BENDIX BW2262 User's Manual
Contents
1. FIGURE 25 Typical 4S 2M Side Control ABS Electrical and Air System Top View 20 a Valve A Emergency Brake Chamber Diagnostic P ort Wheel Sensor Ze Ro A Side vice Cp Side Parts List Description Quantity ECU Relay Valve 1 Stand Alone Relay Valve Sensor Diagnostic Cable Valve P ower Cable Sensors 0 4m Cable Sensor Friction Sleeve SensorA Lift Axle Sensor C Gen 4 Only Warning Lamp Connector Stand r gt ABS Warning Lamp Q Top View BIN CN Valve A gt Harness Side G Warning N Road Side Light Side QA 6 4S 2M Axle Control Air System Configuration Top View 3 8 0 D Nylon Tubing om 3 8 0 D Nylon Tubing Alt 1 2 0 D Lift Axle 3 8 D Hose Gen 4 Only Gladhand Front ne O4 upply Line Gladhand ms ol Ci Top View a TEV or STEV Service Brake Chamber Emergency Brake Chamber Spring Brake Control Road Side FIGURE 26 Typical 4S 2M Axle Control ABS Electrical and Air System Tank Mount Shown Top View 21 End Of Line Diagnostics Automatic System Configuration The Bendix A 18 trailer ABS system automatically configures itself to any valid ABS system installed on the trailer The automatic configuration process occurs each time the system receives power at the permanent power input In most cases this ECU input is connected2. GEN 4 AND GEN 5 ABS INTRODUCTION This manual describes the Bendix A 18 trailer ABS system and contains two primary sections e Installation e Service The Installation section provides the information required for the proper installation of aFMVSS 121 compliant trailer air brake systems that incorporate the Bendix Trailer ABS system and complementary trailer components The Service section ofthe manual includes the information necessary to properly maintain troubleshoot and repairthe A 18 trailer ABS system Following the installation service and troubleshooting procedures contained in this manual will produce a high performance long life low maintenance antilock braking system For assistance in your area call Bendix at 1 800 247 2725 or RoadRanger at 1 800 826 4357 Benefits of Trailer ABS ABS controlled trailer braking ensures optimum vehicle stability while minimizing the stopping distance During vehicle operation the trailer ABS Electronic Control Unit ECU continuously monitors all wheel speed sensors Data input from the wheel speed sensors allows the ECU to e Detect impending wheel lock e Maintain optimum wheel slip e Maximize overall braking effectiveness e Minimize tendencies for trailer swing out during hard braking conditions Document Revision Level This document is subject to revision For updates please visit www bendix com FIGURE 1 ABS Controller Assemblies Table of Content
3. Valve Operation Modes 1 4 Apply Treadle pressure is applied to the top of the piston The sleeve is depressed until the outlet pressure matches the pressure at the top of the piston Normal Release Pressure at the top of the piston is vented through the treadle valve The sleeve rises to block the inlet while allowing the chamber air to exhaust through the center of the sleeve ABS Hold Hold solenoid blocks treadle pressure The piston stabilizes holding the chamber pressure at the same level as that which is above the piston ABS Release The release solenoid vents air at the top of the piston while blocking treadle pressure The sleeve rises to block the inlet while allowing the chamber air to exhaust through the center of the sleeve Outlet Exhaust FIGURE 12 Normal Release Control FIGURE 14 ABS Release 13 Installation Installation of the Bendix A 18 trailer ABS system is similar from one configuration to another All systems use the same speed sensors and valves The differences are in placement and quantity and the type of ECU either standard or basic Refer to the following general component instructions and to the wiring and plumbing diagrams for specific system configuration Suggested Order Of Installation Following is a suggested order of installation of the A 18 trailer ABS 1 Install Wheel Speed Sensors often part of a dressed axle 2 Inst
4. accessing configuration codes refer to Accessing Codes on page 30 System Application Chart Trailer Type 25 1M 25 2M 45 2M Side Control 45 2M Axle Control Trailer or lst Trailer lst 2nd or 3rd Trailer Trailer FIGURE 5 System Application Chart Trailer ABS Component Overview Bendix A 18 trailer ABS system includes the following components Electronic Control Unit ECU The ECU monitors wheel speeds and controls the trailer ABS valves It also diagnoses ABS malfunctions and stores failure specific fault codes The ECU is usually attached to a relay valve with a mounting bracket The ECU may also be directly frame mounted One ECU can monitor either two or four speed sensors and control either one or two relay valves If necessary more than one ECU may be used on a single trailer Relay Valve This component regulates brake chamber air pressure It houses the hold and release solenoids Each relay valve can control either two or four brake chambers on an ABS equipped trailer A relay valve can have the ECU mounted to it valve A in the installation diagrams or be a stand alone relay valve valve B in the installation diagrams that is controlled remotely by the ECU mounted on valve A Trailer Mounte
5. and stopping distance while addressing cost complexity and reliability issues Speed sensors monitor wheel rotation f Speed signal to ECU Braking force remains at optimum level ECU interprets speed signals and activates valves Hold and release solenoids control air pressure in the brake chambers FIGURE 4 Overview of Trailer ABS Operation Independent Regulation The most obvious control concept is independent wheel control In this case a single sensor controls a valve that operates the brakes at one wheel site Individual control makes the best trade off between stability and stopping distance However these systems have greater complexity and higher cost with potentially lower reliability than less complex systems In many cases it is necessary to control a single valve with inputs from two sensors Select Low Select low systems monitor several wheels and controls them with a single valve Control is based on the wheel that is at the lowest speed Select low systems are very stable but sacrifice stopping distance on split coefficient surfaces Modified select low systems incorporate a delay before releasing to reduce the bias slightly away from the low speed wheel Select High Select high systems also monitor several wheels and control them with a single valve Control is based on the wheel which is at the highest speed Modified select high systems activate a release before th
6. are registered trademarks of Eaton Corporation 1 Tractor and trailer ABS systems operate independently of each other Therefore systems will work together properly even if they are not supplied by the same manufacturer For information on disassembly installation and service of related axle and brake components refer to their individual Bendix Service Manuals For assistance in your area call Bendix at 1 800 247 2725 or RoadRanger at 1 800 826 4357 These ABS controllers and systems were originally marketed under the Eaton Brand name For more information contact Bendix or refer to your local authorized Bendix dealer or RoadRanger Power Requirements for ABS Since March 1998 the trailer wiring systems provide two sources of power for the antilock system The two power sources are 1 Full time power when ignition is on must be provided by the tractor This full time power source may be shared with other trailer circuits The SAE J560 Blue AUX circuit is commonly used as the full time power source In other cases a separate ISO3731 connector is provided 2 Brake light power is provided as a secondary source of power in cases where an older tractor that does not provide full time power is used to operate an ABS equipped trailer The industry requires that the tractor provide at least 10 amps at 12 volts at the trailer end of the SAE J560 or ISO cable on all ABS power circuits These specifications meet T
