WORK INSTRUCTION FOR BRAKE KIT

INSTALLATION

- 2 AXLE TRAILER
- 3 AXLE TRAILER
- AIR SUSPENSION AXLE

CONTENTS
Installation Guide ……………………………………....…Page 1-11

2 Axle Brake Parts & Installation Circuit ….......................Page 12-13

3 Axle Brake Parts & Installation Circuit ….......................Page 14-16

2 Axle Air Suspension Brake Parts and

Installation Circuit…………………………………………Page 17

Brake Linkage & Installation Details ……………………..Page 18-21

Air Braking System Operation ……………………………Page 22-28

Approved By Rev. No. 0 MTD-WI-04 Page

If this is a paper copy, it is uncontrolled. You must verify the on-line revision before using.
 BRAKE SYSTEM

WARNING!
To prevent serious eye injury, always wear safe eye
protection when you perform vehicle maintenance
Installation Guide or service.

The Anti-lock Braking System (ABS) is an

electrical system. When you work on the ABS,
Differences between Easy – Stop take the same precautions that you must take
and Enhanced Easy Stop with any electrical system to avoid serious
personal injury. As with any electrical system,
the danger of electrical shock or sparks exists
There are some charges to Enhanced Easy – that can ignite flammable substances. You must
Stop that you need to be aware of before you always disconnect the battery ground cable
begin the installation: before working on the electrical system.
 Enhanced Easy-Stop includes Power Line Park the vehicle on a level surface. Block the
Communication (PLC) function. wheels to prevent the vehicle from moving.
 The ECU/single modulator valve assembly Support the vehicle with safety stands. Do not
may be mounted or serviced separately. work under a vehicle supported only by jacks.
 The assembly is shipped with valve cable Jacks can slip and fall over. Serious personal
between the ECU and valve disconnected injury can result.
from the ECU.
 The LED on top of the ECU has been Note: End of line testing must be done after all
eliminated. installations. WABCO recommends using
 The blink code tool LED does not operate TOOLBOX Software to perform this testing. If
simualtaneously with the ABS lamp on the you do not have TOOLBOX Software, this
trailer bulletin also includes instructions for testing
 The control port on the Enhanced Easy – without the software.
Stop single modulator valve is 3/8 inch – on
previous versions it was ¼-inch.

Approved By Rev. No. 0 MTD-WI-04 Page

If this is a paper copy, it is uncontrolled. You must verify the on-line revision before using.
.
Preparation
1. Before beginning the installation procedure, inspect
the ECU/single modulator valve assembly for
damage that may have occurred during shipping or
storage.
 Look for crushed or bent connectors.
 Make sure the retainer clips have not been bent or
otherwise damaged
 Attach the ABS relay valve cable to the ECU with the
WABCO ID face down. Make sure the cable is free
from cuts or breaks.
 Do not install a damaged ECU/single modulator valve
assembly. Notify your supervisor, or contact WABCO
if there is any apparent damage.
Approved By Rev. No. 0
If this is a paper copy, it is uncontrolled. You must verify the on-line revision before using.
2. Have installation material available:
 ECU/single modulator valve assembly.
 Power cable or power/diagnostic cable.
 Sensor extension cables (two pcs.).
 Sensors (2) for non-ABS prepped axles
 ABS indicator Label (TP-95172)
5/8 inch O.D nylon tubing for supply (frame
mounts)
Pipe plug (3/4-inch NPTF)
Schedule 80 pipe nipple (3/4-inch NPTF) for air tank mounts
or two Grade 8 bolts (3/8-inch) and prevailing toque nuts for
frame mounts.
SAE standard, DOT-approved thread sealant.
ABS indicator lamp (DOT-approved).
WABCO Components
3. Study the ECU/single modulator valve assembly.
Note location of various ports and electrical
connections on the ECU. Figure 1.
MTD-WI-04 Page
Approved By Rev. No. 0 MTD-WI-04 Page

If this is a paper copy, it is uncontrolled. You must verify the on-line revision before using.
Approved By Rev. No. 0 MTD-WI-04 Page

If this is a paper copy, it is uncontrolled. You must verify the on-line revision before using.
Approved By Rev. No. 0 MTD-WI-04 Page

If this is a paper copy, it is uncontrolled. You must verify the on-line revision before using.
Approved By Rev. No. 0 MTD-WI-04 Page

If this is a paper copy, it is uncontrolled. You must verify the on-line revision before using.
Approved By Rev. No. 0 MTD-WI-04 Page

If this is a paper copy, it is uncontrolled. You must verify the on-line revision before using.
Approved By Rev. No. 0 MTD-WI-04 Page

If this is a paper copy, it is uncontrolled. You must verify the on-line revision before using.
Approved By Rev. No. 0 MTD-WI-04 Page

If this is a paper copy, it is uncontrolled. You must verify the on-line revision before using.
Approved By Rev. No. 0 MTD-WI-04 Page

If this is a paper copy, it is uncontrolled. You must verify the on-line revision before using.
Approved By Rev. No. 0 MTD-WI-04 Page

If this is a paper copy, it is uncontrolled. You must verify the on-line revision before using.
Approved By Rev. No. 0 MTD-WI-04 Page

If this is a paper copy, it is uncontrolled. You must verify the on-line revision before using.
L

Approved By Rev. No. 0 MTD-WI-04 Page

If this is a paper copy, it is uncontrolled. You must verify the on-line revision before using.
2 AXLE BRAKE PARTS WITH INSTALLATION CIRCUIT

Pos. QTY DESCRIPTION Remarks.

