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Anti-Lock Brake System (ABS), Rockwell Wabco

1. W5001213 Pin Circuit No Description 1 ABS ECU with housing closed 1 737 LR Sensor Signal 2 ABS ECU with housing open 3 Cab connector gray 2 738 LR Sensor Return 4 Front connector black 3 757 RR Sensor Signal 5 Rear connector green 6 6 channel connector brown used on vehi 4 758 RR Sensor Return cles with 6 sensors only 5 780 Traction Control Solenoid Source Cab Gray ECU Connector 6 781 Traction Control Solenoid Ground 5 e h Pin Circuit No Description 2 99 AA Modulator 4 777A 12V Supply 8 761 RR Modulator Common 2 7778 12V Supply 9 760 RR Modulator Hold 3 774 Traction Control System TCS Lamp n 799 4 400 J1587 1708 Data Link ju OE Common 5 772 Engine Brake Disable not used with 12 210 41939 405 1922 Data Link 6 Channel Brown ECU Connector or 6 Pin Circuit No Description 407 J1939 L 3 735 LR3 Sensor Signal 404 J1922 Data Link 4 736 LR3 Sensor Return 7 5 755 RR3 Sensor Signal 406 J1939 H 5 6 756 RR3 Sensor Return 8 408 41939 shield not used with J1922 1 2 Not Used 9 401 1587 1708 Data Link 742 10 778 ABS Warning Lamp Enable 11 ABS A Ground Used for 6S 4M only 12 ABS B Ground 68 Feedback One of our objectives is that workshop personnel should have access to correct and appropriate service man
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3. W5000579 W5000635 Spider Mounting Bolts Mounting Bracket Sensor Spring Clip Tooth Wheel Group 59 Anti Lock Brake System ROCKWELL WABCO Modulator Valve The ABS modulator valve is an air solenoid valve It has two solenoid coils One of the coils is energized to iso late the brake chamber from the brake system supply and vent the brake pressure from the brake chamber The other coil is energized to isolate the brake chamber from the brake system supply and hold the pressure that is in the brake chamber During normal braking compressed air for braking flows freely through the modulator valves to the brake cham bers When ABS function is required the modulator valve for the affected wheel is energized on and off in order to quickly but incrementally reduce the braking air pres sure to the point where the wheel begins to spin freely The modulator valves are located in the air supply path between the relay valve or quick release valve and the brake chambers They are physically attached to the frame rail near the front wheels which they supply and on the crossmember nearest the rear wheels 16 4 2 3 Port 1 In Port 2 Out Solenoid Connector Design and Function W5000658 Group 59 Anti Lock Brake System ROCKWELL WABCO R 14 Relay Valve The relay valve in an air brake system functions as a re lay station to speed up the application and release of the brakes The valve is normally mounted a
4. 5 Disconnect the ABS modulator valve connector 6 Disconnect the supply line from the ABS Modulator Valve coming from the brake chamber 7 Remove the two mount bolts from the ABS modulator valve 8 Using a wrench remove the two fittings J 44775 from the ABS modulator valve 9 Using a wrench install the two fittings J 44775 into the replacement ABS modulator valve with the correct pipe sealant 10 Install the replacement ABS modulator valve onto the proper mounting bracket 11 Connect the supply air line into the ABS Modulator Valve coming from brake chamber Group 59 Anti Lock Brake System ROCKWELL WABCO 12 Connect the ABS modulator valve con nector 13 Connect the ABS modulator valve sup ply airline at the brake chamber and the relay valve supply airline on top of the ABS modulator valve 14 Replace the removed zip ties to sup port airlines and various harnesses Service Procedures 5631 03 02 25 ABS ATC Valve Replacement Before beginning this procedure read the General Work Practices section General Work Practices page 57 for further procedural information AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death Before beginning this service procedure be sure to read and understand the general information and
5. An amber ABS warning lamp is provided in the instru ment cluster Its function is to notify the operator that the ABS system has detected an unusual condition or fault in the system The lamp will illuminate under the follow ing conditions e When the ignition switch is turned ON the lamp comes ON momentarily for a bulb check then goes out After servicing the ABS the lamp will stay ON until the vehicle speed reaches approximately 7 mph 11 km h then the lamp goes out e f the ABS self monitoring circuits detect a fault in the system e To display ROCKWELL WABCO blink codes for troubleshooting 22 Design and Function DIAGNOSTIC MESSAGES W5000659 TCS Lamp There is an amber TCS warning lamp on the instrument cluster The lamp has the following function e fthe TCS switch is off in Mud Snow mode the TCS lamp will blink continuously to remind the driver that TCS is in Mud Snow mode The Mud Snow function increases available traction on soft surfaces like snow slush or mud by slightly increasing the al lowable wheel spin Diagnostic Display The graphic display is on the left side of the instrument cluster It can be used to display diagnostic messages from the ABS The system uses the SAE J1587 J1708 data link Refer to Anti Lock Brake System page 29 for information on how to troubleshoot ABS problems Group 59 Anti Lock Brake System ROCKWELL WABCO Traction Control System The ABS on a vehicl
6. self Then remove all of the securing zip ties and disconnect the sensor har ness from inside the framerail 6 Remove the wheel speed sensor hous ing from the Backing Plate Bracket 7 Remove the wheel speed sensor from the vehicle 8 Install the replacement wheel speed sensor in the bracket 9 Route the replacement wheel speed sensor harness through the backing plate and the framerail 10 Install the wheel speed sensor bracket 11 Connect the wheel speed sensor se cure the two removed tie downs and replace all the removed zip ties 12 Install the brake drum 13 Reinstall the removed tire and wheel and adjust the brakes 14 Insuring that the jack is in a safe loca tion lift the vehicle and remove the jackstand 65 Group 59 Anti Lock Brake System ROCKWELL WABCO 5939 03 02 03 Wheel Speed Sensor Replace ment Heavy Duty Axle and or Aluminum Hub Before beginning this procedure read the General Work Practices section General Work Practices page 57 for further procedural information 1 AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death Before beginning this service procedure be sure to read and understand the safety information found in Anti Lock Brake System page 3 Park the vehic
7. Adjustment Before beginning this procedure read the General Work Practices section General Work Practices page 57 for further procedural information AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death Before beginning this service procedure be sure to read and understand the general information and safety precautions found in Anti Lock Brake System page 3 W5000941 Service Procedures Potential sensor damage DO NOT use a screwdriver or sharp instrument to adjust sensor Use of sharp in strument could cause sensor damage Slide the open end of a blunt instru ment such as a dowel rod through the sensor opening in the brake spider un til it rests against the sensor the ABS Sensor Adjustment Tool J 42942 will go in the hole at a slight angle Note It is not necessary to remove the wheel or drum to adjust sensors using this method J 42942 Potential sensor damage DO NOT use a hammer to drive the sensor into position Hammering the sensor could cause the sensor to be inoperative Press the sensor toward the wheel hub until the sensor contacts the tooth wheel 3 Remove the ABS Sensor Adjustment Tool J 42942 Sensor will self adjust after wheel rotation J 42942 4 Verify proper sensor
8. Note Disconnect the engine ECU ground wire if the vehicle is equipped with one Remove the battery box cover and dis connect the negative battery cables 3 Disconnect the three ABS ECU con nectors from the ECU 4 Cut the two zip ties securing the chan neled wiring harnesses to the brackets supported by the ECU studs and nuts Group 59 Anti Lock Brake System ROCKWELL WABCO 5 Remove the two ABS ECU stud nuts and remove the ABS ECU from the vehicle 6 Remove the three mounting bracket bolts from the ABS ECU 7 Install the mounting bracket on the re placement ABS ECU 8 Install the replacement ABS ECU on the vehicle 9 Secure the channeled wiring har nesses to the support bracket with zip ties 10 Connect the three ABS ECU connec tors 11 Reconnect the engine ECU ground wire Connect the negative battery ca bles and install the battery box cover Service Procedures 67 Group 59 Anti Lock Brake System ROCKWELL WABCO Appendix ABS ECU Connections Appendix ABS ECU Connections Front Black ECU Connector Pin Circuit No Description 2 733 LF Modulator Hold 3 752 RF Modulator Exhaust 4 753 RF Modulator Hold 5 750 RF Sensor Signal 6 751 RF Sensor Return 7 730 LF Sensor Signal 8 731 LF Sensor Return 9 754 RF Modulator Common 10 732 LF Modulator Exhaust 11 734 LF Modulator Common 1 12 Not Used Rear Green ECU Connector
9. be automatically applied to the spinning wheels Design and Function The ROCKWELL WABCO ABS System consists of the following components e Tooth Wheel 4 or 6 e Magnetic Sensor 4 or 6 e Sensor Brackets and Locks 4 or 6 e Modulator Valve 4 e One of the following Electronic Control Units ECUs ECU 4S 4M ABS Only ECU 4S 4M ABS with TCS ECU 6S 4M ABS with TCS e Fuses and Relays e ABS Warning Lamp e TCS Indicator Lamp e Connectors e TCS Switch if TCS is installed e TCS Valve if TCS is installed For design and function information about specific ABS components see the following Tooth Wheel page 15 Sensor page 15 Modulator Valve page 16 Electronic Control Unit ECU page 19 Electrical page 21 Instrumentation page 22 Traction Control System page 23 ABS Fault Detection page 24 ABS Self Tests page 25 Group 59 Anti Lock Brake System ROCKWELL WABCO Tooth Wheel The tooth wheel is an alloy ring that resembles a gear It usually has 100 teeth cut into its surface The purpose of the teeth are to cause a pulsating current flow in the sensor circuit As the high side of each tooth passes near the sensor it causes a small current to flow in the sensor When the area between two teeth is in front of the sensor the current flow stops As the tooth wheel rotates the starting and stopping of the current flow is seen by the ECU as pulses The greater the spee
10. be certain that the air pressure has been released Failure to do so may cause a component to violently separate which can result in serious per sonal injury Drain the complete air system 3 Remove any zip ties securing the air lines plumbed to this relay valve 4 Disconnect the six airlines with the J 44773 push lock fittings using special airline J 42189 release tools J 44773 and J 42189 5 Remove the two torx bolts that mount the brake relay valve mount bracket Service Procedures 6 Snug the brake relay valve in a vice J 44775 and remove all six airline fittings 7 Snug the replacement relay valve in a J 44775 vice and install the six airline fittings using pipe sealant 8 Install the replacement relay valve onto the vehicle 9 Connect the six airlines Note Push airline in completely and remove to insure proper seal 10 Replace all removed zip ties to secure the airlines plumbed to the relay valve 11 Start the engine to build the air sys tem in order to check for leaks and proper operation 63 Group 59 Anti Lock Brake System ROCKWELL WABCO 5939 03 02 02 Wheel Speed Sensor Replace ment Rear Axle Before beginning this procedure read the General Work Practices section General Work Practices page 57 for further procedural information 1 AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels F
