WABCO SMARTTRAC MM1543 Maintenance Manual Download Page 2

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Summary of Contents for SMARTTRAC MM1543

Page 1: ...SMARTTRAC HYDRAULIC ANTI LOCK BRAKING SYSTEMS MAINTENANCE MANUAL MM1543...

Page 2: ......

Page 3: ...fety Information 8 2 1 Provisions for a safe work environment 8 3 Introduction 9 3 1 About This Manual 9 3 2 Manual Information 9 3 3 Overview 9 3 4 System Components 12 4 Troubleshooting and Testing...

Page 4: ...erica LLC reserves the right to revise the information presented or to discontinue the production of parts described at any time You will find the current edition at https zf com cvliterature 5 Compon...

Page 5: ...ored CAUTION Description of a possible situation which may result in irreversible injury if the warning is ignored NOTICE Description of a possible situation which may result in material damage if the...

Page 6: ...ghway Traffic Safety Administration NHTSA website to find all current documents referenced in the manual at www nhtsa gov 1 3 How to Obtain Parts and Kits Contact the WABCO Customer Care Center at 855...

Page 7: ...General Information 1 7 Your Direct Contact to ZF CVS ZF CV Systems North America LLC 1220 Pacific Drive Auburn Hills MI 48326 Customer Care Center 855 228 3203 www zf com cv wabconacustomercare zf co...

Page 8: ...spiratory protection and ear protectors Read and observe all Danger Warning and Caution hazard alert messages in this publication They provide information that can help prevent serious personal injury...

Page 9: ...ydraulic Power Brake MM1543 SmartTrac HABS Copies of these manuals are posted on our website https zf com cvliterature 3 3 Overview WABCO SmartTrac Hydraulic Anti lock Braking System HABS is an electr...

Page 10: ...e wheel starts to spin ATC pulses hydraulic pressure to reduce the wheel spin This transfers engine torque to the wheels with better traction b If all drive wheels spin ATC reduces engine torque to pr...

Page 11: ...ucing totally eliminating the rolling back of the vehicle while launching on a grade When requested from the transmission HSA holds pressure in the service brakes of all axles of the towing vehicle wh...

Page 12: ...lator assembly s orientation 4013016a 0 20 360 Z 1 2 5 5 X Y 3 4 System Components The SmartTrac hydraulic ABS unit consists of an electronic control unit ECU mounted directly on a modulator assembly...

Page 13: ...ilure The modulator assembly houses the system s solenoid control valves There are three valves per wheel including an inlet and outlet for controlling ABS and the third to control ATC rear axle only...

Page 14: ...Produces an output voltage proportional to the wheel speed 1004685a 3 4 3 2 Sensor Spring Clip Holds the wheel speed sensor in close proximity to the tooth wheel 1004686a 3 4 3 3 Tooth Wheel A machine...

Page 15: ...ESC system It measures the vehicle yaw rate as well as vehicle lateral acceleration The ESC module includes part of the ESC control algorithm It exchanges data with the ECU via the ESC system internal...

Page 16: ...d due to a failure The ATC lamp will flash when ATC is active See the How ATC Works section of this manual for details about ATC ABS and ATC warning lamps are included as part of the instrument cluste...

Page 17: ...egularly scheduled maintenance required for the WABCO SmartTrac hydraulic ABS unit However ABS does not change current vehicle maintenance requirements For example it is important that the vehicle bra...

Page 18: ...uit Label 1 Pump Motor Supply 12v KL30_P 2 Not Used 3 Not Used 4 Not Used 5 Not Used 6 Not Used 7 Not Used 8 Ignition 12v IGN 9 Not Used 10 Not Used 11 Not Used 12 J1939 High CAN_1H Vehic Bus 13 J1939...

Page 19: ...IGN ATC SWITCH IN SC SUPPLY SC GND CAN_2H CAN_2L CAN_1H VEHICLE BUS CAN_1L VEHICLE BUS KL30_P KL30_VS GND 33 45 46 43 42 36 37 8 14 12 13 1 32 47 34 SENSOR FRONT RIGHT 2x0 75 mm 2 TWISTED SENSOR FRON...

Page 20: ...to the User s Manual at https zf com cvliterature under Service and Support TOOLBOX Software Contact the WABCO Customer Care Center at 855 228 3203 for information about TOOLBOX Software 4 3 2 SmartT...

Page 21: ...ta and ESC End of Line EOL Calibration procedure Miscellaneous Components Allows the ABS and ATC lamps to be toggled on and off Also allows ABS pump activation All vehicles may not have an ATC lamp En...

Page 22: ...area or route the exhaust hose outside WARNING To avoid serious personal injury keep away and keep test equipment away from all moving or hot engine parts CAUTION When testing set the parking brake an...

Page 23: ...on but do not go out after three seconds check all ABS fuses See the System Diagnostics section of this manual to check lamp function using TOOLBOX Software Not all vehicles are equipped with an ATC l...

