ABS Guide

Anti-Lock Brake System

Hyundai Commercial Vehicles
Published by
Chonan Technical Service Training Center
1


Foreword
This training guide has been published to help all the service personnel of
HYUNDAI distributors, authorized HYUNDAI workshops and commercial
vehicle fleet companies be familiar with the electrical system of HYUNDAI
vehicles.
The applicable vehicles are all kinds of Hyundai Truck and Bus.
All the contents of this guide, including, drawings and specifications are the
latest available at the time of publication.
All the contents of this guide will be helpful when you provide efficient and
correct service on electrical system.
For detailed service specifications and service procedures, please refer to the
relevant shop manuals.
ⓒ2003. Hyundai Motor Company
All rights reserved.
This publication may not be reproduced in whole or in part without the written consent of
HMC.


Contents
1. General 7
1.1 Characteristics 7
1.2 Operation 7
1.3. ASR 10
1.4 ABS Control Cycle 10
1.5 Cautions 12
2. HD 65,72 Truck and County Bus 13

2.1 General 13
2.2 System Components 14
2.3 Wheel Speed Sensor 15
2.4 Modulator and Relay 16
2.5 Hydraulic Circuit 17
2.6 ABS Control Module 19
2.7 Control Logic 20
2.8 Diagnosis 20
2.9 Fault Codes 21
2.10 Service Data 22
2.11 Cautions 24
2.12 Wiring Diagram 25
2.13 Troubleshooting 26
3. Medium and Heavy Duty Truck 29

3.1 System Layout 29
3.2 ABS Control Module 31
3.4 Pressure Control Valve 35
3.5 Fault Codes 37
4. Aero Bus 44
4.1 System Layout 44
4.2 ABS Electronic Control Unit 47
4.4 Pressure Modulator Valve 51
4.5 Anti Spin Regulator 53
5
4.6 Diagnosis 54



1. General
1.1 Characteristics
Under repair braking or slippery road condition by rain or snow, braking a vehicle in
running is apt to generate skid condition. The skid may decrease braking force to increase
braking distance, generate spin by traverse slipping, and or disable steering control, resulting
to an accident. Therefore the ABS system is designed to prevent from wheel locking and slip
upon braking for ensuring :
1.1.1 Stability
When driving on slippery road surfaces, ABS prevents the wheels from excessive slip
and thus keeps the car from wandering or running off the road.
1.1.2 Steerability
When a car runs the curved road at decelerated speed, ABS reduces the slip caused by
wheel locked by wheel locking thus guarantees the stable cornering.
1.1.3 Optimum stopping distance

A.B.S provides optimum-stopping distance by reducing the slip caused by wheel locking
and ensures better stopping ability.
1.2 Operation
Antilock Brake System (A.B.S) automatically adjusts air pressure to the brake, if over
braked, to prevent wheel lock up and to optimize utilization of available traction. By
preventing wheel lock up while braking, ABS ensures the vehicle remains steerable and
stable. By optimization of the available traction, ABS can reduce stopping distances.
When ABS is installed, an Anti Spin Regulation (ASR) can also be installed. ASR
automatically prevents spinning of drive wheel when starting upon accelerating. ASR also
transfers drive torque to the wheel with the greatest traction.
The Anti-lock Brake System consists of the following components:
▶ Wheel speed sensor
▶ Electronic Control Module (ECM)
▶ Pressure Modulator
▶ ABS warning lamp
▶ ABS diagnostic lamp / wheel slip indicator
▶ ASR valve (if equipped)
1.2.1 ABS Operating Principle

If the driver applies the brakes too hard, the wheel will begin to lock. By monitoring the
wheel speeds, the ABS Electronic Control Module (ECM) will determine when locking is
8
about to occur. When a specified difference wheel speed vs. vehicle speed is reached and

one or more wheels show a tendency to lock, the ECM will adjust the brake pressure to the
appropriate wheel to prevent wheel lock and achieve optimum adhesion. The brake pressure
is controlled by the Pressure Control Valves (PCV), which can reduce, hold or increase air
pressure (up to pressure applied by the driver) in precise increments. Anti-Lock Brake System
The ABS is not activated unless the wheels show a tendency to lock during braking. In
ABS Operating Principle
the event of an ABS will shut off the affected part of the system and will urn on the ABS
If the driver applies the brakes too hard, the wheel will begin to lock. By monitoring the
warningwheel
lamp. The part
speeds, the of
ABStheElectronic
ABS which is shut
Control off will
Module (ECM)revert
will to conventional
determine non – ABS
when locking is
brakingabout to occur. When a specified difference wheel speed vs.vehicle speed is reached and
one or more wheels show a tendency to lock, the ECM will adjust the brake pressure to
1.2.2 ASR operating principle
the appropriate wheel to prevent wheel lock and achieve optimum adhesion. The brake
Under adverse
pressure conditions
is controlled thePressure
by the drive wheels
Control may slip (PCV)
Valves while attempting to drivehold
which can reduce, away
or or
increase
accelerate. air pressure
If traction (up to pressure
is different on bothapplied
sides ofby the driver) in precise
vehicle, increments.
the wheel with the lowest
The ABS is not activated unless the wheels show a
traction may slip and in many cases the vehicle may not be able to move. tendency to lock during braking. In the
event of an ABS will shut off the affected part of the system and will urn on the ABS
The ASR lamp.
warning (traction Thecontrol) system
part of the can remedy
ABS which is shut offthis
willsituation by braking the
revert to conventional non slipping
– ABS
wheel through the use of the ASR solenoid valve and the ABS pressure control valves. The
braking
drive torque is then transferred to the wheel with traction allowing the vehicle to drive away.
ASR operating principle Brake control ASR
In this manner ASR acts
Under adverse as an automatic
conditions differential
the drive wheels maylock.
slip while attempting to drive away or
1.2.3 Slip rate(λ)
accelerate.
If traction
Upon braking is different
a vehicle,on both
whichsides of the vehicle,the
is running, slip rate wheel
changeswithfrom
the lowest tractionuntil
0 to 100% maythe
slip and in many cases the vehicle may not be able to move.
wheel are locked and the vehicle stops completely. The slip rate λ may be indicated as the
The ASR(traction control) system can remedy this situation by braking the slipping wheel
below :through the use of the ASR solenoid valve and the ABS pressure control valves. Anti-Lock The drive Brake S
torque is then transferred
λ = (A-B / A) ×100(%) to the wheel with traction allowing the vehicle to drive away. In
this manner ASR acts as an automatic differential lock.
A=Vehicle speed A
B=Wheel speed B
Slip rate(λ)
Upon braking a vehicle which is running, slip rate changes from 0 to 100% until the wheel
are locked and the vehicle stops completely. The slip rate λ may be indicated as the
below :
λ = (A-B / A) ×100(%)
A=Vehicle speed
B=Wheel speed
Tire - Road Friction Coefficient
Stable Unstable
S : Lateral force
1.0 The slip rate(λ) and the surface friction coefficient(μB) may be correlated as the
coefficient
illustration.The slip rate(λ) at the max. μB differs by the road condition but the max
is approx,8∼30%. The cornering force(transverselyB : Braking force force) decreas
slip preventing
0.8 B coefficient
increasing slip late. Once wheel are locked, surface friction coefficient μB decreas
slip friction coefficient μS becomes to “0”, and then wheels are easy to slip.
0.6 ABS High frictional
In fact locked rear wheels generate spinning and locked front wheels disables stee
road surface
The ABS system controls braking force to maintain the slip rate in the range of 8
0.4 ∼13%,in order to generate max.surface friction coefficient, control slip friction coe
at higher range, and provide stability and steerability.Low frictional
B road surface
0.2 9
ABS EffectS Lock
S braking under
The ABS system provides stable extreme condition.Even braking ra
frozen or snowy road,wheels are not locked and maintain max.friction with the roa
Free 0 20 to provide60
surface 40 optimum80braking 100%
Chonan Technical
distance. Servicethe
Restricting Training Center
pressure in the cham
rolling locked at the wheel sideBrake
on theslip()
road surface, the system ensures straight forward
A
B
The slip rate(λ) and the surface friction coefficient(μB) may be correlated as the
illustration. The slip rate(λ) at the max. μB differs by the road condition but the max. range is
approx,8∼30%. The cornering force (transversely slip preventing force) decreases with
increasing slip late. Once wheel are locked, surface friction coefficient decreases and slip
friction coefficient becomes
The slip rate(λ) and theto “0”, and
surface then
friction wheels are
coefficient(μB) mayeasy to slip.as the
be correlated
illustration.The slip rate(λ) at the max.
In fact locked rear wheels generate spinning and locked
μB differs by the road condition but the max.
frontrange
wheels disables
is approx,8∼30%. The cornering force(transversely slip preventing force) decreases with
steerability. The ABS
increasing system
slip late. Once controls braking
wheel are locked, force
surface to maintain
friction coefficient the slip rateand
μB decreases in the range of 8
slip friction coefficient μS becomes to “0”, and then wheels are easy to slip.
∼30%, inIn fact order to generate maximum surface friction coefficient, control slip friction
locked rear wheels generate spinning and locked front wheels disables steerability.
coefficientThe at ABS
higher range,
system and
controls provide
braking forcestability
to maintainandthe steerability.
slip rate in the range of 8
∼13%,in order to generate max.surface friction coefficient, control slip friction coefficient
1.2.4 ABSatEffect
higher range, and provide stability and steerability.
The ABS system provides stable braking under extreme condition. Even braking rapidly
ABS Effect
on frozenThe or ABS
snowy systemroad, wheels
provides are not
stable braking locked
under extreme and maintain braking
condition.Even max. rapidly
friction
on with the road
frozen or snowy road,wheels are not locked and maintain max.friction with the road
surface tosurface
provide optimum braking distance. Restricting the pressure in the chamber locked
to provide optimum braking distance. Restricting the pressure in the chamber
at the wheel side onwheel
locked at the the road
side onsurface, the system
the road surface, ensures
the system ensuresstraightforward motion. The driver
straight forward motion.
The driver may acquire correct alignment of the vehicle by adjusting the steering wheel
may acquire onlycorrect
a little. alignment of the vehicle by adjusting the steering wheel only a little.
Asphalt
Slippery road
Asphalt
Slippery road
1.3 ASR
When one side wheel is caught at slippery road or muddy surface, the slipping wheel
7 Chonan Technical Service Training Center
idles, that the vehicle is hard to run and power train (differential, axle shaft). In order to
compensate idling for stability, the ASR, feature controls to brake the idling wheel properly
and transfer the rotating force to the other wheel to enable launching. The ASR feature is
traction control, and an extensive application of the ABS system. Only ASR control valves
(solenoid valves) integrated on the ABS system to make the ASR feature.
1.3.1 ASR Effect
Upon starting or accelerating the vehicle, a wheel may idle on a slippery road surface or
10
so. Then the vehicle may not start or may be unstable to incur accident. When speeds of

