MM 0112

Maintenance Manual MM-0112
Anti-Lock Braking System (ABS) for Trucks, Tractors and Buses

For E Version ECUs 12-Volt and 24-Volt Systems
Revised 01-11
Service Notes
About This Manual

This manual contains maintenance procedures for Meritor WABCOs Anti-Lock Braking System (ABS) for trucks, tractors and buses.
Literature on Demand DVD (LODonDVD)

The LODonDVD contains product, service and warranty information for ArvinMeritor components. To order the DVD, visit Literature on Demand at arvinmeritor.com and specify TP-0742.
Before You Begin

1. 2. Read and understand all instructions and procedures before you begin to service components. Read and observe all Warning and Caution hazard alert messages in this publication. They provide information that can help prevent serious personal injury, damage to components, or both. Follow your companys maintenance and service, installation and diagnostics guidelines. Use special tools when required to help avoid serious personal injury and damage to components.
How to Obtain Tools and Supplies Specified in This Manual

Call ArvinMeritors Commercial Vehicle Aftermarket at 888-725-9355 to obtain Meritor tools and supplies.
3. 4.
Hazard Alert Messages and Torque Symbols

WARNING
A Warning alerts you to an instruction or procedure that you must follow exactly to avoid serious personal injury and damage to components.
CAUTION
A Caution alerts you to an instruction or procedure that you must follow exactly to avoid damage to components. This symbol alerts you to tighten fasteners to a specified torque value.
@
How to Obtain Additional Maintenance and Service Information

On the Web
Visit Literature on Demand at arvinmeritor.com to access and order product, service, aftermarket, and warranty literature for ArvinMeritors truck, trailer and specialty vehicle components.
Information contained in this publication was in effect at the time the publication was approved for printing and is subject to change without notice or liability. Meritor WABCO reserves the right to revise the information presented or to discontinue the production of parts described at any time.
Meritor WABCO Maintenance Manual MM-0112 (Revised 01-11)
Contents
pg. i 1
Asbestos and Non-Asbestos Fibers Section 1: Introduction

Contents Description How ABS Works ABS Configuration ABS Indicator Lamp Trailer ABS Indicator Lamp ABS Modulator Valves ABS Valve Packages ABS Sensors Off-Road ABS Automatic Traction Control (ATC) System Components
pg. 67
Section 4: Component Replacement

Component Removal and Installation Wheel Speed Sensors ABS Modulator Valve ATC Valve Trailer Active Braking Valve ABS Valve Packages Active Braking Valve on the ABS Valve Package Electronic Stability System (ESC) Component Replacement
2 3 4 6 7 8 9 12
69 70 71 72 74 78
Section 5: Appendix I System Configurations

ABS Configurations
80 91
Section 6: Appendix II Wiring Diagrams

ECU Connector Pin Assignments
Section 2: Stability and Safety Enhancement Systems: Automatic Traction Control (ATC), Roll Stability Control (RSC), Electronic Stability Control (ESC) and Hill Start Aid (HSA)
ATC Deep Snow and Mud Switch Roll Stability Control (RSC) Electronic Stability Control (ESC)
Section 7: Appendix III Additional ABS Information

Troubleshooting Meritor WABCO ABS Valve Package Reconfiguration Procedure How to Reconfigure an ECU (E Version) TOOLBOX Software Manual Reconfiguration
13 14 16 20
92 93 95 102
Section 3: Diagnostics, Troubleshooting and Testing

General Maintenance Information Diagnostics TOOLBOX Software Diagnostics Blink Code Diagnostics (Tractor ABS Only) Pro-Link Plus Diagnostics J1939 Datalink Verification Pro-Link Plus SID-FMI Troubleshooting and Repair Wheel Speed Sensors Modulator Valves Active Braking Valves (ABV) Power Supply Brake Pressure Sensor ESC Module Steering Angle Sensor (SAS) Hill Start Aid (HSA) J1939 Serial Communications Internal ABS ECU Retarder Relay Tire Size Range Testing Dynamometer Testing Vehicles with ATC
Section 8: Appendix IV ESC Calibrations

ESC End of Line Calibration Procedure
Section 9: Appendix V TOOLBOX Software and Pro-Link Plus

Using the TOOLBOX Software
21 29 31 32 38 43 47 49 51 54 56 59 61 64 65
Asbestos and Non-Asbestos Fibers
ASBESTOS FIBERS WARNING

The following procedures for servicing brakes are recommended to reduce exposure to asbestos ber dust, a cancer and lung disease hazard. Material Safety Data Sheets are available from ArvinMeritor.
NON-ASBESTOS FIBERS WARNING

The following procedures for servicing brakes are recommended to reduce exposure to non-asbestos ber dust, a cancer and lung disease hazard. Material Safety Data Sheets are available from ArvinMeritor.
Hazard Summary
Because some brake linings contain asbestos, workers who service brakes must understand the potential hazards of asbestos and precautions for reducing risks. Exposure to airborne asbestos dust can cause serious and possibly fatal diseases, including asbestosis (a chronic lung disease) and cancer, principally lung cancer and mesothelioma (a cancer of the lining of the chest or abdominal cavities). Some studies show that the risk of lung cancer among persons who smoke and who are exposed to asbestos is much greater than the risk for non-smokers. Symptoms of these diseases may not become apparent for 15, 20 or more years after the rst exposure to asbestos. Accordingly, workers must use caution to avoid creating and breathing dust when servicing brakes. Speci c recommended work practices for reducing exposure to asbestos dust follow . Consult your employer for more details.
Hazard Summary
Most recently manufactured brake linings do not contain asbestos bers. These brake linings may contain one or more of a variety of ingredients, including glass bers, mineral wool, aramid bers, ceramic bers and silica that can present health risks if inhaled. Scientists disagree on the extent of the risks from exposure to these substances. Nonetheless, exposure to silica dust can cause silicosis, a non-cancerous lung disease. Silicosis gradually reduces lung capacity and ef ciency and can result in serious breathing dif culty . Some scientists believe other types of non-asbestos bers, when inhaled, can cause similar diseases of the lung. In addition, silica dust and ceramic ber dust are known to the State of California to cause lung cancer . U.S. and international agencies have also determined that dust from mineral wool, ceramic bers and silica are potential causes of cancer. Accordingly, workers must use caution to avoid creating and breathing dust when servicing brakes. Speci c recommended work practices for reducing exposure to non-asbestos dust follow. Consult your employer for more details.
Recommended Work Practices

1. Separate Work Areas. Whenever feasible, service brakes in a separate area away from other operations to reduce risks to unprotected persons. OSHA has set a maximum allowable level of exposure for asbestos of 0.1 f/cc as an 8-hour time-weighted average and 1.0 f/cc averaged over a 30-minute period. Scientists disagree, however, to what extent adherence to the maximum allowable exposure levels will eliminate the risk of disease that can result from inhaling asbestos dust. OSHA requires that the following sign be posted at the entrance to areas where exposures exceed either of the maximum allowable levels: DANGER: ASBESTOS CANCER AND LUNG DISEASE HAZARD AUTHORIZED PERSONNEL ONLY RESPIRATORS AND PROTECTIVE CLOTHING ARE REQUIRED IN THIS AREA. 2. Respiratory Protection. Wear a respirator equipped with a high-ef ciency (HEP A) lter approved by NIOSH or MSHA for use with asbestos at all times when servicing brakes, beginning with the removal of the wheels. Procedures for Servicing Brakes. Enclose the brake assembly within a negative pressure enclosure. The enclosure should be equipped with a HEPA vacuum and worker arm sleeves. With the enclosure in place, use the HEPA vacuum to loosen and vacuum residue from the brake parts. b. As an alternative procedure, use a catch basin with water and a biodegradable, nonphosphate, water-based detergent to wash the brake drum or rotor and other brake parts. The solution should be applied with low pressure to prevent dust from becoming airborne. Allow the solution to ow between the brake drum and the brake support or the brake rotor and caliper. The wheel hub and brake assembly components should be thoroughly wetted to suppress dust before the brake shoes or brake pads are removed. Wipe the brake parts clean with a cloth. c. If an enclosed vacuum system or brake washing equipment is not available, employers may adopt their own written procedures for servicing brakes, provided that the exposure levels associated with the employers procedures do not exceed the levels associated with the enclosed vacuum system or brake washing equipment. Consult OSHA regulations for more details. d. Wear a respirator equipped with a HEPA lter approved by NIOSH or MSHA for use with asbestos when grinding or machining brake linings. In addition, do such work in an area with a local exhaust ventilation system equipped with a HEPA lter . e. NEVER use compressed air by itself, dry brushing, or a vacuum not equipped with a HEPA lter when cleaning brake parts or assemblies. NEVER use carcinogenic solvents, ammable solvents, or solvents that can damage brake components as wetting agents. 4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA lter or by wet wiping. NEVER use compressed air or dry sweeping to clean work areas. When you empty vacuum cleaners and handle used rags, wear a respirator equipped with a HEPA lter approved by NIOSH or MSHA for use with asbestos. When you replace a HEPA lter , wet the lter with a ne mist of water and dispose of the used lter with care. 5. Worker Clean-Up. After servicing brakes, wash your hands before you eat, drink or smoke. Shower after work. Do not wear work clothes home. Use a vacuum equipped with a HEPA lter to vacuum work clothes after they are worn. Launder them separately. Do not shake or use compressed air to remove dust from work clothes. 6. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA lters with care, such as in sealed plastic bags. Consult applicable EPA, state and local regulations on waste disposal. 3. a.
Recommended Work Practices

1. Separate Work Areas. Whenever feasible, service brakes in a separate area away from other operations to reduce risks to unprotected persons. 2. Respiratory Protection. OSHA has set a maximum allowable level of exposure for silica of 0.1 mg/m3 as an 8-hour time-weighted average. Some manufacturers of non-asbestos brake linings recommend that exposures to other ingredients found in non-asbestos brake linings be kept below 1.0 f/cc as an 8-hour time-weighted average. Scientists disagree, however, to what extent adherence to these maximum allowable exposure levels will eliminate the risk of disease that can result from inhaling non-asbestos dust. Therefore, wear respiratory protection at all times during brake servicing, beginning with the removal of the wheels. Wear a respirator equipped with a high-ef ciency (HEP A) lter approved by NIOSH or MSHA, if the exposure levels may exceed OSHA or manufacturers recommended maximum levels. Even when exposures are expected to be within the maximum allowable levels, wearing such a respirator at all times during brake servicing will help minimize exposure. 3. Procedures for Servicing Brakes. Enclose the brake assembly within a negative pressure enclosure. The enclosure should be equipped with a HEPA vacuum and worker arm sleeves. With the enclosure in place, use the HEPA vacuum to loosen and vacuum residue from the brake parts. b. As an alternative procedure, use a catch basin with water and a biodegradable, nonphosphate, water-based detergent to wash the brake drum or rotor and other brake parts. The solution should be applied with low pressure to prevent dust from becoming airborne. Allow the solution to ow between the brake drum and the brake support or the brake rotor and caliper. The wheel hub and brake assembly components should be thoroughly wetted to suppress dust before the brake shoes or brake pads are removed. Wipe the brake parts clean with a cloth. c. If an enclosed vacuum system or brake washing equipment is not available, carefully clean the brake parts in the open air. Wet the parts with a solution applied with a pump-spray bottle that creates a ne mist. Use a solution containing water, and, if available, a biodegradable, non-phosphate, water-based detergent. The wheel hub and brake assembly components should be thoroughly wetted to suppress dust before the brake shoes or brake pads are removed. Wipe the brake parts clean with a cloth. d. Wear a respirator equipped with a HEPA lter approved by NIOSH or MSHA when grinding or machining brake linings. In addition, do such work in an area with a local exhaust ventilation system equipped with a HEPA lter . e. NEVER use compressed air by itself, dry brushing, or a vacuum not equipped with a HEPA lter when cleaning brake parts or assemblies. NEVER use carcinogenic solvents, ammable solvents, or solvents that can damage brake components as wetting agents. 4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA lter or by wet wiping. NEVER use compressed air or dry sweeping to clean work areas. When you empty vacuum cleaners and handle used rags, wear a respirator equipped with a HEPA lter approved by NIOSH or MSHA, to minimize exposure. When you replace a HEPA lter , wet the lter with a ne mist of water and dispose of the used lter with care. 5. Worker Clean-Up. After servicing brakes, wash your hands before you eat, drink or smoke. Shower after work. Do not wear work clothes home. Use a vacuum equipped with a HEPA lter to vacuum work clothes after they are worn. Launder them separately. Do not shake or use compressed air to remove dust from work clothes. 6. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA lters with care, such as in sealed plastic bags. Consult applicable EPA, state and local regulations on waste disposal. a.
Regulatory Guidance
References to OSHA, NIOSH, MSHA, and EPA, which are regulatory agencies in the United States, are made to provide further guidance to employers and workers employed within the United States. Employers and workers employed outside of the United States should consult the regulations that apply to them for further guidance.
Regulatory Guidance
References to OSHA, NIOSH, MSHA, and EPA, which are regulatory agencies in the United States, are made to provide further guidance to employers and workers employed within the United States. Employers and workers employed outside of the United States should consult the regulations that apply to them for further guidance.
1 Introduction
Contents
1 Introduction
This manual contains service information for E version Meritor WABCO Anti-Lock Braking System (ABS) and ABS with Automatic Traction Control (ATC) for trucks, tractors and buses. E version ABS incorporates Power Line Carrier Communication (PLC), an optional feature that allows tractor/trailer communication. For the driver, this means that a trailer ABS indicator lamp located on the vehicle dash will come on if a trailer ABS fault occurs on a trailer equipped with PLC. NOTE: For diagnostic and testing procedures for systems with C version ECUs, use Maintenance Manual 28, Anti-Lock Braking Systems (ABS) for Trucks, Tractors and Buses. For D version ECUs, use Maintenance Manual 30, Anti-Lock Braking Systems (ABS) for Trucks, Tractors and Buses. The ABS version is marked on the ECU. Figure 1.1. If you cannot identify the ECU version installed on your vehicle, contact ArvinMeritors Customer Service Center at 866-OnTrac1 (668-7221).
In the event of a malfunction in the system, the ABS in the affected wheel(s) is disabled; that wheel still has normal brakes. The other wheels keep the ABS function. Two ABS indicator lamps, one for tractor and one for trailer, let drivers know the status of the system. The tractor ABS lamp is also used to display tractor blink code diagnostics. Figure 1.2. The location of the ABS indicator lamps varies depending on the make and model of the vehicle.
Figure 1.2
1002000a
Figure 1.1
MANUFACTURING INFORMATION
Figure 1.2
E PART NUMBER 4003972a
Do not open the ECU. Opening the ECU to gain access to the internal components will void the warranty. If the vehicle is equipped with optional Automatic Traction Control (ATC), with ATC and Roll Stability Control (RSC), or with ATC and Electronic Stability Control (ESC), the ATC indicator lamp is used to indicate ATC, RSC or ESC. Refer to Section 2. Blink code diagnostics information for trailer ABS is not included in this manual. Refer to Maintenance Manual 33, Easy-Stop Trailer ABS, or Maintenance Manual MM-0180, Enhanced Easy-Stop Trailer ABS with PLC, for trailer diagnostics.
ABS CONFIGURATION
ECU VERSION
Figure 1.1
Description
How ABS Works
Meritor WABCO ABS is an electronic system that monitors and controls wheel speed during braking. The system works with standard air brake systems. ABS monitors wheel speeds at all times and controls braking during wheel lock situations. The system improves vehicle stability and control by reducing wheel lock during braking. The ECU receives and processes signals from the wheel speed sensors. When the ECU detects a wheel lockup, the unit activates the appropriate modulator valve, and air pressure is controlled.
1 Introduction
ABS Configuration
With the E Basic ECU, 4S/4M is the only configuration used. Figure 1.3.
Figure 1.3
UNIVERSAL ECU
FRAME-MOUNTED ECU
BASIC ECU
Figure 1.3
4003974a
The ABS configuration is defined by the number of wheel-end sensors and modulator valves. There are three common ABS configurations used with E version ECUs. 4S/4M (4 wheel speed sensors, 4 modulator valves). Figure 1.4. 6S/4M (6 wheel speed sensors, 4 modulator valves) 6S/6M (6 wheel speed sensors, 6 modulator valves) Typical illustrations in this manual use the 4S/4M configuration as a sample. Layouts for 4S/4M, 6S/4M and 6S/6M configurations are included in Section 5.
1 Introduction
Figure 1.4
4S/4M CONFIGURATION ABS ONLY
WHEEL SPEED SENSORS ABS MODULATOR VALVES
LAMPS ECU
RELAY VALVE
ABS MODULATOR VALVE
WHEEL SPEED SENSORS QUICK RELEASE VALVE AIR LINES ELECTRICAL LINES
ABS MODULATOR VALVE
1002004h
Figure 1.4
ABS Indicator Lamp

The ABS indicator lamp works as follows:
Ignition ON
OFF ON
Normal Operation
ABS lamp comes on at ignition momentarily for a bulb check, then goes out. ABS lamp does not go out at ignition. ABS lamp flashes during vehicle operation. ABS lamp does not go out at ignition.
System is OK.
After servicing ABS
When vehicle is driven at speeds above 4 mph (6 km/h), lamp goes out. System is OK. The vehicles normal ABS function is being modified due to road conditions. Lamp does not go out at speeds above 4 mph (6 km/h) a fault exists in the ABS system.
1002005a
Off-road ABS operation. Refer to the off-road ABS information in this section. Existing Fault
NOTE: If the ECU senses a tractor ABS fault during normal vehicle operation, the ABS indicator lamp will come on and stay on.
1 Introduction
Trailer ABS Indicator Lamp

The trailer ABS indicator lamp on the vehicle dash applies to Trailer ABS only. The lamp is controlled by a signal to the tractor ECU, sent over the power line (PLC function). When a trailer ABS fault is detected, an ON message is sent; when no fault is detected, the ECU receives an OFF message. Table A illustrates trailer ABS lamp operation at power-up, or ignition on. Table B depicts lamp responses that occur during operation. Lamp turn ON and OFF messages do not turn the lamp ON or OFF instantly. The delay between the receipt of the message and the lamp response time is intentional. It prevents erratic lamp activity. NOTE: For doubles or triples, the lamp does not distinguish between trailers. A system fault in any of the trailers will activate the trailer ABS indicator lamp. Table A: Dash-mounted Trailer ABS Indicator Lamp Operation Bulb Check (Information for Drivers) Signal from Trailer to Tractor ECU Single or Multiple Trailers
message lamp on lamp off 0.5 sec OFF OFF OFF OFF OFF OFF OFF
Status of Trailer ABS Lamp on Vehicle Dash Trailer ABS lamp comes on at ignition, OFF message is detected within three seconds of ignition, Trailer ABS lamp goes out.
Explanation Bulb Check performed AND Trailer ABS system is OK. In this case, the lamp is ON for a Bulb Check only.
4003977a
Single or Multiple Trailers

message lamp on lamp off ign on 0.5 sec No ON or OFF messages OFF OFF
Trailer ABS lamp does not come on within three seconds of ignition.
No Bulb Check, trailer added after initial power-up, system OK. There was no trailer PLC message for at least three seconds following ignition ON.
t > 3 sec 4003978a
ON = Turn ON message to the trailer ABS lamp OFF = Turn OFF message to the trailer ABS lamp Removing a trailer with a fault will cause the ABS lamp to turn off. Remember to have the trailer with the fault repaired as soon as possible before returning it to service.
1 Introduction
Table B: Dash-mounted Trailer ABS Indicator Lamp Operation (Information for Service Technicians) Signal from Trailer to Tractor ECU Single or Multiple Trailers
message lamp on lamp off 0.5 sec 4003979a No ON or OFF messages
Status of Trailer ABS Lamp on Vehicle Dash Trailer ABS lamp does not come on within three seconds of ignition.
Explanation Not using the PLC system (no trailer connected) or trailer not equipped with PLC or fault in PLC system. Trailer ABS fault(s) occurred during operation and still exists.
Action Use lamp on side of trailer to identify fault. Make necessary repairs.
Single Trailer
message lamp on lamp off 0.5 sec 4003980a OFF OFF OFF ON ON ON ON ON
Trailer ABS lamp comes on.
Multiple Trailers/Dollies
message lamp on lamp off 0.5 sec 4003981a OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON ON ON ON
Single Trailer
message lamp on lamp off 0.5 sec t + 2.5 4003982a ON ON OFF OFF OFF OFF OFF OFF
Trailer ABS lamp comes on but goes out after 2.5 seconds after fault is detected.
Trailer ABS fault occurred during operation and the fault was corrected.
None
message lamp on lamp off OFF OFF OFF OFF OFF OFF OFF ON ON OFF OFF OFF OFF OFF OFF 0.5 sec t + 2.5 4003983a
Single Trailer
message lamp on lamp off ON ON ON 0.5 sec t No ON or OFF messages t + 10 sec 4003984a
ABS lamp is off, comes on, then goes off, 10 seconds after loss of messages.
ABS fault existed, then signal was lost because trailer disconnected or PLC fault. ABS fault existed, then trailer with fault lost signal because trailer was disconnected or PLC fault.
Use lamp on side of trailer to identify fault. Make necessary repairs.
message lamp on lamp off OFF OFF OFF OFF OFF OFF OFF ON ON 0.5 sec t + 2.5 4003985a
1 Introduction
Table B: Dash-mounted Trailer ABS Indicator Lamp Operation (Information for Service Technicians Signal from Trailer to Tractor ECU Single Trailer to Multiples
message lamp on lamp off OFF OFF OFF ON ON ON ON ON ON 0.5 sec
Status of Trailer ABS Lamp on Vehicle Dash ABS lamp is on and stays on when a new trailer with no new fault is added.
Explanation There was a fault in existence before the new trailer was added AND the ignition was not turned off before the trailer was added. ABS fault was in existence before the new trailer was added AND the ignition was not turned off before the trailer was added AND the new trailer has an ABS fault.
Action Use lamp on side of trailer to identify fault. Make necessary repairs.
4003986a
Single Trailer to Multiples

message lamp on lamp off 0.5 sec 4003987a ON ON ON ON ON ON ON ON ON
ABS lamp is on and stays on when a new trailer with a new fault is added.
ON = Turn ON message to the trailer ABS lamp OFF = Turn OFF message to the trailer ABS lamp Removing a trailer with a fault will cause the ABS lamp to turn off. Remember to have the trailer with the fault repaired as soon as possible before returning it to service.
ABS Modulator Valves

Modulator valves control the air pressure to each affected brake during an ABS function.
Valve Arrangement Option

In Figure 1.4, the modulator valves on the rear axle are mounted separately and a relay valve is used to deliver air pressure to the modulator valves. There is also an optional valve package available from Meritor WABCO, the ABS valve package, which may be found on certain vehicle models. The ABS valve package may be used on all D and E version units, including D and E Basic, and is available for front or rear axle installation. Easy Listening Tip! To ensure the ABS valves are working just listen! Figure 1.5.
1 Introduction
Figure 1.5
ABS Valve Packages