7. keyed Basic Plug the green harness connector into the ECU connector labeled X1 This connector is also keyed and is the only connector on the ECU Install the ECU cover by first engaging the alignment tabs and then hinging the cover closed ensuring that the convoluted tubing is captured in the strain relief slots Slide the cover lock to the locked position An optional tie wrap may be used to lock the cover in place Route harness to designated locations Make sure that the harness is properly routed and secured to prevent damage to the harness BASIC One Bayonett Connector at Relay Valve ee Diagnostic 5 Pin Weatherpack 6 Pigtail Male Bayonet Two Speed Sensors K Road Side Install the Diagnostic Port Standard System To Frame I Diagnostic On standard systems the diagnostic port is installed on Port the road side of the trailer on the frame forward of the trailer axle s To install the diagnostics port bolt or weld the diagnostic port bracket to the trailer frame Install the Trailer Mounted Warning Light The warning light is mounted on the road side of the trailer forward of the marker light according to the following Diagnostic drawing Port Bracket FIGURE 21 Diagnostic Port Installation Standard 23 6 600mm Rear Side Marker ABS Warn
8. signal check tone ring Sensor D Excessive wheel lock Intermittent sensor signal Sensor shorted or open Short circuit from the release solenoid to voltage Short circuit from the release solenoid to ground Open circuit atthe release solenoid Open circuit on the common line to the valve Short circuit from the hold solenoid to voltage Short circuit from the hold solenoid to ground Open circuit at the hold solenoid System guration is incorrect Short circuit from the release solenoid to voltage Short circuit from the release solenoid to ground Open circuit at the release solenoid Valve B Open circuit on the common line to the valve t t t Short circuit from the hold solenoid to voltage Short circuit from the hold solenoid to ground Open circuit atthe hold solenoid System configuration is incorrect Common side of valve s stray voltage detected Common side of valve s shorted high Common side of valve s shorted to ground ECU internal error ECU Over voltage on ECU power line Low voltage on ECU power line PU Paper Lre Warning light shorted high or J 1587 shorted to ground Warning Light or J 1587 Sensor signal check required Pull trailer or turn wheels one after the other Sensors 1 2 2 2 2 2 2 3 3 3 3 3 3 4 4 4 4 4 4 5 5 5 5 5 5 8 8 8 8 8 8 8 8 9 9 9 9 9 9 9 oo ON SP WNY FF IOWA UO HP WN oo u pP WY RID vr BS WN RID UO BP WYRE oo o
9. 2 FIGURE 39 ECU Pin Identification Chart Description Brake Light Power Secondary Power Source Warning Light Power Trailer Mounted Diagnostic Plug Valve A Release Solenoid Speed Sensor B Negative Speed Sensor B Positive 33 White Ground Top Looking into Harness Blue Switched 12V Constant Power From Tractor Brake Light P ower ECU Side LJ Wheel Side 4 Front Warning A Hamess Side g E A 7 Light Side Ss S lt stom Lo xtension No Connection Ti j 2 3 Brake Light N Common Hold Perm Power C Not Used f D Warning Lamp Top View Looking Into Valve K Road Side FIGURE 40 2S 1M Electrical Connections 34 White Ground Blue Switched 12V Constant Power From Tractor Red Brake Light Power Top Looking into Harness Vou GND DIA ll 12 1587 1587 4 Front Na Harness Side Light Side Brake Light Perm Power C Not Used D Warning Lamp E Ground A SAE J 1587 B SAE J 1587 a Connection ia or Not Use 2 3 OOO E Ground F NotUsed Common FIGURE 41 2S 2M Electrical Connections Top VIEW Looking Into Valve K Road Side 35 White Ground Top Looking into Harness Blue Switched 12V Constant Power From Vow GND DIA Sy N ie Tractor aa 8 8 2 1587 15
10. 710 Standard System Serial Number Date Code FIGURE 7 Electronic Control Unit Identification Tags BASIC Blank Connector ECU Cover STANDARD ECU Cover FIGURE 8 Trailer ABS ECU Configurations 10 Outputs SensorA 2 j Valve A Common Hold Sensor B Release ET standard Common Trailer ECU i Hold Trailer Mounted 2 Connectors Warning Light Sensor D Brake Light P ower J 1587 1587 Full Time Power E Diagnostic Link J 1587 Gnd ss F t Diagnostic Switch SensorA Release Valve A Common Sensor B 3 f Hold Basic Trailer Mounted Warning Light Trailer EN ae ECU Brake Light Power 9 1 Connector tJ Diagnostic Plug Full Time Power FIGURE 9 Standard and Basic ECU Block Diagrams 11 Relay Valve The trailer ABS relay valve controls air pressure to individual brake assemblies and functions as a standard relay valve when there are no ABS control signals Depending on the particular ABS configuration a system may utilize one or two relay valves See Figure 10 Each relay valve contains two solenoids for air control The hold solenoid maintains air pressure the release solenoid removes pressure from the brake The Electronic Control Unit signals the relay valve s for air hold and release by acti
11. 87 0O Wheel Side op Warning NS Harness Side Light Side Se K Road Side Power R Cable L A Brake Light ECU Side a N Perm Power ot Used A SAE J 1587 B SAE 1587 Common ue C 12 Volts D Not Used Looking Into Valve E Ground F Not Used FIGURE 42 4S 2M Side Control and Axle Control Electrical Connections 36 STANDARD SYSTEM All Views Looking into Harness Connectors Diagnostic Ground Diagnostic 12V Sensor A Sensor A 00000 osounum Sensor D Sensor D J1587 X2 Black Coding B Common B Common A Full Time Power Brake Light Power No Connection Warning Light Trailer Release B Trailer Mounted Coding A Warning Light 000000 Chassis Ground J560 White BASIC SYSTEM All Views Looking into Harness Connectors Sensor At Common A Brake Light Power Diagnostic Plug Warning Light Trailer Sensor B Trailer Mounted A RUHE Coding C J560 White J560 Blue J560 Red FIGURE 43 Electrical Schematic 37 Glossary ABS Antilock Brake System A control system that maintains wheel slip at a level that minimizes stopping distance while maintaining lateral stability to the extent possible Air Gap Distance between the sensor pole piece and tone ring Anti Compounding A method to prevent the application of the service brakes and spring brakes atthe same time to pre
12. 91 5 meters 300092 8 meters 300093 N A MPSI Scan Tool Diagnostic P ort Deutsch HD10 6 12P Pin Deutsch 0460 204 12141 114017 Deutsch N A N A N A Power Cable Packard ECU Side 12034342 Socket Packard 12124580 Seal Packard 12015323 12010293 D 12010300 Packard lt D Power Cable Packard Trailer Harness Side 12065158 FIGURE 27 ABS Parts Identification Chart Pin Packard 12124582 Seal Packard 12015323 12010293 D 12010300 Packard lt D 23 Troubleshooting and Fault Codes An important feature of the Bendix A 18 trailer ABS system is the diagnostics that are reported via the Electronic Control Unit This section describes how to use error codes to identify ABS system operating problems There are three ways to retrieve and display trailer ABS fault codes e ServiceRanger PC software Displays configuration information and fault codes on the PC monitor Refer to the ServiceRanger PC software information later in this section e Automatic retrieval via a hand held tester Displays fault codes on the hand held tester s display Refer to the hand held tester information later in this section to retrieve and display fault codes The low cost diagnostic cable provided with the 2S 1M system does not accommodate the hand held tester Manual blink code diagnostics Flashes the codes on the ABS indicator lamp Refer to
