WABCO 973 002 User manual

1/9
© 2006 American Standard All rights reserved 973 002 981 3/05.2006
Explanation of Symbols
Important instructions, information or tips that you
should always observe.
•List
–Step
Carefully read through all the safety information be-
fore starting the testing.
General safety instructions
Fig. 1 Trailer Control Valve 973 002 ... 0 / functional symbol
Test instruction for device 973 002 ... 0
Equipment/tools required
• Test bench 435 197 000 0 or adequate testing
equipment (see fig. 3 and 4)
• Rake angle (with fixing nuts M8
(2x) for devices), see the adja-
cent diagram
• Two tees
• Soapsuds and brush
• Nozzle: ∅1.3 mm
Additional documents required
The documents are available on the WABCO web-
site http://www.wabco-auto.com - simply enter
the product or document number in INFORM.
• Test Bench 435 197 000 0 - Operating Instructions
• General Repair and Test Information
Potential hazard situation which can
cause serious personal injury or death
if the safety instruction is not observed.
Potential hazard situations that can
cause minor or moderate personal inju-
ry if the safety instruction is not ob-
served.
Potential hazard situations that can
cause material loss if the safety in-
struction is not observed.
Only qualified skilled personnel with
specific system knowledge are author-
ized to perform the device testing at the
test bench.
Comply with the company and national accident pre-
vention/health & safety regulations.
Danger of bodily injury
Undo the screw plugs, hoses and
equipment parts only when the respec-
tive lines have been vented.
WARNING
CAUTION
CAUTION
!
!
WARNING
CAUTION
500 505
501 508
503
!
Test instruction for
Trailer Control Valves
973 002 (E)

2/9 © 2006 American Standard All rights reserved 973 002 981 3/05.2006
Testing
Perform the following test steps in the specified or-
der.
Never start testing until you have read and under-
stood all the information required for the test.
Test the device on a calibrated test bench only.
In case of doubt, use test values specified by the
vehicle manufacturer.
While testing the device, always adhere to the con-
tents of this test instruction.
Default value V and test value P see table 3.
If test values do not fit, the device must be readjust-
ed.
Reservoir pressure is 8 bar max.
1 External inspection
– Inspect the device for external visible damage.
– Visually inspect all the device's ports for blockag-
es.
2 Preparations
Test bench
– Before starting each test, ensure that the stop-
cocks are in their correct normal position (see ta-
ble 1). The output side of pressure regulator D
must be unpressurised.
Table 1: Normal position of stopcocks on the test bench
If you do not have test bench 435 197 000 0 you
must test the device according to the following test-
ing diagram (see fig. 3).
– Fix the rake angle on the device and clamp into
the bench vice.
– Connect the device to the test bench ports (see
fig. 2) or according to the test diagram.
Test bench
Set pressure regulator D to 8 bar.
Fig. 2 Connection diagram for test bench 435 197 000 0
Do not install a repaired device in the
vehicle unless it has passed the follow-
ing tests.
Shut-off cocks A B C F L V 2346711122122
open x x x x
closed x xxx xxxxx x x
WARNING
!
Never directly clamp the device in the
vice. This could damage the device.
Danger of bodily injury
Ensure that the plug-in connections on
the test bench and the device are se-
curely inserted.
!
CAUTION
!
CAUTION
41 42 43
11 21
12 22
4
72134
7213
41 43
11 21
12 22
Te s t m a i n v a l v e Test side valve
Test instruction for
Trailer Control Valves
973 002 (E)

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© 2006 American Standard All rights reserved 973 002 981 3/05.2006
3 Test main valve
Fig. 3 Test diagram "Main Valve"
Fine control valve 11
8 bar
Manometer 11
Manometers 12/21
20 dcm³
Shut-off cock 11
42
1 dcm³
Manometers 41/42 Shut-off cock 41
Precision control valve 41/42
8 bar
8 bar
Fine control valve 43
Shut-off cock 42
11
41
22
12
Shut-off cock 21
Manometer 22
21
43
Manometer 43
Test step
Manometer (M)
Comment
Default value Test value
M 11
bar
M 41
bar
M 42
bar
M 43
bar
M 12 /
M 21
bar
M 22
bar
Shut-off cocks 11, 12/21
and 43: Open the pass.
00 00 00
Fine control valves 11 and
43: Increase pressure
slowly.
80 08 80
Fine control valve 43:
Increase and lower the
pressure rapidly twice.
8
8
0
0
0
0
8...0
0...8
-
-
-
-
M 22 (test bench: Manome-
ter 4) must display an
immediate rise or drop in
pressure.
Check for leaks
Check tightness at exhaust
of the shut-off cock 42 and
at the exhaust of the
device.
8 0 0 8 - - Permissible leakage:
8 cm3/min
Never install
a leaking
trailer con-
trol valve on
the vehicle.
WARNING
Test instruction for
Trailer Control Valves
973 002 (E)

