WABCO 400 500 320 0 Maintenance Manual Download Page 29

Page: 29 / 188

System Con

gurations

5.2 Power Cable Wiring Diagrams

Fig. 5.9

ECU POWER CONNECTOR

GROUND

WHITE

BLUE

RED

GREEN AND WHITE

TRAILER ABS

INDICATOR LAMP

(CONSTANT POWER)

(STOP LAMP)

(GROUND)

Junction box not shown.

4013987a

Fig. 5.10

4016467

B-6

B-2

B-3

B-1

B-7

B-8

B-5

B-4

NOT USED
NOT USED
NOT USED

A-A
A-B
A-C
A-D

A-E

B
B-2
B-1
NOT USED
B-5
B-4
B-6
B-7
B-8

A-A

A-B

POWER CABLE FOR iABS

P/N 449 306 XXX 0

A-E

A-C

A-D

Summary of Contents for 400 500 320 0

Page 1: ...iABS TRAILER ABS SYSTEM WITH PLC AND CAN MAINTENANCE MANUAL 2S 1M 2S 2M 4S 2M AND 4S 3M STANDARD PREMIUM MM19001...

Page 2: ...ponents 11 4 ABS Questions and Answers 15 4 1 The ECU 15 4 2 Power Line Carrier PLC 15 4 3 ABS Indicator Lamps 16 4 4 Types of Faults 18 4 5 Frequently Asked Questions 19 5 System Configurations 20 5...

Page 3: ...em Troubleshooting 168 9 6 Integrated Speed Switch System 172 10 Appendix I 175 10 1 TraiIer ABS Indicator Lamp on Vehicle Dash 175 11 Appendix II 177 11 1 Installing Sensors on Non ABS Prepped Axles...

Page 4: ...ed NOTICE Description of a possible situation which may result in material damage if the warning is ignored Important information notes and or tips Reference to information on the internet 1 Action st...

Page 5: ...Traffic Safety Administration NHTSA website to find all current documents referenced in the manual at www nhtsa gov WABCO TOOLBOX PLUS Software The TOOLBOX PLUS Software provides PC diagnostics for W...

Page 6: ...tands Do not work under a vehicle supported only by jacks Jacks can slip or fall over Serious personal injury and damage to components can result WARNING It is also recommended to disable or lower any...

Page 7: ...te During Electrostatic Painting the Trailer Frame or Bogie Disconnect all cable connections to devices and components and protect the plug ins and connections from contamination and humidity 2 2 Vehi...

Page 8: ...a ground strap electrically connecting the axle to the chassis must be added to ensure adequate protection from unwanted electrical noise This can be verified by measuring the maximum resistance betwe...

Page 9: ...0 2S 2M 4S 2M and 4S 3M Premium 400 500 350 0 2S 1M Premium Fig 3 1 Cntry of Origin Last Two Digits Build Year 4017190a WABCO ID No Data Coding PRI Optional 0701 400 500 102 0 Date of Manufacture Cod...

Page 10: ...sensor Figure 3 2 Fig 3 2 4015787a EXTERNAL ABS MODULATOR VALVE FOR 3M CONFIGURATIONS ECU VALVE ASSEMBLY WHEEL SPEED SENSOR TOOTH WHEEL 3 4 System Configuration The ABS configuration defines the numb...

Page 11: ...still has normal brakes The other wheels keep the ABS function Two ABS indicator lamps one on the dash of the tractor and one on the side of the trailer let drivers know the status of the system 3 6...

Page 12: ...uces an output voltage proportional to wheel speed 3 6 4 Sensor Clip Figure 3 6 Holds the wheel speed sensor in close proximity to the tooth wheel 3 6 5 Tooth Wheel Figure 3 7 A machined ring mounted...

Page 13: ...arning label on your trailer let your supervisor know Labels are available from WABCO Ask for Part Number TP95172 3 6 8 TOOLBOX PLUS Software Figure 3 9 TOOLBOX PLUS Software is a PC based diagnostics...

Page 14: ...ly Currently replaced by the heavy duty trailer diagnostic adapter Fig 3 10 4017175a Available from Noregon not provided by WABCO 3 6 10 Noregon Heavy Duty Trailer Diagnostic Adapter Figure 3 11 Simul...

Page 15: ...res and connectors which otherwise would be needed Without multiplexing it could take several wires and connections in order to transmit several different signals to various locations on a vehicle but...

Page 16: ...ly and does not need to be replaced however there could be a problem in the trailer s wiring harness Check the wiring system and make the necessary repairs If the problem persists contact the WABCO Cu...

Page 17: ...m it is important not to ignore this indicator If the indicator lamp indicates a malfunction the vehicle can be operated to complete the trip but it is important to have it serviced as soon as possibl...

Page 18: ...cked on the system System Power Comes from Activating the Stoplight Circuit Brakes Fault in System Vehicle Speed Indicator Lamp Released N A N A OFF Applied NO Less than 4 mph ON for 3 seconds then go...

Page 19: ...e 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 AB...

