Wabco troubleshooting manual

Wabco troubleshooting manual DEFAULT

Meritor WABCO TOOLBOX Software User's Manual

User’s Manual

TOOLBOX

TM

SOFTWARE

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TOOLBOX

ME R I T O R WA B C O

SOFTWARE

TP-99102

Rev 01-04

Diagnostic and On-Screen Service Instructions For:

� Pneumatic ABS (D and E Versions)

� Trailer ABS (Easy-StopTM and Enhanced Easy-StopTM with PLC)

� Hydraulic ABS (HABS)

W H A T Y O U N E E D T O K N O W

� Hydraulic Power Brake (HPB)

� Electronic Leveling Module (ELM) for Tractors

� Electronic Leveling Module (ELM) for Trailers


Table of Contents

Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Starting TOOLBOX TM Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Select ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

COM Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Vendor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

System Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Update Applications (Versions 5.0 and Higher) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

About . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Tractor ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Reference Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Main Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Restart Exit Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Tractor ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Wheel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Memorized Data (E Version ABS Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

RSC Data (E Version ABS Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Component Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

RSC Trailer Valve (E Version ABS Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Engine Data Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Disable ATC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Enable ATC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Reset Memorized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Trailer ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Reference Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Main Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Restart Exit Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Trailer ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Language Restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Manual Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Fault Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Component Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Valve and Lamp Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Sensor Orientation Test (For Enhanced Easy-Stop TM Only) . . . . . . . . . . . . . . . . . . . . .32

Modify . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Tire Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Reconfigure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Notebook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Lift Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Plant Location/OEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

TP-99102

Revised 01-04 Page -1


Table of Contents

Hydraulic ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Reference Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Main Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Restart Exit Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Tractor ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Language Restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Component Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Actuate Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Reset Memorized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

End of Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Hydraulic Power Brake (HPB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Technical Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Main Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Restart Exit Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Tractor ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Wheel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Component Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Engine Data Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Disable ATC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Enable ATC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Miscellaneous Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Reset Memorized (For Systems Equipped with a Retarder Relay) . . . . . . . . . . . . . . . 57

ELM for Tractors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Reference Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Computer to Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Main Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Restart Exit Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

ELM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Modify . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

ELM for Trailers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Reference Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Computer to Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Main Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Restart Exit Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

ELM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Modify . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Driver Select Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Communication Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Adapter Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Selecting an Adapter Box in TOOLBOX TM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Connecting the Adapter Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Fault Information Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

TOOLBOX TM Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

System Information (Versions 5.0 and Higher) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

About . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72


Introduction

Introduction

Introduction MeritorWABCOTOOLBOXTM Software is a

PC-based diagnostics program that runs in

Windows ® 98, Me, NT, 2000 or XPa .

TOOLBOXTM Software provides PC diagnostic

capabilities for MeritorWABCO tractor and

trailer pneumatic ABS, hydraulic ABS and the

electronic leveling module (ELM) for both

tractor and trailer. The program provides four

basic functions:

Displays both constant (e.g., ECU number)

and changing (e.g., RPMs) information

from the system under test.

Displays both active and stored system

faults, as well as the appropriate repair

instructions.

Provides a link to service information

testing procedures, etc. (ABS and

HABS only)

Activates system components to verify

system integrity, correct component

operation and installation wiring.

NOTE: For complete MeritorWABCO

maintenance information, refer to the

appropriate maintenance manual which is

listed in this manual at the beginning of each

product section. For copies of Meritor

WABCO service literature, contact the

ArvinMeritor Customer Service Center at

800-535-5560 or visit our website:

meritorwabco.com

a Early versions of TOOLBOX TM (Version 4.2 or lower) will run in

Windows ® 95.

TP-99102

Revised 01-04 Page 1


Introduction

System

Requirements

Pentium-based personal computer

Microsoft Windows ® 98, Me, 2000 or XP a .

Internet Explorer version 3.02 or higher

must be installed.

NOTE: You must have Administrator

Privileges to install and run TOOLBOX TM

Software on Windows ® NT.

64 MB RAM

Approximately 10.0 MB hard disk space for

each program. 60 MB hard disk space for

full install

CD-ROM drive

RS232 to SAE J1708 or RS232 to PLC

converter cable

Serial Port. RS232-SAE J1708 interface

adapter required

MeritorWABCO recommends using a

mouse with this program

Windows ® is a registered trademark of the Microsoft Corporation.

a Windows ® versions approved for use with TOOLBOX TM as of 01/04.

TP-99102

Page 2 Revised 01-04


Installation

Starting

TOOLBOX TM

Software

Introduction

Follow the instructions included with

TOOLBOXTM Software to install the program

on your computer.

The installation screen offers three types of

installations: Typical, Compact and Custom.

Select Typical or Compact to install tractor,

trailer and hydraulic ABS diagnostic

programs. Select Custom to install only one

or two of these programs.

After installation, MeritorWABCO

TOOLBOXTM Software will be available on

your desktop as an icon and under the

Windows ® start menu.

Refer to “System Setup” on page 5 for

first-time use instructions.

NOTE: An RS232 to J1708 or RS232 to PLC

converter box attached to the

communications port on your computer

(COM1 or COM2) is required. Converter boxes

that have been tested and proven satisfactory

are Noregon, MPSI, B&B Devices,

Kent-Moore and Dearborn Group.

1. Attach the RS232 to J1708 converter cable

from your computer’s serial port to the

converter box.

2. Attach the diagnostic cable (Deutsch) to

the vehicle.

TO VEHICLE

J1587

CONNECTOR

SERIAL

CABLE

J1708-TO-RS232

CONNECTOR

At start-up, select the TOOLBOX TM Software

icon from Desktop or from the Windows ®

Start Menu to display the MAIN MENU.

TP-99102

Revised 01-04 Page 3


Introduction

Main Menu

ABS Menus and Toolbars are illustrated and

explained in this manual, as follows:

Tractor ABS pages 11-21

Trailer ABS pages 23-36

Hydraulic ABS pages 37-47

Hydraulic Power Brake (HPB) pages 48-57

ELM for Tractors pages 58-62

ELM for Trailers pages 63-68

Most TOOLBOXTM features are accessible

through pull down menus. Many of these

features may also be accessed by a shortcut

icon. When a shortcut is available, the

appropriate icon is illustrated to the left of

the copy.

At the Main Menu you may select a shortcut

icon to:

Exit TOOLBOXTM Go to Tractor ABS diagnostics

Go to Trailer ABS diagnostics

Go to Hydraulic ABS (HABS) diagnostics

OR Go to Hydraulic Power Brake (HPB)

diagnostics

Go to Electronic Leveling Module (ELM) for

Tractors

Go to Electronic Leveling Module (ELM) for

Trailers

TP-99102

Page 4 Revised 01-04


Main Menu

Main Menu

Main Menu

System Setup Select System Setup from the Main Menu.

Language Select Language from the System Setup

menu. The default is English. To change the

default to French or Spanish (ABS only):

1. Select the appropriate language.

2. Click OK to accept the selection.

TP-99102

Revised 01-04 Page 5


Main Menu

Select

ECU

ELM

Tractor

ELM

Trailer

Tractor

ABS

Trailer

ABS

Hydraulic

ABS/HPB

Click on Select ECU from the System Setup

menu, then select the type of ABS to be

tested. Click on the appropriate Meritor

WABCO product icon to display the Main

Menu for that program.

Roll Call displays all actively broadcasting

ECUs.

NOTE: TOOLBOXTM diagnostics cover only

MeritorWABCO ECUs.

