WABCO OptiTire User manual
INSTALLATION MANUAL
OptiTireTM
TIRE PRESSURE MONITORING SYSTEM
OptiTireTM
TIRE PRESSURE MONITORING
SYSTEM
INSTALLATION MANUAL
Edition 1
This publication is not subject to any update service.
You will nd the current version on the internet at
http://www.wabco.info/8150102303
© 2016 WABCO Europe BVBA – All rights reserved.
WABCO
The right of amendment is reserved.
Version 1 / 03.2016(de)
815 010 230 3
4
Table of Content General information
Table of Content
1 General information ......................................................................................................................................... 5
2 Safety information............................................................................................................................................ 8
3 OptiTireTM RF Declaration of Conformity ....................................................................................................... 9
4 Components ................................................................................................................................................... 10
5 Installation ...................................................................................................................................................... 11
5.1 Safety information .................................................................11
5.2 Pre-installation checklist ............................................................11
5.3 ECU ............................................................................12
5.3.1 Trailer ...................................................................................................................................... 12
5.3.2 Truck........................................................................................................................................ 14
5.4 External module & balancing plate ....................................................16
5.5 PA tubes.........................................................................16
5.6 Display..........................................................................17
6 ECU programming ......................................................................................................................................... 18
6.1 Required tools ....................................................................18
6.2 OptiTireTM ECU installation ..........................................................18
7 Appendix......................................................................................................................................................... 19
7.1 Wheel module ID numbers ..........................................................19
7.2 Circuit diagram....................................................................22
5
General information
1 General information
Purpose of the document
This publication describes the installation of the tire pressure monitoring system
OptiTireTM.
Copyright and trademark notice
The content, particularly technical information, descriptions and gures,
correspond to the state current at the time of printing and are subject to change
without notice.
This document, including all its parts, in particular texts and gures, are
protected by copyright. Use outside the statutory or contractual limits require
authorisation by the copyright owner. All rights reserved.
Any brand names, even if not indicated as such, are subject to the rules of the
trademark and labelling rights.
Technical documents
– Open the WABCO INFORM online product catalogue:
http://inform.wabco-auto.com
– Search for documents by entering the document number.
The WABCO online product catalogue INFORM provides you with convenient
access to the complete technical documentation.
All documents are available in PDF format. Please contact your WABCO
partner for printed versions.
Please note that the publications are not always available in all language
versions.
Document Title Document Number
OptiTireTM – Installation Manual 815 XX0 230 3
OptiTireTM – System Description 815 XX0 229 3
Diagnosis – Product Overview 815 XX0 037 3
SmartBoard – User Manual 815 XX0 138 3
TEBS E System Description 815 XX0 093 3
TEBS C/D System Description 815 XX0 020 3
*Language code XX: 01 = English, 02 = German, 03 = French, 04 = Spanish, 05 = Italian,
06 = Dutch, 07 = Swedish, 08 = Russian, 09 = Polish, 10 = Croatian, 11 = Romanian,
12 = Hungarian, 13 = Portuguese (Portugal), 14 = Turkish, 15 = Czech, 16 = Chinese,
17 = Korean, 18 = Japanese, 19 = Hebrew, 20 = Greek, 21 = Arabic, 24 = Danish, 25 = Lithuanian,
26 = Norwegian, 27 = Slovenian, 28 = Finnish, 29 = Estonian, 30 = Latvian, 31 = Bulgarian,
32 = Slovakian, 34 = Portuguese (Brazil), 35 = Macedonian, 36 = Albanian, 97 = German/English
98 = = multilingual, 99 = non-verbal
6
General information General information
Structure of the WABCO product number
WABCO product numbers consist of 10 digits.
Production date
Type of device
Variant
Status digit
0 = New device (complete device), black/silver
1 = New device (subassembly)
2 = Repair set or subassembly
4 = Individual part
7 = Replacement part, red/silver
R = Reman product, green/silver
Choose genuine WABCO parts
Genuine WABCO parts are made of high quality materials and are rigorously
tested before they leave our factories. You also have the assurance that the
quality of every WABCO product is supported by a powerful customer service
network.
As a leading supplier to the industry, WABCO collaborates with the world’s
leading original equipment manufacturers and disposes of the experience
and capacitive capability required to also satisfy the most stringent production
standards. The quality of every genuine WABCO part is supported by:
Tooling made for serial production
Regular sub-supplier audits
Exhaustive end-of-line tests
Quality standards < 50 PPM
Installing replica parts can cost lives – genuine WABCO parts protect your
business.
