WABCO ABS User manual

ANTI-LOCK BRAKING SYSTEM
(ABS) AND ELECTRONIC
STABILITY CONTROLS (ESC):
FOR E VERSION ECUs
MAINTENANCE MANUAL

Service Notes
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.
WABCO reserves the right to revise the information presented or to discontinue the
production of parts described at any time.
WABCO Maintenance Manual MM-0112 (Revised 07-18)
About This Manual
This manual contains maintenance procedures for WABCO’s
Anti-Lock Braking System (ABS), Roll Stability System (RSC),
Electronic Stability Controls (ESC) and Hill Start Aid (HSA).
Before You Begin
1. Read and understand all instructions and procedures before
you begin to service components.
2. Read 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 both.
3. Follow your company’s maintenance and service, installation
and diagnostics guidelines.
4. Use special tools when required to help avoid serious personal
injury and damage to components.
Hazard Alert Messages and Torque
Symbols
Read 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 both.
WARNING
A Warning alerts you to an instruction or procedure that you
must follow exactly to avoid serious personal injury and
damage to components.
CAUTION
A Caution alerts you to an instruction or procedure that you
must follow exactly to avoid damage to components.
@This symbol alerts you to tighten fasteners to a specified torque
value.
WARNING
To prevent serious personal injury, always wear safe eye
protection when you perform vehicle maintenance or service.
Release all air from the air systems before you remove any
components. Pressurized air can cause serious personal
injury.
CAUTION
When welding on an ABS- or ABS/ATC-equipped vehicle is
necessary, disconnect the power connector from the ECU to
prevent damage to the electrical system and ABS/ATC
components.
How to Obtain Additional Maintenance,
Service and Product Information
Visit wabco-auto.com to access and order additional information.
Contact WABCO North America Customer Care at 855-228-3203
(United States and Canada); 001-800-889-1834 (Mexico).
If Tools and Supplies are Specified in
This Manual
Call Meritor’s Commercial Vehicle Aftermarket at 888-725-9355 to
obtain Meritor tools and supplies.

Asbestos and Non-Asbestos Fibers
i
WABCO Maintenance Manual MM-0112 (Revised 07-18)
ASBESTOS FIBERS WARNING
The followingproceduresfor servicingbrakesare recommendedto reduce exposure to
asbestosfiber dust, a cancer andlungdisease hazard. Material Safety Data Sheetsare
available from WABCO.
Hazard Summary
Becausesomebrakelinings contain asbestos, workers who servicebrakes must understandthe
potential hazards of asbestos andprecautions for reducing risks. Exposureto airborneasbestos
dust can causeserious andpossibly fatal diseases, including asbestosis (achronic lung disease)
andcancer, principally lung cancer andmesothelioma(acancer of thelining of thechest or
abdominal cavities). Somestudies show that therisk of lung cancer among persons who smoke
andwho areexposed to asbestos is much greater than therisk for non-smokers. Symptoms of
thesediseases may not becomeapparent for 15, 20 or moreyears after thefirst exposureto
asbestos.
Accordingly, workers must usecaution to avoidcreating andbreathing dust when servicing brakes.
Specific recommended work practices for reducing exposureto asbestos dust follow. Consult your
employer for moredetails.
Recommended Work Practices
1. SeparateWork Areas. Whenever feasible, servicebrakes in aseparatearea away from other
operations to reducerisks to unprotected persons. OSHA has set amaximum allowablelevel of
exposurefor asbestos of 0.1 f/cc as an 8-hour time-weighted averageand1.0 f/cc averaged over
a30-minuteperiod. Scientists disagree, however, to what extent adherenceto themaximum
allowableexposurelevels will eliminatetherisk of diseasethat can result from inhaling asbestos
dust. OSHA requires that thefollowing sign be posted at theentranceto areas whereexposures
exceed either of themaximum allowablelevels:
DANGER: ASBESTOS
CANCER AND LUNGDISEASE HAZARD
AUTHORIZED PERSONNEL ONLY
RESPIRATORSAND PROTECTIVE CLOTHING
ARE REQUIRED IN THISAREA.
2. Respiratory Protection. Wear arespirator equipped with ahigh-efficiency (HEPA) filter
approved by NIOSH or MSHA for usewith asbestos at all times when servicing brakes, beginning
with theremoval of thewheels.
