WABCO TP0735 User manual

INSTALLING TIRE INFLATION
SYSTEMS COMPATIBLE
WITH WABCO TRAILER ABS
INSTALLATION INSTRUCTIONS
TP0735

3
Table of Contents
Table of Contents
1 General Information. ...................................................................................................................................................5
1.1 Symbols Used in this Document ........................................................................................................................5
1.2 How to Obtain Additional Maintenance, Service and Product Information.........................................................6
1.3 How to Obtain Parts and Kits.............................................................................................................................6
1.4 WABCO TOOLBOX PLUS™ Software ..............................................................................................................6
1.5 WABCO Academy..............................................................................................................................................6
1.6 WABCO Online Product Catalog .......................................................................................................................6
1.7 Your Direct Contact to ZF CVS ..........................................................................................................................7
2 Safety Information.......................................................................................................................................................8
2.1 Provisions for a safe work environment .............................................................................................................8
3 Introduction. ................................................................................................................................................................9
4 Installation. ................................................................................................................................................................10
4.1 InstallationofMeritorTireInationSystem ......................................................................................................10
4.2 InstallationofCompatibleTireInationSystems(HendricksonTiremaaxTireInationSystem
andSTEMCOAerisTireInationSystem).......................................................................................................13
4.3 ActivatingtheTireInationSystemwithTOOLBOX™Software .....................................................................15
5 TireInationCommunicationSystemTroubleshooting. ......................................................................................17
6 Appendix I..................................................................................................................................................................19
6.1 InstallingSensorsonNon-ABS-PreppedAxles ...............................................................................................19
7 Appendix II.................................................................................................................................................................21
7.1 Cable Strain Relief Guidelines .........................................................................................................................21
8 Appendix III................................................................................................................................................................26
8.1 Vehicle Electrical Grounding Guidelines..........................................................................................................26

Edition 1
Version 2 (03.2022)
TP0735 (en)
This publication is not subject to any update service. Information contained in this
publication was in effect at the time the publication was approved for printing and is
subject to change without notice or liability. ZF CV Systems North America LLC reserves
the right to revise the information presented or to discontinue the production of parts
described at any time.
Youwillndthecurrenteditionat:https://zf.com/cvliterature

1 General Information
1.1 SymbolsUsedinthisDocument
DANGER
Description of an immediate situation which will result in irreversible injury or death if the warning is
ignored.
WARNING
Description of a possible situation which may result in irreversible injury or death if the warning is
ignored.
CAUTION
Description of a possible situation which may result in irreversible injury if the warning is ignored.
NOTICE
Description of a possible situation which may result in material damage if the warning is ignored.
Importantinformation,noticesand/ortips
Reference to information on the Internet
Descriptivetext
– Action step
1. Actionstep1(inascendingorder)
2. Actionstep2(inascendingorder)
ÖResult of an action
• Listing
Indicatingtheuseofatool/WABCOtool
5
General Information

6
General Information
1.2 How to Obtain Additional Maintenance, Service and Product
Information
If you have any questions about the material covered in this publication, or for more
information about the WABCO product line, please contact WABCO Customer Care
Centerat855-228-3203,byemailat[email protected],orvisitourwebsite:
www.zf.com/cv.
Refer to the Society of Automotive Engineers (SAE) website to nd all current SAE
documentsandstandardsapplicabletoWABCOproducts(suchasSAEJ447andSAE
J908atwww.sae.org).
Referto theNationalHighwayTrafcSafetyAdministration(NHTSA) websitetond all
current documents referenced in the manual at www.nhtsa.gov.
1.3 How to Obtain Parts and Kits
ContacttheWABCOCustomerCareCenterat855-228-3203(UnitedStatesandCanada);
800-953-0248(Mexico).Email:[email protected].
1.4 WABCO TOOLBOX PLUS™ Software
TOOLBOX PLUS™ Software provides PC diagnostic for WABCO products and can be
purchasedanddownloadedfromhttps://wabco.snapon.com.
The software User Guide, MM19047 can be obtained by visiting our Literature Center.
Purchase and Download TOOLBOX PLUS™
https://wabco.snapon.com
ZF Commercial Vehicle Literature Center
https://zf.com/cvliterature
1.5 WABCO Academy
www.wabco-academy.com
1.6 WABCOOnlineProductCatalog
www.wabco-customercenter.com

7
General Information
1.7 YourDirectContacttoZFCVS
ZFCVSystemsNorthAmericaLLC
1220PacicDrive
Auburn Hills, MI 48326
CustomerCareCenter:(855)228-3203
www.zf.com/cv
[email protected]