CAB
4M CHANNEL
CURBSIDE
The front ABS valve package can consist of either a quick release valve or a relay valve with two ABS modulator valves and is mounted in the front of the vehicle. The rear ABS valve package combines a service brake relay valve with two ABS modulator valves and is mounted in the rear of the vehicle. Depending on the application, these valve packages may or may not have a 3/2 solenoid valve (active braking valve) mounted to the quick release or relay valve. Figure 1.6.
CAB
6M CHANNEL
CURBSIDE
2 5
1002006d
Figure 1.5
1. 2. 3.
Apply the brakes. Turn on the ignition. Wait for the ABS indicator lamp to come on. NOTE: In previous versions of ABS, the valves are cycled diagonally. Diagonal cycling does not occur with E version ABS.
4.
Listen to the valves cycle one by one as follows: 4M (channel) valve cycle order: 1234 6M (channel) valve cycle order: 1 2 3 4 5 6
1 Introduction
Figure 1.6
WHEEL SPEED SENSORS
xxxxx xxxxx xxxxx xxxxx
REAR ABS VALVE PACKAGE
ECU
LAMPS
WHEEL SPEED SENSORS
001 20/98 472 500 30. 0
MADE IN GERMANY
FRONT ABS VALVE PACKAGE AIR LINES ELECTRICAL LINES
4S/4M CONFIGURATION ABS ONLY

1002007e
Figure 1.6
ABS Sensors
ABS sensor systems consist of a tooth wheel mounted on the hub or rotor of each monitored wheel and a sensor installed so that its end is against the tooth wheel. The sensor continuously sends wheel speed information to the ECU. A sensor clip holds the sensor in place at the tooth wheel. The type of axle determines sensor mounting location. Steering axle sensors are installed in the steering knuckle or in a bolted-on bracket. Drive axle sensors are mounted in a block attached to the axle housing or in a bolted-on bracket.
Check the wheel speed sensors for correct alignment and apply lubricant to the sensor and sensor clip whenever wheel-end maintenance is performed. Refer to Section 3 and Section 4.
Off-Road ABS
On some vehicles, an off-road ABS function may be selected. Off-road ABS improves vehicle control and helps reduce stopping distances in off-road conditions or on poor traction surfaces such as loose gravel, sand and dirt.
1 Introduction
NOTE: On vehicles equipped with an off-road switch, the off-road ABS mode is manually selected by the driver. On some vehicles, the off-road mode may be fully automatic. Refer to the vehicle specifications for information about the off-road ABS feature. The ABS indicator lamp on the dash will flash while the vehicle is in the off-road mode. This alerts the driver that the vehicles normal ABS function is being modified.
Figure 1.8
SENSOR
Automatic Traction Control (ATC)

ATC is an option with Basic and frame-mounted E version ECUs and is available with all Universal ECUs. ATC can be used with individual valves, or with an integrated ABS/ATC valve package. Universal and frame-mounted E version ECUs with ATC may have stability control. Basic ECUs with ATC do not have RSC or ESC. Section 2 describes ATC, RSC and ESC in detail.
TOOTH WHEEL
SENSOR CLIP 1002009b
Figure 1.8
System Components
The ECU is the brain of the ABS system. It receives information from the sensors and sends signals to the ABS valves. ECUs are available for cab- or frame-mounted applications. Basic and universal ECUs are cab-mounted. Universal and frame-mounted E version ECUs with ATC may have Roll Stability Control (RSC) or Electronic Stability Control (ESC). Basic ECUs with ATC do not have RSC or ESC. Figure 1.7.
Figure 1.7
NOTE: The sensor and clip must be greased with Meritor WABCO-recommended lubricant whenever wheel-end maintenance is performed. Refer to Section 4 for lubrication specifications. An ABS modulator valve controls air pressure to each affected brake during an ABS event. The modulator valve is usually located on a frame rail or cross member near the brake chamber. The modulator valve is available in bayonet-style, Figure 1.9, or open-style connector.
Figure 1.9
AIR OUT (PORT 2)
Also available with open-style connector.

AIR IN (PORT 1)
UNIVERSAL ECU
BAYONET-STYLE CONNECTOR
FRAME-MOUNTED ECU
Figure 1.9
PRODUCT IDENTIFICATION TAG 4003992a
BASIC ECU
Figure 1.7
The ABS valve package is an alternative to individual valves.

4003974a
The rear ABS valve package combines two modulator valves, one service relay valve, and depending on the vehicle configuration, an active braking valve (ABV). Figure 1.10.
A tooth wheel is mounted at, or cast in, the hub or rotor of each sensed wheel, with a sensor installed so that its end is against the tooth wheel. A sensor clip holds the sensor in place at the tooth wheel. Figure 1.8.
1 Introduction
Figure 1.10
Figure 1.13
1002011a
Figure 1.10 Figure 1.13
1002012a
The front ABS valve package combines two modulator valves, a quick release valve or a relay valve, and depending on the vehicle configuration, an active braking valve (ABV). Figure 1.11.
Figure 1.11
TOOLBOX Software is a PC-based diagnostics program that can display wheel speed data, test individual components, verify installation wiring and more. Runs in Windows 2000, NT, XP and Vista. Internet Explorer version 3.02 or higher must be installed. RS232 to J1708 convertor box is required. Figure 1.14.
Figure 1.14
001 20/98 472 500 30. 0
MADE IN GERMANY
1003359a
Figure 1.11
Sensor cables connect the sensor to the ECU. Figure 1.12.

Figure 1.12
AVAILABLE FROM SPX SERVICE SOLUTIONS, 800-328-6657

Figure 1.14
1004690d
1002013a
Figure 1.12
The MPSI Pro-Link Plus with a multiple protocol cartridge (MPC) and Meritor WABCO applications card, version 2.0 or higher, provides diagnostic and testing capabilities for the E version ABS. Figure 1.15.
ABS modulator valve cables connect the modulator valve to the ECU. Figure 1.13.
10
1 Introduction
Figure 1.15
AVAILABLE FROM SPX SERVICE SOLUTIONS, 800-328-6657

Figure 1.15
1002014a
NOTE: The RSC/ESC functions of E version ABS cannot be tested with the Pro-Link Plus.
11
2 Stability and Safety Enhancement Systems: Automatic Traction Control (ATC), Roll Stability Control (RSC), Electronic Stability Control (ESC) and Hill Start Aid (HSA) ATC
2 Stability and Safety Enhancement Systems: Automatic Traction Control (ATC), Roll Stability Control (RSC), Electronic Stability Control (ESC) and Hill Start Aid (HSA)
Automatic traction control is available as an option on all E version ABS ECUs and is standard on most. ATC helps improve traction when vehicles are on slippery surfaces by reducing drive wheel overspin. ATC works automatically in two different ways. A. If a drive wheel starts to spin, ATC applies air pressure to brake the wheel. This transfers engine torque to the wheels with better traction. If all drive wheels spin, ATC reduces engine torque to provide improved traction.
B.
ATC turns itself on and off, drivers do not have to select this feature. If drive wheels spin during acceleration, the ATC indicator lamp comes on, indicating ATC is active. It goes out when the drive wheels stop spinning. Figure 2.1.
Figure 2.1
EXCESSIVE WHEEL SPIN ATC OPERATIONAL (ATC LAMP COMES ON)
NORMAL VEHICLE OPERATION (ATC LAMP IS OFF)
WHEELS STOP SPINNING (ATC LAMP GOES OUT)

1002015a
Figure 2.1
NOTE: Some vehicle manufacturers may refer to ATC as Anti-Spin Regulation (ASR). If ATC is installed, there will be an indicator lamp on the vehicle dash or instrument panel marked ATC, ASR, or potentially Stability Control, depending on the application. An ATC installation may use an individually mounted valve, or the valve may be part of the ABS valve package. Figure 2.2.
12
Figure 2.2
4S/4M ABS/ATC
VALVE PACKAGE INSTALLATION (REAR)
LAMPS
ATC VALVE AIR LINES VALVE PACKAGE INSTALLATION (FRONT) LAMPS (UP TO THREE: ABS, TRAILER ABS, ATC) 1002004g
Figure 2.2
ATC Components
ATC may be used with individual ABS modulator valves, or installed with the ABS valve package. When installed with individual ABS modulator valves, an ATC solenoid valve is mounted on the frame or cross member, near the rear of the vehicle. When it is part of the ABS valve package, an ATC valve is attached to the relay valve. A cable connects the ECU to the ATC valve. ATC components are illustrated in Figure 2.3.
Figure 2.3
CABLE ATC VALVE

4005303a
Figure 2.3
Deep Snow and Mud Switch

A deep snow and mud option switch is included with ATC. This function helps to increase available traction on extra soft surfaces like snow, mud or gravel, by slightly increasing the permissible wheel spin. Drivers use a deep snow and mud switch to select this feature. When this function is in use, the ATC indicator lamp blinks continuously. Figure 2.4.
13
Figure 2.4
RSC uses many of the same components used by ABS and ATC. Additional solenoid valves control the trailer service brakes and depending on the application, the front axle brakes during an RSC event. The solenoid for the trailer braking is a stand-alone valve that is not available as part of the ABS/ATC valve package. Depending on the application, a modulator valve may be located downstream of the solenoid valve. Figure 2.5.
1002018a
Figure 2.4
Switch and lamp locations will vary, depending on the vehicle make and model. Heres how the deep snow and mud feature works. Function Driver Action Press deep snow and mud switch Press switch again System Response ATC lamp blinks continuously ATC lamp stops blinking Active X X Not Active
NOTE: Turning off the ignition will also deactivate the deep snow and mud feature.
Roll Stability Control (RSC)

Roll stability control is an option designed to assist drivers in managing the conditions that may result in commercial vehicle rollovers. When RSC senses conditions that may result in a rollover, it reduces engine torque, engages the engine retarder, applies pressure to the drive axle brakes and may modulate the trailer brakes to slow the vehicle down (depending on the application and vehicle configuration, the steer axle brakes may be applied as well). Like ATC, RSC works automatically. The driver does not have to select this feature.
14
Figure 2.5
4S/4M RSC/ATC (ALSO AVAILABLE IN 6S CONFIGURATIONS)
TRAILER STABILITY CONTROL MODULATOR (OPTIONAL) TRAILER ACTIVE BRAKING VALVE LAMPS
TRACTOR PROTECTION VALVE VALVE PACKAGE INSTALLATION (REAR)
PRESSURE SENSOR (OPTIONAL)
VALVE PACKAGE INSTALLATION (FRONT)
FRONT AXLE ACTIVE BRAKING VALVE (OPTIONAL)
ATC VALVE
AIR LINES ELECTRICAL LINES 4007813a
Figure 2.5
ATC and RSC/ESC functions share the same dash indicator lamp, understanding how the ABS and ATC/RSC/ESC lamps work is very important. If the vehicle is equipped with ATC, but not RSC/ESC, when the ignition is turned to the ON position, the ABS and ATC lamps will light for approximately three seconds, then both lamps will turn off simultaneously. Figure 2.6. If the vehicle is equipped with ATC and RSC/ESC, when the ignition is turned to the ON position, the ABS and ATC/RSC/ESC will both light . . . but the ATC/RSC/ESC lamp will stay lit briefly after the ABS lamp goes out.
15
ABS
ATC
ABS
ATC
Both lamps come on at ignition ON and turn off after approximately three seconds. Vehicle equipped with ABS and ATC. CABLE
4007846a
SOLENOID VALVE (ACTIVE BRAKING VALVE)

ABS ATC
ABS
ATC
Both lamps come on at ignition ON. ATC/RSC/ESC lamp stays on briefly after ABS lamp goes out. Vehicle equipped with ABS, ATC and RSC/ESC.
Figure 2.7
Electronic Stability Control (ESC)

Electronic Stability Control (ESC) combines the rollover prevention of Roll Stability Control (RSC) with directional stability in order to keep the vehicle traveling on its intended path by providing spinout and driftout control. Like RSC, ESC is automatic. It becomes active when the system senses imminent directional or roll instabilities, often before the driver is aware. You will notice a difference in the vehicle when stability control is functioning, but you should continue to drive as normal and provide any additional needed corrections. You may again notice a reduction in engine torque and additional deceleration from the retarder, if so equipped. You also may notice individual or all brakes applying depending on whether the vehicle is in a roll or directional control event. ESC is built from the ABS platform and uses many of the same components as ATC and RSC. An additional solenoid valve to control the front axle brakes, a pressure sensor, an ESC module, and a Steering Angle Sensor (SAS) are required in addition to the components necessary for RSC. These components are described in the following section. Figure 2.8.
4005299d
Figure 2.6
NOTE: Active mode means RSC/ESC is installed and will become active if it is needed. TOOLBOX Software can also be used to determine if RSC/ESC is active. Refer to Section 9.
RSC Components
Additional solenoid valves are needed for RSC. These valves control the trailer service brakes and in some applications, the front axle brakes during an RSC event. The solenoid valve for the trailer control is a stand-alone valve. The valve is not part of an ABS valve package. Figure 2.7. In some applications, a modulator may be located downstream of the solenoid valve to control trailer braking.
16
Figure 2.8
4S/4M ESC/ATC (ALSO AVAILABLE IN 6S CONFIGURATIONS)
TRAILER STABILITY CONTROL MODULATOR (OPTIONAL) TRAILER ACTIVE BRAKING VALVE
TRACTOR PROTECTION VALVE VALVE PACKAGE INSTALLATION (REAR)
ESC MODULE
LAMPS
PRESSURE SENSOR
SAS ATC VALVE FRONT AXLE ACTIVE BRAKING VALVE AIR LINES ELECTRICAL LINES 4007814a
Figure 2.8
ESC Components
The following components are required for ESC in addition to the components required for RSC. Note that for ESC applications on a non-towing vehicle (straight truck), the RSC trailer solenoid valve is not required.
The ESC ABS ECU contains a parameter setting which is specific to a vehicle configuration validated by Meritor WABCO Engineering. It is imperative that the correct ECU is installed on your vehicle(s) in service. Meritor WABCO or your respective vehicle OEM should be contacted with any questions regarding this. See below for the cab-mounted version ECU. Figure 2.9.
Figure 2.9
ESC ABS ECU

The ESC ABS ECU is available in both Cab and Frame-mounted versions. The ABS Universal Cab-Mounted ECU with ESC is an upgraded version of the current Universal Cab ECU with a fourth connector containing the necessary inputs/outputs required for full stability control. The ABS Frame-Mounted ECU with ESC is an upgraded version of the current ABS Frame-Mounted ECU with six additional pins on both the X1 and X2 connectors of the ECU. These ECUs support 4S4M, 6S4M and 6S6M vehicle configurations and are compatible with 12V electrical systems. For pinout information, refer to section 6 of this manual.
4006871a
Figure 2.9
17
See below for the frame-mounted version. Figure 2.10.
4006872a 4007218a
Brake Pressure Sensor

The brake pressure sensor provides the system with the drivers brake demand. The sensor can be located in the primary or secondary delivery circuit depending on the application. Figure 2.13.
Figure 2.13
Steering Angle Sensor (SAS)

The SAS delivers the drivers steering input (steering wheel position) to the ABS ECU using a dedicated ESC system internal data link. The ABS ECU supplies the sensor with power and ground. The SAS must be calibrated using diagnostic tools (refer to Section 8). The Meritor WABCO SAS is pictured below. Figure 2.11.
Figure 2.11
4006870a
Figure 2.13
4006873a
Front Axle Brake Valve

Figure 2.11
ESC Module
The ESC module is part of the ESC system. It measures the vehicle yaw rate as well as vehicle lateral acceleration. The ESC module includes part of the ESC control algorithm. It exchanges data with the ESC ABS ECU via the ESC system internal data link. The ABS ECU supplies the module with power and ground. The ESC module must be activated by diagnostic tools (refer to Section 8). Figure 2.12.
For ESC (and in some RSC applications) an additional solenoid valve is used to control steer axle braking during a stability control event. This valve is a 3/2 solenoid valve such as what is used for ATC and RSC/ESC trailer braking. It may either be part of a front axle valve package or may be mounted as a stand-alone valve.
18
Trailer Modulator Valve
In some stability control applications an additional modulator valve (same as what is used for ABS modulation) will be located in the trailer control line downstream of the 3/2 solenoid valve used to control the trailer. This additional modulator valve provides a more tightly controlled pressure to the trailer and will often be used on vehicles equipped with OnGuard Collision Safety systems or on vehicles which pull multiple trailers. ATC and RSC/ESC functions share the same dash indicator lamp. Understanding how the ABS and ATC/RSC/ESC lamps work is very important. If the vehicle is equipped with ATC, but not RSC/ESC, when the ignition is turned to the ON position, the ABS and ATC lamps will light for approximately three seconds, then both lamps will turn off simultaneously. Figure 2.14. If the vehicle is equipped with ATC and RSC/ESC, when the ignition is turned to the ON position, the ABS and ATC/RSC/ESC will both light . . . but the ATC/RSC/ESC lamp will stay lit briefly after the ABS lamp goes out.
Figure 2.14
TOOLBOX Software can also be used to determine if RSC/ESC is active. Refer to Section 3.
Hill Start Aid

Description Hill Start Aid (HSA) supports automated manual transmission in reducing/eliminating rolling back of vehicle while launching on grade. Currently, it can only be used with Eaton Ultrashift Plus. Upon request from transmission, HSA holds pressure in the service brakes of all axles of the towing vehicle during vehicle standstill. HSA will hold pressure for a maximum of three seconds following full release of the brake pedal. Communication between transmission and ABS takes place via J1939 data link. Components A. B. ABS ECU (E4.3 generation and higher) w/Universal E4.4 software. ATC valve at front axle (similar to Figure 2.7): This valve helps maintain the HSA trapped pressure. Each failure detected on the 3/2 solenoid valve leads to HSA no availability or shut-off. To troubleshoot, please refer to Active Braking Valves (ABV) in Section 3 Diagnostics, Troubleshooting and Testing. ATC valve at rear axle (similar to Figure 2.7): This valve, similar to front axle ATC valve, helps to maintain the HSA trapped pressure. Each failure detected on the 3/2 solenoid valve leads to HSA no availability or shut-off. To troubleshoot, please refer to Active Braking Valves (ABV) in Section 3 Diagnostics, Troubleshooting and Testing. Pressure sensor (similar to Figure 2.13): A pressure sensor provides the system with the drivers brake demand. The measured pressure is used in case of HSA to set the trapped pressure and/or activate the HSA function. Each failure detected on the pressure sensor leads to HSA no availability or shut-off. To troubleshoot, please refer to Brake Pressure Sensor in Section 3 Diagnostics, Troubleshooting and Testing. The pressure sensor shall be installed according to the system specification. HSA switch (dashboard or hard wired). HSA lamp (hard wired only).
ABS
ATC
ABS
ATC
Both lamps come on at ignition ON and turn off after approximately three seconds. Vehicle equipped with ABS and ATC.
C.
D.
ABS
ATC
ABS
ATC
Both lamps come on at ignition ON. ATC/RSC/ESC lamp stays on briefly after ABS lamp goes out. Vehicle equipped with ABS, ATC and RSC/ESC.
E. F.
4005299d
Figure 2.14
NOTE: Active mode means RSC/ESC is installed and will become active if it is needed.
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3 Diagnostics, Troubleshooting and Testing
General
Attach the cable from your computer to the J1708 to RS232 converter box. Attach the diagnostic cable (Deutsch) to the vehicle. Figure 3.1.
Figure 3.1
Maintenance Information
There is no regularly scheduled maintenance required for the Meritor WABCO ABS or ABS/ATC. However, ABS does not change current vehicle maintenance requirements. Lamp Check: To ensure the ABS tractor lamp is operating, drivers should check the lamp every time the vehicle is started. When the vehicle is started, the ABS lamp should come on momentarily. If it does not come on, it could mean a burned-out bulb. ABS Wheel Speed Sensors: Check the wheel speed sensor adjustment and lubricate the sensor and sensor clip whenever wheel-end maintenance is performed. Use only Meritor WABCO-recommended lubricant, as specified in Section 4.
SERIAL CABLE
TO VEHICLE J1587 CONNECTOR
Diagnostics
Use any of the following methods to diagnose E version ABS: TOOLBOX Software, a PC-based ABS diagnostic and testing program that runs in Windows 2000, NT, XP or Vista. Internet Explorer version 3.02 or higher must be installed. Refer to the information in this section. Blink Codes. Refer to the information in this section.
Figure 3.2
J1708-TO-RS232 CONNECTOR 4003998a
Figure 3.1
2.
Select TOOLBOX Software from the Desktop or from the Windows Start Menu to display the TOOLBOX Main Menu. From the Main Menu, select Tractor ABS. The ABS Main Screen will appear. Figure 3.2.
MPSI Pro-Link Plus with MPC and Meritor WABCO applications card, version 2.0 or higher. Refer to the information in this section. OEM Diagnostic Displays. Refer to the vehicle operators manual. Information about TOOLBOX Software, MPSI Pro-Link Plus and blink codes follows. If you have any questions about system diagnostics, please contact ArvinMeritors Customer Service Center at 866-OnTrac1 (668-7221).
TOOLBOX Software Diagnostics

NOTE: For complete instructions for using TOOLBOX Software, refer to the Users Manual. The manual is posted on meritorwabco.com/TOOLBOX.
4004036a
If you have TOOLBOX Software installed on your computer, use it to identify system faults. Then, follow the on-screen repair information to make the necessary repairs or replacements. To display E version ABS faults: 1. Connect the computer to the vehicle:
Figure 3.2
3. 4.
Select Display for a pull-down menu. From the pull-down menu, select Faults to bring up the Fault Information screen. Figure 3.3.
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Figure 3.3
ABS Indicator Lamp: This lamp serves two purposes: it alerts drivers to an ABS tractor fault and it is used during diagnostics to display the blink code. Blink Code: A series of blinks or flashes that describe a particular ABS system fault or condition. Blink Code Cycle: Two sets of flashes with each set separated by a one-and-one-half second pause. Blink codes are defined in the blink code identification information in this section. Blink Code Switch: A momentary switch that activates blink code diagnostic capabilities. Switch types and locations vary, depending on the make and model of the vehicle.
4005322a
Clear: The process of erasing faults from the ECU.

