TEBS E2 Electronic Braking System for Trailers
TEBS E2 Electronic Braking System for Trailers System Description Edition 4 This publication is not subject to any update service. You will find the latest version in INFORM www.wabco-auto.com © 2010 The right of amendment is reserved. Version 1/10.
TEBS E2 Abbreviations 24N Brake light supply 4S/3M 4 sensors / 3 modulators 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 German Ordinance Regulating Passenger Transport BVA (German: Bremsbelagveschleißanzeige); Brake pad wear indicator CAN Controller Area Network; asynchronous, serial bus system for networking control devices in vehicl
Table of Contents TEBS E2 1 Instructions and safety instructions 9 1.1 Symbols used 9 1.2 Avoiding electro-static charge and uncontrolled discharging (ESD) 9 1.3 Information and Disclaimer 10 1.4 Safety instructions 11 2 Introduction 2.1 2.1.1 2.1.2 2.1.3 System design Brake system Description of the trailer braking system with conventional air suspension Electronically controlled levelling system (ECAS) 3 Brake system 12 14 14 16 18 20 3.1 System version 20 3.
TEBS E2 Table of Contents 4 GIO Functions 4.1 Lift axle controller 49 4.2 Tag axle control with residual pressure maintenance 52 4.3 4.3.1 4.3.2 4.3.3 4.3.4 Electronically controlled air suspension (ECAS) Nominal level control Driving level Green warning lamp Deactivation of the automatic level control 53 56 57 59 60 4.4 Speed switches (ISS 1 and ISS 2) 61 4.5 RSS active signal 61 4.6 ABS active signal 62 4.7 Traction help 62 4.8 External axle load sensor 65 4.9 4.9.1 4.9.2 4.9.
Table of Contents 5.6 Telematics (TrailerGUARD) TEBS E2 101 6 Installation notes for vehicle construction and installation 102 6.1 General data on the TEBS E modulator 102 6.2 Connection designations 104 6.3 6.3.1 Install in vehicle RSS installation regulations 106 106 6.4 Cable mounting / Cable fastening 109 6.5 Pipes / Hoses 111 6.6 Installation Distance sensor 112 6.7 Installation components for immobilizer 113 6.8 Installing TailGUARD components 114 6.
TEBS E2 10.2 Pin assignment 166 10.3 Cable overview 171 10.4 Features of the GIO functions of TEBS E 178 10.5 GIO diagrams 181 10.
Instructions and safety instructions 1 Instructions and safety instructions 1.1 Symbols used TEBS E2 1 DANGER Imminent hazard situation which can cause serious personal injury or death if the safety instruction is not observed. 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.
1 TEBS E2 Instructions and safety instructions – Use electrically conductive bolted connections when fastening the ECUs to the vehicle frame. – Use only cable conforming to WABCO specifications or WABCO original cable. – 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.
Instructions and safety instructions 1.4 TEBS E2 1 Safety 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 manufacturer.
2 2 TEBS E2 Introduction Introduction This document is meant for the manufacturer of trailer vehicles and workshops. Since the Trailer EBS E is a very complex system, this system description is extensive. Here are a couple of notes on the structure of the document: Braking system Here, you find a description of the functions that are required to meet legal guidelines, such as the ABS, RSS and other functions of the braking control.
Introduction TEBS E2 2 Further information Technical documents, posters and forms can be obtained via the Internet at http://www.wabco-auto.com/ by entering an index work or the document number in the online product catalogue INFORM.
2 2.1 TEBS E2 Introduction System design This chapter provides you with a general overview of function and structure of the basic systems. 2.1.1 Brake system Components of the TEBS E brake system for the semitrailer (without PEM) • • Park-release emergency valve (PREV) • Cabling and pipework of the components.
Introduction TEBS E2 2 Drawbar trailer example This configuration is named the 4S/3M system for the typical drawbar trailer.
2 2.1.2 TEBS E2 Introduction Description of the trailer braking system with conventional air suspension With the introduction of the new Trailer EBS E braking system the tubing and cabling of the trailer braking and air suspension system has been simplified considerably.
