Transcription

L300306/03PLC, PLC Plus and PLC SelectTrailer ABSInstallation/Service ManualInnovative Vehicle TechnologyPLC4Trucks 7.00

PLC, PLC Plus, & PLC SelectTechnical ServiceandEngineering SupportIn the U.S., please call:Brake Systems DivisionWorld Headquarters1-800-643-2374 (Press 2)In Canada, please callBrake Systems DivisionHaldex, Limited1-800-267-9247

PLC, PLC Plus, & PLC SelectTable of ContentsContents:Table of Contents. 1General Operation . . 2-3Sensor Block Installation . 4Exciter Ring Installation. . 5Wheel Speed Sensor Installation. 6-12ABS System Plumbing. . 13-18PLC Family Application. .19PLC Select. . 20- Hardware- Electrical Wiring- Installation Test- Road Test- Troubleshooting/Diagnostics - PLC SelectPLC. . 32- Hardware- Electrical Wiring- Installation Test- Road Test- Troubleshooting/Diagnostics - PLCPLC Plus. . 47- Hardware- Electrical Wiring- Installation Test- Road Test- Troubleshooting/Diagnostics - PLC PlusDiagnostics. . 62- Blink Codes- PLC Info Center- PLC - PC Diagnostics- Diagnostic Fault Code ListInfoCenter. . 72Safety First!Please follow your company’s safety procedure when you install this equipment. Besure that you understand all instructions before you begin.Note: Remove all air pressure and electrical power from the brake system beforebeginning work.1

PLC, PLC Plus, & PLC SelectGeneral OperationGeneral OperationABS Basics:The PLC family of Trailer ABS, is the latest in a full line of Haldex trailer ABS systemsthat provide stability and control during braking by preventing wheel lock up. As withother ABS systems, PLC uses a combination of valves, sensors, exciter rings, and theElectronic Control Unit (ECU) working in union to maximize the control of a brakingtrailer.When the ECU detects the rapid decrease in speed of a wheel about to lock up, itreleases the air pressure from the brake chambers of the affected wheel via one or twomodulator valves. The release of air from the chambers prevents the wheels fromlocking 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 brakechambers 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 complexand simplest to install. There are 2 sensors and 1 ABS Modulator Relay Valve. Thesystem meets the minimum FMVSS-121 ABS requirements for semi-trailers anddollies, 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 significantbenefit of a 2S/2M system over the 2S/1M SLH product. Consult Haldex Engineeringfor assistance in this area.A 4S/2M system offers the best performance overall on multiple axle trailers and isrequired by FMVSS 121 for full trailers. The control is provided through 4 sensors and2 Modulator valves. The system has the flexibility to be installed as 4S/2MSide-By-Side control, with lift axle compatibility, or 4S/2M Axle-By-Axle control. Allconfigurations meet the requirements of FMVSS-121. The 4S/2M system can beinstalled on a variety of trailers. Full trailers, spread axle trailers, and multiple axletrailers are particularly well suited to this system.2

PLC, PLC Plus, & PLC SelectGeneral OperationAvailable Options:PLC, PLC Plus and PLC Select systems are available in 2 valve platforms: With apatented Haldex Full Function ABS (FFABS) Valve or an ABS Relay Valve. The difference is that FFABS uses a single valve to provide the ABS function and control thespring (emergency) brakes as well as the service brakes (along with pressure protection and anti-compounding features). The ABS Relay is a 2 valve system which requires 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 isrequired on dollies and single axle trailers. Do not use SLH-A7 on dollies or singleaxle trailers.PLC, PLC Plus and PLC Select Trailer ABS all come standard with an Electronic HubOdometer. This feature can be accessed through a Haldex Info Center or through PCDiagnostics and the appropriate adapter.Installation:Installation of the PLC systems can be completed in 4 easy steps:1.2.3.4.Installation of wheel speed sensors and related hardware, if required (seepage 4 - 5).Installation of ABS Relay Valve(s) and related hardware (see page 6 - 9,13 - 18).Installation of electrical system (see pages 22, 34 - 38, 49 - 53) PLC,PLC Plus and PLC Select).Final system checkout (see pages 23 - 25, 39 - 40, 54 - 55).An important consideration of installing ABS is placement of the wheel sensors. This isespecially true when an ABS relay (modulator) valve controls multiple axles. Haldexrecommends that the sensors be placed on the axle that will lock first during a brakeapplication. Information on which axle that is mostly likely to lock is included in thisManual. Refer to (pages 6 - 11) for sensor placement on standard suspension configurations.In the Event of a Malfunction:In the event of a failure in the permanent power circuit, the system will receive power fromthe stoplight circuit and work normally. If the power fails in both circuits, the system reverts to a standard braking system. Refer to the Troubleshooting section of this manualon pages 26 - 31, 41 - 46, 56 - 61 and the diagnostics section on (pages 62 - 71).3