COM Port The correct Vendor, Protocol and Device

Palm Pilot

Setup:

Go to Palm

Pilot Setup

Menu

Change

COM port to

COM port 3

Reboot PC

selections are essential. TOOLBOXTM will not

operate correctly if these selections are not

accurate. For assistance, contact the

ArvinMeritor Customer Service Center at

800-535-5560.

From the System Setup pull down menu,

select COM Port to display the Device Settings

menu. Current settings will be shown.

TP-99102

Page 6 Revised 01-04


Vendor

(Vendor name

should appear

on the parts label

on the connector

box)

To change these selections:

Main Menu

Click on the down arrow for a list of vendor

choices. Select the appropriate vendor.

Protocol Click on the down arrow for the protocol

choices.

TP-99102

Revised 01-04 Page 7


Main Menu

Device Click on the down arrow for the device

choices. Select the device and port to which

the data cable is connected.

Click OK to accept the selections and close the

Device Settings window.

Help Select the Help icon for help in using Meritor

WABCOTOOLBOX TM Software. Help is

accessible from all TOOLBOX TM pages. Search

by title (contents) or type in a specific topic

(search for help on).

System

Information

Select System Information and follow the

screen prompts to print a report of system

hardware: operating system version, drivers,

etc. Run this report whenever you contact the

ArvinMeritor Customer Service Center.

TP-99102

Page 8 Revised 01-04


Update

Application

(Versions 5.0 and

Higher)

Main Menu

Select Update Application to download future

revisions to TOOLBOX TM . This option is

available for TOOLBOX TM version 5.0 and

higher. Follow the screen prompts to

complete the download.

About Select About from the pull down menu for

information about MeritorWABCO

TOOLBOX TM Software, including the version

number. You may need this information if

you call the ArvinMeritor Customer Service

Center.

TP-99102

Revised 01-04 Page 9


Notes

Notes

TP-99102

Page 10 Revised 01-04


Reference

Material

Main Screen

Tractor ABS

Tractor ABS

Tractor ABS

For maintenance and repair information, refer

to the appropriate MeritorWABCO Truck,

Tractor and Bus ABS Maintenance Manual:

MM-30 D Version ABS

MM-0112 E Version ABS

NOTE: TOOLBOXTM Software must be

connected to the vehicle and the vehicle

ignition must be ON in order to display

information.

TRACTOR ABS MENUS AND TOOLBARS

Select Tractor ABS from the TOOLBOXTM Main Menu. The Tractor ABS Main Screen will

appear.

This screen provides icons and pull down

menu task selections. It also provides

information about the current state of Meritor

WABCO ABS. ECU information is read once

from the ECU and does not change. All other

information (e.g., wheel sensors, control

status, voltages, faults and road speed) is read

and updated continuously.

The status of ABS switches and lamps as well as

other data may be observed from this screen.

TP-99102

Revised 01-04 Page 11


Tractor ABS

Restart

Exit

Help

Tractor ECU

Display

From the Main Screen you can select Restart,

Exit or Help.

Select Tractor ECU from the Tractor ABS Main

Screen. A pull down menu will appear.

Refer to page 5 of this manual for information

about using the Language selection.

Select Restart to refresh (update) ECU

information.

Select Display from the Tractor ABS Main

Screen. A pull down menu will appear.

TP-99102

Page 12 Revised 01-04


Tractor ABS

Faults Select Faults from the pull down menu. The

Fault Information screen will appear.

Bookmarks —

Complete

listing of ABS

fault codes by

SID/FMI. Click

to display.

Thumbnails

— Click

individual

pages to

display.

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.

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.

TP-99102

Revised 01-04 Page 13


Tractor ABS

Wheel Speed Select wheel speed from the pull down menu

to display wheel speed data in both numeric

and graph form.

Wheel speed information may be viewed in

RPM (revolutions per minute) or MPH (miles

per hour). Select the appearance and style

from the options menu.

Display wheel speed data vertically or

horizontally.

TP-99102

Page 14 Revised 01-04


Memorized

Data

(E Version

ABS Only)

Tractor ABS

Select Memorized Components from the pull

down menu.

NOTE: Use Display/Memorized Components

to view data. To clear a memorized

component, use the Memorized Components

function that appears on the Component

Tests Menu.

TP-99102

Revised 01-04 Page 15


Tractor ABS

RSC Data

(E Version

ABS Only)

Select RSC Data from the pull down menu for

RSC status information:

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.

A green background in this field indicates

voltage is within the acceptable range.

TP-99102

Page 16 Revised 01-04


Component

Tests

Tractor ABS

Select Component Tests from the Tractor ABS

Main Screen. A pull down menu will appear.

NOTE: Components for test may also be

selected from the icons on the Tractor ABS

Main Screen.

Valves 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.

Select all valves from the menu to cycle all

available ABS valves in the order shown

below.

NOTE: Verification of the ATC valve is also

available from this menu.

TP-99102

Revised 01-04 Page 17


Tractor ABS

RSC Trailer

Valve

(E Version

ABS Only)

Select RSC Trailer Valve from the pull down

menu to cycle the RSC trailer valve.

NOTE: Do not activate the service brake

while testing the RSC trailer valve.

Press Start to begin the test.

TP-99102

Page 18 Revised 01-04


Tractor ABS

Lamps Select Lamps from the pull down menu to

turn the tractor ABS, trailer ABS or ATC

(wheel spin) indicator lamps on or off.

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.

This is helpful in verifying correct operation,

installation and wiring of the unit under test.

TP-99102

Revised 01-04 Page 19


Tractor ABS

Engine

Data Link

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.

Disable ATC 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.

TP-99102

Page 20 Revised 01-04


Tractor ABS

Enable ATC 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).

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 data link 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.

Because 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.

TP-99102

Revised 01-04 Page 21


Notes

Notes

TP-99102

Page 22 Revised 01-04


Reference

Material

Main Screen

Tr ailer ABS

Trailer ABS

Trailer ABS

For maintenance and repair information, refer

to the appropriate MeritorWABCO Trailer

ABS Maintenance Manual:

MM-33 Easy-StopTM Trailer ABS

MM-0180 Enhanced Easy-StopTM with PLC

Trailer ABS

NOTE: TOOLBOXTM Software must be

connected to the vehicle and the vehicle

ignition must be ON in order to display

information.

TRAILER ABS MENUS AND TOOLBARS

Select Trailer ABS from the TOOLBOXTM Main

Menu. The Trailer ABS Main Screen will

appear.

This screen provides icons and pull down

menu task selections. It also provides

information about the current status of

MeritorWABCO ABS.

TP-99102

Revised 01-04 Page 23


Trailer ABS

Restart

Exit

Help

Trailer ECU

Language

Restart

ECU information is read once from the ECU

and does not change. All other information

(e.g., wheel sensors, voltages and fault

information) is read and updated continuously.

NOTE: Double click on Yes in the Existing or

Stored Faults fields to bring up the Fault

Information screen. This screen is illustrated

on page 40.

Service Information may also be observed

from the Trailer ABS main screen.

From the Main Screen, you can select Restart,

Exit or Help.

Select Trailer ECU from the Trailer ABS MAIN

SCREEN. A pull down menu will appear.

Refer to page 5 of this manual for information

about using the Language selection.

Select Restart to refresh (update) ECU

information.

TP-99102

Page 24 Revised 01-04


Trailer ABS

Manual Setup The Manual Setup menu selection is not

available.

Print

Save

To print vehicle data in a report format.

1. From the Trailer ECU pull down menu,

select Print. The Report Information

Screen will appear.

