Electronically Controlled Brake System (EBS)

IMPACT 3.
0 Monday, 16 January 2017
Chassis ID Path
/Description, Design and function/FH12, BSYS-EBS, DOWNLOADER: PART NO
3173233/Electronically controlled brake system (EBS)
Model Identity
FH12 113155360
Publish date Operation No.

Saturday, 28 July
2007
Electronically controlled brake system (EBS)
1. Foot brake valve (6077)

2. Modulator EBS (6076) (1-channel)
3. Modulator EBS (6076) (2-channel)
4. Modulator EBS (6076) (trailer)
5. Control unit (9082)
6. Wheel speed sensor (7057)
7. Sensor brake lining wear (7085)
8. COPYRIGHT Copyright Volvo Parts Corporation

The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
1 / 18
IMPACT 3.0 Monday, 16 January 2017
8. Sensor air pressure/suspension (7064) (axle load sensor)

9. Compressed air reservoir, primary tank
10. Compressed air tank, front wheel circuit
11. Compressed air tank, rear wheel circuit
12. Compressed air tank, parking brake
13. Four-way protection valve
14. Spring brake cylinder
15. Air pressure gauge, instruments
16. Distributor nipple (Compressed air socket optional equipment)
17. Brake lamp switch
18. ISO 11992, trailer link
19. SAE J1708, information link. SAE J1939, control link
General information about EBS
EBS is an electronic regulated brake system with a pneumatic reserve system. The aim of the EBS is primarily to
increase traffic safety.
Trailers equipped with ABS, EBS or with a normal brake system can all be connected to tractors with EBS.
Distinguishing features for EBS are:
Shorter braking distance.

Increased stability (especially for vehicle combinations).
Balanced brake forces between axles and vehicle parts.
Even and reduced wear of brake linings and tyres.
Optimised and adapted brake characteristics and brake sensitivity.
ABS and TCS (Traction Control System) are standard.
Simplified diagnostics of service and fault tracing.
In principle the footbrake valve is an ordinary footbrake valve with an additional electrical component. The old brake
valves have been replaced by modulators, located by the wheels, providing shorter brake application and release
times.
The reserve system consists of two independent pneumatic brake circuits, similar to current conventional brake
systems, but with smaller brake pipe dimensions, without load sensing valves and without ABS.
The parking brake is still pneumatically controlled, and is available on both the front and the drive axle brakes.
Function
The EBS system's function

