presentation on abs by amit ghawari
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Presentation on Abs by Amit GhawariTRANSCRIPT
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A B S Anti-lock Brake System
Safe Journey … Always !
Presentation
on
Anti-lock Brake System
(ABS)
By AMIT GHAWARI
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A B S Anti-lock Brake System
Safe Journey … Always !
Agenda
• Need
• Function
• Benefits
• Major aggregates
• Installation
• Legislation on ABS in India
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A B S Anti-lock Brake System
Safe Journey … Always !
European Braking System Trend
1950 1960 197 0 1980 19 90 2000 2010
Year
Single LineSingle Line
Brake SystemBrake System
DualDual
Brake SystemBrake System
Dual BrakeDual Brake
SystemSystem
ABSABS
EBSEBS
VDCVDC
India
ASRASR
Gap
ACCACC
1950 1960 197 0 1980 19 90 2000 2010
Year
Single LineSingle Line
Brake SystemBrake System
DualDual
Brake SystemBrake System
Dual BrakeDual Brake
SystemSystem
ABSABS
EBSEBS
VDCVDC
India
ASRASR
Gap
ACCACCAdaptive Cruise Control
Vehicle Dynamic Control
Electronically controlled Braking System
Anti-Spin Regulation
Anti-lock Brake System
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A B S Anti-lock Brake System
Safe Journey … Always !
Vehicle skidding on wet roads and higher speeds
due to wheel lock
Vehicle going out of control
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A B S Anti-lock Brake System
Safe Journey … Always !
Wheel lock ?
Rotation of wheel stops while the vehicle in motion
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A B S Anti-lock Brake System
Safe Journey … Always !
Reasons for wheel locking?
Normal roads at higher speeds
Wet roads at lower speeds
Effects of wheel locking?
Front wheel locking – loss of steerability
Rear wheel locking – loss of stability
Tyre wear - Tyre flat spot
Wheel lock ?
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Effects of ‘Wheel locking’
Tractor - Trailer
Steering Wheelslocked
Tractor RearWheels locked
Trailer Wheelslocked
Plow Out(Can’t Steer)
Jack knife(Tractor Spins)
Trailer Swing(Trailer Spins)
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Tractor-Trailer : Plow-out
Tractor is not turning as per driver’s commend
Tractor front wheel locked condition
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Tractor-Trailer : Jack-knifing
Tractor rear wheel locked condition
Tractor is turning on its own way
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Tractor-Trailer : Swing
Tractor is in on lane and trailer is in another lane
Trailer wheel locked condition
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Preventing wheel locking
How driver tries to manage wheel lock
• Avoids applying sudden braking
• Avoids panic braking
• Pumping on wet roads
Which requires,
• Experienced driver
• Always drivers to be alert
•
Road and vehicle maintenance in good condition
Is it possible always?
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Preventing wheel locking
How to avoid wheel lock
Individual wheel brake pressure tobe controlled precisely based on
- Road
- Load
- Speed
- Brake lining condition
which driver may not be able to judge &control always
Solution : Anti-lock Brake System (ABS)
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ABS Function
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ABS Function
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Benefits of ABS
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Purpose
To prevent vehicle skid in a panic braking situation
and to bring vehicle to a controlled stop.
How does ABS work?
Wheel lock ABS functionWet Basalt road at 50kmph speed unladen
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Method
Detect impending wheel lock and by repeatedly
modulating the brake pressure avoid wheel lock.
Benefits
Improved safety
Vehicle stability
Vehicle steerability
Controlled stopping
Avoids jack-knifing
How does ABS work?
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Anti-lock Brake System Safe Journey … Always !
Braking on Wet Asphalt / Wet Basalt 50kmph
ABS performance - Vehicle Stability
With ABS
Without ABS
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Safe Journey … Always ! Lane Change maneuver in Wet basalt at 40kmph
ABS performance - Steerability
With ABS
Without ABS
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Safe Journey … Always ! Braking on Wet Asphalt at 50kmph
ABS Performance- Controlled stopping
With ABS
Without ABS
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ABS Performance – Avoid Jack-knifing
Braking on Wet tar road / Slippery road at 35kmph
With ABS
Without ABS
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Major aggregates
S j
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Electronic
Control Unit
Speed SensorPolewheel
Modulator Valve
ABS – Major aggregates
Cables : Frame harness: Power Harness
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ABS Schematic Layout – 4S 4M
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ABS schematic Layout – 4S 4M MAV
ABS P l h l
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Product Description:
• Polewheel is a toothed wheel made of ferrous material.• It has 100 evenly spaced teeth.