13. Configuration 3 Monitor Data Wheel Speeds Cut Out Speeds System Volts Clear Faults Codes ravel bisane 4 Component Test Valve Routines WL Trailer WL Cab optional 6 English Metric 5 System Setup System Config FIGURE 29 Hand Held Tester Operation Procedures 25 ServiceRanger PC Software ServiceRanger PC software can be used to read and clear CAUTION ServiceRanger PC software can activate output error codes and obtain a short description of failures The tests for all output devices Since these tests can affect software can initiate test sequences for controller outputs operation of the vehicle braking system the ECU and can also read system data such as voltage atthe ECU incorporates special safety protection One axle must show wheel speeds and cutout speeds zero speed or the test will be halted Deutsch HD 10 Zo To Diagnostic Connector Connector O Serial Communication Laptop PC Interface me ServiceR anger Main Menu Options 1 Monitor Data 2 Retrieve Fault Codes 3 Advanced Product Functions 4 Product Downloads L Monitor Data i ex 3 Adv Prod iong 4 Product Downloads Wheel Speeds Retrieve Fault Codes Test Valves Read ECU Configuration Cut Out Speeds Clear Fault Codes Test Lights Configure ECU Input Voltages Switch States FIGURE 30 ServiceRanger Menus amp Hardware Setup 26 Troubleshooting Procedures ABS Valve Troubleshooting Follow the steps listed below t
14. MC RP 137 and are consistent with SAE 2247 There are no formal requirements However suppliers of Trailer ABS have agreed to provide for proper antilock brake operation down to a minimum of 8 5 volts at which time the warning lamp will activate A new TMC RP Recommended Practice is being developed which recommends that trailer manufacturers provide a 1 0 volt safety margin over the 8 5 volt minimum System current requirements will not exceed 0 5 amps per control unit and three amps per valve A 18 trailer ABS system modulators have a nominal resistance of 5 5 ohms and require approximately two amps to operate The control unit is designed to power warning lamps with a typical current of 300mA for trailer mounted warning lamps and 100mA for cab mounted warning lamps Trailer Mounted ABS Warning Light Rules for the location color labeling intensity and photometrics for external ABS warning lamps have been established by the National Highway Transportation Safety Administration NHTSA These requirements were effective as of March 1 1998 Location The lamp mounting location shall be near the left side rear of the trailer no closer than 150 mm 5 9 inches and not more than 600 mm 23 6 inches from the rear red side marker indicator lamp Refer to Figure 22 On a converter dolly the lamp mounting location shall be on a permanent structure of the dolly at least 375 mm 14 inches above the road surface Color and L
15. O HB WY HM 1hHf P FIGURE 38 Gen 5 ABS Fault Code Chart 32 Connector Ref GNDDIA VDIA SSA SSA SSB SSB SSc SSC SSD SSD 1587 Connector Pin Ref SSA SSA CMNA HLDA GNDEcu VECU Guides STANDARD SYSTEM Top Looking into Harness Connector Cover Lock ECU Cover Alignment Tabs X2 CODING B BLACK Description Pin Ref HLDB CMNB CMNA HLDA GNDEcU VECU Diagnostic P ort Ground Diagnostic P ort Power 12V Speed SensorA Negative Speed SensorA Positive Speed Sensor B Negative Speed Sensor B Positive Speed Sensor C Negative Speed Sensor C Positive Speed Sensor D os won non wo A W N e egative rm oO Speed Sensor D Positive rm he Diagnostic Link Positive Diagnostic Link Negative BASIC SYSTEM Cover Lock ECU Cover X1 CODING A GREY Description Valve B Hold Solenoid Valve B Common Valve A Common Valve A Hold Solenoid ECU Ground ECU Continuous Power with Ignition ON Brake Light Power Secondary P ower Source No Connection Warning Light P ower Trailer Mounted Valve A Release Solenoid No Connection Valve B Release Solenoid Top Looking into Harness Connector X1 CODING C GREEN Alignment Guides Tabs Description Pin Speed Sensor A Positive 7 Speed SensorA Negative 8 Valve A Common 9 Valve A Hold Solenoid 10 ECU Ground 11 ECU Continuous Power with Ignition ON 1
16. abeling The malfunction indicator lamp must be yellow in color and identified with the letters ABS to distinguish the lamp from other yellow side markers The letters may be on the lens on the lens housing or on the trailer itself near the lamp Intensity and Photometric Requirements The external ABS malfunction indicator lamp must conform to SAE J592 JUN92 Trailers shall use a combination clearance side marker lamps marked with a PC or P2 These lamps offer a widely diffused beam pattern throughout a full 180 degree left and right range General Air Brake Requirements Basic design requirements for trailer air brake systems are set forth in FMVSS 121 FMVSS 121 covers requirements for new construction Once put into operation the trailer s brake systems must be maintained in accord with the following FHWA OMC standards FMCSR 393 Covers required equipment FMCSR 396 Covers inspection and repair Air Timing Requirements FMVSS 121 specifies the maximum times that are permitted for application and release of brake chamber pressure Refer to Figure 2 ABS equipped trailers must meet the same air timing requirements as prior non ABS equipped trailers Reservoirs Trailers must be equipped with air reservoirs that provide a volume of air eight times that of the service brake chambers Vehicle Classification From pedal movement Application Time seconds Peda
17. all Relay Valve s ECU assembly Install the Power Cable but do not apply power until the installation is complete Route and connect the main ABS Harness Install the Diagnostic Port Connector Install the trailer mounted ABS Warning Lamp Perform the End of Line Checkout N O pi R FIGURE 15 Speed Sensor Installation 14 Install the Wheel Speed Sensors and Sensor Friction Sleeves Refer to the appropriate diagram for your system and locate the wheel speed sensors Refer to Figures 23 26 1 Install the sensor friction sleeve with the flange stops towards the inboard side of the vehicle 2 Apply high temperature silicon based grease to the body of the speed sensor 3 Push the speed sensor completely into sensor friction sleeve by hand until it stops against the tone ring The speed sensor is properly installed and adjusted when it is touching the tone ring Allowable TIR for the tone ring is 0 008 inches NOTE The speed sensor must be able to slide freely in and out of the sensor friction sleeve bore Operating the vehicle with seized components will damage the speed sensor and the tone ring 4 Route the cable to the frame Use tie wraps as required to restrain cable Use care not to stress sensor cables 5 Connect sensor cable to harness and install fasteners to hold the sensor cable in position Sensor Zz Friction Sleeve ABS Sensor NV SE g Busting 6 cy ZD en 7 C0 FIGURE 16 Wh
18. ary pressurized air systems make certain to drain the air pressure from all reservoirs before beginning ANY work on the vehicle If the vehicle is equipped with an AD IS air dryer system or a dryer reservoir module be sure to drain the purge reservoir 5 Following the vehicle manufacturer s recommended procedures deactivate the electrical system in a manner that safely removes all electrical power from the vehicle 10 Never exceed manufacturer s recommended pressures Never connect or disconnect a hose or line containing pressure it may whip Never remove a component or plug unless you are certain all system pressure has been depleted Use only genuine Bendix replacement parts components and kits Replacement hardware tubing hose fittings etc must be of equivalent size type and strength as original equipment and be designed specifically for such applications and systems Components with stripped threads or damaged parts should be replaced rather than repaired Do not attempt repairs requiring machining or welding unless specifically stated and approved by the vehicle and component manufacturer Prior to returning the vehicle to service make certain all components and systems are restored to their proper operating condition Hold Solenoid Release Solenoid Piston Control Control Outlet FIGURE 13 ABS Hold Exhaust Relay
