Operating and Installation BPW THE QUALITY FACTOR. Version 1.4. ECO Tronic EBS. Operating and Installation Instructions. Version 1.

Transcription

1 Operating and Installation Instructions Version.4 BPW THE QUALITY FACTOR ECO Tronic EBS. Operating and Installation Instructions Version.4

2 BPW Operating and Installation Instructions

3 Introduction Page. ECO Tronic EBS 4. Abbreviations 7.3 Safety information 8.4 System layout 9.5 General components.5. Location of components in the trailer 0.5. Primary features of the Modulator.5.3 ECU connector identification Overview of electrical connections Wiring diagram - M Wiring diagram - 3M Overview of pneumatic connections 7 4 Piping Table of Contents Page 3.. Connectors / Blanking plugs Sensor / AUX plugs Sensor / AUX connections Sensor connections / cabling COLAS + / ILAS -E connections Auxiliary equipment wiring Multimeter measurements Pipe recommendations Brake piping layout 4.. M, 3-axle semi trailer, side by side M, 3-axle semi trailer M, -axle drawbar trailer (full trailer) Air suspension system piping layout Air suspension levelling valve, COLAS + 53 and ILAS -E Installation options (Configurations). Semi and centre axle drawbar trailers.. S/M and 4S/M, side by side 8.. 4S/3M 9..3 S/M + SL, side by side 0. Drawbar trailers (full trailers) 4S/3M 3 Chassis installation 3. Mounting of the Modulator 3.. Position without Trailer Roll Stability (TRS) function 3.. Position with Trailer Roll Stability (TRS) 3 function 3..3 Identification of ECO Tronic EBS ports 4 and fixing - Main Modulator - Additional Modulator 3..4 Painting - protected areas Mounting Electrical wiring 3.. Wiring schematic Wiring diagram Auxiliary equipment wiring General installation recommendations 3 - cabling 3..5 General installation recommendations 3 - ISO General installation recommendations 33 - junction box 3..7 POWER / DIAG /Sensor / AUX cabling POWER (ISO 7638) connections POWER (ISO 85) / 36 Super AUX connections 3..0 DIAG connections DIAG / Side of vehicle connection 38 5 Operating and installation instructions 5. Brake system Coupling heads Trailer Control Module TrCM Trailer Control Module TrCM Brake lining wear sensoring Air suspension Standard air suspension valve Level adjustable air suspension valve Air suspension valve with zero point 70 adjustment 5..4 COLAS ILAS -E Shut-off cock /-ways magnetic valve Steering axle lock application Soft Docking 80 6 Hazardous Goods / ADR Installations 87 7 Programming 89 8 System diagnostics 8. System diagnostics Warning lamp System check procedure Power up ECO Tronic EBS Other errors shown by the warning lamp Diagnostic Trouble Codes (DTC) 94 9 Recommended maintenance schedule 97 3

4 . Introduction.. ECO Tronic EBS Notes on the content These installation and operating instructions for the ECO Tronic EBS describe the individual components and functions, as well as possible configurations. This publication provides assistance for first installation of an ECO Tronic EBS in a semi trailer, centre axle drawbar trailer or drawbar trailer (full trailer). It deals with the configurations S/M, 4S/M and 4S/3M. As well as presenting the installation of the ECO Tronic EBS, the document also discusses possible electrical cablings and provides cable recommendations. Furthermore, it contains a description of the extensive options for system diagnosis and fault analysis. New ECO Tronic product range ECO Tronic stands for a new product family of intelligent BPW electronic products in the trailer. The first step is a complete brake system consisting of, for example, the ECO Tronic EBS, Trailer Control Module (TrCM), cable sets, Trailer Monitor and a complete air installation. With the new product range, BPW has developed its own electronic trailer components so that you can obtain the entire trailer running gear from a single supplier. From now on, you will only have one contact for the entire system. From the axle to the brake, from the air suspension to the electronic control unit. The ECO Tronic EBS offers everything that you would expect from a modern electronic brake system. And much more as well: this is because in addition to brake control, the ECO Tronic EBS also offers numerous additional functions. Running gear data is ready for download at any time, vehicle usage is recorded and documented, while clever solutions are available for determining the ideal brake quality with the new ECO Tronic EBS from BPW, you can achieve sustainable optimisations in your fleet management. Basic functions of an EBS Companies which want to transport goods from A to B as safely and efficiently as possible find that an EBS is practically essential nowadays. This is because EBS offers a whole range of advantages compared to conventional pneumatic brake systems: It increases safety due to shorter response times, thereby reducing braking distances, optimises brake performance because of improved matching and also simplifies installation and maintenance processes. These are practical and commercial advantages with specific benefits, and most commercial vehicle manufacturers and transport professionals can no longer do without them nowadays. In contrast to pneumatically operated brake systems, an EBS controls the brake cylinder pressure of the disc or drum brakes individually using electronics. The mechanical pressure applied to the brake pedal is converted into an electrical signal and passed on to the control unit. This uses information available in the data network to calculate the optimum brake pressure, ensuring that brake forces are optimally distributed throughout the system. The EBS is connected by a trailer control module through the CAN interface. In addition to its straightforward braking function, EBS has driver assistance functions such as ABS (anti-lock brake system), ALB (automatic load-dependent braking), as well as a TRS function (trailer roll stability, not included in the basic kit), thereby offering additional safety. What is more, each EBS has a pneumatic fall-back level which is a statutory requirement for use in emergencies, and permits conventionally controlled braking in case of an electrical fault. ECO Tronic is the name of the BPW product range for electronic trailer components. The first product is the ECO Tronic EBS with special trailer-specific features. ECO Tronic EBS means BPW is the system supplier with overall responsibility for the intelligent trailer running gear. 4

5 Features of ECO Tronic EBS The core of the ECO Tronic EBS is the EBS Modulator. Its compact dimensions mean that it can be installed without difficulty in all current semi trailers, drawbar trailers (full trailers) and centre axle drawbar trailers. Its enclosed design ensures fault-free operation and consists of a corrosion-resistant plastic module and a weatherproof die-cast aluminium module. Trailer Roll Stability.. ECO Tronic EBS In the background, there is an electronic safety system for the trailer which automatically intervenes in critical driving situations to provide stability. Sensors integrated in the EBS permanently measure the lateral acceleration of the trailer for this purpose. If a critical driving situation is reached then the trailer is immediately braked. As a result, the risk of skidding and tipping over - e.g. when cornering or due to a shifting load - is reduced to a minimum thanks to Trailer Roll Stability. Lifting axle control Another practical performance feature of EBS is the automatic function for lifting and lowering a lifting axle depending on the load and speed. This allows you to benefit from a significant convenience feature compared to manual lifting axle operation, and also reduces your running costs. Using an axle lift reduces tyre wear when unladen. It goes without saying that the lifting axle control can be switched over to manual operation on request at any time, e.g. if the lifting axle is required as a manoeuvring aid or starting traction control, or when the trailer needs to be put onto the dynamometer test rig. Automatic steering axle lock The basic functions of EBS also include the automatic steering axle lock. This is activated when reversing and automatically blocks deflection of the wheels on the trailer s steering axle. All cable connections of the ECO Tronic EBS are grouped together on one level for a clear layout, thereby permitting optimum access. In addition, ease of installation is ensured by connection designations on the side and the lid of the housing. The ECO Tronic EBS can be used in a wide range of applications with its five AUX connections. There is a user-configurable Super AUX connection available as an option which gives up to three more functions. Furthermore, the housing has an integrated quick release valve for the parking brake and two test connections for pressure gauges. The numerous basic functions provided as standard mean the ECO Tronic EBS offers greater safety and convenience. This includes practical features such as stability control, lifting axle control or steering axle lock which soon pay their way in dayto-day operations. Automatic service brake activation In conjunction with an extendable drawbar installation, automatic actuation of the service brake reduces the gap between the vehicles, thereby allowing for convenient throughloading. The ideal solution for greater safety and operating convenience at the loading ramp. Safety braking This EBS function automatically applies the brakes on vehicles such as tankers when the instrument cabinet is open, therefore preventing it from moving off. This is a sensible additional feature because it ensures that lack of attention does not immediately become a danger. Paver brake function This is the perfect EBS function for ensuring the correct distance between the paver machine and the trailer during road building. In this case, the paver machine pushes the braked trailer in front of it, thereby optimising handling and the production process. 5

