WABCO OPTITIRE Tire Pressure Monitoring System User Manual OptiTire System description V7 draft

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OptiTire
Tire Pressure Monitoring
for Commercial Vehicles
OptiTire
Tire Pressure Monitoring
for Commercial Vehicles
System Description
Edition 7
This publication is not subject to any update service.
You will find the current version at
http://www.wabco.info/xxxxxxxxxx
© 2013/2015 WABCO Europe BVBA – All rights reserved.
The right of amendment is reserved.
Draft Version 1.2015(en)
Xxx xxx xxx x
OPTITIRE
Table of Contents
1 Important instructions ............................................................................................................ 6
1.1
Information and Disclaimer........................................................................................... 6
1.2
Symbols used ............................................................................................................... 6
1.3
General information ...................................................................................................... 7
1.4
General safety instructions ........................................................................................... 7
2 Introduction ............................................................................................................................. 8
2.1
OPTITIRE prevents tire blow-outs ................................................................................ 8
2.2
OPTITIRE reduces cost ............................................................................................... 8
3 System Description .............................................................................................................. 10
3.1
OPTITIRE Basic Functions ........................................................................................ 10
3.2
OPTITIRE at trailer-towing operation ......................................................................... 11
3.3
Configuration for bus and towing vehicle ................................................................... 11
3.4
Configuration for trailers ............................................................................................. 13
3.5
Certificates .................................................................................................................. 16
4 Components .......................................................................................................................... 18
4.1
Wheel module WM2 ................................................................................................... 18
4.2
Wheel Internal Sensor (WIS) ...................................................................................... 21
4.3
Electronic Control Unit (ECU)..................................................................................... 22
4.4
The display ................................................................................................................. 23
4.5
Connecting cable ........................................................................................................ 24
4.6
Connecting tube ......................................................................................................... 27
5 Operation ............................................................................................................................... 28
5.1
Warning signals .......................................................................................................... 28
5.2
Switch on of ignition.................................................................................................... 28
5.3
Checking pressure values .......................................................................................... 29
5.4
Display of faults .......................................................................................................... 30
5.5
Adjusting tire pressures .............................................................................................. 31
5.6
Display of System Errors ............................................................................................ 31
5.7
Operation via SmartBoard .......................................................................................... 33
6 Installation ............................................................................................................................. 34
6.1
Mounting the wheel modules – WM2 ......................................................................... 35
6.2
Mounting the wheel modules – WIS ........................................................................... 37
9.3
Mounting the ECU in bus / towing vehicle .................................................................. 39
6.3
Wiring in towing vehicle/bus ....................................................................................... 40
6.4
Mounting the ECU in the trailer .................................................................................. 41
6.5
Wiring in trailer............................................................................................................ 41
6.6
Start-up ....................................................................................................................... 42
7 Workshop instructions ......................................................................................................... 44
7.1
Diagnosis .................................................................................................................... 45
7.2
Wheel Changes .......................................................................................................... 46
7.3
Replacing PA tubes .................................................................................................... 47
7.4
Replacing hose connections ...................................................................................... 47
7.5
Replacing wheel module I with wheel module II ........................................................ 48
7.6
Creeping pressure loss .............................................................................................. 48
7.7
No reception of the wheel module .............................................................................. 49
Table of Contents
7.8
OPTITIRE
Disposal ...................................................................................................................... 51
1
OPTITIRE
Important instructions
1.1
Information and Disclaimer
Important instructions
We assume no liability for the correctness, completeness or actuality of the information in this document. All technical information, descriptions and images are applicable 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 documentation remain unaffected thereby in their content and validity.
1.2
Symbols used
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 to severe injury, or
material loss, if the safety instruction is not observed.
Important instructions, information, or tips that you should always observe.
Reference to information and publications on the Internet
• List
– Step
Consequence of an action
Important instructions
1.3
OPTITIRE
General information
This publication is directed at trained service technicians employed at workshops
for commercial vehicles.
Proper use
The OPTITIRE system is designed exclusively for monitoring the tire pressure in
commercial vehicles.
Carefully read all the safety instructions as well as all the repair and maintenance
instructions in this document before you start maintenance work, repairs or replacing parts.
These instructions must be observed to avoid personal injury or material damage.
WABCO only guarantees the reliability and performance of its products and systems if all instructions, notes and safety instructions are observed.
1.4
General safety instructions
Before you perform any work on the vehicle (repair, maintenance, replacing parts,
etc.), you must ensure the following:
WARNING
Severe damage to property and injuries to health may result due to improper
assembly or repair work.
– Only trained and qualified personnel may perform repairs on the vehicle.
– Always follow the specifications and instructions of the vehicle manufacturer.
– Always comply with the Company and national accident prevention guidelines
and Health and Safety regulations.
– Wear suitable protective clothing as the situation requires.
– Ensure that the workplace is dry and provided with sufficient lighting.
2
OPTITIRE
Introduction
Introduction
This chapter gives you an overview of the benefits OPTITIRE provides.
2.1
OPTITIRE prevents tire blow-outs
OPTITIRE stands for Integrated Vehicle Tire Pressure Monitoring. The system is
continuously monitoring tire pressure on all wheels by means of sensors. In the
event of a critical pressure drop, a display in the driver cabin of the towing vehicle
warns the driver in time. Since around 85% of all punctures are caused by driving
with wrong air pressure or creeping pressure loss while in motion, risk of tire burst
can be reduced down to 15% thanks to OPTITIRE.
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fig. 2-1:
Root causes for roadside emergencies (source: ADAC 2011)
A Tires 31.6%
B Electrics 29.2%
C Engine 20.7%
D Others 18.5%
2.2
OPTITIRE reduces cost
By selecting the correct tires and having them properly maintained, substantial savings can be achieved per vehicle and year. Maintaining correct inflation pressure
for instance: In practice, about every second tire is run at an air pressure falling below 10 percent of the specified one. Also 20% under nominal pressure is not rarely
observed and this will reduce tire mileage by as much as 20%. This will push up
fuel consumption in each case.
Full tire pressure checks usually take around 30 minutes per vehicle, OPTITIRE
can help reduce or even eliminate this extra work.
So OPTITIRE minimises cost and makes a great contribution to safety on our
roads.
OPTITIRE allows employment of Super Singles instead of twin wheels.
OPTITIRE can be easily retrofitted.
Introduction
OPTITIRE
Return of Investment Calculator
Using our Return of Investment Calculator on our website http://www.OptiTire.com
or http://www.wabco-auto.com, you are able to calculate use your OPTITIRE offers
within a few stages.
You can either enter your individual application data or use standard profiles for
determining which savings you are able to achieve using the OPTITIRE.
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fig. 2-2:
Dependence of tire service life from air pressure
Tire pressure
Service life reduction
Tire pressure too low
Tire pressure too high
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fig. 2-3:
Consumption vs. air pressure dependency
Tire pressure
Fuel consumption
Tire pressure too low
Tire pressure too high
3
OPTITIRE
System Description
System Description
This chapter describes the mode of operation of the OPTITIRE system. Furthermore, you will also obtain information concerning technical reports for installing and
retrofitting.
3.1
OPTITIRE Basic Functions
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fig. 3-1:
Solo system
A Electronic Control Unit (ECU)
B Wheel module
C Display
Each wheel continuously transmits actual tire pressure to a central electronic control unit (ECU). The signals of all wheels are evaluated there and the information is
conveyed to a display in the driver's cab.
