L30030W 6/03 PLC, PLC Plus and PLC Select Trailer ABS Installation/Service Manual Innovative Vehicle Technology PLC4Trucks $7.00 PLC, PLC Plus, & PLC Select Technical Service and Engineering Support In the U.S., please call: Brake Systems Division World Headquarters 1-800-643-2374 (Press 2) In Canada, please call Brake Systems Division Haldex, Limited 1-800-267-9247 PLC, PLC Plus, & PLC Select Table of Contents Contents: Table of Contents........................................ 1 General Operation………………….…..... 2-3 Sensor Block Installation…………............ 4 Exciter Ring Installation...........……............5 Wheel Speed Sensor Installation............... 6-12 ABS System Plumbing....…………............13-18 PLC Family Application....…………...........19 PLC Select..........…………........................ 20 - Hardware - Electrical Wiring - Installation Test - Road Test - Troubleshooting/Diagnostics - PLC Select PLC....................................………............ 32 - Hardware - Electrical Wiring - Installation Test - Road Test - Troubleshooting/Diagnostics - PLC PLC Plus...............................………............47 - Hardware - Electrical Wiring - Installation Test - Road Test - Troubleshooting/Diagnostics - PLC Plus Diagnostics..........................………............ 62 - Blink Codes - PLC Info Center - PLC - PC Diagnostics - Diagnostic Fault Code List InfoCenter..........................………............ 72 Safety First! Please follow your company’s safety procedure when you install this equipment. Be sure that you understand all instructions before you begin. Note: Remove all air pressure and electrical power from the brake system before beginning work. 1 PLC, PLC Plus, & PLC Select General Operation General Operation ABS Basics: The PLC family of Trailer ABS, is the latest in a full line of Haldex trailer ABS systems that provide stability and control during braking by preventing wheel lock up. As with other ABS systems, PLC uses a combination of valves, sensors, exciter rings, and the Electronic Control Unit (ECU) working in union to maximize the control of a braking trailer. When the ECU detects the rapid decrease in speed of a wheel about to lock up, it releases the air pressure from the brake chambers of the affected wheel via one or two modulator valves. The release of air from the chambers prevents the wheels from locking up and ensures vehicle stability. As soon as the wheels begin to rotate again, the ECU signals the modulator valve(s) to reapply the pressure in the affected brake chambers to maximize brake effort. If the condition that caused the lock up remains, the cycle is repeated until either the vehicle is stopped, or the brake has been released. This function is totally automatic and can occur up to six times per second. Configurations: A 2S/1M system is the most popular configuration. This system is the least complex and simplest to install. There are 2 sensors and 1 ABS Modulator Relay Valve. The system meets the minimum FMVSS-121 ABS requirements for semi-trailers and dollies, and is designed to work on 1, 2, or 3 axle trailers, or dollies. A 2S/2M system is the least popular configuration. In most cases, there is no significant benefit of a 2S/2M system over the 2S/1M SLH product. Consult Haldex Engineering for assistance in this area. A 4S/2M system offers the best performance overall on multiple axle trailers and is required by FMVSS 121 for full trailers. The control is provided through 4 sensors and 2 Modulator valves. The system has the flexibility to be installed as 4S/2M Side-By-Side control, with lift axle compatibility, or 4S/2M Axle-By-Axle control. All configurations meet the requirements of FMVSS-121. The 4S/2M system can be installed on a variety of trailers. Full trailers, spread axle trailers, and multiple axle trailers are particularly well suited to this system. 2 PLC, PLC Plus, & PLC Select General Operation Available Options: PLC, PLC Plus and PLC Select systems are available in 2 valve platforms: With a patented Haldex Full Function ABS (FFABS) Valve or an ABS Relay Valve. The differ- ence is that FFABS uses a single valve to provide the ABS function and control the spring (emergency) brakes as well as the service brakes (along with pressure protec- tion and anti-compounding features). The ABS Relay is a 2 valve system which re- quires a separate spring brake control valve such as the Haldex RT-4. PLC PLus, and PLC system have two Select Low High software versions available. The SLH-A7 software is designed for multiple axle trailers. The SLH-A8 software is required on dollies and single axle trailers. Do not use SLH-A7 on dollies or single axle trailers. PLC, PLC Plus and PLC Select Trailer ABS all come standard with an Electronic Hub Odometer. This feature can be accessed through a Haldex Info Center or through PC Diagnostics and the appropriate adapter. Installation: Installation of the PLC systems can be completed in 4 easy steps: 1. Installation of wheel speed sensors and related hardware, if required (see page 4 - 5). 2. Installation of ABS Relay Valve(s) and related hardware (see page 6 - 9, 13 - 18). 3. Installation of electrical system (see pages 22, 34 - 38, 49 - 53) PLC, PLC Plus and PLC Select). 