11. cuit via the ABS ECU power relay R7 for the VN or PR2 for the VHD Also attached is a Terminating Resistor 2 For more information refer to page 27 and page 27 Relays Relays are mounted in the Truck Electrical Center TEC in the center dash The ABS ECU Power Relay R7 and PR2 are battery powered through a 30A maxi fuse Re lay R7 PR2 is energized by the ignition circuit 196B through a 40A maxi fuse and a 5A fuse R7 PR2 is grounded to the bus bar The ABS Warning Lamp Relay R3 for the VN and R9 for the VHD is powered through the same ignition circuit 196B as R7 PR2 with the 40A maxi fuse and 5A fuse The relay coil is controlled by the 778 circuit from the ABS ECU which is a ground signal R3 provides a ground from the bus bar to the 779 circuit in the instru ment cluster to turn the warning lamp off Relay R3 R9 can also be used to request blink codes and clear fault codes See Diagnosing Faults using Blink Codes page 44 and Clearing Fault Codes by Removing R3 R9 page 48 Wiring The wiring for the ABS is incorporated in the main cab and chassis wiring harnesses Refer to VN VHD Series Electrical Schematics for more information on routing and location of ABS wiring Design and Function In line fuses and Terminating Resistor Relay location in TEC in center dash W3004432 W5001200 21 Group 59 Anti Lock Brake System ROCKWELL WABCO Instrumentation ABS Warning Lamp Tractor
12. safety precautions found in Anti Lock Brake System page 3 Removal 1 Park the vehicle on a level surface ap ply the parking brake and block the wheels Ensure vehicle ignition is OFF 2 Bleed the air pressure from systems A and B 3 Disconnect the electrical connector from the valve 61 Group 59 Anti Lock Brake System ROCKWELL WABCO W5000672 Traction valve mounted on LH frame rail at rear crossmember Disconnect the air supply and dis 9 42189 charge lines from the valve fittings by pushing in on the air line and fitting collar with release tool J 42189 and pulling on the air line If air pressure is still in the system it is difficult to re lease the air line Be sure to drain all air before starting procedure 5 Remove the 2 valve mounting bolts 6 Release the exhaust air line from the valve using release tool J 42189 and remove the valve 7 Remove the air line fittings from the TCS ATO valve Note the position of the fittings for correct installation and alignment of air lines Installation 1 Apply sealant to the fitting threads In stall the fittings in the original position for connecting the air lines 2 Connect the air line for the exhaust port on the TCS valve Pull on the air line to be sure that it is locked into the fitting 62 Service Procedures 3 Install the valve to the mounting 24 Nm bracket using the two mounting bolts 18 ft lb
13. ABS modulator valve right forward rear tandem drive axle Remove R3 Stored Faults foris Displays all stored eE ES I PERERA Se faults once last fault 158 5492 OE e 9 Xe3 a s 209 269922992 stored is displayed first Light ON 1st Digit 2nd Digit 1st Digit 2nd Digit 1st Stored Fault 2nd Stored Fault 5 2 3 4 Blink Code 5 2 Sensor signal erratic left front steer axle 3 4 Too much sensor gap left forward rear tandem drive axle Remove R3 System O K fori S Blink Code 1 1 System OK Light ON 1 1 W5000667 45 Group 59 Anti Lock Brake System ROCKWELL WABCO Blink Code Diagnostics Chart Troubleshooting Rockwell WABCO Blink Codes First digit Second digit Specific location of fault 1 No faults 1 No faults 2 ABS modulator valve 1 Right front steer axle 3 Too much sensor gap 2 Left front steer axle 4 Sensor short or open 3 Right forward rear tandem drive axle 5 Sensor signal erratic 4 Left forward rear tandem drive axle 6 Tooth wheel 5 Right rear rear tandem drive axle 6 Left rear rear tandem drive axle 1 J1922 or J1939 data link 2 ATC valve 3 Retarder relay third brake 4 ABS warning lamp 5 TCS configuration 6 Not used 1 Low power supply 2 High power supply 8 ABS ECU 3 Internal fault 4 System configuration error 5 Ground 46 Group 59 Anti Lock Brake System ROCKWELL WABCO Troubleshooting Clearing Fault Codes
14. Fault codes may be cleared with the Pro Link and ROCK Note For information on the proper use of VCADS Pro WELL WABCO ABS cartridge or by removing relay R3 refer to the VCADS Pro User s Manual Publication PV776 030 600SM Clearing Fault Codes with the Pro Link Note Existing faults cannot be cleared until they have CLEAR ALL been repaired Clear faults from the ECU after the faults have been recorded on the work order and repaired STORED FAULT S 1 Connect the Pro link to the diagnostic socket lo cated under the left side of the dash CLEAR Y gt N 2 Turn the vehicle ignition ON 3 Important Record all fault codes on the work order 6 When the faults have been cleared the Pro Link before they are cleared They cannot be retrieved screen displays the following after clearing STORED FAULT S 4 Follow the Pro Link menus to select stored faults Existing faults cannot be cleared only stored faults CLEARED TRACTOR ABS MENU ENTER TO CONTINUE SELECTIONS 1 STORED FAULTS 5 Press the FUNC key To clear all stored faults use the and keys to place brackets around the Y in the last line of the display then press ENTER 47 Group 59 Anti Lock Brake System ROCKWELL WABCO Troubleshooting Clearing Fault Codes by Removing R3 R9 If a Pro Link is not available fault codes may be cleared 5 Check faults to verify that there are no faults re as f
15. Light ning Transmissions 27 28 Group 59 Anti Lock Brake System ROCKWELL WABCO Troubleshooting Troubleshooting Anti Lock Brake System 1 VCADS Pro See VCADS Pro page 30 2 Pro Link 9000 4 the Application card and MPC Cartridge version 4 0 or higher the Pro Link also provides a number of component tests See Diagnosing Faults using the Pro Link 9000 with Cartridge page 36 3 Instrument cluster diagnostic display see Diagnosing Faults using the Instrument Cluster page 42 4 ROCKWELL WABCO blink codes see Diagnosing Faults using Blink Codes page 44 5 Byremoving a relay see Clearing Fault Codes by Removing R3 R9 page 48 For additional troubleshooting information see e Component Troubleshooting page 49 e Other Component Troubleshooting page 53 All codes must be in a stored or inactive state before clearing Note Tire size range For proper ABS TCS operation with the standard ECU front and rear tire size must be within 1496 of each other Exceeding this size allowance with out electronically resetting the ECU may cause the warning lamp to illuminate and the System to deactivate If the difference between front and rear tire sizes will be greater than 14 contact ROCKWELL WABCO for instructions on how to reset the ECU Calculate the tire size with the following equation t Difference PIONEER is 100 RPM Drive RPM tire revolutions per mile 29 Group 59 Anti L
16. Menu Structure The application menu structure will assist you in locating specific functions of the Wabco ABS ATC application card Meritor Wabco ABS ATC File Structure Tractor Tractor NON D Trailer 8 lt Summary Summary Existing Fault Existing Fault Existing Fault Stored Faults Stored Faults Stored Faults Program Program Program e o SL 5113 2 5 2 a e o e v 2 5 2 Tests Tests Tests Vehicle Vehicle Trailer Voltages Voltages Voltages ABS Valves Valves Valves ATC Sensors Valves Service Info Tire Calibration ABS ATC Lamps ABS ATC Switches Valve System Setup Sensors Lamp Trailer Engine Lamp Datalink ABS Valves ABS ATC Retarder Reconfigure 9 g 5 3 3 3 gt gt 3 3168 Sa HS gt Switches Rela System Sensors Retarder Datalink Senor System Outputs Setup Sensor Voltages Display Tire Size Adjust Tire Size Engine Datalink Retarder Rela Tractor ABS ATC Retarder Datalink System Setup System Tractor ABS ATC 5 5 5001144 35 Group 59 Anti Lock Brake System ROCKWELL WABCO Troubleshooting Diagnosing Faults using the Pro Link 9000 with Cartridge AN DANGER AN DANGER Before working on a vehicle set the parking brakes Exhaust gases contain carbon monoxide When test place the transmission in neutral and block the ing a vehicle with the engine running
17. Pro Link configuration 8 Correct the faulty condition 4 If the display f isting fault tored faults i ES E pres tia FUNG Kei lo ABS S 9 Erase the fault from the ECU by cycling the ignition MENU OFF then back to ON 10 Repeat the process for any other existing faults TRACTOR ABS ATC MENU 11 When an existing fault has been repaired it changes to a stored fault Vemm SELECTIONS 12 Stored faults may also be displayed See Clearing Fault Codes page 47 for instructions on clearing a REASON SS stored fault Refer to the Pro Link manual for com plete diagnostic and testing information 36 Group 59 Anti Lock Brake System ROCKWELL WABCO Troubleshooting Component Tests Component tests are available using the Pro Link for the following ABS TCS components ABS VALVES Cycles the valves one at a time There is an audible click as the valve cycles ATC TCS Checks the traction control valve There is an audible click as the valve cycles ABS LAMP Check change the status on off of the ABS warning lamp ATC TCS LAMP Check change the status on off of the TCS lamp ABS ATC SWITCHES Checks the status of the ABS and TCS switches on the dash SENSORS Monitors the inputs to the ECU from the wheels ENGINE DATA LINK Checks J1922 wiring connections between the engine and the ECU for throttle back RETARDER RELAY Activates the relay to verify function a click will be heard Also checks wiring con necti
18. Torque the bolts to 24 Nm 18 ft lb W5000672 Traction valve mounted on LH frame rail at rear crossmember Connect the supply and delivery lines to the valve Pull on the air lines to be sure that they are locked into the fit tings 5 Connect the valve electrical connector and tighten the fastening ring 6 Build air pressure in the systems to J 38500 1 operating pressure approx 120 psi J 38500 404 Check for leaks and operation of the traction valve Operation of the valve can be checked with the Pro link tool J 38500 1 and ROCKWELL WABCO cartridge J 38500 404 Refer to Component Tests in the cartridge manual Group 59 Anti Lock Brake System ROCKWELL WABCO 5631 03 02 26 Brake Relay Valve Replace ment Before beginning this procedure read the General Work Practices section General Work Practices page 57 for further procedural information AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death Before beginning this service procedure be sure to read and understand the safety information found in Anti Lock Brake System page 3 1 Park the vehicle on a level surface with the transmission in neutral and the front wheels chocked Before beginning any service work on any part of the air system
