abs wabco manutec

8/3/2019 Abs Wabco Manutec

1/56

Enhanced Easy-StopTM

Trailer ABS with PLCMaintenance Manual MM-0180Issued 05-01

$2.50

2S/1M Basic

2S/2M Standard 2S/2M, 4S/2M, 4S/3M Premium

TRAILERA

B


2/56

Service Notes

Service NotesBefore You Begin

This manual contains maintenance procedures forMeritor WABCOs Enhanced Easy-Stop TrailerABS with PLC. Before you begin procedures:

1. Read and understand all instructions andprocedures before you begin to servicecomponents.

2. Read and observe all Caution and Warningsafety alerts that precede instructions orprocedures you will perform. These alerts helpto avoid damage to components, seriouspersonal injury, or both.

3. Follow your companys maintenance andservice, installation, and diagnosticsguidelines.

4. Use special tools when required to help avoid

serious personal injury and damage tocomponents.

Safety Alerts, Torque Symboland Notes

Access Information onArvinMeritors Web Site

Additional maintenance and service informationfor ArvinMeritors commercial vehicle systems

component lineup is also available atarvinmeritor.com.

To access information, click on Products &Services/Tech Library Icon/HVS Publications.The screen will display an index of publicationsby type.

Additional Information

Call ArvinMeritors Customer Service Center at800-535-5560 to order the following publications.

Enhanced Easy-Stop

TM

Installation Guide

(Wall Chart) (TP-0155)

Blink Code Diagnostics Card for Easy-Stop

TM

and Enhanced Easy-Stop

TM

(TP-0173)

Driver Tips(SP-93161)*

How to Brake with ABS audio cassette

(SP-94126)*

Enhanced Easy-Stop

TMTraining Guide Workbook

(TP-0143)

Trailer ABS Service and Support Reference Card

(TP-9803)

Trailer ABS Technical Service Support

Reference Card

(TP-9804)

What Every Driver Should Know About ABS

(T-96159V)

Enhanced Easy-Stop

TM

Training Video(T-0197V)

Drivetrain Plus

TM

by ArvinMeritor TechnicalElectronic Library

on CD. Features productand service information on most Meritor,ZF Meritor and Meritor WABCO products.$20. Order TP-9853.

*For Spanish version, add SP to the item number.For French version, add FR to the item number.

WARNING

A Warning alerts you to aninstruction or procedurethat you must followexactly to avoid seriouspersonal injury anddamage to components.

CAUTION

A Caution alerts you to aninstruction or procedurethat you must followexactly to avoid damage tocomponents and possibleserious injury.

A torque symbol alerts youto tighten fasteners to aspecified torque value.

NOTE

A Note providesinformation or suggestionsthat help you correctly

service a component.


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Table of Contents

Asbestos and Non-Asbestos Fibers Warnings

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Section 1: Introduction

Maintenance Manual Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Identifying Enhanced Easy-Stop Trailer ABSEnhanced Easy-Stop Trailer ABS Parts

What Is Meritor WABCOs Enhanced Easy-Stop Trailer ABS? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

System Configuration

How Trailer ABS Works

Section 2: System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Section 3: ABS Questions and Answers

The Electronic Control Unit (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Power Line Carrier (PLC) Communications Questions and Answers

ABS Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

ABS Indicator Lamp (on Dash)

ABS Indicator Lamp (on Trailer)Types of Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Section 4: System Configurations

Enhanced Easy-Stop Installation Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Power Cable Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Section 5: Diagnostics

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Important PLC Information for Blink Code Diagnostics

TOOLBOX Software

Blink Code Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Diagnostic Tool (Blink Code Check) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Section 6: Component Replacement

Wheel Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

How to Remove a Sensor

How to Install a Sensor

ABS Relay Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

How to Remove a Standard ABS Relay Valve

How to Install a Standard ABS Relay Valve

The ECU/Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

How to Remove the ECU/Valve Assembly

How to Install the ECU/Valve Assembly

Tank-Mounted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36Bracket-Mounted to Cross Member of Vehicle (2S/1M Basic)

Mounted to Cross Member of Vehicle Standard and Premium MountingBracket Not Supplied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Replacing the ECU or Modulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38


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Table of Contents

Section 7: Sensor Adjustment & Component Testing

How to Test Wheel Speed Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Sensor Test Procedure

Sensor Output Voltage Test

Check ABS FunctionsABS External Modulator Valve

End of Line Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

End of Line Testing Procedure Using TOOLBOX Software (All Installations)

End of Line Testing without TOOLBOX Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

2S/1M Basic

Inspect the Sensor and Air Line Installation (2S/2M Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Inspect the Sensor and Air Line Installation (2S/2M, 4S/2M and 4S/3M Premium) . . . . . . . . . . . . . . . 45

Perform End of Line Test (Standard and Premium Installations) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Fault Code Check (All Installations)

Appendix I

Trailer ABS Indicator Lamp on Vehicle Dash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1


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Asbestos and Non-Asbestos Fibers

MM-0180

Issued 05-01 Page

ASBESTOS FIBERS WARNING

The following procedures for servicing brakes are recommended to reduceexposure to asbestos fiber dust, a cancer and lung disease hazard. Material SafetyData Sheets are available from ArvinMeritor.

Hazard Summary

Because some brake linings contain asbestos, workers who service brakes mustunderstand the potential hazards of asbestos and precautions for reducing risks.Exposure to airborne asbestos dust can cause serious and possibly fatal diseases,including asbestosis (a chronic lung disease) and cancer, principally lung cancer andmesothelioma (a cancer of the lining of the chest or abdominal cavities). Some studiesshow that the risk of lung cancer among persons who smoke and who are exposed toasbestos is much greater than the risk for non-smokers. Symptoms of these diseasesmay not become apparent for 15, 20 or more years after the first exposure to asbestos.

Accordingly, workers must use caution to avoid creating and breathing dust whenservicing brakes. Specific recommended work practices for reducing exposure toasbestos dust follow. Consult your employer for more details.

Recommended Work Practices

1. Separate Work Areas. Whenever feasible, service brakes in a separate area awayfrom other operations to reduce risks to unprotected persons. OSHA has set a maximumallowable level of exposure for asbestos of 0.1 f/cc as an 8-hour time-weighted averageand 1.0 f/cc averaged over a 30-minute period. Scientists disagree, however, to whatextent adherence to the maximum allowable exposure levels will eliminate the risk ofdisease that can result from inhaling asbestos dust. OSHA requires that the followingsign be posted at the entrance to areas where exposures exceed either of the maximum

allowable levels:

DANGER: ASBESTOSCANCER AND LUNG DISEASE HAZARD

AUTHORIZED PERSONNEL ONLYRESPIRATORS AND PROTECTIVE CLOTHING

ARE REQUIRED IN THIS AREA.

2. Respiratory Protection.

Wear a respirator equipped with a high-efficiency (HEPA)filter approved by NIOSH or MSHA for use with asbestos at all times when servicingbrakes, beginning with the removal of the wheels.

3. Procedures for Servicing Brakes.

a. Enclose the brake assembly within a negative pressure enclosure. The enclosureshould be equipped with a HEPA vacuum and worker arm sleeves. With theenclosure in place, use the HEPA vacuum to loosen and vacuum residue from thebrake parts.

b. As an alternative procedure, use a catch basin with water and a biodegradable,non-phosphate, water-based detergent to wash the brake drum or rotor and otherbrake parts. The solution should be applied with low pressure to prevent dust frombecoming airborne. Allow the solution to flow between the brake drum and thebrake support or the brake rotor and caliper. The wheel hub and brake assemblycomponents should be thoroughly wetted to suppress dust before the brake shoesor brake pads are removed. Wipe the brake parts clean with a cloth.

c. If an enclosed vacuum system or brake washing equipment is not available,employers may adopt their own written procedures for servicing brakes, providedthat the exposure levels associated with the employers procedures do not exceedthe levels associated with the enclosed vacuum system or brake washingequipment. Consult OSHA regulations for more details.

d. Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA for usewith asbestos when grinding or machining brake linings. In addition, do such work inan area with a local exhaust ventilation system equipped with a HEPA filter.

e.

NEVER

use compressed air by itself, dry brushing, or a vacuum not equipped with aHEPA filter when cleaning brake parts or assemblies. NEVER

use carcinogenicsolvents, flammable solvents, or solvents that can damage brake components aswetting agents.

4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filter orby wet wiping. NEVER

use compressed air or dry sweeping to clean work areas. Whenyou empty vacuum cleaners and handle used rags, wear a respirator equipped with aHEPA filter approved by NIOSH or MSHA for use with asbestos. When you replace aHEPA filter, wet the filter with a fine mist of water and dispose of the used filter with care.

5. Worker Clean-Up

.

After servicing brakes, wash your hands before you eat, drink orsmoke. Shower after work. Do not wear work clothes home. Use a vacuum equippedwith a HEPA filter to vacuum work clothes after they are worn. Launder them separately.Do not shake or use compressed air to remove dust from work clothes.

6. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA filterswith care, such as in sealed plastic bags. Consult applicable EPA, state and localregulations on waste disposal.

Regulatory Guidance

References to OSHA, NIOSH, MSHA, and EPA, which are regulatory agencies in theUnited States, are made to provide further guidance to employers and workersemployed within the United States. Employers and workers employed outside of theUnited States should consult the regulations that apply to them for further guidance.