both side wheels are different, the ASR system brakes operate to the faster wheel (idling
wheel) to make the both wheels speed same. The system does not operate at or above
30km/h.
1. Starting at a surface of which one side is frozen (ex : bus stop) or accelerating or
starting at a cornering range, the system provides optimum drivability.
2. Idling wheels as well as locked wheels do not transfer driving force, to decrease
steerability and put the rearmost part of the vehicle out of track. The ASR system
maintains the vehicle under control.
3. The system decreases wear or driving mechanism (differential, axle) and tires.
1.4 ABS Control Cycle

The figure below shows, in principle, an example of a control cycle with the most
important control variables, wheel deceleration threshold –b, wheel acceleration threshold +b
and slip thresholds Lambda 1 and Lambda 2.
If the brake pressure increases, the wheel is progressively decelerated. At point 1 wheel
deceleration exceeds a value that cannot physically be reached by vehicle deceleration. The
reference speed and the wheel speed, which up to this. Point had been the same, now
diverge until at point 2 the wheel speed has achieved a high deceleration. A maximum value
is derived from the reference speeds of the wheels of a diagonal and of the other front wheel
speed, is then generally used as a common reference speed for all three wheels of this
diagonal. Wheel slip is calculated from actual wheel speed (i.e. sensor output) and the
corresponding reference speed.
The deceleration threshold –b is exceeded at point 2. The wheel now moves into the
unstable region of the ц-λ slip curve at which point the wheel has reached its maximum
braking force and any further increase in braking torque increase only the rate at which the
wheel decelerates. For this reason brake pressure is quickly reduced and so wheel
deceleration decreases.
The time taken for wheel deceleration is determined by the hysteresis of the wheel brake
and by the characteristic of the ц-λ slip curve in the unstable region. Only after wheel brake
hysteresis has been overcome does a continued reduction in pressure lead to a decrease in
wheel deceleration At point 3 the deceleration signal – b drops below the threshold and the
brake pressure is held at a constant level for a set time T1.
Normally, wheel acceleration will exceed the acceleration threshold +b within this set
time (point 4). So long as this threshold is exceeded, brake pressure is kept constant. If (for
11
example on a low friction surface) the +b signal is not generated within time T1, brake

pressure is further decreased by slip signal Lambda 1. During this control phase the higher
slip threshold Lambda 2 is not reached. After falling below the threshold at point 5 the +b
signal drops. The wheel is now in the stable region of the ц-λ slip curve and the ц- value is a
bit below the maximum.
Brake pressure is now rapidly applied for time T2 to overcome brake hysteresis. The
time T2 is fixed for the first control cycle and then calculated new for each subsequent control
phase. After the initial rapid phase, brake pressure is then increased more gradually by
“pulses”, by alternating pressure hold and pressure increase. The basic logic demonstrated in
this example is not fixed at all; it rather adapts to the corresponding dynamic response of the
wheel to varying coefficients of friction, i.e. it implements an adaptive system control. All
threshold values depend on several different parameters as for instance the driving speed
and the vehicle deceleration etc.
The number of control cycles results from the dynamic response of the overall control
system composed of the ABS – control - the wheel – the road. Here, the frictional connection
is of vital importance. In general, 3 to 5 cycles per second are performed, but significantly
less on wet ice. If an endurance brake is used during an ABS – control cycle, it is on/off –
controlled by the electronic.
1.5 Cautions
1. Upon Ignition on, the ABS warning lamp (red) shall be on and go out at 10km/hbor
more after starting the vehicle.
2. Braking normally on a normal road surface, the driver is hard to feel the ABS effect.
The ABS effect is designed to feel at braking on a certain surface that wheels are apt
to be locked as slippery road-frozen, snowy, rainy road.
Note
On rapidPart
braking or braking on Description
a slippery road, do not pump the brake pedal
Standard Valueas a non-
ABS vehicle. Press the pedal properly depending on situation (hard or light) at once and
ABSCM Location Back of passenger seat
continuously for optimum ABS effect.
Wheel Resistance 1600±10% Ω
Speed
3. ABSSensor
vehicle an integration ofAirthe Gap ABS system on a non-ABS vehicle. The basic
0.65 ±0.01mm
braking system shall be maintained properly, and the ABS system cannot improve the
Minimum output 120mV(at 2.75km/h)
serviceability.Optimum ABS effect regularly put the wheel speed sensors to bottom
Warning
into the Lamp
pulse ring. Upon Operating
removing Voltage
the hub and drum assembly 24 V to replace the
lining/clean off dirt (lining, particles,
Weightdust, oil etc) on the speed sensor.
2.6 kg
2.1 General Operating Pressure 200 kg/㎠(max 250 kg/㎠)
Hydraulic
2.1.1 Specification
Modulator
Operating Temp12
Range -40∼120℃
Resistance EV : 25.6±0.5 Ω
Chonan Technical Service Training Center AV : 18.3±0.5 Ω
2.1.2 System Layout
2.2 System Components
13
Vacuum Tank
Master Front Wheel Rear Wheel
Cylinder Fluid Tank ABS
Brake
Modulator
LSP Valve Cylinder
Brake
Booster
ABS Service reminder indicator
The Anti-lock Brake System (ABS) controls the hydraulic brake pressure of all four gear
wheels during sudden braking and braking on hazardous road surfaces, preventing the
wheels from locking. This ABS provides the following benefits.
1) Enables steering around obstacles with a greater degree of certainty even during
panic braking.
2) Enables stopping during panic braking while allowing stability and steerability to a
minimum, even on curves.
In case a malfunction occurs, a diagnosis function and fail-safe system have been included
for serviceability.
2.3 Wheel Speed Sensor
2.3.1 Disk type
14

