PLC Select 1M - Henry & Wright Corporation
Contents
1. Sensor No more than hn 080 off center Above or Below The clearance between the block and exciter ring should be 0 156 031 Any deviation will result in a reduction of the wheel speed sensor signal output Axle Hub gt dv normally welded to axle housing In general the position of the wheel speed sensor center axis to the exciter right surface should be as close as possible to a 90 angle in both direction Any deviation will result in a reduction of the wheel speed sensor signal output Note The sensor block is t29 generally welded to the axle Refer to axle manufacturer s manual to ensure that welding won t affect structural integrity Squareness PLC Select NN Page 4 Rev 5 0 4 Center Line Wheel End Installation Cont 530 470 Exciter Ring Installation 06 Radius 6 00 Dia Max Seal Bore 6 501 Dia Use a wire brush to 6 499 Dia clean area on hub before mounting the exciter ring 03 x 15 Chamfer Exciter Ring Machining 1 Heat the exciter ring uniformly to approximately 350 F 2 Place the exciter ring on the machined area of the axle hub 3 Make sure the exciter ring fits squarely on the machined surface 4 When the exciter ring cools it will shrink fit onto the hub 5 Make sure the exciter ring fits tightly onto the machined area and does not slip Ensure that the exciter ring fits squarely against the shoulder Exciter Ring 100 Tooth2. 24 PLC Select ABS 2M Installation Manual for 4S 2M Systems 25 PLC Select 2M System CoOmbpoPIells omatakse item v tad Pop ska Uns Ue Su dI card astma 26 PLC Select 2M ECU Valve Units Overview nennen nnns 27 28 PLC Select 2M Installation Overview FFABS System 4S 2M rrranrnnnrnrnnrrnrarennnrnnnnennanennnnn 29 PLC Select 2M Installation Overview ABS Relay System 4S 2M eeeeeeeeese 30 PLC Select 2M PLC Select FFABS 4S 2M Plumbing Schematic Side By Side 31 PLC Select 2M PLC Select 2 Port ABS 4S 2M Plumbing Schematic Side By Side 32 PLC Select 2M PLC Select FFABS 4S 2M Plumbing Schematic Axle By Axle 33 PLC Select 2M PLC Select 2 Port ABS 4S 2M Plumbing Schematic Axle By Axle 34 PLC Select 2M PLC Select 2M ECU Overview 35 PLC Select 2M 4S 2M System Wiring Side By Side 36 PLC Select 2M 4S 2M System Wiring Axle By Axle rrrrrarrrnnrrnnrrrrnrnrnnrrrarernnnrvnnrnvannnnnr 37 PLC Select 2M 4S 2M System Wiring Information nene nne 38 PLC Select 2M Speed Sensor Cable Routing 00000 nenne nene nennen 39 40 Testing and Diagnostic Tools PLC Select 1M 2M End of line Testing Road Testing rrrrrrrnnrnrnrrrrareranernnnrrnnrnvanennannranennnnnn 41
3. wheel end one at a time Refer to pages 6 11 for correct placement Axle By Axle or Side By Side Refer to L31158 for Info Center instructions 6 When using a PC in conjunction with Haldex PC diagnostics information such as the name of the Inspector the date inspected or the trailer VIN can be stored in the ABS ECU a gt Note If the ABS Light never illuminates or stays illuminated during the ABS check refer to Troubleshooting Section on page 53 of this manual Page 41 Rev 5 0 PLC Select End of Line Testing Road Testing PLC Select 1M 2M Road Test PLC Select 2M Procedure 1 Connect a tractor to the trailer and charge the trailer s air tanks Turn on the start switch and ensure that the Warning Light comes on briefly then goes out Pull the trailer at a speed above 6 mph make a brake application and hold until the tractor trailer has come to a complete stop Verify that the ABS Warning Light has remained OFF Ifthe light remained OFF the system is functioning properly If the ABS system detected an error during the stop the Warning Light will be ON If the ABS Warning Light never comes ON when the start switch is turned ON then refer to the No ABS Warning Light Illumination section on page 53 of this manual If the ABS Warning Light stays ON with the start switch on refer to the ABS Warning Light Stays on permanently section on page 53 of this manual Notes L 2 Disconnect powe
4. 42 Diagnostic Tools PLC PG Diagnosi nee rasen 43 45 Diagnostic Tools Blink Code DIAgfiOSllOS aa du 46 50 Info Center Information Info Center Manual L31158 Reference rrnnrrnnnnnnannnnannnnnrnnanennnnnnanennnnnnanennanennennnanennnsnnnnennn 51 Tire Scale Factor Chart PLC Select 1M 2M Tire Scale Factor Chart 022200224002000 0000 nenn anne nnne nenne nenne nennen 52 PLC Select 1M 2M Diagnostics PLC Select 1M 2M Troubleshooting ABS Warning Light erenen 53 PLC Select 1M 2M Diagnostics Codes nee een 54 58 Page 1 Rev 5 0 PLC Select Safety Notice This installation manual describes the correct installation procedures for the Haldex PLC Select 1M and 2M for trailers The PLC Select 1M and 2M may be used with either Drum or Disc Brakes Care must be taken during each phase of the installation in order to ensure the system is installed correctly Safety First Please follow your company s safety procedures when you install this equipment Be sure that you understand all instructions before you begin Note Remove all air pressure and electrical power from the brake system before beginning work IMPORTANT NOTICE The data listed herein is correct to the best of Haldex s knowledge and belief having been compiled from reliable and official sources of information However HALDEX CAN NOT ASSUME ANY RESPONSIBILITY for possible error or misapplication o
5. Blue channel wheel speed sensor wiring S3A has an Open or Short circuit Yellow channel wheel speed sensor wiring S3B has an Open or Short circuit System OK No Active Fault Red channel speed sensor S1A has low sensor output N Red channel speed sensor S1B has low sensor output CO Blue channel speed sensor S2A has low sensor output A Yellow channel speed sensor S2B has low sensor output OI Blue channel speed sensor S3A has low sensor output Yellow channel speed sensor S3B gap too large Gap should be kept to a minimum NO Incorrect exciter tone ring used PLC Select 1M 2M Diagnostics Codes Possible Causes PLC PLC Select Select 1M 2M ABS is operational Displays 00 greater than 6 mph X X Indicates a wheel speed sensor or its wiring has short or open circuit Disconnect the relevant sensor and measure the resistance between the two pins in the sensor connector housing The Ohmmeter reading for the sensor should be between 980 and 2350 Ohm 98K and 2 35 K Ohm If sensor extensions are used verify extension continuity and connections The sensors should be replaced if this is not the case ABS ECU is fully operational Displays 07 greater then 6 mph with no faults and vehicle stationary Sensor is worn or not properly adjusted wiring open or short circuit wheel bearing not properly adjusted these faults will only occur at speeds greater
6. Axle 2 Axle 1 4 Port FFABS a S3A S2A S2B S3B Valve with ECU Yellow Channel Rear Axle m 2 Port ABS Valve Blue Channel TE Power Connection IM Front Axle i S2A CurbSide S3A RoadSide 7 Way Wiring ABS Light 4S 2M Wiring Overview A App HEIGO eee all electrical connections K Distance of ABS Light from road side red rear clearance side Marker light is 5 9 inches to 23 inches max LED ABS lamps are acceptable Page 37 Rev 5 0 PLC Select NN 4S 2M System Wiring PLC Select Solenoid Connection hand tighten collar firmly Solenoid Connector Collar 2 Port ABS Valve 4 Port FFABS Valve SN Lock Tab za 7 zu 4 es 4 z ABS Power Cable Fully push the ABS Power Cable onto the ABS Power Connector and be sure the tab locks into place Insert sensors cable into the correct location on ECU and push sensor clip connector over sensor cable to secure them in place Sensor Clip PLC Select Page 38 Rev 5 0 Speed Sensor Cable Routing Sensor Block Sensor Block Clip n A is FOT 7 H9 E Sensor Sensor Block Exciter Ring Note Lightly grease the sensor with a Lithium based grease Use Dow Corning Molycoat CU7439 or equivalent Push sensor firmly against the exciter ring Insert the sensor clip into the sensor block 2 Insert the sensor into the sensor clip and push until it is firmly agains
