ABS M5 Kit

Manual

1 24/01/2019
Content

Content
1 System Overview............................................................................................................................................................. 4

2 Before Use........................................................................................................................................................................ 5
2.1 Safety Information........................................................................................................................................................................................ 5
2.2 ABS in Motorsport........................................................................................................................................................................................ 5
2.3 Principle of Operation................................................................................................................................................................................. 6
2.4 Features ............................................................................................................................................................................................................ 6

3 Technical Data ................................................................................................................................................................. 8

4 Disposal............................................................................................................................................................................ 10

5 Adaptations to your Vehicle .......................................................................................................................................... 11

6 Included in the Kit .......................................................................................................................................................... 13

6.1 Parts Overview Kit 1..................................................................................................................................................................................... 13
6.2 Parts Overview Kit 2..................................................................................................................................................................................... 13
6.3 Parts Overview Clubsport .......................................................................................................................................................................... 14
6.4 Connectors Overview Kit 1........................................................................................................................................................................ 14
6.5 Connectors Overview Kit 2........................................................................................................................................................................ 15
6.6 Connectors Overview Clubsport ............................................................................................................................................................. 15

7 Optional Accessories ...................................................................................................................................................... 16

7.1 MSA Box II ....................................................................................................................................................................................................... 16
7.2 Wheel Speed Signal Splitter ..................................................................................................................................................................... 16
7.3 Data Logger C 70.......................................................................................................................................................................................... 16
7.4 Displays DDU 9 and DDU 10 .................................................................................................................................................................... 16

8 Assembling the Parts...................................................................................................................................................... 17

8.1 Hydraulic Power Unit with attached Control Unit............................................................................................................................ 17
8.2 Brake Pressure Sensor................................................................................................................................................................................. 18
8.3 Wheel Speed Sensors.................................................................................................................................................................................. 18
8.4 Encoder Wheel............................................................................................................................................................................................... 19
8.5 Distance between the Sensor and the Encoder Wheel.................................................................................................................. 19
8.6 Yaw/Acceleration Sensor ........................................................................................................................................................................... 19
8.7 ABS Map Switch ............................................................................................................................................................................................ 20
8.8 ABS Warning Light (MIL)............................................................................................................................................................................ 20
8.9 Brake Lines....................................................................................................................................................................................................... 21
8.10 General: Brake Calipers............................................................................................................................................................................... 21
8.11 Master Cylinders ........................................................................................................................................................................................... 22

9 Laptop Communication.................................................................................................................................................. 23

10 Programming and Diagnosis Software ........................................................................................................................ 24

10.1 Installing the Programming and Diagnosis Software..................................................................................................................... 24
10.2 Features of the Programming and Diagnosis Software................................................................................................................. 26
10.2.1 Diagnostic Code.......................................................................................................................................................................... 26
10.2.2 Vehicle Data.................................................................................................................................................................................. 26
10.2.3 Testing ............................................................................................................................................................................................ 28
10.2.4 Repair Bleeding Wizard............................................................................................................................................................ 31
10.2.5 ECU Info (Diagnostics) .............................................................................................................................................................. 33

ii / 52 ABS M5 Kit Bosch Motorsport

 Content

11 Startup Checklist............................................................................................................................................................. 36

12 CAN Protocoll V15 customer from 0400 onwards ...................................................................................................... 38

13 Offer Drawing: Hydraulic Unit ...................................................................................................................................... 41

14 Offer Drawing: Wheel Speed Sensor ............................................................................................................................ 42

15 Offer Drawing: Brake Pressure Sensor ......................................................................................................................... 43

16 Mounting Instructions: Brake Pressure Sensor ........................................................................................................... 44

17 Offer Drawing: Yaw/Acceleration Sensor 500 kbaud ................................................................................................. 45

18 Offer Drawing: Yaw/Acceleration Sensor 1 Mbaud .................................................................................................... 46

19 Wiring Diagram............................................................................................................................................................... 47

20 Wiring Diagram ABS M5 Clubsport .............................................................................................................................. 48

21 Wiring Harness................................................................................................................................................................ 49

22 Wiring Harness ABS M5 Clubsport ............................................................................................................................... 50

Bosch Motorsport ABS M5 Kit iii / 52

4 / 52
11

17 to data logger

18
8
1 | System Overview

5 6 12 3

2 3
1 4

16

14 13
4

7 10
15

ABS M5 Kit
to ABS calibration and diagnostic software RaceABS
1 System Overview

Brake lines Measuring channels Hardware

1 Brake pressure front left 7 Wheel speed front left 16 ABS ECU & hydraulic modulator
2 Brake pressure front right 8 Wheel speed front right 17 Brake pedal
3 Brake pressure rear right 9 Wheel speed rear right 18 Brake balance adjustor
4 Brake pressure rear left 10 Wheel speed rear left
5 Brake pressure master cylinder front 11 Signal brake pressure sensor front
6 Brake pressure master cylinder rear 12 Signal brake pressure sensor rear
13 Signal function switch
14 ABS Warning Lamp (MIL)
15 Yaw / Acceleration signal

Bosch Motorsport
 Before Use | 2

2 Before Use
Read these instructions carefully and follow the recommendations for use step by step.
We are happy to give you additional notes and explanations. Our contact information is
on the back cover of this manual.

2.1 Safety Information

The ABS M5 Kit was developed for use by professionals and requires in-depth knowledge
of automobile technology and experience in motorsport. Using the system does not come
without its risks.
It is the duty of the customer to use the system for motor racing purposes only and not
on public roads. We accept no responsibility for the reliability of the system on public
roads. In the event that the system is used on public roads, we shall not be held respons-
ible or liable for damages.
Any maintenance or repair must be performed by authorized and qualified personnel ap-
proved by Bosch Motorsport.
All system parts are designed to work together and may not be replaced with similar parts
without our expressed permission (this includes the wiring harness). For first time pur-
chases, each team or owner must purchase a complete kit which includes a wiring harness.
Spare parts may be purchased after a complete kit has been purchased. The use of unau-
thorized 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 Parts [} 17], the system to run properly. This applies
above all for installing the MIL (malfunction indication lamp) within the driver's range of
visibility.

2.2 ABS in Motorsport

The ABS function is a compromise between drivability and braking performance. Drivabil-
ity is the primary focus for passenger based vehicles. The ABS is designed to keep the pas-
senger vehicle maneuverable and stable under any circumstances and under any conceiv-
able driving conditions.
Race ABS
Brake Performance Operating Range

Standard OEM ABS

Operating Range

Vehicle Stability During Braking

In a motorsport context, this compromise shifts towards braking performance, as experi-

enced drivers can still control a slightly unstable vehicle. Together with different tire struc-
tures and higher braking potential, a racecar is capable of greatly increased deceleration
rates. To consider different chassis tuning and tires, ABS M5 has eleven control settings

Bosch Motorsport ABS M5 Kit 5 / 52

2 | Before Use

plus an OFF-position. With this, the driver can choose the best setting for his vehicle. For
calibration drives, the ABS function can be deactivated separately, whereby all ABS sensor
signals are transmitted and processed furthermore (OFF-position of the ABS switch).

