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WORKSHOP MANUAL

维修手册

HFC1120P71K1D4V-LE359

Chassis

底盘分册

Version No 版本号：JAC-2016050301N4701

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FOREWORD 前言 CONTENT 目录

This Manual is helpful for technical maintenance

staff for JAC and provides effective and correct

maintenance and service for JAC vehicle. To ensure

the customer satisfaction of the JAC products, it is

extremely essential that the professional maintenance

technicians for JAC have the friendly service and the

capability of proper operation; therefore, the

maintenance technicians must fully understand the

contents in this Manual. This Manual shall be

accessible for reference at any time.

本手册用于帮助 JAC 授权的专业维修技术人员，

对江淮汽车提供有效正确的保养及维修。为确保江淮

汽车产品的用户满意，江淮汽车专业维修技术人员的

热情服务和正确操作是十分必要的，因此，维修技术

人员必须充分理解本手册内容。本手册应放在便于使

用的地方，以便随时用来参考。

All contents in this Manual, including pictures, technical parameters are the latest. But if

product modification affects maintenance, JAC will provide technical bulletin or supplementary

volume. Therefore, please obtain the latest information about this Manual. JAC reserves the right

to make change in design, addition or improvement for the product.

本手册的所有内容包括图片、技术参数都是最新的，但是由于产品改进而影响维修时，江淮

汽车将提供技术通报或补充卷。因此，使用本手册应密切注意获取相关信息的最新动态。江淮汽

车保留产品在设计变化、增添或改进方面的权力。

This manual is a guide for vehicle maintenance, maintenance personnel must be strictly in acc

ordance with the maintenance manual operation. This product is a product that has precise requir

ements, maintenance personnel must be professional with relevant skills, and non-professional per

sonnel are forbidden to disassemble vehicle privately. Due to complexity of actual problem, for ite

ms not contained in the manual, please contact with company's customer service, and operate und

er its guidance.

Overview & maintenance

概述与保养分册

Engine

发动机分册

Chassis

底盘分册

Body structure& electrical

车身结构与电器分册

Circuit

电路分册

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本手册为汽车维修的指导文件，维修人员须严格按照维修手册进行操作。本产品是具有相当

精密性要求的产品，维修人员必须是具有相关技能的专业人士，严禁非专业人员私自拆分产品。

因为实际问题的复杂多样性，对于维修手册中未涉及事项请及时联系公司客服，在其指导下进行

操作。

During the process of maintaining JAC vehicle, if genuine parts that are not from JAC or

disqualified oil, the vehicle may be damaged.

在对江淮汽车产品保养及维修过程中，若使用非江淮汽车的纯正配件或不合格油料，有可能

会造成车辆的损坏。

of this manual.

Tel：0086-551-62296644

Fax：0086-551-62296633

JAC 国际公司客户服务部

JAC International Customer Service Depart.

2016.05

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CONTENT 目录

Chapter Ⅰ Clutch 第一章离合

Chapter TransmissionⅡ 第二章变速器

Chapter Front axleⅢ 第三章前桥

Chapter Ⅳ Rear axle 第四章后桥

Chapter Ⅴ Drive shaft 第五章传动轴

Chapter VI Suspension 第六章悬架系统

Chapter VII Steering 第七章转向系统

Chapter Ⅷ Braking system 第八章制动系统

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ChapterⅠ Clutch

第一章离合

I Overview 概述

Clutch is located in the flywheel housing between engine and transmission, fixing clutch assembly

on the surface of fly wheel with screw and the clutch output shaft is the transmission input shaft. In the

process of driving, the operator can press or release the clutch pedal, to let the engine and transmission

temporarily detached and gradually engaged, so as to cut off or transmit the input power through engine

to transmission.

离合器位于发动机和变速箱之间的飞轮壳内，用螺钉将离合器总成固定在飞轮的后平面上，离

合器的输出轴就是变速箱的输入轴。在汽车行驶过程中，驾驶员可根据需要踩下或松开离合器踏板，

使发动机与变速箱暂时分离和逐渐接合，以切断或传递发动机向变速器输入的动力。

Clutch is the common parts in the mechanical transmission, which could make the drive system be

detached or engaged. The basic requirements are: engage smoothly, disengage quickly and thoroughly;

adjust and repair conveniently; small dimensions; light weight; good ability in wearing and sufficient

cooling capacity; convenient to operate and labor saving.

离合器是机械传动中的常用部件，可将传动系统随时分离或接合。对其基本要求有：接合平稳，

分离迅速而彻底；调节和修理方便；外廓尺寸小；质量小；耐磨性好和有足够的散热能力；操作方

便省力。

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Important parameters of the clutch system

离合系统重要参数

Project 项目 Date 参数

Pressure plate static torque

压盘静传递扭矩

1448N.m

Moment of inertia of the pressure plate

压盘总成转动惯量

0.599kg.mm

Static unbalance of the pressure plate

压盘允许静不平衡量

850g.mm

Moment of inertia of the driven plate

从动盘总成转动惯量

0.0629kg.mm

Static unbalance of the driven plate

从动盘允许静不平衡量

700g.mm

Maximum separation form

最大分离行程

13mm

The clutch pedal free stroke

离合器踏板自由行程

15mm-25mm

The clutch pedal work Angle

离合器踏板工作角度

33°

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II Location map and exploded 位置图及爆炸图

1、 Location map 位置图

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2、 Exploded figures 爆炸图

□ Clutch assembly 离合器总成

S/N 序号 Spare parts name description

备件名称

01 gear box assembly 变速器总成

02 clutch platen unit 离合器压盘总成

03 driven plate unit of clutch 离合器从动盘总成

04 release sleeve 分离套筒

05 release fork 分离拨叉

06 guide bearing 导向轴承

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□ The clutch circuit 离合管路

S/N 序号 Spare parts name description 备件名称

01 brake oil pipe perforation bolt 制动油管穿孔螺栓

02 braking oil pipe joint washer 制动油管接头垫圈

03 clutch pedal and bracket assembly 离合踏板支架总成

04 oil storage boat 储油壶总成

05 hexagon flange nuts 六角法兰面螺母

06 hexagon flange bolts 六角法兰面螺栓

07 clutch master cylinder inlet pipe assembly 离合器总泵进油管总成

08 double steel wire ring hoop 双钢丝环箍

09 clutch master cylinder 离合器总泵总成

10 clutch master cylinder tubing assembly 离合器总泵出油管总成

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11 clutch hose assembly 离合软管总成

12 clutch tube bracket 离合器管固定支架

13 clutch pipe assembly 离合钢管总成

14 clip 管夹

15 card 卡片

16 clutch tube bracket 离合器管支架

17 clutch hose assembly 离合器软管总成

18 cylinder booster assembly 离合助力器总成

19 cylinder booster bracket assembly 离合助力器支架总成

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□ Clutch pedal 离合器踏板

S/N 序号 Spare parts name description 备件名称

01 connecting bracket 连接支架

02 bolt 六角螺栓

03 nut 六角螺母

04 flat washer 平垫圈

05 spring washer 弹簧垫圈

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□ Driven plate of clutch pressure plate 离合器压盘从动盘

Note: The above picture is the typical part pictures, there is a slight difference in some type vehicles, here is no

longer remark.

备注：上述图片为典型部件图片，部分车型存在细微区别，此处不再标识

S/N 序号 Spare parts name description 备件名称

01 clutch platen unit 离合器压盘及盖总成

02 driven plate unit of clutch 离合器从动盘总成

03 bolt subassembly 六角头螺栓和弹簧垫圈组合件

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III Remove, install and adjust 拆装与调整

1、 Precautions 注意事项

□ When disassemble transmission assembly, please use a hoist to prevent the damage to the parts and

people

拆解变速箱总成时需用吊具，防止造成人员与零部件的损伤

□ Pay attention to collect abandoned clutch hydraulic oil, prevent environmental pollution

注意收集废弃离合器液压油，防止污染环境

□ Please use the vacuum cleaner to clean the clutch friction plate, do not use compressed air to clean it

清洁离合器摩擦片请使用吸尘器，切勿使用压缩空气清理

2、 Disassembly of clutch control assembly 离合器控制总成拆解

□ Before disassembling, vehicle wheels need to be stopped

by woods to prevent the slide

拆装前，需用掩木将车轮掩实，防止溜车

□ Before disassembling, unscrew the clutch oil drain plug,

put all the clutch fluid out

拆装前，拧开离合器放油螺塞，将离合器液放尽

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□ Disassemble clutch control assembly and disassembly

sequence is: cutch oil jug, clutch linking pipe, clutch

master cylinder, clutch pedal

拆解离合器控制总成，拆解顺序为：离合器储油壶、

离合器连接管路、离合总泵、离合踏板

□ Disassemble oil jug mounting bolts and pipe linking nuts

and remove oil jug

拆解储油壶固定螺栓及管路连接螺母，取下储油壶

□ Disassemble clutch master cylinder mounting bolts and

the clutch lines link nuts and remove the clutch master

cylinder

拆解离合总泵固定螺栓以及离合管路连接螺母，取下

离合总泵

□ Disassemble the clutch pedal and bracket nuts, remove

the clutch pedal

拆解离合踏板与支架固定螺母，取下离合踏板

Assembly: operate in accordance with the removal procedure in reverse order, and note the

following matters:

装配：按照拆解相反步骤开展，并注意以下事项:

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□ Assemble the clutch pedal attaching bolts is critical

operations, and please refer to the overview and

maintenance manual about the specific torque

装配离合器踏板连接螺栓为关键工序，具体拧紧力矩

请参见《概述与保养分册》

□ When assembling the clutch pipe mounting bolts, please

use leak-proof glue, and refers to the overview and

maintenance manual about the specific model number

装配离合器管路固定螺栓时需涂防漏胶，具体型号请

参见《概述与保养分册》

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3、 The removal and installation of clutch circuit 离合管路拆装

□ Disassemble clutch circuit, disassemble order is: clutch

pipes and hoses, clutch pedal, clutch pedal and bracket

assembly, clutch switch or limit bolts, spring, and clutch

cylinder, disassemble all the parts successively along the

clutch pipe

拆解离合管路，拆解顺序为：离合器管和软管、离合

器踏板、离合器踏板和支架总成、离合器开关或限位

螺栓、弹簧、离合器分泵，沿着离合管路走向逐次拆

解各部件

Assembly: operate in accordance with the removal procedure in reverse order.

装配：按照拆解相反步骤开展。

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4、Disassembly of clutch 离合器拆装

□ Disassemble the clutch and the remove order is:

transmission, clutch pressure plate, clutch driven plate,

release sleeve, release fork, pilot bearing

拆解离合器，拆解顺序为：变速箱、离合器压盘、

离合器从动盘、分离套筒、分离拨叉、导向轴承

□ Disassemble the bolts that link transmission to engine,

frame and the driving shaft, then remove transmission

assembly

拆解变速箱与发动机、车架、传动轴连接螺栓，取

下变速箱总成

□ Disassemble clutch pressure plate retaining bolts and

remove clutch pressure plate

拆解离合器压盘固定螺栓，取下离合器压盘

□ Disassemble clutch driven plate retaining bolts and

remove clutch pressure plate. Prevent driven plate

assembly free fall with a guide shaft. Mark on the

flywheel and pressure plate, and make sure that the

marks are aligned when re-install.

拆解离合器从动盘固定螺栓，取下离合器从动盘，

用一个导向轴来阻止从动盘总成自由滑落。在飞轮

和压盘块上做标记，在复装时，用标记对齐。

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□ Disassemble the clutch release sleeve assembly

together with the release sleeve and return spring

拆解离合器分离套筒总成，把分离套筒和回位弹簧

一起拆下

Assembly: operate in accordance with the removal procedure in reverse order, and note the

following matters:

装配：按照拆解相反步骤开展，并注意以下事项

□ Visually check the clutch cover for wear, cracks and

damage. Clutch cover with excessive wear, cracks and

other damage must be replaced

目视检查整个离合器盖的磨损、裂纹和其他损坏。有

过度磨损、裂纹和其他损坏的离合器盖必须更换

□ Insert the guide shaft into splined hub. Guide shaft must

be kept straight, measure the depth of platen rivet. The

driven plate assembly should be replaced if the

measured value exceeds limits

在花键毂内插入导向轴。导向轴必须保持很平直，测

量从动盘铆钉深度，如果测量值超出极限值，应更换

从动盘总成

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IV Fault diagnosis and solutions 故障诊断与处理

1、 Clutch drag (shifting gears with gear grinding sound) 离合器拖滞（换挡时伴随齿轮磨齿声）

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2、 Clutch slip 离合器打滑

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3、 Clutch vibration (part of clutch started make the body vibrate)

离合器振动（离合器部分啮合起动时，使本体发生振动）

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4、 Clutch noise (engage and disengage the clutch to check if clutch has noise, and thus determine what

caused

the noise)

离合器噪音（啮合和脱开离合器时检查是否离合器发出的噪音，从而确定引起噪音的原因）

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Chapter Ⅱ Transmission

第二章变速器（WLY6G120）

一、技术参数：(Main Technical Data)

中心距

Center Distance

120mm

重量

Net Weight

120kg

操纵方式

Control

远距离操纵

Remote control

里程表传动比

Speed Ratio

12/ 4 、 1 1 / 4 、 1 3 / 5 等

12/ 4 、 1 1 / 4 、 1 3 / 5etc.

润滑油牌号及油量

Brand and capacity of lubricating oil.

GL-4 80W/90（冬季）、85W/90（夏季）6L

GL-4 80W/90 (winter ), 85W /90(summer ) 6L

档位传动比：(Gear ratio)

Ⅰ Ⅱ Ⅲ Ⅳ Ⅴ Ⅵ

R

额定输入扭

矩（N·m）

Input Torque

6.012 3.292 2.004 1.367 1.000 0.789 5.395 700

档位示意图

(Shift gear sketch)

5 3 1

6 4 2 R

二、变速器的润滑和保养：(Transmission lubrication and maintenance:)

1、变速器的润滑 (Transmission lubrication)：

严禁使用劣质润滑油，不同牌号的润滑油不应混合使用！

Forbid using lubricating oil of low quality, forbid using different brand lubricating oil mixed!

加注润滑油时，车辆应停放在水平路面上，应加到注油孔的下边缘。

When filling oil the vehicle must stop level road and oil level is just below the filling hole.

润滑脂必须使用符合 GB5671-85 标准要求的汽车通用锂基润滑脂。

Lubricating oil must accord with standard GB5671-85 vehicle general Li base lubricating oil.

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2、变速器的保养（maintenance）

行驶 3000 千米时应检查润滑油平面，油平面以加油口下缘为准，不足时添加。

The oil surface should be checked while driving 3000km. Fill oil if it is not enough.

行驶 5000 千米时，应更换变速器内润滑油，并用煤油清洗变速器。以后每行驶 24000 千米时更换润滑油。

While driving 5000km the oil in the transmission should be replaced and the inner of the transmission cleaned.

Replace lubricating oil after each 24,000km.

行驶 12000 千米时，还应对变速器分离轴承座加注润滑脂。润滑脂嘴装在变速器离合器壳上，注入润滑脂

不能过多，以免玷污离合器摩擦片。48000 千米时应检查变速器各轴承工作情况，必要时更换。

Clutch release bearing should be lubricated with grease after 12000km driving. Grease could not be filled too much

to avoid dirtying the friction disk. Check the state of bearings after 48000km. replace the failed.

通气塞的保养：通气塞应经常清理，清除脏物，保持畅通。

Maintenance of the vent plug: Vent plug should be often cleaned to get rid of the dirty and to keep air flowing.

三、变速器使用注意事项：(Pay for attention)

1、 WLY6G120 变速器的各档均带有锁环式同步器，为了减轻齿轮和同步器的磨损，使同步器和齿轮顺利脱开，防

止打碎齿轮，换档动作要和缓。汽车只有在停稳后才能由前进档换入倒档或由倒档换入前进档。

Since each position in WLY6G120 is with lock-ring synchronizer, in order to lessen the wear between gear and

synchronizer, disengage the synchronizer from the gear, the gear-shifting should be gentle to avoid breaking the gear.

Only after the truck parks completely，can be the forward gear position change into the reverse position or the

reverse into the forward.

2、应特别注意：变速器的六档为超速档，为避免超速齿轮损坏，在整车不超载，路面状况较好，车速达到 50

公里/小时以上才能使用六档。在使用六档时，如遇某种情况致使整车速度降到 50 公里/小时以下，此时应

换入低档，如继续使用六档，极易使六档齿轮打碎。

3、 Warn: Since the sixth gear position is overspeed, it should be engaged only under the condition of good road, being

not overload and speeding more than 50km/h. Otherwise the gear will be broken. If the speed is less than 50km/h,the

lower position should be engaged and the sixth position should not be used any more.

4、根据道路和车辆载重情况，采用Ⅰ档或Ⅱ档起步。According to condition of the road and the load the vehicle gear

shift starting is at 1

st

speed or 2

nd

speed.

5、换倒档时，离合器踏板应踩到底，平稳准确地移动变速杆到所需档位。When shifting reverse speed , clutch pedal

should be stepped to its bottom, then the gear-shift lever should be moved to the required shift position smoothly and

correctly.

6、变速器不应空档滑行，特别是下坡时禁止换入空挡，防止烧损同步器及各类型轴承。When the vehicle running,

the gearshift lever should not be located at the natural position, the transmission is not allowed to coast at the free

speed, especially to coast downhill.

7、换倒档时，必须先停车再挂档，以免损坏倒档齿轮、齿套及相关零件。When shifting reverse speed, the vehicle

must be stopped first and then to shift gear to avoid damaging the reverse gear, sleeve and concern parts.

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四、检查与维修 ( Check and Maintenance )

通过检查如发现零件磨损、损坏或其它故障时，应进行必要的修理或更换。肉眼检查：检查所有拆下零件

的磨损、损坏或其它故障情况，具体要求如下：

Check the wear, break of the parts. Repair or change if necessary The requirements are as following:

1.换档拨块厚度（thickness of the shift

fork）mm

标准（standard）极限(limit)

1/2 1

.0 11.0

3/4、5/6

8.0 7.0

2 齿轮内孔与二轴间的间隙 mm

(clearance between inner hole and mainshaft)

标准（standard）极限(limit)

0.04～0.08

0.2

3.同步器齿环和结合齿间的间隙 mm

（clearance between gear ring and

engaging gear）

标准（standard）极限(limit)

1.3～1.7

0.5

4 变速器二轴径向跳动 mm

(radial jig of mainshaft)

极限(limit)

0.1

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五、变速器常见故障原因及排除

（Common failures and troubleshooting for gearbox）

故障类型

Failure

可能原因

Possible

排除方法

Remedy

噪声过大

或响

Excessive

or

abnormal

noise

1、

一二轴轴承损坏

Bearings of primary shaft or main shaft are

damaged.

2、齿面磕碰、有毛刺或齿面发生点蚀或接触不

良

Gear face is bumped, and there are burrs or

corrosion pitting or poor contact on the teeth

faces.

3、齿轮轴向位置和间隙不当造成齿轮与其他

零件碰撞

Axial location and clearance of gear shaft is

not proper, resulting in contact with or

bouncing against the other parts.

4、润滑油面太低，润滑不充分

Oil level is too low and lubrication is not

sufficient.

5、使用不合格质量要求的劣质润滑油

Lube oil with a poor quality is used, which

does not comply with the quality

requirement.

1、更换轴承

Replace the bearing or the

assembly.

2、修复或更换齿轮

Repair or replace the gear

3、检查、调整

Make inspection and

investigation

4、加油至规定位置

Top up the oil to the

specified level.

5、更换为规定牌号润油

Change the lubricating oil

same as stipulated

渗油

Oil

leakage

1、

加油过多

，

油面过高

Oil is overfilled and oil level is too high.

2、油封过量磨损或损坏

Oil seal is worn out excessively or damaged.

3、密封胶涂抹不均或密封纸垫损坏

Sealing glue is applied unevenly or the paper

gasket is damaged.

4、通气塞堵塞

Failure of breathing plug.

5、结合面磕碰、未及时修平

Bumping of joining faces and are not trimmed

timely.

1、

拆注油螺栓检查油面

Unscrew the oil plug and

check the oil level.

2、更换油封

Removing and checking.

3、重涂胶

Make inspection and

apply sealing glue.

4、更换

Replace it.

5、检查、修平

Inspect and trim it.

挂档困难

Difficult to

get gear

engaged

1、

离合器调整不当

，

分离不彻底

Clutch is not adjusted properly and

disengagement is not thoroughly.

2、选档和换档拉杆调整不当或发生运动障碍

或干涉

Improper adjustment of gearshift and gear

selector pull-wire or movement is hindered.

3、同步器齿环磨损严重近于失效

Synchronizer gear ring is worn-out seriously

and almost failed.

1、调整

Adjust it.

2、调整

Make inspection and

adjustment.

3、更换

Make replacement.

掉档

Shifted

gear

disengage

d

1、滑动齿套与锥体结合齿倒锥面严重磨损

Meshing faces of sliding coupling and

meshing teeth of synchronizer cone are

worn-out excessively.

2、拉杆调整不当

Improper adjustment of pull-wire

1、

更换有关零件

Make replacement of

relevant parts.

2、调整

Make adjustment.

轴承非正

常损坏

Abnormal

damage of

bearings

1、润滑油太脏

Lube oil is too dirty.

2、润滑不充分或润滑油质量太差

Insufficient lubrication or oil does not comply

with requirements and oil quality is too poor.

3、使用不合格的轴承

Unqualified bearing is used.

1、

更换润滑油

Make replacement.

2、检查、更换

Make inspection and

replacement.

3、更换

Make replacement.

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六、保修原则

（service principle）

1、对本公司产品在报废前有服务的义务。

Our company is obligated to provide service before product is scrapped.

2、公司生产的 WLY6G120 系列变速器，在规定使用条件下和使用期限内，无偿为用户更换或维修因产品

设计、制造和材质等质量问题造成的零部件损坏，以确保公司产品正常使用。

In the prescribed running condition or within the fixed time we will change or repair the damaged part of our

WLY6G120 family transmissions that it is caused by product design, manufacturing or material to insure our

company’s product running normally.

3、通过服务可以直接了解本公司产品的质量状况和用户要求，并将信息及时反馈到质量部门，以便采取改

进措施提高产品质量和增加产品品种满足市场需求。

We will directly know quality of our company’s product and customer’s demand by serving and we will take

measures to improve quality of our company’s product and develop new product to meet needs of market.

七、保修范围

（service scope）

1、在保修期限内，由于产品质量原因引起零件损坏和使用性能改变，经鉴定确属我公司的问题给予保修。

The trouble caused by the product quality in the warranty time limit will be in good repair by our company.

2、凡属下列情况之一的不予保修 we have not responsibility for the any situation listed below :

1）超出或无法确定保修期的产品；

The warranty time limit of the product is out or the purchase time could not be confirmed.

2）自行或委托他人改装过的产品；

The product has been refitted by oneself

3）自行拆卸修理造成零件的损坏；

The damaged part is caused by disassembling and repairing of oneself..

4）发现故障未及时排除而继续使用所引起的继发性故障和损坏；

Continual driving caused the parts destroyed as the discovered trouble had not been got rid of in time.

5）不按产品说明书规定进行操作或保养所引发的产品故障；

Trouble is caused by operation or maintenance that they are not in the manner described in the service manual

6）由于使用或操纵不当造成的产品故障；

Trouble caused by incorrect using or operating.

7）交通事故导致的产品故障或损坏；

Trouble or damage caused by traffic accident.

8）凡弄虚作假伪造事实者，我公司将追究其责任，并承担由此给我公司造成的各种损失。We keep the right

for punishing the skullduggery during our service.

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八、变速器零件图解（Spare Parts – Gearbox Housing Group）

1、上盖总成（Transmission Upper Cover）

序号

No

名称

Name

数量

Number

1

换档轴总成

Selecting shaft 1

2

骨架油封

Oil seal 1

3

通气塞

air plug 1

4

顶盖

Top cover assembly 1

5

倒档开关及增压器

总成

Reverse light switch unit 1

6

螺栓

Screw Stopper 1

7

六角头螺栓与锥型

弹性垫圈组合件

Bolt & lock washer

assembly

4

8

六角头螺栓

Bolt 1

9

螺母

Nut 3

10

弹簧垫圈

Spring washer 1

11

平垫圈

Plain washer 3

12

选档臂总成

Outer select rocker arm 1

13

轴用弹性挡圈

Ring 1

14

平垫

Plain washer 1

15

骨架油封

Oil seal 1

16

圆柱销

Cylinder pin 1

17

碗形塞片

Stopper Slice 1

18

自锁装置

Self-lock 1

19

弹簧

Spring 2

20

互锁套

Self-lock sleeve 1

21

换档拨头

Shift guild block 1

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22

选档轴总成

Gear--select rocker arm 1

23

隔套

Bushing 1

24

垫片

Spring pad 1

2．换档机构(Gear—Shift mechanism)

序号

No

名称

图号

Code

Name

数量

Number

1

五、六档换档档拉

杆总成

6G120-6570

Pull-rod assembly 1

2

三四档拉杆

6G120-6371 Pull-rod 1

3

一、二档换档档拉

杆总成

6G120-6170

Pull-rod assembly 1

4

弹性销

Q5280630 Elastic cylinder pin 3

5

倒档拨块

6G120-6875 Dialing block 1

6

五、六档拨叉及衬

套总成

6G120-6579

5

th

/6

th

shift fork and

Bushing assembly

1

7

换档拨块

WTB10*21*8-

6G120

Dialing block 4

8

三、四档拨叉及衬

套总成

6G120-6379

3

rd

/4

th

shift fork and

Bushing assembly

1

9

一二档拨叉

6G120-6173 1

st

/2

nd

shift fork 1

10

换档拨块

WTB10*18*12-6G120

Dialing block 2

11

弹性圆柱销

Q5280430

Elastic cylinder pin

3

12

倒档拨叉

6G120-6873

Reverse shift fork

1

13

变速器叉轴

6G120-6071 Fork shaft

1

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3、变速器总成与离合器壳总成（Housing and Clutch Housing）

序号

No

名称

Name

数量

Number

1

轴承

(192309)-6G120

Bearing 1

2

卡环

Ring 1

3

O 型密封圈

O-seal 1

4

里程表软轴接头

House Fitting 1

5

里程表从动齿轮

Speedometer driven gear 1

6

弹簧垫圈

Spring washer 2

平垫圈

Plain washer 1

螺栓

Bolt 1

7

双头螺柱

Double end studs 12

8

波形弹性垫圈

Cushioning plate washer 12

9

平垫圈

Plain washer 14

10

螺母

Nut 14

11

二轴突缘

Flange 1

12

突缘螺栓(镀锌)

Flange bolt 4

13

突缘锁紧螺母

Nut 1

14

O 型密封圈

O-seal 1

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15

油封

Oil seal 1

16

里程表主动齿轮

Speedometer driven worm 1

17

二轴盖

Rear bearing cover 1

18

倒档增压器

Reverse supercharger 1

19

螺塞

Washer 1

20

变速器外壳

Rear housing 1

21

六角头螺栓

Bolt 1

22

弹簧垫圈

Spring washer 1

23

倒档检查孔盖板

Cover plate

1

24

六角头螺栓和锥形

弹性垫圈组合件

Bolt & lock washer

assembly

8

25

六角头螺栓

Bolt

6

26

弹簧垫圈

Spring washer

9

27

取力器孔盖板

Side cover

1

28

磁性放油螺塞

Oil drain plug

1

29

橡胶垫

Washer oil plug

2

30

螺塞

Bolt

1

31

拨叉支撑销

Backing pin

6

32

波形垫圈

Cushioning plate washer

6

33

变速器前壳体

Front housing

1

34

六角头螺栓和锥形

弹性垫圈组合件

Bolt & lock washer

assembly

20

35

轴承

Bearing

1

36

轴用弹性挡圈

External clip ring

1

37

第一轴

Input shaft

1

38

油封

Oil seal

1

39

一轴盖

Input shaft cover

1

40

波形弹性垫圈

Cushioning plate washer

11

41

六角头螺栓

Bolt

11

42

六角头螺栓

Bolt

2

43

弹垫

Spring washer

2

44

离合器通风盖合件

Clutch vent cover board

assembly

1

45

调整垫片

Plain washer

1

调整垫片

Plain washer

1

调整垫片

Plain washer

1

46

衬套

Bushing

2

47

分离叉轴及叉臂总

成

Clutch fork shaft & lever

assembly

1

48

平键

Key

1

49

分离轴承润滑软管

总成

Lubrication hose

1

50

离合器壳体

Clutch housing

1

51

六角头螺栓

Bolt

1

52

弹簧垫圈

Spring washer

1

53

分离叉

Clutch release fork

1

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54

平垫圈

Plain washer

10

55

弹簧垫圈

Spring washer

10

56

六角头螺栓

Bolt

10

57

离合器分离轴承总

成

Bearing Cover assembly

1

4、变速器第二轴及其附件（Transmission main shift and accessories）

序号

No

名称

Name

数量

Number

1

轴用弹性压扁档圈

External clip ring 1

2

滚针轴承

Needle bearing 1

3

五档轴承座圈

External clip ring 1

4

轴用弹性挡圈

External clip ring 1

轴用弹性挡圈

External clip ring 1

轴用弹性挡圈

External clip ring 1

5

五档同步锥

5

th

synchronizer cone 2

6

三四五六档同步环

3rd/4

th

/5

th

/6

th

Synchronizer

cone-ring

4

7

五六档同步齿套

5

th

/6

th

synchronizer

sleeve

1

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8

五六档同步齿座

5

th

/6

th

synchronizer

hub

1

9

同步器弹簧

Synchronizer spring 3

10

同步器滑块

Synchronizer block 3

11

滚针轴承

Needle bearing 1

12

二轴六档齿轮

Output shaft 6th gear 1

13

轴用弹性挡圈

External clip ring 1

轴用弹性挡圈

External clip ring 1

轴用弹性挡圈

External clip ring 1

14

四档齿轮止推环

Thrust washer 1

15

钢球

Steel ball 1

16

滚针轴承

Needle bearing 1

17

二轴四档齿轮

Output shaft 4th gear 1

18

四档同步锥

Synchronizer cone 1

19

轴用弹性挡圈

External clip ring 1

轴用弹性挡圈

External clip ring 1

轴用弹性挡圈

External clip ring 1

20

三四档同步齿座

3

rd

/4

th

Synchronizer

hub

1

21

三四档同步齿套

3

rd

/4

th

Synchronizer

sleeve

1

22

三档同步锥

Synchronizer cone 1

23

二轴三档齿轮

Output shaft 3nd gear 1

24

滚针轴承

Needle bearing 1

25

二轴倒档轴承座圈

External clip ring 1

26

二轴倒档齿轮

Output shaft rev. gear 1

27

滚针轴承

Needle bearing 2

28

倒档同步齿座

Rev.

Synchronizer

cone

1

29

二轴一档齿轮合件

1

st

gear assy 1

30

轴用弹性挡圈

External clip ring 1

轴用弹性挡圈

External clip ring 1

轴用弹性挡圈

External clip ring 1

31

一二档同步器内环

1

st

/2

nd

Synchronizer

inside cone

2

32

一二档同步器中间

环

1

st

/2

nd

Synchronizer

middle cone

2

33

一二档同步器外环

1

st

/2

nd

Synchronizer

outside cone

2

34

倒档同步器推块

Synchronizer block 3

35

倒档同步器定位块

Spring retainer,

synchronzing

3

36

同步器弹簧

Synchronizer spring 3

37

一二档同步器齿座

1

st

/2

nd

Synchronizer

hub

1

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38

一二档滑动齿套

1

st

/2

nd

Synchronizer

sleeve

1

39

二轴二档齿轮合件

2nd speed gear 1

40

滚针轴承

Needle bearing 1

41

二轴

Mainshaft 1

5、变速器中间轴及倒档轴（Transmission countershaft and reverse gear shaft）

序号

No

名称

Name

数量

Number

1

轴用弹性挡圈

External clip ring 1

2

滚柱轴承

Needle bearing 1

3

中间轴五档齿轮

Count shaft drive gear 1

4

中间轴六档齿轮

Countershaft 6

th

gear 1

5

中间轴四档齿轮

Countershaft 4

th

gear 1

6

中间轴三档齿轮

Countershaft 3

rd

gear 1

7

中间轴

Countershaft 1

8

滚柱轴承

Needle bearing 1

9

倒档惰轮

Rev. idler gear 1

10

倒档轴

Rev. idler shaft 1

11

滚针轴承

Needle bearing 2

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Chassis 底盘分册

Chapter Ⅲ Front axle

第三章前桥

I Overview 概述

Front axle is usually located in the front of the car, which is an important assembly part. Mainly

includes front axle, bend arm, direct arm, knuckle, kingpin and other parts. There are two main functions

for the front axle in the car, one is to withstand part of the payload of the vehicle, the other is for the

steering of the vehicle, therefore, also known as steering axle. Front axle connects with frame through

suspension to withstand the vertical load between ground and frame, also bear braking force and lateral

force, as well as the forces that constitute the torque and to ensure that the rotating wheel move correctly.

During the use of vehicle, the forcing condition of steering axle is comparatively complex, and therefore

should have sufficient strength. To ensure that steering wheel the correct positioning to manipulate light

and reduce tire wear, so steering axle is also expected to have sufficient rigidity. In addition, it should also

be possible to minimize steering axle weight. In sum, when driving, the front axle is under the poor

working environment, with complex performance, the bearing load mostly is alternating load which make

the parts much more easier to be fatigue cracks and even broken. This requires that the structural design,

there must be with sufficient strength, stiffness and fatigue resistance capacity to destroy.

前桥一般位于汽车的前部，是汽车上一个重要的总成件。主要包括前轴、弯臂、直臂、转向

节、转向主销等零部件。前桥在整车上主要有两个功能，其一是承受整车的部分载荷，其二就是

实现车辆的转向，所以也称转向桥。前桥通过悬架与车架相连，用以承受地面与车架之间的垂直

载荷外，还承受制动力和侧向力以及这些力所构成的力矩，并保证转向轮作正确的运动。在汽车

使用中，转向桥的受力状况比较复杂，因此应具有足够的强度。为保证转向车轮的正确定位角

度，使操纵轻便并减轻轮胎的磨耗，转向桥也应有足够的刚度。此外，还应尽量减轻转向桥的重

量。总之，由于在汽车的行驶过程中，前桥所处的工作环境恶劣，工况复杂，其承受的载荷也多

为交变载荷，从而其零部件易出现疲劳裂纹甚至断裂现象。这就要求其在结构设计上必须有足够

的强度、刚度和抗疲劳破坏的能力。

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Front axle important parameters

前桥重要参数

Project 项目 Date 参数

The front wheel camber Angle

前轮外倾角

Empty 空载：1° Full 满载：45′

Kingpin caster Angle

主销后倾角

Empty 空载：4°30′ Full 满载：4°

Kingpin inclination

主销内倾角

Empty 空载：7°30′ Full 满载：7°45′

Axial load

轴向负荷

Common 出厂：27.5-41.1N Maintenance 保养：15-41.1N

Steering knuckle and front axle surface gap

转向节与前轴面间隙

≤0.1mm

Front beam

前束

Oblique tire 斜交胎 1mm-3mm Meridian tire 子午线胎 0mm-2mm

Wheel maximum angle of inside and outside

车轮最大内外转角

33°（26°）

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II Location map and exploded 位置图及爆炸图

1、 Location map 位置图

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2、 Exploded diagrams 爆炸图

S/N 序号 Spare Parts Name 备件名称

00 front axle assembly 前桥总成

01 wheel hub cover 轮毂罩

02 nut 车轮螺母

03 front brake drum with wheel hub assembly 前制动鼓带轮毂总成

04 nut 六角螺母

05 steering arm (right) 转向直臂（右）

06 front axle 前轴

07 nut 转向节螺母

08 lock plate 锁片Ⅱ

09 rear tapered roller bearing assembly, wheel hub 前轮毂外圆锥滚子轴承总成

10 inner tapered roller bearing assembly, wheel hub 前轮毂内圆锥滚子轴承总成

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11 oil seal 前轮油封

12 oil seal seat 油封座

13 seal，o ring O 型密封圈

14 left steering knuckle with jacket unit 左转向节带衬套总成

14 right steering knuckle with jacket unit 右转向节带衬套总成

15 king pin cap assembly 主销盖总成

16 keen pin 主销

17 lock plate 锁片

18 bolt 转角限位螺栓

19 plug 螺塞

20 nut 螺母

21 nut 六角螺母

22 lockpin, king pin 主销锁销

23 steering knuckle arm 转向节弯臂

24 tie rod assy 横拉杆总成

25 thrust bearing 止推轴承

26 steering arm (left) 转向直臂（左）

27 flat washer 平垫圈

28 curve grease nib 弯颈式润滑脂嘴

29 spring washer 弹簧垫圈

Note: The above picture is the typical part pictures, there is a slight difference in some type vehicles, here is no

longer remark.

