WABCO TP2205 Installation Manual Download Page 1

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TRAILERCAST WITH

BATTERY

TP2205

INSTALLATION GUIDE

Summary of Contents for TP2205

Page 1: ...TRAILERCAST WITH BATTERY TP2205 INSTALLATION GUIDE ...

Page 2: ......

Page 3: ...ions 15 6 2 Preferred Installation Standard Trailer with Fixed Trailer Bed 15 6 3 Alternative Installation in Case of Trailer without Fixed Trailer Bed 16 6 4 Preferred Installation for TRAILERCAST with Battery Between Axle 2 and 3 Connector Upwards and to Back of the Trailer 17 6 5 Alternative Installation for TRAILERCAST with Battery Between Axle 1 and 2 Connector Upwards and to the Front of the...

Page 4: ...ime You will find the current edition at https zf com cvliterature 12 Connecting to the Internal Sensors 29 12 2 Connecting to the Internal Sensors SMS 29 12 3 WABCO TPMS Manager 30 12 4 WABCO TPMS Manager Software Update 31 13 Assembly of the Internal Sensor SMS 33 13 1 Safety Information 33 13 2 Preparing the Installation 34 13 3 Installation of the Internal Sensor 34 13 4 Assembly of the Tire 3...

Page 5: ...ury or death if the warning is ignored CAUTION Description of a possible situation which may result in irreversible injury if the warning is ignored NOTICE Description of a possible situation which may result in material damage if the warning is ignored Important information notices and or tips Reference to information on the Internet Descriptive text Action step Action step 1 in ascending order A...

Page 6: ...tration NHTSA website to find all current documents referenced in the manual at www nhtsa gov 1 3 How to Obtain Parts and Kits Contact the WABCO Customer Care Center at 855 228 3203 United States and Canada 800 953 0248 Mexico Email supportwabconacustomercare zf com supportwabconaorders zf com or supportwabconaspecs zf com 1 4 WABCO TOOLBOX PLUS Software TOOLBOX PLUS Software provides PC diagnosti...

Page 7: ...eneral Information 1 7 Your Direct Contact to ZF CVS ZF CV Systems North America LLC 1220 Pacific Drive Auburn Hills MI 48326 Customer Care Center 855 228 3203 https www zf com products en cv home cv html ...

Page 8: ...tory protection and ear protectors Read and observe all Danger Warning and Caution hazard alert messages in this publication They provide information that can help prevent serious personal injury damage to components or both WARNING To help prevent serious eye injury always wear eye protection when you perform vehicle maintenance or service WARNING Park the vehicle on a level surface Block the whe...

Page 9: ...9 Important Information 3 Important Information Use only genuine WABCO components Other manufacturers parts are not designed for use with a WABCO TRAILERCAST system and it may not function correctly ...

Page 10: ...erwards the trainees will be qualified to autonomously assemble the other devices in the trailers The illustrations and specific data of non WABCO products have been checked thoroughly and have been found correct at the time this manual was composed However ZF cannot accept any responsibility for possible adaptations by the manufacturer concerned ZF aims for a continuous improvement of its product...

Page 11: ...d when carrying out such activities 4 3 2 Wire Management All the wire ways shall be smooth and free from sharp edges Wires shall be protected so they do not come in contact with burrs cooling fins moving parts etc which could cause damage to the insulation of the conductors 4 3 3 Operating Conditions Input voltage range 10 32 V Maximum current 1 5 A Operating temperature range Externally powered ...

Page 12: ...r Use NOTICE USE THE DEVICE ONLY FOR ITS INTENDED PURPOSE DO NOT OPEN THE TRAILERCAST WITH BATTERY UNIT DO NOT DRILL INTO THE DEVICE HOUSING In case of damage of any kind which could aﬀect the ingress protection waterproofness of the device the device must be immediately taken out of service The device safety may be endangered when The device is not firmly fastened to the trailer The device has su...