19. Volvo Trucks North America Inc Greensboro NC USA Order number PV776 TSP139834 2000 Volvo Trucks North America Inc Greensboro NC USA All rights reserved No part of this publication may be reproduced stored in retrieval system or transmitted in any forms by any means electronic me chanical photocopying recording or otherwise without the prior written permission of Volvo Trucks North America Inc Contents 3 Anti Lock Brake System cri 3 cce M 5 Eleotronic Control uuum iio 5 TOOS Y Boscia Special Equipment mE 10 Design and Function 13 Anti Lock Brake SystelT u im nnns 13 System an 13 Des Wi u u y T 15 MONSON r M 15 as A e 16 R 14 Relay Yake sn id 12 Electronic Control Unit ECU uu ssim 19 zip Me 21 PESCE isis ideas 22 Traction Control System 23 ABS Faut DACRON 24 ABS ell 25 EIN res m rre 29 Anti Lock Brake System 29 FID u taire alea a 30 MPSI Pro Link 9000 with MPC Cartridge and Card 30 Diagnosing Faults using the Pro Link 9000 with Mm Tc 36 Diagnosing Faults using the Instrument Cluster 42 Diagnosing Faults using Blink Codes 44 Clearing Faul Codes 47 C
20. asbestos fibers could cause diseases of the lung including pneumoconiosis fibrosis and cancer There fore it is recommended that workers use caution to avoid creating and breathing dust when working on brakes that contain non asbestos fibers Before beginning any service work on any part of the AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death air system be certain that the air pressure has been released Failure to do so may cause a component to violently separate which can result in serious per sonal injury AN DANGER Never work under or around a vehicle unless it is sup ported on jack stands of adequate rating Failure to Observe the following precautions when working with use adequate jack stands can result in the vehicle brakes and brake lining material falling which can cause serious injury or death to anyone under the vehicle 1 Whenever possible work on brakes an area sep arate from other operations 2 Always wear a respirator approved by NIOSH or MSHA during all brake service procedures Wear DANGER the respirator from removal of the wheels through assembly If placing a vehicle with Traction Control System TCS on jacks when servicing the TCS must be dis 3 Never use compressed air or dry brushing
21. jury or death Note Refer to the system schematics for circuit information The following table provides additional possible faults within the ABS not previously covered within the Troubleshooting section Troubleshooting 53 Group 59 Anti Lock Brake System ROCKWELL WABCO Troubleshooting Component Troubleshooting Symptom Type of Failure Check Important The following mus t be performed with the ignition ON ABS light stays illuminated Diagnostic faults present Use Pro link or cluster diagnostic menu to check for stored fault codes Refer to previous troubleshooting information No ECU power Fuse blown e Check 5A 30A fuse fuse 10 in electrical center e Check 40A maxi fuse in electrical center e Check the two 10A in line fuses on the ABS ECU crossmember No ECU power Open or short circuit in cab or chassis harness power ground circuits e Check voltage at the gray ABS ECU Cab connector terminals 1 to 11 and 2 to 12 Should read battery voltage with the ignition switch ON Note terminals 1 777A amp 2 777B are power terminals 11 ABS A amp 12 ABS B are ground e Check ECU and Cab connections for cor rosion or loose terminals e Check relay R7 PR2 R9 R3 ground wire circuit OR H for continuity to the ground bus bar in the electrical center No ECU power ABS ECU power relay R7 bad e Check power and ground at relay R7 PR2 R9 R3 coil Measure vo
22. to clean abled If the TCS is not disabled and one of the brake parts or assemblies OSHA recommends that wheels starts to spin the TCS will compensate and brake enclosures be used These enclosures have the vehicle may come off the jack and may cause se vacuums with High Efficiency Particulate Air HEPA rious personal injury or death Group 59 Anti Lock Brake System ROCKWELL WABCO Note Before servicing the vehicle disable the TCS by disconnecting the harness at the TCS control valve Before beginning any service work on any part of the air system be certain that the air pressure has been released Failure to do so may cause a component to violently separate which can result in serious per sonal injury It is preferable to avoid welding on a truck or tractor or on components attached to it Voltage and current Spikes associated with welding could damage the ve hicle electrical system If welding must be performed on any structure on or in contact with the vehicle fol low the recommendations below e Disconnect both negative and positive battery cables Ensure the cables remain separated and are not in contact with the vehicle chassis e Disconnect wiring harnesses from all Electronic Control Units ECUs on the vehicle e Disconnect the main wiring harnesses at the LH and RH pass throughs to the cab 58 Service Procedures Group 59 Anti Lock Brake System ROCKWELL WABCO 5932 05 03 01 ABS Sensor
23. tool J 42883 at approxi mately 30 RPM Troubleshooting Measure the AC voltage across terminals listed on the table below Acceptable reading is greater than 0 200 VAC and steady Note See Appendix ABS ECU Connections page 68 for connector terminal location If voltage in Step 4 was not acceptable perform Step 5 through 7 Otherwise go to Step 8 Refer to the table below for possible causes Adjust or replace the sensor as required Recheck sensor adjustment ABS Sensor Adjustment Check Sensor ABS ECU Connector Terminals Satisfactory Possible Faults Location Condition Left Front Axle 1 Front black harness 7108 No voltage connector e sensor wire broken Right Front Axle 1 5 to 6 gt 0 200 VAC sensor wire shorted Left Rear Axle 2 Rear green harness 1102 sensor gap too large connector Large variations Right Rear Axle 2 3 to 4 e excessive tooth wheel runout Left Rear Axle 3 6 channel brown har 3to 4 tooth wheel damaged Right Rear Axle 3 ness connector 5 to 6 e excessive wheel bearing end play Only used in 6S 4M setup 52 Group 59 Anti Lock Brake System ROCKWELL WABCO Other Component Troubleshooting AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in
24. 5 System Wiring Diagram for Vehicles with Volvo Engines Cummins ISM ISX Engines and Detroit Diesel Engines with AutoShift Transmission or Lightning Transmission 26 Design and Function Group 59 Anti Lock Brake System ROCKWELL WABCO anas aNnou9 IMO tiOlH31NI exv ea1xv HOSN3S HOSN3S uv3y y Yv3y 1 71034405 NOLLOVHL a daiavsia S217 NO ddO NO HOLIMS wass IOHLNOO NOILYNINNTTI 5 HOLSIS38 ONILVNINYSL gl Z nHH1 SSVd 9 HOLO3NNOO TINNVHO s N3349 HOLO3NNOO p HOLO3NNOO HO1O3NNOO avo noa 2 NId 86 NUHL SSVA SISSVHO L YOLOANNOD SOILSONDVIG 31xv HOSN3S H n23 sav OL 1 GAN HOLIMS OL ol 26 5 340338 NINA SATOIHSA NI ATNO AV 13H c 31xv HOSN3S uvau 1 HOLYINDOM v SNINHV A SOL Sav 95345115 LINAWNNYLSNI o 3NION3 Heo anis awnog9 anis 1 3018 3NIDN3 1409 HOSN3S HOSN3S H I1NOHJ 1 vol vol asna 3snd SGA EL W5001 146 System Wiring Diagram for Vehicles with Caterpillar Cummins M11 N14 or Detroit Diesel Engines without AutoShift Il or
25. DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death If a Pro Link tool is not available for troubleshooting 3 ROCKWELL WABCO blink codes may be used The ABS ECU has the ability to produce a series of light flashes called blink codes to display fault codes The ABS warning lamp on the instrument cluster is used to display blink codes When the diagnostic function is activated by removing and reinstalling relay R3 R9 any existing faults will be displayed If more than one fault is current the first fault must be repaired before another existing fault can be displayed After repairing an existing fault cycle the key switch and remove and reinstall the relay to request the next existing fault After all existing faults have been repaired they will be come stored faults and can be cleared from the ECU s memory To display blink codes 1 Turn the vehicle ignition ON 2 Remove relay R3 for 1 second and reinstall 6 7 8 W5001202 Relay Location in Truck Electrical Center in center of dash 44 Troubleshooting This initiates the blink code cycle The blink code cycle consists of light flashes and pauses At the beginning of each cycle the light is on briefly then there is a 1 5 second pause followed by a 1 8 flashes which identifie
26. Fuse The standard power cable contains a replaceable fuse inside the cigarette lighter adapter There is a fuse inside the MPC cartridge that can be reset W5000944 Power data cable earlier version W3003009 Power data cable later version Troubleshooting 33 Group 59 Anti Lock Brake System ROCKWELL WABCO Application Cards Application cards are specific to the vehicle s computer system Before beginning work on the vehicle check the identification label on the application card to make sure you are using the correct vehicle application Installing the Application Card Slide the application card into the PCMCIA card slot on the MPC cartridge The card will seat into the MPC car tridge only one way Do not force the card into place Application cards can be inserted or removed while the Pro Link is powered Removal of the application card will halt the system Reinserting the application card will re boot the ProLink tool When correctly seated the eject button to the left of the PCMCIA card slot will pop out If the card seats but the eject button does not pop out the card has been inserted upside down Pressing the eject button will re move only a properly inserted card Note The Write Protect W P switch must be in the OFF position for the application card to work properly 34 W3003013 Troubleshooting Group 59 Anti Lock Brake System ROCKWELL WABCO Troubleshooting MPC Application
27. L WABCO MPSI Pro Link 9000 Functions with MPC Cartridge and Application Card Readout Window The Pro Link 9000 uses a liquid crystal display LCD The readout contains 4 display lines with 20 characters each and can include letters numbers and special sym bols The display includes a built in backlight so that the display can be read in any light When the readout window shows a menu the first three display lines shows the menu title and other helpful infor mation The last display line shows the first menu choice Press the up or down arrow key to display the next menu item Press ENTER to select the menu item that is displayed on the bottom line of the screen Or press FUNC to re turn to the previous menu next higher level Keypad The keypad features 16 keys which are sealed to pre vent contamination from grease and fluids Basic Key Functions Numeric The 10 numeric keys are arranged and Keys used much as you would use a calcula tor Arrow Keys The up and down arrow keys are used to scroll through the lines of the display Each touch of the key moves the display up or down one line The right and left arrow keys are used to move between choices provided by the display ENTER Key This key is used to select a menu item confirm an answer or instruct the tool to go to the next step FUNC Key This key is used to back out of func tions and menus Cleaning
