WABCO TP19039 User manual

INSTALLING AND CONFIGURING THE
WABCO iABS WITH AUTOMATIC LIFT
AXLE CONTROL OPTION
KITS 400 612 039 0, 400 612 040 0, 400 612 041 0. MUST BE USED WITH THE WABCO
PREMIUM ECU/VALVE ASSEMBLIES: 400 500 350 0 (2S/1M), 400 500 450 0 (4S/2M)
TP19039
TECHNICAL BULLETIN

3
Table of Contents
Edition 1
Version 1 (08.2020)
TP19039 (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. WABCO reserves the right to revise the information
presented or to discontinue the production of parts described at any time.
Table of Contents
1 General Information ......................................................................................................................................... 4
2 Safety Information............................................................................................................................................ 6
3 Important Information...................................................................................................................................... 6
4 Introduction ...................................................................................................................................................... 7
4.1 Configuration of Lift Axles by Functionality ............................................................................................. 7
4.2 Installation............................................................................................................................................... 8
4.3 Automatic Lift Axle Activation Procedure .............................................................................................. 14
4.4 Lift Axle Operation Check ..................................................................................................................... 20
5 Appendix I....................................................................................................................................................... 23
5.1 Installing Sensors on Non-ABS-Prepped Axles .................................................................................... 23
6 Appendix II...................................................................................................................................................... 25
6.1 Cable Strain Relief Guidelines .............................................................................................................. 25
7 Appendix III..................................................................................................................................................... 28
7.1 Vehicle Electrical Grounding Guidelines ............................................................................................... 28
8 Appendix IV ................................................................................................................................................... 29
8.1 Parts and Variant List............................................................................................................................ 29

4
General Information
1 General Information
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, notes and/or tips
Reference to information on the internet
1. Action step
- Action step
Consequence of an action
List
•List
Note on the use of a tool/WABCO tool

5
General Information
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 the WABCO Customer Care Center at 855-228-3203, by email at
[email protected], or visit our website: www.wabco-na.com.
Refer to the latest iABS Maintenance Manual MM19001. To obtain this publication, visit our website at
wabco-na.com, or call the WABCO Customer Care Center at 855-228-3203.
Refer to the Society of Automotive Engineers (SAE) website to find 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 Traffic Safety Administration (NHTSA) website to find all current documents
referenced in the manual at www.nhtsa.gov.
WABCO TOOLBOX PLUS™Software
The TOOLBOX PLUS™ Software provides PC diagnostics for WABCO products and can be purchased
and downloaded from https://wabco.snapon.com. For complete instructions for using TOOLBOX PLUS™
refer to User’s Guide MM19047. To obtain this literature, visit www.wabco-na.com/literature.
WABCO Academy
https://www.wabco-academy.com/home/
WABCO Online product catalog
https://www.wabco-customercenter.com
Your direct contact to WABCO
WABCO North America LLC
WABCO USA LLC
1220 Pacific Drive
Auburn Hills, MI 48326
Customer Care Center: [phone]
www.wabco-na.com

6
Important Information
2 Safety Information
Provisions for a safe work environment
Only trained and qualified auto technicians and auto mechanics 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) specifications and instructions.
Observe all accident regulations of the respective company as well as regional and national regulations.
The workplace should be dry, sufficiently 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.
3 Important Information
Use only genuine WABCO components. Other manufacturers’ parts are not designed for use with a
WABCO ABS system and may not function correctly.