Page 20: ...rol Port Facing Rear of Trailer Figure 5 3 2S 2M Standard Mounted with Control Port Facing Front of Trailer Figure 5 4 2S 2M Standard Mounted with Control Port Facing Rear of Trailer 4S 2M Standard Mo...

Page 21: ...built in North America Fig 5 1 SERVICE CONTROL LINES SENSOR CABLES SERVICE BRAKE SUPPLY AIR SPRING BRAKE AIR SERVICE CONTROL LINES SENSOR CABLES SERVICE BRAKE SUPPLY AIR SPRING BRAKE AIR POWER SUPPLY...

Page 22: ...DIAGNOSTIC 3rd MODULATOR GIO 2 ABS SENSOR E ABS SENSOR C NOTE Spring brake lines not shown SERVICE CONTROL LINES SENSOR CABLES SERVICE BRAKE SUPPLY AIR NOTE Spring brake lines not shown 4013983a D C 2...

Page 23: ...n POWER SUPPLY ABS SENSOR F ABS SENSOR D GIO 1 SUBSYSTEM DIAGNOSTIC 3rd MODULATOR GIO 2 ABS SENSOR E ABS SENSOR C 4S 2M VALVE MOUNTED WITH CONTROL PORT FACING FRONT OFTRAILER SIDE TO SIDE CONTROL FRON...

Page 24: ...3rd MODULATOR GIO 2 ABS SENSOR E ABS SENSOR C 4S 2MTYPICALTRI AXLE VALVE MOUNTED WITH CONTROL PORT FACING FRONT OFTRAILER SIDE TO SIDE CONTROL FRONT OF TRAILER E F C D 4S 2MTYPICALTRI AXLE VALVE MOUNT...

Page 25: ...sors used are C and D If a sensor is plugged into the E or F port when powered up the system will automatically configure to a 4 sensor system To reconfigure an ECU to a 2 sensor configuration TOOLBOX...

Page 26: ...MODULATOR GIO 2 ABS SENSOR E ABS SENSOR C F E D C 4S 3MTYPICALTRI AXLE WITH FRONT LIFT VALVE MOUNTED WITH CONTROL PORT FACING FRONT OFTRAILER FRONT OF TRAILER 4S 3MTYPICALTRI AXLE WITH FRONT LIFT VAL...

Page 27: ...OUNTED WITH CONTROL PORT FACING REAR OFTRAILER FRONT OF TRAILER POWER SUPPLY ABS SENSOR F ABS SENSOR D GIO 1 SUBSYSTEM DIAGNOSTIC 3rd MODULATOR GIO 2 ABS SENSOR E ABS SENSOR C POWER SUPPLY ABS SENSOR...

Page 28: ...rd MODULATOR GIO 2 ABS SENSOR E ABS SENSOR C E F C D F E D C FRONT OF TRAILER 4S 3MTYPICAL FOUR AXLE PULLTRAILER VALVE MOUNTED WITH CONTROL PORT FACING FRONT OFTRAILER 4S 3MTYPICAL FOUR AXLE PULLTRAIL...

Page 29: ...WHITE TRAILER ABS INDICATOR LAMP CONSTANT POWER STOP LAMP GROUND Junction box not shown 4013987a 4 1 8 6 5 7 2 3 Fig 5 10 4016467a B 6 B 2 B 3 B 1 B 7 B B 8 B 5 B 4 NOT USED NOT USED NOT USED A A A A...

Page 30: ...ists that can ignite flammable substances You must always disconnect the battery ground cable before working on the electrical system There are two methods used to get fault information from the ECU T...

Page 31: ...iABS with PLC Displays both constant and changing information from the ECU being tested Displays both active and stored system faults as well as the appropriate repair instructions Activates system co...

Page 32: ...displayed on the Tire Calibration screen The allowable range is dependent on the number of teeth on the tone ring Use the tire manufacturer s recommended tire circumference in millimeters for this va...

Page 33: ...selection Click in the Service field and key in the desired service interval This is the distance to elapse beyond the current mileage displayed when the trailer ABS indicator light should flash and...

Page 34: ...the correct sensors are used The screen display will provide the maximum tested sensor RPM for the installed sensors Visually check the order field to verify that sensors are installed in the correct...

Page 35: ...formation screen allows the user to store information about a specific vehicle including the Vehicle Identification Number VIN and Employee numbers Figure 6 8 Fig 6 8 4012505b An example of a storable...

Page 36: ...VIN OEM and Employee number Refer to Figure 6 8 2 Provide this information and select where you would like the file saved and then press OK 3 You can also Print the report by going back into the head...

Page 37: ...er is less or more than 9 to 14 volts check the wiring for damage and review with the OEM 4 With power on check voltage from pin 2 stop light power to chassis ground with the brake pedal depressed to...

Page 38: ...s is why it is important to recheck the blink codes after repairing a fault If there are additional codes in the memory they only blink after you have repaired the first fault Stored faults clear faul...

Page 39: ...or drive the vehicle above 4 mph 12 External Pressure Sensor Internal failure contact WABCO Customer Care Center at 855 228 3203 for assistance 14 Power Supply Failure Verify correct electrical insta...

