ABS TRAINIING

Anti-Lock- Brake System („ABS“)

and
Anti-Slip-Control („ASR“)
ABS - regulation circuit
 ABS - regulation circuit

1 = sensor
2 = pole wheel
3 = Electronical Control Unit (= ECU)
4 = solenoid regulating valve
 ABS - regulation cycle

pressure OUT
pressure HOLD
pressure IN

(electrical signals solenoid regulate valve)

(vehicle reference speed)

(wheel speed)

(brake pressure)
 system configurations

• 4S / 4M
• 4S / 3M
• 6S / 6M
• 6S / 4M
• 6S / 3M
S = sensors
M = modulators
ABS
 ABS - Special Features
• ABS - regulation of Motor-brake and/ or retarder:
during the ABS - regulation the Motor-brake/ retarder
will be switched off
• ABS - switching off possibility in off road use

• On 6x4 or 6x2 vehicles with a 6S/4M system the

same philosophy is used on the two rearwheels of
one side, which are controlled by one modulator.
This algorithm is called Modified Sidewise Control
(MSR).
ABS/ASR-components
 ABS/ ASR- components

• ECU (Electronic control unit)

• ABS Modulator valve
• Sensors
• Pole wheel
• Differential brake valve (ASR)
• Two way valve (E)
• Proportional valve (ASR)
 ECU - History part 1
A- and B-Version
A - generation (from 1981):
• 2- and 4-channel ECU
• 35-pin plug
B - generation (from 1986):
• 4- and 6-channel ECU
• Optional with ASR
• 35-pin plug
• Downwards compatible
• ASR-motor control only with
solenoid valve (b/ w)
C Version C Version
35pole ECU 54pole ECU
C - generation (from 1990)
• 4- and 6-channel-ECU always with
ASR
• ECU with diagnosis memory
• engine control via prop.-valve or
E- acceleration
• 4-channel C-ECU with 35-pin plug
downwards compatible
• 6-canal C-ECU by now with 54-
pin plug not downwards
compatible
 ECU - History part 2

D Basic D Cab D Cab

4-channel full version 6-channel full version

D - generation (from 1996)

• 4-channel basic ECU without ASR or 4-channel (full) and 6-channel-ECU
with ASR

• With single plug concept / No external valve relays / Only one ASR-valve
ECU ABS D/E - version
Wiring diagram
(4-channel ABS D-basic)
ABS-sensors
 ABS-sensors

task
wheel sensor/pole wheel-combination records the
rotation of the wheel. Pole wheels for middle and
heavy-weight vehicles have 100 teeth. If there are
wheels with a smaller circumference, pole wheels
with 80 teeth are used.The relation of the teeth
numbers between front and rear axle must be 1 -
because off the calculation of the reference speed
in the ECU.

test procedures
resistance of the sensor spool, correct adjustment of
the air gap, correct assignment sensor/wheel and
the signal view
 ABS-sensors
important specifications
pole wheel specification
895 905 000 4
information about the function, the
material, the tolerances and the teeth
numbers for pole wheels for a proper
ABS function
installation hints
teeth value selection in dependence on
the tyre circumference
sensor adaptation specification
441 032 100 4
information about sensor installation
hints for the air gap adjustment and
proposal for a special check of the
installed group sensor/pole wheel
installation examples
 ABS-sensors

function
solenoid
• the wheel sensor
consist of a sensor
permanent solenoid holder
with pole pin and a magnetical
spool stream

• during rotation of the -Umax U=0 +Umax

pole wheel the air
AC
gap changes - in that
change an alternating
voltage (AC) is
generated
• the sensor spool spool
records the AC air gap
• the frequency of the
AC is proportional to
the wheel speed
 ABS-sensors

proper working pole wheel/sensor combination

 ABS-sensors

pole wheel/sensor combination with air gap to large

 ABS-sensors

ABS sensor variants

The sensors are marked in dependence on the used pole pin at the
sensor head with „Z“ (cylindrical pin), „K“(coniccal pin), „S“(stage-formed
pin) or „S+“(stage-formed pin - newer version)

variants of different ABS sensors „S“ /“S+“

S radial S axial

S+ axial
S+ radial
 ABS-sensors

sensor resistance output voltage

example
type

actual universal ABS-sensor set for service case

(including sensor holder and grease for installation help)