4/9 © 2006 American Standard All rights reserved 973 002 981 3/05.2006
Fine control valve 43:
Increase pressure slowly.
8
8
0
0
0
0
≥6.6
6,6...0
-
-
>0
-
M 22 (test bench: M 4) must
indicate pressure.
M 22 (test bench: M 4) must
display an immediate rise in
pressure.
Check for leaks
Check tightness at exhaust
of the shut-off cocks 41
and 43.
8 0 0 0 - 7,2...7,8 Permissible leakage:
8 cm3/min
Never install
a leaking
trailer con-
trol valve on
the vehicle.
Fine control valve 43:
Increase pressure slowly.
8 0 0 0...0,5 - - Start of drop in pressure at
M 22 (Test bench: M 4).
Fine control valve 43:
Increase pressure quickly.
8
8
8
0
0
0
0
0
0
0,5...7,7
7,1...7,7
8
-
-
-
-
0
0
M 22 (test bench: M 4) must
display an immediate drop
in pressure.
Shut-off cock 41:
Open the pass.
80 08 - 0
Fine control valve 41:
Increase and lower the
pressure rapidly twice.
8
8
0...8
8...0
0
0
8
8
-
-
0...8
8...0
M 22 (test bench: Manome-
ter 4) must display an
immediate rise or drop in
pressure.
Fine control valve 41:
Increase pressure slowly.
Perform this step only
for variant 501 and
505:
8>0...≤0,3 0 8 - >0 M 22 (test bench: M 4) must
indicate pressure.
8 2...3 0 8 - P1 Value at M 22 (Test bench:
M 4) adjust via adjusting
screw 891 200 700 2 by
venting device.
Perform this step only
for variant 505:
88 08 - -
Perform this step only
for variant 505:
Fine control valve 41:
Increase and lower the
pressure rapidly three
times.
8
8
8...0
0...8
0
0
8
8
-
-
-
-
Test step
Manometer (M)
Comment
Default value Test value
M 11
bar
M 41
bar
M 42
bar
M 43
bar
M 12 /
M 21
bar
M 22
bar
WARNING
!
!
!
Test instruction for
Trailer Control Valves
973 002 (E)

5/9
© 2006 American Standard All rights reserved 973 002 981 3/05.2006
Perform this step only
for variant 505:
Fine control valve 41:
Lower and increase pres-
sure.
8 2...3 0 8 - 0.2
0
Value at M 22 (Test bench:
M 4) adjust via adjusting
screw 891 221 250 4 by
venting device (final adjust-
ment).
Pressure progression
test (upwards)
8 2...3 0 8 - P2
Fine control valve 41:
Increase the pressure
slowly until a change is
detected at M 22 (test
bench: M 4). Stop the pres-
sure increase at this point
and test M 22.
8- 08 - Pres-
sure
stage:
max. 0.3
bar in
compari-
son to
the value
in the
line
before.
Fine control valve 41:
Increase pressure slowly.
8V3 08 - P3
Pressure progression
test (upwards)
Fine control valve 41:
Increase pressure slowly.
8
8
V4
3...2
0
0
8
8
-
-
-
P5
Pressure display at M 22
(test bench: M 4).
Lower the pressure further
until a change is detected
at M 22 (test bench: M 4).
Stop decreasing pressure
at this point and test M 22.
8- 08 - Pres-
sure
stage:
max. 0.3
bar in
compari-
son to
the value
in the
line
before.
Fine control valve 41:
Carry on decreasing the
pressure slowly.
8 0 0 8 - 0...0,1 Residual pressure
Shut-off cock 42:
Open the pass.
80 08 - -
Test step
Manometer (M)
Comment
Default value Test value
M 11
bar
M 41
bar
M 42
bar
M 43
bar
M 12 /
M 21
bar
M 22
bar
!M41
Test instruction for
Trailer Control Valves
973 002 (E)