2. Enter the VIN and Employee number for

the report you want to print.

3. Click OK to print and close the window.

NOTE: Selecting the Print function does not

save report data. You must save all data

according to the instructions given in Save,

above.

To save vehicle data in a report format:

1. From the Trailer ECU pull down menu,

select Save. The Report Information

Screen with path selections will appear.

2. Enter the VIN and Employee number.

3. Select the file where vehicle reports are

stored; e.g., Main.

4. Click OK to close the window.

TP-99102

Revised 01-04 Page 25


Trailer ABS

NOTE: Trailer ABS reports are not displayed

in TOOLBOX TM . To view a report, use

Windows Explorer to find and open the report

file. The following is a sample report.

MeritorWABCO ABS Fault Report

Date: September 13, 2000

Time: 5:25 PM

Page: 1

VIN: 12345678

Employee Information: KILEY

ABS System Configuration: 4S/2M

ECU Revision: V 3 2 2xxxx

Part Number: 446-108-000-1

Serial Number: 5 9 3 0 3 9 4 8xxxxxxxxx

Date of Manufacture: 13/1999

Current Miles: 0.0

Service Miles: 0.0

Tire Calibration: 495.0

Fault# Description Status SID FMI Count

1 Ext. modulator BLUE open circuit detected Active 9 5 1

2 Ext. modulator BLUE open circuit detected Stored 9 5 1

Sensor Test Results:

Sensor Max RPM Order

YE1 40.0 1

YE2 59.0 2

BU1 50.0 3

BU2 38.0 4

Valve Tests Performed:

Valve Status (Tested / Not Tested / NA)

Yellow Tested

Blue Tested

Red N/A

TP-99102

Page 26 Revised 01-04


Display

Trailer ABS

Select Display from the Trailer ABS Main

Screen. A pull down menu will appear.

Faults Select Faults to display the Fault Information

Screen.

NOTE: The Fault Information Screen is also

accessible from the Trailer ABS Main Screen.

Refer to page 23.

Fault

Information

Bookmarks —

Complete

listing of ABS

fault codes by

SID/FMI. Click

to display.

Thumbnails

— Click

individual

pages to

display.

The Fault Information Screen contains a

description of each fault, including the type of

fault (Active or Stored), SID and FMI number.

Repair instructions for the fault appear at the

bottom of the screen.

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 occur after the screen is displayed

will not appear until a screen update is

requested. Use the Update button at the

bottom of the screen to refresh the fault

information table and display a new list of

faults.

TP-99102

Revised 01-04 Page 27


Trailer ABS

Component

Tests

Valve and

Lamp

Activation

After making any required repairs, use the

Clear Faults button to clear the fault. Clear

each fault as it is repaired.

Use the Save or Print button to save or print

the fault information data. Please refer to

page 25 for complete information about Save

and Print functions.

Select Component Tests from the Trailer ABS

Main Screen. A pull down menu will appear.

NOTE: Sensor Orientation Test option is only

available with TCSII (Enhanced Easy-Stop TM )

ECUs. It will not appear as a menu choice for

Easy-Stop TM ECUs.

Select Valves/Lamp to display the Valve

Activation screen. From this screen you can

check the status of the trailer ABS valves and

the ABS indicator lamp mounted on the trailer.

TP-99102

Page 28 Revised 01-04


Valves 2S/1M Systems

S = Sensors

M = Modulator Valves

Trailer ABS

The Red valve indicator will be selected. Click

on the Activate button and listen for the valve

to click, indicating a good installation.

2S/2M, 4S/2M and 4S/3M Systems

The Yellow valve indicator will be selected.

Click on the Activate button and listen for the

valve to click, indicating a good installation.

Repeat for the Blue valve.

NOTE: Selecting All Valves will sequence all

of the valves, beginning with the Yellow valve.

As each valve is cycled, the Test Status box at

the bottom of the screen will display the

status of the test.

Lamp Click on the Warning Lamp Test button on the

bottom of the valve and lamp activation

screen to activate the lamp that is mounted

on the side of the trailer. The lamp will flash

eight times, indicating the lamp is OK. The

test status box at the bottom of the menu will

display the status.

Message Status

Complete OK

Critical Error Communication error (If this

message occurs, check the

cable connections, recycle

power.)

TP-99102

Revised 01-04 Page 29


Trailer ABS

Sensors This test requires rotating the vehicle wheels.

Refer to the maintenance manual to make

sure the vehicle is correctly prepared for this

test. Follow all of the warnings and cautions

printed in the manual.

Select Sensor Test to display the Sensor Test

screen.

TP-99102

Page 30 Revised 01-04


Trailer ABS

WARNING

To prevent serious eye injury, always wear

safe eye protection when you perform vehicle

maintenance or service.

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.

The ABS is an electrical system. When you

work on the ABS, take the same precautions

that you must take with any electrical

system to avoid serious personal injury. As

with any electrical system, the danger of

electrical shock or sparks exists that can

ignite flammable substances. You must

always disconnect the battery ground cable

before working on the electrical system.

1. Make sure sensed wheel ends are 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 be rotated.

3. Apply 12 volts DC to the ABS.

4. Click on the Start button on the Sensor

Test screen to start the test.

5. Rotate the sensed wheel ends at a rate of

1/2 revolution per second. This rate

equals a wheel speed of approximately

4 mph (7 kph).

6. Check the screen for sensor output: If

Sensor Output is displayed, the sensor

test is complete. If there is no Sensor

Output, verify tone ring installation and

sensor placement (sensor must be

pushed all the way in against the tone

ring). Refer to the maintenance manual

for complete information.

TP-99102

Revised 01-04 Page 31


Trailer ABS

Sensor

Orientation

Test

(For Enhanced

Easy-Stop TM Only)

7. Check the Order fields to verify sensors

were installed in the right location, based

on the orientation of the valves.

If you are using TOOLBOXTM to test an

Enhanced Easy-StopTM system, you can check

sensor installation by performing a sensor

orientation test.

Select Sensor Orientation Test from the pull

down menu. The Sensor Orientation Test

screen will appear.

This test requires that the sensed wheels be

spun in a predetermined order and that you

enter the ECU mounting orientation. The

sensed wheels are rotated in turn, starting at

the front curbside, moving to the rear, and

ending at the front roadside.

A correct sensor installation will be

displayed in green (Pass).

An incorrect installation will be

displayed in red (Fail).

The results of the sensor orientation test will

also appear on the test page printout.

TP-99102

Page 32 Revised 01-04


Modify

Service

Information

Trailer ABS

Select Modify from the Trailer ABS Main

Menu. A pull down menu will appear.

Select Service Information to set, change or

display the odometer reading for scheduled

maintenance.

When the mileage setting selected for

scheduled maintenance is reached, the ABS

indicator lamp on the side of the trailer will

flash eight times. The lamp will continue to

flash eight times whenever the ignition switch

is turned on, or until service is performed and

this parameter is changed. To change the

mileage for the next scheduled maintenance,

type in the new odometer reading, then press

the Write button. Maintenance settings may

be entered in miles or kilometers.

TP-99102

Revised 01-04 Page 33


Trailer ABS

Tire Calibration Select Tire Calibration to set, change or

display the revolutions per mile.

Tip: TOOLBOX TM

will automatically

change some

numeric values;

e.g., you may type

in a number and

see a number

that is slightly

higher or lower

displayed. This

does not affect

calibration

accuracy.

The RPM entry range is 150.0 to 634.0 RPM.