8
Safety Information
2 Safety Information
2.1 Provisions for a safe work environment
Onlyexperienced,trainedandqualiedautomotivetechniciansmaycarryoutworkonthevehicle.
Read this publication carefully.
Follow all warnings, notices and instructions to avoid personal injury and property damage.
Alwaysabidebythevehicle’sOriginalEquipmentManufacturer(OEM)specicationsandinstructions.
Observe all accident regulations of the repair facility as well as regional and national regulations.
Theworkplaceshouldbedry,sufcientlylitandventilated.
Usepersonalprotectiveequipmentifrequired(safetyshoes,protectivegoggles,respiratoryprotection
andearprotectors).
ReadandobserveallDanger,WarningandCautionhazardalertmessagesinthispublication.Theyprovide
information that can help prevent serious personal injury, damage to components, or both.
WARNING
To prevent serious eye injury, always wear safe eye protection when you perform vehicle
maintenance or service.
WARNING
Park the vehicle on a level surface. Block the wheels to prevent the vehicle from moving. Support
thevehiclewithsafetystands.Donotworkunderavehiclesupportedonlybyjacks.Jackscanslip
or fall over. Serious personal injury and damage to components can result.
WARNING
ThisproductcanexposeyoutochemicalsincludingNickel,whichisknowntotheStateofCalifornia
to cause cancer and birth defects or other reproductive harm. For more information, go to
www.P65Warnings.ca.gov.
WARNING
Whenyouworkonanelectricalsystem,thepossibilityofelectricalshockexists,andsparkscan
igniteammablesubstances.Youmustalwaysdisconnectthebatterygroundcablebeforeyouwork
on an electrical system to prevent serious personal injury and damage to components.

9
Introduction
3 Introduction
Tireinationsystemsusecompressedairfromthetrailertoinateanytrailertirethatfallsbelowthetireair
pressuresettingduringoperation.Airfromtheexistingtrailerairsupplyisroutedtoacontrolbox,theninto
eachaxle.
Actingasaconduit,axlescarryairthrougharotaryunionassemblyatthespindleendwhichthen
distributes air to each tire as needed.
Thistechnicalbulletincoversinstallationofthepartsnecessaryfortrailerstohavetireinationsystem
communication.
Anindicatorlightonthefrontofthetrailerinformsthedriverofanexcessiveamountofairow
through the system. If the indicator light is illuminated, appropriate maintenance or repairs to
the system should be performed.

10
Installation
4 Installation
4.1 InstallationofMeritorTireInationSystem
1. Wear safe eye protection.
2. Park the vehicle on a level surface. Block the wheels to prevent the vehicle from moving.
3. Raisethevehiclesothatthewheelstobeservicedareofftheground.Supporttheaxletobeserviced
with safety stands.
4. InstalltheMTIScontrolboxwiththeWABCOMTISpigtailcable(partnumberxxxxxxxxMW).The“MW”
attheendoftheMTISpartnumbersigniesthepigtailcableispre-installedintothecontrolbox.
Figure 1.
Fig. 1
SENSOR
EXTENSION CABLE
P/N 449 712 XXX 0
4006454d
2S/1M BASIC
P/N 400 500 106 0
2S/2M TO 4S/3M
PREMIUM
P/N 400 500 105 0
PRE-INSTALLED
WABCO MTIS
PIGTAIL CABLE
GENERIC I/O
CABLE
P/N 449 324 XXX 0
MTIS
ELECTRICAL CABLE
UNUSED
BLACK
LOCKNUT

11
Installation
5. Insert the black and white wires of the MTIS electrical cable through the unused black locknut and into
theMTISbox.Figure2.TurntheblacklocknutCLOCKWISEtofastensecurely.
Fig. 2
4006529c
12-VOLT RETURN
(BLACK WIRES)
12V
(WHITE
WIRE)
FLOW
SENSING
SWITCH
PETCOCK
DUAL MALE
TAB (BLACK
WIRE)
WABCO PIGTAIL
WIRE
Bothblackwiresmustbeconnectedtoonesideoftheowswitch(sidewiththedualmaletab)
andthewhitewiremustbeconnectedtotheoppositesideoftheowswitch.
6. Fastenthe12-volt(white)wireoftheMTISelectricalcableterminalontothetabontheoppositeside
(bottomshown)oftheowsensingswitch.Conrmthatthe+12-voltreturn(black)wireterminalofthe
WABCOMTISpigtailcableisattachedtotheowsensingswitchasshowninFigure2.
7. Fastenthe12-volt(white)wireoftheMTISelectricalcableterminalontothetabontheoppositeside
(bottomshown)oftheowsensingswitch.Figure2.
Refer to Figure 3 for more detailed assembly, installation, inspection and maintenance
information for MTIS.

