WABCO Easy-Stop Basic, Easy-Stop Standard, TP-97147, TP-97153, TP-97145 Maintenance Manual

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EASY- STOP™ TRAILER

ABS: 2S/1M (BASIC AND

STANDARD), 2S/2M, 4S/2M

AND 4S/3M SYSTEMS

MAINTENANCE MANUAL

Service Notes

WARNING

CAUTION

NOTE

TORQUE

Important Information

This manual contains maintenance procedures for WABCO's Easy-StopTM Trailer Anti-Lock Braking System (ABS). The information contained in this manual was current at time of publication and is subject to change without notice or liability.

You must follow company procedures and understand all procedures and instructions before you begin to service or repair a unit. Some procedures require the use of special tools for safe and correct service. Failure to use special tools when required can cause serious personal injury to service personnel, as well as damage equipment and components.

WABCO uses the following notations to warn the user of possible safety issues and to provide information that will prevent damage to equipment and components.

A WARNING indicates that you must follow a procedure exactly. Otherwise, serious personal injury can occur.

A CAUTION indicates that you must follow a procedure exactly. Otherwise, damage to equipment or components can occur. Serious personal injury can also result, in addition to damaged or malfunctioning equipment or components.

Also Available from WABCO

ABS Tips

앫 Driver Tips (SP-93161)

앫 How to Brake with ABS audio cassette

(SP-94126)

앫 Driver Tips for Trailer ABS Warning Lamps

(TP-97132)

A NOTE indicates an operation, procedure or instruction that is important for proper service. A NOTE can also supply information that can help to make service quicker and easier.

This symbol indicates that you must tighten fasteners to a specific torque value.

Table of Contents

Asbestos and Non-Asbestos Fiber Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

Section 1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Section 2: System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Section 3: ABS Questions and Answers

The Electronic Control Unit (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

The ABS Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Types of Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Section 4: System Configurations

2S/1M Trailer ABS Configuration Installation Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

2S/2M Trailer ABS Configuration Installation Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

4S/2M Trailer ABS Configuration Installation Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

4S/3M Trailer ABS Configuration Installation Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Power Cable Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Section 5: Diagnostics

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Blink Code Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Diagnostic Tools For ECUs with External Diagnostic Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Normal Mode Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Repair Existing Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Section 6: Component Replacement

Wheel Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

ABS Relay Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

The ECU/Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

How to Install the Blink Code Diagnostic Tool into the SAE J1587 Diagnostic Connector . . . . . . . .30

Section 7: Sensor Adjustment & Component Testing

How to Test Wheel Speed Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Sensor Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Sensor Output Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Check ABS Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

ABS External Modulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Final Test Before Returning a Trailer to Service:

For ECU/Valve Assembly Part Number 472 500 011 0

(without external diagnostic connector) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

For ECU/Valve Assembly Part Numbers 472 500 012 0 and

S 472 500 013 0 (Units with External Diagnostic Connector) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Trailer Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Section 8: Appendixes

Appendix A: Expert Mode Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Appendix B: Reconfigure Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Appendix C: Warning Lamp Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

ASBESTOS FIBER WARNING

The following procedures for servicing brakes are recommended to reduce

NON-ASBESTOS FIBER WARNING

exposure to asbestos fiber dust, a cancer and lung disease hazard. Material Safety Data Sheets are available from WABCO.

Hazard Summary

Because some brake linings contain asbestos, workers who service brakes must understand the potential hazards of asbestos and precautions for reducing risks. Exposure to airborne asbestos dust can cause serious and possibly fatal diseases, including asbestosis (a chronic lung disease) and cancer, principally lung cancer and mesothelioma (a cancer of the lining of the chest or abdominal cavities). Some studies show that the risk of lung cancer among persons who smoke and who are exposed to asbestos is much greater than the risk for non-smokers. Symptoms of these diseases may not become apparent for 15, 20 or more years after the first exposure to asbestos.

Accordingly, workers must use caution to avoid creating and breathing dust when servicing brakes. Specific recommended work practices for reducing exposure to asbestos dust follow. Consult your employer for more details.

Recommended Work Practices

1. Separate Work Areas. Whenever feasible, service brakes in a separate area away

from other operations to reduce risks to unprotected persons. OSHA has set a maximum allowable level of exposure for asbestos of 0.1 f/cc as an 8-hour time-weighted average and 1.0 f/cc averaged over a 30-minute period. Scientists disagree, however, to what extent adherence to the maximum allowable exposure levels will eliminate the risk of disease that can result from inhaling asbestos dust. OSHA requires that the following sign be posted at the entrance to areas where exposures exceed either of the maximum allowable levels:

DANGER: ASBESTOS

CANCER AND LUNG DISEASE HAZARD

AUTHORIZED PERSONNEL ONLY

RESPIRATORS AND PROTECTIVE CLOTHING

ARE REQUIRED IN THIS AREA

2. Respiratory Protection. Wear a respirator equipped with a high-efficiency (HEPA)

filter approved by NIOSH or MSHA for use with asbestos at all times when servicing brakes, beginning with the removal of the wheels.

3. Procedures for Servicing Brakes.

a. Enclose the brake assembly within a negative pressure enclosure. The

enclosure should be equipped with a HEPA vacuum and worker arm sleeves. With the enclosure in place, use the HEPA vacuum to loosen and vacuum residue from the brake parts.

b. As an alternative procedure, use a catch basin with water and a biodegradable,

non-phosphate, water-based detergent to wash the brake drum or rotor and other brake parts. The solution should be applied with low pressure to prevent dust from becoming airborne. Allow the solution to flow between the brake drum and the brake support or the brake rotor and caliper. The wheel hub and brake assembly components should be thoroughly wetted to suppress dust before the brake shoes or brake pads are removed. Wipe the brake parts clean with a cloth.

c. If an enclosed vacuum system or brake washing equipment is not available,

employers may adopt their own written procedures for servicing brakes, provided that the exposure levels associated with the employer's procedures do not exceed the levels associated with the enclosed vacuum system or brake washing equipment. Consult OSHA regulations for more details.

d. Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA for

use with asbestos when grinding or machining brake linings. In addition, do such work in an area with a local exhaust ventilation system equipped with a HEPA filter.

e. NEVER use compressed air by itself, dry brushing, or a vacuum not equipped

with a HEPA filter when cleaning brake parts or assemblies. NEVER use carcinogenic solvents, flammable solvents, or solvents that can damage brake components as wetting agents.

4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filter or by wet wiping. NEVER use compressed air or dry sweeping to clean work areas. When you empty vacuum cleaners and handle used rags, wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA for use with asbestos. When you replace a HEPA filter, wet the filter with a fine mist of water and dispose of the used filter with care.

5. Worker Clean-Up. After servicing brakes, wash your hands before you eat, drink or smoke. Shower after work. Do not wear work clothes home. Use a vacuum equipped with a HEPA filter to vacuum work clothes after they are worn. Launder them separately. Do not shake or use compressed air to remove dust from work clothes.

6. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA filters with care, such as in sealed plastic bags. Consult applicable EPA, state and local regulations on waste disposal.

Regulatory Guidance

References to OSHA, NIOSH, MSHA, and EPA, which are regulatory agencies in the United States, are made to provide further guidance to employers and workers employed within the United States. Employers and workers employed outside of the United States should consult the regulations that apply to them for further guidance.

The following procedures for servicing brakes are recommended to reduce exposure to non-asbestos fiber dust, a cancer and lung disease hazard. Material Safety Data Sheets are available from WABCO.

Hazard Summary

Most recently manufactured brake linings do not contain asbestos fibers. These brake linings may contain one or more of a variety of ingredients, including glass fibers, mineral wool, aramid fibers, ceramic fibers and silica that can present health risks if inhaled. Scientists disagree on the extent of the risks from exposure to these substances. Nonetheless, exposure to silica dust can cause silicosis, a non-cancerous lung disease. Silicosis gradually reduces lung capacity and efficiency and can result in serious breathing difficulty. Some medical experts believe other types of non-asbestos fibers, when inhaled, can cause similar diseases of the lung. In addition, silica dust and ceramic fiber dust are known to the State of California to cause lung cancer. U.S. and international agencies have also determined that dust from mineral wool, ceramic fibers and silica are potential causes of cancer.

Accordingly, workers must use caution to avoid creating and breathing dust when servicing brakes. Specific recommended work practices for reducing exposure to non-asbestos dust follow. Consult your employer for more details.

Recommended Work Practices

1. Separate Work Areas. Whenever feasible, service brakes in a separate area away from other operations to reduce risks to unprotected persons.

2. Respiratory Protection. OSHA has set a maximum allowable level of exposure for silica of 0.1 mg/m asbestos brake linings recommend that exposures to other ingredients found in nonasbestos brake linings be kept below 1.0 f/cc as an 8-hour time-weighted average. Scientists disagree, however, to what extent adherence to these maximum allowable exposure levels will eliminate the risk of disease that can result from inhaling nonasbestos dust.

Therefore, wear respiratory protection at all times during brake servicing, beginning with the removal of the wheels. Wear a respirator equipped with a high-efficiency (HEPA) filter approved by NIOSH or MSHA, if the exposure levels may exceed OSHA or manufacturers' recommended maximum levels. Even when exposures are expected to be within the maximum allowable levels, wearing such a respirator at all times during brake servicing will help minimize exposure.

3. Procedures for Servicing Brakes.

a. Enclose the brake assembly within a negative pressure enclosure. The

b. As an alternative procedure, use a catch basin with water and a biodegradable,

c. If an enclosed vacuum system or brake washing equipment is not available,

d. Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA

e. NEVER use compressed air by itself, dry brushing, or a vacuum not equipped

4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filter or by wet wipi ng. NEVER use compressed air or dry sweeping to clean work areas. When you empty vacuum cleaners and handle used rags, wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA, if the exposure levels may exceed OSHA or manufacturers' recommended maximum levels. When you replace a HEPA filter, wet the filter with a fine mist of water and dispose of the used filter with care.

6. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA filters with care, such as in sealed plastic bags. Consult applicable EPA, state and local regulations on waste disposal.

Regulatory Guidance

as an 8-hour time-weighted average. Some manufacturers of non-

enclosure should be equipped with a HEPA vacuum and worker arm sleeves. With the enclosure in place, use the HEPA vacuum to loosen and vacuum residue from the brake parts.

carefully clean the brake parts in the open air. Wet the parts with a solution applied with a pump-spray bottle that creates a fine mist. Use a solution containing water, and, if available, a biodegradable, non-phosphate, water-based detergent. The wheel hub and brake assembly components should be thoroughly wetted to suppress dust before the brake shoes or brake pads are removed. Wipe the brake parts clean with a cloth.

when grinding or machining brake linings. In addition, do such work in an area with a local exhaust ventilation system equipped with a HEPA filter.

with a HEPA filter when cleaning brake parts or assemblies. NEVER use carcinogenic solvents, flammable solvents, or solvents that can damage brake components as wetting agents.

Section 1Introduction

1003290d

SERIAL NUMBER

EASY-STOP™ TRAILER ABS ECU/VALVE ASSEMBLY

DATE CODE FIRST TWO DIGITS = BUILD WEEK LAST TWO DIGITS = BUILD YEAR

PART NUMBER

Overview

This manual describes how WABCO's Easy-Stop™ Trailer Anti-Lock Braking System (ABS) works; answers some basic ABS questions; outlines procedures on how to adjust, test, remove and install ABS components, as well as how to test for faults in the system by using Blink Code Diagnostics; and illustrates ABS components and wiring and plumbing installation diagrams. This manual does not contain Original Equipment Manufacturer (OEM) installation instructions. New installations require the following documentation:

앫 Easy-Stop™ Basic (2S/1M without external

diagnostics): TP-97145

앫 Easy-Stop™ Standard (2S/1M, 2S/2M, 4S/2M

with external diagnostics): TP-97147

앫 Easy-Stop™ Standard (4S/3M with external

diagnostics): TP-97153

Section 1

Introduction

Figure 1.1

Scope of Blink Code Diagnostics in This Manual

This manual contains blink code diagnostics information and instructions for most of the ECU/Valve Assemblies listed in Ta bl e A — Scope of Blink Code Diagnostics. The serial and part numbers are located on the ECU/Valve Assembly. Refer to Figure 1.1 .

Table A — Scope of Blink Code Diagnostics

ECU/Valve Assembly Part Number

472 500 001 0 (Serial Number 3080002745 and lower)

472 500 001 0 (Serial Number 3080002746 and higher)

472 500 011 0 (Serial Number Not Applicable)

472 500 012 0 (Serial Number Not Applicable)

472 500 013 0 (Serial Number Not Applicable)

Blink Code Diagnostics

Contact WABCO for blink code diagnostics information.

See Section 5 and Appendix A and B.

See Section 5 and Appendix C.

See Section 5 and Appendix A, B and C.

Page 1

Section 1

1002071d

Introduction

Easy-Stop™ Trailer ABS Parts

Parts book PB-96133 lists WABCO Easy-Stop™ replacement parts. To obtain a copy, contact WABCO North America Customer Care at 855-228-3203.

What Is WABCO’s Easy-Stop™ Trailer ABS?

WABCO’s Easy-Stop™ Trailer ABS is an electronic, self-monitoring system that works with standard air brakes. The major components of the system are the Electronic Control Unit

(ECU)/Valve Assembly, ABS relay (modulator) valve, tooth wheel and wheel speed sensor.

Refer to Figure 1.2 .

ECU Part Numbers 472 500 001 0, 472 500 012 0 and 472 500 013 0 have an external diagnostics connector for use with a special diagnostic tool. These models are also compatible with an MPSI Pro-Link cartridge. ECU/Valve Assembly 472 500 011 0 does not have a diagnostic connector port. Diagnostic procedures for all of these ECUs are detailed in Section 5, "Diagnostics" of this manual.

Figure 1.2

9000 diagnostic tool and WABCO

The ABS configuration defines the number of wheel speed sensors and ABS relay valves used in a system. For example, a 2S/1M configuration includes two wheel sensors and one ABS relay valve. A 2S/2M configuration includes two wheel sensors and two relay valves. A 4S/2M configuration includes four wheel sensors and two ABS relay valves.

How Trailer ABS Works

WABCO ABS is an electronic system that monitors and controls wheel speed during braking. The system works with standard air brake systems.

ABS monitors wheel speeds at all times and controls braking during wheel lock situations. The system improves vehicle stability and control by reducing wheel lock during braking.

The ECU receives and processes signals from the wheel speed sensors. When the ECU detects a wheel lockup, the unit activates the appropriate modulator valve, and air pressure is controlled.

In the event of a malfunction in the system, the ABS in the affected wheel(s) is disabled; that wheel still has normal brakes. The other wheels keep the ABS function.

An ABS warning lamp lets drivers know the status of the system.

1 ECU/Valve Assembly 2 External ABS Relay Valve (not used in

1M configurations) 3 Tooth Wheel 4 Wheel Speed Sensor

Page 2

Section 2

1002072d

2S/1M BASIC

STANDARD

1002073c

1002074a

1002075a

1002076a

System Components

Section 2System Components

ECU/Valve Assembly

앫 12 volt

앫 Integrated ECU and ABS relay valve

앫 The 2S/1M Basic ECU/Valve Assembly does not

have an external diagnostics connector.

Figure 2.1

1 2S/1M Basic 2 Standard

Sensor with Molded Socket

앫 Measures the speed of a tooth wheel rotating

with the vehicle wheel.

앫 Produces an output voltage proportional to

wheel speed.

Figure 2.3

Sensor Spring Clip

앫 Holds the wheel speed sensor in close proximity

to the tooth wheel.

ABS External Valve

앫 Controls air pressure to the brake chambers

where it is plumbed.

앫 During ABS operation, the valve adjusts air

pressure to the brake chambers to control braking and prevent wheel lock.

앫 Used in conjunction with ECU/Valve Assembly

for 2M or 3M systems.

Figure 2.2

Figure 2.4

Sensor Extension Cable

앫 Two-wire cable with molded-on connector.

앫 Connects the wheel speed sensor to the ECU.

Figure 2.5

Page 3

Section 2

1002077a

1002078b

BLUNT END

INDUSTRY

STANDARD

1002079a

1002080a

System Components

Connection Cable for ABS External Valves

앫 Three-wire cable with connector.

앫 Connects the ABS external valve to the ECU.

앫 “Y” cable for use with 4S/3M configurations

also available.

Figure 2.6

Power Cables

앫 Connects power to the ECU and provides a

connection for the warning lamp.

앫 Available with blunt-end four- or five-wire cable

or four- or five-wire industry standard harness connector at one end.

앫 Molded connector on opposite end used to

attach cable to ECU.

Figure 2.7

Diagnostic Cable

앫 Provides for blink code diagnostics and

diagnostics using the MPSI Pro-Link

9000

diagnostic tool.

앫 Five-wire cable with over-molded connector to

ECU on one end and SAE J1587 diagnostic connector over-molded on the other end.

Figure 2.8

Diagnostic Tool

앫 Sealed switch and lamp that connects to the

SAE J1587 diagnostic connector.

앫 Used to activate blink code diagnostics,

reconfigure the ECU and test the ECU installation.

앫 Protective dust cap included.

앫 Designed to remain on the trailer at all times.

1 Blunt End 2 Industry Standard

Page 4

Figure 2.9

Section 2

1002081a

1002082a

1002083a

1002084a

1002085a

System Components

Diagnostic Cable Mounting Bracket

앫 Bracket used to mount the diagnostic cable

assembly to the trailer.

Figure 2.10

ECU/Valve Assembly Mounting Bracket

앫 Bracket used to remote mount the ECU/Valve

Assembly to the trailer frame.

Figure 2.11

Diagnostic Cable Assembly with Diagnostic Tool

앫 Diagnostic cable mounted to the bracket with a

diagnostic tool connected to the SAE J1587 diagnostic connector.

앫 Protective dust cap included.

Figure 2.13

Tooth Wheel

앫 A machined ring mounted to the

machined surface on the hub of each ABS-monitored wheel.

Diagnostic Cable Assembly with Protective Cap

앫 Diagnostic cable mounted to the bracket

with a protective cap on the SAE J1587 diagnostic connector.

Figure 2.12

Figure 2.14

Page 5

Section 2

NOTE

1003296a

1002094a

System Components

Installation Hardware Kit

앫 Contains Schedule 80 NPT pipe nipple fittings

and Grade 8, 3/8-inch SAE bolts for proper mounting of ABS components to the trailer frame or reinforced air tanks.

Figure 2.15

Easy-Stop™ Trailer ABS Warning Label

앫 Provides information about the operation of the

ABS warning lamp and illustrates blink code fault locations.

앫 Label is self-adhesive and is mounted on the

trailer near the ABS warning lamp.

앫 If there is no warning label on your trailer, let

your supervisor know. Labels are available from WABCO. Ask for Part Number TP-95172.

MPSI Pro-Link

앫 Provides diagnostic and testing capability for

ABS components.

앫 Requires a cartridge (version 4.0 or higher)

designed for use with WABCO ABS.

The Pro-Link® 9000 diagnostic tool is not available from WABCO. Contact Kent-Moore at 800-328-6657 to order.

Figure 2.16

9000 Diagnostic Tool

Page 6

Section 3ABS Qu estions and Answers

The Electronic Control Unit (ECU)

Section 3

ABS Questions and Answers

The ABS Warning Lamp

What is the function of the warning lamp?

How do you activate the ECU?

In a constant-powered system, the ECU activates and then begins a self-diagnostic check of the system when you turn the ignition ON. In a stoplight-powered system, the ECU activates when you apply the brakes. All trailers manufactured on or after March 1, 1998 will be equipped with ABS that has constant power capability with stoplight power as back-up.

