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Systems for Commercial Vehicles

Product Manual

System and Installation Instructions for KB4TA-G2

24VoltMulti-ChannelTrailer-ABS Withintegratedanti-compounding

Disclaimer

The information contained herein is intended for the exclusive use of trained persons within the commercial vehicle industry, and must not be passed on to any third party. This information does not purport to be all-inclusive and no responsibility is assumed as a result of its use. We cannot accept any liability nor offer any guarantee regarding data accuracy, completeness or timeliness. The information does not represent any guarantee or ensured characteristics of the Products or Systems described. No liability can be accepted based on the information, its use, recommendations or advice provided. In no event may we be held liable for any damage or loss except in the case of wilful intent or gross negligence on our part, or if any mandatory legal provisions apply. Brand names mentioned in this information are not identified as such in all cases. We would emphasise however that they are nevertheless subject to the provisions of trademark legislation. Any legal disputes arising from the use of this information shall be subject to German law. Failure of any individual clause of this disclaimer to comply with current legal provisions does not affect the validity of the remaining clauses. This disclaimer is an English translation of a German text, which should be referred to for all legal purposes.

Content

Content

SafetyChecks . . . . . . . . . . . . . . . . . . . . . . . 5

1 . Introduction . . . . . . . . . . . . . . . . . . . . . . . . 6 2 . MainSystemLayouts . . . . . . . . . . . . . . . . . . . . . 7 2.1 2.2 System-Layout for air-suspended semi-trailer . . . . . . . . . . . . . . . . . . 7 7

System-Layout for mechanical-suspended semi-trailer .

3 . ComponentDescription . . . . . . . . . . . . . . . . . . . 8-13 3.1 3.2 Park-/Shunt Valve with integrated Overflow-Valve . Park-/Shunt Valve without integrated Overflow-Valve (for mechanical suspended trailers) . 3.3 3.4 3.5 3.6 3.7 .7.1 .7.2 Load Sensing Valve ­ Air suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 9 9 . . . . . . . . . 8

Load Sensing Valve ­ Mechanical suspension . Levelling Valve . Coupling Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. 10 . 11 . 12

Trailer-ABS-Module .

Pneumaticconnections. . . . . . . . . . . . . . . . . . 12 ECUconnectors. . . . . . . . . . . . . . . . . . . . 1

4 . Layout"3M-Systems" . . . . . . . . . . . . . . . . . . . . 14-16 4.1 4.2 4.3 4.4 4.5 System layout for air-suspended semi-trailer . System layout for air-suspended full trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 . 14 . 15 . 15 . 16

Knorr-Bremse BR9234 ABS Modulator Relay Valve . 3rd. ABS Modulator Connection . Auxiliary I/O Connector . . . . . . . . . . . . . . . .

5 . Wiring/Harness . . . . . . . . . . . . . . . . . . . . . . 17-19 5.1 Laying of extension cable speed sensor and connection cable modulator . . 19

6 . DiagnosticTools . . . . . . . . . . . . . . . . . . . . . . . 20 7 . WheelSpeedSensor . . . . . . . . . . . . . . . . . . . . 21-22

Content

8 . ModuleMainFunction . . . . . . . . . . . . . . . . . . . . 23-24 8.1 8.2 8.3 8.4 8.5 8.5.1 8.6 8.6.1 8.6.2 8.6. 8.7 8.8 8.8.1 8.8.2 8.8. 8.8. Customer Scratch Pad . Power-up Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 . 23 . 23 . 23 . 23 . 23

Trailer ABS indicator lamp .

Modulator Chuff Test at Power-up ABS Operation . . . . . . . . . . .

NormalBraking. . . . . . . . . . . . . . . . . . . . . 2 Odometer Function . Odometer . . . . . . . . . . . . . . . . . . . . . . 2 TripCounter. . . . . . . . . . . . . . . . . . . . . . 2 ServiceInterval. . . . . . . . . . . . . . . . . . . . . 2 Non-standard Tyre Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 . 24

Diagnostic Trouble Code Detection .

Auto-configuration. . . . . . . . . . . . . . . . . . . . 2 PartialABSShutdown. . . . . . . . . . . . . . . . . . . 2 ECUDiagnosticTroubleCode . . . . . . . . . . . . . . . . 2 VoltageDiagnosticTroubleCode. . . . . . . . . . . . . . . 2

9 . BlinkCodeDiagnostics . . . . . . . . . . . . . . . . . . . 25-26 . 9.1 9.2 9.3 9.4 9.5 Display Diagnostic Trouble Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 . 25 . 25 . 25 . 26

Display Diagnostic Trouble Code History Reset Active Diagnostic Trouble Codes . Display Odometer Mileage . . . . . . .

Diagnostic Trouble Codes (DTCs) .

10 .DiagnosticTrouble-shootingFlowcharts . . . . . . . . . . . . . . 27-33 11 .LabelInformation . . . . . . . . . . . . . . . . . . . . . . 34 12 .FixingPoints . . . . . . . . . . . . . . . . . . . . . . . . 35 13 .ServiceReplacementoftheKB4TA-G2 . . . . . . . . . . . . . . . 36 13.1 13.2 Required Checks after replacement . Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 . 36

14 .AdditionalDocumentation . . . . . . . . . . . . . . . . . . . . 37

SafetyChecks

SafetyChecks

Beforeworkingonoraroundairbrakingsystemsanddevices,thefollowingprecautionsshouldbeobserved: · Stoptheenginebeforeworkingunderavehicle. · Parkthevehicleonalevelsurface,applytheparkingbrakes,andalwayschockthewheelsasdepletingvehicleairsystempressuremaycause thevehicletoroll. · Alwayswearsafetyglasseswhenworkingwithairpressure. · Neverexceedmanufacturer'srecommendedairpressures. · Neverlookintoairjetsordirectthematanyone. · Whenworkingunderoraroundthevehicle,andparticularlywhenworkingintheenginecompartment,theengineshouldbeshutoffandthe ignitionkeyremoved.Wherecircumstancesrequirethattheenginebeinoperation,EXTREMECAUTIONshouldbeusedtopreventpersonalinjury resultingfromcontactwithmoving,rotating,leaking,heatedorelectricallychargedcomponents.Additionally,itisadvisabletoplaceaclearsign onornearthesteeringwheeladvisingthatthereisworkinprogressonthevehicle. · Iftheworkisbeingperformedonthevehicle'sairbrakingsystem,oranyauxiliarypressurizedairsystems,ifitisnecessarytodraintheairpressure fromreservoirsetc.keepclearofbrakeactuatorpushrodsandleverssincetheymayapplyassystempressuredrops.Beawarethatifthevehicle isequippedwithanairdryersystem,itcanalsocontainairpressurealongwithitspurgereservoiriffitted. · Neverconnectordisconnectahoseorlinecontainingpressure;itmaywhipasairescapes.Neverremoveadeviceorpipeplugunlessyouare certainallsystempressurehasbeendepleted. · Following the vehicle manufacturer's recommended procedures, deactivate the electrical system in a manner that safely removes all electrical powerfromthevehicle. · Examineallpipeworkforsignsofkinks,dents,abrasion,dryingoutoroverheating.Replacementhardware,tubing,hose,fittings,etc.mustbeof equivalentsize,typeandstrengthasoriginalequipmentandbedesignedspecificallyforsuchapplicationsandsystems.Checktheattachmentof allpipework;itshouldbesupportedsothatitcannotabradeorbesubjectedtoexcessiveheat. · UseonlygenuineKnorr-Bremsereplacementparts,componentsandkits. · Neverattempttoinstall,remove,disassembleorassembleadeviceuntilyouhavereadandthoroughlyunderstandtherecommendedprocedures. Some units contain powerful springs and injury can result if not properly dismantled. Use only the proper tools and observe all precautions pertainingtouseofthosetools. · Components with stripped threads or damaged parts should be replaced rather than repaired. Do not attempt repairs requiring machining or weldingunlessspecificallystatedandapprovedbythevehicleorcomponentmanufacturer. · Priortoreturningthevehicletoservice,makecertainallcomponentsandsystemsarerestoredtotheirproperoperatingcondition.

