TP-20213

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TP-20213 | Manualzz

TP-20213

Revised 11-15

Enhanced Easy-Stop™ Trailer

ABS 2S/2M Standard with PLC

Installation Instructions

Installation Guide

Hazard Alert Messages

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,

Service and Product Information

Refer to Maintenance Manual MM-0180, Enhanced Easy-Stop™

Trailer ABS with PLC; Maintenance Manual 33, Easy-Stop™ Trailer

ABS; and Parts Book PB-96133, Enhanced Easy-Stop™ with PLC and Easy-Stop™ Trailer ABS. To obtain these publications, or for more information about the Meritor WABCO product line, contact the

Meritor OnTrac™ Customer Call Center at 866-OnTrac1

(668-7221) or visit our website: meritorwabco.com

Important Information

Use only genuine Meritor WABCO components. Other manufacturers’ parts are not designed for use with a Meritor

WABCO ABS system and may not function correctly.

Meritor WABCO recommends that a control line filter, part number

432-500-005-0, be installed on the air system’s control line, upstream of the ABS ECU/valve assembly.

Orientation Information

The valve portion of the ECU/dual modulator valve assembly contains two separate modulator valves that share common control and exhaust ports.

Each valve has its own delivery port (three). Therefore, the mounting orientation — whether the valve is facing the front or the rear of the trailer — determines sensor hookup.

If this assembly is mounted facing forward — toward the front of the trailer — sensor connection YE2 goes to the curbside and sensor connection YE1 goes to the roadside. If this assembly is mounted facing the rear, sensor connection YE2 goes to the roadside, and YE1 goes to the curbside. Figure 1.

Figure 1

VALVE MOUNTED WITH SENSORS FACING

FRONT OF TRAILER

CURBSIDE

YE2

ROADSIDE

YE1

CONTROL

PORT

SUPPLY

PORT

YE2

DELIVERY

CURBSIDE

EXHAUST

PORT

PLUG ALL

UNUSED

PORTS

YE1

DELIVERY

ROADSIDE

VALVE MOUNTED WITH SENSORS FACING

REAR OF TRAILER

ROADSIDE

YE2

CURBSIDE

YE1

CONTROL

PORT

SUPPLY

PORT

YE2

DELIVERY

ROADSIDE

EXHAUST

PORT

Figure 1

PLUG ALL

UNUSED

PORTS

YE1

DELIVERY

CURBSIDE

4005503a

Preparation

WARNING

To prevent serious eye injury, always wear safe eye protection 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 substances. You must always disconnect the battery ground cable before working on the electrical system.

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.

1.

Before beginning the installation procedure, inspect the ECU/ dual modulator valve assembly for damage that may have occurred during shipping or storage.

앫 Look for crushed or bent connectors.

앫 Verify that the retainer clips have not been bent or otherwise damaged.

앫 Do not install a damaged ECU/dual modulator valve assembly. Notify your supervisor, or contact Meritor WABCO if there is any apparent damage.

2.

Have the following installation material available.

* ECU/dual modulator valve assembly

* Power cable or power/diagnostic cable

* Sensor extension cables (two pieces)

* Sensors (two) for non-ABS-prepped axles

* ABS Indicator Label (TP-95172)

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 nuts for frame mounts

SAE-standard, DOT-approved thread sealant

To ensure correct lamp operation, use an incandescent-type

DOT-approved lamp, or an LED with integral load resistor.

* Meritor WABCO components

End of line testing must be done after all installations. Meritor

WABCO recommends using TOOLBOX™ Software to perform this testing. If you do not have TOOLBOX™ Software, this bulletin also includes instructions for testing without the software.

Installation

I. Install the ECU/dual modulator valve assembly.

The assembly may be mounted on the air tank or on the cross member of the vehicle.

Tank-Mounted

Refer to Figure 2.

Figure 2

VALVE MOUNTED TO AN AIR TANK

WITH SENSORS FACING FRONT OF TRAILER

CURBSIDE

YE2

ROADSIDE

YE1

VALVE MOUNTED TO AN AIR TANK

WITH SENSORS FACING REAR OF TRAILER

PLUG UNUSED

PORT

Figure 2

CURBSIDE

YE1

ROADSIDE

YE2

Exhaust port must face DOWN.

4005504a

TP-20213

Revised 11-15

Page 2 Copyright Meritor, Inc., 2015

(16579)

Printed in USA

WARNING

You must use a Schedule 80 hex nipple (3/4-inch NPTF) to mount the ECU/dual modulator valve assembly securely to the air tank to avoid possible serious personal injury and damage to the component.