What if the ECU finds a fault in an ABS component during normal operation?

If the ECU senses a fault in the system (with an ABS valve, for example), the ECU turns the trailer ABS warning lamp on and returns the wheel controlled by that valve to standard braking. Or, if the ECU finds a fault with one wheel speed sensor in a system that has four sensors on a tandem axle, the ECU uses information from the other sensor on the same side of the tandem to ensure continuous ABS function. The ECU continues to provide full ABS function to the wheels unaffected by system faults. However, the ECU will turn the trailer ABS warning lamp on to tell the driver a fault has been detected in the system.

How does the ECU respond to a wheel approaching lock-up?

The ECU directs the ABS relay valve to function as a modulator valve and adjust air pressure to the chambers up to five times a second. This pressure adjustment allows a wheel (or wheels) to rotate without locking.

The warning lamp enables a driver to monitor the ABS at all times. Refer to the OEM operating manual for the mounting location of the warning lamp.

How does the warning lamp operate?

How the warning lamp operates depends on whether the ABS is powered by stoplight or constant power:

앫 If the trailer was manufactured prior to February

28, 1998, or was manufactured outside of the United States, the ABS may be either stoplight or constant powered.

앫 If the trailer was manufactured March 1, 1998 or

later — and was manufactured in the United States — it will have constant power capability. This is mandated by Federal Motor Vehicle Safety Standard (FMVSS) 121.

Check your vehicle specification sheet to determine the type of ABS power. Ta b le B — Stoplight Power and Table C — Constant Power, in this section, illustrate warning lamp operation on stoplight and constant powered ABS systems.

Table B — Stoplight Power

System Power Comes from Activating the Stoplight Circuit.

Brakes Fault in System Vehicle Speed Warning Lamp

Released N.A. N.A. OFF

Applied NO Less than 4 mph ON for 3 seconds, then goes OFF.

Applied NO Greater than 4 mph Flashes once, then stays OFF for

Applied YES N.A. ON

remainder of stop.

Page 7

Section 3 ABS Questions and Answers

Table C — Constant Power

System Is Powered When Ignition Is Switched ON.

Brakes Ignition Fault in System Vehicle Speed Warning Lamps (Trailer and Dash)

Released OFF N.A. N.A. OFF

Released ON NO Less than 4 mph ON for 3 seconds, then go OFF.

Released ON NO Greater than 4 mph OFF

Released ON YES N.A. ON

Applied OFF NO Less than 4 mph ON for 3 seconds, then go OFF.

Applied OFF NO Greater than 4 mph Flash once, then stay OFF for

remainder of stop.

Applied OFF YES N.A. ON

Applied ON NO Less than 4 mph ON for 3 seconds, then go OFF.

Applied ON NO Greater than 4 mph OFF

Applied ON YES N.A. ON

An ECU with part number 472 500 001 0 manufactured prior to September 1997 requires all sensed wheels to detect a 4 mph signal to shut off the ABS warning lamp. Do not confuse this with a faulty ABS system. If the warning lamp stays on when the brakes are applied to a moving vehicle, service the ABS system.

Most trailers manufactured prior to February 1998 require that the brakes be applied to operate the ABS warning lamp. If the warning lamp stays on when the brakes are applied to a moving vehicle, service the ABS system.

What does the trailer ABS warning lamp mean to service personnel?

The trailer ABS warning lamp indicates the status of the trailer ABS. If it comes ON and stays ON when you apply the brakes to a moving vehicle, there is an ABS malfunction. It is normal for the lamp to come ON and go OFF to perform a bulb check, but it should not stay ON when the vehicle is moving above 4 mph. As with any safety system, it is important not to ignore this warning. If the warning lamp indicates a malfunction, the vehicle can be operated to complete the trip, but it is important to have it serviced as soon as possible using the appropriate maintenance manual to ensure proper braking performance and that the

benefits of ABS remain available to your drivers. Typical ABS warning lamp mounting locations are illustrated in Figure 3.1 .

Figure 3.1

1 Prior to March 1, 1998 2 On or after March 1, 1998

Typical ABS Warning Lamp Mounting Locations

For more information, contact WABCO North America Customer Care at 855-228-3203.

Page 8

ABS Questions and Answers

NOTE

Can you continue to operate a vehicle when the warning lamp indicates a fault?

Yes. When a fault exists in the ABS, standard braking returns to the affected wheel, and the ABS still controls other monitored wheels. This lets you complete the trip. You should not ignore the warning lamp and should have the vehicle serviced as soon as possible after the lamp comes ON and stays ON.

Types of Faults

What is a “fault” in the system?

A fault in the system is a problem that can exist in the ABS or in the system’s components. Faults can be either existing faults or intermittent stored faults.

What is an existing fault?

An existing fault is a problem that exists currently in the system. For example, a damaged sensor cable is an existing fault that the ECU will detect and store into memory until you identify the cause, repair the cable and clear the fault from the ECU.

Section 3

What is an intermittent fault?

An intermittent fault is a problem that usually occurs only under certain driving conditions. For example, the ECU may detect a loose cable or wire or receive an erratic signal from a wheel sensor. Since intermittent faults can be unpredictable and may only happen periodically, you can use information stored in ECU memory to find and correct the loose cable or wire.

Is an intermittent fault difficult to locate and repair?

It can be, because you may not be able to easily see the cause of the problem. WABCO recommends that you write down intermittent faults to help you isolate a fault that recurs over a period of time.

Can the ECU store more than one fault in memory?

Yes. And the ECU retains existing and intermittent faults in memory even when you turn OFF the power to the ECU.

For part number information, refer to PB-96133. Copies are available from the WABCO North America Customer Care at 855-228-3203.

Page 9

Notes

Page 10

Section 4

NOTE

1003292e

AIR TANK

ECU/VALVE

ASSEMBLY (YE)

YE1

YE2

A Service/Control Lines B Sensor Cables C Service to Brake Lines (Delivery Lines) D Air Supply/Emergency Lines

AIR TANK

System Configurations

Section 4System Configurations

2S/1M Trailer ABS Configuration Without External Diagnostics Capability Installation Diagram

Figure 4.1

A Service/Control Lines B Sensor Cables C Service to Brake Lines (Delivery Lines) D Air Supply/Emergency Lines

1 ECU/Valve Assembly (YE) 2 Air Tanks

For direct tank-mounted installations, see “How to Install the ECU/Valve Assembly,” in Section 6, "Component Replacement".

Typical Application:

Sensors may be installed on either axle, depending upon suspension and other vehicle characteristics.

앫 Single-Axle Dolly

앫 Single- and Tandem-Axle Semi-Trailer

Page 11

Section 4

NOTE

1002086f

AIR TANK

ECU/VALVE

ASSEMBLY (YE)

A Service/Control Lines B Sensor Cables C Service to Brake Lines (Delivery Lines) D Air Supply/Emergency Lines

AIR TANK

YE1

YE2

System Configurations

2S/1M Trailer ABS Configuration with External Diagnostics Capability Installation Diagram

Figure 4.2

For direct tank-mounted installations, see “How to Install the ECU/Valve Assembly” in Section 6, "Component Replacement".

A Service/Control Lines B Sensor Cables C Service to Brake Lines (Delivery Lines) D Air Supply/Emergency Lines

1 ECU/Valve Assembly (YE) 2 Air Tanks

Typical Application:

앫 Single-Axle Dolly

앫 Single- and Tandem-Axle Semi-Trailer

Page 12

Sensors may be installed on either axle, depending upon suspension and other vehicle characteristics.

System Configurations

NOTE

1002087e

BU1

AIR TANK

ECU/VALVE

ASSEMBLY (YE)

AIR TANK

YE1

A Service/Control Lines B Sensor Cables C Service to Brake Lines (Delivery Lines) D Air Supply/Emergency Lines

EXTERNAL

VALVE (BU)

2S/2M Trailer ABS Configuration Installation Diagram

Figure 4.3

Section 4

For direct tank-mounted installations, see “How to Install the ECU/Valve Assembly” in Section 6, "Component Replacement".

A Service/Control Lines B Sensor Cables C Service to Brake Lines (Delivery Lines) D Air Supply/Emergency Lines

1 ECU/Valve Assembly (YE) 2 Air Tanks 3 External Valve (BU)

Typical Application:

앫 Single- and Tandem-Axle Semi-Trailer

Sensors may be installed on either axle, depending upon suspension and other vehicle characteristics.

Page 13

Section 4

1002088e

YE1

YE2

EXTERNAL

VALVE (BU)

AIR TANK

BU1

BU2

AIR TANK

ECU/VALVE

ASSEMBLY (YE)

A Service/Control Lines B Sensor Cables C Service to Brake Lines (Delivery Lines) D Air Supply/Emergency Lines

System Configurations

4S/2M Trailer ABS Configuration Installation Diagram

Figure 4.4

A Service/Control Lines B Sensor Cables C Service to Brake Lines (Delivery Lines) D Air Supply/Emergency Lines

1 ECU/Valve Assembly (YE) 2 Air Tanks 3 External Valve (BU)

For direct tank-mounted installations, see “How to Install the ECU/Valve Assembly” in Section 6, "Component Replacement".

Typical Application:

앫 Tandem and Tri-Axle Semi-Trailer

Page 14

Section 4

1002089e

EXTERNAL

VALVE (BU)

AIR TANK

ECU/VALVE

ASSEMBLY (YE)

AIR TANK

A Service/Control Lines B Sensor Cables C Service to Brake Lines (Delivery Lines) D Air Supply/Emergency Lines

BU2 BU1

YE2

YE1

LIFT AXLE

FIXED AXLE

LIFT AXLE

FIXED AXLE

System Configurations

4S/2M Trailer ABS Configuration Diagram for Lift Axle Applications (Forward Lift Axle Installation Diagram)

Figure 4.5

A Service/Control Lines B Sensor Cables C Service to Brake Lines (Delivery Lines) D Air Supply/Emergency Lines

1 ECU/Valve Assembly (YE) 2 External Valve (BU) 3 Air Tanks 4 Lift Axle 5 Fixed Axle

For direct tank-mounted installations, see “How to Install the ECU/Valve Assembly” in Section 6, "Component Replacement".