PLC, PLC Plus, & PLC SelectSensor Block InstallationNo more than .080”off center.156 .031"SensorCenterline (CL)Exciter RingBBlockCExciter Ring 2.5 CLABlockCLCenterline (CL)No more than .080”off centerSensor 2.5 .156 .031"Sensor Block;allowable placement9 O'clock3 O'clockAxleFigure 1Sensor BlockSensor ClipSensor Block Installation:SensorThe clearance between block and exciter ring should be 0.156 .031”. Any deviationfrom this clearance as a result of hub exciter ring position must be approved by thesensor manufacturer. The radial clocking position should be between 9 and 3 O’clocksee Figure 1A. While the ABS performance is not affected with the sensor located inthe lower half of the axle, the structural integrity of the axle could be compromised. Thesensor block should not interfere with any wheel end hardware.In general, the position of the wheel speed sensor center axis to the exciter ring surfaceshould 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 shouldbe no more than .080” above or .080” below the centerline of the exciter teeth (seeFigure 1C).Note: The sensor block is generally welded to the axle. Refer to axlemanufacturer’s manual to insure that welding won’t affect structural integrity.4

PLC, PLC Plus, & PLC SelectExciter Ring Installation125Figure 2.530.470R .06.03 X 15 Chamfer1256.00 Dia.MaximumSeal Bore6.5016.499 Dia.100 ToothExciter RingExciter 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 3HubPress the exciter ring right to theshoulder allowing no gapsExciter RingExciter Ring Installation:1.2.3.4.5.Heat the exciter ring uniformly to approximate 350 F.Place the exciter ring on the machined area of the axle hub (see figure 3).Make sure the exciter ring fits squarely onto the machined surface of the hub.When the exciter ring cools, it will shrink fit on the hub.Make sure the exciter ring fits tightly onto the machined area and does not slip.5

PLC, PLC Plus, & PLC SelectWheel Speed Sensor Installation2S/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 thecurb 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 valveUse 2 port valveUse 2 port valveMulti- Axle TrailersUse 4 or 6 port ValveSpring SuspensionAir SuspensionSensorFittingECU w/ABS ValveKing Pin6Spring SuspensionAir Suspension

PLC, PLC Plus, & PLC SelectWheel Speed Sensor Installation2S/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 thecurb 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 a2S/1M SLH-A7 configuration, and is not a preferred system. To obtain additionalperformance beyond a 2S/1M configuration, Haldex recommends the use of a4S/2M system.Multi-Axle Trailers:SensorECU w/ValveValveKing Pin7

PLC, PLC Plus, & PLC SelectWheel Speed Sensor Installation4S/2M Axle-by-Axle Configurations:The placement of the sensors at the wheel end is an important consideration. Incorrectinstallation of the sensors and exciters will result in poor or no ABS operation. Sensorsconnected to yellow leads must sense the wheel controlled by the valve connected tothe yellow valve lead. Similarly, sensors connected to blue leads must sense the wheelcontrolled by the valve connected to the blue lead.In the case of a 4S/2M Axle-By-Axle configuration, the blue modulator lead must beconnected to the valve that controls the front axle wheel ends and is sensed by the bluesensors (3A and 2A). The yellow valve cable lead must be connected to the valve thatcontrols 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 (theking pin indicates the front of the trailer). Make sure sensors are pushed firmlyagainst the exciter rings.WrongMulti-Axle Trailers:SensorECU w/ValveValveKing Pin8CorrectWrong

PLC, PLC Plus, & PLC SelectWheel Speed Sensor Installation4S/2M Side-by-Side Configurations:The placement of the sensors at the wheel end is an important consideration. Incorrectinstallation of the sensors and exciters will result in poor or no ABS operation. Sensorsconnected to yellow leads must sense the wheel controlled by the valve connected tothe yellow valve lead. Similarly, sensors connected to blue leads must sense the wheelcontrolled by the valve connected to the blue lead.In the case of a 4S/2M Side-By-Side configuration, the blue modulator lead must beconnected to the valve that controls the curb side wheel ends and are sensed by theblue sensors (3A and 2A). The yellow valve cable lead must be connected to the valvethat controls the road side wheel ends and are sensed by the yellow sensors (3B and2B). The schematic below shows proper placement of the sensor and valve leads (kingpin indicates the front of the trailer). Make sure sensors are pushed firmly against theexciter rings.WrongCorrectWrongMulti-Axle Trailers:SensorECU w/ValveValveKing Pin9