1.

Use a 3/4-inch NPTF Schedule 80 hex nipple to attach the

ECU/dual modulator valve assembly to a reinforced air tank. Do not overtighten.

Meritor WABCO does not recommend the use of a vise when installing the hex nipple. Use of a vise may cause overclamping. Overclamping may damage the internal components of the ECU/dual modulator valve assembly.

2.

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.

3.

Rotate and tighten the ECU/dual modulator valve assembly until the exhaust port faces DOWN and the connection is secure. Use a torque wrench or ratchet with an extension at the

3/4-inch pipe plug installed on the front supply port.

Mounted to Cross Member of Vehicle (Mounting

Bracket Not Supplied)

Refer to Figure 3.

Figure 3

VALVE MOUNTED TO A CROSS MEMBER OF THE

VEHICLE WITH SENSORS FACING FRONT OF TRAILER

Exhaust port must face DOWN.

PLUG ALL

UNUSED PORTS

ROADSIDE

YE1

FRONT OF

TRAILER

CURBSIDE

YE2

VALVE MOUNTED TO A CROSS MEMBER OF THE

VEHICLE WITH SENSORS FACING REAR OF TRAILER

Exhaust port must face DOWN.

ROADSIDE

YE2

PLUG ALL

UNUSED PORTS

CURBSIDE

YE1

FRONT OF

TRAILER

4005505b

When mounting the ECU/dual modulator valve assembly to the trailer cross member, refer to SAE specification J447, Prevention of

Corrosion of 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 two threads.

Pipes with pre-applied thread sealant may also be used.

2.

Attach the assembly to the vehicle cross member midway between the side rails, close to the brake chambers the valve serves.

앫 Drill two 3/8-inch mounting holes. The distance between the two holes (O.D.) must be 6.06-inches (154 mm) and mount directly to the cross member.

OR

앫 Build a mounting bracket with two 3/8-inch mounting holes spaced 6.06-inches (154 mm) O.D. apart.

CAUTION

Place a thin barrier of plastic, mylar or similar material between the bracket and mounting surface. The barrier is necessary to inhibit corrosion, which can occur from contact between dissimilar metals. Galvanic corrosion can result in damage to the ECU/modulator assembly.

3.

Place a thin barrier made of plastic, mylar or similar material between the bracket and mounting surface to inhibit corrosion.

4.

Use two 3/8-inch Grade 8 bolts with prevailing torque nuts to attach the assembly. Tighten the bolts to 18 lb-ft (24 N

폷m). @

II. Connect the air lines.

1.

Connect the air supply line from the supply tank to ECU/dual modulator valve assembly supply Port 1. Plug the unused port.

Use 5/8-inch O.D. min. nylon tubing or heavy-walled Schedule

80 pipe nipple (3/4-inch NPTF) if the ECU/dual modulator valve assembly is mounted directly to the supply tank.

2.

Connect the air delivery lines to the ECU/dual modulator valve assembly Port 2 (3/8-inch NPTF).

3.

Connect the air delivery lines to the appropriate brake chambers (3/8-inch NPTF). Figure 4 and Figure 5.

The valve portion of this assembly contains two separate valves; one dedicated to roadside wheel ends, the other dedicated to curbside wheel ends. This is illustrated in

Figure 1.

Figure 3

(16579)

Printed in USA Copyright Meritor, Inc., 2015

TP-20213

Revised 11-15

Page 3

Figure 4

VALVE MOUNTED WITH SENSORS FACING

FRONT OF TRAILER

1.

Visually inspect the tooth wheel and sensor to ensure no damage occurred during shipping. Perform any necessary repairs.

2.

Connect the sensors and cables on the prepped axles to the sensor extension cables. Figure 6.

Ensure that each connection is secure.

Figure 6

SERVICE/CONTROL LINES

SERVICE BRAKE

SUPPLY AIR

SPRING BRAKE AIR

4005506a

Figure 5

Figure 4

VALVE MOUNTED WITH SENSORS FACING

REAR OF TRAILER

SENSOR

EXTENSION

CABLE

SENSOR

AND CABLE

SERVICE/CONTROL LINES

SERVICE BRAKE

SUPPLY AIR

SPRING BRAKE AIR

4005507a

Figure 5

4.

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

5.

Plug any unused delivery ports.

III. Install the two sensor extension cables.

Meritor WABCO recommends placing sensors on the axle that will provide the most braking performance. The suspension manufacturer can provide this information.