7
Introduction
4 Introduction
The WABCO iABS Automatic Lift Axle Control system uses the generic I/O capability to automatically
control the lift axle function of the trailer. The Lift Axle function may be configured in three different ways.
Each method has its own specific hardware requirement and installation.
Automatic Override Kit 400 612 039 0 is a fully automatic system that uses a combination of switch input
and lifting and lowering pressures all preset by the trailer manufacturer using the WABCO TOOLBOX
PLUS™ Software. This lift axle configuration monitors axle load in order to raise or lower the lift axle
without driver intervention. The system senses the load and raises or lowers the lift axle based on preset
suspension air pressures set by the trailer manufacturer. When the lift axle control valve is activated and
raises the axle, an optional lift axle indicator on the trailer is activated to signal to the driver that the lift axle
is in the “raised” position.
Kit 400 612 039 0 contains hardware for a fully automatic feature that will keep the lift axle in the lowered
position when the parking (spring) brakes are applied. When the parking (spring) brakes are released the
lift axle will move to the load appropriate position.
Manual Override Kit 400 612 040 0 is a fully automatic system that uses a combination of switch input and
lifting and lowering pressures all preset by the trailer manufacturer using the WABCO TOOLBOX PLUS™
Software. This lift axle configuration monitors axle load in order to raise or lower the lift axle without driver
intervention. The system senses the load and raises or lowers the lift axle based on preset suspension air
pressures set by the trailer manufacturer. When the lift axle control valve is activated and raises the axle,
an optional lift axle indicator on the trailer is activated to signal to the driver that the lift axle is in the “raised”
position.
Manual Override Kit 400 612 040 0 contains the required cables for a manual override switch option that
can be activated to keep the lift axle in the lowered position regardless of vehicle load. Please refer to local
governing ordinances.
Automatic/Manual Override Kit 400 612 041 0 is a lift axle system that features both automatic and
manual override modes.
This lift axle configuration monitors axle load in order to raise or lower the lift axle without driver
intervention. The system senses the load and raises or lowers the lift axle based on preset suspension air
pressures set by the trailer manufacturer. When the lift axle control valve is activated and raises the axle,
an optional lift axle indicator on the trailer is activated to signal to the driver that the lift axle is in the “raised”
position.
This kit contains hardware for a fully automatic feature that will keep the lift axle in the lowered position
when the parking (spring) brakes are applied. When the parking (spring) brakes are released the lift axle
will move to the load appropriate position.
This kit also contains the required cables for a manual override switch option that can be activated to keep
the lift axle in the lowered position regardless of vehicle load. Please refer to local governing ordinances.
Note 400 612 039 0, 400 612 040 0 and 400 612 041 0 must be used with a WABCO iABS
Premium ECU/Valve assembly 400 500 350 (2S/1M) or 400 500 430 0 (2S/2M - 4S/2M).
Refer to the instructions in this technical bulletin for installing the WABCO Trailer iABS with Lift Axle Control
Option.
4.1 Configuration of Lift Axles by Functionality
The Lift Axle function may be configured in three different ways.

8
Introduction
Each method has its own specific hardware requirement and installation.
A. Automatic Lift Axle with Manual Override Switch (No spring brake delivery line pressure switch used).
Kit number 400 612 040 0.
This configuration allows the lift axle to automatically raise and lower based upon values put into TOOLBOX
PLUS™ Software which are downloaded into the ECU when it is programmed. This configuration has a
trailer-mounted manual override switch that allows the driver to disable the ECU controlled raise/lower
function and keep the lift axle in the down position. This allows the driver to keep the trailer in compliance
where local ordinances require all lift axles to be kept in the down position regardless of load carried. Refer
to Figure 1 for the Manual Override Switch option.
B. Automated Lift Axle with Automatic Override (Spring brake delivery line pressure switch required).
Kit number 400 612 039 0.
This configuration allows the lift axle to automatically raise and lower based upon values put into TOOLBOX
PLUS™ Software which are downloaded into the ECU when it is programmed. This configuration allows
the driver to lower the lifted axle when parked by pulling the red dash valve in the tractor to remove trailer
supply air. This feature is useful for slider positioning or fast loading operations to ensure that the lift axle
is in the down position. Specifically, when the delivery line from the trailer spring brake chamber meets
or drops below 70 psi (4.82 bar), the ECU will automatically lower the lift axle. Refer to Figure 2 for the
Automatic Override Switch option.
C. Automated Lift Axle with Both Manual and Automatic Override. Kit number 400 612 041 0.
This configuration allows the driver to lower the lifted axle by means of a toggle switch or by pulling the red
dash valve in the tractor to remove trailer supply air when the vehicle is at rest. This requires the technician
to perform the installation instructions for both manual and automatic configurations outlined in Step 10.
Refer to Figure 3 for the installation diagram.
A lift axle can be lowered by removing power to the trailer.
4.2 Installation
WARNING
To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or
service.
WARNING
Remove all pressure from the air system before you disconnect any component. Pressurized air can
cause serious personal injury.
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.

9
Introduction
WARNING
Ensure the trailer has correct electrical grounding; refer to SAE Specification J1908.
WARNING
When you work on an electrical system, the possibility of electrical shock exists, and sparks can ignite
flammable 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.
Fig. 1
4017323a