Figure 3.3
5.
A description of the fault, the number of times the fault occurred, the system identifier (SID) and the failure mode (FMI) are all displayed in the fault information window. Basic repair instructions for each fault are also provided. Figure 3.3. More detailed information about SID and FMI troubleshooting and repair is provided in the following sections. For detailed repair instructions, click on the fault to display a troubleshooting information sheet. Bookmark and Thumbnail tabs at the side of the troubleshooting information sheet provide additional information. A sample troubleshooting information sheet appears in the Appendix. This screen also provides a link to the appropriate system schematic. Faults that may occur after the screen is displayed will not appear until a screen update is requested. Use the update button to refresh the fault information table. After making the necessary repairs, use the clear faults button to clear the fault. Use the update button to refresh the fault information table and display the new list of faults. Use the Save or Print button to save or print the fault information data.
Diagnostics: The process of using blink codes to determine ABS system faults. Fault: An ABS malfunction detected and stored in memory by the Meritor WABCO ECU. System faults may be Active or Stored. Active Fault: A condition that currently exists in the ABS system; for example, a sensor circuit malfunction on the left front steering axle. An active fault must be repaired before it can be cleared from memory and before you can display additional blink code faults. Stored Fault: There are two types of stored faults: A. B. A repaired active fault that has not been cleared from the ECU. A fault that occurred but no longer exists. For example, a loose wire that makes intermittent contact. Because stored faults are not currently active, they do not have to be repaired before they can be cleared from memory.
Meritor WABCO recommends you keep a record of these faults for future reference. System Configuration Code: One digit code displayed during the clear mode. Blink codes for common ABS system configurations are shown in Figure 3.4.
Blink Code Diagnostics (Tractor ABS Only)

Definitions
Before using blink code diagnostics, you should be familiar with a few basic terms. If you used previous versions of Meritor WABCOs blink code diagnostics, review these definitions to identify major changes.
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Figure 3.4
NUMBER OF FLASHES
ABS CONFIGURATION 6S/6M - 6x2 6S/6M - 6x4 4S/4M 6S/4M

1002020c
Figure 3.4
Diagnostic Mode
To enter the diagnostic mode, press and hold the blink code switch for one second, then release.
Clear Mode
To erase faults from the ECU, you must be in the clear mode. To enter the clear mode, press and hold the blink code switch for at least three seconds, then release. If the system displays eight quick flashes followed by a system configuration code, the clear was successful. Stored ABS faults have been cleared from memory. If you do not receive eight flashes, there are still active faults that must be repaired before they can be cleared. NOTE: The clear mode is also used to disable the ATC function.
22
Table C: Troubleshooting with Blink Code Diagnostics Procedure System Response Diagnostics Mode Step I. Turn ignition ON. Possible responses: ABS indicator lamp comes on momentarily then goes out, indicating System OK. ABS indicator lamp does not light, indicating possible wiring fault or burned-out bulb. ABS indicator lamp stays on, indicating: Fault, or faults, in the system. Sensor fault during last operation. Faults cleared from ECU, but vehicle not driven. ECU disconnected. Step II. Press and hold Blink Code Switch for one second, then release. ABS indicator lamp begins flashing two digit blink code(s). Continue with blink code diagnostics. (Go to Step II.) Continue with blink code diagnostics. (Go to Step II.) Drive vehicle lamp will go out when vehicle reaches 4 mph (6 km/h). Connect ECU. Determine if fault is active or stored: Active Fault: Lamp will repeatedly display one code. Stored Fault: Lamp will display code for each stored fault then stop blinking. Faults will be displayed one time only. First Digit: 1-8 flashes, Pause (1-1/2 seconds) Second Digit: 1-6 flashes, Pause (4 seconds) Active Fault Make the necessary repairs. Repeat Step 1, Step II and Step III until System OK, code (1-1) received. Record for future reference. NOTE: Last fault stored is first fault displayed. Clear Mode Step V. Turn ignition ON. Clear Faults from memory: Press and hold blink code switch for at least three seconds, then release. Eight flashes not received. ABS indicator lamp flashes eight times. All stored faults successfully cleared. Turn ignition OFF. Active faults still exist, repeat Step I through Step V. Find definition for blink code on blink code chart. No recognizable active faults in the ABS. No action required. Inspect wiring. Inspect bulb. Make necessary repairs. Action
Step III. Count the flashes to determine the blink code. Step IV. Turn ignition OFF. Repair and record faults.
Stored Fault
23
Blink Code Illustrations

Figure 3.5
1 Second Hold
Pause
Active Fault
1-8 Flashes
Pause
1-6 Flashes
Pause Pause
1.5 s
1.5 s 1st Digit (2) 2nd Digit (3)
4s (2)
1.5 s Repeat of Blink Code (3)
Continues until ignition is turned off
Light ON
Example: Blink Code 2-3: Fault in ABS modulator valve, right rear drive axle.
1 Second Hold
Off
Light ON
Pause
Stored Faults Displays all stored faults oncelast fault stored is displayed first
Pause
Pause
Pause
1.5 s 1st Digit
1.5 s 2nd Digit 1st Stored Fault (5) (2)
4s 1st Digit (3)
1.5 s 2nd Digit 2nd Stored Fault (4)
Example: Blink Code 5-2: Sensor signal erratic, left front steer axle. 3-4: Too much sensor gap, left rear drive axle. 1 Second Hold
Pause
System OK
Pause
Blink Code 1-1: System OK

(1)
1.5 s
1.5 s (1)
Light ON
S = Seconds
1002021b
Figure 3.5
24
Figure 3.6
3 Second Hold
Pause
Note: After faults are cleared and vehicle is started, ABS lamp will stay on until vehicle is driven over 4 mph (6 km/h). Faults Cleared
Pause Pause Pause Pause
1.5 s
4s
4s
4s
4s
Continues until ignition is turned off
Light ON
8 Quick Blinks = Faults Cleared
SYSTEM ID (2)
SYSTEM ID (2)
SYSTEM ID (2)
SYSTEM ID (2)
System Configuration Code 2: 4S/4M System 3 Second Hold

Pause
Faults Not Cleared (Active Faults Still Exist)

Pause Pause Pause
4s
4s
4s
4s
Continues until ignition is turned off SYSTEM ID (2)
Light ON
SYSTEM ID (2)
SYSTEM ID (2)
SYSTEM ID (2)
S = Seconds
Figure 3.6
1002022a
25
Blink Code Conditions

When using blink code diagnostics, the following conditions could occur: Table D: Blink Code Conditions Condition Reason Action Check bulb. Check connections. Make necessary repairs. Voltage not within acceptable range (9.5-14.0 volts) (18-32 for 24V system). Cant use blink code diagnostics. ABS indicator lamp will not go off when blink code is activated. Switch not held for correct length of time: 1 Second Diagnostics Mode 3 Seconds Clear All Mode Incorrect or faulty wiring. Inspect and repair wiring. Check connections. Measure voltage. Make necessary repairs. Repeat procedure, hold switch for correct length of time.
ABS indicator lamp does not Loose or burned-out bulb. come on at ignition.
Fault not erased from ECU after report. Repeat procedure until System O.K. code received. Eight flashes not received after blink code switch pressed for at least three seconds, then released. Active faults still exist. Identify active faults, then make necessary repairs. Turn ignition OFF, then repeat Blink Code Diagnostics.
26
Blink Code Identification

Use the following information to identify the blink code: First Digit (Type of Fault) 1 No faults 2 ABS modulator valve 3 Too much sensor gap 4 Sensor short or open 5 Sensor signal erratic/tire size 6 Tooth wheel 7 System function Second Digit Specific Location of Fault 1 No faults 1 Right front steer axle (curb side) 2 Left front steer axle (drivers side) 3 Right rear drive axle (curb side) 4 Left rear drive axle (drivers side) 5 Right rear/additional axle (curb side) 6 Left rear/additional axle (drivers side) 1CAN, J1939 or ESC proprietary 2 ATC valve 3 Retarder relay (third brake) 4 ABS indicator lamp 5 ATC configuration 6 RSC ESC trailer valve or front axle valve 7 Brake pressure sensor 8 Tire pressure monitoring 8 ECU 1 Low power supply 2 High power supply 3 Internal fault 4 System configuration error 5 Ground 6 RSC accelerometer/SAE/ESC module
27
Blink Code Troubleshooting and Repair

Blink Code 2-1, 2-4 2-2, 2-5 2-3, 2-6 3-1, 3-4 3-2, 3-5 3-3, 3-6 Action Required Check ABS modulator valve, valve cable and connectors. Verify 4.0-9.0 ohms resistance for 12V ABS modulator valve, 11.0-21.0 ohms resistance for 24V ABS modulator. Adjust wheel sensor to touch tooth wheel. Check sensor gap. Check for loose wheel bearings or excessive hub runout. Verify minimum 0.2 volts AC output @ 30 rpm. 3-7 4-1, 4-4 4-2, 4-5 4-3, 4-6 5-1, 5-4 5-2, 5-5 5-3, 5-6 6-1, 6-4 6-2, 6-5 6-3, 6-6 7-1* Check for correct J1939 and ESC (if so equipped) data link connection. Check if fault was caused on dynamometer, see Reference column. Check parameter setting regarding HSA switch and broadcast HSA switch information in EBC 5. 7-2* Check ATC valve (also referred to as ABV), valve cables and connectors. Verify 7.0-14.0 ohms resistance (for 12V system), 26.3-49 ohms resistance for 24V system. 7-3* 7-6* Check retarder relay (third brake) connections. Check RSC and Front Axle Active Brake Valves (ABV) and Stability Control Modulator (if so equipped). For ABV, verify 7.0-14.0 ohms resistance for 12V system, 26.3-49 ohms resistance for 24V system. For Stability Control Modulator, verify 4.0-9.0 ohms resistance for 12V system, 11.0-21.0 ohms resistance for 24V system. Refer to SID-FMI Troubleshooting and Repair: Retarder Relay in this section. Refer to SID-FMI Troubleshooting and Repair: Active Braking Valves and SID-FMI Troubleshooting and Repair: Modulator Valves in this section. Refer to SID-FMI Troubleshooting and Repair: J1939 Serial Communications, ESC Module and Steering Angle Sensor in this section. Refer to SID-FMI Troubleshooting and Repair: HSA System in this section. Refer to SID-FMI Troubleshooting and Repair: Active Braking Valves in this section. Check for damaged tooth wheel. Check for tire size mismatch or tooth wheel difference. Check sensor, sensor cable and connector for intermittent contact. Refer to SID-FMI Troubleshooting and Repair: Wheel Speed Sensors and Tire Size Range in this section. Refer to SID-FMI Troubleshooting and Repair: Wheel Speed Sensors in this section. Check sensor wiring, connectors and sensor. Check sensor, sensor cable and connectors. Verify 900-2000 ohms resistance. Refer to SID-FMI Troubleshooting and Repair: ABS System in this section. Refer to SID-FMI Troubleshooting and Repair: Wheel Speed Sensors in this section. Reference Refer to SID-FMI Troubleshooting and Repair: Modulator Valves in this section.
Refer to SID-FMI Troubleshooting and Repair: Wheel Speed Sensors in this section.
28
Blink Code 7-7*
Action Required Check Brake Pressure Sensor. Verify sensor is getting 8.0-16.0 volts power and that there is continuity between pressure sensor signal and ground or power. Check Brake Light Switch.
Reference Refer to SID-FMI Troubleshooting and Repair: Brake Pressure Sensor in this section.
Refer to SID-FMI Troubleshooting and Repair: Brake Pressure Sensor, Foot Valve Supply Circuit in this section. Refer to SID-FMI Troubleshooting and Repair: Power Supply in this section.
8-1
Check for low voltage. Check vehicle voltage, fuse and supply to ECU (9.0-16.0V for 12V system, 18.0-32.0V for 24V system).
8-2
Check for high voltage. Check vehicle voltage, fuse and supply to ECU (9.0-16.0V for 12V system, 18.0-32.0V for 24V system).
Refer to SID-FMI Troubleshooting and Repair: Power Supply in this section.
8-3
Internal ECU fault. Verify accuracy of blink code.
Contact Meritor WABCO OnTrac.
8-4
Verify all ECU connectors are in place.
Refer to SID-FMI Troubleshooting and Repair: Verify that correct number of sensors and modulators are connected to Internal ABS ECU in this section. the ECU. Contact Meritor WABCO OnTrac to ensure ECU is correct for the application.
8-5
Check all ABS, ECU and ABV grounds.
Refer to SID-FMI Troubleshooting and Repair: Active Braking Valves and SID-FMI Troubleshooting and Repair: Power Supply in this section.
8-6
This blink code is ESC related. Meritor WABCO TOOLBOX must be Refer to SID-FMI Troubleshooting and Repair: Steering Angle Sensor and SID-FMI used for system troubleshooting and calibration. Check Steering Angle Sensor and ESC Module calibration, wiring and Troubleshooting and Repair: ESC Module in this section. condition. Contact Meritor WABCO OnTrac to ensure ECU is correct for the application.
*If this code continues after all repairs have been made or if you receive a code for a component that is not installed on the vehicle it may be necessary to reconfigure the ECU. Refer to the Section 7. TOOLBOX Software may also be used to reconfigure the ECU (refer to Section 7). Contact ArvinMeritors Customer Service Center at 866-OnTrac1 (668-7221) for additional information or assistance.
Pro-Link Plus Diagnostics

NOTE: You must use the Multiple Protocol Cartridge (MPC) and Meritor WABCO applications card, version 2.0 or higher, with E version ECUs. The PLC functions of E version ABS cannot be tested with the Pro-Link Plus. The Pro-Link Plus may be used in place of blink code diagnostic procedures.
29

The Pro-Link Plus screens illustrated appear with E version ECUs. Refer to Maintenance Manual 28, Anti-Lock Braking Systems (ABS) for Trucks, Tractors and Buses, if you are using the Pro-Link Plus with C version ECUs or Maintenance Manual 30, Anti-Lock Braking Systems (ABS) for Trucks, Tractors and Buses, if you are using the Pro-Link Plus with D version ABS.
Fault Information Screens

Existing Faults: Use these screens to identify existing faults. The Pro-Link Plus screen displays a written description of the fault, including the location on the vehicle where each exists. As long as there is an active (existing) fault in the system, the Pro-Link Plus will not let you clear faults. Stored Faults: Use these screens to identify faults stored in the ECU memory. Stored faults may be existing faults that have been repaired, or faults that existed for a short time, then corrected themselves. After displaying the stored faults, the Pro-Link Plus lets you erase them from memory. All stored faults are cleared at one time.
Diagnostic Procedure
1. Slide the MPC into the Pro-Link Plus keypad until the connection is tight. Then, insert the Meritor WABCO applications card into the cartridge. Block the wheels, apply the parking brake, and verify that the ignition power is off. Locate the 6-pin diagnostic receptacle in the vehicle cab. Insert the 6-pin connector from the Pro-Link Plus into the receptacle. Turn the ignition to the ON/RUN position. The Pro-Link Plus screen should power up. If the Pro-Link Plus does not power up, or if the screen indicates NO DATA RECEIVED: Check connections. Verify that the cartridge is correctly connected to the Pro-Link Plus keypad. Verify 9.5-14.0 volts (18-32 for 24V systems) DC power and ground at the connector and ABS ECU. Check the fuse panel for a blown fuse. Check for correct wiring in the diagnostic connector. 5. Refer to the Pro-Link Plus manual for complete diagnostic instructions. The Pro-Link Plus is available from SPX, 800-328-6657.
2. 3.
Pro-Link Plus Display

Depending upon the ECU being tested, the Pro-Link Plus screen will display certain options or components only when recognized by the ECU. These include: ATC, ATC Indicator Lamps, Trailer ABS Indicator Lamp, ATC Valve Engine Datalink Retarder Relay Retarder Datalink
4.
Component Test Screens (Pro-Link Plus)

These screens help you test ABS components. Select this function from the Tractor ABS/ATC menu. ABS VALVES ATC ABS INDICATOR LAMP ABS TRAILER INDICATOR LAMP ATC INDICATOR LAMP ABS/ATC SWITCHES SENSORS ENGINE DATALINK RETARDER RELAY RETARDER DATALINK VEHICLE VOLTAGES Select the appropriate function. Each screen has instructions to guide you through the test. Refer to the Pro-Link Plus Manual for complete instructions.
Pro-Link Plus Screens

This information provides basic screen explanations for the Pro-Link Plus with an MPC and Meritor WABCO application card. For complete operating instructions and test information, refer to the Pro-Link Plus manual.
30

J1939 Datalink Verification Pro-Link Plus
The Pro-Link Plus diagnostic tool may be used to verify J1939 datalink connection. If you do not have a Pro-Link Plus, you can use the blink code switch to verify this connection. 1. Turn ignition ON. Press blink code switch hold for three seconds.
1.
IGNITION ON
OFF ON
3 Second Hold
A.
ATC indicator lamp will come on and stay on for the entire test. If the vehicle is not equipped with ATC, the ATC indicator lamp will not come on.
A.
ATC
B.
ABS indicator lamp will come on and blink eight times. If the lamp does not blink eight times, there are faults that must be cleared before you continue with this test.
B.
8 Quick Blinks = Faults Cleared
C.
The eight quick flashes will be followed by the system configuration code. A 4S/4M (two blinks) system is identified here. The system configuration code will continue during the entire test.
C.
System ID
(2)
Pause
Pause
4s
4s
Continues During Test

System ID
(2)
System ID
(2)
2.
Activate the J1939 engine torque reduction code, as follows: A. Step on the accelerator. Bring the engine to 1000 rpm. Leave your foot on the accelerator during the entire test.
2. A.
1000
IDLE
RPM
B.
While the engine is at 1000 rpm, press the blink code switch twice, as follows: Press for one second Release for one second Press for one second Release for one second
B.
1 Second Hold
Pause
1 Second Hold
Pause
C.
The engine will go to idle for approximately 10 seconds and then return to 1000 rpm.
C.
1000
1000
IDLE
IDLE
RPM
RPM
3.
Turn ignition OFF. Test complete, engine torque reduction command verified.
3.
OFF
ON
4004004a
31
SID-FMI Troubleshooting and Repair

Wheel Speed Sensors
SID 1 2 3 4 5 6 Suspect Component and Location ABS Wheel Speed Sensor, Left Front Steer Axle (Drivers Side) ABS Wheel Speed Sensor, Right Front Steer Axle (Curb Side) ABS Wheel Speed Sensor, Left Rear Second Axle (Drivers Side) ABS Wheel Speed Sensor, Right Rear Second Axle (Curb Side) ABS Wheel Speed Sensor, Left Rear Third Axle (Drivers Side) ABS Wheel Speed Sensor, Right Rear Third Axle (Curb Side)
FMI 1
Fault Description Air Gap
Fault Indication
System Reaction
Cause Sensor air gap is too large, sensor output voltage is too low but is high enough to be read by ECU.
Repair Information Adjust wheel sensor to touch tooth wheel. Check condition of ABS sensor head. Check for loose wheel bearings or excessive hub runout. Check mounting of ABS tooth wheel and condition of teeth. Check condition and retention of ABS sensor clamping sleeve. Check ABS sensor cable routing and clipping. Turn the wheel and read out amplitudes of sensor signals and compare with required values.
ABS Warning ABS Wheel Lamp Disabled ESC/RSC/ATC Disabled
Incorrect Tire ABS Warning ABS Wheel Lamp Disabled ESC/RSC/ATC Disabled
System has detected a significant difference in the proportion of tire diameter to number of tooth wheel teeth between wheel ends.
Check for tire size mismatch. Check for correct number of ABS tooth wheel teeth. Verify that ECU parameter set is correct for vehicle. Contact Meritor WABCO or OEM.
32
FMI 3
Fault Description Shorted to UBATT
Fault Indication
System Reaction
Cause
Repair Information
Continuity between the Check sensor, sensor cable and connectors. sensor leads and Verify 900-2000 ohms resistance. battery voltage (short Check for continuity between the ABS sensor leads and circuit) is detected. voltage. Check for corroded or damaged wiring between the ECU and the ABS wheel speed sensor.
Shorted to Ground
Continuity between the Check sensor, sensor cable and connectors. sensor leads and Verify 900-2000 ohms resistance. ground (short circuit) is Check for continuity between the ABS sensor leads and detected. ground. Check for corroded or damaged wiring between the ECU and the ABS wheel speed sensor.
Open Circuit
An open circuit has Check sensor, sensor cable and connectors. been detected, i.e. ECU Verify 900-2000 ohms resistance. detects a disconnected wheel speed sensor. Continuity between the Check sensor, sensor cable and connectors. sensor leads (short Verify 900-2000 ohms resistance. circuit) has been detected. Wheel speed signal Check for damaged tooth wheel or missing teeth. drops out periodically at speeds higher than 10 kph An excessively long wheel slip has been detected. Adjust wheel sensor to touch tooth wheel. Check sensor gap. Check for loose wheel bearings or excessive hub runout.
Short Circuit
Incorrect Pole ABS Warning ABS Wheel Wheel Lamp Disabled ESC/RSC/ATC Disabled
Slip
Wires Mismatched
A sensor lead from an Check for mismatch fault of another sensor. Correct the incorrect wheel end harness. has been detected.
33
FMI 10
Fault Description Speed Drop-Out
Fault Indication
System Reaction
Cause
Repair Information
A temporary loss of the Adjust wheel speed sensor to touch tooth wheel. ABS wheel speed Check for loose wheel bearings or excessive hub signal has been runout. detected. Check sensor wiring and connectors for intermittent contact. Check condition of ABS sensor head. Check mounting of tooth wheel and condition of teeth. Check condition and retention of ABS sensor clamping sleeve. Check ABS sensor cable routing and clipping. Check for corroded or damaged wiring between the ECU and the ABS wheel speed sensor. Turn the wheel and read out amplitudes of sensor signals and compare with required values.
11
Abnormal Speed (Chatter)
Brake drags or chatters. Abnormal vibrations detected which affect sensor signal.
Check sensor wiring and connectors for intermittent contact. Check toothed wheel for damage. Turn the wheel and read out amplitudes of sensor signals and compare with required values.
12
Frequency Too High
A non-plausible sensor Check sensor wiring and connectors for intermittent frequency has been contact. measured. Check if brake at this location is operating correctly, i.e., potentially dragging. Contact Meritor WABCO OnTrac at 866-OnTrac1 (668-7221) if the fault repeats.
34
ABS Wheel Speed Sensor Testing

Sensor Adjustment Push the sensor in until it contacts the tooth wheel. Do not pry or push sensors with sharp objects. Sensors will self-adjust during wheel rotation. Electrical Checks Take all measurements at the ECU harness connector first to check sensor and harness together. Figure 3.7 and Figure 3.8. Measurements should read as below. Location Between same sensor pins Sensor leads to voltage or ground Sensor output voltage Measurement 900-2000 ohm No continuity At least 0.2 volt AC at 30 rpm
Figure 3.7
CAB MOUNT ECUS: LOOKING INTO WIRE HARNESS CONNECTOR

