WABCO TP19108 User manual

TRAILERCAST
TP19108
INSTALLATION GUIDE

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 .......................................................................................................................7
1.7 Your Direct Contact to ZF CVS ..........................................................................................................................7
2 Safety Information.......................................................................................................................................................8
2.1 Provisions for a safer work environment............................................................................................................8
3 Important Information.................................................................................................................................................9
4 Before Installation.....................................................................................................................................................10
4.1 Liability .............................................................................................................................................................10
4.2 Approvals .........................................................................................................................................................10
4.3 Best Practices in Installation ............................................................................................................................ 11
5 Introduction - Hardware Components.....................................................................................................................13
6 Installation – TRAILERCAST Position.....................................................................................................................14
6.1 General Recommendations .............................................................................................................................14
6.2 Preferred Installation (Standard Trailer With Fixed Trailer Bed) ......................................................................14
6.3 Alternative Installation (in Case of Trailer Without Fixed Trailer Bed)..............................................................15
7 Fastening TRAILERCAST.........................................................................................................................................17
8 Connecting Hardware ...............................................................................................................................................18
8.1 Hardware Activation .........................................................................................................................................18
8.2 Connection to TRAILERCAST for iABS or RSSplus .......................................................................................18
9 WABCO iABS Subsystems.......................................................................................................................................21
9.1 Hardware Connection ......................................................................................................................................21
10 WABCO RSSplus Subsystems ................................................................................................................................23
10.1 Hardware Connection ......................................................................................................................................23
11 Checking the Installation..........................................................................................................................................24
11.1 Installation Wizard............................................................................................................................................26
12 Appendix I..................................................................................................................................................................29
12.1 Vehicle Electrical Grounding Guidelines ..........................................................................................................29
13 Appendix II ................................................................................................................................................................30
13.1 Parts and Variant List.......................................................................................................................................30

4
Edition 1
Version 1 (10.2022)
TP19108 (en)
This publication is not subject to any update service. Information contained in this
publication was in e󰀨ect 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

5
General Information
1 General Information
1.1 Symbols Used in this Document
DANGER
Description of an immediate situation which may 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)
• Listing
Indicating the use of a tool / WABCO tool

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 Tra󰀩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],
[email protected] or [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

7
General Information
1.6 WABCO Online Product Catalog
www.wabco-customercenter.com
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: [phone]
https://www.zf.com/products/en/cv/home/cv.html

8
Safety Information
2 Safety Information
2.1 Provisions for a safer work environment
Only trained and qualied auto technicians and automotive mechanics may carry out work on the
vehicle.
Read this publication carefully
Follow all warnings, notices and instructions to help avoid personal injury and property damage.
Always abide by the vehicle manufacturer’s specications and instructions.
Observe all accident regulations of the respective company as well as regional and national regulations.
The workplace should be dry, su󰀩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 help prevent serious eye injury, always wear eye protection when you perform vehicle maintenance or
service.
WARNING
Park the vehicle on a level surface. Block the wheels to help prevent the vehicle from moving. Support the
vehicle with safety stands. Do not work under a vehicle supported only by jacks. Jacks can slip and 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.

9
Important Information
3 Important Information
Use only genuine WABCO components. Other manufacturers’ parts are not designed for use with a
WABCO TRAILERCAST system and it may not function correctly.

10
Before Installation
4 Before Installation
This installation guide provides you with installation directives and procedures for the installation of
TRAILERCAST.
4.1 Liability
The installation of TRAILERCAST can be carried out either by a ZF/WABCO Certied iABS Service Partner
or by the customer (after ZF training/demo installation). Contact your service partner if the iABS/RSSplus
data still needs to be activated.
Many customers prefer to do the installation themselves: the building-in of the device can then be combined
with regular trailer maintenance services, which helps customers use their time more e󰀩ciently. To this
purpose, ZF provides training for the technical engineers of the installation company. The training consists
of a theoretical part which can be illustrated with a demo installation, and further monitoring. Afterwards, the
trainees will be qualied to autonomously assemble the other devices in the trailers.
The illustrations and specic data of non-WABCO products have been checked thoroughly and have
been found correct at the time this manual was composed. However, ZF cannot accept any responsibility
for possible adaptations by the manufacturer concerned. ZF aims for a continuous improvement of its
products. For the purpose of technical progress, we reserve the right to implement changes at any time,
without prior notice.
4.2 Approvals
4.2.1 FCC Approval
ZF hereby conrms that this wireless device complies with all requirements and other relevant provisions of
the US Federal Regulations.
4.2.2 CE Approval
ZF hereby conrms that this wireless device complies with all requirements and other relevant provisions of
the RED directive.
4.2.3 Mobile Phone Radiance
FREQUENCY RF OUTPUT POWER
LTE-FDD B1/B2/B3/B4/B5/B8/B12/B13/B18/B19/B20/B26/B28 23 dBm ± 2 dB (class 3)
LTE-TDD B39 (for Category M1 only) 23 dBm ± 2 dB (class 3)
GSM850 / EGSM900 33 dBm ± 2 dB
DCS1800 / PCS1900 30 dBm ± 2 dB

