Electronic Brake System (EBS2 Knorr) [PDF]

Zitiervorschau

Electrical System Electronic Brake System (EBS2 Knorr) Electronic Stability Program (ESP) Trucks

Copy deadline 02.2008

81.99593-4732 MAN Nutzfahrzeuge Aktiengesellschaft Dachauer Str. 667 80995 MÜNCHEN oder Postfach 50 06 20 80976 MÜNCHEN

System Description 2nd edition T 61 Systembeschreibung T 61, 2. Ausgabe Elektrische Anlage Elektronisches Bremssystem (EBS2 Knorr) Elektronisches Stabilitätsprogramm (ESP) LKW - Englisch Printed in Germany

System Description T 61 2nd edition

Electrical System Electronic Brake System (EBS2 Knorr) Electronic Stability Program (ESP) Trucks

81.99593-4732

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PREFACE / PRINTER’S IMPRINT PREFACE This repair manual is intended to provide assistance in performing repairs correctly on vehicles and units. The technical details were correct at the time of going to press. This publication assumes that persons who use it possess the requisite technical knowledge in handling vehicles and units. Pictures and the corresponding descriptions are typical one-time representations; they do not always correspond to the unit or peripherals in question, but this does not mean they are incorrect. In such cases, plan and carry out the repair work in accordance with the sense of the instructions. Repair work on complex add-on units should be entrusted to our customer service or to the customer service of the manufacturing company. Special reference is made to these units in the text. Important instructions relating to safety and accident prevention are specially highlighted in the text as follows. CAUTION Type and source of danger Refers to working and operating procedures which must be followed exactly in order to avoid exposing people to risk. WARNING Type and source of danger Refers to working and operating procedures which must be followed exactly in order to avoid serious or irreparable damage to property. Note Explanatory description to aid understanding of the working and operating procedures involved.

Comply with general safety regulations when performing any repair work. Best wishes from MAN Nutzfahrzeuge AG

PRINTER’S IMPRINT We reserve the right to make modications in the course of further development © 2008 MAN Nutzfahrzeuge AG Reprinting, copying or translation, even of extracts, is not allowed without the written approval of MAN. All rights under the copyright law are strictly reserved by MAN Nutzfahrzeuge AG. If any changes are made without the written approval of MAN Nutzfahrzeuge AG then MAN Nutzfahrzeuge AG shall not be liable for any warranty or guarantee claims arising from damage and defects attributable to the unauthorised modication. Furthermore, MAN Nutzfahrzeuge AG shall not be liable for any damage resulting from the unapproved modication. Redaktion: VASID-Y, HA, MR, 02.2008 Satz: VASID-Y Druck: MAN-Werksdruckerei

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TABLE OF CONTENTS Content

Chapter/Page

Index

5

Abbreviations

9

Introduction Safety instructions ....................................................................................................... 15 Model overview .......................................................................................................... 22 Explanatory notes to the wiring diagrams ........................................................................... 24 Device description System description ...................................................................................................... 28 Electronic brake system (EBS) .................................................................................... 28 Electronic Stability Program (ESP) ............................................................................... 36 Interfaces to other systems ........................................................................................ 38 CAN databus system structure .................................................................................... 39 Functional description .................................................................................................. 41 System structure of Electronic Brake System (EBS) / Electronic Stability Program (ESP) ............ 41 Electronic Brake System (EBS) ................................................................................... 43 Electronic Stability Program (ESP) ............................................................................... 54 Description of components ............................................................................................ 65 EBS control unit (A402) ............................................................................................ 65 Service brake valve with integrated brake power sensor (G7.302 / B337) ................................ 66 Pressure control module, 1-channel (G67.304-Y262 / G67.304-Y263) ................................... 68 Pressure control module, 2-channel (G67.305 / Y264) ....................................................... 70 Trailer control module (G17.301 / Y278) ........................................................................ 72 ALB sensor, rear axle (B336) ...................................................................................... 73 Brake sensor (B332, B333, B334, B335, B529, B530, B537, B538) ....................................... 75 Speed sensor (B119, B120, B121, B122, B591, B592) ...................................................... 76 Control unit, ESP (A575) ........................................................................................... 77 Steering angle sensor (B475) ..................................................................................... 78 Rotational speed and lateral acceleration sensor (B476) .................................................... 79 Diagnosis ................................................................................................................. 80 General information ................................................................................................. 80 SPN list (fault codes) and fault code description, EBS ....................................................... 98 Analogue signal fault messages ................................................................................ 102 Fault messages, feedback signals ............................................................................. 105 Fault messages, engine interface .............................................................................. 106 Fault messages, CAN databus .................................................................................. 106 Fault messages, pressure control module (1-channel), left on the front axle ........................... 111 Fault messages, pressure control module (1-channel), right on the front axle ........................ 130 Fault messages, pressure control module (2-channel) on the rear axle (left-hand side) ............. 150 Fault messages, pressure control module (2-channel) on the rear axle (right-hand side) ........... 172 Fault messages, pressure control module (2-channel) on the 2nd rear axle (left-hand side) ....... 193 Fault messages, pressure control module (2-channel) on the 2nd rear axle (right-hand side) ...... 212 Fault messages for trailer control module ..................................................................... 231 SPN list (fault codes) and fault code description, ESP ..................................................... 240 Test step list ........................................................................................................ 261 Wiring diagrams Overviews ............................................................................................................... 277 Overview, EBS, 2-axle vehicle .................................................................................. 278 Overview, EBS, 3-axle vehicle / 4-axle vehicle ............................................................... 280

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INDEX Catchword

Page

A ALB sensor, rear axle (B336) Components ............................................................................................................................................. 73 Function.................................................................................................................................................... 52 B Brake intervention.......................................................................................................................................... 54 Brake sensor (B332, B333, B334, B335, B529, B530, B537, B538) Function.................................................................................................................................................... 53 C CAN databus system structure...................................................................................................................... 39 Compatibility between various brake systems............................................................................................... 33 Components EBS .......................................................................................................................................................... 32 ESP .......................................................................................................................................................... 37 Concept for pressure selection in the pressure control module .................................................................... 44 Contact box ................................................................................................................................................... 95 Control unit, ESP (A575) Components ............................................................................................................................................. 77 Function.................................................................................................................................................... 59 Coupling force control.................................................................................................................................... 34 D Diagnosis socket HD-OBD (X200) ................................................................................................................ 82 Diagnosis socket X200 .................................................................................................................................. 82 Direct sensor monitoring................................................................................................................................ 57 E EBS communication with CAN databus ........................................................................................................ 45 EBS control unit (A402) Components ............................................................................................................................................. 65 Function.................................................................................................................................................... 45 Electro-pneumatic basic concept................................................................................................................... 43 Electronic brake system (EBS) System ..................................................................................................................................................... 28 Electronic Brake System (EBS) Function.................................................................................................................................................... 43 Electronic Stability Program (ESP) Function.................................................................................................................................................... 54 System ..................................................................................................................................................... 36 Engine intervention........................................................................................................................................ 54 ESP sensor calibration .................................................................................................................................. 63 ESP sensors.................................................................................................................................................. 59 Explanatory notes to the wiring diagrams...................................................................................................... 24 F Fault detection time ....................................................................................................................................... 58 Fault indication and reduced ESP functionality ............................................................................................. 58 Faults occurring during an accident............................................................................................................... 58 Features of EBS for commercial vehicles...................................................................................................... 28 Function and connection diagram Trailer ....................................................................................................................................................... 35 Truck 4x2.................................................................................................................................................. 29 G General information ....................................................................................................................................... 80 General information, system.......................................................................................................................... 36

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INDEX I Installation positions for location identiers ................................................................................................... 25 Installation positions, diagnosis socket X200 ................................................................................................ 84 Interfaces to other systems ........................................................................................................................... 38 L Limits of ESP functions.................................................................................................................................. 55 M Main diagnosis functions ............................................................................................................................... 85 Malfunction displays ...................................................................................................................................... 85 Microcontroller tests ...................................................................................................................................... 57 Mode of operation of the subfunctions .......................................................................................................... 30 Model-based sensor monitoring .................................................................................................................... 57 Monitoring of other ESP control unit components ......................................................................................... 57 Monitoring of the ESP control unit in the EBS control unit ............................................................................ 56 O On-board diagnosis ....................................................................................................................................... 89 P Pressure control module, 1-channel (G67.304-Y262 / G67.304-Y263) Components ............................................................................................................................................. 68 Function.................................................................................................................................................... 48 Pressure control module, 2-channel (G67.305 / Y264) Components ............................................................................................................................................. 70 Function.................................................................................................................................................... 50 R Reduced roll-over risk (roll stability program, RSP)....................................................................................... 54 Redundancy of the single-circuit electronic control unit ................................................................................ 43 Rotational speed and lateral acceleration sensor (B476) Components ............................................................................................................................................. 79 Function.................................................................................................................................................... 61 S Safety concept and reduced functions .......................................................................................................... 56 Safety instructions ......................................................................................................................................... 15 General information.................................................................................................................................. 15 Sensor, brake (B332, B333, B334, B335, B529, B530, B537, B538) Components ............................................................................................................................................. 75 Service brake valve with integrated brake power sensor (G7.302 / B337) Components ............................................................................................................................................. 66 Function.................................................................................................................................................... 47 Speed sensor (B119, B120, B121, B122, B591, B592) Components ............................................................................................................................................. 76 Function.................................................................................................................................................... 53 SPN fault code indicated on the display, EBS ............................................................................................... 87 SPN fault code indicated on the display, ESP ............................................................................................... 88 SPN list (fault codes) and fault code description, EBS.................................................................................. 98 SPN list (fault codes) and fault code description, ESP................................................................................ 240 Steering angle sensor (B475) Components ............................................................................................................................................. 78 Function.................................................................................................................................................... 59 Structure of fault texts in diagnosis message ................................................................................................ 86 System structure of Electronic Brake System (EBS) / Electronic Stability Program (ESP) ........................... 41 T Test description............................................................................................................................................ 261 Test step list................................................................................................................................................. 261 Test step list, EBS/ESP ............................................................................................................................... 263 Track stabilisation by ESP............................................................................................................................. 54 6

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INDEX Trailer control module (G17.301 / Y278) Components ............................................................................................................................................. 72 Function.................................................................................................................................................... 51 Troubleshooting program .............................................................................................................................. 96

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LIST OF ABBREVIATIONS Abbreviations A a ABE ABS ABV AC ACC ACK ADC ADR AGB AGND AGR AHK AHV ALB AMA AMR ANH AS ASD ASM ASR ASV ATC ATF AU AV AVS

Acceleration General certication Anti-lock Braking System Anti-skid system Air Conditioning Adaptive Cruise Control Acknowledge Analogue-Digital Converter European agreement for cross-border transport of dangerous goods by road (French title: Accord européen relatif au transport international des marchandises Dangereuses par Route) Automatic road speed limiter Analogue Ground Exhaust Gas Recirculation (EGR) Trailer coupling Trailer brake valve Automatic load balancing Antenna mast system Anisotrop Magneto Resistive Trailer / semitrailer Automatic gearbox Trailer socket Trailer control module Anti-spin regulator (traction control) Trailer control valve Automatic Temperature Control Automatic Transmission Fluid Statutory exhaust emission test Exhaust valve Automatic gear preselection

B BA BBA BBV BITE BKR BUGH BV BVA BVS BVV BW BWG BZ

Operator's manual Service brake system Service brake valve Built-In Test Equipment Brake power regulator Front heater Backup valve Brake wear indicator Brake wear sensor Brake wear sensor supply German Army Brake power sensor Brake cylinder

C CAN CAN-H CAN-L CATS CBU CDC CCVS CKD CNG CPU CRT CRC

Controller Area Network CAN-high data line CAN-low data line Computer-assisted testing and diagnostic system Central Brake Unit Continuous Damping Control Cruise control vehicle speed Completely Knocked Down Compressed Natural Gas Central Processing Unit Continuously Regenerating Trap (exhaust mufer, two-way catalytic converter, diesel particulate lter) Cyclic Redundancy Check T 61 2nd edition

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LIST OF ABBREVIATIONS CS D DAHL DBR DCU DF DFÜ DIA DIAG DIAG MUX DIAK DIAL DIAR DIN DKE DKH DKL DKR DKV DLB DM DNR DPF DRM DRS DS DSV DTC DTCO DV DWA DZG DZM E EBS ECAM ECAS ECE ECU EDC EDC S EDM EDR EEC EEPROM EFR EFS EHAB ELAB ELF EMS EMV EOL EP ER ESAC ESP ESR 10

Comfort Shift

Roof ventilator Auxiliary brake relay Dosing Control Unit (for AdBlue) Speed sensor Data transmission Diagnosis and information display Diagnosis, entire vehicle Diagnosis, entire vehicle – central computer, Multiplex (buses and coaches only) Diagnosis, K-line (data line) Diagnosis, L-line (interrogation line) Diagnosis, further interrogation German industrial standard Throttle valve increase (ASR control) Roof duct heating Roof aps Throttle valve reduction (reduction request from ASR to EDC/EMS) Throttle valve specication (load sensor signal from pedal value sensor, EDC/EMS) Compressed air brake system Diagnostic Message Drive Neutral Reverse (selector lever switch for automatic) Diesel particulate lter Pressure control module Rotational speed sensor Pressure sensor Pressure control valve Diagnostic Trouble Code (OBD fault code) Digital tachograph Throttle valve Anti-theft warning system Speed sensor Rev counter

Electronic brake system Electronically Controlled Air Management Electronically Controlled Air Suspension Emergency shut-off to ECE 36 Electronic Control Unit Electronic Diesel Control Electronic Diesel Control Slave Electronic diesel consumption meter Maximum speed governor Electronic engine controller Electrically erasable and programmable read-only memory Electronic shock absorber control Electric driver's seat Electro-hydraulic shut-off device Electrical shut-off device Electronically controlled air suspension Electronic throttle control (ETC) Electromagnetic compatibility (EMC) End-of-line (programming) Injection pump Engine retarder (engine brake) Electronic Shock Absorber Control Electronic Stability Program Electric sun-blind T 61

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LIST OF ABBREVIATIONS EST EV EVB

Electronic control unit Intake valve Exhaust Valve Brake

F FAP FAQ FBA FBM FDR FDF FFR FGB FGR FHS FIN FM FMI FMS FMR FOC FSCH FSG FSH FTW FUNK FZA FZNR

Driver's area Frequently Asked Questions Parking brake system Pedal brake module Vehicle dynamics control Vehicle data le Vehicle management computer Road speed limiter (RSL) Road speed governor (RSG) Cab Vehicle identication number (17 digits) Vehicle management Failure mode identication Fleet Management Standard (global telematics standard) Vehicle/engine management Front Omnibus Chassis (bus/coach chassis with front-mounted engine) Windscreen heater Ground reinforcement system Window/mirror heating Driver's partition Radio communication unit Destination system Vehicle number (7 digits)

G GDK GEN GET GGVS GND GP GS GV

Closed-loop diesel catalyst Alternator Gearbox European agreement for cross-border transport of dangerous goods by road (French abbreviation: ADR) Ground Gearbox planetary gear group (range-change box) Gearbox control Gearbox splitter gear group (splitter box)

H HA HBA HD-OBD HDS HGB HGS HLUE HOC HSS HST HU HYD HYDRIVE HYDRO HVA Hz HZA HZG

Rear axle Auxiliary brake system Heavy Duty On-Board Diagnosis Urea dosing system Maximum road speed limiter Hydraulic gearshift Hydrostatic fan Rear Omnibus Chassis (bus/coach chassis with rear-mounted engine) Highside switch Main switchboard Main inspection Hydronic auxiliary heater Hydrostatic front axle drive MAN Hydro Drive Hydrostatic front axle drive Hertz (number of cycles per second) Bus stop indicator system Auxiliary speed sensor

I IBEL

Interior lighting T 61 2nd edition

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LIST OF ABBREVIATIONS IBIS IC ID IMR INA INST IR IRM ISO IWZ

Integrated on-board information system Integrated Circuit Identication Integrated mechanical relay (starter control) Information indicator (e.g. check lamp) Instrumentation Individual control (ABS) Modied individual control (ABS) International Standards Organisation Incremental angle/time measuring system

K KBZ KFH KITAS KLI KNEEL KSM KSW KWP

Combination brake cylinder Fuel lter heater Kienzle intelligent tachograph sensor Air-conditioning system Kneeling Customer-specied control module (control unit for external data exchange) Customer's special request Key Word Protocol (protocol for MAN-cats® diagnosis KWP 2000)

L LBH LCD LDA LDF LDS LED LF LGS LL LLA LLR LNA LNG LOE LPG LSVA LWR LWS

Air reservoir Liquid Crystal Display Manifold-pressure compensator (boost control) Boost pressure sensor Air spring/damper system Light emitting diode Air suspension Lane Guard System Idling speed Idling speed increase Idling speed control Steering trailing axle Liqueed Natural Gas Steering oil monitor Liqueed Petroleum Gas Distance-based heavy vehicle toll Headlight beam regulator Steering angle sensor

M M-TCO Modular EU tachograph MAB Solenoid valve shut-off (engine shut-off by high-pressure solenoid valve in injection pump) MAN- cats MAN computer-assisted testing and diagnostic system MAR Solenoid valve shut-off relay (redundant engine shut-off relay) MDB Engine speed range MES Fuel quantity actuator ML Midline MMI Man-machine interface MOTB Engine brake MP Motor power box (cable duct on engine block) MR Engine governor - ASR MSG Engine control unit (EDC) MUX Central computer, Multiplex (bus/coach only) MV Solenoid valve MZ Diaphragm cylinder N n NA NBF 12

Speed Power take-off (PTO) Needle movement sensor T 61

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LIST OF ABBREVIATIONS NES NFZ NLA NSL NSW

New electronic structure Commercial vehicles Trailing axle Rear fog lamp Fog lamps

O OBD OBDU OC OEAB OENF

On-Board Diagnosis Onboard Diagnostic Unit (subsystem of central on-board computer) Occurrence Count (frequency counter of a fault) Oil separator Oil top-up

P p P PBM P-Code PDF PLM PM-Kat PSC PSG PTM PTO PWG PWM

Pressure Powertrain Pulse Breadth Modulation (also see PWM) Powertrain code (fault code) Particulate Diesel Filter Programmable Logic Module Particulate matter catalytic converter Pneumatic Supply Controller – Replacement for ECAM Pump control unit (EDC) Powertrain manager (replacement for FFR) Power take-off Pedal value sensor Pulse Width Modulation (also see PBM)

R RA RAH RAM RAS RAS-EC RDRA RDS RET RET P RET S RKL RKS RLV RME ROM

Repair manual Interior heating Random Access Memory Rear Axle Steering Rear Axle Steering with Electronic Control Tyre pressure control system Radio Data System Retarder Primary retarder Secondary retarder Priority vehicle light Tyre monitoring system – replaced by TPM Relay valve Rape seed oil methyl ester (biodiesel) Read Only Memory

S SA SAE SAMT SB SBW-RA SCR sec SER SG SH SKD SL SML SPN STA SWR

Special equipment Society of Automotive Engineers Semi-automatic mechanical transmission Service outlet Steer By Wire Rear Axle (electronically controlled steering trailing axle) Selective Catalytic Reduction Second Standard Control unit Select-high control (ABS) Semi Knocked Down Select-low control (ABS) Side marker lights Suspect Parameter Number Engine start/stop Headlight cleaning system T 61

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LIST OF ABBREVIATIONS T t TBM TC TCM TCO TCU TEPS TGA TGL TGM TKU TMC TPM TRS TSC TSU TUER

Time On-board telematics module Traction Control Trailer Control Module Tachograph (MTCO, DTCO, TSU etc.) Transmission Control Unit Twin Electronic Platform Systems (bus/coach only) Trucknology Generation A Trucknology Generation Light Trucknology Generation Mid Technical customer document Trafc Message Channel Tyre Pressure Module Technical road transport directive Torque Speed Control (braking torque) Tachograph Simulating Unit (vehicles without MTCO/DTCO) Door control

U UBat UDF UDS

Battery voltage Conversion le Crash recorder

V v VA VDF VG VLA VSM

Road speed Front axle Vehicle data le Transfer case or reference to defence equipment standards Leading axle Transfer case lock management

W WA WAB WaPu WLE WR WS WSK

Maintenance Manual Water separator Water pump Intarder Swap-body unit Warning relay Position sensor Torque converter and clutch unit

Z z ZBR ZBRO ZDR ZE ZFR ZR ZS ZUSH ZWS λ µ µC

Braking rate/deceleration Central on-board computer Central on-board bus computer Intermediate speed governor (ISG) Central electrical system Auxiliary vehicle computer Central computer Central lubrication Auxiliary heater Time-based maintenance system Slip Coefcient of friction Microcontroller (microprocessor)

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INTRODUCTION

INTRODUCTION SAFETY INSTRUCTIONS General information Only trained personnel are allowed to perform operating, maintenance and repair work on trucks, buses and coaches. The following sections include summaries of important regulations, listed according to major topics, which must be complied with. The intention is to provide the knowledge needed to avoid accidents which could lead to injury, damage and environmental pollution. Please note that these are merely brief extracts taken from various accident prevention regulations. Of course, all other safety regulations must be followed and the necessary measures must be taken. Additional references to danger are contained in the instructions at points where there is a potential danger. Accidents may happen in spite of all precautionary measures having been taken. In such an eventuality, obtain immediate medical assistance from a doctor. This is particularly important if the accident involves skin contact with corrosive acid, fuel penetration under the skin, scalding by hot oil, antifreeze spraying into eyes, crushing of limbs etc. 1. Regulations for preventing accidents leading to injury to personnel Checking, setting and repair work – Secure units during their removal. – Support the frame when working on the pneumatic or spring suspension system. – Keep units, ladders, stairs, steps and the surrounding area free from oil and grease. – Only use tools that are in perfect condition. – Only authorised technical personnel are entitled to perform inspection, adjustment and repair work. Working on the brake system – A dust extractor must be used if dust is released when working on the brake system. – Perform visual, function and effectiveness checks on the brake system after carrying out any work on it whatsoever. These checks must be made in accordance with the safety inspection (SP). – Check the function of ABS/ASR systems using a suitable test system (e.g. MAN-cats). – Collect any brake uid that leaks out. – Brake uid is poisonous! Do not allow it to come into contact with food or open wounds. – Treat hydraulic uid/brake uid as hazardous waste! Comply with the safety regulations for preventing environmental pollution. Working on vehicles with compressed natural gas (CNG) system – Vehicles with a defective compressed natural gas system may not be brought into the workshop. This also applies to vehicles whose engine cannot be switched off by automatic emptying of the removal lines. – When working on vehicles with a compressed natural gas system, set up a gas warning device above the vehicle roof and in the engine compartment above the pressure controller. Further gas warning devices must be carried by the persons working on the vehicle. – Smoking is not allowed in areas where work on vehicles with compressed natural gas systems is carried out. All sources of ignition must be removed from these areas. – Before carrying out welding work, the compressed gas tanks must be removed and the gas-carrying lines must be ushed with inert gas. – Compressed gas tanks are only allowed to be exposed to temperatures up to 60° C in paint-drying booths. If the temperatures are any higher, the compressed gas tanks must be removed or degassed using an inert gas such as nitrogen. The gas-carrying lines must also be ushed with inert gas. Working on the compressed natural gas (CNG) system – Work on the compressed natural gas system may only be carried out by persons who have been specically trained to do so. – The working area for the compressed natural gas system must be equipped with an adequate ventilation system. The ventilation system must replace the air in the room with new air at least three times per hour. – After exchanging standard-t components of the compressed natural gas system using the prescribed procedures, check the assembly points for leaks. Perform these checks using leak indicator spray or a gas warning device. T 61

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INTRODUCTION Engine operation – Only authorised personnel are permitted to start and operate an engine. – Do not approach moving parts of a running engine too closely and do not wear baggy clothing. Use an extractor system if working in enclosed spaces. – Danger of burns when working on engines at operating temperature. – Danger of scalding when opening the hot cooling circuit. Suspended loads – People are not allowed to stand below suspended loads. – Only use suitable lifting and gear that is in perfect working order. Use lifting devices with sufcient load-carrying capacity. Attachments and special bodies – Comply with the safety instructions and regulations issued by the body manufacturer in question if attachments or special bodies are tted. Working on high-pressure lines – Do not attempt to tighten or loosen pipe lines and hoses when they are under pressure (e.g. lubrication circuit, coolant circuit and hydraulic oil circuit). Risk of injury due to pressurised uids emerging! Checking injector nozzles – Wear suitable protective equipment. – Do not hold any part of your body under the jet of fuel when checking the injector nozzles. – Do not inhale fuel vapours. Ensure that there is adequate ventilation. Working on the vehicle electrical system – Do not disconnect batteries whilst the engine is running! – Always disconnect batteries when working on the vehicle electronic system, central electrical system, alternator and starter! When disconnecting batteries, remove the negative terminals rst. When connecting batteries, t the positive terminals rst. – Always use suitable test lines and test adapters when measuring at plug connections! – If temperatures of over 80°C are to be expected (e.g. in a drying oven after painting), switch the battery master switch to "OFF" and then remove the control units. – The chassis is not intended for use as an earth return. If attachments are to be tted to the vehicle (e.g. a wheelchair lift), additional earth (ground) lines with an adequate cross-section must be tted as well. Otherwise the earth connection may be created along wire cables, wiring harnesses, gearbox shafts, gears etc. Severe damage could result. Important! Battery gases are explosive! – Oxyhydrogen gas may form in enclosed battery boxes. Take particular care after long journeys and after charging the batteries with a battery charger. – When the batteries are disconnected this gas may be ignited by sparks produced by other continuously operating consumers, the tachograph etc. that cannot be shut down. Blow compressed air through the battery box before disconnecting the batteries! – Always leave the batteries connected when towing the vehicle! Only tow the vehicle if the check lamps are still dimly lit but the battery starting power is not reached. Do not use a rapid-charger to jump-start the vehicle! – Always disconnect the positive and negative leads before charging and rapid-charging batteries! – Do not rapid-charge lead-gel and maintenance-free batteries! (not in the case of "maintenance-free acc. to DIN") The maximum charging capacity is 10% of the indicated capacity per battery. In parallel circuits, the capacity is increased, in accordance with the total number of batteries connected in parallel. – Risk of short-circuits due to incorrect battery polarity! – Do not put metal objects (spanners, mole grips, etc.) on the batteries, since they may connect the terminals together. Risk of short-circuit! – Disconnect the batteries and recharge them every 4 weeks if the vehicle is not in use for prolonged periods. Caution! Battery acid is poisonous and corrosive! – Wear appropriate protective clothing (gloves) when handling batteries. Do not tilt batteries, acid may leak out. Similarly, do not tilt gel batteries. – Measure voltage only using suitable measurement devices! The input resistance of a measuring device should be at least 10 MΩ. 16

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INTRODUCTION – Only disconnect and connect plug connections for electronic control unit when the ignition is switched off! Electric welding – Connect the “ANTIZAP SERVICE SENTRY” protection device (MAN item number 80.78010.0002) as described in the instructions accompanying the device. – If this device is not available, disconnect the batteries and connect the positive cable to the negative cable in order to make a rm conductive connection. – If the battery master switch is manually operated, move it to the driving position. If an electronic battery master switch is tted, bridge “Negative” at the load-disconnecting relay contacts (jumper cable > 1mm2) and “Positive” at the load-disconnecting relay load contacts. In addition, switch on many loads such as: starter switch (ignition) in driving position, hazard warning lights switch “on”, lighting switch in “driving lights on”position, ventilation blower in “maximum” position. The greater number of consumers that are switched on, the greater the protection. After completing welding work, rst switch off all the consumers and remove all jumpers (re-create original state), then connect the batteries. – Always earth the welding equipment as close as possible to the welding area. Do not lay the cables to the welding equipment in parallel to electrical cables in the vehicle. Working on plastic tubes – Danger of damage and re! – Mechanical or thermal loading of plastic tubes is not permitted. Painting – If paint spraying is to be carried out, do not expose the electronic components to high temperatures (max. 95 °C) for more than brief periods; a time of up to 2 hours is permissible at a maximum of 85 °C. Disconnect the batteries. Painting of screw connections in the high-pressure section of the injection system is not permitted. Risk of dirt ingress in the event of repairs. Working with the cab tilted forwards – Keep the tilting area in front of the cab clear. – Keep out of the area between the cab and the chassis during the tilting process. This is a danger area! – Always tilt the cab past the tilting point and secure the cab using a support rod. Working on the air-conditioning system – Refrigerant uids and vapours represent a health hazard, avoid contact with them and protect your eyes and hands. – Do not drain gaseous refrigerants in enclosed rooms. – Do not mix CFC-free refrigerant R 134a with R 12 (CFC) refrigerant. – Dispose of refrigerant in accordance with regulations. Working on airbag or belt tensioner units – Work on airbag or belt tensioner units may only be carried out by staff who have veriably completed a competence course at the MAN Service Academy. – Mechanical loads, vibrations, heating to over 140° C and electrical pulses, including electrostatic discharge, can cause unintentional ring of the airbag or belt tensioner units. – Hot gases are released explosively when the airbag or belt tensioner unit is red. The non-mounted airbag or belt tensioner unit can be tossed around uncontrollably. This poses an injury risk to people in or near the cab. – Risk of burns when touching the hot surfaces after the airbag has red. – Do not open a red airbag. – Do not touch a red, destroyed airbag with your bare hands. Wear nitrile rubber gloves. – Before all work and testing on airbag or belt tensioner units or work on the vehicle that can cause vibrations, switch off the ignition, remove the ignition key, disconnect the ground line from the battery and disconnect the power supply plug connection for the airbag and belt tensioner. – Mount the driver airbag restraint system, MAN part number 81.66900-6035, on the airbag steering wheel in accordance with the operating instructions. – Only use specially designated devices for testing airbag and belt tensioner units. Do not use test lamps, voltmeters or ohmmeters. – After all work and tests, rst switch off the ignition, then connect the plug connection(s) for airbag and belt tensioner. Then connect the battery. There must be no-one in the cab whilst this work is going on. – Always deposit the airbags individually and with the impact cushion upwards. – Do not treat airbags or belt tensioners with grease or cleaners. T 61

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INTRODUCTION – Always store and transport airbag and belt tensioner units in their original packaging. Transport in the passenger compartment is not permitted. – Always store airbag and belt tensioner units in lockable storage areas, up to a maximum of 200 kg. Working on the independent heater – Before commencing work, switch off the heater and allow all hot components to cool down. – Ensure that suitable collecting containers are available and no sources of ignition are present when working on the fuel system. – Keep suitable re extinguishing equipment nearby and within easy reach!! – The heater may not be operated in enclosed areas such as garages or workshops unless an extractor system is used. 2. Notes on preventing damage and premature wear on units General information – Units are only designed for their specied purpose - dened by the manufacturer (designated use): Any other use is classied as not in accordance with the designated use. The manufacturer is not liable for damage caused as a result of such other use. In the event of such other use, the user alone bears the risk. – Designated use also includes compliance with the operating, maintenance and repair conditions specied by the manufacturer. – The unit may only be used, maintained and repaired by persons who are familiar with it and are fully aware of the risks. – Arbitrary changes to the engine mean that the manufacturer is no longer responsible for any damage incurred as a result of such changes. – Similarly, tampering with the injection and control system can affect the unit's performance and exhaust-gas characteristics. This means that compliance with the statutory environmental requirements is no longer assured. – If malfunctions occur, determine the cause and remedy the problem immediately. – Clean units thoroughly before repairs, ensuring that all openings where dirt is not allowed to enter for safety or functioning reasons are closed. – Never run a unit dry, in other words always make sure that it has been lled with oil before running it. – Never run engines without coolant. – Apply a suitable information sign to units that are not ready to be operated. – Only use service products as per the MAN Recommended Service Products booklet, otherwise the manufacturer warranty will be invalidated. Details of approved products can be found online at: http://www.man-mn.com/ > Products & Solutions > E-Business. – Comply with the specied maintenance intervals. – Do not ll engine/gear oil above the maximum level mark. Do not exceed the maximum permitted operational tilt. – The special measures described in MAN Works Standard M 3069 Part 3 apply if buses or trucks are to be withdrawn from service or stored for a period longer than 3 months. 3. Limited liability for parts and accessories General information Only use accessories and genuine MAN parts that have been expressly approved by MAN Nutzfahrzeuge AG for your MAN vehicle. MAN Nutzfahrzeuge AG accepts no liability for any other products. 4. Regulations for avoiding injury and environmental contamination Health protection precautions Avoid prolonged, excessive or repeated skin contact with service products, excipients, thinners or solvents. Protect your skin using a suitable skin protection agent or protective gloves. Do not use service products, excipients, thinners or solvents to clean the skin. Apply a greasy skin cream after cleaning your skin. Service products and excipients Do not use food or drink containers for draining and storing service products or excipients. Comply with local-authority regulations when disposing of service products and excipients. Coolant Treat undiluted antifreeze as hazardous waste. Follow the instructions issued by the relevant local authority when disposing of used coolant (mixture of antifreeze and water). 18

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INTRODUCTION Cleaning the cooling circuit Do not pour cleaning uids and rinsing water down the drain if this practice is restricted by specic local regulations. However, the cleaning uid and rinsing water must in all cases have been passed through an oil trap with a sludge trap. Cleaning the lter insert When blowing compressed air through the lter insert, make sure the lter dust is collected by a vacuum or is blown into a dust collection bag. Otherwise, use a respiratory protection mask. Wear rubber gloves or use a skin barrier hand cream when washing out the elements, because cleaning agents have aggressive grease-dissolving characteristics. Engine/gear oil, lter cartridges, inserts and box-type lters, desiccant cartridges Filter inserts, cartridges and box-type lters (oil and fuel lters, desiccant cartridges for the air dryer) are classied as hazardous waste. Comply with local-authority regulations when disposing of the above parts. Used engine/gear oil Lengthy or repeated skin contact with any type of engine/gear oil removes grease from the skin. This can cause dry skin, irritation or skin inammation. In addition to these hazards, used engine oil contains dangerous materials which can trigger dangerous skin diseases. Wear gloves, especially when changing the oil. Handling AdBlue® AdBlue® is a synthetically produced 32.5 % urea/water solution which is used as an NOx reduction additive for diesel engines with SCR catalytic converter. AdBlue® is not a hazardous substance but does decompose into ammonium hydroxide and carbon dioxide when stored for prolonged periods. For this reason, AdBlue® is classied as a water hazard (water hazard class 1) in Germany and is not allowed to enter sewag or the ground. Ensure good ventilation in the workplace when working on the AdBlue® system. Do not eat, drink or smoke in the workplace. Avoid skin and eye contact with AdBlue®, thoroughly wash your hands and use a skin protection cream before taking breaks and before nishing work. If your skin comes into contact with AdBlue®, wash the skin using water and a skin cleaner, change out of dirty clothes immediately. If the skin is irritated, consult a doctor. If AdBlue® gets into your eyes, rinse your eyes with water or an eye-rinsing products for at least 10 minutes, keeping your eyelids open. Remove any contact lenses beforehand. If symptoms persist, consult a doctor. If AdBlue® is swallowed, consult a doctor immediately. Store AdBlue® containers closed in liquid-tight storage areas. The storage temperature must not exceed 25°C. Soak up leaked or spilt AdBlue® using binding agent and dispose of in the correct manner. 5. Information for working on the common rail system General information – A jet of fuel can cut through the skin. Risk of re due to fuel atomisation. – Never undo the screwed connections on the fuel high-pressure side of the common-rail system whilst the engine is running (high-pressure line from the high-pressure pump to/on the rail and on the cylinder head to the injector). Whilst the engine is running, the lines are constantly carrying fuel under a pressure of 1800 bar or more. Before the screw connections are opened, wait at least one minute until depressurisation has occurred, using MAN-cats to check the depressurisation on the rail as necessary. – Avoid standing near the running engine. – Do not touch the live parts at the injector electrical connection whilst the engine is running. – Any changes to the original wiring can lead to the limit values specied in pacemaker regulations being exceeded. Examples of such changes include non-twisted injector wiring or the addition of the test box (contact box). – There is no danger to operators and persons wearing a pacemaker if units with MAN common-rail engines are used for their intended, i.e. approved, purpose. – A jet of fuel can cut through the skin. Risk of re due to fuel atomisation. – Never undo the screwed connections on the fuel high-pressure side of the common-rail system whilst the engine is running (injection line from the high-pressure pump to/on the rail and on the cylinder head to the injector). – Avoid standing near the running engine. – Whilst the engine is running, the lines are constantly carrying fuel under a pressure of 1800 bar or more. – Before opening the screwed connections, wait for at least one minute so that the system can be depressurised. – Check depressurisation of the rail using MAN-cats if necessary. – Do not touch the live parts at the injector electrical connection whilst the engine is running.

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INTRODUCTION Information for people with pacemakers – Any changes to the original engine wiring can lead to the limit values specied in pacemaker regulations being exceeded. Examples of such changes include non-twisted injector wiring or the addition of the test box (contact box). – There is no danger to drivers and co-drivers wearing a pacemaker if the vehicle is used for its intended, i.e. approved, purpose. – There is no danger to operators wearing a pacemaker if units with MAN common-rail engines are used for their intended, i.e. approved, purpose. – In its original state, the product does not violate any of the currently known pacemaker limit values. Danger of damage due to dirt ingress – Diesel-injection systems consist of precision engineered components that are subject to extreme loads; Due to the highly precise nature of this technology, all work on the fuel system requires the highest possible degree of cleanliness. – Even dirt particles over 0.2 mm can cause component failure. Before commencing work on the clean side – Clean the engine and engine compartment with the fuel system closed. Do not use a powerful jet when cleaning electrical components. – Drive the vehicle into a clean area of the workshop where none of the work causes dust to be swirled up (sanding, welding, brake repairs, brake checks, performance tests etc.). – Avoid air movements (possible swirling up of dust due to starting of engines, the workshop heating/ventilation system, due to draughts etc.). – Clean and dry the area of the still closed fuel system using compressed air. – Use a suitable extractor unit (industrial extractor unit) to remove loose dirt particles such as paint chippings and insulating material. – Use a new and clean cover in areas of the engine compartment where dirt particles can become loose, e.g. tilted cab, bus engine compartment. – Before removing any components, wash your hands and put on clean working clothes. After opening the clean side – The use of compressed air for cleaning is not permitted. – During assembly, remove loose dirt using a suitable extractor unit (industrial extractor unit). – Only lint-free cleaning cloths are allowed to be used on the fuel system. – Clean tools and equipment before commencing work. – Only use tools that show no signs of damage (cracked chrome coatings). – Do not use materials such as cloths, cardboard or wood when removing and installing components as these materials can produce particles and bres. – If the undoing of connections causes the paint to chip (due to possible excess paint), carefully remove these paint chippings before fully undoing the connection. – All removed components on the clean side of the fuel system must be plugged immediately at their connection openings using suitable caps. – These caps must be stored in dustproof packaging until they are used and disposed of after they have been used once. – Then store the components in a clean, sealed container. – Never use used cleaning or test uids for these components. – New parts must not be removed from their original packaging until immediately before use. – Work on removed components may only be carried out in a suitably equipped workplace. – If removed parts are shipped, always use the new part's original packaging. When carrying out work on bus engines, the instructions below must also be followed without fail: Danger of damage due to dirt ingress – Before opening the clean side of the fuel system: Clean the areas of the engine around pressure line ttings, injection lines, the rail and valve cover using compressed air. – Remove the valve cover and then re-clean the areas of the engine around the pressure line ttings, injection lines and rail. – Only loosen pressure pipe connections at rst: Undo the union nuts on the pressure pipe connections and unscrew by 4 turns. Raise the pressure pipe connections using a special tool. Reason: only remove the pressure pipe connections completely once the injectors have been removed so that no dirt can fall into the injectors from above. 20

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INTRODUCTION – Remove the injectors. – After removal, rinse out the injectors with a cleaning uid, making sure that the high-pressure connection hole is facing downwards. – Remove the pressure pipe connections by unscrewing their union nuts. – Clean the injector hole in the cylinder head. 6. Limp-home program for units with electronic control units General information The units have an electronic control system that monitors the unit as well as itself (self-diagnosis). As soon as a malfunction occurs, the malfunction is evaluated and one of the following measures is implemented automatically: – Output of a fault message with fault code. – Switchover to suitable default function for further operation, albeit with restrictions. Have malfunctions remedied by MAN after-sales immediately. – If MAN-cats is used, the fault code is output directly. 7. Installation instructions Installation of piping – Mechanical deformation of piping is not permitted when performing installation work - risk of fracture! Installation of gaskets – Only use genuine MAN gaskets – Make sure the surfaces to be sealed are undamaged and clean. – Do not use adhesives or sealing compounds. If necessary, to facilitate installation, use a little grease to stick the seal to the part to be mounted. – Tighten the bolts evenly to the specied tightening torque. Installation of O-rings – Only use genuine MAN O-rings – Make sure the surfaces to be sealed are undamaged and clean. Engine overhaul – A range of very different factors affect the engine service life. It is therefore not possible to indicate the exact number of operating hours or miles before a major overhaul is due. – In our judgement, it is not advisable to open an engine or perform a major overhaul if the engine has good compression values and the following operating values have not changed signicantly since they were measured and taken during the initial start-up: – Charge pressure – Exhaust gas temperature – Coolant and lubricating oil temperature – Oil pressure and oil consumption – Smoke characteristics The following criteria have a major inuence on the engine service life: – Correct power setting for the application type – Correct installation – Approval of the installation by authorised personnel – Regular maintenance as per the maintenance schedule

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INTRODUCTION MODEL OVERVIEW The System Description T 61 (2nd) Electronic Brake System (EBS) / Electronic Stability Program (ESP) – 02.2008 edition – applies to the Trucknology Generation (TGA) and the rough-terrain trucks (X models). Electronic Brake System (EBS) - TGA Model Model designation

Model Model designation

H01

TGA 18.D28 4X2 BLS-TS

H45

TGA 24.D20 6X2-2 LL-U

H02

TGA 18.D28 4X2 BB

H46

TGA 41.D28 8X4 BB-WW

H03

TGA 18.D20 4X2 BB

H48

TGA 32.D28 8X4 BB

H05

TGA 18.D28 4X2 BL

H49

TGA 32.D20 8X4 BB

H06

TGA 18.D20 4X2 BL

H51

All-wheel drive: TGA 18.D28 4X4 BB

H07

ECT 18.ISM 4X2 BL

H52

All-wheel drive: TGA 18.D20 4X4 BB

H08

TGA 18.D20 4X2 BLS-TS

H54

All-wheel drive: TGA 33.D28 6X6 BB-WW

H09

TGA 18.D28 4X2 LL

H55

All-wheel drive: TGA 26/33.D28 6X6 BB

H10

TGA 18.D20 4X2 LL

H56

All-wheel drive: TGA 26/33.D20 6X6 BB

H12

TGA 18.D28 4X2 LLS-U

H57

All-wheel drive: TGA 40.D28 6X6 BB-WW

H13

TGA 18.D20 4X2 LLS-U

H60

TGA 19.D28 4X2 BB-WW-SKD

H14

TGA 18.D28 4X2 LL-U

H61

TGA 18.D28 4X2 BL-WW-SKD

H15

TGA 18.D20 4X2 LL-U

H62

TGA 33.D28 6X4 BB-WW-SKD

H16

TGA 26.D08 6X2-4 BL

H63

TGA 26.D28 6X4 BB-WW-SKD

H17

TGA 26.D28 6X2-2, 6X2-4 BL

H70

All-wheel drive: TGA 18.D28 4X4 BL

H18

TGA 26.D20 6X2-2, 6X2-4 BL

H71

TGA 28.D28 6X2-4 BL/LL

H19

TGA 26.D08 6X2-4 LL

H72

All-wheel drive: TGA 26/33.D28 6X6 BL

H20

TGA 26.D28 6X2-2, 6X2-4 LL

H73

All-wheel drive: TGA 35/41.D28 8X6 BB

H21

TGA 26.D20 6X2-2, 6X2-4 LL

H74

TGA 28.D20 6X2-4 BL

H23

TGA 26.D28 6X2/2, 6X2/4 BL

H75

TGA 28.D20 6X2-4 LL

H24

TGA 26.D20 6X2/2, 6X2/4 BL

H76

All-wheel drive: TGA 35/41.D28 8X8 BB

H25

TGA 26/33.D28 6X4 BB

H80

All-wheel drive: TGA 18.D20 4X4 BL

H26

TGA 26/33.D20 6X4 BB

H81

All-wheel drive: TGA 28.D28 6X4-4 BL

H27

ECT 26.ISM 6X2-2, 6X2-4 BL

H82

All-wheel drive: TGA 26/33.D20 6X6 BL

H28

TGA 33.D28 6X4 BB-WW

H84

All-wheel drive: TGA 28.D20 6X4-4 BL

H29

TGA 26/33.D28 6X4 BL

H85

TGA 28.D20 6X2-2 LL

H30

TGA 26/33.D20 6X4 BL

H86

TGA 28.D28 6X2-2 BL

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2nd edition

INTRODUCTION Model Model designation

Model Model designation

H31

ECT 26.ISM 6X2-2, 6X2-4 LL

H87

TGA 28.D28 6X2-2 LL

H32

ECT 26.ISM 6X2/2, 6X2/4 BL

H88

TGA 35.D28 8X2/4, 8X2-6 BL

H33

TGA 40.D28 6X4 BB-WW

H89

TGA 28.D20 6X2-2 BL

H36

TGA 35.D28 8X4 BB

H90

TGA 35.D20 8X2-4, 8X2-6 BL

H37

TGA 35.D20 8X4 BB

H91

TGA 35.D28 8X4-4 BLL

H38

TGA 41.D28 8X4 BB

H92

TGA 35.D20 8X4-4 BLL

H39

TGA 41.D20 8X4 BB

H93

All-wheel drive: TGA 35/41.D20 8X6 BB

H40

TGA 32/35.D28 8X4 BL

H94

TGA 41.D28 8X4/4 BB / BL (heavy-duty tractor)

H41

TGA 32/35.D20 8X4 BL

H95

TGA 41.V10 8X4/4 BB / BL (heavy-duty tractor)

H43

TGA 19.D28 4X2 BBS-WW

H96

All-wheel drive: TGA 35/41.D20 8X8 BB

H44

TGA 24.D28 6X2-2 LL-U

H99

TGA 28.D20 6X2-4 LL-Low Entry

Electronic Brake System (EBS) / Electronic Stability Program (ESP) - TGA Model Model designation

Model Model designation

H01

TGA 18.D28 4X2 BL-TS

H09

TGA 18.D28 4X2 LL

H05

TGA 18.D28 4X2 BL

H10

TGA 18.D20 4X2 LL

H06

TGA 18.D20 4X2 BL

H12

TGA 18.D28 4X2 LLS-U

H08

TGA 18.D20 4X2 BLS-TS

H13

TGA 18.D20 4X2 LLS-U

Electronic Brake System (EBS) - X models Model Model designation

Model Model designation

X44

25T 6X6 DFAEG

X60

16T 4X4 FAEX/FAREX

X45

32T 8X8 VFAEG

X66

19T 4X4 FALX

X58

26T 6X6 DFAEX/DFAREX

X77

32T 8X8 VFAEX/VFAREX

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INTRODUCTION EXPLANATORY NOTES TO THE WIRING DIAGRAMS

(1) Electrical component designation (example - Diode V100, central electrical system, number 53) (2) Installation position on the front side of the central electrical system (here -stamped number 53) (3) Plug connection at the rear end of the central electrical system (here - plug 78, connection 8) (4) Cable number, with abbreviated colour name in the case of coloured cable, cross-section information only given if different from 1² (5) Cable designation, number in brackets: conductor pathways on a p.c.b. (6) Line discontinuity and line continuation with sheet number (Sheet 2) and path number (Path 4) (7) Plug connection (example - one-pin plug connection X104) 24

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(8) Installation position of the component (see - identication of installation positions) (9) Current path (numbered from 1 to 55/60 on each diagram)

2nd edition

INTRODUCTION Installation positions for location identiers Installation positions for left-hand drive vehicles (TGA)

(A) (B1) (B2) (C) (C1) (C2) (C3) (E6) (E7) (E8) (F) (F1) (F2) (F3) (F4) (F5) (F6) (F7) (F8) (G) (H1) (H2)

Rear of vehicle Engine Gearbox Front of vehicle Bumper Entrance, right Entrance, left Area of central electrical system Control unit plug-in modules Back wall of cab Instrument panel Mid-section Steering column / steering wheel Pedals Front wall, inside left Front wall, inside right Driver’s seat Co-driver’s seat Shift console Battery box B-pillar, driver’s side A-pillar, driver’s side

(J1) (J2) (L) (N) (P) (R1) (R2) (S1) (S2)

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2nd edition

B-pillar, co-driver's side A-pillar, co-driver’s side Ceiling / roof Front axle Rear axle Front frame sections Rear frame section Door, left Door, right

25

INTRODUCTION Installation positions for right-hand drive vehicles (TGA)

(A) (B1) (B2) (C) (C1) (C2) (C3) (E6) (E7) (E8) (F) (F1) (F2) (F3) (F4) (F5) (F6) (F7) (F8) (G) (H1) (H2) (J1) 26

Rear of vehicle Engine Gearbox Front of vehicle Bumper Entrance, right Entrance, left Area of central electrical system Control unit plug-in modules Back wall of cab Instrument panel Mid-section Steering column / steering wheel Pedals Front wall, inside left Front wall, inside right Co-driver’s seat Driver’s seat Shift console Battery box B-pillar, co-driver's side A-pillar, co-driver’s side B-pillar, driver’s side

(J2) (L) (N) (P) (R1) (R2) (S1) (S2)

T 61

2nd edition

A-pillar, driver’s side Ceiling / roof Front axle Rear axle Front frame sections Rear frame section Door, left Door, right

INTRODUCTION Installation positions for rough-terrain trucks (X models) Installation positions – cab

(C) (E4) (E5) (E6) (E7) (E8) (F) (F1) (F2) (F3) (F4) (F5) (F6) (F7)

Front end Relays, diodes etc. Control units 2 Central electrical system Control units 1 Back wall of cab Instrument panel Mid-section Steering column / steering wheel Pedals Front, inside left Front, inside right Driver’s seat Co-driver’s seat

(F8) (F9) (H1) (H2) (J1) (J2) (L) (S1) (S2) (1) (2) (3) (4) (5)

Shift console Switchboard B-pillar, driver’s side A-pillar, driver’s side B-pillar, co-driver's side A-pillar, co-driver’s side Ceiling / roof Door, left Door, right Connecting points (F1) Connecting points (F3) Centre seat Fuses (E6) Diagnosis socket (E6)

(P) (R1) (R2) (T) (6)

Rear axle Front frame section Rear frame section Support frame behind cab Cab

Installation positions – frame

(A) (B1) (B2) (C1) (C2) (C3) (G) (N)

Rear of vehicle Engine Gearbox Bumper Entrance, right Entrance, left Battery box Front axle T 61

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27

DEVICE DESCRIPTION

DEVICE DESCRIPTION SYSTEM DESCRIPTION Electronic brake system (EBS) The designation for the entire system: EBS – 2.2 Second enhancement of the second generation (without ESP) – 2.3 Third enhancement of the second generation (ESP-compatible) The previous EBS version 2.2 has been adapted to the requirements of ESP, e.g. an interface has been created between ESP and ABS/ASR and the safety functions have been enhanced. For this reason, ESP only functions with EBS version 2.3. EBS sub-functions – EPB electro-pneumatic brake system. EPB performs electronic brake pressure control. Without ABS, the pressure is varied up to maximum pressure output. Additional functions have an effect on electronic brake pressure control, with the result that the brake pressure is distributed variably between the brake cylinders. – ABS Anti-lock Brake System. ABS controls the brake pressure when the wheels are starting to block, and switches off the sustained-action brake. – ASR Anti-Spin Regulator. ASR controls the brake pressure on driven axles when the wheels are starting to spin and/or reduces the engine power. – ESP Electronic Stability Program. ESP controls or reduces the risk of tipping over when cornering and the risk of skidding/jackkning on slippery roads. EBS consists of a two-circuit, purely pneumatic control circuit and a master control circuit which is a one-circuit electro-pneumatic control circuit. The structure of the subordinate dual-circuit pneumatic control circuit is largely identical to that of a conventional brake system. Electronic brake pressure control is assisted by the pneumatic control circuit (back-up circuit) that takes effect automatically if there is an electrical failure. The parking brake system is operated in the conventional mechanical way with pneumatic signal transmission. Features of EBS for commercial vehicles – Conventional parking brake system: Mechanically actuated, with pneumatic signal transmission – Service brake system: Electronically controlled brake system with single-circuit vehicle system voltage and dual-circuit pneumatic backup circuit – 24 volt vehicle system voltage, up to 12.5 bar reservoir pressure, up to 10 bar brake cylinder pressure – Pneumatic two-line brake system with conventional trailer control module – 7-pin electrical plug connection according to DIN ISO 7638 between tractor and trailer – EBS control unit with CAN data transmission: – Powertrain CAN databus – EBS control unit to other systems in the vehicle – Trailer CAN databus – EBS control unit, tractor/trailer, according to DIN ISO 7638 – Brake CAN databus – EBS control unit to the pressure control modules in the tractor and trailer – Single-channel / dual-channel pressure control modules with integrated electronics – Trailer control module for electronic control with conventional trailers – Speed sensors and brake sensors are connected to the pressure control modules – ASR function with brake and engine controller via powertrain CAN databus – Additional function switch (e.g. ASR spin threshold increase) – Automatic load-dependent brake (ALB) integrated in electro-pneumatic brake – EOL-programmable system conguration and pressure curves based on individual optimisation criteria (even application of all wheel brakes, pressure ow, brake wear, even adhesion, maximum deceleration) – Coupling force control (in conjunction with trailer control module only) – Brake wear control, brake wear function indicator – Diagnosis with MAN-cats® II via the 12-pin diagnosis socket X200

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DEVICE DESCRIPTION Function and connection diagram (4x2 truck)

——— ----(1) (2) (3) (4) (5) (6) (7) (8) (9)

Pneumatic lines Electrical lines EBS control unit (A402) Service brake valve with integrated brake power sensor (G7.302 /B337) Pressure control module, front axle, right (G67.304 / 262) Speed sensor, front axle, right (B120) Sensor, brake lining/pad front axle right (B332) Sensor brake lining/pad front axle left (B333) Speed sensor front axle left (B119) Pressure control module, front axle, left (G67.304 / Y263) Trailer control module (G17.301 / Y278) T 61

(10) Pressure control module, rear axle (G67.305 / Y264) (11) ALB sensor, rear axle (pressure sensor) (B336) (12) Speed sensor rear axle right (B122) (13) Brake sensor driven axle right (B334) (14) Brake sensor driven axle left (B335) (15) Speed sensor rear axle left (B121) (16) Trailer socket ABS (X317) (17) Diagnosis socket (X200) for MAN-cats

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29

DEVICE DESCRIPTION Mode of operation of the subfunctions Driving position The dual-circuit pneumatic back-up brake circuit is ready for operation when the ignition is “OFF” and there is sufcient compressed air available (see section on braking using back-up circuit). All the solenoid valves in the brake system are de-energised and adopt their basic positions by mechanical means (springs). The EBS control unit (1) is taken into operation when the ignition is switched on. Providing there are no malfunctions, the EBS is switched on when the brake pedal is released. EBS is supplied from the single-circuit vehicle electrical system. All solenoid valves in the brake system are de-energised when not actuated. EPB – electropneumatic brake system The service brake valve (2) is actuated. The brake power sensor integrated in the service brake valve supplies an electrical signal to the EBS control unit (1). A nominal brake pressure value is generated from this in accordance with EOL specications. This is passed on to the trailer plug connection (16) (Trailer CAN databus). In addition, the nominal pressures generated in the EBS control are passed on to the pressure control modules (3, 8, 10) via the CAN databus brake. These regulate the brake pressure for the down-circuit brake cylinders automatically. The nominal pressures passed on from the EBS control unit to the pressure control modules are adapted according to the axle load. In order to determine the axle load-dependent desired pressures, a value for the axle load is picked up at the air suspension, e.g. by a pressure sensor (11), and the measured value is sent to the EBS control unit. Braking by back-up circuit In the tractor, two pneumatic brake pressures are output by the service brake valve (2) irrespective of the electrical signal of the brake power sensor. These are passed on to the pressure control modules (3, 8, 10) in the tractor. The pneumatic brake pressure is held in “back-up” at the pressure control modules during electronically controlled braking. The pneumatic pressures of the service brake valve are also present at the trailer control module (9) in the tractor. The trailer control module outputs a pressure to the coupling head brake and to the coupling head supply. Braking by the back-up circuit (without “back-up” at the pressure control module) takes place when – the ignition switch is in “OFF” position – the EBS control unit does not supply a nominal electronic value to individual or all pressure control modules – The EBS control unit has switched off individual or all pressure control modules when a malfunction was detected. During braking by the back-up circuit, the solenoid valves in the pressure control modules (3, 8, 10) are not energised. They allow the brake pressure output by the service brake valve (2) and present at the pressure control module control input to pass to the relay valve in the pressure control module and trailer control module. These output a proportional pressure from the connected supply line into the brake cylinders and into the brake line to the trailer. ABS – Anti-lock brake system The speed sensors (4, 7, 12, 15) are connected to the inputs of the pressure control modules (3, 8, 10). The signals are passed on to the EBS control unit (1) via the CAN databus brake and the control unit calculates a vehicle reference speed as well as other values which are then passed on to the pressure control modules via the CAN databus brake. ABS with electropneumatic brake system (EPB with nominal electrical value) Each pressure control module reduces the brake pressure in relation to the specied nominal pressure in its control channel according to a permitted slip value. ABS and sustained-action brake When ABS control is active, this is indicated via the sustained-action brake relay output on the control unit (A402 pin X1/16) and via the “ABS active” information in the EBC1 message on the powertrain CAN databus. The signals are set: – During service braking with ABS – If there is increased slip although the service brakes are not applied These signals enable the sustained-action brake to be switched off during ABS control. 30

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DEVICE DESCRIPTION Control procedure for ABS vehicles Four control strategies are available in the EBS, which take effect according to the combination of pressure control module and speed sensor, and the EOL programming. – Individual regulation (IR) – Individual regulation modied (IRM) – Select-low control (SL) – Select-smart control (SSM) - Individual regulation (IR) The brake pressure in a control channel is individually controlled according to the turning behaviour of the wheel that it monitors. When the coefcients of friction of the road differ on the left and right-hand sides of an axle, the adapted but different brake forces produce a yawing moment about the vertical axis. The control behaviour is principally used on non-steered axles to control the responses of the vehicle during braking. - Individual regulation modied (IRM) The brake pressure in two control channels is individually controlled according to the turning behaviour of the wheels that it monitors. However, the maximum possible brake pressure on the wheel that is not yet blocked is restricted compared to the wheel that is already subject to ABS control. Yawing moments are reduced without signicantly increasing the braking distance. Application is principally on steered axles (axle load-dependent) - Select-low control (SL) The brake pressure in a control channel is controlled according to the turning behaviour of two wheels that are monitored. In this case, the brake pressure is adapted to the monitored wheel which rst indicates a tendency to blocking (low wheel is selected). The braking power that can be transferred is not utilised on the wheel that is rolling on the surface with a high friction coefcient (high wheel). SL has a positive effect on vehicle stability but a negative effect on braking distance. Application on axles with single-channel control (e.g. steered trailing axle) or SL on individual sides. - Select-smart control (SSM) The brake pressure in a control channel is controlled according to the turning behaviour of two wheels that are monitored. When the monitored wheels are rolling on road surfaces with different coefcients of friction, an intelligent evaluation function makes it possible to set a higher brake pressure than in SL. This means that the average braking power is greater. Short blocking phases on the wheel with the low friction coefcient (low wheel) can occur in phases when select-high (SH) is used for control. Application on axles with single-channel control or SSM on individual sides. ASR – Anti-spin regulator (traction control) Turning when moving off and acceleration of both driven wheels is detected by the electronic control unit due to the speed difference between the driven and the non-driven wheels, so it reduces the engine torque (engine governor). When the coefcients of friction are different on the right and left (µ split), it is usually only the wheel with the lower friction coefcient that slips. The ASR brake governor brakes the slipping wheel. The input torque can now take effect on the wheel with the high friction coefcient. In this way, ASR operates as an automatic differential lock. ASR must be switched off for measurements on the test rig. ASR engine governor If the driven wheels are slipping by equivalent amounts, the engine drive torque is reduced until the average speed of rotation of the driven rear axle wheels is slightly above that of the non-driven front axle wheels. The reduction signal required for this is output by the EBS control unit via the CAN databus, powertrain for electronic diesel control (EDC). The engine governor can be activated in all speed ranges. Communication with control unit EDC Communication takes place via the CAN databus, powertrain to the vehicle management computer (A403) and from there via the CAN databus engine to the EDC control unit (A435). Off-road ASR Pressing the ASR off-road button makes it possible to vary the slip in particular off-road driving conditions. Activation of this special status is indicated to the driver using the ASR info check lamp (information display) on the instrument panel or as a symbol to indicate “ABS off-road switch active”. The function is deactivated by pressing the button again or switching the ignition off. T 61

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DEVICE DESCRIPTION ASR brake governor When a wheel slips, the slipping wheel is gradually braked and checked by a pressure sensor and speed sensor. Braking decreases the speed of the slipping wheel, the speed of the driven wheel increases due to the input torque. This synchronises the speeds of the driven wheels. The brake governor is no longer activated at speeds of 40 km/h and above. However, if this function is already active at lower speeds during acceleration, it can remain switched on at above 40 km/h until the next gear change, given a corresponding control procedure. The EBS control unit does not measure the thermal load on the wheel brakes due to the ASR brake governor. An appropriate moving-off style must be used to avoid the possibility of overload during lengthy ASR control. The ASR brake governor is switched off after one second if the reservoir pressure in one of the brake circuits is too low. For this reason, the EBS control unit reads in the voltage of the red warning light or the reservoir pressure information via the CAN databus, powertrain “Reservoir pressure” message. Automatic tyre compensation The system has automatic tyre compensation. Following a tyre change, it is possible that the ASR engine governor might switch on before the procedure of adapting to the new tyre dimensions is completed. This can be cancelled by pressing the ASR off-road button. After a few minutes of driving on a straight road without braking, the adaptation procedure will have nished and the ASR off-road button can be switched off again Components of EBS EBS control unit (A402) The electronic control unit is used for controlling and monitoring the electronically controlled brake system. The voltage supply is from the central electrical system. Data transfer – to other systems is handled via the “Powertrain” CAN databus – to the tractor/trailer via the “Trailer” CAN databus – to the pressure control modules in the tractor/trailer via the “Brake” CAN databus The control unit is EOL-programmed (end of line). At the end of the line, the vehicle manufacturer inputs vehicle-specic parameters alongside the already entered system manufacturer parameters. The entered parameters can be checked – or changed if necessary – using MAN-cats® II. Brake power sensor (B337) The brake power sensor is integrated in the service brake valve. The voltage supply comes from the EBS control unit (A402). 1-channel pressure control module (Y262/Y263) A 1-channel pressure control module with integrated electronic control unit is installed on the right and left of the front axle. The voltage supply comes from the EBS control unit (A402). Data transfer from the pressure control modules to the EBS control unit takes place via the databus brake. 2-channel pressure control module (Y264) A 2-channel pressure control module (Y264) with integrated electronic control unit is installed on the rear axle. The voltage supply comes from the EBS control unit (A402). Data transfer from the pressure control module to the EBS control unit takes place via the CAN databus “brake”. Trailer control module (Y278) A trailer control module with integral electronic control unit is installed for trailer operation. The voltage supply comes from the EBS control unit (A402). Data is transferred from the trailer control module to the EBS control unit via the “trailer” CAN databus. The main functions of the trailer control module are controlling the brake pressure in the trailer control line (connection 22) and the coupling force between the tractor and trailer. The parking brake and the pull-off function work in the conventional way. Speed sensor device The speed sensor device consists of a toothed impulse wheel and an inductive speed sensor (B119/B120 front axle, B591/B592 second front axle, B121/B122 driven axle). The speed sensors are electrically connected to the pressure control modules. An alternating current voltage is generated in the speed sensor when the wheel is turning. The frequency of this voltage is proportional to the wheel speed. 32

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DEVICE DESCRIPTION Brake sensor Each pressure control module on the front axle is tted with one sensor (B332/B333). On the 2nd front axle, the sensors (B537/B538) are also connected to the pressure control modules. In the case of the pressure control module on the rear axles, two sensors (B334/B335 – driven axle and B529/B530 – additional axle) are connected per axle. The sensors are electrically connected to the pressure control module. Each of the sensors is only supplied with voltage during braking, except for the voltage supply for initialisation after the ignition is switched on. Following the completion of braking, the electrical signals in the pressure control modules are recorded. Data is transferred via the CAN databus brake. ALB sensor, driven axle (B336) The ALB sensor is used to convert a physical variable such as pressure or travel into a voltage. The sensor is electrically connected (with a voltage of 5 volts) to the rear axle pressure control module. – Axles with air suspension (pressure sensor). The sensor contains a pressure-sensitive measuring element and a booster circuit. The pneumatic port is connected to the compressed-air line which leads to the air bellows. – Axles with leaf suspension (travel sensor). The sensor is fastened on the vehicle body. The vertical motion of the axle must be transferred to the lever which is located on the actuating shaft. There is a voltage distributor in the sensor. Trailer socket The voltage supply to the trailer socket (X317) comes from the central electrical system (A100). Data is transferred from the tractor to the trailer via the “Trailer” CAN databus (X317 pin 6 and pin 7). The following are required for trailer EBS operation, in order to ensure that tractors and trailers can be interchanged: – Two-line compressed air brake system with compressed air reservoir and control line. – Plug connection for ABS, however with full pin population including pins 6 and 7 (7-pin connection cable). CAUTION: Only the conventional pneumatic control circuit takes effect if an EBS is integrated in the trailer but only a 5-pin ABS connection cable is used between the tractor and trailer. Compatibility between various brake systems As well as vehicle combinations of tractors and trailers with EBS, it is also possible to have combinations of EBS tractors and conventional trailers and trailers in accordance with ISO 11992 and ISO 7638 (7-pin). The effect on the trailer depends on the pneumatic and electrical supply as well as the control lines connected between the tractor and the trailer.