4003567b

Figure 6

3.

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. Figure 6.

Do not overtighten the 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/dual modulator valve assembly to allow for axle jounce and rebound.

4.

Secure the cables every eight inches (203 mm) with tie wraps or cable clips.

5.

Push the sensor retainer clip on the ECU/dual modulator valve assembly UP.

6.

Remove the protective caps from the YE2 and YE1 sensor connectors.

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 sensor connectors to ensure correct connection.

앫 Forward Mounted (Sensors facing front of trailer)

— Connect curbside sensor at YE2.

— Connect roadside sensor at YE1.

TP-20213

Revised 11-15

Page 4 Copyright Meritor, Inc., 2015

(16579)

Printed in USA

앫 Rear Mounted (Sensors facing rear of trailer)

— Connect curbside sensor at YE1.

— Connect roadside sensor at YE2.

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 air hose as close to the fitting as possible. Figure 7.

Figure 7

PORT 4

PORT 1

IV. Install the power and lamp or power and lamp/diagnostic cable.

1.

Identify the type of cable to be installed. Figure 9.

앫 ABS trailer industry-standard pigtail connector power cable

앫 Blunt-cut power cable (not shown)

Figure 9

POWER CABLE

PORT 2 (6)

PORT 4

Attach individual sensor cables to corresponding brake air delivery hoses.

4005456a

Figure 7

9.

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

Figure 8

BUNDLE

EXCESS

CABLE

POWER/DIAGNOSTIC CABLE

4003568a

Figure 9

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.

For a blunt-cut power cable, 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.

Leave enough slack in the cable to compensate for flexing of the trailer and sub-frame.

3.

Bundle any excess cable in a “Z”-shaped loop and secure it in the sub-frame of the trailer body to prevent cable damage.

4.

Push the hinged power/diagnostic connector retainer clip UP and remove the protective cap from the ECU/dual modulator valve assembly. Figure 10.

Figure 10

CAP

4003553a

Figure 8

10. Secure excess cable in the sub-frame of the vehicle or along the air hoses as appropriate. Excess cable should not exceed two feet (0.61 meter).

Various cable lengths are available.

NOTE: Correct strain relief guidelines are described in

Appendix II.

(16579)

Printed in USA

MATING

TRAILER

HARNESS

CONNECTOR

Figure 10

Copyright Meritor, Inc., 2015

Lettering on cable connection must face

DOWN.

4003569b

TP-20213

Revised 11-15

Page 5

5.

Plug the power 8-pin connector on the power or power/ diagnostic cable into the ECU/dual modulator valve assembly.

WABCO identification on the cable connection must face

DOWN. Figure 10.

6.

Pull the hinged power/diagnostic connector retainer clip on the

ECU/dual modulator valve assembly DOWN to secure the connection.

7.

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

8.

If you are installing the power/diagnostic “Y” cable:

A.

Install the diagnostic cable bracket so that the diagnostic plug is accessible. The normal location is on the right front corner of the sub-frame, but will vary depending on the type of trailer.

B.

Route the diagnostic cable from the ECU/dual modulator valve assembly to the diagnostic cable bracket.

C.

Correctly secure the cable in the sub-frame to prevent cable damage.

Leave enough slack in the cable to compensate for flexing of the trailer and sub-frame.

D.

Bundle any excess cable in a loop (bow tie) and secure the cable in the sub-frame. Figure 8.

Figure 11

4 OR 5 WIRE

SCHEMATIC

GROUND

9.

Install the ABS indicator lamp on the trailer. Refer to the vehicle specification sheet for the exact location of the indicator lamp.

Use a DOT-approved lamp with ABS etched on the lens

(available from major trailer parts suppliers).

If you are using the industry-standard connector cable and do not have access to the mating trailer harness, mask the open connector to protect it from paint or grease.

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

For industry-standard connector cables: Attach the power cable’s round Weather Pack connector to the ABS break-out on the trailer power harness. Figure 10.

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 11.

7 WAY

BLK

YEL

WHT

BRN

BLU

RED

GRN

GENERIC INPUT/OUTPUT (EXPANDED CAPABILITY)

WHITE AND YELLOW

WHITE

(GROUND)

BLUE

(CONSTANT POWER)

RED

(STOP LAMP)

GREEN AND WHITE

TRAILER ABS

INDICATOR LAMP

Junction box not shown.

Figure 11

ECU POWER CONNECTOR

4003570b

TP-20213

Revised 11-15

Page 6 Copyright Meritor, Inc., 2015

(16579)

Printed in USA

Typical Easy-Stop™ Trailer ABS Installations

Refer to Figure 12 and Figure 13 for typical Easy-Stop™ trailer ABS installations.

