Table of Contents
Advertisement
Quick Links
Advertisement
Table of Contents
Subscribe to Our Youtube Channel
Related Manuals for WABCO TRAILER iABS 2S STANDARD
Summary of Contents for WABCO TRAILER iABS 2S STANDARD
- Page 1 TRAILER iABS 2S/1M STANDARD AND PREMIUM INSTALLATION INSTRUCTIONS TP18007...
-
Page 3: Table Of Contents
Symbols Used in this Document ........................5 How to Obtain Additional Maintenance, Service and Product Information ............6 How to Obtain Parts and Kits ..........................6 WABCO TOOLBOX PLUS™ Software ......................6 WABCO Academy ..............................6 WABCO Online Product Catalog ........................6 Your Direct Contact to ZF CVS ..........................7 Safety Information. - Page 4 This publication is not subject to any update service. Information contained in this publication was in effect at the time the publication was approved for printing and is Edition 1 subject to change without notice or liability. ZF CV Systems North America LLC reserves Version 2 (06.2022) the right to revise the information presented or to discontinue the production of parts TP18007 (en)
-
Page 5: General Information
Important information, notices and/or tips Reference to information on the Internet Descriptive text – Action step Action step 1 (in ascending order) Action step 2 (in ascending order) Ö Result of an action • Listing Indicating the use of a tool / WABCO tool... -
Page 6: How To Obtain Additional Maintenance, Service And Product Information
Refer to the Society of Automotive Engineers (SAE) website to find all current 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. -
Page 7: Your Direct Contact To Zf Cvs
General Information Your Direct Contact to ZF CVS ZF CV Systems North America LLC 1220 Pacific Drive Auburn Hills, MI 48326 Customer Care Center: (855) 228-3203 www.zf.com/cv wabconacustomercare@zf.com... -
Page 8: Safety Information
Safety Information Safety Information Provisions for a safe work environment Only experienced, trained and qualified automotive technicians may carry out work on the vehicle. „ Read this publication carefully. „ Follow all warnings, notices and instructions to avoid personal injury and property damage. „... -
Page 9: Important 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 filter, part number 432-500-005-0, be installed on the air system’s control line, upstream of the ABS ECU/valve assembly. -
Page 10: Preparation
* WABCO components 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 11 Preparation 1M STANDARD 1M PREMIUM SUPPLY PORT 4014006a SUPPLY DELIVERY PORT PORTS DELIVERY PORTS 4014006b 1M STANDARD 1M PREMIUM POWER SUPPLY ABS SENSOR C ABS SENSOR D 4014010b 1M STANDARD 1M PREMIUM CONTROL SUPPLY PORT PORT CONTROL PORT SUPPLY PORT DELIVERY DELIVERY PORTS...
-
Page 12: Installation
Installation Installation Install the ECU/Single 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 WARNING You must use a Schedule 80 hex nipple (3/4-inch NPT) to mount the ECU/single modulator valve assembly securely to the air tank to avoid possible serious personal injury and damage to the component. -
Page 13: Connect The Air Lines
Installation WARNING When mounting the ECU/dual modulator valve assembly to the trailer cross member, refer to SAE specification J447, Prevention of Corrosion of Motor Vehicle Body and Chassis Components. Follow all recommendations and procedures. Your supervisor should have a copy of this specification. Locate a position for mounting the assembly to the vehicle cross member midway between the side rails, close to the brake chambers the valve serves. -
Page 14: Install The Two Sensor Extension Cables (Abs-Prepped Axles)
Install the Two Sensor Extension Cables (ABS-Prepped Axles) Instructions for installing sensors on non-ABS-prepped axles are included in Appendix I. WABCO recommends placing sensors on the axle that will provide the most braking performance. The suspension manufacturer can provide this information Visually inspect the tooth wheel and sensor to ensure no damage occurred during shipping. - Page 15 Installation Route the sensor cable along the back side of the trailer axle to the ECU/single 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 wrap the molded sensor plug.
-
Page 16: Install The Power Or Power/Diagnostic Cable
Installation Bundle any excess cable in a “Z”-shaped loop. BUNDLE EXCESS CABLE 4003553a 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). Correct strain relief of cables is discussed in Appendix II. Install the Power or Power/Diagnostic Cable Identify the type of cable to be installed. - Page 17 Junction box not shown. 4013987a 5.4.1 Typical Trailer iABS Installation Refer to the following illustrations for typical trailer ABS installations. WABCO recommends placing sensors on the axle that will provide the most braking performance. The suspension manufacturer can provide this information.
- Page 18 Installation 2S/1M PREMIUM VALVE MOUNTED WITH CONTROL PORT FACING FRONT OF TRAILER - SIDE-TO-SIDE CONTROL FRONT OF TRAILER NOTE: Spring brake lines not shown. SERVICE/CONT ROL LINES SENSOR CABLES SERVICE BRAKE SUPPLY AIR 4014005u 2S/1M PREMIUM VALVE MOUNTED WITH CONTROL PORT FACING REAR OF TRAILER - SIDE-TO-SIDE CONTROL FRONT OF TRAILER...