Wheel Speed Sensor
Pulse Ring
2.3.2 Drum Type
Pulse Ring
Wheel Speed Sensor
Wheel Resistance 1600±10% Ω

Speed
Sensor Air Gap 0.65 ±0.01mm
Minimum output 120mV(at 2.75km/h)
15

Drum Wheel Speed Sensor Pulse Ring
2.4 Modulator and Relay
Weight 2.6 kg
Hydraulic
Operating Pressure 200 kg/㎠(max 250kg/㎠)
Modulator
Operating Temp -40∼120℃
EV : 25.6±0.5 Ω
Resistance
AV : 18.3±0.5 Ω
Note
1. Never attempt to disassemble the ABS modulator.
2. The modulator must be transported and stored in upright position and with sealed
ports. The modulator must not be drained.
2.4.1 Removal and Installation
Removal
1. Disconnect motor pump and relay box harness and remove the ABS relay box
mounting nuts.
2. Remove the relay box from relay box mounting.
3. Disconnect the brake tubes from the ABS modulator.
4. Remove the ABS modulator mounting bolts.
Modulator
Relay Box
Installation
16
1. Follow the reverse order of removal.

2. Tighten the modulator mounting bolts and brake tube nuts to the specified torque.
3. Bleed the brake system.
Modulator mounting nut : 12-19 lb.ft (1.7-2.6 kgf.m)
Brake tube nut : 9-12 lb.ft (1.2-1.7 kgf.m)
Tube nut
Mounting nut
Relay box
2.5 Hydraulic Circuit
17

2.5.1 Normal Mode
2.5.2 Hold Mode
2.5.3 Dump Mode
18

2.5.4 Increase Mode
2.6 ABS Control Module
2.6.1 ABSCM Connector Configuration (Component Side)
Pin Plug Assignment Pin Plug Assignment

1 Ignition “ON” 13 Front right wheel speed sensor(+)
5 Front left inlet solenoid valve 14 Front right wheel speed sensor(-)
6 Rear right inlet solenoid valve 16 Data link connector
7 ABS relay control 25 Rear left outlet solenoid valve
9 Front left wheel speed sensor (+) 26 Front right outlet solenoid valve
10 Front left wheel speed sensor (-) 28 Ground
11 Rear right wheel speed sensor (+) 29 Ground
12 Rear right wheel speed sensor (-) 19 30 Ground

Pin Plug Assignment Pin Plug Assignment

31 ABS indicator control 45 ABS relay control
33 Front left outlet solenoid valve 46 Data link connector
34 Rear right outlet solenoid valve 49 Pump motor monitor
35 ABS relay control 53 Rear left inlet solenoid valve
37 ABS relay control 54 Front right inlet solenoid valve
39 Rear left wheel speed sensor(+) 55 Ground
40 Rear left wheel speed sensor(-)
2.6.2 Modulator Connector Configuration (Harness Side)
4 3 2 1
8 7 6 5
PIN Plug Assignment PIN Plug Assignment

1 Rear left Inlet valve ground 5 Rear left outlet valve ground
2 Rear right Inlet valve ground 6 Rear right outlet valve ground
3 Front right Inlet valve ground 7 Front right outlet valve ground
4 Front left inlet valve ground 8 Front left outlet valve ground
2.7 Control Logic
Front Left
Warning Lamp
Wheel
Speed Front Right
Sensor
Rear Left Hydraulic
ABSCM Modulator
Rear Right
Battery (+)
Self Diagnosis EB
Brake Lamp Switch
Exhaust Brake
Cut Relay
20

2.8 Diagnosis
2.8.1 Conditions of warning lamp ON
1. 2 seconds after IG switch “ON”
2. System Fails
3. During self-diagnosis
4. Disconnecting the ECU connector
Note ABS Service reminder indicator
ABS warning lamp should be turned-off when driving the vehicle
2.8.2 System diagnosis step
The ABSCM continuously checks the state of the electrical integrity of ABS and if detects
a failure, it inform the fault codes in SRI lamp flash code.
2.8.3 SRI code check

With ABS check switch turned ON and the ignition switch turned ON, diagnostic trouble
code can be checked, if faults are detected, with the reading of SRI lamp flash.
1. Ground pin 6 of diagnosis connector as shown

in the figure.
2. Turn the ignition switch ON.
3. SRI lamp will be illuminated for 2 seconds and
then read the following Diagnostic trouble code
4. First digit of Diagnostic trouble code is
determined by the number of long flashes
(1.5sec) and after the following 2 seconds brake
second digit is determined by the number of short flashes (0.5sec).
5. Once the SRI lamp flashing is completed. Next active trouble code or history trouble
code stored at ABSCM will be followed after 3sec. brake while the “L” terminal is
shorted to ground or the ignition switch is ON.
6. Diagnosis Trouble code will be retained in the ABSCM until the ignition has been
switched ON and the vehicle speed exceeded 10km/h 20 times.
21

ON
IG
OFF
ON
SRI
OFF
3 sec T1 T2 T1 T3 T2 T2 T2
T1 : 1.5 sec
T2 : 0.5 sec
T3 : 2 sec
2.9 Fault Codes

Fault Codes Description
21 Front right wheel speed sensor short
11 Front right wheel speed sensor open
22 Front left wheel speed sensor short
12 Front left wheel speed sensor open
23 Rear right wheel speed sensor short
13 Rear right wheel speed sensor open
24 Rear left wheel speed sensor short
14 Rear left wheel speed sensor open
15 Wheel speed sensor (Teeth number malfunction)
41 Front right inlet valve malfunction
45 Front right outlet valve malfunction
42 Front left inlet valve malfunction
46 Front left outlet valve malfunction
43 Rear right inlet valve malfunction
47 Rear right outlet valve malfunction
44 Rear left inlet valve malfunction
48 Rear left outlet valve malfunction
51 Valve relay malfunction
53 Pump motor malfunction
16 Voltage out of range
38 Brake lamp switch malfunction
35 Exhaust brake malfunction
22

2.10 Service Data
ECU – ABS Connector (Wiring side connector)
Mounting Pin Subject Pin Value Unit Remark

9 Front left 9+10 1.6±10% KΩ IG OFF
Wheel Speed 13 Front right 13+14 1.6±10% KΩ
Sensor 39 Rear left 39+40 1.6±10% KΩ
40 Rear right 11+12 1.6±10% KΩ
5 Front left 5+(-) 25.6±0.5 Ω IG OFF
54 Front right 54+(-) 25.6±0.5 Ω
Inlet Valve
53 Rear left 53+(-) 25.6±0.5 Ω
(EV)
6 Rear right 6+(-) 25.6±0.5 Ω
33 Front left 33+(-) 18.3±0.5 Ω IG OFF

Outlet Valve 26 Front right 26+(-) 18.3±0.5 Ω
(AV) 25 Rear left 25+(-) 18.3±0.5 Ω
34 Rear right 34+(-) 18.3±0.5 Ω
48+(-) 24 V Brake On
BLS 48 BLS
48+(-) 0 V Brake OFF
Modulator Connector (Modulator side connector)
3 5 7 1
19 21
15 16 17 14

7 EV F/R 7+19 25.6±0.5 Ω At 23 ℃
1 EV F/L 1+19 25.6±0.5 Ω
5 EV R/R 5+19 25.6±0.5 Ω
Modulator 3 EV R/L 3+19 25.6±0.5 Ω
Connector 17 AV F/R 17+19 18.3±0.25 Ω At 23 ℃
14 AV F/L 14+19 18.3±0.25 Ω
16 AV R/R 16+19 18.3±0.25 Ω
15 AV R/L 15+19 18.3±0.25 Ω
23

Modulator Connector (Modulator side connector)
8 10 2
21 19
13 4
9 6 11

Valve relay Supply B+
excitations 2+6 103 ± 10 Ω to terminal
terminal No. 10 (at
Valve relay 23℃)
Valve ∞
switch terminal 10+4 Ω
relay
(NO)
Valve relay
switch terminal 10+8 0 Ω
Relay box (NC)
connector Valve relay at 23℃
excitations 2+11 80 ± 8 Ω
Motor terminal
Relay Valve relay
switch terminal 9+13 ∞ Ω
(NO)
Valve power 10+19 0 Ω Supply B+
Internal
to terminal
circuit Motor power 9+21 0 Ω No. 10
2.11 Cautions
1) Be careful to shock and don’t spray water to ECU.

