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L30041 PLC Select Service Manual 1/11

1. Exciter Ring Note Some applications with small wheel tires may reguire 80 tooth exciters Reference Tire Scale Factor Chart on page 47 PLC Select Page 5 Rev 6 0 Wheel Speed Sensor Installation 2S 1M Configurations Sensors should be installed on the axle as shown below 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 A8 ECU configuration Air Suspension m JA Legend Curb Side 3 a O King Pin M Speed Sensor e JC ECU with ABS Valve with delivery lines Road Side Note Any non sensed axle can be utilized as a lift axle mu 1B Multi Axle Trailers 4 or 6 Port Valves Haldex recommends A7 ECU configuration Spring Suspension Curb Side Road Side TR Road Side Curb Side Road Side Page 6 Rev 6 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 blue sensor should be installed on the curb side and the 2B yellow sensor should be installed on the road side of the trailer Make sure sensors are pushed fir
2. In this mode the ABS light displays a numerical fault code seguence 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 44 48 Example Fault code 23 is indicated by the light flashing ON twice for 1 2 second each time then off for 2 seconds followed by three 1 2 second flashes WIL NIL WIL MIL AIL Second Second 2 Seconds Second Second Second O On Off O On On ist Flash 2nd Flash Seguence Seguence 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 seguence for each stored fault All stored faults not currently active are displayed in this mode The light will display up to nine passive 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 50 54 Stored Mode Fault Occurrences Mode 3 The fault code blink seguence 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 Verify
3. 4 Configuration Mode ON off ON off ON off ON off ON 5 Odometer Mode ON off ON off ON off ON off ON off ON Procedure for Blink Code Diagnostics 1 The trailer must be stationary The trailer must be connected to a DC power supply 10 15 volts Never use a battery charger di Constant DC 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 to reach the desired mode shown above t is recommended that an auxiliary switched power source be used i e light cart Note Stoplight and Permanent 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 3 All codes are separated by 2 seconds of light OFF 4 Stored fault codes mode 3 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 an abbreviated list of fault codes that will display Fault codes are grouped to simplify the diagnostics Up to 3 active codes will be d
4. Fax 1 816 891 9447 E Mail info US Haldex com www haldex com
5. 1 2 or 3 4 NPT Service Control and Emergency Supply ports have serviceable Filter Screen installed FFABS Valve Spring Brake Exhaust Cover White indicates Spring Brake Priority Black indicates Service Brake Priority PLC Select E Page 25 Rev 6 0 PLC Select 2M ECU Valve Units Overview 6 Port ABS Relay Valve PLC Select 2M ECU Service PLC Select 2M ECU Solenoid Service Control Port Service Brake Delivery Ports Reservoir Port Service Brake Delivery Ports 2 Port ABS Relay Valve PLC Select 2M ECU Service M KS Control Port PLC Select 2M ECU i M Solenoid Service Control Port 7 Service Brake Delivery Service Brake Delivery Reservoir Port Note All ports are 3 8 NPT except the reservoir port which is 1 2 NPT Trailer Brake Control Valve Service Control Port Emergency Supply Port 3 8 NPT 3 8 NPT Trailer Floor Exhaust Port Ground 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 which 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 4 Trailer Brake Control Valve Exhaust Port White indicates Spring Brake Priority Black indicates Service Brake Priority Page 26 Rev 6 0 PLC Select PLC Select FFABS 4S 2M 2 Service
6. 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 Top View Sensor 1A i Curb Side Lu M rt mm i i ne I i 908 4 I mL AN 4 yi qi I I I I I I I I I L Sensor 1B ian Road Side l 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 18 Rev 6 0 ABS Power Cord Pin Out O SAE J560 Pin Out for ABS Power Cord Pin 1 Ground White Pin 7 Permanent Blue Pin 4 Stoplight Red A Stop Light Red Haldex recommends that the Red White m B Permanent Blue and Blue should be 12 AWG Min i E Ground White C Not Used 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 an In Cab trailer ABS Lamp Option 1 is through Industry standard PLC4Trucks m
7. By Axle Lift Axle 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 Any non sensed axle can be utilized as a lift axle King Pin Speed Sensor ABS Valve Blue Channel ECU with ABS Valve Yellow Channel Road Side Road Side n Road Side Lift Axle Lift Axle Correct Correct Page 11 Rev 6 0 5 O O 2 s MORTI PLC Select ABS 1M Installation Service Manual tor 2S 1M Systems PLC Select Page 12 Rev 6 0 PLC Select 1M System Components See Haldex Trailer ABS Service Components Catalog L 20243 for additional information on Haldex ABS Products Haldex Supplied Items PLC Select 1M Valves FFABS Valve 2 Port Valve Haldex Diagnostic Tools 7 way Diagnostic Interface Cable Optional Software PLC PC Diagnostics Kit PC not included DLA PLC Adapter PLC Info Center Page 13 Rev 6 0 90 Sensor Cable Additional Supplied Items Trailer Brake Control Valve Haldex TBCV Shown na or RT4 Trailer ABS Power Cable p Sensor Block Clip ABS Light Recommended Installation Aids PN n Power Cord Bracket Sensor Hose Clip p Hole Clamp Sensor Extension
8. Curb Side Yellow Blue i Lan a ionta E eas n K a a og mu EEE L a N Nu Nu Nu N N U U U U U UN N Legend Sensor 3A Road Side Sensor 3B Road Side Blue Yellow A AIR BRAKE COMPONENTS AND SYSTEM SCHEMATIC ARE DESIGNED TO ALLOW COMPLIANCE Service Control Line a THIS SCHEMATIC IS FOR INFORMATION PURPOSE ONLY IT IS THE VEHICLE MANUFACTURERS E M erg en cy S U pply Li ne e ULTIMATE RESPONSIBILITY TO CERTIFY THEIR SYSTEM MEETS ALL APPLICABLE REGULATIONS Sensor Line HIN KNN NN N N N N N ON PIPE NIPPLES USED TO MOUNT BRAKE VALVES MUST BE HEAVY WALL TYPE PER SAE J514 Page 30 Rev 6 0 PLC Select PLC Select FFABS 4S 2M Full Trailer Plumbing Schematic Axle By Axle PLC Select FFABS 2 Port Relay Valve 2 Service Delivery Ports 2 Service Delivery Ports Curb Side Curb Side Yellow O k i 70 psi Pressure Protection Valve Emergency Control Valve n I I I I I I I I I I I I I A N j Service Control j O i il sov E Emergency Supply m O Road Side Road Side Blue Yellow PLC Select Page 31 Rev 6 0 PLC Select 2M ECU Overview Sensor Sensor S2A i S2B If 2S 1M is desired Blue Yellow use sensors S2B and S3B Use Sensor Sensor blanking plugs in S3A S3B unused sens
