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TP -20214 Revised 10 -05 MERITOR WABCO Enhanced Easy -StopTM Trailer ABS 2S /2M, 4S /2M and 4S/3M Premium with Installation Guide Hazard Alert Messages PLC If Read and observe all Warning and Caution hazard alert messages in this publication. They provide information that can help prevent serious personal injury, damage to components, or both. How to Obtain Additional Maintenance and Service Information - this assembly the trailer BU Installation Instructions is mounted facing forward - toward the front of the YE sensor connections go to the curbside and the sensor connections go to the roadside. If this assembly is mounted facing the rear, the YE sensor connections go to the roadside, and the BU sensor connections go to the curbside. Figure 1. All premium systems use the same ECU /dual modulator valve assembly. The ECU /dual modulator assembly cannot be used as a 2S/1 M system. Refer to Maintenance Manual MM -0180, Enhanced Easy -StopTM Trailer ABS with PLC, and Maintenance Manual 33, Easy -StopTM Trailer ABS. To obtain these publications, call ArvinMeritor's ECU /DUAL MODULATOR VALVE MOUNTED WITH SENSORS FACING FRONT OFTRAILER Customer Service Center at 800 -535 -5560, or visit the Tech Library CURBSIDE on our website at meritorwabco.com. Differences Between Easy -StopTM and Enhanced Easy -StopTM There are some changes to Enhanced Easy -StopTM that you need to SUPPLY PORT Enhanced Easy -StopTM includes Power Line Communication (PLC) function. The ECU /dual modulator valve assembly must be mounted as one unit. ABS lamp on the trailer. It is ROADSIDE SUPPLY PORT tat PORTS DELIVERY ROADSIDE / sV. Crsiek fr The valve portion of the ECU /dual modulator valve assembly contains -I¡ßÿ (Th two separate modulator valves that share common control and DELIVERY ROADSIDE whether the valve is facing the front or the rear of the EXHAUST PORT determines sensor hookup. Figure CONTROL PORT in iss exhaust ports. trailer UNUSED ear] 912, Enabling the Lift Axle Function (4S /3M Installations) in the Each valve has three delivery ports. Therefore, the mounting PLUG ALL CURBSIDE BU1 CURBSIDE BU2 YE1 ROADSIDE YE2 not automatically enabled. Refer to Appendix for instructions. For 4S /2M lift axle installations, the lift axle function is automatically enabled. PORT ECU /DUAL MODULATOR VALVE MOUNTED WITH SENSORS FACING REAR OF TRAILER must use TOOLBOXTM Software, version 4.6 or higher, to enable -- at CONTROL PORT For Enhanced Easy -StopTM 4S /3M lift axle installations, you the lift axle function. ROADSIDE BU2 O IkliSid EXHAUST The blink code tool LED does not operate simultaneously with the orientation BUI sSC 1 DELIVERY CURBSIDE The LED on top of the ECU has been eliminated. ' I e. be aware of before you begin the installation. ' ROADSIDE YE1- CURBSIDE YE2 PLUG ALL UNUSED PORTS DELIVERY CURBSIDE 4003566a 1 PDF compression, OCR, web optimization using a watermarked evaluation copy of CVISION PDFCompressor Preparation End of line testing must be done after all installations. Meritor WABCO recommends using TOOLBOXTM Software to perform A WARNING To this testing. If you do not have TOOLBOXTM Software, this bulletin also includes instructions for testing without the prevent serious eye injury, always wear safe eye protection software. when you perform vehicle maintenance or service. The Anti -lock Braking System (ABS) is an electrical system. When you work on the ABS, take the same precautions that you must take with any electrical system to avoid serious personal injury. As with any electrical system, the danger of electrical shock or sparks exists that can ignite flammable Installation I. Install the ECU /dual modulator valve assembly. substances. You must always disconnect the battery ground The assembly may be mounted on the air tank or on the cross cable before working on the electrical system. member of the vehicle. Park the vehicle on a level surface. Block the wheels to prevent the vehicle from moving. Support the vehicle with safety stands. Do not work under a vehicle supported only by jacks. Jacks can slip and fall over. Serious personal injury and damage to components can result. Tank -Mounted Refer to Figure 2. ECU /DUAL MODULATOR VALVE MOUNTED WITH 1. SENSORS FACING FRONT OFTRAILER (TANK- MOUNTED) Before beginning the installation procedure, inspect the modulator valve assembly for damage that may have occurred during shipping or storage. ECU /dual CURBSIDE Look for crushed or bent connectors. VE2 Verify that the retainer clips have not been bent or CURBSIDE otherwise damaged. YE1 Do not install a damaged ECU /dual modulator valve assembly. Notify your supervisor, or contact Meritor WABCO if there is any apparent damage. 2. / ROADSIDE BU1 ROADSIDE BU2 Have the following installation material available. * ECU /dual modulator valve assembly * ABS relay valve and relay valve extension cable with bayonet ECU /DUAL MODULATOR VALVE MOUNTED WITH SENSORS FACING REAR OFTRAILER connector (3M systems) * Power cable or power /diagnostic cable * Sensor extension cables (two pieces for 2S systems, four pieces for 4S systems) CURBSIDE BU2 * Sensors (two or four) for non -ABS prepped axles CURBSIDE BU1 * ABS Indicator Label (TP- 95172) U!! 5/8 -inch O.D. nylon tubing for supply (frame mount) Pipe plug (3/4 -inch NPTF) Schedule 80 hex pipe nipple (3/4 -inch NPTF) for air tank mounts or two Grade 8 bolts (3/8 -inch) and prevailing torque PLUG UNUSED PORT nuts for frame mounts SAE -standard, DOT- approved thread sealant To ROADSIDE R YE1 ROADSIDE VE2 Exhaust port must face DOWN. 4003548a ensure correct lamp operation, use an incandescent -type Figure 2 DOT- approved lamp, or an LED with integral load resistor. * Meritor WABCO components TP -20214 Revised 10 -05 Page 2 i (16579/22882) Copyright ArvinMeritor, Inc., 2005 Printed in USA PDF compression, OCR, web optimization using a watermarked evaluation copy of CVISION PDFCompressor A When mounting the ECU /dual modulator valve assembly to the WARNING trailer cross member, refer to SAE specification J447, Prevention of You must use a Schedule 80 hex nipple (3/4 -inch NPTF) to ECU /dual mount the modulator valve assembly securely to the air tank to avoid possible serious personal injury and damage to the component. Corrosion of Motor Vehicle Body and Chassis Components. Follow all recommendations and procedures. Your supervisor should have a copy of this specification. Install a 3/4 -inch NPTF fitting in the supply port. Use a 3/4 -inch 1. 1. Use a 3/4 -inch NPTF Schedule 80 hex nipple to attach the ECU /dual modulator valve assembly to a NPTF pipe plug to plug the unused supply port (Port 1). reinforced air tank. Apply SAE -standard, DOT- approved Teflon tape or paste -type Do not overtighten. thread sealant to all pipe plugs beyond the first two threads. Meritor WABCO does not recommend the use of a vise when Pipes with pre -applied thread sealant may also be used. installing the hex nipple. Use of a vise may cause Locate a position for mounting the assembly to the vehicle 2. overclamping. Overclamping may damage the internal cross member midway between the side rails, close to the components of the ECU /dual modulator valve assembly. 