WABCO TEBS E Bedienungsanleitung

TEBS E

VERSIONS E0 TO E4

SYSTEM DESCRIPTION

TEBS E

Electronic braking systems

for trailers

(versions TEBS E0 to E4)

System Description

Edition 7

This publication is not subject to any update service.

You will find the current version at

http://www.wabco.info/8150100933

The right of amendment is reserved.

Version 2/01.2014(en)

815 010 093 3

TEBS E

Abbreviations

ABS Anti-Lock Braking System

ADR (French: Accord européen relatif au transport international des marchandises Dangereuses par

Route); European agreement concerning the carriage of dangerous goods by road

BO Factory regulations; BO force circuit = legally defined turning circuit

BVA (German: Bremsbelagverschleißanzeige); Brake lining wear indicator

ELEX Electronic Extension Module

ESD Electrostatic Discharge

eTASC Electronic Trailer Air Suspension Control (Rotary slid valve with RTR function) and ECAS function

GGVS Act governing the road haulage of hazardous goods

GIO Generic Input/Output; programmable input/output

IR (German: Individual-Regelung); Individual control; individual control of sensed wheels on one side

ISS Integrated Speed Switch

LACV-IC Lifting Axle Control Valve, impulse controlled

LIN Local Interconnect Network; specification for a serial communication system, also LIN bus, interface

for the sensors

LSV Load Sensing Valve

MAR (German: Modifizierte Achs-Regelung); Modified axle control; Control of two sensed wheels on one

axle

MSR (German: Modifizierte Seiten-Regelung); Modified side control; Control of two sensed wheels on one

vehicle side

ODR Operating Data Recorder

PEM Pneumatic Extension Module

PLC Power Line Communication; Data communication via cable for power supply

PREV Park Release Emergency Valve

PWM Pulse Width Modulation; modulation type where a technical quantity (e.g. electric current) modulates

between two values

RSS Roll Stability Support; control for vehicle stability

RTR Return To Ride (air suspension)

SHV Select High Valve; Valve for providing the higher pressure

SLV Select Low Valve; Valve for providing the lower pressure

StVZO (German: Straßenverkehrs-Zulassungs-Ordnung); German motor vehicle construction and use regu-

lations; (valid in Germany)

TASC Trailer Air Suspension Control (Rotary slid valve with RTR function)

TEBS Electronic Braking System for trailers

TLI Trailer Length Indication; ‘Current vehicle length’

TT Timer Ticks; internal measurement unit of the height sensors

USB Universal Serial Bus

Table of Contents

TEBS E

1Disclaimer ............................................................................................................................... 8

2Symbols used ......................................................................................................................... 9

3Safety information................................................................................................................ 10

4Introduction........................................................................................................................... 12

4.1 System design............................................................................................................ 14

4.1.1 braking system ........................................................................................................... 14

4.1.2 Braking system with conventional air suspension...................................................... 15

4.1.3 Electronically controlled air suspension system (ECAS) ........................................... 17

4.2 Overview of functions................................................................................................. 19

5braking system ..................................................................................................................... 22

5.1 System design............................................................................................................ 22

5.2 Scope of application................................................................................................... 22

5.3 Expertise and standards ............................................................................................ 23

5.4 ABS configurations..................................................................................................... 24

5.5 Description of the components of the electropneumatic braking system................... 29

5.6 Components of the TEBS E Modulator...................................................................... 31

5.7 Supply ........................................................................................................................ 32

5.7.1 Function test when switching on or coupling ............................................................. 32

5.7.2 Power supply via stop light (24N)............................................................................... 32

5.7.3 Multi-Voltage .............................................................................................................. 33

5.8 System monitoring...................................................................................................... 35

5.8.1 Warnings and system messages ............................................................................... 35

5.8.2 Pneumatic redundancy .............................................................................................. 37

5.9 Brake functions........................................................................................................... 38

5.9.1 Nominal value detection............................................................................................. 38

5.9.2 Load Sensing Valve (LSV) ......................................................................................... 40

5.9.3 Pressure control ......................................................................................................... 44

5.9.4 Overload protection....................................................................................................45

5.9.5 Anti-Lock Braking System (ABS) ............................................................................... 46

5.9.6 Roll Stability Support (RSS) ....................................................................................... 47

5.9.7 Standstill function ....................................................................................................... 48

5.9.8 Emergency braking function....................................................................................... 49

5.9.9 Test mode .................................................................................................................. 49

5.10 ECU-internal functions ............................................................................................... 50

5.10.1 Odometer ................................................................................................................... 50

5.10.2 Service signal ............................................................................................................. 51

5.10.3 ServiceMind................................................................................................................ 51

5.10.4 Axle load output.......................................................................................................... 52

5.10.5 Notebook function ...................................................................................................... 54

5.10.6 Operating data record (ODR)..................................................................................... 54

