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INDEX

Contents

Page No.

1. Product Specifications

2. Packing List

3. Connections & Interface

4. Quick Start Reference

Power ON OFF using battery

Power ON OFF using AC adapter

Operating Modes

Mode Selection

Operation - Auto Mode

Operation - Manual Mode

5. PC Communication

14

6. Operating Instructions & Troubleshooting

14

7. Description of Defects

15

Air Gap

15

Run Out

16

Damaged Pole Wheel

16

8. Calibration Procedure

17

9. Contact Information

20

10. Notes

21

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Product Specifications:

1.

Size:

100 X190X45 mm

2.

Weight:

346 gm (approx)

3.

Operating Temperature:

10 to 50 Deg C

4.

Storage Temperature:

0 to 50 Deg C

5.

Supply voltage range:

7.5 to 15 V DC

6.

Current Consumption:

30mA nominal at 10 V

7.

Battery Type:

9V DC

8.

Key Board:

Non Tactile

9.

AC to DC adapter:

230V AC, 500mA

10.

RS 232 Communication:

Default 9600 Baud rate

11.

Enclosure Protection:

IP 40

12.

Input Signal Range:

4 V RMS

13.

Input Signal Frequency:

44 to 180 Hz (Wheel Speed Range: 5 to 20 KMPH)

14.

LCD display:

16 X 2Line, with backlit

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Packing List:
1. Wheel End Tester Equipment

1 No

2. 12V DC adapter

1 No

3. 9 V Battery

1 No

4. Operating & Instruction CD manual

1 No

5. Sensor Connection Cable

1 No

6. RS232 Cable

1 No

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Connections & Interface:

EXT. DC SUPPLY
7.5 TO 15V

RS232 CONNECT
ION

SENSOR
CONNECTION

POWER ON OFF
SWITCH

LCD DISPLAY

LED INDICATORS

NAVIGATION
KEYS

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Quick Start Reference:


Power ON OFF using batteryConnect 9 V batteries in battery compartment. Switch ON the tester using Power ON-OFF switch. Instrument
will complete self-check, in which each LED will blink one by one. Finally Power LED will glow continuously.
If battery voltage is not sufficient, Power LED will start blinking. LCD will show low battery
Message Display on LCD
Power ON
* KNORR-BREMSE *
* ABS-TE

V2.1 *

Battery.V= x.x V

Resistance Test
Press START.....

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Power ON OFF using AC adapterConnect DC adapter pin to tester. Connect adapter to 230V AC mains domestic supply socket. Switch ON the
230V AC mains supply. Switch ON the tester using Power ON OFF switch. Instrument will complete selfcheck, in which each LED will blink one by one. Finally, Power LED & LCD display backlit will glow
continuously.

Message Display on LCD

Power ON
* KNORR-BREMSE *
* ABS-TE

V2.1 *

Battery.V= x.x V

Resistance Test
Press START.....

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Operating Modes:
The tester can operate in two modes, Auto Mode & Manual Mode
Mode LED indicates operating mode of tester.
Mode LED OFF -> Auto Mode
Mode LED ON -> Manual Mode

Auto Mode: In Auto Mode, tester does all the static & dynamic tests in predefined sequence. This mode is
especially designed for End Of Line test

Manual Mode: Manual Mode is designed for selective test. Operator can select any particulate test, for
example Resistance test. This mode is helpful in some areas like Quality Control, Wheel End troubleshooting,
sensor adaptation & axle proto development, etc

Mode Selection:
Auto Mode: When switched ON, by default tester goes in Auto Mode.
Message Display on LCD
Refer Power ON-OFF section

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Manual Mode:
Switch OFF the tester if it is already ON. Keep Mode Key pressed & Power ON the tester. Release Mode key
after completion of Self Test. Tester will go in manual mode. Power LED & Mode LED will remain ON &
Resistance LED will start blinking. (For further information, refer topic Operation in Manual Mode)
Message Display on LCD
Press MODE + Power ON
* KNORR-BREMSE *
* ABS-TE

V2.1 *

Battery.V= x.x V

Use MODE to sel.


Then Press START

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Operation - Auto Mode:


A. Switch ON the tester (either on Adapter or on internal battery)
B. Tester will complete self test & Power LED will remain ON if supply voltage is sufficient
C. Connect Sensor Extension Cable between sensor & tester
D. Ensure that wheel is stationary.
E. Press Start key
F. (Tester will test Resistance. If Sensor Resistance is not OK, then Resistance LED will glow (Higher
Resistance) or blink (Lower Resistance). If Sensor Resistance is OK then tester will go to next step)
G. NO SIGNAL LED will turn ON.
H. Start wheel rotation such that wheel speed is in the range of 5 to 20 KMPH.
I.

No Signal LED will turn OFF automatically if the speed is sufficient.