28. R7 VN Power Relay PR2 VHD Inputs Wheel speed information 100 pulses per wheel revolution variable voltage Tr ction control iaa mode selection via dash switch Outputs ABS Mod lat r Valve Signal ted iii fog ee pulsating on off Traction control solenoid 2 eiit eee Rete e ERR RET a AER Doe LRL sss on off Engine ECU via SAE J1922 see note reduces engine torque Traction Control System Engine ECU via SAE J1939 see note reduces engine torque Traction Control System Data Link aee SAE J1587 J1708 diagnostic information to instrument cluster Data iia aras SAE J1922 1939 retarder interrupt and traction control functions Dash Lights nit ca ABS warning light via relay R3 TCS warning light VN ABS warning light via relay R9 TCS warning light VHD Available with Caterpillar Cummins and Detroit Diesel engines from 3 1997 Available with Volvo engines from 1 1998 Group 59 Anti Lock Brake System ROCKWELL WABCO Tools Tools Special Tools The following special tools may be required for work on the Anti Lock Braking System The tools can be ordered from the vendor specified in the tool description Please use the corresponding tool number when ordering Kent Moore 1 800 328 6657 W0001492 J 34182 Deutsch universal hand crimp tool Kent Moore W0001489 J 42942 ABS sensor adjustment tool K
29. S is in mud snow mode The mud snow function increases available traction on Soft surfaces like snow slush or mud by slightly increas ing the allowable wheel spin The TCS will resume normal operation when the TCS Switch is again pressed and the TCS lamp goes out or when the ignition is turned OFF Design and Function W5000657 TCS Solenoid Valve Port 1 air supply Port 2 air discharge Port 3 treadle Solenoid Connector Valve Control do not open Q W5000660 W5000661 TCS Switch 23 Group 59 Anti Lock Brake System ROCKWELL WABCO ABS Fault Detection During operation the ABS ECU continuously monitors the system for faulty conditions If the ABS detects that a fault has occurred as determined by the absence of cor rect signal from one of the ABS components the system illuminates the ABS warning lamp This lamp will stay on until the system has been repaired and the fault has been cleared from the ECU s memory When a fault is detected by the system it deactivates the anti lock braking function in the wheel that has the fault Normal braking ability is maintained in the wheel that has the fault however The ROCKWELL WABCO ABS ECU has the ability to store the details of faults that it detects within its own memory so that the technician can easily locate the problem The faults are placed into two categories exist ing and stored Note the instrument cluster graphic display shows thes
30. Service Manual Trucks Group 593 501 Anti Lock Brake System ABS ROCKWELL WABCO VN VHD mE Emm PV776 TSP139834 VOLVO Foreword The descriptions and service procedures contained in this manual are based on de signs and methods studies carried out up to August 2000 The products are under continuous development Vehicles and components produced after the above date may therefore have different specifications and repair methods When this is believed to have a significant bearing on this manual supplementary ser vice bulletins will be issued to cover the changes The new edition of this manual will update the changes In service procedures where the title incorporates an operation number this is a refer ence to an S R T Standard Repair Time Service procedures which do not include an operation number in the title are for gen eral information and no reference is made to an S R T The following levels of observations cautions and warnings are used in this Service Documentation Note Indicates a procedure practice or condition that must be followed in order to have the vehicle or component function in the manner intended Caution Indicates an unsafe practice where damage to the product could occur Warning Indicates an unsafe practice where personal injury or severe damage to the product could occur Danger Indicates an unsafe practice where serious personal injury or death could oc cur
31. TER FUNCTION SELECTIONS SELECT DESIRED MENU ABS ATC Pro Link 10 With the DIAGNOSTIC CODES menu displayed press ENTER to go to the faults menu WABCO ABS ATC 1 DIAGNOSTIC CODES 11 When the ABS MENU appears use the up and down arrow keys to scroll to ACTIVE FAULTS or FAULT HISTORY then press ENTER WABCO ABS ATC 1 ACTIVE FAULTS Group 59 Anti Lock Brake System ROCKWELL WABCO 12 13 14 15 If there are any faults of the type selected the Pro Link 9000 will display them one at a time such as in the example below LEFT FRONT SENSOR SENSOR OPEN T A1 DEV 11 FLT 01 The last line of the display provides information re garding the fault In the example 1 refers to the number of the Active fault assigned by the ECU H1 would refer to the first fault stored in the fault History DEV refers to the device number of the faulty component such as 11 for Left Front Sensor or 22 for Right Rear Modulator FLT identifies the specific type fault such as 01 for sensor open or 80 for shorted modulator Correct the active faults using appropriate Service Procedures or other repair method Press the FUNC key to return to the fault selection menu Use the up or down arrow keys to select CLR AC TIVE FAULTS or CLR FAULT HISTORY then press ENTER The following screen will appear Troubleshooting CLR ACTIVE FAULTS ARE YO
32. TER The Pro Link 9000 will display the current value of four parameters Press the down arrow to view addi tional parameters The status of the following parameters can be displayed by the Pro Link 9000 LFRONT MPH RFRONT MPH L REAR MPH RREAR MPH LMIDDLE MPH RMIDDLE MPH VOLTAGE TRACTOR LAMP WARNING LAMP RETARDER RELAY ENGINE IDLE SBEND RELAY ENGINE DATA LINK RETARDER DATA LINK At any time press FUNC to move back to the previ ous menu one level higher When all testing is complete turn the vehicle igni tion switch to OFF before disconnecting the Pro Link 9000 Troubleshooting 41 Group 59 Anti Lock Brake System ROCKWELL WABCO Troubleshooting Diagnosing Faults using the Instrument Cluster AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death The graphic display of the instrument cluster can be used to display diagnostic messages from the ABS The system uses the SAE J1708 1587 data link and is in stalled in vehicles with electronically controlled engines Fault codes cannot be cleared using the instrument clus ter graphic display To see diagnostic messages 1 Stop the engine 2 Turn the ignition ON 3 Press the MODE button on the vehicle dash until the Diagnostics Men
33. The keypad can be cleaned with a damp cloth or mild cleaner DO NOT immerse the Pro Link MPC tool in fluids as doing so will permanently damage the unit Push Button Located on the left side of the Pro Link MPC tool is a red push button The function of this push button is de termined by the specific application card plugged into the MPC cartridge The tool will instruct you when to press this button Troubleshooting 31 Group 59 Anti Lock Brake System ROCKWELL WABCO Installing and Removing the MPC Cartridge With the MPC cartridge installed in the Pro Link tool you can use the Wabco ABS application card To Install the MPC Cartridge 1 Disconnect the vehicle adapter containing the 12 volt power feed from the vehicle 2 Seat the cartridge on the back of the Pro Link tool Do nat hold the cartridge at an angle It must sit flat It will go only one way Note The connector edgeboard of the cartridge automatically lines up with the connector and the Pro Link unit 3 Slide the cartridge forward until it clicks into place The cartridge may be left in place indefinitely To Remove the MPC Cartridge 1 Place your thumbs on the slanted surface of the keyboard and your fingers on the cartridge 2 Make a motion similar to snapping your fingers The retention latches will release the outer end of the MPC cartridge 3 Continue sliding the cartridge straight out until the edgeboard is clear of the connector in the Pro L
34. U SURE YES NO If sure press the left arrow to place brackets around YES then press ENTER If clearing ACTIVE FAULTS was successful repeat the clearing process for FAULT HISTORY otherwise repeat the entire process to repair and clear AC TIVE FAULTS Press FUNC several times to return to the function selections menu FUNCTION SELECTIONS SELECT DESIRED MENU ABS ATC Pro Link When troubleshooting with the Pro Link 9000 is complete turn the vehicle ignition to OFF then dis connect the Pro Link 9000 Replace the diagnostics connector dust cap 39 Group 59 Anti Lock Brake System ROCKWELL WABCO Troubleshooting System Testing Using the Pro Link 9000 There are several tests that can be run on the Wabco system using the MPSI Pro Link 9000 The available tests are Vehicle voltages ABS modulator valves Traction control valve ABS Wheel spin dash warning lamps Sensors Engine datalink Retarder relay Retarder datalink Perform the following steps to set up the Pro Link 7 Verify that the information displayed matches the ve 9000 to run system tests hicle configuration 4 sensors 4 valves If it does not change the Pro Link 9000 test configuration re 1 Insert the Wabco ABS cartridge into the Pro Link fer to the MPSI Pro Link 9000 manual for the Wabco 9000 ABS ATC System 2 Plug the male end of the data cable into the Pro Link 8 Press ENTER to access the function selec
35. adjustment as specified in Sensor Adjustment Check page 52 59 Group 59 Anti Lock Brake System ROCKWELL WABCO 5635 03 02 01 ABS Modulator Valve Replace ment Before beginning this procedure read the General Work Practices section General Work Practices page 57 for further procedural information AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death Before beginning this service procedure be sure to read and understand the safety information found in Anti Lock Brake System page 3 uf W5000701 1 Park the vehicle on a level surface with the transmission in neutral and the front wheels chocked 2 Remove all zip ties supporting the ABS modulator valve supply airline coming from the brake chamber 60 Service Procedures Before beginning any service work on any part of the air system be certain that the air pressure has been released Failure to do so may cause a component to violently separate which can result in serious per sonal injury Using the Airline release tools J 44773 disconnect the relay valve supply airline on the top of the modu lator valve J 44773 4 Using the Airline release tools J J 44773 44773 disconnect the modulator valve supply airline on the brake chamber
36. ailure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death Before beginning this service procedure be sure to read and understand the safety information found in Anti Lock Brake System page 3 Park the vehicle on a level surface with the transmission in neutral and the front wheels chocked AN DANGER Do not work under a vehicle supported only by jacks Jacks can slip out from under the truck or fall over causing personal injury or death Always use jack stands under the truck Lift and stabilize the portion of the ve hicle to be worked on with the proper jack and jackstand 3 Remove the tires and wheels on the side of the axle to be worked on 4 With the parking brake released back off the brakes on this side and then re move the brake drum 64 Service Procedures 5 Disconnect the wheel speed sensor harness from the truck harness and remove any securing zip ties and then use special tool J 44769 to remove the sensor from the vehicle J 44769 6 Install the replacement wheel speed sensor using special tool J 44769 and route the replacement harness connect and secure with zip ties 9 44769 J 42942 Note Special tool J 42942 can be used to adjust the sensor without the removal of the wheels or brake drum 7 Install the brake drum 8 Reinstall the removed wheels and tires and using a small screwdriver adjust the brakes 9 As