X4 16 13 10 17 14 11 18 15 12 7 8 9 4 5 6 1 2 3 13 10 14 11 15 12 X3 7 8 9 4 5 6 1 2 3 X2 16 13 10 17 14 11 18 15 12 7 8 9 4 5 6 1 2 3 13 10 14 11 15 12 X1 7 8 9 4 5 6 1 2 3
4007203a
Figure 3.7
35
Figure 3.8
FRAME MOUNT ECU WITHOUT ESC: LOOKING INTO WIRE HARNESS CONNECTOR
6 7 5 8 X1-GRAY 4 3 2 9 10 11 1 12 6 7 5 8 X2-BLACK 4 3 2 9 10 11 1 12 6 12 5 11
FRAME MOUNT ECU WITH ESC: LOOKING INTO WIRE HARNESS CONNECTOR
X1-BLACK 4 3 2 10 16 9 8 1 7 6 12 5 11 X2-GREEN 4 3 2 10 16 9 8 1 7
18 17 X4-BROWN (ONLY FOR 6 CHANNEL) 6 5 4 3 2 1 7 8 9 10 11 12 X3-GREEN 6 7 5 8 4 9 3 2 1 12
15 14 13
18 17
15 14 13
10 11
X4-BROWN (ONLY FOR 6 CHANNEL) 6 5 4 3 2 1 7 8 9 10 11 12
X3-GREEN 6 7 5 8 4 9 3 2 1 12
10 11
4007204a
Figure 3.8
ECU Cab-Mounted LF
Sensor
Connector X2-18 pin X2-18 pin X2-18 pin X2-18 pin X3-15 pin X3-15 pin X2-Black X2-Black X3-Green X3-Green X4-Brown X4-Brown X2-Green X2-Green X3-Green X3-Green X4-Brown X4-Brown
Pins 12 and 15 10 and 13 11 and 14 17 and 18 2 and 5 11 and 14 7 and 8 5 and 6
Sensor Testing Available in Meritor WABCO TOOLBOX (PC Diagnostics) In order to compare and test sensor outputs, Meritor WABCO TOOLBOX (PC diagnostics) can be used. Select the wheel speed icon or use the Display drop down menu from the ABS Main screen to display wheel speed data in both numeric and graphical form. This data may be shown in RPM or MPH and in vertical and horizontal graphs. Figure 3.9, Figure 3.10 and Figure 3.11. Select the appearance and style from the Options menu.
Figure 3.9
Universal with ESC, RF Universal or Basic LR RR LR (3rd axle) RR (3rd axle) Frame-Mounted Non-ESC LF RF LR RR LR (3rd axle) RR (3rd axle) Frame-Mounted With ESC LF RF LR RR LR (3rd axle) RR (3rd axle)
1 and 2 3 and 4 3 and 4 5 and 6 17 and 18 5 and 6 1 and 2 3 and 4 3 and 4 5 and 6
4004006a
Figure 3.9
36
Figure 3.10
4004007a
Figure 3.10
Figure 3.11
4004008a
Figure 3.11
37
Modulator Valves
SID 7 8 9 10 11 12 19 Suspect Component and Location ABS Modulator, Left Front Steer Axle (Drivers Side) ABS Modulator, Right Front Steer Axle (Curb Side) ABS Modulator, Left Rear Second Axle (Drivers Side) ABS Modulator, Right Rear Second Axle (Curb Side) ABS Modulator, Left Rear Third Axle (Drivers Side) ABS Modulator, Right Rear Third Axle (Curb Side) Stability Control Modulator, Trailer Circuit (Optional)
FMI 3
Fault Indication
System Reaction
Cause Continuity between Inlet (IV) or Outlet (OV) and battery supply or another modulator wire (short circuit) is detected.
Repair Information Verify 4.0-9.0 ohm between IV to common and OV to common for 12V system (11.0-21.0 ohm for 24V system). Check for continuity between Inlet or Outlet and voltage supply or other modulator wires. Check connectors and modulator for corrosion. Verify 4.0-9.0 ohm between IV to common and OV to common for 12V system (11.0-21.0 ohm for 24V system). Check if connectors are fully seated. Check for broken wires or connectors.
ABS Warning ABS Disabled Lamp ESC/RSC/ATC Disabled
Open Circuit
ABS Warning ABS Wheel Lamp Disabled
ECU has detected that Inlet (IV), Outlet (OV) or ESC/RSC Disabled both are not connected.
Shorted to Ground
Continuity between Inlet (IV) or Outlet (OV) ESC/RSC Disabled and ground (short circuit) is detected.
Verify 4.0-9.0 ohm between IV to common and OV to common for 12V system (11.0-21.0 ohm for 24V system). Check for continuity between Inlet or Outlet and ground. Check connectors and modulators for corrosion.
Shorted to ABS Warning ATC Brake Control Continuity between UBATT for SID Lamp Disabled Inlet (IV) or Outlet (OV) 19 Only ESC/RSC Disabled and battery supply or another modulator wire (short circuit) is detected. Open Circuit for SID 19 Only ABS Warning ESC/RSC Disabled ECU has detected that Lamp Inlet (IV), Outlet (OV) or both are not connected.
Verify 4.0-9.0 ohm between IV to common and OV to common for 12V system (11.0-21.0 ohm for 24V system). Check for continuity between Inlet or Outlet and voltage supply or other modulator wires. Check connectors and modulators for corrosion. Verify 4.0-9.0 ohm between IV to common and OV to common for 12V system (11.0-21.0 ohm for 24V system). Check if connectors are fully seated. Check for broken wires or connectors.
38
FMI 9
Fault Description Short to Ground for SID 19 Only
Fault Indication
System Reaction
Cause
Repair Information Verify 4.0-9.0 ohm between IV to common and OV to common for 12V system (11.0-21.0 ohm for 24V system). Check for continuity between Inlet or Outlet and ground. Check connectors and modulators for corrosion.
ABS Warning ESC/RSC Disabled Continuity between Lamp Inlet (IV) or Outlet (OV) and ground (short circuit) is detected.
Modulator Valve Testing

Electrical Checks Take measurements at the ECU harness to check the modulator and harness together. Figure 3.14 and Figure 3.15. Take measurements at the modulator pins directly to verify the component. Figure 3.12 and Figure 3.13. Measurements should read as below. If resistance exceeds 9.0 ohm for 12V system (21.0 ohm for 24V system), clean the electrical contacts at the modulator and retest. Location IV to Common Measurement 4.0-9.0 ohm for 12V system 11.0-21.0 ohm for 24V system OV to Common 4.0-9.0 ohm for 12V system 11.0-21.0 ohm for 24V system IV or OV to Voltage Supply or Ground No continuity
Figure 3.13
OPEN-STYLE CONNECTOR
GROUND TERMINAL EXHAUST SOLENOID (BLUE WIRE)
INLET SOLENOID (BROWN WIRE)

Figure 3.13
4004021a
Figure 3.12
EXHAUST SOLENOID (BLUE WIRE)
INLET SOLENOID (BROWN WIRE)
GROUND TERMINAL
Figure 3.12
4004022a
39
Figure 3.14

X4 16 13 10 17 14 11 18 15 12 7 8 9 4 5 6 1 2 3 13 10 14 11 15 12 X3 7 8 9 4 5 6 1 2 3 X2 16 13 10 17 14 11 18 15 12 7 8 9 4 5 6 1 2 3 13 10 14 11 15 12 X1 7 8 9 4 5 6 1 2 3
4007205a
Figure 3.14
ECU Cab-Mounted
Modulator Circuit Connector LF IV X2-18 pin X2-18 pin X2-18 pin X2-18 pin X2-18 pin X2-18 pin X2-18 pin X2-18 pin X3-15 pin X3-15 pin X3-15 pin X3-15 pin X3-15 pin X3-15 pin X3-15 pin 3 6 1 4 2 5 8 9 3 6 12 15 7 10 8
Pins
Universal with ESC, LF OV Universal or Basic RF IV (ABS modulators RF OV are grounded LR IV externally, i.e., common is fed to LR OV external ground) RR IV RR OV LR (3rd Axle) IV LR (3rd Axle) OV RR (3rd Axle) IV RR (3rd Axle) OV Optional with Stability Control Trailer IV Trailer OV Trailer Common
40
Figure 3.15
6 7 5 8 X1-GRAY 4 3 2 9 10 11 1 12 6 7 5 8 X2-BLACK 4 3 2 9 10 11 1 12 6 12 5 11
X1-BLACK 4 3 2 10 16 9 8 1 7 6 12 5 11 X2-GREEN 4 3 2 10 16 9 8 1 7
15 14 13
18 17
15 14 13
10 11
X3-GREEN 6 7 5 8 4 9 3 2 1 12
10 11
4007206a
Figure 3.15
ECU Frame-Mounted Non-ESC
Modulator Circuit Connector LF IV LF OV LF Common RF IV RF OV RF Common LR IV LR OV LR Common RR IV RR OV RR Common LR (3rd Axle) IV LR (3rd Axle) OV LR (3rd Axle) Common RR (3rd Axle) IV RR (3rd Axle) OV RR (3rd Axle) Common X2-Black X2-Black X2-Black X2-Black X2-Black X2-Black X3-Green X3-Green X3-Green X3-Green X3-Green X3-Green X4-Brown X4-Brown X4-Brown X4-Brown X4-Brown X4-Brown 2 10 11 4 3 9 12 10 11 9 7 8 12 10 11 9 7 8
Pins
ECU Frame-Mounted With ESC
Modulator Circuit Connector LF IV LF OV LF Common RF IV RF OV RF Common LR IV LR OV LR Common RR IV RR OV RR Common LR (3rd Axle) IV LR (3rd Axle) OV LR (3rd Axle) Common RR (3rd Axle) IV RR (3rd Axle) OV RR (3rd Axle) Common X2-Green X2-Green X2-Green X2-Green X2-Green X2-Green X3-Green X3-Green X3-Green X3-Green X3-Green X3-Green X4-Brown X4-Brown X4-Brown X4-Brown X4-Brown X4-Brown 2 15 14 4 3 16 12 10 11 9 7 8 12 10 11 9 7 8
Pins
41
ECU Optional with Stability Control
Modulator Circuit Connector Trailer IV Trailer OV Trailer Common X2-Green X2-Green X2-Green 1 10 13
Pins
Figure 3.17
Modulator Valve Testing Available in Meritor WABCO TOOLBOX (PC Diagnostics) The ABS and ESC modulator valves can be cycled using Meritor WABCO TOOLBOX. To cycle the modulator valves, choose the option Valves from the Component Tests drop down menu. Figure 3.16.
4005309a
Figure 3.16
Figure 3.17
In order to test the function of the ESC modulator for the trailer circuit, choose E4.3 TBV with ABS Valve from the Component Tests drop down menu. Listen to ensure the correct valve is cycling.
4005308a
Figure 3.16
The screen in the following figure appears where you can choose to cycle each valve individually or you can choose to cycle all valves in a pre-determined order. Figure 3.17. Then, listen to ensure the correct valve is cycling. This is helpful in verifying correct operation, installation and wiring.
42
Active Braking Valves (ABV)

ABV refers to 3/2 solenoid valves used for active braking during ATC, RSC or ESC.
SID 15 18 19
Suspect Component and Location Active Braking Valve Common (Ground Circuit), Drive Axle, Steer Axle or Trailer Circuit Active Braking Valve Supply, Drive Axle Active Braking Valve Supply, Steer Axle or Trailer Circuit
FMI 1
Fault Description
Fault Indication
System Reaction
Cause Continuity between suspect Active Braking Valve circuit and voltage supply (short circuit) is detected.
Repair Information Verify 7.0-14.0 ohm between ABV supply and ABV common for 12V system (26.3-49.0 ohm for 24V system). Check for continuity between suspect Active Braking Valve common circuits and voltage supply. Check connectors and modulator for corrosion. Verify 7.0-14.0 ohm between ABV supply and ABV common for 12V system (26.3-49.0 ohm for 24V system). Check if connectors are fully seated. Check for broken wires or connectors.
Shorted to ABS Warning ATC Brake Control UBATT for SID Lamp Disabled 19 Only ESC/RSC Disabled Specifically for Front Axle ABV Open Circuit for SID 19 Only Specifically for Front Axle ABV
ABS Warning ESC/RSC Disabled ECU has detected that Lamp the suspect Active Braking Valve circuit is not detected.
Shorted to UBATT
ABS Warning ABS Disabled (for Lamp SID 15 Only) ESC/RSC/ATC Disabled
Continuity between suspect Active Braking Valve circuit and voltage supply (short circuit) is detected.
Verify 7.0-14.0 ohm between ABV supply and ABV common for 12V system (26.3-49.0 ohm for 24V system). Check for continuity between suspect Active Braking Valve common circuits and voltage supply. Check connectors and modulator for corrosion.
Short to Ground for SID 19 Only Specifically for Front Axle ABV
ABS Warning ESC/RSC Disabled Continuity between Lamp suspect Active Braking Valve circuit and ground is detected.
Verify 7.0-14.0 ohm between ABV supply and ABV common for 12V system (26.3-49.0 ohm for 24V system). Check for continuity between suspect Active Braking Valve circuit and ground. Check connectors and modulator for corrosion.
43
FMI 5
Fault Description High Impedance for SID 15 Open Circuit for SID 18 and 19 (Trailer Circuit Specifically if SID 19)
Fault Indication
System Reaction
Cause ECU has detected that the suspect Active Braking Valve circuit is not detected or the circuit has been interrupted.
Repair Information Verify 7.0-14.0 ohm between ABV supply and ABV common for 12V system (26.3-49.0 ohm for 24V system). Check if connectors are fully seated. Check for broken wires or connectors. If SID 15 FMI 5 repeats after wiring checked and/or repaired, replace ECU.
ABS Warning ESC/RSC/ATC Lamp Disabled
Short to Ground
ABS Warning ATC Disabled for Lamp SID 15 and 18
Continuity between suspect Active Braking ESC/RSC Disabled Valve circuit and ground is detected.
Verify 7.0-14.0 ohm between ABV supply and ABV common for 12V system (26.3-49.0 ohm for 24V system). Check for continuity between suspect Active Braking Valve circuit and ground. Check connectors and modulator for corrosion.
Active Braking Valve (ABV) Testing

Electrical Checks Take measurements at the ECU harness to check the ABV and harness together. Figure 3.19 and Figure 3.20. Take measurements at the ABV pins directly to verify the component. Figure 3.18. Measurements should read as below. If resistance exceeds 14.0 ohm for 12V system (49.0 ohm for 24V system), clean the electrical contacts at the solenoid and retest. Location ABV Supply to ABV Common Measurement 7.0-14.0 ohm for 12V system 26.3-49.0 ohm for 24V system
Figure 3.18
AIR LINES
PORT 1, AIR SUPPLY
PORT 2, AIR DISCHARGE VALVE CONTROL DO NOT OPEN
PORT 3, TREADLE AIR LINE 1002039a

Figure 3.18
ABV Supply or ABV Common to No continuity Voltage Supply or Ground
44
Figure 3.19

X4 16 13 10 17 14 11 18 15 12 7 8 9 4 5 6 1 2 3 13 10 14 11 15 12 X3 7 8 9 4 5 6 1 2 3 X2 16 13 10 17 14 11 18 15 12 7 8 9 4 5 6 1 2 3 13 10 14 11 15 12 X1 7 8 9 4 5 6 1 2 3
4007207a
Figure 3.19
Figure 3.20
6 7 5 8 X1-GRAY 4 3 2 9 10 11 1 12 6 7 5 8 X2-BLACK 4 3 2 9 10 11 1 12 6 12 5 11
X1-BLACK 4 3 2 10 16 9 8 1 7 6 12 5 11 X2-GREEN 4 3 2 10 16 9 8 1 7
15 14 13
18 17
15 14 13
10 11
X3-GREEN 6 7 5 8 4 9 3 2 1 12
10 11
4007208a
Figure 3.20
ECU Cab-Mounted
Active Braking Valve Circuit
Connector X2-18 pin X2-18 pin X4-18 pin X4-18 pin 16 7 16 13 13 8
Pins
ECU Frame-Mounted Non-ESC
Active Braking Valve Circuit Drive Axle ABV Supply Drive Axle ABV Common
Connector X3-Green X3-Green 5 6 1 12
Pins
Drive Axle ABV Universal with ESC, Supply Universal or Basic Drive Axle ABV Common Steer Axle ABV Supply Steer Axle ABV Common
Trailer ABV Supply X2-Black Trailer ABV Common X2-Black
Trailer ABV Supply X3-15 pin Trailer ABV Common X3-15 pin
45
Active Braking Valve Circuit Drive Axle ABV Supply Drive Axle ABV Common Steer Axle ABV Supply Steer Axle ABV Common
Figure 3.22
Connector X3-Green X3-Green X2-Green X2-Green 5 6 12 11 9 8
Pins
Trailer ABV Supply X1-Black Trailer ABV Common X1-Black
4005309a
Figure 3.22
ABV Testing Available in Meritor WABCO TOOLBOX (PC Diagnostics) The Active Braking Valves can be cycled using Meritor WABCO TOOLBOX. To cycle the ABVs, choose the option Valves from the Component Tests drop down menu. Figure 3.21.
Figure 3.21
In order to test the function of the ABV used for Stability Control pressure application to the trailer circuit, choose either Trailer Brake Valve, E4.3 Trailer Brake Valve or E4.3 TBV with ABS Valve (depending on your vehicle configuration) from the Component Tests drop down menu. Listen to ensure the correct valve is cycling. If you are unsure which test option to choose, please contact Meritor WABCO OnTrac and have your ECU part number available.
4005308a
Figure 3.21
The screen in the following figure appears where you can choose to cycle each valve individually. Figure 3.22. Then, listen to ensure the correct valve is cycling. This is helpful in verifying correct operation, installation and wiring.
46
Power Supply
SID 14 15 251 Suspect Component and Location Supply Voltage, Battery (Could be IGN on Non-ESC Frame ECU) Supply Voltage, Ignition Internal Overvoltage
FMI 3
Fault Description Overvoltage for SID 251 Only
Fault Indication
System Reaction
Cause A supply voltage which is too high has been measured by the ECU for more than 5 seconds.
Repair Information Measure the battery voltage under load. Check the vehicle battery and associated components (alternator). Check the battery and ensure it is correct for the ECU, i.e., ensure a 24V battery is not being used with a 12V ECU. Check for damaged or corroded wiring or connectors.
Supply Voltage is too Low for SID 14 or 15 Only
ABS Warning ABS Disabled Lamp (while ESC/RSC/ATC supply Disabled voltage is detected as too low)
The supply voltage is temporarily too low.
Measure the battery or ignition voltage under load. Check the vehicle battery and associated components (alternator). Check for damaged or corroded wiring or connectors. Check condition of fuses.
ECU Central ABS Warning ESC/RSC/ATC Ground Open Lamp Disabled Circuit
The ECUs connection Check for damaged or corroded wiring or connectors. to central ground has been interrupted or the resistance measured is too high. The internal relay does Change ECU if fault detection repeats. not open the power line.
Supply ABS Warning ESC/RSC/ATC Voltage, Lamp Disabled Ignition Internal Relay (SID 15 Only)
Power Supply Testing

Electrical Checks Take measurements at the ECU harness. Figure 3.23 and Figure 3.24. Measurements should read as below. Location Supply Voltage, Battery to Ground Supply Voltage, Ignition to Ground Measurement 9.0-16.0V for 12V system 18.0-32.0V for 24V system 9.0-16.0V for 12V system 18.0-32.0V for 24V system
47
Figure 3.23

X1 13 14 15 10 11 12 7 8 9 4 5 6 1 2 3 4007214a
Figure 3.23
Power Supply Circuit Supply Voltage, Battery Supply Voltage, Ignition Central Ground
Connector X1-Black X1-Black X1-Black 1 2
Pins
13, 14
Figure 3.24
6 7 5 8 X1-GRAY 4 3 2 9 10 11 1 12
6 12 5 11 X1-BLACK 4 3 2 10 16 9 8 1 7
18 17
15 14 13 4007209a
Figure 3.24
ECU Cab-Mounted
Power Supply Circuit
Connector X1-15 pin X1-15 pin X1-15 pin X1-Gray 8 7
Pins
Supply Voltage, Universal with ESC, Battery Universal or Basic Supply Voltage, Ignition Central Ground Frame-Mounted Non-ESC Supply Voltage, Battery (Could be IGN) Supply Voltage, Ignition Central Ground
4, 9 1
X1-Gray X1-Gray
2 11, 12
48

SID 15 or 55 Suspect Component and Location Brake Pressure Sensor, Foot Valve Supply Circuit (could be located in primary or secondary depending on application)
FMI 3
Fault Indication
System Reaction
Cause
Repair Information
ABS Warning ESC/RSC Disabled Continuity between Check for continuity between pressure sensor signal Lamp pressure signal circuit circuit and voltage supply. and voltage supply Check connectors and pressure sensor for corrosion. (short circuit) is detected. ABS Warning ESC/RSC Disabled Continuity between Lamp pressure signal circuit and voltage supply (short circuit) or an open circuit is detected. Check if connectors are fully seated. Check for continuity between pressure sensor signal circuit and ground. Check connectors and pressure sensor for corrosion. Call Meritor WABCO OnTrac at 866-OnTrac1 (668-7221) with part number to ensure ECU is correct for the application.
Open or Shorted to Ground
Brake Pressure Sensor Testing

Electrical Checks Take measurements at the pressure sensor harness connector. Figure 3.25, Figure 3.26 and Figure 3.28. Measurements should read as below.
Figure 3.25

X4 16 17 13 14 15 10 11 12 7 8 9 4 5 6 1 2 3 4007217a
Figure 3.25
Location Power Supply to Ground Pressure Signal to Ground or Power Supply
Measurement 8.0-16.0V No continuity
18
49
Figure 3.26
Figure 3.28
PRESSURE SENSOR CONNECTOR
6 7 5 8 X4-BROWN 4 3 2 9 10 11 1 12
6 12 5 11 X1-BLACK 4 3 2 10 16 9 8 1 7
1 3
18 17 4007210a
15 14 13 4007211a
Figure 3.26
Figure 3.28
Pin 1 2 3
Circuit Power Supply Ground Pressure Signal ECU Cab-Mounted
Pressure Sensor Circuit Connector Power Supply X4-18 pin X4-18 pin X4-18 pin X4-Brown X4-Brown X1-Black X1-Black 8 11 14 2 11 10 11
Pins
Pressure sensor test is available in Meritor WABCO TOOLBOXTM (PC Diagnostics). Pressure sensor test can be accessed through TOOLBOXTM under Component Tests, Pressure Sensor Test. Click Start test and ensure brake pedal position pressure is displayed in the corresponding boxes. Figure 3.27.
Figure 3.27
Universal with ESC Ground or Universal Pressure Signal without ESC Frame-Mounted Non-ESC Frame-Mounted With ESC Ground Pressure Signal Ground Pressure Signal
4008658a
Figure 3.27
50
ESC Module
SID 88 Suspect Component and Location ESC Module, Near Fore/Aft Center of Gravity of Vehicle
FMI 1
Fault Description
Fault Indication
System Reaction ESC Disabled
Cause
Repair Information
ESC ATC Lamp Initialization Blinking Not Complete ESC System ATC Lamp Configuration ESC CAN ATC Lamp Datalink Fault
The ESC initialization is Follow the ESC Initialization (End of Line) Process. Refer not complete. to Section 8. The ESC module is not Contact Meritor WABCO OnTrac at 866-OnTrac1 compatible with the (668-7221) or vehicle OEM to check ESC module/ABS ABS ECU. ECU combination. Loss of CAN communication between the ESC module and the ABS ECU. Data communication between the ESC module and the ABS ECU is missing or incorrect. Verify correct wiring, CAN communication and power supply, between the ESC module and the ABS ECU.
ESC Disabled
ESC Disabled
ESC CAN Datalink
ATC Lamp
ESC Disabled
Verify correct wiring, CAN communication and power supply, between the ESC module and the ABS ECU. Contact Meritor WABCO OnTrac at 866-OnTrac1 (668-7221) to check parameter setting of ABS ECU and ESC module compatibility.
12
ESC Module Failure
ATC Lamp
ESC Disabled
Yaw rate is missing or Check mounting of ESC module. implausible based on Contact Meritor WABCO OnTrac at 866-OnTrac1 system configuration. (668-7221) to ensure ESC module mounting is in accordance with ABS ECU parameters. Verify correct wiring, CAN communication and power supply, between the ESC module and the ABS ECU.
13
ESC ATC Lamp Initialization is Required
ESC Disabled
The system has Follow the ESC Initialization (End of Line) Process. Refer detected that the ABS to Section 8. ECU, ESC module or parameters were exchanged and ESC initialization is required. The ESC module mounting is not in accordance with specification. Check mounting of ESC module. Contact Meritor WABCO OnTrac at 866-OnTrac1 (668-7221) to ensure ESC module mounting is in accordance with ABS ECU parameters. Verify correct wiring, CAN communication and power supply, between the ESC module and the ABS ECU.
14
ESC Module Mounting Fault
ATC Lamp
ESC Disabled
51
SID 19
Suspect Component and Location SAS and ESC Module Power Supply
FMI 12
Fault Description Shorted to Ground
Fault Indication
System Reaction
Cause
Repair Information
ABS Warning ESC/RSC Disabled Continuity between the Check for continuity between the ESC component power Lamp power supply circuit for supply and ground. the ESC module/SAS Check connectors for corrosion or damage. and ground has been detected.
Figure 3.30
ESC Module Testing