2. Use a brake chambers the valve serves. 3/4 -inch NPTF pipe plug to plug the unused supply port. Drill two 3/8 -inch mounting holes. The distance between Apply SAE -standard, DOT- approved Teflon tape or paste -type the two holes (O.D.) must be 6.06- inches (154 mm) and thread sealant to all pipe threads beyond the first two threads. mount directly to the cross member. Pipes with pre -applied thread sealant may also be used. 3. until the exhaust port faces DOWN and the connection is Build a mounting bracket with two 3/8 -inch mounting holes secure. Use a torque wrench or ratchet with an extension at the spaced 6.06- inches (154 mm O.D.) apart. 3/4 -inch pipe plug installed on the front supply port. ' OR Rotate and tighten the ECU /dual modulator valve assembly attach the assembly. Tighten the bolts to 18 lb -ft (24 Nm). Mounted to Cross Member of Vehicle (Mounting Bracket Not Supplied) II. Refer to Figure 3. ECU /DUAL MODULATOR VALVE MOUNTED TO A CROSS MEMBER OF THE VEHICLE WITH SENSORS FACING FRONT OF TRAILER Exhaust port must face DOWN. 1- PLUG ALL UNUSED PORTS - - ROADSIDE BU2 mount the l modulator valve assembly securely to the to the component. Use a 3/4 -inch NPTF Schedule 80 hex nipple to attach the relay valve assembly to a reinforced air tank. Do not CURBSIDE overtighten. VE1 Mentor WABCO does not recommend the use of overclamping. Overclamping may damage the internal components of the ECU /dual modulator valve assembly. 2. PLUG ALL UNUSED PORTS when a vise installing the hex nipple. Use of a vise may cause Exhaust port must face DOWN. I ECU /dual air tank to avoid possible serious personal injury and damage ECU /DUAL MODULATOR VALVE MOUNTED WITH SENSORS FACING REAR OF TRAILER ROADSIDE YE2 WARNING You must use a Schedule 80 hex nipple (3/4 -inch NPTF) to 1. YE2 Attach the ABS external relay valve (4S /3M systems only). A BU1 CURBSIDE O Tank -Mounted ROADSIDE FRONT OF TRAILER Use two 3/8 -inch Grade 8 bolts with prevailing torque nuts to 3. Use a 3/4 -inch NPTF pipe plug to plug the unused supply port. Apply SAE -standard, DOT- approved Teflon tape or paste -type thread sealant to all pipe threads beyond the first two threads. Pipes with pre -applied thread sealant may also be used. ROADSIDE VE1 CURBSIDE BU1 Figure CURBSIDE BU2 FRONT OF TRAILER 4005403b 3 TP -20214 (16579/22882) Printed in USA Revised 10 -05 Copyright ArvinMeritor, Inc., 2005 Page 3 PDF compression, OCR, web optimization using a watermarked evaluation copy of CVISION PDFCompressor Rotate and tighten the relay valve assembly until the exhaust 3. port faces down and the connection is secure. Use a torque 2. Connect the air delivery lines to the appropriate brake chambers (3/8 -inch NPT). Figure 5 and Figure 6. wrench or ratchet with an extension at the 3/4 -inch pipe plug installed on the front supply port. Figure 4. The valve portion of the ECU /dual modulator valve assembly contains two separate valves: one dedicated to roadside wheel ends, the other dedicated to curbside wheel ends, Each valve has three delivery ports. PLUG UNUSED The external relay valve designated RED (RD) PORTS axle is an control valve. It controls brake chambers on one or two Exhaust port must face DOWN. important that delivery lines from Port CONTROL axles. PORT 4 plumbed as shown. Refer to Figure 13 through Figure 19. It is 2 are - SUPPLY PORT 1 TYPICAL 2M INSTALLATION VALVE MOUNTED WITH SENSORS FACING FRONT OFTRAILER ABS EXTERNAL MODULATOR VALVE Il 1002073d Figure 4 . 1 1 I 1 I Mounted to Cross Member of Vehicle (Mounting Bracket Not Supplied) 141--r :_ - 1 ;' I I . ;. j -.I I - ' ,,.,: I '1`tI yv' I A I When mounting the relay valve assembly to the trailer cross member, refer to SAE specification J447, Prevention of Corrosion of I 11 r:5°-------! I------------ Motor Vehicle Body and Chassis Components. Follow all recommendations and procedures. Your supervisor should have ----------- a copy of this specification. 1. - - - -- Install a 3/4 -inch NPTF fitting in the supply port. Use a 3/4 -inch NPTF pipe plug to plug the unused supply port (Port 1). Apply SAE -standard, DOT- approved Teflon tape or paste -type thread sealant to all pipe plugs beyond the first I SERVICE /CONTROL LINES SERVICE BRAKE SUPPLY AIR SPRING BRAKE AIR 4003550a Figure 5 two threads. Pipes with pre -applied thread sealant may also - be used. 2. Install the valve with two locknuts and washers as required. Tighten the hex nuts to 18 lb -ft (24 Nm). III. TYPICAL 2M INSTALLATION VALVE MOUNTED WITH SENSORS FACING REAR OFTRAILER -----------------1 -' 'T-------c&- O I Connect the air lines. Before connecting the air lines, plumb the spring brake relay or emergency brake relay into the system as usual. If you are o I i I 1 1 e a. 1 mounting on a bracket, connect the air supply line from W .. i e the supply tank to the supply Port 1. Plug the unused port. 1 Use II 1 I supply tank. - - - -- Connect the air delivery lines to the ECU /dual modulator valve assembly Port 2. For 4S /3M installations, connect the air delivery lines to Port 2 on the external relay valve (3/8 -inch NPTF). .., . .I -----------' I-----------------r -- - 5/8 -inch O.D. min. nylon tubing or heavy -walled Schedule 80 pipe nipple (3/4 -inch NPTF) if you are mounting directly to the 1. i 1If i Figure SERVICE /CONTROL LINES SERVICE BRAKE SUPPLY AIR SPRING BRAKE AIR 4003551a 6 TP -20214 Revised 10 -05 Page 4 (16579/22882) Copyright ArvinMeritor, Inc., 2005 Printed in USA PDF compression, OCR, web optimization using a watermarked evaluation copy of CVISION PDFCompressor 3. 4. Connect the brake service (control) line to the ECU /dual Do not overtighten the tie wraps on a cable. Overtightening can modulator valve assembly Port damage the cable. Do not tie wrap the molded sensor plug. 4 (1 /4 -inch NPTF). The sensor extension cable must follow the brake hose to the For 4S/3M installations, perform the following procedures. ECU /dual A. Connect the brake service (control) line to the ECU /dual modulator valve assembly Port 4 modulator valve assembly to allow for axle jounce and rebound. (1/4-inch NPTF) and ABS external relay valve control Port 4 (3/8 -inch NPTF). 4. Secure the cables every eight inches (203 mm) with tie wraps or cable clips. B. Use an ABS relay valve connection cable to connect the ECU /dual modulator valve assembly with the ABS external 5. assembly relay valve. 5. 6. Plug any unused delivery ports. Push the sensor retainer clip on the ECU /dual modulator valve UP. Remove the protective caps from YE2 and YE1 sensor connectors. IV. Install the sensor extension cables (ABS- prepped axles). 7. Plug the sensor extension cables into the ECU /dual modulator valve assembly. To secure the connection, push the sensor retainer clip DOWN. Retainer clips must fit in the groove of the Instructions for installing sensors on non -ABS- prepped axles are included in sensor connectors to ensure correct connection. the Appendix. ECU /Dual Meritor WABCO recommends placing sensors on the axle that will Modulator Valve Assembly Mounted with Sensors Facing Front of Trailer provide the most braking performance. The suspension 2S/2M manufacturer can provide this information. 