Page 13: ...ction 7 Fastening TRAILERCAST with Battery page 20 Installation Bracket In case the installation includes a TPMS system with internal sensors an installation bracket must be used to fix the TRAILERCAST with Battery If no TPMS system is used the installation brackets are not required Bracket Dimensions 251 8 x 205 x 4 mm Hardware Description Front view 4019844c iABS RSSplus PORT FIXING POINTS Back ...

Page 14: ...14 Introduction Hardware Components Side view 4019847a Pin Assignment Device serial number TPXX XXXXXXXXXXXXXXX All WABCO component part number information can be found in Appendix II ...

Page 15: ...t all times for the correct installation and connection of the hardware unit Always verify that sufficient GPS coverage is guaranteed during installation and a good GPS position has been received via https install us wabco fleet com search device trailercast Check this for every installation 6 2 Preferred Installation Standard Trailer with Fixed Trailer Bed In case the installation includes a Tire...

Page 16: ...CAST with Battery Find a suitable location and make sure that the front of the unit has a clear view as much as possible min 150 cm Keep the sides of the unit at a minimum distance of 20 cm from obstacles also keep a minimum distance of 20 cm above the unit Always verify that suﬃcient GPS coverage is guaranteed and a good GPS position has been received using https install us wabco fleet com search...

Page 17: ...ix the TRAILERCAST with Battery Install the unit between axle 2 and 3 with the connector facing towards back of the trailer Make sure that the unit is placed with the connector on the upper side Install the unit at around 70 cm from the ground Install the unit centered between the wheels in the middle of the axle Install the unit at a max distance of 2 3 m from the center of any of the wheels If p...

Page 18: ...o fix the TRAILERCAST with Battery Install the unit between axle 1 and 2 with the connector facing towards front of the trailer Make sure that the unit is placed with the connector on the upper side Install the unit at around 70 cm from the ground Install the unit centered between the wheels in the middle of the axle Install the unit at a max distance of 2 3 m from the center of any of the wheels ...

Page 19: ...onents e g air tanks etc The unit requires a clear view to the ground 4019854a 6 5 2 Installation Instructions for Cables The general installation instructions to be observed for cables and connectors can be downloaded from http inform wabco auto com intl drw 9 4490000000 pdf After connecting all hardware to TRAILERCAST with Battery ZF recommends using cable ties to relieve tension from the connec...

Page 20: ...allation Please observe the following recommendations Install the unit centered between the wheels in the middle of the axle Make sure that the unit has clear view to all wheels not obstructed by other components Install the unit at a max distance of 2 3 m from the center of any of the wheels Install the unit at around 70 cm from the ground 7 1 Fixing the bracket to the Trailer Make sure that the ...

Page 21: ...21 Fastening TRAILERCAST with Battery ...

Page 22: ...s using M8 bolts or screws to mount the TRAILERCAST with Battery unit When fastening TRAILERCAST with Battery on the vehicle when bracket is not used use 2 hexagon head bolts M8 x 1 25 class 8 8 and tighten the bolts with a maximum torque of 25 4 Nm dry Make sure that TRAILERCAST with Battery is mounted on a rigid flat surface Use both fixing points to fasten the TRAILERCAST with Battery device CA...

Page 23: ...Splus The connector on the specific iABS or RSSplus connection cable is connected to the iABS or RSS port of the TRAILERCAST with Battery unit All iABS and RSSplus connection cables use the same type of connector Always make sure that all connectors are correctly plugged in to help ensure a waterproof connection The TRAILERCAST with Battery unit can be powered by the iABS or RSSplus All iABS and R...

Page 24: ...nnector will help prevent you from plugging it in incorrectly 4019857a 2 Press down the connector By pressing down the connector the yellow clip will automatically move down 4019858a 3 Finally press the yellow clip to lock the connection A distinct click should be heard 4019859a ...

Page 25: ...25 Connecting Hardware 4 The connector has been plugged in correctly 4019860a ...

Page 26: ...emium 400 500 430 0 you can connect TRAILERCAST with Battery to the modulator SUBSYSTEMS port using the iABS connection cable The connector on the iABS unit remains the same for all cables 4019749a iABS STANDARD OR iABS PREMIUM 400 500 350 0 480 500 420 0 480 500 425 0 480 500 430 0 Configuration Cable s Connections iABS port 1 iABS Premium Standard 449 943 050 0 4019761a Subsystems 4019862a 2 TRA...