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DEVICE DESCRIPTION The following combinations are listed below for: Tractor with EBS and differently equipped trailers (see vehicle combinations 1-4)

Trailer vehicle

Vehicle combination 1

Pneumatic brake system without ABS

Vehicle combination 2

Pneumatic brake system with ABS and brake lamp supply

Vehicle combination 3

Pneumatic brake system with ABS and 5-pin connection according to ISO 7638

Vehicle combination 4

Control according to ISO 11992 via 7-pin connection according to ISO 7638 and EBS with pneumatic and electrical brake line

EBS tractor with pneumatic and electrical brake line, control according to ISO 11992 via 7-pin connection according to ISO 7638 Functions in the trailer with the following vehicle combinations. 1 The trailer is connected to the tractor via the pneumatic two-line system and brakes according to the equipment tted in it. 2 The trailer is connected to the tractor via the pneumatic two-line system and brakes, including ABS via brake lamp supply, according to the equipment tted in it. 3 The trailer is connected to the tractor via the pneumatic two-line system and the 5-pin ABS connection, including ABS according to ISO 7638 directives, according to the equipment tted in it. 4 The trailer is connected to the tractor via the pneumatic 2-line system and the 7-pin EBS connection and brakes according to the pneumatic pressure of the brake line or according to the nominal values from the CAN databus trailer. The trailer makes the selection according to the brake guidelines. Caution! If EBS is integrated in the trailer but only a 5-pin ABS connection cable is used between the tractor and trailer, then the function in the trailer corresponds to that of combination number 3. Coupling force control The tractor and trailer brake pressures are adjusted in the trailer control valve.

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DEVICE DESCRIPTION Function and connection diagram (trailer)

——— ----(1) (2) (3)

Pneumatic lines Electrical lines ABS trailer socket EBS control unit ALB sensor (pressure sensor)

(4) (5) (6) (7) (8)

Brake sensor Speed sensor Pressure-control modules Reservoir pressure switch Trailer brake valve

Function in the trailer The trailer is supplied by a two-line system as in conventional vehicles. As soon as EBS is operating, the EBS control unit is informed about the braking procedure via the 7-pin trailer socket ABS with pin 6 (CAN High) and pin 7 (CAN Low). Electronically controlled braking is possible even if the vehicle is only equipped with a 5-pin trailer socket, because the control unit can evaluate the pneumatic nominal value via the back-up circuit. This means all pressure control functions as well as ALB control via the ALB sensor and ABS are maintained.

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DEVICE DESCRIPTION Electronic Stability Program (ESP) General information ABS prevents the wheels from blocking during braking and ASR prevents the wheels from spinning during acceleration. Based on these systems, ESP provides for a stabilised driving behaviour in critical driving conditions. Accident statistics have shown that approx. 15 % of all accidents are caused by vehicles skidding, in particular when the carriageway has a low and medium coefcient of friction (in ice, snow, rain). ESP takes effect above all in rapid avoidance manoeuvres, panic responses or understeer, oversteer and jackkning of the vehicle. ESP even takes effect under changing carriageway (coefcient of friction) conditions by braking individual wheels and intervening in the engine control system to stabilise the vehicle. Whereas ABS and ASR principally intervene in the longitudinal dynamics of the vehicle, ESP has the additional task of stabilising the vehicle about its vertical axis. This is referred to as yawing moment control. Yawing refers to rotation about the vertical axis of the vehicle. Vehicle types and variants/modication ESP is a system that controls vehicle dynamics by braking. It is dependent on the current vehicle dynamics, i.e. the current driving behaviour. In turn, the current driving behaviour depends on the vehicle type and the vehicle conguration. As a result, ESP must be adapted to a specic vehicle type (target vehicle) so that certain variants of this vehicle type will be covered. Changes to the vehicle The ESP function with its associated controller parameter set is adapted to a special vehicle. The following table lists some important vehicle parameters by way of example. These parameters inuence the conguration of the ESP function. Vehicle components

Vehicle parameters

Running gear

Geometrical data such as axle centre distance, installation location of ESP sensors, etc.

Engine

Power and torque, particularly the accuracy of the data transmitted via CAN databus engine control

Brakes

Braking torque of engine brake and retarder, also retarder in semitrailer

Steering

Steering ratio between steering wheel and steering angle

Axles

Axle design, spring/damper behaviour, number of axles

Built-on parts

Position of centre of gravity and overall weight of the vehicle

Tyre

Diameter, special versions

Power take-off

With active power consumption of more than 5 % of the engine torque when driving

Important: Changes to the vehicle that have an effect on the parameters and/or the driving and/or steering behaviour are not permitted without an ESP inspection. In particular, engine tuning without correct adaptation of the transmitted engine data can signicantly reduce the performance of the ESP. Changes to the vehicle without an ESP inspection can have an effect on safety.

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DEVICE DESCRIPTION Components of ESP Control unit, dynamic handling control, ESP (A575) The control unit housing contains a printed circuit board with a soldered multipoint connector. The entire electronic circuit with all accompanying components is integrated on the printed circuit board. The ESP control unit communicates with the EBS control unit via the brake CAN databus. In order to take into account the various requirements of ESP, additional messages are dened on the brake CAN databus. As a consequence of this, the existing EBS 2.2 message structure had to be enhanced. Steering angle sensor (B475) The steering angle sensor is a self-monitoring sensor that belongs to the safety concept of ESP. The sensor signals are transmitted to the ESP control unit via a CAN databus. Rotational speed and lateral acceleration sensor (B476) This is a micromechanical, combined rotational speed and lateral acceleration sensor. The output signals (rotational speed and lateral acceleration) are transmitted to the ESP control unit via a CAN databus.

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DEVICE DESCRIPTION Interfaces to other systems The following control units communicate with the instrumentation via the CAN databus, powertrain (T-CAN), CAN databus bodymaker (A-CAN), CAN databus highline (H-CAN), CAN databus engine (M-CAN) and CAN databus instrumentation (I-CAN). A fault in or a failure of a system (e.g. EBS, EDC, ECAS, etc.) is notied to the central on-board computer via the CAN databus, powertrain (T-CAN). The absence of a regularly expected CAN message is also interpreted as a timeout error and is displayed if necessary, e.g. if a control unit is no longer participating in CAN communication due to a total failure. The central on-board computer sends the signal to the instrumentation via the CAN databus instrumentation (I-CAN). There, the fault is displayed for the driver using check lamps and a symbol and text display.

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DEVICE DESCRIPTION CAN databus system structure TGA

(A143) (A144) (A148) (A302) (A312) (A330) (A384) (A402) (A403) (A407) (A408) (A409) (A435) (A479) (A574) (A577) (A609) (A635) (A . . .) (AB)

ECAS control unit Retarder/Intarder control unit Radio/cassette player Central on-board computer 2 (ZBR2) with terminating resistor, I-CAN Customer-specic control module with terminating resistor, A-CAN AS-TRONIC control unit (on gearbox) Rear axle steering control unit (RAS-EC) EBS control unit Vehicle management computer with terminating resistors, M-CAN and T-CAN Instrumentation with terminating resistors H-CAN, FS-CAN and I-CAN Tachograph with terminating resistor FS-CAN ECAM control unit with terminating resistor, T-CAN EDC control unit with terminating resistor, M-CAN ACC control unit Control, MMI Telematics, on-board module LGS control unit Truck-Gate with terminating resistor, H-CAN Other systems can be networked Body builder electronic unit on CAN connection, e.g. FMS Systems T 61

(A-CAN) CAN databus bodymaker (simultaneously connection for FMS interface) (FS-CAN)CAN databus tachograph (H-CAN) CAN databus Highline (I-CAN) CAN databus instrumentation (M-CAN) CAN databus engine control (T-CAN) CAN databus, powertrain

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DEVICE DESCRIPTION Rough terrain truck (X types)

(A146) Gearbox control unit (A302) Central on-board computer 2 (ZBR2) with terminating resistors I-CAN and T-CAN (A312) Customer-specic control module with terminating resistor, A-CAN (A402) Control unit, EBS, KNORR (A403) Vehicle management computer with terminating resistors, M-CAN and T-CAN (A407) Instrumentation with terminating resistors, I-CAN and K-CAN (A408) Tachograph with terminating resistor, I-CAN (A435) EDC control unit with terminating resistor, M-CAN (A574) MMI control with terminating resistor K-CAN (only with Highline instrumentation) (A...) Other systems can be networked (AB) Body manufacturer - electronics at CAN connection, e.g. FMS systems (A-CAN) CAN databus bodymaker (simultaneously connection for FMS interface) (I-CAN) CAN databus instrumentation (K-CAN) CAN databus comfort (only with Highline instrumentation) (M-CAN) CAN databus engine control (T-CAN) CAN databus, powertrain

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DEVICE DESCRIPTION FUNCTIONAL DESCRIPTION System structure of Electronic Brake System (EBS) / Electronic Stability Program (ESP)

(A302) (A402) (A407) (A408) (A575) (B119) (B120) (B121)

Central processing unit 2 EBS control unit Instrumentation Tachograph Vehicle dynamics control unit Speed sensor left front axle Speed sensor right front axle Speed sensor driven axle left

(B122) (B332) (B333) (B334) (B335) (B336) (B337) (B475) T 61

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Speed sensor driven axle right Brake sensor right front axle Brake sensor left front axle Brake sensor driven axle right Brake sensor driven axle left ALB sensor, live axle Brake power sensor ESP steering angle sensor 41

DEVICE DESCRIPTION (B476) (B529) (B530) (B537) (B538) (B591) (B592) (S256) (Y262) (Y263) (Y264) (Y278) (A-CAN) (B-CAN) (I-CAN) (S-CAN) (T-CAN)

42

ESP rotational speed sensor Brake sensor auxiliary axle right Brake sensor auxiliary axle left Brake sensor 2nd front axle left Brake sensor 2nd front axle right Speed sensor 2nd front axle left Speed sensor 2nd front axle right Button, ASR or ASR / ESP spin threshold increase Pressure control module, front axle, right Pressure control module, front axle, left Rear axle pressure control module Trailer control module CAN databus trailer CAN databus brake CAN databus instrumentation CAN databus, sensor CAN databus, powertrain

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DEVICE DESCRIPTION Electronic Brake System (EBS) Function In critical driving situations such as bad weather, smooth carriageway, downhill gradients, narrow bends or the sudden appearance of an obstacle, EBS (electronic brake system) assists the driver in controlling the vehicle better. EBS allows compressed air to enter the brake cylinders of the brake system via solenoid valves of the pressure control modules. The EBS control unit coordinates the signals from the service brake valve and pressure control modules. The brake pressure signals which are now electrical are distributed to all pressure control modules via the CAN databus. The electronically controlled build-up and reduction of brake pressure permits rapid and simultaneous braking on all axles, as well as rapid release of the brakes. On the one hand, this optimises the braking effect on all wheels, on the other hand it ensures more even brake lining wear to give a brake lining life of up to 20 % longer. The pneumatic control circuit (back-up circuit) automatically brakes the vehicle safely if the electronic brake pressure control fails. The EBS control unit co-ordinates all the higher-level functions such as brake management with ABS, ASR and the automatic load-dependent brake (ALB). Components located close to one another (sensors, valves, electronic control units) are grouped together in the pressure control module. Electropneumatic basic concept The basis of the EBS system is the conventional dual-circuit service brake system. The electronic brake system is built on the basic brake system and is electrically powered from the vehicle system voltage. If no EBS functions are active, the service brake system reverts to the safe status of “pneumatic back-up circuit braking”. This also happens if there is a malfunction during EBS functions. Redundancy of the single-circuit electronic control unit The computer core (in the control unit) contains two microcontrollers (µC) in a redundant structure. A self-test of the control unit is performed after the ignition is switched on. Following this, each pressure control module is individually controlled by both microcontrollers, connected to the voltage supply and communication via the CAN databus is instigated. The switch-on sequence means that the control unit knows the installation position of the pressure control modules in the EBS system and therefore the pressure control modules must be specically switched on or off. The ground connection of the pressure control modules from the voltage supply (terminal 30, 31) is integrated into the control unit for monitoring and for redundancy of the warning light activation.

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DEVICE DESCRIPTION Block diagram

(1) (2) (3) (4) (5) (6) (7) (8)

Control unit Brake power sensor Other signals, sensors Ignition switch (terminal 15) Battery master switch Voltage supply (terminal 30) Alternator Ground (terminal 31)

(9) Control unit ground (terminal 31) (10) Pressure control module ground (terminal 31) (11) Load disconnecting relay (12) Pressure control module, front axle, left (13) Pressure control module, front axle, right (14) Rear axle pressure control module (15) Trailer control module

The brake power sensor supplies an electrically redundant signal to the EBS control unit. Electric braking is only initiated if both signals demonstrate permitted actuation. In the EBS control unit, the input signals from the brake power sensor and from other components are processed in both microcontrollers and the results compared. Assuming the comparison is positive, one microcontroller informs each pressure control module or pressure control module pair of the individual brake pressure control setting via the CAN databus. The CAN databus check messages are recorded by a microcontroller and checked in both microcontrollers. Concept for pressure selection in the pressure control module An independent pressure control circuit is integrated in each pressure control module. Each pressure control module consists of 4 units: – Electronic control unit part with a microcontroller – Solenoid valves – Relay valve – Pressure sensor for measuring the actual pressure control setting Normally during braking, there will be a corresponding CAN nominal value and a pneumatic brake pressure at the pressure control module. The electrically applied pressure is forwarded to the brake cylinder. When the electrical section is switched off, the pneumatic pressure is passed through to the brake cylinder. In general, when there is a pneumatic reserve available, the selection can be described as follows: – The brake cylinder pressure is controlled according to the nominal electrical value when the pressure control module is supplied with voltage and the nominal CAN value > than 0, in this case the passage of the pneumatic brake pressure is blocked. – The brake cylinder pressure comes from the pneumatic back-up circuit if the voltage supply is insufcient or the CAN nominal value is 0 or does not exist.

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DEVICE DESCRIPTION EBS communication with CAN databus Sensors that measure the rotation speed and brake lining/pad wear on the wheels are directly connected to the pressure control modules. All information is processed by the electronic control unit integrated in the pressure control module. The pressure control modules with the EBS control unit via the CAN databus brake. Higher-level sensor functions such as axle load that are supplied to the control unit are used for all brake pressure control circuits and also for other systems such as electronically controlled air suspension. Electrical and pneumatic signals are activated as soon as the service brake valve is actuated. If the valves are deenergised, the pneumatic control signals take effect via the back-up circuit. All of the pressure control modules are located with mechanical protection in a safety operating position. Electronic control unit (A402) The EBS control unit centrally co-ordinates the entire EBS and communicates with other systems such as the electronic diesel control (EDC) or the gearbox control unit. Power supply When voltage is supplied, a lter in the "voltage supply" module protects against electrical faults at terminal 15 and terminal 30. A voltage supply for the pressure control modules and a voltage of 5 volts for the sensors are forwarded. In addition, the module supplies a stabilised voltage of 5 volts for internal operation of the control unit. Input circuits The input circuits are for processing the signals for the microcontroller (µC) input. Superimposed interference signals on the inputs are ltered out. Information is transmitted in both directions at the diagnosis interface, i.e. to the control unit and from the control unit, e.g. to the diagnosis unit (MAN-cats®). Computer The computer (in the control unit) contains two redundant microcontrollers with EEPROM and two CAN controllers (CAN powertrain, CAN brake). The microcontrollers evaluate the signals processed by the input circuits and control the output via CAN databus. Pressure control module supply In the pressure control module supply, each pressure control module is switched on by the microcontroller and assigned a CAN address one after the other after the EBS control unit is switched on. The pressure control modules can be switched off individually, e.g. after system malfunctions are detected. CAN interfaces – CAN powertrain: Data exchange with other control units. – CAN trailer: Data exchange with the trailer via the electrical connection DIN ISO 7638 – CAN brake: Data exchange between EBS control unit and pressure control modules in the tractor and trailer. Output stages The output stages control components such as sustained-action brake deactivation, brake lining/pad wear indicator and the yellow ABS check lamp. The red warning light is activated by a self-conducting output stage.

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DEVICE DESCRIPTION Connector pin assignment – control unit

Connector X1 PIN

Line no.

Name

1

blue/white

Powertrain CAN databus, Low signal

3

blue/red

Powertrain CAN databus, High signal

4

40558

Relay, transverse differential lock, rear axle

5

73522

Relay, transverse differential lock, front axle

6

74512

Button, ASR/ESP spin threshold increase

7

73001

Fuse F162 – voltage supply, terminal 15

8

73000

Fuse F161 – voltage supply, terminal 30

10

31000

Earthing point, cab, next to central electrical system

12

31000

Earthing point, cab, next to central electrical system

13

73201

Diagnosis, K-line

15

—-

Detection of interruption (connector drop-out detection)

18

—-

Red warning light, self-conducting

Plug disconnection detection: A switch integrated in the wiring harness plug (pin X1/15) switches on the red warning light by making contacts X1/12 and X1/18 on the wiring harness end as soon as the wiring harness is not connected or drops out after coming loose. The switch is opened again when the wiring harness is connected to the control unit. Connector X2 PIN

Line no.

Name

2

73500

5V voltage supply, brake power sensor

3

73501

Ground, brake power sensor (analogue)

4

73503

Pressure setpoint 2 from brake power sensor

7

73502

Pressure setpoint 1 from brake power sensor

Plug X3 PIN

Line no.

Name

2

CAN 112

Ground, 1-channel pressure control module, left

3

CAN 122

Ground, 1-channel pressure control module, right

5

CAN 114

CAN databus Low signal for 1-channel pressure control module, left

6

CAN 124

CAN databus Low signal for 1-channel pressure control module, right

7

CAN 161

Voltage supply, ESP control unit

8

CAN 113

CAN databus, High signal for 1-channel pressure control module, left

9

CAN 123

CAN databus, High signal for 1-channel pressure control module, right

46

T 61

2nd edition

DEVICE DESCRIPTION PIN

Line no.

Name

11

CAN 111

Voltage supply for pressure control module, left

12

CAN 121

Voltage supply for pressure control module, right

Connector X4 PIN

Line no.

Name

1

green

2

CAN 162

3

white/green

4

CAN 132

5

73521

6

CAN 141

Ground on trailer control module

7

CAN 134

CAN databus, Low signal for 2-channel pressure control module

8

CAN 164

CAN databus, brake, Low signal, ESP control unit

9

CAN 143

CAN databus, Low signal for trailer control module

10

CAN 133

CAN databus, High signal for 2-channel pressure control module

11

CAN 163

CAN databus, brake, High signal, ESP control unit

12

CAN 144

CAN databus, High signal for trailer control module

13

CAN 131

Voltage supply for 2-channel pressure control module

15

CAN 142

Voltage supply for trailer control module

CAN databus, trailer socket Low signal Ground, ESP control unit CAN databus, trailer socket High signal Ground at pressure control module, 2-channel Relay, all-wheel drive

Service brake valve with integrated brake power sensor (G7.302 / B337)

A

Service brake valve

B

Brake power sensor

3

Ventilation

1

Ground

11

Energy inow, circuit 1

2

Pressure setpoint 2

12

Energy inow, circuit 2

3

Pressure setpoint 1

T 61

2nd edition

47

DEVICE DESCRIPTION

A

Service brake valve

B

Brake power sensor

21

Energy outow, brake circuit 1

4

5V voltage supply

22

Energy outow, brake circuit 2

The brake power sensor is electrically connected to the EBS control unit. The signals of both potentiometer sensors for nominal pressure value 1 and nominal pressure value 2 are opposed. Nominal values for the pressure control modules are calculated in the EBS control unit using nominal pressure value 1 and nominal pressure value 2. EOL programming matches up the electrical and pneumatic circuits in the vehicle. Brake power sensor signals The incoming brake power sensor signals are processed and checked. Nominal pressure values 1 and 2 and the service brake valve pressure characteristic stored in the EEPROM (electrically erasable programmable read only memory) produce a nominal value. This is corrected according to EOL specications and passed on to the CAN databus brake. Note Matching during EOL programming can be performed automatically by braking with the back-up circuit or by entering the EOL parameters manually. It should be noted that the brake power sensor voltage is harmonised with the brake pressure at the pressure control module output. Reduction valves in the pneumatic back-up circuit inuence the result. Monitoring The total of the back-e.m.f. (nominal pressure value 1, nominal pressure value 2) is monitored in the EBS control unit. Uneven protective resistors mean that a short circuit of the signal lines during the braking process is also detected. 1-channel pressure control module (G67.304-Y262 / G67.304-Y263)

48

A

Speed sensor, front axle, right (B120), speed sensor, 2nd front axle, left (B591)

D

Speed sensor, front axle, left (B119), speed sensor, 2nd front axle, right (B592)

B

Sensor, brake, front axle (B332, B333) / sensor, brake, 2nd front axle (B537, B538)

1

Solenoid valve, back-up circuit (back-up valve)

T 61

2nd edition

DEVICE DESCRIPTION

Pin 1

Ground

2

Intake valve

Pin 2

Signal from sensor (B537, B538)

3

Exhaust valve

Pin 3

Signal from sensor (B332, B333)

4

Relay valve

Pin 4

5V voltage supply

5

Pressure sensor

CAN databus and voltage supply

6

Back-up circuit

Pin 1

Ground

7

Energy inow (reservoir)

Pin 2

24 V voltage supply

8

Ventilation

Pin 3

CAN High

9

Energy outow (brake cylinder)

Pin 4

CAN Low

C

The sensor for brake lining/pad wear is connected to the voltage by the pressure control module during each braking and the sensor signal is measured in the pressure control module. The incoming signals at the pressure control module from the speed sensor and brake lining wear sensor are passed on to the EBS control unit via the “brake” CAN databus. If no EBS function is active, the pressure sensor measured value (5) is adjusted in line with the current brake cylinder pressure using a time constant (automatic atmospheric pressure setting). The range is limited and may last approx. 1 second after the ignition is switched “ON” and after the service brake is released. The pressure control module performs open-loop or closed-loop control functions in three different statuses: – Normal function: Pressure control module energised and nominal electrical value present or ASR brake control required. When the EBS function is requested, the pressure control module starts brake pressure control by closing the solenoid valve back-up circuit (backup valve) (1) and activating intake valve (2) and exhaust valve (3) accordingly. – Braking with the back-up circuit: Pressure control module energised but no nominal or actual electrical value present. If there is no nominal or actual electrical value, the system switches the pressure control module to the back-up circuit (backup valve is not switched and is opened). The pneumatic pressure controls the pressure to the brake cylinders via the relay valve (4). The speed sensor signals are processed in the pressure control modules and communication between the pressure control module and the EBS control unit is maintained. – Pressure control module de-energised: The solenoid valves are de-energised. The pneumatic service brake valve pressure controls the pressure to the brake cylinders via the relay valve, braking is performed by the back-up circuit.

T 61

2nd edition

49

DEVICE DESCRIPTION 2-channel pressure control module (G67.305 / Y264)

A

Speed sensor, driven axle, left (B121)

B

Sensor, brake, driven axle, left (B335) / sensor, brake, additional axle, left (B530)

Pin 1

Ground

Pin 1

Ground

Pin 2

24V voltage supply

Pin 2

Signal from sensor (B530)

Pin 3

CAN High

Pin 3

Signal from sensor (B335)

Pin 4

CAN Low

Pin 4

5V voltage supply

H

Speed sensor, driven axle, right (B122)

ALB sensor, rear axle (B336)

1

Exhaust valve

Pin 1

Ground

2

Intake valve

Pin 2

Not used

3

Back-up (backup valve)

Pin 3

Signal from sensor

4

Relay valve

Pin 4

5V voltage supply

5

Pressure sensor

Not used

6

Energy outow (brake cylinder)

Sensor, brake, driven axle, right (B334) / sensor, brake, additional axle, right (B529)

7

Ventilation

Pin 1

Ground

8

Back-up circuit

Pin 2

Signal from sensor (B529)

9

Energy inow (reservoir)

Pin 3

Signal from sensor (B334)

Pin 4

5V voltage supply

C

D and E F

G

CAN databus and voltage supply

The sensor for the brake lining wear is supplied with voltage by the pressure control module and the sensor signal is measured in the pressure control module. The signals the pressure control module receives from the speed sensor, brake sensor and ALB sensor are forwarded to the EBS control unit via the “brake” CAN databus. If no EBS function is active, the pressure sensor measured value (5) is adjusted in line with the current brake cylinder pressure using a time constant (automatic atmospheric pressure setting). Adjustment is limited and may last up to 1 second after the ignition is switched “ON” or the service brake is released.

50

T 61

2nd edition

DEVICE DESCRIPTION The pressure control module performs open-loop or closed-loop control functions in three different statuses: – Normal function: Pressure control module energised and nominal electrical value present or ASR brake control required. When the EBS function is requested, the pressure control module starts brake pressure control by closing the solenoid valve back-up circuit (backup valve) (3) and activating intake valve (2) and exhaust valve (1) accordingly. – Braking with the back-up circuit: Pressure control module energised but no nominal or actual electrical value present. If the nominal or actual electrical value is faulty, the system switches the pressure control module to the back-up circuit (backup valve is not switched). The pneumatic pressure controls the pressure to the brake cylinders via the relay valve (4), no automatic load-dependent braking power control or wear control is performed. The speed sensor signals in the pressure control module are processed and communication between the pressure control module and EBS control unit is maintained. – Pressure control module de-energised: The solenoid valves are de-energised. The pneumatic service brake valve pressure controls the pressure to the brake cylinders via the relay valve, braking is performed by the back-up circuit. Trailer control module (G17.301 / Y278)

(1) (2) (3) (4) (5) (6) (7)

Intake valve Exhaust valve Pressure sensor Throttle Relay valve Back-up solenoid valve Service brake circuit, front axle

(8) (9) (10) (11) (12) (13)

Power in (supply) Parking brake circuit Service brake circuit rear axle Ventilation Control line, trailer Trailer reservoir line

The main functions of the trailer control module are controlling the brake pressure on the trailer control line (connection 22, item 12) and adjusting the brake pressures (coupling force control) between the pulling vehicle (tractor) and the pulled vehicle (trailer). The parking brake system (connection 43, no. 9) and the pull-off function work in the conventional way. The nominal pressure value of the EBS control unit is transferred to the control unit integrated in the trailer control module via CAN databus trailer. The trailer control module modies this setpoint using the coupling force regulation algorithm. Whilst the back-up solenoid valve (6) is closed, the electrical signal inputs a pneumatic pressure at output 22 (12) with the electromagnetic intake valve (1) and exhaust valve (2) as well as with the pressure sensor (3), and this pneumatic pressure is passed on to the coupling head of the trailer control line.

T 61

2nd edition

51

DEVICE DESCRIPTION The pneumatic signal of the service brake circuit 41 (7) is blocked via the back-up solenoid valve (6) that is activated for electrical braking. If the back-up function is not active, then the back-up solenoid valve (6) is open and the service brake pressure connection 41 (7) passes on the brake pressure via the relay valve control chamber (5) to the coupling head brake connection 22. The pressure active at the service brake circuit 42 (10) of the trailer control module serves a separate relay valve control chamber. The response pressure of this relay valve component is approx. 2.5 bar. If the trailer control module is intact and there is a pressure of approx. 8 bar at the service brake circuit 42 (10) of the trailer control module, the brake pressure at connection 22 (12) that is electrically controlled with the back-up solenoid valve, intake valve and exhaust valve can be reduced to about 4 bar. If the electrically controlled pressure is reduced further, the pressure at the service brake circuit 42 (10) of the trailer control module determines the brake pressure at connection 22 (12). If the electronic brake system and the service brake circuit 41 (7) fail, the pneumatic characteristic for the service brake circuit 42 (10) automatically changes the sequence. The response pressure remains at approx. 2.5 bar almost irrespective of the reservoir pressure. In this case, when there is 8 bar brake pressure at the service brake circuit 42 (10), there is also about 8 bar at the trailer control line 22 (12), however. The parking brake circuit 43 (9) is pressurised when the parking brake system is released, so that the service brake cylinders in the trailer are not actuated. Activation of the parking brake reduces the pressure in the parking brake circuit. This leads to a pressure increase in the trailer control line 22 (12) and to actuation of the trailer service brake. If the trailer control line connection 22 (12) is pulled off, the supply of pressure to the trailer reservoir line connection 21 (13) is restricted during braking by a restrictor (4) that closes automatically. The supply pressure then drops to below 1.5 bar within 2 seconds and so the trailer is braked. ALB sensor, rear axle (B336) Axles with leaf suspension - travel sensor Axles with air suspension - pressure sensor

Connector pin assignment Pin

Line no.

Name

1

74300

5V voltage supply

2

74304

Ground

3

74306

Signal from sensor

A pressure sensor is used to determine the load on vehicles that have air suspension on the rear axle. This pressure sensor is supplied with a voltage of 5V by the 2-channel pressure control module. The various pressures are converted into electrical voltage signals inside the pressure sensor (analogue/digital converter). These signal values are assigned brake pressure curves which the EBS control unit uses to control the brake pressures. Technical data Voltage supply:

5 +- 0.25 V, max. 32 V (max. 10 min.)

Max. current consumption:

12 mA

52

T 61

2nd edition

DEVICE DESCRIPTION Brake sensors (B332, B333, B334, B335, B529, B530, B537, B538) Sensors with spring-cushioned pins are used as brake sensors in disk brakes. The brake sensor is only supplied with voltage during braking. In this case, the brake sensor passes on a signal to the pressure control module that varies according to the wear or adjustment setting. The voltage is measured at the end of electrical braking. This value is transferred to the EBS control unit via the CAN databus brake for evaluation. The value can be inuenced by the wear on the brake disk depending on the measuring principle used. – The EBS control unit cannot differentiate between wear on the linings and wear on the disc. If the remaining thickness is less than the permitted brake pad thickness, the EBS control unit activates the brake system check and the “Brake pad wear” fault message appears on the display – Brake lining wear control Brake lining wear control calculates brake pressure correction values for each axle, with the objective of keeping the total brake pressure constant in order to harmonise the lining wear and to extend the lining life. There is no wheel-by-wheel control. Speed sensor (B119, B120, B121, B122, B591, B592) The speed sensor set-up consists of an impulse wheel and an inductive speed sensor. The impulse wheel is mounted in accordance with the specications familiar for ABS. An alternating current voltage is generated in the speed sensor when the wheel is turning. The frequency of this voltage is proportional to the wheel speed. The speed sensor is electrically connected to the pressure control module. The assignment of the speed sensors to the wheels when connecting to the pressure control module can be programmed via EOL. – Monitoring The speed sensor is monitored by the pressure control module. The time that elapses before a short circuit between the connections of a speed sensor is detected by the software depends on the vehicle speed. – Speed calculation The speed sensor signals are pre-processed in the pressure control module so that a speed signal is already received in the EBS control unit via the “Brake” CAN databus. Information from all sensed wheels and the signalled pressure control module status signals are used for calculating the vehicle speed, after taking account of different tyre diameters and the slip criteria. The result of this calculation is put on the “Brake” CAN databus.

T 61

2nd edition

53

DEVICE DESCRIPTION Electronic Stability Program (ESP) Functions ESP consists of two stabilising subfunctions. One subfunction is chiey active when driving on a surface with a low and medium coefcient of friction and counteracts oversteer, understeer and jackkning. The other subfunction is chiey active when driving on a surface with a medium and high coefcient of friction and reduces the risk of tipping over. Both subfunctions are connected to the ESP control unit via a CAN databus sensor and they operate together, especially when driving on a surface with a medium coefcient of friction where a vehicle could both tip over and jackknife. To stabilise the vehicle, ESP brakes individual wheels according to the situation until the maximum possible brake pressure is reached. Track stabilisation by ESP ESP stabilises the vehicle when driving on a surface with low and medium coefcients of friction (within the physical limits): – It prevents semitrailer vehicles from jackkning. – It counteracts situation-specic oversteer and understeer in semitrailer tractors without and in combination with a semitrailer. Brake intervention Basically, ESP brakes the wheels on which the build-up of brake force (longitudinal force) and the loss of cornering force have a rectied effect on the yawing moment of the vehicle. In a semitrailer tractor with situation-specic oversteer, it is chiey the front axle wheel on the outside of the curve that is braked. In certain situations, the trailer is braked as well in order to counteract the jackkning of the semitrailer vehicle. Fully functioning trailer ABS is required to avoid skidding (breaking out) of the trailer caused by braking. If the trailer does not have functioning ABS, it is not braked (applies to an empty or semi-laden trailer) or is only braked with limited pressure (applies to a fully laden trailer). In a tractor that has understeer due to a particular situation, it is mainly the rear axle wheel on the inside of the bend which is braked. When there is severe understeer, ESP attempts to reduce the vehicle speed by braking several wheels and the trailer. ESP only ever brakes the trailer for tracking stability for limited periods of time, in order to prevent the trailer from skidding or breaking out during ESP interventions (e.g. due to worn tyres on the trailer). Engine intervention ESP engine intervention is effectively an extension of ASR in EBS 2.2. In addition to ASR, the information from the ESP is used for achieving more or less slip on the driven axle depending on the current driving situation. Important: Driving on a banked curve with ESP active is not permitted. A sticker warning the driver of taking a banked curve with ESP activated must be afxed at a suitable place in the vehicle. On a banked curve, the calculated reference rotational speed is less than the measured rotational speed (the steering wheel could be in the straight ahead position). Therefore, oversteer is detected and this would lead to an unnecessary and dangerous braking of the front wheel on the outside of the curve. Reduced roll-over risk (roll stability program, RSP) RSP is intended to prevent vehicles tipping over in various driving situations and should apply to various vehicle versions (within the physical limits). This is chiey required on surfaces with high and medium coefcients of friction. ESP operates in two steps for this purpose: Step 1: Reducing the vehicle speed As a rst step, the vehicle speed is reduced until the lateral acceleration drops below a limit value that is not critical in terms of tipping over. Reducing the vehicle speed is divided into two blocks: – The rst block (preparation) calculates the maximum permitted vehicle speed for the current driving manoeuvre. This is performed in several sub-steps. Firstly, the maximum permitted stationary lateral acceleration is calculated depending on the maximum relative load of the individual vehicles (tractor vehicle 54

T 61

2nd edition

DEVICE DESCRIPTION and trailer). Following this, the permitted lateral acceleration is reduced by a factor depending on the previous driving situation. This takes account of the kinetic roll energy that occurs, e.g. during a double lane change. The result is a dynamic lateral acceleration value from which the maximum permitted driving speed is calculated according to the prole of the bend. The maximum permitted driving speed can be further reduced depending on the driver’s behaviour, e.g. fast steering wheel movements. In this way, it is possible to take account of hazardous situations in advance. The result is the maximum permitted driving speed that is passed on to the second block (speed control). The driver can inuence the behaviour of ESP using the accelerator and brake pedal. At full acceleration and when uphill driving is detected, the maximum permitted stationary lateral acceleration is increased by a certain factor and the dynamic adaptations of the lateral acceleration and driving speed are reduced. The driver can inuence the behaviour of ESP in the opposite way by braking, which means the lateral acceleration is reduced and the dynamic adaptations of the lateral acceleration and driving speed are increased. This takes account of unsafe behaviour by the driver. – The second block (speed control) controls the vehicle speed by reducing the engine torque and brake interventions in the tractor and trailer. The trailer is only braked if there is fully functional trailer ABS available. Otherwise, only (pressure) limited brake intervention takes place – but only when the trailer is fully laden (to avoid ESP causing the trailer to break out). First, the deviation between the current vehicle speed and the maximum permitted vehicle speed is calculated. This deviation is used in conjunction with a characteristic value table to calculate the desired vehicle acceleration (deceleration) that is subsequently controlled by an acceleration controller in order to compensate for the effect of incorrect brake parameters, roads with uphill inclines, incorrect vehicle dimensions, etc. Step 2: Detecting wheel lift-off In the second step, the lift-off of a wheel on the tractor and on the trailer (only for EBS trailer) is detected. If wheel lift-off is detected, step 2 brakes the entire vehicle combination. – Wheel lift-off in the tractor is detected in two sub-steps: A risk of tipping is assumed when lateral acceleration exceeds a certain limit value (e.g. 80 % of the limit value of step 1). The speed of the rear wheel on the inside of the curve is observed in order to allow wheel lift-off to be detected. When a wheel lifts off, the speed of the wheel changes markedly (under an existing torque). A test brake pressure is applied if the calculated torque (composed of engine and brake torque) at this wheel is too low. The lateral acceleration limit for assumed tipping risk is adapted during the journey. – Wheel lift-off in the trailer is detected based on the same principle (applying a test pressure to cause a change in the wheel speed when the wheel lifts off). ESP does not have any information about the wheel speed of the trailer, therefore major wheel speed changes are detected by activating the trailer ABS. Activation of the trailer ABS is transferred from the trailer EBS to the EBS of the tractor via the CAN databus trailer. Due to different trailer EBS systems, the trailer ABS must be active for a certain minimum time before wheel lift-off is detected. Limits of ESP functions ESP can only assist the driver within the physical limits. The physical limits can be exceeded by deliberate use of the ESP safety margin in order to drive faster. ESP may decelerate the vehicle signicantly in order to avoid tipping over. Therefore, situations arise in which a vehicle with ESP may get into difculties that the same vehicle without ESP would have experienced differently or possibly not at all (e.g. violent avoidance manoeuvres with oncoming trafc). However, this problem applies similarly with ABS (e.g. longer braking distance on loose snow or gravel). If the load and/or its position changes during driving or brake interventions due to inadequate safety, ESP cannot provide optimum support in all cases for physical reasons (ESP initiates powerful braking in certain cases, e.g. to avoid tipping over). In certain driving situations, e.g. a lane change from a surface with a low to a high friction coefcient during which a very considerable yaw moment is built up, the vehicle may skid in spite of ESP. This behaviour is due to physical reasons (physical limit). Also, it is not possible totally to prevent the trailer breaking out, in particular if the trailer has severely worn tyres or the trailer ABS is a seriously limited version and the vehicle combination is already driving at the limits of the coefcient of friction. Furthermore, ESP cannot prevent tipping over in all situations and in all possible vehicle congurations.

T 61

2nd edition

55

DEVICE DESCRIPTION The following circumstances, for example, are also critical for vehicles with ESP: – Large and/or fast steering movements at high speed – Cargo with a very high centre of gravity – Cargo with a low weight but high centre of gravity – Cargo with a high and moving centre of gravity (e.g. part-laden tankers, animal transports) – Driving situations in which the wheels slip sideways against an obstacle (e.g. kerb) – Vehicles with off-road fth-wheel coupling (cardan fth wheel coupling), etc. This list is not intended to be exhaustive, and other critical situations with similar effects are theoretically possible. Step 2 (detecting wheel lift-off) works in the tractor alone if the trailer does not have a CAN connection to the tractor (e.g. trailer without EBS) and therefore there is no “ABS active” information from the trailer. In this case, certain situations cannot be covered in comparison with trailers with a functioning CAN connection (trailer EBS and correct transfer of the ABS active information) because wheel lift-off on the trailer cannot be detected. Note: The driver must be informed of the described details in a suitable way, e.g. in the owner’s manual of the vehicle, so that the driver will be made aware of the peculiarities of ESP function and can adapt his or her driving behaviour accordingly. Safety concept and reduced functions Safety concept ESP is integrated into basic EBS. The ESP control unit and the ESP sensors (steering angle sensor, rate of turn and transverse acceleration sensor) are required as additional components (see “System description” section). The ESP control unit is supplied with voltage from the EBS control unit whilst the ESP sensors are supplied with voltage via the ESP control unit. The ESP request values are transferred to the EBS control unit (engine torque reduction), the pressure control modules (pressure difference, slip) and to the trailer control module (pressure difference) directly via CAN databus brake. If there is a malfunction in the ESP components, two different reactions are possible: – the ESP control unit can be completely deactivated by the EBS control unit (e.g. in the event of a µC fault or if there is no CAN communication) – The ESP function can be switched to passive, this means that the ESP control unit no longer sends any request values via the brake CAN databus (e.g. in the case of sensor faults). In this case, it is still possible to monitor the intact sensor signals. If there are no active ESP components, the system operates like a normal EBS 2.3 system. Monitoring of the system components is divided between the various components. Internal EBS faults are recorded by the EBS control unit, the pressure control modules and the trailer control module. The ESP control unit is informed about these faults by the EBS control unit. The EBS control unit monitors CAN communication with the ESP control unit and the output stage of the ESP control unit, checks the software version, tests the ALU (arithmetic and logical unit) of the ESP control unit and checks the ESP request values for plausibility. The monitoring functions in the ESP control unit consist of microcontroller (µC) self-test functions and data exchange between the two microcontrollers (µCs), monitoring of the supply voltages and the analog/digital converter, direct and model-based sensor monitoring. The sensors (steering angle sensor, rate of turn and transverse acceleration sensor) are additionally equipped with a self-monitoring mechanism. The EBS control unit is responsible for storing the ESP fault numbers, switching on the warning lights and for outputting the fault information on CAN J1939. Monitoring the ESP control unit in the EBS control unit Compatibility The active microcontroller checks whether the software of the pressure control modules and of the trailer control module is compatible with the ESP control unit software. ESP function is switched to passive in case of incompatibility. The system checks whether the ESP control unit is congured for the same supply voltage as the EBS control unit (12V/24V).

56

T 61

2nd edition

DEVICE DESCRIPTION Testing the ESP output stage The checkback signal of the switched-on ESP output stage is checked after each time the ignition is switched on and during the entire ignition on cycle. ALU test The EBS control unit continuously sends random numbers regarding the brake CAN databus to ESP control unit. The random numbers are processed into ALU (arithmetic and logical unit) functions of the ESP microcontrollers (µCs). The result is sent back to the EBS control unit, which then checks the result and the reaction time. CAN communication If ESP was congured in EOL programming, the EBS monitors the resulting trafc on the CAN databus brake. Plausibility The EBS control unit checks the ESP interventions for plausibility (intervention duration, pressure gradient). Microcontroller tests When a voltage is applied to the ESP control unit, a static system test is rst performed. A self-test is performed in both microcontrollers. This test includes testing the watchdog, RAM, ROM, EEPROM, timer and numerous arithmetic and logical functions. Monitoring remains active throughout the entire operating time even after these tests have been performed completely. The microcontrollers monitor one another reciprocally. The RAM, ROM and EEPROM tests are repeated continually whilst the control unit is operating. Monitoring other components of the ESP control unit During the entire operating time of the system, the supply voltages and the analog/digital converters are checked using the checkback signals of the various supply voltages. The system is reinitialised in the event of undervoltage. Direct sensor monitoring The sensors contain self-test functions (BITE test, range monitoring and analysis of fault messages), monitoring of CAN sensor communication, gradient monitoring and monitoring of blocked signals. Steering angle sensor (gradient monitoring) The steering angle signal is checked for implausible steps. The difference between the current and previous steering angle must be less than or equal to a previously dened maximum difference (steering wheel angular velocity). In addition, the difference between the old and the new gradient must be within a certain framework. Gradient monitoring is switched off during certain driving situations. Rotational speed and lateral acceleration sensor The sensor is equipped with a self-test function that is referred to as a built-in test (BITE). The test is triggered by the ESP control unit via CAN. Following this, the sensor stimulates its ground elements with a dened changing rate of turn. The normal (measured) rate of turn has the BITE value superimposed on it during the test cycle. The BITE test is triggered every 40 ms, although it takes almost 20 ms to ramp up the signal. Therefore, the measured rate of turn is the same as the actual rate of turn every 40 ms shortly before the start of the BITE test. The rate of turn signal is interpolated for evaluating the BITE value. Two different monitoring functions are implemented in the control unit software (static and dynamic BITE test monitoring). Not all signal jumps can be recorded by the BITE test. As a result, the ESP system is switched off if the rate of turn signal exceeds a certain limit that is dependent on the driving condition (vehicle speed, steering wheel angle and lateral acceleration). A fault input is performed if the sensor signal noise it too great. ESP is switched off in this case. Model-based sensor monitoring The core of the concept involves calculating a safety reference rate of turn from the various sensor signals. A rate of turn is calculated from each sensor signal using a simple model. The safety reference rate of turn is calculated from four calculated rates of turn with the help of a suitable weighting procedure. The resulting safety reference rate of turn is robust with regard to sensor faults. This reference rate of turn is used for calculating the other reference signals using inverted models. The reference signals measured in this way are used for monitoring the individual sensors and matching their values (see the ESP sensors chapter for a description of the matching procedure for the ESP sensors). There are two main principles for monitoring the sensors signals: – Monitoring of the sensor signals during model validity (comparison with the reference signal). T 61

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DEVICE DESCRIPTION – Monitoring of the sensor signals whilst the rates of turn of all other signals are similar Fault detection time During the time from when a fault occurs to when it is detected, the control unit processes faulty signals and/or outputs faulty signals. Brief ESP interventions may occur with a very few fault types in conjunction with corresponding driving situations. Faults occurring during an accident Shocks, the pulling-off of cables, etc. can give rise to faults that are quickly detected in the control unit. This means it is not possible to make any reliable statement about the system status (fault entries) before the accident. This means the contents of the fault memory can only be used to a limited extent for reconstructing the cause and procedure of the accident. Important: Driving on a banked curve with sensor monitoring functions active is not permitted. On a banked curve, the calculated rates of turn do not match the measured rate of turn. This means unnecessary and dangerous ESP interventions can be triggered and/or unnecessary sensor faults can be detected. Fault display and reduced ESP functions All fault numbers of the EBS/ESP system are stored in the EEPROM of the EBS control unit because the EBS control unit is the master unit (control centre) of the system. The fault numbers can be downloaded from the EBS control unit's fault memory using MAN-cats® II. The status of the ESP function is also indicated via the EBS control unit. For this, the EBS control unit sends information via CAN-J1939 (VDC_1) in the following way: ESP active: – 00 ESP available, passive – 01 ESP active – 10 ESP fault – 11 ESP not available The EBS control unit switches on the yellow central STOP warning light in response to ESP faults and the driving stability check lamp (H415) when ESP is active. Plus the "directional stability" symbol and a text message appear on the driver's display. The ESP fault status is only set for internal ESP faults. The degree of ESP functionality is indicated by the: ESP fully operational: – 00 ESP fully operational – 01 ESP not fully operational messages. In the case of “ESP not fully operational”, ESP functionality is limited (caused by ESP fault, EBS fault or undervoltage, for example). When a fault is detected, the fault number is stored, the corresponding warning light (check lamp) is switched on and changed over to a correspondingly reduced range of functions. The reduced functionality of the ESP system is described for all ESP/EBS faults in the following section. A detected fault as well as the corresponding reduction in ESP functions remain active until the ignition is switched off. This does not apply to temporary faults. A new EBS/ESP start attempt takes place when the ignition is switched on again. If the fault is still active, the warning light (check lamp) is set once again and the reduction in ESP functions remains in effect. Many faults can only be detected in certain driving manoeuvres (plausibility monitoring). In accordance with the ECE13 Regulation (supplement to the new version of regulation no. 13 (ECE)), a fault of this kind must remain active, and therefore with the warning light switched on, until the fault can be excluded by a special monitoring function. Other faults can be detected directly after the ignition is switched on. No special monitoring function is needed in this case. Reduced ESP functionality The EBS and ESP fault numbers are continuously exchanged between the EBS control unit and the ESP control unit so that the fault memory in both computers (in the RAM) is identical. This means that the ESP control unit can react exibly to internal EBS faults. 58

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DEVICE DESCRIPTION For fault messages, see SPN list (fault codes) and fault code description Electronic control unit, dynamic handling control, ESP (A575) Control unit voltage supply The voltage supply for the ESP control unit is 24 V (maximum operating voltage range 18 - 30 V). The EBS control unit connects the voltage supply through to the ESP control unit. The voltage drop between the EBS control unit and the ESP control unit must be less than 1 V. The maximum permissible continuous current must not exceed Imax = 1 A. Connector pin assignment – control unit

Connector X1 Pin

Line no.

Name

1

164

CAN databus, brake, Low signal

2

163

CAN databus, brake, High signal

6

162

Ground, ESP control unit

10

176

Ground, steering angle sensor

11

175

Voltage supply, steering angle sensor

13

177

CAN databus, sensor, High signal, steering angle sensor

14

161

Voltage supply, ESP control unit

16

178

CAN databus, sensor, Low signal, steering angle sensor

Connector X2 Pin

Line no.

Name

1

168

CAN databus, sensor Low signal micromechanical rotational speed sensor

2

167

CAN databus, sensor, High signal, micromechanical rotational speed sensor

4

165

Voltage supply, micromechanical rotational speed sensor

6

166

Ground, micromechanical rotational speed sensor

Connector X1 pin X1/15 has an integral contact which connects contacts X1/12 with X1/18 on the wiring harness side when the connector is pulled off. When the connector is connected, the connection is broken. Connectors X3 and X4 are not used. ESP sensors Sensor - voltage supply The rated voltage of 12 V (8-16 V possible) is provided by the ESP control unit. The voltage drop due to the wiring between the sensor and the ESP control unit must be less than 0.5 V. The sensor signals are sent to the ESP control unit via a sensor CAN databus. Important: The sensors are not allowed to be connected to 24 V. Steering angle sensor (B475) The steering angle sensor is a self-monitoring sensor that belongs to the safety concept of ESP. T 61

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DEVICE DESCRIPTION

Connector pin assignment

Pin

Line no.

1

176

Ground, steering angle sensor

2

175

Voltage supply, steering angle sensor, 12 volts

3

177

CAN databus, sensor, High signal, steering angle sensor

4

178

CAN databus, sensor, Low signal, steering angle sensor

5-7

——-

60

Name

Not used

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DEVICE DESCRIPTION Technical data Operating voltage

8.2 V to 16 V

Rated voltage

12 V

Test voltage

14 V

Overvoltage

18 V at room temperature for max. 1 hour

Min. current

90 mA

Max. current

170 mA

Operating temperature

-40 - 85°C

Function and measuring principle The steering column drives two measuring gears via a gear. Magnets are installed in the measuring gears. AMR (anisotropic magneto resistive) elements that change their resistance depending on the magnetic eld direction record the angle position of the magnets. The analog measurement values are sent to the microcontroller (microprocessor) via an analog/digital converter. The measuring gears have different numbers of teeth and therefore change their rotational position with differing speeds. The overall steering wheel angle can be calculated from the combination of both current angles. Both measuring gears return to their initial position after several steering wheel rotations. As a result, this measuring principle enables a measuring range of several steering wheel rotations to be covered without the need for a revolution counter. There is a mathematical relationship between the steering angle and the angles of both measuring gears. The positions of the measuring gears enable the absolute angle of the steering wheel to be ascertained by a mathematical function. In additional, this function permits fault correction and plausibility checking of the individual signals. Calibration See the “ESP sensor calibration” chapter for sensor calibration Rotational speed and lateral acceleration sensor (B476) This is a micromechanical, combined rotational speed and lateral acceleration sensor. The output signals (rotational speed and lateral acceleration) are transmitted to the ESP control unit via a sensor CAN.

The operating voltage of the sensor is 12 V.

