WABCO TP0223 Service manual

WABCO AIR MANIFOLD
DISTRIBUTION MODULE
ASSEMBLY
TECHNICAL BULLETIN
TP0223

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 Overview. .....................................................................................................................................................................9
4 Maintenance. .............................................................................................................................................................10
5 MountingSpecications........................................................................................................................................... 11
6 Air Lines.....................................................................................................................................................................12
7 Air Supply. .................................................................................................................................................................13
8 Troubleshooting and Testing. ..................................................................................................................................14
8.1 Voltage Check..................................................................................................................................................14
8.2 Resistance Test................................................................................................................................................15
8.3 Air Leakage Test ..............................................................................................................................................15
8.4 Valve Check .....................................................................................................................................................16
9 Replacement Procedures. ........................................................................................................................................17
9.1 Solenoid Valve .................................................................................................................................................17
9.2 Mounting Base/Assembly ................................................................................................................................17

Edition 1
Version 2 (02.2022)
TP0223 (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

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 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].
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: [phone]
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, 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 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
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.
WARNING
Remove all pressure from the air system before you disconnect any component. Pressurized air can
cause serious personal injury.

9
Overview
3 Overview
The air manifold distribution module (AMDM) consists of a mounting base that can hold up to ve
electrically operated air solenoid valves that can be used to operate air system accessories.
The mounting base provides a common air supply and a common electrical connector to operate the
valves. With no electrical power applied, the individual solenoid valves are in a normally closed position
(the air supply is isolated and the delivery is vented to atmosphere). When power is applied, the exhaust is
closed and air pressure is delivered.
The air pressure may be delivered to a variety of accessories including the fan clutch, air horn, suspension
dump, 5th wheel slide and inter-axle di󰀨erential lock. For applications where more than ve functions are
controlled, additional AMDMs may be installed.

10
Maintenance
4 Maintenance
AMDMs require no regularly scheduled maintenance. However, they must be kept clean and free of debris
or ice build-up.

11
MountingSpecications
5 MountingSpecications
The mounting location will vary according to the vehicle manufacturer’s requirements. In general, the
AMDMs must be mounted with the electrical connector in the upper right-hand corner as shown. The
AMDM must be mounted in a location that is not directly exposed to road splash, debris or direct spray from
power washers.
EXHAUST
PORTS
PNEUMATIC
DELIVERY
PORTS
MOUNTING
BASE SOLENOID
VALVE
EIGHT-PIN
ELECTRICAL
CONNECTOR
PNEUMATIC
SUPPLY PORT
SOLENOID
VALVE
MOUNTING
SCREWS
AMDM WITH FOUR SOLENOID VALVES
4016941a
For technical assistance, contact the WABCO Customer Care Center at [phone].

12
Air Lines
6 Air Lines
CAUTION
Identify the air lines before disassembly. If air lines are removed, they must be reinstalled in the same
location to avoid accidental activation of devices or activation of the wrong device.
CAUTION
Never apply voltage to the assembly except by means of the proper connector in the vehicle wire
harness.
All delivery ports are identied by number and delivery ttings may be identied with a color-coded ring.
Refer to the manufacturer’s service manual for color coding identication.

13
Air Supply
7 Air Supply
CAUTION
Air supply must be conrmed prior to attempting any repair or replacement of an AMDM. The air
supply is provided through a pressure protection valve. Air will not be available to the AMDM if the
supply pressure is less than the pressure protection valve setting.
Follow the standard shop procedures for your service area to conrm air supply.

14
Troubleshooting and Testing
8 Troubleshooting and Testing
CAUTION
When troubleshooting and testing the AMDM, do not damage the connector pins.
CAUTION
The mounting base contains diodes that are polarity sensitive and can be damaged if power is
incorrectly applied. To avoid damaging the diodes, apply power using the vehicle manufacturer’s wire
harness connector.
8.1 Voltage Check
If one of the solenoid valves on the AMDM does not operate, test the vehicle to ensure proper voltage.
Measure the voltage on the vehicle harness connector at the vehicle connector pins.
Voltage must be between 9.5 and 15.0 volts.
The ignition must be turned ON for this test.
D C B A
H G F E
HARNESS
PIN
IDENTIFICATION
4016942a