2.3 Principle of Operation

ABS M5 is suitable for front-wheel, rear-wheel and four-wheel drive vehicles. It is
based on a series production ABS and adapted in years of development work to meet mo-
torsport requirements, e.g. FIA requirements for using only eight active valves.
The ABS prevents the wheels from locking during braking. It does this by constantly meas-
uring the individual wheel speeds and comparing them with the vehicle speed predicted
by the system. If, during braking, the measured wheel speed deviates from the system's
predicted vehicle speed, the ABS controller takes 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 separately 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 the master cylinder via a piston pump driven by
an electric motor. The driver can hear this return pumping of the brake fluid and feel the
response of the brake pedal.

2.4 Features
Note: In the following, we only refer to the ABS M5 scale, standard. You can use the ABS
M5 scale, alternative, if your ABS M5 is switched off in position 1.

The ABS M5 has eleven different control settings, selectable via a switch in the cockpit
(position 1 to 11 with OFF on position 12 or position 2 to 12 with OFF on position 1).
The ABS map switch in the cockpit enables the driver to select various control settings
stored in the control device. Using the standard ABS scale, it starts with switch position 1
for the most sensitive controller setting (e.g. heavy rain condition). The configured control
settings allow progressively more slip as the position of the dial gets numerically higher.
With switch position 11, the most aggressive settings are achieved. Your optimal setting is
not necessarily the most aggressive.
– Calibration
In case of need, the calibration of the 11 control maps can be done by Bosch Motors-
port ABS engineers.

6 / 52 ABS M5 Kit Bosch Motorsport

 Before Use | 2

– Switch off ABS functions for calibration drives (OFF on position 1 or 12)
Switching off the ABS functions can be very helpful, e.g. for adjustment of the brake
balance bar. OFF-position will be signalized by lit MIL (Malfunction Indication Lamp).
All ABS sensor signals will still be communicated. ABS should be turned off in any
case where the drive wheels are spinning while the car is stationary, e.g. during warm-
up or when on the dynamometer. No error entry will take place.
– Measuring vehicle dynamics
Due to specially‐adapted chassis and tires, racing vehicles allow for significantly
higher longitudinal and lateral acceleration rates than series production vehicles. Our
ABS M5 sensors constantly measure vehicle acceleration and lateral forces as well as
the pressure of the front and rear brake circuit.
– Programming and diagnosis software
Each ABS M5 can be configured with specific data related to the vehicle, such as
vehicle mass, wheelbase, track width, tire rolling circumference, etc. Should the vehicle
data change at any time, you can adapt the system settings by using the RaceABS
diagnostic software. You find the software for free download on our website
www.bosch-motorsport.com. The new RaceABS diagnostic tool will also work with
older ABS M4 systems.
– Performing a system function test
The system function test can diagnose the functional capability without having to
move the vehicle.
– Reading data from the error log
Any missing part or incorrectly connected electrical connection of ABS operation-crit-
ical components are signaled by a lit MIL. In the error log you can read and analyze
what errors have set the MIL and then delete the errors after the issue has been re-
solved. Noncritical faults are stored without activating the MIL.
– Repair Bleeding Wizzard
Step‐by‐step instructions will guide you through bleeding the ABS unit, see also Re-
pair Bleeding Wizard [} 31].
– Connectivity for data loggers and display
You can connect a data logger (e.g. the C 70 from Bosch Motorsport) to the ABS‐Wir-
ing‐Harness via CAN. The CAN Bus can give you wheel speeds and other readings
from the system. All ABS M5 CAN messages can be displayed on any programmable,
CAN‐compatible display (e.g. the DDU 9 und DDU 10 from Bosch Motorsport), see
also CAN Protocoll V19 customer from 0700 onwards.
– Switch the system on and off
You can switch the system on or off via switch in the cockpit.
– Reset the system
You can reset the system by switching to position OFF and back to ON.

Bosch Motorsport ABS M5 Kit 7 / 52

3 | Technical Data

3 Technical Data
Mechanical Data
Hydraulic unit
Serial housing, dust- and damp-proof
Vibration damped circuit board
38 pin connector
2 hydraulic valves per wheel
2 brake circuits (front and rear)
2 hydraulic high pressures pumps
2 hydraulic accumulators 5 cm3/each
Standard fittings 2 x master cylinders M12 x 1
4 x brake cylinders M10 x 1
Size 122 x 110 x 122 mm
Weight 1,910 g
Operating temperature -30 to 130°C
Max. shock 50 g less than 6 ms

Electrical Data
Supply voltage 10 to 16 V, max. 24 V for 5 min
Max. peak voltage 35 V for 200 ms
Power consumption Pump 230 W
Power consumption Relay 170 W
Power consumption Electronics 8W
Inputs
4 active wheel speed DF11
Brake pressure (front brake circuit / rear brake circuit)
Longitudinal acceleration, lateral acceleration, yaw rate (MM5.10 sensor)
11 adjustment settings (applicable for OEMs)
ABS function can be deactivated (Pos. 1 or Pos. 12)
Outputs
ABS warning light (MIL)
EBD warning light (MIL) if needed
TTL wheel speed signal FL / FR / RL / RR
Communication
ABS and Yaw rate sensor CAN1
Diagnostics MSA Box II

Content of Kit and Weights

Hydraulic unit 1,910 g
2 pressure sensors 40 g/each
Yaw/acceleration sensor 60 g
12 position function switch 50 g

8 / 52 ABS M5 Kit Bosch Motorsport

 Technical Data | 3

4 wheel speed sensors DF11 standard 50 g/each

ABS warning light (MIL) 50 g
Vehicle specific wiring harness with motor- Depends on version
sport connectors
Clubsport wiring harness 1,540 g
Mounting and vibration-damping boards 80 g
Mounting board for hydraulic unit 212 g

Optional Accessories
Data logger C 70 F 02U V02 302-01
Display DDU 9 F 02U V02 300-02
Display DDU 10 F 02U V02 659-01
Communication interface MSA Box II F 02U V00 327-02
Wheel speed signal splitter with 1 motors- F 02U V01 928-01
port connector

Bosch Motorsport ABS M5 Kit 9 / 52

4 | Disposal

4 Disposal
Hardware, accessories and packaging should be sorted for recycling in an environment-
friendly manner.
Do not dispose of this electronic device in your household waste.
Waste electronic equipment must be disposed of properly according to Electrical and
Electronics Act (ElektroG) and the European WEE directive.

