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TR
K
C
A
S
Service Notes
Before You Begin
This manual provides correct service and repair
procedures for Meritor WABCOs anti-lock braking
system for trucks, tractors and buses. Before you
begin procedures:
1.
CAUTION
T
NOTE
Access Information on
ArvinMeritors Web Site
Additional maintenance and service information
for ArvinMeritors commercial vehicle systems
component lineup is also available at
www.arvinmeritor.com.
To access information, click on Products &
Services/Tech Library Icon/HVS Publications.
The screen will display an index of publications
by type.
Additional Information
Call ArvinMeritors Customer Service Center at
800-535-5560 to order the following item.
O Drivetrain Plus by ArvinMeritor Technical
Electronic Library on CD. Features product and
service information on most Meritor, ZF Meritor
and Meritor WABCO products. $20. Order
TP-9853.
Table of Contents
Asbestos and Non-Asbestos Fibers Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Section 1: Introduction
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
How ABS Works
ECU Identification
ABS Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
ABS Indicator Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
ABS Modulator Valves
Valve Arrangement Option
ABS Valve Packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
ABS Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Automatic Traction Control
Off-Road ABS
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Table of Contents
Section 4: Component Replacement
Component Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valves
Sensor Lube Specification
Sensors
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ABS Modulator Valve
ATC Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front or Rear ABS Valve Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ATC Valve on the Rear ABS Valve Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
33
34
35
36
The following procedures for servicing brakes are recommended to reduce exposure
to asbestos fiber dust, a cancer and lung disease hazard. Material Safety Data Sheets
are available from ArvinMeritor.
The following procedures for servicing brakes are recommended to reduce exposure
to non-asbestos fiber dust, a cancer and lung disease hazard. Material Safety Data
Sheets are available from ArvinMeritor.
Hazard Summary
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 first exposure to asbestos.
Most recently manufactured brake linings do not contain asbestos fibers. These brake
linings may contain one or more of a variety of ingredients, including glass fibers,
mineral wool, aramid fibers, ceramic fibers 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 efficiency
and can result in serious breathing difficulty. Some scientists believe other types of
non-asbestos fibers, when inhaled, can cause similar diseases of the lung. In addition,
silica dust and ceramic fiber 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 fibers and silica are potential causes of cancer.
Accordingly, workers must use caution to avoid creating and breathing dust when
servicing brakes. Specific recommended work practices for reducing exposure to
asbestos dust follow. Consult your employer for more details.
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.
Revised 04-01
Accordingly, workers must use caution to avoid creating and breathing dust when
servicing brakes. Specific recommended work practices for reducing exposure to
non-asbestos dust follow. Consult your employer for more details.
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.
MM30
Page 1
Section 1
Introduction
Contents
Section 1Introduction
ECU Identification
NOTE: Do not open the ECU. Opening the ECU to
gain access to the internal components will void
the warranty.
C and D version ECUs are easy to distinguish.
Figure 1.2 and Figure 1.3.
1
2
Cab Mounted
Frame Mounted
Figure 1.3
1
2
3
Cab Mounted
Frame Mounted
Basic
Revised 04-01
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Page 3
Section 1
Introduction
The ECU version, C or D, appears on the part
number identification tag. Figure 1.4.
ABS Configuration
Figure 1.4
Manufacturing Information
Part Number
ECU Version
ABS Configuration
Figure 1.5
1002004c
A
B
Air Lines
Electrical Lines
1
2
3
4
Relay Valve
ECU
4S/4M Configuration
NOTE: 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 Appendix I.
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Page 4
Revised 04-01
Section 1
Introduction
ABS Indicator Lamp
The ABS indicator lamp works as follows:
Ignition ON
Normal Operation
System is O.K.
Existing Fault
Figure 1.6
Revised 04-01
A
B
4 Channel
6 Channel
1
2
Cab
Curbside
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Page 5
Section 1
Introduction
ABS Valve Packages
The front ABS valve package combines a quick release 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. The valve package front or rear
must be mounted near the brake chambers it serves. Figure 1.7.
