tebs g2 - load sensing for s e r v i c e m a n u a l ... · electrical connection to the tebs g2...

C o m m e r c i a l V e h i c l e S y s t e m s

S e r v i c e M a n u a l

TEBS G2 - Load Sensing for Mechanical Suspensions

Disclaimer

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. 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. Any legal disputes arising from the use of this information shall be subject to German law.

Note: If service work is carried out on a vehicle as a result of information taken from this document, it is the responsibility of the workshop to ensure the vehicle is fully tested and in full functional order before the vehicle is returned into service. Knorr-Bremse accepts no liability for problems caused as a result of appropriate tests not being carried out.

This disclaimer is an English translation of a German text, which should be referred to for all legal purposes.

Disposal of Waste Equipment by Business Users in the European UnionThis symbol on the product, packaging or in user instructions, indicates that this product must not be disposed of with other general waste. Instead, it is your responsibility to dispose of the waste electrical and electronic parts of this product by handing them over to a company or organisation authorised for the recycling of waste electrical and electrical equipment. For more information about arrangements for waste equipment disposal please contact your Knorr-Bremse distributor or local Knorr-Bremse representative.

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TEBS G2 - Load Sensing for Mechanical Suspensions

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Note: The safety advice below is applicable to general service and diagnostic work on air braking systems and may not all be directly relevant to the activities and products described in this document.

Before and whilst working on or around air braking systems and devices, the following precautions should be observed in addition to any specific advice given in this document:

• Always wear safety glasses when working with air pressure.

• Never exceed manufacturer’s recommended air pressures.

• Never look into air jets or direct them at anyone.

• Never connect or disconnect a hose or line containing pressure; it may whip as air escapes.

• Never remove a device or pipe plug unless you are certain all system pressure has been depleted.

• Park the vehicle on a level surface, apply the parking brakes, and always chock the wheels as depleting vehicle air system pressure may cause the vehicle to roll.

• If work is being performed on the vehicle’s air braking system, or any auxiliary pressurised air systems, and if it is necessary to drain the air pressure from reservoirs, etc., keep clear of brake actuator push rods and levers since they may move as system pressure drops. Be aware that if the vehicle is equipped with an air dryer system, it can also contain air pressure along with its purge reservoir, if fitted, even after pressure has been drained from the other reservoirs.

• When working under or around the vehicle, and particularly when working in the engine compartment, the engine should be shut off and the ignition key removed. Where circumstances require that the engine be running, EXTREME CAUTION should be taken to prevent personal injury resulting from contact with moving, rotating, leaking, heated or electrically charged components. Additionally, it is advisable to place a clear sign on or near the steering wheel advising that there is work in progress on the vehicle.

• Examine all pipework for signs of kinks, dents, abrasion, drying out or overheating. Be aware that kinks in pipework may result in air pressure being trapped in the pipework and associated equipment. Replacement hardware, tubing, hose, fittings, etc. must be of equivalent size, type and strength as original equipment and be designed specifically for such applications and systems. Check the attachment of all pipework; it should be supported so that it cannot abrade or be subjected to excessive heat.

• Components with stripped threads or damaged/corroded parts should be replaced rather than repaired. Do not attempt repairs requiring machining or welding unless specifically stated and approved by the vehicle or component manufacturer.

• Never attempt to install, remove, disassemble or assemble a device until you have read and thoroughly understood the recommended procedures. Some units contain powerful springs and injury can result if not properly dismantled. Use only the correct tools and observe all precautions pertaining to use of those tools. Before removing any device note its position and the connections of all pipework so that the replacement/serviced device can be properly installed. Ensure that adequate support or assistance is provided for the removal/installation of heavy items.

• Use only genuine Knorr-Bremse replacement parts, components and kits.

• Prior to returning the vehicle to service, make certain all components and systems are leak free and restored to their proper operating condition.

Welding

To avoid damage to electronic components when carrying out electrical welding, the following precautions should be observed:

• In all cases, before starting any electrical welding, remove all connections from any electronic control units or modules, noting their position and the order in which they are removed.

• When re-inserting the electrical connectors (in reverse order) it is essential that they are fitted to their correct assigned position - if necessary this must be checked by PC Diagnostics.

S a f e t y A d v i c e

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T E B S G 2 - L o a d S e n s i n g f o r M e c h a n i c a l S u s p e n s i o n s

Contents

Page

1. Introduction ................................................................................................. 6

2. Load Sensing ............................................................................................... 6

3. Sensor Installation ........................................................................................ 7

4. Configuration and Adjustment .................................................................... 10

4.1 OE Installation with Knorr-Bremse BSD Parameter File ..............................................10

4.2 Manual Configuration with ECUtalk® for TEBS G2 ......................................................12

Annex A - Sensor Dimensions ............................................................................15

Annex B - Lever length relation to suspension deflection ....................................16

Annex C - Alternative mounting options .............................................................17

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1


I n t r o d u c t i o n

1. IntroductionFor mechanically suspended trailers, fitted with the Knorr-Bremse TEBS G2 system, a Knorr-Bremse Deflection Sensor Kit should also be fitted.

