ABS Service Data Sheet
ABS Service Data Sheet
ECU Connector
Cover
Integrated (Removable)
Modulator
Relay Valve Wheel Speed The Standard TABS-6
Sensor Module uses a
Connectors 5-Pin Connector
Through-holes
for Frame
(Chassis)
3/4" NPT Mounting
Supply Port
Four (4) 3/8" NPT The Premium TABS-6
Part Number Module uses an
Delivery Ports Label To Remove Cover Slide
(To Brake Chambers) 18-Pin Connector
(See Page 31) Lock Tab
ECU Connectors
Standard TABS-6 module ECU connectors use a TTMA
97-99 5-pin Packard Weather Pack connector for brake
light power, constant power, ground, the trailer-mounted
ABS indicator lamp and a single auxiliary input/output (I/O).
Premium TABS-6 module ECU connectors use an 18-pin
FIGURE 3 - POWER LINE WITH PLC SIGNAL Deutsch DT series connector for the same function as
above, plus additional modulators, wheel speed sensors
Suggested oscilloscope settings are (AC coupling, 1 volt/ and auxiliary I/O’s.
div, 100 μsec/div). The signal should be measured on pin
7 of the J560 connector at the nose of the trailer.
2-Pin Additional
Wheel Speed
Sensor
Connectors
5-Pin Power and (SAL & SAR) 18-Pin ECU Connector
Indicator
Lamp (POWER/
WL)
3-Pin Modulator 2
(MOD2)
3-Pin Modulator 3
(MOD3) (Optional)
5XXX....
B
A E
5XXX...
D C
3
Power/ABS Indicator Lamp Connector 7-Pin 5-Pin 5-Pin 18-Pin
The TABS-6 module pigtail uses a TTMA RP 97-99 5-pin Circuit Trailer ABS ECU ECU
Packard Weather Pack connector for brake light power, Conn. Conn. Conn. Conn.
constant power, ground and the trailer-mounted ABS
Ignition Power
indicator lamp. 7 B B 6
PLC (Blue Wire)
The Power/ABS indicator lamp lead of the pigtail harness
Brake Light
is available in several lengths to satisfy most installation
Power 4 A A 12
requirements (e.g. slider axles).
(Red Wire)
Wheel Speed Sensor Connectors Ground
1 E E 18
Two 2-pin connectors are provided for additional wheel (White Wire)
speed sensors for 4S ABS applications. These 2-pin Indicator Lamp
connectors are labeled Additional Sensor Left (SAL), and (White/green N/A D D 5
Additional Sensor Right (SAR). Extension cables are Wire)
available in various lengths from Bendix.
CHART 2 – POWER AND GROUND
ABS Modulator Connectors
On Premium TABS-6 module pigtail harnesses, one or two
modulator connectors are provided for trailers using two
or three modulators. These 3-pin connectors are labeled
MOD2 and MOD3. (Note: MOD1 designates the internal
modulator of the TABS-6 module). Remote modulator
harnesses are available in many lengths to satisfy most
installation requirements.
Diagnostic Connector
Premium TABS-6 module pigtail harnesses provide a 4-pin
diagnostic connection for a diagnostic tool to monitor ECU FIGURE 5 - TRAILER-MOUNTED ABS INDICATOR LAMP
ignition power, ground and data information. Remote
diagnostic cables are available from Bendix to provide a ABS INDICATOR LAMP
standard J1708/J1587 diagnostic port at the side of the
Trailer-mounted Lamp
trailer.
The TABS-6 module controls an ABS indicator lamp to show
Auxiliary I/O Connector the trailer ABS status. With power supplied by the towing
vehicle, the module illuminates the ABS indicator lamp by
Standard TABS-6 module pigtails provide an option for
providing a 12.0 VDC signal. (The other side of the lamp
a single auxiliary I/O. An optional auxiliary connector
is grounded.) The ABS indicator lamp output uses Pin D
provides a connection to the TABS-6 module auxiliary I/O
of the 5-pin Standard module connector, and Pin 5 of the
ECU pins. Premium ECU pigtails provides an option for
18-pin Premium module connector.
up to six auxiliary I/O’s.
Dash-mounted Lamp (PLC Controlled)
POWER AND GROUND
TABS-6 modules use SAE J2497 standards to support
Trailer electrical power is supplied to the TABS-6 module Power Line Carrier (PLC) communication. The TABS-6
from the ignition and brake light circuits. See Charts 1 and module transmits a signal over the power line to the towing
2 for output values and pin locations. vehicle. This information is used by towing vehicle’s
ABS controller to know when to illuminate the trailer ABS
Function Mode Value indicator lamp mounted on the dash.
Operating Range 8.0 to 16.0 VDC The status of the trailer ABS is transmitted over the ignition
ECU Active 135 mA @ 12 VDC power wire (blue wire of the J560 connector), Pin B of the
5-pin Standard module connector, or Pin 6 of the 18-pin
ABS Active 3.7 A @ 12 VDC Premium module connector.