Measuring
Wheel modules measure the air pressures on the conventional valves every 15
minutes (WM2) or 1 min (WIS) and transmit them to the ECU. If the pressure
changes critically then the wheel module would sent the values in shorter periods.
Evaluating
Evaluation is far more than just comparing a current pressure value with an allowed one and sending a warning message on falling below. The ECU discriminates a real problem situation from usual pressure fluctuations during vehicle operation also on bad road conditions or uneven load.
In the event that an irregularity occurs then this fact would not only be reported on
the display but the wheel in question would be exactly indicated too.
An OPTITIRE ECU can receive and process data from up to 20 wheel modules
each and further ECUs. Dual tires will each be fitted with individual sensors. Sensor pressure range is between 2 and 14 bar corresponding to nominal pressure
values from 3 to 10.5 bar.
10
System Description
OPTITIRE
Displays
WABCO is offers a driver's display for indicating warning messages and tire pressure checking.
For certain vehicles the data can also be transmitted to an integrated display as an
alternative. Detailed description of display functionality is given in chapter "Operation"(see chapter 5, page 28).
OPTITIRE, and therefore TPI, cannot announce sudden, extreme tire damage
caused by external effects.
3.2
OPTITIRE at trailer-towing operation
Operating mode
Initially, the OPTITIRE system on the trailers will work self-sufficiently if there is a
power supply. In order to display tire pressure and trailer warnings to the driver
during driving, however, it is necessary to install OPTITIRE to both parts of vehicle,
which means one control unit to the trailer and one unit to the towing vehicle.
Any towing vehicle equipped with OPTITIRE could be connected to any trailer
equipped with OPTITIRE.
Variants
The OPTITIRE for trailer vehicles can be operated using the WABCO SmartBoard
as well as for stand-alone versions.
Tire pressure values, in connection with WABCO TCE or EBS, can be transferred
to the towing vehicle's CAN bus via standard CAN data connection according to
ISO 11992 (only in connection with appropriately prepared towing vehicle).
Automatic trailer recognition
Control unit of towing vehicle identifies control unit of trailer automatically: The stop
light is enabled on towing vehicle and trailer when hitting the brake. The trailer
ECU radios a signal with this voltage pulse that is expected by the towing vehicle's
ECU that instant. The towing vehicle thus clearly detects that the trailer belongs to
the tractor/trailer combination and subsequently transmits trailer ECU messages to
the display.
As trailers are usually not permanently powered, it is possible that due to the frequency of wheel modules transmission the tire pressure data for all the wheels of
the trailer is not available in the display for up to 15 minutes after starting the drive.
3.3
Configuration for bus and towing vehicle
In this chapter, you will learn which components you require for your vehicle.
Selection of OPTITIRE components depends on vehicle type, type and number of
wheels and type of systems connected to OPTITIRE but not on the vehicle system
voltage.
ECU
Trucks, buses or articulated buses are equipped with the ECU 446 220 100 0.
Display
IVTM display 446 221 000 0 is used for the retrofitting of the display and operation
devices. Original equipment, however, will often address a central computer via
CAN with the latter controlling indication of the integrated dashboard-mounted display.
11
3
OPTITIRE
System Description
Wheel modules
Select wheel modules and counterweights according to their axle configuration.
The table contains components for three vehicle type examples. Further information in chapter "Components", see chapter 4, page 18.
Order
Number
Component
446 220 100 0 ECU
Comment
4x2 6x2 Articulated
bus 6x2
Communication with trailer
ECU / warning lamps
446 221 000 0 Display
894 607 390 0 Wiring harness
Cable set, 7-pin
optional 894 607 295 0
(5-pin, no trailer-towing
operation)
960 731 051 0 L shape wheel
module
for the front axle, rim 22.5",
10 holes
960 731 031 0 Wheel module
for rear axle, rim 22.5", 10
holes
960 730 822 2 Counterweight
Balance weight for front
axle wheel module
960 731 802 0 PA tube
for front axle wheel module, 2
L-shape
960 731 822 2 PA tube
for rear axle wheel module, 2
outside
960 731 804 0 PA tube
for rear axle wheel module, 2
inside
960 731 801 0 PA tube
Super Single
Table: 3-1: Components for bus / towing vehicle
Operation via CAN bus
Provided the trailer is equipped appropriately, data exchange can also be made via
CAN bus besides wireless connection between towing vehicle and trailer. Towing
vehicle ECU needs to be connected to vehicular CAN Bus for this purpose too.
Circuit diagrams
Detailed circuit diagrams are – as are the outline drawings of the components –
available on the Online Product Catalogue INFORM at http://www.wabco-auto.com.
Enter wiring diagram product number for opening the file:
• 841 801 970 0: Solobus
• 841 801 971 0: Articulated bus
• 841 801 972 0: Articulated truck / truck
12
System Description
3.4
OPTITIRE
Configuration for trailers
Transmission types
Trailer and towing vehicle must be equipped with OPTITIRE for displaying trailer
OPTITIRE data in the diver's cab.
Alternatively, trailer data can display in towing vehicle only then when it is equipped
with an integrated display. When the trailer is also equipped with TCE or TEBS
then data transfer can be made to the towing vehicle central computer via CAN.
The following illustration compares both transmission types, wireless connection
and CAN bus, with each other.
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fig. 3-2:
Data transfer wireless connection (top) and CAN
IVTM display
Wheel modules
OPTITIRE-ECU
Wireless connection
OPTITIRE Trailer ECU
Integrated display
G Central computer
TEBS/TCE
Stand-alone trailer towing operation
If the trailer should be independently equipped with OPTITIRE, then the pressure
release can be carried out via telemetry or the vehicles own display. When using
the OPTITIRE display, it requires a special box for splash protection or another
protected attachment location. The WABCO SmartBoard can be installed as an alternative.
The driver cannot receive fault messages without OPTITIRE support while the towing vehicle is in motion.
OPTITIRE 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; roadtrains need CAN bus connection with special ECUs.
Please contact your WABCO partner for more information.
13
3
OPTITIRE
System Description
OPTITIRE with TEBS D, TEBS E or TCE
Installation in a vehicle with TEBS D, TEBS E or TCE is simple because this merely has to be plugged into pre-assembled cables. Other systems would require open
wiring that needs to be enclosed by protective housing.
Observe the current installation instructions for the control unit of the ABS / EBS in
the WABCO product database INFORM http://www.wabco-auto.com and / or those
of the vehicle manufacturer.
The circuit diagrams illustrated in the following table in excerpt form can be retrieved from INFORM.
Wiring diagrams for trailers
The circuit diagrams shown in excerpt form below can be retrieved from the WABCO online product database NFORM at http://www.wabco-auto.com. To retrieve
them, enter the desired circuit diagram number in the "Product number" input field.
Wiring diagram 841 801 943 0:
Trailer ABS VCS
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Cable position 8 (449 314 ... .) is opened and connected to cable position 3 (449 674 273 0) and a
line to the stop light in a wiring box.
Wiring diagram 841 801 946 0:
Trailer ABS VCS II
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Cable position 8 (449 336 ... .) is opened and connected to cable position 3 (449 674 273 0), cable
position 11 (449 621 ... .) and a line to the stop light
in a wiring box.
Wiring diagram 841 801 941 0:
Trailer EBS with CAN connection
Cable position 8 (449 614 ... .) is opened and connected to cable position 3 (449 674 273 0) and a
line to the stop light in a wiring box. The ISS output
must not be used and needs to be set to 0 km/h.
14
The link ed image cannot be display ed. The file may hav e been mov ed, renamed, or deleted. Verify that the link points to the correct file and location.