Figure 1.7
x
x xxxx x
xxxx x xxxx
xxxx
5
6
001 20/98
472 500 30. 0
MADE IN GERMANY
A
B
1002007e
A Air Lines
B Electrical Lines
1
2
3
4
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Page 6
Revised 04-01
Section 1
Introduction
ABS Sensors
ABS sensor systems consist of a tooth wheel
mounted on the hub 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:
O Steering axle sensors are installed in the
steering knuckle or in a bolted-on bracket.
O Drive axle sensors are mounted in a block
attached to the axle housing or in a bolted-on
bracket.
Off-Road ABS
On some vehicles, an off-road ABS function may
be selected. This optional feature improves vehicle
control and helps reduce stopping distances in
off-road conditions or on poor traction surfaces
such as loose gravel, sand and dirt.
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.
Revised 04-01
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Page 7
Section 1
Introduction
System Components
Figure 1.8
1002008a
1
2
3
Cab-Mounted ECU
Frame-Mounted ECU
D Basic ECU
Figure 1.9
A tooth wheel (A) is mounted at, or cast in, the hub
of each sensed wheel, with a sensor (B) installed
so that its end is against the tooth wheel. A sensor
clip (C) holds the sensor in place at the tooth
wheel. Figure 1.9.
NOTE: The sensor and clip must be greased with
Meritor WABCO-recommended lubricant. Refer to
Sensor Lube Specification in Section 4 for lube
specification.
Figure 1.10
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Page 8
Air In (Port 1)
Air Out (Port 2)
Revised 04-01
Section 1
Introduction
Figure 1.11
Figure 1.12
Figure 1.13
Figure 1.14
Revised 04-01
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Page 9
Section 1
Introduction
Figure 1.15
1002014a
Available from SPX (Kent-Moore), 800-328-6657
Figure 1.16
Easy-Stop
1005521b
Available from SPX (Kent-Moore), 800-328-6657
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Page 10
Revised 04-01
Section 2
Automatic Traction Control (ATC)
ATC
Figure 2.2
Figure 2.3
Figure 2.1
1002017b
ABS/ATC Valve Package
1002015a
Revised 04-01
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Page 11
Section 2
Automatic Traction Control (ATC)
Deep Snow and Mud Switch
ATC Components
System
Response
Press switch
again
Active
Not
Active
1
2
3
ATC Valve
ABS/ATC Valve Package
Cable
X
X
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Page 12
Revised 04-01
Section 3
Troubleshooting & Testing
General Maintenance
Information
Section 3Troubleshooting & Testing
Figure 3.1
LAMP CHECK
To make sure the ABS 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.
System Diagnostics
2
1005522a
1
2
3
Serial Cable
J1708-to-RS232 Connector
To Vehicle J1587 Connector
O TOOLBOX Software
O Blink Code Diagnostics
O Pro-Link 9000
O OEM Diagnostic Displays (refer to Vehicle
Operators Manual)
TOOLBOX Software
NOTE: For complete instructions for using
TOOLBOX Software, refer to the Users Manual.
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.
Revised 04-01
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Page 13
Section 3
Troubleshooting & Testing
3. From the Main Menu, select Tractor ABS
Diagnostics, or use the pull down menu to
make your selection. Figure 3.3. The ABS Main
Screen will appear. Figure 3.4.
Figure 3.5
Figure 3.3
Figure 3.4
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Revised 04-01
Section 3
Troubleshooting & Testing
Blink Code Diagnostics
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.
1
2
Number of Flashes
ABS Configuration
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.
Revised 04-01
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Page 15
Section 3
Troubleshooting & Testing
Blink Code Diagnostics
Troubleshooting with Blink Code Diagnostics
Mode
Procedure
System Response
Step I.
Possible responses:
A.
B.
C.
O
O
DIAGNOSTIC
O
O
Step II.
Press and hold Blink Code
Switch for one second, then
release.
Step III.
Count the flashes to determine
the blink code.
Step IV.
ECU disconnected.
Connect ECU.
Stored Faults.
Action
CLEAR
Step V.
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Page 16
Revised 04-01
Section 3
Troubleshooting & Testing
Blink Codes Illustrated
Figure 3.8
Revised 04-01
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Page 17
Section 3
Troubleshooting & Testing
Blink Codes Illustrated (Continued)
1002022a
Reason
Action
Check bulb.