9. Delivery Ports PLC Select FFABS 2 Port Relay Valve 2 Service Delivery Ports 2 Service Delivery Ports Plumbing Schematic Side By Side Top View Sensor 3A Curb Side Sensor 2A Curb Side Blue Blue 1 VOR III TT TTS sas Samuels an aa n ann an mi am sil n ad Sensor 3B Road Side I Yellow Sensor 2B Road Side Yellow Legend AIR BRAKE COMPONENTS AND SYSTEM SCHEMATIC ARE DESIGNED TO ALLOW COMPLIANCE WITH FMVSS 121 Service Control Line THIS SCHEMATIC IS FOR INFORMATION PURPOSE ONLY IT IS THE VEHICLE MANUFACTURERS I ULTIMATE RESPONSIBILITY TO CERTIFY THEIR SYSTEM MEETS ALL APPLICABLE Emergency Supply Line 7 IE n REGULATIONS CMS GE EE s ma i s mn an il am HR ansi si PIPE NIPPLES USED TO MOUNT BRAKE VALVES MUST BE HEAVY WALL TYPE PER SAE 514 Page 27 Rev 6 0 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 Service Delivery Ports 2 Service Delivery Ports Plumbing Schematic Side By Side Top View Sensor 3A Curb Side Sensor 2A Curb Side Blue Blue 1 TEEN ss m m muu m mu uu mu TF i I N I in H muu muu Sensor 3B Road Side Sensor 2B Road Side Hagene Yellow Yeliow egend AIR BRAKE COMPONENTS AND SYSTEM SCHEMATIC ARE DESIGNED TO ALLOW COMPLIANCE WITH FMVSS 121 Service Control Line A THIS SCHEMATIC IS FOR INFORMATION PUR
10. ECU and the solenoid energizes click click If not disconnect the main wire harness 5 pin connector and check for positive power between either stop light power with brakes applied or permanent power and ground Refer to ABS Power Cord Pin Out page 19 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 3 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 19 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 PLC Select Page 49 Rev 6 0 Troubleshooting PLC Select 1M 2M Diagnostics Codes PLC PLC Explanation Possible Causes pe sa Occurs only when vehicle is stationary System OK with vehicle traveling gt 6 mph da ie 6 MEIS Displays 00 when Red channel wheel speed sensor wiring S1A ON eee Open or Short circuit Indicates a wheel speed sensor or its xP wiring has short or open circuit 02 Red channel wheel speed sensor wiring S1B Disconnect the relevant sensor and has an Open or Short c
11. 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 Page 41 Rev 6 0 Diagnostic Tools 3 PLC PC Diagnostic Optional SAE 560 7 Way Diagnostic Interface Cable ABS PC Diagnostic Software Also available at www haldex com DLA PLC S Adapter i far I PS O F I b L mm PC Diagnostics Kit PC not included PLC PC Diagnostics 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 3 Read Write Trailer and or Service data internally to ABS ECU Minimum requirements MS Windows 2000 32 MB RAM 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 42 Rev 6 0 PLC Select Blink Code Diagnostics Haldex There are 5 Blink Code Modes Apply service brakes and then cycle permanent power 1 second on 1 second off Mode Desoroion Permanent Power Cycles 1 second ON P 1 second OFF with stoplight power applied Simple Wheel Speed Mode ON off ON Active Faults Mode ON off ON off ON 8 Stored Faults Clear Mode ON off ON off ON off ON
12. 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 Page 2 Rev 6 0 PLC Select 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 exciters The inductive sensors are mounted at the designated wheel ends in conjunction with exciter notched rings The ECU reads electric impulses generated from the rotating exciter as the wheels turn The ECU is d
13. co Co O N Short circuit on ABS ECU internal relay ABS Corrupt Memory gt ABS Corrupt Memory PLC PLC Possible Causes Select Select 1M 2M Modulator valve solenoid failure or valve cable damage Indicates that the solenoid or its cable has a short circuit to positive power 12 volts DC The most likely cause is a damage cable or solenoid Disconnect the indicated solenoid and check the resistance at the solenoid pins Refer to solenoid page Page 54 for proper settings If solenoid checks good and 80 89 code still exists check ECU 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 Replace ECU Page 53 Rev 6 0 Fault Code Explanation Troubleshooting PLC Select 1M 2M Diagnostics Codes Display Information Codes A x and C x displayed when power is applied to the ABS ECU They should not be displayed for more then 2 seconds if code remains permanently displayed repair is necessary Trailer 25 1M SLH on Red channel 2S 2M or 4S 2M SLH on yellow channel gt HE 00 N Trailer 25 1M MSLH on Red Channel dollies steerable or single axle only Programmed for tandem or multi axle trailer Displays current configuration Programmed for dollies s
14. dielectric grease to all electrical connections PLC Select __ Page 35 Rev 6 0 Speed Sensor Cable Routing Sensor Sensor Sensor Block Block Sensor Block Clip N Fa E ja n fi 5 al Sensor Grease Exciter Ring Note Lightly grease the sensor with a Lithium based grease Use Dow Corning Molycoat CU7439 or eguivelant Push sensor firmly against the exciter ring Insert the sensor block clip into the sensor block as shown above Grease the sensor with a lithium based grease or anti seize then insert the sensor into the sensor block clip and push until it is firmly against the exciter ring as shown above 3 Route all sensor cables through vacant holes etc Use a grommet or corrugated tubing if 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 hose clip when attaching the cables to the air hoses Sensor cable hose clips should be no farther than 8 10 inches apart N Be Oo OLS Note Haldex does not recommend the use of tie straps to secure sensor wires to rubber air hoses Expansion of rubber air hoses will damage sensor wires causing ABS sensor failure Page 36 Rev 6 0 PLC Select Speed Sensor Cable Routing Although it is possible to route cables along the axle the preferred approach is to route the speed sensor cables along