COPYRIGHT Copyright Volvo Parts Corporation
2 / 18
The EBS system uses electrically controlled relay valves located near the wheels in order to regulate the brake
pressure instead of the pneumatic valves that are used at present. This means that application and release times in the
brake system are reduced.
Many of the various functions such as ABS, TCS, LSV, QRV etc have previously been made possible using a number
of different valves. The EBS system simplifies the installation by integrating all these functions in one valve.
The EBS system regulates the complete braking cycle. When the driver depresses the footbrake pedal a signal
(voltage) goes from the potentiometers in the footbrake valve to the EBS control unit. At the same time, the control unit
receives data concerning the vehicle's load from the load sensing sensor. Using these signals, the control unit
calculates how hard the driver wants brake and how large a brake pressure is required.
The control unit then sends signals with the calculated values to the wheel's modulators. The modulators convert the
electrical signal to the corresponding air pressure in each wheel brake cylinder. The pressure in the wheel brake
cylinders applies the wheel brakes. When the pressure requested has been reached, the modulators maintain the
pressure at a constant level.
When the driver depresses the brake pedal, it also activates the normal pneumatic braking system. The EBS system
however, prevents the pneumatic brake system from coming into operation as long as the EBS system is functioning.
The pneumatic brake system does not have the ABS, BCS, TCS, and load sensing functions.
With the EBS system it is possible to optimise the brake system for both normal braking and braking in emergency
situations. This makes it possible to obtain even wear of the brake friction material on all the vehicle's axles. For normal
braking this is achieved by the same brake forces being used on all the axles. The electronics (BCS function) also
ensures that braking of trailers without the EBS system and disc brakes function properly. The brakes on the trailer
must however meet the legal requirements and be in good condition.
In the event of an emergency braking situation the distribution between the axles is changed to achieve the maximum
utilisation of road-holding, the best possible retardation and shortest possible braking distance. If the brakes are
applied so hard that a wheel has a tendency to lock, the ABS function is engaged.
Pressure regulation
The EBS with disc brakes works with a higher pressure in the brake system than earlier systems with drum brakes.
The pressure in the primary tank and front and rear circuit tanks is 12 bar, normal for High pressure-systems, and the
modulators are supplied with 12 bar. The pressure in the parking tank is limited to 8.5 bar with a new pressure limiting
valve.
Maximum pressure to the brake cylinders during EBS braking is 9 bar, compared with 7.5 bar for drum brakes.
Reserve circuit control pressure is limited to 8.5 bar. If the EBS system has gone into reserve mode the maximum
pressure to the brake cylinder is therefore 8.5 bar.
Trailer control pressure is also a maximum 8.5 bar. The trailer brakes are supplied via the parking tank as before. The
pressure is a maximum 8.5 bar. This is the legal maximum supply pressure for trailers.
For more information about the pressure limiting valve see the separate Service Information Higher pressure in the
brake system primary tank, front and rear circuit tanks. Group 563.
The pressure is requested by the footbrake valve and balanced by the modulators. The pressure balance and certain
functions depend on the system that is operating. See table.
Maximum pressure EBS mode Pneumatic mode

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Unladen Loaded Unladen Loaded

vehicle vehicle vehicle vehicle
Tractor, front axle 6 bar 9 bar 8.5 bar 8.5 bar
Tractor, rear axle 9 bar 9 bar 8.5 bar 8.5 bar
Trailer 8.5 bar 8.5 bar 8.5 bar 8.5 bar
ABS function, see ABS function Yes No
BCS function, see Automatic brake Yes No

adaptation function (BCS)
LSV function, see Load sensing function Yes No

(LSV)
TCS function, see Traction control function Yes No

(TCS)
ABS function
The ABS function uses the capabilities in the EBS system in order to achieve a more efficient ABS control, which gives
shorter braking distances, increased comfort, reduced consumption of air and increased stability.
Warning lamp ABS (5009) lights up in combination with the yellow information lamp or red stop lamp depending on the
fault. A lit ABS warning lamp indicates that the ABS function is reduced.
When ABS control is in progress this display symbol is shown.
Lining wear sensor function (LWS)
On each brake calliper there is a wear sensor that shows the average thickness of both brake linings. When there is
less than 20% of the brake linings remaining, a fault code is set. A yellow information lamp lights, at the same time as a
warning is shown on the driver information display Check brakes next stop. In order to read out the fault code, the
vehicle must be stationary.
Using the PC tools you can read out the stored value, remaining brake linings in per cent for each wheel. Reading a
new wear value via the modulators can only be done when the brakes have been applied.

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The wear sensors must be re-calibrated when changing the brake pads, this is done via the diagnostics socket using
the PC tools.
Automatic brake adaptation function (BCS)
Wear distribution per axle
By regulating the pressure between the front axle and the rear axle by 0.3 bar, based on information from the wear
sensors, the EBS system evens out the wear on the brakes between the vehicle axles. However, overall brake
pressure is the same.
Brake adaptation tractor-trailer
Automatic brake adaptation optimises the brake pressure between the tractor and trailer. This leads to a more even
brake lining wear. The brake pressure for the trailer can be changed +1,5 /0,5bar in relation to the tractor brake
pressure. For a stationary vehicle, no adjustment of the brake pressure is carried out. The automatic brake adaptation
functions on all trailers with legally required component compositions and a well functioning brake system. The
automatic brake adaptation cannot be affected.
Traction control function (TCS)
If the drive wheels are spinning, the EBS system senses this and reduces the engine tractive force by evaluating the
speed difference between the driven and the non-driven wheels. At the same time brake control is carried out to
increase the traction to the non-spinning wheel. When TCS control is in progress, this display symbol is shown.
Engine control TCS
If the drive wheels are spinning, the engine torque is reduced until the average rotation speed is a little over that of the
non-driven front wheels.
If the driver opens the throttle to show that he wants to spin the wheels, the drive wheels are allowed to spin more.
Engine control operates at all speeds.