(1 Modulator)
ABS Active 5.2 A @ 12 VDC
(2 Modulators)
CHART 1 – VALUES FOR OUTPUTS
4
BENDIX® WS-24™ WHEEL SPEED SENSORS 5. Engage the connectors, and push together until the
Wheel speed data is provided to the TABS-6 module from lock tab snaps into place.
the WS-24™ wheel speed sensors (see Figure 6). Vehicles NOTE: It is important for the wheel bearings to be
have an exciter ring (or “tone ring”) as part of the wheel adjusted per the manufacturer's recommendations.
assembly, and as the wheel turns, the teeth of the exciter The friction fit allows the WS-24™ sensor to slide back and
ring pass the wheel speed sensor, generating an AC signal. forth under force but to retain its position when the force
The TABS-6 module receives the AC signal, which varies in is removed. When the WS-24™ sensor is inserted all the
voltage and frequency as the wheel speed changes. (The way into the mounting block and the wheel is installed on
default setting expects a 100-tooth tone ring to be used.) the axle, the hub exciter contacts the sensor, which pushes
Vehicle axle and ABS control configurations determine if the sensor back. Also, normal bearing play will “bump” the
two or four wheel speed sensors are required. See page sensor away from the exciter. The combination of these
17 for electrical system schematics showing wheel speed two actions will establish a running clearance or air gap
sensor connector pin locations. between the sensor and exciter.
A proper sensor installation is critical to correct ABS Excessive wheel end play can result in diagnostic trouble
operation. codes in cases where the sensor is pushed too far away
Typically, the WS-24™ sensor is installed in mounting blocks from the tone ring.
that are welded to the axle housing. WS-24™ wheel speed
sensors are protected by a stainless steel sheath. They BENDIX® BR9235™ ABS
are designed to be used with beryllium copper clamping MODULATOR RELAY VALVES
sleeves (sometimes referred to as a “retainer bushing”, Bendix® BR9235™ modulator relay valves (MRV) are
“friction sleeve” or “clip”) (See Figure 6). The clamping required when additional modulator relay valves are
sleeve provides a friction fit between the mounting block needed for multichannel brake systems (e.g. 2S/2M, 4S/3M
bore and the WS-24™ sensor. ABS configurations).
The MRV is an electro-pneumatic control valve and is the
last valve that air passes through on the way to the brake
chambers. The normally-open hold solenoid and normally-
Sensor
Clamping closed exhaust solenoid are activated to precisely modify
90° Speed
Sensors Sleeve the brake pressure on command. During normal braking,
the BR9235™ MRV functions as a standard relay valve. As
Logo Stamped
into Sleeve brakes are applied or released by the driver, the control
signal from the tractor foot valve causes the BR9235™ MRV
to apply proportional pressure to the trailer brake chambers.
Straight Speed The BR9235™ MRV is available in both tank and bracket
Sensors mounting styles.
5
Tank (Nipple) Mounted ABS FLEX™ PROGRAM
The BR9235™ MRV can be tank-mounted using a schedule The ABS Flex™ program uses Auxiliary Design Language
80 (heavy gauge steel) 3/4" NPT nipple directly between (ADL) to allow customized auxiliary functions to be carried
the trailer supply tank and the supply port. A tank with a out by the TABS-6 module. Programs developed in the ABS
reinforced port must be used. Flex™ program may be downloaded at the production line
or in the field to control non-braking functions of the trailer.
Bracket (Chassis) Mounted
For example, ABS Flex ™ program can potentially
The BR9235™ MRV provides an option with a bracket communicate the status of: tire inflation and/or temperature;
for frame mounting directly to the trailer frame rail or reefer temperature; load presence; slider pin position; lift
crossmember. It is recommended to use two Grade 5, axle position; proximity/reverse alarm; and vehicle weight.
3/8-16 bolts, torqued to 180 – 220 in-lbs.
ABS Flex™ programs monitor the auxiliary I/Os and/or the
J1708/J1587 DIAGNOSTIC LINK SAE J1587 diagnostics and SAE J2497 PLC data links.
Contact your Bendix Account Manager to discuss an ABS
The Premium TABS-6 module provides a J1708/J1587
Flex™ program for your vehicle(s).
diagnostic link with data and power to communicate with
the vehicle and various diagnostic tools. Diagnostics, CUSTOMER SCRATCH PAD
testing, configuration, data transfer and other functions
can be performed using this link. Diagnostic tools such as The TABS-6 module has a Customer Scratch Pad feature
the MPSI Pro-Link™ device and Bendix® ACom® Diagnostic which allows the customer, or end-user, to store up to 756
Software (version 4.0 and higher) support the TABS-6 bytes of information. This information can then be read
Module. using the Bendix® ACom® Diagnostic Software (version
4.0 and higher).
Ignition power must be provided to the TABS-6 module for
the diagnostic link to be active. If additional scratch pad space is needed, this storage
space can be expanded to 1K (1,008 bytes total of data).
AUXILIARY I/O Contact Bendix for further details.
The Standard module provides for one auxiliary I/O POWER-UP SEQUENCE
function.
At power-up, the TABS-6 module performs a series of self-
The Premium module provides for up to five auxiliary checks that can assist a technician to determine the ABS
functions and one additional ground. See Chart 3, below. system status and configuration.
Bendix® ACom® Diagnostic Software (version 4.0 and
higher) supports the configuration of the TABS-6 module
auxiliary I/O’s.
6
braking pressure at the wheel ends. The ECU is able to
pump the brakes on individual wheels (or pairs of wheels),
ABS System Power
Application independently, and with greater speed and accuracy than
Status Indicators a driver.
0.5 1.5 2.0 2.5 3.0 (sec.)
