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Mounting and Operating Instructions ETS Electronic

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1. ADVICE Mounting the actuating cylinder on the single axis is described in the following In the case of a double axle the actuating cylinder is mounted on the front axle using the same principle Preparing the trailer Secure the trailer by means of chocks Release the handbrake Preparing the brake Remove the main brake linkage with the brake compensation balance Unscrew the fork head from the main brake linkage The fork head can remain on the brake cable At the axle release the bowden cables at the cable counterbearing Release the screws and push forward Pull the bowden cables downwards through the slotted holes and detach Mounting and Operating Instructions ETS Model ETSO2 19 03 2010 V2 0 KNOTTjj BRAKE AND TRAILER TECHNOLOGY Mount the brake cable at the actuating cylinder Plug the slotted washers on the fixing threads of the brake cable Remove the actuating cylinder from the packaging and manually detach the two restoring springs on the side of the actuating cylinder The restoring springs only actuate a force of 20 N and can be manually mounted and detached without the need for tools V2 0 19 03 2010 Mounting and Operating Instructions ETS Model ETS02 GROUP KNOTTjj BRAKE AND TRAILER TECHNOLOGY Manually extend the cylinder Insert the brake cable in the slotted counterbearing 4 itil y idi i Fasten the brake cab
2. V2 0 19 03 2010 Mounting and Operating Instructions ETS Model ETS02 GROUP KNOTT ADVICE When the trailer is parked the 13 pin trailer plug should be placed in a parking socket 5 3 Displays P Using the 2 colour LED display the status of the system can be observed gt gee Display Status Consequence Continuous GREEN ETS active All OK light Oo Flashing GREEN light ETS active or brake Continued driving setting faulty possible dy Continuous RED light ETS inactive or self Continued driving test not yet performed possible oO Flashing RED light ETS braking Continued driving intervention possible after or self test active releasing the parking or parking brake brake and switching applied off the ignition for at least 10 seconds LED does not light up ETS inactive Continued driving possible Mounting and Operating Instructions ETS Model ETSO2 19 03 2010 V2 0 6 1 6 2 6 3 6 4 V2 0 GROUP KNOTT BRAKE AND TRAILER TECHNOLOGY Maintenance Overview What How When What needs to be done Visual inspection Visual inspection Regularly Repair replace if of ETS for damage necessary components Visual inspection Visual inspection Regularly If applicable of 13 pin trailer for corrosion repair 13 pin plug missing contacts trailer plug Check brake fluid Check the filling Annually Top up brake fluid level at the ETS DOT4 valve block compensating tank Check brake
3. Mounting in the trailer superstructure Make two boreholes in the selected position with a diameter of 12 13 mm placed 50 mm apart See the sketch below Agree the position of the boreholes with the trailer manufacturer as particularly in caravans power cables water hoses are often laid in the floor WARNING Possible hazard due to defects in the liquid gas system It is NOT admissible to mount the ETS near the gas system In order to guarantee subsequent correct laying of hoses cables the shaded area around the ETS valve block must be kept free Screw the ETS valve block using two hexagonal screws M10x60 with washer to the floor from below Tightening torque 45 Nm V2 0 19 03 2010 Mounting and Operating Instructions ETS Model ETS02 GROUP KNOTT Clearance area around the valve block Drilling pattern for fixture of the ETS valve block with indication of minimum distances from the edge view from below b Mounting using a bracket directly on the trailer drawbar Remove any existing drawbar cover in accordance with the trailer manufacturer s instructions CAUTION Danger of injury due to incorrect function of the brake system There must be sufficient free space left between the bracket and the overrun coupling to ensure that the handbrake lever can be swivelled back without obstruction Check the remaining dimension in accordance with the sketch below Mounting and Operating I
4. operating elements for the overrun coupling There are two different mounting scenarios a Drawbar without enclosure 19 03 2010 Mounting and Operating Instructions ETS Model ETS02 b Drawbar with enclosure a Mounting in drawbar without enclosure Mount the LED display beforehand into the supplied retainer Do this by slotting the LED into the retainer until it projects around 6 mm at the top ca 6 mm Push on the lateral cover plate Push on the cover plate with the inscription Screw the whole assembly using the two M3 countersunk head screws This securely mounts the LED display in the retainer Mounting and Operating Instructions ETS Model ETSO2 19 03 2010 V2 0 Assemble the LED display and the overrun coupling by releasing the rear left hand screw of the screw union between the overrun coupling and the A frame Screw the LED display to the overrun coupling and A frame Lock nut ADVICE Use a new lock nut This must have the same strength class as the relevant screw see impression on the screw head ADVICE The tightening torque of the screw union must be checked using a torque wrench prior to driving off Screw Strength class Tightening torque M14 10 9 180 Nm Roll up any surplus cable to form a bundle and fasten the bundle using several hose clips in a protected location CAUTION Danger of short circuits due to cable damage The cable mu
5. with you in the vehicle The KNOTT ETSO2 complies with the following regulations ECE R13 Annex 18 ECE R13 H Annex 8 ECE R79 Annex 6 The system has also been tested and approved in accordance with the EMC Directive ECE R10 1 3 Warranty The following actions in particular will result in rendering any warranty or guarantee claims null and void and in the exclusion of any liability claims Modifications made to the system Use of any other than KNOTT original parts Failure to adhere to the mounting and operating instructions Mounting and Operating Instructions ETS Model ETSO2 19 03 2010 V2 0 GROUP KNOTTjj BRAKE AND TRAILER TECHNOLOGY 2 Function 2 1 Application The ETS system ETSO2 is designed to supplement an existing mechanical overrun brake system with the addition of active braking intervention to stabilize the tractor trailer combination Objective To assist the driver in critical situations by actively initiating a stabilization process and so prevent accidents 2 2 Overall view BETS components Trailer components A 4 m Sensor fars A a Actuateya cylinder amp Kr Brake compensali n balance Reliable detection T ETS valve block with The mounting g BONNET precessor position of the acceleration sensor Electrical distributer bax J e well to the rear ensures reliable registration of trailer 4 st Rapid stabilization snaking mo