Typical Application:

앫 Tandem and Tri-Axle Semi-Trailer

Page 15

Section 4

1002090e

EXTERNAL

VALVE (BU)

AIR TANK

ECU/VALVE

ASSEMBLY (YE)

AIR TANK

FIXED AXLE

LIFT AXLE

FIXED AXLE

LIFT AXLE

BU1

BU2

YE1

YE2

A Service/Control Lines B Sensor Cables C Service to Brake Lines (Delivery Lines) D Air Supply/Emergency Lines

System Configurations

4S/2M Trailer ABS Configuration Diagram for Lift Axle Applications (Rear Lift Axle Installation Diagram)

Figure 4.6

For direct tank-mounted installations, see “How to Install the ECU/Valve Assembly” in Section 6, "Component Replacement".

Typical Application:

앫 Tandem and Tri-Axle Semi-Trailer

A Service/Control Lines B Sensor Cables C Service to Brake Lines (Delivery Lines) D Air Supply/Emergency Lines

1 ECU/Valve Assembly (YE) 2 External Valve (BU) 3 Air Tanks 4 Fixed Axle 5 Lift Axle

Page 16

System Configurations

NOTE

1003293e

BU1

BU2

YE2

YE1

AIR TANK

ECU/VALVE ASSEMBLY (YE)

AIR TANK

EXTERNAL

VALVE (BU)

EXTERNAL

VALVE (RED)

A Service/Control Lines B Sensor Cables C Service to Brake Lines (Delivery Lines) D Air Supply/Emergency Lines

4S/3M Trailer ABS Configuration Installation Diagram

Figure 4.7

Section 4

A Service/Control Lines B Sensor Cables C Service to Brake Lines (Delivery Lines) D Air Supply/Emergency Lines

1 ECU/Valve Assembly (YE) 2 External Valve (RED) 3 External Valve (BU) 4 Air Tanks

Typical Application:

앫 Tandem with Lift Axle

앫 Tri-Axle Semi-Trailer

앫 Semi-Trailer with Lift Axle

앫 Full Trailer (Drawbar Trailers)

Sensors may be installed on either axle, depending upon suspension and other vehicle characteristics.

Page 17

Section 4

1003302e

4 OR 5 WIRE SCHEMATIC

P/N 449 315 XX0 0 OR 894 60X XXX 0 (INDUSTRY STANDARD CABLE)

ECU INTERNAL GROUND (5 WIRE CABLE ONLY)

TRAILER ABS

INDICATOR LAMP

IN TRACTOR

7 WAY

POWER

SOURCE

WHITE AND YELLOW

WHITE

(GROUND)

BLUE (CONSTANT POWER)

RED

(STOP LAMP)

GREEN AND WHITE

TRAILER ABS

INDICATOR LAMP

GROUND

Trailers Produced March 1, 1998 or Later

ECU POWER CONNECTOR

1003305d

CONSTANT POWER/STOPLIGHT POWER CIRCUIT

BLACK

YELLOW

BLUE

WHITE

BROWN

GREEN

RED

GREEN

RED/WHITE

RED

WHITE

Connect to Easy-Stop™.

SWITCHED 12 VOLTS DC

FROM TRACTOR

P/N 449 312 XX0 0

4 CONDUCTOR CABLE

Trailers produced prior to March 1, 1998.

Tractors produced during 1997 model year and later have the blue wire of the 7-way (SAE J560) connector wired to provide constant power to trailer ABS.

System Configurations

Power Cable Wiring Diagrams

Figure 4.8

Figure 4.9

Page 18

Power Cable Wiring Diagrams

1003303c

STOPLIGHT POWER CIRCUIT

WHITE

BLUE

BLACK

YELLOW

RED

BROWN

GREEN

RED

GREEN

INDICATOR LAMP

WHITE

Connect to Easy-Stop™.

P/N 894 604 19X 2

3 CONDUCTOR CABLE

Trailers produced prior to March 1998.

1003304c

WHITE

BLUE

BLACK

YELLOW

RED

GREEN

BROWN

WHITE

RED

RED/WHITE

RED

INDICATOR LAMP

GREEN

Connect to Easy-Stop™.

STOPLIGHT POWER CIRCUIT

P/N 449 312 XX0 0

4 CONDUCTOR CABLE

Trailers produced prior to March 1998.

Figure 4.10

Section 4

System Configurations

Figure 4.11

Page 19

Notes

Page 20

Section 5 Diag nosti cs

NOTE

WARNINGS

Section 5

Diagnostics

To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service.

The ABS is an electrical system. When you work on the ABS, take the same precautions that you must take with any electrical system to avoid serious personal injury. As with any electrical system, the danger of electrical shock or sparks exists that can ignite flammable substances. You must always disconnect the battery ground cable before working on the electrical system.

Introduction

Blink code diagnostic procedures in this section cover:

앫 ECU Part Number 472 500 011 0

WABCO Basic ECU without an external diagnostic connector

앫 ECU Part Number:

472 500 001 0

472 500 012 0

472 500 013 0

WABCO ECUs with external diagnostic connectors

This section covers Normal Mode diagnostics (Codes for system faults that cause the ABS warning lamp to come on and stay on when the vehicle is in operation.)

For ECU Part Numbers 472 500 012 0 and 472 500 013 0 ONLY:

If you do not have a diagnostic blink code tool, follow the procedure given for ECU 472 500 011 0 (see “Using the Blink Code” in this section), but use Table E — Normal Mode Fault Code Table to identify the fault codes.

For additional diagnostic procedures refer to:

Appendix A Expert Mode Diagnostics

(ECU P/Ns 472 500 001 0, 472 500 012 0, 472 500 013 0)

This mode is used to identify intermittent faults, such as a loose connector.

Appendix B Reconfigure Mode. Use only as

indicated in the reconfiguration table in Appendix B.

Appendix C Warning Lamp Diagnostics

(ECU P/Ns 472 500 011 0, 472 500 012 0, 472 500 013 0)

Blink Code Diagnostics

To use blink code diagnostics you need to know whether or not the ECU has an external diagnostic connector. See Section 2, "System Components" in this manual for details. If you are unable to make this determination, contact WABCO North America Customer Care at 855-228-3203 for assistance.

On-Site Assistance

WABCO has provided an ABS Trailer warning label that illustrates possible system fault locations. This label should be mounted on the trailer near the ABS warning lamp. If there is no ABS warning label on the trailer, let your supervisor know. Labels are available from WABCO. Ask for Part Number TP-95172.

Page 21

Section 5

1003306a

Diagnostics

Using the Blink Code

For ECU Part Number 472 500 011 0 without diagnostic connector:

1. Make sure the vehicle is stationary:

앫 Emergency brake ON

앫 Wheels properly chocked

2. Provide 12 volts DC power (9.5 to 14 volts is acceptable range) to the ECU/Valve Assembly.

3. Check the ABS warning lamp on the trailer. If:

앫 The warning lamp comes ON briefly, then

goes OFF: There is no fault in system.

앫 The warning lamp comes ON and stays ON:

There is an existing fault. Go to Step 4.

4. Check the blink code lamp on the ECU. See Figure 5.1 .

앫 If blink code lamp is OFF, there is no

system fault.

앫 If the blink code lamp is flashing, count the

number of flashes to identify the fault. Check

Table D — ECU Part Number 472 500 011 0 Blink Codes to determine the problem.

Follow the suggested corrective action.

Figure 5.1

1 Blink Code Lamp

Table D — ECU Part Number 472 500 011 0 Blink Codes

Blink Code Problem Area Action

4 Sensor YE1 (curbside sensor) Check sensor installation and connections.

Verify proper sensor resistance and air gap.

Make necessary repairs.

6 Sensor YE2 (roadside sensor) Check sensor installation and connections.

Verify proper sensor resistance and air gap.

Make necessary repairs.

10 ECU/Valve Assembly Verify proper installation. Make sure all connections

are secure.

If code continues, contact WABCO for assistance.

14 Power Supply Verify proper electrical installation and connections.

Check power supply.

Make necessary corrections.

15 ECU Failure Verify proper installation.

If code continues, contact WABCO for assistance.

Page 22

Section 5

NOTE

1002094a

1002092a

Diagnostics

Diagnostic Tools For ECUs with External Diagnostic Connectors

MPSI Pro-Link® 9000 Diagnostic Tool

(WABCO Cartridge Model J 38500-404)

The MPSI Pro-Link® 9000 diagnostic tool can test for existing and stored faults, read and clear fault codes, and test components, for WABCO tractor and trailer ABS.

Figure 5.2

MPSI Pro-Link

Kent-Moore offers Kit J 38500-404 that contains the WABCO ABS diagnostic cartridge, version 4.0 or higher, and the manual “WABCO ABS/ATC Systems,” which contains complete information and operating instructions for the MPSI Pro-Link 9000 diagnostic tool. Order the kit from KentMoore, 28635 Mound Road, Warren, MI 480923499; phone 800-345-2233.

Diagnostic Tool

Diagnostic Activation Tool

For ECU Part Numbers 472 500 001 0, 472 500 012 0 and 472 500 013 0.

Figure 5.3

The blink code diagnostic tool inserts into the SAE J1587 diagnostic connector to activate the blink code diagnostics, reconfigure the ECU and test ECU installation. (See “How to Install the Blink Code Diagnostic Tool into the SAE J1587 Diagnostic Connector” in Section 6, "Component Replacement".)

Normal Mode Diagnostics

If the blink code lamp displays a blink code for a fault that is not listed in the Normal Mode Fault Code Table or the Expert Mode Fault Code Table in Appendix A:

A J 38500-60A Deutsch cable is also required. It is available from Kent-Moore.

