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Installation Guide

1. SENSOR EXTENSION CABLE SENSOR AND CABLE 4003567b 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 16579 22882 Printed in USA 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 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 ECU Dual Modulator Valve Assembly Mounted with Sensors Facing Front of Trailer 2S 2M Connect curbside sensor at YE1 Connect roadside sensor at BUT 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 of installation Refer to the diagrams on the following pages for specific Sensor locations
2. 1 2 Sensors Facing ee MexRPM Order aur En 7 5 ve YEI YE2 EE NET m2 7 oe 4005514a Warning Massage This tast damands that the whaels ba spun in predetermined order and Ihat ihe ECU mounting orientation is antared by the operator Wis applicable to the following TCS2 configurations only S 1M 400 500 101 n R 28 1M 400 1040 28 2M 400 600 102 0 25 2 400 500 103 0 45 2M 400 500103 0 NOTE 25 2 installations use YE1 and BU1 locations 6 Click on Start to begin the test Figure 25 Sensor Orientation Test X Sansor Orientation Teast Spln tira number 1 as shown on tha diagram Sensors Facing G From C Raer Sensors MexRPM Order YEI BUI E BU2 mE Lie n 4005459a TP 20214 Copyright ArvinMeritor Inc 2005 Revised 10 05 Page 17 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 24 Grben background Correct sensor location Spin the next sensed wheel as indicated by the screen prompt Red background Incorrect sensor location If you get
3. POWER DIAGNOSTIC CABLE Figure 10 2 Forindustry 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 4003568a Attach individual sensor For blunt cut power cables route the cable from the ECU dual cables to corresponding modulator valve assembly to a junction box which interfaces brake air delivery hoses with the seven way connector at the front of the trailer 4005457b Leave enough slack in the cable to compensate for flexing of the trailer and sub frame TP 20214 Revised 101 05 16579 22882 Page 6 Copynght ArvinMeritor Inc 2005 Printed in USA 3 Bundle any excess cable a loop bow tie 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 11 KEYED CABLE CONNECTOR MATING TRAILER HARNESS CONNECTOR 4003569 5 Plug the power 8 pin connector on the power or power diagnostic cable into the ECU dual modulator valve assembly 6 Pull the hinged power diagnostic connector retainer clip on the ECU dual modulator valve assembly DOWN to secure the connection 7 fyou are installing the power cable only go to Step 9 8 If you are installing the power diagnostic Y cable A Install
4. Changa 9 Interna Message Center art JESI 23 2001 1027453 edb EGU Component Tests Midiy gia ECU Indoimetion ECU Type Trader TCS I Menutacture Date E aa Pan Nu Lit Anie Stam fave Stored VoRage Seconday I Intemad Center ES jag 23 2001 16579 22882 Figure 3 Printed in USA Copyright ArvinMeritor Inc 2005 4005428a aioi xj 4005428a TP 20214 Revised 10 05 Page 21 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 he sensor spring clip the body of the sensor and the bore of he sensor block The grease must be anti corrosive and contain adhesive properties that will continuously endure emperatures from 40 to 300 F 40 to 150 C 2 Push the spring clip into the sensor holder from the inboard site 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
5. 4S 2M Connect curbside front sensor at YET Connect curbside rear sensor at YE2 Connect roadside front sensor at BUT 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 Stop 4S 3M lift axle installations you must use TOOLBOX 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 Connect curbside sensor at YET Connect curbside sensor at YE2 Connect roadside sensor at BUT Connect roadside sensor at BU2 f 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 Revised 10 05 Copyright ArvinMeritor Inc 2005 Page 5 ECU Dual Modulator Valve Assembly Mounted with 9 Bundle any excess cable in a loop bow tie Figure 9 Sensors Facing Rear of Trailer 25 2 4 Connect curbside sensor at BUT N Connect roadside sensor at YE1 e 45 2 P y BUNDLE EXCESS CABLE Connect curbside front sensor at BUT Connect curbside rear sensor at BU2 Connect roadside front sensor at YET Connect roadside rear sensor at YE2 4003553 4S 3M