37. ation Traction control in Mud snow mode Press switch a second time to disengage mud snow mode or cycle ignition off and on TCS light stays illuminated Short circuit in TCS switch Disconnect TCS switch and cycle ignition off and on Short circuit in harness Disconnect the instrument cluster RH connector green 22 way for the TCS lamp Check circuits 774 774 A and 774 B for short to ground 55 56 Group 59 Anti Lock Brake System ROCKWELL WABCO Service Procedures Service Procedures General Work Practices filter and worker arm sleeves If such equipment is not available carefully clean brake parts and as DANGER semblies in the open air 4 Clean brake parts and assemblies in the open air Before working on a vehicle set the parking brakes During disassembly carefully place all parts on the place the transmission in neutral and block the floor to avoid getting dust into the air Use an indus wheels Failure to do so can result in unexpected trial vacuum cleaner with a HEPA filter system to vehicle movement and can cause serious personal in clean dust from the brake drums torque plate spi jury or death der and other brake parts After using the vacuum remove any remaining dust with a rag soaked in wa ter and wrung until nearly dry AN CAUTION 5 Avoid grinding or machining brake linings 6 Properly clean the work area Never use com Some older original equipment brake linings c
38. conduct the test wheels Failure to do so can result in unexpected outdoors or use a properly vented exhaust hose Pro vehicle movement and can cause serious personal in longed or excessive exposure may cause serious jury or death illness or death 5 When the ABS MENU appears use the up and AN CAUTION down arrow keys to scroll to existing faults or stored faults Then press ENTER Possible damage to electronic components Turn the 6 there any faults of the type selected the Pro Link will display them one at a time such as in the example below vehicle ignition switch OFF before disconnecting or connecting any electrical components Failure to de energize circuits may result in electronic equip ment damage iw 2 3 1X Perform the following steps to determine faults us R REAR ABS VALVE ing the Pro Link OPEN OR CABLE DAMAGE 1 Connect the Pro link with the ROCKWELL WABCO t ABS cartridge version 4 0 or higher to the diagnos tic socket located under the left side of the dash The number blink codes number of occurrences 2 Turn the vehicle ignition ON and description of the fault is displayed 3 Verify the information displayed by the Pro Link 7 Important Record all fault codes on the work order matches the vehicle configuration i e 4 sensors 4 before they are cleared They cannot be retrieved modulator valves If it does not refer to the Pro after clearing Link manual to change the
39. d of the tooth wheel past the sensor the more pulses are registered per second which is a direct indication of wheel speed The tooth wheel is manufactured either as a ring that is pressed onto the wheel hub or is machined as an inte gral part of the hub itself Sensor The sensor is a magnetic inductor that allows current to flow through it from the ECU when the tooth wheel is passing in front of it It continuously provides wheel speed information in the form of an AC signal to the ECU whenever the ignition is ON regardless of whether or not the vehicle is in motion The sensors are installed in brackets that are bolted to the brake spider Each sensor is held in place by a spring clip The sensor is installed by pushing it all the way into the spring clip until it touches the tooth wheel The ABS is available in a 4 or 6 sensor configuration The standard 4 sensor 4 modulator ABS has a sensor on each front wheel On a 4x2 vehicle each rear wheel also has a sensor On a 6x4 vehicle with air suspension the rear drive axle has sensors For other suspensions the forward drive axle has sensors The 6 sensor configuration also utilizes 4 modulator valves and has a sensor on each front wheel and on each drive axle wheel Note On Heavy Duty Steer Axles and steer axles with Aluminum Hubs some sensors are installed without the use of a bracket bolted to the Brake Spider Q Design and Function W5000530
40. e may also include traction control The Traction Control System TCS uses the same wheel sensors as the ABS to determine if one drive wheel is spinning much more rapidly than the others If the TCS determines that a wheel is spinning and the ve hicle speed is below 25 mph 40 km h it opens the relay valve to apply some braking force to stop the wheels from spinning If all drive wheels are spinning the system sends a sig nal to the engine ECU to reduce the engine torque to provide improved traction This action helps reduce the amount of wheel spin and gives the driver greater vehi cle control To prevent the wheel brake from overheating the differ ential brake threshhold is increased linearly at vehicle speeds exceeding 22 mph 35 km h Slip is controlled by engine reduction Also when the vehicle speed exceeds 31 mph 50 km h the differential brake control doesn t start but relies on the already existent brake control The traction control system includes an extra relay valve mounted on the left hand frame rail close to the rear crossmember Note TCS is available only with engines which support SAE J1922 J1939 TCS Mud Snow Function The TCS includes a TCS mud snow option switch la beled as shown It is a momentary switch In the normal position the TCS operates normally to increase traction to the spinning wheels When the switch is pressed once the TCS lamp on the dash will blink continuously to indicate that the TC
41. e pressure balances the delivery pressure As delivered air pressure is changed the valve reacts instantly to the change holding the appli cation at that level Exhaust or release When air pressure is released from the service port and air pressure in the cavity above the relay piston is ex hausted air pressure beneath the piston lifts the relay piston and the exhaust seat moves away from the ex haust valve opening the exhaust passage With the exhaust passage open the air pressure in the brake chambers is then permitted to exhaust through the ex haust port releasing the brakes Design and Function Fig 1 R 14 Relay valve W5000234 17 Group 59 Anti Lock Brake System ROCKWELL WABCO Anti compounding Simultaneous service and park application When the R 14 Relay valve is used to control the spring brake chambers use the anti compound feature With the anti compound feature of the R 14 connected a ser vice application made while the vehicle is parked is countered by a release of the parking brakes To use this feature the exhaust cover of the quick release portion of the R 14 is removed and a line is connected to the deliv ery of the service brake valve or brake application is made air from the service brake valve enters the ex haust port of the quick release of the R 14 and moves the diaphragm blocking the service port Air then pro ceeds into the cavity above the relay piston The piston closes the exhaust a
42. e two categories as active and inac tive Existing or active faults are those present in the System such as a short circuited data link Stored or in active faults are faults which have been repaired or intermittent faults Intermittent faults are those that oc curred in the system and have not been repaired but are no longer present such as a temporary open sensor circuit that might be caused by a loose connector If the fault is existing the details of the fault will be stored in the ABS ECU memory and will remain there until the fault has been repaired and the technician clears the fault memory If the fault was intermittent the System stores the details of the fault but the fault may be cleared from memory without repair Following detection of any fault the ABS warning lamp will come ON and stay on until the ignition is switched OFF The warning lamp will remain ON when the ignition is on until the fault is repaired and cleared The ABS ECU can store the details of several faults al though they are not necessarily stored in the order they are received If using the blink codes for display of faults the faults must be repaired and cleared from memory one at a time in order to display additional faults The ABS warning lamp will not go out when driving until all faults have been corrected and cleared Note Proper ABS TCS operation requires that front and rear tire size be within 1496 of one another Exceeding this range wi
43. ector Detail insertion side view 404 J1922 Data Link to engine Rear Green ECU Connector 7 or EGU for action control Pin Circuit No Description 406 J1939 H 1 737 LR Sensor Signal 8 408 J1939 shield not used with 2 738 LR Sensor Return 41922 3 757 RR Sensor Signal 9 401 J1587 1708 Data Link 4 758 RR Sensor Return 19 TIR ABS warmina Lamp Enable 5 780 Traction Control Solenoid Source aroung 6 781 Traction Control Solenoid Ground 1 BBS Pruna 7 759 Modulator Exhaust 8 761 RR Modulator Common Front Black ECU Connector 9 760 RR Modulator Hold Pin Circuit No Description 10 739 LR Modulator Exhaust em OOOO 11 741 LR Modulator Common 3 752 RF Modulator Exhaust 12 740 LR Modulator Hold 4 753 RF Modulator Hold 90 EPSON ETUR 6 Channel Brown ECU Connector 91 Pin Circuit Description i 490 IPP Senser Signal 3 735 183 Sensor Signal 8 ua Sensor 4 736 LR3 Sensor Return 9 754 RF Modulator Common 5 755 RR3 Sensor Signal 10 732 LF Modulator Exhaust 6 756 RR3 Sensor Return 11 734 LF Modulator Common 1 2 Not Used 1 12 Not Used 7 1 Used for 6S 4M only 20 Group 59 Anti Lock Brake System ROCKWELL WABCO Electrical Fuses The two power inputs to the ABS ECU are fused through individual 10 amp in line fuses These fuses are located on the crossmember directly to the right of the ECU The power to the in line fuses 1 comes from the ignition cir
44. ent Moore W0001493 J 37451 Deutsch heavy duty contact re moval tool Kent Moore 0001490 9 35123 Metri Pack hand crimp tool Kent Moore d 0001491 E J 38125 Metri Pack contact removal tool Kent Moore W0001198 J 42189 Air line release tool Kent Moore Group 59 Anti Lock Brake System ROCKWELL WABCO 0001731 J 44399 Air System Tester J 43143 W0001560 J 43143 Tie Strap Tensioner W0001488 J 42883 Sensor pin out cable Kent Moore Tools W5000945 Fluke 87 Digital Multimeter John Fluke Mfg J 44775 J 44773 Corp W0001873 Valve Assembly Fixture W0001874 Airline Release Tool M J 44769 001896 Wheel Speed Sensor Extractor Group 59 Anti Lock Brake System ROCKWELL WABCO W5001199 J 44966 Wheel Speed Sensor Remover for Heavy Duty Steer Axle and Alu minum Hub Tools Group 59 Anti Lock Brake System ROCKWELL WABCO Tools Special Equipment The following special equipment may be required for troubleshooting the Anti Lock Brake System and can be ordered from the vendor specified in the equipment descrip tion W5000944 9 38500 2 Power Data Cable earlier version Kent Moore W5001198 1 108004 Pro Link 9000 with cartridge 2 208040 MPC Cartridge 3 808014 Wabco Application Card J 38500 60A W5000946 J 38500 60A Diagnostic cable adapter Kent Moore W3003017 J 38500 1100 MPSI Wabco ABS cartridge Kent Moo