10 / 52 ABS M5 Kit Bosch Motorsport

 Adaptations to your Vehicle | 5

5 Adaptations to your Vehicle

Physical vehicle data
For optimum brake performance, each ABS M5 unit has to be customized to suit the
vehicle in which it is to be used. To do this, the system can be programmed by the user
with certain data, such as the vehicle weight, vehicle dimensions, wheel circumference,
and wheel weight. The system then uses this data as basis for calculation. Bosch will also
program this data ahead prior to delivery, however, it is very important that you calibrate
or verify the data prior to operating the vehicle.
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 pro-
grammed by Bosch.

Wiring harness
Each ABS system is delivered with a wiring harness that we have specifically created in ac-
cordance with customer requests.
With every Clubsport ABS you receive a standard wiring harness, which is not customized.
Please see Wiring Harness ABS M5 Clubsport [} 50].

CAUTION

Use of ABS M4 wiring loom on ABS M5 system will damage the unit.
Though the connectors of both systems are identical, both systems require their own wir-
ing loom.

System environment and related requirements

Is the ABS system being used as a closed stand-alone system? Or is it net-worked with a
control unit?
If the system is networked with a standard control unit, we recommend that you use our
speed/acceleration sensor with a CAN rate of 500 kBaud to avoid compatibility issues.
Check the CAN speed in order to choose the same value for the ABS Kit.
If the system is networked with a motorsport control unit or used as self-sufficient stand-
alone-system, we recommend that you use our speed/acceleration sensor with a CAN rate
of 1 MBaud. This version features a greater measuring range.
If the system is networked with an ECU MS 6 or MS 7, we recommend that you use our
speed/acceleration sensor with a CAN rate of 1 MBaud to avoid compatibility issues.

NOTICE

To avoid message ID conflicts care should be taken when networking

with a production CAN bus.

Was or is the vehicle already fitted with an ABS system? Was or is it an old BOSCH ABS sys-
tem?

Bosch Motorsport ABS M5 Kit 11 / 52

5 | Adaptations to your Vehicle

ABS M5 requires signals from differential dual Hall sensors such as the Bosch DF11 or sim-
ilar to function correctly. These sensor types are used in new vehicles for ABS and ESP®
systems and can be carried over for the ABS M5. The DF11 sensor element was first de-
ployed by Bosch in 2006. Conventional inductive and Hall sensors found in older series
production ABS units will not function as transmitters for the ABS M5. If your vehicle con-
tains an older ABS system, you have to remove the wheel speed sensors and replace them
by the sensors includes in the package to be able to use the ABS M5.
If you are not sure if your sensors are compatible with ABS M5, Bosch Motorsport will
gladly check that for you.
If you are fitting your vehicle with an ABS system for the first time, you may need an en-
coder wheel for each wheel and a sensor mount to record the wheel speeds. Please pay
attention to the fitting position of the wheel speed sensors.

Do the wheel speed signals need to be communicated to other control units?

1. Option CAN
2. Option Wheel Speed TTL
ABS M5 delivers wheel speed Hall signals for FL, FR, RL and RR wheels as output. Con-
nector is available on wiring harness under Wheel Speed TTL for FL, FR, RL and RR,
see also System Overview [} 4]. The following graphic shows the spec as it is in the
ECU. An example of the front left wheel is shown.
Signal Name: WSO_FL Pin Number: 23
Schematic (vehicle side) Interface circuit (ECU side)

WSO_xy WSO_xy

GND_ECU GND_ECU

Item Min Typ Max Unit Remarks

Reference GND_ECU
DC output current, Iout 50m A
H voltage level, Uout_high V Open collector
L voltage level, Uout_low 1.5 V #,ืP$

3. Option Wheel Speed Interface

We developed a wheel speed signal splitter that duplicates the signal from the wheel
speed sensor. This is useful for providing a DF11 signal to other systems in the car,
which are also adapted to this signal type, such as specially adapted displays and data
loggers. This is not intended to transmit signals to OEM controllers.

12 / 52 ABS M5 Kit Bosch Motorsport

 Included in the Kit | 6

6 Included in the Kit

6.1 Parts Overview Kit 1
ABS M5 Kit 1 (F 02U V05 289-01) includes the following parts, which are also available as
individual spare parts (Hydraulic unit only in exchange):

Description Part Number

Hydraulic unit DF11i F 02U V05 286-01
Hydraulic unit DF11S F 02U V05 287-01
Hydraulic unit DF11V F 02U V05 288-01 (available from 05/2018)
Mounting plate for Hydraulic unit 0 265 Y40 T56-02
2 brake pressure sensors PSS-260 0 261 545 040
4 wheel speed sensors DF11S with 0 265 008 022
production type connectors (in combination with DF11S module)
Yaw/Acceleration sensor MM5.10 500 kbaud: F 02U V02 589-01
or
1 Mbaud: F 02U V02 590-01 (required for
system combination with ECU MS 6 or MS
7)
Damping plate for MM5.10 1 271 032 390
12-position ABS map switch F 02U V00 111-05
ABS M5 scale, standard (OFF on 12) F 02U 004 709-01
ABS M5 scale, alternative (OFF on 1) F 02U 004 708-01
ABS warning light LED (MIL) F 02U V00 112-02
Wiring harness with motorsport connectors, customer-specific layout, wheel speed
sensors with production type connectors.

6.2 Parts Overview Kit 2

ABS M5 Kit 2 (F 02U V05 290-01) includes all parts of Kit 1 with the following differences:

Description Part Number

4 wheel speed sensors DF11S with F 02U V00 534-02
motorsport connectors (same sensor head as 0 265 008 022)
Wiring harness with motorsport connectors, customer-specific layout

Bosch Motorsport ABS M5 Kit 13 / 52

6 | Included in the Kit

6.3 Parts Overview Clubsport

There are a few variants of the ABS M5 Clubsport available:

Description Part Number

Kit Clubsport (500 kbaud, for DF11i) F 02U V05 291-01
Kit Clubsport (1 Mbaud, for DF11i) F 02U V05 292-01
Kit Clubsport (500 kbaud, DF11S) F 02U V05 293-01
Kit Clubsport (1 Mbaud, DF11S) F 02U V05 294-01

ABS M5 Clubsport includes all parts of Kit 1, but a different wiring harness, which cannot
be modified. By default, the wiring harness includes a 60 Ohm terminal resistance, which
can be replaced customer specific by a 120 Ohm or deleted completely, see Wiring Har-
ness ABS M5 Clubsport [} 50].