11
Before Installation
4.3 Best Practices in Installation
DANGER
During the entire connection procedure, the voltage must be turned o󰀨.
Vehicle electrical grounding guidelines are included in Appendix I.
4.3.1 Assembly
The assembly of the parts must be done using the accessories provided. ZF cannot be held responsible
for any errors resulting from the use of other materials. ZF wishes to point out that activities which require
welding to the trailer, can cause damage to the electronics of the device. It is imperative that the device is
disconnected when carrying out such activities.
4.3.2 Wire Management
All the wire ways shall be smooth and free from sharp edges. Wires shall be protected, so they do not come
in contact with burrs, cooling ns, moving parts, etc., which could cause damage to the insulation of the
conductors.
4.3.3 Operating Conditions
Input voltage range: 10 - 32 V
Maximum current: 1.5 A
Operating temperature range: -40°C ~ +75° C
Storage temperature range: -40°C ~ +75° C
Nominal power consumption: 24 V x 25 mA = 0.6 W
Maximum power consumption: 24 V x 80 mA = 1.9 W
Ingress protection: IP6K6K / IP6K9K
Compliance with: ISO 16750 – E – K – E - D - D – IP6K6K / IP6K9K

12
Before Installation
4.3.4 Disposal
4019842a
In case you no longer want to use the TRAILERCAST unit, it is prohibited to dispose of it together with
domestic waste as the system components are electronic scrap. Dispose of hazardous waste in an
environmentally friendly manner and in compliance with relevant local, state and federal regulations.
ZF strives to help protect the environment. As with other old devices, all components can be returned to ZF.
4.3.5 Improper Use
NOTICE
USE THE DEVICE ONLY FOR ITS INTENDED PURPOSE! DO NOT OPEN THE TRAILERCAST
UNIT. DO NOT DRILL INTO THE DEVICE HOUSING!
In case of damage of any kind, which could a󰀨ect the ingress protection/waterproofness of the device, the
device must be immediately taken out of service.
The device safety may be endangered when:
The device is not rmly fastened to the trailer
The device has su󰀨ered from transportation damages
The temperature limits are exceeded
The device is visibly damaged.
NOTICE
IF THE DEVICE IS VISIBLY DAMAGED, IT MUST BE TAKEN OFF OF THE VEHICLE
IMMEDIATELY AND SENT BACK TO ZF.
All other instructions, notes and regulations in this operation manual must be closely followed.

13
Introduction - Hardware Components
5 Introduction - Hardware Components
TRAILERCAST is a trailer tracking device with an embedded SIM card, GSM antenna and GPS antenna. It
is designed for outside use. It is designed to be installed under the trailer. TRAILERCAST connects to the
trailer’s iABS or RSSplus.
TRAILERCAST UNIT DIMENSIONS (L x W x H)
4019843a
Including xing points (center to center):
105 x 103 x 45 mm
Including xing points: 125 x 103 x 45 mm
Excluding xing points: 84 x 103 x 45 mm
(Cf. Section 7 Fastening TRAILERCAST, page 17)
Hardware Description: Front view
4019844b
iABS/RSSplus PORT
FIXING
POINTS
(HEIGHT
15 MM)
Back view
4019845b
AIR VENT
CF. NOTE
NOTE: Make sure that the air vent of the TRAILERCAST
unit is always accessible to air. Make sure that nothing
can block the air access of the air vent (DO NOT apply
glue/tape/silicone along the edges of the unit.) Mounting
the unit on any bracket should not block the air vent.
Side view
4019847a
Pin Assignment
4019846a
Device serial number: TPXX-XXXXXXXXXXXXXXX

