Professional Documents
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$2.50
BS
Anti-Lock
Braking System
Training Program
Student Manual
TP-9738
Revised 3-99
Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ABS System Overview and Components . . . . . . . . . . . . . . . . . . . . 3
System Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1-1
1-2
Section Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Anti-Lock Braking System (ABS) Overview . . . . . . . . . . . . . . . . . 5
ABS Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ABS Operation Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ABS Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ABS Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Wheel-Speed Sensing System Components . . . . . . . . . . . . . . . 7
Tooth Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Wheel Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Sensor Holder and Spring Clip . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Sensor Extension Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electronic Control Unit (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ECU Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ABS Modulator Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Vehicle Wheel/ABS Configurations . . . . . . . . . . . . . . . . . . . . 13
ABS Indicator Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Blink Code Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
J-1587 Diagnostic Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Section Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Progress Check 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1-3
1-4
ABS Operation
Summary
ABS takes over control of the air pressure whenever a wheel starts
to lock up. Sensors continuously monitor wheel speed and send
this information to an Electronic Control Unit (ECU). When a
wheel starts to lock, the ECU, using the wheel-speed information
and programmed data, sends output signals to control the
operation of the ABS valves. The ECU causes the ABS valves to
adjust air pressure supplied to the brake chambers to control
braking and prevent wheel lockup.
1-5
Features
Benefits
Individual control of
steering and drive
wheels
Fail-safe system
Automatic traction
control (optional)
1-6
Tooth Wheel
The tooth wheel normally has 100 evenly spaced teeth and is
usually mounted to the barrel of the hub on each sensed wheel.
Tooth Wheel
1-7
Sensor Extension
Cable
1-8
ECU Types
1-9
CAB-MOUNTED
ECU
FRAME-MOUNTED
ECU
ECU
1-10
The ABS modulator valve regulates air pressure to each ABScontrolled brake. During normal braking, the ABS modulator
valves are not activated and air flows through the ABS valve into
the brake chambers. During ABS operation, the ABS valves
modulate air pressure in the brake chambers to control braking
and prevent wheel lockup.
The ABS valve is a solenoid-controlled air valve, consisting of two
electrically operated solenoids and two diaphragm valves. The
ECU controls the solenoids, which are extremely fast acting. They
control pressure on the diaphragms, which then open or close
passages to supply pressure to, or exhaust pressure from, the
brake chamber.
The ABS valve has three air ports:
r The supply port receives air pressure from the relay valve.
r The delivery port delivers air pressure to the brake
chambers.
r The exhaust port exhausts air pressure only from the
delivery-port side during ABS control.
2
1
ABS Valve
1-11
A typical 4S/4M ABS will have four ABS valves, one for each side
of the steering axle and one for each side of the drive axle(s). The
valves are usually attached to a frame rail or crossmember,
between the relay valve or quick-release valve and the brake
chamber. For a tandem drive axle, both wheels on the same side
are controlled by a single valve.
An ABS Valve Package is an alternative to individual valves on
the rear axle. The rear axle package combines two ABS valves and
one service relay valve. The front axle valve package combines
two ABS valves and one quick release valve. The valve package is
usually attached to a frame crossmember.
ABS harnesses connect the valve solenoids to the ECU.
xxx
x xx
xxxx x xxxxx
xxxx
001 20/98
472 500 30. 0
MADE IN GERMANY
1-12
The ABS indicator lamp is located on the dash panel. The lamp is
lit when the ABS system is performing a self-test or when a fault
has been detected in system. The lamp is also used to display
fault codes.
This switch signals the ECU to activate the ABS indicator lamp
so that it can blink out the fault codes. Switch types and
locations vary depending on the make and model of the vehicle.