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A Permitted wheel spin km/h.
B Driver influence by opening the throttle.
Brake control TCS
For road conditions with different amounts of friction under the left and right wheels, it is usually only the drive wheel
with the lowest friction that spins. This wheel is then braked by the TCS brake control. As much as this wheel is braked,
an equivalent drive torque is transferred to the other drive wheel. In this way the TCS operates as an automatic
differential brake. The process synchronises the speeds of the drive wheels. The brake control is not activated at
speeds above 40 km/h. If however, it is already active during acceleration at low speed, it can remain active above 40
km/h in the corresponding control sequence until the next gear change. The thermal overload on the wheel brakes is
not registered by the EBS control unit and overload under the extended TCS-control must therefore be avoided by
suitable method of acceleration
Off-road TCS
In addition to the ordinary TCS function, the driver can also increase the reference speed for the TCS function by 10
km/h by pressing the Terrain TCS button. Terrain TCS lets the driver have more wheelspin which could be necessary
under difficult terrain conditions such as sand, gravel, clay or snow.
Note: Terrain TCS allows a very high spin on the drive wheels. This can make the vehicle unstable from side to side.
An active terrain TCS is indicated by a continuously lit lamp in the TCS button. When the button is pressed again, the
function is reset to normal TCS function. The function also returns to its normal mode when the starter key is turned off
or on.

6 / 18
A Permitted wheel spin km/h.
B Driver influence by opening the throttle.
C Normal TCS.
D Terrain TCS.
Differential lock function
The purpose of the differential lock function is to facilitate the driver's engagement of the differential lock and to protect
the differential lock against functional faults. The differential lock is only engaged if the drive wheels are turning at the
same speed.
The system uses TCS functions to actively synchronise the drive wheels using engine torque reduction and braking of
the drive wheels, if required. This means that the differential lock can be activated in all the driving conditions, but only
when the drive wheels have the same speed. Synchronisation is not carried out at the same time as the driver requests
Terrain TCS. In this case tractive force is given priority, and engagement is carried out when the driver reduces throttle
opening to give the drive wheels the same speed.
The wheel synchronisation returns to normal TCS using the TCS function if:
The differential lock is engaged correctly.

At least ten seconds after the driver has requested the differential lock irrespectively of whether the was carried
out correctly or not.

7 / 18
Trailer brake function (TB)
This function allows you to carry out a safety check when changing the trailer, or when adjusting the fifth wheel. The
function can be engaged when vehicle speed is lower than 4 km/h. The function is engaged when the button is kept
pressed in. The function is disengaged when speed exceeds 7 km/h or when the button is released. The selected
speed limits are a safety precaution. The function is indicated by a continuously lit indicator lamp in the switch when the
brake function is being controlled by the control unit. When the function is engaged, the EBS system supplies a
constant pressure of 4 bar to the trailer.
Load sensing function (LSV)
The load sensing function regulates brake pressure distribution between the front and rear axles in relation to vehicle
load.
Information about the vehicle load is registered in different ways, depending on whether the vehicle has leaf springs or
air suspension on the rear axle.
Trucks with leaf springs
On trucks with leaf springs, the EBS system receives information about vehicle load from the axle load sensor located
on the rear modulator bracket. The sensor is of the same type as the air suspension system level sensor. It detects the
distance between the frame and rear axle that corresponds to a particular axle load. The control unit requests different
8 / 18
brake pressures front and rear (brake balance), depending on the sensor position and brake pedal pressure position
(Usm1).
Air suspension vehicles
On trucks with air suspension, the EBS system receives information about vehicle load from the axle load sensor
located on the cross member in front of the rear axle. The sensor is a pressure sensor, it detects the pressure in the air
suspension bellows corresponding to a particular rear axle load. The control unit requests different brake pressures
front and rear (brake balance), depending on the sensor pressure signal and brake pedal position (Usm1).

