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ABS M4

Manual

V 1.2 1/11/2018

Summary of Contents for ABS M4

Page 1: ...ABS M4 Manual V 1 2 1 11 2018 ...

Page 2: ...sembling the Parts 18 7 1 Hydraulic Power Unit with attached Control Unit 18 7 2 Brake Pressure Sensor 19 7 3 Wheel Speed Sensors 19 7 4 Encoder Wheel 20 7 5 Distance between the Sensor and the Encoder Wheel 20 7 6 Gyro Acceleration Sensor 20 7 7 ABS Map Switch 21 7 8 ABS Warning Light MIL 21 7 9 Diagnosis Interface 22 7 10 Brake Light Switch 22 7 11 Brake Lines 23 7 12 General Brake Calipers 23 8...

Page 3: ...ake Pressure Sensor 45 14 Offer Drawing Wheel Speed Sensor 46 15 Offer Drawing Gyro Acceleration Sensor 47 16 Wiring Diagram 48 17 Wiring Diagram ABS M4 Clubsport 49 18 Wiring Harness 50 19 Wiring Harness Clubsport 51 Table of Contents Bosch Motorsport ABS M4 Manual 3 54 ...

Page 4: ...via CAN Measuring channels optional 19 Signal brake pressure front right 20 Signal brake pressure front left 21 Signal brake pressure rear right 22 Signal brake pressure rear left 23 Brake pressure master cylinder front 24 Brake pressure master cylinder rear Hardware 25 Wheel speed sensor front right 26 Wheel speed sensor front left 27 Wheel speed sensor rear right 28 Wheel speed sensor rear left ...

Page 5: ...ich includes a wiring harness Spare parts may be purchased after a complete kit has been purchased The use of unauthorized parts or wiring harnesses will not be supported by Bosch Motorsport additionally the system cannot be guaranteed to work properly and or without limitations It is essential that the predefined Bosch Motorsport assembly guidelines are complied with see section Assembling the Pa...

Page 6: ... over correcting the brake force to keep the wheel at the optimum slip level and so achieving the highest possible deceleration rate This is carried out sepa rately for each wheel When the brake force is reduced by the ABS brake fluid is released from the brake caliper and fed into the pressure reservoir of the hydraulic power unit of the ABS The hydraulic power unit then feeds the fluid back into...

Page 7: ...le acceleration and rotation rates as well as the pressure of the front brake circuit The ABS control algorithms at the front brake circuit rely on the measurements of ac celeration and pressure Programming and diagnosis software Each ABS M4 is preprogrammed with specific data related to the vehicle such as vehicle mass wheelbase track width tire rolling circumference etc Should the vehicle data c...

Page 8: ...n switch the system ON or OFF by moving the switch in the cockpit for one time Reset the System with a switch in the cockpit You can reset the system by moving the switch to the position OFF and then directly again ON 2 Before Use 8 54 ABS M4 Manual Bosch Motorsport ...

Page 9: ...al Data Supply voltage 8 to 16 V max 26 V for 5 min Max peak voltage 35 V for 200 ms Power consumption 8 W stand by 230 W in operation Inputs 4 active wheel speed DF11 Brake pressure front brake circuit Longitudinal acceleration lateral acceleration yaw rate 9 adjustment settings applicable for OEMSs Pos 1 9 2 adjustment settings applicable for Temas Pos 10 and 11 ABS function can be deactivated P...

Page 10: ...tor F 02U V00 335 03 Porsche 991 with 1 motorsport connec tor F 02U V01 928 01 Field of application ABS for front wheel rear wheel or four wheel drive racing cars Part numbers ABS M4 Package 1 incl wiring harness with motorsport connectors individual layout depending on customer requirements wheel speed sensors with production type connectors F 02UV00 289 01 ABS M4 Package 2 incl wiring harness wi...

Page 11: ...e our speed acceleration sensor with a CAN rate of 500 Kbaud s to avoid com patibility issues If the system is networked with a motorsport control unit or used as self suffi cient stand alone system we recommend that you use our speed acceleration sensor with a CAN rate of 1 Mbaud s This version features a greater measuring range Was or is the vehicle already fitted with an ABS system Was or is it...

Page 12: ...l units and da ta logging systems The splitter provides an input signal like as it is shown in the diagram in chapter Wheel Speed Signal Splitter 16 This module can be used for traction control display and gear units For ordering information see al so Wheel Speed Signal Splitter 16 4 Adaptations to Your Vehicle 12 54 ABS M4 Manual Bosch Motorsport ...

