Euro_IV_BH117L_ABS6_Diagnostic_sys_for_DwBus_080226 (1) (1).pdf

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Knorr-Bremse Group Knorr-Bremse ABS6 Diagnostic system Knorr-Bremse Korea, April, 2007 Area to fit in a picture - facultative For Daewoo Bus application Ver.1.4

Transcript of Euro_IV_BH117L_ABS6_Diagnostic_sys_for_DwBus_080226 (1) (1).pdf

Knorr-Bremse Group

Knorr-BremseABS6 Diagnostic system

Knorr-Bremse Korea, April, 2007

Area to fit in a picture - facultative

For Daewoo Bus application

Ver.1.4

Knorr-Bremse Group

The enclosed document describes how to approach an ABS6 specific problem and provides repair hints.

Enclosed provided information is a scope of possible failures and search/repair advises, therefore doesn’t lay claim to be complete.

This document is property of KNORR-BREMSE Korea Ltd.. Copies of the document or file or parts out of it and/or further distribution require a written permit of KNORR-BREMSE KOREA Ltd.. The document is subjected to a continuous rework but is not part of an automatic update service.

KNORR-BREMSE is not responsible for any failures in service work or others resulting out of this document.

With entering this document/file you accept the terms above.

I agree

Knorr-Bremse Group 3

Feature

Agenda

point 1

point 2

Overview

Troubleshooting and Fault-findingpoint 3

System Componentspoint 4

Wiring Diagramspoint 5

3.1 Blink code 3.2 Fault code list 3.3 PC diagnostics 3.4 Workshop diagnositcs

Knorr-Bremse Group

ABS6 ECU Family Overview

+ Covers the complete range from “basic ABS” to “hig h end drive stability features”

with one modular system family

- STANDARD - a cost optimized ABS system up to 4S/4M

(coverage > 80% of the vehicles)

- PREMIUM - system including configurations up to 6S/6M

and additional functions (ATC, brake diagnostic, et c.)

- ADVANCED - system including configurations up to 6S/4M

with ABS based drive stability

+ Available for cab and frame mounting (Advanced fo r cab only)

+ Available for 12V and 24V power supply

+ Pin compatible ECU family with modular connectors and similar mounting

1. Overview

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ABS6 – Design for Global Application of Global Customers

1. Overview

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ABS6 – Cab ECU Mounting

2. Feature

P/No : 0 486 107 007 P/No : 0 486 107 105

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ABS6 – Modular Connector (Cab-ECU)

2. Feature

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ABS6 – Standard System

2. Feature

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ABS6 – Premium System

2. Feature

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ABS6 – 4 x 2 Vehicles, 4S/4M

2. Feature

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Fault DetectionThe ECU continuously monitors the condition of the ABS components while the

vehicle is in use. If the ECU detects any malfuncti on or problem (either with the

brake released or applied) it will switch on the AB S warning lamp and shut down,

either partially or completely, the operation of th e ABS.

Once the ABS warning lamp has been switched on to s ignify that a fault exists in

the system the nature and location of the fault mus t be identified as soon as

possible by one of two methods :

- Use of the Blink Codes

- Use of PC Diagnostics

3. Troubleshooting and Fault-finding

Note: Even a not working ABS (warning lamp “on”) has no i nfluence to the normal brake function, the safety aspect and country speci fic regulations require anImmediate repair work in an authorized workshop !

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Using Blink Codes

The ABS warning Lamp is used not only to display th e fact that a fault exists but

also to display blink codes.

The blink code function within the ECU can be used to display two types of blink

code :