Page 27: ... while connecting it to the power port of the modulator You can connect the TRAILERCAST with Battery to the SUBSYSTEMS port on the hub cable using the iABS connection cable 4019745a iABS STANDARD OR iABS PREMIUM 400 500 320 0 Configuration Cable s Connections iABS port 1 iABS Premium Standard 894 600 151 2 4019764a Power Hub Cable goes to Power port 2 TRAILER CAST with Battery 449 943 050 0 401976...

Page 28: ...50 0 and TRAILERCAST connection cable 894 600 001 2 G105 G104 GENERIC IN OUTPUTS G103 G102 G101 ABS f G106 ABS d MODULATOR POWER SUBSYSTEMS IN OUT G107 ABS e ABS c 4019863b RSSplus 480 107 001 0 Configuration Cable s Connections iABS port 1 RSSplus 449 913 050 0 Subsystems G105 G104 GENERIC IN OUTPUTS G103 G102 G101 ABS f G106 ABS d MODULATOR POWER SUBSYSTEMS IN OUT G107 ABS e ABS c 4019863b 2 TRA...

Page 29: ...MS solution 12 2 Connecting to the Internal Sensors SMS For selecting the required valve set and further sensor installation instructions we refer to the sensor installation instructions https www wabco customercentre com catalog docs 8150102293 pdf see the following Section 13 3 Installation of the Internal Sensor page 34 Internal Sensor SMS Grey WABCO part number 960 733 001 0 Remember to write ...

Page 30: ...ensions H x W x D 16 5 cm x 9 5 cm x 3 8 cm Housing material high impact ABS Response frequency Main frequencies 315 MHz and 433 92 MHz support of most specific frequencies Low battery indication LCD bar display Weight approx 1 kg Temperatures Operation 20 C to 55 C Storage 40 C to 60 C Working height up to 2000 m 12 3 2 Purpose and Function The WABCO TPMS Manager can be used to stimulate and read...

Page 31: ... C PSI F To control the internal sensor SMS you may need to update the software version on the ZF WABCO TPMS Manager 12 4 WABCO TPMS Manager Software Update 1 Start the WebVT software 2 Connect the WABCO TPMS Manager to your PC using the supplied USB cable 3 Click on the My Tools tab 4 Click Update and select Full 5 Wait until the update is complete ...

Page 32: ...st software version must be installed on the WABCO TPMS Manager see Section 12 3 WABCO TPMS Manager page 30 Select an internal sensor SMS from the READ OUT SENSOR menu of the WABCO TPMS Manager Hold the WABCO TPMS Manager close to the internal sensor either from the side of the tire sidewall or from the tread The adjacent wheel may interfere with the radio signal in which case the respective wheel...

Page 33: ...ps www wabco customercentre com catalog docs 8150102293 pdf Remember to write down the sensor IDs with the corresponding wheel positions when installing the sensors Use the install form below Do not apply compressed air assembly paste detergents or other cleaners to the internal sensor Never clean the rim with high pressure when the tires are removed and the internal sensor still installed Remove ...

Page 34: ... wheel 3 Use a suitable assembly device to remove the tire It is sufficient to pull the tire over the rim on one side free access to the drop center and valve is all that is required 13 3 Installation of the Internal Sensor 1 Slide the sensor on the inside of the fastening strap unmarked side with the rounded side first into the pocket provided Inside unmarked Outside marked 2 Guide the fastening ...

Page 35: ...force of 100 Nm and close the Velcro fastener The sensor must lie flat on the drop center with the concave underside The Velcro fastener must be pressed firmly over its length The two layers of the Velcro fastener must lie flush on top of each other over the entire length the Velcro fastener must not be pressed literally offset ...

