MK PRAKTIKUM KONTROL CHASSIS

(ABS-ESP)
System Description of ESP

DR Muchammad Harly , ST, MT

HP/WA 081252389115
Email : muchammadharly.ft@um.ac.id

TEAM PRODI PTO UNIVERSITAS NEGERI MALANG

BL BOSCH 5.3 ABS
BL BOSCH 5.3 ABS
BL BOSCH 5.3 ABS
BL BOSCH 5.3 ABS
BL BOSCH 5.3 ABS
BL BOSCH 5.3 ABS
BL BOSCH 5.3 ABS
BL BOSCH 5.3 ABS
BL BOSCH 5.3 ABS
BL BOSCH 5.3 ABS
BL BOSCH 5.3 ABS
 SENSOR
BL BOSCH 5.3 ABS WHEEL SPEED ABS
TYPE HALL TYPE INDUCTIVE COIL

1= Rumah 1= Rumah
2 = 3 kabel 2 = 2 kabel
3 = IC hall 3 = isolasi
4 = Magnet permanen 4 = Magnet permanen
5 = Batang besi lidah sensor 5 = Kumparan (coil)

CR-27
6 = Batang besi lidah sensor
2 MODEL-KONSTRUKSI SENSOR CKP / CMP
KIRI = TERGANTUNG KANAN = MANDIR
BL BOSCH 5.3 ABS
BL BOSCH 5.3 ABS
BL BOSCH 5.3 ABS
BL BOSCH 5.3 ABS
BL BOSCH 5.3 ABS
BL BOSCH 5.3 ABS
BL BOSCH 5.3 ABS
BL BOSCH 5.3 ABS
BL BOSCH 5.3 ABS
BL BOSCH 5.3 ABS
BL BOSCH 5.3 ABS
BL BOSCH 5.3 ABS
BL ABS Specification
Operating volt. 8 ~ 16V
ECU Operating Temp. -40℃ ~ 120 ℃
Reverse volt. -13.5V
Weight 2.7 Kg
HECU
Pump capacity 4.8 cc/sec
(HU+ECU)
Power consum. 230W
Inlet Valve (EV) : 8.54Ω ± 0.5Ω
Solenoid
Resistance Outlet Valve (AV) :4.29Ω ± 0.25Ω
Valve
EV AV
Operating 45A or less
Return current (10.5V ± 0.5V , 23 ℃ ± 5 ℃)
Pump
Motor 145A or less
Max. current
(16V ± 0.1V , 23 ℃ ± 5 ℃) PUMP MOTOR
Wheel Coil resistance 1600Ω ± 10% - Air Gap
Speed Insulation resist. 1MΩ Front : 0.3~1.2 mm
Sensor Tone wheel 48 EA Rear : 0.3~1.2 mm
HECU
▶ABS5.3 model
RR RL MC2 MC1

ECU housing
FR

ECU connector
FL

Connecting bolt
Pump Motor

Return pump
HECU Location
HECU Appearance
ECU connector

▶Top view
Motor Power line

▶ABS 5.3 Damping

Chamber

Accumulator
▶Bottom view
ABSCM Housing

▶ Never Disassemble HECU

▶ valve seat coil assembly

a b c d a Inlet valve (RR)

b Inlet valve (FL)
e f g h c Inlet valve (FR)
d Inlet valve (RL)
e Outlet valve (RR)
f Outlet valve (FL)
g Outlet valve (FR)
h Outlet valve (RL)
Valve/Pump motor relay fuse

VALVE, MOTOR RELAY FUSE

Acceleration Sensor
Diagonal Circuit of BL ABS5.3

Hydraulic Unit

Return Pump

FL RR FR RL
Hydraulic Unit (Modulator)

▣ Normal Condition

LFEV/RFEV/LREV/RREV NO
Solenoid Valve
LFAV/RFAV/LRAV/RRAV NC
Pump Motor OFF

LF : LEFT WHEEL OF FRONT LR : LEFT WHEEL OF REAR

RF : RIGHTWHEEL OF FRONT RR : RIGHT WHEEL OF REAR

EV : INLET VALVE NO : NORMAL OPEN

AV : OUTLET VALVE NC : NORMAL CLOSE
 Normal Brake pressure from the M/C directly delivers to wheel cylinders
ABSCM does not operate
condition Normal braking without the operation of NO, NC valves

EV OPEN (OFF)
Solenoid valve
AV CLOSE (OFF)

PUMP MOTOR OFF

D D
Pressure Stiff braking pressure → reduced friction, Wheel Lock-up tendency
ABSCM reduces the brake pressure of corresponding wheels
Dump Pump Motor dumps brake pressure to the M/C side

EV CLOSE (ON)
Solenoid valve
AV OPEN (ON)

PUMP MOTOR ON

D D
Pressure To make a proper decision of wheel rotation while pressure dump
or pressure increase mode
Hold To hold the brake pressure of wheel cylinder