J-1587 Diagnostic
Connector
1-13
PNEUMATIC
ELECTRIC
TOOTH WHEEL
TOOTH WHEEL
SENSOR
ECU
SENSOR
ABS
VALVE
PACKAGE
ABS
MODULATOR
VALVES
SENSOR
SENSOR
TOOTH WHEEL
TOOTH WHEEL
6S/4M System
PNEUMATIC
ELECTRIC
TOOTH WHEEL
TOOTH WHEEL
TOOTH WHEEL
SENSOR
SENSOR
ECU
SENSOR
ABS
VALVE
PACKAGE
ABS
MODULATOR
VALVES
SENSOR
SENSOR
SENSOR
TOOTH WHEEL
TOOTH WHEEL
TOOTH WHEEL
6S/6M System
PNEUMATIC
ELECTRIC
TOOTH WHEEL
TOOTH WHEEL
ECU
TOOTH WHEEL
SENSOR
SENSOR
SENSOR
ABS
MODULATOR
VALVES
ABS
VALVE
PACKAGE
SENSOR
SENSOR
SENSOR
TOOTH WHEEL
TOOTH WHEEL
ABS Configurations
1-14
TOOTH WHEEL
1-15
2.
The blink code switch and lamp allow access to stored fault
___________ without using a diagnostic tool.
3.
4.
5.
6.
1-16
System Operation
Table of Contents
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Wheel Speed Sensor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
ECU Operation (ABS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
ABS Modulator Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . 24
Normal (Without Anti-Lock) Brake Application Supply. . . 24
Normal (Without Anti-Lock) Brake Application Exhaust . . 24
Anti-Lock Brake Control Exhaust . . . . . . . . . . . . . . . . . . . . . . 25
Anti-Lock Brake Control Hold. . . . . . . . . . . . . . . . . . . . . . . . . 26
Anti-Lock Brake Control Reapply . . . . . . . . . . . . . . . . . . . . . . 27
ABS Indicator Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Retarder Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Section Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Progress Check 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1-17
System Operation
Overview
Inputs
Processing
Outputs
1-18
System Operation
INPUTS
Overview
1-19
System Operation
Wheel Speed Sensor
Operation
TIME
SENSOR
VOLTAGE
1-20
System Operation
TOOTH
WHEEL
TOOTH
WHEEL
SENSOR
SENSOR
BLINK
CODE
SWITCH
J1587
DIAGNOSTIC
CONNECTOR
ECU
TOOTH
WHEEL
TOOTH
WHEEL
SENSOR
SENSOR
1-21
System Operation
PROCESSING
Overview
1-22
System Operation
OUTPUTS
Output Signals
1-23
System Operation
ABS Modulator Valve
Operation
1-24
System Operation
ABS Modulator Valve
Operation (Cont.)
1-25
System Operation
ABS Modulator Valve
Operation (Cont.)
Pressure Constant
1-26
System Operation
ABS Modulator Valve
Operation (Cont.)
1-27
System Operation
ABS Indicator Lamp
The ABS indicator lamp is located on the dash panel. When the
ignition switch is turned to the ON position, it lights, indicating
that the ABS is performing a self-test. When the self-test is
complete, the lamp goes out.
If the indicator lamp remains lit or comes on at any other time
during vehicle operation, a potential fault exists in the ABS
system. Additionally, if a sensor adjustment fault existed the last
time the ignition was shut off, but has been repaired, the indicator
lamp will not go off until the vehicle has been driven over four
mph. This allows the ECU to verify that the fault has been
corrected.
The ABS indicator lamp operation is controlled either by the ECU
or by the main connector to the ECU.
The ABS indicator lamp receives power from the ignition switch
whenever it is turned on. The other side of the lamp is grounded
both through the ECU and either the specially designed main
connector or an electrical relay. Either device can complete the
ground circuit, thereby turning on the lamp.
The Meritor WABCO electronic control unit uses the ABS
indicator lamp to flash blink codes, identifying specific faults in
the ABS.
The procedures for displaying, interpreting and erasing blink
code faults are presented in the Blink Code Diagnostics and
Fault Analysis section of Module Two.
Retarder Control
During an ABS event, the ECU sends a signal to shut off the
retarder. It can do this in one of two ways:
1.
2.
