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Summary of Contents for WABCO 2S/2M
- Page 1 TRAILER iABS 2S/2M, 4S/2M AND 4S/3M INSTALLATION INSTRUCTIONS TP18006...
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Page 3: Table Of Contents
05.2020 subject to change without notice or liability. WABCO reserves the right to revise the TP18006 1 (en) information presented or to discontinue the production of parts described at any time. -
Page 4: General Information
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 action List • List Note on the use of a tool/WABCO tool... - Page 5 How to Obtain Additional Maintenance, Service and Product Information If you have any questions about the material covered in this publication, or for more information about the WABCO product line, please contact WABCO Customer Care Center at 855-228-3203, by email at wnacustomercare@wabco-auto.com, or visit our website: www.wabco-na.com.
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Page 6: Safety Information
Use only genuine WABCO components. Other manufacturers’ parts are not designed for use with a WABCO ABS system and may not function correctly. WABCO recommends that a control line fi lter, part number 432-500-005-0, be installed on the air system’s control line, upstream of the ABS ECU/valve assembly. -
Page 7: Preparation
All WABCO component part number information can be found in Appendix IV. End of line testing must be done after all installations. WABCO recommends using TOOLBOX PLUS™ Software to perform this testing. If you do not have TOOLBOX PLUS™ Software, this bulletin also includes instructions for testing without the software. - Page 8 Preparation 3. Study the ECU/single modulator valve assembly. Note the location of the various ports and electrical connections on the ECU. Figure 1, Figure 2, and Figure 3. Fig. 1 SUBSYSTEM/ POWER SUPPLY DIAGNOSTIC ABS SENSOR F ABS SENSOR E ABS SENSOR C ABS SENSOR D GIO 1...
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Page 9: Installation
Installation 5 Installation 5.1 Install the ECU/Dual Modulator Valve Assembly The assembly may be mounted on the air tank or on the cross member of the vehicle. 5.1.1 Tank-Mounted Refer to Figure 4. Fig. 4 ECU/DUAL MODULATOR VALVE MOUNTED WITH CONTROL PORT FACING FRONT OF TRAILER (TANK-MOUNTED) ECU/DUAL MODULATOR VALVE MOUNTED WITH... - Page 10 NOTICE WABCO does not recommend the use of a vise when installing the hex nipple. Use of a vise may cause overclamping. Overclamping may damage the internal components of the ECU/dual modulator valve assembly.
- Page 11 Do not overtighten, potential damage to the valve could occur. NOTICE WABCO does not recommend the use of a vise when installing the hex nipple. Use of a vise may cause overclamping. Overclamping may damage the internal components of the ECU/dual modulator valve assembly.
- Page 12 Installation 3. Rotate and tighten the relay valve assembly until the exhaust port faces down and the connection is secure. Use a torque wrench or ratchet with an extension at the 3/4-inch pipe plug installed on the front supply port. Figure 6. Fig.
- Page 13 Installation 4. For 4S/3M installations, perform the following procedures. Connect the brake service (control) line to the ECU/dual modulator valve assembly Port 4 (3/8-inch NPTF) and ABS external relay valve control Port 4 (3/8-inch NPTF). Use an ABS relay valve connection cable to connect the ECU/dual modulator valve assembly with the ABS external relay valve.
- Page 14 Installation Fig. 8 BUNDLE EXCESS CABLE 4003553a 8. Secure excess cable in the sub-frame of the vehicle or along the air hoses as appropriate. Excess cable should not exceed two feet (0.61 meter). Various cable lengths are available, see Appendix IV. 5.1.8 Install the Power Cable 1.
- Page 15 Installation 5. Plug the power connector into the power supply port of the ECU/Modulator valve assembly. 6. Push the yellow locking tab IN to secure the connection. Note: If it will not push in, make sure the power cable is fully seated. Once the locking clip is secured, install a cable tie to secure the cable to the cable mounting bracket.
- Page 16 Refer to Figure 12 through Figure 18 for typical trailer ABS installations. WABCO recommends placing the sensors on the axle that will provide the most braking performance. This is based on the way the suspension reacts during heavy braking applications. The trailer manufacturer can help provide this information.