Introduction TEBS E2 2 Trailer brake system The trailer vehicle is connected to the towing vehicle via two hose couplings for supply pressure (3) and control pressure (2). The parking release emergency valve (PREV, 20) is used to conduct the control pressure to the TEBS E (19). The PREV is equipped with a red button (13) for actuating the parking brake, as well as a further black actuating button (14) for releasing the brake which is automatically actuated when the trailer vehicle is unhitched.
2 2.1.3 TEBS E2 Introduction Electronically controlled levelling system (ECAS) An electronically controlled air suspension system (ECAS) is included in the TEBS E Premium variant. Components of electronically controlled air suspension (ECAS) • • • • Supporting Bellows • • • Integrated bellows pressure sensor for the lift axle control Distance sensor ECAS solenoid valve Operation, e.g.
Introduction TEBS E2 2 Electronically controlled air suspension system (2 distance sensors) Legend 1 TEBS E Modulator 2 Electronic expansion module (ELEX) 3 Battery box 446 156 090 0 4 ECAS solenoid valve 472 880 001 0 Optionally 472 905 111 0 (+ pulse-controlled lift axle) 5 External control unit, e.g. SmartBoard 6 Distance sensors 7 Cable "TEBS E battery supply" (GIO16) 449 808 ... 0 8 Distributor cable "Battery" (GIO10) 449 803 ... 0 9 Cable "SmartBoard" 449 906 ...
3 TEBS E2 3 Brake system 3.1 System version Brake system The brake system Trailer EBS E is an electronically controlled brake system with load-dependent brake pressure control, automatic antiblocking system (ABS) and electronic stability control (RSS).
Brake system 3.3 TEBS E2 3 Certification and standards Certificates Certificates On the Internet, call up Website http://www.wabco-auto.com. Click on Product Catalogue INFORM => Index. Enter Reports into the search field. Click the Start button. Certificate (Language) Subject EB 123.9E (en) ID EB 123.9E (en) ABS EB 124.5E (includes ID EB 124.5E) (de, en) EBS (contains chapter "Electromagnetic compatibility" as well) EB 167.
3 3.4 TEBS E2 Brake system ABS configuration ABS configurations Application Comment 2S/2M (TEBS E Standard-Modulator) 1x TEBS E Modulator 2x ABS rotationalspeed sensor 1 to 3 axle semitrailers / central axle trailers with air suspension and 1 to 3 axles, hydraulic or mechanical suspension Each control channel has one ABS rotational-speed sensor and one pressure control channel of the TEBS E.
Brake system TEBS E2 3 Multi-axle units Axles or wheels which have had no sensors fitted are indirectly controlled by directly controlled axles or wheels. Multi-axle units require an almost identical adhesion utilisation on these axles when braking. If not all wheels have sensors, those axles that have the greatest tendency to lock up are to be applied with ABS rotational-speed sensors.
3 TEBS E2 Brake system ABS configurations and allocation of sensors/modulators Modulator ABS rotational-speed sensors System axle Control type Trailer c-d Main axle (not lifting) IR/MSR Trailer e-f Additional axle (lifting) MSR ABS / EBS e-f Additional axle, steering axle or lift axle MAR Legend Driving direction Trailer modulator Double Check Valve (SHV) Sensed wheel (directly controlled) EBS relay valve ABS relay valve Select Low Valve (SLV) Non-sensed wheel (indirectly controlle
Brake system 3.5 TEBS E2 3 Component descriptions for electro-pneumatic brake system Components / Part number Application Purpose/Function Comment TEBS E Modulator 480 102 ... 0 (Part numbers see chapter 10.1 "Overview of variants/ Pneumatic connections for TEBS E", page 164) All trailer vehicles Control and monitoring of the electro-pneumatic brake system. Installation In the area of the axles to be controlled. For RSS, special installation regulations apply see chapter 6.
3 TEBS E2 Components / Part number Brake system Application Select-High-Valve Vehicles with 4S/2M+1M (Double check valve/Two-way system for actuating the separate ABS relay valve. valve) 434 208 055 0 ABS rotational-speed sensors 441 032 578 0 (0.4 m) 441 032 579 0 (1.
