Académique Documents
Professionnel Documents
Culture Documents
Issue 1 en
EBS 5.0
Troubleshooting
Contents
Troubleshooting components in
EBS 5.0 Introduction .............................................................. 3
Cable harness and overlay ........................................ 4
Measurements and connections................................ 6
Service brake module ............................................. 11
Wear sensor ............................................................ 17
Wheel speed sensor ................................................ 22
ABS control valve .................................................. 23
Control module....................................................... 24
Trailer control module............................................ 31
Introduction
Instructions are given below on how to go about
troubleshooting components and circuits in
EBS 5.0.
For troubleshooting you need:
• SDP3
• Test box 588 887
• Extension cable 588 888
• Cable harness for EBS 99 605
• Overlay for EBS 99 608
305 249
• Manometer 99 399 (0-15 bar)
• Wiring diagram for EBS Test box 588 887
The test box and cable harness for EBS are used
to measure the components of the EBS system.
The measurements are used in addition to the
diagnostics tool when troubleshooting.
Start by asking the customer whether they
noticed anything unusual when the problem
occurred or whether there is anything else that
might be linked to the problem. Use SDP3 and
always work from the fault codes that are
available and anything else you can read off in
307 526
307 526
A7 Outlet valve
B3 Not used
B4 Potentiometer signal 1 A = Black
B5 Potentiometer signal 2 B = Grey
B6 Wake-up signal C = Red
C1 Earth E = Yellow
Component Pin Signal type Measurement Pin on test box Pin (control
unit)
Trailer control 1 Intake valve Resistance = approx. A1 and A2 D5
module 16-20 ohms
2 Solenoid valves, Battery voltage A2 and A5 D4
voltage supply (approx. 24 V)
3 Back-up valve Approx. 10-14 ohms A3 and A2 D7
4 Pressure sensor, Approx. 5 V A4 and A5 D1
voltage supply
5 Pressure sensor, A5 D3
earth
6 Pressure sensor, A6 and A5 D2
signal
Component Pin Signal type Measurement Pin (test box) Pin (control
unit)
Service brake 1 Voltage supply 4.8-5.2 V B1 and B4 A7
module, trucks
2 Not used
3 Potentiometer 4.7-0.46 V (decreasing B3 and B4 A8
signal 2 when the brake pedal is
depressed)
4 Earth B4 A4
5 Wake-up signal Brake pedal released = B4 and B5 A6
Battery voltage
Pedal halfway = Half of
battery voltage
Brake pedal fully
depressed = Battery
voltage
6 Potentiometer 0.46-4.7 V (increasing B6 and B4 A5
signal 1 when the brake pedal is
depressed)
Component Pin Signal type Measurement Pin (test box) Pin (control
unit)
Service brake 1 Earth B1 A4
module, buses
2 Voltage supply 4.8-5.2 V B2 and B1 A7
3 Not used
4 Potentiometer 0.46-4.7 V (increasing Pins B4 and B1 A5
signal 1 when the brake pedal
is depressed)
5 Potentiometer 4.7-0.46 V (decreasing B5 and B1 A8
signal 2 when the brake pedal
is depressed)
6 Wake-up signal Brake pedal released = B6 and B1 A6
Battery voltage
Pedal halfway = Half
of battery voltage
Brake pedal fully
depressed = Battery
voltage
Component Pin Signal type Measurement Pin on test box Pin (control
unit)
ABS control valve 1 Outlet valve 24 V (when F1 and F2 B10
reducing pressure)
2 Earth F2 B18
3 Intake valve 24 V (when F3 and F2 B13
maintaining or
reducing pressure)
There are inactive fault codes for the potentiometers. Fault codes can switch
between active and inactive. The potentiometer signals show the correct values in
SDP3 when the brake pedal is released or depressed.
Continue troubleshooting from the section "Potentiometer signals can be read off in
SDP3".
There are active fault codes for the potentiometers. No potentiometer signals or
potentiometer signals provide incorrect values in SDP3.
Continue troubleshooting from the section "No potentiometer signals or potentiometer
signals provide incorrect values in SDP3".
The wake-up signal is not activated in SDP3 when the brake pedal is depressed.
