ABS WABCO GUIA DE INSTALAÇÃO2

8/3/2019 ABS WABCO GUIA DE INSTALAO2

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TP-20214Issued 03-01

Installation Guide

TP-2021416579/ArvinMeritor Issued 03-0

Printed in the USA Copyright ArvinMeritor, Inc., 2001 Page

Enhanced Easy-StopTrailer ABS

2S/2M, 4S/2M and 4S/3MPremium with PLC

Installation Instructions

Differences Between Easy-Stopand Enhanced Easy-Stop

There are some changes to Enhanced Easy-Stopthat you need to be aware of before you begin theinstallation:

Enhanced Easy-Stop includes Power LineCommunication (PLC) function.

The ECU/dual modulator valve assembly mustbe mounted as one unit.

The LED on top of the ECU has been eliminated.

The blink code tool LED does not operatesimultaneously with the ABS lamp on thetrailer.

The valve portion of the ECU/dual modulator valveassembly contains two separate modulator valvesthat share common control and exhaust ports.

Each valve has its own delivery ports (3).Therefore, the mounting orientation whetherthe valve is facing the front or the rear of thetrailer determines sensor hookup.

If this assembly is mounted facing forward toward the front of the trailer the YE sensorconnections go to the curbside and the BU sensorconnections go to the roadside. If this assembly ismounted facing the rear, the YE sensorconnections go to the roadside, and the BU sensorconnections go to the curbside. Figure 1

.

All premium systems use the same ECU/dualmodulator valve assembly.

The ECU/dual modulator assembly cannot be usedas a 2S/1M system.

Figure 1

PLUG ALLUNUSEDPORTS

ECU/DUAL MODULATOR VALVE MOUNTED WITHSENSORS FACING REAR OF TRAILER

ECU/DUAL MODULATOR VALVE MOUNTED WITHSENSORS FACING FRONT OF TRAILER

PLUG ALLUNUSEDPORTS

DELIVERYROADSIDE

DELIVERYCURBSIDE

DELIVERYCURBSIDE

DELIVERYROADSIDE

SUPPLYPORT

SUPPLYPORT

EXHAUSTPORT

CONTROLPORT

EXHAUST

PORT

CURBSIDEYE2

CURBSIDEYE1

ROADSIDEYE2

ROADSIDEYE1

ROADSIDEBU2

ROADSIDEBU1

CURBSIDEBU2

CURBSIDEBU1

CONTROLPORT


2/24

TP-20214Issued 03-01 16579/ArvinMeritor

Page 2 Copyright ArvinMeritor, Inc., 2001 Printed in the USA

Preparation

1. Before beginning the installation procedure,inspect the ECU/dual modulator valveassembly for damage that may have occurredduring shipping or storage:

Look for crushed or bent connectors.

Make sure the retainer clips have not beenbent or otherwise damaged.

Do not install a damaged ECU/dualmodulator valve assembly. Notify yoursupervisor, or contact Meritor WABCO ifthere is any apparent damage.

2. Have installation material available:

*

ECU/dual modulator valve assembly

*

ABS relay valve and relay valve extensioncable with bayonet connector(3M systems)

*

Power cable or power/diagnostic cable

*

Sensor extension cables (two pcs. for 2Ssystems, four pcs. for 4S systems)

*

Sensors (2 or 4) for non-ABS prepped axles

*

ABS Indicator Label (TP-95172)

5/8-inch O.D. nylon tubing for supply (framemount)

Pipe plug (3/4-inch NPTF)

Schedule 80 pipe nipple (3/4-inch NPTF) for airtank mounts or two Grade 8 bolts (3/8-inch)and prevailing torque nuts for frame mounts

SAE-standard, DOT-approved thread sealant

To ensure proper lamp operation, use anincandescent-type DOT-approved lamp, or an

LED with integral load resistor.

* Meritor WABCO components

WARNING

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

The Anti-lock Braking System (ABS) is anelectrical system. When you work on the ABS,take the same precautions that you must takewith any electrical system to avoid seriouspersonal injury. As with any electrical system, thedanger of electrical shock or sparks exists that canignite flammable substances. You must alwaysdisconnect the battery ground cable beforeworking on the electrical system.

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.