Description Part Number

Wiring harness Clubsport F 02U V02 642-01

6.4 Connectors Overview Kit 1

ABS M5 Kit 1 (F 02U V05 289-01) includes the following connectors, which are also avail-
able as individual spare parts:

Connector for Part Number

Control unit
Departure on top F 02U B00 238-01
Departure on bottom F 02U B00 237-01
Brake pressure sensor D 261 205 335-01
Compact 3-pin connector
12-positon ABS map switch F 02U 000 230-01
ASL 006-05SE-HE
ABS warning light (MIL) F 02U 000 226-01
ASL 006-05SA-HE
Wheel speed sensor F 02U B00 241-01
Tyco 2-pin connector
Yaw/acceleration sensor F 02U B00 435-01
Tyco 4-pin connector
Diagnosis connector F 02U 000 258-01
AS 012-35 SN
Wheel speed signal splitter ABS-sided F 02U 000 443-01
AS 612-35 SN
Data-logger intersection F 02U 000 229-01
ASL 006-05SD HE

14 / 52 ABS M5 Kit Bosch Motorsport

 Included in the Kit | 6

6.5 Connectors Overview Kit 2

ABS M5 Kit 2 (F 02U V05 290-01) includes all connectors from Kit 1 with the following dif-
ferences:

Connector for Part Number

Wiring harness side F 02U 000 342-01
ASL 006-05PN-HE
Sensor side F 02U 000 416-01
ASL 606-05SN-HE

6.6 Connectors Overview Clubsport

ABS M5 Kit Clubsport (F 02U V05 291-01, F 02U V05 292-01, F 02U V05 293-01 or F 02U
V05 294-01) includes all connectors of Kit 1 with the following differences:

Connector for Part Number

Encoding connector CAN harness-side F 02U B00 246-01
Super Seal 2-pole
Encoding connector CAN with a 60 Ohm res- F 02U B00 247-01
istor
Super Seal 2-pole

Bosch Motorsport ABS M5 Kit 15 / 52

7 | Optional Accessories

7 Optional Accessories
7.1 MSA Box II
ABS M5 communicates with your laptop via the MSA Box II. It has a USB connection to the
laptop and a motorsport connector to interface with the ABS M5 wiring harness. Commu-
nication via CAN.

Description Part Number

MSA Box II F 02U V00 327‐03

7.2 Wheel Speed Signal Splitter

The ABS M5 from Bosch Motorsport relies on specifically‐designed wheel speed signals,
delivered exclusively from active speed sensors, e.g. from the Bosch DF11 family. These
sensors are used in current ABS and ESP® systems. The four speed sensors included in
the ABS M5 Kit meet this classification. Regular speed sensors, as found in older series
production ABS applications, are not compatible with ABS M5. They cannot be used as
signal providers.

Description Part Number

Wheel speed signal splitter with 1 motors- F 02U V01 928‐01
port connector

7.3 Data Logger C 70

All ABS M5 data can be stored on a CAN-compatible data logger. We recommend to use
our C 70 data logger for storing and analyzing ABS M5 data.
Bosch Motorsport provides a standardized CAN log in DBC format for analyzing recorded
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

7.4 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

16 / 52 ABS M5 Kit Bosch Motorsport

 Assembling the Parts | 8

8 Assembling the Parts

8.1 Hydraulic Power Unit with attached Control
Unit

The hydraulic power unit with attached control unit has six hydraulic connections: two for
the master cylinders (one for the front and one for the rear axle) and four for the brake
cylinders.

CAUTION

The hydraulic power unit is prefilled with brake fluid. During as-
sembly, make sure as little brake fluid as possible is lost.

When installing the hydraulic power unit, make sure the wheel brake line connections are
facing upwards to ensure air can be bled out. Secure the hydraulic power unit to the as-
sembly plate supplied with the ABS M5 using the M10x1 screw thread on the underside of
the casing. To reduce vibration, rubber pads should be fitted between the assembly plate
and the vehicle chassis. To allow easy connection of the main ABS ECU connector, main-
tain a 10 mm distance between the vehicle chassis and the bottom of the assembly plate.

NOTICE

Correct position for installation: wheel brake line connections should

face upwards.
Install with rubber pads/blocks to reduce vibration.
Leave 10 mm or larger gap in between the vehicle chassis and bot-
tom of assembly plate.
For more on assembly see Offer Drawing: Hydraulic Unit [} 41].

NOTICE

Conform to FIA rules for GT3

With only 8 active hydraulic valves, the ABS M5 conforms to FIA
rules regarding brake modulation hardware.

Bosch Motorsport ABS M5 Kit 17 / 52

8 | Assembling the Parts

8.2 Brake Pressure Sensor

Install the brake pressure sensors into the front and rear axle brake circuits between the
master cylinders and the hydraulic power unit. The sensors are metric thread, M10x1. Be-
fore assembly, fill the sensors with brake fluid, e.g. with a small medical syringe. So the
brake system can be fully bled, the measuring holes of the brake pressure sensors should
point upwards.

NOTICE

The use of other than the supplied sensors will destroy the unit per-
manently. ABS M4 sensors are not compatible with ABS M5.
Install into the front and rear axle brake circuit between the master cylinder and the hy-
draulic power unit as far away from the ABS unit as possible to avoid damages due to vi-
bration.
Fill sensor with brake fluid before installing.
For more on assembly see Offer Drawing: Brake Pressure Sensor [} 43].

8.3 Wheel Speed Sensors

Bosch Motorsport ABS M5 needs specific wheel speed signals, which are supplied only
from active speed sensors like e.g. from Bosch DF11-family. These double hall sensors op-
erate on the differential principle. The ABS M5 needs all four speed sensors to function;
otherwise the system assumes there is an error and shuts down. Therefore, you should ex-
clusively use the speed sensors as supplied in the ABS M5-Kit (see section Offer Drawing:
Wheel Speed Sensor [} 42]). Existing wheel speed sensors can be tested and approved
by us.
Pay attention to the polarity when you are connecting wheel speed sensors.
Install the sensor in the right direction, i.e. the encoder wheel and sensor must lie in the
defined installation position (fixation screw in rotation position of the encoder wheel). The
sensor will not work if you install it in a position other than the recommended installation
position. Make sure the sensor is mounted and secured as tight as possible to prevent
sensor errors or failures from vibration. You can find the sensor's dimensions and how to
install the sensor on Offer Drawing: Wheel Speed Sensor [} 42].

NOTICE

Use only differential sensors, like Bosch DF11 or similar. Supported

sensors: DF11i, DF11S and DF11V.

18 / 52 ABS M5 Kit Bosch Motorsport

 Assembling the Parts | 8

Securely mount sensors and pay attention to correct mounting position (sensors direction
sensitive). Choose sensor mounts that are as still as possible. Sensor dimensions and
mounting requirements can be found in the Offer Drawing: Wheel Speed Sensor [} 42].

8.4 Encoder Wheel

Encoder wheels usually have 48 teeth. The tooth/gap ratio should be 50 % and the teeth
should be 3 mm in height. The encoder wheel must be made of a ferromagnetic material.
If required, Bosch Motorsport can provide technical documentation on positioning the en-
coder wheel. See the back cover of this booklet for our contact information.

8.5 Distance between the Sensor and the

Encoder Wheel
You can adjust the distance between the sensor and the encoder wheel to fit the encoder
wheel's dimensions and other installation conditions, but gap is normally between 0.8 ±
0.1 mm.

NOTICE

Use a ferromagnetic incremental wheel.

Leave a 0.8 ± 0.1 mm gap between sensor and encoder wheel.
For more on assembly see Offer Drawing: Wheel Speed Sensor [} 42].