12
Installation
Fig. 3
4009668a
MTIS WARNING
LIGHT
BATTERY
RETURN
GROUND
MTIS CONTROL BOX
FLOW
SWITCH
PIGTAIL
W/DIODE
12 VDC FROM
J560 CONNECTOR
CONNECTED
TO POWER
CABLE D1
MTIS STATUS DETECTION BY MW TRAILER ABS SYSTEM
8. RemovetheprotectivecapsfromtheWABCOMTISpigtailcableandthegenericinput/output(I/O)
cable.
9. ConnecttheWABCOMTISpigtailcabletothesensorextensioncable.Figure1.
10. ConnectthesensorextensioncabletothegenericI/Ocable.Figure1.
11. Secure the cable as appropriate with the correct strain relief to prevent overtightening or overstretched
condition that would damage the wire.
The MTIS indicator light must be either a load resisted LED lamp, part number 31263-20, or an
incandescent light. Refer to the Meritor part list on page 14.

13
Installation
4.2 InstallationofCompatibleTireInationSystems
(HendricksonTiremaaxTireInationSystemand
STEMCOAerisTireInationSystem)
RefertoFigure4forcorrectconnectionofthetrailerABSsystem,partnumber4005001050(4S2M)or
4005001060(2S1M),tothetireinationsystem.
Fig. 4
TRAILER ABS SYSTEM
P/N 400 500 105 0
P/N 400 500 106 0
SUPPLY/ GIO CABLE
P/N 449 324 XXX 0
4014797b
CONTROLLER
ASSEMBLY
CONNECTOR
FIVE-PIN
CONNECTOR
FIVE-PIN
POWER SUPPLY
CONNECTOR
INDICATOR
CONNECTION
TIRE INFLATION
SYSTEM
JUMPER HARNESS
TIREMAAX: P/N 449 025 XXX 0
STEMCO: P/N 449 027 XXX 0
COMPATIBLE TIRE INFLATION SYSTEMS FOR ENHANCED EASY STOP
1. Connectthesupply/GIOcable,partnumber449324XXX0,intotheECU’spowerconnectorportand
secure it with the locking tab.
2. Usingthejumperharness,eitherTIREMAAX(449025XXX0)orSTEMCO(449027XXX0),connect
thetireinationsystemtotheconnectoronthesupply/GIOcable,partnumber449324XXX0.
3. Usingthejumperharness,connecttireinationsystemtotheve-pinpowersupplyconnector.

14
Installation
WABCO Part List
DESCRIPTION LENGTH PART
NUMBER
2S/1MPremiumSystem 400 500 106 0
2S/2M-4S/3MPremiumSystem 400 500 105 0
PowerGenericI/O“Y”Cable 0.5 meter 449 324 005 0
PowerGenericI/O“Y”Cable 1.0 meter 449 324 010 0
PowerGenericI/O“Y”Cable 3.0 meters 449 324 030 0
PowerGenericI/O“Y”Cable 4.7 meters 449 324 047 0
PowerGenericI/O“Y”Cable 6.0 meters 449 324 060 0
SensorExtensionCable 0.76 meter 449 712 008 0
SensorExtensionCable 1.78 meters 449 712 018 0
SensorExtensionCable 1.90 meters 449 712 019 0
SensorExtensionCable 3.8 meters 449 712 038 0
SensorExtensionCable 5.1 meters 449 712 051 0
SensorExtensionCable 6.35 meters 449 712 064 0
SensorExtensionCable 10.0 meters 449 025 100 0
SensorExtension90° 0.8 meter 449 713 008 0
SensorExtension90° 1.8 meters 449 713 018 0
SensorExtension90° 3.0 meters 449 713 030 0
SensorExtension90° 5.0 meters 449 713 050 0
SensorExtension90° 7.0 meter 449 713 070 0
SensorExtension90° 9.0 meter 449 713 090 0
SensorExtension90° 12.0 meter 449 713 120 0
SensorExtension90° 17.0 meter 449 713 170 0
HendricksonTiremaaxJumperHarness 1.0 meter 449 025 010 0
HendricksonTiremaaxJumperHarness 2.5 meters 449 025 025 0
HendricksonTiremaaxJumperHarness 5.0 meters 449 025 050 0
StemcoAerisJumperHarness 1.0 meter 449 027 010 0
StemcoAerisJumperHarness 2.5 meters 449 027 025 0
StemcoAerisJumperHarness 5.0 meters 449 027 050 0
Meritor Part List
DESCRIPTION PART
NUMBER
LED Lamp with Resistor 31263-20 31263-20
LED Bracket 31263-21 31263-21
LED Pigtail 31263-16 31263-16
LED Kit — Includes LED lamp with
resistor, bracket, sealing grommet, label
forunderLEDtwolabels(oneforeach
sideoftherearofthetrailer)
H1263-06-MW
MTIS Cable Pigtail 31184-00 31184-00

