BOSCH BAS100 eBike ABS System Instruction Manual

BOSCH BAS100 eBike ABS System

Product Information

The Bosch eBike ABS (Anti-lock Braking System) BAS100 is a safety feature designed for eBikes. It is manufactured by Robert Bosch GmbH, based in Reutlingen, Germany. The system includes various components such as a board computer, ABS control indicator, operating unit, front brake lever, brake calliper, wheel speed sensor, and sensor disc. The ABS control indicator can be either an external indicator or integrated into the display of the board computer (BUI330 and BUI350). The installation position of the components may vary depending on the bicycle manufacturer. The ABS operates within a temperature range of -5°C to +40°C and has an IPx7 protection rating. It weighs approximately 1.0 kg. Please refer to the brake manufacturer’s instructions for proper installation and maintenance of the brakes.

Safety instructions

Read all the safety information and instructions. Failure to observe the safety information and follow instructions may result in electric shock, fire and/or serious injury. Save all safety warnings and instructions for future reference.  The term battery is used in these instructions to mean all original Bosch eBike rechargeable battery packs.

• Read and observe the safety warnings and directions contained in all the eBike system operating instructions and in the operating instructions of your eBike.

The safety information in these operating instructions is divided into the following categories:

• WARNING – Danger with a moderate degree of risk. Failure to observe this instruction may result in death or serious injury.
• CAUTION – Danger with a low degree of risk. Failure to observe this instruction may result in minor to moderate injury.
• NOTE – Specific information to improve handling. This is used in reference to operating instructions, checks, adjustments and maintenance work.

Safety information for anti-lock braking systems (ABS)

• Tampering with the system components is not permitted under any circumstances. The rider must adapt their riding style to the environmental conditions (e.g. the coefficient of friction between the tyres and the ground, steep inclines, weather, additional loads, etc.). Carrying an additional load that changes the vehicle’s centre of gravity in any way (e.g. a basket or a child seat on the handlebars), which could increase the tendency to pitch over, is not recommended.

• WARNING – Tampering with components of the ABS will prevent it from working correctly.
  If any components of the braking system or the ABS are tampered with, modified, or replaced with unauthorised components, this may prevent the ABS from working as it should. Correct operation cannot be guaranteed and there is a greater risk of falling over. Servicing and repairs must only be carried out by professionals. Defective parts must always be replaced with original parts.

• WARNING – use of exclusively original brake fluid Only the original brake fluid intended for the respective foundation brake may ever be used as brake fluid. If another brake fluid is used, correct operation cannot be guaranteed and there is a greater risk of falling over. Servicing and repairs must only be carried out by professionals.

• WARNING – ABS increases braking distance
  The ABS prevents the front wheel from locking. This significantly improves rider safety by reducing the risk of skidding on low-friction surfaces and pitching over on high-friction surfaces. In some situations, however, system intervention may increase your braking distance. Always adapt your riding style to the present environmental conditions and your personal cycling abilities.

• WARNING – Reckless riding
  The presence of the ABS does not absolve the rider of the need to exercise due caution. The system is primarily designed to provide an additional safeguard in emergency situations. The rider is always responsible for adapting their riding style to the situation on the road.

• WARNING – Braking around corners
  The ABS is a safety system that reduces the risk of the wheels locking when braking in a straight line with no lateral forces acting on the vehicle. There is an inherently greater risk of falling over when braking around corners. The rider is always responsible for adapting their riding style to the situation on the road.

• WARNING – ABS intervention is limited.
  In extreme riding situations, the ABS may not be able to control the bicycle all the way through to the wheel coming to a complete stop. The ABS function can be re-enabled for braking by briefly releasing the front-wheel brake. Always adapt your riding style to the present environmental conditions and your personal cycling abilities.

• WARNING – eBike pitch over
  The ABS is not always able to prevent the vehicle from pitching over in extreme riding situations (e.g. when carrying a heavy bag with a high centre of gravity or the vehicle having a high centre of gravity, e.g. due to the saddle being set high or variations in the road surface or steep descents). Always adapt your riding style to the present environmental conditions and your personal cycling abilities.