6 . Introduction.. ECO Tronic EBS Intelligent software packages for setting parameters and operating data analysis To ensure that the brake system and other running gear parameters are set perfectly, ECO Tronic EBS has a software system that is as extensive as it is user-friendly, for setting parameters and analysing the operating data of the trailer. Operation and evaluation of the EBS could hardly be easier. The special feature of ECO Tronic EBS: BPW not only offers you numerous standard EBS functions but also additional trailer-specific functions that help you to optimise your fleet management, reduce service times and therefore save operating costs. The Trailer Manager is a software programme for setting the parameters of ECO Tronic EBS. It is used for the factory configuration of the available brake and additional functions. A clear menu system with step-by-step configuration allows for trouble-free inputs. Missing information is displayed as a safety feature in order to avoid possible mistakes in the system. Do you sometimes find it difficult to identify vehicle components? It is not rare for valuable time to be lost finding out which spare part can be obtained from where in the shortest possible time. The additional function of Assembly Data Management (ADM) in ECO Tronic EBS will be greatly appreciated in this context. This function gives you a practical tool for reading in and managing information about the specific running gear and vehicle. Just one look at the ADM data set allows you to identify spare parts and maintenance documents unambiguously. At the touch of a button, you can call them up or request them directly from the BPW customer network. This saves costs because ADM can significantly reduce the length of time spent in workshops and on repair jobs. The Trailer Analyser allows transport companies to benefit from a clear evaluation software that offers practical functions to deliver precise information about journeys and displays meaningful vehicle bar charts. Whether these functions are for analysing journeys or for special functions developed by BPW for the vehicle history, ECO Tronic EBS means that you are always precisely informed about the status of your trailers, which gives you the perfect tool for optimum fleet management. Priority on safety. This is especially important in the transport business. ECO Tronic EBS software offers the perfect solution for this as well. Brake Performance Monitoring (BPM) is an intelligent additional function developed by BPW for the Trailer Analyser, and provides you with information about the brake. Reliable service With the new ECO Tronic EBS, BPW is for the first time offering you a complete trailer running gear system including all electronic components from a single supplier. And this also means that you benefit from reliable service and fast spare part delivery, as with all BPW system components. And what s more, our range of services also includes training courses. In these, we can on request provide you with valuable knowledge about the new ECO Tronic EBS that you can put to use in your day-to-day business from professionals for professionals. Assembly Data Managment This is a tool in the Trailer Manager for reading in and managing information specific to the running gear and vehicle. Road Condition Monitoring This function of the Trailer Analyser can be used for recording and evaluating road profiles exactly. Brake Performance Monitoring An intelligent additional function of the Trailer Analyser for calculating and evaluating brake quality. For example, the Trailer Analyser stores up to 000 journeys and can output a trip-based evaluation request. Numerous bar charts on brake pressure, axle load, air suspension pressure and other key figures of the running gear provide detailed information about the operating status of trailers. A practical additional function in the Trailer Analyser has been specially developed by BPW for ECO Tronic EBS: Road Condition Monitoring (RCM). This function makes it possible to record and evaluate precisely what are the profiles of the roads on which your trailers drive. This means you have a diagnostic tool at your disposal that gives you a precise insight into vehicle usage. As a result, Road Condition Monitoring also offers you the opportunity to increase the resale value of your vehicles. 6

7 . Abbreviations Abbreviations Explanation Description S/M Sensors / Modulators ABS system with rotational speed sensors and modulators ABS Anti-Lock Braking System Prevents the locking of braked wheels to maintain lateral grip ADM Assembly Data Management Software function for storing all important vehicle data ADR Accord européen relatif au transport European agreement on international transport of dangerous goods by international des marchandises road Dangereuses par Route ASC Adaptive Surface Control ABS control that dynamically adapts to road conditions AUX AUXiliary Additional input / output for sensors or actuators / valves BPM Brake Performance Monitoring Software function for monitoring brake performance CAN Controller Area Network Data bus system, used for controller communication in vehicles, among others COLAS + Lift and lower valve Valve for lifting and lowering the vehicle body in the case of air-sprung vehicles DCV Double Check Valve Anti-compounding valve to prevent simultaneous application of service brakes and emergency brakes DTC Diagnostic Trouble Codes Brake system error / warning codes for diagnosis and repair EBS Electronic Braking System Electro-pneumatic brake system with CAN communication between the truck and the trailer ECE R3 Economic Comission for European regulation No. 3 - Brake systems Europe Regulation No. 3 ECU Electronic Control Unit Electronic controller EEPROM Electrically Erasable Programmable Read Only Memory ELS Electronic Load Sensing Function for automatically adapting the braking force to the load of the vehicle (LSV) Load Sensing Valve EOLT End Of Line Test End of line system check to ensure correct system installation EPRV Electro Pneumatic Relay Valve Electro pneumatically piloted relay valve of the EBS GGVS Gefahrgut Verordnung Straße Act governing the road haulage of hazardous materials GPI General Purpose Input AUX option GPO General Purpose Output AUX option ILAS -E Integrated Lift Axle Steering EBS controlled lift axle valve ISO 85 Standardised interface between truck and trailer for lighting control ISO 99 CAN bus communication standard between truck and trailer for brake control ISO 7638 Standardised interface between truck and trailer supplying ABS/EBS systems with power, transferring a signal for a warning device and, if fitted, enabling CAN communication as standardised in ISO 99 LWS Lining Wear System Brake pad wear sensing LSV Load-Sensing Valve PPV Pressure Protection Valve Pressure protection valve that separates the brake and air suspension circuits PTC Push To Connect Pneumatic connectors to ease installation QRV Quick Release Valve RCM Road Condition Monitoring Software function for recording and evaluating road profiles REV Relay Emergency Valve Relay valve with emergency brake function RtR Reset to Ride Height Automatic return to ride height SAUX Super AUX Installation-optimized possibility for three digital inputs TA Traction Assist Starting traction control TrCM Trailer Control Module Parking and manoeuvring valve with emergency brake function (and integrated pressure protection) TRS Trailer Roll Stability Function that reduces the risk of the trailer rolling over 7

