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Sales divisionTechnical network leadership
TECHNICAL TRAINING
-
ANTI BLOCKING SYSTEMPOWER BRAKING SYSTEM-2
P/N.: FRE.005.03/2008.GB
Sales division
Technical network leadership
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
TABLE OF CONTENTS
1Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
TABLE OF CONTENTS
TABLE OF CONTENTS..................................................................................................................................... 1
SYSTEM ADVANTAGES .................................................................................................................................. 2
REMINDER OF FUNCTIONING OF THE DIFFERENT BRAKING SYSTEMS................................................. 3
ABS/PBS. FIRST GENERATION...................................................................................................................... 4
GENERAL VIEW. (ABS/PBS-2) ........................................................................................................................ 5
DESCRIPTION OF THE HYDRAULIC COMPONENTS ................................................................................... 6
SYNOPTICS ...................................................................................................................................................... 7
SYSTEM OPERATION...................................................................................................................................... 8
Integral brake .............................................................................................................................................8
Secondary brake......................................................................................................................................10
Braking without assistance ......................................................................................................................11
Wheel anti-lock function...........................................................................................................................12
WIRING DIAGRAM.......................................................................................................................................... 13
DIAGNOSTIC................................................................................................................................................... 14
Faults stored by the ECU ABS/PBS-2 .....................................................................................................15
Problems which do not feed back fault codes ..........................................................................................16
SYSTEM ADVANTAGES
2Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
SYSTEM ADVANTAGES
Using power assistance provides powerful braking thus reducing stopping distances.
This system makes it simpler to use the vehicle: the heft hand brakes, and the right hand accelerates.
The rider brakes with the left-hand lever (integral braking), and the right-hand lever (braking on the front wheel only) becomes the secondary brake.
The rider brakes with the left lever (integral braking), and the right lever (braking on the front wheel only) becomes an emergency brake.
Combined front and rear braking system controlled by the LH brake lever:
Its integral braking function enables the front brake to be operated at the same time as the rear brake and therefore provide powerful braking. The stopping distance may be halved.
At 60 km/h the stopping distance is:
• With the rear brake only 26 m. • With both brakes 13 m.
This system is used in conjunction with a wheel anti-lock system enabling very harsh braking in complete safety. The rider no longer needs to apply the brakes in relation to the road condition, it is the system which adjusts the braking pressure as required.
On a dry or wet road, the system monitors braking to prevent the front wheel from locking.
The braking pressure on the rear wheel is purposely reduced to prevent it from locking, this is why there is no need for an anti-lock system on the rear wheel.
An inexperienced rider never uses his brakes to maximum capacity as he hesitates to brake hard for fear of locking the front wheel. With this system, he can brake fully in complete safety.
Advantages of the new system:
• Pressure sensors instead of brake contact switches. • ABS Control optimization. • Modulator is less noisy. • Lighter. • Brake lever feel is improved. • No more "spongy lever" when the vehicle is stopped.
REMINDER OF FUNCTIONING OF THE DIFFERENT BRAKING SYSTEMS
3Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
REMINDER OF FUNCTIONING OF THE DIFFERENT BRAKING SYSTEMS
Conventional hydraulic system
SBC integral hydraulic braking system SBC2 integral hydraulic braking system
ABS/PBS. FIRST GENERATION
4Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
ABS/PBS. FIRST GENERATION
UCE
TEP 2005
by xxotest
OK
PIN
+-
GENERAL VIEW. (ABS/PBS-2)
5Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
GENERAL VIEW. (ABS/PBS-2)
1. Modulator. 2. Right-hand brake lever. (Front brake). 3. Front brake caliper. 4. Left-hand brake lever. (integral brake). 5. Rear brake caliper. 6. Speed sensor and pulse wheel.
A. Main brake circuit. B. Rear brake circuit. C. Front brake circuit.
2
3
6
4
5
1
A
B
C
DESCRIPTION OF THE HYDRAULIC COMPONENTS
6Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
DESCRIPTION OF THE HYDRAULIC COMPONENTS
1. Braking control unit. A. ECU. B. Electric engine. C. High pressure pump. D. Brake fluid reservoir. E. Regulation solenoid valve. F. Diaphragm. G. Reed valve. 1. H. Reed valve. 2. J. Pressure sensor. 1. K. Pressure sensor. 2. L. Shock absorber.