NOTE: End of line testing must be done after allinstallations. Meritor WABCO recommends usingTOOLBOX Software to perform this testing. If youdo not have TOOLBOX Software, this bulletin alsoincludes instructions for testing without thesoftware.

Installation

I. Install the ECU/dual modulator valveassembly.

NOTE: Assembly may be mounted on the air tank,Figure 2

or on the cross member of the vehicle.Figure 3

.

Tank-Mounted

WARNING

You must use a Schedule 80 hex nipple (3/4-inchNPTF) to mount the ECU/dual modulator valve

assembly securely to the air tank to avoidpossible serious personal injury and damage tothe component.

1. Use a 3/4-inch Schedule 80 hex nipple toattach ECU/dual modulator valve assembly toa reinforced air tank. Do not overtighten.

NOTE: Meritor WABCO does not recommenduse of a vise when installing the hex nipple.Use of a vise may cause overclamping.Overclamping may damage the internalcomponents of the ECU/dual modulator valveassembly.

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

3. Rotate and tighten the ECU/dual 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. Figure 2

.


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Printed in the USA Copyright ArvinMeritor, Inc., 2001 Page 3

Mounted to Cross Member ofVehicle (Mounting BracketNot 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. Yoursupervisor should have a copy of thisspecification.

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 also beused.

2. Attach the assembly to vehicle cross membermidway between the side rails, closeto the brake chambers the valve serves.

Drill two 3/8-inch mounting holes. Distancebetween the two holes (O.D.) must be6.06-inches (154 mm) and mount directly tocross member.

OR

Build a mounting bracket with two 3/8-inchmounting holes with 6.06-inches(154 mm O.D.) between the two holes.

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

Figure 2



PLUG UNUSEDPORT

Exhaust portmust face DOWN.

CURBSIDEYE2

CURBSIDEYE1

ROADSIDEBU1

ROADSIDEBU2

CURBSIDEBU2

CURBSIDEBU1

ROADSIDEYE1

ROADSIDEYE2

Figure 3

FRONT OF

TRAILER


FRONT OFTRAILER



PLUG ALLUNUSED PORTS

PLUG ALLUNUSED PORTS


ROADSIDEYE1

CURBSIDEBU2CURBSIDE

BU1

ROADSIDEYE2

ROADSIDEBU1

CURBSIDEYE2 CURBSIDE

YE1

ROADSIDEBU2


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II. Attach the ABS external relay valve(4S/3M systems only).

Tank-Mounted

CAUTION

You must use Schedule 80 hex nipple (3/4-inchNPTF) to nipple-mount the ABS relay valve

securely to the air tank to avoid possible seriouspersonal injury and damage to components.

1. Use a 3/4-inch Schedule 80 hex nipple toattach relay valve assembly to a reinforced airtank. Do not overtighten.

NOTE: Meritor WABCO does not recommenduse of a vise when installing the hex nipple.Use of a vise may cause overclamping.Overclamping may damage the internalcomponents of the relay valve assembly.

2. Use a 3/4-inch pipe plug to plug unused

supply port. Apply SAE-standard,DOT-approved Teflon tape or paste-type threadsealant to all pipe threads beyond the first twothreads. Pipes with pre-applied thread sealantmay also be used.

3. Rotate and tighten the relay valve assemblyuntil the exhaust port faces down and theconnection is secure. Use a torque wrench orratchet with extension at the 3/4-inch pipe pluginstalled on the front supply port. Figure 4

.

Mounted to Cross Member ofVehicle (Mounting BracketNot Supplied)

NOTE: When mounting the relay valve assemblyto the trailer cross member, refer to SAEspecification J447, Prevention of Corrosion ofMotor Vehicle Body and Chassis Components

.Follow all recommendations and procedures. Your

supervisor should have a copy of thisspecification.

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 also beused.

III. Connect the air lines.

NOTE: Before connecting the air lines, plumb thespring brake relay or emergency brake relay intothe system as usual.

If bracket mounting, connect the air supply linefrom the supply tank to supply Port 1. Plugunused port.

Use 5/8-inch O.D. min. nylon tubing orheavy-walled Schedule 80 pipe nipple (3/4-inchNPTF) if mounting directly to the supply tank.

1. Connect the air delivery lines to the ECU/dual

modulator valve assembly Port 2. For 4S/3Minstallations, connect the air delivery lines toPort 2 on the external relay valve (3/8-inchNPTF).