Electrical Checks Take measurements at the ESC module harness connector. Figure 3.29 and Figure 3.30. Measurements should read as below. Location Power Supply to Ground Measurement 8.0-16.0V
CAB MOUNT ECU: LOOKING INTO WIRE HARNESS CONNECTOR

X4
16 13 10 17 14 11 18 15 12 7 8 9 4 5 6 1 2 3
X2-GREEN
6 12 18 5 11 17 4 10 16 3 9 2 8 1 7 13
15 14
ESC CAN-High to ESC CAN-Low Approximately 90 ohm ESC CAN-High or CAN-LOW to Power or Ground No continuity
Figure 3.30
4007215a
Figure 3.29
ESC MODULE CONNECTOR
ECU Cab-Mounted
ESC Module Circuit Power Supply
Connector X4-18 pin X4-18 pin X4-18 pin X4-18 pin X2-Green X2-Green X2-Green X2-Green 7 10 1 3 9
Pins
Universal with ESC Ground

3
ESC CAN-Low ESC CAN-High Frame-Mounted With ESC

4007213a
Power Supply Ground ESC CAN-Low
External 7 8
Figure 3.29
ESC CAN-High Pin Circuit Power Supply Ground CAN-High CAN-Low Additional Checks
1 2 3 4
The ESC module contains sensors which measure both lateral acceleration and yaw rate. Thus, it is critical that the module is firmly mounted to the vehicle and that the module is mounted as expected by the ABS ECU.
52
The module must be mounted in a manner where the WABCO name on the unit is right-side up. Figure 3.31. The module will always be mounted perpendicular to the frame rails of the vehicle and the connector of the module could be facing the front or rear of the vehicle depending on the OEMs specified mounting. It is critical that the unit be mounted in the exact location and manner as originally installed by the vehicle manufacturer.
Figure 3.31
4006872a
Figure 3.31
53
Steering Angle Sensor (SAS)

SID 89 Suspect Component and Location Steering Angle Sensor (SAS), interfaced to steering shaft
FMI 1
Fault Description SAS Offset Fault
Fault Indication ATC Lamp
System Reaction ESC Disabled
Cause
Repair Information
The Steering Angle Check installation of the SAS. Sensor offset is out of If work has been performed on the vehicle which affects tolerance. the steering system or front end alignment, perform SAS Calibration and ESC Initialization. Refer to Section 8. The ESC module has detected an implausible steering angle compared to the measured yaw rate. Check mounting of the SAS and ESC module. Contact Meritor WABCO OnTrac at 866-OnTrac1 (668-7221) to ensure that the ECU parameter setting is correct for the vehicle.
SAS not Plausible
ATC Lamp
ESC Disabled
Steering Ratio ATC Lamp Fault
ESC Disabled
The calculated steering Check mounting of the SAS and ESC module. ratio of the vehicle is Contact Meritor WABCO OnTrac at 866-OnTrac1 not plausible. (668-7221) to ensure that the ECU parameter setting is correct for the vehicle. Repeat ESC initialization procedure.
SAS Calibration Fault
ATC Lamp
ESC Disabled
The Steering Angle Sensor calibration failed. Data communication between the SAS and ABS ECU is missing or incorrect.
Re-perform the SAS calibration process. If the fault persists, replace the SAS. Verify correct wiring, CAN communication and power supply, between the SAS and the ABS ECU. Contact Meritor WABCO OnTrac at 866-OnTrac1 (668-7221) to check the parameter setting of ABS ECU and SAS compatibility. Verify correct wiring, CAN communication and power supply, between the SAS and the ABS ECU. Contact Meritor WABCO OnTrac at 866-OnTrac1 (668-7221) to check the parameter setting of ABS ECU and SAS compatibility.
SAS Datalink ATC Lamp Fault
ESC Disabled
12
SAS Failure
ATC Lamp
ESC Disabled
The Steering Angle Sensor is communicating an internal error to the ABS ECU.
13
SAS not Calibrated SAS Internal Fault
ATC Lamp
ESC Disabled
The ECU has detected Follow the SAS calibration procedure. Refer to Section that a new SAS has 8. been installed. The Steering Angle Sensor is communicating an internal error to the ABS ECU. Check the installation and condition of the SAS and steering system.
14
ATC Lamp
ESC Disabled
54
SID 19
Suspect Component and Location SAS and ESC Module Power Supply
FMI 10 11 12
Fault Description Shorted to Plus Open Circuit Shorted to Ground
Fault Indication
System Reaction
Cause
Repair Information
ABS Warning N.A. Lamp ABS Warning N.A. Lamp
Short circuit to battery Check and correct wire. supply. Open circuit. Check and correct wire.
ABS Warning ESC/RSC Disabled Continuity between the Check for continuity between the ESC component power Lamp power supply circuit for supply and ground. the ESC module/SAS Check connectors for corrosion or damage. and ground has been detected.
Figure 3.32
Steering Angle Sensor (SAS) Testing

Electrical Checks Take measurements at the SAS harness connector. Pins 3 and 4 of the Steering Angle Sensor are internally connected to each other. In the harness which mates to the SAS, one of these two circuits will have a jumper to pin 2 of the SAS. This jumper must be present for correct sensor operation. The other CAN-High circuit which is not jumped to pin 2 of the SAS will be connected to the ECU at the pins specified below. Figure 3.32, Figure 3.33 and Figure 3.34. Measurements should read as below.
STEERING ANGLE SENSOR CONNECTOR
65 4 3 21
4007216a
Figure 3.32
Location Power Supply to Ground
Measurement 8.0-16.0V 1 2 3 4 5 6
Pin CAN-Low
Circuit
ESC CAN-High to ESC CAN-Low Approximately 90 ohm ESC CAN-High or CAN-Low to Power or Ground No continuity
Terminating Resistor CAN-High CAN-High Power Ground
55
Figure 3.33
All three mounting tabs of the SAS must be secured to the column assembly by screws. The driving tab of the SAS should be firmly fit into the machined groove in the steering shaft. If the driving tab or the mounting tabs of the sensor appear to be damaged, replace the sensor.
Hill Start Aid (HSA)

HSA can be accessed through TOOLBOX Software. Under Component Test, you have the ability to monitor switch status and toggle the lamp. Figure 3.35.
Figure 3.35
4006873a
Figure 3.33
Figure 3.34
CAB MOUNT ECU: LOOKING INTO WIRE HARNESS CONNECTOR

X4
16 13 10 17 14 11 18 15 12 7 8 9 4 5 6 1 2 3
X2-GREEN
6 12 18 5 11 17 4 10 16 3 9 2 8 1 7 13
15 14
4007215a
Figure 3.34
4008454a
Figure 3.35
ECU Cab-Mounted
SAS Circuit Power Supply
Connector X4-18 pin X4-18 pin X4-18 pin X4-18 pin X2-Green X2-Green X2-Green X2-Green 7 10 1 3 9
Pins
Universal with ESC Ground ESC CAN-Low ESC CAN-High Frame-Mounted With ESC Power Supply Ground ESC CAN-Low ESC CAN-High Additional Checks
SID 19
Suspect Component and Location Stability Control Modulator, Trailer Circuit (Optional) OR Active Braking Valve Supply, Steer Axle, Braking Circuit or HSA Lamp or Switch
External 7 8
When checking the mounting of the SAS to the column, it is critical that the sensor is mounted in the position originally specified by the vehicle OEM. Failure to do so will result in a fault code.
56
FMI 8
Fault Description HSA Lamp or Switch, RSC Modulator, Open Circuit
Fault Indication Warning Lamp
System Reaction
Cause
Repair Information Check wire and connectors.
ESC/RSC Disabled Output wire is interrupted.
HSA Lamp or Warning Switch, RSC Lamp Modulator, Short to Ground
ESC/RSC Disabled Output wire is shorted Check wire, connectors and valve. to ground.
SID 94
Suspect Component and Location HSA System
FMI 2
Fault Description HSA Active Fault
Fault Indication
System Reaction
Cause The driver remained on the service brake while HSA was active. Driver got a HSA warning message after 80 seconds but did not react. The failure has been displayed after 90 seconds of HSA activation. There was no HSA switch information in the EBCS Message; the HSA switch information is to be received from the CAN Bus according to the HSA switch parameter setting. (Only applicable if instead of a hardwired HSA switch a HSA switch information is provided in EBCS).
Repair Information The following actions are only applicable if instead of a hardwired HSA switch a HSA switch information is provided in EBCS: Check the parameter setting regarding the HSA switch Broadcast the HSA switch information in EBCS OR Install a HSA switch Set the parameter regarding the HSA switch to Hardwired Switch
HSA Warning HSA Disabled Lamp
57
Figure 3.36

X4 16 13 10 17 14 11 18 15 12 7 8 9 4 5 6 1 2 3 13 10 14 11 15 12 X3 7 8 9 4 5 6 1 2 3 X2 16 13 10 17 14 11 18 15 12 7 8 9 4 5 6 1 2 3 13 10 14 11 15 12 X1 7 8 9 4 5 6 1 2 3
4008455a
Figure 3.35
Figure 3.37
X1-BLACK 5 4 3 2 11 10 16 9 8 X2-GREEN 5 4 3 2 11 10 16 9 8 X4-BROWN (ONLY FOR 6 CHANNEL) 6 5 4 3 2 1 7 8 9 10 11 12 X3-GREEN 6 7 5 8 4 9 3 2 1 12
6 12
1 7
6 12
1 7
10 11
18 17
15 14 13
18 17
15 14 13 4008456b
Figure 3.36
ECU Cab-Mounted
Circuit
Connector X3-15 pin X3-15 pin 1 4
Pins
HSA Lamp, must Universal with ESC be hard wired HSA Switch, can be hard wired or muliplexed Ground Frame ECU With ESC HSA Lamp, must be hard wired Ground HSA Switch, can be hard wired or muliplexed ABV Trailer Control, must be grounded to pin 8
X3-15 pin X1-Black X1-Black X1-Black
8 7 8 9
58
J1939 Serial Communications

SID 231 Suspect Component and Location J1939 Data Link Fault Description Fault Indication
FMI 5
System Reaction
Cause SAE J1939 communication is not possible.
Repair Information If ABS ECU is only vehicle ECU not communicating, verify J1939 wiring between ABS ECU and J1939 backbone. Resistance should be 60 ohms between J1939 high and low. Verify J1939 low and high are not switched.
SAE J1939 ABS Warning ESC/RSC/ATC Disabled Open or Short Lamp Circuit J1939 Communication Switched to Inactive SAE J1939 No Access ABS Warning ESC/RSC/ATC Lamp Disabled If Communication Cannot be Restored After 10 Seconds, J1939 Communication Switched to Inactive
SAE J1939 communication is not possible.
If ABS ECU is only vehicle ECU not communicating, verify J1939 wiring between ABS ECU and J1939 backbone. Resistance should be 60 ohms between J1939 high and low. Verify J1939 low and high are not switched.
SAE J1939 Time-Out EEC1
ABS Warning ESC/RSC/ATC Lamp Disabled
There is either too Verify J1939 wiring between engine ECU and vehicle much time in between J1939 backbone. EEC1 broadcasts from the engine or the message content is not as expected. The external brake request message (XBR) is expected but is not being received in expected time or not at all. Verify J1939 wiring between external ECU which is sending request and J1939 backbone. This message is most likely to come from Adaptive Cruise or a Collision Mitigation system such as OnGuard.
10
XBR Disabled SAE J1939 Temporary XBR Time-Out ABS Warning Lamp
12
SAE J1939 ABS Warning ABS Disabled Internal Error Lamp ESC/RSC/ATC Disabled XBR Checksum Counter ABS Warning XBR Disabled Lamp
An internal fault related Verify J1939 wiring between ABS ECU and J1939 to the CAN controller is backbone. detected. If fault repeats, contact Meritor WABCO OnTrac at 866-OnTrac1 (668-7221). The external brake request message (XBR) has been received incorrectly. Verify J1939 wiring between external ECU which is sending request and J1939 backbone. This message is most likely to come from Adaptive Cruise or a Collision Mitigation system such as OnGuard.
13
59
FMI 14
Fault Description SAE J1939 ESC1 Time-Out
Fault Indication
System Reaction
Cause The electronic steering control message (ESC1) is expected but is not being received in expected time or not at all.
Figure 3.39
Repair Information Verify J1939 wiring between external ECU which is sending request and J1939 backbone. This message is most likely to come from a steering tag axle controller.
Temporary ESC Disabled ABS Warning Lamp
J1939 Serial Communications Testing

Electrical Checks If the ABS ECU is the only ECU on the J1939 datalink which cannot communicate, then take measurements at the ABS ECU connector. If other ECUs are not communicating, then troubleshoot the vehicle datalink backbone and contact the vehicle OEM for technical assistance if required. For resistance measurements, the vehicle battery must be disconnected and the ignition must be Off. Figure 3.37 and Figure 3.38. Measurements should read as below.
FRAME MOUNT ECU WITHOUT ESC LOOKING INTO WIRE HARNESS CONNECTOR
6 7 5 8 X1-GRAY 4 3 2 9 10 11 1 12
FRAME MOUNT ECU WITH ESC LOOKING INTO WIRE HARNESS CONNECTOR
6 12 5 11 X1-BLACK 4 3 2 10 16 9 8 1 7
18 17
15 14 13 4007374a
Figure 3.38
Location J1939 High to J1939 Low J1939 High or J1939 Low to Ground or Power Supply
Measurement Approximately 60 ohm No continuity ECU Cab-Mounted All Frame-Mounted J1939 Datalink Circuit J1939 High J1939 Low J1939 High J1939 Low J1939 High J1939 Low Connector X1-15 pin X1-15 pin X1-Gray X1-Gray X1-Black X1-Black 3 1 7 6 18 6 Pins
Figure 3.38
Without ESC
CAB MOUNT ECUS LOOKING INTO WIRE HARNESS CONNECTOR
X1 13 14 15 10 11 12 7 8 9 4 5 6 1 2 3 4007373a
Figure 3.37
Frame-Mounted With ESC
60
Internal ABS ECU

SID 22 Suspect Component and Location ABS System Fault Description ABS Complete Shut-off Fault Indication Warning Lamp
FMI 14
System Reaction
Cause
Repair Information
Complete Shut-Off The number of stored Check sensor wiring, connectors and sensor. wheel speed sensor failures is checked. To avoid that, the degree of sensor pole wheel failures for instance, progress because of lack of maintenance response, ignorance of repair instructions (warning lamp ignorance), that critical driving situations due to ABS faulty controls arise, special measures are undertaken dependent on the number of wheel sensor failures, collective error count stored in the EEPROM (without electrical failure).
SID 253
Suspect Component and Location ABS ECU (Consult OEM Manual for Location)
61
FMI 2
Fault Description
Fault Indication
System Reaction
Cause The ECU memorized system is not in accordance with the harness. There are loads detected at outputs which should be open circuits. Wheel parameters (number of tone ring teeth or tire size) are out of tolerance.
Repair Information Check number of sensors and modulators and correct wiring and compare to ECU type. Call Meritor WABCO OnTrac at 866-OnTrac1 (668-7221) with part number to ensure ECU is correct for the application.
ABS System ABS Warning ABS Disabled Configuration Lamp ESC/RSC/ATC Disabled EEPROM Wheel Parameter Incorrect
12
EEPROM Checksum
There is an incorrect checksum in the EEPROM. A diagnostic tool may have been disconnected during active diagnosis.
Reset ECU by cycling the ignition or by using the reset option in TOOLBOX. If fault persists, contact Meritor WABCO OnTrac at 866-OnTrac1 (668-7221).
13
ABS System Fault
The ECU memorized system is not in accordance with the harness.
Check number of sensors and modulators and correct wiring and compare to ECU type. Call Meritor WABCO OnTrac at 866-OnTrac1 (668-7221) with part number to ensure ECU is correct for the application.
14
EEPROM ESC ATC Lamp Parameter Incorrect
ESC Disabled
The stability control Call Meritor WABCO OnTrac at 866-OnTrac1 parameters set in the (668-7221) with part number to ensure ECU is correct ECU are not in for the application. accordance with what is detected or learned on the vehicle.
SID 254
Suspect Component and Location ABS ECU (Consult OEM manual for location)
62
FMI 5
Fault Description No Loads Detected
Fault Indication
System Reaction
Cause The ECU detects that no modulators are connected. This is a common fault during end of line testing or programming if only the X1 connector is connected.
Repair Information Check harness to ensure that modulators are connected and check fuses.
ABS Warning ABS Disabled Lamp ESC/RSC/ATC Disabled Fault is not Memorized
Excessive Slip ABS Warning ABS Disabled Lamp ESC/RSC/ATC Disabled
One axle is detected to Use the Disable ATC diagnostic command when the be rotating much faster vehicle is on a dynotester. than another. Check for excessive ABS sensor gap on multiple wheel This fault is common ends. on dynotesters if the detection is not disabled via diagnostic command. It is also possible that there are excessive sensor air gaps on multiple wheel ends.
Excessive Modulator Activation Time
An ABS modulator was Check subject ABS tooth wheel for damage or activated for an corrosion. abnormally long time. If fault repeats, contact Meritor WABCO OnTrac at ESC/RSC Disabled 866-OnTrac1 (668-7221). ATC Disabled if Fault on Driven Wheel
12
Internal Error ABS Warning ABS Disabled Lamp ESC/RSC/ATC Disabled
There are multiple causes. Valves may have been activated too long during diagnostic testing. The measured lateral acceleration by the ECU is out of range.
Reset ECU by cycling the ignition or by using the reset option in TOOLBOX. If fault persists, contact Meritor WABCO OnTrac at 866-OnTrac1 (668-7221). Verify that the ECU is mounted firmly and per OEM specification. Call Meritor WABCO OnTrac at 866-OnTrac1 (668-7221) with part number to ensure ECU is correct for the application. Verify that the ECU is mounted firmly and per OEM specification. Call Meritor WABCO OnTrac at 866-OnTrac1 (668-7221) with part number to ensure ECU is correct for the application.
13
AcceleroABS Warning RSC Disabled meter Out of Lamp Range
14
ECU Mounting, Accelerometer Not Plausible
ABS Warning RSC Disabled Lamp
The measured lateral acceleration is not plausible or the learned off-set is too high. ECU may be mounted incorrectly.
63
Retarder Relay
SID 13 Suspect Component and Location Retarder Relay Fault Description Shorted to UBATT Fault Indication
FMI 3
System Reaction
Cause
Repair Information Check for continuity between the retarder relay output and voltage supply. Check connectors and retarder relay for corrosion or damage.
Continuity between the ABS Warning Hardwired Lamp Retarder Control is retarder relay output and the battery supply Disabled has been detected.
Open Circuit
ABS Warning Hardwired ECU has detected that Check if connections are fully seated. Lamp Retarder Control is the retarder relay is not Check for broken wires or connectors. Disabled connected but was If hardwired retarder control is not installed on the previously learned. vehicle but this fault is present, the operator should perform Reset Memorized Components TOOLBOX procedure. ABS Warning Hardwired Continuity between the Lamp Retarder Control is retarder relay output Disabled and ground has been detected. Check for continuity between the retarder relay output and ground. Check connectors and retarder relay for corrosion or damage.
Shorted to Ground
Retarder Relay Testing

Electrical Checks Take measurements at the ECU harness connector. Measurements should read as below.
Additional Checks If fault code 13 SID-5 FMI Retarder Relay Open Circuit is active and the vehicle does not require a hardwired control of the retarder, it is possible that the retarder relay was learned either during diagnostic testing or while the ECU was installed on a different vehicle. In this case, the Reset Memorized command described in Section 7 can be used. Pins 14 The function of the retarder relay can also be verified using Meritor WABCO TOOLBOX. Under the Component Tests drop down menu, select the Relay option. The following screen will appear. Figure 3.39. This is helpful in verifying the correct operation, installation and wiring of the unit under test.
ECU Cab-Mounted
J1939 Datalink Circuit
Connector X1-15 pin
Retarder Relay Universal with ESC, Output Universal or Basic Frame-Mounted Non ESC Frame-Mounted With ESC Retarder Relay Output Retarder Relay Output
X1 Gray
X1-Black
64
Figure 3.40
Dynamometer Testing Vehicles with ATC

Activate Relay
WARNING
The automatic traction control (ATC) function must be disabled before any type of dynamometer testing is conducted on the vehicle. If the ATC is not disabled, the vehicle ATC may actuate and cause the vehicle to move forward without warning to the operator. If the vehicle moves forward unexpectedly, the vehicle may cause damage or injuries to individuals who are in the path of the vehicle.
4007375a
Relay
Turn Relade Relay On
Close
Figure 3.39
CAUTION
Do not cycle the vehicle ignition while the vehicle is on a dynamometer. Cycling the vehicle ignition will enable the ATC. Vehicles with ATC must have the ATC disabled to test the vehicle on a dynamometer. To disable the ATC, use one of the following methods: 1. Blink Code Switch Press and hold the blink code switch for at least three seconds. Refer to the blink code diagnostics information in this section for a description of how the blink code display will appear. Once the system configuration code begins, ATC has been disabled.
Tire Size Range Testing

ABS
For correct ABS/ATC operation with the standard ECU, front and rear tire sizes must be within 14% of each other. When this tire size range is exceeded without electronically modifying the ECU, the system performance can be affected and the indicator lamp can illuminate. Calculate the tire size with the following equation:
% Difference = RPM Steer 1 x 100 RPM Drive

RPM tire revolutions per mile
The ATC lamp comes on and stays on while ATC is disabled. ATC will remain disabled until the vehicle ignition is cycled.
RSC
RSC requires that the steer axle tire size range be within 5% of a pre-set value. Call Meritor WABCO at 866-OnTrac1 (668-7221) if you plan a tire size range greater than those specified. 2.
After testing, ATC will automatically reactivate the first time the vehicle ignition is cycled. Remove Power Remove the ABS circuit breaker/fuse or remove the ECU power connector to disable the ABS and ATC. After testing, re-install the circuit breaker/fuse and the ATC will automatically reactivate the first time the vehicle power is applied to the ECU. 3. TOOLBOX Software At the ABS Main Menu, select the Disable ATC icon or use the pull down menu to send the command to the ECU to disable the ATC. Refer to the TOOLBOX Software Owners Manual for complete instructions for using TOOLBOX. ATC will remain disabled until the enable command is sent or the vehicle ignition is cycled.
ESC
ESC requires that the steer axle tire size range be within 3% of a pre-set value. Call Meritor WABCO at 866-OnTrac1 (668-7221) if you plan a tire size range greater than those specified.
65
After testing, ATC will automatically reactivate the first time the vehicle ignition is cycled. 4. MPSI Pro-Link Plus Refer to the MPSI Pro-Link Plus Owners Manual for instructions. ATC will remain disabled until the enable command is sent or the vehicle ignition is cycled. After testing, ATC will automatically reactivate the first time the vehicle ignition is cycled.
66
4 Component Replacement
Hazard Alert Messages