45. erwise go to Step 7 5 Disconnect the connector on that valve 6 Measure the resistance across terminals 1 1 and 2 and across terminals 1 and 3 4 If both resistance values are outside tol g erance the modulator valve must be replaced If the resistance values AS correct the problem is in the cable 2 3 7 Reconnect the connector Traction Control Valve To check resistance perform the following 1 Verify that the vehicle ignition is OFF 2 Disconnect the cable to the Traction Control valves at the ECU connector for rear components 3 Measure the resistance across terminals listed on the table below Acceptable reading is between 8 0 and 14 0 0 Note See Appendix ABS ECU Connections page 68 for connector terminal location 4 If resistance in Step was not within tolerance for either valve perform Steps 5 through 7 Otherwise go to Step 8 5 Disconnect the connector on that valve 6 Measure the resistance across terminals 1 and 2 7 If resistance value is not within tolerance the Traction Control valve must be replaced If the resis tance value is correct the problem is in the cable 8 Reconnect the connector 49 Group 59 Anti Lock Brake System ROCKWELL WABCO Troubleshooting ABS Traction Valve Resistance Component ABS ECU Con Terminals Satisfactory Possible Faults nector Resistance ABS inlet left fron
46. g hard braking or slippery road conditions The ABS improves the vehicle s stability and control by reducing wheel lock during braking If the ABS detects a problem in the system the ABS in the affected wheel s is disabled but that wheel still has normal brakes Signals from the wheel speed sensors are received and 11922 11939 CONNECTOR TOOTHED HUB OR TOOTH WHEEL SS W5000662 processed by the ABS Electronic Control Unit ECU When the ECU determines that a wheel is going to a locked condition the appropriate modulator valve is acti vated and pressure to the brake chamber is reduced When the wheel speed enters the stable region again the air pressure is increased Traction Control System Some vehicles are equipped with a Traction Control Sys tem TCS or ATC TCS prevents the drive wheels from spinning when starting from a standing position on a slip pery surface or when accelerating The TCS utilizes the ABS ECU for control but requires an additional control valve to automatically apply compressed air to the spin ning wheels to increase traction TCS is available with engines that support the SAE J1922 or J1939 data link Group 59 Anti Lock Brake System ROCKWELL WABCO The Anti Lock Brake System ABS is an important com ponent of the foundation brake system Its purpose is to prevent wheels from locking up when the brakes are ap plied with great intensity under normal road co
47. inals listed on tance value is correct the problem is in the cable the table below Acceptable reading is between 700 and 3000 ohms 9 Reconnect the connector ABS Sensor Resistance Sensor ABS ECU Connector Terminals Satisfactory Possible Faults Location Resistance Left Front Axle 1 Front black harness 7108 connector Right Front Axle 1 5 to 6 Wiring between ECU and sensor damaged Left Rear Axle 2 Rear green harness 1102 700 to 3000 0 Damaged sensor con connector nector Right Rear Axle 2 3104 Defective sensor Left Rear Axle 3 6 channel brown har 3 to 4 ness connector Right Rear Axle 3 5to6 Only used in 6S 4M setup 51 Group 59 Anti Lock Brake System ROCKWELL WABCO Sensor Adjustment Check To check the proper adjustment of a sensor perform the following 1 Verify that the vehicle ignition is OFF 2 Disconnect the cable to the sensors at the ECU connector for front or rear sensors as appropriate AN DANGER If placing a vehicle with Traction Control System TCS on jacks when servicing the TCS must be dis abled If the TCS is not disabled and one of the wheels starts to spin the TCS will compensate and the vehicle may come off the jack and may cause se rious personal injury or death Note Before servicing the vehicle disable the TCS by disconnecting the harness at the TCS control valve Spin the wheel for the sensor to be checked by using the Sensor pin out
48. ink tool Non Volatile Memory The MPC cartridge has a non volatile memory This means that data is not lost when the Pro Link MPC tool is disconnected from the vehicle s power source When the Pro Link MPC tool is connected to an external power source using the power cable in conjunction with the data cable the Pro Link MPC tool recognizes that it is not communicating with an ECU The func key is still active and you can access stored data for review and printing This includes Utilities and Recall Data 32 Troubleshooting W3003011 W3003012 Group 59 Anti Lock Brake System ROCKWELL WABCO Power Data Cable The data and power cable must be connected to the ve hicle or an external 12 volt power source before the Pro Link MPC tool can function Connecting the Power Data Cable Earlier cables consisted of a single assembly both the data cable and power cable are attached by a single molded connector Later versions have two separate ca bles In both cases the power cable includes a cigarette lighter adapter 1 Locate the vehicle power data cable part number 501002 or J 38500 2 The cable has a large 15 pin connector with two thumbscrews Note that part 501002 is a two piece cable and permits the re moval of the power cable containing the cigarette lighter adapter 2 Plug the connector into the top of the Pro Link MPC tool 3 Tighten the two thumbscrews to secure the cable
49. le on a level surface with the transmission in neutral and the front wheels chocked 2 Cut and remove the six zip ties secur ing the wheel speed sensor harness to the air brake chamber and inside the frame rail 3 Disconnect the wheel speed sensor from the chassis harness in side the frame rail 4 Remove the wheel speed sensor har ness hold down from the top kingpin cap 5 Remove the wheel speed sensor from the housing in the spindle using tool J 44966 J 44966 6 Remove the wheel speed sensor har ness from the vehicle 66 Service Procedures 7 Install the removed wheel speed sen sor hold down to the replacement wheel speed sensor harness and se cure 8 Replace the removed zip ties to se cure the replacement wheel speed sensor harness 5931 03 02 01 ABS ECU Replacement Before beginning this procedure read the General Work Practices section General Work Practices page 57 for further procedural information 1 AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death Before beginning this service procedure be sure to read and understand the safety information found in Anti Lock Brake System page 3 Park the vehicle on a level surface with the transmission in neutral and the front wheels chocked 2
50. llowing for line 1 Fault Description MID Message ID Brakes 136 The following is a list of the possible faulty component messages for the Instrument Cluster graphic display Line 2 and the corresponding SAE J1587 J1708 code Fault Description SID s Subsys tem ID s ABS Snsr axle 1 L 1 ABS Snsr axle 1 R 2 ABS Snsr axle 2 L 3 ABS Snsr axle 2 R 4 ABS Snsr axle 3 L 5 ABS Snsr axle 3 R 6 ABS valve axle 1 L 7 ABS valve axle 1 R 8 ABS valve axle 2 L 9 ABS valve axle 2 R 10 ABS valve axle 3 L 11 ABS valve axle 3 R 12 ABS rtrdr ctrl relay 13 ABS relay diagonal 1 14 ABS relay diagonal 2 15 ABS dif 1 ASR valve 18 ABS dif 2 ASR valve 19 Troubleshooting The following is a list of the possible fault condition mes sages for the Instrument Cluster graphic display Line 3 and the corresponding SAE J1587 J1708 code Fault Description FM s Failure Modes Data valid but high 0 Date valid but low 1 Data erratic 2 Voltage shorted high 3 Voltage shorted low 4 Current low or open C 5 Current high or short C 6 Mech syst no respons 7 Abnormal freq or PW 8 Abnormal update rate 9 Abnormal change rate 10 Failure unknown 11 Bad device 12 Out of calibration 13 Special instructions 14 43 Group 59 Anti Lock Brake System ROCKWELL WABCO Diagnosing Faults using Blink Codes AN
51. ltage from circuits 196B to OR H pins 86 to 85 of the relay holder e Try replacing relay R7 PR2 R9 R7 with a known good relay Relay R3 bad or short circuit in harness e Unplug relay R3 PR2 R9 R7 ABS light should go out If not check circuit 779 for short to ground e Check power and ground at relay R3 PR2 R9 R7 coil Measure voltage from circuits 196B to 778 pins 86 to 85 of the relay holder e Check circuit 778 from the ABS ECU for a short to ground e Try replacing relay R3 PR2 R9 R7 with a known good relay 54 Group 59 Anti Lock Brake System ROCKWELL WABCO Troubleshooting Component Troubleshooting Symptom Type of Failure Check Important The following mus t be performed with the ignition ON ABS warning lamp does not illuminate at key ON ABS warning bulb burned out Perform an instrument cluster bulb test from the cluster diagnostic menu screen CLUSTER SELF TEST BULB TEST Relay R3 is bad or short circuit in har ness Try replacing relay R3 PR2 R9 R7 with a known good relay Remove relay R3 and check for battery voltage at circuit 779 pin 87A of R3 PR2 R9 R7 relay holder Should read 12V Check connections in the harness Bad ground to relay R3 Check relay R3 PR2 R9 R7 ground wire cir cuit OR F for continuity to the ground bus bar in the electrical center TCS light flashing TCS switch pressed once Normal oper
52. m ID 2 2 2 2 Note The System ID code is 2 blinks for 4S 4M 4 blinks for 6S 4M W5001201 Group 59 Anti Lock Brake System ROCKWELL WABCO Component Troubleshooting AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death Troubleshooting If diagnostics indicate that there is a problem with the ABS the following component tests may be used to determine whether the problem is in the component or the wiring Prior to performing any component tests make a visual in spection of the cables connectors and valves for loose connections corrosion and breakage The ABS modulator valves and TCS valves can be checked by measuring the resistance of the coils This measure ment can be made at the valve or at the ECU connector ABS Modulator Valve To check resistance perform the following 1 Verify that the vehicle ignition is OFF 2 Disconnect the cable to the modulator valves at the ECU connector for front or rear components as ap propriate 3 Measure the resistance across terminals listed on the table below Acceptable reading is between 4 0 and 8 0 9 Note See Appendix ABS ECU Connections page 68 for connector terminal location 4 If resistance in Step was not within tolerance for any valve perform Steps 5 through 6 Oth
