WABCO Truck Training Model User manual

Truck
Training Model
Operating Instructions

Original document:
The German version is the original document.
Translation of the original document:
All non-German language editions of this document are translations of
the original document.
Edition 2, Version 4 (04.2021)
Document no.: 815 010 281 3 (en) You will nd the current edition at:
http://www.wabco.info/i/1767

3
Table of contents
Table of contents
1 List of abbreviations ........................................................................................................................................ 5
2 Information about this document ................................................................................................................... 6
2.1 General equal treatment ......................................................................................................................... 6
2.2 Symbols used ......................................................................................................................................... 6
3 Basic safety instructions................................................................................................................................. 7
3.1 Proper use .............................................................................................................................................. 7
3.2 Obvious misuse ...................................................................................................................................... 7
3.3 Qualication and knowledge of the personnel ........................................................................................ 7
3.4 Structure and explanation of the warning notes...................................................................................... 7
3.4.1 Structure of the warning notes .................................................................................................. 7
3.4.2 Explanation of the warning notes .............................................................................................. 8
3.5 General safety instructions ..................................................................................................................... 8
3.6 Personal protective equipment ............................................................................................................... 8
4 Introduction ...................................................................................................................................................... 9
5 Technical description .................................................................................................................................... 10
5.1 Scope of supply .................................................................................................................................... 10
5.2 Technical data ....................................................................................................................................... 10
5.3 Overview graphics ................................................................................................................................ 11
5.3.1 Structure.................................................................................................................................. 11
5.3.2 Connections and operating elements on the training model ................................................... 12
5.3.3 Indicator lights ......................................................................................................................... 13
5.4 Installed systems/components.............................................................................................................. 13
5.5 ECAS remote control unit ..................................................................................................................... 14
6 Setting up........................................................................................................................................................ 15
7 Start-up ........................................................................................................................................................... 16
7.1 Establishing the compressed air supply................................................................................................ 16
7.2 Establishing the power supply .............................................................................................................. 16
7.3 Switching on the ignition ....................................................................................................................... 17
7.4 Initial start-up of EBS 3 ......................................................................................................................... 18
8 Function and operation ................................................................................................................................. 19
8.1 Brake function ....................................................................................................................................... 19
8.2 Air suspension (ECAS) ......................................................................................................................... 20
8.3 Operation with switches in the driver's cab........................................................................................... 20
8.3.1 Lighting.................................................................................................................................... 20
8.3.2 Reverse monitoring system..................................................................................................... 20
8.3.3 Lifting and lowering the lifting axle .......................................................................................... 20
8.3.4 Activating and deactivating the traction help........................................................................... 21
8.3.5 Regulation of the driving level ................................................................................................. 21
8.4 Operation with the ECAS remote control unit ....................................................................................... 21

4
Table of contents
9 Diagnosis and parameter setting ................................................................................................................. 22
9.1 Introduction ........................................................................................................................................... 22
9.2 System training and PIN ....................................................................................................................... 22
9.3 Hardware .............................................................................................................................................. 23
9.4 Installation and activation...................................................................................................................... 24
9.4.1 Registration at myWABCO...................................................................................................... 24
9.4.2 Ordering the Diagnostic Software ........................................................................................... 25
9.4.3 Installing the Diagnostic Software ........................................................................................... 29
9.4.4 Activating the Diagnostic Software.......................................................................................... 35
9.5 Starting the diagnosis ........................................................................................................................... 44
9.6 Calling up the diagnostic memory......................................................................................................... 45
9.7 Parameter setting.................................................................................................................................. 45
10 Procedure in case of accidents or malfunctions ........................................................................................ 47
11 Taking out of operation ................................................................................................................................. 48
11.1 Switching o󰀨 the power supply ............................................................................................................. 48
11.2 Disconnecting the power supply ........................................................................................................... 48
11.3 Disconnecting the compressed air supply ............................................................................................ 48
11.4 Venting the compressed air tanks......................................................................................................... 49
12 Maintenance ................................................................................................................................................... 50
12.1 Maintenance and cleaning .................................................................................................................... 50
12.2 Repair ................................................................................................................................................... 50
13 Noise emission data ...................................................................................................................................... 51
14 EEC declaration of conformity...................................................................................................................... 52
15 WABCO Contact ............................................................................................................................................. 53