8.6 Yaw/Acceleration Sensor

ABS M5 uses a yaw rate sensor from the MM5.10 generation with CAN speeds of 500
kBaud or 1 MBaud. The yaw/acceleration sensor is specific to the system and should be
mounted as close as possible to the center of gravity of the vehicle. The sensor should be
assembled with the supplied damping plate. Position the sensor so that the connector is
pointing towards the rear of the vehicle.

NOTICE

For system combination with ECU MS 6 or MS 7, the 1 MBaud sensor

is required.
The ABS system will not work if you choose any alternative yaw rate sensor.

Bosch Motorsport ABS M5 Kit 19 / 52

8 | Assembling the Parts

NOTICE

Only use the provided kit sensor.

Use the damping plate.
Make sure the sensor is facing the correct direction see image above.
See also: Offer Drawing: Yaw/Acceleration Sensor 500 kbaud [} 45] and Offer Drawing:
Yaw/Acceleration Sensor 1 Mbaud [} 46].

8.7 ABS Map Switch

While driving, the driver can use the ABS map switch to select different control settings
and find the optimum setting for his/her driving style. For this reason, make sure the
switch is mounted within reach of the driver. Many have found it helpful to fit a diagram
showing the current switch position, see also Features [} 6], diagram in chapter. 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 retaining hardware.

8.8 ABS Warning Light (MIL)

LED Front-panel cut

The included wiring harness is structured in such a way that the power supply to the ABS
warning light (MIL) is branched off before the main switch for ABS M5 (terminal 30). This is
the only way to ensure that the ABS warning light (MIL) is lit when ABS M5 is not working.
Cable length connector to electronic board: 600 mm

NOTICE

The MIL will stay illuminated in the following cases:

ABS map switch is in the OFF position
The user is connected to the car via the RaceABS tool and MSA Box
There is an active fault disabling ABS

20 / 52 ABS M5 Kit Bosch Motorsport

 Assembling the Parts | 8

8.9 Brake Lines

Use rigid steel brake lines for as much of the plumbing as possible. Flexible line should be
kept to an absolute minimum for optimal ABS control and pedal feel.
The ABS M5 units use a DIN (bubble) flare convention common to European OEM applica-
tions. The best and simplest way to adapt the system hydraulically is with an M10x1 DIN
tube nut on the outlet (wheel side) ports and M12x1 DIN on the inlet (MC side) ports.
Tube nut size should be fitting to the hard line size used. Adapters should be avoided if
possible. For sizes, also see Offer Drawing: Hydraulic Unit [} 41].
115°±2°

Tool marks øA
acceptable

Radius required,
øA > øB øB no nicks allowed

The hydraulic unit is secured in the vehicle on the provided mounting plate. During opera-
tion, the hydraulic unit will vibrate. These vibrations are then transferred to the brake lines.
To prevent vibration-induced damage to the brake lines, they must not be secured at a
distance of up to 20 cm from the hydraulic unit so that they can vibrate freely.

NOTICE

We recommend using rigid metal brake lines; use flexible lines only
at points where they are necessary.
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.

8.10 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 performance.
During ABS operation there will be a significantly higher load on the brake piston seals.
For this reason, brake piston seals will require more frequent monitoring.

NOTICE

Monitor brake piston seals more often.

Use brake calipers that are as stiff as possible.

The higher the brake pressure is, the larger is the elasticity of the brake. A locking pres-
sure of max. 80 bar is optimal.

Bosch Motorsport ABS M5 Kit 21 / 52

8 | Assembling the Parts

8.11 Master Cylinders

The master cylinders in a race car equipped with ABS are heavily exposed to piston vibra-
tions due to ABS return fluid pump.
Test and inspect the master cylinders frequently, both to ensure safety as well as to avoid
damage to the ABS unit.

CAUTION

Test and inspect the master cylinder frequently.

22 / 52 ABS M5 Kit Bosch Motorsport

 Laptop Communication | 9

9 Laptop Communication
The MSA Box II from Bosch Motorsport is the communication interface between ABS M5
and the programming and diagnostic software on your laptop. The MSA Box II has two
connectors: a USB connector for connection to the laptop and a motor sports connector
for connection to the mating connector in the vehicle wiring harness.

Installing the MSA Box II driver:

Before using the MSA Box II for the first time, you need to install a specific driver on your
laptop. Find the driver for free download on our website www.bosch-motorsport.com.

NOTICE

Please make sure that the MSA Box II is not connected to the laptop
while you are installing the driver.

Connect the MSA Box II to the laptop after installing the driver. This will trigger the initial
communication between the laptop and the MSA Box II. Follow any prompts that may fol-
low 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 M5 to a laptop with the MSA Box II via the "diagnosis interface"
connector. The diagnosis interface connector should be placed so it is easily accessible.
You can use programming and diagnosis software, see section Programming and Dia-
gnosis Software [} 24], to program settings specific to the vehicle and open/delete error
messages.

Bosch Motorsport ABS M5 Kit 23 / 52

10 | Programming and Diagnosis Software

10 Programming and Diagnosis Software

10.1 Installing the Programming and Diagnosis
Software
After installing the MSA Box II you need to install the programming and diagnostic soft-
ware RaceABS. You can find the software for free download on our website: www.bosch-
motorsport.com
Switch on the ignition
Plug the MSA Box's USB connector into your laptop and its motorsport connector into the
ABS M5 wire harness diagnostic interface to enable communication.
The installation creates a shortcut on your desktop to the RaceABS software. Klick it to
start the application. A green status indicator shows when the connection 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 / yellow and an error message appears in the status bar:

24 / 52 ABS M5 Kit Bosch Motorsport

 Programming and Diagnosis Software | 10

The following problem message pops up when either the ABS-ECU gets no power supply
(e.g. ignition OFF) or the MSA Box II is not connected to the wiring harness. Please make
sure that the connection between the diagnosis software and MSA Box II is assured:

Colors of the status indicator

The status indicator can shine in the following colors:

Red No connection
Yellow Connection in progress
or
MSA Box II cannot create a connection with the ABS (e.g. ABS switched off)
Green Connection successful, Online mode
White Offline mode
Red / Yel- MSA Box II is not connected to the laptop
low flashing

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 indicator to choose
between online and offline mode:

Bosch Motorsport ABS M5 Kit 25 / 52

10 | Programming and Diagnosis Software

A green status indicator signalizes the online mode; a white status indicator signalizes the
offline mode.

NOTICE

You can only change the status when the ABS tree is closed.