Continue troubleshooting from the section "The wake-up signal is not activated in
SDP3 when the brake pedal is depressed".
4,7 2
0,46 1
307 529
1 Potentiometer 1
2 Potentiometer 2
A = Brake pedal position
B = Signal voltage
The signals from potentiometers 1 and 2 are
opposed, and should follow the movement of
the brake pedal uniformly.
Correct values
Continue with step 3.
A B C D
1 4 7 10 13 16 1 4 7 10 13 16 1 4 7 10 13 1 4 7 10
2 5 8 11 14 17 2 5 8 11 14 17 2 5 8 11 14 2 5 8 11
3 6 9 12 15 18 3 6 9 12 15 18 3 6 9 12 15 3 6 9 12
132 840
Supply voltage = 0 V
1 Measure the voltage between pin B4
(earth) and the chassis to rule out earthing
faults.
Voltage = 5 V
Break in the ground connection.
Voltage = 0 V
Continue with step 2.
Supply voltage = 5 V
Short-circuit in the service brake module.
Supply voltage = 0 V
Short-circuit in the cable harness between the
earth and the supply voltage or fault on the
control unit.
Supply voltage = 0 V
Fault on the control unit.
The wake-up signal is not activated in SDP3 when the brake pedal is
depressed
1 Measure the voltage of the wake-up signal
on the service brake module, pins B5 and
B4 (grey), with brake pedal released.
Voltage = 0 V
Continue from section "Voltage = 0 V".
Voltage = 0 V
1 Disconnect the cable harness from the
service brake module and measure on the
cable harness.
Voltage = 0 V
Short-circuit in the cable harness or fault on
the control unit.
Voltage = 0 V
Short-circuit in the cable harness or fault on
the control unit.
A B C D
1 4 7 10 13 16 1 4 7 10 13 16 1 4 7 10 13 1 4 7 10
2 5 8 11 14 17 2 5 8 11 14 17 2 5 8 11 14 2 5 8 11
3 6 9 12 15 18 3 6 9 12 15 18 3 6 9 12 15 3 6 9 12
132 840
Wear sensor
1 Connect SDP3 to the vehicle.
2 Check the fault codes for the wear sensors.
Check which wear sensor the fault code
refers to and which control module the wear
sensor is connected to.
309 081
B
C
If signal voltage in SDP3 = No, continue from section "No signal voltage in
SDP3".
If signal voltage in SDP3 = Yes, continue from section "Signal voltage shown
in SDP3".
307 532
Supply voltage = 0 V, continue below.
Supply voltage = 5V, continue from section "Supply voltage 5 V".
Supply voltage = 0 V
1 Disconnect the other wear sensor (B in this
example) from the brake caliper and Supply voltage = 5 V
measure the supply voltage to wear Wear sensor B OK. Continue with step 6.
sensor A.
Supply voltage = 0 V
Supply voltage = 5 V
Continue with step 7 on the next page.
Short-circuit in wear sensor B.
6 Test the cable harness to wear sensor A. If
Supply voltage = 0 V the cable harness has no faults, there is a
fault on wear sensor A.
Continue with step 2.
Supply voltage = 5 V
Short-circuit in the cable harness or fault on
both wear sensors.
Supply voltage = 0 V
Continue with step 10.
Voltage = 5 V
Break in the ground connection.
Voltage = 0 V
Earthing OK; indicates a fault in the supply
voltage from the control module.
Supply voltage = 5 V
1 Measure the signal voltage at wear sensor
A, pins D1 and D3 (green).
Signal voltage = 0 V
Continue with step 2.
Voltage = 5 V
Break in the ground connection.
Voltage = 0 V
Earthing OK; indicates fault on the wear
sensor.
3 Switch off the voltage and connect the test Signal voltage = 1-3.5 V
box to the control module connector for the
wear sensor. Fault on control module or with CAN
communication from the control module.
4 Switch on the power supply. Check whether there are any CAN-related
fault codes for the control module.
5 Measure the signal voltage at the control
module between signal and earth. Signal voltage = 0 V
Wear sensors B and D (right-hand side*), Continue with step 6.
pins E1 and E2 (yellow).