- Configuration Blink Codes

showing the system configuration of the ECU program ming

- Fault Blink Codes

giving information on faults detected and stored by the ECU

3. Troubleshooting and Fault-finding

Knorr-Bremse Group

Operation of the Blink Codes Switch

3. Troubleshooting and Fault-finding

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Configuration Blink Codes

3. Troubleshooting and Fault-finding

Knorr-Bremse Group

Configuration Blink Codes

3. Troubleshooting and Fault-finding

6S/4M9,10

6S/3M11

Invalid configuration15

6S/5M7,8

6S/6M6

Reserved5

4S/3M single PCV on drive axle4

4S/3M single PCV on steer axle3

4S/4M22nd

24V2

12V11st1

ConfigurationBlinksNumberBlock

Knorr-Bremse Group

Configuration Blink Codes

3. Troubleshooting and Fault-finding

2nd

No J1939 engine link, with tcv on drive axle4

with J1939 engine link, with tcv on drive axle5

with J1939 engine link, no tcv on drive axle3

No J1939 engine link, no tcv on drive axle2

with J1939 retarder link, with retarder relay4

No J1939 retarder link, with retarder relay3

With J1939 retarder link, no retarder relay2

No J1939 retarder link, no retarder relay11st2

ConfigurationBlinksNumberBlock

Knorr-Bremse Group

Reconfiguration with Diagnostic button

- Hold the diagnostic button on

- Switch on the ignition

- After approximately several seconds, release the button

3. Troubleshooting and Fault-finding

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Configuration Blink Codes

3. Troubleshooting and Fault-finding

Knorr-Bremse Group

Fault code list

3. Troubleshooting and Fault-finding

XXWSS SA leftShorted low/high or broken wire or two sensors shor ted06026541h

X

X

X

X

X

X

X

X

X

X

WL

W.Lampstatus

WSS SA right

WSS SA right

WSS SA right

WSS SA right

WSS SA left

WSS SA left

WSS SA left

WSS SA left

WSS SA left

WSS SA left

component

XLong term instability04027349h

xLong term instability040313789h

XBad tooth wheel, long term ABS control030313385h

XMissing sensor signal at drive off020313688h

XLarge air gap 010313587h

XReserved for wheel speed sensor0702754Bh

XLoss of sensor signal0502744Ah

XBad tooth wheel, long term ABS control03026945h

xMissing sensor signal at drive off02027248h

xLarge air gap 01027147h

No failure0101000h

TCLDezHex

DescriptionStd

Blink code

Internal code

Knorr-Bremse Group

Fault code list

3. Troubleshooting and Fault-finding

XXWSS DA leftLong term instability0404169A9h

X

X

X

X

X

X

X

X

X

X

X

WL

W.Lampstatus

WSS DA right

WSS DA right

WSS DA left

WSS DA left

WSS DA left

WSS DA left

WSS DA left

WSS DA left

WSS SA right

WSS SA right

WSS SA right

component

XMissing sensor signal at drive off0204168A8h

xMissing sensor signal at drive off020510468h

XLarge air gap 010510367h

XReserved for wheel speed sensor0704171ABh

XShorted low/high or broken wire or two sensors shor ted0604161A1h

XLoss of sensor signal0504170AAh

XBad tooth wheel, long term ABS control0304165A5h

XLarge air gap 0104167A7h

xReserved for wheel speed sensor07031398Bh

xShorted low/high or broken wire or two sensors shor ted060312981h

XLoss of sensor signal05031388Ah

TCLDezHex

DescriptionStd

Blink code

Internal code

Knorr-Bremse Group

Fault code list

3. Troubleshooting and Fault-finding

XXWSS AA leftMissing sensor signal at drive off0206808h

X

X

X

X

X

X

X

X

X

X

X

WL

W.Lampstatus

WSS AA left

WSS AA left

WSS AA left

WSS AA left

WSS AA left

WSS AA left

WSS DA right

WSS DA right

WSS DA right

WSS DA right

WSS DA right

component

XReserved for wheel speed sensor07051076Bh

xReserved for wheel speed sensor0706110Bh

XShorted low/high or broken wire or two sensors shor ted0606101h

XLoss of sensor signal0506100Ah

XLong term instability0406909h

XBad tooth wheel, long term ABS control0306505h

XLarge air gap 0106707h

XShorted low/high or broken wire or two sensors shor ted06059761h

xLoss of sensor signal05051066Ah

xLong term instability040510569h