- Page 17 Installation Fig. 13 4S/2M VALVE MOUNTED WITH CONTROL PORT FACING FRONT OF TRAILER — SIDE-TO-SIDE CONTROL FRONT OF TRAILER Typical Tandem Axle Trailer NOTE: Spring brake lines not shown. 4S/2M VALVE MOUNTED WITH CONTROL PORT FACING REAR OF TRAILER — SIDE-TO-SIDE CONTROL Typical Tandem Axle Trailer FRONT OF TRAILER...
- Page 18 Installation Fig. 14 4S/2M TYPICAL TRI-AXLE — VALVE MOUNTED WITH CONTROL PORT FACING FRONT OF TRAILER — SIDE-TO-SIDE CONTROL FRONT OF TRAILER NOTE: Spring brake lines not shown. 4S/2M TYPICAL TRI-AXLE — VALVE MOUNTED WITH CONTROL PORT FACING REAR OF TRAILER — SIDE-TO-SIDE CONTROL FRONT OF TRAILER NOTE: Spring brake...
- Page 19 Installation Fig. 15 SERVICE/CONTROL LINES SENSOR CABLES SERVICE BRAKE 4013991b SUPPLY AIR...
- Page 20 Installation Fig. 16 4S/3M TYPICAL TRI-AXLE WITH FRONT LIFT — VALVE MOUNTED WITH CONTROL PORT FACING FRONT OF TRAILER FRONT OF TRAILER NOTE: Spring brake lines not shown. 4S/3M TYPICAL TRI-AXLE WITH FRONT LIFT — VALVE MOUNTED WITH CONTROL PORT FACING REAR OF TRAILER FRONT OF TRAILER SERVICE/CONTROL LINES...
- Page 21 Installation Fig. 17 4S/3M TYPICAL TRI-AXLE — VALVE MOUNTED WITH CONTROL PORT FACING FRONT OF TRAILER FRONT OF TRAILER NOTE: Spring brake lines not shown. SERVICE/CONTROL LINES SENSOR CABLES Typical Tandem SERVICE BRAKE Axle Trailer SUPPLY AIR 4S/3M TYPICAL TRI-AXLE — VALVE MOUNTED WITH CONTROL PORT FACING REAR OF TRAILER FRONT OF TRAILER Typical Tandem...
- Page 22 Installation Fig. 18 4S/3M TYPICAL FOUR AXLE PULL TRAILER — VALVE MOUNTED WITH CONTROL PORT FACING FRONT OF TRAILER FRONT OF NOTE: Spring brake TRAILER lines not shown. SERVICE/CONTROL LINES SENSOR CABLES SERVICE BRAKE SUPPLY AIR 4S/3M TYPICAL FOUR AXLE PULL TRAILER — VALVE MOUNTED WITH CONTROL PORT FACING REAR OF TRAILER FRONT OF TRAILER...
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Page 23: End Of Line Testing
Installation 5.2 End of Line Testing End of line testing is required on all iABS installations. To run these tests, WABCO recommends you use TOOLBOX PLUS™ Software. TOOLBOX PLUS™ general test procedures are included in this document. 5.2.1 Trailer iABS 2S/2M, 4S/2M and 4S/3M Installation — End of Line Testing Procedure with TOOLBOX PLUS™... - Page 24 Installation 3. Verify the power supply. Apply 12 (9.5 to 14 is acceptable) volts DC to the blue wire (constant power). Check the screen for the correct voltage, it is displayed in the Primary Voltage fi eld. Figure 20. Fig.
- Page 25 Installation 5.2.2 End of Line Test with TOOLBOX PLUS™ Software 5.2.2.1 Verify Correct Valve and Lamp Installation To verify valve and lamp installations with TOOLBOX PLUS™ Software: 1. Apply 12 volts DC to the ABS. 2. Apply air to the emergency line to fi ll the air tanks and release the spring brakes. 3.
- Page 26 Installation 8. For 4S/3M installations: Repeat this test for the L valve. L Valve: The external relay valve designated L valve is an axle control valve. It controls brake chambers on one or two axles. It is important that delivery lines from Port 2 are plumbed as shown on the installation drawings.
