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TP-20212 Revised 08-18 Installation Guide Enhanced Easy-Stop™ Trailer ABS 2S/1M

TP-20212 Revised 08-18 Installation Guide Enhanced Easy-Stop™ Trailer ABS 2S/1M Basic with PLC Installation Instructions TP-20212 Revised 08-18 1 Technical Bulletin Hazard Alert Messages Read and observe all Warning and Caution hazard alert messages in this publication. They provide information that can help prevent serious personal injury, damage to components, or both. How to Obtain Additional Maintenance, Service and Product Information Refer to Maintenance Manual MM-0180, Enhanced Easy-Stop™ Trailer ABS with PLC; Maintenance Manual 33, Easy-Stop™ Trailer ABS; and Parts Book PB-96133, Enhanced Easy-Stop™ with PLC and Easy-Stop™ Trailer ABS. To obtain these publications, or for more information about the WABCO product line, contact WABCO North America Customer Care at 855-228-3203 or visit our website: wabco-na.com Important Information This bulletin contains instructions for mounting the ECU/single modulator valve assembly as one unit. If you are mounting the ECU and valve separately, please contact WABCO North America Customer Care at 855-228-3203 for specific installation requirements and instructions. 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. Preparation WARNING To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. 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 flammable substances. You must always disconnect the battery ground cable before working on the electrical system. 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 and fall over. Serious personal injury and damage to components can result. End of line testing must be done after all installations. WABCO recommends using TOOLBOX™ Software to perform this testing. If you do not have TOOLBOX™ Software, this bulletin also includes instructions for testing without the software. 1. Before beginning the installation procedure, inspect the ECU/ single modulator valve assembly for damage that may have occurred during shipping or storage. Look for crushed or bent connectors. Verify that the retainer clips have not been bent or otherwise damaged. Attach the ABS relay valve cable to the ECU with the WABCO ID face down. Ensure the cable is free from cuts or breaks. Do not install a damaged ECU/single modulator valve assembly. Notify your supervisor, or contact WABCO if there is any apparent damage. 2. Have the following installation material available. * ECU/single modulator valve assembly * Power cable or power/diagnostic cable * Sensor extension cables (two pieces) * Sensors (two) for non-ABS-prepped axles TP-20212 Revised 08-18 (16579) Page 2 Copyright WABCO, Inc., 2018 Printed in USA * ABS Indicator Label (TP-95172) 5/8-inch O.D. nylon tubing for supply (frame mounts) Pipe plug (3/4-inch NPTF) Schedule 80 hex pipe nipple (3/4-inch NPTF) for air tank mounts or two Grade 8 bolts (3/8-inch) and prevailing torque nuts for frame mounts SAE-standard, DOT-approved thread sealant To ensure correct lamp operation, use an incandescent-type DOT-approved lamp, or an LED with integral load resistor. * WABCO components 3. Study the ECU/single modulator valve assembly. Note the location of the various ports and electrical connections on the ECU. Figure 1. Figure 1 Figure 1 POWER CABLE POWER DIAGNOSTIC CABLE *Power cable available with blunt cut or with industry standard connector (shown). YE 2/6 YE 1/4 BU 2/5 BU 1/3 PBT -GF 30 MOD RD 7 14/15 POWER/DIAGN YE 2/6 YE 2/6 YE 1/4 MODULATOR VALVE CABLE CONNECTOR REAR OF ECU SENSOR CONNECTORS POWER CABLE CONNECTOR EXHAUST PORT (ON UNDERSIDE CENTER) PORT 4 CONTROL PORT PORT 1 (FRONT OR REAR) SUPPLY PORT PROTECTIVE CAPS FOR SENSORS FOUR DELIVERY PORTS (ON UNDERSIDE) 4005515b TP-20212 (16579) Revised 08-18 Printed in USA Copyright WABCO, Inc., 2018 Page 3 Installation I. Install the ECU/single modulator valve assembly. The assembly may be mounted on the air tank or on the cross member of the vehicle. Tank-Mounted WARNING You must use a Schedule 80 hex nipple (3/4-inch NPTF) to mount the ECU/single 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 NPTF Schedule 80 hex nipple to attach the ECU/single modulator valve assembly to a reinforced air tank. Do not overtighten. 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/single modulator valve assembly. 2. Use a 3/4-inch NPTF pipe plug to plug the unused supply port (Port 1). Apply SAE-standard, DOT-approved Teflon tape or paste-type thread sealant to all pipe threads beyond the first two threads. Pipes with pre-applied thread sealant may also be used. 3. Rotate and tighten the ECU/single modulator 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 (Port 1). Figure 2. Figure 2 Bracket-Mounted to Cross Member of Vehicle 1. Install a 3/4-inch NPTF fitting in the supply port (Port 1). Use a 3/4-inch NPTF pipe plug to plug the unused supply port (Port 1). Apply SAE-standard, DOT-approved Teflon tape or paste-type thread sealant to all pipe threads beyond the first two threads. Pipes with pre-applied thread sealant may also be used. 2. Mark the location of two mounting holes on the vehicle cross member. Mounting holes must be 4-3/4 inches apart. Figure 3. Figure 3 3. Drill two 3/8-inch holes into the center of the vehicle cross member. CAUTION Place a thin barrier of plastic, mylar or similar material between the bracket and mounting surface. The barrier is necessary to inhibit corrosion, which can occur from contact between dissimilar metals. Galvanic corrosion can result in damage to the ECU/modulator assembly. 4. Place a thin barrier made of plastic, mylar or similar material between the bracket and mounting surface to inhibit the possibility of corrosion. 5. Attach the mounting bracket to the vehicle cross member midway between the side rails, close to the brake chambers the valve serves. 6. 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 18 lb-ft (24 Nm). @ Figure 2 PLUG UNUSED PORT SCHEDULE 80 HEX NIPPLE Rear of assembly faces air tank. Exhaust port must face DOWN. AIR TANK 4005516a Figure 3 4005517a TEMPLATE PLUG UNUSED PORT Exhaust port must face DOWN. 4-3/4“ TP-20212 Revised 08-18 (16579) Page 4 Copyright WABCO, Inc., 2018 Printed in USA II. 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. 2. Connect the air delivery lines from the service chambers to the ECU/single modulator valve assembly Port 2 (3/8-inch NPTF). Figure 4. Attach the opposite ends of the air delivery lines to the appropriate brake chambers (3/8-inch NPTF). Figure 4 3. Connect the brake service control line to the ECU/single modulator valve assembly Port 4 (3/8-inch NPTF). Figure 4. 4. Plug any unused delivery ports. Apply SAE-standard, DOT-approved Teflon tape or paste-type thread sealant to all pipe threads beyond the first two threads. Pipes with pre-applied thread sealant may also be used. III. 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. Figure 5. Ensure that each connection is secure. Figure 5 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. Figure 5. 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 eight inches (203 mm) with tie wraps or cable clips. 5. Push the sensor retainer clip on the ECU/single modulator valve assembly UP. 6. Remove the protective caps from the YE2 and YE1 sensor connectors. Figure 6. Figure 6 Figure 4 uploads/Geographie/ wabco-guide.pdf