10.2 Features of the Programming and Diagnosis

Software

10.2.1 Diagnostic Code

The ABS-ECU sends the stored errors as coded data to RaceABS. Those codes are then
translated by a translation file and displayed as plain text on the “Ecu Info” page in
RaceABS.
After installation of RaceABS, a default file will be used for the translation. If you don´t see
plain text or if there is an orange colored warning, you do not have the matching transla-
tion file to your software. With a not matching file, some codes cannot be translated or
might be translated in the wrong way. Therefor it is important to use the correct transla-
tion file.
To get the correct translation file, please conduct the following steps:
– Check on the top of the “ECU Info” page which software number and software version
is used in your ABS.
– Go to the Bosch Motorsport homepage and download the matching diagnostic trans-
lation file to your software. You will find in the naming of the diagnostic translation
file the software number as BB number and the version as a V number, zeros at the
end might be skipped in the naming. The numbers of the file need to match the num-
bers of the software. The file is an .XML file.
– For example if your ABS runs on the software 96242 and the version
03.00.00.00.00.00. You will need the file TKWINX_FAILUREMEMORYDESCRIP-
TION_BB96242_V0300.XML
– Store the file on your computer.
– Click in RaceABS on “Properties” - “Diagnostic Errors” and select the matching dia-
gnostic translation file.
You will find the most common translation files on our homepage. If your needed file is
missing, please contact your dealer or the OEM customer service.

10.2.2 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 pro-
grammed by Bosch.
If you need to replace the ECU or modify the programmed vehicle data, you can update
the data in the software by yourself.

26 / 52 ABS M5 Kit Bosch Motorsport

 Programming and Diagnosis Software | 10

Within the window “Vehicle Data ABS” a short declaration or the measuring unit for each
value can be shown. By holding the cursor over a data range, a small window with the de-
claration occurs.

You can save and open the vehicle data of the window “Vehicle Data ABS” separately.
Therefore, click with the right mouse button in the window. In this way, 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 function switch
fails for any reason, the switch automatically takes the position of the default value. To as-
sign a position for the default value, select a number between one and twelve under
“MultiSwitch” in the field “Default Position”:

Bosch Motorsport ABS M5 Kit 27 / 52

10 | Programming and Diagnosis Software

NOTICE

You may want to be strategic about how you make this setting, for
example, making it the best compromise position for all conditions.

10.2.3 Testing
After assembling the system components, you need to carry out a function test before the
first test drive. This test will ensure all components (electrical and hydraulic) were as-
sembled correctly and are functioning properly. The vehicle should be placed on four jack
stands or on a hoist so that all four wheels can be moved freely. If there is no other op-
tion, you can lift and test each wheel separately. You will need an assistant to help you
check the hydraulic allocation of the wheels.
Step 1: Testing the communication with the ABS M5 ECU
See section Laptop Communication [} 23].
Step 2: Testing the wheel speed allocations
With the vehicle jacked up, spin individually all four wheels clockwise and check for the
proper front/back, left/right allocation. When you spin each wheel, the corresponding po-
sition should show a value in the RaceABS software under the “Testing” tab:

28 / 52 ABS M5 Kit Bosch Motorsport

 Programming and Diagnosis Software | 10

You just do this to see if a signal is received by the ABS unit. This is not a signal quality
check.
Step 3: Testing the hydraulic allocations
Have an assistant apply the brake pedal and maintain the brake pressure so all four
wheels of the jacked up vehicle are locked. Therefore, a brake pressure 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 over-

come 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
the button again.

Step 5: Testing the function of the brake pressure sensor and brake light switch
Start the RaceABS with connection to the MSA Box II and press the brake pedal for a few
seconds with slowly rising pressure. The digital display “Brake switch“ bit should toggle
from 0 to 1, see screenshot below.

Bosch Motorsport ABS M5 Kit 29 / 52

10 | Programming and Diagnosis Software

30 / 52 ABS M5 Kit Bosch Motorsport

 Programming and Diagnosis Software | 10

If the bit does not toggle, check the pressure sensors. The brake light switch bls is a func-
tion of the pressure sensors.
The digital display „Pressure sensor“ should show a logical value, e.g. 3.87, in the screen-
shot below.

If the software displays no value or an illogical value, open the “ECU Info” tab and check
the error memory. Do you find errors relating to the brake pressure sensor? See section
ECU Info (Diagnostics) [} 33] for more information regarding ECU diagnostic errors.
Step 6: Testing the function of the ABS Map switch
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.

10.2.4 Repair Bleeding Wizard

Under the “Testing” tab of the RaceABS software you will also find an area at the bottom
right, labeled “Repair Bleeding” with the button “Start Wizard”. With this button, you will
be guided through the bleed of the ABS unit. This might be required if air might got

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10 | Programming and Diagnosis Software

trapped in the accumulator of the ABS unit. It is recommended to perform the ABS unit
bleed after installation or if air got trapped in the brake lines and might got caught in the
ABS unit.
Click on the button “Start Wizard”, a new window will open and lead you step by step
through the instruction for bleeding the ABS unit. You will need three people to conduct
the instruction.

NOTICE

The Bleeding Wizard is only for bleeding the ABS hydraulic power
unit. The Bleeding Wizard is NOT to be used or substituted for
bleeding the other parts of the brake system, like lines and brake cyl-
inders. Make sure to bleed these other hydraulic parts of the brake
system before and after bleeding the hydraulic unit with the Repair
Bleeding Wizard.
During the ABS bleeding process the brake pedal should be actuated continuously except
when opening or closing brake bleeder valves.

32 / 52 ABS M5 Kit Bosch Motorsport

 Programming and Diagnosis Software | 10

Repair Bleeding (Tandem MC)

You choose “Repair Bleeding (Tandem MC)” if your system always delivers the proportion-
ally equal pressure ratio to front and rear axle when you actuate the brake pedal. You also
choose “Repair Bleeding (Tandem MC)” if your car has only one master cylinder for both
axles like a street car.
Click on the button “Repair Bleeding (Tandem MC)”: A new window will open and lead
you step by step through the instruction for bleeding the hydraulic aggregate. You will
need an assistant to perform the ABS bleeding procedure.

Repair Bleeding (Balance Bar)

You choose “Repair Bleeding (Balance Bar)” if the vehicle is equipped with dual master cyl-
inders and a balance 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 aggregate. 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.

10.2.5 ECU Info (Diagnostics)

Indication lamp
When you turn on the ignition or the ABS M5, the ABS warning light (MIL) comes on
briefly and then turns off again. This indicates the light's self-testing process. If the ABS
warning light (MIL) does NOT light up when you turn on the ignition or the ABS M5, you
must establish the reason for this before taking any further action or before driving the
vehicle.

Bosch Motorsport ABS M5 Kit 33 / 52

10 | Programming and Diagnosis Software

NOTICE

The MIL will stay illuminated as long as the diagnostic tool is

switched on.

Error log
If the warning light (MIL) is illuminated PERMANENTLY when you turn on the ignition or
the ABS M5, or while driving, there is a system error. Extract the system's internal error log
to analyze the error. You can access the log by clicking on the “ECU Info” tab in the
RaceABS software.

You’ll find a complete overview of error log entries in an Excel sheet on the ABS M5
product 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 dealer or the
OEM customer service. Communication would be easier if you also send a copy of your
error log entries.
Click on the right button named “Save Faults” to get a copy of the error log entry.

