WABCO OptiTire System Description Download

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SYSTEM DESCRIPTION

OptiTire

TIRE PRESSURE MONITORING

FOR COMMERCIAL VEHICLES

Summary of Contents for OptiTire

Page 1: ...SYSTEM DESCRIPTION OptiTireTM TIRE PRESSURE MONITORING FOR COMMERCIAL VEHICLES ...

Page 2: ......

Page 3: ...WABCO display 32 5 4 Connecting cables 33 6 Installation 36 6 1 Safety information 36 6 2 Assembly of the external sensors WM2 37 6 3 Assembly of the internal sensor 40 6 4 Mounting the ECU in bus towing vehicle 44 6 5 Wiring in towing vehicle bus 46 6 6 Mounting the ECU in the trailer 47 6 7 Wiring in trailer 48 7 Requirements for the start up 49 7 1 Training 49 7 2 Diagnostic Software 49 7 3 Dia...

Page 4: ...cement and repair 63 10 2 1 Replacing an IVTM ECU with an OptiTireTM ECU 63 10 2 2 Replacing 1st generation external sensor with a 2nd generation sensor 63 10 2 3 Wheel change 63 10 2 4 Replacing PA tubes external sensor 65 10 2 5 Creeping pressure loss 65 10 2 6 No signal received from the sensor 66 10 3 Disposal recycling 68 Edition 1 Version 4 09 2017 815 010 229 3 en This publication is not su...

Page 5: ...system Copyright and trademark notice The content particularly technical information descriptions and figures corresponds to the state current at the time of printing and is subject to change without notice This document including all its parts in particular texts and figures is protected by copyright Use outside the statutory or contractual limits require authorisation by the copyright owner All ...

Page 6: ...ons Please note that the publications are not always available in all language versions DOCUMENT TITLE DOCUMENT NUMBER OptiTireTM System Description 815 XX0 229 3 OptiTireTM Installation instructions 815 XX0 230 3 General Repair and Test Information 815 XX0 109 3 Diagnosis Product Overview 815 XX0 037 3 SmartBoard Operating Instructions 815 XX0 138 3 TEBS E system description 815 XX0 093 3 TEBS C ...

Page 7: ...roduction standards The quality of every genuine WABCO part is supported by Tooling made for serial production Regular audits of suppliers Exhaustive end of line tests Quality standards 50 PPM Installing replica parts can cost lives genuine WABCO parts protect your business WABCO additional services The package you will get with a genuine WABCO part 24 month product warranty Overnight delivery Tec...

Page 8: ... to help you at our WABCO Service Partners to directly answer any technical or business related questions you may have Contact us if you need assistance Find the right product Diagnosis support Training System support Order management You can find your WABCO partner here http www wabco auto com en how to find us contact ...

Page 9: ...as regional and national regulations Make provisions for a safe work environment Only trained and qualified technicians may carry out work on the vehicle Use personal protective equipment if required safety goggles respiratory protection ear protectors etc Ensure that the workplace is dry and provided with sufficient lighting Pedal actuations can lead to severe injuries if persons are in the vicin...

Page 10: ...re than 10 With under inflated tires there is an increased risk of sustained overheating This can cause terminal damage to the casing WABCO OptiTireTM helps to maintain the correct tire pressure and to detect slow punctures early Downtimes Tire damage is the most frequent reason for commercial vehicle vehicles to be out of service Verbrauchsstoffe 4 Bremsen 6 Motor 21 Reifen 32 Elektrik 29 Sonstig...

Page 11: ...re pressure reduces the life of a tire by more than 10 0 2 10 10 20 30 20 30 2 4 6 8 40 50 10 60 0 10 10 5 15 20 25 30 15 20 20 30 25 40 30 5 10 50 Änderung des Kraftstoffverbrauchs Abweichung vom empfohlenen Reifendruck Abweichung vom empfohlenen Reifendruck Zu niedriger Druck Zu hoher Druck Verkürzung der Reifenlebensdauer Zu hoher Druck Zu niedriger Druck Reduce risk improve safety Incorrect ti...

Page 12: ...ressure is measured by sensors The measured values are repeatedly transmitted to the electronic control unit by radio signal The actual tire pressure of each wheel is transmitted to a central ECU The signals of all wheels are evaluated there and the information is conveyed to a display in the driver s cab Evaluating In the ECU the measured values are compared to one another and to standard values ...