Page 40: ...d Sensor C N A Wheel Speed Difference System has detected a significant difference in the proportion of tire diameter to number of tone ring teeth between wheel ends Check for tire size mismatch Check...

Page 41: ...de changes locations replace the suspect sensor 3 3 6 Wheel Speed Sensor C N A Short Circuit Continuity interruption between the sensor connections short circuit has been detected Check sensor sensor...

Page 42: ...ve Slip Wheel slip over 16 seconds continuously has been detected Adjust wheel sensor to touch tone ring Check sensor gap Check for loose wheel bearings or excessive hub runout 3 3 9 Wheel Speed Senso...

Page 43: ...lipping Check for corroded or damaged wiring between the ECU and the ABS wheel speed sensor Turn the wheel at half a revolution per second and verify 0 2 AC volt sensor output voltage 3 3 11 Wheel Spe...

Page 44: ...sive hub runout Check sensor wiring and connectors for intermittent contact Check mounting of tone ring and condition of teeth If tone ring and sensor block are not aligned properly oscillation may oc...

Page 45: ...BS sensor cable routing and clipping Turn the wheel at half a revolution per second and verify 0 2 AC volt sensor output voltage 4 4 2 Wheel Speed Sensor D N A Wheel Speed Difference System has detect...

Page 46: ...ode changes locations replace the suspect sensor 4 4 5 Wheel Speed Sensor D N A Open Circuit An open circuit has been detected i e ECU detects a disconnected wheel speed sensor Check sensor sensor cab...

Page 47: ...th adjacent sensor at the ECU If the fault code stays in the same location replace ECU If the fault code changes locations replace the suspect sensor 4 4 7 Wheel Speed Sensor D N A Tone Ring Damaged W...

Page 48: ...k for corroded or damaged wiring between the ECU and the ABS wheel speed sensor Turn the wheel at half a revolution per second and verify 0 2 AC volt sensor output voltage 4 4 10 Wheel Speed Sensor D...

Page 49: ...condition of teeth Check condition and retention of ABS sensor spring clip as well as the mounting block Check for corroded or damaged wiring between the ECU and the ABS wheel speed sensor Turn the wh...

Page 50: ...d properly oscillation may occur Small dimensional deviations can result in this failure code Issue occurs shortly after going into service and after driving Check condition and retention of ABS senso...

Page 51: ...BS sensor cable routing and clipping Turn the wheel at half a revolution per second and verify 0 2 AC volt sensor output voltage 5 5 2 Wheel Speed Sensor E N A Wheel Speed Difference System has detect...

Page 52: ...ode changes locations replace the suspect sensor 5 5 5 Wheel Speed Sensor E N A Open Circuit An open circuit has been detected i e ECU detects a disconnected wheel speed sensor Check sensor sensor cab...

Page 53: ...th adjacent sensor at the ECU If the fault code stays in the same location replace ECU If the fault code changes locations replace the suspect sensor 5 5 7 Wheel Speed Sensor E N A Tone Ring Damaged W...

Page 54: ...k for corroded or damaged wiring between the ECU and the ABS wheel speed sensor Turn the wheel at half a revolution per second and verify 0 2 AC volt sensor output voltage 5 5 10 Wheel Speed Sensor E...

Page 55: ...condition of teeth Check condition and retention of ABS sensor spring clip as well as the mounting block Check for corroded or damaged wiring between the ECU and the ABS wheel speed sensor Turn the wh...

Page 56: ...ip as well as the mounting block Check for corroded or damaged wiring between the ECU and the ABS wheel speed sensor Turn the wheel at half a revolution per second and verify 0 2 AC volt sensor output...

Page 57: ...BS sensor cable routing and clipping Turn the wheel at half a revolution per second and verify 0 2 AC volt sensor output voltage 6 6 2 Wheel Speed Sensor F N A Wheel Speed Difference System has detect...

Page 58: ...ode changes locations replace the suspect sensor 6 6 5 Wheel Speed Sensor F N A Open Circuit An open circuit has been detected i e ECU detects a disconnected wheel speed sensor Check sensor sensor cab...

Page 59: ...th adjacent sensor at the ECU If the fault code stays in the same location replace ECU If the fault code changes locations replace the suspect sensor 6 6 7 Wheel Speed Sensor F N A Tone Ring Damaged W...

Page 60: ...k for corroded or damaged wiring between the ECU and the ABS wheel speed sensor Turn the wheel at half a revolution per second and verify 0 2 AC volt sensor output voltage 6 6 10 Wheel Speed Sensor F...

Page 61: ...condition of teeth Check condition and retention of ABS sensor spring clip as well as the mounting block Check for corroded or damaged wiring between the ECU and the ABS wheel speed sensor Turn the wh...

Page 62: ...er going into service and after driving Check condition and retention of ABS sensor spring clip as well as the mounting block Check for corroded or damaged wiring between the ECU and the ABS wheel spe...

Page 63: ...he ABS ECU Verify if no cable is attached that the external modulator cap is sealed and there are no signs of moisture or corrosion on the pins of the ABS ECU If no external modulator valve is used an...

