Model : All LCVs, M/HCVs

SC/2008/01 Group: 42 January 2008

with air brakes

ALL DEALERS / TASSs

SUBJECT: Introduction of Anti Lock Braking System (ABS) on LCV & M/HCV
vehicles with air brake system.

We are pleased to inform you about introduction of Anti Lock Braking System (ABS) on commercial
vehicles. This is to meet requirement of CMVR regulation which makes Anti Lock Braking System
(ABS) conforming to IS: 11852:2003 (Part 9) mandatory on the following type/class of vehicles
(i) N2 category of vehicles (GVW >3.5 Ton & < 12 Ton) and N3 category of vehicles (GVW more than
12 Tons) other than tractor-trailer combination manufactured on and after the 1st day of October,
2006 meant for carrying hazardous goods and liquid petroleum gas;

(ii) N3 category vehicles manufactured on and after the 1st day of October, 2007, which are double
decked transport vehicles;

(iii) N3 category vehicles used as tractor-trailer combinations which are manufactured on and after
the 1st day of October, 2007, they are used as tractor-trailer combinations.

(iv) M3 category of buses (vehicle having more than 25 seats and GVW greater than 5 Tons) that ply
on All India Tourist permit, manufactured on and after the 1st day of October, 2007

We are attaching details on following topics on ABS for air brake system for your ready reference:
1. Introduction, advantages & Working principle of ABS
2. Suppliers of ABS system
3. ABS –Instructions to User (Operator)
4. General Instructions to Mechanics (Working with ABS)
5. ABS configuration
6. Functions of individual components of ABS
7. Troubleshooting with Blink Code Diagnostics
8. Diagnostic Kit & diagnostic software installation.
9. List of service representatives from Knorr Bremse & WABCO.

Please bring this information to the notice of all concerned in your workshop and educate customers.
1) Introduction, advantages & working principle of ABS

Anti Lock braking system is an electronically controlled an add on system, to existing air
brake system, used to prevent vehicle skidding during wheel lock under all circumstances of
load, tyre/road grip coefficient. The ABS modulates the air pressure in the brake actuator to
prevent wheel lock and provides precise vehicle control during braking.

Advantages
¾ Improves Stability
- Prevents vehicle skidding by avoiding front & rear wheel lock.

¾ Improves Steerability while braking

- Helps driver to steer around obstacles during panic braking even on slippery roads.

¾ Shorter stopping distance

- Helps to stop the vehicle at lesser stopping distance on dry as well as slippery roads.
-
¾ Prevents Jack Knifing
- Prevents tractor swinging around the fifth wheel coupling in tractor trailer combination.

Working Principle :

ABS consists of an Electronic Control Unit (ECU), pressure modulator valves, sensing rings or pole
wheel, wheel speed sensors, Diagnostic switch, Warning lamp and associated electrical wiring.

ABS system takes over the control of the air pressure whenever a wheel is about to lock. Each
rotating wheel hub is fitted with a Sensing ring or Polewheel. A Wheel Speed Sensor (magnetic
sensor) which is mounted on each wheel in close proximity to the Sensing ring or Polewheel
generates electrical pulses when the wheel rotates. The electric pulses generated will be in the form
of sinusoidal pulses. The frequency at which the pulses are generated is a measure of the wheel
speed. The generated electrical pulse signal is sent to Electronic Control Unit (ECU) for processing.

Diagnostics
Switch
Electronic Warning
Control Lamp
Unit

Wheel
Speed Modulator
Sensors
Valve

INPUT CONTROL
The ECU after receiving the input signals from all wheel speed sensors processes and compares the
sensor signals and detects an impending wheel lock situation.

When a wheel is about to lock, the ECU sends an electrical signal to the corresponding modulator
valve solenoid (Modulator Valve is fitted in the delivery pipeline coming from dual brake valve), which
releases pressure from the brake actuator. When the wheel recovers sufficiently, the brake pressure is
reapplied by the ECU by switching off the signal to the modulator valve. This signal is sent to the
Electronic Control Unit (ECU) through connecting cables and processed by the ECU.

The modulator valve has an additional 'HOLD' state, which maintains pressure in the brake actuator,
in order to optimize the braking process. The cycling of the modulator valve is continued till the
vehicle comes to a controlled stop.

During ABS operation, ECU switches the modulator valve to the above three states (Pressure release,
Pressure hold and Pressure re-apply) five six times per second to regulate the brake pressure.

