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Section 7(End of Line Testing)

End of Line Testing

End of line testing is required on all Enhanced Easy-Stop installations.  To run these tests, Meritor WABCO recommends you use TOOLBOX Software.

TOOLBOX Software and general test procedures are included in this manual.  If you are using a Pro-Link, refer to the operating manual for test instructions.

End of Line Testing Procedure Using TOOLBOX  Software (All Installations)

NOTE:  If you are testing an installation that has power only cable, temporarily install a Meritor WABCO combination power/diagnostic "Y" style cable or use the PLC/J1708 Adapter.

1. Connect the diagnostic connector on the cable to the PC serial port/SAE diagnostic interface (J1587/J1708 to RS232 interface).

NOTE:  Refer to the Software Owner's Manual, TP-99102, for instructions for running TOOLBOX Software.

2. Display the Trailer ABS Main Screen

3. Verify power supply.

Apply 12 volts DC to the blue wire (constant).  Check the screen for proper voltage (9.5 to 14 volts). Constant power voltage is displayed in the Primary field. Figure 7.3.

Apply 12 volts DC to the red wire (stoplight power). Check the screen for proper voltage (9.5 to 14 volts). Stoplight power voltage is displayed in the Secondary field. Figure 7.3.

NOTE:  The internal field is not applicable to this test.

4. Check the Faults field on the Main Screen:

NONE =  No faults present, proceed with end of line test.

YES    =  Faults present, double click on "YES" to bring up the fault information screen

Figure 7.3

Use the information in the Repair Instructions field to make the necessary repairs.  Figure 7.4.

Figure 7.4

Verify Proper Valve and Lamp Installation

(2S/1M Basic)

To verify valve and lamp installations with TOOLBOX Software:

1. At the Trailer Main Screen click on Components Test, then select Valves/Lamps to display the Valve Activation Screen.  Figure 7.5.

2. The Red valve indicator will be selected.  Click on the Activate button and listen for the valve to click, indicating a good installation.  The Test Status box at the bottom of the menu will also display the status of this test.

3. Click on the Test button to activate the ABS indicator lamp --  this lampis the lamp that is mounted on the side of the trailer.  The lamp will flash eight times, indicating lamp installation is OK.  The Test Status box at the bottom of the menu will also display the status of this test.

4. Click on Close to exit.

Figure 7.5

2S/2M, 4S/2M, 4S/3M (Standard and Premium)

To verify valve and lamp installations with TOOLBOX Software:

1. Apply 12 volts DC to the ABS.

2. Apply air to the emergency line to fill the air tanks and release the spring brakes.

3. Apply air to control line

4. At the Trailer Main Screen click on Component Test, then select Valves/Lamps to display the Valve Activation Screen.  The Yellow valve indicator will be highlighted.  Figure 7.6

NOTE:  Selecting "All Valves" will sequence all of the valves beginning with the Yellow valve.

5. Click on the Activate button.

6. Check for proper air line installation.  To do this, observe the slack adjusters:

If the ECU faces the front of the trailer, the slack adjusters will move in and out as the curbside portion of the dual modulator valve cycles.  If this does not happen, the air lines are not properly connected,  Make the necessary repairs.

If the ECU faces the rear of the trailer, the slack adjusters will move in and out as the roadside portion of the dual modulator valve cycles.  If this does not happen, the air lines are not properly connected,  Make the necessary repairs.

NOTE:  The Test Status box at the bottom of the menu will display the status of this test.

7. Repeat this test for the Blue valve.

a. Repeat Step 1-3.

b. Select the Blue valve from the valve activation screen.

c. Click on the activate button to verify proper valve installation (Blue). 

d. Check for proper air line installation.  To do this, observe the slack adjusters.

If the ECU faces the front of the trailer, the slack adjusters will move in and out as the curbside portion of the dual modulator valve cycles.  If this does not happen, the air lines are not properly connected,  Make the necessary repairs.

If the ECU faces the rear of the trailer, the slack adjusters will move in and out as the roadside portion of the dual modulator valve cycles.  If this does not happen, the air lines are not properly connected,  Make the necessary repairs.

8. For 4S/3M installations:  Repeat this test for red valve.

Red:  The external relay valve designated RED (RD) is an axle control valve.  It controls brake chambers on one or two axles.  It  is important that delivery lines from port #2 are plumbed as shown on the installation drawings.  The 4S/3M system is designed to be used with a variety of trailer configurations.  Call ArvinMeritor's Customer Service Center at 800-535-5560 for additional information.

9. Click on the Test button to activate the ABS indicator lamp --  this lampis the lamp that is mounted on the side of the trailer.  The lamp will flash eight times, indicating lamp installation is OK.  The Test Status box at the bottom of the menu will also display the status of this test.

