Opening the battery compartment on the Cannondale Monterra 3

[Rowena]

Hi everyone,

I have difficulty removing the plastic battery cover to access the battery on my Cannondale Monterra 3 ebike.
There is a small plastic dail at the top that feels impossible to turn to the open position.
Does anyone know a trick or the right way to turn this dail to the open position?

Thanks in advance

 

[Gionnirocket]

There may be a key also associated with the battery lock and dial.

 

[Rowena]

Thank you for your reply, and yes there is a key which I turned in the hopes that this might release the dial so that I can turn it to open.
It only released the battery inside the frame but I still can’t turn the dial to open the cover.
I wonder what other people do?

 

[Chazmo]

@stompandgo ??

 

[Gionnirocket]

The way the instructions read there is a latch that you release with your finger at the bottom end of the battery. It's only possible with the key in the unlocked position.

 

[BlackHand]

@Gionnirocket I think that latch is for the battery and is only accessible after the cover is off. It keeps the battery from falling to the ground when you remove the cover or turn the key.
.
@Rowena Is this what your latch looks like? You might try pushing in on the cover/knob to try to relieve some pressure while you turn it.

The latch on my cover is in the same spot, but is a sliding mechanism. Can be real pain if it gets fouled with grit.

 

[Gionnirocket]

I don't own similar... I was just reading the instructions for the bike mentioned.
My Zen has a key and a turn knob to remove the battery. Takes 5 seconds and ever without issue.
ymmv

 

[Rowena]

@Gionnirocket I think that latch is for the battery and is only accessible after the cover is off. It keeps the battery from falling to the ground when you remove the cover or turn the key.
.
@Rowena Is this what your latch looks like? You might try pushing in on the cover/knob to try to relieve some pressure while you turn it.

The latch on my cover is in the same spot, but is a sliding mechanism. Can be real pain if it gets fouled with grit.
View attachment 200393

Thank you for your reply
I tried these suggestions but the cover is super tight and there is no possibility of pushing it inwards.
Eventually I used a rubber mallet to tap the lever down. It’s not something that I’ll do often

 

[Gionnirocket]

Thank you for your reply
I tried these suggestions but the cover is super tight and there is no possibility of pushing it inwards.
Eventually I used a rubber mallet to tap the lever down. It’s not something that I’ll do often

That's Bosch for you. Over_designed/over complex for no reason.
@BlackHand probably has given some good insight on the problem. I'd give everything a good cleaning.

 

[stompandgo]

It sounds like the battery has slipped in it's mount, making the cover difficult to remove. It shouldn't be. Check the alignment of the battery and the latch, and adjust accordingly. Cannondale publishes an owners manual supplement for their e-bikes. Find the one for your Moterra. There should be an exploded diagram inside that shows the battery mounts and the screws used to adjust them.

 

[BlackHand]

Or, if the bike is new(ish) take it to the dealer and ask them to adjust it. It should be snug - you don't want the latch rotating open while you're riding! - but if it is more than finger tight then something is out if adjustment.

 

[Rowena]

That's Bosch for you. Over_designed/over complex for no reason.
@BlackHand probably has given some good insight on the problem. I'd give everything a good cleaning.

Actually, th

That's Bosch for you. Over_designed/over complex for no reason.
@BlackHand probably has given some good insight on the problem. I'd give everything a good cleaning.

No, I don’t think Bosch designed the battery compartment cover, which is part of the frame and Bosch didn’t design the frame.
The cover was likely designed so that it’s cannot easily open could fall off on a bumpy track

 

[Gionnirocket]

Actually, th

No, I don’t think Bosch designed the battery compartment cover, which is part of the frame and Bosch didn’t design the frame.
The cover was likely designed so that it’s cannot easily open could fall off on a bumpy track

Blame whomever you like.... Just be sure to keep a

in your tool bag.

 

[stompandgo]

Actually, th

No, I don’t think Bosch designed the battery compartment cover, which is part of the frame and Bosch didn’t design the frame.
The cover was likely designed so that it’s cannot easily open could fall off on a bumpy track

That's correct. The battery covers and battery mounting choices are determined by the bike manufacturer.