7. BRAKE VALVES MUST BE HEAVY WALL TYPE PER SAE J514 Page 31 Rev 5 0 PLC Select ANN PLC Select 2 Port ABS 4S 2M with Trailer Brake Control Valve Trailer Brake Control Valve PLC Select ABS 2M 2 Port Relay Valve TBCV 2 Delivery Ports Plumbing Schematic Side By Side Sensor 3A Sensor 2A CurbSide CurbSide ull Dae Sensor 3B Sensor 2B Legend RoadSide RoadSide AIR BRAKE COMPONENTS AND SYSTEM SCHEMATIC ARE DESIGNED TO ALLOW COMPLIANCE Service Control Line WITH FMVSS 121 A THIS SCHEMATIC IS FOR INFORMATION PURPOSE ONLY IT IS THE VEHICLE MANUFACTURERS E M erg en cy S U pply Li ne mn m ULTIMATE RESPONSIBILITY TO CERTIFY THEIR SYSTEM MEETS ALL APPLICABLE REGULATIONS Sensor Line PIPE NIPPLES USED TO MOUNT BRAKE VALVES MUST BE HEAVY WALL TYPE PER SAE J514 Page 32 Rev 5 0 PLC Select FFABS 4S 2M 2 Delivery Ports PLC Select FFABS 2 Port Relay Valve 2 Delivery Ports Plumbing Schematic Axle By Axle Sensor 2A Sensor 2B CurbSide CurbSide a E MAI KI KI eee MM IML mn e Sensor 3A Sensor 3B RoadSide RoadSide Legend AIR BRAKE COMPONENTS AND SYSTEM SCHEMATIC ARE DESIGNED TO ALLOW COMPLIANCE Service Control Line WITH FMVSS 121 THIS SCHEMATIC IS FOR INFORMATION PURPOSE ONLY IT IS THE VEHICLE MANUFACTURERS Em erg en cy S U pply Line ULTIMATE RESPONSIBILITY TO CERTIFY THEIR SYSTEM MEETS AL
8. Rev 5 0 Possible Causes PLC PLC Select Select 1M 2M Modulator valve solenoid failure or valve cable damage Indicates that the solenoid or its cable has a short circuit to B positive 12 volts The most likely cause is a damage cable or solenoid Disconnect the indicated solenoid and check the resistance at the cable end Reading from each bottom pin to ground should be at least 13K Ohm Disconnect the indicated solenoid and check the resistance at the solenoid pins Read ing across the two bottom pins should be between 7 and 9 Ohm 7 0 9 0 Ohm Verify 12 VDC power source Do Not Use Battery Charger as Power Supply ECU minimum operating voltage is 8 5 VDC Verify permanent power is present Verify 12 VDC power source Do Not Use Battery Charger as Power Supply ECU maximum operating voltage is 16 0 VDC ECU Failure PLC Select Explanation x displayed when power is applied to the ABS ECU They should not be displayed for more then 2 Auxiliary Codes Codes A x PLC Select 1M 2M Diagnostics Codes Possible Causes PLC PLC Select Select 1M 2M seconds if code remain permanently displayed repair is necessary A7 Trailer SLH on Yellow Red 2S 1M channel gt X TI C2 NO Co Trailer MSLH on Red channel single axles only Steerable or O O 2S 1M configuration O 2S 2M configuration 4S 2M configuration O 4S 2M configuration gt Erase mem
9. and abrasion A sensor clip is placed on the hose and sensor wire 6 Single Sensor Hose Clip Excess cable length may be taken up in either a short bone or a long bone arrangement and secured with tie straps Do not coil the cable into a loop smaller then 4 inches in diameter Do not over tighten the tie straps when the cable is coiled as this could cause a cable failure O 2 O Push up and and attach tie Short Cable short bone straps Long cable long bone PLC Select NN Page 40 Rev 5 0 End of Line Testing Road Testing PLC Select 1M 2M Installation Test This step will ensure the ABS system is functioning properly before the chassis is assembled to the trailer Test Equipment 12 VDC power source Do Not use a battery charger power cable with a Packard 5 pin male power connection an ABS test light attached and shop air Chassis Test End Of Line ABS Check Procedure 1 Charge the Emergency Supply and Service Control air systems 2 Apply power source to 7 Way receptacle permanent power 3 The ABS Valve s should blow down first You will hear a brief shot of air from each valve The Blue Channel remote valve should blow down first followed by the Yellow Channel ECU valve for a 25 1M system the Yellow Channel valve only The ABS light should illuminate for about 3 seconds and then turn off Using a Info Center or PC verify correct sensor placement by spinning each
10. displays the most information Available functions include all the functions of the PLC Info Center as well as 1 View ABS ECU Part Number 2 Save ABS diagnostic results for a print out of test verification O Read Write Trailer and or Service data internally to ABS ECU Minimum requirements Pentium Il 33 MB Ram 233 MHz Windows 95B RS232 9 pin com port Note PLC Info Center and PLC PC Diagnostics are not compatible with older generations of ABS manufactured prior to March 2001 Reference PC Diagnostic Instruction Manual L31154 Page 45 Rev 5 0 PLC Select Blink Code Diagnostics There are 4 Blink Code Modes Mode Description Permanent Power Cycles 1 second ON 1 second OFF with service brakes applied JE Speed Mode ON off ON Active Faults Mode ON off ON off ON Faults Clear Mode ON off ON off ON off ON IA Mode ON off ON off ON off ON off ON Procedure for Blink Code Diagnostics 1 2 The trailer must be connected to a DC power supply 10 15 volts Do not use a battery charger 9 Constant power 10 15 volts must be provided to the stoplight circuit apply trailer service brakes 4 Permanent power must be cycled on and off trailer auxiliary circuit at 1 second intervals The trailer must be stationary to reach the desired mode shown above f a power source other than a truck is used a switch must be used to simulate a truck start switch Note Stoplight and Perma
11. dry bearings broken 7 ow wheel recovery on Red valve channel return spring restricted piping Modulator TE eut Check for kinks and blockage etc Incorrect piping wiring For a 2M System Slow wheel recovery on Blue valve channel verify the sensors and valve configuration is correct See Side By Side and Slow wheel recovery on Yellow valve channel Axle By Axle configurations NO QD Hold solenoid Open circuit on Red valve Modulator valve solenoid failure solenoid channel connection or valve cable damage The most likely causes include a bad solenoid or a loose Hold solenoid Open circuit on Blue valve solenoid connection Disconnect the indicated channel solenoid and check the resistance at the solenoid pins Reading across the two bottom pins to ground should be between 7 and 9 Ohm Check the female terminals on the connector for excessive pin spread or corrosion Replace defective hardware as reguired and Dump solenoid Open circuit on Red valve retest channel Hold solenoid Open circuit on Yellow valve channel O N O O O O D A O amp N Q CD Dump solenoid Open circuit on Blue valve channel Dump solenoid Open circuit on Yellow valve channel 7 0 9 0 Ohm Hold solenoid Short circuit to ground on Red Modulator valve solenoid failure or valve cable valve channel damage The most likely causes include a damaged cable or solenoid An example of Hold solenoid Short circuit to ground on
12. in each code 3 Code 07 system OK vehicle at rest is displayed as a continuous light ON condition Mode 4 Configuration Mode ON OFF ON OFF ON OFF ON OFF ON This Mode displays Configuration and Auxiliary Codes The Configuration Code is displayed prior to Auxiliary Codes The tables on page 50 show a list of Configuration Codes and a list of Auxiliary Codes which supported by Blink Codes Auxiliary Codes are displayed low to high Each blink code digit will refer to a digit in the Haldex configuration codes Clear Configuration Mode The configuration codes may be cleared by switching Permanent power OFF ON OFF ON while the brakes are applied during the 10 seconds of light energization that occurs prior to each repeat of the fault code blink seguence The light will flash rapidly for 10 seconds to indicate that the configuration has been erased from the ECU s memory The ECU will then store its full configuration on the next power up Page 49 Rev 5 0 PLC Select Blink Code Diagnostics m Code Blinks Function AE Lifted ei Used 2S 1M Im S1B eo Mw EE jts e 3 45 2M S3A S2A S2B S3B Blue Yellow MNE 45 2M wu S2A S2B S3B Blue Yellow S 1 Not Applicable S s aj a S E II ag Poes od BEL AAA ME EEE A OU AA ALAI Mode 5 Odometer Mode 6 ONS This mode displays the odometers Example 4364 7 miles 4 on off 1 2 sec flashes 3 on off 1 2 sec flashes 6 on off 1 2 sec flashes 4 on off 1 2