6GIO functions........................................................................................................................ 58

6.1 Lifting axle control ...................................................................................................... 59

6.2 Tag axle control with residual pressure maintenance................................................ 63

6.3 Integrated electronically controlled air suspension system (ECAS) .......................... 64

6.3.1 Nominal level control.................................................................................................. 69

6.3.2 Normal level ............................................................................................................... 70

TEBS E Table of Contents

6.3.3 Green warning lamp ...................................................................................................72

6.3.4 Temporary deactivation of automatic level control.....................................................73

6.4 Speed switch (ISS 1 and ISS 2) and RTR .................................................................75

6.5 RSS active signal (TEBS E2 or higher)......................................................................77

6.6 ABS active signal (TEBS E2 or higher)......................................................................77

6.7 Traction help...............................................................................................................78

6.8 External axle load sensor ...........................................................................................81

6.9 Dynamic wheelbase control .......................................................................................82

6.9.1 Manoeuvering assistance (OptiTurnTM)......................................................................82

6.9.2 Drawbar load reduction (OptiLoadTM).........................................................................84

6.9.3 Connecting the components.......................................................................................85

6.10 Forced lowering and deactivation of the lifting axle function......................................89

6.11 Brake lining wear indicator .........................................................................................91

6.12 Power supply and data communication on GIO5.......................................................93

6.13 Speed signal...............................................................................................................94

6.14 Steady positive voltage 1 and 2 .................................................................................95

6.15 Road finisher brake ....................................................................................................96

6.15.1 Proximity switch..........................................................................................................99

6.16 Trailer Extending Control..........................................................................................101

6.17 Current vehicle length (Trailer Length Indication) (as of version TEBS E4) ............103

6.18 Tilt warning (Tilt Alert) ..............................................................................................105

6.19 Overload detection ...................................................................................................107

6.20 SafeStart...................................................................................................................108

6.21 Electronic parking brake (with version TEBS E4 or higher) .....................................110

6.22 Relaxation function (Bounce Control).......................................................................112

6.23 Steering axle lock .....................................................................................................113

6.24 Forklift control ...........................................................................................................115

6.25 Brake release function..............................................................................................117

6.26 Emergency stop light (Emergency Brake Alert) .......................................................118

6.27 Immobilizer ...............................................................................................................120

6.28 Freely configurable functions ...................................................................................125

7External systems ................................................................................................................126

7.1 Electronic expansion module (ELEX).......................................................................126

7.1.1 TailGUARD functions ...............................................................................................127

7.1.2 Connection from ISO 12098.....................................................................................133

7.1.3 Battery supply and battery charging.........................................................................134

7.2 Trailer Remote Control .............................................................................................136

7.3 External ECAS..........................................................................................................137

7.4 Trailer Central Electronic..........................................................................................138

7.5 Tire pressure monitoring system (IVTM)..................................................................139

7.6 Telematics (TrailerGUARD) .....................................................................................141

8Installation notes for vehicle installation and retrofitting ..............................................142

8.1 Data on the TEBS E Modulator................................................................................142

8.2 Connections..............................................................................................................144

8.3 Installation in vehicle ................................................................................................145

8.3.1 RSS installation regulation .......................................................................................146

Table of Contents

TEBS E

8.4 Cable installation / Cable fastening.......................................................................... 148

8.5 Installation height sensor ......................................................................................... 150

8.6 Installation of Immobilizer components.................................................................... 152

8.7 Installation of Trailer Remote Control....................................................................... 152

8.8 Installation of TailGUARD components ................................................................... 153

8.9 Installation of eTASC ............................................................................................... 164

9Start-up................................................................................................................................ 165

9.1 Parameter definition with TEBS E Diagnostic Software .......................................... 165

9.2 Functional test .......................................................................................................... 166

9.3 Start-up of the LIN ultrasonic sensors...................................................................... 167

9.4 Calibrate the height sensors .................................................................................... 169

9.4.1 Calibration for vehicles with mechanical suspension............................................... 170

9.5 Documentation ......................................................................................................... 171

10 Operation............................................................................................................................. 172

10.1 Warning messages .................................................................................................. 172

10.2 Operation with Trailer Remote Control..................................................................... 172

10.3 Operation of ECAS level control .............................................................................. 180

10.4 Operation of traction help.........................................................................................182

10.5 Operation OptiLoad / OptiTurn................................................................................. 182

10.6 Lifting axles operation .............................................................................................. 183

10.7 Operating the Immobilizer ........................................................................................ 183

11 Workshop notes .................................................................................................................184

11.1 Maintenance............................................................................................................. 184

11.2 System training and PIN .......................................................................................... 184

11.3 Diagnostic Hardware................................................................................................ 185

11.4 Tests / Simulations................................................................................................... 186

11.5 Replacement and repair........................................................................................... 188

11.6 Tuning the vehicle .................................................................................................... 190

