WABCO TRAILER iABS 2S STANDARD User manual

INSTALLATION INSTRUCTIONS
TP18007
TRAILER iABS 2S/1M
STANDARD AND PREMIUM

3
Table of Contents
Table of Contents
1 General Information. ...................................................................................................................................................5
1.1 Symbols Used in this Document ........................................................................................................................5
1.2 How to Obtain Additional Maintenance, Service and Product Information.........................................................6
1.3 How to Obtain Parts and Kits.............................................................................................................................6
1.4 WABCO TOOLBOX PLUS™ Software ..............................................................................................................6
1.5 WABCO Academy..............................................................................................................................................6
1.6 WABCO Online Product Catalog .......................................................................................................................6
1.7 Your Direct Contact to ZF CVS ..........................................................................................................................7
2 Safety Information.......................................................................................................................................................8
2.1 Provisions for a safe work environment .............................................................................................................8
3 Important Information.................................................................................................................................................9
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 Power or Power/Diagnostic Cable...................................................................................................16
5.5 End of Line Testing ..........................................................................................................................................20
5.6 End of Line Test with TOOLBOX PLUS™ Software ........................................................................................22
5.7 End of Line Test without TOOLBOX PLUS™ Software ...................................................................................25
6 Appendix I..................................................................................................................................................................27
6.1 Installing Sensors on Non-ABS-Prepped Axles ...............................................................................................27
7 Appendix II.................................................................................................................................................................29
7.1 Cable Strain Relief Guidelines .........................................................................................................................29
7.2 Excess Cable Length .......................................................................................................................................29
8 Appendix III................................................................................................................................................................34
8.1 Vehicle Electrical Grounding Guidelines ..........................................................................................................34
9 Appendix IV . .............................................................................................................................................................35
9.1 Parts and Variant List.......................................................................................................................................35

Edition 1
Version 2 (06.2022)
TP18007 (en)
This publication is not subject to any update service. Information contained in this
publication was in e󰀨ect 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 presented or to discontinue the production of parts
described at any time.
You will nd the current edition at: https://zf.com/cvliterature

1 General Information
1.1 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, notices and/or tips
Reference to information on the Internet
Descriptive text
– Action step
1. Action step 1 (in ascending order)
2. Action step 2 (in ascending order)
ÖResult of an action
• Listing
Indicating the use of a tool / WABCO tool
5
General Information

6
General Information
1.2 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 [email protected], or visit our website:
www.zf.com/cv.
Refer to the Society of Automotive Engineers (SAE) website to nd 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 Tra󰀩c Safety Administration (NHTSA) website to nd 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 855-228-3203 (United States and Canada);
800-953-0248 (Mexico). Email: [email protected].
1.4 WABCO TOOLBOX PLUS™ Software
TOOLBOX PLUS™ Software provides PC diagnostic for WABCO products and can be
purchased and downloaded from https://wabco.snapon.com.
The software User Guide, MM19047 can be obtained by visiting our Literature Center.
Purchase and Download TOOLBOX PLUS™
https://wabco.snapon.com
ZF Commercial Vehicle Literature Center
https://zf.com/cvliterature
1.5 WABCO Academy
www.wabco-academy.com
1.6 WABCO Online Product Catalog
www.wabco-customercenter.com

7
General Information
1.7 Your Direct Contact to ZF CVS
ZF CV Systems North America LLC
1220 Pacic Drive
Auburn Hills, MI 48326
Customer Care Center: [phone]
www.zf.com/cv
[email protected]

8
Safety Information
2 Safety Information
2.1 Provisions for a safe work environment
Only experienced, trained and qualied 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.
Always abide by the vehicle’s Original Equipment Manufacturer (OEM) specications and instructions.
Observe all accident regulations of the repair facility as well as regional and national regulations.
The workplace should be dry, su󰀩ciently 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.
WARNING
This product can expose you to chemicals including Nickel, which is known to the State of California
to cause cancer and birth defects or other reproductive harm. For more information, go to
www.P65Warnings.ca.gov.
WARNING
The Anti-lock Braking System (ABS) is an electrical system. When you work on the ABS, take the
same precautions that you must take with any electrical system to avoid serious personal injury. As
with any electrical system, the danger of electrical shock or sparks exists that can ignite
ammable substances. You must always disconnect the battery ground cable before working on the
electrical system.

