WABCO TEBS E User manual

TEBS E
VERSIONS E0 TO E4
SYSTEM DESCRIPTION

TEBS E
Electronic braking systems
for trailers
(versions TEBS E0 to E4)
System Description
Edition 7
This publication is not subject to any update service.
You will find the current version at
http://www.wabco.info/8150100933
© 2014 WABCO Europe BVBA – All rights reserved
The right of amendment is reserved.
Version 2/01.2014(en)
815 010 093 3

TEBS E
4
Abbreviations
ABS Anti-Lock Braking System
ADR (French: Accord européen relatif au transport international des marchandises Dangereuses par
Route); European agreement concerning the carriage of dangerous goods by road
BO Factory regulations; BO force circuit = legally defined turning circuit
BVA (German: Bremsbelagverschleißanzeige); Brake lining wear indicator
ELEX Electronic Extension Module
ESD Electrostatic Discharge
eTASC Electronic Trailer Air Suspension Control (Rotary slid valve with RTR function) and ECAS function
GGVS Act governing the road haulage of hazardous goods
GIO Generic Input/Output; programmable input/output
IR (German: Individual-Regelung); Individual control; individual control of sensed wheels on one side
ISS Integrated Speed Switch
LACV-IC Lifting Axle Control Valve, impulse controlled
LIN Local Interconnect Network; specification for a serial communication system, also LIN bus, interface
for the sensors
LSV Load Sensing Valve
MAR (German: Modifizierte Achs-Regelung); Modified axle control; Control of two sensed wheels on one
axle
MSR (German: Modifizierte Seiten-Regelung); Modified side control; Control of two sensed wheels on one
vehicle side
ODR Operating Data Recorder
PEM Pneumatic Extension Module
PLC Power Line Communication; Data communication via cable for power supply
PREV Park Release Emergency Valve
PWM Pulse Width Modulation; modulation type where a technical quantity (e.g. electric current) modulates
between two values
RSS Roll Stability Support; control for vehicle stability
RTR Return To Ride (air suspension)
SHV Select High Valve; Valve for providing the higher pressure
SLV Select Low Valve; Valve for providing the lower pressure
StVZO (German: Straßenverkehrs-Zulassungs-Ordnung); German motor vehicle construction and use regu-
lations; (valid in Germany)
TASC Trailer Air Suspension Control (Rotary slid valve with RTR function)
TEBS Electronic Braking System for trailers
TLI Trailer Length Indication; ‘Current vehicle length’
TT Timer Ticks; internal measurement unit of the height sensors
USB Universal Serial Bus

Table of Contents
TEBS E
5
1Disclaimer ............................................................................................................................... 8
2Symbols used ......................................................................................................................... 9
3Safety information................................................................................................................ 10
4Introduction........................................................................................................................... 12
4.1 System design............................................................................................................ 14
4.1.1 braking system ........................................................................................................... 14
4.1.2 Braking system with conventional air suspension...................................................... 15
4.1.3 Electronically controlled air suspension system (ECAS) ........................................... 17
4.2 Overview of functions................................................................................................. 19
5braking system ..................................................................................................................... 22
5.1 System design............................................................................................................ 22
5.2 Scope of application................................................................................................... 22
5.3 Expertise and standards ............................................................................................ 23
5.4 ABS configurations..................................................................................................... 24
5.5 Description of the components of the electropneumatic braking system................... 29
5.6 Components of the TEBS E Modulator...................................................................... 31
5.7 Supply ........................................................................................................................ 32
5.7.1 Function test when switching on or coupling ............................................................. 32
5.7.2 Power supply via stop light (24N)............................................................................... 32
5.7.3 Multi-Voltage .............................................................................................................. 33
5.8 System monitoring...................................................................................................... 35
5.8.1 Warnings and system messages ............................................................................... 35
5.8.2 Pneumatic redundancy .............................................................................................. 37
5.9 Brake functions........................................................................................................... 38
5.9.1 Nominal value detection............................................................................................. 38
5.9.2 Load Sensing Valve (LSV) ......................................................................................... 40
5.9.3 Pressure control ......................................................................................................... 44
5.9.4 Overload protection....................................................................................................45
5.9.5 Anti-Lock Braking System (ABS) ............................................................................... 46
5.9.6 Roll Stability Support (RSS) ....................................................................................... 47
5.9.7 Standstill function ....................................................................................................... 48
5.9.8 Emergency braking function....................................................................................... 49
5.9.9 Test mode .................................................................................................................. 49
5.10 ECU-internal functions ............................................................................................... 50
5.10.1 Odometer ................................................................................................................... 50
5.10.2 Service signal ............................................................................................................. 51
5.10.3 ServiceMind................................................................................................................ 51
5.10.4 Axle load output.......................................................................................................... 52
5.10.5 Notebook function ...................................................................................................... 54
5.10.6 Operating data record (ODR)..................................................................................... 54
6GIO functions........................................................................................................................ 58
6.1 Lifting axle control ...................................................................................................... 59
6.2 Tag axle control with residual pressure maintenance................................................ 63
6.3 Integrated electronically controlled air suspension system (ECAS) .......................... 64
6.3.1 Nominal level control.................................................................................................. 69
6.3.2 Normal level ............................................................................................................... 70