XBad tooth wheel, long term ABS control030510165h

TCLDezHex

DescriptionStd

Blink code

Internal code

Knorr-Bremse Group

Fault code list

3. Troubleshooting and Fault-finding

XXWSS AA rightShorted low/high or broken wire or two sensors shor ted0607193C1h

X

X

X

X

X

X

X

X

X

X

X

WL

W.Lampstatus

PCV SA left

PCV SA left

PCV SA left

WSS AA right

WSS AA right

WSS AA right

WSS AA right

WSS AA right

WSS AA right

WSS AA right

WSS AA left

component

XLong term instability0407201C9h

Release solenoid broken wire03088555h

Release solenoid shorted low02088656h

XRelease solenoid shorted high01088757h

XSensor detected but not configured0807195C3h

xReserved for wheel speed sensor0707203CBh

XLoss of sensor signal0507202CAh

XBad tooth wheel, long term ABS control0307197C5h

XMissing sensor signal at drive off0207200C8h

XLarge air gap 0107199C7h

XSensor detected but not configured0806303h

TCLDezHex

DescriptionStd

Blink code

Internal code

Knorr-Bremse Group

Fault code list

3. Troubleshooting and Fault-finding

XAux. I/ODifflock solenoid shorted low or broken wire1108221DDh

X

X

X

X

X

X

X

X

X

X

X

WL

W.Lampstatus

PCV SA right

PCV SA right

PCV SA right

PCV SA right

PCV SA right

Aux. I/O

PCV SA left

PCV SA left

PCV SA left

PCV SA left

PCV SA left

component

Valve configuration error0808935Dh

XHold solenoid shorted high050914793h

Valve ground broken wire040914894h

Release solenoid broken wire030914995h

Release solenoid shorted low020915096h

XRelease solenoid shorted high010915197h

XDifflock solenoid shorted high1008220DCh

Hold solenoid broken wire07088151h

Hold solenoid shorted low06088252h

XHold solenoid shorted high05088353h

Valve ground broken wire04088454h

TCLDezHex

DescriptionStd

Blink code

Internal code

Knorr-Bremse Group

Fault code list

3. Troubleshooting and Fault-finding

XXPCV DA leftValve ground broken wire0410180B4h

X

X

X

X

X

X

X

X

X

X

X

WL

W.Lampstatus

PCV

PCV DA left

PCV DA left

PCV DA left

PCV DA left

PCV DA left

PCV DA left

PCV DA left

PCV SA right

PCV SA right

PCV SA right

component

XRelease solenoid shorted low0210182B6h

XValve ground or solenoid shunt to supply voltage10104129h

XValve configuration error0810189BDh

XHold solenoid broken wire0710177B1h

XHold solenoid shorted low0610178B2h

XHold solenoid shorted high0510179B3h

XRelease solenoid broken wire0310181B5h

XRelease solenoid shorted high0110183B7h

Valve configuration error08091579Dh

Hold solenoid broken wire070914591h

Hold solenoid shorted low060914692h

TCLDezHex

DescriptionStd

Blink code

Internal code

Knorr-Bremse Group

Fault code list

3. Troubleshooting and Fault-finding

XXPCV DA rightHold solenoid shorted low061111472h

X

X

X

X

X

X

X

X

X

X

X

WL

W.Lampstatus

PCV AA left

PCV AA left

PCV AA left

PCV DA right

PCV DA right

PCV DA right

PCV DA right

PCV DA right

PCV DA right

PCV DA right

PCV

component

XValve ground broken wire041111674h

XRelease solenoid broken wire0312229E5h

XRelease solenoid shorted low0212230E6h

XRelease solenoid shorted high0112231E7h

XValve configuration error08111257Dh

XHold solenoid broken wire071111371h

XHold solenoid shorted high051111573h

XRelease solenoid broken wire031111775h

XRelease solenoid shorted low021111876h

XRelease solenoid shorted high011111977h

XValve GND or sol. shunt to GND or int.GND SW defecti ve1110422Ah

TCLDezHex

DescriptionStd

Blink code

Internal code

Knorr-Bremse Group

Fault code list

3. Troubleshooting and Fault-finding

XXPCV AA rightRelease solenoid shorted low0213246F6h

X

X

X

X

X

X

X

X

X

X

X

WL

W.Lampstatus

PCV AA right

PCV AA right

PCV AA right

PCV AA right

PCV AA right

PCV AA right

PCV AA left

PCV AA left

PCV AA left

PCV AA left

PCV AA left

component

XValve configuration error0812237EDh

XHold solenoid broken wire0713241F1h

XHold solenoid shorted low0613242F2h

XHold solenoid shorted high0513243F3h

