kb fault codes and trouble shooting

8/4/2019 KB Fault Codes and Trouble Shooting

1/11

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

Pune, IndiaKNORR-BREMSE ABS6 ERROR CODES AND TROUBLE SHOOTING CHART PROVISIONAL

CONFIDENTIAL

ERROR DESCRIPTION PROBABLE CAUSE (AREA OF FAULT) TROUBLE SHOOTING TIPS

Block 1 Block 2

1 1 No Error - No Fault present. ABS is OK.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 2Battery supply temporary low voltage/low

voltage during ABS controlbattery


2) If voltage is less than 9V (12V system) / 19V (24V system), re-charge or replaceBattery, 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 4Supply 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, else3) Check Alternator Regulator.

16 9 Ignition supply -- temporary overvoltage battery charging circuit


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 10 Ignition Supply -- temporary low voltage battery circuit


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 5Asupply Fuse, Fuse box, Terminals and if error persists check & rectify Alternator

Regulator.

16 11Ignition Supply -- low voltage during ABS

controlBattery Terminals 1) Check and rectify Battery condition & Battery Terminal conditions

ERROR CODE

70839733.xls.ms_office.xls SHEET 1 OF 11


2/11



CONFIDENTIAL


Block 1 Block 2

ERROR CODE

WHEEL SPEED SENSOR FRONT AXLE LEFT SIDE

2 1 Air gap too bigGap 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.

2 2 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)

2 3 erratic signal from speed sensor Sensor & pole wheel assembly1) Check Pole wheel allignment and wheel bearing adjustment.

2) Check pole wheel for any teeth damage or contamination.

2 4 Unstable signal from speed sensorAlignment 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.

WHEEL SPEED SENSOR FRONT AXLE RIGHT SIDE


than 0.6mm



OFF.

3) If error repeats, check and replace Sensor clamping sleeve, else check & rectifypole wheel run-out or Wheel Bearing adjustment.





Contamination)



3/11



CONFIDENTIAL


Block 1 Block 2

ERROR CODE

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




wiring


2) Replace Sensor





3) Replace Sensor


1) Check resistance (1750 175 Ohms) between pins 11 & 14 of X2 Connector.2) If it is open, check and replace Sensor, else



WHEEL SPEED SENSOR REAR AXLE LEFT SIDE


than 0.6mm



OFF.







Contamination)




wiring


2) Replace Sensor





3) Replace Sensor


1) Check resistance (1750 175 Ohms) between pins 15 & 18 of X2 Connector.

2) If it is open, check and replace Sensor, else





4/11



CONFIDENTIAL


Block 1 Block 2

ERROR CODE

WHEEL SPEED SENSOR REAR AXLE RIGHT SIDE


than 0.6mm



OFF.







Contamination)




wiring


2) Replace Sensor





3) Replace Sensor


1) Check resistance (1750 175 Ohms) between pins 10 & 11 of X1 Connector.2) If it is open, check and replace Sensor, else


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.

PRESSURE MODULATOR VALVE FRONT AXLE LEFT SIDE

8 1 Release Solenoid- shorted to battery 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.

8 2 Release Solenoid shorted to ground Modulator Valve or Modulator Valve Cable

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.




5/11



CONFIDENTIAL


Block 1 Block 2

ERROR CODE

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

8 3 Release solenoid wire broken Modulator Valve or Modulator Valve Cable




system)

2) Check and replace Modulator Valve Cable, if wire is open.


8 4 Valve ground wire broken Modulator Valve or Modulator Valve Cable

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.


8 5 Hold Solenoid- shorted to battery Modulator Valve or Modulator Valve Cable






8 6 Hold Solenoid shorted to ground Modulator Valve or Modulator Valve Cable

1) Check resistance between Hold and Ground pins of Modulator Valve and iffound faulty, replace Modulator Valve. (Coil resistance between Ground and Hold




8 7 Hold solenoid wire broken Modulator Valve or Modulator Valve Cable

1) Check resistance between Hold and Ground pins of Modulator Valve and if

found faulty, replace Modulator Valve. (Coil resistance between Ground and Hold




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.