11.7 Disposal / Recycling................................................................................................. 192

12 Appendix ............................................................................................................................. 193

12.1 Pneumatic ports for TEBS E .................................................................................... 193

12.2 Pin assignment TEBS E Modulators and ELEX....................................................... 195

12.3 Cable overview......................................................................................................... 201

12.4 GIO diagram............................................................................................................. 210

12.5 Brake diagram .......................................................................................................... 212

Index.......................................................................................................................................... 217

1 TEBS E

Disclaimer

1 Disclaimer

We assume no liability for the correctness, completeness or actuality of the infor-

mation in this document. All technical information, descriptions and images are ap-

plicable for the day of printing this document or respective supplements. We retain

the right to any changes as a result of continuous further development.

The content of this document provides no guarantees nor warranted characteristics

nor can it be construed as such. Liability for damages is strictly excluded, as long

as there has been no respective intention or gross negligence on our part or any

forced legal provisions in opposition.

Text and graphics are subjected to our utilisation rights, copying or distribution in

any form require our approval.

Any brand markings, even if not indicated as such, are subject to the rules of the

labelling rights. If legal disputes arise from the utilisation of the information in this

document, these are exclusively to be handled under the regulations of national

law.

In so far as components or individual formulations of this applicable legal status

documentation are no longer or not fully relevant, the remaining parts of the docu-

mentation remain unaffected thereby in their content and validity.

TEBS E 2

Symbols used

2 Symbols used

WARNING

Potential hazard situation which can cause death or serious personal injury if the

safety instruction is not observed.

CAUTION

Potential hazard situations that can cause minor or moderate personal injury if the

safety instruction is not observed.

Important instructions, information, or tips that you should always observe.

Reference to information on the Internet

• List

– Step

Consequence of an action

TEBS E version The system comprises:

• TEBS E as of version 0 (July 2007)

• TEBS E as of version 1 (September 2008)

• TEBS E as of version 1.5 (December 2009)

• TEBS E as of version 2 (November 2010)

• ELEX as of version 0 (November 2010)

• TRC as of version 0 (November 2010)

• TEBS E as of version 2.5 (January 2012)

• ELEX as of version 1 (January 2012)

• TRC as of version 1 (January 2012)

• TEBS E as of version 4 (January 2014)

• ELEX as of version 2 (January 2014)

3 TEBS E

Safety information

3 Safety information

Observe all required regulations and instructions:

– Read this publication thoroughly.

Adhere to all instructions, information and safety information to prevent injury to

persons and damage to property.

WABCO will only guarantee the security, reliability and performance of their

products and systems if all information in this publication is adhered to.

– Make sure to follow the specifications and instructions of the vehicle manufac-

turer.

– Maintain all accident regulations of the business as well as regional and na-

tional regulations.

Make provisions for a safe work environment:

Only trained and qualified technicians are to perform any work on the vehicle.

– Use personal protective equipment if required (protective goggles, respiratory

protection, ear protectors, etc.).

Pedal actuations can lead to severe injuries if persons are in the vicinity of the ve-

hicle. Make sure that pedals cannot be actuated as follows:

– Switch the transmission to ‘neutral’ and actuate the park brake.

– Secure the vehicle against rolling with chocks.

– Fasten a visible note to the steering wheel indicating the work is being per-

formed on the vehicle and that the pedals are not to be actuated.

Avoid electrostatic charge and uncontrolled discharging (ESD):

Note during construction and building the vehicle:

– Prevent potential differences between components (e. g. axles) and the vehicle

frame (Chassis).

Make sure that the resistance between metallic parts of the components to the

vehicle frame is lower than 10 Ohm.

Connect moving or insulated vehicle parts such as axles electrically conductive

with the frame.

– Prevent potential differences between the towing vehicle and the trailer.

Make sure that an electrically conductive connection is made between metal

parts in the towing vehicle and the coupled trailer via the coupling (king pin, fifth

wheel, claws with pins), even without a cable being connected.

– Use electrically conductive bolted connections when fastening the ECUs to the

vehicle frame.

– Run the cable in metallic casing if at all possible (e. g. inside the U-beam) or

behind metallic and grounded protective plating, to minimise the influence of

electro-magnetic fields.

– Avoid the use of plastic materials if they can cause electrostatic charging.

– For electrostatic painting, connect the ground line of the ISO 7638 plug connec-

tion (pin 4) to the paint ground (vehicle chassis).

Note during repair and welding work on the vehicle:

– Disconnect the battery - if installed in the vehicle.

– Disconnect cable connections to devices and components and protect the plug-

ins and connections from contamination and humidity.

– Always connect the grounding electrode directly with the metal next to the weld-

ing position when welding, to prevent magnetic fields and current flow via the

cable or components.

– Make sure that current is well conducted by removing paint or rust.

– Prevent heat influences on devices and cabling when welding.

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