Welding ToavoiddamagetotheEBS-modulewhencarryingoutelectricalwelding,thefollowingprecautionsshouldbeobserved: · Inallcasesbeforestartinganyelectricalwelding,firstremoveallconnections. · Note:Whenreinsertingthesensorplugs(inreverseorder)itisessentialthattheyarefittedtotheircorrectassignedposition-ifnecessarythismust becheckedbyPC-diagnostics.

5

1 Introduction

The Knorr-Bremse KBTA-G2 module is an integrated trailerABScontrollerandmodulatorforair-brakedheavyduty trailers, semi-trailers and full trailers. The module actsastworelayvalvesduringnormalbraking,butduring ABS events, it will intervene to help improve stability. All modulesincludeanElectronicControlUnit(ECU)andtwo ModulatorRelayValves(MRV).

6

2 MainSystemLayouts

2 MainSystemLayouts 2 .1SystemLayoutforairsuspendedsemi-trailer

Legend: (1) CouplingHeadwithFilter"Supply" (2) CouplingHeadwithFilter"Control" (3) ElectricalConnection "Lighting"acc.toISO1185 (4) ABS-ConnectorISO7638 (5) Park-/ShuntValveAE4311 withEmergencyFunctionand ChargingValve (6) AirReservoir[e.g.100litre] (7) Overflow-Valve (8) Load-SensingValveBR5522(e.g.) (9) ABS-Modulewith6Ports (10) TestConnector (11) BrakeChamber (12) SensingRingandSpeedSensor (13) AirSpringBellow (14) SpringBrake (15) LevelingValve

2 .2SystemLayoutformechanicalsuspendedsemi-trailer

Legend: (1) CouplingHeadwithFilter"Supply" (2) CouplingHeadwithFilter"Control" (3) ElectricalConnection"Lighting" acc.toISO1185 (4) ABS-ConnectorISO7638 (5) Park-/ShuntValveAE4311with EmergencyFunction (6) AirReservoir[e.g.100litre] (7) Load-SensingValveBR4370(e.g.) (8) ABS-Modulewith6Ports (9) TestConnector (10) BrakeChamber (11) SensingRingandSpeedSensor (12) SpringBrake

7

3 ComponentDescription

3 . ComponentDescription 3 .1Park-/ShuntValvewithintegratedOverflow-Valve

Features: · Prioritytoservicebrakingsystemduringcharging · Springbrakesheldoffduringenergyconsumptiontest · Spring brakes fully applied when reservoir pressure <.0bar

3 .2Park-/ShuntValvewithoutintegratedOverflow-Valve(formechanicalsuspendedtrailers)

Features: · Prioritytoservicebrakingsystemduringcharging · Springbrakesheldoffduringenergyconsumptiontest · Spring brakes fully applied when reservoir pressure <.0bar

8

3 ComponentDescription

3 .3LoadSensingValve-Airsuspension

Function: The load sensing valve is used to modify the applied servicebrakepressureinrelationtotheloadimposedon thevehicle'saxles.Theairsuspensionloadsensingvalve uses the pressure in the suspension air bags to ,,sense" theloadimposedontheaxlesanddeterminethevalve's brakingratio. Versionsofthevalveareavailablewithorwithoutrelayand emergencyfeatures,andwithstaticordynamicoperation. Astaticvalveusesthebrakingratioatcommencementof braking application, a dynamic valve adjusts the braking ratiothroughoutthebrakeapplicationtohelpcounteract theeffectofloadtransfer. Atrailerdataplate,showingthesettingsoftheloadsensing valveisrequiredbylaw. TechnicalFeatures: · Maximumoperationpressure:. . . . . . .8,5bar · Operatingtemperaturerange:. . . -0°Cto+80°C

Trailer Data Plate

Symbol as DIN ISO 1219

3 .4LoadSensingValve-Mechanicalsuspension

Function: Theloadsensingvalveisusedtoadjusttheappliedservice brake pressure in relation to the load imposed on the vehicle's axles. The mechanical suspension load sensing valve uses the movement between the vehicle's chassis andaxlesto,,sense"theloadimposedontheaxles. The valve is installed on the chassis and a linkage is required to connect the control arm of the valve to the axle(s).Anymovementofthechassischangestheposition ofthevalve'scontrolarmwhich,inturn,alterstheratioof inputpressuretooutputpressure. Versionsofthevalveareavailablewithorwithoutrelayand emergencyfeatures,andwithstaticordynamicoperation.

3 ComponentDescription

Astaticvalveusesthebrakingratioatcommencementof braking application, a dynamic valve adjusts the braking ratio throughout the brake application to counteract the effectofaxleloadchangeduetoloadtransfer. A Trailer Data Plate, showing the settings of the Load SensingValveisrequiredbylaw. TechnicalFeatures: · Maximumoperationpressure:. . . . . . .8,5bar · Operatingtemperaturerange:. . . -0°Cto+80°C · WorkingAngle: . . . . . . . . . . . . . 20°

Symbol as DIN ISO 1219 Trailer Data Plate

Automatisch-Lastabhängige Bremskraftregeleinrichtung (ALB) für Typ: Load Sensing Device for Type: Dispositif de correction automatique de freinage pour type:

KNORR- BREMSE AG

Vorderachse, Front Axle, Essieu avant Feder-Nr Spring No Ressort No Ventile Nr Valves No Valves No

l

Hinterachse, Rear Axle, Essieu arrière Feder-Nr Spring No Ressort No Ventile Nr Valves No Valves No Eingangsdruck Input Pressure Pression de entrée Weg s am Hebel Stroke s at Lever Course s ou Levier mm Achslast Axle Load Charge essieu kg bar

l

S

l=

mm Ausgangsdruck Output Pressure Pression de sortie bar

S

l= Weg s am Hebel Stroke s at Lever Course s ou Levier mm

mm

Achslast Axle Load Charge essieu kg

Ausgangsdruck Output Pressure Pression de sortie bar

VF 00075/31

3 .5LevellingValve

Function: On vehicles fitted with air suspension, the leveling valve ensures that the axle Suspension air bags maintain a constantchassisheightirrespectiveofthevehicleload Versions with the ,,Height Limitation" feature prevent the chassisheightbeingmanuallyraisedaboveasetlimit. Versions with the ,,Second Ride Height" feature allow the driver to pneumatically signal the valve and raise the chassistoanalternativerideheight. Transversethrottlingpreventstherapidflowofairbetween thetwooutletports21(leftandrightsideofthevehicle). TechnicalFeatures: · Maximumoperationpressure:. . . . . . .12bar · Operatingtemperaturerange:. . . -0°Cto+80°C

Symbol as DIN ISO 1219

10

3 ComponentDescription

3 .6CouplingHeads

Function: Couplingheadsareusedtoconnectthebrakingsystemof thetowingvehicleandtrailer.Anintegralfilterprotectsthe airbrakesystemandtheauxiliarysystemofthetrailerfrom contamination. To prevent a blocked filter trapping air pressure in the supplyorcontrollines,aby-passfeatureallowsairtoflow backthroughthevalve. Coupling heads are colour coded to indicate the control (yellow) and supply (red) air line connections and are designed as defined in DIN ISO 1728 to prevent wrong connection. The versions for semi-trailers are designed to prevent the rotation of the coupling head when connecting or disconnectingtheairline. TechnicalFeatures: · Maximumoperationpressure:. . . . . . .8,5bar · Operatingtemperaturerange:. . . -0°Cto+80°C · Medium:. . . . . . . . . . . Compressedair · Filter: . . . . . . . . . . . . . . . Integrated · Approximateweight:. . . . . . . . . . 0.kg · Yellowandredcouplingheadsarenotinterchangeable

VF001_162 VF001_162 VF001_161

KU1400(Supply-Red)

KU1410(Control-Yellow)

SymbolasDINISO1219

11

3 ComponentDescription

3 .7TrailerABSModule 3 .7 .1 PneumaticConnections

KB4TA-G2:24VoltTrailerAnti-lockSystem:Pneumaticconnections

Spring Brake M16

Park-/Shunt Valve M22

Brake Chamber left M22

Test Port M16 Brake Chamber right M22 Control (yellow) M16

Supply (red) M22

Features: · MechatronicModuleformulti-channel -application -Systemconfigurations -2S/2M-S/2M-S/M · Auxiliaryfunctions: · Applications: -Semi-trailer -Centre-axletrailer -Fulltrailer -*Speedpulse -*Programmablespeedswitch -Brakewearmonitoring -Stoplamppowering -Headboardwarninglamp -2VSupply

* OnlyavailablewithspecialPartNumbers · AutomaticSystemConfigurationuptoS/2M · Blink-CodeactivationviaStoplight

12

3 ComponentDescription

3 .7 .2 ECUConnectors

The Knorr-Bremse KBTA-G2 module ECU connectors usea12-pinDeutschDTseriesconnectorforISO768 powersupply,diagnosticsandauxiliaryI/OslikeISO1185 stop light power supply, additional rd modulator and 1 additionalInput/Output.Themodulealsoutilizesup to wheelspeedsensor-inputs X1 - Code A

(grey connector)

Right Front Wheel Speed

Left Front Wheel Speed

Pin .

