Service

Maintenance instructions

Service Maintenance instructions

Edition 1

This publication is not subject to any update service. New versions are available in INFORM at www.wabco-auto.com

© 2007 WABCO

The right of amendment is reserved.Version 1/09.2007(en)

815 010 140 3

Service Table of Contents

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1 General Information 5 1.1 Brake servo units and electronic control systems 5 1.2 Foundation brakes 5 1.3 Further information 5 1.4 WABCO Service Centre and authorised workshops 6

2 Maintenance instructions 7 2.1 Before starting to drive 7 2.2 After you start driving 8 2.3 Weekly maintenance 8 2.4 Quarterly maintenance 9 2.5 Foundation brakes 9

Service 1General Information

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1 General Information

This document is meant for forwarding agents and drivers who handle vehicles with WABCO systems. It is designed to provide information on WABCO products supplementing the operating instructions for the vehicle. If in doubt, the specifications in the operating instructions of the vehicle manufac-turer shall be binding.

CAUTION

Risk of injury and accident – Repair work on the safety systems of vehicles (e.g. the braking system) may

only be carried out by trained personnel in specialist workshops.

Vehicle inspections are subject to national regulations. It is imperative that these regulations are adhered to.

1.1 Brake servo units and electronic control systems

Usually brake servo units and electronic control systems are maintenance-free and can be used within a temperature range from - 40° to + 80° C. You will find further information on the different products on the pages below. Monitoring procedures run continually in the electronic control systems and keep checking the entire system. Any faults that occur are indicated to the driver via warning lamps in the instrument panel. If there are any doubts regarding the cor-rect function of a unit or a system, a workshop must be entrusted to perform a di-agnosis. Electronic control systems must not be opened!

1.2 Foundation brakes

Brake linings and brake discs are subject to regular wear, the extent of which de-pends on the driving behaviour and the type of routes driven. Service intervals as-sessing the wear condition must be observed and wear parts must be replaced as required. Wear indicators on the brake linings can be used to trigger a signal in the instru-ment panel when the wear limit has been reached. If wear sensors are installed, it is possible to display the wear condition continuously. When the wear limit has been reached, the vehicle must be taken to the workshop. You will find further instructions on foundation brakes in the chapter "Maintenance instructions".

1.3 Further information

Further information on the different products can be obtained by means of the part number and the type plate of the product. At www.wabco-auto.com you can access the product catalogue INFORM which, apart from data sheets and outline drawings, also contains all publications. At www.wabco-auto.com/worldwide you can obtain the contact data of WABCO contact persons, as well as a directory of suppliers and workshops.

1 Service

General Information

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1.4 WABCO Service Center and authorised workshops

If discrepancies occur when checking the braking system and these cannot be re-solved by simple means, we recommend you seek the assistance of an authorised workshop. Only original parts are used in WABCO service centers and workshops. The bene-fits of this practice are repairs that last, reducing the time the vehicle spends in workshops.

Service 2Maintenance instructions

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2 Maintenance instructions

2.1 Before starting to drive

Hand-filled compressors The oil level must be checked if manually refilled compressors are installed. The oil level shown must be between the markings on the dipstick. To top up, use the same oil as for the engine. When the engine oil is changed, the oil for compressors should be changed as well. As soon as the charging process is complete, the on-load operation of the com-pressors should stop audibly.

Unloader valve Observe the operation of the unloader valve and check the cut-out and cut-in pres-sure. The cut-out pressure has been reached when the unloader valve vents audi-bly; the cut-in pressure has been reached when the bleeder valve of the unloader closes. When filling the air reservoirs, check the function of the low-pressure warn-ing facility.

Air dryer The standard cartridge, as well as the WABCO Air System Protector, the desiccant cartridge with coalescence filter, should be replaced after two years. Your WABCO partner guarantees that he will accept the return of the old cartridges.

Frost protection Check level of antifreeze in the reservoir and replenish if necessary. WABCO anti-freeze should be used for replenishment. During frost or the danger of frost, the frost protection system should be put into operating position (winter position). In the case of brake systems with air dryers, this procedure is not required.

Air Reservoirs In vehicles with manual drain valves, the reservoirs – especially in the winter (tem-perature below 7° C) – must be drained on a regular basis, e.g. daily if there are substantial amounts of condensate. This procedure is not required if automatic drain valves are installed.

Coupling Head Disengaged coupling heads must be closed by turning the covers. When driving with a trailer, ensure that the sealing washers of the coupling heads are in good condition and that no dirt enters the braking system.

Load Sensing Valve Manual brake-power regulators are frequently installed in agricultural vehicles as well as in older vehicles. In this case, the lever of the brake-power regulator must positioned in accordance with the respective loading condition. If the vehicle has automatic load-sensing brake-power regulation, the controller is set automatically when the vehicle is loaded or unloaded. In the case of leaf-sprung vehicles, ensure that the adjusting shaft of the control valve can move freely and check the linking for any damage.