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DEVICE DESCRIPTION Connector pin assignment

Pin

Line no.

Name

1

165

Voltage supply micromechanical rotational speed sensor

2

166

Ground, micromechanical rotational speed sensor

3

167

CAN databus, sensor High signal micromechanical rotational speed sensor

4

168

CAN databus, sensor Low signal micromechanical rotational speed sensor

Measuring principle The rotational speed sensor contains two micromechanical oscillating masses. Each of the masses has two micromechanical acceleration sensors integrated into their surface. These register the Coriolis acceleration. The measuring principle is based on the Coriolis force that is caused by a rotational movement (rotational speed) at right angles to the given oscillation direction of the seismic masses. The lateral acceleration is measured by an additional micromechanical acceleration sensor. Compensation of the rotational speed and lateral acceleration sensor The rotational speed sensor signal is calibrated when the switch is turned “on”. Standstill calibration (normal case) is performed if the vehicle is at a standstill; rapid calibration is performed if the vehicle is already driving. The calculated offset value is continuously compared with the permitted limit value. Standstill calibration The standstill calibration is performed when the wheel speeds, the steering angle and the rotational speed indicate that the vehicle is at a standstill. The procedure is cancelled if “Driving” is detected before the end of calibration. Rapid calibration Rapid calibration only takes place once per switch-on cycle (switch on) if it was not possible to perform a standstill calibration previously. The offset is calculated as the difference between the measured and calculated rotational speed. Normal calibration The normal calibration is performed during operation after the standstill or rapid calibration has been performed. The principle of the normal calibration is the same as for rapid calibration. Sensor sensitivity calibration The sensitivity of the sensor is measured during cornering with the help of a calculated reference rotational speed and the measured rotational speed.

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DEVICE DESCRIPTION ESP sensor calibration Following service work (removal, installation, exchange of sensors) the sensors (steering angle sensor and rotational speed sensor) must be calibrated with the diagnostic function of the MAN-cats®® II test system. This is done by sending a calibration request to the sensors via the EBS control unit. The menu structure in MAN-cats® II is shown below – Select the entry type in MAN-cats® II. Activate the “Diagnosis” menu and conrm with the tick symbol (bottom right). – Select the “Brakes” system group and conrm. – Select the “EBS 2.2/2.3, KNORR” system type and conrm. – Information about maintenance and repair work is displayed, conrm this. – “Communication Interface” menu. Please connect the MAN-cats® II Communication Interface to the diagnosis socket (X200). The green LED indicates that the interface is connected and the power supply is OK. Press the “YES” button to conrm if the light-emitting diode is on. – “Communication Interface” menu. Now establishing the connection to the communication interface. This process may take a few seconds. The connection is made when all three LEDs in the interface are on. Press the “YES” button to conrm if all light-emitting diodes are on. – Conrm the “Switch on ignition” user action. – Establishment of communication with the control unit. Please wait! – Conrm the “EBS fault overview” menu. – EBS menu. Activate and conrm “EBS/ESP commercial vehicles”. – EBS diagnosis menu Select and conrm “ESP sensor calibration”. – Warning information is displayed about calibration of the ESP sensors – conrm this. – “Information on calibration of ESP sensors”. Events following which the steering angle sensor has to be calibrated (faults 03473, 03527). – Replacement of steering angle sensor. – Interruption of the “path” from the steering angle sensor to the wheel. – Setting the steering linkage, steering gear and other steering components. – Setting the track. – Accident involving steering damage. Events following which the rotational speed sensor has to be calibrated (fault 03526). – Replacement of rotational speed sensor. – Removal/installation of the rotational speed sensor. – Accident involving damage to the frame and/or damage to/deformation of the sensor holder. – Conrm the information with the tick symbol (bottom right). – Select “Rotational speed sensor – perform calibration” and conrm. – “Rotational speed sensor calibration” menu. Park the vehicle on at, level ground. Press the “YES” button to conrm if the vehicle is standing on at, level ground. – “Rotational speed sensor calibration” menu. Calibrating the rotational speed sensor. Please wait! – Conrm the “Switch off ignition” user action. – “Rotational speed sensor calibration” menu. The rotational speed sensor has been calibrated. – EBS diagnosis menu. Select and conrm “ESP sensor calibration”. – Warning information is displayed about calibration of the ESP sensors – conrm this. – “Information on calibration of ESP sensors”. Events after which the steering angle sensor has to be calculated (faults 03473; 03527) – list as above. Events after which the rotational speed sensor has to be calculated (fault 03526) – list as above. – Conrm the information with the tick symbol (bottom right). – Select “Steering angle sensor – perform calibration” and conrm. – “Steering angle sensor calibration” menu. Calibration of the steering angle sensor takes place in 2 steps. Step 1 - Standstill calibration Step 2 - Rapid calibration The following preconditions must be met • For the standstill calibration - Flat, level ground - Axle measuring system • For rapid calibration - A straight stretch of approx. 3 km in length, avoid severe steering movements. – Press the “YES” button to conrm if these preconditions are met. – “Steering angle sensor calibration step 1” menu. Step 1 - Standstill calibration: T 61

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DEVICE DESCRIPTION Important: During calibration of the steering angle sensor, the steering angle is set to 0 degrees irrespective of the current steering wheel position. Therefore it is important that the front wheels are in the straight ahead position when this is done. • Park the vehicle on at, level ground. • Use the steering wheel to set the front wheels to “driving straight ahead”. (maximum tolerance +/- 1 degree) – Press the “YES” button to conrm when the front wheels are aligned. – Conrm the “Switch on ignition” user action. – “Steering angle sensor calibration” menu. The yellow ESP check lamp in the panel of check lamps is activated. Please wait! Conrm the “Switch off ignition” user action. – “Steering angle sensor calibration” menu. Step 2 - Rapid calibration: • Drive along as straight a stretch of road as possible with a length of about 3 km. The length of the stretch depends on the steering movements you make when driving. • The calibration process is started automatically when a speed > 40 km/h is reached. Calibration is nished when the yellow ESP check lamp in the panel of check lamps goes out. MAN-cats® II is not essential for the remainder of the calibration, conrm. – “Steering angle sensor calibration” menu. Important: Please delete the EBS fault memory after successful calibration.

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DEVICE DESCRIPTION DESCRIPTION OF COMPONENTS EBS control unit (A402) Design

The housing contains a printed circuit board with a multipoint connector. The control unit electronic system has integrated circuits, microcontrollers and other electronic components. Installation location (TGA)

The EBS control unit (1) is located in the centre console, on the left next to the central electrical system (remove device cover). Installation location (X types)

The EBS control unit (1) is located in the control unit plug-in module (control unit 1) below the central electrical system. T 61

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DEVICE DESCRIPTION Service brake valve with integrated brake power sensor (G7.302 / B337) Design

An electric brake power sensor (2) is integrated in the dual-circuit pneumatic service brake valve (1). The brake power sensor is used for generating electrical / pneumatic signals for admitting and removing air in the electronically controlled brake system. A tappet is used for actuation in each case. The tappet actuates the brake power sensor and, by means of the usual springs, a reaction piston and valve assembly for applying the pneumatic pressure. A single electrical circuit supplies the voltage for the brake power sensor (constant 5V from the EBS control unit). Two potentiometer sensors are actuated at the same time.

Installation location (TGA)

The service brake valve (1) with integrated brake power sensor is installed on the front end of the cab.

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DEVICE DESCRIPTION Installation location (X models)

The service brake valve (1) with integrated brake power sensor is installed on the front end of the cab.

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DEVICE DESCRIPTION Pressure control module, 1-channel (G67.304-Y262 / G67.304-Y263) Design

The pressure control module (1) on the front axle is a 1-channel electro-pneumatic component comprising relay valve, lter, silencer, solenoid valves for back-up circuit (back-up valve), inlet valve / outlet valve, pressure sensor, electronic control (2) as well as pneumatic and electrical connections. At the same time, it is the node for transmitting the signals of the connected sensors, such as – Speed sensor – Brake sensor to the EBS control unit via the "brake" CAN databus. Installation location (TGA)

The pressure control module is installed on the right and left of the front axle with a downwards pointing silencer.

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DEVICE DESCRIPTION Installation location (X models)

Left pressure control module (1) and right pressure control module (2) for the front axle with downwards pointing silencers.

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DEVICE DESCRIPTION Pressure control module, 2-channel (G67.305 / Y264) Design

The pressure control module (1) on the rear axle is a 2-channel electro-pneumatic component comprising relay valve, lter, silencer, solenoid valves for back-up circuit (back-up valve), inlet valve / outlet valve, pressure sensor, electronic control (2) as well as pneumatic and electrical connections. At the same time, it is the node for transmitting the signals of the connected sensors, such as – Speed sensor – Brake wear sensors – Rear axle ALB sensor to the EBS control unit via the “brake” CAN databus. Installation location (TGA)

The 2-channel pressure control module is installed on the rear axle, with the silencer pointing downwards.

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DEVICE DESCRIPTION Installation location (X models)

The 2-channel pressure control module is installed on the rear axle.

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DEVICE DESCRIPTION Trailer control module (G17.301 / Y278) Design

The trailer control module (1) essentially comprises a relay valve with 2 control chambers for the service brake system, one control chamber for the parking brake system, a lter, a throttle valve, electro-magnetic valves (input, output, back-up), a pressure sensor like the one in the 1-channel pressure control module and an integral control unit (2). The trailer control module has electrical and pneumatic connections. The electrical connections contain the voltage supply and the connection between the “trailer” CAN databus and the EBS control unit. The pneumatic ports on the input end consist of the energy supply (reservoir 11) and 3 control lines (from the service brake valve with integral brake value sensor to ports 41 and 42 and from the parking brake valve to port 43). Those on the output end consist of the dual-line brake system to the trailer (supply and control line).

Installation position

The trailer control module (1) is installed in the rear part of the chassis. The installation position may be slightly different (depends on the chassis).

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DEVICE DESCRIPTION ALB sensor, rear axle (B336) Design

The ALB sensor is electrically connected to the pressure control module on the rear axle. A pressure sensor that measures the bellows pressure is used to determine the load in the case of vehicles with air suspension on the rear axle. It contains a pressure-sensitive measuring element and a booster circuit. The pneumatic port is connected to a compressed air line which leads to the air bellows. The air suspension pressure is sensed by the pressure sensor. This information is analysed together with the specic vehicle parameters to calculate the current load status.

Installation location (TGA)

Pressure sensor (1) for air suspension.

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DEVICE DESCRIPTION Installation location (X models)

Position sensor (1) for leaf suspension.

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DEVICE DESCRIPTION Brake sensor (B332, B333, B334, B335, B529, B530, B537, B538) Design

The brake sensors are electrically connected to the pressure control module. Data is transferred via the “brake” CAN databus. Electrical circuit The permanently measuring brake wear sensor is part of the wheel brake.

Installation position

Brake sensor on the brake anchor plate.

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DEVICE DESCRIPTION Speed sensor (B119, B120, B121, B122, B591, B592) Design

The speed sensor consists of a coil and a permanent magnet that are rmly bedded in a high-grade steel jacket to protect against vibrations. The speed sensor is electrically connected to the pressure control module. In this case, one speed sensor is connected to each of the 1-channel pressure control modules (on the right and left of the front axle) and two speed sensors are connected to the 2-channel pressure control module (on the rear axle).

Installation position

Speed sensor, right front axle (1).

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DEVICE DESCRIPTION Control unit, ESP (A575) Design

The ESP control unit communicates with the EBS control unit via the brake CAN databus. The control unit housing contains a printed circuit board with a soldered multipoint connector. The entire electronic circuit with all accompanying components is integrated on the printed circuit board.

Installation location (TGA)

The ESP control unit (1) is located on the right in the direction of travel, behind the front ap (remove cover)

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DEVICE DESCRIPTION Steering angle sensor (B475) Design

The steering angle sensor is a self-monitoring sensor which is part of the ESP safety concept.

Installation location (TGA)

The steering angle sensor (1) is tted on the steering column inside the cab.

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DEVICE DESCRIPTION Rotational speed and lateral acceleration sensor (B476) Design

This is a micro-mechanical, combined rotational speed and lateral acceleration sensor.

Installation location (TGA)

The rate of turn and transverse acceleration sensor (1) is encapsulated in an additional housing and is attached outside the cab on the frame or crossmember.

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DEVICE DESCRIPTION DIAGNOSIS General information Most control units testable using MAN-cats® are connected with diagnosis socket X200 pin 3 / 4 via a K-line. The diagnosis system stimulates a specic control unit via the K-line. The control unit responds and transmits the faults stored in its fault memory via the K-line in digital code. "KWP-on-CAN" control units such as TBM and ECAS2 do not have a K-line. Control units with KWP-on-CAN diagnosis are stimulated by the vehicle management computer K-line (A403). The vehicle management computer (FFR) opens a gateway to the control unit in question via the CAN. System structure, K-lines TGA

(A143) Electronically Controlled Air Suspension (ECAS); note: ECAS2 has KWP-on-CAN diagnosis (A144) Control, retarder/Intarder (A266) Control unit, torque converter and clutch system/retarder (A302) Central on-board computer 2 (ZBR2) (A312) Customer-specic control module 80

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(A330) (A402) (A403) (A407) (A409) (A435) (A451) (A452) 2nd edition

Gearbox control, Tipmatic AS-TRONIC Electronic Brake System Vehicle management computer Instrumentation Electronically Controlled Air Management Electronic Diesel Control Door module, driver side Door module, co-driver side

DEVICE DESCRIPTION (A474) (A479) (A483) (A486) (A494) (A688)

Air-conditioning system Control unit, ACC Auxiliary air heater Control unit, airbag Auxiliary water heater Additional vehicle computer (for heavy-duty tractor only)

(A713) (A . . . ) (X200) (X2544)

Control unit in distributor unit Further systems can be networked Diagnosis socket Potential distributor 21-pin K-line

Rough-terrain trucks (X models)

(A146) (A302) (A312) (A402) (A403) (A407) (A435) (A483) (A494) (A . . .) (X200)

Control unit, gearbox Central computer 2 Customer-specic control module Electronic Brake System Vehicle management computer Instrumentation Electronic Diesel Control Auxiliary air heater Auxiliary water heater Further systems can be networked Diagnosis socket

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DEVICE DESCRIPTION Diagnosis socket X200 The SPN fault codes can be downloaded from the fault memory of various control units using MAN-cats® II (connection on diagnosis socket X200). The results are displayed on the MAN-cats® display. View of socket from cable end

(A) Arrow in middle points to pin 1 Connector pin assignment Diagnosis socket X200

Address

Pin

Function

Terminal

Line number

1

Option: HD-OBD CAN High

Not used

2

Option: HD-OBD CAN Low

Not used

4

K-line KWP 2000

16202

9

Negative potential

31

31000

Earthing point, central electrical system X1644 via X1829

10

Voltage supply

30

30009

via X1535 to fuse F412 / 10A

A2/11

11

Voltage supply

15

16000

via X1833 to fuse F376 / 10A

F/3

12

Alternator signal

W

59101

Alternator G102 pin 1

from

via

CES pin

X2544 to the control units

Diagnosis socket HD-OBD (X200) As of 01.01.2005, all vehicles with Euro 4 engines are legally required to have a standardised diagnosis interface to ISO 15031-3. In the case of MAN vehicles, the required HD-OBD diagnosis socket will be introduced into production for the rst vehicles from 01.10.2004 (not for all vehicles at the same time). HD-OBD stands for Heavy Duty On Board Diagnosis. Heavy-duty here in the sense of heavy-duty commercial vehicles. The installation position and the position designation (X200) remain unchanged as this diagnosis socket replaces the previous one.

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DEVICE DESCRIPTION Table of connector pin assignment Pin

Line number

Function

1

59101

2

—-

3

16202

K-line

4

31000

Ground terminal 31

5

—-

Not used

6

186

HD-OBD-CAN High

7

—-

Not used

8

16000

9 - 13

—-

Not used

14

185

HD-OBD-CAN Low

15

—-

Not used

16

30009

Speed signal, alternator, tl. W Not used

Voltage supply, term. 15

Voltage supply, term. 30

Adapter cable, HD-OBD

There is an adapter cable available for MAN-cats® applications. This cable can be ordered by quoting item number 07.98901-0002 using the "MAN-cats® II – spare parts" order form. All newly ordered diagnostic systems come with the adapted cable supplied as standard. Note: If the Communication Interface T200 is used, an adapter cable is not required as this interface can be connected to the diagnosis socket HD-OBD (X200) directly.

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DEVICE DESCRIPTION Installation positions, diagnosis socket X200 TGA - old version

The old installation position of the diagnosis socket (1) is on the rear side of the central electrical system. TGA - new version

The new installation position of the diagnosis socket (1) is behind a cover below the cup holder on the co-driver's side. Rough-terrain trucks (X models)

The diagnosis socket (1) is located on the co-driver’s side in the central electrical system area.

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DEVICE DESCRIPTION Diagnosis socket HD-OBD (X200) for TGA

The installation position and the position designation (X200) remain unchanged as this diagnosis socket (1) replaces the previous one. Main diagnosis functions – Fault detection – Fault analysis Occurrence Meaning Identication Fault type (static, sporadic, etc.) – Fault storage – Simulation for troubleshooting Malfunction displays The EBS control unit and the ESP control unit have self-diagnosis functions for all outputs and various inputs. The faults at the inputs and outputs, as well as internal faults, are detected, analysed and saved. The faults are also indicated on the instrumentation display and/or by the central STOP warning light (H111). In the case of STOP commands, the word STOP also appears on the display and the central STOP warning light (H111) ashes RED at 1-second intervals. The central STOP warning light (H111) lights up: – YELLOW to indicate either a function or a warning – RED to indicate a fault red always has priority over yellow. Functions or warnings (YELLOW) are always overridden by malfunctions (RED). In the event of an I-CAN failure (instrumentation - central on-board computer), the central STOP warning light (H111) lights up RED. All current malfunction indicators are available when the ignition is switched ON (terminal 15), irrespective of the vehicle status. The faults diagnosed and stored in the control unit may involve different risks. Therefore, each individual fault is assigned a priority. Display priorities The display cannot show all the information at once. It therefore shows information according to priorities. Lower-priority information can be overwritten by higher-priority information. Pieces of information that have the same priority are shown alternately if there is not enough room on the display. Diagnosis requires priorities 1 – 5.

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DEVICE DESCRIPTION Some function indicators have the same or a higher priority than fault indicators. In other words, a function indicator (YELLOW) can have the same priority as a RED fault or even a STOP fault. If the display area is already full and additional function indicators and fault indicators with the same priority occur, the function indicator is given priority. Indicator / diagnostic priorities Central warning light (H111)

Priority

Display

1

Indicator critical to safety

2

Indicator critical to functioning

3

RED ashing

Diagnosis meaning Drivability or safety is endangered (STOP fault, RED)

RED steady light

Driving information with recommended action, check (RED fault)

Indicator not necessary for purely normal operation

YELLOW steady light

Information before starting to drive or active safety not restricted (YELLOW fault)

4

—

—

No effect on drivability

5

Information about fault whilst vehicle in motion

YELLOW steady light

Warning (YELLOW fault)

The display only ever shows one fault at a time. Structure of fault texts in diagnosis message There are 2 lines of 16 characters available for the fault texts in the diagnostic message. The fault text message structure always includes: – Fault location/fault designation – Fault information/recommended action There are 2 types of fault text message: – Global fault text messages – Specic fault text messages Global fault text message In the global fault text message, only the priority and the source address from the DM1 message (diagnostic message 1) are evaluated. A general message is displayed, indicating the defective system and the transmitted fault number. Diagnosis

Central warning light

Fault text

Remarks

1

RED ashing

Sysname no. xxxxx-yy Diagnosis

In conjunction with STOP symbol. Engine must be stopped!

2

RED steady light

Sysname no. xxxxx-yy Diagnosis

Possibly workshop-relevant fault! Indicates malfunction

Sysname no. xxxxx-yy Diagnosis

Display at standstill, fault information only; no recommended action necessary

—

No display

3 4 5

YELLOW steady light — YELLOW steady light

Sysname no. xxxxx-yy Diagnosis

Display when vehicle in motion and at standstill; fault information only

– “Sysname”: Indicates the defective system from the source address of DM1 (e.g.: EBS or ESP) – xxxxx: Indicates the fault number from the fault location number (SPN) in the DM1 message (e.g.: EBS no. 03001 or ESP no. 03456) – yy: Indicates the fault type number (FMI) (e.g.: EBS no. 03001- 09 or ESP no. 03456-09) SPN –> Suspect Parameter Number (fault location) FMI –> Failure Mode Identication (fault type) 86

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DEVICE DESCRIPTION Specic fault text message In the case of specic fault text messages, the priority, SPN fault number and fault type (FMI) transmitted in the DM1 message are also evaluated. There is specic recommended action and naming of the specic fault cause. The SPN fault number is not displayed in the case of specic fault text messages. Note: Several different faults can trigger the same specic fault text message. SPN fault code indicated on the display, EBS The display is integrated in the instrument panel (A407). All the driver and service information is displayed. View of the display Baseline instrumentation (basic display setting)

(1) Symbol for Electronic Brake System (check lamp, general brake check)

(2) Check lamp, general brake check (H108) (3) Central STOP warning light (H111)

Highline instrumentation (basic display setting)

(1) Symbol for Electronic Brake System (check lamp, general brake check) (2) Check lamp, general brake check (H108) (3) Central STOP warning light (H111)

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DEVICE DESCRIPTION SPN fault code indicated on the display, ESP The display is integrated in the instrument panel (A407). All the driver and service information is displayed. View of the display Baseline instrumentation (basic display setting)

(1) Symbol for Electronic Stability Program (check lamp, directional stability)

(2) Check lamp, directional stability (H415) (3) Central STOP warning light (H111)

Highline instrumentation (basic display setting)

(1) Symbol for Electronic Stability Program (check lamp, directional stability) (2) Check lamp, directional stability (H415) (3) Central STOP warning light (H111)

88

T 61

2nd edition

DEVICE DESCRIPTION On-board diagnosis Faults present can be read out on the driver's display using the menu structure from the main "Diagnosis" menu. Baseline instrumentation Call up the “Diagnosis” vehicle menu:

(1) "MMI" button

(2) "ACKN./TRIP" button

The menu structure is controlled using buttons (1) and (2). There are two ways of using the buttons: Pressing and touching – Pressing - press and hold (for more than 3 
seconds), e.g. to call up the menu or to conrm. – Touching - briey press (for less than 2 seconds), e.g. to scroll through the menu or to exit the menu.

The functions performed by the "MMI" button (1) are indicated by left-hand icon (3), whilst those performed by the "ACKN./TRIP" button (2) are indicated by right-hand icon (4) on the driver's display. The "Diagnosis" vehicle menu is called up when the vehicle is stationary in order to check whether a fault is indicated. Press the "MMI" button (1) and hold it down for 
longer than 3 seconds. – Press the "MMI" button (1) until the vehicle menu 
appears on the display for symbols and text – Keep touching the "MMI" button (1) until the "Diagnosis" menu item (5) has been selected. The selected menu item is marked with a cursor. – Touch the "ACKN./TRIP" button (2) to call up "Diagnosis". The "Diagnosis" main menu contains further submenus, the number of which depends on how many systems are installed in the vehicle (e.g. central on-board computer, EBS, ECAM, EDC, vehicle management computer, ECAS, INST, etc...). These submenus display the content of the fault memory concerned. If the "MMI" (1) or "ACKN./TRIP" (2) buttons are not pressed within a certain time (approx. 30 seconds), the menu structure disappears from the screen and is replaced by the display that was in view before the menu structure was called up. T 61

2nd edition

89

DEVICE DESCRIPTION Various menus are available, depending on the vehicle operating status: The main menus – Vehicle Conguration, Operating Data, Diagnosis, Lamp Test, Maintenance, First Registered and Trailer Conguration – cannot be called up unless: – Vehicle is at a standstill – The parking brake is applied – Ignition is "ON" – The vehicle engine is not running If the vehicle is at a standstill with the parking brake applied and the vehicle engine running, the only main menu that can be called up is Operating Data. When the vehicle is in driving status – vehicle engine running – the only main menu that can be called up is Operating Data. Highline instrumentation Call up the “Diagnosis” vehicle menu:

– Button (1) vehicle menu Press to call up the vehicle menu – Button (2) rotary/pressure switch Turn (anti-clockwise/clockwise) to select a menu item Press to call up a menu item – Button (3) previous menu Press to exit a menu item – Button (4) exit menu Press to exit the selected menu (e.g. diagnosis). The "Diagnosis" vehicle menu is called up when the vehicle is stationary in order to check whether a fault is indicated. – Button (1) "vehicle menu" - Press until the vehicle menu appears on the driver's display for symbols and text.

– Turn the rotary/pressure switch (2) and select the "Diagnosis" menu item (5). The selected menu item is marked with a bar. 90

T 61

2nd edition

DEVICE DESCRIPTION – Press the rotary/pressure switch to call up "Diagnosis". Note: Press the "previous menu" button (3) to exit the menu item just selected without leaving the Vehicle menu. Press the "Exit menu" button (4) to exit the Vehicle menu. The "DIAGNOSIS" main menu contains further submenus, the number of which depends on how many systems are installed in the vehicle (e.g. central on-board computer, EBS, ECAM, EDC, vehicle management computer, ECAS, INST, etc...). These submenus display the content of the fault memory concerned. If the Vehicle menu button (1), rotary/pushbutton switch (2), previous menu level button (3) and exit menu button (4) are not pressed within a certain time (approx. 30 seconds), the menu structure disappears automatically and is replaced by the display that appeared before the menu structure was accessed. Various menus are available, depending on the vehicle operating status: The main menus – Instrumentation Conguration, Trip Data, Operating Data, Vehicle Conguration, Maintenance and Diagnosis – cannot be called up unless: – Vehicle is at a standstill – The parking brake is applied – Ignition is "ON" – The vehicle engine is not running If the vehicle is at a standstill with the parking brake applied and the vehicle engine running, the main menus that can be called up are Instrumentation Conguration, Trip Data and Operating Data. When the vehicle is in driving status – vehicle engine running – the main menus Instrumentation Conguration, Trip Data and Operating Data can also be called up. The following abbreviations are used in the submenus for Baseline and Highline instrumentation: Abbreviations

Meaning

ZBR

Central on-board computer 2

EBS

Electronic Brake System

ESP

Electronic Stability Program

ECAM

Electronically Controlled Air Management

EDC

Electronic Diesel Control

EDC S

Electronic Diesel Control Slave

FFR

Vehicle management computer

ZFR

Additional vehicle computer

DIAG

Entire vehicle (on-board diagnostic memory)

ECAS / EFR

Electronically Controlled Air Suspension / electronic shock absorber control

RET S

Secondary retarder

RET P

Primary retarder

TCU

Transmission Control Unit (automated/automatic gearbox)

INST

Instrumentation

ACC

Adaptive Cruise Control

GDK / DPF

Exhaust-gas control

LGS

Lane Guard System

NLA / VLA

Trailing axle/leading axle

M-TCO

Tachograph

TPM

Tyre Pressure Monitor

TBM

Telematics on-board module

WSK

Torque converter and clutch system

T 61

2nd edition

91

DEVICE DESCRIPTION 2 displays are shown below. The graphics show the display of fault codes. Baseline instrumentation:

Highline instrumentation

92

T 61

2nd edition

DEVICE DESCRIPTION Malfunction indicator and emergency functions Malfunctions and faults in the EBS system are indicated by a warning light and on the instrument panel display. A new attempt is made to start EBS when the ignition is switched ON again. If the malfunction is still present and is detected, the light and the emergency function are activated but the fault is not stored again. A malfunction is detected when a certain time passes by after the fault occurs. The malfunction is then classied as a "permanent" fault. Certain EBS functions are switched off, depending on the type and the severity of the fault. These faults and the resultant operating state (back-up level) are indicated on the following chart. EBS function levels The scope of function changes after a malfunction is detected in the system. Subfunctions of the basic function are deactivated or switched to the pneumatic back-up circuit (back-up levels). Function level Function

1

1a

2

3

4

5

6

7

8

9

10

11

12

Control unit

●

●

●

●

●

●

●

●

●

●

●

♦

–

Pressure control module

●

●

●

●

●

●

●

●

♦

♦

♦

–

–

Electro-pneumatic brake

●

●

●

●

●

●

●

●

♦

–

–

–

–

Back-up circuit

+

+

+

+

+

+

+

+

♦

●

●

●

●

ALB

●

●

●

●

●

–

●

●

♦

–

–

–

–

ABS

●

●

●

●

●

●

♦

–

♦

–

–

–

–

●

–

●

●

●

●

–

–

–

–

–

–

–

brake governor

●

●

●

●

●

●

–

–

–

–

–

–

–

Sustained-action brake relay

●

●

●

●

–

●

–

–

–

–

–

–

–

Speed sensor

●

●

●

●

●

●

♦

–

♦

●

●

–

–

Brake wear sensor

●

●

●

–

●

●

●

●

♦

●

●

–

–

Brake wear indicator

●

●

●

●

–

●

●

●

●

●

●

–

–

Braking-value sensor

●

●

●

●

●

●

●

●

●

●

–

●

–

Trailer CAN

♦

●

–

●

●

●

●

●

●

●

♦

–

–

Brake CAN

●

●

●

●

●

●

●

●

♦

●

●

–

–

General CAN

●

–

●

●

●

●

●

●

●

●

●

–

–

ASR engine governor ASR

● = functioning ♦ = partially functioning (individual components have failed or one component only partially functioning) – = not functioning + = ready

T 61

2nd edition

93

DEVICE DESCRIPTION Description of function levels Level

94

Description

1

EBS functions without restrictions in the tractor or trailer. If the yellow warning light comes on in this state, then only 1-wire communication via trailer CAN or EOL adjustment not performed (fault code 3011).

1a

EBS functions without restrictions with the exception of the ASR engine governing and/or the CAN general communication and its associated functions.

2

The trailer EBS functions are maintained via the 5-pin trailer plug connection and the sensed pneumatic activation pressure for the trailer.

3

The brake wear monitor has failed. All other EBS functions are present.

4

EBS functions operate without restriction. The EBS control unit continues to attempt to activate the sustained-action brake and/or brake wear sensor.

5

EBS operates using the EOL-programmed value "L = ALB-Fehl" (ALB fault) for brake pressure distribution when braking with service brake (EPB) and using the ALB value L = 0 in the case of ABS for IRM (modied individual control) on the front axle.

6

The brake pressure in the control channel concerned is controlled based on the electrical setpoint (EPB). In the case of ABS, the wheel with the defective speed sensor is treated as if it were running unlocked on the road with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The ASR functions (brake and engine control) are deactivated. The sustained-action brake output is not activated.

7

The brake pressure at the control channel concerned is controlled based on the electrical setpoint (EPB). The vehicle has no ABS. The ASR functions (brake and engine control) are deactivated. The sustained-action brake output is not activated.

8

The affected pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no ALB control and no ABS control. The ASR functions (brake and engine control) are deactivated.

9

The EBS control unit and pressure control module are energised, all sensor signals are processed. Communication is maintained between the pressure control module and EBS control unit. Solenoid valves remain in the basic position. They are not electrically activated. Braking is via the pneumatic back-up circuit (without ALB, ABS, ASR).

10

The EBS control unit and pressure control module are energised. The signals in the pressure control module are processed and communication is maintained between the pressure control module and EBS control unit. The EBS control unit always sends the setpoint "zero" to the pressure control module. Braking is via the pneumatic back-up circuit. There is no ALB control and no ASR control (brake and engine controller).

11

All pressure control modules are deenergised. The EBS control unit is energised. Braking is via the pneumatic back-up circuit. The system has no ALB, no ABS and no ASR (brake and engine controller).

12

The EBS is de-energised. Braking is via the pneumatic back-up circuit. The system has no ALB, no ABS and no ASR (brake and engine controller).

T 61

2nd edition

DEVICE DESCRIPTION Contact box The contact box is used to check the functioning of all EBS control unit components (valves, sensors, ...) in installed state. No measuring with the contact box is foreseen for the ESP control unit. Example of contact box connection, TGA: Components:

Components connected:

Item

Name

Item number

1

Contact box

97 0 010

2

Diagnosis template for EBS

97 0 077

3

Wiring harness for connecting to the vehicle wiring harness

Conguration 97 0 070

4

Wiring harness for connecting to the control unit

Conguration 97 0 070

5

Connection to vehicle wiring harness "A402/X3: brown"

6

Connection to vehicle wiring harness "A402/X4: green"

7

Connection to vehicle wiring harness "A402/X2: yellow"

8

Connection to vehicle wiring harness "A402/X1: blue"

9

Connection to EBS control unit "A402/X4: green"

10

Connection to EBS control unit "A402/X1: blue"

11

Connection to EBS control unit "A402/X2: yellow"

12

Connection to EBS control unit "A402/X3: brown"

T 61

2nd edition

95

DEVICE DESCRIPTION Connecting the contact box: – Secure the vehicle to prevent it from rolling away inadvertently (parking brake, chocks). – Switch off the engine and the ignition. – Check whether the EBS control unit is protected with the specied fuses, F161 - EBS/ABS voltage supply, pressure control valve, terminal 30 (battery) with 15A and F162 - EBS/ABS control, terminal 15 (ignition) with 5A. – Disconnect the EBS control unit. – Connect the contact box between the EBS control unit and the vehicle wiring harness. The test step list enables you to check the EBS control unit components or functions using the contact box and a multimeter (e.g. FLUKE 77 or 87). Rectangular signals can also be checked using an oscilloscope or FLUKE Scopemeter 123. Troubleshooting program The following troubleshooting program contains the faults that can be detected by the fault memory. The test sequence corresponds to the numerical sequence of the fault codes (SPNs), irrespective of the fault “valency”. During initial vehicle testing, the entire fault memory must always be read out and all the stored faults documented. This is important because cables and/or components have to be disconnected during troubleshooting and this means the corresponding fault messages may be set and saved. Consequently, the fault memory should always be deleted after intermediate inspections. If parts are exchanged, send a printout from MAN-cats® verifying the fault together with the returned part in order to claim back the costs. (The printout is an extract from the fault memory, see above.) Other procedures are only permitted subject to consultation with the Service Department in Munich! Equally, control units are only allowed to be exchanged under warranty subject to consultation with the Service Department in Munich. Repeat the check and delete the fault memory after correcting the fault and checking the repair. The fault memory should always be deleted using MAN-cats® Always delete the fault memory and observe the fault before replacing any component or control unit. If several faults are entered, always rst perform the test instructions that do not require any components or control units to be exchanged. It is essential to switch off the ignition before carrying out the repair and exchanging components or control units. If the ignition is not switched off, faults (SPNs) will be entered in the various electronic control units. Always carry out the “Check cables” step as follows: – Discontinuity or contact resistance (e.g. receptacles bent open, connectors or receptacles pushed back
 or corroded plug and socket connections) – Short circuit to negative – Short circuit to positive – Short circuit to adjacent lines – Loose connections – Water or moisture in the cable line Cable lines may be damaged even though the corrugated tube appears undamaged from the outside! Break the connection to the control unit before measuring resistance values. Refer to the diagrams for the vehicle!

96

T 61

2nd edition

DEVICE DESCRIPTION Resistance measurement – Ignition “OFF” – The contact box is connected between the EBS control unit and the vehicle. – All the jumpers in the contact box must be closed. The jumper at which the value is being measured must be open. – A contact box is not used for the ESP Control unit; here only a multimeter is used for measurements. The connector at which the measurement is taken must be disconnected. Voltage measurement – Ignition “ON” – The contact box is connected between the EBS control unit and the vehicle. – All the jumpers in the contact box must be closed. – A contact box is not used for the ESP Control unit; here only a multimeter is used for measurements. The connector at which the measurement is taken must be connected. Voltage is measured with the engine running and the vehicle stationary. The operating voltage is approximately 28 V, the operating voltage range is 16 - 32 V.

T 61

2nd edition

97

DEVICE DESCRIPTION SPN list (fault codes) and fault code description, EBS This section presents the fault codes that are shown on the instrumentation display or MAN-cats® screen in the event of a fault. SPN Suspect Parameter Number – Fault location Address: 2a - Electronic Braking System Version: 1.80 In the case of the fault codes below, the following check lamps on the instrumentation are activated: Brake wear indicator Brake wear indicator check lamp (appears as icon on the display) with central STOP warning light H111 (yellow) H108 - Check lamp, general brake check (red) with central STOP warning light H111 (red) H111 - Central STOP warning light (yellow) H140 - Check lamp, ASR info. (information indicator) H415 - Check lamp, directional stability Note: See test step list for test step Control unit fault messages SPN

SPN-Plain text Description

03000

No fault Fault display: — Emergency function (function level 1): There are no faults in the electronic brake system (EBS) of the tractor vehicle and the trailer and they are functioning without restrictions.

03001

Control unit defective; unknown µC interrupt, µC self-test, RAM or ROM test Fault display: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Remedy: Delete the fault memory. Effect of fault: Switch-off of electropneumatic pressure modulation of the front, rear, additional axle and trailer control valve. ABS, ASR, ESP are switched off. Cause of fault: Internal fault in control unit. Note: Always delete the fault memory and observe the fault before replacing any control unit. In addition, if several faults are entered, always rst perform the test instructions that do not require any control units to be exchanged. Remedy: Delete the fault memory and read out the fault memory again. Fit a new EBS control unit (A402) if the fault reoccurs. Emergency function (function level 11): All pressure control modules are deenergised. The EBS control unit is energised. Braking is via the pneumatic back-up circuit. The system does not have any ALB, ABS or ASR (brake regulator and engine governor).

98

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03002

Control unit defective, timeout in data exchange µC active – µC passive Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Remedy: Delete the fault memory. Effect of fault: Switch-off of electropneumatic pressure modulation of the front axle, rear axle, additional axle and trailer control valve. ABS, ASR, ESP are switched off. Cause of fault: Internal fault in control unit. Note: Always delete the fault memory and observe the fault before replacing any control unit. In addition, if several faults are entered, always rst perform the test instructions that do not require any control units to be exchanged. Remedy: Delete the fault memory and read out the fault memory again. Fit a new EBS control unit (A402) if the fault re-occurs. Emergency function (function level 11): All pressure control modules are deenergised. The EBS control unit is energised. Braking is via the pneumatic back-up circuit. The system does not have any ALB, ABS or ASR (brake regulator and engine governor).

03003

Control unit defective; redundancy fault µc input signal Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Remedy: Delete the fault memory. Effect of fault: The EBS electronic control unit (A402) contains 2 redundant computers, and both pick up the input signals from the control unit at the same time. The input values picked up by each computer are compared with one another. The “Redundancy fault input signal” fault message appears if there are discrepancies. Cause of fault: Internal fault in control unit. Note: Always delete the fault memory and observe the fault before replacing any control unit. In addition, if several faults are entered, always rst perform the test instructions that do not require any control units to be exchanged. Remedy: Delete the fault memory and read out the fault memory again. Fit a new EBS control unit (A402) if the fault re-occurs. Emergency function (function level 11): All pressure control modules are deenergised. The EBS control unit is energised. Braking is via the pneumatic back-up circuit. The system does not have any ALB, ABS or ASR (brake regulator and engine governor).

03004

Control unit defective, testsum data exchange µC active µC passive Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Remedy: Delete the fault memory. Cause of fault: Internal fault in control unit. Note: Always delete the fault memory and observe the fault before replacing any control unit. In addition, if several faults are entered, always rst perform the test instructions that do not require any control units to be exchanged. Remedy: Delete the fault memory and read out the fault memory again. Fit a new EBS control unit (A402) if the fault re-occurs. Emergency function (function level 11): All pressure control modules are deenergised. The EBS control unit is energised. Braking is via the pneumatic back-up circuit. The system does not have any ALB, ABS or ASR (brake regulator and engine governor).

T 61

2nd edition

99

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03005

Control unit defective; EEPROM fault: Checksum not correct Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Remedy: Delete the fault memory. The checksum must be entered in the EBS electronic control unit (A402) using MAN-cats II®. Effect of fault: Switch-off of electropneumatic pressure modulation of the front axle, rear axle, additional axle and trailer control valve. ABS, ASR, ESP are switched off. Cause of fault: Internal fault in control unit. Note: Always delete the fault memory and observe the fault before replacing any control unit. In addition, if several faults are entered, always rst perform the test instructions that do not require any control units to be exchanged. Remedy: Delete the fault memory and read out the fault memory again. Fit a new EBS control unit (A402) if the fault re-occurs. Emergency function (function level 11): All pressure control modules are deenergised. The EBS control unit is energised. Braking is via the pneumatic back-up circuit. The system does not have any ALB, ABS or ASR (brake regulator and engine governor).

03006 03007

No valid fault denition

03008

Control unit defective; test transfer from µc to CAN trailer IC Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Remedy: Delete the fault memory. Cause of fault: Internal fault in control unit. Note: Always delete the fault memory and observe the fault before replacing any control unit. In addition, if several faults are entered, always rst perform the test instructions that do not require any control units to be exchanged. Remedy: Delete the fault memory and read out the fault memory again. Fit a new EBS control unit (A402) if the fault re-occurs. Emergency function (function level 11): All pressure control modules are deenergised. The EBS control unit is energised. Braking is via the pneumatic back-up circuit. The system does not have any ALB, ABS or ASR (brake regulator and engine governor).

03009

Control unit defective; redundancy fault µc output signal Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Remedy: Delete the fault memory. Cause of fault: Internal fault in control unit. Note: Always delete the fault memory and observe the fault before replacing any control unit. In addition, if several faults are entered, always rst perform the test instructions that do not require any control units to be exchanged. Remedy: Delete the fault memory and read out the fault memory again. Fit a new EBS control unit (A402) if the fault re-occurs. Emergency function (function level 11): All pressure control modules are deenergised. The EBS control unit is energised. Braking is via the pneumatic back-up circuit. The system does not have any ALB, ABS or ASR (brake regulator and engine governor).

100

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03010

Control unit defective; wheel diameter compensation value not correct Fault indication: Central STOP warning light (H111) lights up yellow. Remedy: The parameters for wheel diameter compensation must be corrected by writing the default values to the EEPROM using the end of line (EOL) programming. Remedy: Delete the fault memory and read out the fault memory again. Fit a new EBS control unit (A402) if the fault reoccurs. Emergency function (function level 7): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). The anti-lock brake system (ABS) of the vehicle is deactivated and the anti-spin regulator (ASR) functions (brake regulator and engine governor) are no longer carried out. The retarder relay (DBR) output is not activated.

03011

Control unit defective; fault in service brake valve characteristic Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The EBS electronic control unit (A402) is delivered with a temporarily functioning data record for the service brake valve characteristic. It must be calibrated for the specic vehicle in order to ensure fault-free operation. Calibration corrects the data record of the service brake valve (with integrated brake power sensor). Remedy: The service brake valve (with integrated brake power sensor B337) must be recalibrated. The service brake valve calibration must be performed using MAN-cats® II. Emergency function (function level 1): EBS functions without restrictions in the tractor or trailer. If the yellow warning light comes on in this status then there is only 1-wire communication with the trailer via CAN or EOL calibration was not performed.

03012

Control unit defective; incompatibility in data record version number Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Remedy: Delete the fault memory. The data record must be corrected by writing the default values to the EEPROM using the end of line (EOL) programming. The vehicle-specic data record must be loaded. Remedy: Delete the fault memory and read out the fault memory again. Fit a new EBS control unit (A402) if the fault re-occurs. Emergency function (function level 12): All EBS components are deenergised. Braking is via the pneumatic back-up circuit. The system does not have any ALB, ABS or ASR (brake regulator and engine governor).

03013

Control unit defective; characteristic in EEPROM not plausible Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Remedy: Delete the fault memory. The characteristic curves in the EEPROM data record must be checked using MAN-cats® II. Remedy: Delete the fault memory and read out the fault memory again. Fit a new EBS control unit (A402) if the fault re-occurs. Emergency function (function level 12): All EBS components are de-energised. Braking is via the pneumatic back-up circuit. The system has no ALB, no ABS and no ASR (brake and engine controller).

03014 03019

No valid fault denition

T 61

2nd edition

101

DEVICE DESCRIPTION Analogue signal fault messages SPN

SPN-Plain text Description

03020

Faulty supply voltage (5 volts) for analog sensors Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: The 5 V voltage between pin X2/3 (brake power sensor ground) and pin X2/2 (brake power sensor voltage supply) of the EBS electronic control unit (A402) must be in the range 5 V ±0.45 V. This voltage can also be read out using MAN-cats® II. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit. Remedy: The 5 volt cable to the brake power sensor (B337) (installed in the service brake valve) and the automatic load-balancing (ALB) sensor (B336) must be checked for parallel connection. Emergency function (function level 10): The EBS electronic control unit and pressure control module are energised. The signals in the pressure control module are processed and communication between the pressure control module and the EBS control unit is maintained. The EBS control unit always sends the nominal value “zero” to the pressure control module. Braking is via the pneumatic back-up circuit. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control (brake regulator and engine governor).

03021

Defective service brake valve-potentiometer signal Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: Permitted value range of the potentiometer signal at the EBS electronic control unit (A402): Brake power sensor signal 1: The signal of potentiometer 1 between pin X2/3 (brake power sensor ground) and pin X2/7 should have the voltage values 0.5 -0.2 V and 4.3 +0.2 V. Brake power sensor signal 2: The signal of potentiometer 2 between pin X2/3 (brake power sensor ground) and pin X2/4 should have the voltage values 4.4 +0.2 V and 0.5 -0.2 V. Permitted value range of the supply voltage at the EBS electronic control unit: Between pin X2/2 (5 V brake power sensor voltage supply) and pin X2/3, the measured voltage value should be 5 V ±0.45 V. These voltage values can also be read out using MAN-cats® II. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit. Remedy: On the service brake valve (with integrated brake power sensor), the cables and plug connections between the EBS electronic control unit (A402) and the brake power sensor (B337) must be checked for short circuit or line discontinuity. The supply voltages at the brake power sensor and the potentiometer resistor of the brake power sensor must be measured. Nominal pressure values of the brake power sensor with plug disconnected, without actuation Pin X2/7 4.2 kΩ= R = 7.5 kΩ (desired pressure 1 from brake power sensor) Pin X2/4 4.9 kΩ= R = 2.1 kΩ (desired pressure 2 from brake power sensor) Emergency function (function level 10): The EBS electronic control unit and pressure control module are energised. The signals in the pressure control module are processed and communication between the pressure control module and the EBS control unit is maintained. The EBS control unit always sends the nominal value “zero” to the pressure control module. Braking is via the pneumatic back-up circuit. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control (brake regulator and engine governor).

102

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03022

Faulty axle load sensor 1 Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: Permitted value ranges of the ALB sensor (measured at the rear axle pressure control module Y264): Between pin 3/3 and pin 3/1, the voltage range should be > 0.1 V (air bag pressure low) and < 4.9 V (air bag pressure high). These voltage values can be read out using MAN-cats® II. Compatibility between the EOL parameters and the connected ALB sensor must be assured. Remedy: The cables and plug connectors between the rear axle pressure control module (Y264) and the automatic load-balancing (ALB) sensor (B336) must be checked for short circuit or line discontinuity. The compatibility of the end of line (EOL) parameter and the connected sensors must be checked. The resistance values on this sensor must be measured when the plug is disconnected. Between pin 2 and pin 3: 2.2 kΩ = R = 8.4 kΩ. Pin 1: Voltage supply (5 V), pin 2: Sensor ground Between pin 1 and pin 2: 4.0 kΩ = R = 6.0 kΩ. Pin 3: Sensor data line (supply voltage 5 V – measured at ALB sensor B336) Effect of fault: Permitted value ranges of the ALB sensor (measured at the 2-channel rear axle pressure control module): Between pin 3/2 and pin 3/1, the voltage range should be > 0.1 V (air bag pressure low) and < 4.9 V (air bag pressure high). These voltage values can be read out using MAN-cats® II. Compatibility between the EOL parameters and the connected ALB sensor must be assured. Emergency function (function level 5): The EBS system operates with the value “L = ALB-Fehl” programmed via EOL for brake pressure distribution during braking with the service brakes (EPB) and with the ALB value L = 0 in the ABS for IRM (individual regulation modied) at the front axle.

03023

Faulty axle load sensor 2 Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: Permitted value ranges of the ALB sensor (measured at the 2-channel rear axle pressure control module): Between pin 3/2 and pin 3/1, the voltage range should be > 0.1 V (air bag pressure low) and < 4.9 V (air bag pressure high). These voltage values can be read out using MAN-cats® II. Compatibility between the EOL parameters and the connected ALB sensor must be assured. Remedy: The cables and plug connectors between the 2-channel rear axle pressure control module and the automatic load-balancing (ALB) sensor must be checked for short circuit or line discontinuity. Compatibility of the EOL parameters and the connected sensors or the resistance values on this sensor with the plug disconnected must be checked. Between pin 2 and pin 3: 2.2 kΩ = R = 8.4 kΩ. Pin 1: Voltage supply (5 V). Pin 2: Sensor ground Between pin 1 and pin 2: 4.0 kΩ = R = 6.0 kΩ. Pin 3: Sensor data line (supply voltage 5 V – measured at ALB sensor B336) Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 5): The EBS system operates with the value “L = ALB-Fehl” programmed via EOL for brake pressure distribution during braking with the service brakes (EPB) and with the ALB value L = 0 in the ABS for IRM (individual regulation modied) at the front axle.

03024

Brake wear: Incorrect tendency between the axles Fault indication: Central STOP warning light (H111) lights up yellow and the brake wear indicator check lamp comes on (appears as a pictogram on the display). Effect of fault: Lining wear control cannot reverse the wear trend of an axle in spite of being fully adjusted. Remedy: Delete the fault memory. Furthermore, all wear indicator sensors (brake sensor, 1st axle, right (B332), brake sensor, 1st axle, left (B333), brake sensor, 2nd axle, right (B334) and brake sensor, 2nd axle, left (B335)) and the wheel brakes on the entire vehicle must be checked for wear, oil contamination, sticking, etc. Emergency function: —

T 61

2nd edition

103

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03025

Brake wear: Incorrect tendency between the wheels of axle 1 Fault indication: Central STOP warning light (H111) lights up yellow and the brake wear indicator check lamp comes on (appears as a pictogram on the display). Effect of fault: The wheel wear trend of this axle does not correspond to the average wear trend of the vehicle. Remedy: Delete the fault memory. Furthermore, the wear indicator sensors on axle 1 (brake sensor, 1st axle, right (B332), brake sensor, 1st axle, left (B333)) and the wheel brakes on axle 1 must be checked for wear, oil contamination, sticking, etc. Emergency function: —

03026

Brake wear: Incorrect tendency between the wheels of axle 2 Fault indication: Central STOP warning light (H111) lights up yellow and the brake wear indicator check lamp comes on (appears as a pictogram on the display). Effect of fault: The wheel wear trend of this axle does not correspond to the average wear trend of the vehicle. Remedy: Delete the fault memory. Furthermore, the brake wear indicator sensors on axle 2 (brake sensor, 2nd axle, right (B334), brake sensor, 2nd axle, left (B335) and the wheel brakes on axle 2 must be checked for wear, oil contamination, sticking, etc. Emergency function: —

03027

Brake wear: Incorrect tendency between the wheels of axle 3 Fault indication: Central STOP warning light (H111) lights up yellow and the brake wear indicator check lamp comes on (appears as a pictogram on the display). Effect of fault: The wheel wear trend of this axle does not correspond to the average wear trend of the vehicle. Remedy: Delete the fault memory. Furthermore, the brake wear indicator sensors on axle 3 and the wheel brakes on axle 3 must be checked for wear, oil contamination, sticking, etc. Emergency function: —

03028

Brake wear: Incorrect tendency between the wheels of axle 4 Fault indication: Central STOP warning light (H111) lights up yellow and the brake wear indicator check lamp comes on (appears as a pictogram on the display). Effect of fault: The wheel wear trend of this axle does not correspond to the average wear trend of the vehicle. Remedy: Delete the fault memory. Furthermore, the brake wear indicator sensors on axle 4 and the wheel brakes on axle 4 must be checked for wear, oil contamination, sticking, etc. Emergency function: —

03029

104

No valid fault denition

T 61

2nd edition

DEVICE DESCRIPTION Fault messages, feedback signals SPN

SPN-Plain text Description

03030

Defective brake wear and sustained-action brake relay output stage feedback Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The output stage of the lining wear display or the retarder relay may be defective. If the fault reoccurs after the fault memory has been deleted then replace the EBS electronic control unit (A402). The checkback test can be switched off using end of line (EOL) programming. If the checkback test should be switched on, the lining wear display or retarder relay are not allowed to be switched by external systems. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit. Remedy: Delete the fault memory. The cables and plug connectors between the lining wear display and the retarder relay must be checked for short circuit to ground or 24 volts or line discontinuity. Emergency function (function level 4): EBS functions operate without restriction. The EBS electronic control unit continues trying to activate the sustained-action brake and/or brake lining wear sensor.

03031

Faulty retarder relay output stage checkback Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The output stage of the retarder relay may be defective. If the fault reoccurs after the fault memory has been deleted then replace the EBS electronic control unit (A402). The checkback test can be switched off using end of line (EOL) programming. If the checkback test is activated, the retarder relay is not allowed to be switched by external systems. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit. Remedy: Delete the fault memory. The cables and plug connectors of the retarder relay must be checked for short circuit to ground or 24 volts or line discontinuity. Emergency function (function level 4): EBS functions operate without restriction. The EBS electronic control unit continues trying to activate the sustained-action brake and/or brake lining wear sensor.

03032

Defective brake wear output stage feedback Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The output stage of the lining wear display may be defective. If the fault reoccurs after the fault memory has been deleted then replace the EBS electronic control unit (A402). The checkback test can be switched off using end of line (EOL) programming. If the checkback test is activated, the retarder relay is not allowed to be switched by external systems. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit. Remedy: Delete the fault memory. The cables and plug connectors of the retarder relay must be checked for short circuit to ground or 24 volts or line discontinuity. Emergency function (function level 4): EBS functions operate without restriction. The EBS electronic control unit continues trying to activate the sustained-action brake and/or brake lining wear sensor.

03033

Invalid check-back signal for the yellow warning light Fault indication: Central STOP warning light (H111) lights up yellow.

03034

Invalid check-back signal for the red warning light

03035

No valid fault denition

T 61

2nd edition

105

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03036

Short-circuit at one of the module output stages Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: A module output stage may be defective. If the fault reoccurs after the fault memory has been deleted then replace the EBS electronic control unit (A402). The checkback test can be switched off using end of line (EOL) programming. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit. Remedy: Delete the fault memory. The cables and plug connectors of the EBS modules (right front axle pressure control module (Y262), left front axle pressure control module (Y263), rear axle pressure control module (Y264) and trailer control valve (Y278)) must be checked for short circuit to 24 volts. Emergency function (function level 11): All pressure control modules are deenergised. The EBS electronic control unit is energised. Braking is via the pneumatic back-up circuit. The system does not have automatic load balancing (ALB), anti-lock brake system (ABS) and anti-spin regulator (ASR) (brake regulator and engine governor).

03037 03040

No valid fault denition

Fault messages, engine interface SPN

SPN-Plain text Description

03041

Engine interface, DKV input permanently low, > 400 ms Active fault indication: H140

03042

Engine interface, DKV input permanently high, > 400 ms Active fault indication: H140

03043

Engine interface, DKV input frequency > 220 Hz Active fault indication: H140

03044

Engine interface, DKV input frequency > 95 Hz Active fault indication: H140

03045

Engine interface, DKV input, mark-to-space ratio < 5 % Active fault indication: H140

03046

Engine interface, DKV input, mark-to-space ratio > 95 % Active fault indication: H140

03047

DKV input permanently low or high 80 ..... 400 ms Active fault indication: H140

03048

No valid fault denition

Fault messages, CAN databus SPN

SPN-Plain text Description

03049

CAN databus, powertrain, receive time exceeded Fault indication: Central STOP warning light (H111) lights up yellow.

106

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03050

CAN databus, powertrain, bus off Fault indication: Central STOP warning light (H111) lights up yellow. Remedy: Check the cables and plug connectors of the CAN databus, powertrain (T-CAN) for short circuit or line discontinuity. The total resistance between the EBS control unit A402 pin X1/1 and A402 pin X1/3 should be 60Ω. Make sure that the control units connected with CAN databus, powertrain (T-CAN) are fully functional. Emergency function: The EBS is functioning with restrictions. EBS functions that require the CAN J 1939 Powertrain are not performed. The EBS electronic control unit (A402) is still trying to establish a connection.

03051

CAN databus, powertrain, receive time exceeded in EEC1 message from the EDC Fault indication: Central STOP warning light (H111) lights up yellow. Remedy: Check the cables and plug connectors of the CAN databus, powertrain (T-CAN) for short circuit or line discontinuity. The total resistance between the EBS control unit A402 pin X1/1 and A402 pin X1/3 should be 60Ω. Make sure the control units used are fully functional! Emergency function (function level 1a): EBS functions without restrictions with the exception of the anti-spin regulator (ASR) engine governing and/or the CAN general communication and its associated functions.

03052 03055

No valid fault denition

03056

CAN databus, powertrain, receive time exceeded in ERC1_D message from retarder Fault indication: Central STOP warning light (H111) lights up yellow. Remedy: Check the cables and plug connectors of the CAN databus, powertrain (T-CAN) between the EBS electronic control unit (A402) and the retarder control unit (A144) for short circuit or line discontinuity. The total resistance between the EBS control unit A402 pin X1/1 and A402 pin X1/3 should be 60Ω. The control unit used should be fully functional. Emergency function (function level 1a): EBS operates without functions that use the ERC1_D message. The EBS electronic control unit is still trying to establish a connection. EBS functions without restrictions with the exception of the anti-spin regulator (ASR) engine governing and/or the CAN general communication and its associated functions.

03057

CAN databus, powertrain, receive time exceeded in ERC1_E message from retarder Fault indication: Central STOP warning light (H111) lights up yellow. Remedy: Check the cables and plug connectors between the CAN databus, powertrain (T-CAN) and the corresponding retarder control unit (A144) for short circuit or line discontinuity. The total resistance between the EBS control unit A402 pin X1/1 and A402 pin X1/3 should be 60Ω. The control unit used should be fully functional. Emergency function (function level 1a): EBS operates without functions that use the ERC1_E message. The EBS electronic control unit is still trying to establish a connection. EBS functions without restrictions with the exception of the anti-spin regulator (ASR) engine governing and/or the CAN general communication and its associated functions.