15. if stored codes 11 16 or 21 26 are present the problem needs to be resolved before the ABS lamp will shut off when permanent powered vehicle travels gt 6 MPH 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 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 show that the fault s are being erased PLC Select n Page 45 Rev 6 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 1 2 second each time then off for 2 seconds followed by three 1 2 second flashes The third flash is the occurrence count and as 1 4 second flashes MIL NIL WIL MIL AIL Second Second 2 Seconds Second Second On Off On On a a WIL NIL Second 2 Seconds 14 Second 14 Second On Off On On 1st Flash 2nd Flash 3rd Flash Seguence Seguence Seguence 2 There is a two second light OFF delay between the digits in each code 3 Code 07 system OK vehicle at rest is displayed as a continuous light ON condition Page 46 Rev 6 0 IM ek CT E es Blin
16. liguid thread sealant sparingly on all fittings Loctite PST565 or eguivalent 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 performance could be effected N 7 Reservoir Port 1 2 and 3 4 NPT Tighten nipple torque 50 ft Ib Jam Nut torque 30 ft Ib Warning Proper installation orientation shown above otherwise warranty Is void Installation behind the tank is recommended facing the back of the trailer PLC Select Page 16 Rev 6 0 PLC Select FFABS 2S 1M 4 Service Delivery Ports 4 Spring Brake Ports e Air suspension typically have the sensors on the rear axle e Spring suspension typically have the sensors on the front axle PLC Select 1M FFABS Plumbing Schematic 2S 1M Top View Sensor 1A Curb Side ee KNM Sensor 1B Road Side N Legend AIR BRAKE COMPONENTS AND SYSTEM SCHEMATIC ARE DESIGNED TO ALLOW COMPLIANCE Service Control Line ajaa 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 17 Rev 6 0 PLC Select PLC Select 6 Port ABS 2S 1M with Trailer Brake Control Valve e
17. operating conditions and applications for these products or systems the user through their own analysis and testing is solely responsible for making the final selection of the products and systems and assuring that all performance safety and warning reguirements are met 2009 Haldex AB This material may contain Haldex trademarks and third party trademarks trade names corporate logos graphics and emblems which are the property of their respective companies 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 Ltda Sao 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 CA Haldex com China Haldex International Trading Co Ltd Shanghai Tel 86 21 5240 0338 Fax 86 21 5240 0177 E Mail info CN OHaldex com France Haldex Europe SAS Weyersheim Strasbourg Tel 33 3 88 68 22 00 Fax 33 3 88 68 22 09 E Mail info EURQHaldex com Germany Haldex Brake Products GmbH He
18. the air hoses between the ABS valve and the brake actuators Tie straps should not be used to secure the speed sensor cable to air hoses For a more reliable installation use sensor hose clips to secure speed sensor cables to rubber air hoses Leave some slack in cables to accommodate movement between chassis components Excess cable must not be allowed to hang free and must be bundled and attached to the chassis to prevent damage due to vibration and abrasion Route sensor wire on backside of axle housing to avoid damage from road debris A sensor hose clip is placed on the hose and sensor wire 0 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 D LL X Push up and and attach tie Short Cable short bone straps Long cable long bone PLC Select Page 37 Rev 6 0 Chasis End of Line Testing PLC Select 1M 2M Test Eguipment 12 Volt DC power source Never use a battery charger or internal ECU damage will occur 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 100 120 psi 2 Apply power sour
19. 5 3 5 4 5 Ohms A A Ohms Hold Dump gt lt 7 0 9 0 Ohms New Style Solenoid DIN September 2009 Present gt 3 5 4 5 Ohms Dump 7 0 9 0 A Ohms Common Hold gt lt 3 5 4 5 Ohms PLC Select Page 55 Rev 6 0 Notes Notes Notes Haldex offers proprietary vehicle technology solutions to the global vehicle industry within specific 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 service life ethical business practices and commitment to long term partnerships Haldex operations are divided into three business areas Commercial Vehicle Systems Hydraulic Systems and Traction Systems Warning The products described within this literature including without limitation product features specifications designs availability and pricing are subject to change by Haldex and its subsidiaries at any time without notice This document and other information from Haldex its subsidiaries and authorized distributors provide product and or system options for further investigation by users having technical expertise It is Important that you analyze all aspects of your application and review the information concerning the product or system in the current literature or catalog Due to the variety of
20. Bottom e Exciter Ring Apply dielectric grease to all electrical connections ABS Power Connection ECU Sensor Retainer Clip S1B Road Side Red Channel ABS Light mounted on Road Side of trailer at the rear LED ABS warning lamp is acceptable Power Cord Bracket The ABS Power Cord is secured to the power cord bracket page 13 and is secured with a hose clamp preferred or tie strap Page 20 Rev 6 0 Speed Sensor Cable Routing Sensor Block Sensor Sensor Block Clip Sensor Grease Exciter Ring Note Lightly grease the sensor with a Lithium based grease Use Dow Corning Molycoat CU7439 or eguivelant Push sensor firmly against the exciter ring Insert the sensor block clip into the sensor block as shown above Grease the sensor with a lithium based grease or anti seize then insert the sensor into the sensor block clip and push until it is firmly against the exciter ring as shown above Route all sensor cables through vacant holes etc Use a grommet or corrugated tubing if 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 hose clip when attaching the cables to the air hoses Sensor cable hose clips should be no farther than 8 10 inches apart RE ONS VOB Note Haldex does not recommend the use of tie straps t
