abs mbs 2-04a - peugeot motocyclesinfotech.peugeot-motocycles.fr/doc/sav/abs_mbs_2-04b.pdf · c....

Sales divisionTechnical network leadership

TECHNICAL TRAINING

-

ANTI BLOCKING SYSTEMPOWER BRAKING SYSTEM-2

P/N.: FRE.005.03/2008.GB

Sales division

Technical network leadership

Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles

TABLE OF CONTENTS

1Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles

TABLE OF CONTENTS

TABLE OF CONTENTS..................................................................................................................................... 1

SYSTEM ADVANTAGES .................................................................................................................................. 2

REMINDER OF FUNCTIONING OF THE DIFFERENT BRAKING SYSTEMS................................................. 3

ABS/PBS. FIRST GENERATION...................................................................................................................... 4

GENERAL VIEW. (ABS/PBS-2) ........................................................................................................................ 5

DESCRIPTION OF THE HYDRAULIC COMPONENTS ................................................................................... 6

SYNOPTICS ...................................................................................................................................................... 7

SYSTEM OPERATION...................................................................................................................................... 8

Integral brake .............................................................................................................................................8

Secondary brake......................................................................................................................................10

Braking without assistance ......................................................................................................................11

Wheel anti-lock function...........................................................................................................................12

WIRING DIAGRAM.......................................................................................................................................... 13

DIAGNOSTIC................................................................................................................................................... 14

Faults stored by the ECU ABS/PBS-2 .....................................................................................................15

Problems which do not feed back fault codes ..........................................................................................16

SYSTEM ADVANTAGES


SYSTEM ADVANTAGES

Using power assistance provides powerful braking thus reducing stopping distances.

This system makes it simpler to use the vehicle: the heft hand brakes, and the right hand accelerates.

The rider brakes with the left-hand lever (integral braking), and the right-hand lever (braking on the front wheel only) becomes the secondary brake.

The rider brakes with the left lever (integral braking), and the right lever (braking on the front wheel only) becomes an emergency brake.

Combined front and rear braking system controlled by the LH brake lever:

Its integral braking function enables the front brake to be operated at the same time as the rear brake and therefore provide powerful braking. The stopping distance may be halved.

At 60 km/h the stopping distance is:

• With the rear brake only 26 m. • With both brakes 13 m.

This system is used in conjunction with a wheel anti-lock system enabling very harsh braking in complete safety. The rider no longer needs to apply the brakes in relation to the road condition, it is the system which adjusts the braking pressure as required.

On a dry or wet road, the system monitors braking to prevent the front wheel from locking.

The braking pressure on the rear wheel is purposely reduced to prevent it from locking, this is why there is no need for an anti-lock system on the rear wheel.

An inexperienced rider never uses his brakes to maximum capacity as he hesitates to brake hard for fear of locking the front wheel. With this system, he can brake fully in complete safety.

Advantages of the new system:

• Pressure sensors instead of brake contact switches. • ABS Control optimization. • Modulator is less noisy. • Lighter. • Brake lever feel is improved. • No more "spongy lever" when the vehicle is stopped.

REMINDER OF FUNCTIONING OF THE DIFFERENT BRAKING SYSTEMS


REMINDER OF FUNCTIONING OF THE DIFFERENT BRAKING SYSTEMS

Conventional hydraulic system

SBC integral hydraulic braking system SBC2 integral hydraulic braking system

ABS/PBS. FIRST GENERATION


ABS/PBS. FIRST GENERATION

UCE

TEP 2005

by xxotest

OK

PIN

+-

GENERAL VIEW. (ABS/PBS-2)


GENERAL VIEW. (ABS/PBS-2)

1. Modulator. 2. Right-hand brake lever. (Front brake). 3. Front brake caliper. 4. Left-hand brake lever. (integral brake). 5. Rear brake caliper. 6. Speed sensor and pulse wheel.

A. Main brake circuit. B. Rear brake circuit. C. Front brake circuit.

2

3

6

4

5

1

A

B

C

DESCRIPTION OF THE HYDRAULIC COMPONENTS


DESCRIPTION OF THE HYDRAULIC COMPONENTS

1. Braking control unit. A. ECU. B. Electric engine. C. High pressure pump. D. Brake fluid reservoir. E. Regulation solenoid valve. F. Diaphragm. G. Reed valve. 1. H. Reed valve. 2. J. Pressure sensor. 1. K. Pressure sensor. 2. L. Shock absorber.