2 Service

Maintenance instructions

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Anti-Lock Brake System (ABS) Apart from the 24 N plug connection, the ABS plug connection (ISO 7638) must also be connected when hitching the trailer vehicle in order to supply the electronic control unit of the trailer with power. The towing vehicle is usually equipped with up to three warning of info lamps indicating functions and for system monitoring.

2.2 After you start driving

You must only commence driving when there is sufficient supply pressure in the air tanks. If warning lamps light up during the drive indicating insufficient supply pres-sure, there is a fault within the air supply system or a leak and this must be at-tended to immediately.

CAUTION

If there is a fault in the compressed air supply system, the vehicle can only be braked in a controlled manner a few more times. Spring brake actuators can brake the vehicle suddenly. – Stop the vehicle immediately at a suitable place taking into account the traffic

situation. If it is not possible to increase the supply pressure despite increasing the idle speed, the vehicle must be inspected with regard to air delivery or leaks and repaired as necessary. The vehicle must not be driven without sufficient supply pressure!

The effectiveness of the foot brake, hand brake, and endurance brake must be checked taking road conditions into account. Here attention should be paid to good graduation of the towing vehicle brake valve. In the case of vehicles with ABS or EBS, corresponding warning lamps light up af-ter switching on the ignition. The latest point at which these lamps will go out again is when the vehicle speed exceeds 7 km/h and no fault was detected by the safety circuit of the system. If a warning lamp does not go out or lights up while driving, a fault is present in the system. An info lamp in the instrument panel is continuously lit if the ABS connector of a towed trailer vehicle is not plugged in. In this case, the ABS or EBS of the trailer vehicle is not operational. In the case of Trailer EBS, this also means that the brak-ing force adjustment according to the loading condition no longer functions increas-ing the tendency of the individual wheels to block.

WARNING

A fault in the ABS or EBS system of the towing vehicle or the trailer can alter the braking behaviour and impair the road safety of the vehicle or the tractor-trailer combination.

=> Wheels may lock on slippery roads. Only minor steering action is now possible, more vigorous steering action will cause the vehicle to skid. – Drive very carefully! – Visit a specialist workshop immediately to eliminate the fault.

2.3 Weekly maintenance

The brake pedal must be actuated and fixated while the engine is off and while there is a reservoir pressure that corresponds to the cut-out pressure of the unloader valve. When inspecting the compressed air braking system in this condi-tion, ensure that there are no leaks. If the stroke of a brake cylinder reaches half the total stroke, the foundation brake must be readjusted. The dust protection bel-lows must be in good condition and seated firmly.

Service 2Maintenance instructions

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2.4 Quarterly maintenance

Compressor intake filters If the compressor is not connected to the air filter of the engine, the intake filter of the compressor must be cleaned with benzine, dried, and wetted with motor oil. In the case of oil bathe air filters, the filter must be washed out with benzine and the oil content replaced (use motor oil) as soon as the the filter begins to silt-up. Dis-pose of the used oil in accordance with the regulations regarding protection of the environment.

filter Open filter in unloader valve, line filter, and filters integrated in the coupling heads, clean the inner parts with benzine, and dry them. Check tightness after reassembly.

Linkages and joints Yoke joints on brake cylinders and brake linkages must be lightly oiled.

2.5 Foundation brakes

WARNING

Lubricating the brake linings, brake hoses, and friction surface

=> Danger of accidents due to failure of the brake – Brake linings, brake hoses, and friction surface must never come into contact

with greases or oils.

Renewing brake linings The permissible extent of brake lining wear must be observed and checked. Worn, burnt, glazed, or oil-contaminated brake linings must be replaced by the workshop. It is always necessary to replace the linings of both brakes on one axle. Only the brake linings approved for the respective vehicle by WABCO or the vehicle manu-facturer may be used.

Replacement of brake discs or brake drums Brake discs or brake drums must be checked for damage and wear on a regular basis. The maximum permitted degree of wear must not be exceeded.

Other brake components Pressure and tension springs, seals, protective caps, as well as bellows must be replaced after two years, respectively. Only replacement parts approved by WABCO or the vehicle manufacturer may be used.

Running-in instructions, brake linings New brake linings must be run in for the brakes to attain optimal braking effect. This is possible by sequenced braking action at low to medium vehicle speeds.

Permanent braking action over longer periods or drastic braking at high speeds are

not permissible for running-in the new brake linings.

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WABCO Vehicle Control Systems, is one of the world's leading providers of electronic braking, stability, suspension and transmission control systems for heavy duty commercial vehicles. WABCO products are also increasingly used in luxury cars and sport utility vehi-cles (SUVs). Customers include the world’s leading commercial truck, trailer, bus and passenger car manufacturers. Founded in the U.S. in 1869 as West-inghouse Air Brake Company, WABCO

was acquired by American Standard in 1968 and spun off in 2007. Headquar-tered in Brussels, Belgium, the business today employs more than 7,000 people in 34 offices and production facilities worldwide. In 2006, total sales were $2 billion. WABCO is a publicly traded company and is listed on the New York Stock Exchange with the stock symbol WBC. www.wabco-auto.com