15
Installation
4.3 ActivatingtheTireInationSystemwithTOOLBOX™Software
Oncethehardwarehasbeeninstalled,thetireinationsystemmustbeactivatedusingWABCO
TOOLBOX™Softwareversion12.4orlater.Wheninstallingtireinationsystemsoptiononnewor
replacement ECUs, the activation process is part of the normal programming procedure.
1. ClicktheTOOLBOXicononthedesktopandthenclicktheJ1708/PLCicon.Figure5.
Fig. 5
4014793a
2. Click on the Trailer ABS Diagnostics icon to initiate the ABS portion of TOOLBOX™ Software. Figure 6.
To enable trailer and TOOLBOX™ Software communication, make sure the correct adapter is
selected under Adapter Selection on TOOLBOX main screen under Utility Tab for TOOLBOX
12 or Adapter selection for TOOLBOX PLUS main screen.
Fig. 6
4014794a

16
Installation
3. Fromthetopmenubar,gototheModifypull-downmenuandselectGIOConguration.Figure7.
Fig. 7
4014795a
4. WhentheGIOCongurationscreenisdisplayed,clicktheTireInationCommunicationradialbutton.
Ensurethatacircleappearsinthebox.Then,presstheDownloadbuttonatthebottomofthescreen.
Figure 8.
Fig. 8
4014796a
5. Onceamessageisdisplayedconrmingasuccessfulsave,clickExitinthemainscreentoclosethe
TOOLBOX™ Software.
6. Cycle the power on the trailer in order to reset the ECU.

17
Tire Ination Communication System Troubleshooting
5 Tire Ination Communication System Troubleshooting
ECUs 400 500 105 0 and 400 500 106 0 are the only trailer ABS valves that have Tire Ination
Communication functionality.
The rst step taken when troubleshooting the Tire Ination Communication System is to ensure that the
system is electrically connected correctly. Refer to Figure 10.
If the Tire Ination system status lamp is not present or is not functioning, then the Tire Ination
Communication System will not function.
TIO les enable additional functionality such as tire monitoring, for the InfoLink-capable ECUs. If a TIO
needs to be replaced or removed, contact the WABCO North America Customer Care Center at
855-228-3203.
This troubleshooting section is based on the use of TOOLBOX™ Software version 12 or higher. If you have
an earlier version of TOOLBOX™ Software, visit https://wabco.snapon.com.
Fig. 9
4012497c
Condition
Experienced Action To Ta ke Tr oubleshooting Details
MTIS LED Illuminates with
a Dim Glow All the Time
Confirm the MTIS LED is an incandescent
or Meritor LED with resistor part number
31263-20.
Replace light as necessary.
Ensure light is grounded correctly.
WABCO Tire
Inflation Communication
System is not Broadcasting
a “Low Tire Pressure”
Message When There is a
Fill Event and the MTIS
Light is Illuminated
Correct installation needs to be verified.Confirm WABCO MTIS Communication System is installed per
Figures 2 and 10.
Make sure all electrical connections are fully seated.
ECU valve should audibly click during its
power-up self-test.
Ensure that 12 volts is present at pin A-3 and (Ground Pin) on the ECU
power connector.
Check continuity of the power/I/O cable.
Check diode on pre-installed MTIS cable pigtail. Place the volt/ohm meter
to “Diode”. Place red lead on single male pin. Place the black lead on the
dual tab connector. Continuity should be observed on the volt/ohm meter.
Switching the leads in the opposite direction, an “Open” should be
displayed on the volt/ohm meter. Refer to Figure 11.
Confirm part number 400 500 105 0 or
400 500 106 0 is installed.
Connect TOOLBOX™ Software 12 or higher and part number can be
viewed on the Trailer ABS main screen.
Confirm T_0109b.tio has been installed to
the ECU.
To access the Notebook section of the ECU, perform the following:
1. Select Modify on the top toolbar of the Trailer ABS TOOLBOX
application.
2. Select Notebook to confirm T_0109b.tio can be viewed in the
“Service Information” area.
3. If T_0109b.tio is not visible in the Notebook, go back to Loading TIO
Files section of this publication.
“Low Tire Pressure”
Message is Being
Broadcasted All the Time
Correct installation needs to be verified.
Make sure all electrical connections are fully seated.
Confirm the MTIS LED is an incandescent
or Meritor LED w/resistor part number
31263-20.
Replace light as necessary.
Ensure light is grounded correctly.
MTIS LED Does Not
Illuminate During a Fill
Event
Correct installation needs to be verified. Confirm MTIS system is installed per MM14P.
Confirm MTIS LED is not burned out.
Replace MTIS LED as required with Meritor part number 31263-20.
The Parameter File
T_0109b.tio Has Been
Successfully Downloaded
to the ECU, but MTIS
Message is Not Being
Broadcast
Confirm T_0109b.tio is visible in the
“Notebook” section of TOOLBOX™
Software 12 or higher.
Contact the WABCO Customer Care Center at 855-228-3203.
Check continuity for the 449 324 XXX X D1 cable from the 8-pin
connector (Pin 5) to the 2-pin sensor socket (C1). Refer to Figure 10.
Confirm WABCO MTIS communication system is installed per
illustration Figures 2 and 10.