Trailer-mounted ABS ON Axle Control
Indicator Lamp OFF
TABS-6 module axle control uses a single modulator relay
Dash-mounted Trailer ON valve to control wheels on both sides of a given axle or
ABS Indicator Lamp axles. In the case of an ABS event on road surfaces with
OFF
(PLC Detected)* poor traction (worn, slippery, or loose gravel roads) or areas
Dash-mounted Trailer ON of poor traction, (e.g. asphalt road surfaces with patches of
ABS Indicator Lamp ice), axle control will maintain the wheel that is not slipping
(PLC Not Detected) OFF at just under the speed that will lock the wheel. Temporary
periods of wheel lock are permitted on the other wheel that
*Some vehicle manufacturers may illuminate the trailer ABS is experiencing slippage.
indicator lamp at power-up regardless of whether a PLC
signal is detected from the trailer or not. Consult the vehicle Axle control should not be used on 5th wheel dollies or
manufacturer’s documentation for more details. steerable axles. When braking on even surfaces, an
axle-control system will perform similar to a side control,
FIGURE 8 - TRAILER ABS LAMP START UP SEQUENCE two-modulator system. Axle control is available in 2S/1M,
2S/2M and 4S/2M installations, and for Modulator 3
Trailer ABS Indicator Lamp (MOD3) in a 4S/3M installation.
At power-up without detected faults, the trailer ABS
indicator lamp will turn on for 2.5 seconds as a bulb check Dolly-Axle Control (Select Low)
and then turn off. See Figure 8. TABS-6 module dolly-axle control uses a single ABS
modulator valve to control wheels from both sides of a
If a PLC-ready towing vehicle and trailer are powered at
given axle or axles. In the case of an unbalanced braking
the same time, the TABS-6 module will also trigger a bulb
surface, (e.g. asphalt road surfaces with patches of ice),
check on the dash-mounted trailer ABS indicator lamp.
dolly axle control will control the low coefficient (slipping)
Modulator Chuff Test at Power-Up wheel just under the lock limit. Vehicle stability is assisted
by not allowing the high coefficient wheel (where traction
At power-up, the TABS-6 module activates a modulator
is still being maintained) to sustain wheel lock.
chuff test. This electrical and pneumatic ABS modulator
test can help the technician identify problems with When braking on even surfaces, a dolly axle control system
modulator installations and/or wiring. will perform similar to side control or axle control system.
Dolly axle control is only available in 2S/1M installations.
With brake pressure applied, a properly installed modulator
will cause five rapid audible chuffs of air pressure. If Side Control
additional modulators are installed, the TABS-6 module
The TABS-6 module uses a single modulator relay valve
activates 5 chuffs at the internal modulator (MOD1) then
to control one or more wheels on a given vehicle side. In
for each additional modulator in sequence (e.g. MOD1,
the case of an unbalanced braking surface, the side control
then MOD2, and then MOD3). The chuff sequence is
will individually control wheels on each side just under the
then repeated.
point where they would lock up.
If the modulator is wired incorrectly, the modulator will only
Side control is available in 2S/2M and 4S/2M installations,
produce one chuff, or no chuff at all. If an issue is detected
and for the internal modulator (MOD1) and Modulator 2
during the modulator chuff test, compare the modulator
(MOD2) in the 4S/3M installation.
wiring and plumbing to the TABS-6 module’s electrical
system schematic (see page 17) and make repairs.
Normal Braking
ABS OPERATION During normal braking, the TABS-6 module functions as a
The TABS-6 module uses wheel speed sensors, modulator standard relay valve. If the ECU does not detect excessive
relay valves and an ECU to control trailer wheels by axle wheel slip, it will not activate ABS control, and the vehicle
or by side. By monitoring individual wheel turning motion stops with normal braking.
during braking, and adjusting or pulsing the brake pressure
at each wheel, the TABS-6 module is able to optimize slip
between the tires and the road surface. When excessive
wheel slip, or wheel lock-up, is detected, the ECU will
activate the Pressure Modulator Valves to modulate
7
AUTO-CONFIGURATION Service Interval
The Standard TABS-6 module is available only in the 2S/1M The TABS-6 module provides a feature that can be used
ABS configuration and does not use auto-configuration. to indicate a service interval for the trailer. The service
interval can be accessed via PC or hand-held diagnostic
For the Premium TABS-6 module, the default ABS
tools. If configured, the TABS-6 module can flash the
configuration is 2S/1M. At power-up, if a Premium ECU
indicator lamp when the vehicle is at standstill to indicate
detects additional sensors and modulators it will perform
when the service interval has been exceeded.
an auto-configuration. Auto-configuration only adjusts
upward (e.g. 2S/2M Side to a 4S/2M Side configuration).
NON-STANDARD TIRE SIZE
Additional detected components that do not conform to a The module allows for tire rolling radius and tone ring
legitimate configuration will generate the appropriate faults. tooth count parameters to be set for each axle using a
If the vehicle begins moving before the new configuration diagnostic tool. These adjustments may be necessary for
has been accepted, the reconfiguration will not take place the module to accurately calculate the vehicle velocity and
at this time. odometer mileage. Wheels of the same axle must be set
to the same rolling radius and tone ring tooth count. In
Default
Additional Components
Auto-Configuration most cases, these parameters are set by the trailer OEM
Sensors Modulators and do not need to be adjusted. In the case of a service
- - 2S/1M (Dolly-Axle) replacement unit, always check that these parameters are
set to match the vehicle.
2S/1M - 1 to 2S/2M (Side)
The tire-rolling radius is defaulted to 500 revs/mile and can
Dolly Axle 2 1 to 4S/2M (Side)
be adjusted from 300 to 700 revolutions per mile. Refer
2 2 to 4S/3M (Side/Axle) to the manufacturer’s tire specification for correct values.
- - 2S/1M (Axle) Tone ring tooth count is defaulted to 100 teeth and can be
2S/1M
set from 60 to 140 teeth.
Axle - 1 to 2S/2M (Axle)
2 1 to 4S/2M (Axle) DIAGNOSTIC TROUBLE CODE DETECTION
The TABS-6 module contains self-testing diagnostic
CHART 4 – PREMIUM TABS-6 MODULE AUTO-
CONFIGURATION MATRIX circuitry that monitors the ABS components and wiring.
