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Knorr Diagram PDF
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Iveco
MAN
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Renault Trucks
Scania
Volvo
Ne
12
w
fo r 20
2011/
System Diagnostics
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.
This disclaimer is an English translation of a German text, which should be referred to for all legal purposes.
Any legal disputes arising from the use of this information shall be subject to German law.
EBS Product Catalogue
Contents
Glossary of Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Introduction to Electronic Braking Systems (EBS) . . . . . . . . . . . . . . . . . . . . . 5
NEO System Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
NEO | green . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
NEO | orange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
NEO | blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
NEO Connecting Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Foot Brake Modules (FBM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Electronic Control Units (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1-Channel Electro-Pneumatic Modules (EPM). . . . . . . . . . . . . . . . . . . . . . 17
2-Channel Electro-Pneumatic Modules (EPM). . . . . . . . . . . . . . . . . . . . . . 19
Trailer Control Modules (TCM). . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
EBS Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Pressure Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Yaw Rate Sensors (YRS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Steering Angle Sensors (SAS) . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Pressure Modulators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
EBS Product Catalogue
Glossary of Abbreviations
Abbreviation Description
EBS Product Catalogue
Introduction to EBS
1. Compressor
2.
3.
Air Processing Unit
Air Reservoir Circuit 1 1
2 16 Knorr-Bremse Electronic Braking System for Trucks (EBS 2.x)
4. Air Reservoir Circuit 2 0 2
5. Pressure Switch Circuit 1
6. Pressure Switch Circuit 2
23
21
3
KNORR BREMSE
22 22
7. EBS Foot Brake Module 1 25
24 23
8. EBS 1-Channel Module
4 11
9. Brake Chamber 3 41 21
Supply 4 15
Service Brake 22 21
1
Parking Brake 4
2 3 3
Air Suspension 1
3 11 12
Auxiliary Equipment
CAN-Signal “Control”
WL IL WL WL 28
CAN-Signal “Trailer” EBS ASR Trailer EBS Parking
CAN-Signal “J1939” 29
Electrical Signal
WL IL WL
WL Warning Lamp EBS Brake Wear Trailer EBS Truck EBS 2x master_2
IL Information Lamp
EBS
WL Trailer EBS
WL Parking
IL Brake Wear
IL ATC
WL EBS
WL EBS
IL ATC
IL Brake Wear
WL Trailer EBS
WL Trailer EBS
Parking
Trailer
WLWL
Truck E
Truck EBS 5 master
1 Compressor 6 EBS One Channel Module 11 Wheel Speed Sensor 16 Relay Valve 21 EBS Connection ISO 7638
2 Electronic Air Control (EAC) Unit 7 Pressure Control Modulator 12 Wear
Sensor 17 Spring Brake 22 ESP Steering Angle Sensor
3 Air Reservoir Circuit 1 8 Brake Chamber 13 EBS Electronic Control Unit (ECU) 18 EBS Trailer Control Module 23 ESP Yaw Rate Sensor
4 Air Reservoir Circuit 2 9 Air Disc Brake 14 EBS Two Channel Module 19 Coupling Head "Supply" 24 Test Connector
5 EBS Foot Brake Module 10 Brake Disc and Sensing Ring 15 Hand Brake Valve 20 Coupling Head "Control"
EBS Product Catalogue
Introduction to EBS
Operation
When the driver depresses the brake pedal, the FBM triggers the ‘brake’ function via EBS. The central ECU recognises the
fact that the driver is applying the brakes and controls the electronics in the EPMs via CAN-brake. Electronics within each EPM
trigger their respective solenoid valves and evaluate the signals from the wheel speed sensors (implementing the ABS function
when necessary) and brake wear sensors. The EPMs feed air to the brake actuators and control the pressure in accordance
with the control input. The TCM controls the pressure in the trailer braking system and ensures minimal coupling forces. The
pneumatic dual circuit design ensures that secondary braking performance requirements are achieved in the unlikely event of
an EBS failure.
Faster brake reaction time, reduced stopping distance
Knorr-Bremse EBS results in braking pressure not only building up faster but also simultaneously in all brake actuators. This
reduces the stopping distance since the brake pressure is applied directly by the EPMs to the actuators. The brakes respond
without delay. At the same time, the excellent control sensitivity serves to increase braking comfort. The EBS coupling force
control precisely matches the braking effects between towing vehicle and trailer. This ensures that both vehicles brake smoothly
and at precisely the same time.
Less wear, longer service intervals
EBS results in an equal demand being placed on each brake. When the brakes are released, all the brake actuators are
exhausted immediately. The EBS optimises brake management by utilising the effects of the retarder or engine brake to reduce
load on the wheel brakes. Furthermore, brake wear control ensures that the brake pad/disc wear is uniform throughout their
service life. This means an increase in the useful life of the brakes of up to 20%.