1-28
System Operation
ABS
MODULATOR
VALVES
RETARDER
RELAY
J1922/J1939
DATA LINK
J1587
DIAGNOSTIC
CONNECTOR
ECU
ABS VALVE
PACKAGE
1-29
System Operation
Section Summary
1-30
System Operation
Progress Check 1-2
2.
3.
4.
5.
1-31
System Operation
Notes
1-32
Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Electronic Diagnostics Overview . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Blink Code Diagnostics and Fault Analysis . . . . . . . . . . . . . . . . .11
Using MPSI Pro-Link 9000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Component Removal and Installation . . . . . . . . . . . . . . . . . . . . . .33
2-1
Section Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electronic Diagnostic Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Error Detection and Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Error Detection Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Start-Up Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Continuous Passive Monitoring . . . . . . . . . . . . . . . . . . . . . . . 6
Control System Response to Errors. . . . . . . . . . . . . . . . . . . . . 7
Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Section Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Progress Check 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2-3
2-4
2-5
Start-Up Self-Test
The ECU briefly triggers the ABS valves during each ignition
cycle. At the same time, it checks wheel speed sensors and other
essential ABS electronic components. It will then shut off the ABS
indicator lamp if no failures are found and if the wheel speed
sensors were in adjustment the last time the ignition was shut off.
Note: If the gap between a sensor and tooth wheel is too large for proper
wheel-speed output during low vehicle speeds, the indicator lamp
will come on, even if normal ABS operation would be possible at
higher vehicle speeds.
Continuous Passive
Monitoring
2-6
The table below lists possible ABS system errors and responses.
Detected Error
Component or wiring
failure
Individual electronic
component fails
internally in the ECU.
2-7
2-8
2-9
1.
With each ignition cycle, the ECU briefly triggers the ABS
______________.
2.
3.
2-10
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Blink Code Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Blink Code Operating Parameters. . . . . . . . . . . . . . . . . . . . . . . . . 13
Blink Code Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Blink Code Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Clearing Faults from ECU Memory . . . . . . . . . . . . . . . . . . . . . . . 16
System Configuration Blink Code . . . . . . . . . . . . . . . . . . . . . . . . . 16
Circuit Pinpoint Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Pinpoint Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Testing Resistance at Component . . . . . . . . . . . . . . . . . . . . . . . . . 18
Diagnostic Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Section Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Progress Check 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2-11
The blink code system allows you to identify fault codes stored in
the electronic control unit memory. This section will show you
how to:
r Access stored fault codes through the blink code switch and
lamp
r Interpret fault codes.
r Clear fault codes from the ECU memory
r Check ABS system configuration
2-12
With D version ABS, the blink code system uses the ABS
indicator lamp to display blink codes.
2-13
Follow these steps to access fault codes through the blink code
feature:
1.
2.
Press and hold the blink code switch for one second, then
release.
3.
4.
5.
After activating the ABS blink code switch, the blink code cycle is
as follows (refer to the illustrations on the facing page):
1.
2.
3.
4.
5.
6.
7.
The blink code cycle keeps repeating for an active fault code
until the ignition switch is turned OFF.
8.
For stored fault codes, each of the stored codes are displayed
once and then the cycle stops. To repeat the stored fault codes
again, press the blink code switch for one second.
If there are no faults in the ECU memory, the displayed blink code
will be 1-1.
2-14
1 Second
Hold
Active Fault
1-8 Flashes
1-6 Flashes
Pause
Pause
Pause
Pause
1.5 s
1.5 s
4s
1.5 s
Light ON
1st Digit
2nd Digit
(2)
(3)
Continues until
ignition is turned off
(3)
1 Second
Hold
Off
Stored Faults
Pause
Pause
Pause
Pause
1.5 s
1.5 s
4s
1.5 s
Light ON
1st Digit
2nd Digit
1st Digit
(2)
2nd Digit
2nd Stored Fault
(3)
(4)
1 Second
Hold
System O.K.