2) Do not remove and/or rework wiring or connector at ignition switch ON.
3) Do not remove battery terminal while engine is running.
4) Tighten all of bolt (ground,etc) with specified torque after removing all of dirties.
5) Charge the battery after removing it from the vehicle.
6) Turn-off the all of switch and remove the battery (-) terminal before welding.
24

Wiring Diagram 24
2.12 Wiring Diagram
ELECTRONIC CONTROL UNIT(24V)
RR-AV VALVE
RR-EV VALVE
FR-AV VALVE
FR-EV VALVE
RL-AV VALVE
RL-EV VALVE
FL-AV VALVE
FL-EV VALVE
RR SENSOR
FR SENSOR
RL SENSOR
FL SENSOR
SIS LAMP
GND
GND
GND
GND
GND
GND
GND
GND
EBM
+ES
BLS
UM
MR
DK
UR
EB
VR
DL
5 33 542653 25 6 34 49 7 35 45 19 37 4846 16 31 28 29 3055 1 9 10 1314 39 40 11 12
⑮ 17
⑬
⑫ ⑪ ①
⑧
⑥
5A
⑭ ⑩
⑤
16
④ SIS LAMP
40A
15A
⑨ IGN
21 1 14 7 17 3 15 5 16 19
⑦
9 11 2 13 10 6 4 8 ②
③
FL EV
FR EV
FR AV
RL EV
RL AV
RR EV
RR AV
FL AV
+24V
30 85 86 87 30 86 85 87 87a
PM
FL FR RL RR
MR VR
HYDRAURIC UNIT RELAY BOX ASSY
25

2.13 Troubleshooting
Trouble
Trouble Parts Probable Cause Symptom Repair Instruction
Code
Front right
21 wheel speed
sensor short
Front left wheel - Abnormal ABS - Visual check for

- Interfered sensor
22 speed sensor control wiring
short wire
- Other wheels are - Check
- Malfunction of
Rear right wheel normal resistance of
sensor coil
23 speed sensor - System shut off sensor
short - Improper air gap
after ABS event - Check air gap
Rear left wheel
24 speed sensor
short
Front right
11 wheel speed - Check
sensor open
- Abnormal ABS connection of
Front left wheel - Disconnected
12 speed sensor control sensor
sensor connector
open - Other wheels are - Visual check for
- Cut sensor cable
Rear right wheel normal sensor cable or
13 speed sensor or wire
- System shut off wire
open - Cut sensor coil
after ABS event - Check sensor
Rear left wheel
14 speed sensor resistance
open
- Cut sensor cable - Abnormal ABS
Wheel speed or wire control
15 sensor - Malfunction of - System shut off
malfunction sensor coil when non ABS
- Improper air gap control
Malfunction of - Check improper
41 front right inlet
- Disconnected installation for
valve
Malfunction of connector valve relay and
42 front left inlet - Malfunction of - Abnormal ABS modulator
valve
sensor coil control connector
- Blown fuse (15A) - System shut off - Check
Malfunction of
43 rear right inlet - Malfunction of resistance for
valve valve relay valve relay
26 - Check fuse

Trouble
Code
Malfunction of
44 rear left inlet
valve - Check improper
Malfunction of - Disconnected installation for
45 front right outlet connector valve relay and
valve
- Malfunction of - Abnormal ABS modulator
Malfunction of
46 front left outlet sensor coil control connector
valve - Blown fuse (15A) - System shut off - Check
Malfunction of
- Malfunction of resistance for
47 rear right outlet
valve valve relay valve relay
Malfunction of - Check fuse
48 rear left outlet
valve
- Disconnected
valve relay
- Check improper
connector - Unable to drive
Malfunction of connection
51 - Malfunction of valve
valve relay - Check ABS relay
valve relay - Shut off system
box
- Malfunction of
wiring harness
- Disconnected - Check improper
pump/motor connection
connector - Check ground
- Unusual dump
Malfunction of - Bad ground point
53 mode control
pump/motor contact - Check ABS relay
- Shut off system
- Malfunction of box
relay - Check fusible
- Blown fuse (30A) link
- Malfunction of
valves and
pump/motor
- Warning lamp ON - Check battery
Abnormal - Low voltage
16 but system is not voltage
voltage - High voltage
shut off - Check alternator
- Unable to control
ABS while
warning lamp ON
27

Trouble
Code
- Unable to control
Malfunction of - Malfunction of
63 ABS - Replace ABSCM
ABSCM ABSCM
- Shut off System
- Check brake
- Disconnected - Warning lamp is
Malfunction of lamp switch
switch connector on
38 brake lamp terminals
switch - Cut brake lamp - System is not
- Check brake
wire shut off
lamp bulb
28

3. Medium and Heavy Duty Truck

3.1 System Layout
3.1.1 A.O.H Brake – 6  4 Dump Truck
7
2 4 6
8
5
1 3
10
5
16 16
17 14 12 11
19 18
13 15
10 14 12 11
16
11 12 16 16
16 10
9 15
10
1. Air Compressor 11. Air Master

2. Air Drier 12. Pressure Control Valve
3. Purge Tank 13. ASR Valve
4. 4-circuit Protection Valve 14. Double Check Valve
5. Air Tank 15. Brake Oil Reservoir
6. Parking Brake Valve 16. Wheel Speed Sensor
7. Quick Release Valve 17. 3-way Magnetic Valve
8. Remote Chamber 18. Exhaust Brake
9. Dual Brake Valve 19. Intake Silencer
10. Wheel Cylinder
29

3.1.2 Full Air Brake – 6  4 Tractor
20
17
2 15
4
5
4 18 18
1 3
4 16 19
7 4
8
9 12 12
12 21
13
10 10
15
11 14
6 13
10 10
12 13
9
12 21 12
1. Air Compressor 12. Wheel Speed Sensor

2. Air Drier 13. R-12 Relay Valve
4. Air Tank 15. Double Check Valve
5. 4-Circuit Protection Valve 16. Synchronizer Valve
6. Dual Brake Valve 17. Parking Brake Valve
7. 3-Way Magnetic Valve 18. R-14 Valve
8. Exhaust Brake 19. Air Service Valve
9. Brake Chamber 20. Trailer Brake Valve
10. Pressure Modulator Valve 21. Spring/Brake Chamber
11. Quick Release Valve
30

3.2 ABS Control Module

The ECM is the brain of the ABS system. It receives
information from the sensors and sends signals to the ABS
valves. ECM is installed at the underneath the seat of the
passenger side.
18 6 9 15
Front Left Pressure

Module Valve
Wheel Front Right
Speed Solenoid Valve
Sensor
Rear Left
ECU Warning Lamp
Rear Right
ASR
Information
Battery(+) Indicating
Self Diagnosis Initiate Line Self Diagnosis Valve Relay
31

3.2.1 Connector Configuration
7 Main power supply 1.FRT/LH PMV outlet

8 Main power supply 2.FRT/LH PMV inlet
9 Main power supply 3.FRT/LH PMV ground
10 Ground 4.FRT/LH Wheel speed sensor
11 Ground 5.FRT/LH Wheel speed sensor
12 Ground
13 Self diagnosis “K” terminal
14 Self diagnosis “L” terminal
16 ASR Warning Lamp
17 DBR Relay
18 ABS Warning
1.RR/LH PMV outlet