6. Copyright ArvinMeritor Inc 2005 Printed in USA 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 f the ECU dual modulator valve assembly is mounted with sensors facing the FRONT of the trailer the air lines for three delivery ports located under the YE sensor connectors must be routed to CURBSIDE the air lines for three delivery ports on the opposite side of the valve must be routed to roadside Figure 26 f the ECU dual modulator valve assembly is mounted with he sensors facing the REAR of the trailer the air lines for he three delivery ports located under the YE sensor connectors must be routed to ROADSIDE the air lines for e three delivery ports on the opposite side of the valve must be routed to curbside Figure 27 ECU DUAL MODULATOR VALVE MOUNTED WITH SENSORS FACING FRONT OF TRAILER CURBSIDE ROADSIDE curBsipe YE BU1 ROADSIDE YE I UN Bu CURBSIBE SS ose DELIVERY ROADSIDE 40035642 ECU DUAL MODULATOR VALVE MOUTED WITH SENSORS FACING REAR OFTRAILER ROADSIDE CURBSIDE Roapsipe YE BUT CURBSIDE PLUG ALL UNUSED PORTS YE BU DELIVERY TO NES 4003565a 16579 22882 Printed in USA 3 For 48 3M installations Repeat this test for the red valve Red The external
7. airs Determine sensor Check sensor installation Perform necessary repairs Verify correct electrica installation External ABS modulator valve Check power supply Perform necessary repairs Intemal modulator failure inlet valve 2 Internal modulator failure inlet valve 1 Internal modulator failure outlet valve Verify correct installation If code continues contact Meritor WABCO for assistance Verify correct installation If code continues contact Meritor WABCO for assistance Verify correct installation If code continues contact Meritor WABCO for assistance 20214 Revised 10 05 20 Copyright ArvinMeritor Inc 2005 Blink Code Chart Biink Code Problem Area 1 Power Supply 14 15 ECU Failure SAE J1708 Failure SAE J2497 Failure Action Verify correct electrical installation Check power supply Perform necessary repairs Verify correct installation If code continues contact Meritor WABCO for assistance Internal failure contact Meritor WABCO Internal failure contact Meritor WABCO 18 Generic 1 0 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
8. For Enhanced Easy Stop 4S 3M lift axle installations you must use TOOLBOX 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 Connect curbside sensor at YE1 Connect curbside sensor at YE2 Connect roadside sensor at BUT Connect roadside sensor at BU2 f 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 Revised 10 05 Copyright ArvinMeritor Inc 2005 Page 5 3 Connect the brake service control line to the ECU dual modulator valve assembly Port 4 1 4 inch NPTF 4 4S 3M installations perform the following procedures Connect the brake service control line to the ECU dual modulator valve assembly Port 4 1 4 inch NPTF and ABS external relay valve contro Port 4 3 8 inch NPTF B Use an ABS relay valve connection cable to connect the ECU dual modulator valve assembly with the ABS external relay valve 5 Plug any unused delivery ports IV Install the sensor extension cables ABS prepped axles 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
9. ECU single modulator valve assembly to the trailer Generally this will be applied near the ABS trailer indicator lamp Figure 28 Refer to the vehicle specification sheet for the correct location NOTICE Tf the ABS indicator lamp comes 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 95172 Rev 4 98 4005501a ETE 28 NOTE If this label is not included with the assembly let your supervisor know Labels are available from Meritor WABCO Ask for part number 95172 For additional assistance contact Meritor WABCO at 800 535 5560 16579 22882 Printed in USA Appendix Enabling the Lift Axle Function 4S 3M Installations To enable the lift axle function you will need a PC with TOOLBOX Software version 4 6 or higher installed Refer to the TOOLBOX User s manual for complete operating instructions This manual is posted on our website at meritorwabco com 1 Display the Trailer ABS Main Screen Click on Modify to display the pull down menu Figure 1 2 Click on Lift Axle The default lift axle screen will appear and display the default lift axle status Not Active Figure A 2 3 Tochange the default status and activate the lift axle function click on Change The Lift Axle Status will change to Active Figu
