WABCO 2S/2M, Installation Instructions Manual

Page 1: ...TRAILER iABS 2S 2M 4S 2M AND 4S 3M INSTALLATION INSTRUCTIONS TP18006 ...

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Page 3: ...tion presented or to discontinue the production of parts described at any time Table of Contents 1 General Information 4 2 Safety Information 6 3 Important Information 6 4 Preparation 7 5 Installation 9 5 1 Install the ECU Dual Modulator Valve Assembly 9 5 2 End of Line Testing 23 6 Appendix I 31 6 1 Installing Sensors on Non ABS Prepped Axles 31 7 Appendix II 33 7 1 Cable Strain Relief Guidelines...

Page 4: ...lt in irreversible injury or death if the warning is ignored CAUTION Description of a possible situation which may result in irreversible injury if the warning is ignored NOTICE Description of a possible situation which may result in material damage if the warning is ignored Important information notes and or tips Reference to information on the internet 1 Action step Action step Consequence of an...

Page 5: ...nt SAE documents and standards applicable to WABCO products such as SAE J447 and SAE J908 at www sae org Refer to the National Highway Traffic Safety Administration NHTSA website to find all current documents referenced in the manual at www nhtsa gov WABCO TOOLBOX PLUS Software The TOOLBOX PLUS Software provides PC diagnostics for WABCO products can be purchased and downloaded from https wabco sna...

Page 6: ...l Danger 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 To prevent serious eye injury always wear safe eye protection when you perform vehicle maintenance or service WARNING Park the vehicle on a level surface Block the wheels to prevent the vehicle from moving Support the veh...

Page 7: ...ch O D nylon tubing for supply frame mount Pipe plug 3 4 inch NPT Schedule 80 hex pipe nipple 3 4 inch NPT for air tank mounts or two Grade 8 bolts 3 8 inch and prevailing torque nuts for frame mounts ABS sensor clip lubricant the following are approved by WABCO Mobilith SHC 220 Mobil TEK 662 Roy Dean Products Staburags NBU 30 PTM Kluber Lubrication Valvoline EP 633 SAE standard DOT approved seali...

Page 8: ...014012a POWER SUPPLY ABS SENSOR F ABS SENSOR D GIO 1 SUBSYSTEM DIAGNOSTIC 3rd MODULATOR GIO 2 ABS SENSOR E ABS SENSOR C Fig 2 4014013a BOTTOM VIEW DELIVERY PORTS DELIVERY PORTS EXHAUST PORT POWER SUPPLY SUBSYSTEM DIAGNOSTIC GIO 1 3RD MODULATOR GIO 2 ABS SENSOR D ABS SENSOR F ABS SENSOR C ABS SENSOR E Fig 3 4014007b CONTROL PORT DELIVERY PORTS 2 2 DELIVERY PORTS 2 1 SUPPLY PORT ...

Page 9: ...TOR VALVE MOUNTED WITH CONTROL PORT FACING FRONT OFTRAILER TANK MOUNTED ECU DUAL MODULATOR VALVE MOUNTED WITH CONTROL PORT FACING REAR OFTRAILER 4013982a PLUG UNUSED PORT Exhaust port must face DOWN POWER SUPPLY ABS SENSOR F ABS SENSOR D GIO 1 SUBSYSTEM DIAGNOSTIC 3rd MODULATOR GIO 2 ABS SENSOR E ABS SENSOR C POWER SUPPLY ABS SENSOR F ABS SENSOR D GIO 1 SUBSYSTEM DIAGNOSTIC 3rd MODULATOR GIO 2 ABS...

Page 10: ...bly 2 Use a 3 4 inch NPT pipe plug to plug the unused supply port Apply SAE standard DOT approved sealing paste to either the first few threads or over the whole length Pipes with pre applied thread sealant may also be used 3 Rotate and tighten the ECU dual modulator valve assembly a minimum of 3 turns and verify the exhaust port faces DOWN and the connection is secure Use a torque wrench on the 3...

Page 11: ...ches 97 2 mm O D apart 3 Use two 3 8 inch Grade 8 bolts with prevailing torque nuts to attach the assembly Tighten the bolts to 26 lb ft 35 3 Nm 5 1 3 Attach the ABS External Relay Valve 4S 3M Systems Only The ABS external relay valve part number 472 195 033 0 may be mounted on the air tank or on the cross member of the vehicle 5 1 4 Tank Mounted WARNING You must use a Schedule 80 hex nipple 3 4 i...