Pause
1.5 s
Light ON
Pause
System OK
1.5 s
(1)
(1)
S = Seconds
Interpreting Blink Codes
2-15
Press the blink code switch and hold it for three seconds, then
release. This will place the blink code system into the clear
mode.
The system will display eight quick flashes to indicate that the
fault(s) was cleared. This will be followed by the system
configuration code, which will keep repeating until the ignition
is shut off. If there were no quick flashes, then no fault codes
have been erased.
Note: Active fault codes must be repaired before they can be erased
from ECU memory. However, it is possible to erase stored fault
codes from ECU memory as long as the condition does not exist
at that time.
If you cannot clear a corrected fault from the ECU memory,
either the fault was not properly repaired or a problem may exist
within the ECU. Contact your Meritor District Service Manager
at 1-800-535-5560 in the U.S. or Canada.
System Configuration
Blink Code
2-16
3 Second
Hold
Faults Cleared
Pause
Pause
Pause
Pause
Pause
1.5 s
4s
4s
4s
4s
Light ON
System ID
System ID
(2)
(2)
Continues until
ignition is
turned off
System ID
System ID
(2)
(2)
3 Second
Hold
Light ON
Pause
Pause
Pause
4s
4s
4s
4s
System ID
System ID
System ID
System ID
(2)
(2)
(2)
(2)
S = Seconds
Clearing Fault Codes
2-17
2-18
Testing Resistance at
Component
2-19
A driver reports that his vehicles ABS lamp came on and stayed
on during his last trip. A technician activates the blink code
system and retrieves active fault code 3-5. The technician consults
the latest Maintenance Manual to determine where the fault is
located.
The Blink Code Identification chart identifies the fault as:
Too much sensor gap in the right rear/rear tandem drive axle (curb
side).
2-20
Sensor
LF
Connector
6-Pin
Pins
4 and 5
RF
LR
9-Pin
15-Pin
4 and 5
5 and 6
RR
15-Pin
8 and 9
Sensor
LF
Connector
X2 Black
Pins
7 and 8
RF
LR
X2 Black
X3 Green
5 and 6
1 and 2
RR
X3 Green
3 and 4
2-21
2-22
The blink code cycle is repeated for an active fault code until
the ___________________ switch is turned OFF.
2.
3.
4.
2-23
2-24
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
MPSI Pro-Link 9000 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Using the Pro-Link 9000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Pro-Link Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Component Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
System Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Section Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Progress Check 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2-25
2-26
ADAPTER
DATA
CARTRIDGE
2-27
Pro-Link Functions
There are seven major functions that can be performed using the
Pro-Link 9000:
r Existing Fault This function provides descriptions of the
existing faults recorded in the ECU memory.
r Stored Fault This function provides descriptions of the
stored (intermittent) faults recorded in the ECU memory.
r Program ID This function provides information about the
ECU, including the software version number, ECU part
number and ECU build date.
r Component Tests This function allows you to test a variety
of ABS and ATC components. The available tests are
described on the following pages.
r System Setup This function allows you to configure the ProLink tool to match the vehicles ABS component
configuration.
r RS-232 Serial Port This selection allows you to configure
the serial port on the Pro-Link for use with a printer or
personal computer.
r Contrast Adjust The Pro-Link display screen contrast can
be adjusted either lighter or darker through this function.
Consult Pro-Link 9000 users manual for more information on
accessing and using these functions.
2-28
2-29
2-30
2-31
2.
2-32
Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Front Wheel Speed Sensor Replacement . . . . . . . . . . . . . . . . . . . . 35
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Rear Wheel Speed Sensor Replacement . . . . . . . . . . . . . . . . . . . . . 36
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
ABS Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Checking Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Road Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Progress Check 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2-33
2-34
Removing
1. Place blocks under the rear tires to stop the vehicle from
moving. Raise the front of the vehicle until the tires are off the
ground. Place safety stands under the axle.
2. Use a twisting motion to remove the sensor from the steering
knuckle. Do not pull on the sensor cable.
3.
4.
5.