10
Introduction
Fig. 2
4017324a

11
Introduction
Fig. 3
4017173a

12
Introduction
1. Wear safe eye protection.
2. Park the vehicle on a level surface. Block the wheels to prevent the vehicle from moving.
The trailer must not be loaded during this component installation.
3. Drain the brake and suspension systems of air before starting this procedure.
4. Disconnect the electrical power before starting this procedure.
5. Start with connecting the GIO hub cable, P/N 894 600 161 2, into the ECU‘s GIO 1 port and push in until
the locking clip seats. Then, if using the optional lift axle indicator light cable, install another GIO hub
cable, P/N 894 600 161 2, into the ECU‘s GIO 2 port and push in until the locking clip seats. Refer to
Figures 1, 2 and 3 depending on the override functionality selected.
6. If the optional lift axle indicator light is not used, plug the pressure sensor cable, P/N 449 826 XXX 0
into the ECU‘s GIO port 2. If the lift axle indicator light is used, plug the cable into the hub cable port 1.
The bayonet connector end of the cable will plug into the pressure sensor, P/N 441 044 106 0. Refer to
Figures 1, 2 and 3, depending on the override functionality selected.
The pressure sensor must be attached to the ride bag air circuit of the trailer‘s air suspension in order to
determine the load on the trailer.
7. Connect the lift axle control valve cable, P/N 449 408 XXX 0 to the GIO hub cable port 2 that is plugged
into the ECU GIO 1 port. Push the cable in completely until the lock engages. The bayonet cable end
of the cable will connect to the lift axle control valve, P/N 463 084 050 0. Refer to Figures 1, 2 and 3,
depending on the override functionality selected.
8. Ensure that the lift axle control valve is installed correctly. Refer to Figure 4.
A barrier of plastic or mylar should be placed between the lift axle control valve and the surface it
will be mounted on. This will help inhibit potential corrosion between dissimilar metals.
Fig. 4
4007073a
2.1 – TO THE
LIFTING
AIR BAGS
2.2 – TO THE
RIDE CONTROL
AIR BAGS OF
THE LIFTING
AXLE(S)
3.0 – EXHAUST
OUTLET
THIS SIDE UP
1.1 – SUPPLY
PRESSURE
1.2 – FROM THE
SUSPENSION
AIR BAGS OF
THE NON-
LIFTING AXLE(S)

13
Introduction
9. Perform one of the following depending on the trailer you are servicing.
A. For Trailers with Both Manual and Automatic Lift Axle Override.
Connect the override switch cable, P/N 449 826 XXX 0 to the GIO hub cable port 1 of the GIO hub
cable connected to the ECU GIO 1 port. Then connect the single wire leg of the lift axle "Y" cable,
P/N 894 601 100 0 to the other end of the override switch cable. This "Y" cable splits the override
switch cable into two leads. Then the next step is to plug the manual override cable, P/N 449 428
XXX 0 into either one of the other legs of the "Y" cable. The other end of the manual override switch
cable must be connected to a single-pole, single-throw, weatherproof toggle switch that is mounted
on the trailer in a driver-accessible location.
To wire the switch connect the blue wire of the cable to one side of the toggle switch and the brown
wire to the other side of the switch. The yellow/green wire is not used and must be capped or termi-
nated to prevent any corrosion. This switch overrides the settings that govern the raise/lower feature
and keeps they lift axle in the lowered position as long as the switch is activated.
Then to install the automatic override portion of the system, connect the other end of the "Y" cable to
the pressure switch, P/N 431 700 002 0.
Then pressure switch, P/N 431 700 002 0 must be connected between the delivery port of the
parking (spring) brake valve and the parking (spring) brake chamber using a tee in the delivery line.
When supply air is removed from the trailer, the pressure switch overrides the settings that control
raise/lower feature and keeps the lift axle in the lowered position as long as the parking (spring)
brakes are set. This is achieved by pulling the red dash valve in the towing vehicle to remove supply
air from the trailer.
B. For Trailers with Automatic Lift Axle Override.
Connect the override switch cable, P/N 449 826 XXX 0 to the GIO hub cable port 1 of the GIO hub
cable connected to the ECU GIO 1 port. Then connect the other end of the override switch cable to
the pressure switch, P/N 431 700 002 0.
Then pressure switch, P/N 431 700 002 0 must be connected between the delivery port of the
parking (spring) brake valve and the parking (spring) brake chamber using a tee in the delivery line.
When supply air is removed from the trailer, the pressure switch overrides the settings that control
raise/lower feature and keeps the lift axle in the lowered position as long as the parking (spring)
brakes are set. This is achieved by pulling the red dash valve in the towing vehicle to remove supply
air from the trailer.
C. For Trailers with Manual Lift Axle Override.
Connect the manual override switch cable, P/N 449 827 XXX 0 to the GIO hub cable port 1 of the
GIO hub cable connected to the ECU GIO 1 port. The other end of the manual override switch cable
must be connected to a single-pole, single-throw, weatherproof toggle switch that is mounted on the
trailer in a driver-accessible location.
This switch is not provided by WABCO. Ensure that the "on" and "off" positions are clearly
labeled.
To wire the switch, connect the green wire of the cable to one side of the toggle switch and the
brown wire to the other side of the switch. The red wire and yellow wires are not used and must be
capped or terminated to prevent any corrosion. This switch overrides the settings that govern the
raise/lower feature and keeps they lift axle in the lowered position as long as the switch is activated.