Meritor WABCO recommends placing sensors on the axle that will provide the most braking performance. The suspension manufacturer can provide this information.

Figure 12

VALVE MOUNTED WITH SENSORS FACING FRONT OF TRAILER

FRONT OF

TRAILER

YE2

YE2

YE1

Typical Tandem Axle Trailer

Spring Suspension Installation with Sensors on Front Axle

YE1

YE2

FRONT OF

TRAILER

Typical Tandem Axle Trailer

Air Suspension Installation with Sensors on Rear Axles

Figure 12

(16579)

Printed in USA

SERVICE/CONTROL LINES

SENSOR CABLES

SERVICE BRAKE

SUPPLY AIR

SPRING BRAKE AIR

Copyright Meritor, Inc., 2015

YE1

YE2

YE1

4005508a

TP-20213

Revised 11-15

Page 7

Meritor WABCO recommends placing sensors on the axle that will provide the most braking performance. The suspension manufacturer can provide this information.

Figure 13

VALVE MOUNTED WITH SENSORS FACING REAR OF TRAILER

FRONT OF

TRAILER

YE1

YE1 Typical Tandem Axle Trailer

Spring Suspension Installation with Sensors on Front Axle

YE2

YE2

YE1

FRONT OF

TRAILER

Typical Tandem Axle Trailer

Air Suspension Installation with Sensors on Rear Axles

Figure 13

TP-20213

Revised 11-15

Page 8

SERVICE/CONTROL LINES

SENSOR CABLES

SERVICE BRAKE

SUPPLY AIR

SPRING BRAKE AIR

YE2

Copyright Meritor, Inc., 2015

YE1

YE2

4005509a

(16579)

Printed in USA

End of Line Testing

End of line testing is required on all Enhanced Easy-Stop™ installations. To run these tests, Meritor WABCO recommends you use TOOLBOX™ Software.

TOOLBOX™ Software and general test procedures are included in this bulletin. If you are using a Pro-Link, refer to the operating manual for test instructions.

Enhanced Easy-Stop™ 2S/2M Standard

Installation — End of Line Testing Procedure with TOOLBOX™ Software

If you are testing an installation that has a power only cable, temporarily install a Meritor WABCO combination power/diagnostics

“Y” style cable.

1.

Connect the diagnostic connector on the cable to the PC serial port/SAE diagnostic interface (J1587/J1708 to RS232 interface).

Refer to the Software Owner’s Manual, TP-99102, for instructions for running TOOLBOX™ Software.

2.

Display the Trailer ABS Main Screen.

3.

Verify the power supply.

앫 Apply 12 volts DC to the blue wire (constant). Check the screen for the correct voltage (9.4 to 14 volts). Constant power voltage is displayed in the Primary field. Figure 14.

앫 Apply 12 volts DC to the red wire (stoplight power). Check the screen for the correct voltage (9.4 to 14 volts). Stoplight power voltage is displayed in the Secondary field.

Figure 14.

The Internal field is not applicable to this test.

Figure 14

4003560a

Figure 14

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 “YES” to bring up the fault information screen. Figure 15.

Use the information in the Repair Instructions field to perform the necessary repairs.

Figure 15

(16579)

Printed in USA

4003561a

Figure 15

End of Line Test with TOOLBOX™ Software

Verify Correct Valve and Lamp Installation

To verify valve and lamp installations with TOOLBOX™ Software:

1.

Apply 12 volts DC to the ABS.

Copyright Meritor, Inc., 2015

TP-20213

Revised 11-15

Page 9

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 Component Test, then select Valves/Lamp to display the Valve Activation Screen.

The Yellow valve indicator will be highlighted. Figure 16.

Figure 16

4003562b

Figure 16

5.

Click on the Activate button.

6.

Check for correct air line installation. To accomplish this, observe the slack adjusters.

앫 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.

앫 If the ECU faces the REAR of the trailer, the slack adjusters will move in and out as the ROADSIDE portion of the dual modulator valve cycles. 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.

7.

Repeat this test for the Blue valve.

A.

Repeat Steps 1-3.

B.

Select the Blue valve from the valve activation screen.

C.

Click on the Activate button to verify correct valve installation (Blue).

D.

Check for correct air line installation. To accomplish this, observe the slack adjusters.