8 Introduction.3 Safety information All work must be performed by trained specialists in qualified workshops and authorised companies which have all the necessary tools and knowledge for performing this work. Various safety information is indicated by different icons in these installation and operating instructions. Their significance is described in the overview below. The parameters of the system are only allowed to be set by specialists who have completed a suitable training course for this purpose. The parameters for the brake system can be found in the brake calculation prepared for the vehicle in question. The brake system calculation must take account of statutory requirements of the country in question, as well as the necessary safety provisions. If the set values are changed, the person who performs this change is responsible for complying with the statutory requirements of the country in question where the vehicle is operated, as well as for maintaining safe function of the system. When repairs are carried out on the vehicle, the brake system must be protected against mechanical, thermal and surge voltage damage. Local safety and accident prevention regulations as well as regional and national regulations must be complied with. The relevant operation and service regulations as well as safety regulations of the vehicle manufacturer and of the manufacturers of other vehicle parts shall be adhered to. Do not perform repair and installation work unless wearing protective clothing (gloves, safety boots, safety goggles, etc.) and using the recommended tools. The vehicle must be secured against rolling away during repair work. Please observe the relevant safety regulations for repair work on commercial vehicles, in particular the safety regulations for jacking up and securing the vehicle. Following each repair, it is necessary to perform a function check or a test drive in order to make sure that the brakes are functioning correctly. All exchanged components must be reused or disposed of in accordance with the applicable environmental regulations, laws and directives. Tighten screws and nuts with the prescribed tightening torque. BPW can only guarantee the safety, reliability and performance of systems, in particular those of ECO Tronic EBS, if all instructions are complied with. Icon Significance This symbol informs you that an acoustic check is necessary in order to avoid potential damage to property or follow-on damage. This symbol informs you that an optical check is necessary in order to avoid potential damage to property or follow-on damage. This symbol informs you that the connection must be clean and dry before being attached. Warning note! Failure to comply with the warning note can result in a potential hazardous situation, leading to injury to personnel. 8

9 The system fitted to your trailer may have or 4 sensors and or 3 Modulators, the variants available being S/M, 4S/M and 4S/3M. The power supply of the system is via: ISO pin connection - the full EBS function is guaranteed Fig.. The power supply of the ECO Tronic EBS with a 5 pin ISO 7638 connection is also possible. In this case the response time (time between applying the brake pedal and reaction of the brake chambers) is increased due to the missing CAN databus while ABS and ELS functionality is still available (see Fig. ). In the optional emergency solution (M systems only) with stop light electrical power supply, the ECO Tronic EBS is supplied with electrical power via the ISO 85 (4N) plug if the power.4 System layout supply via the ISO 7638 plug fails. In this case, only the ABS function and, optionally, the ALB function are in effect. (see Fig. 3). ECO Tronic EBS controls a warning device in the dashboard (pin 5 of ISO 7638 connector). The warning lamp has two functions: As soon as the ECO Tronic EBS is powered via the ISO 7638 plug (Figs. 63 and 64 on page 9), the system performs a self-test. The result of this test is displayed by means of a sequence of warning lights. The warning lamp indicates by a permanent display, if a fault has been detected while the vehicle is moving. ISO Pin Fig. EBS ECO Tronic EBS = full EBS function ISO Pin Fig. ABS ECO Tronic EBS = EBS function with increased response time (No CAN data bus) ISO 85 - (4N) Fig. 3 ABS/EBS ECO Tronic EBS = on foot brake application ABS function only + ELS optional 9

10 Introduction.5 General components.5. Location of components in the trailer Modulator ISO pin connector Sensor and Exciter optional Driver s information plate Trailer Monitor optional Trailer Control Module (TrCM) (modified 0.0.0) Fig. 4 - Overview of the main components and their location in the trailer 0

11 .5 General components.5. Primary features of the Modulator Integrated quick release valve An integrated quick release valve provides a rapid installation and reduces the need for separate pipe fittings and connections. In addition the spring brake air, once exhausted, is silenced using the silencing mechanism. Fig. 5 Integrated quick valve Service brake test connections The EBS Modulator provides two additional service brake connections, which can allow direct connections to the exterior test points. Fig. 6 Test connections service brake Integrated double check valve with distributor An integrated anti-compounding spring brake distribution manifold eliminates the need for a secondary manifold and associated fittings, hence saving installation time and potential errors. Fig. 7 Integrated double check valve Bulk head mounting Three stud mountings, provide interchangeability with competitor systems. In addition, the mounting method allows much easier installation. Fig. 8

12 Introduction.5 General components Individual electrical connections The EBS Modulator utilises well-recognised sliding connectors, and the slide lock mechanism has been improved to allow each connector to be removed and inserted individually. This improves installation time and reliability. Fig. Reservoir connections The EBS Modulator provides two reservoir connections, which allows complete installation flexibility for vehicle manufacturers. This flexibility not only provides a rapid installation, but allows the reduction of pipe lengths. Fig. 3 Alignment of connections The EBS Modulator has been deliberately designed to ensure ease of vehicle installation. All the ports and electrical connection positions have been chosen to provide easy identification and are aligned to allow brake pipes to be bundled together, thus providing an efficient cost effective, overall installation package. Fig. 4 ECU The EBS Modulator provides a sealed for life encapsulated ECU, thus eliminating interconnections. Technical Data Working pressure: Air bar (max. 9.5 bar) Operating voltage: 4 V DC (min. 9 V to max. 3 V) Current consumption: max. 3. A Operating temperature: - 40 C to +70 C Operating medium: Air Exciter ring: 60 to 0 teeth BPW EBS Modulator (5 AUX, stability, with integrated quick release valve and double check valve).

13 .5 General components.5.3 ECU connector identification - S/M, 4S/M system 4 V Switched Output, Speed indicator 4 V Switched Output, Input for switching signal Analogue Input, 5 V Power supply Analogue Input, 5 V Power supply ISO 85 power supply, three digital inputs, 4 V power supply AUX COLAS + Retarder Trailer Lamp ILAS -E Front ILAS -E Rear AUX Power Steer Axle Lock Service Lamp Overload Lamp Remote Overload Lamp Stability Lamp (TRS) General Purpose Output TA+ Info Point Info Point / COLAS + AUX, AUX 3 COLAS + Retarder Trailer Lamp ILAS -E Front ILAS -E Rear AUX Power Steer Axle Lock Service Lamp Overload Lamp Remote Overload Lamp Stability Lamp (TRS) ILAS -E Front Manual ILAS -E Rear Manual General Purpose Output TA+ AUX 4 Lining Wear Sensor General Purpose Input Control Line Sensor Soft Docking Mechanical Height Sensor AUX 5 Lateral Accelerometer General Purpose Input Control Line Sensor Soft Docking Mechanical Height Sensor 4 Super AUX Input A Input B Input C ISO 85- connection White B- Red B+ Black 4 V Yellow Input A Brown Input B Junction box Pin configuration Green Input C Blue (not in use) PC Interface ISO 85 ISO 7638 Trailer Monitor Pin 4 Pin Sensor SB Sensor SA Sensor SB Sensor SA Fig. 5 Version without SAUX Version with SAUX 3