NON-ASBESTOS FIBERS WARNING

The following procedures for servicing brakes are recommended to reduceexposure to non-asbestos fiber dust, a cancer and lung disease hazard. MateriaSafety Data Sheets are available from ArvinMeritor.

Hazard Summary

Most recently manufactured brake linings do not contain asbestos fibers. These brakelinings may contain one or more of a variety of ingredients, including glass fibers,mineral wool, aramid fibers, ceramic fibers and silica that can present health risks ifinhaled. Scientists disagree on the extent of the risks from exposure to thesesubstances. Nonetheless, exposure to silica dust can cause silicosis, a non-cancerouslung disease. Silicosis gradually reduces lung capacity and efficiency and can result inserious breathing difficulty. Some scientists believe other types of non-asbestos fibers,when inhaled, can cause similar diseases of the lung. In addition, silica dust andceramic fiber dust are known to the State of California to cause lung cancer. U.S. andinternational agencies have also determined that dust from mineral wool, ceramic fibersand silica are potential causes of cancer.

Accordingly, workers must use caution to avoid creating and breathing dust whenservicing brakes. Specific recommended work practices for reducing exposure tonon-asbestos dust follow. Consult your employer for more details.

Recommended Work Practices

1. Separate Work Areas. Whenever feasible, service brakes in a separate area awayfrom other operations to reduce risks to unprotected persons.

2. Respiratory Protection.

OSHA has set a maximum allowable level of exposure forsilica of 0.1 mg/m

3

as an 8-hour time-weighted average. Some manufacturers of non-

asbestos brake linings recommend that exposures to other ingredients fou nd in non -asbestos brake linings be kept below 1.0 f/cc as an 8-hour time-weighted average.Scientists disagree, however, to what extent adherence to these maximum allowableexposure levels will eliminate the risk of disease that can result from inhaling non-asbestos dust.

Therefore, wear respiratory protection at all times during brake servicing, beginningwith the removal of the wheels. Wear a respirator equipped with a high-efficiency(HEPA) filter approved by NIOSH or MSHA, if the exposure levels may exceed OSHA ormanufacturers recommended maximum levels. Even when exposures are expected tobe within the maximum allowable levels, wearing such a respirator at all times duringbrake servicing will help minimize exposure.

3. Procedures for Servicing Brakes.

a. Enclose the brake assembly within a negative pressure enclosure. The enclosureshould be equipped with a HEPA vacuum and worker arm sleeves. With the enclosurein place, use the HEPA vacuum to loosen and vacuum residue from the brake parts

b. As an alternative procedure, use a catch basin with water and a biodegradable,non-phosphate, water-based detergent to wash the brake drum or rotor and otherbrake parts. The solution should be applied with low pressure to prevent dust frombecoming airborne. Allow the solution to flow between the brake drum and thebrake support or the brake r otor and caliper. The wheel hub and brake assemblycomponents should be thoroughly wetted to suppress dust before the brake shoesor brake pads are removed. Wipe the brake parts clean with a cloth.

c. If an enclosed vacuum system or brake washing equipment is not available,carefully clean the brake parts in the open air. Wet the parts with a solution appliedwith a pump-spray bottle that creates a fine mist. Use a solution containing water,and, if available, a biodegradable, non-phosphate, water-based detergent. Thewheel hub and brake assembly components should be thoroughly wetted tosuppress dust before the brake shoes or brake pads are removed. Wipe the brakeparts clean with a cloth.

d. Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA whengrinding or machining brake linings. In addition, do such work in an area with a locaexhaust ventilation system equipped wi th a HEPA filter.

e.

NEVER

use compressed air by itself, dry brushing, or a vacuum not equipped with aHEPA filter when cleaning brake parts or assemblies. NEVER

use carcinogenicsolvents, flammable solvents, or solvents that can damage brake components aswetting agents.

4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filteror by wet wiping. NEVER

use compressed air or dry sweeping to clean work areas.When you empty vacuum cleaners and handle used rags, wear a respirator equipped

with a HEPA filter approved by NIOSH or MSHA, to minimize exposure. When youreplace a HEPA filter, wet the filter with a fine mist of water and dispose of the used filterwith care.

5. Worker Clean-Up.

After servicing brakes, wash your hands before you eat, drink orsmoke. Shower after work. Do not wear work clothes home. Use a vacuum equippedwith a HEPA filter to vacuum work clothes after they are worn. Launder them separatelyDo not shake or use compressed air to remove dust from work clothes.

6. Waste Disposal

.

Dispose of discarded linings, used rags, cloths and HEPA filterswith care, such as in sealed plastic bags. Consult applicable EPA, state and localregulations on waste disposal.

Regulatory Guidance

References to OSHA, NIOSH, MSHA, and EPA, which are regulatory agencies in theUnited States, are made to provide further guidance to employers and workersemployed within the United States. Employers and workers employed outside of theUnited States should consult the regulations that apply to them for further guidance.


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Notes

MM-0180

Page 2 Issued 05-01


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Section 1Introduction

MM-0180

Issued 05-01 Page 3


Maintenance ManualInformation

This manual contains service and diagnosticinformation for Meritor WABCO Enhanced

Easy-Stop Trailer ABS with Power Line Carrier(PLC) capability.

Identifying Enhanced Easy-StopTrailer ABS

To identify Enhanced Easy-Stop, check theidentification tag on the Electronic Control Unit(ECU). Figure 1.1

. The part numbers for EnhancedEasy-Stop systems are:

400 500 101 0 (2S/1M Basic for standard trailers)

400 500 104 0 (2S/1M Basic for dollies andsteerables)

400 500 102 0 (2S/2M Standard)

400 500 103 0 (2S/2M, 4S/2M and 4S/3MPremium)

If you are servicing or using blink code diagnosticsfor Easy-Stop Trailer ABS (Easy-Stop ECUs withpart numbers other than those listed above),please use Meritor WABCO MaintenanceManual 33.

If you are not able to identify the version, or torequest service literature, please contactArvinMeritors Customer Service Center at800-535-5560.

This manual does not contain Original Equipment

Manufacturer (OEM) installation instructions. Newinstallations require the following documentation:

Enhanced Easy-Stop Basic (2S/1M): TP-20212

Enhanced Easy-Stop Standard (2S/2M):TP-20213

Enhanced Easy-Stop Premium (2S/2M, 4S/2Mand 4S/3M): TP-20214

Enhanced Easy-Stop TrailerABS Parts

Parts book PB-96133 lists Meritor WABCO

Easy-Stop replacement parts. To obtain a copy,contact ArvinMeritors Customer Service Center at800-535-5560.

For warranty information, contact ArvinMeritorsCustomer Service Center (800-535-5560) and askfor TP-99128, Meritor WABCO Trailer ABSWarranty Procedure

.

Figure 1.1

Part No.

Date CodeFirst 2 Digits = Build WeekLast 2 Digits = Build Year

0701400 500 102 0


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MM-0180

Page 4 Issued 05-01

What Is Meritor WABCOsEnhanced Easy-Stop Trailer ABS?

Meritor WABCOs Easy-Stop Trailer ABS is anelectronic, self-monitoring system that works

with standard air brakes. In addition, EnhancedEasy-Stop includes Power Line Carrier (PLC)capability. PLC information is included in theABS Q & A Section of this manual. The majorcomponents of the system are the ElectronicControl Unit (ECU)/Valve Assembly, ABSmodulator valve (for 3M systems), tooth wheeland

wheel speed sensor.

Figure 1.2

.

System Configuration

The ABS configuration

defines the number ofwheel speed sensors and ABS modulator valvesused in a system. For example, a 2S/1M

configuration includes two wheel sensors and oneABS modulator valve. A 2S/2M

configurationincludes two wheel sensors and two ABSmodulator valves. A 4S/2M

configuration includesfour wheel sensors and two ABS modulatorvalves.

A 4S/3M configuration consists of an ECU/dualmodulator valve assembly and one external ABSmodulator valve.

There is a specific ECU/valve assembly for eachconfiguration:

For 2S/1M Basic, the assembly consists of anECU and a single modulator valve assembly

For 2S/2M Standard and 2S/2M, 4S/2M and4S/3M Premium, the assembly consists of anECU and a dual modulator valve assembly (onevalve that combines the function of twomodulator valves). The 2S/2M Standard valvehas only two sensor outlets and cannotbe upgraded.

How Trailer ABS Works

Meritor WABCO ABS is an electronic system thatmonitors and controls wheel speed duringbraking. The system works with standard air brake

systems.ABS monitors wheel speeds at all times andcontrols braking during wheel lock situations. Thesystem improves vehicle stability and control byreducing wheel lock during braking.

The ECU receives and processes signals from thewheel speed sensors. When the ECU detects awheel lockup, the unit activates the appropriatemodulator valve, and air pressure is controlled.

In the event of a malfunction in the system, theABS in the affected wheel(s) is disabled; thatwheel still has normal brakes. The other wheelskeep the ABS function.

Two ABS indicator lamps (one on the dash andone on the side of the trailer) let drivers know thestatus of the system.

Figure 1.2

1. ECU/Valve Assembly2. External ABS Modulator Valve (for 3M configurations)3. Tooth Wheel4. Wheel Speed Sensor

2

1

4

3


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Section 2System Components

MM-0180

Issued 05-01 Page 5


ECU/Valve Assembly (Figure 2.1)

12 volt

Integrated ECU and ABS relay valve

ECU and valve assembly are serviceable

items.