앫 If the ECU faces the FRONT of the trailer, the slack adjusters will move in and out as the ROADSIDE portion of the dual modulator valve cycles. If this does not happen, the air lines are not correctly connected.

Perform the necessary repairs.

앫 If the ECU faces the REAR 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.

8.

Click on the Test button to activate the ABS indicator lamp — this 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 status of this test. Figure 16.

9.

Click on Close to exit.

Sensor Orientation Test

The sensor orientation test must be performed as part of the end of line testing procedure.

Sensor Orientation Test Screen

Before beginning this test, look at the ECU to see if the wheel end sensors face the front or rear of the trailer. TOOLBOX™ will ask for this information to start the test (Step 5). To perform the sensor orientation test:

1.

Raise the sensed wheel ends off the ground.

2.

Apply air to the emergency (supply) line to fill the air tanks and release the spring brakes so that the wheels can be rotated.

3.

Apply 12 volts DC to the ABS.

4.

At the Trailer Main Menu, click on Component Test, then select Sensor Orientation Test to display the Sensor

Orientation Test screen. Figure 17.

When the Sensor Orientation Test screen first appears, the

Sensors Facing field will display the default —Front. This will occur regardless of the actual sensor orientation of the installation being tested.

TP-20213

Revised 11-15

Page 10 Copyright Meritor, Inc., 2015

(16579)

Printed in USA

Figure 17 Figure 19

4005502a

Figure 17

5.

Click on Front or Rear in the Sensors Facing field to select the mounting orientation of the ECU/dual modulator valve assembly.

Refer to Figure 17 and Figure 18 for illustrations of the ECU mounted with sensors facing forward and rear. The correct mounting orientation must be selected prior to starting the test.

Figure 18

4005459c

Figure 19

7.

Follow the screen prompts, starting with 1, to rotate each sensed wheel end at a rate of 1/2 revolution per second. This rate equals a wheel speed of approximately 4 mph (7 kph). As each sensed wheel is rotated, check the color of the sensor identification block on the screen for results. Sensor identification boxes are located in the bottom left portion of the

Sensor Orientation Test screen. Figure 18.

NOTE: Spinning the wheels 10 mph (16 kph) or faster may cause the TOOLBOX™ Software to terminate the sensor test.

Green background: Correct sensor location. Spin the next sensed wheel as indicated by the screen prompt.

Red background: Incorrect sensor location. If you get a red background, you must stop the test (click on Stop), make the necessary corrections and repeat Steps 3 through 6.

8.

To finish the Sensor Orientation Test, click on Stop, then on

Close.

9.

Verify there is sensor output. If there is no sensor output, verify that a tone ring has been installed and that the sensor is pushed all the way in against the tone ring. Perform the necessary repairs and repeat the test. If the problem persists, contact the Meritor OnTrac™ Customer Call Center at

866-OnTrac1 (668-7221). Sensor output appears in the

Sensors field located in the bottom right portion of the Sensor

Orientation Test screen. Figure 17 and Figure 18.

4005513a

Figure 18

6.

Click on Start to begin the test. Figure 19.

(16579)

Printed in USA Copyright Meritor, Inc., 2015

TP-20213

Revised 11-15

Page 11

End of Line Test without TOOLBOX™

Software

Inspect the Sensor and Air Line Installation.

Sensor Installation

1.

Look at the YE2 and YE1 sensor connectors on the ECU/dual modulator valve assembly. Ensure that the connectors are routed to the correct wheel end location, as follows:

앫 If the ECU/dual modulator valve assembly is mounted with the sensors facing the front of the trailer:

— Sensor YE2 must be routed to the curbside wheel end location.

— Sensor YE1 must be routed to the roadside wheel end location.

앫 If the ECU/dual modulator valve assembly is mounted with the sensors facing the rear of the trailer:

— Sensor YE2 must be routed to the roadside wheel end location.

— Sensor YE1 must be routed to the curbside wheel end location.

2.

If sensors are not correctly installed, perform the necessary repairs.

Air Line Installation

1.

Ensure that all unused air ports are plugged and that the exhaust port is facing DOWN.

2.

Look at the air line installation to verify that all air lines are correctly installed.

앫 If the ECU/dual modulator valve assembly is mounted with the sensors facing the FRONT of the trailer, the air lines for the three delivery ports located under the YE2 sensor connector must be routed to CURBSIDE; the air lines for the three delivery ports on the opposite side of the valve must be routed to ROADSIDE. Figure 20.

앫 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 YE2 sensor connector 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 21.