The default value is 502.0. RPM figures are

calculated based on a 100-tooth tone ring.

To change a value, type in the RPM figure,

then press the Write button.

Trailers with 12-1/4-inch brakes use an

80-tooth tone ring. Use a value of

80 percent of the tire manufacturer’s

recommended RPM

(revolutions x 0.80).

TP-99102

Page 34 Revised 01-04


Trailer ABS

Reconfigure This option is used to reconfigure an ECU that

has been installed on a system with fewer

sensors or modulator valves than the original

system. It is not necessary to reconfigure an

ECU installed on a system with more sensors

or modulator valves than the original system.

In these cases, reconfiguration is automatic.

Select Reconfigure to display the following

screen, then mark the appropriate

configuration.

Notebook Select Notebook to enter or view information

about a specific vehicle.

NOTE: The O.E.M. location and production

date are automatically saved in Notebook and

will appear on this screen once they have

been saved to the registry. V.I.N. and

inspector must be saved after entering.

TP-99102

Revised 01-04 Page 35


Trailer ABS

Tip: The registry

function of

Notebook is

especially useful

to an OEM.

To enter information, type the data, then click

on the Write button to send the information to

the ECU. Use the Print button to print the

displayed data.

Lift Axle Select Lift Axle to observe or change lift axle

status.

Plant Location/

OEM

Select Plant Location/OEM to observe or

enter plant and OEM information.

TP-99102

Page 36 Revised 01-04


Reference

Material

Main Screen

Hydraulic ABS

Hydraulic ABS

Hydraulic ABS

For maintenance and repair information, refer

to the MeritorWABCO Trailer ABS

Maintenance Manual:

MM-39 Hydraulic ABS for Medium-Duty

Trucks, Buses and Motor Home

Chassis

NOTE: TOOLBOXTM Software must be

connected to the vehicle and the vehicle

ignition must be ON in order to display

information.

HYDRAULIC ABS MENUS AND TOOLBARS

Select Hydraulic ABS from the TOOLBOXTM Main Menu. TOOLBOXTM will recognize the

HABS or Hydraulic Power Brake (HPB) ECU

and display the appropriate screen. If you are

working with HPB, refer to the HPB section of

this manual.

TP-99102

Revised 01-04 Page 37


Hydraulic ABS

Restart

Exit

Help

The Main Screen provides icons and pull

down menu task selections. It also provides

information about the current status of

MeritorWABCO HABS.

ECU information is read once from the ECU

and does not change. All other information

(e.g., wheel sensors, voltages and fault

information) is read and updated

continuously.

NOTE: Double click on Yes in the Existing or

Stored Faults fields of the HABS Main Screen

to bring up the Fault Information screen.

Service Information may also be observed

from this screen.

From the Main Screen, you can select Restart,

Exit or Help.

TP-99102

Page 38 Revised 01-04


Tractor ECU

Language

Restart

Hydraulic ABS

Select Tractor ECU from the HABS Main

Screen. A pull down menu will appear.

Refer to page 5 of this manual for information

about using the Language selection.

Select Restart to refresh (update) ECU

information.

Exit Select Exit to exit HABS and return to the

TOOLBOX TM Main Menu.

Display Select Display from the HABS Main Screen.

A pull down menu will appear.

TP-99102

Revised 01-04 Page 39


Hydraulic ABS

Faults Select Faults to display the Fault Information

screen.

NOTE: The Fault Information Screen is also

accessible from the HABS Main Menu.

Bookmarks —

Complete

listing of ABS

fault codes by

SID/FMI. Click

to display.

Thumbnails

— Click

individual

pages to

display.

The Fault Information screen contains a

description of each fault, including the type of

fault (Active or Stored), SID and FMI number.

Repair instructions for the fault appear at the

bottom of the screen.

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 occur after the screen is displayed

will not appear until a screen update is

requested. Use the Update button at the

bottom of the screen to refresh the fault

information table and display a new list of

faults.

After making any required repairs, use the

Clear Faults button to clear the fault. Clear

each fault as it is repaired.

Use the Save or Print button to save or print

the fault information data. Please refer to

page 25 for more information about Save and

Print functions. Select Exit to close this

screen.

TP-99102

Page 40 Revised 01-04


Component

Tests

Hydraulic ABS

Select Component Tests from the HABS Main

Screen. A pull down menu will appear.

Valves Select Valves to display the Valve Activation

screen.

The Valve Activation screen lets you activate

the four valves, the pump and the retarder

relay. In addition to checking for correct

activation, this screen provides an easy way

to make sure the valves are wired correctly —

and that wiring is not reversed.

Click on the valve, pump or retarder relay you

wish to test, then click on the Send button to

actuate the component. Component activation

status appears in the status box field. Use the

Close button to close this screen.

TP-99102

Revised 01-04 Page 41


Hydraulic ABS

Actuate

Outputs

Select Actuate Outputs to display the Actuate

Miscellaneous Output screen.

This screen provides a check of the ABS

indicator lamp. In addition, it provides a way

to check either inlet or outlet activity of the

valves, pump or retarder relay.

Click on the component you wish to test, then

click on the Send button to actuate the

component. Component activation status

appears in the status box field. Use the Close

button to close this screen.

TP-99102

Page 42 Revised 01-04


Reset

Memorized

Hydraulic ABS

Select Reset Memorized to display the

Learned Component screen.

Relay is an automatic default and cannot be

de-selected. It indicates the ECU has

memorized the installed retarder relay. Once

the ECU has seen a retarder, it expects to see

it every time the vehicle is powered up.

Because there are times when an ECU is

moved to another vehicle — or during

diagnostic testing — you may want the ECU

to disregard this learned component. Use the

Reset Memorized command for this purpose.

End of Line The End of Line Brake Bleed Procedure is

accessed from the HABS main screen. Use

Tip: Have a copy

of MM 39 or

Installation Guide

TP-99124 available

BEFORE you

perform a brake

bleed. For your

convenience,

these publications

are posted on

meritorwabco.com.

the Brake Bleed feature to bleed the

expansion chambers. (See page 45.)

NOTE: Before connecting the vehicle to the

computer, bleed the circuit and master

cylinder. Follow the standard bleed

procedures used by your facility, or use the

procedures listed in MeritorWABCO HABS

Installation Guide TP-99124 or HABS

Maintenance Manual 39.

TP-99102

Revised 01-04 Page 43


Hydraulic ABS

WARNING

Failure to bleed the system whenever any

hydraulic system fitting 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 correctly. This

will cause the stopping distance to increase

and can result in serious personal injury.

Correctly discard hydraulic brake fluid that is

removed from the brake system. Hydraulic

brake fluid that is removed can be

contaminated and can cause damage, loss

of braking and serious personal injury.

Use only the type of hydraulic brake fluid

specified by the equipment manufacturer.

Do not use or mix different types of hydraulic

brake fluid. The wrong hydraulic brake fluid

will damage the rubber parts of the brake

caliper and can cause damage, loss of

braking and serious personal injury.

Do not let the brake master cylinder fluid

get below the minimum level during the

bleeding operation. Keep the master cylinder

reservoir filled with new DOT-approved brake

fluid, as specified 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.

NOTE: Use DOT 3 or DOT 4 hydraulic brake

fluid. Refer to the vehicle specifications to

determine which fluid to use.

TP-99102

Page 44 Revised 01-04


Hydraulic ABS

CAUTION

Hydraulic brake fluid is a caustic substance.