34 / 52 ABS M5 Kit Bosch Motorsport

 Programming and Diagnosis Software | 10

Delete error log entries

After carrying out the problem-solving actions, delete the entry from the error log by
clicking on the “Clear Faults” button, as seen below:

Then turn ABS M5 off and on again. After you deactivated the software, the indication
lamp will no longer glow.

NOTICE

If the faults are not all clearly described or if there is no error de-
scription, 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 same values, it is an actual fault.

Bosch Motorsport ABS M5 Kit 35 / 52

11 | Startup Checklist

11 Startup Checklist
This short checklist is intended to supplement the ABS M5 Kit’s manual, not replace it.
Prior to using this checklist the user/installer should read the ABS manual, especially sec-
tion Assembling the Parts [} 17] to Laptop Communication [} 23].

Basics
– Hydraulic unit with attached control unit mounted correctly (mounting plate used,
brake lines facing upwards), see section Hydraulic Power Unit with attached Control
Unit [} 17].
– Brake pressure sensor and Yaw/Acceleration sensor installed in proper locations? See
section Brake Pressure Sensor [} 18] and Yaw/Acceleration Sensor [} 19].
– Everything plugged in to harness, power ring terminals connected to battery, ground
ring terminals connected to solid and clean chassis ground, circuit breakers installed
properly, ABS toggle switch turns off system. See section Brake Pressure Sensor [} 18]
and Yaw/Acceleration Sensor [} 19].

Software Tool and Error Checking

– Connect to the ABS M5 control unit with MSA Box II using RaceABS Software and en-
sure 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 harness,

the ABS warning light (MIL) will light up and remain lit until it is dis-
connected. See section Testing [} 28], Step 2. If the MSA Box II is not
connected to the laptop, the indication lamp illuminates yellow.
– With the system on, switch to the “ECU Info” page and clear errors with clicking on
Clear FPS. Wait a moment (system will self-refresh error stack). Reset the system by
switching off/on. Check if any errors reappear in the error stack. If errors reappear,
diagnose errors before proceeding. If anything was unplugged during the diagnostic
process, errors will be present and need to be removed from the error stack. Next,
cycle ABS on/off switch and verify no errors are present after cycling power, see sec-
tion ECU Info (Diagnostics) [} 33].

Error Notes
– In case of use of a wheel speed signal splitter: If the wheel speed signal splitter is dis-
connected, all four wheel speed sensors will have error entries.

Function Check
– While connected with the RaceABS software switch to the “Testing” page. Check all
sensors for plausibility and proper function. Delete the balance bars. Press brake
pedal: brake switch bit should toggle between 0 and 1, the display “Pressure sensor”
should show a logical value. Check sensor and balance bar, if the brake switch doesn’t
toggle. Rotate ABS map switch, the value “Multiswitch” should turn up clockwise.
Manually move yaw/accelerometer sensor to the right and left as well as to the front
and rear. The “Ax” and “Ay”-values should increase positive or negative analogue to
the Tilt. See section Testing [} 28].

36 / 52 ABS M5 Kit Bosch Motorsport

 Startup Checklist | 11

– Put the car on jack stands so all wheels can be freely rotated. While connected with
the RaceABS software and viewing the "Testing" page, rotate each wheel and verify
the correct wheel speed responds in the "Testing" page, see section Testing [} 28].
– Click "Pump On" button on the “Testing”-page. The pump now runs for 10 seconds or
until you press the button again. After the pump shuts off, an assistant hold the brake
pedal down (Please check: all wheels have to be locked!) Next, while the assistant still
holds brake pedal down, click the "Release Brake" button for a given wheel (one at a
time). Verify that brake releases at that wheel by rotating the wheel before clicking
the next button. Repeat for each wheel.

NOTICE

During this release test, the pump may switch on repetitively.

See chapter: Testing [} 28]

– 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
right. Follow the instructions listed in the sub window in order to bleed the ABS hy-
draulic unit.

NOTICE

This will bleed the ABS hydraulic unit only, not the brake lines or the
wheel brake cylinders.
See chapter: Repair Bleeding Wizard [} 31]
– Bleed brakes in normal fashion, starting with the furthest brake from the master cylin-
der and finishing with the nearest. Check errors one last time, diagnosis any errors
present, then disconnect MSA Box II from ABS harness. Once MSA Box II is disconnec-
ted verify that MIL lamp turns off and stays off.
– Check for proper brake operation at low speeds first. Start with ABS map switch in a
neutral position (position 5 to 7).

NOTICE

Refer to manual for more information regarding the ABS map switch
position function. See chapter: ABS in Motorsport [} 5] and Features
[} 6]
– ABS warning light (MIL) on for a short time when you switch on the ignition, on per-
manent when map switch in position 12 (OFF).

Bosch Motorsport ABS M5 Kit 37 / 52

12 | CAN Protocoll V15 customer from 0400 onwards

12 CAN Protocoll V15 customer from 0400

onwards
ABS-M5 Version 15 16.02.201

CAN 8

Customer

version

Input

Name ID Start [Bit] Length Byte Or- Value Initial Factor Offset Minimum Max- Unit Comment

[Bit] der Type Value imum

ABS_Swit 0x24C 0 8 Intel Unsigned 0 1 0 0 11 Channel to send the

chposi- swich position via CAN

tion to the ABS.

Rate must be 10 ms /

100 Hz.

ABS

Name ID Start [Bit] Length Byte Or- Value Initial Factor Offset Minimum Max- Unit Comment

[Bit] der Type Value imum

RG_VL_Br 0x24A 0 16 Intel Unsigned 0 0.015625 0 0 100 m/s Wheel speed direct FL

emse2

RG_VR_Br 0x24A 16 16 Intel Unsigned 0 0.015625 0 0 100 m/s Wheel speed direct FR

emse2

RG_HL_Br 0x24A 32 16 Intel Unsigned 0 0.015625 0 0 100 m/s Wheel speed direct RL

emse2

RG_HR_B 0x24A 48 16 Intel Unsigned 0 0.015625 0 0 100 m/s Wheel speed direct RR

remse2

SPK_FA 0x342 0 8 Intel Unsigned 0 0.05 0 0 10 cm3 Fill level of the fluid

reservoir of the front

axle.

SPK_RA 0x342 8 8 Intel Unsigned 0 0.05 0 0 10 cm3 Fill level of the fluid

reservoir of the rear

axle.

WheelQu 0x342 32 8 Intel Unsigned 0 1 0 0 32 Identification bit for

ality_FL wheel sped signal dis-

turbances, check the

WheelQu 0x342 40 8 Intel Unsigned 0 1 0 0 32
sensor and the sur-
ality_FR
rounding if bit is >1.
WheelQu 0x342 48 8 Intel Unsigned 0 1 0 0 32

ality_RL

WheelQu 0x342 56 8 Intel Unsigned 0 1 0 0 32

ality_RR

Brake_bal 0x560 16 8 Intel Unsigned 0 1 0 0 60 Bar Calculated rear axle

_at50 brake pressure if the

front pressure is at 50

bar.