WABCO additional services
The package you will get with a genuine WABCO part:
24-month product warranty
Overnight delivery
Technical support from WABCO
Professional training solutions from the WABCO University
Access to diagnostics tools and support from the WABCO Service Partner
network
Straightforward claims handling
Plus, of course, the condence that the Original Equipment Manufacturers’
rigorous quality standards are met.
7
General information
WABCO Service Sartner
WABCO Service Partners – the network you can rely on. You can access 2000
high quality workshops with more than 6000 specialist mechanics, all trained
to WABCO’s exacting standards and equipped with our most up-to-the-minute
systems diagnostic and support technology.
Your direct contact to WABCO
In addition to our online services, trained members of staff are there to help you
at our WABCO Service Partners to directly answer any technical or business-
related questions you may have.
Contact us if you need assistance:
Find the right product
Diagnosis support
Training
System support
Order management
You can nd your WABCO partner here:
http://www.wabco-auto.com/en/how-to-nd-us/contact/
8
Safety information OptiTireTM RF Declaration of Conformity
2 Safety information
Observe all required provisions and instructions:
Read this publication carefully.
Adhere to all instructions, information and safety information to prevent injury
to persons and damage to property.
WABCO will only guarantee the security, reliability and performance of their
products and systems if all information in this publication is adhered to.
Always follow the specications and instructions of the vehicle manufacturer.
Observe all accident regulations of the respective company as well as
regional and national regulations.
Make provisions for a safe work environment:
Only trained and qualied technicians are allowed to perform work on the
vehicle.
Use personal protective equipment if required (protective goggles,
respiratory protection, ear protectors, etc.).
Pedal actuations can lead to severe injuries if persons are in the vicinity of
the vehicle. Make sure that pedals cannot be actuated as follows:
– Switch the transmission to "neutral" and actuate the park brake.
– Secure the vehicle against rolling with chocks.
– Fasten a visible note to the steering wheel indicating that work is being
performed on the vehicle and that the pedals are not to be actuated.
9
OptiTireTM RF Declaration of Conformity
3 OptiTireTM RF Declaration of Conformity
OptiTireTM FCC Declaration for FCC ID: SA4-OPTITIRE and SA4-WM731
"This device complies with Part 15 of the FCC Rules. Operation is subject to the
following two conditions:
(1) this device may not cause harmful interference, and
(2) this device must accept any interference received, including interference that
may cause undesired operation"
OptiTireTM IC Declaration for model: IC: 6970A-OPTITIRE and 6970A-WM731
"This device complies with Industry Canada’s licence-exempt RSSs. Operation
is subject to the following two conditions:
(1) This device may not cause interference; and
(2) This device must accept any interference, including interference that may
cause undesired operation of the device."
"Le présent appareil est conforme aux CNR d’Industrie Canada applicables
aux appareils radio exempts de licence. L’exploitation est autorisée aux deux
conditions suivantes:
1) l’appareil ne doit pas produire de brouillage;
2) l’utilisateur de l’appareil doit accepter tout brouillage radioélectrique subi,
même si le brouillage est susceptible d’en compromettre le fonctionnement."
!CAUTION TO USERS: "Changes or modications not expressly approved by
the party responsible for compliance could void the user’s authority to operate
the equipment."
10
Components Installation
4 Components
FIGURE NAME OF COMPONENT
ECU
External wheel sensor (WM2)
ECU bracket
WABCO Display
Balancing plate
PA tube
Adapter
Wiring harness, truck
Wiring harness, trailer (example)
11
Installation
5 Installation
5.1 Safety information
– Observe the occupational health and safety regulations of the respective
country, the workshop as well as the vehicle manufacturer’s instructions.
Risk of accident due to loose wheel nuts
Loose wheel nuts may lead to accidents when driving on roads.
– Wheel nuts must be tightened with torque specied by vehicle manufacturer.
– Check the tightness of the wheel nuts after 500 km.
Risk of accident due to unsecured vehicle
Vehicles not secured may roll away during the assembly. This might lead to
severe injuries or even death.
– Secure the vehicle against rolling away before carrying out work on the
vehicle.
Danger to health due to dust
Dusts that are dangerous to health are generated when the rim is cleaned using
compressed air.