Function: • The polewheel rotates along with the hub and cut the
magnetic flux generated by the wheel speed sensor.
Fitment: • It is fitted on the wheel hub.(Either fastened or shrink fitted)
ABS components - Polewheel
ABS t S
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Product Description: • It is a magnetic sensor (passive sensor) consists of a permanent magnet
and a coil assembly.Function:
• To generate electrical pulses in proportional to wheel speed and transmitsto the ECU as a sinusoidal signal.
Fitment :
• Fitted with a sensor bush in a bracket mounted in the carrier plate as astationery part.
• The air gap of < 0.2 mm is maintained between polewheel and sensor.
ABS components - Sensor
ABS t ECU
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A B S Anti-lock Brake System Safe Journey … Always !
ABS components - ECU
Product Description: The ECU acts as the processing unit(brain) of the system.
Function: • Based on the inputs from sensors, it computes vehicle
speed and deceleration and detects an impending wheel
lock situation and sends signals to modulator valve of
corresponding wheel which tends to lock.• It has built-in self diagnostics and fault logging and
warning lamp indication.
Fitment:
• Mounted at drivers cabin.
Variant :• 12 V and 24 V system• E basic version, 4S/4M, KWP 2000 (Diagnostic protocol) andSAE J1939 (Engine interface).
ABS t M d l t V l
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A B S Anti-lock Brake System Safe Journey … Always !
ABS components - Modulator Valve
Product Description:
• This is a fast response electrically operated solenoid valve which modulates
the air pressure in the brake actuator.Function:
• To modulate air pressure of the brake actuators in three states viz.Apply, Hold, Release and operates according to the command from ECUduring ABS operation.
• It is normally open type and acts as a pipe during normal braking.Fitment: • Fitted between dual brake valve and brake actuator in the service line.Varient: • 24 V and 12 V.
ABS t S E t i C bl
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A B S Anti-lock Brake System Safe Journey … Always !
ABS components – Sensor Extension Cable
Product Description: • A two core cable interfaces the respective wheel speed sensors
with ECU.
Function:
• Transmit the signals from wheel speed sensors to ECU.
Fitment: • Connects the ECU and Sensors individually.• One end with two pin socket connected to sensor.• Other end connected to ECU through 18 pin connector.
ABS t M d l t V l C bl
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A B S Anti-lock Brake System Safe Journey … Always !
ABS components - Modulator Valve Cable
Product Description:
• A three core cable interfaces modulator valve with ECU.(one core for inlet line, one core for outlet line and one core for common
ground line).
Function: • Transmit the signals from ECU to modulator valves during ABS operation.
Fitment: • Connects the ECU and all modulator valves individually.• One end with three pin molded DIN Bayonet socket for the MV solenoid.• Other end connected to ECU 18 pin connector.
W i L & Bli k C d S it h
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A B S Anti-lock Brake System Safe Journey … Always !
Warning Lamp & Blink Code Switch
Product Description: • A lamp and a switch are used to indicate the failure of a circuit or componentof ABS stored in ECU memory.
Function: • To display the two digit number stored in the ECU.• To indicate whether the faults are rectified.
Fitment:
• Fitted in dash board visible to driver.
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A B S Anti-lock Brake System Safe Journey … Always !
ABS Components - Installation
ABS components Polewheel : Front
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A B S Anti-lock Brake System Safe Journey … Always !
ABS components – Polewheel : Front
ABS components Polewheel : Rear
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A B S Anti-lock Brake System Safe Journey … Always !
ABS components – Polewheel : Rear
ABS components Sensor Bush & Bracket
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A B S Anti-lock Brake System Safe Journey … Always !
ABS components – Sensor, Bush & Bracket
ABS components Sensor & Grommet
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A B S Anti-lock Brake System Safe Journey … Always !
ABS components – Sensor & Grommet
ABS components ECU
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A B S Anti-lock Brake System Safe Journey … Always !