Page 64: ...port of the ABS ECU Verify if no cable is attached that the external modulator cap is sealed and there are no signs of moisture or corrosion on the pins of the ABS ECU If no external modulator valve i...

Page 65: ...of the ABS ECU Verify if no cable is attached that the external modulator cap is sealed and there are no signs of moisture or corrosion on the pins of the ABS ECU If no external modulator valve is us...

Page 66: ...erify if no cable is attached that the external modulator cap is sealed and there are no signs of moisture or corrosion on the pins of the ABS ECU If no external modulator valve is used and all previo...

Page 67: ...the exhaust and inlet valve to ground is between 4 to 8 ohms through the whole circuit Verify there is no continuity on any of the pins of the external modulator valve cable to chassis ground 7 7 11 E...

Page 68: ...uit 9 9 5 Internal Modulator Valve N A H1 Trailer Modulator Solenoid Valve Control Supply Cable Interruption ECU has detected an open circuit on the internal H1 modulator Verify the ABS ECU power conn...

Page 69: ...gnal line Check the cable between modulator and the connected component Check for tight seat of the connectors Test the cable Check whether moisture has entered into one of the connectors and check th...

Page 70: ...e Load Sensor External axle c d Under voltage Short Circuit to Ground The cable to the external axle load sensor axle c d is defective Check the cable between modulator and the connected component Che...

Page 71: ...Sensor Signal Overvoltage Short to Supply Voltage The cable to the external supply pressure sensor is defective The measured values from the supply pressure sensor in the trailer modulator are above t...

Page 72: ...Calibration or Checksum is Faulty The axle load calibration was not performed correctly Redo the axle load calibration 14 251 1 Power Supply N A Power Supply Under voltage A slight undervoltage has oc...

Page 73: ...rosion Check all contacts in the power plug of the trailer modulator for corrosion Check the connection cable between the trailer modulator and the trailer plug connector Check the connection cable be...

Page 74: ...3 12 Internal ECU Error N A Parameter Setting FSC AC Configur ation Failed Internal checksum error Define the modulator parameters again If failure is still present contact WABCO Customer Care Center...

Page 75: ...0 4 GIO Component Multiple ITP Func tions Free Configurable Function AIn1 Under voltage Short Circuit to Ground A short circuit to ground was detected at the freely configurable function analoge input...

Page 76: ...e Function DIn3 Voltage Above Normal or Shorted High A short circuit to supply voltage was detected at the freely configurable function digital input 3 Verify connectors are properly seated and have n...

Page 77: ...rrent Too High or Circuit Grounded Overload was detected at the freely configurable function digital output 1 Verify connectors are properly seated and have no signs of moisture or corrosion Check for...

Page 78: ...on DOut3 Voltage Above Normal or Shorted High A short circuit to supply voltage was detected at the freely configurable function digital output 3 Verify connectors are properly seated and have no sign...

Page 79: ...e ITP Func tions Free Configurable Function DOut4 Under voltage Short Circuit to Ground A short circuit to ground was detected at the freely configurable function digital output 4 Verify connectors ar...

Page 80: ...mponent Multiple ITP Func tions GIO_ Powerstage PwrStage1 Voltage Above Normal or Shorted High A short circuit to supply voltage was detected at GIO1 pin 1 Verify connectors are properly seated and ha...

Page 81: ...parameter settings was detected at GIO1 pin 1 Check the parameter setting Check whether the correct cables are used Verify connectors are properly seated and have no signs of moisture or corrosion 18...

Page 82: ...ions GIO_ Powerstage PwrStage2 Supply Cable Interruption Cable break detected to load at GIO1 pin 4 The trailer modulator has detected an interruption on the load to GIO1 pin 4 connection Check the ca...

Page 83: ...heck the seals for proper fit 18 1664 1 GIO Component Multiple ITP Func tions GIO_ Powerstage PwrStage3 Load Too Low Insufficient current consumption Check if correct component is installed on GIO2 pi...

Page 84: ...he cable between modulator and the connected component Check for tight seat of the connectors Test the cable for continuity from end to end Check whether the cable is frayed 18 1664 5 GIO Component Mu...

Page 85: ...cables are used Verify connectors are properly seated and have no signs of moisture or corrosion Check the cable between modulator and the connected component Check whether the cable is frayed If no o...

Page 86: ...between modulator and the connected component Check for tight seat of the connectors Test the cable for continuity from end to end Check whether the cable is frayed 18 1680 4 GIO Component Multiple I...

Page 87: ...d into the connector dummy cap and check the seals for proper fit Check whether a function has been parameterised on this slot in addition if this is the case then Check the cable between modulator an...

Page 88: ...Circuit to Ground A short circuit to ground was detected at Subsystems pin 1 cl 30 Check the cable between modulator and the connected component Check for tight seat of the connectors Test the cable...

Page 89: ...Circuit to Ground A short circuit to ground was detected at Subsystems pin 5 cl 15 Check the cable between modulator and the connected component Check for tight seat of the connectors Test the cable...

Page 90: ...Circuit Grounded Overload was detected at power supply to SmartBoard Check the cable between modulator and the connected component Check for tight seat of the connectors Test the cable for continuity...