1. Visually inspect the tooth wheel and sensor to ensure no damage occurred during shipping. Perform any necessary repairs. - Connect curbside sensor at YE1. Connect roadside sensor at BU1. 4S /2M* 2. Connect the sensors and cables on the prepped axles to the sensor extension cables. Figure 7. Ensure that each connection is secure. Connect curbside front sensor at YE1. Connect curbside rear sensor at YE2. Connect roadside front sensor at BU1. Connect roadside rear sensor at BU2. 4S /3M* SENSOR EXTENSION CABLE - Sensor locations vary by type of installation. Refer to the diagrams on the following pages for specific sensor locations. For Enhanced Easy- StopTM 4S /3M lift axle installations, you must use TOOLBOXTM Software, SENSOR AND CABLE version 4.6 or higher, to enable the lift axle function. It is not automatically enabled. Refer to Enabling the Lift Axle Function (4S/3M Installations) in the Appendix for instructions. 4003567b Figure ' 3. 7 Route the sensor cable along the back side of the trailer axle to the ECU /dual modulator valve assembly. Route the cable with the brake hose. - Connect curbside sensor at YE1. Connect curbside sensor at YE2. Connect roadside sensor at BU1. Connect roadside sensor at BU2. * If the lift axle is sensed in 4S /2M and 4S /3M installations: Sensors YE2 and BU2 must always be used on the lift axle to avoid an unwanted ABS indicator lamp illumination. TP -20214 (16579/22882) Printed in USA Revised 10 -05 Copyright ArvinMeritor, Inc., 2005 Page 5 PDF compression, OCR, web optimization using a watermarked evaluation copy of CVISION PDFCompressor 3. 4. Connect the brake service (control) line to the ECU /dual Do not overtighten the tie wraps on a cable. Overtightening can modulator valve assembly Port 4 (1/4 -inch NPTF). damage the cable. Do not tie wrap the molded sensor plug. The sensor extension cable must follow the brake hose to the For 4S /3M installations, perform the following procedures. ECU /dual A. Connect the brake service (control) line to the ECU /dual modulator valve assembly Port 4 modulator valve assembly to allow for axle jounce and rebound. (1/4-inch NPTF) and ABS external relay valve control Port 4 (3/8 -inch NPTF). 4. Secure the cables every eight inches (203 mm) with tie wraps or cable clips. B. Use an ABS relay valve connection cable to connect the ECU /dual modulator valve assembly with the ABS external 5. assembly relay valve. 5. 6. Plug any unused delivery ports. Push the sensor retainer clip on the ECU /dual modulator valve UP. Remove the protective caps from YE2 and YE1 sensor connectors. IV. Install the sensor extension cables (ABS- prepped axles). 7. Plug the sensor extension cables into the ECU /dual modulator valve assembly. To secure the connection, push the sensor retainer clip DOWN. Retainer clips must fit Instructions for installing sensors on non -ABS- prepped axles are included in the Appendix. Meritor WABCO recommends placing sensors on the axle that will provide the most braking performance. The suspension the groove of the ECU /Dual Modulator Valve Assembly Mounted with Sensors Facing Front of Trailer 2S /2M manufacturer can provide this information. 1. in sensor connectors to ensure correct connection. Visually inspect the tooth wheel and sensor to ensure no damage occurred during shipping. Perform any necessary repairs. - Connect curbside sensor at YE1. Connect roadside sensor at BU1. 4S /2M* 2. Connect the sensors and cables on the prepped axles to the sensor extension cables. Figure 7. Ensure that each connection is secure. Connect curbside front sensor at YE1. Connect curbside rear sensor at YE2. Connect roadside front sensor at BU1. Connect roadside rear sensor at BU2, 4S/3M* - Sensor locations vary by type of installation. Refer to the diagrams on the following pages for specific sensor locations. For Enhanced Easy- StopTM 4S /3M lift axle installations, you must use TOOLBOXTM Software, version 4.6 or higher, to enable the lift axle function. It is not automatically enabled. Refer to Enabling the Lift Axle Function (4S /3M Installations) in the Appendix for instructions. Figure 3. 7 Route the sensor cable along the back side of the trailer axle to the ECU /dual modulator valve assembly. Route the cable with the brake hose. - Connect curbside sensor at YE1. Connect curbside sensor at YE2. Connect roadside sensor at BU1. Connect roadside sensor at BU2. * If the lift axle is sensed in 4S /2M and 4S /3M installations: Sensors YE2 and BU2 must always be used on the lift axle to avoid an unwanted ABS indicator lamp illumination. TP -20214 (16579/22882) Printed in USA Revised 10 -05 Copyright ArvinMeritor, Inc., 2005 Page 5 PDF compression, OCR, web optimization using a watermarked evaluation copy of CVISION PDFCompressor ECU /Dual Modulator Valve Assembly Mounted with 9. Bundle any excess cable in a loop (bow tie). Figure 9. Sensors Facing Rear of Trailer 2S /2M - Connect curbside sensor at BU1. Connect roadside sensor at YE1. 4S /2M* Connect curbside front sensor at BU1. Connect curbside rear sensor at BU2. Connect roadside front sensor at YE1. Connect roadside rear sensor at YE2. 4S/3M* - Figure 9 Sensor locations vary by type of installation. Refer to the diagrams for specific sensor locations. 10. Secure excess cable For Enhanced Easy- StopTM 4S /3M lift axle in the sub -frame of the vehicle or along the air hoses as appropriate. Excess cable should not exceed installations, you must use TOOLBOXTM Software, two feet (0.61 meter). version 4.6 or higher, to enable the lift axle function. It is Various cable lengths are available. not automatically enabled. Refer to Enabling the Lift Axle Function (4S/3M Installations) in the Appendix for V. instructions. - Connect curbside sensor at BU1. 1. Connect curbside sensor at BU2. Install the power and lamp or power and lamp /diagnostic cable. Identify the type of cable to be installed. Figure 10. Connect roadside sensor at YE1. ABS trailer industry- standard pigtail connector power cable Connect roadside sensor at YE2. Blunt -cut power cable (not shown) * If the lift axle is sensed in 4S /2M and 4S /3M installations: Sensors YE2 and BU2 must always be used on the lift axle to avoid an unwanted ABS indicator lamp illumination. 8. Create a strain relief to protect the sensor extension connector terminals. Without this strain relief, normal trailer jounce and vibration will cause the terminals to spread and loosen. Use a tie wrap or clip to secure the cable to the brake air delivery hose as close to the fitting as possible. Figure 8. Figure 10 2. For industry- standard pigtail connector power cables, route the cable from the harness connector to the ECU /dual modulator valve assembly and secure it to prevent damage. Attach individual sensor cables to corresponding brake air delivery hoses. For blunt -cut power cables, route the cable from the ECU /dual modulator valve assembly to a junction box which interfaces with the seven -way connector at the front of the trailer. 