Page 12: ... to 18 lb ft 24 Nm 5 1 6 Connect the Air Lines Before connecting the air lines plumb the spring brake relay or emergency brake relay into the system as usual If you are mounting on a bracket connect the air supply line from the supply tank to the supply Port 1 Plug the unused port Use 5 8 inch O D min nylon tubing or heavy walled Schedule 80 pipe nipple 3 4 inch NPTF if you are mounting directly t...

Page 13: ...rs and cables on the prepped axles to the sensor extension cables Figure 7 Ensure that each connection is secure Fig 7 SENSOR EXTENSION CABLE SENSOR AND CABLE 4003567b 3 Route the sensor cable along the back side of the trailer axle to the ECU dual modulator valve assembly Route the cable with the brake hose Do not overtighten the tie wraps on a cable Overtightening can damage the cable Do not tie...

Page 14: ...ck power cables route the cable from the harness connector to the ECU dual modulator valve assembly and secure it to prevent damage For blunt cut power cables route the cable from the ECU dual modulator valve assembly to a junction box which interfaces with the seven way connector at the front of the trailer Leave enough slack in the cable to compensate for flexing of the trailer and sub frame 3 B...

Page 15: ...racket G Correctly secure the cable in the sub frame to prevent cable damage Leave enough slack in the cable to compensate for flexing of the trailer and sub frame H Bundle excess cable in a loop bow tie and secure the cable in the sub frame Figure 10 10 Install the ABS indicator lamp on the trailer Refer to the the Federal Moter Vehicle Safety Standard FMVSS 121 Regulation from NHTSA for the exac...

Page 16: ...any of the standard trailers built in North America Fig 12 POWER SUPPLY ABS SENSOR F ABS SENSOR D GIO 1 SUBSYSTEM DIAGNOSTIC 3rd MODULATOR GIO 2 ABS SENSOR E ABS SENSOR C POWER SUPPLY ABS SENSOR F ABS SENSOR D GIO 1 SUBSYSTEM DIAGNOSTIC 3rd MODULATOR GIO 2 ABS SENSOR E ABS SENSOR C NOTE Spring brake lines not shown SERVICE CONTROL LINES SENSOR CABLES SERVICE BRAKE SUPPLY AIR NOTE Spring brake line...

Page 17: ...WER SUPPLY ABS SENSOR F ABS SENSOR D GIO 1 SUBSYSTEM DIAGNOSTIC 3rd MODULATOR GIO 2 ABS SENSOR E ABS SENSOR C 4S 2M VALVE MOUNTED WITH CONTROL PORT FACING FRONT OFTRAILER SIDE TO SIDE CONTROL FRONT OF TRAILER FRONT OF TRAILER 4S 2M VALVE MOUNTED WITH CONTROL PORT FACING REAR OFTRAILER SIDE TO SIDE CONTROL 4013989a POWER SUPPLY ABS SENSOR F ABS SENSOR D GIO 1 SUBSYSTEM DIAGNOSTIC 3rd MODULATOR GIO ...

Page 18: ...MODULATOR GIO 2 ABS SENSOR E ABS SENSOR C 4S 2MTYPICALTRI AXLE VALVE MOUNTED WITH CONTROL PORT FACING FRONT OFTRAILER SIDE TO SIDE CONTROL FRONT OF TRAILER E F C D 4S 2MTYPICALTRI AXLE VALVE MOUNTED WITH CONTROL PORT FACING REAR OFTRAILER SIDE TO SIDE CONTROL FRONT OF TRAILER NOTE Spring brake lines not shown SERVICE CONTROL LINES SENSOR CABLES SERVICE BRAKE SUPPLY AIR NOTE Spring brake lines not ...

Page 19: ...19 Installation Fig 15 SERVICE CONTROL LINES SENSOR CABLES SERVICE BRAKE SUPPLY AIR 4013991b ...

Page 20: ...ULATOR GIO 2 ABS SENSOR E ABS SENSOR C F E D C 4S 3MTYPICALTRI AXLE WITH FRONT LIFT VALVE MOUNTED WITH CONTROL PORT FACING FRONT OFTRAILER FRONT OF TRAILER 4S 3MTYPICALTRI AXLE WITH FRONT LIFT VALVE MOUNTED WITH CONTROL PORT FACING REAR OFTRAILER E F C D FRONT OF TRAILER NOTE Spring brake lines not shown SERVICE CONTROL LINES SENSOR CABLES SERVICE BRAKE SUPPLY AIR NOTE Spring brake lines not shown...