备注：上述图片为典型部件图片，部分车型存在细微区别，此处不再标识。

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III Remove, install and adjust 拆装与调整

1、 Remove front axle assembly 前桥总成拆卸

□ Before disassembling, vehicle wheels need to be stopped

by woods to prevent the slide

拆装前，需用掩木将车轮掩实，防止溜车

□ Lift the vehicle to safety height with jack

用千斤顶将车辆举升至安全高度

□ Remove the tyre retaining bolts and remove the front

wheel vehicles

拆卸轮胎固定螺栓，拆下车辆前轮

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□ Remove joint nut of steering lever and power steering

machine

拆卸转向直拉杆与动力转向器连接螺母

□ Remove the front saddle bolts ， r

emove the front

bumper blocks

拆卸前骑马螺栓，拆下前缓冲块

□ Remove the front brake and vehicle connect pneumatic

tubing and remove the front axle assembly

拆卸前制动器与车辆连接气动管路并取下前桥总成

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2、 Decomposition front axle assembly 前桥总成分解

□ □ Remove the hub caps and remove the front wheel nuts

拆下轮毂罩，拆卸前轮外螺母

□ Remove the front wheel hub with brake drum assembly

卸下前轮毂带制动鼓总成

□ Remove the sleeve and front brake mounting nut and

remove the front brake assembly

卸下衬套与前制动器固定螺母，取下前制动器总成

□ Remove the main pin cover

拆下主销盖

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□ Remove the cotter pin and remove steering lever and

steering bend arm retaining nut and remove steering

lever

取下开口销，卸下转向直拉杆与转向弯臂固定螺母，

取下转向直拉杆

□ Remove the cotter pin and remove joint nut of steering

lever and steering arm

拆下开口销，拆卸转向横拉杆与转向直臂连接螺母

□ Remove the joint nut of steering lever and steering arm,

and remove steering lever

拆卸转向横拉杆与转向弯臂连接螺母，取下转向直拉

杆

□ Remove fixing nut of steering straight arm and bushing,

steering bend arm and bushing mounting nuts, remove

steering straight arm and steering bend arm

分别拆卸转向直臂与衬套固定螺母、转向弯臂与衬套

固定螺母，取下转向直臂与转向弯臂

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□ Remove the main pin retaining nuts and remove thrust

bearing

拆卸主销固定螺母、取下止推轴承

□ Remove the main pin and bushing

拆下主销、衬套

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3、 Front axle assembly 前桥装配

□ Multiple steps in contrast to the disassembly sequence 复装的步骤与拆解顺序相反

□ Assembly considerations 装配注意事项

 Before assembly parts outside surface should be clean, no rust, burrs, cracks and other defects;

装配前各零部件外表面应清洁，无锈蚀、毛刺、裂纹和其他缺陷；

 Before the brake assembly should be checked before assembly, brake shoe surface can not have oil,

brake tendon plate and brake wheel cylinder pump tank should have clearance, no clearance does not

allow assembly, each pipe joint shall be installed firmly;

前制动器总成装配前应进行检查，制动蹄片外表面不得有油污，制动蹄筋板与制动分泵泵槽

应有间隙，无间隙的不允许装配，各管接头应安装牢固；

 Before assembly, front axle and steering knuckle, steering arm straight forgings convex mesa is

convex, dept. of mark to use file file;

装配前，前轴、转向节、转向直臂等锻件凸台面上有凸起、磕痕处要用锉刀锉平；

 Front axle assembly to make a comprehensive inspection, all nut must be tightened according to the

specified torque value, the assembly lubrication mouth parts should be injection lubrication, until

from a crack in the parts of extrusion, front axle and steering knuckle end clearance and wheel hub

bearing looseness should carry on the sampling inspection;

前轴总成要进行综合检查，所有螺母必须按规定扭矩值拧紧，各装配润滑嘴部位应注入润滑脂，

直至从零部件的缝隙中挤出为止，前轴与转向节端面间隙和轮毂轴承松紧度应进行抽样检查；

 Left and right steering knuckle, thrust bearing, type O sealing ring and adjusting shim, guarantee the

steering knuckle and front axle end single side clearance is not greater than 0.1 mm; Unilateral

adjusting shim not more than 2 slices;

装左、右转向节、止推轴承、O 型密封圈及调整垫片，保证转向节与前轴端面单侧间隙不大于

0.1mm；要求单侧调整垫片不多于 2 片；

 Section will turn to dust cover in the steering knuckle (lower) king pin hole hole steps, a flat surface

rung up tight, along the circumferential and rivet rivet at three;

将转向节防尘盖放入转向节（下端）主销孔台阶孔内，将曲面敲平涨紧后，沿周向冲铆三点铆

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紧；

 Both inside and outside the front wheel hub bearing race between roller and thoroughly lithium base

grease, fitting within the hub, two bearing between the inner surface, end face and hub bearing block

filling 190 + 10 g lithium grease (unilateral), fill inside hubcap;

在前轮毂内外轴承座圈和滚柱之间充分涂抹锂基润滑脂，合件轮毂内、两轴承挡内表面、端面

及轮毂轴承挡之间填充 190±10g 锂基润滑脂（单侧），轮毂罩内填充；

 Front wheel hub oil seal, use special tools by the oil seal pressure into the front wheel hub oil seal

seat inside the hole, the pressure of the oil seal pressure into the 2.94 x 106 n/m2, oil seal face shall

not be higher than that of wheel hub face;

装前轮毂油封，用专用工具经油封压入前轮毂内油封座孔内，油封压入的压力为 2.94×106N/m2，

油封端面不得高出轮毂端面；

 From the steering knuckle small end into the oil seal seat, the wheel hub and brake drum and woolly

steering knuckle petiole, in turn into the lock, nut, screw the nut, nut tightening torque: 147 ~ 176

N · m, to turn 50 ° ~ 80 ° make nut notches on the recent split pin hole, again into the split pin.

从转向节小端套入油封座，将轮毂及制动鼓合件套转向节柄部，依次装入锁片、螺母、拧紧螺

母，螺母拧紧力矩：147～176 N·m，再回转 50°～80°使螺母槽口对准最近的开口销孔，再装入

开口销。

Requirements: brake drum can be moved freely, check its axial load is 10 ~ 25 n, but there is no

obvious axial channeling and oscillating phenomenon; Inspection method: use a spring balance hook

outside the tire bolts of twisting the tangent direction of fine line, tension within the scope of the 10 ~ 25

n, brake drum assembly can free uniform rotation is unqualified, less than 10 n rotation for loose, greater

than 25 n turns too tight. Turn the brake drum assembly 10 ~ 20 times before inspection, make the bearing

grease evenly distributed.

要求：制动鼓能够自由转动，检查其轴向负荷为10～25N，但不允许有明显的轴向窜动和摆动

现象；检查方法：用弹簧秤钩挂在缠绕轮胎螺栓外圆切线方向的细线上，拉力在 10～25N 范围

内，制动鼓总成能够自由匀速转动为合格，小于 10N 转动为过松，大于 25N 才转动为过紧。检

查前转动制动鼓总成 10～20 圈，使轴承润滑脂均匀分布。

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4、 Front Axle Adjustment 前桥调整

 Front wheel toe-in measurement and adjustment 前轮前束测量和调整

□ Let front wheel on a flat position

将前轮置于平坦的位置

□ Mark in the center of the tire wheel track

, and place the

equipment of toe-in measuring in the center of the wheel

用笔在轮胎轮距中心部位做标记，放置测量前束装置

在车轮的中心位置

□ Measuring the distance between the center line of the

tire in front of the vehicle (A), push the vehicle to the

rear or forward to let each wheel rotate 180 degrees, in

accordance with the original mark measure the distance

between the tire center line of front-wheel rear side(B).

The toe-in is equal to the B subtract A

在车辆前面测量轮胎中心线之间的距离(A)，把车辆

向后或向前推，将每个车轮转动 180°，按照原标记

测量前轮后侧的轮胎中心线之间的距离(B)，前束等于

B 减 A

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□ If the toe-in does not match, loosen the end of the

connecting rod clamping bolt. Use a wrench reverse link

to adjust the front harness

如果前束不符合，松开连杆端头的夹紧螺栓，用扳手

扭转连杆以调整前束

 Turn radius adjustment 转向半径调整

□ Put the front wheels on a flat position and put wooden

block under the rear wheels, and its thickness and

measuring instruments thickness are the same. Put the

front wheel on the instruments, and to ensure it is in the

center of instruments. Turn the front wheels in clockwise

and counter-clockwise separately to the maximum

position

将前轮置于平坦的位置在后轮下加木垫块，其厚度和

测量仪器的厚度相同。把前轮放置在仪器上，并保证

置于仪器的中央。分别以顺时针和逆时针方向转动前

轮到最大位置

□ Note: when turn the front wheels, depress the brake

pedal

注意：在转动前轮时，要踩下制动踏板

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 The inner and outer wheels angle adjustment 内轮和外轮转角调整

□ The put the front wheels on a flat position loosen the

adjusting screw lock nut of the steering section and

adjust the screws height, till steering angle meeting

requirement and tighten the lock nut

将前轮置于平坦的位置拧松转向节上的调整螺栓的

锁紧螺母，调整螺栓的高度，直到转向角达到要求，

拧紧锁紧螺母

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IV Fault diagnosis and solutions 故障诊断与处理

Front axle bearing anti-competitiveness in vertical direction surface from the ground, horizontal

direction braking force, inertial force, braking resistance and torque resulted from braking and so on. As

front axles long endure the serious impact load, following may occur:

前桥承受来自地面的垂直方向反力、水平方向制动力、惯性力、制动阻力和制动时引起的转矩

等。汽车前桥长期承受这些交变冲击载荷，可能发生以下故障：

Faults 故障 Fault cause 故障原因

Fault repai

r

故障维修

Front axle fatigue

damage, cracks or

broken fault

前桥疲劳损伤、裂纹或

断裂故障

Front axle load is too large, long-term

overload

前桥负荷过大，长期过载

Parts should be replaced timely

应及时更换新件

The front axle happens

bent failure in the

vertical direction

前桥在垂直方向产生

弯曲变形故障

As front axle bear large

anti-competitiveness in the vertical

direction from the ground and it is

easy to cause bent, will change the

pin pitch, outside of the wheel angle,

the diesel vehicle steering heavy,

wheel hub bearing load increases, and

reduce its life

前桥在垂直方向上承受来自地面的

反力很大，易产生弯曲变形，会改

变主销内倾角、车轮外倾角，会使

柴油车转向沉重，轮毂轴承负荷增

大、降低使用寿命

Beams should be corrected timely

应及时校正横梁

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The front axle happens

bent failure in the

horizontal direction

前桥在水平方向产生

弯曲变形故障

Front axle bear the braking force in

the horizontal direction from under

ground ,which is easy to cause bent,

will change Front Wheel toe-in and

increase tire wear

前桥在水平方向承受来自地面的制

动力易产生弯曲变形，会改变前轮

前束，增大轮胎磨损

There should be timely correction

front beams

应及时校正前横梁

The front axle has

distorted fault

前桥产生扭曲变形故

障

Front axle with a reverse deformation

will change the caster angle, and

impact front-wheel driving stability

前桥产生扭转变形会改变主销后倾

角，影响前轮行驶稳定性

Replace the front beam or to correct

repair

更换前横梁或进行校正修理

The front axle shaft

with Thermal fault

前桥轴头发热故障

Shaft heat typically occurs after

maintenance, and often resulted from

bearing pre-pressure too tight to seat

bearings with too tight when

assembly wheel hub. Wheel hub

bearing damage or pitting will not

only result in heat but also with some

noise. Wheel hub bearing lacking oil

can also cause shaft thermal failure

轴头发热一般发生在修理保养之

后，往往是在装配轮毂时，轴承预

压过紧使轴承配合过紧所致。轮毂

轴承损坏或点蚀不仅会发热而且还

会有噪声。轮毂轴承缺油也会造成

轴头发热的故障

Check the bearings for tightness and

wheel hub bearings for the oil

检查轴承配合松紧和轮毂轴承是否

缺油

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The front axle brake

drums heat failure

前桥制动鼓发热故障

The main reason of brake drum heat

is air brake chamber diaphragm do

not return to the original place or

return too slow; brake shoe return

spring broken or weak will cause

brake drum heat

制动鼓发热的主要原因是气制动室

膜片不回位或回位太缓慢所致；制

动蹄回位弹簧断裂或弹力不足也会

造成制动鼓发热

There is no gap between brake shoes

and brake drum, which will obviously

cause brake drum heat. At this time

except check adjust clearance, should

check the problem of air chamber

diaphragm without returning, and

when the brake air chamber

diaphragm does not return, the air

problem should check and check

whether the brake camshaft stocked

制动蹄片与制动鼓没有间隙，显然

也会造成制动鼓发热。此时除检查

调整间隙外应检查气室膜片不回位

的问题，制动气室膜片不回位除检

查气路故障外应检查制动凸轮轴是

否发卡

The master pin bushing,

main pin, thrust bearing

wear-out failure

主销衬套、主销、止推

轴承磨损故障

The pin bushing, the main pin, thrust

bearings are worn, the absenteeism,

will affect the wheel alignment, lower

the lever stability

主销衬套、主销、止推轴承磨损、

松旷，会影响前轮定位，降低操纵

杆稳定性

Replace worn parts and re-front wheel

alignment

应更换磨损件并重新进行前轮定位

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Step brake lightly with

the front wheels failure

轻踩制动时前轮发摆

故障

This is mainly caused by the drum

round error value, while the two front

wheels in part-load when the brakes

are applied, since the brake force is a

little, the two front wheels have a

braking effect are not in sync, and

some times in the left brake, and

sometimes in right brake resulting

front wheel wiggle

这主要是制动鼓圆度误差超值所

致，当两前轮在部分负荷制动时，

由于制动力小，两前轮产生制动效

果不同步，时而左刹、时而右刹从

而造成前轮摆动

Removal brake drum checks and

makes the cut. Tire rims deformed

sometimes will also cause this

problem

此时应将制动鼓拆卸检查并进行光

削修理。轮胎钢圈变形有时也会产

生这种故障

The front brake drum

rotor oil

前制动鼓甩油故障

Front brake drum swings oil, which is

clearly because of hub oil seal

damage. Wheel Hub Oil Seal Leak

not only caused shaking oil, but will

also enable brake failure

前制动鼓向外甩油显然是轮毂油封

损坏所致。轮毂油封漏油不仅造成

甩油，而且会使刹车失灵

Replace it with a new oil seal to

troubleshooting

更换新油封才能将故障排除

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Steering heavy fault

转向沉重故障

Front axle steering system mechanical

failure; steering hydraulic power

system failure

前桥转向系统机械部分故障；转向

液压动力系统的故障

Steering heavily owing to the

mechanical portion of the burden is

mainly due to the steering joint pin

lacking of the oil. Long-term without

maintenance, not apply grease to

steering joint pin, which cause the

pin-to-Bushing dry friction, not only

increase steering resistance heavily,

and can be as severe as the

pin-to-bushing sintered. Therefore, the

service require apply grease to

steering joint pin, generally first, lift

up the I frame of front axle ,apply oil

with a grease gun to oil mouth which

is installed on the camshaft holder

until the beam with pin holes, the flat

extruder oil

由于机械部分造成的转向沉重主要

原因是转向节主销缺油。长期不保

养，不向转向节主销内加注润滑脂，

造成主销与衬套干燥摩擦，不仅增

加转向阻力，使转向沉重，而且严

重时会造成主销与衬套烧结。因此，

要求在保养中应向转向节主销中加

润滑脂，一般先将前桥工字梁顶起，

用黄油枪向安装在凸轮轴座上的黄

油嘴注油，直到工字梁与销孔上、

下平面挤出油为止

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The front tire wear and

tear are not normal fault

前轮胎磨损不正常故

障

The reason of that front tire wear and

tear are not are much complex, and

toe-

in value is not right clearly will

worn front tire, Steel ring

deformation, shaft and the

absenteeism, the beam is deformed,

the main pin clearance, and so on, all

of which can cause wear front tire

failure

前轮磨损不正常的因素较为复杂，

前束值不对显然会磨损前轮胎，钢

圈变形、轴头松旷、工字梁变形、

主销间隙过大等都会造成磨损前轮

胎的故障

Troubleshooting the issue is a

complex work, it is necessary to take

into account the front wheel alignment

of the parameters of the change, but

also to take into account other factors

排除此故障是一项复杂的工作，既

要考虑到前轮定位各项参数的变

化，又要考虑其他方面因素的影响

The front-wheel brake

drift

前轮制动跑偏故障

There are two reasons for front wheel

brake deviation. The clearance

difference between left and right

brake make the braking starting time

is not synchronized; left and right

brake shoes and brake drum to contact

different size or the oil causing

contact friction torque of the

differences, which results in different

brake torque to the brake run in

deviation

前轮制动跑偏有两个方面的原因。

左、右制动蹄片间隙不同，使开始

投入的制动时间不同步而造成的；

When the vehicle's braking drift, by

adjusting brake shoes clearance

cannot be excluded when it is, and

should be remove brake drum

inspection and the mill

当汽车制动跑偏、通过调整制动蹄

片间隙不能排除故时，应拆卸制动

鼓进行检查和光磨

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左右制动蹄片与制动鼓接触面积不

同或由于油污造成接触摩擦力矩的

差异，从而产生不同的制动力矩导

致制动跑偏

The brake failure

doesn't work

制动不灵故障

Brake inefficiency is the problem of

braking drum and braking shoe except

the reason of braking control system.

In the actual repair, Check brake

effect often using the brake drum and

brake shoes contact area, and the

general requirements for brake shoes

and brake drum contact area should

be more than 70 per cent. From the

practical experience, two end-engaged

of the brake shoes are much more

productive than the median engage

制动不灵除制动控制系统原因外，

就是制动鼓与制动蹄片的问题。在

实际维修中，往往用制动鼓与制动

蹄片接触面积来检查制动效果，一

般要求制动蹄片与制动鼓接触面积

应在 70% 以上。从实践经验看来，

制动蹄片两端啮合要比中间啮合效

果好的多

In the mill foot-and-mouth, its

diameter should be slightly larger than

the diameter, in order to ensure that

shoes engage both ends, in order to

get the most recent braking

effectiveness

在光磨蹄片时，其直径应略大于鼓

的直径，以保证制动蹄片啮合两端，

以便获得最近制动效果

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Chapter Ⅳ Rear axle

第四章后桥

Ⅰ Overview 概述

This series drive axle is for two-wheel drive, rear suspension is not single suspension construct. it

comprises reducer、bevel gear differential and drive axle housing and some of other parts. It is the last

stage reducing speed mechanism in automotive driving system.

Final reduction can enlarge torque and reduce rotate speed, at the same time change the direction. It

is composed of driving gear and driven gear. Driving gear, in which side there is spine, connects with

coupling assembly of driving axle by driving gear’s flange. It is sustained by two cone bearings, which is

reverse assembled, in its middle for supporting axial force and radial force. The axle neck on small end of

driving gear, bearing radial force, is assembled columnar bearing. Driven gear is fastened to left housing

of differential of some bolts.

Differential, which can make the right and left wheel’s rev different, consists of the housing of

differential, spider, four spider gears, and two side gears and some of other parts.

Drive axle’s half-shaft is connected with half-shaft gear by spine in one side, and with hub by some

bolts in flange in another side.

该系列后桥是两轮驱动汽车驱动桥，后悬挂是非独立悬挂结构。由主减速器、差速器及桥壳等

部分组成，是汽车传动系中末级减速传动机构。

主减速器即能改变传动方向，又能降低转速、增大扭矩。它由主动齿轮和从动齿轮组成，主动

齿轮有花键的一端通过主齿凸缘与传动轴万向节总成连接，中间支撑在两个安装方向相反的圆锥轴

承上，以承受轴向力和切向力。主动齿轮小端面颈则安装在圆柱滚子轴承上，仅承受径向力。从动

齿轮用螺栓紧固在差速器左壳上。

差速器是使左、右车轮可产生不同转速，它由差速器左右壳、十字轴、二/四个行星齿轮、两

个半轴齿轮等零件组成。

后桥半轴的一端用花键与半轴齿轮连接，另一端凸缘用螺栓与轮毂带制动鼓总成连接。

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Rear axle important parameters

后桥重要参数

Project 项目 Date 参数

Load rating of rear axle

后桥额定载荷

9 T

Maximum input torque

最大输入扭矩

24000 N.m

Rear axle model

后桥型号

2400000LE359

Gear oil model

齿轮油型号

（GL-5)75W / 90

Gear oil filling quantity

齿轮油加注量

11L

The main reduction ratio

主减速比

4.875

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Ⅱ Location map and exploded 位置图及爆炸图

1、Location map 位置图

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2、Exploded diagrams 爆炸图

□ Rear axle assembly 后桥总成

S/N 序号 Spare Parts Name 备件名称

01 bolt 半轴螺栓

02 spring washer 重型弹簧垫圈

03 shaft 半轴

04 oil seal 半轴油封

05 lock washer 锁止垫圈

06 nut 后轮毂轴承锁紧螺母

07 the rear wheel hub with brake drum assembly (left) 后轮毂带制动鼓总成（左）

08 nut 六角螺母

10 hex nut 六角螺栓

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12 bolt 减壳螺栓

14 bolt 减壳螺栓

15 main reducer unit 主减速器总成

16 bleeding plug 放油塞

17 plug coke 放油塞密封垫圈

18 rear axle assembly 后桥壳总成

19 vent-plug 常开式通气塞

20 plug coke 加油塞密封垫圈

21 plug cock 加油塞

22 brake assay(l) 制动器本体(左）

22 brake assy(r) 制动器本体(右）

23 braket 气制动支架（左）

23 braket 气制动支架（右）

24 spring brake chamber assembly(l) 弹簧制动气室总成（左）

24 spring brake chamber assembly(r) 弹簧制动气室总成（右）

25 adjusting arm assembly (l) 调整臂总成（左）

25 adjusting arm assembly (r) 调整臂总成（右）

26 camshaft(l) 凸轮轴（左）

26 camshaft(r) 凸轮轴（右）

27 ABS sensor ABS 传感器

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□ Drum assembly 轮毂总成

S/N 序号 Spare Parts Name 备件名称

01 inner oil seal 后轮毂内油封

02 rear brake drum 后制动鼓

03 wheel hub-outer bearing 轴承

04 rear hub 后轮毂

05 wheel hub-outer bearing 轴承

06 wheel bolt 轮胎螺栓

06 wheel nut inside 轮毂内螺母

07 toothed ring 齿圈

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□ Main reducer assembly 主减速器总成

S/N 序号 Spare Parts Name 备件名称

01 gear assembly 主动齿轮总成

02 shim 主齿轴承座调整垫片

03 guided bearing 主动齿轮导向轴承

04 final drive housing assembly 主减速器壳总成

05 differential unit 差速器总成

06 bolt 螺栓-从动齿轮

07 bolt 螺栓

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□ Differential assembly 差速器总成

S/N 序号 Spare Parts Name 备件名称

01 bearing 差速器轴承

02 differential case 差速器壳总成

03 thrust plate 半轴齿轮止推垫片

04 side gear combination 侧卫齿组件

05 spinder 行星齿轮轴

Note: The above picture is the typical part pictures, there is a slight difference in some type vehicles, here is no

longer remark.

备注：上述图片为典型部件图片，部分车型存在细微区别，此处不再标识。

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Ⅲ Remove, install and adjust 拆装与调整

1、Matters needing attention 注意事项

□ Check the parts with special inspection implement or tool

应使用专门的测量仪器或工具来检查零件

□ Decide whether one part can reuse or not according to maintenance standard table. Broke part must

be repaired or replaced. If one of partner parts wore, leading

clearance out of set standard, we must

change the partner parts and other accessories in accordance with relevant requirements.

根据指定维修标准表来断定零件是否能继续使用。损坏零件按要求进行修理和更换。如果在

配对零件中有一个被磨损，使间隙超出了规定的间隙，按有关要求更换此零件以及其他配件。

□ Some repairing parts which still in limited tolerance must be change according to pre-maintenance

opinion.

从预防保养的观点出发，某些仍在修理或磨损极限内的零件，在超出极限之前就应更换。

□ All rubber parts, such as O loop, oil seal, shim etc., can not be reused after disassembly.

所有的橡胶件，如O形圈、油封、垫片等在拆下之后应抛弃，不准再使用。

□ When there have noise or shake in transmission system, check the total clearance of rear axle firstly

then decide whether to disassembly differential carrier assy.

传动系统产生异响或震动时，先测量后桥的总游隙，决定是否需要拆卸主减速器总成。

□ Stop the truck on flat ground, push the transmission or transfer into empty speed position, rise the

truck after braking with hand brake rod, turn the flange clockwise to bottom, mark matching sign on

dust cover & carrier, then turn the flange counterclockwise to bottom, measure the mark moving

distance. The limit windage is 6mm，if measured date is bigger then the limit, we must disassembly

rear axle and adjust it.

将车辆放在水平地面上，将变速器及分动箱置于空档位置，拉上驻车制动杆后将车辆顶起。顺

时针方向旋转凸缘到底，并在凸缘防尘罩和减壳上做匹配标记，再反时针方向将凸缘旋转到底，

测量两匹配标记所移动的距离，极限游隙为6mm，游隙大于极限，说明后桥的齿轮间隙过大，

必须拆卸后加以调整。

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□ Abnormal noise, which belong to noise, such as clash or harshness etc. abnormal sound under

different condition, some can die away after normal wear, some change much bigger, and the main

reason is improper adjustment assembly, we can solve them through adjusting the parts assembly

clearance if all parts are good.

异响属噪音的一种，主要表现为在不同的使用条件下（如车速、路况）会产生撞击声或刺耳的

尖叫声等非正常声响，有些声响会通过磨合逐渐消失，有些声响会不断加大；主要是因为装配

调整不当造成的，在零件合格的前提下，其解决方法大多可通过调整零件装配间隙解决。

2、Remove rear axle assembly 后桥总成拆卸

□ Before disassembling, vehicle wheels need to be stopped

by woods to prevent the slide

拆装前，需用掩木将车轮掩实，防止溜车

□ Lift the vehicle to the safety height with jack

用千斤顶将车辆举升至安全高度

□ Remove the tyre retaining bolt and remove the rear

wheel of the vehicle

拆卸轮胎固定螺栓，拆下车辆后轮

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□ Disassemble the link bolts between transmission shaft

and differential carrier assembly

拆卸传动轴与主减速器的连接螺栓

□

Remove the front saddle bolts. Remove the front

bumper blocks

拆卸前骑马螺栓，拆下前缓冲块

□ Remove the Rear brake and vehicle Connect pneumatic

tubing and remove the front axle assembly

拆卸后制动器与车辆连接液力制动管路并取下前桥

总成

3、 Decomposition rear axle assembly 后桥总成分解

□ Remove the half shaft

拆卸半轴

 Loosen the half shaft nuts

松开半轴螺母

 Disassemble the half shaft. if difficult, strike the shaft

slightly with copper hammer until it loose

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拆下半轴。如果半轴卸不下，用铜锤轻轻的敲击半轴

法兰，直到半轴松动

□ Disassemble wheel hub

分解轮毂

 Disassemble the lock washer

拆下锁止垫圈

□ Disassemble the wheel hub bearing lock nut

卸下轮毂轴承锁紧螺母

□ Disassemble the wheel hub assembly

拆下轮毂总成

□ Disassemble oil seal bush with inner bearing inner ring

同内轴承内圈一起，拆下油封衬套

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□ Disassemble the brake drum

拆除制动鼓

□ Disassemble differential carrier assembly

分解主减速器总成

 Check and record the backlash of pinion & ring gear

before disassembly

在分解之前，测量和记录主被动齿轮的齿侧间隙

 Note: check the mesh condition of gears after adjust

注意：调整后，检查齿轮啮合情况

□ Disassemble lock plate

拆除锁片

□ Mark matching sign on the bearing cover and shell

在轴承盖和壳体上，作上装配标记

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□ Loose bolt of bearing cover, then disassemble adjusting

nut with differential wrench

拧松轴承盖的固定螺栓，利用差速器扳手，拆下调整

螺母

□ Disassemble bearing cover and bolt

拆下轴承盖和螺栓

□ Disassemble the differential case assembly

拆下差速器总成

□ Disassemble the pinion gear assembly with special

disassembly implement, at the same time remove the

adjusting shim

利用拆卸器拆下主动齿轮总成，同时拆下调整垫片

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□ Disassemble differential case assembly

分解差速器总成

 Disassemble right case

拆下差速器右壳

□ Disassemble shaft gear and shim

拆下半轴齿轮和支承垫圈

□ Inspection and record the backlash of planet gear

测量和记录行星齿轮的齿侧间隙

 Note: locking the cross shaft when check backlash

注意：测量齿侧间隙时，要压住行星齿轮十字轴

□ Disassemble the cross shaft and

planet gear assembly

then take out the planet gear and washer

拆除行星齿轮十字轴总成，再从十字轴上拆下行星齿

轮和支承垫圈

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□ Take out shaft gear and shim

拿出半轴齿轮和半轴齿轮的止推垫圈

 Remove the driven gea

r

拆下从动齿轮

□ Disassemble differential case bearing

从差速器壳上拆下差速器轴承

□ Disassemble of drive gear

主动齿轮的拆卸

 Disassemble the

m

ain gear flange nut

拆除主齿凸缘螺母

□ Disassemble spring loop and remove the driving gear

guide bearing

拆除轴用弹性挡圈和取下主动齿轮导向轴承

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□ Push out the

driving gear

从轴承座上压出主动齿轮

□ Disassemble adjusting washer and bearing bushing

拆除调整垫圈和轴承隔套

□ Disassemble the bearing from the driving gear

从主动齿轮上拆下轴承

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4、 Rear axle assembly and adjustment 后桥装配及调整

□ The assembly of differential carrier assembly is reverse with disassembly. All parts need to be

cleaned before assembly, no oil, iron and other impurities, which are coated with oil lubrication

assembly, the 10th and adjusted according to the requirements of the following:

主减速器总成装配按以上拆卸逆过程装配，装配前所有零件许保持清洁，无油污、铁屑等杂物

存在，涂以 10 号机油润滑装配，并按以下要求进行调整：

 Preload of pinion fear inner and outer bearing

主动齿轮内外轴承预紧

The taper bearing must preload when assembly differential carrier assy, that is on the basis of

removing backlash of bearing, press somewhat preload more, the aim is to decrease pinion gear axis

movement in transmission. But the preload can not press too much, or the bearing will be worn

rapidly.

装配主减速器时，圆锥滚子轴承应有一定的装配预紧度，即在消除轴承间隙的基础上，再给予

一定的预紧力。其目的是为了减少在锥齿轮传动过程中产生的轴向力引起的轴向位移，以提高

轴的支承刚度，保证锥齿轮副的正常啮合。但也不能过紧，若过紧则传动效率低，且加速轴承

磨损。

 Adjustment of pinion gear preload: after tight pinion nut, assembly pinion oil seal and adjust the

preload(without ring gear) through remove or add shim between inner and outer bearing. adding shim,

preload also add and remove shim, it will be decrease.

主动齿轮轴承预紧力调整：在主齿凸缘螺母拧紧力矩的条件下，装上主齿油封，主动齿轮未与

从动齿轮啮合，保证主齿轴承预紧力矩。预紧度的调整在主齿内外轴承之间增加或减少主齿轴

承调整垫圈。调整垫片减少，预紧力矩增加；调整垫片增多，则预紧力矩减少。

□ Adjustment of differential case bearing preload

差速器轴承预紧调整

 Adjust of differential bearing: differential bearing should have suitable preload, make two side

over0.01-0.02mm. the bearing start torque is 0.686-1.586 N.m when lubricating the bearing with gear

oil under pinion & ring gear non-match condition. It can get through tight side nut. Tight cover bolt,

then adjust preload. After adjustment, the lock slot should align to lock plate and ring gear have no

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axis movement.

差速器轴承的调整：差速器轴承应调整使其具有预紧力，使其两侧得到 0.01-0.02 的过盈,在主

从动齿轮未啮合条件下在轴承转动部分加注齿轮油,起动摩擦力矩为 0.686-1.586N.m。差速器轴

承预紧力调整是借拧紧差速器轴承螺母调整来进行的，调整时应先将轴盖自由地盖上，待调整

环拧动自如时，再将轴承盖螺栓拧紧，然后再调整预紧力。调整后的调整螺母上的锁槽应对准

锁片位置。调整后被动齿轮应无轴向窜动。

 Adjust backlash of differential case gear

差速器齿轮间隙调整

Measuring planet gear backlash with gauge. Note: check more than 3 point, standard

values:0-0.15mm;

limiting value: 0.3mm.

用百分表在行星齿轮上测量差速器齿轮啮合间隙。注意：测量三个以上点，标准值：0～0.15mm；

极限值：0.3mm。

□ Adjust of pinion and ring gear backlash and pattern

主被动齿轮齿侧间隙、啮和印迹的调整

 Adjust backlash

齿侧间隙的调整

The standard backlash and vary (according to table 5), should check it along ring gear edge 4 points,

and the gauge head should be perpendicularity to check point.

主、从动齿轮正常啮合间隙及侧隙变动量见表 5，调整齿侧间隙时，应在从动齿轮沿圆周大致

均布的四个位置上进行测量，所用千分表的测量头应垂直与被测点表面。

 Adjust pattern

主被动齿轮啮印迹调整

Applying red paint on the ring gear tooth, turning the ring gear come-and-go, then checking the print

of tooth’s both side. If the print lie in medium and near to small side, total to 60% of whole tooth

surface, we can decide the pattern is good(according to attached picture1). We can get the pattern

through adjusting the pinion gear housing shim(table 6) and adjusting differential case bearing nut.

先在主动齿轮轮齿上涂红丹粉，然后用手使主从动齿轮反复转动，于是从动齿轮的两侧工作面

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上出现红色印迹，若从动齿轮正转和反转工作面上的印迹位于齿高的中间偏于小端，并占齿面

的 60%以上，为正确啮合。见附图。正确啮合的印迹位置通过主齿轴承座调整垫片及差速器轴

承调整螺母来调整的。

One bearing nut out circle should equal to another side nut in circle, thus the preload of side bearing

will not change. Recheck backlash and lock the lock plate.