4005457b Leave enough slack in the cable to compensate for flexing of Figure 8 the trailer and sub -frame. TP -20214 Revised 10 -05 Page 6 (16579/22882) Copyright ArvinMeritor, Inc., 2005 Printed in USA PDF compression, OCR, web optimization using a watermarked evaluation copy of CVISION PDFCompressor 3. Bundle any excess cable in a loop (bow tie) and secure it in the 8. sub -frame of the trailer body to prevent cable damage. 4. If you are installing the power /diagnostic "Y" cable: Install the diagnostic cable bracket so that the diagnostic A. Push the hinged power /diagnostic connector retainer clip UP plug is accessible. The normal location is on the right and remove the protective cap from the ECU /dual modulator front corner of the sub -frame, but will vary depending on valve assembly. Figure 11. the type of trailer. Route the diagnostic cable from the ECU /dual modulator B. valve assembly to the diagnostic cable bracket. -4- - l' CAP Correctly secure the cable in the sub -frame to prevent C. cable damage. KEYED CABLE Leave enough slack in the cable to compensate for flexing CONNECTOR of the trailer and sub -frame. Bundle excess cable in a loop (bow tie) and secure the D. cable 9. in the sub -frame. Figure 9. Install the ABS indicator lamp on the trailer. Refer to the vehicle specification sheet for the exact location of the indicator lamp. MATING TRAILER HARNESS CONNECTOR Use a DOT- approved lamp with ABS etched on the lens (available from major trailer parts suppliers). To 4003569a Figure ensure correct lamp operation, use an incandescent -type DOT- approved lamp or an LED with integral load resistor. If 11 you are using the industry- standard connector cable and do not have access to the mating trailer harness, mask the open 5. connector to protect it from paint or grease. Plug the power 8 -pin connector on the power or power/ diagnostic cable into the ECU /dual modulator valve assembly. 6. 10. Pull the hinged power/diagnostic connector retainer clip on the ECU /dual For industry- standard connector cables: Attach the power modulator valve assembly DOWN to secure the connection. 7. Connect the power. Use the industry- standard connector cable or a blunt -cut power cable. If you cable to the harness on the trailer. are installing the power cable only, go to Step 9. For an optional blunt -cut power cable: Wire the cable and ABS indicator lamp to the seven -way connector on the trailer according to the following diagram. Figure 12. GENERIC INPUT /OUTPUT (EXPANDED CAPABILITY) WHITE AND YELLOW WHITE WHT 4 OR 5 WIRE BLK SCHEMATIC 7 WAY o BLU o BRN o GRN L RO (GROUND) o' 1 BLUE (CONSTANT POWER) :#1 RED (STOP LAMP) GREEN AND WHITE ( 1 r77 GROUND C TRAILER ABS INDICATOR LAMP ECU POWER CONNECTOR Junction box not shown. 4003570a Figure 12 TP -20214 (16579/22882) Printed in USA Revised 10 -05 Copyright ArvinMeritor, Inc., 2005 Page 7 PDF compression, OCR, web optimization using a watermarked evaluation copy of CVISION PDFCompressor Typical Easy- StopTM Trailer ABS Installations Refer to Figure 13 through Figure 19 for typical Easy- StopTM trailer ABS installations. Mentor WABCO recommends placing sensors on the axle that will provide the most braking performance. The suspension manufacturer can provide this information. == ==j YE 2S /2M VALVE MOUNTED WITH SENSORS FACING FRONT OFTRAILER SIDE -TO -SIDE CONTROL - I 4. TRAILER FRONT OF W - -, !Ì YE o . BU1 NOTE: Spring brake lines not shown. rTh fTk- 1 ------ I I , == ¡_ == =_= == BU7 -----J M. WO l 2S /2M VALVE MOUNTED WITH SENSORS FACING REAR OFTRAILER SIDE -TO -SIDE CONTROL - aut 411. FRONT OF TRAILER 114-- - - - - -__ -__-_-_-_-_-_-_-_--_-_-_-_-_ _____________ -I I:6I -d W I 1 I I II euB o ri' iir BU1 o IÌ ii YE1 II YE2 I ----------------------------------I 1 131 === C-= r--- _` __- NOTE: Spring brake 1 lines not shown. YE1 SERVICE /CONTROL LINES -- - - - SENSOR CABLES SERVICE BRAKE SUPPLY AIR 40035543 Figure 13 TP -20214 Revised 10 Page 8 -05 (16579/22882) Copyright ArvinMeritor, Inc., 2005 Printed in USA PDF compression, OCR, web optimization using a watermarked evaluation copy of CVISION PDFCompressor Meritor WABCO recommends placing sensors on the axle that will provide the most braking performance. The suspension manufacturer can provide this information. 4S /2M VALVE MOUNTED WITH SENSORS FACING FRONT OFTRAILER I___ YE1 I y - SIDE -TO -SIDE CONTROL lllllllllll /11111/11 YE2 .. f FRONT OF TRAILER Ii'r Typical Tandem Axle Trailer o rlñ ¡- ---------- ----- 1 =.= =7_3 == BU1 ; NOTE: Spring brake BU2 ' lines not shown. 1 4S /2M VALVE MOUNTED WITH SENSORS FACING REAR OFTRAILER - SIDE -TO-SIDE CONTROL 7- = = r--- _- BU1 I] BU2 4 t C Typical Tandem Axle Trailer 4. FRONT OF TRAILER BU2 Ij BU1 O YE1 NOTE: Spring brake S'itirOr 700- lines not shown. YE2 fTP- l-- SERVICE /CONTROL LINES ----- SENSOR CABLES YE1 SERVICE BRAKE SUPPLY AIR L__ == __=_ YE2 ÍJ.LI.L1.Ll.0 4003555a Figure 14 TP (16579/22882) Printed in USA -20214 Revised 10 -05 Copyright ArvinMeritor, Inc., 2005 Page 9 PDF compression, OCR, web optimization using a watermarked evaluation copy of CVISION PDFCompressor Mentor WABCO recommends placing sensors on the axle that will provide the most braking performance. The suspension manufacturer can provide this information. - 4S /2MTYPICALTRI -AXLE VALVE MOUNTED WITH SENSORS FACING FRONT OFTRAILER SIDE -TO -SIDE CONTROL =:_= =-= - =__= L_ -= L_ YE2 YE1 FRONT OF TRAILER r ------r I I ) -.. --ri O 9F. 4411. -- __ nnnu C I II YE2 .. NOTE: Spring brake YE1 lines not shown. o But ;71} BU2 ' II 1-, DIY BU1 --------------- J4 D:W C1=03 ) === L Anta ' _C L _J _ - 4S /2MTYPICALTRI -AXLE VALVE MOUNTED WITH SENSORS FACING REAR OFTRAILER SIDE -TO -SIDE CONTROL -= C==J L_ - =0;0 77= C=== C C;=) BU2 BU1 D:W tI I. I +..... Dt I- FRONT OF TRAILER ) J, r--- r --------I III NOTE: Spring brake lines not shown. BU2 o BU7 '«I[ SERVICE /CONTROL LINES YE1 YE2 -- --- SENSOR CABLES SERVICE BRAKE SUPPLY AIR JJL----1 I CCFYE1 __ L__J J C=á-= L_ E6- L _J 4003556a Figure 15 TP -20214 (16579/22882) Revised 10 -05 Page 10 Copyright ArvinMeritor, Inc., 2005 Printed in USA PDF compression, OCR, web optimization using a watermarked evaluation copy of CVISION PDFCompressor Meritor WABCO recommends placing sensors on the axle that will provide the most braking performance. The suspension manufacturer can provide this information. - 4S /2M TYPICAL AXLE CONTROL INSTALLATION VALVE MOUNTED WITH SENSORS FACING FRONT OFTRAILER -- L L_.____J =1;13 BU1 111/ L_ IIIIIIIII .._ VE7 FRONT YE2 o o NOTE: Spring brake lines not shown. 