14 Introduction.5 General components.5.4 Overview of electrical connections ISO ISO 85 (4N) B B 4 3 A 5 A Fig. 6 - Chassis components with electrical connections Item Description Notes ECO Tronic EBS label ISO pin connector 3 Safety back-up cable - ISO 85 (4N) / or SAUX optional 4 Trailer Monitor (side of vehicle connection) 5 Modulator 6 ABS sensor 7 Exciter ring 8 COLAS + AUX, or 3 9 ILAS -E AUX, or 3 0 Lining wear system (LWS) AUX 4 only External roll stability sensor AUX 5 only (as an option for the ECO Tronic EBS of the basic kit) N.B. AUX to be configured accordingly with Trailer Manager 4

15 .5 General components.5.5 Wiring diagram - M B B A A DIAG PWR-B PWR-A POWER A POWER B SUPER AUX DIAGN DIAGN CABLE x 4.0mm² 5 x.5mm² RD BN CABLE x.5mm² W B- RD B+ W B- RD B+ BK 4V Y AUX A BN AUX B G AUX C BU BK RD BN/W GN/W YE W BN B+IGN B+P CAN L CAN H B-IGN LAMP B- N 6 x x.5mm².5mm² W RD 4 ISO 7638 (EBS/ABS) ISO 85 (4N) SEN SEN AUX AUX AUX AUX AUX SEN SEN B B A A CABLE 7 x.5mm² CABLE x.5mm² 3 x.5mm² BK YE CABLE TRAILER LIFT x.0mm² AXLE LIFT CLOSE TO LIFT YE AUXILIARY SOLENOID BK RD RIGHT REAR SENSOR RIGHT FRONT SENSOR N 3 N 8 CABLE 3 x 0.75mm² N 3 AUX B CABLE x 0.75mm² B SEN A SEN A AUX AUX AUX AUX AUX SEN A A SEN CABLE x 0.75mm² 5 AUX AUX A 4 5 A N 3 N 3 CABLE 3 x 0.75mm² N 5 ACCELEROMETER CABLE 3 x 0.75mm² LEFT REAR SENSOR N LEFT FRONT SENSOR N PRESSURE SENSOR N N 9 CAN B- B+ CABLE 4 x 0.75mm² CABLE 4 x 0.75mm² N 4 GY 8 N 6 7 RD PK W 4 PC INTERFACE CONNECTOR ISO 098 (5 PIN) Fig. 7 BK YE RD BK YE RD N N 7 CABLE 3 x 0.75mm² CABLE 3 x 0.75mm² YE BK RD YE BK RD YE BK RD N N 7 Key: W - White BK - Black BN - Brown BU - Blue RD - Red YE - Yellow GN - Green PK - Pink GY - Grey N Auxiliary cabling termination is given in the table below: Wire colour AUX AUX AUX 3 AUX 4 AUX 5 Red 0 V / 4 V 0 V / 4 V 0 V / 4 V 5 V 5 V Black B- B- B- B- B- Yellow Tacho / Tell-Tale D input D input A/D input A/D input 0 V / 4 V : switchable output B-: earth D input: digital input (0 V to 4 V) A/D input: analogue input (0 V to 5 V) or digital input (0 V to 4 V) Availability of auxiliaries and pressure sensor function depend on ECU variant and configuration. N Right is viewed sitting in the driver seat facing forward. N 3 Sensor connector. N 4 Side diagnostic connector for use with Trailer Monitor or PC interface N 5 Roll stability function accelerometer if fitted, must be plugged into AUX 5. Mounting orientation of accelerometer must be as per instructions supplied by BPW. N 6 Cable length junction box to ISO 85 (4N) or ISO 098 (5 Pin) must not exceed 4 m. N 7 Maximum load from any auxiliary output not to exceed A. All solenoids connected electrically to this unit must be diode suppressed. N 8 If the solenoid is not approved by BPW, fit a A, 00 V minimum, diode as shown. N 9 Pressure sensor can be fitted to AUX 4 or 5. 5

16 Introduction.5 General components.5.6 Wiring diagram - 3M DIAG PWR-B PWR-A POWER A POWER B DIAGN CABLE x 4.0mm² 5 x.5mm² RD BN CABLE x 4.0mm² 5 x.5mm² BK RD BN/W GN/W YE W BN B+IGN B+P CAN L CAN H B-IGN LAMP B- POWER B ISO 7638 (EBS/ABS) B B A A DIAGN SEN SEN AUX AUX AUX AUX AUX SEN SEN B B A A AUXILIARY SOLENOID BK RD N 7 AUX SEN A SEN A AUX AUX AUX AUX AUX SEN A A SEN 5 AUX AUX 4 5 CABLE 3 x 0.75mm² N 5 AUX S A S A DIAGN B POWER Brake Systems A PSW S B S B AUX AUX 3 AUX 4 AUX 5 SLAVE ECU ASSEMBLY YE RIGHT REAR SENSOR RIGHT FRONT SENSOR N 3 CABLE 3 x 0.75mm² N 3 B CABLE x 0.75mm² B CABLE x 0.75mm² A A N 3 N 3 ACCELEROMETER CABLE 3 x 0.75mm² LEFT REAR SENSOR N LEFT FRONT SENSOR N PRESSURE SENSOR N N 8 CAN B- B+ CABLE 4 x 0.75mm² CABLE 4 x 0.75mm² N 4 PC INTERFACE CONNECTOR Fig. 8 BK YE RD BK YE RD N N 6 CABLE 3 x 0.75mm² CABLE 3 x 0.75mm² YE BK RD YE BK RD YE BK RD N N 6 Key: W - White BK - Black BN - Brown BU - Blue RD - Red YE - Yellow GN - Green PK - Pink GY - Grey N Auxiliary cabling termination is given in the table below: Wire colour AUX AUX AUX 3 AUX 4 AUX 5 Red 0 V / 4 V 0 V / 4 V 0 V / 4 V 5 V 5 V Black B- B- B- B- B- Yellow Tacho / Tell-Tale D input D input A/D input A/D input 0 V / 4 V : switchable output B-: earth D input: digital input (0 V to 4 V) A/D input: analogue input (0 V to 5 V) or digital input (0 V to 4 V) Availability of auxiliaries and pressure sensor function depend on ECU variant and configuration. N Right is viewed sitting in the driver seat facing forward. N 3 Sensor connector. N 4 Side diagnostic connector for use with Trailer Monitor or PC interface. N 5 Roll stability function accelerometer if fi tted, must be plugged into AUX 5. Mounting orientation of accelerometer must be as per instructions supplied by BPW. N 6 Maximum load for each auxiliary output shall not exceed A. All solenoids connected electrically to the Modulator must be diode suppressed. N 7 If the solenoid is not approved by BPW, fit a A, 00 V minimum, diode as shown. N 8 Pressure sensor can be fitted to AUX 4 or 5. 6