Page 91: ...e to the diagnostic socket has a short circuit to supply voltage Check the cable between modulator and the connected component Check for tight seat of the connectors Test the cable for continuity from...

Page 92: ...erload was detected at power supply to Telematics Check the cable between modulator and the connected component Check for tight seat of the connectors Test the cable for continuity from end to end Che...

Page 93: ...Grounded Overload was detected at power supply to IVTM Check the cable between modulator and the connected component Check for tight seat of the connectors Test the cable for continuity from end to en...

Page 94: ...speed output has a short circuit to supply voltage Check the cable between modulator and the connected component Check for tight seat of the connectors Test the cable for continuity from end to end C...

Page 95: ...dulator and the connected component Check for tight seat of the connectors Test the cable for continuity from end to end Check whether water or moisture has entered into one of the connectors and chec...

Page 96: ...IO Component Multiple ITP Func tions Permanent Power 1 Supply Cable Interruption The cable to the component on the permanent power output 1 is not connected or is defective Check the cable between mod...

Page 97: ...ltiple ITP Func tions Permanent Power 2 Under voltage Short Circuit to Ground The cable to the component on the permanent power output 2 has a short circuit to ground Check the cable between modulator...

Page 98: ...onent on the output ABS active has a short circuit to supply voltage Check the cable between modulator and the connected component Check for tight seat of the connectors Test the cable for continuity...

Page 99: ...n modulator and the connected component Check for tight seat of the connectors Test the cable for continuity from end to end Check whether water or moisture has entered into one of the connectors and...

Page 100: ...5 GIO Component Inte grated Speed Switch Speed Switch 2 Supply Cable Interruption The cable to the component on the speed switch 2 ISS 2 is not connected or is defective Check the cable between modul...

Page 101: ...t Inte grated Speed Switch Speed Switch 1 Under voltage Short Circuit to Ground The cable to the component on the speed switch 1 ISS 1 has a short circuit to ground Check the cable between modulator a...

Page 102: ...e to lifting axle valve 2 has a short circuit to supply voltage Check the cable between modulator and the connected component Check for tight seat of the connectors Test the cable for continuity from...

Page 103: ...modulator and the connected component Check for tight seat of the connectors Test the cable for continuity from end to end Check whether water or moisture has entered into one of the connectors and c...

Page 104: ...2272 5 GIO Component Lift Axle Lifting Axle Valve 1 Supply Cable Interruption The cable to the lifting axle valve 1 is not connected or is defective Check the cable between modulator and the connected...

Page 105: ...2352 4 GIO Component Lift Axle Lifting Axle Status Lamp Under voltage Short Circuit to Ground The cable to the lifting axle status lamp has a short circuit to ground Check the cable between modulator...

Page 106: ...ckup light detection has a short circuit to ground Check the cable between modulator and the connected component Check for tight seat of the connectors Test the cable for continuity from end to end Ch...

Page 107: ...he cable for the steering axle lock function is not connected or cable is defective Check the cable between modulator and the connected component Check for tight seat of the connectors Test the cable...

Page 108: ...nent Steering Axle Lock Steering Axle Lock Switch Switch Open Check the cable for the steering axle lock switch It may be that the wrong cable was installed or that it is defective Plus switch was par...

Page 109: ...dialogue ELEX and follow the error information there Contact WABCO customer service for further help If no other fault can be found replace the connected components 18 2752 4 Subsystem Connection ELE...

Page 110: ...alogue ELEX and follow the error information there Contact WABCO customer service for further help If no other fault can be found replace the connected components 18 2752 11 Subsystem Connection ELEX...

Page 111: ...follow the error information there Contact WABCO Customer Care Center at 855 228 3203 for assistance If no other fault can be found replace the connected components 18 2753 4 Subsystem Connection ELE...

Page 112: ...frayed Please open the fault memory dialogue ELEX and follow the error information there Contact WABCO Customer Care Center at 855 228 3203 for assistance If no other fault can be found replace the c...

Page 113: ...o Supply Voltage The cable for the working light has a short circuit to supply voltage Check the cable between modulator and the connected component Check for tight seat of the connectors Test the cab...

Page 114: ...efective Check the cable between modulator and the connected component Check for tight seat of the connectors Test the cable for continuity from end to end Check whether water or moisture has entered...

Page 115: ...sparks exists that can ignite flammable substances You must always disconnect the battery ground cable before working on the electrical system Disconnect power from the ECU Valve Assembly before you r...

Page 116: ...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 The use of non approved lubricants is at y...

Page 117: ...han 1 2 of a revolution per second the reading will likely be higher It is important to spin the wheel at the correct speed to determine the output is in fact correct If minimum output is less than 0...

Page 118: ...with Schedule 80 pipe nipple 3 4 inch NPTF 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 th...

Page 119: ...ng bolts and lock nuts that hold the assembly to the cross member Remove the assembly B Nipple mounted to Air Tank Unscrew the assembly from the air tank 6 If the assembly being replaced is under warr...

Page 120: ...when installing the hex nipple Use of a vise may cause overclamping Overclamping may damage the internal components of the ECU single modulator valve assembly 2 Use a 3 4 inch pipe plug to plug unuse...