Page 13: ...art number 446 220 100 0 Display In the case of original equipment the tire pressures are retrieved by a central on board computer via CAN and displayed on an integrated display in the dashboard If retrofitted the WABCO display WABCO part number 446 221 000 0 is used for retrieving the tire pressures Sensors Select sensors and counterweights according to their axle configuration The table contains...

Page 14: ... axle sensor outside 2 2 4 960 731 804 0 PA tube For rear axle sensor inside 2 2 4 960 731 801 0 PA tube Super Single 2 2 4 Example Parts list for bus towing vehicle with internal sensor WIS WABCO PART NUMBER COMPONENT COMMENT 4X2 6X2 ARTICULATED BUS 6X2 446 220 100 0 ECU Communication with trailer ECU warning lamps 1 1 1 446 220 000 4 Mount Support for mounting the ECU 1 1 1 446 221 000 0 Display...

Page 15: ...n the trailer is also equipped with WABCO Trailer EBS the data can transferred to the towing vehicle s central computer via CAN The following illustrations compare both transmission types wireless connection and CAN bus with each other Data transmission via a CAN bus Data transmission via radio link The data can only be transmitted via a radio link if both the towing vehicle and the trailer are eq...

Page 16: ...BS E system description see section Technical documents on page 6 OptiTireTM with several trailers Equipment of tractor trailer combinations with more than one trailer is possible Tractor trailer combinations with two trailers can still be made with wireless connections road trains need CAN bus connection with special ECUs Please contact your WABCO partner for more information OptiTireTM with TEBS...

Page 17: ...ote If the OptiTireTM system is installed instead of the IVTM system additionally use the adapter cable with the WABCO part number 894 600 001 2 Circuit diagram 841 801 945 0 Trailer EBS D mit CAN Connection is implemented using cable position 3 WABCO part number 449 377 XXX 0 449 378 XXX 0 The ISS output must not be used and needs to be set to 0 km h The OptiTireTM diagnosis is carried out using ...

Page 18: ...em is installed instead of the IVTM system additionally use the adapter cable with the WABCO part number 894 600 001 2 Circuit diagram 841 802 066 0 Trailer EBS E The circuit diagram shows different connection options with Trailer EBS E 1 Standard TEBS E WABCO part number 480 102 03X 0 2 Premium TEBS E WABCO part number 480 102 06X 0 3 Multi Voltage TEBS E WABCO part number 480 102 08X 0 4 OptiTir...

Page 19: ...hicle this data can also be transmitted directly to the haulage company by means of telematics The combination of OptiTireTM with TX TRAILERGUARDTM is of particular interest if the trailer is transported by subcontractors or rented to third parties Automatic trailer recognition The towing vehicle ECU automatically detects the combination with a trailer ECU The stop light is enabled on towing vehic...

Page 20: ... requirements Expert s report certificate WM2 Associated EU type test certificate TÜV 04 ATEX 2418 X Application area ADR G potentially explosive gas atmospheres II 2G Ex ib IIC T4 The device is rated as being a small piece of electrical equipment and therefore the marking does not contain the complete information in accordance with directives or standards The manufacturer of the sensor is WABCO G...

Page 21: ... cause interference and 2 This device must accept any interference including interference that may cause undesired operation of the device Le présent appareil est conforme aux CNR d Industrie Canada applicables aux appareils radio exempts de licence L exploitation est autorisée aux deux conditions suivantes 1 l appareil ne doit pas produire de brouillage 2 l utilisateur de l appareil doit accepter...

Page 22: ... and self contained Integrated components Pressure sensor Circuit for evaluation Radio transmitter and battery Radio transmission 433 MHz signal Transmission intervals depends on the sensor type the transmission frequency is increased when there are pressure changes Repairs Not possible Warning messages With position on the vehicle Battery Lithium Service life up to 9 years Around 6 months before ...

Page 23: ...rew or remove the sensor from the bracket Information and technical data THE EXTERNAL SENSOR WM2 WABCO part numbers Variants of External sensors see page 24 Depending on rim crank use of the normal external sensor or the so called L shape or T shape version is recommended Pressure range 2 to 14 bar correspond to the nominal values of pressures from 3 to 10 bar Temperature range 40 C to 90 C 24h up...