6/11



CONFIDENTIAL


Block 1 Block 2

ERROR CODE

PRESSURE MODULATOR VALVE FRONT AXLE RIGHT SIDE











system)2) Check and replace Modulator Valve Cable, if wires are shorted.






system)





and if found faulty, replace Modulator Valve. (Coil resistance between Ground andHold / 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.
















7/11



CONFIDENTIAL


Block 1 Block 2

ERROR CODE

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











PRESSURE MODULATOR VALVE REAR AXLE LEFT SIDE











system)







system)







24V system)





8/11



CONFIDENTIAL


Block 1 Block 2

ERROR CODE

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











2) Check and replace Modulator Valve Cable, if wires are shorted.3) Clear error and re-check ABS system.











PRESSURE MODULATOR VALVE, VALVE COMMON GROUND

10 10 Shorted to battery Frame Harness AssemblyCheck Frame harness assembly for short between any of the Modulator valve

cable ground wire and any supply wire running aside.

10 11Shorted to ground (not through ECU or

internal valve defect).Frame Harness Assembly

Check Frame harness assembly for short between any of the Modulator valve

cable ground wire and any vehicle ground.

PRESSURE MODULATOR VALVE REAR AXLE RIGHT SIDE









9/11



CONFIDENTIAL


Block 1 Block 2

ERROR CODE

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





system)







system)2) Check and replace Modulator Valve Cable, if wire is open.






24V system)




1) Check resistance between Release and Hold pins of Modulator Valve and iffound faulty, replace Modulator Valve. (Coil resistance between Hold and Release


















10/11



CONFIDENTIAL


Block 1 Block 2

ERROR CODE

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

11 8 System configuration errorModulator Valve or Modulator Valve Cable,

or ECU Configuration




ECU INTERNAL FAILURES

15 1 Internal microprocessor fault ECU failure1) Clear error from memory and re-check ABS system

2) Replace ECU if this error repeats



15 3 ECU data error ECU failure 1) Clear error from memory and re-check ABS system2) Replace ECU if this error repeats

15 4 ECU not programmable ECU failure1) Clear error from memory and re-check ABS system








15 9 Invalid configuration in ECU ECU failure1) Clear error from memory and re-check ABS system


15 10 Internal relay not switching ECU failure1) Clear error from memory and re-check ABS system


15 11 Internal Relay permanently switched on ECU failure1) Clear error from memory and re-check ABS system


15 15 ABS software not compatible with hardware ECU system configuration

1) Check system installation (E.g.: 4S4M - All 4 sensors and 4 Modulators are

connected)

2) Re-configure the ECU.

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

17 1Relay controlling endurance braking device

shorted to battery

Auxilliary brake device (Engine Exhuast

Brake or Retarder Brake, etc.) control relay

and related wiring (Vehicle Harness and Pig

tail harness)

1) Check wiring - Remove Relay and check shorting of Pin 17 of X1 connector to

Ignition supply (Pin 3 of X1 connector). If short, check and rectify wiring.

2) If wiring is O.K, replace Relay and re-check ABS system.

17 2Relay controlling endurance braking device

shorted to ground or broken wire

Auxilliary brake device (Engine Exhuast

Brake or Retarder Brake, etc.) control relay

and related wiring (Vehicle Harness and Pig

tail harness)

1) Check wiring - Remove Relay and check shorting of Pin 17 of X1 connector to

ground connection (Pin 1 of X1 connector). If short, check and rectify wiring.

2) If wiring is O.K, replace Relay and re-check ABS system.



11/11



CONFIDENTIAL


Block 1 Block 2

ERROR CODE

TYRE SIZE ALLIGNMENT17 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

- shorted to battery

- broken wire

Vehicle Harness Assembly, Pig tail

assembly or Warning Lamp

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 12Wheel speed sensor failure in previous

'Power On' cycle

To check and confirm Sensor and Pole

wheels are functioning correctly.

1) Drive vehicle at 10 to 15 kmph, if Warning lamp goes off automatically, ABSsystem is O.K., else

2) Check Error memory and rectify Sensor / Pole wheel related fault that is present.

17 13Wheel speed sensors incorrectly wired (left to

right) on font or rear axle

Frame Harness Assembly or Pig tail

harness assembly

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 ECU1) check Can-bus connections

2) Replace ECU and re-check ABS system.


kb fault codes and trouble shooting

Documents