MECHANICAL ENGINEERING

DEPARTMENT

WORK SHEET
COURSE CODE

JA607

COURSE NAME

AUTOTRONIC
LABORATORY

PROGRAMME

DAD6

SECTION

CHASSIS IN DRIVING
: SAFETY
(ANTILOCK BRAKE SYSTEM
TRAINER)

JA607 AUTOTRONIC LABORATORY (JKM PSAS)

ABS TRAINER

Course Code & Name: JA607 Autotronic Laboratory

Programme
: Diploma in Mechanical Engineering (Automotive)

Lecturer :
Date :

Practical Task : Antilock Brake System Trainer

Section : Chassis in Driving Safety

LEARNING OUTCOMES: CLO3 & LD2

CLO3: Demonstrate the ability to fixing the electronic - based problems on the simulator boards.
LD2 : Practical Skills
TITLE

Anti-lock Braking System (ABS)

JA607 AUTOTRONIC LABORATORY (JKM PSAS)

ABS TRAINER

SPECIFIC OUTCOMES

Upon completion the task, students should be able to:

1. Study the difference in stopping time, stopping distance and brake pressure for non-ABS
vehicle with ABS vehicle on different road condition.
2. Understanding the hydraulic circuits in the ABS system and understanding the meaning of
pressure increase, pressure holding and pressure reduction in the ABS Hydraulic Modulator.
3. Learning the diagnosis methods on fault on the ABS system by using lamp blinking method
and ABS Scanner.

TOOLS & EQUIPMENTS:

No Component
1
Analogue Multimeter

Quantity
1 unit

1 manual

Experiment Manual

COMPONENTS:
No. Component
1
ABS Trainer

Quantity
1 unit

SAFETY PRECAUTIONS:
1.
2.
3.
4.

Understand the safety procedures specified by the lecturer.

Always aware, any machine or tool used in the practical task.
Perform your task in an organized manner as this can minimize the risk of accident occur.
Read and follow the experimental method and check with the lecturer if any problem occurs.

JA607 AUTOTRONIC LABORATORY (JKM PSAS)

ABS TRAINER

THEORY

JA607 AUTOTRONIC LABORATORY (JKM PSAS)

ABS TRAINER

PROCEDURE

A) Determine stopping time, stopping distance and brake pressure for non-ABS vehicle with
ABS vehicle on different road condition.

1. Find the ABS Control Panel.

2. Set the ABS to Real Mode and make sure the ABS switch is ON.
3. Set ignition in ON position and adjust the vehicle speed to 30 km/hr.
4.

In Road Condition section of the ABS Control Panel, press the Enter Mode switch and
then press the Dry Asphalt conditions and followed by System Reset.

5. At this point the wheels shall rotate at the speed that you have specified previously.
6. The trainer has a display for showing the braking time and distance for every braking
trial/experiment. The braking time is shown in seconds and braking distance in meter.
7. Press and hold the Brake Simulator push button while watching the wheel rotation and
braking pressure.
8. Observe the braking pressure is not stable which shows ABS change the braking pressure so
that the wheel is not locked.
9. Now we try to disable the ABS and do the same braking trial/experience.
10. Turn the ABS Mode into OFF position. Press and hold the Brake Simulator push button
while watching the wheel rotation and braking pressure.
11. Repeat step 1-9 with different vehicle speed (30,60,90,120,150 km/hr)
12. Repeat the experiment using Wet Asphalt conditions and Icy/ Snowy conditions. Turn
off the trainer and make sure everything is in good and clean condition when you finish your
experiment.