1=6- TIPYE2 MUMS ®82 I C =_ _ ) - 4S /2M TYPICAL AXLE CONTROL INSTALLATION VALVE MOUNTED WITH SENSORS FACING REAR OFTRAILER CT= ) IIUIIIII BU1 YE1 Q. s ' LJ.I BU2 ION FRONT .i'nr o o NOTE: Spring brake lines not shown. YE2 1-- i SERVICE /CONTROL LINES SENSOR CABLES BU2 SERVICE BRAKE YE2 Iluunl SUPPLY AIR L____J 4002773a Figure 16 TP -20214 (16579/22882) Printed in USA Revised 10 -05 Copyright ArvinMeritor, Inc., 2005 Page 11 PDF compression, OCR, web optimization using a watermarked evaluation copy of CVISION PDFCompressor NOTE: For Enhanced Easy- StopTM 4S /3M lift axle installations, you must use TOOLBOXTM Software, version 4.6 or higher, to enable the lift axle function. It is not automatically enabled. Refer to Enabling the Lift Axle Function (4S /3M Installations) in the Appendix for instructions. Meritor WABCO recommends placing sensors on the axle that will provide the most braking performance. The suspension manufacturer can provide this information. 4S == L__=J I I' Q 1 ) Q I---- I . I y === YE1 YEI FRONT OF TRAILER - -AXLE WITH FRONT LIFT VALVE MOUNTED WITH SENSORS FACING FRONT OFTRAILER I YE2 YE1 o 'r"" o ',c1,f: BU1 Ll BU2 ee -------------- I BU2 - NOTE: Spring brake BUi Le__J 1--, lines not shown 77_ C==C J - 4S /3MTYPICALTRI -AXLE WITH FRONT LIFT VALVE MOUNTED WITH SENSORS FACING REAR OFTRAILER == =PPP= =L.= := C __ = BU2 BU1 4 sr 4. - -I FRONT OF TRAILER ==-7 - r +.... 1--------s--------7 i I L 1 W SERVICE /CONTROL LINES I o - 1711 I t,,i - - - -- SENSOR CABLES I l ,_, BU2 BU1 SERVICE BRAKE SUPPLY AIR rl YE1 I Á1 YE2 NOTE: Spring brake l lines not shown. 1 _J r- 1g YEI 1 = === LLF YEl lllll 1111 C=_ r C--= 4003557a Figure 17 TP -20214 Revised 10 -05 Page 12 (16579/22882) Copyright ArvinMeritor, Inc., 2005 Printed in USA PDF compression, OCR, web optimization using a watermarked evaluation copy of CVISION PDFCompressor Meritor WABCO recommends placing sensors on the axle that will provide the most braking performance. The suspension manufacturer can provide this information. 4S /3MTYPICALTRI -AXLE == -- - - VALVE MOUNTED WITH SENSORS FACING FRONT OFTRAILER --- L--- L,--_ 0=0:1 YE1 ..... YE2 V.4 S FRONT OF TRAILER I I _ o o . I o ± 1=r1 4 -------- ¡- ------- I 1 NOTE: Spring brake o o E2 o YE1 SERVICE /CONTROL LINES Typical Tandem Axle Trailer I I lines not shown. . ---- - But BU2 SENSOR CABLES SERVICE BRAKE SUPPLY AIR 1 1 -1-----------------L I10- == == BU2 4S /3MTYPICALTRI -AXLE Buz -d- S 40. FRONT OF TRAILER I BU1 .J I - VALVE MOUNTED WITH SENSORS FACING REAR OFTRAILER == 7-7 r- L____a._J C®R= G® ® == == == 11111111111 ¢Q BUt D?I I II O 13 1 BU2 I 1, o r2 Typical Tandem Axle Trailer !IA I IIII4J I o nI Il YE1 LIT Sf .EI L YE2 Imo, I =rJ¡ .,1' YJ L_l.- _ NOTE: Spring brake lines not shown. - BU1 i Em- =:= == YE1 ___J 4003558a Figure 18 TP -20214 (16579/22882) Printed in USA Revised 10 -05 Copyright ArvinMeritor, Inc., 2005 Page 13 PDF compression, OCR, web optimization using a watermarked evaluation copy of CVISION PDFCompressor Meritor WABCO recommends placing sensors on the axle that will provide the most braking performance. The suspension manufacturer can provide this information. - 4S /3M TYPICAL FOUR AXLE PULLTRAILER VALVE MOUNTED WITH SENSORS FACING FRONT OFTRAILER =1C =C CIC C==C C__C C=_C 111111111 YE2 --I ¢ S 114. FRONT OF TRAILER T i 1rI 1 1 I NOTE: Spring brake lines not shown. la. i - YE2 It I 1 I o 4 ___ I SERVICE /CONTROL LINES - - - -- SENSOR CABLES SERVICE BRAKE SUPPLY AIR 81.12 II I_ J I i1 . Le __A__ E6Bata, B US = T___D IN. NO L______) - 4S /3M TYPICAL FOUR AXLE PULLTRAILER VALVE MOUNTED WITH SENSORS FACING REAR OF TRAILER =_= COI= === L.:7r= = C__ FRONT OF TRAILER BU7 ¢ + 0,* S? 11 la o ` I1>U$ID BU2 II-I ÌI I 4 a I W 11 n BUS r g NOTE: Spring brake lines not shown. C ... A1 BU7- I. Á o YrS r -- -I l.F I 1:3! == =C ==e7 YE2 YE1 C==C C==C C==C C==C ¡¡ 11 L__ 4003559a Figure 19 TP -20214 Revised 10 -05 Page 14 (16579/22882) Copyright ArvinMeritor, Inc., 2005 Printed in USA PDF compression, OCR, web optimization using a watermarked evaluation copy of CVISION PDFCompressor End of Line Testing I( It Mentor WADCO rr installations. To run these tests, Meritor WABCO recommends you use TOOLBOXTM Software. ECU own Tresin ADS Dnaannstscs gads, ÇanponereTesh NOON deb Teak. ECU End of line testing is required on all Enhanced Easy- StopTM "i, ritSq A0I tnte, euon ro#.lrs Marwiactue Date TOOLBOXTM Software and general test procedures are included in ECU Type this bulletin. Cabala, 45/111 Sed Mambo Pact Wade. 446ICECCO1 Scene* Review. If you are using a Pro -Link, refer to the operating manual for test instructions. I - bream Ecy I Voted hS ),;r., B::.r Voltages ' AMITYY you are testing an installation that has a power only cable, temporarily install a t YE2 (. SWUM Ivan BONI =^aÌ - FT- EU1 7 I 1 r7"-- eU2 Saurian InfaacMìron . .1 ¡1;, ] 109+2000 I Curer* Mint lci Sera We: p Revs/Mb 495 I World 13 G6i rJ I1 Meritor WABCO combination power /diagnostics Menage Center' "Y" style cable. 1. , II YE1 13 G6; Secondary If - r i Wheel Sena Kr Fault. Enhanced Easy- StopTM 2S /2M, 4S /2M and 4S /3M Premium Installation End of Line Testing Procedure with TOOLBOXTM Software i Connect the diagnostic connector on the cable to the PC serial port/SAE diagnostic interface (J1587/J1708 to RS232 interface). - ' . 4003560a Figure 20 Refer to the Software Owner's Manual, TP- 99102, for instructions for running TOOLBOXTM Software. 2. Display the Trailer ABS Main Screen. 3. Verify the power supply. Check the Faults field on the Main Screen, 4. NONE = No faults present, proceed with end of line test. YES = Faults present, double -click on "YES" to bring up the Apply 12 volts DC to the blue wire (constant). Check the fault information screen. screen for the correct voltage (9.5 to 14 volts). Constant power voltage is Use the information in the displayed in the PRIMARY field. Figure 20. Repair Instructions field to perform the necessary repairs. Figure 21. Apply 12 volts DC to the red wire (stoplight power). Check the screen for the correct voltage (9.5 to 14 volts). Stoplight power voltage is displayed in the SECONDARY field. c Figure 20. The internal field is not applicable to this test. t AAA rda,...d,n la] lases r UI trau: IaillEMEINIEMIMH'KA1110 mII 11® ..,.... ......,o... Rawl J j twMro411oaY llY..p.-'.V rear awes C.i.': s.,+-:u..vr.y+t:,eUav *Weep d'.,a Pula ea.a.ea.x.e *NO to ^.lFJc.V..l.',(: 1 çlaors I( _f Qw resh 1 + Dirt ( S.,. I eel I 4003561a Figure 21 TP (16579/22882) Printed in USA -20214 Revised 10 -05 Copyright ArvinMeritor, Inc., 2005 Page 15 PDF compression, OCR, web optimization using a watermarked evaluation copy of CVISION PDFCompressor End of Line Test with TOOLBOXTM Software 7. Verify Correct Valve and Lamp Installation To verify valve and lamp installations with TOOLBOXTM Software: 1. Apply 12 volts DC to the ABS. 2. Apply air to the emergency line to fill the air tanks and release Repeat this test for the Blue valve. A. Repeat Steps B. Select the Blue valve from the valve activation screen. C. Click on the Activate button to verify correct valve 1 -3. installation (Blue). D. the spring brakes. Check for correct air line installation. To accomplish this, observe the slack adjusters. 