Author Topic: K1600GT - ESA - Hall Effect Sensor Error  (Read 8861 times)

RoyF

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K1600GT - ESA - Hall Effect Sensor Error
« on: August 23, 2015, 11:46:25 PM »
Hi,

I have a 2011 K1600GT, but the rear suspension is not adjusting (both damping and pre-load).

On connectiing the GS-911, I got the following error showing under XESA:-

XESA
480DB6: Hall effect sensor of rear ESA
The fault is not present now.
The fault occurred 199 times.
Logistics counter: 0
MIL set: No
Fault code history

ABS time - 16356717.00
Odometer - 31899.0 km
Engine Speed - 980.00
Vehicle Speed 94.0km/h



The full AutoScan outputs is below.
Interestingly, the Firmware date stated against the XESA is 14/10/02, which is the same day as the bike had it's 18,000 mile service.
If I clear the error log, I can get the error to reproduce immediately regardless of whether I switch the damping settings or the pre-load settings


If you could give me more detail of what to look for or any advice around the code, that would be appreciated, Is it related to the pre-load motor, damping motor or the central electronics? I would have thought that I would have only got the error when changing damping or pre-load settings but not both ??...Which leads me currently to gues it may be central electronics related ??

AutoScan Report

GS-911 version: 1503.2 Datapack version: 2.0 Serial Number: GS1 000 5** Registered to: ************
Date: 19/08/2015 Time: 11:25:12
Motorcycle Information
VIN: WB1060107CZY*****
Mileage: 21506.0 miles
Cluster date: 19 August 2015
Next service date: 02 October 2015
Next service distance: 24349 miles

XAUDIO
Controller:   0F8900
Serial Number:   6310814776
Manufacture Date (YY/MM/DD):   11/08/28
Program Count:   0
Program Count Maximum:   1024
Firmware Date (YY/MM/DD):   99/99/99
Number of FW configurations:   5
HW Electronics (HWEL):   
   Firmware ID:   0A46
   Firmware Version:   001.000.000
Bootloader (BTLD):   
   Firmware ID:   0FDE
   Firmware Version:   001.000.002
SW Memory Image (SWFL):   
   Firmware ID:   0A47
   Firmware Version:   001.004.000
SW Memory Image (SWFL):   
   Firmware ID:   0CBA
   Firmware Version:   001.004.000
Coding Data (CAFD):   
   Firmware ID:   0A48
   Firmware Version:   000.005.001
No fault codes found

XDWA
Controller:   0F8700
Serial Number:   ??
Manufacturer:   META System
Manufacture Date (YY/MM/DD):   11/09/13
Program Count:   1
Program Count Maximum:   1024
Firmware Date (YY/MM/DD):   14/10/02
Number of FW configurations:   4
HW Electronics (HWEL):   
   Firmware ID:   0A4C
   Firmware Version:   001.000.000
Bootloader (BTLD):   
   Firmware ID:   0A49
   Firmware Version:   001.000.000
SW Memory Image (SWFL):   
   Firmware ID:   0A4A
   Firmware Version:   001.006.003
Coding Data (CAFD):   
   Firmware ID:   0A4B
   Firmware Version:   001.005.005
No fault codes found

XESA
Controller:   0F8400
Serial Number:   
Manufacture Date (YY/MM/DD):   11/09/16
Program Count:   1
Program Count Maximum:   1024
Firmware Date (YY/MM/DD):   14/10/02
Number of FW configurations:   4
HW Electronics (HWEL):   
   Firmware ID:   08AC
   Firmware Version:   001.000.000
Bootloader (BTLD):   
   Firmware ID:   0897
   Firmware Version:   001.000.000
SW Memory Image (SWFL):   
   Firmware ID:   0898
   Firmware Version:   001.002.000
Coding Data (CAFD):   
   Firmware ID:   089A
   Firmware Version:   001.002.000
1 fault codes found:
480DB6   Hall effect sensor of rear ESA
The fault is currently present.

XBCO
Controller:   0F8A00
Serial Number:   1123628741
Manufacturer:   Loewe Lear
Manufacture Date (YY/MM/DD):   11/09/01
Program Count:   2
Program Count Maximum:   1024
Firmware Date (YY/MM/DD):   14/10/02
Number of FW configurations:   4
HW Electronics (HWEL):   
   Firmware ID:   08AF
   Firmware Version:   001.006.001
Bootloader (BTLD):   
   Firmware ID:   0891
   Firmware Version:   004.000.003
SW Memory Image (SWFL):   
   Firmware ID:   0892
   Firmware Version:   006.006.002
Coding Data (CAFD):   
   Firmware ID:   0893
   Firmware Version:   006.050.017
No fault codes found