2) Suppliers for ABS System for Commercial vehicles (with S-Cam brakes)
There are two suppliers for ABS system for Tata vehicles.
i) Knorr Bremse ii) WABCO
The working principle, components and their functions for both the suppliers are same.
These systems can be identified by the name of supplier on the individual components.
Parts for Knorr Bremse & WABCO are not interchangeable between the two suppliers.

3) ABS instructions to User (Operator)

™ As soon as you switch on the ignition switch, ABS warning lamp on the dash-board should come
“ON” for 5 seconds and go “OFF”.

™ In case ABS warning lamp does not come “ON” momentarily or remains “ON” or comes
“ON” any other time, then it indicates fault in the ABS. In such case, ABS may not function.
However the basic brake system will continue to function normally, and will provide normal
stopping ability.

™ In case ABS warning lamp remains “ON”, take the vehicle to the nearest service station for
attending to the fault.

™ In case of vehicle being driven with ABS warning lamp in “ON” condition, applying panic
brake or braking on wet road may result in wheel locking, as it would happen in a vehicle
without ABS.

™ Do not assume that with ABS fitted to a vehicle, it is safe to drive faster or more
aggressively.

™ Under panic braking conditions, press hard on the brakes and continue to hold it down.
ABS does not come into action unless wheel is about to lock during brake application.

™ Do not switch 'off' the ignition while driving. This makes ABS non-operational.

™ For any welding job on the vehicle, disconnect all ECU connectors. For removing the electrical
connector, do not hold & pull the wires. Hold connector body firmly & then pull it.
4) General Instructions to Mechanics (Working with ABS)

™ Ensure wheel bearings are adjusted appropriately to ensure that the run-out of the pole wheel is
within acceptable limits. Always ensure that the wheel run-out is within specified limits

™ To push the sensor, use soft non pointed tool (Nylon bar, plastic bar, etc). Do not use any metallic
sharp tool like screw driver

™ After removing the hub, keep the hubs with the pole wheel facing upwards.

™ Don’t try repairing any of the ABS parts. Replace with new genuine parts.

™ ABS prevents vehicle skidding/ pulling by avoiding the front & rear wheel lock. However in case of
vehicle pulling to one side during partial braking condition is not due to ABS. The reason could be
the basic brake system and investigation for brake pulling on vehicle without ABS system needs to
be performed.

™ When installing ancillary electrical equipment on the vehicle do not use the electrical supply to the
ABS as a power source for the equipment.

™ Do not connect or disconnect any ABS component with the ignition switched on.

™ Never remove the battery while engine is running. Voltage spikes caused by the alternator could
possibly damage the ECU if they were not absorbed by the battery.

™ While replacing sensor, replace the sensor bush also and apply recommended grease (part of
spares kit) on Sensor.

5) ABS Configuration

™ ABS configuration is based on the no of Sensors (S) & Modulators (M) used in the system.

™ For twin axle 4 x 2 Truck, 4S /4M (i.e. 4 Sensors & 4 Modulators) system is used.
- 4 sensors one on each wheel and
- 4 modulator valves, one for each wheel brake actuator

™ For multi axle vehicle 6 x 2 truck, 4S/4M system is used.

- 4 sensors two for front wheels and two for rear live axle wheels
- 4 modulator valves, two for front wheel brake actuators
one for both rear left brake actuator
one for both rear right brake actuator

Please refer the following brake circuit diagrams on ABS configuration for Twin axle & Multi axle
vehicles.
Twin axle 4 x 2 Truck, 4S /4M system

Multi axle 6 x 2 Truck, 4S /4M system

 6) Functions of individual components of ABS:

a) Sensing ring or Polewheel

Sensing ring or Polewheel is a toothed wheel made of ferrous material. It has 100 evenly spaced
teeth. The Sensing ring or Polewheel rotates along with the hub and cuts the magnetic flux generated
by the wheel speed sensor. It is fitted on the wheel hub.

b) Sensor ('L' type)

It is a magnetic sensor (passive type) consists of a permanent magnet and a coil assembly. It
generates electrical pulses proportional to wheel speed and transmits to the ECU as a sinusoidal signal
It is fitted with a sensor bush in a bracket mounted in the carrier plate as a stationery part. The air
gap of < 0.2 mm is maintained between Sensing ring or Polewheel and sensor.