10.Click on Close to exit.

Figure 7.6

Sensor Installation Test (All Installations)

To test sensor installation:  

1. Raise both sensed wheel ends off of the ground.

2. Apply air to the emergency line to fill the air tanks and release the spring brakes so that the wheels can rotated.

3. Apply 12 volts DC to the ABS.

4. At the Trailer Main Menu, click on Component Test, then select Sensor Test to display the Sensor Test screen.

5. Click on the Start button to start the test.

6. Rotate the sensed wheel ends at a rate of 1/2 revolutions per second.  This rate equals a wheel speed of approximately 4 mph (7 kph).

7. Check the screen for sensed output. Figure 7.7

Make sure there is sensor output.  If sensor output is displayed, sensor test is complete.

If there is no sensor output, verify that a tone ring has been installed and that the sensor is pushed all the way in against the tone ring.  Make necessary repairs and repeat the sensor test.  If the problem persists, contact Meritor WABCO.

8. Check Order fields to verify sensors were installed in the right location based on orientation of the valves.  Figure 7.7.

NOTE:  For sensor locations click here.

Figure 7.7

End of Line Testing without TOOLBOX Software

2S/1M Basic

1. Apply 12 volts DC power to the ABS.

2. The ECU/single modulator valve assembly should click two times.

3. If the indicator lamp comes on for three seconds and goes out:

This indicates a proper installation.  The end of line test is complete.

If the ABS indicator lamp comes on and stays on, check the sensor installation:

a. Remove the power from the ABS and raise the sensed wheels so they may be rotated.

b. Repeat Steps 1 and 2.

c. Rotate each sensed wheel-- one at a time-- at a rate less than 25 rpm.

The ABS indicator lamp should now go out and stay out indicating a proper installation.  The end of line test is complete.

4. If the ABS lamp does not go out, there is a sensor gap problem or hardware fault.  Adjust the sensor and, if necessary, perform a fault code check.

Inspect the Sensor and Air Line Installation (2S/2M Standard)

Sensor Installation

1. Look at the YE2 and YE1 sensor connectors on the ECU/dual modulator valve assembly.  Make sure the connectors are routed to the proper wheel end location, as follows:

If the ECU/dual modulator valve assembly is mounted with sensors facing the front of the trailer:

-- Sensor YE2 must be routed to the curbside wheel end location

-- Sensor YE1 must be routed to the roadside wheel end location

If the ECU/dual modulator valve assembly is mounted with sensors facing the rear of the trailer:

-- Sensor YE2 must be routed to the roadside wheel end location

-- Sensor YE1 must be routed to the curbside wheel end location

2. If sensors are not properly installed, make the necessary repairs.

Air Line Installation

1. Make sure all unused air ports are plugged and that the exhaust port is facing DOWN.

2. Look at the air line installation to make sure all air lines are properly installed.

If the ECU/dual modulator valve assembly is mounted with the sensors facing the front of the trailer, the air lines for the three delivery ports located under the YE2 sensor connector must be routed to curbside; the air lines for the three delivery ports on the opposite side of the valve must be routed to roadside. Figure 7.8.

If the ECU/dual modulator valve assembly is mounted with the sensors facing the rear of the trailer, the air lines for the three delivery ports located under the YE2 sensor connector must be routed to roadside; the air lines for the three delivery ports on the opposite side of the valve must be routed to curbside. Figure 7.9.

3. If air lines are not properly routed, make the necessary repairs.

Figure 7.8

Figure 7.9

Inspect the Sensor and Air Line Installation (2S/2M, 4S/2M and 4S/3M Premium)

Sensor Installation

1. Look at the sensor connectors on the ECU/dual modulator valve assembly.  Make sure the connectors are routed to the proper wheel end location, as follows:

ECU/Dual Modulator Valve Assembly Mounted with Sensors Facing Front of Trailer

2S/2M

--Connect curbside sensor at YE1

--Connect roadside sensor at BU1

*4S/2M

--Connect curbside front sensor at YE1

--Connect curbside rear sensor at YE2

--Connect roadside front sensor at BU1

--Connect roadside rear sensor at BU2

*4S/3M -- Sensor locations vary by type of installation.  Refer to diagrams for specific sensor locations.