T 61

2nd edition

107

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03058

CAN databus, powertrain, receive time exceeded in ERC1_EX message from vehicle management computer Fault indication: Central STOP warning light (H111) lights up yellow. Remedy: Check the cables and plug connectors between the CAN databus, powertrain (T-CAN) and the corresponding vehicle management computer control unit (A403) for short circuit or line discontinuity. The total resistance between the EBS control unit A402 pin X1/1 and A402 pin X1/3 should be 60Ω. The control unit used should be fully functional. Emergency function (function level 1a): EBS operates without functions that use the ERC1_EX message. The EBS electronic control unit is still trying to establish a connection. EBS functions without restrictions with the exception of the ASR engine governing and/or the CAN general communication and its associated functions.

03059

CAN databus, powertrain, receive time exceeded for message “High Resolution Vehicle Distance” from tachograph Fault indication: Central STOP warning light (H111) lights up yellow. Remedy: Check the cables and plug connectors between the CAN databus, powertrain (T-CAN) and the corresponding tachograph control unit (A408) for short circuit or line discontinuity. The total resistance between the EBS control unit A402 pin X1/1 and A402 pin X1/3 should be 60Ω. The control unit used should be fully functional. Emergency function (function level 1a): EBS operates without functions that use the ECV message. The EBS electronic control unit is still trying to establish a connection. EBS functions without restrictions with the exception of the ASR engine governing and/or the CAN general communication and its associated functions.

03060

CAN databus, powertrain, receive time exceeded for message “Supply Pressure” from ECAM Fault indication: Central STOP warning light (H111) lights up yellow. Remedy: Check the cables and plug connectors between the CAN databus, powertrain (T-CAN) and the corresponding ECAM control unit (A409) for short circuit or line discontinuity. The total resistance between the EBS control unit A402 pin X1/1 and A402 pin X1/3 should be 60Ω. The control unit used should be fully functional. Emergency function (function level 1a): EBS operates without functions that use the ECAM message. The EBS electronic control unit is still trying to establish a connection. EBS functions without restrictions with the exception of the anti-spin regulator (ASR) engine governing and/or the CAN general communication and its associated functions.

03061

CAN databus, powertrain, receive time exceeded in EEC3 message from the EDC Fault indication: Central STOP warning light (H111) lights up yellow. Remedy: Check the cables and plug connectors between the CAN databus, powertrain (T-CAN) and the corresponding EDC control unit (A435) for short circuit or line discontinuity. The total resistance between the EBS control unit A402 pin X1/1 and A402 pin X1/3 should be 60Ω. The control unit used should be fully functional. Emergency function (function level 1a): EBS operates without functions that use the EEC3 message. The EBS electronic control unit is still trying to establish a connection. EBS functions without restrictions with the exception of the anti-spin regulator (ASR) engine governing and/or the CAN general communication and its associated functions.

108

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03062

CAN databus, powertrain, receive time exceeded for “Cruise Control/Vehicle Speed” message from the EDC via vehicle management computer Fault indication: Central STOP warning light (H111) lights up yellow. Remedy: Check the cables and plug connectors between the CAN databus, powertrain (T-CAN) and the corresponding EDC control unit (A435), the signal of which is output from the vehicle management computer (A403), for short circuit or line discontinuity. The total resistance between the EBS control unit A402 pin X1/1 and A402 pin X1/3 should be 60Ω. The control unit used should be fully functional. Emergency function (function level 1a): EBS operates without functions that use the ECC message. The EBS electronic control unit is still trying to establish a connection. EBS functions without restrictions with the exception of the anti-spin regulator (ASR) engine governing and/or the CAN general communication and its associated functions.

03063

CAN databus, powertrain, receive time exceeded for message “vehicle weight measurement” from ECAS Fault indication: Central STOP warning light (H111) lights up yellow. Remedy: Check the cables and plug connectors between the CAN databus, powertrain (T-CAN) and the corresponding ECAS control unit (A143) for short circuit or line discontinuity. The total resistance between the EBS control unit A402 pin X1/1 and A402 pin X1/3 should be 60Ω. The control unit used should be fully functional. Emergency function (function level 1a): EBS operates without functions that use the EVW (electronic vehicle weight) message. The EBS electronic control unit is still trying to establish a connection. EBS functions without restrictions with the exception of the anti-spin regulator (ASR) engine governing and/or the CAN general communication and its associated functions.

03064

CAN databus, powertrain, values for vehicle weight in the “Vehicle Weight” message from the ECAS outside the range Fault indication: Central STOP warning light (H111) lights up yellow. Remedy: Check the function of the system that is providing information about the vehicle weight. The total resistance between the EBS control unit A402 pin X1/1 and A402 pin X1/3 should be 60Ω Emergency function (function level 1a): EBS operates without functions that use the EVW message. The EBS electronic control unit is still trying to establish a connection. EBS functions without restrictions with the exception of the anti-spin regulator (ASR) engine governing and/or the CAN general communication and its associated functions.

03065

CAN databus, powertrain, receive time exceeded in TSC1_ACC message from the ACC Fault indication: Central STOP warning light (H111) lights up yellow. Remedy: Check the cables and plugs of the CAN databus, powertrain (T-CAN) for short circuit or line discontinuity. Make sure that TSC1_ACC is fully functional. TSC1_ACC = the control unit from which the ACC brake intervention comes. Emergency function: Brake intervention by ACC is no longer possible. The central EBS control unit is still trying to establish a connection.

03066

No valid fault denition

03067

CAN databus, powertrain, receive time exceeded for message TCO1 from tachograph Fault indication: Central STOP warning light (H111) lights up yellow. Remedy: Check the cables and plugs of the CAN databus, powertrain (T-CAN) for short circuit or line discontinuity. Make sure that TCO1 is fully functional. Emergency function: EBS operates without the function that uses the external speed signal. Only internal wheel matching is performed. Coupling force control is switched off.

T 61

2nd edition

109

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03068

CAN databus, powertrain, values for message “TCO1-Vehicle Speed” from tachograph not plausible Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This monitoring is active when at least one of the EBS functions requires the external speed signal. The fault is detected if there is no braking and no ABS or ASR intervention. The fault is detected if the speed signal from the tachograph is implausible. - Noise or uctuations of more than 2.5 km/h for a duration of at least 20 seconds. - Jumps of more than 21 km/h within 160 seconds for a duration of at least 3.2 seconds. - More than 40 % discrepancy between wheel speeds for a duration of at least 20 seconds. The fault is also signalled if the CAN source address of the tachograph is not specied in the EBS EOL data record. Remedy: Check the external speed signal from the tachograph. Emergency function: EBS operates without functions that use the external speed signal. Only internal wheel matching is performed. Coupling force control is switched off.

03069 03071

No valid fault denition

03072

CAN databus, powertrain, receive time exceeded for message ETC2 from VMC

03073

CAN databus, powertrain, receive time exceeded

03074

CAN databus, powertrain, receive time exceeded

03075

CAN databus, powertrain, receive time exceeded

03076

CAN databus, powertrain, receive time exceeded

03077

CAN databus, powertrain, receive time exceeded

03078 03099

No valid fault denition

110

T 61 2nd edition

DEVICE DESCRIPTION Fault messages, pressure control module (1-channel), left on the front axle SPN

SPN-Plain text Description

03100

Pressure control module, front axle, left, no fault

03101

Pressure control module, front axle, left, discontinuity, short-circuit, wheel sensor, left Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The sensor resistance should be between 950Ω and 1930Ω (measure from Y263 pin 4/2 to Y263 pin 4/1). This fault is displayed if a voltage < 1 V or > 4 V is measured at the front axle speed sensor. As soon as there is a cable break, this is indicated by the central STOP warning light (H111) lighting up yellow. After the fault has been remedied, the central STOP warning light goes out, providing an adequate signal (v > 20 km/h) is measured at all speed sensors (left front axle speed sensor (B119), right front axle speed sensor (B120), left rear axle speed sensor (B121) and right rear axle speed sensor (B122)). (Memory function.) Remedy: The cables and plug connectors between left front axle pressure control module (Y263) and left front axle speed sensor (B119) must be checked for cable break or short circuit (B119: Brown cable - Y263: Pin 4/2 and B119: Black cable - Y263: pin 4/1). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective front axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03102

Pressure control module, left front axle, left wheel sensor: Deceleration excessive Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The sensor resistance should be between 950Ω and 1930Ω (measure from Y263 pin 4/2 to Y263 pin 4/1). This fault is displayed when the signal of the front axle speed sensor fails abruptly and v > 30 km/h, and also when there is a short circuit between two speed sensor cables and the front axle speed sensor has dropped out of its holder. After the fault has been remedied, the yellow central STOP warning light (H111) goes out, providing an adequate signal (v > 20 km/h) is measured at all speed sensors (left front axle speed sensor (B119), right front axle speed sensor (B120), left rear axle speed sensor (B121) and right rear axle speed sensor (B122)) (memory function). Remedy: The cables and plug connectors between left front axle pressure control module (Y263) and left front axle speed sensor (B119) must be checked for cable break or short circuit (B119: Brown cable - Y263: Pin 4/2 and B119: Black cable - Y263: pin 4/1). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective front axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

T 61

2nd edition

111

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03103

Pressure control module, left front axle, left wheel sensor: Starting-off fault Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The gap between the front axle speed sensor and the impulse wheel is too great. This fault also occurs if v > 18 km/h is measured at n-1 wheels and no signal has been received from one wheel for longer than 20 seconds, or v > 40 km/h is measured on one speed sensor and no signal is measured at the other speed sensors for longer than 20 seconds. The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out, providing an adequate signal (v > 20 km/h) is measured at all speed sensors (left front axle speed sensor (B119), right front axle speed sensor (B120), left rear axle speed sensor (B121) and right rear axle speed sensor (B122)) (memory function). Remedy: The front axle speed sensor must be pushed in by hand (do not strike it!). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03104

Pressure control module, left front axle, left wheel sensor: Excessive clearance Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs if the limit gap speed v > 10 km/h. The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out, providing an adequate signal (v > 20 km/h) is measured at all speed sensors (left front axle speed sensor (B119), right front axle speed sensor (B120), left rear axle speed sensor (B121) and right rear axle speed sensor (B122)) (memory function). Remedy: Check the gap between the front axle speed sensor and the impulse wheel. The front axle speed sensor must be pushed in by hand (do not strike it!). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective front axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

112

T 61 2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03105

Pressure control module, front axle, left, perpetual control, wheel sensor, left Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: Controlled wheels are monitored during anti-lock brake system (ABS) regulation. The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out, providing an adequate signal (v > 20 km/h) is measured at all speed sensors (left front axle speed sensor (B119), right front axle speed sensor (B120), left rear axle speed sensor (B121) and right rear axle speed sensor (B122)) (memory function). Remedy: The cables and plug connectors between left front axle pressure control module (Y263) and left front axle speed sensor (B119) must be checked for cable break or short circuit (B119: Brown cable - Y263: Pin 4/2 and B119: Black cable - Y263: pin 4/1). The sensor resistance should be between 950Ω and 1930Ω (measure from Y263 pin 4/2 to Y263 pin 4/1). Furthermore, the impulse wheel should be checked for contamination by metallic particles, the gap between the front axle speed sensor and the impulse wheel should be checked, the impulse wheel should be checked for damage (missing teeth), the impulse wheel should be checked for damage (wobble < 0.3 mm) and the impulse wheel should be checked for the right number of teeth and any pitch error. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03106

Pressure control module, front axle, left, long instability, wheel sensor, left Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs if a wheel controlled by the anti-lock brake system (ABS) is not being regulated in a stable manner after 20 seconds. The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out, providing an adequate signal (v > 20 km/h) is measured at all speed sensors (left front axle speed sensor (B119), right front axle speed sensor (B120), left rear axle speed sensor (B121) and right rear axle speed sensor (B122)) (memory function). Remedy: The cables and the plug connectors to the front axle speed sensor must be checked for cable breaks, short-circuits and chang (B120 - brown and black cables). Furthermore, the brake cylinders should be checked for residual pressure, the impulse wheel should be checked for contamination by metallic particles, the impulse wheel should be checked for damage (missing teeth), the impulse wheel should be checked for damage (wobble < 0.3 mm) and the impulse wheel should be checked for the right number of teeth and any pitch error. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective front axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

T 61 2nd edition

113

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03107

Pressure control module, front axle, left, pulse ring fault, wheel sensor, left Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out, providing an adequate signal (v > 20 km/h) is measured at all speed sensors (left front axle speed sensor (B119), right front axle speed sensor (B120), left rear axle speed sensor (B121) and right rear axle speed sensor (B122)) (memory function). Remedy: The impulse wheel should be checked for contamination by metallic particles, the impulse wheel should be checked for damage (missing teeth), the impulse wheel should be checked for damage (wobble < 0.3 mm) and the impulse wheel should be checked for the right number of teeth and any pitch error. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective front axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03108

Pressure control module, front axle, left, fault on lifting axle, wheel sensor, left Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs if one of the two lifting axle wheels is turning at v < 15 km/h, the other lifting axle wheel is turning with the vehicle speed and the speed of the vehicle is > 30 km/h. Remedy: Check that both wheels of the lifting axle are either in the air or on the ground. Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective front axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03109 - 03110

114

Pressure control module, front axle, left, no valid fault denition

T 61 2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03111

Pressure control module, front axle, left, discontinuity, short-circuit, wheel sensor, right Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The sensor resistance should be between 950Ω and 1930Ω. This fault is displayed if a voltage less than 1 V or more than 4 V is measured at the front axle speed sensor. As soon as there is a cable break, this is indicated by the central STOP warning light (H111) lighting up yellow. After the fault has been remedied, the central STOP warning light goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: The cables and plug connectors between the front axle pressure control module and front axle speed sensor must be checked for cable break or short-circuit. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective front axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03112

Pressure control module, front axle, left, wheel sensor, right: Deceleration excessive Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The sensor resistance should be between 950Ω and 1930Ω. This fault is displayed when the signal of the front axle speed sensor fails abruptly and v > 30 km/h, and also when there is a short-circuit between two speed sensor cables and the front axle speed sensor has dropped out of its holder. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: The cables and plug connectors between the front axle pressure control module and front axle speed sensor must be checked for cable break or short-circuit. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective front axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

T 61 2nd edition

115

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03113

Pressure control module, front axle, left, wheel sensor, right: Starting-off fault Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The gap between the front axle speed sensor and the impulse wheel is too great. This fault also occurs if v > 18 km/h is measured at n-1 wheels and no signal has been received from one wheel for longer than 20 seconds, or v > 40 km/h is measured on one speed sensor and no signal is measured at the other speed sensors for longer than 20 seconds. The wheel speeds and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: The front axle speed sensor must be pushed in by hand (do not strike it!). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective front axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03114

Pressure control module, front axle, left, wheel sensor, right: Excessive clearance Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs when the gap speed v > 10 km/h is calculated. The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: Check the gap between the front axle speed sensor and the impulse wheel. The front axle speed sensor must be pushed in by hand (do not strike it!). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective front axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

116

T 61 2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03115

Pressure control module, front axle, left, perpetual control, wheel sensor, right Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The wheels are controlled and monitored during intervention by the anti-lock brake system (ABS). The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: The cables and plug connectors between the front axle pressure control module and front axle speed sensor must be checked for cable break or short-circuit. The sensor resistance should be between 950Ω and 1930Ω. Furthermore, the impulse wheel should be checked for contamination by metallic particles, the gap between the front axle speed sensor and the impulse wheel should be checked, the impulse wheel should be checked for damage (missing teeth), the impulse wheel should be checked for damage (wobble < 0.3 mm) and the impulse wheel should be checked for the right number of teeth and any pitch error. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is regulated according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective front axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03116

Pressure control module, front axle, left, long instability, wheel sensor, right Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs if a wheel controlled by the anti-lock brake system (ABS) is not being regulated in a stable manner after 20 seconds. The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: The cables and the plug connectors to the front axle speed sensor must be checked for cable break, short-circuit and chang. Furthermore, the brake cylinders should be checked for residual pressure, the impulse wheel should be checked for contamination by metallic particles, the impulse wheel should be checked for damage (missing teeth), the impulse wheel should be checked for damage (wobble < 0.3 mm) and the impulse wheel should be checked for the right number of teeth and any pitch error. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective front axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

T 61 2nd edition

117

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03117

Pressure control module, front axle, left, pulse ring fault, wheel sensor, right Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: The impulse wheel should be checked for contamination by metallic particles, the impulse wheel should be checked for damage (missing teeth), the impulse wheel should be checked for damage (wobble < 0.3 mm) and the impulse wheel should be checked for the right number of teeth and any pitch error. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is regulated according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective front axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03118

Pressure control module, front axle, left, fault on lifting axle, wheel sensor, right Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs if one of the two lifting axle wheels is turning at v < 15 km/h, the other lifting axle wheel is turning with the vehicle speed and the speed of the vehicle is > 30 km/h. Remedy: Check that both wheels of the lifting axle are either in the air or on the ground. Emergency function (function level 6): The brake pressure in the affected control channel is regulated according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective front axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03119

Pressure control module, front axle, left, no valid fault denition

03120

Pressure control module, left front axle, voltage supply fault, lining wear sensor Fault indication: Central STOP warning light (H111) lights up yellow and the brake wear indicator check lamp comes on (appears as a pictogram on the display). Effect of fault: The 5 V voltage at the left front axle pressure control module (Y263) - output between pin 2/4 (voltage supply) and pin 2/1 (ground) should be 5 V (±0.45 V) after braking (approx. 2 seconds after the brake is released). Remedy: The 5 V cable to the 1st axle left brake sensor (B333) should be checked for short circuit or parallel connection (pin 4: 5 V voltage supply) The cables and plug connectors from the left front axle pressure control module (Y263) to the 1st axle brake sensor left from Y263 pin 2/1 to B333 pin 1 (ground) from Y263 pin 2/3 to B333 pin 3 (sensor signal) from Y263 pin 2/4 to B333 pin 4 (5 V voltage supply) The 1st axle brake sensor left itself and the ground connection of the sensor (pin 1: ground) should be checked. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 3): Lining wear monitoring has failed. All other EBS functions are present.

118

T 61 2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03121

Pressure control module, front axle, left, left brake wear sensor out of permitted value range Fault indication: Central STOP warning light (H111) lights up yellow and the brake wear indicator check lamp comes on (appears as a pictogram on the display). Effect of fault: The 5 V voltage at the left front axle pressure control module (Y263) - output between pin 2/4 (voltage supply) and pin 2/1 (ground) should be 5 V (±0.45 V) after braking (approx. 2 seconds after the brake is released). Voltages can be read out using MAN-cats® II. End of line (EOL) parameters must be compatible with the lining wear sensors used. Remedy: The 5 V cable to the 1st axle left brake sensor (B333) should be checked for short circuit or parallel connection (pin 4: 5 V voltage supply) The signal line to the 3rd axle brake sensor left should be checked for cable break, short circuit or parallel connection (pin 1: Signal from 1st axle brake sensor left (B333) to the left front axle pressure control module (Y263 pin 2/3)). The voltage from Y263 pin 2/3 to Y263 pin 2/1 should be < 4.9 V (approx. 2 seconds - wear limit) and > 0.5 V (approx. 2 seconds - new lining) and the ground connection of the sensor (pin 1: ground) should be checked. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 3): Lining wear monitoring has failed. All other EBS functions are present.

03122

Pressure control module, front axle, left, right brake wear sensor out of permitted value range Fault indication: Central STOP warning light (H111) lights up yellow and the brake wear indicator check lamp comes on (appears as a pictogram on the display). Effect of fault: The 5 V voltage at the left front axle pressure control module - output between voltage supply and ground should be 5 V (±0.45 V) after braking (approx. 2 seconds after the brake is released). These voltages are read out using MAN-cats® II. The connected brake sensor must be compatible with end of line (EOL). Remedy: The 5 V cable to the brake sensor should be checked for cable break, short circuit or parallel connection (pin 4: 5 V voltage supply), The signal line to the brake sensor should be checked for cable break, short circuit or parallel connection (pin 3: The signal from the brake sensor to front axle pressure control module and the ground connection of the sensor (pin 1: ground) should be checked. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 3): Lining wear monitoring has failed. All other EBS functions are present.

T 61 2nd edition

119

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03123

Pressure control module, front axle, left, pressure sensor out of permitted value range Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: There is an internal pressure control module malfunction or the plausibility check of the pressure control is not taking place successfully. If the fault reoccurs after the fault memory has been deleted then replace the left front axle pressure control module (Y263). If this fault occurs repeatedly in normal operation then a new front axle pressure control module must also be tted. These pressures are read out using MAN-cats® II (not if there is a fault). The measuring range of the pressure sensors is between 0 bar and 13 bar. Remedy: Delete the fault memory. Furthermore, the correct functioning of the left front axle pressure control module (Y263) should be checked. Pressure modulation should be performed via diagnosis (with MAN-cats® II) and a comparison with an external pressure gauge. Check the supply lines to the front axle pressure control module. Electrical: Y263 pin 3/2: 24 V voltage supply from the EBS electronic control unit (A402 pin X3/11) and Y263 pin 3/1: Ground connection from the EBS electronic control unit (A402 pin X3/2) Pneumatic: Connection 1 for air supply (reservoir) Replace the defective left front axle pressure control module. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The front axle pressure control module concerned is de-energised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03124

Pressure control module, front axle, left, time for inquiry “current pressure” too long Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: There is an internal pressure control module malfunction or the plausibility check of the pressure control is not taking place successfully. If the fault reoccurs after the fault memory has been deleted then replace the left front axle pressure control module (Y263). If this fault occurs repeatedly in normal operation then the front axle pressure control module must also be replaced. Remedy: Delete the fault memory. The correct function of the left front axle pressure control module (Y263) must be checked. If the fault occurs again after the fault memory has been cleared, exchange the front axle pressure control module. Check that the silencer for the front axle pressure control module has sufcient throughput. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no ALB and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

120

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03125

Pressure control module, left front axle, poor ventilation Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: If ventilation of the front axle pressure control module is hindered during release of the brake, this falsies the measurement results. This can be caused by a blocked or hardened exhaust mufer element. This fault message can also be caused if the distance from surrounding objects is too short. A defective exhaust valve or a defective pressure sensor in the left front axle pressure control module (Y263) can trigger this fault message. There is an internal pressure control module malfunction or the plausibility check of the pressure control is not taking place successfully. If the fault occurs again after the fault memory has been cleared, exchange the front axle pressure control module. If this fault occurs repeatedly in normal operation then a new front axle pressure control module must also be tted. These pressures are read out using MAN-cats® II. Remedy: Delete the fault memory. The ventilation openings (connection 3 for venting) of the left front axle pressure control module (Y263) must be checked. Furthermore, the correct functioning of the front axle pressure control module must be checked. Replace the defective front axle pressure control module. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The front axle pressure control module concerned is de-energised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governing) are deactivated.

T 61

2nd edition

121

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03126

Pressure control module, left front axle, excessive pressure during pulse test Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: This malfunction occurs if the automatic pulse test after the ignition is switched on does not cover the set pressure range. This occurs if the pneumatic lines are squeezed or blocked, or the pulse test length is not adapted to the volume of the brake cylinders used, or the left front axle pressure control module is not functioning. These values are read out using MAN-cats® II. If the fault reoccurs after the fault memory has been deleted then replace the left front axle pressure control module. Remedy: Delete the fault memory. The brake function diagram (with trailer) was used when referring to the pneumatic connections listed below between the individual components. The pneumatic connections of the left front axle pressure control module (Y263) must be checked, as follows: The pneumatic lines from left front axle pressure control module (Y263 connection 2) to the left diaphragm cylinder (G10.301), left front axle pressure control module (Y263 connection 4) to the service brake valve (G7.302 connection 21), to the right front axle pressure control module (Y262 connection 4) and to the trailer control module (G17.301/Y278 connection 41) and the supply lines of the left front axle pressure control module (Y263 connection 1): The left front axle pressure control module is supplied by the 1-cylinder compressor (G1.1 connection 2) and safety valve 17+2 bar (G5.121) to the ECAM 12.5 bar (G25.300 connection 1). From the ECAM 12.5 bar (G25.300 connection 21), the line runs to the compressed air tank 40 l, 12.5 bar (G50.300), from where the right front axle pressure control module (Y262 connection 1) and the service brake valve (G7.302 connection 11) are connected to connection 1 of the left front axle pressure control module. Connection 1 (supply line) is responsible for the energy supply. Connection 2 is responsible for dissipating the energy, while connection 4 is provided for the back-up circuit (back-up circuit solenoid valve). Furthermore, correct functioning of the pressure control module must be checked. If it is not functioning, replace the defective left front axle pressure control module. The test pulse duration in the end of line (EOL) data memory must be checked using MAN-cats® II. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). The pneumatic connection are to be found in the functional description and in the function diagrams. Emergency function: The EBS is functioning without restrictions.

122

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03127

Pressure control module, left front axle, residual pressure after braking Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The fault occurs if the pneumatic lines are blocked or contaminated, or the left front axle pressure control module is not functioning, or the service brake valve with integrated brake power sensor is not functioning. Remedy: The brake function diagram (with trailer) was used when referring to the pneumatic connections listed below between the individual components. The pressure in connection 4 (left front axle pressure control module (Y263 connection 4) connected to the right front axle pressure control module (Y262 connection 4), the service brake valve (G7.302 connection 21) and the trailer control module (G17.301/Y278 connection 41)) of the back-up circuit must be checked. The pneumatic connections of the left front axle pressure control module (Y263) must be checked, as follows: The pneumatic lines from left front axle pressure control module (Y263 connection 2) to the left diaphragm cylinder (G10.301), left front axle pressure control module (Y263 connection 4) to the service brake valve (G7.302 connection 21), to the right front axle pressure control module (Y262 connection 4) and to the trailer control module (G17.301/Y278 connection 41) and the supply lines of the left front axle pressure control module (Y263 connection 1): The left front axle pressure control module is supplied by the 1-cylinder compressor (G1.1 connection 2) and safety valve 17+2 bar (G5.121) to the ECAM 12.5 bar (G25.300 connection 1). From the ECAM 12.5 bar (G25.300 connection 21), the line runs to the compressed air tank 40 l, 12.5 bar (G50.300), from where the right front axle pressure control module (Y262 connection 1) and the service brake valve (G7.302 connection 11) are connected to connection 1 of the left front axle pressure control module. Connection 1 (supply line) is responsible for the energy supply. Connection 2 is responsible for dissipating the energy, while connection 4 is provided for the back-up circuit (back-up circuit solenoid valve). Furthermore, correct functioning of the pressure control module must be checked. If it is not functioning, replace the defective left front axle pressure control module. The pressure gradient of the service brake valve with integrated brake power sensor (B337) in connection 4 of the back-up circuit (to the back-up circuit solenoid valve) must be checked. Emergency function (function level 8): The affected left front axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

T 61

2nd edition

123

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03128

Pressure control module, left front axle, pressure sensor fault without braking Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The fault occurs if the pneumatic lines are blocked or contaminated, or the left front axle pressure control module is not functioning, or the service brake valve with integrated brake power sensor is not functioning. Remedy: The brake function diagram (with trailer) was used when referring to the pneumatic connections listed below between the individual components. The pressure in connection 4 (left front axle pressure control module (Y263 connection 4) connected to the right front axle pressure control module (Y262 connection 4), the service brake valve (G7.302 connection 21) and the trailer control module (G17.301/Y278 connection 41)) of the back-up circuit must be checked. The pneumatic connections of the left front axle pressure control module (Y263) must be checked, as follows: The pneumatic lines from left front axle pressure control module (Y263 connection 2) to the left diaphragm cylinder (G10.301), left front axle pressure control module (Y263 connection 4) to the service brake valve (G7.302 connection 21), to the right front axle pressure control module (Y262 connection 4) and to the trailer control module (G17.301/Y278 connection 41) and the supply lines of the left front axle pressure control module (Y263 connection 1): The left front axle pressure control module is supplied by the 1-cylinder compressor (G1.1 connection 2) and safety valve 17+2 bar (G5.121) to the ECAM 12.5 bar (G25.300 connection 1). From the ECAM 12.5 bar (G25.300 connection 21), the line runs to the compressed air tank 40 l, 12.5 bar (G50.300), from where the right front axle pressure control module (Y262 connection 1) and the service brake valve (G7.302 connection 11) are connected to connection 1 of the left front axle pressure control module. Connection 1 (supply line) is responsible for the energy supply. Connection 2 is responsible for dissipating the energy, while connection 4 is provided for the back-up circuit (back-up circuit solenoid valve). Furthermore, correct functioning of the pressure control module must be checked. If it is not functioning, replace the defective left front axle pressure control module. The pressure gradient of the service brake valve with integrated brake power sensor (B337) in connection 4 of the back-up circuit (to the back-up circuit solenoid valve) must be checked. Emergency function (function level 8): The affected left front axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03129

Pressure control module, front axle, left, no valid fault denition

03130

Pressure control module, left front axle, wheel sensor IC defective Fault indication: Central STOP warning light (H111) lights up yellow. Remedy: Delete the fault memory. Remedy: There is an internal pressure control module malfunction. If the fault reoccurs after the fault memory has been deleted then replace the left front axle pressure control module (Y263). If this fault occurs repeatedly in normal operation then the left front axle pressure control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected left front axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

124

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03131

Pressure control module, left front axle, faulty backup valve checkback Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: Delete the fault memory. Furthermore, the correct functioning of the left front axle pressure control module (Y263) must be checked. If it is not functioning, t a new front axle pressure control module. Remedy: There is a fault in the signal pathways for the back-up circuit solenoid valve (backup valve) in the left front axle pressure control module. If the fault is detected again after the fault memory has been cleared, exchange the front axle pressure control module. If this fault occurs repeatedly in normal operation then a new front axle pressure control module must also be tted. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected left front axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03132

Pressure control module, front axle, left, defective inlet valve, feedback Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: Delete the fault memory. Furthermore, correct functioning of the left front axle pressure control module (Y263) must be checked. If it is not functioning, replace the left front axle pressure control module. Remedy: There is a fault on the signal path for the back-up circuit solenoid valve (backup valve) in the left front axle pressure control module. If the fault is detected again after the fault memory has been cleared, exchange the front axle pressure control module. If this fault occurs repeatedly in normal operation then a new front axle pressure control module must also be tted. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected left front axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03133

Pressure control module, front axle, left, defective inlet and back-up valve, feedback Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: Delete the fault memory. Furthermore, correct functioning of the left front axle pressure control module (Y263) must be checked. If it is not functioning, t a new left front axle pressure control module. Remedy: There is a fault on the signal path for the back-up circuit solenoid valve (backup valve) in the left front axle pressure control module. If the fault is detected again after the fault memory has been cleared, exchange the front axle pressure control module. If this fault occurs repeatedly in normal operation then a new front axle pressure control module must also be tted. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected left front axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

T 61

2nd edition

125

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03134

Pressure control module, front axle, left, defective outlet valve, feedback Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: Delete the fault memory. Furthermore, correct functioning of the left front axle pressure control module (Y263) must be checked. If it is not functioning, t a new front axle pressure control module. Remedy: There is a fault on the signal path for the back-up circuit solenoid valve (backup valve) in the left front axle pressure control module. If the fault is detected again after the fault memory has been cleared, exchange the front axle pressure control module. If this fault occurs repeatedly in normal operation then a new front axle pressure control module must also be tted. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected left front axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03135

Pressure control module, front axle, left, defective outlet and back-up valve, feedback Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: Delete the fault memory. Furthermore, correct functioning of the left front axle pressure control module (Y263) must be checked. If it is not functioning, t a new left front axle pressure control module. Remedy: There is a fault on the signal path for the back-up circuit solenoid valve (backup valve) in the left front axle pressure control module. If the fault is detected again after the fault memory has been cleared, exchange the front axle pressure control module. If this fault occurs repeatedly in normal operation then a new front axle pressure control module must also be tted. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected left front axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03136

Pressure control module, front axle, left, defective outlet and inlet valve, feedback Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: Delete the fault memory. Furthermore, correct functioning of the left front axle pressure control module (Y263) must be checked. If it is not functioning, t a new left front axle pressure control module. Remedy: There is a fault on the signal path for the back-up circuit solenoid valve (backup valve) in the left front axle pressure control module. If the fault is detected again after the fault memory has been cleared, exchange the front axle pressure control module. If this fault occurs repeatedly in normal operation then a new front axle pressure control module must also be tted. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected left front axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

126

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03137

Pressure control module, front axle, left, defective outlet and inlet and back-up valve, feedback Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: Delete the fault memory. Furthermore, correct functioning of the left front axle pressure control module (Y263) must be checked. If it is not functioning, t a new left front axle pressure control module. Remedy: There is a fault on the signal path for the back-up circuit solenoid valve (backup valve) in the left front axle pressure control module. If the fault is detected again after the fault memory has been cleared, exchange the front axle pressure control module. If this fault occurs repeatedly in normal operation then a new front axle pressure control module must also be tted. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected left front axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03138 03139

Pressure control module, front axle, left, no valid fault denition

03140

Pressure control module, left front axle, no CAN reception from module Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: CAN brake Baud rate: 250 kbaud Peak voltage values: Recessive CAN Low 2.5 V, CAN High 2.5 V; dominant CAN Low 1.5 V, CAN High 3.5 V Header length: 11-bit Message length: 8-byte Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Also check the ground signal (resistance < 1Ω) from A402 pin X1/12 (pressure control module input ground) to X618 (terminal board distributor X102 cable 31000) and the battery voltage (24 V) of the EBS control unit (A402) from A402 pin X1/8 (voltage supply terminal 30) to X618 (terminal board distributor X102 cable 31000). Remedy: The connections from the EBS control unit (A402) to the left front axle pressure control module (Y263) Pin X3/2 (EBS control unit) - pin 3/1 (left front axle pressure control module ground); Pin X3/11 (EBS control unit) - pin 3/2 (left front axle pressure control module 24 V); Pin X3/8 (EBS control unit) - pin 3/3 (CAN High for left front axle pressure control module) and Pin X3/5 (EBS control unit) - pin 3/4 (CAN Low for left front axle pressure control module) must be checked (in particular, look for chang points). Check the plug connectors on the EBS electronic control unit and on the left front axle pressure control module. The battery voltage from A402 pin X3/11 (voltage supply Y263) to A402 pin X3/2 (ground Y263) should be measured. As the next step, measure the overall resistance of 64Ω, from A402 pin X3/8 (CAN high Y263) to A402 pin X3/5 (CAN low Y263). Furthermore, the ground connections of all connected pressure control modules (left front axle pressure control module (Y263), right front axle pressure control module (Y262) and rear axle pressure control module (Y264)) should be checked. Emergency function (function level 8): The affected left front axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

T 61

2nd edition

127

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03141

Pressure control module, front axle, left, software incompatibility between control unit and pressure control module Fault indication: Central STOP warning light (H111) lights up yellow. Remedy: The EBS electronic control unit (A402) or the left front axle pressure control module (Y263) must be replaced by one with a compatible software version. Emergency function (function level 8): The affected left front axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03142

Pressure control module, front axle, left, 12/24 volt incompatibility between control unit and pressure control module Fault indication: Central STOP warning light (H111) lights up yellow. Remedy: The EBS electronic control unit (A402) or the left front axle pressure control module (Y263) must be replaced by one with a compatible voltage version. Emergency function (function level 8): The affected left front axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03143

Pressure control module, front axle, left, high cycle protection, inlet valve active, 
 pressure < 4 bar Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs if the nominal value is not achieved for a relatively long time when the brake cylinder pressure is low. If the supply pressure < 4 bar, a fault message is triggered after the pressure sensor for the supply pressure has been checked. The ECAM message on CAN J1939 (reservoir pressure circuits 1 and 2) must be checked. The current values for the pressure sensor of the pressure control module are read out using MAN-cats® II. Remedy: The correct function of the left front axle pressure control module (Y263) must be checked. If it is not functioning, replace the left front axle pressure control module. Furthermore, the continuity of the pneumatic supply lines to the pressure control modules (left front axle pressure control module (Y263), right front axle pressure control module (Y262) and rear axle pressure control module (Y264)) must be checked. Sensor inputs 1 and 2 of the supply pressure measurement must be checked. (External monitoring of the central STOP warning light (H111) (pressure sensor for the supply pressure – is installed in the front axle pressure control module) must be checked.) Emergency function (function level 8): The affected left front axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03144

Pressure control module, left front axle, arithmetic test not successful Fault indication: Central STOP warning light (H111) lights up yellow. Remedy: Delete the fault memory. Remedy: If the fault reoccurs after the fault memory has been deleted then replace the left front axle pressure control module (Y263). Emergency function (function level 8): The affected left front axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

128

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03145

Pressure control module, front axle, left, wheel adjustment fault, wheel sensor, left Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The left front axle speed sensor (B119) transfers this information to the EBS control unit. This malfunction occurs if the calculated wheel speed deviates by more than 9 % between the axles. This is displayed by the yellow central STOP warning light (H111) and the fault is stored in the EBS control unit. Fault-free operation is possible until the next switch-off if the wheel speed after compensation deviates by < 9 %. However, the fault remains in the fault memory. The compensated wheel diameter continues to be output until the maximum permitted deviation stored in the end of line (EOL) is reached (e.g. 25 %). Diameter compensation is operating when the road speed is in the range from 25 km/h to 100 km/h, the brake is not active, no anti-lock brake system (ABS) or anti-spin regulator (ASR) intervention is taking place and the road speed is almost constant. Remedy: The tyre sizes on the front and rear axle must be checked. The ASR spin threshold increase button (S256) must be actuated for a driving distance of at least 10 km at a road speed of more than 25 km/h. The ASR info check lamp (H140) ashes (information display). The fault memory of the EBS electronic control unit (A402) must be deleted and then the control unit should be reset. Emergency function (function level 6): The brake pressure in the affected control channel is regulated according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03146

Pressure control module, front axle, left, wheel adjustment fault, wheel sensor, right Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The right front axle speed sensor (B120) transfers this information to the EBS control unit. This malfunction occurs if the calculated wheel speed deviates by more than 9 % between the axles. This is displayed by the central STOP warning light (H111) and the fault is stored in the EBS control unit. Fault-free operation is possible until the next switch-off if the wheel speed after compensation deviates by < 9 %. However, the fault remains in the fault memory. The compensated wheel diameter continues to be output until the maximum permitted deviation stored in the end of line (EOL) is reached (e.g. 25 %) Diameter compensation is operating when the road speed is in the range from 25 km/h to 100 km/h, the brake is not active, no anti-lock brake system (ABS) or anti-spin regulator (ASR) intervention is taking place and the road speed is almost constant. Remedy: The tyre sizes on the front and rear axle must be checked. The ASR spin threshold increase button (S256) must be actuated for a driving distance of at least 10 km at a road speed of more than 25 km/h. The ASR info check lamp (H140) ashes. The fault memory of the EBS electronic control unit (A402) must be deleted and then the control unit should be reset. Emergency function (function level 6): The brake pressure in the affected control channel is regulated according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

T 61

2nd edition

129

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03147

Pressure control module, front axle, left, fault at voltage supply, axle load sensor Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The supply voltage must be checked - permitted supply voltage range at the rear axle pressure control module: The voltage measured between pin 3/4 and pin 3/1 at the rear axle pressure control module should have the voltage value 5 V ±0.45 V. Remedy: The cables and plug connectors between the rear axle pressure control module (Y264) and the rear axle automatic load-balancing sensor (B336) must be checked for short circuits or line discontinuities, between pin 3/4 (rear axle pressure control module) and pin 1 (voltage supply ALB sensor rear axle), between pin 3/1 (rear axle pressure control module) and pin 2 (ground ALB sensor rear axle), between pin 3/3 (rear axle pressure control module) and pin 3 (signal line ALB sensor rear axle). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 5): The EBS system operates with the value “L = ALB-Fehl” programmed via EOL for brake pressure distribution during braking with the service brakes (electropneumatic brake system EPB) and with the automatic load balancing (ALB) value L = 0 in the anti-lock brake system (ABS) for IRM (individual regulation modied) at the front axle.

03148

Pressure control module, left front axle, pressure differential on pressure control module pair, front axle Fault indication: Central STOP warning light (H111) comes on red at the same time as the red check lamp for the general brake check (H108) Effect of fault: This malfunction occurs when a pressure differential > 0.8 bar occurs for longer than 3 seconds on one axle in one of the pressure control modules. The current values for the pressure sensors of the left front axle pressure control module are read out using MAN-cats® II. Remedy: The correct function of the left front axle pressure control module (Y263) must be checked. If it is not functioning, replace the left front axle pressure control module. The brake function diagram (with trailer) was used when referring to the pneumatic connections listed below between the individual components. Free passage of the pneumatic supply lines to the left front axle pressure control module (Y263) and right front axle pressure control module (Y262) must be checked: The left front axle pressure control module and the right front axle pressure control module are supplied by the 1-cylinder compressor (G1.1 connection 2) and safety valve 17+2 bar (G5.121) to the ECAM 12.5 bar (G25.300 connection 1). From the ECAM 12.5 bar (G25.300 connection 21), the line runs to the compressed air tank 40 l, 12.5 bar (G50.300), from where the left front axle pressure control module (Y263 connection 1), the right front axle pressure control module (Y262 connection 1) and the service brake valve (G7.302 connection 11) are connected together. Emergency function (function level 8): The affected left front axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03149

Pressure control module, front axle, left, no valid fault denition

Fault messages, pressure control module (1-channel), right on the front axle SPN

SPN-Plain text Description

03150

130

Pressure control module, front axle, right, no fault

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03151

Pressure control module, front axle, right, discontinuity, short-circuit, wheel sensor, left Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The sensor resistance should be between 950Ω and 1930Ω. This fault is displayed if a voltage < 1 V or > 4 V is measured at the left front axle speed sensor. As soon as there is a cable break, this is indicated by the central STOP warning light (H111) lighting up yellow. After the fault has been remedied, the central STOP warning light goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors. (Memory function.) Remedy: The cables and plug connectors between the right front axle pressure control module and left front axle speed sensor must be checked for cable break or short circuit. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective front axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03152

Pressure control module, front axle, right, wheel sensor, left: Deceleration excessive Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The sensor resistance should be between 950Ω and 1930Ω. This fault is displayed when the signal of the left front axle speed sensor fails abruptly and v > 30 km/h, and also when there is a short circuit between two speed sensor cables and the left front axle speed sensor has dropped out of its holder. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: The cables and plug connectors between the right front axle pressure control module and left front axle speed sensor must be checked for cable break or short circuit. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective front axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

T 61

2nd edition

131

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03153

Pressure control module, front axle, right, wheel sensor, left: Starting-off fault Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The gap between the right front axle speed sensor and the impulse wheel is too great. This fault also occurs if v > 18 km/h is measured at n-1 wheels and no signal has been received from one wheel for longer than 20 seconds, or v > 40 km/h is measured on one speed sensor and no signal is measured at the other speed sensors for longer than 20 seconds. The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: The left front axle speed sensor (B119) must be pushed in by hand (do not strike it!). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective front axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03154

Pressure control module, front axle, right, wheel sensor, left: Excessive clearance Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs if the limit gap speed v > 10 km/h. The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: Check the gap between the right front axle speed sensor and the impulse wheel. The front axle speed sensor must be pushed in by hand (do not strike it!). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective front axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

132

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03155

Pressure control module, front axle, right, perpetual control, wheel sensor, left Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: Controlled wheels are monitored during anti-lock brake system (ABS) regulation. The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: The cables and plug connectors between the right front axle pressure control module and right front axle speed sensor must be checked for cable break or short-circuit. The sensor resistance should be between 950Ω and 1930Ω. Furthermore, the impulse wheel should be checked for contamination by metallic particles, the gap between the left front axle speed sensor and the impulse wheel should be checked, the impulse wheel should be checked for damage (missing teeth), the impulse wheel should be checked for damage (wobble < 0.3 mm) and the impulse wheel should be checked for the right number of teeth and any pitch error. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective left front axle speed sensor (B119) is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03156

Pressure control module, front axle, right, long instability, wheel sensor, left Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs if a wheel controlled by the anti-lock brake system (ABS) is not being regulated in a stable manner after 20 seconds. The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out, providing an adequate signal (v > 20 km/h) is measured at all speed sensors (left front axle speed sensor (B119), right front axle speed sensor (B120), left rear axle speed sensor (B121) and right rear axle speed sensor (B122)) (memory function). Remedy: The cables and the plug connectors to the left front axle speed sensor must be checked for cable break, short circuit and chang points. Furthermore, the brake cylinders should be checked for residual pressure, the impulse wheel should be checked for contamination by metallic particles, the impulse wheel should be checked for damage (missing teeth), the impulse wheel should be checked for damage (wobble < 0.3 mm) and the impulse wheel should be checked for the right number of teeth and any pitch error. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective front axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

T 61

2nd edition

133

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03157

Pressure control module, front axle, right, pulse ring fault, wheel sensor, left Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: The impulse wheel should be checked for contamination by metallic particles, the impulse wheel should be checked for damage (missing teeth), the impulse wheel should be checked for damage (wobble < 0.3 mm) and the impulse wheel should be checked for the right number of teeth and any pitch error. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective left front axle speed sensor (B119) is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03158

Pressure control module, front axle, right, fault on lifting axle, wheel sensor, left Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs if one of the two lifting axle wheels is turning at v < 15 km/h, the other lifting axle wheel is turning with the vehicle speed and the speed of the vehicle is > 30 km/h. Remedy: Check that both wheels of the lifting axle are either in the air or on the ground. Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective left front axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03159 03160

134

Pressure control module, front axle, right, no valid fault denition

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03161

Pressure control module, front axle, right, break, short-circuit, wheel sensor, right Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The sensor resistance should be between 950Ω and 1930Ω (measure from Y262 pin 1/2 to Y262 pin 1/1). This fault is displayed if a voltage < 1 V or > 4 V is measured at the right front axle speed sensor. As soon as there is a cable break, this is indicated by the central STOP warning light (H111) lighting up yellow. After the fault has been remedied, the central STOP warning light goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (left front axle speed sensor (B119), right front axle speed sensor (B120), left rear axle speed sensor (B121) and right rear axle speed sensor (B122)) (memory function). Remedy: The cables and plug connectors between the right front axle pressure control module (Y262) and right front axle speed sensor (B120) must be checked for cable break or short circuit. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective front axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03162

Pressure control module, front axle, right, wheel sensor, right: Deceleration excessive Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The sensor resistance should be between 950Ω and 1930Ω (measure from Y262 pin 1/2 to Y262 pin 1/1). This fault is displayed when the signal of the right front axle speed sensor fails abruptly and v > 30 km/h, and also when there is a short circuit between two speed sensor cables and the right front axle speed sensor has dropped out of its holder. After the fault has been remedied, the yellow central STOP warning light (H111) goes out, providing an adequate signal (v > 20 km/h) is measured at all speed sensors (left front axle speed sensor (B119), right front axle speed sensor (B120), left rear axle speed sensor (B121) and right rear axle speed sensor (B122)) (memory function). Remedy: The cables and plug connectors between the right front axle pressure control module (Y262) and right front axle speed sensor (B120) must be checked for cable break or short circuit. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective right front axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

T 61

2nd edition

135

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03163

Pressure control module, front axle, right, wheel sensor, right: Starting-off fault Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The gap between the right front axle speed sensor and the impulse wheel is too great. This fault also occurs if v > 18 km/h is measured at n-1 wheels and no signal has been received from one wheel for longer than 20 seconds, or v > 40 km/h is measured on one speed sensor and no signal is measured at the other speed sensors for longer than 20 seconds. The wheel speeds and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out, providing an adequate signal (v > 20 km/h) is measured at all speed sensors (left front axle speed sensor (B119), right front axle speed sensor (B120), left rear axle speed sensor (B121) and right rear axle speed sensor (B122)) (memory function). Remedy: The right front axle speed sensor (B120) must be pushed in by hand (do not strike it!). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective front axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03164

Pressure control module, front axle, right, wheel sensor, right: Excessive clearance Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs when the gap speed v > 10 km/h is calculated. The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out, providing an adequate signal (v > 20 km/h) is measured at all speed sensors (left front axle speed sensor (B119), right front axle speed sensor (B120), left rear axle speed sensor (B121) and right rear axle speed sensor (B122)) (memory function). Remedy: Check the gap between the right front axle speed sensor (B120) and the impulse wheel. The right front axle speed sensor must be pushed in by hand (do not strike it!). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective front axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

136

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03165

Pressure control module, front axle, right, perpetual control, wheel sensor, right Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The wheels are controlled and monitored during intervention by the anti-lock brake system (ABS). The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out, providing an adequate signal (v > 20 km/h) is measured at all speed sensors (left front axle speed sensor (B119), right front axle speed sensor (B120), left rear axle speed sensor (B121) and right rear axle speed sensor (B122)) (memory function). Remedy: The cables and plug connectors between the right front axle pressure control module (Y262) and right front axle speed sensor (B120) must be checked for cable break or short circuit. The sensor resistance should be between 950Ω and 1930Ω (measure from Y262 pin 1/2 to Y262 pin 1/1). Furthermore, the impulse wheel should be checked for contamination by metallic particles, the gap between the right front axle speed sensor and the impulse wheel should be checked, the impulse wheel should be checked for damage (missing teeth), the impulse wheel should be checked for damage (wobble < 0.3 mm) and the impulse wheel should be checked for the right number of teeth and any pitch error. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is regulated according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective front axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03166

Pressure control module, front axle, right, long instability, wheel sensor, right Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs if a wheel controlled by the anti-lock brake system (ABS) is not being regulated in a stable manner after 20 seconds. The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out, providing an adequate signal (v > 20 km/h) is measured at all speed sensors (left front axle speed sensor (B119), right front axle speed sensor (B120), left rear axle speed sensor (B121) and right rear axle speed sensor (B122)) (memory function). Remedy: The cables and the plug connectors to the right front axle speed sensor (B120) must be checked for cable break, short circuit and chang points. Furthermore, the brake cylinders should be checked for residual pressure, the impulse wheel should be checked for contamination by metallic particles, the impulse wheel should be checked for damage (missing teeth), the impulse wheel should be checked for damage (wobble < 0.3 mm) and the impulse wheel should be checked for the right number of teeth and any pitch error. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective front axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

T 61

2nd edition

137

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03167

Pressure control module, front axle, right, pulse ring fault, wheel sensor, right Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out, providing an adequate signal (v > 20 km/h) is measured at all speed sensors (left front axle speed sensor (B119), right front axle speed sensor (B120), left rear axle speed sensor (B121) and right rear axle speed sensor (B122)) (memory function). Remedy: The impulse wheel should be checked for contamination by metallic particles, the impulse wheel should be checked for damage (missing teeth), the impulse wheel should be checked for damage (wobble < 0.3 mm) and the impulse wheel should be checked for the right number of teeth and any pitch error. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is regulated according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective right front axle speed sensor (B120) is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03168

Pressure control module, front axle, right, fault on lifting axle, wheel sensor, right Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs if one of the two lifting axle wheels is turning at v < 15 km/h, the other lifting axle wheel is turning with the vehicle speed and the speed of the vehicle is > 30 km/h. Remedy: Check that both wheels of the lifting axle are either in the air or on the ground. Emergency function (function level 6): The brake pressure in the affected control channel is regulated according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective right front axle speed sensor (B120) is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03169

138

Pressure control module, front axle, right, no valid fault denition

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03170

Pressure control module, right front axle, voltage supply fault, lining wear sensor Fault indication: Central STOP warning light (H111) lights up yellow and the brake wear indicator check lamp comes on (appears as a pictogram on the display). Effect of fault: The 5 V voltage at the right front axle pressure control module (Y262) - output between pin 2/4 (voltage supply) and pin 2/1 (ground) should be 5 V (±0.45 V) after braking (approx. 2 seconds after the brake is released). Remedy: The 5 V cable to the 1st axle right brake sensor (B332) should be checked for short circuit or parallel connection (pin 4: 5 V voltage supply) The cables and plug connectors from the right front axle pressure control module (Y262) to the 1st axle brake sensor left from Y262 pin 2/1 to B332 pin 1 (ground) from Y262 pin 2/3 to B332 pin 3 (sensor signal) from Y262 pin 2/4 to B332 pin 4 (5 V voltage supply) The 1st axle brake sensor left itself and the ground connection of the sensor (pin 1: ground) should be checked. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 3): Lining wear monitoring has failed. All other EBS functions are present.

03171

Pressure control module, front axle, right, left brake wear sensor out of permitted value range Fault indication: Central STOP warning light (H111) lights up yellow and the brake wear indicator check lamp comes on (appears as a pictogram on the display). Effect of fault: The 5 V voltage at the right front axle pressure control module - output between voltage supply and ground pin should be 5 V (±0.45 V) after braking (approx. 2 seconds after the brake is released). Voltages can be read out using MAN-cats® II. End of line (EOL) parameters must be compatible with the lining wear sensors used. Remedy: The 5 V cable to the brake sensor should be checked for cable break, short circuit or parallel connection (pin 4: 5 V voltage supply) The signal line to the brake sensor should be checked for cable break, short circuit or parallel connection (pin 3: Signal from brake sensor to right front axle pressure control module) the ground connection of the sensor (pin 1: ground) should be checked. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 3): Lining wear monitoring has failed. All other EBS functions are present.

03172

Pressure control module, front axle, right, right brake wear sensor out of permitted value range Fault indication: Central STOP warning light (H111) lights up yellow and the brake wear indicator check lamp comes on (appears as a pictogram on the display). Effect of fault: The 5 V voltage at the right front axle pressure control module - output between voltage supply and ground should be 5 V (±0.45 V) after braking (approx. 2 seconds after the brake is released). These voltages are read out using MAN-cats® II. The connected brake sensor must be compatible with end of line (EOL). Remedy: The 5 V cable to the brake sensor should be checked for cable break, short circuit or parallel connection (pin 4: 5 V voltage supply), The signal line to the brake sensor should be checked for cable break, short circuit or parallel connection (pin 3: Signal from brake sensor to right front axle pressure control module) and the ground connection of the sensor (pin 1: ground) should be checked. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 3): Lining wear monitoring has failed. All other EBS functions are present.

T 61

2nd edition

139

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03173

Pressure control module, front axle, right, pressure sensor out of permitted value range Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: There is an internal pressure control module malfunction or the plausibility check of the pressure control is not taking place successfully. If the fault reoccurs after the fault memory has been deleted then replace the right front axle pressure control module (Y262). If this fault occurs repeatedly in normal operation then the right front axle pressure control module must also be replaced. These pressures are read out using MAN-cats® II (not if there is a fault). The measuring range of the pressure sensors is between 0 bar and 13 bar. Remedy: Delete the fault memory. Furthermore, check for correct functioning of the right front axle pressure control module (Y262). Pressure modulation should be performed via diagnosis (with MAN-cats® II) and a comparison with an external pressure gauge. Check the supply lines to the right front axle pressure control module. Electrical: Y262 pin 3/2: 24 V voltage supply from the EBS electronic control unit (A402 pin X3/12) and Y262 pin 3/1: Ground connection from the EBS electronic control unit (A402 pin X3/23) Pneumatic: Connection 1 for air supply (reservoir) Replace the defective right front axle pressure control module. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected right front axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03174

Pressure control module, front axle, right, time for “Current pressure” inquiry too long Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: There is an internal pressure control module malfunction or the plausibility check of the pressure control is not taking place successfully. If the fault reoccurs after the fault memory has been deleted then replace the right front axle pressure control module (Y262). If this fault occurs repeatedly in normal operation then the right front axle pressure control module must also be replaced. Remedy: Delete the fault memory. The correct function of the right front axle pressure control module (Y262) must be checked. Replace the defective right front axle pressure control module. The mufer of the right front axle pressure control module must be checked for sufcient air ow. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no ALB and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

140

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03175

Pressure control module, right front axle, poor ventilation Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: If ventilation of the right front axle pressure control module is hindered whilst the brake is being released, this leads to incorrect measuring results. This can be caused by a blocked or hardened exhaust mufer element. This fault message can also be caused if the distance from surrounding objects is too short. A defective exhaust valve or a defective pressure sensor in the right front axle pressure control module (Y262) can trigger this fault message. There is an internal pressure control module malfunction or the plausibility check of the pressure control is not taking place successfully. If the fault occurs again after the fault memory has been cleared, exchange the pressure control module, front axle, right. If this fault occurs repeatedly during normal operation, also exchange pressure control module, front axle, right. These pressures are read out using MAN-cats® II. Remedy: Delete the fault memory. The ventilation openings (connection 3 for venting) of the right front axle pressure control module (Y262) must be checked. Furthermore, check for correct functioning of the right front axle pressure control module. Replace the defective right front axle pressure control module. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected right front axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governing) are deactivated.

T 61

2nd edition

141

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03176

Pressure control module, right front axle, excessive pressure during pulse test Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: This malfunction occurs if the automatic pulse test after the ignition is switched on does not cover the set pressure range. This occurs if the pneumatic lines are squeezed or blocked, or the pulse test length is not adapted to the volume of the brake cylinders used, or the right front axle pressure control module is not functional. These values are read out using MAN-cats® II. If the fault is detected again after the fault memory has been cleared, exchange the right front axle pressure control module. Remedy: Delete the fault memory. The brake function diagram (with trailer) was used when referring to the pneumatic connections listed below between the individual components. The pneumatic connections of the right front axle pressure control module (Y262) must be checked, as follows: The pneumatic lines from right front axle pressure control module (Y262 connection 2) to the left diaphragm cylinder (G10.300), right front axle pressure control module (Y262 connection 4) to the service brake valve (G7.302 connection 21), to the left front axle pressure control module (Y263 connection 4) and to the trailer control module (G17.301/Y278 connection 41) and the supply lines of the right front axle pressure control module (Y262 connection 1): The right front axle pressure control module is supplied by the 1-cylinder compressor (G1.1 connection 2) and safety valve 17+2 bar (G5.121) to the ECAM 12.5 bar (G25.300 connection 1). From the ECAM 12.5 bar (G25.300 connection 21), the line runs to the compressed air tank 40 l, 12.5 bar (G50.300), from where the right front axle pressure control module (Y262 connection 1), the service brake valve (G7.302 connection 11) and the left front axle pressure control module (Y263 connection 1) are connected to each other. Connection 1 (supply line) is responsible for the energy supply. Connection 2 is responsible for dissipating the energy, while connection 4 is provided for the back-up circuit (back-up circuit solenoid valve). Furthermore, correct functioning of the pressure control module must be checked. Exchange the defective pressure control module, front axle, right if it is not functioning. The test pulse duration in the end of line (EOL) data memory must be checked using MAN-cats® II. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). The pneumatic connections can be found in the functional description and in the function diagrams. Emergency function: The EBS is functioning without restrictions.