Check connections.
Make necessary repairs.
Check connections.
Measure voltage.
Make necessary repairs.
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Page 18
Revised 04-01
Section 3
Troubleshooting & Testing
Blink Code Identification
Use the following information to identify the blink code:
Blink Code Identification
First Digit (Type of Fault)
No faults
No Faults
Tooth wheel
ATC valve
ATC configuration
Internal fault
Ground
System function**
ECU
* Tandem, lift, tag or pusher axle depending upon the type of suspension.
** 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 reconthe ECU.
Contact ArvinMeritors Customer Service Center at 800-535-5560 for reconfiguration
information.
Revised 04-01
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Page 19
Section 3
Troubleshooting & Testing
Blink Code Troubleshooting and Repair
Blink Code
Action Required
Reference
2-1
2-4
2-2
2-5
2-3
2-6
3-1
3-4
3-2
3-5
3-3
3-6
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
Check for proper data link connection (J1922 and J1939).
Verify wheel spin on each axle.
7-1*
7-2*
Verify 7 to 14 ohms resistance for a 12-volt system, 28-49 ohms resistance for a
24-volt system.
7-3*
7-4*
7-6*
8-1
8-4
* 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. Contact ArvinMeritors Customer Service Center at 800-535-5560 for
reconfiguration information.
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Page 20
Revised 04-01
Section 3
Troubleshooting & Testing
J1922 or J1939 Datalink Verification
The Pro-Link diagnostic tool provides the easiest way to verify the J1922 or J1939 datalink connection.
If you do not have a Pro-Link, you can use the blink code switch to verify this connection.
1.
A.
B.
C.
2.
A.
B.
C.
3.
Revised 04-01
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Page 21
Section 3
Troubleshooting & Testing
Component Tests and
Functions
Figure 3.10
TOOLBOX Software
NOTE: Refer to page 22 of this manual for
instructions for running TOOLBOX Software, or
refer to the Software Owners Manual, TP-99102,
for complete instructions.
Use TOOLBOX Software to display wheel speeds,
cycle ABS valves, activate ABS and ATC lamps,
including the trailer ABS lamp, and turn the
retarder relay on or off. In addition, the J1939
engine datalink connection may be quickly verified
by using TOOLBOX Software.
Wheel Speed
Select the wheel speed icon or use the pull 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 format
(Figure 3.9) and in vertical or horizontal graphs
(Figure 3.10 and Figure 3.11). Select the
appearance and style from the options menu.
Figure 3.11
Figure 3.9
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Page 22
Revised 04-01
Section 3
Troubleshooting & Testing
Valve Activation
Select the Engine Data Link icon from the Main ABS
Screen or use the pull down menu to send a limit
engine torque command to the engine or a disable
retarder command to the retarder. Figure 3.14.
Figure 3.14
Figure 3.12
Lamp Activation
Select the lamp icon or use the pull down menu to
turn the tractor and trailer ABS and/or the ATC
(wheel spin) lamps on or off. This is helpful when
verifying proper operation, installation and wiring
of the lamps to the ECU. Figure 3.13.
Figure 3.13
Revised 04-01
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Page 23
Section 3
Troubleshooting & Testing
Select the Enable ATC icon or use the pull down
menu on the ABS Main Screen to send a command
to the ECU to enable ATC. This is the normal state
of the ECU. Figure 3.16.
Figure 3.16
Component Tests
Components that may be tested with the Pro-Link
9000 are:
O
O
O
O
O
O
O
O
O
Vehicle Voltages
ABS Modulator Valves
ATC Valves
ABS/ATC Indicator Lamps
Sensors
Engine Datalink
Retarder Relay
Retarder Datalink
ABS/ATC Switches
1002033a
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Page 24
Revised 04-01
Section 3
Troubleshooting & Testing
4. Turn the ignition to the ON/RUN position. The
Pro-Link screen should power up.
If the Pro-Link does not power up, or if the
screen indicates NO DATA RECEIVED:
O Check connections.
O Make sure the cartridge is properly
connected to the Pro-Link keypad.