System Description
Wiring diagram 841 801 945 0:
Trailer EBS D with CAN
OPTITIRE
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Connection is made with cable position 3
(449 377 ... 0 / 449 378 ... 0). The ISS output must
not be used and needs to be set to 0 km/h.
OPTITIRE diagnosis through diagnostic cable
446 300 329 2 via TEBS diagnostic port.
Trailer TCE
Wiring like 841 801 945 0
Connection like on Trailer EBS D with CAN but with
cable 449 302 ... 0.
Wiring diagram 841 801 940 0:
Trailer ECAS
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Cable position 3 (449 674 273 0) is introduced into
bottom box of ECAS-ECU and connected there.
One cable to stop light (position 7) is installed additionally. You need screwed cable glands (PG 11:
894 130 312 2) for two cables.
Wiring diagram 841 801 944 0:
Vario-C
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Cable position 3 (449 674 273 0) is introduced into
bottom box of ABS-ECU and connected there. One
cable to stop light (position 7) is installed additionally. You need screwed cable glands (PG 11:
894 130 312 2) for two cables.
Wiring diagram 841 801 942 0:
Trailer EBS and ELM
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Cable position 8 (449 344 ... .) is opened and connected to cable position 3 (449 674 273 0) and a
line to the stop light in a wiring box.
15
3
OPTITIRE
System Description
Wiring diagram 841 801 913 0:
Trailer EBS D and SmartBoard
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(from year of manufacture 2004)
The SmartBoard and OPTITIRE are connected to
the Trailer EBS D modulator on port IN/OUT2. CAN
2 must be activated (activation via diagnostic software).
1 Trailer EBS D Modulator 480 102 014 0
2 Cable family 449 377 ... 0
3 SmartBoard 446 192 110. 0
4 OPTITIRE
5 Distributor housing
Wiring diagram 841 802 155 0
Trailer EBS-E
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OPTITIRE is connected to sub-systems using cable
(449 911 ... .).
Wiring diagram 841 802 155 0
TEBS E with SmartBoard
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OPTITIRE and SmartBoard are connected to subsystems using cable (449 916 ... .).
Table: 3-2: Components for trailers
3.5
Certificates
Certificates for mounting and additional mounting of OPTITIRE are available, which
significantly facilitate approval of vehicle registration papers.
The certificates are not part of this document but can be retrieved from the WABCO
online product database INFORM at http://www.wabco-auto.com. To retrieve them,
enter the search term in the "Index" input field.
Following certificates are stored there:
• Expertise TÜH ATC TB 2002-108.00
• Part certificate of TÜH ATC - TB 2003-023.00
• Type approval 94/9/EG CE 0032, TÜV03 ATEXxxxx
16
System Description
•
OPTITIRE
Operating range: εx II 2G EEx ib IIC T4
OptiTire FCC Declaration for FCC ID: SA4-OPTITIRE and SA4-WM731:
„This device complies with Part 15 of the FCC Rules. Operation is subject to the
following two conditions:
(1) this device may not cause harmful interference, and
(2) this device must accept any interference received, including interference that
may cause undesired operation“
OptiTire IC Declaration for model: IC: 6970A-OPTITIRE and 6970A-WM731:
„This device complies with Industry Canada’s licence-exempt RSSs. Opera-tion
is subject to the following two conditions:
(1) This device may not 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 tout brouillage radioélectrique subi,
même si le brouillage est susceptible d’en compromettre le fonctionnement.“
For operation in the USA following statement has to be considered:
„. CAUTION TO USERS: “Changes or modifications not expressly approved
by the party responsible for compliance could void the user’s authority to
operate the equipment.”
17
4
OPTITIRE
Components
Components
This component description details the properties of basic components.
Other details, such as dimensions, can be accessed via the WABCO online product
database NFORM at http://www.wabco-auto.com. To retrieve them, enter the desired product number in the "Product number" input field.
4.1
Wheel module WM2
CAUTION
Risk due to incorrect handling
– Do not unscrew or remove the module from the bracket.
Any changes of manipulation to the wheel module of any type, especially attempts made to change the battery will destroy the device and may lead to
injuries.
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fig. 4-1:
Wheel module with connecting hose
The wheel module consists of a compound-filled plastic unit comprising a pressure
sensor, an evaluation circuit, a radio transmitter and a lithium battery.
Battery life under normal operating conditions is minimum 6.5 years. If the battery
is dead the module would not transmit any longer and needs to be replaced with a
new one.
The wheel module is mounted to the rim by the standard lug nuts and is connected
to valve via a PA tube. The result is an easy installation. You will not need to remove the tire from the rim when retrofitting.
Data transfer
Wireless transmission is made by 433 MHz signal. If pressure is constant, measured values are transmitted every 18 minutes (9 minutes with versions that do not
have acceleration sensor), if pressure is changing, frequency of data transfers is
faster.
OPTITIRE can be interrupted in its function if other devices or systems in the vicinity are also transmitting in the area of 433 MHz. These can be radio sets, radio remote controls (e.g. for door actuation, cranes, fork lift), insufficiently shielded electrical drives with high power or other radio transmitters. When OPTITIRE system is
removed from the influencing area, the function is guaranteed again.
18
Components
OPTITIRE
Depending on rim crank, use of the normal module according to Figure 4-1 or the
so-called L-shape or T-shape version is recommended. For details see Table 4-1
and also the chapter on configuration (see chapter 3.3, page 11 and see chapter 3.3, page 11).
Application
WABCO
number
Trailer: Independent wheel (no Super-Single)
Hole, wheel
bolt
Bolt circle
Ø
Angle Figure
960 731 011 0 26 mm
335 mm
0°
Trailer: Independent wheel (no Super-Single), 20° for
special purposes (e.g. Iveco)
960 731 013 0 23 mm
335 mm
0°
Trailer: Independent wheel (no Super-Single), 23 mm
pitch circle diameter
960 731 017 0 23 mm
335 mm
0°
Trailer: Independent wheel (no Super-Single)
960 731 021 0 32 mm
335 mm
0°
Twin tires, Super-Single
960 731 031 0 26 mm
335 mm
70°
Twin tires, Super-Single
960 731 041 0 32 mm
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°
19
4
OPTITIRE
Components
Application
WABCO
number
Towing vehicle: Front axle, load axle
Hole, wheel
bolt
Bolt circle
Ø
Angle Figure
960 731 061 0 32 mm
335 mm
33°
Twin tires, Super-Single
960 731 073 0 26 mm
285,75 mm
70°
Towing vehicle: Front axle, load axle
960 731 075 0 26 mm
285,75 mm
33°
Twin tires, Super-Single
960 731 081 0 26 mm
225 mm
70°
Counterweight for L-shape wheel module
960 730 822 2 26 mm
960 730 828 2 32 mm
335 mm
0°
Counterweight independent wheels
960 730 820 4 26 mm
960 730 825 4 32 mm
335 mm
0°
Table: 4-1: Wheel modules and counterweights
With twin wheels and Super Single rims, problems may occur with the radio transmission due to the immersion depth. To ensure the quality of the reception, wheel
modules with the T-shape should be used (960 731 031 0 or 960 731 041 0).
20
Components
OPTITIRE
Counter weight
To prevent the wheel module causing an imbalance on the wheel, a counterweight
is mounted on the opposite side, see figure 4-2 "Module with counterweight",
page 21.
Axles with twin tires do not need counterweight. In this case, the wheel module of
one wheel serves as counterweight for the wheel module of the other wheel. They
are mounted opposite to one another, see figure 4-3 "Module for twin wheels",
page 21.