6 Check the signal cable in the cable harness.
Wear sensors A and C (left-hand side*),
pins E4 and E6 (yellow). 7 If the signal cable is OK, measure the
voltage between the earth and the chassis
to rule out earthing faults.
* On 8x2, 8x2*6 and 8x4, pins E1-E3 are for the left-hand side and pins E4-E6 for the right-hand
side.
If signal voltage = 5 V
Short circuit to supply voltage.
Signal voltage = 0 V
Short-circuit in the wear sensor.
Signal voltage = 5 V
Short-circuit in the cable harness or fault in the
control module.
Signal voltage = 0 V
Short-circuit in the cable harness.
Signal voltage = 5 V
Internal short-circuit in the control module.
Troubleshooting
The ABS control valves have shared earthing at
the cab grommet.
1 Connect a manometer to the brake chamber
on the side on which you want to check the
ABS control valve.
2 Switch off the voltage with the starter key
and connect the test box to the ABS control
valve.
3 Apply the service brake with the brake
pedal, and activate the ABS control valves
with SDP3 according to the table below.
4 Read the brake pressure in the brake
chamber with the manometer and measure
the voltage with the test box.
Brake pressure Control valve position Intake valve Outlet valve Brake chamber
applied (voltage) (voltage) brake pressure
2 bar Pressure increase 0V 0V 2 bar
(normal position)
4 bar Pressure maintenance 24 V 0V 2 bar
4 bar Pressure reduction 24 V 24 V 0 bar
Control module
For some fault codes, the control unit switches
off the voltage supply to the control module; we
call this back-up mode. The brake warning lamp
comes on at the same time. This does not
indicate a fault on the control unit.
1 Connect SDP3 to the vehicle.
2 Check fault codes for the control modules.
308 962
Back-up mode, voltage supply switched off,
driver not active and question mark displayed.
Voltage = 24 V
Fault in the ground connection.
Voltage = 0 V
Continue with step 6.
Supply voltage = 0 V
Continue with step 5.
Supply voltage = 24 V
Continue from section "Troubleshooting
CAN".
Voltage = 24 V
Fault in the ground connection.
Voltage = 0 V
Earthing OK; indicates fault on the wear
sensor. Continue with step 6.
Resistance = 90 kOhms
Resistance OK, continue with step 3 in the
section "Troubleshooting CAN".
Resistance = 0 ohm
Short-circuit, check the cable harness.
Resistance = infinite
Break, check the cable harness.
Troubleshooting CAN
1 Connect the test box to the control module.
2 Measure the resistance on the CAN cables
between CAN high and CAN low.
Pins C3 and C4 (red).
The resistance depends on how many
control modules are connected.
If signal voltage in SDP3 = Yes, continue from section "Signal voltage shown
in SDP3".
If signal voltage in SDP3 = No, continue from section "No signal voltage in
SDP3".
Voltage = 5 V
Break in the ground connection between the
trailer control module and the control unit.
Voltage = 0 V
Earthing is OK.
A B C D
1 4 7 10 13 16 1 4 7 10 13 16 1 4 7 10 13 1 4 7 10
2 5 8 11 14 17 2 5 8 11 14 17 2 5 8 11 14 2 5 8 11
3 6 9 12 15 18 3 6 9 12 15 18 3 6 9 12 15 3 6 9 12
132 840
• Connection D for trailer
-5V
Fault in trailer control module.
-0V
Continue with step 2.
-5V
Short-circuit in the trailer control module.
-0V
Fault in the cable harness or control unit.
Supply voltage = 0 V
Fault on the control unit.
Supply voltage = 5 V
Fault in the cable harness.
307 534
Check on the venting function
1 Place chocks in front of and behind the
wheels.
2 Release the parking brake.
3 Use an adapter to simulate a break in the
control line (yellow 22).
4 Connect a manometer to the trailer
connection control line (red 21). The
manometer should show full supply
pressure.
5 Quickly fully depress the brake pedal. The
supply pressure should drop to less than
1.5 bar for two seconds.
Troubleshooting the trailer control module intake valve, outlet valve and
check valve
307 533
5 If the supply voltage is correct. Switch off
the ignition voltage and measure the
resistance at the valves.