- Page 27 Installation When the Sensor Orientation Test screen fi rst appears, the Control Port Facing fi eld will display the default Front. This will occur regardless of the actual control port orientation of the installation being tested. Fig. 24 4014084a 5. Click on Front or Rear in the Control Port Facing fi eld to select the mounting orientation of the ECU/dual modulator valve assembly.
- Page 28 Perform the necessary repairs and repeat the test. If the problem persists, contact WABCO North America Customer Care at 855-228-3203. Sensor output appears in the Sensors fi eld located in the bottom right portion of the...
- Page 29 1. Look at the control port on the ECU/dual modulator valve assembly. Ensure that the connectors are routed to the correct wheel-end location for a standard semi-trailer, as follows: ECU/Dual Modulator Valve Assembly Mounted with Control Port Facing Front of Trailer 2S/2M • Connect curbside sensor at D. •...
- Page 30 Installation 5.2.4.2 Air Line Installation 1. Ensure that all unused air ports are plugged and that the exhaust port is facing DOWN. 2. Look at the air line installation to verify that all air lines are correctly installed. If the ECU/dual modulator valve assembly is mounted with the control port facing the FRONT of the trailer, the air lines for the three delivery ports labeled 2.1 must be routed to CURBSIDE;...
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Page 31: Installing Sensors On Non-Abs-Prepped Axles
2. Push the spring clip into the sensor holder from the inboard side, until the spring clip tabs are against the sensor holder. Push the sensor into the spring clip as far as possible. Use WABCO spring clips to ensure a correct fi t. - Page 32 The sensor extension cable must follow the 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"...
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Page 33: Cable Strain Relief Guidelines
WABCO has many lengths of cables available so it is a best practice to obtain a length that best suits the requirements of the installation. Refer to the Parts List in Appendix IV to fi nd the different cable lengths that WABCO offers. - Page 34 If the cable is 1/4-inch (6.35 mm) in diameter, then the bend should be a minimum of 2-1/2-inches (64 mm). Refer to Figure 31 for the ECU mounting of 2S/2M-4S/3M ABS. Fig. 31...
- Page 35 In these cases, securing the cable may be accomplished by fastening the cable to nearby air lines. It is important to note that cables should be secured only to the extent that the cable is held suffi ciently in place. Refer to Figure 32 for 2S/2M-4S/3M ABS. Fig. 32...
- Page 36 Appendix II Fig. 33 SENSOR EXTENSION CABLES - ECU FRONT VIEW FASTENER FASTENER ZIP TIE ZIP TIE 4" 4" Max. Max. 12" 12" 4014394c 7.1.5 Cable-to-Cable Connections It is important to ensure all cable-to-cable connections maintain good strain relief. Cable restraints must be placed between 2- and 4-inches (51-102 mm) from the cable connector to ensure correct strain relief.
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Page 37: Vehicle Electrical Grounding Guidelines
If a common chassis ground point is present, but not suffi cient, ensure that there is no paint or debris inhibiting electrical contact at the ground point. If a common chassis ground point is not present, WABCO recommends adding one. -
Page 38: Parts And Variant List
Appendix IV 9 Appendix IV 9.1 Parts and Variant List VARIANT LIST iABS 2M Standard Semi iABS 2M Standard iABS 2M Premium Variants Trailer Full Trailer Max System 4S/2M 4S/2M 4S/3M Confi guration Part Number 400 500 420 0 400 500 425 0 400 500 430 0 CAN Capable GIO Capable... - Page 39 Appendix IV PARTS LIST Slot on iABS Modulator Application Part Number Length 449 733 008 0 0.8 M 449 733 013 0 1.3 M 449 733 018 0 1.8 M 449 733 030 0 Sensor Ports C,D,E,F Sensor Extension Cable 449 733 050 0 449 733 070 0 449 733 090 0...
- Page 40 WABCO’s differentiating technologies. Powered by its vision for accident- free driving and greener transportation solutions, WABCO is also at the forefront of advanced fl eet management systems and digital services that contribute to commercial fl eet effi ciency. In 2019, WABCO reported sales of over $3.4 billion and had nearly 14,000 employees in 40 countries.
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