Engine JAC HFC4DA1-2C. Manual — part 140
ABS
ABS
ABS
ABS Anti-lock
Anti-lock
Anti-lock
Anti-lock Brake
Brake
Brake
Brake System
System
System
System
- 81 -
Diagnosis
Diagnosis
Diagnosis
Diagnosis and
and
and
and Testing
Testing
Testing
Testing
Detection
Detection
Detection
Detection by
by
by
by diagnostic
diagnostic
diagnostic
diagnostic instrument
instrument
instrument
instrument
Remarks:
Data of switches, sensors, actuators and so on can be
read through data stream of diagnostic instrument
without removal/installation of any element.
Therefore,
the
reading
of
data
stream
before
troubleshooting is one of the methods for shortening
maintenance time.
Functions of diagnostic instrument shall be determined
based on actual development of customer’s instrument.
Please refer to corresponding instruction manual of
diagnostic instrument for certain vehicle for details.
The diagnostic contents (BOSCH diagnostic instrument)
listed below is only for reference.
(a)
Connect the diagnostic instrument to data link
connector (DLC).
(b) Turn on the ignition switch.
(c)
Read data stream based on display of diagnostic
instrument.
Remarks: Apply the diagnostic instrument to test ABS,
which should be performed in road test. DTC can be
cleared when necessary to ensure normal operation of
ABS and conventional brake system.
Please finish the following procedures before the
replacement of ABS:
1.
Dynamic self-checking: ABS lamp won’t go out
when the ignition switch is turned on again after
some faults (such as wheel speed sensor signal
reliability failure or motor failure) are eliminated
and the lamp shall go out after ABS dynamic
self-checking is qualified with the vehicle speed no
less than 15Km/h.
2.
Cross validation: Install the removed ABS onto a
normal vehicle equipped with the same ABS model,
with ABS harness connectors connected but no oil
pipe in need of connection, and ensure ABS
connectors and wheel speed sensors are firmly and
reliably connected. Start the vehicle to run for a
few circles to enable ABS dynamic self-checking.
�
If the ABS lamp goes out, there is no failure in
ABS.
�
If the lamp keeps on, there is failure in ABS.
The ABS may be replaced.
Item
Display Valve/Range
Normal State
Remarks
Left front wheel speed
1.75Km/h~350Km/h
Actual wheel speed
Right front wheel speed
1.75Km/h~350Km/h
Actual wheel speed
Left rear wheel speed
1.75Km/h~350Km/h
Actual wheel speed
Right rear wheel speed
1.75Km/h~350Km/h
Actual wheel speed
Battery voltage
0~+20.40V
9.3~16.9V
Left front oil inlet valve
ON/OFF
With ignition switch turned on:
Power failure
Other conditions: Based on
control
Relevant to ABS conditions:
Pressure boosting:
Oil inlet valve - power failure
Oil outlet valve - power failure
Pressure maintenance:
Oil inlet valve - continuity
Oil outlet valve - power failure
Pressure reducing:
Oil inlet valve - continuity
Oil outlet valve - continuity
Left front oil outlet valve
ON/OFF
Right front oil inlet valve
ON/OFF
Right front oil outlet valve
ON/OFF
Left rear oil inlet valve
ON/OFF
Left rear oil outlet valve
ON/OFF
Right rear oil inlet valve
ON/OFF
Right rear oil outlet valve
ON/OFF
Brake lamp switch
ON/OFF
ON: With brake pedal
depressed
OFF: With brake pedal released
Reflux pump motor
ON/OFF
Solenoid valve relay
ON/OFF
With ignition switch turned on:
Continuity
Occupied state of hydraulic
governor
Already occupied and normal or
BOSCH supply status
Already occupied and normal
ABS
ABS
ABS
ABS Anti-lock
Anti-lock
Anti-lock
Anti-lock Brake
Brake
Brake
Brake System
System
System
System
- 82 -
Diagnosis
Diagnosis
Diagnosis
Diagnosis and
and
and
and Testing
Testing
Testing
Testing
Brake
Brake
Brake
Brake bleeding
bleeding
bleeding
bleeding
Note:
Brake bleeding can be performed in the first and second
circuits.
Brake
bleeding
should
be
performed
after
the
replacement of brake system components (such as
change of brake fluid, replacement of brake system
components and hydraulic unit) or when the brake pedal
is soft.
The hydraulic unit for replacement must be wet-type
ABS hydraulic governor with ECU.
During exhaust, please ensure the brake system is of
complete structure and all hydraulic units are properly
connected.
Before brake bleeding, shift to P gear (for AMT) or N
gear (for MT) and apply the parking brake lever.
Brake fluid is toxic, so please clean your skin if any
fluid touches your skin.
1.
Manual brake bleeding procedures
Step
Operation
1
Fill the brake fluid reservoir.
2
Repeat the procedures below for bleeding of
each wheel cylinder in order of left rear, left
front, right front and right rear.
3
Open the bleed screw.
4
Depress and release brake pedal repeatedly.
5
Close the bleed screw.
6
Release the brake pedal.
7
Check the pedal travel.
8
If failed, repeat bleeding.
9
Check if brake fluid level is within upper and
lower limit marks.
Remarks: Brake fluid level in reservoir shall be over the
lower limit mark during the whole bleeding process.
2.