19. ber after a brake application To balance the system quick release valves may have hold off springs that produce higher crack pressures when the valves open Relay Valve A pneumatic amplifier A relay valve provides large quantities of air from supply reservoirs located nearby in response to a low flow control signal originating from a remote source Relay valves have an associated crack pressure No pressure is delivered until the control pressure reaches the crack pressure Release Timing The time from initial brake pedal movement release for a set of brake chambers initially at 95 PSI to reach 5 PSI Select High An ABS control strategy in which several sensed wheels are controlled by a single valve The pressure at both wheels is controlled by the wheel that has the least tendency towards locking Select Low An ABS control strategy in which several sensed wheels are controlled by a single valve The pressure at both wheels is controlled by the wheel that has the greatest tendency towards locking Select Smart An ABS control strategy in which several sensed wheels are controlled by a single valve If the wheels are determined to be on significantly different surfaces e g ice on one side and asphalt on the other select high operation is chosen If the surfaces are close to homogeneous a select low strategy is chosen Sensor Bushing A bushing which is pressed into axles to hold a wheel speed sensor and f
20. clear historic faults 5 After completion of the End of Line checkout procedure disconnect the tool or PC from the trailer diagnostic port 6 Verify that the ABS warning light turns off and remains off after the bulb test If there was a past speed sensor fault in the system the warning light will not turn off until the trailer has been operated at a speed sufficiently high to be read at the ECU typically 3 to 5 mph 22 End of Line Checkout Procedure Basic Note Itis not possible to miswire the components on a 2S 1M Basic system Therefore the checkout procedure does not require the use of a hand held tester 1 Apply power to ECU do not use a battery charger as a power source 2 Verify that the ABS warning light turns OFF and remains OFF after the bulb test Note If there was a past speed sensor fault in the system the warning light will not turn OFF until the trailer has been operated at a speed sufficiently high to be read at the ECU typically 3 to 5 mph Harness Connector Shell Deutsch DT Deutsch DT06 12SA BK01 Grey DT06 12SB BK01 Black DT06 12SC B016 Green L RN a IA A DI LT N ABS Component Harness Terminal Socket Deutsch 0462 201 16141 gt Wire Seal N A W12S P012 Deutsch 114017 Deutsch Bayonett Socket Amp Seal Amp 14414 627 626 2 Pin Kostal w overmold Wheel End Sensor Length Eaton Part No 2meters 300090 3 meters 3000
21. connections on European trailers However this connector is used to provide interface to trailer ABS in some U S applications In Europe another connector designated as ISO 7638 is used to provide interface to the trailer braking system Main Speed Sensor Gladhand Electrical Connector Inline Power SAE J560 0 Connector K Road Side ABS Test Port Connector Warning Light for Handheld and PC Based ac u ECU with Diagnostics a ABS Relay Valve FIGURE 6 ABS Trailer Components Electronic Control Unit ECU The Bendix A 18 ECU is the trailer ABS control center Identification Identification information for the ECU is located on the connector pinout label refer to Figure 7 The label is located under the ECU cover Refer to the label for the Part Number e Serial Number e Date Code Depending on configuration the A 18 trailer ABS system ECUs may be equipped with either one connector basic system or two connectors standard system Refer to Figure 8 Bendix Part Number Bendix x fol gt 3 a 3 HI Ea Oy CPS HIN Gh loon k uk h 1 10 k SEF g Wa RR a Wo Hr NENNEERNENENE oth T III IML I p Vn ILI TTL Date Code bee g end Herufacly es by Enger ens g ajb 0z SQ Pace IN KaXxXXXx LEER Basic System Serial Number T 3 7 dv GND Von SSe SSe SSe SSe X2 12 1109 8 7 1587 1587 SS SS 5 S8 CODE B ACTUAL UNTIL MG2U43970115
22. d NOTE If asluggish response is noted at all wheels inspect for kinked or obstructed air line leading to or from valve 6 Increase system air pressure to governor cut off With brakes released coat exhaust port of relay valve with a soap solution Leakage of a 1 bubble in 5 seconds is permissible 7 Depress foot valve and keep depressed Coat exhaust port with a soap solution Leakage of a 1 bubble in 3 seconds is permissible Frame Member Relay Valve FIGURE 18 Frame Mounted Relay Valve 15 Install the Inline Power Connector The inline power connector is on the end of the main ABS 1 harness and connects the ABS system to the trailer 2 electrical system 3 Modulator Valve Trailer Side Power 4 Cable ECU Side FIGURE 19 Inline Power Connector STANDARD Bayonett Connector at Relay Valve Up to 2 5 Pin Weatherpack 6 Pigtail Deutsch Hd 10 Diagnostic Speed Sensor 2 or 4 K Road Side FIGURE 20 Standard and Basic ABS Harnesses Warning Light Chassis Ground 16 Warning Light Install the Main ABS Harness Remove power from the trailer Unlock the ECU cover and remove Install the ECU connectors as follows Standard Plug the grey harness connector into the ECU connector labeled X1 The connector is keyed and can only fit in one direction Plug the black harness connector into the ECU connector labeled X2 This connector is also
23. d ABS Warning Lamp This indicator lamp located on the Road Side near the rear of the trailer warns the driver of ABS malfunctions steady ON It is also capable of blinking diagnostic fault codes Cab Mounted ABS Warning Lamp This indicator lamp located on the driver instrument panel also warns the driver of ABS malfunctions It is not capable of blinking diagnostic fault codes Wheel End Speed Sensor and Tone Wheel Single point variable reluctance magnetic sensor that generates an alternating current signal in response to the movement of teeth on a tone wheel The signal is interpreted by the ECU to monitor wheel speed Diagnostic Port Connector The diagnostic port connector is an industry standard connector which is used to provide a connection to the J1587 diagnostic link This connector also provides power and ground for diagnostic test equipment Gladhand The gladhands used on the ABS system are the same as those used on non ABS trailers Seven Way Main Electrical Connector The seven way receptacle is the same as those used on non ABS systems This receptacle provides full time power backup power via the brake light switch and ground for the ABS electrical system Optional ISO 3731 connector This is a 7 pin connector similar to the J560 connector The most noticeable difference is that the ground terminal has a gender opposite that of the other terminals The primary use for ISO 3731 is for the lighting
24. d the relay valve when reorienting ports or when attaching fittings If a vise is used there is a potential danger of distorting the barrel and piston within the valve rendering the valve inoperative It is recommended that a fixture be used that avoids the potential for stressing the valve 12 Three Pin ECU Connector Out 3 8 Delivery Port to Brake Chamber Figure 10 Relay Valve WARNING PLEASE READ AND FOLLOW THESE INSTRUCTIONS TO AVOID PERSONAL INJURY OR DEATH When working on or around a vehicle the following general precautions should be observed at all times 1 Park the vehicle on a level surface apply the parking brakes and always block the wheels Always wear safety glasses 2 Stop the engine and remove ignition key when working under or around the vehicle When working in the engine compartment the engine should be shut off and the ignition key should be removed Where circumstances require that the engine be in operation EXTREME CAUTION should be used to prevent personal injury resulting from contact with moving rotating leaking heated or electrically charged components 3 Do not attempt to install remove disassemble or assemble a component until you have read and thoroughly understand the recommended procedures Use only the proper tools and observe all precautions pertaining to use of those tools 4 If the work is being performed on the vehicle s air brake system or any auxili