10. Sensor locations vary by type of installation Refer to the diagrams for specific sensor locations For Enhanced Easy Stop 4S 3M lift axle installations you must use TOOLBOX Software 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 version 4 6 or higher to enable the lift axle function t is not automatically enabled Refer to Enabling the Lift Various cable lengths are available Axle Function 4S 3M Installations in the Appendix for instructions V Install the power and lamp or power and i Connect curbside sensor at BUT lam p diagnostic cable Connect curbside sensor at BU2 1 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 2 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 4 POWER CABLE 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 tle wrap or clip to secure the cable to the brake air delivery hose as close to the fitting as possible Figure 8
11. provide this information 4S 2M VALVE MOUNTED WITH SENSORS FACING FRONT OFTRAILER SIDE TO SIDE CONTROL FRONT OF TRAILER Typical Tandem Axle Trailer NOTE Spring brake lines not shown NN RR 4S 2M VALVE MOUNTED WITH SENSORS FACING REAR OF TRAILER SIDE TO SIDE CONTROL Typical Tandem Axle Trailer FRONT OF TRAILER NOTE Spring brake lines not shown SERVICE CONTROL LINES SENSOR CABLES SERVICE BRAKE SUPPLY AIR 4003555a TP 20214 16579 22882 Revised 10 05 Printed in USA Copyright ArvinMeritor Inc 2005 Page 9 Meritor 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 FRONT OF TRAILER l i NOTE Spring brake bd lines not shown Di EET ee z aaa pui p a gu 45 2 TYPICALTRI AXLE VALVE MOUNTED WITH SENSORS FACING REAR OFTRAILER SIDE TO SIDE CONTROL Cassa Casa Sa DIDI 4 FRONT OF v E TRAILER 4 EEN E EE NOTE Spring brake lines not shown SERVICE CONTROL LINES SENSOR CABLES SERVICE BRAKE SUPPLY AIR 4003556a TP 20214 Revised
12. a red background you must stop the test click on stop make the necessary corrections and repeat Steps 3 through 6 To finish the Sensor Orientation Test click on Stop then on Close Verify there is sensor output If there is no sensor output verify that a tone ring has been installed and that the sensor 1 pushed all the way in against the tone ring Perform the necessary repairs and repeat the test If the problem persists contact Meritor WABCO 800 535 5560 Sensor output appears in the Sensors field located in the bottom right portion of the Sensor Orientation Test screen Figure 24 End of Line Testing without TOOLBOX Software Sensor Installation 16 Look at the sensor connectors on the ECU dual modulator valve assembly Ensure that the connectors are routed to the correct wieel end location as follows ECU Dual Modulator Valve Assembly Mounted with Sensors Facing Front of Trailer 25 2 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 Revised 10 05 Page 18 4S 3M Sensor locations vary by type of installation Refer to the diagrams for specific sensor locations For Enhanced Easy Stop 4S 3M lift axle installations you must use TOOLBOX Software version 4 6 or higher to
13. distance between the two holes O D must be 6 06 inches 154 mm and mount directly to the cross member 3 Rotate and tighten the ECU dual modulator valve assembly OR 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 0 0 apart ee ue 3 two 3 8 inch Grade 8 bolts with prevailing torque nuts to Mounted to Cross Member of Vehicle Mounting attach the assembly Tighten the bolts to 18 Ib ft 24 Nem Bracket Not Supplied sis Attach the ABS external relay valve Refer to Figure 3 4S 3M systems only ECU DUAL MODULATOR VALVE MOUNTED Tank Mounted TO A CROSS MEMBER OFTHE VEHICLE WITH SENSORS FACING FRONT OF TRAILER AX WARNING Exhaust port You must use a Schedule 80 hex nipple 3 4 inch NPTF to must face DOWN 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 relay valve assembly to a reinforced air tank Do not CURBSIDE overtighten FRONT OF TRAILER Meritor WABCO does not recommend the use of a vise when Edi cos Phelps installing the hex nipple Use of a vise may cause Exhaust port overclamping Overclamping may damage the internal must face DOWN components of the ECU dual