21. Installation Service Guide L30041 Rev 6 1 11 PLC Select ABS 2M PLC Select ABS 1M Installation Service Manual for 2S 1M 4S 2M 2S 2M Systems 7 00 Technical Service amp Engineering Support 1 800 643 2374 Press 2 In Canada please call Brake Systems Division Haldex Limited 500 Pinebush Road Unit 1 Cambridge ON NYT OA5 Canada 1 800 267 9247 Table of Contents Section ETNE sussa Rosaa Koo ia ala aa 1 STE NO Leese pen 2 General Operation of PLC Select 1M and 2M rrrarnnnrnnnrnnnrnnnrnnnennnennnennnennnennnennnenennnennnnsenunnnusnnnennee 3 Wheel End NOS ANN 4 5 Wheel Speed Sensor Installation Configurations 1M and 2M SystemS n 6 11 PLC Select ABS TM Installation Service Manual for 2S 1M Systems 12 PLC Select 1M System Components cca 13 PLC Select 1M ECU Valve Units OverView i 14 15 PLC Select 1M and 2M Valve Orientation iii 16 PLC Select 1M Installation Overview 4 Port FFABS Systems 2 S1M manne neenenn 17 PLC Select 1M PLC Select FFABS 2S 1M Plumbing SchemAaLtic i 17 PLC Select 1M Installation Overview 6 Port ABS System 2S 1M maannainen 18 PLC Select 1M PLC Select 6 Port ABS 2S 1M Plumbing Schematic nn nnnnnnenn 18 PLC Select 1M ABS Power Cord Pin Out 1M ECU OverVieW 19 PLC SelectlM 25 1M Sys
22. No sensor more than The clearance between the block and 080 off exciter ring should be 0 156 031 center Any deviation will result in a reduction Above or of the wheel speed sensor signal Below output Axle Hub In general the position of the wheel speed van sensor center axis to the exciter right surface Vat R 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 Page 4 Rev 6 0 PLC Select n N Center Line Wheel End Installation Continued 530 470 06 Radius Exciter Ring Installation 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 sguarely 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 6 Damage to any teeth on exciter ring may cause a dynamic fault Ensure that the exciter ring fits sguarely against the shoulder Exciter Ring
23. POSE ONLY ITIS THE VEHICLE MANUFACTURERS Emergency Supply Line MN _ Elja dill TO CERTIFY THEIR SYSTEM MEETS ALL APPLICABLE Sensor Line EE EEE oo a PIPE NIPPLES USED TO MOUNT BRAKE VALVES MUST BE HEAVY WALL TYPE PER SAE J514 Page 28 Rev 6 0 PLC Select PLC Select FFABS 4S 2M 2 Service Delivery Ports PLC Select FFABS 2 Port Relay Valve 2 Service Delivery Ports 2 Service Delivery Ports Plumbing Schematic Axle By Axle Top View Sensor 2B Curb Side Sensor 2A Curb Side Yellow Blue L ks o I EEE EN I I I L E if v a og Sam l I I l l m 5 a ss I I i i I N i NM i J Sensor 3A Road Side IR Blue Sensor 3B Road Side Legend Yellow AIR BRAKE COMPONENTS AND SYSTEM SCHEMATIC ARE DESIGNED TO ALLOW COMPLIANCE WITH FMVSS 121 Service Control Line 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 H N MN N CNN N N N N PIPE NIPPLES USED TO MOUNT BRAKE VALVES MUST BE HEAVY WALL TYPE PER SAE J514 Page 29 Rev 6 0 PLC Select 2 Port ABS 4S 2M with Trailer Brake Control Valve Trailer Brake PLC Select ABS 2M 2 Port Relay Valve sc ve 2 Service Delivery Ports 2 Service Delivery Ports Plumbing Schematic Axle By Axle Top View Sensor 2B Curb Side Sensor 2A
24. Retainer Clip Tie Strap PLC Select PLC Select 1M ECU Valve Units Overview 4 Port FFABS Valve PLC Select 1M ECU Reservoir Service Brake Delivery Ports Service Brake Delivery Ports Service Brake Exhaust Emergency Supply Port Spring Brake Spring Brake Delivery Ports Spring Brake Delivery Ports Exhaust TX Reservoir Port 1 2 and 3 4 NPT Tighten nipple torgue 50 ft Ib Jam Nut torque 30 ft Ib Notes 4 Service Brake Port FFABS Valve is the most commonly used for Tandem Axle Irailers For Single Axle Trailers use 2 Service Brake Port FFABS Valve All ports are 3 8 NPT except reservoir nipple which accommodates either 1 2 or 3 4 NPT Ports Service Control and Emergency Supply ports have serviceable Filter Screen installed FFABS Valve Spring Brake Exhaust Cover White Indicates Spring Brake Priority Black indicates Service Brake Priority PLC Select Page 14 Rev 6 0 PLC Select 1M ECU Valve Units Overview 6 Port ABS Relay Valve PLC Select 1M ECU Control Service Port Solenoid Service Brake Delivery Ports Service Brake Delivery Ports 1 2 NPT Reservoir Port Requires heavy wall reservoir nipple 2 Port ABS Relay Valve PLC Select 1M ECU Control Service Port 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 Control T
25. Select Page 23 Rev 6 0 Haldex Supplied Items PLC Select 2M System Components See Haldex Trailer ABS Service Components Catalog L 20243 for additional information on Haldex ABS Products 6 Port Relay 2 Port Relay Haldex Diagnostic Tools way Diagnostic Interface Cable Software PLC PC Diagnostics Kit PC not included DLA PLC Adapter PLC Info Center Page 24 Rev 6 0 Solenoid Cable Optional Additional Supplied Items Trailer Brake Control Valve Haldex TBCV Shown or RT4 Trailer ABS Power Cable 90 Sensor Cable Sensor Block Clip ABS Light Recommended Installation Aids Sensor Hose Clip Power Cord Bracket GE MD m Hose Clamp VA Sensor Extension Retainer Tie Strap Clip PLC Select PLC Select 2M ECU Valve Units Overview Reservoir Port 4 Port FFABS Valve Service Control Port Solenoid Service Brake Delivery Ports PLC Select 2M ECU VA Service Control Port Service Brake Delivery Ports Service Brake Exhaust Spring Brake Delivery Ports Emergency Supply Spring Brake Exhaust Spring Brake Delivery Ports N 7 Reservoir Port 1 2 and 3 4 NPT Tighten nipple torgue 50 ft Ib Jam Nut torque 30 ft Ib Notes 4 Service Brahe Port FFABS Valve is the most commonly used for Tandem Axle Trailers Spring Brake Delivery ports come in two variations 2 or 4 ports All ports are 3 8 NPT except reservoir nipple
26. amage The most likely causes include abad solenoid or a loose solenoid connection Disconnect the indicated solenoid and check the resistance at the solenoid pins Check the female terminals on the connector for excessive pin spread or corrosion Replace defective hardware as reguired and retest Refer to solenoid page Page 55 Modulator valve solenoid failure or valve cable damage The most likely causes include a damaged cable or solenoid An example of this is a worn or chafed cable that has exposed wires contacting the trailer Disconnect the indicated solenoid and check the resistance at the solenoid pins Refer to solenoid page Page 55 Troubleshooting PLC Select 1M 2M Diagnostics Codes Fault Code Explanation Output leakage or poor insulation on any of the valve channels Hold solenoid short circuit to Permanent Power on Red valve channel CO Hold solenoid short circuit to Permanent Power on Blue valve channel 00 N Hold solenoid short circuit to Permanent Power on Yellow valve channel 00 QD Dump solenoid out shorted on Permanent Power on Red valve channel Dump solenoid out shorted on Permanent Power on Blue valve channel Dump solenoid out shorted on Permanent Power on Yellow valve channel Low supply voltage fault This code is not stored in memory No internal ABS ECU solenoid voltage available CO CO N Povver input over voltage fault CO QD O