17 .5 General components.5.7 Overview of pneumatic connections Emergency Service 8 AUX = Item = Port 9 Fig. 9 : 3-axle semi trailer - S/M side by side configuration - -line air brake system with Trailer Control Module and spring brake chambers Item Description Notes Emergency coupling with integrated filter Service coupling with integrated filter 3 Trailer Control Module (TrCM) 4 Air reservoir - brake 5 Air reservoir - air suspension 6 Drain valve 7 Modulator 8 Air suspension levelling valve 9 COLAS + 0 Suspension air bags (bellows) Single diaphragm brake chamber Spring brake chamber 3 Test point 4 Test point (if not integrated in COLAS +) 7

18 L.H. Power Cable Connector 4S/M S/M R.H. Power Cable Connector L.H. Power Cable Connector R.H. Power Cable Connector Installation options (Configurations). Semi and centre axle drawbar trailers.. S/M and 4S/M, side by side SB SB SB SA SA SA SB SA SB SB SB SA SA SA SB SA SB SB SB SB SA SA SA SA SB SB SB SB Fig. 0 SA SA SA SA Either (but only one) directly controlled axle may be lifted - 4S/M Any axle without directly controlled wheels may be a lift axle - S/M Any axle may be a steered axle - S/M and 4S/M Key Modulator ECU power connectors 8

19 L.H. Power Cable Connector 4S/3M R.H. Power Cable Connector.. 4S/3M (recommended for self-steering axle). Semi and centre axle drawbar trailers SB SB SB SB SB SB SA SA SA SA SA SA SB SB SB SB SB SB SA SA SA SA SA SA SB SB SB SB SB SB SA SA SA SA SA SA SB SB SB SB SB SB Fig. SA SA SA SA SA SA Any axle without directly controlled wheels may be lifted. Any axle can be a steered axle. Master ECU is mounted to EPRV s. All sensors must be connected to this Master ECU. Directly controlled wheels connected pneumatically to EPRV s / cannot be lifted. Slave ECU is mounted to EPRV and is controlled by Master ECU. Slave ECU/EPRV is shown facing rear but can also be installed facing forward, left or right, as EPRV is always select low control. Sensed wheel connected pneumatically to EPRV can be lifted. Key Modulators ECU power connectors Slave ECU Modulator 9

20 L.H. Power Cable Connector S/M R.H. Power Cable Connector Installation options (Configurations). Semi and centre axle drawbar trailers..3 S/M + SL, side by side (not recommended for self-steered axle) SB SB SB A A A SA SA SA SB SB SB A A A SA SA SA Fig. Any axle without directly controlled wheels may be a lift axle. Key A Modulators ECU power connectors Select low valve (SL) 0

21 L.H. Power Cable Connector 4S/3M R.H. Power Cable Connector. Drawbar trailers (full trailers) 4S/3M SB SB SA SA SB SB SB SB SA SA SA SA SB SB SA SA SB SB SB SB Fig. 3 SA SA SA SA Sensed axles cannot be lifted. Any axle without directly controlled wheels (unsensed) may be a lift axle. Master ECU is mounted to EPRV s /. All Sensors must be connected to this Master ECU. Slave ECU is mounted to EPRV and is controlled by Master ECU. Slave ECU/EPRV is shown facing rear but can also be installed facing forward, left or right, as EPRV is always select low control. Key Modulators ECU power connectors Slave ECU Modulator

22 3 Chassis installation 3. Mounting of the Modulator 3.. Position without Trailer Roll Stability (TRS) function 360º Note: The following is applicable to installations and configurations without TRS function. The unit should be orientated and positioned so that the Power Cable connections face towards the required installation option (configuration) of the trailer. See Figs. 0 to 3. The distance between port () and the air reservoir should be as short as possible (Fig. 4). Fig. 4 () Mount the Modulator centrally to the brake chambers (Fig. 5). A : Single axle B : Tandem axle C : Tri-axle For corrosion reasons do not attach the Modulator directly onto stainless steel. A B C Fig. 5

23 3.. Position with Trailer Roll Stability (TRS) function 3. Mounting of the Modulator Rear End view The following installation parameters are required for correct TRS operation. Roll angle : ± 3 (:0) (Fig. 6). 3º 3º Fig. 6 3º 3º Yaw angle : ± 5 (Fig. 7). 5º 5º Top view Fig. 7 5º 5º Pitch angle: The Modulator must be mounted vertically (Fig. 8). Fig. 8 The Modulator must be mounted within distances x and y from the centre of the axle (s) (including possible lift axles). Single or tri-axle Vehicle x y Semi trailer.5 m.5 m Centre axle drawbar trailer.5 m.5 m Drawbar trailer 3.0 m.5 m Within LH and RH chassis members The Modulator has to be mounted inside the main left hand (LH) and right hand (RH) chassis members of the vehicle (Fig. 9). Tandem axle x y For any other applications please refer to BPW Bergische Achsen KG. The unit should not be in direct spray or splash water area and should be protected against high pressure cleaning. Within LH and RH chassis members Fig. 9 x y 3

24 3 Chassis installation 3. Mounting of the Modulator 3..3 Identification of ECO Tronic EBS ports and fixing - Main Modulator Studs x 3 M 0 x.5 mm, mm long 83.5 mm 30.5 mm 4 Delivery test port () 90.4 mm 4 Delivery test port () Delivery port () Delivery port () mm 90 mm 67.7 mm Fig mm Weight: approx. 6.5 kg Port No. Description Thread Notes Reservoir port M x.5 3 Exhaust port 4 Control port M 6 x.5 Double Check Valve (DCV) M 6 x.5 / Delivery ports M 6 x.5 / Delivery test ports M x.5 3 Spring brake port M 6 x.5 4 Air suspension port M 6 x.5 4

25 3. Mounting of the Modulator 3..3 Identification of ECO Tronic EBS ports and fixings - Additional Modulator 6.5 mm Fixing bolts x 4 M 8 x.5 mm, Tightening torque: 34 Nm (3-35 Nm) 58 mm 85 mm 6.6 mm Air suspension port (4) Remove blanking plugs when using and connect air bag pressure line. Control port (4) 4.6 mm Power supply Blanking plug Blanking plug 4.6 mm mm mm 7.5 mm 7.5 mm Delivery port () 7.65 mm 55.3 mm 7.65 mm 55.3 mm Delivery port () 8 mm 85.5 mm 3.6 mm 78 mm Fig. 3 Reservoir port () Exhaust port (3) Weight: approx. 3.5 kg Port No. Description Thread Notes Reservoir port M x.5 Delivery ports M 6 x.5 3 Exhaust port 4 Control port M 6 x.5 4 Air suspension port M 6 x.5 5

