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Knorr-Bremse TEBS KB4TA-D Service Manual

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Doc. No. Y364866 (EN - Rev. 000)
March 2020
SERVICE MANUAL
TEBS KB4TA-D

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Summary of Contents for Knorr-Bremse TEBS KB4TA-D

  • Page 1 Doc. No. Y364866 (EN - Rev. 000) March 2020 SERVICE MANUAL TEBS KB4TA-D...
  • Page 2 The information contained in this document is intended for the exclusive use of trained persons within the commercial vehicle industry, and must not be passed on to any third party. All recommendations regarding products and their servicing or usage are with reference to Knorr-Bremse products and should not be considered applicable to products from other manufacturers.

  • Page 3: Table Of Contents

    » Service Manual - KB4TA-D Contents Safety and Environment Guidelines ..........6 1 KB4TA-D System Overview .
  • Page 4 » Y364866 – (EN - REV. 000) | March 2020 Contents 5 KB4TA -D System Diagnostics And Configuration ........33 5.1 Description .
  • Page 5 » Service Manual - KB4TA-D Contents...

  • Page 6: Safety And Environment Guidelines

    The use of impact screwdrivers or impact wrenches in conjunction with Knorr-Bremse service tools for air disc brakes is not permitted. The service tools are not designed for such use. It is likely that the tools or the vehicle will be damaged and there is a serious risk of injury – see Caution above.
  • Page 7 For more information about arrangements for waste equipment disposal please contact your Knorr-Bremse distributor or local Knorr-Bremse representative.
  • Page 8 » Y364866 – (EN - REV. 000) | March 2020...

  • Page 9: Kb4Ta-D System Overview

    KB4TA-D System Overview 1.1 Function The Basic Knorr-Bremse KB4TA-D brake system comprises a KB4TA-D ECU ES1220 plus two ABS Modulator Valves. It is designed for air braked trailers with mechanical or air suspension. KB4TA D is designed to work in trailer systems powered via ISO 7638 but the addition of ISO 1185 stop lamp powering is included as standard as a safety feature so, in the event that there is no ISO 7638 powering, the ABS function is maintained.
  • Page 10 » Y364866 – (EN - REV. 000) | March 2020 KB4TA-D System Overview BOM list for Fig. 2 Description Part No. TABS ECU K068353N00 TABS Relay Modulator Valve K019290TY TABS Relay Modulator Valve Cable K159651N49 Power Supply Cable K159650N49 TABS 3m Extension Cable K159652N49 Park and Shunt Valve K015380N00...
  • Page 11 » Service Manual - KB4TA-D KB4TA-D System Overview BOM list for Fig. 3 Description Part No. TABS ECU K068353N00 TABS Relay Modulator Valve K019290TY TABS Relay Modulator Valve Cable K159651N49 Power Supply Cable K159650N49 TABS 3m Extension Cable K159652N49 Park and Shunt Valve K015380N00 Palm Coupling Brake-Yellow K000954...

  • Page 12: System Description

    » Y364866 – (EN - REV. 000) | March 2020 KB4TA-D System Overview BOM list for TABS Kit Description Part No. TABS Kit K188808 TABS Relay Modulator Valve Cable K159651N49 Power Supply Cable K159650N49 TABS 3m Extension Cable K159652N49 Park and Shunt Valve K015380N00 Palm Coupling Brake-Yellow K000954...

  • Page 13: Abs Operation

    » Service Manual - KB4TA-D KB4TA-D System Overview 1.2.5 ABS Operation KB4TA-D provides basic service braking in addition to the ABS function. The KB4TA D ECU is used to prevent the wheels of a trailer locking whilst braking. The friction between the tyre and the road is created by relative movement between their two surfaces, i.e. difference in surface speeds of road and tyre and is referred to as ‚slip‘...

  • Page 14: Service Interval

    1.2.12 Auxiliary Configuration ADL is a programming language, developed and patented by Knorr-Bremse, that enables the expansion of the functionality of the TEBS Brake Module without having to update the basic hard coded software; this enables significant flexibility. By using an ADL program it is possible to adapt the individual or combined functionality of any combination of configured AUXIO functions as well as update the content of the J1939 CAN communications to realise specific customer objectives.