13. 4 Using a 1 1 2 wrench on the jam nut while holding the nipple with the 7 8 wrench see detail below s Attach hoses to appropriate brake chambers Use liguid thread sealant sparingly on all fittings Loctite PST565 or equivalent Note If frame mounted follow same procedure for valve orientation Valve solenoid on a 2 port relay 6 port relay or FFABS must be facing up when the trailer is in normal operation or service ABS performace could be effected Tighten nipple torque 50 ft Ib Jam Nut torque 30 ft Ib Use 7 8 Wrench Use 1 1 2 Wrench Page 16 Rev 5 0 PLC Select PLC Select 1M Installation Overview 4 Port FFABS System Plumbing 25 1M Note The slider chassis is shown upside down in figure below Blue Service Control Red Emergency Supply 5 Way ABS Power Connector PLC Select 1M FFABS These are the general components that make up the Haldex PLC Select 1M The PLC Select 1M can be used on Single Tandem and Tri Axle vehicles For other configurations contact Haldex Engineering Support PLC Select Page 17 Rev 5 0 PLC Select 1M Installation Overview 6 Port ABS System Plumbing 25 1M Trailer Brake Control Valve is required Note The slider chassis is shown upside down in figure below x KA N w Trailer Brake Control Valve TBCV Fa 4 ul INLA L is V na PLC Select 6 Port ABS Valve Red Emergency Sup
14. 80 Tooth Note Some application with small wheel tires may require 80 tooth exciters Reference Tire Scale Factor Chart on page 52 Page 5 Rev 5 0 PLC Select Wheel Speed Sensor Installation 2S 1M Configurations Sensors should be installed on the axle that locks first when the trailer is unloaded Recommended locations are shown below The 1A sensor should be installed on the curb side and the 1B sensor should be installed on the road side of the trailer Make sure sensors are pushed firmly against the exciter rings Dollies and Single Axle Trailers 2 or 6 Ports Valve For Dollies Single Axle Trailers and Steer Axles Haldex recommends the A8 ECU configuration Spring Suspension Legend CurbSide King Pin M Speed Sensor O ME ECU with ABS Valve RoadSide CurbSide i L CurbSide RoadSide RoadSide CurbSide RoadSide RoadSide MAI Page 6 Rev 5 0 Wheel Speed Sensor Installation 2S 2M Configurations Side By Side Sensors should be installed on the axle that locks first when the trailer is unloaded Recommended locations are shown below The 2A sensor should be installed on the curb side and the 2B sensor should be installed on the road side ofthe trailer Make sure sensors are pushed firmly against the exciter rings Note The 2S 2M configuration does not offer any meaningful performance benefit over a 2S 1M SLH A7 configuration and is not a
15. Blue this is a worn or chafed cable that has exposed valve channel wires contacting the trailer Disconnect the De indicated solenoid and check the resistance Hold solenoid Short circuit to ground on Yellow at the cable end of solenoid Reading from ee eh bottom pin to ground should be at least x 13K Ohm Replace defective hardware as Dump solenoid Short circuit to ground on Red required and retest Disconnect the indicated solenoid and check the resistance at the xl 8 Dump solenoid Short circuit to ground on Blue ee nn AN De qx valve channel X 9 Dump solenoi ort circuit to ground on T X Page 56 Rev 5 0 71 2 7 C2 PLC Select 1M 2M Diagnostics Codes Explanation Output leakage or poor insulation on any of the valve channels Hold solenoid short circuit to B on Red valve channel Hold solenoid short circuit to B on Blue valve channel Co QD Hold solenoid short circuit to B on Yellow valve channel Co N O O 00 00 00 O Co N Q D Dump solenoid out shorted on B on Red valve channel Dump solenoid out shorted on B on Blue valve channel Dump solenoid out shorted on B on Yellow valve channel Low supply voltage fault Does Not latch Is not stored in memory co No internal ABS ECU solenoid voltage available co NO Power input over voltage fault co QD Short circuit on ABS ECU internal relay ABS Corrupt Memory gt ABS Corrupt Memory Page 57
16. Installation Guide L30041 Rev 9 07 PLC Select ABS 2M PLC Select ABS 1M Installation Service Manual for 2S 1M 4S 2M 2S 2M Systems 7 00 Table of Contents Section TENNE hr 1 SAA NOE E 2 General Operation of PLC Select 1M and 2M ene 3 Wheel ENG ae EE EEE EEE uu au 4 5 Wheel Speed Sensor Installation Configurations 1M and 2M Systems 6 11 PLC Select ABS 1M Installation Manual for 2S 1M Systems 12 PLC Select 1M System COImpOFIells nee ee 13 PLC Select 1M ECU Valve Units OverView ane 14 15 PLC Select 1M and 2M Valve Orientation 00000 nenne nennen nano nenne nnns 16 PLC Select 1M Installation Overview 4 Port FFABS Systems 2 S1M 17 PLC Select 1M Installation Overview 6 Port ABS System 2S 1M sese 18 PLC Select 1M PLC Select FFABS 2S 1M Plumbing Schematic 19 PLC Select 1M PLC Select 6 Port ABS 2S 1M Plumbing Schematic 20 PLC Select 1M ABS Power Cord Pin Out 1M ECU OwVverView eene 21 PLC Select 1M 25111 System WIHNG een un uc aidati 22 PLC Select 1M Speed Sensor Cable Routing u0 u02220020000200 00000 nenne nenn anne nnnne anne 23
17. L APPLICABLE REGULATIONS PIPE NIPPLES USED TO MOUNT BRAKE VALVES MUST BE HEAVY WALL TYPE PER SAE J514 Page 33 Rev 5 0 PLC Select ANN PLC Select 2 Port ABS 4S 2M with Trailer Brake Control Valve Trailer Brake Control Valve PLC Select ABS 2M 2 Port Relay Valve TBCV 2 Delivery Ports Plumbing Schematic Axle By Axle Sensor 2A Sensor 2B CurbSide CurbSide l l l l S Dl FE EEE Sensor 3A Sensor 3B Legend RoadSide RoadSide AIR BRAKE COMPONENTS AND SYSTEM SCHEMATIC ARE DESIGNED TO ALLOW COMPLIANCE Service Control Line WITH FMVSS 121 Emergency Supply Line THIS SCHEMATIC IS FOR INFORMATION PURPOSE ONLY IT IS THE VEHICLE MANUFACTURERS ULTIMATE RESPONSIBILITY TO CERTIFY THEIR SYSTEM MEETS ALL APPLICABLE REGULATIONS PIPE NIPPLES USED TO MOUNT BRAKE VALVES MUST BE HEAVY WALL TYPE PER SAE J514 Page 34 Rev 5 0 PLC Select 2M ECU Overview Most compact package offers the best ABS solution for 4S 2M application Sensors S2A and S3A are Sensor Sensor Not Used with 2S 1M S2A S2B Configuration Blue Yellow Sensor Sensor S3A S3B Blue Yellow Modulator Valve Solenoid Cable PLC Select 2M Yellow Channel Electronic Control Unit ECU ABS Power Connector A Modulator Valve Solenoid Cable Blue Channel low Not Used with 2S 1M Configuration ABS Power Cable Verify connection locking
18. ads electric impulses generated from the rotating exciter as the wheels turn The ECU is designed to recognize when the rate of wheel speed deceleration is approaching wheel lock no longer rotating which would result in skidding During a braking event the ECU continuously monitors the rate of deceleration so that it can automatically intervene into the operation of the ABS Modulator Valve s to maintain stability during braking When the rate of deceleration approaches wheel lock the ECU sends electrical signals to the ABS Modulator Valve s to reduce air pressure to the service brake chambers which reduces braking to maximize stability When the rate of deceleration returns to a level above the wheel lock threshold the ECU sends electrical signals to the ABS Modulator Valve s to increase pressure to the service brake chambers which increases braking This iterative process of decreasing and increasing braking takes place in milliseconds and continues as long as the deceleration rate is in jeopardy of wheel lock to help assure vehicle stability The Haldex PLC Select 1M is positioned as a 2S 1M system for Semi Trailers and Dollies using 2 Sensors and 1 Modulator ABS Valve Note Haldex recommends our 2S 1M SLH product as a more cost effective solution to meet minimum FMVSS121 requirements for Semi Trailer and Dollies and in most applications can provide comparable performance as 2M systems The Haldex PLC Select 2M is position