JA607 AUTOTRONIC LABORATORY (JKM PSAS)

ABS TRAINER

RESULTS:
A)
i) Dry Asphalt
Speed
(km/hr)

Stopping
Distance (m)
Without ABS
ABS

Stopping Time
(s)
Without ABS
ABS

Brake
Pressure
(psi)
ABS Only

Total
Wheel
Brake
Pressure
(psi)

Stopping Time
(s)
Without ABS
ABS

Brake
Pressure
(psi)
ABS Only

Total
Wheel
Brake
Pressure
(psi)

Stopping Time
(s)
Without ABS
ABS

Brake
Pressure
(psi)
ABS Only

Total
Wheel
Brake
Pressure
(psi)

30
60
90
120
150
ii) Wet Asphalt
Speed
(km/hr)

Stopping
Distance (m)
Without ABS
ABS

30
60
90
120
150
iii) Icy / Snowy
Speed
(km/hr)

Stopping
Distance (m)
Without ABS
ABS

30
60
90
120
150

JA607 AUTOTRONIC LABORATORY (JKM PSAS)

ABS TRAINER

WORK PROCEDURE:
B. Understanding the hydraulic circuits in the ABS system and understanding the meaning of
pressure increase, pressure holding and pressure reduction in the ABS Hydraulic Modulator.
Actuator
The actuator controls hydraulic brake pressure to each disc brake caliper or wheel cylinder based on
input from the system sensors, thereby controlling wheel speed. These solenoids provide three
operating modes during ABS operation:
Pressure Holding.
Pressure Reduction.
Pressure Increase.

1. Prepare the ETS-ABS trainer for this experiment.

2. Make sure the wheels in stop condition.
3. Observe the ABS hydraulic system simulator panel. This panel simulates the hydraulic
function of an ABS system and shows the pressure increase. Pressure holding and
Pressure Reducing simulation.
4. Turn mode switch to TEST in ABS control panel and ABS switch ON/OFF.
5. Study the hydraulic circuit when the system is in Pressure Holding, Pressure Reduction and
Pressure Increase condition.
6. Draw the circuits as the result for this experiment.

JA607 AUTOTRONIC LABORATORY (JKM PSAS)

ABS TRAINER

RESULTS:
1. Draw ABS Hydraulic circuit while the condition is pressure increase, pressure hold and pressure
decrease.

JA607 AUTOTRONIC LABORATORY (JKM PSAS)

ABS TRAINER

WORK PROCEDURE:
C) Determine the malfunction code on the ABS system by using vehicle diagnostic method.
HOW TO READ SELF-DIAGNOSTIC RESULTS (Malfunction codes)
1. Turn ON the Trainer. Switch the ABS to Diagnostic mode (the mode switch is located in the
Main ABS control panel)
2. If the ABS already has problem in the system the warning lamp will blink to indicate the
malfunction codes.
3. Determine the code No. by counting the number of times the warning lamp flashes on and
off.
4. The code also can be determined by using an analog multimeter. Insert the positive terminal
into the TP15 and negative terminal into TP16.
5. When several malfunctions occur at one time, up to three code numbers can be stored; the
latest malfunction will be indicated first.
6. The indication begins with the start code 12. After that a maximum of three code
numbers appear in the order of the latest one first. The indication then returns to the start code
12 to repeat.

JA607 AUTOTRONIC LABORATORY (JKM PSAS)

ABS TRAINER

HOW TO READ SELF-DIAGNOSTIC RESULTS with ABS Scanner:

1. Turn ON the Trainer. Switch the ABS to Normal mode (the mode switch is located in the
Main ABS control panel)
2. Turn ON the ABS scanner and press SCAN button. If the ABS already has problem in the
system the scanner will display the trouble code complete with the trouble explanation.
(Activate one of the fault simulator from the fault simulator panel to insert a fault to the ABS
electrical system)
3. Up to three trouble codes can be stored in scanner memory.
4. To erase the trouble codes press ERASE button.

i)

Fault Simulator

1. Prepare the ABS trainer for this experiment. Turn ON the ignition.
2. Make sure the electric motors are in stop condition.
3. Find the ABS System Electrical Panel and switch the ABS system to Normal mode.
4. From the fault insertion panel, activate fault no 1.
5. Observe the ABS warning lamp. The default code is 12.
6. To start the self-diagnostic results mode, switch the ABS to DIAGNOSTIC mode. Count
the number of ABS warning lamp blinking with the aid of a multimeter.
7. Deactivate the fault by pressing RESET button in the fault simulator panel.
8.