ABS components - ECU
ABS components Modulator Valve
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A B S Anti-lock Brake System Safe Journey … Always !
ABS components – Modulator Valve
ABS components WL & Blink Code Switch
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A B S Anti-lock Brake System Safe Journey … Always !
ABS components – WL & Blink Code Switch
ABS components – ECU
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A B S Anti-lock Brake System Safe Journey … Always !
ABS components – ECU
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A B S Anti-lock Brake System Safe Journey … Always !
ABS Diagnosis
ABS Diagnostics
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A B S Anti-lock Brake System Safe Journey … Always !
Built - in Diagnostics
1. Failure detection 2. Driver indication 3. System action 4. Fault storage
Failure detection , Drivers indication and System action
• ECU continuously monitors the electrical status of the ABS components.
• In the event of a failure in any ABS component the warning lamp comes „on‟
• The error code can be read through WL flashes by actuating BC switch.
Fault Storage
• A component or circuit malfunction detected by the ECU is stored in it.
• There are two types of faults :- active error and stored error.• The stored data can be retrieved / erased from the ECU memory using :
- Blink Code display- Compact Tester- PC Based tester
ABS Diagnostics
ABS Diagnostics
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A B S Anti-lock Brake System Safe Journey … Always !
Active error
• The error represents a live failure which needs repair.
• It causes the ABS warning lamp to remain „on‟ after the ignition is „on‟. • Active error can not be erased until it is rectified or repaired.
Example:- Sensor circuit failure or broken wire or an inoperative MV.
Stored error
• Faults that affect ABS operation only at certain times.
• The ABS WL comes „on‟ when the fault is first detected. • If ignition is restarted and the fault does not exist, the ABS WL will goes
„off‟ and the fault will be stored in memory of ECU.
• The ABS will function as normal.Example:- Loose connector or instant air gap error.
It is possible to erase stored error from ECU memory if the conditiondoes not exist at that time.
ABS Diagnostics
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A B S Anti-lock Brake System Safe Journey … Always !
Blink Code mechanism
ABS Diagnostics
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A B S Anti-lock Brake System Safe Journey … Always !
Blink Code Display
The ABS Warning lamp is used to display blink codes.
Warning Lamp Blink Code Switch
ABS Diagnostics
ABS Diagnostics
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A B S Anti-lock Brake System Safe Journey … Always !
ABS Diagnostics
System without error
• Switch ‘on’ ignition.
• Warning Lamp comes ‘on’.
• Warning Lamp goes ‘off’.
• (Observe Modulator Valve noise.
- D Basic : 6 times.
- E Basic : 4 times).
System is okay.
To see the stored error• Press blink code switch for 0.5 second
• WL comes ‘on’ and goes ‘off’ • Observe the WL flashes
: 1 - 1 Okay. No stored error.: 3 - 1 etc. All stored errors will be shown one by one.
ABS Diagnostics
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A B S Anti-lock Brake System Safe Journey … Always !
Only one active error will be shown at a time.
After rectification of the first active error, next active error
will be shown if any.
ABS Diagnostics
System with active error
• Switch ‘on’ ignition.
• WL will glow continuously.
• Press BC switch for 0.5 second.
• Warning Lamp goes ‘off’.
• Observe WL flashes .
say 4 – 2. FL Sensor short / open.• Switch off ignition.
• Rectify the active error.
Active error once rectified, it becomes stored error automatically.
Blink Code reading
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A B S Anti-lock Brake System Safe Journey … Always !
g
Block 1 (Component / Nature of error) Block 2 (Location)
1 - No fault 1 - No fault
2 - ABS Modulator Valve 1 - Front Right (FR)
3 - Sensor Air Gap 2 - Front Left (FL)
4 - Sensor short / open 3 - Rear Right (RR)
5 - Sensor Intermittence 4 - Rear Left (RL)
6 - Sesnor, Polewheel
1 - Engine control data link
3 - Third brake relay short / broken wire4 - Warning lamp
1 - Battery under voltage
2 - Battery over voltage
3 - Internal fault
4 - Configuration error
5 - Ground
7- System function
8 - ECU
ABS Diagnostics
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A B S Anti-lock Brake System Safe Journey … Always !