1 1 Coupling head supply
2 1 Supply line tag
3 1 Control line tag
4 2 Air line filter
5 1 Load sensing relay o.valve
5a 1 Plate
6 1 Air reservoir
7 2 Clamp
8 1 Drain valve
9 4 Brake chamber 30”
9 4 By pack
10 2 Bulk head connector
11 2 Bulk head connector
12 2 Stud connector
13 2 Connector
14 2 Stud connector
15 8 Hose nipple
16 8 Hose clip
17 4 Plug
18 4 Pressure ring
19 4 O ring
20 6 Hose
21 10 Pipe clip
2 Pipe clip
25 Nylon pipes
4 Nylon pipes
10 Sleeve insert

Approved By Rev. No. 0 MTD-WI-04 Page

If this is a paper copy, it is uncontrolled. You must verify the on-line revision before using.
 4 Sleeve insert
1 Test connection

Approved By Rev. No. 0 MTD-WI-04 Page

If this is a paper copy, it is uncontrolled. You must verify the on-line revision before using.
Approved By Rev. No. 0 MTD-WI-04 Page

If this is a paper copy, it is uncontrolled. You must verify the on-line revision before using.
3 AXLE BRAKE PARTS WITH INSTALLATION CIRCUIT

Pos. QTY DESCRIPTION Remarks

1 1 Coupling Head Assembly
2 1 Coupling Head Control
3 1 Supply Line Tag
4 1 Control Line Tag
5 2 Air Line Filter
6 1 Relay Emergency Valve
7 1 Air Reservoir, 80 Ltr.
8 2 Clamp
9 1 Drain Valve
10 6 Brake Chamber Type 30”
11 6 Bypack
12 2 Bulk Head Connector, M16 x 1.5/12mm
13 2 Bulk Head Connector, M22 x 1.5/12mm
14 2 Stud Connector, M22 x 1.5/12mm
15 2 Plug M22 x 1.5
16 2 Stud Connector, M22 x 1.5/15mm
17 6 Hose Nipple, M16 x 1.5/ 13 x 6
18 10 Hose Clip 13 x 6
19 8 Pressure Ring, M 16 x 1.5
20 8 O-Ring, M16 x 1.5
21 11 Pressure Ring M22 x 1.5
22 11 O Ring, M22 x 1.5
9m Hose 13 x 6
10 Pipe Clip 12mm
2 Pipe Clip 15mm
25m Nylon Pipe 12 x1.5
4m Nylon Pipe 15 x1.5
14 Sleeve insert for Nylon pipe 12 x 1.5

Approved By Rev. No. 0 MTD-WI-04 Page

If this is a paper copy, it is uncontrolled. You must verify the on-line revision before using.
 8 Sleeve insert for Nylon pipe 15 x 1.5
23 1 Tee with Lock Nut M22 x 1.5
24 2 Stud Connector, M22 x 1.5
25 1 Nylon Pipe 8 x 1
26 2 Sleeve insert for Nylon Pipe 8 x 1
27 2 Pipe Clip 8mm
28 2 Pipe Nut for Hose Nozzle M22 x 1.5
29 6 Sealing Washer 15mm
30 4 Pipe Nut M22 x 1.5
31 4 Cutting ring 15mm
32 4 Thrust ring 15mm
33 1 Thrust ring M22 x 1.5
34 1 O Ring M22 x 1.5

Approved By Rev. No. 0 MTD-WI-04 Page

If this is a paper copy, it is uncontrolled. You must verify the on-line revision before using.
Approved By Rev. No. 0 MTD-WI-04 Page

If this is a paper copy, it is uncontrolled. You must verify the on-line revision before using.
 AIR SUSPENSION BRAKE SYSTEM

Sl # QTY DESCRIPTION REMARKS

1 2 Air Reservoir 60 Ltr

2 4 Holder (air reservoir)
3 16 Straight Male Stud Coupl.
4 2 Plug M22 x 1.5
5 1 Male Stud Elbow Coupl.
6 1 Male Stud Tee Coupling
7 4 Equal Tee Coupling
8 1 Charging Valve (Over Flow)
9 2 Drain Valve
10 1 Pipe \Filter
11 1 Link Connection
12 1 Test Connection
13 1 Load Sensing Valve
14 1 Rotary Disc Valve
15 1 Leveling Valve

AIR SUSPENSION BRAKE SYSTEM (Circuit Layout)

Approved By Rev. No. 0 MTD-WI-04 Page

If this is a paper copy, it is uncontrolled. You must verify the on-line revision before using.
Approved By Rev. No. 0 MTD-WI-04 Page

