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Table of Contents
Summary of Contents for WABCO 421 351 0 Series
- Page 1 ELECTRO-PNEUMATIC SWITCHING SYSTEM 3 INSTALLATION MANUAL...
- Page 2 The German version of this document is the original document. Translation of the original document: All non-German language editions of this document are translations of the original document. Edition 1 (02.2019) You will find the current edition at: Document number: 815 010 254 3 (en) http://www.wabco.info/i/1186...
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Page 3: Table Of Contents
Removing the GP cylinder ........................15 Installing the GP cylinder ........................16 Supporting videos ............................17 Checking the Electro-Pneumatic Switching System 3 ................18 Learning procedure ............................18 Workshop notes ............................. 19 10.1 Spare parts ............................19 Disposal ................................19 WABCO regional offices ..........................20... -
Page 4: List Of Abbreviations
List of abbreviations 1 List of abbreviations ABBREVIATION MEANING GP cylinder (German: Getriebe-Planet-Zylinder); Planetary gear cylinder (German: Vorortelektronik); Local electronics... -
Page 5: Symbols Used In This Document
Reference to information on the internet Descriptive text – Action step 1. Action step 1 (in ascending order) 2. Action step 2 (in ascending order) Ö Consequence of an action Listing „ • Listing Note on the use of a tool / WABCO tool... -
Page 6: Safety Information
– Before performing any work on the gearbox, secure the vehicle against rolling away using wheel chocks. Proper working practice – Only use original WABCO replacement parts. – Perform the repair work using only the recommended tools and tightening torques. – Always undertake a test drive after completing the repair work. -
Page 7: Functional Description
Functional description 5 Functional description The Electro-Pneumatic Switching System 3 is a switching system for commercial vehicles. It can be used in Mercedes-Benz gearboxes with up to 16 gears. The system regulates gear changes depending on the driving situation, and is available for both claw and synchromesh gearboxes. The Electro-Pneumatic Switching System 3 comprises 3 components: NAME FIGURE... - Page 8 Needle bearing of the gear cylinder A needle bearing, type HK4020 (DIN 618-1/ ISO 3245), is installed in the gear cylinder. The bearing is fitted on several models of the WABCO gear cylinder and is available as a spare part from the vehicle manufacturer.
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Page 9: Installation/Removal
The vehicle cab must be tilted forwards in accordance with the vehicle manufacturer's instructions. 6.1 Identifying the device – Determine the device product number from its type plate. WABCO type plate LEGEND Vehicle manufacturer part number Production date WABCO part number Assembly number 6.2 Safety information... -
Page 10: Preparatory Activities
Installation/removal 6.3 Preparatory activities – Mark the position where the device is to be installed (piping with connecting port). – Designate cable connections. – Release the supply pressure from the system. – Only use suitable tools for removal and installation work. TOOLS AND EQUIPMENT Side cutter Interior Torx screw size T30... -
Page 11: Removing The Lane Cylinder
Installation/removal 6.4 Removing the lane cylinder CAUTION Risk of injury from supply pressure When removing the top section from the device, single parts can be ejected at high speed. – Do not remove the device until it has cooled down and is depressurised. The top section has to be removed before disconnecting the pneumatic connections when removing the lane cylinder. -
Page 12: Installing The Gate Cylinder
Installation/removal 6.5 Installing the gate cylinder Observe the stipulated torques. 1. Clean the mating surface of the gearbox and the split connections. Please contact the vehicle manufacturer regarding new ring seals. 2. Place the ring seals into the grooves in the exterior connections on the bottom section. Please contact the vehicle manufacturer regarding the sealing paste. -
Page 13: Removing The Gear Cylinder
Installation/removal 8. Make sure that the pneumatic connections are attached correctly and firmly and are not leaking. 9. Fix the cable harness onto the top section of the gate cylinder using cable ties and cable tie holders. 6.6 Removing the gear cylinder 1. -
Page 14: Installing The Gear Cylinder
Installation/removal 6.7 Installing the gear cylinder Observe the stipulated torques. 1. Clean the mating surface of the gearbox. 2. Apply the sealing paste to the mating surfaces of the device see "Fig. 4 Sealing paste to be applied on the gear cylinder". Fig. -
Page 15: Removing The Gp Cylinder
Installation/removal 6.8 Removing the GP cylinder 1. Disconnect the electrical connections from the device. 2. Loosen the union nuts on the pneumatic connection. 3. Pull the clips off the pneumatic connection (hose nipple). 4. Pull the union nuts off the hose nipple. Ö... -
Page 16: Installing The Gp Cylinder
Installation/removal 6.9 Installing the GP cylinder Observe the stipulated torques. Please contact the vehicle manufacturer regarding new ring seals. 1. Grease ring seal 1 and place it in the groove in the bottom section see "Fig. 6 Position of the ring seals". -
Page 17: Supporting Videos
7 Supporting videos Please note that individual work steps may differ. Under the following links, you can watch a WABCO video showing how to remove and install the gate, gear and PG cylinders, and how to teach them in: Gate cylinder http://www.wabco.info/i/948... -
Page 18: Checking The Electro-Pneumatic Switching System 3
Learning procedure 8 Checking the Electro-Pneumatic Switching System 3 – Restore the corrosion protection if necessary. – Check the tightness of the pneumatic connections. – Check the functionality of the entire complete system after replacing or repairing any parts. – Document test, e.g. in a test log. 9 Learning procedure 1. -
Page 19: Workshop Notes
Disposal 10 Workshop notes 10.1 Spare parts Spare parts can be found using the WABCO part number on the following page: http://inform.wabco-auto.com/ 11 Disposal The final and professional decommissioning and disposal of the product must be carried out in „... -
Page 20: Wabco Regional Offices
T: +33 1 60 26 62 06 Poland Italy T: +48 71 78 21 888 T: +39 011 4010 411 WABCO España S. L. U. WABCO Automotive AB WABCO Automotive U.K. Ltd Av de Castilla 33 Drakegatan 10, Box 188... - Page 21 WABCO regional offices WABCO Australia Pty Ltd WABCO do Brasil Indústria e WABCO Hong Kong Limited Comércio De Freios Ltda Unit 3, 8 Anzed Court 14/F Lee Fund Centre Rodovia Anhanguera, km 106 Mulgrave, Victoria 3170 31 Wong Chuk Hang Road CEP 13180-901...
- Page 22 Notes...
- Page 24 Westinghouse Air Brake vision for accident-free driving and Company founded nearly greener transportation solutions, 150 years ago, WABCO is WABCO is also at the forefront powerfully “Mobilizing Vehicle of advanced fleet management Intelligence” to support the systems and digital services...
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