Figure 20

VALVE MOUNTED WITH SENSORS FACING

FRONT OF TRAILER

CURBSIDE YE2 ROADSIDE YE1

YE2

DELIVERY

CURBSIDE

PLUG ALL

UNUSED

PORTS

YE1

DELIVERY

ROADSIDE

4005511a

Figure 20

Figure 21

VALVE MOUTED WITH SENSORS FACING

REAR OF TRAILER

ROADSIDE YE2 CURBSIDE YE1

YE2

DELIVERY

ROADSIDE

PLUG ALL

UNUSED

PORTS

YE1

DELIVERY

CURBSIDE

4005512a

Figure 21

3.

If the air lines are not correctly routed, perform the necessary repairs.

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.

3.

If the indicator lamp comes on for three seconds and then goes out, this indicates a correct installation. The end of line test is complete.

If the ABS indicator lamp comes on and stays on, check the sensor installation.

A.

Remove 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.

TP-20213

Revised 11-15

Page 12 Copyright Meritor, Inc., 2015

(16579)

Printed in USA

C.

Repeat Steps 1 and 2.

D.

Rotate each sensed wheel — one at a time — at a rate of 1/2 revolution per second. This rate equals a wheel speed of approximately 4 mph (7 kph).

The ABS indicator lamp should now go out and stay out indicating a correct installation. The end of line test is complete.

4.

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 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.

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.

Fault Code Check

Use constant power activation to perform the following fault code check.

1.

Apply constant power to the ECU/dual modulator valve assembly for more than one, but less than five seconds.

2.

Remove the power.

3.

Reapply the power.

4.

Check the trailer ABS indicator lamp on the side of the trailer.

The fault code will be displayed three times.

5.

Find the fault on the chart and perform the necessary repairs.

6.

After performing the necessary repairs, repeat the end of line test.

Blink Code Chart

Blink Code Problem Area

4 Sensor YE1

6 Sensor YE2

Action

Determine sensor location.

Check sensor installation.

Perform necessary repairs.

Determine sensor location.

Check sensor installation.

Perform necessary repairs.

Blink Code Chart

Blink Code Problem Area

9

10

Internal modulator failure, inlet valve

#2

Internal modulator failure, inlet valve

#1

11

14

15

Action

Verify correct installation. If code continues, contact Meritor

WABCO for assistance.

Verify correct installation. If code continues, contact Meritor

WABCO for assistance.

Internal modulator failure, outlet valve

Power Supply

ECU Failure

Verify correct installation. If code continues, contact Meritor

WABCO for assistance.

Verify correct electrical installation.

Check power supply.

Perform necessary repairs.

Verify correct installation. If code continues, contact Meritor

WABCO for assistance.

16

17

18

SAE J1708 Failure Internal failure, contact Meritor

WABCO.

SAE J2497 Failure Internal failure, contact Meritor

WABCO.

Generic I/O Failure Verify correct electrical installation.

Check power supply.

Perform necessary repairs.

Trailer Identification

After ensuring the Enhanced Easy-Stop™ trailer ABS has been correctly installed, attach the ABS indicator label included with the

ECU/dual modulator valve assembly to the trailer. Generally, this will be applied near the ABS trailer indicator lamp. Figure 22. Refer to the vehicle specification sheet for the correct location.

Figure 22

Figure 22

NOTICE:

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.

TP-95172 Rev. 4/98

4005501a

(16579)

Printed in USA Copyright Meritor, Inc., 2015

TP-20213

Revised 11-15

Page 13

If this label is not included with the assembly, let your supervisor know. Labels are available from Meritor WABCO. Ask for part number TP-95172.

For additional assistance, contact the Meritor OnTrac™ Customer

Call Center at 866-668-7221.

Parts List

Parts

Part Number

400 500 102 0

899 759 815 4

449 326 005 0

449 326 047 0

449 713 018 0

449 713 030 0

449 713 050 0

441 032 808 0

441 032 809 0

432 500 005 0

899 201 842 4

TP-95172

Description Detail

2S/2M ECU Assembly ECU Valve

Assembly

Sensor Spring Clip

Power Cable 0.5 meter

Power Cable 4.7 meter

Sensor Extension Cable 1.8 meter

Sensor Extension Cable 3.0 meter

Sensor Extension Cable 5.0 meter

Wheel End Sensor

Wheel End Sensor

0.4 meter

1.0 meter

In-Line Air Filter

In-Line Air Filter Label

ABS Warning Label

A complete part listing can be found in Meritor WABCO Parts Book

PB-96133 available at meritorwabco.com.

