TRS ECU-Power Adapter Kit Installation Guide

TRS ECU-Power Adapter Kit Installation Guide
Installation
Guide
L31240
TRS ECU-Power Adapter Kit
4/08
(Replacing the Phase 1 TRS ECU
and Power Adapter With a Phase 2
TRS ECU)
Servicing the TRS ECU and power adapter is a simple
procedure, not requiring air tools, just simple hand tools.
However, it does require care to be taken to make sure the
replacement TRS ECU is wired & installed correctly.
This TRS system has as a standard feature an automatic
stop lamp illumination during a roll over intervention. In
other words, when the TRS intervenes to prevent a roll over
it automatically applies the trailer brakes and automatically
illuminates the trailer stop lamps as a warning to following
traffic that the trailer is braking. To verify that this feature is
working correctly, the stop lamps will perform a “bulb
check” upon trailer power up equal in duration to the ABS
lamp bulb check. This feature works only with trailer’s
equipped with LED stop lamps. Note: Incandescent lamps
present too much electrical load to the system and this
feature will not operate under these conditions.
Kit Contents:
Qty.
1
4
1
1
1
1
Part Description
Part Number
TRS ECU Phase 2
ECU Mounting Bolts
Power Cord Stop Lamp
2M Long Power Cord Extension
Dielectric Grease
Instruction sheet
832 002 001
051510909
300569BA
201199EB
102819AA
L31240
For engineering and technical support:
In the United States, please call: 1–800-643-2374 (press 2)
or ask for the ABS help desk
In Canada, please call: 1-800-267-9247
Servicing these components involve: removing the TRS
power adapter, removing the TRS ECU, reinstalling the
service replacement ECU, and finally checking the system
out. The air valve pack, speed sensor extension cables and
diagnostic cable are not changed and remain with the
trailer. For all cabling, examine each connector contacts for
corrosion, contaminants, worn, cut, or missing moisture
seals, or jacketing, and broken connector shells. Replace
cabling with these problems as needed; otherwise carefully
clean each connector before reinsertion into the
replacement ECU. Note: Apply dielectric grease sparingly to
all electrical contacts.
Refer to L30040 TRS Installation/Service Manual.
Before beginning work:
Remove all electrical power from the vehicle, disconnect
red and blue glad hands and drain the trailer’s air tank(s).
Be safe, work safely, and follow all of your companies
safety rules.
Remove the TRS Power Adapter
1. Disconnect the TRS power adapter from the trailer’s
5-way Packard Delphi ABS power connector or junction
box if so wired.
2. Trace this cable back to the power adapter box
removing any tie wraps or fasteners securing this cable
to the vehicle.
3. Unlock the slide lock on the TRS ECU and remove the
Power A (Blue) and Power B (Orange) cables, and the
Diagnostic (Green) cable by pulling the cable end out of
the ECU. Refer to Figure 1.
Locked Position
Slide Lock Unlocked Position
Slide Lock
The connectors for Aux 2 and sensor
extensions have a locking tab inserted
into the holes on the ECU.
4. Remove the auxiliary cable from the AUX 2 connector, by
pressing in on the connector’s locking tab through the
locking hole in the side of the TRS ECU when pulling the
connector out . Refer to Figure 1.
5. Trace the Aux & Power cables back to the TRS power
adapter box removing any tie wraps or fasteners
securing these cables to the vehicle.
6. Unbolt the power adapter box from the vehicle
(2 bolts).
Remove the TRS ECU
1. Remove the speed sensor connections in the old TRS
ECU one at a time. Be sure to label each sensor
extension as to its location socket in the ECU face.
Refer to the chart for pulling the identification tags if the
extension is unmarked. Refer to Figure 2.
2. Verify that the cable seal keeper ring is still in place on
each speed sensor cable end. If missing look or probe
the sensors socket connection in the old TRS ECU with a
small screwdriver and replace the keeper onto the
extension’s connector by snapping it back into place.
See Figure 2 for the location of the keeper ring.
3. The TRS ECU is held onto the valve body by four
mounting bolts and is plugged into an electrical
connector on the valve body. Carefully remove each
mounting bolt and pull the TRS ECU straight out from
the valve body. On some units the mounting bolts are
threaded on both ends with the ECU held on by screw
caps. Remove and discard the old mounting bolts.
Locking holes for
the auxiliary ports
are on the bottom
side of the ECU
Locking holes for
the sensor extensions are on both
sides of the ECU
Figure 1. TRS ECU Slide Lock Mechanism and Speed sensor locking tab, locking
hole locations. Open the slide lock to remove the Power and Diagnostic cables.
To remove the speed sensor and auxiliary cables: depress the locking tab in the
locking hole while pulling on the connector shell.
Figure 2. Label each sensor extension by cutting off tabs as per the table
shown.
ECU
Iden.
Tab Removed
Component
1
2
3
4
A
S1A
cut cut cut
S1B
cut cut cut cut
S2A
cut
cut cut
S2B
cut
cut cut cut
B
P
5
cut cut cut
cut cut
cut cut cut
cut cut
Roadside Front
S1A
Curbside Front
S1B
Roadside Rear
S2A*
Curbside Rear
S2B*
DO NOT cut items shown in the gray
boxes.
Example: S1B
Front Axle, Curbside
Sensor extension identification is
used for traceability from the
wheel end to the ECU. This is
easily accomplished by
removing the identification tabs
for each sensor extension as
shown.
cut tab with
scissors
Seal Keeper
Ring
Install the Replacement TRS ECU
1. Remove the shipping connector cover from the rear
electrical connector on the replacement TRS ECU. Inspect
the connector pins and make sure all pins are straight and
not bent over or otherwise damaged. It is recommended
that a bead of petroleum based dielectric grease be applied
to the connector contacts before mounting the ECU.