1. Visually inspect all connections and components.

2. Try to erase the fault from ECU memory. If you cannot erase the fault, a problem can exist within the ECU/Valve Assembly.

3. Contact the contact WABCO North America Customer Care at 855-228-3203.

Page 23

Section 5

1002095a

3 Flashes = Existing Fault = Sensor BU1

1S 1S

Power ON; ECU activated

S = Second(s)

Diagnostics

How to Test for Existing Faults Using the Normal Mode

When you use Normal Mode diagnostics, the blink code lamp displays a numerical fault code sequence for each existing fault, one at a time. If the ECU stores more than one existing fault in memory, you must repair the first fault before Normal Mode diagnostics will display the second existing fault. In the Normal Mode, the lamp only identifies the component that needs repair; for example, THREE FLASHES = SENSOR BU1. To identify and display intermittent faults, use Expert Mode diagnostics. (See Appendix A.)

The ECU stores existing faults into memory in the order in which they occur, but the blink code lamp displays the most recent fault first. To identify and display intermittent stored faults (such as a loose cable or wire) from ECU memory, you must use Expert Mode diagnostics.

To activate Normal Mode diagnostics:

1. The vehicle must be stationary. Power the ECU with 12 volts DC (9.5–14 is an acceptable range). The warning lamp on the trailer will come ON.

2. Locate the diagnostic tool: Plug the diagnostic tool into the diagnostic cable socket located usually on the right side of the trailer sub-frame.

Figure 5.4

1 Blink Code Switch 2 LED Lamp

6. When there are existing faults: You must repair

existing faults.

7. After you identify an existing fault, turn the

power to the ECU OFF. Repair the fault. Turn the power to the ECU back ON.

8. ECU Part Number 472 500 001 0: Repeat

Steps 3, 5, 6, and 7 until the blink code lamp goes OFF, comes back ON and remains ON. This sequence signals that there are no other existing faults.

ECU Part Numbers 472 500 012 0 and 472 500 013 0: Repeat Step 3. If there are no

other existing faults in the system, the blink code lamp will come ON, go remain OFF.

9. If you have just repaired a sensor fault, the ECU is “waiting” to see a 4-mph signal on sensed wheels. Until this 4 mph is sensed by the ECU, the ABS warning lamp on the trailer will remain ON.

OFF and

Table E — Normal Mode Fault Code Table

Blink Code Location

0 No Faults

3Sensor BU1

4Sensor YE1

5Sensor BU2

6Sensor YE2

7 Ext. Modulator (Red) 4S/3M Only

9 Ext. Modulator (BU)

10 ECU Modulator (YE)

14 System Configuration/Power

Supply

15 ECU Failure

Figure 5.5

3. Press the blink code switch once for one second and release the switch.

4. If there are no existing faults in the system: When activated, the blink code lamp will

–Come ON –Go OFF – Remain OFF

5. When there is an existing fault: The blink code lamp will flash between three and fifteen times to identify the existing fault. Refer to Table E —

Normal Mode Fault Code Table, below, for Normal Mode fault codes. See Figure 5.5 .

Page 24

Section 5

1002097b

1 S

8 Rapid Flashes =

ECU Faults Cleared

2.5 S

3 Flashes = I.D.

= 4S/2M

OFF

1 S

OFF

1 S

OFF

2.5 S

OFF

2.5 S

OFF

2.5 S

Continuously Identifies Configuration

Power ON; ECU activated

= light ON

S = Second(s)

Perform the ECU Installation Test.

Diagnostics

Repair Existing Faults

앫 With Normal Mode diagnostics, you must repair

an existing fault before you can identify and repair the next existing fault stored in ECU memory. Follow these steps:

앫 Turn off the power to the ECU.

앫 Repair the fault.

앫 Repeat Normal Mode diagnostics.

앫 Clear stored faults (if necessary).

How to Clear Repaired Faults from the ECU

1. Power the ECU with 12 volts DC (9.5–14.0 is an acceptable range).

2. To clear repaired faults from ECU memory, press the blink code lamp switch three times for one second each time as follows:

a. Depress the blink code lamp switch once

for one second. The lamp will come ON.

b. Release the switch for one second. The

lamp will go OFF.

c. Immediately depress the switch once for

one second. The blink code lamp will come back ON.

d. Immediately release the switch once

for one second. The blink code lamp will go OFF.

e. Immediately depress the switch once for

one second. The blink code lamp will come back ON.

f. Release the switch.

g. The blink code lamp will flash rapidly for

eight times to indicate that the repaired faults have been erased from ECU memory.

h. The lamp will continue to flash the

system configuration until you turn OFF the power to the ECU. System configuration codes are:

– 2 Flashes = 4S/3M

– 3 Flashes = 4S/2M

– 4 Flashes = 2S/2M

– 5 Flashes = 2S/1M

Blink Code Example (4S/2M Configuration)

Clear-All Mode

Figure 5.6

Page 25

Notes

Page 26

Section 6

NOTE

CAUTION

SENSOR

HOLDER

SPRING

CLIP

SPRING

CLIP TAB

SENSOR

1002100b

SENSOR

CABLE

1002101b

Component Replacement

Section 6Component Replacement

WARNINGS

To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service.

Block the wheels to prevent the vehicle from moving. Support the vehicle with safety stands. Do not work under a vehicle supported only by jacks. Jacks can slip and fall over. Serious personal injury can result.

Disconnect power from the ECU/Valve Assembly before you remove any components. Failure to disconnect power from the ECU can cause faults to be recorded and stored in ECU memory.

1. Apply a mineral oil-based grease that contains molydisulfide to the sensor spring clip and to the body of the sensor. The grease must be anti-corrosive and contain adhesive properties that will continuously endure temperatures from –40° to 300°F (–40° to 150°C).

2. Push the spring clip into the sensor holder from the inboard side, until the spring clip tabs are against the sensor holder. Push the sensor into the spring clip as far as possible. Refer to

Figure 6.1 .

Figure 6.1

Use the following procedures to avoid damage to the electrical system and ABS components.

When welding on an ABS-equipped vehicle is necessary, disconnect the power connector from the ECU.

Wheel Speed Sensor

How to Remove a Sensor

1. Follow the vehicle manufacturer's instructions to back off the slack adjuster and remove the tire, wheel and drum.

2. Hold the sensor, not the cable, and use a twisting motion to pull the sensor out of its mounting block.

3. Remove the spring clip from the mounting block.

4. Remove any fasteners that hold the sensor cable to other components.

5. Disconnect the sensor cable from the extension cable.

How to Install a Sensor

1 Sensor Holder 2 Spring Clip 3 Spring Clip Tab 4 Sensor

3. Route the sensor cable toward the brake chamber, over the brake spider, and behind the axle. Secure the cable to the axle between the brake spider and the suspension brackets. Continue to route the sensor cable behind the spring seats. Secure the cable to the axle one inch from the molded sensor plug. Refer to

Figure 6.2 .

Figure 6.2

Sensor locations vary according to suspension types. Typically, a spring suspension has sensors

on the forward axle, and an air suspension has sensors on the rear axle.

1 Sensor Cable

Page 27

Section 6

WARNING

CAUTION

WARNING

CAUTION

1002102b

Component Replacement

4. Install the wheel hub carefully, so that the tooth wheel pushes against the sensor as you adjust the wheel bearings. After installation there should be no gap between the sensor and the tooth wheel. During normal operation a gap of 0.04-inch is allowable.

5. Sensor Output Voltage Test: Use a Volt/Ohm meter to check the AC output voltage of the sensors while rotating the wheel at approximately one-half revolution per second. Minimum output must be greater than

0.2 volts AC. If minimum output is less than

0.2 volts AC, push the sensor toward the tooth wheel. Recheck the sensor output.

ABS Relay Valve

Figure 6.3

How to Install a Standard ABS Relay Valve

You must use Schedule 80 pipe nipple (3/4-inch NPT) to nipple-mount the ABS relay valve securely to the reinforced air tank to avoid possible serious personal injury and damage to components.

1. Install the valve with two lock nuts and washers as required. Tighten the hex nuts to a torque of 18 lb-ft (24 N폷m) or nipple-mount the valve directly to the air tank with Schedule 80 pipe nipple (3/4-inch NPT).

2. Connect the air lines to the ports according to the labels installed when the air lines were disconnected.

3. Connect the cable to the valve.

4. Pressurize the brake system. Apply the brakes and verify there are no air leaks.

The ECU/Valve Assembly

Release all pressure from the air system before you disconnect any components. Pressurized air can cause serious personal injury.

How to Remove a Standard ABS Relay Valve

1. Release all pressure from the air system.

2. Disconnect the cable from the valve.

3. Attach labels to identify all of the air lines.

4. Disconnect the air lines from the valve.

5. Remove the mounting fasteners if the valve is not nipple-mounted directly to the air tank.

6. Remove the valve.

Release all pressure from the air system before you disconnect any components. Pressurized air can cause serious personal injury.

The ECU and valve assembly are sealed together as one unit. To ensure product integrity and avoid possible damage to the components, do not attempt to separate the ECU from the valve.

How to Remove the ECU/Valve Assembly

1. Release all pressure from the air system.

2. Attach labels to identify all air lines.

3. Disconnect the air lines from the ECU/Valve Assembly.

4. Disconnect the power cable, diagnostic cable, additional relay valve cable (if used), and all sensor cables from the ECU/Valve Assembly. Refer to Figure 6.4 .

5. Remove the ECU/Valve Assembly from its mounting location:

a. Bracket-mounted: Loosen and remove the

two mounting bolts and lock nuts that hold the assembly to the mounting bracket. Remove the assembly.

b. Nipple-mounted to Air Tank: Unscrew the

assembly from the air tank.

Page 28

Section 6

NOTE

CAUTION

1002103c

1002104b

BRACKET

Plug unused port

MODULATOR

POWER

DIAGN.

