TEBS G2 - Load Sensing For Mechanical Suspensions: Service Manual

Commercial Vehicle Systems
TEBS G2 - Load Sensing for

Service Manual Mechanical Suspensions
Y053529: EN: 000: MAX1: Released:Webmaster: 2008/10/15-12:12:50

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 Union

This 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.

TEBS G2 - Load Sensing for

Mechanical Suspensions

Service Manual
S a fe t y Ad v i ce
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.

TEBS G2 - Load Sensing for Mechanical Suspensions
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

Service Manual
1
I n t ro d u c t i o n
1. Introduction
For mechanically suspended trailers, fitted with the Knorr-Bremse TEBS G2 system, a Knorr-Bremse Deflection
Sensor Kit should also be fitted.
2. Load Sensing
The load carried by the trailer‘s axle(s) is sensed by means of the Sensor Kit - part number K026919. 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

3
S ensor A ssem b l y
3. Sensor Installation
Location on the trailer
CAUTION - At the time of installation/commissioning, the trailer load must be at the minimum
value, as specified on the trailer data plate.
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
Rubber link
Designer program (BSD). For retrofit, either BSD can Sensor operating lever
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, Lever length
see Annex B).
Axle connection linkage
Fig.2: Typical positioning of sensor installation
Note: Knorr-Bremse recommends using the longest lever length possible taking into account the
suspension deflection.
2)
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. 1)
Fig.3: Section of Lever Length Deflection Sensor chart (Annex B)

Service Manual
3
S e n s o r A s s e mbl y
Installation on the trailer
The sensor must be installed so that the mounting

holes are horizontal (see fig.4).
Mounting holes
Rubber link
Sensor operating lever
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
Lugs
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
Lever length
axle connection linkage.
Note: Knorr-Bremse
��
recommends to
have vertical axle connection linkage not Axle connection linkage
shorter than 20 cm.
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.
Note: The lever length is measured from

the central pivot point of the sensor
operating lever to the fixing point of the Fig.5: Mounted deflection sensor kit
connecting rod (see fig. 4).
4) Tighten the clamp bolts.

3
S ensor A ssem b l y
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 Pin No. Pin No.
Cable
InOut Signal Deflection
means of a bayonet connector. The cable is then Colour
Connector Sensor
connected to the InOut connector of the TEBS G2
brake module by using the pins defined (fig.6). 4 SENS_Sup Black 1
5 SENS_IN1 Yellow 3
6 SENS_GND White 2
Fig.6: Pinning of the sensor
Pin 1 Pin 1
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
Fig.7: Pinning of the TEBS G2 brake module

Service Manual
4
Co n f i g u r at i o n and Adjustment
4. Configuration and Adjustment

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.
Configuration with ECUtalk® for TEBS G2
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.
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)
3
1
Fig.8: Configuration window
10

4
Configuration and Adjustm e n t
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) M��
ove the rubber link up or down.
3) ��
Tighten the rubber link clamp screw.
Rubber link clamp screw
Fig.9: Adjusting sensor signal LS1 voltage
11

Service Manual
4
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
Setup load sensing type TEBS G2
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. For Load sensing type,

select “External load
sensor LS1” . 1
2
2. For External load sensor
type, select “KB Deflection
Sensor”.
Fig.10: Load sensing configuration window

3. Navigate with “Next” button to AUXIO settings.
12

4
4. For SENS_IN1 under Type,

select “Input Analogue”.
5. For SENS_IN1 under

Function name, select “LS1”.
4 5
6. Finish configuration with “OK”.

Fig.11: AUX IO settings window
7. Save the configuration to the TEBS G2 brake module (ECU)�.
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:
Fig.12: Read sensor signal voltage settings window.
1) Loosen the rubber
��
link clamp screw. NOTE: Scale is coloured red because the Unladen and Laden voltages are yet to be set.
2) M��
ove the rubber link up or down.
3) ��
Tighten the rubber link clamp screw.
13

Service Manual
4
Configuration of unladen and laden threshold
Make sure the configuration window is active.
Start configuration change
Navigate with “Next” button to load sensing configuration
8. For “LS1 voltage

unladen [V]” enter value
(for example 1.50 V).
7
9. For “LS1 voltage laden 8
[V]” enter value. This is 9
the unladen voltage plus 10
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
11
(for example 84.00 mm).
12. Finish configuration with