J. When No Signal LED turns OFF, press Start key.


K. Ensure that there is no abrupt change in wheel rotation speed during testing
L. Tester will check sensor signal for few rotations & then it will declare result.
M. Disconnect sensor & press Reset Key.
Repeat step C to M for next test

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Message Display on LCD


Power ON
* KNORR-BREMSE *
* ABS-TE

V2.1 *

Battery.V= x.x V

Resistance test
Press START..
After pressing START Button
Resistance: OK
R=xxxx
After aprox 3 sec
SP=

0 m/hrLO

Increase Speed
Start Wheel Rotation in speed range 5 to 20KMPH
SP= xxxxx m/hr
Press START

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After Pressing START button


SS= xx% RO= xx%
DP= OK RESET

Operation - Manual Mode:


A. Connect Sensor Extension Cable between sensor & tester
B. Keep Mode key pressed & Switch ON the tester (either on Adapter or on internal battery)
C. Tester will complete self test & Power LED will remain ON if supply voltage is sufficient
D. Release Mode key
E. Power & Mode LED will glow continuously & Resistance LED will start blinking which indicates
Resistance test alone is to be conducted. For selection of any other test in manual mode, press Mode
key & corresponding LED will start blinking
F. Select any required test
G. If Resistance Test is selected, press start key & the tester will test sensor resistance alone. If
resistance is ok No Defects LED will glow else Resistance LED will Glow (More resistance) or Blink
(less resistance) Ensure that wheel is stationary during resistance test
H. For any other test, after step F press Start key
I.

NO SIGNAL LED will turn ON.

J. Start wheel rotation such that wheel speed is in the range of 5 to 20 KMPH.
K. No Signal LED will turn OFF automatically if the speed is sufficient.
L. When No Signal LED turns OFF, press Start key.

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M. Ensure that there is no abrupt change in wheel rotation speed during testing
N. Tester will check sensor signal for few rotations & then it will declare result only for test selected in
step F
O. Disconnect sensor & press Reset Key.
P. Repeat step G &O or from H to O based on selected test

Message Display on LCD for Sensor Resistance test:


Press MODE + Power ON
* KNORR-BREMSE *
* ABS-TE

V2.1 *

Battery.V= x.x V

Use MODE to sel.


Then Press START
After pressing START Button

Resistance Test
Press START..
After pressing START Button

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Resistance: OK
R= xxxxx
After 3 Sec

Press RESET

Message Display on LCD for all other tests:


Press MODE + Power ON

* KNORR-BREMSE *
* ABS-TE

V2.1 *

Battery.V= x.x V

Use MODE to sel.


Then Press START
After pressing START Button

Resistance Test
Press START..
After pressing START Button

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Resistance: OK
R= xxxxx
After 3 Sec

Press RESET

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PC Communication:
A. Connect PC cable between PC & Tester
B. Set communication parameters to default
C. Run the communication Program
D. PC will display all the test data & instructions

Important Instructions & Troubleshooting:


A. Key Press Acknowledge: When any of the keys is pressed, Power LED will Turn OFF (Blinks) for
moment to acknowledge the key
B. Low Battery Indication: If battery voltage I not sufficient, Power LED blinks continuously
C. Speed range: The tester can perform all dynamic tests in the speed range of 5 to 20 KMPH. If the
wheel speed is less than 5 KMPH the No Signal LED will Glow continuously. If wheel speed is more
than 20KMPH the No signal LED starts blinking.
D. Test Results: If any defect is detected, repeat the test after correction of defect,
E. 9 V Battery: Battery charging facility is not available in tester.
F. Noise: In case if any electrical drive is used for wheel rotation, provide proper earth connection.
Electrical noise can affect the tester performance & tester may malfunction due to noise
G. Battery Contact Protection: Remove the battery when instrument is not to be used for long duration
(more than 20 days).
H. Battery Life: For more battery life, switch-off the tester when not in use.
I.

Resistance Test: In Manual as well as Auto mode, ensure that Wheel is not rotating during Resistance
Test. Resistance Test is static test. If wheel speed signal is available during resistance test, then the
tester measures wrong resistance value & may declare Resistance Defect .The tester declare
Resistance Defect If sensor resistance is not in the range of 1950

+/10%

& 1200

-10 %

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Description of Defects:
Air Gap:
Air gap is the gap between Pole Wheel & Sensor. The Maximum gap allowed is 0.6 mm. If Air Gap is more
than 0.6 mm, then the wheel speed signal strength will not be sufficient at lower speed. So ABS will not be
able to perform properly at lower speed.

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Run Out:
If Pole Wheel axis of rotation is not parallel to Wheel axis then the gap between Pole Wheel & sensor keeps
changing periodically with respect to each 360 Deg rotation. Because of this, signal strength also keeps on
varying. In such situations ABS ECU cannot understand wheel speed information properly
This phenomenon can be seen on oscilloscope as shown in following fig

Vp-p
Min

Vp-p
Max

Damaged Pole Wheel:


In case if pole wheel is physically damaged or if the pole wheel has any manufacturing defects or if metallic
dirt is trapped/ deposited on pole wheel, then the sensor cannot produce proper wheel speed signal. In such
situations ABS ECU cannot understand wheel speed information properly.

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Calibration Procedure:
Step 1: Open + headed screws (4Nos) on rear side of tester as shown below

Step 2: Open the top lid of the tester carefully. Fold the lid on right side & do not try to detach it from the main
unit

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Step 3: Switch ON the tester & connect calibrated DC volt meter (Multi meter) between two test points on the
PCB as shown below

5.000 V DC
DC VOLT METER

--

TRIMMER
Step 4: If DC volt meter (Multi meter) doesnt show 5.000 V DC, then adjust calibration trimmer (shown above)
to adjust it to 5.000V

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Contact Information:

Knorr-Bremse Systems for commercial vehicles India Pvt. Ltd.


280/ 280, Phase II, Village mann, Hinjawadi, Pune 411057
Website: www.knorr-bremse.com
Tel No: +91 20 66746800, 66746807
Fax No +91 20 66746899

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Notes:

Copyright 2006 Knorr-Bremse AG. All rights reserved, including industrial property rights applications.
Knorr-Bremse AG retains any power of disposal, such as for copying and transferring
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