Page 21: ...ED WITH CONTROL PORT FACING REAR OFTRAILER FRONT OF TRAILER POWER SUPPLY ABS SENSOR F ABS SENSOR D GIO 1 SUBSYSTEM DIAGNOSTIC 3rd MODULATOR GIO 2 ABS SENSOR E ABS SENSOR C POWER SUPPLY ABS SENSOR F ABS SENSOR D GIO 1 SUBSYSTEM DIAGNOSTIC 3rd MODULATOR GIO 2 ABS SENSOR E ABS SENSOR C NOTE Spring brake lines not shown SERVICE CONTROL LINES SENSOR CABLES SERVICE BRAKE SUPPLY AIR NOTE Spring brake lin...

Page 22: ...ODULATOR GIO 2 ABS SENSOR E ABS SENSOR C E F C D F E D C FRONT OF TRAILER 4S 3MTYPICAL FOUR AXLE PULLTRAILER VALVE MOUNTED WITH CONTROL PORT FACING FRONT OFTRAILER 4S 3MTYPICAL FOUR AXLE PULLTRAILER VALVE MOUNTED WITH CONTROL PORT FACING REAR OFTRAILER FRONT OF TRAILER NOTE Spring brake lines not shown SERVICE CONTROL LINES SENSOR CABLES SERVICE BRAKE SUPPLY AIR NOTE Spring brake lines not shown 4...

Page 23: ...M Installation End of Line Testing Procedure with TOOLBOX PLUS Software 1 Connect the diagnostic adapter RP1210 and or RP1210B compliant to the PC USB port Then connect the other end of the diagnostic adapter to either the Trailer main power line J560 connection or to the separately installed diagnostic cable part number 449 606 030 0 2 Open the iABS Diagnostics from the TOOLBOX PLUS Main Screen b...

Page 24: ... 20 4017110b 4 Check the Faults field on the Main Screen NONE No faults present proceed with end of line test YES Faults present double click on YES to bring up the fault information screen You may also select the Display menu at the top and then click on Faults to bring up the Fault Information Screen 5 Use the information in the Repair Instructions field to perform the necessary repairs Figure 2...

Page 25: ... faces the REAR of the trailer the slack adjusters will move in and out as the ROADSIDE portion of the dual modulator valve cycles If this does not happen the air lines are not correctly connected Perform the necessary repairs The Test Status box at the bottom of the menu will display the status of this test 7 Repeat this test for the H2 valve A Repeat Steps 1 4 but select H2 Valve Figure 22 B Sel...

Page 26: ...t 5 2 3 Sensor Orientation Test This test is not for use on 4S 3M installations For 4S 3M installations use the standard Sensor Test To run the standard test select Sensor Test from the Components Test Menu The sensor orientation test must be performed as part of the end of line testing procedure Figure 23 Fig 23 4017112a 5 2 3 1 Sensor Orientation Test Screen Before beginning this test look at th...

Page 27: ...on being tested Fig 24 4014084a 5 Click on Front or Rear in the Control Port Facing field to select the mounting orientation of the ECU dual modulator valve assembly Figure 25 Refer to Figure 24 and Figure 25 for illustrations of the ECU dual modulator assembly mounted with the control port facing forward and rear The correct mounting orientation must be selected prior to starting the test Step 5 ...

Page 28: ...re located in the bottom left portion of the Sensor Orientation Test screen Figure 24 Green background Correct sensor location Spin the next sensed wheel as indicated by the screen prompt Red background Incorrect sensor location If you get a red background you must stop the test click on stop make the necessary corrections and repeat Steps 3 through 6 9 To finish the Sensor Orientation Test click ...

Page 29: ...ations Connect curbside sensor at D Connect curbside sensor at F Connect roadside sensor at C Connect roadside sensor at E ECU Dual Modulator Valve Assembly Mounted with Control Port Facing Rear of Trailer 2S 2M Connect curbside sensor at C Connect roadside sensor at D 4S 2M Connect curbside front sensor at C Connect curbside rear sensor at E Connect roadside front sensor at D Connect roadside rea...

Page 30: ... routed to ROADSIDE the air lines for the three delivery ports labeled 2 2 on the opposite side of the valve must be routed to CURBSIDE Figure 28 Fig 27 4014007a CONTROL PORT DELIVERY PORTS 2 2 DELIVERY PORTS 2 1 Fig 28 4014011a CONTROL PORT DELIVERY PORTS 2 2 DELIVERY PORTS 2 1 3 3 For 4S 3M installations For 4S 3M installations Repeat this test for the external modulator valve The external relay...