9 / 18
Tyre dimension function
The control unit can compensate for a difference in tyre dimensions of 20%. If, for any reason, the difference in tyre
size is greater, the control unit must be re-programmed. If this is not done a yellow warning lamp will be lit and a fault
code generated.
Warning lamps
Under the display there are two lamps, a yellow information lamp (info) and a red stop lamp (stop). At the same time as
an automatically activated message is shown on the display, one of the two lamps lights up. The lamp that lights
depends on how serious the fault is. If the fault is serious the red lamp lights up and a warning signal is sounded (if the
engine is running). The yellow lamp lights when an abnormal state or a risk situation is indicated.
Yellow information lamp
The yellow information lamp lights when;
the ignition key is turned to the drive position. If no fault is registered, the lamp goes out after approximately
three seconds.
functional faults occur in the EBS system.
tests have been carried out using the PC tool.
The EBS control unit has been programmed.
Red stop lamp
The red stop lamp lights up when;
the ignition key is turned to the drive position. If no fault is registered, the lamp goes out after approximately
three seconds.
the pressure supply in the tractor is too low.
the performance of the service brake system is considered to be insufficient.
the pressure supply to the trailer is too low.
10 / 18
the trailer sends the request for a warning signal.
Warning lamp ABS (5009)
Warning lamp ABS (5009) lights up in combination with the yellow information lamp or red stop lamp depending on the
fault. A lit ABS warning lamp indicates that the ABS function is reduced.
Warning lamp ABS (5009) lights up when;
the ignition key is turned to the drive position. If no faults are registered the lamp goes out after approx. 3
seconds.
there are faults that affect the ABS function.
error codes concerning wheel speed sensor have been stored from the previous driving occasion. The lamp
lights up until the tractor reaches 20 km/h (if the error persists, the lamp continues to be lit).
the tyre dimensions, front and rear, are different. The warning lamp lights up and remains lit during the entire
trip. The system can adapt itself to differences up to 20%. If the difference is any greater than that a fault code
will be set and the lamp remains lit.
Design

11 / 18
EBS system construction
The footbrake valve (1) is in principle an ordinary footbrake valve, the difference is that it has an additional electrical
part. Via two potentiometer signals, the footbrake valve sends the desired brake pressure to the control unit (5).
The control unit (5) communicates via CAN cables with the modulators (2.3.4). The control unit communicates also with
other systems in the vehicle, via SAE J1939 and SAE J1708.
Communication with trailers equipped with EBS is carried out via trailer link ISO 11992.
The modulator is a solenoid control valve with built in electronics that controls braking. The modulator and the control
unit (5) use the wheel speed sensor (6) and the wear sensor (7) in order to determine the braking reactions. At the front
is a 1-channel modulator (2) fitted on the frame at each front wheel. At the rear is a 2-channel modulator (3) fitted
between the frame sides that controls the rear wheels. The 2-channel modulator has a right-hand and a left-hand part.
Each modulator is connected to the EBS control unit via a CAN link, where it receives information about how much
brake force that should be applied and when the brakes are to be released. In addition, each modulator sends
information to the EBS control unit concerning for example wheel speed and wear of brake pads.
The trailer modulator (4) is used for trailers without the EBS system in order to regulate the brake force to the trailer
and to supply the trailer's brake system with compressed air.
The trailer modulator is located in front of the battery box and is constructed in the same way as other modulators. The
trailer modulator also communicates with the EBS control unit via a CAN link. Via the link, the modulator receives
information about how much brake force that is to be sent to the trailer, as well as when the brakes are to be released.