6. 2250 358 955 2260 CH Willy Erny AG 41 5233 72121 41 5233 73530 S AB Ernst H Rydahls 46 54 856200 46 54 851058 TR Teknom Otomotiv Ltd 90 532 2354093 90 312 2959855 N Mounting and Operating Instructions ETS Model ETSO2 19 03 2010 V2 0 KNOTT BREMSEN ACHSEN Kraftfahrt Bundesamt DE 24932 Flensburg ALLGEMEINE BETRIEBSERLAUBNIS ABE nach 22 in Verbindung mit 20 Stra enverkehrs Zulassungs Ordnung StVZO in der Fassung vom 28 09 1988 BGBI I S 1793 Nummer der ABE 91171 Gerat Stabilisierungseinrichtung f r Anh Typ ETS 02 Inhaber der ABE Knott GmbH und Hersteller DE 83125 Eggst tt F r die obenbezeichneten reihenweise zu fertigenden oder gefertigten Ger te wird diese Genehmigung mit folgender Ma gabe erteilt Die genehmigte Einrichtung erh lt das Typzeichen KBA 91171 Dieses von Amts wegen zugeteilte Zeichen ist auf jedem St ck der laufenden Fertigung in der vorstehenden Anordnung dauerhaft und jederzeit von au en gut lesbar anzubringen Zeichen die zu Verwechslungen mit einem amtlichen Typzeichen Anlass geben k nnen d rfen nicht angebracht werden Montage und Betriebsanleitung ETS Typ ETS02 19 03 2010 V2 0 V2 0 KNOTT BREMSEN ACHSEN Kraftfahrt Bundesamt DE 24932 Flensburg Nummer der ABE 91171 Die Stabilisierungseinrichtungen Typ ETS 02 d rfen ausschlie lich zum Anbau an auflaufgebremste Anh nger feilgeboten werden die alle in den beiliegenden
7. E 49 5 1 Hitching up the traller cccccscccssecessseeceeseeeseeeseseeseseeeneaees 49 5 2 UTI FUE Elisa en as och perience E soker ee 49 99 DIS AV S nie ea ee er 50 6 MalNnlenance 2 000 51 6 1 OVETVI W E E ndra nes au TR Rise SNRA s d SNR ERNA KR 51 6 2 CISA GE en ee 51 6 3 Visual inspection for CCaMAOJJCs sssesssrresrrrerrrresrrrerrerenrrrerrr rn rna ann 51 6 4 Visual inspection of contacts for corrosion and correct fit 51 6 5 Check the brake fluiCh ssnnssssssressrressrrsrrensrrnr ren rrrrrrrrr rann rr rr rn rann nn 52 6 6 Changing the brake flViCh ssssossressrrresrrrsrrrrerrrrerrrrrrrrrerrr rr nennen 52 6 7 Checking the actuating cylinder and brake compensation Dell ANC C ee ee een 53 6 8 TroubleShOOtiNO sssessressrrsssrnrrrnrrrnererr narr r rr ris rr nn rr rn rr nr rna rna 54 6 9 Service INTO GU ON crcicnn2cnndccmasasccanaesancvesveesasweacsussuarasusiesaeennieas 56 V2 0 19 03 2010 Mounting and Operating Instructions ETS Model ETS02 GROUP BRAKE AND IO TECHNOLOGY D 1 General 1 1 Manufacturer Knott GmbH Obingerstrasse 15 83125 Eggstatt GERMANY Tel 49 8056 906 0 Fax 49 8056 906 106 Email info knott de Internet www knott de 1 2 Approval The KNOTT ETSO2 has type approval and a General Operating Licence ABE has been granted for Germany No separate approval by an independent automotive expert is necessary Always carry the General Operating Licence ABE
8. Hexagonal screw M10x16 Hexagonal screw M10x60 i Mounting and Operating Instructions ETS Model ETSO2 19 03 2010 V2 0 Hexagonal nut M10 GROUP KNOTT Item Quantity Designation 20 Lock nut M14 21 Lock nut M12 22 Lock nut M10 23 Washer A10 5 24 Washer A 13 25 Washer dia 20x12 5x2 slotted 26 Cover for ETS valve block 15 16 14 11 9 10 13 6 7 8 20 21 22 V2 0 19 03 2010 Mounting and Operating Instructions ETS Model ETS02 BRAKE AND lO TECHNOLOGY y 2 4 Functional characteristics An acceleration sensor mounted on the trailer signals the current acceleration rate in both directions The processor calculates the current driving stability status of the trailer based on this information The nerve centre of the system is the pump valve block which is designed as a single unit together with the processor It features a micropump which fills the hydraulic piston accumulator The actuating cylinder at the axle is actuated from this reservoir within just a few milliseconds If the control processor detects an unstable vehicle status hydraulic pressure is applied to the actuating cylinder at the axle which applies the mechanical wheel brakes by means of the wheel brake bowden cables By applying the wheel brakes the trailer is lightly braked straightening out the tractor trailer rig and so stabilizing the trailer Once the impending risk of rig destabilization has passed the actuating cylinder
9. Pr funterlagen aufgef hrten Anforderungen entsprechen In einer mitzuliefernden Anbauanweisung sind die Bezieher auf den eingeschr nkten Verwendungsbereich hinzuweisen Der Anbau hat nach dieser Anweisung zu erfolgen An jedem Ger t mu an einer gegen Besch digung gesch tzten auch nach dem Anbau sichtbaren Stelle gut lesbar und dauerhaft ein Fabrikschild angebracht sein das folgende Angaben enth lt Hersteller oder Herstellerzeichen Typ und Typzeichen Statt der Kennzeichnung der Ger te mit dem Fabrikschild k nnen die geforderten Angaben auch eingepr gt sein Im brigen gelten die im beiliegenden Gutachten nebst Anlagen des TUV SUD AUTOMOTIVE GMBH TUV SUD Gruppe Garching vom 07 05 2009 festgehaltenen Angaben Das gepr fte Muster ist so aufzubewahren dass es noch f nf Jahre nach Erl schen der ABE in zweifelsfreiem Zustand vorgewiesen werden kann Flensburg 27 05 2009 Im Auftrag Mario Quade Anlagen Nebenbestimmungen und Rechtsbehelfsbelehrung 1 Gutachten Nr 09 00107 CX GBM 19 03 2010 Montage und Betriebsanleitung ETS Typ ETS02 59 BREMSEN ACHSEN Knott GMbH Bremsen Achsen Obingerstrasse 15 83125 Eggstatt GERMANY Tel 49 8056 906 0 Fax 49 8056 906 106 Email info knott de www knott de