26 3 Chassis installation 3. Mounting of the Modulator 3..4 Painting - protected areas When painting/coating all non-used electrical connections, pneumatic and exhaust ports must be protected. Mounting face These are indicated by the shaded areas marked in Fig. 3. Adequate protection should be used to avoid penetration of the paint/coating. All electrical ports have to be closed by connectors / blanking plugs. All pneumatic ports have to be closed by pipe fittings/blanking plugs. The exhaust ports and connector locking devices have to be protected. Painting recommendations: Water based, baking for hour at 00 C. Underside Indicates areas to be protected. Front Left side Right side Fig. 3 6

27 3..5 Mounting Additional bracket design has to be as rigid as possible (Fig. 33). The mounting fixing must provide an electrical connection between the Modulator bracket and the trailer chassis. The installation angle must be 0.5 mm out of level. Use non-corrosive M 0 nuts, torque to Nm. After that, check the earth continuity between the EBS bracket and trailer chassis (Fig. 33). 3. Mounting of the Modulator 0.5 Mounting bracket Fixing holes 0 < R < 5 min. 4.0 mm Fig. 33 Care should be taken to provide reasonable access to the Modulator for replacement of cables (Fig. 34). D = min. 50 mm E =. Modulator to be above axle centre line.. The position should be as high as possible in the frame. E D Fig. 34 Position the Modulator as high as possible in the chassis to provide optimum protection from direct spray and other road dirt and also to achieve an acceptable hose routing (Fig. 35). Deck of trailer Note: To prevent water from flowing into the Modulator cables should always run up to the EBS. to brake chambers Ground level to brake chambers Fig. 35 Piping Avoid elbow connectors as much as possible. If necessary, use swept elbow fittings (Fig. 36). The inner diameter of joints should be the same as the diameter of the corresponding piping. Fig. 36 7

28 3 Chassis installation 3. Electrical wiring 3.. Wiring schematic ISO Core 5 x.5 mm² x 4.0 mm² Safety back-up Core x.5 mm² Sensor Core x 0.75 mm² ISO 7638 max. 4 m ISO 85 (4N) N Fig. 37 Junction box Diagnostic 4 Core 4 x 0.75 mm² Trailer Monitor or side of vehicle connector Auxiliary 3 Core 3 x 0.75 mm² ( cores used) Semi trailer and centre axle drawbar trailer (full trailer) Installation option N The distance between ISO 85 (4N connector) and the junction box should not exceed 4 m. Failure to comply with the above recommendation may result in insufficient voltage at the ECU. 8

29 3. Electrical wiring 3.. Wiring diagram B Sensors Black Red + A Sensors ISO 85 ISO 7638 Black Red + Pin4 Pin Sensor SB Black Red + Sensor SA PC Interface Trailer Monitor Fig Sensors - ISO7638 & ISO85 with Trailer Monitor (3 AUX s fitted) ISO7638 ISO85 DIAG SA SB SA SB AUX AUX AUX 3 AUX 4 AUX 5 9

30 3 Chassis installation 3. Wiring diagram 3..3 Auxiliary equipment wiring Brake pad wear sensing NB B Sensors Black Red + External stability sensor (option for basic kit) ISO 85 ISO 7638 A Sensors Black Red + NB Pin4 Pin Sensor SB Black Red + Sensor SA PC Interface Sensor SB Sensor SA Trailer Monitor Fig Sensors - ISO7638 & ISO85 with Trailer Monitor & LWS (5 AUX s fitted) ISO7638 ISO85 DIAG SA SB SA SB AUX AUX AUX 3 AUX 4 AUX 5 NB - Lining Wear System to be fitted in AUX 4 only NB - External acceleration sensor to be fitted in AUX 5 only 30

31 3. Electrical wiring 3..4 General installation recommendations - cabling Anti-vibration support Excess cable must not be allowed to hang free, but must be attached to the chassis (Fig. 40/) to prevent damage due to vibration and abrasion. Fig. 40 Ø max. 50 mm Ø min. 00 mm Excess cable Cable lengths less than m to be coiled into loops of 00 mm minimum and 50 mm maximum diameter (Fig. 40). Excessive cable lengths which will not form a complete loop may be left to hang in partial loops having a cable bend radius of 50 mm minimum. Cable lengths greater than m to be coiled and then flattened in the centre (Fig. 4/) to produce a dog bone shape (Fig. 4). Fig. 4 The resulting loops at the end must have a minimum bend radius of 50 mm. Cable ties are to be used to fix the cable in the flattened loop shape. Ø min. 00 mm More than one looped cable must not be looped together. Fig. 4 3

32 3 Chassis installation 3. Electrical wiring 3..5 General installation recommendations - ISO 7638 ISO 7638 Connector Should be positioned/grouped with other electrical connections (Fig. 43) Pin Pin detail No. and Designation identification key location. Red (RD) 4 mm Plus electro valve Black (BK).5 mm Plus electronics 3 Yellow (YE).5 mm Minus electronics 4 Brown (BN) 4 mm Minus electro valve 5 White (W).5 mm Warning device 6 White/Green (W/GN).5 mm CAN H 7 White/Brown (W/BN).5 mm CAN L Fig. 43 ISO 85 (4 N) ISO 7638 When installing ISO 7638 it is important that sufficient extra length of cable is allowed to expose the socket assembly for replacement in service (Fig. 43). Trailer headboard approx. 350 mm It will be necessary to pull the ISO 7638 socket clear from the trailer headboard to undo the gland nut (Fig. 44). Fig. 44 Gland nut Clearance dimensions (Fig. 45). max. 0 mm min. 0 mm 45º Fig. 45 Socket mounting dimensions (Fig. 46). Ø 57 mm Ø 55 mm Ø 9 mm Ø 8.5 mm 50.3 mm 48.7 mm 5.5 mm 4.5 mm max. 60 mm min. 55 mm min. min. 60 mm 60 mm min. 80 mm mm 37.5 mm Fig mm 74.3 mm 3

33 3. Electrical wiring 3..6 General installation recommendations - Junction box Junction box The junction box should be mounted on a flat surface (Fig. 47). Mounting holes to be drilled min. 6.5 mm diameter to avoid stress at the box from incorrect location. On mounting ensure cable runs are up to the junction box (Fig. 47). Cable Junction box drain hole Drain hole to be shielded by chassis as shown to provide as much protection from direct spray and other road debris (Fig. 47). min. 5 mm Fig. 47 Ensure outer insulation of the cable is inside the junction box by 5 mm minimum (Fig. 48). Junction box Outer insulation cable Fig

34 3 Chassis installation 3. Electrical wiring 3..7 Power / DIAG / Sensor / AUX cabling Deck of trailer 4 V Sensor cable route should follow the centre line or outer radius of pipe or hose (Fig. 49). Tie wraps not to be overtightened because on brake application rubber hose expands, i.e. tie could damage the hose and sensor cable. max. 400 mm Cable tie Do not run sensor leads in spiral wrapping on hoses. Power leads should be secured down the chassis rail in trunking or to piping and should be secured at not more than 400 mm intervals (Fig. 49). max. 50 mm NOTE: All cables should run up to ECU connections. Axle Fig. 49 All cables - the route of the cable from the connector should not start to bend so that the connector/s are strained. Allow distance before bending of cable as shown in Fig. 50. min.0 mm 0 mm 0 mm ISO 7638 min.00 mm 0 mmm bend radius 0 mm Fig. 50 PWR-A, PWR-B and DIAG connection Feed all connectors through the chassis with the protective cap in place to avoid connector sockets being contaminated (Fig. 5). Remove protective cap () from end of connector before connecting into the ECU (Fig. 5). Trailer chassis min. Ø 0 mm Fig. 5 34

