WABCO Easy-Stop Basic, Maintenance Manual

Page 1: ...EASY STOP TRAILER ABS 2S 1M BASIC AND STANDARD 2S 2M 4S 2M AND 4S 3M SYSTEMS MAINTENANCE MANUAL...

Page 2: ...the user of possible safety issues and to provide information that will prevent damage to equipment and components WARNING A WARNING indicates that you must follow a procedure exactly Otherwise serio...

Page 3: ...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 Too...

Page 4: ...ety 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...

Page 5: ...pe 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 Table A Scope of Blink Code Diagnost...

Page 6: ...ed 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 val...

Page 7: ...ing and prevent wheel lock Used in conjunction with ECU Valve Assembly for 2M or 3M systems Sensor with Molded Socket Measures the speed of a tooth wheel rotating with the vehicle wheel Produces an ou...

Page 8: ...tach cable to ECU Diagnostic Cable Provides for blink code diagnostics and diagnostics using the MPSI Pro Link 9000 diagnostic tool Five wire cable with over molded connector to ECU on one end and SAE...

Page 9: ...Diagnostic cable mounted to the bracket with a protective cap on the SAE J1587 diagnostic connector Diagnostic Cable Assembly with Diagnostic Tool Diagnostic cable mounted to the bracket with a diagno...

Page 10: ...ault locations Label is self adhesive and is mounted on the trailer near the ABS warning lamp If there is no warning label on your trailer let your supervisor know Labels are available from WABCO Ask...

Page 11: ...irects 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 lockin...

Page 12: ...h 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 s...

Page 13: ...y until you identify the cause repair the cable and clear the fault from the ECU What is an intermittent fault An intermittent fault is a problem that usually occurs only under certain driving conditi...

Page 14: ...Notes Page 10...

Page 15: ...lication Single Axle Dolly Single and Tandem Axle Semi Trailer NOTE Sensors may be installed on either axle depending upon suspension and other vehicle characteristics Figure 4 1 A Service Control Lin...

Page 16: ...xle Dolly Single and Tandem Axle Semi Trailer NOTE Sensors may be installed on either axle depending upon suspension and other vehicle characteristics Figure 4 2 A Service Control Lines B Sensor Cable...

Page 17: ...NOTE Sensors may be installed on either axle depending upon suspension and other vehicle characteristics Figure 4 3 A Service Control Lines B Sensor Cables C Service to Brake Lines Delivery Lines D Ai...

Page 18: ...l Application Tandem and Tri Axle Semi Trailer 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 Tan...

Page 19: ...cation Tandem and Tri Axle Semi Trailer 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...

Page 20: ...tion Tandem and Tri Axle Semi Trailer Figure 4 6 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 B...

Page 21: ...nding upon suspension and other vehicle characteristics Figure 4 7 A Service Control Lines B Sensor Cables C Service to Brake Lines Delivery Lines D Air Supply Emergency Lines 1 ECU Valve Assembly YE...

Page 22: ...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 BRO...

Page 23: ...ROWN GREEN RED 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...

Page 24: ...Notes Page 20...

Page 25: ...l 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 procedure...

Page 26: ...the fault Check Table D ECU Part Number 472 500 011 0 Blink Codes to determine the problem Follow the suggested corrective action Table D ECU Part Number 472 500 011 0 Blink Codes Figure 5 1 1 Blink...

Page 27: ...available from Kent Moore Diagnostic Activation Tool For ECU Part Numbers 472 500 001 0 472 500 012 0 and 472 500 013 0 The blink code diagnostic tool inserts into the SAE J1587 diagnostic connector t...

Page 28: ...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 fifte...

Page 29: ...ly 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 on...

Page 30: ...Notes Page 26...

Page 31: ...ster 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...

Page 32: ...ank 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 N m or nipple moun...

Page 33: ...inch Grade 8 bolts with prevailing torque nuts to attach the assembly to the mounting bracket Tighten to 18 lb ft 24 N m Plug unused supply port Port 1 Refer to Figure 6 5 b Nipple mounted to air tan...

Page 34: ...agnostic 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 c...

Page 35: ...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...

Page 36: ...N Minimum power requirement not met or wiring problem exists Check electrical connections and power source Make necessary repairs OR Blink code lamp on ECU does not come ON Trailer ABS warning lamp co...

Page 37: ...esting required Trailer ABS warning lamp does not go OFF AND There is no blink code flashing on the ECU There is a sensor gap problem Adjust sensor gap Push sensor into its holder until it contacts th...

Page 38: ...and power source Make necessary repairs OR Blink code lamp on ECU does not come ON Trailer ABS warning lamp comes ON Hardware fault code Identify fault location Make necessary repairs to the installat...

Page 39: ...nsor 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 If this does not occur repeat Step 4 At...

Page 40: ...symptom complaint What is the component doing or not doing 3 What is the ABS blink code or MPSI Pro Link 9000 reading 4 Have any resistance and or voltage measurements been taken 5 What is the result...

Page 41: ...tch 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 sec...

Page 42: ...ut of Adjustment Adjust sensor 4 10 X Sensor YE1 Speed Erratic Check for excessive hub runout a sensor gap that is too wide or damage to the tooth wheels 5 5 X Sensor BU2 Cable Break Short Circuit Che...

Page 43: ...Failure Check ABS valve and cable Replace as required 10 3 X ECU Valve Assembly Modulator YE Short to Power Check ABS valve and cable Replace as required 10 5 X ECU Valve Assembly Modulator YE Cable B...

Page 44: ...ure 8 2 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 2M 2 5 S 2 5 S 8 Rapid Flashes ECU Rec...

Page 45: ...cation example shown below NOTE 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 thi...

Page 46: ...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...

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Page 48: ...in 40 countries For more information visit www wabco na com NYSE WBC is a leading global supplier of technol ogies and services that improve the safety efficiency and con nectivity of commercial vehi...