Service Handout
Service Handout
Service Handout
Regulatory Road Map on Brakes in Domestic vehicles S. N o 1 Regulation Implemen tation Date Apr06
(Already Implemented )
IS 118522001 norms
ABS on vehicles carrying hazardous goods & LPG containers Automatic adjusters ABS on double decked transport vehicles ABS on TractorTrailers ABS on Tourist Buses
Oct06
N2 & N3
(Other than Tractor Trailers)
LPT 1613 BS II, LPT 1615 BS III, LPT 2515 BS II, LPT 2518 BS III, SE 1613, LPT 709 BS II, LPT 712 - BS III, LPT 909 BS II, LPT 912 BSIII, LPT 1109 - BS II, LPT 1112 BS III, SFC 410 BS III All Vehicles Car Carriers LPO 1510 BS II, LPO 1610 BS II
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Apr07 Oct07
All vehicles N3
Oct07
N3
LPS 4018 - BS II & BS III, LPS 3516 - BS II & BS III LPO 1616 BS II, High deck Bus, LP 709 BS II & LP 712 - BS III, LP 1109 - BS II & LPT 1112 - BS III, LP 1510 & LP 1512 BS II etc
Oct07
M3
ABS is currently mandatory on all Heavy vehicles in Europe, USA, China, Japan, Korea and Australia. This trend is rapidly catching over in developing countries also.
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ABS Basics
Why Wheel Lock during Braking? When the Brake force applied is more than the friction between Road and Tire then than wheel will lock. Wheels will lock under critical Braking systems like Panic Brake due to unanticipated obstacle Braking on wet or Slippery surfaces
Brake chamber size, Slack adjuster length, Foundation brake geometry and lining material friction
Brake torque
Tire
Direction of wheel rotation
Brake torque
It is not possible for a driver to continuously control individual wheel brake pressure precisely based on - Road condition & dynamic Load condition on each wheel.
ABS Function
To continuously detect impending wheel lock during braking and if wheel lock is foreseen, then to continuously modulate the brake pressure of that wheel to just avoid the wheel lock. Braking torque developed by the wheel corresponds to the maximum frictional force that can be sustained by the tyre road interface
Additional Changes made in the brake circuit of 6X2 & 6X4 for ABS
Brake split changes from X split to H split Handbrake valve changed to more graduated valve Additional 15 litre Air tank fitted in the parking brake circuit
ECU
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ABS Components
Pole wheel Sensor ECU Modulator valves ABS Wiring Harness (cables and connectors) Blink code lamp and switch Electrical Relays
Two Globally Renowned Suppliers: M/s Wabco Germany with M/s Sundaram Clayton as an Indian Partner M/s Knorr Bremse Germany represented by M/s Knorr Bremse India
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Air Gap
Magnetic type Version - L type or Straight type Generates sinusoidal voltage signal. The frequency of voltage generated is proportional to the wheel speed. The voltage signal is fed to the ECU for detecting the wheel lock
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Air gap between sensor and pole wheel to be maintained to 0.7 mm maximum
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The amplitude of the signal, that is, the extent of the voltage induced, is influenced by the distance between the tone wheel and the sensor.
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Polewheel
Movie
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Sensor
Polewheel
Movie
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Modulator Valve Purpose : To modulate brake chamber Pressure as per electrical signal received from ECU
Type : Twin Solenoid operated (Inlet, Exhaust) Normally open Acts as pipe during normal braking No. of ports : 3 Inlet , Delivery & Exhaust Operating voltage : 24V & 12V DC Method of pressure modulation : By operating in three states Pressure Apply - Normal state Pressure Hold - Inlet solenoid energised
solenoid energised
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Driver tips
Do what good drivers have always been doing; Brake just the way you always have
Always remember that you are the most important element in the safe operation of your vehicle
ABS is not an excuse to take unnecessary risks. Always drive carefully and stay a safe distance away from the vehicle in front of you.
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Driver tips
Safety aspect ABS and other integrated functions improve safety, however it cannot extend performance beyond the limits of physics, e.g. it cannot prevent consequences related to tailgating ( excessive vehicle velocity in a curve)
System failure
Should a system failure occur the driver should continue to drive normally since normal brake function is guaranteed to full capacity. ABS system failure should be corrected at the end of the trip. Keep ABS working Do not ignore the fault for a prolonged period. Keep the system fault free to ensure maximum safety.
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1.