2. Before replacing the TRS ECU, inspect the mating
electrical connector on the valve body; carefully clean any
dirt, salt, or contaminants away from the connector. Be
sure the rectangular orange cable seal is intact and in place.
3. Carefully line up the replacement ECU with the valve
body and push the ECU rear electrical connector straight
into the valve body’s electrical connector.
8. Secure the power cable to the vehicle with fasteners to prevent
the cable from chafing or bouncing against the vehicle’s chassis or
road surface. If needed, use split loom to protect the cable jacketing
from chafing.
9. Note that the ABS power cable extension may be needed.
Connect the ABS power cord extension to the power cable and route
this extension to the vehicle’s 5-way Packard-Delphi ABS power
connector or junction box, if used.
10.Before reattaching the power cord to the vehicle’s power
connector, inspect the vehicle ABS power connector for corrosion,
bent or missing pins, or contaminants. Service this connector as
needed, then reattach the connectors.
Figure 3. Insert Power, Diagnostic and Speed Sensor Cables into the new TRS ECU.
4. Replace the four ECU mounting bolts; be careful not to
over tighten the mounting bolts. Do not use air tools to
tighten; hand tight & snug with a screw driver is sufficient.
Do not exceed a torque of 3 lb-ft when tightening.
5. Remove the blanking plugs from speed sensor sockets
(S1A, S2A, S1B and S2B) on the ECU and reinsert each
sensor extension in its proper connector on the ECU. Refer
to Figure 3 for details on sensor cable installation.
Open the Slide Lock
6. Open the slide lock on the replacement ECU; remove the
temporary plug from the grey ringed socket label “Power
A”. Remove the sealed blanking plug from the green ringed
diagnostic port. Reinsert the green diagnostic cable end
into the green ringed socket. Note that this cable is keyed
and inserts with the molded lettering on the cable facing up. Insert Connectors
Push the cable end fully into the connector socket. Test the
fit, by closing the slide lock, if the slide lock closes easily
Ensure the molded label faces
then the cable is fully inserted, if the slide lock won’t close
upwards when inserting the
connectors
or closes part way, the cable is not fully inserted or is
twisted slightly in the socket. Retry the insertion until the
slide lock closes easily. Reopen the slide lock. Refer to
Figure 3.
7. Insert the gray power cable into the grey ringed socket
on the TRS ECU. As with the green cable be sure the
lettering on the cable faces up. Fully insert the cable into
the socket, test the fit by closing the slide lock. Verify the
red rectangular seal is not protruding from the slide lock.
If so, open the slide lock and roll the seal back into its
indentation and reclose the slide lock.
Position the Connectors
Close the Slide Lock
Molded Label
Locking Tab
Reinsert Speed Sensors into the
TRS ECU
Make Sure Locking Tabs Click Into
The Locking Holes On The TRS ECU
TRS System Checkout.
Troubleshooting (Continued)
1. Apply 12 volt power to the trailer. Do not use a battery
charger, or an AC voltage supply. If a 12 volt battery is
used make sure it is fully charged.
The ABS lamp never goes OFF.
Possible causes for this are:
2. Verify the trailer mounted ABS lamp comes ON and goes
OFF. Listen for the valve pack solenoids to “click” or
“blow down”. If the ABS lamp either remains ON, or
does not come ON at all, proceed to the Troubleshooting
section below.
An active fault (Contact Haldex technical support
for assistance).
3. Upon the electrical power up the trailers stop lamps
should illuminate for a few seconds. If the lamps do not
come on refer to the Troubleshooting section below.
Insufficient electrical voltage/power to operate.
4. If the ABS lamp comes ON and then goes OFF attach a
tractor to the trailer, connect all hoses and cables, charge
the trailer’s air system, and drive the vehicle over 6 mph.
Make a few service brake applications and verify that the
vehicle service brakes are working correctly and that the
ABS light remains OFF. Do Not attempt to test the roll
over prevention feature by attempting to roll over the
vehicle. Do not test the vehicle on icy surfaces, with
worn out tires, or with a trailer that is known to be
mechanically unsound. Drive safely and obey all
pertinent traffic laws when drive testing the TRS system.
Troubleshooting
The ABS lamp never comes ON.
Replacement TRS mis-configured (Contact Haldex
technical support for assistance).
Shop air used to charge air system on trailer is set
over 145 psi
The stop lamps do not come on upon vehicle power up.
Possible causes for this are:
Power cable not plugged in or faulty.
Incandescent stop lamps are used.
Trailer wiring harness is faulty or stop lamps are not
plugged into trailer wiring harness.
ECU is not configured correctly (Contact Haldex
technical support for assistance).
The optional non-stop lamp activated power cable
is used.
Possible causes for this are:
ABS lamp burned out or disconnected.
The trailer wiring harness short circuited or open
circuited between the ABS 5 way power drop and the
trailer mounted ABS lamp.
A power connector not fully plugged in or unplugged.
Insufficient voltage/current to operate the TRS.
Faulty power cable/extension.
Faulty replacement ECU.
Haldex Commercial Vehicle Systems
Haldex Brake Products Corporation
10707 NW Airworld Drive
Kansas City, MO 64153-1215
Phone: (816) 891-2470 • Fax: (816) 801-4198
Haldex Limited
525 Southgate Drive, Unit 1
Guelph, Ontario Canada N1G 3W6
Phone: (800) 267-9247 • Fax: (519) 826-9497
www.haldex.com - www.hbsna.com
L31240 US 4/08 1M ART
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