WABCO 973 002 Test Instruction

Explanation of Symbols

Test instruction for

Trailer Control Valves

973 002 (E)

WARNING

CAUTION

CAUTION

Important instructions, information or tips that you

!

should always observe.

•List

–Step

Carefully read through all the safety information be-

!

fore starting the testing.

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 inju­ry if the safety instruction is not ob­served.

Potential hazard situations that can
cause material loss if the safety in­struction is not observed.

Fig. 1 Trailer Control Valve 973 002 ... 0 / functional symbol

Test instruction for device 973 002 ... 0

500 505

501 508

503

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 adja­cent diagram

• Two tees

General safety instructions

WARNING

Comply with the company and national accident pre­vention/health & safety regulations.

CAUTION

Only qualified skilled personnel with
specific system knowledge are author­ized to perform the device testing at the
test bench.

Danger of bodily injury

Undo the screw plugs, hoses and
equipment parts only when the respec­tive lines have been vented.

• 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

© 2006 American Standard All rights reserved 973 002 981 3/05.2006

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973 002 (E)

Test instruction for
Trailer Control Valves

Testing

WARNING

Perform the following test steps in the specified or-

!

der.

Never start testing until you have read and under­stood 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 con­tents of this test instruction.

Default value V and test value P see table 3.

If test values do not fit, the device must be readjust­ed.

Reservoir pressure is 8 bar max.

1 External inspection

Do not install a repaired device in the
vehicle unless it has passed the follow­ing tests.

If you do not have test bench 435 197 000 0 you

!

must test the device according to the following test­ing diagram (see fig. 3).

CAUTION

– 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.

CAUTION

7

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 se­curely inserted.

21

4

3

2

7

1

4

3

– Inspect the device for external visible damage.

– Visually inspect all the device's ports for blockag-

es.

2 Preparations

Test ben c h

– Before starting each test, ensure that the stop-

cocks are in their correct normal position (see ta­ble 1). The output side of pressure regulator D
must be unpressurised.

Shut-off cocks A B C F L V 2346711122122

open x x x x

closed x xxx xxxxx x x

Table 1: Normal position of stopcocks on the test bench

42

41

11

12

Te s t ma i n v a lv e

Fig. 2 Connection diagram for test bench 435 197 000 0

43

21
22

41

11
12

Test side valve

43

21
22

2/9

© 2006 American Standard All rights reserved 973 002 981 3/05.2006

3 Test main valve

Fine control valve 11

8 bar

Test instruction for

Trailer Control Valves

Shut-off cock 11

Manometer 11

20 dcm³

Manometers 12/21

973 002 (E)

Shut-off cock 21

Precision control valve 41/42

8 bar

Fig. 3 Test diagram "Main Valve"

Manometers 41/42

Test step

Shut-off cock 41

11

41

Manometer 43

Fine control valve 43

8 bar

Shut-off cock 42

43

42

Manometer (M)

Default value Test value

M 11
bar

M 41
bar

M 42
bar

M 43
bar

21

22

12

M 12 /
M 21
bar

Manometer 22

1 dcm³

Comment

M 22
bar

Shut-off cocks 11, 12/21
and 43: Open the pass.

Fine control valves 11 and
43: Increase pressure
slowly.

Fine control valve 43:
Increase and lower the
pressure rapidly twice.

Check for leaks

Check tightness at exhaust
of the shut-off cock 42 and
at the exhaust of the
device.

© 2006 American Standard All rights reserved 973 002 981 3/05.2006

00 00 00

80 08 80

8

0

0

8...0

-

-

M 22 (test bench: Manome­ter 4) must display an

8

0

0

0...8

-

-

immediate rise or drop in
pressure.

8 0 0 8 - - Permissible leakage:

3

8 cm

/min

WARNING

Never install
a leaking
trailer con­trol valve on
the vehicle.

3/9

Test step

973 002 (E)

M 11
bar

Test instruction for
Trailer Control Valves

Manometer (M)

Default value Test value

M 41
bar

M 42
bar

M 43
bar

M 12 /
M 21
bar

M 22
bar

Comment

Fine control valve 43:
Increase pressure slowly.

Check for leaks

Check tightness at exhaust
of the shut-off cocks 41
and 43.

Fine control valve 43:
Increase pressure slowly.

Fine control valve 43:
Increase pressure quickly.

Shut-off cock 41:
Open the pass.

8

8

8 0 0 0 - 7,2...7,8 Permissible leakage:

8 0 0 0...0,5 - - Start of drop in pressure at

8

8

8

80 08 - 0

0

0

0

0

0

0

0

0

0

0

≥6.6

6,6...0--

0,5...7,7

7,1...7,7

8

>0

-

-

-

-

-

0

0

M 22 (test bench: M 4) must
indicate pressure.

M 22 (test bench: M 4) must
display an immediate rise in
pressure.

3

8 cm

/min

WARNING

M 22 (Test bench: M 4).

M 22 (test bench: M 4) must
display an immediate drop
in pressure.

Never install
a leaking
trailer con­trol valve on
the vehicle.

Fine control valve 41:
Increase and lower the
pressure rapidly twice.

Fine control valve 41:
Increase pressure slowly.

Perform this step only

!

for variant 501 and
505:

Perform this step only

!

for variant 505:

Perform this step only

!

for variant 505:

Fine control valve 41:
Increase and lower the
pressure rapidly three
times.