Page 24: ... a good quality of reception T shaped external sensors should be used WABCO part numbers 960 731 031 0 or 960 731 041 0 External sensors WM2 variants The various types of external sensors are illustrated in the table APPLICATION WABCO PART NUMBER HOLE WHEEL BOLT BOLT HOLE Ø ANGLE FIGURE Trailer Independent wheel no Super Single 960 731 011 0 26 mm 335 mm 0 Trailer Independent wheel no Super Single...

Page 25: ... 335 mm 70 Towing vehicle Front axle load axle 960 731 051 0 26 mm 335 mm 60 Towing vehicle Front axle load axle 960 731 053 0 32 mm 335 mm 0 Towing vehicle Front axle load axle 960 731 055 0 26 mm 335 mm 60 Towing vehicle Front axle load axle 960 731 061 0 32 mm 335 mm 33 Twin tires Super Single 960 731 073 0 26 mm 285 75 mm 70 ...

Page 26: ... Counterweight independent wheels North America 960 905 824 4 26 mm 285 75 mm 0 Counterweight To prevent the external sensor causing an imbalance on the wheel a counterweight is mounted on the opposite side Axles with twin tires do not need a counterweight In this case the external sensor of one wheel serves as counterweight for the external sensor of the other wheel The external sensors are oppos...

Page 27: ...d in the chart PA tube variants WABCO PART NUMBER FIGURE ORDER NUMBER FIGURE 960 731 800 0 960 731 810 0 960 731 801 0 960 731 816 0 960 731 802 0 960 731 821 0 960 731 803 0 960 731 822 0 960 731 804 0 960 731 825 0 960 731 808 0 960 731 827 0 Check PA tubes frequently for damages and replace them if necessary Replace defective hose connections with PA tubes Fit a new external sensor at the same ...

Page 28: ...R WIS WABCO part numbers 960 732 000 0 Pressure range 0 to 13 bar correspond to the nominal values of pressures from 3 to 10 bar Transmission intervals Every minute Counterweight Not required Installation Installation on the rim by means of valve neck Fastened to a special tire inflation valve with a 6 mm hollow screw coated with locking varnish The tire valve must match the installation condition...

Page 29: ...104 0 960 732 133 0 22 50 x 11 75 Aluminium Alcoa 819510DB Dura Flange 960 732 104 0 960 732 133 0 22 50 x 11 75 Aluminium Alcoa 819511DB Dura Flange 960 732 104 0 960 732 133 0 22 50 x 11 75 Aluminium Alcoa 81951 EU 960 732 104 0 960 732 133 0 22 50 x 11 75 Aluminium Alcoa 81952 EU 960 732 104 0 960 732 133 0 22 5 x 11 75 Aluminium Alcoa 81251 EU 960 732 105 0 22 5 x 11 75 Aluminium Alcoa 81252 E...

Page 30: ...l Kronprinz 803 WA 960 732 100 0 960 732 101 0 22 50 x 11 75 Steel Mefro 15083 960 732 100 0 960 732 101 0 22 50 x 11 75 Steel Mefro 15095 960 732 100 0 960 732 101 0 22 50 x 11 75 Steel Mefro 15084 960 732 100 0 960 732 101 0 22 50 x 09 00 Steel Mefro KPB15099OE 960 732 100 0 960 732 101 0 22 50 x 09 00 Steel Mefro CU 852XAF 960 732 100 0 960 732 101 0 22 50 x 11 75 Steel Südrad 15084 960 732 100...

Page 31: ...s ensured You should use special brackets for good radio contact Fixing bracket WABCO part number 446 220 000 4 Radio contact is provided by antenna integrated in the ECU housing that guarantees interference free pressure signal reception from all sensors Information and technical data ECU THE ELECTRONIC CONTROL UNIT WABCO part numbers 446 220 100 0 Towing vehicle and bus 446 220 110 0 Trailer and...

Page 32: ...page 57 Manual checks of the tire pressure are superfluous Faulty tire pressures should be corrected directly at the tire valve Since warnings are also signalised acoustically the display does not need to be installed within driver s direct field of vision Optical warnings are indicated by integrated lights red stop immediately yellow drive slowly Information and technical data WABCO DISPLAY WABCO...