The ECU/Valve Assembly may be mounted withthe sensors facing either the front or rear of thetrailer.

ABS External Modulator Valve (Figure 2.2)

Controls air pressure to the brake chamberswhere it is plumbed.

During ABS operation, the valve adjusts airpressure to the brake chambers to controlbraking and prevent wheel lock.

Used in conjunction with ECU/Valve Assemblyfor 3M systems.

Sensor with Molded Socket (Figure 2.3)

Measures the speed of a tooth wheel rotatingwith the vehicle wheel.

Produces an output voltage proportional towheel speed.

Sensor Spring Clip (Figure 2.4)

Holds the wheel speed sensor in closeproximity to the tooth wheel.

Tooth Wheel (Figure 2.5)

A machined ring mounted to the machinedsurface on the hub of each ABS-monitoredwheel.

Figure 2.1

1. 2S/1M Basic2. Standard3. Premium

21

3

Figure 2.2

Figure 2.3

Figure 2.4

Figure 2.5


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MM-0180

Page 6 Issued 05-01

Cables for Enhanced Easy-Stop (Figure 2.6) Easy-Stop Trailer ABS Indicator Label

Provides information about the operation of theABS indicator lamp and illustrates blink codefault locations.

Label is self-adhesive and is mounted on thetrailer near the ABS indicator lamp.

If there is no warning label on your trailer, letyour supervisor know. Labels are available fromMeritor WABCO. Ask for Part Number TP-95172.

TOOLBOX Software (Figure 2.7)

TOOLBOX Software is a PC-based diagnosticsprogram that can display wheel speed data, testindividual components, verify installation wiringand more.

Version 4.1 (or higher) supports EnhancedEasy-Stop with PLC, and runs in Windows 95, 98,NT, 2000 and Me. An RS232 to J1708 converterbox is required.

Figure 2.6POWER CABLE AVAILABLE WITH

INDUSTRY-STANDARD CONNECTOR

(SHOWN) OR BLUNT CUT

OPTIONAL POWER

DIAGNOSTIC CABLE (ALL)

2S/1M BASIC CONNECTS VALVE TO ECU

ABS MODULATOR VALVE CABLE

(4S/3M ONLY)

OPTIONAL ABS MODULATOR VALVE

GENERIC I/O CABLE

(4S/3M PREMIUM ONLY)

OPTIONAL GENERIC I/O CABLE

(2S/2M OR 4S/2M PREMIUM ONLY)

SENSOR EXTENSION CABLE CONNECTS THE

WHEEL SPEED SENSORS TO THE ECU

Figure 2.7

Available from SPX (Kent-Moore), 800-328-6657

vvvvvvvvvvvvvvvvvvvvv

vvvvvvvvvvv

vvvvvvvvvvvvvvvv

v

MER

ITOR

WABC

O

W

H

ATYOU N E E

D T

O

KN

O

WTOOLBOX

SOFTWARE

TOOLBOXSOFTWARE

$98.00

Easy-StopTMTrailer ABS Diagnostics

Hydraulic ABS Diagnostics

Pneumatic ABS Diagnostics (D and E Versions)

Includes Spanish and French Versions


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MM-0180

Issued 05-01 Page 7

PLC/J1708 Adapter (Figure 2.8)

Simulates the tractor ABS lamp, ensuring thatthe trailer ABS is capable of lighting the light.

Simulates the trailer ABS lamp, ensuring that

the tractor is capable of lighting the light.

Use as a trailer/tractor tester to ensure that PLCis functioning properly.

MPSI Pro-Link 9000 Diagnostic Tool(Figure 2.9)

Provides diagnostic and testing capability forABS components.

Requires a Multiple Protocol Cartridge (MPC)and Meritor WABCO applications card, version2.0 or higher, for use with Enhanced Easy-Stopwith PLC.

Figure 2.8

Available from Noregon Systems, 336-768-4337

Figure 2.9

Available from SPX (Kent Moore), 800-328-6657


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Notes

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Section 3ABS Questions and Answers

MM-0180

Issued 05-01 Page 9

Section 3ABS Questions and AnswersThe Electronic ControlUnit (ECU)

How do you activate the ECU?

In a constant-powered system, the ECU activatesand then begins a self-diagnostic check of thesystem when you turn the ignition ON. In astoplight-powered system, the ECU activateswhen you apply the brakes. All trailersmanufactured on or after March 1, 1998 will beequipped with ABS that has constant powercapability with stoplight power as back-up.

How does the ECU respond to a wheelapproaching lock-up?

The ECU directs the ABS relay valve to function asa modulator valve and adjust air pressure to the

chambers up to five times a second. This pressureadjustment allows a wheel (or wheels) to rotatewithout locking.

Power Line Carrier (PLC)Communications Questionsand Answers

What is PLC communications?

PLC stands for Power Line Carrier, which is amethod used to communicate information bymultiplexing data on the same wire used for theABS electrical power. PLC communicationsconvert signal message data to a radio frequency(RF) signal on top of the +12V power lineproviding electrical power to the trailer.

What is multiplexing?

Multiplexing means communicating multiplesignals or messages on the same transmissionmedia. This provides an efficient and cost effectivemeans by decreasing the number of wires andconnectors which otherwise would be needed.Without multiplexing, it could take several wiresand connections in order to transmit severaldifferent signals to various locations on a vehicle,

but with multiplexing these wires and connectorscan be significantly reduced.

Why add PLC technology to tractor and trailer ABS?

By adding PLC technology to the tractor and trailerABS the industry is able to have the most costeffective means to meet the March 1, 2001FMVSS-121 in-cab trailer indicator lamp mandatewith no additional external hardware, harnessesor connectors. Additionally, this new capability ofcommunicating other information between tractorand trailers provides many more opportunities to

further improve productivity and safety. Withevery tractor and trailer currently built having ABStechnology, integrating PLC technology into thePC board was the logical choice.

How does it work?

The trailer ABS with PLC takes messageinformation to be sent to the tractor and convertsit to an RF signal. The signal is then sent over thetrailer ABS power line (blue wire) and the tractorABS with PLC receives the signal. Messages canalso be sent from the tractor to the trailer via PLC.

What if a tractor is equipped with PLC technologyand the trailer is not, or vice-versa? Can you drivethe combination safely in that situation?

Absolutely. If the tractor is equipped with PLC andthe trailer is not, or vice-versa, your ABS in-cabtrailer indicator lamp will not illuminate, but your

ABS will continue to function as normal. To ensurethat the trailer ABS is functioning properly, thetrailer ABS indicator lamp mounted on the trailershould be utilized.

What if a tractor has one manufacturers ABS withPLC and the trailer has another manufacturersABS with PLC? Will the two systems becompatible and operate the trailer ABS lampas expected?

Yes. ABS with PLC from different manufacturersare designed to be compatible by controlling thetrailer ABS lamp according to the FMVSS-121standard, even when systems from different

manufacturers are connected to each other.However, certain features beyond the control ofthe trailer ABS indicator lamp may or may not besupported by all devices communicating via PLC.SAE task forces continue to standardize commonmessages so that maximum compatibility mayexist in the future.

How do I diagnose PLC?

PLC can be diagnosed over the J1587/J1708diagnostic connector on the tractor and trailerusing tools designed for PLC diagnostics.

Can I use blink code diagnostics on Enhanced

Easy-Stop to diagnose PLC?

Yes. Section 5 of this manual describes themethod of performing a blink code check usingConstant Power (ignition activation). Blink Code 17indicates a PLC failure.


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Page 10 Issued 05-01

If PLC does not seem to be operating properly, butI dont get a Blink Code 17 when I run a blink codecheck, what else could be wrong?

If there is no Blink Code 17, the ECU is functioningproperly and does not need to be replaced;

however, there could be a problem in the trailerswiring harness. Check the wiring system and makethe necessary repairs. If the problem persists,contact Meritor WABCO for assistance.

ABS Indicator Lamps

NOTE: When replacing the bulb, to ensure properlamp operation use an incandescent typeDOT-approved lamp, or a LED with integral loadresistor.

ABS Indicator Lamp (on Dash)With Enhanced Easy-Stop there are two ABSindicator lamps; one on the vehicle dash and oneon the side of the trailer. Refer to Appendix I forinformation about the operation of this lamp.

ABS Indicator Lamp (on Trailer)

What is the function of the ABS indicator lamp?

The indicator lamp enables a driver to monitorthe ABS at all times. Refer to the OEM operatingmanual for the mounting location of the indicatorlamp.

How does the indicator lamp operate?

How the indicator lamp operates depends onwhether the ABS is powered by stoplight orconstant power:

If the trailer was manufactured prior to February28, 1998, or was manufactured outside of theUnited States, the ABS may be either stoplightor constant powered.

If the trailer was manufactured March 1, 1998 orlater and was manufactured in the UnitedStates it will have constant power capability.This is mandated by Federal Motor Vehicle

Safety Standard (FMVSS) 121.Check your vehicle specification sheet todetermine the type of ABS power. Table A andTable B in this section illustrate indicator lampoperation on stoplight and constant poweredABS systems.

An ECU with part number 472 500 001 0manufactured prior to September 1997 requiresall sensed wheels to detect a 4 mph signal to shutoff the ABS indicator lamp. Do not confuse thiswith a faulty ABS system. If the indicator lamp

stays on when the brakes are applied to a movingvehicle, service the ABS system.