8

8

8>0...≤0,3 0 8 - >0 M 22 (test bench: M 4) must

8 2...3 0 8 - P1 Value at M 22 (Test bench:

88 08 - -

8

8

0...8

8...0

8...0

0...8

0

0

0

0

8

8

8

8

-

-

-

-

0...8

8...0

-

-

M 22 (test bench: Manome­ter 4) must display an
immediate rise or drop in
pressure.

indicate pressure.

M 4) adjust via adjusting
screw 891 200 700 2 by
venting device.

4/9

© 2006 American Standard All rights reserved 973 002 981 3/05.2006

Test step

Test instruction for

Trailer Control Valves

Manometer (M)

Default value Test value

M 11
bar

M 41
bar

M 42
bar

M 43
bar

M 12 /
M 21
bar

973 002 (E)

Comment

M 22
bar

Perform this step only

!

for variant 505:

Fine control valve 41:
Lower and increase pres­sure.

Pressure progression
test (upwards)

Fine control valve 41:
Increase the pressure
slowly until a change is
detected at M 22 (test
bench: M 4). Stop the pres­sure increase at this point
and test M 22.

Fine control valve 41:
Increase pressure slowly.

Pressure progression
test (upwards)

Fine control valve 41:
Increase pressure slowly.

8 2...3 0 8 - 0.20Value at M 22 (Test bench:

8 2...3 0 8 - P2

8- 08 - Pres-

8 V3 08 - P3

8

8

V4

3...2

0

0

8

8

-

-

M41

sure
stage:
max. 0.3
bar in
compari­son to
the value
in the
line
before.

-

P5

M 4) adjust via adjusting
screw 891 221 250 4 by
venting device (final adjust­ment).

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.

Fine control valve 41:
Carry on decreasing the
pressure slowly.

Shut-off cock 42:
Open the pass.

© 2006 American Standard All rights reserved 973 002 981 3/05.2006

8- 08 - Pres-

sure
stage:
max. 0.3
bar in
compari­son to
the value
in the
line
before.

8 0 0 8 - 0...0,1 Residual pressure

80 08 - -

5/9

Test step

973 002 (E)

M 11
bar

Test instruction for
Trailer Control Valves

Manometer (M)

Default value Test value

M 41
bar

M 42
bar

M 43
bar

M 12 /
M 21
bar

M 22
bar

Comment

Fine control valve 42:
Increase pressure slowly.

Fine control valve 41:
Increase pressure slowly.

Check for leaks

Check the tightness of the
entire device (separation
joints including exhaust).

Precision control valves
11, 41, 42 and 43: Reduce
the pressure.

Table 2: Test steps "Main Valve"

8

8

88 88 8P6

88 88 8P7 Permissible leakage:

00 00 0-

0

0

0...1,488

-

8

-

>0

≥7.4

M 22 (test bench: M 4) must
indicate pressure.

3

8 cm

/min

WARNING

Never install
a leaking
trailer con­trol valve on
the vehicle.

6/9

© 2006 American Standard All rights reserved 973 002 981 3/05.2006

Test and default values

7

Test instruction for

Trailer Control Valves

973 002 (E)

973 002 ... 0

Variant

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

503 - M41-0.2 8 ≥7.7 ≥7.2 M41+0.2 ≥7.7 ≥7.7

505 M41+1

508 - M41-0.2 8 ≥7.7 ≥7.2 M41+0.2 - -

Table 3: Test and default values:

P1 P2 V3 P3 V4 P5 P6 P7

0

-0.4

M41 7.2...7.8

+0.2

-0

7.2...7.8 8

-0.8

-1.2

M41+0.

M41+0.2 ≥7.7 ≥7.7

--

© 2006 American Standard All rights reserved 973 002 981 3/05.2006

7/9

4 Test side valve

Shut-off cock 11

8 bar

Fine control valve 41

Fig. 4 Test diagram "Side Valve"

Test step

8 bar

Shut-off cock 43

Manometer 11

Manometers 12/21

Manometer 41

11

21

41

Shut-off cock 41

Manometer 43

43

42

22

12

Manometer (M)

Default value Test value

M 11
bar

M 41
bar

M 22
bar

M 43
bar

M 12 /
M 21
bar

Shut-off cock 21

Manometer 22

1 dcm³

Shut-off cock 22

Comment

Orifice diameter 2.5

Fine control valve 22

8 bar

Shut-off cocks 12, 21 and 22:
Open the pass.
Shut-off cock 12/21: Shut the
pass.

Fine control valve 41:
Increase pressure.

Fine control valve 22:
Increase pressure.

Fine control valves 11 and 43:
Increase pressure.

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).

Precision control valve 11, 22,
41 and 43: Reduce the pres­sure.

00 00 0

02,7 00 0

02,7 2,50 0

5,5 2,2 2,5 5,5 - Pressure flows off via nozzle at

connection 21:

-

2,7

2,5

5,5

M 12/21

- 3.5 bar in
compari­son to the
value in
the line
before.

-

4,5...5,3

2,5

5,5

-

00 00 0

© 2006 American Standard All rights reserved 973 002 981 3/05.2006

8/9

Test step

Manometer (M)

Default value Test value

M 11
bar

M 41
bar

M 22
bar

M 43
bar

Comment
M 12 /
M 21
bar

Shut-off cocks 12, 21 and 22:
Shut the pass. Shut-off cocks
11, 41, 42 and 43: Open the
vent.

Table 4: Test steps "Side Valve"

0 0 0 0 0 Clean device and unclamp.

© 2006 American Standard All rights reserved 973 002 981 3/05.2006

9/9