27. ce to 7 Way receptacle PIN 7 permanent power di The ABS Valve s should blow down first You will hear a brief exhaust 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 Red Channel valve only 4 The ABS light should illuminate for about 3 seconds and then turn off De Using an Info Center or PC verify correct sensor placement by spinning each 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 Note If the ABS Light never illuminates or stays illuminated during the ABS check refer to Troubleshooting Section on page 49 of this manual Page 38 Rev 6 0 IM ek CT E es Road Testing PLC Select 1M 2M Road Test PLC Select 1M 2M Procedure I VA 9 Connect a tractor to the trailer and charge the trailer s air tanks 100 120 psi Turn on the start switch and ensure that the ABS 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 func
28. d then go OFF If the Light stays ON it may be caused by improper light wiring or by a fault in the ABS system 1 Check for diagnostic fault codes If anything other than a 07 is displayed review the Troubleshooting section of this manual page 50 54 for possible solutions After the problem is repaired clear all stored faults 2 If a 07 is displayed but there was a 11 16 or 21 26 stored in memory then correct the problem and drive the trailer using permanent power above 6 mph to get the ABS Light to turn OFF 3 If there are no stored faults and a 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 19 and trailer ABS 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 4 If the solenoid does not energize click click 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 Refer to ABS Power Cord pin out page 19 No ABS Warning Light Illumination 1 Check the bulb to verify that it is functional If not functional replace it 2 Verify that there is power to the
29. e 51 Rev 6 0 Code Explanation DN Slow wheel recovery on Red valve channel Slow wheel recovery on Blue valve channel Slow wheel recovery on Yellow valve channel 42 D gt CO O N a Hold solenoid Open circuit on Red valve channel Hold solenoid Open circuit on Blue valve channel Hold solenoid Open circuit on Yellow valve channel Dump solenoid Open circuit on Red valve channel O N Dump solenoid Open circuit on Blue valve channel Dump solenoid Open circuit on Yellow valve channel 71 72 73 77 8 7 Dump solenoid Short circuit to ground on Yellow valve channel HE CO Page 52 Rev 6 0 wiring plumbing is correct See Side By Side Hold solenoid Short circuit to ground on Red valve channel Hold solenoid Short circuit to ground on Blue valve channel Hold solenoid Short circuit to ground on Yellow valve channel Dump solenoid Short circuit to ground on Red valve channel Dump solenoid Short circuit to ground on Blue valve channel Troubleshooting PLC Select 1M 2M Diagnostics Codes PLC PLC Possible Causes Select Select 1M 2M For a 2M System verify sensor and valve and Axle By Axle configurations Slow brake release foundation brake mechanical faults dry bushings broken ABS valve restricted piping Check for kinks and blockage etc Incorrect air lines wiring Modulator valve solenoid failure solenoid connection or valve cable d
30. e TestiN iii 38 PLC Select 1M 2M Road SINO atei 39 Diagnostic Tools PLC PC DANN ane ae rieti 40 42 Diagnostic Tools Blink Code Diagnostics oonan aan aani ankan seen annan 43 47 Tire Scale Factor Chart PLC Select 1M 2M Tire Scale Factor Chart ii 48 PLC Select 1M 2M Diagnostics PLC Select 1M 2M Troubleshooting ABS Warning Light i 49 PLC Select 1M 2M Diagnostics Codes iii 50 55 PLC Select Page 1 Rev 6 0 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 of the product Final determination of the suitability of the products for the use contemplated
31. e at least Blue channel wheel speed sensor S3A has an 200 millivolts 0 2 VAC erratic output voltage N OI 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 tooth exciter ring If these faults re occur at the same speed inspect Yellow channel wheel speed sensor S3B has exciter ring for damage an erratic output voltage Smaller wheels and tires reguire 80 tooth exciter rings Reference Tire Scale Factor Chart Verify sensor and valve wiring plumbing is correct See side by side and axle by axle configurations Occurs only when vehicle is stationary Auxiliary channel 1 fault digital channel 1 PLC Select 2M Plus ABS Auxiliary Codes output only N ote These Codes are only used with PLC Select 2M Plus ABS that supports trailer Auxiliaries Auxiliary channel 2 fault digital channel 2 output only Auxiliary channel 3 fault digital channel 3 Auxiliary Channel has an open circuit or the input only ECU Electronic Control Unit has auxiliary device connected and is not Auxiliary channel 4 fault digital analog programmed to be channel 1 input only Note These codes do not affect ABS Auxiliary channel 5 fault digital analog performance and do not illuminate the channel 2 input only tractor or trailer ABS warning lamps PLC Select Pag
32. ensor extensions are used verify extension continuity and connections Yellow channel speed sensor S2B has low Replace sensor and or extension cable sensor output Inspect exciter teeth for minor damage or teeth filled with debris Verify all exciters have the same number Blue channel speed S3A has ue channel speed sensor as IOVV of teeth sensor output Verify sensor and valve wiring plumbing is correct Yellow channel speed sensor S3B gap too large Gap should be kept to a minimum See side by side axle by axle configurations Page 50 Rev 6 0 PLC Select Troubleshooting PLC Select 1M 2M Diagnostics Codes PLC PLC Explanation Possible Causes Select Select 1M 2M Occurs only when vehicle is moving Red channel wheel speed sensor S1A has an Loose sensor connection bracket or exciter damaged exciter sensor is not properly adjusted or has worn cable Red channel wheel speed sensor S1B has an insulation or worn sensor block clip erratic output voltage wheel bearing failure wheel bearing is not properly adjusted these faults will only Blue channel wheel speed sensor S2A has an occur at speeds greater than 6 mph erratic output voltage N N N QD N N N O N Measure the AC voltage at the sensor in Yellow channel wheel speed sensor S2B has guestion while rotating the wheel at a rate an erratic output voltage of about one revolution every two seconds The output should b