X1-1 X1-2 X1-3 X1-4 X1-5 X1-6

Signal

AUXI01 AUXRET23 TI_CANL GND_M TI_CANH BAT

Description

Auxiliary Input/Output

(4S/3M: Valve 3rd Modulator)

Pin .

X1-7 X1-8 X1-9 X1-10 X1-11 X1-12

Signal

GND_H WL IGN AUXI03 (DIA) AUXI02/ GND_BL AUXRET1/BL

Description

Warning Lamp Ground

(ISO 7638 - ABS connector - Pin 3)

Return Line for AUXI02 and AUXI03

(Diagnosis Ground)

Warning Lamp

(ISO 7638 - ABS connector - Pin 5)

5V-CAN Low for Diagnosis System Ground

(ISO 7638 - ABS connector - Pin 4)

ECU Supply Voltage Auxiliary Input/Output

(Diagnosis Supply Voltage)

5V-CAN High for Diagnosis Valve Supply Voltage

(ISO 7638 - ABS connector - Pin 1)

Auxiliary Input/Output

(Brake Light ground)

Return Line for AUXI01 (Brake Light Supply)

(4S/3M: Return Line 3rd Modulator)

ISO7638Connection(5Pins) X1.= ISO768Pinvalve-ground X1.6= ISO768Pin1valvesupply X1.7= ISO768PinIgnition/warninglamp Ground X1.8= ISO768Pin5warninglamp X1.= ISO768Pin2ignition

DiagnosticConnector KBTA-G2harnessesprovidea-pin5VoltJ1CAN diagnostic connection for a diagnostic tool. Remote diagnostic cables are available from Knorr-Bremse to provideaJ1diagnosticportatthesideofthetrailer. X1.2= Diagnosisground X1.= 5VoltCANlow X1.5= 5VoltCANhigh X1.10=2Voltdiagnosissupply

1

4 Layout"3M-System"

4 . Layout"3M-System" 4 .1Systemlayoutforair-suspendedsemi-trailer

Legend: (1) CouplingHeadwithFilter "Supply" (2) CouplingHeadwithFilter "Control" (3) ABS-ConnectorISO7638 (4) Park-/ShuntValveAE4311 withEmergencyFunctionand ChargingValve (5) AirReservoir[e.g.100litre] (6) Overflow-Valve (7) Load-SensingValveBR5522(e.g.) (8) ABS-Modulewith6Ports (9) SpringBrake (10) SensingRingandSpeed Sensor (11) AirSpringBellow (12) BrakeChamber (13) LevellingValve

4 .2Systemlayoutforair-suspendedfull-trailer

Legend: (1) CouplingHeadwithFilter "Supply" (2) CouplingHeadwithFilter "Brake" (3) ABS-ConnectorISO7638 (4) Park-/Shunt-ValveAE4311 withEmergencyFunctionand ChargingValve (5) AirReservoir[e.g.100litre] (6) Overflow-Valve (7) Load-Sensing-ValveBR5522(e.g.) (8) LevellingValve (9) BrakeChamber (10) ABS-Modulewith6Ports (11) SensingRingandSpeed Sensor (12) SpringBrake (13) AirSpringBellow

1

4 Layout"3M-System"

4 .3Knorr-BremseBR9234ABS ModulatorRelayValve

Knorr-Bremse BR2 modulator relay valves (MRV) is required for "M" Antilock-applications. The MRV is an electro-pneumatic control valve and is the last valve that airpassesthroughonthewaytothebrakechambers.The normally-closedexhaustsolenoidisactivatedtoprecisely modify the brake pressure on command. During normal braking, the BR2 MRV functions as a standard relay valve. As brakes are applied or released by the driver, the control signal from the tractor foot brake causes the BR2MRVtoapplyproportionalpressuretothetrailer brakechambers.

4 .43rdABSModulatorConnection

X1.1ConnectiontoexhaustcoilofBR2MRV X1.12ConnectiontoCommon(GND)

Relay Valve

X1.12

X1.1

Frontviewshowingpinconnection

Perspectiveview

15

4 Layout"3M-System"

4 .5AuxiliaryI/OConnector

The KBTA-G2 module provides an option for a single auxiliary Input/Output on pin X1.1 e.g. external warning lamp

Installation:ExternalWarningLamp

ISO1185

1

4

12 11 10

9

8

7

Pin 1 2 5 6 7

ISO1185Connector

Commonreturn Left-handrearpositionandendoutlinemarkerlightandrearregistrationplateilluminatingdevice Left-handdirection-indicatorlight Stoplight Right-handdirection-indicatorlight Right-handrearpositionandendoutlinemarkerlightandrearregistrationplateilluminatingdevice Brakingcontrolfortrailers

16

5 Wiring/Harness

5 Wiring/Harness

Several wiring harnesses are available to connect the KBTA-G2moduleandothertrailersystemcomponents. Harnessesareweathersealedattheconnectorinterface andareclearlylabelledforproperinstallation. Because of the over-moulded design of the KBTA-G2 modulewiringharnesses,Knorr-Bremserecommendsthat a complete harness be replaced if damage or corrosion occurs. Thefollowingconnectoroptionsmaybepresent: · ext.Modulator(M2) · auxiliary · diagnostic · additionalaxlewheelspeedsensors.

Note:

All KB4TA-G2 modules include the four wheel speed sensor connections.

Four 2-pin connectors are provided for additional wheel speedsensorsforSABSapplications: · SL&SRareforeseenfor2S/2Mapplications · SAL & SAR are additional connections for S/XMApplication (X=2 or ). Additional Sensor Left (SAL), andAdditionalSensorRight(SAR)canbeinstalledat certainconfigurationsonliftaxles.

TableofpowersupplycablesavailablefromKnorr-Bremse. PartNo . Description Cable Length (m) 8.0 12.0 14.0 8.0 10.0 6.0

(DIA) (DIA)

WiringDiagram

Picture

226626 226627 226628 22662 2266200 K01088

Powersupplycable withsocket (forSemi-trailers) Powersupplycable withplug (fordrawbartrailers andcentreaxletrailers) Powersupply +Diagnostics

Red Black Yellow Brown White

BAT IGN GND_H GND_M WL

Yellow

AUXI03 (DIA)

0.5

(ISO768)

Black White Brown

AUXRET23 TI_CANL TI_CANH AUXI01 AUXI02/GND_BL AUXRET1/BL

(ISO 7638)

Red Black Yellow Brown White

BAT IGN GND_H GND_M WL

continuedonfollowingpage.....

17

5 Wring/Harness

Tableofpowersupplycablescontinued . . . PartNo . Description Cable WiringDiagram Length (m)

(Ext. WL)

Picture

K016660

Powersupply +Externalwarning lamp

15.0

(Ext.WL)

Yellow

AUXI01 AUXRET23 TI_CANL TI_CANH AUXI03

(ISO 1185)

15.0

(ISO1185)

Black Yellow

GND_BL BL

(ISO768)

K0161*)

Powersupply +Diagnostics +rdABSModulator

6.0

(DIA) (DIA)

(ISO 7638)

0.5

Red Black Yellow Brown White

BAT IGN GND_H GND_M WL

Yellow Black White Brown Black Yellow

AUXI03 (DIA) AUXRET23 TI_CANL TI_CANH AUXI01 AUXRET1/BL AUXI02/GND_BL

(rdMod.)

(ISO768) availablefrom Qu./2006

*)

K0151

Power supply cable with socket - Direct to X1 Connector

12.0

(ISO 1185)

(ISO 7638)

0.5

(3rd Mod.)