3. Procedures for Servicing Brakes.
a. Enclosethebrakeassembly within anegativepressureenclosure. Theenclosureshouldbe
equipped with aHEPA vacuum andworker arm sleeves. With theenclosurein place, usethe
HEPA vacuum to loosen andvacuum residuefrom thebrakeparts.
b. As an alternativeprocedure, useacatch basin with water andabiodegradable,
non-phosphate, water-based detergent to wash thebrakedrum or rotor andother brake
parts. Thesolution shouldbe applied with low pressureto prevent dust from becoming
airborne. Allow thesolution to flow between thebrakedrum andthebrakesupport or the
brakerotor andcaliper. Thewheel hubandbrakeassembly components shouldbe thoroughly
wetted to suppress dust beforethebrakeshoes or brakepads areremoved. Wipethebrake
parts clean with acloth.
c. If an enclosed vacuum system or brakewashing equipment is not available, employers may
adopt their own written procedures for servicing brakes, provided that theexposurelevels
associated with theemployer’s procedures do not exceed thelevels associated with the
enclosed vacuum system or brakewashing equipment. Consult OSHA regulations for more
details.
d. Wear arespirator equipped with aHEPA filter approved by NIOSH or MSHA for usewith
asbestos when grinding or machining brakelinings. In addition, do such work in an area with
alocal exhaust ventilation system equipped with aHEPA filter.
e. NEVER usecompressed air by itself, dry brushing, or avacuum not equipped with aHEPA
filter when cleaning brakeparts or assemblies. NEVER usecarcinogenic solvents, flammable
solvents, or solvents that can damagebrakecomponents as wetting agents.
4. Cleaning Work Areas. Clean work areas with avacuum equipped with aHEPA filter or by wet
wiping. NEVER usecompressed air or dry sweeping to clean work areas. When you empty vacuum
cleaners andhandleused rags, wear arespirator equipped with aHEPA filter approved by NIOSH
or MSHA for usewith asbestos. When you replaceaHEPA filter, wet thefilter with afinemist of
water anddisposeof theused filter with care.
5. Worker Clean-Up. After servicing brakes, wash your hands beforeyou eat, drink or smoke.
Shower after work. Do not wear work clothes home. Useavacuum equipped with aHEPA filter to
vacuum work clothes after they areworn. Launder them separately. Do not shakeor use
compressed air to removedust from work clothes.
6. WasteDisposal. Disposeof discarded linings, used rags, cloths andHEPA filters with care,
such as in sealed plastic bags. Consult applicableEPA, stateandlocal regulations on waste
disposal.
Regulatory Guidance
References to OSHA, NIOSH, MSHA, andEPA, which areregulatory agencies in theUnited States,
aremade to provide further guidanceto employers andworkers employed within theUnited States.
Employers andworkers employed outside of theUnited States shouldconsult theregulations that
apply to them for further guidance.
NON-ASBESTOS FIBERS WARNING
The followingproceduresfor servicingbrakesare recommendedto reduce exposure to
non-asbestosfiber dust, a cancer andlungdisease hazard. Material Safety Data Sheets
are available from WABCO.
Hazard Summary
Most recently manufactured brakelinings do not contain asbestos fibers. Thesebrakelinings may
contain oneor moreof avariety of ingredients, including glass fibers, mineral wool, aramidfibers,
ceramic fibers andsilicathat can present health risks if inhaled. Scientists disagree on theextent
of therisks from exposureto thesesubstances. Nonetheless, exposureto silicadust can cause
silicosis, anon-cancerous lung disease. Silicosis gradually reduces lung capacity andefficiency
andcan result in serious breathing difficulty. Somescientists believeother types of non-asbestos
fibers, when inhaled, can causesimilar diseases of thelung. In addition, silicadust andceramic
fiber dust areknown to theStateof Californiato causelung cancer. U.S. andinternational
agencies havealso determined that dust from mineral wool, ceramic fibers andsilicaarepotential
causes of cancer.
Accordingly, workers must usecaution to avoidcreating andbreathing dust when servicing brakes.
Specific recommended work practices for reducing exposureto non-asbestos dust follow. Consult
your employer for moredetails.
Recommended Work Practices
1. SeparateWork Areas. Whenever feasible, servicebrakes in aseparatearea away from other
operations to reducerisks to unprotected persons.
2. Respiratory Protection. OSHA has set amaximum allowablelevel of exposurefor silicaof
0.1 mg/m3 as an 8-hour time-weighted average. Somemanufacturers of non-asbestos brake
linings recommendthat exposures to other ingredients foundin non-asbestos brakelinings be
kept below 1.0 f/cc as an 8-hour time-weighted average. Scientists disagree, however, to what
extent adherenceto thesemaximum allowableexposurelevels will eliminatetherisk of disease
that can result from inhaling non-asbestos dust.