When the module senses an erroneous system condition,
ODOMETER FUNCTION it activates the external trailer-mounted ABS indicator lamp,
disables all or part of the affected ABS functions, and it
Odometer stores the fault code in memory, even when the power is
The TABS-6 module includes an odometer function to removed. The module also uses PLC communications to
provide a means of storing the accumulated mileage of the send the system status to the towing vehicle.
vehicle. The mileage is computed by utilizing information
For some trouble codes, the TABS-6 module will
calculated from the vehicle wheel speeds.
automatically reset (“self-heal”) the active diagnostic
This feature is accurate to within 0.62 miles per power-up trouble code when the error is corrected (e.g. when a
and will typically store mileage up to 1,000,000 miles. The wheel speed sensor is re-aligned). However, repeated
mileage can be displayed using PC diagnostics or through occurrences of a given trouble code can cause the code to
blink codes. “latch” - that is, be retained as active, even if the condition
Whenever the module is towed using a pre-1997 tractor, is only intermittent. Once the code is latched, a manual
the electronic odometer does not function, and the mileage reset will be necessary. Technicians can use these latched
can be considered out-of-calibration. codes to assist them in troubleshooting intermittent errors.
After the problem is repaired, trouble codes can be reset
Trip Counter using blink code diagnostics or with a diagnostic tool.
The module provides a counter to record the trip mileage. When a trouble code self-heals or is manually reset, the
The feature is accessed through PC or hand-held code remains stored in the ECU memory. This trouble
diagnostic tools. code history can be retrieved using blink code diagnostics
or with a diagnostic tool.
8
PARTIAL ABS SHUTDOWN Wait until after the modulator chuff test before activating
Depending on the trouble code detected, the ABS ECU the brake light power. Following a single display of all
partly or completely disables the ABS functionality. available messages, the ABS indicator lamp will remain on
The trailer ABS system, for vehicles that only have one for five seconds and then return to normal operating mode.
modulator, are disabled by any single fault. In the case of Blink code diagnostics can only be activated following a
vehicles with two or three modulators, depending on the power-up, where wheel speeds have not been detected. If
trouble code, the trailer ABS system may still provide some the vehicle moves during blink code diagnostics mode, the
level of ABS function on axles/wheels that are not affected module will cancel the blink code diagnostics and return to
by the fault, but the ABS indicator lamp will remain on. In normal operating mode.
cases where the ABS is completely disabled, the vehicle Blink code diagnostics must be activated within the first 15
reverts to normal braking (without ABS interventions). seconds of ignition power being applied.
Always repair ABS shutdowns at the earliest opportunity.
If brake light power is continuously applied for greater than
ECU Diagnostic Trouble Codes five seconds, blink code diagnostics will be disabled until
All ABS functions are completely disabled. The system the next time the ignition power is cycled.
reverts to normal braking.
Display Active Diagnostic Trouble Codes
Voltage Diagnostic Trouble Code To display active codes, apply ignition power and depress
While voltage is out of range, the ABS functionality is / release the brake pedal 3 times within 15 seconds.
disabled and the system reverts to normal braking. When Following activation, there will be a 5-second delay followed
the correct voltage level is restored, full ABS is typically by a blink code display of all active fault codes. (See pages
available again. The operating voltage range is 8.0 to 10-12 for more information.)
16.0 VDC.
Display Diagnostic Trouble Code History
BLINK CODE DIAGNOSTICS To display trouble code history, apply ignition power
The TABS-6 module provides diagnostic and configuration and depress / release the brake pedal 4 times within 15
functions through blink code diagnostics. This means that seconds. Following activation, there will be a 5-second
the technician, even without diagnostic tools, can read a delay followed by a blink code display of all history fault
series of ABS indicator lamp blinks to diagnose the trouble codes. (See pages 10-12 for more information.)
codes being generated.
The blink code diagnostics mode is entered by providing Reset Active Diagnostic Trouble Codes
constant power to the ignition circuit and toggling the To reset active codes, apply ignition power and depress
brake light power input three times. With a parked towing / release the brake pedal 5 times within 15 seconds.
vehicle attached, this is done by applying ignition power Following activation, there will be a 5-second delay followed
and after the power up sequence is complete, depressing by a blink code message of:
and releasing the brake pedal three or more times, see
chart 5 below. 1-1, (System Fully Operational - No Codes Detected) or a
blink code display of all remaining active fault codes.
Depending on the blink code mode activated, the TABS-6
module will blink the trailer-mounted ABS indicator The ABS indicator lamp will stay on if active DTCs are still
lamp to display: active fault codes; fault code history; present.
ABS configurations; and odometer mileage. Blink code Resetting active fault codes with blink code diagnostics
diagnostics can also be used to reset active fault codes. does not clear information from trouble code history. Both
blink code diagnostics or diagnostic tools can retrieve
trouble code history, but only diagnostic tools can erase
With Ignition Power Blink Code this information.
Applied, Cycle Brake Action
Light Power
3 times Display Active DTCs
4 times Display Inactive DTCs
5 times Clear Active DTCs
6 times Display Configuration
7 times Display Odometer Mileage
8 times Reset Configuration
10
Diagnostic Trouble Codes (DTCs) (continued)
POWER
6 1 Over-voltage • Power supply diagnostic trouble code. 251 3
Go to Section F, page 28.
6 2 Low-voltage • Power supply diagnostic trouble code. 251 4
Go to Section F, page 28.
6 3 Excessive power line resistance • Power supply diagnostic trouble code. 251 13
Go to Section F, page 28.