YE2

YE1

BU1

BU2

1002105c

Component Replacement

6. If the assembly being replaced is under warranty, please return it to the trailer OEM for replacement.

How to Install the ECU/Valve Assembly

The ECU/Valve Assembly is supplied with black protective caps on each sensor connector.

When a sensor cable is not plugged into a sensor connector, the black cap must remain on the connector to protect it from dirt and contamination. See Figure 6.4 .

Figure 6.4

Figure 6.5

1 Bracket

Plug unused port.

You must use a Schedule 80 pipe nipple (3/4-inch NPT) to nipple mount the ECU/Valve Assembly securely to the air tank to avoid possible serious personal injury and damage to components.

1. Attach the ECU/Valve Assembly to the vehicle:

a. Bracket-mounted: Use two 3/8-inch Grade

8 bolts with prevailing torque nuts to attach the assembly to the mounting bracket. Tighten to 18 lb-ft (24 N폷m).

Plug unused supply port (Port 1). Refer to Figure 6.5 .

b. Nipple-mounted to air tank: Attach the

ECU/Valve Assembly to the air tank, using a Schedule 80 pipe nipple (3/4-inch NPT). Tighten securely with exhaust port facing down. Do not overtighten.

1 Control Port (Port 4) 2 Black Protective Caps on Unused

Cable Connectors

3 External Relay Valve Cable

Plug unused supply port (Port 1). Refer to

Figure 6.6 .

Figure 6.6

4 Supply Port (Port 1) 5 Sensor Cables 6 Port 2 (Any Port May Be Used) 7 Diagnostic Cable (if applicable) 8 Power Cable

* Plug unused port. Use front supply port

for bracket-mounted. Use rear port for nipple mount.

Plug unused port.

Page 29

Section 6

NOTE

1002106b

SAE J1587 CONNECTOR

1002107b

Component Replacement

2. Connect the air lines to the ports. Follow the label markers installed when the air lines were disconnected.

3. Connect the sensor cables, external relay valve cable (if used), diagnostic cable, and power cable to the ECU/Valve Assembly. Use the black protective connector caps included with the replacement assembly to cover unused cable connectors.

4. Test the installation using blink code diagnostics

5. Perform the “Final Test Before Returning A Trailer to Service” test in Section 7.

How to Install the Blink Code Diagnostic Tool into the SAE J1587 Diagnostic Connector

The blink code switch and LED lamp are sealed against dust and contaminants. The red dust cap protects the switch and lamp during use but is not an integral part of the diagnostic tool.

1. Remove the grey protective cap from the SAE J1587 diagnostic connector. Figure 6.7 .

a. Turn the cap counterclockwise.

b. Pull off the cap.

2. Install the diagnostic tool into the diagnostic connector.

a. Align the notch on the diagnostic tool with

the notch on the diagnostic connector. Refer to Figure 6.8 .

b. Push the diagnostic tool firmly into the

connector. Refer to Figure 6.8 .

You must replace the grey protective cap if you remove the diagnostic tool from the diagnostic connector. Dirt and contaminants can damage the connector.

c. Rotate the grey ring on the diagnostic tool

to securely lock the diagnostic tool into the plug.

Figure 6.8

1 Diagnostic Connector

3. If the diagnostic tool will remain permanently installed into the connector:

a. Remove the protective cap and guide wire

that are attached to the mounting bracket.

Figure 6.7

1 SAE J1587 Connector

Page 30

b. Attach the diagnostic tool and guide wire to

the mounting bracket.

Sensor Adjustment & Component Testing

NOTE

1003297a

GROUND TERMINAL

EXHAUST SOLENOID

INLET

SOLENOID

4003950a

Section 7Sensor Ad justment & Compone nt Testing

How to Test Wheel Speed Sensors

At initial installation, no gap must exist between the sensor and the tooth wheel.

After you install a hub, always check that the sensor is adjusted properly.

Operating the trailer can cause a gap to develop between the sensor and the tooth wheel. If the gap exceeds 0.040-inch, the system may not function correctly.

To adjust the sensor, twist and push the sensor through the sensor bracket as far as possible or until the sensor touches the tooth wheel.

Section 7

Check ABS Functions

앫 WABCO recommends that you test a vehicle's

ABS after a new installation and after you diagnose, repair and erase faults in the ABS.

앫 Perform installation tests and blink code

diagnostics using the blink code diagnostic tool or the MPSI Pro-Link Model J 38500-404, version 4.0 or higher).

9000 (WABCO Cartridge

ABS External Modulator Valve

Measure resistance across each valve solenoid coil terminal and ground on the ABS valve to ensure

4.0 to 8.0 ohms. Valve and cable pinouts are illustrated in Figure 7.1 .

Sensor Test Procedure

1. Disconnect power to the ECU/Valve Assembly.

2. Disconnect the sensor electrical connector from the ECU/Valve Assembly.

3. Connect the Volt/Ohm meter leads to the two wire component terminals inside the disconnected connector.

4. When checking the resistance, the meter must read 500–2000 ohms.

5. Check and replace the sensor and cables as required.

6. Repeat Steps 1-5 for each sensor in the system.

Sensor Output Voltage Test

1. Disconnect power from the ECU/Valve Assembly.

2. Connect the AC Volt/Ohm meter leads to the sensor terminals inside the connector.

3. Rotate the corresponding wheel at a constant speed of one-half revolution per second.

4. The output voltage must be greater than

0.2 volts AC.

5. When there is no reading:

a. Trace the cable to verify that the cable

connects to the wheel you turned.

b. Check that you turned the correct wheel.

c. Check that the system is wired correctly.

d. Check that the sensor touches the

tooth wheel.

6. If the Volt/Ohm meter still indicates no reading or a low reading after following the above

procedures, check and replace the component and cables as required.

7. Repeat Steps 1-5 for each sensor in the system.

Figure 7.1

앫 To check the cable and the ABS valve as one

unit, measure resistance across the pins on the ECU connector of the harness. See Figure 7.2 .

– For 2S/1M, 2S/2M, and 2S/4M systems,

measure the resistance across pins 1 and 3 and pins 2 and 3.

– For 4S/3M systems (“Y” cable connectors),

measure across pins 3 and 4 and pins 3 and 5.

– Resistance should be between 4.0 and

8.0 ohms for each measurement. Figure 7.2 .

Figure 7.2

1 Exhaust Solenoid 2 Inlet Solenoid 3 Ground Terminal 4 Exhaust Solenoid (4S/3M only) 5 Inlet Solenoid (4S/3M only)

앫 If the resistance is greater than 8.0 ohms clean

the electrical contacts in the solenoid. Check the resistance again.

Page 31

Section 7

NOTE

Sensor Adjustment & Component Testing

Final Test Before Returning a Trailer to Service

For ECU/Valve Assembly Part Number 472 500 011 0 (without external diagnostic connector)

If you are testing ECU 472 500 001 0, contact WABCO North America Customer Care at 855-228-3203.

ABS Electrical/Hardware Installation Test

1. Provide 12 volts DC power (9.5–14 volts is an acceptable range) to the ECU/Valve Assembly.

– Suggested power source: 12-volt battery.

Table F — ECU Part Number 472 500 011 0

If Status Action

Trailer ABS warning lamp does not come ON.

Blink code lamp on ECU does not come ON.

Trailer ABS warning lamp comes ON.

AND # Blinks Location

Blink code lamp on ECU continues to flash.

Trailer ABS warning lamp comes ON and stays ON.

AND

ECU clicks twice.

AND

Blink code lamp on ECU comes ON briefly, then goes OFF.

Trailer ABS warning lamp comes ON for 3 seconds, then goes OFF.

AND

ECU clicks twice.

AND

Blink code lamp on ECU comes ON briefly, then goes OFF.

Minimum power requirement not met or wiring problem exists.

Hardware fault code Identify fault location. Make

Proper hardware installation. Perform Sensor Installation Test.

Proper hardware installation.

Proper sensor installation.

2. Observe the ABS warning lamp and the blink code lamp on the ECU. Check the results in Ta bl e F.

Check electrical connections and power source. Make necessary repairs.

necessary repairs to the installation:

4 Sensor YE1 (curbside)

6 Sensor YE2 (roadside)

10 ECU/Valve Assembly

14 Power Supply

15 ECU Failure

None required.

Page 32

Sensor Adjustment & Component Testing

ABS Sensor Installation Test (ECU Part Number 472 500 011 0)

1. Remove power.

2. Raise both sensed wheels off of the ground. Apply air to emergency line to fill air tanks and release parking brake.

3. Provide 12 volts DC power (9.5–14 volts is an acceptable range) to ECU/Valve Assembly. (Make sure trailer ABS warning lamp and ECU blink code lamp operate correctly, as described in “ABS Electrical/Hardware Installation Test”.)

4. Rotate the sensed wheels — ONE AT A TIME — at a rate of 1/2 revolution per second.

5. Check Table G — Sensor Installation Test, “Sensor Installation Test.”

Table G — Sensor Installation Test

If Status Action

Trailer ABS warning lamp goes OFF.

Trailer ABS warning lamp does not go OFF.

AND

There is no blink code flashing on the ECU.

ECU senses proper speed. Sensors properly installed.

There is a sensor gap problem.

No further testing required.

Adjust sensor gap. Push sensor into its holder until it contacts the tooth wheel.

Measure the AC voltage output. Value should be 0.2 volts AC when wheel is rotated at a rate of 1/2 revolution per second.

Section 7

Trailer ABS warning lamp does not go OFF.

AND

Blink code is on and flashing on ECU.

Table H — Blink Code Table

Blink Code

4Sensor YE1

6Sensor YE2

10 ECU/Valve

Problem Area Action

Check sensor installation. (curbside sensor)

(roadside sensor)

Assembly

Make necessary repairs.

Check sensor installation.

Make necessary repairs.

Verify proper installation.

If blink code continues,

contact WABCO for

assistance.

Make necessary repairs.

System fault exists. Count the number of flashes.

This is the blink code.

Using Table H — Blink Code Table, identify the blink code.