35 3. Electrical wiring 3..8 Power (ISO 7638) connections Electric wiring power connection From the slide lock housing (Fig. 5/) (top horizontal connector housing). Remove transit cover from PWR-A position. Unlock the housing by sliding down lever (Fig. 5/). Make sure slider is in the unlock position (Fig. 5/3). Ensure contact pins and seal are kept clean and free of any contamination prior to installation. 3 Fig. 5 PWR-A (ISO 7638) connection Make sure that all connections (socket and plug) are clean and dry before assembly (Fig. 53). Fig. 53 Identify orientation of the ISO 7638 blue coloured connector (Fig. 54). Ensure contact pins and seal are clean and free of any contamination prior to installation. In position PWR-A, on the slide lock housing, insert connector fully home. Then lock the housing. Blue connector Fig

36 3 Chassis installation 3. Electrical wiring 3..9 Power (ISO 85) Super AUX connections PWR-B (ISO 85, 4 N) connection Remove blanking plug from position PWR-B (Fig. 55). Fig. 55 Identify orientation of the ISO 85 orange coloured connector or the black SAUX connector (Fig. 56). Ensure contact pins and seal are clean and free of any contamination prior to installation. In position PWR-B, on the slide lock housing, insert connector fully home. Then lock the housing. Orange connector or black connector Fig

37 3. Electrical wiring 3..0 DIAG connections Diagnostic DIAG connection - Option If no diagnostic units are to be installed retain blanking plug in position marked DIAG (Fig. 57). Fig. 57 Diagnostic DIAG connection - Option If a remote mounted Trailer Monitor is installed remove blanking plug (Fig. 58). Fig. 58 Identify orientation of the diagnostic green coloured connector (Fig. 59). Ensure contact pins and seal are clean and free of any contamination prior to installation. In position DIAG, on the slide lock housing, insert connector fully home. Then lock the housing. Green connector Fig

38 3 Chassis installation 3. Electrical wiring 3.. DIAG / Side of vehicle connection Diagnostic DIAG - side of vehicle connection - Option 3 Mount the diagnostic connector on the outside of the main chassis rail. The position must be in an accessible area but not in the direct spray of the wheels (Fig. 60). Clearance and mounting dimensions (Fig. 6). Shaded area around hole to be flat and free from raised markings or surface imperfections which may prevent flush fitting of the connector. Fig. 60 min. 40 mm max. Ø 50 mm Alt min. 40 mm The connector must be mounted horizontally. max. Ø 4 mm min. 0 mm min. 65 mm Tighten nut (Fig. 6/) to a torque of 3-4 Nm. ECU connection is as Fig 58/59. Cable to run up to connector and secured to the chassis, or appropriate cable or pipe runs, with cable ties at 400 mm intervals. min. 00 mm Fig. 6 max. 400 mm Ensure that the cover is fitted and correctly locked in place (Fig. 6). Fig. 6 38

39 3. Electrical wiring 3.. Connectors / Blanking plugs Make sure that all connectors/blanking plugs are fully inserted into the ECU slide lock housing (Fig. 63). Fig. 63 Push in lock slider (Fig. 64/) to secure in place all plugs/ connectors. Note: Do not use extreme force to push in slider. Make sure slider is in the lock position (Fig. 64/). Fig. 64 WARNING If difficulty is encountered in locking the slider, check plug or connector for correct fitment (Fig. 65). If the white O-ring is visible, the plug is not installed correctly and slider will not lock into position (Fig. 65). Fig

40 3 Chassis installation 3. Electrical wiring 3..3 Sensor / AUX plugs Sensor Plug Identification tags are incorporated on either side of the sensor / ECU connector (Fig. 66). These must be removed to identify the appropriate sensor before connecting into the ECU (Fig. 66). BLACK } front case Example: Sensor B ECU Identification SA SB SA SB Tags Removed 3 4 A B P 5 Component Sensor A Sensor B Sensor A Sensor B Fig. 66 Auxilliary Plug Identification tags are incorporated on either side of the Auxilliary connector (Fig. 67). These must be removed to identify the appropriate usage before connecting into the ECU (Fig. 67). ECU Identification Tags Removed 3 4 A B P 5 Component Example only AUX COLAS + } BLUE front case Example: COLAS + AUX ILAS -E AUX 3 AUX 4 AUX 5 Warning lamp LWS TRS Fig

41 3. Electrical wiring 3..4 Sensor / AUX connections The ECU is supplied with blanking plugs in positions indicated (Fig. 68). These require to be removed to allow fi tment of additional sensors or permitted ancillary equipment. Fig. 68 Example - AUX connection Identify the AUX position on the top or front face of the ECU. Note the locking tag position (Fig. 69/arrow). Fig. 69 With a tool having a flat end of Ø - 3 mm insert and press in locking tab of plug. While depressed pull out plug from housing (Fig. 70). ECU ECU Ø - 3 mm P Tool Fig. 70 Identify orientation of the: Sensor black body connector Auxiliary blue body connector Ensure contact pins and seal are kept clean and free of any contamination prior to installation. Insert fully home in the ECU s housing into appropriate marked positions (Fig. 7). ECU Fig. 7 4

42 3 Chassis installation 3. Electrical wiring 3..5 Sensor connections/ cabling Extension cable plug Sensor cable socket Sensor Connection Sensor extension cable plug must be pushed fully into sensor cable socket till they clip into place to prevent falling out with axle vibration (Fig. 7). Clip to click Fig. 7 Where possible use a clip and bracket to secure sensor cable connection (Fig. 73). Axle Dust cover Connection assembled into clip and bracket Sensor cable Extension cable Axle Dirt shield fixing bolts Fig. 73 Alternatively: Sensor cable connection to be positioned on axle or between axle U bolts and supported with cable ties within 50 mm of each end (Fig. 74). Axle Connection Cable tie Cable tie Axle Fig. 74 U bolts U bolts 4

43 3. Electrical wiring 3..6 COLAS + / ILAS -E connections Nm ( lbft) 4-6 Nm (3-4.4 lbft) DIN connector COLAS + / ILAS -E cable should be secured down the chassis rail on piping and should be secured at not more than 400 mm intervals. NOTE: All cables should run up to connector. Position rubber seal (Fig. 75/) in position shown. Fig

44 3 Chassis installation 3. Electrical wiring 3..7 Auxiliary equipment wiring COLAS + ILAS -E Fig. 76 Fig. 77 Warning lamp Red (+) Black (-) Fig. 78 Steer axle lock (incl. reversing axle lock) AUX AUX Red (+) Black (-) Red (+) Black (-) Lock Sol. Lock Sol. Relay Relay (+) Red (+) Black (-) Reverse lamp Diode ( A, 00 V min.) Fig