4. Final system checkout (see pages 23 - 25, 39 - 40, 54 - 55). An important consideration of installing ABS is placement of the wheel sensors. This is especially true when an ABS relay (modulator) valve controls multiple axles. Haldex recommends that the sensors be placed on the axle that will lock first during a brake application. Information on which axle that is mostly likely to lock is included in this Manual. Refer to (pages 6 - 11) for sensor placement on standard suspension configu- rations. In the Event of a Malfunction: In the event of a failure in the permanent power circuit, the system will receive power from the stoplight circuit and work normally. If the power fails in both circuits, the system re- verts to a standard braking system. Refer to the Troubleshooting section of this manual on pages 26 - 31, 41 - 46, 56 - 61 and the diagnostics section on (pages 62 - 71). 3 PLC, PLC Plus, & PLC Select Sensor Block Installation No more than .080” .156 ± .031" Sensor off center Centerline (CL) B Exciter Ring Block C Exciter Ring Block ± 2.5° C L Centerline (CL) C ± 2.5° L No more than .080” Sensor A off center .156 ± .031" Sensor Block; allowable placement 9 O'clock 3 O'clock Figure 1 Axle Sensor Block Sensor Clip Sensor Sensor Block Installation: The clearance between block and exciter ring should be 0.156 ± .031”. Any deviation from this clearance as a result of hub exciter ring position must be approved by the sensor manufacturer. The radial clocking position should be between 9 and 3 O’clock see Figure 1A. While the ABS performance is not affected with the sensor located in the lower half of the axle, the structural integrity of the axle could be compromised. The sensor block should not interfere with any wheel end hardware. In general, the position of the wheel speed sensor center axis to the exciter ring surface should be as close as possible to a 90° angle in both directions (see Figure 1B). Deviation will result in a reduction of the wheel speed sensor signal output. The sensor block must be mounted to provide adequate sensor to exciter ring contact. When the sensor is pushed against the exciter ring, the centerline of the sensor should be no more than .080” above or .080” below the centerline of the exciter teeth (see Figure 1C). Note: The sensor block is generally welded to the axle. Refer to axle manufacturer’s manual to insure that welding won’t affect structural integrity. 4 PLC, PLC Plus, & PLC Select Exciter Ring Installation Figure 2 .530 .470 .03 X 15° Chamfer 5 R .06 2 1 125 6.00 Dia. 6.501 Maximum 6.499 Dia. Seal Bore 100 Tooth Exciter Ring Exciter Ring Machining: 1. Remove the hub and drum assemblies of all wheel ends. 2. Ensure the hub has a seal bore of 6.00” inches or less (see figure 2). 3. Machine area to the dimensions indicated in Figure 2. Figure 3 Hub Press the exciter ring right to the shoulder allowing no gaps Exciter Ring Exciter Ring Installation: 1. Heat the exciter ring uniformly to approximate 350° F. 2. Place the exciter ring on the machined area of the axle hub (see figure 3). 3. Make sure the exciter ring fits squarely onto the machined surface of the hub. 4. When the exciter ring cools, it will shrink fit on the hub. 5. Make sure the exciter ring fits tightly onto the machined area and does not slip. 5 PLC, PLC Plus, & PLC Select Wheel Speed Sensor Installation 2S/1M Configurations: Sensors should be installed on the axle that locks first when the trailer is loaded. Recommended locations are shown below. The 1A sensor should be installed on the curb side, and the 1B sensor should be installed on the road side of the trailer. Make sure sensors are pushed firmly against the exciter rings. Dollies and Single Axle Trailers: Use 6 port valve Use 2 port valve Use 2 port valve Multi- Axle Trailers Use 4 or 6 port Valve Spring Suspension Spring Suspension Air Suspension Air Suspension Sensor Fitting ECU w/ABS Valve King Pin 6 PLC, PLC Plus, & PLC Select Wheel Speed Sensor Installation 2S/2M Configurations: Sensors should be installed on the axle that locks first when the trailer is loaded. Recommended locations are shown below. The 2A sensor should be installed on the curb side, and the 2B sensor should be installed on the road side of the trailer. Make sure sensors are pushed firmly against the exciter rings. Note: The 2S/2M configuration does not offer any meaningful performance benefit over a 2S/1M SLH-A7 configuration, and is not a preferred system. To obtain additional performance beyond a 2S/1M configuration, Haldex recommends the use of a 4S/2M system. Multi-Axle Trailers: Sensor ECU w/Valve Valve King Pin 7 PLC, PLC Plus, & PLC Select Wheel Speed Sensor Installation 4S/2M Axle-by-Axle Configurations: The placement of the sensors at the wheel end is an important consideration. Incorrect installation of the sensors and exciters will result in poor or no ABS operation. Sensors connected to yellow leads must sense the wheel controlled by the valve connected to the yellow valve lead. Similarly, sensors connected to blue leads must sense the wheel controlled by the valve connected to the blue lead. In the case of a 4S/2M Axle-By-Axle configuration, the blue modulator lead must be connected to the valve that controls the front axle wheel ends and is sensed by the blue sensors (3A and 2A). The yellow valve cable lead must be connected to the valve that controls the rear axle wheel ends and is sensed by the yellow sensors (3B and 2B). The schematic below shows the proper placement of the sensor and valve leads (the king pin indicates the front of the trailer). Make sure sensors are pushed firmly against the exciter rings. Wrong Correct Wrong Multi-Axle Trailers: Sensor ECU w/Valve Valve King Pin 8