Figure 4.1
Read and observe all Warning and Caution hazard alert messages in this publication. They provide information that can help prevent serious personal injury, damage to components, or both.
SENSOR SPRING CLIP
WARNING
To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. Release all air from the air systems before you remove any components. Pressurized air can cause serious personal injury.
WHEEL SPEED SENSOR 4004479a
Figure 4.1
CAUTION
When welding on an ABS- or ABS/ATC-equipped vehicle is necessary, disconnect the power connector from the ECU to prevent damage to the electrical system and ABS/ATC components.
Wheel Speed Sensor Removal Front Axle

NOTE: When replacing the wheel speed sensor, the sensor spring clip must also be replaced. To remove the sensor from the front axle:
Component Removal and Installation

Wheel Speed Sensors
Sensor Lubricant Specification
Meritor WABCO specifications call for a sensor lubricant with the following characteristics: Lubricant must be mineral oil-based and contain molydisulfide. It should have excellent anti-corrosion and adhesion characteristics, and be capable of continuous function in a temperature range of 40 to 300F (40 to 150C). Lubricants approved for use on Meritor WABCO sensors and spring clips are as follows. Figure 4.1. Mobilith SHC-220 (Mobil) TEK 662 (Roy Dean Products) Staburags NBU 30 PTM (Kluber Lubrication) Valvoline EP 633
WARNING
Park the vehicle on a level surface. Block the wheels to prevent the vehicle from moving. Support the vehicle with safety stands. Do not work under a vehicle supported only by jacks. Jacks can slip and fall over. Serious personal injury and damage to components can result. 1. 2. 3. 4. 5. Place blocks under the rear tires to stop the vehicle from moving. Apply the parking brake. If necessary, raise the front tires off the ground. Place safety stands under the axle. Disconnect the fasteners that hold the sensor cable to other components. Disconnect the sensor cable from the chassis harness. Remove the sensor from the sensor holder. Use a twisting motion if necessary. Do not pull on the cable. Figure 4.2.
67
Figure 4.2
Wheel Speed Sensor Removal Rear Axle

NOTE: When replacing the wheel speed sensor, the sensor spring clip must also be replaced. To remove the sensor from the rear axle:
WARNING
Park the vehicle on a level surface. Block the wheels to prevent the vehicle from moving. Support the vehicle with safety stands. Do not work under a vehicle supported only by jacks. Jacks can slip and fall over. Serious personal injury and damage to components can result. 1. 2.
1002036a
Place blocks under the front tires to stop the vehicle from moving. Raise the rear tire off the ground. Place safety stands under the axle. Release the parking brake and back off the slack adjuster to release the brake shoes. Remove the wheel and tire assembly from the axle. Remove the brake drum. Remove the sensor from the mounting block in the axle housing. Use a twisting motion if necessary. Do not pull on the cable. Remove the sensor spring clip from the mounting block. Disconnect the fasteners that hold the sensor cable and the hose clamp to other components. Disconnect the sensor cable from the chassis harness.
KNUCKLE-MOUNTED SENSOR
Figure 4.2
3. 4.
6.
Remove the sensor spring clip.
5. 6.
Wheel Speed Sensor Installation Front Axle

To replace the sensor in the front axle: 1. 2. 3. 4. 5. 6. Connect the sensor cable to the chassis harness. Install the fasteners used to hold the sensor cable in place. Apply a Meritor WABCO recommended lubricant to the sensor spring clip and sensor. Install the sensor spring clip. Make sure the spring clip tabs are on the inboard side of the vehicle. Push the sensor spring clip into the bushing in the steering knuckle until the clip stops. Push the sensor completely into the sensor spring clip until it contacts the tooth wheel. NOTE: After installation, there should be no gap between the sensor and the tooth wheel. During normal operation, a gap of up to 0.04-inch (1.016 mm) is allowable. 7. Remove the blocks and safety stands.
7. 8. 9.
Wheel Speed Sensor Installation Rear Axle

1. 2. 3. Apply a Meritor WABCO recommended lubricant to the sensor spring clip and sensor. Install the sensor spring clip. Verify that the spring clip tabs are on the inboard side of the vehicle. Push the sensor spring clip into the mounting block until it stops. NOTE: After installation, there should be no gap between the sensor and the tooth wheel. During normal operation, a gap of up to 0.04-inch (1.016 mm) is allowable.
68
4.
Push the sensor completely into the sensor spring clip until it contacts the tooth wheel. Figure 4.3.
2. 3.
Place blocks under the front and rear tires to stop the vehicle from moving. If necessary, raise the vehicle off the ground and place safety stands under the axle. Disconnect the wiring connector from the ABS valve. Disconnect the air lines from Ports 1 (air supply) and 2 (air discharge) of the ABS valve. Figure 4.4.
Figure 4.3
SPRING CLIP
SENSOR HOLDER
4. 5.
SENSOR
SPRING CLIP TAB
Figure 4.4
PORT 2, AIR OUT
PORT 1, AIR IN
1002037a
Figure 4.3
1002038a
5.
Insert the sensor cable through the hole in the spider and axle housing flange. Route the cable to the frame rail. Be sure to route the cable in a way that will prevent pinching or chafing and will allow sufficient movement for suspension travel. Connect the sensor cable to the chassis harness. Install the fasteners that hold the sensor cable in place. Install the brake drum on the wheel hub. Complete the installation per the vehicle manufacturers manual.
Figure 4.4
6. 7.
Remove the two mounting capscrews and nuts. Remove the ABS valve.
6. 7. 8. 9.
Installation CAUTION
Moisture can affect the performance of all ABS/ATC systems, as well as the standard braking system. Moisture in air lines can cause air lines to freeze in cold weather. 1. Install the ABS valve with two mounting capscrews and nuts. Tighten the capscrews per the manufacturers recommendation. Connect the line to the brake chambers to Port 2 of the ABS valve. Connect the air supply line to Port 1 of the ABS valve. Connect the wiring connector to the ABS valve. Hand tighten only. Remove the blocks and stands. Test the installation.
ABS Modulator Valve

Removal
1. Turn the ignition switch to the OFF position. Apply the parking brake. 2. 3. 4. 5.
WARNING
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.
69
Checking the Installation

1. 2. Apply the brakes. Listen for leaks at the modulator valve. Turn the ignition on and listen to the modulator valve cycle. If the valve fails to cycle, check the electrical cable connection. Make repairs as needed. Drive the vehicle. Verify that the ABS indicator lamp operates correctly.
Figure 4.5
AIR LINES
PORT 1, AIR SUPPLY
3.
ATC Valve
Removal
1. Turn the ignition switch to the OFF position. Apply the parking brake.
Figure 4.5
WARNING
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. 2. 3. 4. 5. 6. Place blocks under the front and rear tires to stop the vehicle from moving. If necessary, raise the vehicle off the ground. Place safety stands under the axle. Relieve line pressure by bleeding the air from the appropriate supply tank. Disconnect the wiring from the ATC valve. Disconnect the air lines from Port 1 (air supply), Port 2 (air discharge) and Port 3 (treadle) of the ATC valve. Figure 4.5. 2. 3. 4. 5. 7. Remove the two mounting capscrews and nuts. Remove the ATC valve.
Installation
1. Install the ATC valve with two mounting capscrews and nuts. Tighten the capscrews per the manufacturers recommendation. Connect the air supply, discharge and treadle lines to Ports 1, 2 and 3 of the ATC valve. Connect the harness connector to the ATC valve. Hand tighten only. Remove the blocks and stands. Test the installation.

To test the ATC valve: 1. 2. 3. 4. 5. 6. 7. 8. Start the vehicle. Fully charge the reservoirs with air. Shut off the vehicle. Apply the brakes. Listen for air leaks at the ATC valve. Release the brakes. Activate the ATC valve using the MPSI tool. Disconnect the MPSI tool. Drive the vehicle. Verify that the ATC indicator lamp operates correctly.
70
Trailer Active Braking Valve

Removal
1. 2. 3. 4. 5. 6. Turn the ignition switch to the OFF position. Apply the parking brake. Place blocks under the front and rear tires to stop the vehicle from moving. If necessary, raise the vehicle off the ground. Place safety stands under the axle. Relieve line pressure by bleeding the air from the appropriate supply tank. Disconnect the wiring from the trailer active braking valve (solenoid valve). Disconnect the air lines from Port 1 (air supply), Port 2 (air discharge) and Port 3 (treadle) of the solenoid valve. Figure 4.6.
3. 4. 5.
Connect the harness connector to the solenoid valve. Hand tighten only. Remove the blocks and stands. Test the installation.

To test the trailer active braking valve (solenoid valve): 1. 2. 3. 4. 5. 6. 7. Connect the blue glad hand to a 50 cu. in. (819 cu. cm) air tank. Start the vehicle. Fully charge the reservoirs with air. Shut off the vehicle. Activate the solenoid valve using TOOLBOX Software. Listen for air leaks at the solenoid valve. Make necessary repairs. Turn the ignition on. Verify that the ATC/Stability Control indicator lamp operates correctly.
Figure 4.6
AIR LINES
PORT 1, AIR SUPPLY
ABS Valve Packages

Removal and Installation Complete Package
1. 2. 3. 4. Place blocks under tires to stop the vehicle from moving. If necessary, raise the tires off the ground. Drain the air from all system air tanks. Remove all the air lines and connections from the ABS valve package. Figure 4.7 and Figure 4.8.
PORT 3, TREADLE AIR LINE

Figure 4.7
1002039a
Figure 4.6
SUPPLY PORT 1/2" NPT QUICK RELEASE VALVE
7.
Remove the two mounting capscrews and nuts. Remove the solenoid valve.
Installation
1. Install the solenoid valve with two mounting capscrews and nuts. Tighten the capscrews per the manufacturers recommendation. Do not exceed 15 ft-lb (20 N m). @ 2. Connect the air supply, discharge and treadle lines to Ports 1, 2 and 3 of the solenoid valve.
001 20/98 472 500 30. 0
MADE IN GERMANY
MODULATOR VALVE
1/2" NPT DELIVERY PORTS 4007847a
ABS QUICK RELEASE VALVE PACKAGE

Figure 4.7
71
Figure 4.8
2.
RELAY VALVE CONTROL PORT 1/4" NPT ABS MODULATOR VALVE
Use a 6 mm Allen wrench to loosen and remove the Allen-head bolts. Carefully separate the ABS modulator valve(s) from the relay or quick release valve. Remove and discard old O-rings. Lubricate replacement O-rings with the grease provided. Plug any unused ports on the replacement valve(s). Attach the ABS modulator valve(s) to the relay or quick release valve. Use a 6 mm Allen wrench to tighten the Allen-head bolts to 13-15 lb-ft (18-20 N m). @ Replace the ABS valve package: Tighten the bolts to the vehicle manufacturers recommendation. Remove the blocks and safety stands as necessary. Check the valves for leaks: Modulator valve(s). Refer to the procedure for checking the modulator valve installation in this section. Relay or quick release valve. Refer to the procedure for checking the quick release or relay valve installation in this section.
ABS MODULATOR VALVE
3. 4. 5. 6.
DELIVERY PORTS 1/2" NPT
SUPPLY PORT 1/2" NPT
7.
4007848a
ABS RELAY VALVE PACKAGE

Figure 4.8
8. 5. 6. Remove the mounting bolts from the valve package. Remove the valve package from the vehicle. Replace the ABS valve package: Tighten the bolts to the vehicle manufacturers recommendation. Remove the blocks and safety stands as necessary. Test the installation.
7.
Removal and Installation Component Valves

1.
Figure 4.9
Active Braking Valve on the ABS Valve Package

Removal
Remove the ABS valve package from the vehicle. Figure 4.9.
ALLEN-HEAD BOLTS 13-15 LB-FT (18-20 Nm)
NOTE: If there is enough room to work, it is not necessary to remove the valve package from the vehicle before replacing the active braking valve (solenoid valve). If the valve package must be removed, follow the instructions for removing and replacing the ABS Valve Package that appear in this section of the manual. When installing the new active braking valve (solenoid valve) on the valve package, you must use the new O-rings, seals, mounting bolts and lubricant included with the replacement kit. 1. 2. 3. 4. Turn the ignition switch to the OFF position. Apply the parking brake. Place blocks under the front and rear tires to stop the vehicle from moving. If necessary, raise the vehicle off the ground. Place safety stands under the axle. Relieve line pressure by bleeding the air from the appropriate supply tank.
ALLEN-HEAD BOLTS
001 20/98 472 500 30. 0 MADE IN GERMANY
13-15 LB-FT (18-20 Nm)

1002041c
Figure 4.9
72
5. 6. 7.
Disconnect the wiring from the solenoid valve. Disconnect the supply air line from the adapter and the treadle air line from the solenoid valve. Use a 5 mm Allen wrench to remove the two screws that hold the adapter piece to the relay valve portion of the valve package. Use a 6 mm Allen wrench to remove the two mounting bolts that hold the solenoid valve to the adapter piece. Remove the solenoid valve from the adapter piece. Remove the solenoid valve. Remove the adapter piece, seal and O-rings from the valve package. Figure 4.10.
Figure 4.11
MOUNTING BOLTS 12-13 FT-LB (18-20 Nm) ACTIVE BRAKING VALVE (SOLENOID VALVE)
O-RING SEAL ADAPTER
Figure 4.10
MOUNTING BOLTS ACTIVE BRAKING VALVE (SOLENOID VALVE) TREADLE AIR LINE SEAL ADAPTER O-RINGS
Figure 4.11
4007850a
2.
Lubricate the replacement seal and install it in Port 2 of the solenoid valve. Lubricate the large replacement O-ring and install it in the groove of the relay valve supply port. Figure 4.12.
Figure 4.12
SUPPLY AIR LINE 4007849a

Figure 4.10
Installation
1. Clean and lubricate the small adapter piece O-ring. Install the O-ring on the adapter piece. Use the two new M8 Allen-head bolts to attach the solenoid valve to the adapter piece. Use a 6 mm Allen-head tool to tighten to 13-15 lb-ft (18-20 N m). Figure 4.11. @ 3.
Figure 4.12
RELAY VALVE SUPPLY PORT
1002044a
NOTE: Use Meritor WABCO-recommended lubricant. Use the two M6 Allen-head bolts to attach the adapter to the relay valve. Use a 5 mm Allen-head tool to tighten to 4-5 lb-ft (6-8 N m). Figure 4.13. @
73
Figure 4.13
2.
ATC VALVE AND ADAPTER SUPPLY PORT CONTROL PORT ABS VALVE PACKAGE
Place blocks under the front and rear tires to prevent the vehicle from moving. Disconnect the wiring harness connectors from the ESC ECU. Remove the mounting hardware. Remove the ESC ECU.
3. 4.
Installation 1. Install the ESC ECU using the manufacturers mounting hardware. Tighten the hardware per the manufacturers recommendation. Install the wiring harness connectors to the ESC ECU. Remove the blocks. Test the installation.
2.
MOUNTING BOLTS 4-5 LB-FT (6-8 Nm)
3.
O-RING (INSTALLED) 1002045a
4.
Figure 4.13
Testing the Installation To test the ECU installation, the system must be calibrated:
4.
Connect the supply air line to the supply port on the adapter. Connect the treadle air line to the control port on the solenoid valve. Place a wrench on the adapter to prevent the control port from twisting. Tighten the fitting to 15 ft-lb (20 N m). Do not over tighten. @ Attach the wiring connector to the solenoid valve. Hand tighten only.
1. 2.
Follow the ESC End of Line Calibration Procedure described in this manual. When the ESC End of Line Calibration Procedure is completed, the ABS and ATC/ESC lamps should come on and go back off when ignition power is turned on. The ATC/ESC lamp may remain on briefly after the ABS lamp goes off. There should not be any active faults displayed in the ECU memory.
5. 6. 7.
3. Remove the blocks and stands. Test the installation.
Front Axle Active Braking Valve (Solenoid Valve)

Removal 1. Turn the ignition switch to the OFF position. Apply the parking brake.

1. 2. 3. 4. 5. Start the vehicle. Fully charge the reservoirs with air. Shut off the vehicle. Apply the brakes. Listen for air leaks at all valves. Drive the vehicle. Verify that the ABS indicator lamp operates correctly.
WARNING
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. 2. 3. 4. Place blocks under the front and rear tires to prevent the vehicle from moving. If necessary, raise the vehicle off the ground and place safety stands under the vehicle. Relieve line pressure by bleeding the air from the appropriate supply tank.
Electronic Stability System (ESC) Component Replacement

ESC ECU
74
5. 6.
Disconnect the wiring harness connector from the front axle active braking valve (solenoid valve). Disconnect the air line from Port 1 (Air Supply), Port 2 (Air Discharge) and Port 3 (Treadle) of the front axle active braking valve (solenoid valve). Figure 4.14.
5. 6.
Activate the solenoid valve using the TOOLBOX software. Verify that the front brakes apply.
Steering Angle Sensor (SAS) Meritor WABCO Only

Removal 1. Center the steering wheel with the front wheels positioned straight ahead. Turn the ignition switch to the OFF position. Apply the parking brake. Place blocks under the front and rear tires to prevent the vehicle from moving. Locate the SAS on the steering column shaft, either near the universal joint on the bottom of the column or under the steering wheel near the top of the column.
Figure 4.14
AIR LINES
PORT 1, AIR SUPPLY
2. 3.
4.

Figure 4.14
WARNING
If equipped, disable the supplemental restraint system (air bag) to avoid serious personal injury. Refer to the vehicle manufacturers service publication for further information. 5. If the SAS is located at the top of the steering column, remove the vehicle steering wheel using the recommended steering wheel puller. The SAS is attached by three screws to the steering column with the center tab located in the grooved steering column shaft. Figure 4.15.
7.
Remove the two mounting capscrews and nuts. Remove the solenoid valve. 6.
Installation 1. Install the solenoid valve with the two capscrews and nuts. Tighten the capscrews per the manufacturers recommendation.
Figure 4.15
2. 3. 4. 5.
Connect the air supply, discharge and treadle lines to Ports 1, 2 and 3 of the solenoid valve. Connect the wiring harness connector to the ESC valve. Hand tighten only. Remove the stands and blocks. Test the installation.
Testing the Installation To test the solenoid valve: 1. 2. 3. 4. Turn the ignition on and verify that the ATC/Stability Control lamp operates correctly. Start the vehicle. Fully charge the reservoirs with air. Shut off the vehicle. 8. Apply the brakes and check for air leaks at the solenoid valve. Remove the attaching screws and slide the SAS off of the steering column shaft.
Figure 4.15
4006873a
7.
Disconnect the wiring harness connector from the SAS. (Note the position of the connector either facing up or down.)
75
Installation
WARNING
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. 2. 3. 4. Place blocks under the front and rear tires to prevent the vehicle from moving. If necessary, raise the vehicle off the ground and place safety stands under the vehicle. Disconnect the wiring harness connector from the ESC module. Figure 4.16.
CAUTION
If the SAS is not installed in the correct orientation, it will not function correctly and may become damaged. 1. Apply a small amount of the supplied grease to the tab in the center of the SAS and to the machined groove on the steering shaft. Install the SAS with the connector facing the same direction as the original. Place the SAS over the steering column shaft and slide it into place with the SAS tab placed in the groove that is machined on the steering column shaft. Using the new furnished screws, replace the attaching screws and tighten to a maximum of 22 in-lb (2.5 N m). @
2.
3. 4. 5. 6. 7.
Figure 4.16
Install the SAS wiring harness connector by pushing the connector together until the small tab snaps into place. Install the steering wheel and tighten per the manufacturers recommendation. Remove the blocks. Test the installation.
4006872a
Figure 4.16
Testing the Installation To test the SAS installation, the system must be calibrated. 1. 2. Follow the ESC End of Line Calibration Procedure described in this manual. When the ESC End of Line Calibration Procedure is completed, the ABS and ATC/ESC lamps should come on and go back off when ignition power is turned on. The ATC/ESC lamp may remain on briefly after the ABS lamp goes off. There should not be any active faults displayed in the ECU memory. 1.
5.
Remove the two mounting capscrews and nuts. Remove the ESC module.
Installation NOTE: It is important that the module is aligned correctly and the tab on the ESC mounting surface fits into the appropriate hole. Install the ESC module with the two capscrews and nuts. Tighten the capscrews per the manufacturers recommendation. Connect the wiring harness connector to the ESC module. Hand tighten only. Remove the stands and blocks. Test the installation.
3.
ESC Module
2. 3. 4.
Test the Installation To test the ESC module installation, the system must be calibrated.
76
1. 2.
Follow the ESC End of Line Calibration Procedure described in this manual. When the ESC End of Line Calibration Procedure is completed, the ABS and ATC/ESC lamps should come on and go back off when ignition power is turned on. The ATC/ESC lamp may remain on briefly after the ABS lamp goes off. There should not be any active faults displayed in the ECU memory.
7.
Remove the brake pressure sensor.
Installation 1. 2. 3. 4. Connect the brake pressure sensor to the air line or attach the sensor to the air line fitting. Connect the wiring harness connector to the brake pressure sensor. Hand tighten only. Remove the stands and blocks. Test the installation.
3.