PLC, PLC Plus, & PLC SelectWheel Speed Sensor Installation4S/2M Axle-by-Axle Lift Control:Lift AxleLift Axle2A2B2B2A3B3A 3B3AWrongWrongLift AxleLift Axle2A 2B2A3ACorrect3B2B3B3ACorrectOn 4S/2M Axle-By-Axle installations, sensed wheels (wheels with ABS sensors) can notbe lift axles. Lifting a sensed axle in this configuration will create an ABS fault. ABSoperation will then be suspended until the power has been cycled and all sensedwheels are again rolling on the road surface.Note:Indirectly controlled axles (axles without sensors, but controlled by ABS valves) may belifted regardless of the configuration.10

PLC, PLC Plus, & PLC SelectWheel Speed Sensor Installation4S/2M Side-by-Side Lift Control:Lift AxleLift Axle2A2A3A3A2B2B3BCorrect3BWrongLift Axle2A3ALift Axle2A3ACorrect2B3B2B3BCorrectOn 4S/2M Side-By-Side installations, the sensed wheels “3A” and “3B” can be used ona lift axle. The sensed wheels “2A” and “2B” must remain on the ground at alltimes.Attention:The trailer has to roll over 6 MPH with the lift axle UP, after each ignition key “on” cyclein order for the ABS system to recognize that a lift axle is present. Once this is done, theaxle can be raised or lowered without issue for that ignition “on” cycle. If the trailer rollsover 6 MPH with the lift axle down after an ignition “on” cycle, lifting the axle will causean ABS fault to occur.Note:Indirectly controlled axles (axles without sensors, but controlled by ABS valves)may be lifted regardless of the configuration.11

PLC, PLC Plus, & PLC SelectWheel Speed Sensor InstallationCable Routing:BlockClipSensorTie strapPush sensorfirmly againstexciter3-Way Clip(optional)Lightly greasethe sensorwith a lithiumbasedgrease. UseDow CorningMolycoatCU7439 orequivalent.Sensor CableClip3-WayClip6-12”Sensor cable clip orDouble tie strapsrecommendedLeave some slack in cable to accommodatemovement between components. Bundleexcess cable with tie straps as shown below.4” Diameter LoopsLong (dog bone) cableTie strap4” Diameter LoopDon’t over tighten tie straps.This could cause a cable failure,especially where attached to airlines, since air lines flex.1. Insert the sensor clip into the sensor block.2. Insert the sensor into the sensor clip and push until it is firmly against the exciterring. (First grease the sensor with a lithium based grease.)3. Route all sensor cables through vacant bolt holes, etc. Use a grommet orcorrugated tubing when the cable is touching sharp edges.4. Attach cable ties as needed to ensure the cable is secured.5. Typical routing of cable is along the brake chamber air hose (see detail above).6. Use sensor cable clip (highly recommended) or double tie straps when attaching thecables to the air lines.7. Sensor cable clip or double tie straps should be no closer than 6” and no fartherthen 12” inches apart.Use caution when attaching tie straps to air lines. Over tightening can cause acable failure down the road.12

PLC, PLC Plus, & PLC SelectABS System Plumbing2S/1M FFABS System Plumbing:Service/ControlEmergency/Supply1. Install fittings into valve. Sealant is not required on plastic threads or on fittings thatgo into plastic. Do not use teflon tape on fittings. It can break off and contaminatethe air system.2. For plastic ports, hand tighten fittings then rotate 1 to 1 1/2 additional turns. Themaximum torque valve allowed is 210 in-lb.3. Install valve nipple into reservoir port. Rotate valve by hand until resistance is felt.4. Using a wrench on the nipple hex, continue tightening valve to the correct valveorientation (see detail below).5. Attach hoses to appropriate brake chambers. Use thread sealant sparingly on allfittings (Loctite PST565 or similar).PLC SelectNote: This End Up(Alternate ECU)Jam Nut(torque 30 ft.lb.)ECUSolenoidControl(with serviceable filter)Tighten nipple(Torque 50 ft. lb.)Reservoir PortService BrakeDelivery (4 places)Spring BrakeDelivery (2 places)Supply (Emergency)(with serviceable filter)All ports are 3/8” except nipple (1/2” or 3/4”). Torque to 210 in. lb. max (plastic threads)13