12 / 18
The trailer modulator can adjust the pressure (advance braking) +1,5 /0,5bar in relation to the brake pressure on the
tractor. This adjustment is automatic during driving and can not be programmed or changed. See Automatic brake
adaptation function (BCS). Via the adjustment the brake forces are adapted so that the correct brake balance between
the tractor and trailer, i.e. each part of the vehicle combination, brakes its own weight. While the vehicle is stationary,
no adjustment is carried out.
The sensor for the axle load (8) read off the pressure in the air bellows for the rear axle and from this calculates how
large a load the vehicle has. This value is used to determine the brake force distribution between the front and rear
wheels, (LSV function).
On each brake calliper there is a wear sensor (7) that shows the average thickness of both the brake linings. When
there is 20% of the brake linings remaining an error code is set.
The wheel speed sensor (6) uses a pole wheel fitted on the wheel hub to register the road wheel speed. The wheel
speed sensor is also used for the ABS function.
The sensors are connected directly to the modulators. All information is processed by the electronics in each of the
modulators, which communicate with the EBS control unit via the CAN data link.
Signals of a higher order, e.g. the axle load signals are sent on to the central EBS control unit where they are used for
all the control circuits for the brake pressure.
Footbrake valve
The new footbrake valve is in principle an ordinary footbrake valve with an additional electrical part. The electrical part
contains two potentiometers which register the footbrake valve's position. From these two potentiometers signals are
sent to the control unit concerning the desired brake pressure.
EBS control unit
The purpose of the EBS system is to regulate the complete braking cycle. In addition to regulating the braking cycle the
ABS and TCS are also controlled by the EBS control unit.
The EBS calculates the brake forces and balances braking using modulators, a 1-channel modulator for each front
wheel and a 2-channel modulator for the drive wheels as well as a modulator for any trailer. In addition, there are a
13 / 18
number of integrated functions such as LWS and BCS.
The wear sensor function (LWS) warns of worn brake linings and the automatic brake adaptation function (BCS) evens
out the wear on the tractor brake linings and optimises brake pressure between the tractor and trailer.
The EBS control unit replaces the ABS control unit in the cab and is fitted in the same location.
The communication between the EBS and the modulators is carried out via the CAN link and with other systems via
SAE J1939 and SAE J1708. Communication with trailers equipped with EBS is carried out via ISO 11992.
For more detailed information about the EBS system see the separate service information: Electronically controlled
braking system EBS in Group 56.
EBS control unit
EBS control unit, location in the cab
Modulator
The modulator is a relay valve with electrical and pneumatic control (reserve system) of the brakes.
For the front wheels brakes, there is a 1-channel modulator fitted on the outside of the frame at each wheel. A
2-channel modulator is used to control the drive wheels. This is fitted to a bracket at the rear of the frame. The
2-channel modulator has a right and a left part.
Each modulator is connected to the EBS control unit via a CAN link along which the control signals and information are
14 / 18
sent.
The trailer modulator, which is located in front of the battery box, is used for trailers that do not have EBS. Its purpose
is to supply the trailer's brake system with compressed air as well as to regulate the brake force to the trailer so that
each section of the vehicle brakes its own weight.
Electrical signals from the EBS control unit with calculated values for each wheel are sent via the CAN link to each
respective wheel's modulator. The signals are converted by each modulator to a corresponding brake pressure for
each respective wheel's brake cylinder. The modulator in turn sends information from the wheel speed sensor, wear
sensor and axle load sensor to the EBS control unit. Information that is used to determine the braking cycle.
1-channel and 2-channel modulators
Modulator, trailer
Sensor, axle load
Instead of the traditional load sensing valve a pressure sensor measures the pressure of the air suspension on the
drive axle and converts it to an electrical signal. The signal from the sensor is processed in the EBS control unit and is
used to balance the brake force between the front and drive axle.