19. alve Service Control Port PLC Select 2M ECU Solenoid Service Control Port Service Brake Delivery Service Brake Delivery Reservoir Port Note All ports are 3 8 NPT except the reservoir port is 1 2 NPT Trailer Brake Control Valve 3 8 NPT Control Port 3 8 NPT Supply Port E 3 8 NPT Spring Brake 1 2 NPT Reservoir Port 3 8 NPT Spring Brake Delivery Ports Delivery Ports Note 1 All ports are 3 8 NPT except the reservoir port is 1 2 NPT 2 Service Control and Emergency Supply ports have Serviceable Filter Screen installed 3 Install this valve as shown Exhaust port pointing horizontal PLC Select Page 28 Rev 5 0 PLC Select 2M Installation Overview FFABS System Plumbing 45 2M These are the general components that make up the Haldex PLC Select 2M and they can be configured in a Side By Side or Axle By Axle installation The PLC Select 2M can be used on other vehicle configurations contact Haldex Engineering Support Note The slider chassis is shown upside down and plumbed Axle By Axle in figure below 2 Port ABS Relay Valve Blue Channel D 7 Service Control E Blue Channel Emergency Supply Red Channel z p A s za ZA Way ma 4 PLC Select 2M FFABS ower Connector Yellow Channel Page 29 Rev 5 0 PLC Select PLC Select 2M Installation Overview ABS Relay System Plumbing 45 2M Trailer Brake Control Valve is required The
20. ceptable Tie Strap Only the ABS power cord should be routed through the support clip The ABS Power Cord is secured to the bracket and is secured with a tie strap Page 22 Rev 5 0 PLC Select Speed Sensor Cable Routing Sensor Block Sensor Sensor Block Clip Ar Fo LE Sensor Sensor Block Exciter Ring Note Lightly grease the sensor with a Lithium based grease Use Dow Corning Molycoat CU7439 or equivalent Push sensor firmly against the exciter ring 1 Insert the sensor block clip into the sensor block 2 Insert the sensor into the sensor block clip and push until it is firmly against the exciter ring first grease the sensor with a lithium based grease 3 Route all sensor cables through vacant holes etc Use a grommet or corrugated tubing if the cables are touching sharp edges 4 Attach cable ties as needed to ensure the cable is secured to the axle housing 5 Typical routing of cable is along the brake chamber air hose 6 Use sensor cable hose clip highly recommended or double tie straps when attaching the cables to the air hoses T Sensor cable hose clip or double tie straps should be no farther then 12 inches apart Note Use caution when attaching tie strap to air hoses Over tightening can damage a cable and cause an ABS sensor failure PLC Select Page 23 Rev 5 0 Speed Sensor Cable Routing This manual depicts speed sensor cable routing along the vehicle axl
21. device Page 55 Rev 5 0 Auxiliary channel 0 fault digital channel 0 I O 1 Auxiliary channel 1 fault digital channel 1 Auxiliaries Possible Causes PLC PLC Select Select 1M 2M Loose sensor connection bracket or exciter damaged exciter sensor is not properly adjusted or has worn cable insulation or worn spring clip wheel bearing failure wheel bearing is not properly adjusted these faults will only occur at speeds greater than 6 mph Measure the AC voltage at the sensor in question while rotating the wheel at a rate of about one revolution every two seconds The output should be at least 200 millivolts 0 2 Vac If this is not the case push in the sensor until it touches the exciter and rotate the wheel again If this doesn t correct the problem then the sensor should be replaced Verify tire and wheel size is large enough for 100 teeth exciter ring If these faults re occur at the same speed inspect exciter ring for damage Smaller wheels and tires require 80 teeth exciter rings Reference Tire Scale Factor These Codes are only used with PLC Select 2M Plus ABS that supports trailer the ECU Electronic Control Unit has auxiliary device connected and should not PLC Select PLC Select 1M 2M Diagnostics Codes Explanation Possible Causes PLC PLC Select Select 1M 2M 40 Sensor wiring crossed across an axle Slow brake release foundation brake mechanical faults
22. e 8 Rev 5 0 Wheel Speed Sensor Installation 4S 2M Side By Side Lift Control On 45 2M Side By Side installation the sensed wheels 3A and 3B can be used on a lift axle The sensed wheels 2A and 2B must remain on the ground at all times Note Indirectly controlled axles axles without sensors but controlled by ABS valves may be lifted regardless of the configuration Make sure sensors are pushed firmly against the exciter rings Direct axle has ABS Sensors Indirect axle has no sensors but is ABS modulated by an ABS valve Legend King Pin Speed Sensor ABS Valve Blue Channel ECU with ABS Valve Yellow Channel CurbSide P x CurbSide RoadSide J RoadSide Lift Axle CurbSide CurbSide RoadSide Lift Axle Correct Correct Page 9 Rev 5 0 Wheel Speed Sensor Installation 4S 2M Configurations Axle By Axle The placement of the sensors at the wheel end is an important consideration Incorrect installation of the sensors and exciter will result in poor or no ABS operation The yellow markings sensors connections and axle locations must go to the yellow ABS valve as shown below The same holds true for the blue markings valve On a 4S 2M Axle By Axle configuration the blue modulator lead must be connected to the valve that controls the Front Axle wheel ends and is sensed by the blue sensors 3A and 2A The yellow valve cable lead must be connected
23. e braking air pressure in response to the input from the speed sensors Incorrect installation or location of speed sensors and exciter rings will result in poor ABS performance or sensors crossed leading to incorrect diagnostics troubleshooting The figure below shows the correct power and speed sensor connections on the PLC Select 1M ECU Electronic Control Unit PLC Select 1M ABS Power Connector ECU Electronic Control Unit ABS Power Cord SLH A7 2302 DO NOT USE ON STEERABLE AXLES 354428001 T065 OR DOLLIES ABS modulator valve solenoid connector a Sensor S1A CurbSide Red Channel Sensor S1B RoadSide Red Channel 364429001 HALDEX sen Note When servicing always apply small amount of dielectric grease to electrical connections PLC Select Page 21 Rev 5 0 2S 1M System Wiring PLC Select Note Cover all exposed connections before painting Exciter Ring STA CurbSide Apply dielectric grease to Red Channel all electrical connections ABS Power Connection e y ECU Sensor Retainer Clip Solenoid Connection N hand tighten collar firmly P Exditer Rino JJ 44 f dam S1A Top S1B Bottom 51B RoadSide Red Channel ABS Light mounted on RoadSide of trailer at the rear LED ABS lamp is acceptable 7 Way Wiring SAEJ560 Distance of ABS Light from Red rear clearance side marker light is 5 9 inches to 23 inches max LED lamp are ac
24. ed as a 45 2M system using 4 Sensor and 2 Modulators ABS Valves Although it can be used for 25 2M applications Haldex recommends our 2S 1M SLH product as comparable performance and more economical Although a 4S 2M is only required for Full Trailers to comply with FMVSS 121 it can provide improved performance in certain applications and we encourage you to consult your Haldex representative for a recommendation to fit your specific application needs and or preferences All other braked Semi Trailer and Dollies comply with FMVSS 121 using a 2S 1M system FMVSS 121 specifies that Blue Wire J560 connector be allocated as permanent power for ABS operation In the event of a failure or malfunction of the permanent power circuit the ABS system will operate on power from the stoplight circuit i e when the brakes are applied If the power fails in both circuits the ABS system reverts to a standard braking system Page 3 Rev 5 0 PLC Select Wheel End Installation The radial clocking position should be between 9 and 3 o clock While the ABS performance is not affected with sensor location in the lower half of the 12 o clock axle the structural integrity of the axle could be compromised Note The sensor block should not interfere with any wheel end hardware 3 o clock Sensor Blocks Axle Sensor Block allowable placement 156 031 Sensor Block Exciter Ring 4 CenterLine CL