- Page 19 Installation 2S/1M PREMIUM VALVE MOUNTED WITH CONTROL PORT FACING FRONT OF TRAILER - SIDE-TO-SIDE CONTROL FRONT OF TRAILER NOTE: Spring brake lines not shown. 4014005y 2S/1M PREMIUM VALVE MOUNTED WITH CONTROL PORT FACING REAR OF TRAILER - SIDE-TO-SIDE CONTROL FRONT OF TRAILER NOTE: Spring brake lines not shown.
-
Page 20: End Of Line Testing
Installation 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™ Software and general test procedures are included in this bulletin. 5.5.1 iABS 2S/1M Basic Installation — End of Line Testing Procedure Using TOOLBOX PLUS™... - Page 21 Installation Verify the power supply. Apply 12 volts DC to the blue wire (constant). Check the screen for the correct voltage (9.4 to 14 „ volts). Constant power voltage is displayed in the PRIMARY field. 4017037b 4017033a Check the Faults field on the Main Screen. NONE = No faults present, proceed with end of line test.
-
Page 22: End Of Line Test With Toolbox Plus™ Software
Installation End of Line Test with TOOLBOX PLUS™ Software 5.6.1 Verify Correct Valve and Lamp Installation To verify valve and lamp installations with TOOLBOX PLUS™ Software: Apply 12 volts DC to the ABS. Apply air to the emergency line to fill the air tanks and release the spring brakes. Apply air to the control line. - Page 23 Installation 5.6.2 Sensor Orientation Test The sensor orientation test must be performed as part of the end of line testing procedure. Sensor Orientation Test Screen Before beginning this test, look at the control port to see if it faces the front or rear of the trailer. TOOLBOX PLUS™...
- Page 24 Installation Click on Front or Rear in the Control Port Facing field to select the mounting orientation of the ECU/single modulator valve assembly. Refer to the following illustrations for the ECU mounted with sensors facing forward and rear. The correct mounting orientation must be selected prior to starting the test. 4017035a Click on Start to begin the test.
-
Page 25: End Of Line Test Without Toolbox Plus™ Software
Perform the necessary repairs and repeat the test. If the problem persists, contact the WABCO Customer Care Center at 855-228-3203. Sensor output appears in the Sensors field located in the bottom right portion of the Sensor Orientation Test screen. - Page 26 Rev. 4/98 4005501a If this label is not included with the assembly, let your supervisor know. Labels are available from WABCO. Ask for part number TP95172. A complete part listing can be found in WABCO Parts Book PB96133 available at www.zf.com/cv.
-
Page 27: Installing Sensors On Non-Abs-Prepped Axles
Appendix I Installing Sensors on Non-ABS-Prepped Axles Sensor locations vary due to suspension type. WABCO recommends placing the sensor on the axle that will provide the most braking performance. Contact your suspension manufacturer for further information. Apply a mineral oil-based grease that contains molydisulfide to the sensor spring clip, the body of the sensor and the bore of the sensor block. - Page 28 Appendix I Brake hose clips with a provision for the sensor extension cable are recommended as opposed to tie wraps. WABCO does not supply this part. SENSOR CABLE 3" (76 MM) 4003573a Install the wheel hub carefully so that the tooth wheel pushes against the sensor as the wheel bearings are adjusted.
-
Page 29: Cable Strain Relief Guidelines
Fasten the excess cable to an area that is free of sharp edges and moving components. 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. - Page 30 Strain Relief at the ECU — Bracket Mounting WABCO recommends 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 line.
- Page 31 Appendix II 7.2.2 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 line. This first anchor point should be a minimum 6-inches (152 mm) of cable length from the cable/component connection and a maximum of 12-inches (305 mm).
- Page 32 Appendix II 7.2.3 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 that cables should be fastened in a manner where the cable is secured enough where the cable will not move or chafe against what it is mounted to.
- Page 33 Appendix II 7.2.4 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. 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.
-
Page 34: Vehicle Electrical Grounding Guidelines
If a common chassis ground point is present, but not sufficient, 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 35: Parts And Variant List
Appendix IV Appendix IV Parts and Variant List VARIANT LIST Variants System Configuration 2S/1M Standard 2S/1M Premium Part Number 400 500 320 0 400 500 350 0 CAN Capable GIO Capable Direction of Control Side to Side Side to Side... - Page 36 Appendix IV PARTS LIST Slot on iABS Modulator Application Part Number Length 449 306 005 0 0.5 M 449 306 010 0 Power 449 306 030 0 Power Cable 4019726a 449 306 047 0 4.7 M 449 307 010 0 449 307 030 0 Power Power Cable Blunt Cut...
- Page 37 Appendix IV PARTS LIST Slot on iABS Modulator Application Part Number Length 449 836 013 0 1.3 M 449 836 030 0 GIO 1 or 2 4019735a Brake Pad Wear Cable 449 743 010 0 449 743 030 0 GIO 1 or 2 GIO Cable Tire Inflation 4019736a 449 928 050 0...
- Page 38 CVS unites ZF’s former Commercial Vehicle Technology and Commercial Vehicle Control Systems divisions, the latter being formed following ZF’s acquisition of WABCO in Spring 2020. For more information, visit: www.zf.com/cv...
Need help?
Do you have a question about the TRAILER iABS 2S STANDARD and is the answer not in the manual?
Questions and answers