2. Connect the air delivery lines to theappropriate brake chambers (3/8-inch NPT).Figures 5 and 6

.

NOTE: The valve portion of the ECU/dualmodulator valve assembly contains twoseparate valves; one dedicated to roadsidewheel ends, the other dedicated to curbsidewheel ends. Each valve has three delivery

ports.

NOTE: The external relay valve designatedRED (RD) is an axle control valve. It controlsbrake chambers on one or two axles. It isimportant that delivery lines from Port 2 areplumbed as shown on the installationdrawings. Figures 13,

14

and

15

.

Figure 4

Exhaustport must

face DOWN.

PLUGUNUSEDPORTS

ABS EXTERNAL RELAY VALVE

CONTROLPORT 4

SUPPLYPORT 1


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3. Connect the brake service (control) line to theECU/dual modulator valve assembly Port 4(1/4-inch NPTF).

4.

For 4S/3M installations:

Connect the brakeservice (control) line to the ECU/dualmodulator valve assembly Port 4(1/4-inch NPTF) and ABS external relay valvecontrol Port 4 (3/8-inch NPTF).

5.

For 4S/3M installations:

Use an ABS relay

valve connection cable to connect theECU/dual modulator valve assembly with theABS external relay valve.

6. Plug any unused delivery ports.

IV. Install the sensor extension cables.

NOTE: Meritor WABCO recommends placingsensors on the axle that will provide the mostbraking performance. The suspensionmanufacturer can provide this information.

1. Visually inspect the tooth wheel and sensor toensure there was no damage during shipping.Make necessary repairs.

2. Connect sensor and cables on the preppedaxles to the sensor extension cables.Figure 7

.

Make sure each connection is secure.

3. Route sensor cable along back side of thetrailer axle to the ECU/dual modulator valveassembly. Route with brake hose.

NOTE: Do not overtighten tie wraps on acable. Overtightening can damage the cable.Do not tie wrap the molded sensor plug.Sensor extension cable must follow brake

hose to ECU/dual modulator valve assembly toallow for axle jounce and rebound.

4. Secure every eight inches with tie wraps orcable clips.

5. Push sensor retainer clip on ECU/dualmodulator valve assembly UP.

6. Remove protective caps from YE2 and YE1sensor connectors.

Figure 5

Figure 6

SERVICE/CONTROL LINESSERVICE BRAKESUPPLY AIRSPRING BRAKE AIR

TYPICAL 2M INSTALLATION VALVE MOUNTEDWITH SENSORS FACING FRONT OF TRAILER

SERVICE/CONTROL LINESSERVICE BRAKESUPPLY AIRSPRING BRAKE AIR

TYPICAL 2M INSTALLATION VALVE MOUNTEDWITH SENSORS FACING REAR OF TRAILER

Figure 7

SENSOREXTENSIONCABLE

SENSORAND CABLE


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7. Plug sensor extension cables into ECU/dualmodulator valve assembly. To secureconnection, push sensor retainer clip DOWN.Retainer clips must fit in groove of sensorconnectors to ensure proper connection.Connect sensors.

ECU/Dual Modulator Valve AssemblyMounted with Sensors Facing Front of Trailer

2S/2M

Connect curbside sensor at YE1.

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.

*

4S/3M Sensor locations vary by type ofinstallation. See diagrams on the followingpages for specific sensor locations.





ECU/Dual Modulator Valve AssemblyMounted with 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 Sensor locations vary by type ofinstallation. See diagrams for specificsensor locations.





*

If the lift axle is sensed in 4S/2M and 4S/3M

installations:

Sensors YE2 and BU2 must always beused on the lift axle to avoid an unwanted ABSindicator lamp illumination.

8. Bundle any excess cable in loop (bow tie) asillustrated. Figure 8

.

9. Secure excess cable in sub-frame of vehicle oralong air hoses as appropriate. Excess cableshould not exceed two feet.

NOTE: Various cable lengths are available.

V. Install the power and lamp or powerand lamp/diagnostic cable.

1. Identify the type of cable to be installed.

Figure 9

.

ABS trailer industry-standard pigtailconnector power cable

Blunt-cut power cable (not shown)

2. For industry-standard pigtail connector powercables, route cable from harness connector toECU/dual modulator valve assembly andsecure to prevent damage.