Page 121: ...a position for mounting the assembly to the vehicle cross member midway between the side rails close to the brake chambers the valve serves Drill two 3 8 inch mounting holes The distance between the t...

Page 122: ...ts Exhaust port must face DOWN Plug all unused ports CONTROL PORT CONTROL PORT 4014264a 2 Locate a position for mounting the assembly to the vehicle cross member midway between the side rails close to...

Page 123: ...he volt ohm meter leads to the two wire component terminals inside the disconnected connector 4 When checking the resistance the meter must read 900 2000 ohms 5 Check and replace the sensor and cables...

Page 124: ...3676a EXHAUST SOLENOID BLUE WIRE INLET SOLENOID BROWN WIRE GROUND TERMINAL To check the cable and the ABS valve as one unit measure resistance across pins 1 and 2 and 2 and 3 on the ECU connector of t...

Page 125: ...ostic adapter to the J560 adapter and the USB cable to the computer with the WABCO TOOLBOX PLUS Software Refer to the MM19047 User Guide for instructions for running TOOLBOX PLUS Software The manual c...

Page 126: ...ONE No faults present proceed with end of line test YES Faults present double click on YES to bring up the fault information screen Use the information in the Repair Instructions field to make the nec...

Page 127: ...e the ABS indicator lamp this is the lamp that is mounted on the side of the trailer The lamp will flash multiple times indicating lamp installation is OK The Test Status box at the bottom of the menu...

Page 128: ...necessary repairs If the control port faces the rear of the trailer the slack adjusters will move in and out as the roadside portion of the dual modulator valve cycles If this does not happen the air...

Page 129: ...dicator lamp this is the lamp that is mounted on the side of the trailer The lamp will flash multiple times indicating lamp installation is OK The Test Status box at the bottom of the menu will displa...

Page 130: ...le Control installations use the standard Sensor Test To run the standard test select Sensor Test from the Components Test Menu The sensor orientation test must be performed as part of the end of line...

Page 131: ...5 Click on Front or Rear in the Control Port Facing field to select the mounting orientation of the ECU dual modulator valve assembly Figure 8 11 Refer to Figure 8 10 and Figure 8 11 for illustrations...

Page 132: ...e is no sensor output verify that a tone ring has been installed and that the sensor is pushed all the way in against the tone ring Perform the necessary repairs and repeat the test If the problem per...

Page 133: ...or C must be routed to the curbside wheel end location 2 If sensors are not correctly installed make the necessary repairs 8 6 2 Air Line Installation 1 Ensure that all unused air ports are plugged an...

Page 134: ...ler as follows ECU Dual Modulator Valve Assembly Mounted with Control Port Facing Front of Trailer 2S 2M Connect curbside sensor at D Connect roadside sensor at C 4S 2M Connect curbside front sensor a...

Page 135: ...Ensure that all unused air ports are plugged and that the exhaust port is facing DOWN 2 Look at the air line installation to verify that all air lines are correctly installed If the ECU dual modulato...

Page 136: ...lamp comes on and stays on check the sensor installation Remove the power from the ABS and raise the sensed wheels so they may be rotated Apply emergency air to fill the air tanks and release the spri...

Page 137: ...ck sensor installation Perform necessary repairs 7 External ABS Modulator Valve Verify correct electrical installation Check power supply Perform necessary repairs 9 Internal ABS Modulator Valve Verif...

Page 138: ...he component doing or not doing 3 What is the ABS blink code or SPN FMI code 4 Have any resistance and or voltage measurements been taken 5 What is the result of visual inspection of connectors harnes...

Page 139: ...of electrical shock exists and sparks can ignite flammable substances You must always disconnect the battery ground cable before you work on an electrical system to prevent serious personal injury an...

Page 140: ...ECU valve should audibly click during its power up self test ABS warning light will illuminate and extinguish as a light test If warning light remains on begin diagnostics with TOOLBOX PLUS Software...

Page 141: ...nd Air Applied Using TOOLBOX PLUS Software ensure there are no active faults Repair and clear all active faults Cycle the ECU power Inspect pressure switch 431 700 002 0 installation Ensure pressure s...

Page 142: ...le should lower Verify toggle switch operation Ensure the toggle switch is functional using an ohm meter Switch output should show infinity ohms when the switch is in the OFF position and less than 1...

Page 143: ...ameter Settings Inspect pressure sensor 441 044 106 0 installation Ensure that there are no air leaks in the air circuit where pressure sensor 441 044 106 0 is attached Inspect lift axle control valve...

Page 144: ...ensure that a 12v light is being used Check light output cable integrity Using a volt ohm meter check for a shorted or open circuit on lift axle indicator light cable 449 827 XXX 0 Refer to Figure 9 6...

Page 145: ...016467a B 6 B 2 B 3 B 1 B 7 B B 8 B 5 B 4 NOT USED NOT USED NOT USED A A A A B A C A D A E B B 2 B 1 NOT USED B 5 B 4 B 6 B 7 B 8 A A A B A POWER CABLE FOR iABS P N 449 306 XXX 0 A E A C A D B A Fig 9...