MODULATOR (MOD)
7 1 MOD1 Hold solenoid shorted or open 42 3, 4, 5
• Clear faults. 6 or 12
7 2 MOD1 Release solenoid shorted or • If faults return, replace the TABS-6 Module. 48 3, 4, 5
open 6 or 12
8 1 MOD2 Hold solenoid shorted or open 43 3, 4, 5
6 or 12
9 1 MOD3 Hold solenoid shorted or open 44 3, 4, 5
Static ABS Modulator Fault. 6 or 12
8 2 MOD2 Release solenoid shorted or Go to Section H, on Page 30. 49 3, 4, 5
open 6 or 12
9 2 MOD3 Release solenoid shorted or 50 3, 4, 5
open 6 or 12
7 3 MOD1 ABS modulator dynamic error Dynamic ABS Modulator Fault. 7 7
8 3 MOD2 ABS modulator dynamic error Go to Section H, on Page 30. 8 7
9 3 MOD3 ABS modulator dynamic error 9 7
8 4 MOD2 Valve configuration error • Verify correct ABS configuration using blink codes 8 13
or other diagnostic tools.
9 4 MOD3 Valve configuration error • If needed, reset to the default ABS configuration 9 13
and power-up to initiate auto-configuration.
COMMON
10 1 Valve MOD1/2 low-side switch shorted • Check for corroded/damaged wiring or connectors 7 4
to ground between the ECU and MOD.
At the MOD harness connector, verify:
10 2 Valve MOD3 low-side switch shorted • No continuity from modulator/AUX leads to ground. 9 4
to ground • After repairs or if no issues found, then clear faults.
• If faults return, replace the TABS-6 Module.
10 3 ABS modulator dynamic error - all Dynamic ABS Modulator Fault. 7 7
valves Go to Section H, on Page 30.
10 4 Excessive ABS activity Dynamic Wheel Speed Sensor Fault. 1 7
Go to Section G, on Page 29.
(Continued over . . .)
11
Diagnostic Trouble Codes (DTCs) (continued)
J1587 DIAGNOSTIC
12 1 J1587 diagnostics shorted or open • Check for corroded/damaged wiring or connectors 250 3, 4, 5
between the ECU and J1587 Diagnostic. or 12
• Verify the following:
- At the 18-pin ECU harness connector:
(a) Continuity of the J1587 Diagnostic wiring to the
lamp (auxiliary device).
(b) +12V is not measured at J1587 Diagnostic lead.
- At J1587 Diagnostic connector:
(a) No continuity of the J1587 Diagnostic lead to
ground.
(b) No continuity from J1587 Diagnostic lead to any
other ECU pin(s).
(c) Replace/repair J1587 Diagnostic wiring or
components as required.
TRAILER-MOUNTED ABS INDICATOR LAMP
13 1 ABS lamp shorted or open • Check for corroded/damaged wiring or connectors 81 3, 4, 5
between the ECU and ABS Indicator Lamp. or 12
• Verify the following:
- At the 5-pin or 18-pin ECU harness connector:
(a) Continuity of the ABS Indicator Lamp wiring
to the lamp (auxiliary device).
(b) +12V is not measured at ABS Indicator Lamp lead.
- At ABS Indicator Lamp connector:
(a) No continuity of the ABS Indicator Lamp lead to
ground.
(b) No continuity from ABS Indicator Lamp lead to any
other ECU pin(s).
(c) Replace/repair ABS Indicator Lamp wiring or
components as required.
12
Troubleshooting: Using Hand-Held or
PC-Based Diagnostic Tools
USING HAND-HELD OR PC- LED lights
illuminate
BASED DIAGNOSTICS Diagnostic
Trouble Codes
Troubleshooting and diagnostic trouble code clearing, as (10 LEDs)
well as beginning a reconfiguration, may also be carried
out using hand-held or PC-based diagnostic tools such
as the Bendix® Trailer Remote Diagnostic Unit (TRDU™),
Bendix® ACom® Diagnostics software, or the ProLink tool.
14
Monday through Friday, 8:00 A.M. to 6:00 P.M. EST, and SERVICING THE CONTROL PORT FILTER
follow the instructions in the recorded message. The TABS-6 module has an in-line filter in the control port
Alternatively, you may e-mail the Bendix technical (See Figure 1). This filter should be inspected and cleaned
assistance team at: techteam@bendix.com. (if any contamination is found), every four months, 34,000
miles or 1,200 operating hours. For severe applications,
To better serve you, please record the following this inspection interval may be reduced. If the filter is found
information before you call the Bendix Tech Team, to be damaged, install a replacement. The filter should
or include this information in your e-mail: also be inspected as part of any troubleshooting where
• Bendix product model number, part number and the service brakes are slow to apply and other possible
configuration. causes have been ruled out.
• Vehicle make and model. SERVICE REPLACEMENT OF
• Vehicle configuration. (Number of axles, tire size, etc.) OTHER ABS CONTROLLERS
• System performance symptoms: When do they occur?