10. axle by axle curb weight designation on with central compensation of the the back of the compensation balances trailer in kg wheel brake 16 1365 20 2425 1 25 2025 ETS02 002 1000 20 2425 1 25 2025 ETS02 003 ETS02 103 1801 2400 kg 1400 20 2425 1 25 2025 ETSO2 004 ETSO2 104 2401 3500 kg 1800 20 2425 1 25 2025 ETSO2 005 ETSO2 105 650 900 kg ETSO2 005 ETSO2 105 901 1200 kg 500 750 400 16 1365 20 2425 1 25 2025 V2 0 19 03 2010 Mounting and Operating Instructions ETS Model ETS02 GROUP KNOTT Single axle Tandem Weight range Required KNOTT wheel and tandem trailers with minimum brakes model axle trailers axle by axle curb weight designation on with central compensation of the the back of the compensation balances trailer in kg wheel brake ETS02 006 ETS02 106 1201 1600kg 900 20 2425 1 25 2025 ETS02 007 ETS02 107 1601 2100 kg 1200 20 2425 1 25 2025 ETS02 008 ETS02 108 2101 2700 kg 1500 20 2425 1 25 2025 ETSO2 011 450 1000 kg 300 16 1365 ETSO2 011 600 1400 kg 450 20 2425 1 25 2025 ETS02 012 840 1800kg 600 20 2425 1 25 2025 ETSO2 013 11080 2400 kg 40 20 2425 1 25 2025 ETSO2 014 1440 3500 kg 1080 20 2425 1 25 2025 00 ETS02 015 360 900kg 240 16 1365 ETSO2 015 540 1200kg 360 20 2425 1 25 2025 ETSO2 016 720 1600kg 540 20 2425 1 25 2025 ETS02 017 960 2100kg 720 20 2425 1 25 2025 ETS02 018 1260 270
11. bundle using several hose clips or cable ties in a protected position Mounting and Operating Instructions ETS Model ETSO2 19 03 2010 V2 0 a ETS valve block in the trailer superstructure on the bracket at the trailer drawbar Remove the sealing plug at the actuating cylinder and at the ETS valve and dispose of it responsibly Connect the brake hose to the port at the actuating cylinder using the hexagonal screw M10 Tightening torque 15 3 Connection of the brake hose at the Nm actuating cylinder Lay the brake hose along the trailer frame on the underfloor of the trailer caravan from the actuating cylinder to the ETS valve block Fasten the brake hose every 300 mm using a hose clip Connect the brake hose to the port at the ETS valve block using the M10 hexagonal screw Tightening torque 15 3 Nm Connection of the brake hose at the ETS valve block V2 0 19 03 2010 Mounting and Operating Instructions ETS Model ETS02 KNOTT b HOBBY variant ETS valve block on the mover bracket at the HOBBY caravan chassis Lay the brake hose along the trailer frame or on the underfloor of the trailer caravan from the ETS valve as far as the actuating cylinder Fasten the brake hose every 300 mm using a hose clip Remove the sealing plug at the actuating cylinder and dispose of it responsibly Connect the brake hose to the port at the actuating cylinder using the M1
12. cylinder and the brake compensation balance at the bowden cable counterbearing for heavy soiling If necessary clean the actuating cylinder and the brake compensation balance at the bowden cable counterbearing V2 0 19 03 2010 Mounting and Operating Instructions ETS Model ETS02 KNOTT BRAKE AND TRAILER TECHNOLOGY 6 8 Troubleshooting Display Status Consequence Self help Display after self help Status after self help GREEN ETS active All OK continuous GREEN ETS active or Continued Readjust braking system in accordance with separate Turns GREEN continuous Continued driving possible flashing brake setting driving possible instructions Setting and adjusting the overrun braking system faulty RED ETS inactive or Continued Wai P Turns GREEN continuous All OK continuous self test not yet driving possible ait 10 seconds performed Unplug the 13 pin trailer cable from the towing vehicle Turns GREEN flashing Brake setting faulty Wait appr 5 seconds Turns RED continuous ETS inactive Connect the 13 pin trailer cable at the towing vehicle Continued driving possible look Visual inspection for repair workshop Check of brake fluid RED ETS braking Continued Turns GREEN continuous All OK flashing intervention or driving possible Check the parking brake release if applicable i are self test active after releasing Switch the ignition off for at least 10 seconds Turns RED continuous ETS ina
13. 0 hexagonal screw Tightening torque 15 3 Nm Connection of the brake hose at the actuating cylinder 4 2 6 Mounting the sensor Mounting position of the sensor Along the longitudinal trailer axis aS far as possible behind the axle but no more than 4000 mm behind the axle centre The optimum position for the sensor is 3000 mm behind the centre of the axle tube Mounting and Operating Instructions ETS Model ETSO2 19 03 2010 V2 0 GROUP KNOTT ADVICE Note the orientation of the sensor The arrow on the sensor housing must be pointing towards the front in the direction of travel The cable outlet is then also pointing forwards relative to the axle Mount the sensor housing using suitable screws not included in the scope of delivery to the underneath of the trailer Fasten the sensor cable using a cable clip View from below to the sensor marked on the trailer red arrow direction of travel V2 0 19 03 2010 Mounting and Operating Instructions ETS Model ETS02 GROUP BRAKE AND IO TECHNOLOGY D 4 2 7 Mounting the cable harness CAUTION Danger of fire due to short circuiting Do not connect the ETS system without a fuse Never connect the ETS system directly to the car battery CAUTION Short circuiting hazard as a result of incorrect laying Ensure that electrical installation is performed by a suitably qualified technician When laying the cables When connecting th
14. 0 kg 900 20 2425 1 25 2025 4 2 Mounting 4 2 1 Preparations Before starting the mounting process apply the parking brake at the trailer _ Secure the wheels with chocks Secure the trailer against tilting during mounting by Coupling to the towing vehicle or By using outriggers or supports at the front and back of the frame The ETS components are mounted in the following order see following chapter for details Mounting ETS component sequence See chapter Mounting and Operating Instructions ETS Model ETSO2 19 03 2010 V2 0 GROUP KNOTT Mounting ETS component Note See chapter sequence 2 Actuating cylinder Safety relevant 4 2 4 component We recommend having this mounted by a professional workshop 3 Brake hose Safety relevant 4 2 5 component We recommend having this mounted by a professional workshop 8 Cover on ETS valve 4 2 9 block WARNING Possible danger due to trailer instability No drilling or welding work may be performed on trailer frames or A frames V2 0 19 03 2010 Mounting and Operating Instructions ETS Model ETS02 GROUP KNOTT BRAKE AND TRAILER TECHNOLOGY 4 2 2 Mounting areas for ETS components Area for mounting ETS valve block in protected lscationlsprung mass Front edge of trailer structure Do not mount in cylinder storage ed box a Area for mounting Area for mounting optical Lateral accelerat