Most trailers manufactured prior to February 1998require that the brakes be applied to operate theABS indicator lamp. If the indicator lamp stays on

when the brakes are applied to a moving vehicle,service the ABS system.

What does the trailer ABS indicator lamp mean toservice personnel?

The trailer ABS indicator lamp on the side of thetrailer indicates the status of the trailer ABS. If itcomes ON and stays ON when you apply thebrakes to a moving vehicle, there is an ABSmalfunction. It is normal for the lamp to come ONand go OFF to perform a bulb check, but it shouldnot stay ON when the vehicle is moving above4 mph. As with any safety system, it is importantnot to ignore this indicator. If the indicator lamp

indicates a malfunction, the vehicle can beoperated to complete the trip, but it is important tohave it serviced as soon as possible using theappropriate maintenance manual to ensure properbraking performance and that the benefits of ABSremain available to your drivers. Typical ABSindicator lamp mounting locations are illustratedin Figure 3.1.

For more information, call ArvinMeritorsCustomer Service Center at 800-535-5560.

Can you continue to operate a vehicle when theindicator lamp indicates a fault?

Yes. When a fault exists in the ABS, standardbraking returns to the affected wheel, and theABS still controls other monitored wheels. Thislets you complete the trip. You should not ignorethe indicator lamp and should have the vehicleserviced as soon as possible after the lamp comesON and stays ON.

Figure 3.1

Typical ABS Indicator Lamp Mounting Location on Side ofTrailer


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Issued 05-01 Page 1

Table A: Stoplight Power

Table B: Constant Power

System Power Comes from Activating the Stoplight Circuit.

Brakes Fault in System Vehicle Speed Indicator Lamp

Released N.A. N.A. OFFApplied NO Less than 4 mph ON for 3 seconds, then goes OFF.

Applied NO Greater than 4 mph Flashes once, then stays OFF forremainder of stop.

Applied YES N.A. ON

System Is Ignition Powered.

Brakes IgnitionFault inSystem Vehicle Speed Indicator Lamps (Trailer and Dash)

Released OFF N.A. N.A. OFF

ON NO Less than 4 mph ON for 3 seconds, then go OFF.

ON NO Greater than 4 mph OFF

ON YES N.A. ON

Applied OFF NO Less than 4 mph ON for 3 seconds, then go OFF.

OFF YES N.A. ON

ON NO Less than 4 mph ON for 3 seconds, then go OFF.

ON NO Greater than 4 mph OFF

ON YES N.A. ON


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Types of Faults

What is a "fault" in the system?

A fault in the system is a problem that can exist inthe ABS or in the systems components. Faults can

be either existing faults or intermittent storedfaults.

What is an existing fault?

An existing fault is a problem that exists currentlyin the system. For example, a damaged sensorcable is an existing fault that the ECU will detectand store into memory until you identify thecause, repair the cable and clear the fault fromthe ECU.

What is an intermittent fault?

An intermittent fault is a problem that usuallyoccurs only under certain driving conditions.For example, the ECU may detect a loose cableor wire or receive an erratic signal from awheel sensor. Since intermittent faults can beunpredictable and may only happen periodically,you can use information stored in ECU memoryto find and correct the loose cable or wire.An intermittent fault cannot be retrieved usingblink codes.

Is an intermittent fault difficult to locate andrepair?

It can be, because you may not be able to easilysee the cause of the problem. Meritor WABCO

recommends that you write down intermittentfaults to help you isolate a fault that recurs over aperiod of time.

Can the ECU store more than one fault inmemory?

Yes. And the ECU retains existing and intermittentfaults in memory even when you turn OFF thepower to the ECU.

What if the ECU finds a fault in an ABScomponent during normal operation?

If the ECU senses a fault in the system (with anABS valve, for example), the ECU turns the trailer

ABS indicator lamp on and returns the wheelcontrolled by that valve to standard braking. Or, ifthe ECU finds a fault with one wheel speed sensorin a system that has four sensors on a tandemaxle, the ECU uses information from the othersensor on the same side of the tandem to ensurecontinuous ABS function. The ECU continues toprovide full ABS function to the wheels unaffectedby system faults. However, the ECU will turn thetrailer ABS indicator lamp on to tell the driver afault has been detected in the system.


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Section 4System Configurations

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Issued 05-01 Page 13

Section 4System ConfigurationsEnhanced Easy-Stop Installation Diagrams

With Enhanced Easy-Stop, Standard 2S/2M and Premium 2S/2M, 4S/2M and 4S/3M sensor locationdesignations will change depending on how the ECU/dual modulator valve assembly is mounted. It maybe mounted facing either the front or the rear of the trailer. It is important that you identify the location

of these sensors before beginning any diagnostics. Sensor locations for both front and rear-facinginstallations are depicted in Figures 4.1 through4.10.

NOTE: Sensor locations for the 2S/1M Basic will not change.

Configuration Figure/Page

2S/1M Basic ECU Figure 4.1/page 14

2S/2M Standard Mounted with Sensors Facing Front of Trailer Figure 4.2/page 15

2S/2M Standard Mounted with Sensors Facing Rear of Trailer Figure 4.3/page 16

2S/2M Premium Mounted with Sensors Facing Front of Trailer Figure 4.4/page 17

2S/2M Premium Mounted with Sensors Facing Rear of Trailer

4S/2M Premium Mounted with Sensors Facing Front of Trailer Figure 4.5/page 18

4S/2M Premium Mounted with Sensors Facing Rear of Trailer

4S/2M Premium Typical Tri-Axle Mounted with Sensors Facing Front of Trailer Figure 4.6/page 19

4S/2M Premium Typical Tri-Axle Mounted with Sensors Facing Rear of Trailer

4S/2M Premium Typical Axle Control Installation Mounted with SensorsFacing Front of Trailer

Figure 4.7/page 20

4S/2M Premium Typical Axle Control Installation Mounted with SensorsFacing Rear of Trailer

4S/3M Premium Typical Tri-Axle with Front Lift Mounted with Sensors FacingFront of Trailer

Figure 4.8/page 21

4S/3M Premium Typical Tri-Axle with Front Lift Mounted with Sensors FacingRear of Trailer

4S/3M Premium Typical Tri-Axle Valve Mounted with Sensors Facing Front ofTrailer

Figure 4.9/page 22

4S/3M Premium Typical Tri-Axle Valve Mounted with Sensors Facing Rear ofTrailer

4S/3M Premium Typical Four Axle Pull Trailer Valve Mounted with SensorsFacing Front of Trailer

Figure 4.10/page 23

4S/3M Premium Typical Four Axle Pull Trailer Valve Mounted with SensorsFacing Rear of Trailer


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Typical Easy-Stop Trailer ABS installations are illustrated in Figure 4.1 through Figure 4.10:

NOTE: Meritor WABCO recommends placing sensors on the axle that will provide the most brakingperformance. The suspension manufacturer can provide this information.

Figure 4.1

SERVICE/CONTROL LINES

SENSOR CABLES

SERVICE BRAKE

SUPPLY AIR

SPRING BRAKE AIR

Typical Tandem Axle TrailerSpring Suspension Installation

with Sensors on Front AxleYE1

YE2

YE1

YE2

YE2

YE1

YE2

YE1

Typical Tandem Axle TrailerAir Suspension Installationwith Sensors on Rear Axles

2S/1M BASIC


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Figure 4.2


SENSOR CABLES

SERVICE BRAKE

SUPPLY AIR

SPRING BRAKE AIR


with Sensors on Front AxleYE1

YE2

YE1

YE2

YE2

YE1

YE2

YE1


2S/2M STANDARD MOUNTED WITH SENSORS FACING FRONT OF TRAILER

FRONT OFTRAILER

FRONT OFTRAILER


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Figure 4.3


SENSOR CABLES

SERVICE BRAKE

SUPPLY AIR

SPRING BRAKE AIR


with Sensors on Front Axle

YE1

YE2


2S/2M STANDARD MOUNTED WITH SENSORS FACING REAR OF TRAILER

YE1

YE2

FRONT OFTRAILER

FRONT OFTRAILER

YE1

YE2

YE1

YE2


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Figure 4.4

NOTE: Spring brakelines not shown.