25. ervice life ethi cal business practices and commitment to long term partnerships Haldex operations are divided into four business areas Commercial Vehicle Systems Hydraulic Systems Garphyttan Wire and Traction Systems C2007 This material may contain Haldex trademarks and third party trademarks trade names corporate logos graphics and emblems which are the property of their respective com panies The contents of this document may not be copied distributed adapted or displayed for commercial purposes or otherwise without prior written consent from Haldex Commercial Vehicle Systems Austria Haldex Wien Ges m b H Vienna Tel 43 1 8 65 16 40 Fax 43 1 8 65 16 40 27 E Mail info AT Haldex com Belgium Haldex N V S A Balegem Ghent Tel 32 9 363 90 00 Fax 32 9 363 90 09 E Mail info BE Haldex com Brazil Haldex do Brasil Ind e Com Lida S o Paulo Tel 55 11 213 55 000 Fax 55 11 503 49 515 E Mail info BR Haldex com Canada Haldex Ltd Guelph Ontario Tel 1 519 826 7723 Fax 1 519 826 9497 E Mail info CAQHaldex com China Haldex International Trading Co Ltd Shanghai Tel 86 21 5240 0338 Fax 86 21 5240 0177 E Mail info CN Haldex com France Haldex Europe SAS Weyersheim Strasbourg Tel 33 3 88 68 22 00 Fax 35 5 88 68 22 09 E Mail info EURQHaldex com Germany Haldex Brake Products GmbH Heidelberg Tel 49 6221 7030 Fax 49 6221 703400 E Mail
26. es This was shown for clarity Although it is possible to route cables this way the preferred approach is to route the speed sensor cables along the air hoses between the ABS valve and the brake actuators Tie straps may be used to secure sensor cable to the axle Although tie straps may be used a more reliable installation results if single clips are used to secure speed sensor cables to air hoses Leave some slack in cables to accommodate movement between chassis components Ex cess cable must not be allowed to hang free and must be bundled and attached to the chassis or air lines to prevent damage due to vibration and abrasion A sensor clip is placed on the hose and sensor wire oingle Sensor Hose Clip Excess cable length may be taken up in either a short bone or a long bone arrangement and secured with tie straps Do not coil the cable into a loop smaller then 4 inches in diameter Do not over tighten the tie straps when the cable is coiled as this could cause a cable failure C Push up and and attach tie straps Short Cable short bone Long cable long bone Page 24 Rev 5 0 PLC Select PLC Select ABS 2M Installation Service Manual for 4S 2M 2S 2M Systems Page 25 Rev 5 0 PLC Select PLC Select 2M System Components See Haldex Trailer ABS Service Components Catalog L20243 for additional information on Haldex ABS Products Haldex Supplied Items Required Optional S
27. f the product Final determination of the suitability of the products for the use contemplated by the Buyer is the sole responsibility of the Buyer Haldex shall have no responsibility in connection with this suitability IMPORTANT NOTICE The description and specifications contained in this Installation Service Manual are current at the time of printing Haldex Brake Products Corp reserves the right to discontinue or modify its models and or procedure and to change specifications at any time without notice All rights reserved Material may only be reproduced with written permission of Haldex PLC Select Page 2 Rev 5 0 General Operation of PLC Select 1M and 2M The Haldex PLC Select 1M and 2M are the newest ECU platforms in the PLC family of Trailer ABS products and is the latest offering in the state of art PLC Select concept As with other ABS systems PLC Select 1M and 2M are designed to use electronic management of service braking to avoid wheel lock up during all types of braking conditions and on all road surface conditions to improve control and stability of a braking trailer to permit air brake compliance with FMVSS 121 The primary components of Haldex ABS are the ECU Electronic Control Unit ABS Modulator Valves solenoid operated air valves wheel speed sensor Sensors and Exciter Rings exciter The inductive sensors are mounted at the designated wheel ends in conjunction with exciter notched rings The ECU re
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29. is not activated until the ECU has received a signal from the wheel speed sensor of a spinning wheel The hold solenoid of the modulator valve associated with the particular sensed spinning wheel will be cycled the same number of times as the lamp flashes The blink codes for the sensed wheels are as follows S1A 1 Flash S1B 2 Flashes S2A 3 Flashes S2B 4 Flashes S3A 5 Flashes S3B 6 Flashes Note 1 Spin only one wheel at a time Note 2 Once a wheel is rotated the ABS light will remain on after the wheel is stopped until the next wheel is rotated Page 47 Rev 5 0 PLC Select Blink Code Diagnostics Mode 2 Active Faults Mode ON OFF ON OFF ON In this mode the ABS light displays a numerical fault code sequence for each existing fault up to nine fault codes at a time The nine faults must be repaired before additional active faults can be displayed The blink codes used in the Active Fault Mode are related to the Haldex standard fault codes and are shown on pages 54 58 Example Fault code 23 is indicated by the light flashing ON twice for one half second each time followed by two seconds of light off followed by three 1 2 second flashes Mode 3 Stored Passive Faults Clear Mode ON OFF ON OFF ON OFF ON In this mode the ABS light displays a numerical fault code sequence for each stored fault All stored faults not currently active are displayed in this mode The light will display up to nine passi
30. nent power must be independent for blink code troubleshooting If Permanent power is required for your brake lights to operate then the blink code diagnostics will not function Procedure Notes 1 Once a blink mode is entered that mode can only be terminated by completely disconnecting all trailer power sources 2 All modes repeat endlessly Each repeat is separated by 10 seconds of continuous light energization 9 All codes are separated by 2 seconds of light OFF 4 Stored fault codes are followed by an occurrence count which display a blink rate twice as fast as the fault code blink rate Mode 1 Simple Mode Diagnostics This mode has a abbreviated list of fault codes that will display Fault codes are grouped to simplify the diagnostics Up to 3 active codes will be display at one time These faults need to be repaired before other active faults can be displayed See Simple Mode Faults Code Table on next page PLC Select Page 46 Rev 5 0 Blink Code Diagnostics Haldex Mode 1 Simple Mode Diagnostics Faults Table ON OFF ON Flash Count Actual Fault ee Sensor 1B 2 Flashes Ka EE EN 5 Sers prens P uTTT Blue Valve 8 Flashes ow aa po Paes ja zv gt oo o Note If the simple mode does not show a fault code but the ABS light remains ON after powering the ABS there are no active faults present Wheel Speed Mode Wheel Speed Mode is accessible only when in Simple Mode This Mode