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7. All ground connections of the modulator assembly and ECU MUST have separate grounding points. We recommend that no other loads be connected to the grounds. 8. When painting or undercoating, make sure all connections are securely fastened. 9. Protect unfastened or exposed connectors. 10. Any ABS component removed during modification must be reinstalled as per OE specification 11. Before putting the vehicle into operation, perform the appropriate end of line test.
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ABS COMPONENTS
ELECTRONIC CONTROL UNIT (ECU)
POLE WHEEL
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ABS COMPONENTS
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OFF
(0.5 to 5 s) + 1.0s
FAULT TYPE
ON
1 2 1 2 3
OFF
1.5s
1.5s
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DAMAGED TOOTH
CORRECT TOOTH
CONTAMINAT ED TOOTH
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YES
TURN OFF THE IGNITION BEFORE CARRYING OUT ANY RECTIFICATION SUCH AS REPLACING SENSOR OR SENSOR EXTENSION CABLE
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IF AIR GAP ERROR REPEATS FREQUENTLY IN THE SAME WHEEL, CHECK AND RECTIFY EXCESSIVE WHEEL BEARING RUNOUT POLE WHEEL RUNOUT
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Diagnostics: Methods
1) Blink Code
Blink code is the easiest method of ABS diagnostics & can be used effectively in most of the failure cases. In this method, only required tool for diagnostics is Blink Code Chart. In case of any error in ABS, ABS warning lamp on dash board will glow so that driver will understand that there is some fault in ABS. To further understand exact fault, a blink code switch can be operated so that the warning lamp will flash in certain fashion. The number of flashings can be counted manually & based on this count actual fault can be located on blink code chart. After troubleshooting, error can be erased from ABS memory using blink code switch. For specific errors, after troubleshooting, the vehicle should be driven at a speed of 10 to 15 Kmph during when the ECU does dynamic diagnostics and puts OFF the WL if no error is present.
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Diagnostics: Methods
2) PC Based Diagnostics
PC base diagnostics is more useful for troubleshooting in service workshops. One can directly read error messages on PC screen & accordingly decide on further action Trouble shooting guidelines are part of it. Required equipments are Laptop with diagnostics software installed, interface module, interface cable & adapters for connection with ECU. Multi-meter for checking sensors, Modulator Valve Solenoids, Voltages etc We can read information like ECU manufacturing data, software version etc. Vehicle wise data base for recording history can be generated & updated for future use.
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Service Intervals:
3 years or 300,000 km check the functionality of the system using Diagnostics cum End Of Line test equipment. In the case of failure, the defective part is to be replaced. There are no serviceable ABS components in the system. Note: The electrical functionality of the ABS components Electronic Control Unit, modulators, sensors and cabling is checked automatically by in-built self diagnostic software and the driver is warned of any malfunction or failure. Sensor Clamping Sleeve along with Sensor Grease is available as a spares kit For use whenever Sensor is replaced.
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Dos: Always insert the Bush until its lug touches the bracket
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Pole wheel
Note: Always push the sensor until it touches the pole wheel (Air gap < 0.2mm)
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Inlet port
Exhaust port
Note: Mount the modulator valve in the Chassis member with exhaust port facing the ground
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Note: Connect DBV delivery to Port 1 of MV and Port 2 of MV to Brake Chamber or spring brake actuator
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Cable routing
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Warning ! Do not over tighten (Will cause damage to the cable inner leads )
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Warning ! Remove vehicle battery connection and ECU connectors while doing any welding work in the vehicle
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Warning ! Protect the Valve hoses / cables / extension cable while welding in the vehicle.
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Instructions for covering the ECU before transporting the cowl (SCL ABS dat.pdf) Instructions for ECU location in the Bus Instructions for bus body builders and cab builders (SCL ABS data.pdf)
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Sensor insertion with bush and grease use only approved grease (Staburags NPU 30 PTM of Kluber) Push sensor bush fully in first and then insert the sensor. Check the seating of Sensor bush lugs in the bracket Sensor cable routing protect the sensor cable with corrugated tube Possibly route it along with brake hose by tying it to hose with cable tie Air gap setting by pushing the sensor to touch the polewheel by special tool provided for pushing the sensor Do not hit or strike the sensor or push it with sharp edge Rear axle Sensor extension cable to pass through a grommet while coming out from a brake torque plate Do not pull the sensor cable as it can easily get damaged.
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General installation guidelines 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 Remove battery connections, ECU connector and protect the valve hoses, cables and extension cables while doing welding work on vehicle
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