WABCO 2S/2M Bedienungsanleitung
TRAILER iABS
2S/2M, 4S/2M AND 4S/3M
INSTALLATION INSTRUCTIONS
TP18006
3
Table of Contents
Edition 2
05.2020
TP18006 1 (en)
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
subject to change without notice or liability. WABCO reserves the right to revise the
information 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 .............................................................................................................. 33
8 Appendix III..................................................................................................................................................... 37
8.1 Vehicle Electrical Grounding Guidelines ............................................................................................... 37
9 Appendix IV ................................................................................................................................................... 38
9.1 Parts and Variant List............................................................................................................................ 38
4
General Information
1 General Information
Symbols used in this document
DANGER
Description of an immediate situation which will result in irreversible injury or death if the warning is
ignored.
WARNING
Description of a possible situation which may result 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 action
List
•List
Note on the use of a tool/WABCO tool
5
General Information
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
Refer to the latest iABS Maintenance Manual MM19001. To obtain this publication, visit our website at
wabco-na.com/literature, or call WABCO North America Customer Care at 1-855-228-3203.
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.
WABCO TOOLBOX PLUS™Software
The TOOLBOX PLUS™ Software provides PC diagnostics for WABCO products can be purchased and
downloaded from https://wabco.snapon.com. For complete instructions for using TOOLBOX PLUS™ refer
to User’s Guide MM19047. To obtain this literature, visit www.wabco-na.com/literature.
WABCO Academy
https://www.wabco-academy.com/home/
WABCO Online product catalog
http://www.wabco-customercenter.com
Your direct contact to WABCO
WABCO North America LLC
WABCO USA LLC
1220 Pacific Drive
Auburn Hills, MI 48326
Customer Care Center: (855) 228-3203
www.wabco-na.com
6
Important Information
2 Safety Information
Provisions for a safe work environment
Only trained and qualified auto technicians and auto mechanics may carry out work on the vehicle.
Read this publication carefully.
Follow all warnings, notices and instructions to avoid personal injury and property damage.
Always abide by the vehicle manufacturer’s specifications and instructions.
Observe all accident regulations of the respective company as well as regional and national regulations.
The workplace should be dry, sufficiently lit and ventilated.
Use personal protective equipment if required (safety shoes, protective goggles, respiratory protection
and ear protectors).
Read and observe all 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
vehicle with safety stands. Do not work under a vehicle supported only by jacks. Jacks can slip or fall
over. Serious personal injury and damage to components can result.
3 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.
7
Preparation
4 Preparation
1. Before beginning the installation procedure, inspect the ECU/dual modulator valve assembly for
damage that may have occurred during shipping or storage.
Look for damaged or broken connectors.
Do not install a damaged ECU/dual modulator valve assembly. Notify your supervisor, or contact
WABCO if there is any apparent damage.
2. Have the following installation material available.
WABCO Components:
ECU/dual modulator valve assembly
ABS relay valve and relay valve extension cable (3M system only)
Power cable or power/diagnostic cable
Sensor extension cables (two pieces for 2S systems, four pieces for 4S systems)
ABS sensors (two or four) for non-ABS prepped axles
ABS Indicator Label (TP-95172)
Non-WABCO Components:
5/8-inch 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 sealing paste
ABS indication lamp (to ensure correct lamp operation, use an incandescent-type DOT-approved
lamp, or an LED with integral load resistor)
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. The TOOLBOX PLUS™ Software can be purchased and
downloaded from www.wabco-snapon.com.
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
4014012a
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
9
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 OFTRAILER
(TANK-MOUNTED)
ECU/DUAL MODULATOR VALVE MOUNTED WITH
CONTROL PORT FACING REAR OF TRAILER
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/GIO2
ABS SENSOR E
ABS SENSOR C
10
Installation
WARNING
You must use a Schedule 80 hex nipple (3/4-inch NPT) to mount the ECU/dual modulator valve
assembly securely to the air tank to avoid possible serious personal injury and damage to the
component.
1. Use a 3/4-inch NPT Schedule 80 hex nipple to attach the ECU/dual modulator valve assembly to a
reinforced air tank. Apply SAE-standard, DOT-approved sealing paste to either the first few threads or
over the whole length. Hand-tighten it with a minimum of 2.5 turns. Note if a minimum of 2.5 turns
cannot be achieved, remove and inspect.
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.
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 3/4-inch pipe
plug installed on the front supply port to verify the valve is tightened to 59-148 lb-ft (80-200 Nm).
5.1.2 Mounted to Cross Member of Vehicle (Mounting Bracket Not Supplied)
Refer to Figure 5.
Fig. 5
ECU/DUAL MODULATOR VALVE MOUNTED
TO A CROSS MEMBER OFTHE VEHICLE WITH
CONTROL PORT FACING FRONT OF TRAILER
FRONT OF
TRAILER
ECU/DUAL MODULATOR VALVE MOUNTED WITH
CONTROL PORT FACING REAR OF TRAILER
FRONT OF
TRAILER
Exhaust
port
must face
DOWN.
Plug all unused
ports.
Exhaust
port
must face
DOWN.
Plug all
unused ports.
CONTROL
PORT
CONTROL
PORT
4014264a
Dieses Handbuch passt für folgende Modelle
2
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