53. nd opens the inlet to deliver air to the spring brake cavity as described in R 14 Relay Valve page 17 Maintenance Every 100 000 miles 160 000 km 12 months or 3 600 operating hours check the valve function using the pro cedure found in R 14 Relay Valve page 17 If the R 14 does not function properly replace it with a new or re manufactured valve Design and Function Group 59 Anti Lock Brake System ROCKWELL WABCO Electronic Control Unit ECU The ABS ECU controls the ABS TCS system lt receives wheel speed information from the sensors and sends signals to the ABS modulator valves lt is powered from the ignition bus via the ABS ECU power relay R7 for VN Power Relay PR2 for the VHD and two in line fuses mounted on the crossmember close to the ABS ECU The microprocessors in the ECU compare the speed of each wheel to the speed of the other wheels to deter mine if any one wheel is spinning This comparison is performed many times every second If any wheel is de termined to be locked not spinning or spinning very slowly in relation to the other wheels while the other wheels are spinning the ABS sends signals to the mod ulator valve for the locked wheel to reduce its braking force until it starts to spin again This series of events occurs many times each second giving the modulator valve the appearance of having a pulsating action In addition to the outputs provided to the modulator valves the ABS ECU s
54. nditions or when applied normally on slippery road surfaces The ABS electronically monitors the rotational speed of both front wheels and the wheels on the rear axle The wheel rotation signals are sent to an Electronic Control Unit ECU which sends signals to the ABS modulator valves if it detects that a wheel has locked up or is about to lock up The modulator valves control the pressure to the service brake chambers Wheel rotation is determined by an electronic sensor mounted on the brake spider by a bracket A signal is generated by the sensor as teeth on a tooth wheel which is mounted on the wheel hub pass by the sensor When the ECU senses that a wheel or set of wheels is about to lock during braking a signal is sent to the ap propriate modulator valve solenoid to intermittently open and close it This opening and closing occurs very rapidly several times per second to reduce brake pres sure and ensure that the wheel returns to rotating while still maintaining most of the brake capacity Some vehicles have a Traction Control System TCS in cluded with the ABS TCS is only available with engines which support the SAE J1922 1939 data link The TCS functions to stop a set of drive wheels from spinning when the driver attempts to accelerate the vehicle from a stand still or when a wheel is spinning due to road con ditions such as ice or loose gravel under the wheel The TCS requires an additional valve that allows brakes to
55. ock Brake System ROCKWELL WABCO Troubleshooting VCADS Pro VCADS Pro is a Windows based software tool used to perform tests and calibrations on ECUs on the vehicle A PC tool with VCADS Pro software is connected to the vehicle s diagnostic connector using adapters and a communication interface unit VCADS Pro Test and Calibration applications makes it possible to test and to calibrate the ECUs The applica tions consist of standard graphical interfaces displaying graph presentations and continuous reading of parame ters The Test and Calibration applications are organized according to function group Wabco ABS units installed on Volvo VN and VHD trucks are tested using the VCADS Pro tool This tool conducts troubleshooting and diagnostics for the ABS unit Note For further information to properly use VCADS Pro reference the VCADS Pro User s Manual Publica tion PV776 030 600SM MPSI Pro Link 9000 with MPC Cartridge and Application Card The MPSI Pro Link 9000 is a hand held electronic diag nostic instrument When used with the MPC cartridge and Wabco ABS application card or with the Wabco ABS cartridge the Pro Link tool provides easy diagnosis of faults within the ABS including e afaulty input e a faulty command or e a faulty reaction to a command In addition the Pro Link 9000 provides the ability to run a series of component tests on the ABS ATC system 30 Group 59 Anti Lock Brake System ROCKWEL
56. ollows maining Note An existing or active fault cannot be cleared until it has been repaired Clear each fault from the ECU after it has been recorded on the work order and repaired Faults are cleared when the ECU is powered up and the fault no longer exists Clear faults as follows 1 2 3 48 Ignition ON Remove relay R3 R9 for 3 seconds and reinsert The ABS warning lamp should quickly blink on and off about 8 times then after a 4 sec delay will show the blink code for the system configuration 2 blinks for 45 4 4 blinks for 65 4 The 4 sec delay and System blink code will repeat until the ignition is cy cled Note If the 8 quick blinks are not displayed the Ws001202 fault has not been cleared Repeat the procedure Relay Location in Truck Electrical Center in center and check for existing faults if the fault will not clear of dash Ignition OFF Note After faults are cleared and vehicle is started ABS lamp will stay R9 Stored on until vehicle is driven over 4 mph 6 km h Continues until EE ata E A B gt uy ignition is HeJ 05 eA NE turned off Light ON 8 Quick Blinks Faults Cleared System ID System ID System ID System ID 2 2 2 2 System Configuration Code 2 4S 4M System Remove R3 R9 Faults Not Cleared Active Faults Still Exist for3S Continues until ignition is turned off Light ON System ID System ID System ID Syste
57. omponent Troubleshooting 49 Other Component Troubleshooting 53 Service Procedures 57 General Work Practices 57 ABS Sensor Adjustmant 59 ABS Modulator Valve Replacement 60 ABS ATC Valve Replacement 61 Brake Relay Valve Replacement 63 Wheel Speed Sensor Replacement Rear Axle 64 Wheel Speed Sensor Replacement Steer Axle 65 Wheel Speed Sensor Replacement Heavy Duty Axle and or Aluminum Hub 66 ABS ECU Replacement u u u uU uuu uu 66 Appendix ABS ECU Connections 68 Feedback Operation Numbers Group 59 Anti Lock Brake System ROCKWELL WABCO General General Anti Lock Brake System This service information describes the design operation and service procedures of the ROCKWELL WABCO Series D Anti Lock Braking System installed on Volvo VN and VHD series vehicles B 0 W5000526 Group 59 Anti Lock Brake System ROCKWELL WABCO Specifications Specifications Electronic Control Unit Make Model una needle u e aenea canoes NOE Icd au ud So Eod cod yau d Rockwell WABCO Series D Power requirement E 12 VDC two 10 amp fuses in line ABS ECU power relay cit euet Relay
58. ons RETARDER DATALINK Checks J1922 wiring connections between the retarder and the ECU 37 Group 59 Anti Lock Brake System ROCKWELL WABCO Using the Wabco ABS Cartridge Perform the following steps to determine faults us ing the Pro Link 9000 4 5 6 38 Insert the Wabco ABS cartridge into the Pro Link 9000 MPC tool Plug the male end of the data cable into the Pro Link 9000 Tighten the thumbscrews to secure the cable Remove the dust cap from the vehicle diagnostics connector and connect the data cable to the diag nostics connector 1 on the vehicle W5000547 1 Diagnostics connector location Place the vehicle ignition switch ON Verify the Pro Link 9000 powers up properly by ob serving the following display MPSI Pro Link 9000 SOFTWARE COPYRIGHT 1995 VERSION 1 0 WABCO ABS ATC Verify the Pro Link establishes communication with the ABS by observing a display similar to the follow ing 4 SENSOR ABS ACTIVE FAULTS YES FAULT HISTORY YES ENTER TO CONTINUE Troubleshooting 7 Verify the information displayed matches the vehicle configuration 4 sensor or 6 sensors If it does not refer to the MPSI Pro Link 9000 manual for the Wabco ABS ATC System to change the Pro Link 9000 test configuration 8 Press ENTER to access the function selections menu 9 If ABS ATC does not have brackets around it press the left arrow to place brackets around ABS ATC then press EN
59. ontain pressed air or dry sweeping to clean the work area asbestos fibers a cancer and lung disease hazard Use an industrial vacuum with a HEPA filter and which could result in serious illness or death Some rags soaked in water and wrung until nearly dry brake linings contain non asbestos fibers the long Dispose of rags with care to avoid getting dust into term effects of which are unknown Caution should be the air Use an approved respirator when emptying exercised in handling non asbestos materials vacuum cleaners and handling rags F 7 After working on brakes workers should wash their Most recently manufactured brake linings no longer con hands before eating drinking or smoking Clothes tain asbestos fibers In place of asbestos these linings worn during brake maintenance should not be worn contain a variety of ingredients including glass fibers home Vacuum work clothes after use and launder mineral wool aramid fibers ceramic fibers and carbon them separately without shaking to prevent fiber fibers At present OSHA does not specifically regulate dust from getting into the air these non asbestos fibers except as maintenance dust Medical experts do not agree about potential long term 8 Material Safety Data Sheets MSDS on this prod risks from working with and inhaling non asbestos fibers uct as required by OSHA are available from the Some experts think that long term exposure to certain brake lining manufacturer non
60. re W0001696 9 44012 Interface Adapter ProLink W3003009 501002 Power Data Cable current version MPSI 10 Group 59 Anti Lock Brake System ROCKWELL WABCO Tools VCADS Pro Tools The following hardware is used to operate VCADS Pro The tools can be ordered from Volvo Trucks North America quoting the specified part number 5001142 C0000285 1 tool package 5 J 43939 9 pin Diagnostic adapter for vehicles built JH from January 1999 2 9998555 Communication interface unit 6 9998496 Pressure gauge 3 9812331 Extension cable 7 9998495 Air Pressure Hose 4 43999 6 pin Diagnostic adapter for vehicles prior to 1999 12 Group 59 Anti Lock Brake System ROCKWELL WABCO Design and Function Design and Function Anti Lock Brake System TOOTHED HUB OR TOOTH WHEEL SENSOR 4S AM ABS with Traction Control System Description The ROCKWELL WABCO Anti Lock Braking System ABS is an electronically controlled system that continu ally monitors wheel speed and controls wheel braking during extreme braking situations The ABS works in conjunction with the standard vehicle braking system A typical ABS configuration uses 4 wheel speed sensors and 4 air modulator valves This is known as a 4S 4M configuration A 65 4 6 sensors 4 modulator valves configuration is also available The ABS monitors the wheel speed at all times and helps control braking dur in
61. s the first digit of the fault Af ter another 1 5 second pause the second set of 1 6 short flashes identifies the second digit of the fault Note the blink code s e For an existing fault the ABS warning lamp will repeatedly display one code with a 4 sec ond pause in between codes until the ignition has been cycled The system will not display another existing blink code until the fault for the one displayed has been corrected and erased from the ECU e Fora stored fault the lamp will display a code for each stored fault then stop blinking Faults will be displayed one time only Turn the vehicle ignition switch OFF Refer to the Blink Code Diagnostics table to deter mine the fault information Note Perform Steps 6 through 8 only if a blink code is received that is not listed in the Blink Code Diag nostics table Verify all ABS electrical connections are tight Check for corrosion and damaged wiring Attempt to clear the fault from the ECU see Clearing Fault Codes page 47 If the fault will not clear the problem may be in the ECU itself Contact ROCKWELL WABCO for addi tional instructions Group 59 Anti Lock Brake System ROCKWELL WABCO Troubleshooting Example Blink Codes Remove R3 Active Fault foris 1 8 Flashes 1 6 Flashes E IEEE EE Continues until 4 55549 9 9 ignition is turned off Light ON 1st Digit 2nd Digit Repeat of Blink Code 2 3 2 8 Blink Code 2 3 Fault in