Page 13: ...72 08 4 wheel speed sensors DF11 0 265 008 022 0 285 007 871 old model Yaw acceleration sensor Standard 1 MBaud s 0 265 005 838 Alternative 500 kBaud s F 02U V00 049 02 Damping plate for yaw acceleration sensor 1 271 032 390 12 position ABS map switch F 02U V00 111 03 ABS warning light MIL with electronic control module Bulb F 02U V00 112 01 LED F 02U V00 112 02 Incl wiring harness with motorsport...

Page 14: ...ng diagram ABS M4 Clubsport Description Part Number Wiring harness Clubsport F 02U V01 917 01 See also 2 Wiring Diagram ABS M4 Clubsport 49 Connectors Overview Kit 1 ABS M4 Kit 1 with part number F 02U V00 289 01 includes the following connec tors which are also available as individual spare parts Connector for Part Number Attached control unit connector Standard wire departure on top F 02U B00 23...

Page 15: ...2U B00 241 01 Yaw acceleration sensor F 02U B00 435 01 Connectors Overview Kit 2 ABS M4 Kit 2 with part number F 02U V00 290 01 includes a harness with all the connectors from Kit 1 with the exception of different connectors for the wheel speed sensors Connector for Part Number Wiring harness sided ASL 006 05PN HE F 02U 000 342 01 Sensor sided ASL 606 05SN HE F 02U 000 416 01 Connectors Overview K...

Page 16: ...ABS applications is not com patible withv they could not be used as signal providers It is an open collector signal which grounds the voltage at the ECU input with every flank Bosch Motor sport has developed a wheel speed signal splitter that converts the sensor sig nals in such a way that they can be processed by peripheral ECUs and data re cording systems This signal splitter is available e g fo...

Page 17: ...orded CAN data A reduced version of the dbc file could be found at our homepage www bosch motorsport com Description Part Number Data Logger C 70 F 02U V02 302 01 Displays DDU 9 and DDU 10 The DDU 9 and DDU 10 displays have up to 3 GB of onboard data storage and can be used as a logger Description Part Number Display DDU 9 F 02U V02 300 02 Display DDU 10 F 02U V02 659 01 6 3 6 4 Optional Accessori...

Page 18: ... for the brake lines Caution The hydraulic power unit is prefilled with brake fluid During assembly make sure as little brake fluid as possible is lost When installing the hydraulic power unit make sure the brake line connections are facing upwards to ensure air can be bled out to the brakes Secure the hy draulic power unit to the assembly plate supplied with the ABS M4 Kit using the three M6x1 sc...

Page 19: ...ly fill the sensor with brake fluid e g with a small medical syringe So the brake system can be fully bled the measuring hole of the brake pressure sensor should point upwards Notice Only use the supplied brake pressure sensor otherwise ABS M4 will be destroyed Install into the front axle brake circuit between the master cyl inder and the hydraulic power unit as far away from the power unit as pos...

Page 20: ...ice Use only differential sensors like Bosch DF11 or similar Securely mount sensors and pay attention to correct mounting position sensors direction sensitive Sensor holder as stiff as possible Sensor measures and implementation of sensor holder you can also find in the MISSING LINK Encoder Wheel Encoder wheels usually have 48 teeth The tooth gap ratio should be 50 and the teeth should be 3 mm in ...

Page 21: ...osition see also diagram in chapter Features The switch position is also broadcast on the CAN Bus so it can be displayed with a dash e g the DDU 9 and DDU 10 from Bosch Motorsport Notice Only use the supplied ABS Map Switch Do not exceed the max tightening torque of 1 to 2 Nm Over torquing can damage the switch or make it difficult to turn Remove the front cover of the switch to access the retaini...

Page 22: ...light switch signal is not available or incorrect there may be a delay in ABS control If a brake light switch is already fitted in your vehicle During braking the brake light switch emits 12 Volts to pin 30 of the ABS M4control unit see the wiring diagram at the end of this manual Wiring Dia gram 48 Terminal 15 on the brake light switch cable remains open If a brake light switch has not yet been f...

Page 23: ...sary Do not secure brake lines 0 to 20 cm from the hydraulic unit The unit vibrates and would cause risk of damage to the lines Please use brake lines with a minimum inside diameter of 3 2 mm General Brake Calipers Use brake calipers that are as stiff as possible Any flex in the brake caliper causes extra fluid volume that must be regulated by the ABS which reduces perform ance During ABS operatio...