ESP Function
ESP only intervenes to restore directional stability when there is a difference between the driver’s input (the direction wished
for by the driver) and the vehicle’s actual movement. During “understeer”, i.e. when the vehicle travels on a greater radius than
that defined by the steering wheel angle, the vehicle is turned back onto the ‘correct’ course by ESP applying the brakes at
the inside rear wheel. In the case of “oversteer”, the rear of the tractor drifts to the outside of the curve. In order to put the
tractor/semi-trailer combination back on course, ESP now applies the brakes on the tractor’s outside front wheel and all of the
semi-trailer’s wheels.
Protection against Roll-Over
Especially in the case of articulated vehicles, ESP reduces the possibility of roll-over occurring. The system evaluates a variety
of different sensor signals and, with the help of lateral acceleration data, detects the possibility of roll-over at a very early stage.
As a result, ESP reduces engine torque and the brakes are selectively applied via EBS. The vehicle slows down and the danger
of roll over is reduced.
Electronic Stability Program
Without ESP
Dynamic Stability Program Roll Stability Program
Jackknifing Cornering
With ESP
Oversteering Lane changing
Understeering Obstacle avoidance
EBS Product Catalogue
EBS Diagnostics
System Diagnostics
NEO is an innovative solution that offers automated testing and measurement routines enabling modern workshops to provide
high integrity, professional diagnostic services for many types of commercial vehicle electronic braking systems. NEO is available
in three main versions that provide a range of functionality designed to meet the specific requirements of different sizes and
type of workshop. Depending upon the version selected, NEO can be directly linked to the braking system’s ECU and the
vehicle peripherals, and offers automatic or semi-automatic recognition of the braking system, irrespective of manufacturer
or configuration. NEO can communicate with the vehicle’s electronic systems, carry out measurements, conduct diagnosis,
provide clear service instructions and ultimately check that the servicing has been carried out correctly.
Inexpensive to purchase, the NEO diagnostics solution represents a future-proof investment as it can be updated/upgraded at
any time. Users of earlier Knorr-Bremse diagnostics systems will also be able to use all of their existing peripherals with the NEO
solution. NEO is user friendly and provides accessible, detailed advice on systems and service; in some cases using computer
animation. Knorr-Bremse’s NEO Training Courses provide practical training on the system’s broad range of functions, either
in-house or at a Knorr-Bremse training facility.
+ | green
Basic diagnostics
The easy-to-use NEO | green system provides an inexpensive introduction to the world of professional diagnostics for
electronic braking systems. The robust hard case contains everything required for communication with the Electronic Control Unit
(ECU) via the diagnostics interface, including a Universal Diagnostics Interface (UDIF) and a number of vehicle-specific adaptors.
The NEO | green software runs on any Windows®-based computer that meets certain technical specifications. A DVD with the
latest version of the software is also included in this introductory package. Should you require additional functionality from your
diagnostics tool for more sophisticated requirements you can upgrade from NEO | green to NEO | orange or NEO | blue at any time.
EBS Product Catalogue
EBS Diagnostics
+ | orange
Diagnostics and more
This is the ideal version for workshops wishing to offer their customers more than just failure codes: with NEO | orange
failures can be precisely located through targeted measurement. The automatic evaluation of measurement results and detailed
service instructions mean this version is set to rapidly become an indispensable tool in any workshop’s servicing routines. Yet
NEO | orange fits into a single, robust hard case. The package includes a Communication and Measuring Unit (CMU) and a number
of vehicle-specfic adaptors for connection to the diagnostics interface; all contained in a separate case. The NEO | orange
software runs on any Windows®-based computer that meets certain technical requirements. A DVD with the latest version of
the NEO | orange software rounds off this complete diagnostics and measurement package. Anyone also wishing to carry out
fully-automated system diagnostics and measurements has the option of upgrading from NEO | orange to NEO | blue at any stage.
+ | blue
Full version for advanced requirements
NEO | blue, the top-of-the-range version of the diagnostics platform from Knorr-Bremse, offers a unique range of functions. The
package comes in two robust hard cases, one of which includes a Communication and Measuring Unit (CMU) as well as a number
of vehicle-specific adaptors for connection to the diagnostics interface. A further case contains the Main Adaptor and Switchbox.
The NEO | blue software runs on any Windows®-based computer that meets certain technical requirements. A DVD with the latest
version of NEO | blue software rounds off this complete package of diagnostics, measurement and automatic failure recognition.
An important feature of the system is its ability to connect either via the diagnostics interface or directly to the Electronic Control
Unit (ECU) of the braking system. This ability to access the system independently of the central vehicle controller underlines the
advanced capabilities of NEO | blue. The system’s scalability enables it to meet servicing requirements of varying complexity.