14. 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 Connect curbside sensor at YE1 Connect curbside sensor at YE2 Connect roadside sensor at BU1 Connect roadside sensor at BU2 ECU Dual Modulator Valve Assembly Mounted with Sensors Facing Rear of Trailer e 25 2 Connect curbside sensor at BU1 Connect roadside sensor at YE e 4S 2M Connect curbside front sensor at BUT 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 of installation Refer to the diagrams for specific sensor locations For Enhanced Easy Stop 4S 3M lift axle installations you must use TOOLBOX 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 Connect curbside sensor at BUT 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 16579 22882
15. 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 TP 20214 Revised 10 05 Copyright ArvinMeritor Inc 2005 Page 19 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 R apply the power 4 Check the trailer ABS indicator lamp on the side of the trailer The fault code will be displayed three times 5 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 Problgm Area Action Sensor BU1 Determine sensor location Check sensor installation Perform necessary repairs Determine sensor location Check sensor installation Perform necessary repairs Sensot YE1 Sensor BU2 Determine sensor location Check sensor installation Perform necessary
16. relay valve designated RED RD is an axle control valve It controls the brake chambers on one or two axles It is important that delivery lines from Port 2 are plumbed as shown in Figure 17 Figure 18 and Figure 19 The 4S 3M system is designed to be used with a variety of trailer configurations Call ArvinMeritor s Customer Service Center at 800 535 5560 for additional information 4 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 Listen for the ECU dual modulator valve assembly to click four limes six times for a 4S 3M 3 If the indicator lamp comes on for three seconds 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 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 Repeat Steps 1 and 2 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
17. 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 ihe 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 excess cable in a loop bow tie and secure the cable in the sub frame Figure 9 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 To ensure correct lamp operation use an incandescent type DOT approved lamp or an LED with integral load resistor 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 to the harness on the trailer 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 INPU
18. to the You must use a Schedule 80 hex nipple 3 4 inch NPTF to E ie rode i ie n pra mount the ECU dual modulator valve assembly securely to the SITO M Vb n i 5 s S all recommendations and procedures Your supervisor should have a air tank to avoid possible serious personal injury and damage ae copy of this specification to the component 1 Install a 3 4 inch NPTF fitting in the supply port Use a 3 4 inch 1 Use a3 4 inch NPTF Schedule 80 hex nipple to attach the NPTF pipe plug to plug the unused supply port Port 1 ECU dual modulator valve assembly to a reinforced air tank Do not overtighten Apply SAE standard DOT approved Teflon tape or paste type thread sealant to al 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 overclamping Overclamping may damage the internal components of the ECU dual modulator valve assembly 2 Locate a position for mounting the assembly to the vehicle cross member midway between the side rails close to the brake chambers the valve serves 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 Drill two 3 8 inch mounting holes The