SENSOR CABLES

SERVICE BRAKE

SUPPLY AIR


YE1

BU1

2S/2M PREMIUM MOUNTEDWITH SENSORS

FACING FRONT OF TRAILER

FRONT OFTRAILER

BU1

YE1

2S/2M PREMIUM MOUNTED WITH SENSORS

FACING REAR OF TRAILER

FRONT OFTRAILER

BU1

YE1

YE2

BU2

YE1

BU1

BU2

YE2


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Figure 4.5

Typical Tandem Axle Trailer

YE1

BU1

BU2

YE1

YE2

BU2

BU1

YE2

Typical Tandem Axle Trailer



SENSOR CABLES

SERVICE BRAKE

SUPPLY AIR


4S/2M PREMIUM MOUNTED WITH SENSORS FACING FRONT OF TRAILER

FRONT OFTRAILER

FRONT OFTRAILER

4S/2M PREMIUM MOUNTED WITH SENSORS FACING REAR OF TRAILER

BU1

YE1

YE2

BU2

YE1

BU1

BU2

YE2


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Figure 4.6

YE1

BU1

YE2

BU2

4S/2M PREMIUM TYPICAL TRI-AXLE MOUNTED WITH SENSORS FACING FRONT OF TRAILER

FRONT OFTRAILER

BU1

YE1

BU2

YE2

4S/2M PREMIUM TYPICAL TRI-AXLE MOUNTED WITH SENSORS FACING REAR OF TRAILER

FRONT OFTRAILER

BU1

YE1

YE2

BU2

YE1

BU1

BU2

YE2



SENSOR CABLES

SERVICE BRAKE

SUPPLY AIR



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Figure 4.7

4S/2M PREMIUM TYPICAL AXLE CONTROL INSTALLATION

MOUNTED WITH SENSORS FACING FRONT OF TRAILER

BU1 YE1

BU2 YE2

FRONT

FRONT

BU1 YE1

BU2 YE2

4S/2M PREMIUM TYPICAL AXLE CONTROL INSTALLATION

MOUNTED WITH SENSORS FACING REAR OF TRAILER

BU1

YE1

YE2

BU2

YE1

BU1

BU2

YE2



SENSOR CABLES

SERVICE BRAKE

SUPPLY AIR



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Issued 05-01 Page 2

Figure 4.8

YE2

BU2

YE1

BU1

4S/3M PREMIUM TYPICAL TRI-AXLE WITH FRONT LIFT


FRONT OFTRAILER

4S/3M PREMIUM TYPICAL TRI-AXLE WITH FRONT LIFT


BU2

YE2

BU1

YE1

FRONT OFTRAILER

BU1

YE1

YE2

BU2

YE1

BU1

BU2

YE2NOTE: Spring brakelines not shown.


SENSOR CABLES

SERVICE BRAKE

SUPPLY AIR



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Figure 4.9

Typical Tandem

Axle Trailer

YE2

BU2

YE1

BU1

4S/3M PREMIUM TYPICAL TRI-AXLE


FRONT OFTRAILER

Typical TandemAxle Trailer

BU2

YE2

BU1

YE1

4S/3M PREMIUM TYPICAL TRI-AXLE


FRONT OFTRAILER

BU1

YE1

YE2

BU2

YE1

BU1

BU2

YE2



SENSOR CABLES

SERVICE BRAKE

SUPPLY AIR



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Figure 4.10

BU2

YE2

BU1

YE1

YE2

BU2

YE1

BU1

FRONT OFTRAILER

4S/3M PREMIUM TYPICAL FOUR AXLE PULL TRAILER


4S/3M PREMIUM TYPICAL FOUR AXLE PULL TRAILER


FRONT OFTRAILER

BU1

YE1

YE2

BU2

YE1

BU1

BU2

YE2



SENSOR CABLES

SERVICE BRAKE

SUPPLY AIR



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Power Cable Wiring Diagrams

Figure 4.11

ECU POWER CONNECTOR

GROUND

7 WAY

WHITE

BLUE

RED

GREEN AND WHITE

TRAILER ABSINDICATOR LAMP

4 OR 5 WIRESCHEMATIC

GENERIC INPUT/OUTPUT (EXPANDED CAPABILITY)

WHITE AND YELLOW

(CONSTANT POWER)

(STOP LAMP)

(GROUND)

BLK

BLU

YEL GRN

BRN

WHT

RED

1

2

3

4

5

6

7

8

Junction box not shown.

PLC WIRING SCHEMATIC


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Section 5Diagnostics

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WARNING

To prevent serious eye injury, always wear safeeye protection when you perform vehiclemaintenance or service.

The ABS is an electrical system. When you workon the ABS, take the same precautions that youmust take with any electrical system to avoidserious personal injury. As with any electricalsystem, the danger of electrical shock or sparksexists that can ignite flammable substances. Youmust always disconnect the battery ground cablebefore working on the electrical system.

Diagnostics

There are three methods used to get fault

information from the ECU: TOOLBOX Software

Pro-Link 9000

Blink code diagnostics

Ignition power activation

Diagnostic tool

There is also a new diagnostic tool for checkingPLC, the PLC/J1708 adapter. Figure 5.1.

Important PLC Information forBlink Code Diagnostics

Blink Code 17 indicates a PLC failure. If PLC doesnot seem to be operating properly, but there is no

Blink Code 17, the ECU is functioning properly anddoes not need to be replaced; however, therecould be a problem in the trailers wiring harness.Check the wiring system and make the necessaryrepairs. If the problem persists, contact thecustomer service center for assistance.

TOOLBOX Software

Meritor WABCO TOOLBOX Software is a PC-baseddiagnostic program. Version 4.1 (or higher) runs inWindows 95, 98, NT, 2000 or Me and providesdiagnostic capabilities by communicating with theECU. Trailer ABS screens are described in this

manual. Refer to the owners manual for detailedoperating instructions.

TOOLBOX Software has the following functions.

Supports Enhanced Easy-Stop with PLC.

Displays both constant and changinginformation from the ECU being tested.

Displays both active and stored system faults,as well as the appropriate repair instructions.

Activates system components to verify:

System integrity

Proper component operation

Installation wiring

NOTE: A J1587/J1708 to RS232 or PLC to J1708interface is required to run this software.

TOOLBOX Software is available from SPX(Kent-Moore), 800-345-2233.

Figure 5.1

Available from Noregon Systems, 336-768-4337


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Main Screen

This screen provides icon and pull-down menutask selections. It also provides information aboutthe current state of the Meritor WABCO EnhancedEasy-Stop Trailer ABS. ECU information is readonce from the ECU and does not change. Wheel

speed, voltages, faults and information are readand updated continuously.

In the Service Information field, the ECU, workingwith a constant powered tractor, can act as amileage counter. This field can also be used to setservice intervals. Figure 5.2.

Tire Calibration

The programmed number of tire Revs Per Mile isdisplayed on the Tire Calibration screen. Range is150.0 to 634.0 rpm. The default value is 502.0. Tochange this value, type in the Revs Per Mile, thenpress the Write button. Figure 5.3.

NOTE: Trailers with 12-1/4" brakes use an80-tooth tone ring (tooth wheel). Use a value of80% of the tire manufacturers recommendedrevolutions per mile (Revs Per Mile X 0.80).

Service Information

The mileage between scheduled maintenances isdisplayed on the Service Information screen in kmor miles.

When the mileage displayed elapses, theEnhanced Easy-Stop Trailer ABS indicator lampon the side of the trailer will flash eight times.It will continue to flash eight times whenever theignition switch is turned on until this parameteris changed. Figure 5.4.

Figure 5.2

Figure 5.3

Figure 5.4


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Notebook

The Notebook Form field of this screen is used tostore and review information about a specificvehicle. Figure 5.5.

Sensor Test

The Sensor Test screen is used to determine thecorrect installation, wiring and functionality of thewheel speed sensors.

The screen display will provide maximum sensorRPM for installed sensors (unused sensor

positions will be grayed out). Check the order fieldto verify sensors are installed in the correctlocation. Figure 5.6.

Report Information

The Report Information screen allows the user tostore and retrieve information about a specificvehicle, including the Vehicle IdentificationNumber (VIN) and Employee numbers. Figure 5.7.

An example of a storable (or printable) report isdisplayed in Figure 5.8.

Figure 5.5

Figure 5.6

Figure 5.7


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Meritor WABCO ABS Fault Report

Save and Print

1. Click on the heading Trailer ECU and clickSave. A window will appear asking for the VINand Employee number.

2. Provide this information and close the

window.3. Go back to the heading Trailer ECU and click

Print.

4. You will be asked to input the VIN andEmployee number.

5. Click Print.

Figure 5.8

Meritor WABCO ABS Fault Report

Date: September 13, 2000Time: 5:25 PMPage: 1VIN: 12345678Employee Information: KILEYABS System Configuration: 4S/2MECU Revision: V 3 2 2 Part Number: 446-108-000-1Serial Number: 5 9 3 0 3 9 4 8 Date of Manufacture: 13/1999Current Miles: 0.0Service Miles: 0.0Tire Calibration: 495.0

Fault # Description Status SID FMI Count

1 Ext. modulator BLUE open circuit detected Active 9 5 12 Ext. modulator BLUE open circuit detected Stored 9 5 1

Sensor Max RPM Order

YE1 40.0 1YE2 59.0 2BU1 50.0 3BU2 38.0 4

Sensor Test Results:

Valve Status (Tested / Not Tested / NA)

Yellow TestedBlue TestedRed N/A

Valve Tests Performed:


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Blink Code Diagnostics

The Meritor WABCO Enhanced Easy-Stop TrailerABS ECU detects any electrical fault in the trailerABS. Each of the faults has a code. When a faultoccurs, the ECU stores the code for that fault inthe memory.

There are two kinds of faults: active and stored.Active faults are those currently existing in thesystem, such as a broken wire. Stored faults arefaults that have occurred but do not presentlyexist. Active faults can be cleared only afterrepairs are completed. Stored faults can only bediagnosed with TOOLBOX Software or thePro-Link 9000.

The ECU signals a malfunction by lighting boththe internal and external indicator lamp when afault exists. The external ABS indicator lamp is

usually mounted on the left rear of the trailer, nearthe rear wheels.

There are two ways to obtain blink codes:

Ignition Power Activation (recommendedmethod)

Diagnostic Tool

NOTE: In previous versions of Easy-Stop, theblink code tool and the ABS indicator lamp wouldflash the blink code at the same time. WithEnhanced Easy-Stop, this does not happen. Thecodes are displayed one blink at a time, first on

the trailer ABS lamp, then on the blink code tool,as illustrated in Figure 5.9.