O Verify 9.5-14 volts (12-volt system) or
18-30 volts (24-volt system) DC power and
ground at the connector and ABS ECU.
O Check the fuse panel for a blown fuse.
O Check for proper wiring in the diagnostic
connector.
5. Refer to the Pro-Link manual for complete
diagnostic and testing instructions.
The Pro-Link 9000 is available
from Kent-Moore, 800-328-6657.
Pro-Link Screens
Pro-Link Display
Depending upon the ECU being tested, the
Pro-Link screen will display certain options or
components only when recognized by the ECU.
These include:
O
O
O
O
J1922*
Revised 04-01
EXISTING FAULT
YES
STORED FAULTS
YES
DATA LINK
J1922
EXISTING FAULT
YES
STORED FAULTS
YES
SELECTIONS
EXISTING FAULT
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Page 25
Section 3
Troubleshooting & Testing
Press ENTER to select. The following screen
appears.
The first line displays the number of existing faults
(1 of 1), the blink code (2-3), and the number of
times the fault occurred (1 time). Lines two and
three provide a written description of the fault.
1 of 1
(2, 3)
1X
FAULTS. REPAIR
EXISTING FAULT(S)
[ENTER] TO CONTINUE
DATA LINK
REPAIR EXISTING
FAULT
[FUNC] TO EXIT
J1922*
EXISTING FAULT
NO
STORED FAULTS
YES
SELECTIONS
STORED FAULTS
DATA LINK
J1922
EXISTING FAULT
NO
STORED FAULTS
YES
1 of 1
(2, 3)
1X
SELECTIONS
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Page 26
STORED FAULTS
Revised 04-01
Section 3
Troubleshooting & Testing
Press ENTER to display stored faults.
Pro-Link displays number, blink code, number of
occurrences, and written description of stored
faults.
1 of 1
(2, 3)
2X
ABS VALVES
ATC
ABS INDICATOR LAMP
ATC INDICATOR LAMP
ABS/ATC SWITCHES
SENSORS
ENGINE DATALINK
RETARDER RELAY
RETARDER DATALINK
Select the appropriate function. Each screen has
instructions to guide you through the test. Refer to
the Pro-Link Manual for complete instructions.
System Information
With some ECUs, the Pro-Link will display system
information components or options supported
by the ECU. Access these screens through System
Setup (main ABS menu).
The following screens illustrate:
O A 4S/4M ABS/ATC system
O Where the ECU has not recognized a retarder
relay
O Where the ECU has recognized a J1922 or J1939
datalink
O The ECU is capable of supporting ABS and ATC
switches (these may not be installed on the
vehicle)
TRACTOR ABS/ATC
STORED FAULT(S)
SYSTEM INFORMATION
CLEARED
SENSORS
MODULATORS
[ENTER] TO CONTINUE
ATC VALVE
RETARDER RELAY
J1922
J1939
DIFF LOCK
ABS SWITCH
ATC SWITCH
YES
NO
YES
NO
NO
YES
YES
VEHICLE VOLTAGES
Revised 04-01
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Page 27
Section 3
Troubleshooting & Testing
The following definitions explain the function of
each test.
Component
Test
Function
Vehicle
Voltages
ABS Valves
ATC
ATC Lamp
ABS/ATC
Switches
Sensors
Engine
Datalink
Retarder
Relay
Retarder
Datalink
RPM Steer
RPM Drive
x 100
ABS Lamp
Testing Components
CAUTION
When troubleshooting and testing the ABS
system, do not damage the connector terminals.
Voltage Check
Measure voltage at the pins indicated in Table A.
O Voltage must be between 9.5 and 14 volts for a
12-volt system (18 and 30 for a 24-volt system).
O The ignition must be turned ON for this test.
Table A: Voltage Check Pins
ECU
Connector
Pins
Cab-Mounted
18-Pin
7 and 10
8 and 11
9 and 12
Basic
15-Pin
7 and 4
8 and 9
Frame-Mounted
X1-Grey
1 and 12
2 and 11
Location of Sensors
On steering axles, the sensor is accessible on the
in-board side of the steering knuckle.
On drive axles, the drum assembly may have to be
pulled to gain access to the sensor.