19. 10 05 16579 22882 Page 10 Copyright ArvinMeritor Inc 2005 Printed in USA Meritor WABCO recommends placing sensors on the axle that will provide the most braking performance The suspension manufacturer can provide this information 4S 2MTYPICAL AXLE CONTROL INSTALLATION VALVE MOUNTED WITH SENSORS FACING FRONT OF TRAILER ri 522220 ic la LEL i TRE o l TAN o i nun lines not shown BU2 o d 2 DEREN gl 4S 2M TYPICAL AXLE CONTROL INSTALLATION VALVE MOUNTED WITH SENSORS FACING REAR OF TRAILER NOTE Spring brake BUI YET Scant nennen e rj D E GE OF syi m EB 1 TE NOTE Spring brake lines not shown A i SERVICE CONTROL LINES OF LIE SENSOR CABLES Buz SERVICE BRAKE SUPPLY AIR J C 2 Ell EE II TP 20214 16579 22882 Revised 10 05 Printed in USA Copyright ArvinMeritor Inc 2005 Page 11 NOTE For Enhanced Easy Stop 45 3 lift axle installations you must use TOOLBOX Software version 4 6 or higher to enable the ift 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 w
20. 652 Curent Mies fo Secondary 00 Service fe 13662 495 0 Canter EN 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 4003560a Use the information in the Repair instructions field to perform the necessary repairs Figure 21 Hah formation Fouke laniuciram Open or vert caput desscled Crack rence vnrg oannecini o ranio ihoss be 4 60 de 4003561 Figure 21 TP 20214 Revised 10 05 Copyright ArvinMeritor Inc 2005 Page 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 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 Atthe 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 22 Volvo Activation x Select Valve to Activate Bue R Activate C Red C AlValve Test Warning Lamp Warning Lamp lon Test Status _ 4003562b 5 Click on the Activate button 6 C
21. Enhanced Easy Stop 2S 2M 4S 2M and 4S 3M Premium 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 Apply 12 volts DC to the blue wire constant Check the Screen for the correct voltage 9 5 to 14 volts Constant power voltage is displayed in the PRIMARY field Figure 20 Apply 12 volts DC to the red wire stoplight power Check screen for the correct voltage 9 5 to 14 volts Stoplight power voltage is displayed in the SECONDARY field Figure 20 The internal field is not applicable to this test 16579 22882 Printed in USA EF Mentor WABCU Frater ASS Diagnostics EDU Lomponere gia CI EZ 3 ECU Intoumatian ECU Vries 1 Date 09 2000 iM Sena Nunes Pat 1251080001 SotmueRewen VIZ Fouts Wheel Sensor Speed RPM Ewing lh ve 5 bur 7 Stored x2 7 7 Smvicelniomalon Voltages 13
22. 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 and Service Information Refer to Maintenance Manual MM 0180 Enhanced Easy Stop Trailer ABS with PLC and Maintenance Manual 33 Easy Stop Trailer ABS To obtain these publications call ArvinMeritor s Customer Service Center at 800 535 5560 or visit the Tech Library on our website at meritorwabco com Differences Between Easy Stop and Enhanced Easy Stop There are some changes to Enhanced Easy Stop that you need to be aware of before you begin the installation Enhanced Easy Stop includes Power Line Communication PLC function The ECU dual modulator valve assembly must be mounted as one unit The LED on top of the ECU has been eliminated The blink code tool LED does not operate simultafeously with the ABS lamp on the trailer For Enhanced Easy Stop 4S 3M lift axle installations you must use TOOLBOX 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 For 4S 2M lift axle installations the lift axle function is automatically enabled The valve portion of the ECU dual mod
23. S FACING REAR OF TRAILER E BU2 FRONT OF TRAILER Typical Tandem Axle Trailer NOTE Spring brake lines not shown T can 40035588 Fig re 18 TP 20214 16579 22882 Revised 10 05 Printed in USA Copyright ArvinMeritor Inc 2005 Page 13 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 al NOTE Spring brake lines not shown SERVICE CONTROL LINES SENSOR CABLES SERVICE BRAKE SUPPLY AIR eaa 4S 3MTYPICAL FOUR AXLE PULLTRAILER VALVE MOUNTED WITH SENSORS FACING REAR OF TRAILER ow ee 0 ees sedeo SS ae ae BU2 ja n TRAILER le I li NOTE Spring brake wooed lines not shown 4003659a TP 20214 Revised 1 05 16579 22882 Page 14 Copyright ArvinMeritor Inc 2005 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