2.RR/LH PMV inlet
3.RR/LH PMV ground
4.ASR Ground
5.RR/LH Wheel speed sensor
6.RR/LH Wheel speed sensor
4.FRT/RH Wheel speed sensor 7.ASR Power supply
5.FRT/RH Wheel speed sensor 8.RR/RH Wheel speed sensor
7.FRT/RH PMV outlet 9.RR/RH Wheel speed sensor
8.FRT/RH PMV inlet 10.RR/RH PMV outlet
9.FRT/RH PMV ground 11.RR/RH PMV inlet
12.RR/RH PMV ground
32


The 4-channel ABS uses four-wheel speed sensor. The sensor consists of a permanent
magnet connected to metal rod, around which a coil has been would. A pulse wheel mounted
to the hub induces an alternating voltage in the sensor coil. The frequency of the alternating
voltage is managed signal in the control unit.
Wheel Speed Sensor
3.3.1 Removal – Front Axle

1. Put blocks under the rear tires to stop the vehicle from
Sensor
moving. Apply the parking brake.
2. If necessary, raise the front tires off the ground. Put
Sensor
safety stands under the axle. Holder
3. Disconnect the fasteners that hold the sensor cable to
other components.
4. Disconnect the sensor cable from the chassis harness. Spring Clip
5. Remove the sensor from the sensor holder. Use
twisting motion if necessary. Do not pull on the cable.
3.3.2 Installation – Front Axle

1. Connect the sensor cable to the chassis harness.
2. Install the fasteners used to hold the sensor cable in place.
3. Apply WABCO recommended lubricant to the sensor spring clip and sensor.
4. Install the sensor spring clip. Make sure the spring clip tabs are on the inboard side of
the vehicle.
5. Push the sensor spring clip into the bushing in the steering knuckle until the clip
stops.
6. Push the sensor completely into the sensor spring clip until it contacts the tooth
wheel.
7. Remove the blocks and safety stands.
33
3.3.3 Removal – Rear Axle

1. Put blocks under the front tires to stop the Spring Clip Sensor
vehicle from moving. Holder
2. Raise the rear tire off the ground. Put safety

stands under the axle.
Sensor
3. Release the parking brake and back off the
slack adjuster to release the brake shoes.
4. Remove the wheel and tire assembly from the
axle.
5. Remove the brake drum.
6. Remove the sensor from the mounting block in
the axle housing. Use a twisting motion if
necessary. Do not pull on the cable.
7. Remove the sensor spring clip from the mounting block.
8. Disconnect the fasteners that hold the sensor cable and the hose clamp to other
components.
9. Disconnect the sensor cable from the chassis harness.
3.3.4 Installation – Rear Axle

1. Apply WABCO recommended lubricant to the sensor spring clip and sensor.
2. Install the sensor spring clip. Make sure the spring clip tabs are on the inboard side of
the vehicle.
3. 3.Push the sensor spring clip into the mounting block until it stops.
4. Push the sensor completely into the sensor spring clip until it contacts the tooth
wheel.
5. Insert the sensor cable through the hole in the spider and axle housing flange. Route
the cable to the frame rail. Be sure to route the cable in a way that will prevent
pinching or chafing and will allow sufficient movement for suspension travel.
6. Connect the sensor cable to the chassis harness.
7. Install the fasteners that hold the sensor cable in place.
8. Install the brake drum on the wheel hub.
3.4 Pressure Control Valve

1. Apply the brakes. Listen for leaks at the modulator valve.
34
2. Turn the ignition on and listen to the modulator operating sound. If the valve fails to

cycle:
- Check the electrical cable connection.
- Use the Troubleshooting Guide to diagnose and repair the problem.
3. Drive the vehicle. Verify that the ABS warning lamp operates properly.
PIN 1
(Green/Yellow) Resistance : 11 ~ 16.5 Ω
(Pin 1 & 2, Pin 1 & 3)
PIN 2
(Blue) Resistance Check
Specification : 11 ~ 16.5 Ω
PIN 3 Pin 1 & 2, Pin 1 & 3
(Brown)
3.4.1 Location
P.C.V Valve
ASR
Valve
Operational Principle
Pressure Dump Mode
A.O.H Type – 4sensor 3module

Full Air Type – 4sensor 4module
3.4.2 Pressure Control Valve Operation
Dump Mode
35

Solenoid Valve A ON
Solenoid Valve B ON
Operational
Hold ModePrinciple
Pressure Hold Mode
Solenoid Valve A ON
Solenoid Valve B OFF
2
7
Increase
Pressure Mode
Dump Mode
Solenoid Valve A OFF
2
8
36

3.5 Fault Code

3.5.1 System diagnosis step indicator check
To make sure the ABS lamp is operating, drivers should check the lamp every time the
vehicle is started. The ABSCM continuously checks the state of the electrical integrity of ABS
and if it detects a failure, it informs the fault codes through the SRI lamp flash.
3.5.2 SRI (Service Reminder Indicator) code check

With the ignition switch turned ON and ABS indicator terminal of data link connector
shored to ground, diagnostic trouble code No. can be checked, if faults are detected, with the
reading of SRI lamp flash.
1. Turn the ignition switch ON.
2. Turn on the ABS check switch for 0.5~0.3 seconds.
3. SRI lamp will be illuminated for 3 seconds and then read the Diagnostic trouble code.
Active Faults
Blink code 2-3 : Fault in ABS modulator valve, right rear drive axle
37

Blink code 5-2 : Sensor signal erratic, left front steer axle.
3-4 : Excessive air gap, left rear drive axle.
Troubleshooting
ClearingBlink code 1-1 : System OK
faults
ABS Check
Switch ON
IG. ON Pause 1.5 sec.
3~6.3 sec. 3 sec.
8 Quick blinks - faults cleared Pause 4 sec. System ID (3)
Continuous until
ignition is turned off
Pause 4 sec. System ID (3) Pause 4 sec. System ID (3)
System code
System configuration code 3 : 4S/3M system
1:6S/6M, 2: 4S/4M, 3:4S/3M, 4:6S/4M, 5:6S/6M, 6:4S/3M, 7:4S/2M
3
7
case faults are not cleared (Active faults still exist)
38
First Digit Second Digit

1 No fault 1 No fault
2 ABS modulator valve 1
3 2 Right front
Excessive air gap
4 3 Left front
Sensor short or open
5 4 Right rear
Abnormal sensor signal
6 Left rear
Tooth wheel
1 Data link
7 System function 4 ABS warning lamp
1 Low power supply
2 High power supply
8 ABSCM 3 Internal fault
4 Ground
Working with blink codes

Condition Cause Action
ABS lamp does not come Loose or burred-out bulb Check bulb
on at ignition ON Check connections
Low voltage(9V or less) or Check connections
high voltage(15V or high) Check voltage
Can’t use blink code Switch not held for proper Repeat procedure and
diagnosis : ABS lamp does time hold ABS check switch for
not go off when blink code 1 sec. – diagnostic mode proper time
was activated 3 sec. – clear all mode
Improper or faulty wiring Inspect and repair
Eight flashes are not Active faults still exist Identify active faults, then
received after holding repair
check switch for 3 sec.
then released
39

3.5.3 Troubleshooting with blink code

Wheel speed sensor
Blink Code
Fault Description Reaction R.I.
L/F R/F L/R R/R
Air gap 3-2 3-1 3-4 3-3 1
Incorrect tire 5-2 5-1 5-4 5-3 2
Short to B+ 4-2 4-1 4-4 4-3 3
Short to ground 4-2 4-1 4-4 4-3 4
Incorrect pole wheel 6-2 6-1 6-4 6-3 7
Wheel disabled
Slip 3-2 3-1 3-4 3-3 8
Misconnected wire 5-2 5-1 5-4 5-3 9
Speed drop – out 3-1 3-1 3-4 3-3 10
Abnormal speed (chatter) 5-2 5-1 5-4 5-3 11
Frequency is too high 5-2 5-1 5-4 5-3 12
Modulator
Blink Code
Fault Description Reaction R.I.
L/F R/F L/R R/R
Open circuit in/outlet 2-2 2-1 2-4 2-3 13
Open circuit 2-2 2-1 2-4 2-3 15
Wheel disabled
Short to ground 2-2 2-1 2-4 2-3 16
Short to B+ 2-2 2-1 2-4 2-3 14
Retarder
Fault Description Blink Code Reaction R.I.
Short to B+ 7-3 17
DBR control
Open circuit 7-3 59
disabled
Short to ground 7-3 19
ABSCM
Fault Description Blink Code Reaction R.I.
Low voltage/open circuit R/F, R/R disabled 21
8-1
Warning amp ON
Low voltage/open circuit 8-1 R/F, R/R disabled 26
Warning lamp 7-4 No reaction 40
Over voltage 8-2 All valves disabled 49
Internal error 8-3 No ABS 54
40

