Abs Wabco Habs
Abs Wabco Habs
Installation Guide
Hydraulic Anti-Lock Braking System (HABS) Installation Guide for OEMs and Body Builders (Includes Body Builder Installation Information)
D Version Hydraulic ABS
This guide addresses frequently asked questions regarding Meritor WABCO D Version Hydraulic ABS components and installation procedures for trucks, buses, and motor home chassis. It also includes information for body builders who are modifying or altering vehicle chassis equipped with Meritor WABCO Hydraulic ABS. An example of a typical hydraulic ABS installation appears on page 4 of this bulletin. This publication is to be used as an OEM installation reference guide only. If service or maintenance is required on Hydraulic ABS and related components, follow the complete instructions and procedures found in Maintenance Manual 39, Hydraulic ABS for Medium-Duty Trucks, Buses and Motor Home Chassis.
Contents
General Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Electronic Control Unit (ECU) Electrical Wiring, Cables and Connectors Tire Size Range and Mismatch ABS Indicator Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Sensor/Tooth Wheel ABS Modulator Assembly Blink Code Diagnostic Switch SAE J1587 Diagnostics Data Link System Layouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 System Wiring Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Cab-Mounted ECU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Frame-Mounted ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Modulator Assembly Connector Pin Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Meritor WABCO D Version Hydraulic ABS Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Hydraulic ABS Bleeding Procedures for Prelled (Wet) Modulator Assembly . . . . . . . . . . . . . . . . . . . . . . . .13 Pressure Fill and Bleed (Wet Modulator Assembly) Manual Bleed Procedure (Wet Modulator Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Hydraulic ABS Bleeding Procedure for Unlled (Dry) Modulator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .15 Evacuation and Fill Procedure Manual Bleed Procedure with Electronic Control Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Body Builder Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
WARNING
To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. To avoid damage to the electrical system or ABS components when welding on an ABS-equipped vehicle, disconnect the power connector from the ECU.
General Guidelines
r To avoid damage to internal components, do not store ABS parts in areas where temperatures exceed 194F (90C). r ABS components must be installed where they are best protected from the environment, yet accessible for service. r Inspect each vehicle installation using the Meritor WABCO Diagnostic Controller with Hydraulic ABS program card or Meritor WABCO TOOLBOX Software, a PC-based diagnostics program. A sample checklist that can be used to record the results of these inspections appears on page 11. You may want to make extra copies of this form.
Figure 1
MOTOR
5 5 5 TO 30
Sensor/Tooth Wheel
r Ensure total tooth wheel runout does not exceed 0.008-inch. r Do not install tooth wheels that show signs of damage such as chipped, deformed or missing teeth. r At installation, the sensor must be installed to initially contact the tooth wheel. The center of the sensor must contact the tooth wheel near the center of the tooth width, at least 0.12-inch (3 mm) from the edge of the tooth. Meritor WABCO specications call for a sensor lubricant with the following characteristics: Lube must be mineral oil-based and contain molydisulde. 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).
r Mount hydraulic brake lines on the chassis in areas where they will not be pinched or scraped. The inside of the frame rail is ideal for mounting hydraulic brake lines. r Whenever any hydraulic brake system components are installed, ttings are loosened, or lines are disconnected, air can enter the system. This air must be removed from the brake system to allow sufcient hydraulic pressure for applying the brakes. Follow the instructions in Hydraulic ABS Bleeding Procedures for Prelled (Wet) Modulator Assembly/ found in this installation guide (pages 13-15), or in Maintenance Manual 39. r All prelled (Wet) modulators require a manual or pressure bleed procedure. Follow the instructions in Hydraulic ABS Bleeding Procedures for Prelled (Wet) Modulator Assembly on page 13. r All unlled (Dry) modulators require a ll and bleed procedure that activates each solenoid valve in order to remove air trapped in the valve cavities. Follow the instructions in Hydraulic ABS Bleeding Procedure for Unlled (Dry) Modulator Assembly on page 15.