POLE WHEEL AND WHEEL SPEED SENSOR WITH BUSH ON VEHICLE VIEW OF POLE WHEEL &
WHEEL SPEED SENSOR

< 0.2 mm Air Gap

Wheel Speed Adjustment of Polewheel & sensor Gap
Sensor The spring-loaded sensor bush is used to hold the
wheel speed sensor whilst allowing easy
adjustment of the gap between it and the teeth
of the sensing ring. The wheel speed sensor can
slide in the sensor bush, so the gap between the
wheel speed sensor and the teeth of the sensing
ring can be set by manually pushing the sensor
Pole wheel gently into contact with the teeth and then
turning the wheel by hand. After pushing the
wheel speed sensor into contact with the sensing
ring, while ignition is turned off, the wheel should
be rotated by hand. Any run-out of the wheel
bearings will cause the teeth of the sensing ring to
MINIMUM AIR GAP TO BE MAINTAINED BETWEEN push away the wheel speed sensor thereby
POLEWHEEL & WHEEL SPEED SENSOR setting the air gap between the two parts.
c) Electronic Control Unit (ECU)

ECU acts as the processing unit (brain) of the system. Based on the inputs from the 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.

d) Modulator Valve
This is a fast responding electrically operated solenoid valve which modulates the air pressure in the
brake actuator. It modulate the air pressure of brake actuator in three states viz. Apply, Hold, Release
and operates according to the command from ECU during ABS operation.
It is normally open type and acts as a pipe during normal braking. This modulator valve is fitted
between dual brake valve and brake actuator in the service line & mounted on chassis long member
for front wheels & chassis cross member nearest to rear brake chambers for rear wheels.

Exhaust (3)
MODULATOR VALVE FOR FRONT WHEEL

e) Sensor Extension Cable

A two core cable interfaces the respective wheel speed sensors
with ECU. It transmits the signals from wheel speed sensors to
ECU. It Connects the ECU and sensors individually. One end
with two pin socket connected to sensor. Other end connected
to ECU through connector
f) Modulator Valve Cable
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). It transmits the signals from ECU to modulator valves
during ABS operation. It Connects the ECU and all modulator valves
individually. One end with three pin moulded socket to the MV

g) Wiring Harness

Two types of harnesses are used namely

i) Cab harness
ii) Frame Harness

The cab harness takes care of power supply, warning lamp & blink code switch fitted in the dash
board. This may be connected directly to ECU or may be connected through a intermediate harness
called pigtail harness.

The frame harness connects the ECU with sensors and modulator valves. The cables are made out of
polyurethane in order to work reliably in vehicle under chassis environment

h) Warning Lamp and Blink Code Switch

The Warning Lamp & Blink Code Switch are used for indicating faults in ABS system to the driver. The
warning lamp glows whenever the system detects a fault. After rectification of fault, the lamp
automatically goes 'off'. When the ABS system detects a fault the ECU will store the fault in the
memory. These faults are read through blink codes or using special diagnostic tools. With the ECU
powered (‘ignition on’), wait at least 1 second then press the blink code switch once and release. The
transmission of the fault blink code is triggered.

7) Troubleshooting with Blink code diagnostics

A) Blink code reading method:

The blink code will be displayed as short illuminations (blinks) of the ABS warning lamp. The blink
code for a fault is split into two series of ‘blinks’ - the first series of blinks (approximately 0.5 seconds
each) should be counted to give a “1st Number” and, after a pause of approximately 1.5 seconds, a
second series of blinks (approximately 0.5 seconds each) should be counted to give a “2nd Number”
(see Fig.) Using the charts on the following pages, it is possible to identify the component and its
fault. If there is more than one fault, the next blink code will start approximately 4 seconds later. The
ABS ECU is able to store specific codes for every fault detected. The memory can store a maximum of
16 faults. Fault codes for failures that are most recently detected are displayed first and oldest
detected faults are displayed last. The blink code sequence, i.e. one blink code per fault, can be
repeated by pressing the blink code switch again at the end of the sequence. Note that pressing the
blink code switch during the sequence will terminate the transmission of the blink codes. During
output of the blink codes, normal operation of the ECU is disabled (i.e. no ABS function).
B) Block Diagram showing blink code reading Method

The number of times the blink code flashes indicates the type of fault that can be referred from the
blink code chart.