为保持已调整好的差速器轴承预紧度不变，一端调整螺母拧入的圈数应等于另一端螺母拧出的

圈数。再确认间隙后，锁紧锁片。

□ The rear wheel hub with brake drum assembly according to remove the inverse process of assembly,

assembly time adjustment is as follows:

后轮毂带制动鼓总成装配按拆卸逆过程装配，装配时调整如下：

 The rear wheel hub bearing clearance adjustment

后轮毂轴承游隙调整

Tighten bearing nut to brake drum is not moving or rotating heavy, slightly loose bearing nut 1/6-1/8,

and then turn the brake drum, without any contact with the brake drum brake friction disc, should be

able to rotate freely.

将轴承螺母拧紧至制动鼓不动或转动沉重，然后稍松轴承螺母 1/6-1/8 圈，转动制动鼓，制动

摩擦片不与制动鼓接触情况下，应能转动自如。

□ The rear brake clearance adjustment

后制动器制动间隙调整

 Bidirectional balance brake according to the direction arrow on bottom plate adjustment hole, first

pump adjustment tooth pulled move two points respectively, brake drum and the friction plate die,

and then adjust the cylinder gear, respectively, and virtually back to 5 ~ 9 after the tooth, the brake

drum to flexible rotation.

双向平衡式制动器按底板调整孔处的箭头方向，先分别拔动两个分泵调整齿，使制动鼓与摩擦

片贴死，然后将分泵调整齿分别跋回 5~9 齿后，使制动鼓能灵活转动。

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□ Adjustment of backlash

齿轮啮合间隙调整方法图

Passive work gear tooth surface contact

Reason

Adjustment ways:

A

、

gear contact zone adjustment

B

、

gear side clearance adjustment

Partial gear top

Main gear is too far

from the driven gear

1、Driven gear moves away from

main gear

2、Main moves to the driven

gear to get the right

clearance

(Add gasket）

Partial gear roof

Main gear is too near

from the driven gear

1、Driven gear moves to main

gear

2、 Main moves away from the

driven gear to get the right

clearance

(Reduce gasket）

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Partial gear little side

The driven gear is too

near from Main gear

1、Driven gear moves away from

main gear

2、Main moves away from the

driven gear to get the right

clearance

(Reduce gasket）

Partial gear big side

The driven gear is too

far from Main gear

1、Driven gear moves to main

gear

2、Main moves to the driven gear

to get the right clearance

(Add gasket）

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Gear depth

Gear length

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Ⅳ Fault diagnosis and solutions 故障诊断与处理

Failures 故障 Causes 原因 Action 措施

Problem of wheel hub

bearing

轮毂轴承滞涩

preload is big

轮毂轴承预紧力大

adjust preload

调整预紧力

lack lubrication or misusing

轴承缺乏润滑或润滑脂不正确

add lubrication or change

加注或更换润滑脂

bearing is contaminated with dust

轴承沾灰尘

clean and add lubrication

清洗并加注润滑脂

problem of wheel

车轮发涩

camshaft may not be well lubricated or adjusting

arm can not get back to the original position

凸轮轴润滑不良或调整臂不回位

add lubrication or rectify failure part

加润滑脂或校正有故障部件

brake shoe or spring is broken or fatigued

制动蹄或气室回位弹簧折断或疲劳

exchange the failure part

更换有故障部件

abnormal noise

传动非正常声音

the gap of differential gear is not right

差速器齿轮间隙不当

exchange washer or gear

更换垫片或齿轮

preload of drive gear bearing is too small

主动齿轮轴承预紧力过小

adjust preload diff pinion

调整预紧力

lack lubrication

油平面过低

add enough lubrication

加足润滑油

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lubrication leak

润滑油泄漏

problem of oil seal

油封磨损、松动或损伤

Replace the oil seal

更换油封

The main reduction fastening bolt loose or

sealant damage

主减紧固螺栓松或密封胶损坏

Tighten bolts or recoat sealant

拧紧螺栓或重涂密封胶

The bolt bearing loose.

轴承座紧固螺栓松

In accordance with the provisions,

torque screw down the bolt

按规定力矩拧紧螺栓

Oil drain screw loose or pad damage

放油螺塞松或衬垫有损伤

Tighten the screw or replace the

gasket

拧紧螺塞或更换衬垫

Due to the overload bridge shell deformation

由于超载使桥壳变形

Correction or replacement of the

bridge shell

校正或更换桥壳

Air plug stuck or damage

通气塞被堵或损伤

Clean or replace vent plug

清洁或更换通气塞

problem of brake

制动力不足

malfunction of camshaft

凸轮轴旋转不灵

check camshaft

检查凸轮轴工作情况

the stroke of pushing rod is not well adjusted

推杆行程调整不当

adjust stroke

调整行程

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problem of brake

制动力不足

the problem of brake shoe lining

摩擦片过热或变质

exchange the brake shoe lining

更换摩擦片

the position of brake shoe lining is incorrect

摩擦片贴合不当

rectify the position

校正摩擦片贴合位置

water get into brake drum

制动鼓进水

press pedal and drain the water

行驶中轻踩踏板，排干水

the contacting face of brake shoe lining or brake

drum has grease

摩擦片或制动鼓接触面上有油脂

clear up the brake shoe lining or

exchange

清除油脂或更换摩擦片

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ChapterⅤ Drive shaft

第五章传动轴

I Overview 概述

Drive shaft is an important component that transmits power in the automotive driveline. It functions

with gearbox and drive axle to transmit the power of engine to the wheels, making the vehicle generates

driving force.

传动轴是汽车传动系中传递动力的重要部件，它的作用是与变速箱、驱动桥一起将发动机的动

力传递给车轮，使汽车产生驱动力。

The movable or rotatable circular parts that are connected or assembled to the drive shaft are usually

made of alloy-steel tube which is light and with good torsional resistance. For the front-engine rear-wheel

drive vehicle, drive shaft transfers the rotation of the transmission to the final drive shaft, which can be

made up of several sections and connected by universal joints. It is a rotating body with high rotating

speed and less support, which means the dynamic balance is of great importance. Generally, dynamic

balance test of drive shaft should be carried out before drive shaft leaves the factory, and adjustment of

drive shaft should be performed on the balance machine.

传动轴连接或装配各项配件，而又可移动或转动的圆形物体配件，一般均使用轻而抗扭性佳的

合金钢管制成。对前置引擎后轮驱动的车来说是把变速器的转动传到主减速器的轴，它可以是好几

节由万向节连接。它是一个高转速、少支承的旋转体，因此它的动平衡是至关重要的。一般传动轴

在出厂前都要进行动平衡试验，并在平衡机上进行了调整。

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Drive shaft important parameters

传动轴重要参数

Project 项目 Date 参数

Angular 摆角 ≥25°

Grease type 润滑脂型号 Mobil EP-2.5 美孚 EP-2.5

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II Location plan and exploded view 位置图及爆炸图

1、 Location map 位置图

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2、 Exploded view 爆炸图

S/N 序号 spare parts name 备件名称

01 spring washer 弹簧垫圈

02 nut 六角螺母

03 middium drive shaft assembly 中间传动轴总成

04 bolt, transmission shaft 传动轴螺栓

05 spring washer 弹簧垫圈

06 nut 螺母

07 drive shaft protection bracket assembly 传动轴保护架总成

08 rear axle drive shaft assembly 后桥传动轴总成

09 bolt 六角头螺栓

10 flat washer 平垫圈

11 spring washer 弹簧垫圈

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12 nut 六角螺母

13 hex nut 六角螺栓

14 nut 六角螺母

15 flat washer 平垫圈

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III Removal and Adjustment 拆装与调整

1、 Precautions 注意事项

□ Protection should be taken in the process of removing and installing parts to avoid scratches.

拆卸和安装部件过程中，应做好防护，以免出现划伤。

□ Check if there is poor lubrication of the parts when removing them, if necessary smear "Grease."

拆装某些部件时，检查部件是否润滑不良，如果有必要，进行润滑。

□ Multi-man cooperation is required in the removing process because of the complexity of auto parts.

由于汽车部件结构的复杂性，拆卸过程可能需多人配合进行。

□ Do not use excessive force when removing which may cause deformation of parts.

拆卸时请勿用力过大，因此可能导致零部件变形过大。

2、 Driveshaft Removal 传动轴拆装

□ When disassembling the drive shaft assembly, the

disassembly order is differential end nut, middle

hanging, transmission end nut, drive shaft assembly.

拆解传动轴总成，拆解顺序为差速器端螺母、中间吊

挂、变速器端螺母、传动轴总成

□ Make the vehicle in a steady state to prevent it from

slipping before removal and installation. Flat cart

should be put at the bottom of vehicle to prevent the

falling damage of drive shaft.

拆装前，使车辆处于平衡稳定状态，防止溜车。拆解

前须将平板推车放入车底部，防止传动轴跌落损伤

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□ Disassemble drive shaft and differential side coupling

nut

拆解传动轴与差速器端连接螺母，拆解时需在螺母上

做好标记

□ Disassemble the middle hanging mounting bolt

拆解中间吊挂固定螺栓

□ Disassemble drive shaft and transmission side coupling

nut

拆解传动轴与变速器端连接螺母，拆解时需在螺母上

做好标记

□ Remove the drive shaft, and disassemble the coupling

nut of front and rear axle

取下传动轴总成，拆解前轴与后轴连接螺母

Installation: Please note the following procedures and install in the reverse order of removal:

装配：按照拆解相反步骤开展,但是需要注意以下事项

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□ Caution: Make an assembling mark on the universal

joint when disassembling, because the drive shaft

requires a good balance performance.

注意：因为传动轴要求有良好的平衡性能,所以在拆

卸时，应在万向节上作好装配记号

3、 Universal joint tear open outfit

万向节拆装

□ When disassembling the universal joint, the disassembly

order is grease nipple of universal-joint pin, bearing

retainer of universal joint, needle roller bearings,

universal-joint pin, and flange yoke.

拆解万向节，拆解顺序为十字轴滑脂嘴、万向节轴承

挡圈、滚针轴承、十字轴、突缘叉

□ Gently knock on the universal-joint pin, and then

disassemble the needle roller bearings. Disassemble

other bearings with the same method.

轻轻敲击十字轴，拆下滚针轴承。用同样的方法将其

他轴承拆解

Installation: Please note the following procedures and install in the reverse order of removal:

装配：按照拆解相反步骤开展，但是需要注意以下事项：

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□ The flange yoke of drive shaft must be installed as the

picture shows: spline shaft and spline should be

assembled in alignment as the arrow shows.

传动轴的突缘叉必须如图所示安装，花键轴与花键叉

如箭所示对齐装配

□ Smear grease on the oil seal and needle roller bearings.

Assemble the needle roller bearings into flange yoke

with the universal joint pin as a guider. During assembly,

please use a soft faced hammer to knock.

把油封和滚针轴承涂上油脂。用十字轴做导向将滚针

轴承装进突缘叉中。装时用软面锤敲击

□ Install grease nipple to universal joint pin by a specified

angle. Make sure that the grease nipple is upwards.

安装润滑脂油嘴至十字轴规定角度。必须保证滑脂嘴

朝上

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4、 Removal of Center Bearing 中心轴承拆装

□ When disassembling the center bearing, the disasse mbly

order is intermediate rubber, center bearing, dustproof

cover, connecting fork, washers, and nuts.

拆解中心轴承，拆解顺序为中间橡胶、中心轴承、防

尘罩、连接叉、垫圈、螺母

Installation: Please note the following procedures and install in the reverse order of removal:

装配：按照拆解相反步骤开展，但是需要注意以下事项：

□ The seal lip and the center bearing should be coated with

bearing grease when in re-installation.

复装时把油封唇和中心轴承涂上轴承油脂

□ After the middle nut is tightened up, make a mark on the

nut and make two symmetric piling in the

circumferential direction.

中间螺母上紧后在螺母上打标桩。在圆周方向对称打

两个

□ Check the diameter of universal joint pin, and replace it

if there is any abnormal wear.

检查十字轴销直径，如果异常磨损就要进行更换

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□ Check spline backlash, and replace it if there is any

abnormal wear.

检查花键侧隙，如果异常磨损想要进行更换

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IV Trouble Diagnosis and Troubleshooting 故障诊断与处理

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Chapter Ⅵ Suspension

第六章悬架

I Overview 概述

The suspension system is the general term for all power transmission and connecting devices that

connected between the frame and axles or wheels. Its function is to transmit force and moment that

function between the wheels and the frame, cushion the impact coming from the uneven road and

attenuate the vibration resulted from the impact, in order to ensure smooth running. Functions that

suspension system should have are to support the body and improve the driving feeling, for different

suspension settings make drivers get different driving experience. Deceptively simple as it looks, the

suspension system integrates a variety of forces and determines the stability, comfort and safety of the

vehicle, becoming one of the crucial components of modern automobiles.

悬架系统是汽车的车架与车桥或车轮之间的一切传力连接装置的总称，其功能是传递作用在车

轮和车架之间的力和力矩，并且缓冲由不平路面传给车架或车身的冲击力，并衰减由此引起的震动，

以保证汽车平顺行驶。悬挂系统应有的功能是支持车身，改善乘坐的感觉，不同的悬挂设置会使驾

驶者有不同的驾驶感受。外表看似简单的悬挂系统综合多种作用力，决定着汽车的稳定性、舒适性

和安全性，是现代汽车十分关键的部件之一。

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II Location plan and exploded view 位置图及爆炸图

1、 Location map 位置图

Front suspension 前悬

Rear suspension 后悬

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2、 Exploded view 爆炸图

Front suspension 前悬

S/N 序号 Spare Parts Name 备件名称

01 front spring fix rack 前簧固定支架

02 rear spring fastness pin 后钢板固定销

03 spring washer 弹簧垫圈

04 nut 螺母

05 straight slide grease nib 直通式滑脂嘴

06 front left leaf spring assembly 前左钢板弹簧总成

06 front right leaf spring assembly 前右钢板弹簧总成

07 front cushion restrict-place block 前缓冲块限位铁

08 front u-bolt 前骑马螺栓

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09 spring washer 弹簧垫圈

10 front u-shape bolt nut 前骑马螺栓螺母

11 front cushion block 前缓冲块总成

12 front shock absorber 前减震器总成

13 hex nut 六角螺栓

14 spring washer 弹簧垫圈

15 nut 六角螺母

16 upper bracket, front shock absorber 前减震器上支架

17 bolt 六角头螺栓

18 spring washer 弹簧垫圈

19 washer 垫圈

20 washer 垫圈

21 down pin ,front shock absorber 前减震器下销

22 outside washer 外侧垫片

23 inner side washer 内侧垫片

24 nut 六角螺母

25 hex thin nut 六角薄螺母

26 rear spring fastness pin 后钢板固定销

27 spring suspend ,front steel spring 前簧吊耳总成

28 hex nut 六角螺栓

29 spring washer 弹簧垫圈

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Rear suspension 后悬

S/N 序号 Spare Parts Name 备件名称

01 rear leaf spring assembly(left) 后钢板弹簧总成（左）

01 rear leaf spring assembly(right) 后钢板弹簧总成（右）

02 rear spring iron cover plate 后簧上盖板

03 bolt 六角头螺栓

04 spring washer 弹簧垫圈

05 nut 六角螺母

06 horizontal stabilizer bar bush 横向稳定杆衬套

07 transverse stabilizer rod bracket 横向稳定杆支架

08 rear stabilizer bar 后稳定杆

09 nut, front u-bolt 骑马螺栓螺母

10 spring washer 弹簧垫圈

11 rear u bolt 后骑马螺栓

12 rear spring suspend pin 后板簧吊耳销

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13 straight slide grease nib 直通式滑脂嘴

14 rear stabilizer bar pin 后稳定杆销

15 rear stabilizer bar pad 后稳定杆胶垫

16 absorbers outer gasket 减震器外垫片

17 spring washer, light type 轻型弹簧垫圈

18 nut 六角螺母

19 rear spring suspend unit 后簧吊耳总成

20 connecting rod assy 连接杆总成

21 washer 垫圈

22 washer 垫圈

23 rear cushion block unit 后缓冲块总成

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III Removal and Adjustment 拆装与调整

1、 Front suspension removal 前悬拆装

□ When disassembling the front suspension, the

disassembly order is front shock absorber、U-bolt、 lug

pin、steady pin、leaf spring

拆解前悬，拆解顺序为前减振器、U 型螺栓、吊耳销、

固定销、钢板弹簧

□ Preparations: fix rear –wheel, and jack the vehicle, then

jack front axle with lift equipment.

准备工作：先抵住后轮，顶起汽车，然后再用举升装

置顶起前轴

□ Removal of U-bolt:

拆解 U 形螺栓：

 Loosen(not removing) U-bolt and nut

松开(不要拆下来)U 型螺栓和螺母

 Raise the vehicle ,and support it with the chassis holder

将车辆升起并将它支承在底盘支架上

 Remove U-bolt and nut

拆下 U 型螺栓和螺母

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□ Removal of front shock absorber

拆解前减震器

 Remove front shock absorber upper bracket and front

axle hold-down nut

拆解前减震器上支架与前轴固定螺母

 Remove front shock absorber lower bracket and front

axle hold-down nut

拆解前减震器下支架固定螺母

□ Remove front axle assembly

拆解前桥总成

 Removal of front leaf spring

拆解前板簧

 Remove front leaf spring hold-down nut

拆解前板簧固定螺母

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 Remove front leaf spring lug pin

拆解前板簧吊耳销

 Take down front leaf spring assembly

取下前板簧总成

Installation: Please note the following procedure and install in the reverse order of removal:

装配：按照拆解相反步骤开展，并注意以下事项

□ Make a assembling mark on the leaf spring intersecting

surface before removal leaf spring

拆卸钢板弹簧之前，要在钢板弹簧横面上做安装标记

□ Smear lubricating grease on two sides of leaf spring

在每个钢板弹簧两面上涂润滑脂

□ Remove center bolt cannot be reused and should be

replaced with new one

拆下的中心螺栓不要再使用，应更换新的中心螺栓

□ Use leaf spring with same sagitta ,when changing leaf

spring

更换钢板弹簧时，使用相同弧高的钢板弹簧

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□ Check the clearance between leaf spring bushing and

leaf spring pin. If the clearance is too big, leaf spring

bushing or leaf spring pin should be replaced.

查看板簧衬套与板簧销的间隙。如果间隙过大，应更

换板簧衬套或板簧销

□ Pay attention to filling lubricating oil (until the oil oozes

a little) when assemble lug pin.

装配吊耳销时应注意加注润滑油，至有少许渗出为止

□ Check the absorber leakage, and a little leakage is

acceptable.

检查减振器的泄露，允许有少量渗漏

□ Check the temperature of shock absorber rises or not,

after driving for some distance, if the temperature does

not rise, it indicates that the shock absorber is not

working and should be replaced.

车辆行使一段行程后，检查减振器的温度是否升高，

如果温度没有升高，说明减振器不工作，应予更换

□ Stretch shock absorber, if there is no heavy resistance, it

indicates the absorber does not work and should be

replaced

拉伸减振器，如果感觉不到有较大阻力，说明减振器

不工作，应予更换

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2、后悬拆装 Removal rear suspension

□ When disassembling the rear suspension, the

disassembly order is front shock absorber、U-bolt、lug

pin、steady pin、leaf spring

拆解后悬，拆解顺序为后减振器、U 形螺栓、吊耳、

板簧销、钢板弹簧

□ Fix rear –wheel, and jack automobile, then jack front

axle with lift equipment.

先抵住前轮，顶起汽车，然后再用举升装置顶起后桥

□ Removal U-bolt

拆解 U 形螺栓

 Loosen(not dismantle) U-bolt and nut

松开(不要拆下来)U 型螺栓和螺母

 Raise the vehicle ,and let it supports on the chassis

holder

将车辆升起并将它支承在底盘支架上

 Remove U-bolt and nut

拆下 U 型螺栓和螺母

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□ Remove rear shock absorber

拆解后减震器

 Remove rear shock absorber upper bracket and front

axle hold-down nut

拆解后减震器上支架与前轴固定螺母

 Remove rear shock absorber lower bracket and front

axle hold-down nut

拆解后减震器下支架固定螺母

□ Remove rear axle assembly

拆解后桥总成

□ Remove rear leaf spring

拆解后板簧

 Remove rear leaf spring hold-down nut

拆解后板簧固定螺母

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 Remove rear leaf spring lug pin, and take down rear leaf

spring assembly

拆卸后板簧吊耳销，取下后板簧总成

Installation: Please note the following procedure and install in the reverse order of removal:

装配：按照拆解相反步骤开展，但是需要注意以下事项：

□ Make a assembling mark on the leaf spring surface,

before removal leaf spring

拆卸钢板弹簧之前，要在钢板弹簧横面上做安装标记

□ Smear lubricating grease on two sides of leaf spring

在每个钢板弹簧两面上涂润滑脂

□ Remove center bolt can’t be reused ,should use new one

拆下的中心螺栓不要再使用，应更换新的中心螺栓

□ Use the leaf spring with same sagitta , when changing

leaf spring

更换钢板弹簧时，使用相同弧高的钢板弹簧

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□ Check the clearance between leaf spring bushing and

leaf spring pin. If the clearance is too big, leaf spring

bushing or leaf spring pin should be replaced

查看板簧衬套与板簧销的间隙。如果间隙过大，应更

换板簧衬套或板簧销

□ Pay attention to fill lubricating oil(until the oil oozes a

little),when assembling lug pin

装配吊耳销时应注意加注润滑油，至有少许渗出为止

□ Check the absorber leakage, and a little leakage is

acceptable

检查减振器的泄露，允许有少量渗漏

□ Check the temperature of shock absorber rises or not,

after driving for some distance, if the temperature does

not rise, it indicates that the shock absorber is not

working and should be replaced.

车辆行使一段行程后，检查减振器的温度是否升高，

如果温度没有升高，说明减振器不工作，应予更换。

□ Stretch shock absorber, if feel no heavy resistance, it

indicates the absorber does not work and should be

replaced.

拉伸减振器，如果感觉不到有较大阻力，说明减振器

不工作，应予更换。

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IV Trouble Diagnosis and Troubleshooting 故障诊断与处理

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Chapter Ⅶ Steering

第七章转向

I Description 概述

A series of devices used to change or keep the vehicle running or reversing are called automotive

steering systems .The function of steering system is to control of the driving direction in accordance with

the driver's will. Automobile steering system is critical to the driving safety, so auto steering system parts

are called security pieces. Automotive steering systems and braking systems are two important systems in

auto safety that must be paid attention to.

用来改变或保持汽车行驶或倒退方向的一系列装置称为汽车转向系统。汽车转向系统的功能就

是按照驾驶员的意愿控制汽车的行驶方向。汽车转向系统对汽车的行驶安全至关重要，因此汽车转

向系统的零件都称为保安件。汽车转向系统和制动系统都是汽车安全必须要重视的两个系统。

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Steering important parameters

转向系统重要参数

Project 项目 Date 参数

For maximum front axle load

适用最大前轴负荷

3.5 T

Theory of maximum output torque

最大理论输出力矩

2976N.m

Drive ratio

传动比

21.04 : 1

Turning laps

转向圈数

5.3±0.1

Output Angle

输出角

±45°

Input spline (diameter x number of teeth)

输入花键(外径×齿数)

Φ17.5×36

Output spline (big end diameter x number of teeth)

输出花键（大端外径×齿数）

Φ38.5×32

Oil pressure

工作油压

13MPa

Appropriate working temperature

适用工作温度

-40℃～+120℃

Oil pump rated flow

油泵额定流量

(12～14)L/min

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II Location plan and exploded view 位置图及爆炸图

1、 Location plan 位置图

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2、 Exploded view 爆炸图

S/N 序号 Spare Parts Name 备件名称

01 steering wheel 转向盘总成

02 dustproof cover 防尘罩

03 steering gear adjust rack unit 转向可调支架总成

04 steering column cover unit 转向柱护罩总成

05 steering shaft and driving universal joint 转向轴及传动万向节总成

06 steering gear assembly 转向器总成

07 hexagon flange bolts 六角法兰面螺栓

08 hex head bolt, spring washer, flat washer assembly 六角头螺栓、弹簧垫圈和平垫圈组合件

09 hex nut and taper washer 六角螺母和锥形弹性垫圈组合件

10 cross recessed pan head screw and washer assemblies 十字槽盘头螺钉和平垫圈组合件

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11 steering cover button 转向护罩卡扣

S/N 序号 Spare Parts Name 备件名称

01 power steering oil tank 动转油壶总成

01 power steering oil tank 动转油壶

02 bracket 动力转向油罐支架总成

03 worm drive type hose clamp B 型蜗杆传动式软管环箍

04 clip 蜗杆传动式环箍

05 hex nut 六角螺栓

06 spring washer 弹簧垫圈

07 flat washer 平垫圈

08 nut 六角螺母

09 bolt 六角头螺栓

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10 spring washer 弹簧垫圈

11 flat washer 平垫圈

12 nut 六角螺母

13 steering pump 动转油泵

14 pump inlet hose 油泵进油软管

15 power steering return pipe 动力转向回油软管

16 power steering return pipe 动力转向回油软管总成

16 power steering return pipe 向回油软管总成

17 bracket 支架

18 hose clamp (φ10) 平管夹

19 hose clip 橡胶管夹

20 hex nut 六角螺栓

21 bracket 支架

22 power steering oil inlet pipe assembly 动力转向进油管总成

23 power steering return pipe assembly 动力转向回油管总成

24 bracket 支架

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III Removal and Adjustment 拆装与调整

1、 Precautions 注意事项

□ In the process of disassembly and installation parts should be protection, lest appear scratches

拆卸和安装部件过程中，应做好防护，以免出现划伤

□ Check if there is poor lubrication of the parts when removing them, if necessary

smear "Grease"

拆装某些部件时，检查部件是否润滑不良，如果有必要，需进行润滑

□ Multi-man cooperation is required in the removing process because of the complexity of auto parts

由于汽车部件结构的复杂性，拆卸过程可能需多人配合进行

□ Do not use excessive force when removing, because it may cause deformation of parts

拆卸时请勿用力过大，因为可能导致零件变形

2、 Steering System Removal 转向系统拆装

□ When disassembling the steering system,the disassembly

order is steering wheel, combination switch, steering

column, steering shaft, power steering gear, dynamic

steering oiler, steering lines

拆解转向系统，拆解顺序为方向盘、组合开关、转向

管柱、转向轴、动力转向器、动转油壶、转向管路

□ Preparations: Make the vehicle in a steady state to

prevent it from slipping; The oil in the dynamic steering

oiler should be dumped before disassembling

准备工作：使车辆处于平衡稳定状态，防止溜车；拆

解前需将动力转向油壶中的动转油放尽

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□ Turn the cab over and remove the coupling nut between

steering shaft and power steering gear. Pre-mark on the

steering shaft and mounting bolts of the power steering

gear to ensure the corresponding installation

翻转驾驶室，拆解转向轴与动力转向器连接螺母。拆

卸前预先在转向轴与动力转向器固定螺栓上做标记，

安装时确保标记对应

c

□ Removal of steering wheel

拆解方向盘

□ Remove the steering wheel cover with both hands, and

remove the retaining nut that fixing the steering wheel

with sleeve

双手扣下方向盘上盖，并用套筒拆解下方向盘固定螺

母

□ Unscrewed the retaining nut, and disassemble the upper

cover of the steering column

拧下固定螺母，拆解转向管柱上护罩

□ Remove the retaining nut, and unplug the connectors,

then disassemble combination switch assembly

拆下固定螺母，拔下接插件，拆解组合开关总成

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□ Remove the lower cover assembly of steering column.

取下转向管柱下护罩总成

□ Remove the instrument panel (consult the cab

disassembling section).Disassemble the adjustable

steering bracket and steering column assembly

拆解仪表台（参见拆装驾驶室章节）。拆解转向可调

支架与转向管柱总成

□ Disconnect steering fluid pipe and steering gear coupling

nut

断开转向液钢管与转向器连接螺母

□ Remove the coupling nut between steering gear and

steering drag link

拆解转向器与转向直拉杆连接螺母

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□ Remove the retaining nut between steering gear and

frame and remove steering gear assembly

拆解转向器与车架固定螺母，拆下转向器总成

□ Remove the connection clamps between power steering

oil tank and oil in-and-back software

拆解动力转向油罐与进回油软件连接卡箍

□ Disassemble the coupling nut that connect the power

steering oil tank and the frame, then remove the tank.

Remove the power steering pump and power steering

hose steel pipe

拆解动力转向油罐与车架连接螺母，拆下油罐。拆解

动力转向泵及动力转向钢管软管

Installation: Please note the following procedure and install in the reverse order of removal:

装配：按照拆解相反步骤开展，并注意以下事项

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□ Power steering oil refueling 动力转向油的加注

Refueling process: First fill up the tank, then start the engine and make the drive pump running in

low speed to fill the hydraulic system. During engine operation, the oil in the tank will continue to decline,

refueling must be continued so as to avoid air inflow. Meanwhile turn the steering wheel to the both ends

of the limit position of the left and right respectively, and repeat it several times until the oil in the tank no

longer decreases.

加油过程：先将油罐加满，起动发动机，低速运行驱动油泵，使油液充满液压系统。在发动机

运转过程中，油罐的油面会不断下降，必须不断加油，以免油泵吸入空气。同时分别向左右打方向

盘至两端极限位置,反复几次，至油罐中油液不再下降为止。

Oil change process: Jack up the front axle, and open the tank cover and fuel returning port of

steering gear. Then start the engine in less than 15 seconds, and turn the steering wheel in both directions

consecutively to each extreme position to drain the oil .Then refuel according to the refueling procedures.

换油过程：顶起前轴，打开油罐盖，将转向器回油口打开，短时间起动发动机，不超过 15 秒，

连续两个方向转动方向盘至两极限位置，将油液全部排出。然后再按加油程序进行加油。

Exhaust process: Jack up the front axle (or remove drag link) and make the engine idling, turn the

steering wheel to the limit position of the left and right respectively, repeat it several times so as to

exhaust air and vaporized fluid. With the bubble discharging, the oil in the tank will fall. At this time oil

should be added continuously until the oil surface keep placid, which completes the exhaust process.

排气过程：顶起前轴（也可卸去直拉杆）发动机怠速，左、右转动方向盘至极限位置，反复转

动数次，让空气和汽化的油液排出。随着汽泡的排出，油罐油面将下降，这时要不断补充油液，直

到油面稳定，这就完成了排气过程。

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Precautions 注意事项：

 Oil with inconsistent model is forbidden to mix.

禁止型号不一致的油液混用。

 Filter screen that on the oil tank must be used when filling the oil.

加注油液时必须经过转向系统油罐上的过滤网过滤。

 The volume of oil filling must be between two scale marks specified by the tank gauge (Keep the

engine start in 3min-5mins after oil filling, check if the oil filling volume is between the scale marks.

If too much oil, oil spilling is tend to occur after the engine is started；If too less oil, Ablation of vane

pump of the steering system is tend to occur.

油量加注必须在油罐标尺规定的两刻线之间（油量加注后启动发动机 3min-5min,检查补加油量

至规定标尺刻度线间。过多，发动机启动后易造成油液溢出；过少，易造成转向叶片泵烧蚀）。

 When regularly change the oil, the tank and the tank filter should be cleaned at the same time, not

allowing any debris mixed with the oil. Pay special attention to that do not use cotton fiber materials

(such as cotton yarn, emery cloth, etc.) to clean parts, which is to avoid their entry into the system

and causing malfunction.

定期换油时，应同时清洗油罐和油罐中的滤芯，不允许有任何杂物混入油内。特别注意不能用

棉织纤维物品（如棉纱、砂布等）擦试零件，以免带入系统内，造成故障。

□ When assemble the new steering gear, make sure that

there is no foreign material or damage in the steering

gear and steering column joint

装配新转向器时要确保转向器与转向管柱接头处无

异物，无损伤

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□ The steel pipe of power steering fluid and steering gear

should be coated with leak-proof glue when assembling.

Specific brands and smear standard, please consult

"Overview and maintenance manual "

装配动力转向液钢管与转向器需要涂防漏胶。具体品

牌与涂抹标准请参见《概述与保养分册》

□ It should make sure that the steering wheel is in the

middle position under the condition of straight driving

when reinstall, or mark on the steering wheel before

removal or installation

复装必须保证车辆处于直线行驶状态下方向盘处于

中间位置进行，或在拆装前预先在方向盘上作好标识

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IV Trouble Diagnosis and Troubleshooting 故障诊断与处理

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Chapter Ⅷ Braking system

第八章制动系统

I Interview 概述

Braking system mainly consists of brakes, air reservoir, brake pipe, brake pedal and other

components, which is a series of specialized devices used to enable outside object (mainly the road) to

apply a certain force to some automotive parts (mainly the wheels), so that it can apply constraint braking

force to the vehicle. The function of Braking system role to make the running vehicle slow down or even

stop mandatory in accordance with the willing of the driver; ensure the parking vehicle be stably parked

under various road conditions (including the ramp); make the downhill running vehicle remain a stable

speed. The vehicle braking action can only come from the apposite direction external force while the

magnitude of these external forces are random, uncontrollable, so a series special devices need to be

installed on the vehicle to achieve the above functions.

