WABCO TRAILER iABS 2S STANDARD Installation Instructions Manual Download Page 19 | Manualshive

Page: 19 / 38

background image

19

Installation

4014005y

D

C

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/CONTROL LINES
SENSOR CABLES
SERVICE BRAKE
SUPPLY AIR

4014005z

FRONT OF

TRAILER

C

D

2S/1M PREMIUM VALVE MOUNTED WITH CONTROL PORT

FACING REAR OF TRAILER - SIDE-TO-SIDE CONTROL

NOTE: Spring brake

lines not shown.

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Summary of Contents for TRAILER iABS 2S STANDARD

Page 1: ...INSTALLATION INSTRUCTIONS TP18007 TRAILER iABS 2S 1M STANDARD AND PREMIUM...

Page 2: ......

Page 3: ...4 Preparation 10 5 Installation 12 5 1 Install the ECU Single Modulator Valve Assembly 12 5 2 Connect the Air Lines 13 5 3 Install the Two Sensor Extension Cables ABS Prepped Axles 14 5 4 Install the...

Page 4: ...was in effect at the time the publication was approved for printing and is subject to change without notice or liability ZF CV Systems North America LLC reserves the right to revise the information pr...

Page 5: ...ored 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...

Page 6: ...ghway Traffic Safety Administration NHTSA website to find all current documents referenced in the manual at www nhtsa gov 1 3 How to Obtain Parts and Kits Contact the WABCO Customer Care Center at 855...

Page 7: ...General Information 1 7 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 co...

Page 8: ...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...

Page 9: ...PLC and CAN 2S 1M Basic 2S 2M 4S 2M and 4S 3M Premium Use only genuine WABCO components Other manufacturers parts are not designed for use with a WABCO ABS system and may not function correctly WABCO...

Page 10: ...s 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 SAE standard DOT approved sealing paste...

Page 11: ...PLY PORT DELIVERY PORTS 4014010b 1M STANDARD 1M PREMIUM POWER SUPPLY ABS SENSOR D ABS SENSOR C DELIVERY PORTS DELIVERY PORTS SUPPLY PORT SUPPLY PORT EXHAUST PORT CONTROL PORT DELIVERY PORTS DELIVERY P...

Page 12: ...unused supply port Port 1 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 7 Rotate and ti...

Page 13: ...n the two holes O D must be 3 25 32 inches 96 mm and mount directly to the cross member OR Build a mounting bracket with two 3 8 inch mounting holes spaced 3 25 32 inches 96 mm O D apart 4014001b TEMP...

Page 14: ...3 8 inch NPT 4 Plug any unused delivery ports 5 3 Install the Two Sensor Extension Cables ABS Prepped Axles Instructions for installing sensors on non ABS prepped axles are included in Appendix I WAB...

Page 15: ...he cables every 8 inches 203 mm with tie wraps or cable clips 5 Plug the sensor extension cables into the ECU dual modulator valve assembly To secure push the sensor extension connection in until the...

Page 16: ...her pack cables route the cable from the harness connector to the ECU single modulator valve assembly and secure it to prevent damage For a blunt cut power cable route the cable from the ECU single mo...

Page 17: ...of the trailer and sub frame E Bundle any excess cable in a loop bow tie and secure the cable in the sub frame 9 Install the ABS indicator lamp on the trailer Refer to the vehicle specification sheet...

Page 18: ...NT OF TRAILER NOTE Spring brake lines not shown SERVICE CONTROL LINES SENSOR CABLES SERVICE BRAKE SUPPLY AIR SERVICE CONTROL LINES SENSOR CABLES SERVICE BRAKE SUPPLY AIR 4014005x FRONT OF TRAILER C D...

Page 19: ...AILER SIDE TO SIDE CONTROL FRONT OF TRAILER NOTE Spring brake lines not shown SERVICE CONTROL LINES SENSOR CABLES SERVICE BRAKE SUPPLY AIR 4014005z FRONT OF TRAILER C D 2S 1M PREMIUM VALVE MOUNTED WIT...

Page 20: ...re Using TOOLBOX PLUS Software 1 Connect a PLC diagnostic adapter to the PC USB port then connect the other end of the diagnostic adapter to the Trailer main power line J560 connection Note a list of...

Page 21: ...ld 4017037b 4017033a 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 Yo...

Page 22: ...t Valves Lamp to display the Valve Activation Screen The H1 valve indicator will be selected 4017038a 5 Click on the Activate button and listen for the valve to click indicating a good installation Th...

Page 23: ...ntation test 1 Raise the sensed wheel ends off the ground 2 Apply air to the emergency supply line to fill the air tanks and release the spring brakes so that the wheels can be rotated 3 Apply 12 volt...

Page 24: ...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 s...

Page 25: ...nter at 855 228 3203 Sensor output appears in the Sensors field located in the bottom right portion of the Sensor Orientation Test screen 5 7 End of Line Test without TOOLBOX PLUS Software 1 Apply 12...

Page 26: ...he correct location 4005501a If the ABS indicator lamp comes on and stays on when you apply the brakes to a moving vehicle the trailer ABS is not working properly The ABS must be serviced as soon as p...

Page 27: ...g clip as far as possible Use WABCO spring clips to ensure a correct fit 3 Push the spring clip into the sensor holder from the inboard side until the spring clip tabs are against the sensor holder Pu...

Page 28: ...eel pushes against the sensor as the wheel bearings are adjusted There should be no gap between the sensor and the tooth wheel 6 Test the sensor output voltage Use a volt ohm meter to check the output...

Page 29: ...sture could intrude Unnecessary wear at bend points can be the result of a cable under tension Cable strain relief is a universal practice It applies to all WABCO product lines from Anti Lock Brake Sy...

Page 30: ...s should be secured at intervals not greater than 18 inches 457 mm to avoid cable vibration Ideally cables should be affixed to the rigid structure of the trailer A good rule of thumb is to have the b...

Page 31: ...eater than 18 inches 457 mm to avoid cable vibration Ideally cables should be affixed to the rigid structure of the trailer However structure is not always available on tank mounted installations In t...

Page 32: ...astened in a manner where the cable is secured enough where the cable will not move or chafe against what it is mounted to A small amount of slack should be present to ensure that the cables do not be...

Page 33: ...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 n...

Page 34: ...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 m...

Page 35: ...V 9 1 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 Yes Yes GIO Capable No Yes Direction of Control...

Page 36: ...F 4019730a Sensor Extension Cable 449 733 008 0 449 733 013 0 449 733 018 0 449 733 030 0 449 733 050 0 449 733 070 0 449 733 090 0 449 733 120 0 0 8 M 1 3 M 1 8 M 3 M 5 M 7 M 9 M 12 M Modulator 40197...

Page 37: ...030 0 1 M 3 M Subsystem 4019737a Subsystem Cable OptiLink IVTM Trailer CAST 449 928 050 0 449 943 050 0 449 928 120 0 449 943 120 0 5 M 5 M 12 M 12 M Subsystem 4019738a Subsystem Cable Smartboard II 4...

Page 38: ...n serves the full commercial vehicle industry value chain As the automotive industry progresses towards an increasingly autonomous connected and electrified ACE future ZF s CVS division innovates inte...

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