31. ory invitation not a configuration code Q O Erase configuration prompt not a configuration code Unacceptable combination of sensors and solenoid EO thru EF are generated when internal Codes problems exist within the ABS ECU Trailer Auxiliary option on Yellow Red 2S 1M valve channel Trailer Auxiliary option on Red valve channel S1A S1B sensors Red modulator ECU is configured as a 2M andis powered up as a 1M S2A S2B sensors Blue Yellow modulator ECU is configured as a 4S 2M and powered up as a 2S 2M S3A S2A S2B S3B sensors Blue Yellow modulators S3A S2A S2B S3B sensors Blue Yellow modulators S3A and S3B sensed lift axle Only reguired when configured ABS System from a 4S 2M to a 2S 2M or any 2M configured to a 1M Unrecognized ABS configuration Verify all sensors and valve connections ABS ECU is defective Replace the ABS ECU Page 58 Rev 5 0 Notes Page 59 Rev 5 0 PLC Select Notes PLC Select Page 60 Rev 5 0 Notes Page 61 Rev 5 0 Notes PLC Select Page 62 Rev 5 0 Haldex offers proprietary vehicle technology so lutions to the global vehicle industry within spe cific niches We focus on products to improve safety the environment and vehicle dynamics We are enhancing our competitive capabilities and building long term customer relationships through high performance low total costs to the customer through the product s s
32. ply 5 Way ABS y Power Connector These are the general components that make up the Haldex PLC Select 1M When an ABS Relay Valve is used a Trailer Brake Control Valve is required such as Haldex TBCV or RT 4 valve The PLC Select 1M can be used on Single Tandem and Tri Axle vehicles For other configurations contact Haldex Engineering Support Page 18 Rev 5 0 PLC Select PLC Select FFABS 2S 1M 4 Delivery Ports Air suspension typically sense rear axle Spring suspension typically sense front axle PLC Select 1M FFABS Plumbing Schematic 2S 1M Sensor 1A CurbSide L EEE Sensor 1B RoadSide I Legend AIR BRAKE COMPONENTS AND SYSTEM SCHEMATIC ARE DESIGNED TO ALLOW COMPLIANCE Service Control Line WITH FMVSS 121 THIS SCHEMATIC IS FOR INFORMATION PURPOSE ONLY IT IS THE VEHICLE MANUFACTURERS Em erg en cy S U pply line ULTIMATE RESPONSIBILITY TO CERTIFY THEIR SYSTEM MEETS ALL APPLICABLE REGULATIONS PIPE NIPPLES USED TO MOUNT BRAKE VALVES MUST BE HEAVY WALL TYPE PER SAE J514 PLC Select Page 19 Rev 5 0 PLC Select 6 Port ABS 2S 1M with Trailer Brake Control Valve Air suspension typically sense rear axle e Spring suspension typically sense front axle PLC Select Trailer Brake Control Valve 6 Port ABS Valve TBCV Plumbing Schematic 2S 1M Sensor 1A CurbSide L
33. preferred system To obtain additional performance beyond a 2S 1M configuration Haldex recommends the use of a 4S 2M System King Pin Speed Sensor ABS Valve Blue Channel ECU with ABS Valve Yellow Channel Spring Suspension CurbSide 4 L CurbSide RoadSide Hi RoadSide CurbSide RoadSide Page 7 Rev 5 0 Wheel Speed Sensor Installation 4S 2M Configurations Side By Side The placement of the sensors at the wheel end is an important consideration Incorrect installation of the sensors and exciter will result in poor or no ABS operation The yellow markings sensors connections and axle locations must go to the yellow ABS valve as shown below The same holds true for the blue markings valve On a 4S 2M Side By Side configuration the blue modulator lead must be connected to the valve that controls the Curb Side wheel ends and are sensed by the blue sensors 3A and 2A The yellow valve cable lead must be connected to the valve that controls the Road Side wheel ends and Is sensed by the yellow sensors 3B and 2B The schematic below shows the proper placement of the sensors and valve leads the king pin indicates the front of the trailer Make sure sensors are pushed firmly against the exciter rings Legend King Pin Speed Sensor ABS Valve Blue Channel ECU with ABS Valve Yellow Channel Spring Suspension 3A mm CurbSide RoadSide Air Suspension 3A E 2A Pag
34. r from the ABS system before testing or making any repairs Most ABS problems are related to Cut or abraded wires Corroded connector or terminals Connector terminals not latched or seated correctly to mating assemblies Excessive sensor air gap sensor clip retention or wheel bearing end play Verify sufficient power at the ABS Power Cable 12 15V DQANTN After making any repairs go to the Diagnostic Tools section of this manual see pages 44 45 to confirm that the fault is corrected If fault codes 11 16 or 21 26 has occurred the Warning Light will remain on with a code 07 when repowered until the problem has been corrected The vehicle must be driven above 6 MPH for the ABS to recognize the problem has been corrected Then the light will turn off PLC Select Page 42 Rev 8 0 Diagnostics Tools SAE 560 7 way Diagnostic Interface Cable PLC PC Diagnostics Kit PC not included Blink Codes J1708 PLC Adapter PLC Info Center Page 43 Rev 5 0 PLC Select Diagnostic Tools Haldex provides 3 Methods for ABS Diagnostics 1 Blink Codes 2 PLC Info Center 3 PLC PC Diagnostics 1 Blink Codes ABS fault codes can be accessed using the ABS light without the use of any other tools The blink code Simple Fault Mode can be activated by pressing on the brake pedal to activate the trailer brakes and switching ignition power ON OFF ON in 1 second intervals See Blink Code info
35. rmation on pages 46 50 2 PLC Info Center The PLC Info Center has a screen that can display ABS fault codes plus a number of other functions The PLC Info Center only needs to be connected to vehicle permanent power and ground A diagnostic Interface Cable is included to accommodate this connection An optional SAE 560 7 Way Diagnostic Interface Cable is also available SAE 560 7 Way Diagnostic Interface Cable ml PLC Info Center Available functions include 1 View active fault code s 2 digit code and fault occurrence count 2 View stored fault code s and fault occurrence count 3 Clear stored fault code s 4 View wheel speed sensor identification corresponding to each individual wheel when rotated 5 View sensor and valve configuration code 6 View ABS ECU type and serial number T Energize valve solenoid s 8 Odometer a View Odometer Tire Scale Factor Miles or Kilometer Service Interval and Trip Distance b Program Tire Scale Factor miles or kilometers and Service Interval Reference PLC Info Center Instruction Manual L31158 PLC Select gt Page 44 Rev 5 0 Diagnostic Tools Optional SAE 560 7 Way Diagnostic Interface Cable 3 PLC PC Diagnostic ABS PC Diagnostic Software E m a l 1 i 9 to 25 I Way Cable l J1708 PLC Adapter I PLC J Interface Cable PC Diagnostics Kit PC not included PLC PC Diagnostics
36. rning Light PLC Select 1M 2M ABS Warning Light Stays On Permanently Upon power up of the ABS system Permanent or Stoplight Power the ABS Warning Light should come ON for about 3 seconds then go OFF If the Light stays ON it may be caused by improper light wiring or by a fault in the ABS system or the ABS system 1 Check for diagnostic fault code If anything other than an 07 is displayed review the Troubleshooting section of this manual page 54 58 for possible solutions After the problem is repaired clear all stored faults If an 07 is displayed but there was a 11 16 or 21 26 stored in memory then correct the problem and drive the trailer above 6 mph to get the ABS Light to turn OFF If there are no stored faults and an 07 is displayed and the ABS Light is still ON then the ABS Light is mis wired Remove the main wire harness 5 pin connector at the ECU and verify continuity between pin D Refer to ABS Power Cord Pin Out page 21 and trailer light The remaining light wire must be grounded to the trailer chassis or connected to the SAE J560 7 Way connector ground wire Check for continuity between the ABS Light wire and ground Repair as necessary and retest If no blow down of the solenoid occurs when power is applied or the diagnostic tool has nothing on the display check power on the blue or red wire of the 7 Way connector as well as the ABS Power Cord No ABS Warning Light Ill