Page 24: ...s will trigger the initial communication between the laptop and the MSA Box II Follow any prompts that may follow to install the MSA Box II Once you complete any prompts and computer recognizes the MSA Box II the MSA Box II is ready for use Steps 1 Unplug the MSA Box II from the laptop 2 Install the driver 3 Plug the MSA Box II into the laptop You can connect ABS M4 to a laptop with the MSA Box II...

Page 25: ...ur desktop to the RaceABS software Klick it to start the application A green status indicator shows when the connec tion is successful A window pops up where you can select your ABS system If you try to launch the software without the MSA Box II to laptop connection the status indicator in Explorer lights red and an error message appears in the status bar The following problem message pops up when...

Page 26: ...White Offline mode Change between Online and Offline Mode If a connection does not exist it is easier to operate with the diagnosis software in offline mode Please click with the right mouse button on the green status in dicator to choose between online and offline mode A green status indicator signalizes the online mode a white status indicator sig nalizes the offline mode 9 Programming and Diagn...

Page 27: ...ur home page where you can find the most common versions If you need a changed and individual adapted version of the diagnosis software please contact your dealer or the OEM customer service After this we will deliver you the suitable FPS File To select the file of the diagnosis software please open the window Properties on the upper left side and choose Diagnostic Errors Click on the quadratic bu...

Page 28: ... yourself In this case please send a log and export file Click with the right mouse button in the window and click on Open in the drop down menu to find the log file Vehicle Data You can find a form to fill in your vehicle data on www bosch motorsport com This form should be provided to you by your dealer with the order of the kit if the kit shall be programmed by Bosch If you need to replace the ...

Page 29: ...y a text file can be loaded into the system or the actual window can be saved Notice Only the active window will be saved Default value for the ABS map switch For the 12 position ABS map switch you can specify a default value If the func tion switch fails for any reason the switch automatically takes the position of the default value To assign a position for the default value select a number betwe...

Page 30: ...our wheels can be moved freely If there is no other option you can lift and test each wheel sepa rately You will need an assistant to help you check the hydraulic allocation of the wheels Step 1 Testing the communication with the ABS M4 ECU See section Laptop Communication 24 Step 2 Testing the wheel speed allocations With the vehicle jacked up spin individually all four wheels clockwise and check...

Page 31: ...ssure of 15 to 20 bar is sufficient Unlock each wheel successively by clicking on Release Brake The selected wheel should run free now Notice Certain vehicles require a high torque input at the wheel to overcome the effect of residual brake pressure and resulting torque Step 4 Testing the electrical pump motor If you click the Pump button the pump motor should run for 10 seconds or till you click ...

Page 32: ...rising pressure The digital display Brake switch bit should toggle from 0 to 1 see screenshot below If the bit does not toggle check the pressure sensors The brake light switch bls is a function of the pressure sensors The digital display Pressure sensor should show a logical value e g 3 87 in the screenshot below 9 Programming and Diagnosis Software 32 54 ABS M4 Manual Bosch Motorsport ...

Page 33: ... Turn the 12 position ABS Map switch through full rotation With every step the number of measuring points should increase by 1 Notice MIL shines permanently in diagnosis mode See also 2 Brake Light Switch 22 Repair Bleeding Wizard Under the Testing tab of the RaceABS software you will also find two buttons at the bottom right labeled Repair Bleeding Tandem MC and Repair Bleeding Balance Bar with t...

Page 34: ...e used or substitu ted for bleeding the other parts of the brake system like lines and brake cylinders Make sure to bleed these other hydraulic parts of the brake system after bleeding the hydraulic unit with the Repair Bleeding Wizard During the ABS bleeding process the brake pedal should be ac tuated continuously except when opening or closing brake bleeder valves 9 Programming and Diagnosis Sof...

Page 35: ...ance bar Click on the button Repair Bleeding Balance Bar A new window will open and lead you step by step through the instruction for bleeding the hydraulic aggre gate You will need three people to perform the instruction Notice For vehicles with brake balance bar please open one front and one rear bleeder valve for proper function of the balance bar during the bleeding routine procedure ECU Info ...

Page 36: ...ct side at www bosch motorsport com Notice Multi switch ABS Map switch Notice System reset after drive cycle defaults Drive cycle defaults e g because of wheel speed sensor bug need an ABS ECU reset Power off Power on After the reset the car has to accelerate to more than 12 km h for system check Save error log entries If any error log entries occur which are not listed above please contact your d...