Contact with hydraulic brake fluid can cause

skin irritation. Do not let hydraulic brake fluid

touch any painted surfaces, as it will remove

the paint. Hydraulic brake fluid may also

damage certain non-metal surfaces. Do not let

fluid get on brake pads, shoes, rotors or disks.

1. Apply the parking brake and block the

tires. Turn the ignition off.

2. Perform brake bleed procedure for wet

module, bleeding the circuit and master

cylinder if required, prior to connecting

laptop to truck.

3. Connect laptop to the vehicle using the

J1587 diagnostic port in the cab of the

truck.

4. Launch MeritorWABCOTOOLBOX TM

Diagnostic Software.

5. From the Main Menu select the HABS icon.

6. Select End of Line from the HABS Main

Menu.

7. Select Bleed Procedure from the End of

Line Menu.

TP-99102

Revised 01-04 Page 45


Hydraulic ABS

8. Choose axle to bleed from the select axle

screen.

9. Follow on-screen prompts.

Click OK to continue.

Click OK to continue.

TP-99102

Page 46 Revised 01-04


Hydraulic ABS

10. Repeat procedure two additional times on

this axle. This should eliminate all of the

air in the chamber.

11. Perform manual bleed on this axle.

12. Repeat Steps 8-11 for the other axle.

13. Test drive the vehicle after bleeding the

brakes.

If a firm brake pedal resistance is felt

and the brake pedal pushes back when

you perform an ABS stop, the system

bleed procedure is complete.

If there is no firm pedal resistance,

check the brake system for defects

(leaks, etc.) and make the necessary

repairs, then repeat the bleed

procedure.

TP-99102

Revised 01-04 Page 47


Hydraulic Power Brake (HPB)

Technical

Assistance

Main Screen

Hydraulic Power Brake (HPB)

Hydraulic Power Brake (HPB)

For technical assistance, please contact the

ArvinMeritor Customer Service Center at

800-535-5560

NOTE: TOOLBOXTM Software must be

connected to the vehicle and the vehicle

ignition must be ON in order to display

information.

HYDRAULIC POWER BRAKE MENUS AND

TOOLBARS

Select Hydraulic ABS from the TOOLBOXTM Main Menu. TOOLBOXTM will sense the type

of ECU being used and will display the HPB

Main Screen.

This screen provides icons and pull down

menu task selections. It also provides

information about the current status of

MeritorWABCO HPB.

ECU information is read once from the ECU

and does not change. All other information

(e.g., wheel sensors, voltages and fault

information) is read and updated

continuously.

TP-99102

Page 48 Revised 01-04


Restart

Exit

Help

Tractor ECU

Hydraulic Power Brake (HPB)

From the Main Screen you can select Restart,

Exit or Help.

Select Tractor ECU from the HPB Main

Screen. A pull down menu will appear.

Language Refer to page 5 of this manual for information

about using the Language selection.

Restart Select Restart to refresh (update) ECU

information.

Exit Select Exit to exit HPB and return to the

TOOLBOX TM Main Menu.

Display Select Display from the HPB Main Screen.

A pull down menu will appear.

TP-99102

Revised 01-04 Page 49


Hydraulic Power Brake (HPB)

Faults Select Faults to display the Fault Information

screen.

NOTE: The Fault Information screen is also

accessible from the HPB Main Menu.

The Fault Information screen contains a

description of each fault, including the type of

fault (Active or Stored), SID and FMI number.

Repair instructions for the fault appear at the

bottom of the screen.

Faults that occur after the screen is displayed

will not appear until a screen update is

requested. Use the Update button at the

bottom of the screen to refresh the fault

information table and display a new list of

faults.

After making any required repairs, use the

Clear Faults button to clear the fault. Clear

each fault as it is repaired.

Use the Save or Print button to save or print

the fault information data. Please refer to

page 25 for more information about Save and

Print functions. Select Exit to close this

section.

TP-99102

Page 50 Revised 01-04


Wheel Speed

Hydraulic Power Brake (HPB)

Select Wheel Speed to display the Wheel

Speed screen.

Use the Wheel Speed screen to verify that

sensors are connected at each wheel. Speed

at a sensed wheel (FL, FR, RL, RR) indicates

sensors are installed, but does not verify

correct sensor installation.

Counters Select Counters to display the Counters screen.

The Counters screen provides an overview of

HPB component performance (pump hours,

brake events, etc.) as well as general vehicle

activity such as ignition cycles. Occurrences

displayed on this screen accumulate until the

Clear button is selected.

TP-99102

Revised 01-04 Page 51


Hydraulic Power Brake (HPB)

Component

Tests

Select Component Tests from the HPB Main

Screen. A pull down menu will appear.

Valves Select Valves to display the Valve Activation

test screen.

The Valve Activation test screen lets you activate

the HPB valves and verify correct brake line

installation.

Click on the valve you wish to test, then click the

send button to actuate the component.

Component activation status appears in the

Status box field. Select Close to exit this screen.

TP-99102

Page 52 Revised 01-04


Hydraulic Power Brake (HPB)

Lamps Select Lamps to display the Lamp Test screen.

As each lamp is tested, check the actual lamp

to verify correct operation. Select Close to exit

this screen.

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.

Parking Brake Select Parking Brake to display the Parking

Brake test screen.

Select Release or Apply, then select Send to

test the parking brake. Select Close to exit this

screen.

TP-99102

Revised 01-04 Page 53


Hydraulic Power Brake (HPB)

Relay Select Relay to display the Activate Relay test

screen.

Engine Data

Link

This screen allows you to turn the Retarder

Relay on or off. This is helpful in verifying

correct operation, installation and wiring of

the unit under test. Select Close to exit this

screen.

Select Engine Data Link to display the Data

Link test screen.

This screen allows you to send a “limit

engine torque” command to the engine or a

“disable retarder” command to the retarder.

Select the data link destination (engine or

retarder), then select Send to test. Use the

Stop button to end testing. Select Close to

exit this screen.

TP-99102

Page 54 Revised 01-04


Hydraulic Power Brake (HPB)

Disable ATC Select Disable ATC to send a command to the

ECU to disable automatic traction control.

ATC will remain disabled until the enable

command is sent, or until the vehicle ignition

is cycled. ATC must be disabled for ATC

testing.

Enable ATC Select Enable ATC to send a command to the

ECU to enable automatic traction control.

This is the normal state of the ECU.

NOTE: The status bar on the HPB Main Menu

reflects the current ATC status (enabled,

disabled or not available).

TP-99102

Revised 01-04 Page 55


Hydraulic Power Brake (HPB)

Miscellaneous

Outputs

Select Miscellaneous Outputs to display the

Activate Miscellaneous Outputs test screen.

NOTE: Use TOOLBOXTM to test the following

components: Retarder Relay, Brake Light

Relay, Supply Valve, Cut-Off Valve, ABS

Lamp, Traction Lamp, Brake Warning, Pump

Front, Pump Rear, Buzzer.

This screen provides a check of several HPB

components, as well as a way to check either

inlet or outlet activity of the valves, pump or

retarder relay.

Highlight the component you wish to test,

then select the Send button to actuate the

component. Component activation status

appears in the Status Box field. Select Close

to exit this screen.

TP-99102

Page 56 Revised 01-04


Reset

Memorized

(For Systems

Equipped with a

Retarder Relay)

Hydraulic Power Brake (HPB)

Select Reset Memorized to display the

Learned Component screen.

Relay is an automatic default and cannot be

de-selected. It indicates the ECU has

memorized the installed retarder relay. Once

the ECU has seen a retarder, it expects to see

it every time the vehicle is powered up.