6/9 © 2006 American Standard All rights reserved 973 002 981 3/05.2006
Table 2: Test steps "Main Valve"
Fine control valve 42:
Increase pressure slowly.
8
8
0
0
0...1,4
8
8
8
-
-
>0
≥7.4
M 22 (test bench: M 4) must
indicate pressure.
Fine control valve 41:
Increase pressure slowly.
88 88 8P6
Check for leaks
Check the tightness of the
entire device (separation
joints including exhaust).
88 88 8P7 Permissible leakage:
8 cm3/min
Never install
a leaking
trailer con-
trol valve on
the vehicle.
Precision control valves
11, 41, 42 and 43: Reduce
the pressure.
00 00 0-
Test step
Manometer (M)
Comment
Default value Test value
M 11
bar
M 41
bar
M 42
bar
M 43
bar
M 12 /
M 21
bar
M 22
bar
WARNING
Test instruction for
Trailer Control Valves
973 002 (E)

7/9
© 2006 American Standard All rights reserved 973 002 981 3/05.2006
Test and default values
Table 3: Test and default values:
973 002 ... 0
Variant
P1 P2 V3 P3 V4 P5 P6 P7
500 - M41-0.2 8 ≥7.7 ≥7.2 M41+0.2 ≥7.7 ≥7.7
501 M41+0.2±0.1 M41+0.2±0.1 7.5...8 8 ≥7.2 0
-0.4 --
503 - M41-0.2 8 ≥7.7 ≥7.2 M41+0.2 ≥7.7 ≥7.7
505 M41+1 +0.2
-0 7.2...7.8 8 -0.8 -1.2 M41+0.2 ≥7.7 ≥7.7
508 - M41-0.2 8 ≥7.7 ≥7.2 M41+0.2 - -
M41+0.
7
M41 7.2...7.8
Test instruction for
Trailer Control Valves
973 002 (E)

8/9
© 2006 American Standard All rights reserved 973 002 981 3/05.2006
4 Test side valve
Fig. 4 Test diagram "Side Valve"
Orifice diameter 2.5
8 bar
Manometer 11
Manometers 12/21
Shut-off cock 11
42
1 dcm³
Manometer 41
Shut-off cock 41
Fine control valve 41
8 bar
Shut-off cock 22
Shut-off cock 43
11
41
22
12
Shut-off cock 21
Manometer 22
21
43
Manometer 43
8 bar
Fine control valve 22
Test step
Manometer (M)
Comment
Default value Test value
M 11
bar
M 41
bar
M 22
bar
M 43
bar
M 12 /
M 21
bar
Shut-off cocks 12, 21 and 22:
Open the pass.
Shut-off cock 12/21: Shut the
pass.
00 00 0
Fine control valve 41:
Increase pressure.
02,7 00 0
Fine control valve 22:
Increase pressure.
02,7 2,50 0
Fine control valves 11 and 43:
Increase pressure.
5,5 2,2 2,5 5,5 - Pressure flows off via nozzle at
connection 21:
Fine control valve 41:
Increase the pressure until the
pressure drops by 3.5 bar at
M 12/21 (test bench: M 3).
Wait for this value at M 12/21,
then test M 41 (test bench:
M2).
-
-
2,7
4,5...5,3
2,5
2,5
5,5
5,5
M 12/21
- 3.5 bar in
compari-
son to the
value in
the line
before.
-
Precision control valve 11, 22,
41 and 43: Reduce the pres-
sure.
00 00 0

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© 2006 American Standard All rights reserved 973 002 981 3/05.2006
Table 4: Test steps "Side Valve"
Shut-off cocks 12, 21 and 22:
Shut the pass. Shut-off cocks
11, 41, 42 and 43: Open the
vent.
0 0 0 0 0 Clean device and unclamp.
Test step
Manometer (M)
Comment
Default value Test value
M 11
bar
M 41
bar
M 22
bar
M 43
bar
M 12 /
M 21
bar