C) Blink code chart WABCO ABS

Block 1 ( Component / Nature of Error) Block 2 ( Location)

1 - No faults 1 - No faults
2 - ABS Modulator Valve 1 - Front Right (FR)
3 - Sensor Air Gap 2 - Front Left (FL)
4 - Sensor Short I Open
5 - Sensor Intermittence 3 - Rear Right (RR)
6 - Sensor, Pole wheel 4 - Rear Left (RL)
1 - Engine control data link
7 - System function 3 - Third brake relay short I broken wire
4 - Warning lamp
1 - Battery under voltage
2 - Battery over voltage
8-ECU 3 - Internal fault
4 - Configuration error
5 - Ground

Example: 1-1: No Faults; 3-4: Sensor gap rear left is excess

D) Blink Code Chart Diagnostics WABCO ABS

Mode Procedure System response Action

Step I. Possible responses:
Turn ignition 1. ABS warning lamp comes on
ON. momentarily then goes out,
indicating system O.K.
2. ABS warning lamp does not light,
indicating possible wiring fault or
burned-out bulb.
3. ABS warning lamp stays on,
indicating:
i) Fault or faults in the
system/sensor.
ii) Faults cleared from ECU.
Sut vehicle not driven.
DIGNOSTICS
No active faults in the ABS.
No action required.
Inspect wiring.
Inspect bulb.
Make necessary repairs
Continue with blink code diagnostics.
(Go to Step II)
Continue with blink code diagnostics.
(Go to Step II)
Drive vehicle -lamp will goes 'off'
when vehicle reaches 7 km/h speed.

iii) ECU disconnected Connect ECU.

Step II. ABS warning lamp begins flashing Determine if fault is active or stored:
Press and hold two-digit blink code(s). Active error: Lamp will repeatedly
blink code Refer blink code chart. display one code.
switch for half a Stored error: Lamp will display code
for each stored fault then stop
second, then
blinking.
release. Faults will be displayed one time only.
Step III. First Digit: 1 - 8 flashes, Find definition for blink code on blink
Count the Pause (1.5 seconds). code chart.
flashes to Second Digit: 1 - 6 flashes,
determine the Pause (4 seconds).
blink code.
Step IV. Active errors. Make the necessary repairs.
Turn ignition Repeat Steps I, II, and III until system
OFF. O.K. code (1-1) received.
Repair and Stored errors. Record for future reference.
record faults NOTE: Last error stored is first
error displayed.
Step V. ABS warning lamp flashes eight All errors are successfully cleared.
Turn ignition times quickly and then repeats 2-2. Turn ignition OFF.
ON.
Clear Faults
CLEAR

from memory: Eight flashes not received. Active errors still exist, repeat the
Press and hold steps I through V.
blink code
switch
for at least three
seconds, then
release.
 E) Blink Code Chart With Diagnostics Knorr Bremse ABS

Block Location Block Fault Description

1 2
1 --------------------------------------- 1 No faults recorded by the ECU.

2 Wheel speed sensor, front axle, 1 Air gap too big

left side
3 Wheel speed sensor, front axle, 2 Missing speed sensor signal at drive off
right side
4 Wheel speed sensor, rear axle, left 3 Damaged contaminated tooth on sensing ring, erratic
side signal from speed sensor, check sensing ring
alignment and wheel bearing adjustment
5 Wheel speed sensor, rear axle, 4 Unstable signal from speed sensor, check sensing ring
right side alignment and wheel bearing adjustment, check wiring
for possible source of interference.
5 Loss of speed sensor signal.
6 Sensor wires shorted or broken

8 Pressure modulator valve, front 1 Release solenoid – shorted to battery

axle, left side
9 Pressure modulator valve, front 2 Release solenoid - shorted to ground
axle, right side
10 Pressure modulator valve, rear 3 Release solenoid wire broken
axle, left side
11 Pressure modulator valve, rear 4 Valve ground wire broken
axle, right side
5 Hold solenoid – shorted to battery
6 Hold solenoid – shorted to ground
7 Hold solenoid wire broken
8 System configuration error, check valve and system
wiring and check ECU configuration

10 Pressure modulator valve, valve 10 Shorted to battery, remove X2 Plug from ECU and
common ground check for voltage on valve ground connections, replace
wiring if necessary
10 Pressure modulator valve, valve 11 Shorted to ground not through ECU or internal valve
common ground defect, remove X2 Plug and check resistance between
valve ground connections and chassis ground
8) Diagnostic Kit & diagnostic software installation
The Diagnostic tester communicates with the ECU (Electronic Control Unit). This tester comprises of a
Vehicle interface unit, Custom built application software installed in a Laptop/Desktop

Diagnostic tester is used to check for any errors being reported by the ABS system. ECU reports the
driver of an error with the help of a diagnostic lamp provided on the dashboard. The details of the
errors reported by the ECU can be viewed with the help of a diagnostic kit. Error code and error
description can be viewed for trouble shooting. Ignition key has to be ON for Diagnostic tester to read
errors from ECU.