Activate fault no.2

Note: To see all code from ABS warning lamp use button up and down.
9. Deactivate the fault by pressing RESET button in the fault simulator panel.
10. Activate fault no. 3
11. Using the self-diagnostic method, find the trouble code and problem location for all the fault
except fault 19, 21, 24.
12. Make sure you erase the codes when you finish with each fault diagnosis.
13. After all the codes and problem have been troubleshoot, double check your results with ABS
Scanner.(refer to ABS Scanner diagnosis method above)

JA607 AUTOTRONIC LABORATORY (JKM PSAS)

ABS TRAINER

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ii)

Erasing codes

1. ABS will keep up to three trouble codes in the memory even after the fault is no longer exist.
The code need to be erased.
2. In real situation, to erase this trouble codes you have to follow the instruction in the car
service manual. As an example the instruction from the car service manual may say :
a. Disconnect the check terminal from ground (ABS warning lamp will stay lit).
b. Within 12.5 seconds, ground the check terminal 3 times. Each terminal ground must
last more than 1 second.
c. The ABS warning lamp goes out after the erase operation has been completed.
d. Perform self-diagnosis again. Only the start code should appear normal function
codes.
3. Another method of erasing trouble codes memory is using ABS scanner.
4. Follow the steps below to erase the trouble codes memory.
a) Switch the ABS to NORMAL mode.
b) Turn on the ABS scanner.
c) Press SCAN to check if the trouble codes are store in the memory.
d) Press ERASE to clear those codes from memory.
e) Perform self-diagnosis again to check for trouble codes. The trouble codes should be
gone.

JA607 AUTOTRONIC LABORATORY (JKM PSAS)

ABS TRAINER

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RESULTS:
C. Determine the Malfunction Code
Table 1: Fault Simulator
Fault
No.

Troubles Code

Problem Location

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
20
22
23

JA607 AUTOTRONIC LABORATORY (JKM PSAS)

ABS TRAINER

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DISCUSSION
1. Using the data obtained from experiment A, sketch the following graph and explain the finding
on each graph.
a) Speed (km/hr) versus Stopping Distance for non- ABS vehicle and ABS vehicle on each road
condition.
b) Speed (km/hr) versus Stopping Time for non- ABS vehicle and ABS vehicle on each road
condition.
2. Explain about the ABS brake system and the relationship of slip ratio with the different road
condition.
3. State 2 main components in the ABS system.
4. Explain the method of ABS system functions.
5. List down the damage that often happens on the ABS system.

JA607 AUTOTRONIC LABORATORY (JKM PSAS)

ABS TRAINER

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QUESTIONS:
1. Refer to the ABS Electrical Circuit diagram, how many wheel sensors that located in the
ABS system and what is the function of this sensor.
2. Individual wheel brake pressure meter is moving ________________ before the wheel is stop
because the ABS changes the brake pressure in the __________________ in order to prevent
the wheel from _______________.
3. ABS system reduces brake pressure on __________________in order to prevent the wheel
from ____________ while maintaining the slip ratio is between _________%.
4. Different road condition had different ________.
5. Name component 1 until 9 in the figure below.

JA607 AUTOTRONIC LABORATORY (JKM PSAS)

ABS TRAINER

14

CONCLUSION:
1. Do a conclusion about the task performed.

REFERENCES:

1. Manual Labtech ABS Trainer

Initial Check by,

Approved by,

Programme coordinator
ABDUL RAZAK BIN NAINA MOHAMED
(Signature and Stamp)

.
Head of Department / Head of Programme
(Signature and Stamp)
Session:

JA607 AUTOTRONIC LABORATORY (JKM PSAS)

ABS TRAINER

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