5
Table of contents
1 List of abbreviations
Abbreviation Meaning
6S/5M 6 Sensors/5 Modulators
ABS Anti-Lock Braking System
CAN Controller Area Network; serial bus system
EBS Electronic Braking System
ECAS Electronically Controlled Air Suspension
ECU Electronic Control Unit
ISO International Organization for Standardization
LSV Load Sensing Valve
NW Nominal Width
OBD On-Board Diagnostics

6
Information about this document
2 Information about this document
2.1 General equal treatment
In this document, the masculine form, according to grammar, is used in a neutral sense. This
serves to make the text more understandable and easier to read. People of all genders are always
addressed in the same way. We ask for your understanding for this simplication in the text.
2.2 Symbols used
These information boxes contain important information, hints and/or tips.
Descriptive text
For individual action steps
1. Action step 1
2. Action step 2
ªConsequence of an action
• Listing
See:ÂCross-reference

7
Basic safety instructions
3 Basic safety instructions
3.1 Proper use
The truck training model is a reduced scale towing vehicle that is used to provide knowledge about
WABCO's brake and air suspension systems.
The training model can be used in conjunction with the trailer training model or alone.
The training model is intended for professional use and not for private use. Intended use also
includes that you have read and understood this document completely.
3.2 Obvious misuse
The training model must not be used as a vehicle.
Any use other than that described in the intended use is not in accordance with the intended use
and is therefore not permitted.
WABCO accepts no liability for damage caused by improper use. The risks of improper use lie solely
with the user.
3.3 Qualication and knowledge of the personnel
The activities described in this documentation require basic knowledge of mechanics, electrics,
pneumatics and knowledge of the associated technical terms.
To ensure operational safety, the training model may only be used by trained persons with
demonstrable technical expertise in an educational environment for training or demonstration
purposes.
3.4 Structure and explanation of the warning notes
3.4.1 Structure of the warning notes
Warnings are structured as follows:
• Signal word and pictogram
• Correct naming of the hazard
• Description of the consequences if the hazard is ignored
• Description of the measure(s) to prevent the danger

8
Basic safety instructions
3.4.2 Explanation of the warning notes
CAUTION
Indicates a hazard that may result in slight or moderately serious injury if not avoided.
NOTICE
Indicates a hazard that may result in material damage if not avoided.
3.5 General safety instructions
Follow all safety information, instructions and notices in this document to avoid personal injury
and material damage.
Follow regional and national regulations on accident prevention.
Ensure cleanliness throughout the application.
Keep this document and other documentation supplied with the product.
Make sure your workplace is dry as well as adequately lit and ventilated.
Only place the training model on a stable and level surface.
Ensure that the compressed air lines are connected safely and correctly.
Ensure that all the training model's connecting cables are laid in such a way that there is no risk
of people tripping over them.
Apply the brakes on the swivel castors to prevent the training model from rolling away. Only
release the brakes if the training model is to be moved. If the training model moves uncontrolled,
these castors can cause crushing.
Keep hands and ngers away from all moving parts of the training model when operating.
Always keep loose-tting clothing, long, open hair, necklaces and limbs away from the moving
parts of the training model as they can be pulled in.
Use the training model indoors only.
Do not make any changes to the training model as this will invalidate the warranty.
Repairs may only be carried out by authorised personnel of the manufacturer or by authorised
personnel of WABCO.
Use the training model with the supplied power supply unit only in mains with 230 V and 50 Hz.
Otherwise, the operator must use his own compatible power supply unit that provides a safe
output voltage of 24 V DC.
3.6 Personal protective equipment
Wear personal protective equipment to prevent injury:
• Safety boots
• Safety goggles
• Ear protectors