Testing the Installation To test the brake pressure sensor: 1. 2. 3. Turn the ignition on and verify that the ATC/ESC lamp operates correctly. Start the vehicle and fully charge the reservoirs with air. Shut off the vehicle. Apply the brakes and check for air leaks at the brake pressure sensor.
WARNING
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. 2. 3. 4. 5. Place blocks under the front and rear tires to prevent the vehicle from moving. If necessary, raise the vehicle off the ground and place safety stands under the vehicle. Relieve line pressure by bleeding the air from the appropriate supply tank. Disconnect the wiring harness connector from the brake pressure sensor. Figure 4.17.
Figure 4.17
4006870a
Figure 4.17
6.
Disconnect the air line or unscrew the brake pressure sensor from the air line fitting.
77
5 Appendix I System Configurations
ABS Configurations
Figure 5.3
Refer to Figure 5.1, Figure 5.2, Figure 5.3, Figure 5.4, Figure 5.5, Figure 5.6 and Figure 5.7 for system configuration layouts.
Figure 5.1
6S/6M ABS
STANDARD OR BASIC 4S/4M ABS

LAMPS
LAMPS
VALVE PACKAGE INSTALLATION (FRONT) AIR LINES ELECTRICAL LINES VALVE PACKAGE INSTALLATION (FRONT) AIR LINES ELECTRICAL LINES
Figure 5.1
Figure 5.4
1003365e
Figure 5.3
1003363e
4S/4M ABS/ATC
Figure 5.2
LAMPS
6S/4M ABS
LAMPS
ATC VALVE
VALVE PACKAGE INSTALLATION (FRONT) AIR LINES ELECTRICAL LINES VALVE PACKAGE INSTALLATION (FRONT) AIR LINES ELECTRICAL LINES
1003366e
1003364e
78
Figure 5.5
Figure 5.7
6S/4M ABS/ATC
4S/4M ESC/ATC (ALSO AVAILABLE IN 6S CONFIGURATIONS)

TRACTOR PROTECTION VALVE
LAMPS
TRAILER ACTIVE BRAKING VALVE LAMPS ESC MODULE
TRAILER STABILITY CONTROL MODULATOR (OPTIONAL)
ATC VALVE
VALVE PACKAGE INSTALLATION (FRONT) AIR LINES ELECTRICAL LINES

Figure 5.5
ATC VALVE SAS 1003367e PRESSURE SENSOR AIR LINES ELECTRICAL LINES FRONT AXLE ACTIVE BRAKING VALVE 4007814b
Figure 5.6
4S/4M RSC/ATC (ALSO AVAILABLE IN 6S CONFIGURATIONS)

TRAILER STABILITY CONTROL MODULATOR (OPTIONAL) TRAILER ACTIVE BRAKING VALVE LAMPS TRACTOR PROTECTION VALVE VALVE PACKAGE INSTALLATION (REAR)
Figure 5.7
ATC VALVE FRONT AXLE ACTIVE BRAKING VALVE (OPTIONAL) AIR LINES ELECTRICAL LINES 4007813b
VALVE PACKAGE INSTALLATION (FRONT) PRESSURE SENSOR (OPTIONAL)

Figure 5.6
79
6 Appendix II Wiring Diagrams
ECU Connector Pin Assignments

Refer to Figure 6.1, Figure 6.2, Figure 6.3, Figure 6.4, Figure 6.5, Figure 6.6, Figure 6.7, Figure 6.8, Figure 6.9, Figure 6.10, Figure 6.11, Figure 6.12, Figure 6.13 and Figure 6.14 for ECU wiring diagrams.
Figure 6.1
BASIC
1 2 3
4 5 6
7 8 9
10 11 12
13 14 15
16 17 18
1 2 3
4 5 6
7 8 9
10 11
13 14 15
18
BASIC ECU (CAB-MOUNTED)
Figure 6.1
14
4004024a
Figure 6.2
UNIVERSAL
1 2 3
4 5 6
7 8 9
10 11 12
13 14 15
1 2 3
4 5 6
7 8 9
10 11 12
13 14 15
16 17 18
1 2 3
4 5 6
7 8 9
10 11
13 14 15
15
UNIVERSAL ECU (CAB-MOUNTED)
Figure 6.2
18
14
4004025a
Figure 6.3
UNIVERSAL ECU (CAB-MOUNTED) WITH ESC

X4
1 2 3 4 5 6 7 8 9 10 13 16 14 11 17 12 15 18 1 2 3 4 5 6
X3
7 8 9 10 13 11 14 12 15 1 2 3 4 5 6
X2
7 8 9 10 13 16 14 11 17 12 15 18 1 2 3 4 5 6
X1
7 8 9 10 13 11 14 12 15
4007395a
UNIVERSAL ECU (CAB-MOUNTED) WITH ESC

Figure 6.3
80
Figure 6.4
X1-GRAY
2 1 2 3 4 5 6 1 11 12
X2-BLACK
3 4 5 10 6
12
11
10
X4-BROWN (ONLY FOR 6 CHANNEL)

1 2 3 4 5 6 1 12 11 10 12
X3-GREEN
2 3 4 5 6
11
10
4004026a
FRAME-MOUNTED ECU
Figure 6.4
ECU (Frame-mounted) with ESC

Figure 6.5
1 7
2 8
X1-BLACK 3 4 5 9 15 10 11
FRAME MOUNT ECU WITH ESC

6 12 1 7 2 8
X2-GREEN 3 4 5 9 15 10 11
6 12
13 14
16 17 18
13 14
16 17 18
X3-GREEN 1 7 2 8 3 9 4 5 6 12
10 11
4007396a
Figure 6.5
81
Basic ECU (Cab-mounted)

Figure 6.6
INLET VALVE
INLET VALVE
INLET VALVE
OUTLET VALVE
OUTLET VALVE
OUTLET VALVE
4
18 PIN CONNECTOR
OUTLET VALVE
INLET VALVE
DIF-
SENSOR
12
SENSOR
11
SENSOR 10
SENSOR
15
SENSOR
14
SENSOR 13
INLET VALVE OUTLET VALVE INLET VALVE OUTLET VALVE INLET VALVE OUTLET VALVE DIFINLET VALVE OUTLET VALVE SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR DIF+ SENSOR SENSOR
1
16 AWG
1 4 3 16 AWG 6 2 16 AWG 5
4 3 6 2 5 7 8
16 AWG
IV GND OV IV GND OV IV GND OV
RIGHT FRONT ABS VALVE
LEFT FRONT ABS VALVE
LEFT REAR ABS VALVE
8 9 TP 10 13 TP 11 14 TP 12 15 TP
9 10 13 11 14 12 15 16 17 18
IV GND OV
RIGHT REAR ABS VALVE
RIGHT FRONT SENSOR LEFT REAR SENSOR LEFT FRONT SENSOR
DIF VALVE
SENSOR
18
SENSOR
17
DIF+
16
17 18
RIGHT REAR SENSOR
BACK VIEW OF HARNESS CONNECTOR
SAE J1939 H
TR-WL
SAE J1939 L
J1587 B J1587 A J1939 L J1939 H BATTERY ECU+

14 PIN CONNECTOR
10 11 1 3 8 7
TP
10 11
J1587 B J1587 A J1939 L J1939 H BAT IGN
TP
1 3
14 AWG
15A AMP 5A AMP
8 7
ATC
ABS
ECU-
86
30
GND
BAT
ECU+
JUMPER
12
SAE J1587 A
11
SAE J1587 B
10
RETARDER 14 TRAILER 2 INDICATOR LAMP ATC LAMP 13 TRACTOR 15 INDICATOR LAMP ATC SWITCH ABS OFF ROAD ECUGND 6 5 4 9
RETARDER
85 14
87
87A 2 13 15
ATC SWITCH
TRAILER INDICATOR LAMP ATC LAMP TRACTOR INDICATOR LAMP BLINK CODE SWITCH
ABS OFF ROAD SWITCH
ABS LAMP
15
3RD BRK
14
ATC LAMP
13
4 9 GND*
4004027a *All connected to a common star ground.

Figure 6.6
82
6S/6M Universal ECU (Cab-mounted)

Figure 6.7
SAE J1939 H
TR-WL
SAE J1939 L
J1587 B J1587 A J1939 L J1939 H BATTERY ECU+

14 PIN CONNECTOR
10 11 1 3 8 7
TP
10 11
J1587 B J1587 A J1939 L J1939 H BAT IGN
TP
1 3
14 AWG 14 AWG 86
15A AMP 10 AMP 30
8 7
ATC
ABS
ECU-
X1
GND
BAT
ECU+
JUMPER
SAE J1587 A
11
SAE J1587 B
10
RETARDER 14 TRAILER 2 INDICATOR LAMP ATC LAMP 13 15 TRACTOR INDICATOR LAMP ATC SWITCH 6 ABS OFF ROAD ECUGND 5 4 9
RETARDER
85 14
87
87A 2 13 15
ATC SWITCH
TRAILER INDICATOR LAMP ATC LAMP TRACTOR INDICATOR LAMP BLINK CODE SWITCH
ABS OFF ROAD SWITCH
ABS LAMP
15
3RD BRK
14
ATC LAMP
13
4 9

GND* INLET VALVE
SENSOR
L1
15 PIN CONNECTOR
OUTLET VALVE
SENSOR
L2
X3
NOT USED 9 SENSOR SENSOR INLET OUTLET SENSOR SENSOR INLET OUTLET 2 5 3 6 11 14 12 15
16 AWG 15 16 AWG 6 11 14 12 IV GND OV 2 5 3 IV GND OV 3RD AXLE LEFT SENSOR 3RD AXLE LEFT ABS VALVE 3RD AXLE RIGHT SENSOR 3RD AXLE RIGHT ABS VALVE
X2 X1
X3
NOT USED
I/O-OV
L3
INLET VALVE
12
SENSOR
11
L4
10
OUTLET VALVE
15
SENSOR
14
L5
13
BACK VIEW OF HARNESS CONNECTOR INLET VALVE OUTLET VALVE INLET VALVE OUTLET VALVE INLET VALVE OUTLET VALVE DIFINLET VALVE OUTLET VALVE SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR DIF+
SENSOR
1
16 AWG
1 4 3 16 AWG 6 2 16 AWG 5
INLET VALVE
INLET VALVE
INLET VALVE
4 3 6 2 5 7 8
16 AWG
OUTLET VALVE
OUTLET VALVE
OUTLET VALVE
4
18 PIN CONNECTOR
LEFT REAR ABS VALVE
OUTLET VALVE
INLET VALVE
DIF-
8 9 TP 10 13 TP 11 14 TP 12 15 TP
X2
SENSOR
9 10 13 11 14 12 15 16 17 18
IV GND OV
12
SENSOR
11
SENSOR 10
SENSOR
15
SENSOR
14
SENSOR 13
DIF VALVE
18
SENSOR
17
DIF+
16
SENSOR SENSOR
17 18
RIGHT REAR SENSOR
4004030f
Figure 6.7
83
6S/6M Universal ECU (Cab-mounted) with RSC (6S/4M and 4S/4M Configurations are also available)
Figure 6.8
INLET VALVE
INLET VALVE
INLET VALVE
OUTLET VALVE
OUTLET VALVE
OUTLET VALVE
4
18 PIN CONNECTOR
OUTLET VALVE
INLET VALVE
DIF-
X2
SENSOR
12
SENSOR
11
SENSOR 10
1 INLET VALVE OUTLET 4 VALVE 3 INLET VALVE OUTLET 6 VALVE 2 INLET VALVE OUTLET 5 VALVE 7 DIF8 INLET VALVE OUTLET 9 VALVE SENSOR 10 SENSOR SENSOR 13 11 14 12 15 16 17 18
1 16 AWG 4 3 16 AWG 6 2 16 AWG 5
LEFT REAR ABS VALVE
8 16 AWG 9 TP 10 13 TP 11 14 TP 12 15 TP
IV GND OV
SENSOR
15
SENSOR
14
SENSOR 13
SENSOR SENSOR SENSOR DIF+
DIF VALVE
SENSOR
18
SENSOR
17
DIF+
16
SENSOR SENSOR
17 18
RIGHT REAR SENSOR
15 PIN CONNECTOR
8 13 NOT USED 9 NOT USED 2 NOT USED 5 NOT USED 3

16 AWG
8 RSC VALVE 13
X3
X2 X1
X3
RSC +
2 5 3 6 11 14 12 16 AWG 15 IV GND OV IV GND OV
3RD AXLE LEFT SENSOR 3RD AXLE LEFT ABS VALVE 3RD AXLE RIGHT SENSOR 3RD AXLE RIGHT ABS VALVE
12
11
10
NOT USED 6 NOT USED 11 NOT USED 14
15
14
RSC
13
NOT USED 12 NOT USED 15
BACK VIEW OF HARNESS CONNECTOR J1587 B

SAE J1939 H
TR-WL
SAE J1939 L
J1587 A J1939 L J1939 H BATTERY ECU+

14 PIN CONNECTOR
10 11 1 3 8 7
14 AWG 14 AWG 86 15A AMP 5 AMP 30
TP
10 11
J1587 B J1587 A J1939 L J1939 H BAT IGN
TP
1 3 8 7
ATC
ABS
ECU-
X1
GND
BAT
ECU+
RETARDER 14 TRAILER 2 INDICATOR LAMP ATC LAMP 13 15
RETARDER
85 14
87
87A 2 13 15
ATC SWITCH
TRAILER INDICATOR LAMP ATC/RSC LAMP TRACTOR INDICATOR LAMP BLINK CODE SWITCH
JUMPER
SAE J1587 A
11
SAE J1587 B
10
ABS LAMP
15
3RD BRK
14
ATC LAMP
13
TRACTOR INDICATOR LAMP ATC SWITCH 6 5 ABS OFF ROAD 4 ECUGND 9
ABS OFF ROAD SWITCH
4 9 GND*
Momentary Switch Optional Equipment Twisted Pair = TP All unmarked wires should be 16 or 18 AWG. All fuses should be blade type. *All connected to a common star ground.
4004030g
Figure 6.8
84
6S/6M Universal ECU (Cab-mounted) with RSC with Front Axle Brake (6S/4M and 4S/4M Configurations are also available)
Figure 6.9
INLET VALVE
INLET VALVE
INLET VALVE
OUTLET VALVE
OUTLET VALVE
OUTLET VALVE
4
18 PIN CONNECTOR
OUTLET VALVE
INLET VALVE
DIF-
X2
SENSOR
12
SENSOR
11
SENSOR 10
1 INLET VALVE OUTLET 4 VALVE 3 INLET VALVE OUTLET 6 VALVE 2 INLET VALVE OUTLET 5 VALVE 7 DIF8 INLET VALVE OUTLET 9 VALVE SENSOR 10 SENSOR SENSOR 13 11 14 12 15 16 17 18
1 16 AWG 4 3 16 AWG 6 2 16 AWG 5
FRONT AXLE BRAKE (OPTIONAL) 16 GND 13 7 10 1 3 2 5 4
LEFT REAR ABS VALVE
8 16 AWG 9 TP 10 13 TP 11 14 TP 12 15 TP
IV GND OV
GND POWER p
PRESSURE SENSOR
11 14 8 9
X4
U
SENSOR
15
SENSOR
14
SENSOR 13
SENSOR SENSOR SENSOR DIF+
DIF VALVE
12 6 15
SENSOR
18
SENSOR
17
DIF+
16
SENSOR SENSOR
17 18
RIGHT REAR SENSOR
17 18
BACK VIEW OF HARNESS CONNECTOR IV 7 3 2 1 OV 10

GND
15 PIN CONNECTOR
STABILITY CONTROL MODULATOR (OPTIONAL)

16 AWG
8 RSC VALVE 13
X3
RSC +
X4
X3
12
11
10
X2 X1
15
14
RSC
13
BACK VIEW OF HARNESS CONNECTOR J1587 B

SAE J1939 H
TR-WL
SAE J1939 L
J1587 A J1939 L J1939 H BATTERY ECU+

14 PIN CONNECTOR
10 11 1 3 8 7
14 AWG 14 AWG 86 15A AMP 5 AMP 30
TP
10 11
J1587 B J1587 A J1939 L J1939 H BAT IGN
TP
1 3 8 7
ATC
ABS
ECU-
X1
GND
BAT
ECU+
RETARDER 14 TRAILER 2 INDICATOR LAMP ATC LAMP 13 15
RETARDER
85 14
87
87A 2 13 15
ATC SWITCH
JUMPER
SAE J1587 A
11
SAE J1587 B
10
ABS LAMP
15
3RD BRK
14
ATC LAMP
13
TRACTOR INDICATOR LAMP ATC SWITCH 6 5 ABS OFF ROAD 4 ECUGND 9
ABS OFF ROAD SWITCH
4 9 GND*
4004030h
Figure 6.9
85
6S/6M Universal ECU (Cab-mounted) with ESC (6S/4M and 4S/4M Configurations are also available)
Figure 6.10
INLET VALVE
INLET VALVE
INLET VALVE
OUTLET VALVE
OUTLET VALVE
OUTLET VALVE
4
18 PIN CONNECTOR
OUTLET VALVE
INLET VALVE
DIF-
X2
SENSOR
12
SENSOR
11
SENSOR 10
1 INLET VALVE OUTLET 4 VALVE 3 INLET VALVE OUTLET 6 VALVE 2 INLET VALVE OUTLET 5 VALVE 7 DIF8 INLET VALVE OUTLET 9 VALVE SENSOR 10 SENSOR 13 SENSOR SENSOR SENSOR SENSOR DIF+ SENSOR SENSOR 11 14 12 15 16 17 18
1 16 AWG 4 3 16 AWG 6 2 16 AWG 5
SAS MODULE (LWS)
FRONT AXLE BRAKE 16 GND U 13 7 10
ESC MODULE CAN
GND
LEFT REAR ABS VALVE
L 1 H 3 2 5 4
8 16 AWG 9 TP 10 13 TP 11 14 TP 12 15 TP
IV GND OV
GND
11 14 8 9
X4
POWER
PRESSURE SENSOR
U
SENSOR
15
SENSOR
14
SENSOR 13
DIF VALVE
12 6 15
SENSOR
18
SENSOR
17
DIF+
16
17 18
RIGHT REAR SENSOR
17 18
BACK VIEW OF HARNESS CONNECTOR IV 7 3 2 1 OV 10

GND
15 PIN CONNECTOR
STABILITY CONTROL MODULATOR

16 AWG
X4
8
RSC VALVE
13
X3
X2 X1
X3
RSC +
12
11
10
15
14
RSC
13
BACK VIEW OF HARNESS CONNECTOR J1587 B J1587 A

SAE J1939 H
10 11 1 3 8 7
14 AWG 14 AWG 86 15A AMP 10 AMP 30
TP
10 11
J1587 B J1587 A J1939 L J1939 H BAT IGN
TR-WL
SAE J1939 L
J1939 L J1939 H BATTERY ECU+

14 PIN CONNECTOR
TP
1 3 8 7
ATC
ABS
ECU-
X1
GND
BAT
ECU+
JUMPER
SAE J1587 A
11
SAE J1587 B
10
ABS LAMP
15
3RD BRK
14
ATC LAMP
13
RETARDER 14 TRAILER 2 INDICATOR LAMP ATC LAMP 13 15 TRACTOR INDICATOR LAMP ATC SWITCH 6 5 ABS OFF ROAD 4 ECUGND 9
RETARDER
85 14
87
87A 2 13 15
ATC SWITCH
ABS OFF ROAD SWITCH
4 9 GND*
4007397a
Figure 6.10
86
Hill Start Aid (HSA) for 6S/6M Universal ECU (Cab-mounted) with ESC (6S/4M and 4S/4M Configurations are also available)
Figure 6.11
INLET VALVE
INLET VALVE
INLET VALVE
OUTLET VALVE
OUTLET VALVE
OUTLET VALVE
4
18 PIN CONNECTOR
OUTLET VALVE
INLET VALVE
DIF-
X2
SENSOR
12
SENSOR
11
SENSOR 10
1 INLET VALVE OUTLET 4 VALVE 3 INLET VALVE OUTLET 6 VALVE 2 INLET VALVE OUTLET 5 VALVE 7 DIF8 INLET VALVE OUTLET 9 VALVE SENSOR 10 SENSOR 13 SENSOR SENSOR SENSOR SENSOR DIF+ SENSOR SENSOR 11 14 12 15 16 17 18
1 16 AWG 4 3 16 AWG 6 2 16 AWG 5
SAS MODULE (LWS)
FRONT AXLE BRAKE 16 GND U 13 7 10
ESC MODULE CAN
GND
LEFT REAR ABS VALVE
L 1 H 3 2 5 4
8 16 AWG 9 TP 10 13 TP 11 14 TP 12 15 TP
IV GND OV
GND
11 14 8 9
X4
POWER
PRESSURE SENSOR
U
SENSOR
15
SENSOR
14
SENSOR 13
DIF VALVE
12 6 15
SENSOR
18
SENSOR
17
DIF+
16
17 18
RIGHT REAR SENSOR
17 18
BACK VIEW OF HARNESS CONNECTOR IV 7 3 2 1 OV 10 HSA SWITCH 4 HSA LAMP 1 8 13 NOT USED 9 NOT USED 2 NOT USED 5 NOT USED 3 12 11 10 NOT USED 6 NOT USED 11 NOT USED 14 15 14
RSC 13
STABILITY CONTROL MODULATOR

GND GND
8
X4
RSC VALVE
13
15 PIN CONNECTOR
X3
X2 X1
X3
RSC +
2 5 3 16 AWG 6 11 14 12 16 AWG 15 IV GND OV IV GND OV
BACK VIEW OF HARNESS CONNECTOR J1587 B J1587 A

SAE J1939 H
10 11 1 3 8 7
14 AWG 14 AWG 86 15A AMP 5 AMP 30
TP
10 11
J1587 B J1587 A J1939 L J1939 H BAT IGN
TR-WL
SAE J1939 L
J1939 L J1939 H BATTERY ECU+

14 PIN CONNECTOR
TP
1 3 8 7
ATC
ABS
ECU-
X1
GND
BAT
ECU+
JUMPER
SAE J1587 A
11
SAE J1587 B
10
ABS LAMP
15
3RD BRK
14
ATC LAMP
13
RETARDER 14 TRAILER 2 INDICATOR LAMP ATC LAMP 13 15 TRACTOR INDICATOR LAMP ATC SWITCH 6 5 ABS OFF ROAD 4 ECUGND 9
RETARDER
85 14
87
87A 2 13 15
ATC SWITCH
ABS OFF ROAD SWITCH
4 9 GND*
4008457a
Figure 6.11
87
Frame-mounted ECU
Figure 6.12
+12V IGN OR BATTERY TP SENSOR R3RD (6S/4M AND 6S/6M ONLY) 12V IGN 6 7 OUTLET 5 8 16 AWG COMMON INLET 4 9 TP 86 30 OUTLET 2 11 16 AWG ABS OFF ROAD SWITCH COMMON INLET TO RETARDER
GND
15AMP 14 AWG 14 AWG 5 OR 10 AMP*
*4 VALVES 5 AMP *6 VALVES 10 AMP +12V +12V
14 AWG 14 AWG
GND GND
ABS VALVE RIGHT 3RD (6S/6M ONLY)
GND
BLINK CODE SWITCH
12
SENSOR L3RD
(6S/4M AND 6S/6M ONLY)
85 87A 87 ABS LAMP BLINK CODE LAMP

GND
11 ATC SWITCH (OPTIONAL) TP
10 ABS VALVE LEFT 3RD (6S/6M ONLY)
10
ATC/RSC LAMP 30 86
J1587 -B J1587 +A
12
8 TO RETARDER 87A 85 RETARDER
X4-BROWN (FOR 6 CHANNEL ONLY)
TP TRAILER WL
J1939 - H J1939 - L
X1-GRAY
RSC VALVE 6 7 ATC 5 8 16 AWG OUTLET COMMON INLET 4 9 TP ABS VALVE RIGHT REAR ABS VALVE LEFT FRONT INLET COMMON OUTLET 16 AWG
12
11
10 SENSOR RIGHT REAR OUTLET ABS VALVE RIGHT FRONT OUTLET ABS VALVE LEFT REAR SENSOR LEFT FRONT SENSOR RIGHT FRONT TP 7 TP COMMON INLET 8 16 AWG 9
10
11
16 AWG
COMMON INLET
12
TP
SENSOR LEFT REAR
X3-GREEN
X2-BLACK 4004031a
Figure 6.12
88
6S/6M Frame-mounted ECU with ESC (6S/4M and 4S/4M Configurations are also available)
Figure 6.13
STABILITY CONTROL MODULE (OPTIONAL) DIF2
IV LD-GND OV LD-GND 1 13 ** 10 FRONT (X2b) GREEN 12 11 9 IV GND OV IGM IG IGM IG TWISTED IV GND OV A2l A2r TWISTED A2l A2l
** Ub
12 11 ** REAR (X3) GREEN ABS-E FRAME MOUNTED 10 2 1 3 4 9 8 ** 7 5 6 **
ESC MODULE
SAS1
L 7 WABCO CAN 8 H IV GND OV 4 ** 16 3 IGM 5 TWISTED IG 6 IGM 17 TWISTED IG 18 ** 2 14 15 9 LD-GND ** ABS OFF-ROAD 8 7 12 B 16 A 4 L 6 H 18 17 17
A1r
A1r A1l
A1l
IV GND OV
DIF LD-GND
TRAILER ABV (OPTIONAL) AUX1
12 11 10 2. REAR (X4) BROWN **
IV GND OV A3l
SAE J1587 SAE J1939 IGN IGN Trlr. WL
CABIN (X 1b) BLACK
3 4 5 6 9 8 7 1 2
IGM IG IGM IG TWISTED IV ** GND OV A3r A3r TWISTED A3l
ATC/RSCL ATC TRACTION
PRESSURE SENSOR PRESSURE SENSOR GND PRESSURE SENSOR SIGNAL 15A U