Page 24: ...ck for correct ground Verify that the resistance between pin 47 and chassis ground is less than 1 ohm 5 Perform load impedance test Contact the WABCO Customer Care Center at 855 228 3203 for simple wa...

Page 25: ...the ECU pins indicated in Table A Refer to figure for pin identification 3 To measure the resistance at the sensor connector disconnect the sensor from the sensor extension cable Measure across each...

Page 26: ...ecks all of the ECU connectors must be plugged in as well as the SAS The ECU provides voltage ground and CAN communication to ESC module Take measurements at the ESC module harness connector Measure v...

Page 27: ...r ground No continuity 3 and 4 With ECU disconnected check CAN lines for battery voltage or ground No continuity 3 CAN High Voltage to Chassis Ground 2 5 5 0V 4 CAN Low Voltage to Chassis Ground 0 1 2...

Page 28: ...28 Troubleshooting and Testing 4015710a 4015711a...

Page 29: ...ltage on Pin 4 Check Key On Voltage Supply on Pin 5 Check Key Off resistance across CAN low Pin 1 and CAN High Pin 4 Location Measurement WABCO SAS terminating resistor on sensor Approximately 180 ohm...

Page 30: ...NGLE SENSOR 4007216a STEERING ANGLE SENSOR CONNECTOR 1 2 3 4 5 6 Pin Circuit 1 CAN Low 2 Terminating Resistor 3 CAN High 4 CAN High 5 Power 6 Ground Do not load test across power and ground at the SAS...

Page 31: ...ound to chassis ground Less than 1 ohm resistance 4 12 J1939 Serial Communications Testing Electrical Checks If the ABS ECU is the only ECU on the J1939 datalink which cannot communicate then take mea...

Page 32: ...ts approved for use on WABCO sensors and spring clips are as follows Mobilith SHC 220 Mobil TEC 662 Roy Dean Products Staburags NBU 30 PTM Kluber Lubrication Valvoline EP 633 5 1 2 Wheel Speed Sensor...

Page 33: ...Correctly bundle and store any excess cable in the sub frame at a minimum of a 0 6 inch 15 mm radius Bundle excess cable 1004707a 8 Remove the blocks and safety stands 9 Perform a voltage output check...

Page 34: ...interference the entire bracket and valve assembly can be removed The SmartTrac hydraulic ABS assembly is manufactured and sold as one part Replacement of the individual components is not available 1...

Page 35: ...and tighten the bracket to frame fasteners to the OEM specification 3 Connect and tighten the brake line connections to 11 2 2 ft lb 15 3 Nm Ensure that the thread savers are not tightened beyond 15 2...

Page 36: ...T 4 brake fluid Refer to the vehicle specifications in the vehicle manual to determine which fluid to use WARNING Failure to bleed the system whenever any hydraulic system fitting is loosened or disco...

Page 37: ...of manufacturers and include instructions for use 1004709a 5 2 3 Service Replacement Bleed Procedure If a service replacement ABS module was purchased these units have been pre filled from the factor...

Page 38: ...l line 6 Release pressure for three to five seconds Apply pressure for five to 10 seconds 7 Repeat Step 5 and Step 6 approximately 10 times If necessary add fluid to the reservoir making sure that the...

Page 39: ...uid begins to flow about 3 4 turn Allow the hydraulic brake fluid flow out of the fitting until it is free of air bubbles Ensure that all four wheel ends are free of air bubbles and the bleeder fittin...

Page 40: ...Switching Sequence FRONT Axle 4013020a 13 Repeat Steps 8 and 9 to bleed all four wheel ends again to ensure any air released from the ABS module has been pushed out of the system Bleed in sequence of...

Page 41: ...rake pedal five times using the stroke between 1 3 travel and maximum travel 4 Release the pedal for five to 10 seconds Air bubbles may rise into the reservoir while depressing and releasing the pedal...

Page 42: ...peat Step 7 for the remaining three wheel ends Ensure all four wheel end bleed fittings are closed 1004710a 9 Open the TOOLBOX Software using the icon then open the SmartTrac screen by selecting the T...

Page 43: ...lves is removed 11 Follow the on screen bleed procedure instructions as they are displayed to ensure correct bleeding sequence The sequence is Pump Flush ESC Switching Sequence REAR Axle then ESC Swit...

Page 44: ...prevent the vehicle from moving 4 Locate the SAS on the steering column shaft either near the universal joint on the bottom of the column or under the steering wheel near the top of the column 5 If t...

Page 45: ...When the ESC End of Line Calibration Procedure is completed the ABS and ATC ESC lamps should come on and go back off when ignition power is turned on The ATC ESC lamp may remain on briefly after the A...

Page 46: ...ule is aligned correctly and the tab on the ESC mounting surface fits into the appropriate hole 1 Install the ESC module with the two capscrews and nuts Tighten the capscrews per the manufacturer s re...