Page 146: ...146 Troubleshooting Fig 9 4 4012470a 1 4 2 1 1 LIFT AXLE CONTROL VALVE P N 463 084 050 0 1 2 Fig 9 5 4012471a 3 8 18 NPTF 1 1 8 HEX PRESSURE SWITCH P N 431 700 002 0 1 3 2 NORMALLY CLOSED...

Page 147: ...bleshooting Fig 9 6 4017179a Fig 9 7 4017177a Fig 9 8 4012667a ABS LIFT AXLE Y CABLE P N 894 601 100 0 3 1 X X X B C Z Z A 2 1 2 3 4 1 2 3 4 B A BU BN N C YE GN BU BN N C YE GN 1 2 3 1 2 3 4 C BU BN N...

Page 148: ...148 Troubleshooting Fig 9 9 4017182a...

Page 149: ...149 Troubleshooting Fig 9 10 4017180a...

Page 150: ...150 Troubleshooting Fig 9 11 4017173a...

Page 151: ...CONNECTSTO PRESSURE SENSOR P N 441 044 106 0 CONNECTSTO PRESSURE SWITCH P N 431 700 002 0 FITTING PSI TEE FITTING PRESSURE REGULATOR WITH GAUGE SIMULATED SPRING BRAKE LINE 0 100 PSI PSI 0 100 PSI Fig...

Page 152: ...ke Troubleshooting Details Tag Axle Function Unavailable in TOOLBOX PLUS Software Inspect WABCO iABS part number Ensure that GIO capable WABCO iABS is installed Only 400 500 350 0 and 400 500 430 0 ha...

Page 153: ...e valve cable 449 408 XXX 0 integrity Using a volt ohm meter check for shorted or open circuits on the tag axle valve cable Refer to Figure 9 18 Verify tag axle valve cable 449 408 XXX 0 is correctly...

Page 154: ...Ensure that the air volume capacity of the trailer meets trailer OEM standards for operating a tag axle Verify the output of the towing vehicle s air compressor to the trailer Optional Tag Axle Indic...

Page 155: ...hooting Fig 9 14 4016467a B 6 B 2 B 3 B 1 B 7 B B 8 B 5 B 4 NOT USED NOT USED NOT USED A A A A B A C A D A E B B 2 B 1 NOT USED B 5 B 4 B 6 B 7 B 8 A A A B A POWER CABLE FOR iABS P N 449 306 XXX 0 A E...

Page 156: ...156 Troubleshooting Fig 9 15 4017183a...

Page 157: ...157 Troubleshooting Fig 9 16 4017187a Fig 9 17 4012475b 3 2 SOLENOID VALVE CABLE P N 472 170 997 0 1 2...

Page 158: ...AG DUMP AXLE LIFT AXLE CONTROL VALVE SEALCO P N 110591 ORDER SEPARATELY NOT INCLUDED IN KITS RESIDUAL PRESSURE VALVE OPTIONAL SEALCO P N 1300 05 OPTIONAL COMPONENTS TAG AXLE VALVE CONFIGURATION EXHAUS...

Page 159: ...ownload the latest version of the software Condition Experienced Action to Take Troubleshooting Details Axle Load Monitoring Function Unavailable in TOOLBOX PLUS Software Inspect WABCO iABS part numbe...

Page 160: ...epair all faults found Ensure that Axle Load Monitoring function is activated From the main screen of Trailer ABS diagnostics select the Modify pull down Select GIO configurations and active settings...

Page 161: ...STEM DIAGNOSTIC ABS SENSOR C GIO 2 4015099c WABCO PPV HEIGHT CONTROL VALVE AXLE LOAD MONITORING WITH 2S 1M PREMIUM P N 400 500 350 0 RIDE BAG RIDE BAG RIDE BAG RIDE BAG STATIC AXLE STATIC AXLE PRESSUR...

Page 162: ...AGNOSTIC 3rd MODULATOR GIO 2 ABS SENSOR E ABS SENSOR C 4015099d WABCO PPV HEIGHT CONTROL VALVE AXLE LOAD MONITORING WITH 4S 2M PREMIUM P N 400 500 430 0 RIDE BAG RIDE BAG RIDE BAG RIDE BAG STATIC AXLE...

Page 163: ...Manual available at www wabco na com If the Tire Inflation system status lamp is not present or is not functioning then the Tire Inflation Communication System will not function The TOOLBOX PLUS Softw...

Page 164: ...meter Switching the leads in the opposite direction an Open should be displayed on the volt ohm meter Refer to Figure 9 24 Check jumper harnesses P N 449 025 XXX 0 for Hendrickson Tiremaax Tire Infla...

Page 165: ...B 4 NOT USED NOT USED NOT USED A A A A B A C A D A E B B 2 B 1 NOT USED B 5 B 4 B 6 B 7 B 8 A A A B A POWER CABLE FOR iABS P N 449 306 XXX 0 A E A C A D B A Fig 9 24 4012493b 1 BLACK 2 NOT CONNECTED D...