25. e N Warning Lamp Connector ECU i A Stand ABS Warning Lamp Relay N ns Alone j Valve A SD Oe Ve Relay Harness Side Top View AKEN yA Valve B Warning Light Side QA Road Side 25 2M Air System Configuration Top View Key Kr 3 8 0 D Nylon Tubing 3 8 O D Nylon Tubing Alt 1 2 O D 3 8 D Hose Service Brake Chamber Gladhand OF x Service Control Line Front Supply Line Gladhand cS achan TEV or STEV Spring Brake Control ne Valve A Top View Emergency Brake Chamber Road Side FIGURE 24 Typical 2S 2M ABS Electrical and Air System 19 45 2M Side Control Electrical Configuration Top View 560 Connector Power Cable Wheel Sensor ECU Side Ns iie OC Side Parts List Description ECU Relay Valve Stand Alone Relay Valve Sensor Diagnostic Cable Valve P ower Cable Sensors 0 4m Cable Sensor Friction Sleeve Warning Lamp Connector Top View Waming CX Harness Side Light Side K Road Side 4S 2M Side Control Air System Configuration Top View Key Tee ae Sensor D Sensor C Kr 3 8 0 D Nylon Tubing 3 8 O D Nylon Tubing Alt 1 2 0 D 3 8 D Hose Gladhand aN Service Control Line Service Brake Chamber Supply Line Gladhand Road Side
26. e a method such as counting one thousand one one thousand two This will allow more accurate fault code retrieval and reduce the possibility of misreading blink code information Before attempting any repairs first retrieve the fault codes and write them down Next clear the fault codes Then once again retrieve the fault codes Only active codes will now be displayed Retrieving Fault Codes Live Feed Gen 5 ABS PLC Capable ECUs 1 Turn ignition key ON 2 Use appropriate jumper method Apply the jumper for 2 seconds and remove 3 Record the 2 digit blink codes as they are flashed on the external trailer warning lamp BASIC SYSTEM ABS ojo 1 ECU ABS Wiring Harness With ignition ON jump the diagnostic plug to chassis ground for 2 seconds to activate the blink codes on the ABS warning light FIGURE 36 Jumper Method of Accessing Blink Codes 30 Retrieving Fault Codes Gen 4 ABS 1 Turn ignition key ON 2 Use appropriate jumper method Apply the jumper for 2 seconds and remove 3 Two digit blink codes are retrieved and displayed Clearing Fault Codes 1 With the power OFF use the appropriate jumping method 2 Turnthe power ON while continuing to apply the jumper e Wait at least 3 seconds and remove the jumper e Blink fault codes are cleared e Repeat the Retrieving Fault Codes procedure to verify that fault codes are cleared e Active fault codes will be re established unt
27. e low speed wheel becomes severely locked Select high systems generally have good stopping distances at the expense of stability These systems may also have an increased risk of tire flat spotting Select Smart Select Smart systems operate as select low systems when there is little difference in traction between wheel control sites They operate as select high systems when there is a significant difference in traction between sites These systems offer many of the advantages of individual control systems while using a simpler design and fewer components Bendix A 18 Trailer ABS Control Strategy Select Smart is used for the most common applications Select low is used on the standard system 4S 2M Axle Control configuration and is available as an option on the basic system TRAILER ABS CONFIGURATIONS Application Recommendations Refer to the chart on page 8 to determine a recommended ABS installation for your application Basic System 2S 1M The basic system includes two speed sensors and one modulator valve for direct control of one axle and indirect control of an additional axle Other features of the basic system include one ECU connector and a single pin diagnostic lead Standard System 2S 1M 2S 2M and 4S 2M Bendix s standard systems offer either two or four speed sensors and up to two modulator valves Standard systems can directly control one or two axles and allow full diagnostics via J1587 The standard sy
28. eel Speed Sensor Components Install the ECU Relay Valve and Stand Alone Relay Valve In all installations the ECU Relay Valve assembly appears as Relay Valve A inthe diagrams The Stand Alone Relay Valve is identical to the ECU Relay Valve except it does not have the ECU and ECU mounting bracket The relay valves may be installed on the reservoirs or a frame member The Stand Alone Relay Valve is the second relay valve in systems with two relay valves and is labeled Relay Valve B in the diagrams Pipe Fitting Torques Refer to the following torque specifications when installing pipe nipples Torques are for NPT threads with thread sealant applied Do not use thread tape Contamination by thread tape can cause component failure Tighten pipe nipples as follows e With Thread Sealant Finger tight plus 1 1 2 turns e Without Thread Sealant Finger tight plus 2 turns 3 4 Heavy Wall Steel Pipe Nipple FIGURE 17 Tank Mounted ECU Relay Valve Leak and Performance Test 1 Park vehicle on level surface and block wheels 2 Make and hold brake application No audible air leaks are permitted 3 Release parking brake and fully charge the air system governor cut out point 4 Turn engine OFF Apply the service brake several times then hold and check for prompt brake air chamber application and release at all wheels 5 Apply brake then hold Coat outside of relay valve with a soap solution No leakage is permitte
29. esistance Chart 27 Speed Sensor Troubleshooting esl Speed Sand Follow the steps listed below to locate and correct sensor Harness Connector related ABS diagnostic trouble codes 1 Access active diagnostic trouble code s using the blink code procedure the hand held tester or ServiceRanger software 2 Look up the code description the possible causes and the repair procedures provided in this section 3 Perform the recommended repair procedures Speed Sensor Resisitance Test 4 After the repairs are completed clear all codes and The correct resistance for the check for any additional codes speed sensor circuit is between Wheel Speed Note Drive the vehicle The indicator lamp will remain Sensor Sun on until proper sensor output is detected even though the diagnostic trouble code has been cleared Measure resistance at the wheel location to check the speed sensor Measure resistance at the appropriate ECU harness connector pins to check the cable and speed sensor Note Refer to the chart for pin identification FIGURE 33 Typical Wheel Speed Sensor Circuit 654321 654321 654321 000000 000000 7 8 9 10 11 12 7 8 9 10 11 12 7 8 9 10 11 12 X2 Black X1 Grey X1 Green Coding B Coding A Coding C Harness Connector Pin Circuit Description Harness Connector Pin Circuit Description X2 Black Coding B 3 Sensor A X1 Gree
30. for retrieving configuration and fault codes Refer to the retrieving codes section of this manual Example A blink code of one flash a pause then one more flash 1 1 indicates a 2S 1M system configuration when retrieving configuration codes However 1 1 indicates No Trouble Found when retrieving fault codes Retrieving Configuration Codes Live Feed Gen 5 ABS PLC Capable ECUs 1 Turn ignition key ON 2 Use appropriate jumper method Apply the jumper for 2 seconds and remove 3 Immediately apply the jumper again for 2 seconds and remove 4 Record the 2 digit blink code as it is flashed on the external trailer warning light Retrieving Configuration Codes Gen 4 ABS 1 Turn ignition key ON 2 Use appropriate jumper method Apply the jumper for 2 seconds and remove 3 Two digit blink codes are retrieved and displayed 29 Fault Code Charts Fault codes can be retrieved as two digit blink codes Refer to Figures 37 and 38 for a description of these codes Blink codes are retrieved by jumping pins A and E on Standard Systems and jumping the diagnostic bullet to the frame on basic systems The jumping method can also be used to clear codes To perform the activities listed below follow the steps exactly as given If you make a mistake during one of the steps stop and start over at the beginning of the procedure Note When using the jumping method for a designated amount of time to retrieve blink codes us
