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WABCO TP19039 Manual

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INSTALLING AND CONFIGURING THE
WABCO iABS WITH AUTOMATIC LIFT
AXLE CONTROL OPTION
KITS 400 612 039 0, 400 612 040 0, 400 612 041 0. MUST BE USED WITH THE WABCO
PREMIUM ECU/VALVE ASSEMBLIES: 400 500 350 0 (2S/1M), 400 500 450 0 (4S/2M)
TECHNICAL BULLETIN
TP19039

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Summary of Contents for WABCO TP19039

  • Page 1 WABCO iABS WITH AUTOMATIC LIFT AXLE CONTROL OPTION KITS 400 612 039 0, 400 612 040 0, 400 612 041 0. MUST BE USED WITH THE WABCO PREMIUM ECU/VALVE ASSEMBLIES: 400 500 350 0 (2S/1M), 400 500 450 0 (4S/2M)

  • Page 3: Table Of Contents

    TP19039 (en) 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.

  • Page 4: General Information

    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...
  • Page 5 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 the WABCO Customer Care Center at 855-228-3203, by email at wnacustomercare@wabco-auto.com, or visit our website: www.wabco-na.com.

  • Page 6: Safety Information

    For more information, go to www.P65Warnings.ca.gov. 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.

  • Page 7: Introduction

    Please refer to local governing ordinances. Note 400 612 039 0, 400 612 040 0 and 400 612 041 0 must be used with a WABCO iABS Premium ECU/Valve assembly 400 500 350 (2S/1M) or 400 500 430 0 (2S/2M - 4S/2M).

  • Page 8: Installation

    Introduction Each method has its own specifi c hardware requirement and installation. A. Automatic Lift Axle with Manual Override Switch (No spring brake delivery line pressure switch used). Kit number 400 612 040 0. This confi guration allows the lift axle to automatically raise and lower based upon values put into TOOLBOX PLUS™...
  • Page 9 Introduction WARNING Ensure the trailer has correct electrical grounding; refer to SAE Specifi cation J1908. WARNING When you work on an electrical system, the possibility of electrical shock exists, and sparks can ignite fl ammable substances. You must always disconnect the battery ground cable before you work on an electrical system to prevent serious personal injury and damage to components.
  • Page 10 Introduction Fig. 2 4017324a...
  • Page 11 Introduction Fig. 3 4017173a...
  • Page 12 Introduction 1. Wear safe eye protection. 2. Park the vehicle on a level surface. Block the wheels to prevent the vehicle from moving. The trailer must not be loaded during this component installation. 3. Drain the brake and suspension systems of air before starting this procedure. 4.
  • Page 13 This switch is not provided by WABCO. Ensure that the "on" and "off " positions are clearly labeled. To wire the switch, connect the green wire of the cable to one side of the toggle switch and the brown wire to the other side of the switch.

  • Page 14: Automatic Lift Axle Activation Procedure

    (The lift axle indicator light cable is not part of the kit. Please choose the appropriate length for your application. Refer to Appendix IV.) WABCO requires that an LED light or incandescent light of less than 1 amp is used. Ensure the LED light has a load resistor to prevent unwanted illumination of the light.
  • Page 15 Introduction Fig. 6 4017111a 2. From the top menu bar, go to the Modify pull-down menu and select "GIO Confi guration". Figure 7. Fig. 7 4015076a...
  • Page 16 Introduction 3. When the GIO Confi guration screen is displayed, select the check box "Automatic Lift Axle". A pop-up will appear asking if the optional lift axle indicator light will be used. Select Yes or No depending on the trailer application. Figure 8. Fig.
  • Page 17 Introduction Fig. 9 CABLE CONNECTIONS WITH INDICATOR LIGHT 4017328a Fig. 10 CABLE CONNECTIONS WITHOUT INDICATOR LIGHT 4017329a...
  • Page 18 Introduction 4. After reviewing the cable connections, select the Download button which will bring up the Lift Axle Lifting/Lowering Pressures screen. Figure 11. Fig. 11 4017330a 5. The Lift Axle Lifting/Lowering Pressures screen appears, allowing for the selection of the optional light being used if previously selected.
  • Page 19 Introduction The values must fall within the following restrictions:  Valid range: 5-100 psi  Lowering Pressure must be greater than Lifting Pressure  Lowering and Lifting pressures must diff er by at least 15 psi 6. The values are validated and programmed when the OK button is pressed. When a confi rmation message appears, press the OK button to continue.

