2. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Welcome to AfterSalesTraining

3. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE R264 Anti Lock Braking Systems Steve Baker

4. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Comfort & Convenience Coffee Breaks Lunch Arrangements Telephones Messages Start & Finish Times Toilets Smoking Policy Fire Precautions

5. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Introduction Course Code : R264 Course Title : Anti Lock Braking Systems Course Duration : 1 Day

6. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Purposes of a Braking System Stop the vehicle Reduce vehicle speed Change kinetic energy to heat energy Hold the the vehicle stationary when unattended

7. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Advantages of Disc Brakes Over Drum Brakes Greater heat dissipation Cleaner braking surfaces Lighter in weight Simpler construction Easier to service Equal braking forwards & backwards Self adjusting

8. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Disadvantages of Disc Brakes No self servo action Handbrake mechanism is more complicated

9. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Front / Rear Split System 1. ABS modulator unit 2. Electronic control unit 3. Master cylinder 4. Brake pressure proportioning valve 5. Brake pedal 6. Servo unit 7. Brake calliper

10. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Non ABS Master Cylinder Components 1. Brake Fluid Reservoir 2. Seals 3. Cylinder Body 4. Spring 5. Seal Support 6. Seal 7. Secondary Piston 8. Seal 9. Primary Piston Assembly 10. ’O’ Ring 11. Vacuum Seal Backing Ring 12. Vacuum Seal 13. Transfer Housing

11. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Master Cylinder Non ABS

12. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Brake Caliper Assembly 1. Disc 2. Carrier 3. Inboard Pad 4. Piston 5. Piston Seal 6. Guide Pin 7. Outboard Pad

13. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Antilock Braking Systems A.B.S Originally developed for trains during the early 1930’s System developed & adapted for aircraft after WW 2 Late 1960’s saw the first ABS system fitted to “Luxury” cars developed by Bosch

14. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Why A.B.S? To reduce the possibility of locking a wheel(s) during panic braking in an emergency resulting in loss of control

15. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Three Types of Behaviour to Be Considered Locked wheel(s) won’t steer Locked wheel(s) generally brake with less efficiently than rolling ones except on certain surfaces – i.E. Snow & ice Locked rear wheel(s) induce directional instability

16. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE ABS Avoids Problems By:- Automatically sensing when the wheel(s) are about to lock Cyclically releasing and re-applying the brakes (modulating) to that wheel(s) until the vehicle has slowed sufficiently This maintains wheel rotation allowing the vehicle to be steered around an obstacle

17. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Major Advantages of A.B.S It allows the driver to retain steering control under maximum braking so that an obstacle can be avoided in an emergency Braking distances can be reduced by up to 10%

18. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Limitations It will not stop a vehicle in shorter distances than physics will allow It will not stop a vehicle sliding sideways if the curve limit speed is exceeded – i.E. - If you steer around a obstacle at too high a speed It is not an “insurance policy” to exceed normal driving standards

19. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Situations Where ABS May Not Be So Effective? Chippings,snow & ice where sufficient depth could occur to build a “wedge” in front of the locked wheel Severe frost where a “locked” wheel may burn through it achieving grip Aquaplaning where brakes of any description are useless

20. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Road Surfaces Surface Type Coefficient of Friction Dry tar 1.0 Wet tar 0.7 Wet pebbles 0.5 Ice 0.1 Wet ice 0.1 or less

21. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Braking Efficiency 1.Optimum braking performance 2.Longitudinal adhesion 3.Lateral adhesion 4.Adhesion 5.% of wheel slip

22. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE ABS Operation Phases Increase pressure phase Maintain pressure phase Decrease pressure phase

23. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Increase Pressure Phase

24. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Maintain Pressure Phase

25. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Decrease Pressure Phase

26. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE ABS Master Cylinder Components 1. Brake fluid reservoir 2. Seals 3. Cylinder body 4. Spring 5. Secondary piston assembly 6. Stop pin - secondary piston 7. Pin securing screw 8. Spring 9. Primary piston assembly 10. Washer 11. Circlip 12. Flat washer 13. Transfer housing

27. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE ABS Master Cylinder

28. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Wheel Speed Signal

29. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Heritage A.B.S Systems Used by Rover Group A.B.S 2 – Rover 800 A.B.S 2E – Rover 200,400,600 (Rover Engines),800 A.L.B – Early Rover 200/400 A.B.S 6 – Rover 200,400,600 BY4 – Rover 600 (Honda Engines Only)

30. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE A.B.S 2 1. Servo 2. Master cylinder (centre valve type) 3. Hydraulic modulator 4. Solenoid valves relay 5. Return pump relay 6. ECU 7. Over voltage relay 8. Pulser ring 9. Wheel sensor 10 Warning lamp

31. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE A.B.S. 2E 3. 1. 2.4. 5. 1.Servo 2.Master Cylinder 3.Warning Lamp 4.Modulator & ECU 5.Sensor & Reluctor

32. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE ALB & A.B.S 6 1. Servo assembly 2.Master cylinder 3.Brake fluid reservoir 4.Hydraulic modulator 5.Hydraulic pump and motor 6.Pulser ring - 50 teeth 7.Speed sensor 8.Warning lamp 9.ECU 10.Hydraulic pump relay/fuse box 11.Handbrake switch 12.ABS6 diagnostic socket 13. ABS6 failsafe relays

33. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Diagnosis & Service A.B.S.2 Fast checkNormal bleeding sequence

34. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Diagnosis & Service A.B.S.2E Locate service DTC connector (under drivers seat or drivers lower dash) Bridge black & yellow/green wires Turn on ignition Count flash codes(up to 3 stored) Clear memory – turn ignition on & off 20 times Normal bleed sequence

35. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Diagnosis & Service A.B.S.6 & A.L.B Locate service check connector (200 R/H A post,600 L/H A post) Bridge wires Read DTC codes Clear faults- remove fuse 3 (200),fuse 47 (600) for over 3 secs Microcheck ( in depth diagnosis) Replace high pressure hose at 48 months Bleed high pressure system using :- SMD 4081& 18G1568 Bleed normal braking system as normal

36. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE High Pressure Bleed A. Filler cap B. T wrench C. Pump reservoir cap D. Bleed screw cap E. Bleed screw adapter F. Bleed control unit G. Cycle start button

37. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Diagnosis & Service BY4 Locate service check connector (lower L/H A post) Fit tool no 18G1724 Switch on ignition Read DTC codes Clear memory ( remove fuse B2 for 3 secs) Microcheck (connector under drivers seat) Open modulator bleed screw Run engine at idle speed until fluid removed Connect SMD 4081 & carry out bleed sequence Top up fluid & repeat until no air present

38. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE A.B.S Types Used by MG Rover Bosch ABS 5.0 – RF 200 – RT 400 – MGF Bosch ABS 5.3 – RF 25(98MY on) – RT 45(98MY on) MGF(2000MY) MG ZR,ZS MG TF Bosch ABS 5.7 – Rover 75 MG ZT ZT-T

39. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE ABS ECU Inputs Wheel speed sensor signal Brake pedal switch Low fluid level indicator Diagnostic line Live feed Earth Ignition feed

40. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE ABS Modulator & ECU

41. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE ABS ECU Sections Section A Logic Section B Safety Section C Input Section D Output

42. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Hydraulic Circuit – non Traction Control 1.Master cylinder 2.Recirculation pump 3.Poppet valve 4.Inlet solenoid valve 5.Expansion/damper chamber 6.Outlet solenoid valve

43. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Wheel Speed Sensors

44. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Wheel Bearing 1.Flange drive assembly 2.Circlip 3.Wheel bearing 4.Front hub 5.Pinch joints

45. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Electronic Brake Distribution Replaces conventional PCRV Active during normal braking Electronically distributes braking force Calculates distribution using wheel speed sensors Begins with a ratio of 1:1

46. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Warning lamps Traction Control ABS Warning EBD Warning Brake Pad Wear

47. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Traction Control Traction control prevents the driven wheels from spinning and helps the driver to maintain vehicle control Fitted to rover 75 KV6 – 2.0 & 2.5 M47r - diesel

48. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE KV6 Traction Control Additional Components Four extra hydraulic solenoid control valves – 2 inlet & 2 outlet Traction control warning light Can-bus link Additional throttle butterfly Additional throttle cable Throttle cable actuator Traction control “off” switch

49. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Traction Control Actions –KV6 Request for a reduction of engine torque Reduction of air entering the engine via secondary throttle butterfly Application of the brakes

50. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE M47R Traction Control Additional Components Four extra hydraulic solenoids control valves – 2 inlet & 2 outlet Traction control warning light Can-bus link Traction control off switch

51. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Traction Control Actions –M47R Request for a reduction of engine torque Application of brakes

52. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Traction Control Switch

53. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Bleed Sequence Rover 25/45 LHF RHR RHF LHR

54. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Rover 75/MGF Bleed Sequence LHR RHR RHF LHF

55. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Brake System Precautions CAUTION: Never re-use fluid that has been bled from the brake system. Do not allow fluid level in master cylinder to fall below ’MIN’ mark during bleeding. Do not fill reservoir above ’MAX’ mark. CAUTION: Do not allow brake fluid to contact paint finished surfaces as paint may be damaged. If spilled, remove fluid and clean area with clean warm water.

56. R 264 Anti locking braking systems 6 June 2016 AfterSalesTraining RAVE Brake System Precautions CAUTION: Use only new brake fluid of the recommended grade. CAUTION: Maintain brake fluid level above ’MIN’ mark during this procedure. CAUTION: Braking efficiency may be seriously impaired if wrong bleed sequence is used.