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Sensor lining wear
Each brake calliper is provided with an electrical sensor in order to measure the wear on the brake linings. The sensor
gives an average value of the wear on both the brake linings. When approx 20% of the brake linings remain, a fault
code is shown in the driver information display indicating that the brake linings must be changed. Lining wear can only
be read off using the PC tool. The wear value is only updated when the brakes have been applied.
When changing the brake pads the sensors for lining wear must be calibrated. Calibration is carried out via the
diagnostics socket using the PC tool.
The sensors on the drive axle brake calliper is connected to the connection box on the drive axle and the sensors on
the front axle brake calliper to the cable harness.
The sensors are provided with heat resistant cable and have a 3-pin KE connector at the end.
The brake callipers are also equipped with a mechanical sensor for lining wear.
Wheel speed sensor, ABS
A new wheel speed sensor has been developed and there are different designs for the front and drive axle. The
sensors themselves are the same, what differentiates them is the length of the cable for installation at the front and
rear.
16 / 18
Wheel speed sensor, front
The wheel speed sensor front is fitted radially against the pole wheel that is located on the hub. The sensor is located
in a holder which in turn is located in the brake anchorage with two bolts.
Location of wheel speed sensor, front axle
Wheel speed sensor, rear
The wheel speed sensors for the drive axle wheels are fitted axially in the cast holder on the drive axle. The sensors
can be replaced without the wheel, hub or brake disc having to be removed. It is replaced using two special tools, one
for removing and one for fitting.

17 / 18
Removing the wheel speed sensor, drive wheel

18 / 18

Electronically Controlled Brake System (EBS)

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IMPACT 3.

0 Monday, 16 January 2017

Publish date Operation No.

Electronically controlled brake system (EBS)

1. Foot brake valve (6077)

8. COPYRIGHT Copyright Volvo Parts Corporation

8. Sensor air pressure/suspension (7064) (axle load sensor)

General information about EBS

Distinguishing features for EBS are:

Shorter braking distance.

The EBS system's function

Maximum pressure EBS mode Pneumatic mode

Unladen Loaded Unladen Loaded

Tractor, front axle 6 bar 9 bar 8.5 bar 8.5 bar

Tractor, rear axle 9 bar 9 bar 8.5 bar 8.5 bar

Trailer 8.5 bar 8.5 bar 8.5 bar 8.5 bar

ABS function, see ABS function Yes No

BCS function, see Automatic brake Yes No

LSV function, see Load sensing function Yes No

TCS function, see Traction control function Yes No

When ABS control is in progress this display symbol is shown.

Lining wear sensor function (LWS)

COPYRIGHT Copyright Volvo Parts Corporation

Automatic brake adaptation function (BCS)

Wear distribution per axle

Brake adaptation tractor-trailer

Traction control function (TCS)

Engine control TCS

Engine control operates at all speeds.

COPYRIGHT Copyright Volvo Parts Corporation

A Permitted wheel spin km/h.

B Driver influence by opening the throttle.

Brake control TCS

COPYRIGHT Copyright Volvo Parts Corporation

A Permitted wheel spin km/h.

B Driver influence by opening the throttle.

Differential lock function

The differential lock is engaged correctly.

COPYRIGHT Copyright Volvo Parts Corporation

Trailer brake function (TB)

Load sensing function (LSV)

Trucks with leaf springs

Air suspension vehicles

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Tyre dimension function

Yellow information lamp

The yellow information lamp lights when;

Red stop lamp

The red stop lamp lights up when;

the trailer sends the request for a warning signal.

Warning lamp ABS (5009)

Warning lamp ABS (5009) lights up when;

COPYRIGHT Copyright Volvo Parts Corporation

EBS system construction

COPYRIGHT Copyright Volvo Parts Corporation

EBS control unit

number of integrated functions such as LWS and BCS.

EBS control unit

EBS control unit, location in the cab

1-channel and 2-channel modulators

Sensor, axle load

COPYRIGHT Copyright Volvo Parts Corporation

Sensor lining wear

Wheel speed sensor, ABS