10.0

Red Black Yellow Brown White

BAT IGN GND_H GND_M WL

(ISO 7638)

(ISO 1185)

12.0

AUXI03 AUXRET23 TI_CANL TI_CANH AUXI01 Black Yellow GND_BL BL

K01568

(ISO 1185)

12.0

(ISO 7638)

(ISO 7638)

Power supply cable without socket or plug - Direct to X1 Connector.

12.0

Red Black Yellow Brown White

BAT IGN GND_H GND_M WL

possible connection for: - Socket K002290 - Plug K002291

TableofextensioncablesavailablefromKnorr-Bremse. PartNo .

Description

Cable WiringDiagram Length (m) 2.0 3.0 4.0 5.0 6.0 8.0 10.0 12.0 15.0

Picture

II36756...

Extension cable for speed sensor

Red Black

18

5 Wiring/Harness

TableofmodularsystemcablesavailablefromKnorr-Bremse . PartNo .

Description

Cable WiringDiagram Length (m) 2.0 6.5 10.0 15.0 4.0

Yellow Black White Brown Black Yellow

Picture

K002274* K002275* K002276* K017003* K013194

Connecting cable for 3rd ABS Modulator

Diagnostic cable

K016629 K016630

External Warning Lamp

7.0 15.0

Yellow

* Startingfromproductiondate(ww/yy):27/06(Cableimprint)

5 .1Layingofextensioncablespeedsensor andconnectioncablemodulator

The rotation angle of the fifth wheel and the suspension travelmustbetakenintoaccountwhencalculatingcable lengthandduringinstallation. Toreducetheriskoffaultsinthesystemwerecommend thefollowing: 1) Tolaythemodulatorcableandthesensorcablesseparatelyonthevehicleframe.Thesensorcableshouldhave a minimum distance to other cables ofapproximately 5­10cm.Ifitispossiblethecablingshouldnotrunparallel tothemaincablingharness. 2) Cablesinstalledinconduitmustbeprotectedwithcable grommetsaswellasconsidermaximumofspringtravel. ) It is not permitted to `lose' any excessive length of the extensionandconnectioncablesincircularloopsorring form. Excess cable should be detoured or folded (see diagram). Wire cross section · Modulatorcable: . . . . . . . . . . . . 1.0mm² · Sensorcable:. . . . . . . . . . . . .0.75mm²

Correct laying of excessive cable length

Circular looping is not permissible

Permissible methods

1

6 DiagnosticTools

6 DiagnosticTools

InordertoconfiguretheKBTA-G2,carryoutEndOfLine testingandsystemchecks,specialhardwareandsoftware isrequired.Therequiredpartsarelistedbelow:

Pos

1 2

Name

Diagnostic cable Diagnostic Set UDIF 1) Connection cable Diagnostic software

Type-No.

EZ1037 EZ1031

Part-No.

K010837 II39809F

Description

length = 3m included connection cable Z005474 (9-pin sub-D-plug and 9-pin sub D-socket) optional for USB-connection to PC CD-ROM "ECUTalk"

3 4

Z007887 K015844

1) UDIF = Universal Diagnostic Interface

Diagramshowingthediagnosticconnectionset-up

AdaptercableavailablefromKnorr-Bremse. TypeNo .

+Description

PartNo .

Cable WiringDiagram Length (m) 3

Black Brown White Yellow GND GND CAN-H (5V) CAN-L (5V) UZ (24V) UZ (24V) Coded Resistor

Picture

EZ1037

Adapter cable for UDIF ( for 5V CAN Diagnostics)

K010837

20

7 WheelSpeedSensor

7 WheelSpeedSensor

Wheel speed data is provided to the KBTA-G2 module from the DF wheel speed sensors. Vehicles have an exciterring(or"tonering")aspartofthewheelassembly, andasthewheelturns,theteethoftheexciterringpass the wheel speed sensor, generating an AC signal. The KBTA-G2modulereceivestheACsignal,whichvariesin voltageandfrequencyasthewheelspeedchanges.(The defaultsettingexpectsa100-toothtoneringtobeused.) Vehicle axle and ABS control configurations determine if twoorfourwheelspeedsensorsarerequired. ApropersensorinstallationiscriticalforcorrectABS operation . 1) For increased corrosion protection we recommend thatahigh-temperatureratedsilicon-orlithium-based greasebeappliedtotheinteriorofthemountingblock, thesensor,andtothenewclampingsleeve. 2) Install the new clamping sleeve fully into the block, withtheretainingtabstowardtheinsideofthevehicle. PleasenotethatDFwheelspeedsensorsmustuse the correct clamping sleeve to avoid problems associated with reduced retention force, such as sensor movement,andresultingABStroublecodes. ) Gently push (DO NOT STRIKE) the sensor into the mounting block hole until it contacts the face of the tone ring. Secure the cable lead wire to the knuckle/ axlehousing10-15cmfromthesensor. ) Applyamoderateamountofdielectricnon-conductive

grease to both the sensor connector and harness connector. 5) Engage the connectors, and push together until the locktabsnapsintoplace. NOTE: It is important for the wheel bearings to be adjustedperthemanufacturer`srecommendations The friction fit allows the DF sensor to slide back and forthunderforcebuttoretainitspositionwhentheforce isremoved.WhentheDFsensorisinsertedalltheway intothemountingblockandthewheelisinstalledonthe axle, the hub exciter contacts the sensor, which pushes thesensorback.Also,normalbearingplaywill"bump"the sensor away from the exciter. The combination of these two actions will establish a running clearance or air gap betweenthesensorandexciter.

Excessivewheelendplaycanresultindiagnostictrouble codesincaseswherethesensorispushedtoofaraway fromthetonering.

Letusstartfromtheassumptionthatthepolewheelandthe speed sensor are available. Before installation you should grease the location bore and the outer diameter of the clampingsleeveII1677. Ordernumber: I90693(25gtube)

Theclampingsleeveshouldbepushedintheborebyhand untilitreachesthestopØ18H11,neveruseexcessiveforce

Typically,theDFsensorisinstalledinmountingblocks thatareweldedtotheaxlehousing.DFwheelspeed sensors are protected by a stainless steel sheath. Theyaredesignedtobeusedwithaberylliumcopper clamping sleeve (sometimes referred to as a "retainer bushing","frictionsleeve"or"clip").Theclampingsleeve providesafrictionfitbetweenthemountingblockbore andtheDFsensor.

StraightSpeedSensor SensorClampingSleeve 90°SpeedSensor

21

7 WheelSpeedSensor

(e.g. by hitting it with a hammer), as this may damage the sensor,sensorsleeveorsurroundingarea. NextinserttheDFuntilitmakescontactwiththepolewheel. Thenecessaryairgapbetweenthepolewheeland speed sensor is obtained automatically after a few wheel turns (assumingthewheel-bearingsareperformingcorrectly). Iftheairgapis>1mmor,thesignalistoolow,thespeed sensorhastobeadjust.

theclampingsleevealsobereplaced(PartNo.II1677). TheDFcableshouldbefixedatashortdistanceofapprox. 50mmbehindtheDF,toavoidpossibledamageandlimit vibration at the axle tube. A longitudinal displacement may notbehindered. Nextfixthecableatthebrakehose.Bythecableinstallation itisimportantthatmaximumdistancefromtheheatradiation components(wheelbrake)isachieved. The plug connection between sensor and extension cable shouldbefixedatbothsides.

Attention: Neveruseexcessiveforcewhenfittingthespeedsensor(e.g. usingahammerorsimilartool)asthespeedsensorheads couldbedamaged. InsuchcaseswhentheDFisreplaced,itisrecommended

Diagram showing mounting position of sleeve and sensor

Installationpositionoftheclampingsleeve Installation position optional

Fastencablesusingcableclips(notavailablebyKB),individual suspension travel should be taken into account to avoid possibledamage.Ifnecessarythecableshouldbesecured atthecoversheetofthewheelbrakewithacablegrommet!