33. esigned 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 vehicle 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 25 1M system for Semi Trailers and Dollies using 2 Sensors and 1 Modulator ABS Valve Note Haldex recommends our 2S 1M A8 product as a more cost effective solution to meet minimum FMVSS121 reguirements for Semi Trailer and Dollies and in most applications can provide comparable performance as 2M systems The Haldex PLC Select 2M is positioned as a 4S 2M system using 4 Sensors and 2 Modulators ABS Valves Although it can be
34. h ABS Valve amp delivery lines Yellow Channel Curb Side Correct Correct Page 9 Rev 6 0 Wheel Speed Sensor Installation 4S 2M Configurations Axle By Axle e 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 and result in fault codes with the ABS warning lamp on 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 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 Note Legend O King Pin M Speed Sensor Any non sensed axle can be utilized as a lift axle THE ABS valve with delivery lines Blue Channel Multi Axle Trailers d E ECU with ABS Valve 8 delivery lines Yellow Channel Spring Suspension Spring Suspension 2A m m 2B Curb Side W W Curb Side MW HE Road Side IA JA ma m 3B SA m m 3B Air Suspension Air Suspension 2A m m 2B Curb Side Road Side W Road Side JA m Page 10 Rev 6 0 PLC Select Wheel Speed Sensor Installation 4S 2M Axle
35. idelberg Tel 49 6221 7030 Fax 49 6221 703400 E Mail info DEQHaldex com Hungary Haldex Hungary Kft Szentl rinck ta Tel 36 29 631 300 Fax 50 29 651 501 E Mail info HUQHaldex com India Haldex India Limited Nasik Tel 91 253 2380094 Fax 91 253 2380729 E Mail info IN Haldex com Italy Haldex Italia Srl Biassono Tel 039 47 17 02 Fax 039 27 54 309 E Mail info IT Haldex com L30041 US Rev 1 11 3M CM Mexico Haldex de Mexico S A De C V Monterrey Tel 52 81 8156 9500 Fax 52 81 8313 7090 Poland Haldex Sp 7 0 0 Praszka Tel 48 34 350 11 00 Fax 48 34 350 11 11 E Mail info PL Haldex com Russia 000 Haldex RUS Moscow Tel 7 495 747 59 56 Fax 7 495 786 39 70 E Mail info RU Haldex com South Korea Haldex Korea Ltd Seoul Tel 82 2 2636 7545 Fax 82 2 2636 7548 E Mail info KR Haldex com Spain Haldex Espafia S A Parets del Valles Barcelona Tel 34 93 573 10 30 Fax 34 93 573 07 28 E Mail info ES Haldex com Sweden Haldex Brake Products AB Landskrona Tel 46 418 47 60 00 Fax 46 418 47 60 01 E Mail info SE Haldex com United Kingdom Haldex Ltd Newton Aycliffe Tel 44 1325 310 110 Fax 44 1325 311 834 E Mail info GBAy Haldex com Haldex Brake Products Ltd Redditch Tel 44 1527 499 499 Fax 44 1527 499 500 E Mail info GBRe Haldex com USA Haldex Brake Products Corp Kansas City MO Tel 1 816 891 2470
36. ingle or steer axle trailer Displays current configuration Only display when viewing stored fault codes O O 2S 1M configuration 2 2S 2M configuration N 4S 2M configuration information not a fault code 4S 2M configuration information not a fault code O gt Clear all fault codes O O QD Clear configuration O R Configuration fault EO thru EF are generated when internal problems exist within the ABS ECU Page 54 Rev 6 0 S1A S1B sensors Red modulator ECU is configured as a 2M and is powered up as a 1M See CC cause below Displays current configuration S2A S2B sensors Blue Yellow modulator ECU is configured as a 4S 2M and powered up as a 2S 2M See CC cause below Displays current configuration S3A S2A S2B S3B sensors Blue Yellow modulators Displays current configuration S3A S2A S2B S3B sensors Blue Yellow modulators S3A and S3B sensed lift axle Displays current configuration Occurs when clearing fault codes with the Info Center Only reguired when configured ABS System from a 4S 2M to a 25 2M or any 2M configured to a 1M Clear fault codes 3 times the with uninterrupted power to reconfigure Unrecognized ABS configuration Verify all sensors and valve connections are correct Verify sufficient power ABS ECU is defective Replace the ABS ECU PLC Select Solenoids Haldex Old Style Solenoid Pre DIN Common 3 5 4
37. ircuit measure the resistance between the two 03 Blue channel wheel speed sensor wiring S2A pins in the sensor connector housing has an Open or Short circuit If sensor extensions are used verify 04 Yellow channel wheel speed sensor wiring extension continuity and connections S2B has an Open or Short circuit Replace sensor and or extension cable 05 Blue channel wheel speed sensor wiring S3A The Ohm meter reading for the sensor or has an Open or Short circuit sensor and extension cable should be between 980 and 2350 Ohm 98K and Yellow channel wheel speed sensor wiring 2 35 K Ohm If not replace sensor S3B has an Open or Short circuit and or extension cable ca over Occurs only when vehicle is moving Sensor or spring clip is worn or not properly adjusted wiring open or short circuit wheel bearing 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 Red channel speed sensor S1B has low 0 2 VAC If this is not the case push in SSAS9EDLIROL the sensor until it touches the exciter and rotate the wheel again If this doesn t correct the problem then the sensor and Blue channel speed sensor S2A has low sensor block clip should be replaced sensor output Red channel speed sensor S1A has low sensor output If s
38. isplayed 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 n Page 43 Rev 6 0 Haldex Blink Code Diagnostics Mode 1 Simple Mode Diagnostics Faults Table ON OFF ON See the diagnostic codes pages 50 54 for possible causes e Low votage jois mm IA 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 Verify in mode 3 stored codes If any faults 11 16 or 21 26 are present the problem needs to be resolved before the lamp will turnoff when permanent powered vehicle travels gt 6 MPH Wheel Speed Mode Wheel Speed Mode is accessible only when in Simple Mode This Mode 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 1Flash 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 44 Rev 6 0 PLC Select Blink Code Diagnostics Mode 2 Active Faults Mode ON OFF ON OFF ON