XValve ground broken wire0413244F4h

XRelease solenoid broken wire0313245F5h

XRelease solenoid shorted high0113247F7h

XHold solenoid broken wire0712225E1h

XHold solenoid shorted low0612226E2h

XHold solenoid shorted high0512227E3h

XValve ground broken wire0412228E4h

TCLDezHex

DescriptionStd

Blink code

Internal code

Knorr-Bremse Group

Fault code list

3. Troubleshooting and Fault-finding

XXECUABS-CPU fault02151711h

X

X

X

X

X

X

X

X

X

WL

W.Lampstatus

ECU

ECU

ECU

ECU

ECU

ECU

TCV DA

TCV DA

TCV DA

TCV DA

PCV AA right

component

TC valve configuration error0814613Dh

XABS-CPU fault07151812h

XABS-CPU fault06152014h

XABS-CPU fault05151913h

XABS-CPU EEPROM not programmable04152418h

XABS-CPU EEPROM data error03152317h

XABS-CPU fault01151610h

XTC solenoid broken wire0714583Ah

XTC solenoid shorted low0614593Bh

XTC solenoid shorted high0514603Ch

XValve configuration error0813253FDh

TCLDezHex

DescriptionStd

Blink code

Internal code

Knorr-Bremse Group

Fault code list

3. Troubleshooting and Fault-finding

XSupplyU-bat temporary low voltage02163624h

X

X

X

X

X

X

X

X

X

X

X

WL

W.Lampstatus

Supply

Supply

Supply

Supply

Supply

Supply

ECU

ECU

ECU

ECU

ECU

component

XABS software not compatible with hardware151512880h

U-ign temporary over voltage09163220h

XSupply voltage powerline noise041613183h

XSupply voltage temporary powerline noise041613082h

XU-bat broken wire03163826h

XU-bat low voltage during ABS control02163725h

U-bat temporary over voltage01163523h

Internal relay permanently turned on 1115271Bh

XInternal relay not switchable1015261Ah

XABS-CPU invalid configuration in EEPROM09152216h

XABS-CPU fault08152115h

TCLDezHex

DescriptionStd

Blink code

Internal code

Knorr-Bremse Group

Fault code list

3. Troubleshooting and Fault-finding

XXTire sizeReserved c3-signal plausibility check0617311Fh

X

X

X

X

X

X

X

X

WL

W.Lampstatus

ATC function

Lamps

ABS function

ATC function

Stop light

Tire size

ABS function

Ret.relay

Ret.relay

Supply

Supply

component

ABS disabled due to engaged difflock0317219DBh

XATC brake control time limit exceeded1117175AFh

GND-WL broken wire or WL switched to GND permanentl y1017209D1h

ABS disabled due to off road mode0917215D7h

XATC or ESP disabled or rollerbench mode active0817214D6h

XStop light switch not activated in this power on cy cle0717213D5h

XTires or learned parameters(FRT,RR) out of range0517210D2h

Retarder relay shorted low or broken wire02174931h

Retarder relay shorted high01174830h

XU-ign low voltage during ABS control10163422h

U-ign temporary low voltage10163321h

TCLDezHex

DescriptionStd

Blink code

Internal code

Knorr-Bremse Group

Fault code list

3. Troubleshooting and Fault-finding

XJ1939/IESTimeout or invalid data on ETC1..2 (J1939) / INS,EP S (IES)06185436h

X

X

X

X

X

WL

W.Lampstatus

J1939/IES

J1939/IES

J1939/IES

Stop light

WSS

WSS

component

Timeout or invalid data on ERC1 (J1939) / FMR2 (IES )04185234h

All others reserved or unused

XTimeout or invalid data on EEC1..3 (J1939) / FMR1.. 3 (IES)05185335h

XJ1939 or IES CAN bus off detected03185133h

Stop light switch defective1417216D8h

XWSS mixed up1317212D4h

XWSS failure in previous power on cycle1217208D0h

TCLDezHex

DescriptionStd

Blink code

Internal code

Note: When WSS or Airgap related fault occurred, the warni ng lamp won’t go off even after the cause is corrected. Fault code D0h will be erase automatically after ECU get valid WSS signal in several driving.

Knorr-Bremse Group

Erasing Fault codes from the ECU memory

To erase all fault codes from the memory of the ECU

- Press and hold the blink code switch

- Switch on the ignition

- After approximately 3 seconds, release the blink code switch

3. Troubleshooting and Fault-finding

Knorr-Bremse Group

PC Diagnostics

A computer based program ECUtalk ® – ABS Diagnostics is available and provides

several functions :

- Assists workshop diagnosis of ABS problems.