Condition System response Reason Action
ABS lamp comes 'on' at ignitionmomentarily, then goes 'off'
System is okay. No action required.
Bulb is loose in
holder
Tight the bulb in holder
properly.
Fused bulb Replace with new bulb
Improper or fauly
wiring
Inspect and repair the
wiring
After
servicing
ABS
ABS lamp does not go 'off' at
ignition
Blink code switch
was pressed for
three seconds (or)
sensor related
complaints are
attended.
Drive the vehicle at
speed above 7 kmph.
Ensure lamp goes 'off'.
ABS lamp goes 'off' System is okay. No action required.
ABS lamp does not go 'off'Active error(s) still
exists.
Rectify the active
error(s).
ABS lamp does not come 'on'.
Normal
operation
Drive the
vehicle at
speed above
7 kmph.
Ignition 'On'
The ABS warning lamp works as follows:
ABS Diagnostics
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A B S Anti-lock Brake System Safe Journey … Always !
ABS – Maintenance
Daily Checking
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A B S Anti-lock Brake System Safe Journey … Always !
Daily Checking
• Switch „on‟ ignition
• Warning lamp comes „on‟
• Warning lamp goes „off‟
System is Okay
Vehicle System Maintenance for ABS
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A B S Anti-lock Brake System Safe Journey … Always !
Battery Voltage: ABS working voltage range is
9 to 16 Volts – 12 Volt system
18 to 32 Volts – 24 Volt system
Foundation Brake:
ABS CANNOT COMPENSATE FOR FOUNDATION
BRAKE INEFFICIENCIES.
Normal brake maintenance to be carried out as usual.
y
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A B S Anti-lock Brake System Safe Journey … Always !
Trouble shooting
Air gap adjustment
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A B S Anti-lock Brake System Safe Journey … Always !
g p j
< 0.2 mm
Sensor
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A B S Anti-lock Brake System Safe Journey … Always !
Note: Always push the sensor until ittouches the pole wheel(Air gap < 0.2mm)
i) Sensor air gap ( 3-1, 3-2, 3-3, 3-4)
< 0.2 mm Wheel Speed Sensor
Polewheel
Note: Always push the sensor until it
touches the pole wheelNote:
• Push sensor until it touches polewheel
• Do not push sensors with sharp objects
• Rotate the hub to self adjust the air gap
• Air gap < 0.2mm is recommended
• Maximum allowable air gap is 0.7mm
< 0.2 mm
System Maintenance Air gap adjustment
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A B S Anti-lock Brake System Safe Journey … Always !
System Maintenance
Electrical System:
Ensure battery connection to ECU is removed before doing
any electrical work like welding.
Air Gap:
When carrying out hub greasing , lining change etc. ensure
that the sensor is pushed back towards the pole wheel.
g p j
Sensor
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ii) Sensor Short/Open (Error: 4-1, 4-2, 4-3, 4-4)
The sensor short /open error may be due to
a) faulty sensorb) faulty sensor extension cable
a) Sensor• The sensor can be checked by measuring the resistance of the
sensor coil using a multimeter as detailed below:-- Disconnect the sensor and sensor extension cable.- Measure the sensor coil resistance between terminals at sensor endby using a digital multimeter.
• If the sensor coil resistance is 1150+100/-50 ohms, the sensor is okay.
• If the resistance value is not with in specified range, replace the sensorwith a new one.(If sensor coil is short, the resistance value will be zero ohm.If sensor coil is open, the resistance value will be infinite.)
Sensor
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A B S Anti-lock Brake System Safe Journey … Always !
b) Sensor Extension cable• If the sensor is okay, then sensor short/ open error may be due to fault in thecorresponding sensor extension cable.
• To confirm the faulty sensor extension cable,- Connect the sensor with sensor extension cable properly.- Disconnect the 18 pin connector from the ECU.- Measure the sensor coil resistance at the ECU end 18 pin connectorbetween IG (sensor input) & IGM (sensor ground) using a digital multimeter.
- If the sensor coil resistance is not 1150+100/-50 ohms, it confirms faultysensor extension cable. Replace the entire frame harness assembly as a whole.