制动系统主要包含制动器、储气筒、制动管路、制动踏板等零部件，是汽车上用以使外界（主

要是路面）在汽车某些部分（主要是车轮）施加一定的力，从而对其进行一定程度的强制制动的一

系列专门装置。制动系统作用是：使行驶中的汽车按照驾驶员的要求进行强制减速甚至停车；使已

停驶的汽车在各种道路条件下（包括在坡道上）稳定驻车；使下坡行驶的汽车速度保持稳定。对汽

车起制动作用的只能是作用在汽车上且方向与汽车行驶方向相反的外力，而这些外力的大小都是随

机的、不可控制的，因此汽车上必须装设一系列专门装置以实现上述功能。

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II Location drawing and exploded view 位置图及爆炸图

1、

Schematic Diagram 原理图

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2、 Exploded view 爆炸图

□ Front Brake 前制动器

S/N 序号 Spare Parts Name 备件名称

01 return spring-brake shoe 回位弹簧-制动蹄

02 front brake shoe with friction lining(upper) 前制动蹄带摩擦片总成（上）

03 front brake shoe with friction lining(lower) 前制动蹄带摩擦片总成（下）

04 front brake bottom board(r) 前制动器底板总成（右）

05 shaft of front brake shoe 前制动蹄片轴

06 front brake cam(R) 前制动凸轮轴（右）

07 nut 六角螺母

08 front brake chamber assembly(r) 前制动器室支架总成（右）

09 front brake chamber assembly(r) 前制动气室总成（右）

10 front brake adjustable arm assembly(r) 前自动调整臂总成（右）

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11 hex nut 六角螺栓

12 dustproof cover of front brake 前制动器防尘罩

□ Rear Brake 后制动器

S/N 序号 Spare Parts Name 备件名称

01 dust proof cover 防尘罩

02 assembly of brake shoe with friction plate (lower) 制动蹄带摩擦片总成（下）

03 return spring-brake shoe 回位弹簧-制动蹄

04 assembly of brake shoe with friction plate (upper) 制动蹄带摩擦片总成（上）

05 assembly of left brake bottom board(l) 左制动器底板

06 shoe pin 蹄销

07 rear left brake cam 后左制动凸轮

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□ Brake Pipe 制动管路

S/N 序号 Spare Parts Name 备件名称

01 brake valve push rod 制动阀推杆

02 transmission fork 传力叉

03 brake pedal and driving gear assembly 制动踏板及传动机构总成

04 air outlet hose unit ,upper chamber, brake valveⅠ 制动阀上腔出气尼龙管总成 1

05 air outlet hose unit ,lower chamber, brake valve 制动阀下腔出气尼龙管总成

06 brake valve assembly 制动阀总成

07 seal board unit of air outlet hose, brake valve 制动阀出气密封板总成

08 front quick release valve intake hose assembly 前快放阀进气软管总成

09 air outlet hose unit ,upper chamber, brake valveⅡ 制动阀上腔出气尼龙管总成 2

10 abs combinations module 前 ABS 组合模块

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11 air inlet hose unit ,upper chamber, brake valveⅡ 制动阀上腔进气尼龙管总成 2

12 air inlet hose unit ,lower chamber, brake valveⅡ 制动阀下腔进气尼龙管总成 2

13 exhaust hose-brake valve 制动阀排气管

14 seal board unit of air inlet hose, brake valve 制动阀进气密封板总成

15 air inlet hose unit ,upper chamber, brake valveⅠ 制动阀上腔进气尼龙管总成 1

16 air inlet hose unit ,lower chamber, brake valveⅠ 制动阀下腔进气尼龙管总成 1

17 protect bracket unit 保护支架总成

18 bracket 支架

19 muffler assembly 消声器总成

20 card 卡片

21 bracket of brake pipe 制动管支架

22 front brake nylon pipe unit 前制动尼龙管总成

23 intake nylon tube assembly 前回路进气尼龙管总成

24 nylon tube assembly 1 后回路控制尼龙管总成(Ⅰ)

25 intake nylon tube assembly 后回路进气尼龙管总成

26 lock washer 外锯齿锁紧垫圈

27 hex thin nut 六角薄螺母

28 brake tube unit 制动软管总成

29 joint 管接头

30 joint 测试接头

31 blast pump air outlet elbow 打气泵出气弯头

32 outlet pipe of air compressor 压缩机出气钢管

33 brake valve air inlet hose joint 制动阀进气软管接头

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34 outlet hose of air compressor 压缩机出气软管总成

35 insulation panel assembly 隔热板总成

36 connecting hose unit 连接软管总成

37 bracket 支架

S/N 序号 Spare Parts Name 备件名称

01 air inlet nylon tube of clutch exhaust auxiliary 离合排辅取气尼龙管总成

02 helical tube 螺旋钢管总成

03 air drier with four-way valve assembly 空气干燥器带四回路阀总成

04 desiccator bracket 干燥器支架

05 inlet hose of air reservoir 驻车储气筒进气尼龙管总成

06 rear brake air inlet pipe 后制动进气管

07 front brake air inlet pipe 前制动进气管

08 brake valve seal head (1) 制动阀封头 1

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09 safe valve unit 安全阀总成

10 automatic water drain valve assembly 自动放水阀总成

11 seal head, brake valve (Ⅱ) 制动阀封头 2

12 joint 过渡接头

13 main air reservoir with bracket unit 主储气筒及支架总成

14 sub air reservoir with bracket unit 副储气筒带支架总成

15 fixing clip of helical tube 螺旋钢管固定管夹

16 helical tube bracket 螺旋钢管支架

S/N 序号 Spare Parts Name 备件名称

01 joint 过渡接头

02 sub air reservoir with bracket unit 副储气筒带支架总成

03 gas reservoir bracket 副储气筒支架

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04 sub air reservoir with bracket unit 副储气筒及支架总成

05 ASR electromagnetic valve assembly ASR 电磁阀总成

06 ABS combinations module 后 ABS 组合模块

07 air inlet hose of rear brake chamber 后气室进气软管总成

08 air inlet hose of rear brake chamber 后气室进气软管总成

09 intake nylon tube assembly 后回路进气尼龙管总成

10 intake nylon tube assembly 前回路进气尼龙管总成

11 rear brake air inlet pipe 后制动进气管

Remarks: The above pictures are typical component pictures, there is subtle difference between

some models and we didn’t mark them here

备注：上述图片为典型部件图片，部分车型存在细微区别，此处不再标识

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III Remove, install and adjust 拆装与调整

1、 Cautions 注意事项

□ Good protection should be conducted to avoid scratches in removing and installing components

process;

拆卸和安装部件过程中，应做好防护，以免出现划伤；

□ When remove and install some parts, check the lubrication of parts. If necessary, smear "Grease";

拆装某些部件时，检查部件是否润滑不良，如果有必要，涂抹“润滑脂”；

□ Several persons may be required to cooperate in removing and installing because of the complexity

of the structure of vehicle parts;

由于汽车部件结构的复杂性，拆卸过程可能需多人配合进行；

□ Do not use excessive force when removing, because it may cause deformation of parts.

拆卸时请勿用力过大，因为可能导致零件变形。

2、Removal and Installation of air reservoir 储气筒拆装

□ Remove air reservoir, removal order: brake pipe,

dual-circuit protection valve, air reservoir fixing bolts.

拆解储气筒，拆解顺序为：制动管路、双回路保护阀、

储气筒固定螺栓

□ Preparation: pull the clip ring of air release hole of air

reservoir until the air is released clearly.

准备工作：用手拉住储气筒放气孔卡环，直至空气放

完为止

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□ Remove the connecting nuts between brake pipe and air

reservoir.

拆解制动管路与储气筒连接螺母

□ Remove the connecting nuts between dual-circuit

protection valve and air reservoir.

拆解双回路保护阀与储气筒连接螺母

□ Remove the fixing nuts between air reservoir and

ground.

拆解储气筒与底盘固定螺母

Installation: Install according to the opposite order of removal and please be noted with the

following items:

装配：按照拆解相反步骤开展，并注意以下事项

□ Please smear leakage-proof glue when installing the

connecting bolts of brake pipe, dual-circuit protection

valve and air reservoir.

装配制动管路、双回路保护阀与储气筒连接螺栓时需

要涂防漏胶。

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3、Removal and Installation of brake pipe 制动管路拆装

□ Remove brake pipe: remove the brake pipe one by one

along with pipe alignment.

拆解制动管路，沿着制动管路走向逐一拆解各段制动

管路

□ Preparation: pull the clip ring of air release hole of air

reservoir until the air is released clearly.

准备工作：用手拉住储气筒放水孔卡环，直至空气放

完为止

Installation: Install according to the opposite order of removal

装配：按照拆解相反步骤开展

4、Removal and Installation of brakes 制动器拆装

□ Remove brakes, removal order: brake chamber, brake

chamber bracket, brake shoe with friction plate

assembly.(Please refer to Front axle and Rear axle for

the removal of brakes assembly from front and rear

axle )

拆解制动器，拆解顺序为：制动器室、制动器室支架、

制动蹄带蹄片总成（制动器总成从前轴、后桥拆解下

的步骤请参见《前桥》、《后桥》章节）

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□ Remove the connecting bolts between brake chamber

and brake chamber bracket, take off brake chamber

拆解制动器室与前制动器室支架连接螺栓，取下制动

器室

□ Remove the fixing bolts between brake chamber and

dust-proof cover, take off brake chamber bracket.

拆解制动器室支架与防尘罩固定螺栓，拆下制动器室

支架

□ Remove the fixing bolts of brake shoe shaft, take off

brake shoe shaft and return spring and take off brake

shoe

拆解制动蹄片轴固定螺栓，取下制动蹄片轴与回位弹

簧，拆下制动蹄片

□ Remove brake camshaft

拆解制动凸轮轴

Installation: Install according to the opposite order of removal and please be noted with the

following items:

装配：按照拆解相反步骤开展，并注意以下事项

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□ Adjust brake clearance

调整制动间隙

□ It’s required to adjust brake clearance when re-installing:

first press down the lock of brake adjustment arm, then

rotate adjustment bolts to adjust brake clearance. Rotate

clockwise to narrow the clearance. Rotate anti-clockwise

to increase the clearance.

复装时必须调整制动间隙：先压下制动调整臂上的锁

止套，然后旋转调整螺栓调整制动间隙。顺时针旋转

减少间隙，逆时针旋转增加间隙。

5、Brake lever removal of parking brake 驻车制动制动手柄拆装

□ Remove the fixing bolts of the parking brake control

lever, and remove the parking brake control lever

拆解驻车手柄固定螺栓，取下驻车手柄总成

Installation: Install according to the opposite order of removal and please be noted with the

following items

装配：按照拆解相反步骤开展，并注意以下事项

□ Preparation: pull the clip ring of air release hole of air

reservoir until the air is released clearly.

准备工作：用手拉住储气筒放水孔卡环，直至空气放

完为止

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6、Removal and installation of brake pedal 制动踏板拆装

□ Removal the bolts and remove the brake pedal

拆解制动踏板固定螺母，取下制动踏板

Installation: Install according to the opposite order of removal

装配：按照拆解相反步骤开展

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IV Diagnosis and treatment 故障诊断与处理

1、 Brake block

制动不灵

□ Fault phenomenon: when the car brake, driving people feel inadequate deceleration; When the car

emergency braking, braking distance is too long.

故障现象：汽车制动时，驾驶人感到减速度不足；汽车紧急制动时，制动距离太长。

□ The cause of the problem

故障原因：

 The poor work of air compressor results in the low-pressure or no air within air reservoir. The reasons

may be the loose or broken of air compressor belt, leakage of exhaust valve, the spring of exhaust

valve being too soft or broken, leakage of piston or piston ring.

空气压缩机工作不良，而使贮气筒内气压低或无气。可能是空气压缩机皮带过松或折断，空气

压缩机排气阀漏气，空气压缩机排气阀弹簧过软或折断，活塞或活塞环漏气。

 Pipe cracks or connections loosen

气管破裂或接头松动。

 Brake diaphragm or brake chamber diaphragm cracks

制动阀膜或制动气室膜片破裂。

 The stroke of brake pedal is too large

制动踏板自由行程过大。

 Improperly adjustment of brake arm worm makes the brake chamber push rod outstretch too long.

制动臂蜗杆调整不当，使制动气室推杆伸出过多。

 The clearance between friction plate and brake drum is too big or there is oil spill on the friction

plate.

摩擦片与制动鼓间隙过大或摩擦片有油污。

□ Diagnosis and Trouble clearing

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诊断与排除：

 If the barometer indicates the number "0", please depress the brake pedal, if there is a sound of

deflating when lift the pedal, it means the barometer is broken and please replace it. If there is no

sound of deflating, please check the air compressor belt and the pipes between air compressor and air

reservoir.

如压表指示数为“0”可踏下制动踏板，松起时如有放气声，即说明气压表有故障，应更换气压

表。如无放气声，则检查空气压缩机皮带和由空气压缩机至贮气筒一段气管的情况。

 After the above inspection, if the barometer indicates a low pressure level, it means there are faults

within air compressor. Please check the exhaust valve and inner cylinder and clear the trouble.

经上述检查，情况良好，如气压表指示数很低，则故障在空气压缩机，应检查排气阀或汽缸内

部技术状况，予以修复。

 If barometer indicates a normal pressure level, then depress the brake pedal and check whether there

is leakage among brake valve and each wheel. If there is no leakage, please check the stroke of brake

pedal and adjust the clearance between brake friction plate and brake drum.

如气压表指示压力数值合乎标准，可踏下踏板，检查由制动阀至各车轮间有无漏气之处。如无

漏气处，则检查踏板自由行程和调整制动蹄摩擦片与制动鼓的间隙。

2、Made brake bite

制动发咬

□ Phenomenon: when lifting the brake pedal, the exhaust brake valve exhausts slow or does not exhaust,

resulting in no release of brake immediately; Or the exhaust valve exhausts normally, but there is still

a left braking effect that causes the car running hard or weakness. Original car:

现象：抬起制动踏板后，制动阀排气缓慢或不排气，不能立即解除制动，或排气虽快，但仍有

制动作用，致使汽车起步困难或行车无力。原车：

 No free stroke of brake pedal

制动踏板无自由行程

 Brake exhaust valve adjustment pads is too thin, the return spring is too soft or broken or Rubber seat

is aging.

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制动阀的排气阀调整垫片过薄，其回位弹簧过软、折断或橡胶阀座老化发胀。

 Brake valve lever rusts

制动阀挺杆锈蚀

 The transmission parts between the brake pedal and brake valve arm get stuck

制动踏板至制动阀位臂之间传动件发卡

 Brake camshaft and brackets bushings rust and get stuck

制动凸轮轴与支架衬套锈蚀发卡

 The clearance between brake drum and brake friction plate is too small

制动鼓与摩擦蹄片间隙过小

 Brake shoe pins rust or the return spring is too soft or broken

制动蹄支销锈污或回位弹簧过软、折断

 The match section between axle tube and its rear axle housing or wheel bearings wear, resulting in

loosening

半轴套管与其后桥壳或轮毂轴承配合处磨损造成松动

 Brake chamber diaphragm is deformed and aged, single-layer film ruptured or a brake hose is aged,

the air flow is not smooth

制动气室膜片老化变形，单层胶膜破裂鼓起或制动软管老化，气流不畅

□ Diagnosis

诊断

 The exhaust brake valve exhausts slow or does not exhaust when lifting the brake pedal, it is the

brake valve fault in most cases and the symptom is that all the brake drums get hot.

抬起制动踏板时制动阀排气缓慢或不排气，多属制动阀故障，表现为各轮制动鼓均发热。若排

气声怯或继续排气而制动发咬，一般为个别轮制动发咬，摸试各轮制动鼓温度高者即为有故障

之轮。

 If it’s confirmed that its fault of brake valve, please the free stroke of brake pedal first. If the free

stroke is too small, please adjust it. If the free stroke is normal, please loosen the exhaust valve to test.

If the situation gets better, then the fault is the exhaust valve adjustment pads is too thin. If the

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situation remains bad, please check whether the exhaust valve return spring and film are fine, if yes,

please check the whether the brake lever rusts or not and brake passing rod is flexible or not.

若确定制动阀有故障，应先检查制动踏板自由行程。若自由行程太小或没有，应予以调整。若

自由行程正常，可旋松排气阀试验。如有好转，则为排气阀调整垫片过薄。仍无好转，可检查

排气阀回位弹簧及胶座以上均正常，则应检查制动挺杆是否锈污及制动传递杆件是否活动灵

活。

 Individual gears bite. Please observe the brake chamber push rod returning situation when lifting the

brake pedal. If it returns slowly or does not return, please check whether there is no lubrication

between the brake camshaft and its bracket cover or too large angle of different axles that causes

stuck. If the clearance is found normal when lifting the wheel, but the clearance changes when

putting down the wheel, then it means the wheel bearing loosens or the match of axle tube and its rear

axle housing loosens. If the clearance remains normal, please check whether there are problems with

brake chamber diaphragm and return spring.

个别轮发咬，可在抬起制动踏板时，观察制动气室推杆回位情况。若其回位缓慢或不回位，应

检查制动凸轮轴与其支架套是否失去润滑或不同轴度过大而发卡。若架起车轮检查该间隙正

常，而落下车轮后间隙在变化，则系轮毂轴承松旷或半轴套管与后桥壳配合松动。若间隙正常，

可检查制动气室膜片及回位弹簧是否有问题。

3、Brake deviation (unilateral)

制动跑偏(单边)

□ Phenomenon: Two wheels can not brake concertedly when brake, the vehicle cannot stop along with

straight direction while deviate to one side

现象：制动时，同轴两车轮不能同时制动，汽车不能沿立脚点直行方向停车而偏向一侧

□ Causes

原因

 The clearance of friction plate and brake drum of left and right side is different.

左右车轮摩擦片与制动鼓的间隙大小不均

 There are oil spill, hardening or rivet head exposed of some friction plate.

个别车轮摩擦片有油污、硬化或铆钉头露出

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The friction plate material of left and right side is inconsistent or poor contact.

 左右车轮摩擦片材料不一致或接触不良

 Camshaft stuck or brake chamber fault of some wheels

个别车轮凸轮轴发卡或制动气室有问题

 The brake drum of some wheels goes out of roundness or the surface of the drum gets grooves of

some wheels

个别轮制动鼓失圆度过大或鼓壁磨出沟槽

 Two front leaf springs elastic is unequal

两前轮钢板弹簧的弹力不等

 Uneven front beam

有负前束

 Horizontal connecting rod pin loosens or vertical arm loosens.

横、直接杆球头销或垂臂松旷

□ Diagnosis

诊断

 First, please conduct road test. If the vehicle deviates to left side when braking, it means that the right

brake is not effective. If the vehicle deviates to right side it means the left brake is not effective. After

parking, please check the grinding crack of left and right wheels on the ground. The brake of the side

is not effective if its grinding crack is short and light. Referring to the exclusion of the above reasons,

if it’s the problem of friction plate, please repair, replace, adjust, tighten and so on. There are many

similarities of brake deviation of air brake and hydraulic brake, please refer to each other.

首先进行路试。制动时，汽车向左偏斜即为右边车轮制动不灵，向右边偏斜好为左边车轮制动

不灵。停车后察看左右两边车轮在地面上的拖痕，拖痕短而轻的一边车轮制动不灵。参照上述

原因进行排除，如是摩擦片有问题，可进行修复、更换、调整、紧固等。气压制动跑偏与液压

制动跑偏有许多相同之处，可以互相参考。

Maintenance Manual ABS ABS

1

INDEX

What is ABS.......................................................................... 2

Different ABS systems.......................................................... 3

What can ABS do for you..................................................... 5

What can ABS not do for you............................................... 5

What can you do for your ABS system ................................ 6

The ABS control loop......................................................... 10

The ABS components ......................................................... 10

The ABS components ......................................................... 11

ABS system schematic: ABS, ASR, CAN.......................... 12

ABS system schematic: ABS, ASR, CAN.......................... 13

ABS system schematic: ABS.............................................. 13

ABS system schematic: ABS.............................................. 14

The ABS cable harness ....................................................... 14

The ABS cable harness ....................................................... 15

Failure handling .................................................................. 17

Reading failure flash codes................................................. 19

Deleting failure storage....................................................... 20

Failure code table................................................................ 21

ECU configuration.............................................................. 27

Reset ECU (re-configuration)............................................. 27

Reading the ECU configuration.......................................... 28

Configuration code table..................................................... 29

Tooling................................................................................ 30

Special service precautions................................................. 31

Service Hints....................................................................... 32

Warranty..............................................................................33

Disclaimer........................................................................... 33

Maintenance Manual ABS ABS

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ABS 8 DRIVER MANUAL

Congratulation, your vehicle is equipped with the most

advanced and latest ABS technology from Knorr-Bremse

(Germany). In order to keep your ABS system always in a

functioning condition, we kindly ask you studying following

manual and advices carefully.

What is ABS

ABS is a German acronym for “Anti Lock System” which

belongs to the so called passive brake safety systems.

The ABS purpose is to prevent the tires of your vehicles from

long lasting lock-up cycle during a strong brake application on

a slippery road surface. This is realized by a controlled

stepwise pressure build-up and reduction in the brake cylinders

during a vehicle brake process.

It is a physical principle that a vehicle with locking tires,

especially in the situation the rear-axle tires lock up, is not

stable anymore and may spin on the road (the vehicle is out of

control) what may often end up in fatal accidents. This

dangerous situation can be easily controlled with an ABS

system since the vehicle is due to non locking wheels easily

tractable, you can steer your vehicle comfortable away from

the dangerous obstacle ahead of you, thus avoiding a collision

accident.

If you have an opportunity, we recommend you to train ABS

brake maneuvers and learn about the advantageous of your

safety add-on system on an especially prepared and blocked off

square. Please contact your vehicle manufacturer.

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For completeness is shall be remarked that some ABS system

have in addition a so called ASR function. ASR function is the

German acronym for “Traction Enhancement System”, which

helps you accelerating on a slippery surface. The ASR system

works according a similar principle as a mechanical differential

lock. Refer to your vehicle manual or ask your manufacturer

whether your system is additionally equipped with an ASR

option.

Different ABS systems

Various ABS systems with different add-on functions, so

called optional functions, require that you, respectively your

service are carefully checking the system and its installed

components prior to any service action in a work shop. We

recommend prior to any service activities to read the Knorr-

Bremse part number on ECU and read the configuration code

(see page: ECU Configuration). In case you feel not

comfortable with this process, please contact your

manufacturers’ service department.

Maintenance Manual ABS ABS

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ECU part number Function description

(configuration)

K054348 ABS function on 4 wheels

K054353 ABS function on 4 wheels

with ASR&HSA function

ECU part number

ABS ECU

(Electronic Control Unit)

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What can ABS do for you

As previously mentioned, ABS is a passive braking safety

system.

 ABS enables you maneuvering the vehicle during an

emergency braking situation around the obstacle in

order to avoid collision accidents.

 ABS protects tires against so called brake flats which

usually appear after a full or emergency brake with

locked tires.

 ABS substitutes load sensing valves* which are

commonly used in trucks and tractors (*optional)

It is recommended practice ABS supported emergency brakes,

maneuvering etc, on an especially secured and prepared test

ground.

What can ABS not do for you

An ABS system has also limitations.

 ABS usually does not shorten the brake distance.

 ABS does not exempt you from keeping enough safety

distance from vehicles driving ahead of you.

 ABS does not shorten brake response times.

 ABS is only as good as the drivers driving skills

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What can you do for your ABS system

The ABS system needs less maintenance, mainly the wheel

speed sensors position, located in each individual controlled

wheel, needs during each brake maintenance be newly

positioned (pushed) closely to the tone wheel (the tone wheel is

located in the hub). Cables need to be securely tightened to the

chassis avoiding scrubbing damages.

Avoid High Voltage stress on your ABS electronic:

 The voltage supply shall in no case exceed 30 volt.

 Never run the motor with a disconnected battery.

 Do not turn off the battery main switch while the motor

is still running.

 Damaged, empty or not securely connected batteries

can damage the ABS ECU (Electronic Control Unit).

Maintain your battery, battery poles and cables. Care

always for a securely connected battery (poles and

cables), especially after each service work.

 Welding work on vehicles may damage ECUs

(Electronic Control Unit). ABS ECUs must be

disconnected for any electrical welding work at the

vehicle chassis.

 Jump starts with energy sources other than the vehicle

battery may damage the ABS ECU. It is recommended

disconnecting the ABS ECU for jump starts.

Maintenance Manual ABS ABS

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 The operation or later installation of electrical

components such as batteries, alternators, starters,

electromagnets, electro motors or solenoid valves which

are not approved by your vehicle manufacturer may

damage the ABS ECU.

Prior to any additional installation or changes of one of

the aforementioned components or alterations in the

cable harness, the written approval of your vehicle

manufacturer must be obtained.

Solenoid valves used in the system shall be equipped

with so called “suppressor diodes”.

 Never open or repair ABS ECUs.

 Use only genuine parts.

Maintenance Manual ABS ABS

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Avoid mechanical stress

 Do not expose the ABS ECU (Electronic Control Unit)

to splash water or extreme humidity.

 Do not drop the ECU nor expose to other “stress”.

 For installation or maintaining do not use for instance

hammers, always use appropriated tools.

 Never open ABS components. ABS components shall

never be repaired except cable parts and connectors for

ECU and valves (refer to your manufacturer’s advice).

 ABS sensor cables are not allowed

to be repaired and

shall be replaced in case of any damage.

 ABS components and connector parts shall be securely

connected, harness and cable parts securely fixed to the

chassis in order to avoid scrubbing damages.

 Do not strongly bend cable parts, never bunch too long

cable parts together in narrow loops.

 Push on regular base the WSS (wheel speed sensors) in

their correct position, towards the tone wheel.

 A big wheel bearing adjustment, for instance due to

insufficient service, leads to wheel speed sensor failures.

Adjust the wheel bearing gap on regular base, for closer

information contact your vehicle manufacturer.

 Do not change to tire sizes other than specified by your

vehicle manufacturer.

 Never open or repair ABS ECUs.

 Use only genuine parts.

Not observing aforementioned points or other inadmissible

misuse may lead to an inoperative or damaged ABS system

Maintenance Manual ABS ABS

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with the eventual consequence of fatal accidences. Furthermore

an abuse may annul any warranty obligations.

Damages resulting out of aforementioned and similar reasons

are not subject to a free service.

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ECU

PCM

WSS

Brake

The ABS control loop

The ECU (Electronic Control Unit) is the overall controlling

“brain”, receiving tire speed information from all of the WSS

(Wheel Speed Sensors) and comparing them with each other

and the current vehicle velocity. In case the speed of one or

more tires, detected by the WSS, differs strongly from the

vehicle velocity, for instance due to an extensive brake

application on a slippery road with consequence of a locking

wheel, the ECU controls by means of the related PCM

(Pressure Control Module) the brake pressure in the related

brake cylinder by holding the brake pressure in the cylinder or

releasing the brake pressure in the wheel brake cylinder. The

changed brake cylinder pressure leads to a changed wheel

speed behavior (increasing or decreasing the wheel speed)

which is again monitored by the ECU and compared with the

ECU set values. The control loop is closed and starts

repeatedly. During the active or passive control cycle, the ECU

continuously monitors the system for any system or component

failures.

ABS control loop

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The ABS components

ECU (Electronic Control Unit)

PCM (Pressure Control Module)

Note: Air flow is always from valve port 1 (in) to valve

port 2 (out). For valve installation details please

contact your vehicle manufacturer for closer

information.

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WSS (Wheel Speed Sensor) with Bush

ASR valve, 3/2 way solenoid valve

(optional)

grey shaded: Bush

Note: Air flow is always from valve port 1 (in) to valve

port 2 (out). For valve installation details please

contact your vehicle manufacturer for closer

information.

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ABS system schematic: ABS, ASR, CAN

ABS 4s/4m (4 WSS and 4 PCM), ASR and CAN optional

1. WSS

2. ABS ECU

3. PCM

4. ASR Valve

5. Double check valve

6. Foot brake valve

7. Brake cylinder

8. Acceleration pedal sensor

9. Motor ECU

10. Engine

12. CAN with resistors

13. Warning lamp

14. ASR lamp

17. Stop-lamp switch

(for ASR only)

18. Stop-lamp

Note:

Engine CAN is

optionally installed.

Please contact your

vehicle manufacturer

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ABS system schematic: ABS

ABS 4S/4M (4 WSS and 4 PCM), without ASR

1. WSS

2. ABS ECU

3. PCM

6. Foot brake valve

7. Brake cylinder

8. Warning lamp

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The ABS cable harness

Connector X1

- for ABS part number K054348

X1

16

18

1

3

X1

3 Diagnostic button

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Connector X2

- for ABS part number K054348

X2

16

18

1

3

X2

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Failure handling

The ABS electronic is equipped with a failure self-monitoring

function. In case of a system failure, 16 different failures by

means of failure codes can be stored in the ECU storage at the

same time and indicated by a failure flash code by means of a

yellow warning lamp in your dashboard on demand. Any ABS

malfunction is in general indicated by the yellow ABS warning

lamp (in some cases the color of the ABS warning lamp can be

different).

Warning lamp functions:

 Indication of a system malfunction

 Indication of a WSS failure in a previous power-on

cycle (before last time ignition key turned on)

 Flashing of stored failure code information

 Flashing of system configuration information

In the case of an indicated system malfunction, warning lamp

permanently on, it is easily possible flashing out the failure

cause (failure code) with this on-board diagnosis tool. As

mentioned, the ECU storage can store up to 16 failures out of

in total 141 possible failure reasons.

The failure flashing process is started by pushing the diagnosis

push button for a couple of seconds (4s) with the ignition

turned on (see schematic next page).

In case no diagnosis push button is installed, the ECU contact

18 in connector X1 can be alternatively connected with a

separate cable in parallel to the vehicle chassis ground for

around 4 seconds and released again. The warning lamp starts

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flashing out the failure codes. During the entire flashing

process the ignition must be turned on.

During the failure flashing and counting it is recommended to

have a paper and pen at hand for noticing the individual blink

code failures. It is possible that old but repaired failures were

still persistent in the ECU storage, thus after the first reading

all stored failures shall be deleted and the ECU reset (see

deleting the failure storage). The failures shall be flashed out

again in order to make the difference feasible.

After repairing the failures the failure storage need to be

emptied by means of an ECU reset.

Reset process:

Turn off the ignition, push the diagnosis button, or connect

X1/18 to the vehicle chassis ground, turn on the ignition and

keep the diagnosis button for 3 seconds depressed alternatively

the ground cable connected to the chassis ground). The failure

store is now deleted.

Note: If an optionally installed ASR valve is during the

reset process not connected to the ECU, the

ECU will be reconfigured to an ABS system.

Wheel speed sensor related failures will despite

a repair indicated by the warning lamp until the

vehicle drives a few meters and the ECU can

recognize a proper sensor signal.

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Reading failure flash codes

Digit 1 Digit 2

Diag. button

Warning lamp

Component

code

on

off

pressed

release

Example

2-2 2-2

During the entire process the

i

g

nition ke

y

need to be turned on

Failure

code

Component

code

Failure

code

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Deleting failure storage

Ignition turned…

Diagnostic button

on

off

Pressed

Release

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Failure code table

Flash

Code

Description Component

01-01 no failure

02-01 large air gap WSS sa left

02-02 missing sensor signal at drive off WSS sa left

02-03 bad tooth wheel, long term ABS control WSS sa left

02-04 long term instability WSS sa left

02-05 loss of sensor signal WSS sa left

02-06

shorted low/high or broken wire or two sensors

shorted

WSS sa left

02-07 reserved for wheel speed sensor (run-out) WSS sa left

02-09 reserved for tire size alignment steer axle left tire size

03-01 large air gap WSS sa right

03-02 missing sensor signal at drive off WSS sa right

03-03 bad tooth wheel, long term ABS control WSS sa right

03-04 long term instability WSS sa right

03-05 loss of sensor signal WSS sa right

03-06 shorted low/high or broken wire or two sensors shorted WSS sa right

03-07 reserved for wheel speed sensor (run-out) WSS sa right

03-09 reserved for tire size alignment steer axle right tire size

04-01 large air gap WSS da left

04-02 missing sensor signal at drive off WSS da left

04-03 bad tooth wheel, long term ABS control WSS da left

04-04 long term instability WSS da left

04-05 loss of sensor signal WSS da left

04-06 shorted low/high or broken wire or two sensors shorted WSS da left

04-07 reserved for wheel speed sensor (Taumelschlag) WSS da left

04-09 reserved for tire size alignment drive axle left tire size

Flash Description Component

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05-01 large air gap WSS da right

05-02 missing sensor signal at drive off WSS da right

05-03 bad tooth wheel, long term ABS control WSS da right

05-04 long term instability WSS da right

05-05 loss of sensor signal WSS da right

05-06 shorted low/high or broken wire or two sensors shorted WSS da right

05-07 reserved for wheel speed sensor (run-out) WSS da right

05-09 reserved for tire size alignment drive axle right tire size

06-01 large air gap wss aa left

06-02 missing sensor signal at drive off WSS aa left

06-03 bad tooth wheel, long term ABS control WSS aa left

06-04 long term instability WSS aa left

06-05 loss of sensor signal WSS aa left

06-06 shorted low/high or broken wire or two sensors shorted WSS aa left

06-07 reserved for wheel speed sensor (run-out) WSS aa left

06-08 sensor detected but not configured WSS aa left

06-09 reserved for tire size alignment add axle left tire size

07-01 large air gap WSS aa right

07-02 missing sensor signal at drive off WSS aa right

07-03 bad tooth wheel, long term ABS control WSS aa right

07-04 long term instability WSS aa right

07-05 loss of sensor signal WSS aa right

07-06 shorted low/high or broken wire or two sensors shorted WSS aa right

07-07 reserved for wheel speed sensor (run-out) WSS aa right

07-08 sensor detected but not configured WSS aa right

07-09 reserved for tire size alignment add axle right tire size

Maintenance Manual ABS ABS

- 23 -

08-03 release solenoid broken wire PCM sa left

08-04 valve ground broken wire. PCM sa left

08-05 hold solenoid shorted high PCM sa left

08-06 hold solenoid shorted low PCM sa left

08-07 hold solenoid broken wire PCM sa left

08-08 valve configuration error PCM sa left

09-01 release solenoid shorted high PCM sa right

09-02 release solenoid shorted low PCM sa right

09-03 release solenoid broken wire PCM sa right

09-04 valve ground broken wire PCM sa right

09-05 hold solenoid shorted high PCM sa right

09-06 hold solenoid shorted low PCM sa right

09-07 hold solenoid broken wire PCM sa right

09-08 valve configuration error PCM sa right

10-01 release solenoid shorted high PCM da left

10-02 release solenoid shorted low PCM da left

10-03 release solenoid broken wire PCM da left

10-04 valve ground broken wire PCM da left

10-05 hold solenoid shorted high PCM da left

10-06 hold solenoid shorted low PCM da left

10-07 hold solenoid broken wire PCM da left

10-08 valve configuration error PCM da left

10-10 valve ground or solenoid shunt to supply voltage PCM

10-11

valve ground or solenoid shunt to ground or int.

ground switch defective

PCM

Flash

Code

Description Component

08-01 release solenoid shorted high PCM sa left

08-02 release solenoid shorted low PCM sa left

Maintenance Manual ABS ABS

- 24 -

Flash

Code

Description Component

11-01 release solenoid shorted high PCM da right

11-02 release solenoid shorted low PCM da right

11-03 release solenoid broken wire PCM da right

11-04 valve ground broken wire PCM da right

11-05 hold solenoid shorted high PCM da right

11-06 hold solenoid shorted low PCM da right

11-07 hold solenoid broken wire PCM da right

11-08 valve configuration error PCM da right

12-01 release solenoid shorted high PCM aa left

12-02 release solenoid shorted low PCM aa left

12-03 release solenoid broken wire PCM aa left

12-04 valve ground broken wire PCM aa left

12-05 hold solenoid shorted high PCM aa left

12-06 hold solenoid shorted low PCM aa left

12-07 hold solenoid broken wire PCM aa left

12-08 valve configuration error PCM aa left

13-01 release solenoid shorted high PCM aa right

13-02 release solenoid shorted low PCM aa right

13-03 release solenoid broken wire PCM aa right

13-04 valve ground broken wire PCM aa right

13-05 hold solenoid shorted high PCM aa right

13-06 hold solenoid shorted low PCM aa right

13-07 hold solenoid broken wire PCM aa right

13-08 valve configuration error PCM aa right

14-05 TC solenoid shorted high ASR da

14-06 TC solenoid shorted low ASR da

14-07 TC solenoid broken wire ASR da

14-08 TC valve configuration error ASR da

Maintenance Manual ABS ABS

25

Flash

Code

Description Component

15-01 ABS-CPU timeout ECU

15-02 ABS-CPU run time error ECU

15-03 ABS-CPU EEPROM data error ECU

15-04 ABS-CPU EEPROM not programmable ECU

15-05 ABS-CPU communication checksum error ECU

15-06 failure on speed sensor input circuit ECU

15-07 valve output signal mismatch ECU

15-08

ABS-CPU master/slave different configuration or

ROM checksum error

ECU

15-09 ABS-CPU invalid configuration in EEPROM ECU

15-10 internal relay does not switch ECU

15-11 internal relay permanently turned on ECU

15-15 ABS software not compatible with hardware ECU

16-01 U-bat temporary over voltage supply voltage or cable

16-02 U-bat temporary low voltage supply voltage or cable

16-02 U-bat low voltage during ABS Control supply voltage or cable

16-03 U-bat broken wire supply voltage or cable

16-04 supply voltage temporary power-line noise supply voltage or cable

16-04 supply voltage power-line noise supply voltage or cable

16-09 U-ign temporary over voltage supply voltage or cable

16-10 U-ign temporary low voltage supply voltage or cable

16-10 U-ign low voltage during ABS Control supply voltage or cable

Maintenance Manual ABS ABS

26

Abbreviations

sa steering axle (usually front axle)

da driving axle

aa additional axle (in case a 5 or 6 channel ABS is used)

ASR traction control system valve

PCM pressure control module valve

WSS wheel speed sensor (4 or 6 pcs in a system)

ECU electronic control module

CPU micro controller inside the ECU

CAN controller area network

J1939 SAE CAN standard

C3 pulse wide modulated speed signal (from speedometer)

high plus cable connection

low chassis ground connection

GND ground (eg. battery minus)

WL warning lamp

Flash

Code

Description Component

17-01 retarder relay shorted high retarder relay

17-02 retarder relay shorted low or broken wire retarder relay

17-05

tires or learned parameters (front or rear or front to rear)

out of range

tire size

17-06 reserved c3-signal plausibility check tire size

17-07 stop light switch not activated in this power on cycle stop light

17-08 ASR or ESP disabled or roller-bench mode active ASR function

17-09 ABS disabled due to off road mode ABS function

17-10

GND-WL broken wire or WL switched to ground

permanently

lamps

17-11 ASR brake control time limit exceeded ASR function

17-12 wheel speed sensor failure in previous power on cycle WSS

17-13 wheel speed sensors mixed up WSS

17-14 stop light switch defective stop light

18-03 J1939 CAN bus off detected J1939

18-04 timeout or invalid data on ERC1 J1939

18-05 timeout or invalid data on EEC1 / EEC2 / EEC3 J1939

18-12 timeout or invalid data on AUXIO J1939

Maintenance Manual ABS ABS

- 27 -

ECU configuration

ECUs are produced in standard configurations, it means with

standard functions only.