System Layouts
A typical Meritor WABCO Hydraulic ABS with cab-mounted ECU is illustrated below. Figure 2. Figure 2
ECU BRAKE ABS INDICATOR LAMP
BRAKE
BRAKE
A typical Meritor WABCO Hydraulic ABS with frame-mounted ECU is illustrated below. Figure 3. Figure 3
ECU
BRAKE
BRAKE
CAB
1 2 3 4 5 6 7 10 13 8 11 14 9 12 15
1 2 3
4 5 6
7 8 9
1 2 3
4 5 6
7 8 9
10 13 16 11 14 17 12 15 18
Figure 4
M
RECIRCULATION PUMP MOTOR MONITOR 86 87 30 PUMP RELAY SENSOR FRONT RIGHT 85 SENSOR FRONT LEFT REAR RIGHT REAR LEFT FRONT RIGHT FRONT LEFT
12V IV OV IV OV IV +
INDEPENDENT FUSED IGNITION CONNECTION (E.G. USED FOR 5A OTHER WARNING CIRCUITRY) MAX. 2W (ORANGE) IGNITION ABS INDICATOR LAMP ABS INDICATOR LAMP BLINK CODE SWITCH GROUND
18 12 15
1 4 7
10
13
16
2 5 8
11
14
17
CAB
12
15
18
12
13
7 6 3
PUMP RELAY
RETARDER RELAY
REFERENCE GROUND
12
15
10
13
11
14
12
15
FRAME
Figure 5
VALVE
VALVE
VALVE
VALVE
VALVE
VALVE
VALVE
OUTLET
OUTLET
OUTLET
OUTLET
VALVE
12 AWG
5A
5A
25A
11
10
12
13
3
UES
MOTOR MONITOR
PUMP RELAY
MAX. 2W (ORANGE) 85 30
GROUND 14 AWG
RETARDER
86
87a
10
10
6 10 2
11
12
FRAME
USE A WIRE GAUGE OF 16 AWG WHERE NOT SPECIFIED. RECIRCULATION PUMP MOTOR MONITOR 12 AWG PUMP RELAY 30 85 86 87
SENSOR REAR RIGHT REAR RIGHT REAR LEFT FRONT RIGHT FRONT LEFT
30A
15
30
14 AWG
13 12
11 10
10 11
12 13
PUMP CONNECTOR
MAIN GROUND
+ -
Pin Number
1 2 3 4 5 6 7
Circuit Description
Outlet Valve RL Inlet Valve RL Inlet Valve FR Outlet Valve FR
Pin Number
8 9 10 11 12 13
Circuit Description
Reference Ground Outlet Valve RR Inlet Valve RR Inlet Valve FL Outlet Valve FL
YES
5. Perform component tests for each sensor and modulator valve operation which checks both the location and function. For sensors, spin each wheel indicated at 1/2 revolution per second, approximately 30 rpm, which should indicate about 2 mph on the Diagnostic Controller screen. For modulator valves, lightly depress brake pedal until indicated wheel is hard to turn. Press Continue on Diagnostic Controller. The brake should release and reapply four times during the rst part of the test (T1) and should not release during the second part of the test (T2). NO (Repair and retest.)
Function Tested Front Right Sensor (FR) FR Modulator Valve Front Left Sensor (FL) FL Modulator Valve Rear Right Sensor (RR) RR Modulator Valve Rear Left Sensor (RL) RL Modulator Valve
System Performs as Described 3 mph indicated Brake performs as described 3 mph indicated Brake performs as described 3 mph indicated Brake performs as described 3 mph indicated Brake performs as described
YES
6. ABS Lamp goes out approximately four seconds after turning ignition on. (After initial drive exceeding speed of 5 mph.)
YES
NO
Notes
CAUTION
Hydraulic brake uid is a caustic substance. Contact with hydraulic brake uid can case skin irritation. Do not let hydraulic brake uid touch any painted surfaces, as it will remove the paint. Hydraulic brake uid may also damage certain non-metal surfaces. Do not let uid get on brake pads, shoes, rotors or drums.
WARNING
Failure to bleed the system whenever any hydraulic system tting is loosened or disconnected will allow air to remain in the system. This will prevent the hydraulic pressure in the brake system from rising enough to apply the brakes properly. This will cause the stopping distance to increase and can result in serious personal injury. Properly discard hydraulic brake uid that is removed from the brake system. Hydraulic brake uid that is removed can be contaminated and can cause damage, loss of braking and serious personal injury. Use only DOT 3 or DOT 4 hydraulic brake uid, as specied by the original equipment manufacturer. Do not use or mix different types of hydraulic brake uid. The wrong hydraulic brake uid will damage the rubber parts of the brake caliper and can cause damage, loss of braking and serious personal injury.
NOTE: Use DOT 3 or DOT 4 hydraulic brake uid. Refer to the vehicle specications to determine which uid to use.
5. Turn on bleed equipment until uid level in reservoir reaches approximately 0.875-inches (20 mm). 6. Release pressure for 3 to 5 seconds. Apply pressure for 5 to 10 seconds. 7. Repeat Steps 5 and 6 approximately 10 times. After releasing the pressure, air bubbles should rise up into the reservoir.
10. 11.
WARNING
Do not let the brake master cylinder uid get below the minimum level during the bleeding operation. Keep the master cylinder reservoir lled with new DOT-approved brake uid as specied by the original equipment manufacturer. Failure to keep the brake reservoir level above minimum could result in more air entering system, making it impossible to effectively bleed the system.