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that the link points to the correct file and location.
fig. 4-2:
Module with counterweight
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that the link points to the correct file and location.
fig. 4-3:
Module for twin wheels
ID code
Special identification code of each wheel module allows unique assignment of
modules to particular wheels. The wheel module will "report" to ECU using this
code. This will exclude pressure signals from other vehicles to be assigned to own
system. Code is determined when module is manufactured and cannot be changed.
This number is imprinted on the wheel module when commissioning.
Assignment between wheel and wheel module must be absolutely maintained tirechange procedure. If tires were confused, OPTITIRE could not set off required
alarm when a wheel with low pressure has been wrongly assigned to an axle on
which this pressure is still permissible.
Identification code assignment to a wheel is determined during initial start-up of the
diagnostic software on commissioning, see chapter 6.6 "Start-up", page 42.
4.2
Wheel Internal Sensor (WIS)
The wheel internal sensor WIS 960 732 000 0 consists of a compound-filled plastic
unit comprising a pressure sensor, an evaluation circuit, a radio transmitter and a
lithium battery.
Battery life under normal operating conditions is minimum 10 years. If the battery is
dead the module would not transmit any longer and needs to be replaced with a
new one.
The wheel module is mounted on the rim on the backside of a specific filling valve.
Therefore it will be assembled inside the tire and is able to measure pressure and
temperature. Data transfer
Wireless transmission is made by 433 MHz signal. If pressure is constant, measured values are transmitted every 1minute , if pressure is changing, additional
messages will be transmitted.
21
4
4.3
OPTITIRE
Components
Electronic Control Unit (ECU)
The link ed image cannot be display ed. The file may hav e been mov ed, renamed, or deleted. Verify that the link points to the correct file and location.
fig. 4-4:
ECU
Mode of function
The ECU immediately recognises all changes from programmed nominal tire pressure values by combined comparison with threshold pressure values and pressure
changes.
Incorrect values of tire pressures are already displayed before departure (if ECU is
permanently powered).
The system may be extended up to 20 wheel modules per ECU.
After system installation, commissioning by PC diagnostic software must be performed.
Any faults occurring during operation are stored in the electronic unit for diagnostic
purposes.
Design
Three standard versions of the electronic control unit (ECU) are employed:
• Towing vehicle and bus: 446 220 100 0
• Trailer: 446 220 110 0
• Trailer Train: 446 220 110 0 ( by parameter adaptation, can be cascaded up to
5 times wit h20 modules each)
ECUs essentially differ by radio communication signal structure and CAN bus (ID)
connection. External distinguishing mark by type label only.
Further ECU types are tailored to specific customer requests and have other pin
assignments.
All ECUs are suitable for 12 or 24 volt operation and can be mounted on the vehicle frame.
Software change
ECUs produced after calendar week 43/07 already have new software installed.
The setting range for the reference pressure has been extended downward to between 3 and 10.5 bar. The software change allows the reference pressure to be set
within certain tolerances on-board. Furthermore, it is also possible to measure the
signal quality of the radio contact to the wheel modules and to display them using
the diagnostic software. The new software allows different reference pressures to
be set per axle.
22
Components
OPTITIRE
Radio transmission
The ECU is mounted to chassis in central part of vehicle, so that perfect radio contact with all wheel modules and connection between trailer ECU and towing vehicle
ECU is ensured. You should use special brackets for good radio contact.
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fig. 4-5:
Bracket 960 901 050 4
Radio contact is provided by antenna integrated in the control unit housing that
guarantees pressure signal reception from all wheel modules even under most difficult operating conditions.
4.4
The display
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fig. 4-6:
Display 446 221 000 0
The display serves for showing and checking all necessary information on the
OPTITIRE system. It is connected to ECU via CAN bus. Supply voltage may be 12
or 24 volt.
All tire pressures can be queried by push of a button (Manometer button). Manual
checks of the tire pressure are superfluous. Faulty tire pressures should be corrected directly via tire inflation valve.
Since warnings are also signalised acoustically the display does not need to be installed within driver's direct field of vision. Optical warning messages display by integrated lights: red (stop immediately) and amber (drive slowly).
For other instructions of operating the display, see chapter 5 "Operation", page 28.
The display is available in the standard version 446 221 000 0 and under
446 221 100 0 as special version for Portal lifting wagons.
23
4
4.5
OPTITIRE
Components
Connecting cable
Connection OPTITIRE to vehicle wiring on towing vehicle / bus performed in two
sections:
The first section comprises the connection of the ECU to the distribution element in
the vicinity of the driver's workplace. This section is splash-proof allowing external
installation on vehicle.
The second section is a cable set designed for interior installation only and distribution to display, diagnosis interface and, using the free cable ends, to the terminals
of vehicle wiring from coupling of first cable is made from here.
Basic wiring principle for towing vehicle / bus is displayed in the following illustration. As cable are based on IVTM connector a suitable cable adapter 894 600 001
2 must be included.
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fig. 4-7:
Wiring of towing vehicle
A Display
B Diagnosis
C Vehicle electric system
D ECU
24
external
inside
Pin No.
Connector pin assignment
Cable colour 5-pin
Cable colour 7-pin
CAN High
CAN Low
GND
blue
blue
+24 V or 12 V
red
red
Ignition
amber & grey
grey
Stop light / warning lamp 2
amber
Components
Pin No.
Connector pin assignment
Warning lamp 1
OPTITIRE
Cable colour 5-pin
Cable colour 7-pin
green
Table: 4-2: Cable set assignment
Connection to +12 V/24 V and ignition to be fused through 5 ampere fuses. Since
OPTITIRE has low current consumption an existing fused circuit can be used.
25
4
OPTITIRE
Components
Cable set towing vehicle, 7-pin
The 7-pin wiring is implemented to match cable set 894 607 390 0, see figure 4-7
"Wiring of towing vehicle", page 24. Pin assignment on the connecting plugs corresponds to the 5-pin variant. In addition, either connection to stop light (for synchronising with trailer ECU) and warning lamp or connection of two warning lamps is
possible.
Cable set towing vehicle, 5-pin
Simpler wiring is intended as 5-pin variant for bus retrofitting: 894 607 295 0. Employment of this wiring allows driving of warning lamps inside display or via CAN
respectively but not separate warning lamps on dashboard.
Cable set, trailer
Information about the different interconnections with CAN-enables systems (with
TEBS or TCE), see chapter 3.3 "Configuration for bus and towing vehicle", page 11
and see chapter 3.4 "Configuration for trailers ", page 13.
Cable set 449 674 273 0 should be used if data transmission is made through wireless connection only, see figure 4-8 "Trailer wiring", page 26.
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fig. 4-8:
Trailer wiring
A ECU
B Brown: Ground
C Red: +12 V/24 V
D White: Stop light
Diagnosis
Diagnostic cable
Cable 446 300 348 0 connects diagnostic connector on vehicle with Diagnostic Interface during diagnosis. More information on the subject of "Diagnosis" see chapter 7.1 "Diagnosis", page 45.
26
Components
4.6
OPTITIRE
Connecting tube
The wheel modules WM2 must be continuously connected to tires for sensing tire
pressures. Use WABCO pre-assembled PA tubes for this purpose. The connection
does not have to be disconnected for inflating the tires as valves for inflating the
tire are located on the wheel modules.
Depending on wear situation, a replacement of the PA tube is recommended after
1,000,000 km.