Installing
1. Connect the sensor cable to the chassis harness.
2. Install the fasteners that hold the sensor cable in place.
3. Apply a mineral oil-based lubricant that contains
molydisulfide to the sensor spring clip and body of the
sensor. Use a lubricant that has excellent anti-corrosion and
adhesion characteristics and is capable of continuous
function in a temperature range of -40 to 300F (-40 to
149C).
4. Install the sensor spring clip into the bushing in the steering
knuckle. The spring clip must be installed with the flange
stops on the inboard side of the vehicle.
5. Push the sensor completely into the sensor spring clip until it
contacts the tooth wheel. If the hub is not yet installed, push
the sensor all the way into its holder.
6. Remove blocks and safety stands.
2-35
Removing
1. Place blocks under the front tires to stop the vehicle from
moving.
2. Raise the rear of the vehicle until the tires are off the ground.
3. Place safety stands under the axle.
4. Release the parking brake.
5. Remove the wheel and tire assembly from the axle.
6. Remove the brake drum. It may be necessary to back off the
slack adjuster before removing the drum.
7. Use a twisting motion to remove the sensor from the
mounting block in the axle housing. Do not pull on the
sensor cable.
8. Remove the sensor spring clip from the mounting block.
9. Disconnect the fasteners that hold the sensor cable to other
components.
10. Disconnect the sensor cable from the chassis harness.
Installing
1.
2.
Install the sensor spring clip into the mounting block. The
spring clip must be installed with the flange stops on the
inboard side of the wheel end.
3.
Push the sensor completely into the sensor spring clip until it
contacts the tooth wheel. If the hub is not yet installed, push
the sensor all the way into its holder.
2-36
4.
Insert the sensor cable through the hole in the spider and
axle housing flange. Route the cable to the frame rail. Be
sure to route the cable in a way that prevents pinching or
chaffing, and allows for sufficient movement for suspension
travel.
SPRING CLIP
SENSOR
SENSOR
HOLDER
SPRING
CLIP TAB
5.
6.
7.
8.
9.
2-37
Removing
1.
2.
Disconnect the air supply line from ABS valve port 1 and
disconnect the air delivery line from port 2.
3.
4.
Installing
1.
2.
3.
4.
ABS Valve
Checking Installation
1.
2.
3.
2-38
Always road test the vehicle after repairing or servicing the ABS
or ATC system. The procedure is:
1.
2.
Check that all sensor, ABS valve and ATC valve connectors
are securely attached.
3.
4.
5.
6.
7.
8.
2-39
2.
3.
2-40
3-1
3-2
3-3
3-4
Section Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Automatic Traction Control (ATC) Overview. . . . . . . . . . . . . . . . . 7
ATC Operation Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ATC Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electronic Control Unit (ECU) ATC Operation. . . . . . . . . . . . 8
ATC Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ATC Solenoid Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . 9
ATC Solenoid Valve Location . . . . . . . . . . . . . . . . . . . . . . . . . 10
SAE J1922/J1939 Data Link . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ATC Indicator Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DEEP SNOW/MUD Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Section Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Progress Check 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-5
3-6
Features
Benefits
Differential braking
and electronic
engine control
DEEP SNOW/MUD
switch (optional)
3-7
3-8
ATC Valve
3-9
ATC
VALVE
SUPPLY
LINE
FOOT VALVE
CONTROL LINE
DELIVERY
LINES
CONTROL
LINE
SUPPLY
LINE
ATC
VALVE
FOOT VALVE
CONTROL
3-10
DEEP SNOW/MUD
Switch
3-11
3-12
2.
3.
4.
5.
3-13
3-14
ATC Diagnostics
Table of Contents
Section Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Blink Code Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Dynamometer Testing of Vehicles with ATC . . . . . . . . . . . . . . . . 17
ATC Valve Pinpoint Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
MPSI Pro-Link 9000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Component Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Section Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Progress Check 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3-15
ATC Diagnostics
Section Overview
3-16
ATC Diagnostics
Blink Code
Diagnostics
The blink code system allows you to identify fault codes stored
in the electronic control unit memory. Refer to modules 2 and 3
for instruction on accessing and interpreting blink codes.