Although the ECU can store multiple faults in itsmemory, it only displays one blink code at a time.This is why it is important to recheck the blinkcodes after repairing a fault. If there are additionalcodes in the memory, they only blink after you

have repaired the first fault.Stored faults, clear all and end of line test modesare available with the TOOLBOX Software or thePro-Link 9000.

Ignition Power Activation

Ignition Power Activation is the process of usingthe vehicles ignition switch (or interrupting thepower on the blue wire by some other means) todisplay blink codes on the trailer ABS indicatorlamp located on the side of the trailer. Thismethod is for constant power vehicles only.

To obtain blink codes using ignition poweractivation, perform the following procedure:

1. Turn the ignition switch on for no longerthan 5 seconds. The ABS indicator lamp willbe on.

2. Turn the ignition switch off. The ABS indicatorlamp will go out.

3. Turn the ignition switch on. The ABS indicatorlamp will then come on, then go out.

4. The blink code will be displayed three times bythe ABS indicator lamp on the trailer.

NOTE: For ignition power activation, power isprovided by the ignition switch.

Figure 5.9

Lamp

Tool

BLINK CODE 4, SENSOR YE1


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Table C: Blink Codes Diagnostic Tool (Blink Code Check)

The red dust cap on the diagnostic tool protectsthe tool during shipping. The tool and the LED areindependently sealed against contamination.

The SAE J1587 connector must be protected fromcontamination when the diagnostic tool is notinstalled. Reinstall the gray cap when theconnector is not in use.

Use the following procedures to install thediagnostic tool in the SAE J1587 connector.

1. Remove the gray protective cap from theJ1587 connector.

Turn the cap counterclockwise.

Pull off the cap.

2. Align the notches on the tool with the notches

on the connector.3. Insert the tool firmly in the connector.

4. Firmly turn the gray ring of the tool clockwiseto secure it in place. Figure 5.10.

5. After removing the diagnostic tool, replace thegray protective cap.

6. Make sure the vehicle is stationary:

Emergency brake ON

Wheels properly chocked

7. Provide 12 volts DC power (9.5 to 14 volts isacceptable range) to the ECU/Valve Assembly.

BLINK CODES

Blink CodeProblemArea Action

3 Sensor BU1 Determine sensor location.

Check sensor installation.

Make necessary repairs.

4 Sensor YE1 Determine sensor location.



5 Sensor BU2 Determine sensor location.



6 Sensor YE2 Determine sensor location.



7 ExternalABSmodulatorvalve

Verify proper electricalinstallation. Check powersupply. Make necessarycorrections.

9 Internalmodulatorfailure, inletvalve #2

Verify proper installation.If code continues, contactMeritor WABCO forassistance.

10 Internalmodulatorfailure, inletvalve #1

Verify proper installation.If code continues, contactMeritor WABCO forassistance.

11 Internalmodulator

failure,outlet valve

Verify proper installation.If code continues, contact

Meritor WABCO forassistance.

14 PowerSupply

Verify proper electricalinstallation. Check powersupply. Make necessarycorrections.

15 ECU Failure Verify proper installation.If code continues, contactMeritor WABCO forassistance.

16 SAE J1708Failure

Internal failure, contactMeritor WABCO.

17 SAE J2497(PLC) Failure

Internal failure, contactMeritor WABCO.

18 Generic I/O

Failure

Verify proper electrical

installation. Check powersupply. Make necessarycorrections.

Figure 5.10


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Issued 05-01 Page 3

8. Check the ABS indicator lamp on the trailer. If:

The indicator lamp comes ON briefly, thengoes OFF: There is no fault in system.

The indicator lamp comes ON and stays ON:

There is an existing fault. Go to Step 9.9. Press the blink code switch once for one

second and release the switch.

10. When there is an existing fault: The ABSindicator lamp will flash between three andeighteen times to identify the existing fault.

11. When there are existing faults: You mustrepair existing faults.

12. After you identify an existing fault, turn thepower to the ECU OFF. Repair the fault. Turnthe power to the ECU back ON.

13. Repeat Step 9. If there are no other existingfaults in the system, the ABS indicator lampwill come ON, go OFF and remain OFF.

14. If you have just repaired a sensor gap fault,the ECU is waiting to see a 4-mph signal onsensed wheels. Until this 4 mph is sensed bythe ECU, the ABS indicator lamp on the trailerwill remain ON.

MPSI Pro-Link 9000 Diagnostic Tool

The MPSI Pro-Link 9000 diagnostic tool can testfor existing and stored faults, read and clear faultcodes, and test components, for Meritor WABCOtractor and trailer ABS.

SPX (Kent-Moore) offers Kit J 38500-404 thatcontains the Meritor WABCO ABS MultipleProtocol Cartridge (MPC), a Meritor WABCOapplications card, and the manual Meritor WABCOABS/ATC Systems, which contains complete

information and operating instructions for theMPSI Pro-Link 9000 diagnostic tool. Order the kitfrom SPX (Kent-Moore), 28635 Mound Road,Warren, MI 48092-3499; phone 800-345-2233.

NOTE: A J 38500-60A Deutsch cable is alsorequired. It is available from SPX (Kent-Moore).


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Section 6Component Replacement

MM-0180



WARNING

To prevent serious eye injury, always wear safeeye protection when you perform vehiclemaintenance or service.

Park the vehicle on a level surface. Block thewheels to prevent the vehicle from moving.Support the vehicle with safety stands. Do notwork under a vehicle supported only by jacks.Jacks can slip and fall over. Serious personal injurycan result.

The ABS is an electrical system. When you workon the ABS, take the same precautions that youmust take with any electrical system to avoidserious personal injury. As with any electricalsystem, the danger of electrical shock or sparksexists that can ignite flammable substances. Youmust always disconnect the battery ground cablebefore working on the electrical system.

NOTE: Disconnect power from the ECU/ValveAssembly before you remove any components.Failure to disconnect power from the ECU cancause faults to be recorded and stored in ECUmemory.

CAUTION

Use the following procedures to avoid damage tothe electrical system and ABS components.

When welding on an ABS-equipped vehicle isnecessary, disconnect the power connector fromthe ECU.

Wheel Speed Sensor

How to Remove a Sensor

1. Follow the vehicle manufacturers instructionsto back off the slack adjuster and remove thetire, wheel and drum.

2. Hold the sensor, not the cable, and use atwisting motion to pull the sensor out of itsmounting block.

3. Remove the spring clip from the mountingblock.

4. Remove any fasteners that hold the sensorcable to other components.

5. Disconnect the sensor cable from theextension cable.

How to Install a Sensor

Sensor locations vary according to suspensiontypes. Typically, a spring suspension has sensorson the forward axle, and an air suspension hassensors on the rear axle.

1. Apply a mineral oil-based grease that containsmolydisulfide to the sensor spring clip and tothe body of the sensor. The grease must beanti-corrosive and contain adhesive propertiesthat will continuously endure temperaturesfrom 40 to 300F (40 to 150C).

2. Push the spring clip into the sensor holderfrom the inboard side, until the spring clip tabsare against the sensor holder. Push the sensorinto the spring clip as far as possible.Figure 6.1.

3. Route the sensor cable toward the brakechamber, over the brake spider, and behindthe axle. Secure the cable to the axle betweenthe brake spider and the suspension brackets.Continue to route the sensor cable behind thespring seats. Secure the cable to the axle oneinch from the molded sensor plug. Figure 6.2.

Figure 6.1

1. Sensor Holder

2. Spring Clip3. Spring Clip Tab4. Sensor

31

24


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4. Install the wheel hub carefully, so that thetooth wheel pushes against the sensor as youadjust the wheel bearings. After installationthere should be no gap between the sensorand the tooth wheel. During normal operationa gap of 0.040-inch is allowable.

5. Sensor Output Voltage Test: Use a volt/ohmmeter to check the AC output voltage of thesensors while rotating the wheel atapproximately one-half revolution per second.Minimum output must be greater than0.2 volts AC. If minimum output is less than0.2 volts AC, push the sensor toward the toothwheel. Recheck the sensor output.

ABS Relay Valve (Figure 6.3)

WARNING

Release all pressure from the air system beforeyou disconnect any components. Pressurized aircan cause serious personal injury.

How to Remove a Standard ABSRelay Valve

1. Release all pressure from the air system.

2. Disconnect the cable from the valve.

3. Attach labels to identify all of the air lines.

4. Disconnect the air lines from the valve.

5. Remove the mounting fasteners if the valve isnot nipple-mounted directly to the air tank.

6. Remove the valve.

How to Install a Standard ABSRelay Valve

CAUTION

You must use Schedule 80 pipe nipple (3/4-inchNPTF) to nipple-mount the ABS relay valvesecurely to the reinforced air tank to avoidpossible serious personal injury and damage tocomponents.

1. Install the valve with two lock nuts andwashers as required. Tighten the hex nuts to atorque of 18 lb-ft (24 Nm) or nipple-mount thevalve directly to the air tank with Schedule 80pipe nipple (3/4-inch NPTF).

2. Connect the air lines to the ports according tothe labels installed when the air lines weredisconnected.

3. Connect the cable to the valve.

4. Pressurize the brake system. Apply the brakesand verify there are no air leaks.

Figure 6.2

1. Sensor Cable

Figure 6.3

1

1

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The ECU/Valve Assembly

WARNING

Release all pressure from the air system before

you disconnect any components. Pressurized aircan cause serious personal injury.