441 032 921 2 cable length 400mm

441 032 922 2 cable length 1000mm
 ABS-sensors
hints for maintenance

• After service jobs at the wheel

brake the sensor should be
pushed untill stop by hand.

• Do not use any strength or

unsuitable tool by the
correction of the sensor
position.

• By changing the sensor also

change the sensor holder.

no air gap adjustment

special hint necessary !
The adjustment of a minimum push the sensor untill the stop
air gap is not necessary.
 ABS solenoid valves
task
• The task of the ABS solenoid valves is to adapt the brake pressure on
dependence of the regulation signals of the ECU during a brake
performance .
• 3 functions are possible
- Brake pressure increasing
- Hold the brake pressure
- Brake pressure decreasing

variants of ABS solenoid valves

• On electrical side - different kinds of the connection threat and of the
connection design ( Kostal = „screw+insert“, Bajonett = bolted
connection).
• On pneumatical side - different kinds of the connection threat design (for
normal fittings or for quick-plug-in fittings
ABS solenoid valves
 ASR valve

• Differential brake valve is connected in

series to solenoid valves
• Controlled by the ECU the dif- brake valve
controls the pressure for the solenoid
valves
• B-/ C- generation:
For each driven wheel a differential brake
valve is necessary
• D-/ E- generation:
Just one differential brake valve
necessary.
If an ABS valve doesn't get a brake-info,
the wheel will be blocked.
ASR proportional valve

• The proportional valve is connected in

series to the engine-acceleration
cylinder, it regulates the speed-
position on the injection pump
• The controlled pressure is in
proportion to the PWM signal of the
ABS/ ASR- ECU
(pulse-wide modulation)
 Safety concept

Safety check

• Electronic check of the ABS components after ignition ON

• Warning lamp switches off by driving speed over 7 km/h and if

the system is free of error (newer vehicles switches off the
warning lamp after 2 sec)

Monitoring during driving

• Components like solenoids, sensors and wiring.
 Safety concept

System reaction at errors

• If electrically errors in the ABS system appear, the warning lamp
in the dashboard illuminates.
• According to the strength of an error the system will shut off
partly or total.
• At C- and D-generation the errors are memorized in the EEPROM.

Mechanical errors
• Mechanical errors inside the ABS components like leaking
solenoid valves can not be memorized by the ECU.
 Safety concept

ABS-warning lamp truck (red)

ABS-warning lamp trailer (red)
ABS-info lamp (yellow)
• After ignition on the warning lamp ( truck and/ or trailer ) illuminates
and extinguishes after 2 s or. 7 km/h, if no error memorized.
• The info lamp (not required) shows if a trailer with or without ABS is
connected.
Yellow illuminates if ABS coupling isn’t connected or present in the
trailer.
• Vehicles with ASR have an extra yellow ASR- lamp
 Warning lamp function
stationary after ignition on
ABS in solo truck

Truck trailer combination Truck trailer combination

ABS only in truck ABS only in truck
 Warning lamp function
stationary after ignition on without error

Ignition on > 7 km/h

1. Possibility 22 ss
 Warning lamp function
stationary after ignition on with error

Ignition on > 7 km/h

Current error

At last ignition off

memorized sensor
error but actually
not present
(e.g. air gap)
 Warning lamp
in truck ECE 13/09

Yellow v Red truck Yellow v

& trailer
truck trailer

No error v
Small error in truck v
Heavy error in truck v
Small error in trailer v
Heavy error in trailer v
 diagnostic possibillities
ABS warning-lamp or ASR-lamp in
the truck