38 / 52 ABS M5 Kit Bosch Motorsport

 CAN Protocoll V15 customer from 0400 onwards | 12

ABS

Brake_bal 0x560 24 8 Intel Unsigned 0 1 0 0 60 Bar Recommended rear

_at50_ad- axle brake pressure if

vice the front pressure is at

50 bar.

Brake_bal 0x560 32 8 Intel Unsigned 0 1 0 0 100 % Percental brake bal-

_proc ance on the front axle.

Brake_bal 0x560 40 8 Intel Unsigned 0 1 0 0 100 % Recommended per-

_proc_ad- cental brake balance

vice on the front axle.

Diag_FL 0x541 0 2 Intel Unsigned 0 1 0 0 3 Value to show faults re-

lated to the wheel

Diag_FR 0x541 2 2 Intel Unsigned 0 1 0 0 3
speed sensor.
Diag_RL 0x541 4 2 Intel Unsigned 0 1 0 0 3

0 - Signal ok,
Diag_RR 0x541 6 2 Intel Unsigned 0 1 0 0 3

1 - Wiring related fault,

2 - Signal related fault

Diag_AB- 0x541 8 1 Intel Unsigned 0 1 0 0 0 Bit to show, if an ABS

SUnit error related to the hy-

draulic unit is present

Diag_Fus 0x541 9 1 Intel Unsigned 0 1 0 0 0 Bit to show, if an ABS

ePump error related to the

fuse or power supply of

the ABS pump is

present.

Diag_Fu- 0x541 10 1 Intel Unsigned 0 1 0 0 0 Bit to show, if an ABS

seValve error related to the

fuse or power supply of

the ABS valves is

present.

Switch- 0x5C0 0 8 Intel Unsigned 0 1 0 1 12 Used switch position of

Position the ABS.

P_FA 0x5C0 8 8 Intel Unsigned 0 1 0 0 255 bar Brake pressure on the

front axle.

P_RA 0x5C0 16 8 Intel Unsigned 0 1 0 0 255 bar Brake pressure on the

rear axle.

BLS 0x5C0 24 1 Intel Unsigned 0 1 0 0 1 Bit for the brake light

switch.

ABS_Mal- 0x5C0 28 1 Intel Unsigned 0 1 0 0 0 Bit will jump to 1, if the

function ABS control is deactiv-

ated by a fault.

ABS_Act- 0x5C0 29 1 Intel Unsigned 0 1 0 0 1 Bit will jump to 1, when

ive the ABS control is act-

ive.

EBD_Lam 0x5C0 30 1 Intel Unsigned 0 1 0 0 1 Bit will jump to 1, when

p the EBD is deactivated

due to a fault.

Bosch Motorsport ABS M5 Kit 39 / 52

12 | CAN Protocoll V15 customer from 0400 onwards

ABS

ABS_Lam 0x5C0 31 1 Intel Unsigned 0 1 0 0 1 Bit will jump to 1, when

p the ABS control is de-

activated due to a fault,

switched to the off po-

sition or while working

with RaceABS.

AX1_Bre 0x5C0 32 16 Intel Unsigned 0 0.000127 -4.1768 -4.1768 4.17367 g Used longitudinal ac-

mse60 42 celeration value in the

ABS.

AY1_Bre 0x5C0 48 16 Intel Unsigned 0 0.000127 -4.1768 -4.1768 4.1765 g Used lateral accelera-

mse60 42 tion value in the ABS.

MM5.10

Name ID Start [Bit] Length Byte Or- Value Initial Factor Offset Minimum Max- Unit Comment

[Bit] der Type Value imum

Yaw_Rate 0x70 0 16 Intel Unsigned 0 0.005 -163.84 -163.84 163.83 °/s Measured yaw rate

around the Z axle.

AY1 0x70 32 16 Intel Unsigned 0 0.000127 -4.1768 -4.1768 4.1765 g Measured lateral accel-

465 eration.

Roll_Rate 0x80 0 16 Intel Unsigned 0 0.005 -163.84 -163.84 163.835 °/s Measured roll rate

around the X axle.

AX1 0x80 32 16 Intel Unsigned 0 0.000127 -4.1768 -4.1768 4.1765 g Measured longitudinal

465 acceleration.

AZ 0x576 32 16 Intel Unsigned 0 0.000127 -4.1768 -4.1768 4.1765 g Measured vertical ac-

465 celeration.

Other IDs in use from ABS M5

0x140

0x141

0x142

0x143

0x340

0x341

0x343

0x75

40 / 52 ABS M5 Kit Bosch Motorsport

 Offer Drawing: Hydraulic Unit | 13

13 Offer Drawing: Hydraulic Unit

Bosch Motorsport ABS M5 Kit 41 / 52

14 | Offer Drawing: Wheel Speed Sensor

14 Offer Drawing: Wheel Speed Sensor

42 / 52 ABS M5 Kit Bosch Motorsport

 Offer Drawing: Brake Pressure Sensor | 15

15 Offer Drawing: Brake Pressure Sensor

Stutzen nach oben gerichtet.

Empfohlene Lage: 0...90°
in allen Richtungen zur Senkrechten.
ORIFICE DIRECTED UPWARDS.
RECOMMENDED POSITION: 0...90°
FROM VERTICAL.

0 261 B08 072 06

Bosch Motorsport ABS M5 Kit 43 / 52

16 | Mounting Instructions: Brake Pressure Sensor

16 Mounting Instructions: Brake Pressure

Sensor Bosch Gasoline 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

44 / 52 ABS M5 Kit Bosch Motorsport

 Offer Drawing: Yaw/Acceleration Sensor 500 kbaud | 17

17 Offer Drawing: Yaw/Acceleration Sensor

500 kbaud

Bosch Motorsport ABS M5 Kit 45 / 52

18 | Offer Drawing: Yaw/Acceleration Sensor 1 Mbaud

18 Offer Drawing: Yaw/Acceleration Sensor

1 Mbaud

46 / 52 ABS M5 Kit Bosch Motorsport

 Wiring Diagram | 19

19 Wiring Diagram

Bosch Motorsport ABS M5 Kit 47 / 52

20 | Wiring Diagram ABS M5 Clubsport

20 Wiring Diagram ABS M5 Clubsport

48 / 52 ABS M5 Kit Bosch Motorsport

 Wiring Harness | 21

21 Wiring Harness

Bosch Motorsport ABS M5 Kit 49 / 52

22 | Wiring Harness ABS M5 Clubsport

22 Wiring Harness ABS M5 Clubsport

50 / 52 ABS M5 Kit Bosch Motorsport

Bosch Motorsport ABS M5 Kit 51 / 52
Bosch Engineering GmbH
Motorsport
Robert-Bosch-Allee 1
74232 Abstatt
Germany
www.bosch-motorsport.com