39. k Code Diagnostics 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 54 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 Config Code Lift Axle Sensor Used indicates lift axle Modulators Used STN STA SB Ra o amus 2 2S 2M saa S2B Blue Yellow AS 2M SA S2A S2B S3B Blue Yellow 3 4 e fa 4S 2M is S3A SA S2B S3B Blue Yellow Description Not Applicable Not Applicable Not Applicable Not Applicable o load sense valve momentarily displayed when power is applied A5 6 Not Applicable Not Applicable AT 8 SLH programming for yellow valve channel red valve is 2S 1M A8 9 MSLH programming for yellow valve channel red valve is 2S 1M 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 Mode 5 Od
40. 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 Note Legend O King Pin MW Speed Sensor Any non sensed axle can be utilized as a lift axle THE ABS valve with delivery lines Blue Channel Multi Axle Trailers ECU with ABS Valve amp delivery lines Yellow Channel Spring Suspension Spring Suspension Curb Side Road Side Air Suspension JA m Curb Side E Curb Side Page 8 Rev 6 0 Wheel Speed Sensor Installation 4S 2M Side By Side Lift Axle 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 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 Cl M Speed Sensor ABS Valve with delivery lines Blue Channel J E ECU wit
41. mly against the exciter rings The yellow markings sensor connections and axle locations must go to the yellow ABS valve as shown below The same holds true for the blue markings valve On 25 2M side by side configurations The blue modulator lead must be connected to the valve that controls the curb side wheel end and are sensed by sensor S2A The yellow modulator valve cable lead must be connected to the valve that controls the road side wheel end and are sensed by sensor 2B Note The 2S 2M configuration does not offer any meaningful performance benefit over a 25 1M SLH A7 configuration and is not a preferred system To obtain additional performance beyond a 2S 1M configuration Haldex recommends the use of a 4S 2M System Nate Legend Any non sensed axle can be O King Pin utilized as a Iift axle El Speed Sensor THE ABS valve with delivery lines Blue Channel Multi Axle Trailers I E ECU with ABS Valve amp delivery lines Yellow Channel Spring Suspension Spring Suspension Curb Side i Curb Side JIMI Air Suspension 2A m Page 7 Rev 6 0 Wheel Speed Sensor Installation 4S 2M Configurations Side By Side e The placement of the sensors at the wheel end is an important consideration e Incorrect installation of the sensors and exciter will result in poor or no ABS operation and result in fault codes with the ABS warning lamp on On a 4S 2M Side By Side configuration the blue modulator
42. o secure sensor wires to rubber air hoses Expansion of rubber air hoses will damage sensor wires causing ABS sensor failure Page 21 Rev 6 0 PLC Select Speed Sensor Cable Routing Although it is possible to route cables along the axle the preferred approach is to route the speed sensor cables along the air hoses between the ABS valve and the brake actuators Tie straps should not be used to secure the speed sensor cable to air hoses For a more reliable installation use sensor hose clips to secure speed sensor cables to rubber air hoses Leave some slack in cables to accommodate movement between chassis components Excess cable must not be allowed to hang free and must be bundled and attached to the chassis to prevent damage due to vibration and abrasion Route sensor wire on backside of axle housing to avoid damage from road debris A sensor hose clip is placed on the hose and sensor wire 0 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 OO Push up and and attach tie straps Short Cable short bone Long cable long bone E 6 7 9 1 es Page 22 Rev 6 0 PLC Select ABS 2M Installation Service Manual tor 4S 2M 2S 2M Systems PLC
43. ometer Mode ON off ON off ON off ON off ON off ON This mode displays the odometer value 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 sec flashes then 2 on off 1 4 sec flashes if set for miles 1 on off 1 4 sec flash if set for kms PLC Select Page 47 Rev 6 0 PLC Select 1M 2M Tire Scale Factor Chart Trailer Scaling Factor Scaling Factor Scaling Factor Scaling Factor Tire 100T miles 100T km 80T miles SOT km 579 360 80T Smallest Tire 100T Smallest Tire 580 305 70R19 5 574 11R17 5HC 568 10 00R15TR 566 255 70R22 5 566 275 70R22 5 545 10R22 5 520 519 518 504 503 501 491 80T Largest Tire 11 00R20 488 305 75R24 5 488 478 478 472 471 i 466 100T Largest Tire 391 Haldex Factory Tire Scale Set At Default 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 Note Scale factor does not affect ABS performance but does affect odometer accuracy Page 48 Rev 6 0 PLC Select Troubleshooting ABS Warning 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 3 seconds an
44. or Blue Yellow connections Modulator Valve Solenoid Cable Yellow Channel Attached to ECU PLC Select 2M Electronic Control Unit ECU ABS Power Connector Modulator Valve Solenoid Cable Blue Channel Remote Valve Not Used with 2S 1M Configuration ABS Power Cable Verify connection locking tab shown below 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 Incorrect installation or location of speed sensors and exciter rings will result in poor ABS performance or sensors crossed leading to incorrect diagnostic troubleshooting The figure above shows the correct 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 32 Rev 6 0 PLC Select 4S 2M System Wiring PLC Select Side By Side 4S 2M Wiring Overview For a detailed view of sensor ECU connections see 2M ECU Overview on Page 32 Curb Side Road Side FFABS S3A S2A S2B S3B Valve with ECU S2A Curb Side Yellow Channel Blue Road Side 7 S2B Road Side Yellow S3A Curb Side Blue S3B Road Side ABS Valve Yellow Blue Channel Curb Side ABS Power Connection 7 Wa
45. please call 1 800 267 9247 Diagnostics Tools SAE 560 way Diagnostic Interface Cable PLC PC Diagnostics Kit PC not included Blink Codes Data Link Adapter DLA PLC PLC Info Center Page 40 Rev 6 0 PLC Select Diagnostic Tools Haldex provides 3 Methods for ABS Diagnostics 1 Blink Codes 2 PLC Info Center 3 PLC PC Diagnostics RE R W 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 information on pages 43 47 1 Blink Codes 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 An optional SAE 560 7 Way Diagnostic Interface Cable is also available Available functions include 1 View active fault code s 2 digit code and fault occurrence count 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
