: Male connector for power supply at the drive unit
• d: Female connector for power supply at the battery

Steps:

1. Link the female connector (8 pin) for EB-BUS 'a' to the male connector (8 pin) at the drive unit 'A'.
2. Link the male connector (8 pin) for EB-BUS 'c' to the female connector (8 pin) at the drive unit 'C'.
3. Link the power connectors together.

Note: The connection of the 6-pin EB-BUS to the drive unit depends on customer functional requirements.

[Diagram: Shows the electrical connections for the BAFANG M510 Mid Motor. It details the various male and female connectors (labeled A, B, C, D and a, b, c, d respectively) for EB-BUS, other devices, and power supply, indicating their pin counts and locations (drive unit or battery).]

Cable connector and method of using BAFANG tool

Steps:

1. Hold the cable connector with your left hand.
2. Insert the BAFANG tool into the bottom of the cable connector with your right hand.
3. Turn the BAFANG tool clockwise to ensure a tight fit.
4. Insert the unit into its corresponding position at the drive unit.
5. After insertion, turn the BAFANG tool counterclockwise to remove it.

[Diagram: Illustrates the use of the BAFANG tool for connecting and disconnecting cables. It shows the tool being inserted into a cable connector and rotated.]

Bash Guard and Cover Installation

Components:

• A: Hexalobular socket pan head screw M3*8
• B: Covering case

Procedure: Use a T10 Torx screw driver to tighten 3 M3*8 screws through the hole sites on the covering case to the frame interface. The tightening torque should be 1 N.m.

[Diagram: Shows the installation of the covering case (B) onto the drive unit using M3*8 screws (A).]

Components:

• A: Hexagonal socket head cap screw M5*8
• B: Bash guard

Procedure: Use an internal hex wrench to tighten 4 M5*8 screws through the hole sites on the bash guard to the frame interface. The tightening torque should be 4 N.m.

[Diagram: Shows the installation of the bash guard (B) onto the drive unit using M5*8 screws (A).]

Chain Wheel Installation

Components:

• A: Chain wheel (Note: Chain wheel shall be made according to customer orders.)
• B: Lock ring
• C: BAFANG tool

Steps:

1. Place the chain wheel onto the spline shaft of the drive unit.
2. Use the BAFANG tool to fasten the lock ring onto the spline shaft. The tightening torque should be 35 N.m.

[Diagram: Illustrates the chain wheel installation process. It shows the chain wheel (A) being placed onto the spline shaft of the drive unit, followed by the lock ring (B) being secured using the BAFANG tool (C).]

Crank Installation

Components:

• A: Left crank
• B: Right crank
• C: Screw M16 (for the crank)
• D: Hexagonal socket head cap screw M6*20

Steps:

1. After mounting the right crank (B) on the right shaft, fasten the M16 screw (C) on the shaft using the internal hex wrench. The torque is 1.5 N.m.
2. Alternately fasten 2 M6*20 screws (D) with an internal hex wrench. Note: Do not fasten them from one side at a time. The torque for the wrench is 15 N.m.
3. Install the left crank (A) in the same way. Note: Please ensure both cranks are parallel.

[Diagram: Depicts the installation of the left (A) and right (B) cranks onto the drive unit. It shows the M16 crank screw (C) and M6*20 screws (D) used for securing the cranks, with indications for torque and fastening procedures.]

External Speed Sensor Installation

Model: SR SD021.01

Components:

• A: Speed sensor
• B: Magnet for the speed sensor

Steps:

1. Fasten the mounting screws through the speed sensor (A) using a cross screwdriver.
2. Tighten the speed sensor onto the frame.
3. Place the rubber seal on the speed sensor to cover the screw. Torque requirement: 1.5 N.m - 2 N.m.
4. Note: Ensure the gap between the speed sensor and the magnetic unit (B) is between 10 and 20 mm.

[Diagram: Shows the installation of a speed sensor (A) and its corresponding magnet (B). Arrows indicate the placement and orientation of the sensor and magnet relative to each other, with a note on the required gap.]

Model: SR SD051.02

Components:

• A: Rear flat fork
• B: Speed sensor

Steps:

1. Place the sensor (B) in the mounting area of the rear flat fork (A).
2. Tighten the M5*12 countersunk head plum screw clockwise, and install the plug. Torque: 3 N.m.
3. Install the magnet on the disc brake, and use a screwdriver to tighten 2 M5*12 countersunk head plum screws. Torque: 3 N.m.

[Diagram: Illustrates the installation of a speed sensor (B) onto the mounting area of a rear flat fork (A). It also shows the magnet being installed on the disc brake.]

[Diagram: Shows the mounting area of the magnet on a disc brake, with dimensions and specifications for placement.]

Maintenance

• Maintenance must be carried out by authorized personnel with the correct equipment.
• Do not disassemble the motor.
• Do not use thinners or other solvents to clean the components, as these substances can damage surfaces.
• Avoid submerging the unit in water to keep components protected.
• Avoid using high-pressure cleaning jets.
• For prolonged storage, turn off the battery and avoid storing near heat sources.

Documents / Resources

For further information, refer to the official BAFANG M510 Mid Motor User Manual [pdf].

BAFANG M510 Mid Motor User Manual