• WARNING – Air in the hydraulic system
  The air in the system means that less braking force can be built up, especially following intervention by the ABS, in which the brake lever also moves a little closer to the handlebars. There is an additional risk of crushing fingers which are not wrapped around the brake lever and remain on the handle while braking. Before every journey, you should therefore apply the brake to check whether there is a clearly noticeable centre of pressure and whether there is sufficient clearance between the brake lever and the handlebar grip. The centre of pressure should be at approximately 1/3 of the brake lever travel. In case of doubt, set the brake lever to the maximum possible length of travel. If air finds its way into the brake system, please have it bled by a professional. Always adapt your riding style to the present environmental conditions and your personal cycling abilities.

• CAUTION – Damage to components or risk of crushing Take care not to trap components such as brake lines, cable harnesses or parts of the body between the ABS control unit and the frame. This will help prevent damage to components and bodily injury, even in the event of the handlebars fully locking.

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

Product Description and Specifications

Product Features
The numbering of the components shown refers to the illustrations on the graphics pages at the beginning of the manual. Individual illustrations in these operating instructions may differ slightly from the actual conditions depending on the equipment of your eBike.

1. ABS control unit with casing
2. On-board computer
3. ABS indicator light
4. Operating unit
5. Front-wheel brake lever
6. Brake caliper
7. Wheel speed sensor b)
8. Sensor disc

• a) The indicator light may be an external indicator light (as shown in the figure) or an indicator light integrated into the display (BUI330 and BUI350) of the onboard computer.
• b) The attachment position may vary depending on the wheel manufacturer.

Technical data
Note: For a description of the brakes and how they function, please refer to the instructions provided by the brake manufacturer.

How it works

When the brakes are operated, the ABS function identifies critical slippage using the wheel speed sensors on the front and rear wheels and limits slippage on the front wheel by reducing the braking pressure and thereby stabilising the wheel.
Once the wheel has been stabilised, precise increases in pressure bring the wheel back up to the locking limit. This causes the lever to move a small distance towards the handlebars with every braking impulse. If the wheel locks again, the pressure is reduced as before. This process is repeated in order to keep the wheel at the grip limit at all times and therefore optimise exploitation of the coefficient of friction between the tyres and the ground.
The ABS function is ended when one of the following happens:

• The memory of the ABS control unit is full.
• The eBike comes to a stop.
• The rider releases the brake.

In addition to the ABS function, a system has been integrated that detects when the rear wheel lifts off the ground during heavy braking. This means that, within certain limits, forward pitchover can be counteracted during very hard braking manoeuvres.

Fitting
The anti-lock braking system is fully assembled by the manufacturer and must not be modified.
Warning! If you would like to attach other accessories to the handlebars, bear in mind that the handlebars must be able to turn freely at least 60° to either side from the centre position. Crushing of fingers can be prevented by leaving a clearance of 25 mm. Steering limiters may need to be fitted.

Operation

Before every journey
Check to ensure that the ABS indicator lamp is working correctly whenever you switch the system on. You can find more information about this in the section entitled (see “The anti-lock braking system indicator lamp”. Please check the condition and roadworthiness of the eBike before every journey. The eBike must be in perfect working order during use. Always check to ensure that the front- and rear-wheel brakes are working correctly before setting off. Check to ensure that the thickness of the brake pads and the brake discs meet the manufacturer’s specifications before setting off.

Before the first journey
Familiarise yourself with how the brakes and ABS work and how they respond when you actuate them, for example by practising your braking technique away from busy roads. Disc brakes need a while to take effect and their braking power increases over time. You should therefore bear in mind that the braking force may increase while braking. This also happens after replacing the brake pads or the disc. For information on changing the brake discs and brake pads, as well as what to do when applying the brakes, please refer to the instructions provided by the brake manufacturer.