37. ru r o8 nmm Sensor 1B ma d RoadSide Legend AIR BRAKE COMPONENTS AND SYSTEM SCHEMATIC ARE DESIGNED TO ALLOW COMPLIANCE Service Control Line nn WITH FMVSS 121 THIS SCHEMATIC IS FOR INFORMATION PURPOSE ONLY IT IS THE VEHICLE MANUFACTURERS Em erg en cy S U pply line ULTIMATE RESPONSIBILITY TO CERTIFY THEIR SYSTEM MEETS ALL APPLICABLE REGULATIONS PIPE NIPPLES USED TO MOUNT BRAKE VALVES MUST BE HEAVY WALL TYPE PER SAE J514 Page 20 Rev 5 0 PLC Select ABS Power Cord Pin Out Q SAE J560 Pin Out for ABS Power Cord A Stop Light Red Haldex recommends that the Red White B Permanent Blue and Blue should be 12 AWG Min E Ground White C Cab Light White Yellow D Trailer Light Green White Note Federal regulations mandate that new trailers built after 3 1 2001 have the capability to provide an ABS fault signal from the trailer ABS into the tractor for a In Cab trailer ABS Lamp Option 1 is through Industry standard PLC4 Trucks multiplexing the signal is carried on Pin Option 2 is hard wire through Pin C of the power connector via the ISO 3731connector The requirement for the trailer mounted ABS light remains in effect until March of 2009 PLC Select 1M ECU Overview Correct location of the speed sensors at the wheel ends is critical for proper ABS operation and troubleshooting The PLC Select 1M will adjust th
38. se are the general components that make up the Haldex PLC Select 2M and they can be configured in a Side By Side or Axle By Axle installation The PLC Select 2M can be use on other vehicle configurations contact Haldex Engineering Support When an ABS Relay Valve is used a Trailer Brake Control Valve is required such as a Haldex TBCV or RT4 Valve Note The slider chassis is shown upside down and plumbed Axle By Axle in figure below 2 Port ABS Relay Valve Blue Channel Trailer Brake Control Valve TBCV 1 ilp P Service Control 4 Blue Channel P Emergency Supply Red Channel 5 Way ABS Power Connector PLC Select 2M ABS Relay Valve Yellow Channel PLC Select Page 30 Rev 5 0 PLC Select FFABS 4S 2M 2 Delivery Ports PLC Select FFABS 2 Port Relay Valve 2 Delivery Ports Plumbing Schematic Side By Side Sensor 3A Sensor 2A CurbSide CurbSide Du s Fi ul TI I JA 1 i tiit ss mM T Sensor 3B Sensor 2B RoadSide RoadSide Legend AIR BRAKE COMPONENTS AND SYSTEM SCHEMATIC ARE DESIGNED TO ALLOW COMPLIANCE Service Control Line WITH FMVSS 121 Emergency Supply Line THIS SCHEMATIC IS FOR INFORMATION PURPOSE ONLY IT IS THE VEHICLE MANUFACTURERS ULTIMATE RESPONSIBILITY TO CERTIFY THEIR SYSTEM MEETS ALL APPLICABLE REGULATIONS Sensor Line sm m PIPE NIPPLES USED TO MOUNT
39. sec flashes then 2 1 4 sec flashes if set for miles 1 1 4 sec flash if set for kms PLC Select Page 50 Rev 5 0 Info Center Diagnostic Fault Code List INFO CENTER INSTRUCTION See Info Center Manual L31158 Info Center is a diagnostic tool used for readout of fault codes and odometer as well as other information within the ABS Electronic Control Unit ECU The Info Center is normally connected to the ECU s power source While the ECU is powered from its normal sources information is transferred to the Info Center on the permanent power circuit A Diagnostic Interface cable is included with the PLC Info Center Info Center can be used in conjunction with our premium PLC Select PLUS ABS Platform Contact Haldex Brake Products for further details Page 51 Rev 5 0 PLC Select PLC Select 1M 2M Tire Scale Factor Chart Trailer Scaling Factor Scaling Factor Scaling Factor Scaling Factor Tire 100T miles 100T km 80T miles OT Smallest Tire 215 75R17 5 8R17 5 100T Smallest Tire 305 70R19 5 11R17 5HC 100T Largest Tire Factory Tire Scale Set At 502 Rev Mile USEFUL NUMBERS 1 mile 1 6093 km 1km 0 6214 miles SCALE FACTOR SF FOR OTHER TIRE SIZE Option 1 SF 1000 Rc x T 100 Option 2 SF Nx T 1000 Rc Rolling Circumference in meters N Revolutions per mile T Exciter actual teeth count T Exciter actual teeth count PLC Select Page 52 Rev 5 0 Troubleshooting ABS Wa
40. stalled Page 14 Rev 5 0 PLC Select PLC Select 1M ECU Valve Units Overview 6 Port ABS Relay Valve PLC Select 1M ECU Solenoid Control Port Service Brake Deliveries Service Brake Deliveries 1 2 NPT Reservoir Port 2 Port ABS Relay Valve PLC Select 1M ECU doma Lem Control Port ve Service Brake Delivery Service Brake Delivery 1 2 NPT Reservoir Port Note All ports are 3 8 NPT except the reservoir port is 1 2 NPT Service Trailer Brake Control Valve Emergency 3 8 NPT Supply Port 3 8 NPT Control Port 3 8 NPT Spring Brake 3 8 NPT Spring Brake 1 2 NPT Reservoir Port Delivery Ports Delivery Ports Note 1 All ports are 3 8 NPT except the reservoir port is 1 2 NPT 2 Service Control and Emergency Supply ports have Serviceable Filter Screen installed PLC Select Page 15 Rev 5 0 PLC Select 1M amp 2M Valve Orientation The ABS Valve Solenoid must be installed toward the top of the trailer UP GROUND Typical tank mount valve orientation 1 Install fittings into valve Sealant is not required on plastic threads or on fittings that go into plastic DO NOT use teflon tape on fittings It can break off and contaminate the air system 2 For plastic ports hand tighten fittings then rotate 1 to 1 1 2 additional turns The maximum torque valve allowed is 210 in Ib 3 Install valve nipple into reservoir port Use 7 8 wrench to tighten the nipple
41. t the exciter ring first grease the sensor with a lithium based grease 3 Route all sensor cables through vacant holes etc Use a grommet or corrugated tubing when the cables are touching sharp edges Attach cable ties as needed to ensure the cable is secured to the axle housing Typical routing of cable is along the brake chamber air hose Use sensor cable clip highly recommended or double tie straps when attaching the cables to the air hoses f Sensor cable clip or double tie straps should be no closer than 6 inches and no farther then 12 inches apart NER Note Use caution when attaching tie strap to air hoses Over tightening can damage a cable and cause an ABS sensor failure Page 39 Rev 5 0 PLC Select Speed Sensor Cable Routing This manual depicts speed sensor cable routing along the vehicle axles This was shown for clarity Although it is possible to route cables this way the preferred approach is to route the speed sensor cables along the air hoses between the ABS valve and the brake actuators Tie straps may be used to secure sensor cable to the axle Although tie straps may be used a more reliable installation results if single clips are used to secure speed sensor cables to air hoses Leave some slack in cables to accommodate movement between chassis components Ex cess cable must not be allowed to hang free and must be bundled and attached to the chassis or air lines to prevent damage due to vibration
42. tab is facing downward and secure If cable can be removed without releasing locking tab verify connector orientation Locking Tab Tab locked in position Correct location of the speed sensors at the wheel ends is critical for proper ABS operation The PLC Select 2M will adjust the braking air pressure in response to the input from the speed sensors Incorrect installation or location of speed sensors and exciter rings will result in poor ABS performance or sensors crossed leading to incorrect diagnostic troubleshooting In the figure above shows the cor rect power and speed sensor connections on the PLC Select 45 2M ECU Electronic Control Unit See Haldex Trailer ABS Service Components Catalog L20243 for sensor extensions if short sensors are used Page 35 Rev 5 0 PLC Select 4S 2M System Wiring PLC Select Side By Side S2A CurbSide S2B RoadSide Curbside Roadside a a S3A S2A S2B 3B 4 Port FFABS Valve with ECU Yellow Channel RoadSide am Loss Power Connection 2 Port ABS Valve Blue Channel CurbSide S3A CurbSide Ai RoadSide ABS Light 4S 2M Wiring Overview Apply dielectric grease to all electrical connections 7 Way Wiring Distance of ABS Light from road side red rear clearance side Marker light is 5 9 inches to 23 inches max LED ABS lamps are acceptable Page 36 Rev 5 0 4S 2M System Wiring PLC Select Axle By Axle 52B CurbSide S3B RoadSide