Page 166: ...WIRE Fig 9 26 4016454b PRE INSTALLED WABCO MTIS PIGTAIL CABLE SENSOR EXTENSION CABLE OPTIONAL P N 449 712 XXX 0 MERITORTIRE INFLATION SYSTEM MTIS POWER SUPPLY ABS SENSOR F ABS SENSOR D GIO 1 SUBSYSTE...

Page 167: ...ONNECTOR MTIS STATUS DETECTION BY WABCO iABS SYSTEM Fig 9 28 POWER CABLE P N 449 306 XXX 0 TIS CABLE P N 449 743 XXX 0 4016466a CONTROLLER ASSEMBLY CONNECTOR FIVE PIN POWER SUPPLY CONNECTOR INDICATOR...

Page 168: ...the override switch configuration For additional information refer to TP19015 Door Ajar Installation Manual available at www wabco na com This troubleshooting section is based on the use of TOOLBOX P...

Page 169: ...Door Ajar Cable P N 449 827 XXX 0 is used Check the Door Ajar Cable connection at ECU Check if Door Ajar Cable P N 449 827 XXX 0 is connected at GIO port 1 Refer to Figures 9 30 and 9 31 for correct...

Page 170: ...S SENSOR D GIO 1 SUBSYSTEM DIAGNOSTIC ABS SENSOR C 4016883a JUNCTION BOX PROXIMITY SWITCH P N 446 147 XXX 4 DOOR AJAR WITH 2S 1M PREMIUM P N 400 500 350 0 POWER CABLE P N 449 306 XXX 0 DOOR AJAR CABLE...

Page 171: ...GIO 1 SUBSYSTEM DIAGNOSTIC 3rd MODULATOR GIO 2 ABS SENSOR E ABS SENSOR C DOOR AJAR WITH 4S 2M PREMIUM P N 400 500 430 0 4016882a JUNCTION BOX PROXIMITY SWITCH P N 446 147 XXX 4 POWER CABLE P N 449 30...

Page 172: ...e visit wabco snapon com to purchase and download the latest version of the software Condition Experienced Action to Take Troubleshooting Details Integrated Speed Switch Function Unavailable in TOOLBO...

Page 173: ...gs will be displayed If it is not activated then follow the procedures to activate the function Check the plumbing and electrical connections Refer to Figures 9 33 and 9 34 for correct installation Fi...

Page 174: ...174 Troubleshooting Fig 9 35 4017186a...

Page 175: ...S INDICATOR LAMP OPERATION BULB CHECK INFORMATION FOR DRIVERS Signal from trailer to tractor ECU Status of Trailer ABS Lamp on vehicle dash Explanation n o s e m o c p m a l S B A r e l i a r T s r e...

Page 176: ...ault d n a n o s i p m a l S B A s e l p i t l u M o t r e l i a r T e l g n i S stays on when a new trailer with no new fault is added There was a fault in existence before the new trailer was added...

Page 177: ...e EP 633 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 Use WABCO...

Page 178: ...st the sensor output voltage Use a volt ohm meter to check the output voltage of the sensors while rotating the wheel at approximately 1 2 revolution per second Minimum output must be 0 2 volts AC tho...

Page 179: ...but not tight enough to pinch the internal wires Refer to technical bulletins TP20212 and TP1593 for more information Figure 12 1 Fig 12 1 4012600a X Wiring should NEVER go through any bare unprotecte...

Page 180: ...e connector Internal wire stress at bend points can be the result of a cable under tension Cable strain relief is a universal practice It applies to all WABCO product lines from Anti Lock Brake ABS sy...

Page 181: ...ER FASTENER ZIPTIE ZIPTIE Bend radius R equal to or greater than 10 times cable diameter D R 10 x D First fastener must be a minimum 6 inches 152 mm and a maximum of 12 inches 305 mm from connector BR...

Page 182: ...e remote mounted cables the sensor extension cables are attached to the air lines Cable clips are preferred over zip ties It is important to remember that cables should be fastened in a manner where t...

Page 183: ...train relief Ensure that cables are not pinched bent or wrapped around any fittings in the cable proximity 12 2 6 Connection of Cables It is important to ensure all cable to cable connections maintain...

Page 184: ...uch as axles should also be electrically connected to the common chassis ground If the axles are not correctly grounded to the chassis a ground strap electrically connecting the axle to the chassis ma...

Page 185: ...e Yes Yes Yes Yes Yes GIO Capable No Yes No No Yes Direction of Control Side to Side Side to Side Side to Side Axle to Axle Side to Side PARTS LIST Slot on iABS Modulator Application Part Number Lengt...

Page 186: ...M 10 M GIO 1 or 2 GIO Cable 2 Pin 449 408 010 0 449 408 040 0 449 408 060 0 1 M 4 M 6 M GIO 1 or 2 GIO Cable Blunt Cut 4 Wire 449 827 030 0 449 827 060 0 449 827 120 0 449 827 180 0 3 M 6 M 12M 18 M G...

Page 187: ...187 Notes Notes...

Page 188: ...ology milestones in autonomous mobility and apply its extensive expertise to integrate the complex control and fail safe systems required to efficiently and safely govern vehicle dynamics at every sta...

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