62. suring that the jack is in a safe loca tion lift the vehicle and remove the jackstand Group 59 Anti Lock Brake System ROCKWELL WABCO 5939 03 02 01 Wheel Speed Sensor Replace ment Steer Axle Before beginning this procedure read the General Work Practices section General Work Practices page 57 for further procedural information 1 AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death Before beginning this service procedure be sure to read and understand the safety information found in Anti Lock Brake System page 3 Park the vehicle on a level surface with the transmission in neutral and the front wheels chocked AN DANGER Do not work under a vehicle supported only by jacks Jacks can slip out from under the truck or fall over causing personal injury or death Always use jack stands under the truck Lift and stabilize the portion of the ve hicle to be worked on with the proper jack and jackstand 3 Remove the tire and wheel from the side to be replaced 4 Back the brakes off on this side by us ing a small screwdriver to pry out the spring loaded pawl while releasing the brakes and then remove the brake drum Service Procedures 5 Remove the two wheel speed sensor harness tie downs on the spindle it
63. t axle Front black har 11 to 2 t ABS exhaust left front axle basi 11 to 10 Wiring between ECU and valve damaged ABS inlet right front axle 9to 4 ABS exhaust right front axle 9 to 3 4 0 to 8 0 Q ABS inlet left rear axle Rear green har 11 to 12 Ground lead to valve dis ness connector connected ABS exhaust left rear axle 11 to 10 ABS inlet right rear axle 8 to 9 Solenoid valve shorted ABS exhaust right rear axle 8 to 7 Traction Control valve 5 to 6 8 0 to 14 0 Q 50 Group 59 Anti Lock Brake System ROCKWELL WABCO Troubleshooting Sensors To check the resistance of a sensor perform the follow Note See Appendix ABS ECU Connections ing page 68 for connector terminal location 5 If resistance in Step 3 was not within tolerance for the sensor perform Steps 5 through 7 Otherwise 2 Disconnect the cable to the sensors at the ECU go to Step 8 connector for front or rear sensors as appropriate 1 Verify that the vehicle ignition is OFF 6 Disconnect the connector for the sensor 3 Use the Sensor Pin out Cable Tool J 42883 and the Digital Multimeter Fluke 87 to check the Wheel 7 Speed Sensor Coil Resistance Ground Resistance and Output Voltage on Rockwell Wabco ABS Measure the resistance across terminals 1 and 2 8 If resistance value is not within tolerance shown in the table the sensor must be replaced If the resis 4 Measure the resistance across term
64. t the rear of the vehicle near the chambers it serves The valve operates as a remote controlled brake valve that delivers or re leases air to the chambers in response to the control air delivered to it from the foot brake valve The R 14 relay valve is designed for either reservoir or frame mounting The R 14 incorporates a quick release and anti compounding feature located above the hori zontal service port The R 14 anti compound feature allows it to be conveniently used as either a service or spring brake relay valve An exhaust cover is installed that protects the 3 mm 1 8 in balance port when the R 14 anti compound feature is not in use Operation Application Air pressure delivered to the service port enters the small cavity above the piston and moves the piston down The exhaust seat moves down with the piston and seats on the inner or exhaust portion of the inlet exhaust valve sealing off the exhaust passage At the same time the outer or inlet portion of the inlet exhaust valve moves off its seat permitting air supply flow from the reservoir past the open inlet valve and into the brake chambers Balance The air pressure being delivered by the open inlet valve also is effective on the bottom area of the relay piston When air pressure beneath the piston equals the service air pressure above the piston lifts slightly and the inlet spring returns the inlet valve to its seat The exhaust re mains closed as the service lin
65. thout electronically resetting the ECU may cause the ABS warning lamp to illuminate and the sys tem to deactivate 24 Design and Function Group 59 Anti Lock Brake System ROCKWELL WABCO ABS Self Tests The ROCKWELL WABCO ABS has a variety of self monitoring features When the ignition is turned ON the ABS warning lamp in the instrument cluster illuminates to tell the operator that the system is powered and that it is conducting self tests There are two tests performed by the system at this point The first test cycles the modulator valves to ensure the circuits and valves are functional This is an audible test The valves cycle in the following order Right front Left rear Left front Right rear Right front and left rear together Left front and right rear together One additional self test is performed by the ABS This test occurs once the vehicle begins moving As the vehi cle starts to speed up from a standstill the ABS monitors the output from each of the wheel speed sen sors and verifies that they are reading correctly and within the correct range compared with the other wheels If the test is satisfactory the ABS warning goes out when the vehicle speed reaches approximately 4 mph 6 km h If the test is not satisfactory the warning lamp will remain illuminated Design and Function 25 Design and Function Group 59 Anti Lock Brake System ROCKWELL WABCO anis
66. tions 9000 Tighten the thumbscrews to secure the cable menu 3 Connect the female end of the data cable to the 9 If ABS ATC does not have brackets around it press data link connector on the vehicle the left arrow to place brackets around ABS ATC 4 Place the vehicle ignition switch ON hen press ENTER 5 Verify the Pro Link 9000 powers up properly by ob serving the following display FUNCTION SELECTIONS SELECT DESIRED MPSI Pro Link 9000 MENU SOFTWARE COPYRIGHT ABS ATC Pro Link 1995 VERSION 1 0 WABCO ABS ATC 10 With the DIAGNOSTIC CODES menu displayed press ENTER to go to the faults menu Note ATC on the MPSI Pro Link 9000 displays WABCO ABS ATC refers to the Traction Control System 6 Verify the Pro Link establishes communication with the ABS by observing a display similar to the follow ing 1 DIAGNOSTIC CODES 4 SENSOR ABS ACTIVE FAULTS YES FAULT HISTORY NO ENTER TO CONTINUE 40 Group 59 Anti Lock Brake System ROCKWELL WABCO 11 12 13 14 15 16 When the ABS selections menu appears use the down arrow key to scroll to TEST SYSTEM Then press ENTER ABS MENU 1 TEST SYSTEM Use the up and down arrow keys to scroll to the test of your choice then press ENTER to run the test When system testing is complete press FUNC to return to the selections menu Use the up or down arrow keys to scroll to DATA LIST then press EN
67. u is displayed Use the Up and Down buttons to display DIAGNOSTIC MESSAGES D Diagnostic messages G N 4 Press the SET button to have the datalink retrieve data D Retrieving data A Please Wait G N 42 5 6 7 Press the DOWN button until the brake screen is displayed Brakes ABS Snsr Axle 3 L Current hi or Short C Active Count 1 2 0 2 0 The Set button can be pressed to toggle the display between the text description and the received data If the display shows UNKNOWN any line press the Set button to display the MID PID or SID and FMI a If the condition that caused the currently dis played fault still exists the cluster will display ACTIVE b If the condition that caused the currently dis played fault is no longer occurring the cluster will display INACTIVE c The number of times a fault has occurred will be displayed when available In some cases a short message may also be displayed Record all codes displayed To display the next stored fault press the Down but ton Group 59 Anti Lock Brake System ROCKWELL WABCO Diagnostic Messages Diagnostic messages in the Pro Link and instrument cluster graphic display may be provided as text descrip tions or SAE J1587 J1708 fault codes MID SID and FMI A list of these fault codes for ABS follows All ABS fault codes in the Instrument Cluster graphic dis play have the fo
68. uals where it concerns fault tracing repairs and maintenance of Volvo trucks In order to maintain the high standards of our literature your opinions and experience when using this manual would be greatly appreciated If you have any comments or suggestions make a copy of this page write down your comments and send them to us either via telefax or mailing directly to the address listed below To From Volvo Trucks North America INC Dept 516 Service Publications 7825 National Service Road RO Box20115 Greensboro NC 27402 6115 USA Fax 336 393 3170 Comments proposals 5631 03 02 25 5631 03 02 26 5635 03 02 01 5931 03 02 01 5932 05 03 01 5939 03 02 01 5939 03 02 02 5939 03 02 03 Operation Numbers ABS Valve 61 Brake Relay Valve 63 ABS Modulator Valve Replacement 60 ABS ECU Replacement s a s a oraaa eoe j R Q 66 ABS Sensor Adjustment 59 Wheel Speed Sensor Replacement Steer Axle 65 Wheel Speed Sensor Replacement Rear Axle 64 Wheel Speed Sensor Replacement Heavy Duty Axle and or Aluminum Hub 66 VOLVO Volvo Trucks North America Inc P O Box 26115 Greensboro NC 27402 6115 Volvo Trucks Canada Ltd 6490 Vipond Dri
69. upplies inputs to the engine ECU for Traction Control 1922 1939 where available and to the J1587 1708 Data Link for the instrument cluster lights and diagnostics The ECU is housed in a sealed enclosure that protects the electronic circuits from the environment The stresses on the cables resulting from vehicle operation are taken up by the ECU housing which supports each cable as it exits the housing The ECU housing is mounted to the rear of the intermediate crossmember Design and Function W5001213 ABS ECU with housing closed ABS ECU with housing open Cab Connector gray Front Connector black Rear Connector green 6 channel Connector brown used on vehicles with 6 sensors only Group 59 Anti Lock Brake System ROCKWELL WABCO Design and Function ECU Connectors The pin designations for each of the ECU connectors is located in the following tables All ABS ECU connectors are 12 pin Deutsch connectors Cab Gray ECU Connector Pin Circuit No Description 1 777A 12V Supply 2 777B 12V Supply 3 774 Traction Control System TCS Lamp 4 400 J1587 1708 Data Link 5 772 Engine Brake Disable not used with J1939 405 J1922 Data Link to engine 6 Bi ECU for traction control 5000666 407 J1939 L ABS ECU Conn
70. ve Mississauga Ontario L5T 1W8 http Awww volvotrucks volvo com PV776 TSP139834 1000 8 2000 Volvo Trucks North America Inc 2000

Anti-Lock Brake System (ABS), Rockwell Wabco

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