Brake system 3.6 TEBS E2 3 Components of the TEBS E Modulators The TEBS E Modulator is an electronic controller with four input channels for rotational-speed sensors and one CAN interface "Towing vehicle". The components of the modulator are: • • • • • • • • 3.
3 TEBS E2 Brake system response behaviour, the setpoint is specified by an additional, external braking setpoint pressure sensor in the control line. The pressure is modulated by pressure control loops with pulsed relay valves. In order to adapt the brake forces to various loading conditions, the axle loads on vehicles with air suspension and vehicles with hydraulic suspension are measured by sensing the bellows pressures.
Brake system TEBS E2 3 Connection of the multi-voltage modulator with the tractor. For the installation and utilisation in mixed operation, an extra 12 V coded connection socket must be installed in addition to the 24 V coded ISO 7638 connection socket: • 24 V connection socket with CAN signal (446 008 380 2 or 446 008 381 2) Use power cable 449 173 … 0 for connecting the 24 V connection socket for example.
3 TEBS E2 Brake system Warnings after switching on the ignition Based on ECE R13, two reactions are permitted when switching on the ignition and can be defined with the TEBS E Diagnostic Software see chapter 7.1 "Parameter definition with TEBS E Diagnostic Software", page 125 => Window TEBS ABS/RSS => Warning lamp function. Type 1 When the vehicle is at a standstill: The warning lamp in the towing vehicle illuminates after switching the ignition on.
Brake system 3.9 Brake functions 3.9.1 Setpoint detection TEBS E2 3 The braking request issued by the driver is referred to as the setpoint. If the trailer is towed by an EBS towing vehicle with a 7-pin (ABS) plug connection according to ISO 7638, the TEBS E gets the nominal value from the EBS vehicle via the trailer interface (CAN). If no nominal value is available from the trailer interface, e.g.
3 TEBS E2 Brake system Components 3.9.2 Components / Part number Connecting cable External setpoint value sensor 441 044 101 0 441 044 102 0 449 812 ... 0 Automatic load-dependent brake force control (LSV) 1-circuit Axle load calculation Application For all suspension types. Purpose Trailer EBS E includes a load-dependent brake pressure control, with which the brake pressure is adapted to the load status.
Brake system • • TEBS E2 3 Measuring the compression travel with a distance sensor for mechanically suspended vehicles Determining the axle load via slip detection in 4S/3M systems Safety function "Vehicle on buffer" If the bellows pressure is less than 0.15 bar or is 50 % of the defined empty bellows pressure, the LSV characteristic "Laden" is actuated, since the vehicle frame is probably on the buffer of the axle and therefore no reliable inference to the load status exists.
3 TEBS E2 Brake system In this example, the control pressure increases in the application range from 0 bar to 0.7 bar. With this control pressure, the brake pressure increases from 0 to 0.4 bar. At 0.7 bar, the response pressure in the wheel brake is reached and therefore the vehicle can start to build up braking force from that point on. This point, i.e.
Brake system 3 TEBS E2 For example: Hydraulic bellows pressure "unladen" = 50 bar Hydraulic bellows pressure "laden" = 125 bar The pressure input for the parameter TEBS LSV "laden" and "unladen" is sought after. Default: Search for hydraulic pressure sensor, which corresponds with the measuring range from 125 bar. Technical data for the implementation of a hydraulic pressure sensor: Pressure sensor "hydraulic": 0 to 250 bar => 0.5 to 4.
3 TEBS E2 Brake system Installation Information on installing see chapter 6.6 "Installation Distance sensor", page 112. Calibration Information on calibrating see chapter 7.4.1 "Calibration on vehicles with mechanical suspension", page 142. 3.9.3 Pressure control The pressure control circuits take the setpoint pressures specified by the LSV function and convert them into cylinder pressures.
Brake system TEBS E2 3 TEBS E modulator with overload protection valve (without PEM) TEBS E modulator with integrated overload protection in PEM 3.9.5 Anti-Lock Brake System (ABS) Application All trailer vehicles Purpose Prevents locking one or more wheels. Function The control logic determines from the wheel rotation speed whether one wheel or more wheels can be locked and decides whether to decrease, maintain, or increase the braking pressure on it.