Appendix I

Installing Sensors on Non-ABS-Prepped

Axles

Sensor locations vary due to suspension type. Meritor 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 −40° to 300°F (−40° to 150°C).

2.

Push the spring clip into the sensor holder from the inboard side, until the spring clip tabs are against the sensor holder.

Push the sensor into the spring clip as far as possible.

Use Meritor WABCO spring clips to ensure a correct fit.

3.

Push the spring clip into the sensor holder from the inboard side until the spring clip tabs are against the sensor holder.

Push the sensor into the spring clip as far as possible.

Figure 23.

Figure 23

SPRING

CLIP TAB

SENSOR

HOLDER

SENSOR

SPRING

CLIP

4003572a

Figure 23

4.

Route the sensor cable toward the brake chamber, over the brake spider or through the pre-stamped hole dedicated to

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 24.

NOTE: Brake hose clips with a provision for the sensor extension cable are recommended as opposed to tie wraps.

Meritor WABCO does not supply this part.

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.

Figure 24

SENSOR

CABLE

3"

(76 MM)

4003573a

Figure 24

5.

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.

TP-20213

Revised 11-15

Page 14 Copyright Meritor, Inc., 2015

(16579)

Printed in USA

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 must be 0.2 volt AC. If minimum output is less than 0.2 volt

AC, push the sensor toward the tooth wheel. Recheck the sensor output.

Appendix II

Cable Strain Relief Guidelines

It is important that cabling follow good strain relief practices to ensure maximum performance and durability. Failure to provide adequate strain relief on the cables can result in future maintenance that is not covered under warranty.

Strain relief is defined as a small amount of slack in the cable at the area of connection. This lack of cable tension allows for slight movement of the cable during times when components of the suspension and air system may be in motion. A small amount of slack also eases access to other system components.

A taut cable can affect the lifespan of the cable. Cables without adequate strain relief can potentially stress a cable connection enough that moisture could intrude. Unnecessary wear at bend points can be the result of a cable under tension.

Cable strain relief is a universal practice. It applies to all Meritor

WABCO product lines from Anti-Lock Brake Systems (ABS) to Roll

Stability Systems (RSS).

Excess Cable Length

In cases where the length of cable exceeds what is required, the excess must be bundled in an efficient manner. It should not be draped or wrapped around components or left unsecured. Any slack remaining in the cable once the connections are made can be gathered up in a Z-shaped loop. Do not coil the cable and pinch into a bowtie or dog-bone shape. All cable zip ties should be tightened in a manner only to the extent that the cable is held sufficiently in place. Fasten the excess cable to an area that is free of sharp edges and moving components.

Meritor WABCO has many lengths of cables available so it is a best practice to obtain a length that best suits the requirements of the installation.

Strain Relief at the ECU — Bracket Mounting

Meritor WABCO recommends that cable connections to a component, such as an ECU valve assembly, display a visible amount of slack in the cable up to the first tie or clip that secures the cable to the trailer structure or air line. This first anchor point should be a minimum 6-inches (152 mm) of cable length from the cable/component connection and maximum of 12-inches

(305 mm). This applies to all sensor, power, valve and GIO cables.

Regardless of whether zip ties or cable clips are used, cables should be secured at intervals not greater than 18-inches (457 mm) to avoid cable vibration.

Ideally, cables should be affixed to the rigid structure of the trailer. A good rule of thumb is to have the bend of the cable, also known as bend radius, be greater than or equal to ten times the diameter of the cable. If the cable is 1/4-inch (6.35 mm) in diameter, then the bend should be a minimum of 2-1/2-inches (64 mm). Refer to

Figure 25 for the ECU mounting of 2S/2M-4S/3M ABS.

Figure 25

Z = ZIP TIE

R R

Z

D

R

10 X D

Bend radius (R) equal to or greater than

10 times cable diameter (D).

First fastener must be a minimum 6-inches

(152 mm) and a maximum of 12-inches (305 mm) from connector.

ABS 2S/2M-4S/3M

Figure 25

D

R

10 X D

Z

4011414a

(16579)

Printed in USA Copyright Meritor, Inc., 2015

TP-20213

Revised 11-15

Page 15

Strain Relief at the ECU — Tank Mounting

It is necessary that cable connections to a component, such as an

ECU valve assembly, display a visible amount of slack in the cable up to the first tie or clip that secures the cable to the trailer structure or air line. This first anchor point should be a minimum 6-inches

(152 mm) of cable length from the cable/component connection and a maximum of 12-inches (305 mm). This applies to all sensor, power, valve and GIO cables. Regardless of whether zip ties or cable clips are used, cables should be secured at intervals not greater than 18-inches (457 mm) to avoid cable vibration.

