TP1388 - Meritor WABCO
Contents
1. Valve Mounting Nuts 5 16 Valve Mounting Bolts 2 1 2 inch 5 16 Bracket Mounting Nuts 5 8 Bracket Mounting Bolts 2 inch 5 8 Additional Air Line Incandescent Amber Light DO NOT USE LED Lights Incandescent Red Light DO NOT USE LED Lights Three Position Momentary Switch Two Position Momentary Switch J1939 Y Connector J1939 Connectors Printed in USA Copyright Meritor Inc 2013 4010898a Quantity As needed AIAI ey BY PO As needed 1 TP 1388 Issued 09 13 Page 3 Procedures Leveling Valve Installation Must Be Mounted on the Drive Axle Valve and Bracket Installation 1 Verify the nominal ride height and measurement location 1 Wear safe eye protection Park the vehicle on a level surface per OEM specifications This information will be used to Block the wheels to prevent the vehicle from moving set the electronic height sensor as well as calibrate the system 2 Lower and exhaust all air from the suspension system 2 Connect the leveling valve to the drive axle of the tractor In most cases the existing pneumatic air valve bracket can be used to mount the electronic height sensor Figure 9 3 Determine the valve mounting location Verify the valve has correct clearance from the suspension and ensure it is positioned so the valve s exhaust silencer is NOT pointing upward NOTE The mounting brackets are not pre drilled so they can be used for any mounting location2. Figure 8 SENSOR ae ae BRACKET AQS N O AY gt NY ys s Sy Ex g L SS 3 ay NO I f X W g sr Q SILENCER NOTE Brackets are not pre drilled 4010893a NOTE The sensor must be installed with the mounting bolts above the 4 Position the brackets to the frame at the chosen mounting sensor housing location Drill out the frame and brackets as required Figure 8 5 Remove the existing metric fittings from the ECAS valve and replace them with the M22 fitting adapters part number 9400 851 002 0 provided in the kit 6 Install the quick connect fitting to port 11 which is the air supply port to the valve 7 Install quick connect fittings to the adapters on port 22 and 23 4010894a These ports allow the air to travel to and from the bellows Figure 9 3 Connect the rod ends using a 1 4 6 35 mm smooth or threaded rod Verify that the height sensor can reach full travel without contacting the frame or wiring 4 Loosely tighten the connection Final tightening will be made with air in the bellows TP 1388 Issued 09 13 16579 Page 4 Copyright Meritor Inc 2013 Printed in USA Air Supply Fitting and Bellow Fittings 6 Verify the air lines for the bellows are connected to the Installation corresponding valve Tag or Drive The bellows on the Tag must be connected to the valve designated as the Tag axle curbside 1 Remove the air line and fitting from both passenger side air to
3. pin outs that can be 5 Activate Rear axle and Lifting axle by clicking both Middle used buttons and lower the frame totally by clicking Vent 7 Route the harness verifying correct reach to switches lamps 6 Check the current level and pressure screen to make sure the ECU and the Deutsch connector values move in the correct direction and are within 8 Once the location and routing have been determined make the approximately 2 9 psi 20 kPa of each other correct modifications to the dash panel to accommodate and 7 Click the Middle button of the lifting axle so only the rear install the following axle is activated e Three position momentary switch 8 Raise the frame by clicking Charge e lwo position momentary switch 9 Check that the air bags at the rear axle are full and the air bags e Red incandescent lamp X3 pin 8 at the lifting axle are empty e Amber incandescent lamp X1 pin 14 10 Lower the ride height again NOTE You must use incandescent indicator lights 11 Click both Middle buttons so the lifting axle is activated NOTE Indicator light X1 14 and X3 8 ignition power source 12 Raise the frame by clicking Charge must be separate from ECU ignition power source X1 10 13 Check that the air bags at the lifting axle are full and the air 9 Deactivate the manual air suspension dump valve in the cab bags at the rear axle are empty Refer to the valve manufacturer or OEM info