3 TEBS E2 Brake system Drawbar trailer The sensed axles are neither to be a lift- or tag-axle with ABS rotational-speed sensors c-d or with ABS rotational-speed sensors e-f. The ABS rotational-speed sensors c-d are always to be put on the modulator side. In this case the modulator can either be installed at the front, on the drawbar or at the rear. The status of the lift axles is understood by the ABS control logic.
Brake system TEBS E2 3 RSS-control is started in the unbraked or partially braked driving condition. The RSS control is deactivated if the driver brakes heavily enough (deceleration above the level of RSS deceleration). If the driver defines a pneumatic or electrical braking setpoint for the trailer while an RSS control is taking place, and this is higher than the RSS control, the RSS control is interrupted and the respective setpoint is used for the braking procedure.
3 3.9.8 TEBS E2 Brake system Test mode Application Integrated function in TEBS E modulator. Purpose Check of the LSV characteristic curve in stationary vehicle. Function In this test mode, automatic load-dependent brake force control can be checked depending on the hose coupling pressure and the current axle load or the current bellows pressure. The standstill function and the emergency brake function are deactivated for test purposes.
Brake system TEBS E2 3 3.9.10 Emergency brake function Application Integrated function in TEBS E modulator. Purpose Applying the maximum possible brake force. Function If the braking wish of the driver (electrical or pneumatic) is greater than 90 % of the available supply pressure or > 6.4 bar, i.e. panic braking is evident, a steady increase of braking pressure is applied up to the characteristic curve of the laden vehicle and up to the possible intervention of ABS control.
3 TEBS E2 Brake system 3.10.2 Service signal The service signal is there to remind the driver that service work is due to be performed. In the condition as the TEBS E modulator is supplied, the service signal is not active. The function must be activated in the TEBS E Diagnostic Software see chapter 7.1 "Parameter definition with TEBS E Diagnostic Software", page 125 => Window TEBS-E Diagnostic Software => Extras => Service interval. When the vehicle has covered a defined distance (e.g.
Brake system TEBS E2 3 vated in the TEBS E Diagnostic Software with a special parameter definition CAN messages ISO 11992 see chapter 7.1 "Parameter definition with TEBS E Diagnostic Software", page 125 => Window TEBS E - ABS/RSS => EBS22 no output of total axle load or RGE22 no output for single axle loads. Fine calibration In order to attain higher precision of the axle load output, a calibration of the output can be performed with the SmartBoard.
3 TEBS E2 Brake system Loading, processing and saving a file – Open the notebook function (Tools => Notebook). – Press button Read from file. – If necessary, edit the content and save the change in the TEBS E with button Write to file. Loading and saving an external table – Open the notebook function (Tools => Notebook). – A CSV file (e.g. from Excel) can be saved, which must be located on the diagnostics PC or a connected USB stick. This is done by loading the file using the button Read from file.
Brake system TEBS E2 3 The following data is recorded per trip: • Kilometres at start of drive • Distance driven in kilometres • Operating hours at start of drive • Driving hours • Maximum speed • Average speed • Medium control pressure • Brake actuations • Braking frequency • Aggregate load at beginning of trip • ABS brake actions • RSS interventions, stage 1 • RSS interventions, stage 2 If a SmartBoard connected, the trips are provided with time and date information.
3 TEBS E2 • • Brake system Immobilizer events events definable by GIO parameter settings (e. g. if a connected door contact switch indicates the opening of a door) Components Components / Part number Description ODR tracker program 446 301 536 0 (de) 446 301 692 0 (en) SmartBoard 446 192 110 0 On USB stick for use with computers having Windows operating systems. Optional Expands the ODR data with time and date information. 46 Connecting cable 449 911 ...
GIO Functions 4 TEBS E2 4 GIO Functions This chapter describes functions that can be created using the GIO interfaces of the TEBS modulator and other components. Normally, a Premium modulator is required for these functions (see following table "Overview of GIO functions"). Introduction to GIO GIO means Generic Input/Output and designates programmable inputs and outputs. The Standard variant of the Trailer EBS E Modulator has 4 GIO slots, the Premium variant has 7 GIO slots.