24. SENSORS FACING FRONT OF TRAILER SERVICE CONTROL LINES SERVICE BRAKE SUPPLY AIR SPRING BRAKE AIR 40035502 TYPICAL 2M INSTALLATION VALVE MOUNTED WITH SENSORS FACING REAR OFTRAILER SERVICE CONTROL LINES SERVICE BRAKE SUPPLY AIR SPRING BRAKE AIR Figure 6 40035518 16579 22882 Printed in USA 3 Connect the brake service control line to the ECU dual modulator valve assembly Port 4 1 4 inch NPTF 4 For 4S 3M installations perform the following procedures A Connect the brake service control line to the EGU dual modulator valve assembly Port 4 1 4 inch NPTF and ABS external relay valve control Port 4 3 8 inch NPTF B Usean ABS relay valve connection cable to connect the ECU dual modulator valve assembly with the ABS external relay valve 5 Plug any unused delivery ports IV Install the sensor extension cables ABS prepped axles 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 manufacturer can provide this information 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 7 Ensure that each connection is secure
25. T OUTPUT EXPANDED CAPABILITY WHITE AND YELLOW WHITE 4 OR 5 WIRE GROUND BLUE SCHEMATIC CONSTANT POWER RED GROUND Junction box not shown 7 TRAILER ABS INDICATOR LAMP STOP LAMP GREEN AND WHITE a ECU POWER CONNECTOR 4003570a 16579 22882 Printed in USA Revi Copyright ArvinMeritor Inc 2005 TP 20214 ised 10 05 Page 7 Typical Easy Stop Trailer ABS Installations Refer to Figure 43 through Figure 19 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 20214 Revised 10 05 8 25 2 VALVE MOUNTED WITH SENSORS ecc FACING FRONT OFTRAILER SIDE TO SIDE CONTROL eee ee FRONT OF TRAILER NOTE Spring brake lines not shown 28 2M VALVE MOUNTED WITH SENSORS FACING REAR OFTRAILER SIDE TO SIDE CONTROL ececoqeoccccccccsocs i oo FRONT OF b Cere i NOTE Spring brake lines not shown SERVICE CONTROL LINES SENSOR CABLES i SERVICE BRAKE SUPPLY AIR 4003554a 16579 22882 Copyright ArvinMeritor inc 2005 Printed in USA Meritor WABCO recommends placing sensors on the axle that will provide the most braking performance The suspension manufacturer can
26. ads 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 Ib ft 24 Nem Ill Connect the air lines Before connecting the air lines plumb the spring brake relay or emergency brake relay into the system as usual fyou are mounting on a bracket connect the air supply line from the supply tank to the 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 you are mounting directly to the Supply tank 1 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 TP 20214 Revised 10 05 Page 4 Copyright ArvinMeritor Inc 2005 2 Connect the air delivery lines to the appropriate brake chambers 3 8 inch NPT Figure 5 and Flgure 6 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 The external relay valve designated RED RD is an axle contro valve it controls brake chambers on one or two axles It is important that delivery lines from Port 2 are plumbed as shown Refer to Figure 13 through Figure 19 TYPICAL 2M INSTALLATION VALVE MOUNTED WITH
27. cond 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 16579 22882 Page 2 Copyright ArvinMeritor Inc 2005 Printed in USA Oe e a MERITOR WABCO Meritor WABCO Vehicle Control Systems 2135 West Maple Road Troy MI 48084 7121 USA 800 535 5560 meritorwabco com DRIVETRAIN PLUS THE COMPLETE SYSTEM ArvinMeritor 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 2005 TP 20214 ArvinMeritor Inc Revised 10 05 Ali Righis Reserved Printed in USA 16579 22882
28. heck for correct air line installation To accomplish this observe the slack adjusters ifthe 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 f 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 20214 Revised 10 05 16 Copyright ArvinMeritor Ine 2005 7 Repeatthis test for the Blue valve A RepeatSteps 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 e f 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 e f 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 thi