Various types of PA tubes are illustrated in the chart:
Order Number
Figure
Order Number
960 731 800 0
960 731 810 0
960 731 801 0
960 731 811 0
960 731 802 0
960 731 812 0
960 731 803 0
960 731 816 0
960 731 804 0
960 731 822 0
960 731 808 0
960 731 827 0
Figure
Table: 4-3: Connecting tube
Check PA tubes frequently for damages and replace them if necessary.
Replace defective hose connections with PA tubes. At the same time, install a new
wheel module type II, see chapter 7.5 "Replacing wheel module I with wheel module II", page 48.
Vehicles with OE equipment
Rubber hoses can be fitted in vehicles installed with OE equipment. Before replacing the hoses, observe the release notes of the manufacturer.
Valve extension
Do not use valve extensions made of plastic
Do not use plastic valve extensions. These will not remain tight under permanently
existing pressure.
27
5
OPTITIRE
Operation
Operation
In this chapter, the handling of the OPTITIRE system is described by means of the
WABCO display.
Additionally installed warning lamp indicates the same warning like the display.
Please refer to manufacturer's operating instructions when operating by means of
an integrated display.
5.1
Warning signals
Different alarm levels are indicated. The colour of the signal lam and the type of
audio signal indicate the severity of the fault:
• A red warning lamp (STOP) and audio warnings at one minute intervals indicate a severe fault and the vehicle must be stopped immediately (potential danger for persons and vehicle).
• A yellow warning lamp (turtle) and audio warning signals at 10 minute intervals indicate a more minor fault; the vehicle speed should be reduced and the
tire pressure corrected at the first opportunity.
The faults detected by OPTITIRE are saved in the ECU for diagnostic purposes.
5.2
Switch on of ignition
After ignition is switched on, system performs an internal check procedure where
all internal functions are tested. All symbols are displayed for one second, all pilot
lights and audio signals are enabled. This procedure is repeated twice.
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fig. 5-1:
28
Initialisation
Operation
OPTITIRE
After initialisation, if tire pressures are within specified values, the following picture
will show for a few seconds:
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fig. 5-2:
System check
The display will change to normal mode if all pressures are correct.
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fig. 5-3:
5.3
Normal mode
Checking pressure values
Proceed as follows to display the pressure values of the individual tires:
– Push left button.
The axle of which the pressures are displayed, is marked on the display.
Left pressure value on the display corresponds to left tire in driving direction.
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fig. 5-4:
Requesting the pressure values
– Repeatedly push left button to display pressure values of further axles.
Axles with twin tires have their wheels represented outside and inside one
after the other.
29
5
OPTITIRE
Operation
– Repeatedly push left button to display the axles of the towing vehicle as well the
axles of the towing vehicle.
The display will switch back to normal mode if no button has been pushed for a
period of 20 seconds.
5.4
Display of faults
When the OPTITIRE detects a fault, an amber or red warning lamp illuminates.
Proceed as follows to display the type of fault on the vehicle:
– Push right button after lighting up of amber or red warning lamp.
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 current defect is found the system does not react to pressing right button.
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fig. 5-5:
Display of faults
If the system warns about several tires then the tire with the most serious fault is
indicated first.
Repeated pressing of right button will show further faults.
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fig. 5-6:
Creeping pressure loss
The individual fault types are shown in the following:
30
Operation
Error
Displayed
1. Extremely low pressure
2. Low pressure
3. Creeping pressure
loss
4. High pressure
OPTITIRE
Action
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The file may
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correct file and
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The link ed
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The file may
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deleted. Verify
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points to the
correct file and
location.
The link ed
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The file may
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deleted. Verify
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points to the
correct file and
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The file may
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The file may
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The file may
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–
–
–
Stop the vehicle immediately.
Look for the cause.
If necessary, also change the tire.
–
–
Reduce your driving speed.
Adjust air pressure at the next opportunity.
–
–
–
–
Reduce your driving speed.
Stop the vehicle at the next opportunity.
Look for the cause of the pressure loss.
If necessary, also change the tire.
–
–
–
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.
–
Table: 5-1: Fault type overview
5.5
Adjusting tire pressures
Proceed as follows to adjust the tire pressures on the vehicle:
Do not adjust tire pressure with the ignition switch on - this may cause faulty warning messages on display.
– Turn off the ignition.
– Adjust air pressure.
– Switch on ignition again.
If leakage warning has been active, reset on display and stored on diagnostic
memory of the ECU.
5.6
Display of System Errors
If "OPTITIRE" is represented crossed out then there are one or more system faults.
System should be checked in the workshop.
31
5
OPTITIRE
Operation
No reception
Marked wheel has not transmitted pressure value for over one hour. OPTITIRE has
stopped sending warning messages for this wheel, driver needs to check tire pressures on the wheel manually.
The link ed image cannot be display ed. The file may hav e been mov ed, renamed, or deleted. Verify that the link points to the correct file and location.
fig. 5-7:
No reception
Repair note
With an older system, the wheel module battery is exhausted. The wheel module
must be replaced.
– Replace the wheel module.
– Start operating the new wheel module using diagnostic software by setting a
new ID in the parameters.
If it is a newer system, the radio connection between the wheel module and the
ECU is disturbed.
– Remove any possible dirt.
– Select a better attachment location for the ECU.
Additional information see chapter 7 "Workshop instructions", page 44.
System failure
System faults are given if display shows crossed-out "OPTITIRE" only.
OPTITIRE does not signal warning messages for any wheel. The driver must
check the tire pressures manually on the wheel.
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fig. 5-8:
System error
Repair note
– Check the supply voltage of the ground line.
– Check the cable connections.
– Carry out a system diagnosis.
32
Operation
5.7
OPTITIRE
Operation via SmartBoard
OPTITIRE can be controlled via the WABCO SmartBoard. The SmartBoard can be
used to operate OPTITIRE as a stand-alone variant for trailers.
– On the SmartBoard select the functional group "Tire pressure monitoring".
The pressures for the individual tires, the nominal tire pressure value and the configuration are displayed in this functional group.
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The key  is used to switch between the different tires.
The tire symbol flashes if the tire pressure is too low.
If the tire has a fault, the warning LED and the menu item for this functional group
flashes in the main menu.
Notation
Description
Note
Nominal pressure value
The nominal pressure value
is set in the parameters of
the OPTITIRE electronic
control unit.
The value applies to a cold
tire.
The link ed image cannot be display ed. The file may hav e been mov ed, renamed, or deleted. Verify that the link points to the correct
file and location.
Currently saved pressure for
the selected tire.
33
6
OPTITIRE
Installation
Installation
In this chapter, you will learn how the OPTITIRE is installed your vehicle.
Observe all safety instructions when carrying out assembly work on the vehicle.
WARNING
Regulations / Instructions
– Observe the occupational health and safety regulations of the respective country, the workshop as well as the vehicle manufacturer's instructions.
WARNING
Rolling away of the vehicle
Vehicles not secured may roll away during the assembly. This might lead to severe
injuries or even death.
– Secure the vehicle against rolling away before carrying out work on the vehicle.
WARNING
Danger to health due to dust
Dust that are dangerous to health are generated when the rim is cleaned using
compressed air.
– For this purpose, do not clean the rims using compressed air.
WARNING
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.
34
Installation
6.1
OPTITIRE
Mounting the wheel modules – WM2
The vehicle does not need to be jacked up when only four wheel nuts are removed.
Assembly preparation
– Read the following chapter, see chapter 4.1 "Wheel module", page 18 and see
chapter 4.5 "Connecting tube", page 27.
– If necessary, also remove the rim protecting ring.