  • Page 15: Error Detection

    » Service Manual - KB4TA-D ERROR DETECTION The KB4TA D ECU contains self-testing diagnostic circuitry that monitors the ABS components and wiring. When the ECU senses an erroneous system condition, it activates the trailer ABS warning lamp in the towing vehicle (and headboard if installed), disables all or part of the ABS functions and stores the error in memory as a Diagnostic Trouble Code (DTC).

  • Page 16: Kb4Ta-D Abs Ecu

    This can be activated via the stop lamp supply by depressing the foot brake valve in the towing vehicle. For more information see PD-403-390, Document No. Y250910. The KB4TA D ECU with external ABS modulators is designed to be used as the service replacement part for the Knorr-Bremse KB3TA, A9 & A18 trailer ABS modules.

  • Page 17: Electrical Connections

    3.2 Electrical Connections The Knorr-Bremse KB4TA D ECU connectors use a 12-pin Deutsch DT series connector (Code A) for ISO 7638 power supply, diag- nostics and auxiliary I/Os such as ISO 1185 stop lamp power supply, additional third modulator and one additional Input/Output.

  • Page 18: Stop Lamp Power

    Diagnostic Connector KB4TA D harnesses provide a 4-pin 5 Volt J1939 CAN diagnostic connection for a diagnostic tool. Remote diagnostic cables are available from Knorr-Bremse to provide a J1939 diagnostic port at the side of the trailer. X1-2 = Diagnostics ground...

  • Page 19: Stop Lamp Power

    » Service Manual - KB4TA-D KB4TA-D ABS ECU 3.2.3 Stop Lamp Power KB4TA D offers two independent possibilities for diagnostics: • Blink Code diagnostics (ABS warning lamp in the cab and/or headboard warning lamp). This function is integrated in ECU. •...

  • Page 20: Label Information

    » Y364866 – (EN - REV. 000) | March 2020 KB4TA-D ABS ECU Fit the KB4TA D ECU to the trailer either: - on a cross member in the centre of the rear axle bogie or - on the trailer headboard. If required fit the additional axle modulator, normally on a cross member in the centre of the front axle bogie.

  • Page 21: Kb4Ta-D System Components

    4.1 Functions The Knorr-Bremse KB4TA and KB4TA D brake systems are comprised of the KB4TA module/ECU plus pneumatic components, such as the Park/Shunt Valve and Load Sensing Valve, which allow complete control of the service and parking brakes on the trailer.

  • Page 22: Park / Shunt Valve

    » Y364866 – (EN - REV. 000) | March 2020 KB4TA-D System Components 4.1.2 Park / Shunt Valve Valve for trailers with air suspension Features: • Incorporates emergency brake function • Priority to service braking system during charging • Spring brakes held off during energy consumption test •...
  • Page 23 » Service Manual - KB4TA-D KB4TA-D System Components Technical Data: • Maximum operation pressure: 10 bar • Operating temperature range: -40 °C to +75 °C Connections to ECU K140786: • 6.2 (Common (GND)) to X2-9 and X2-10 connections for 2M systems and X1-12 Connection for the 3rd modulator in 3M systems •...

  • Page 24: Wheel Speed Sensor

    » Y364866 – (EN - REV. 000) | March 2020 KB4TA-D System Components 4.1.4 Wheel Speed Sensor 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 of the sensing ring.
  • Page 25 » Service Manual - KB4TA-D KB4TA-D System Components 5. Applyamoderateamountofdielectricnon-conductive grease to both the sensor connector and harness connector. 6. Engage the connectors, and push together until the lock tab snaps into place. 7. The sensor cable and extension cable should be fixed on either side of the connection. 8.

  • Page 26: Tabs Bracket

    » Y364866 – (EN - REV. 000) | March 2020 KB4TA-D System Components 4.1.5 TABS Bracket ABS bracket can change the installation mode of ABS products from split type to integrated type, our ABS ECU and ABS relay valves are fixed by three bolts each, ECU is installed above the bracket horizontal, and two ABS relay valves are fixed below the bracket, when installing on the trailer, only three bolts on the back side of the bracket need to be fixed.