For blunt-cut power cable, route the cable

from the ECU/dual modulator valve assemblyto a junction box which interfaces with theseven-way connector at the front of the trailer.

NOTE: Leave enough slack in cable tocompensate for flexing of trailer andsub-frame.

Figure 8

Figure 9

BUNDLEEXCESSCABLE

POWER CABLE

POWER/DIAGNOSTIC CABLE


7/24



3. Bundle any excess cable in loop (bow tie) andsecure in sub-frame of trailer body to preventcable damage.

4. Push the hinged power/diagnostic connectorretainer clip UP and remove the protective capfrom the ECU/dual modulator valve assembly.Figure 10

.

5. Plug the power 8-pin connector on the poweror power/diagnostic cable into the ECU/dualmodulator valve assembly.

6. Pull the hinged power/diagnostic connectorretainer clip on ECU/dual modulator valveassembly DOWN to secure connection.

7. If installing the power cable only, go to Step 9.

8. If installing the power/diagnostic Y cable:

A. Install the diagnostic cable bracket so thatthe diagnostic plug is accessible. Normallocation is on the right front corner of thesub-frame, but will vary depending on thetype of trailer.

B. Route the diagnostic cable from theECU/dual modulator valve assembly to thediagnostic cable bracket.

C. Properly secure the cable in the sub-frameto prevent cable damage.

NOTE: Leave enough slack in the cable tocompensate for flexing of the trailer andsub-frame.

D. Bundle excess cable in loop (bow tie) andsecure the cable in the sub-frame.

Figure 8

.

Figure 10

KEYED CABLECONNECTOR

MATING

TRAILERHARNESS

CONNECTOR

CAP


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9. Install the ABS indicator lamp on the trailer.Refer to the vehicle specification sheet forexact location of indicator lamp. Use aDOT-approved lamp with ABS etched on thelens (available from major trailer partssuppliers).

To ensure proper lamp operation, use anincandescent-type DOT-approved lamp or anLED with integral load resistor.

NOTE: If you are using the industry-standardconnector cable and do not have access to themating trailer harness, mask the openconnector to protect it from paint or grease.

10. Connect power. Use the industry-standardconnector cable or a blunt-cut power cable.

Industry-standard connector cable:

Attachpower cable to harness on trailer. Figure 10

.

Optional blunt-cut power cable: Wire the cableand ABS indicator lamp to the seven-wayconnector on the trailer per the following

diagram. Figure 11.

Figure 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.


9/24



Typical Easy-Stop Trailer ABS installations are illustrated below:

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

Figure 12

NOTE: Spring brakelines not shown.

SERVICE/CONTROL LINES

SENSOR CABLES

SERVICE BRAKE

SUPPLY AIR

NOTE: Spring brake

lines not shown.

YE1

BU1

2S/2M VALVE MOUNTED WITH SENSORS

FACING FRONT OF TRAILER

FRONT OFTRAILER

BU1

YE1

2S/2M VALVE MOUNTED WITH SENSORS

FACING REAR OF TRAILER

FRONT OFTRAILER

BU1

YE1

YE2

BU2

YE1

BU1

BU2

YE2


10/24



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

Figure 13

Typical Tandem Axle Trailer

YE1

BU1

BU2

YE1

YE2

BU2

BU1

YE2

Typical Tandem Axle Trailer



SENSOR CABLES

SERVICE BRAKE

SUPPLY AIR


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

FRONT OFTRAILER

FRONT OFTRAILER

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

BU1

YE1

YE2

BU2

YE1

BU1

BU2

YE2


11/24



Figure 14

YE1

BU1

YE2

BU2

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

FRONT OFTRAILER

BU1

YE1

BU2

YE2

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

FRONT OFTRAILER

BU1

YE1

YE2

BU2

YE1

BU1

BU2

YE2



SENSOR CABLES

SERVICE BRAKE

SUPPLY AIR



12/24



Figure 15

4S/2M TYPICAL AXLE CONTROL INSTALLATION VALVE MOUNTED

WITH SENSORS FACING FRONT OF TRAILER

BU1 YE1

BU2 YE2

FRONT

FRONT

BU1 YE1

BU2 YE2

4S/2M TYPICAL AXLE CONTROL INSTALLATION VALVE MOUNTED

WITH SENSORS FACING REAR OF TRAILER

BU1

YE1

YE2

BU2

YE1

BU1

BU2

YE2



SENSOR CABLES

SERVICE BRAKE

SUPPLY AIR



13/24



Figure 16

YE2

BU2

YE1

BU1

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


FRONT OFTRAILER

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


BU2

YE2

BU1

YE1

FRONT OFTRAILER

BU1

YE1

YE2

BU2

YE1

BU1

BU2

YE2NOTE: Spring brake

lines not shown.