2. Left-hand brake master cylinder. (integral brake).

3. Right-hand brake master cylinder. 4. Front brake caliper. 5. Rear brake caliper. 6. Machine speed sensor.

UCE

TEP 2005

by xxotest

OK

PIN

+-

L

K

G

1

D

C B

H

E

F

J

A

2 3

6

4

5

SYNOPTICS


SYNOPTICS

Rear circuit pressure sensor

Hydraulic pump

Front circuit pressure sensor

ECUABS/PBS-2

Regulation solenoid valve

Front wheel speed Software

It controls the system's operation

CalibratingVehicle's

specific values (mapping)

Main relay

Battery voltageInstrument

panel

Vehicle's wiring harness PIN

code

Starter motor relay

Diagnostic plugDiagnostic

light

SYSTEM OPERATION


SYSTEM OPERATION

Integral brake

Functioning: The fact of pressing the LH brake master cylinder (2) creates a pressure inside the rear calliper (5), and the ECU (A) is informed of the action on the lever by the pressure sensors (J). The ECU (A) controls the electric motor (B) which drives the pump (C), and the created pressure moves the diaphragm (F), opens the reed valve (G) and actuates the front calliper (4).

Braking assistanceThe sensors (J) inform the ECU (A) of the effort on the brake master cylinder (2).

A. If the effort is low, the solenoid valve (E) is controlled, the reed valve (H) opens, a large quantity of brake fluid is pumped out back to the reservoir (D) by the pump (C), and the pressure inside the front calliper (4) is low.

UCE

+-

L

K

G

1

D

C B

H

E

F

J

A

2 3

6

4

5

SYSTEM OPERATION


Integral brake

B. If the effort is high, the ECU (A) reverses the current circulation in the solenoid valve (E), the reed valve closes (H), and all the pressure created by the pump (C) acts on the front calliper (4).

UCE

L

K

G

1

D

C B

H

E

F

J

A

2 3

6

4

5

SYSTEM OPERATION


Secondary brake

Functioning: The fact of pressing the RH brake master cylinder (3) creates a pressure, and the sensor (K) informs the ECU (A) which controls the electric motor (B) and the pump (C). The braking assistance operates according to the same principle as the integral braking circuit.

UCE

L

K

G

1

D

C B

H

E

F

J

A

2 3

6

4

5

SYSTEM OPERATION


Braking without assistance

Safety: If there is a malfunction in the modulator (1), the vehicle's braking system operates like a conventional system. The action on the LH master cylinder (2) creates a pressure which directly actuates the rear calliper (5). The action on the RH master cylinder (3) penetrates the modulator (1), thus the high pressure pump (C) does not operate, the reed valve (G) opens, the pressure goes through the modulator (1) and acts on the front calliper (4).

UCE

L

K

G

1

D

C B

H

E

F

J

A

2 3

6

4

5

SYSTEM OPERATION


Wheel anti-lock function

Functioning: In the integral braking phase with braking assistance, when the speed sensor (6) informs the ECU (A) about a sharp deceleration of the front wheel, the ECU controls the solenoid valve (E), and the reed valve (H) opens completely. The front calliper (4) is connected to the reservoir (D) of the modulator (1), the pressure drops in the front calliper (4) and prevents thus the front wheel from locking.

UCE

L

K

G

1

D

C B

H

E

F

J

A

2 3

6

4

5

WIRING DIAGRAM


WIRING DIAGRAM

SATELIS 125cc

1. Modulator. 2. Machine speed sensor. 3. Battery. 4. Ignition switch. 5. ABS/PBS relay. 6. Power supply relay. 7. Starter motor switch.

8. Starter motor relay. 9. Diagnostic plug. 10. Instrument panel (diagnostic lamp, machine speed).

SATELIS. PIN code: 35 GEOPOLIS. PIN code: 30

-

UPPER

LEV

EL

LOW

ER L

EVEL

A3

A2

A1 B1

B3 1123 9

314517

1921

25

20

13101

12V - 25A

1 23 4 5

12V - 25A

2 13 4 512V - 25A

1 23 4 5

6 3

OFF

ON

ABS

km

°C

C

F

E

H

Trip

EFI

km/h

mph

70

1020

30

4050 60

8090

100110

100

30

5070

90 110

130150

170

X1000 r/min

01

23

45 6 7

8

910

1112

24132623

START

PIN

VI

VI

VE

VE

RG/NR

MR/BA

JN/BAJN/VE

VE

GR

BA

OR

RG RG

JN

NR

NR

VE

VE

VE

10A

30A

5A

30A

RG

RG

BE

BE

RG

GR/BE

GR/BE

GR/BE

10 5 6

7

8

9

34

2

1

1123 9

314517

1921

25

20

13101

PIN

+

1123 9

314517

1921

25

20

13101

PIN

DIAGNOSTIC


DIAGNOSTIC

Before servicing the system, carry out a diagnosis using the diagnostic tool and print out a parameter report.