Installationexample:WheelSpeedSensoradaption

Sleevepressedin againstthestop Sensorcarefully inserted(donot useahammer!) Ø21 Ø18H11

3+2

0.2 A 54 30±0.4 90 ±2 .5

>3.5

A

0.6±0.2x45°

Pressedinfully

Permissiblevertical installationposition

22

8 ModuleMainFunction

8 ModuleMainfunction 8 .1CustomerScratchPad

TheKBTA-G2modulehasacustomerscratchpadfeature whichallowsthecustomer,orend-user,tostoreupto756 bytes of information. This information can then be read usingtheKnorr-BremseKBTA-G2DiagnosticSoftware.

incorrectly, the modulator will only produce one chuff, or nochuffsatall.Ifafaultisdetectedduringthemodulator chufftest,comparethemodulatorwiringandplumbingto theKBTA-G2module'selectricalsystemschematicand makeanynecessaryrepairs.

8 .5ABSOperation

The KBTA-G2 module uses wheel speed sensors, modulatorrelayvalvesandanECUtocontroltrailerwheels either distributed by axle or vehicle side. By monitoring individual wheel turning motion during braking, and adjustingorpulsingthebrakepressureateachwheel,the KBTA-G2 module is able to optimize slip between the tyres and the road surface. When excessive wheel slip, or wheel lock-up, is detected, the ECU will activate the pressure modulator valves to modulate braking pressure atthewheelends.TheECUisabletopumpthebrakeson individualwheels(orpairsofwheels),independently,and withgreaterspeedandaccuracythanadriver. 8 .5 .1 NormalBraking During normal braking, the KBTA-G2 module functions astwostandardrelayvalvesinparallel.IftheECUdoesnot detectexcessivewheelslip,itwillnotactivateABScontrol, andthevehiclestopswithnormalbraking.

8 .2Power-upSequence

Atpower-up,theKBTA-G2moduleperformsaseriesof self-checksthatcanassistatechniciantodeterminethe ABSsystemstatusandconfiguration.

8 .3TrailerABSIndicatorLamp

Atpower-up(whennofaultsaredetected)thetrailerABS indicatorlampwillturnonfor2.5secondsasabulbcheck andthenturnoff.Ifafaulthasbeendetectedthebulbwill remainon.

8 .4ModulatorChuffTestatPower-up

Atpower-up,theKBTA-G2moduleactivatesamodulator chufftest.ThiselectricalandpneumaticABSmodulatortest canhelpthetechnicianidentifyproblemswithmodulator installationsand/orwiring.Withbrakepressureapplied,a properly installed modulator will cause five rapid audible chuffsofairpressure.Ifadditionalmodulatorsareinstalled, the KBTA-G2 module activates 5 chuffs at the internal modulatorsthenfortheadditionalmodulator(MOD).The chuffsequenceisthenrepeated.Ifthemodulatoriswired

8 .6OdometerFunction

8 .6 .1 Odometer TheKBTA-G2includesanodometerfunctiontoprovidea meansofstoringtheaccumulatedmileageofthevehicle. Themileageiscomputedbyutilizinginformationcalculated fromthevehiclewheelspeeds.Thisfeatureisaccurateto within0.62kmperpower-upandwilltypicallystoremileage upto1,000,000kmThemileagecanbedisplayedusing PCdiagnosticsorthroughblinkcodes. 8 .6 .2 TripCounter

ABS System Status Indicators

PowerApplication

0.5 1.5 2.0 2.5 .0 (sec.)

Trailer-mounted ABSindicatorlight

ON OFF

Themoduleprovidesacountertorecordthetripmileage. ThefeatureisaccessedthroughPC. 8 .6 .3 ServiceInterval The KBTA-G2 module provides a feature that can be usedtoindicateaserviceintervalforthetrailer.Theservice

Dash-mountedTrailer ON ABSindicatorlight OFF (Pin5ISO768)

2

8 ModuleMainFunction

intervalcanbeaccessedviaPC.Ifconfigured,theKBTAG2modulecanflashtheindicatorlampwhenthevehicleis atstandstilltoindicatewhentheserviceintervalhasbeen exceeded.

8 .8 .1 Auto-configuration The KBTA-G2 module is by default configured in the 2S/2MABSconfiguration.Atpower-up,iftheKBTA-G2 detectsadditionalsensors,itwillperformanauto-configuration. An Auto-configuration only adjusts upward (from 2S/2MSidetoaS/2MSideconfigurationonly).Additional detectedcomponentsthatdonotconformtoalegitimate configuration will generate the appropriate faults. If the vehicle begins moving before the new configuration has beenaccepted,thereconfigurationwillnottakeplaceat thistime. 8 .8 .2 PartialABSShutdown Depending on the trouble code detected, the ABS ECU partly or completely disables the ABS functionality. The trailer ABS system, on vehicles that only have two modulators,isdisabledbyanysinglefault.Inthecaseof vehicles with more than two sensors or more than two modulators, depending on the trouble code, the trailer ABSsystemmaystillprovidesomelevelofABSfunction on axles that are not affected by the fault, but the ABS indicatorlampwillremainon.IncaseswheretheABSis completelydisabled,thevehiclerevertstonormalbraking (withoutABSinterventions).AlwaysrepairABSshutdowns attheearliestopportunity. 8 .8 .3 ECUDiagnosticTroubleCodes All ABS functions are completely disabled. The system revertstonormalbraking. 8 .8 .4 VoltageDiagnosticTroubleCode While voltage is out of range, the ABS functionality is disabledandthesystemrevertstonormalbraking.When the correct voltage level is restored, full ABS is typically available again. The operating voltage range is 18.0 to 2.0VDC.

8 .7Non-standardTyreSize

The module allows for tyre rolling radius and tone ring tooth count parameters to be set for each axle using a diagnostictool.Theseadjustmentsmaybenecessaryfor themoduletoaccuratelycalculatethevehiclevelocityand odometermileage.Wheelsofthesameaxlemustbesetto thesamerollingradiusandtoneringtoothcount.Inmost cases,theseparametersaresetbythetrailerOEManddo notneedtobeadjusted. In the case of a service replacement unit, always check thattheseparametersaresettomatchthevehicle.Refer tothemanufacturer'styrespecificationforcorrectvalues. Toneringtoothcountisdefaultedto100teethandcanbe setto60to10teeth.

8 .8DiagnosticTroubleCodeDetection

The KBTA-G2 module contains self-testing diagnostic circuitry that monitors the ABS components and wiring. Whenthemodulesensesanerroneoussystemcondition, it activates the trailer-ABS indicator lamp, disables all or partoftheaffectedABSfunctions,anditstoresthefault codeinmemory. For some trouble codes, the KBTA-G2 module will automaticallyreset("self-heal")theactivediagnostictrouble code when the error is corrected. However, repeated occurrencesofagiventroublecodecancausethecodeto "latch"-thatis,beretainedasactive,evenifthecondition isonlyintermittent. Oncethecodeislatched,amanualresetwillbenecessary. Technicians can use these latched codes to assist them in troubleshooting intermittent errors. After the problem is repaired, trouble codes can be reset using blink code diagnosticsorwithadiagnostictool.Whenatroublecode self-healsorismanuallyreset,thecoderemainsstoredin theECUmemory.Thistroublecodehistorycanberetrieved usingblinkcodediagnosticsorwithadiagnostictool.

2

9 BlinkCodeDiagnostics

9 BlinkCodeDiagnostics

TheKBTA-G2moduleprovidesdiagnosticandconfigurationfunctionsthroughblinkcodediagnostics.Thismeans thatthetechnician,evenwithoutdiagnostictools,canread a series of ABS indicator lamp(s) blinks to diagnose the troublecodesbeinggenerated. Theblinkcodediagnosticsmodeisenteredbyproviding constantpowertotheignitioncircuitandtogglingthebrake lightpowerinputthreetimes.Withaparkedtowingvehicle attached,thisisdonebyapplyingignitionpowerandafter the power up sequence is complete, depressing and releasingthebrakepedalthreeormoretimes.Depending ontheblinkcodemodeactivated,theKBTA-G2module willblinkthetrailerABSindicatorlamp(s)todisplay: - active fault codes - fault code history - ABS configurations - Odometer mileage. Blink code diagnostics can also be used to reset active faultcodes.Waituntilafterthemodulatorchufftestbefore activatingthebrakelightpower.Followingasingledisplay ofallavailablemessages,thetrailerABSindicatorlamp(s) willremainonforfivesecondsandthenreturntonormal operatingmode. Blink code diagnostics can only be activated following a power-up,wherewheelspeedshavenotbeendetected.If thevehiclemovesduringblinkcodediagnosticsmode,the modulewillcanceltheblinkcodediagnosticsandreturn to normal operating mode. Blink code diagnostics must beactivatedwithinthefirst15secondsofignitionpower beingapplied. Ifbrakelightpoweriscontinuouslyappliedforgreaterthan fiveseconds,blinkcodediagnosticswillbedisableduntil thenexttimetheignitionpoweriscycled.

9 .1DisplayActiveDiagnosticTrouble Codes

Todisplayactivecodes,applyignitionpoweranddepress /release the brake pedal times within 15 seconds. Followingactivation,therewillbea5seconddelayfollowed byablinkcodedisplayofallactivefaultcodes.

9 .2DisplayDiagnosticTroubleCode History

To displaytroublecode history, applyignitionpower and depress/releasethebrakepedaltimeswithin15seconds. Followingactivation,therewillbea5seconddelayfollowed byablinkcodedisplayofallhistoryfaultcodes.

9 .3ResetActiveDiagnosticTrouble Codes

To reset active codes, apply ignition power and depress /release the brake pedal 5 times within 15 seconds. Following activation, there will be a 5 second delay followed by a blink code message of: 1-1, (System Fully Operational-NoCodesDetected)orablinkcodedisplay ofallremainingactivefaultcodes.TheABSindicatorlamp willstayonifactiveDTCsarestillpresent.Resettingactive fault codes with blink code diagnostics 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 this information.

9 .4DisplayOdometerMileage

To display the trailer odometer mileage, apply ignition poweranddepress/releasethebrakepedal7timeswithin 15seconds.Followingactivation,therewillbea5-second delay followed by a blink code display of the odometer information(x1000).Example:152,1kmwillbedisplayed as: 152 (x1000) or 1 blink (pause), 5 blinks (pause), 2 blinks.ZeroswillbedisplayedbytheABSindicatorlamp flashing twice. Odometer mileage cannot be altered with blink code diagnostics. Complete odometer information canberetrievedusingadiagnostictool.

25

9 BlinkCodeDiagnostics

9 .5DiagnosticTroubleCodes(DTCs)

ALB sign attached to the vehicle showing the DTCs

26

10 DiagnosticTrouble-shootingFlowcharts

10 DiagnosticTrouble-shooting Flowcharts

Diagnostictroublecodeinformationcanberetrievedfrom theKBTA-G2modulebyusingblinkcodediagnostics,or adiagnostictool.Thefollowingtroubleshootingflowcharts willhelpthetechnicianisolatethecauseofthefaultand confirmwhetherthefaultresidesinthecomponent,wiring orconnectors. Thefollowingpagescontaindetailedinformationon:

SectionA:(DiagnosticTroubleCode) BlinkCodeQuickReference

Troubleshooting should always begin by observing the dash or trailer-mounted ABS indicator lamp during the KB4TA-G2 module`s power-up sequence.

SectionB:(Power-Up-Sequence) Dash-MountedABSIndicatorLamp

Ifitisnecessarytomakeelectricalmeasurements,always beginbytakingvoltageandresistancemeasurementsat the12-pinECUpigtailharnessconnector. Once the circuit fault is found, isolate the area needing repair by repeating the measurements at all connections intheaffectedcircuittowardsthemodulator,wheelspeed sensor,etc. Novoltageorresistancemeasurementsaretobemadeon thebulkheadconnectorpinsofthemodule.

SectionC:(Power-Up-Sequence) Trailer-MountedABSIndicatorLamp

SectionD: TroubleshootingtheTrailer-MountedABS IndicatorLampCircuitry

SectionE: TroubleshootingtheISO7638(andISO1185if connected)Power-Supply

SectionF: TroubleshootingtheWheel-Speed-Sensors

SectionG: TroubleshootingtheModulatorRelayValve (BR9234)

27

10 DiagnosticTrouble-shootingFlowcharts

SectionA:(DiagnosticTroubleCode)BlinkCodeQuickReference

1stBlinkCode Code 1 2 3 4 5 Location All Sensor SL Sensor SR Sensor SAL Sensor SAR Code 1 1 2 3 4 5 Description No Faults Sensor signal valid - large air gap Sensor signal valid - loss of signal Sensor signal valid - noisy Sensor shorted or open Tyre diameter out of range 2ndBlinkCode RepairInformation System fully operational - no faults detected Go to Section F - Dynamic WSS DTCs Go to Section F - Dynamic WSS DTCs Go to Section F - Dynamic WSS DTCs Go to Section F - Static WSS DTCs Verify correct tyre size, proper tyre inflation & correct number of exciter ring teeth. Verify that the ECU has the proper tyre size settings. Verify correct ABS configuration. If needed, reset to the default ABS configuration and power-up to initiate auto-configuration. Go to Section E - Power Supply Go to Section E - Power Supply Go to Section E - Power Supply Go to Section G - ABS Modulator DTCs Go to Section G - ABS Modulator DTCs Verify correct ABS configuration. If needed, reset to the default ABS configuration and power-up to initiate auto-configuration. Go to Section G - ABS Modulator DTCs Go to Section G - ABS Modulator DTCs Go to Section G - ABS Modulator DTC Go to Section F - Dynamic WSS DTCs Go to Section G - ABS Modulator DTCs Check for damaged or corroded connectors. Check for damaged wiring. After repairs or if no issues found, then clear faults. If faults return, replace the module. Verify correct ABS configuration. If needed, reset to the default ABS configuration and power-up to initiate auto-configuration. Check for corroded/damaged wiring or connectors Check for corroded/damaged wiring or connectors between the ECU and J1939 Diagnostics. Replace/repair J1939 diagnostic wiring or components as required. ...

6 6 Power 1 2 3 7 8 9 10 Valve M22 (Int) Valve M21 (Int) AUXIO1 / M2 Common 2 3 4 1 2 3 4 5 11 ECU 1

Sensor configuration error Over-voltage Low-voltage Excessive resistance ISO 7638 pin 1 Exhaust solenoid shorted or open ABS modulator dynamic error Valve configuration error Internal low-side switch shorted to ground AUXIO1 (M2) low-side switch shorted to ground ABS modulator dynamic error - all valves Excessive ABS activity AUXIO1 (M2) low-side switch shorted to battery ECU internal error

2 12 13 AUXIO2 AUXIO3 1 1

ECU configuration error Shorted or open J1939 diagnostics shorted or open

14

System

2

Service Interval Exceeded

ToRead/ClearDiagnosticTroubleshootingCodes(DTCs): 1) Applyconstantpowertothetrailer(ignitionswitch). 2) Within15seconds,apply/releasethebrakepedalat1secondintervals: (a)timesfordisplayingActiveDTCs. (b)timesfordisplayingInactiveDTCs. (c)5timesforclearingActiveDTCs.After5secondsdelay,theblinkcodeswillbedisplayed.

) Observethetrailer-mountedABSindicatorlampandrecordblinkcode(s). ) Refertoblinkcodechartfordescription. 5) AftermakingrepairsandclearingActiveDTCs,verifylampisnolongerilluminated.

28

10 DiagnosticTrouble-shootingFlowcharts

SectionB:(Power-upSequence)Dash-MountedABSIndicatorLamp

Dash-mounted Trailer ABS Indicator Lamp at Power-up

Verify that the trailer is connected to the tractor via the 5-pin ISO 7638 connector. Turn ignition on and observe the dashmounted trailer ABS indicator lamp

Trailer ABS indicator lamp does not come on. If the trailer ABS lamp does not come on at power-up, troubleshoot the dash mounted trailer lamp circuit on the tractor

NO

Verify that the dash-mounted trailer ABS indicator lamp illuminates within 2 seconds of ignition power being applied to the vehicle

YES

The dash-mounted trailer ABS indicator lamp stays "ON". This is an indication that the trailer ABS unit has a fault. Go to Section A If the dash-mounted trailer ABS indicator lamp remains "ON" with no trailer connected, troubleshoot the dashmounted trailer lamp circuit on the tractor. If the trailer ABS lamp remains "ON" with a trailer connected, rerun the power-up sequence for trailermounted ABS indicator lamp. Go to Section A Verify that the dash-mounted ABS indicator lamp stays "ON" for 2.5 seconds and then turns "OFF"

NO

YES

The ABS units are functioning normally. No service to the ABS components is needed

SectionC:(Power-upSequence)Trailer-MountedABSIndicatorLamp

ABS Indicator Lamp at Power-up

Apply ignition or brake light power and observe the trailer-mounted ABS indicator lamp

Troubleshooting the trailer-mounted ABS Indicator Lamp circuitry. Go to section ,,D"

NO

The trailer-mounted ABS indicator lamp should immediately illuminate when the power is applied to the trailer

YES

Troubleshooting the trailer-mounted ABS Indicator Lamp circuitry. Go to section ,,D" Verify that the trailer-mounted ABS indicator lamp stays "ON" for 2.5 seconds and then stays "OFF"

NO

YES

The KB4TA-G2 module is functioning normally. No service to the ABS unit is needed

2

10 DiagnosticTrouble-shootingFlowcharts

SectionD:TroubleshootingtheTrailer-MountedABS-IndicatorLampCircuitry

Trailer-mounted ABS indicator lamp did not illuminate during the power-up sequence

Trailer-mounted ABS indicator remains "ON" during the power-up sequence

Troubleshoot the power supply to the module. Go to Section E Verify stoplight-supply at the ISO 1185 connector. Verify the correct installation of the Trailer-Mounted Warning lamp. Continue if power (ISO1185 - pin 4) and ground (ISO1185 - pin 1) wiring are OK.

Determine if a module Diagnostic Troubleshooting Code (DTC) exists using any of the following methods: - KB4TA-G2 Blink Code Diagnostic. Got to Section A - PC-diagnostic tools If DTC(s) exist and repairs are made are made, rerun the power-up sequence. Continue if no DTCs are found and the ABS module appears to be functioning normally.

. Turn off the power to the module. Inspect the condition of the ABS indicator lamp, connector and ground. Using a volt/ohm meter, verify continuity across the bulb. Verify continuity from the ISO 1185 ground (pin 1) to the ABS indicator lamp ground pin. If repairs are made, rerun the power-up sequence. Continue if the indicator lamp and ground wire check out OK.

With power off to the module, disconnect the 12-pin ECU connector. Using a volt meter, verify that there is no a short to Vbat between the external ABS WL pin (pin 1) of the ECU connector and the ABS indicator lamp connector. if repairs are made, rerun the power-up sequence.

With power off to the module, disconnect the 12-pin ECU connector. Verify continuity from external ABS WL pin (pin 1) of the ECU connector and the ABS indicator lamp connector. if repairs are made, rerun the power-up sequence. Ground

12 11 10

9

8

7

Power Looking into ISO1185-connector (Pin 1 - ground / Pin 4 - power)

Looking into KB4TA-G2-Module Wire Harness (Pin 1 - ABS Indicator Lamp)

0

10 DiagnosticTrouble-shootingFlowcharts

SectionE:TroubleshootingtheISO7638(andISO1185ifconnected)Power-Supply

Check for high resistance (corrosion, wire-connector-damage or improper termination of the power lines, resulting in high voltage drop across the lines measure the voltage under load by placing a load such as brake light bulb with ignition-power, battery-power & stoplight-power to the trailer measure voltage between the ignition pin and it`s corresponding gnd, measure voltage between the battery pin and it`s corresponding gnd, measure voltage between the stoplightsupply and stoplight-gnd the operating range is between 18 - 32 vdc. verify that the voltage drop measurements are no less than 1 vdc at the vehicle voltages (ignition, battery, stoplight)

Turn off power to module, disconnect the 12-pin-connector.

with ignition-power, battery-power & stoplight-power to the trailer measure voltage between the ignition pin and it`s corresponding gnd, measure voltage between the battery pin and it`s corresponding gnd, measure voltage between the stoplight-supply and stoplight-gnd the operating range is between 18 - 32 vdc

YES

NO

With the voltage meter, check the power and gnd wires, look for corroded or damaged wires or pins if repairs are made, rerun the power-up sequence.

With a voltmeter check power- and gnd-wires. look for corroded or damaged wires or pins if repairs are made, rerun the power-up sequence.

12 11 10

9

8

7

12 11 10

9

8

7

12 11 10

9

8

7

KB4TA-G2-Module Wire Harness, ECU Connector Measure: Pin 9 (Ignition Power) to Pin 7 (ground)

KB4TA-G2-Module Wire Harness, ECU Connector Measure: Pin 6 (Battery Power) to Pin 4 (ground)

KB4TA-G2-Module Wire Harness, ECU Connector Measure: Pin 12 (Brake Light Power) to Pin 11 (ground)

1

10 DiagnosticTrouble-shootingFlowcharts

SectionF:TroubleshootingtheWheel-SpeedSensors

Turn off power to module, disconnect the 12-pin-connector.

If Dynamic WSS DTCs are present: Rotate the effected wheel and verify a minimum of 0,25 VAC sensor output @ 0,5 RPS across the wheel speed sensor pins. A properly positioned sensor can output more than 2,0 VAC @ 1 RPS. Verify/Inspect the following:

- Speed sensors property contact tone ring. - Condition and retention force of sensor clips. - Proper sensor lead routing and clamping. - Condition of tone ring mounting and teeth. - Proper number of tone ring teeth per sensed wheel. - Proper adjustment of wheel bearings. - Condition of foundation brakes.

If Static WSS DTCs are present: Using a volt/ohm meter to measure the connector pins of the faulted sensor, verify 950-1950 OHMS across sensor connector pins. Verify/Inspect the following: - No continuity from sensor connector pins

to ground. - Vbat no measured at either sensor connector pins. - Sensor/ECU wiring and connectors are not damaged or corroded. - Proper sensor lead routing and clamping.

If an issue with the wiring is found isolate the area needing repair by repeating the measurements at all connections. Make repairs as needed (replace wiring and/or ABS components). Reconnect all connectors to the module. Reset active DTCs by using any of the following methods: - Blink Code Diagnostics. - PC-diagnostic tools Then check for Dynamic WSS DTCs, see left column. Then rerun the power-up sequence.

Make repairs as needed (replace wiring and/or ABS components). Reconnect all connectors to the module. Reset active DTCs by using any of the following methods: - Blink Code Diagnostics. - PC-diagnostic tools Then rerun the power-up sequence.

Note: Both Static and Dynamic WSS DTCs may be present

KB4TA-G2-ModulePinning

SR SAR-

Right Sensor Additional Right Sensor

X1 12-pin ECU connection

SL SAL-

Left Sensor Additional Left Sensor

2

10 DiagnosticTrouble-shootingFlowcharts

SectionG:TroubleshootingtheModulatorRelayValve(BR9234)

Remote ABS-Modulator (M2) DTCs: Dynamic ABS Modulator DTCs: Verify/Inspect the following: Verify proper modulator-valve activation with brake pressure applied, at power-up (Chuff Test) and/or using diagnostic tool. The wiring to the modulator may be reversed. Check for: - dragging brakes - dry bearings - faulty return springs - parking brake system faults - restricted brake air lines - over adjusted slacks - out-of-round drums - damaged/loose tone rings Turn off the power to the module, disconnect the 12-pin ECU connector

Static ABS Modulator DTCs: Verify/Inspect the following: - 13 to 17 OHMS across Exhaust/ Common connector pins. - No continuity from modulator connector pins to ground. - Vbat is not measured at any modulator connector pins. - Modulator/ECU wiring and connectors are not damaged or corroded. If an issue with the wiring is found, isolate the area needing repair by repeating the measurements at all connections. Issue with modulator relay valve circuit identified?

NO

Make repairs as needed (replace wiring and/or ABS components). Reconnect all connectors to the module. Reset active DTCs by using any of the following methods: - Blink Code Diagnostics. - PC-diagnostic tools Then rerun the power-up sequence .

YES

1

4

12 11 10

9

8

7

3

2

Looking into KB4TA-G2-Module Pin 1 AUXI01 (Valve 3rd Modulator) Pin 12 AUXRET1 (Return Line 3rd Modulator)

Looking into Modulator Connector Pins Pin 1 AUXI01 (Release) Pin 2 AUXRET1 (Common)

11 LabelInformation

11 Labelinformation

The small identification label (1) is located on the top of the module. A further label (2) containing additional information is located under the removable cover of the KBTA-G2module.Ifthepartnumberlabelisnotreadable orispaintedover,theECUpartnumberandrevisioncan bereadusingadiagnostictool.Thenumberoftheinitial softwareloadedontheECUisalsoindicated.Themodule partnumber,andpin-outinformationisshownonthelabel beneaththeremovablecover.