46. railer Brake Control Valve Emergency Supply 3 8 NPT Port 3 8 NPT Port Exhaust Port Trailer Floor Ground 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 which 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 4 Trailer Brake Control Valve Exhaust Port White indicates Spring Brake Priority Black indicates Service Brake Priority Page 15 Rev 6 0 PLC Select PLC Select 1M amp 2M Valve Orientation The ABS Valve Solenoid must be installed as shown below as A TRAILER FLOOR GROUND Typical tank mount valve orientation 1 Install fittings into valve Sealant is not reguired 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 Liguid pipe sealant is approved for use if reguired PA 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 4 Using a 1 1 2 wrench tighten the jam nut to 30 ft Ib while holding the nipple with a 7 8 wrench see detail below SJ Attach hoses to appropriate brake chambers Use
47. tem Wide 20 PLC Select 1M Speed Sensor Cable Routing i 21 22 PLC Select ABS 2M Installation Service Manual for 4S 2M Systems 23 PLC Select 2M System Components siriani 24 PLC Select 2M ECU Valve Units OVerview annan aan naan aan aan aan aa annan 25 26 PLC Select 2M Installation Overview FFABS System 45 2M naene annan nan 27 PLC Select 2M PLC Select FFABS 4S 2M Plumbing Schematic Side By Side 27 PLC Select 2M Installation Overview ABS Relay System 45 2M ada lana 28 PLC Select 2M PLC Select 2 Port ABS 4S 2M Plumbing Schematic Side By Side 28 PLC Select 2M PLC Select FFABS 4S 2M Plumbing Schematic Axle By Axle 29 PLC Select 2M PLC Select 2 Port ABS 4S 2M Plumbing Schematic Axle By Axle 30 PLC Select 2M Full Trailer Plumbing Schematic Axle By AXle nunnan 31 PLC Select 2M PLC Select 2M ECU Overview 32 PLC Select 2M 4S 2M System Wiring Side By Side mmenneennnee nene eea 33 PLC Select 2M 45 2M System Wiring Axle By Axle nunnan nene 34 PLC Select 2M 4S 2M System Wiring PLC SEelect iii 35 PLC Select 2M Speed Sensor Cable Routing i 36 37 Testing and Diagnostic Tools PLC Select 1M 2M Chasis End of Lin
48. tioning 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 49 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 49 of this manual Notes i 2 Disconnect power from the ABS system before making any repairs Most ABS problems are related to Cut or damaged 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 15 Volts DC D 6 95 6 9 After making any repairs go to the Diagnostic Tools section of this manual see pages 40 42 to confirm that the fault is corrected If dynamic fault codes 11 16 or 21 26 has occurred the ABS Warning Light will remain on with a code 07 when repowered until the problem has been corrected After correcting the stored fault the vehicle must be driven above 6 MPH utilizing permanent power for the ABS to recognize the problem has been corrected Verify the ABS light turns off before clearing stored dynamic codes PLC Select n Page 39 Rev 6 0 Technical Service amp Engineering Support 1 800 643 2374 press 2 In Canada
49. ultiplexing the signal is carried on Pin 7 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 the braking air pressure in response to the input from the speed sensors Incorrect installation or location of speed sensors sensor block clips 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 OA LLIES 364429001 T8065 DOLLIES ABS modulator valve solenoid connector B Sensor S1A Curb Side Red Channel OT Sensor S1B Road Side Red Channel Note When installing and servicing always apply small amount of dielectric grease to all electrical connections Page 19 Rev 6 0 E ek 7 9 E e 364429001 HALDEX sa 2S 1M System Wiring PLC Select Note Cover all exposed electrical connections before painting SIA Curb Side Red Channel A Solenoid Connection hand tighten collar firmly 7 Way Wiring SAEJ560 Distance of ABS Light from Red rear clearance side marker light is 5 9 inches to 23 inches max Hose Clamp md MOT N I hv B
50. used for 25 2M applications Haldex recommends our 2S 1M A7 product as comparable performance and more economical Although a 4S 2M is only reguired 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 25 1M system FMVSS 121 specifies that Blue Wire J560 connector Pin no 7 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 PLC Select Page 3 Rev 6 0 Wheel End Installation The radial clocking position of the sensor block should be between 9 and 3 o clock While the ABS performance Is not affected with sensor location in 12 o clock the lower half of the 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 Exciter Ring 1596 037 Sensor Block Sensor Block Retainer Clip E o Center Line CL of Sensor And Block Sensor
51. y Wiring bhus ABS Light Apply dielectric grease to all electrical connections Distance of ABS Light from road side red rear clearance side Marker light is 5 9 inches to 23 inches max An LEDABS warning lamp is acceptable PLC Select Page 33 Rev 6 0 4S 2M System Wiring PLC Select Axle By Axle 4S 2M Wiring Overview For a detailed view of sensor ECU connections see 2M ECU Overview on Page 32 Axle 1 Axle 2 EFABS S3A S2A S2B S3B Valve with ECU i Yellow Channel ao Rear Axle S3B Road Side Yellow S2A Curb Side Blue AN S3A Road Side mai i ti i Blue ABS Valve Blue Channel ABS Power Connection Front Axle 7 Way Wiring N ABS Light Apply dielectric grease to all electrical connections i 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 34 Rev 6 0 PLC Select 4S 2M System Wiring PLC Select Solenoid Connection hand tighten collar firmly Solenoid Connector Collar FFABS Valve ABS Valve Fully push the ABS Power Cable onto the ABS Power Connector and be sure the tab locks into place Insert sensor cable into the correct location on the ECU and push sensor retainer clip over sensor cable to secure them in place Sensor Retainer Clip ECU Sensor Retainer Clip Note When installing and servicing always apply small amount of

L30041 PLC Select Service Manual 1/11

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