Depending on the country of use (vehicle manufacturer) are

three different basic ABS systems available (see Different ABS

systems).

In order to adjust each ECU to the individual vehicle

configuration or layout, the ECU must be program before it can

be used. This process is called configuration process and is

usually done by your vehicle manufacturer during the initial

installation. The configuration process, same as the reset

process, is also deleting all failure from the ECU failure store

(see Deleting failure storage).

Reading the configuration works similar as reading a failure

code, except that the diagnosis button must be pushed two

times within 1.5 seconds (see picture below). The configuration

will be flashed out by the ABS warning lamp in two blocks,

each with two digits.

Reset ECU (re-configuration)

The configuration process or also called reset process checks

the system for installed, missing or not working components.

Newly detected functions or components, e.g. an ASR valve,

will be learned and configured during this process.

A reset must be done after each service work on the ABS

system.

Maintenance Manual ABS ABS

- 28 -

Reading the ECU configuration

Diagnostic button

Warning lamp

Digit 1

Configuration block 1 Configuration block 2

Digit 1

Digit 2

on

off

Digit 2

Example

2-2 2-2

The diagnostic button needs to be pushed

and ke

p

t

p

rior to turnin

g

the i

g

nition on.

Maintenance Manual ABS ABS

- 29 -

Configuration code table

Blink-

Block

tens

Digit I

Units

Digit II

description

1 12 V System 1

2 24 V System

2 4S/4M

3

4S/3M

select low at steer axle

4

4S/3M

select low at driving axle

5 reserved

6 6S/6M

7

6S/5M

select low at add. axle

8

6S/5M

select low at steer axle

9

6S/4M

drive and add axle sharing 1 valve

per side

10

6S/4M

select low at steer and add axle

11

6S/3M

select low at steer axle, aa and da

sharing 1 valve per side

I

2

15 invalid

1 no J1939 retarder control, no retarder relay

2 J1939 retarder control, no retarder relay

3 no J1939 retarder control, retarder relay

1

4 J1939 retarder control, retarder relay

2 no J1939 engine control, no ASR at driving axle

3 J1939 engine control, no ASR at driving axle

4 No J1939 engine control, ASR at driving axle

II

2

5 J1939 engine control, ASR at driving axle

Sample configuration for ABS type K054348

2-2 1-2 : 24V, 4 sensors and 4 control modules, no retarder relay

2-2 3-2 : 24V, 4 sensors and 4 control modules, with retarder relay

Maintenance Manual ABS ABS

- 30 -

Tooling

ABS System Tester (ETT)

Diagnosis and Test software

Timer extraction tool

System Tester for wiring harness and

component test.

Note: not suitable for ECU failure

storage reading

Part number: 0 684 101 605

Cable number: B 265 052 947

Knorr-Bremse provides upon

request a PC* diagnosis and

system test software in various

languages.

P/N: EZ1031 II39809

Language code “Chinese”

Bosch extraction tool for removing

electrical terminals from plug-housing

P/N: 1 987 352 125

Maintenance Manual ABS ABS

- 31 -

Special service precautions

In the event of a part exchange, cable repair or other service

matters, it is necessary following specified installation

instructions such as maximum fixing moment for screws or

secured fixing of cable and harness parts (please refer to your

manufacturer service organization).

Detailed component test and installation information are

available from your vehicle manufacturer.

Special attention must be paid on a correct valve port

installation, inlet port (1) must not be confused with outlet

ports (2).

Electrical connections shall not be confused and correct system

fuses (5A and 20A) shall be installed.

Each system maintenance must be finalized by a system test,

Knorr-Bremse can provide the tooling upon request, and a test

drive.

ECU failure storage shall be emptied by a system reset.

Knorr-Bremse offers in Shanghai specific ABS system and

tooling training. Contact your nearest Knorr-Bremse dealer.

A proper ABS System function is only guaranteed with diligent

service work and the use of genuine parts from Knorr-Bremse.

The installation of not original Knorr-Bremse parts may lead to

an inoperative or damaged ABS system and voids any warranty

obligations.

Maintenance Manual ABS ABS

- 32 -

Service Hints

 Retarder relay

Vehicles with a retarder must have a retarder relay

installed which turns off the retarder during an ABS

cycle.

 WSS failure

In general a wheel with a defective WSS is without

ABS control. Once a WSS failure appeared in a

previous “power-on” cycle, the WL will not distinguish

event. The failure reason is solved until the vehicle is

driven. After receiving all wheel speed signals with

current values again, the WL will be turned off.

 Air gap speed failure, wheel bearing adjustment

The air gap speed failure means that speed is below the

wheel speed sensor can provide a signal which is

suitable for efficient evaluation. The larger the air gap,

the higher is the air gap speed failure. The maximum

accepted air gap speed is 14 km/h, in case the gap

between sensor and tone wheel increases, the WL will

be turned on. After rework pushing the sensor to the

tone wheel, the vehicle must be driven for a certain

times with start-stop cycles.

Maintenance Manual ABS ABS

- 33 -

Vehicle warranty times exceeding the Knorr-Bremse standard

warranty time, are not applied to Knorr-Bremse service centers,

in this case, claims must be directly addressed to the vehicle

manufacturer service. Knorr-Bremse standard warranty period

is one (1) year without mileage limitation from the date of the

vehicle release.

Disclaimer

Enclosed document is a driver information only and as such

only to be considered as an information supplement to the

official vehicle manufacturer’s documentation. Knorr-Bremse

is not responsible for any failures, not updated technical

changes or missing information and any consequences

resulting out of aforementioned nor for misinterpretation of the

document or for out of misinterpretation resulting failures and

consequences. This document is not subject to regular updates

Warranty

Document name: ABS8 Diagnostic Trouble Code list

Document no.: Y134941 Rev: 006

Customer: GEN

2013.05.02.

Display

No.

Display No. Text

Type

No.

Type text

SPN

No.

SPN text

FMI

No.

FMI text

ABS WL

state

EBC1/

Hardwire

Red WL

state

EBC1/

DM1

Amber

WL

state

DM1

ASR

Lamp

state

EBC1/

Hardwire

HSA

Lamp

Blink Codes Workshop action Driver Action

0xF000

Electronic Control

Unit

0x49

internal electronic

failure

629 Controller #1 12

bad intelligent

device or

component

Active Active Active Active Active

15-1; 15-10;

15-14; 15-16

Do the workshop action of the following failures too:

-Display number-type: 0x5003-0x12; SPN-FMI: 802-3

-Display number-type: 0x5003-0x11; SPN-FMI: 802-4

Clear DTC, when the failure returns then replace the ABS ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0xF000

Electronic Control

Unit

0x61

signal calculation

failure

629 Controller #1 13 out of calibration Active Active Active Active Active 15-5

Clear DTC, when the failure returns then replace the ABS ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0xF000

Electronic Control

Unit

0x05

system

programming

failures

630

Calibration

Memory

11

root cause not

known

Active Active Active Active Active 15-3;15-4

Clear DTC, when the failure returns then reprogram the software and/or the dataset.

When the failure still returns replace the ABS ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0xF000

Electronic Control

Unit

0x46

calibration /

parameter

memory failure

630

Calibration

Memory

13 out of calibration Passive Passive Active Passive Passive

15-13; 15-18;

15-19; 15-20;

15-21; 15-22

Clear DTC, when the failure returns then reprogram the software and/or the dataset.

When the failure still returns replace the ABS ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x5200

Roller Bench

Mode

0x68 event information 576

ASR Off-road

Switch

14

special

instructions

Active Passive Active Active Active 17-8

Deactivate roller bench mode. (with diagnostic routine.)

Verification Procedure:

Deactivate roller bench mode with diagnostic program.

Go to workshop

0x406C Stability System 0x64

signal plausibility

failure

609 Controller #2 2

data erratic,

intermittent or

incorrect

Passive Passive Active Passive Passive 15-17

Clear DTC, when the failure returns then replace the ABS ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x5201

Stability System

Deactivated By

Switch

0x68 event information 609 Controller #2 14

special

instructions

Passive Passive Passive Passive Passive 17-8

Activate the Stability System by the switch.

Verification Procedure:

Activate the ASR/Stability System by the switch.

Stability System is in Off-

road mode

0xF000

Electronic Control

Unit

0x09

component

failures

629 Controller #1 3

voltage above

normal, or

shorted to high

source

Active Passive Active Passive Active 15-11

Clear DTC, when the failure returns then replace the ABS ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x5202

ABS Component

Configuration

Failure

0x95

incorrect

assembly

629 Controller #1 11

root cause not

known

Active Active Active Active Active 15-9; 15-26

Check the configuration of the vehicle (number of valves and sensors) and correct it. If necessary reconfigure ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x5003

Valve common

ground

0x12

circuit short to

battery

802

Valve common

ground

3

voltage above

normal, or

shorted to high

source

Active Active Active Active Active 10-10

Check all the valve ground cables if they have a short-cut to the vehicle voltage (UB).

Measure insulation resistance of solenoid and cabling to vehicle voltage (UB). (Connector-PIN: vehicle UB: X1-16, valve grounds

depending on configuraton: X1-4, X2-3, X2-6, X2-9, X2-12, X3-3, X3-6, X3-9, X4-12)

Resistance should be > 200 kOhm.

If insulation is correct then Clear DTCs. If the failure returns, replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x5003

Valve common

ground

0x11

circuit short to

ground

802

Valve common

ground

4

voltage below

normal, or

shorted to low

source

Active Active Active Active Active 10-11

Check all the valve ground cables if they have a short-cut to vehicle ground.

Measure insulation resistance of solenoid and cabling to vehicle GND. (Connector-PIN: vehicle GND: X1-1, valve grounds depending

on configuraton: X1-4, X2-3, X2-6, X2-9, X2-12, X3-3, X3-6, X3-9, X4-12)

Resistance should be > 200 kOhm.

Verify if the valves are connected.

If insulation is correct then Clear DTCs. If the failure returns, replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x5221 AUXIO 2 Or 3 0x12

circuit short to

battery

925

Auxiliary Output

#2

3

voltage above

normal, or

shorted to high

source

Passive Passive Passive Passive Passive 17-18

Check for corroded / damaged wiring between the ECU and Auxiliary Input/Output device. (Connector-PIN: X3-5)

Measure insulation resistance of Auxiliary Input/Output device and cabling to vehicle voltage (UB). Resistance should be > 200

kOhm.

If insulation is correct then Clear DTCs. If the failure returns, replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

1/29

Document name: ABS8 Diagnostic Trouble Code list

Document no.: Y134941 Rev: 006

Customer: GEN

2013.05.02.

Display

No.

Display No. Text

Type

No.

Type text

SPN

No.

SPN text

FMI

No.

FMI text

ABS WL

state

EBC1/

Hardwire

Red WL

state

EBC1/

DM1

Amber

WL

state

DM1

ASR

Lamp

state

EBC1/

Hardwire

HSA

Lamp

Blink Codes Workshop action Driver Action

0xF003 Battery Voltage 0x16

circuit voltage

below threshold

168

Battery Potential /

Power Input 1

4

voltage below

normal, or

shorted to low

source

Active Active Active Active Active 16-2

Check the supply voltage of the ECU: The voltage level shall be between 22V and 32V (11V and 16V).

Check for damaged wiring.

Check condition of fuse.

Check for corroded connectors and connections.

Verification Procedure:

Clear DTC.

Check the vehicle voltage

0xF003 Battery Voltage 0x17

circuit voltage

above threshold

168

Battery Potential /

Power Input 1

3

voltage above

normal, or

shorted to high

source

Active Active Active Active Active 16-1

Check the supply voltage of the ECU: The voltage level shall be between 22V and 32V (11V and 16V).

Check the alternator (voltage regulator).

Verification Procedure:

Clear DTC.

Check the vehicle voltage

0x6001

Anti-Lock Braking

System

0x64

signal plausibility

failure

629 Controller #1 7

mechanical

system not

responding or out

of adjustment

Active Active Active Active Active 15-27

Check the mechanical parts of the wheel brakes, if there any stuck part which results one or more wheel being overbraked.

Check the pneumatic piping and the exhaust port of the PCVs, TCVs, Relay valves to be sure that the air can be released normally

from all brake chambers.

Check the wheel sizes on the vehicle and in the configuration.

Check the mounting of the Wheel Speed Sensors and the condition of the Tone Wheel.

Check if there are wheel(s) which can be lifted up, but they are not configured for wheels on lift axle.

Verification Procedure:

Clear DTC.

Go to workshop

0x6001

Anti-Lock Braking

System

0x63

circuit /

component

protection time-

out

629 Controller #1 8

abnormal

frequency or

pulse width or

period

Active Active Active Active Active 15-28

Check tyre, check pneumatic and mechanical parts of wheel brakes.

Check wheel speed signal components: check cable, sensor and tone wheel.

Check if configuration stored in the ECU corresponds to wheel rolling circumference and tone-wheel teeth number.

If those do not conform, then correct the configuration values or change the part of the vehicle.

Verification Procedure:

Clear DTC.

Go to workshop

0x5205

Anti-Lock Brake

System

Deactivated By

Difflock

0x68 event information 612 ABS disabled 14

special

instructions

Active Passive Active Passive Active 17-3

Disengage the difflock on the front axle.

Verification Procedure:

Failure will be cleared when the difflock of the front axle will be disengaged.

ABS is disabled due to

engaged difflock

0x5206

Off-road ABS Is

Activated

0x68 event information 575

ABS Off-road

Switch

14

special

instructions

Active Passive Active Passive Active 17-9

Deactivate the Off-road ABS function by its switch.

Verification Procedure:

Failure will be cleared when the Off-road ABS function is turned off by its switch.

ABS is in Off-road mode

0xF000

Electronic Control

Unit

0x41

general

checksum failure

630

Calibration

Memory

12

bad intelligent

device or

component

Active Active Active Active Active 15-4

Clear DTC, when the failure returns then replace the ABS ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0xF000

Electronic Control

Unit

0x04

system internal

failures

629 Controller #1 14

special

instructions

Active Active Active Active Active 15-4

Clear DTC, when the failure returns then replace the ABS ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0xC010 Vehicle CAN 0x88 bus off 639

J1939 Network

#1, Primary

Vehicle Network

11

root cause not

known

Active Passive Active Active Active 18-3

Check baud rate settings.

Check the device which is not transmitting the missing message.

Check for open circuit, damaged or reversed J1939 wiring.

Check for termination resistor (2x120 Ohm).

Check for damaged or corroded connectors.

Check for other devices inhibiting J1939 communication.

Verification Procedure:

Clear DTC.

Go to workshop

0xC010 Vehicle CAN 0x87 missing message 639

J1939 Network

#1, Primary

Vehicle Network

2

data erratic,

intermittent or

incorrect

Passive Passive Active Passive Passive 18-13

Check the device which is not transmitting the missing message.

Check for open circuit, damaged or reversed J1939 wiring.

Check for termination resistor (2x120 Ohm).

Check for damaged or corroded connectors.

Check for other devices inhibiting J1939 communication.

Verification Procedure:

Clear DTC.

Go to workshop

2/29

Document name: ABS8 Diagnostic Trouble Code list

Document no.: Y134941 Rev: 006

Customer: GEN

2013.05.02.

Display

No.

Display No. Text

Type

No.

Type text

SPN

No.

SPN text

FMI

No.

FMI text

ABS WL

state

EBC1/

Hardwire

Red WL

state

EBC1/

DM1

Amber

WL

state

DM1

ASR

Lamp

state

EBC1/

Hardwire

HSA

Lamp

Blink Codes Workshop action Driver Action

0xC010 Vehicle CAN 0x08

bus signal /

message Failures

1671

J1939 Network

#7

2

data erratic,

intermittent or

incorrect

Passive Passive Active Passive Passive 18-13

Check the device which is not transmitting the missing message.

Check for open circuit, damaged or reversed J1939 wiring.

Check for damaged or corroded connectors.

Check for other devices inhibiting J1939 communication.

Verification Procedure:

Clear DTC.

Go to workshop

0xD010

Timedate Signal

Not Available

0x88 bus off 609 Controller #2 11

root cause not

known

Passive Passive Active Passive Passive 19-11

Check for damaged or reversed Sensor CAN wiring.

Check for damaged or corroded connectors.

Check for other devices inhibiting Sensor CAN communication.

Verification Procedure:

Clear DTC.

Go to workshop

0xD013

Timedate Signal

Not Available

0x87 missing message 521010

Timedate Signal

Not Available

2

data erratic,

intermittent or

incorrect

Passive Passive Passive Passive Passive 18-14

Check the device which is not transmitting the missing message.

Check for open circuit, damaged or reversed J1939 wiring.

Check for damaged or corroded connectors.

Check for other devices inhibiting J1939 communication.

Verification Procedure:

Clear DTC.

-

0xD011

Vehicle Distance

Signal Not

Available

0x87 missing message 521011

Vehicle Distance

Signal Not

Available

2

data erratic,

intermittent or

incorrect

Passive Passive Passive Passive Passive 18-15

Check the settings of the tachograph signal.

Check the wheel size and Tone wheel settings of the ABS ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0xC010 Vehicle CAN 0x81

invalid serial data

received

639

J1939 Network

#1, Primary

Vehicle Network

14

special

instructions

Passive Passive Active Passive Passive 18-16

Check the device which is not transmitting the missing message.

Check for open circuit, damaged or reversed J1939 wiring.

Check for damaged or corroded connectors.

Check for other devices inhibiting J1939 communication.

Verification Procedure:

Clear DTC.

-

0xD012

Time/Date

Message Timeout

0x87 missing message 521012

Time/Date

Message Timeout

2

data erratic,

intermittent or

incorrect

Passive Passive Passive Passive Passive 18-14

Check the device which is not transmitting the missing message.

Check for open circuit, damaged or reversed J1939 wiring.

Check for damaged or corroded connectors.

Check for other devices inhibiting J1939 communication.

Verification Procedure:

Clear DTC.

-

0xD014

High Resolution

Vehicle Distance

Message Timeout

Occurred

0x87 missing message 521014

High Resolution

Vehicle Distance

Message Timeout

Occurred

2

data erratic,

intermittent or

incorrect

Passive Passive Passive Passive Passive 18-15

Clear DTC, when the failure returns then replace the ABS ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0xF000

Electronic Control

Unit

0x44

data memory

failure

630

Calibration

Memory

14

special

instructions

Active Active Active Active Active 15-3

Check the device which is not transmitting the missing message.

Check for open circuit, damaged or reversed J1939 wiring.

Check for damaged or corroded connectors.

Check for other devices inhibiting J1939 communication.

Verification Procedure:

Clear DTC.

-

0xD016

CAN Message

EAC1_SCH

Timeout Or

Invalid Signal

0x87 missing message 521016

CAN Message

EAC1_SCH

Timeout Or

Invalid Signal

2

data erratic,

intermittent or

incorrect

Passive Passive Passive Passive Passive 18-17

Check the device which is not transmitting the missing message.

Check for open circuit, damaged or reversed J1939 wiring.

Check for damaged or corroded connectors.

Check for other devices inhibiting J1939 communication.

Verification Procedure:

Clear DTC.

-

0xD017

CAN Message

ASC1_CLCS

Timeout Or

Invalid Signal

0x87 missing message 521017

CAN Message

ASC1_CLCS

Timeout Or

Invalid Signal

2

data erratic,

intermittent or

incorrect

Passive Passive Passive Passive Passive 18-18

Check the device which is not transmitting the missing message.

Check for open circuit, damaged or reversed J1939 wiring.

Check for damaged or corroded connectors.

Check for other devices inhibiting J1939 communication.

Verification Procedure:

Clear DTC.

-

3/29

Document name: ABS8 Diagnostic Trouble Code list

Document no.: Y134941 Rev: 006

Customer: GEN

2013.05.02.

Display

No.

Display No. Text

Type

No.

Type text

SPN

No.

SPN text

FMI

No.

FMI text

ABS WL

state

EBC1/

Hardwire

Red WL

state

EBC1/

DM1

Amber

WL

state

DM1

ASR

Lamp

state

EBC1/

Hardwire

HSA

Lamp

Blink Codes Workshop action Driver Action

0xD018

CAN Message

VW_CLCS

Timeout Or

Invalid Signal

0x87 missing message 521018

CAN Message

VW_CLCS

Timeout Or

Invalid Signal

2

data erratic,

intermittent or

incorrect

Passive Passive Passive Passive Passive 18-19

Check the device which is not transmitting the missing message.

Check for open circuit, damaged or reversed J1939 wiring.

Check for damaged or corroded connectors.

Check for other devices inhibiting J1939 communication.

Verification Procedure:

Clear DTC.

Go to workshop

0xD019

CAN Message

ETC1_TCU

Timeout Or

Invalid Signal

0x87 missing message 521019

CAN Message

ETC1_TCU

Timeout Or

Invalid Signal

2

data erratic,

intermittent or

incorrect

Passive Passive Active Passive Passive 18-6

Check the device which is not transmitting the missing message.

Check for open circuit, damaged or reversed J1939 wiring.

Check for damaged or corroded connectors.

Check for other devices inhibiting J1939 communication.

Verification Procedure:

Clear DTC.

Go to workshop

0xD020

CAN Message

ETC2 Timeout Or

Invalid Signal

0x87 missing message 521020

CAN Message

ETC2 Timeout Or

Invalid Signal

2

data erratic,

intermittent or

incorrect

Passive Passive Active Passive Passive 18-6

Check the device which is not transmitting the missing message.

Check for open circuit, damaged or reversed J1939 wiring.

Check for damaged or corroded connectors.

Check for other devices inhibiting J1939 communication.

Verification Procedure:

Clear DTC.

Go to workshop

0xD021

CAN Message

EEC1_CPC3

Timeout Or

Invalid Signal

0x87 missing message 521021

CAN Message

EEC1_CPC3

Timeout Or

Invalid Signal

2

data erratic,

intermittent or

incorrect

Passive Passive Active Active Active 18-5

Check the device which is not transmitting the missing message.

Check for open circuit, damaged or reversed J1939 wiring.

Check for damaged or corroded connectors.

Check for other devices inhibiting J1939 communication.

Verification Procedure:

Clear DTC.

Go to workshop

0xD022

CAN Message

EEC2_CPC3

Timeout Or

Invalid Signal

0x87 missing message 521022

CAN Message

EEC2_CPC3

Timeout Or

Invalid Signal

2

data erratic,

intermittent or

incorrect

Passive Passive Active Active Active 18-5

Check the device which is not transmitting the missing message.

Check for open circuit, damaged or reversed J1939 wiring.

Check for damaged or corroded connectors.

Check for other devices inhibiting J1939 communication.

Verification Procedure:

Clear DTC.

Go to workshop

0xD023

CAN Message

EEC3_CPC3

Timeout Or

Invalid Signal

0x87 missing message 521023

CAN Message

EEC3_CPC3

Timeout Or

Invalid Signal

2

data erratic,

intermittent or

incorrect

Passive Passive Active Active Active 18-5

Check the device which is not transmitting the missing message.

Check for open circuit, damaged or reversed J1939 wiring.

Check for damaged or corroded connectors.

Check for other devices inhibiting J1939 communication.

Verification Procedure:

Clear DTC.

Go to workshop

0xD024

CAN Message

ERC1_RET

Timeout Or

Invalid Signal

0x87 missing message 521024

CAN Message

ERC1_RET

Timeout Or

Invalid Signal

2

data erratic,

intermittent or

incorrect

Active Passive Active Passive Active 18-4

Check the device which is not transmitting the missing message.

Check for open circuit, damaged or reversed J1939 wiring.

Check for damaged or corroded connectors.

Check for other devices inhibiting J1939 communication.

Verification Procedure:

Clear DTC.

Go to workshop

0xD025

CAN Message

CCVS_CPC

Timeout Or

Invalid Signal

0x87 missing message 521025

CAN Message

CCVS_CPC

Timeout Or

Invalid Signal

2

data erratic,

intermittent or

incorrect

Passive Passive Active Passive Passive 18-20

Check the device which is not transmitting the missing message.

Check for open circuit, damaged or reversed J1939 wiring.

Check for damaged or corroded connectors.

Check for other devices inhibiting J1939 communication.

Verification Procedure:

Clear DTC.

-

0xD026

CAN Message

TCO1_TCO

Timeout Or

Invalid Signal

0x87 missing message 521026

CAN Message

TCO1_TCO

Timeout Or

Invalid Signal

2

data erratic,

intermittent or

incorrect

Passive Passive Passive Passive Passive 18-21

Check the device which is not transmitting the missing message.

Check for open circuit, damaged or reversed J1939 wiring.

Check for damaged or corroded connectors.

Check for other devices inhibiting J1939 communication.

Verification Procedure:

Clear DTC.

-

4/29

Document name: ABS8 Diagnostic Trouble Code list

Document no.: Y134941 Rev: 006

Customer: GEN

2013.05.02.

Display

No.

Display No. Text

Type

No.

Type text

SPN

No.

SPN text

FMI

No.

FMI text

ABS WL

state

EBC1/

Hardwire

Red WL

state

EBC1/

DM1

Amber

WL

state

DM1

ASR

Lamp

state

EBC1/

Hardwire

HSA

Lamp

Blink Codes Workshop action Driver Action

0xD027

CAN Message

TD_TCO Timeout

Or Invalid Signal

0x87 missing message 521027

CAN Message

TD_TCO Timeout

Or Invalid Signal

2

data erratic,

intermittent or

incorrect

Passive Passive Passive Passive Passive 18-21

Check the device which is not transmitting the missing message.

Check for open circuit, damaged or reversed J1939 wiring.

Check for damaged or corroded connectors.

Check for other devices inhibiting J1939 communication.

Verification Procedure:

Clear DTC.

Go to workshop

0xD028

CAN Message

AIR1 Timeout Or

Invalid Signal

0x87 missing message 521028

CAN Message

AIR1 Timeout Or

Invalid Signal

2

data erratic,

intermittent or

incorrect

Passive Passive Active Passive Passive 18-9

Check the device which is not transmitting the missing message.

Check for open circuit, damaged or reversed J1939 wiring.

Check for damaged or corroded connectors.

Check for other devices inhibiting J1939 communication.

Verification Procedure:

Clear DTC.

Go to workshop

0xD029

CAN Message

AUXIO Timeout

Or Invalid Signal

0x87 missing message 521029

CAN Message

AUXIO Timeout

Or Invalid Signal

2

data erratic,

intermittent or

incorrect

Passive Passive Active Passive Passive 18-12

Check the device which is not transmitting the missing message.

Check for open circuit, damaged or reversed J1939 wiring.

Check for damaged or corroded connectors.

Check for other devices inhibiting J1939 communication.

Verification Procedure:

Clear DTC.

Go to workshop

0xD030

Timeout or invalid

data on XBR

0x87 missing message 521030

Timeout or invalid

data on XBR

2

data erratic,

intermittent or

incorrect

Passive Passive Active Passive Passive 18-10

Check the device which is not transmitting the missing message.

Check for open circuit, damaged or reversed J1939 wiring.

Check for damaged or corroded connectors.

Check for other devices inhibiting J1939 communication.

Verification Procedure:

Clear DTC.

Go to workshop

0xD031

CAN Message

ETC7 Timeout

0x87 missing message 521031

CAN Message

ETC7 Timeout

2

data erratic,

intermittent or

incorrect

Passive Passive Active Passive Active 18-7

Wheel speed sensors reversed on an axle (left to right).

Verify proper installation, connection and wiring of sensors and verifying location of sensors on the vehicle.

Verification Procedure:

Clear DTC. Verification of the wheel speed signal required by End of Line test or driving of the vehicle.

Curve driving also has to be performed.

The sensor DTC will remain active until (without clearing DTCs):

After power off-on the ABS ECU, vehicle is driven above 15-20 km/h and the ABS ECU reads good wheel speed data from all

sensors.

Go to workshop

0x5207

Wheel Speed

Sensors

Interchanged

0x95

incorrect

assembly

810

Speed Signal

Input

7

mechanical

system not

responding or out

of adjustment

Active Active Active Active Active 17-13

Check the configuration of the vehicle (number of sensors) and correct it. If necessary reconfigure ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x5219

WSS

Configuration

Failure

0x95

incorrect

assembly

815

Wheel Sensor

ABS Axle 3

Average

13 out of calibration Active Active Active Active Active 14-10

Check for voltage and ground at pressure sensor wire harness.

Verify wiring between pressure sensor signal and the ECU. The signal line voltage range is 0.5V to 4.5V.

Verify there is no continuity between the pressure sensor and power / ground.

If the failure returns the change the pressure sensor.

Verification Procedure:

Clear DTC.

Go to workshop

0x5046

Axle Load

Pressure Sensor

0x01

general electrical

failure

1059 Axle Load Sensor 2

data erratic,

intermittent or

incorrect

Passive Passive Active Passive Passive 21-1

Check for voltage and ground at pressure sensor wire harness.

Verify wiring between pressure sensor signal and the ECU. The signal line voltage range is 0.5V to 4.5V.

Verify there is no continuity between the pressure sensor and power / ground.

If the failure returns the change the pressure sensor.

Verification Procedure:

Clear DTC.

Go to workshop

0x4046

Brake Pressure

Sensor 1/2

0x29 signal invalid 1066

Brake Signal

Transmitter

11

root cause not

known

Passive Passive Active Passive Active 21-4

Fill up the reservoirs, and then make a full brake application for a few sec. and release the pedal.

Verification Procedure:

Calibrate, and clear DTC.

Apply brake with full

pressure to calibrate

pressure sensor

0x4046

Brake Pressure

Sensor 1/2

0x54

missing

calibration

1066

Brake Signal

Transmitter

13 out of calibration Passive Passive Active Passive Active 21-6

Check for voltage and ground at pressure sensor wire harness.

Verify wiring between pressure sensor signal and the ECU. The signal line voltage range is 0.5V to 4.5V.

Verify there is no continuity between the pressure sensor and power / ground.

Verification Procedure:

Clear DTC.

Go to workshop

5/29

Document name: ABS8 Diagnostic Trouble Code list

Document no.: Y134941 Rev: 006

Customer: GEN

2013.05.02.

Display

No.

Display No. Text

Type

No.

Type text

SPN

No.

SPN text

FMI

No.

FMI text

ABS WL

state

EBC1/

Hardwire

Red WL

state

EBC1/

DM1

Amber

WL

state

DM1

ASR

Lamp

state

EBC1/

Hardwire

HSA

Lamp

Blink Codes Workshop action Driver Action

0x4044

Brake Pressure

Sensor 1

0x01

general electrical

failure

1067

Brake Signal

Sensor 1

2

data erratic,

intermittent or

incorrect

Passive Passive Active Passive Active 21-2

Check for voltage and ground at pressure sensor wire harness.

Verify wiring between pressure sensor signal and the ECU. The signal line voltage range is 0.5V to 4.5V.

Verify there is no continuity between the pressure sensor and power / ground.

Verification Procedure:

Clear DTC.

Go to workshop

0x4045

Brake Pressure

Sensor 2

0x01

general electrical

failure

1068

Brake Signal

Sensor 2

2

data erratic,

intermittent or

incorrect

Passive Passive Active Passive Active 21-3

Check for voltage and ground at pressure sensor wire harness. The supply voltage range is 4.75 to 5.25 volts.

Verify there is no continuity between the pressure sensor and power / ground.

If the failure returns replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x4046

Brake Pressure

Sensor 1/2

0x16

circuit voltage

below threshold

1066

Brake Signal

Transmitter

4

voltage below

normal, or

shorted to low

source

Passive Passive Active Passive Active 21-5

Check for voltage and ground at pressure sensor wire harness. The supply voltage range is 4.75 to 5.25 volts.

Verify there is no continuity between the pressure sensor and power / ground.

If the failure returns replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x4046

Brake Pressure

Sensor 1/2

0x17

circuit voltage

above threshold

1066

Brake Signal

Transmitter

3

voltage above

normal, or

shorted to high

source

Passive Passive Active Passive Active 21-5

Check for voltage and ground at pressure sensor wire harness. The supply voltage range is 4.75 to 5.25 volts.

Verify wiring between pressure sensor signal and the ECU. The signal line voltage range is 0.5V to 4.5V.

Verify there is no continuity between the pressure sensor and power / ground.

If the failure returns the replace the pressure sensor.

Verification Procedure:

Clear DTC.

Go to workshop

0x4046

Brake Pressure

Sensor 1/2

0x19

circuit current

above threshold

1066

Brake Signal

Transmitter

6

current above

normal or

grounded circuit

Passive Passive Active Passive Active 21-5

Check the cables and connectors between ECU and wheel-speed sensor for short-circuits and open-circuits. The resistance of the

sensor (with wiring) should be 900-2000 Ohm. (Connector-PIN: X2-5 and X2-8)

Check insulation resistance of sensor and cabling to vehicle GND and to UB. Resistance should be >200 kOhm.

Check for corroded / damaged wiring or connectors between the ECU and sensor.

Verification Procedure:

Clear DTC.

Go to workshop

0x4031

Steer Axle Left

Wheel Speed

Sensor

0x01

general electrical

failure

789

Wheel Speed

Sensor 1

2

data erratic,

intermittent or

incorrect

Active Passive Active Active Active 2-6

The speed signal of the sensor was suddenly lost.

Measure resistance of Sensor and cabling. Resistance should be 900-2000 Ohm. (Connector-PIN: X2-5 and X2-8)

Measure insulation resistance of sensor and cabling to vehicle GND. Resistance should be > 200 kOhm.

Verify proper bearing end-play.

Check the tone wheel for dirt and metallic particles, for wobble, for pitch error, for damaged teeth.

Verify condition of sensor head.

Verify condition and retention of clamping sleeve.

Check for corroded / damaged wiring or connectors between the ECU and sensor.

Verification Procedure:

Clear DTC. Verification of the wheel speed signal required by End of Line test or driving of the vehicle.

The sensor DTC will remain active until (without clearing DTCs):

After power off-on the ABS ECU, vehicle is driven above 15-20 km/h and the ABS ECU reads good wheel speed data from all

sensors.