15. E The lighting switched power supply and continuous supply ground cables must NOT be connected to each other during electrical installation in the trailer a Laying the sensor cable to the plug coupling at the sensor Lay the sensor cable as far as the sensor plug coupling V2 0 19 03 2010 Mounting and Operating Instructions ETS Model ETS02 GROUP BRAKE AND lO TECHNOLOGY Insert the plug of the sensor cable into the sensor plug coupling Fasten the sensor cable every 300 mm using a cable clip Roll up any surplus cable to form a bundle and fasten the bundle using several hose clips in a protected location b Laying the cable with LED display Lay the cable with LED display as far as the LED display mounting position at the trailer drawbar Fasten the cable with LED display every 300 mm using a cable clip c Laying the electrical cable to the distributor box Lay the electrical cable as far as the distributor box of the trailer caravan Fasten the electrical cable every 300 mm with a cable clip ADVICE The distributor box and cable colours are NOT standardized For details of the function of the relevant cables refer to the operating instructions of the trailer caravan manufacturer Terminal plan 13 pin 12V Connect the electrical cable in the distributor box by connecting the White red core ground from the ETS cable in the distributor box to the switched gr
16. KNOTT BRAKE AND TRAILER TECHNOLOGY Mounting and Operating Instructions ETS Electronic Trailer Stabilization System Model ETS 02 77 i AN D 205743 001 Original Operating Instructions KNOTTjj BRAKE AND TRAILER TECHNOLOGY Contents _ md 2 2 2 2 3 2 4 2 9 2 6 3 1 3 2 3 3 3 4 3 5 3 6 3 1 3 8 4 1 4 1 1 4 1 2 4 2 4 2 1 4 2 2 4 2 3 4 2 4 4 2 5 4 2 6 4 2 1 4 2 8 ET e EEE E SEES EIEREE 4 Maniace aan ana aa aan an en Rani 4 PROV a irantisedsnentid actos ned BURSNEER EN cena EINE VEREIN essence eee 4 MART VAY ee E E 4 PUNCO een ae 5 AD PICS U 0 1 SRERRERERESERTEIIEEEBERTREREERERFEPRERRSERTSEEEEERERSPREEREETERERERSERSERTERTERERE 5 Overa VEN een 5 SCOPE Of SU DPLY barns ts asien ee nenne seen 6 Functional characteristics 00 202200220022002nnnnnennne nennen 8 Design features uuu00220suennnnnnennnnnnnnnnnnn nennen neuen nennen nennen 8 Oe ICA ONS ee ee ee 9 Safety INnsStrUCHIOnS a nn nee 10 Intended appliCatiON sserresrrsrresrerrrrrrrsrrr rens nin rrrr nenne nennen 10 Sale CORE Beeren seele 10 Misuse of the SyYSt M cccccsscceceeseeecsseeceesseeseeaseessegeeessees 10 Pe TAA AN Gls seen are 11 Mechanical NaZards cccccccecceecceseceeecceceeeeeeseeeeueeeneeseeees 11 Environmental PprOoteCtiON seesresresrrrrrresrrsrrrrrrnrrrr rerna rr rn rr nr an 11 Residual EIS Kane ee
17. a protected location View from below nn AD se Ready mounted LED display seen from the top 19 03 2010 Mounting and Operating Instructions ETS Model ETS02 GROUP KNOTT e Ready mounted LED display seen from below CAUTION Danger of short circuits due to cable damage The cable must never be exposed to abrasion pulled around sharp edges or crushed 4 2 9 Mounting the cover on the ETS valve block a ETS valve block within the trailer structure Drill fastening holes for the cover into the floor The cover can be used as a drilling template for this Drilling diameter appr 7 mm drilling depth 15 25 mm Agree the position of the boreholes with the trailer manufacturer as power cables water pipes can be laid in the floor particularly in the case of caravans Turn the cover upside down over the ETS valve block Fasten the cover at the bracket using the seven expanding rivets Knock in the mandrels of the expanding rivets using a hammer b ETS valve block on bracket at the towbar Mounting and Operating Instructions ETS Model ETSO2 19 03 2010 V2 0 KNOTT Turn the cover upside down over the ETS valve block Fasten the cover at the bracket using the seven expanding rivets Knock in the mandrels of the expanding rivets using a hammer c HOBBY variant ETS valve block on mover bracket at the HOBBY caravan chassis Fasten the cover
18. at the bracket using the seven expanding rivets Knock in the mandrels of the expanding rivets using a hammer 4 2 10 Venting the system CAUTION Risk of injury by toxic brake fluid Brake fluid is aggressive and toxic Take particular care when handling brake fluid V2 0 19 03 2010 Mounting and Operating Instructions ETS Model ETS02 GROUP KNOTT Unplug the 13 pin trailer plug from the towing vehicle ADVICE We recommend having a professional workshop vent the system by means of a pressure filling 1 Venting using on board equipment At the venting screw attach Say N a suitable collecting vessel made of plastic Open the venting screw by half a turn Connect the 13 pin trailer plug from the towing vehicle Wait for the self test This entails the ETS valve block first pumping to an adequate pressure level After reaching a pressure pulse of appr 1 second in duration the valve block switches to the actuating cylinder This flushes the air out of the connecting hose Unplug the 13 pin trailer plug from the towing vehicle After a pause of around 2 seconds reconnect the 13 pin trailer plug Repeat this process until no more air emerges from the venting screw of the actuating cylinder Close the venting screw with a tightening torque of appr 15 Nm Check the fluid level in the compensating tank and top it up with brake fluid DOT4 if necessary see Cha
19. at the axle is returned to its idle position 2 5 Design features The system is based on the following design features Trailer as an autonomous system Interfaces reduced to the ball hitch and 13 pin trailer plug max contact load capability 10A Consistent separation between the braking system and stabilization system Conventional overrun braking system as fallback Fail safe design i e in case of system failure no negative impact on trailer braking behaviour Communication of important statuses to the driver by signalling device Mounting and Operating Instructions ETS Model ETSO2 19 03 2010 V2 0 GROUP KNOTT BRAKE AND TRAILER TECHNOLOGY 1 4 Wheel brakes 12h Ove aa mm a tea Os Transmission unit I D one er ey m Actuating cylinder i Spring with integrated f Z 22 Lz oil damper a Yaw rate sensor cabins cable 2 colour display unit fel ets TS Venting device high presgure M q Venting device pressure Control processor integrated in the trailer to evaluate the yaw rate and 177 derive the correct actuating pressure to be applied at the wheel brakes El Pressure senior Pressure sensor Venting device high pressure y el i low pressure 2 6 Specifications Mounting location Vehicle frame on suspended axle Supply voltage 9 16V DC Max current consumption 6 A Operating temper
