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Group: 42
January 2008
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. 2. 3. 4. 5. 6. 7. 8. 9. Introduction, advantages & Working principle of ABS Suppliers of ABS system ABS Instructions to User (Operator) General Instructions to Mechanics (Working with ABS) ABS configuration Functions of individual components of ABS Troubleshooting with Blink Code Diagnostics Diagnostic Kit & diagnostic software installation. List of service representatives from Knorr Bremse & WABCO.
Please bring this information to the notice of all concerned in your workshop and educate customers.
Advantages
-
Improves Stability
Prevents vehicle skidding by avoiding front & rear wheel lock. Helps driver to steer around obstacles during panic braking even on slippery roads. Helps to stop the vehicle at lesser stopping distance on dry as well as slippery roads. Prevents tractor swinging around the fifth wheel coupling in tractor trailer combination.
Improves Steerability while braking Shorter stopping distance Prevents Jack Knifing
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.
Modulator 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.
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.
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
MINIMUM AIR GAP TO BE MAINTAINED BETWEEN POLEWHEEL & WHEEL SPEED SENSOR
Adjustment of Polewheel & sensor Gap 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 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 push away the wheel speed sensor thereby setting the air gap between the two parts.
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
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
The number of times the blink code flashes indicates the type of fault that can be referred from the blink code chart.
Block 1 ( Component / Nature of Error) 1 - No faults 2 - ABS Modulator Valve 3 - Sensor Air Gap 4 - Sensor Short I Open 5 - Sensor Intermittence 6 - Sensor, Pole wheel 7 - System function
Block 2 ( Location) 1 - No faults 1 - Front Right (FR) 2 - Front Left (FL) 3 - Rear Right (RR) 4 - Rear Left (RL) 1 - Engine control data link 3 - Third brake relay short I broken wire 4 - Warning lamp 1 - Battery under voltage 2 - Battery over voltage 3 - Internal fault 4 - Configuration error 5 - Ground
8-ECU
System response
Possible responses: 1. ABS warning lamp comes 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.
Action
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. Connect ECU.
DIGNOSTICS
Step II. Press and hold blink code switch for half a second, then release. Step III. Count the flashes to determine the blink code. Step IV. Turn ignition OFF. Repair and record faults Step V. Turn ignition ON. Clear Faults from memory: Press and hold blink code switch for at least three seconds, then release.
ABS warning lamp begins flashing two-digit blink code(s). Refer blink code chart.
First Digit: 1 - 8 flashes, Pause (1.5 seconds). Second Digit: 1 - 6 flashes, Pause (4 seconds). Active errors.
Determine if fault is active or stored: Active error: Lamp will repeatedly display one code. Stored error: Lamp will display code for each stored fault then stop blinking. Faults will be displayed one time only. Find definition for blink code on blink code chart.
Stored errors.
Make the necessary repairs. Repeat Steps I, II, and III until system O.K. code (1-1) received. Record for future reference. NOTE: Last error stored is first error displayed. All errors are successfully cleared. Turn ignition OFF.
ABS warning lamp flashes eight times quickly and then repeats 2-2.
CLEAR
Block 1
1 2 3 4
Location
--------------------------------------Wheel speed sensor, front axle, left side Wheel speed sensor, front axle, right side Wheel speed sensor, rear axle, left side Wheel speed sensor, rear axle, right side
Block 2
1 1 2 3 Air gap too big
Fault Description
No faults recorded by the ECU.
Missing speed sensor signal at drive off Damaged contaminated tooth on sensing ring, erratic signal from speed sensor, check sensing ring alignment and wheel bearing adjustment Unstable signal from speed sensor, check sensing ring alignment and wheel bearing adjustment, check wiring for possible source of interference. Loss of speed sensor signal. Sensor wires shorted or broken Release solenoid shorted to battery Release solenoid - shorted to ground Release solenoid wire broken Valve ground wire broken Hold solenoid shorted to battery Hold solenoid shorted to ground Hold solenoid wire broken System configuration error, check valve and system wiring and check ECU configuration Shorted to battery, remove X2 Plug from ECU and check for voltage on valve ground connections, replace wiring if necessary Shorted to ground not through ECU or internal valve defect, remove X2 Plug and check resistance between valve ground connections and chassis ground
5 6 8 9 10 11 Pressure modulator valve, front axle, left side Pressure modulator valve, front axle, right side Pressure modulator valve, rear axle, left side Pressure modulator valve, rear axle, right side 1 2 3 4 5 6 7 8
10
Pressure modulator valve, valve common ground Pressure modulator valve, valve common ground
10
10
11
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.
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.
210322739995 210322739996
Diagnostic software for :- Wabco ABS Diagnostic software for :- KnorrBremse - 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,
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.
Region
North East West South
WABCO
Name
Naresh Kumar Avijit Mujumdar Dharmedra Chandratre Vijaygopal Balaji
Responsible Area/Region/Zone
99997 99663 Delhi,Rajsthan,Hariyana,Punjab,Himachal,UP, UA,Jammu 92305 69728 West Bengal,Jharkhand,Orisa,Bihar,Assam,North East States 98811 38148 Maharashtra,Goa,Gujrat,Madhya Pradesh,Chattisgarh 98405 55826 Tamilnadu,Andhra Pradesh,Karnataka Kerala
Region
North
Name
New Delhi New Delhi New Delhi Jaipur Jalandhar Kanpur Kolkata Kolkata Guwahati Cuttack
Responsible Area/Region/Zone
North Zone North Zone Haryana, Delhi & Uttranchal state Rajasthan state J&K, Punjab & HP states UP state East Zone West Bengal(Except Siliguri), Bihar states & Dhanbad North East states & Siliguri area of WB Orissa, Jharkhand states (Except Dhanbad) West Zone West Zone Mumbai & Aurangabad region of Maharashtra Gujarat state Nagpur region of Maharashtra & Chattisgarh state Pune region of Maharashtra MP state South Zone Kerala state South & North part of TN & Chennai Karnataka state Telugana & Rayalasema East Godavari, West Godavari & Coastal area of AP Central & Western part of TN
East
Raghuraman B Ananya Chowdhury Somenath Datta Amit Kumar Bose Hussain Mohamed K Sujit K Tambat Arumugam B Jitendra Patel Sushil Kumar Maurya Jameel Babu L Dhanasekar M
West
Mumbai Mumbai Mumbai Ahmedabad Nagpur Pune Indore Chennai Cochin Chennai Bangalore Vijayawada Salem
Sivakumar S David Amalraj A Ramasubramanian V South Punithavelu T Rajendran G S Sambasiva Rao S P Kumar K