“OK” button.
Fig.13: Load sensing configuration window II
13. Save the configuration to the TEBS G2 brake module (ECU)�.
14

4
ANNEX A - Sensor Dimensions (mm)
68
50
12
6.5
57.5
100
min. assembly hole

50
3
19 45
83
Fig.14: Sensor dimensions
15

Service Manual
4
ANNEX B - Lever length relation to suspension deflection
Fig.15: Graph of deflection to lever length
16

4
ANNEX C - Alternative mounting options
‘Lugs’ ‘Lugs’
Installation with mounting holes oriented upwards -

lugs point towards axle connection linkage.
‘Lugs’
Installation with mounting holes oriented downwards -

lugs point away from axle connection linkage.
Fig.16: Sensor mounting options
17

Knorr-Bremse Systeme für

Nutzfahrzeuge GmbH
Moosacher Straße 80
80809 Munich
Germany
Tel: +49 89 3547-0
Fax: +49 89 3547-2767
www.knorr-bremseCVS.com
This documentat is subject to alteration without notice. A printed copy of this document may not be the latest revision. Please check our website www.knorr-bremseCVS.com for the latest update or contact your local
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Commercial Vehicle Systems

TEBS G2 - Load Sensing for

Y053529: EN: 000: MAX1: Released:Webmaster: 2008/10/15-12:12:50

Disposal of Waste Equipment by Business Users in the European Union

Y053529: EN: 000: MAX1: Released:Webmaster: 2008/10/15-12:12:50

TEBS G2 - Load Sensing for

Y053529: EN: 000: MAX1: Released:Webmaster: 2008/10/15-12:12:50

• 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.

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

Y053529: EN: 000: MAX1: Released:Webmaster: 2008/10/15-12:12:50

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

Y053529: EN: 000: MAX1: Released:Webmaster: 2008/10/15-12:12:50

Fig.1 Load Sensing Plate

Y053529: EN: 000: MAX1: Released:Webmaster: 2008/10/15-12:12:50

Location on the trailer

Length of sensor operating lever

For OE fitment it is recommended that the lever length

be used or the manual method described below.

The axle connecting linkage must be connected to the

see Annex B).

Axle connection linkage

Fig.2: Typical positioning of sensor installation

1. Using known suspension deflection (unladen to

2. Read the corresponding lever length required

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

Y053529: EN: 000: MAX1: Released:Webmaster: 2008/10/15-12:12:50

Installation on the trailer

The sensor must be installed so that the mounting

Assembly and connecting procedure:

2) Assemble the sensor operating lever to the clamp,

3) Move the sensor operating lever to give exactly the

Note: The lever length is measured from

4) Tighten the clamp bolts.

Y053529: EN: 000: MAX1: Released:Webmaster: 2008/10/15-12:12:50

Electrical connection to the TEBS G2 brake module

Connect the extension cable (K002277 or K002278;

Fig.6: Pinning of the sensor

Fig.7: Pinning of the TEBS G2 brake module

Y053529: EN: 000: MAX1: Released:Webmaster: 2008/10/15-12:12:50

4. Configuration and Adjustment

4.1. OE installation with Knorr-Bremse BSD parameter file

Configuration with ECUtalk® for TEBS G2

Turn the ignition on.

2. Choose parameter file and click on “Open”

3. After defining all necessary parameters save the

Fig.8: Configuration window

Y053529: EN: 000: MAX1: Released:Webmaster: 2008/10/15-12:12:50

Adjustment of the sensor signal voltage

Start “System check”

Read “LS1 voltage”.

If the LS1 voltage deviates from 1.0 V then adjust it

1) Loosen the rubber

Rubber link clamp screw

Fig.9: Adjusting sensor signal LS1 voltage

Y053529: EN: 000: MAX1: Released:Webmaster: 2008/10/15-12:12:50

4.2. Manual configuration with ECUtalk® for TEBS G2

Setup load sensing type TEBS G2

Start configuration change

Navigate with “Next” button to load sensing configuration

1. For Load sensing type,

Fig.10: Load sensing configuration window