- Enables system check after servicing of the ABS system

- Includes a database to enable storage and retrieval of information

relating to customer, vehicle and test results

- Knowledge base covering the function and servicing advice for ABS systems

and their components, wiring diagrams and a software manual for the program

3. Troubleshooting and Fault-finding

Knorr-Bremse Group

PC DiagnosticsSystem Requirements

3. Troubleshooting and Fault-finding

The required operating system should follow this specification :

Pentium processor or higher,

100 Mbytes of HDD

Windows 98 and/or NT4 with service pack 4 or higher

800x600 display resolution

For optimum performance the following system specification is recommended :

1024x768 display resolution (or higher)

Pentium Ⅱ processor

Laser printer

Windows 2000 or XP

UDIF software

Version 1.15r or later is a must

Knorr-Bremse Group

PC DiagnosticsConnection of ECU, UDIF, and PC

3. Troubleshooting and Fault-finding

Knorr-Bremse Group 35

PC Dongle

Cable1 (UDIF to PC) Cable2 (ECU to UDIF)

PC Diagnostics

Test tool component

: PC, ECUtalk ®, dongle

UDIF, Cables

UDIF

ECUtalk ® (S/W)

3. Troubleshooting and Fault-finding

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PC DiagnosticsECUtalk ® start-up

3. Troubleshooting and Fault-finding

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PC DiagnosticsECUtalk ® EOL test

3. Troubleshooting and Fault-finding

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PC DiagnosticsECUtalk ® Workshop test

3. Troubleshooting and Fault-finding

Knorr-Bremse Group

Workshop Diagnostics

3. Troubleshooting and Fault-finding

21-29 V- Measure the voltage between X1-1 and X1-16

OnPower supply of PCV4

SW on- Disconnect X1-1 and X1-17OnOpt.Retarder relay -switch on6

SW off- Switch the RET on.- Connect X1-1 and X1-17

OnOpt.Retarder relay -switch off5

21-29 V- Measure the voltage between X1-1 and X1-3

OnPower supply of ECU3

≤3Ω- Remove fuse for permanent vehicle supply, replace fuse after test step- Connect pin X1-1 to battery ground

OffGround for ECU2

≤3Ω- Remove fuse for permanent vehicle supply, replace fuse after test step- Connect pin X1-12 to battery ground

OffGround for Warning lamp1

- Disconnect ECU and UDIF from the vehicle peripheries

OffPreparation for test0

Spec’Command descriptionIGNOpt.test itemNo

Knorr-Bremse Group

Workshop Diagnostics

3. Troubleshooting and Fault-finding

14-21Ω- Measure the resistance between X2-12 and X2-16

OffResistance of PCV - inlet valve -D/Axle LH

13

≤4.5Ω- Remove fuse for permanent vehicle supply, replace fuse after test step- Switch the ABS off-road switch on- Measure the resistance between X1-1 and X3-1

OffOpt.ABS off-road switch - switch on7

14-21Ω- Measure the resistance between X2-3 and X2-2

OffResistance of PCV - outlet valve -S/Axle LH

10

14-21Ω- Measure the resistance between X2-12 and X2-17

OffResistance of PCV - outlet valve -D/Axle LH

14

14-21Ω- Measure the resistance between X2-6 and X2-7

OffResistance of PCV - outlet valve -S/Axle RH

12

14-21Ω- Measure the resistance between X2-6 and X2-4

OffResistance of PCV - inlet valve -S/Axle RH

11

14-21Ω- Measure the resistance between X2-3 and X2-1

OffResistance of PCV - inlet valve -S/Axle LH

9

≥1 MΩ- Switch the ABS off-road switch off- Measure the resistance between X1-1 and X3-1