Make necessary repairs.

Blink Code

14 Power

15 ECU

After making the necessary corrections, repeat the sensor installation test to verify proper sensor installation.

Problem Area Action

Verify proper electrical

Supply

Failure

installation. Check power supply. Make necessary corrections.

Verify proper installation. If code continues, contact WABCO for assistance.

Page 33

Section 7

NOTE

Sensor Adjustment & Component Testing

For ECU/Valve Assembly Part Numbers 472 500 012 0 and S 472 500 013 0 (Units with External Diagnostic Connector)

If you are testing ECU Part Number 472 500 001 0, contact WABCO North America Customer Care at 855-228-3203.

ABS Electrical/Hardware Installation Test

1. Provide 12 volts DC (9.5–14 volts is an acceptable range) to the ECU/Valve Assembly. Suggested power source: 12-volt battery.

2. Observe the ABS warning lamp and the blink code lamp on the ECU. Check the results in Ta bl e I .

Ta b le I

If Status Action

Trailer ABS warning lamp does not come ON.

Blink code lamp on ECU does not come ON.

Trailer ABS warning lamp comes ON.

AND # Blinks Location

Blink code lamp on ECU continues to flash.

Trailer ABS warning lamp comes ON and stays ON.

AND

ECU clicks twice.

AND

Blink code lamp on ECU comes ON briefly then goes OFF or flashes 14 times, then goes out.

Trailer ABS warning lamp comes ON for 3 seconds, then goes OFF.

AND

ECU clicks twice.

AND

Blink code lamp on ECU comes ON briefly, then goes OFF.

Minimum power requirement not met or wiring problem exists.

Hardware fault code Identify fault location. Make

Proper hardware installation. Perform Sensor Installation Test.

Proper hardware installation.

Proper sensor installation.

Check electrical connections and power source. Make necessary repairs.

necessary repairs to the installation:

3Sensor BU1

4Sensor YE1

5Sensor BU2

6Sensor YE2

7 External Modulator (Red)

9 External Modulator (BU)

10 ECU Modulator (YE)

14 System Configuration or

15 ECU (contact WABCO)

None required.

4S/3M only

Power Supply

Page 34

Section 7

1002093a

1003299a

SLACK ADJUSTER

Sensor Adjustment & Component Testing

Sensor Installation Test (ECU Part Numbers 472 500 012 and 472 500 013 0)

Purpose of Test: To verify proper sensor gap, sensor hook-up to the ECU, ABS valve operation, and pneumatic plumbing connections of the WABCO Easy-Stop™ ABS on a new trailer.

1. Remove power from the ABS.

2. Raise sensed wheels so that they may be rotated.

3. Go to the diagnostic tool. Reapply power to the ABS.

앫 If there is no diagnostic tool on the trailer,

temporarily install one for this test. You must use a diagnostic tool to complete the Sensor Installation Test.

4. Check the diagnostic tool to verify the status of the yellow LED. Figure 7.3 .

앫 If LED comes ON and stays ON, go to Step 5.

앫 If LED does not light, verify adequate power

is applied to the system. Make the necessary repairs.

앫 If this does not occur, repeat Step 4.

앫 Attach the emergency and control air lines to

the trailer. Fill air tanks to release the spring brakes.

6. Rotate each sensed wheel — ONE AT A TIME — at a rate of 1/2 revolution per second. Apply control pressure to activate the brakes. Refer to

Figure 7.4 .

Figure 7.4

Figure 7.3

1 Blink Code Switch 2 LED Lamp

5. Press and release the blink code switch three times for Sensor Installation Test Mode, one second each time, separated by a release time of one second.

앫 The LED should display eight rapid flashes.

This indicates the Sensor Installation Test Mode. Then, the LED will continuously display the system configuration code:

– 2 Flashes = 4S/3M

– 3 Flashes = 4S/2M

– 4 Flashes = 2S/2M

– 5 Flashes = 2S/1M

1 Slack Adjuster

7. Observe the automatic slack adjuster on the rotated wheel. It must move in and out as the ABS valve cycles. This indicates a proper installation.

앫 If the slack adjuster on the rotated wheel

does not move — but the slack adjuster on the opposite wheel does move — the sensor leads are reversed or the air line is plumbed wrong. Correct the installation.

앫 If the slack adjuster on the rotated wheel

does not move, there may be a sensor gap problem. Check the sensor gap and make the necessary repairs.

8. Repeat Steps 6 and 7 on the remaining sensed wheels.

9. If you installed a diagnostic blink code tool for this test, remove it. Replace the protective cap over the connector.

Page 35

Section 7 Sensor Adjustment & Component Testing

Trailer Identification

An Easy-Stop™ Trailer ABS warning label is generally affixed to the trailer near the ABS trailer warning lamp.

If this label is not on the trailer, let your supervisor know. Labels are available from WABCO. Ask for Part Number TP-95172.

For additional assistance, contact WABCO North America Customer Care at 855-228-3203.

Before calling the WABCO North America Customer Care, be prepared to provide the following information about the trailer you are working on:

1. Trailer make and model year.

2. What is the symptom/complaint? What is the component doing or not doing?

3. What is the ABS blink code or MPSI Pro-Link

4. Have any resistance and/or voltage measurements been taken?

5. What is the result of visual inspection of connectors, harness and components?

6. When does the symptom occur (vehicle moving, compressor unloading, etc.)?

7. Does the trailer have any unusual characteristics (for example, mismatched tires or larger than normal air consumption)?

8. Were maintenance manuals available? If so, which ones were used?

9. What is the part number of the ECU/Valve Assembly? What is the system configuration?

By having the above information ready when you call, your customer support technician will be better equipped to assist you.

9000 reading?

WABCO North America Customer Care, 855-228-3203

Page 36

Section 8

NOTE

NOTES

Appendixes

Section 8Appendixes

Appendix A

Expert Mode Diagnostics

When you use Expert Mode diagnostics, the blink code lamp identifies and displays existing and intermittent faults consecutively in three-digit fault code sequences, with a short pause between each fault. Refer to Expert Mode Blink Code Example

(4S/2M Configuration) and Table J — Expert Mode Fault Code, all in this section.

Expert Mode identifies:

앫 System configuration

앫 Components that need repair;

앫 Cause (or type) of fault, such as a cut sensor

cable; and

앫 Number of times a fault has occurred.

The ECU stores intermittent and existing faults into memory in the order in which they occur. However, the blink code lamp displays the most

recent fault first.

How to Test for Intermittent Stored Faults Using the Expert Mode

Before you use Expert Mode diagnostics, be prepared to count and write down the blink code lamp flashes for each fault.

1. The vehicle must be stationary to activate the blink code. Power the ECU with a minimum of 12 volts DC (9.5–14 is an acceptable range). The warning lamp on the trailer will come ON.

2. Identify the fault. If not already attached, plug the diagnostic tool into the diagnostic cable socket usually located on the right side of the trailer.

b. Release the switch. The blink code lamp

will go OFF.

c. Depress the blink code lamp switch once

for one second. The blink code lamp will come ON.

d. As soon as the blink code lamp comes ON,

release the blink code button.

4. Determine whether or not there are Intermittent Stored faults in the system.

If there are no Intermittent Stored faults, the blink code lamp will come back ON and identify the system configuration one time by displaying:

– 2 Flashes = 4S/3M

– 3 Flashes = 4S/2M

– 4 Flashes = 2S/2M

– 5 Flashes = 2S/1M

After the blink code lamp displays the system configuration once, the lamp will remain OFF.

If There Are Intermittent Stored Faults in the System

1. The blink code lamp will come back ON and identify the system configuration one time by displaying:

– 2 Flashes = 4S/3M

– 3 Flashes = 4S/2M

– 4 Flashes = 2S/2M

– 5 Flashes = 2S/1M

2. The blink code lamp will go OFF for

2.5 seconds, come back ON for 2.5 seconds, and go OFF for 2.5 seconds.

앫 The blink code lamp will display the most

recent fault in a three-digit fault code sequence. For example, a fault code sequence of 3-5-2 reads as follows:

앫 For an alternate blink code access procedure,

see “Warning Lamp Diagnostics” in Appendix C.

앫 You can restart the Expert Mode fault sequence

at any time by depressing the blink code lamp switch as described in Step 3 below.

3. Depress the blink code lamp switch located in

the diagnostic tool two times for one second each time as follows:

a. Depress the blink code lamp switch once

for one second. The lamp will come ON.

First Digit 3 Flashes = Sensor BU1

Second Digit 5 Flashes = Cut Sensor Cable

Third Digit (X)

3. The blink code lamp will then go OFF for

2.5 seconds, then display each remaining fault code sequence.

4. When all fault code sequences have been displayed, the blink code lamp will come ON and go OFF, and remain OFF.

2 Flashes = Number of

= Fault Occurrences

Page 37

Section 8

1002096b

1 S 1 S

OFF

1 S

OFF

1 S

OFF

2.5 S

OFF

2.5 S

OFF

2.5 S

OFF

2.5 S

OFF

2.5 S

1st Digit

3 Flashes = I.D.

= 4S/2M 2nd Digit 3rd Digit

FAULT CODE

Lamp stays ON after all fault code sequences have been displayed.

Power ON; ECU activated

= Light ON S = Second(s)

BLINK CODE 3-5-2 = CUT SENSOR CABLE

Appendixes

Blink Code Example (4S/2M Configuration)

Expert Mode

Figure 8.1

Table J — Expert Mode Fault Code

Blink Code

1st Digit

2nd Digit

3rd Digit (X)

Component or Location

000 No Faults No action needed.

35X Sensor BU1 Cable Break,

37X Sensor BU1 Out of Adjustment Adjust sensor.

310X Sensor BU1 Speed Erratic Check for excessive hub

45X Sensor YE1 Cable Break,

47X Sensor YE1 Out of Adjustment Adjust sensor.

410X Sensor YE1 Speed Erratic Check for excessive hub

55X Sensor BU2 Cable Break,

57X Sensor BU2 Out of Adjustment Adjust sensor.