TP-99102

Revised 01-04 Page 57


ELM for Tractors

Reference

Material

Computer to

Vehicle

Main Screen

ELM for Tractors

Electronic Leveling Module

(ELM) for Tractors

For Maintenance and Repair information,

refer to MeritorWABCO ELM Service Bulletin

number TP0324. A copy of this bulletin is

posted on our website,

www.meritorwabco.com.

NOTE: TOOLBOXTM Software must be

connected to the vehicle and the vehicle

ignition must be on in order to display

information.

ELM ABS MENUS AND TOOLBARS

Select Tractor ELM from the TOOLBOXTM Main Menu. The ELM Main Screen will

appear.

TP-99102

Page 58 Revised 01-04


Restart

Exit

Help

ELM for Tractors

This screen provides icons and pull down

menu task selections. It also provides

information about the current state of the

MeritorWABCO ELM. ECU information (e.g.,

part number, serial number, etc.) is read once

and does not change. All other information,

such as wheel sensor speed and voltages, is

read and updated continuously.

From the Main Screen you can select Restart,

Exit or Help.

ELM Select ELM from the ELM Main Screen. A pull

down menu will appear with English listed.

This program is available in English only.

Display Select Display from the ELM Main Screen.

A pull down menu will appear.

Faults Select faults from the pull down menu. The

Fault Information screen will appear.

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. Repair

instructions for each fault are also provided.

TP-99102

Revised 01-04 Page 59


ELM for Tractors

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.

Components Select Component Tests from the ELM Main

Screen. A pull down menu will appear.

Select Raise/Lower to raise or lower the

chassis. The Raise/Lower screen will appear.

Select Raise to raise the vehicle chassis to the

ride height or Lower to lower the vehicle

chassis to the ride height low level.

TP-99102

Page 60 Revised 01-04


Modify

CAUTION:

Do not modify

ELM parameters

unless instructed

to do so by the

fleet or terminal

manager.

ELM for Tractors

Select Stop to halt the raising or lowering.

The height of the vehicle chassis during

raising or lowering is displayed on the screen

in the Height field. Note that the

measurement is in centimeters.

Select Close to return to the ELM Main Menu.

Select Modify from the ELM Main Screen.

The Edit ELM Parameters screen will appear.

Calibrate At the ELM Main Menu click on the

Calibration icon.

CALIBRATION ICON

TP-99102

Revised 01-04 Page 61


ELM for Tractors

Select Start Calibration. The Calibrate ELM

screen will appear.

Follow the on-screen prompts to raise and

lower the vehicle to the normal ride height

selected by the vehicle manufacturer.

Press Calibrate to set.

After ride height is set, raise the vehicle to

the upper level. Press Calibrate to set.

After upper level is set, lower the vehicle to

the low level. Press Calibrate to set.

Check the screen to verify that the

calibration was successful.

TP-99102

Page 62 Revised 01-04


Reference

Material

Computer to

Vehicle

Main Screen

ELM for Trailers

ELM for Trailers

Electronic Leveling Module

(ELM) for Trailers

For Maintenance and Repair information,

refer to MeritorWABCO ELM Service Bulletin

number TP0326. A copy of this bulletin is

posted on our website,

www.meritorwabco.com.

NOTE: TOOLBOXTM Software must be

connected to the vehicle and the vehicle

ignition must be ON in order to display

information.

ELM ABS MENUS AND TOOLBARS

Select Trailer ELM from the TOOLBOXTM Main

Menu. The ELM Main Screen will appear.

TP-99102

Revised 01-04 Page 63


ELM for Trailers

Restart

Exit

Help

This screen provides icons and pull down

menu task selections. It also provides

information about the current state of the

MeritorWABCO ELM. ECU information (e.g.,

part number, serial number, etc.) is read once

and does not change. All other information,

such as wheel sensor speed and voltages, is

read and updated continuously.

From the Main Screen you can select Restart,

Exit or Help.

ELM Select ELM from the ELM Main Screen. A pull

down menu will appear with English listed.

This program is available in English only.

Display Select Display from the ELM Main Screen. A

pull down menu will appear.

Faults Select faults from the pull down menu. The

Fault Information screen will appear.

TP-99102

Page 64 Revised 01-04


ELM for Trailers

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. Repair

instructions for each fault are also provided.

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.

Components Select Components from the ELM Main

Screen. A pull down menu will appear.

Select Raise/Lower to raise or lower the

chassis. The Raise/Lower screen will appear.

TP-99102

Revised 01-04 Page 65


ELM for Trailers

Modify

CAUTION:

Do not modify

ELM parameters

unless instructed

to do so by the

fleet or terminal

manager.

Select Raise to raise the vehicle chassis to the

ride height or Lower to lower the vehicle

chassis to the ride height low level.

Select Stop to halt the raising or lowering.

The height of the vehicle chassis during

raising or lowering is displayed on the screen

in the Height field. Note that the

measurement is in centimeters.

Select Close to return to the ELM Main Menu.

Select Modify from the ELM Main Screen.

The Edit ELM Parameters screen will appear.

4003012b

TP-99102

Page 66 Revised 01-04


ELM for Trailers

Calibrate At the ELM Main Menu, click on the

Calibration icon.

CALIBRATION ICON

Select Start Calibration. The Calibrate ELM

screen will appear.

TP-99102

Sours: https://www.yumpu.com/en/document/view/9567093/meritor-wabco-toolbox-software-users-manual

Maintenance Manual MM-0401 Meritor WABCO …

1MaintenanceManualMM-0401MeritorWABCOhydraulicpowerbrake (HPB) SystemRevised 01-17 Service NotesInformation 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. MeritorWABCO reserves the right to revise the information presented or to discontinue the production of parts described at any WABCOMaintenanceManualMM-0401 (Revised 01-17)About This ManualThis Manual contains Maintenance procedures for MeritorWABCO s hydraulicpowerbrake (HPB) system for trucks, tractors and You and understand all instructions and procedures before you begin to service 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 your company s Maintenance and service, installation, and diagnostics special tools when required to help avoid serious personal injury and damage to Alert Messages and Torque SymbolsWARNINGA Warning alerts you to an instruction or procedure that you must follow exactly to avoid serious personal injury and damage to Caution alerts you to an instruction or procedure that you must follow exactly to avoid damage to components.

2 @ This symbol alerts you to tighten fasteners to a specified torque to Obtain Additional Maintenance , Service and Product InformationPublicationsRefer to the following publications for more information on servicing MeritorWABCO s hydraulicpowerbrake (HPB) systems. MaintenanceManual 38, hydraulic ABS for Medium-Duty Trucks, Buses and Motor Home Chassis (C Version hydraulic ABS) MaintenanceManual 39, hydraulic ABS for Medium-Duty Trucks, Buses and Motor Home Chassis (D Version hydraulic ABS) MaintenanceManual MM-0677, hydraulic Anti-Lock Braking Systems (HABS) for Medium-Duty Trucks, Buses and Motor Home Chassis (E Version hydraulic ABS)Visit Literature on Demand on to access and order additional information. Contact the Meritor OnTrac Customer Call Center at 866-668-7332 (United States and Canada); 001-800-889-1834 (Mexico); or email Tools and Supplies are Specified in This ManualCall Meritor s Commercial Vehicle Aftermarket at 888-725-9355 to obtain Meritor tools and and Non-Asbestos Fibers1 Section 1: IntroductionOverviewSystem Components3 How the HPB System Works5 Section 2: Wiring DiagramHPB Wiring Diagram for Multiplex Vehicles6 HPB Connector Diagram for Multiplex Vehicles7 HPB Wiring Diagram for Non-Multiplexed Vehicles8 HPB Connector Diagram for Non-Multiplexed Vehicles9 Section 3: Troubleshooting and TestingTesting the SystemMeritor WABCO TOOLBOX SoftwareConnecting TOOLBOX Software10 hydraulicpowerbrake Menus and Toolbars14 Standard TestingTest Equipment.