4 TEBS E2 GIO Functions Overview of GIO functions Standard Premium Modulator Modulator Lift axle control with LACV Lift axle control with LACV-IC Tag axle control with residual pressure maintenance Electronic levelling control (ECAS 1 point control) Switching off from ECAS Green warning light Deactivating the automatic levelling control Speed switch (ISS1, ISS2) RSS active signal ABS active signal Traction help External axle load sensor OptiTurnTM (manoeuvring aid) OptiLoadTM (drawbar load reduction) For
GIO Functions 4.1 TEBS E2 4 Lift axle controller Application Trailer vehicle with one lift axle or multiple lift axles. Lift axle control in drawbar trailer With 3-axle drawbar trailer, it is possible to have axle 2 or 3 as a lift axle. If the TEBS Modulator is installed on the front axle of the vehicle, the rear axle, which remains on the ground must be monitored with an external pressure sensor.
4 TEBS E2 GIO Functions Lift axle control LA1 The following connections are possible: A spring-return lift axle control valve 464 084 0.. 0 or a pulse-controlled lift axle valve 463 084 100 0 or a pulsecontrolled ECAS solenoid valve block with lift axle control 472 905 114 0 Lift axle control LA2 You have the following connecting methods available for controlling the 2nd lift axle: A spring-return lift axle valve 463 084 0..
GIO Functions Components / Part number ECAS solenoid valve 472 905 114 0 Application Purpose/Function Semitrailer/drawbar 1-point control trailer (with lifting axle) Control of the vehicle level for one axle or multiple axles. TEBS E2 Description 4 Connecting cable 2 circuit, pulsecontrolled 449 445 ... 0 (2x) 2-circuit Cable "Valve" 449 445 ... 0 Raise/lower one or two parallel controlled lift axles. Electrical actuation and monitoring are effected by TEBS E.
4 TEBS E2 GIO Functions WABCO recommendation for the valve selection for lift axles Lifting axle Lifting axle valve valve spring returned spring returned 463 084 010 0 463 084 031 0 Lifting axle valve pulsecontrolled 463 084 100 0 ECAS solenoid valve pulsecontrolled 472 905 114 0 ECAS solenoid valve pulsecontrolled 472 905 111 0 Behaviour of the lift axle with the ignition switched off Lift axle remains in the desired and defined position (lifted or lowered). Lift axle lowers.
GIO Functions TEBS E2 4 The integrated function helps avoid tyre damage with a residual pressure maintenance in the support bellows, increased tyre wear and possible damage to the bellows. No further components are required for the residual pressure maintenance. Installation With tag axles, the wheel speed must be sensed and the braking controlled via a separate modulator. (WABCO recommendation: Brake the tag axle using an EBS relay valve (4S/3M).
4 Application TEBS E2 GIO Functions 1-point control 2-point control Semitrailers or central axle trailers with one distance sensor Drawbar trailer with two distance sensors (1x on front axle, 1x on rear axle) Semitrailer with independent wheel suspension, with two distance sensors (1x right vehicle side, 1x left vehicle side defective above the average axle combination) Utilisation with semitrailers or central axle trailers and rigid axles is not permitted.
GIO Functions Components / Part number Application Purpose/Function ECAS solenoid valve 472 880 001 0 Semitrailer/drawbar trailer (without lifting axle) 2-point control ECAS solenoid valve 472 905 114 0 Semitrailer/drawbar trailer (with lifting axle) 1-point control 4 TEBS E2 Comment 2-point control, only possible in combination with ELEX and Control of the vehicle level on one or multiple TEBS E2. axles on parallel circuits (lift/lower).
4 TEBS E2 Components / Part number ECAS control unit 446 056 117 0 GIO Functions Application Purpose/Function Semitrailer / Drawbar trailer Control unit (with 9 buttons), installed in the trailer. Comment Cable Cable "ECAS control unit" 449 628 ... 0 Influence of the level and the lift axle control by the driver. ECAS remote control unit 446 056 25.