If this is a paper copy, it is uncontrolled. You must verify the on-line revision before using.
 Installation:
It is important to ensure that the Linkage is installed so that
vertical movement of the chassis under load is accurately
detected by the Load Sensing Valve. The following
guidelines should therefore be noted:

1. Mount the Load Sensing Valve on the chassis as

close as possible to the center of the axle span and
with its operating lever parallel to the vehicle
center line.
2. The connecting link should be as nearly vertical as
possible and have its pickup point on top of the
axle casing to minimize any effects of axle
windup. For a tri-axle configuration, the pickup
point should be on top of the center axle. Refer to
Fig 1a & 2.
3. In the case of a tandem axle, the pickup point
should be at the center of the tubular link, midway
between the axles. Refer to Fig 1c & 3.
4. Where possible over travel of the Load Sensing
valve operating lever needs to be avoided , a
spring linkage may be used. Refer to Figs 1b & 4.

Function: These linkages connect the vehicle axle (or axles) to the Load Sensing
Valve operating lever. As the Load Sensing Valve is fixed to the chassis, changes in
the vehicle loading causing vertical movement of the chassis relative to the axle(s)
are transmitted by the linkage to the Load Sensing Valve operating lever.

Where over travel of the Load Sensing Valve operating lever is possible, a Spring
Link may be employed. Fig. 1 outlines some typical installations. Note that the
linkage lubes and bars are not supplied by Bendix Limited.

Dimensions and other data are for information only. Where there is a specific
requirement please ask for an outline drawing.

Every effort has been made to ensure that the information in this Fact Sheet is
correct but we reserve the right to amend or change this information without
notice.

Approved By Rev. No. 0 MTD-WI-04 Page

If this is a paper copy, it is uncontrolled. You must verify the on-line revision before using.
Approved By Rev. No. 0 MTD-WI-04 Page

If this is a paper copy, it is uncontrolled. You must verify the on-line revision before using.
LOAD SENSING VALVE
Application
These load sensing valves are used in the braking systems of trailers
with mechanical suspensions. They modulate the pressure delivered
to the brakes in relation to the load being carried. When fitted, the
relay emergency valve operates the trailer brakes if there is a failure
of the red supply line.

A feature of this valve is that if the linkage to the axle fails, the lever
will drop and the valve ratio will move to 2:1.

Technical Features

Maximum Operating Pressure: 8.5 bar

Temperature Range: 40Deg C + 80 Deg C
Meedium: - Compressed Air
Working Angle 20 Deg.

These dimensions and datas are for information only. When there is a specific
requirement please ask for an outline drawing.

Every effort has been made to ensure that this information is

correct, but we reserve the right to amend or change it without
notice.

RELAY AIR PORT THREADS

TYPE OPERATION EMERGENCY RELAY
1 1-2 2 3 4
NO. VALVE FEATURE
BR 4351 Dynamic No Yes M22 x 1.5 - M16 x 1.5 (4x) M22 x 1.5 M16x1.5
M22 x 1.5 (2x)

BR 4352 Dynamic Yes Yes M16 x 1.5 M22 x 1.5 M16 x 1.5 (4x) M22 x 1.5 M16x1.5
M22 x 1.5 (2x)

BR 4370 Static No No M22 x 1.5 - M16 x 1.5 (2x) M22 x 1.5 -

BR 4371 Dynamic No No M22 x 1.5 - M16 x 1.5 (2x) M22 x 1.5 -

Note : The value to axle lower linkage is supplied with the valve but is also available separately as Part No. 1142519000

Approved By Rev. No. 0 MTD-WI-04 Page

If this is a paper copy, it is uncontrolled. You must verify the on-line revision before using.
PERFORMANCE CHARTS

Approved By Rev. No. 0 MTD-WI-04 Page

If this is a paper copy, it is uncontrolled. You must verify the on-line revision before using.
OPERATIONS OF AIR BRAKING SYSTEM

Approved By Rev. No. 0 MTD-WI-04 Page

If this is a paper copy, it is uncontrolled. You must verify the on-line revision before using.
Approved By Rev. No. 0 MTD-WI-04 Page

If this is a paper copy, it is uncontrolled. You must verify the on-line revision before using.
Approved By Rev. No. 0 MTD-WI-04 Page

If this is a paper copy, it is uncontrolled. You must verify the on-line revision before using.
AUTOMATIC LOADING SENSING VALVES

Approved By Rev. No. 0 MTD-WI-04 Page

If this is a paper copy, it is uncontrolled. You must verify the on-line revision before using.
Approved By Rev. No. 0 MTD-WI-04 Page

If this is a paper copy, it is uncontrolled. You must verify the on-line revision before using.
Approved By Rev. No. 0 MTD-WI-04 Page

If this is a paper copy, it is uncontrolled. You must verify the on-line revision before using.
Approved By Rev. No. 0 MTD-WI-04 Page

If this is a paper copy, it is uncontrolled. You must verify the on-line revision before using.
Approved By Rev. No. 0 MTD-WI-04 Page

If this is a paper copy, it is uncontrolled. You must verify the on-line revision before using.
Approved By Rev. No. 0 MTD-WI-04 Page

If this is a paper copy, it is uncontrolled. You must verify the on-line revision before using.