9
Important Information
3 Important Information
For more information, refer to the latest iABS Maintenance Manual MM19001, iABS Trailer ABS System
with 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 recommends that a control line lter, part number 432-500-005-0, be installed on the air system’s
control line, upstream of the ABS ECU/valve assembly.

10
Preparation
4 Preparation
3. Before beginning the installation procedure, inspect the ECU/single 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/single modulator valve assembly. Notify your supervisor, or contact
WABCO if there is any apparent damage.
4. Have the following installation material available.
* ECU/single modulator valve assembly
* Power cable or power cable/power HUB cable/diagnostic cable
* Sensor extension cables (two pieces)
* Sensors (two) for non-ABS-prepped axles
* ABS Indicator Label (TP95172)
5/8-inch O.D. nylon tubing for supply (frame mounts)
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
To ensure correct lamp operation, use an incandescent-type DOT-approved lamp, or an LED with
integral load resistor.
* 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.
5. Study the ECU/single modulator valve assembly. Note the location of the various ports and electrical
connections on the ECU.
4014008a
CONTROL
PORT
SUPPLY
PORT
POWER
CABLE
DELIVERY PORTS
1M STANDARD 1M PREMIUM
CONTROL
PORT
SUPPLY
PORT
POWER
CABLE
DELIVERY PORTS
SUBSYSTEM
DIAGNOSTIC

11
Preparation
4014006b
1M STANDARD 1M PREMIUM
SUPPLY
PORT
DELIVERY PORTS
4014006a
SUPPLY
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
PORTS
CONTROL
PORT SUPPLY
PORT
EXHAUST
PORT
SUPPLY
PORT
4014009b
1M STANDARD 1M PREMIUM

12
Installation
5 Installation
5.1 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.
Use a 3/4-inch NPT Schedule 80 hex nipple to attach the ECU/single modulator valve assembly to a re-
inforced air tank. Apply SAE-standard, DOT-approved sealing paste to either the rst 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.
6. Use a 3/4-inch NPTF pipe plug to plug the unused supply port (Port 1). Apply SAE-standard, DOT-
approved sealing paste to either the rst few threads or over the whole length. Pipes with pre-applied
thread sealant may also be used.
7. Rotate and tighten the ECU/single 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).
4014000b
POWER SUPPLY
ABS SENSOR D
ABS SENSOR C
PLUG
UNUSED
PORT
SCHEDULE
80 HEX
NIPPLE
Rear of assembly
faces
air tank.
Exhaust
port
must face
DOWN.
AIRTANK
5.1.2 Bracket-Mounted to Cross Member of Vehicle
1. Install a 3/4-inch NPT tting in the supply port (Port 1). Use a 3/4-inch NPT pipe plug to plug the
unused supply port (Port 1). Apply SAE-standard, DOT-approved sealing paste to either the rst few
threads or over the whole length. Pipes with pre-applied thread sealant may also be used.

13
Installation
WARNING
When mounting the ECU/dual modulator valve assembly to the trailer cross member, refer to SAE
specication J447, Prevention of Corrosion of Motor Vehicle Body and Chassis Components. Follow
all recommendations and procedures. Your supervisor should have a copy of this specication.
2. 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.
Drill two 3/8-inch mounting holes. The distance between 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
TEMPLATE
PLUG UNUSED PORT
Exhaust port must face DOWN.
3-13/16“
4014006a
3. Use two 3/8-inch Grade 8 bolts with prevailing torque nuts and washers to attach the assembly to the
vehicle cross member. Tighten the bolts to 20 lb-ft (27 Nm).
5.2 Connect the Air Lines
Plumb the spring brake relay or emergency relay valve into the system as usual.
1. For bracket mounts, connect the air supply line from the supply tank to ECU/single modulator valve
assembly supply Port 1.
Use 5/8-inch O.D. min. nylon tubing for frame mounts.