Note :- No rework of the sensor cable or sensor extension cable is allowed.(The ECU 18 Pin connector and pin number details are shown below)
Sensor Pin Number FL 12 and 15 FR 10 and 13 RL 11 and 14 RR 17 and 18
18 Pin connector
View from back
Sensor
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A B S Anti-lock Brake System Safe Journey … Always !
iii) Sensor intermittence error ( 5-1, 5-2, 5-3, 5-4)
Normally the sensor intermittence error will be a stored error.To avoid reoccurrence, it is necessary to check the following points in thesensor cable routing from axle end to ECU and rectify:a) Any loose connections
- Check for proper fixing of sensor connector with sensor extensioncable connector.
- Check for proper insertion of sensor wires in 18 pin connector.b) Any rubbing of cables and any damage to the outer sheathing.
Polewheel
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DAMAGED TOOTH CORRECT TOOTH CONTAMINATED TOOTH
Sensor - Polewheel error (6-1, 6-2, 6-3, 6-4)
This error will occur in case of any of the following problems:-
• Any damage to the polewheel teeth or any missing teeth.• Any uneven spacing of the polewheel teeth.• Any facial run out of the polewheel
- Replace polewheel if any of the above problems are noticed.- Clean foreign particles such as burr, dust etc. that have accumulated
between the teeth.
Modulator Valve
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Modulator Valve errors (2-1, 2-2, 2-3, 2-4)
The modulator valve error may be due toa) faulty modulator valveb) faulty modulator valve cablec) improper connection of bayonet connector with modulator valve
This can be checked bya) measuring the resistance of modulator valve solenoid coilsb) cable continuity
Modulator Valve
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1) Resistance checka) Remove the bayonet connector of the corresponding modulator valve
having error.
b) Check for the resistance of the solenoid coils using a digital multimeter.The resistance shall be as below:
24V System 12V System Inlet coil (EV) to ground 14.0 to 15.5 Ohms 5.1 to 5.8 OhmsOutlet coil (AV) to ground 14.0 to 15.5 Ohms 5.1 to 5.8 OhmsBetween inlet and outlet 28.0 to 31.0 Ohms 10.0 to 12.0 Ohms
c) If resistance value is not tallying, replace modulator valve assembly as a whole.
Solenoid Coil details 18 Pin connector details
Modulator Valve
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2) Modulator valve cable checkThe correctness of the corresponding modulator valve cable can be checkedby carrying out the following steps:-
a) Carryout modulator valve check as stated above & ensure the valve is okay.b) Check for proper insertion and locking of bayonet connector in modulator valve.c) Check the proper insertion of modulator valve cable terminals in 18 pin connector.d) Remove the 18 pin connector and check the resistance of modulator valve coils
at connector end as below:
24V System 12V SystemInlet pin to ground 14.0 to 15.5 Ohms 5.1 to 5.8 OhmsOutlet pin to ground 14.0 to 15.5 Ohms 5.1 to 5.8 OhmsBetween inlet and outlet 28.0 to 31.0 Ohms 10.0 to 12.0 Ohms
Modulator Valve Pin Number FL Inlet- 3, Outlet -6 FR Inlet- 1, Outlet -4 RL Inlet- 2, Outlet -5 RR Inlet- 8, Outlet -9
e) If resistance value is not with in the specified limits, replace the frame harness.
18 Pin connector detailsSolenoid Coil details
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System function error
Engine control data link ( Error: 7-1)
The engine data link error will occur due to any of the following:
a) Improper insertion of pins 1in 1 and 3 of the 14(15) pin connector.
b) Improper connection of CAN-L (pin no.1) and CAN-H (pin no.3) connections in
14(15) pin connector of ABS ECU to the EMS ECU.
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Third Brake Relay short/broken wire (Error: 7 –3)This error will occur if the vehicle is fitted with engine brake system.The error may occur due to the following defects:1) Improper insertion of terminals in relay base.2) Improper insertion of third brake relay wire in 14(15) pin connector.
Rectify if found loose.3) Improper insertion of relay in relay base. Insert the relay properly.4. Improper insertion of terminal at pedal switch of exhaust brake system.
Insert the terminal properly.5) Check the continuity from pin 86 of third brake relay base to ECU pin14(DBR). If found faulty, replace the cab harness as a whole.