  • Page 20: Lift Axle Operation Check

    Introduction 4.4 Lift Axle Operation Check The Lift Axle Operation Check is performed after the ABS system has been properly programmed and the Sensor Orientation Test has been successfully performed. The trailer must have constant power applied and have air supplied to the supply/emergency (red) line. Activate the manual override switch (if equipped) to confi...
  • Page 21 4.4.2 Using the Lift Axle Test Rig — Automatic Override Prior to beginning the test, the WABCO ABS with Lift Axle Control must be installed and have successfully completed the End of Line testing. Do not proceed without accomplishing this fi rst.
  • Page 22 4.4.3 Using the Lift Axle Test Rig — Manual Override Prior to beginning the test, the WABCO ABS with Lift Axle Control must be installed and have successfully completed the End of Line test. Do not proceed without accomplishing this fi rst.

  • Page 23: Installing Sensors On Non-Abs-Prepped Axles

    2. Push the spring clip into the sensor holder from the inboard side, until the spring clip tabs are against the sensor holder. Push the sensor into the spring clip as far as possible. Use WABCO spring clips to ensure a correct fi t.
  • Page 24 The sensor extension cable must follow the brake hose to the ECU/valve assembly to allow for axle jounce and rebound. Brake hose clips with a provision for the sensor extension cable are recommended as opposed to tie wraps. WABCO does not supply this part. Fig. 18 SENSOR CABLE 3"...

  • Page 25: Cable Strain Relief Guidelines

    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. Refer the Parts List in Appendix IV to fi nd the different cable lengths that WABCO offers.
  • Page 26 Appendix II Fig. 19 BRACKET MOUNTING - ECU REAR VIEW First fastener must be Bend radius (R) equal to a minimum 6 inches (152 mm) or greater than 10 times and a maximum of 12-inches cable diameter (D). (305 mm) from connector. FASTENER FASTENER ZIP TIE...
  • Page 27 Appendix II Fig. 20 TANK MOUNTING - ECU FRONT VIEW ZIP TIE ZIP TIE FASTENER FASTENER Max. Max. 12" 12" 4" 4" R ≥10 x D R ≥10 x D First fastener must be Bend radius (R) equal to a minimum 6 inches (152 mm) or greater than 10 times and a maximum of 12-inches cable diameter (D).

  • Page 28: Vehicle Electrical Grounding Guidelines

    If a common chassis ground point is present, but not suffi cient, ensure that there is no paint or debris inhib- iting electrical contact at the ground point. If a common chassis ground point is not present, WABCO recommends adding one.

  • Page 29: Parts And Variant List

    Appendix IV Additionally, all standard trailer components, 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 may be added to ensure adequate protection from unwanted electrical noise.
  • Page 30 Appendix IV AUTOMATIC LIFT AXLE KIT BOMs Part Number Description Quantity Notes Automatic Override (Kit 400 612 039 0) 463 084 050 0 Lift Axle Control Valve 449 408 040 0 Lift Axle Control Valve Cable Qty 1- If indication light is not used 894 600 120 2 GIO HUB Cable 1 or 2...
  • Page 31 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 449 306 047 0 4.7 M 449 733 008 0 0.8 M 449 733 013 0 1.3 M 449 733 018 0...
  • Page 32 Appendix IV PARTS LIST Slot on iABS Modulator Application Part Number Length 463 084 050 0 Lift Axle Control Valve 431 700 002 0 Pressure Switch...
  • Page 33 Notes Notes...
  • Page 34 ZF, which acquired WABCO Holdings Inc. on May 29, 2020, now has 162,000 employees worldwide with approximately 260 locations in 41 countries. In 2019, the two then-independent companies achieved sales of €36.5 billion (ZF) and $3.4 billion (WABCO). For more information, visit www.wabco-na.com.

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