4. port 22 and street side to port 23 Figure 12 bags Figure 10 _____ SUPPLY AIR SUSPENSION BELLOW AIR SUPPLY TANK na a as a a a a a ee ee ee porcc 4006870a 4010864a Figure 10 Figure 12 2 Replace the fittings with 1 4 6 35 mm street T fittings 7 Once all of the connections have been made secure the air Figure 11 lines in place ECAS Frame Harness Installation 1 Untie the ECAS frame harness bundle part number 5400 850 918 0 and stretch it out on the floor Note that one end has a 23 pin female Deutsch connector and the other has five separate connectors Secure the harness by taping the bundle every 24 30 610 762 mm This will assist in routing and securing the harness for final installation Figure 13 For a wiring diagram refer to Figure 14 4010863a Figure 11 3 Once the T fittings are in place install the pressure sensors so they are on top of the T fittings Suspension Air Line Installation 1 Locate and trace the air supply source to the suspension 2 Deactivate the manual air suspension dump switch v 4010895a Deactivation of the manual air suspension dump switch may be made here or at the dash lever in the cab Contact the Figure 13 manufacturer or OEM for correct disabling procedures 3 Replace the air lines for the rear suspension if necessary 4 Ensure the air supply line runs from the supply tank fitting to port 11 on both valves 5 Make sure th
5. straight connector existing OEM connector These pins may be installed in the ECAS CAN II Deutsch connector as there are 13 vacant pin outs that can be used e Pressure sensor cable tag axle with a 90 degree connector e Pressure sensor cable drive axle with a 90 degree connector e Height sensor cable drive axle with a straight connector 3 Route the harness to the corresponding valve and pressure e solenoid valve cable tag axle with a straight connector sensor making sure to allow for correct installation of Deutsch connector Verify all connections prior to securing the harness TP 1388 Issued 09 13 16579 Page 6 Copyright Meritor Inc 2013 Printed in USA ECAS Cab Harness Installation 1 Untie the ECAS cab harness bundle part number S400 850 916 0 and stretch it out on the floor Note that one end has a 23 pin male Deutsch connector The other has three separate pre pinned ECU connectors and a blunt cut wiring section Figure 15 Refer to Figure 16 for pin locations For a wiring diagram refer to Figure 17 4010898a Figure 15 16 13 10 7 mT EE E E 17 14 1 8 5 2 EE EE ES a 9 6 EE 4010865a VIEW LOOKING INTO THE HARNESS CONNECTOR Figure 16 TP 1388 16579 Issued 09 13 Printed in USA Copyright Meritor Inc 2013 Page 7 Table C X 1 ECU 18 Pin Connector Component Pin Description Location J1939 Low Twisted Pair Blunt Cut 1939 Low J1939 High Twisted Pair Blunt Cut 1939 High Lif
6. MERITOR WABCO Technical Bulletin 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 4 amp WARNING To prevent serious eye injury always wear safe eye protection when you perform vehicle maintenance or service 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 Release all air from the air systems before you remove any components Pressurized air can cause serious personal injury Refer to the vehicle manufacturer s service manual for instructions How to Obtain Additional Maintenance service and Product Information Refer to Maintenance Manual MM 1315 Electronically Controlled Air Suspension ECAS for Buses and Trucks with CAN II SAE 1939 and User Guide SP 1372 Electronically Controlled Air Suspension ECAS Driver Tips If you have any questions about the material covered in this publication or for more information about the Meritor WABCO product line please contact the OnTrac Customer Service Center at 866 OnTracl 668 7221 or visit our website meritorwabco com How to Obtain Parts and Kits Contact Meritor s Commercial Vehicle Aft
7. Printed in USA X1 WIRE LENGTH 10 FT 1__J1939 LOW UNLESS OTHERWISE SPECIFIED 3__J1939 HIGH Kyo TWISTED PAIR 6 TRACTION SW 7__ BATTERY 12V al 10_IGNITION IGN p1 5A 12 GROUND 13_ RA LOSW POSR__POWER an WARNING LP Pin 17 to Pin 13 will raise Pin 17 to ground will lower Amber non LED PIN RAISE LOW SW 1 PRESS SENS _ _ POWER DRIVE PRESSURE SENSOR TAG PRESSURE SENSOR __L VALVE POWER DRIVE MODULATOR TAG MODULATOR M HEIGHT SENS HEIGHT SENSOR LEFT _N 4 DRIVE PRES DRIVE PRESSURE SENSOR LEFT O 5 DRIVE PRESSURE SENSOR TAG PRESSURE SENSOR HEIGHT SENSOR _P 6 7 DRIVE MODULATOR QO DRIVE MODULATOR _R TAG MODULATOR S SENS GRND 10 2 2D VALVE 11 3 2D VALVE TAG PRESSURE SENSOR LEFT V TAG MODULATOR W 14 2 2T VALVE 3 TAG PRES Power source must be separate from ECU ign ae power source X1 10 8 SAFETY LP AN IGN Red non LED SWITCH KIT 400 891 006 0 ECAS CAB WIRING DIAGRAM VIEW LOOKING INTO THE HARNESS CONNECTOR 4010896a ECAS CAB WIRING DIAGRAM VIEW LOOKING INTO THE HARNESS CONNECTOR Figure 17 2 Obtain and refer to the following location information provided e Incandescent red lamp Non LED by the OEM e Three position momentary switch Ignition power supply e Two position momentary switch mauler POWGrSUDDIY e J1939 Y connector e Ground e J1939 HI and LOW connection e J1939 connectors e Fu