– Do not clean the rims using compressed air.
5.2 Pre-installation checklist
– Check if the latest diagnostic software version is installed (requirements: PC
running Windows XP or higher, 100 MB free hard disk space).
– A vehicle wiring diagram or knowledge of the vehicle electrical system will be
helpful to complete the installation.
12
Installation Installation
5.3 ECU
5.3.1 Trailer
– Determine the best possible installation position, depending on the type of
the trailer:
– Drawbar trailer: Install the ECU between the rst axle and the middle of
the trailer.
– Semitrailer/Central axle: Mount the ECU next to the rst axle of the trailer.
The ECU plug must point to the side (to the right or left) but not up or
down.
The ECU should be parallel to the main frame, in line with the driving
direction.
The housing of the ECU must have clearance at the front and back
surfaces to ensure the proper reception of signals from the wheel
modules.
Semitrailer: Assembly on cross member
– Mount the ECU on the bracket.
– Tighten ECU to bracket using torque of 15 ± 1.5 Nm.
– Mount the bracket + ECU on the chassis.
– Connect the ECU with the WABCO Trailer EBS modulator using the provided
cable and the adapter.
The provided cable may be routed along the same path as the current trailer
cables.
13
Installation
Trailer wiring
LEGEND
AECU (via adapter cable with WABCO part number: 894 600 001 2)
BBrown: Ground
CRed: +12 V/24 V
DWhite: Stop light
EDiagnosis
14
Installation Installation
5.3.2 Truck
The ECU should be mounted on the chassis in the middle of the vehicle so that
the distance to the wheel modules is as equal as possible.
The ECU plug must point to the side (to the right or left) but not up or down.
Assembly on the longitudinal beam
If the vehicle is equipped with a low lying coupling for central axle trailer, install
the ECU on the right side of the vehicle so that the wireless connection to the
trailer is not shielded off by the coupling.
The housing of the ECU must have clearance at the front and back surfaces to
ensure the proper reception of signals from the wheel modules.
– Mount the ECU on the bracket.
– Tighten ECU to bracket applying torque of 15 ± 1.5 Nm.
– Mount the bracket and ECU on the chassis.
– Connect the ECU to the vehicle using the provided cable and the adapter.
– Fit the diagnostic socket to a suitable attachment location and label it with
"Diagnostic OptiTire".
– Install cables according to the wiring diagram using cable ties in parallel with
already existing wiring harnesses.
15
Installation
Wiring of towing vehicle
!It is mandatory to use the additional adapter cable (not displayed in the
illustration)
LEGEND
ADisplay
BDiagnosis
CVehicle electrical system
DECU (via adapter cable with WABCO part number: 894 600 001 2)
Eexternal
Finternal
Cable set assignment
PIN NO.
CONNECTOR PIN
ASSIGNMENT
CABLE COLOUR
5-PIN
CABLE COLOUR
7-PIN
2 CAN High
1 CAN Low
8 GND blue blue
7 +24 V or 12 V red red
6 Ignition yellow & grey grey
4Stop light / warning
lamp 2 yellow
3 Warning lamp 1 green
16
Installation Installation
5.4 External module & balancing plate
Maintaining a list of the wheel module numbers and location on the vehicle is
required for proper ECU programming:
– Assign each wheel module to the designated wheel.
– Enter each wheel module ID on the paper form (form can be found in the
appendix of this manual).
Wheel modules are always mounted on the outside wheels.
– Check which position of the wheel module is suitable for connecting the
PA tube to the wheel module and the valvesee chapter „5.5 PA tubes“ on
page 16.
The wheel module should be positioned as close as possible to the tire
valve. The minimum length of the PA tube from valve to external wheel
module should be 10 cm.
The PA tube should be guided to the tire valve without stretching,
deformation or twisting.
– Remove the wheel nuts on which the external modules and balancing plates
are to be mounted. The vehicle does not need to be jacked up when only
four wheel nuts are removed.
– If necessary, also remove the rim protecting ring.
– Position the wheel module and the balancing plate on the wheel bolts.
The wheel modules should be located directly opposite the balancing plates,
except on twin tires where no balancing plates are required.
Twin tires: Both wheel modules should be mounted on the outer wheel. The
wheel modules should be located directly opposite each other.
– Screw the wheel nuts back on.
– Tighten the wheel nuts with the torque specied by the vehicle manufacturer.