20. ature 20 C to 65 C range Operating medium Brake fluid DOT4 Weight ETS valve block 5 kg Actuating cylinder 1 2 kg Other components in total 2 5 kg V2 0 19 03 2010 Mounting and Operating Instructions ETS Model ETS02 BRAKE AND lO TECHNOLOGY 3 Safety instructions The ETS max only be used in combination with KNOTT components 3 1 Intended application The ETS is a retrofit safety system for trailers caravans with mechanical overrun braking system which can be used both in conjunction with single and tandem axles It automatically recognizes critical roll movements and where applicable intervenes to stabilize the tractor trailer rig by means of a selective braking action at the trailer The ETS only works with fixed drawbar trailers caravans 3 2 Safety concept The mechanical overrun braking system is strictly separated from all control circuits In the event of total failure of the vehicle computer system the actuating cylinder is returned to the starting position by the restoring springs so releasing the wheel brakes Because the wheel brakes are connected by means of the brake linkage to the mechanical overrun system the trailer braking system remains fully functional without restrictions even in this situation The control processor is fitted with an ingenious safety concept and is self monitoring 3 3 Misuse of the system Despite the enhanced safety assurance afforded by ETS never be tempted t
21. ctive i or parking brake the parking Switch the ignition back on Continued driving possible look applied brake Wait for the self test for repair workshop Drive the rig appr 50 metres at a speed of at least 10 kph Recheck the display LED ETS inactive Continued Restart troubleshooting as does not light driving possible Check whether continuous plus available switch on outlined by this table up ignition Unplug the 13 pin trailer cable from the towing vehicle Wait appr 5 seconds Plug in the 13 pin trailer cable at the towing vehicle Visual inspection Mounting and Operating Instructions ETS Model ETSO2 19 03 2010 V2 0 GROUP KNOTT Inthe case of problems which cannot be repaired on the basis of this table look for a Knott service support point or a repair workshop V2 0 19 03 2010 Mounting and Operating Instructions ETS Model ETS02 GROUP KNOTT 6 9 Service information If you have questions or problems look on our website www knott de or contact one of the following Knott service support points Country Company Tel Fax D Knott GmbH 49 9402 9317 0 49 9402 9317 99 KNOTT S p A 39 051 6516445 49 051 6516336 GB IRL KNOTT Avonride Ltd 44 1283 531541 44 1283 534840 USA KNOTT Brake Company 1 330 948 0144 1 330 723 2399 SK KNOTT spol s r o 421 33 69025 11 421 33 69025 55 O HU Autoflex Knott Kft 36 76 481515 36 76 481494 FIN Autoflex Knott OQ 358 955
22. e cables CAUTION Short circuiting hazard due to cable damage Only use supplied cables Do not guide cables around sharp edged corners Use corner edge protectors Do not lay cables near to devices where temperatures exceed 50 C Lay with a minimum distance of 10 cm from cables carrying mains voltage 230V Plug in the cable harness at the ETS valve block The cable harness branches into three individual cables a Sensor cable to the sensor plug coupling at the sensor b Cable with display LED to the mounting position of the LED display at the trailer drawbar c Electrical cable to the distributor box Guide the cable provisionally to the relevant end position Mounting and Operating Instructions ETS Model ETSO2 19 03 2010 V2 0 GROUP KNOTT If the cables have to be guided through floors or walls the position of the cable passage must be clarified with the caravan manufacturer Drill a hole in the caravan floor dia 15 mm Push through the cable Seal the hole in the caravan floor silicone rubber Plug coupling ETS connecting plug FF al Nyda iy Display unit 2 colour LED f p i i PIN 10 12 blue white i i ag ale Agel oe on Please note i Blue and white core Plus Red and white core Ground PIN 11 Ground to PIN 10 red white jj Vehicle plug 13 pin contacts seen from the front Wiring diagram ADVIC
23. fluid Check brake fluid Every two years Change brake for continued fluid usability Check actuating Check for heavy Depending If applicable cylinder and brake soiling on application clean actuating compensation conditions cylinder and brake balance compensation balance at the bowden cable counterbearing Cleaning Do not clean the 13 pin trailer plug and ETS system with a high pressure cleaner Visual inspection for damage Carry out a regular check of ETS components for damage Visual inspection of contacts for corrosion and correct fit Regularly check the trailer plug in connectors for corrosion missing contacts 19 03 2010 Mounting and Operating Instructions ETS Model ETS02 GROUP BRAKE AND lO TECHNOLOGY D 6 5 Check the brake fluid Check the filling level of the compensating tank of the ETS valve block once a year The brake fluid indicator must show a level between the minimum and maximum markings WARNING Danger of injury due to toxic brake fluid Brake fluid is aggressive and toxic Take particular care when handling brake fluid If necessary top up the brake fluid DOT4 Check the brake fluid every two years for continued usability If necessary change the brake fluid see following chapter 6 6 Changing the brake fluid 1 Changing using on board equipment Connect the 13 pin trailer plug at the towing vehicle Pull out the trailer plug connector shortl
24. from the 2009 season onwards Place the mover bracket on the bottom ridge of the longitudinal support Place the M10 safety screws through the drillholes 4 pcs Screw the self locking M10 nuts onto the safety screws Tighten them evenly to appr 45 5 Nm V2 0 19 03 2010 Mounting and Operating Instructions ETS Model ETS02 KNOTT Connecting the brake hose Place the ETS valve block on the bracket Remove the sealing plug at the ETS valve block and dispose of it responsibly Connect the brake hose to the port at the actuating cylinder using the hexagonal screw M10 Tightening torque 15 3 Nm Mounting the ETS valve block ADVICE Note the mounting direction Outgoing cable towards the back Place the cover on the ETS valve block Push the ETS valve block with the cover to its position on the bracket Screw the ETS valve block from below to the bracket using the two hexagonal screws M10 x16 using Mounting and Operating Instructions ETS Model ETSO2 19 03 2010 V2 0 GROUP KNOTT BRAKE AND TRAILER TECHNOLOGY washers A10 5 Tightening torque 45 5 Nm Do not fix the cover until assembly is complete see Mounting the cover on the ETS valve block Page 44 Finish mounted ETS valve block on the bracket of the HOBBY caravan chassis V2 0 19 03 2010 Mounting and Operating Instructions ETS Model ETS02 4 2 4 Mounting the actuating cylinder