2. Left-hand brake master cylinder. (integral brake).
3. Right-hand brake master cylinder. 4. Front brake caliper. 5. Rear brake caliper. 6. Machine speed sensor.
UCE
TEP 2005
by xxotest
OK
PIN
+-
L
K
G
1
D
C B
H
E
F
J
A
2 3
6
4
5
SYNOPTICS
7Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
SYNOPTICS
Rear circuit pressure sensor
Hydraulic pump
Front circuit pressure sensor
ECUABS/PBS-2
Regulation solenoid valve
Front wheel speed Software
It controls the system's operation
CalibratingVehicle's
specific values (mapping)
Main relay
Battery voltageInstrument
panel
Vehicle's wiring harness PIN
code
Starter motor relay
Diagnostic plugDiagnostic
light
SYSTEM OPERATION
8Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
SYSTEM OPERATION
Integral brake
Functioning: The fact of pressing the LH brake master cylinder (2) creates a pressure inside the rear calliper (5), and the ECU (A) is informed of the action on the lever by the pressure sensors (J). The ECU (A) controls the electric motor (B) which drives the pump (C), and the created pressure moves the diaphragm (F), opens the reed valve (G) and actuates the front calliper (4).
Braking assistanceThe sensors (J) inform the ECU (A) of the effort on the brake master cylinder (2).
A. If the effort is low, the solenoid valve (E) is controlled, the reed valve (H) opens, a large quantity of brake fluid is pumped out back to the reservoir (D) by the pump (C), and the pressure inside the front calliper (4) is low.
UCE
+-
L
K
G
1
D
C B
H
E
F
J
A
2 3
6
4
5
SYSTEM OPERATION
9Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Integral brake
B. If the effort is high, the ECU (A) reverses the current circulation in the solenoid valve (E), the reed valve closes (H), and all the pressure created by the pump (C) acts on the front calliper (4).
UCE
L
K
G
1
D
C B
H
E
F
J
A
2 3
6
4
5
SYSTEM OPERATION
10Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Secondary brake
Functioning: The fact of pressing the RH brake master cylinder (3) creates a pressure, and the sensor (K) informs the ECU (A) which controls the electric motor (B) and the pump (C). The braking assistance operates according to the same principle as the integral braking circuit.
UCE
L
K
G
1
D
C B
H
E
F
J
A
2 3
6
4
5
SYSTEM OPERATION
11Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Braking without assistance
Safety: If there is a malfunction in the modulator (1), the vehicle's braking system operates like a conventional system. The action on the LH master cylinder (2) creates a pressure which directly actuates the rear calliper (5). The action on the RH master cylinder (3) penetrates the modulator (1), thus the high pressure pump (C) does not operate, the reed valve (G) opens, the pressure goes through the modulator (1) and acts on the front calliper (4).
UCE
L
K
G
1
D
C B
H
E
F
J
A
2 3
6
4
5
SYSTEM OPERATION
12Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Wheel anti-lock function
Functioning: In the integral braking phase with braking assistance, when the speed sensor (6) informs the ECU (A) about a sharp deceleration of the front wheel, the ECU controls the solenoid valve (E), and the reed valve (H) opens completely. The front calliper (4) is connected to the reservoir (D) of the modulator (1), the pressure drops in the front calliper (4) and prevents thus the front wheel from locking.
UCE
L
K
G
1
D
C B
H
E
F
J
A
2 3
6
4
5
WIRING DIAGRAM
13Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
WIRING DIAGRAM
SATELIS 125cc
1. Modulator. 2. Machine speed sensor. 3. Battery. 4. Ignition switch. 5. ABS/PBS relay. 6. Power supply relay. 7. Starter motor switch.
8. Starter motor relay. 9. Diagnostic plug. 10. Instrument panel (diagnostic lamp, machine speed).
SATELIS. PIN code: 35 GEOPOLIS. PIN code: 30
-
UPPER
LEV
EL
LOW
ER L
EVEL
A3
A2
A1 B1
B3 1123 9
314517
1921
25
20
13101
12V - 25A
1 23 4 5
12V - 25A
2 13 4 512V - 25A
1 23 4 5
6 3
OFF
ON
ABS
km
°C
C
F
E
H
Trip
EFI
km/h
mph
70
1020
30
4050 60
8090
100110
100
30
5070
90 110
130150
170
X1000 r/min
01
23
45 6 7
8
910
1112
24132623
START
PIN
VI
VI
VE
VE
RG/NR
MR/BA
JN/BAJN/VE
VE
GR
BA
OR
RG RG
JN
NR
NR
VE
VE
VE
10A
30A
5A
30A
RG
RG
BE
BE
RG
GR/BE
GR/BE
GR/BE
10 5 6
7
8
9
34
2
1
1123 9
314517
1921
25
20
13101
PIN
+
1123 9
314517
1921
25
20
13101
PIN
DIAGNOSTIC
14Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
DIAGNOSTIC
Before servicing the system, carry out a diagnosis using the diagnostic tool and print out a parameter report.