Hardware & Software (in CD ) required for the diagnostic kit to be procured from SPD by placing
order, detailed part nos for hardware & software are given below.

i) Hardware required for ABS Diagnostics

TML Part No Product Name

210322379944 Silicon Engine (For RS232 Port)
210922089901 OBD Cable
210322749944 USB Silicon Engines Interface
Note: The hardware for ABS Diagnostic is the same as used for BS-III (VP-37)
Channel Partners who had already purchased for BS-III need not buy the Hardware again.

ii) Software required for ABS Diagnostics

TML Part No Product Name Description

Diagnostic software for :- Wabco -
210322739995 Wabco - ABS
ABS
Diagnostic software for :- Knorr-
210322739996 Knorr-Bremse - ABS
Bremse - ABS
iii) Diagnostic software installation:

The Installation CD of the software is supplied with the kit.

Installation Procedure:-

1) Insert the CD in the CD Rom

2) Set-up will start running automatically
3) After this the program will guide you for further installation.
4) After successful installation, a short-cut to program will appear on desk-top.
5) When user clicks the short-cut, following screen will appear –

Note: MID and Site code are

machine dependent. The software
can be installed only in a specific
PC/Laptop. The same CD cannot
be used to install software in
multiple PCs / Laptops.

The Application status will be ‘LOCKED’, for unlocking the program user has to log on to the
following website
6) https://ed.tatamotors.com Once you log on the following screen will appear, click on
unlock code.

7) After the above step following screen will appear, click on the service request
8) Once you click on service request website will give following screen,

Part No & Sr. no

are written on the
Top of the CD

Fill all the data asked by the website and click Save, the site will provide you with INIT code.

Please enter that code in the Init code box. (Refer step 5)

9) Then Application status will change to ‘LICENSED’ .Click Continue to start the application.
List of service representatives
Knorr Bremse

Region Name Location Mobile No. Responsible Area/Region/Zone

North Naresh Kumar Delhi 99997 99663 Delhi,Rajsthan,Hariyana,Punjab,Himachal,UP, UA,Jammu
East Avijit Mujumdar Kolkata 92305 69728 West Bengal,Jharkhand,Orisa,Bihar,Assam,North East States
West Dharmedra Chandratre Pune 98811 38148 Maharashtra,Goa,Gujrat,Madhya Pradesh,Chattisgarh
South Vijaygopal Balaji Chennai 98405 55826 Tamilnadu,Andhra Pradesh,Karnataka Kerala

WABCO

Region Name Location Mobile No. Responsible Area/Region/Zone

Murthy K S N New Delhi 98117 99037 North Zone
Venkat Giri S New Delhi 98116 13013 North Zone
Vimal Bhat New Delhi 98115 44944 Haryana, Delhi & Uttranchal state
North
Nethaji S Jaipur 99280 84549 Rajasthan state
Manoj Garg Jalandhar 98766 25381 J&K, Punjab & HP states
Arumugam N Kanpur 99350 47237 UP state
Raghuraman B Kolkata 99031 94444 East Zone
Ananya Chowdhury Kolkata 98319 62993 West Bengal(Except Siliguri), Bihar states & Dhanbad
East
Somenath Datta Guwahati 99541 89711 North East states & Siliguri area of WB
Amit Kumar Bose Cuttack 98610 45579 Orissa, Jharkhand states (Except Dhanbad)
Hussain Mohamed K Mumbai 98215 30441 West Zone
Sujit K Tambat Mumbai 98215 30446 West Zone
Arumugam B Mumbai 98335 81814 Mumbai & Aurangabad region of Maharashtra
West Jitendra Patel Ahmedabad 98980 39141 Gujarat state
Sushil Kumar Maurya Nagpur 98232 87463 Nagpur region of Maharashtra & Chattisgarh state
Jameel Babu L Pune 99606 24253 Pune region of Maharashtra
Dhanasekar M Indore 98260 24824 MP state
Sivakumar S Chennai 98409 15870 South Zone
David Amalraj A Cochin 98950 48148 Kerala state
Ramasubramanian V Chennai 98407 12061 South & North part of TN & Chennai
South Punithavelu T Bangalore 98440 71866 Karnataka state
Rajendran G S Secunderabad 98492 55172 Telugana & Rayalasema
Sambasiva Rao S P Vijayawada 98490 86592 East Godavari, West Godavari & Coastal area of AP
Kumar K Salem 98409 78091 Central & Western part of TN