--Connect curbside sensor at YE1

--Connect curbside sensor at YE2

--Connect roadside sensor at BU1

--Connect roadside sensor at BU2

ECU/Dual Modulator Valve Assembly Mounted with Sensors Facing Rear of Trailer

2S/2M

--Connect curbside sensor at BU1

--Connect roadside sensor at YE1

*4S/2M

--Connect curbside front sensor at BU1

--Connect curbside rear sensor at BU2

--Connect roadside front sensor at YE1

--Connect roadside rear sensor at YE2

*4S/3M-- Sensor locations vary by type of installation.  Refer to diagrams for specific sensor locations.

--Connect curbside sensor at BU1

--Connect curbside sensor at BU2

--Connect roadside sensor at YE1

--Connect roadside sensor at YE2

2. If sensors are not properly installed, make the necessary repairs.

Air Line Installation

1. Make sure all unused air ports are plugged and that the exhaust port is facing DOWN.

2. Look at the air line installation to make sure all air lines are properly installed.

If the ECU/dual modulator valve assembly is mounted with the sensors facing the front of the trailer, the air lines for the three delivery ports located under the YE sensor connectors must be routed to curbside; the air lines for the three delivery ports on the opposite side of the valve must be routed to roadside. Refer to Figure 7.10.

If the ECU/dual modulator valve assembly is mounted with the sensors facing the rear of the trailer, the air lines for the three delivery ports located under the YE sensor connectors must be routed to roadside; the air lines for the three delivery ports on the opposite side of the valve must be routed to curbside. Refer to Figure 7.11.

Figure 7.10

Figure 7.11

3. For 4S/3M installations:  Repeat this test for the red valve.

Red:  The external relay valve designated RED (RD) is an axle control valve.  It controls brake chambers on one or two axles.  It  is important that delivery lines from port #2 are plumbed as shown on the installation drawings. (Refer to Figures 4.8, 4.9, and 4.10)  The 4S/3M system is designed to be used with a variety of trailer configurations.  Call ArvinMeritor's Customer Service Center at 800-535-5560 for additional information.

4. If air lines are not properly routed, make the necessary repairs.

Perform End of Line Test (Standard and Premium Installations)

1. Apply 12 volts DC power to the ABS

2. The ECU/dual modulator valve assembly should click four times (six times for 4S/3M).

3. If indicator lamp comes on for three seconds the goes out, this indicates a proper installation.  The end of line test is complete.

If the ABS indicator comes on and stays on, check sensor installation.

a. Remove the power from the ABS and raise the sensed wheels so they may be rotated. 

b. Apply emergency air to fill the air tanks and release the spring brakes so that the wheels may be rotated. 

c. Repeat Step 1 and Step 2.

d. Rotate each sensed wheel -- one at a time -- at a rate of less than 25 rpm. 

The ABS indicator lamp should now go out and stay out indicating a proper installation.  The end of line test is complete.

4. If the ABS lamp does not go out, there is a sensor gap problem or hardware fault.  Adjust the sensor and, if necessary, perform a fault code check.

Sensor Gap Adjustment (All Installation)

Push sensor into its holder until it contacts the tooth wheel.  At installation, there must be no gap between the sensor and the tooth wheel.

Measure the AC voltage output.  Valve should be 0.2 volt AC when wheel is rotated at a rate of 1/2 revolution per second.

Fault Code Check (All Installations)

Use constant power activation to perform the fault code check, as follows:

1. Apply constant power to the ECU/dual modulator valve assembly for more than one, but less than five seconds.

2. Remove power.

3. Reapply power.

4. Check the trailer ABS indicator lamp on the side of the trailer.  The fault code will be displayed three times.

5. Find the fault on the table and make the necessary repairs.

6. After making the necessary corrections, repeat the end of line test.

Blink Codes

Trailer Identification

An Easy-Stop Trailer ABS warning label is generally affixed to the trailer near the ABS trailer indicator lamp.

If this label is not on the trailer, let your supervisor know.  Labels are available from Meritor WABCO.  Ask for Part Number TP-95172.

For additional assistance, contact ArvinMeritor's Customer Service Center at 800-535-5560.

Before calling the ArvinMeritor Customer Service Center, be prepared to provided the following information about the trailer you are working on:

1. Trailer make and model.

2. What is the symptom/complaint? What is the component doing or not doing?

3. What is the ABS blink code or MPSI Pro-Link 9000 reading?

4. Have any resistance and/or voltage measurements been taken?

5. What is the result of visual inspection of connectors, harness and components.

6. When does the symptom occur (vehicle moving, compressor unloading, etc.)?

7. Does the trailer have any unusual characteristics (for example, mismatched tires or larger than normal air consumption)?

8. Were maintenance manuals available?  If so, which ones were used?

9. What is the part number of the ECU/Valve Assembly?  What is the system configuration?

By having the above information ready when you call, your customer service technician will be better equipped to assist you.  Figure 7.12.

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