WABCO Easy-Stop Basic Maintenance Manual
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WABCO Easy-Stop Basic Maintenance Manual

WABCO Easy-Stop Basic Maintenance Manual

2s/1m (basic and standard), 2s/2m, 4s/2m and 4s/3m systems.
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EASY-STOP™ TRAILER
ABS: 2S/1M (BASIC AND
STANDARD), 2S/2M, 4S/2M
AND 4S/3M SYSTEMS
MAINTENANCE MANUAL

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Summary of Contents for WABCO Easy-Stop Basic

  • Page 1 EASY-STOP™ TRAILER ABS: 2S/1M (BASIC AND STANDARD), 2S/2M, 4S/2M AND 4S/3M SYSTEMS MAINTENANCE MANUAL...
  • Page 2 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.

  • Page 3: Table Of Contents

    Table of Contents Asbestos and Non-Asbestos Fiber Warnings ........ii Section 1: Introduction .
  • Page 4 Material exposure to non-asbestos fiber dust, a cancer and lung disease hazard. Material Safety Data Sheets are available from WABCO. Safety Data Sheets are available from WABCO. Hazard Summary...

  • Page 5: Section 1: Introduction

    Section 1 Introduction Overview Section 1Introduction Figure 1.1 This manual describes how WABCO's Easy-Stop™ Trailer Anti-Lock Braking System (ABS) works; SERIAL NUMBER 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;...
  • Page 6 What Is WABCO’s Easy-Stop™ Trailer ABS? How Trailer ABS Works WABCO’s Easy-Stop™ Trailer ABS is an electronic, WABCO ABS is an electronic system that monitors self-monitoring system that works and controls wheel speed during braking. The with standard air brakes. The major components...

  • Page 7: Section 2: System Components

    Section 2 System Components Sensor with Molded Socket Section 2System Components ECU/Valve Assembly Measures the speed of a tooth wheel rotating 12 volt with the vehicle wheel. Integrated ECU and ABS relay valve Produces an output voltage proportional to The 2S/1M Basic ECU/Valve Assembly does not wheel speed.
  • Page 8 Section 2 System Components Connection Cable for ABS External Valves Diagnostic Cable Three-wire cable with connector. Provides for blink code diagnostics and ® diagnostics using the MPSI Pro-Link 9000 Connects the ABS external valve to the ECU. diagnostic tool. “Y” cable for use with 4S/3M configurations Five-wire cable with over-molded connector to also available.
  • Page 9 Section 2 System Components Diagnostic Cable Mounting Bracket Diagnostic Cable Assembly with Diagnostic Tool Bracket used to mount the diagnostic cable Diagnostic cable mounted to the bracket with a assembly to the trailer. diagnostic tool connected to the SAE J1587 diagnostic connector.
  • Page 10 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 for Part Number TP-95172. ® MPSI Pro-Link 9000 Diagnostic Tool Provides diagnostic and testing capability for ABS components.

  • Page 11: Section 3: Abs Questions And Answers

    Section 3 ABS Questions and Answers The Electronic Control The ABS Warning Lamp Section 3ABS Questions and Answers Unit (ECU) What is the function of the warning lamp? How do you activate the ECU? The warning lamp enables a driver to monitor the ABS at all times.
  • Page 12 For more information, contact WABCO North ensure proper braking performance and that the America Customer Care at 855-228-3203.

  • Page 13: Types Of Faults

    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.
  • Page 14 Notes Page 10...

  • Page 15: Section 4: System Configurations

    Section 4 System Configurations Section 4System Configurations 2S/1M Trailer ABS Configuration Without External Diagnostics Capability Installation Diagram Figure 4.1 ECU/VALVE ASSEMBLY (YE) AIR TANK AIR TANK A Service/Control Lines B Sensor Cables C Service to Brake Lines (Delivery Lines) D Air Supply/Emergency Lines 1003292e Service/Control Lines Sensor Cables...
  • Page 16 Section 4 System Configurations 2S/1M Trailer ABS Configuration with External Diagnostics Capability Installation Diagram Figure 4.2 ECU/VALVE ASSEMBLY (YE) AIR TANK AIR TANK A Service/Control Lines B Sensor Cables C Service to Brake Lines (Delivery Lines) D Air Supply/Emergency Lines 1002086f Service/Control Lines Sensor Cables...