31. il corrected action has been taken STANDARD SYSTEM J ump Pins A and E and Release To Access Blink Codes Blink Code Sequence CONFIGURATION CODES Flashes Description 2S 1M Select Smart 2S 2M IR Side Control 4S 2M Side Control IR Side Control 4S 2M Axle Control Select Low DIAGNOSTIC TROUBLE CODES Flashes Description Action 1 Configuration OK no fault Sensor ACode Sensor Codes Sensor B Code Check sensor resistance 1500 2500 ohms Sensor C Code If sensor resistance is out of range replace sensor Sensor D Code Clean and lubricate sensor Press sensor into mounting hole until it bottoms against tone wheel Examine tone ring for damage Replace tone ring and or hub if necessary Check wheel bearing adjustment Adjust wheel bearings if necessary Check mechanical function of brake Check for kinked or restricted hoses Clear fault code and test drive the vehicle NOTE Drive the vehicle The indicator lamp will remain on until proper sensor output is detected even though the trouble code has been cleared Valve A Code Valve Codes Valve B Code Check valve resistance with multimeter Replace valve if resistance is incorrect f resistance is correct check harness for short in wiring See Figure 32 ECU Internal Error ECU Internal Error Clear diagnostic trouble code and test drive vehicle If diagnostic trouble code recurs or cannot be cleared replace ECU Faulty Supply Voltage Faulty Sup
32. ing Lamp FIGURE 22 Warning Light Location 17 2S 1M Electrical Configuration Top View Power Cable Diagnostic Port Wheel Sensor Speed Sensor PT Shown with Rir E amp amp Extension J X ECU J Pe Side CP K e Wheel GA i Side Parts List Zi Description Quantity ECU Relay Valve Sensor B Sensor Diagnostics Cable Front Valve P ower Cable Sensors 0 4m Cable SensorA Sensor Friction Sleeve J 560 Connector Warning Lamp Connector x Modulator T mil Warning N Harness Side Top View 7 Light Side A Road Side 2S 1M Air System Configuration Top View Kr 3 8 0 D Nylon Tubing 3 8 O D Nylon Tubing Alt 1 2 O D 3 8 D Hose Gladhand OR Service Control Line er ee er ee er er n Brake Front U ae Chamber Supply Line TEV or STEV Gladhand Spring Brake Control 3 4 Heavy Wall Top View Steel Pipe Nipple Road Side FIGURE 23 Typical 2S 1M ABS Electrical and Air System 18 25 2M Electrical Configuration Top View J 560 Connector Power Cable Diagnostic Port Wheel Sensor Speed Sensor pP WA ZS ECU Side m Wheel RT Side Parts List Description Quantity ECU Relay Valve Sensor B Stand Alone Relay Valve Sensor Diagnostic Cable Valve P ower Cable IL ka Sensor A j Sensors 0 4m Cable Sensor Friction Sleev
33. ingers cut into it It is pressed between an ABS sensor and mounting hole to hold the sensor in place Full Treadle Brake Application A brake application in which the treadle valve pressure in any of the valve s output circuits reaches 100 psi within 0 2 seconds after the application is initiated Independently Controlled Wheel Directly controlled wheel for which the modulator does not adjust the brake actuating forces for any other wheel on the axle Indirectly Controlled Wheel A wheel whose braking is adjusted in response to wheel speed information from an adjacent wheel IR Independent Regulation A control method in which a wheel is controlled at optimum slip a point where retardation and stability are maximized The brake pressure that is best for the wheel in question is directed individually into each brake chamber 38 MIR Modified Independent Regulation Amethod of controlling the opposite sides of a steer axle during ABS operation so that torque steer and stopping distance are minimized Usually control begins at pure select low and moves towards independent control as the cycle progresses Peak Friction Coefficient PFC The ratio of the maximum value of braking test wheel longitudinal force to the simultaneous vertical force occurring prior to wheel lockup as the braking torque is progressively increased QR Quick Release Quick release valves allow faster release of air from the brake cham
34. ir is held constant When required air is applied to the chamber at a controlled rate by modulating the hold side of the valve The antilock system does not apply additional braking power Rather it controls air pressure to release and hold brake torque thereby increasing a vehicle s capacity for quick straight stops With ABS installed vehicle operation is safer resulting in improved protection of driver cargo and equipment ABS Component Function Figure 4 shows an overview of the operation of the Bendix A 18 trailer ABS system Speed sensors 1 monitor wheel rotation and provide information 2 on wheel rotation to the central electronic control unit The Electronic Control Unit 3 receives the sensor signal interprets the pulse information and constantly calculates the relationship of speed acceleration and deceleration Acontrol signal 4 is sent to the ABS relay valve 5 which then controls the pressure to the air chambers System Designs When operating on high traction surfaces with a loaded vehicle there is little difference between types of ABS control Performance differences appear when vehicles are lightly loaded and operating on variable and poor traction surfaces Examples of poor traction surfaces are ice and combinations of ice snow and asphalt Operating a vehicle in a curve highlights differences in stability between various systems ABS system designs provide compromises between stability
35. l movement to reach 60 PSI For example a type 30 air chamber has an effective surface area of 30 sq in For short stroke type 30 air chambers the volume is typically 89 CID For a typical two axle trailer the minimum required volume is therefore 2848 CID Reservoir size requirements for non ABS and ABS equipped systems are the same Air Consumption During ABS activation there is a loss of reservoir pressure There are no specific requirements limiting air consumption in the U S In Europe Regulation R13 states specific limitations ABS manufacturers take air consumption into account when developing and evaluating ABS control algorithms There has been no need to change reservoir size requirements as a result of the ABS mandate Release Time seconds From pedal From movement movement to of the pedal until for chambers to reach 60 PSI Tractors Trailers and Buses Towing Trailer Converter Dolly Single Trailer at50 cu Res at gladhand reach 5 PSI w 95 PSI initial chamber pressure 50 cu in reservoir reaches 5 PSI With 95 PSI initial chamber pressure Note A 50 cubic inch reservoir is used to simulate the towed trailer volume at the gladhands of towing units FIGURE 2 Air Timing Requirements Chart Brake Priority Options In prior years there were requirements for a protected reservoir separate from the main reservoir The purpose of the protected reservoir was to hold off the s
36. n Coding C 1 Sensor At X2 Black Coding B 4 Sensor At X1 Green Coding C 2 Sensor A X2 Black Coding B 5 Sensor B X1 Green Coding C 11 Sensor B X2 Black Coding B 6 Sensor B X1 Green Coding C 12 Sensor B X2 Black Coding B 7 Sensor C X2 Black Coding B 8 Sensor C X2 Black Coding B 9 Sensor D X2 Black Coding B 10 Sensor D FIGURE 34 Sensor Pin Identification 28 Accessing Codes The ABS Warning Lamp outputs a two part blink code To interpret the blink code record the number of flashes in each part and compare with the Gen 4 or Gen 5 ABS charts On Gen 4 ABS systems the first part of the flash sequence indicates the configuration while the second part of the flash sequence indicates any fault codes that exist Example A blink code of three flashes a pause then three more flashes 3 3 indicates a 4S 2M side control configuration with a fault on Sensor B 2 Short Terminals A and E and Release to Access the Configuration Code CONFIGURATION CODES 1 2S 1M 2 25 2M 3 45 2M Side Control 4 45 2M Axle Control Configuration Blink Code Configuration 1 25 1M 2 25 2M 3 4S 2M Side to Side 4 45 2M Axle to Axle FIGURE 35 Accessing Trailer ABS Configuration Codes On Gen 5 ABS systems both the configuration codes and the fault codes are reported separately as two part blink codes There are different procedures