 

[Gionnirocket]

That's correct. The battery covers and battery mounting choices are determined by the bike manufacturer.

Are you sure about this?
The power acceptance cradle in the frame I would think would have to be Bosch and it makes sense for them to build the locking mechanism to be sure it's secure as a poorly designed latch could lead to battery warranty issues.
I know that the SYR battery case used on my bike can be purchased as a set; case/power acceptance cradle/locking mechanism all made by SYR.
It also has a removable cover that manufactures could customize if they wanted, but the attachment to the bike does not involve the cover.
At worst I'd think a close collaboration with Bosch is necessary....if not mandatory to use their system.

Actually, th

No, I don’t think Bosch designed the battery compartment cover, which is part of the frame and Bosch didn’t design the frame.
The cover was likely designed so that it’s cannot easily open could fall off on a bumpy track

So did you figure out what the issue was? Grit? Misalignment?

 

[Base]

... the battery dock (upper part en lower part) and the battery itself are Bosch specific parts. The rail where these are bolted on and the frame closures are ODP's per brand. So in this case it is a PON.bike specific part. The lock for the battery itself is not a Bosch part, this would be from either Abus or Axa. In this case Abus.

The way the battery is mounted in the frame has indeed some design rules from Bosch which you need to comply to to get OEM warranty from Bosch. That's all

This parts is c'dale branded

This part is and ODP for C'dale

this is a lower battery mount for the intube

the top part, where the battery lock is attached to

these last 2 parts are Bosch

 

[stompandgo]

Bosch does provide parts for the manufacturer to use, but the manufacturer has choices, and must design them into their frame. For example, Bosch provides both horizontal or vertical PowerTube batteries. Each type is mounted differently. Bosch has to approve every design they source in order to honor their warranty.

 

[stompandgo]

Sorry, reply clash.

 

[Rowena]

Are you sure about this?
The power acceptance cradle in the frame I would think would have to be Bosch and it makes sense for them to build the locking mechanism to be sure it's secure as a poorly designed latch could lead to battery warranty issues.
I know that the SYR battery case used on my bike can be purchased as a set; case/power acceptance cradle/locking mechanism all made by SYR.
It also has a removable cover that manufactures could customize if they wanted, but the attachment to the bike does not involve the cover.
At worst I'd think a close collaboration with Bosch is necessary....if not mandatory to use their system.



So did you figure out what the issue was? Grit? Misalignment?

No

Are you sure about this?
The power acceptance cradle in the frame I would think would have to be Bosch and it makes sense for them to build the locking mechanism to be sure it's secure as a poorly designed latch could lead to battery warranty issues.
I know that the SYR battery case used on my bike can be purchased as a set; case/power acceptance cradle/locking mechanism all made by SYR.
It also has a removable cover that manufactures could customize if they wanted, but the attachment to the bike does not involve the cover.
At worst I'd think a close collaboration with Bosch is necessary....if not mandatory to use their system.



So did you figure out what the issue was? Grit? Misalignment?

No, the issue wasn’t grit or misalignment. The cover is just a VERY ‘snug’ fit. And even looks as though it’s a sealed unit - absolutely no give or gaps anywhere. I suppose this is what keeps water and (the majority) of dust away from the battery.
I used a rubber mallet and a wooden dowel to tap the dial into the open position.
This isn’t something I’d need to do on a regular basis (about once every 12months seems enough) to keep the battery compartment clean.
Based on the minimal amount of dust that I found after 12 months of cycling on dusty gravel roads, I’m now convinced that the tightness of the compartment cover is not a mistake but for the protection of the most expensive part of the bike.
I’d rather have that option than a loose cover that doesn’t provide enough protection.
It does mean I won’t be able remove the battery for transporting the bike for example, but I don’t think that’s a good idea anyway because it leaves the terminals open to weather and dust that will certainly cause problems

 

[Gionnirocket]

Without seeing it first hand I'm not sure what else you can do.
Perhaps put a thin coat of dielectric grease on the culprit component moving parts... That is if it won't attract dust.
Or perhaps a few drops of isopropyl alcohol on it when you try to remove it. Alcohol is slippery when wet and evaporates quickly with no residue.