  • Page 17: 2S/2M Trailer Abs Configuration Installation Diagram

    Section 4 System Configurations 2S/2M Trailer ABS Configuration Installation Diagram Figure 4.3 ECU/VALVE ASSEMBLY (YE) EXTERNAL VALVE (BU) AIR TANK AIR TANK A Service/Control Lines B Sensor Cables C Service to Brake Lines (Delivery Lines) D Air Supply/Emergency Lines 1002087e Service/Control Lines Sensor Cables Service to Brake Lines (Delivery Lines)

  • Page 18: 2M Trailer Abs Configuration Installation Diagrams

    Section 4 System Configurations 4S/2M Trailer ABS Configuration Installation Diagram Figure 4.4 ECU/VALVE ASSEMBLY (YE) EXTERNAL VALVE (BU) AIR TANK AIR TANK A Service/Control Lines B Sensor Cables C Service to Brake Lines (Delivery Lines) D Air Supply/Emergency Lines 1002088e Service/Control Lines Sensor Cables Service to Brake Lines (Delivery Lines)
  • Page 19 Section 4 System Configurations 4S/2M Trailer ABS Configuration Diagram for Lift Axle Applications (Forward Lift Axle Installation Diagram) Figure 4.5 FIXED AXLE LIFT AXLE ECU/VALVE ASSEMBLY (YE) EXTERNAL VALVE (BU) AIR TANK AIR TANK LIFT AXLE FIXED AXLE A Service/Control Lines B Sensor Cables C Service to Brake Lines (Delivery Lines) D Air Supply/Emergency Lines...
  • Page 20 Section 4 System Configurations 4S/2M Trailer ABS Configuration Diagram for Lift Axle Applications (Rear Lift Axle Installation Diagram) Figure 4.6 FIXED AXLE LIFT AXLE ECU/VALVE ASSEMBLY (YE) EXTERNAL VALVE (BU) AIR TANK AIR TANK LIFT AXLE FIXED AXLE A Service/Control Lines B Sensor Cables C Service to Brake Lines (Delivery Lines) D Air Supply/Emergency Lines...

  • Page 21: 4S/3M Trailer Abs Configuration Installation Diagram

    Section 4 System Configurations 4S/3M Trailer ABS Configuration Installation Diagram Figure 4.7 ECU/VALVE ASSEMBLY (YE) EXTERNAL VALVE (RED) AIR TANK AIR TANK EXTERNAL VALVE (BU) A Service/Control Lines B Sensor Cables C Service to Brake Lines (Delivery Lines) D Air Supply/Emergency Lines 1003293e Service/Control Lines Sensor Cables...

  • Page 22: Power Cable Wiring Diagrams

    Section 4 System Configurations Power Cable Wiring Diagrams Figure 4.8 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) WHITE AND YELLOW TRAILER ABS WHITE INDICATOR LAMP (GROUND)
  • Page 23 Section 4 System Configurations Power Cable Wiring Diagrams Figure 4.10 STOPLIGHT POWER CIRCUIT P/N 894 604 19X 2 3 CONDUCTOR CABLE WHITE BLUE BLACK BROWN YELLOW WHITE GREEN Connect to Easy-Stop™. GREEN Trailers produced prior to March 1998. INDICATOR LAMP 1003303c Figure 4.11 STOPLIGHT POWER CIRCUIT...
  • Page 24 Notes Page 20...

  • Page 25: Section 5: Diagnostics

    Customer Care at 855-228-3203 for assistance. vehicle is in operation.) 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.
  • Page 26 Verify proper sensor resistance and air gap. Make necessary repairs. ECU/Valve Assembly Verify proper installation. Make sure all connections are secure. If code continues, contact WABCO for assistance. Power Supply Verify proper electrical installation and connections. Check power supply. Make necessary corrections.

  • Page 27: Diagnostic Tools For Ecus With External Diagnostic Connectors

    (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 1002092a The blink code diagnostic tool inserts into the...
  • Page 28 Section 5 Diagnostics How to Test for Existing Faults 6. When there are existing faults: You must repair existing faults. Using the Normal Mode After you identify an existing fault, turn the When you use Normal Mode diagnostics, the blink power to the ECU OFF.

  • Page 29: Repair Existing Faults

    Section 5 Diagnostics Repair Existing Faults c. Immediately depress the switch once for one second. The blink code lamp will come back ON. With Normal Mode diagnostics, you must repair an existing fault before you can identify and d. Immediately release the switch once repair the next existing fault stored in ECU for one second.
  • Page 30 Notes Page 26...

  • Page 31: Section 6: Component Replacement

    Section 6 Component Replacement WARNINGS Apply a mineral oil-based grease that contains Section 6Component Replacement molydisulfide to the sensor spring clip and to To prevent serious eye injury, always wear the body of the sensor. The grease must be safe eye protection when you perform vehicle anti-corrosive and contain adhesive properties maintenance or service.

  • Page 32: Abs Relay Valve

    Section 6 Component Replacement 4. Install the wheel hub carefully, so that the How to Install a Standard ABS tooth wheel pushes against the sensor as you Relay Valve adjust the wheel bearings. After installation there should be no gap between the sensor and the tooth wheel.
  • Page 33 Section 6 Component Replacement 6. If the assembly being replaced is under Figure 6.5 warranty, please return it to the trailer OEM for replacement. BRACKET How to Install the ECU/Valve Assembly NOTE 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...