TEBS E Table of Contents
6
6.3.3 Green warning lamp ...................................................................................................72
6.3.4 Temporary deactivation of automatic level control.....................................................73
6.4 Speed switch (ISS 1 and ISS 2) and RTR .................................................................75
6.5 RSS active signal (TEBS E2 or higher)......................................................................77
6.6 ABS active signal (TEBS E2 or higher)......................................................................77
6.7 Traction help...............................................................................................................78
6.8 External axle load sensor ...........................................................................................81
6.9 Dynamic wheelbase control .......................................................................................82
6.9.1 Manoeuvering assistance (OptiTurnTM)......................................................................82
6.9.2 Drawbar load reduction (OptiLoadTM).........................................................................84
6.9.3 Connecting the components.......................................................................................85
6.10 Forced lowering and deactivation of the lifting axle function......................................89
6.11 Brake lining wear indicator .........................................................................................91
6.12 Power supply and data communication on GIO5.......................................................93
6.13 Speed signal...............................................................................................................94
6.14 Steady positive voltage 1 and 2 .................................................................................95
6.15 Road finisher brake ....................................................................................................96
6.15.1 Proximity switch..........................................................................................................99
6.16 Trailer Extending Control..........................................................................................101
6.17 Current vehicle length (Trailer Length Indication) (as of version TEBS E4) ............103
6.18 Tilt warning (Tilt Alert) ..............................................................................................105
6.19 Overload detection ...................................................................................................107
6.20 SafeStart...................................................................................................................108
6.21 Electronic parking brake (with version TEBS E4 or higher) .....................................110
6.22 Relaxation function (Bounce Control).......................................................................112
6.23 Steering axle lock .....................................................................................................113
6.24 Forklift control ...........................................................................................................115
6.25 Brake release function..............................................................................................117
6.26 Emergency stop light (Emergency Brake Alert) .......................................................118
6.27 Immobilizer ...............................................................................................................120
6.28 Freely configurable functions ...................................................................................125
7External systems ................................................................................................................126
7.1 Electronic expansion module (ELEX).......................................................................126
7.1.1 TailGUARD functions ...............................................................................................127
7.1.2 Connection from ISO 12098.....................................................................................133
7.1.3 Battery supply and battery charging.........................................................................134
7.2 Trailer Remote Control .............................................................................................136
7.3 External ECAS..........................................................................................................137
7.4 Trailer Central Electronic..........................................................................................138
7.5 Tire pressure monitoring system (IVTM)..................................................................139
7.6 Telematics (TrailerGUARD) .....................................................................................141
8Installation notes for vehicle installation and retrofitting ..............................................142
8.1 Data on the TEBS E Modulator................................................................................142
8.2 Connections..............................................................................................................144
8.3 Installation in vehicle ................................................................................................145
8.3.1 RSS installation regulation .......................................................................................146

Table of Contents
TEBS E
7
8.4 Cable installation / Cable fastening.......................................................................... 148
8.5 Installation height sensor ......................................................................................... 150
8.6 Installation of Immobilizer components.................................................................... 152
8.7 Installation of Trailer Remote Control....................................................................... 152
8.8 Installation of TailGUARD components ................................................................... 153
8.9 Installation of eTASC ............................................................................................... 164
9Start-up................................................................................................................................ 165
9.1 Parameter definition with TEBS E Diagnostic Software .......................................... 165
9.2 Functional test .......................................................................................................... 166
9.3 Start-up of the LIN ultrasonic sensors...................................................................... 167
9.4 Calibrate the height sensors .................................................................................... 169
9.4.1 Calibration for vehicles with mechanical suspension............................................... 170
9.5 Documentation ......................................................................................................... 171
10 Operation............................................................................................................................. 172
10.1 Warning messages .................................................................................................. 172
10.2 Operation with Trailer Remote Control..................................................................... 172
10.3 Operation of ECAS level control .............................................................................. 180
10.4 Operation of traction help.........................................................................................182
10.5 Operation OptiLoad / OptiTurn................................................................................. 182
10.6 Lifting axles operation .............................................................................................. 183
10.7 Operating the Immobilizer ........................................................................................ 183
11 Workshop notes .................................................................................................................184
11.1 Maintenance............................................................................................................. 184
11.2 System training and PIN .......................................................................................... 184
11.3 Diagnostic Hardware................................................................................................ 185
11.4 Tests / Simulations................................................................................................... 186
11.5 Replacement and repair........................................................................................... 188
11.6 Tuning the vehicle .................................................................................................... 190
11.7 Disposal / Recycling................................................................................................. 192
12 Appendix ............................................................................................................................. 193
12.1 Pneumatic ports for TEBS E .................................................................................... 193
12.2 Pin assignment TEBS E Modulators and ELEX....................................................... 195
12.3 Cable overview......................................................................................................... 201
12.4 GIO diagram............................................................................................................. 210
12.5 Brake diagram .......................................................................................................... 212
Index.......................................................................................................................................... 217