Page 47: ...erified using one of the following allowed faults SAS not calibrated SPN 1807 FMI 08 ESC initialization required SPN 520210 FMI 14 CAUTION Additional faults must not be active Any other faults must be...

Page 48: ...48 Component Replacement 4015712a To access the ESC EOL From the bar menu at the initial screen click on the Components button A drop down menu will appear Select the option ESC 4015713a...

Page 49: ...ts have been replaced it is necessary to recalibrate SAS regardless of current calibration The vehicle needs to be sitting still during SAS calibration To complete the SAS Calibration position the ste...

Page 50: ...driving adjustment can be done in segments as the ECU will accumulate the information until the 273 yards is reached Cornering and stopping is allowed as long as calibration is done within the same i...

Page 51: ...splay the ESC straight driving Steering Ratio Learning and ESC End of Line Status as Complete 4012629a The ESC EOL Initialization procedure is completed Click the Close button to close the screen If E...

Page 52: ...that was being attempted reload parameters 13 Incorrect parameter or checksum failure 629 ECU System component 2 ECU internal failure Reset the ECU by cycling the ignition or by using the reset optio...

Page 53: ...ion in the TOOLBOX Software If the fault persists check the ABS ECU powers and grounds After checking powers and grounds if fault still persists it may indicate the unit has failed 933 Inlet valve rig...

Page 54: ...the TOOLBOX Software If the fault persists check the ABS ECU powers and grounds After checking powers and grounds if the fault still persists it may indicate the unit has failed 10 2 13 1052 Pressure...

Page 55: ...ed Check for the correct sensor setting air gap 0 2 to 1 7 mm Check the bearing clearance and tone ring run out Eliminate the cause of the increased air gap and correct the sensor setting Check the to...

Page 56: ...ing damaged or corroded Check correct sensor setting air gap 0 2 to 1 7 mm Check the bearing clearance and tone ring run out Eliminate the cause of the increased air gap and correct the sensor setting...

Page 57: ...gap 0 2 to 1 7 mm Check the bearing clearance and tone ring run out Eliminate the cause of the increased air gap and correct the sensor setting Check the tone ring for damage missing teeth and corros...

Page 58: ...utput signal Check for the correct sensor setting air gap 0 2 to 1 7 mm Check bearing clearance and tone ring run out Eliminate cause for increased air gap and correct sensor setting Check the tone ri...

Page 59: ...grammed correctly for vehicle 5 Sensor defective Open connection Sensor impedance out of normal operating range Check the sensor wiring harness and connection for damage interruptions Replace the sens...

Page 60: ...sensor output signal Check for the correct sensor setting air gap 0 2 to 1 7 mm Check the bearing clearance and tone ring run out Eliminate the cause of the increased air gap and correct the sensor se...

Page 61: ...tact the WABCO Customer Care Center at 855 228 3203 to check the parameter setting of the ECU and SAS compatibility 7 The calculated steering ratio of the vehicle is not plausible Check for correct mo...

Page 62: ...ECU and SAS for interruptions and short circuits Check for corroded or damaged wiring between the ECU SAS and ESC module 10 ESC system detects a plausibility issue while driving Verify the SAS and ESC...

Page 63: ...guration file into the new programmable SmartTrac hydraulic ABS module using WABCO s TOOLBOX Software Aftermarket Programming application and an RP1210 diagnostic adapter See Minimum Requirements for...

Page 64: ...t explaining how to complete the service operation 4013301a Step 2 Install the SmartTrac hydraulic ABS module into the vehicle following the procedures in Section 5 When the replacement SmartTrac hydr...

Page 65: ...creen If TOOLBOX Software is not available at the point of service it can be purchased by clicking the TOOLBOX Software button 4013303a Enter the part details for the vehicle being worked on and the p...

Page 66: ...IN part number and SmartTrac hydraulic ABS module functionality matches the SmartTrac hydraulic ABS module being replaced If this information is correct click the Add to shopping cart button 4013306a...

Page 67: ...late based on login information all fields can be edited Click on Bill To This Address when contact info is filled out Aftermarket Programming Configuration Files will not be charged and you will not...

Page 68: ...configuration file will be available in your account for seven days from purchase The configuration file must be downloaded to a computer within that time The following message will be displayed regar...

Page 69: ...start programming the SmartTrac hydraulic ABS module Wireless diagnostic adapters should not be used for aftermarket programming or any other WABCO programming operation It is recommended that afterm...

Page 70: ...ic ABS module Aftermarket Programming will change the SmartTrac hydraulic ABS module parameters 4013316a The Aftermarket Programming application will then locate the configuration file Click OK to sel...

Page 71: ...bottom of the aftermarket programming application window Within the text box an error code will be displayed with instructions If the programming operation cannot be completed record the error code a...

Page 72: ...n serves the full commercial vehicle industry value chain As the automotive industry progresses towards an increasingly autonomous connected and electrified ACE future ZF s CVS division innovates inte...

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