25. he extension and the fork head with M10 hexagonal nuts yellow Tightening torque 45 5 Nm Minimum screw in depth in each case 15 mm Mounting and Operating Instructions ETS Model ETS02 19 03 2010 V2 0 GROUP KNOTT Hexagonal nut Extension Hexagonal nut Fork head lacked yellow Mi0 M10 blue locked yellow WARNING Danger of scraping or brakes running hot The intrinsic weight of long brake linkages can create a load on the wheel brake bowden cables If the brake linkage is longer than 1 5m Suspend brake linkage once so as to be FREELY MOVABLE IN THE LENGTHWAYS DIRECTION If the brake linkage is longer than 2 5m Suspend brake linkage twice so as to be FREELY MOVABLE IN THE LENGTHWAYS DIRECTION V2 0 19 03 2010 Mounting and Operating Instructions ETS Model ETS02 GROUP KNOTT BRAKE AND TRAILER TECHNOLOGY 4 2 5 Mounting the brake hose WARNING Danger of environmental pollution due to escape of brake fluid The brake hose must not be kinked under any circumstances Minimum laying radius 75 mm For rigid formation laying on the floor 50 mm The brake hose must not rub against any other parts in particular against hose guides At the actuating cylinder the brake hose must be laid in a wide arc as shown in the sketch to ensure that it is able to move freely when actuating the cylinder gt 200 mm I If the brake hose is too long Roll up the brake hose Fasten the hose
26. ion sensor signal display 2 colour LED i J MUSTbe f A Pa BE O eee visible when e 1 NR IN ty ie gt aS A coupling L et ANA S N er Area for mounting ETS Front edge of valve block with control trailer structure processor N Area f r mounting sks s kn jf Lateral acceleration sensor rea for mounting i PET a en i optical signal display RS ht ro Tete A us a F 7 2 calour LED n i N eee T g MUST be visible when EA EN N N H coupling vr kn BET OOOO OA u re z pa Lateral acceleration E z sensor centrally on For single axle measurements longitudinal axis relative to centre of axle Optimum position For tandem axle measurements 700mm behind centre relative to centre between two axle on short structures axles as far back as possible Far tridern axle measurements relative to centre of middle axle 4 2 3 Mounting the ETS valve block Mounting position of the ETS valve block Suitable and protected location in a horizontal position between the overrun coupling and axle optionally a in the trailer superstructure e g under the bench seat of a caravan b on the bracket directly on the drawbar c for HOBBY variant on mover bracket in line with mover hole pattern on the HOBBY caravan chassis from season Mounting and Operating Instructions ETS Model ETSO2 19 03 2010 V2 0 GROUP BRAKE AND lO TECHNOLOGY D 2009 underfloor mounting on the left seen in the direction of travel a
27. le at the counterbearing using nuts When doing so please note The slot of the washer must be turned 90 relative to the slot of the counterbearing The brake cables must be mounted in the oblong holes of the counterbearing at a distance which corresponds to the distance of the brake cable suspension of the Mounting and Operating Instructions ETS Model ETS02 19 03 2010 KNOTT brake compensation balance Retract the actuating cylinder manually and mount the restoring springs Mounting the actuating cylinder at the axle In order to mount the actuating cylinder with the assembled brake cables at the axle counterbearing proceed as follows Place the actuating cylinder against the axle counterbearing ADVICE To allow the brake cable with the assembled fork heads or mushroom shaped ends to be mounted when placing the actuating cylinder against the counterbearing the brake cables must be pushed downwards so that they can be suspended through the slots in the counterbearing V2 0 19 03 2010 Mounting and Operating Instructions ETS Model ETS02 KNOTT Position the washers and tighten the M12 8 lock nuts at a torque of 80 5 Nm Ifthe fork heads were removed mount them and secure with counternut Suspend the brake linkage in position if necessary using the linkage extension Tighten the screw unions between the brake linkage and the extension and between t
28. mounting the ETS valve block Check the freedom of movement of the handbrake lever by pushing the trailer caravan back by hand on a level surface at the same time applying the handbrake CAUTION Danger of injury caused by uncontrolled rolling of the trailer When carrying out this test ensure there is plenty of clearance to bring the trailer to a standstill without danger if the handbrake does not function correctly v2 0 19 03 2010 Mounting and Operating Instructions ETS Model ETS02 GROUP BRAKE AND TRAILER TECHNOLOGY D The hand held brake lever will now swivel backwards automatically as a result of the automatic reverse system During this movement the lever must not be obstructed in any way by any parts Danger of injury due to incorrect function of the braking system In the rearmost position of the handbrake lever a minimum distance of 50 mm must remain from any existing components Also check the jockey wheel for adequate clearance and optimum function in order to ensure troublefree later manoeuvring of the trailer Minimum clearance 50 mm Mounting and Operating Instructions ETS Model ETSO2 19 03 2010 V2 0 GROUP KNOTT c HOBBY variant Mounting by means of the mover bracket at the HOBBY caravan chassis Mounting the mover bracket ADVICE for HOBBY variant The mover bracket for the ETS valve block can only be mounted at the mover hole pattern of the HOBBY caravan chassis
29. n en ee eh me nee en 11 F RRE UV CS era teen ee ee ae 11 MOUNTO sisena aerei 12 COMICON ER 12 Selection of the system CONfiQJUratiON ssrrresrrrrrrrrrrrererrrrerrrrrrnrnn 12 Check of the right ETS SYStOM ccccccceceeeeeeeeeeeeeeeeeseeeeeeeeaeeeeeeeeaes 13 OUT euren zen riesen 14 PONAT IO Senne ee ee 14 Mounting areas for ETS COMPONENMS 0cccccceseeeeeeseeeeeeeeaeeeeeeeeaaes 16 Mounting the ETS valve DIOCK ccccccsseeeeeeeeeeeeeeeaeeeeeeesaaeeeeeesaaaees 16 Mounting the actuating CYliNCIGN sssesssressrresrrrererrerrrnrrrrer ennen ennen rer n nr ere n nan 26 Mounting the brake NOSG cccccssecccsssceeceescesseseeeseeseesseuseessuseessonss 32 Mounting the S NSOM ccccssccccssececsssececsseceeseeeeceeeeeeseseeseeeesnsaeeees 34 Mounting the Cable harNeSS sssmnesssrersrrssrrersrrerrrrrrrrrrrrrrrr nennen nennen nr nr nana 36 Mounting the LED CiSPlQY sssessrrssrrssrrrersrrerrrerrrrerrererrrrnrrrnrrrrrrrrrnr erna rna 39 Mounting and Operating Instructions ETS Model ETSO2 19 03 2010 V2 0 GROUP BRAKE AND IO TECHNOLOGY 4 2 9 Mounting the cover on the ETS valve DIOCK ccccccsseeeeeeeeeeeaeees 44 4 2 10 Venting the SYVStS Maracas sven sesevdecsivneaasaveadtauensesscebnieushivagyiarbesesedaettesvinvas 45 4 2 11 Final CHECKS viccacascessedssensecsiuccnacssvdvsccentesstectaceescaddeadenasnecsnsecaoeasendentseacsaes 47 9 PPET AU P ace ce cies ve cece onsale E