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Page 28
Revised 04-01
Section 3
Troubleshooting & Testing
Sensor Adjustment
Sensor Resistance
1.
Sensor
Connector
Pins
Cab-Mounted
LF
6-Pin
4 and 5
RF
9-Pin
4 and 5
LR
15-Pin
5 and 6
RR
15-Pin
8 and 9
LR (3rd Axle)
12-Pin
5 and 6
RR (3rd Axle)
12-Pin
8 and 9
LF
18-Pin
12 and 15
RF
18-Pin
10 and 13
LR
18-Pin
11 and 14
RR
18-Pin
17 and 18
LF
X2 Black
7 and 8
RF
X2 Black
5 and 6
LR
X3 Green
1 and 2
RR
X3 Green
3 and 4
LR (3rd Axle)
X4 Brown
3 and 4
RR (3rd Axle)
X4 Brown
5 and 6
Basic
FrameMounted
Revised 04-01
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Page 29
Section 3
Troubleshooting & Testing
Valve Tests
ATC Valve
Figure 3.18
Open-Style Connector
3
1
2
3
1002034b
Ground Terminal
Exhaust Solenoid (blue wire)
Inlet Solenoid (brown wire)
Bayonet-Style Connector
3
1002034b
1
2
3
MM30
Page 30
Revised 04-01
Section 4
Component Replacement
Component Removal
and Installation
Section 4Component Replacement
Valves
O ABS Modulator Valves
Sensors
Wheel Speed Sensor Removal
Front Axle
To remove the sensor from the front axle:
O ATC Valve
O ABS Valve Package (Front or Rear)
Modulator Valves
Relay Valve or Quick Disconnect Valve
ATC Valve
WARNING
To prevent serious eye injury, always wear safe eye
protection when you perform vehicle maintenance
or service.
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
can result.
1.
CAUTION
Use the following procedures to avoid damage to
the electrical system and ABS/ATC components.
Knuckle-Mounted Sensor
Revised 04-01
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Page 31
Section 4
Component Replacement
Wheel Speed Sensor Installation
Front Axle
1.
1.
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 can result.
1.
1
2
3
4
Spring Clip
Sensor Holder
Spring Clip Tab
Sensor
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Page 32
Revised 04-01
Section 4
Component Replacement
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.
Figure 4.3
Valves
ABS Modulator Valve
Removal
1.
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 can result.
2. Put blocks under the front and rear tires to stop
the vehicle from moving.
3. If necessary, raise the vehicle off the ground
and put safety stands under the axle.
4. Disconnect the wiring connector from the
ABS valve.
5. Disconnect the air lines from Ports 1 (air
supply) and 2 (air discharge) of the ABS valve.
Figure 4.3.
1
2
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.
To install the ABS modulator valve:
1.
Revised 04-01
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Section 4
Component Replacement
Checking the Installation
Figure 4.4
ATC Valve
Removal
1.
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 can result.
2. Put blocks under the front and rear tires to stop
the vehicle from moving.
3. If necessary, raise the vehicle off the ground.
Put safety stands under the axle.
1
2
3
4
5
6
7.
Air Lines
Port 1 (Air Supply)
Air Line
Port 3 (Treadle)
Valve Control Do Not Open
Port 2 (Air Discharge)
Installation
1.
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Revised 04-01
Section 4
Component Replacement
Checking the Installation
Figure 4.6
Start vehicle.
1
2
3
4
5
6
7
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 can result.
1.
Revised 04-01
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Section 4
Component Replacement
Removal and Replacement
Component Valves
WARNING
1002041c
1
2
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Revised 04-01
Section 4
Component Replacement
7.
Figure 4.9
1
2
3
4
5
1
2
3
4
5
6
7
Mounting Bolts
ATC Valve
Treadle Air Line
Seal
O-Rings
Supply Air Line
Adapter
Installation
1.
Revised 04-01
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Section 4
Component Replacement
3. 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 Nm).
Figure 4.11. T
Figure 4.11
1
2
3
4
5
6
Supply Port
ATC Valve and Adapter
Control Port
ABS Valve Package
O-Ring (Installed)
Mounting Bolts 4-5 lb-ft (6-8 Nm)
Start vehicle.