Diagnostic tool TEP 2005Diagnostic tool functions:

• Reading fault codes. • Reading the parameters. • Activation of actuators. • Downloading the ECU updates.

Diagnostic code

Incident ECU code Fault description Assistance functionABS functi

onLED state

A ECU fault

1 Pump motor fault

No No On2 Solenoid valve fault

3 Error current measurement

8 EEPROM error Yes Yes On

10 Pressure fault

No No On

15 RAM ROM... error

17 AD converter error

18 Speed sensor signal fault

21Machine parameter error in EEPROM

22 Pressure fault

24 Temperature sensor fault

BECU power supply fault

4 Main rele faultNo No On

19 Power supply fault

5 Diagnostic light fault No No On

6 Speed sensor signal fault No No On

7 Power supply fault +APC (+ after the ignition) No No On

9 Module condition fault No No On

14 PIN code fault No No On

16 Wheel locking too long No No On

23 Starter motor relay line fault Yes Yes On

OK

TEP 2005

by xxotest

DIAGNOSTIC


Faults stored by the ECU ABS/PBS-2

A-ECU fault (Fault codes: 1-2-3-8-10-15-17-18-21-22-24)

Occurs when an ECU internal fault is detected.

In this case, note the FTE fault codes shown in a diagnostic page and change the modulator without clearing the codes in the memory. Return the modulator to Peugeot Motocycles with the diagnostic sheet.

B-ECU power supply fault (Fault codes: 4-19)

Appears when an electrical problem occues on the ECU power supply circuit.

Check the battery charge state and condition of the terminals, the modulator electrical circuit (the power supplies and earth), operation of the main relay.

5-Diagnostic light fault

It appears when an electric problem occurs on the diagnostic telltale's power supply circuit.


Check the diagnostic light and its harness.

6-Speed sensor signal fault

Occurs when the speed sensor signal is not that of the signal expected.

Check the speed sensor, gap not in compliance, phonic wheel bent, defective sensor.

7-Power supply fault +APC (+ after the ignition)

Occurs when there is no +APC power supply on terminal 13 of the ECU.


Check the +APC circuit, the fuse, the wiring harness.

9-Module condition fault

Occurs when the modulator is not recognized as the main module (main or secondary). Check the modulator's wiring harness and connector.

14-PIN code fault

Occurs when there is no match between the ECU PIN code, harness and possible code for this ECU.

Check the harness PIN code (terminals 19, 20, 21), the ECU PIN code and its match with the machine, and that the ECU accepts the PIN code.

The diagnosis of the battery voltage is inhibited when the starter motor is activated.

DIAGNOSTIC


16-Wheel locking too long

Occurs when the wheel locks due to a mechanical problem with the braking circuit (seizure of the calliper).

Check the mechanical operation of the calipers if the wheel is actually locking.

Check the speed sensor, gap not in compliance, phonic wheel bent, defective sensor.

23-Starter motor relay line fault

Occurs when the information from the starting relay is not consistent with the operation of the modulator.

Check the starter motor relay and its harness.

Problems which do not feed back fault codes

Machine speed display error on instrument panel

Use the diagnostic tool to check the machine speed calculated by the ECU. (read parameters).

• Check the machine speed sensor and its harness. • Check the harness between the instrument panel and the ECU.

Diagnostic light always off

Use the diagnostic tool to check functioning of the diagnostic light (activate actuator).


Diagnostic light always on and no fault memorised


Poor braking

• Check the fluid level in the master cylinder reservoirs. (When filling never exceed the maximum level).

• Check the brake fluid level in the control unit reservoir.• Bleed the front and rear brake circuits.• Bleed the modulator

Drain the braking circuit

Refer to the workshop manual: Satelis 400/500 cc. P/N 759562.

DIAGNOSTIC


abs mbs 2-04a - peugeot motocyclesinfotech.peugeot-motocycles.fr/doc/sav/abs_mbs_2-04b.pdf · c....

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