14
Installation
2. Connect the air delivery lines from the service chambers to the ECU/single modulator valve assembly
Port 2 (3/8-inch NPT).
Attach the opposite ends of the air delivery lines to the appropriate brake chambers (3/8-inch NPT).
SERVICE/CONTROL LINES
SERVICE BRAKE
SUPPLY AIR
SPRING BRAKE AIR
4014002a
POWER SUPPLY
ABS SENSOR D
ABS SENSOR C
3. Connect the brake service control line to the ECU/single modulator valve assembly Port 4 (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.
WABCO recommends placing sensors on the axle that will provide the most braking performance. The
suspension manufacturer can provide this information
1. Visually inspect the tooth wheel and sensor to ensure no damage occurred during shipping. Perform
any necessary repairs.
2. Connect the sensor and cables on the prepped axles to the sensor extension cables.
Ensure that each connection is secure.
SENSOR
EXTENSION
CABLE
SENSOR
AND CABLE
4003567b

15
Installation
3. 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. The sensor extension cable must follow the brake hose to the ECU/single
modulator valve assembly to allow for axle jounce and rebound.
4. Secure the 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 locking tab seats.
Connect the curbside sensor at C.
Connect the roadside sensor at D.
SENSOR
CABLE C
SENSOR
CABLE D
C
D
SENSOR
CABLE C
SENSOR
CABLE D
D
C
4013999s
1M STANDARD 1M PREMIUM
6. To provide proper strain relief to the sensor extension connections, use a tie wrap to secure the cable
to the built in strain relief connections points on the valve.
CABLE
RETAINER
TIE WRAPS
CABLE
RETAINER
4013999t
1M STANDARD 1M PREMIUM

16
Installation
7. Bundle any excess cable in a “Z”-shaped loop.
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).
Correct strain relief of cables is discussed in Appendix II.
5.4 Install the Power or Power/Diagnostic Cable
1. Identify the type of cable to be installed.
ABS trailer weather pack connector cable
Blunt-cut power cable
2. For industry-standard weather 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 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 exing of the trailer and sub-frame.
3. Bundle any excess cable in a loop (bow tie) and secure it in the sub-frame of the trailer body to
prevent cable damage.
4. Pull the yellow locking tab OUT to allow the power cable to be plugged in.
POWER CABLE
MATING
TRAILER
HARNESS
CONNECTOR END
4013986s
1M STANDARD 1M PREMIUM

17
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.
7. Be sure to secure the power cable with a tie wrap to the built-in strain relief connection on the valve. If
you are only installing the power cable go to Step 9.
8. If you are installing the the HUB Cable Power (1M Only) P/N 894 600 151 2:
A. Install the HUB Cable Power, p/n 894 600 151 2, by connecting it to the power connector. Be sure
to secure the connection by pushing in the yellow locking tab. Note if it will not push in, make sure
the cable is fully seated.
B. Connect the power cable to the Power HUB cable, and then connect the other end of the power
cable to the trailer main power supply.
C. Connect the diagnostic cable to the Power HUB cable, and route it to the side of the trailer.
Mount it using the built in bracket to the side of the trailer for easy diagnostic access.
D. Correctly secure the cable in the sub-frame to prevent cable damage.
Leave enough slack in the cable to compensate for exing 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 specication sheet for the exact
location of the indicator lamp. Use a DOT-approved lamp with ABS etched on the lens (available from
major trailer parts suppliers).
If you are using the industry-standard connector cable and do not have access to the mating trailer
harness, mask the open connector to protect it from paint or grease.
10. Connect the power. Use the industry-standard connector cable or a blunt-cut power cable.
For industry-standard connector cables: Attach the power cable’s round Weather Pack
connector to the ABS break-out connector on the trailer power harness.
For an optional blunt-cut power cable: Wire the cable and ABS indicator lamp to the seven-way
connector on the trailer according to the following diagram.
ECU POWER CONNECTOR
GROUND
WHITE
BLUE
RED
GREEN AND WHITE
TRAILER ABS
INDICATOR LAMP
(CONSTANT POWER)
(STOP LAMP)
(GROUND)
Junction box not shown. 4013987a
41
86
5
7
2
3
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.

18
Installation
4014005u
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/CONT ROL LINES
SENSOR CABLES
SERVICE BRAKE
SUPPLY AIR
SERVICE/CONT ROL LINES
SENSOR CABLES
SERVICE BRAKE
SUPPLY AIR
4014005x
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.

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/CONT ROL 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.

20
Installation
5.5 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™ 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 diagnostic adapters supported
by the TOOLBOX PLUS™ Software can be found in the Owners Manual OM1618.
Refer to the Software Owner’s Manual, OM1618, for instructions for running TOOLBOX PLUS™
Software.
2. Open the iABS Diagnostics from the TOOLBOX PLUS™ Main Screen by clicking on the Trailer ABS
selection.
4016948c