2. Load SensingThe load carried by the trailer‘s axle(s) is sensed by means of the Sensor Kit - part number K026919B90. This electro -mechanical device is a variable voltage transducer that constantly monitors suspension deflection.

The sensor is connected to the TEBS G2 brake module via Sensor Input (Sens_In) and requires a 5V power supply (Sens_Sup) and ground connection (Sens_Gnd), both of which are provided by the module.

Any load on the trailer results in a suspension deflection which is converted into a voltage and read by the ECU. Based on the respective load / voltage settings, the TEBS G2 brake module calculates the corresponding load for the purposes of determining the degree of brake pressure modulation required.

In all cases the difference in sensor output voltage between the unladen and laden conditions is recommended to be 1.0 V. This is achieved by correctly setting the sensor lever length. Note that lever lengths of less than 50 mm will result in an inaccurate load measurement. Furthermore, it must be ensured that the sensor lever length is greater than the maximum laden to unladen deflection dimension.

Fig.1 Load Sensing Plate

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S e n s o r A s s e m b l y

3. Sensor Installation

CAUTION - At the time of installation/commissioning, the trailer load must be at the minimum value, as specified on the trailer data plate.

Location on the trailer

The sensor shall be positioned in the centre of the axle; in the case of a bogie, as close to the centre of the bogie as practical. The axle connection linkage must be as vertical as practically possible.

Length of sensor operating lever

For OE fitment it is recommended that the lever length is calculated using the Knorr-Bremse Brake System Designer program (BSD). For retrofit, either BSD can be used or the manual method described below.

The axle connecting linkage must be connected to the sensor operating lever at the lever length determined either using BSD or from the graph fig. 3 (for full graph, see Annex B).

Note: Knorr-Bremse recommends using the longest lever length possible taking into account the suspension deflection.

Using Fig 3. (or for full graph,see Annex B)

1. Using known suspension deflection (unladen to

laden) of e.g. 25mm.

2. Read the corresponding lever length required

from the graph - in this case 84 mm.

Fig.3: Section of Lever Length Deflection Sensor chart (Annex B)

Sensor operating leverRubber link

Axle connection linkage

Lever length

Fig.2: Typical positioning of sensor installation

1)

2)

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Installation on the trailer

The sensor must be installed so that the mounting holes are horizontal (see fig.4).

The sensor operating lever must be fitted in the correct orientation to ensure a voltage increase as load increases. There are four different mounting orientations of the sensor body, sensor operating lever, and axle conection linkage that will achieve this - see figure 4 and Annex C, noting the direction of the steel ‘lugs’ relative to the axle connection linkage.

Fig.4: Typical sensor arrangement

Assembly and connecting procedure:

1) Loosely fit the clamp to the sensor using the two clamp bolts provided (arrowed in fig. 5), the bolt threads should have a good quality, propriety thread-lock applied.

2) Assemble the sensor operating lever to the clamp, and locate the rubber link over the vertical axle connection linkage.

3) Move the sensor operating lever to give exactly the required lever length.

4) Tighten the clamp bolts.

Fig.5: Mounted deflection sensor kit

Note: Knorr-Bremse recommends to have vertical axle connection linkage not shorter than 20 cm.

Sensor operating leverRubber link

Axle connection linkage

Lever length

Mounting holes

Lugs

Note: The lever length is measured from the central pivot point of the sensor operating lever to the fixing point of the connecting rod (see fig. 4).

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Electrical connection to the TEBS G2 brake module

Connect the extension cable (K002277 or K002278; 3 m or 9 m respectively) directly to the sensor by means of a bayonet connector. The cable is then connected to the InOut connector of the TEBS G2 brake module by using the pins defined (fig.6).

Fig.6: Pinning of the sensor

Fig.7: Pinning of the TEBS G2 brake module

Pin 1Pin 1

Pin No. InOut Connector

SignalCable Colour

Pin No.Deflection Sensor

4 SENS_Sup Black 1

5 SENS_IN1 Yellow 3

6 SENS_GND White 2

Pin No. Signal

1 AUXI0 1

2 AUXI0 2

3 AUXI0 3

4 SENS_Sup (Supply ext. sensor (5 V))

Tristate 1

5 SENS_IN1 (Input ext. sensor Tristate 2)

6 SENS_GND (GND ext. sensor)

7 Stop Lamp 24 V

8 Stop Lamp GND

9 5 V-CAN-L

10 5 V-CAN-H

11 AUXI0 1/2 RET

12 AUXI0 3 RET

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C o n f i g u r a t i o n a n d A d j u s t m e n t

Configuration with ECUtalk® for TEBS G2

For configuration and adjustment, the Knorr-Bremse ECUtalk® TEBS G2 diagnostic tool is required. Software download, installation manual and user manual can be found in the Internet (http://www.knorr-bremseCVS.com).