6) Check the resistance of the coil of the third brake relay using a digitalmultimeter. The relay pin positions are illustrated below. The resistancevalue between the pins 85 and 86 shall be 326±3 ohms for 24V and
92.5±3 ohms for 12V system. If the resistance value exceeds, replacethe relay.
7) Check for the supply at pin 85 of relay base using a digital multimeter.It shall be 24V or 12V depending upon the vehicle system voltage.
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Warning lamp (Error: 7 –4)
The warning lamp error will occur due to the following defects:
1) Warning lamp fused. Replace the bulb.
2) Warning lamp found loose in its holder. Fix it properly.
3) Improper connection from warning lamp to ECU pin 15 of
14(15) pin connector. This can be checked by measuring
the voltage in the supply line from ignition switch to warning
lamp point by using a multimeter. The voltage value depends
upon the vehicle system voltage. Rectify the defective wire if needed.
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ECU related defects (Error: 8-1, 8-2, 8-3, 8-4 and 8-5)Battery under voltage (Error 8 – 1)The battery under voltage error will occur due to the following defects:
1) Battery voltage is lesser than 18V in 24V system and lesser than
9V in 12V system..
a) Check the voltage at the pins 7 and 8 with respect to ground in 14(15)
pin connector. Using a digital multimeter.
b) If the battery voltage is lesser than the above mentioned value, chargeor replace the battery and also ensure correct functioning of battery and
alternator circuits as per vehicle manufacturer‟s specifications.
2) Failure of 15A fuse. Replace the fuse with new one.
3) Battery fuse rating is not 15A. Check for the correct fuse rating andreplace with 1A fuse.
4) Loose connection of single pole connector of ABS frame harness
and pigtail harness. Rectify for proper connection.
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ECU related defects (Error: 8-1, 8-2, 8-3, 8-4 and 8-5)
Battery over voltage (Error 8 – 2)The battery over voltage error will occur due to the following defects:
1) Battery voltage is greater than 32V in 24V system and greater than
16V in 12V system..
a) Check the voltage at the pins 7 and 8 with respect to ground in 14(15)
pin connector. Using a digital multimeter.
b) If the battery voltage is higher than the above mentioned value, replace
the battery.
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ECU related defects (Error: 8-1, 8-2, 8-3, 8-4 and 8-5)
ECU internal fault (Error 8 – 3)If the blink code error 8 – 3 is noticed, replace the ECU as a whole unit.
ECU configuration fault (Error 8 – 4)If the blink code error 8 – 4 is noticed,- Check for proper connections of 4 sensors and 4 modulator values withframe harness. Rectify if found not connected.
- Replace the ECU as a whole unit, if the connections are okay.
Note:- Do not open the ECU. It is not repairable at workshops. Opening theECU to gain access to the internal components will void the warranty.
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ECU related defects (Error: 8-1, 8-2, 8-3, 8-4 and 8-5)
ECU ground error (Error 8 – 5)
In order to rectify the error ECU to ground 8-5, check and rectify the
following points:
1) Proper connection of single pole connector of the ABS frame harness
and the ABS pigtail harness.
2) Firm fixing of vehicle battery negative terminal.
3) Firm fixing of ABS ground wire in battery negative terminal.
(Ground wire is connected to battery negative terminal)
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Do’s and Don’ts
DO’S and DON’TS
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During Air brakes / ABS installation and service, the following
precautions should be observed in the interest of safety:- • Always block vehicle wheels during installation /service. • Stop engine when working under a vehicle. • Support vehicle with rigid structure only.
• Ensure the battery connections are disconnected. • Wind off spring brake actuator fully.
• Deplete the compressed air fully.
DO’S and DON’TS
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Sensor greasing Sensor bush insertion
Do’s: Always insert the Bush until its
lug touches the bracket
Do’s:
Use only approved grease to the sensor (WABCO SPECIAL)
Don’t s:
Do not hit or strike the sensor !
DO’S and DON’TS
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Do’s: Protect the sensor cable with
Corrugated sleeve
Warning ! “ Terminate the corrugated
sleeve at foundation brake assembly entry point”
Sensor InstallationSensor assembling
DO’S and DON’TS
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Cable routing
Note : Clip the cable firmly
Cable routing
Warning !
Do not over tighten.