XKOMBI
Controller:   0F8800
Serial Number:   0000014065
Manufacturer:   Preh
Manufacture Date (YY/MM/DD):   12/02/06
Program Count:   2
Program Count Maximum:   1024
Firmware Date (YY/MM/DD):   14/10/02
Number of FW configurations:   6
HW Electronics (HWEL):   
   Firmware ID:   08A7
   Firmware Version:   001.000.000
Bootloader (BTLD):   
   Firmware ID:   0C4D
   Firmware Version:   001.001.000
SW Memory Image (SWFL):   
   Firmware ID:   0CBC
   Firmware Version:   001.007.000
SW Memory Image (SWFL):   
   Firmware ID:   0CBB
   Firmware Version:   000.003.002
Coding Data (CAFD):   
   Firmware ID:   08A6
   Firmware Version:   001.006.018
Hardware Type (HWAP):   
   Firmware ID:   08A9
   Firmware Version:   255.255.255
No fault codes found

XFSA
Controller:   0F8000
Serial Number:   1123628428
Manufacturer:   Loewe Lear
Manufacture Date (YY/MM/DD):   11/08/24
Program Count:   2
Program Count Maximum:   1024
Firmware Date (YY/MM/DD):   14/10/02
Number of FW configurations:   4
HW Electronics (HWEL):   
   Firmware ID:   08B0
   Firmware Version:   002.005.001
Bootloader (BTLD):   
   Firmware ID:   0894
   Firmware Version:   004.000.000
SW Memory Image (SWFL):   
   Firmware ID:   0895
   Firmware Version:   006.005.006
Coding Data (CAFD):   
   Firmware ID:   0896
   Firmware Version:   006.024.010
No fault codes found

XASW
Controller:   0F8200
Serial Number:   1124300259
Manufacture Date (YY/MM/DD):   11/08/31
Program Count:   3
Program Count Maximum:   1024
Firmware Date (YY/MM/DD):   14/10/02
Number of FW configurations:   4
HW Electronics (HWEL):   
   Firmware ID:   089E
   Firmware Version:   000.003.000
Bootloader (BTLD):   
   Firmware ID:   089B
   Firmware Version:   001.002.000
SW Memory Image (SWFL):   
   Firmware ID:   089C
   Firmware Version:   001.004.000
Coding Data (CAFD):   
   Firmware ID:   089D
   Firmware Version:   001.000.004
No fault codes found

XRDC
Controller:   0F8100
Serial Number:   2311100757
Manufacturer:   Schrader
Manufacture Date (YY/MM/DD):   11/08/19
Program Count:   1
Program Count Maximum:   1024
Firmware Date (YY/MM/DD):   14/10/02
Number of FW configurations:   4
HW Electronics (HWEL):   
   Firmware ID:   0B49
   Firmware Version:   000.001.008
Bootloader (BTLD):   
   Firmware ID:   0CB1
   Firmware Version:   000.002.025
SW Memory Image (SWFL):   
   Firmware ID:   0CB2
   Firmware Version:   001.000.070
Coding Data (CAFD):   
   Firmware ID:   0B4B
   Firmware Version:   000.005.000
No fault codes found

XABS
Controller:   0F8300
Serial Number:   6033200167
Manufacturer:   Continental Automotive
Manufacture Date (YY/MM/DD):   11/09/10
Program Count:   2
Program Count Maximum:   1000
Firmware Date (YY/MM/DD):   14/10/02
Number of FW configurations:   3
HW Electronics (HWEL):   
   Firmware ID:   08BC
   Firmware Version:   001.000.000
Bootloader (BTLD):   
   Firmware ID:   08BA
   Firmware Version:   001.001.000
SW Memory Image (SWFL):   
   Firmware ID:   08BB
   Firmware Version:   002.001.000
No fault codes found

BMSX
Controller:   0F8B00
Serial Number:   0170010792
Manufacture Date (YY/MM/DD):   11/09/08
Program Count:   3
Program Count Maximum:   60
Factory I-Level:   K001-12-02-500
Actual I-Level:   K001-14-08-510
Firmware Date (YY/MM/DD):   14/10/02
Number of FW configurations:   5
HW Electronics (HWEL):   
   Firmware ID:   08A3
   Firmware Version:   002.000.000
Bootloader (BTLD):   
   Firmware ID:   0C49
   Firmware Version:   004.000.000
SW Memory Image (SWFL):   
   Firmware ID:   0CBD
   Firmware Version:   008.000.001
SW Memory Image (SWFL):   
   Firmware ID:   0CBE
   Firmware Version:   008.010.000
Coding Data (CAFD):   
   Firmware ID:   08A2
   Firmware Version:   000.003.010
VIN model year:   2012
No fault codes found