3. Apply air to the control line. 4. At the Trailer Main Screen, click on Component Test, then adjusters will move in and out as the ROADSIDE select Valves/Lamp to display the Valve Activation Screen. portion of the dual modulator valve cycles. If this does The Yellow valve indicator will be highlighted. Figure 22. not happen, the air lines are not correctly connected. If the ECU faces the FRONT of the trailer, the slack Perform the necessary repairs. : Valve Activation the ECU faces the REAR of the trailer, the slack Select Valve to Activate adjusters will move r. portion of the dual modulator valve cycles. r r r Yellow in and out as the CURBSIDE If this does not happen, the air lines are not correctly connected. Skie Actnate Perform the necessary repairs. ( Red 8. AI Wives r Test Warning Lamp , If 111 -- For 4S /3M installations: Repeat this test for the red valve. Red: The external relay valve designated RED (RD) is an axle - control valve. Warning Lamp lest II It is It controls brake chambers on one or two axles. important that delivery lines from Port 2 are plumbed as shown on the installation drawings. The 4S/3M system is Test Status designed to be used with a variety of trailer configurations. Call ArvinMeritor's Customer Service Center at 800 -535 -5560 for additional information. 9. 40035620 Click on the Test button to activate the ABS indicator lamp this Figure 22 is - the lamp that is mounted on the side of the trailer. The lamp will flash eight times, indicating lamp installation is OK. The Test Status box at the bottom of the menu will display the 5. Click on the Activate button. 6. Check for correct air line installation. To accomplish this, status of this test. Figure 22. 10. Click on Close to exit. observe the slack adjusters. Sensor Orientation Test If the ECU faces the FRONT of the trailer, the slack adjusters will move in and out as the CURBSIDE portion of the dual modulator valve cycles. If this does not happen, the air lines are not correctly connected. Perform the necessary repairs. If the ECU faces the REAR of the trailer, the slack adjusters This test is not for use on 4S/3M installations. For 4S /3M installations, use the standard Sensor Test. To run the standard test, select Sensor Test from the Components Test Menu. will move in and out as the ROADSIDE portion of the dual The sensor orientation test must be performed as part of the end of modulator valve cycles. line testing procedure. If this does not happen, the air lines are not correctly connected. Perform the necessary repairs. The Test Status box at the bottom of the menu will display the status of this test. TP -20214 Revised 10 -05 Page 16 (16579/22882) Copyright ArvinMeritor, Inc., 2005 Printed in USA PDF compression, OCR, web optimization using a watermarked evaluation copy of CVISION PDFCompressor Sensor Orientation Test Screen 01 ICS I1 Sensor Before beginning this test, look at the ECU to see if the sensors face Orientation Test the front or rear of the trailer. TOOLBOXTM will ask for this information to start the test (Step 5). To perform the sensor orientation test: Mlle 400 1. Raise the sensed wheel ends off the ground. 2. Apply air to the emergency line to fill the air tanks and release X ... Warning Message: This test demands that the wheels be spun in a predetermined order and that the ECU mounting orientation is entered by the operator. It is applicable to the following TCS2 configurations only: 2S/1M 25/2M 2S/2M 46/2M 500 101 500 104 500 102 500 103 400 400 400 400 Ut 0 0 0 500 103 0 1 the spring brakes so that the wheels can be rotated. t 0 Sensors Facing 2 r r Peer Front Sensors 3. Apply 12 volts DC to the ABS. 4. At the Trailer Main Menu, click on Component Test, then Max RPM But B a A wo Bue select Sensor Orientation Test to display the Sensor YE1 Orientation Test screen. Figure 23. - OMB When the Sensor Orientation Test screen first appears, the Sensors Facing field will display the default YE2 Front. This 4 will occur regardless of the actual sensor orientation of the installation being tested. S !3 YE1 <7 YE2 <7 But <7 BU2 E J E E E <7 sign Order J Close 4005514a SP Figure 24 J sein outstation ism Warning Message: This test demands that the wheels be spun in a predetermined order and that the ECU mounting orientation is entered by the operator. It is applicable to the following TCS2 configurations only ICs 11 2S/1 M 400 2S/1M 400 2S/2M 400 2S/2M 400 4812M 400 1 500 500 500 500 500 NOTE: 2S/2M installations use YE1 and BU1 locations. Sensors Facing front Rear 2 Vas_ Click on 6. 101 0 104 0 102 0 103 0 103 0 r r - ml ¡YEi BU1 _ frE2 YeI Ye] BU2 A B S YE1 <7 BUt F-7 BU2 t7 r Front ( rgp ' 3 NMI NIB YE1 Bu1 Max RPM YE1 BU2 A B S YE2 BU1 Front or Rear in the Sensors Facing field to select 411111113 assembly. Figure 24. Order p- E r rrr- pr _ ÿ E2 C Rear Sensors But the mounting orientation of the ECU /dual modulator valve . I WWI __ 4005459a Refer to Figure 23 and Figure 24 for illustrations of the ECU Sensors Facing 2 Figure 23 I as shown on the diagram... 1 4005458a Click on 1 Order ......_oore 5. x r YE2 sign Intl Sensor orientation Test Spin tire number Max RPM <7 begin the test. Figure 25. -Sensor Orientation Test- - Sensors 1 Start to Figure 25 mounted with sensors facing forward and rear. The correct mounting orientation must be selected prior to starting the test (Step 5). TP -20214 (16579/22882) Printed in USA Revised 10 -05 Copyright ArvinMeritor, Inc., 2005 Page 17 PDF compression, OCR, web optimization using a watermarked evaluation copy of CVISION PDFCompressor 7. 4S /3M* sensed wheel end at a rate of 1/2 revolution per second. This Refer to the diagrams for specific sensor locations. rate equals a wheel speed of approximately 4 mph (7 kph). lift axle installations, you must use TOOLBOXTM Software, identification block on the screen for results. Sensor version 4.6 or higher, to enable the lift axle function. identification boxes are located in the bottom left portion of the Axle Function (4S /3M Installations) in the Appendix for Green background: Correct sensor location. Spin the next instructions. - sensed wheel as indicated by the screen prompt. If you get a red background, you must stop the test (click on stop), make the necessary corrections and repeat Steps 3 through 6. finish the Sensor Orientation Test, click on Stop, then on To Close. 9. a Connect curbside sensor at YE2. Connect roadside sensor at BU1. Connect roadside sensor at BU2. tone ring has been installed and that the sensor is necessary repairs and repeat the test. If 2S/2M - the problem persists, contact Meritor WABCO (800- 535 -5560). Sensor output appears in the Sensors field located in Modulator Valve Assembly Mounted with Sensors Facing Rear of Trailer pushed all the way in against the tone ring. Perform the the bottom right portion Connect curbside sensor at BU1. Connect roadside sensor at YE1. 