9
Introduction
4 Introduction
The truck training model is a reduced scale towing vehicle that is used to provide knowledge about
WABCO's brake and air suspension systems.
The training model is equipped with the following systems/components:
• Braking system Truck EBS (Generation 3) with ABS conguration (6S/5M)
• Electronically controlled air suspension ECU ECAS CAN2
• Lifting axle control valve
• ECAS remote control unit
• System for targeted fault simulation
WABCO braking system Truck EBS
The Truck EBS braking system is an electronically controlled braking system with load-dependent
braking pressure control, automatic anti-lock braking system (ABS), integrated automatic traction
control and electronic stability control (ESC).
EBS controls and monitors all available functions in the truck training model.
Detailed information on the Truck EBS braking system can be found here:
http://www.wabco.info/i/528

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Technical description
5 Technical description
5.1 Scope of supply
The scope of supply includes:
• training model on a trolley
• external power supply
Accessories such as cable or diagnostic cases are not part of the scope of supply and must
be ordered separately.
5.2 Technical data
WABCO part number 300 000 001 0
Weight 408 kg
Substructure dimensions (L x W x H) 180 cm x 85.5 cm x 70 cm
Dimensions of substructure and truck with
coupling heads (L x W x H) 180 cm x 85.5 cm x 155 cm
Mains connection (via separate power supply unit) 230 V, 50 Hz
Compressed air supply Plug nipple NW 7.2
Permissible ambient temperature 0 °C to 35 °C
Max. permissible humidity 80 %

11
Technical description
5.3 Overview graphics
5.3.1 Structure
The truck training model consists of the substructure and the truck training model. The substructure
has four swivel castors, which allow easy movement of the training model. Each swivel castor has
a locking mechanism that secures the training model against unintentional rolling away.
The truck training model has one engine truck brake valve and one hand brake valve each mounted
on the outside of the vehicle frame on the driver's side for realistic operation of the service and
parking brake. In addition, the model has a display with numerous measuring sockets for taking
measured values and a control panel for targeted fault simulation.
Position no. Element
1 Coupling heads/ISO connection
2Brake pedal
3Tristop™ brake cylinder
4 Control switches and indicator lights
5Measurement sockets
6 ECU ECAS CAN2 and EBS electronics
7ECAS remote control unit
8Park brake

12
Technical description
5.3.2 Connections and operating elements on the training model
Position no. Element Description
1 Rear and brake lights Indication of driving, reversing and stop lights
2Connection ISO 7638, 7-pin Transmission of the CAN signals to the trailer
3 Coupling head red Supply of the trailer with supply pressure
4 Coupling head yellow Supply of the trailer with control pressure
5Connection ISO 12098, 15-pin Transmission of the light signals to the trailer
6 Display of braking pressure Shows the pressure during braking
7Display of air suspension
pressure
Shows the pressure prevailing in the air
suspension
Eight switches are provided in the driver's cab for operating the training model.
Switch Description
Ignition Switches the training model to operating mode
Light Switches the lighting of the training model o󰀨/on
Reverse Light
If a trailer training model is connected, the reverse monitoring
system (TailGUARD) is activated and the TEBS E is switched
into reverse gear
Lift Axle Ensures that the additional axle of the truck training model is
raised
ESC Module Switches the ESC modules o󰀨/on
Traction Help Activates the air suspension (ECAS)
Driving Level I-II (normal level I-II) Changes the driving level of the truck training model
Lift Axle Trailer If a trailer training model is connected, the additional axle is
lifted

13
Technical description
5.3.3 Indicator lights
You can see the status from the indicator lights in the driver's cab of the training model.
If an indicator lamp lights up, this is an indicator for a fault in the respective component.
The indicator lights should only light up when specically simulating a fault.
If an indicator light illuminates even without simulation, contact your WABCO contact
person.
5.4 Installed systems/components
This section briey describes the systems/components installed on the training model.
Further information on the installed systems/components can be found here:
http://www.wabco.info/i/1365
Element Description
Lifting axle Liftable and lowerable axle
Rear area lighting Fully functional rear lighting
Control panel for targeted fault simulation Can specically simulate faults and enables
subsequent identication and evaluation
Braking system with brake pedal and park
brake Execution of braking commands
ECAS CAN2 Air suspension control system
EBS 3
• Main component of the truck training model
• Electronic Braking System
• Has an anti-lock braking system (ABS),
an electronic stability control