Modulator – valve
8-3 No ABS 57
Activation - time
3.5.4 ABSCM Service Data
Pin Pin
Component Connector Value Unit
(ABSCM) (Harness)
ECU power supply 15P 3-2 3-4 9.6-15 V
Memory power 15P 8-13 8-13 9.6-15 V
DBR relay control 15P 3-10 3-6 64-152 Ω
PCV inlet valve, front 18P-15P 14-13 17-13 5.1-5.8 Ω
PCV outlet Valve, front 18P-15P 13-13 18-13 5.1-5.8 Ω
PCV inlet Valve, R/LH 18P-15P 8-13 11-13 5.1-5.8 Ω
PCV outlet Valve, R/LH 18P-15P 7-13 12-13 5.1-5.8 Ω
PCV inlet Valve, R/RH 18P-15P 15-13 16-13 5.1-5.8 Ω
PCV outlet Valve, R/RH 18P-15P 9-13 10-13 5.1-5.8 Ω
Sensor resistance(F/LH) 18P 16-17 14-15 0.9-2.0 KΩ
18P-15P 16-13 14-13 45 or more KΩ

Sensor to ground(F/LH)
18P-15P 17-13 15-13 45 or more KΩ
Sensor resistance(F/RH) 18P 4-5 2-3 0.9-2.0 KΩ
18P-15P 4-13 2-13 45 or more KΩ

Sensor to ground(F/RH)
18P-15P 5-13 3-13 45 or more KΩ
Sensor resistance(R/LH) 18P 10-11 8-9 0.9-2.0 KΩ
18P-15P 10-13 8-13 45 or more KΩ

Sensor to ground(R/LH)
18P-15P 11-13 9-13 45 or more KΩ
Sensor resistance(R/LH) 18P 12-18 7-13 0.9-2.0 KΩ
18P-15P 12-13 7-13 45 or more KΩ

Sensor to ground(R/LH)
18P-15P 18-13 13-13 45 or more KΩ
41

42

3.5.5 Repair Instruction

R.I. Description
Amplitude of sensor signal is too low. After checking axle bearing play and
1
rotor run out, reinstall sensor to rotor.
2 The number of rotor tooth and size of tire is different between other wheels
DC signal is detected from sensor. Check sensor wiring and replace if
3
necessary.
4 Short to the ground. Check sensor wiring and replace if necessary.
5 Open circuit is detected. Check sensor wiring and replace if necessary.
6 Short between two wires. Check sensor wiring and replace if necessary.
7 Check rotor run out/missing teeth and air gap.
Adjust air gap. When checking on the dynamo-tester, slip has occurred for 16
8
seconds, same trouble code will be appeared.
9 Check for mismatch between other sensors.
10 Wheel speed signal is abnormal. Adjust air gap and check sensor wiring.
11 Check bad connections, and rotor tooth. Check sensor output signal.
12 Check bad connections. If trouble code is shown repeatedly, replace ABSCM.
Check modulator valve wiring. Common terminal between inlet and outlet valve
13 is open temporarily or permanently. Resistance between AV ~ common, EV ~
common is 5.5Ω, AV ~ EV is 11Ω.
14 Short inlet or outlet valve circuit to B+. Check modulator valve wiring.
15 Open inlet or outlet valve circuit. Check modulator valve wiring.
16 Short inlet or outlet valve circuit to ground. Check modulator valve wiring.
17 Check wire. Output is shorted to B+
19 Check wire. Output is shorted to ground
21 Check fuse and power line. Voltage is too low.
26 Check fuse and power line. Voltage is too low
Check wire and bulb. Was ABS check switch activated longer than 16 sec.?
40
Output terminal has no load.
49 Check alternator ban battery. Supply voltage too high for more than 5 sec.
54 Replace ABSCM if trouble code is show repeatedly.
55 No modulator connected. Trouble is not memorized.
56 Check air gap respectively. One axle had rotated faster than other axles.
The modulator was activated longer than 3 minutes. After delay time function is
57
normal.
58 Replace ABSCM if trouble code is show repeatedly.
Check wire. DBR has no load. Load was detected before. If there is no DBR
59 43
actually, reset parameters.

51
Relay
ABS ECU
INTERFACE
INTEVFACE
ASR S/VLV
JIS-4P
ECU -UB2
DBR RLY
EC] -UB1
ECU(UB)
SR-L
GND
GND
GND
GND
GND
GND
GND
GND
W/L
AV
EV
AV
EV
AV
EV
AV
EV
Schematic Diagram
AMP-18P AMP-6P AMP-9P AMP-15P

18 3 16 4 15 1 13 2 9 10 8 3 1 2 4 6 1 4 7 5 2 6 3 4 2 7 125 1015 8 13 9 14
40 0. 5TWIST
11 0.85GB
15 0. 85YR
38 1.25R
5 2.0LR
1 0.85YR
30 2.0BW
21 0.5TWIST
20 0.5TWIST
39 0.5TWIST
43 2.0B
28 2.0RW
53 1.25BR
2 0.85YR
50 1.25L
35 1.25BY
26 1.25LR
18 0.5TWIST
17 0.5TWIST
29 0.85YB
3 0.85YL
25 1.25LgR
44 0.5TWIST
23 1.25BL
7 1.25LgY
45 0.5TWIST
31 2.0G
54 1.25LgW
33 1.25LgB
27 1.25BW
55 1.25LW
8 1.25LY
34 1.25LB
DBR Relay이
6 1.25B
1 3 2 4
16 0.85BY
15 0.85YR
11 0.85GB
6
260-6P
9 0.85Lg
2 47 0.85LY
1 48 0.85LR
3
20 0.5TWIST
8 L2
21 0.5TWIST
MAIN WR`G CONN 3
Clutch switch 39 0.5TWIST
4
090-8P
L1
0902P
Exhst. Brake 163 0.85LR 1 40 0.5TWIST

1
CHASSIS WR`G 68 0.85L 2 18 0.5TWIST
2
17 0.5TWIST A2
5
44 0.5TWIST
7 A1
45 0.5TWIST
44
43 2.OB 6
30 2.OBW
206 31 2.OG
CENTRAL GND
Truck A.B.S
13 0.85B
16 0.85BY Wheel Speed Sensor
403 2.0LR 5 2.0LR
F-33(10A) 2
399 1.25R
090-8P
38 1.25R
F-27(5A) 1
402 2.0RW 28 2.0RW

F-32(10A) 4
400 0.85YB 290.85YB 090-10P 090-8P
5 3 0.85YL
401 0.85YL 6 2 3 1 8 9 10 6 5 6 7 2 4 5 3
54 1.25LgW
25 1.25LgR
33 1.25LgB
27 1.25BW
MAIN WR`G CONN
55 1.25LW
53 1.25BR
35 1.25BY
26 1.25LR
7 1.25LgY
34 1.25LB
23 1.25BL
8 1.25LY
6 1.25B6
50 1.25L
SP-12P SP-12P
12 10
3.6 Wiring Diagram
SWP-3P SWP-3P SWP-3P SWP-3P