The TABS-6 module is designed to be used as the
• What faults have been identified using LEDs, blink service replacement part for the Bendix ® MC-12 ™ ,
codes or diagnostic tools? MC-30 ™ and A-18 ™ trailer ABS controllers. When
• What troubleshooting/measurements have been controller service replacement parts are required, a
performed? TABS-6 module and pigtail harness must replace the
• What Bendix service data literature do you have or entire MC-12™, MC-30™ or A-18™ controller assembly and
need? pigtail harness. When replacing an MCE-12™ controller,
the integral emergency function (EV-2™ valve) must be
SERVICING THE TABS-6 MODULE replaced by a DC-4® and TR-3™ valve combination. See
pages 18-21 for plumbing details. TABS-6 module kits are
CAUTION: All TABS-6 modules are initially
available to replace MC-12™, MC-30™ and A-18™ controller
defaulted to 2S/1M and may auto-configure to assemblies and harnesses. For more information, contact
another ABS configuration if additional sensors Bendix or your local authorized Bendix parts outlet.
and/or ABS modulators are detected. An incorrect 1. Disconnect the power connector and wheel speed
ABS configuration may cause fault indication or sensors from the MC-12™, MC-30™ or A-18™ controller
degraded ABS performance. Before and after pigtail harness.
activating a self-configuration, always check the 2. Remove all air hoses and plugs connected to the
current ABS configuration by using blink code unit.
diagnostics or a diagnostic tool. 3. Remove the MC-12™, MC-30™ or A-18™ controller
Prior to performing service to the TABS-6 module, always assembly and pigtail from the vehicle by removing the
perform the following steps: mounting bracket nuts or by rotating the entire assembly
counter clockwise from the tank nipple mount.
1. Follow all Safe Maintenance Practices including, but
not limited to, those on page 2 of this document. 4. Install the new pigtail, starting at the power connector
and properly securing the harness every 18 inches to
2. Turn power off.
the ECU location.
3. Drain the air pressure from all reservoirs.
5. Next, refer to the Reinstallation of the TABS-6 Module
4. Remove as much contamination as possible prior to section.
disconnecting electrical connections and air hoses.
5. Note the TABS-6 module's mounting position on the REINSTALLATION OF THE TABS-6 MODULE
vehicle. CAUTION! All TABS-6 module service replacement
parts are initially defaulted to 2S/1M and may auto-
REMOVING THE TABS-6 MODULE configure to another ABS configuration if additional
1. Open the cover by sliding the locking tab to the left. sensors and/or ABS modulators are detected. An
Retain the cover. incorrect ABS configuration may cause fault indication
2. Disconnect the 5- or 18-pin ECU connector and the two or degraded ABS performance. Before and after
2-pin wheel speed sensor connectors. activating a self-configuration, always determine the
3. Mark for reinstallation and then remove all air hoses current ABS configuration by activating blink code
and plugs connected to the module. diagnostics.
4. Remove the module from the vehicle by removing the Inspect the original mounting hardware: If it is in good
mounting fasteners or by rotating the entire assembly condition, it can be reused for installation. If replacement
counter-clockwise from the tank mount. hardware is needed, use grade-5 3/8-18 bolts, nuts and
15
lock washers for the frame-mount unit, or a schedule 80 emergency and service sides of the spring brake
(heavy gauge steel) ¾" nipple for the tank-mount unit. chamber. However, if the relay exhaust port
Inspect the location selected for installation and clean as continues to leak excessively, replace the TABS-6
necessary. module.
NOTE: Inspect all components, including the 5. Apply power and monitor the power-up sequence to
replacement trailer ABS module, for any external verify proper system operation. See page 6.
damage, such as cracked valve ports, electronic 6. Determine the current ABS configuration by activating
housings, etc. Any components found to be damaged blink code diagnostics or using a diagnostic tool. If
should not be installed on the vehicle and must be necessary, reset the ABS configuration and allow the
replaced. module to auto-configure. See page 8.
1. Position and secure the unit in the original mounting 7. Calibrate and set odometer parameters if necessary
orientation (the exhaust port must point straight down): using a diagnostic tool. Refer to the Odometer Function
For tank-mount modules: Install the nipple fitting into section on page 8.
the modulator-valve supply port. Then rotate the entire 8. Where a safe location (e.g. restricted access area
assembly into the tank port until secure. Over-torquing or test track) is available, it is possible to road test
of the tank nipple could cause damage to the valve the ABS function by making an abrupt stop from a
body. vehicle speed of about 20 MPH to check for proper
For frame-mount modules: Torque the mounting nuts function. The wheels should not enter a prolonged lock
to 180-220 in-lbs. condition and ABS function should be audible. It is the
responsibility of the technician to perform this test in a
2. Reconnect all air hoses and plugs to the module.
safe location.
Depending on the installation, additional plugs may be
necessary. Make certain that no thread sealing material ABS WIRING
enters the valve. All air hoses and fittings should be
All connector leads of the TABS-6 module pigtail harness
checked for leaks prior to returning the vehicle to
are weather sealed at the connector interface and are
service.
clearly labeled for proper installation.
3. Reconnect the ECU and wheel speed sensor electrical
Bendix provides over-molded versions of the TABS-6
connectors to the unit. Apply a moderate amount of
wiring harness and Bendix recommends that the complete
non-conductive electrical grease to each connector pin
harness be replaced if corrosion or damage occurs.
before reconnecting.
4. The new TABS-6 module may need to be reconfigured When troubleshooting ABS wiring, some general rules
for proper operation. See page 8. should be followed where applicable.
5. Leakage and Operational Tests must be performed 1. Check all wiring and connectors to ensure they are
before returning the vehicle to service. secure and free from visible damage (e.g. cuts,
abrasions, etc.).
LEAKAGE AND OPERATIONAL TESTS 2. Check for evidence of wire chafing due to poor routing,
1. Before performing leak tests, block the wheels. or poor securing, of wires.
2. Fully charge air brake system and verify proper brake 3. Check connectors for proper insertion and locking.
adjustment. 4. Verify that the connector pins are properly greased with
3. Make several trailer brake applications and check for a non-conductive electrical grease compound.
prompt application and release at each wheel. 5. Connector terminals must not show signs of corrosion
4. Check the module, modulator valve(s) and all air hose or exposure to the environment.
fittings for leakage using a soap solution: 6. Never pierce wire insulation when checking for
Check the ABS solenoid body with the trailer service continuity.
brakes fully applied. If leakage is excessive, more than 7. Do not deform individual pins or sockets during probing
a single 1" bubble within 1 minute, replace the module. with a volt/ohm meter.
