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LPO 1623 GLOBUS

Bus Body Builders Instruction Manual


Chapter
Number
Table of contents

BRAKE SYSTEM

1) Introduction.
2) Brake Schematic Circuit Layout.
3) List of components.
4) Position configuration & Nylon Pipe connection details
5) Precautions.
1) Introduction
The Bus Body brake System Manual consists of Brake Schematic Circuit diagram and
contains detail information about the brake aggregates used in brake system. The
Brake schematic circuit also contains details about the auxiliary system, which uses
compressed air.
The Manual comprises of a list of components with information of the components in
the Air - Brake system. The information covers the Part Numbers, description, make,
type, technical details and function of each component. The information is explained
by giving suitable figures of the component.
The Manual also contains the position configuration. It shows where the components
are positioned in a bus and details about the Nylon pipe connections from Front
Module to Rear Module.
It covers the precautions to be taken at the time of body building.
Written by Checked by
Approved by

Brake System

TATA MOTORS
LIMITED
1

Date of Release
10-10-2005
Revision Revision
No: 0
Date:
TATA Motors Limited

2) Brake Schematic Circuit Layout

The Brake Schematic Circuit layout consists of a skeleton diagram with


description of all the valves used in the brake system. It also shows in detail
about all the Auxiliary system operating on the compressed air. It shows
how the various components are connected to one another, how the
compressed air lines are routed in the chassis. Pipe connections and joints
are displayed in the diagram.
On the Brake aggregates the air connections are marked with a number
describing what each connection is intended for. The designations are as
follows
Intake is normally 1, if there are two intakes, they are designated as 11 and
12.
Outlet is normally designated 2; if there are several they receive the
numbers 21, 22, 23
Number 3 is for Exhaust.
There is an END OF LINE CHECK given in the Air Brake Schematic
Sheet No. 2. This End of the Line Check is required to be done after
building the bus body. This End of the Line Check ensures correct
functioning of the Brake System. Hence END OF THE LINE CHECK to be
done mandatory after completion of bus body.
The Brake Schematic Circuit is divided in Two Sheets.
Sheet 1/2 Shows the Nylon Pipe connections from Front Module to Rear
Module.
Sheet 2/2 is divided into four tables
Table I for Pneumatic Actuation System.
Table II for Characteristic of System Protection Valve.
Table III for Foundation Brake Details.
Table IV for End of the Line Check to be done after complete Brake
assembly.

Please Refer Attached Drawing No. 2892 4390 00 01 for Brake Schematic
Circuit.
Brake System

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Brake System

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Brake System

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3) List of Components
Brake system
o Aggregate Details
o Compressor

Function:
This compressor is used for building air pressure in reservoirs of air
brake system in vehicles.
o Drying and Distribution Unit Integrated with Quadruple System
Protection Valve

Drying and distribution unit (DDU) combines the function of the Air
dryer with unloader valve, purge tank (fitted with the air dryer) and
the Quadruple System Protection Valve (QSPV)

Function:

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Air Drying Removes moisture completely from the compressed air


Unloading Regulates system pressure by exhausting the compressor
delivery air to atmosphere when system pressure is reached and
allows re-charging of the system when the system pressure reduces.
Safety Valve In case of any malfunctioning of the unloader, protects
the compressor and system by blowing off the excess pressure. This
device is integral with the unloader mechanism.
Quadruple System Protection Valve (QSPV) This function is
integrated into the DDU, which protects the healthy circuits of the air
brake system, in case of failure in one of the circuits. The non-return
valves in this portion prevent back flow of stored compressed air
upstream
Tyre inflator This device helps in tapping air from the DDU for
inflation of vehicle tyres.
Purge tank This tank which is integral with the DDU stores dry air
for regeneration of desiccant bed.
o Reservoir

o Dual treadle valve

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Function:
The unit gives a sensitive, graduated actuation during brake
application and release of dual circuit brake systems on
commercial vehicles.

o Relay Valve

Function:
Relay valve is used to reduce the response time of brake
application when the driver applies the brake. The relay valve is
connected in rear brake circuit.
o Quick Release Valve

o Brake Chamber

Function :
The Brake chamber is used in the compressed air brake system
to generate the braking force, by actuating the Slack adjuster to
decelerate / stop the vehicle.
It can also be used as a working cylinder for the operation of
other equipment

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o Spring Brake Actuator

Function:
The brake chamber applies the force of the compressed air to the
service brake. The spring brake chamber has a compression spring
for applying the parking brake. The brake is released by
compressed air. The spring brake chambers are combined with a
diaphragm section for the service brake section.
o Hand Brake Valve
Delivery

Inlet

Function:
This is an inverted, graduated ON-OFF valve and is used to control
air pressure in the spring brake chambers to gradually apply and
release the parking / hand brakes in proportion to the hand
movement. This valve can also be used as an upright valve to
deliver air pressure in a graduated manner to any auxiliary circuit.
The valve can also be locked in brakes OFF or ON position by
means of a sleeve to prevent accidental operation. This valve is
generally mounted on the dash board on the drivers cabin.