Page 33: ...e adapter cable WABCO part number 894 600 001 2 The second section is a cable set designed exclusively for the interior Here there is a split connection from the connection of the first cable to the WABCO display to the diagnostic port and a connection to the vehicle wiring terminals using free cable ends Basic wiring principle for towing vehicle bus is displayed in the following illustration Wiri...

Page 34: ...s corresponds to the 5 pin variant In addition either a connection to the stop light for synchronising with the trailer ECU or connection of one or two warning lamps is possible Cable set Towing vehicle 5 pin 894 607 295 0 A simpler wiring WABCO part number 894 607 295 0 is provided as a 5 pin variant for retrofitting in buses Employment of this wiring allows driving of warning lights inside displ...

Page 35: ...35 Components Trailer wiring LEGEND A ECU via adapter cable with WABCO part number 894 600 001 2 B Brown Ground C Red 12 V 24 V D White Stop light E Diagnosis ...

Page 36: ...y information Observe the occupational health and safety regulations of the respective country the workshop as well as the vehicle manufacturer s instructions Risk of accident due to loose wheel nuts Loose wheel nuts may lead to accidents when driving on roads Wheel nuts must be tightened with torque specified by vehicle manufacturer Check the tightness of the wheel nuts after 500 km Risk of accid...

Page 37: ...e position of the external sensor is suitable for connecting to the PA tube and the valve The PA tube should be able to be guided to the tire valve without stretching upsetting deformation or twisting Position the external sensor on the wheel bolts Screw the wheel nuts back on Remove the white protective cap from the pressure connection Assembly of the counterweight Loosen the wheel nuts that are ...

Page 38: ...mber 960 731 800 0 bis 960 731 802 0 to the required length if necessary Also consider that the PA tube disappears to 20 mm in the connection For this purpose the PA tube should be cut 20 mm behind the marking Use a suitable right angled cutting tool such as those that are also used for shortening plastic brake lines Tube cutting tool for ø 4 to ø 12 Tube cutting tool for ø 4 to ø 22 Mount the con...

Page 39: ... sensor ID next to the respective wheel module Adjust tires to correct operating pressure according to the vehicle manufacturer s instructions Note pertinent nominal pressure values per axle for later nominal pressure parametrization through diagnostic Avoid standing water or moisture in the filling tool or in the tire inflating device Check wheel nuts for tightness after 500 km WARNING Risk of ac...

Page 40: ...with locking varnish always use new screws with every assembly Never re tighten self locking screws and union nuts Use self locking fastening screws only once Use the valve that matches the rim Select the correct valve using an assignment table see chapter 5 1 2 The internal sensor WIS on page 28 Do not apply compressed air assembly paste detergents or other cleaners to the internal sensor Never c...

Page 41: ... inflation valve figure 1 Observe the tightening torque specified for the rim and correct alignment of the valve Figure 1 After the valve is fitted the internal sensor is placed on the valve head on the rim s inside figure 2 and fastened with the screw figure 3 The following must be observed during this procedure The internal sensor must be aligned parallel to the rim figures 4 5 The sensor must m...

Page 42: ...case of steel rims the internal sensor sits flat on the rim Figure 7 In the case of aluminium rims only the rear section of the wheel electronics sits on the rim Figure 8 Figure 9 Correct fit of the internal sensor Incorrect fit of the internal sensor ...

Page 43: ... the tire bead and rim flange Now push the bead to be fitted onto the rim over the rim flange During assembly the tire bead must not be pressed against the wheel electronics Otherwise there is a risk of the internal sensor coming off at the fastening point Then pull the second tire bead onto the rim During this procedure the bead must never be pressed onto the internal sensor or pulled over it Dur...

Page 44: ... the tightening torques specified by the vehicle manufacturer 6 4 Mounting the ECU in bus towing vehicle ECU position on vehicle Towing vehicle The ECU connector must point to side to the right or left but not up or down Choose the fitting position in accordance with the figure Assembly on the longitudinal beam If the vehicle is equipped with a low lying coupling for central axle trailer install t...