Diagnostic tool TEP 2005Diagnostic tool functions:
• Reading fault codes. • Reading the parameters. • Activation of actuators. • Downloading the ECU updates.
Diagnostic code
Incident ECU code Fault description Assistance functionABS functi
onLED state
A ECU fault
1 Pump motor fault
No No On2 Solenoid valve fault
3 Error current measurement
8 EEPROM error Yes Yes On
10 Pressure fault
No No On
15 RAM ROM... error
17 AD converter error
18 Speed sensor signal fault
21Machine parameter error in EEPROM
22 Pressure fault
24 Temperature sensor fault
BECU power supply fault
4 Main rele faultNo No On
19 Power supply fault
5 Diagnostic light fault No No On
6 Speed sensor signal fault No No On
7 Power supply fault +APC (+ after the ignition) No No On
9 Module condition fault No No On
14 PIN code fault No No On
16 Wheel locking too long No No On
23 Starter motor relay line fault Yes Yes On
OK
TEP 2005
by xxotest
DIAGNOSTIC
15Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Faults stored by the ECU ABS/PBS-2
A-ECU fault (Fault codes: 1-2-3-8-10-15-17-18-21-22-24)
Occurs when an ECU internal fault is detected.
In this case, note the FTE fault codes shown in a diagnostic page and change the modulator without clearing the codes in the memory. Return the modulator to Peugeot Motocycles with the diagnostic sheet.
B-ECU power supply fault (Fault codes: 4-19)
Appears when an electrical problem occues on the ECU power supply circuit.
Check the battery charge state and condition of the terminals, the modulator electrical circuit (the power supplies and earth), operation of the main relay.
5-Diagnostic light fault
It appears when an electric problem occurs on the diagnostic telltale's power supply circuit.
Check the battery charge state and condition of the terminals, the modulator electrical circuit (the power supplies and earth), operation of the main relay.
Check the diagnostic light and its harness.
6-Speed sensor signal fault
Occurs when the speed sensor signal is not that of the signal expected.
Check the speed sensor, gap not in compliance, phonic wheel bent, defective sensor.
7-Power supply fault +APC (+ after the ignition)
Occurs when there is no +APC power supply on terminal 13 of the ECU.
Check the battery charge state and condition of the terminals, the modulator electrical circuit (the power supplies and earth), operation of the main relay.
Check the +APC circuit, the fuse, the wiring harness.
9-Module condition fault
Occurs when the modulator is not recognized as the main module (main or secondary). Check the modulator's wiring harness and connector.
14-PIN code fault
Occurs when there is no match between the ECU PIN code, harness and possible code for this ECU.
Check the harness PIN code (terminals 19, 20, 21), the ECU PIN code and its match with the machine, and that the ECU accepts the PIN code.
The diagnosis of the battery voltage is inhibited when the starter motor is activated.
DIAGNOSTIC
16Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
16-Wheel locking too long
Occurs when the wheel locks due to a mechanical problem with the braking circuit (seizure of the calliper).
Check the mechanical operation of the calipers if the wheel is actually locking.
Check the speed sensor, gap not in compliance, phonic wheel bent, defective sensor.
23-Starter motor relay line fault
Occurs when the information from the starting relay is not consistent with the operation of the modulator.
Check the starter motor relay and its harness.
Problems which do not feed back fault codes
Machine speed display error on instrument panel
Use the diagnostic tool to check the machine speed calculated by the ECU. (read parameters).
• Check the machine speed sensor and its harness. • Check the harness between the instrument panel and the ECU.
Diagnostic light always off
Use the diagnostic tool to check functioning of the diagnostic light (activate actuator).
Check the diagnostic light and its harness.
Diagnostic light always on and no fault memorised
Check the diagnostic light and its harness.
Poor braking
• Check the fluid level in the master cylinder reservoirs. (When filling never exceed the maximum level).
• Check the brake fluid level in the control unit reservoir.• Bleed the front and rear brake circuits.• Bleed the modulator
Drain the braking circuit
Refer to the workshop manual: Satelis 400/500 cc. P/N 759562.
DIAGNOSTIC
17Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles