KB Fault Codes and Trouble Shooting

Knorr-Bremse Systems for Commercial Vehicles India (P) Ltd. Pune, India

ERROR CODE

KNORR-BREMSE ABS6 ERROR CODES AND TROUBLE SHOOTING CHART

ERROR DESCRIPTION

PROVISIONAL CONFIDENTIAL

PROBABLE CAUSE (AREA OF FAULT)

TROUBLE SHOOTING TIPS

-

No Fault present. ABS is OK.

Bloc Block k 1 Bloc Block k2 1 1 No Error

POWER SUPPLY

16

1

Battery supply – temporary over voltage

battery charging circuit

1) Check battery voltage across pins 1 & 16 of X1 while cranking the engine 2) If voltage is more than 15V (12V system) / 28V (24V system), check & rectify Alternator Regulator, Else 3) If voltage is within 9V to 15V (12V system) / 19V to 28V (24V system), Clear Error and re-check ABS system.

16

2

Battery supply – temporary low voltage/low voltage during ABS control

battery

1) Check battery voltage across pins 1 & 16 of X1 while cranking the engine 2) If voltage is less than 9V (12V system) / 19V (24V system), re-charge or replace Battery, Else 3) If voltage is within 9V to 15V (12V system) / 19V to 28V (24V system), check 20A Fuse, Fuse box, Terminals and if error persists check & rectify Alternator Regulator.

16

3

Battery supply – broken wire

Connection from Battery to ECU

1) Check and replace 20A ABS Fuse, if blown. 2) Check and rectify battery supply wire from vehicle harness. 3) Check and rectify battery supply wire crimping at X1 battery connector.

16

4

Supply voltage – power line noise/temporary power line noise

Any Device connected in battery circuit

1) Clear error and re-check ABS system. 2) If error repeats, check battery supply wire routing, else 3) Check Alternator Regulator.

batt batter ery y cha charg rgin ing g cir circu cuit it

1) Check battery voltage across pins 1 & 3 of X1 while cranking the engine 2) If voltage is more than 15V (12V system) / 28V (24V system), check & rectify Alternator Regulator, Else 3) If voltage is within 9V to 15V (12V system) / 19V to 28V (24V system), Clear Error and re-check ABS system.

16

9

Igni Igniti tion on supp supply ly -- temp tempor orar ary y ove overv rvol olta tage ge

16

10

Igni Igniti tion on Supp Supply ly -- tem tempo pora rary ry low low vol volta tage ge

batt batter ery y cir circu cuit it

1) Check battery voltage across pins 1 & 3 of X1 while cranking the engine 2) If voltage is less than 9V (12V system) / 19V (24V system), re-charge or replace Battery, Else 3) If voltage is within 9V to 15V (12V system) / 19V to 28V (24V system), check 5A supply Fuse, Fuse box, Terminals and if error persists check & rectify Alternator Regulator.

16

11

Ignition Supply -- low voltage during ABS control

Battery Terminals

1) Check and rectify Battery condition & Battery Terminal conditions

70839733 xls ms office xls

SHEET 1 OF 11


ERROR CODE


ERROR DESCRIPTION




Block 1 Block 2

WHEEL SPEED SENSOR FRONT AXLE LEFT SIDE Gap between sensor & pole wheel is more than 0.6mm

1) Push the sensor till it touches pole wheel 2) Drive the vehicle at 10 to 15 KMPH speed and observe that warning lamp goes OFF. 3) If error repeats, check and replace Sensor clamping sleeve, else check & rectify pole wheel run-out or Wheel Bearing adjustment.

Missing speed sensor at drive off

Sensor

1) Push Sensor till it touches Pole wheel 2) Drive vehicle at 10 to 15 Kmph 3) If error repeats, check and replace Sensor / Pole wheel (Heavy runout or Contamination)

3

erratic signal from speed sensor

Sensor & pole wheel assembly

1) Check Pole wheel allignment and wheel bearing adjustment. 2) Check pole wheel for any teeth damage or contamination.

2

4

Unstable signal from speed sensor

Alignment of sensor or loose connection in wiring

1) check Pole wheel allignment and wheel bearing adjustment. 2) Replace Sensor 3) Check Sensor / Sensor extension cable routing.

2

5

loss of sensor speed signal

Sensor and Pole wheel

1) Check for Sensor Air gap too large. 2) Check for Pole wheel teeth 3) Replace Sensor

2

6

Sensor wires shorted or broken

Sensor or Sensor Extension Cable

1) Check resistance (1750 ± 175 Ohms) between pins 5 & 8 OF X2 Connector 2) If it is open, check and replace Sensor, else 3) Check and replace Sensor Extension Cable. 4) If error repeats, check for loose connection of terminal at X2 connector.

2

1

2

2

2

Air gap too big

WHEEL SPEED SENSOR FRONT AXLE RIGHT SIDE

3

1

Air gap too big

Gap between sensor & pole wheel is more than 0.6mm


3

2


Sensor



SHEET 2 OF 11


ERROR CODE


ERROR DESCRIPTION




Block 1 Block 2

WHEEL SPEED SENSOR FRONT AXLE RIGHT SIDE (CONTINUED. . .) 3

3




3

4




3

5




3

6



1) Check resistance (1750 ± 175 Ohms) between pins 11 & 14 of X2 Connector. 2) If it is open, check and replace Sensor, else 3) Check and replace Sensor Extension Cable. 4) If error repeats, check for loose connection of terminal at X2 connector.



WHEEL SPEED SENSOR REAR AXLE LEFT SIDE

4

1

Air gap too big

4

2


Sensor


4

3




4

4




4

5




4

6



1) Check resistance (1750 ± 175 Ohms) between pins 15 & 18 of X2 Connector. 2) If it is open, check and replace Sensor, else 3) Check and replace Sensor Extension Cable. 4) If error repeats, check for loose connection of terminal at X2 connector.


SHEET 3 OF 11


ERROR CODE


ERROR DESCRIPTION




Block 1 Block 2

WHEEL SPEED SENSOR REAR AXLE RIGHT SIDE

5

1

Air gap too big



5

2


Sensor


5

3




5

4




5

5





1) Check resistance (1750 ± 175 Ohms) between pins 10 & 11 of X1 Connector. 2) If it is open, check and replace Sensor, else 3) Check and replace Sensor Extension Cable. 4) If error repeats, check for loose connection of terminal at X1 connector and 2 pin Interface connector of both Frame Harness & Pig tail assemblies.

5

6


PRESSURE MODULATOR VALVE FRONT AXLE LEFT SIDE

8

8

1

2

Release Solenoid- shorted to battery

Release Solenoid shorted to ground


Modulator Valve or Modulator Valve Cable

1) Check resistance between Release and Hold pins of Modulator Valve and if found faulty, replace Modulator Valve. (Coil resistance between Hold and Release shall be 9.4 to 11.4 Ohms - For 12V system and 24 to 38 Ohms - For 24V system) 2) Check and replace Modulator Valve Cable, if wires are shorted. 3) Clear error and re-check ABS system.


1) Check resistance between Release and Ground pins of Modulator Valve and if found faulty, replace Modulator Valve. (Coil resistance between Ground and Release shall be 4.7 to 5.7 Ohms - For 12V system and 12 to 19 Ohms - For 24V system) 2) Check and replace Modulator Valve Cable, if wires are shorted. 3) Clear error and re-check ABS system.

SHEET 4 OF 11


ERROR CODE

ERROR DESCRIPTION





Block 1 Block 2

PRESSURE MODULATOR VALVE FRONT AXLE LEFT SIDE (CONTINUED . . .)

8

8

8

8

3

4

5

6

Release solenoid wire broken

Valve ground wire broken

Hold Solenoid- shorted to battery

Hold Solenoid shorted to ground


1) Check resistance between Release and Ground pins of Modulator Valve and if found faulty, replace Modulator Valve. (Coil resistance between Ground and Release shall be 4.7 to 5.7 Ohms - For 12V system and 12 to 19 Ohms - For 24V system) 2) Check and replace Modulator Valve Cable, if wire is open. 3) Clear error and re-check ABS system.


1) Check resistance between Hold / Release and Ground pins of Modulator Valve and if found faulty, replace Modulator Valve. (Coil resistance between Ground and Hold / Release shall be 4.7 to 5.7 Ohms - For 12V system and 12 to 19 Ohms - For 24V system) 2) Check and replace Modulator Valve Cable, if ground wire is open. 3) Clear error and re-check ABS system.




1) Check resistance between Hold and Ground pins of Modulator Valve and if found faulty, replace Modulator Valve. (Coil resistance between Ground and Hold shall be 4.7 to 5.7 Ohms - For 12V system and 12 to 19 Ohms - For 24V system) 2) Check and replace Modulator Valve Cable, if wires are shorted. 3) Clear error and re-check ABS system.

8

7

Hold solenoid wire broken


1) Check resistance between Hold and Ground pins of Modulator Valve and if found faulty, replace Modulator Valve. (Coil resistance between Ground and Hold shall be 4.7 to 5.7 Ohms - For 12V system and 12 to 19 Ohms - For 24V system) 2) Check and replace Modulator Valve Cable, if wire is open. 3) Clear error and re-check ABS system.

8

8

System configuration error

In general system

1) Check whether Modulator Valve is connected. 2) Check whether Modulator Valve Cable is cut (all wires) 3) Clear error and re-check ABS system. If error repeats, re-configure ECU.

70839733.xls.ms office.xls

SHEET 5 OF 11


ERROR CODE

ERROR DESCRIPTION





Block 1 Block 2

PRESSURE MODULATOR VALVE FRONT AXLE RIGHT SIDE

9

9

9

9

9

9

1

2

3

4

5

6




















SHEET 6 OF 11


ERROR CODE

ERROR DESCRIPTION





Block 1 Block 2

PRESSURE MODULATOR VALVE FRONT AXLE RIGHT SIDE (CONTINUED . . .)

9

7




9

8


In general system


PRESSURE MODULATOR VALVE REAR AXLE LEFT SIDE

10

10

10

10

1

2

3

4














SHEET 7 OF 11


ERROR CODE

ERROR DESCRIPTION





Block 1 Block 2

PRESSURE MODULATOR VALVE REAR AXLE LEFT SIDE (CONTINUED . . .)

10

10

5

6

Hold Sole noid- sho rted to ba ttery

Hold Sole noid shor ted to gro und

Modulator Valv e or Modula tor Valv e C able


Modulator Valv e or Modula tor Valv e C able


10

7




10

8


In general system


PRESSURE MODULATOR VALVE, VALVE COMMON GROUND 10

10

Shorted to battery

Frame Harness Assembly

Ch eck Frame h arnes s ass embly f or short betwee n any of the Modula tor v alve cable ground wire and any supply wire running aside.

10

11

Shorted to ground (not through ECU or internal valve defect).

Frame Harness Assembly

Ch eck Frame h arnes s ass embly f or short betwee n any of the Modula tor v alve cable ground wire and any vehicle ground.

PRESSURE MODULATOR VALVE REAR AXLE RIGHT SIDE

11

1





SHEET 8 OF 11


ERROR CODE

ERROR DESCRIPTION





Block 1 Block 2

PRESSURE MODULATOR VALVE REAR AXLE RIGHT SIDE (CONTINUED . . .)

11

11

11

11

11

11

2

3

4

5

6

7




















SHEET 9 OF 11


ERROR CODE

KNORR-BREMSE ABS6 ERROR CODES AND TROUBLE SHOOT ING CHART

ERROR DESCRIPTION




Block 1 Block 2

PRESSURE MODULATOR VALVE REAR AXLE RIGHT SIDE (CONTINUED . . .) 11

8


1) Check whether Modulator Valve is connected. Modulator Valve or Modulator Valve Cable, 2) Check whether Modulator Valve Cable is cut (all wires) or ECU Configuration 3) Clear error and re-check ABS system. If error repeats, re-configure ECU.

ECU INTERNAL FAILURES 15

1

Internal microprocessor fault

ECU failure

1) Clear error from memory and re-check ABS system 2) Replace ECU if this error repeats

15

2


ECU failure


15

3

ECU data error

ECU failure


15

4

ECU not programmable

ECU failure


15

5


ECU failure


15

6


ECU failure


15

7


ECU failure


15

9

Invalid configuration in ECU

ECU failure


15

10

Internal relay not switching

ECU failure


15

11

Internal Relay permanently switched on

ECU failure


15

15

ABS software not compatible with hardware

ECU system configuration

1) Chec k s ys tem in stallation (E.g.: 4S4M - All 4 sens ors an d 4 Mod ulators are connected) 2) Re-configure the ECU.

ENDURANCE BRAKING DEVICE (ENGINE EXHAUST BRAKE OR DRIVE LINE RETARDER) 17

1

Relay controlling endurance braking device shorted to battery

17

2

Relay controlling endurance braking device shorted to ground or broken wire


Auxilliary brake device (Engine Exhuast 1) Check wiring - Remove Relay and check shorting of Pin 17 of X1 connector to Brake or Retarder Brake, etc.) control relay Ignition supply (Pin 3 of X1 connector). If short, check and rectify wiring. and related wiring (Vehicle Harness and Pig 2) If wiring is O.K, replace Relay and re-check ABS system. tail harness) Auxilliary brake device (Engine Exhuast 1) Check wiring - Remove Relay and check shorting of Pin 17 of X1 connector to Brake or Retarder Brake, etc.) control relay ground connection (Pin 1 of X1 connector). If short, check and rectify wiring. and related wiring (Vehicle Harness and Pig 2) If wiring is O.K, replace Relay and re-check ABS system. tail harness)

SHEET 10 OF 11


ERROR CODE


ERROR DESCRIPTION




Block 1 Block 2

TYRE SIZE ALLIGNMENT 17

5

Tyre size out of range (Either on front or rear wheels)

Tyre

1) Check that correct tyre sizes are fitted 2) Check and ensure air pressure in all tyres are correct

WARNING LAMP 17

10

Warning lamp ground or warning lamp supply is either Vehicle Harness Assembly, Pig tail - shorted to battery assembly or Warning Lamp - broken wire

1) Check warning lamp wiring and ensure no shorting with battery or ground 2) Check warning lamp wiring is not open 3) Replace defective Warning Lamp

WHEEL SPEED SENSORS 17

12

Wheel speed sensor failure in previous 'Power On' cycle

To check and confirm Sensor and Pole wheels are f unctioning correctly.

17

13

Wheel speed sensors incorrectly wired (left to Frame Harness Assembly or Pig tail right) on font or rear axle harness assembly

1) Drive vehicle at 10 to 15 kmph, if Warning lamp goes off automatically, ABS system is O.K., else 2) Check Error memory and rectify Sensor / Pole wheel related fault that is present. 1) check and rectify wiring of X2 connector or X1 Connector (For Rear Right Sensor) based on the wiring layout

J1939 CAN DATA LINK 18

3

CAN-BUS OFF

Wiring

check Can-bus connections and terminating resistor

18

4

Time out or invalid data on ERC-1

Wiring or ECU

1) check Can-bus connections 2) Replace ECU and re-check ABS system.


SHEET 11 OF 11

KB Fault Codes and Trouble Shooting

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