Page 45: ...n in the geometric centre of all axles with coaches also on the luggage compartment if the luggage compartment components are at least in part of wood or plastic Mounting the ECU Read the chapter see chapter 5 2 ECU The electronic control unit page 31 Mount ECU so that the distance to the sensors is as equal as can be Select distance to truck driver s cab such that length of ECU cable 8 m is suffi...

Page 46: ...a suitable attachment location The display must not necessarily be located inside driver s direct field of vision Fit the diagnostic socket to a suitable attachment location and label it with Diagnostic OptiTireTM Locations where diagnostic ports are already located would be specially suitable as the attachment location Install cables according to the wiring diagram using cable ties in parallel wi...

Page 47: ... so that this is pointing to the towing vehicle Central axle trailer Install the ECU in front of the first axle on the right hand side of the vehicle For the towing vehicle use the bracket WABCO part number 446 220 000 4 Screw on bracket to vehicle Welding could impede frame stability Attach the ECU below on the frame ECU longitudinal axis must be in parallel with the vehicle axis Maintaining good...

Page 48: ... a suitable attachment location and label it with Diagnostic OptiTireTM Locations where diagnostic ports are already located would be specially suitable as the attachment location De energize the trailer Consider any risks of short circuits through batteries inside the vehicle Install cables according to the wiring diagram using cable ties in parallel with already existing wiring harnesses Form la...

Page 49: ...egistered and logged in you can book training courses and work through E Learnings via myWABCO Please contact your WABCO partner if you have any questions 7 2 Diagnostic Software With the Diagnostic Software you have the following options Retrieving the diagnostic memory data Retrieving current measured values Parameter setting Display of measures to remedy faults if faults are indicated The ECU s...

Page 50: ... since 2004 VCS II ISO 7638 breakout box with CAN socket 446 300 360 0 Diagnostic Interface DI 2 with USB port for connection to a PC 446 301 030 0 CAN diagnostic cable 446 300 361 0 5 m TEBS E Premium External diagnostic socket with yellow cap 449 611 XXX 0 Diagnostic Interface DI 2 with USB port for connection to a PC 446 301 030 0 CAN diagnostic cable 446 300 348 0 7 4 Installing the Diagnostic...

Page 51: ...e data Select the vehicle configuration to use under System configuration If the vehicle is not included under the standard system configurations a spare tire is used with the internal sensor select the free System configuration Define the type and position of the axles for this free configuration Select the Sensor type Internal sensor WIS or External sensor WM2 Module configuration tab Enter IDs ...

Page 52: ... WM 2 4 TRIG Hold the WABCO OptiTireTM handheld tool near the external sensor The adjacent wheel may interfere with the radio signal in which case the respective wheel must be turned Alternative For this purpose touch the housing of each wheel module below the sticker OptiTireTM for 5 seconds using a magnet 2 kg retention force or using a bar magnet parallel to the OptiTireTM logo External sensor ...

Page 53: ...um value 120 C Tire status messages Here the transmission of trailer data in the towing vehicle and the transmission of the vehicle configuration can be deactivated The latter can be useful for telemetry configurations With external sensors the temperature transmission can be deactivated Tire pressure limit values Here the nominal pressure values that can be defined in the module configuration can...

Page 54: ...nt of diagnostic memory start window Messages Diagnostic memory Check if data has been received from all sensors start window Measured values Module reception Print out the start up log by clicking the accompanying button Start up window Print the vehicle label onto self adhesive aluminium foil WABCO part number 899 200 922 4 Start up window Attach the vehicle label to the vehicle where it is prot...

Page 55: ...rnings at one minute intervals Critical fault The vehicle must be stopped immediately potential risk to persons and vehicle Yellow warning lamp turtle symbol on the WABCO Display and acoustic warnings at ten minute intervals Minor fault The vehicle speed should be reduced and the tire pressure corrected at the next opportunity The faults identified by OptiTireTM are stored in the ECU for diagnosti...

Page 56: ...on After initialisation if tire pressures are within specified values the following picture will show for a few seconds System check The display will change to normal mode if all pressures are correct Normal mode ...

Page 57: ...t pressure value on the display corresponds to left tire in driving direction Checking pressure values Repeatedly push button with the tire symbol to display pressure values of further axles Axles with twin tires have their wheels represented outside and inside one after the other Repeatedly push button with the tire symbol to display the axles of the towing vehicle as well as the axles of the tow...