(Will cause damage to the cableinner leads)
DO’S and DON’TS
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A B SAnti-lock Brake System Safe Journey … Always !
Warning !
Remove vehicle battery connectionand ECU connectors while doing anywelding work in the vehicle
Vehicle service related
Warning !Protect the Valve hoses,Cables, extension cablewhile welding in the vehicle
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Potential field problems
Potential field problems
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‘L’ type sensor - cable damage at head portion
• High temperature and grease melted and deposited
• Strain at the head portion due to sharp bend – To be avoided
• Combined effect of both
Potential field problems
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Cable damage at head portion
Sharp bend at the Cable head portion
Potential field problems
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Potential field problems
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Causes and analysis for sensor cable cut / short other than neck portion
1. Over tightening of sensor cable with supporting hose / pipe with tie
WABCO recommendation
• Over tightening of sensor
cable results in cut /
short in cable inner lead
• Externally no physical
damage can be noticed
but the sensor will show
open / short
AVOID OVER TIGHTENING
OF SENSOR CABLE WITH
CABLE TIE
Potential field problems
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A B SAnti-lock Brake System Safe Journey … Always !
Damage of sensor cable dueto over tighten by cable tie
Inner lead get cut due toover tighten
Potential field problems
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Causes and analysis for sensor cable cut / short other than neck portion
2. Tight routing of cable over air hoses will get squeezed
when air hose expand
WABCO recommendation
• Tightening of sensor
cable over expanding
hose will damage it.
AVOID TIGHTENING OF
SENSOR CABLE OVER
EXPANDING HOSE
Drivers Tips
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• While ignition is switched „on‟, ensure the ABS warning lamp comes „on‟ and goes „off‟.
• If ABS warning lamp stays „on‟, get system checked by an authorised service center
after completing the trip.
• Under panic braking conditions, press hard on the brakes and continue to hold it down.
• “Brake & Steer”:– with ABS, you can steer the vehicle around an obstacle while braking.
• To familiarise, practice ABS braking in non-traffic roads.
• ABS does not come in to action unless wheel about to lock during brake application.
• Always drive carefully and keep safe distance.
• Do not drive aggressively or over speed as there is ABS.
• Braking an ABS vehicle on sand, gravel and loose snow, the vehicle stability is ensured
with a longer stopping distance.
• Do not switch „off‟ the ignition while driving. This makes ABS non-operational.
• Do not pump the brake during panic braking. This makes ABS non-operational.
Anti-lock Brake System
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ABS is an add on system to existing brake system.
The ABS is designed to help driver remain in control of the vehicle while he
brakes, no matter how slippery the surface.
By preventing wheel lock, ABS helps driver in preventing skids and allows
maneuvering sudden obstacles while he brake – “Steer and Brake”.
ABS brake will come „ON‟ while wheel about to lock situation.
Any failure in ABS, the normal brake will be functional.
Any failure in ABS in one wheel, ABS will be operative in remaining wheels.
Legislation on ABS in India
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As per CMVR Rules 96,
The following category of vehicles shall be fitted with Anti-lock Braking Systemconforming to IS:11852:2003 (Part 9)
Vehicles manufactured on and after the 1st day of October 2006
N2 and N3 category vehicles (Vans & Trucks- N2: 3.5T to 12T; N3:above 12T)other than tractor-trailer combination meant for carrying hazardous goods and LPG:
- Petroleum and other flammable liquids
- Explosives
- Chemicals
- LPG
Legislation on ABS in India
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Vehicles manufactured on and after the 1st day of October 2007
• N3 category vehicles which are double decked transport vehicles.
• N3 category vehicles used as tractor-trailer combinations.
• M3 category buses (>8 passengers & >5T)that ply on All India Tourist permit.
• M2 category buses (>8 passengers & <5T)including those plying on All IndiaTourist permit in hill areas.
Models to be fitted with ABS
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AL models
4x2 - 1612 /1613 / 1616 - 24V
4xs – 1611 - 12 V
6x2 (MAV) 2213 / 2214 - 24V
3516/4018/4921 Tractors - 24 V
12 mtr FE bus - 24 V
Viking bus(222”WB) - 24 V
Luxura bus - 24 V
Lynx bus - 12 V
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End of presentation