EBS Product Catalogue
1) The NEO | green Upgrade Kit is specially designed for customers who already have the Knorr-Bremse ECUtalk® trailer software and would like to upgrade to the NEO | green.
EBS Product Catalogue
K017180N00 13 Truck/Bus Renault Trucks I8, EU12, ABS 2x, Wabco C, Green, Orange & Blue
EBS 2 & Clutch (ECA)
K017181N00 14 Truck/Bus - OBD Truck/Bus Various Green, Orange & Blue
K017182N00 15 Truck/Bus Scania Gamma 2E/2P, Wabco C/D & Green, Orange & Blue
EBS 2
K017185N00 18 Truck/Bus Volvo KB92, EBS 2, Wabco C/D & Green, Orange & Blue
Clutch (ECA)
K017187N00 20 Truck/Bus - 12 pin MAN KB92, KB3AL, Gamma Green, Orange & Blue
2E/2M/3M & CI12
K017500N00 11 Connecting Cable Iveco, MAN, EBS 5 Blue
(Peripheral equipment) Renault Trucks,
Scania & Volvo
K017501N00 12 Connecting Cable Iveco, MAN, EBS 5 Blue
Renault Trucks,
Scania & Volvo
K017503N00 23 EBS 5 ECU X1 CAN Adapter Iveco, MAN, EBS 5 Green, Orange & Blue
Renault Trucks,
Scania & Volvo
K018306N00 24 Connecting Cable 3 (black) Various Green, Orange & Blue
K034101N00 29 EBS Breakout Box Cable Scania, Renault EBS 5 Orange & Blue
(1-Channel EPM) Trucks & Volvo
K034102N00 31 EBS Breakout Box Cable Scania, Renault EBS 5 Orange & Blue
(2-Channel EPM) Trucks & Volvo
10
EBS Product Catalogue
K015615N00 37 Wireless Card for CMU Various Various Orange & Blue
11
EBS Product Catalogue
Vehicle Manufacturer Part Number Fig. System IAM Preferred Part Number
12
EBS Product Catalogue
Vehicle Manufacturer Part Number Fig. System IAM Preferred Part Number
13
EBS Product Catalogue
Note: all replacement EBS electronic control units require programming either using data mirroring (which can be carried out using
the NEO System diagnostics) or by the Vehicle Manufacturer with suitable dataset.
14
EBS Product Catalogue
15
EBS Product Catalogue
16
EBS Product Catalogue
Vehicle Manufacturer Part Number Fig. System IAM Preferred Part Number
17
EBS Product Catalogue
Vehicle Manufacturer Part Number Fig. System IAM Preferred Part Number
18
EBS Product Catalogue
Vehicle Manufacturer Part Number Fig. System IAM Preferred Part Number
19
EBS Product Catalogue
Vehicle Manufacturer Part Number Fig. System IAM Preferred Part Number
20
EBS Product Catalogue
Vehicle Manufacturer Part Number Fig. System IAM Preferred Part Number
21
EBS Product Catalogue
EBS Sensors
Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 5
Pressure Sensor Yaw Rate Sensor (YRS) Yaw Rate Sensor (YRS) Steering Angle Sensor (SAS) Steering Angle Sensor (SAS)
Vehicle Manufacturer Description Part Number Fig. System IAM Preferred Part Number
Iveco - Irisbus Yaw Rate Sensor (YRS) 0486020009 2 EBS 2 & 5 0486020007N50 1)
Iveco - Irisbus Yaw Rate Sensor (YRS) K020568 3 EBS 5.X K020568N50 1)
Renault Trucks Yaw Rate Sensor (YRS) 0486020001 2 EBS 2 & 5 0486020007N50 1)
Renault Trucks Yaw Rate Sensor (YRS) K020568 3 EBS 5.X K020568N50 1)
Iveco - Irisbus Steering Angle Sensor (SAS) 0486021010 4 EBS 2 & 5 0486021007N50 1)
1) All Yaw Rate & Steering Angle Sensors require calibrating after installation, this can be carried out with NEO System diagnostics
22
EBS Product Catalogue
Pressure Modulators
Fig. 1 Fig. 2 Fig. 3 Fig. 4
Vehicle Manufacturer Part Number Type Number Fig. Electrical Connection Compressed Air Port IAM Preferred Part Number
Thread M22X1.5
Iveco - Irisbus II17776 BR9154 2 DIN Bayonet VOSS VG230 II17776N00
Iveco - Irisbus II15492 BR9150 2 Schlemmer Bayonet DIN K015676N00 2)
MAN II38665F BR9182 2 DIN Bayonet VOSS VG230 II17776N00
MAN II40864F BR9159 2 DIN Bayonet VOSS VG230/DIN II17776N00
MAN 0265351118 2 DIN Bayonet VOSS VG230 II17776N00
Mercedes Benz 0265351122 2 DIN Bayonet VOSS VG230 II17776N00
Mercedes Benz II37086 BR9180 2 DIN Bayonet VOSS VG230 II17776N00
Mercedes Benz II17776 BR9154 2 DIN Bayonet VOSS VG230 II17776N00
Mercedes Benz 0486201017 1) 3 DIN Bayonet VOSS VG230 0486201017N50
Mercedes Benz 0265351101 1 M24x1 DIN K015677N00 2)
Mercedes Benz II16278 BR9152 1 M24x1 DIN K015677N00 2)
23
EBS Product Catalogue
Vehicle Manufacturer Part Number Fig. Electrical Connection Length (mm) IAM Preferred Part Number
24
EBS Product Catalogue
Vehicle Manufacturer Part Number Fig. Electrical Connection Length (mm) IAM Preferred Part Number
25
EBS Product Catalogue
Vehicle Manufacturer Part Number Fig. Electrical Connection Length (mm) IAM Preferred Part Number
1) Product is not yet available. Please refer to www.knorr-bremsecvs.com to see when part number is available.