142

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03177

Pressure control module, right front axle, residual pressure after braking Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The fault occurs if the pneumatic lines are blocked or contaminated, or the right front axle pressure control module is not functional or the service brake valve with integrated brake power sensor is not functioning. Remedy: The brake function diagram (with trailer) was used when referring to the pneumatic connections listed below between the individual components. The pressure in connection 4 (right front axle pressure control module (Y262 connection 4) connected to the left front axle pressure control module (Y263 connection 4), the service brake valve (G7.302 connection 21) and the trailer control module (G17.301/Y278 connection 41)) of the back-up circuit must be checked. The pneumatic connections of the right front axle pressure control module (Y262) must be checked, as follows: The pneumatic lines from right front axle pressure control module (Y262 connection 2) to the left diaphragm cylinder (G10.300), right front axle pressure control module (Y262 connection 4) to the service brake valve (G7.302 connection 21), to the left front axle pressure control module (Y263 connection 4) and to the trailer control module (G17.301/Y278 connection 41) and the supply lines of the right front axle pressure control module (Y262 connection 1): The right front axle pressure control module is supplied by the 1-cylinder compressor (G1.1 connection 2) and safety valve 17+2 bar (G5.121) to the ECAM 12.5 bar (G25.300 connection 1). From the ECAM 12.5 bar (G25.300 connection 21), the line runs to the compressed air tank 40 l, 12.5 bar (G50.300), from where the right front axle pressure control module (Y262 connection 1), the service brake valve (G7.302 connection 11) and the left front axle pressure control module (Y263 connection 1) are connected to each other. Connection 1 (supply line) is responsible for the energy supply. Connection 2 is responsible for dissipating the energy, while connection 4 is provided for the back-up circuit (back-up circuit solenoid valve). Furthermore, correct functioning of the pressure control module must be checked. Exchange the defective pressure control module, front axle, right if it is not functioning. The pressure gradient of the service brake valve with integrated brake power sensor (B337) in connection 4 of the back-up circuit (to the back-up circuit solenoid valve) must be checked. Emergency function (function level 8): The affected right front axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

T 61

2nd edition

143

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03178

Pressure control module, right front axle, pressure sensor fault without braking Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The fault occurs if the pneumatic lines are blocked or contaminated, or the right front axle pressure control module is not functional or the service brake valve with integrated brake power sensor is not functioning. Remedy: The brake function diagram (with trailer) was used when referring to the pneumatic connections listed below between the individual components. The pressure in connection 4 (right front axle pressure control module (Y262 connection 4) connected to the left front axle pressure control module (Y263 connection 4), the service brake valve (G7.302 connection 21) and the trailer control module (G17.301/Y278 connection 41)) of the back-up circuit must be checked. The pneumatic connections of the right front axle pressure control module (Y262) must be checked, as follows: The pneumatic lines from right front axle pressure control module (Y262 connection 2) to the left diaphragm cylinder (G10.300), right front axle pressure control module (Y262 connection 4) to the service brake valve (G7.302 connection 21), to the left front axle pressure control module (Y263 connection 4) and to the trailer control module (G17.301/Y278 connection 41) and the supply lines of the right front axle pressure control module (Y262 connection 1): The right front axle pressure control module is supplied by the 1-cylinder compressor (G1.1 connection 2) and safety valve 17+2 bar (G5.121) to the ECAM 12.5 bar (G25.300 connection 1). From the ECAM 12.5 bar (G25.300 connection 21), the line runs to the compressed air tank 40 l, 12.5 bar (G50.300), from where the right front axle pressure control module (Y262 connection 1), the service brake valve (G7.302 connection 11) and the left front axle pressure control module (Y263 connection 1) are connected to each other. Connection 1 (supply line) is responsible for the energy supply. Connection 2 is responsible for dissipating the energy, while connection 4 is provided for the back-up circuit (back-up circuit solenoid valve). Furthermore, correct functioning of the pressure control module must be checked. Exchange the defective pressure control module, front axle, right if it is not functioning. The pressure gradient of the service brake valve with integrated brake power sensor (B337) in connection 4 of the back-up circuit (to the back-up circuit solenoid valve) must be checked. Emergency function (function level 8): The affected right front axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03179

Pressure control module, front axle, right, no valid fault denition

03180

Pressure control module, right front axle, wheel sensor IC defective Fault indication: Central STOP warning light (H111) lights up yellow. Remedy: Delete the fault memory. Remedy: There is an internal pressure control module malfunction. If the fault reoccurs after the fault memory has been deleted then replace the right front axle pressure control module (Y262). If this fault occurs repeatedly in normal operation then the right front axle pressure control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected right front axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

144

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03181

Pressure control module, right front axle, faulty backup valve checkback Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: Delete the fault memory. Furthermore, the correct functioning of the right front axle pressure control module (Y262) must be checked. Exchange the pressure control module, front axle, right if it is not functioning. Remedy: There is a fault on the signal path of the back-up circuit solenoid valve (back-up valve) in the right front axle pressure control module. If the fault is detected again after the fault memory has been cleared, exchange the right front axle pressure control module. If this fault occurs repeatedly in normal operation then the right front axle pressure control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected right front axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03182

Pressure control module, front axle, right, defective inlet valve, feedback Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: Delete the fault memory. Furthermore, the correct functioning of the right front axle pressure control module (Y262) must be checked. Exchange the pressure control module, front axle, right if it is not functioning. Remedy: There is a fault on the signal path of the back-up circuit solenoid valve (back-up valve) in the right front axle pressure control module. If the fault is detected again after the fault memory has been cleared, exchange the right front axle pressure control module. If this fault occurs repeatedly in normal operation then the right front axle pressure control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected right front axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03183

Pressure control module, front axle, right, defective inlet and back-up valve, feedback Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: Delete the fault memory. Furthermore, check for correct functioning of the right front axle pressure control module (Y262). Exchange the right front axle pressure control module if it is not functioning. Remedy: There is a fault on the signal path of the back-up circuit solenoid valve (back-up valve) in the right front axle pressure control module. If the fault is detected again after the fault memory has been cleared, exchange the right front axle pressure control module. If this fault occurs repeatedly in normal operation then the right front axle pressure control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected right front axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

T 61

2nd edition

145

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03184

Pressure control module, front axle, right, defective outlet valve, feedback Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: Delete the fault memory. Furthermore, check for correct functioning of the right front axle pressure control module (Y262). Exchange the right front axle pressure control module if it is not functioning. Remedy: There is a fault on the signal path of the back-up circuit solenoid valve (back-up valve) in the right front axle pressure control module. If the fault is detected again after the fault memory has been cleared, exchange the right front axle pressure control module. If this fault occurs repeatedly in normal operation then the right front axle pressure control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected right front axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03185

Pressure control module, front axle, right, defective outlet and back-up valve, feedback Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: Delete the fault memory. Furthermore, check for correct functioning of the right front axle pressure control module (Y262). Exchange the right front axle pressure control module if it is not functioning. Remedy: There is a fault on the signal path of the back-up circuit solenoid valve (back-up valve) in the right front axle pressure control module. If the fault is detected again after the fault memory has been cleared, exchange the right front axle pressure control module. If this fault occurs repeatedly in normal operation then the right front axle pressure control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected right front axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03186

Pressure control module, front axle, right, defective outlet and inlet valve, feedback Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: Delete the fault memory. Furthermore, check for correct functioning of the right front axle pressure control module (Y262). Exchange the right front axle pressure control module if it is not functioning. Remedy: There is a fault on the signal path of the back-up circuit solenoid valve (back-up valve) in the right front axle pressure control module. If the fault is detected again after the fault memory has been cleared, exchange the right front axle pressure control module. If this fault occurs repeatedly in normal operation then the right front axle pressure control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected right front axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

146

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03187

Pressure control module, front axle, right, defective outlet and inlet and back-up valve, feedback Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: Delete the fault memory. Furthermore, check for correct functioning of the right front axle pressure control module (Y262). Exchange the right front axle pressure control module if it is not functioning. Remedy: There is a fault on the signal path of the back-up circuit solenoid valve (back-up valve) in the right front axle pressure control module. If the fault is detected again after the fault memory has been cleared, exchange the right front axle pressure control module. If this fault occurs repeatedly in normal operation then the right front axle pressure control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected right front axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03188 03189

Pressure control module, front axle, right, no valid fault denition

03190

Pressure control module, front axle, right, no CAN reception from module Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: CAN brake Baud rate: 250 kbaud Peak voltage values: Recessive CAN Low 2.5 V, CAN High 2.5 V; dominant CAN Low 1.5 V, CAN High 3.5 V Header length: 11-bit Message length: 8-byte Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Also check the ground signal (resistance < 1Ω) from A402 pin X1/12 (pressure control module input ground) to X618 (terminal board distributor X102 cable 31000) and the battery voltage (24 V) of the EBS control unit (A402) from A402 pin X1/8 (voltage supply terminal 30) to X618 (terminal board distributor X102 cable 31000). Remedy: The connections from the EBS control unit (A402) to the right front axle pressure control module (Y262) Pin X3/3 (EBS control unit) - pin 3/1 (right front axle pressure control module ground); Pin X3/12 (EBS control unit) - pin 3/2 (right front axle pressure control module 24 V); Pin X3/9 (EBS control unit) - pin 3/3 (CAN High for right front axle pressure control module) and Pin X3/6 (EBS control unit) - pin 3/4 (CAN Low for right front axle pressure control module) must be checked (in particular, look for chang points). Check the plug connectors on the EBS electronic control unit and on the right front axle pressure control module. The battery voltage from A402 pin X3/12 (voltage supply Y262) to A402 pin X3/3 (ground Y262) should be measured. As the next step, measure the overall resistance of 64Ω, from A402 pin X3/9 (CAN high Y262) to A402 pin X3/6 (CAN low Y262). Furthermore, the ground connections of all connected pressure control modules (left front axle pressure control module (Y263), right front axle pressure control module (Y262) and rear axle pressure control module (Y264)) should be checked. Emergency function (function level 8): The affected right front axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

T 61

2nd edition

147

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03191

Pressure control module, front axle, right, software incompatibility between control unit and pressure control module Fault indication: Central STOP warning light (H111) lights up yellow. Remedy: The EBS electronic control unit (A402) or the right front axle pressure control module (Y262) must be replaced by one with a compatible software version. Emergency function (function level 8): The affected right front axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03192

Pressure control module, right front axle, 12/24 volt incompatibility between control unit and pressure control module Fault indication: Central STOP warning light (H111) lights up yellow. Remedy: The EBS electronic control unit (A402) or the right front axle pressure control module (Y262) must be replaced by one with a compatible voltage version. Emergency function (function level 8): The affected right front axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03193

Pressure control module, front axle, right, high cycle protection, inlet valve active, pressure < 4 bar Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs if the nominal value is not achieved for a relatively long time when the brake cylinder pressure is low. If the supply pressure < 4 bar, a fault message is triggered after the pressure sensor for the supply pressure has been checked. The ECAM message on CAN J1939 (reservoir pressure circuits 1 and 2) must be checked. The current values for the pressure sensor of the pressure control module are read out using MAN-cats® II. Remedy: The correct function of the right front axle pressure control module (Y262) must be checked. Exchange the right front axle pressure control module if it is not functioning. Furthermore, the continuity of the pneumatic supply lines to the pressure control modules (left front axle pressure control module (Y263), right front axle pressure control module (Y262) and rear axle pressure control module (Y264)) must be checked. Sensor inputs 1 and 2 of the supply pressure measurement must be checked. (External monitoring of the central STOP warning light (H111) (pressure sensor for the supply pressure – is installed in the front axle pressure control module) must be checked.) Emergency function (function level 8): The affected right front axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03194

Pressure control module, right front axle, arithmetic test not successful Fault indication: Central STOP warning light (H111) lights up yellow. Remedy: Delete the fault memory. Remedy: If the fault reoccurs after the fault memory has been deleted then replace the right front axle pressure control module (Y262). Emergency function (function level 8): The affected right front axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

148

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03195

Pressure control module, front axle, right, wheel adjustment fault, wheel sensor, left Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The left front axle speed sensor (B119) transfers this information to the EBS control unit. This malfunction occurs if the calculated wheel speed deviates by more than 9 % between the axles. This is displayed by the yellow central STOP warning light (H111) and the fault is stored in the EBS control unit. Fault-free operation is possible until the next switch-off if the wheel speed after compensation deviates by < 9 %. However, the fault remains in the fault memory. The compensated wheel diameter continues to be output until the maximum permitted deviation stored in the end of line (EOL) is reached (e.g. 25 %). Diameter compensation is operating when the road speed is in the range from 25 km/h to 100 km/h, the brake is not active, no anti-lock brake system (ABS) or anti-spin regulator (ASR) intervention is taking place and the road speed is almost constant. Remedy: The tyre sizes on the front and rear axle must be checked. The ASR spin threshold increase button (S256) must be actuated for a driving distance of at least 10 km at a road speed of more than 25 km/h. The ASR info check lamp (H140) ashes (information display). The fault memory of the EBS electronic control unit (A402) must be deleted and then the control unit should be reset. Emergency function (function level 6): The brake pressure in the affected control channel is regulated according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03196

Pressure control module, front axle, right, wheel adjustment fault, wheel sensor, right Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The right front axle speed sensor transfers this information to the EBS control unit. This malfunction occurs if the calculated wheel speed deviates by more than 9 % between the axles. This is displayed by the central STOP warning light (H111) and the fault is stored in the EBS control unit. Fault-free operation is possible until the next switch-off if the wheel speed after compensation deviates by < 9 %. However, the fault remains in the fault memory. The compensated wheel diameter continues to be output until the maximum permitted deviation stored in the end of line (EOL) is reached (e.g. 25 %) Diameter compensation is operating when the road speed is in the range from 25 km/h to 100 km/h, the brake is not active, no anti-lock brake system (ABS) or anti-spin regulator (ASR) intervention is taking place and the road speed is almost constant. Remedy: The tyre sizes on the front and rear axle must be checked. The ASR spin threshold increase button (S256) must be actuated for a driving distance of at least 10 km at a road speed of more than 25 km/h. The ASR info check lamp (H140) ashes. The fault memory of the EBS electronic control unit (A402) must be deleted and then the control unit should be reset. Emergency function (function level 6): The brake pressure in the affected control channel is regulated according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

T 61

2nd edition

149

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03197

Pressure control module, front axle, right, fault at voltage supply, axle load sensor Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The supply voltage must be checked - permitted supply voltage range at the rear axle pressure control module: The voltage measured between pin 3/4 and pin 3/1 at the rear axle pressure control module should have the voltage value 5 V ±0.45 V. Remedy: The cables and plug connectors between the rear axle pressure control module (Y264) and the rear axle automatic load-balancing sensor (B336) must be checked for short-circuits or line discontinuity, between pin 3/4 (rear axle pressure control module) and pin 1 (voltage supply, ALB sensor, rear axle), between pin 3/1 (rear axle pressure control module) and pin 2 (ground, ALB sensor, rear axle), between pin 3/3 (rear axle pressure control module) and pin 3 (signal line, ALB sensor, rear axle). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 5): The EBS system operates with the value “L = ALB-Fehl” programmed via EOL for brake pressure distribution during braking with the service brakes (electropneumatic brake system EPB) and with the automatic load balancing (ALB) value L = 0 in the anti-lock brake system (ABS) for IRM (individual regulation modied) at the front axle.

03198

Pressure control module, right front axle, pressure differential on pressure control module pair, front axle Fault indication: Central STOP warning light (H111) comes on red at the same time as the red check lamp for the general brake check (H108) Effect of fault: This malfunction occurs when a pressure differential > 0.8 bar occurs for longer than 3 seconds on one axle in one of the pressure control modules. The current values for the pressure sensors of the right front axle pressure control module are read out using MAN-cats® II. Remedy: Check for correct functioning of the right front axle pressure control module (Y262). Exchange the right front axle pressure control module if it is not functioning. The brake function diagram (with trailer) was used when referring to the pneumatic connections listed below between the individual components. Free passage of the pneumatic supply lines to the left front axle pressure control module (Y263) and right front axle pressure control module (Y262) must be checked: The left front axle pressure control module and the right front axle pressure control module are supplied by the 1-cylinder compressor (G1.1 connection 2) and safety valve 17+2 bar (G5.121) to the ECAM 12.5 bar (G25.300 connection 1). From the ECAM 12.5 bar (G25.300 connection 21), the line runs to the compressed air tank 40 l, 12.5 bar (G50.300), from where the right front axle pressure control module (Y262 connection 1), the left front axle pressure control module (Y263 connection 1) and the service brake valve (G7.302 connection 11) are connected together. Emergency function (function level 8): The affected right front axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03199

Pressure control module, front axle, right, no valid fault denition

Fault messages, pressure control module (2-channel) on the rear axle (left-hand side) SPN

SPN-Plain text Description

03200

150

Pressure control module, rear axle, left, no fault

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03201

Pressure control module, rear axle, left, discontinuity, short-circuit, wheel sensor, left Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The sensor resistance should be between 950Ω and 1930Ω (measure from Y264 pin 1/2 to Y264 pin 1/1). This fault is displayed if a voltage < 1 V or > 4 V is measured at the left rear axle speed sensor. As soon as there is a line discontinuity, this is displayed by the central STOP warning light (H111) lighting up yellow. After the fault has been remedied, the central STOP warning light goes out, providing an adequate signal (v > 20 km/h) is measured at all speed sensors (left front axle speed sensor (B119), right front axle speed sensor (B120), left rear axle speed sensor (B121) and right rear axle speed sensor (B122)). (Memory function.) Remedy: The cables and plug connectors between rear axle pressure control module (Y264) and left rear axle speed sensor (B121) must be checked for cable break or short circuit (B121: Brown cable - Y264: Pin 1/2 and B121: Black cable - Y264: pin 1/1). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective left rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03202

Pressure control module, rear axle, left, wheel sensor, left: Deceleration excessive Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The sensor resistance should be between 950Ω and 1930Ω (measure from Y264 pin 1/2 to Y264 pin 1/1). This fault is displayed when the signal of the rear axle speed sensor fails abruptly and v > 30 km/h, and also when there is a short circuit between two speed sensor cables and the rear axle speed sensor has dropped out of its holder. After the fault has been remedied, the yellow central STOP warning light (H111) goes out, providing an adequate signal (v > 20 km/h) is measured at all speed sensors (left front axle speed sensor (B119), right front axle speed sensor (B120), left rear axle speed sensor (B121) and right rear axle speed sensor (B122)) (memory function). Remedy: The cables and plug connectors between rear axle pressure control module (Y264) and left rear axle speed sensor (B121) must be checked for cable break or short-circuit (B121: Brown cable - Y264: Pin 1/2 and B121: Black cable - Y264: pin 1/1). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective left rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

T 61

2nd edition

151

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03203

Pressure control module, rear axle, left, wheel sensor, left: Starting-off fault Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The gap between the left rear axle speed sensor and the impulse wheel is too great. This fault also occurs if v > 18 km/h is measured at n-1 wheels and no signal has been received from one wheel for longer than 20 seconds, or v > 40 km/h is measured on one speed sensor and no signal is measured at the other speed sensors for longer than 20 seconds. The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out, providing an adequate signal (v > 20 km/h) is measured at all speed sensors (left front axle speed sensor (B119), right front axle speed sensor (B120), left rear axle speed sensor (B121) and right rear axle speed sensor (B122)) (memory function). Remedy: The left rear axle speed sensor (B121) must be pushed in by hand (do not strike it!). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective left rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03204

Pressure control module, rear axle, left, wheel sensor, left: Excessive clearance Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs if the limit gap speed v > 10 km/h. The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out, providing an adequate signal (v > 20 km/h) is measured at all speed sensors (left front axle speed sensor (B119), right front axle speed sensor (B120), left rear axle speed sensor (B121) and right rear axle speed sensor (B122)) (memory function). Remedy: Check the gap between the left rear axle speed sensor (B121) and the impulse wheel. The left rear axle speed sensor must be pushed in by hand (do not strike it!). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective left rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

152

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03205

Pressure control module, rear axle, left, perpetual control, wheel sensor, left Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: Controlled wheels are monitored during anti-lock brake system (ABS) regulation. The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out, providing an adequate signal (v > 20 km/h) is measured at all speed sensors (left front axle speed sensor (B119), right front axle speed sensor (B120), left rear axle speed sensor (B121) and right rear axle speed sensor (B122)) (memory function). Remedy: The cables and plug connectors between rear axle pressure control module (Y264) and left rear axle speed sensor (B121) must be checked for cable break or short-circuit (B121: Brown cable - Y264: Pin 1/2 and B121: Black cable - Y264: pin 1/1). The sensor resistance should be between 950Ω and 1930Ω (measure from Y264 pin 1/2 to Y264 pin 1/1). Furthermore, the impulse wheel should be checked for contamination by metallic particles, the gap between the left rear axle speed sensor and the impulse wheel should be checked, the impulse wheel should be checked for damage (missing teeth), the impulse wheel should be checked for damage (wobble < 0.3 mm) and the impulse wheel should be checked for the right number of teeth and any pitch error. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective left rear axle speed sensor (B121) is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03206

Pressure control module, rear axle, left, long instability, wheel sensor, left Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs if a wheel controlled by the anti-lock brake system (ABS) is not being regulated in a stable manner after 20 seconds. The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out, providing an adequate signal (v > 20 km/h) is measured at all speed sensors (left front axle speed sensor (B119), right front axle speed sensor (B120), left rear axle speed sensor (B121) and right rear axle speed sensor (B122)) (memory function). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Remedy: The cables and the plug connectors to the left rear axle speed sensor (B121) must be checked for cable break, short circuit and chang points (B121 - brown and black cables). Furthermore, the brake cylinders should be checked for residual pressure, the impulse wheel should be checked for contamination by metallic particles, the impulse wheel should be checked for damage (missing teeth), the impulse wheel should be checked for damage (wobble < 0.3 mm) and the impulse wheel should be checked for the right number of teeth and any pitch error. Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective left rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

T 61

2nd edition

153

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03207

Pressure control module, rear axle, left, pulse ring fault, wheel sensor, left Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out, providing an adequate signal (v > 20 km/h) is measured at all speed sensors (left front axle speed sensor (B119), right front axle speed sensor (B120), left rear axle speed sensor (B121) and right rear axle speed sensor (B122)) (memory function). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Remedy: The impulse wheel should be checked for contamination by metallic particles, the impulse wheel should be checked for damage (missing teeth), the impulse wheel should be checked for damage (wobble < 0.3 mm) and the impulse wheel should be checked for the right number of teeth and any pitch error. Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective left rear axle speed sensor (B121) is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03208

Pressure control module, rear axle, left, fault on lifting axle, wheel sensor, left Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs if one of the two lifting axle wheels is turning at v < 15 km/h, the other lifting axle wheel is turning with the vehicle speed and the speed of the vehicle is > 30 km/h. Remedy: Check that both wheels of the lifting axle are either in the air or on the ground. Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective left rear axle speed sensor (B121) is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03209 03210

154

Pressure control module, rear axle, left, no valid fault denition

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03211

Pressure control module, rear axle, left, discontinuity, short-circuit, wheel sensor, right Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The sensor resistance should be between 950Ω and 1930Ω. This fault is displayed if a voltage < 1 V or > 4 V is measured at the right rear axle speed sensor. As soon as there is a cable break, this is indicated by the central STOP warning light (H111) lighting up yellow. After the fault has been rectied, the central STOP warning light goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: The cables and plug connectors between the rear axle pressure control module and right rear axle speed sensor must be checked for cable break or short circuit. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective right rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03212

Pressure control module, rear axle, left, wheel sensor, right: Deceleration excessive Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The sensor resistance should be between 950Ω and 1930Ω. This fault is displayed when the signal of the right rear axle speed sensor fails abruptly and v > 30 km/h, and also when there is a short circuit between two speed sensor cables and the right rear axle speed sensor has dropped out of its holder. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: The cables and plug connectors between the rear axle pressure control module and right rear axle speed sensor must be checked for cable break or short circuit. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective right rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

T 61

2nd edition

155

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03213

Pressure control module, rear axle, left, wheel sensor, right: Starting-off fault Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The gap between the right rear axle speed sensor and the impulse wheel is too great. This fault also occurs if v > 18 km/h is measured at n-1 wheels and no signal has been received from one wheel for longer than 20 seconds, or v > 40 km/h is measured on one speed sensor and no signal is measured at the other speed sensors for longer than 20 seconds. The wheel speeds and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: The right rear axle speed sensor must be pushed in by hand (do not strike it!). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective right rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03214

Pressure control module, rear axle, left, wheel sensor, right: Excessive clearance Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs when the gap speed v > 10 km/h is calculated. The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: Check the gap between the right rear axle speed sensor and the impulse wheel. The right rear axle speed sensor must be pushed in by hand (do not strike it!). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective right rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

156

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03215

Pressure control module, rear axle, left, perpetual control, wheel sensor, right Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The wheels are controlled and monitored during intervention by the anti-lock brake system (ABS). The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: The cables and plug connectors between the left rear axle pressure control module and right rear axle speed sensor must be checked for cable break or short circuit. The sensor resistance should be between 950Ω and 1930Ω. Furthermore, the impulse wheel should be checked for contamination by metallic particles, the gap between the rear axle speed sensor and the impulse wheel should be checked, the impulse wheel should be checked for damage (missing teeth), the impulse wheel should be checked for damage (wobble < 0.3 mm) and the impulse wheel should be checked for the right number of teeth and any pitch error. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is regulated according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective right rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03216

Pressure control module, rear axle, left, long instability, wheel sensor, right Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs if a wheel controlled by the anti-lock brake system (ABS) is not being regulated in a stable manner after 20 seconds. The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: The cables and the plug connectors to the right rear axle speed sensor must be checked for cable break, short circuit and chang points. Furthermore, the brake cylinders should be checked for residual pressure, the impulse wheel should be checked for contamination by metallic particles, the impulse wheel should be checked for damage (missing teeth), the impulse wheel should be checked for damage (wobble < 0.3 mm) and the impulse wheel should be checked for the right number of teeth and any pitch error. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective right rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

T 61

2nd edition

157

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03217

Pressure control module, rear axle, left, pulse ring fault, wheel sensor, right Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: The impulse wheel should be checked for contamination by metallic particles, the impulse wheel should be checked for damage (missing teeth), the impulse wheel should be checked for damage (wobble < 0.3 mm) and the impulse wheel should be checked for the right number of teeth and any pitch error. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is regulated according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective right rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03218

Pressure control module, rear axle, left, fault on lifting axle, wheel sensor, right Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs if one of the two lifting axle wheels is turning at v < 15 km/h, the other lifting axle wheel is turning with the vehicle speed and the speed of the vehicle is > 30 km/h. Remedy: Check that both wheels of the lifting axle are either in the air or on the ground. Emergency function (function level 6): The brake pressure in the affected control channel is regulated according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective right rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03219

Pressure control module, rear axle, left, no valid fault denition

03220

Pressure control module, left rear axle, voltage supply fault, lining wear sensor Fault indication: Central STOP warning light (H111) lights up yellow and the brake wear indicator check lamp comes on (appears as a pictogram on the display). Effect of fault: The 5 V voltage at the rear axle pressure control module (Y264) - output between pin 2/4 (voltage supply) and pin 2/1 (ground) should be 5 V (±0.45 V) after braking (approx. 2 seconds after the brake is released). Remedy: The 5 V cable to the 2nd axle left brake sensor (B335) should be checked for short circuit or parallel connection (pin 4: 5 V voltage supply) The cables and plug connectors from the rear axle pressure control module (Y264) to the 2nd axle brake sensor left from Y264 pin 2/1 to B335 pin 1 (ground) from Y264 pin 2/3 to B335 pin 3 (sensor signal) from Y264 pin 2/4 to B335 pin 4 (5 V voltage supply) The 1st axle brake sensor left itself and the ground connection of the sensor (pin 2: ground) should be checked. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 3): Lining wear monitoring has failed. All other EBS functions are present.

158

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03221

Pressure control module, rear axle, left, left brake wear sensor out of permitted value range Fault indication: Central STOP warning light (H111) lights up yellow and the brake wear indicator check lamp comes on (appears as a pictogram on the display). Effect of fault: The 5 V voltage at the rear axle pressure control module (Y264) - output between pin 2/4 (voltage supply) and pin 2/1 (ground) should be 5 V (±0.45 V) after braking (approx. 2 seconds after the brake is released). The voltages can be read out using MAN-cats® II. The connected 2nd axle brake sensor left must be compatible with end of line (EOL). Remedy: The 5 V cable to the 2nd axle left brake sensor (B335) should be checked for short circuit or parallel connection (pin 4: 5 V voltage supply) The signal line to the 3rd axle brake sensor left should be checked for cable break, short circuit or parallel connection (pin 2: Signal from 2nd axle brake sensor left (B335) to the rear axle pressure control module (Y264 pin 2/3)) The voltage from Y264 pin 2/3 to Y264 pin 2/1 should be < 4.9 V (approx. 2 seconds - wear limit) and > 0.5 V (approx. 2 seconds - new lining) and the ground connection of the sensor (pin 1: ground) should be checked. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 3): Lining wear monitoring has failed. All other EBS functions are present.

03222

Pressure control module, rear axle, left, right brake wear sensor out of permitted value range Fault indication: Central STOP warning light (H111) lights up yellow and the brake wear indicator check lamp comes on (appears as a pictogram on the display). Effect of fault: The 5 V voltage at the left rear axle pressure control module - output between voltage supply and ground should be 5 V (±0.45 V) after braking (approx. 2 seconds after the brake is released). These voltages are read out using MAN-cats® II. The connected brake sensor must be end-of-line (EOL) compatible. Remedy: The 5 V cable to the brake sensor should be checked for cable break, short circuit or parallel connection (pin 4: 5V voltage supply), The signal line to the brake sensor should be checked for cable break, short circuit or parallel connection (pin 3: Signal from brake sensor to left rear axle pressure control module) and the sensor ground connection (pin 1: ground) should be checked. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 3): The pad wear monitor has failed. All other EBS functions are available.

T 61

2nd edition

159

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03223

Pressure control module, rear axle, left, pressure sensor outside permitted value range Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: There is an internal pressure control module malfunction or the plausibility check of the pressure control is not taking place successfully. If the fault reoccurs after the fault memory has been deleted then replace the rear axle pressure control module (Y264). If this fault occurs repeatedly in normal operation then the left rear axle pressure control module must also be replaced. These pressures are read out using MAN-cats® II (not if there is a fault). The measuring range of the pressure sensors is between 0 bar and 13 bar. Remedy: Delete the fault memory. Furthermore, check for correct functioning of the rear axle pressure control module (Y264). Pressure modulation should be performed via diagnosis (with MAN-cats® II) and a comparison with an external pressure gauge. Check the supply lines to the left rear axle pressure control module. Electrical: Y264 pin 6/2: 24 V voltage supply from the EBS electronic control unit (A402 pin X4/13) and Y264 pin 6/1: Ground connection from the EBS electronic control unit (A402 pin X3/2) Pneumatic: Connection 1 for air supply (reservoir) Replace the defective rear axle pressure control module. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected left rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03224

Pressure control module, rear axle, left, time for “Current pressure” inquiry too long Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: There is an internal pressure control module malfunction or the plausibility check of the pressure control is not taking place successfully. If the fault reoccurs after the fault memory has been deleted then replace the rear axle pressure control module (Y264). If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. Remedy: Delete the fault memory. The correct function of the rear axle pressure control module (Y264) must be checked. Replace the defective rear axle pressure control module. The mufer of the rear axle pressure control module must be checked for sufcient air ow. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no ALB and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

160

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03225

Pressure control module, left rear axle, poor ventilation Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: If the venting of the rear axle pressure control module is preventing during release of the brake, this falsies the measurement results. This can be caused by a blocked or hardened exhaust mufer element. This fault message can also be caused if the distance from surrounding objects is too short. A defective exhaust valve or a defective pressure sensor in the rear axle pressure control module (Y264) can trigger this fault message. There is an internal pressure control module malfunction or the plausibility check of the pressure control is not taking place successfully. If the fault reoccurs after the fault memory has been deleted then replace the rear axle pressure control module. If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. These pressures are read out using MAN-cats® II. Remedy: Delete the fault memory. The ventilation openings (connection 3 for venting) of the rear axle pressure control module (Y264) must be checked. Furthermore, check for correct functioning of the rear axle pressure control module. Replace the defective rear axle pressure control module. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governing) are deactivated.

T 61

2nd edition

161

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03226

Pressure control module, rear axle, left, excessive pressure during the pulse test Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: This malfunction occurs if the automatic pulse test after the ignition is switched on does not cover the set pressure range. This occurs if the pneumatic lines are squeezed or blocked, or the pulse test length is not adapted to the volume of the brake cylinders used, or the rear axle pressure control module is not functioning. These values are read out using MAN-cats® II. If the fault reoccurs after the fault memory has been deleted then replace the left rear axle pressure control module. Remedy: Delete the fault memory. The brake function diagram (with trailer) was used when referring to the pneumatic connections listed below between the individual components. The pneumatic connections of the rear axle pressure control module (Y264) must be checked, as follows: The pneumatic lines from rear axle pressure control module (Y264 connection 21) to the left combination cylinder (G11.301 connection 11), rear axle pressure control module (Y264 connection 21) to the double check valve (G21.11 connection 11), to the rear axle pressure control module (Y264 connection 4) and to the service brake valve (G7.302 connection 22) and to the trailer control module (G17.301/Y278 connection 42) and the supply lines of the rear axle pressure control module (Y264 connection 1): The rear axle pressure control module is supplied by the 1-cylinder compressor (G1.1 connection 2) and safety valve 17+2 bar (G5.121) to the ECAM 12.5 bar (G25.300 connection 1). From the ECAM 12.5 bar (G25.300 connection 22), the line runs to the compressed air tank 40 l, 12.5 bar (G50.300), from where the service brake valve (G7.302 connection 12) is connected to connection 1 of the rear axle pressure control module. Connection 1 (supply line) is responsible for the energy supply. Connection 21 is responsible for dissipating the energy, while connection 4 is provided for the back-up circuit (back-up circuit solenoid valve). Furthermore, check for correct functioning of the pressure control module. If it is not functioning, replace the defective rear axle pressure control module. The test pulse duration in the end of line (EOL) data memory must be checked using MAN-cats® II. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). The pneumatic connections can be found in the functional description and in the function diagrams. Emergency function: The EBS is functioning without restrictions.

162

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03227

Pressure control module, left rear axle, residual pressure after braking Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: The fault occurs if the pneumatic lines are blocked or contaminated, or the rear axle pressure control module is not functioning, or the service brake valve with integrated brake power sensor is not functioning. Remedy: The brake function diagram (with trailer) was used when referring to the pneumatic connections listed below between the individual components. The pressure in connection 4 (rear axle pressure control module (Y264 connection 4) - trailer control module (G17.301/Y278 connection 42) - service brake valve (G7.302 connection 22) of the back-up circuit must be checked. The pneumatic connections of the rear axle pressure control module (Y264) must be checked, as follows: The pneumatic lines from rear axle pressure control module (Y264 connection 21) to the left combination cylinder (G11.301 connection 11), rear axle pressure control module (Y264 connection 21) to the double check valve (G21.11 connection 11), to the rear axle pressure control module (Y264 connection 4) and to the service brake valve (G7.302 connection 22) and to the trailer control module (G17.301/Y278 connection 42) and the supply lines of the rear axle pressure control module (Y264 connection 1): The rear axle pressure control module is supplied by the 1-cylinder compressor (G1.1 connection 2) and safety valve 17+2 bar (G5.121) to the ECAM 12.5 bar (G25.300 connection 1). From the ECAM 12.5 bar (G25.300 connection 22), the line runs to the compressed air tank 40 l, 12.5 bar (G50.300), from where the service brake valve (G7.302 connection 12) is connected to connection 1 of the rear axle pressure control module. Connection 1 (supply line) is responsible for the energy supply. Connection 21 is responsible for dissipating the energy, while connection 4 is provided for the back-up circuit (back-up circuit solenoid valve). Furthermore, check for correct functioning of the pressure control module. If it is not functioning, replace the defective rear axle pressure control module. The pressure gradient of the service brake valve with integrated brake power sensor (B337) in connection 4 of the back-up circuit (to the back-up circuit solenoid valve) must be checked. Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

T 61

2nd edition

163

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03228

Pressure control module, left rear axle, pressure sensor fault without braking Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: The fault occurs if the pneumatic lines are blocked or contaminated, or the rear axle pressure control module is not functioning, or the service brake valve with integrated brake power sensor is not functioning. Remedy: The brake function diagram (with trailer) was used when referring to the pneumatic connections listed below between the individual components. The pressure in connection 4 (rear axle pressure control module (Y264 connection 4) - trailer control module (G17.301/Y278 connection 42) - service brake valve (G7.302 connection 22) of the back-up circuit must be checked. The pneumatic connections of the rear axle pressure control module (Y264) must be checked, as follows: The pneumatic lines from rear axle pressure control module (Y264 connection 21) to the left combination cylinder (G11.301 connection 11), rear axle pressure control module (Y264 connection 21) to the double check valve (G21.11 connection 11), to the rear axle pressure control module (Y264 connection 4) and to the service brake valve (G7.302 connection 22) and to the trailer control module (G17.301/Y278 connection 42) and the supply lines of the rear axle pressure control module (Y264 connection 1): The rear axle pressure control module is supplied by the 1-cylinder compressor (G1.1 connection 2) and safety valve 17+2 bar (G5.121) to the ECAM 12.5 bar (G25.300 connection 1). From the ECAM 12.5 bar (G25.300 connection 22), the line runs to the compressed air tank 40 l, 12.5 bar (G50.300), from where the service brake valve (G7.302 connection 12) is connected to connection 1 of the rear axle pressure control module. Connection 1 (supply line) is responsible for the energy supply. Connection 21 is responsible for dissipating the energy, while connection 4 is provided for the back-up circuit (back-up circuit solenoid valve). Furthermore, check for correct functioning of the pressure control module. If it is not functioning, replace the defective rear axle pressure control module. The pressure gradient of the service brake valve with integrated brake power sensor (B337) in connection 4 of the back-up circuit (to the back-up circuit solenoid valve) must be checked. Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03229

Pressure control module, rear axle, left, no valid fault denition

03230

Pressure control module, left rear axle, wheel sensor IC defective Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Remedy: Delete the fault memory. Remedy:There is an internal pressure control module malfunction. If the fault reoccurs after the fault memory has been deleted then replace the rear axle pressure control module (Y264). If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

164

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03231

Pressure control module, left rear axle, faulty backup valve checkback Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: There is a fault in the signal pathways for the back-up circuit solenoid valve (backup valve) in the rear axle pressure control module. If the fault reoccurs after the fault memory has been deleted then replace the rear axle pressure control module. If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. Remedy: Delete the fault memory. Furthermore, check for correct functioning of the rear axle pressure control module (Y264). If it is not functioning, replace the rear axle pressure control module. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03232

Pressure control module, rear axle, left, defective inlet valve, feedback Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: Delete the fault memory. Furthermore, check for correct functioning of the rear axle pressure control module (Y264). If it is not functioning, replace the rear axle pressure control module. Remedy: There is a fault in the signal pathways for the back-up circuit solenoid valve (backup valve) in the rear axle pressure control module. If the fault reoccurs after the fault memory has been deleted then replace the rear axle pressure control module. If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03233

Pressure control module, rear axle, left, defective inlet and back-up valve, feedback Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: Delete the fault memory. Furthermore, check for correct functioning of the rear axle pressure control module (Y264). If it is not functioning, replace the rear axle pressure control module. Remedy: There is a fault on the signal path for the back-up circuit solenoid valve (back-up valve) in the rear axle pressure control module. If the fault reoccurs after the fault memory has been deleted then replace the rear axle pressure control module. If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

T 61

2nd edition

165

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03234

Pressure control module, rear axle, left, defective outlet valve, feedback Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: Delete the fault memory. Furthermore, check for correct functioning of the rear axle pressure control module (Y264). If it is not functioning, replace the rear axle pressure control module. Remedy: There is a fault on the signal path for the back-up circuit solenoid valve (back-up valve) in the rear axle pressure control module. If the fault reoccurs after the fault memory has been deleted then replace the rear axle pressure control module. If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03235

Pressure control module, rear axle, left, defective outlet and back-up valve, feedback Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: Delete the fault memory. Furthermore, check for correct functioning of the rear axle pressure control module (Y264). If it is not functioning, replace the rear axle pressure control module. Remedy: There is a fault on the signal path for the back-up circuit solenoid valve (back-up valve) in the rear axle pressure control module. If the fault reoccurs after the fault memory has been deleted then replace the rear axle pressure control module. If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03236

Pressure control module, rear axle, left, defective outlet and inlet valve, feedback Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: Delete the fault memory. Furthermore, check for correct functioning of the rear axle pressure control module (Y264). If it is not functioning, replace the rear axle pressure control module. Remedy: There is a fault on the signal path for the back-up circuit solenoid valve (back-up valve) in the rear axle pressure control module. If the fault reoccurs after the fault memory has been deleted then replace the rear axle pressure control module. If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

166

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03237

Pressure control module, rear axle, left, defective outlet and inlet and back-up valve, feedback Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: Delete the fault memory. Furthermore, check for correct functioning of the rear axle pressure control module (Y264). If it is not functioning, replace the rear axle pressure control module. Remedy: There is a fault on the signal path for the back-up circuit solenoid valve (back-up valve) in the rear axle pressure control module. If the fault reoccurs after the fault memory has been deleted then replace the rear axle pressure control module. If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03238 03239

Pressure control module, rear axle, left, no valid fault denition

03240

Pressure control module, rear axle, left, no CAN reception from module Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: CAN brake Baud rate: 250 kbaud Peak voltage values: Recessive CAN Low 2.5 V, CAN High 2.5 V; dominant CAN Low 1.5 V, CAN High 3.5 V Header length: 11-bit Message length: 8-byte Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Also check the ground signal (resistance < 1Ω) from A402 pin X1/12 (pressure control module input ground) to X618 (terminal board distributor X102 cable 31000) and the battery voltage (24 V) of the EBS control unit (A402) from A402 pin X1/8 (voltage supply terminal 30) to X618 (terminal board distributor X102 cable 31000). Remedy: The connections from the EBS control unit (A402) to the rear axle pressure control module (Y264) Pin X4/4 (EBS control unit) - pin 6/1 (rear axle pressure control module ground); Pin X4/13 (EBS control unit) - pin 6/2 (rear axle pressure control module 24 V voltage supply); Pin X4/10 (EBS control unit) - pin 6/3 (CAN High for rear axle pressure control module) and Pin X4/7 (EBS control unit) - pin 6/4 (CAN Low for rear axle pressure control module) must be checked (in particular, look for chang points). Check the plug connectors on the EBS electronic control unit and on the rear axle pressure control module. The battery voltage from A402 pin X4/13 (voltage supply Y264) to A402 pin X4/4 (ground Y264) should be measured. As the next step, measure the overall resistance of 64Ω, from A402 pin X4/10 (CAN high Y264) to A402 pin X4/7 (CAN low Y264). Furthermore, the ground connections of all connected pressure control modules (left front axle pressure control module (Y263), right front axle pressure control module (Y262) and rear axle pressure control module (Y264)) should be checked. Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

T 61

2nd edition

167

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03241

Pressure control module, rear axle, left, software incompatibility between control unit and pressure control module Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Remedy: The EBS electronic control unit (A402) or the rear axle pressure control module (Y264) must be replaced by one with a compatible software version. Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03242

Pressure control module, left rear axle, 12/24 volt incompatibility between control unit and pressure control module Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Remedy: The EBS electronic control unit (A402) or the rear axle pressure control module (Y264) must be replaced by one with a compatible voltage version. Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03243

Pressure control module, rear axle, left, high cycle protection, inlet valve active, pressure < 4 bar Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: This malfunction occurs if the nominal value is not achieved for a relatively long time when the brake cylinder pressure is low. If the supply pressure < 4 bar, a fault message is triggered after the pressure sensor for the supply pressure has been checked. The ECAM message on CAN J1939 (reservoir pressure circuits 1 and 2) must be checked. The current values for the pressure sensor of the pressure control module are read out using MAN-cats® II. Remedy: The correct function of the rear axle pressure control module (Y264) must be checked. If it is not functioning, replace the rear axle pressure control module. Furthermore, the continuity of the pneumatic supply lines to the pressure control modules (left front axle pressure control module (Y263), right front axle pressure control module (Y262) and rear axle pressure control module (Y264)) must be checked. Sensor inputs 1 and 2 of the supply pressure measurement must be checked. (External monitoring of the central STOP warning light (H111) and the general brake check lamp (H108) (pressure sensor for the supply pressure – is installed in the front axle pressure control module) must be checked.) Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

168

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03244

Pressure control module, left rear axle, arithmetic test not successful Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Remedy: Delete the fault memory. Remedy: If the fault reoccurs after the fault memory has been deleted then replace the rear axle pressure control module (Y264). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03245

Pressure control module, rear axle, left, wheel adjustment fault, wheel sensor, left Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The rear axle speed sensor (B121) transfers this information to the EBS control unit. This malfunction occurs if the calculated wheel speed deviates by more than 9 % between the axles. This is displayed by the yellow central STOP warning light (H111) and the fault is stored in the EBS control unit. Fault-free operation is possible until the next switch-off if the wheel speed after compensation deviates by < 9 %. However, the fault remains in the fault memory. The compensated wheel diameter continues to be output until the maximum permitted deviation stored in the end of line (EOL) is reached (e.g. 25 %). Diameter compensation is operating when the road speed is in the range from 25 km/h to 100 km/h, the brake is not active, no anti-lock brake system (ABS) or anti-spin regulator (ASR) intervention is taking place and the road speed is almost constant. Remedy: The tyre sizes on the front and rear axle must be checked. The ASR spin threshold increase button (S256) must be actuated for a driving distance of at least 10 km at a road speed of more than 25 km/h. The ASR info check lamp (H140) ashes (information display). The fault memory of the EBS electronic control unit (A402) must be deleted and then the control unit should be reset. Emergency function (function level 6): The brake pressure in the affected control channel is regulated according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

T 61

2nd edition

169

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03246

Pressure control module, rear axle, left, wheel adjustment fault, wheel sensor, right Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The rear axle speed sensor transfers this information to the EBS control unit. This malfunction occurs if the calculated wheel speed deviates by more than 9 % between the axles. This is displayed by the central STOP warning light (H111) and the fault is stored in the EBS control unit. Fault-free operation is possible until the next switch-off if the wheel speed after compensation deviates by < 9 %. However, the fault remains in the fault memory. The compensated wheel diameter continues to be output until the maximum permitted deviation stored in the end of line (EOL) is reached (e.g. 25 %) Diameter compensation is operating when the road speed is in the range from 25 km/h to 100 km/h, the brake is not active, no anti-lock brake system (ABS) or anti-spin regulator (ASR) intervention is taking place and the road speed is almost constant. Remedy: The tyre sizes on the front and rear axle must be checked. The ASR spin threshold increase button (S256) must be actuated for a driving distance of at least 10 km at a road speed of more than 25 km/h. The ASR info check lamp (H140) ashes. The fault memory of the EBS electronic control unit (A402) must be deleted and then the control unit should be reset. Emergency function (function level 6): The brake pressure in the affected control channel is regulated according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03247

Pressure control module, rear axle, left, fault at voltage supply, axle load sensor Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The supply voltage must be checked - permitted supply voltage range at the rear axle pressure control module: The voltage measured between pin 3/4 and pin 3/1 at the rear axle pressure control module should have the voltage value 5 V ±0.45 V. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Remedy: The cables and plug connectors between the rear axle pressure control module (Y264) and the rear axle automatic load-balancing sensor (B336) must be checked for short circuits or line discontinuities, between pin 3/4 (rear axle pressure control module) and pin 1 (voltage supply ALB sensor rear axle), between pin 3/1 (rear axle pressure control module) and pin 2 (ground ALB sensor rear axle), between pin 3/3 (rear axle pressure control module) and pin 3 (signal line ALB sensor rear axle). Emergency function (function level 5): The EBS system operates with the value “L = ALB-Fehl” programmed via EOL for brake pressure distribution during braking with the service brakes (electropneumatic brake system EPB) and with the automatic load balancing (ALB) value L = 0 in the anti-lock brake system (ABS) for IRM (individual regulation modied) at the front axle.

170

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03248

Pressure control module, rear axle, left, pressure differential on pressure control module pair, front axle Fault indication: Central STOP warning light (H111) comes on red at the same time as the red check lamp for the general brake check (H108) Effect of fault: This malfunction occurs when a pressure differential > 0.8 bar occurs for longer than 3 seconds on one axle in one of the pressure control modules. The current values for the pressure sensors of the rear axle pressure control module are read out using MAN-cats® II. Remedy: Check for correct functioning of the rear axle pressure control module (Y264). If it is not functioning, replace the rear axle pressure control module. The brake function diagram (with trailer) was used when referring to the pneumatic connections listed below between the individual components. Free passage of the pneumatic supply lines to the rear axle pressure control module (Y264) must be checked: The rear axle pressure control module is supplied by the 1-cylinder compressor (G1.1 connection 2) and safety valve 17+2 bar (G5.121) to the ECAM 12.5 bar (G25.300 connection 1). From the ECAM 12.5 bar (G25.300 connection 22), the line runs to the compressed air tank 40 l, 12.5 bar (G50.300), from where the service brake valve (G7.302 connection 12) is connected to connection 1 of the rear axle pressure control module. Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03249

Pressure control module, rear axle, left, no valid fault denition

T 61

2nd edition

171

DEVICE DESCRIPTION Fault messages, pressure control module (2-channel) on the rear axle (right-hand side) SPN

SPN-Plain text Description

03250

Pressure control module, rear axle, right, no fault

03251

Pressure control module, rear axle, right, discontinuity, short-circuit, wheel sensor, left Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The sensor resistance should be between 950Ω and 1930Ω (measure from Y264 pin 1/2 to Y264 pin 1/1). This fault is displayed if a voltage < 1 V or > 4 V is measured at the left rear axle speed sensor. As soon as there is a cable break, this is indicated by the central STOP warning light (H111) lighting up yellow. After the fault has been remedied, the central STOP warning light goes out, providing an adequate signal (v > 20 km/h) is measured at all speed sensors (left front axle speed sensor (B119), right front axle speed sensor (B120), left rear axle speed sensor (B121) and right rear axle speed sensor (B122)). (Memory function.) Remedy: The cables and plug connectors between rear axle pressure control module (Y264) and left rear axle speed sensor (B121) must be checked for cable break or short-circuit (B121: Brown cable - Y264: Pin 1/2 and B121: Black cable - Y264: pin 1/1). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective left rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03252

Pressure control module, rear axle, right, wheel sensor, left: Deceleration excessive Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The sensor resistance should be between 950Ω and 1930Ω. This fault is displayed when the signal of the rear axle speed sensor fails abruptly and v > 30 km/h, and also when there is a short circuit between two speed sensor cables and the rear axle speed sensor has dropped out of its holder. After the fault has been remedied, the yellow central STOP warning light (H111) goes out, providing an adequate signal (v > 20 km/h) is measured at all speed sensors (left front axle speed sensor (B119), right front axle speed sensor (B120), left rear axle speed sensor (B121) and right rear axle speed sensor (B122)) (memory function). Remedy: The cables and plug connectors between rear axle pressure control module (Y264) and left rear axle speed sensor (B121) must be checked for cable break or short circuit. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective left rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

172

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03253

Pressure control module, rear axle, right, wheel sensor, left: Starting-off fault Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The gap between the left rear axle speed sensor and the impulse wheel is too great. This fault also occurs if v > 18 km/h is measured at n-1 wheels and no signal has been received from one wheel for longer than 20 seconds, or v > 40 km/h is measured on one speed sensor and no signal is measured at the other speed sensors for longer than 20 seconds. The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out, providing an adequate signal (v > 20 km/h) is measured at all speed sensors (left front axle speed sensor (B119), right front axle speed sensor (B120), left rear axle speed sensor (B121) and right rear axle speed sensor (B122)) (memory function). Remedy: The left rear axle speed sensor (B121) must be pushed in by hand (do not strike it!). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective left rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03254

Pressure control module, rear axle, right, wheel sensor, left: Excessive clearance Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs if the limit gap speed v > 10 km/h. The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out, providing an adequate signal (v > 20 km/h) is measured at all speed sensors (left front axle speed sensor (B119), right front axle speed sensor (B120), left rear axle speed sensor (B121) and right rear axle speed sensor (B122)) (memory function). Remedy: Check the gap between the left rear axle speed sensor (B121) and the impulse wheel. The left rear axle speed sensor must be pushed in by hand (do not strike it!). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective left rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

T 61

2nd edition

173

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03255

Pressure control module, rear axle, right, perpetual control, wheel sensor, left Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: Controlled wheels are monitored during anti-lock brake system (ABS) regulation. The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out, providing an adequate signal (v > 20 km/h) is measured at all speed sensors (left front axle speed sensor (B119), right front axle speed sensor (B120), left rear axle speed sensor (B121) and right rear axle speed sensor (B122)) (memory function). Remedy: The cables and plug connectors between rear axle pressure control module (Y264) and left rear axle speed sensor (B121) must be checked for cable break or short-circuit (B121: Brown cable - Y264: Pin 1/2 and B121: Black cable - Y264: pin 1/1). The sensor resistance should be between 950Ω and 1930Ω (measure from Y264 pin 1/2 to Y264 pin 1/1). Furthermore, the impulse wheel should be checked for contamination by metallic particles, the gap between the left rear axle speed sensor and the impulse wheel should be checked, the impulse wheel should be checked for damage (missing teeth), the impulse wheel should be checked for damage (wobble < 0.3 mm) and the impulse wheel should be checked for the right number of teeth and any pitch error. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective left rear axle speed sensor (B121) is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03256

Pressure control module, rear axle, right, long instability, wheel sensor, left Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs if a wheel controlled by the anti-lock brake system (ABS) is not being regulated in a stable manner after 20 seconds. The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out, providing an adequate signal (v > 20 km/h) is measured at all speed sensors (left front axle speed sensor (B119), right front axle speed sensor (B120), left rear axle speed sensor (B121) and right rear axle speed sensor (B122)) (memory function). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Remedy: The cables and the plug connectors to the left rear axle speed sensor (B121) must be checked for cable break, short circuit and chang points (B121 - brown and black cables). Furthermore, the brake cylinders should be checked for residual pressure, the impulse wheel should be checked for contamination by metallic particles, the impulse wheel should be checked for damage (missing teeth), the impulse wheel should be checked for damage (wobble < 0.3 mm) and the impulse wheel should be checked for the right number of teeth and any pitch error. Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective left rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

174

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03257

Pressure control module, rear axle, right, pulse ring fault, wheel sensor, left Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out, providing an adequate signal (v > 20 km/h) is measured at all speed sensors (left front axle speed sensor (B119), right front axle speed sensor (B120), left rear axle speed sensor (B121) and right rear axle speed sensor (B122)) (memory function). Remedy: The impulse wheel should be checked for contamination by metallic particles, the impulse wheel should be checked for damage (missing teeth), the impulse wheel should be checked for damage (wobble < 0.3 mm) and the impulse wheel should be checked for the right number of teeth and any pitch error. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective left rear axle speed sensor (B121) is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03258

Pressure control module, rear axle, right, fault on lifting axle, wheel sensor, left Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs if one of the two lifting axle wheels is turning at v < 15 km/h, the other lifting axle wheel is turning with the vehicle speed and the speed of the vehicle is > 30 km/h. Remedy: Check that both wheels of the lifting axle are either in the air or on the ground. Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective left rear axle speed sensor (B121) is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03259 03260

Pressure control module, rear axle, right, no valid fault denition

T 61

2nd edition

175

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03261

Pressure control module, rear axle, right, discontinuity, short-circuit, wheel sensor, right Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The sensor resistance should be between 950Ω and 1930Ω (measure from Y264 pin 5/2 to Y264 pin 5/1). This fault is displayed if a voltage < 1 V or > 4 V is measured at the right rear axle speed sensor. As soon as there is a line discontinuity, this is displayed by the central STOP warning light (H111) lighting up yellow. After the fault has been remedied, the central STOP warning light (H111) goes out, providing an adequate signal (v > 20 km/h) is measured at all speed sensors (left front axle speed sensor (B119), right front axle speed sensor (B120), left rear axle speed sensor (B121) and right rear axle speed sensor (B122)) (memory function). Remedy: The cables and plug connectors between rear axle pressure control module (Y264) and right rear axle speed sensor (B122) must be checked for cable break or short circuit (B122: Brown cable - Y264: Pin 5/2 and B122: Black cable - Y264: pin 5/1). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective right rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03262

Pressure control module, rear axle, right, wheel sensor, right: Deceleration excessive Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The sensor resistance should be between 950Ω and 1930Ω (measure from Y264 pin 5/2 to Y264 pin 5/1). This fault is displayed when the signal of the right rear axle speed sensor fails abruptly and v > 30 km/h, and also when there is a short circuit between two speed sensor cables and the right rear axle speed sensor has dropped out of its holder. After the fault has been remedied, the yellow central STOP warning light (H111) goes out, providing an adequate signal (v > 20 km/h) is measured at all speed sensors (left front axle speed sensor (B119), right front axle speed sensor (B120), left rear axle speed sensor (B121) and right rear axle speed sensor (B122)) (memory function). Remedy: The cables and plug connectors between rear axle pressure control module (Y264) and right rear axle speed sensor (B122) must be checked for cable break or short circuit (B122: Brown cable - Y264: Pin 5/2 and B122: Black cable - Y264: pin 5/1). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective right rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

176

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03263

Pressure control module, rear axle, right, wheel sensor, right: Starting-off fault Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The gap between the right rear axle speed sensor and the impulse wheel is too great. This fault also occurs if v > 18 km/h is measured at n-1 wheels and no signal has been received from one wheel for longer than 20 seconds, or v > 40 km/h is measured on one speed sensor and no signal is measured at the other speed sensors for longer than 20 seconds. The wheel speeds and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out, providing an adequate signal (v > 20 km/h) is measured at all speed sensors (left front axle speed sensor (B119), right front axle speed sensor (B120), left rear axle speed sensor (B121) and right rear axle speed sensor (B122)) (memory function). Remedy: The right rear axle speed sensor must be pushed in by hand (do not strike it!). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective right rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03264

Pressure control module, rear axle, right, wheel sensor, right: Excessive clearance Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs when the gap speed v > 10 km/h is calculated. The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out, providing an adequate signal (v > 20 km/h) is measured at all speed sensors (left front axle speed sensor (B119), right front axle speed sensor (B120), left rear axle speed sensor (B121) and right rear axle speed sensor (B122)) (memory function). Remedy: Check the gap between the right rear axle speed sensor (B122) and the impulse wheel. The right rear axle speed sensor must be pushed in by hand (do not strike it!). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective right rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

T 61

2nd edition

177

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03265

Pressure control module, rear axle, right, perpetual control, wheel sensor, right Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The wheels are controlled and monitored during intervention by the anti-lock brake system (ABS). The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out, providing an adequate signal (v > 20 km/h) is measured at all speed sensors (left front axle speed sensor (B119), right front axle speed sensor (B120), left rear axle speed sensor (B121) and right rear axle speed sensor (B122)) (memory function). Remedy: The cables and plug connectors between rear axle pressure control module (Y264) and right rear axle speed sensor (B122) must be checked for cable break or short circuit (B122: Brown cable - Y264: Pin 5/2 and B122: Black cable - Y264: pin 5/1). The sensor resistance should be between 950Ω and 1930Ω (measure from Y264 pin 5/2 to Y264 pin 5/1). Furthermore, the impulse wheel should be checked for contamination by metallic particles, the gap between the rear axle speed sensor and the impulse wheel should be checked, the impulse wheel should be checked for damage (missing teeth), the impulse wheel should be checked for damage (wobble < 0.3 mm) and the impulse wheel should be checked for the right number of teeth and any pitch error. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is regulated according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective right rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03266

Pressure control module, rear axle, right, long instability, wheel sensor, right Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs if a wheel controlled by the anti-lock brake system (ABS) is not being regulated in a stable manner after 20 seconds. The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out, providing an adequate signal (v > 20 km/h) is measured at all speed sensors (left front axle speed sensor (B119), right front axle speed sensor (B120), left rear axle speed sensor (B121) and right rear axle speed sensor (B122)) (memory function). Remedy: The cables and the plug connectors to the right rear axle speed sensor (B122) must be checked for cable break, short circuit and chang points (B122 - brown and black cables). Furthermore, the brake cylinders should be checked for residual pressure, the impulse wheel should be checked for contamination by metallic particles, the impulse wheel should be checked for damage (missing teeth), the impulse wheel should be checked for damage (wobble < 0.3 mm) and the impulse wheel should be checked for the right number of teeth and any pitch error. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective right rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

178

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03267

Pressure control module, rear axle, right, pulse ring fault, wheel sensor, right Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out, providing an adequate signal (v > 20 km/h) is measured at all speed sensors (left front axle speed sensor (B119), right front axle speed sensor (B120), left rear axle speed sensor (B121) and right rear axle speed sensor (B122)) (memory function). Remedy: The impulse wheel should be checked for contamination by metallic particles, the impulse wheel should be checked for damage (missing teeth), the impulse wheel should be checked for damage (wobble < 0.3 mm) and the impulse wheel should be checked for the right number of teeth and any pitch error. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is regulated according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective right rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03268

Pressure control module, rear axle, right, fault on lifting axle, wheel sensor, right Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs if one of the two lifting axle wheels is turning at v < 15 km/h, the other lifting axle wheel is turning with the vehicle speed and the speed of the vehicle is > 30 km/h. Remedy: Check that both wheels of the lifting axle are either in the air or on the ground. Emergency function (function level 6): The brake pressure in the affected control channel is regulated according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective right rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03269

Pressure control module, rear axle, right, no valid fault denition

T 61

2nd edition

179

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03270

Pressure control module, right rear axle, voltage supply fault, lining wear sensor Fault indication: Central STOP warning light (H111) lights up yellow and the brake wear indicator check lamp comes on (appears as a pictogram on the display). Effect of fault: The 5 V voltage at the rear axle pressure control module (Y264) - output between pin 7/4 (voltage supply) and pin 2/1 (ground) should be 5 V (±0.45 V) after braking (approx. 7 seconds after the brake is released). Remedy: The 5 V cable to the 2nd axle right brake sensor (B334) should be checked for short circuit or parallel connection (pin 4: 5 V voltage supply) The cables and plug connectors from the rear axle pressure control module (Y264) to the 2nd axle brake sensor right from Y264 pin 7/1 to B334 pin 1 (ground) from Y264 pin 7/3 to B334 pin 3 (sensor signal) from Y264 pin 7/4 to B334 pin 4 (5 V voltage supply) The 2nd axle brake sensor right itself and the ground connection of the sensor (pin 1: ground) should be checked. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 3): Lining wear monitoring has failed. All other EBS functions are present.