14
Technical description
5.5 ECAS remote control unit
Position no. Description
1Indicator lamp, front axle towing vehicle
2 Indicator lamp, rear axle towing vehicle
3 Indicator lamp, front axle trailer
4 Indicator lamp, rear axle trailer
5Preselect button, lifting axle trailer
6 Preselect button, lifting axle towing vehicle
7 Normal level button
8Stop button
9 Lower button
10 M2 button (memory level 2)
11 Preselect button, rear axle towing vehicle
12 Preselect button, rear axle trailer
13 Lift button
14 M1 button (memory level 1)
15 Preselect button, front axle towing vehicle
16 Preselect button, front axle trailer

15
Setting up
6 Setting up
1. Remove the packaging.
NOTICE
Damage to the training model
The training model can be damaged if transported with a forklift without the protection of the
original packaging.
Only transport the training model with the forklift if it is still in its original packaging.
CAUTION
Crushing hazard for feet
If the training model moves uncontrollably, your feet can be crushed by the castors.
Apply the brakes on the swivel castors to prevent rolling away.
2. Move the training model to the desired location.
Only move the training model using the swivel castors attached to the substructure.
3. Operate the locking mechanism of the swivel castors.
ªThe training model can now be put into operation.

16
Start-up
7 Start-up
Once the training model has been placed in the desired location, follow the steps below to prepare
the training model for use.
7.1 Establishing the compressed air supply
To be able to use the full functionality of the training model, the training model must be supplied with
external compressed air.
For faultless operation, the set pressure must (or should?) be between 7 and 8 bar.
To prevent damage to the training model by excessive external pressure, a pressure limiter
is built into the training model. Pressures > 8.5 bar are throttled by the pressure limiter.
Connect an external compressor via a compressed air line.
For this purpose there is a connection for compressed air (NW 7.2) on the side of the
substructure.
7.2 Establishing the power supply
To be able to use all the electrical functions of the training model, the training model must be
connected to a power supply.
The power supply required by the training model can be found in the technical data.
See:Âchapter "5.2 Technical data", page 10
The training model is powered by an external power supply unit and is only live when switched
on (24 V). A CE-certied power supply unit, which ensures the power supply with low voltage, is part
of the scope of supply.
NOTICE
Damage to the power supply unit
Do not switch on the mains unit immediately if it has been moved from a cold to a warm room.
The temperature di󰀨erence can cause condensation to form and possibly damage or destroy the
power supply unit.
Wait until the power supply unit has warmed up to room temperature before switching it on.
1. Check the power cable for visible damage before performing the following steps.
2. Connect the power cable of the training model to the power supply unit via the two connectors.

17
Start-up
Insert the plus plug into the left-hand, red connector.
Insert the minus plug into the right-hand, blue connector.
3. Insert the connector of the power supply unit into a socket.
4. Switch on the power supply unit.
On the side of the substructure there is a rotary Main Switch for switching on the power supply.
5. Turn the rotary Main Switch to position 1 to turn on the power supply.
ªThe power supply is on.
7.3 Switching on the ignition
CAUTION
Risk of crushing ngers and hands
When the ignition of the training model is switched on, the level of the training model may change
and the lifting axle may move.
Keep ngers and hands away from the moving parts of the training model.
Operate the switch Ignition.
ªThe training model is ready for operation.