1 TEBS E
Disclaimer
8
1 Disclaimer
We assume no liability for the correctness, completeness or actuality of the infor-
mation in this document. All technical information, descriptions and images are ap-
plicable for the day of printing this document or respective supplements. We retain
the right to any changes as a result of continuous further development.
The content of this document provides no guarantees nor warranted characteristics
nor can it be construed as such. Liability for damages is strictly excluded, as long
as there has been no respective intention or gross negligence on our part or any
forced legal provisions in opposition.
Text and graphics are subjected to our utilisation rights, copying or distribution in
any form require our approval.
Any brand markings, even if not indicated as such, are subject to the rules of the
labelling rights. If legal disputes arise from the utilisation of the information in this
document, these are exclusively to be handled under the regulations of national
law.
In so far as components or individual formulations of this applicable legal status
documentation are no longer or not fully relevant, the remaining parts of the docu-
mentation remain unaffected thereby in their content and validity.

TEBS E 2
Symbols used
9
2 Symbols used
WARNING
Potential hazard situation which can cause death or serious personal injury if the
safety instruction is not observed.
CAUTION
Potential hazard situations that can cause minor or moderate personal injury if the
safety instruction is not observed.
Important instructions, information, or tips that you should always observe.
Reference to information on the Internet
• List
– Step
Consequence of an action
TEBS E version The system comprises:
• TEBS E as of version 0 (July 2007)
• TEBS E as of version 1 (September 2008)
• TEBS E as of version 1.5 (December 2009)
• TEBS E as of version 2 (November 2010)
• ELEX as of version 0 (November 2010)
• TRC as of version 0 (November 2010)
• TEBS E as of version 2.5 (January 2012)
• ELEX as of version 1 (January 2012)
• TRC as of version 1 (January 2012)
• TEBS E as of version 4 (January 2014)
• ELEX as of version 2 (January 2014)

3 TEBS E
Safety information
10
3 Safety information
Observe all required regulations and instructions:
– Read this publication thoroughly.
Adhere to all instructions, information and safety information to prevent injury to
persons and damage to property.
WABCO will only guarantee the security, reliability and performance of their
products and systems if all information in this publication is adhered to.
– Make sure to follow the specifications and instructions of the vehicle manufac-
turer.
– Maintain all accident regulations of the business as well as regional and na-
tional regulations.
Make provisions for a safe work environment:
Only trained and qualified technicians are to perform any work on the vehicle.
– Use personal protective equipment if required (protective goggles, respiratory
protection, ear protectors, etc.).
Pedal actuations can lead to severe injuries if persons are in the vicinity of the ve-
hicle. Make sure that pedals cannot be actuated as follows:
– Switch the transmission to ‘neutral’ and actuate the park brake.
– Secure the vehicle against rolling with chocks.
– Fasten a visible note to the steering wheel indicating the work is being per-
formed on the vehicle and that the pedals are not to be actuated.
Avoid electrostatic charge and uncontrolled discharging (ESD):
Note during construction and building the vehicle:
– Prevent potential differences between components (e. g. axles) and the vehicle
frame (Chassis).
Make sure that the resistance between metallic parts of the components to the
vehicle frame is lower than 10 Ohm.
Connect moving or insulated vehicle parts such as axles electrically conductive
with the frame.
– Prevent potential differences between the towing vehicle and the trailer.
Make sure that an electrically conductive connection is made between metal
parts in the towing vehicle and the coupled trailer via the coupling (king pin, fifth
wheel, claws with pins), even without a cable being connected.
– Use electrically conductive bolted connections when fastening the ECUs to the
vehicle frame.
– Run the cable in metallic casing if at all possible (e. g. inside the U-beam) or
behind metallic and grounded protective plating, to minimise the influence of
electro-magnetic fields.
– Avoid the use of plastic materials if they can cause electrostatic charging.
– For electrostatic painting, connect the ground line of the ISO 7638 plug connec-
tion (pin 4) to the paint ground (vehicle chassis).
Note during repair and welding work on the vehicle:
– Disconnect the battery - if installed in the vehicle.
– Disconnect cable connections to devices and components and protect the plug-
ins and connections from contamination and humidity.
– Always connect the grounding electrode directly with the metal next to the weld-
ing position when welding, to prevent magnetic fields and current flow via the
cable or components.
– Make sure that current is well conducted by removing paint or rust.
– Prevent heat influences on devices and cabling when welding.