  • Page 34: How To Install The Blink Code Diagnostic Tool Into The Sae J1587 Diagnostic Connector

    Section 6 Component Replacement 2. Connect the air lines to the ports. Follow the b. Push the diagnostic tool firmly into the label markers installed when the air lines were connector. Refer to Figure 6.8 . disconnected. NOTE 3. Connect the sensor cables, external relay valve cable (if used), diagnostic cable, and power You must replace the grey protective cap if you cable to the ECU/Valve Assembly.

  • Page 35: Section 7: Sensor Adjustment & Component Testing

    How to Test Wheel Check ABS Functions Section 7Sensor Adjustment & Component Testing Speed Sensors WABCO recommends that you test a vehicle's ABS after a new installation and after you NOTE diagnose, repair and erase faults in the ABS. At initial installation, no gap must exist between Perform installation tests and blink code the sensor and the tooth wheel.

  • Page 36: Final Test Before Returning A Trailer To Service

    For ECU/Valve Assembly Part Number 472 500 011 0 (without external diagnostic connector) NOTE If you are testing ECU 472 500 001 0, contact WABCO North America Customer Care at 855-228-3203. ABS Electrical/Hardware Installation Test 2. Observe the ABS warning lamp and the blink Provide 12 volts DC power (9.5–14 volts is an...
  • Page 37 Sensor YE2 Check sensor installation. (roadside Verify proper installation. Make necessary repairs. sensor) Failure If code continues, contact WABCO for ECU/Valve Verify proper installation. assistance. Assembly If blink code continues, contact WABCO for After making the necessary corrections, repeat assistance.

  • Page 38: For Ecu/Valve Assembly Part Numbers 472 500 012 0 And S 472 500 013 0 (Units With External Diagnostic Connector)

    2. Observe the ABS warning lamp and the blink code lamp on the ECU. Check the results NOTE in Table I . If you are testing ECU Part Number 472 500 001 0, contact WABCO North America Customer Care at 855-228-3203. Table I Status Action...
  • Page 39 6. Rotate each sensed wheel — ONE AT A TIME — WABCO Easy-Stop™ ABS on a new trailer. at a rate of 1/2 revolution per second. Apply control pressure to activate the brakes. Refer to Remove power from the ABS.

  • Page 40: Trailer Identification

    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...

  • Page 41: Appendix A: Expert Mode Diagnostics

    Section 8 Appendixes Appendix A b. Release the switch. The blink code lamp Section 8Appendixes will go OFF. c. Depress the blink code lamp switch once Expert Mode Diagnostics for one second. The blink code lamp will come ON. When you use Expert Mode diagnostics, the blink code lamp identifies and displays existing and d.
  • Page 42 Section 8 Appendixes Blink Code Example (4S/2M Configuration) Expert Mode Figure 8.1 BLINK CODE 3-5-2 = CUT SENSOR CABLE FAULT CODE 3 Flashes = I.D. = 4S/2M 1st Digit 2nd Digit 3rd Digit Lamp stays ON after all fault code sequences 2.5 S 2.5 S 2.5 S...
  • Page 43 ECU/Valve Assembly Internal Failure Erase fault. ECU/Valve Assembly Internal Failure Erase fault. Electromagnetic Various Contact WABCO North America Interference Customer Care, 855-228-3203. ECU/Valve Assembly Internal Failure Contact WABCO North America Customer Care, 855-228-3203. X = Number of Fault Occurrences Page 39...

  • Page 44: Appendix B: Reconfigure Mode

    Section 8 Appendixes Appendix B Reconfigure Mode Blink Code Example (4S/2M Configuration) Reconfigure Mode Figure 8.2 3 Flashes = I.D. 3 Flashes = I.D. 3 Flashes = I.D. 8 Rapid Flashes = = 4S/2M 2.5 S = 4S/2M 2.5 S = 4S/2M ECU Reconfigured 2.5 S...
  • Page 45 Do NOT reconfigure the ECU LAMP COMES ON 2.5 SECONDS LAMP GOES OFF 2.5 SECONDS unless system usage has 2002111b changed. Contact WABCO North America Customer Care at 855- 228-3203 for assistance. NOTE How to Use the Reconfigure Mode To accept the ECU reconfiguration, you must...

  • Page 46: Appendix C: Warning Lamp Diagnostics

    Section 8 Appendixes Appendix C For Normal Mode: Turn ignition ON ONCE for ONE SECOND. Warning Lamp Diagnostics Turn ignition OFF for ONE SECOND. ECU Part Numbers 472 500 011 0, 472 500 012 0, Turn ignition back ON. and 472 500 013 0 –...
  • Page 48 Partnering with the transportation industry as it maps a route toward autonomous driving, WABCO also uniquely © 2018 WABCO North America – All rights reserved – MM-33 / 07.2018...

This manual is also suitable for:

Easy-stop standardTp-97147Tp-97153Tp-97145

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