29. ill provide the most braking performance The suspension manufacturer can provide this information 4S 3MTYPICALTRI AXLE WITH FRONT LIFT VALVE MOUNTED WITH SENSORS FACING FRONT OFTRAILER a ssi See bem ewww FRONT OF TRAILER NOTE Spring brake e lines not shown ER E E 4S 3MTYPICAL TRI AXLE WITH FRONT LIFT VALVE MOUNTED WITH SENSORS FACING REAR OF TRAILER rege TRAILER loi E n SERVICE CONTROL LINES SENSOR CABLES SERVICE BRAKE SUPPLY AIR NOTE Spring brake lines not shown pesti LIT TP 2021 ii Revised 10 05 16579 22882 Page 12 Copyright ArvinMeritor Inc 2005 Printed in USA Meritor WABCO recommends placing sensors on the axle that will provide the most braking performance The suspension manufacturer provide this information 45 3 TYPICAL TRI AXLE VALVE MOUNTED WITH SENSORS FACING FRONT OF TRAILER Comer pn Er YE2 SERVICE CONTROL LINES SENSOR CABLES TEN 00 FRONTOF ve TRAILER I boana E NOTE Spring brake M H H lines not shown v eae d BU Typical Tandem Axle Trailer SERVICE BRAKE SUPPLY AIR BU2 u BUI g RE a CER CCS 4S 3M TYPICAL TRI AXLE VALVE MOUNTED WITH SENSOR
30. manufacturer can provide this information 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 7 Ensure that each connection is secure SENSOR EXTENSION CABLE SENSOR AND CABLE 40035670 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 16579 22882 Printed in USA Do not overtighten the tie wraps on a cable Overtightening cari 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 Pushthe sensor retainer clip on the ECU dual modulator valve assembly UP 6 Remove the protective caps from 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 ECU Dual Modulator Valve Assembly Mounted with Sensors Facing Front of Trailer 28 2M Connect curbside sensor at YET Connect roadside sensor at BUT
31. modulator valve assembly 2 Usea3 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 PLUG ALL ROADSIDE UNUSED PORTS ROADSIDE Pipes with pre applied thread sealant may also be used YE1 4 CURBSIDE CURBSIDE TRAILER BUI BU2 P A 4005403b 1P 20214 16579 22882 Revised 10 05 Printed USA Copyright ArvinMeritor Inc 2005 Page 3 3 Rotate and tighten the relay valve assembly until the exhaust porti 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 Figure 4 PLUG UNUSED PORTS Exhaust port must CONTROL face DOWN PORT4 SUPPLY PORT 1 ABS EXTERNAL MODULATOR VALVE 1002073d Mounted to Cross Member of Vehicle Mounting Bracket Not Supplied When mounting the relay 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 thre
32. r orientation test 1 Raise the sensed wheel ends off the ground 2 Apply air to the emergency 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 Testto display the Sensor Orientation Test screen Figure 23 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 cs Sensor Orientation Test E x Warning Message This te demands that the wheels be spun in a predetermined order and that the ECU mounting orlentation is entered by the oparator I is applicable to the fallowing TCS2 canligurations only 28 1M 400 500 101 0 28 1M 400 500 104 0 25 2M 400 500 102 0 28 2M 400 500 103 0 4S 2M 400 500 103 0 C Rear T Order rer fer ga is m p BUT BU2 S rs 4 me e Dee 4005458a E 5 Click on Front or Rear in the Sensors Facing field to select the mounting orientation of the ECU dual modulator valve assembly Figure 24 Refer to Figure 23 and Figure 24 for illustrations of the ECU mounted with sensors facing forward and rear The correct mounting orientation must be selected prior to starting the test Step 5 16579 22880 Printed in USA
33. r service The Ant lock Braking System ABS is an electrical system When 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 EClj dual modulator valve assembly for damage that may have occurred during shipping or storage Look for crushed or bent connectors Verify that the retainer clips have not been bent or otherwise damaged e 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 ABS relay valve and relay valve extension cable with bayonet connector 3M systems Power cable or power diagnostic cable Sensor extension cables two pieces for 2S systems four pieces for 4S systems Sensors two or four for non ABS prepped a