8. Bleed the brake system: r Set lling pressure to 20 to 30 psi (1.5 to 2.0 bar). r Put a wrench on the brake actuator bleeder tting. Start with the farthest from the modulator, (typically the right rear), then attach a length of clear plastic tubing to the bleeder tting. Make sure the tube ts snugly. 9. Submerge the tubing in a container of clean hydraulic brake uid. Figure 7. NOTE: Both the tubing and container must be able to withstand the effects of hydraulic brake uid. Figure 7
12.
13.
Loosen the bleeder tting until the uid begins to ow (about 3/4 turn). Let the hydraulic uid ow out of the tting until it is free of air bubbles. Tighten rmly to secure the tting. Repeat Steps 5 through 8 to bleed the remaining three brake actuators. Bleed in sequence of the longest to shortest circuit from the modulator assembly. Turn off bleed equipment and remove pressure. Remove bleed device and check uid level in reservoir. Fill if required. Replace reservoir cap and dispose of used brake uid. Remove wheel chocks.
WARNING
Do not let the brake master cylinder uid get below the minimum level during the bleeding operation. Keep the master cylinder reservoir lled with new DOT-approved brake uid as specied by the original equipment manufacturer. Failure to keep the brake reservoir level above minimum could result in more air entering system, making it impossible to effectively bleed the system.
6. Bleed the brake system. Put a wrench on the brake actuator bleeder tting. Start with the farthest from the modulator, (typically the right rear), then attach a length of clear plastic tubing to the bleeder tting. Make sure the tube ts snugly. 7. Submerge the tubing in a container of clean brake uid. Figure 7. NOTE: Both the tubing and container must be able to withstand to the effects of brake uid.
8. Depress the brake pedal 10 to 15 times, using the maximum available stroke. 9. Loosen the bleeder tting until the uid begins to ow, (about 3/4 turn), while depressing the brake pedal through its maximum available stroke. 10. Tighten the tting rmly prior to releasing the brake pedal. 11. Repeat Steps 6 through 8 several times until the discharged uid is free of air bubbles. 12. Repeat Steps 3 through 9 to bleed the remaining three brake actuators. Bleed in sequence of the longest to the shortest circuit from the modulator. 13. Check the travel of the brake pedal. If a rm resistance is felt the manual bleeding procedure is complete. 14. Check the uid level in reservoir and ll if required. Replace reservoir cap and dispose of used brake uid. 15. Remove wheel chocks.
WARNING
Failure to bleed the system whenever any hydraulic system tting is loosened or disconnected will allow air to remain in the system. This will prevent the hydraulic pressure in the brake system from rising enough to apply the brakes properly. This will cause the stopping distance to increase and can result in serious personal injury. Properly discard hydraulic brake uid that is removed from the brake system. Hydraulic brake uid that is removed can be contaminated and can cause damage, loss of braking and serious personal injury. Use only DOT 3 or DOT 4 hydraulic brake uid, as specied by the original equipment manufacturer. Do not use or mix different types of hydraulic brake uid. The wrong hydraulic brake uid will damage the rubber parts of the brake caliper and can cause damage, loss of braking and serious personal injury.
CAUTION
Hydraulic brake uid is a caustic substance. Contact with hydraulic brake uid can case skin irritation. Do not let hydraulic brake uid touch any painted surfaces, as it will remove the paint. Hydraulic brake uid may also damage certain non-metal surfaces. Do not let uid get on brake pads, shoes, rotors or drums.
2. Evacuate system to 2.2 mmHg (0.0425 lbs per square inch absolute [psia]/3 mbar), measured at the furthest brake, for approximately 60 seconds. 3. Check for vacuum leakage for 10 seconds. If pressure rises above 6.65 mmHg (0.13 psia/9 mbar), then additional evacuation is required for approximately 10 seconds. 4. Brake uid lling phase requires pressure to reach 14.5 to 43.5 psi (1 to 3 bar) measured at the brake. Filling time approximately 30 to 60 seconds.
10. Repeat Steps 5 through 9 for the remaining 2 brake actuators. NOTE: If a rm brake pedal resistance is felt and the brake pedal pushes back when the solenoids and pump are simultaneously actuated for each brake circuit, the system bleed procedure is complete. If there is no rm pedal resistance, repeat the bleed procedure and/or look into brake system defect, (leaks, etc.).
Notes
Notes
Meritor WABCO Vehicle Control Systems 3331 West Big Beaver Road, Suite 300 Troy, MI 48084 USA 800-535-5560 www.arvinmeritor.com
Information contained in this publication was in effect at the time the publication was approved for printing and is subject to change without notice or liability. Meritor WABCO reserves the right to revise the information presented or discontinue the production of parts described at any time. Copyright 2000 Meritor WABCO All Rights Reserved TP-99124 Revised 09-00 16579/24240