3 Volt-Ohm Meter (VOM)System Requirements and Component TestsTire Size RangeChecking power , Ground and Load Test15 Standard Component TestingIndicator LampsSensor AdjustmentVehicle Test Drive16 Safety FeaturesTowing Procedure for Navistar CE Buses17 Warning Lamps18 SPN, SID, FMI Diagnostic Trouble Code List52 Section 4: Removal and InstallationRemovalHydraulic Compact Unit55 InstallationHydraulic Compact Unit56 RemovalHCU Reservoir57 InstallationHCU Reservoir58 RemovalHCU Accumulators60 InstallationHCU Accumulators62 RemovalElectronic Control Unit (ECU)64 InstallationElectronic Control Unit (ECU)65 Parameter Downloading68 RemovalHydraulic Compact Unit (HCU) Relay Valve69 InstallationHydraulic Compact Unit (HCU) Relay Valve70 RemovalHydraulic Compact Unit (HCU) Pump71 InstallationHydraulic Compact Unit (HCU) Pump72 RemovalMaster Cylinder Replacement InformationMaster Cylinder75 InstallationMaster Cylinder77 RemovalMaster Cylinder Reservoir79 InstallationMaster Cylinder Reservoir81 RemovalMaster Cylinder Foot brake Switch82 InstallationMaster Cylinder Foot brake SwitchRemovalMaster Cylinder Fluid Level Sensor SwitchInstallationMaster Cylinder Fluid Level Sensor83 RemovalParking brake Pressure Supply Valve85 InstallationParking brake Pressure Supply Valve87 RemovalLow Pressure Hose88 InstallationLow Pressure Hose89 LubricationWheel Speed Sensor Specification90 RemovalFront Axle Wheel Speed SensorInstallationFront Axle Wheel Speed Sensor91 RemovalRear Axle Wheel Speed SensorInstallationRear Axle Wheel Speed Sensor92 Section 5.

4brake Bleeding Procedures93 brake Bleeding ProceduresPressure Bleed ProceduresMaster Cylinder Caliper Circuit97 Spring-Applied/ hydraulic Release Parking brake Circuit98 Changing hydraulicbrake Fluid99 brake Fluid Replacement RequirementFilling the hydraulicpowerbrake (HPB) Master Cylinder Reservoir101 Section 6: AppendixLeak Check Procedure for MeritorWABCO HPB SystemCheck the HPB System for brake Fluid LeaksSystem TestAsbestos and Non-Asbestos FibersiMeritor WABCOMaintenanceManualMM-0401 (Revised 01-17) ASBESTOS FIBERS WARNING 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 Meritor . Hazard SummaryBecause some brake linings contain asbestos, workers who service brakes must understand the potential hazards of asbestos and precautions for reducing risks.

5 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 , 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 Work Practices1. 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 f/cc as an 8-hour time-weighted average and f/cc averaged over a 30-minute period.

6 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: ASBESTOSCANCER AND LUNG DISEASE HAZARDAUTHORIZED PERSONNEL ONLYRESPIRATORS AND PROTECTIVE CLOTHINGARE REQUIRED IN THIS AREA. 2. Respiratory Protection. Wear a respirator equipped with a high-efficiency (HEPA) filter approved by NIOSH or MSHA for use with asbestos at all times when servicing brakes, beginning with the removal of the Procedures for Servicing 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 As an alternative procedure, use a catch basin with water and a biodegradable, non-phosphate, water-based detergent to wash the brake drum or rotor and other brake parts.

7 The solution should be applied with low pressure to prevent dust from becoming airborne. Allow the solution to flow between the brake drum and the brake support or the brake rotor and caliper. T he 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 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 employer s procedures do not exceed the levels associated with the enclosed vacuum system or brake washing equipment. Consult OSHA regulations for more Wear a respirator equipped with a HEPA filter 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 NEVER use compressed air by itself, dry brushing, or a vacuum not equipped with a HEPA filter when cleaning brake parts or assemblies.

8 NEVER use carcinogenic solvents, flammable solvents, or solvents that can damage brake components as wetting Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filter 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 filter approved by NIOSH or MSHA for use with asbestos. When you replace a HEPA filter, wet the filter with a fine mist of water and dispose of the used filter with 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 filter to vacuum work clothes after they are worn. Launder them separately. Do not shake or use compressed air to remove dust from work Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA filters with care, such as in sealed plastic bags.

9 Consult applicable EPA, state and local regulations on waste GuidanceReferences 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. NON-ASBESTOS FIBERS WARNING 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 Meritor . Hazard SummaryMost 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.

10 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 , 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 Work Practices1. Separate Work Areas. Whenever feasible, service brakes in a separate area away from other operations to reduce risks to unprotected persons.

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Truck Troubleshooting Guide - Meritor WABCO

001 20/98

472 500 30. 0

MADE IN GERMANY

x

x

TruckTroubleshootingGuide

13 20

20

13

15

12

20

ECU

17

18B

INSET (A)

20

16

20B

11

20A

10

14

SECONDARY

CONTROL

18A

16

12

20

1

6

2

4

3

8

2

SECONDARY

9

13

20

15

FROM PARK

VALVE

TO SERVICE

RELAY

PRIMARY

TANK

INSET (A) OPTION

PRIOR TO MARCH 1, 1998 FMVSS-121 REGULATIONS

INVERSION VALVE AND QUICK RELEASE VALVE

(INCLUDES ANTI-COMPOUNDING)

13

20

19

SUPPLY

(WET TANK)

5

7

5

5

2

PRIMARY

9

20

COLOR KEY

SUPPLY

SECONDARY

PRIMARY

PARK/EMERGENCY

ABS ELECTRICAL

ISSUED 10/99 TP-9974


1

2

3

4

5

5

6

TruckTroubleshootingGuide

CONDITION/REMEDY CONDITION/REMEDY CONDITION/REMEDY CONDITION/REMEDY

COMPRESSOR

FOR TROUBLESHOOTING INFORMATION REFER TO THE OEM

OPERATING INSTRUCTIONS.

NOTE: If the compressor is manufactured by MeritorWABCO,

refer to Maintenance Manual 31 (318 Compressor for Mack

E Tech Engines) or contact the Meritor Customer Support

Center at 800-535-5560.

SUPPLY, PRIMARY AND SECONDARY AIR

TANKS

FOR TROUBLESHOOTING INFORMATION REFER TO THE OEM

OPERATING INSTRUCTIONS.

LOW PRESSURE INDICATOR SWITCH

BUZZER OR LIGHT INOPERABLE

Check ground and wiring on switch and buzzer/light.

Replace switch or buzzer/light.

WON’T OPERATE AT PRESSURES BELOW 60 P.S.I.

Check dash gauge for accuracy.

Replace switch or buzzer/light.

SAFETY VALVE

“POPS” OFF EXCESSIVELY

Check system pressure.

Valve operating properly when venting at 140/150 P.S.I.

(as required).

Check unloader/governor.