18
Tire Ination Communication System Troubleshooting
Fig. 10
4012492a
A-4
A-3
A-2
A-1
A-8
A
A-7
A-6
A-5
C
NOT USED
NOT USED
NOT USED
B
B-D
B-A
B-B
B-E
C
C-2
C-1
A
A-1
A-2
A-3
A-4
A-5
A-6
A-7
A-8
C-2
C-1
B-A
B-B BPOWER GENERIC I/O “Y” CABLE
P/N 449 324 XXX X
B-E
B-C B-D
A
B
Fig. 11
4012493b
1 BLACK
2 NOT CONNECTED
DIODE
BLACK
1
2
WABCO TIRE INFLATION SYSTEM CABLE PIGTAIL
P/N 31184-00

19
Appendix I
6 Appendix I
6.1 InstallingSensorsonNon-ABS-PreppedAxles
Sensorlocationsvaryduetosuspensiontype.WABCOrecommendsplacingthesensorontheaxlethat
will provide the most braking performance. Contact your suspension manufacturer for further information.
1. Applyamineraloil-basedgreasethatcontainsmolydisuldetothesensorspringclip,thebodyofthe
sensor and the bore of the sensor block. The grease must be anti-corrosive and contain adhesive
propertiesthatwillcontinuouslyenduretemperaturesfrom−40°to300°F(−40°to150°C).
2. Push the spring clip into the sensor holder from the inboard side, until the spring clip tabs are against
the sensor holder. Push the sensor into the spring clip as far as possible.
UseWABCOspringclipstoensureacorrectt.
3. Push the spring clip into the sensor holder from the inboard side until the spring clip tabs are against
the sensor holder. Push the sensor into the spring clip as far as possible. Figure 12.
Fig. 12 SPRING
CLIP TAB
SENSOR
SPRING
CLIP
SENSOR
HOLDER
4003572a
4. Route the sensor cable toward the brake chamber, over the brake spider or through the pre-stamped
holededicatedtoABSsensors.Routetothebacksideoftheaxle.Securethecabletotheaxle
between the brake spider and the suspension brackets. Continue to route the sensor cable behind the
springseats.Securethecabletotheaxleoneinchfromthemoldedsensorplug.Figure13.
Do not overtighten tie wraps on a cable. Overtightening can damage the cable. Do not tie wrap
themoldedsensorplug.ThesensorextensioncablemustfollowthebrakehosetotheECU/valve
assemblytoallowforaxlejounceandrebound.
Brakehoseclipswithaprovisionforthesensorextensioncablearerecommendedasopposedtotie
wraps. WABCO does not supply this part.
Fig. 13
SENSOR
CABLE
3"
(76 MM)
4003573a

20
Appendix I
5. Install the wheel hub carefully so that the tooth wheel pushes against the sensor as the wheel bearings
are adjusted. There should be no gap between the sensor and the tooth wheel.
6. Testthesensoroutputvoltage.Useavolt/ohmmetertochecktheoutputvoltageofthesensorswhile
rotatingthewheelatapproximately1/2revolutionpersecond.Minimumoutputmustbe0.2voltAC.If
minimum output is less than 0.2 volt AC, push the sensor toward the tooth wheel. Recheck the sensor
output.