During the journey
Adapt your riding style to the present riding situation, the road conditions and your cycling abilities. Please be aware that the anti-lock braking system may increase your braking distance. On slippery surfaces, the tyres skid more easily and there is a greater risk of falling over. You should therefore reduce your speed, applying the brakes in good time using a steady pressure.

The anti-lock braking system indicator lamp
The anti-lock braking system indicator lamp must come on after starting the system and must go out again once you start riding at a speed of approximately 5 km/h. If the ABS indicator lamp does not come on after starting your eBike system, this means that the ABS is defective. A fault code to this effect will also be shown on the display to notify the rider.

• Please make sure you have all repairs carried out by a professional.
  If the indicator lamp does not go out once you have started riding or comes on while riding, this means that there is a fault with the anti-lock braking system. This means the anti-lock braking system is no longer active. The brake system will continue working, simply without the control provided by the anti- lock braking system. The functionality of the rear-wheel brake is not affected by whether or not the anti-lock braking system is working.

• WARNING – ABS indicator lamp lit.
  If the ABS indicator lamp is lit, this means that the ABS function is disabled.
  Note: The anti-lock braking system indicator lamp may come on in extreme riding situations where the front wheel and the rear wheel are turning at very different speeds, for example when riding solely on the rear wheel or if the wheel is turning for an unusual long period without making contact with the ground (assembly stands). This will switch the anti-lock braking system off. To re-enable the anti-lock braking system, you will need to stop the eBike and restart it (switch it off and on again).

• CAUTION – Faults with the ABS cannot be signalled if the ABS indicator lamp is defective.
  When starting the eBike system, the rider must therefore check to ensure that the ABS indicator lamp is present and lit; otherwise, the indicator lamp is defective.

Riding with the eBike battery drained
If the battery’s state of charge falls below a defined threshold, the system will disable motor assistance first. The system (including display, light and ABS) will nevertheless remain enabled until the battery’s reserve has been used up too. The eBike system – and therefore the ABS – will not switch off until the battery is almost completely drained. The indicator lamp will come on again for approximately five seconds before the system switches off completely. From this point onwards, the ABS indicator lamp will remain off despite ABS control being unavailable. If the eBike is not fitted with a battery or its battery is drained, ABS is disabled. The brake system will continue working, simply without the control provided by the anti-lock braking system. You will need to charge the battery before you can re-enable your eBike system and the ABS function.

WARNING – ABS will be disabled without a power supply!
If the power fails, the battery is drained or the battery is not fitted, the ABS will be disabled and the ABS indicator lamp will not come on.

Maintenance and servicing

Maintenance and cleaning

• Servicing and repairs must only be carried out by professionals. Defective parts must always be replaced with original parts.
  Have your eBike system checked by an expert at least once a year (including mechanical parts, and up-to-date of system software). Please have your eBike serviced and repaired by an authorised bicycle dealer.

After-sales service and advice on using products
If you have any questions about the eBike system and its components, contact an authorised bicycle dealer. For contact details of authorised bike dealerships, please visit www.bosch-ebike.com.

Disposal
The drive unit, onboard computer incl. operating unit, battery, speed sensor, accessories and packaging should be disposed of in an environmentally correct manner. Check that your personal data has been deleted from the device. Do not dispose of eBikes and their components with household waste.

Check that your personal data has been deleted from the device. Do not dispose of eBikes and their components with household waste. Please return Bosch eBike components that are no longer usable free of charge to an authorised bicycle dealer or to a recycling facility. Subject to change without notice.

In accordance with Directive 2012/19/EU and Directive 2006/66/EC respectively, electronic devices that are no longer usable and defective/ drained batteries must be collected separately and recycled in an environmentally friendly manner. Please return Bosch eBike components that are no longer usable free of charge to an authorised bicycle dealer or to a recycling facility. Subject to change without notice.

References

• Bosch eBike Systems | Premium eBike systems & smart features - Bosch eBike Systems
• Bosch eBike Systems | Premium eBike systems & smart features - Bosch eBike Systems

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