Therefore, wear respiratory protection at all times during brakeservicing, beginning with the
removal of thewheels. Wear arespirator equipped with ahigh-efficiency (HEPA) filter approved by
NIOSH or MSHA, if theexposurelevels may exceed OSHA or manufacturers’recommended
maximum levels. Even when exposures areexpected to be within themaximum allowablelevels,
wearing such arespirator at all times during brakeservicing will help minimizeexposure.
3. Procedures for Servicing Brakes.
a. Enclosethebrakeassembly within anegativepressureenclosure. Theenclosureshouldbe
equipped with aHEPA vacuum andworker arm sleeves. With theenclosurein place, usethe
HEPA vacuum to loosen andvacuum residuefrom thebrakeparts.
b. As an alternativeprocedure, useacatch basin with water andabiodegradable,
non-phosphate, water-based detergent to wash thebrakedrum or rotor andother brake
parts. Thesolution shouldbe applied with low pressureto prevent dust from becoming
airborne. Allow thesolution to flow between thebrakedrum andthebrakesupport or the
brakerotor andcaliper. Thewheel hubandbrakeassembly components shouldbe thoroughly
wetted to suppress dust beforethebrakeshoes or brakepads areremoved. Wipethebrake
parts clean with acloth.
c. If an enclosed vacuum system or brakewashing equipment is not available, carefully clean
thebrakeparts in theopen air. Wet theparts with asolution applied with apump-spray bottle
that creates afinemist. Useasolution containing water, and, if available, abiodegradable,
non-phosphate, water-based detergent. Thewheel hubandbrakeassembly components
shouldbe thoroughly wetted to suppress dust beforethebrakeshoes or brakepads are
removed. Wipethebrakeparts clean with acloth.
d. Wear arespirator equipped with aHEPA filter approved by NIOSH or MSHA when grinding or
machining brakelinings. In addition, do such work in an area with alocal exhaust ventilation
system equipped with aHEPA filter.
e. NEVER usecompressed air by itself, dry brushing, or avacuum not equipped with aHEPA
filter when cleaning brakeparts or assemblies. NEVER usecarcinogenic solvents, flammable
solvents, or solvents that can damagebrakecomponents as wetting agents.
4. Cleaning Work Areas. Clean work areas with avacuum equipped with aHEPA filter or by wet
wiping. NEVER usecompressed air or dry sweeping to clean work areas. When you empty vacuum
cleaners andhandleused rags, wear arespirator equipped with aHEPA filter approved by NIOSH
or MSHA, to minimizeexposure. When you replaceaHEPA filter, wet thefilter with afinemist of
water anddisposeof theused filter with care.
5. Worker Clean-Up. After servicing brakes, wash your hands beforeyou eat, drink or smoke.
Shower after work. Do not wear work clothes home. Useavacuum equipped with aHEPA filter to
vacuum work clothes after they areworn. Launder them separately. Do not shakeor use
compressed air to removedust from work clothes.
6. WasteDisposal. Disposeof discarded linings, used rags, cloths andHEPA filters with care,
such as in sealed plastic bags. Consult applicableEPA, stateandlocal regulations on waste
disposal.
Regulatory Guidance
References to OSHA, NIOSH, MSHA, andEPA, which areregulatory agencies in theUnited States,
aremade to provide further guidanceto employers andworkers employed within theUnited States.
Employers andworkers employed outside of theUnited States shouldconsult theregulations that
apply to them for further guidance.