26
EBS Product Catalogue
Spare Parts
27
EBS Product Catalogue
Spare Parts
28
EBS Product Catalogue
Spare Parts
1) Contains only ONE side cover, two are required for 2-Channel EPMs
2) Contains only ONE silencer, two are required when servicing 2-Channel EPMs
29
EBS Product Catalogue
Spare Parts
1) Contains only ONE side cover, two are required for 2-Channel EPMs
2) Contains only ONE silencer, two are required when servicing 2-Channel EPMs
30
EBS Product Catalogue
31
EBS Product Catalogue
32
EBS Product Catalogue
33
EBS Product Catalogue
34
EBS Product Catalogue
35
EBS Product Catalogue
36
EBS Product Catalogue
5010 457 146 Renault Trucks - Magnum 0486203004 0486203030N50 1-Channel EPM 17
0486203030X50**
5010 457 257 Renault Trucks - Premium 0486203017 0486203030N50 1-Channel EPM 17
0486203030X50**
5010 457 367 Renault Trucks 0486106024 0486106024N50 2) ECU 15
5010 457 556 Renault Trucks 0486203028 0486203030N50 1-Channel EPM 17
0486203030X50**
5010 457 557 Renault Trucks 0486203030 0486203030N50 1-Channel EPM 17
0486203030X50**
5010 457 619 Renault Trucks 0486205017 0486205022N50 TCM 21
5010 457 643 Renault Trucks 0486106067 0486106305N50 2) ECU 15
5010 457 739 Renault Trucks 0486106057 0486106305N50 2) ECU 15
5010 612 854 Renault Trucks - Magnum K000919 K020623N50 TCM 21
5010 633 320 Renault Trucks - Magnum K001428 K040158N50 FBM 12
5010 633 321 Renault Trucks - Premium K001894 K040156N50 FBM 12
5010 143 029 Renault Trucks 0265050109 0265050109N00 Wheel Speed Sensor 26
5010 143 030 Renault Trucks 0265050110 0265050110N00 Wheel Speed Sensor 26
5010 143 046 Renault Trucks 0265351118 II17776N00 Pressure Modulator 23
5010 143 056 Renault Trucks 0265351118 II17776N00 Pressure Modulator 23
37
EBS Product Catalogue
38
EBS Product Catalogue
39
EBS Product Catalogue
40
EBS Product Catalogue
41
EBS Product Catalogue
42
EBS Product Catalogue
Index
43
EBS Product Catalogue
Index
44
EBS Product Catalogue
Index
Knorr-Bremse Australia
Systèmes pour Véhicules Poland System für Nutzfahrzeuge GmbH Knorr-Bremse Knorr-Bremse
Utilitaires France Knorr-Bremse Polska SfN Sp. z o.o. Bassersdorf Australia Pty.Ltd. Korea Ltd. Truck Brake Division
Lisieux Cedex Warsaw Tel: +41 44 888 77-55 Granville NSW Seoul
Tel: +33 2 3132 1200 Tel: +48 22 887-3870 Fax: +41 44 888 77-50 Tel: +612 8863-6500 Tel: +82 2 2273-1182
Fax: +33 2 3132 1303 Fax: +48 22 531-4170 Fax: +612 8863-6510 Fax: +82 2 2273-1184
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. Note: If service work is carried out on a vehicle based on
information provided herein, 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. Copyright © Knorr-Bremse AG - all rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as for copying and transferring. Knorr-Bremse Systeme für, Nutzfahrzeuge GmbH, Moosacher Straße 80, 80809 Munich, Germany
System Diagnostics