• Blinkcode
from ignition connection to ABS
(pin15) ECU

tip switch to ground for activation

• Compact Tester

• Diagnostic Controller

• PC-Diagnose
 diagnostic possibillities

ABS warning-lamp or ASR-lamp in the truck

from ignition (pin15) connection to ABS ECU

tip switch to ground for activation

blink code diagnose

• no additional diagnostic hardware necessary - tip switch for blink code actvation
• blink code list to decode necessary
• very complicate - not easy to handle, follow the blinking closely
• only for first service - not useful for manufacturers
Blink Code Description
For blink code activation warning lamp respectively the ASR-L has to be grounded for a
given time by a push button switch. Which signal lamp has to be used depends on ECU
type respectively its parameter setting. The duration defines the mode. After release of the
switch the signal light will be on for further 0,5 sec. to confirm that the grounding was
detected and accepted by the Electronic Control Unit, ECU.

If a fault occurs or signal lamp is grounded for longer than 6.3 sec. blink code will be
terminated. If grounding is detected for more than 15 sec., fault detection of warning lamp
open circuit can be detected and stored in ECU EEPROM (non-volatile memory).
 Diagnostic Mode

For diagnostic mode activation signal lamp or ASR-L has to be grounded for
0.5 sec. to 3.0 sec.

FC1 repeated because fault is actual

If one fault was detected during current „IGNITION ON“ (actual fault) the ECU blinks out
that fault. If more faults were detected during that period blink code shows just the latest
detected fault. For termination ignition must be switched off / on or vehicle has to move
(measured speed of more than one axle).
 Diagnostic Mode

If there is no actual fault, the last fault will be blinked out first. Further fault numbers
may not represent the sequence of occurrence. The stored fault blink mode is self
terminating.
Fault Code Table
System mode, CLEAR ALL MEMORIZED FAULTS:

System mode is activated if the signal lamp is grounded for a time of 3 to 6.3 sec. All
stored faults are erased, if no fault is actual.

For termination ignition has to be switched off / on or vehicle has to move (measured
speed of more than one axle).

System code (one number) represents the expected system and should be used to check
correct ECU Type.

After activating system mode ASR (ATC) is disabled for dyno tests. With WL blinkode
ECU’s ASR (ATC) lamp is permanently on indicating ASR(ATC) disabling.
 diagnostic possibillities

compact tester (for truck ABS C- and D-version)

446 310 410 0

Compact Tester 446 310 410 0

• only for ABS-C and D-Version, not for ABS-E-Version

• simple handling for service, not to recommend for manufacturers
• supporting by numbers and symbols on the display
• cabling necessary to connect with the vehicle ECU
 diagnostic possibillities
diagnostic controller
446 300 320 0

additional components of
the diagnostic
controller

diagnostic controller card - extra order

446 300 xxx 0

Diagnostic Controller 446 300 320 0 cable adapter - extra order

(In this example for ABS C, ECAS ...)

• Universal WABCO diagnostic tool

• additional card necessary („credit card“) - depends on the ECU to
diagnose - different language versions
• simple handling - robust
• adapter cabling necessary to connect with the vehicle ECU
 diagnostic possibillities
PC diagnosis (You have
to take your own PC!)

diagnostic interface
446 301 021 0

PC software ...
...from disks 446 301 xxx 0
or
...from the „abo“ 246 301 xxx 0

PC diagnosis
• most modern WABCO diagnostic tool - diagnostic interface 446 301 021 0
necessary urgently
• further adapter cabling necessary to connect with the vehicle ECU - same
cabling like for diagnostic controller can be taken
• PC software from disks 446 301 xxx 0 or via internet subscription („diagnose
abo“) 246 301 xxx 0 - software depend on the system to diagnose and the
language
DIAGNOSTIC SOCKET

1 Ignition (15)
2 Batery (-)
8 Diagnostic K Line (10/14)
10 Diagnostic L Line (11/14)