– Inate tires to proper air pressure according to manufacturer or eet
recommendations.
5.5 PA tubes
CAUTION Increased wear due to incorrect installation
With tubes that rest on the edge of enclosures there
is increased wear due to vibrations. This might lead
to leakages.
–PA tubes need to be installed such that they
neither exert tensile or compressive stress on
connections nor rest on the rim.
–Avoid excess lengths to prevent undesired
vibrations.
–Avoid moisture in the PA tube or at the pressure
port of the external sensor.
– Hold the PA tube with the connection to the tire valve.
– Hold the other end of the PA tube to the wheel module.
17
Installation
– Stick the PA tube onto the tire valve without tightening it to avoid loss of
pressure.
– Mark the position on the tube where the PA tube meets with the edge of the
wheel module (e.g. using adhesive tape).
– Adjust the length of the PA tube (PA tube should be long enough so it is not
under tension).
– Also note that the PA tube reaches 20 mm into the connection. For this
reason the PA tube should be cut 20 mm after the marking. Use a suitable
right-angled cutting tool, such as those used for shortening plastic brake
lines.
!Do not use valve extensions made of plastic. They are not designed to be
constantly pressurised.
Tube cutting tool for
ø 4 to ø 12
Tube cutting tool for
ø 4 to ø 22
– Mount the connecting tube to the wheel module by inserting the end of
the PA tube into the wheel module opening. After pressing with force, the
PA tube is locked in position and can then only be removed again after
unscrewing the brass screw connection (V203).
– Using the marking, check if the PA tube has been pushed up to the stop.
– Pull on the PA tube to check if the PA tube has been inserted and connected
with sufcient tightness.
– Connect the other side of the PA tube to the tire valve.
– Tighten union nuts on the tire valve hand tight.
– Check that the connection is tight using a leakage indicating spray.
5.6 Display
!Comply with all safety and vehicle manufacture guidelines.
– Determine where to install the WABCO display unit. The display housing
is mounted with screws and the display is snapped into the housing.
Modications may be necessary to install this unit.
– Follow the instruction to install the cabling of the Truck ECU.
– Locate the diagnostic connector near the fuse panel for accessibility. This is
required for programming of functions and system diagnostics.
18
ECU programming Appendix
6 ECU programming
6.1 Required tools
– Check if the latest OptiTireTM diagnostic software version is installed
(requirements: PC running Windows XP or higher, 100 MB free hard disk
space).
Diagnostic interface (e.g. 446 301 003 0) is supplied separately.
Diagnostic cable (446 300 348 0) is supplied separately.
6.2 OptiTireTM ECU installation
– If OptiTireTM is installed in both the truck and the trailer, remember that both
ECUs need to be programmed.
– Turn on the vehicle ignition.
– Connect the external diagnostic plug to the WABCO diagnostic interface
using the diagnostic cable.
– Select the vehicle type and type of diagnostic connection. It is also possible
to automatically search for all connected ECUs (more time-consuming than
the manual procedure).
– Select system check. Click on Start.
– Enter the vehicle data. Click OK and save.
– Select the vehicle conguration and sensor type (WM2 for external
modules). Click Continue.
– Enter the wheel module IDs and recommended tire pressure.
– Click Continue after module IDs and tire pressures have been entered.
– Click Continue if no additional warning lamp should be activated.
– Click Continue if no changes to country-specic entries are required (only
valid for USA).
– Click on Write to ECU.
– If required, enter the provided PIN into the "PIN2" eld and click OK.
– Click OK again.
– Wheel module reception will appear in the module table.
– Click OK after the reception column indicates at least one bar for each
module. Module stimulation can reduce installation time.
ÖAssignment test of module allocation will be started.
– Stimulate the wheel modules with a bar magnet according to the prescribed
sequence in the diagnosis. The magnet must be hold minimum 5 seconds to
the OptiTireTM logo of the wheel module.
– Click on OK.
– If faults occur, they will be displayed and should be repaired.
– Click OK.
– Click on System Check Label to print out the protocol. Store it with other
vehicle-related information.
– Click on System Label to print out the system sticker. Attach accordingly.
19
Appendix
7 Appendix
7.1 Wheel module ID numbers
Make a record of wheel module ID numbers by noting the IDs and/or attaching ID stickers at each
wheel location:
20
Appendix Appendix
Other manuals for OptiTire
2
Table of contents