Page 58: ...hts up The pressure value of the affected wheel will be indicated and the position on the vehicle is indicated by a flashing wheel icon If no fault is found the system does not react when the button with the question mark is pressed Display of faults If the system warns about several tires the tire with the most serious fault is indicated first Repeated pressing of the button with the question mar...

Page 59: ...the tire High pressure Reduce your speed for preventing the tire from bursting Stop the vehicle at the next opportunity Search for the cause of excess pressure e g defective overheated brake Correct the tire pressure in the event of overpressure when the tire is cold 9 5 Adjusting tire pressures Proceed as follows to adjust the tire pressures on the vehicle Do not adjust tire pressure with the ign...

Page 60: ... for this wheel driver needs to check tire pressure on the wheel manually No reception Repair note With an older system the sensor battery may be exhausted Renew the sensor Start operating the new sensor using diagnostic software by setting a new ID in the parameters If it is a newer system the radio connection between the sensor and the ECU may be disturbed Remove any possible dirt Define the ins...

Page 61: ...the wheel System error Repair note Check the supply voltage of the ground line Check the cable connections Carry out a system diagnosis Battery warning If the wheel sensor battery s end of life has been reached after around 9 years a battery warning is set around half a year beforehand This is indicated in the display by a flashing sensor and a corresponding battery symbol No warning lamp is indic...

Page 62: ...tion number VIN Nominal values and actual value pressures Tire status OK not OK ID of a sensor if the sensor is activated with a solenoid ECU data Tire pressure menu FUNCTION DISPLAY DESCRIPTION OPTIONS Display of tire pressure information Displays the actual and nominal pressure value of the tire from the OptiTireTM system Continue to the next tire pressure Tools menu FUNCTION DISPLAY DESCRIPTION...

Page 63: ... with a 2nd generation sensor To select the correct 2nd generation external sensors the rim shape ET size is also important alongside the 1st generation external sensors that are to be replaced The appropriate 2nd generation external sensor and matching PA tube can then be selected on this basis 10 2 3 Wheel change Wheel with external sensor Due to the external fixation of the sensor on the wheel ...

Page 64: ...g the wheel make sure that the tire valve gets its original position With twin tires the tire valves should be placed in opposite position Place the respective external sensor to its original position and fix it with wheel nuts With individual wheels assemble the counterweight in the opposite of the external sensor Screw the union nut of the hose back on to the tire valve Tighten union nuts manual...

Page 65: ...h a tightening torque of 3 Nm hand tight Remove the protective cap of the V203 connection Insert the new cut to length PA tube into the V203 connection Check if the PA tube has been pushed in until the stop into the V203 connection Check if the PA tube has a tight connection approx 20 N Connect the PA tube to the valve Tighten union nuts on the valve hand tight Check that the connection is tight u...

Page 66: ...list to determine if the sensor should be replaced Copy in this table line per line the default value to the Result column if the description matches Total the standard values in the Result column You will find more information on your items in the section Test result see page 67 Ensure while troubleshooting that the vehicle is not in vicinity of high frequency radiation see chapter 5 1 1 The exte...

Page 67: ... sensor is indicated with a crossed out battery symbol 4 7a During diagnosis only one bar is indicated on the sensor in the module reception test 10 7b During diagnosis no bar is indicated on the sensor in the module reception test 12 Total Test result Sum between 0 and 11 points The battery of the sensor is in order The loss of the sensor from time to time might be caused by very low temperatures...

Page 68: ...ry This applies in particular to sensors that contain lithium batteries These are solidly potted inside the housing and can not be replaced Once they have reached the end of their life dispose of the sensors while observing all the laws and regulations that apply in your country WABCO strives to protect the environment As with other old devices all components can be returned to WABCO Speak to your...

Page 69: ...69 Notes ...

Page 70: ...Notes 70 ...

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Page 72: ...illion in 2016 Headquartered in Brussels Belgium WABCO has 13 000 employees in 40 countries For more information visit www wabco auto com WABCO NYSE WBC is a leading global supplier of technologies and services that improve the safety efficiency and connectivity of commercial vehicles Founded nearly 150 years ago WABCO continues to pioneer breakthrough innovations for advanced driver assistance br...

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