SENSOR CABLES

SERVICE BRAKE

SUPPLY AIR



14/24



Figure 17

Typical TandemAxle Trailer

YE2

BU2

YE1

BU1

4S/3M TYPICAL TRI-AXLE VALVE MOUNTED WITH SENSORS FACING FRONT OF TRAILER

FRONT OFTRAILER

Typical TandemAxle Trailer

BU2

YE2

BU1

YE1

4S/3M TYPICAL TRI-AXLE VALVE MOUNTED WITH SENSORS FACING REAR OF TRAILER

FRONT OFTRAILER

BU1

YE1

YE2

BU2

YE1

BU1

BU2

YE2



SENSOR CABLES

SERVICE BRAKE

SUPPLY AIR



15/24



Figure 18

BU2

YE2

BU1

YE1

YE2

BU2

YE1

BU1

FRONT OFTRAILER

4S/3M TYPICAL FOUR AXLE PULL TRAILER VALVE MOUNTED


4S/3M TYPICAL FOUR AXLE PULL TRAILER VALVE MOUNTED


FRONT OFTRAILER

BU1

YE1

YE2

BU2

YE1

BU1

BU2

YE2



SENSOR CABLES

SERVICE BRAKE

SUPPLY AIR



16/24



End of Line Testing

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

TOOLBOX Software and general test proceduresare included in this bulletin. If you are using aPro-Link, refer to the operating manual for testinstructions.

Enhanced Easy-Stop 2S/2M, 4S/2Mand 4S/3M Premium Installation End of Line Testing Procedure withTOOLBOX Software

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

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 propervoltage (9.5 to 14 volts). Constant powervoltage is displayed in the Primary field.Figure 19.

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 19.

NOTE: The internal field is not applicable tothis test.

4. Check the Faults field on the Main Screen:

NONE = No faults present, proceed with endof line test.

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

Use the information in the Repair Instructionsfieldto make the necessary repairs. Figure 20.

Figure 19

Figure 20


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End of Line Test with TOOLBOX Software

Verify Proper Valve and Lamp Installation

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 airtanks 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 21.

5. Click on the Activate button.

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 dualmodulator valve cycles. If this does not

happen, 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 plumbed asshown on the installation drawings. (Refer toFigures 10 through 17) The 4S/3M system isdesigned to be used with a variety of trailerconfigurations. Call ArvinMeritors Customer

Service Center at 800-535-5560 for additionalinformation.

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 thebottom of the menu will display the status ofthis test. Figure 21.

10. Click on Closeto exit.

Sensor Installation Test

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 21


18/24



7. Check the screen for sensor output. Figure 22.

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

NOTE: 2S/2M installations utilize YE1 and BU1locations.

If there is no sensor output, verify that atone 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 22.

End of Line Testing without

TOOLBOX Software

Inspect the Sensor and Air LineInstallation.

Sensor Installation

1. Look at the sensor connectors on the ECU/dualmodulator valve assembly. Make sure theconnectors are routed to the proper wheel endlocation, as follows:

ECU/Dual Modulator Valve Assembly

Mounted with Sensors Facing Front of Trailer

2S/2M



* 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.

* 4S/3M Sensor locations vary by type ofinstallation. See diagrams for specificsensor locations.

Connect curbside sensor at YE1. Connect curbside sensor at YE2.



ECU/Dual Modulator Valve AssemblyMounted with Sensors Facing Rear of Trailer

2S/2M



* 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 Sensor locations vary by type ofinstallation. See diagrams for specificsensor locations.





* If the lift axle is sensed in 4S/2M and 4S/3Minstallations: Sensors YE2 and BU2 must always beused on the lift axle to avoid an unwanted ABSindicator lamp illumination.

