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Installation Guide
WARNING
To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. The ABS is an electrical system. When you work on the ABS, take the same precautions that you must take with any electrical system to avoid serious personal injury. As with any electrical system, the danger of electrical shock or sparks exists that can ignite ammable substances. You must always disconnect the battery ground cable before working on the electrical system. Park the vehicle on a level surface. Block the wheels to prevent the vehicle from moving. Support the vehicle with safety stands. Do not work under a vehicle supported only by jacks. Jacks can slip and fall over. Serious personal injury and damage to components can result.
R955318 and R955319 Meritor WABCO Enhanced Easy-Stop Trailer ABS Replacement Kits for Easy-Stop ECU/Modulator Valve Assembly Part Number 472 500 011 0
Enhanced Easy-StopTM Trailer ABS ECU/modulator valve assembly, Part Number 400 500 104 0, has replaced ECU/modulator valve assembly, Part Number 472 500 011 0. This replacement assembly meets the March 1, 2001 FMVSS 121 in-cab trailer indicator lamp mandate. The new assemblies are packaged as a kit, so that you will have all of the necessary components to complete an installation. Replacement Kits contain the following:
2S/1M ECU/Single Modulator Valve with Power Cable, Replacement Kit R955318
Installation Guide (TP-0261) Enhanced Easy-StopTM Maintenance Manual, MM-0180 12-volt integrated ECU/modulator valve assembly, Part Number 400 500 104 0 Power cable, Part Number 449 326 047 0
For Complete Maintenance and Service Instructions for Meritor WABCO Enhanced Easy-StopTM Trailer ABS, Including Information About Power Line Carrier (PLC)
Refer to Maintenance Manual MM-0180, Enhanced Easy-StopTM Trailer ABS. A copy of the manual is included in the replacement kit. If you require technical assistance, contact our Customer Service Center at 1-800-535-5560. Our technical publications are also available on our web site: www.meritorwabco.com
2S/1M ECU/Single Modulator Valve with Power/Diagnostics Cable, Replacement Kit R955319
Installation Guide (TP-0261) Enhanced Easy-StopTM Maintenance Manual, MM-0180 12-volt integrated ECU/modulator valve assembly, Part Number 400 500 104 0 Power/Diagnostics cable with mounting bracket, Part Number 449 364 152 0
3. Attach labels to identify all air lines. 4. Disconnect and remove the air lines from the ECU/modulator valve assembly. 5. A. Replacement Kit R955318: Disconnect and remove the Easy-StopTM power cable from the ECU/modulator valve assembly and remove the cable from the trailer. B. Replacement Kit R955319: Disconnect and remove the Easy-StopTM power and diagnostic cables from the ECU/modulator valve assembly and remove them from the trailer. 6. Disconnect the sensor cables from the ECU/modulator valve assembly. 7. Remove the ECU/modulator valve assembly from its mounting location (either on the air tank or on the frame of the vehicle).
Enhanced Easy-StopTM replacement parts, as well as the Easy-StopTM components, are illustrated in Figure 1. Figure 1
Easy-StopTM Parts Enhanced Easy-StopTM Replacement Parts
POWER CABLE
POWER CABLE
DIAGNOSTICS CABLE
POWER/DIAGNOSTIC Y CABLE
YE 2/6
YE 1/4
WARNING
ECU/SINGLE MODULATOR VALVE ASSEMBLY ECU/SINGLE MODULATOR VALVE ASSEMBLY
You must use a Schedule 80 hex nipple (3/4-inch NPTF) to mount the ECU/modulator valve assembly securely to the air tank to avoid possible serious personal injury and damage to the component. 1. Use a 3/4-inch Schedule 80 hex nipple to attach the ECU/modulator valve assembly to a reinforced air tank. Do not overtighten. Meritor WABCO does not recommend use of a vise when installing the hex nipple. Use of a vise may cause overclamping. Overclamping may damage the internal components of the assembly.
2. Use a 3/4-inch pipe plug to plug the unused supply port.* 3. Rotate and tighten the ECU/modulator valve assembly until the exhaust port faces down and the connection is secure. Use a torque wrench or ratchet with extension at the 3/4-inch pipe plug installed on the front supply port. Figure 2. Figure 2
Figure 3
Exhaust port must face DOWN.
Rear of assembly faces air tank. Exhaust port must face DOWN.