510X Sensor BU2 Speed Erratic Check for excessive hub

65X Sensor YE2 Cable Break,

X = Number of Fault Occurrences

Cause or Type of Fault Solution

Short Circuit

Check sensor, sensor cable and cable connection.

runout, a sensor gap that is too wide or damage to the tooth wheels.

Check sensor, sensor cable and cable connection.

runout, a sensor gap that is too wide or damage to the tooth wheels.

Check sensor, sensor cable and cable connection.

runout, a sensor gap that is too wide or damage to the tooth wheels.

Check sensor, sensor cable and cable connection.

Page 38

Table J — Expert Mode Fault Code (continued)

Blink Code

Section 8

Appendixes

1st Digit

67X Sensor YE2 Out of Adjustment Adjust sensor.

610X Sensor YE2 Speed Erratic Check for excessive hub

73X External Modulator

75X External Modulator

76X External Modulator

712X External Modulator

93X External Modulator

95X External Modulator

96X External Modulator

912X External Modulator

10 3 X ECU/Valve Assembly

10 5 X ECU/Valve Assembly

10 6 X ECU/Valve Assembly

10 1 2 X ECU/Valve Assembly

14 2 X ECU Data Erratic Unexpected System.

14 3 X Power Supply Over Voltage Repair vehicle power supply.

14 4 X Power Supply Under Voltage Check vehicle voltage output

14 5 X Power Supply Current Low Check for proper ground on

14 9 X ECU/Valve Assembly Internal Failure Erase fault.

14 12 X ECU/Valve Assembly Internal Failure Erase fault.

15 9 X Electromagnetic

15 12 X ECU/Valve Assembly Internal Failure

X = Number of Fault Occurrences

2nd Digit

3rd Digit (X)

Component or Location

(Red)

(BU)

Modulator (YE)

Interference

Cause or Type of Fault Solution

runout, a sensor gap that is too wide or damage to the tooth wheels.

Short to Power Check ABS valve and cable.

Replace as required.

Cable Break or Open Check ABS valve and cable.

Replace as required.

Short to Ground or Cable Damaged

ECU/Valve Assembly Failure

Short to Power Check ABS valve and cable.

Cable Break or Open Check ABS valve and cable.

Short to Ground or Cable Damaged

ECU/Valve Assembly Failure

Short to Power Check ABS valve and cable.

Cable Break or Open Check ABS valve and cable.

Short to Ground or Cable Damaged

ECU/Valve Assembly Failure

Various

Check ABS valve and cable. Replace as required.

Replace as required.

Check ABS valve and cable. Replace as required.

Replace as required.

Check ABS valve and cable. Replace as required.

and connector.

power cable.

Contact WABCO North America Customer Care, 855-228-3203.

Page 39

Section 8

1002098b

1 S 1 S 1 S

OFF

2.5 S

OFF

2.5 S

OFF

2.5 S

OFF

2.5 S

OFF

2.5 S

OFF

2.5 S

OFF

1 S

OFF

1 S

3 Flashes = I.D.

= 4S/2M

3 Flashes = I.D.

= 4S/2M

3 Flashes = I.D.

= 4S/2M2.5 S 2.5 S

8 Rapid Flashes =

ECU Reconfigured

Power ON; ECU activated

= Light ON

S = Second(s)

Depress Switch

3 Seconds

Continuously

Identifies

Configuration

Appendixes

Appendix B

Reconfigure Mode

Blink Code Example (4S/2M Configuration)

Reconfigure Mode

Figure 8.2

Page 40

Section 8

NOTE

2002111b

THREE FLASHES LAMP GOES OFF 2.5 SECONDS

LAMP COMES ON 2.5 SECONDS LAMP GOES OFF 2.5 SECONDS

THREE FLASHES

LAMP GOES OFF 2.5 SECONDS

LAMP COMES ON 2.5 SECONDS

THREE FLASHES

4S/2M SYSTEM IDENTIFICATION

Appendixes

When to Use the Reconfigure Mode

Use the Reconfigure Mode to (1) reconfigure the ECU if necessary (see Table K — ECU Reconfiguration); or (2) to clear repaired faults from ECU memory. (Refer to Figure 8.2 for a

Reconfigure blink code example.)

Table K — ECU Reconfiguration

ECU Part Number

472 500 001 0 Manual reconfiguration required

472 500 011 0 2S/1M only. No reconfiguration

471 500 012 0 & 472 500 013 0

Reconfiguration Requirements

if ECU is installed on other than a 2S/2M configuration.

See “How to Use the Reconfigure Mode”.

required.

Automatic reconfiguration for upward configurations (e.g., 2S/2M to 4S/2M). If downward, manual reconfiguration required.

Do NOT reconfigure the ECU unless system usage has changed. Contact WABCO North America Customer Care at 855228-3203 for assistance.

d. Release the switch once for one second.

The blink code lamp will go OFF.

e. Depress the switch once for one second.

The blink code lamp will come back ON.

f. Release the switch. The blink code lamp

will go OFF.

4. The blink code lamp will display the system's identification three times. For example, three flashes identify a 4S/2M system. (Refer to the system identification example shown below.)

Figure 8.3

How to Use the Reconfigure Mode

For an alternate blink code access procedure, see “Warning Lamp Diagnostics”, in Appendix C.

1. The vehicle must be stationary to activate and reconfigure the ECU. Power the ECU with 12 volts DC (9.5–14 is an acceptable range).

2. If the diagnostic tool is not attached to the diagnostic cable: Plug the diagnostic tool into the diagnostic cable socket usually located on the right side of the sub-frame.

3. Activate the Reconfigure Mode: Press the blink code lamp switch three times for one second each time as follows:

a. Depress the blink code lamp switch once

for one second.

b. Release the switch for one second. The

lamp will go OFF.

c. Depress the switch once for one second.

The blink code lamp will come back ON.

To accept the ECU reconfiguration, you must depress the blink code lamp switch for three seconds during the third display of the system's identification.

5. During the third time the lamp displays the

system's identification, depress the blink code lamp switch for three seconds and release the switch to accept the system reconfiguration.

6. The blink code lamp will flash rapidly eight times to acknowledge that the ECU is reconfigured. The lamp will continue to flash the system's identification until you turn OFF the power to the ECU.

7. If you repaired or replaced the ECU/Valve Assembly or ABS Modulator Valve, refer to “Final Test Before Returning a Trailer to Service” in Section 7, "Sensor Adjustment & Component Testing".

Page 41

Section 8 Appendixes

Appendix C

Warning Lamp Diagnostics

ECU Part Numbers 472 500 011 0, 472 500 012 0, and 472 500 013 0

If you do not have easy access to either the diagnostic tool or blink code lamp on the ECU, the ABS warning lamp on the trailer may be used to display blink codes.

The lamp is capable of displaying faults in Normal, Expert, Clear-All, and Sensor Installation Tes t m od es .

System requirements:

앫 Trailer with mandated ABS (with ECU/Valve

Assembly part number listed above).

앫 Tractor/trailer hook-up with switched ignition

power on tractor/trailer connector or a DC-powered tester.

앫 Technician and assistant recommended.

Read the description of each mode and use the blink code tables for Normal, Expert, and Reconfigure/Clear-All modes that appear in this manual.

To display the blink codes on the ABS warning lamp:

1. Make sure the vehicle is stationary and that the trailer is hooked to a properly equipped tractor (see system requirements).

2. Remove power from the tractor and trailer (Turn off ignition).

3. Step on the brake pedal. Foot must remain on the brake for the entire procedure.

4. Provide Power. Turn on ignition for desired mode (Normal, Expert, or Clear-All). Once you enter the mode you plan to use, follow the instructions for that mode.

Reminder:

Brakes must be applied (foot on brake pedal) for the entire procedure.

For Normal Mode:

앫 Turn ignition ON ONCE for ONE SECOND.

앫 Turn ignition OFF for ONE SECOND.

앫 Turn ignition back ON.

– Warning lamp will display the blink code one

time. See Table E — Normal Mode Fault Code Ta b l e , in Section 5, "Diagnostics", for blink code identification.

For Expert Mode:

앫 Turn ignition ON ONCE for ONE SECOND.

앫 Turn ignition OFF for ONE SECOND.

앫 Turn ignition ON A SECOND TIME for

ONE SECOND.

앫 Turn ignition OFF for ONE SECOND.

앫 Turn ignition back ON.

– Warning lamp will display the blink code one

time. See Table J — Expert Mode Fault Code, in “Appendixes”, for blink code identification.

For Clear-All or Sensor Installation Te s t M o d e :

앫 Turn ignition ON ONCE for ONE SECOND.

앫 Turn ignition OFF for ONE SECOND.

앫 Turn ignition ON A SECOND TIME for

ONE SECOND.

앫 Turn ignition OFF.

앫 Turn ignition ON A THIRD TIME for

ONE SECOND.

앫 Turn ignition OFF for ONE SECOND.

앫 Turn ignition back ON.

– The blink code lamp will flash rapidly eight

times to indicate that stored faults have been

cleared from ECU memory.

NOTE

To exit any mode, release foot brake pedal and turn ignition off for AT LEAST 10 SECONDS.

Page 42

connects trucks, trailers, cargo, drivers, business partners and

ﬂ eet operators through advanced ﬂ eet management systems and

mobile solutions. WABCO reported sales of $2.8 billion in

2016. Headquartered in Brussels, Belgium, WABCO has 13,000 employees in 40 countries. For more information, visit:

www.wabco-na.com

(NYSE: WBC) is a leading global supplier of technologies and services that improve the safety, efﬁ ciency and con- nectivity of commercial vehicles. Founded nearly 150 years ago, WABCO continues to pioneer breakthrough innovations for advanced driver assistance, braking, stability control, suspension, transmission automation and aerodynamics. Partnering with the transportation industry as it maps a route toward autonomous driving, WABCO also uniquely

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