 

Many Thanks,

Roy.

schuppi

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Re: K1600GT - ESA - Hall Effect Sensor Error
« Reply #1 on: August 24, 2015, 10:41:06 AM »
Hello Roy,

at first welcome to GS-911 User Forum :)

Now, to figure it out:
-ESA detected short circuit or wiring break > check connectors and wiring
-DC-motor and hall sensor measuring > multimeter
-check ESA ecu > connectors and wiring

It is necessary to use a wiring diagram
Schönen Tag
Wolfgang
                                       talk less, drive more

RoyF

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Re: K1600GT - ESA - Hall Effect Sensor Error
« Reply #2 on: August 24, 2015, 11:12:12 AM »
Many Thanks for the reply Schuppi, much appreciated...

Couple of quick questions if I may?......Would I be right in thinking then that the ECU looks for a valid signal from the Hall Sensor (i.e not open circuit or short circuit) prior to starting either the damper or pre load motors? I was expecting that one of the motors might energise briefly prior to an error being logged but that doesn't seem to be the case?

Also, is the hall sensor only used in the Pre-load adjustment? If so how does the damper motor know it's position?

Thanks in advance,

Roy.

schuppi

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Re: K1600GT - ESA - Hall Effect Sensor Error
« Reply #3 on: August 24, 2015, 12:50:16 PM »
Hi Roy,
you're right.
DC-motor for pre-load will be disabled when faults are detected.  Damper motor is running and that are stepper motors who
gives feedback to the ecu.

Hope this helps
Schönen Tag
Wolfgang
                                       talk less, drive more

RoyF

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Re: K1600GT - ESA - Hall Effect Sensor Error
« Reply #4 on: August 24, 2015, 02:32:47 PM »
Thanks Schuppi,

I'll check the cables and connectors from the shock back to the ESA ECU first.

Looks like the pre-load sensor goes back to pins 57 & 58 on the ECU, and the pre-load motor goes back to pins 4 & 6. At least this is what my wiring diagram tells me for the R1200GS, GSA, R1200R and R1200RT, but will double check on the K1600 to make sure.

Regards,

Roy

schuppi

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Re: K1600GT - ESA - Hall Effect Sensor Error
« Reply #5 on: August 24, 2015, 09:22:30 PM »
Hello Roy,

ESA Hall
Connector X9736 Pin 2+3 > Yellow/brown + grey/white up to ECU pin 7+9

pre-load motor
Connector X9736 Pin 1+4 > Blue/grey + blue/yellow up to ECU pin 5+6
Schönen Tag
Wolfgang
                                       talk less, drive more

RoyF

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Re: K1600GT - ESA - Hall Effect Sensor Error
« Reply #6 on: August 25, 2015, 12:45:55 AM »
Thanks again Schuppi,

Just been and unplugged the rear pre-load plug and had a look........

On pins 2 & 3 the Yellow/brown & grey/white where they go down to the ESA in the top of the rear shock I have an open circuit, even with the meter right up on the 2meg range. Not sure if that is to be expected or not with a hall sensor?.

Whilst I was there, I did put 12v onto pins 1 & 4 and can get the preload motor to run all the way down to full pre-load and back up again to min pre-load when I swap the leads around, so at least I know the motor is working.

Is it looking like the sensor in the top of the shock or is there another test I can do to cnfirm?

Cheers Schuppi

Regards,

Roy

schuppi

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Re: K1600GT - ESA - Hall Effect Sensor Error
« Reply #7 on: August 25, 2015, 10:26:13 AM »
Hi Roy
this hall sensor is some thing like this :http://sensing.honeywell.com/vf401%20ps_005884-2-en_final_11dec09.pdf
but I just don't know how to measure it.

I would check the lines between ECU and sensor for breaks, also if connected the power supply to this sensor.

Hope this helps
Schönen Tag
Wolfgang
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RoyF

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Re: K1600GT - ESA - Hall Effect Sensor Error
« Reply #8 on: August 31, 2015, 08:35:29 AM »
Hi Schuppi,

I've had chance to look a bit deeper into my Hall Effect Sensor Error.

The wiring checks out, I used a pin in the wire between the ESA connector and the ESA unit on the shock and it all meters out good.

I also have a 2013 GSA with fully functional ESA fitted, I didn't go as far as removing the GSA rear shock to test it plugged into my K16 electronics, but it did give me some comparitve readings.