Page 36: ... onto the sewn end of the fastening strap Outside marked 13 4 Assembly of the Tire The internal sensor can be damaged by the penetration of fluids Make sure that the internal sensor does not come into contact with fluids e g assembly fluid Do not fill the tires with water 1 Fit the wheel onto the assembly machine so that the assembly head is on the opposite of the valve i e offset by 180 degrees ...

Page 37: ...nge 4 Pull the second tire bead onto the rim During assembly the assembly head must have a minimum distance of 20 cm to the internal sensor The remaining part of the bead can be pressed over the rim flange in the normal way 5 Remove the complete wheel from the assembly machine 6 Inflate the tire as usual If a filling bell is used the tire must not exert any pressure on the internal sensor housing ...

Page 38: ...n the following QR code with your smartphone a QR code reader app installed on your smartphone is required 2 On the WABCO Fleet Installer page tap Scan QR code and scan the QR code on the TRAILERCAST with Battery device label back top side 4019868a 4019869a Or you can also enter the 15 digit device serial number manually in the input field The serial number can be found on the device label for exa...

Page 39: ...nection on your smartphone 3 Before checking the data with WABCO Fleet Installer Make sure iABS or RSSplus is not connected to the TOOLBOXPLUS software Turn ON the vehicle contact Select the Installation Wizard Installation wizard step by step wizard for the first installation ...

Page 40: ...dentify the vehicle by entering the parameters below Vehicle Identification Number VIN iABS RSS Brand Trailer Utilization Trailer Manufacturer License Plate Customer Number of axles Axle Brand Axle Model Tire Type Tire Brand Tire Model Mandatory input field Press Next to continue ...

Page 41: ...is enabled Turn ON the vehicle contact In case the Battery status is not OK verify all cable connections from iABS RSS to TRAILERCAST with Battery or truck to trailer are connected and powered Press Next to continue 3 iABS RSS status OK Not OK Verify the iABS RSS connection status In case the iABS RSSplus status is not OK verify all cable connections ...

Page 42: ...Number of satellites covering the trailer A minimum 3 but preferably 5 satellites are necessary for a good GPS position History Last received valid position Press Next to continue 5 TPMS Configuration Configure the type of sensor installed on tires Set the number of axles 1 6 Set the tire type single twin Add the sensor IDs per location by clicking next to the tire location in the Sensor ID column...

Page 43: ... the sensor to make it visible and or read the sensor ID Repeat these steps until a sensor has been assigned to all tires 6 Create and send a report Email Send a report via email to confirm the installation Enter the required parameters Email address Installer Workshop Comment ...

Page 44: ...44 Checking the Installation Press Send to complete the process ...

Page 45: ... 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 provide protection from unwanted electrical noise This can be verified by measuring the resistance between the vehicle chassis frame and the other trailer component then confirming tha...

Page 46: ...00 500 425 0 400 500 430 0 CAN Capable Yes Yes Yes Yes Yes Subsystems Port No Yes Yes Yes Yes PARTS LIST Slot on iABS Modulator Application Part Number Length Power 4019750a Power Cable 449 306 005 0 449 306 010 0 449 306 030 0 449 306 047 0 0 5 M 1 M 3 M 4 7 M Power 4019764a Power HUB Cable 894 600 151 2 0 5 M Subsystem 4019761a Subsystem Cable TRAILERCAST 449 943 050 0 5 M Pici 4019745a 4019746a...

Page 47: ...us Modulator Application Part Number Length Power Power Cable 449 351 010 0 449 351 047 0 1 M 4 7 M Subsystem TRAILER CAST RSS Subsystem Cable 449 913 050 0 5 M RSS Subsystem Cable Socket TRAILERCAST RSS Cable 894 600 001 2 0 15 M TRAILERCAST VARIANT LIST Variants TRAILERCAST with Battery Mounting Bracket Part Number 346 292 000 0 346 297 000 4 ...

Page 48: ...on serves the full commercial vehicle industry value chain As the automotive industry progresses towards an increasingly autonomous connected and electrified ACE future ZF s CVS division innovates integrates and supplies components and advanced control systems that help make commercial vehicles and fleets operate more safely and sustainably CVS unites ZF s former Commercial Vehicle Technology and ...

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