8. e air lines for the bellows are connected to the corresponding valve Tag or Drive The bellows on the drive must be connected to the valve designated as the drive axle curbside to port 22 and street side to port 23 TP 1388 16579 Issued 09 13 Printed in USA Copyright Meritor Inc 2013 Page 5 SOLENOID VALVE CABLE DRIVE AXLE SOLENOID VALVE CABLE TAG AXLE 2 C5 L DRIVE PRESSURE SENSOR TAG PRESSURE SENSOR 4 SKT M _DRIVE MODULATOR TAG MODULATOR N HEIGHT SENSOR LEFT SIDE PRESSURE SENSOR E O DRIVE PRESSURE SENSOR LEFT a CABLE P DRIVE PRESSURE SENSOR TAG PRESSURE SENSOR HEIGHT SENSOR _ DRIVE AXLE Q DRIVE MODULATOR foal 1 Gy T AF R DRIVE MODULATOR S TAG MODULATOR V___TAG PRESSURE SENSOR LEFT N z W TAG MODULATOR PRESSURE SENSOR CABLE TAG AXLE BULKHEAD COMM JN I Q k3 4 SKT HEIGHT SENSOR CABLE DRIVE AXLE 1 LOOKING INTO THE HARNESS CONNECTOR TC 2 SKT 4010897a ECAS FRAME WIRING DIAGRAM Figure 14 2 Locate the entry point for the Deutsch connector at the front of 4 Make the following connections with the wiring harness as the cab Secure the retaining nut from the pass through labeled connector for reuse Note The retaining nut is not included in the kit The unit may have a blank on the passenger side that may be used or installation may require use of the existing Deutsch connector location This will require re pinning of the e Solenoid valve cable drive axle with a
9. ermarket at 888 725 9355 TOOLBOX Software This procedure requires TOOLBOX Software version 11 0 or higher To download this software visit meritorwabco com TP 1388 Issued 09 13 Electronically Controlled Air Suspension ECAS Retrofit Kit Installation Instructions for Meritor WABCO 6S 6M ATC Brake systems ECAS Overview The Meritor WABCO ECAS is an electrically controlled air suspension system designed to enhance the performance of the vehicle s air suspension when equipped with a Meritor WABCO 6S 6M ATC brake system The ECAS maintains an accurate leveling of the chassis height through the use of height sensors electronic control unit ECU and solenoid valves Because of the variety of suspension types and vehicle features a particular set of parameters was developed for each vehicle type These parameters determine some of the features and characteristics for the ECAS configuration In the event of a malfunction in the system the ECAS indicator lamp will alert the driver and the suspension will retain the existing air pressure in the air Suspension bellows Several of the features provided by ECAS include the following e Automatic Level Control The ECAS continually monitors the vehicle s height axle to frame distances through the ECU and the use of height and pressure sensors When the height deviates from the preset nominal level a correction is made quickly exhausting or pressurizing the air suspension be
10. llows by actuating solenoid valves The ECAS will maintain the nominal vehicle level regardless of the number of passengers boarding or unloading There are pre selected restrictions for when the height corrections can be made e Driver Controlled Level Adjustment Other than the nominal vehicle level there can be additional levels selected by the driver to raise the vehicle for rough surfaces or lower vehicle height These levels can be selected by switches on the vehicle dash panel The driver can also return the vehicle to the nominal level Recovery There are pre selected restrictions for when the height changes can be made e Automatic Traction Helo Load Transfer When wheel slippage is detected by the vehicle s ABS due to slippery road surface conditions a signal from the ABS triggers the ECAS system The ECAS can transfer weight from the non drive axle tag to the vehicle s drive axle by changing air pressures in the rear axles air suspension bellows By transferring pressure from the tag axle to the drive axle air bellows additional weight is transferred to the drive axle increasing drive wheel traction This function may also be initiated by the driver activating a switch on the vehicle dash panel There are pre selected restrictions for when the traction help can be activated and how much weight can be transferred 4010354a The ECAS will continue to hold the transferred load until the ECAS ECU preset speed limit has been