Check the relay exhaust port with the trailer service 8. It is strongly recommended to properly secure all wiring
brakes released to be sure that leakage is less than harness and sensor leads at least every 18 inches.
a single 1" bubble within 3 seconds. If excessive
9. Apply a moderate amount of non-conductive electrical
leakage is detected at the relay exhaust port, perform
grease to each connector pin before reconnecting.
the following test before replacing the module:
• Apply the trailer spring brakes. Recheck for leakage
around the relay exhaust port. If the exhaust port
stops leaking, this indicates a leak between the
16
Troubleshooting: Electrical Schematics
STANDARD
TABS-6
Trailer
ABS
Controller
FIGURE 15 - STANDARD TABS-6 MODULE (5-PIN ECU CONNECTOR) ELECTRICAL SCHEMATIC - 2S/1M
1
SENSOR RIGHT SR (+)
SENSOR 1 1
SENSOR RIGHT SR (-)
7 RIGHT SR 2 2
4 GROUND
18
IGNITION VOLTAGE
6
BRAKE LAMP VOLTAGE 12
ABS WARNING LAMP (AUX7) 5
SENSOR ADD. RIGHT SAR (+)
SENSOR ADD. 1 11
SENSOR ADD. RIGHT SAR (-)
TRAILER-MOUNTED RIGHT SAR 2 17
MOD2 RELEASE
ABS WARNING LAMP 1 9
MODULATOR VALVE MOD1/2 COMMON
2 3
MOD2
3
MOD2 HOLD
15 PREMIUM
1
MOD3 RELEASE 10 TABS-6
MODULATOR VALVE MOD3 COMMON 4 Trailer
2
MOD3 MOD3 HOLD ABS
3 16
FIGURE 16 - PREMIUM TABS-6 MODULE (18-PIN ECU CONNECTOR) ELECTRICAL SCHEMATIC - 4S/3M
17
Troubleshooting: System Schematics
Bendix® WS-24™
2S/1M - AXLE Wheel Speed
Right - Sensor "SR"
CONTROL
“Curb-Side”
A Brake Light Power
B Ignition Power
D C
C NC A E
D Warning Lamp B
E Ground
CONTROL
LINE
Trailer Trailer ABS
Chassis 5-PIN
CONNECTOR Pigtail
7-PIN
Harness Harness
CONNECTOR
TABS-6
TABS
Ground SUPPLY Bendix® Bendix®
LINE SR-5™ Trailer TABS-6
Spring Brake Trailer
Ignition Valve ABS
Power
Module
Brake
Light
Power
PR-3™ Pressure
Ground SUPPL Y Protection Valve Trailer
LINE ABS
Module
SV-4™ Synchronizing TABS-6
Ignition
Power Valve
TR-3™
Inversion
Valve
Brake Light
Power
ABS
ABS Light
18
Troubleshooting: System Schematics (continued)
WS-24™ Wheel Speed Sensor
2S/2M - AXLE CONTROL "SR"
Right - “Curb-Side”
A Brake Light Power
B Ignition Power D C
C NC A E
D Warning Lamp B
E Ground
CONTROL
LINE
BR9235™
SR-5™ Trailer “MOD2”
TABS
Ground SUPPL Y
LINE
Spring Brake Modulator
Valve Relay TABS6
Ignition Valve “MOD1”
Power Trailer
ABS
Module
Brake Light
Power
Left - “Road-Side”
WS-24™ Wheel Speed Sensor
Installation Guidelines for the TABS-6 2S/2M Axle ABS Configuration: "SL"
CONTROL
LINE
BR9235™
“MOD2”
5-PIN
Trailer Trailer ABS Modulator
CONNECTOR
7-PIN Chassis Harness Pigtail Harness Relay
CONNECTOR Valve
SR-5™ Trailer
TABS
Ground SUPPL Y
LINE Spring Brake
Valve TABS6 “MOD1”
Ignition Trailer ABS
Power Module
Brake Light
Power
Left - “Road-Side”
WS-24™ Wheel Speed Sensor
"SL"
Installation Guidelines for the TABS-6 2S/2M Side ABS Configuration:
• MOD1 (TABS-6 ABS Unit) controls the left “road-side” wheel(s) of a primary axle(s).
• MOD2 (BR9235™ Modulator Unit) controls the right “curb-side” wheel(s) of a primary axle(s).
• For lift axle applications, SL & SR (Primary Sensors) senses the wheels of the stationary, non lift-able axle
19
Troubleshooting: System Schematics (continued)
WS Sensor WS-24™ Wheel Speed Sensor
A Brake Light Power
4S/2M - AXLE CONTROL "SAR" B Ignition Power
D C "SR"
C NC A E Right -
D Warning Lamp B
E Ground “Curb-Side”
CONTROL
LINE
BR9235™
TABS
Ground SUPPLY SR-5™ Trailer “MOD2”
LINE Spring Brake Modulator
Valve Relay TABS6
Trailer ABS
Ignition Valve
Power Module
“MOD1”
Brake Light
Power
ABS Light
Full Trailer
ABS
Left -
WS Sensor “Road-Side”
"SAL" "SL"
WS-24™ Wheel Speed Sensor
Right - “Curb-Side”
A Brake Light Power
B Ignition Power D C
C NC A E
D Warning Lamp B
E Ground
CONTROL
LINE BR9235™
“MOD2”
Trailer 5-PIN Trailer ABS Modulator
CONNECTOR Pigtail Harness
7-PIN Chassis Harness Relay
CONNECTOR Valve
SR-5™ Trailer
TABS
Ground SUPPL Y
LINE Spring Brake
Valve TABS6
Ignition
Trailer ABS
Power Module
“MOD1”
Brake Light
Power
Left - “Road-Side”
"SAL" "SL"
WS-24™ Wheel Speed Sensors
Installation Guidelines for the TABS-6 4S/2M Side ABS Configuration:
• MOD1 (TABS-6 ABS Unit) controls the left “road-side” wheel(s) of a primary axle(s).