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Revised 04-01
Appendix I
System Configuration Layouts
System Configuration Layouts
A
B
C
A
B
C
A
B
C
1
2
3
AIR LINES
ELEC. LINES
LAMPS (UP TO THREE: ABS, TRAILER ABS, ATC)
VALVE PACKAGE INSTALLATION (FRONT)
VALVE PACKAGE INSTALLATION (REAR)
LAMPS (UP TO THREE: ABS, TRAILER ABS, ATC)
1003363f
A
B
C
1
2
3
AIR LINES
ELEC. LINES
LAMPS (UP TO THREE: ABS, TRAILER ABS, ATC)
VALVE PACKAGE INSTALLATION (FRONT)
VALVE PACKAGE INSTALLATION (REAR)
LAMPS (UP TO THREE: ABS, TRAILER ABS, ATC)
1003365f
6S/4M ABS
2
A
B
C
A
B
C
1
2
3
AIR LINES
ELEC. LINES
LAMPS (UP TO THREE: ABS, TRAILER ABS, ATC)
VALVE PACKAGE INSTALLATION (FRONT)
VALVE PACKAGE INSTALLATION (REAR)
LAMPS (UP TO THREE: ABS, TRAILER ABS, ATC)
1003364f
Revised 04-01
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Appendix I
System Configuration Layouts
D Version 4S/4M ABS/ATC
1
1
A
B
C
A
B
A
B
1
2
AIR LINES
ELEC. LINES
VALVE PACKAGE INSTALLATION (FRONT)
VALVE PACKAGE INSTALLATION (REAR)
1003366g
A
B
C
1
2
3
AIR LINES
ELEC. LINES
LAMPS (UP TO THREE: ABS, TRAILER ABS, ATC)
VALVE PACKAGE INSTALLATION (FRONT)
VALVE PACKAGE INSTALLATION (REAR)
LAMPS (UP TO THREE: ABS, TRAILER ABS, ATC)
1003368f
1
A
B
A AIR LINES
B ELEC. LINES
1 VALVE PACKAGE INSTALLATION (FRONT)
2 VALVE PACKAGE INSTALLATION (REAR)
1003367g
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Revised 04-01
Appendix II
Wiring Diagrams
Revised 04-01
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Appendix II
Wiring Diagrams
D Basic ECU All D Basic ECUs Are Cab-Mounted
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Revised 04-01
Appendix II
Wiring Diagrams
Revised 04-01
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Appendix II
Wiring Diagrams
D Version Cab-Mounted ABS/ATC ECU
1002048b
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Revised 04-01
Appendix II
Wiring Diagrams
Revised 04-01
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Appendix II
Wiring Diagrams
D Version Frame-Mounted ABS/ATC ECU
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Revised 04-01
Appendix II
Wiring Diagrams
Revised 04-01
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Appendix III
Additional ABS Information
Troubleshooting Guide Meritor WABCO ABS Valve Package
This Troubleshooting Guide 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.
ABS Valve Package Troubleshooting Guide
Condition
Possible Cause
Recommended Action
Broken wire.
or
Loose or broken terminal
connection.
Corroded connector pins.
or
Problem with solenoid.
1
2
3
ABS valve package damaged.
Ground Terminal
Exhaust Solenoid (blue wire)
Inlet Solenoid (brown wire)
O Road Hazards.
or
O Vehicle Damage.
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Revised 04-01
Appendix III
Additional ABS Information
Reconfiguration Procedure
How to Reconfigure an ECU
(D Version)
Before reconfiguring the ECU, contact
ArvinMeritors Customer Service Center at
800-535-5560 for additional information.
Result
Reason
Revised 04-01
Successfully reconfigured.
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Appendix III
Additional ABS Information
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Revised 04-01
Information contained in this publication was in effect at the time the publication was approved for
printing and is subject to change without notice or liability. Meritor WABCO reserves the right to revise
the information presented or to discontinue the production of parts described at any time.
Copyright 2001
ArvinMeritor, Inc.
All Rights Reserved
Printed in USA
Maintenance Manual 30
Revised 04-01
16579/22882