11. met which is 25 mph If the load l l l Figure 1 transfer is active all chassis height control functions are suspended until the load transfer has ended e Inclination Level Control Pressure Equality The ECAS ECU can adjust pressures in all air suspension bellows together or in individual air bellows This allows the ECAS to compensate for inclinations caused by unbalanced loads or uneven road surfaces Kit Parts List Locate and verify that the kit is complete and that you have access to TOOLBOX Software version 11 0 or higher prior to beginning the installation of this kit Table A Kit Parts Description Part Number Quantity ECAS ECU S400 850 920 0 1 ECAS Cab Harness S400 8509160 1 Ia ECAS Frame Harness S400 8509180 1 hakis ECAS Solenoid Valves 9472 880 073 0 2 Distance Sensor 5441 050 100 0 1 ECAS Sensor Lever 9441 050 718 2 1 ECAS Sensor Linkage 9433 401 003 0 1 Pressure Sensors 9441 044 106 0 2 M22 Fitting Adapters 1 2 9400 851 002 4 6 ECAS Valve Bracket 5400 850 055 4 2 4010363a DISTANCE SENSOR Figure 3 TP 1388 Issued 09 13 16579 Page 2 Copyright Meritor Inc 2013 Printed in USA 4010860a PRESSURE SENSOR Figure 4 mm mm 4010861a M22 FITTING ADAPTERS 1 2 Figure 5 4010895a ECAS FRAME HARNESS Figure 6 16579 ECAS CAB HARNESS Figure 7 Table B Additional Items Required Description Various quick connect fittings for the air lines Street T Fittings 1 4
12. rmation for correct 14 Lower the ride height again If the ride height does not move as procedures expected the air line plumbing or electrical system should be 10 Once the lamps and switches are installed make the changed and the ECAs retested appropriate connections according to the diagram 15 Charge the bellows until the nominal ride height is reached NOTE Use the J1939 Y connector and J1939 connectors to Refer to the ride height and measurement location per OEM complete the J1939 installation with terminating resistor if specifications necessary 16 Secure the electronic height sensor rod at a 90 degree angle 17 Refer to Maintenance Manual MM 1315 for calibration procedures To obtain this publication visit meritorwabco com TP 1388 Issued 09 13 16579 Page 10 Copyright Meritor Inc 2013 Printed in USA Notes MERITOR WABCO Meritor WABCO Vehicle Control Systems 2135 West Maple Road Troy MI 48084 7121 USA 866 OnTracl 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 2013 TP 1388 Meritor Inc Issued 09 13 All Rights Reserved Printed in USA 16579
13. se tap 3 Have the following parts ready to complete the cab harness 4 Determine the switch lamp and ECAS ECU mounting locations installation in the cab e ncandescent amber lamp Non LED TP 1388 16579 Issued 09 13 Printed in USA Copyright Meritor Inc 2013 Page 9 5 Create access to the ECU mounting location power sources Check Suspension Lifting and Lowering and indicator light location These will vary depending on the Calibration manufacturer of the tractor Contact the OEM for specific locations You may need to remove the dash panel glove box 1 After verifying all connections build air in the system to verify and lower dash covers to create access Refer to the vehicle correct component installation manufacturer s recommended procedures for removal 2 With accessory power on connect the TOOLBOX Software 6 Locate the Deutsch connector on the inside of the cab 11 0 and select ECAS CAN II TRUCK AND BUS bulkhead Secure the retaining nut from the pass through 3 Select diagnostic port 3 CANII bus front and truck and verify unit may have a blank on the passenger side that may be used corner or installation may require use of the existing Deutsch ee ae l connector location This will require re pinning of the existing 4 Click Lifting and Lowering oth Ty from left side When OEM connector These pins may be installed in the ECAS CAN II the warning screen appears click OK Deutsch connector as there are 13 vacant
14. tAxlesW NOT USED Traction Switch Blunt Cut Connect to Traction Switch Manual Load Transfer Battery Blunt Cut Connect to Fused Power Source Location per OEM 10 Ignition Blunt Cut Connect to Fused Power Source Location per OEM 12 Ground Blunt Cut Connect to Ground Source Verify Location per OEM 13 RaiserLowsW Blunt Cut Connect to switch 4 1 RideHeightLP AMBER Blunt Cut Connected to Lamp lgnition Power Source per QEM 17 RaiseLow SW Blunt Cut Connected to Switch TP 1388 Issued 09 13 Page 8 Copyright Meritor Inc 2013 Table D X 2 ECU 15 Pin Connector Pin Deutsch Location Description Component Pin Connector Location Power to Pressure Sensors Drive and Tag PressSens L Height SEN DrivePres signal to ECU from Drive Pressure Sensor 7 sensGnd Ground to Pressure sensor Drive Tag Height Sensor z m Power to Solenoid Valves Drive and Tag Signal to ECU from Height Sensor 2 2DValve Ground from ECU to Drive Solenoid 2 2 Valve 3 2DValve Ground from ECU to Drive Solenoid 3 2 Valve 14 2 2 Valve S Ground from ECU to Tag Solenoid 2 2 Valve Table E X 3 ECU 9 Pin Connector Pin Deutsch Component Pin Location Description Connector Location 3 TagPres V Signal to ECU from Tag Pressure Sensor 3 2 1Valve W Ground from ECU to Tag Solenoid 3 2 Valve 7 safetyLP RED Blunt Cut Connected to Lamp Ignition Power Source per OEM o pme or 16579
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