14
Installation – TRAILERCAST Position
6 Installation – TRAILERCAST Position
All WABCO component part number information can be found in Appendix II.
6.1 General Recommendations
When installing TRAILERCAST, keep the area around the antennas away from metal or other
obstructions as much as possible to help avoid signal disturbance.
As ZF cannot document all di󰀨erent trailer congurations, we recommend validating the installation of
the unit with a ZF technician before deploying on a large scale.
Make sure that the unit will not be continuously exposed to direct sunlight.
Make sure that the label of the unit is always visible.
The installation technician remains responsible at all times for the correct installation and connection of
the hardware unit.
Always verify that su󰀩cient GPS coverage is guaranteed during installation, and a good GPS position
has been received via https://install.us.wabco-eet.com/search/?device=trailercast. Check this for every
installation.
6.2 Preferred Installation (Standard Trailer With Fixed Trailer Bed)
The unit must be installed below the trailer bed with the front of the TRAILERCAST unit directed to the
ground.
Make sure that the front of the unit has a clear view to the ground (not obstructed by other
components).
Keep the sides of the unit at a minimum distance of 20 cm from obstacles.
Always verify that su󰀩cient GPS coverage is guaranteed and a good GPS position has been
received using https://install.us.wabco-eet.com/search/?device=trailercast (Section 11 Checking the
Installation, page 24).

15
Installation – TRAILERCAST Position
6.3 Alternative Installation (in Case of Trailer Without Fixed Trailer Bed)
Find a suitable location and make sure that the front of the unit has a clear view as much as possible
(min. 150 cm).
Keep the sides of the unit at a minimum distance of 20 cm from obstacles (also keep a minimum
distance of 20 cm above the unit).
Always verify that su󰀩cient GPS coverage is guaranteed and a good GPS position has been
received using https://install.us.wabco-eet.com/search/?device=trailercast (Section 11 Checking the
Installation, page 24).

16
Installation – TRAILERCAST Position
6.3.1 Incorrect Installation
INCORRECT: Do NOT install the unit on or inside the trailer beams.
4019853a
INCORRECT: Do NOT install the unit above other components (e.g., air tanks …). The unit requires a clear
view to the ground.
4019854a
6.3.2 Installation Instructions for Cables
The general installation instructions to be observed for cables and connectors can be downloaded from:
http://inform.wabco-auto.com/intl/drw/9/4490000000.pdf.
After connecting all hardware to TRAILERCAST, ZF recommends using cable ties to relieve tension from
the connectors.

17
Fastening TRAILERCAST
7 Fastening TRAILERCAST
The 2 xing points have a diameter of 8.8 mm. ZF recommends using M8 bolts or screws to mount the
TRAILERCAST unit.
When fastening TRAILERCAST on the vehicle, use 2 hexagon head bolts M8 x 1.25, class 8.8 and tighten
the bolts with a maximum torque of 25.4 Nm (dry).
Make sure that TRAILERCAST is mounted on a rigid, at surface. Use both xing points to fasten the
TRAILERCAST device.
CAUTION
DO NOT DRILL INTO THE CHASSIS/FRAME OF THE TRAILER!
4019855a
45 ±0.2
125 ±0.2
103
105 ±0.2
84 ±0.2
38 ±0.2
16.5
2X Ø8.9
TIGHTENING TORQUE
MAX. 25.4 Nm DRY FOR
M8X1.25 CLASS
8.8 ISO898 BOLT

18
Connecting Hardware
8 Connecting Hardware
8.1 Hardware Activation
The TRAILERCAST unit is preactivated and will start sending positions as soon as the unit is connected to
a power source (iABS system or RSSplus).
8.2 Connection to TRAILERCAST for iABS or RSSplus
The connector on the specic iABS or RSSplus connection cable is connected to the iABS or RSSplus port
of the TRAILERCAST unit.
All iABS and RSSplus connection cables use the same type of connector. Always make sure that all
connectors are correctly plugged in to help ensure a waterproof connection. The TRAILERCAST unit can
be powered by the iABS or RSSplus.
All iABS and RSSplus connection cables use the same type of connector.
4019856a
4019843a

19
Connecting Hardware
1. Plug the connector into the port. The design of the connector will help prevent you from plugging it in
incorrectly.
4019857a
2. Press down the connector. By pressing down the connector, the yellow clip will automatically move
down.
4019858a
3. Finally, press the yellow clip to lock the connection. A distinct “click” should be heard.
4019859a

20
Connecting Hardware
4. The connector has been plugged in correctly.
4019860a