OffOpt.ABS off-road switch - switch off8

Spec’Command descriptionIGNOpt.test itemNo

Knorr-Bremse Group

Workshop Diagnostics

3. Troubleshooting and Fault-finding

0.8 - 2.2 kΩ

- Measure the resistance between X2-11 and X2-14

OffResistance of Speed sensor - S/Axle RH

22

0.8 - 2.2 kΩ

- Measure the resistance between X2-5 and X2-8

OffResistance of Speed sensor - S/Axle LH

21

14-21Ω- Measure the resistance between X2-9 and X2-10

OffResistance of PCV - inlet valve -D/Axle RH

15

14-21Ω- Measure the resistance between X3-6 and X3-7

OffResistance of PCV - outlet valve -A/Axle LH

18

0.8 - 2.2 kΩ

- Measure the resistance between X2-15 and X2-18

OffResistance of Speed sensor - D/Axle LH

23

14-21Ω- Measure the resistance between X3-9 and X3-13

OffResistance of PCV - outlet valve -A/Axle RH

20

14-21Ω- Measure the resistance between X3-9 and X3-10

OffResistance of PCV - inlet valve -A/Axle RH

19

14-21Ω- Measure the resistance between X3-6 and X3-4

OffResistance of PCV - inlet valve -A/Axle LH

17

14-21Ω- Measure the resistance between X2-9 and X2-13

OffResistance of PCV - outlet valve -D/Axle RH

16

Spec’Command descriptionIGNOpt.test itemNo

Knorr-Bremse Group

Workshop Diagnostics

3. Troubleshooting and Fault-finding

0.8 - 2.2 kΩ

- Measure the resistance between X1-10 and X1-11

OffResistance of Speed sensor - D/Axle RH

24

0.8 - 2.2 kΩ

- Measure the resistance between X3-11 and X3-14

OffResistance of Speed sensor - A/Axle LH

25

0.8 - 2.2 kΩ

- Measure the resistance between X3-12 and X3-15

OffResistance of Speed sensor - A/Axle RH

26

The wheels on SAare freely rotating

- Lift the Steer axle- Connect the pins X1/16 and X2/1- Connect the pins X1/1 and X2/3 (max. 15 sec)- Push the brake pedal- Turn the wheels and check the result

OnPCV pressure test - S/Axle LH

step 1.

27

are freely rotating

- Keep brake pushed- Connect the pins X1/16, X2/1 and X2/2- Connect the pins X1/1 and X2/3 (max. 15 sec)- Turn the wheels and check the result

Onstep 3.

are braked

- Keep brake pushed- Disconnect the pins X1/1 and X2/3

Onstep 2.

Spec’Command descriptionIGNOpt.test itemNo

Knorr-Bremse Group

Workshop Diagnostics

3. Troubleshooting and Fault-finding

- X1/16, X2/16 and X2/17- X1/1 and X2/12 (max. 15 sec)

Onstep 3.

- X1/1 and X2/12Onstep 2.

<same as No.27>

- X1/16 and X2/16- X1/1 and X2/12 (max. 15 sec)

OnPCV pressure test - D/Axle LH

step 1.

29

- X1/1 and X2/6Offstep 4.

- X1/16, X2/4 and X2/7- X1/1 and X2/6 (max. 15 sec)

Onstep 3.

- Disconnect the pins X1/1 and X2/3- Release the brake pedal- Disconnect the pins and put down the wheels

Offstep 4.27

<same as No.27>

- X1/16 and X2/4- X1/1 and X2/6 (max. 15 sec)

OnPCV pressure test - S/Axle RH

step 1.

28

- X1/1 and X2/12Onstep 4.

- X1/1 and X2/6Onstep 2.

Spec’Command descriptionIGNOpt.test itemNo

Knorr-Bremse Group

Workshop Diagnostics

3. Troubleshooting and Fault-finding

- X1/16, X3/4 and X3/7- X1/1 and X3/6 (max. 15 sec)

Onstep 3.

- X1/1 and X3/6Onstep 2.

<same as No.27>

- X1/16 and X3/4- X1/1 and X3/6 (max. 15 sec)

OnPCV pressure test - A/Axle LH

step 1.

31

- X1/1 and X2/9Offstep 4.

<same as No.27>

- X1/16 and X2/10- X1/1 and X2/9 (max. 15 sec)

OnPCV pressure test - D/Axle RH

step 1.

30

- X1/1 and X2/9Onstep 2.

- X1/1 and X3/6Offstep 4.

- X1/16, X2/10 and X2/13- X1/1 and X2/9 (max. 15 sec)

Onstep 3.

Spec’Command descriptionIGNOpt.test itemNo

Knorr-Bremse Group

Workshop Diagnostics

3. Troubleshooting and Fault-finding

≥ 95 mV-Turn the wheel at approx. 0.5 1/sec by hand or by rolling test bench

- Measure the voltage between X2-11 and X2-14

OffSpeed sensor – S/Axle RH34

≥ 95 mV-Turn the wheel at approx. 0.5 1/sec by hand or by rolling test bench

- Measure the voltage between X2-5 and X2-8

OffSpeed sensor – S/Axle LH33

- X1/1 and X3/9Offstep 4.

<same as No.27>

- X1/16 and X3/10- X1/1 and X3/9 (max. 15 sec)

OnPCV pressure test - A/Axle RH

step 1.

32

- X1/1 and X3/9Onstep 2.