30. nging the brake fluid Mounting and Operating Instructions ETS Model ETSO2 19 03 2010 V2 0 GROUP BRAKE AND lO TECHNOLOGY D N Venting by means of pressure filling workshop Unscrew the protective cap from the compensating tank at the ETS valve block Connect a filling adapter and connect it with a filling device Apply appr 2 0 bar pressure to the system Vent the actuating cylinder using the venting screw until no more air bubbles appear Close the venting screw with a tightening torque of appr 15 Nm Test the fluid level in the compensating tank and if necessary top up with brake fluid DOT4 4 2 11 Final checks After the ETS has been mounted Check whether the LED display of the vehicle computer lights up when connecting the 13 pin trailer plug to the towing vehicle Using the 2 colour LED display the status of the system can be observed see Displays Page 50 Carry out a test drive paying particular attention to the function of the overrun braking system and also the automatic reverse system After the test drive check The temperature of the wheel brakes at the rim for abnormally high temperatures over 180 C of the kind that can occur for example as a result of an insufficiently released wheel brake running hot That the wheel brakes are running freely in order to avoid running hot When turning the wheels no scraping noises should be audible If the se
31. nstructions ETS Model ETSO2 19 03 2010 V2 0 GROUP KNOTT BRAKE AND TRAILER TECHNOLOGY Centre Dearing Bolt Hanclbrake level Minimum distance 400mm Free space between the bracket and the overrun coupling The bracket comprises two parts The bracket and the reinforcement ai Reinforcement Bracket V2 0 19 03 2010 Mounting and Operating Instructions ETS Model ETS02 Insert the bracket from below onto the right hand A frame section Insert the reinforcement under the bracket plate so that both the webs on the face sides are resting on the inside against the vertical web of the A frame Insert the ends of the bow screws with the correct length through the boreholes of the bracket and the reinforcement from above Screw the self locking nuts M10 onto the ends of the bow screws Tighten them evenly to appr 45 5 Nm Bracket with reinforcement mounted on the A frame Mounting and Operating Instructions ETS Model ETSO2 19 03 2010 V2 0 BRAKE AND lO TECHNOLOGY y Mount the ETS block on the bracket by placing the ETS valve block onto the bracket from above ADVICE Note the mounting direction Outgoing cable towards the back Screw the ETS valve block using two hexagonal screws M10 x16 with washers A10 5 to the reinforcement and the bracket from below Tightening torque 50 55 Nm ETS valve block mounted on the bracket at the A frame After
32. o enter into any safety risk Always adjust your driving speed to the weather the road surface and traffic situation Mounting and Operating Instructions ETS Model ETS02 19 03 2010 V2 0 GROUP 3 4 Fire hazard CAUTION Fire hazard The continuous plus pole of the 13 pin socket in the towing vehicle must be safeguarded by at least a 10A fuse 3 5 Mechanical hazards CAUTION Danger of crushing Only connect to the power supply AFTER mounting Never reach into the actuating cylinder s area of movement 3 6 Environmental protection DANGER Risk of environmental pollution due to ground water contamination Never pour brake fluid into the sewage system or allow to soak or drain away into the ground 3 7 Residual risks The driving stability of the trailer and the effectiveness of the ETS system depend to a high degree also on the tyre pressure the condition of the tyres and the position of the centre of gravity in the trailer structure elevated risk of tilting 3 8 Directives When mounting the ETS the technical and administrative regulations and directives of the country in which the vehicle is originally licensed must be observed V2 0 19 03 2010 Mounting and Operating Instructions ETS Model ETS02 GROUP KNOTT 4 Mounting 4 1 Conditions 4 1 1 Selection of the system configuration The ETS system ETSO2 is suitable for retrofitting on trailers caravans with single and tandem a
33. ound from the trailer cable pin 11 in the distributor box Connect the blue white core plus 12V from the ETS cable in the distributor box with the switched plus from the trailer cable pin 10 Roll up any surplus cable to form a bundle and fasten the bundle using several hose clips in a protected location Check the terminals Mounting and Operating Instructions ETS Model ETSO2 19 03 2010 V2 0 4 2 8 V2 0 GROUP KNOTTjj BRAKE AND TRAILER TECHNOLOGY Check of the terminals Plug in the 13 pin trailer cable at the towing vehicle _ Switch on the ignition in the towing vehicle Check the function of the lighting system at the trailer caravan Check the function of electrical consumers at in the trailer Check the LED of the LED display at the trailer drawbar see Displays Page 50 Mounting the LED display Preparing the LED display Push the rubber grommet at the cable back slightly Plug the cable core with the red plug marked 2 at the display LED pin marked R Plug the cable with the blue Blue 1 red 2 plug marked 1 at the other pin of the LED display Pull the rubber grommet back over the connector as far as the LED shank LED display connected to the cable harness Mounting position of the LED display Easily visible at the front on the trailer drawbar Select the mounting position in such a way that the LED display is placed in the visual range by the