4) POSITION CONFIGURATION

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2
3

POSITION CONFIGURATION FOR REAR MODULE


1) Air Tank For Retarder is placed on Air suspension below mounting
bracket in rear module as shown in fig.
2) Quick release Valve is provided in rear brake parking lining and
mounted on rear axle through a mounting bracket.
3) Relay Valve Provided in rear brake service line and mounted on
cross member just before the rear axle through a mounting bracket.

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3
4

POSITION CONFIGURATION FOR FRONT MODULE


1) The Air Tank for front Brake, Rear Brake, Air Suspension and
Auxiliary Air Tank are placed in Front Module as shown in fig.
2) Dual Treadle Valve Place on floor panel in driver cabin.
3) Hand Brake Valve Placed on Dash Board through a mounting
Bracket.
4) Drying &Distribution Unit Place on cross Member in front module.
NYLON PIPING CONNECTION DETAILS
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Precautions
1)

The Nylon pipe connections from front module to rear module


should be done as per Brake Schematic circuit layout.

2)

The area near the air tank should be accessible for draining the
moisture from the air tank, for this a flap type cover should be
provided in that area.

3)

Care should be taken for accessibility of all the valves after doing
body building or Paneling work on the vehicle. All the valves
should be accessible for repair or ease in changing them.

4)

Nylon pipe should be protected from welding spatters or any other


hot objects at the time of body building on the vehicle.

5)

After completing all the nylon pipe connections as per Brake


schematic circuit, do the End of the Line Check as mentioned in
the brake schematic circuit.

6)

The Nylon Pipe Routing should be done in such a way that, it


should be accessible for checking any leakages, cut or Kink in the
Nylon pipe.

7)

Ensure that all pipes & fittings are free of dust from inside &
outside.

8)

Ensure that the routing of nylon pipes should be such that it should
not touch to any hot objects.

9)

Ensure that the nylon pipes do not rub against any sharp edges.

10)

Ensure that there are no Kinks or Folds in the nylon pipes.

11)

For the requirement of additional Auxiliary connections (i.e.


Pneumatic Horn, driver seat suspension and locking of luggage
compartment hatch) connection should be taken from 24 Port of
DDU from where all the auxiliary connections are given.

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Connection to Pneumatic horn should not be given from Dual


Brake valve connections. It affects the function of brake system.
12)

The Bus Body builder should not tamper the setting of the valves.
In case of some brake problem or system not generating sufficient
pressure. It should be informed to chassis manufacturer.

13)

The Bus Body builder should not change the location of any brake
aggregates for ease in Body Building. If there is a requirement for
changing the location of brake aggregates, it should be done after
approval from Chassis Manufacturer.

14)

The Air pipelines should be cleaned with a compressed air before


connecting.

15)

Work on Brake system should be carried out by persons with


sufficient earlier experience in doing brake-piping connections.

16)

Ensure that the relief outlets and draining outlets are not plugged
or painted by Bus Body builder.

Retarder installation instructions


Precautions to be taken for Retarder while assembling the Body on Chassis
system.
1. There should be enough clearance between Retarder cooling circuit
pipes and body member to ensure
That there should not be fouling with pipes in the extreme
movement conditions of components on bump.
There should be air column of 50 mm min. so that there will be
sufficient heat transfer to air from pipes to atmosphere.
2. Pipes of the retarder should be maintained at a height which is well
above lowest part of the vehicle i.e. Engine Oil sump or Differential
housing.
3. Retarder ECU Location should be easily accessible.

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4. Retarder ECU should be located close to ABS ECU so that the wiring
length can be minimized.
5. All the ECUs should be nicely covered with a casing to protect it
from dust, stones, mud etc.
6. 3 stage air pressure control switch for retarder should have an easy
access.
7. If possible body panel should cover the accelerator sensor switch to
protect it from dirt, mud, stone etc. Enclosure should not affect
accelerator linkage movement.
8. Retarder Hand lever switch should be ergonomically positioned with
respect to Driver seat, so that it is easily operable in all the driving
conditions.
9. There should be provision made on dashboard panel for audio &
visual signal while operating retarder.
10. No NVH pad should cover retarder; this is required for effective heat
transfer to atmosphere.
11. While welding, brazing care should be taken that the any of the air
connections, electrical wiring, ECU and Proportionate valve should
not get damaged.
12. Please ensure that the following before cranking the engine.
Proper amount of specified oil grade is there in retarder before
cranking the engine.
Please ensure recommended amount of coolant is present in the
Engine & retarder cooling circuit.