43. tallation Service Manual for 2S 1M Systems Page 12 Rev 5 0 PLC Select Haldex Supplied Items PLC Select 1M Valves i lis A A 6 Port Valve 2 Port Valve Haldex Diagnostic Tools 7 way Diagnostic Interface Cable Software PLC PC Diagnostics Kit PC not included J1708 PLC Adapter PLC Info Center PLC Select PLC Select 1M System Components See Haldex Trailer ABS Service Components Catalog L20243 for additional information on Haldex ABS Products Required Optional Supplier Section Trailer Brake Control Valve Haldex TBCV or RT4 Trailer ABS Power Cable 90 Degree Sensor and Sensor Extension sensor Block Clip ABS Light Recommended Installation Aids 3 Way Clip VA Tie Strap Sensor Extension Retainer Clip Sensor Hose Clip Page 13 Rev 5 0 PLC Select 1M ECU Valve Units Overview 2 Port FFABS Valve PLC Select 1M ECU Service Control Port Spring Brake m ON Exhaust b Service Brake Delivery Service Brake Exhaust Service Brake Delivery Spring Brake Delivery Emergency Supply Reservoir Port 1 2 and 3 4 NPT Spring Brake Delivery Tighten nipple torque 50 ft Ib Jam Nut torque 30 ft Ib Notes 4 Port FFABS Valve is the most commonly used for Tandem Axle Trailers All ports are 3 8 NPT except reservoir nipple 1 2 and 3 4 NPT Service Control and Emergency Supply ports have serviceable filter screen in
44. than 6 mph Measure the AC voltage at the sensor in question while rotating the wheel at a rate of about one revolution every two seconds The output should be at least 200 millivolts 0 2 Vac If this is not the case push in the sensor until it touches the exciter and rotate the wheel again If this doesn t correct the problem then the sensor and spring clip should be replaced If sensor extensions are used verify extension continuity and connections The sensors should be replaced if this is not the case Replace exciter verify all exciters are the same number of teeth Page 54 Rev 5 0 PLC Select 1M 2M Diagnostics Codes Explanation NO ad Red channel wheel speed sensor S1A has an erratic output voltage NO NO Red channel wheel speed sensor S1B has an erratic output voltage NO QD O Q2 N O o CI O OD Blue channel wheel speed sensor S2A has an erratic output voltage N IA Yellow channel wheel speed sensor S2B has an erratic output voltage NO Blue channel wheel speed sensor S3A has an erratic output voltage Yellow channel wheel speed sensor S3B has an erratic output voltage 30 32 Auxiliary channel 2 fault digital channel 2 I O nput Auxiliary Channel has an open circuit or BM y channel 3 fault digital channel 3 i only M y channel 4 fault digital channel 1 input only 35 Auxiliary channel 5 fault digital channel 2 input only 37 Light signaled by external
45. to the valve that controls the Rear Axle wheel ends and is sensed by the yellow sensors 3B and 2B The schematic below shows the proper placement of the sensors and valve leads the king pin indicates the front of the trailer Make sure sensors are pushed firmly against the exciter rings Legend King Pin Speed Sensor ABS Valve Blue Channel ECU with ABS Valve Yellow Channel Spring Suspension CurbSide RoadSide a 3 RoadSide 3A mu m 3B Air Suspension ZA mm m 2B CurbSide CurbSide RoadSide W RoadSide JA mm PLC Select Page 10 Rev 5 0 Wheel Speed Sensor Installation 4S 2M Axle By Axle Lift Control On 4S 2M Axle By Axle installation sensed wheels wheels with ABS sensors CAN NOT be on lift axles Lifting a sensed axle in this configuration will create an ABS fault ABS operation will then be suspended until the ABS power has been cycled and all sensed wheels are again rolling on the road surface Note Indirectly controlled axles axles without sensors but controlled by ABS valves may be lifted regardless of the configuration Make sure sensors are pushed firmly against the exciter rings King Pin Speed Sensor ABS Valve Blue Channel ECU with ABS Valve Yellow Channel CurbSide RoadSide N S RoadSide CurbSide CurbSide RoadSide m RoadSide Lift Axle Lift Axle Correct Correct Page 11 Rev 5 0 PLC Select PLC Select ABS 1M Ins
46. umination di 2 Check the bulb to verify that it is functional If not functional replace it Verify that there is power to the ECU Disconnect the main wire harness 5 pin connector and check for B positive power between either stop light or permanent power and ground Refer to ABS Power Cord Pin Out page 21 The voltage drop between the SAE J560 7 Way and the ECU should not exceed 2 volts If no power exists at either stoplight or permanent power in reference to ground then check continuity from these pins to the SAE J560 7 Way connector red and blue circuits Make necessary repairs and retest If the problem is still present remove the main wire harness 5 pin connector at the ECU and verify continuity between pin D Refer to ABS Power Cord Pin Out page 21 and the light The remaining light wire must be grounded to the trailer chassis or connected to the SAE J560 7 Way connector ground wire Check for continuity between the ABS light wire and ground Repair as necessary and retest Page 53 Rev 5 0 PLC Select Explanation System OK with vehicle greater than 6 mph Red channel wheel speed sensor wiring S1A has an Open or Short circuit O Red channel wheel speed sensor wiring S1B has an Open or Short circuit QD O O I NO O D Blue channel wheel speed sensor wiring 52A has an Open or Short circuit O BA Yellow channel wheel speed sensor wiring S2B has an Open or Short circuit O Ol
47. upplier Section Trailer Brake Control Valve Haldex TBCV or RT4 6 Port Relay Trailer ABS Power Cable 90 Degree Sensor and Sensor Extension 2 Port Relay Solenoid Cable Sensor Block Clip ABS Light Haldex Diagnostic Tools Recommended Installation Aids way Diagnostic Interface Cable Software 3 Way Clip Sensor Hose Clip PLC PC Diagnostics Kit PC not included J1708 PLC SN be Adapter Needed for PC Diagnostic Tie Strap Sensor only Extension PLC Info Center Retainer Clip PLC Select Page 26 Rev 5 0 PLC Select 2M ECU Valve Units Overview 4 Port FFABS Valve PLC Select 2M ECU Control Port Control Port Solenoid Service Brake Deliveries WEN Service Brake Exhaust ii Service Brake Deliverie Spring Brake Delivery Reservoir Port Emergency Supply Spring Brake Exhaust opring Brake Delivery Tighten nipple torque 50 ft Ib Tighten jam nut torque 30 ft Ib Notes 2 Port FFABS Valve is the most commonly used for Tandem Axle Trailers All ports are 3 8 NPT except reservoir nipple 1 2 or 3 4 NPT Service Control and Emergency Supply ports have serviceable filter screen installed Page 27 Rev 5 0 PLC Select PLC Select 2M ECU Valve Units Overview 6 Port ABS Relay Valve Service Control Port PLC Select 2M ECU Solenoid Service Control Port Service Brake Deliveries Service Brake Deliveries Reservoir Port 2 Port ABS Relay V
48. ve stored faults at a time The most recent stored fault is displayed last The blink codes used in the Passive Stored Fault Mode are related to the Haldex standard fault codes and are shown on page 54 58 Clearing Stored Codes Mode 3 The passive stored fault codes may be cleared by switching ignition power OFF ON OFF ON while the brakes are applied during 10 seconds of light energization that occur prior to each repeat of the fault code blink sequence The light will flash rapidly for 10 seconds to show that the fault s are being erased Stored Mode Fault Occurrences Mode 3 The fault code blink sequence is followed by the occurrence count for that fault in Passive Mode The occurrence count is displayed after each pair of fault code flashes in order to differentiate between the code and its occurrence count Blink code rate twice as fast as the fault code blink rate PLC Select gt Page 48 Rev 5 0 Blink Code Diagnostics Stored Fault Mode Notes Mode 3 1 A zero for codes such as 01 is indicated by a two second light ON condition All other digits are indicated by a half second light ON condition Example Fault code 23 is indicated by the light flashing ON twice for one half second each time followed by two seconds of light off followed by three 1 2 second flashes The third flash is the occurrence count and as 1 4 second flashes 2 There is a two second light OFF delay between the digits
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