(1)

(2)

ApplicationSoftwareIdentification CircuitBoardproductiondate Moduleproductiondate(year,week,day,serialnumber) P=EndOfLineteststand(A=Geitner&Austin,B=RESA)

SoftwareRevisionLevel Thecurrentsoftwarerevisionnumbercanbereadusinga diagnostictool. DocumentRevisionLevel Please visit www.knorr-bremseSfN.com to ensure you havethelatestversionofthisdocument.

12 FixingPoints

12 FixingPoints

DiagramshowingfixingpointsoftheKB4TA-G2Module

Clearanceforconnectorcover

5

13 ServiceReplacementoftheKB4TA-G2

13 ServiceReplacementoftheKB4TA-G2

The KBTA-G2 module is designed to be used as the service replacement part for the Knorr-Bremse KBTA, A&A18trailerABScontrollers. Formoreinformation,contactKnorr-Bremse.

testtrack)isavailable,itispossibletoroadtestthe ABSfunctionbymakinganabruptstopfromavehicle speedofabout0km/h.Thewheelsshouldnotenter aprolongedlockconditionandABSfunctionshould beaudible.Itistheresponsibilityofthetechnicianto performthistestinasafelocation.

13 .1RequiredChecksafterreplacement

1. 2. . . Beforeperformingleaktests,blockthewheels. Fullychargeairbrakesystemandverifyproperbrake adjustment. Makeseveraltrailerbrakeapplicationsandcheckfor promptapplicationandreleaseateachwheel. Checkthemodule,modulatorvalve(s)andallairhose fittingsforleakageusingasoapsolution ChecktheABSsolenoidbodywiththetrailerservice brakes fully applied. If leakage is excessive, more thanasingle1"bubblewithin1minute,replacethe module. Checktherelayexhaustportwiththetrailerservice brakesreleasedtobesurethatleakageislessthan a single 1" bubble within seconds. If excessive leakageisdetectedattherelayexhaustport,perform thefollowingtestbeforereplacingthemodule: ·Applythetrailerspringbrakes.Recheckforleakage around the relay exhaust port. If the exhaust port stops leaking, this indicates a leak between the emergency and service sides of the spring brake chamber.However,iftherelayexhaustportcontinues toleakexcessively,replacetheKBTA-G2module. Applypowerandmonitorthepower-upsequenceto verifypropersystemoperation. DeterminethecurrentABSconfigurationbyactivating blink code diagnostics or using a diagnostic tool. If necessary,resettheABSconfigurationandallowthe moduletoauto-configure.Seesection8.8.1 Calibrateandsetodometerparametersifnecessary using a diagnostic tool. Refer to the Odometer Functionsection8.6 Whereasafelocation(e.g.restrictedaccessareaor

13 .2 Wiring

AllconnectorleadsoftheKBTA-G2moduleharnessare weathersealedattheconnectorinterfaceandareclearly labelledforproperinstallation. Knorr-Bremse provides over-moulded versions of the KBTA-G2 wiring harness and recommends that the complete harness be replaced if corrosion or damage occurs. When troubleshooting ABS wiring, some general rules shouldbefollowedwhereapplicable. 1. Check all wiring and connectors to ensure they are secure and free from visible damage (e.g. cuts, abrasions,etc.). Check for evidence of wire chafing due to poor routing,orpoorsecuringofwires. Checkconnectorsforproperinsertionandlocking. Verify that the connector pins are properly greased withanon-conductiveelectricalgreasecompound. Connector terminals must not show signs of corrosionorexposuretotheenvironment. Never pierce wire insulation when checking for continuity. Do not deform individual pins or sockets during probingwithavolt/ohmmeter. It is strongly recommended to properly secure all wiringharnessandsensorleadsatleastevery5cm. Apply a moderate amount of non-conductive electrical grease to each connector pin before reconnecting.

2. . . 5. 6. 7. 8.

5. 6.

.

7.

8.

6

14 AdditionalDocumentation

14 AdditionalDocumentation

LinktootherKB4TA-G2-Documents: · Type-ApprovalStatement(RDW-00050205) · Informationdocument"AlternativeProcedureforTesting ofTrailer-Anti-LockBrakingSystems"(Y02866) · Information document "Safety Aspects of Complex ElectronicVehicleControlSystems"(Y02867) · *Installation Instructions "Wiring/Harness, Modular System"(Y011788)

*DownloadversionavailablefromtheKnorr-Bremsewebsite: www.knorr-bremseSfN.com

7

Systems for Commercial Vehicles

Knorr-Bremse Systeme für Nutzfahrzeuge GmbH Moosacher Str. 80 80809 Munich Germany Tel: +49 89 3547-0 Fax: +49 89 3547-2767

Knorr-Bremse GmbH Systeme für Nutzfahrzeuge 2340 Mödling Austria Tel: +43 2236 409-436 Knorr-Bremse Benelux B.V.B.A 2220 Heist-op-den-Berg Belgium Tel: +32 1525 7900 Knorr-Bremse GmbH Sistemas para Veículos Comerciais Brasil Ltda São Paulo - SP Cep : 04696-902 Brazil Tel: +55 11 5681 1104 Knorr-Bremse Far East Ltd. Truck Brake Systems Division Hong Kong China Tel: +852 2861 2669 Knorr-Bremse Brake Equipment (Shanghai) Co. Ltd. Truck Brake Systems Division Shanghai, 200131 China Tel: +86 21 5046-0776 Knorr-Bremse Systemy pro uzitkova vozidla, CR, s.r.o. 463 62 Hejnice Czech Republic Tel: +420 482 363-611 Knorr-Bremse Systèmes pour Véhicules Utilitaires France S.A. 14104 Lisieux Cedex France Tel: +33 2 3132 1200

Hasse & Wrede GmbH 12681 Berlin Germany Tel: +49 30 9392-3101 Knorr-Bremse Fékrendszerek Kft. 6000 Kecskemt Hungary Tel: +36 76 511 100 Knorr-Bremse Systems for Commercial Vehicles India Private Ltd. (Joint Venture of Knorr-Bremse Far East and Tata Autocomp Systems Ltd.) Pune 411 057 India Tel: +91 20 2293-9141-47 Knorr-Bremse Sistemi per Autoveicoli Commerciali S.p.A. 20043 Arcore Italy Tel: +39 039 6075-1 Knorr-Bremse Commercial Vehicle Systems Japan Ltd. Tokyo 171 0021 Japan Tel: +81 3 3971-8501 Knorr-Bremse Korea Ltd. Truck Brake Division Seoul 100-391 Korea Tel: +82 2 2273-1182 Knorr-Bremse Benelux B.V.B.A 3641 SK Mydrecht Netherlands Tel: +31 297 239-330

Knorr-Bremse Systeme für Nutzfahrzeuge GmbH 119017 Moscow Russian Federation Tel: +7 095 234-4995 Knorr-Bremse S.A. Pty. Ltd. 1610 Kempton Park South Africa Tel: +27 11 961-7800 Bost Ibérica, S.L. 20303 Irun Spain Tel: +34 902 100-569 Knorr-Bremse System for Tunga Fordon AB 200 11 Malmoe Sweden Tel: +46 40 680 5880 Knorr-Bremse Systeme für Nutzfahrzeuge GmbH 8303 Bassersdorf Switzerland Tel: +41 44 888 77-55 Knorr-Bremse Systeme für Nutzfahrzeuge GmbH 80040 Findikli - Istanbul Turkey Tel: +90 212 293-4742 Knorr-Bremse Systems for Commercial Vehicles Ltd. Bristol BS16 7FE United Kingdom Tel: +44 117 9846-100 Bendix Commercial Vehicle Systems LLC Elyria, OH 44035 USA Tel: +1 440 329-9100

www.knorr-bremse.com

Y026787-EN-0002006

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Knorr-Bremse Australia Pty. Ltd. Granville NSW 2142 Australia Tel: +61 1300 309-991

Knorr-Bremse Systeme für Nutzfahrzeuge GmbH 80809 Munich Germany Tel: +49 89 3547-0

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