  • Page 27: Cables For Kb4Ta-D

    » Service Manual - KB4TA-D KB4TA-D System Components 4.1.6 Cables for KB4TA-D Cables are used in trailer ABS systems to: • provide electrical power to the components in the system. • communicate signals to the ECU from sensors monitoring trailer characteristics.
  • Page 28 All cables are environmentally sealed at the connector interface and are clearly labelled for correct installation. Because of the moulded design of the KB4TA module/KB4TA D ECU wiring harnesses and individual cables, Knorr-Bremse recom- mends that a complete harness or cable be replaced if damage or corrosion occurs.
  • Page 29 » Service Manual - KB4TA-D KB4TA-D System Components Pin Configuration: ISO 7638 Plug (24 V) (24 V) Pin 1 Valve supply voltage Pin 2 black ECU supply voltage Pin 3 yellow ECU ground Pin 4 brown Valve ground Pin 5 white Warning lamp Pin 6...
  • Page 30 » Y364866 – (EN - REV. 000) | March 2020 KB4TA-D System Components Split Power supply cable(with fuse integrated)with ISO 7638 Socket Cable length Part No. Type No. Comments L1: 12 K193521 Split Power supply cable L2: 1 Power supply cable (for drawbar and centre-axle trailers) with ISO 7638 Socket Cable length Part No.
  • Page 31 » Service Manual - KB4TA-D KB4TA-D System Components Split power supply cable for tank safety function (with fuse integrated) Cable length Part No. Type No. Comments L1: 12 Split power supply cable for AUX1 used K191977 L2: 1 (with fuse integrated) L3: 5 Power Supply Wiring Harness (ISO 7638 and ISO 1185) with external Warning Lamp Cable length...
  • Page 32 » Y364866 – (EN - REV. 000) | March 2020 KB4TA-D System Components Diagnostic cable for 5V CAN diagnostics Cable length Part No. Type No. Comments L1: 0.4 K119198 L2: 0.3 Connecting cable for ABS modulators 1&2 Cable length Part No. Type No.

  • Page 33: Kb4Ta -D System Diagnostics And Configuration

    Pin 5 of the ISO 7638 connector. 5.2.2 Diagnostic Program ECUtalk® ECUtalk® is a software platform produced specifically to assist the user in the configuration, fault diagnosis and system check of KB4TA/KB4TA D and other Knorr-Bremse trailer electronically controlled products. Its functionality includes: •...

  • Page 34: Adl (Auxiliary Design Language) Configuration

    If a modified functionality is desired for an auxiliary function, the user now has the possibility of reaching a timely implementation through a Knorr-Bremse representative. Knorr-Bremse has set up a database in which all enquiries and their solutions are stored and this makes it possible to react very quickly, since the majority of the function variants are covered.
  • Page 35 » Service Manual - KB4TA-D KB4TA-D System Diagnostics And Configuration Fig. 22 ADL Safely Function Configuration Step 2 Step 3 The download of the ADL-file is done within the “Other functions tab”. If a new ADL function is needed, the last one must be clear. (Use the Clear ADL bottom to clear ADL program).

  • Page 36: Diagnostic Components/Tools

    Diagnostic Set (UDIF1) II39809F EZ1031 (9-pin sub-D-plug and 9-pin sub D-socket) optional for USB-connection to PC (not Connecting cable (DB9) supply by Knorr-Bremse) “ECUtalk® KB4TA” Software - download Diagnostic software from: www.Knorr-BremseCVS.com Connects to trailer Diagnostic Socket or Adaptor Cable Fig.

  • Page 37: Blink Code Diagnostics

    » Service Manual - KB4TA-D KB4TA-D System Diagnostics And Configuration 5.3.2 Blink Code Diagnostics The KB4TA module/KB4TA-D ECU provides diagnostic and configuration functions through blink code diagnostics. This means that the technician, even without diagnostic tools, can read a series of blinks of the ABS warning lamp(s) (in the cab of the towing vehicle and/or on the trailer headboard) to diagnose the trouble codes being generated.