03271

Pressure control module, rear axle, right, left brake wear sensor out of permitted value range Fault indication: Central STOP warning light (H111) lights up yellow and the brake wear indicator check lamp comes on (appears as a pictogram on the display). Effect of fault: The 5 V voltage at the rear axle pressure control module (Y264) - output between pin 2/4 (voltage supply) and pin 2/1 (ground) should be 5 V (±0.45 V) after braking (approx. 2 seconds after the brake is released). The voltages can be read out using MAN-cats® II. The connected 2nd axle brake sensor left must be compatible with end of line (EOL). Remedy: The 5 V cable to the 2nd axle left brake sensor (B335) should be checked for short circuit or parallel connection (pin 4: 5 V voltage supply) The signal line to the brake sensor should be checked for cable break, short circuit or parallel connection (pin 3: Signal from 2nd axle brake sensor left) and the ground connection of the sensor (pin 1: ground) should be checked. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 3): Lining wear monitoring has failed. All other EBS functions are present.

03272

Pressure control module, rear axle, right, right brake wear sensor out of permitted value range Fault indication: Central STOP warning light (H111) lights up yellow and the brake wear indicator check lamp comes on (appears as a pictogram on the display). Effect of fault: The 5 V voltage at the rear axle pressure control module (Y264) - output between pin 7/4 (voltage supply) and pin 2/1 (ground) should be 5 V (±0.45 V) after braking (approx. 7 seconds after the brake is released). These voltages are read out using MAN-cats® II. The connected 2nd axle brake sensor right must be compatible with end of line (EOL). Remedy: The 5 V cable to the brake sensor should be checked for cable break, short circuit or parallel connection (pin 4: 5 V voltage supply), The signal line to the 2nd axle brake sensor right should be checked for cable break, short circuit or parallel connection (pin 3: Signal from 2nd axle brake sensor right (B334) to rear axle pressure control module (Y264 pin 7/3)) and from Y264 pin 7/3 to Y264 pin 7/1 should be < 4.9 V (approx. 2 seconds - wear limit) and > 0.5 V (approx. 2 seconds - new lining) and the ground connection of the sensor (pin 1: ground) should be checked. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 3): Lining wear monitoring has failed. All other EBS functions are present.

180

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03273

Pressure control module, rear axle, right, pressure sensor outside permitted value range Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: There is an internal pressure control module malfunction or the plausibility check of the pressure control is not taking place successfully. If the fault reoccurs after the fault memory has been deleted then replace the rear axle pressure control module (Y264). If this fault occurs repeatedly in normal operation then the left rear axle pressure control module must also be replaced. These pressures are read out using MAN-cats® II (not if there is a fault). The measuring range of the pressure sensors is between 0 bar and 13 bar. Remedy: Delete the fault memory. Furthermore, check for correct functioning of the rear axle pressure control module (Y264). Pressure modulation should be performed via diagnosis (with MAN-cats® II) and a comparison with an external pressure gauge. Check the supply lines to the left rear axle pressure control module. Electrical: Y264 pin 6/2: 24 V voltage supply from the EBS electronic control unit (A402 pin X4/13) and Y264 pin 6/1: Ground connection from the EBS electronic control unit (A402 pin X3/2) Pneumatic: Connection 1 for air supply (reservoir) Replace the defective rear axle pressure control module. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected left rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03274

Pressure control module, rear axle, right, time for “Current pressure” inquiry too long Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: There is an internal pressure control module malfunction or the plausibility check of the pressure control is not taking place successfully. If the fault reoccurs after the fault memory has been deleted then replace the rear axle pressure control module (Y264). If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. Remedy: Delete the fault memory. The correct function of the rear axle pressure control module (Y264) must be checked. Replace the defective rear axle pressure control module. The mufer of the rear axle pressure control module must be checked for sufcient air ow. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no ALB and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

T 61

2nd edition

181

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03275

Pressure control module, right rear axle, poor ventilation Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: If ventilation of the rear axle pressure control module is hindered whilst the brake is being released, this falsies the measurement results. This can be caused by a blocked or hardened exhaust silencer element. This fault message can also be caused if the distance from surrounding objects is too short. A defective exhaust valve or a defective pressure sensor in the rear axle pressure control module (Y264) can trigger this fault message. There is an internal pressure control module malfunction or the plausibility check of the pressure control is not taking place successfully. If the fault reoccurs after the fault memory has been deleted, then replace the rear axle pressure control module. If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. These pressures are read out using MAN-cats® II. Remedy: Delete the fault memory. The ventilation openings (connection 3 for venting) of the rear axle pressure control module (Y264) must be checked. Furthermore, check for correct functioning of the rear axle pressure control module. Replace the defective rear axle pressure control module. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governing) are deactivated.

182

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03276

Pressure control module, rear axle, right, excessive pressure during the pulse test Fault indication: Central STOP warning light (H111) comes on red at the same time as the red check lamp for the general brake check (H108) Effect of fault: This malfunction occurs if the automatic pulse test after the ignition is switched on does not cover the set pressure range. This occurs if the pneumatic lines are squeezed or blocked, or the pulse test length is not adapted to the volume of the brake cylinders used, or the rear axle pressure control module is not functioning. These values are read out using MAN-cats® II. If the fault reoccurs after the fault memory has been deleted then replace the left rear axle pressure control module. Remedy: Delete the fault memory. The brake function diagram (with trailer) was used when referring to the pneumatic connections listed below between the individual components. The pneumatic connections of the rear axle pressure control module (Y264) must be checked, as follows: the pneumatic lines from the rear axle pressure control module (Y264 connection 22) to the right combination cylinder (G11.300 connection 11), rear axle pressure control module (Y264 connection 22) to the double check valve (G21.11 connection 112), to the rear axle pressure control module (Y264 connection 4) and to the service brake valve (G7.302 connection 22) and to the trailer control module (G17.301/Y278 connection 42) and the supply lines of the rear axle pressure control module (Y264 connection 1): The rear axle pressure control module is supplied by the 1-cylinder compressor (G1.1 connection 2) and safety valve 17+2 bar (G5.121) to the ECAM 12.5 bar (G25.300 connection 1). From the ECAM 12.5 bar (G25.300 connection 22), the line runs to the compressed air tank 40 l, 12.5 bar (G50.300), from where the service brake valve (G7.302 connection 12) is connected to connection 1 of the rear axle pressure control module. Connection 1 (supply line) is responsible for the energy supply. Connection 22 is responsible for dissipating the energy, while connection 4 is provided for the back-up circuit (back-up circuit solenoid valve). Furthermore, check for correct functioning of the pressure control module. If it is not functioning, replace the defective rear axle pressure control module. The test pulse duration in the end of line (EOL) data memory must be checked using MAN-cats® II. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). The pneumatic connections can be found in the functional description and in the function diagrams. Emergency function: The EBS is functioning without restrictions.

T 61

2nd edition

183

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03277

Pressure control module, right rear axle, residual pressure after braking Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: The fault occurs if the pneumatic lines are blocked or contaminated, or the rear axle pressure control module is not functioning, or the service brake valve with integrated brake power sensor is not functioning. Remedy: The brake function diagram (with trailer) was used when referring to the pneumatic connections listed below between the individual components. The pressure in connection 4 (rear axle pressure control module (Y264 connection 4) - trailer control module (G17.301/Y278 connection 42) - service brake valve (G7.302 connection 22) of the back-up circuit must be checked. The pneumatic connections of the rear axle pressure control module (Y264) must be checked, as follows: The pneumatic lines from rear axle pressure control module (Y264 connection 22) to the right combination cylinder (G11.300 connection 11), rear axle pressure control module (Y264 connection 22) to the double check valve (G21.11 connection 12), to the rear axle pressure control module (Y264 connection 4) and to the service brake valve (G7.302 connection 22) and to the trailer control module (G17.301/Y278 connection 42) and the supply lines of the rear axle pressure control module (Y264 connection 1): The rear axle pressure control module is supplied by the 1-cylinder compressor (G1.1 connection 2) and safety valve 17+2 bar (G5.121) to the ECAM 12.5 bar (G25.300 connection 1). From the ECAM 12.5 bar (G25.300 connection 22), the line runs to the compressed air tank 40 l, 12.5 bar (G50.300), from where the service brake valve (G7.302 connection 12) is connected to connection 1 of the rear axle pressure control module. Connection 1 (supply line) is responsible for the energy supply. Connection 22 is responsible for dissipating the energy, while connection 4 is provided for the back-up circuit (back-up circuit solenoid valve). Furthermore, check for correct functioning of the pressure control module. If it is not functioning, replace the defective rear axle pressure control module. The pressure gradient of the service brake valve with integrated brake power sensor (B337) in connection 4 of the back-up circuit (to the back-up circuit solenoid valve) must be checked. Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

184

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03278

Pressure control module, right rear axle, pressure sensor fault without braking Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: The fault occurs if the pneumatic lines are blocked or contaminated, or the rear axle pressure control module is not functioning, or the service brake valve with integrated brake power sensor is not functioning. Remedy: The brake function diagram (with trailer) was used when referring to the pneumatic connections listed below between the individual components. The pressure in connection 4 (rear axle pressure control module (Y264 connection 4) - trailer control module (G17.301/Y278 connection 42) - service brake valve (G7.302 connection 22) of the back-up circuit must be checked. The pneumatic connections of the rear axle pressure control module (Y264) must be checked, as follows: the pneumatic lines from the rear axle pressure control module (Y264 connection 22) to the right combination cylinder (G11.300 connection 11), rear axle pressure control module (Y264 connection 22) to the double check valve (G21.11 connection 12), to the rear axle pressure control module (Y264 connection 4) and to the service brake valve (G7.302 connection 22) and to the trailer control module (G17.301/Y278 connection 42) and the supply lines of the rear axle pressure control module (Y264 connection 1: The rear axle pressure control module is supplied by the 1-cylinder compressor (G1.1 connection 2) and safety valve 17+2 bar (G5.121) to the ECAM 12.5 bar (G25.300 connection 1). From the ECAM 12.5 bar (G25.300 connection 22), the line runs to the compressed air tank 40 l, 12.5 bar (G50.300), from where the service brake valve (G7.302 connection 12) is connected to connection 1 of the rear axle pressure control module. Connection 1 (supply line) is responsible for the energy supply. Connection 22 is responsible for dissipating the energy, while connection 4 is provided for the back-up circuit (back-up circuit solenoid valve). Furthermore, check for correct functioning of the pressure control module. If it is not functioning, replace the defective rear axle pressure control module. The pressure gradient of the service brake valve with integrated brake power sensor (B337) in connection 4 of the back-up circuit (to the back-up circuit solenoid valve) must be checked. Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03279

Pressure control module, rear axle, right, no valid fault denition

03280

Pressure control module, right rear axle, wheel sensor IC defective Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Remedy: Delete the fault memory. Remedy: There is an internal pressure control module malfunction. If the fault reoccurs after the fault memory has been deleted then replace the rear axle pressure control module (Y264). If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

T 61

2nd edition

185

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03281

Pressure control module, right rear axle, faulty backup valve checkback Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Remedy: There is a fault in the signal pathways for the back-up circuit solenoid valve (backup valve) in the rear axle pressure control module. If the fault reoccurs after the fault memory has been deleted then replace the rear axle pressure control module. If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. Effect of fault: Delete the fault memory. Furthermore, check for correct functioning of the rear axle pressure control module (Y264). If it is not functioning, replace the rear axle pressure control module. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03282

Pressure control module, rear axle, right, defective inlet valve, feedback Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: Delete the fault memory. Furthermore, check for correct functioning of the rear axle pressure control module (Y264). If it is not functioning, replace the rear axle pressure control module. Remedy: There is a fault on the signal path for the back-up circuit solenoid valve (back-up valve) in the rear axle pressure control module. If the fault reoccurs after the fault memory has been deleted, then replace the rear axle pressure control module. If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03283

Pressure control module, rear axle, right, defective inlet and back-up valve, feedback Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: Delete the fault memory. Furthermore, check for correct functioning of the rear axle pressure control module (Y264). If it is not functioning, replace the rear axle pressure control module. Remedy: There is a fault on the signal path for the back-up circuit solenoid valve (back-up valve) in the rear axle pressure control module. If the fault reoccurs after the fault memory has been deleted, then replace the rear axle pressure control module. If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

186

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03284

Pressure control module, rear axle, right, defective outlet valve, feedback Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: Delete the fault memory. Furthermore, check for correct functioning of the rear axle pressure control module (Y264). If it is not functioning, replace the rear axle pressure control module. Remedy: There is a fault on the signal path for the back-up circuit solenoid valve (back-up valve) in the rear axle pressure control module. If the fault reoccurs after the fault memory has been deleted, then replace the rear axle pressure control module. If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03285

Pressure control module, rear axle, right, defective outlet and back-up valve, feedback Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: Delete the fault memory. Furthermore, check for correct functioning of the rear axle pressure control module (Y264). If it is not functioning, replace the rear axle pressure control module. Remedy: There is a fault on the signal path for the back-up circuit solenoid valve (back-up valve) in the rear axle pressure control module. If the fault reoccurs after the fault memory has been deleted, then replace the rear axle pressure control module. If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03286

Pressure control module, rear axle, right, defective outlet and inlet valve, feedback Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: Delete the fault memory. Furthermore, check for correct functioning of the rear axle pressure control module (Y264). If it is not functioning, replace the rear axle pressure control module. Remedy: There is a fault on the signal path for the back-up circuit solenoid valve (back-up valve) in the rear axle pressure control module. If the fault reoccurs after the fault memory has been deleted, then replace the rear axle pressure control module. If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

T 61

2nd edition

187

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03287

Pressure control module, rear axle, right, defective outlet and inlet and back-up valve, feedback Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: Delete the fault memory. Furthermore, check for correct functioning of the rear axle pressure control module (Y264). If it is not functioning, replace the rear axle pressure control module. Remedy: There is a fault on the signal path for the back-up circuit solenoid valve (back-up valve) in the rear axle pressure control module. If the fault reoccurs after the fault memory has been deleted, then replace the rear axle pressure control module. If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03288 03289

Pressure control module, rear axle, right, no valid fault denition

03290

Pressure control module, rear axle, right, no CAN reception from module Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: CAN brake Baud rate: 250 kbaud Peak voltage values: Recessive CAN Low 2.5 V, CAN High 2.5 V; dominant CAN Low 1.5 V, CAN High 3.5 V Header length: 11-bit Message length: 8-byte Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Also check the ground signal (resistance < 1Ω) from A402 pin X1/12 (pressure control module input ground) to X618 (terminal board distributor X102 cable 31000) and the battery voltage (24 V) of the EBS control unit (A402) from A402 pin X1/8 (voltage supply terminal 30) to X618 (terminal board distributor X102 cable 31000). Remedy: The connections from the EBS control unit (A402) to the rear axle pressure control module (Y264) Pin X4/4 (EBS control unit) - pin 6/1 (rear axle pressure control module ground); Pin X4/13 (EBS control unit) - pin 6/2 (rear axle pressure control module 24 V voltage supply); Pin X4/10 (EBS control unit) - pin 6/3 (CAN High for rear axle pressure control module) and Pin X4/7 (EBS control unit) - pin 6/4 (CAN Low for rear axle pressure control module) must be checked (in particular, look for chang points). Check the plug connectors on the EBS electronic control unit and on the rear axle pressure control module. The battery voltage from A402 pin X4/13 (voltage supply Y264) to A402 pin X4/4 (ground Y264) should be measured. As the next step, measure the overall resistance of 64Ω, from A402 pin X4/10 (CAN high Y264) to A402 pin X4/7 (CAN low Y264). Furthermore, the ground connections of all connected pressure control modules (left front axle pressure control module (Y263), right front axle pressure control module (Y262) and rear axle pressure control module (Y264)) should be checked. Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

188

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03291

Pressure control module, rear axle, right, software incompatibility between control unit and pressure control module Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Remedy: The EBS electronic control unit (A402) or the rear axle pressure control module (Y264) must be replaced by one with a compatible software version. Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03292

Pressure control module, right rear axle, 12/24 volt incompatibility between control unit and pressure control module Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Remedy: The EBS electronic control unit (A402) or the rear axle pressure control module (Y264) must be replaced by one with a compatible voltage version. Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03293

Pressure control module, rear axle, right, high cycle protection, inlet valve active, pressure < 4 bar Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: This malfunction occurs if the nominal value is not achieved for a relatively long time when the brake cylinder pressure is low. If the supply pressure < 4 bar, a fault message is triggered after the pressure sensor for the supply pressure has been checked. The ECAM message on CAN J1939 (reservoir pressure circuits 1 and 2) must be checked. The current values for the pressure sensor of the pressure control module are read out using MAN-cats® II. Remedy: Check for correct functioning of the rear axle pressure control module (Y264). If it is not functioning, replace the rear axle pressure control module. Furthermore, the continuity of the pneumatic supply lines to the pressure control modules (left front axle pressure control module (Y263), right front axle pressure control module (Y262) and rear axle pressure control module (Y264)) must be checked. Sensor inputs 1 and 2 of the supply pressure measurement must be checked. (External monitoring of the central STOP warning light (H111) and the general brake check lamp (H108) (pressure sensor for the supply pressure – is installed in the front axle pressure control module) must be checked.) Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

T 61

2nd edition

189

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03294

Pressure control module, right rear axle, arithmetic test not successful Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Remedy: Delete the fault memory. Remedy: If the fault reoccurs after the fault memory has been deleted then replace the rear axle pressure control module (Y264). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03295

Pressure control module, rear axle, right, wheel adjustment fault, wheel sensor, left Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The rear axle speed sensor (B121) transfers this information to the EBS control unit. This malfunction occurs if the calculated wheel speed deviates by more than 9 % between the axles. This is displayed by the yellow central STOP warning light (H111) and the fault is stored in the EBS control unit. Fault-free operation is possible until the next switch-off if the wheel speed after compensation deviates by < 9 %. However, the fault remains in the fault memory. The compensated wheel diameter continues to be output until the maximum permitted deviation stored in the end of line (EOL) is reached (e.g. 25 %). Diameter compensation is operating when the road speed is in the range from 25 km/h to 100 km/h, the brake is not active, no anti-lock brake system (ABS) or anti-spin regulator (ASR) intervention is taking place and the road speed is almost constant. Remedy: The tyre sizes on the front and rear axle must be checked. The ASR spin threshold increase button (S256) must be actuated for a driving distance of at least 10 km at a road speed of more than 25 km/h. The ASR info check lamp (H140) ashes (information display). The fault memory of the EBS electronic control unit (A402) must be deleted and then the control unit should be reset. Emergency function (function level 6): The brake pressure in the affected control channel is regulated according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

190

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03296

Pressure control module, rear axle, right, wheel compensation fault, wheel sensor, right Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The rear axle speed sensor transfers this information to the EBS control unit. This malfunction occurs if the calculated wheel speed deviates by more than 9 % between the axles. This is displayed by the central STOP warning light (H111) and the fault is stored in the EBS control unit. Fault-free operation is possible until the next switch-off if the wheel speed after compensation deviates by < 9 %. However, the fault remains in the fault memory. The compensated wheel diameter continues to be output until the maximum permitted deviation stored in the end of line (EOL) is reached (e.g. 25 %) Diameter compensation is operating when the road speed is in the range from 25 km/h to 100 km/h, the brake is not active, no anti-lock brake system (ABS) or anti-spin regulator (ASR) intervention is taking place and the road speed is almost constant. Remedy: The tyre sizes on the front and rear axle must be checked. The ASR spin threshold increase button (S256) must be actuated for a driving distance of at least 10 km at a road speed of more than 25 km/h. The ASR info check lamp (H140) ashes. The fault memory of the EBS electronic control unit (A402) must be deleted and then the control unit should be reset. Emergency function (function level 6): The brake pressure in the affected control channel is regulated according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03297

Pressure control module, rear axle, right, fault at voltage supply, axle load sensor Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The supply voltage must be checked - permitted supply voltage range at the rear axle pressure control module: The voltage measured between pin 3/4 and pin 3/1 at the rear axle pressure control module should have the voltage value 5 V ±0.45 V. Remedy: The cables and plug connectors between the rear axle pressure control module (Y264) and the rear axle automatic load-balancing sensor (B336) must be checked for short-circuits or line discontinuity, between pin 3/4 (rear axle pressure control module) and pin 1 (voltage supply, ALB sensor, rear axle), between pin 3/1 (rear axle pressure control module) and pin 2 (ground, ALB sensor, rear axle), between pin 3/3 (rear axle pressure control module) and pin 3 (signal line, ALB sensor, rear axle). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 5): The EBS system operates with the value “L = ALB-Fehl” programmed via EOL for brake pressure distribution during braking with the service brakes (electropneumatic brake system EPB) and with the automatic load balancing (ALB) value L = 0 in the anti-lock brake system (ABS) for IRM (individual regulation modied) at the front axle.

T 61

2nd edition

191

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03298

Pressure control module, rear axle, right, pressure differential on pressure control module pair, front axle Fault indication: Central STOP warning light (H111) comes on red at the same time as the red check lamp for the general brake check (H108) Effect of fault: This malfunction occurs when a pressure differential > 0.8 bar occurs for longer than 3 seconds on one axle in one of the pressure control modules. The current values for the pressure sensors of the rear axle pressure control module are read out using MAN-cats® II. Remedy: Check for correct functioning of the rear axle pressure control module (Y264). If it is not functioning, replace the rear axle pressure control module. The brake function diagram (with trailer) was used when referring to the pneumatic connections listed below between the individual components. Check for free passage in the pneumatic supply lines to the rear axle pressure control module (Y264): The rear axle pressure control module is supplied by the 1-cylinder compressor (G1.1 connection 2) and safety valve 17+2 bar (G5.121) to the ECAM 12.5 bar (G25.300 connection 1). From the ECAM 12.5 bar (G25.300 connection 22), the line runs to the compressed air tank 40 l, 12.5 bar (G50.300), from where the service brake valve (G7.302 connection 12) is connected to connection 1 of the rear axle pressure control module. Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03299

192

Pressure control module, rear axle, right, no valid fault denition

T 61

2nd edition

DEVICE DESCRIPTION Fault messages, pressure control module (2-channel) on the 2nd rear axle (left-hand side) These fault codes are only signicant if the vehicle has a 2nd rear axle and a 2-channel pressure control module is also located on this. SPN

SPN-Plain text Description

03300

Pressure control module, 2nd rear axle, left, no fault

03301

Pressure control module, 2nd rear axle, left, discontinuity, short-circuit, wheel sensor, left Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The sensor resistance should be between 950Ω and 1930Ω. This fault is displayed if a voltage < 1 V or > 4 V is measured at the left rear axle speed sensor. As soon as there is a line discontinuity, this is displayed by the central STOP warning light (H111) lighting up yellow. After the fault has been remedied, the central STOP warning light goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors. (Memory function.) Remedy: The cables and plug connectors between the rear axle pressure control module and left rear axle speed sensor must be checked for cable break or short circuit. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective left rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03302

Pressure control module, 2nd rear axle, left, wheel sensor, left: Deceleration excessive Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The sensor resistance should be between 950Ω and 1930Ω. This fault is displayed when the signal of the rear axle speed sensor fails abruptly and v > 30 km/h, and also when there is a short circuit between two speed sensor cables and the rear axle speed sensor has dropped out of its holder. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: The cables and plug connectors between the rear axle pressure control module and left rear axle speed sensor must be checked for cable break or short circuit. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective left rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

T 61

2nd edition

193

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03303

Pressure control module, 2nd rear axle, left, wheel sensor, left: Starting-off fault Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The gap between the left rear axle speed sensor and the impulse wheel is too great. This fault also occurs if v > 18 km/h is measured at n-1 wheels and no signal has been received from one wheel for longer than 20 seconds, or v > 40 km/h is measured on one speed sensor and no signal is measured at the other speed sensors for longer than 20 seconds. The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: The left rear axle speed sensor must be pushed in by hand (do not strike it!). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective left rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03304

Pressure control module, 2nd rear axle, left, wheel sensor, left: Excessive clearance Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs if the limit gap speed v > 10 km/h. The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: Check the gap between the left rear axle speed sensor and the impulse wheel. The left rear axle speed sensor must be pushed in by hand (do not strike it!). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective left rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

194

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03305

Pressure control module, 2nd rear axle, left, perpetual control, wheel sensor, left Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: Controlled wheels are monitored during anti-lock brake system (ABS) regulation. The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: The cables and plug connectors between the rear axle pressure control module and left rear axle speed sensor must be checked for cable break or short circuit. The sensor resistance should be between 950Ω and 1930Ω. Furthermore, the impulse wheel should be checked for contamination by metallic particles, the gap between the left rear axle speed sensor and the impulse wheel should be checked, the impulse wheel should be checked for damage (missing teeth), the impulse wheel should be checked for damage (wobble < 0.3 mm) and the impulse wheel should be checked for the right number of teeth and any pitch error. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective left rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03306

Pressure control module, 2nd rear axle, left, long instability, wheel sensor, left Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs if a wheel controlled by the anti-lock brake system (ABS) is not being regulated in a stable manner after 20 seconds. The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: The cables and the plug connectors to the left rear axle speed sensor must be checked for cable break, short circuit and chang points. Furthermore, the brake cylinders should be checked for residual pressure, the impulse wheel should be checked for contamination by metallic particles, the impulse wheel should be checked for damage (missing teeth), the impulse wheel should be checked for damage (wobble < 0.3 mm) and the impulse wheel should be checked for the right number of teeth and any pitch error. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective left rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

T 61

2nd edition

195

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03307

Pressure control module, 2nd rear axle, left, pulse ring fault, wheel sensor, left Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: The impulse wheel should be checked for contamination by metallic particles, the impulse wheel should be checked for damage (missing teeth), the impulse wheel should be checked for damage (wobble < 0.3 mm) and the impulse wheel should be checked for the right number of teeth and any pitch error. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective left rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03308

Pressure control module, 2nd rear axle, left, fault on lifting axle, wheel sensor, left Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs if one of the two lifting axle wheels is turning at v < 15 km/h, the other lifting axle wheel is turning with the vehicle speed and the speed of the vehicle is > 30 km/h. Remedy: Check that both wheels of the lifting axle are either in the air or on the ground. Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective left rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03309 03310

196

Pressure control module, 2nd rear axle, left, no valid fault denition

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03311

Pressure control module, 2nd rear axle, left, discontinuity, short-circuit, wheel sensor, right Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The sensor resistance should be between 950Ω and 1930Ω. This fault is displayed if a voltage < 1 V or > 4 V is measured at the right rear axle speed sensor. As soon as there is a cable break, this is indicated by the central STOP warning light (H111) lighting up yellow. After the fault has been rectied, the central STOP warning light goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: The cables and plug connectors between the rear axle pressure control module and right rear axle speed sensor must be checked for cable break or short circuit. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective right rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03312

Pressure control module, 2nd rear axle, left, wheel sensor, right: Deceleration excessive Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The sensor resistance should be between 950Ω and 1930Ω. This fault is displayed when the signal of the right rear axle speed sensor fails abruptly and v > 30 km/h, and also when there is a short circuit between two speed sensor cables and the right rear axle speed sensor has dropped out of its holder. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: The cables and plug connectors between the rear axle pressure control module and right rear axle speed sensor must be checked for cable break or short circuit. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective right rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

T 61

2nd edition

197

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03313

Pressure control module, 2nd rear axle, left, wheel sensor, right: Starting-off fault Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The gap between the right rear axle speed sensor and the impulse wheel is too great. This fault also occurs if v > 18 km/h is measured at n-1 wheels and no signal has been received from one wheel for longer than 20 seconds, or v > 40 km/h is measured on one speed sensor and no signal is measured at the other speed sensors for longer than 20 seconds. The wheel speeds and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: The right rear axle speed sensor must be pushed in by hand (do not strike it!). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective right rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03314

Pressure control module, 2nd rear axle, left, wheel sensor, right: Excessive clearance Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs when the gap speed v > 10 km/h is calculated. The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: Check the gap between the right rear axle speed sensor and the impulse wheel. The right rear axle speed sensor must be pushed in by hand (do not strike it!). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective right rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

198

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03315

Pressure control module, 2nd rear axle, left, perpetual control, wheel sensor, right Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The wheels are controlled and monitored during intervention by the anti-lock brake system (ABS). The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: The cables and plug connectors between the left rear axle pressure control module and right rear axle speed sensor must be checked for cable break or short circuit. The sensor resistance should be between 950Ω and 1930Ω. Furthermore, the impulse wheel should be checked for contamination by metallic particles, the gap between the rear axle speed sensor and the impulse wheel should be checked, the impulse wheel should be checked for damage (missing teeth), the impulse wheel should be checked for damage (wobble < 0.3 mm) and the impulse wheel should be checked for the right number of teeth and any pitch error. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is regulated according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective right rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03316

Pressure control module, 2nd rear axle, left, long instability, wheel sensor, right Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs if a wheel controlled by the anti-lock brake system (ABS) is not being regulated in a stable manner after 20 seconds. The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: The cables and the plug connectors to the right rear axle speed sensor must be checked for cable break, short circuit and chang points. Furthermore, the brake cylinders should be checked for residual pressure, the impulse wheel should be checked for contamination by metallic particles, the impulse wheel should be checked for damage (missing teeth), the impulse wheel should be checked for damage (wobble < 0.3 mm) and the impulse wheel should be checked for the right number of teeth and any pitch error. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective right rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

T 61

2nd edition

199

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03317

Pressure control module, 2nd rear axle, left, pulse ring fault, wheel sensor, right Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: The impulse wheel should be checked for contamination by metallic particles, the impulse wheel should be checked for damage (missing teeth), the impulse wheel should be checked for damage (wobble < 0.3 mm) and the impulse wheel should be checked for the right number of teeth and any pitch error. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is regulated according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective right rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03318

Pressure control module, 2nd rear axle, left, fault on lifting axle, wheel sensor, right Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs if one of the two lifting axle wheels is turning at v < 15 km/h, the other lifting axle wheel is turning with the vehicle speed and the speed of the vehicle is > 30 km/h. Remedy: Check that both wheels of the lifting axle are either in the air or on the ground. Emergency function (function level 6): The brake pressure in the affected control channel is regulated according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective right rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03319

Pressure control module, 2nd rear axle, left, no valid fault denition

03320

Pressure control module, 2nd rear axle, left, fault, voltage supply, brake wear sensor Fault indication: Central STOP warning light (H111) lights up yellow and the brake wear indicator check lamp comes on (appears as a pictogram on the display). Effect of fault: The 5 V voltage at the rear axle pressure control module - output between voltage supply and ground should be 5 V (±0.45 V) after braking (approx. 2 seconds after the brake is released). Remedy: The 5 V cable to the 3rd axle left brake sensor should be checked for short circuit or parallel connection (pin 4: 5 V voltage supply) the cables and plug connectors to the 3rd axle brake sensor left (pin 3: Signal from left brake sensor), The 1st axle brake sensor left itself and the ground connection of the sensor (pin 3: ground) should be checked. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 3): Lining wear monitoring has failed. All other EBS functions are present.

200

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03321

Pressure control module, rear axle, left, left brake wear sensor out of permitted value range Fault indication: Central STOP warning light (H111) lights up yellow and the brake wear indicator check lamp comes on (appears as a pictogram on the display). Effect of fault: The 5 V voltage at the rear axle pressure control module - output between voltage supply and ground should be 5 V (±0.45 V) after braking (approx. 2 seconds after the brake is released). The voltages can be read out using MAN-cats® II. The connected 3rd axle brake sensor left must be compatible with end of line (EOL). Remedy: The 5 V cable to the 3rd axle left brake sensor should be checked for short circuit or parallel connection (pin 4: 5 V voltage supply) The signal line to the 3rd axle brake sensor left should be checked for cable break, short circuit or parallel connection (pin 3: Signal from 3rd axle brake sensor left) and the ground connection of the sensor (pin 1: ground) should be checked. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 3): Lining wear monitoring has failed. All other EBS functions are present.

03322

Pressure control module, 2nd rear axle, left, right brake wear sensor out of permitted value range Fault indication: Central STOP warning light (H111) lights up yellow and the brake wear indicator check lamp comes on (appears as a pictogram on the display). Effect of fault: The 5 V voltage at the left rear axle pressure control module - output between voltage supply and ground should be 5 V (±0.45 V) after braking (approx. 2 seconds after the brake is released). These voltages are read out using MAN-cats® II. The connected brake sensor must be end-of-line (EOL) compatible. Remedy: The 5 V cable to the brake sensor should be checked for cable break, short-circuit or parallel connection (pin 4: 5V voltage supply), The signal line to the brake sensor should be checked for cable break, short circuit or parallel connection (pin 3: Signal from brake sensor to left rear axle pressure control module) and the sensor ground connection (pin 1: ground) should be checked. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 3): The brake wear monitor has failed. All other EBS functions are available.

T 61

2nd edition

201

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03323

Pressure control module, 2nd rear axle, left, pressure sensor outside permitted value range Fault indication: Central STOP warning light (H111) comes on red at the same time as the red check lamp for the general brake check (H108) Effect of fault: There is an internal pressure control module malfunction or the plausibility check of the pressure control is not taking place successfully. If the fault reoccurs after the fault memory has been deleted then replace the rear axle pressure control module. If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. These pressures are read out using MAN-cats® II (not if there is a fault). The measuring range of the pressure sensors is between 0 bar and 13 bar. Remedy: Delete the fault memory. Furthermore, the correct functioning of the rear axle pressure control module should be checked. Pressure modulation should be performed via diagnosis (with MAN-cats® II) and a comparison with an external pressure gauge. Check the supply lines to the left rear axle pressure control module. Replace the defective rear axle pressure control module. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected left rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03324

Pressure control module, 2nd rear axle, left, time for “Current pressure” inquiry too long Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: There is an internal pressure control module malfunction or the plausibility check of the pressure control is not taking place successfully. If the fault reoccurs after the fault memory has been deleted then replace the rear axle pressure control module. If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. Remedy: Delete the fault memory. The correct function of the rear axle pressure control module must be checked. Replace the defective rear axle pressure control module. The mufer of the rear axle pressure control module must be checked for sufcient air ow. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no ALB and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

202

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03325

Pressure control module, 2nd rear axle, left, poor ventilation Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: If ventilation of the rear axle pressure control module is hindered whilst the brake is being released, this falsies the measurement results. This can be caused by a blocked or hardened exhaust silencer element. This fault message can also be caused if the distance from surrounding objects is too short. A defective exhaust valve or a defective pressure sensor in the rear axle pressure control module (Y264) can trigger this fault message. There is an internal pressure control module malfunction or the plausibility check of the pressure control is not taking place successfully. If the fault reoccurs after the fault memory has been deleted, then replace the rear axle pressure control module. If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. These pressures are read out using MAN-cats® II. Remedy: Delete the fault memory. The ventilation openings (connection 3 for venting) of the rear axle pressure control module must be checked. Furthermore, check for correct functioning of the rear axle pressure control module. Replace the defective rear axle pressure control module. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governing) are deactivated.

03326

Pressure control module, 2nd rear axle, left, excessive pressure during the pulse test Fault indication: Central STOP warning light (H111) comes on red at the same time as the red check lamp for the general brake check (H108) Effect of fault: This malfunction occurs if the automatic pulse test after the ignition is switched on does not cover the set pressure range. This occurs if the pneumatic lines are squeezed or blocked, or the pulse test length is not adapted to the volume of the brake cylinders used, or the rear axle pressure control module is not functioning. These values are read out using MAN-cats® II. If the fault reoccurs after the fault memory has been deleted then replace the left rear axle pressure control module. Remedy: Delete the fault memory. The brake function diagram (with trailer) was used when referring to the pneumatic connections listed below between the individual components. The pneumatic connections of the rear axle pressure control module must be checked, as follows: The pneumatic lines from rear axle pressure control module (connection 21) to the left combination cylinder, rear axle pressure control module (connection 4) to the service brake valve and the supply lines of the rear axle pressure control module (connection 1) Connection 1 (supply line) is responsible for the energy supply. Connection 21 is responsible for dissipating the energy, while connection 4 is provided for the back-up circuit (back-up circuit solenoid valve). Furthermore, check for correct functioning of the pressure control module. If it is not functioning, replace the defective rear axle pressure control module. The test pulse duration in the end of line (EOL) data memory must be checked using MAN-cats® II. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). The pneumatic connections can be found in the functional description and in the function diagrams. Emergency function: The EBS is functioning without restrictions.

T 61

2nd edition

203

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03327

Pressure control module, 2nd rear axle, left, residual pressure after braking Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: The fault occurs if the pneumatic lines are blocked or contaminated, or the rear axle pressure control module is not functioning, or the service brake valve with integrated brake power sensor is not functioning. Remedy: The pressure in connection 4 (rear axle pressure control module (connection 4) service brake valve) of the back-up circuit must be checked. The pneumatic connections of the rear axle pressure control module (Y264) must be checked, as follows: The pneumatic lines from rear axle pressure control module (connection 21) to the left combination cylinder, rear axle pressure control module (connection 4) and to the service brake valve and the supply lines of the rear axle pressure control module (connection 1) Connection 1 (supply line) is responsible for the energy supply. Connection 21 is responsible for dissipating the energy, while connection 4 is provided for the back-up circuit (back-up circuit solenoid valve). Furthermore, check for correct functioning of the pressure control module. If it is not functioning, replace the defective rear axle pressure control module. The pressure gradient of the service brake valve with integrated brake power sensor (B337) in connection 4 of the back-up circuit (to the back-up circuit solenoid valve) must be checked. Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03328

Pressure control module, 2nd rear axle, left, pressure sensor fault without braking Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: The fault occurs if the pneumatic lines are blocked or contaminated, or the rear axle pressure control module is not functioning, or the service brake valve with integrated brake power sensor is not functioning. Remedy: The pressure in connection 4 (rear axle pressure control module (connection 4) service brake valve) of the back-up circuit must be checked. The pneumatic connections of the rear axle pressure control module (Y264) must be checked, as follows: The pneumatic lines from rear axle pressure control module (connection 21) to the left combination cylinder, rear axle pressure control module (connection 4) and to the service brake valve and the supply lines of the rear axle pressure control module (connection 1) Connection 1 (supply line) is responsible for the energy supply. Connection 21 is responsible for dissipating the energy, while connection 4 is provided for the back-up circuit (back-up circuit solenoid valve). Furthermore, check for correct functioning of the pressure control module. If it is not functioning, replace the defective rear axle pressure control module. The pressure gradient of the service brake valve with integrated brake power sensor (B337) in connection 4 of the back-up circuit (to the back-up circuit solenoid valve) must be checked. Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03329

204

Pressure control module, 2nd rear axle, left, no valid fault denition

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03330

Pressure control module, 2nd rear axle, left, wheel sensor IC defective Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Remedy: Delete the fault memory. Remedy: There is an internal pressure control module malfunction. If the fault reoccurs after the fault memory has been deleted then replace the rear axle pressure control module (Y264). If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03331

Pressure control module, 2nd rear axle, left, faulty backup valve feedback Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: Delete the fault memory. Furthermore, check for correct functioning of the rear axle pressure control module. If it is not functioning, replace the rear axle pressure control module. Remedy: There is a fault on the signal path for the back-up circuit solenoid valve (back-up valve) in the rear axle pressure control module. If the fault reoccurs after the fault memory has been deleted, then replace the rear axle pressure control module. If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03332

Pressure control module, 2nd rear axle, left, defective inlet valve, feedback Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: Delete the fault memory. Furthermore, check for correct functioning of the rear axle pressure control module. If it is not functioning, replace the rear axle pressure control module. Remedy: There is a fault on the signal path for the back-up circuit solenoid valve (back-up valve) in the rear axle pressure control module. If the fault reoccurs after the fault memory has been deleted, then replace the rear axle pressure control module. If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

T 61

2nd edition

205

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03333

Pressure control module, 2nd rear axle, left, defective inlet and back-up valve, feedback Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: Delete the fault memory. Furthermore, check for correct functioning of the rear axle pressure control module. If it is not functioning, replace the rear axle pressure control module. Remedy: There is a fault on the signal path for the back-up circuit solenoid valve (back-up valve) in the rear axle pressure control module. If the fault reoccurs after the fault memory has been deleted, then replace the rear axle pressure control module. If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03334

Pressure control module, 2nd rear axle, left, defective outlet valve, feedback Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: Delete the fault memory. Furthermore, check for correct functioning of the rear axle pressure control module. If it is not functioning, replace the rear axle pressure control module. Remedy: There is a fault on the signal path for the back-up circuit solenoid valve (back-up valve) in the rear axle pressure control module. If the fault reoccurs after the fault memory has been deleted, then replace the rear axle pressure control module. If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03335

Pressure control module, 2nd rear axle, left, defective outlet and back-up valve, feedback Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: Delete the fault memory. Furthermore, check for correct functioning of the rear axle pressure control module. If it is not functioning, replace the rear axle pressure control module. Remedy: There is a fault on the signal path for the back-up circuit solenoid valve (back-up valve) in the rear axle pressure control module. If the fault reoccurs after the fault memory has been deleted, then replace the rear axle pressure control module. If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

206

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03336

Pressure control module, 2nd rear axle, left, defective outlet and inlet valve, feedback Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: Delete the fault memory. Furthermore, check for correct functioning of the rear axle pressure control module. If it is not functioning, replace the rear axle pressure control module. Remedy: There is a fault on the signal path for the back-up circuit solenoid valve (back-up valve) in the rear axle pressure control module. If the fault reoccurs after the fault memory has been deleted, then replace the rear axle pressure control module. If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03337

Pressure control module, 2nd rear axle, left, defective outlet and inlet and back-up valve, feedback Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: Delete the fault memory. Furthermore, check for correct functioning of the rear axle pressure control module. If it is not functioning, replace the rear axle pressure control module. Remedy: There is a fault on the signal path for the back-up circuit solenoid valve (back-up valve) in the rear axle pressure control module. If the fault reoccurs after the fault memory has been deleted, then replace the rear axle pressure control module. If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03338 03339

Pressure control module, 2nd rear axle, left, no valid fault denition

T 61

2nd edition

207

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03340

Pressure control module, 2nd rear axle, left, no CAN reception from module Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: CAN brake Baud rate: 250 kbaud Peak voltage values: Recessive CAN Low 2.5 V, CAN High 2.5 V; dominant CAN Low 1.5 V, CAN High 3.5 V Header length: 11-bit Message length: 8-byte Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Also check from A402 pin X1/12 (pressure control module input ground) and from A402 pin X1/8 (voltage supply terminal 30) of the EBS control unit (A402). Remedy: The connections from the EBS control unit (A402) to the rear axle pressure control module (ground, 24 V voltage supply, CAN High and CAN Low) must be checked (in particular, look for chang points). Check the plug connectors on the EBS electronic control unit and on the rear axle pressure control module. Furthermore, the ground connections of all connected pressure control modules should be checked. Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03341

Pressure control module, 2nd rear axle, left, software incompatibility between control unit and pressure control module Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Remedy: The EBS electronic control unit (A402) or the rear axle pressure control module must be replaced by one with a compatible software version. Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03342

Pressure control module, 2nd rear axle, left, 12/24 volt incompatibility between control unit and pressure control module Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Remedy: The EBS electronic control unit (A402) or the rear axle pressure control module must be replaced by one with a compatible voltage version. Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

208

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03343

Pressure control module, 2nd rear axle, left, high cycle protection, inlet valve active, pressure < 4 bar Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: This malfunction occurs if the nominal value is not achieved for a relatively long time when the brake cylinder pressure is low. If the supply pressure < 4 bar, a fault message is triggered after the pressure sensor for the supply pressure has been checked. The ECAM message on CAN J1939 (reservoir pressure circuits 1 and 2) must be checked. The current values for the pressure sensor of the pressure control module are read out using MAN-cats® II. Remedy: The correct function of the rear axle pressure control module must be checked. If it is not functioning, replace the rear axle pressure control module. Furthermore, the continuity of the pneumatic supply lines to the pressure control modules must be checked. Sensor inputs 1 and 2 of the supply pressure measurement must be checked. (External monitoring of the central STOP warning light (H111) and the general brake check lamp (H108) (pressure sensor for the supply pressure – is installed in the front axle pressure control module) must be checked.) Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03344

Pressure control module, 2nd rear axle, left, arithmetic test not successful Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Remedy: Delete the fault memory. Remedy: If the fault reoccurs after the fault memory has been deleted then replace the rear axle pressure control module. Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

T 61

2nd edition

209

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03345

Pressure control module, 2nd rear axle, left, wheel adjustment fault, wheel sensor, left Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The left rear axle speed sensor transfers this information to the EBS control unit. This malfunction occurs if the calculated wheel speed deviates by more than 9 % between the axles. This is displayed by the yellow central STOP warning light (H111) and the fault is stored in the EBS control unit. Fault-free operation is possible until the next switch-off if the wheel speed after compensation deviates by < 9 %. However, the fault remains in the fault memory. The compensated wheel diameter continues to be output until the maximum permitted deviation stored in the end of line (EOL) is reached (e.g. 25 %). Diameter compensation is operating when the road speed is in the range from 25 km/h to 100 km/h, the brake is not active, no anti-lock brake system (ABS) or anti-spin regulator (ASR) intervention is taking place and the road speed is almost constant. Remedy: The tyre sizes on the front and rear axle must be checked. The ASR spin threshold increase button (S256) must be actuated for a driving distance of at least 10 km at a road speed of more than 25 km/h. The ASR info check lamp (H140) ashes (information display). The fault memory of the EBS electronic control unit (A402) must be deleted and then the control unit should be reset. Emergency function (function level 6): The brake pressure in the affected control channel is regulated according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03346

Pressure control module, 2nd rear axle, left, wheel adjustment fault, wheel sensor, right Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The rear axle speed sensor transfers this information to the EBS control unit. This malfunction occurs if the calculated wheel speed deviates by more than 9 % between the axles. This is displayed by the central STOP warning light (H111) and the fault is stored in the EBS control unit. Fault-free operation is possible until the next switch-off if the wheel speed after compensation deviates by < 9 %. However, the fault remains in the fault memory. The compensated wheel diameter continues to be output until the maximum permitted deviation stored in the end of line (EOL) is reached (e.g. 25 %) Diameter compensation is operating when the road speed is in the range from 25 km/h to 100 km/h, the brake is not active, no anti-lock brake system (ABS) or anti-spin regulator (ASR) intervention is taking place and the road speed is almost constant. Remedy: The tyre sizes on the front and rear axle must be checked. The ASR spin threshold increase button (S256) must be actuated for a driving distance of at least 10 km at a road speed of more than 25 km/h. The ASR info check lamp (H140) ashes. The fault memory of the EBS electronic control unit (A402) must be deleted and then the control unit should be reset. Emergency function (function level 6): The brake pressure in the affected control channel is regulated according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

210

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03347

Pressure control module, 2nd rear axle, left, fault at voltage supply, axle load sensor Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The supply voltage must be checked - permitted supply voltage range at the rear axle pressure control module: The voltage measured between pin 3/4 and pin 3/1 at the rear axle pressure control module should have the voltage value 5 V ±0.45 V. Remedy: The cables and plug connectors between the rear axle pressure control module and the rear axle automatic load-balancing sensor must be checked for short circuits or line discontinuities, between pin 3/4 (rear axle pressure control module) and pin 1 (voltage supply, ALB sensor, rear axle), between pin 3/1 (rear axle pressure control module) and pin 2 (ground, ALB sensor, rear axle), between pin 3/3 (rear axle pressure control module) and pin 3 (signal line, ALB sensor, rear axle). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 5): The EBS system operates with the value “L = ALB-Fehl” programmed via EOL for brake pressure distribution during braking with the service brakes (electropneumatic brake system EPB) and with the automatic load balancing (ALB) value L = 0 in the anti-lock brake system (ABS) for IRM (individual regulation modied) at the front axle.

03348

Pressure control module, 2nd rear axle, left, pressure differential on pressure control module pair, front axle Fault indication: Central STOP warning light (H111) comes on red at the same time as the red check lamp for the general brake check (H108) Effect of fault: This malfunction occurs when a pressure differential > 0.8 bar occurs for longer than 3 seconds on one axle in one of the pressure control modules. The current values for the pressure sensors of the rear axle pressure control module are read out using MAN-cats® II. Remedy: The correct function of the rear axle pressure control module must be checked. If it is not functioning, replace the rear axle pressure control module. The brake function diagram (with trailer) was used when referring to the pneumatic connections listed below between the individual components. Free passage of the pneumatic supply lines to the rear axle pressure control module must be checked: The rear axle pressure control module is supplied by the 1-cylinder compressor (G1.1 connection 2) and safety valve 17+2 bar (G5.121) to the ECAM 12.5 bar (G25.300 connection 1). From the ECAM 12.5 bar (G25.300 connection 22), the line runs to the compressed air tank 40 l, 12.5 bar (G50.300), from where the service brake valve (G7.302 connection 12) is connected to connection 1 of the rear axle pressure control module. Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03349

Pressure control module, 2nd rear axle, left, no valid fault denition

T 61 2nd edition

211

DEVICE DESCRIPTION Fault messages, pressure control module (2-channel) on the 2nd rear axle (right-hand side) SPN

SPN-Plain text Description

03350

Pressure control module, 2nd rear axle, right, no fault

03351

Pressure control module, 2nd rear axle, right, discontinuity, short-circuit, wheel sensor, left Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The sensor resistance should be between 950Ω and 1930Ω. This fault is displayed if a voltage < 1 V or > 4 V is measured at the left rear axle speed sensor. As soon as there is a cable break, this is indicated by the central STOP warning light (H111) lighting up yellow. After the fault has been remedied, the central STOP warning light goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors. (Memory function.) Remedy: The cables and plug connectors between the rear axle pressure control module and left rear axle speed sensor must be checked for cable break or short circuit. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective left rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03352

Pressure control module, 2nd rear axle, right, wheel sensor, left: Deceleration excessive Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The sensor resistance should be between 950Ω and 1930Ω. This fault is displayed when the signal of the rear axle speed sensor fails abruptly and v > 30 km/h, and also when there is a short circuit between two speed sensor cables and the rear axle speed sensor has dropped out of its holder. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: The cables and plug connectors between the rear axle pressure control module and left rear axle speed sensor must be checked for cable break or short circuit. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective left rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

212

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03353

Pressure control module, 2nd rear axle, right, wheel sensor, left: Starting-off fault Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The gap between the left rear axle speed sensor and the impulse wheel is too great. This fault also occurs if v > 18 km/h is measured at n-1 wheels and no signal has been received from one wheel for longer than 20 seconds, or v > 40 km/h is measured on one speed sensor and no signal is measured at the other speed sensors for longer than 20 seconds. The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: The left rear axle speed sensor must be pushed in by hand (do not strike it!). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective left rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03354

Pressure control module, 2nd rear axle, right, wheel sensor, left: Excessive clearance Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs if the limit gap speed v > 10 km/h. The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: Check the gap between the left rear axle speed sensor and the impulse wheel. The left rear axle speed sensor must be pushed in by hand (do not strike it!). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective left rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

T 61

2nd edition

213

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03355

Pressure control module, 2nd rear axle, right, perpetual control, wheel sensor, left Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: Controlled wheels are monitored during anti-lock brake system (ABS) regulation. The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: The cables and plug connectors between the rear axle pressure control module and left rear axle speed sensor must be checked for cable break or short circuit. The sensor resistance should be between 950Ω and 1930Ω. Furthermore, the impulse wheel should be checked for contamination by metallic particles, the gap between the left rear axle speed sensor and the impulse wheel should be checked, the impulse wheel should be checked for damage (missing teeth), the impulse wheel should be checked for damage (wobble < 0.3 mm) and the impulse wheel should be checked for the right number of teeth and any pitch error. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective left rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03356

Pressure control module, 2nd rear axle, right, long instability, wheel sensor, left Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs if a wheel controlled by the anti-lock brake system (ABS) is not being regulated in a stable manner after 20 seconds. The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: The cables and the plug connectors to the left rear axle speed sensor must be checked for cable break, short circuit and chang points. Furthermore, the brake cylinders should be checked for residual pressure, the impulse wheel should be checked for contamination by metallic particles, the impulse wheel should be checked for damage (missing teeth), the impulse wheel should be checked for damage (wobble < 0.3 mm) and the impulse wheel should be checked for the right number of teeth and any pitch error. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective left rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

214

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03357

Pressure control module, 2nd rear axle, right, pulse ring fault, wheel sensor, left Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: The impulse wheel should be checked for contamination by metallic particles, the impulse wheel should be checked for damage (missing teeth), the impulse wheel should be checked for damage (wobble < 0.3 mm) and the impulse wheel should be checked for the right number of teeth and any pitch error. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective left rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03358

Pressure control module, 2nd rear axle, right, fault on lifting axle, wheel sensor, left Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs if one of the two lifting axle wheels is turning at v < 15 km/h, the other lifting axle wheel is turning with the vehicle speed and the speed of the vehicle is > 30 km/h. Remedy: Check that both wheels of the lifting axle are either in the air or on the ground. Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective left rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03359 03360

Pressure control module, 2nd rear axle, right, no valid fault denition

T 61

2nd edition

215

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03361

Pressure control module, 2nd rear axle, right, discontinuity, short-circuit, wheel sensor, right Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The sensor resistance should be between 950Ω and 1930Ω. This fault is displayed if a voltage < 1 V or > 4 V is measured at the right rear axle speed sensor. As soon as there is a line discontinuity, this is displayed by the central STOP warning light (H111) lighting up yellow. After the fault has been rectied, the central STOP warning light goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: The cables and plug connectors between the rear axle pressure control module and right rear axle speed sensor must be checked for cable break or short circuit. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective right rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03362

Pressure control module, 2nd rear axle, right, wheel sensor, right: Deceleration excessive Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The sensor resistance should be between 950Ω and 1930Ω. This fault is displayed when the signal of the right rear axle speed sensor fails abruptly and v > 30 km/h, and also when there is a short circuit between two speed sensor cables and the right rear axle speed sensor has dropped out of its holder. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: The cables and plug connectors between the rear axle pressure control module and right rear axle speed sensor must be checked for cable break or short circuit. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective right rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

216

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03363

Pressure control module, 2nd rear axle, right, wheel sensor, right: Starting-off fault Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The gap between the right rear axle speed sensor and the impulse wheel is too great. This fault also occurs if v > 18 km/h is measured at n-1 wheels and no signal has been received from one wheel for longer than 20 seconds, or v > 40 km/h is measured on one speed sensor and no signal is measured at the other speed sensors for longer than 20 seconds. The wheel speeds and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: The right rear axle speed sensor must be pushed in by hand (do not strike it!). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective right rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03364

Pressure control module, 2nd rear axle, right, wheel sensor, right: Excessive clearance Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs when the gap speed v > 10 km/h is calculated. The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: Check the gap between the right rear axle speed sensor and the impulse wheel. The right rear axle speed sensor must be pushed in by hand (do not strike it!). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective right rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

T 61

2nd edition

217

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03365

Pressure control module, 2nd rear axle, right, perpetual control, wheel sensor, right Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The wheels are controlled and monitored during intervention by the anti-lock brake system (ABS). The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: The cables and plug connectors between the rear axle pressure control module and right rear axle speed sensor must be checked for cable break or short circuit. The sensor resistance should be between 950Ω and 1930Ω. Furthermore, the impulse wheel should be checked for contamination by metallic particles, the gap between the rear axle speed sensor and the impulse wheel should be checked, the impulse wheel should be checked for damage (missing teeth), the impulse wheel should be checked for damage (wobble < 0.3 mm) and the impulse wheel should be checked for the right number of teeth and any pitch error. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is regulated according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective right rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03366

Pressure control module, 2nd rear axle, right, long instability, wheel sensor, right Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs if a wheel controlled by the anti-lock brake system (ABS) is not being regulated in a stable manner after 20 seconds. The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: The cables and the plug connectors to the right rear axle speed sensor must be checked for cable break, short circuit and chang points. Furthermore, the brake cylinders should be checked for residual pressure, the impulse wheel should be checked for contamination by metallic particles, the impulse wheel should be checked for damage (missing teeth), the impulse wheel should be checked for damage (wobble < 0.3 mm) and the impulse wheel should be checked for the right number of teeth and any pitch error. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is controlled according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective right rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

218

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03367

Pressure control module, 2nd rear axle, right, pulse ring fault, wheel sensor, right Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The wheel speed and the limit gap are read out using MAN-cats® II. Differences in the tyre diameters occur due to mixed tyres or tyre wear. The specied limit values from 0.8 to 1.2 must not be violated in this case. After the fault has been remedied, the yellow central STOP warning light (H111) goes out providing an adequate signal (v > 20 km/h) is measured at all speed sensors (memory function). Remedy: The impulse wheel should be checked for contamination by metallic particles, the impulse wheel should be checked for damage (missing teeth), the impulse wheel should be checked for damage (wobble < 0.3 mm) and the impulse wheel should be checked for the right number of teeth and any pitch error. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 6): The brake pressure in the affected control channel is regulated according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective right rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03368

Pressure control module, 2nd rear axle, right, fault on lifting axle, wheel sensor, right Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs if one of the two lifting axle wheels is turning at v < 15 km/h, the other lifting axle wheel is turning with the vehicle speed and the speed of the vehicle is > 30 km/h. Remedy: Check that both wheels of the lifting axle are either in the air or on the ground. Emergency function (function level 6): The brake pressure in the affected control channel is regulated according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective right rear axle speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03369

Pressure control module, 2nd rear axle, right, no valid fault denition

03370

Pressure control module, 2nd rear axle, right, fault, voltage supply, brake wear sensor Fault indication: Central STOP warning light (H111) lights up yellow and the brake wear indicator check lamp comes on (appears as a pictogram on the display). Effect of fault: The 5 V voltage at the rear axle pressure control module - output between voltage supply and ground should be 5 V (±0.45 V) after braking (approx. 2 seconds after the brake is released). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Remedy: The 5 V cable to the 3rd axle right brake sensor should be checked for short circuit or parallel connection (pin 4: 5 V voltage supply) the cables and plug connectors to the 3rd axle brake sensor right (pin 3: Signal from 3rd axle brake sensor right), The 3rd axle brake sensor right itself and the ground connection of the sensor (pin 1: ground) should be checked. Emergency function (function level 3): Lining wear monitoring has failed. All other EBS functions are present.