How to Remove theECU/Valve Assembly

1. Release all pressure from the air system.

2. Attach labels to identify all air lines.

3. Disconnect the air lines from the ECU/ValveAssembly.

4. Disconnect the power (or power/diagnostic)cable, additional relay valve cable (if used),

and all sensor cables from the ECU/ValveAssembly. Figure 6.4.

5. Remove the ECU/Valve Assembly from itsmounting location:

A. Bracket-mounted: Loosen and remove thetwo mounting bolts and lock nuts that holdthe assembly to the cross member.Remove the assembly.

B. Nipple-mounted to Air Tank: Unscrew theassembly from the air tank.

6. If the assembly being replaced is underwarranty, please return it to the trailer OEM forreplacement.

How to Install theECU/Valve Assembly

NOTE: The ECU/Valve Assembly is supplied withblack protective caps on each sensor connector.

NOTE: When a sensor cable is not plugged into asensor connector, the black cap must remain onthe connector to protect it from dirt andcontamination. Figure 6.4.

Figure 6.4

Y E 2 /6 Y E 1 /4

EXHAUST PORT

(ON UNDERSIDE CENTER)

PORT 4

CONTROL

PORT

PORT 1

(FRONT OR REAR)

SUPPLY PORT

PROTECTIVE CAPS

FOR SENSORS

FOUR DELIVERY PORTS

(ON UNDERSIDE)

PLUG ALLUNUSEDPORTS

YE2

YE1DELIVERY

YE2DELIVERY

YE1 CONTROLPORT

SUPPLYPORT

EXHAUSTPORT

PLUG ALLUNUSEDPORTS

BUDELIVERY

YEDELIVERY

SUPPLYPORT

EXHAUSTPORT

CONTROLPORT

YE2YE1

BU2BU1

2S/1M Basic

2S/2M Standard

2S/2M, 4S/2M, 4S/3M Premium


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CAUTION

You must use a Schedule 80 pipe nipple (3/4-inchNPTF) to nipple mount the ECU/Valve Assemblysecurely to the air tank to avoid possible serious

personal injury and damage to components.

Tank-Mounted

WARNING

You must use a Schedule 80 hex nipple (3/4-inchNPTF) to mount the ECU/single modulator valveassembly securely to the air tank to avoidpossible serious personal injury and damage tothe component.

1. Use a 3/4-inch Schedule 80 hex nipple to

attach ECU/single modulator valve assemblyto a reinforced air tank. Do not overtighten.

NOTE: Meritor WABCO does not recommend useof a vise when installing the hex nipple. Use of avise may cause overclamping. Overclamping maydamage the internal components of theECU/single modulator valve assembly.

2. Use a 3/4-inch pipe plug to plug unusedsupply port (Port 1). Apply SAE-standard,DOT-approved Teflon tape or paste-type threadsealant to all pipe threads beyond the first twothreads. Pipes with pre-applied thread sealant

may also be used.

3. Rotate and tighten the ECU/single modulatorvalve assembly until the exhaust port facesdown and the connection is secure. Use atorque wrench or ratchet with extension at the3/4-inch pipe plug installed on the front supplyport (Port 1). Figure 6.5.

Bracket-Mounted to Cross Memberof Vehicle (2S/1M Basic)

1. Install a 3/4-inch NPTF fitting in supply port(Port 1). Use a 3/4-inch pipe plug to plugunused supply port (Port 1).

Use a 3/4-inch pipe plug to plug unusedsupply port (Port 1). Apply SAE-standard,DOT-approved Teflon tape or paste-typethread sealant to all pipe threads beyondthe first two threads. Pipes with pre-appliedthread sealant may also be used.

2. Attach mounting bracket to vehicle cross

member midway between the side rails, closeto the brake chambers the valve serves.

3. Use two 3/8-inch Grade 8 bolts with prevailingtorque nuts and washers to attach assembly tothe vehicle cross member. Tighten bolts to18 lb-ft (24 Nm).

Figure 6.5

TEMPLATE

PLUG UNUSED PORT

Exhaust port must face DOWN.

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Mounted to Cross Member ofVehicle Standard and PremiumMounting Bracket Not Supplied

NOTE: When mounting the ECU/dual modulatorvalve assembly to the trailer cross member, referto SAE specification J447, Prevention of Corrosionof Motor Vehicle Body and Chassis Components.Follow all recommendations and procedures.Your supervisor should have a copy of thisspecification. Figure 6.6.

1. Install a 3/4-inch NPTF fitting in supply port.Use a 3/4-inch pipe plug to plug unusedsupply port (Port 1).

Apply SAE-standard, DOT-approved Teflontape or paste-type thread sealant to all pipeplugs beyond the first two threads. Pipeswith pre-applied thread sealant may alsobe used.

2. Use two 3/8-inch Grade 8 bolts with prevailingtorque nuts to attach assembly. Tighten boltsto 18 lb-ft (24 Nm).

3. Connect the air lines to the ports. Follow thelabel markers installed when the air lines weredisconnected.

4. Connect the sensor cables, external relay valvecable (if used), and power or power/diagnosticcable to the ECU/Valve Assembly. Use theblack protective connector caps included with

the replacement assembly to cover unusedcable connectors.

5. Perform End of Line Check before returningthe trailer to service.

T

Figure 6.6

FRONT OFTRAILER

Exhaust portmust face DOWN.

CURBSIDEYE2FRONT OF

TRAILER

Exhaust portmust face DOWN.

ROADSIDEYE1

VALVE MOUNTED WITH SENSORS FACINGREAR OF TRAILER

PLUG ALLUNUSED PORTS

PLUG ALLUNUSED PORTS

VALVE MOUNTED WITH SENSORS FACINGFRONT OF TRAILER

CURBSIDEYE1

ROADSIDEYE2


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Replacing the ECU orModulator Valve

With Enhanced Easy-Stop, the ECU and modulatorvalve may be replaced individually. To do this,

follow the instructions for removing the completeassembly, then remove the valve from the ECU.

NOTES:

For 2S/1M installations where the valve is readilyaccessible, it may not be necessary to remove theentire assembly to replace the valve.

For 2S/1M bracket-mounted installations, thebracket does not need to be removed to replacethe ECU or valve.

2S/1M Basic Only

To separate the ECU from the bracket, loosen andremove the three hex nuts from the underside ofthe bracket. These three hex nuts hold theassembly together.

To separate the bracket from the valve, removethe three hex nuts. Figure 6.7.

To attach the ECU to the bracket, tighten the threehex nuts to 6 lb-ft (8 Nm).

To attach the valve to the bracket, tighten the threehex nuts to 12 lb-ft (16 Nm).

All Standard and Premium Installations

Loosen and remove the four hex nuts holding theassembly together. Figure 6.7.

To attach the valve to the ECU, tighten the fourhex nuts to 5 lb-ft (6 Nm).

T

T

T

Figure 6.7

HEX NUTS

HEXNUTS

HEXNUTS

HEX NUT

HEX

NUT

HEXNUT

HEXNUT

HEXNUT

BASIC

PREMIUM

STANDARD


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Section 7Sensor Adjustment & Component Testing

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Section 7Sensor Adjustment & Component TestingHow to Test WheelSpeed Sensors

NOTE: At initial installation, no gap must exist

between the sensor and the tooth wheel.

NOTE: After you install a hub, always check thatthe sensor is adjusted properly.

Operating the trailer can cause a gap to developbetween the sensor and the tooth wheel. If the gapexceeds 0.040-inch, the system may not functioncorrectly.

To adjust the sensor, twist and push the sensorthrough the sensor bracket as far as possible oruntil the sensor touches the tooth wheel.

Sensor Test Procedure1. Disconnect power to the ECU/Valve Assembly.

2. Disconnect the sensor electrical connectorfrom the ECU/Valve Assembly.

3. Connect the volt/ohm meter leads to the twowire component terminals inside thedisconnected connector.

4. When checking the resistance, the meter mustread 900-2000 ohms.

5. Check and replace the sensor and cables asrequired.

6. Repeat Steps 1-5 for each sensor in thesystem.

Sensor Output Voltage Test

1. Disconnect power from the ECU/ValveAssembly.

2. Connect the AC volt/ohm meter leads to thesensor terminals inside the connector.

3. Rotate the corresponding wheel at a constantspeed of one-half revolution per second.

4. The output voltage must be greater than0.2 volts AC.

5. When there is no reading:

A. Trace the cable to verify that the cableconnects to the wheel you turned.

B. Check that you turned the correct wheel.

C. Check that the system is wired correctly.

D. Check that the sensor touches the toothwheel.

6. If the volt/ohm meter still indicates no readingor a low reading after following the aboveprocedures, check and replace the componentand cables as required.

7. Repeat Steps 1-5 for each sensor in the

system.

Check ABS Functions

Meritor WABCO recommends that you test avehicles ABS after a new installation and afteryou diagnose, repair and erase faults in theABS.

Perform end of line check using TOOLBOXSoftware or the Pro-Link 9000.

ABS External Modulator Valve

Measure resistance across each valve solenoidcoil terminal and ground on the ABS valve toensure 4.0 to 8.0 ohms. Valve and cable pinoutsare illustrated in Figure 7.1.