- X1/16, X3/10 and X3/13- X1/1 and X3/9 (max. 15 sec)

Onstep 3.

Spec’Command descriptionIGNOpt.test itemNo

Knorr-Bremse Group

Workshop Diagnostics

3. Troubleshooting and Fault-finding

≥ 95 mV-Turn the wheel at approx. 0.5 1/sec by hand or by rolling test bench

- Measure the voltage between X3-12 and X3-15

OffSpeed sensor – A/Axle RH38

≥ 95 mV-Turn the wheel at approx. 0.5 1/sec by hand or by rolling test bench

- Measure the voltage between X2-15 and X2-18

OffSpeed sensor – D/Axle LH35

≥ 95 mV-Turn the wheel at approx. 0.5 1/sec by hand or by rolling test bench

- Measure the voltage between X1-10 and X1-11

OffSpeed sensor – S/Axle RH36

≥ 95 mV-Turn the wheel at approx. 0.5 1/sec by hand or by rolling test bench

- Measure the voltage between X3-11 and X3-14

OffSpeed sensor – A/Axle LH37

Spec’Command descriptionIGNOpt.test itemNo

Knorr-Bremse Group

Workshop Diagnostics

3. Troubleshooting and Fault-finding

> 30 kΩ-Measure the resistance between X2-8 and X1-3

OffSpeed sensor up to Ubatt - S/Axle LH

45

> 30 kΩ-Measure the resistance between X2-14 and X1-3

OffSpeed sensor up to Ubatt - S/Axle RH

46

> 30 kΩ-Measure the resistance between X2-11 and X1-1

OffSpeed sensor up to GND - S/Axle RH40

> 30 kΩ-Measure the resistance between X2-15 and X1-1

OffSpeed sensor up to GND - D/Axle LH41

> 30 kΩ-Measure the resistance between X1-10 and X1-1

OffSpeed sensor up to GND - D/Axle RH42

> 30 kΩ-Measure the resistance between X3-11 and X1-1

OffSpeed sensor up to GND - A/Axle LH43

> 30 kΩ-Measure the resistance between X3-12 and X1-1

OffSpeed sensor up to GND - A/Axle RH44

> 30 kΩ-Measure the resistance between X2-5 and X1-1

OffSpeed sensor up to GND - S/Axle LH39

> 30 kΩ-Measure the resistance between X2-18 and X1-3

OffSpeed sensor up to Ubatt - D/Axle LH

47

Spec’Command descriptionIGNOpt.test itemNo

Knorr-Bremse Group

Workshop Diagnostics

3. Troubleshooting and Fault-finding

> 30 kΩ-Measure the resistance between X3-14 and X1-3

OffSpeed sensor up to Ubatt - A/Axle LH

49

> 30 kΩ-Measure the resistance between X3-15 and X1-3

OffSpeed sensor up to Ubatt - A/Axle RH

50

≤1Ω-Connect DIAL and DIAK pins in diag. connector

-Measure the resistance between X1-13 and X1-14

OffOpt.DIAK and DIAL51

21-29 V- Push brake pedal- Check the proc result- Release the brake pedal

- Measure the voltage between X1-9 and X1-1

OnStop light switch52

32-42 Ω-Measure the resistance between X1-4 and X1-5

OffInternal resistance of ATC valve53

> 30 kΩ-Measure the resistance between X1-11 and X1-3

OffSpeed sensor up to Ubatt - D/Axle RH

48

Spec’Command descriptionIGNOpt.test itemNo

Knorr-Bremse Group

Workshop Diagnostics

3. Troubleshooting and Fault-finding

The wheels L and Ron DAare braked

- Connect the pins X1/4 and X1/1- Connect the pins X1/5 and X1/16

OnPressure test of ATC valve

step 1

54

are freely rotating

- Disconnect the pinsOnstep 2

Spec’Command descriptionIGNOpt.test itemNo

Knorr-Bremse Group

System componentsECU

4. System components

The ECU is the brains of the ABS. It receives the input data

from the wheel speed sensors, processes the information

and during a service brake application it decides upon any

action necessary. Having made such a decision the ECU

will instruct the relevant pressure modulator valve to take

the appropriate action and will then monitor the affect of this

action and make any corrections necessary.

Knorr-Bremse Group

System componentsABS Warning Lamp

4. System components

The ABS warning lamp is mounted in the vehicle dashboard

and is used to signal the presence of a fault with any of the ABS

components.