Page 37: ... clearly described or if there is no error description please check if you used the correct FPS File or contact Bosch Motorsport for update Ignition Cycle Counter The ignition cycle counter shows how often you switched on the ignition If you compare the values of the ignition cycle counter and ICC at Failure Occurrence you can trace back at what time the faults occurred If both fields show the sam...

Page 38: ... ABS M4 control unit with MSA Box II using RaceABS Software and ensure that all vehicle data has been entered correctly The vehicle data can be saved and or loaded by right clicking in the screen Notice Once the diagnosis software RaceABS is connected to the har ness the ABS warning light MIL will light up and remain lit until it is disconnected See section Testing 30 Step 2 If the MSA Box II is n...

Page 39: ...button for a given wheel one at a time Verify that brake relea ses at that wheel by rotating the wheel before clicking the next button Re peat for each wheel Notice During this release test the pump may switch on repetitively See chapter Testing 30 On the Testing page now decide between the Repair Bleeding Tandem MC and Repair Bleeding Balanced Bar Click on the button Start wizard at the bottom ri...

Page 40: ...ffset Min Max Unit Rate ms Comment PSIP1 Yaw 0 005 163 84 163 84 163 83 s 10 Yaw Rate AY1 0 00012742 4 1768 4 1768 4 1765 g 10 Lateral Acceleration Ay PSIPP YawAcc 0 125 4096 4096 4095 s 10 Yaw Acceleration AX1 0 00012742 4 1768 4 1768 4 1765 g 10 Longitudinal Acceleration Ax WS_FL 0 015625 0 0 100 m s 10 Wheel Speed Front Left WS_FR 0 015625 0 0 100 m s 10 Wheel Speed Front Right WS_RL 0 015625 0...

Page 41: ... ABS CAN to the vehicle CAN please keep in mind that the ABS system sends further messages as fol lows 0x140 0x340 0x542 0x75 0x141 0x341 0x560 0x80 0x142 0x342 0x576 0x143 0x343 0x5C0 0x24A 0x541 0x70 Appendix 10 Bosch Motorsport ABS M4 Manual 41 54 ...

Page 42: ...10 Appendix 42 54 ABS M4 Manual Bosch Motorsport ...

Page 43: ...Offer Drawing Hydraulic Power Unit with attached Control Unit 11 Offer Drawing Hydraulic Power Unit with attached Control Unit 11 Bosch Motorsport ABS M4 Manual 43 54 ...

Page 44: ...Offer Drawing Brake Pressure Sensor 0 261 B08 072 06 12 12 Offer Drawing Brake Pressure Sensor 44 54 ABS M4 Manual Bosch Motorsport ...

Page 45: ...Systems P81 2703373053 DRW 001 03 SAP Status 40 Labor F28 Change F030GD000901 Ausdrucke und Kopien unterliegen nicht dem Änderungsdienst Ausgedruckt am 13 02 2009 von ole2fe 13 Mounting Instructions Brake Pressure Sensor 13 Bosch Motorsport ABS M4 Manual 45 54 ...

Page 46: ...Offer Drawing Wheel Speed Sensor 14 14 Offer Drawing Wheel Speed Sensor 46 54 ABS M4 Manual Bosch Motorsport ...

Page 47: ...Offer Drawing Gyro Acceleration Sensor 15 Offer Drawing Gyro Acceleration Sensor 15 Bosch Motorsport ABS M4 Manual 47 54 ...

Page 48: ...Wiring Diagram 16 16 Wiring Diagram 48 54 ABS M4 Manual Bosch Motorsport ...

Page 49: ...Wiring Diagram ABS M4 Clubsport 17 Wiring Diagram ABS M4 Clubsport 17 Bosch Motorsport ABS M4 Manual 49 54 ...

Page 50: ...Wiring Harness 18 18 Wiring Harness 50 54 ABS M4 Manual Bosch Motorsport ...

Page 51: ...Wiring Harness Clubsport 19 Wiring Harness Clubsport 19 Bosch Motorsport ABS M4 Manual 51 54 ...

Page 52: ...19 Wiring Harness Clubsport 52 54 ABS M4 Manual Bosch Motorsport ...

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Page 54: ...Bosch Engineering GmbH Motorsport Robert Bosch Allee 1 74232 Abstatt Germany www bosch motorsport com ...

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