T 61

2nd edition

219

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03371

Pressure control module, 2nd rear axle, right, left brake wear sensor out of permitted value range Fault indication: Central STOP warning light (H111) lights up yellow and the brake wear indicator check lamp comes on (appears as a pictogram on the display). Effect of fault: The 5 V voltage at the rear axle pressure control module - output between voltage supply and ground should be 5 V (±0.45 V) after braking (approx. 2 seconds after the brake is released). Voltages can be read out using MAN-cats® II. The connected brake sensor must be compatible with end of line (EOL). Remedy: The 5 V cable to the brake sensor should be checked for cable break, short circuit or parallel connection (pin 4: 5 V voltage supply), The signal line to the brake sensor should be checked for cable break, short circuit or parallel connection (pin 3: Signal from 2nd axle brake sensor left) and the ground connection of the sensor (pin 1: ground) should be checked. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 3): Lining wear monitoring has failed. All other EBS functions are present.

03372

Pressure control module, 2nd rear axle, right, right brake wear sensor out of permitted value range Fault indication: Central STOP warning light (H111) lights up yellow and the brake wear indicator check lamp comes on (appears as a pictogram on the display). Effect of fault: The 5 V voltage at the rear axle pressure control module - output between voltage supply and ground should be 5 V (±0.45 V) after braking (approx. 2 seconds after the brake is released). These voltages are read out using MAN-cats® II. The connected 3rd axle brake sensor right must be compatible with end of line (EOL). Remedy: The 5 V cable to the 3rd axle right brake sensor should be checked for cable break, short circuit or parallel connection (pin 4: 5 V voltage supply), The signal line to the 3rd axle brake sensor right should be checked for cable break, short circuit or parallel connection (pin 3: Signal from 3rd axle brake sensor right) and the ground connection of the sensor (pin 1: ground) should be checked. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 3): Lining wear monitoring has failed. All other EBS functions are present.

220

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03373

Pressure control module, 2nd rear axle, right, pressure sensor outside permitted value range Fault indication: Central STOP warning light (H111) comes on red at the same time as the red check lamp for the general brake check (H108) Effect of fault: There is an internal pressure control module malfunction or the plausibility check of the pressure control is not taking place successfully. If the fault reoccurs after the fault memory has been deleted then replace the rear axle pressure control module. If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. These pressures are read out using MAN-cats® II (not if there is a fault). The measuring range of the pressure sensors is between 0 bar and 13 bar. Remedy: Delete the fault memory. Furthermore, the correct functioning of the rear axle pressure control module should be checked. Pressure modulation should be performed via diagnosis (with MAN-cats® II) and a comparison with an external pressure gauge. Check the supply lines to the rear axle pressure control module. Replace the defective rear axle pressure control module. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03374

Pressure control module, 2nd rear axle, right, time for “Current pressure” inquiry too long Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: There is an internal pressure control module malfunction or the plausibility check of the pressure control is not taking place successfully. If the fault reoccurs after the fault memory has been deleted then replace the rear axle pressure control module. If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. Remedy: Delete the fault memory. The correct function of the rear axle pressure control module must be checked. Replace the defective rear axle pressure control module. The mufer of the rear axle pressure control module must be checked for sufcient air ow. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no ALB and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

T 61

2nd edition

221

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03375

Pressure control module, 2nd rear axle, right, poor ventilation Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: If the venting of the rear axle pressure control module is preventing during release of the brake, this falsies the measurement results. This can be caused by a blocked or hardened exhaust mufer element. This fault message can also be caused if the distance from surrounding objects is too short. A defective exhaust valve or a defective pressure sensor in the rear axle pressure control module can trigger this fault message. There is an internal pressure control module malfunction or the plausibility check of the pressure control is not taking place successfully. If the fault reoccurs after the fault memory has been deleted then replace the rear axle pressure control module. If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. These pressures are read out using MAN-cats® II. Remedy: Delete the fault memory. The ventilation openings (connection 3 for venting) of the rear axle pressure control module must be checked. Furthermore, check for correct functioning of the rear axle pressure control module. Replace the defective rear axle pressure control module. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governing) are deactivated.

03376

Pressure control module, 2nd rear axle, right, excessive pressure during the pulse test Fault indication: Central STOP warning light (H111) comes on red at the same time as the red check lamp for the general brake check (H108) Effect of fault: This malfunction occurs if the automatic pulse test after the ignition is switched on does not cover the set pressure range. This occurs if the pneumatic lines are squeezed or blocked, or the pulse test length is not adapted to the volume of the brake cylinders used, or the rear axle pressure control module is not functioning. These values are read out using MAN-cats® II. If the fault reoccurs after the fault memory has been deleted then replace the rear axle pressure control module. Remedy: Delete the fault memory. The brake function diagram (with trailer) was used when referring to the pneumatic connections listed below between the individual components. The pneumatic connections of the rear axle pressure control module must be checked, as follows: The pneumatic lines from rear axle pressure control module (connection 22) to the right combination cylinder, rear axle pressure control module (connection 4) to the service brake valve and the supply lines of the rear axle pressure control module (connection 1) Connection 1 (supply line) is responsible for the energy supply. Connection 22 is responsible for dissipating the energy, while connection 4 is provided for the back-up circuit (back-up circuit solenoid valve). Furthermore, check for correct functioning of the pressure control module. If it is not functioning, replace the defective rear axle pressure control module. The test pulse duration in the end of line (EOL) data memory must be checked using MAN-cats® II. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). The pneumatic connections can be found in the functional description and in the function diagrams. Emergency function: The EBS is functioning without restrictions.

222

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03377

Pressure control module, 2nd rear axle, right, residual pressure after braking Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: The fault occurs if the pneumatic lines are blocked or contaminated, or the rear axle pressure control module is not functioning, or the service brake valve with integrated brake power sensor is not functioning. Remedy: The brake function diagram (with trailer) was used when referring to the pneumatic connections listed below between the individual components. The pressure in connection 4 (rear axle pressure control module (connection 4) - service brake valve) of the back-up circuit must be checked. The pneumatic connections of the rear axle pressure control module must be checked, as follows: The pneumatic lines from rear axle pressure control module (connection 22) to the right combination cylinder, rear axle pressure control module (connection 4) to the service brake valve and the supply lines of the rear axle pressure control module (connection 1) Connection 1 (supply line) is responsible for the energy supply. Connection 22 is responsible for dissipating the energy, while connection 4 is provided for the back-up circuit (back-up circuit solenoid valve). Furthermore, check for correct functioning of the pressure control module. If it is not functioning, replace the defective rear axle pressure control module. The pressure gradient of the service brake valve with integrated brake power sensor (B337) in connection 4 of the back-up circuit (to the back-up circuit solenoid valve) must be checked. Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03378

Pressure control module, 2nd rear axle, right, pressure sensor fault without braking Effect of fault: The fault occurs if the pneumatic lines are blocked or contaminated, or the rear axle pressure control module is not functioning, or the service brake valve with integrated brake power sensor is not functioning. Fault display: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Remedy: The brake function diagram (with trailer) was used when referring to the pneumatic connections listed below between the individual components. The pressure in connection 4 (rear axle pressure control module (connection 4) - service brake valve) of the back-up circuit must be checked. The pneumatic connections of the rear axle pressure control module (Y264) must be checked, as follows: The pneumatic lines from rear axle pressure control module (connection 22) to the right combination cylinder, rear axle pressure control module (connection 4) to the service brake valve and the supply lines of the rear axle pressure control module (connection 1): Connection 1 (supply line) is responsible for the energy supply. Connection 22 is responsible for dissipating the energy, while connection 4 is provided for the back-up circuit (back-up circuit solenoid valve). Furthermore, check for correct functioning of the pressure control module. If it is not functioning, replace the defective rear axle pressure control module. The pressure gradient of the service brake valve with integrated brake power sensor (B337) in connection 4 of the back-up circuit (to the back-up circuit solenoid valve) must be checked. Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03379

Pressure control module, 2nd rear axle, right, no valid fault denition

T 61

2nd edition

223

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03380

Pressure control module, 2nd rear axle, right, wheel sensor IC defective Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Remedy: Delete the fault memory. Effect of fault: There is an internal pressure control module malfunction. If the fault reoccurs after the fault memory has been deleted then replace the rear axle pressure control module. If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03381

Pressure control module, 2nd rear axle, right, faulty backup valve feedback Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: Delete the fault memory. Furthermore, check for correct functioning of the rear axle pressure control module. If it is not functioning, replace the rear axle pressure control module. Remedy: There is a fault on the signal path for the back-up circuit solenoid valve (back-up valve) in the rear axle pressure control module. If the fault reoccurs after the fault memory has been deleted, then replace the rear axle pressure control module. If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03382

Pressure control module, 2nd rear axle, right, defective inlet valve, feedback Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: Delete the fault memory. Furthermore, check for correct functioning of the rear axle pressure control module. If it is not functioning, replace the rear axle pressure control module. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Remedy: There is a fault in the signal pathways for the back-up circuit solenoid valve (backup valve) in the rear axle pressure control module. If the fault reoccurs after the fault memory has been deleted then replace the rear axle pressure control module. If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

224

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03383

Pressure control module, 2nd rear axle, right, defective inlet and back-up valve, feedback Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault:Delete the fault memory. Furthermore, check for correct functioning of the rear axle pressure control module. If it is not functioning, replace the rear axle pressure control module. Remedy: There is a fault on the signal path for the back-up circuit solenoid valve (back-up valve) in the rear axle pressure control module. If the fault reoccurs after the fault memory has been deleted, then replace the rear axle pressure control module. If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03384

Pressure control module, 2nd rear axle, right, defective outlet valve, feedback Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: Delete the fault memory. Furthermore, check for correct functioning of the rear axle pressure control module. If it is not functioning, replace the rear axle pressure control module. Remedy: There is a fault on the signal path for the back-up circuit solenoid valve (back-up valve) in the rear axle pressure control module. If the fault reoccurs after the fault memory has been deleted, then replace the rear axle pressure control module. If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03285

Pressure control module, 2nd rear axle, right, defective outlet and back-up valve, feedback Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: Delete the fault memory. Furthermore, check for correct functioning of the rear axle pressure control module. If it is not functioning, replace the rear axle pressure control module. Remedy: There is a fault on the signal path for the back-up circuit solenoid valve (back-up valve) in the rear axle pressure control module. If the fault reoccurs after the fault memory has been deleted, then replace the rear axle pressure control module. If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

T 61

2nd edition

225

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03386

Pressure control module, 2nd rear axle, right, defective outlet and inlet valve, feedback Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: Delete the fault memory. Furthermore, check for correct functioning of the rear axle pressure control module. If it is not functioning, replace the rear axle pressure control module. Remedy: There is a fault on the signal path for the back-up circuit solenoid valve (back-up valve) in the rear axle pressure control module. If the fault reoccurs after the fault memory has been deleted, then replace the rear axle pressure control module. If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03387

Pressure control module, 2nd rear axle, right, defective outlet and inlet and back-up valve, feedback Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: Delete the fault memory. Furthermore, check for correct functioning of the rear axle pressure control module. If it is not functioning, replace the rear axle pressure control module. Remedy: There is a fault on the signal path for the back-up circuit solenoid valve (back-up valve) in the rear axle pressure control module. If the fault reoccurs after the fault memory has been deleted, then replace the rear axle pressure control module. If this fault occurs repeatedly in normal operation then the rear axle pressure control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03388 03389

226

Pressure control module, 2nd rear axle, right, no valid fault denition

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03390

Pressure control module, 2nd rear axle, right, no CAN reception from module Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: CAN brake Baud rate: 250 kbaud Peak voltage values: Recessive CAN Low 2.5 V, CAN High 2.5 V; dominant CAN Low 1.5 V, CAN High 3.5 V Header length: 11-bit Message length: 8-byte Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Also check pin X1/12 (pressure control module input ground) and pin X1/8 (voltage supply terminal 30) of the EBS control unit (A402). Remedy: The connections from the EBS control unit (A402) to the rear axle pressure control module (ground, 24 V voltage supply, CAN High and CAN Low) must be checked (in particular, look for chang points). Check the plug connectors on the EBS electronic control unit and on the rear axle pressure control module. Furthermore, the ground connections of all connected pressure control modules should be checked. Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03391

Pressure control module, 2nd rear axle, right, software incompatibility between control unit and pressure control module Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Remedy: The EBS electronic control unit (A402) or the rear axle pressure control module must be replaced by one with a compatible software version. Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03392

Pressure control module, 2nd rear axle, right, 12/24 volt incompatibility between control unit and pressure control module Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Remedy: The EBS electronic control unit (A402) or the rear axle pressure control module must be replaced by one with a compatible voltage version. Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

T 61

2nd edition

227

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03393

Pressure control module, 2nd rear axle, right, high cycle protection, inlet valve active, pressure < 4 bar Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. Effect of fault: This malfunction occurs if the nominal value is not achieved for a relatively long time when the brake cylinder pressure is low. If the supply pressure < 4 bar, a fault message is triggered after the pressure sensor for the supply pressure has been checked. The ECAM message on CAN J1939 (reservoir pressure circuits 1 and 2) must be checked. The current values for the pressure sensor of the pressure control module are read out using MAN-cats® II. Remedy: The correct function of the rear axle pressure control module must be checked. If it is not functioning, replace the rear axle pressure control module. Furthermore, the continuity of the pneumatic supply lines to the pressure control modules must be checked. Sensor inputs 1 and 2 of the supply pressure measurement must be checked. (External monitoring of the central STOP warning light (H111) and the general brake check lamp (H108) (pressure sensor for the supply pressure – is installed in the front axle pressure control module) must be checked.) Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03394

Pressure control module, 2nd rear axle, right, arithmetic test not successful Fault indication: Central STOP warning light (H111) lights up red and, at the same time, the check lamp for the general brake check (H108) lights up red. RemedyDelete the fault memory. Remedy:If the fault reoccurs after the fault memory has been deleted then replace the rear axle pressure control module. Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

228

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03395

Pressure control module, 2nd rear axle, right, wheel adjustment fault, wheel sensor, left Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The left rear axle speed sensor transfers this information to the EBS control unit. This malfunction occurs if the calculated wheel speed deviates by more than 9 % between the axles. This is displayed by the yellow central STOP warning light (H111) and the fault is stored in the EBS control unit. Fault-free operation is possible until the next switch-off if the wheel speed after compensation deviates by < 9 %. However, the fault remains in the fault memory. The compensated wheel diameter continues to be output until the maximum permitted deviation stored in the end of line (EOL) is reached (e.g. 25 %). Diameter compensation is operating when the road speed is in the range from 25 km/h to 100 km/h, the brake is not active, no anti-lock brake system (ABS) or anti-spin regulator (ASR) intervention is taking place and the road speed is almost constant. Remedy: The tyre sizes on the front and rear axle must be checked. The ASR spin threshold increase button (S256) must be actuated for a driving distance of at least 10 km at a road speed of more than 25 km/h. The ASR info check lamp (H140) ashes (information display). The fault memory of the EBS electronic control unit (A402) must be deleted and then the control unit should be reset. Emergency function (function level 6): The brake pressure in the affected control channel is regulated according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

03396

Pressure control module, 2nd rear axle, right, wheel adjustment fault, wheel sensor, right Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The rear axle speed sensor transfers this information to the EBS control unit. This malfunction occurs if the calculated wheel speed deviates by more than 9 % between the axles. This is displayed by the central STOP warning light (H111) and the fault is stored in the EBS control unit. Fault-free operation is possible until the next switch-off if the wheel speed after compensation deviates by < 9 %. However, the fault remains in the fault memory. The compensated wheel diameter continues to be output until the maximum permitted deviation stored in the end of line (EOL) is reached (e.g. 25 %) Diameter compensation is operating when the road speed is in the range from 25 km/h to 100 km/h, the brake is not active, no anti-lock brake system (ABS) or anti-spin regulator (ASR) intervention is taking place and the road speed is almost constant. Remedy: The tyre sizes on the front and rear axle must be checked. The ASR spin threshold increase button (S256) must be actuated for a driving distance of at least 10 km at a road speed of more than 25 km/h. The ASR info check lamp (H140) ashes. The fault memory of the EBS electronic control unit (A402) must be deleted and then the control unit should be reset. Emergency function (function level 6): The brake pressure in the affected control channel is regulated according to the electrical nominal value (by the electropneumatic brake system EPB). In the anti-lock brake system (ABS), the wheel with the defective speed sensor is treated as if it were rolling along the carriageway unblocked and with a high coefcient of friction. The brake pressure is regulated according to the conditions applicable to the axle or pressure control channel by IRM (individual regulation modied). The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off. The sustained-action brake output is not activated.

T 61

2nd edition

229

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03397

Pressure control module, 2nd rear axle, right, fault at voltage supply, axle load sensor Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The supply voltage must be checked - permitted supply voltage range at the rear axle pressure control module: The voltage measured between pin 3/4 and pin 3/1 at the rear axle pressure control module should have the voltage value 5 V ±0.45 V. Remedy: The cables and plug connectors between the rear axle pressure control module and the rear axle automatic load-balancing sensor must be checked for short circuits or line discontinuities, between pin 3/4 (rear axle pressure control module) and pin 1 (voltage supply, ALB sensor, rear axle), between pin 3/1 (rear axle pressure control module) and pin 2 (ground, ALB sensor, rear axle), between pin 3/3 (rear axle pressure control module) and pin 3 (signal line, ALB sensor, rear axle). Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Emergency function (function level 5): The EBS system operates with the value “L = ALB-Fehl” programmed via EOL for brake pressure distribution during braking with the service brakes (electropneumatic brake system EPB) and with the automatic load balancing (ALB) value L = 0 in the anti-lock brake system (ABS) for IRM (individual regulation modied) at the front axle.

03398

Pressure control module, 2nd rear axle, right, pressure differential on pressure control module pair, front axle Fault indication: Central STOP warning light (H111) comes on red at the same time as the red check lamp for the general brake check (H108) Effect of fault: This malfunction occurs when a pressure differential > 0.8 bar occurs for longer than 3 seconds on one axle in one of the pressure control modules. The current values for the pressure sensors of the rear axle pressure control module are read out using MAN-cats® II. Remedy: The correct function of the rear axle pressure control module must be checked. If it is not functioning, replace the rear axle pressure control module. Free passage of the pneumatic supply lines to the rear axle pressure control module must be checked (connection 1). Emergency function (function level 8): The affected rear axle pressure control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

03399

230

Pressure control module, 2nd rear axle, right, no valid fault denition

T 61

2nd edition

DEVICE DESCRIPTION Fault messages for trailer control module SPN

SPN-Plain text Description

03400

Trailer control module, no fault

03401

Trailer control module electronic control, unknown µC interrupt, µC self-test, RAM or ROM test Fault indication: Central STOP warning light (H111) lights up yellow. RemedyDelete the fault memory. Correcting the faultIf the fault reoccurs after the fault memory has been deleted then replace the trailer control module (Y278). If this fault occurs repeatedly in normal operation then the trailer control module must also be replaced. Emergency function: The EBS of the tractor vehicle is not impaired by this fault. The trailer control module is deenergised. The electrical braking value with offset values programmed by end of line (EOL) are passed on to the trailer (the resistance between the EBS control unit A402 pin X4/1 (CAN low Y278) and the trailer socket X317 pin 7 should be < 1Ω. The same also applies from A402 pin X4/3 (CAN high Y278) to the trailer socket X317 pin 6). Coupling force control and mass estimation are not activated. The trailer control module behaves like a conventional trailer control valve, however without any lead in the pneumatic brake line.

03402

Trailer control module, no valid fault denition

03403

Trailer control module control electronics, EEPROM, too many write accesses Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: Delete the fault memory. The coupling force control must be reset. Remedy: If the fault reoccurs after the fault memory has been deleted then replace the trailer control module (Y278). If this fault occurs repeatedly in normal operation then the trailer control module must also be replaced. Emergency function: The EBS of the tractor vehicle is not impaired by this fault. The trailer control module is energised. Coupling force control and mass estimation start with the values stored most recently in the EEPROM (incorrect values are replaced by default parameters). Coupling force control and mass estimation operate in full until the next power off, however no current values are stored in the EEPROM any longer.

03404

Trailer control module electronic control unit, EEPROM, checksum error or EOL data invalid Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The checksum in the trailer control module (Y278) must be corrected using MAN-cats® II. The coupling force control must be reset. Remedy: If the fault reoccurs after the fault memory has been deleted then replace the trailer control module (Y278). If this fault occurs repeatedly in normal operation then the trailer control module must also be replaced. Emergency function: The EBS of the tractor vehicle is not impaired by this fault. The trailer control module is energised. Incorrect values are replaced by default parameters. Coupling force control and mass estimation operate in full.

03405

Trailer control module control electronics, EEPROM, too many data repairs required Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: Delete the fault memory. The coupling force control must be reset. Remedy: If the fault reoccurs after the fault memory has been deleted then replace the trailer control module (Y278). If this fault occurs repeatedly in normal operation then the trailer control module must also be replaced. Emergency function: The EBS of the tractor vehicle is not impaired by this fault. The trailer control module is energised. Incorrect values are replaced by default parameters. Coupling force control and mass estimation operate in full.

T 61

2nd edition

231

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03406

Trailer control module control electronics, EEPROM, monitoring time exceeded when writing data Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: Delete the fault memory. The coupling force control must be reset. Remedy: If the fault reoccurs after the fault memory has been deleted then replace the trailer control module (Y278). If this fault occurs repeatedly in normal operation then the trailer control module must also be replaced. Emergency function: The EBS of the tractor vehicle is not impaired by this fault. The trailer control module is energised. Incorrect values are replaced by default parameters. Coupling force control and mass estimation operate in full. However, writing current values into the EEPROM memory is not possible.

03407

Trailer control module, no valid fault denition

03408

Trailer control module control electronics, EEPROM, fault in dynamic parameter setting Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: Delete the fault memory. The coupling force control must be reset. Remedy: If the fault reoccurs after the fault memory has been deleted then replace the EBS electronic control unit (A402). If this fault occurs repeatedly in normal operation then the EBS control unit must also be replaced. Emergency function: The EBS of the tractor vehicle is not impaired by this fault. The trailer control module is energised. Coupling force control and mass estimation are initialised with the default parameters when the system is next switched on.

03409

Trailer control module electronic control unit, EEPROM, dynamic parameters out of the permitted value range Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: Delete the fault memory. The coupling force control must be reset. Remedy: If the fault reoccurs after the fault memory has been deleted then replace the EBS electronic control unit (A402). If this fault occurs repeatedly in normal operation then the EBS control unit must also be replaced. Emergency function: The EBS of the tractor vehicle is not impaired by this fault. The trailer control module is energised. Coupling force control and mass estimation are initialised with the default parameters when the system is next switched on.

03410 03415

Trailer control module, no valid fault denition

03416

Trailer control module, fault in coupling force control Fault indication: Central STOP warning light (H111) lights up yellow.

03417 03418

Trailer control module, no valid fault denition

03419

Trailer control module, fault in weight estimation Fault indication: Central STOP warning light (H111) lights up yellow.

03420 03421

232

Trailer control module, no valid fault denition

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03422

Trailer control module, pressure sensor out of the permitted value range Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: There is an internal trailer control module malfunction. If the fault reoccurs after the fault memory has been deleted then replace the trailer control module. If this fault occurs repeatedly in normal operation then the trailer control module must also be replaced. These pressures are read out using MAN-cats® II providing this malfunction does not occur. The measuring range of the pressure sensors is between 0 bar and 8.5 bar. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Remedy: Delete the fault memory. Furthermore, - the correct function of the trailer control module (Y278) should be checked, - the trailer control module should be replaced if it is malfunctioning, - the permeability of the pneumatic supply lines to the trailer control module (connection 11 for air supply) should be checked and - the trailer control module supply pressure (maximum 8.5 bar) should be measured. Emergency function: The EBS of the tractor vehicle is not impaired by this fault. The trailer control module is deenergised. The electrical braking value with offset values programmed by end of line (EOL) are passed on to the trailer (the resistance between the EBS control unit A402 pin X4/1 (CAN low Y278) and the trailer socket X317 pin 7 should be < 1Ω. The same also applies from A402 pin X4/3 (CAN high Y278) to the trailer socket X317 pin 6). Coupling force control and mass estimation are not activated. The trailer control module behaves like a conventional trailer control valve, however without any lead in the pneumatic brake line.

03423

Trailer control module, implausible pressure sensor value when no braking Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: If the fault reoccurs after the fault memory has been deleted then replace the EBS electronic control unit (A402). If this fault occurs repeatedly in normal operation then the EBS electronic control unit must also be replaced. The pressure values are read out using MAN-cats® II. A faulty pressure sensor, residual pressure or an unexpectedly long activation of the parking brake at speeds above 13 km/h can trigger this fault. Remedy: Delete the fault memory. Furthermore, - the air venting pathways of the trailer control module (Y278) should be checked (connection 3 for venting), - the correct function of the trailer control module should be checked (the value of the pressure sensor must be 0 bar if there is no braking). - the trailer control module should be replaced if it is malfunctioning and - the parking brake switch (pressure-operated switch, parking brake check lamp B369) should be checked. Emergency function: The EBS of the tractor vehicle is not impaired by this fault. The trailer control module is deenergised. The electrical braking value with offset values programmed by end of line (EOL) are passed on to the trailer (the resistance between the EBS control unit A402 pin X4/1 (CAN low Y278) and the trailer socket X317 pin 7 should be < 1Ω. The same also applies from A402 pin X4/3 (CAN high Y278) to the trailer socket X317 pin 6). Coupling force control and mass estimation are not activated. The trailer control module behaves like a conventional trailer control valve, however without any lead in the pneumatic brake line.

03424

Trailer control module, no valid fault denition

T 61

2nd edition

233

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03425

Trailer control module, pressure dissipation too slow and fault on parking brake switch Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: Any blockage in the air ow through and out of the trailer control module during opening of the brake triggers this malfunction. This can be caused by a blocked or hardened exhaust mufer element. This fault message can also be caused if the distance from surrounding objects is too short. A defective exhaust valve or a defective pressure sensor in the trailer control module can also trigger this fault message. There is an internal trailer control module malfunction or the plausibility check of the pressure control is not taking place successfully. If the fault reoccurs after the fault memory has been deleted then replace the trailer control module. If this fault occurs repeatedly in normal operation then the trailer control module must also be replaced. The current values are read out using MAN-cats® II. Remedy: Delete the fault memory. Furthermore, - the air venting pathways of the trailer control module (Y278) should be checked (connection 3), - the correct function of the trailer control module should be checked, - the trailer control module should be replaced if it is malfunctioning and - the parking brake switch (pressure-operated switch, parking brake check lamp B369) should be checked for short circuit and line discontinuity. The parking brake check lamp (H117) comes on when the parking brake is used or the pressure at connection 43 (parking brake circuit - is pneumatically connection to the parking brake valve with test valve (G8.205 connection 22)) on the trailer control module drops below 5 bar. The switch must be deactivated when the parking brake is deactivated and the supply pressure is correct at the same time. The parking brake signal must be checked on CAN databus, powertrain (T-CAN) SAE J 1939 and the supply pressure of the parking brake system should also be checked. Emergency function: The EBS of the tractor vehicle is not impaired by this fault. The trailer control module is deenergised. The electrical braking value with offset values programmed by end of line (EOL) are passed on to the trailer (the resistance between the EBS control unit A402 pin X4/1 (CAN low Y278) and the trailer socket X317 pin 7 should be < 1Ω. The same also applies from A402 pin X4/3 (CAN high Y278) to the trailer socket X317 pin 6). Coupling force control and mass estimation are not activated. The trailer control module behaves like a conventional trailer control valve, however without any lead in the pneumatic brake line.

234

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03426

Trailer control module, residual pressure after pressure dissipation greater than threshold value on parking brake switch Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: Any blockage in the air ow through and out of the trailer control module during opening of the brake triggers this malfunction. This can be caused by a blocked or hardened exhaust mufer element. This fault message can also be caused if the distance from surrounding objects is too short. A defective exhaust valve or a defective pressure sensor in the trailer control module can also trigger this fault message. There is an internal trailer control module malfunction or the plausibility check of the pressure control is not taking place successfully. If the fault reoccurs after the fault memory has been deleted then replace the trailer control module. If this fault occurs repeatedly in normal operation then the trailer control module must also be replaced. The current values are read out using MAN-cats® II. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Remedy: Delete the fault memory. Furthermore, - the air venting pathways of the trailer control module (Y278) should be checked (connection 3), - the correct function of the trailer control module should be checked, - the trailer control module should be replaced if it is malfunctioning and - the parking brake switch (pressure-operated switch, parking brake check lamp B369) should be checked for short-circuit and line discontinuity. The parking brake check lamp (H117) comes on when the parking brake is used or the pressure at connection 43 (parking brake circuit - is pneumatically connection to the parking brake valve with test valve (G8.205 connection 22)) on the trailer control module drops below 5 bar. The switch must be deactivated when the parking brake is deactivated and the supply pressure is correct at the same time. The parking brake signal must be checked on CAN databus, powertrain (T-CAN) SAE J 1939 and the supply pressure of the parking brake system should also be checked. Emergency function: The EBS of the tractor vehicle is not impaired by this fault. The trailer control module is deenergised. The electrical braking value with offset values programmed by end of line (EOL) are passed on to the trailer (the resistance between the EBS control unit A402 pin X4/1 (CAN low Y278) and the trailer socket X317 pin 7 should be < 1Ω. The same also applies from A402 pin X4/3 (CAN high Y278) to the trailer socket X317 pin 6). Coupling force control and mass estimation are not activated. The trailer control module behaves like a conventional trailer control valve, however without any lead in the pneumatic brake line.

03427

Trailer control module, residual pressure after braking Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: Leaks inside the trailer control module trigger this fault message. If the fault reoccurs after the fault memory has been deleted then replace the trailer control module. If this fault occurs repeatedly in normal operation then the trailer control module must also be replaced. The current values are read out using MAN-cats® II. Remedy: Delete the fault memory. The correct function of the trailer control module (Y278) should be checked and, if it is not functioning correctly, the defective trailer control module must be replaced. Emergency function: The EBS of the tractor vehicle is not impaired by this fault. The trailer control module is deenergised. The electrical braking value with offset values programmed by end of line (EOL) are passed on to the trailer (the resistance between the EBS control unit A402 pin X4/1 (CAN low Y278) and the trailer socket X317 pin 7 should be < 1Ω. The same also applies from A402 pin X4/3 (CAN high Y278) to the trailer socket X317 pin 6). Coupling force control and mass estimation are not activated. The trailer control module behaves like a conventional trailer control valve, however without any lead in the pneumatic brake line.

03428 03430

Trailer control module, no valid fault denition

T 61

2nd edition

235

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03431

Trailer control module, faulty backup valve checkback Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: There is a fault in the signal pathway of the check valve in the trailer control module. If the fault reoccurs after the fault memory has been deleted then replace the trailer control module. If this fault occurs repeatedly in normal operation then the trailer control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Remedy: Delete the fault memory. The correct function of the trailer control module (Y278) should be checked and, if it is not functioning correctly, the defective trailer control module must be replaced. Emergency function: The EBS of the tractor vehicle is not impaired by this fault. The trailer control module is deenergised. The electrical braking value with offset values programmed by end of line (EOL) are passed on to the trailer (the resistance between the EBS control unit A402 pin X4/1 (CAN low Y278) and the trailer socket X317 pin 7 should be < 1Ω. The same also applies from A402 pin X4/3 (CAN high Y278) to the trailer socket X317 pin 6). Coupling force control and mass estimation are not activated. The trailer control module behaves like a conventional trailer control valve, however without any lead in the pneumatic brake line.

03432

Trailer control module, defective inlet valve, feedback Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: There is a fault in the signal pathway of the check valve in the trailer control module. If the fault reoccurs after the fault memory has been deleted then replace the trailer control module. If this fault occurs repeatedly in normal operation then the trailer control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Remedy: Delete the fault memory. Correct functioning of the trailer control module (Y278) should be checked and, if it is not functioning correctly, the defective trailer control module must be replaced. Emergency function: The EBS of the tractor vehicle is not impaired by this fault. The trailer control module is deenergised. The electrical braking value with offset values programmed by end of line (EOL) are passed on to the trailer (the resistance between the EBS control unit A402 pin X4/1 (CAN low Y278) and the trailer socket X317 pin 7 should be < 1Ω. The same also applies from A402 pin X4/3 (CAN high Y278) to the trailer socket X317 pin 6). Coupling force control and mass estimation are not activated. The trailer control module behaves like a conventional trailer control valve, however without any lead in the pneumatic brake line.

03433

Trailer control module, no valid fault denition

03434

Trailer control module, defective outlet valve, feedback Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: There is a fault in the signal pathway of the check valve in the trailer control module. If the fault reoccurs after the fault memory has been deleted then replace the trailer control module. If this fault occurs repeatedly in normal operation then the trailer control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Remedy: Delete the fault memory. Correct functioning of the trailer control module (Y278) should be checked and, if it is not functioning correctly, the defective trailer control module must be replaced. Emergency function: The EBS of the tractor vehicle is not impaired by this fault. The trailer control module is deenergised. The electrical braking value with offset values programmed by end of line (EOL) are passed on to the trailer (the resistance between the EBS control unit A402 pin X4/1 (CAN low Y278) and the trailer socket X317 pin 7 should be < 1Ω. The same also applies from A402 pin X4/3 (CAN high Y278) to the trailer socket X317 pin 6). Coupling force control and mass estimation are not activated. The trailer control module behaves like a conventional trailer control valve, however without any lead in the pneumatic brake line.

03435

236

Trailer control module, no valid fault denition

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03436

Trailer control module, fault, outlet and inlet valve, feedback Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: There is a fault in the signal pathway of the check valve in the trailer control module. If the fault reoccurs after the fault memory has been deleted then replace the trailer control module. If this fault occurs repeatedly in normal operation then the trailer control module must also be replaced. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit (A402). Remedy: Delete the fault memory. Correct functioning of the trailer control module (Y278) should be checked and, if it is not functioning correctly, the defective trailer control module must be replaced. Emergency function: The EBS of the tractor vehicle is not impaired by this fault. The trailer control module is deenergised. The electrical braking value with offset values programmed by end of line (EOL) are passed on to the trailer (the resistance between the EBS control unit A402 pin X4/1 (CAN low Y278) and the trailer socket X317 pin 7 should be < 1Ω. The same also applies from A402 pin X4/3 (CAN high Y278) to the trailer socket X317 pin 6). Coupling force control and mass estimation are not activated. The trailer control module behaves like a conventional trailer control valve, however without any lead in the pneumatic brake line.

03437 03439

Trailer control module, no valid fault denition

03440

Trailer control module, no CAN reception from trailer control module Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: CAN brake Baud rate: 250 kbaud Peak voltage values: Recessive CAN Low 2.5 V, CAN High 2.5 V; dominant CAN Low 1.5 V, CAN High 3.5 V Header length: 11-bit Message length: 8-byte Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit. If the fault reoccurs after the fault memory has been deleted then replace the trailer control module. If this fault occurs repeatedly in normal operation then the trailer control module must also be replaced. Remedy: Delete the fault memory. The connections from the EBS control unit (A402) to the trailer control module (Y278): from pin X4/15 (EBS control unit) to pin 1 (trailer control module): Voltage supply for trailer control module from pin X4/6 (EBS control unit) to pin 2 (trailer control module): Ground on trailer control module from pin X4/12 (EBS control unit) to pin 3 (trailer control module): CAN High for trailer control module from pin X4/9 (EBS control unit) to pin 4 (trailer control module): CAN Low for trailer control module must be checked (in particular, look for chang points). The battery voltage (24 V) from A402 pin X4/15 (voltage supply Y278) to A402 pin X4/6 (ground Y278) should be measured. As the next step, measure the overall resistance of approx. 60Ω, from A402 pin X4/12 (CAN high Y278) to A402 pin X4/9 (CAN low Y278). Furthermore, the plug connectors on the EBS electronic control unit and on the trailer control module should be checked. Following this, the ground connection of the trailer control module must be checked. Emergency function: The EBS of the tractor vehicle is not impaired by this fault. The trailer control module is deenergised. The electrical braking value with offset values programmed by end of line (EOL) are passed on to the trailer (the resistance between the EBS control unit A402 pin X4/1 (CAN low Y278) and the trailer socket X317 pin 7 should be < 1Ω. The same also applies from A402 pin X4/3 (CAN high Y278) to the trailer socket X317 pin 6). Coupling force control and mass estimation are not activated. The trailer control module behaves like a conventional trailer control valve, however without any lead in the pneumatic brake line.

T 61

2nd edition

237

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03441

Trailer control module, software incompatibility between control unit and trailer control module Fault indication: Central STOP warning light (H111) lights up yellow. Remedy: The EBS electronic control unit (A402) or the trailer control module (Y278) must be replaced by one with a compatible software version. Emergency function: The EBS of the tractor vehicle is not impaired by this fault. The trailer control module is deenergised. The electrical braking value with offset values programmed by end of line (EOL) are passed on to the trailer (the resistance between the EBS control unit A402 pin X4/1 (CAN low Y278) and the trailer socket X317 pin 7 should be < 1Ω. The same also applies from A402 pin X4/3 (CAN high Y278) to the trailer socket X317 pin 6). Coupling force control and mass estimation are not activated. The trailer control module behaves like a conventional trailer control valve, however without any lead in the pneumatic brake line.

03442

Trailer control module, 12/24 V incompatibility between control unit and trailer control module Fault indication: Central STOP warning light (H111) lights up yellow. Remedy: The EBS electronic control unit (A402) or the trailer control module (Y278) must be replaced by one with a compatible voltage version. Emergency function: The EBS of the tractor vehicle is not impaired by this fault. The trailer control module is deenergised. The electrical braking value with offset values programmed by end of line (EOL) are passed on to the trailer (the resistance between the EBS control unit A402 pin X4/1 (CAN low Y278) and the trailer socket X317 pin 7 should be < 1Ω. The same also applies from A402 pin X4/3 (CAN high Y278) to the trailer socket X317 pin 6). Coupling force control and mass estimation are not activated. The trailer control module behaves like a conventional trailer control valve, however without any lead in the pneumatic brake line.

03443

Trailer control module; high cycle protection, inlet valve, active, pressure < 4 bar Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: This malfunction occurs if the nominal value is not achieved for a relatively long time when the brake cylinder pressure is low. If the supply pressure < 4 bar, a fault message is triggered after the pressure sensor for the supply pressure has been checked. The fault is shown on the display if relatively large leaks are detected in the supply line, the brake line, at the coupling heads or on the components of the trailer brake. The current values for the pressure sensors of the trailer control module are read out using MAN-cats® II. Remedy: The following should be checked: - the correct function of the trailer control module (Y278) should be checked, - the trailer control module should be replaced if it is malfunctioning, - free passage of the pneumatic supply lines to the trailer control module (connection 11 for air supply) (example: see brake function diagram (with trailer)). The trailer control module is supplied by the 1-cylinder compressor (G1.1 connection 2) and safety valve 17+2 bar (G5.121) to the ECAM 12.5 bar (G25.300 connection 1). From ECAM 12.5 bar (G25.300 connection 23), the line runs to the non-return valve (G23.1 connection 1), from the non-return valve (G23.1 connection 2) on to the compressed air tank 4 l, 12.5 bar (G50.40) and from there on to connection 11 of the trailer control module, - the sensors of circuits 1, 2 and 3 should be checked with regard to supply pressure measurement, - the external monitoring of the red warning light (pressure sensor/switch for the supply pressure) should be checked, - the supply pressure of the trailer control module should be checked to see if it is correct, - the supply line (connection 21) and the brake line (connection 22), the coupling heads and the components of the trailer brake should be checked for leaks. Emergency function (function level 8): The trailer control module is deenergised. Braking is performed on the affected axle using the pneumatic back-up circuit, even if the pressure control module is still intact. There is no automatic load balancing (ALB) and no anti-lock brake system (ABS) control. The anti-spin regulator (ASR) functions (brake regulation and engine governor) are switched off.

238

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03444

Trailer control module, arithmetic test not successful Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: CAN brake Baud rate: 250 kbaud Peak voltage values: Recessive CAN Low 2.5 V, CAN High 2.5 V; dominant CAN Low 1.5 V, CAN High 3.5 V Header length: 11-bit Message length: 8-byte Refer to the EBS electrical circuit diagram for the pin assignments of the components and the EBS electronic control unit. If the fault reoccurs after the fault memory has been deleted then replace the trailer control module. Remedy: Delete the fault memory. The connections from the EBS control unit (A402) to the trailer control module (Y278): from pin X4/15 (EBS control unit) to pin 1 (trailer control module): Voltage supply for trailer control module from pin X4/6 (EBS control unit) to pin 2 (trailer control module): Ground on trailer control module from pin X4/12 (EBS control unit) to pin 3 (trailer control module): CAN High for trailer control module from pin X4/9 (EBS control unit) to pin 4 (trailer control module): CAN Low for trailer control module must be checked (in particular, look for chang points). If the fault reoccurs after the fault memory has been deleted then replace the trailer control module. If this fault occurs repeatedly in normal operation then the trailer control module must also be replaced. Emergency function: The EBS of the tractor vehicle is not impaired by this fault. The trailer control module is deenergised. The electrical braking value with offset values programmed by end of line (EOL) are passed on to the trailer (the resistance between the EBS control unit A402 pin X4/1 (CAN low Y278) and the trailer socket X317 pin 7 should be < 1Ω. The same also applies from A402 pin X4/3 (CAN high Y278) to the trailer socket X317 pin 6). Coupling force control and mass estimation are not activated. The trailer control module behaves like a conventional trailer control valve, however without any lead in the pneumatic brake line.

03445

Trailer control module, impermissible pressure at coupling head Fault indication: Central STOP warning light (H111) lights up yellow. Remedy:Delete the fault memory. Remedy:This fault is shown on the display if the nominal trailer pressure calculated by the coupling force control is outside the permitted range. If the fault reoccurs after the fault memory has been deleted then replace the trailer control module (Y278). If this fault occurs repeatedly in normal operation then the trailer control module must also be replaced. Emergency function: The EBS of the tractor vehicle is not impaired by this fault. The trailer control module is deenergised. The electrical braking value with offset values programmed by end of line (EOL) are passed on to the trailer (the resistance between the EBS control unit A402 pin X4/1 (CAN low Y278) and the trailer socket X317 pin 7 should be < 1Ω. The same also applies from A402 pin X4/3 (CAN high Y278) to the trailer socket X317 pin 6). Coupling force control and mass estimation are not activated. The trailer control module behaves like a conventional trailer control valve, however without any lead in the pneumatic brake line.

03446 03447

Trailer control module, no valid fault denition

T 61

2nd edition

239

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03448

Trailer control module, pressure differential between pressure control modules and trailer control module Fault indication: Central STOP warning light (H111) lights up yellow. Effect of fault: The fault is shown on the display if relatively large leaks are detected in the reservoir line, the brake line, at the coupling heads or on the components of the trailer brake. Remedy: Delete the fault memory. The following should be checked: - free passage of the pneumatic supply line to the trailer control module (connection 11 for air supply) (example: see brake function diagram (with trailer)). The trailer control module is supplied by the 1-cylinder compressor (G1.1 connection 2) and safety valve 17+2 bar (G5.121) to the ECAM 12.5 bar (G25.300 connection 1). From ECAM 12.5 bar (G25.300 connection 23), the line runs to the non-return valve (G23.1 connection 1), from the non-return valve (G23.1 connection 2) on to the compressed air tank 4 l, 12.5 bar (G50.40) and from there on to connection 11 of the trailer control module, - the sensors/switches of circuits 1, 2 and 3 should be checked with regard to supply pressure measurement, - the external monitoring of the red warning light (pressure sensor/switch for the supply pressure) should be checked, - the supply pressure of the trailer control module should be checked to see if it is correct, - the supply line (connection 21) and the brake line (connection 22), the coupling heads and the components of the trailer brake should be checked for leaks. Emergency function: The EBS of the tractor vehicle is not impaired by this fault. The trailer control module is deenergised. The electrical braking value with offset values programmed by end of line (EOL) are passed on to the trailer (the resistance between the EBS control unit A402 pin X4/1 (CAN low Y278) and the trailer socket X317 pin 7 should be < 1Ω. The same also applies from A402 pin X4/3 (CAN high Y278) to the trailer socket X317 pin 6). Coupling force control and mass estimation are not activated. The trailer control module behaves like a conventional trailer control valve, however without any lead in the pneumatic brake line.

03449

Trailer control module, no valid fault denition

SPN list (fault codes) and fault code description, ESP Address: 42 - Electronic Stability Program SPN

SPN-Plain text Description

03451

ESP, internal control unit fault Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: Internal monitoring functions: Analog/digital converter, unused interrupts, RAM test check of the data exchange between the active and passive microcontroller. Cause of fault: Internal fault in the active or passive microcontroller or communication interface fault. Remedy: Replace the ESP control unit (A575). Emergency function: The ESP control unit is deenergised. The electronic brake system is functioning without ESP. No sensor signals are output.

240

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03453

ESP, checkback, voltage implausible Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: ESP voltage supply is checked; voltage supply of 12 V and current consumption of the sensor. This fault is active if there is already a 12 V voltage at the voltage supply before the 12 V voltage regulator is activated, if there is an overvoltage on the 12 V voltage supply during operation, if there is an undervoltage < 8.3 V in the voltage supply of the sensor but the voltage supply of the ESP with > 15 V is sufcient and if the current owing in the supply line of the sensor is too high. Cause of fault: Internal fault in the ESP control unit, external short circuit on the sensor supply line. Remedy: Check the earthing and cables of the ESP rotational speed sensor (B476) or ESP steering angle sensor for short circuit. The sensor may be defective if there is/was a short circuit. Renew the ESP control unit (A575) or sensor if the cause of the fault is unclear. Emergency function: The electronic brake system is functioning without ESP. The steering angle and rotational speed sensors are not supplied with voltage. Furthermore, no sensor signals are output.

03455

ESP conguration not valid Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: The EBS conguration (number and type of pressure control modules, number and installation position of the speed sensors) is received and checked using the CAN databus CAN brake. Other conguration data (retarder, engine, parameters for ASR) are also received via the CAN databus CAN brake after the ignition is switched on. This fault is active if the EBS conguration is not valid for the function of the ESP; if the conguration data was not received correctly or if there was a timeout error during the automatic data update. Cause of fault: The EBS conguration does not match the function of ESP. The EOL data of the EBS conguration is incorrect or there is a malfunction on the CAN databus CAN brake after the ignition is switched on. Remedy: Check whether the EBS conguration can be used for the ESP function and change the data record if it cannot. Emergency function: The electronic brake system is functioning without ESP. Furthermore, no sensor signals are output.

03456

ESP, EEPROM, checksum invalid Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: During a complete update of the EEPROM (e.g. during data record programming), the ESP control unit calculates a checksum using the ROM data and writes this to the EEPROM. The checksum includes EOL parameters, hardware and software numbers, customer identication and other easily stored data. After the ignition is switched on, a checksum is calculated from the data stored in the EEPROM and then compared with the stored checksum. The electronic control unit is supplied with a default data record in the EEPROM and an incorrect checksum. This fault is then displayed and a new data record must be loaded. Cause of fault: This fault appears with a brand new ESP control unit, when individual data items in the EEPROM are modied or if there is an internal fault in the EEPROM. This fault message is not triggered if a new, valid data record is downloaded. Remedy: Load a valid EOL data record into the ESP control unit. Replace the ESP control unit if the fault then continues. Emergency function: The electronic brake system is functioning without ESP. Furthermore, no sensor signals are output.

T 61

2nd edition

241

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03457

ESP, EEPROM, parameter defective Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: Learned data is stored three times. It is read out and checked after the ignition is switched on. If one of these values is damaged, the original data is restored using the other two values. If two of the three values are damaged (e.g. due to switching off the control unit whilst the second value is being written into the EEPROM), the original data is reproduced using the third data record. This fault is displayed if two or more of the three data records are damaged. Cause of fault: Internal fault in the EEPROM, the microcontroller or com port fault. Remedy: Replace the ESP control unit (A575). Emergency function: The electronic brake system is functioning without ESP. Furthermore, no sensor signals are output.

03458

ESP, EEPROM, parameter out-of-range Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: Critical ESP parameters, e.g. the wheelbase, the steering ratio and also applied parameters are checked to see if they are in the physically plausible range (range monitoring). This check is performed after the ignition is switched on, when the EEPROM values are being read. Cause of fault: This fault appears if there are incorrect parameters in the data record, if there is an internal fault in the EEPROM or the EBS control unit. Remedy: Check or load the correct EEPROM data record. If the fault reoccurs after the fault memory has been deleted then replace the ESP control unit. Emergency function: The electronic brake system is functioning without ESP. Furthermore, no sensor signals are output.

03459

ESP, EEPROM, not programmable Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: This fault appears if a write operation to the EEPROM failed on three occasions. The write procedure is taking too long or the read-back value does not match the written value. Cause of fault: Internal fault in the EEPROM, the microcontroller or communication interface fault. Remedy: Replace the ESP control unit (A575). Emergency function: The electronic brake system is functioning without ESP. Furthermore, no sensor signals are output.

03461

ESP EOL data in the EBS ECU not compatible with ESP software version Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: The data record version identier specied the data record structure in the EEPROM. This identier is changed if new EOL parameters are needed, e.g. due to a software change. After the ignition is switched on, the data record version identier of the EEPROM is compared with the data record version identier of the ROM. Cause of fault: An update of the ESP software (ROM) without a corresponding update of the EEPROM or a faulty EEPROM data record. Remedy: Loading a correct EEPROM data record. Emergency function: The electronic brake system is functioning without ESP. Furthermore, no sensor signals are output.

242

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03467

ESP, lateral acceleration sensor out of permitted range Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: The signal of the lateral acceleration sensor is outside the permitted range. Cause of fault: An incorrectly mounted lateral acceleration sensor or an internal malfunction in the lateral acceleration sensor. Remedy: Check whether the lateral acceleration sensor is correctly mounted. Emergency function: The electronic brake system is functioning without ESP. Furthermore, no sensor signals are output.

03469

ESP, lateral acceleration sensor, long-time alignment Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: This fault appears if the offset of the lateral acceleration sensor is greater than 2.5 m/s². Cause of fault: An incorrectly mounted lateral acceleration sensor or an internal malfunction in the lateral acceleration sensor. Remedy: Check whether the lateral acceleration sensor is correctly mounted. Furthermore, check the sensor signal. Replace the lateral acceleration sensor if the fault continues. Test steps: Perform a voltage measurement: Lateral acceleration sensor voltage supply; ESP control unit - pin X2/4 (+) and pin X2/6 (-): approx. 12 V CAN databus, sensor S-CAN High signal; ESP control unit - pin X2/2 (+) and pin X1/6 (-) ground: approx. 2.5 - 3.5 V (square-wave signal) CAN databus, sensor S-CAN Low signal; ESP control unit - pin X2/1 (+) and pin X1/6 (-) ground: approx. 1.5 - 3.5 V (square-wave signal) Perform a resistance measurement: CAN databus, sensor S-CAN; ESP control unit - pin X2/2 (+) and pin X2/1 (-): approx. 64Ω (ESP control unit disconnected) Emergency function: The electronic brake system is functioning without ESP.

03470

ESP, lateral acceleration sensor, standstill alignment Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: The standstill calibration of the lateral acceleration sensor is only performed after the corresponding diagnostic command has been performed. This fault is displayed if the standstill offset is greater than 1.5 m/s². Cause of fault: An incorrectly mounted lateral acceleration sensor or an internal malfunction in the lateral acceleration sensor; the vehicle is parked on an sideways incline during the calibration. Remedy: Check whether the lateral acceleration sensor is correctly mounted. Furthermore, check the sensor signal. Replace the lateral acceleration sensor if the fault continues. Test steps: Perform voltage measurement: Lateral acceleration sensor voltage supply; ESP control unit - pin X2/4 (+) and pin X2/6 (-): ~12V CAN databus, sensor, S-CAN High signal; ESP control unit - pin X2/2 (+) and pin X1/6 (-) ground: approx. 2.5 - 3.5 V (square-wave signal) CAN databus, sensor, S-CAN Low signal; ESP control unit - pin X2/1 (+) and pin X1/6 (-) ground: approx. 1.5 - 3.5 V (square-wave signal) Perform resistance measurement: CAN databus, sensor, S-CAN; ESP control unit - pin X2/2 (+) and pin X2/1 (-): approx. 64Ω (ESP control unit disconnected) Emergency function: The electronic brake system is functioning without ESP.

T 61

2nd edition

243

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03471

ESP, lateral acceleration sensor, plausibility monitoring valid for model Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: This signal from the lateral acceleration sensor is checked against other ESP sensor signals for plausibility. Cause of fault: An incorrectly mounted lateral acceleration sensor or an internal malfunction in the lateral acceleration sensor; incorrect sensor offsets (this is possible if the lateral acceleration sensor was replaced without the EEPROM offset being readjusted); the lateral acceleration sensor is delivering incorrect values. Remedy: Check whether the lateral acceleration sensor is correctly mounted. Furthermore, check the sensor signal. Replace the lateral acceleration sensor if the fault continues. Test steps: Perform voltage measurement: Lateral acceleration sensor voltage supply; ESP control unit - pin X2/4 (+) and pin X2/6 (-): ~12V CAN databus, sensor, S-CAN High signal; ESP control unit - pin X2/2 (+) and pin X1/6 (-) ground: approx. 2.5 - 3.5 V (square-wave signal) CAN databus, sensor, S-CAN Low signal; ESP control unit - pin X2/1 (+) and pin X1/6 (-) ground: approx. 1.5 - 3.5 V (square-wave signal) Perform resistance measurement: CAN databus, sensor, S-CAN; ESP control unit - pin X2/2 (+) and pin X2/1 (-): approx. 64Ω (ESP control unit disconnected) Emergency function: The electronic brake system is functioning without ESP.

03472

ESP, lateral acceleration sensor, plausibility monitoring not valid for model Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: This signal from the lateral acceleration sensor is checked against other ESP sensor signals for plausibility. Cause of fault: An incorrectly mounted lateral acceleration sensor or an internal malfunction in the lateral acceleration sensor; incorrect sensor offsets (this is possible if the lateral acceleration sensor was replaced without the EEPROM offset being readjusted); the lateral acceleration sensor is delivering incorrect values (e.g. incorrect EOL parameters). Remedy: Check whether the lateral acceleration sensor is correctly mounted. Furthermore, check the sensor signal. Replace the lateral acceleration sensor if the fault continues. Test steps: Perform voltage measurement: Lateral acceleration sensor voltage supply; ESP control unit - pin X2/4 (+) and pin X2/6 (-): ~12V CAN databus, sensor, S-CAN High signal; ESP control unit - pin X2/2 (+) and pin X1/6 (-) ground: approx. 2.5 - 3.5 V (square-wave signal) CAN databus, sensor, S-CAN Low signal; ESP control unit - pin X2/1 (+) and pin X1/6 (-) ground: approx. 1.5 - 3.5 V (square-wave signal) Perform resistance measurement: CAN databus, sensor, S-CAN; ESP control unit - pin X2/2 (+) and pin X2/1 (-): approx. 64Ω (ESP control unit disconnected) Emergency function: The electronic brake system is functioning without ESP.

244

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03473

ESP, steering angle sensor not calibrated Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: The steering angle sensor is not calibrated, therefore an invalid signal is delivered. The ESP control unit is also informed about this. Cause of fault: This fault appears if a new steering angle sensor has been mounted or the calibration of the steering angle sensor was incorrect. Remedy: Recalibrate the ESP steering angle sensor (B475). During calibration, make sure that the front wheels are in the straight-ahead position. Emergency function: The electronic brake system is functioning without ESP. There are no steering angle sensor values available for external functions.