When the ABS is powered (ignition switched on) the ABS

warning lamp should illuminate for 2 second while the ECU

carries out a static test of the system and it should then go out. If

the ABS warning lamp does not illuminate when the ignition is

first switched on, the condition of the bulb should be checked

immediately and it must be replaced if found to be faulty. If the

bulb is found to be satisfactory then check the power supply to

the ECU

If the ABS warning lamp fails to go out, or if it has gone out

after 2 sec. and then illuminates again, this is an indication of a

malfunction of the system. This should be investigated ASAP.

Knorr-Bremse Group

System componentsSensing Ring

4. System components

The sensing ring is a toothed ring rigidly mounted to the

axle end so that it rotates with the wheel.

The sensing ring rotates relative to the wheel speed

sensor, which in turn provides a sinusoidal electrical signal

to the ECU. This signal can be used to measure the

rotational speed of the wheel.

* If any of the teeth become chipped, then the ECU will recognize that the signal

received from WSS is of poor quality.

Knorr-Bremse Group

System componentsWheel Speed sensor

4. System components

The wheel speed sensor is mounted, using a spring-

loaded bush, in a housing on the axle in such a position that

the end of the sensor is as close as possible to the teeth to

the sensing ring. The wheel speed sensor contains an

internal permanent magnet whose magnetic field extends a

short distance beyond the end of the sensor case. A

When a wheel rotates, the teeth of the sensing ring pass in turn through the

magnetic and disturb the field thereby creating an induced voltage in the sensor coil.

This voltage is monitored by the ECU via the output cable. The voltage generated

takes the form of a sine wave with both the voltage and frequency increasing as the

rotational speed of the wheel increases.

Knorr-Bremse Group

System componentsWheel Speed sensor

4. System components

Note: If the normal WSS (made by Knorr-Bremse) isn’t used in ABS6 sys., it may cause malfunction such as time lag, signal loss, mi s-calculation etc.

Knorr-Bremse Group 55

4. System components

System componentsWheel Speed sensor

The spring-loaded sensor bush is used to hold the wheel speed sensor whilst allowing easy adjustment of the gap between it and the teeth of the sensing ring.

Under normal conditions this gap should not be greater than 0.6mm.

Knorr-Bremse Group 56

4. System components

System componentsWheel Speed sensor

The wheel speed sensor and its extension cable can be checked with multi-meter.

Knorr-Bremse Group

System componentsSensor Extension

Cable

4. System components

The sensor extension cable is used to connect the wheel

speed sensor to the ECU. The connector on the wheel speed

sensor output cable is designed to join with the sensor extension

cable and provide a weatherproof seal. It is therefore important

that the connectors are inserted correctly and are fully engaged.

If a sensor extension cable is replaced and it is secured with

cable ties then they should never by tightened excessively as the

insulation of the cable can become crushed and a short circuit

could result.

Knorr-Bremse Group

System componentsPressure Control Valve

4. System components

The pressure control valve is rigidly mounted on the

vehicle chassis as close as possible to the brake

actuator that it controls. The valve is part of the

service brake system, its inlet port (labeled ‘1’) is

supplied with air pressure from the foot valve when

the brake is applied and the delivery port (labeled ‘2’)

supplies air pressure to the service brake actuator.

The valve is connected electrically to the ECU,

enabling it to the operation of the two internal

solenoids ‘C’ and ‘D’ (normally de-energized). The

valve has two internal non-return valves ‘A’ and ‘B’

held closed by light springs.

Knorr-Bremse Group

System componentsPressure Control Valve

4. System components

Knorr-Bremse Group 60

4. System components

System components

The pressure control valve can be checked with multimeter.

Pressure Control Valve

Knorr-Bremse Group

Wiring Diagrams

5. Wiring Diagrams

Knorr-Bremse Group

Wiring Diagrams

5. Wiring Diagrams

X1 PLUG Layout

Knorr-Bremse Group

Wiring Diagrams

5. Wiring Diagrams

X2 PLUG Layout

Knorr-Bremse Group 64

Thank you for your attention.

Contact

KNORR-BREMSE Korea Ltd.Truck Brake Division6th Floor, Bongwoo B/D, 31-7, 1-Ga, Jangchung-Dong,Jung-Gu, Seoul, 100-391, KoreaPhone: +82 2 2273 1182~3 Fax: +82 2 2273 1184mailto: [email protected]://www.knorr-bremse.com