Go to workshop

0x4031

Steer Axle Left

Wheel Speed

Sensor

0x31 no signal 789

Wheel Speed

Sensor 1

5

current below

normal or open

circuit

Active Passive Active Active Active 2-5

The air-gap is too large between the sensor and the tone wheel.

Sensor voltage output is minimally 0.25 VAC at 0.5 revs / sec. (Connector-PIN: X2-5 and X2-8) If signal too small push back the

sensor completely to the tone wheel.

Verify proper bearing end-play.

Verify condition and retention of clamping sleeve.

Verify condition of sensor head.

Check for corroded / damaged wiring or connectors between the ECU and sensor.

Verification Procedure:

Clear DTC. Verification of the wheel speed signal required by End of Line test or driving of the vehicle.

The sensor DTC will remain active until (without clearing DTCs):

After power off-on the ABS ECU, vehicle is driven above 15-20 km/h and the ABS ECU reads good wheel speed data from all

sensors.

Go to workshop

6/29

Document name: ABS8 Diagnostic Trouble Code list

Document no.: Y134941 Rev: 006

Customer: GEN

2013.05.02.

Display

No.

Display No. Text

Type

No.

Type text

SPN

No.

SPN text

FMI

No.

FMI text

ABS WL

state

EBC1/

Hardwire

Red WL

state

EBC1/

DM1

Amber

WL

state

DM1

ASR

Lamp

state

EBC1/

Hardwire

HSA

Lamp

Blink Codes Workshop action Driver Action

0x4031

Steer Axle Left

Wheel Speed

Sensor

0x25

signal shape /

waveform failure

789

Wheel Speed

Sensor 1

1

below normal

operational range -

most severe level

Active Passive Active Active Active 2-1

Check the tone wheel for dirt and metallic particles, for wobble, for pitch error, for the correct number of teeth. Replace if faulty.

Verification Procedure:

Clear DTC. Verification of the wheel speed signal required by End of Line test or driving of the vehicle.

The sensor DTC will remain active until (without clearing DTCs):

After power off-on the ABS ECU, vehicle is driven above 15-20 km/h and the ABS ECU reads good wheel speed data from all

sensors.

Go to workshop

0x4031

Steer Axle Left

Wheel Speed

Sensor

0x2F signal erratic 789

Wheel Speed

Sensor 1

7

mechanical

system not

responding or out

of adjustment

Active Passive Active Active Active 2-3

Check if the air-gap is too large between the sensor and the tone wheel. If it too large, push back the sensor completely to the tone

wheel.

Measure resistance of Sensor and cabling. Resistance should be 900-2000 Ohm. (Connector-PIN: X2-5 and X2-8)

Check the mechanical parts of the brake (dragging, jammed brake).

Verification Procedure:

Clear DTC. Verification of the wheel speed signal required by End of Line test or driving of the vehicle.

The sensor DTC will remain active until (without clearing DTCs):

After power off-on the ABS ECU, vehicle is driven above 15-20 km/h and the ABS ECU reads good wheel speed data from all

sensors.

Go to workshop

0x4031

Steer Axle Left

Wheel Speed

Sensor

0x38

signal frequency

incorrect

789

Wheel Speed

Sensor 1

10

abnormal rate of

change

Active Passive Active Active Active 2-2

Check if tire size of all tires is according vehicle specification.

Check C3 Signal calibration, check tachograph for additional fault codes.

Check number of teeth on tone wheel on all wheels.

Verification Procedure:

Clear DTC. Verification of the wheel speed signal required by End of Line test or driving of the vehicle.

The sensor DTC will remain active until (without clearing DTCs):

After power off-on the ABS ECU, vehicle is driven above 15-20 km/h and the ABS ECU reads good wheel speed data from all

sensors.

Go to workshop

0x4031

Steer Axle Left

Wheel Speed

Sensor

0x54

missing

calibration

789

Wheel Speed

Sensor 1

13 out of calibration Active Passive Active Active Active 2-9

Check if the sensor mounting is vibration-free.

Check the tone wheel for dirt and metallic particles, for wobble, for pitch error, for the correct number of teeth.

Verify condition of sensor head.

Verify proper bearing end-play.

Verify condition and retention of clamping sleeve.

Check the mechanical parts of the brake.

Check for corroded / damaged wiring or connectors between the ECU and sensor.

Measure resistance of Sensor and cabling. Resistance should be 900-2000 Ohm. (Connector-PIN: X2-5 and X2-8)

Verification Procedure:

Clear DTC. Verification of the wheel speed signal required by End of Line test or driving of the vehicle.

The sensor DTC will remain active until (without clearing DTCs):

After power off-on the ABS ECU, vehicle is driven above 15-20 km/h and the ABS ECU reads good wheel speed data from all

sensors.

Go to workshop

0x4031

Steer Axle Left

Wheel Speed

Sensor

0x29 signal invalid 789

Wheel Speed

Sensor 1

8

abnormal

frequency or

pulse width or

period

Active Passive Active Active Active 2-4

Check the cables and connectors between ECU and wheel-speed sensor for short-circuits and open-circuits. The resistance of the

sensor (with wiring) should be 900-2000 Ohm. (Connector-PIN: X2-11 and X2-14)

Check insulation resistance of sensor and cabling to vehicle GND and to UB. Resistance should be >200 kOhm.

Check for corroded / damaged wiring or connectors between the ECU and sensor.

Verification Procedure:

Clear DTC.

Go to workshop

0x4034

Steer Axle Right

Wheel Speed

Sensor

0x01

general electrical

failure

790

Wheel Speed

Sensor 2

2

data erratic,

intermittent or

incorrect

Active Passive Active Active Active 3-6

The speed signal of the sensor was suddenly lost.

Measure resistance of Sensor and cabling. Resistance should be 900-2000 Ohm. (Connector-PIN: X2-11 and X2-14)

Measure insulation resistance of sensor and cabling to vehicle GND. Resistance should be > 200 kOhm.

Verify proper bearing end-play.

Check the tone wheel for dirt and metallic particles, for wobble, for pitch error, for damaged teeth.

Verify condition of sensor head.

Verify condition and retention of clamping sleeve.

Check for corroded / damaged wiring or connectors between the ECU and sensor.

Verification Procedure:

Clear DTC. Verification of the wheel speed signal required by End of Line test or driving of the vehicle.

The sensor DTC will remain active until (without clearing DTCs):

After power off-on the ABS ECU, vehicle is driven above 15-20 km/h and the ABS ECU reads good wheel speed data from all

sensors.

Go to workshop

7/29

Document name: ABS8 Diagnostic Trouble Code list

Document no.: Y134941 Rev: 006

Customer: GEN

2013.05.02.

Display

No.

Display No. Text

Type

No.

Type text

SPN

No.

SPN text

FMI

No.

FMI text

ABS WL

state

EBC1/

Hardwire

Red WL

state

EBC1/

DM1

Amber

WL

state

DM1

ASR

Lamp

state

EBC1/

Hardwire

HSA

Lamp

Blink Codes Workshop action Driver Action

0x4034

Steer Axle Right

Wheel Speed

Sensor

0x31 no signal 790

Wheel Speed

Sensor 2

5

current below

normal or open

circuit

Active Passive Active Active Active 3-5

The air-gap is too large between the sensor and the tone wheel.

Sensor voltage output is minimally 0.25 VAC at 0.5 revs / sec. (Connector-PIN: X2-11 and X2-14) If signal too small push back the

sensor completely to the tone wheel.

Verify proper bearing end-play.

Verify condition and retention of clamping sleeve.

Verify condition of sensor head.

Check for corroded / damaged wiring or connectors between the ECU and sensor.

Verification Procedure:

Clear DTC. Verification of the wheel speed signal required by End of Line test or driving of the vehicle.

The sensor DTC will remain active until (without clearing DTCs):

After power off-on the ABS ECU, vehicle is driven above 15-20 km/h and the ABS ECU reads good wheel speed data from all

sensors.

Go to workshop

0x4034

Steer Axle Right

Wheel Speed

Sensor

0x25

signal shape /

waveform failure

790

Wheel Speed

Sensor 2

1

below normal

operational range -

most severe level

Active Passive Active Active Active 3-1

Check the tone wheel for dirt and metallic particles, for wobble, for pitch error, for the correct number of teeth. Replace if faulty.

Verification Procedure:

Clear DTC. Verification of the wheel speed signal required by End of Line test or driving of the vehicle.

The sensor DTC will remain active until (without clearing DTCs):

After power off-on the ABS ECU, vehicle is driven above 15-20 km/h and the ABS ECU reads good wheel speed data from all

sensors.

Go to workshop

0x4034

Steer Axle Right

Wheel Speed

Sensor

0x2F signal erratic 790

Wheel Speed

Sensor 2

7

mechanical

system not

responding or out

of adjustment

Active Passive Active Active Active 3-3

Check if the air-gap is too large between the sensor and the tone wheel. If it too large, push back the sensor completely to the tone

wheel.

Measure resistance of Sensor and cabling. Resistance should be 900-2000 Ohm. (Connector-PIN: X2-11 and X2-14)

Check the mechanical parts of the brake (dragging, jammed brake).

Verification Procedure:

Clear DTC. Verification of the wheel speed signal required by End of Line test or driving of the vehicle.

The sensor DTC will remain active until (without clearing DTCs):

After power off-on the ABS ECU, vehicle is driven above 15-20 km/h and the ABS ECU reads good wheel speed data from all

sensors.

Go to workshop

0x4034

Steer Axle Right

Wheel Speed

Sensor

0x38

signal frequency

incorrect

790

Wheel Speed

Sensor 2

10

abnormal rate of

change

Active Passive Active Active Active 3-2

Check if tire size of all tires is according vehicle specification.

Check C3 Signal calibration, check tachograph for additional fault codes.

Check number of teeth on tone wheel on all wheels.

Verification Procedure:

Clear DTC. Verification of the wheel speed signal required by End of Line test or driving of the vehicle.

The sensor DTC will remain active until (without clearing DTCs):

After power off-on the ABS ECU, vehicle is driven above 15-20 km/h and the ABS ECU reads good wheel speed data from all

sensors.

Go to workshop

0x4034

Steer Axle Right

Wheel Speed

Sensor

0x54

missing

calibration

790

Wheel Speed

Sensor 2

13 out of calibration Active Passive Active Active Active 3-9

Check if the sensor mounting is vibration-free.

Check the tone wheel for dirt and metallic particles, for wobble, for pitch error, for the correct number of teeth.

Verify condition of sensor head.

Verify proper bearing end-play.

Verify condition and retention of clamping sleeve.

Check the mechanical parts of the brake.

Check for corroded / damaged wiring or connectors between the ECU and sensor.

Measure resistance of Sensor and cabling. Resistance should be 900-2000 Ohm. (Connector-PIN: X2-11 and X2-14)

Verification Procedure:

Clear DTC. Verification of the wheel speed signal required by End of Line test or driving of the vehicle.

The sensor DTC will remain active until (without clearing DTCs):

After power off-on the ABS ECU, vehicle is driven above 15-20 km/h and the ABS ECU reads good wheel speed data from all

sensors.

Go to workshop

0x4034

Steer Axle Right

Wheel Speed

Sensor

0x29 signal invalid 790

Wheel Speed

Sensor 2

8

abnormal

frequency or

pulse width or

period

Active Passive Active Active Active 3-4

Check the cables and connectors between ECU and wheel-speed sensor for short-circuits and open-circuits. The resistance of the

sensor (with wiring) should be 900-2000 Ohm. (Connector-PIN: X2-15 and X2-18)

Check insulation resistance of sensor and cabling to vehicle GND and to UB. Resistance should be >200 kOhm.

Check for corroded / damaged wiring or connectors between the ECU and sensor.

Verification Procedure:

Clear DTC.

Go to workshop

8/29

Document name: ABS8 Diagnostic Trouble Code list

Document no.: Y134941 Rev: 006

Customer: GEN

2013.05.02.

Display

No.

Display No. Text

Type

No.

Type text

SPN

No.

SPN text

FMI

No.

FMI text

ABS WL

state

EBC1/

Hardwire

Red WL

state

EBC1/

DM1

Amber

WL

state

DM1

ASR

Lamp

state

EBC1/

Hardwire

HSA

Lamp

Blink Codes Workshop action Driver Action

0x4037

Drive Axle Left

Wheel Speed

Sensor

0x01

general electrical

failure

791

Wheel Speed

Sensor 3

2

data erratic,

intermittent or

incorrect

Active Active Active Active Active 4-6

The speed signal of the sensor was suddenly lost.

Measure resistance of Sensor and cabling. Resistance should be 900-2000 Ohm. (Connector-PIN: X2-15 and X2-18)

Measure insulation resistance of sensor and cabling to vehicle GND. Resistance should be > 200 kOhm.

Verify proper bearing end-play.

Check the tone wheel for dirt and metallic particles, for wobble, for pitch error, for damaged teeth.

Verify condition of sensor head.

Verify condition and retention of clamping sleeve.

Check for corroded / damaged wiring or connectors between the ECU and sensor.

Verification Procedure:

Clear DTC. Verification of the wheel speed signal required by End of Line test or driving of the vehicle.

The sensor DTC will remain active until (without clearing DTCs):

After power off-on the ABS ECU, vehicle is driven above 15-20 km/h and the ABS ECU reads good wheel speed data from all

sensors.

Go to workshop

0x4037

Drive Axle Left

Wheel Speed

Sensor

0x31 no signal 791

Wheel Speed

Sensor 3

5

current below

normal or open

circuit

Active Active Active Active Active 4-5

The air-gap is too large between the sensor and the tone wheel.

Sensor voltage output is minimally 0.25 VAC at 0.5 revs / sec. (Connector-PIN: X2-15 and X2-18) If signal too small push back the

sensor completely to the tone wheel.

Verify proper bearing end-play.

Verify condition and retention of clamping sleeve.

Verify condition of sensor head.

Check for corroded / damaged wiring or connectors between the ECU and sensor.

Verification Procedure:

Clear DTC. Verification of the wheel speed signal required by End of Line test or driving of the vehicle.

The sensor DTC will remain active until (without clearing DTCs):

After power off-on the ABS ECU, vehicle is driven above 15-20 km/h and the ABS ECU reads good wheel speed data from all

sensors.

Go to workshop

0x4037

Drive Axle Left

Wheel Speed

Sensor

0x25

signal shape /

waveform failure

791

Wheel Speed

Sensor 3

1

below normal

operational range -

most severe level

Active Active Active Active Active 4-1

Check the tone wheel for dirt and metallic particles, for wobble, for pitch error, for the correct number of teeth. Replace if faulty.

Verification Procedure:

Clear DTC. Verification of the wheel speed signal required by End of Line test or driving of the vehicle.

The sensor DTC will remain active until (without clearing DTCs):

After power off-on the ABS ECU, vehicle is driven above 15-20 km/h and the ABS ECU reads good wheel speed data from all

sensors.

Go to workshop

0x4037

Drive Axle Left

Wheel Speed

Sensor

0x2F signal erratic 791

Wheel Speed

Sensor 3

7

mechanical

system not

responding or out

of adjustment

Active Active Active Active Active 4-3

Check if the air-gap is too large between the sensor and the tone wheel. If it too large, push back the sensor completely to the tone

wheel.

Measure resistance of Sensor and cabling. Resistance should be 900-2000 Ohm. (Connector-PIN: X2-15 and X2-18)

Check the mechanical parts of the brake (dragging, jammed brake).

Verification Procedure:

Clear DTC. Verification of the wheel speed signal required by End of Line test or driving of the vehicle.

The sensor DTC will remain active until (without clearing DTCs):

After power off-on the ABS ECU, vehicle is driven above 15-20 km/h and the ABS ECU reads good wheel speed data from all

sensors.

Go to workshop

0x4037

Drive Axle Left

Wheel Speed

Sensor

0x38

signal frequency

incorrect

791

Wheel Speed

Sensor 3

10

abnormal rate of

change

Active Active Active Active Active 4-2

Check if tire size of all tires is according vehicle specification.

Check C3 Signal calibration, check tachograph for additional fault codes.

Check number of teeth on tone wheel on all wheels.

Verification Procedure:

Clear DTC. Verification of the wheel speed signal required by End of Line test or driving of the vehicle.

The sensor DTC will remain active until (without clearing DTCs):

After power off-on the ABS ECU, vehicle is driven above 15-20 km/h and the ABS ECU reads good wheel speed data from all

sensors.

Go to workshop

9/29

Document name: ABS8 Diagnostic Trouble Code list

Document no.: Y134941 Rev: 006

Customer: GEN

2013.05.02.

Display

No.

Display No. Text

Type

No.

Type text

SPN

No.

SPN text

FMI

No.

FMI text

ABS WL

state

EBC1/

Hardwire

Red WL

state

EBC1/

DM1

Amber

WL

state

DM1

ASR

Lamp

state

EBC1/

Hardwire

HSA

Lamp

Blink Codes Workshop action Driver Action

0x4037

Drive Axle Left

Wheel Speed

Sensor

0x54

missing

calibration

791

Wheel Speed

Sensor 3

13 out of calibration Active Active Active Active Active 4-9

Check if the sensor mounting is vibration-free.

Check the tone wheel for dirt and metallic particles, for wobble, for pitch error, for the correct number of teeth.

Verify condition of sensor head.

Verify proper bearing end-play.

Verify condition and retention of clamping sleeve.

Check the mechanical parts of the brake.

Check for corroded / damaged wiring or connectors between the ECU and sensor.

Measure resistance of Sensor and cabling. Resistance should be 900-2000 Ohm. (Connector-PIN: X2-15 and X2-18)

Verification Procedure:

Clear DTC. Verification of the wheel speed signal required by End of Line test or driving of the vehicle.

The sensor DTC will remain active until (without clearing DTCs):

After power off-on the ABS ECU, vehicle is driven above 15-20 km/h and the ABS ECU reads good wheel speed data from all

sensors.

Go to workshop

0x4037

Drive Axle Left

Wheel Speed

Sensor

0x29 signal invalid 791

Wheel Speed

Sensor 3

8

abnormal

frequency or

pulse width or

period

Active Active Active Active Active 4-4

Check the cables and connectors between ECU and wheel-speed sensor for short-circuits and open-circuits. The resistance of the

sensor (with wiring) should be 900-2000 Ohm. (Connector-PIN: X1-10 and X1-11)

Check insulation resistance of sensor and cabling to vehicle GND and to UB. Resistance should be >200 kOhm.

Check for corroded / damaged wiring or connectors between the ECU and sensor.

Verification Procedure:

Clear DTC.

Go to workshop

0x403A

Drive Axle Right

Wheel Speed

Sensor

0x01

general electrical

failure

792

Wheel Speed

Sensor 4

2

data erratic,

intermittent or

incorrect

Active Active Active Active Active 5-6

The speed signal of the sensor was suddenly lost.

Measure resistance of Sensor and cabling. Resistance should be 900-2000 Ohm. (Connector-PIN: X1-10 and X1-11)

Measure insulation resistance of sensor and cabling to vehicle GND. Resistance should be > 200 kOhm.

Verify proper bearing end-play.

Check the tone wheel for dirt and metallic particles, for wobble, for pitch error, for damaged teeth.

Verify condition of sensor head.

Verify condition and retention of clamping sleeve.

Check for corroded / damaged wiring or connectors between the ECU and sensor.

Verification Procedure:

Clear DTC. Verification of the wheel speed signal required by End of Line test or driving of the vehicle.

The sensor DTC will remain active until (without clearing DTCs):

After power off-on the ABS ECU, vehicle is driven above 15-20 km/h and the ABS ECU reads good wheel speed data from all

sensors.

Go to workshop

0x403A

Drive Axle Right

Wheel Speed

Sensor

0x31 no signal 792

Wheel Speed

Sensor 4

5

current below

normal or open

circuit

Active Active Active Active Active 5-5

The air-gap is too large between the sensor and the tone wheel.

Sensor voltage output is minimally 0.25 VAC at 0.5 revs / sec. (Connector-PIN: X1-10 and X1-11) If signal too small push back the

sensor completely to the tone wheel.

Verify proper bearing end-play.

Verify condition and retention of clamping sleeve.

Verify condition of sensor head.

Check for corroded / damaged wiring or connectors between the ECU and sensor.

Verification Procedure:

Clear DTC. Verification of the wheel speed signal required by End of Line test or driving of the vehicle.

The sensor DTC will remain active until (without clearing DTCs):

After power off-on the ABS ECU, vehicle is driven above 15-20 km/h and the ABS ECU reads good wheel speed data from all

sensors.

Go to workshop

0x403A

Drive Axle Right

Wheel Speed

Sensor

0x25

signal shape /

waveform failure

792

Wheel Speed

Sensor 4

1

below normal

operational range -

most severe level

Active Active Active Active Active 5-1

Check the tone wheel for dirt and metallic particles, for wobble, for pitch error, for the correct number of teeth. Replace if faulty.

Verification Procedure:

Clear DTC. Verification of the wheel speed signal required by End of Line test or driving of the vehicle.

The sensor DTC will remain active until (without clearing DTCs):

After power off-on the ABS ECU, vehicle is driven above 15-20 km/h and the ABS ECU reads good wheel speed data from all

sensors.

Go to workshop

0x403A

Drive Axle Right

Wheel Speed

Sensor

0x2F signal erratic 792

Wheel Speed

Sensor 4

7

mechanical

system not

responding or out

of adjustment

Active Active Active Active Active 5-3

Check if the air-gap is too large between the sensor and the tone wheel. If it too large, push back the sensor completely to the tone

wheel.

Measure resistance of Sensor and cabling. Resistance should be 900-2000 Ohm. (Connector-PIN: X1-10 and X1-11)

Check the mechanical parts of the brake (dragging, jammed brake).

Verification Procedure:

Clear DTC. Verification of the wheel speed signal required by End of Line test or driving of the vehicle.

The sensor DTC will remain active until (without clearing DTCs):

After power off-on the ABS ECU, vehicle is driven above 15-20 km/h and the ABS ECU reads good wheel speed data from all

sensors.

Go to workshop

10/29

Document name: ABS8 Diagnostic Trouble Code list

Document no.: Y134941 Rev: 006

Customer: GEN

2013.05.02.

Display

No.

Display No. Text

Type

No.

Type text

SPN

No.

SPN text

FMI

No.

FMI text

ABS WL

state

EBC1/

Hardwire

Red WL

state

EBC1/

DM1

Amber

WL

state

DM1

ASR

Lamp

state

EBC1/

Hardwire

HSA

Lamp

Blink Codes Workshop action Driver Action

0x403A

Drive Axle Right

Wheel Speed

Sensor

0x38

signal frequency

incorrect

792

Wheel Speed

Sensor 4

10

abnormal rate of

change

Active Active Active Active Active 5-2

Check if tire size of all tires is according vehicle specification.

Check C3 Signal calibration, check tachograph for additional fault codes.

Check number of teeth on tone wheel on all wheels.

Verification Procedure:

Clear DTC. Verification of the wheel speed signal required by End of Line test or driving of the vehicle.

The sensor DTC will remain active until (without clearing DTCs):

After power off-on the ABS ECU, vehicle is driven above 15-20 km/h and the ABS ECU reads good wheel speed data from all

sensors.

Go to workshop

0x403A

Drive Axle Right

Wheel Speed

Sensor

0x54

missing

calibration

792

Wheel Speed

Sensor 4

13 out of calibration Active Active Active Active Active 5-9

Check if the sensor mounting is vibration-free.

Check the tone wheel for dirt and metallic particles, for wobble, for pitch error, for the correct number of teeth.

Verify condition of sensor head.

Verify proper bearing end-play.

Verify condition and retention of clamping sleeve.

Check the mechanical parts of the brake.

Check for corroded / damaged wiring or connectors between the ECU and sensor.

Measure resistance of Sensor and cabling. Resistance should be 900-2000 Ohm. (Connector-PIN: X1-10 and X1-11)

Verification Procedure:

Clear DTC. Verification of the wheel speed signal required by End of Line test or driving of the vehicle.

The sensor DTC will remain active until (without clearing DTCs):

After power off-on the ABS ECU, vehicle is driven above 15-20 km/h and the ABS ECU reads good wheel speed data from all

sensors.

Go to workshop

0x403A

Drive Axle Right

Wheel Speed

Sensor

0x29 signal invalid 792

Wheel Speed

Sensor 4

8

abnormal

frequency or

pulse width or

period

Active Active Active Active Active 5-4

Check the cables and connectors between ECU and wheel-speed sensor for short-circuits and open-circuits. The resistance of the

sensor (with wiring) should be 900-2000 Ohm. (Connector-PIN: X3-11 and X3-14)

Check insulation resistance of sensor and cabling to vehicle GND and to UB. Resistance should be >200 kOhm.

Check for corroded / damaged wiring or connectors between the ECU and sensor.

Verification Procedure:

Clear DTC.

Go to workshop

0x6031

Add Axle Left

Wheel Speed

Sensor

0x01

general electrical

failure

793

Wheel Speed

Sensor 5

2

data erratic,

intermittent or

incorrect

Active Active Active Active Active 6-6

The speed signal of the sensor was suddenly lost.

Measure resistance of Sensor and cabling. Resistance should be 900-2000 Ohm. (Connector-PIN: X3-11 and X3-14)

Measure insulation resistance of sensor and cabling to vehicle GND. Resistance should be > 200 kOhm.

Verify proper bearing end-play.

Check the tone wheel for dirt and metallic particles, for wobble, for pitch error, for damaged teeth.

Verify condition of sensor head.

Verify condition and retention of clamping sleeve.

Check for corroded / damaged wiring or connectors between the ECU and sensor.

Verification Procedure:

Clear DTC. Verification of the wheel speed signal required by End of Line test or driving of the vehicle.

The sensor DTC will remain active until (without clearing DTCs):

After power off-on the ABS ECU, vehicle is driven above 15-20 km/h and the ABS ECU reads good wheel speed data from all

sensors.

Go to workshop

0x6031

Add Axle Left

Wheel Speed

Sensor

0x31 no signal 793

Wheel Speed

Sensor 5

5

current below

normal or open

circuit

Active Active Active Active Active 6-5

The air-gap is too large between the sensor and the tone wheel.

Sensor voltage output is minimally 0.25 VAC at 0.5 revs / sec. (Connector-PIN: X3-11 and X3-14) If signal too small push back the

sensor completely to the tone wheel.

Verify proper bearing end-play.

Verify condition and retention of clamping sleeve.

Verify condition of sensor head.

Check for corroded / damaged wiring or connectors between the ECU and sensor.

Verification Procedure:

Clear DTC. Verification of the wheel speed signal required by End of Line test or driving of the vehicle.

The sensor DTC will remain active until (without clearing DTCs):

After power off-on the ABS ECU, vehicle is driven above 15-20 km/h and the ABS ECU reads good wheel speed data from all

sensors.

Go to workshop

0x6031

Add Axle Left

Wheel Speed

Sensor

0x25

signal shape /

waveform failure

793

Wheel Speed

Sensor 5

1

below normal

operational range -

most severe level

Active Active Active Active Active 6-1

Check the tone wheel for dirt and metallic particles, for wobble, for pitch error, for the correct number of teeth. Replace if faulty.

Verification Procedure:

Clear DTC. Verification of the wheel speed signal required by End of Line test or driving of the vehicle.

The sensor DTC will remain active until (without clearing DTCs):

After power off-on the ABS ECU, vehicle is driven above 15-20 km/h and the ABS ECU reads good wheel speed data from all

sensors.

Go to workshop

11/29

Document name: ABS8 Diagnostic Trouble Code list

Document no.: Y134941 Rev: 006

Customer: GEN

2013.05.02.

Display

No.

Display No. Text

Type

No.

Type text

SPN

No.

SPN text

FMI

No.

FMI text

ABS WL

state

EBC1/

Hardwire

Red WL

state

EBC1/

DM1

Amber

WL

state

DM1

ASR

Lamp

state

EBC1/

Hardwire

HSA

Lamp

Blink Codes Workshop action Driver Action

0x6031

Add Axle Left

Wheel Speed

Sensor

0x2F signal erratic 793

Wheel Speed

Sensor 5

7

mechanical

system not

responding or out

of adjustment

Active Active Active Active Active 6-3

Check if the air-gap is too large between the sensor and the tone wheel. If it too large, push back the sensor completely to the tone

wheel.

Measure resistance of Sensor and cabling. Resistance should be 900-2000 Ohm. (Connector-PIN: X3-11 and X3-14)

Check the mechanical parts of the brake (dragging, jammed brake).

Verification Procedure:

Clear DTC. Verification of the wheel speed signal required by End of Line test or driving of the vehicle.

The sensor DTC will remain active until (without clearing DTCs):

After power off-on the ABS ECU, vehicle is driven above 15-20 km/h and the ABS ECU reads good wheel speed data from all

sensors.

Go to workshop

0x6031

Add Axle Left

Wheel Speed

Sensor

0x38

signal frequency

incorrect

793

Wheel Speed

Sensor 5

10

abnormal rate of

change

Active Active Active Active Active 6-2

Check if tire size of all tires is according vehicle specification.

Check C3 Signal calibration, check tachograph for additional fault codes.

Check number of teeth on tone wheel on all wheels.

Verification Procedure:

Clear DTC. Verification of the wheel speed signal required by End of Line test or driving of the vehicle.

The sensor DTC will remain active until (without clearing DTCs):

After power off-on the ABS ECU, vehicle is driven above 15-20 km/h and the ABS ECU reads good wheel speed data from all

sensors.

Go to workshop

0x6031

Add Axle Left

Wheel Speed

Sensor

0x54

missing

calibration

793

Wheel Speed

Sensor 5

13 out of calibration Active Active Active Active Active 6-9

Check if the sensor mounting is vibration-free.

Check the tone wheel for dirt and metallic particles, for wobble, for pitch error, for the correct number of teeth.

Verify condition of sensor head.

Verify proper bearing end-play.

Verify condition and retention of clamping sleeve.

Check the mechanical parts of the brake.

Check for corroded / damaged wiring or connectors between the ECU and sensor.

Measure resistance of Sensor and cabling. Resistance should be 900-2000 Ohm.(Connector-PIN: X3-11 and X3-14)

Verification Procedure:

Clear DTC. Verification of the wheel speed signal required by End of Line test or driving of the vehicle.

The sensor DTC will remain active until (without clearing DTCs):

After power off-on the ABS ECU, vehicle is driven above 15-20 km/h and the ABS ECU reads good wheel speed data from all

sensors.

Go to workshop

0x6031

Add Axle Left

Wheel Speed

Sensor

0x29 signal invalid 793

Wheel Speed

Sensor 5

8

abnormal

frequency or

pulse width or

period

Active Active Active Active Active 6-4

Check the cables and connectors between ECU and wheel-speed sensor for short-circuits and open-circuits. The resistance of the

sensor (with wiring) should be 900-2000 Ohm. (Connector-PIN: X3-12 and X3-15)

Check insulation resistance of sensor and cabling to vehicle GND and to UB. Resistance should be >200 kOhm.

Check for corroded / damaged wiring or connectors between the ECU and sensor.

Verification Procedure:

Clear DTC.

Go to workshop

0x6034

Add Axle Right

Wheel Speed

Sensor

0x01

general electrical

failure

794

Wheel Speed

Sensor 6

2

data erratic,

intermittent or

incorrect

Active Active Active Active Active 7-6

The speed signal of the sensor was suddenly lost.

Measure resistance of Sensor and cabling. Resistance should be 900-2000 Ohm. (Connector-PIN: X3-12 and X3-15)

Measure insulation resistance of sensor and cabling to vehicle GND. Resistance should be > 200 kOhm.

Verify proper bearing end-play.

Check the tone wheel for dirt and metallic particles, for wobble, for pitch error, for damaged teeth.

Verify condition of sensor head.

Verify condition and retention of clamping sleeve.

Check for corroded / damaged wiring or connectors between the ECU and sensor.

Verification Procedure:

Clear DTC. Verification of the wheel speed signal required by End of Line test or driving of the vehicle.

The sensor DTC will remain active until (without clearing DTCs):

After power off-on the ABS ECU, vehicle is driven above 15-20 km/h and the ABS ECU reads good wheel speed data from all

sensors.

Go to workshop

12/29

Document name: ABS8 Diagnostic Trouble Code list

Document no.: Y134941 Rev: 006

Customer: GEN

2013.05.02.

Display

No.

Display No. Text

Type

No.

Type text

SPN

No.

SPN text

FMI

No.

FMI text

ABS WL

state

EBC1/

Hardwire

Red WL

state

EBC1/

DM1

Amber

WL

state

DM1

ASR

Lamp

state

EBC1/

Hardwire

HSA

Lamp

Blink Codes Workshop action Driver Action

0x6034

Add Axle Right

Wheel Speed

Sensor

0x31 no signal 794

Wheel Speed

Sensor 6

5

current below

normal or open

circuit

Active Active Active Active Active 7-5

The air-gap is too large between the sensor and the tone wheel.

Sensor voltage output is minimally 0.25 VAC at 0.5 revs / sec. (Connector-PIN: X3-12 and X3-15) If signal too small push back the

sensor completely to the tone wheel.

Verify proper bearing end-play.

Verify condition and retention of clamping sleeve.

Verify condition of sensor head.

Check for corroded / damaged wiring or connectors between the ECU and sensor.

Verification Procedure:

Clear DTC. Verification of the wheel speed signal required by End of Line test or driving of the vehicle.

The sensor DTC will remain active until (without clearing DTCs):

After power off-on the ABS ECU, vehicle is driven above 15-20 km/h and the ABS ECU reads good wheel speed data from all

sensors.

Go to workshop

0x6034

Add Axle Right

Wheel Speed

Sensor

0x25

signal shape /

waveform failure

794

Wheel Speed

Sensor 6

1

below normal

operational range -

most severe level

Active Active Active Active Active 7-1

Check the tone wheel for dirt and metallic particles, for wobble, for pitch error, for the correct number of teeth. Replace if faulty.

Verification Procedure:

Clear DTC. Verification of the wheel speed signal required by End of Line test or driving of the vehicle.

The sensor DTC will remain active until (without clearing DTCs):

After power off-on the ABS ECU, vehicle is driven above 15-20 km/h and the ABS ECU reads good wheel speed data from all

sensors.

Go to workshop

0x6034

Add Axle Right

Wheel Speed

Sensor

0x2F signal erratic 794

Wheel Speed

Sensor 6

7

mechanical

system not

responding or out

of adjustment

Active Active Active Active Active 7-3

Check if the air-gap is too large between the sensor and the tone wheel. If it too large, push back the sensor completely to the tone

wheel.

Measure resistance of Sensor and cabling. Resistance should be 900-2000 Ohm. (Connector-PIN: X3-12 and X3-15)

Check the mechanical parts of the brake (dragging, jammed brake).

Verification Procedure:

Clear DTC. Verification of the wheel speed signal required by End of Line test or driving of the vehicle.

The sensor DTC will remain active until (without clearing DTCs):

After power off-on the ABS ECU, vehicle is driven above 15-20 km/h and the ABS ECU reads good wheel speed data from all

sensors.

Go to workshop

0x6034

Add Axle Right

Wheel Speed

Sensor

0x38

signal frequency

incorrect

794

Wheel Speed

Sensor 6

10

abnormal rate of

change

Active Active Active Active Active 7-2

Check if tire size of all tires is according vehicle specification.

Check C3 Signal calibration, check tachograph for additional fault codes.

Check number of teeth on tone wheel on all wheels.

Verification Procedure:

Clear DTC. Verification of the wheel speed signal required by End of Line test or driving of the vehicle.