37. o troubleshoot the ABS system A multimeter or digital volt ohmmeter DVOM e Eaton ServiceRanger PC software or an MPSI ProLink hand held tester This section covers the use of testtools and equipment to find and correct system problems Hand Held Tester The hand held tester employs menu driven tests for reading ABS fault codes See the documentation provided with the tool for more information An MPSI hand held tester with Bendix proprietary cartridge can be used to read and clear error codes and obtain a short description of failures The tester can initiate valve test sequences and can also read system parameters example wheel speeds Note The hand held tester activates output tests for all output devices Since these tests can affect operation of the vehicle s braking system the test units incorporate special safety protection At least one axle mustshow zero speed or the test will be halted A standard heavy duty truck cartridge may also be used but cannot initiate test sequences Figure 29 shows hand held tester menu option Multimeter Schematics error codes and a multimeter can be used to check sensor and solenoid resistances and to find wiring harness defects Eaton ABS Press Enter System INFO Fault Codes Monitor Data Component Test System Set up English Metric Exit 1 System INFO 2 Fault Codes PartNo Date Read Fault Codes Serial No Software No System
38. o locate and correct ABS modulator valve problems 1 Access active fault code s using the blink code procedure the hand held tester or ServiceRanger software 78910112 78910112 X2 Black X1 Grey Coding B Coding A STANDARD Harness Connector P Circuit Description X1 Grey Coding A Valve B Hold X1 Grey Coding A Valve B Com X1 Grey Coding A Valve A Com X1 Grey Coding A Valve A Hold X1 Grey Coding A Valve A Rel X1 Grey Coding A Valve B Rel No Connection Release 3 en L 2 Hold Common Looking Into Valve Valve Resistance Test w Lookup the code description the possible causes and the repair procedures provided in this section Perform the recommended repair procedures After the repairs are completed clear all codes and check for any additional codes 7 8 9 101112 X1 Green Coding C Harness Connector Pin Circuit Description X1 Green Coding C 3 Valve A Com X1 Green Coding C 4 Valve A Hold X1 Green Coding C 10 Valve A Rel Measure Measure Resistance From To Range Pin2 Pinl 3 8 Ohms Pin2 Pin3 3 8 Ohms Pin1 Pin 3 6 16 Ohms Measure resistance at the ABS valve location to check the solenoid Measure resistance at the appropriate ECU harness connector pins to check the cable and valve Note Refer to the chart for pin identification FIGURE 32 Valve Pin Identification and R
39. ort 3 u 1 4 Reservoir a Port 0 f ap 3 8 Delivery Delivery Ports Ports FIGURE 3 Spring Brake Control Valves ABS PERFORMANCE CHARACTERISTICS Routine Braking During routine braking operations there is no indication of excessive wheel slip The electronic control unit interprets this condition as normal and ABS remains inactive ABS Controlled Braking The control unit continuously monitors all available wheel speed sensors Data from the sensors is used to calculate values of wheel speed and wheel slip and to make a best estimate of the true vehicle speed This data allows the control unit to detect impending wheel lock and to hold the wheel slip at an optimum value to maximize braking effectiveness The best possible vehicle stability is assured while stopping distance is minimized Control is accomplished by operation of relay based modulator valves The control unit makes a new assessment of conditions and updates the control signal to the modulator valves at a rate of approximately 100 times per second Under normal non ABS conditions trailer ABS relay valves operate exactly like conventional mechanical relay valves Refer to Figures 11 through 14 During ABS operation the control unit operates the valves to override the supply of air to the chambers During an ABS release supply air is held off while the chambers are vented to the atmosphere In hold mode supply air is blocked and chamber a
40. ply Voltage Clear diagnostic trouble code and power the system If trouble code recurs Check supply voltage and ground with multimeter Check connectors for corrosion Low Voltage Operation If the system powers up with a voltage below 8 5 volts a low voltage trouble code code 12 is logged and the indicator lamp remains on until the system is repowered at a proper voltage level as measured at the ECU If the system voltage drops below 8 5 volts after the initial check out phase no trouble code is logged but the indicator lamp turns on indicating that ABS is no longer operational If the voltage recovers the indicator lamp turns off and normal operation resumes FIGURE 37 Gen 4 ABS Diagnostic Trouble Code Chart 31 Blink Code Description Location No trouble found Sensor air gap too large Sensor air gap too large or sensor shorted SensorA Noisy signal check tone ring Excessive wheel lock Intermittent sensor signal Sensor shorted or open Sensor air gap too large Sensor air gap too large or sensor shorted Noisy signal check tone ring Sensor B Excessive wheel lock Intermittent sensor signal Sensor shorted or open Sensor air gap too large Sensor air gap too large or sensor shorted Noisy signal check tone ring SensorC Excessive wheel lock Intermittent sensor signal Sensor shorted or open Sensor air gap too large Sensor air gap too large or sensor shorted Noisy
41. pring brakes in the event of a failure of the service brake system In 1994 FMVSS 121 was revised to allow other approaches to reservoir management The protected reservoir approach although not required is still acceptable Conventional trailers are designed for either Spring Brake Priority or e Service Brake Priority Spring Brake Priority The advantage of spring brake priority is that the parking brakes spring brake can be released quickly to permit moving the trailer at start up However spring brake priority systems have failure modes under which the parking brakes can be released and the vehicle operated without functional service brakes Service Brake Priority The advantage of the service brake priority system is that it assures that the service brakes have adequate air pressure available to them before release of the spring brakes is allowed However service brake priority systems require more time to bring a vehicle up to operational level The Bendix A 18 trailer ABS system is compatible with both Spring Brake Priority and Service Brake Priority systems and does not require special installation procedures Anumber of spring brake control valves are suitable for meeting current requirements Bendix offers spring brake valves suitable for a range of applications TEV 1 4 Supply Port 1 4 Control 3 u Reservoir Port Port 3 8 _ 3 8 Delivery Delivery Ports Ports STEV 1 4 Supply P
42. riction sleeve Stored Faults A fault that occurred Tone Ring Aring that is usually pressed into a wheel hub that has a series of teeth usually 100 and provides actuation for the speed sensor Note maximum run out is 008 TIR Warning Light An amber light which indicates the operating status of an antilock system When the warning lamp is on ABS is disabled and the vehicle reverts to normal brake operation 39 40 BW2262 2004 Bendix Commercial Vehicle Systems LLC All rights reserved 5 2004 Printed in U S A