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fig. 6-1:
The link ed image cannot be display ed. The file may hav e been mov ed, renamed, or deleted. Verify that the link points to the correct file and location.
Front wheel with protective ring
fig. 6-2:
Front wheel with counterweight
Mounting the wheel module
– Loosen and remove two wheel nuts positioned next to each other near to the
valve.
– Check if the position of the wheel module is suitable for connecting to the PA
tube wheel module and the valve.
The PA tube should be able to be guided to the tire valve without stretching, upsetting deformation or twisting.
– Screw the wheel nuts back on.
– Remove the white protective cap from the pressure connection.
Mounting the counter weights
– Loosen and remove two wheel nuts that are exactly opposite from each other
(180°).
– Position the counterweight on the wheel bolts.
– Screw the wheel nuts back on.
Mounting the PA tube
CAUTION
Increased wear due to incorrect installation
With tubes that rest on the edge of enclosures, there is an increased wear due to
vibrations. This might lead to leakages.
– PA tubes need to be installed such that they neither exercise tensile or compressive stress on connections nor rest on the rim.
– Hold the PA tube with the connection to the tire valve.
– Hold the other end of the PA tube to the wheel module.
– Mark the position on the tube where the PA tube meets with the edge of the
wheel module (e.g. using adhesive tape).
– Cut the PA tube (960 731 800 0 to 960 731 802 0) to the required length when
necessary.
35
6
OPTITIRE
Installation
Also consider that the PA tube disappears to 20 mm in the connection. For this
purpose, the PA tube should be cut 20 mm after the marking.
Use a suitable right-angled cutting tool, such as those that are also used for
shortening plastic brake lines (see illustrations below).
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fig. 6-3:
Tube cutting tool for ø 4 to ø 12
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fig. 6-4:
Tube cutting tool for ø 4 to ø 22
– Mount the connecting tube to wheel module by inserting the end of the PA tube
into the wheel module opening.
After pressing with force, the PA tube is locked in position and can then only be
removed again after unscrewing the brass screw connection (V203).
– Using the marking, check if the PA tube has been pushed in until the stop.
– Pull on the PA tube to check if the PA tube has been inserted with a tight connection (approx. 20 N).
– Connect the PA tube to the tire valve.
– Tighten union nuts on the tire valve hand tight.
– Check that the connection is tight using a leakage indicating spray.
Make the wheel module ready for operation
– Tighten wheel nuts crosswise as per vehicle manufacturer's instructions.
– Re-tighten the rim protective ring if necessary.
Correct assignment of wheel module ID vs. connected wheel is essential for later
commissioning.
– Note position of installed wheel modules on a sheet of paper. Affix stickers with
wheel module ID codes next to the respective wheel module.
– Adjust tires to correct operating pressure according to vehicle manufacturer's
instructions.
– Note pertinent nominal pressure values per axle for later nominal pressure parameterisation through diagnostic.
– Check wheel nuts for tightness after 500 km.
WARNING
Risk of accidents due to loosening the fastening screws of the wheel module
The safe fixing of the wheel module is only possible when the wheel module housing has a tight fit to the bracket.
– Never loosen the fastening screws fixing the wheel module housing on the
bracket.
36
Installation
OPTITIRE
Valve extension
Do not use valve extensions made of plastic
Do not use plastic valve extensions. These will not remain tight under permanently
existing pressure.
Use flexible valve extensions with tightening clamps (e.g. alligator) or WABCO
valve extensions 960 731 805 0 instead.
The link ed image cannot be display ed. The file may hav e been mov ed, renamed, or deleted. Verify that the link points to the correct file and location.
fig. 6-5:
6.2
Twin wheels (outer wheel)
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fig. 6-6:
Twin wheels (inner wheel)
Mounting the wheel modules – WIS
For Tire assembly the vehicle must be secured properly.
Assembly preparation
– Read the following chapter, see chapter 4.2 "Wheel module", page 17
– If necessary, also remove the rim protecting ring.
Mounting the wheel module
–
–
–
–
Loosen and remove the tire
remove original filling valve
identify suitable filling valve for WIS sensors and place it into the hole
fix nut with 9..12Nm
screw in the WIS by applying the hollow screw included in set
apply torque of 4 Nm
Make the wheel module ready for operation
– Fix the wheel on the vehicle
- Tighten wheel nuts crosswise as per vehicle manufacturer's instructions.
– Re-tighten the rim protective ring if necessary.
Correct assignment of wheel module ID vs. connected wheel is essential for later
commissioning.
– Note position of installed wheel modules on a sheet of paper. Affix stickers with
wheel module ID codes next to the respective wheel module.
or readout ID with a suitable tool (e.g. Ateq VT36)
or follow sequential allocation with OptiTire diagnostic SW
37
6
OPTITIRE
Installation
– Adjust tires to correct operating pressure according to vehicle manufacturer's
instructions.
– Note pertinent nominal pressure values per axle for later nominal pressure parameterisation through diagnostic.
– Check wheel nuts for tightness after 500 km.
WARNING
Risk of accidents due to loosening the fastening screws of the wheel module
The safe fixing of the wheel module is only possible when the wheel module housing has a tight fit to the bracket.
– Never loosen the fastening screws fixing the wheel module housing on the
bracket.
38
Installation
9.3
OPTITIRE
Mounting the ECU in bus / towing vehicle
ECU position on vehicle
Towing vehicle
The ECU plug must point to side (to the right or left) but not up or down.
– Choose a fitting position according to the following illustration.
– If the vehicle is equipped with a low lying coupling for central axle trailer, install
the ECU on the right side of the vehicle, so that the wireless connection to the
trailer is not shielded of by the coupling.
The link ed image cannot be display ed. The file may hav e been mov ed, renamed, or deleted. Verify that the link points to the correct file and location.
fig. 6-7:
Assembly at longitudinal beam
39
6
OPTITIRE
Installation
Bus
The ECU plug must show up.
– Use threaded rods for hanging assembly at the roof frame in the cabin.
– Position ECU in solo bus in the vehicle's centre, on articulated bus in driving direction in front of the swivel joint.
Further possible installation positions are:
• in the roof rounding opposite to the entrances
• in the roof lining
• with articulated buses, in the rear area of the front section (in the geometric
centre of all axles)
• with touring coaches, also in the ceiling of the luggage compartment
Mounting the ECU
– Read the chapter, see chapter 4.2 "Electronic Control Unit (ECU)", page 21.
– Mount ECU so that the distance to the wheel modules is as equal as can be.
Select distance to truck driver's cab such that length of ECU cable (8 m) is sufficient to reach driver's cab.
– Attach ECU to roof area of bus and to bottom of frame on truck.
ECU longitudinal axis must be in parallel with longitudinal vehicle axis. Maintaining good radio contact the ECU should not be shielded off by metal walls in its
direct vicinity, e.g. by a U-section.
Ensuring optimal radio reception through the integrated antenna you particularly
need to leave out the longitudinal floor.
– Use bracket 960 901 050 4 see figure 4-5 "Bracket 960 901 050 4", page 23 on
towing vehicle. Screw the bracket to the vehicle.
Welding could impair the stability of the frame.
– Tighten ECU to bracket using torque of 15±1.5 Nm.
6.3
Wiring in towing vehicle/bus
Proceed as follows to install the wires of the OPTITIRE into the bus or the towing
vehicle:
– Read the chapter, see chapter 4.4 "Connecting cable", page 24.
– Select the appropriate circuit diagram according to the chapter, see chapter 3.3
"Configuration for bus and towing vehicle", page 11.
– Attach display to support supplied at 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 OPTITIRE".