34. rvice brake requires more than a 50 mm actuating distance when driving forward v2 0 19 03 2010 Mounting and Operating Instructions ETS Model ETSO2 GROUP KNOTT Check the brake system again in accordance with the special setting instructions of the overrun braking system Mounting and Operating Instructions ETS Model ETSO2 19 03 2010 V2 0 GROUP 5 Operation 9 1 Hitching up the trailer ADVICE Use of an adapter plug from the 7 pin socket on the towing vehicle to a 13 pin trailer plug is not admissible in conjunction with this system Hitch the trailer to the towing vehicle Crank up the supports Plug the 13 pin trailer plug in at the towing vehicle Hook the overrun brake breakaway cable into place Release the parking brake Remove the chocks if necessary Switch on the ignition run nr The ETS system launches a self test _ Check the LED display of the ETS system The LED initially lights up RED Once the system is ready for operation after around 3 seconds the LED lights up GREEN When the green LED is alight or flashing the tractor trailer rig is ready to drive 5 2 Unhitching Secure the trailer against rolling away by actuating the parking brake Secure the wheels with chocks Raise the drawbar with jockey and open the ball hitch Detach the overrun brake breakaway cable Unplug the 13 pin trailer plug at the towing vehicle Close the socket P P P P P
35. st never be exposed to abrasion pulled around sharp edges or crushed V2 0 19 03 2010 Mounting and Operating Instructions ETS Model ETS02 BRAKE AND lO TECHNOLOGY b Mounting on drawbar with enclosure When mounting the LED display in the enclosure only the inscribed cover plate is required from the supplied retainer Take off the enclosure in accordance with the manufacturer s instructions Drill three holes in the detached enclosure in accordance with the sketch below Two dia 3 3 5mm holes One dia 16 17 mm hole ADVICE Use the inscribed cover plate of the LED display shown punctured as a template to mark the drilling positions for instance with a pencil 200 50 Insert the cable with the LED display through the dia 16 17 mm hole from below Mounting and Operating Instructions ETS Model ETSO2 19 03 2010 V2 0 V2 0 Push the cover plate with the inscription onto the LED and tighten the nut by hand F Insert the two M3 D countersunk head screws from the upper side through aJ the cover plate and the I enclosure lt 2 Insert the shims from the e underneath Ses Use the lock nuts to turn the screw union as tight as possible by hand Fasten the enclosure again in accordance with the manufacturer s instructions Roll up any surplus cable to form a bundle and fasten the bundle using several hose clips in
36. vements r i ge gt the hydraulic m Display unit actuating cylinder 3 actuates the brake within just a few 13 pin trader plug ihe milliseconds Convenient information A two colour LED display shows the current status of the ETS system at all times V2 0 19 03 2010 Mounting and Operating Instructions ETS Model ETS02 GROUP KNOTT 2 3 Scope of supply Alongside the standard version the ETS system ETSO2 is also available in a version specifically designed for HOBBY Caravans from season 2009 denoted as HOBBY variant in these operating instructions Item Quantity Designation 1 Actuating cylinder ETS valve block complete Extension of brake linkage M10 M10 35 mm Retainer complete for display LED for HOBBY variant Cover plate for display LED 2 3 4 Bracket for ETS valve block complete for HOBBY variant Mover bracket for ETS valve block complete with fixing material Bow screw LH 60 mm LW 74 mm for bracket not applicable for HOBBY variant Bow screw LH 75 mm LW 74 mm for bracket not applicable for HOBBY variant Bow screw LH 90 mm LW 74 mm for bracket not applicable for HOBBY variant Cable harness with LED display 10 Sensor complete 11 12 13 Mounting and operating instructions N Cable clip Brake hose M10x1 outside 4500 mm HOBBY variant 1400 mm Cable tape 3 5 x 140 Pipe clip for brake hose 14 15 16 17 18 19 NO N oO Expanding rivet
37. xles Trailers with single axle Single axle with brake compensation balance and mounted ETS actuating cylinder case gt Case Single axle with brake compensation balance and mounted ETS actuating cylinder Trailer with tandem axle In trailers with tandem axle a distinction must be made between two types Tandem with central compensation The brake linkage branches to the bowden cable via case Il a Tandem with central compensation one brake compensation balance picture case II a or Mounting and Operating Instructions ETS Model ETSO2 19 03 2010 V2 0 GROUP KNOTT Tandem with axle by axle brake compensation balances The brake linkage branches to the bowden cables via axle by axle brake compensation balances picture case II b Case II b Tandem with axle by axle brake compensation balances Select the system configuration applicable to your trailer and then ensure the correct procedure for mounting the actuating cylinder on the axle 4 1 2 Check of the right ETS system Check the range for the admissible overall weight Also check the necessary minimum curb weight of the trailer caravan In accordance with the following table Check whether you have the right ETS system for your trailer In case of doubt please contact your dealer Single axle Tandem Weight range Required KNOTT wheel and tandem trailers with minimum brakes model axle trailers
38. y after starting the self test Unscrew the protective cap of the ETS valve block compensating tank Take out the sieve Extract the old brake fluid as far as possible from above for example using a disposable syringe Top up with fresh brake fluid DOT4 as far as the maximum marking Replace the sieve Screw the protective cap of the compensating tank back on Vent the system as described in Chapter 4 2 10 2 Changing using workshop equipment Connect the 13 pin trailer plug at the towing vehicle Mounting and Operating Instructions ETS Model ETSO2 19 03 2010 V2 0 Pull out the trailer plug connector shortly after starting the self test Unscrew the protective cap of the ETS valve block compensating tank Connect the filling adapter Connect the filling adapter to the filling device Apply appr 2 0 bar pressure to the system Connect the hose of a collecting tank to the venting device Open the venting screw by half a turn Flush the system through for appr 10 seconds Close the venting screw with a tightening torque of appr 15 Nm Remove the collecting tank Reduce the pressure from the filling device Unscrew the filling device from the compensating tank Screw the protective cap of the compensating tank back on rrrryrenpfFrf i T TF vt T 6 7 Checking the actuating cylinder and brake compensation balance Depending on the application conditions check the actuating

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