34. re A 3 4 Click on Close to close the screen Exit TOOLBOX 5 Remove power from the vehicle then reapply power 6 Follow Steps 2 and 3 to display the Lift Axle Status screen Verify the lift axle status display indicates the lift axle function is active as illustrated in Figure A 3 If the lift axle function does not indicate active status verify TOOLBOX version 4 6 or higher is installed If you continue to receive a not active status message contact the for assistance 7 Disconnect TOOLBOX from the vehicle and proceed with end of line testing as described in this bulletin ertor WAULU Trailer ADS Oradnostics 10i xj Traklar cU Display Modfy Help Service nformation t B ECU Informetion ECU Type Trae TCS Configuration 4S 73M Pat Numbet 4455001030 SollwseFlevinon Fauke Wheel Sentio Speed RPM Existing vt 7 Ke Stored YE2 7 lt 7 Volt amp get Service lotormation Primary 135 Current Mies 00 Secondary 00 SeMceMies 0 13 Revi Mie 5026 Mexsage Centor 4005427a Mentor Trailer ANS D Trak Display Component Tests gia ECU Information Pu type Trailer TCS Il Menulactue Date Configuration 46 3 Serial Number y dh PotNumbet 3465001036 Sofware Revision reso IUE NN xen Stored LN axe Status NoAdwe Voltage Pumas
35. s does not happen the air lines are not correctly connected Perform the necessary repairs 8 For 4S 3M installations Repeat this test for the red valve Red The external relay valve designated RED RD is an axle control valve It controls brake chambers on one or two axles It is important that delivery lines from Port 2 are plumbed as shown on the installation drawings The 4S 3M system is designed to be used with a variety of trailer configurations Call ArvinMeritor s Customer Service Center at 800 535 5560 for additional information 9 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 22 10 Click on Close to exit Sensor Orientation Test 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 The sensor orientation test must be performed as part of the end of line testing procedure 16579 22882 Printed in USA Sensor Orientation Test Screen Before beginning this test look at the ECU to see if the sensors face the front or rear of the trailer TOOLBOX will ask for this information to start the test Step 5 To perform the senso
36. 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 4 SPRING SENSOR CLIP TAB HOLDER SENSOR SPRING 4003572 4 Route the sensor cable toward the brake chamber over the brake spider or through the pre stamped hole dedicated for ABS sensors Roule 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 Meritor WABCO does not supply this part TP 20214 Revised 10 05 40035730 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 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 se
37. ulator valve assembly contains two separate modulator valves that share common control and exhaust ports Each valve has three delivery ports Therefore the mounting orientation whether the valve is facing the front or the rear of the trailer determines sensor hookup TP 20214 Revised 10 05 Enhanced Easy Stop Trailer ABS 2S 2M 4S 2M and 4S 3M Premium with PLC Installation Instructions If this assembly is mounted facing forward toward the front of the trailer the YE sensor connections go to the curbside and the BU 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 1M system ECU DUAL MODULATORVALVE MOUNTED WITH SENSORS FACING FRONT OFTRAILER CURBSIDE ROADSIDE cURBSIDE YE ROADSIDE supply _ PORT WO 7 port PLUG ALL UNUSED PORTS DELIVERY CURBSIDE ZN DELIVERY ROADSIDE ECU DUAL MODULATOR VALVE MOUNTED WITH SENSORS FACING REAR OF TRAILER ROADSIDE CURBSIDE ROADSIDE YE BU CURBSIDE SUPPLY PORT PLUG ALL UNUSED PORTS DELIVERY ROADSIDE DELIVERY CURBSIDE 4003566a Preparation 4 WARNING To prevent serious eye injury always wear safe eye protection when you perform vehicle maintenance o
38. xles ABS Indicator Label TP 95172 5 8 inch nylon tubing for supply frame mount Pipe plug 3 4 inch NPTI 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 TP 20214 Revised 10 05 Page 2 Copyright ArvinMeritor Inc 2005 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 1 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 ECU DUAL MODULATOR VALVE MOUNTED WITH SENSORS FACING FRONT OF TRAILER TANK MOUNTED ROADSIDE 8 Bul P ROADSIDE BU2 lom ECU DUAL MODULATOR VALVE MOUNTED WITH SENSORS FACING REAR OF TRAILER CURBSIDE BU2 CURBSIDE BU1 ROADSIDE YE1 ROADSIDE YE2 PLUG UNUSED Exhaust port PORT must face DOWN 4003548a 16579 22882 Printed in USA A WARNING When mounting the ECU dual modulator valve assembly

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