“POPS” OFF AT LESS THAN 140 P.S.I.

Replace.

LEAKS

Replace.

WON’T FUNCTION

Periodic Test: remove and test above 150 P.S.I. with shop air.

Replace if non-functional.

DRAIN VALVES - MANUAL

LEAKS

Replace.

DRAIN VALVES - AUTOMATIC

WON’T DRAIN

Repair or replace.

WON’T DRAIN IN COLD WEATHER

Replace with heated unit.

LEAKS - MALFUNCTIONS

Repair or replace.

Periodic Test: with system pressure stabilized (compressor

unloaded) no leak evident at discharge port - make several foot

brake applications to reduce wet tank pressure. Moisture

should drain from discharge port.

GOVERNOR

FLUTTERS

Check gauge.

Check unloader line size (5/16” x 5’ maximum).

Check air actuated accessory. Is the air volume requirement

greater than governor capacity

Check for plugged governor reservoir line.

Repair, adjust or replace governor.

WON’T PASS AIR TO UNLOADER TO “CUT-OUT” COMPRESSOR

Check governor reservoir line.

Repair or replace.

7

8

9

10

11

12

13

14

SINGLE CHECK VALVE

ALLOW BLEED BACK TO SUPPLY RESERVOIR

Periodic Test: bleed supply reservoir and observe gauges.

Check valves should maintain primary and secondary reservoir

pressure.

Replace if test results are negative.

PRESSURE CONTROL CHECK VALVE

WILL NOT PERMIT AIR TO PURGE AIR DRYER.

CHECK THAT ONE-WAY CHECK HAS BEEN REMOVED.

AIR GAUGE

FOR TROUBLESHOOTING INFORMATION REFER TO THE OEM

OPERATING INSTRUCTIONS.

DUAL SYSTEM FOOT BRAKE VALVE

LEAKS AT EXHAUST WITH ALL BRAKES RELEASED

Check anti-compound double check valve #16.

Check #18A & 18B for back flow into service control line.

Check seal in spring brake for back-flow of spring “hold-off”

pressure through service port to open exhaust on valve.

Replace #15 Spring Parking Brake.

CAUTION: CHOCK WHEELS - REPAIR AND REPLACE ITEMS AS

NECESSARY.

LEAKS AT EXHAUST WITH FOOT BRAKE APPLIED

Foot valve defective. Repair or replace.

LEAKS AT EXHAUST WITH ALL PARK BRAKES SET IN PARK

POSITION AND FOOT BRAKE RELEASED

Foot valve defective. Repair or replace.

QUICK RELEASE VALVE

LEAKS AT EXHAUST PORT WITH ALL BRAKES RELEASED

Check and replace #18A or 18B if back flow occurs into

secondary control line.

LEAKS WHEN SERVICE BRAKES ARE APPLIED

Repair or replace.

SERVICE BRAKE CHAMBER

FOR TROUBLESHOOTING INFORMATION REFER TO THE OEM

OPERATING INSTRUCTIONS.

SLACK ADJUSTER

FOR TROUBLESHOOTING INFORMATION REFER TO THE OEM

OPERATING INSTRUCTIONS.

NOTE: If the slack adjusters are manufactured by Meritor, refer

to Maintenance Manual 4B (Automatic Slack Adjusters) or

contact the Meritor Customer Support Center at 800-535-5560

(Ilamasin costo desde Mexico 001-800-889-1834).

RELAY VALVE

LEAKS AT EXHAUST PORT WITH ALL BRAKES RELEASED

Check seal in spring brake for back-flow of spring “hold-off”

pressure through service port to open exhaust on valve.

Replace #15 Spring Parking Brake.

Check reservoir port for evidence of contamination, check

supply lines for rusty fittings or carbon deposits. Repair or

replace.

LEAKS AT EXHAUST PORT WITH SERVICE BRAKES APPLIED

Exhaust valve not seating properly. Repair or replace.

15

16

17

18A

18B

19

SPRING PARKING BRAKE

(SERVICE ONLY SERVICE CHAMBER SIDE

OF SPRING BRAKE)

FOR TROUBLESHOOTING INFORMATION REFER TO THE OEM

OPERATING INSTRUCTIONS.

QUICK RELEASE AND DOUBLE CHECK

VALVE COMBINATION

FOOT VALVE EXHAUST LEAK PARK BRAKES RELEASED YELLOW

DASH CONTROL V VALVE EXHAUST LEAK IN PARK POSITION

AND SERVICE BRAKES APPLIED

Check anti-compound double check valve portion for feedback

to foot or dash control valve. Repair or replace.

STOP LIGHT SWITCH

LEAKS

Replace.

FAILS TO SIGNAL A GOOD BULB THROUGH SOUND WIRING AT

3-6 P.S.I.

Replace.

INVERSION RELAY VALVE WITH THE LOSS

OF REAR SERVICE BRAKES,

APPLICATION OF SPRING BRAKE BY

USING THE EMERGENCY SECTION

SHOULD BE AVAILABLE ALONG WITH

FRONT SERVICE BRAKE BY APPLYING

FOOT VALVE

PERIODICALLY TEST BY BLEEDING PRIMARY SERVICE TANK AND

OBSERVING FRONT BRAKE AND REAR SPRING BRAKE

APPLICATION UPON DEPRESSING FOOT PEDAL. REPAIR OR

REPLACE, IF AFTER CHECKING INVERSION VALVE IS NOT

FUNCTIONING PROPERLY.

LEAKS

Repair or replace.

AIR DRYER

AIR LEAKING CONSTANTLY FROM PURGE VALVE

Purge valve seal damaged. Replace.

Purge valve frozen.

Inspect heater (see heater problems).

HEATER INOPERATIVE

Blown Fuse. Check fuse and replace with 8-10 amp fuse

Broken wires or poor connections. Repair or replace wiring to

heater.

SLOW WET TANK BUILD-UP

Filter and/or desiccant plugged. Service air dryer.

If a System Saver Series air dryer is installed, refer to Meritor

WABCO Maintenance Manual 34 (Single Canister) or

35 (TWIN).

20

ABS ELECTRONIC CONTROL UNIT,

MODULAR VALVES, SENSORS, AND

TOOTH RINGS

FOR TROUBLESHOOTING INFORMATION REFER TO THE OEM

OPERATING INSTRUCTIONS.

20A

20B

FRONT AXLE VALVE PACKAGE

(OPTIONAL)

COMBINES TWO MODULATOR VALVES AND QUICK

RELEASE VALVE.

REAR AXLE VALVE PACKAGE

(OPTIONAL)

COMBINES TWO MODULATOR VALVES AND RELAY

VALVE.

NOTE: If the vehicle has MeritorWABCO ABS, refer to Meritor

WABCO Maintenance Manual 28 (C version ABS) or 30

(D version ABS).

MeritorWABCO Vehicle Control Systems

2135 West Maple Road

Troy, MI 48084-7121 USA

800-535-5560

meritorwabco.com

Information contained in this publication was in effect at the time the publication was approved for printing and is subject to

change without notice or liability. MeritorWABCO reserves the right to revise the information presented or to discontinue the

production of parts described at any time.

Copyright 1999

ArvinMeritor, Inc.

All Rights Reserved

Printed in USA

TP-9974

Issued 10-99

16579/22882

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Magazine: Truck Troubleshooting Guide - Meritor WABCO

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Manual wabco troubleshooting

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Manually Troubleshooting Meritor Wabco ABS System Blink Codes on a Freightliner

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