ABS ASR 213 213 21 213 213
SWP-2P
Cluster Cluster
050-4P
2 4 3 1
PCV-A1 PCV-A1 S/VLV
2.3 (LH)
PCV-A2 PCV-A1
DTC (RH) (RH) (LH) Rear Wheel
Front Wheel
4. Aero Bus
4.1 System Layout
4.1.1 Aero City Bus
9
2 4
8
7
10
3
1 4
5
6
15 16
17
15
12 12
11 8
14
18
12 13
12
15 15
16
17
1. Air Compressor 10. Quick Release and Double Check Valve

2. Air Dryer 11. Dual Brake Valve
3. Purge Tank 12. Pressure Modulator Valve
4. Air Tank 13. ASR Valve
5. 3-Way Magnetic Valve 14. Relay Valve
6. Exhaust Brake 15. Wheel Speed Sensor
7. Inversion Double Check Valve 16. Spring/Brake Chamber
8. Double Check Valve 17. Brake Chamber
9. Parking Brake Valve 18. Quick Release Valve
45

4.1.2 Aero Space
7 8
2
4 18 4
4 9
3
1 4
5
6
17
13
14 14
11 11
16
7
15
10 12
11
11
14 14
13 17
1. Air Compressor 10. Dual Brake Valve

2. Air Dryer 11. Pressure Modulator Valve
4. Air Tank 13. Brake Chamber
5. 3-Way Magnetic Valve 14. Wheel Speed Sensor
6. Exhaust Brake 15. Quick Release Valve
7. Double Check Valve 16. Relay Valve
8. Parking Brake Valve 17. Spring/Brake Chamber
9. Quick Release and Double Check Valve 18. 4-Circuit Protection Valve
46

4.1.3 Aero Express
4
8
2
4 7
9
3
5
6
13 18
14
14
11 11
16
17
12
10 15
11
11
14 14
18
13
1. Air Compressor 10. Dual Brake Valve

2. Air Dryer 11. Pressure Modulator Valve
3. Purge Tank 12. Quick Release Valve
4. Air Tank 13. Brake Chamber
5. 3-Way Magnetic Valve 14. Wheel Speed Sensor
6. Exhaust Brake 15. ASR Valve
7. 4-Circuit Protection Valve 16. Double Check Valve
8. Parking Brake Valve 17. Relay Valve
9. Quick Release and Double Check Valve 18. Spring/Brake Chamber
47

4.2 ABS Electronic Control Unit
2.2 Bus A.B.S(CI-12) 23
4.2.1 ECM Configuration

2.2.6 E.C.M Connector
During the configuration process, the ECM automatically detects the degree of
expansion by checking vehicle wiring harness for ASR components
18 Pin Connector installed and by checking
the electrical system voltage.
7 ECU Main Power
4.2.2 ECM Self-Test-Feature
9 PMV Inlet
When the ignition
1 is switched
4 7 10 ON,
13 the16ECM microprocessors run a self-test. The self-test
consists of checking the computer memory, the timer 10 andECUa Earth

number of arithmetic and logic
2 5 8 11 14 17
functions. During operation, the ECM continuously runs 11 a1L/2R
test ofPMV Earth
the permanent memory.
4.2.3 ABS Warning 3 Lamp
6 and
9 ASR/Diagnostic
12 15 18 Lamp
35
12 1L/2R PMV Earth
The driver is responsible for monitoring the ABS warning lamp and(if equipped)the ASR
13 Self Diagnosis “K”
lamp (wheel slip indicator).The ASR
18 Pin Connector light should illuminate for a moment after ignition is
14 Self Diagnosis “L”
switched on and, if the ABS warning lamp does not illuminate immediately after the ignition
has been switched on, then the bulb or lamp circuit is 16defective
DBR Relay
and must be repaired.
4.2.4 ABS Failure Modes 17 ASR Lamp
If a failure in the ABS/ASR system is detected18during
ABS vehicle
Warningoperation,
Lamp the failure is
recorded in the ECM memory and the defective portion of the system is switched off. The
ABS warning lamp will illuminate (and remain illuminated),indicating to the driver that there is
a failure. The intact portion of the ABS/ASR system will continue to be operational.
1 4 7
4.2.5 Connector Configuration 9 Pin Connector

2 5 8
48 3 Brake Lamp Switch

3 6 9

9 Pin Connector
2.2 Bus A.B.S(CI-12) 24
12 Pin Connector
1 1L Outlet
1 4 7 10 2 1L Inlet
3 1L Valve Earth
2 5 8 11 4 1L WSS
5 1L WSS
3 6 9 12
7 1R WSS
8 1R WSS
12 Pin Connector 10 1R Outlet
11 1R Inlet
12 1R Valve Earth
15 Pin Connector
1 2L PMV Outlet
2 2L PMV Inlet
1 4 7 10 13
3 2L PMV Valve Earth
2 5 8 11 14 4 ASR Earth
5 2L WSS
3 6 9 12 15
6 2L WSS
7 ASR Power
15 Pin Connector 8 2R WSS
9 2R WSS
49
10 2R PMV Outlet
11 2R PMV Inlet
12 2R PMV Earth
4.2.6 On-Board Diagnostics

In the ECM detects a failure, the corresponding failure code is stored. The failure code
50
remains stored until it is deleted from the ECM memory by pressing the diagnostic button

while simultaneously turning the ignition on. The button should remain depressed for a brief
moment after the ignition has been turned on.
This procedure will also cause the ECM to reconfigure itself to the vehicle system and
the ABS/ASR components, which may be installed. If no response is received after the button
has been depressed, test the diagnostic button per ABS Test 5,Section 11.

The 4-channel ABS uses four wheel speed sensor. The sensor consists of a permanent
magnet connected to metal rod, around which a coil has been wound. A pulse wheel
mounted to the hub induces an alternating voltage in the sensor coil. The frequency of the
alternating voltage is proportional to the wheel speed.
Tone
N
Wheel
S
Air Gap 0.2mm
Wheel Speed
Sensor
WSS
Brake Lining
Use long bar to adjust air gap

Tone Ring
Spindle
Anchor Bracket
 Air gap : 0.2mm

 Minimum output voltage : 0.75 V
 Resistance : 1,570∼1,980Ω
4.3.1 Sensor Check
1. Disconnect sensor connector.
51
2. Measure resistance value with a VOM.

3. Resistance value should be between 1570∼1980 Ω.

4. Wiggle sensor wire looking for an intermittent connection.
5. If resistance value changes during sensor wire movement or value doesn’t fall
between 1570∼1980Ω replace the sensor.
6. If sensor is OK reconnect connector.
7. Re-install connector lock.
8. Check ABS/ASR Tester, if sensor is good,
reconnect and check harness for opens/shorts.
4.4 Pressure Modulator Valve

The Bosch 4-channel ABS used four pressure control valves. The PCV consists of two
diaphragm valves which are pilot controlled by two solenoid valves. The driver controls the
brake pressure through the foot valve. The compressed air passes through the PCV
unrestricted and reaches the brake chambers. If the ECM detects a wheel about to lock, the
pressure must be reduced in this brake chamber. To achieve this, both solenoid valves must
be actuated simultaneously. The pressure in the brake chamber is held by actuating the inlet
valve. To allow pressure build-up, none of the solenoid valves are actuated.
Pressure Dump Mode
4.4.1 Operation
Dump Mode
52 Solenoid Valve A ON

Solenoid Valve B ON
Operational
Hold ModePrinciple
Pressure Hold Mode
Solenoid Valve A ON
2
7
Increase
Pressure Mode
Dump Mode
Solenoid Valve A OFF
2
8
4.4.2 PMV Check

1. Disconnect PMV connector from valve.
2. Check resistance between pins 1&2 and pins Pin 1
1&3 on PMV (Green/
Yellow wire)
53 Pin 2
(Blue
wire)
PinTraining
Chonan Technical Service 3 Center
(Brown
wire)
3. If Pins 1&3 and 1&2 measure between 3 and 14∼21Ω,valve is OK. Check ABS/ASR
harness with tester.
4. If resistance value is out of range, perform replace PMV.
4.4.3 Replace
1. Disconnect PMV connector.
2. Disconnect air lines. Inlet
3. Unfasten PMV from mounting.