03474

ESP, steering angle sensor, CAN timeout Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: This fault is displayed if the ESP control unit does not receive any messages from the steering angle sensor or from the CAN databus CAN sensor for more than 120 ms. Cause of fault: This fault appears if there is a discontinuity in the connection cables between the steering angle sensor and the ESP control or there is an internal malfunction in the steering angle sensor. If the SPN fault code 03483 appears at the same time as the SPN fault code 03474, there is either a fault in the electronic CAN component of the CAN databus CAN sensor in the ESP control unit, a short circuit between the CAN databus lines CAN sensor high and CAN sensor low or a short circuit between other lines and the CAN databus CAN sensor high and CAN sensor low or electromagnetic compatibility problems. Remedy: The voltage supply of the steering angle sensor, the cables between the CAN databus sensor CAN and the ESP control unit (including looking for chang points) and the plug connections of the ESP control unit must be checked. Replace the steering angle sensor if the fault continues. Test steps: Perform a voltage measurement: Steering angle sensor voltage supply; ESP control unit - pin X1/11 (+) and pin X1/10 (-): approx. 12 V CAN databus, sensor S-CAN High signal; ESP control unit - pin X1/13 (+) and pin X1/6 (-) ground: approx. 2.5 - 3.5 V (square-wave signal) CAN databus, sensor S-CAN Low signal; ESP control unit - pin X1/16 (+) and pin X1/6 (-) ground: approx. 1.5 - 3.5 V (square-wave signal) Perform a resistance measurement: CAN databus, sensor S-CAN; ESP control unit - pin X1/13 (+) and pin X1/16 (-): approx. 60Ω (ESP control unit disconnected) Emergency function: The electronic brake system is functioning without ESP. No steering angle sensor values are available.

T 61

2nd edition

245

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03475

ESP, steering angle sensor out of permitted range Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: This fault is displayed if the failure mode identication signal displays a higher value than the maximum possible value (maximum steering angle). This value depends on the vehicle and is derived from the “Maximum steering range left/right” EOL parameter. Cause of fault: This fault appears if the steering angle sensor is incorrectly calibrated, the “Maximum steering range left/right” EOL parameter is incorrect, the steering angle sensor is not secured correctly (the steering angle sensor is not attached to the steering track rod) or if there is an internal malfunction in the steering angle sensor. Remedy: Check the attachment, the zero point and the maximum steering angle left/right using the diagnostic values and the EOL parameter data record, in particular the “Maximum steering range left/right” EOL parameter. Recalibrate the sensor if the offset of the steering angle sensor is too large. Replace the steering angle sensor if the fault continues. All work and modications that exert an inuence on the steering system can result in an offset of the steering angle sensor. Therefore, the steering angle sensor must be recalibrated after such work. During calibration, make sure that the front wheels are in the straight-ahead position. Test steps: Perform a voltage measurement: Steering angle sensor voltage supply; ESP control unit - pin X1/11 (+) and pin X1/10 (-): approx. 12 V CAN databus, sensor S-CAN High signal; ESP control unit - pin X1/13 (+) and pin X1/6 (-) ground: approx. 2.5 - 3.5 V (square-wave signal) CAN databus, sensor S-CAN Low signal; ESP control unit - pin X1/16 (+) and pin X1/6 (-) ground: approx. 1.5 - 3.5 V (square-wave signal) Perform a resistance measurement: CAN databus, sensor S-CAN; ESP control unit - pin X1/13 (+) and pin X1/16 (-): approx. 60Ω (ESP control unit disconnected) Emergency function: The electronic brake system is functioning without ESP.

03476

ESP, steering angle sensor, defective CAN message content Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: The steering angle sensor has an internal monitoring function and its status is displayed using the CAN databus. The ESP control unit monitors the status of the sensors and the range of the sensor values. Cause of fault: This fault appears when there is an internal malfunction in the steering angle sensor. Remedy: Replace the ESP steering angle sensor (B475) Emergency function: The electronic brake system is functioning without ESP.

246

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03477

ESP, steering angle sensor, gradient error Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: This fault is displayed if the steering signal is changing faster than is physically possible or the steering acceleration is too great. Cause of fault: This fault appears if the sensor attachment is loose, there is an internal malfunction in the steering angle sensor or the “Maximum steering range left/right” EOL parameter is incorrect. Remedy: Check the sensor attachment and the “Maximum steering range left/right” EOL parameter. Replace the steering angle sensor if the fault continues. Test steps: Perform a voltage measurement: Steering angle sensor voltage supply; ESP control unit - pin X1/11 (+) and pin X1/10 (-): = 12 V CAN databus, sensor S-CAN High signal; ESP control unit - pin X1/13 (+) and pin X1/6 (-) ground: approx. 2.5 - 3.5 V (square-wave signal) CAN databus, sensor S-CAN Low signal; ESP control unit - pin X1/16 (+) and pin X1/6 (-) ground: approx. 1.5 - 3.5 V (square-wave signal) Perform a resistance measurement: CAN databus, sensor S-CAN; ESP control unit - pin X1/13 (+) and pin X1/16 (-): approx. 60Ω (ESP control unit disconnected) Emergency function: The electronic brake system is functioning without ESP.

03478

ESP, steering angle sensor, long-time alignment Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: This fault is displayed if the offset of the steering angle sensor > +/- 30 degrees. Cause of fault: This fault appears if the steering angle sensor is incorrectly calibrated due to modications to the steering system, the steering angle sensor is not secured correctly (the steering angle sensor is not attached to the steering column) or if there is an internal malfunction in the steering angle sensor. Remedy: Check the sensor attachment. Calibrate the steering angle sensor. Replace the steering angle sensor if the fault continues. Test steps: Perform a voltage measurement: Steering angle sensor voltage supply; ESP control unit - pin X1/11 (+) and pin X1/10 (-): approx. 12 V CAN databus, sensor S-CAN High signal; ESP control unit - pin X1/13 (+) and pin X1/6 (-) ground: approx. 2.5 - 3.5 V (square-wave signal) CAN databus, sensor S-CAN Low signal; ESP control unit - pin X1/16 (+) and pin X1/6 (-) ground: approx. 1.5 - 3.5 V (square-wave signal) Perform a resistance measurement: CAN databus, sensor S-CAN; ESP control unit - pin X1/13 (+) and pin X1/16 (-): approx. 60Ω (ESP control unit disconnected) Emergency function: The electronic brake system is functioning without ESP.

T 61

2nd edition

247

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03479

ESP, steering angle sensor, constant signal Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: This fault is displayed if a right-hand and left-hand bend have been detected after the vehicle was stationary and the steering angle sensor signal has not changed. Cause of fault: This fault appears if the steering angle sensor is not secured correctly (the steering angle sensor is not attached to the steering column) or if there is an internal malfunction in the steering angle sensor. Remedy: Check the sensor attachment. Replace the steering angle sensor if the fault continues. Test steps: Perform a voltage measurement: Steering angle sensor voltage supply; ESP control unit - pin X1/11 (+) and pin X1/10 (-): approx. 12 V CAN databus, sensor S-CAN High signal; ESP control unit - pin X1/13 (+) and pin X1/6 (-) ground: approx. 2.5 - 3.5 V (square-wave signal) CAN databus, sensor S-CAN Low signal; ESP control unit - pin X1/16 (+) and pin X1/6 (-) ground: approx. 1.5 - 3.5 V (square-wave signal) Perform a resistance measurement: CAN databus, sensor S-CAN; ESP control unit - pin X1/13 (+) and pin X1/16 (-): approx. 60Ω (ESP control unit disconnected) Emergency function: The electronic brake system is functioning without ESP.

03480

ESP, steering angle sensor incorrectly mounted, incorrect steering angle sign Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: The rotational speed calculated from the steering angle is compared to the corrected rotational speed sensor signal and a rotational speed calculated from the wheel speed. This fault appears if the sign of the rotational speed calculated from the steering angle is different from the sign of the other rates of turn. Cause of fault: This fault appears if the steering angle sensor is not mounted correctly or there is an internal malfunction in the steering angle sensor. Remedy: Check whether the steering angle sensor is mounted correctly. Furthermore, the steering angle sensor signal must be checked. Replace the steering angle sensor if the steering angle sensor signal continues to be incorrect. Test steps: Perform a voltage measurement: Steering angle sensor voltage supply; ESP control unit - pin X1/11 (+) and pin X1/10 (-): approx. 12 V CAN databus, sensor S-CAN High signal; ESP control unit - pin X1/13 (+) and pin X1/6 (-) ground: approx. 2.5 - 3.5 V (square-wave signal) CAN databus, sensor S-CAN Low signal; ESP control unit - pin X1/16 (+) and pin X1/6 (-) ground: approx. 1.5 - 3.5 V (square-wave signal) Perform a resistance measurement: CAN databus, sensor S-CAN; ESP control unit - pin X1/13 (+) and pin X1/16 (-): approx. 60Ω (ESP control unit disconnected) Emergency function: The electronic brake system is functioning without ESP.

248

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03481

ESP, steering angle sensor, plausibility monitoring between steering angle and rotational speed Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: This fault is displayed if there is no plausibility between the rotational speed sensor signal and the steering angle sensor signal. Cause of fault: This fault appears if the steering angle sensor is not calibrated correctly, there is an internal malfunction in the steering angle sensor or the steering angle sensor is not mounted correctly. Remedy: Check the sensor attachment. Calibrate the steering angle sensor. Replace the steering angle sensor if the fault continues. All work and modications that exert an inuence on the steering system can result in an offset of the steering angle sensor. Therefore, the steering angle sensor must be recalibrated after such work and modications. During calibration, make sure that the front wheels are in the straight-ahead position. Test steps: Perform a voltage measurement: Steering angle sensor voltage supply; ESP control unit - pin X1/11 (+) and pin X1/10 (-): approx. 12 V CAN databus, sensor S-CAN High signal; ESP control unit - pin X1/13 (+) and pin X1/6 (-) ground: approx. 2.5 - 3.5 V (square-wave signal) CAN databus, sensor S-CAN Low signal; ESP control unit - pin X1/16 (+) and pin X1/6 (-) ground: approx. 1.5 - 3.5 V (square-wave signal) Perform a resistance measurement: CAN databus, sensor S-CAN; ESP control unit - pin X1/13 (+) and pin X1/16 (-): approx. 60Ω (ESP control unit disconnected) Emergency function: The electronic brake system is functioning without ESP.

T 61

2nd edition

249

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03483

ESP, rotational speed sensor, CAN timeout Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: This fault is displayed if the ESP control unit does not receive any messages from the rotational speed sensor or from the CAN databus CAN sensor for more than 120 ms. Cause of fault: This fault appears if there is a discontinuity in the connection cables between the rotational speed sensor and the ESP control or there is an internal malfunction in the rotational speed sensor. If the SPN fault code 03474 appears at the same time as the SPN fault code 03483, there is either a fault in the electronic CAN component of the CAN databus CAN sensor in the ESP control unit, a short circuit between the CAN databus lines CAN sensor high and CAN sensor low or a short circuit between other lines and the CAN databus CAN sensor high and CAN sensor low or electromagnetic compatibility problems. Remedy: The voltage supply of the rotational speed sensor, the cables between the CAN databus, sensor CAN and the ESP control unit (including looking for chang points) and the plug connections of the ESP control unit must be checked. Replace the rotational speed sensor if the fault continues. Test steps: Perform a voltage measurement: Lateral acceleration sensor voltage supply; ESP control unit - pin X2/4 (+) and pin X2/6 (-): approx. 12 V CAN databus, sensor S-CAN High signal; ESP control unit - pin X2/2 (+) and pin X1/6 (-) ground: approx. 2.5 - 3.5 V (square-wave signal) CAN databus, sensor S-CAN Low signal; ESP control unit - pin X2/1 (+) and pin X1/6 (-) ground: approx. 1.5 - 3.5 V (square-wave signal) Perform a resistance measurement: CAN databus, sensor S-CAN; ESP control unit - pin X2/2 (+) and pin X2/1 (-): approx. 60Ω (ESP control unit disconnected) Test steps: Perform a resistance measurement: Emergency function: The electronic brake system is functioning without ESP. No rotational speed sensor values are available.

03484

ESP, rotational speed sensor signal out of permitted range Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: This fault is displayed if the rotational speed sensor signal has an incorrect trend. Cause of fault: There is an internal rotational speed sensor fault. Remedy: Replace the rotational speed sensor. Emergency function: The electronic brake system is functioning without ESP.

250

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03485

ESP, rotational speed sensor, defective CAN message content Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: The ESP control unit monitors the following rotational speed sensor CAN databus messages: Undervoltage and overvoltage ag of the rotational speed sensor; rotational speed sensor signals that are outside the permitted range (internal faults mean that the rotational speed sensor signals are outside the permitted range) and message counter. Cause of fault: Either there is an internal fault in the rotational speed sensor or the connection to the rotational speed sensor cables is inadequate. Remedy: Check the supply lines of the rotational speed sensor. Replace the rotational speed sensor if the cause of the fault is not clear. Test steps: Perform a voltage measurement: Lateral acceleration sensor voltage supply; ESP control unit - pin X2/4 (+) and pin X2/6 (-): approx. 12 V CAN databus, sensor S-CAN High signal; ESP control unit - pin X2/2 (+) and pin X1/6 (-) ground: approx. 2.5 - 3.5 V (square-wave signal) CAN databus, sensor S-CAN Low signal; ESP control unit - pin X2/1 (+) and pin X1/6 (-) ground: approx. 1.5 - 3.5 V (square-wave signal) Perform a resistance measurement: CAN databus, sensor S-CAN; ESP control unit - pin X2/2 (+) and pin X2/1 (-): approx. 60Ω (ESP control unit disconnected) Emergency function: The electronic brake system is functioning without ESP.

T 61

2nd edition

251

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03486

ESP, rotational speed sensor, static BITE error Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: The rotational speed sensor is equipped with a self-test function that is dened as a built-in test (BITE). The test is triggered by the ESP control unit using the CAN databus. The rotational speed sensor itself then stimulates the mass elements with a specied alternating rotational speed. During the test cycle, the normal rotation speed is underlaid with a BITE value. The BITE is triggered every 40 ms, although it takes almost 20 ms for the signal to settle. This means the measured signal matches the correct rotational speed signal every 40 ms shortly before the start of the BITE. The rotational speed sensor signal is interpolated in order to be compared with the BITE value and evaluated. The nominal BITE value is 25 degrees/s. The nominal tolerance is +/- 7 degrees/s and includes sensor tolerances, temperature changes, ageing, interpolation errors and signal noise. The fault message is triggered if the BITE value is outside the tolerance range for several cycles (200 ms). The monitoring functions are deactivated when the normal rotation speed is at the edge of the measuring range. Cause of fault: There is either an internal fault in the rotational speed sensor or the rotational speed sensor attachment has come loose. Remedy: Check the attachment of the rotational speed sensor and the rotational speed sensor data. Replace the rotational speed sensor if the fault reoccurs after the engine has been switched off. Test steps: Perform a voltage measurement: Lateral acceleration sensor voltage supply; ESP control unit - pin X2/4 (+) and pin X2/6 (-): ~= 12 V CAN databus, sensor S-CAN High signal; ESP control unit - pin X2/2 (+) and pin X1/6 (-) ground: approx. 2.5 - 3.5 V (square-wave signal) CAN databus, sensor S-CAN Low signal; ESP control unit - pin X2/1 (+) and pin X1/6 (-) ground: approx. 1.5 - 3.5 V (square-wave signal) Perform a resistance measurement: CAN databus, sensor S-CAN; ESP control unit - pin X2/2 (+) and pin X2/1 (-): approx. 60Ω (ESP control unit disconnected) Emergency function: The electronic brake system is functioning without ESP.

252

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03487

ESP, rotational speed sensor, dynamic BITE error Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: The rotational speed sensor is equipped with a self-test function that is dened as a built-in test (BITE). The test is triggered by the ESP control unit using the CAN databus. The rotational speed sensor itself then stimulates the mass elements with a specied alternating rotational speed. During the test cycle, the normal rotation speed is underlaid with a BITE value. The BITE is triggered every 40 ms, although it takes almost 20 ms for the signal to settle. This means the measured signal matches the correct rotational speed signal every 40 ms shortly before the start of the BITE. The rotational speed sensor signal is interpolated in order to be compared with the BITE value and evaluated. This function monitors the difference between a weakly ltered BITE signal and a strongly ltered one. This fault message is displayed if the difference is more than 3-4 degrees/s for 7 cycles (280 ms) (depending on the driving situation). The monitoring functions are deactivated when the normal rotation speed is at the edge of the measuring range. Cause of fault: There is either an internal fault in the rotational speed sensor or the rotational speed sensor attachment has come loose. Remedy: Check the attachment of the rotational speed sensor and the rotational speed sensor data. Replace the rotational speed sensor if the fault reoccurs after the engine has been switched off. Test steps: Perform a voltage measurement: Lateral acceleration sensor voltage supply; ESP control unit - pin X2/4 (+) and pin X2/6 (-): approx. 12 V CAN databus, sensor S-CAN High signal; ESP control unit - pin X2/2 (+) and pin X1/6 (-) ground: approx. 2.5 - 3.5 V (square-wave signal) CAN databus, sensor S-CAN Low signal; ESP control unit - pin X2/1 (+) and pin X1/6 (-) ground: approx. 1.5 - 3.5 V (square-wave signal) Perform a resistance measurement: CAN databus, sensor S-CAN; ESP control unit - pin X2/2 (+) and pin X2/1 (-): approx. 60Ω (ESP control unit disconnected) Emergency function: The electronic brake system is functioning without ESP.

T 61

2nd edition

253

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03488

ESP, steering angle sensor, gradient error Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: This fault is displayed if the gradient of the rotational speed sensor signal exceeds a certain threshold that is dependent on the road speed, the steering wheel angle and the lateral acceleration (between 0.17 rad/s and 0.4 rad/s in 20 ms). Cause of fault: There is either an internal fault in the rotational speed sensor or the rotational speed sensor attachment has come loose. Remedy: Check the attachment of the rotational speed sensor and the rotational speed sensor data. Replace the rotational speed sensor if the fault reoccurs after the engine has been switched off. Test steps: Perform a voltage measurement: Lateral acceleration sensor voltage supply; ESP control unit - pin X2/4 (+) and pin X2/6 (-): approx. 12 V CAN databus, sensor S-CAN High signal; ESP control unit - pin X2/2 (+) and pin X1/6 (-) ground: approx. 2.5 - 3.5 V (square-wave signal) CAN databus, sensor S-CAN Low signal; ESP control unit - pin X2/1 (+) and pin X1/6 (-) ground: approx. 1.5 - 3.5 V (square-wave signal) Perform a resistance measurement: CAN databus, sensor S-CAN; ESP control unit - pin X2/2 (+) and pin X2/1 (-): approx. 60Ω (ESP control unit disconnected) Emergency function: The electronic brake system is functioning without ESP.

03490

ESP, rotational speed sensor, fast alignment Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: This fault is displayed if the offset of the rotational speed sensor is more than 15 degrees/s when driving. Cause of fault: There is an internal rotational speed sensor fault. Remedy: A rotational speed sensor must be tted if this is the case. Emergency function: The electronic brake system is functioning without ESP.

03491

ESP, rotational speed sensor, standstill alignment Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: This fault is displayed if the offset of the rotational speed sensor is more than 5.25 degrees/s when the vehicle is stationary. Cause of fault: This fault occurs if there is an internal fault in the rotational speed sensor or if the vehicle is vibrating. Remedy: A rotational speed sensor must be tted if this is the case. Emergency function: The electronic brake system is functioning without ESP.

03492

ESP, rotational speed sensor, normal alignment Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: This fault is displayed if the offset of the rotational speed sensor is more than 7.5 degrees/s when driving. Cause of fault: There is an internal rotational speed sensor fault. Remedy: A rotational speed sensor must be tted if this is the case. Emergency function: The electronic brake system is functioning without ESP.

254

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03493

ESP, rotational speed sensor, sensitivity error Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: The sensitivity of the rotational speed sensor when cornering is determined by the use of rates of turn that are calculated from other sensor signals. This fault is displayed if the sensitivity is about 20% too high or too low. Cause of fault: There is an internal fault in the rotational speed sensor or the rotational speed sensor is not mounted correctly. Remedy: Check the attachment of the rotational speed sensor. If the rotational speed sensor is not mounted horizontally, this impairs its sensitivity. Replace the rotational speed sensor if the cause of the fault is not clear. Emergency function: The electronic brake system is functioning without ESP.

03494

ESP, rotational speed sensor, plausibility monitoring valid for model Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: The rotational speed sensor signal is checked for plausibility with the signals from the other ESP sensors. This fault is displayed if the deviation between the rotational speed sensor and the reference signals is too great. Cause of fault: There is an internal fault in the rotational speed sensor or the rotational speed sensor is not mounted correctly or the rotational speed sensor signal has an incorrect sign (e.g. with an incorrect EOL parameter). Remedy: Check the attachment of the rotational speed sensor and the rotational speed sensor signal, in particular the EOL parameter. If the fault reoccurs after the fault memory has been deleted then replace the rotational speed sensor. Test steps: Perform voltage measurement: Lateral acceleration sensor voltage supply; ESP control unit - pin X2/4 (+) and pin X2/6 (-): ~12V CAN databus, sensor, S-CAN High signal; ESP control unit - pin X2/2 (+) and pin X1/6 (-) ground: approx. 2.5 - 3.5 V (square-wave signal) CAN databus, sensor, S-CAN Low signal; ESP control unit - pin X2/1 (+) and pin X1/6 (-) ground: approx. 1.5 - 3.5 V (square-wave signal) Perform resistance measurement: CAN databus, sensor, S-CAN; ESP control unit - pin X2/2 (+) and pin X2/1 (-): approx. 60Ω (ESP control unit disconnected) Emergency function: The electronic brake system is functioning without ESP.

T 61

2nd edition

255

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03495

ESP, rotational speed sensor, plausibility monitoring not valid for model Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: The rotational speed sensor signal is checked for plausibility with the signals from the other ESP sensors. This fault is displayed if the deviation between the rotational speed sensor and the reference signals is too great. Cause of fault: There is an internal fault in the rotational speed sensor or the rotational speed sensor is not mounted correctly or the rotational speed sensor signal has an incorrect sign (e.g. with an incorrect EOL parameter). Remedy: Check the attachment of the rotational speed sensor and the rotational speed sensor signal, in particular the EOL parameter. If the fault reoccurs after the fault memory has been deleted then replace the rotational speed sensor. Test steps: Perform voltage measurement: Lateral acceleration sensor voltage supply; ESP control unit - pin X2/4 (+) and pin X2/6 (-): ~12V CAN databus, sensor, S-CAN High signal; ESP control unit - pin X2/2 (+) and pin X1/6 (-) ground: approx. 2.5 - 3.5 V (square-wave signal) CAN databus, sensor, S-CAN Low signal; ESP control unit - pin X2/1 (+) and pin X1/6 (-) ground: approx. 1.5 - 3.5 V (square-wave signal) Perform resistance measurement: CAN databus, sensor, S-CAN; ESP control unit - pin X2/2 (+) and pin X2/1 (-): approx. 60Ω (ESP control unit disconnected) Emergency function: The electronic brake system is functioning without ESP.

03496

ESP, rotational speed sensor incorrectly mounted, incorrect steering angle sign Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: The measured rotation speed is compared with the rotation speed calculated from the steering angle and the wheel speeds. This fault is displayed if the sign of the measured rotational speed deviates from the sign of the calculated rates of turn. Cause of fault: There is an internal fault in the rotational speed sensor or the rotational speed sensor is not mounted correctly or the rotational speed sensor signal has an incorrect sign (e.g. with an incorrect EOL parameter). Remedy: Check the attachment of the rotational speed sensor and the rotational speed sensor signal, in particular the EOL parameter. If the fault reoccurs after the fault memory has been deleted then replace the rotational speed sensor. Test steps: Perform a voltage measurement: Lateral acceleration sensor voltage supply; ESP control unit - pin X2/4 (+) and pin X2/6 (-): approx. 12 V CAN databus, sensor S-CAN High signal; ESP control unit - pin X2/2 (+) and pin X1/6 (-) ground: approx. 2.5 - 3.5 V (square-wave signal) CAN databus, sensor S-CAN Low signal; ESP control unit - pin X2/1 (+) and pin X1/6 (-) ground: approx. 1.5 - 3.5 V (square-wave signal) Perform a resistance measurement: CAN databus, sensor S-CAN; ESP control unit - pin X2/2 (+) and pin X2/1 (-): approx. 60Ω (ESP control unit disconnected) Emergency function: The electronic brake system is functioning without ESP.

256

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03497

ESP, rotational speed sensor, plausibility monitoring between rotational speed and steering angle Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: This fault is displayed if there is no plausibility between the rotational speed sensor signal and the steering angle sensor signal. Cause of fault: There is an internal rotational speed sensor fault. Remedy: Check the attachment of the rotational speed sensor. Replace the rotational speed sensor if the cause of the fault is not clear. Emergency function: The electronic brake system is functioning without ESP.

03500

ESP, no CAN communication with ESP Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: This fault is displayed if the EBS control unit does not receive any information from the ESP control unit for more than 80 ms. Cause of fault: This fault appears if the ESP control unit is not connected to the EBS control unit (in particular the control unit voltage supply, ESP control unit ground, CAN databus brake high and CAN databus brake low); if there is a short circuit between CAN databus brake high and CAN databus brake low or other of its connection cables; if there is a short circuit between ground and the ESP control unit voltage supply or other voltage sources; if there is a fault on the electronic CAN component for the CAN databus brake in the ESP control unit; if there is a fault on another CAN databus brake component; if there is a fault in the internal hardware (if the microcontroller in the ESP control unit detects such a fault, it attempts to deactivate the system); if the software is faulty (a program was deleted or not written in full); if the ESP control unit is not transmitting any information because it is not receiving any information from the EBS control unit (e.g. due to a short circuit between the ESP control unit voltage supply and Ubat or another voltage source or if there are electromagnetic compatibility problems. Remedy: Check the attachment of the rotational speed sensor and the connection cables to the rotational speed sensor. Replace the rotational speed sensor if the cause of the fault is not clear. Test steps: Perform a voltage measurement: CAN databus brake B-CAN High signal; ESP control unit - pin X1/2 (+) and pin X1/6 (-) ground: approx. 2.5 - 3.5 V (square-wave signal) CAN databus brake B-CAN Low signal; ESP control unit - pin X1/1 (+) and pin X1/6 (-) ground: approx. 1.5 - 3.5 V (square-wave signal) Perform a resistance measurement: CAN databus brake B-CAN; ESP control unit - pin X1/2 (+) and pin X1/1 (-): approx. 60Ω (ESP control unit disconnected) Emergency function: The electronic brake system is functioning without ESP.

03501

ESP, software incompatible Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: The software version of the ESP is transmitted to the EBS control unit via the CAN databus brake. This fault is displayed if the version number does not match the version number or the ESP in the EBS (ROM). Cause of fault: This fault appears if the EBS control unit or the ESP control unit has been swapped with another software version or the software in the ESP control unit has been updated with the software of another version without the software of the EBS control unit having been updated rst (or vice versa). Remedy: This EBS control unit or the ESP control unit must be replaced by a component with a compatible software version. Alternatively, update the software of the original control units. Emergency function: The ESP control unit is deenergised. The electronic brake system is functioning without ESP. Furthermore, no sensor signals are available. T 61

2nd edition

257

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03502

ESP, 12/24V incompatible with EBS Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Remedy: The EBS control unit or the ESP control unit must be replaced by one with a compatible voltage version. Emergency function: The ESP control unit is deenergised. The electronic brake system is functioning without ESP. Furthermore, no sensor signals are available.

03504

ESP, ALU test failed Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: The EBS control unit repeatedly transits random numbers to the ESP control unit with the held of the CAN databus brake. These numbers are used for performing a calculation involving a function test of the unit in the ESP controller and a register test. The result is sent back to the EBS control unit, where the result and the response time are checked. Cause of fault: This fault appears if there is an internal microcontroller fault in the ESP control unit; if there is a transmission fault (CAN component, overload of CAN databus brake) or there are electromagnetic compatibility problems. Remedy: If the fault reoccurs after the fault memory has been deleted then replace the ESP control unit. Emergency function: The ESP control unit is deenergised. The electronic brake system is functioning without ESP. Furthermore, no sensor signals are available.

03505

ESP, output stage defective Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: The EBS control unit briey interrupts the voltage supply of the ESP control unit that is monitored by the feedback from the supply lines. Cause of fault: This fault appears if there is a short circuit in the voltage supply from the ESP or if there is a defect in the EBS hardware, e.g. an voltage supply or feedback line. Remedy: Check the voltage supply of the ESP control unit. The value should be 0 V after the fault message if the EBS control unit is deenergised or the ESP is not congured. If the voltage is greater than 0 V, check the cable system for possible short circuit to the voltage supply of the ESP control unit 24 V. Replace the EBS control unit if there is no short circuit. The output end stage test is deactivated by the EOL programming. Refer to the EBS electrical circuit diagram for the pin assignments of the components and the control unit. Test step: Perform a voltage measurement: ESP control unit voltage supply; ESP control unit - pin X1/14 (+) and pin X1/6 (-) ground: ~Ubat Emergency function: The ESP control unit is deenergised. The electronic brake system is functioning without ESP. Furthermore, no sensor signals are available.

03506

ESP, intervention not plausible Priority: 5 - Display when driving and at a standstill; fault information only Fault display: Central STOP warning light (H111) and driving stability check lamp (H415) light up yellow. Effect of fault: The EBS control unit performs a simple plausible test of the ESP output. The duration and the type of ESP intervention are monitored. Cause of fault: This fault occurs if there is an internal fault in the ESP or EBS (e.g. in CAN). Remedy: Replace the ESP control unit. Replace the EBS control unit if the fault reoccurs. Emergency function: The ESP control unit is deenergised. The electronic brake system is functioning without ESP. Furthermore, no sensor signals are available.

03507 - 03511 258

OBD, no valid fault denition

T 61

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03512

OBD, request, red warning lamp during diagnosis Fault display:Central STOP warning light (H111) comes on with a steady red light. Effect of fault: None. Cause of fault:Red warning light request. Remedy: There is no system fault in this diagnostic code. There is no need to perform a repair.

03513

OBD, request, yellow warning lamp during diagnosis Fault indication: Central STOP warning light (H111) comes on with a steady yellow light. Effect of fault: none. Cause of fault: Yellow warning light request. Remedy: There is no system fault in this diagnostic code. There is no need to perform a repair.

03514

OBD, no valid fault denition

03515

OBD, signal, brake pad wear sensor Fault display:Central STOP warning light (H111) comes on with a steady yellow light. Effect of fault: none. Cause of fault: none. Remedy: There is no system fault in this diagnostic code. There is no need to perform a repair.

03516

OBD, trailer, EBS, no fault Remedy: There is no system fault in this diagnostic code.

03517

OBD, voltage too high or too low Remedy: There is no system fault in this diagnostic code.

03518

OBD, trailer interface in single-line mode Remedy: There is no system fault in this diagnostic code.

03519

OBD, wheel speed sensor, fault during last switch-on cycle Fault display: Central STOP warning light (H111) comes on with a steady yellow light. Effect of fault: None. Cause of fault: Memory function speed sensing. Remedy: 1) Check for the presence of the causative fault: Drive away until the speed exceeds 7 km/h. 2) Check all faults in the fault memory (in terms of speed sensing) and rectify them until there are no more remaining after 1) Memory function has been performed.

03520

OBD, limit gap speed, warning level, repeated every second Remedy: There is no system fault in this diagnostic code.

03521

OBD, frequent-stop brake active Remedy: There is no system fault in this diagnostic code.

03522

OBD, chassis dynamometer mode active Fault display:Central STOP warning light (H111) comes on with a steady yellow light. Effect of fault: none. Cause of fault: none. Remedy: There is no system fault in this diagnostic code. There is no need to perform a repair.

03523 03524

OBD, no valid fault denition

03525

OBD, external wheel adjustment (speedo signal/speed sensor) Remedy: There is no system fault in this diagnostic code.

03526

OBD, alignment, lateral acceleration sensor not completed Remedy: There is no system fault in this diagnostic code.

T 61

2nd edition

259

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03527

OBD, steering angle sensor, fast alignment not completed Remedy: There is no system fault in this diagnostic code.

03528

OBD, ESP, control unit, overvoltage or undervoltage Remedy: There is no system fault in this diagnostic code.

03529

OBD, ESP is passive Remedy: There is no system fault in this diagnostic code.

260

T 61

2nd edition

DEVICE DESCRIPTION Test step list Test description The test step list enables the components and/or functions of the EBS/ESP to be checked with a multimeter (e.g. FLUKE 77 or 87). In the list of test steps given in this section (example: test step 1), the rst test contact is identied with “Pin X1/12” and the second test contact with “Pin X1644 (earthing point, cab, next to central electrical system)”. Use a multimeter to measure the resistance between these pins. Measure directly on the EBS control unit. The measuring mode to be set on the measuring instrument (multimeter) is shown between test contacts (pins) listed in column 3. Example:

Setting “V” = Voltage measurement

Example:

Setting “Ω” = Resistance measurement

Once the test conditions have been met, the value displayed on the measuring instrument (actual property) can be compared with the nominal value (nominal property). Sample measurements are described below: EBS sample measurement

When measuring voltages, switch on the ignition and leave the plug of the EBS control unit connected. In this example, the EBS control unit voltage supply is measured between pin X1/8 – positive line and pin X1 /10 – ground line. The measured value obtained using the FLUKE 77 multimeter is 23.92V (battery voltage).

When measuring resistance values, switch off the ignition and disconnect the plug at which the resistance value is to be measured.

T 61

2nd edition

261

DEVICE DESCRIPTION In this example with the powertrain CAN databus, the resistance is measured between pin X1/1 (powertrain CAN databus High signal) and pin X1/3 (powertrain CAN databus Low signal). The value measured with the FLUKE 77 multimeter is 60.2Ω. ESP sample measurement

Voltage measurement with FLUKE 77 multimeter ESP steering angle sensor voltage supply between pin X1/11 (+) and pin X1/10 (-): ~ 11.47V.

Resistance measurement with FLUKE 77 multimeter - connector X2 disconnected Resistance, sensor CAN databus - ESP rotational speed sensor between pin X2/2 (CAN High) and pin X2/1 (CAN-Low): ~ 120.6Ω.

262

T 61

2nd edition

DEVICE DESCRIPTION Test step list, EBS/ESP Service company:

Tested by:

Customer:

First registration:

Vehicle type:

Chassis number:

Engine model:

Engine number: Control unit no.: Date:

Mileage (km):

Read out the EBS control unit (A402) fault memory and the ESP control unit (A575) fault memory using MAN-cats® II. Use the test step list to localise the entered active faults. – Use brief overviews and/or diagrams for the specic vehicle in question when troubleshooting. – Voltage measurements are taken with the ignition switched on, the engine running and the vehicle stationary. – Resistance measurements are taken with the ignition switched off. – Voltage and resistance values are measured between the positive connection (Pin+) and negative connection (Pin-) on the multimeter (e.g. FLUKE 77 or 87). – Never measure at the plug contacts themselves without using suitable test probes! Danger of bending open the contacts! Resistance measurement – Ignition OFF – Disconnect the plug at which the measurement is to be taken from the control unit. Ground line, control unit Measuring device EBS control unit pin designation

Pin+

Pin-

Resistance between EBS control unit ground line and cab earthing point next to central electrical system

X1/12

X1644

Line number

31000

31000

Resistance between EBS control unit ground line and cab earthing point next to central electrical system

X1/10

X1644

Line number

31000

31000

Nominal value [Ω]

Measured value [Ω]

~= < 1Ω

..................

~= < 1Ω

..................

Desired value [Ω]

Measured value [Ω]

~= < 1Ω

..................

Button, ASR spin threshold increase (S256) Measuring instrument EBS control unit pin designation Resistance between positive line for ASR spin threshold increase button and ground line for EBS control unit Line number

Pin+

Pin-

X1/6

X1/10

74512

31000

T 61

2nd edition

263

DEVICE DESCRIPTION Trailer socket, ABS (X317) Measuring instrument Pin+

Pin-

Desired value [Ω]

Resistance between CAN databus Low signal of trailer socket and ABS trailer socket

X4/1

X317 pin 7

~= < 1Ω

..................

Cable colour

green

green

Resistance between CAN databus High signal of trailer socket and ABS trailer socket

X4/3

X317 pin 6

~= < 1Ω

..................

EBS control unit pin designation

white /green

Line colour

Measured value [Ω]

white /green

CAN databus EBS control unit pin designation

Measuring instrument Pin+

Pin-

Resistance between CAN databus High signal for right front axle pressure control module and CAN databus Low signal for right front axle pressure control module - EBS control unit disconnected

X3/8

X3/5

Line number

113

114

Resistance between CAN databus High signal for right front axle pressure control module and CAN databus Low signal for right front axle pressure control module - EBS control unit disconnected

X3/9

X3/6

Line number

124

125

X4/10

X4/7

133

134

X4/12

X4/9

144

143

Resistance between CAN databus High signal for rear axle pressure control module and CAN databus Low signal for rear axle pressure control module - EBS control unit disconnected Line number Resistance between CAN databus High signal for trailer control module and CAN databus Low signal for trailer control module - EBS control unit disconnected Line number

264

T 61

2nd edition

Desired value [Ω]

Measured value [Ω]

~= 64Ω

..................

~= 64Ω

..................

~= 64Ω

..................

~= 64Ω

..................

DEVICE DESCRIPTION

EBS control unit pin designation Resistance between T-CAN Low signal and T-CAN High signal - EBS control unit disconnected Line colour

Measuring instrument Pin+

Pin-

X1/1

X1/3

Desired value [Ω]

~= 60Ω * blue /white

Measured value [Ω]

..................

blue/red

* Note: There is no 120Ω terminating resistor integrated in the EBS control unit. Speed sensor, front axle, left (B119) Left front axle pressure control module pin designation Resistance between positive signal sensor line and negative signal sensor line - Sensor disconnected Line colour

Measuring instrument Pin+

Pin-

X4/2

X4/1

brown

Black

Desired value [Ω]

~= 950 - 1930Ω

Measured value [Ω]

..................

Speed sensor, front axle, right (B120) Right front axle pressure control module pin designation Resistance between positive signal sensor line and negative signal sensor line - Sensor disconnected Line colour

Measuring instrument Pin+

Pin-

X1/2

X1/1

brown

black

Desired value [Ω]

~= 950 - 1930Ω

Measured value [Ω]

..................

Speed sensor, driven axle, left (B121) Rear axle pressure control module pin designation Resistance between positive signal sensor line and negative signal sensor line - Sensor disconnected Line colour

Measuring instrument Pin+

Pin-

X1/2

X1/1

brown

black

Desired value [Ω]

~= 950 - 1930Ω

Measured value [Ω]

..................

Speed sensor, driven axle, right (B122) Rear axle pressure control module pin designation Resistance between positive signal sensor line and negative signal sensor line - Sensor disconnected Line colour

Measuring instrument Pin+

Pin-

X5/2

X5/1

brown

black

T 61

2nd edition

Desired value [Ω]

~= 950 - 1930Ω

Measured value [Ω]

..................

265

DEVICE DESCRIPTION Speed sensor, 2nd front axle, left (B591) Left front axle pressure control module pin designation Resistance between positive signal sensor line and negative signal sensor line - Sensor disconnected Line colour

Measuring instrument Pin+

Pin-

X1/2

X1/1

brown

black

Desired value [Ω]

~= 950 - 1930Ω

Measured value [Ω]

..................

Speed sensor, 2nd front axle, right (B592) Right front axle pressure control module pin designation Resistance between positive signal sensor line and negative signal sensor line - Sensor disconnected Line colour

266

Measuring instrument Pin+

Pin-

X4/2

X4/1

brown

black

T 61

2nd edition

Desired value [Ω]

~= 950 - 1930Ω

Measured value [Ω]

..................

DEVICE DESCRIPTION Voltage measurement – Ignition ON – Measured directly on the components to be measured (EBS control unit, pressure control modules for left front axle, right front axle and rear axle, ALB sensor). The operating voltage is between 20 V and 28 V, depending on the status of the battery. Voltage supply Measuring instrument EBS control unit pin designation Voltage supply, EBS control unit terminal 15 fuse, EBS/ABS control (F162) Line number Voltage supply, EBS control unit terminal 30 fuse, EBS/ABS, voltage supply, pressure control valve (F161) Line number

Pin+

Pin-

X1/7

X1/10

73001

31000

X1/8

X1/10

73000

31000

Nominal value [V]

Measured value [V]

16 – 32 V (Ubat)

............

16 - 32 V (Ubat)

............

Brake power sensor, EBS (B337) Measuring instrument EBS control unit pin designation Voltage supply, brake power sensor between brake power sensor positive line and brake power sensor negative line Line number Voltage supply, brake power sensor, desired pressure 1 between brake power sensor data line for desired pressure 1 and brake power sensor ground line Line number Voltage supply, brake power sensor, desired pressure 2 between brake power sensor data line for desired pressure 2 and brake power sensor ground line Line number

Pin+

Pin-

X2/2

X2/3

73500

73501

X2/7

X2/3

73502

73501

X2/4

X2/3

73503

73501

Desired value [V]

Measured value [V]

~= 5 V

............

~= 4.3 0.5V

............

~= 0.5 4.4V

............

Sensor, brake, 1st front axle, left (B333) Left front axle pressure control module pin designation Voltage supply, brake sensor between brake sensor positive line and brake sensor ground line Line colour

Measuring instrument Pin+

Pin-

X2/4

X2/1

Yellow

white

T 61

2nd edition

Desired value [V]

~= 5V around 2 sec when brake released

Measured value [V]

..................

267

DEVICE DESCRIPTION Left front axle pressure control module pin designation Signal measurement, brake between brake sensor signal line and brake sensor ground line Line colour Signal measurement, brake between brake sensor signal line and brake sensor ground line Line colour

Measuring instrument Pin+

Pin-

X2/3

X2/1

red

white

X2/3

X2/1

red

white

Desired value [V]

Measured value [V]

< 4.9V around 2 sec wear limit

..................

> 0.5V around 2 sec new pad

..................

Sensor, brake, 1st front axle, right (B332) Right front axle pressure control module pin designation Voltage supply, brake sensor between brake sensor positive line and brake sensor ground line Line colour Signal measurement, brake between brake sensor signal line and brake sensor ground line Line colour Signal measurement, brake between brake sensor signal line and brake sensor ground line Line colour

Measuring instrument Pin+

Pin-

X2/4

X2/1

yellow

white

X2/3

X2/1

red

white

X2/3

X2/1

red

white

Desired value [V]

Measured value [V]

~= 5V around 2 sec when brake released

..................

< 4.9V around 2 sec wear limit

..................

> 0.5V around 2 sec new pad

..................

Sensor, brake, driven axle, left (B335) Rear axle pressure control module pin designation Voltage supply, brake sensor between brake sensor positive line and brake sensor ground line Line colour Signal measurement, brake between brake sensor signal line and brake sensor ground line Line colour

268

Measuring instrument Pin+

Pin-

X2/4

X2/1

yellow

white

X2/3

X2/1

red

white

T 61

2nd edition

Desired value [V]

Measured value [V]

~= 5V around 2 sec when brake released

..................

< 4.9V around 2 sec wear limit

..................

DEVICE DESCRIPTION

Rear axle pressure control module pin designation Signal measurement, brake between brake sensor signal line and brake sensor ground line Line colour

Measuring instrument Pin+

Pin-

X2/3

X2/1

red

white

Desired value [V]

> 0.5V around 2 sec new pad

Measured value [V]

..................

Sensor, brake, driven axle, right (B334) Rear axle pressure control module pin designation Voltage supply, brake sensor between brake sensor positive line and brake sensor ground line Line colour Signal measurement, brake between brake sensor signal line and brake sensor ground line Line colour Signal measurement, brake between brake sensor signal line and brake sensor ground line Line colour

Measuring instrument Pin+

Pin-

X7/4

X7/1

yellow

white

X7/3

X7/1

red

white

X7/3

X7/1

red

white

Desired value [V]

Measured value [V]

~= 5V around 2 sec when brake released

..................

< 4.9V around 2 sec wear limit

..................

> 0.5V around 2 sec new pad

..................

Sensor, brake pad, 2nd front axle, left (B537) Left front axle pressure control module pin designation Voltage supply, brake sensor between brake sensor positive line and brake sensor ground line Line colour Signal measurement, brake between brake sensor signal line and brake sensor ground line Line colour Signal measurement, brake between brake sensor signal line and brake sensor ground line Line colour

Measuring instrument Pin+

Pin-

X2/4

X2/1

yellow

white

X2/2

X2/1

red

white

X2/2

X2/1

red

white

T 61

2nd edition

Desired value [V]

Measured value [V]

~= 5V around 2 sec when brake released

..................

< 4.9V around 2 sec wear limit

..................

> 0.5V around 2 sec new pad

..................

269

DEVICE DESCRIPTION Sensor, brake pad, 2nd front axle, right (B538) Right front axle pressure control module pin designation Voltage supply, brake sensor between brake sensor positive line and brake sensor ground line Line colour Signal measurement, brake between brake sensor signal line and brake sensor ground line Line colour Signal measurement, brake between brake sensor signal line and brake sensor ground line Line colour

Measuring instrument Pin+

Pin-

X2/4

X2/1

yellow

white

X2/2

X2/1

red

white

X2/2

X2/1

red

white

Desired value [V]

Measured value [V]

~= 5V around 2 sec when brake released

..................

< 4.9V around 2 sec wear limit

..................

> 0.5V around 2 sec new pad

..................

Sensor, brake pad, additional axle, left (B530) Rear axle pressure control module pin designation Voltage supply, brake sensor between brake sensor positive line and brake sensor ground line Line colour Signal measurement, brake between brake sensor signal line and brake sensor ground line Line colour Signal measurement, brake between brake sensor signal line and brake sensor ground line Line colour

Measuring instrument Pin+

Pin-

X2/4

X2/1

yellow

white

X2/2

X2/1

red

white

X2/2

X2/1

red

white

Desired value [V]

Measured value [V]

~= 5V around 2 sec when brake released

..................

< 4.9V around 2 sec wear limit

..................

> 0.5V around 2 sec new pad

..................

Sensor, brake, additional axle, right (B529) Rear axle pressure control module pin designation Voltage supply, brake sensor between brake sensor positive line and brake sensor ground line Line colour

270

Measuring instrument Pin+

Pin-

X7/4

X7/1

yellow

white

T 61

2nd edition

Desired value [V]

~= 5V around 2 sec when brake released

Measured value [V]

..................

DEVICE DESCRIPTION

Rear axle pressure control module pin designation Signal measurement, brake between brake sensor signal line and brake sensor ground line Line colour Signal measurement, brake between brake sensor signal line and brake sensor ground line Line colour

Measuring instrument Pin+

Pin-

X7/2

X7/1

red

white

X7/2

X7/1

red

white

Desired value [V]

Measured value [V]

< 4.9V around 2 sec wear limit

..................

> 0.5V around 2 sec new pad

..................

ALB sensor, driven axle (B336) Driven axle ALB sensor pin designation ALB sensor voltage supply between ALB sensor positive line and ALB sensor ground line Line number Voltage supply, ALB sensor, data line between ALB sensor data line desired pressure 1 and ALB sensor ground line Line number Voltage supply, ALB sensor, data line between ALB sensor data line desired pressure 1 and ALB sensor ground line Line number

Measuring instrument Pin+

Pin-

1

2

74300

73304

3

2

73306

73304

3

2

73306

73304

Desired value [V]

Measured value [V]

~= 5V

..................

> 0.1V Bellows pressure low

..................

< 4.9V Bellows pressure high

..................

Pressure control module, front axle, left (Y263) EBS control unit pin designation Voltage supply, pressure control module, front axle, left between pressure control module positive line and pressure control module ground line Line number

Measuring instrument Pin+

Pin-

X3/11

X3/2

111

112

T 61

2nd edition

Desired value [V]

16 - 32 V (Ubat)

Measured value [V]

..................

271

DEVICE DESCRIPTION Pressure control module, front axle, right (Y262) EBS control unit pin designation Voltage supply, pressure control module, front axle, right between pressure control module positive line and pressure control module ground line Line number

Measuring instrument Pin+

Pin-

X3/12

X3/3

121

122

Desired value [V]

16 - 32 V (Ubat)

Measured value [V]

..................

Rear axle pressure control module (Y264) EBS control unit pin designation Voltage supply rear axle pressure control module between pressure control module positive line and pressure control module ground line Line number

Measuring instrument Pin+

Pin-

X4/13

X4/4

131

132

Desired value [V]

16 - 32 V (Ubat)

Measured value [V]

..................

Trailer control module (Y278) EBS control unit pin designation Trailer control module voltage supply between trailer control module positive line and trailer control module ground line Line number

Measuring instrument Pin+

Pin-

X4/15

X4/6

142

141

Desired value [V]

16 - 32 V (Ubat)

Measured value [V]

..................

Diagnosis, K-line EBS control unit pin designation

Measuring instrument Pin+

Pin-

Diagnosis, K-line Diagnosis socket (X200) Condition: No data trafc on K-line

X1/13

X1/10

Line number

73201

31000

Diagnosis, K-line Diagnosis socket (X200) With data trafc on K-line

X1/13

X1/10

Line number

73201

31000

272

T 61

2nd edition

Desired value [V]

Measured value [V]

16 - 32 V (Ubat -2 V) (MAN-cats® II not connected)

..................

0 - 32 V (Ubat -2 V) (MAN-cats® II connected)

..................

DEVICE DESCRIPTION CAN databus, voltage measurement EBS control unit pin designation

Measuring instrument Pin+

Pin-

Voltage between CAN databus, right front axle pressure control module High signal and ground

X3/8

X1/10

Line number

113

31000

Voltage between CAN databus, right front axle pressure control module Low signal and ground

X3/5

X1/10

Line number

114

31000

Voltage between CAN databus, right front axle pressure control module High signal and ground

X3/9

X1/10

Line number

123

31000

Voltage between CAN databus, right front axle pressure control module Low signal and ground

X3/6

X1/10

Line number

124

31000

X4/10

X1/10

Line number

133

31000

Voltage between CAN databus, rear axle pressure control module Low signal and ground

X4/7

X1/10

Line number

134

31000

X4/12

X1/10

Line number

144

31000

Voltage between CAN databus trailer control module Low signal and ground

X4/9

X1/10

Line number

143

31000

Voltage between CAN databus, rear axle pressure control module High signal and ground

Voltage between CAN databus trailer control module High signal and ground

Desired value [V]

Measured value [V]

~= 2.5 - 3.5V Rectangular signal*

..................

~= 1.5 - 2.5V Rectangular signal*

..................

~= 2.5 - 3.5V Rectangular signal*

..................

~= 1.5 - 2.5V Rectangular signal*

..................

~= 2.5 - 3.5V Rectangular signal*

..................

~= 1.5 - 2.5V Rectangular signal*

..................

~= 2.5 - 3.5V Rectangular signal*

..................

~= 1.5 - 2.5V Rectangular signal*

..................

* Check with an oscilloscope or Scopemeter 123 made by FLUKE

T 61

2nd edition

273

DEVICE DESCRIPTION

The diagram above shows signal characteristics for the powertrain CAN databus High signal (channel A) and the powertrain CAN databus Low signal (channel B). ESP voltage supply ESP control unit pin designation

Measuring instrument Pin+

Pin-

X1/14

X1/6

161

162

X1/11

X1/10

Line number

175

176

Voltage supply, ESP, rotational speed sensor (B476) between rotational speed sensor positive line and rotational speed sensor ground line

X2/4

X2/6

Line number

165

166

Voltage supply ESP control unit (A575) between ESP control unit positive line and ESP control unit ground line Line number Voltage supply, ESP, steering angle sensor (B475) between steering angle sensor positive line and steering angle sensor ground line

274

T 61

2nd edition

Desired value [V]

Measured value [V]

16 – 32 V (Ubat)

..................

~= 12 V

..................

~= 12V

..................

DEVICE DESCRIPTION CAN databus, ESP, resistance measurement ESP control unit pin designation

Measuring instrument Pin+

Pin-

Resistance between brake CAN databus High signal for ESP control unit and brake CAN databus Low signal for ESP control unit - ESP control unit disconnected

X1/2

X1/1

Line number

163

164

X1/13

X1/16

Line number

177

178

Resistance between sensor CAN databus rotational speed sensor High signal for ESP control unit and sensor CAN databus rotational speed sensor Low signal for ESP control unit - ESP control unit disconnected

X2/2

X2/1

Line number

167

168

Resistance between sensor CAN databus steering angle sensor High signal for ESP control unit and sensor CAN databus steering angle sensor Low signal for ESP control unit - ESP control unit disconnected

Desired value [Ω]

Measured value [Ω]

~= 64Ω

..................

~= 120Ω

..................

~= 120Ω

..................

CAN databus, ESP, voltage measurement ESP control unit pin designation

Measuring instrument Pin+

Pin-

Voltage between brake CAN databus High signal and ground

X1/2

X1/6

Line number

163

162

Voltage between brake CAN databus Low signal and ground

X1/1

X1/6

Line number

164

162

X1/13

X1/6

177

162

X1/16

X1/6

178

162

Voltage between sensor CAN databus rotational speed sensor High signal and ground Line number Voltage between sensor CAN databus steering angle sensor Low signal and ground Line number

T 61

2nd edition

Desired value [V]

Measured value [V]

~= 2.5 - 3.5V Rectangular signal*

..................

~= 1.5 - 2.5V Rectangular signal*

..................

~= 2.5 - 3.5V Rectangular signal*

..................

~= 1.5 - 2.5V Rectangular signal*

..................

275

DEVICE DESCRIPTION

ESP control unit pin designation

Measuring instrument Pin+

Pin-

Voltage between sensor CAN databus rotational speed sensor High signal and ground

X2/2

X1/6

Line number

167

162

Voltage between sensor CAN databus rotational speed sensor Low signal and ground

X2/1

X1/6

Line number

168

162

Desired value [V]

Measured value [V]

~= 2.5 - 3.5V Rectangular signal*

..................

~= 1.5 - 2.5V Rectangular signal*

..................

* Check with an oscilloscope or Scopemeter 123 made by FLUKE

The diagram above shows signal characteristics for the brake CAN databus High signal (channel A) and the brake CAN databus Low signal (channel B). Delete fault memory No more active faults are allowed to be stored in the fault memory once all tests have been performed and no faults are found! Before deleting the fault memory, download it using MAN-cats® II and if it contains any non-diagnosed faults then these must be archived. Then delete the fault memory. There must not be any faults in the memory when the ignition is switched back on. Otherwise, search for the fault and remedy the problem.

276

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2nd edition

WIRING DIAGRAMS

WIRING DIAGRAMS OVERVIEWS

T 61

2nd edition

277

WIRING DIAGRAMS OVERVIEW, EBS, 2-AXLE VEHICLE Revision: 03.01 Legend A100 A302 A402 B119 B120 B121 B122 B332 B333 B334 B335 B336 B337 F161 F162 S256 X1644 X200 X2541 X2542 X2544 X317 Y262 Y263 Y264 Y278 ——1

Central electrical system Central computer 2 EBS control unit Speed sensor left front axle Speed sensor right front axle Speed sensor left rear axle Speed sensor right rear axle Brake sensor 1st axle right Brake sensor 1st axle left Brake sensor 2nd axle right Brake sensor 2nd axle left ALB sensor, rear axle Brake power sensor, EBS Fuse, EBS/ABS, voltage supply, pressure control valve Fuse, EBS/ABS, control Button, ASR spin threshold increase Earthing point, cab, next to central electrical system Pl. con. 37-pin, diagnosis (MAN-cats) Potential distributor 21-pin line 31000 Potential distributor 21-pin line 58000 Potential distributor 21-pin K-line ABS trailer socket Pressure control module, front axle, right Pressure control module, front axle, left Rear axle pressure control module Trailer control module —————————————————————– Plug disconnection detection: Short-circuit spring insulated by control unit cell X1/15 when inserted. Pin X1/12 and pin X1/18 short-circuit if not inserted. 2 In the case of ASR with ESP, S256 is replaced by S788.

T 61

2nd edition

278

WIRING DIAGRAMS OVERVIEW, EBS, 2-AXLE VEHICLE

T 61

2nd edition

279

WIRING DIAGRAMS OVERVIEW, EBS, 3-AXLE VEHICLE / 4-AXLE VEHICLE Status: 04.02 Legend A100 A302 A402 B119 B120 B121 B122 B332 B333 B334 B335 B336 B337 B529 B530 B537 B538 B591 B592 F161 F162 S256 X1644 X200 X2431 X2432 X2539 X2540 X2541 X2542 X2544 X317 Y262 Y263

Central electrical system Central computer 2 Control unit, EBS Speed sensor, front axle, left Speed sensor, front axle, right Speed sensor, rear axle, left Speed sensor, rear axle, right Sensor, brake, 1st axle, right Sensor, brake, 1st axle, left Sensor, brake, 2nd axle, right Sensor, brake, 2nd axle, left ALB sensor, rear axle Brake power sensor, EBS Brake sensor auxiliary axle right Brake sensor auxiliary axle left Sensor, brake, 2nd front axle, left (omitted on 3-axle vehicle) Sensor, brake, 2nd front axle, right (omitted on 3-axle vehicle) Speed sensor, 2nd front axle, left (omitted on 3-axle vehicle) Speed sensor, 2nd front axle, right (omitted on 3-axle vehicle) EBS/ABS voltage supply fuse, pressure control valve Fuse, EBS/ABS control Button, ASR spin threshold increase Earthing point, cab, next to central electrical system Plug connection, 37-pin, diagnosis (MAN-cats) Distributor, sensor, brake, left Distributor, sensor, brake, right Distributor, sensor, brake, left Distributor, sensor, brake, right Potential distributor, 21-pin, line 31000 Potential distributor, 21-pin, line 58000 Potential distributor, 21-pin, K-line Trailer socket, ABS Pressure control module, front axle, right Pressure control module, front axle, left

Y264 Y278 ——1

Pressure control module, rear axle Trailer control module —————————————————————– Plug disconnection detection: Short-circuit spring insulated by control unit cell X1/15 when inserted. Pin X1/12 and pin X1/18 short-circuit if not inserted. 2 In the case of ASR with ESP, S256 is replaced by S788.

T 61

2nd edition

280

WIRING DIAGRAMS OVERVIEW, EBS, 3-AXLE VEHICLE / 4-AXLE VEHICLE

T 61

2nd edition

281