Manual brake bleeding schematic diagram
Manual brake bleeding schematic diagram for 4-channel ABS X type circuit: Left front wheel
Function mode:
The brake fluid flows into wheel cylinder through master cylinder and hydraulic unit. Open the bleed screw on the left
front wheel with the screws on other wheels closed. Depress and release brake pedal until air bubbles and impurities
are fully drained and the brake fluid is pure. Perform the same process on the other three wheels.
ABS
ABS
ABS
ABS Anti-lock
Anti-lock
Anti-lock
Anti-lock Brake
Brake
Brake
Brake System
System
System
System
- 83 -
Diagnosis
Diagnosis
Diagnosis
Diagnosis and
and
and
and Testing
Testing
Testing
Testing
Component activation test
1.
Component activation test for reflux pump:
(1) Turn off the ignition switch.
(2) Connect the diagnostic instrument to DLC.
(3) Turn on the ignition switch with engine off.
(4) Apply the “Component Test” function of
diagnostic instrument to activate the reflux
pump.
Normal state: Operation sound of reflux pump can
be heard.
2.
Component activation test for solenoid valve:
Remarks:
�
Before testing solenoid valve, please test he
reflux pump to see if it operates normally.
�
Two repair men are required to finish this test.
(1)
Turn off the ignition switch.
(2)
Connect the diagnostic instrument to DLC.
(3) One repair man should sit in the vehicle and the
vehicle should be lifted by lifter with wheels
suspended.
(4)
Turn on the ignition switch with engine off.
(5) Apply the “Component Test” function of
diagnostic instrument to activate the solenoid
valve as per prompt of diagnostic instrument.
(6) Firstly, test the oil inlet valve and oil outlet
valve of left front wheel, during which, the
repair man in the vehicle should depress the
brake pedal with force and hold it.
�
Conventional braking phase:
Normal state: The repair man outside
cannot rotate the left front wheel by
hand.
�
Boosting
phase:
Use
diagnostic
instrument
to
access
the
“boosting
phase”.
Normal state: The repair man outside
cannot rotate the left front wheel by
hand.
�
Pressure
maintenance
phase:
Use
diagnostic
instrument
to
access
the
“pressure maintenance phase”.
Normal state: The repair man outside
cannot rotate the left front wheel by
hand.
�
Pressure reducing phase: Use diagnostic
instrument
to
access
the
“pressure
reducing phase”.
Normal state: The repair man outside can
rotate the left front wheel by hand.
(7) Perform testing for right front, left rear and
right rear wheels in sequence. The test results
should be the same as those of left front
wheel.
3.
Component activation test for ABS and EBD
warning lamps
(1) Turn off the ignition switch.
(2) Connect the diagnostic instrument to DLC.
(3) When performing the component activation
test for ABS and EBD warning lamps, they
should lighten or go out corresponding to the
control of diagnostic instrument.
ABS
ABS
ABS
ABS Anti-lock
Anti-lock
Anti-lock
Anti-lock Brake
Brake
Brake
Brake System
System
System
System
84
DTC
DTC
DTC
DTC List
List
List
List
Attention:
Attention:
Attention:
Attention:
Please turn off the ignition switch before removal of parts.
Note:
Note:
Note:
Note:
Please use the diagnostic instrument to read DTC.
If no fault is detected during the detection of components, ABS hydraulic governor with ECU and its ground
point/power line should be inspected.
When more than two DTC is in memory, the fault relevant DTC and circuits should be inspected at first.
DTC
DTC
DTC
DTC list
list
list
list
DTC
Detection Item
Possible Failure Areas
C0035
Left front wheel speed sensor circuit fault
Left front wheel speed sensor circuit, gear ring or sensor itself
C0040
Right front wheel speed sensor circuit fault
Right front wheel speed sensor circuit, gear ring or sensor itself
C0045
Left rear wheel speed sensor circuit fault
Left rear wheel speed sensor circuit, gear ring or sensor itself
C0050
Right rear wheel speed sensor circuit fault
Right rear wheel speed sensor circuit, gear ring or sensor itself
C0060
Left front oil outlet valve circuit fault of hydraulic
governor
ABS hydraulic governor with ECU
C0065
Left front oil inlet valve circuit fault of hydraulic
governor
ABS hydraulic governor with ECU
C0070
Right front oil outlet valve circuit fault of
hydraulic governor
ABS hydraulic governor with ECU
C0075
Right front oil inlet valve circuit fault of hydraulic
governor
ABS hydraulic governor with ECU
C0080
Left rear oil outlet valve circuit fault of hydraulic
governor
ABS hydraulic governor with ECU
C0085
Left rear oil inlet valve circuit fault of hydraulic
governor
ABS hydraulic governor with ECU
C0090
Right rear oil outlet valve circuit fault of hydraulic
governor
ABS hydraulic governor with ECU
C0095
Right rear oil inlet valve circuit fault of hydraulic
governor
ABS hydraulic governor with ECU
C0110
Reflux pump motor fault: Operation or stopping
failed
ABS hydraulic governor with ECU
Ground/power supply for ABS hydraulic governor with ECU
C0121
Solenoid valve relay circuit fault
ABS hydraulic governor with ECU
Ground/power supply for ABS hydraulic governor with ECU
C0161
ABS brake lamp switch circuit fault
Brake lamp switch and its circuit
ABS hydraulic governor with ECU and its circuit
C0245
General fault of wheel speed sensor
Wheel speed sensor circuit, gear ring or sensor itself
C0550
ABS ECU fault
Battery
Ground/power supply for ABS hydraulic governor with ECU
ABS hydraulic governor with ECU
C0800
Voltage out of range
Battery
Charging system
Power/ground circuit
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