Service Training HANDOUT ON Anti-lock Braking System [ABS]

TATA MOTORS LIMITED

Customer Service Commercial Vehicle Business Unit Mumbai, Jamshedpur, Pune, Lucknow & Dharwad

Regulatory Road Map on Brakes in Domestic vehicles S. N o 1 Regulation Implemen tation Date Apr06
(Already Implemented )

Vehicle Categor y All vehicles

Affected Vehicles (Identified by NPI / Mktg)

All Vehicles

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

3 4

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

Effects of Wheel Lock:

Front wheel locking going out of control Rear wheel locking in Tractors More Tyre wear Loss of Steerability & Vehicle Loss of stability, Jackknifing - Strong Abrasion of Tyres

How to avoid Wheel lock

Individual wheel brake pressure to be controlled precisely based on - Road condition Load condition Speed of the vehicle Brake lining condition

ABS Basics Driver presses brake pedal

Brake chamber pressure increases

Brake chamber size, Slack adjuster length, Foundation brake geometry and lining material friction
Brake torque

When a Wheel can Lock During Braking

Fx max = Co-efficient of friction between Road and Tyre (m) X Fz; Fx required to keep the wheel rotating =Brake Torque / Tyre Dynamic Radius When Fx required > Fx max, wheel will Lock . i.e. if Brake Torque / R > m X Fz, the wheel will lock. Hence wheel locking tendency increases with 1) Less co-efficient of friction between road and Tyre (wet or icy roads, bald Tyres), 2) Less axle load (Rear wheels in Unladen condition) 3) Higher brake torque (panic braking)

Tire
Direction of wheel rotation

Brake torque

Longitudinal Normal force force FX F

Z

Normal force Lateral force FZ FY

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Consequences of Wheel lock

1) Substantial Reduction in braking force from the road, hence higher stopping distance 2) Reduction in Lateral stability, hence vehicle can spin out 3) Increased Tyre wear

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

Facts to be Understood about ABS

ABS does not apply the brake by itself, neither it can increase the magnitude of the brake intensity applied by the driver ABS does not come in to action unless there is a possibility of a wheel lock during braking ABS does not save the driver from reckless driving If ABS is not working due to a fault, the normal brake system continues to work in its full capacity. When ABS is not working on one wheel, the ABS of the opposite diagonal wheels will still function normally to provide partial benefits.

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

Typical ABS layout on a 4x2 vehicle

ECU

1. ABS Modulator 2. Wheel Speed Sensor 3. Electronic Control Unit

Typical ABS Schematic for 6X2 & 6X4 Vehicle

Typical ABS System Brake Schematic circuit with ABS

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ABS Working Process and components:

A Polewheel is fitted to the Rotating wheel hub on all four wheels. A Magnetic sensor is mounted on each wheel In close proximity to the Polewheel, The Sensor generates electrical pulses when the Polewheel rotates. The rate at which the pulses are generated is the measure of each wheel speed. This wheel speed signal is transferred to the Electronic control unit (ECU) When the wheel is about to lock, the ECU sends the signal to the corresponding Modulator Valve Solenoid, which releases pressure from the Brake Chamber of that wheel brake. When the Wheels recovers sufficiently pressure is re-applied again by the ECU by switching off the signal to the Modulator valve.

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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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Pole wheel and sensor

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Functions of ABS components

Wheel Speed Sensors:
Product Description: The wheel speed sensor is a magnetic sensor consists of a permanent magnet and coil assembly. Function: It generates electrical pulses when the pole wheel rotates. The rate at which the pulses are generated (frequency) is a measure of the wheel speed. Fitment: It is fitted with a special bush with spring clips to retain the sensor in position. The sensor pushed at the pole wheel by ~10 kg force so that optimum clearance is achieved after pole wheel rotation..
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Voltage peak to peak

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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Sensor and Pole wheel mounting on 109RR rear Axle

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Sensor fitment Photos on Rear Axle

Polewheel

Axle Bracket Sensor Mounting Bracket

Movie

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Sensor fitment Photos on Front Axle

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

Pressure release - Both Inlet & Exhaust

solenoid energised

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ABS Fitment Modulator Valve Front Axle

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Driver tips
Do what good drivers have always been doing; Brake just the way you always have

Apply brakes as normal to stop in time.

Maintain pressure as required on your brake pedal while steering clear of any obstacles. During a brake application that could result in a wheel lock, ABS automatically releases and applies the brakes much faster than you could do with the brake pedal.

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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Body Builder precautions

Before modifying a bus, truck or motor home chassis equipped with ABS, review the following information. These tips will help you understand the ABS system and help avoid possible damage to that system when the chassis is altered. Do not mount extreme heat sources (sources exceeding 85C) near the ECU.These include cab heater, engine exhaust, etc. Do not install RFI-emitting devices (such as radios, electric motors or pumps) on or near the ECU or other ABS components to help isolate the system from electrical interference. Perform all chassis welding with all connections to the ECU disconnected. When installing other components, be aware of and do not damage the ABS harness or connectors. Do not cut or splice the ABS harness to provide power to other sources on the vehicle. Cutting or splicing the ABS harness may cause the system to malfunction.

1.

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Body Builder precautions

6 When extending an OEM chassis, use the appropriate ABS harness extension cables and connectors.

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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ANTI-LOCK BRAKING SYSTEM (ABS6) DIAGNOSTICS

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ABS COMPONENTS
ELECTRONIC CONTROL UNIT (ECU)

POLE WHEEL

WHEEL SPEED SENSOR (WSS)

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ABS COMPONENTS CLAMPING SLEEVE (SENSOR BUSH)

MODULATOR VALVE (MV OR PCV)

X1 CONNECTOR OF POWER INTERFACE HARNESS (PIG TAIL HARNESS)

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ABS COMPONENTS

X2 CONNECTOR OF FRAME HARNESS ASSEMBLY

MODULATOR VALVE CABLE

SENSOR EXTENSION CABLE

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POLE WHEEL FAULT DAMAGED OR CONTAMINATED TOOTH

Error Code: 2 3 Front Axle Left Side (Steer Axle Left side) (A1L, FL or SL)
PRESS BLINK CODE SWITCH FOR 0.5 to 5 SECONDS AS SHOWN BELOW:
0.5s to 5 sec. ON

OFF

WARNING LAMP GLOWS (FLASHES AS SHOWN BELOW)

(0.5 to 5 s) + 1.0s

COMPON ENT NUMBER

FAULT TYPE

ON
1 2 1 2 3

OFF

1.5s

1.5s

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POLE WHEEL FAULT DAMAGED OR CONTAMINATED TOOTH

Error Code: 2 3 Front Axle Left Side

DAMAGED TOOTH

CORRECT TOOTH

CONTAMINAT ED TOOTH

If Pole Wheel run-out is observed Damaged Tooth Contaminated Tooth

Replace Pole wheel - Replace Pole wheel - Clean Pole wheel

Note: If error persists, check for wheel bearing adjustment

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SENSOR FAULT SHORT OR BROKEN WIRE

Error Code: 2 6 Front Axle Left Side (Steer Axle Left side) (A1L, FL or SL)
USE A MULTIMETER AND CHECK FOR RESISTANCE BETWEEN PINS 5 & 8 OF X2 CONNECTOR RESISTANCE > 1925 OHMS

SENSOR BROKEN WIRE

USE A MULTIMETER AND CHECK RESISTANCE BETWEEN PINS OF SENSOR CONNECTOR

NO RESISTANCE > 1925 OHMS

YES

REPLACE SENSOR EXTENSION CABLE

REPLACE WITH NEW SENSOR

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SENSOR FAULT SHORT OR BROKEN WIRE

Error Code: 2 6 Front Axle Left Side (Steer Axle Left side) (A1L, FL or SL)
AFTER RECTIFICATION OF ANY SENSOR FAULT, FOLLOW THESE STEPS: TURN ON IGNITION & CLEAR ERROR FROM THE ERROR MEMORY TURN OFF AND ON THE IGNITION AGAIN ONCE VEHICLE IS READY, DRIVE THE VEHICLE AT A SPEED OF ABOUT 10 - 15 KMPH CONFIRM WARNING LAMP GOES OFF AUTOMATICALLY NOTE:

TURN OFF THE IGNITION BEFORE CARRYING OUT ANY RECTIFICATION SUCH AS REPLACING SENSOR OR SENSOR EXTENSION CABLE

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SENSOR FAULT AIR GAP TOO LARGE

Error Code: 4 1 Rear Axle Left Side (Drive Axle Left side) (A2L, RL or DL)
LARGE AIR GAP BETWEEN POLE WHEEL AND SENSOR ( AC Voltage < 100 mV) TURN OFF THE IGNITION PUSH THE SENSOR TILL IT BUTS WITH THE POLE WHEEL, USING A TOOL (TOOL SHALL NOT HAVE ANY SHARP EDGE) ROTATE THE HUB MANUALLY TURN ON IGNITION & CLEAR ERROR FROM THE ERROR MEMORY TURN OFF AND ON THE IGNITION AGAIN ONCE VEHICLE IS READY, DRIVE THE VEHICLE AT A SPEED OF ABOUT 10 15 KMPH CONFIRM WARNING LAMP GOES OFF AUTOMATICALLY

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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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ABS ECU READING CONFIGURATION

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ABS ECU READING CONFIGURATION

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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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Blink Code To Clear Error from Memory

To Erase errors from the memory Press and hold the Blink Code Switch
Switch ON the Ignition After approximately 3 seconds release the blink code Notes: The ABS warning lamp will glow when the blink code switch is pressed, if the ignition is already switched ON, however the ECU error memory will NOT be erased. If any Sensor related errors were erased from the ECU memory, then the ABS warning lamp will glow during subsequent turning ON of the Ignition and will remain ON until the vehicle is driven to a speed of 10-15 Kmph and no active errors are present in the system.

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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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Need of EOL Test

1) Ensuring correctness of entire ABS electrical wiring 2) Ensuring correctness of pneumatic connections 3) Ensuring proper electrical contacts of all devices in system 4) Ensuring proper operation of all ABS components 5) Ensure proper operation of entire ABS EOL for ABS is also recommended for Service: 1) Pole wheel tooth damages or run-out, if present can be detected. 2) To detect Sensor air gap developed during fitment of Wheel Hub. 3) To Confirm functioning of replaced Modulator Valve 4) To confirm correct wiring, In case of replacement of Harness Assembly 5) To Configure ECU, when ECU is replaced. 6) To confirm pneumatic connections to Modulator valve etc.

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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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Typical Field Problems on ABS:

Sensor Air Gap too Large

Sensor Short / Broken Wire

Modulator Valve Short / Broken Wire Polewheel Damage / Sensor defective signal Wrong Cable Connection of Modulator & Sensor FL X FR interchange Battery Over voltage / Under Voltage ABS Warning Lamp blown

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DOS AND DONTS DURING ABS INSTALLATION

Sensor Installation

Dos: Use only approved grease (WABCO SPECIAL) to the sensor

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DOS AND DONTS DURING ABS INSTALLATION Sensor Installation

Dos: Always insert the Bush until its lug touches the bracket

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DOS AND DONTS DURING ABS INSTALLATION Sensor Installation

Dos: Protect the sensor cable with Corrugated sleeve

Warning ! Terminate the corrugated sleeve at foundation brake assembly entry point

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DOS AND DONTS DURING ABS INSTALLATION Sensor Installation

< 0.2 mm Wheel Speed Sensor

Pole wheel

Note: Always push the sensor until it touches the pole wheel (Air gap < 0.2mm)

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DOS AND DONTS DURING ABS INSTALLATION Modulator valve Installation

Delivery port

Inlet port

Exhaust port

Note: Mount the modulator valve in the Chassis member with exhaust port facing the ground

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DOS AND DONTS DURING ABS INSTALLATION Modulator Valve Installation

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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DOS AND DONTS DURING ABS INSTALLATION

Cable routing

Note : Clip the cable firmly

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DOS AND DONTS DURING ABS INSTALLATION

Cable routing

Warning ! Do not over tighten (Will cause damage to the cable inner leads )

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DOS AND DONTS DURING ABS INSTALLATION

Vehicle service related

Warning ! Remove vehicle battery connection and ECU connectors while doing any welding work in the vehicle

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DOS AND DONTS DURING ABS INSTALLATION

Warning ! Protect the Valve hoses / cables / extension cable while welding in the vehicle.

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Installation Demonstration on the vehicle

Showing installation locations in the vehicle Installation and dismantling Demonstration and Tips (SCL ABS data.pdf)
Sensor Modulator ECU Cables Connectors Blink code lamp and button

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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ABS component Installation Demonstration

Sensor Installation Pole wheel fitment
Hub machining Pole wheel checking for damaged tooth etc., Heating polewheel for 1 hr at 180 C deg Ensure pole wheel is facing upward while placing hub on ground Press fitting pole wheel on hub fully Always ensure correct seating of pole wheel on hub collar Check axial run-out of the pole wheel and ensure it within 0.1 mm

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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ABS component Installation Demonstration (. Contd)

Modulator Valve fitment Ensure same make and voltage as that of ECU. Exhaust facing downwards Connect MV Inlet to DBV outlet and MV delivery to SBA/BC do not swap Length of pipe + hose from MV delivery to SBA/BC less than 1.5 m Fit the electrical connector properly. Ensure that RH modulator valve is connected to RH wheel chamber / actuator only. Steer the front wheels to maximum positions and verify that there is no rubbing of MV delivery hose with the Tyres. ECU fitment Vertical position Away from heat sources Location of ECU protection against water splashing Connectors facig downward Proper grounding to be provided. For transporting the cowl, cover the ECU with watertight plastic cover to prevent water entry. All ground connections of the modulator assembly and ECU must have Separate grounding points. It is recommended to connect no other loads to the ground.

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ABS component Installation Demonstration (. Contd)

Cable routing Cables to be covered with corrugated tubes Cable ties to put at equal intervals Clip the cables firmly - Over tightening of cables to be avoided All frame harness cables to be routed along long member/ cross member. ABS ground connections to be isolated from all other grounds Power to ECU through ignition key Power to valves through ECU Warning lamp and blink code switch are integrated in the dash board Fuse, retarder relay and diagnostic connector are mounted inside the cabin

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ABS component Installation Demonstration (. Contd)

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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