GIO Functions TEBS E2 4 In other words, If the loading condition changes, the vehicle remains at the set level, whereas in vehicles with conventional air suspension this level must be adjusted manually or the vehicle body lowers when laden and raises when unladen. If the power supply is interrupted or if the air supply is insufficient, e.g. when the ignition is switched off, no further nominal level control occurs when the ignition is switched of.
4 TEBS E2 GIO Functions Driving level II Driving level II is defined as the difference to driving level I (normal level). If driving level II is lower than driving level I, this value must be entered as a negative in the TEBS E Diagnostic Software see chapter 7.1 "Parameter definition with TEBS E Diagnostic Software", page 125 => Window TEBS - GIO parameter 2 => Height control.
GIO Functions TEBS E2 4 If the parameterised unloading level is outside the parameterised lower or upper level, the stroke is restricted to this level. An unloading level is only realised between the upper and lower calibration level even when the parameter settings specify a value outside this range. The unloading level can be switched off at times with the SmartBoard, e.g. for operating before road finishers.
4 TEBS E2 GIO Functions Activating the function / selecting the warning light In menu item Extended ECAS parameter, the function can be activated and the parameters can be defined see chapter 7.1 "Parameter definition with TEBS E Diagnostic Software", page 125 => Window TEBS - GIO parameter 2. – Activate the function by clicking on Warning light installed. With an LED, click on parameter as LED (no cable break detection).
GIO Functions 4.4 TEBS E2 4 Speed switches (ISS 1 and ISS 2) Application All trailer vehicles Purpose By means of the two integrated speed switches ISS 1 and ISS 2 it is possible to control two functions in the trailer, independently of one another. Function The switching condition of the output changes if the vehicle drives faster than or slower than a speed limit set in the parameters. Consequently it is possible to switch on and off solenoid valves dependent on the speed.
4 TEBS E2 GIO Functions A signal is sent to the towing vehicle via the CAN data connection and the brake light is requested. Depending of the construction of the towing vehicle, the actuation of the brake lights is supported. In addition, the RSS active signal also makes it possible to actuate the brake lights when the RSS function is active by the TEBS E. For this purpose it is necessary to parameterize this output via the GIO function. Control may be realised via a relay.
GIO Functions • • TEBS E2 4 In countries where axle loads of 3 times 9 t are permitted, traction help is cancelled as soon as the load on the axles that remain in the ground exceeds 23.4 t. The effect of traction help is thus linked to the loading condition.
4 TEBS E2 GIO Functions Traction help The traction help function is supported for lift axles on the last axle for semitrailers or central axle trailers, i.e. the lift axle is raised or lowered upon request. Activation: 1-time actuation of the button (less than 5 seconds). Traction help "type Northern": A time-dependent control of the traction help is also possible (in 1 second steps, max. 1,200 seconds). For lift axle valve 463 084 3..
GIO Functions 4.8 TEBS E2 4 External axle load sensor An external axle load sensor may be used instead of the internal axle load sensor. For axle c-d Application Vehicles with hydraulic suspension for example because suspension pressures of up to 200 bar are required here (vehicles that cannot connected to the TEBS E modulator because of too high pressures). Purpose The external axle load sensor may be retrofitted on the main axle should the internal sensor fail.
4 TEBS E2 GIO Functions 4.9 Dynamic wheelbase control 4.9.1 Drawbar load reduction (OptiLoadTM) Application Semitrailers with 2 or 3 axles, rear axle as a tag axle or lifting axle. Purpose Avoid overloading fifth wheel and towing vehicle drive axle on semitrailers with loads that are unevenly distributed in the direction of the towing vehicle.
GIO Functions TEBS E2 4 The Manoeuvre assistance button or the Trailer Remote Control (only in combination with ELEX and TEBS E2) can be used to put the Automatic function into Forced lowering mode by pressing the button for > 5 seconds. The OptiLoadTM is reactivated after the ignition has been switched off and on again (Trip function).
4 TEBS E2 GIO Functions Parameter settings OptiTurnTM Information on parameter definition see chapter 7.1 "Parameter definition with TEBS E Diagnostic Software", page 125 => Window TEBS - GIO parameter 1. Activation condition selections When dropping below the speed (maximum 30 km/h): The function starts with a delay of 60 seconds under the defined speed. Observe the following: After each time the ignition is switched on, the vehicle must exceed the set speed at least one time to activate the function.