B
* 13 * 14 10 11 * 1 * 2
BLINKCODE
BATT UECU IGN
15A
15 5
DBR WL
4007398a
Figure 6.13
89
Hill Start Aid (HSA) for 6S/6M Frame-mounted ECU with ESC (6S/4M, 4S/4M and HSA without ESC are also available)
Figure 6.14
STABILITY CONTROL MODULE (OPTIONAL) DIF2
IV LD-GND OV LD-GND 1 13 ** 10 FRONT (X2b) GREEN 12 11 9 IV GND OV IGM IG IGM IG TWISTED IV GND OV A2l A2r TWISTED A2l A2l
** Ub
12 11 ** REAR (X3) GREEN ABS-E FRAME MOUNTED 10 2 1 3 4 9 8 ** 7 5 6 **
ESC MODULE
SAS1
L 7 WABCO CAN 8 H IV GND OV 4 ** 16 3 IGM 5 TWISTED IG 6 IGM 17 TWISTED IG 18 ** 2 14 15 9 8 7 ABS OFF-ROAD 12 B 16 A 4 L 6 H 18 17 17
A1r
A1r A1l
A1l
IV GND OV
DIF LD-GND
TRAILER ABV (OPTIONAL) AUX1 HSA LAMP-HARD WIRED
HSA SWITCH LD-GND **
12 11 10 2. REAR (X4) BROWN **
IV GND OV A3l
SAE J1587 SAE J1939 IGN IGN Trlr. WL
CABIN (X 1b) BLACK
3 4 5 6 9 8 7 1 2
IGM IG IGM IG TWISTED IV ** GND OV A3r A3r TWISTED A3l
ATC/RSCL ATC TRACTION
PRESSURE SENSOR PRESSURE SENSOR GND PRESSURE SENSOR SIGNAL 15A U

B
* 13 * 14 10 11 * 1 * 2
BLINKCODE
BATT UECU IGN
15A
15 5
DBR WL
4008458a
Figure 6.14
90
7 Appendix III Additional ABS Information
Troubleshooting
Meritor WABCO ABS Valve Package

This troubleshooting information is a reference tool to help identify possible malfunctions of the ABS modulator or relay valves. It does not take the place of diagnostic tests or other service instructions.
Condition Air constantly leaks from exhaust port of relay valve. Air leaks from exhaust port of ABS modulator valve or relay valve when parking brake is released. Rear service brakes releasing slowly (brakes dragging).
Possible Cause Internal relay valve problem.
Recommended Action Replace the relay valve.
Parking brake problem. OR Anti-compound 2-way check valve problem.
Service the appropriate component. Refer to manufacturers service manual for instructions.
Kinked air line. Dirt buildup inside relay valve.
Inspect/repair lines, brakes. If the condition is not corrected: Replace the relay valve.
91
Condition Valves dont cycle at power-up. OR Indicator lamp comes on (blink code or diagnostic tool indicates electrical problem with ABS valve).
Possible Cause Broken wire. OR Loose or broken terminal connection. Corroded connector pins. OR Problem with solenoid.
OPEN-STYLE CONNECTOR
Recommended Action Check the wires and connections. Make repairs as needed. If condition is not corrected: Measure resistance across each valve solenoid coil terminal and ground on the ABS modulator valve to ensure 4.0 to 8.0 ohms (11-21 for 24V system). If greater than 8.0 ohms or 21 ohms for 24V system, clean the valve and repeat the measurement. If cleaning does not solve the problem, replace the ABS modulator valve. If less than 4.0 ohms (11 for 24V system), replace the ABS modulator valve.
GROUND TERMINAL EXHAUST SOLENOID (BLUE WIRE) INLET SOLENOID (BROWN WIRE)
4004032a
EXHAUST SOLENOID (BLUE WIRE) INLET SOLENOID (BROWN WIRE) GROUND TERMINAL 4004033a
ABS valve package damaged.
Road hazards. OR Vehicle damage.
Replace the complete ABS valve package or individual component as required.
Reconfiguration Procedure
How to Reconfigure an ECU (E Version)
Before reconfiguring the ECU, contact ArvinMeritors Customer Service Center at 866-OnTrac1 (668-7221) for additional information.
E version ECUs memorize the following components if they are connected at power-up: ATC valve Retarder relay Datalink SAE J1939 NOTE: The ATC valve and Datalink SAE J1939 are required for RSC/ESC. The RSC/ESC ECUs cannot be reconfigured to remove these components. Only the retarder relay is memorized or cleared.
92
Once these components have been memorized, the ECU will look for them at each power-up. If a memorized component is not present, the ECU will record a fault. For example, if an ATC valve is memorized, but is not present at the next power-up, the ECU records a fault. This can occur if an ECU is moved from one truck to another and one or more of the memorized components are not available on the new truck. If this occurs, use TOOLBOX Software to reconfigure the ECU. If you do not have TOOLBOX Software, follow the manual reconfiguration instructions in this section.
TOOLBOX Software
NOTE: For complete instructions for using TOOLBOX Software, refer to the TOOLBOX Users Manual, TP-99102. To reconfigure the ECU with TOOLBOX Software, use the Reset Memorized command. Select Reset Memorized from the pull down menu to tell the ECU to reset the memorized or learned components. Figure 7.1 and Figure 7.2.
Figure 7.1
4004034a
Figure 7.1
Figure 7.2
4004035a
Figure 7.2
Manual Reconfiguration
Refer to Table E and Figure 7.3 for information on manual reconfiguration.
93
Table E: Action 1. 2. Turn the ignition ON. Press and hold the blink switch for at least three seconds. NOTE: Do not hold this switch longer than seven seconds. Result The ABS lamp displays the ABS system configuration code: One blink: 6S/6M Two blinks: 4S/4M Four blinks: 6S/4M NOTE: The ABS lamp may display eight quick flashes before the system configuration code begins. The ATC lamp comes on and stays on. Reason Stored faults cleared, no active faults present. Continue with reconfiguration. NOTE: The reconfiguration procedure cannot be conducted if there are active faults present. These must be repaired before proceeding with the reconfiguration.
Observe the ABS and ATC lamps.
A complete ATC system including an ATC lamp is installed. If not, the ATC lamp will not come on. ECU reconfiguring the system. The ECU checks the following components and reprograms itself based on the new system: ATC valve AND/OR Retarder relay AND/OR Datalink J1939 Successfully reconfigured.
The ABS lamp will continuously blink the system configuration code.
While the configuration code is flashing, press the blink code switch three times (one second each, with a one second pause between each). Turn the ignition OFF.
The ABS lamp displays four quick flashes, followed by a continuous display of the system configuration code. NOTE: The system configuration code continues until ignition is turned OFF.
Figure 7.3
A system reconfiguration is illustrated below:

IGNITION ON
-1s -1s -1s
SWITCH 3 Second Hold

-1s -1s
ATC Reset Confirmation

Pause Pause Pause Pause Pause Pause Pause
1.5 s
4s
4s
4s
4s
4s
4s
Continues until power is turned off
System ID (2)
System ID (2)
System ID (2)
System ID (2)
System ID (2)
System ID (2)
ATC
ATC Lamp Dyno Function (remains lit for entire test) Light ON* *ATC Lamp will light only if ATC is connected. 1003371a
Figure 7.3
94
8 Appendix IV ESC Calibrations
ESC End of Line Calibration Procedure

Figure 8.1
This procedure is performed as part of the final assembly of the vehicle at the manufacturing site. Also, this procedure must be performed in the field by a trained technician if components are replaced such as the Steering Angle Sensor (SAS), the Electronic Stability Control (ESC) module or the ESC Electronic Control Unit (ECU). This calibration should also be performed when a major steering repair or replacement has taken place. The process consists of two operations. The first one is the SAS Calibration, followed by the ESC Initialization. The status of the ESC End of Line (EOL) procedure can be verified using one of the following allowed faults. SAS not calibrated SID 89, FMI 13 ESC initialization required SID 88, FMI 13
Figure 8.1
4007260a
ESC initialization not completed SID 88, FMI 1 NOTE: To prevent incorrect activations, SAS Calibration and ESC Initialization must be done separately. It is necessary to perform the SAS calibration prior to the ESC initialization. For any questions or assistance, please contact the Meritor WABCO OnTrac customer service center at 866-OnTrac1 (668-7221) or visit www.meritorwabco.com for further details. From the message box that appears, click on the Pneumatic ABS button. Figure 8.2.
Figure 8.2
CAUTION
Additional faults must not be active. Any other faults must be resolved before one of the main menu items is available.
SAS Calibration
NOTE: The SAS Calibration must be done after a front wheel alignment has been performed. To access the Meritor WABCO TOOLBOX Software, from the desktop screen, double click on the Meritor WABCO PC Diagnostics (TOOLBOX) icon. Figure 8.1.
Figure 8.2
4007261a
To verify the status of the ESC EOL, from the initial screen, double click on the Faults box. Figure 8.3.
95
Figure 8.3
Figure 8.5
4007262a
4007264a
This message shows the Steering Angle Sensor code SID 89, FMI 13. Figure 8.4.
Figure 8.4
In the message box that appears, click the SAS Calibration button. Figure 8.6.
Figure 8.6
4007263a
Figure 8.4
4007265a
Figure 8.6
To access the ESC EOL, from the bar menu at the initial screen, click on the ESC Menu button. A drop box will illuminate. Select the option End of Line. Figure 8.5.
Follow the instructions in the message box that appears. Figure 8.7.
96
Figure 8.7
Figure 8.8
4007266a
4007267a
The message will let you know when the SAS has been calibrated. Once the SAS is calibrated, press the Close button or the space bar to continue. Figure 8.8.
The SAS calibration is now completed.
ESC Initialization
To verify the status of the ESC Initialization, from the initial screen, double click on the Faults box. Figure 8.9.
Figure 8.9
4007262a
Figure 8.9
The message that appears shows the ESC Initialization Not Complete code SID 88, FMI 1. Figure 8.10.
97
Figure 8.10
Figure 8.12
4007268a
Figure 8.10
4007269a
Figure 8.12
From the bar menu at the initial screen, click on the ESC Menu button. Select the option End of Line. Figure 8.11.
Figure 8.11
Check the message box that appears. Press the space bar or click the Continue button when ready to proceed. Figure 8.13.
Figure 8.13
4007264a
Figure 8.11
This time, click on the ESC Initialization button. Figure 8.12.
4007270a
Figure 8.13
Carefully follow the instructions that are in the message box. Figure 8.14. The ESC Initialization procedure requires that the vehicle be driven to complete.
98
The ATC lamp will start blinking when the 15 mph speed has been reached. When the Straight Driving Adjustment is completed after about 800 feet, the ATC lamp will stop blinking and will be ON solid. NOTE: The Straight Driving Adjustment can be done in segments as the ECU will accumulate the information until the 800 feet is reached, but must be done within the same ignition cycle. Click the Continue button.
Figure 8.14
Figure 8.15
4007272a
Figure 8.15
Read this message box carefully. Figure 8.16. The ATC lamp will start blinking when the required conditions are met. Keep driving until the ATC lamp turns off. Stop the vehicle and click the Continue button.
4007271a
Figure 8.14
This message will appear after the Straight Driving Adjustment is completed. Figure 8.15. Carefully read the message for the Calculation of Steering Ratio and follow the instructions. Click the Continue button and start driving the vehicle in a circle with the steering wheel rotated 360 degrees in one direction. NOTE: The circle driving (Calculation of Steering Ratio) can be done in segments as the ECU will accumulate the information until the desired distance is reached, but must be done within the same ignition cycle. The calibration requires driving in both directions with the steering wheel rotated 360 degrees.
99
Figure 8.16
Figure 8.17
4007273a
4007274a
Turn the steering wheel 360 degrees in the opposite direction and repeat the driving conditions. Again, the ATC lamp will start blinking when the required conditions are met. Keep driving until the lamp turns off. Figure 8.17. Click the Continue button.
A message box (ESC End of Line Data) with the Steering Ratios and Steering Angle Offset values will appear. Click the Close button. Figure 8.18.
100
Figure 8.18
Figure 8.19
4007276a 4007275a
Read the message box and carefully follow the instructions. Click the Close button and cycle the ignition. Figure 8.19.
When the ignition is turned back ON, check that no active or stored faults are logged in the ECU and that the ABS and ATC/ESC warning lamps are OFF. Figure 8.20.
Figure 8.20
4007277a
Figure 8.20
The ESC EOL Initialization procedure is completed.
101
9 Appendix V TOOLBOX Software and Pro-Link Plus Using the TOOLBOXTM Software
9 Appendix V TOOLBOX Software and Pro-Link Plus
Figure 9.2
Display
Select Display from the Tractor ABS Main Screen. A pull down menu will appear. In addition to fault identification and repair information, the display option on the Tractor Main Screen provides Wheel Speed, Memorized Data and RSC Data. Figure 9.1.
Figure 9.1
4004006a
Figure 9.2
Figure 9.3
4005305a
Figure 9.1
Wheel Speed
Select the wheel speed icon or use the Display menu from the ABS Main Screen to display wheel speed data in both numeric and graphical form. This data may be shown in RPM or MPH format, Figure 9.2, and in vertical or horizontal graphs, Figure 9.3 and Figure 9.4. Select the appearance and style from the options menu.
4004007a
Figure 9.3
102
Figure 9.4
RSC Data
Select RSC Data from the pull down menu for RSC status information. Figure 9.6. For RSC Control Status: NA RSC is not an option OFF RSC is installed but is not currently active For Accelerometer sensor: Acceptable range is 2.21-2.78 volts. A red background in this field indicates voltage is outside of the acceptable range.
4004008a
Figure 9.4
Figure 9.6
A green background in this field indicates voltage is within the acceptable range.
Memorized Data
Select Memorized Components from the Display menu. NOTE: Use Display/Memorized Components to view data. Figure 9.5. To clear a memorized component, use the Memorized Components function that appears on the Component Tests Menu.
Figure 9.5
4005307a
Figure 9.6
NOTE: Trailer Brake Valve = RSC Valve
Component Tests
Select Component Tests from the Tractor ABS Main Screen. A pull down menu will appear. Figure 9.7.
4005306a
Figure 9.5
NOTE: Trailer Brake Valve = RSC Valve
103
Figure 9.7
RSC Trailer Valve

Select RSC Trailer Valve from the pull down menu to cycle the RSC trailer valve. Do not activate the service brake while testing the RSC trailer valve. Figure 9.9.
Figure 9.9
4005308a
Figure 9.7
NOTE: Components for test may also be selected from the icons on the Tractor ABS Main Screen. Select Valves from the pull down menu to select and cycle individual ABS modulator valves. Then, listen to ensure the correct valve is cycling. This is also helpful in verifying correct operation, installation and wiring. Figure 9.8.
4005310a
Figure 9.9
Press Start to begin the test. Figure 9.10.
4005311a 4005309a
Select all valves from the menu to cycle all available ABS valves in the order shown below. Verification of the ATC valve is also available from this menu.
104
Lamps
Select Lamps from the pull down menu to turn the tractor ABS, trailer ABS or ATC (wheel spin) indicator lamps on or off. Figure 9.11.
Figure 9.11
Figure 9.13
4005314a
Figure 9.13
4005312a
Figure 9.11
Select Disable ATC from the pull down menu to send a command to the ECU to disable automatic traction control. ATC will remain disabled until the enable command is sent or the vehicle ignition is cycled. The status bar on the Main Screen reflects the current state of the ATC function, either Enabled, Disabled or N/A (not available). Using the Disable ATC command is useful and essential for dynamometer testing. Figure 9.14.
Figure 9.14
This is helpful in verifying correct operation, installation and wiring of the lamps to the ECU.
Relay
Select Relay from the pull down menu to turn the Retarder Relay on or off. Figure 9.12.
Figure 9.12
4005315a
Figure 9.14
Enable ATC
4005313a
Figure 9.12
Select Enable ATC from the pull down menu to send a command to the ECU to enable automatic traction control. This is the normal state of the ECU. The status bar on the Main Screen reflects the current state of the ATC function, either Enabled, Disabled or N/A (not available). Figure 9.15.
This is helpful in verifying correct operation, installation and wiring of the unit under test. Select Engine Data Link from the pull down menu to send a limit engine torque command to the engine or a disable retarder command to the retarder. Figure 9.13.
105
Figure 9.15
TRACTOR ABS/ATC SYSTEM INFORMATION SENSORS MODULATORS 4 4
ATC VALVE RETARDER RELAY J1939

4005316a
YES NO YES YES YES
ABS SWITCH
Figure 9.15
ATC SWITCH
Reset Memorized
Select Reset Memorized from the pull down menu to tell the ECU to reset the memorized or learned components. The ECU has the ability to learn the following components: ATC valve, engine datalink and retarder relay. Once any of these have been detected, the ECU expects to see them each time the ECU is powered on. If they are not seen, the ECU records a fault. There are times when an ECU is moved to another vehicle or during diagnostic testing you may want the ECU to disregard these learned components. Use the Reset Memorized command for this purpose.
Component Test Screens

These screens help you test ABS components. Select this function from the Tractor ABS/ATC menu. ABS VALVES ATC ABS INDICATOR LAMP ATC INDICATOR LAMP ABS/ATC SWITCHES SENSORS ENGINE DATALINK
Pro-Link Plus Display

With some ECUs, the Pro-Link Plus will display system information components or options supported by the ECU. Access these screens through System Setup (main ABS menu). The following screens illustrate: A 4S/4M ABS/ATC system Where the ECU has not recognized a retarder relay Where the ECU has recognized a J1939 datalink The ECU is capable of supporting ABS and ATC switches. NOTE: Yes indicates the ECU is capable of supporting these options. These may or may not be installed on the vehicle.
RETARDER RELAY RETARDER DATALINK VEHICLE VOLTAGES Select the appropriate function. Each screen has instructions to guide you through the test. Refer to the Pro-Link Plus Manual for complete instructions.
Component Tests and Functions (Pro-Link Plus)

These screens help you test ABS components. Select this function from the Tractor ABS/ATC menu.
TRACTOR COMP TESTS SELECTIONS VEHICLE VOLTAGES
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Select the appropriate function. Each screen has instructions to guide you through the test. Refer to the Pro-Link Plus Manual for complete instructions. The following definitions explain the function of each test. Table F: Definitions Component Test Vehicle Voltages ABS Valves Function Monitors the voltage signals powering the ECU. Cycles the valves, one at a time. With brake pedal applied, you should hear four short air exhausts, then one long air pressure hold. A menu selection lets you choose from four or six valves. This test is used to verify valve locations and correct wiring. NOTE: The treadle must be applied to pressurize the brake chambers. ATC Checks the ATC valve. You will hear a click as the valve cycles. NOTE: TOOLBOX Software or the Pro-Link Plus may be used to shut off ATC for dynamometer testing. ABS Tractor Lamp ABS Trailer Lamp ATC Tractor Lamp ABS/ATC Switches Sensors Engine Datalink Retarder Relay Retarder Datalink Monitors the commanded (on/off) states of the ABS tractor lamp. Follow the screen prompts (1 On, 2 Off) to change the status of the lamp on the instrument panel. Monitors the commanded (on/off) states of the ABS trailer lamp. Follow the screen prompts (1 On, 2 Off) to change the status of the lamp on the instrument panel. Monitors the commanded (on/off) states of the ATC tractor lamp. Follow the screen prompts (1 On, 2 Off) to change the status of the lamp on the instrument panel. Checks the status of ABS and ATC/Deep Snow and Mud switches on the instrument panel. Monitors the input to the ECU from the wheel. Vehicle must be stationary and wheels must be rotated during this test. Checks wiring connections and response between the engine and the ECU. Activates the relay to verify function (a click will be heard). This test also checks wiring connections. Checks wiring connections and retarder response between the retarder and the ECU.
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Meritor WABCO Vehicle Control Systems 2135 West Maple Road Troy, MI 48084-7121 866-OnTrac1 (668-7221) Copyright 2011 meritorwabco.com ArvinMeritor, Inc.
Printed in USA Revised 01-11 Maintenance Manual MM-0112 (16579)

MM 0112

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Maintenance Manual MM-0112

Anti-Lock Braking System (ABS) for Trucks, Tractors and Buses

About This Manual

Literature on Demand DVD (LODonDVD)

Before You Begin

How to Obtain Tools and Supplies Specified in This Manual

Hazard Alert Messages and Torque Symbols

How to Obtain Additional Maintenance and Service Information

Meritor WABCO Maintenance Manual MM-0112 (Revised 01-11)

Asbestos and Non-Asbestos Fibers Section 1: Introduction

Section 4: Component Replacement

Section 5: Appendix I System Configurations

Section 6: Appendix II Wiring Diagrams

Section 7: Appendix III Additional ABS Information

Section 3: Diagnostics, Troubleshooting and Testing

Section 8: Appendix IV ESC Calibrations

Section 9: Appendix V TOOLBOX Software and Pro-Link Plus

Asbestos and Non-Asbestos Fibers

ASBESTOS FIBERS WARNING

NON-ASBESTOS FIBERS WARNING

Recommended Work Practices

Recommended Work Practices

Meritor WABCO Maintenance Manual MM-0112 (Revised 01-11)

E PART NUMBER 4003972a

Meritor WABCO Maintenance Manual MM-0112 (Revised 01-11)

Meritor WABCO Maintenance Manual MM-0112 (Revised 01-11)

4S/4M CONFIGURATION ABS ONLY

WHEEL SPEED SENSORS ABS MODULATOR VALVES

ABS MODULATOR VALVE

ABS MODULATOR VALVE

ABS Indicator Lamp

After servicing ABS

Meritor WABCO Maintenance Manual MM-0112 (Revised 01-11)

Trailer ABS Indicator Lamp

Single or Multiple Trailers

t > 3 sec 4003978a

Meritor WABCO Maintenance Manual MM-0112 (Revised 01-11)

Trailer ABS lamp comes on.

Use lamp on side of trailer to identify fault. Make necessary repairs.

Meritor WABCO Maintenance Manual MM-0112 (Revised 01-11)

Single Trailer to Multiples

ABS Modulator Valves

Valve Arrangement Option

Meritor WABCO Maintenance Manual MM-0112 (Revised 01-11)

ABS Valve Packages

Meritor WABCO Maintenance Manual MM-0112 (Revised 01-11)

WHEEL SPEED SENSORS

xxxxx xxxxx xxxxx xxxxx

REAR ABS VALVE PACKAGE

WHEEL SPEED SENSORS

001 20/98 472 500 30. 0

FRONT ABS VALVE PACKAGE AIR LINES ELECTRICAL LINES

4S/4M CONFIGURATION ABS ONLY

Meritor WABCO Maintenance Manual MM-0112 (Revised 01-11)

Automatic Traction Control (ATC)

SENSOR CLIP 1002009b

AIR OUT (PORT 2)

Also available with open-style connector.

PRODUCT IDENTIFICATION TAG 4003992a

The ABS valve package is an alternative to individual valves.

Meritor WABCO Maintenance Manual MM-0112 (Revised 01-11)

xxxxx xxxxx xxxxx xxxxx