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 with already existing wiring harnesses.
Form large loops from long lengths.
– Turn off the ignition.
– In the fuse box, search for appropriate fused circuits or connect 5 A fuses "on
the fly" to terminals 15 (ignition) and 30 (U Batt). Designate the flying fuses with
"OPTITIRE".
– Connect the cable set with the fuses. Connect the ground line to the ground
contact.
– Connect display and ECU.
40
Installation
6.4
OPTITIRE
Mounting the ECU in the trailer
– Read the chapter, see chapter 4.2 "Electronic Control Unit (ECU)", page 21.
– Determine the best possible installation position, depending on the type of the
trailer:
Draw-bar trailer
Install the ECU between the first axle and the middle of the trailer.
Semitrailer
Mount the ECU at the cross member in the front area, so that this is pointing to
the towing vehicle.
Central axle trailer
Mount the ECU at the right vehicle side ahead of the front axle.
Use bracket 960 901 050 4, see figure 4-5 "Bracket 960 901 050 4", page 23.
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 radio contact the ECU must not be shielded off by metal walls
in its direct vicinity.
The link ed image cannot be display ed. The file may hav e been mov ed, renamed, or deleted. Verify that the link points to the correct file and location.
fig. 6-8:
Semitrailer: Assembly at cross member
– Tighten ECU to bracket using torque of 15±1.5 Nm.
6.5
Wiring in trailer
Proceed as follows to install the wires of the OPTITIRE into the trailer:
– Read the chapter, see chapter 4.4 "Connecting cable", page 24.
– Select the appropriate circuit diagram according to the chapter, see chapter 3.4
"Configuration for trailers ", page 13.
– Fit the diagnostic socket to a suitable attachment location and label it with "Diagnostic OPTITIRE".
41
6
OPTITIRE
Installation
Locations where diagnostic ports are already located would be specially suitable as the attachment location.
– Install the cable joint box if required, such as, for example, the WABCO VCS II
cable joint box 446 010 092 2.
Also suitable is the AK 192 of Apparatebau Kirchheim-Teck GmbH & Co.
– Pull off the ABS plug.
Consider any risks with regard to the short circuiting of batteries inside the vehicle.
– Install cables according to the wiring diagram using cable ties in parallel with already existing wiring harnesses.
Form large loops from long lengths.
– Connect OPTITIRE cabling to existing cabling.
– Connect the ECU.
6.6
Start-up
Commissioning requires a system training course. You may ask WABCO for the
PIN (PIN 2) after the training course.
No WABCO diagnosis is possible on vehicles having integrated display. In this
case the OPTITIRE is basically parameterised through manufacturer-specific diagnosis.
Proceed as follows to put the diagnostic software of the OPTITIRE into operation:
Commissioning schedule:
– Make sure that the OPTITIRE system is installed according to the instructions in
chapter, see chapter 6 "Installation", page 34.
– Check for correctly set tire pressures on the wheel module.
– Connect the computer to the vehicle using the diagnostic cable and interface.
– Start the diagnostic software and enter Pin2.
– Switch on ignition. Ensure power supply of trailer if necessary.
– Start "Startup" menu in diagnostic program.
– Enter vehicle type and vehicle data.
– Enter IDs of wheel modules and values of tire pressure (according to vehicle
manufacturer) in list of axes and wheels.
– Stimulate the wheel modules.
- WM2: For this purpose, touch the housing of each wheel module below the
sticker "OPTITIRE" for 5 seconds using a magnet (2 kg retention force) or using
a bar magnet parallel to the OPTITIRE logo.
The wheel modules afterwards will transmit for the following hours their
pressures any 30 s.
- WIS: For this purpose apply a TPMS handtool like ATEQ VT36 with suitable diagnositc capability on the area where the sensor is mounted (near the filling
valve)
The wheel modules afterwards will transmit specific diagnostic mode for 5
min.
42
Installation
OPTITIRE
The link ed image cannot be display ed. The file may hav e been mov ed, renamed, or deleted. Verify that the link points to the correct file and location.
fig. 6-9:
–
–
–
–
–
–
–
–
Stimulation wheel module
Check if data has been received from all wheel modules.
Configure possible warning lamps.
Delete content of diagnostic memory.
Print the commissioning protocol.
Print the vehicle type plate on self-adhesive tin foil (WABCO no. 899 200 922 4).
Affix vehicle type plate to protected, easy readable location on the vehicle.
End the start-up in the diagnostic software.
Check operation on OPTITIRE display and data exchange with towing vehicle
respectively.
43
7
OPTITIRE
Workshop instructions
Workshop instructions
This chapter provides information for the repair. Furthermore, you will also receive
help in the case that the product does not function as expected. Please observe
the instructions for disposal at the end of the chapter.
WARNING
Regulations / Instructions
– Observe the occupational health and safety regulations of the respective country, the workshop as well as the vehicle manufacturer's instructions.
WARNING
Rolling away of the vehicle
Vehicles not secured may roll away during the assembly. This might lead to severe
injuries or even death.
– Secure the vehicle against rolling away before carrying out work on the vehicle.
WARNING
Danger to health due to dust
Dust that are dangerous to health are generated when the rim is cleaned using
compressed air.
– For this purpose, do not clean the rims using compressed air.
WARNING
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.
Maintenance
OPTITIRE system is maintenance-free.
Only when the display indicates a malfunction, fault finding must be performed with
diagnosis.
44
Workshop instructions
7.1
OPTITIRE
Diagnosis
Diagnostic components
The OPTITIRE diagnostic cable 446 300 348 0 is used for diagnosis on towing vehicles.
When carrying out diagnosis on trailers, please extract the product number of the
required diagnostic components from the chart.
System in trailer vehicles
Type of diagnosis
Required components
Vario C
VCS
ECAS
TCE
VCS II
TEBS before 2004
Diagnosis using diagnostic
cable 446 300 329 2
Diagnostic cable 446 300 329 2
TEBS since 2004
VCS II
Diagnosis via Diagnostic
Interface (serial)
446 301 021 0
Diagnostic Interface (serial)
446 301 021 0
CAN converter 446 300 470 0
Connection adapter ISO 7638
with CAN socket 446 300 360 0
TEBS since 2004
VCS II
Diagnosis via Diagnostic
Interface (USB)
446 301 022 0
Diagnostic Interface (USB)
446 301 022 0
Diagnostic cable 446 300 361 0
Connection adapter ISO 7638
with CAN socket 446 300 360 0
TEBS E Premium (Diagnostic port with yellow
cap)
Diagnosis via Diagnostic
Interface (USB or serial)
Diagnostic Interface (USB or
serial)
Diagnostic cable 446 300 348 0
Table: 7-1: Diagnostic components for trailer vehicles
Diagnostic Software
The diagnostic software is available in various languages.
Information concerning the current version of the diagnostic software and language
versions available can be obtained at
https://www.am.wabco-auto.com/mywabco/.
The WABCO diagnostic software is self-explanatory. The function of the diagnostic
software is described in help texts.
The diagnostic memory and current measuring data can be obtained using the diagnostic software. In the event of malfunctions, the fault will be described and possible countermeasures will be indicated.
The ECU settings can not be changed in diagnostic mode. Entering a PIN is required for the parameter settings.
45
7
7.2
OPTITIRE
Workshop instructions
Wheel Changes
Due to the external fixation of the wheel modules on the wheel bolts after wheel
change a new sensor is not needed. It is only to be ensured, that after wheel exchange the wheel module is fitted exactly to the same position as before.
As long as the wheel module itself is not exchanged, there is no need for new settings of system parameters.