4S/2M* of the Sensor Orientation Test screen. Figure 24. End of Line Testing without TOOLBOXTM Software Sensor Installation 1. Connect curbside sensor at YE1. ECU /Dual Verify there is sensor output. If there is no sensor output, verify that not automatically enabled. Refer to Enabling the Lift It is Sensor Orientation Test screen. Figure 24. Red background: Incorrect sensor location. Sensor locations vary by type of installation. For Enhanced Easy- StopTM 4S /3M As each sensed wheel is rotated, check the color of the sensor 8. - Follow the screen prompts, starting with 1, to rotate each Look at the sensor connectors on the ECU /dual modulator valve Connect curbside front sensor at BU1. Connect curbside rear sensor at BU2. Connect roadside front sensor at YE1. Connect roadside rear sensor at YE2. - assembly. Ensure that the connectors are routed to the correct 4S /3M* wheel-end location, as follows: Refer to the diagrams for specific sensor locations. ECU /Dual For Enhanced Easy- StopTM 4S /3M lift axle Modulator Valve Assembly Mounted with Sensors Facing Front of Trailer Sensor locations vary by type of installation. installations, you must use TOOLBOXTM Software, version 4.6 or higher, to enable the lift axle function. 2S /2M I - not automatically enabled. Refer to Enabling the Lift It is Axle Function (4S/3M Installations) in the Appendix for Connect curbside sensor at YE1. instructions. - Connect roadside sensor at BU1. 4S /2M* Connect curbside front sensor at YE1. Connect curbside rear sensor at YE2. Connect roadside front sensor at BU1. Connect roadside rear sensor at BU2. Connect curbside sensor at BU1. Connect curbside sensor at BU2. Connect roadside sensor at YE1. Connect roadside sensor at YE2. * If the lift axle is sensed in 4S /2M and 4S /3M installations: Sensors YE2 and BU2 must always be used on the lift axle to avoid an unwanted ABS indicator lamp illumination. 2. If sensors are not correctly installed, perform the necessary repairs. TP -20214 Revised 10 -05 Page 18 (16579/22882) Copyright ArvinMeritor, Inc., 2005 Printed in USA PDF compression, OCR, web optimization using a watermarked evaluation copy of CVISION PDFCompressor Air Line Installation ' ' 1. 2. 3. For 4S /3M installations: Repeat this test for the red valve. Ensure that all unused air ports are plugged and that the Red: The external relay valve designated RED (RD) is an axle exhaust port control valve. is facing DOWN. axles. It is Look at the air line installation to verify that all air lines are It controls the brake chambers on one or two important that delivery lines from Port plumbed 2 are as shown in Figure 17, Figure 18 and Figure 19. The correctly installed. 4S/3M system is designed to be used with a variety of trailer If the ECU /dual modulator valve assembly is mounted with configurations. Call ArvinMeritor's Customer Service Center at the sensors facing the FRONT of the trailer, the air lines for 800 -535 -5560 for additional information. the three delivery ports located under the YE sensor connectors must be routed to CURBSIDE; the air lines for 4. If the air lines are not correctly routed, perform the necessary repairs. the three delivery ports on the opposite side of the valve must be routed to roadside. Figure 26. If the ECU /dual modulator valve assembly is mounted with the sensors facing the REAR of the trailer, the air lines for the three delivery ports located under the YE sensor connectors must be routed to ROADSIDE; the air lines for the three delivery ports on the opposite side of the valve must be routed to curbside. Figure 27. Perform End of Line Test 1. Apply 12 volts DC power to the ABS. 2. Listen for the ECU /dual modulator valve assembly to click four times (six times for 3. If the indicator lamp comes on for three seconds then goes out, this indicates ` '] I[ó l! SENSORS FACING FRONT OFTRAILER YE1 If /i=I L O-O CURBSIDE the ABS indicator lamp comes on and stays on, check the BU1 - ROADSIDE BU2 `r/r ,1`=i'9''.,y_u Il YE DELIVERY correct installation. The end of line test is sensor installation. CURBSIDE ROADSIDE YE2 a complete. ECU /DUAL MODULATOR VALVE MOUNTED WITH CURBSIDE a 4S/3M). A. Remove the power from the ABS and raise the sensed wheels so they may be rotated. B. Apply emergency air to fill the air tanks and release the spring brakes so that the wheels may be rotated. PLUG ALL UNUSED PORTS C. Repeat Steps D. Rotate each sensed wheel 1 and 2. - one at a time - at a rate of 1/2 revolution per second. This rate equals a wheel BU DELIVERY ROADSIDE speed of approximately 4 mph (7 kph). 4003564a The ABS indicator lamp should now go out and stay out Figure 26 indicating a correct installation. The end of line test is complete. I^ ECU /DUAL MODULATOR VALVE MOUTED WITH SENSORS FACING REAR OFTRAILER ROADSIDE YE2 Cs YE DELIVERY ROADSIDE VA. i BU1 CURBSIDE BU2 .419 iV O GLlt,- L7 If the ABS lamp does not go out, there is a sensor gap problem or hardware fault. Adjust the sensor and, if necessary, perform a ROADSIDE CURBSIDE YE1 4. fault code check. Sensor Gap Adjustment Push the sensor into its holder until it contacts the tooth wheel. At installation, there must be no gap between the sensor and the tooth wheel. PLUG ALL UNUSED PORTS BU DELIVERY CURBSIDE 4003565a Measure the AC voltage output. The value should be 0.2 volt AC when the wheel is rotated at a rate of 1/2 revolution per second. Perform any necessary repairs. Repeat the end of line test. If the trailer lamp still does not go out, a system fault exists. Perform a fault code check. Figure 27 TP -20214 (16579/22882) Printed in USA Revised 10 -05 Copyright ArvinMeritor, Inc., 2005 Page 19 PDF compression, OCR, web optimization using a watermarked evaluation copy of CVISION PDFCompressor Fault Code Check Blink Code Chart Use constant power activation to perform the following fault Blink Code Problem Area Action 14 Verify correct electrical code check. 1. Power Supply Apply constant power to the ECU /dual modulator valve installation. assembly for more than one, but less than five seconds. Check power supply. 2. Remove the power. 3. Reapply the power. 4, Check the trailer ABS indicator lamp on the side of the trailer. Perform necessary repairs. 15 ECU Failure If code 16 Find the fault on the chart and perform the necessary repairs. 6. After performing the necessary repairs, repeat the end of continues, contact Meritor WABCO for assistance. The fault code will be displayed three times. 5. Verify correct installation. SAE J1708 Failure Internal failure, contact Meritor WABCO. 17 SAE J2497 Failure line test. Internal failure, contact Meritor WABCO. 18 Generic I/O Failure Blink Code Chart Verify correct electrical installation. Blink Code Problem Area Action 3 Sensor BU1 Determine sensor location. Check power supply. Perform necessary repairs. Check sensor installation. 4 Sensor YE1 Perform necessary repairs. Trailer Identification Determine sensor location. After ensuring the Enhanced Easy- StopTM trailer ABS has been Check sensor installation. correctly installed, attach the ABS indicator label included with the ECU Perform necessary repairs. 5 Sensor BU2 /single modulator valve assembly to the trailer. Generally, this will be applied near the ABS trailer indicator lamp. Figure 28. Refer Determine sensor location. to the vehicle specification sheet for the correct location. Check sensor installation. Perform necessary repairs. 6 Sensor YE2 NOTICE: Determine sensor location. If the ABS indicator lamp comes on and stays on when you apply the brakes to a moving vehicle, the trailer ABS is not working properly. The ABS must be serviced as soon as possible upon completion of your trip to ensure full anti -lock braking capability. Check sensor installation. Perform necessary repairs. 