  • Page 38: Blink Code Label

    » Y364866 – (EN - REV. 000) | March 2020 KB4TA-D System Diagnostics And Configuration 5.3.4 Blink Code Label ABS sign attached to the vehicle showing the DTC 1st Blink Code 2nd Blink Code Code Location Code Description No faults present Sensor SL Wheel speed sensor air gap too big Trailer-ABS KB4TA...

  • Page 39: Diagnostic Trouble Codes - Blink Code Quick Reference

    » Service Manual - KB4TA-D KB4TA-D System Diagnostics And Configuration 5.3.5 Diagnostic Trouble Codes — Blink Code Quick Reference Blink Code Blink Code Information on action required Code Location Code Location No faults System fully operational - no faults detected Sensor SL Wheel speed sensor air gap is too larger Go to Chart 5...

  • Page 40: Diagnostic Troubleshooting Flow Charts

    » Y364866 – (EN - REV. 000) | March 2020 KB4TA-D System Diagnostics And Configuration 5.3.6 Diagnostic Troubleshooting Flow Charts Diagnostic trouble code information can be retrieved from the KB4TA module/KB4TA D ECU by using blink code diagnostics or the PC diagnostic tool ECUtalk®.
  • Page 41 » Service Manual - KB4TA-D KB4TA-D System Diagnostics And Configuration Chart 2 Power-up Sequence − Trailer-mounted ABS Warning Lamp Apply ignition or stop lamp power and observe ABS Warning Lamp at Power up. the trailer-mounted ABS warning lamp. The trailer-mounted ABS warning lamp should Troubleshoot the trailer-mounted ABS Warning immediately illuminate when the power is Lamp circuitry.
  • Page 42 » Y364866 – (EN - REV. 000) | March 2020 KB4TA-D System Diagnostics And Configuration Chart 3 Troubleshooting the Trailer-mounted ABS Warning Lamp Circuitry Trailer-mounted ABS warning lamp did not Trailer-mounted ABS warning lamp remains “ON” illuminate during the power-up sequence. during the power-up sequence.
  • Page 43 » Service Manual - KB4TA-D KB4TA-D System Diagnostics And Configuration Chart 4 Troubleshooting the ISO 7638 (and ISO 1185 if connected) Power Supply Check for high resistance (corrosion, wire/con- nector damage or improper termination of the Turn off power to module, disconnect the power line) resulting in high voltage drop across 12-pin-connector.
  • Page 44 » Y364866 – (EN - REV. 000) | March 2020 KB4TA-D System Diagnostics And Configuration Chart 5 Troubleshooting the Wheel Speed Sensors Turn off power to module. If static WSS DTC(s) is present: * If Dynamic WSS DTC(s) is present: * Using a volt/ohm meter to measure the connec- Rotate the effected wheel and verify a minimum tor pins of the problem sensor, verify 950-1950...
  • Page 45 » Service Manual - KB4TA-D KB4TA-D System Diagnostics And Configuration Chart 6 Troubleshooting the Modulator Relay Valve (BR9234, K019290 and K019299) Dynamic ABS Modulator DTCs: External ABS Modulator DTCs: Turn off the power to the module, disconnect Verify/Inspect the following: the 12- pin ECU connector Verify proper modulator valve activation with brake pressure applied, at power-up (‘Chuff Test’)
  • Page 46 » Y364866 – (EN - REV. 000) | March 2020 Notes...
  • Page 47 » Service Manual - KB4TA-D Notes...
  • Page 48 The information contained herein is subject to alteration without notice and therefore may not be the latest release. Please check our website www.knorr-bremseCVS.com for the latest update or contact your local Knorr-Bremse representative. The figurative mark “K” and the trademarks KNORR and KNORR-BREMSE are registered in the name of Knorr-Bremse AG. Additional terms and conditions apply; please refer to our website knorr-bremseCVS.com for full Disclaimer.

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