Cross Member-Mounted NOTE: If attaching the replacement assembly to the vehicle cross member, it will be necessary to drill new mounting holes. 1. Install a 3/4-inch NPTF tting in supply port. 2. Use a 3/4-inch pipe plug to plug unused supply port.* 3. Mark the location of the two mounting holes on the vehicle cross member, then drill two 3/8-inch holes into the vehicle cross member. Recommended mounting location is midway between the side rails, close to the brake chambers the valve serves. 4. Attach replacement assembly to vehicle. 5. Use two 3/8-inch Grade 8 bolts with prevailing torque nuts and washers to attach the assembly to the vehicle cross member. Tighten bolts to 18-lb-ft (24 Nm). Figure 3. T
* Apply SAE-standard, DOT-approved Teon tape or paste-type thread sealant to all pipe threads beyond the rst two threads. Pipes with pre-applied thread sealant may also be used.
IV. Attach the Two Sensor Extension Cables to the Replacement Assembly
1. Remove the protective caps from YE2 and YE1 sensor connectors on the ECU/single modulator valve assembly. Figure 5. Figure 5
PROTECTIVE CAPS FOR SENSORS
1. For cables with industry-standard harness connectors, route the cable from the harness connector to the ECU/ modulator valve assembly and secure to prevent damage. 2. For trailers where the old ABS power cable was run into a junction box, route the cable from the ECU/modulator valve assembly to a junction box, which interfaces with the seven-way connector at the front of the trailer. When routing the cable, leave enough to compensate for exing of trailer and sub-frame. 3. Push the hinged power connector retaining clip UP and remove the protective cap from the ECU/modulator valve assembly. Plug the power 8-pin connector on the power or power/diagnostics cable into the ECU/ modulator valve assembly. WABCO identication (lettering on cable connection) must face DOWN. Pull the hinged power connector retainer clip on the ECU/single modulator valve assembly DOWN to secure connection. Figure 6. Figure 6
CAP
YE 2/6
YE 1/4
2. Plug the sensor extension cable into the ECU/single modulator valve assembly. To secure the connection, push sensor retainer clip DOWN. The retainer clips must t in the groove of the sensor connectors to ensure proper connection. Connect curbside sensor at YE1 Connect roadside sensor at YE2
4. For power cable installations, go to Step 5. For power/diagnostics cable installations: Install the diagnostic cable bracket so that the diagnostic plug is accessible. Normal location is on the right front corner of the sub-frame, but will vary depending on the type of trailer.
When routing the diagnostics cable from the ECU/modulator valve assembly to the bracket, leave enough slack in the cable to compensate for exing of the trailer and sub-frame. Properly secure the cable in the sub-frame to prevent cable damage.
GENERIC INPUT/OUTPUT (EXPANDED CAPABILITY) WHITE AND YELLOW WHITE (GROUND) BRN BLU 7 WAY YEL RED GRN BLUE (CONSTANT POWER) RED (STOP LAMP) GREEN AND WHITE TRAILER ABS INDICATOR LAMP
WHT
4 OR 5 WIRE SCHEMATIC
BLK
GROUND
Enhanced Easy-StopTM 2S/1M Basic Installation End of Line Testing Procedure Using TOOLBOXTM Software
NOTE: If you are testing an installation that has a power only cable, temporarily install a Meritor WABCO combination power/diagnostics Y style cable.
1 5
2 6
3 7
4 8
Figure 8
Figure 9
Figure 10
8. Check Order elds to verify sensors were installed in the right location.
Blink Code
4
Problem Area
Sensor YE1 (curbside sensor) Sensor YE2 (roadside sensor) ECU/single modulator valve assembly Power Supply
Action
Check sensor installation. Make necessary repairs. Check sensor installation. Make necessary repairs. Verify proper installation. If code continues, contact Meritor WABCO for assistance. Verify proper electrical installation. Check power supply. Make necessary corrections. Verify proper installation. If code continues, contact Meritor WABCO for assistance. Internal failure, contact Meritor WABCO. Internal failure, contact Meritor WABCO. Verify proper electrical installation. Check power supply. Make necessary corrections.
14
15
ECU Failure
16 17 18
Meritor WABCO Vehicle Control Systems 3331 West Big Beaver Road, Suite 300 Troy, MI 48084 USA 800-535-5560 meritorwabco.com
Information contained in this publication was in effect at the time the publication was approved for printing and is subject to change without notice or liability. Meritor WABCO reserves the right to revise the information presented or discontinue the production of parts described at any time. Copyright 2002 ArvinMeritor, Inc. All Rights Reserved TP-0261 Issued 05-02 16579/24240