18
Start-up
7.4 Initial start-up of EBS 3
WABCO o󰀨ers EBS 3 as a universal system that must be adapted to the vehicle type in question
during start-up based on vehicle parameters. EBS 3 cannot function without such a conguration.
When the training model is delivered, EBS 3 is parameterised with an implausible standard
parameter set for safety reasons. Before using the training model for the rst time, a one-o󰀨
start-up of the EBS 3 via the WABCO Diagnostic Software must be carried out. During start-up,
the parameters for the components installed on the training model are set.
Information on the installation and activation of the Diagnostic Software as well as the
required hardware can be found here:
See:Âchapter "9 Diagnosis and parameter setting", page 22
An EBS 3 system training is required in order to obtain a PIN for parameterisation or
creation of a parameter set.
You can nd more information here:
See:Âchapter "9 Diagnosis and parameter setting", page 22
Carrying out the initial start-up
1. Connect the PC or laptop on which the Diagnostic Software is installed to the training model via
a Diagnostic Interface.
2. Switch on the ignition of the training model.
3. Start the Diagnostic Software.
4. Select the menu item Start-up.
5. Start the parameter setting.
The training model is parameterised manually.
• Manual parameterisation (creation of your own parameter set)
After starting the start-up procedure, a menu can be used to select which steps are to be carried out.
Some steps are mandatory and cannot be deselected.
Required steps:
• Parameter setting
• EBS pressure test
• Redundancy test
• ABS sensor assignment
• Test of warning lamp control
Optional:
• Testing the CAN lines
Only after a fully completed and successful start-up can all functions of the training model be used.

19
Function and operation
8 Function and operation
To use the functions of the training model, rst carry out the following steps:
1. Start-up
See:Âchapter "7 Start-up", page 16
2. Switching on the ignition
See:Âchapter "7.3 Switching on the ignition", page 17
3. Parameterisation of EBS 3 (only required for initial start-up)
See:Âchapter "7.4 Initial start-up of EBS 3", page 18
The most versatile functions of a modern truck can be demonstrated on the training model.
The training model has the following functions:
• ECAS air suspension including liftable and lowerable lifting axle
• Brake with brake pedal
• Lighting
• System for targeted fault simulation
• Quick release fasteners for line replacement
• Control switch in the training model driver's cab
• External remote control unit: ECAS remote control unit
• LEDs to indicate faults
8.1 Brake function
The brakes of the training model can be controlled either by the brake pedal or the park brake.
• The harder you depress the brake pedal, the stronger the braking force on the wheels.
• The motors that drive the wheels switch o󰀨 automatically when the pedal is pressed.
• The brake functions even if the training model is not connected to a power source.

20
Function and operation
8.2 Air suspension (ECAS)
ECAS is an electronic level control for air-suspended trailers. For this purpose, displacement
sensors record the distance between vehicle axle and vehicle body at certain intervals. ECAS uses
the measured values of the displacement sensors to control the air suspension via solenoid valves.
The ECAS basic function is to compensate for level changes caused by a change in the load status
or by new nominal value specications (e.g. via the remote control unit). These control deviations
cause a change in the distance between the vehicle axle and the vehicle body. ECAS balances
these control deviations by means of level control.
In addition to controlling the driving level, ECAS also allows the control of enhanced functions via the
external remote control units, such as the storage of di󰀨erent target levels (memory level function).
The ECAS air suspension functions can only be used if the training model is connected to a power
supply and is switched on.
8.3 Operation with switches in the driver's cab
8.3.1 Lighting
The training model has rear and front lighting.
Flip the Light switch in the driver's cab of the training model to activate the lighting.
ªThe lighting is switched on.
8.3.2 Reverse monitoring system
The training model can use the TailGUARD system in combination with the trailer training model.
Flip the Reverse Light switch in the cab of the training model to activate the reverse monitoring
by means of TailGUARD.
ªThe reverse monitoring system is now switched on and the TEBS E of the trailer training
model is switched to reverse gear.
For more information on reverse monitoring with the TailGUARD system, see the trailer
training model operating manual: http://www.wabco.info/i/1377
8.3.3 Lifting and lowering the lifting axle
The training model is equipped with a lifting axle that can be raised and lowered. This lifting axle can
be used to demonstrate the functions and operation of a lifting axle.