EV CLOSE (ON)
Solenoid valve
AV CLOSE (OFF)
PUMP MOTOR ON

D D
Pressure If a frictional force between tire and road surface increases,
ABSCM increases brake pressure again
Increase
EV OPEN (OFF)
Solenoid valve
AV CLOSE (OFF)
PUMP MOTOR ON

D D
BL BOSCH 5.3 ABS
Posisi 2 valve TCS saat ti
dak diakslerasi dan kondi
si ABS satu roda bekerja
/ direm pedal
BL BOSCH 5.3 ABS

Posisi akselerasi 2 valve TCS

saat kondisi slip slip satu ro
da penggerak > 20% ditam
bah rem oleh pompa.
BL BOSCH 5.3 ABS
Posisi akselerasi 2 valve TCS saat
kondisi slip slip satu roda pengge
rak < 20% dikurangi rem oleh p
ompa
BL BOSCH 5.3 ABS
Posisi akselerasi 2 valve TCS
saat kondisi slip satu roda pe
nggerak = 20% tekanan ole
h pompa di tahan
BL BOSCH 5.3 ABS
ABS REM ANGIN
BL BOSCH 5.3 ABS
BL BOSCH 5.3 ABS
BL BOSCH 5.3 ABS
BL BOSCH 5.3 ABS
BL BOSCH 5.3 ABS
BL BOSCH 5.3 ABS
BL BOSCH 5.3 ABS
BL BOSCH 5.3 ABS
ABS & EBD Warning Lamp

Illuminate for 3
EBD & Parking brake lamp seconds after ABS Warning Lamp
IG key ON

• ECU Failure • Wheels sensor failure (Open or short) •

• Solenoid Valve Failure Pump Motor & Valve Fuse Open
• Paring Brake • Low / High Voltage
• Lacking of Brake Oil • While diagnosis
• Short ’ G Bar failure • Short ’ G Bar failure
ABS & EBD Warning Lamp(Passive Type)
ABS External Wiring Diagram
 60A

Wiring Diagram 17

18
10A
15
Ignition EBD
S witch 21
HAS 19
S top 20
ABS
S witch
14

S top 11
Lamp
diagnosis

S ignal ground
30
Acceleration longitudinal A BSC M
10
S ensor V(5V)
28
TOD
S ignal 13
4WD ECU
16

7
FL
6
5
W heel FR
4
S peed
9
S enso r RL
8
2
RR
1
ABSCM Connector

15 UZ 26 ---
15 31 31 ---
26 14 BLS
14 30 25 --- 30 AGND
25 13 TOD
13 29 24 --- 29 ---
24 12 ---
12 28 23 --- 28 UST
23 11 DIAGK
11 27 22 --- 27 ---
22 10 AL
10 21 EBVSILA
21 9 DFRL
9 20 ABSSILA
20 8 MDFRL
8 19 SGND
7 DFFL
7 19
6 MDFFL 18 UB-VR
6
5 DFFR
5 18
4 MDFFR 17 UB-MR
4
17 3 ---
3
2 DFRR 16 MGND
2
16 1 MDFRR
1
Troubleshooting

DTC list

DTC Description W/L Check point

C0800 High voltage (over 16V) O Battery voltage, Wire, Fuse
C0800 Low voltage (8V or less) O Battery voltage, Wire, Fuse
C0035 WSS FL - Continuity O WSS, Conn., Wire Harness
C0035 WSS FL - Plausibility O Wire check, Short, Air gap, Tooth
C0040 WSS FR - Continuity O WSS, Conn., Wire Harness
C0040 WSS FR - Plausibility O Wire check, Short, Air gap, Tooth
C0045 WSS RL - Continuity O WSS, Conn., Wire Harness
C0045 WSS RL - Plausibility O Wire check, Short, Air gap, Tooth
C0050 WSS RR - Continuity O WSS, Conn., Wire Harness
C0050 WSS RR - Plausibility O Wire check, Short, Air gap, Tooth
Troubleshooting
DTC list
DTC Description W/L Check point
C0930 Acceleration sensor O Plug Conn., Sensor failure, Wire open
C0060 Solenoid Valve - LF(AV) O Short, MV line open
C0065 Solenoid Valve - LF(EV) O Short, MV line open
C0070 Solenoid Valve - RF(AV) O Short, MV line open
C0075 Solenoid Valve - RF(EV) O Short, MV line open
C0080 Solenoid Valve - RL(AV) O Short, MV line open
C0085 Solenoid Valve - RL(EV) O Short, MV line open
C0090 Solenoid Valve - RR(AV) O Short, MV line open
C0095 Solenoid Valve - RR(EV) O Short, MV line open
C0110 Motor pump O Motor or Relay circuit failure
C0121 Valve Relay O Valve relay failure
Troubleshooting

DTC list

DTC Description W/L Check Point

C0161 Brake Switch X SW failure, Brake lamp
C0245 WSS frequency error O Poor Tooth Gear or damage
C0550 ECU malfunction O ECU failure