14
Introduction
The "Port 1" and "Port 2" lettering is located on the GIO hub cable, P/N 894 600 161 2.
Refer to Figure 5 below for an example.
Fig. 5
TO ECU GIO PORT TO GIO CABLES
10. If used, connect the (optional) lift axle indicator light cable, P/N 449 827 XXX 0 to the HUB cable
plugged into GIO 2, P/N 894 600 161 2 port 2. To connect the other end of the cable to the light, the
brown wire needs to be connected to the light ground, and then the yellow wire needs to be connected
to the power side of the light. The other two wires (green, red) are not used and can be capped. Refer to
Figures 1, 2 and 3.
(The lift axle indicator light cable is not part of the kit. Please choose the appropriate length for your
application. Refer to Appendix IV.)
WABCO requires that an LED light or incandescent light of less than 1 amp is used. Ensure
the LED light has a load resistor to prevent unwanted illumination of the light.
11.The next step is to connect the TOOLBOX PLUS™ software and activate the Automatic Lift Axle function
and set the lifting and lowering pressures.
4.3 Automatic Lift Axle Activation Procedure
The following steps detail the process to activate the Automatic Lift Axle function via the TOOLBOX PLUS™
Software.
The Automatic Lift Axle function can only be enabled on premium ECUs (part numbers 400 500
350, 400 500 430).
1. Open the iABS Diagnostics from the TOOLBOX PLUS™ Main Screen by selecting the Trailer ABS
diagnostic section. Figure 6.

15
Introduction
Fig. 6
4017111a
2. From the top menu bar, go to the Modify pull-down menu and select "GIO Configuration". Figure 7.
Fig. 7
4015076a

16
Introduction
3. When the GIO Configuration screen is displayed, select the check box "Automatic Lift Axle". A pop-up
will appear asking if the optional lift axle indicator light will be used. Select Yes or No depending on the
trailer application. Figure 8.
Fig. 8
4017327a
Once you select whether the optional indicator light will be used or not, the connections for the
necessary cables will be shown below in the window. Figure 9 and Figure 10.

17
Introduction
Fig. 9
4017328a
CABLE CONNECTIONS WITH INDICATOR LIGHT
Fig. 10
4017329a
CABLE CONNECTIONS WITHOUT INDICATOR LIGHT

18
Introduction
4. After reviewing the cable connections, select the Download button which will bring up the Lift Axle
Lifting/Lowering Pressures screen. Figure 11.
Fig. 11
4017330a
5. The Lift Axle Lifting/Lowering Pressures screen appears, allowing for the selection of the optional light
being used if previously selected. The lifting and lowering pressures can then be entered. Figure 12.
Fig. 12
4017331a
Determining Lifting and Lowering Pressures
Values will be obtained from the suspension manufacturer and modified according to the customer’s
performance expectations. Ensure these values comply with government regulations where the trailer will
be in service.
Type the Lowering and Lifting Pressures in the fields provided.

19
Introduction
The values must fall within the following restrictions:
Valid range: 5-100 psi
Lowering Pressure must be greater than Lifting Pressure
Lowering and Lifting pressures must differ by at least 15 psi
6. The values are validated and programmed when the OK button is pressed. When a confirmation
message appears, press the OK button to continue. Figure 13.
Fig. 13
4017332a
7. After selecting OK on the Lift/Lowering Pressures window, it will go back to the GIO Configuration
Window, and the ECU will reset 2 times. Once the resets are complete, a Download Complete window
will pop up. Click OK and the programming is now finished. Figure 14.
Fig. 14
4017333a

20
Introduction
4.4 Lift Axle Operation Check
The Lift Axle Operation Check is performed after the ABS system has been properly programmed and the
Sensor Orientation Test has been successfully performed.
The trailer must have constant power applied and have air supplied to the supply/emergency (red) line.
Activate the manual override switch (if equipped) to confirm that the lift axle lowers in an unladen state.
Once confirmed, return the switch to its original position and the lift axle should raise.
Testing the automatic override configuration (if equipped) that has the delivery line pressure switch in place
of the manual toggle switch requires a tractor. Correct operation should be tested after the trailer Sensor
Orientation Test has been completed. Attach the unladen trailer to a tractor and ensure both air and power
are hooked up. Release the trailer spring brakes using the red trailer brake valve on the tractor dash. The
lift axle should move to the raised position once the spring brake has released.
Apply the spring brakes (evacuating air) using the red trailer brake valve on the tractor dash. The lift axle
should lower. This completes the pressure switch test.
Add the appropriate amount of weight to the trailer so that the ride bag pressure equals or exceeds the
“Lowering Pressure” value entered into the Parameter screen. The lift axle should lower from the raised
position and the indicator lamp should extinguish.
This completes the Lift Axle Operation Check.
4.4.1 Lift Axle Test Rig
Some trailer OEMs may choose to construct an assembly to rapidly test the performance of automatic lift
axle installations using the spring brake delivery line pressure switch. Components used in the construction
of this assembly are commonly found at trailer OEM facilities. Figure 15.