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

Figure 22


19/24



Air Line Installation

1. Make sure all unused air ports are pluggedand that the exhaust port is facing DOWN.

2. Look at the air line installation to make sure allair 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 YE sensor connectorsmust be routed to curbside; the air lines forthe three delivery ports on the opposite sideof the valve must be routed to roadside. Referto Figure 23 on the next page.

If the ECU/dual modulator valve assembly ismounted with the sensors facing the rear ofthe trailer, the air lines for the three deliveryports located under the YE sensor connectorsmust be routed to roadside; the air lines forthe three delivery ports on the opposite sideof the valve must be routed to curbside. Referto Figure 24 on the next page.

3. 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 plumbed asshown on the installation drawings. (Refer toFigures 16,17and18.) The 4S/3M system isdesigned to be used with a variety of trailerconfigurations. Call ArvinMeritors CustomerService Center at 800-535-5560 for additionalinformation.

4. If air lines are not properly routed, make the

necessary repairs.

Perform End of Line Test

1. Apply 12 volts DC power to the ABS.

2. The ECU/dual modulator valve assemblyshould click four times (six times for a 4S/3M).

3. If the indicator lamp comes on forthree seconds then goes out, this indicates aproper installation. The end of line test iscomplete.

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

A. Remove the power from the ABS and raisethe sensed wheels so they may be rotated.

B. Apply emergency air to fill the air tanksand release the spring brakes so that the

wheels may be rotated.

C. Repeat Step 1 and Step 2.

D. Rotate each sensed wheel one at atime at a rate of 1/2 revolution persecond. This rate equals a wheel speed ofapproximately 4 mph (7 kph).

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 a

sensor gap problem or hardware fault. Adjustthe sensor and, if necessary, perform a faultcode check.

Figure 23

BUDELIVERYROADSIDE

YEDELIVERYCURBSIDE

PLUG ALLUNUSEDPORTS


CURBSIDEYE2

CURBSIDEYE1

ROADSIDEBU2

ROADSIDEBU1

Figure 24

BUDELIVERYCURBSIDE

YEDELIVERY

ROADSIDE

ECU/DUAL MODULATOR VALVE MOUTED WITHSENSORS FACING REAR OF TRAILER

PLUG ALLUNUSEDPORTS

ROADSIDEYE2

ROADSIDEYE1

CURBSIDEBU2

CURBSIDEBU1


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Installing Sensors onNon-ABS-Prepped Axles

NOTE: Sensor locations vary due to suspensiontype. Typically, a spring suspension has sensorson the forward axle and an air suspension hassensors on the rear axle. Contact your suspensionmanufacturer for further information.

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.

NOTE: Use Meritor WABCO spring clips toensure proper fit.

3. 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 25.

4. Route the sensor cable toward the brakechamber, over the brake spider, on the backside of the axle. Secure the cable to the axlebetween the brake spider and the suspensionbrackets. Continue to route the sensor cablebehind the spring seats. Secure the cable tothe axle one inch from the molded sensorplug. Figure 26.

NOTE: Do not overtighten tie wraps on acable. Overtightening can damage the cable.Do not tie wrap the molded sensor plug.Sensor extension cable must follow brakehose to ECU/valve assembly to allow for axlejounce and rebound.

5. Install the wheel hub carefully so that thetooth wheel pushes against the sensor as thewheel bearings are adjusted. There should beno gap between the sensor and the toothwheel.

6. Sensor Output Voltage Test: Use a volt/ohmmeter to check the output voltage of the

sensors while rotating the wheel atapproximately one-half revolution per second.Minimum output must be 0.2 volts AC. Ifminimum output is less than 0.2 volts AC,push the sensor toward the tooth wheel.Recheck sensor output.

Figure 25

SPRINGCLIP TAB

SENSOR

SPRINGCLIP

SENSORHOLDER

Figure 26

SENSORCABLE

1"


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Meritor WABCO

Vehicle Control Systems3331 West Big Beaver Road, Suite 300Troy, MI 48084 USA800-535-5560

Information contained in this publication was in effect at the time the publication was approved forprinting and is subject to change without notice or liability. ArvinMeritor Commercial Vehicle Systemsreserves the right to revise the information presented or discontinue the production of parts described atany time.

ABS WABCO GUIA DE INSTALAÇÃO2

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