15
Troubleshooting and Testing
8.2 Resistance Test
If the voltage is within the acceptable range of 9.5 to 15 volts but the valve still does not operate, test the
solenoid. Use a volt-ohm meter to check the resistance of both the valve and the module base as follows:
1. Remove the electrical connector from the module base. Select the appropriate pin numbers.
STATION
NUMBER
POSITIVE
CONNECTOR
PIN
NEGATIVE
CONNECTOR
PIN
RESISTANCE
1 E B
35-60 ohms
2 F G
3 D H
4 C H
5 A H
A B C D
E F G H
AMDM PIN IDENTIFICATION
4016943a
2. Connect the volt-ohm meter to the appropriate pins and measure the resistance. Coil resistance must
be between 35 and 60 ohms.
3. If the resistance is less than 35 ohms, the circuit may be shorted. Identify which station is causing the
short and remove the solenoid from that station. If that connector circuit remains shorted, the base
must be replaced.
If the base connector pins are no longer shorted, the solenoid valve is likely causing the short. Check
the resistance across its pins. If that check results in a resistance less than 35 ohms, the solenoid
valve must be replaced.
8.3 Air Leakage Test
If the voltage and resistance are within the acceptable ranges (9.5-15 volts/35-60 ohms resistance) but the
valve does not deliver air, inspect the air supply. A pressure-protected air circuit provides air to the valve
and the valve will not function unless the reservoir pressure exceeds the pressure protection setting,
typically 85 psi (585 kPa).
Excessive leakage may also be a reason for replacing the solenoid valve module. The source of a supply
line leak may not be readily apparent because all valves are vented through two common exhaust ports.
Check for air leakage from the assembly as follows:
1. Apply a soap and water leakage detection uid to all potential leakage sites on the front and sides of
the valve.

16
Troubleshooting and Testing
2. If no leakage is found on the front and sides of the valve, loosen the two mounting screws that attach
the assembly to the vehicle and inspect for leaks from the back side of the assembly.
4016944a
3. Replace the leaking solenoid valve (refer to Replacement Procedures).
8.4 Valve Check
CAUTION
The mounting base contains diodes that are polarity sensitive and can be damaged if power is
incorrectly applied. To avoid damaging the diodes, apply power using the vehicle manufacturer’s wire
harness connector.
Solenoid valves mounted on the module base may be inspected individually as follows:
1. Drain the air from the system.
2. Disconnect the air supply and electrical connector.
3. Remove the two screws that hold the solenoid valve to the mounting base. Pull the solenoid valve
directly o󰀨 the base. Be careful to locate the air supply and electrical connector O-rings.
4. Test the solenoid function by applying voltage to the two electrical pins on the valve. With voltage
(9.5-15 vdc) applied, listen for the solenoid actuation. Do not disassemble further.
5. If the solenoid valve does not function, replace the entire solenoid valve. Refer to Replacement
Procedures.

17
Replacement Procedures
9 Replacement Procedures
9.1 Solenoid Valve
1. Follow the removal procedure above to remove the valve from the module.
2. Position the air supply and electrical connector O-rings in the proper location on the base of the
module.
O-RING
ELECTRICAL PINS
4016945a
3. Install the new solenoid valve by engaging the electrical pins rst. Press the solenoid valve assembly
onto the mounting base.
4. Use a Phillips head screwdriver to install the two self-tapping screws. Tighten to 8-11 lb-in
(0.9-1.2 Nm).
9.2 Mounting Base/Assembly
Replace the mounting base if it is broken or cracked.
1. Drain the reservoirs to eliminate air pressure.
2. Disconnect the battery.
3. Remove and carefully identify each air line.
4. Remove the electrical connector.
5. Remove the two bolts that mount the base plate to the vehicle.
6. Remove any solenoid valves that are to be reused. Take care to collect the two O-rings between the
individual solenoid valves and the mounting base for reuse when assembling solenoid valves to the
mounting base.
7. Reinstall the solenoid valves (if they are to be reused) or attach replacement valves as required.
8. Position the module on the vehicle with the eight-pin electrical connector in the upper right-hand
corner.
9. Replace the two mounting bolts that attach the module to the vehicle. Tighten the screws to
103.2 ± 18 lb-ft (140 ± 25 Nm).
10. Reconnect the pneumatic lines and electrical connector. Air lines must be reinstalled in the same
location they were in before they were removed. Refer to the vehicle manufacturer’s service manual
for complete instructions.
11. Connect the battery and pressurize the air system to 100 psi (689 kPa) minimum. Test each device
controlled by the assembly to verify that the air lines have been installed in the correct position.

For further details, contact the
WABCO Customer Care Center at 855-228-3203.
About CVS Division
ZF’s Commercial Vehicle Solutions (CVS) division is helping shape the future of commercial transportation ecosystems. Our mission is
to be the preferred global technology partner to the commercial vehicle industry. Powerfully combining ZF’s commercial vehicle systems
expertise, extensive technology portfolio and global operations, the division serves the full commercial vehicle industry value chain. As the
automotive industry progresses towards an increasingly autonomous, connected, and electried (ACE) future, ZF’s CVS division innovates,
integrates and supplies components and advanced control systems that help make commercial vehicles and eets operate more safely and
sustainably. CVS unites ZF’s former Commercial Vehicle Technology and Commercial Vehicle Control Systems divisions, the latter being
formed following ZF’s acquisition of WABCO in Spring 2020.
For more information, visit: www.zf.com/cv
© 2022 ZF CV Systems North America LLC – All Rights Reserved – TP0223 / 02.2022