The wheel modules are not allowed to be swapped with each other.
Make sure that the wheel modules are respectively located in the same position on
the vehicle after the wheel change.
Especially with dual tires, the accurate relationship to the inner or outer wheel must
be observed.
Please perform wheel changes as follows:
– Remove any dirt from the wheel module and PA tube.
– Note ID code of wheel module (engraved on top of the housing) and its position
on the vehicle, e.g. rear axle left, outside.
Alternative: Fix a plate with the description of the location to each module.
– Release the union nut of the PA tube on the tire valve and remove the PA tube
from the tire valve.
– Unscrew firstly only those wheel nuts fixing wheel module(s).
– Remove wheel module completely, together with the PA tube.
Do not turn the PA tube at the wheel module and do not remove the PA tube
from wheel module unnecessarily.
Prevent dirt from entering into the PA tube.
– Check the PA tube for any damage.
Replace the PA tube if ageing ruptures or rubbing wear is visible, see chapter 7.3 "Replacing PA tubes", page 47.
– Now remove the residual wheel nuts and change the wheel or the tire.
– Put on the wheel or the wheels again and fix them with some wheel nuts on
wheel bolts not used to fix wheel module or counterweight.
– While assembling 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 wheel module to its original position and fix it with wheel nuts.
With individual wheels, assemble the counterweight in the opposite of the wheel
module.
– Screw the union nut of the hose back on to the tire valve. Tighten union nuts
manually only.
– Check that the connection is tight using a leakage indicating spray.
– Tighten wheel nuts crosswise as per vehicle manufacturer's instructions.
46
Workshop instructions
7.3
OPTITIRE
Replacing PA tubes
Proceed as follows when replacing a defective PA tube:
– Loosen the PA tube from the valve.
– Unscrew the V203 connection together with the PA tube from the wheel module.
When removing the PA tube from the wheel module, take care that the thread on
the wheel module is kept clean.
– Check the thread on the wheel module for damage.
With damaged thread, replace the complete wheel module.
– Screw the new V203 connection into the thread of the wheel module.
A new V203 connection can be obtained using the WABCO product number
893 770 005 2.
The link ed image cannot be display ed. The file may hav e been mov ed, renamed, or deleted. Verify that the link points to the
correct file and location.
fig. 7-1:
–
–
–
–
–
–
–
–
7.4
VOSS SV 203 connection
Tighten the V203 connection with a torque of 3 Nm (hand tight).
Remove the protective cap of the V203 connection.
Insert the new, cut to length PA tube (see page 35) 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 using a leakage indicating spray.
Replacing hose connections
– Replace defective hose connections with PA tubes.
– At the same time, install a new wheel module type II, see chapter 7.5 "Replacing wheel module I with wheel module II", page 48.
47
7
7.5
OPTITIRE
Workshop instructions
Replacing wheel module I with wheel module II
Always replace wheel module I with wheel module II.
Replace the rubber hoses with PA tubes at the same time.
Vehicles with OE equipment
Rubber hoses can be fitted in vehicles installed with OE equipment. Before replacing the hoses, observe the release notes of the manufacturer.
The following table facilitates the replacement.
You will obtain further information on the use of wheel module II on our website
http://www.wabco-auto.com => WABCO online product database INFORM. Enter
the search term "OPTITIRE" in the input field. Open the application table.
In this table, the rims are sorted according to their attachment location, size and
manufacturer. Next to an illustration of the respective installation situation, you will
also be provided with the product number of the wheel module and connecting
tube.
7.6
Wheel module I
Wheel module II
960 730 001 0(Independent wheel)
960 731 011 0
960 730 001 0 (twin tires, Super Single)
960 731 031 0
960 730 006 0 (Independent wheel)
960 731 021 0
960 730 006 0 (twin tires, Super Single)
960 731 041 0
960 730 013 0
960 731 061 0
960 730 037 0
960 731 019 0
Creeping pressure loss
– When the display hints to a creeping pressure loss, first check the hose connection between valve and wheel module of the relevant wheel with leakage indicating spray.
– If these connections are tight, check bearing surface and edges.
So-called indicators at the tire edges point on damages at the carcass, which
usually causes creeping pressure loss of the wheel.
If the carcass is damaged, the tire must be replaced.
48
Workshop instructions
7.7
OPTITIRE
No reception of the wheel module
Battery life
Wheel modules get their power supply via an internal lithium battery. In reason of
the mechanical demands and tightness, the battery is coated within the wheel
module and cannot be exchanged. The battery life-time depends on certain factors.
Under usual circumstances the life-time will be longer than 5 years.
Since significant pressure deviation increases transmission frequency for shortterm warning, frequent pressure changes cause a shorter life time.
Check list
– If the warning "no reception wheel module" is repeated often in the display, see
figure 5-7 "No reception", page 32, using the check list, you are able to determine if the wheel module should be replaced.
– Copy in this table line per line the default value to the result column if the description matches.
– Then compare the sum of all results with the details below.
Ensure while trouble shooting that the vehicle is not in vicinity of high-frequency
radiation, see chapter 4.1 "Wheel module", page 18.
49
7
OPTITIRE
Workshop instructions
No. Description
Default Result
1a
Warning "no reception" is not active but stored in diagnostic
memory (failure shown blue in diagnosis)
1b
Warning "no reception" is active (failure shown in red in diagnosis)
2a
Warning "no reception" is given for one wheel module
2b
Warning "no reception" is given for several wheel modules
3a
The age of the wheel module (according to the engraved production date in format ww/yy) is less than 5 years
3b
The age of the wheel module lies between 5 and 7 years
3c
The age of the wheel module is more than 7 years
4a
The average outside temperature was -20 ° C while occurrence of
the failure
4b
The average outside temperature was 0 ° C while occurrence of the 3
failure
4c
The average outside temperature was +20 ° C while occurrence of
the failure
5a
The activation of the wheel module with bar magnet, see figure 6-9
"Stimulation wheel module", page 43, was successful
5b
The activation of the wheel module with bar magnet was not successful
Sum
Table: 7-2: Check list wheel module
Test results
Sum between 0 and 11 points
The battery of the wheel module is in order. The loss of the wheel module from
time to time might be caused by deep temperature, contamination of wheel module
/ ECU or a not optimised installation position of the ECU.
Sum between 12 and 15 points
– Monitor the correct reception of the wheel module and replace as required.
Sum between 16 and 22 points
Battery of wheel module exhausted.
– Replace wheel module with a new one.
– Parameterise ID of the new module to the ECU via diagnosis.
50
Workshop instructions
7.8
OPTITIRE
Disposal
The link ed image cannot be display ed. The file may hav e been mov ed,
ren amed, or deleted. Verify that the link points to the correct file and
location.
The system components are electronic scrap and must not be
disposed of together with domestic waste. When disposing
components, observe all the laws and regulations applicable in
your country.
This applies in particular to wheel modules 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 wheel modules 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 WABCO sales partner about this.
51
Founded over 140 years ago, WABCO continues to pioneer breakthrough electronic, mechanical and
mechatronic technologies for braking,
stability and transmission automation
systems supplied to the world’s leading commercial truck, bus and trailer
manufacturers.
With sales of $2.8 billion in 2011,
WABCO is headquartered in Brussels,
Belgium. For more information, visit
http://www.wabco-auto.com
© 2013 WABCO All rights reserved. 815 010 045 3/02.2013
WABCO (NYSE: WBC) is a leading
global supplier of technologies and
control systems for the safety and
efficiency of commercial vehicles.

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