What I do know. Firstly, the stepper motor white plug for the damping. On both bikes, this meters out at around 40 ohms across both pairs of coils, so pretty happy that this is all ok. On the pre-load black plug, the outer two wires to the motor I conected a 12v battery to the other day and could wind the pre-load all the way down and back up, so I know the pre-load motor is good.
With the bike running, I can change between 'soft', 'normal' and 'sport', and the front end changes as it should, the rear however doesn't change at all, peobably as you mentioned in an earlier post the rear end is disabled as it is seeing an error.

This just leaves the two centre wires of the black plug for the Hall Effect Sensor.

Using my meter on 'diode' test range, my GSA was giving me 0.8 (volt drop) one way, and if I reversed the leads 1.9 the other way across the sensor. On my K1600, I was getting open circuit both ways. The supply going to one side of the hall effect sensor was around 8v on my GSA, but 12v on my K1600. I did read somewhere that anything from around 5v to 15v is a typical hall effect sensor supply voltage.

This is bringing me to the conclusion that the actual hall effect sensor in the ESA unit itself has gone, but not having an identical bike / ESA shock to compare it against I can't say for certain. It was interesting that the 2011 K1600 has a supply of 12v to the hall sensor, but my 2013 GSA has an 8v supply. Makes me wonder if the hall efect supply voltage has been turned down on the later bikes / software to improve component reliability?

I'm thinking that the next step may be a visit to the BMW dealer, see if their diagnostics / testing can go any deeper or if an ESA controller re-flash / upgrade has an outside chance to resolve it? When I interrogate the ESA with my GS-911, in the serial number field I get a row of strange characters, something like this ( ?* !. *  ?-!). Which makes me think there could be some firmware corruption here.

Although in my mind it's all pointing towards the sensor, I want to be 100% certain before spending a load of money on a new shock.

Appreciate your thoughts on this.

Many Thanks,

Roy.

schuppi

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Re: K1600GT - ESA - Hall Effect Sensor Error
« Reply #9 on: August 31, 2015, 11:47:04 AM »
#Using my meter on 'diode' test range, my GSA was giving me 0.8 (volt drop) one way, and if I reversed the leads 1.9 the other way across the sensor. On my K1600, I was getting open circuit both ways. The supply going to one side of the hall effect sensor was around 8v on my GSA, but 12v on my K1600#

Hello Roy,
very good measurements. Respect! 8)

That's why I think the hall-sensor is defective.

Schönen Tag
Wolfgang
                                       talk less, drive more

RoyF

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Re: K1600GT - ESA - Hall Effect Sensor Error
« Reply #10 on: September 03, 2015, 06:17:18 PM »
Hi Schuppi,

Latest is that I have the bike booked into my local BMW dealer on the 15th of September. I have asked them to:-

1) - Run their BMW diagnosis, see if that gives me anything new.
2) - Update all the bike S/W / F/W as needed.   
3) - Reflash the ESA F/W.
4) - Re-calibrate the rear ESA unit if it comes back to life. 

In that order as a guess. Like you, I'm 99% certain the sensor has gone, but this could be worth an outside shot at getting it working again.

I'll let you know the outcome from my visit a week on Tuesday, but in preparation, I have already requested through a couple of forum's if anyone has an old ESA unit somewhere I can get a sensor out of....... From BMW, I can only get a new unit complete at a new price is £1,600 ($2.5k) !! :( 

schuppi

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Re: K1600GT - ESA - Hall Effect Sensor Error
« Reply #11 on: September 03, 2015, 11:21:15 PM »
Hello Roy,
that are bad news.
I never had such a unit in my hands to disassemble it. Dont know if there is a way to change the hall-sensor :(

All the best to you
Schönen Tag
Wolfgang
                                       talk less, drive more

2wheeler

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Re: K1600GT - ESA - Hall Effect Sensor Error
« Reply #12 on: March 28, 2016, 09:20:44 PM »
Hello RoyF
Think You own os to tell the end of story regarding to your ESA problems.

RoyF

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Re: K1600GT - ESA - Hall Effect Sensor Error
« Reply #13 on: March 29, 2016, 11:58:02 AM »
The end result was that BMW said that there was a communications error reading rear ESA unit, they offered to investigate the wiring to the shock, but as I had already confirmed as far as I could that the sensor in the rear shock had gone open circuit, then checking the wiring to the unit was a pointless exercise..... The good news for me was that the dealer put in a goodwill claim with BMW, even though it was out of warranty, but with a full BMW service historay and added to that I also have an R1200GSA purchased new from the same dealer, then this added some weight and I paid 20% towards the cost of the new part. They replaced the shock and all has been well since, so never did have the chance to rip the old unit apart and try and fix the sensor.
 

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Re: K1600GT - ESA - Hall Effect Sensor Error
« Reply #14 on: March 30, 2016, 09:55:40 AM »
Congratulation  :)