Dynamometer
Testing of Vehicles
with ATC
Note: If all faults are cleared, the blink code lamp will flash eight times
before it enters the configuration mode. If faults are present, the
blink code lamp will immediately enter the configuration mode.
3-17
ATC Diagnostics
ATC Valve Pinpoint
Test
3-18
ATC Diagnostics
MPSI Pro-Link 9000
Module 2 described how to use the MPSI Pro-Link 9000 handheld electronic service tools to diagnose ABS faults. ATC
diagnostics is accomplished in the same manner. Also refer to
the Pro-Link 9000 users manual for more information.
Component Tests
3-19
ATC Diagnostics
Section Summary
3-20
ATC Diagnostics
Progress Check 3-2
2.
3-21
ATC Diagnostics
Notes
3-22
Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
ATC Valve Replacement (Individually Mounted) . . . . . . . . . . . . 25
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
ATC Valve Replacement (ABS Valve Package). . . . . . . . . . . . . . . 27
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Checking ATC Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Progress Check 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3-23
3-24
Removing
1.
2.
Block the front and rear tires. Raise the vehicle, if necessary.
3.
Bleed air pressure from the supply reservoir that feeds the
ATC valve.
4.
5.
Disconnect the air supply line from ATC valve port 1, the
control line from port 2 and the foot valve control line from
port 3.
CONTROL LINE
TO RELAY VALVE
PORT 1
(AIR SUPPLY
FROM RESERVOIR)
PORT 2
VALVE CONTROL
DO NOT OPEN
PORT 3
FOOT VALVE
CONTROL LINE
6.
CAPSCREWS
7.
3-25
Installing
1.
2.
3.
4.
Lower the vehicle if it has been raised and remove the blocks.
5.
3-26
Removing
Note: If there is enough room to work, it is not necessary to remove
the valve package from the vehicle before replacing the ATC
valve.
1. Turn the ignition switch to the OFF position.
2. Block the front and rear tires. Raise the vehicle, if necessary.
3. Bleed air pressure from the supply tank that feeds the valve.
4. Disconnect the harness connector from the ATC valve.
5. Disconnect the air supply line from the supply port on the
adapter.
6. Disconnect the foot valve control line from the ATC valve.
7. Use a 5 mm Allen wrench to remove the two screws that
hold the adapter to the relay valve portion of the valve
package.
8. Use a 6 mm Allen wrench to remove the two mounting bolts
that hold the ATC valve to the adapter.
9. Remove the ATC valve from the adapter.
10. Remove the adapter, seal and O-ring from the valve
package.
MOUNTING BOLTS
ATC VALVE
FOOT VALVE
CONTROL LINE
SEAL
ADAPTER
O-RINGS
SUPPLY
AIR LINE
3-27
Installing
Note: When installing the new ATC valve on the valve package, you
must use new O-rings, seal, mounting bolts, and lubricant
included with the replacement kit.
1. Clean and lubricate the small adapter O-ring and install the
O-ring on the adapter.
2. Use two new bolts to attach the ATC valve to the adapter.
3. Lubricate the replacement seal and install it in port 2 of the
ATC valve.
4. Lubricate the large replacement O-ring and install it in the
groove of the relay valve supply port.
xxxxx
xxxxx xxxxx
xxxxx
RELAY VALVE
SUPPLY PORT
3-28
1.
2.
3.
4.
5.
6.
7.
If the ABS and ATC indicator lamp does not go out, check for
faults.
8.
9.
3-29
2.
3-30
3-31
Information contained in this publication was in effect at the time the publication was approved for printing and is subject to
change without notice or liability. Meritor WABCO reserves the right to revise the information presented or to discontinue the
production of parts described at any time.
Copyright 1999
ArvinMeritor, Inc.
All Rights Reserved
Printed in USA
TP-9738
Revised 3-99
16579/22882