Contents
pg. pg.iAsbestos and Non-Asbestos Fibers
1Section 1: Introduction
Contents
Anti-Lock Braking System (ABS)
System Components
Electronic Control Unit (ECU)
Wheel Speed Sensing Systems
2 Pressure Modulator Valves
3 Active Braking Valves (ABV)
Brake Pressure Sensor (BPS)
Steering Angle Sensor (SAS)
4 Electronic Stability Control (ESC) Module
Trailer Modulator Valve
Off-Road ABS Switch
ATC Switch
Blink Code Switch
System Configuration
6Section 2: Stability and Safety Enhancement
Systems
ATC
ATC Components
ATC Switch
7 Roll Stability Control (RSC)
RSC Components
9 Electronic Stability Control (ESC)
ESC Components
11 Hill Start Aid (HSA)
HSA Components
12 Drag Torque Control
Lift Axle Capability
13 Section 3: Diagnostics, Troubleshooting and
Testing
General
Maintenance Information
ABS Indicator Lamp
14 Diagnostics
TOOLBOX™ Software Diagnostics
17 Blink Code Diagnostics (ABS Only)
23 Testing
Wheel Speed Sensor Testing
25 Modulator Valve Testing
29 Active Braking Valves (ABV) Testing
32 Brake Pressure Sensor Testing
33 ESC CAN Network Testing
ESC Module Testing
35 Steering Angle Sensor (SAS) Testing
37 ECU Circuit Testing
J1939 Serial Communications Testing
39 Section 4: Component Replacement
Component Removal and Installation
Wheel Speed Sensors
40 Modulator Valves
41 Active Braking Valves (ABV)
42 ABS Valve Packages
44 Active Braking Valve on the ABS Valve Package
45 Electronic Control Unit (ECU)
46Steering Angle Sensor (SAS) — WABCO Only
47 Electronic Stability Control (ESC) Module
48 Brake Pressure Sensor
50 Section 5: System Configurations
System Configuration Layouts
52 Section 6: Wiring Diagrams and Connectors
ECU Connector Pin Assignments
65 Section 7: SPN, SID, FMI Fault Codes
SPN, SID, FMI Diagnostic Trouble Code List
94 Section 8: Appendix I
Reconfiguration Procedure
How to Reconfigure an ECU (E Version)
TOOLBOX™ Software
95 Manual Reconfiguration
97 Section 9: Appendix II
E4 ESC End of Line Calibration Procedure
104 Section 10: Appendix III
E8 ESC End of Line Calibration Procedure
108 Section 11: Appendix IV
Aftermarket Programming
Aftermarket Programming Procedures
116Aftermarket Programming Failure Codes List

1 Introduction
1
WABCO Maintenance Manual MM-0112 (Revised 07-18)
1 Introduction
Contents
This manual contains service information for the following systems.
앫E version WABCO Anti-Lock Braking System (ABS)
앫Automatic Traction Control (ATC)
앫Roll Stability Control (RSC)
앫Electronic Stability Controls (ESC) for trucks, tractors and buses
The ABS version is marked on the ECU. Figure 1.1. If you cannot
identify the ECU version installed on your vehicle, contact WABCO
North America Customer Care at 855-228-3203.
Figure 1.1
For Additional Information
Diagnostic and testing procedures for other ECU versions can be
found in the following manuals.
앫C version ECUs — Maintenance Manual 28, Anti-Lock Braking
Systems (ABS) for Trucks, Tractors and Buses
앫D version ECUs — Maintenance Manual 30, Anti-Lock Braking
Systems (ABS) for Trucks, Tractors and Buses
Refer to the following manuals for Trailer ABS diagnostics and
information.
앫Maintenance Manual 33, Easy-Stop™ Trailer ABS
앫Maintenance Manual MM-0180, Enhanced Easy-Stop™ Trailer
ABS with PLC
Anti-Lock Braking System (ABS)
ABS is a system designed to provide and maintain the best possible
traction and steering control during an extreme braking event.
During a potential wheel lock event, the ABS ECU, using information
provided by the wheel speed sensors, sends a signal(s) to the
appropriate modulator valve(s) to hold, apply or release the brakes
as needed. ABS works automatically, the driver does not have to
select this feature.
System Components
Electronic Control Unit (ECU)
The ECU is the control center or “brain” of the ABS, RSC and ESC
systems. It receives information from the sensors, processes data
and sends signals to modulators and active braking valves to
achieve different tasks. Depending on the system and vehicle
configuration, ECUs are available for cab- or frame-mounted
applications and are divided into Basic Cab, Universal Cab, Frame
and Advance Frame models. RSC and ESC systems are only
available on universal and advance frame ECUs. Figure 1.2.
Figure 1.2
Wheel Speed Sensing Systems
Wheel speed sensing systems consist of a tooth wheel mounted on
the hub or rotor of each monitored wheel and a speed sensor
installed with its end against the tooth wheel. The sensor
continuously sends wheel speed information to the ECU. A sensor
clip holds the sensor in place and against the tooth wheel.
Figure 1.3.
Figure 1.1
4010603a
Figure 1.2
UNIVERSAL
ECU FRAME-MOUNTED
ECU
BASIC
ECU
4003974a