GIO Functions 4.9.3 TEBS E2 4 Recommended components OptiLoadTM/OptiTurnTM in combination with ECAS For an optimal and efficient utilisation of the functions (response time & optimal weight distribution), an electronically controlled air suspension system is recommended (raising & lowering + control of the Opti-function axle). GIO diagram 841 802 235 0 / 841 802 236 0 GIO diagrams see chapter 10.5 "GIO diagrams", page 181.
4 Components / Part number External bellows pressure sensor 441 044 ... 0 SmartBoard 446 192 11. 0 TEBS E2 GIO Functions Application Purpose/Function Comment On one of the support bellows of the axle to be monitored. Axle load measurement. Optional Measurement pressure at the yellow coupling head.
GIO Functions TEBS E2 4 Components / Part number Application Purpose/Function Lifting axle valve LACV-IC 463 084 100 0 All trailer vehicles with lift axle Utilisation of a lift axle for actuating the addi- Pulse-controlled tional axle in 3-axle semitrailers for dynamic wheelbase control. When using a second lift axle for the first axle: Utilisation for the immobilizer for actuating Up to TEBS E2: In combination the spring accumulator.
4 TEBS E2 GIO Functions 4.10 Forced lowering of the lift axle Application All trailer vehicles with lift axle Purpose Switch off automatic axle lift to lower the raised lift axles. Function The function can be activated with a button, a switch to ground or via the SmartBoard or the Trailer Remote Control. The lifting axle control is deactivated. Activation with switch The switch is closed: All axles are lowered. The switch is opened: The automatic lifting axle control is activated.
GIO Functions TEBS E2 4 4.11 Brake lining wear indication (BVA) Application All trailer vehicles with disc brakes Purpose Wear indicators, a wire integrated into the brake lining, monitor the wear of both linings of a disc brake. Function Wear indicators can be connected on up to 6 brakes on the ECU. All wear indicators are connected in series and are connected to the wear input. The supply voltage is 24 V. 1st warning level: At 95 % brake pad wear. A short-circuit occurs.
4 TEBS E2 GIO Functions 4.12 Voltage supply from Telematics to GIO5 Application All trailer vehicles Purpose Voltage supply from connected systems, e.g. Telematics to GIO5. Telematics The Telematics unit can be connected to the SUBSYSTEMS slot or on GIO5 (only with Premium). (WABCO recommendation: Connect Telematics to GIO5, so that the subsystems plug can be used e. g. for the SmartBoard or IVTM.
GIO Functions 4 TEBS E2 for example, connected electronic systems or solenoid valves. The stand-by time corresponds with the stand-by time of the ECU. Function Two 24 V outputs with a steady load of max. 1.5 A can be connected to the Trailer EBS E Modulator. The output is monitored only when the TEBS E is switched on. Optionally, monitoring can be deactivated if, for example, components are connected via a switch.
4 TEBS E2 GIO Functions Connection to GIO Mechanical switch I for road finishers Mechanical switch II for road finishers Switching option with proximity switch for road finishers Legend A Switch "Road finisher brake on/off" B Unloading level switch C Raise/lower dumper D Proximity switch Parameter Road finisher brake = Mechanical switch Unloading level switch = Proximity switch Parameters for switching off the unloading level can be defined in the TEBS E Diagnostic Software see chapter 7.
GIO Functions TEBS E2 4 This proximity switch can be used for functions "Unloading level" and "Road finisher brake". Every proximity switch has a different switching threshold concerning the distance away from the tipping body object to be detected. If both functions are to be active, two additional switch inputs are required so that both functions can be switched on and off separately.
4 TEBS E2 GIO Functions On semitrailers, the function can be selected in combination with parameter without load-dependent brake pressure (LSV) see chapter 7.1 "Parameter definition with TEBS E Diagnostic Software", page 125 => Window TEBS - GIO parameter 2. If the function is activated with a switch or the SmartBoard, the multi-axle combination brakes with full brake pressure (without LSV characteristic curve) so that the trailer can be extended by slowly driving the towing vehicle.