4.1. OE installation with Knorr-Bremse BSD parameter file

This chapter is for OE installation of the deflection sensor kit where a configuration file (.dpv file) has been prepared using Knorr-Bremse BSD.

Turn the ignition on.

Start the ECUtalk® TEBS G2 diagnostic tool and make sure the configuration window is active.

Follow steps 1 – 3 below to load the BSD parameter file (.dpv) into the TEBS G2 brake module.

4. Configuration and Adjustment

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2

Fig.8: Configuration window

1. Open dialogue

2. Choose parameter file and click on “Open”

3. After defining all necessary parameters save the parameter file to the TEBS G2 brake module (ECU)

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Adjustment of the sensor signal voltage

Start “System check”

Read “LS1 voltage”.

If the LS1 voltage deviates from 1.0 V then adjust it as follows:

1) Loosen the rubber link clamp screw.

2) Move the rubber link up or down.

3) Tighten the rubber link clamp screw.

Fig.9: Adjusting sensor signal LS1 voltage

Rubber link clamp screw

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4



1. For Load sensing type, select “External load sensor LS1” .

2. For External load sensor type, select “KB Deflection Sensor”.

3. Navigate with “Next” button to AUXIO settings.

Setup load sensing type TEBS G2

4.2. Manual configuration with ECUtalk® for TEBS G2

This chapter shows step by step how to manually configure the deflection sensor kit. The following example uses data found in section 3 above, namely suspension deflection: 25 mm; Lever length: 84 mm; Voltage difference unladen to laden, dUs = 1.0 V

Start the ECUtalk® diagnostic tool and make sure the configuration window is active.

Start configuration change

Navigate with “Next” button to load sensing configuration

1

2

3

Fig.10: Load sensing configuration window

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4. For SENS_IN1 under Type, select “Input Analogue”.

5. For SENS_IN1 under Function name, select “LS1”.

6. Finish configuration with “OK”.

7. Save the configuration to the TEBS G2 brake module (ECU).

4

6

5

Fig.11: AUX IO settings window

Read sensor signal voltage

Start “System check”

Read LS1 voltage and note this for use in configuration. It must be in the range of 1.0 V to 2.0 V. If this is not the case then the operating sensor lever needs adjusting as follows:

1) Loosen the rubber link clamp screw.

2) Move the rubber link up or down.

3) Tighten the rubber link clamp screw.

Fig.12: Read sensor signal voltage settings window. NOTE: Scale is coloured red because the Unladen and Laden voltages are yet to be set.

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8. For “LS1 voltage unladen [V]” enter value (for example 1.50 V).

9. For “LS1 voltage laden [V]” enter value. This is the unladen voltage plus ΔSensorsignal dUs (in this example 2.50 V).

10. For “Spring deflection [mm]” enter value (for example 25 mm).

11. For “Sensor lever length [mm]” enter value

(for example 84.00 mm).

12. Finish configuration with “OK” button.

13. Save the configuration to the TEBS G2 brake module (ECU).

Configuration of unladen and laden threshold

Make sure the configuration window is active.

Start configuration change

Navigate with “Next” button to load sensing configuration

78

910

11

Fig.13: Load sensing configuration window II

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ANNEX A - Sensor Dimensions (mm)

Fig.14: Sensor dimensions

12

19

83

45

3

6.5

68

50

100

57.5

50

min

. ass

embl

y ho

le

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ANNEX B - Lever length relation to suspension deflection

Fig.15: Graph of deflection to lever length

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ANNEX C - Alternative mounting options

Fig.16: Sensor mounting options

Installation with mounting holes oriented upwards -

lugs point towards axle connection linkage.

Installation with mounting holes oriented downwards -

lugs point away from axle connection linkage.

‘Lugs’‘Lugs’

‘Lugs’


Knorr-Bremse Systeme für Nutzfahrzeuge GmbH Moosacher Straße 80 80809 Munich Germany Tel: +49 89 3547-0 Fax: +49 89 3547-2767www.knorr-bremseCVS.com

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A m e r i c a

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A s i a – A u s t r a l i a

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Austria Knorr-Bremse GmbHSysteme für NutzfahrzeugeMödling Tel: +43 2236 409-436Fax: +43 2236 409-434

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tebs g2 - load sensing for s e r v i c e m a n u a l ... · electrical connection to the tebs g2...

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