7 External ABS Verify correct electrical modulator valve installation. Check power supply. 7'P -95172 Perform necessary repairs. 9 10 11 Rev. 4/98 4005501a Internal modulator Verify correct installation. failure, inlet If valve #2 Meritor WABCO for assistance. NOTE: Internal modulator Verify correct installation. supervisor know. Labels are available from Meritor WABCO. Ask for failure, inlet If valve #1 Meritor WABCO for assistance. Internal modulator Verify correct installation. failure, outlet If code valve Meritor WABCO for assistance. Figure 28 code continues, contact If this label is not included with the assembly, let your part number TP- 95172. code continues, contact For additional assistance, contact Meritor WABCO at 800 -535 -5560. continues, contact TP -20214 Revised 10 -05 Page 20 (16579/22882) Copyright ArvinMeritor, Inc., 2005 Printed in USA PDF compression, OCR, web optimization using a watermarked evaluation copy of CVISION PDFCompressor Appendix Enabling the Lift Axle Function (4S /3M Installations) To InJnECU BeYV Comma Tests MaMy 1_4(iN IA I1yric.l 41 ` ECU Information enable the lift axle function, you will need a PC with TOOLBOXTM Software, version 4.6 or higher, installed. Refer to the TOOLBOXTM User's manual for complete operating instructions. This manual l 4U Type IT aller TCS II Configuration 14S Part Nimber (4465001030 /3M 04 Hai, 23/2D41 Serial Number 110027453 Software Revision ledcb I jtl Faaa- -0,MRAA' { -- Manulacture Date is posted on our website at meritorwabco.com. 1. _sow lat1eMbwurn rime. MSDleQ,elta mrv Display the Trailer ABS Main Screen. Click on Modify to SIOrM UI Sole Stalin Not Baia ' display the pull down menu. Figure A -1. I 2. Lift Axle, Click on 1 ÍIIIII I INemel default status and activate the lift axle function, To change the Cbcf9, s«ea I display the default lift axle status Not Active. Figure A -2. 3. q PVm The default lift axle screen will appear and Message Center: click on Change. The Litt Axle Status will change to Active. Figure A -3. ... 4. Click on Close to close the screen. Exit TOOLBOXTM. 5. Remove power from the vehicle; then reapply power. 6. Follow Steps 2 and 3 4005428a Figure Matt., wean inSet MS O.aqtwtin Data CuaarreelTeRS tally ,W 1, the lift axle function does not indicate active status, verify to receive a not active status message, contact the :I iala1 fi)411 Ì`'13,`' + ECU TOOLBOXTM version 4.6 or higher is installed. If you continue Morse/Ion ECU Type I Trailer TCS ¡ Disconnect TOOLBOXTM from the vehicle and proceed with Part Nu ()i Lift Axle Faults end of line testing as described in this bulletin. Lift Axle Status i_ Component Tests , Mealy 'OBI p¡~I (1#i .V44 Part Nurier Feuke Existing Stored TediMatio°n r t'r' II I Software Revision Voltages - Il lAclive I'y'rl J owe Secondary loll Service Miles io Internal 113.5 Revs/Mile 1502.0 L.,r . Message Center. R 2001 r 4465001030 Yes "'" War>tLOCatbn/OEM 4013M 23/2001 san.ae_ Primary q Notebook 'Trailer TCS Configuation Voltage Help Reconfigure ECU Information ECU Type .mJ0J Trailer ADS Diagnostics Cagey Manufactue Date Edstiig Stored Tracer ECU II Confgu.. for assistance. entreat WADLO al215-1I pboasECU active, as illustrated in Figure A -3. 7. A -2 to display the Lift Axle Status screen. Verify the lift axle status display indicates the lift axle function is If .-- 7453 ledcb Wheel Sensor Speed (RPM - YEt <7 BU1 <7 YE2 <7 BU2 <7 I I{ _____40054293 Figure A -3 Service Information Ilia Primary 113.5 Current Secondary 10.0 Service Mies Internal 113.5 Revs/Mie 0.0 10 502.0 Message Center: L r . 4005427a Figure A -1 TP -20214 (16579/22882) Printed in USA Copyright ArvinMeritor, Inc., 2005 Revised 10-05 Page 21 PDF compression, OCR, web optimization using a watermarked evaluation copy of CVISION PDFCompressor Installing Sensors on Non -ABS- Prepped Axles Sensor locations vary due to suspension type. Mentor WABCO recommends placing the sensor on the axle that will provide the most braking performance. Contact your suspension manufacturer for further information. 1. Apply a mineral oil -based grease that contains molydisulfide to the sensor spring clip, the body of the sensor and the bore of the sensor block. The grease must be anti -corrosive and contain adhesive properties that will continuously endure temperatures from 2. -40° to 300 °F ( -40° to 150 °C). Figure side, until the spring clip tabs are against the sensor holder. 5. Push the sensor into the spring clip as far as possible. Install the wheel hub carefully so that the tooth wheel pushes against the sensor as the wheel bearings are adjusted. There should be no gap between the sensor and the tooth wheel. Use Mentor WABCO spring clips to ensure a correct fit. 3. A -5 Push the spring clip into the sensor holder from the inboard Push the spring clip into the sensor holder from the inboard side until the spring clip tabs are against the sensor holder. 6. Test the sensor output voltage. Use a volt/ohm meter to check the output voltage of the sensors while rotating the wheel at approximately 1/2 revolution per second. Minimum output Push the sensor into the spring clip as far as possible. must be 0.2 volt AC. Figure A -4. If minimum output is less than 0.2 volt AC, push the sensor toward the tooth wheel. Recheck the sensor output. Figure 4. A -4 Route the sensor cable toward the brake chamber, over the brake spider or through the pre- stamped hole dedicated for ABS sensors. Route to the back side of the axle. Secure the cable to the axle between the brake spider and the suspension brackets. Continue to route the sensor cable behind the spring seats. Secure the cable to the axle one inch from the molded sensor plug. Figure A -5. Do not overtighten tie wraps on a cable. Overtightening can damage the cable. Do not tie wrap the molded sensor plug. The sensor extension cable must follow the brake hose to the ECU /valve assembly to allow for axle jounce and rebound. Brake hose clips with a provision for the sensor extension cable are recommended as opposed to tie wraps. Mentor WABCO does not supply this part. TP -20214 Revised 10 -05 Page 22 (16579/22882) Copyright ArvinMeritor, Inc., 2005 Printed in USA PDF compression, OCR, web optimization using a watermarked evaluation copy of CVISION PDFCompressor - 1~ 1 DR!VETRAIN PLUS" ¢,THE COMPLETE SYSTEM ArvinMeritor,. o MERITOR WABCO Mentor WABCO Vehicle Control Systems 2135 West Maple Road Troy, MI 48084 -7121 USA 800-535-5560 meritorwabco.com Information contained in this publication was in effect at the time the publication was approved for printing and is subject to change without notice or liability. Mentor WABCO reserves the right to revise the information presented or to discontinue the production of parts described at any time. Copyright 2005 ArvinMeritor, Inc. All Rights Reserved TP -20214 Revised 10 -05 Printed in USA (16579/22882) PDF compression, OCR, web optimization using a watermarked evaluation copy of CVISION PDFCompressor