Page 31: ...the end of line test If the trailer lamp still does not go out a system fault exists Perform a fault code check 6 Appendix I 6 1 Installing Sensors on Non ABS Prepped Axles Sensor locations vary due to suspension type WABCO recommends placing the sensors on the axle that will provide the most braking performance The trailer manufacturer suspension manufacturer along with WABCO work together to det...

Page 32: ...e brake hose to the ECU valve assembly to allow for axle jounce and rebound Brake hose clips with a provision for the sensor extension cable are recommended as opposed to tie wraps WABCO does not supply this part Fig 30 SENSOR CABLE 3 76 MM 4003573a 5 Install the wheel hub carefully so that the tooth wheel pushes against the sensor as the wheel bearings are adjusted There should be no gap between ...

Page 33: ...an efficient manner It should not be draped or wrapped around components or left unsecured Any slack remaining in the cable once the connections are made can be gathered up in a Z shaped loop Do not coil the cable and pinch into a bowtie or dog bone shape All cable zip ties should be tightened in a manner only to the extent that the cable is held sufficiently in place Fasten the excess cable to an...

Page 34: ...er must be a minimum 6 inches 152 mm and a maximum of 12 inches 305 mm from connector BRACKET MOUNTING ECU REARVIEW 4014395a ABS 2S 2M 4S 3M 7 1 3 Strain Relief at the ECU Tank Mounting It is necessary that cable connections to a component such as an ECU valve assembly display a visible amount of slack in the cable up to the first tie or clip that secures the cable to the trailer structure or air ...

Page 35: ...NK MOUNTING ECU FRONT VIEW FASTENER 4014396a 4 Max 12 R 4 R Max 12 CORRECT POWER AND GIO MODULATOR CABLE STRAIN RELIEF FOR ABS 2S 2M 4S 3M 7 1 4 Sensor Extension Cables at the ECU On valves that are tank mounted with no trailer structure nearby or have remote mounted cables the sensor extension cables are attached to the air lines Cable clips are preferred over zip ties It is important to remember...

Page 36: ...straints must be placed between 2 and 4 inches 51 102 mm from the cable connector to ensure correct strain relief Regardless of whether zip ties or cable clips are used cables should be secured at intervals not greater than 18 inches 457 mm to avoid cable vibration Refer to Figure 34 for air line attachment and Figure 35 for axle attachment Fig 34 4012336a 3 76 MM 3 76 MM ZIPTIES ON AIR LINES Fig ...

Page 37: ...such as axles should also be electrically connected to the common chassis ground If the axles are not correctly grounded to the chassis a ground strap electrically connecting the axle to the chassis may be added to ensure adequate protection from unwanted electrical noise This can be verified by measuring the resistance between the vehicle chassis frame and the other trailer component then confirm...

Page 38: ...Capable Yes Yes Yes GIO Capable No No Yes Multivoltage No No Yes Direction of Control Side to Side Axle to Axle Side to Side PARTS LIST Slot on iABS Modulator Application Part Number Length Power Power Cable 449 306 005 0 449 306 010 0 449 306 030 0 449 306 047 0 0 5 M 1 M 3 M 4 7 M Power Power Cable Blunt Cut 449 307 010 0 449 307 030 0 1 M 3 M Subsystem Diagnostic Cable Blunt Cut 4 Wire 449 608 ...

Page 39: ... M 10 M GIO 1 or 2 GIO Cable 2 Pin 449 408 010 0 449 408 040 0 449 408 060 0 1 M 4 M 6 M GIO 1 or 2 GIO Cable Blunt Cut 4 Wire 449 827 030 0 449 827 060 0 449 827 120 0 449 827 180 0 3 M 6 M 12M 18 M GIO 1 or 2 Brake Pad Wear Cable 449 836 013 0 449 836 030 0 1 3 M 3 M GIO 1 or 2 GIO Cable Tire Inflation 449 743 010 0 449 743 030 0 1 M 3 M Subsystem Subsystem Cable OptiLink IVTM 449 928 050 0 449 ...

Page 40: ...ey technology milestones in autonomous mobility and apply its extensive expertise to integrate the complex control and fail safe systems required to efficiently and safely govern vehicle dynamics at every stage of a vehicle s journey on the highway in the city and at the depot Today leading truck bus and trailer brands worldwide rely on WABCO s differentiating technologies Powered by its vision fo...