Outlet
4. Mount new PMV.
5. Reconnect air lines.
6. Reconnect PMV connector.
7. Reconfigure ECU and Erase Failure Memory. PMV Connector
4.5 Anti Spin Regulator

When wheels are about to spin, the valve energizes
Outlet Port
the axle brake cylinder driven by compressed air.
 Resistance : 42∼52 Ω Inlet Port
 Pin 1 & 2, Pin 1 & 3 Outlet Pin 1

Port (Green/Yellow)
Pin 2 (Blue)
Pin 3 (Brown)
When a drive wheel on one side of the vehicle From Air Tank
begins to spin. For example, one wheel on ice, the other

wheel on dry pavement
ASR is activated when wheel speed difference To Brake 24V
between right and left is 25 km/h or more and vehicle Chamber
speed is 40 km/h or lower.
Exhaust
4.6 Diagnosis
When a problem occurs in using the ABS system,
the red ABS lamp comes on for warning in other to
facilitate finding the trouble area by self-diagnosis.
In normal condition, the ABS lamp comes on upon
switching the battery power on and extinguished upon
starting the vehicle and during running. If a trouble
occurs in the ABS system during running, the ABS lamp
comes on even or running.
54
The blink code device reads out error codes of 16 systems that are stored in the ECU

system configuration and error memory. The device check the brake signal, as well.
The blink codes may be read using the ASR lamp, and troubles read with the self-
diagnosis button may be identified using the blink code table.
4.6.1 Reading Blink Code

In order to read the blink code, keep the diagnostic
button pressed at leat 1 second and then release it.
Pressing the button once it will indicate the system
configuration and an error code. Press the diagnostic
button once again to read error codes. The ASR lamp
Diagnosis Switch
indicates an error code each time pressing the button.
1. Battery “On-Off” more then 1 time.
2. Battery “On”
3. Press the Self Diagnosis Switch at least 1 second.
After reading all of error codes stored in the ABS ECU, last stored code may be shown
continually. To stop diagnostic mode, keep diagnostic mode for more than 5minutes or
switching the ignition key off and on again.
For example, the below blink code indicates no brake signal failure, the system
configuration, and two error codes, 312 and 322.
ON
OFF
ABS/ASR 4Times 312 322
Only ABS 2Times
4.6.2 Clear the Memory Power OFF

In order to clear out all of stored fault codes in ABS ECU, pressed diagnosis switch, turn
“Ignition-On” and wait 5seconds or more and turn “Ignition-Off”.
With pushing diagnosis switch
Main and IG switch ON and push diagnosis switch for 5 sec.
Diagnosis switch off

55

Ignition switch, Main Switch Off
2.2 Bus A.B.S(CI-12) 25
Fault codes
121 No Faults 445 WSS RR/RH Incorrect Tire Size
217 Stop Lamp Switch 461 WSS FRT/RH Air Gap
221 ECU 465 WSS FRT/RH Incorrect Tire Size
222 ECU 512 PCV FRT/LH Supply Open(Pin 12, 2or11)
223 ECU 513 PCV FRT/LH Supply GRD(Pin 12, 2or11)
224 ECU 514 PCV FRT/LH Supply (+) Open(Pin 12, 2or11)
225 ECU 515 PCV FRT/LH Exhaust GRD Open(Pin 12, 3)
226 ECU 517 PCV FRT/LH Exhaust GRD(Pin 12, 1)
227 ECU 518 PCV FRT/LH Exhaust Open(Pin 12, 3)

228 Parameter Value Error 522 PCV RR/LH Supply Open(Pin 15, 2)
232 Unmatched Tire with Wheel 523 PCV RR/LH Supply GRD(Pin 15, 2)
242 Low Battery Voltage(Pin 18, 9) 524 PCV RR/LH Supply (+) Open(Pin 15, 2)
243 Battery Faults 525 PCV RR/LH GRD Open(Pin 15, 3)
244 ECU 526 PCV RR/LH Exhaust Open(Pin 15, 1)
251 PCV FRT/RH, RR/LH (Earth) 527 PCV RR/LH Exhaust GRD(Pin 15, 3)
252 PCV FRT/RH, RR/LH (Open Circuit) 528 PCV RR/LH Exhaust (+) Open(Pin 15, 1)
253 PCV FRT/RH, RR/LH (Open, Pin18, 12) 532 PCV RR/RH Supply Open(Pin 15, 11)
254 Reversed Connection PCV FRT/RH, RR/LH 533 PCV RR/RH Supply GRD(Pin 15, 11)
255 PCV FRT/LH, RR/RH(- Open Circuit) 534 PCV RR/RH Exhaust (+) Open(Pin 15, 11)
256 PCV FRT/LH, RR/RH(+ Open Circuit) 535 PCV RR/RH GRD Open(Pin 15, 12)
4.6.3
257Trouble CodeRR/LH(Open Circuit Pin18,11)
PCV FRT/RH, 536 PCV RR/RH Exhaust Open(Pin 15, 10)
258 Reversed Connection PCV FRT/LH, RR/RH 537 PCV RR/RH Exhaust GRD(Pin 15, 10)
312 WSS RR/LH GRD 538 PCV RR/RH Exhaust (+) Open(Pin 15, 10)
316 WSS RR/LH Pulse Ring 552 PCV FRT/RH Exhaust Open(Pin 12, 11)
322 WSS FRT/LH GRD 553 PCV FRT/LH Exhaust GRD(Pin 12,11)
326 WSS FRT/LH Pulse Ring 554 PCV FRT/RH Exhaust (+) Open(Pin 12, 10)
342 WSS RR/RH GRD 555 PCV FRT/RH GRD Open(Pin 12,12)
346 WSS RR/RH Pulse Ring 556 PCV FRT/RH Exhaust Open(Pin 12, 10)
362 WSS FRT/RH GRD 712 ASR Valve Open
366 WSSFRT/RH Pulse Ring 713 ASR GRD Open Circuit
411 WSS RR/LH Air Gap 714 ASR Battery Open Circuit
415 WSS RR/LH Incorrect Tire Size 56 721 ASR Checking
421 WSS FRT/LH Air Gap 817 DBR Open Circuit
425 WSS FRT/LH Incorrect Tire Size 818 DBR Open Circuit,Open
441 WSS RR/RH Air Gap
4.7 Wiring Diagram
57

ABS Guide

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Anti-Lock Brake System

Anti-Lock Brake System

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Chonan Technical Service Training Center

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2. HD 65,72 Truck and County Bus 13

3. Medium and Heavy Duty Truck 29

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4.7 Wiring Diagram 57

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Chonan Technical Service Training Center

1.1.3 Optimum stopping distance

1.2.1 ABS Operating Principle

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Anti-Lock Brake System

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1.4 ABS Control Cycle

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2.1.2 System Layout

2.2 System Components

ABS Service reminder indicator

2.3.1 Disk type

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2.3.2 Drum Type

Wheel Resistance 1600±10% Ω

Minimum output 120mV(at 2.75km/h)

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2.4 Modulator and Relay

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2.5 Hydraulic Circuit

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2.5.1 Normal Mode

2.5.2 Hold Mode

2.5.3 Dump Mode

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2.5.4 Increase Mode

2.6 ABS Control Module

2.6.1 ABSCM Connector Configuration (Component Side)

Pin Plug Assignment Pin Plug Assignment

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Pin Plug Assignment Pin Plug Assignment

2.6.2 Modulator Connector Configuration (Harness Side)

PIN Plug Assignment PIN Plug Assignment

2.7 Control Logic

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2.8.3 SRI code check

1. Ground pin 6 of diagnosis connector as shown

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2.9 Fault Codes

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2.10 Service Data

ECU – ABS Connector (Wiring side connector)

Mounting Pin Subject Pin Value Unit Remark

33 Front left 33+(-) 18.3±0.5 Ω IG OFF

Modulator Connector (Modulator side connector)

Mounting Pin Subject Pin Value Unit Remark

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Modulator Connector (Modulator side connector)

Mounting Pin Subject Pin Value Unit Remark

1) Be careful to shock and don’t spray water to ECU.

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2.12 Wiring Diagram