Figure 7.1

1. Exhaust Solenoid (blue wire)2. Inlet Solenoid (brown wire)3. Ground Terminal

1

2

3

Bayonet-Style Connector


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To check the cable and the ABS valve as oneunit, measure resistance across pins 5 and 6and 5 and 7 on the ECU connector of theharness. Resistance should be between 4.0 and8.0 ohms for each measurement. Figure 7.2.

If the resistance is greater than 8.0 ohms, cleanthe electrical contacts. Check the resistanceagain.

End of Line Testing

End of line testing is required on all EnhancedEasy-Stop installations. To run these tests, MeritorWABCO recommends you use TOOLBOX Software.

TOOLBOX Software and general test proceduresare included in this manual. If you are using a

Pro-Link, refer to the operating manual for testinstructions.

End of Line Testing ProcedureUsing TOOLBOX Software(All Installations)

NOTE: If you are testing an installation that has apower only cable, temporarily install a MeritorWABCO combination power/diagnostics Y stylecable or use the PLC/J1708 Adapter.

1. Connect the diagnostic connector on the cable

to the PC serial port/SAE diagnostic interface(J1587/J1708 to RS232 interface).

NOTE: Refer to the Software Owners Manual,TP-99102, for instructions for runningTOOLBOX Software.

2. Display the Trailer ABS Main Screen.

3. Verify power supply:

Apply 12 volts DC to the blue wire(constant). Check the screen for proper

voltage (9.5 to 14 volts). Constant powervoltage is displayed in the Primary field.Figure 7.3.

Apply 12 volts DC to the red wire (stoplightpower). Check the screen for proper voltage(9.5 to 14 volts). Stoplight power voltage isdisplayed in the Secondary field. Figure 7.3.

NOTE: The internal field is not applicable tothis test.

4. Check the Faults field on the Main Screen:

NONE = No faults present, proceed with end

of line test.

YES = Faults present, double-click on YESto bring up the fault informationscreen.

Figure 7.2

5. Ground Terminal6. Exhaust Solenoid7. Inlet Solenoid

1 2 3 45 6 7 8

Figure 7.3


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Issued 05-01 Page 4

Use the information in the Repair Instructionsfieldto make the necessary repairs. Figure 7.4.

Verify Proper Valve and Lamp Installation(2S/1M Basic)

To verify valve and lamp installations withTOOLBOX Software:

1. At the Trailer Main Screen click on ComponentTest, then select Valves/Lampto display theValve Activation Screen. Figure 7.5.

2. The Red valve indicator will be selected. Clickon the Activatebutton and listen for the valveto click, indicating a good installation. The TestStatusbox at the bottom of the menu will alsodisplay the status of this test.

3. Click on the Testbutton to activate the ABSindicator lamp this is the lamp that ismounted on the side of the trailer. The lampwill flash eight times, indicating lampinstallation is OK. The Test Statusbox at thebottom of the menu will also display the statusof this test.

4. Click on Closeto exit.

2S/2M, 4S/2M, 4S/3M (Standardand Premium)

To verify valve and lamp installations withTOOLBOX Software:

1. Apply 12 volts DC to the ABS.

2. Apply air to the emergency line to fill the air

tanks and release the spring brakes.3. Apply air to the control line.

4. At the Trailer Main Screen click on ComponentTest, then select Valves/Lampto display theValve Activation Screen. The Yellowvalveindicator will be highlighted. Figure 7.6.

NOTE: Selecting All Valves will sequence all ofthe valves beginning with the Yellowvalve.

5. Click on the Activate button.

Figure 7.4

Figure 7.5


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6. Check for proper air line installation. To dothis, observe the slack adjusters:

If the ECU faces the front of the trailer, theslack adjusters will move in and out as thecurbsideportion of the dual modulator

valve cycles. If this does not happen, the airlines are not properly connected. Make thenecessary repairs.

If the ECU faces the rear of the trailer, theslack adjusters will move in and out as theroadsideportion of the dual modulatorvalve cycles. If this does not happen, the airlines are not properly connected. Make thenecessary repairs.

NOTE: The Test Status box at the bottom ofthe menu will display the status of this test.

7. Repeat this test for the Bluevalve.

A. Repeat Steps 1-3.

B. Select the Bluevalve from the valveactivation screen.

C. Click on the activate button to verifyproper valve installation (Blue).

D. Check for proper air line installation. To dothis, observe the slack adjusters.

If the ECU faces the front of the trailer,the slack adjusters will move in and outas the roadsideportion of the dual

modulator valve cycles. If this does nothappen, the air lines are not properlyconnected. Make the necessary repairs.

If the ECU faces the rear of the trailer,the slack adjusters will move in and outas the curbsideportion of the dualmodulator valve cycles. If this does nothappen, the air lines are not properlyconnected. Make the necessary repairs.

8. For 4S/3M installations: Repeat this test forthe red valve.

Red: The external relay valve designated RED

(RD) is an axle control valve. It controls brakechambers on one or two axles. It is importantthat delivery lines from port #2 are plumbedas shown on the installation drawings.The 4S/3M system is designed to be usedwith a variety of trailer configurations. CallArvinMeritors Customer Service Center at800-535-5560 for additional information.

9. Click on the Testbutton to activate the ABSindicator lamp this is the lamp that ismounted on the side of the trailer. The lampwill flash eight times, indicating lampinstallation is OK. The Test Statusbox at

the bottom of the menu will display thestatus of this test. Figure 7.6.

10. Click on Closeto exit.

Sensor Installation Test (All Installations)

To test the sensor installation:

1. Raise both sensed wheel ends off of theground.

2. Apply air to the emergency line to fill the airtanks and release the spring brakes so that thewheels can be rotated.

3. Apply 12 volts DC to the ABS.

4. At the Trailer Main Menu, click on ComponentTest, then select Sensor Testto display theSensor Test screen.

5. Click on the Startbutton to start the test.

6. Rotate the sensed wheel ends at a rate of1/2 revolution per second. This rate equals awheel speed of approximately 4 mph (7 kph).

Figure 7.6


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7. Check the screen for sensor output. Figure 7.7.

Make sure there is sensor output. If sensoroutput is displayed, sensor test is complete.

If there is no sensor output, verify that a

tone ring has been installed and that thesensor is pushed all the way in against thetone ring. Make the necessary repairs andrepeat the sensor test. If the problempersists, contact Meritor WABCO.

8. Check Orderfields to verify sensors wereinstalled in the right location based onorientation of the valves. Figure 7.7.

NOTE: Refer to page 45 of this manual forsensor locations.

End of Line Testing withoutTOOLBOX Software

2S/1M Basic

1. Apply 12 volts DC power to the ABS.

2. The ECU/single modulator valve assemblyshould click two times.

3. If the indicator lamp comes on forthree seconds and goes out:

This indicates a proper installation. Theend of line test is complete.

If the ABS indicator lamp comeson and stayson, check the sensor installation:

A. Remove the power from the ABS and raise

the sensed wheels so they may be rotatedB. Repeat Step 1 and Step 2.

C. Rotate each sensed wheel one at atime at a rate less than 25 rpm.

The ABS indicator lamp should now go outand stay out indicating a properinstallation. The end of line test iscomplete.

4. If the ABS lamp does not go out, there is asensor gap problem or hardware fault. Adjustthe sensor and, if necessary, perform a faultcode check.

Figure 7.7


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Inspect the Sensor and Air LineInstallation (2S/2M Standard)

Sensor Installation

1. Look at the YE2 and YE1 sensor connectors onthe ECU/dual modulator valve assembly. Makesure the connectors are routed to the properwheel end location, as follows:

If the ECU/dual modulator valve assembly ismounted with sensors facing the front of thetrailer:

Sensor YE2 must be routed to thecurbside wheel end location

Sensor YE1 must be routed to theroadside wheel end location

If the ECU/dual modulator valve assembly ismounted with sensors facing the rear of thetrailer:

Sensor YE2 must be routed to theroadside wheel end location

Sensor YE1 must be routed to thecurbside wheel end location

2. If sensors are not properly installed, make thenecessary repairs.

Air Line Installation

1. Make sure all unused air ports are plugged

and that the exhaust port is facing DOWN.2. Look at the air line installation to make sure all

air lines are properly installed.

If the ECU/dual modulator valve assembly ismounted with the sensors facing the front ofthe trailer, the air lines for the three deliveryports located under the YE2 sensor connectormust be routed to curbside; the air lines forthe three delivery ports on the opposite sideof the valve must be routed to roadside.Figure 7.8.

If the ECU/dual modulator valve assembly is

mounted with the sensors facing the rear ofthe trailer, the air lines for the three deliveryports located under the YE2 sensor connectormust be routed to roadside; the air lines forthe three delivery ports on the opposite sideof the valve must be routed to curbside.Figure 7.9.

3. If air lines are not properly routed, make thenecessary repairs.

Figure 7.8

Figure 7.9

CURBSIDE YE2

YE1DELIVERYROADSIDE

YE2DELIVERYCURBSIDE

PLUG ALLUNUSEDPORTS

ROADSIDE YE1

VALVE MOUNTED WITH SENSORS FACINGFRONT OF TRAILER

ROADSIDE YE2

YE1DELIVERYCURBSIDE

YE2DELIVERY

ROADSIDE

CURBSIDE YE1

VALVE MOUTED WITH SENSORS FACINGREAR OF TRAILER

PLUG ALLUNUSED

PORTS


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Inspect the Sensor and Air LineInstallation (2S/2M, 4S/2M and4S/3M Premium)

Sensor Installation1. Look at the sensor co

abs wabco manutec

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