The sensor DTC will remain active until (without clearing DTCs):

After power off-on the ABS ECU, vehicle is driven above 15-20 km/h and the ABS ECU reads good wheel speed data from all

sensors.

Go to workshop

0x6034

Add Axle Right

Wheel Speed

Sensor

0x54

missing

calibration

794

Wheel Speed

Sensor 6

13 out of calibration Active Active Active Active Active 7-9

Check if the sensor mounting is vibration-free.

Check the tone wheel for dirt and metallic particles, for wobble, for pitch error, for the correct number of teeth.

Verify condition of sensor head.

Verify proper bearing end-play.

Verify condition and retention of clamping sleeve.

Check the mechanical parts of the brake.

Check for corroded / damaged wiring or connectors between the ECU and sensor.

Measure resistance of Sensor and cabling. Resistance should be 900-2000 Ohm. (Connector-PIN: X3-12 and X3-15)

Verification Procedure:

Clear DTC. Verification of the wheel speed signal required by End of Line test or driving of the vehicle.

The sensor DTC will remain active until (without clearing DTCs):

After power off-on the ABS ECU, vehicle is driven above 15-20 km/h and the ABS ECU reads good wheel speed data from all

sensors.

Go to workshop

0x6034

Add Axle Right

Wheel Speed

Sensor

0x29 signal invalid 794

Wheel Speed

Sensor 6

8

abnormal

frequency or

pulse width or

period

Active Active Active Active Active 7-4

Replace the valve for the correct voltage rating type (12V-24V)

Verification Procedure:

Clear DTC.

Go to workshop

13/29

Document name: ABS8 Diagnostic Trouble Code list

Document no.: Y134941 Rev: 006

Customer: GEN

2013.05.02.

Display

No.

Display No. Text

Type

No.

Type text

SPN

No.

SPN text

FMI

No.

FMI text

ABS WL

state

EBC1/

Hardwire

Red WL

state

EBC1/

DM1

Amber

WL

state

DM1

ASR

Lamp

state

EBC1/

Hardwire

HSA

Lamp

Blink Codes Workshop action Driver Action

0x4003

Steer Axle

Traction Control

Valve

0x4A

incorrect

component

installed

807 Dif 2 - ASR Valve 14

special

instructions

Active Active Active Active Active 14-9

Check for corroded / damaged wiring between the ECU and TCV.

Measure resistance between TCV GND and TCV. It should be 28 Ohm for 12V system or 128 Ohm for 24V system. (Connector-PIN:

X3-3 and X3-5)

Measure insulation resistance of valve and cabling to vehicle voltage (UB). Resistance should be > 200 kOhm.

Measure insulation resistance of valve and cabling to any other ABS/ASR valve. Resistance should be > 200 kOhm

If insulation is correct then Clear DTCs. If the failure returns, replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x4003

Steer Axle

Traction Control

Valve

0x12

circuit short to

battery

807 Dif 2 - ASR Valve 3

voltage above

normal, or

shorted to high

source

Active Active Active Active Active 14-1

Check for corroded / damaged wiring between the ECU and TCV.

Measure resistance between TCV GND and TCV. It should be 28 Ohm for 12V system or 128 Ohm for 24V system. (Connector-PIN:

X3-3 and X3-5)

Measure insulation resistance of valve and cabling to vehicle GND. Resistance should be > 200 kOhm.

If insulation is correct then Clear DTCs. If the failure returns, replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x4003

Steer Axle

Traction Control

Valve

0x11

circuit short to

ground

807 Dif 2 - ASR Valve 4

voltage below

normal, or

shorted to low

source

Passive Passive Active Passive Passive 14-2

Check for corroded / damaged wiring between the ECU and TCV.

Measure resistance between TCV GND and TCV. It should be 28 Ohm for 12V system or 128 Ohm for 24V system. (Connector-PIN:

X3-3 and X3-5)

Verification Procedure:

Clear DTC.

Go to workshop

0x4003

Steer Axle

Traction Control

Valve

0x13 circuit open 807 Dif 2 - ASR Valve 5

current below

normal or open

circuit

Passive Passive Active Passive Passive 14-3

Check the vehicle documentation for the correct configuration. If necessary reconfigure the ECU.

If vehicle should be without this valve remove connection on the ECU. (Connector-PIN: X3-3 and X3-5 should be empty)

Verification Procedure:

Clear DTC.

Go to workshop

0x4003

Steer Axle

Traction Control

Valve

0x55 not configured 807 Dif 2 - ASR Valve 13 out of calibration Passive Passive Active Active Active 14-4

Replace the valve for the correct voltage rating type (12V-24V)

Verification Procedure:

Clear DTC.

Go to workshop

0x4001

Drive Axle

Traction Control

Valve

0x4A

incorrect

component

installed

806 Dif 1 - ASR Valve 14

special

instructions

Active Active Active Active Active 14-9

Check for corroded / damaged wiring between the ECU and TCV.

Measure resistance between TCV GND and TCV. It should be 28 Ohm for (12V system) or 128 Ohm for (24V system). (Connector-

PIN: X1-4 and X1-5)

Measure insulation resistance of valve and cabling to vehicle voltage (UB). Resistance should be > 200 kOhm.

Measure insulation resistance of valve and cabling to any other ABS/ASR valve. Resistance should be > 200 kOhm

If insulation is correct then Clear DTCs. If the failure returns, replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x4001

Drive Axle

Traction Control

Valve

0x12

circuit short to

battery

806 Dif 1 - ASR Valve 3

voltage above

normal, or

shorted to high

source

Active Active Active Active Active 14-5

Check for corroded / damaged wiring between the ECU and TCV.

Measure resistance between TCV GND and TCV. It should be 28 Ohm for (12V system) or 128 Ohm for (24V system). (Connector-

PIN: X1-4 and X1-5)

Measure insulation resistance of valve and cabling to vehicle GND. Resistance should be > 200 kOhm.

If insulation is correct then Clear DTCs. If the failure returns, replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x4001

Drive Axle

Traction Control

Valve

0x11

circuit short to

ground

806 Dif 1 - ASR Valve 4

voltage below

normal, or

shorted to low

source

Passive Passive Active Active Active 14-6

Check for corroded / damaged wiring between the ECU and TCV.

Measure resistance between TCV GND and TCV. It should be 28 Ohm for (12V system) or 128 Ohm for (24V system). (Connector-

PIN: X1-4 and X1-5)

Verification Procedure:

Clear DTC.

Go to workshop

0x4001

Drive Axle

Traction Control

Valve

0x13 circuit open 806 Dif 1 - ASR Valve 5

current below

normal or open

circuit

Passive Passive Active Active Active 14-7

Check the vehicle documentation for the correct configuration. If necessary reconfigure the ECU.

If vehicle should be without this valve remove connection on the ECU. (Connector-PIN: X1-4 and X1-5 should be empty)

Verification Procedure:

Clear DTC.

Go to workshop

0x4001

Drive Axle

Traction Control

Valve

0x55 not configured 806 Dif 1 - ASR Valve 13 out of calibration Passive Passive Active Active Active 14-8

Measure insulation resistance between UB and retarder disable output. Resistance should be 80-200 Ohm.

Check for corroded / damaged wiring or connectors between ECU and retarder relay.

Verification Procedure:

Clear DTC.

Go to workshop

14/29

Document name: ABS8 Diagnostic Trouble Code list

Document no.: Y134941 Rev: 006

Customer: GEN

2013.05.02.

Display

No.

Display No. Text

Type

No.

Type text

SPN

No.

SPN text

FMI

No.

FMI text

ABS WL

state

EBC1/

Hardwire

Red WL

state

EBC1/

DM1

Amber

WL

state

DM1

ASR

Lamp

state

EBC1/

Hardwire

HSA

Lamp

Blink Codes Workshop action Driver Action

0x5208 Retarder Relay 0x12

circuit short to

battery

801

Retarder Control

Relay

3

voltage above

normal, or

shorted to high

source

Active Passive Active Passive Active 17-1

Check for corroded / damaged wiring or connectors between ECU and retarder relay.

Measure insulation resistance between GND and retarder disable output. Resistance should be 200 kOhm.

Verify vehicle has retarder relay installed.

Verify ECU configuration for retarder relay.

Verification Procedure:

Clear DTC.

Go to workshop

0x5208 Retarder Relay 0x14

circuit short to

ground or open

801

Retarder Control

Relay

2

data erratic,

intermittent or

incorrect

Active Passive Active Passive Active 17-2

Apply and release service brake:

With service brake released, the stop lamp switch input should be 0V.

With service brake applied, verify system voltage is now present at the stop lamp switch input to the ECU.

Check the wiring of the brake signal transmitting device.

Check the wiring of the brake switch input of the ECU or the J1939 message (CCVS).

Verification Procedure:

Clear DTC.

Go to workshop

0x4023 Stop Lamp 0x64

signal plausibility

failure

1045

Brake Light

Switch 1

2

data erratic,

intermittent or

incorrect

Passive Passive Active Active Active 17-14

Apply and release the brake pedal.

If failure still active, check the wiring of the stop lamp switch input or the stop lamp signal transmitting device (timeout of J1939 CCVS

message).

Verification Procedure:

Clear DTC.

Apply the brake once

0x4023 Stop Lamp 0x52 not activated 1045

Brake Light

Switch 1

7

mechanical

system not

responding or out

of adjustment

Passive Passive Passive Active Active 17-7

Valve output signal mismatch.

Verification Procedure:

Clear DTC.

Go to workshop

0x5110

Steer Axle Left

Pressure Control

Valve

0x4A

incorrect

component

installed

795

Pressure

Modulation Valve

ABS Axle 1 Left

14

special

instructions

Active Active Active Active Active 8-9

Replace the valve for the correct voltage rating type (12V-24V)

Verification Procedure:

Clear DTC.

Go to workshop

0x5111

Steer Axle Left

Pressure Control

Valve GND

0x13 circuit open 795

Pressure

Modulation Valve

ABS Axle 1 Left

5

current below

normal or open

circuit

Active Passive Active Passive Active 8-4

Check cables and connectors of the PCV.

Verification Procedure:

Clear DTC.

Go to workshop

0x5110

Steer Axle Left

Pressure Control

Valve

0x55 not configured 795

Pressure

Modulation Valve

ABS Axle 1 Left

13 out of calibration Active Active Active Active Active 8-8

There is a valve connected without being configured.

Check the configuration of the vehicle (2s2m or 2s1m on this axle). If the 2s2m is correct, correct dataset of ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x4010

Steer Axle Left

Pressure Control

Inlet Valve

0x12

circuit short to

battery

932

Brake System

Hold Modulator

Valve Solenoid

Axle 1 Left

3

voltage above

normal, or

shorted to high

source

Active Active Active Active Active 8-5

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X2-3, IV: X2-1, OV: X2-2)

Measure insulation resistance of valve and cabling to vehicle voltage (UB). Resistance should be > 200 kOhm.

Measure insulation resistance of valve and cabling to any other ABS/ASR valve. Resistance should be > 200 kOhm

If insulation is correct then Clear DTCs. If the failure returns, replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x4010

Steer Axle Left

Pressure Control

Inlet Valve

0x11

circuit short to

ground

932

Brake System

Hold Modulator

Valve Solenoid

Axle 1 Left

4

voltage below

normal, or

shorted to low

source

Active Passive Active Passive Active 8-6

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X2-3, IV: X2-1, OV: X2-2)

Measure insulation resistance of valve and cabling to vehicle GND. Resistance should be > 200 kOhm.

If insulation is correct then Clear DTCs. If the failure returns, replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x4010

Steer Axle Left

Pressure Control

Inlet Valve

0x13 circuit open 932

Brake System

Hold Modulator

Valve Solenoid

Axle 1 Left

5

current below

normal or open

circuit

Active Passive Active Passive Active 8-7

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X2-3, IV: X2-1, OV: X2-2)

Verification Procedure:

Clear DTC.

Go to workshop

15/29

Document name: ABS8 Diagnostic Trouble Code list

Document no.: Y134941 Rev: 006

Customer: GEN

2013.05.02.

Display

No.

Display No. Text

Type

No.

Type text

SPN

No.

SPN text

FMI

No.

FMI text

ABS WL

state

EBC1/

Hardwire

Red WL

state

EBC1/

DM1

Amber

WL

state

DM1

ASR

Lamp

state

EBC1/

Hardwire

HSA

Lamp

Blink Codes Workshop action Driver Action

0x4011

Steer Axle Left

Pressure Control

Outlet Valve

0x12

circuit short to

battery

938

Brake System

Dump Modulator

Valve Solenoid

Axle 1 Left

3

voltage above

normal, or

shorted to high

source

Active Active Active Active Active 8-1

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X2-3, IV: X2-1, OV: X2-2)

Measure insulation resistance of valve and cabling to vehicle voltage (UB). Resistance should be > 200 kOhm.

Measure insulation resistance of valve and cabling to any other ABS/ASR valve. Resistance should be > 200 kOhm

If insulation is correct then Clear DTCs. If the failure returns, replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x4011

Steer Axle Left

Pressure Control

Outlet Valve

0x11

circuit short to

ground

938

Brake System

Dump Modulator

Valve Solenoid

Axle 1 Left

4

voltage below

normal, or

shorted to low

source

Active Passive Active Passive Active 8-2

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X2-3, IV: X2-1, OV: X2-2)

Measure insulation resistance of valve and cabling to vehicle GND. Resistance should be > 200 kOhm.

If insulation is correct then Clear DTCs. If the failure returns, replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x4011

Steer Axle Left

Pressure Control

Outlet Valve

0x13 circuit open 938

Brake System

Dump Modulator

Valve Solenoid

Axle 1 Left

5

current below

normal or open

circuit

Active Passive Active Passive Active 8-3

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X2-3, IV: X2-1, OV: X2-2)

Verification Procedure:

Clear DTC.

Go to workshop

0x5114

Steer Axle Right

Pressure Control

Valve

0x4A

incorrect

component

installed

796

Pressure

Modulation Valve

ABS Axle 1 Right

14

special

instructions

Active Active Active Active Active 9-9

Replace the valve for the correct voltage rating type (12V-24V)

Verification Procedure:

Clear DTC.

Go to workshop

0x5115

Steer Axle Right

Pressure Control

Valve GND

0x13 circuit open 796

Pressure

Modulation Valve

ABS Axle 1 Right

5

current below

normal or open

circuit

Active Passive Active Passive Active 9-4

Check cables and connectors of the PCV.

Verification Procedure:

Clear DTC.

Go to workshop

0x5114

Steer Axle Right

Pressure Control

Valve

0x55 not configured 796

Pressure

Modulation Valve

ABS Axle 1 Right

13 out of calibration Active Active Active Active Active 9-8

There is a valve connected without being configured.

Check the configuration of the vehicle (2s2m or 2s1m on this axle). If the 2s2m is correct, correct dataset of ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x4014

Steer Axle Right

Pressure Control

Inlet Valve

0x12

circuit short to

battery

933

Brake System

Hold Modulator

Valve Solenoid

Axle 1 Right

3

voltage above

normal, or

shorted to high

source

Active Active Active Active Active 9-5

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X2-6, IV: X2-4, OV: X2-7)

Measure insulation resistance of valve and cabling to vehicle voltage (UB). Resistance should be > 200 kOhm.

Measure insulation resistance of valve and cabling to any other ABS/ASR valve. Resistance should be > 200 kOhm

If insulation is correct then Clear DTCs. If the failure returns, replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x4014

Steer Axle Right

Pressure Control

Inlet Valve

0x11

circuit short to

ground

933

Brake System

Hold Modulator

Valve Solenoid

Axle 1 Right

4

voltage below

normal, or

shorted to low

source

Active Passive Active Passive Active 9-6

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X2-6, IV: X2-4, OV: X2-7)

Measure insulation resistance of valve and cabling to vehicle GND. Resistance should be > 200 kOhm.

If insulation is correct then Clear DTCs. If the failure returns, replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x4014

Steer Axle Right

Pressure Control

Inlet Valve

0x13 circuit open 933

Brake System

Hold Modulator

Valve Solenoid

Axle 1 Right

5

current below

normal or open

circuit

Active Passive Active Passive Active 9-7

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X2-6, IV: X2-4, OV: X2-7)

Verification Procedure:

Clear DTC.

Go to workshop

16/29

Document name: ABS8 Diagnostic Trouble Code list

Document no.: Y134941 Rev: 006

Customer: GEN

2013.05.02.

Display

No.

Display No. Text

Type

No.

Type text

SPN

No.

SPN text

FMI

No.

FMI text

ABS WL

state

EBC1/

Hardwire

Red WL

state

EBC1/

DM1

Amber

WL

state

DM1

ASR

Lamp

state

EBC1/

Hardwire

HSA

Lamp

Blink Codes Workshop action Driver Action

0x4015

Steer Axle Right

Pressure Control

Outlet Valve

0x12

circuit short to

battery

939

Brake System

Dump Modulator

Valve Solenoid

Axle 1 Right

3

voltage above

normal, or

shorted to high

source

Active Active Active Active Active 9-1

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X2-6, IV: X2-4, OV: X2-7)

Measure insulation resistance of valve and cabling to vehicle voltage (UB). Resistance should be > 200 kOhm.

Measure insulation resistance of valve and cabling to any other ABS/ASR valve. Resistance should be > 200 kOhm

If insulation is correct then Clear DTCs. If the failure returns, replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x4015

Steer Axle Right

Pressure Control

Outlet Valve

0x11

circuit short to

ground

939

Brake System

Dump Modulator

Valve Solenoid

Axle 1 Right

4

voltage below

normal, or

shorted to low

source

Active Passive Active Passive Active 9-2

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X2-6, IV: X2-4, OV: X2-7)

Measure insulation resistance of valve and cabling to vehicle GND. Resistance should be > 200 kOhm.

If insulation is correct then Clear DTCs. If the failure returns, replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x4015

Steer Axle Right

Pressure Control

Outlet Valve

0x13 circuit open 939

Brake System

Dump Modulator

Valve Solenoid

Axle 1 Right

5

current below

normal or open

circuit

Active Passive Active Passive Active 9-3

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X2-6, IV: X2-4, OV: X2-7)

Verification Procedure:

Clear DTC.

Go to workshop

0x5118

Drive Axle Left

Pressure Control

Valve

0x4A

incorrect

component

installed

797

Pressure

Modulation Valve

ABS Axle 2 Left

14

special

instructions

Active Active Active Active Active 10-9

Replace the valve for the correct voltage rating type (12V-24V)

Verification Procedure:

Clear DTC.

Go to workshop

0x5119

Drive Axle Left

Pressure Control

Valve GND

0x13 circuit open 797

Pressure

Modulation Valve

ABS Axle 2 Left

5

current below

normal or open

circuit

Active Active Active Active Active 10-4

Check cables and connectors of the PCV.

Verification Procedure:

Clear DTC.

Go to workshop

0x5118

Drive Axle Left

Pressure Control

Valve

0x55 not configured 797

Pressure

Modulation Valve

ABS Axle 2 Left

13 out of calibration Active Active Active Active Active 10-8

There is a valve connected without being configured.

Check the configuration of the vehicle (2s2m or 2s1m on this axle). If the 2s2m is correct, correct dataset of ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x4018

Drive Axle Left

Pressure Control

Inlet Valve

0x12

circuit short to

battery

934

Brake System

Hold Modulator

Valve Solenoid

Axle 2 Left

3

voltage above

normal, or

shorted to high

source

Active Active Active Active Active 10-5

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X2-12, IV: X2-16, OV: X2-17)

Measure insulation resistance of valve and cabling to vehicle voltage (UB). Resistance should be > 200 kOhm.

Measure insulation resistance of valve and cabling to any other ABS/ASR valve. Resistance should be > 200 kOhm

If insulation is correct then Clear DTCs. If the failure returns, replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x4018

Drive Axle Left

Pressure Control

Inlet Valve

0x11

circuit short to

ground

934

Brake System

Hold Modulator

Valve Solenoid

Axle 2 Left

4

voltage below

normal, or

shorted to low

source

Active Active Active Active Active 10-6

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X2-12, IV: X2-16, OV: X2-17)

Measure insulation resistance of valve and cabling to vehicle GND. Resistance should be > 200 kOhm.

If insulation is correct then Clear DTCs. If the failure returns, replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x4018

Drive Axle Left

Pressure Control

Inlet Valve

0x13 circuit open 934

Brake System

Hold Modulator

Valve Solenoid

Axle 2 Left

5

current below

normal or open

circuit

Active Active Active Active Active 10-7

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X2-12, IV: X2-16, OV: X2-17)

Verification Procedure:

Clear DTC.

Go to workshop

17/29

Document name: ABS8 Diagnostic Trouble Code list

Document no.: Y134941 Rev: 006

Customer: GEN

2013.05.02.

Display

No.

Display No. Text

Type

No.

Type text

SPN

No.

SPN text

FMI

No.

FMI text

ABS WL

state

EBC1/

Hardwire

Red WL

state

EBC1/

DM1

Amber

WL

state

DM1

ASR

Lamp

state

EBC1/

Hardwire

HSA

Lamp

Blink Codes Workshop action Driver Action

0x4019

Drive Axle Left

Pressure Control

Outlet Valve

0x12

circuit short to

battery

940

Brake System

Dump Modulator

Valve Solenoid

Axle 2 Left

3

voltage above

normal, or

shorted to high

source

Active Active Active Active Active 10-1

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X2-12, IV: X2-16, OV: X2-17)

Measure insulation resistance of valve and cabling to vehicle voltage (UB). Resistance should be > 200 kOhm.

Measure insulation resistance of valve and cabling to any other ABS/ASR valve. Resistance should be > 200 kOhm

If insulation is correct then Clear DTCs. If the failure returns, replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x4019

Drive Axle Left

Pressure Control

Outlet Valve

0x11

circuit short to

ground

940

Brake System

Dump Modulator

Valve Solenoid

Axle 2 Left

4

voltage below

normal, or

shorted to low

source

Active Active Active Active Active 10-2

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X2-12, IV: X2-16, OV: X2-17)

Measure insulation resistance of valve and cabling to vehicle GND. Resistance should be > 200 kOhm.

If insulation is correct then Clear DTCs. If the failure returns, replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x4019

Drive Axle Left

Pressure Control

Outlet Valve

0x13 circuit open 940

Brake System

Dump Modulator

Valve Solenoid

Axle 2 Left

5

current below

normal or open

circuit

Active Active Active Active Active 10-3

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X2-12, IV: X2-16, OV: X2-17)

Verification Procedure:

Clear DTC.

Go to workshop

0x511C

Drive Axle Right

Pressure Control

Valve

0x4A

incorrect

component

installed

798

Pressure

Modulation Valve

ABS Axle 2 Right

14

special

instructions

Active Active Active Active Active 11-9

Replace the valve for the correct voltage rating type (12V-24V)

Verification Procedure:

Clear DTC.

Go to workshop

0x511D

Drive Axle Right

Pressure Control

Valve GND

0x13 circuit open 798

Pressure

Modulation Valve

ABS Axle 2 Right

5

current below

normal or open

circuit

Active Active Active Active Active 11-4

Check cables and connectors of the PCV.

Verification Procedure:

Clear DTC.

Go to workshop

0x511C

Drive Axle Right

Pressure Control

Valve

0x55 not configured 798

Pressure

Modulation Valve

ABS Axle 2 Right

13 out of calibration Active Active Active Active Active 11-8

There is a valve connected without being configured.

Check the configuration of the vehicle (2s2m or 2s1m on this axle). If the 2s2m is correct, correct dataset of ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x401C

Drive Axle Right

Pressure Control

Inlet Valve

0x12

circuit short to

battery

935

Brake System

Hold Modulator

Valve Solenoid

Axle 2 Right

3

voltage above

normal, or

shorted to high

source

Active Active Active Active Active 11-5

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X2-9, IV: X2-10, OV: X2-13)

Measure insulation resistance of valve and cabling to vehicle voltage (UB). Resistance should be > 200 kOhm.

Measure insulation resistance of valve and cabling to any other ABS/ASR valve. Resistance should be > 200 kOhm

If insulation is correct then Clear DTCs. If the failure returns, replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x401C

Drive Axle Right

Pressure Control

Inlet Valve

0x11

circuit short to

ground

935

Brake System

Hold Modulator

Valve Solenoid

Axle 2 Right

4

voltage below

normal, or

shorted to low

source

Active Active Active Active Active 11-6

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X2-9, IV: X2-10, OV: X2-13)

Measure insulation resistance of valve and cabling to vehicle GND. Resistance should be > 200 kOhm.

If insulation is correct then Clear DTCs. If the failure returns, replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x401C

Drive Axle Right

Pressure Control

Inlet Valve

0x13 circuit open 935

Brake System

Hold Modulator

Valve Solenoid

Axle 2 Right

5

current below

normal or open

circuit

Active Active Active Active Active 11-7

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X2-9, IV: X2-10, OV: X2-13)

Verification Procedure:

Clear DTC.

Go to workshop

18/29

Document name: ABS8 Diagnostic Trouble Code list

Document no.: Y134941 Rev: 006

Customer: GEN

2013.05.02.

Display

No.

Display No. Text

Type

No.

Type text

SPN

No.

SPN text

FMI

No.

FMI text

ABS WL

state

EBC1/

Hardwire

Red WL

state

EBC1/

DM1

Amber

WL

state

DM1

ASR

Lamp

state

EBC1/

Hardwire

HSA

Lamp

Blink Codes Workshop action Driver Action

0x401D

Drive Axle Right

Pressure Control

Outlet Valve

0x12

circuit short to

battery

941

Brake System

Dump Modulator

Valve Solenoid

Axle 2 Right

3

voltage above

normal, or

shorted to high

source

Active Active Active Active Active 11-1

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X2-9, IV: X2-10, OV: X2-13)

Measure insulation resistance of valve and cabling to vehicle voltage (UB). Resistance should be > 200 kOhm.

Measure insulation resistance of valve and cabling to any other ABS/ASR valve. Resistance should be > 200 kOhm

If insulation is correct then Clear DTCs. If the failure returns, replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x401D

Drive Axle Right

Pressure Control

Outlet Valve

0x11

circuit short to

ground

941

Brake System

Dump Modulator

Valve Solenoid

Axle 2 Right

4

voltage below

normal, or

shorted to low

source

Active Active Active Active Active 11-2

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X2-9, IV: X2-10, OV: X2-13)

Measure insulation resistance of valve and cabling to vehicle GND. Resistance should be > 200 kOhm.

If insulation is correct then Clear DTCs. If the failure returns, replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x401D

Drive Axle Right

Pressure Control

Outlet Valve

0x13 circuit open 941

Brake System

Dump Modulator

Valve Solenoid

Axle 2 Right

5

current below

normal or open

circuit

Active Active Active Active Active 11-3

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X2-9, IV: X2-10, OV: X2-13)

Verification Procedure:

Clear DTC.

Go to workshop

0x6110

Add Axle Left

Pressure Control

Valve

0x4A

incorrect

component

installed

799

Pressure

Modulation Valve

ABS Axle 3 Left

14

special

instructions

Active Active Active Active Active 12-9

Replace the valve for the correct voltage rating type (12V-24V)

Verification Procedure:

Clear DTC.

Go to workshop

0x6111

Add Axle Left

Pressure Control

Valve GND

0x13 circuit open 799

Pressure

Modulation Valve

ABS Axle 3 Left

5

current below

normal or open

circuit

Active Active Active Active Active 12-4

Check cables and connectors of the PCV.

Verification Procedure:

Clear DTC.

Go to workshop

0x6110

Add Axle Left

Pressure Control

Valve

0x55 not configured 799

Pressure

Modulation Valve

ABS Axle 3 Left

13 out of calibration Active Active Active Active Active 12-8

There is a valve connected without being configured.

Check the configuration of the vehicle (2s2m or 2s1m on this axle). If the 2s2m is correct, correct dataset of ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x6010

Add Axle Left

Pressure Control

Inlet Valve

0x12

circuit short to

battery

936

Brake System

Hold Modulator

Valve Solenoid

Axle 3 Left

3

voltage above

normal, or

shorted to high

source

Active Active Active Active Active 12-5

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X3-6, IV: X3-4, OV: X3-7)

Measure insulation resistance of valve and cabling to vehicle voltage (UB). Resistance should be > 200 kOhm.

Measure insulation resistance of valve and cabling to any other ABS/ASR valve. Resistance should be > 200 kOhm

If insulation is correct then Clear DTCs. If the failure returns, replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x6010

Add Axle Left

Pressure Control

Inlet Valve

0x11

circuit short to

ground

936

Brake System

Hold Modulator

Valve Solenoid

Axle 3 Left

4

voltage below

normal, or

shorted to low

source

Active Active Active Active Active 12-6

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X3-6, IV: X3-4, OV: X3-7)

Measure insulation resistance of valve and cabling to vehicle GND. Resistance should be > 200 kOhm.

If insulation is correct then Clear DTCs. If the failure returns, replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x6010

Add Axle Left

Pressure Control

Inlet Valve

0x13 circuit open 936

Brake System

Hold Modulator

Valve Solenoid

Axle 3 Left

5

current below

normal or open

circuit

Active Active Active Active Active 12-7

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X3-6, IV: X3-4, OV: X3-7)

Verification Procedure:

Clear DTC.

Go to workshop

19/29

Document name: ABS8 Diagnostic Trouble Code list

Document no.: Y134941 Rev: 006

Customer: GEN

2013.05.02.

Display

No.

Display No. Text

Type

No.

Type text

SPN

No.

SPN text

FMI

No.

FMI text

ABS WL

state

EBC1/

Hardwire

Red WL

state

EBC1/

DM1

Amber

WL

state

DM1

ASR

Lamp

state

EBC1/

Hardwire

HSA

Lamp

Blink Codes Workshop action Driver Action

0x6011

Add Axle Left

Pressure Control

Outlet Valve

0x12

circuit short to

battery

942

Brake System

Dump Modulator

Valve Solenoid

Axle 3 Left

3

voltage above

normal, or

shorted to high

source

Active Active Active Active Active 12-1

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X3-6, IV: X3-4, OV: X3-7)

Measure insulation resistance of valve and cabling to vehicle voltage (UB). Resistance should be > 200 kOhm.

Measure insulation resistance of valve and cabling to any other ABS/ASR valve. Resistance should be > 200 kOhm

If insulation is correct then Clear DTCs. If the failure returns, replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x6011

Add Axle Left

Pressure Control

Outlet Valve

0x11

circuit short to

ground

942

Brake System

Dump Modulator

Valve Solenoid

Axle 3 Left

4

voltage below

normal, or

shorted to low

source

Active Active Active Active Active 12-2

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X3-6, IV: X3-4, OV: X3-7)

Measure insulation resistance of valve and cabling to vehicle GND. Resistance should be > 200 kOhm.

If insulation is correct then Clear DTCs. If the failure returns, replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x6011

Add Axle Left

Pressure Control

Outlet Valve

0x13 circuit open 942

Brake System

Dump Modulator

Valve Solenoid

Axle 3 Left

5

current below

normal or open

circuit

Active Active Active Active Active 12-3

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X3-6, IV: X3-4, OV: X3-7)

Verification Procedure:

Clear DTC.

Go to workshop

0x6114

Add Axle Right

Pressure Control

Valve

0x4A

incorrect

component

installed

800

Pressure

Modulation Valve

ABS Axle 3 Right

14

special

instructions

Active Active Active Active Active 13-9

Replace the valve for the correct voltage rating type (12V-24V)

Verification Procedure:

Clear DTC.

Go to workshop

0x6115

Add Axle Right

Pressure Control

Valve GND

0x13 circuit open 800

Pressure

Modulation Valve

ABS Axle 3 Right

5

current below

normal or open

circuit

Active Active Active Active Active 13-4

Check cables and connectors of the PCV.

Verification Procedure:

Clear DTC.

Go to workshop

0x6114

Add Axle Right

Pressure Control

Valve

0x55 not configured 800

Pressure

Modulation Valve

ABS Axle 3 Right

13 out of calibration Active Active Active Active Active 13-8

There is a valve connected without being configured.

Check the configuration of the vehicle (2s2m or 2s1m on this axle). If the 2s2m is correct, correct dataset of ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x6014

Add Axle Right

Pressure Control

Inlet Valve

0x12

circuit short to

battery

937

Brake System

Hold Modulator

Valve Solenoid

Axle 3 Right

3

voltage above

normal, or

shorted to high

source

Active Active Active Active Active 13-5

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X3-9, IV: X3-10, OV: X3-13)

Measure insulation resistance of valve and cabling to vehicle voltage (UB). Resistance should be > 200 kOhm.

Measure insulation resistance of valve and cabling to any other ABS/ASR valve. Resistance should be > 200 kOhm

If insulation is correct then Clear DTCs. If the failure returns, replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x6014

Add Axle Right

Pressure Control

Inlet Valve

0x11

circuit short to

ground

937

Brake System

Hold Modulator

Valve Solenoid

Axle 3 Right

4

voltage below

normal, or

shorted to low

source

Active Active Active Active Active 13-6

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X3-9, IV: X3-10, OV: X3-13)

Measure insulation resistance of valve and cabling to vehicle GND. Resistance should be > 200 kOhm.

If insulation is correct then Clear DTCs. If the failure returns, replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x6014

Add Axle Right

Pressure Control

Inlet Valve

0x13 circuit open 937

Brake System

Hold Modulator

Valve Solenoid

Axle 3 Right

5

current below

normal or open

circuit

Active Active Active Active Active 13-7

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X3-9, IV: X3-10, OV: X3-13)

Verification Procedure:

Clear DTC.

Go to workshop

20/29

Document name: ABS8 Diagnostic Trouble Code list

Document no.: Y134941 Rev: 006

Customer: GEN

2013.05.02.

Display

No.

Display No. Text

Type

No.

Type text

SPN

No.

SPN text

FMI

No.

FMI text

ABS WL

state

EBC1/

Hardwire

Red WL

state

EBC1/

DM1

Amber

WL

state

DM1

ASR

Lamp

state

EBC1/

Hardwire

HSA

Lamp

Blink Codes Workshop action Driver Action

0x6015

Add Axle Right

Pressure Control

Outlet Valve

0x12

circuit short to

battery

943

Brake System

Dump Modulator

Valve Solenoid

Axle 3 Right

3

voltage above

normal, or

shorted to high

source

Active Active Active Active Active 13-1

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X3-9, IV: X3-10, OV: X3-13)

Measure insulation resistance of valve and cabling to vehicle voltage (UB). Resistance should be > 200 kOhm.

Measure insulation resistance of valve and cabling to any other ABS/ASR valve. Resistance should be > 200 kOhm

If insulation is correct then Clear DTCs. If the failure returns, replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x6015

Add Axle Right

Pressure Control

Outlet Valve

0x11

circuit short to

ground

943

Brake System

Dump Modulator

Valve Solenoid

Axle 3 Right

4

voltage below

normal, or

shorted to low

source

Active Active Active Active Active 13-2

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X3-9, IV: X3-10, OV: X3-13)

Measure insulation resistance of valve and cabling to vehicle GND. Resistance should be > 200 kOhm.

If insulation is correct then Clear DTCs. If the failure returns, replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x6015

Add Axle Right

Pressure Control

Outlet Valve

0x13 circuit open 943

Brake System

Dump Modulator

Valve Solenoid

Axle 3 Right

5

current below

normal or open

circuit

Active Active Active Active Active 13-3

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X3-9, IV: X3-10, OV: X3-13)

Verification Procedure:

Clear DTC.

Go to workshop

0x6018

Trailer Pressure

Control Valve

0x4A

incorrect

component

installed

1056

Electronic

Pressure Control,

Trailer Control

14

special

instructions

Active Active Active Active Active 14-18

Replace the valve for the correct voltage rating type (12V-24V)

Verification Procedure:

Clear DTC.