PLC, PLC Plus, & PLC SelectABS System Plumbing2S/1M ABS Relay System Plumbing:When an ABS Relay Valve is used,a Spring Brake Control Valve is requiredsuch as a Haldex RT4 Valve.Service/ControlEmergency/Supply1. Apply sealant sparingly to fittings, or use fittings with pre-applied sealant, and installinto valve. Do not use teflon tape on fittings. It can break off and contaminate theair system.2. Install heavy wall nipple into valve reservoir port. Thread nipple into reservoir. Rotatevalve by hand until resistance is felt.3. Using a wrench on the nipple hex, continue tightening valve to the correct valveorientation (see detail below).4. Attach hoses to appropriate brake chambers. Use thread sealant sparingly on allfittings (Loctite PST565 or similar).Supply (Emergency)Note: This End UpControlPLC Select(Alternate ECU)Supply (Emergency)Spring BrakeDelivery (4 places)SolenoidControlTighten nipple(Torque 50 ft. lb.)14Service BrakeDelivery (6 places)ECU

PLC, PLC Plus, & PLC SelectABS System Plumbing2S/2M ABS Relay System Plumbing:When an ABS Relay Valve is used,a Spring Brake Control Valve is requiredsuch as a Haldex RT4 Valve.Service/ControlEmergency/Supply1. Apply sealant sparingly to fittings, or use fittings with pre-applied sealant, and installinto valve. Do not use teflon tape on fittings. It can break off and contaminate theair system.2. Install heavy wall nipple into valve reservoir port. Thread nipple into reservoir. Rotatevalve by hand until resistance is felt.3. Using a wrench on the nipple hex, continue tightening valve to the correct valveorientation (see detail below).4. Attach hoses to appropriate brake chambers. Use thread sealant sparingly on allfittings (Loctite PST565 or similar).Supply(Emergency)ControlNote: This End UpECUSpring BrakeDelivery (4 places)SolenoidControlTighten nipple(Torque 50 ft. lb.)Service BrakeDelivery (2 places)15

PLC, PLC Plus, & PLC SelectABS System Plumbing4S/2M Axle-By-Axle FFABS System Plumbing:Service/ControlEmergency/Supply1. Apply sealant sparingly to fittings, or use fittings with pre-applied sealant, and installinto valve. Do not use teflon tape on fittings. It can break off and contaminate theair system.2. Install heavy wall nipple into valve reservoir port. Thread nipple into reservoir. Rotatevalve by hand until resistance is felt.3. Using a wrench on the nipple hex, continue tightening valve to the correct valveorientation (see detail below).4. Attach hoses to appropriate brake chambers. Use thread sealant sparingly on allECUfittings (Loctite PST565 or similar).SolenoidNote: This End UpSolenoidControlReservoir PortJam Nut(torque 30 ft.-lb.)Service Brake Delivery(2 places)Service BrakeDelivery (2 places)Tighten nipple(Torque 50 ft. lb.)16Control(with Serviceable Filter)Spring Brake Delivery(2 places)Supply/Emergency(with Serviceable Filter)

PLC, PLC Plus, & PLC SelectABS System Plumbing4S/2M Axle-By-Axle Relay System Plumbing:When an ABS Relay Valve is used,a Spring Brake Control Valve is requiredsuch as a Haldex RT4 Valve.Service/ControlEmergency/Supply1. Apply sealant sparingly to fittings, or use fittings with pre-applied sealant, and installinto valve. Do not use teflon tape on fittings. It can break off and contaminate theair system.2. Install heavy wall nipple into valve reservoir port. Thread nipple into reservoir. Rotatevalve by hand until resistance is felt.3. Using a wrench on the nipple hex, continue tightening valve to the correct valveorientation (see detail below).4. Attach hoses to appropriate brake chambers. Use thread sealant sparingly on allfittings (Loctite PST565 or similar).ECUNote: This End UpSupply(Emergency)ControlSolenoidControlSpring BrakeDelivery (4 Places)Tighten nipple(Torque 50 ft. lb.)Service BrakeDelivery (2 places)17

PLC, PLC Plus, & PLC SelectABS System Plumbing4S/2M Side-By-Side FFABS System Plumbing:Service/ControlEmergency/Supply1. Apply sealant to fittings, or use fittings with pre-applied sealant, and install into valve.Do not use teflon tape on fittings. It can break off and contaminate the air system.2. Install heavy wall nipple i