Ideally, cables should be affixed to the rigid structure of the trailer.

However, structure is not always available on tank-mounted installations. In these cases, securing the cable may be accomplished by fastening the cable to nearby air lines. It is important to note that cables should be secured only to the extent that the cable is held sufficiently in place. Refer to Figure 26 for

2S/2M-4S/3M ABS.

Figure 26

4011414b

CORRECT POWER AND GIO/MODULATOR CABLE STRAIN RELIEF FOR ABS 2S/2M-4S/3M

Figure 26

Sensor Extension Cables at the ECU

On valves that are tank mounted with no trailer structure nearby, or have remote-mounted cables, the sensor extension cables are attached to the air lines. Cable clips are preferred over zip ties. It is important to remember that cables should be fastened in a manner where the cable is secured enough where the cable will not move or chafe against what it is mounted to. A small amount of slack should be present to ensure that the cables do not become taut after installation or the servicing of components. Figure 27 illustrates the correct amount of slack in the sensor extension cables and correct attachment to the air delivery lines for ABS ECUs.

Figure 27

Figure 27

SENSOR CABLE STRAIN RELIEF FOR

ABS 2S/2M-4S/3M

4012337a

TP-20213

Revised 11-15

Page 16 Copyright Meritor, Inc., 2015

(16579)

Printed in USA

Cable-to-Cable Connections

It is important to ensure all cable-to-cable connections maintain good strain relief. Cable restraints must be placed between 2- and

4-inches (51-102 mm) from the cable connector to ensure correct strain relief. Regardless of whether zip ties or cable clips are used, cables should be secured at intervals not greater than 18-inches

(457 mm) to avoid cable vibration. Refer to Figure 28 for air line attachment and Figure 29 for axle attachment.

Figure 28

Figure 29

3"

(76 MM)

ZIP TIES ON AIR LINES

3"

(76 MM)

4012336a

Figure 28

3"

(76 MM)

SENSOR

CABLE

ZIP TIES ON AXLE 4011417a

Figure 29

Appendix III

Vehicle Electrical Grounding Guidelines

Ensure that the vehicle includes a correct common chassis ground point. A common chassis ground point connects the trailer frame/ chassis to the ground pin of the J560 seven-way connector and will protect the vehicle electrical system from unwanted electrical noise.

Common chassis ground can be verified by measuring the resistance between the J560 ground pin and the vehicle chassis (or frame) and confirming that the resistance is less than

10 Ohm (< 10

Ω). If this is not the case, the electrical contact at the common chassis ground point is not sufficient or not present. If a common chassis ground point is present, but not sufficient, ensure that there is no paint or debris inhibiting electrical contact at the ground point. If a common chassis ground point is not present,

Meritor WABCO recommends adding one.

NOTE: Do not add more than one common chassis ground point

(connecting the J560 ground pin to the chassis) to avoid potential ground shifts within the vehicle electrical system.

Additionally, all standard trailer components, such as axles, should also be electrically connected to the common chassis ground. If the axles are not correctly grounded to the chassis, a ground strap electrically connecting the axle to the chassis may be added to ensure adequate protection from unwanted electrical noise. This can be verified by measuring the resistance between the vehicle chassis/frame and the other trailer component, then confirming that the resistance is less than 10 Ohm (< 10

Ω).

For more details concerning correct vehicle grounding, reference

SAE standard J1908.

Note during welding work on the trailer:

앫 Disconnect power to the trailer.

앫 Disconnect all cable connections to devices and components and protect the plug-ins and connections from contamination and humidity.

앫 Always connect the grounding electrode directly with the metal next to the welding position when welding, to prevent magnetic fields and current flow via the cable or components.

앫 Make sure that grounding connections are robust by removing paint or rust at the connection points.

앫 Prevent heat influences from the welding activity on devices and cabling when welding.

Note during electrostatic painting the trailer frame or bogie:

앫 Disconnect all cable connections to devices and components and protect the plug-ins and connections from contamination and humidity.

Meritor WABCO Vehicle Control Systems

2135 West Maple Road

Troy, MI 48084-7121 USA

866-OnTrac1 (668-7221) 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. Meritor WABCO reserves the right to revise the information presented or to discontinue the production of parts described at any time.

Copyright 2015

Meritor, Inc.

All Rights Reserved Printed in USA

TP-20213

Revised 11-15

(16579)

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