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ABS installation instructions


Procedure for installing Modulator valve / Sensor extension cable assemblies
(Rear frame harness)
Following aspects to be taken into consideration while installing Rear frame
harness comprising of Modulator valve and sensor extension cable
assemblies
1. Refer the following table for Modulator valve cable assemblies as well as
the sensor extension cable assemblys fitment on 18 pin female housing
Description

EV inlet
solenoid
AV outlet
solenoid
IG- sensor
input
IGM- sensor
input

Where to connect the crimped


end of the Modulator valve
cable assemblies in 18 pin
connector female housing
Rear left (RL)

Where to connect the crimped


end of the Sensor Extension
cable assemblies cable
assemblies in 18 pin connector
female housing
Rear left (RR) Rear left (RL) Rear left (RR)

---

---

---

---

---

---

14

18

---

---

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2. The crimped wires of Modulator valve cable assembly (EV inlet


solenoid and AV - outlet solenoid) and sensor extension cable assemblies
(IG and IGM Sensor inputs) to be inserted fully in the respective slots
as detailed above.
3. After fully inserting the crimped wires ensure that the Junior Power
Terminal (JPT) is crimped to the Modulator valve and sensor extension
cable assemblies are properly locked. This can be ensured by gently
pulling the inserted crimped wires by hand.

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4. Plug the crimped connector to the 18 pin female housing in the Electronic
control unit (ECU) and ensure that the female 18-pin connector is fully
locked with the ECU male connector
5. Modulator valves and Sensor extension cable assemblies to be covered
with corrugated tubes wherever it is routed through sharp edges.
ECU Installation
1. ECU housing must be secured in such a way that the permissible
acceleration of 5g is not exceeded.
2. ECU must be protected from water entry and the installation has to avoid
proximity of heating devices so that hot air is diverted away from ECU.
3. Fixation of the ECU is through screws
End of Line checking procedure using compact tester
Connecting the tester
1. Connect nine pole plug of the WABCO diagnostic cable into the
appropriate socket on the compact tester and connect other end of the
cable to the diagnostic socket located in the cab
2. Switch on the ignition. Now the tester displays 888
3. After approximately 12 seconds the tester tries to establish the diagnostic
connection with the ECU. The display begins to flash. After establishing
connection with ECU successfully the type of system identified will be
displayed
ExTime
0-1 Sec
After 1 Sec or after 2
Sec

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Display
ABS

Comments
Only ABS system is
installed
Signifies D- Version

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1. Error search
Push ERROR button located in the front panel of compact tester to
read errors. The display of error is explained below digit wise
1st Digit
2nd Digit
3rd Digit
Error path
Error type
Frequency
Note: Refer attached file on compact tester for front panel description
2. Error Delete (< CLEAR BUTTON>)
Push the < CLEAR > button located in the compact tester front panel for
more than 0.5 Sec. The whole error memory in ECU is deleted.
Note: a) This is done only provided there is no currently existing error
b) To delete the whole of the error memory the ignition needs to
be switched OFF and then ON again. After this the display
once again shows the type of ECU identified (ABS)
If an ABS D ECU is connected the system used will be shown as
follows
3. Display system (< system>) button
By pushing the < SYSTEM> button the system identified by the ECU
can be displayed
For a 4S4M system the display will be as follows
System
Display
For a 4S / 4M system
4 ----- 4

4. Functional Testing
After initial installation of ABS system the proper pneumatic and
electrical allocation of the components must be checked.
The functional test is activated by pushing the following buttons:
a) Push < SYSTEM> button and release
b) System used (e.g. 4-2) is displayed

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c) Push < CLEAR> button for more than 2 seconds. After 2 seconds
SYS appears on the display.
d) If the warning lamp was ON it will go OFF before the < CLEAR>
button is released
e) Pushing the < CLEAR> button for longer than 0.5Sec causes the
next test step to be addressed.
f) If any other button is pushed for longer than 0.5Sec the
functional test is aborted and the type of ECU identified appears
on the display (ABS)
5. Testing Retarder control
When <CLEAR> button is pushed again for longer than 0.5 Sec the
retarder is in active for 5 Sec (Display: 005 . 000). Depending on
the type of retarder used the effect of this will vary
Note: a) For more information please refer to the test instructions for
the appropriate retarder
b) If no retarder is identified the first digit of the display shows a
dash in place of a zero
6. Allocation testing without control pressure
a) After testing retarder control one wheel can be turned without the
< CLEAR> button is being pushed again. The display shows the
current speed of the wheel being turned in Kilometer per hour
(K.P.H).
(Example: Wheel speed measured for wheel A = 5.6 k.p.h =
display A05)
b) Continue the same procedure as outlined in point (a) for other 3
wheels
c) If ECU detects a speed more than one wheel the display will
show --- --- --- .
d) The sensor / Modulator valve allocation is checked by
determining that the correct sensor / Modulator valve have been
paired by way of listening or feeling.
e) The functional test is aborted by pushing any of the buttons.

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