GIO Functions TEBS E2 4 The tension on the applied brakes is released with the actuation of the brake cylinder from the modulator. The brakes are released by side (for semitrailer/central axle trailer) or by axle (for drawbar trailer) for this purpose. Braking the vehicle is always at over 18% because the brake cylinders are released one after the other. Components Components / Part number Button Description Not part of WABCO's scope of supply Connecting cable Universal cable 449 535 ...
4 TEBS E2 GIO Functions At a standstill (v < 1.8 km/h), the steering axle is locked again. This is maintained by applying the reverse gear (with active reverse lights), to prevent jack-knifing while reversing. If the vehicle moves forward again, the lock is maintained up to a defined speed (> 1.8 km/h), then released and applied again upon exceeding a second defined speed. With an additional parameter, you can also lock the steering axle with the lift axle raised.
GIO Functions TEBS E2 4 Components Components / Part number Description Horn/Rotary beacon Not part of WABCO's scope of supply SmartBoard 446 192 11. 0 Optional Connecting cable 449 911 ... 0 Display for warnings Trailer Remote Control 446 122 080 0 Alternative to SmartBoard Only in combination with ELEX and TEBS E2 see chapter 5.1 "Electronic expansion module (ELEX)", page 89.
4 TEBS E2 GIO Functions Function prerequisites Mechanical switch (pushbutton) or proximity switch for detecting the forklift. The load on the trailer should be distributed evenly to prevent any additional influence of the support load. Parameter setting The Trailer EBS E uses a proximity switch or a mechanical switch to detect whether a forklift is docked on the vehicle and automatically switches between the two lift axle characteristic curves.
GIO Functions 4 TEBS E2 Components Components / Part number Description Button Connecting cable Not part of WABCO's scope of supply Activating / Deactivating the function SmartBoard 446 192 11. 0 Alternative to button 449 911 ... 0 Activating / Deactivating the function 4.22 Additional brake light (Emergency Brake Alert) Application All trailer vehicles Purpose If the vehicle is in a hazardous situation and must brake abruptly, a third brake light can be actuated.
4 TEBS E2 GIO Functions Setting the actuation method / flashing frequency – Under Emergency brake light output, select the actuation method Actuation permanent or Actuation periodic in the TEBS E Diagnostic Software see chapter 7.1 "Parameter definition with TEBS E Diagnostic Software", page 125 => Window TEBS - GIO parameter 3. – Set the flashing frequency if necessary (between 1 Hz and 10 Hz). (WABCO recommendation: 3 Hz). – If LEDs are installed as brake lights, activate the parameter LED installed.
GIO Functions TEBS E2 4 Status display As of TEBS E2, the driver is notified of the immobilizer status with the yellow warning lamp. If the immobilizer is inactive, the warning lamp flashes eight times after switching the ignition on. Logging the events For logging and evaluating the events, certain activities with the immobilizer are stored with an entry in the operating data recorder (ODR) see chapter 3.10.6 "Operating data recorder (ODR)", page 44.
4 TEBS E2 GIO Functions Components / Part number Description Trailer Remote Control 446 122 080 0 Alternative to SmartBoard Only in combination with ELEX and TEBS E2 see chapter 5.1 "Electronic expansion module (ELEX)", page 89. Connecting cable Connecting cable between Trailer Remote Control and fuse box in the HGV and a bracket are contained with the delivery. The operating capabilities are described under section "Operation".
GIO Functions TEBS E2 4 With this voucher code, you can apply for the PUK: http://www.wabco-auto.com/ => Products => Brake & Stability Control => Electronic Braking System (EBS) => Trailer Immobilizer. Task of the PUK • Releasing the immobilizer function in the TEBS E modulator. • Defining / changing the user PIN • Definition of a new PIN after incorrect entry. The PUK is reserved only for the vehicle owner. Handle the PUK with care and protect it from access to third-parties.
4 TEBS E2 GIO Functions Operational capabilities with the SmartBoard / Trailer Remote Control Information on operation see chapter 8.6 "Operating the immobilizers", page 154.