• MOD2 (BR9235™ Modulator Unit) controls the right “curb-side” wheel(s) of a primary axle(s).
• SL & SR (Primary Sensors) are connected to the dedicated 2-pin connector on the TABS-6 ECU.
• SAL & SAR (Additional Sensors) are connected to the 18-pin connector on the TABS-6 ECU.
• For lift axle applications, SAL & SAR (Additional Sensors) senses the wheels of the lift-able axle.
20
Troubleshooting: System Schematics (continued)
WS-24™ Wheel Speed Sensors
4S/3M - SIDE/AXLE CONTROL "SAR" "SR"
Right -
A Brake Light Power “Curb-Side”
B Ignition Power D C
C NC A E
D Warning Lamp B
E Ground
CONTROL
LINE
BR9235™ “MOD3” BR9235™
5-PIN Trailer ABS Modulator
Trailer
CONNECTOR Pigtail Harness Relay Valve
7-PIN Chassis Harness
CONNECTOR
“MOD2”
TABS
Ground SUPPL Y SR-5™ Trailer
LINE Spring Brake
TABS-6
Valve Trailer ABS
Ignition Module
Power “MOD1”
Brake Light
Power
Left -
“Road-Side” "SAL" "SL"
WS-24™ Wheel Speed Sensors
21
Troubleshooting Flowcharts
Diagnostic trouble code information can be retrieved from to make electrical measurements, always begin by taking
the TABS-6 module by using blink code diagnostics, or a voltage and resistance measurements at the 5- or 18-pin
diagnostic tool. The following troubleshooting flow charts ECU pigtail harness connector.
will help the technician isolate the cause of the fault and Once the circuit fault is found, isolate the area needing
confirm whether the fault resides in the component, wiring repair by repeating the measurements at all connections
or connectors. in the affected circuit towards the modulator, wheel speed
Troubleshooting should always begin by observing the sensor, etc.
dash or trailer-mounted ABS indicator lamp during the No voltage or resistance measurements are to be made on
TABS-6 module's power-up sequence. If it is necessary the bulkhead connector pins of the module.
Troubleshooting Flowcharts
22
SECTION A: (POWER-UP SEQUENCE)
TRAILER-MOUNTED ABS INDICATOR LAMP
23
SECTION B: (POWER-UP SEQUENCE)
DASH-MOUNTED ABS INDICATOR LAMP
24
SECTION C: DIAGNOSTIC TROUBLE CODE (DTC)
BLINK CODE QUICK REFERENCE
25
SECTION D: DIAGNOSTIC TROUBLE CODE (DTC)
TRDU™ TOOL LED QUICK REFERENCE
ECU DTC
The red ECU LED is on to indicate a DTC internal to the
ABS Modulator DTC TABS-6 module. Reset the TRDU™ tool with a magnet. If
The red M1, M2 and/or M3 LED is on to indicate a DTC the DTC returns, replace the module.
with an ABS modulator. The example above shows the If the red ECU LED is on and the green VLT LED is off,
LEDs illuminated when there is a DTC for a second ABS the module may have very low voltage. In this case, go
modulator (MOD2). to Section F.
The indicated modulator DTC may be static or dynamic.
Static DTCs are related to wiring or component failures
such as open or short circuits.
Dynamic modulator DTCs are related to abnormal
wheel speed behaviors during ABS. Odometer Mileage - The TRDU will
Go to Section H, page 30. continously display the odometer
information (x1000) by flashing the
blue ODO LED. There will be a 20
second pause between ODO displays.
Magnetic Reset - All LEDs will be on
while a magnet is held in place at the As an example: 152,431 miles will be
RESET location near the “B” in Bendix. displayed as:
When held for less than 6 seconds, the 152 (x1000) ... or 1 blink (pause), 5
OD
DTCs are cleared. When held for more blinks (pause), 2 blinks.
O M1
26
SECTION E: TROUBLESHOOTING THE TRAILER-MOUNTED
ABS INDICATOR LAMP CIRCUITRY
27
SECTION F: TROUBLESHOOTING THE
POWER SUPPLY
Looking into Premium TABS-6 Module Wire Harness, Looking into Standard TABS-6 Module Wire Harness,
ECU Connector Measure: ECU Connector Measure:
Pin 6 (Ignition Power) to Pin 18 (ground) and Pin B (Ignition Power) to Pin E (ground) and
Pin 12 (Brake Light Power) to Pin 18 (ground) Pin A (Brake Light Power) to Pin E (ground)
28
SECTION G: TROUBLESHOOTING THE
WS-24™ WHEEL SPEED SENSORS (WSS)
(Optional)
Looking into Modulator Looking into ECU
Connector Pins: Connector:
Pin 1 (Release) Pin 9 is MOD2 release Pin 10 is MOD3 release
Pin 2 (Common) Pin 3 is MOD2 Common Pin 4 is MOD3 Common
Pin 3 (Hold) Pin 15 is MOD2 Hold Pin 16 is MOD3 Hold
30
Bendix Part Number
31
32 BW2469 ©2010 Bendix Commercial Vehicle Systems LLC • All Rights Reserved • 7/10 • Printed in U.S.A. Printed on recycled paper