43. s Power Requirements for ABS 0055 3 General Air Brake Requirements 4 Brake Priority Options 00000000e 5 ABS Performance Characteristics 6 ABS Controlled Braking 20 00000 6 ABS Component Function 00005 6 Trailer ABS Configurations 0 7 Sensor Placement 0000 eee eee eae 7 Trailer ABS Component Overview 9 Electronic Control Unit ECU 11 Relay Valve 0 00 c cee eee 13 Relay Valve Operation Modes 14 Installation 2 0 cee eee 15 Install the ECU Relay Valve and Stand Alone Relay Valve 222222 16 Install the Inline Power Connector 17 Install the Main ABS Harness 2222222 17 Install the Trailer Mounted Warning Light 18 End Of Line Diagnostics 55 23 Use of Hand Held Tool for Configuration 23 Troubleshooting and Fault Codes 25 Test Equipment 0 0 cece eee 26 ServiceRanger PC Software 245 27 ABS Valve Troubleshooting 4 28 Speed Sensor Troubleshooting 29 Accessing Codes 0 000 cece ee eens 30 Fault Code Charts 00000 cee eee 31 GIOSSaNy ur 2 4 anda Re ernten 39 Bendix is a registered trademark of Bendix Commercial Vehicle Systems LLC Eaton RoadRanger and ServiceRanger
44. stem may be configured in one of four ways to function as follows e 2S 1M This configuration uses two sensors and one modulator valve to directly control one axle and indirectly control an additional axle e 2S 2M This configuration uses two speed sensors and two modulator valves for direct control of one axle and indirect control of up to three additional axles e 4S 2M This configuration uses four speed sensors and two modulator valves for direct control oftwo axles and indirect control of up to two additional axles e 4S 2M Axle Control Special configuration for full trailers and widely spaced axles This configuration uses the select low strategy Sensor Placement When more than one wheel is controlled by a single valve sensors should be mounted at the axle which tends to lock first For spring suspensions this is usually the forward axle For air suspensions this is usually the rear most axle Lift Axles e Gen 4 ABS Sensor inputs C and D of the control unit may be used for lift axle wheel speed sensing Gen 5 ABS Direct lift axle control is not available Use indirect control Reading Configuration Codes On Basic systems the jumper method must be used to access the configuration On Standard systems access to configuration information can be achieved by any of the three methods e ServiceRanger diagnostic software on a PC e Hand held tester Jumper method For more information on
45. the blink codes in this section Before the ABS system can be properly diagnosed and repaired the foundation brake system must be eliminated as a possible cause of the problem Follow the troubleshooting chart in Figure 28 to isolate and identify the brake problem Cycle ignition key OFF to ON Observe ABS warning light operation Light turns OFF after 2 second lamp check ABS system not reporting faults perform traditional foundation brake troubleshooting and repair Activate blink codes with jumper method Use Service Ranger diagnostic software standard ECU only Check ECU configuration Light stays ON communicate with Light never ON E 3 Check for power to ABS ECU Select Eaton ABS diagnostic tool Check waming light and wiring Use MPSI ProLink tool standard ECU only Does tester Check J 1587 data link wiring ECU Check ECU configuration Warning light blinking when activated with jumper method Does configuration information agree Reconfigure ECU with available hardware Read fault codes and descriptions Check power circuit for ECU Take corrective action Clear active and inactive fault codes Recheck fault codes after clearing Reconfigure ECU FIGURE 28 Brake System Troubleshooting Chart 24 If warning light remains lit or 17 12 fault code is set drive vehicle to clear and turn off warning light Test Equipment Eaton recommends the use of the following products t
46. to the SAE J560 connector AUX connection During the automatic configuration process the ECU will only configure upwards That is it will add but not subtract components from its configuration The configuration can be checked by using the hand held diagnostic tool or by activating the blink code as described in the End of Line Checkout Procedure listed below Compare the two part blink code with the chart Part 1 of the blink code is the current system configuration Use of Hand Held Tool for Configuration The system always configures upwards depending on the components which are found connected to it If a lower configuration is desired a hand held tester must be used to reconfigure the system End of Line Checkout Procedure Standard Note For 2S 1M systems it is not possible to miswire the components Therefore it is only necessary to perform step 6 of the end of line checkout 1 Apply power to ECU do not use a battery charger asa power source 2 Remove the weather cap from the trailer diagnostic port 3 Connect either a hand held tester with a Bendix Diagnostic Card or a PC Based Diagnostic system with ServiceRanger s End of Line Software Package to the trailer diagnostic port 4 Follow the appropriate menu selections to verify a That the sensors and valves are connected in their proper locations b That the proper system configuration has been obtained c Thatthere are no faults If necessary
47. vating the appropriate solenoid Each relay valve has a three pin terminal for connection to the Electronic Control Unit Delivery Ports Both 2 port and 4 port versions of the relay valve are available These are all tapped for 3 8 NPT fittings Crack Pressure Standard valves are available with 4 0 PSI 0 5 PSI crack pressure Other crack pressures can be provided For example 6 0 PSI valves may be used with wedge brakes Bracket Valve ECU combinations Various combinations of mounting brackets ECUs and valves are available preassembled to facilitate system installation on a variety of vehicles Refer to the Bendix A 18 trailer ABS Illustrated Parts List for further information Port Orientation If necessary the control and supply ports of the valve can be reoriented with respect to each other Remove the four assembly bolts Rotate top with respect to bottom as required Use care to maintain cleanliness of valve interior Retorque bolts to 10 0 lb ft 13 6 Nem Do not exceed 12 0 lb ft 16 3 Nem Pipe Fitting Torques Refer to the following torque specifications when installing pipe nipples Torques are for NPT threads with thread sealant applied Do not use thread tape Contamination by thread tape can cause component failure Tighten pipe nipples as follows With Thread Sealant Finger tight plus 1 1 2 turns e Without Thread Sealant Finger tight plus 2 turns Clamping A fixture may be necessary to hol
48. vent excessive stress on brake components Apply Timing The time from the first movement of the service brake control for the brake chamber to reach 60 PSI beginning with an initial service reservoir pressure of 100 PSI Channel A controlled wheel site CAN Controller Area Network Clear Codes Method for erasing historical faults from the ECU using either the diagnostic switch input or a hand held diagnostic tool Only repaired faults may be cleared Coefficient of Friction The horizontal force required to move a body on a relatively smooth level surface divided by the weight of the body Configuration Process of identifying a normal set of sensors and modulators for the Electronic Control Unit so that it can identify future missing sensors and modulators Crack Pressure The ascending input pressure or input force to an air valve required to initiate output pressure of flow Diagnostic Connector Deutsch HD 10 Series connector used for interface to hand held testers or PC based diagnostic equipment based on the J1587 protocol The tester can initiate test sequences and can also read system parameters Directly Controlled Wheel A wheel that is sensed to be slipping and is adjusted to correct for that slip ECU Electronic Control Unit FMVSS 121 Federal Motor Vehicle Safety Standard that regulates air brake systems Friction Sleeve A beryllium copper sleeve which has f
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