Go to workshop

0x6018

Trailer Pressure

Control Valve

0x13 circuit open 1056

Electronic

Pressure Control,

Trailer Control

5

current below

normal or open

circuit

Passive Passive Active Passive Passive

14-12; 14-13;

14-16

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X4-12, IV: X4-6, OV: X4-9)

Verification Procedure:

Clear DTC.

Go to workshop

0x6018

Trailer Pressure

Control Valve

0x55 not configured 1056

Electronic

Pressure Control,

Trailer Control

13 out of calibration Active Active Active Active Active 14-17

Check cables and connectors of the PCV.

Verification Procedure:

Clear DTC.

Go to workshop

0x6018

Trailer Pressure

Control Valve

0x12

circuit short to

battery

1056

Electronic

Pressure Control,

Trailer Control

3

voltage above

normal, or

shorted to high

source

Active Active Active Active Active 14-10; 14-14

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X4-12, IV: X4-6, OV: X4-9)

Measure insulation resistance of valve and cabling to vehicle voltage (UB). Resistance should be > 200 kOhm.

Measure insulation resistance of valve and cabling to any other ABS/ASR valve. Resistance should be > 200 kOhm

If insulation is correct then Clear DTCs. If the failure returns, replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x6018

Trailer Pressure

Control Valve

0x11

circuit short to

ground

1056

Electronic

Pressure Control,

Trailer Control

4

voltage below

normal, or

shorted to low

source

Passive Passive Active Passive Passive 14-11; 14-15

Check for corroded / damaged wiring between the ECU and PCV.

Measure resistance between valve GND and hold or release valve. It should be 5.2 Ohm for 12V system and 15 Ohm for 24V

system. (Connector-PIN: GND: X4-12, IV: X4-6, OV: X4-9)

Measure insulation resistance of valve and cabling to vehicle GND. Resistance should be > 200 kOhm.

If insulation is correct then Clear DTCs. If the failure returns, replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x5211

Central

Differential Lock

0x12

circuit short to

battery

564

Differential Lock

State - Central

3

voltage above

normal, or

shorted to high

source

Active Active Active Active Active 8-10

Check for corroded / damaged wiring between the ECU and the connected device on the DIFF Output. (Connector-PIN: X3-2)

Measure insulation resistance of the connected device on the DIFF Output and cabling to vehicle voltage (UB). Resistance should be

> 200 kOhm.

If insulation is correct then Clear DTCs. If the failure returns, replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

21/29

Document name: ABS8 Diagnostic Trouble Code list

Document no.: Y134941 Rev: 006

Customer: GEN

2013.05.02.

Display

No.

Display No. Text

Type

No.

Type text

SPN

No.

SPN text

FMI

No.

FMI text

ABS WL

state

EBC1/

Hardwire

Red WL

state

EBC1/

DM1

Amber

WL

state

DM1

ASR

Lamp

state

EBC1/

Hardwire

HSA

Lamp

Blink Codes Workshop action Driver Action

0x5211

Central

Differential Lock

0x11

circuit short to

ground

564

Differential Lock

State - Central

4

voltage below

normal, or

shorted to low

source

Active Passive Active Passive Active 8-11

Check for corroded / damaged wiring between the ECU and the connected device on the DIFF Output. (Connector-PIN: X3-2)

Measure insulation resistance of the connected device on the DIFF Output and cabling to vehicle GND. Resistance should be > 200

kOhm.

If the GND of the connected device on the DIFF Output is connected to the ECU, then measure resistance between DIFF GND and

DIFF Output. It should be as specified for the connected device. (Connector-PIN: X3-3 and X3-2)

If insulation is correct then Clear DTCs. If the failure returns, replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x5211

Central

Differential Lock

0x13 circuit open 564

Differential Lock

State - Central

5

current below

normal or open

circuit

Active Passive Active Passive Active 8-11

Check for corroded / damaged wiring between the ECU and the connected device on the DIFF Output. (Connector-PIN: X3-2)

Check for corroded / damaged wiring related to the connected device on the DIFF Output.

If the GND of the connected device on the DIFF Output is connected to the ECU, then measure resistance between DIFF GND and

DIFF Output. It should be as specified for the connected device. (Connector-PIN: X3-3 and X3-2)

Verification Procedure:

Clear DTC.

Go to workshop

0x5204 IO3 0x12

circuit short to

battery

926

Auxiliary Output

#3

3

voltage above

normal, or

shorted to high

source

Passive Passive Active Passive Passive 17-18

Check for corroded / damaged wiring between the ECU and Input/Output 3 device. (Connector-PIN: X3-8)

Measure insulation resistance of Input/Output 3 device and cabling to vehicle voltage (UB). Resistance should be > 200 kOhm.

If insulation is correct then Clear DTCs. If the failure returns, replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x5204 IO3 0x11

circuit short to

ground

926

Auxiliary Output

#3

4

voltage below

normal, or

shorted to low

source

Passive Passive Active Passive Passive 17-18

Check for corroded / damaged wiring between the ECU and Input/Output 3 device.

Measure insulation resistance of Input/Output 3 device and cabling to vehicle GND. Resistance should be > 200 kOhm. (Connector-

PIN: X3-8 and X1-1)

If insulation is correct then Clear DTCs. If the failure returns, replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x5204 IO3 0x13 circuit open 926

Auxiliary Output

#3

5

current below

normal or open

circuit

Passive Passive Active Passive Passive 17-18

Check for corroded / damaged wiring between the ECU and Input/Output 3 device. (Connector-PIN: X3-8)

Check for corroded / damaged wiring related to Input/Output 3 device.

If insulation is correct then Clear DTCs. If the failure returns, replace the ECU.

Verification Procedure:

Clear DTC.

Go to workshop

0x4051

Steering Wheel

Position Sensor

0x22

signal amplitude >

maximum

1807

Steering Wheel

Angle

0

above normal

operational range -

most severe level

Passive Passive Active Passive Passive 19-1

Steering Angle Sensor signal incorrect.

Verify proper installation of the steering angle sensor.

Check if correct steering parts are installed.

Check steering parts (steering gearbox, steering rod, steering locks,...) for damage or correct installation.

If all steering parts are ok and correct, check if the steering wheel angle sensor is calibrated in straight line position by checking

output using diagnostics. If necessary, then perform Steering Angle Sensor calibration using Diagnostics.

Check the ABS/ESP dataset for correct value of the parameter.

Verify input voltage to sensor connector. The voltage range is 8 to 16 volts.

Verify proper wiring between ECU and steering angle sensor by checking the continuity between Sensor CAN Low / High of ECU and

SAS wiring connector.

Verify wiring between the Steering Angle Sensor and power/ground. The resistance measurement is open circuit (no continuity).

Verification Procedure:

Clear DTC

or:

After the fault is detected the ignition should be switched off and on, thus the ECU is reset.

- standstill calibration of YRS is finished

- vehicle speed is greater than 11 km/h

- straight line driving (no strong changes of yaw rate)

- curve driving (stationary, no strong steering angle changes)

The sensors are checked during straight line driving and curve driving.

Reverse checking is only successful if both straight line and curve driving tests are successful.

The result of the reverse check is indicated via the VDC Fully Operational info.

Go to workshop

22/29

Document name: ABS8 Diagnostic Trouble Code list

Document no.: Y134941 Rev: 006

Customer: GEN

2013.05.02.

Display

No.

Display No. Text

Type

No.

Type text

SPN

No.

SPN text

FMI

No.

FMI text

ABS WL

state

EBC1/

Hardwire

Red WL

state

EBC1/

DM1

Amber

WL

state

DM1

ASR

Lamp

state

EBC1/

Hardwire

HSA

Lamp

Blink Codes Workshop action Driver Action

0xC126

Lost

Communication

With Steering

Angle Sensor

Module

0x87 missing message 1807

Steering Wheel

Angle

9

abnormal update

rate

Passive Passive Active Passive Passive 19-7

Verify proper wiring between ECU and steering angle sensor by checking.

the continuity between Sensor CAN Low / High of ECU and SAS wiring connector.

Verify wiring between the Steering Angle Sensor and power/ground. The resistance measurement is open circuit (no continuity).

If the failure returns replace the sensor.

Verification Procedure:

Clear DTC.

Go to workshop

0x4051

Steering Wheel

Position Sensor

0x49

internal electronic

failure

1807

Steering Wheel

Angle

12

bad intelligent

device or

component

Passive Passive Active Passive Passive 19-8

Verify proper installation of the steering angle sensor.

Verify input voltage to sensor connector. The voltage range is 8 to 16 volts.

Verify proper wiring between ECU and steering angle sensor by checking the continuity between Sensor CAN Low / High of ECU and

SAS wiring connector.

Verify wiring between the Steering Angle Sensor and power/ground. The resistance measurement is open circuit (no continuity).

Verify the correct steering angle sensor is being used. Clear DTC, if the failure returns, replace the Steering Angle Sensor.

Verification Procedure:

Clear DTC

or:

After the fault is detected the ignition should be switched off and on, thus the ECU is reset.

- standstill calibration of YRS is finished

- vehicle speed is greater than 11 km/h

- straight line driving (no strong changes of yaw rate)

- curve driving (stationary, no strong steering angle changes)

The sensors are checked during straight line driving and curve driving.

Reverse checking is only successful if both straight line and curve driving tests are successful.

The result of the reverse check is indicated via the VDC Fully Operational info.

Go to workshop

0x4051

Steering Wheel

Position Sensor

0x93 no operation 1807

Steering Wheel

Angle

14

special

instructions

Passive Passive Active Passive Passive 19-4

Verify proper installation of the steering angle sensor.

Verify input voltage to sensor connector. The voltage range is 8 to 16 volts.

Verify proper wiring between ECU and steering angle sensor by checking the continuity between Sensor CAN Low / High of ECU and

SAS wiring connector.

Verify wiring between the Steering Angle Sensor and power/ground. The resistance measurement is open circuit (no continuity).

Verify the correct steering angle sensor is being used. Clear DTC, if the failure returns, replace the Steering Angle Sensor.

Verification Procedure:

Clear DTC.

Go to workshop

0x4051

Steering Wheel

Position Sensor

0x55 not configured 1807

Steering Wheel

Angle

11

root cause not

known

Active Active Active Active Active 19-14

Clear DTC, if the failure returns, replace the ABS ECU.

Verification Procedure:

-

Go to workshop

0x4051

Steering Wheel

Position Sensor

0x27

signal rate of

change above

threshold

1807

Steering Wheel

Angle

10

abnormal rate of

change

Passive Passive Active Passive Passive 19-2

It occurs usually during extreme acceleration and yaw-moment events.

If something looks damaged or the failure returns, replace the component(s).

Verify input voltage to sensor connector. The voltage range is 8 to 16 volts.

Verify proper wiring between ECU and steering angle sensor by checking the continuity between Sensor CAN Low / High of ECU and

SAS wiring connector.

Verify wiring between the Steering Angle Sensor and power/ground. The resistance measurement is open circuit (no continuity).

Check steering angle sensor output using Diagnostics.

Verify the correct steering angle sensor is being used.

Clear DTC. If the failure returns, replace steering wheel angle sensor.

Verification Procedure:

Clear DTC

or:

After the fault is detected the ignition should be switched off and on, thus the ECU is reset.

- standstill calibration of YRS is finished

- vehicle speed is greater than 11 km/h

- straight line driving (no strong changes of yaw rate)

- curve driving (stationary, no strong steering angle changes)

The sensors are checked during straight line driving and curve driving.

Reverse checking is only successful if both straight line and curve driving tests are successful.

The result of the reverse check is indicated via the VDC Fully Operational info.

Go to workshop

23/29

Document name: ABS8 Diagnostic Trouble Code list

Document no.: Y134941 Rev: 006

Customer: GEN

2013.05.02.

Display

No.

Display No. Text

Type

No.

Type text

SPN

No.

SPN text

FMI

No.

FMI text

ABS WL

state

EBC1/

Hardwire

Red WL

state

EBC1/

DM1

Amber

WL

state

DM1

ASR

Lamp

state

EBC1/

Hardwire

HSA

Lamp

Blink Codes Workshop action Driver Action

0x4051

Steering Wheel

Position Sensor

0x64

signal plausibility

failure

1807

Steering Wheel

Angle

2

data erratic,

intermittent or

incorrect

Passive Passive Active Passive Passive 19-5

Steering Angle Sensor signal incorrect.

Verify proper installation of the steering angle sensor.

Check if correct steering parts are installed.

Check steering parts (steering gearbox, steering rod, steering locks,...) for damage or correct installation.

If all steering parts are ok and correct, check if the steering wheel angle sensor is calibrated in straight line position by checking

output using Diagnostics. If necessary, then perform Steering Angle Sensor calibration using Diagnostics.

Check the ABS/ESP dataset for correct value of the parameter. Verify input voltage to sensor connector. The voltage range is 8 to 16

volts.

Verify proper wiring between ECU and steering angle sensor by checking the continuity between Sensor CAN Low / High of ECU and

SAS wiring connector.

Verify wiring between the Steering Angle Sensor and power/ground. The resistance measurement is open circuit (no continuity).

After any repair work on the steering a calibration of the steering wheel angle senor is necessary.

Verification Procedure:

Clear DTC

or:

After the fault is detected the ignition should be switched off and on, thus the ECU is reset.

- standstill calibration of YRS is finished

- vehicle speed is greater than 11 km/h

- straight line driving (no strong changes of yaw rate)

- curve driving (stationary, no strong steering angle changes)

The sensors are checked during straight line driving and curve driving.

Reverse checking is only successful if both straight line and curve driving tests are successful.

The result of the reverse check is indicated via the VDC Fully Operational info.

Go to workshop

0x4051

Steering Wheel

Position Sensor

0x07

mechanical

failures

1807

Steering Wheel

Angle

7

mechanical

system not

responding or out

of adjustment

Passive Passive Active Passive Passive 19-3; 19-6

Verify proper installation of the steering angle sensor.

Check if correct steering parts are installed.

Check steering parts (steering gearbox, steering rod, steering locks,...) for damage or correct installation.

If all steering parts are ok and correct, check if the steering wheel angle sensor is calibrated in straight line position by checking

output using Diagnostics. If necessary, then perform Steering Angle Sensor calibration using Diagnostics.

Check the ABS/ESP dataset for correct value of the parameter. Verify input voltage to sensor connector. The voltage range is 8 to 16

volts.

Verify proper wiring between ECU and steering angle sensor by checking the continuity between Sensor CAN Low / High of ECU and

SAS wiring connector.

Verify wiring between the Steering Angle Sensor and power/ground. The resistance measurement is open circuit (no continuity).

After any repair work on the steering a calibration of the steering wheel angle senor is necessary.

Verification Procedure:

Clear DTC

or:

After the fault is detected the ignition should be switched off and on, thus the ECU is reset.

- standstill calibration of YRS is finished

- vehicle speed is greater than 11 km/h

- straight line driving (no strong changes of yaw rate)

- curve driving (stationary, no strong steering angle changes)

The sensors are checked during straight line driving and curve driving.

Reverse checking is only successful if both straight line and curve driving tests are successful.

The result of the reverse check is indicated via the VDC Fully Operational info.

Go to workshop

0x4051

Steering Wheel

Position Sensor

0x54

missing

calibration

1807

Steering Wheel

Angle

13 out of calibration Passive Passive Active Passive Passive 19-9; 19-10

Calibrate or finish the offset calibration of the Steering Angle Sensor.

Verification Procedure:

-

Steering Angle Sensor

calibration not finished

24/29

Document name: ABS8 Diagnostic Trouble Code list

Document no.: Y134941 Rev: 006

Customer: GEN

2013.05.02.

Display

No.

Display No. Text

Type

No.

Type text

SPN

No.

SPN text

FMI

No.

FMI text

ABS WL

state

EBC1/

Hardwire

Red WL

state

EBC1/

DM1

Amber

WL

state

DM1

ASR

Lamp

state

EBC1/

Hardwire

HSA

Lamp

Blink Codes Workshop action Driver Action

0x4063 Yaw Rate Sensor 0x22

signal amplitude >

maximum

1808 Yaw Rate 0

above normal

operational range -

most severe level

Passive Passive Active Passive Passive 20-1

It occurs usually during extreme acceleration and yaw-moment events.

Check correct mounting of the Yaw-Rate Sensor (e.g. original bracket, screws,..)

Check Yaw-Rate Sensor and its mounting for damage.

Check that the Yaw-Rate Sensor is not hit by any parts (eg. pipes).

Clear DTC, if something looks damaged or the failure returns, replace the component(s).

Verification Procedure:

Clear DTC

or:

After the fault is detected the ignition should be switched off and on, thus the ECU is reset.

- standstill calibration of YRS is finished

- vehicle speed is greater than 11 km/h

- straight line driving (no strong changes of yaw rate)

- curve driving (stationary, no strong steering angle changes)

The sensors are checked during straight line driving and curve driving.

Reverse checking is only successful if both straight line and curve driving tests are successful.

The result of the reverse check is indicated via the VDC Fully Operational info.

To check the vibration resistance of the Yaw-Rate and Lateral Acceleration Sensor installation drive a short section on rough road.

Go to workshop

0x4063 Yaw Rate Sensor 0x64

signal plausibility

failure

1808 Yaw Rate 2

data erratic,

intermittent or

incorrect

Passive Passive Active Passive Passive

20-3; 20-4; 20-

10; 20-12; 20-

13

Verify proper installation of the Yaw-Rate Sensor.

Check if correct steering parts are installed.

Check steering parts (steering gearbox, steering rod, steering locks,...) for damage or correct installation.

If all steering parts are ok and correct, check if the steering wheel angle sensor is calibrated in straight line position by checking

output using Diagnostics (incorrect calibration of the Steering wheel Angle Sensor can lead to detection of Yaw-Rate Sensor failure in

special cases). If necessary, then perform Steering Angle Sensor calibration using Diagnostics.

Check the ABS/ESP dataset for correct value of the parameter.

Verify input voltage to sensor connector. The voltage range is 8 to 16 volts.

Verify proper wiring between ECU and Yaw-Rate Sensor by checking the continuity between Sensor CAN Low / High of ECU and

wiring connector.

Verify wiring between the Yaw-Rate Sensor and power/ground. The resistance measurement is open circuit (no continuity).

Clear DTC, when the failure returns, replace the Yaw-Rate Sensor.

Verification Procedure:

Clear DTC

or:

After the fault is detected the ignition should be switched off and on, thus the ECU is reset.

- standstill calibration of YRS is finished

- vehicle speed is greater than 11 km/h

- straight line driving (no strong changes of yaw rate)

- curve driving (stationary, no strong steering angle changes)

The sensors are checked during straight line driving and curve driving.

Reverse checking is only successful if both straight line and curve driving tests are successful.

The result of the reverse check is indicated via the VDC Fully Operational info.

To check the vibration resistance of the Yaw-Rate and Lateral Acceleration Sensor installation drive a short section on rough road.

Go to workshop

0xC123

Lost

Communication

With Yaw Rate

Sensor Module

0x87 missing message 1808 Yaw Rate 9

abnormal update

rate

Passive Passive Active Passive Passive 20-14

Verify proper wiring between ECU and Yaw-Rate Sensor by checking the continuity between Sensor CAN Low / High of ECU and

SAS wiring connector.

Verify wiring between the Yaw-Rate Sensor and power/ground. The resistance measurement is open circuit (no continuity). If the

failure returns replace the sensor.

Verification Procedure:

Clear DTC.

Go to workshop

25/29

Document name: ABS8 Diagnostic Trouble Code list

Document no.: Y134941 Rev: 006

Customer: GEN

2013.05.02.

Display

No.

Display No. Text

Type

No.

Type text

SPN

No.

SPN text

FMI

No.

FMI text

ABS WL

state

EBC1/

Hardwire

Red WL

state

EBC1/

DM1

Amber

WL

state

DM1

ASR

Lamp

state

EBC1/

Hardwire

HSA

Lamp

Blink Codes Workshop action Driver Action

0x4063 Yaw Rate Sensor 0x49

internal electronic

failure

1808 Yaw Rate 12

bad intelligent

device or

component

Passive Passive Active Passive Passive 20-2

Verify proper installation of the Yaw-Rate Sensor.

Check Yaw-Rate Sensor and its mounting for damage.

Check that the Yaw-Rate Sensor is not hit by any parts (eg. pipes).

Verify input voltage to sensor connector. The voltage range is 8 to 16 volts.

Verify proper wiring between ECU and steering angle sensor by checking the continuity between Sensor CAN Low / High of ECU and

wiring connector.

Verify wiring between the Yaw-Rate Sensor and power/ground. The resistance measurement is open circuit (no continuity).

Clear DTC, when the failure returns, replace the Yaw-Rate Sensor.

Verification Procedure:

Clear DTC

or:

After the fault is detected the ignition should be switched off and on, thus the ECU is reset.

- standstill calibration of YRS is finished

- vehicle speed is greater than 11 km/h

- straight line driving (no strong changes of yaw rate)

- curve driving (stationary, no strong steering angle changes)

The sensors are checked during straight line driving and curve driving.

Reverse checking is only successful if both straight line and curve driving tests are successful.

The result of the reverse check is indicated via the VDC Fully Operational info.

To check the vibration resistance of the Yaw-Rate and Lateral Acceleration Sensor installation drive a short section on rough road.

Go to workshop

0x4063 Yaw Rate Sensor 0x2F signal erratic 1808 Yaw Rate 8

abnormal

frequency or

pulse width or

period

Passive Passive Active Passive Passive 20-23

Check the sensor mounting for vibration.

Check the environment of the sensor for other components which could create vibrations by hitting the sensor, or the wiring of the

sensor.

Clear DTC, if the failure returns, replace the Yaw-Rate Sensor.

Verification Procedure:

Clear DTC

or:

After the fault is detected the ignition should be switched off and on, thus the ECU is reset.

- standstill calibration of YRS is finished

- vehicle speed is greater than 11 km/h

- straight line driving (no strong changes of yaw rate)

- curve driving (stationary, no strong steering angle changes)

The sensors are checked during straight line driving and curve driving.

Reverse checking is only successful if both straight line and curve driving tests are successful.

The result of the reverse check is indicated via the VDC Fully Operational info.

To check the vibration resistance of the Yaw-Rate and Lateral Acceleration Sensor installation drive a short section on rough road.

Go to workshop

0x4063 Yaw Rate Sensor 0x92

performance or

incorrect

operation

1808 Yaw Rate 14

special

instructions

Passive Passive Active Passive Passive 20-21

Verify proper installation of the Yaw-Rate Sensor.

Check if correct steering parts are installed.

Check steering parts (steering gearbox, steering rod, steering locks,...) for damage or correct installation.

If all steering parts are ok and correct, check if the steering wheel angle sensor is calibrated in straight line position by checking

output using Diagnostics (incorrect calibration of the Steering wheel Angle Sensor can lead to detection of Yaw-Rate Sensor failure in

special cases). If necessary, then perform Steering Angle Sensor calibration using Diagnostics.

Check the ABS/ESP dataset for correct value of the parameter. Verify input voltage to sensor connector. The voltage range is 8 to 16

volts.

Verify proper wiring between ECU and Yaw-Rate Sensor by checking the continuity between Sensor CAN Low / High of ECU and

wiring connector.

Verify wiring between the Yaw-Rate Sensor and power/ground. The resistance measurement is open circuit (no continuity).

Clear DTC, when the failure returns, replace the Yaw-Rate Sensor.

Verification Procedure:

Clear DTC

or:

After the fault is detected the ignition should be switched off and on, thus the ECU is reset.

- standstill calibration of YRS is finished

- vehicle speed is greater than 11 km/h

- straight line driving (no strong changes of yaw rate)

- curve driving (stationary, no strong steering angle changes)

The sensors are checked during straight line driving and curve driving.

Reverse checking is only successful if both straight line and curve driving tests are successful.

The result of the reverse check is indicated via the VDC Fully Operational info.

To check the vibration resistance of the Yaw-Rate and Lateral Acceleration Sensor installation drive a short section on rough road.

Go to workshop

26/29

Document name: ABS8 Diagnostic Trouble Code list

Document no.: Y134941 Rev: 006

Customer: GEN

2013.05.02.

Display

No.

Display No. Text

Type

No.

Type text

SPN

No.

SPN text

FMI

No.

FMI text

ABS WL

state

EBC1/

Hardwire

Red WL

state

EBC1/

DM1

Amber

WL

state

DM1

ASR

Lamp

state

EBC1/

Hardwire

HSA

Lamp

Blink Codes Workshop action Driver Action

0x4063 Yaw Rate Sensor 0x55 not configured 1808 Yaw Rate 11

root cause not

known

Active Active Active Active Active 20-24

Clear DTC, if the failure returns, replace the ABS ECU.

Verification Procedure:

-

Go to workshop

0x4063 Yaw Rate Sensor 0x27

signal rate of

change above

threshold

1808 Yaw Rate 10

abnormal rate of

change

Passive Passive Active Passive Passive 20-5

It occurs usually during extreme acceleration and yaw-moment events.

Check Yaw-Rate Sensor and its mounting for damage.

Verify input voltage to sensor connector. The voltage range is 8 to 16 volts.

Verify proper wiring between ECU and steering angle sensor by checking the continuity between Sensor CAN Low / High of ECU and

SAS wiring connector.

Verify wiring between the Yaw-Rate Sensor and power/ground. The resistance measurement is open circuit (no continuity).

Clear DTC, if something looks damaged or the failure returns, replace the component(s).

Verification Procedure:

Clear DTC

or:

After the fault is detected the ignition should be switched off and on, thus the ECU is reset.

- standstill calibration of YRS is finished

- vehicle speed is greater than 11 km/h

- straight line driving (no strong changes of yaw rate)

- curve driving (stationary, no strong steering angle changes)

The sensors are checked during straight line driving and curve driving.

Reverse checking is only successful if both straight line and curve driving tests are successful.

The result of the reverse check is indicated via the VDC Fully Operational info.

To check the vibration resistance of the Yaw-Rate and Lateral Acceleration Sensor installation drive a short section on rough road.

Go to workshop

0x4063 Yaw Rate Sensor 0x76

wrong mounting

position

1808 Yaw Rate 7

mechanical

system not

responding or out

of adjustment

Passive Passive Active Passive Passive 20-11

Check the sensor mounting direction. If necessary, then correct sensor mounting direction (use correct brackets if necessary).

If mounting direction is correct, check ABS/ESP dataset.

Verification Procedure:

Clear DTC

or:

After the fault is detected the ignition should be switched off and on, thus the ECU is reset.

- standstill calibration of YRS is finished

- vehicle speed is greater than 11 km/h

- straight line driving (no strong changes of yaw rate)

- curve driving (stationary, no strong steering angle changes)

The sensors are checked during straight line driving and curve driving.

Reverse checking is only successful if both straight line and curve driving tests are successful.

The result of the reverse check is indicated via the VDC Fully Operational info.

To check the vibration resistance of the Yaw-Rate and Lateral Acceleration Sensor installation drive a short section on rough road.

Go to workshop

0x4063 Yaw Rate Sensor 0x96

component

internal failure

1808 Yaw Rate 13 out of calibration Passive Passive Active Passive Passive

20-6; 20-7; 20-

8

Clear DTC, if the failure returns, replace the Yaw-Rate Sensor.

Verification Procedure:

Clear DTC.

Go to workshop

0x4061

Lateral

Acceleration

Sensor

0x22

signal amplitude >

maximum

1809

Lateral

Acceleration

0

above normal

operational range -

most severe level

Passive Passive Active Passive Passive 20-15

It occurs usually during extreme acceleration and yaw-moment events.

Check correct mounting of the Yaw-Rate Sensor (e.g. original bracket, screws,..)

Check Yaw-Rate Sensor and its mounting for damage.

Check that the Yaw-Rate Sensor is not hit by any parts (eg. pipes).

Clear DTC, if something looks damaged or the failure returns, replace the component(s).

Verification Procedure:

Clear DTC

or:

After the fault is detected the ignition should be switched off and on, thus the ECU is reset.

- standstill calibration of YRS is finished

- vehicle speed is greater than 11 km/h

- straight line driving (no strong changes of yaw rate)

- curve driving (stationary, no strong steering angle changes)

The sensors are checked during straight line driving and curve driving.

Reverse checking is only successful if both straight line and curve driving tests are successful.

The result of the reverse check is indicated via the VDC Fully Operational info.

To check the vibration resistance of the Yaw-Rate and Lateral Acceleration Sensor installation drive a short section on rough road.

Go to workshop

27/29

Document name: ABS8 Diagnostic Trouble Code list

Document no.: Y134941 Rev: 006

Customer: GEN

2013.05.02.

Display

No.

Display No. Text

Type

No.

Type text

SPN

No.

SPN text

FMI

No.

FMI text

ABS WL

state

EBC1/

Hardwire

Red WL

state

EBC1/

DM1

Amber

WL

state

DM1

ASR

Lamp

state

EBC1/

Hardwire

HSA

Lamp

Blink Codes Workshop action Driver Action

0x4061

Lateral

Acceleration

Sensor

0x64

signal plausibility

failure

1809

Lateral

Acceleration

2

data erratic,

intermittent or

incorrect

Passive Passive Active Passive Passive 20-18; 20-19

Check the Yaw-Rate Sensor mounting direction. If necessary, then correct sensor mounting direction (use correct brackets if

necessary).

If mounting direction is correct, check ABS/ESP dataset.

Clear DTC, when the failure returns, replace the Yaw-Rate Sensor.

Verification Procedure:

Clear DTC

or:

After the fault is detected the ignition should be switched off and on, thus the ECU is reset.

- standstill calibration of YRS is finished

- vehicle speed is greater than 11 km/h

- straight line driving (no strong changes of yaw rate)

- curve driving (stationary, no strong steering angle changes)

The sensors are checked during straight line driving and curve driving.

Reverse checking is only successful if both straight line and curve driving tests are successful.

The result of the reverse check is indicated via the VDC Fully Operational info.

To check the vibration resistance of the Yaw-Rate and Lateral Acceleration Sensor installation drive a short section on rough road.

Go to workshop

0x4061

Lateral

Acceleration

Sensor

0x96

component

internal failure

1809

Lateral

Acceleration

14

special

instructions

Passive Passive Active Passive Passive 20-17

Clear DTC, when the failure returns, replace the Yaw-Rate Sensor. Calibrate Lateral Acceleration Sensor.

Verification Procedure:

Clear DTC

or:

After the fault is detected the ignition should be switched off and on, thus the ECU is reset.

- standstill calibration of YRS is finished

- vehicle speed is greater than 11 km/h

- straight line driving (no strong changes of yaw rate)

- curve driving (stationary, no strong steering angle changes)

The sensors are checked during straight line driving and curve driving.

Reverse checking is only successful if both straight line and curve driving tests are successful.

The result of the reverse check is indicated via the VDC Fully Operational info.

To check the vibration resistance of the Yaw-Rate and Lateral Acceleration Sensor installation drive a short section on rough road.

Go to workshop

0x4061

Lateral

Acceleration

Sensor

0x28

signal bias level

out of range /

zero adjustment

failure

1809

Lateral

Acceleration

11

root cause not

known

Passive Passive Active Passive Passive 20-16

Check the Yaw-Rate Sensor mounting direction. If necessary, then correct sensor mounting direction (use correct brackets if

necessary).

If mounting direction is correct, check ABS/ESP dataset.

Clear DTC, when the failure returns, replace the Yaw-Rate Sensor and calibrate Lateral Acceleration Sensor.

Verification Procedure:

Clear DTC

or:

After the fault is detected the ignition should be switched off and on, thus the ECU is reset.

- standstill calibration of YRS is finished

- vehicle speed is greater than 11 km/h

- straight line driving (no strong changes of yaw rate)

- curve driving (stationary, no strong steering angle changes)

The sensors are checked during straight line driving and curve driving.

Reverse checking is only successful if both straight line and curve driving tests are successful.

The result of the reverse check is indicated via the VDC Fully Operational info.

To check the vibration resistance of the Yaw-Rate and Lateral Acceleration Sensor installation drive a short section on rough road.

Go to workshop

0x4061

Lateral

Acceleration

Sensor

0x54

missing

calibration

1809

Lateral

Acceleration

13 out of calibration Passive Passive Active Passive Passive 20-20

Calibrate Lateral Acceleration Sensor.

Verification Procedure:

-

Lateral Acceleration

Sensor calibration not

finished

0x4063 Yaw Rate Sensor 0x1C

circuit voltage out

of range

1808 Yaw Rate 3

voltage above

normal, or

shorted to high

source

Passive Passive Active Passive Passive 19-12

Check the wiring of the ESP sensors.

Clear DTC, if the failure returns change the ABS ECU.

Verification Procedure:

-

Go to workshop

0xF003 Battery Voltage 0x1C

circuit voltage out

of range

520563

Supply voltage for

the ESP sensors

4

voltage below

normal, or

shorted to low

source

Passive Passive Active Passive Passive 19-12

Check ESP sensor wiring. Clear DTC, change ECU.

Verification Procedure:

-

Go to workshop

28/29

Document name: ABS8 Diagnostic Trouble Code list

Document no.: Y134941 Rev: 006

Customer: GEN

2013.05.02.

Display

No.

Display No. Text

Type

No.

Type text

SPN

No.

SPN text

FMI

No.

FMI text

ABS WL

state

EBC1/

Hardwire

Red WL

state

EBC1/

DM1

Amber

WL

state

DM1

ASR

Lamp

state

EBC1/

Hardwire

HSA

Lamp

Blink Codes Workshop action Driver Action

0x5217

Trailer Pressure

Control Valve

Plausibility Check

0x64

signal plausibility

failure

1056

Electronic

Pressure Control,

Trailer Control

11

root cause not

known

Passive Passive Active Passive Passive 14-17

Brake Light Activation not seen during ESP Chuff test.

Check the reservoir pressure of the front axle brake circuit.

Check Trailer PCV.

Check ATC on Steer Axle.

Check brake light switch.

Verification Procedure:

Clear DTC.

ESP Stop lamp switch test

not finished

0x5214

Pressure Control

Valve End Of Life

0x68 event information 520250 PCV end of life 14

special

instructions

Passive Passive Passive Passive Passive 17-20

Replace Pressure Control Valves and reset valve actuation counter.

Verification Procedure:

Clear DTC.

Go to workshop

0x5215

HSA disabled due

to impending

overuse of valve

components

0x68 event information 520251

HSA disabled due

to impending

overuse of valve

components

14

special

instructions

Passive Passive Passive Passive Passive 17-21

Replace Traction Control Valves and reset valve actuation counter.

Verification Procedure:

Clear DTC.

Go to workshop

0x4081

ABS Malfunction

Indicator

0x01

general electrical

failure

811

Warning Light

Bulb

2

data erratic,

intermittent or

incorrect

Active Passive Active Passive Active 17-10

Check the wiring of the Warning Lamp or Diagnostic switch for short to GND. (Connector-PIN: X1-18)

Check the wiring of the Warning Lamp GND for open circuit and for short circuit to UB. (Connector-PIN: X1-12)

Verification Procedure:

Clear DTC.

Go to workshop

29/29

Y134941: EN: 006: SDE1: Released:Pelizzari_Rafael: 2013/05/27-12:26:32

J

A

C

-

2

0

1

4

2

5

2

7

江淮汽车部门：客户服务部

Compiling 编制 Champion.Wong 汪庆平

Audit 审核 Youwang.Zhang 张有旺

Approve 批准

ANHUI JIANGHUAI AUTOMOBILE CO., LTD