45 3..7 Auxiliary equipment wiring 3. Electrical wiring Traction assist using ILAS -E, option 4 V from Truck Traction Assist switch 4 V Pink.5 mm² Junction box Yellow from AUX or 3 ISO 098 (5 Pin) Core cable.5 mm² DIN connector ILAS -E Fig. 80 Traction assist is made operative by a 4 V (constant or intermittent) supply to the yellow wire in the 3 core auxiliary cable connected to AUX or AUX 3 and programmed as ILAS -E Front. AUX 4, 5 or SAUX A,B,C can be used as an alternative. Function: On request for traction assist, front axle lifts. The front axle drops when either : The vehicle speed exceeds 30 km/h or The suspension pressure reaches more than 30% of the laden bag pressure. Traction assist using ILAS -E, option Yellow.5 mm² Red Side-of-Vehicle switch From AUX //3 Yellow From AUX /3 Core cable.5 mm² Junction box DIN connector ILAS -E Fig. 8 45

46 3 Chassis installation 3. Electrical wiring 3..8 Multimeter measurements ABS-Sensor connector Earth continuity A B 0 < R < 5 Fig. 8.0 k < R <.4 k min. 0. V AC Fig. 83 COLAS + DIN connector 79 < R < 96 Red (+) Black (-) ILAS -E DIN connector 79 < R < 96 Red (+) Black (-) Fig. 84 Fig. 85 Fig. Checking position Measure between Correct value Remarks 8 Sensor output A B 0. V AC min. Sensor A, B or A, B Sensor disconnected from ECU Wheel rotated at rev/ sec. 8 Sensor resistance A B.0 k < R <.4 k Sensor A, B or A, B Sensor disconnected 83 Earth continuity ECO Tronic EBS 0 < R < 5 bracket and chassis 84 COLAS + Solenoid < R < 96 Cable disconnected resistance 85 ILAS -E Solenoid resistance < R < 96 Cable disconnected 46

47 47

48 4 Piping 4. Pipe recommendation Brake and suspension piping layout 6b 6a Emergency Service a c 3 3c b 6a AUX 3 4a 4 4b 5a 4c 5b 4 3a 3b 7c 6a b 4a 4b 5a 4c 7a 7b 3d 6a 6b = Item = Port Fig. 86 : M- 3-axle semi trailer with Trailer Control Module, spring brake chambers and suspension air bags (bellows) 48

49 Item Description Material Size Remarks Emergency pipe Plastic 8 x Pref 0 x /.5 Alt 0 x.5 Alt a Service pipe Plastic 8 x Pref 0 x Alt 0 x.5 Alt a to be /3 total trailer length b Service pipe Plastic 8 x Pref 0 x Alt 0 x.5 Alt c Service pipe Plastic 8 x Pref 0 x Alt 3a Reservoir pipe Plastic 8 x Pref 0 x Alt x.5 Alt 5 x.5 Alt 3b Reservoir pipe Plastic 5 x.5 Pref 6 x Alt 8 x Alt 3c Reservoir pipe Plastic 8 x Pref 0 x.5 Alt 3d Reservoir pipe Plastic 4a, 4b, 4b Brake pipe BBA Plastic or Rubber hose 5a, 5b Brake pipe FBA Plastic or Rubber hose 8 x Pref 0 x.5 Alt x.5 Pref I.D..0 Alt I.D. 3.0 Alt 8 x Pref I.D..0 Alt 4a and 4c to be similar in length, 4b to be as short as possible 6a Suspension pipe Plastic 8 x 6b Suspension pipe Plastic 0 x x.5 7a, 7b, 7c Suspension pipe Plastic 8 x Pref = Preferred Alt = Alternative BBA = Operating brake system FBA = Parking brake system All pipes and rubber hoses to comply with recognised international standards. Plastic pipe to DIN 7434-, rubber hose to SAE 40. The above pipe sizes are defined as guidelines only. Actual sizes need to be optimised for a given trailer to meet system response time requirements. It is the vehicle manufacturers ultimate responsibility to ensure their systems comply with applicable regulations. 49

50 4 Piping 4. Brake piping layout 4.. M, 3-axle semi trailer, side by side Emergency AUX 4 6 Service = Item = Port Fig. 87 : M - 3-axle semi trailer with Trailer Control Module and spring brake chambers Item Description Notes Emergency coupling with integrated filter Service coupling with integrated filter 3 Trailer Control Module (TrCM) 4 Air reservoir - brake 5 Drain valve 6 Test point 7 Modulator 8 Spring brake chamber 9 Single diaphragm brake chamber 0 Test point Suspension air bags (bellows) 50

51 4. Brake piping layout 4.. 3M, 3-axle semi trailer Emergency AUX 4 6 Service = Item = Port 6 Fig. 88 : 3M - 3-axle semi trailer with Trailer Control Module and spring brake chambers Item Description Notes Emergency coupling with integrated filter Service coupling with integrated filter 3 Trailer Control Module (TrCM) 4 Air reservoir - brake 5 Drain valve 6 Test point 7 Main Modulators ( M) 8 Additional Modulator ( M) 9 Spring brake chamber 0 Single diaphragm brake chamber Test point Suspension air bags (bellows) 5

52 4 Piping 4. Brake piping layout M, -axle drawbar trailer (full trailer) Emergency AUX 4 6 Service = Item 6 = Port Fig. 89 : 3M - -axle drawbar trailer (full trailer) with Trailer Control Module and spring brake chambers Item Description Notes Emergency coupling with integrated filter Service coupling with integrated filter 3 Trailer Control Module (TrCM) 4 Air reservoir - brake 5 Drain valve 6 Test point 7 Main Modulators ( M) 8 Additional Modulator ( M) 9 Spring brake chamber 0 Single diaphragm brake chamber Test point Suspension air bags (bellows) 5

53 4.3 Air suspension system piping layout Air suspension leveling valve, COLAS + and ILAS -E AUX 7 AUX = Item = Port Fig. 90 : 3-axle semi trailer, COLAS + with auto reset to ride (RtR), ILAS -E, air suspension levelling valve Item Description Notes Air reservoir suspension Drain valve 3 ILAS -E 4 Air suspension levelling valve 5 Lift cylinder 6 Test point (if not integrated in COLAS +) 7 Modulator 8 Suspension air bags (bellows) 9 COLAS + 53

54 5 Installation and Operating Instructions 5. Brake system Trailer air braking system Twin-circuit braking system as per Directive 7/30/EEC When the red supply line is connected, on automatic coupling heads in tractor units the valve in the coupling head opens. The compressed air now flows through the line filter to the energy inflow of the Trailer Control Module (TrCM). When the system is filled the first time and is free of pressure, the compressed air flows from the TrCM to the reservoir - and disengages the parking brake via the energy outflow of the TrCM when the red button (disengaging valve) is pressed. This is why the yellow brake line should always be attached first when hitching up, ensuring the service brake in the trailer is operated when the brake is applied in the tractor. If there is no pressure acting on the yellow line, then the spring brakes are bled via the quick release valve integrated in the EBS and the parking brake is thus activated, when the red button of the TrCM is pulled. Actuation of the service brake When the brake is released, the yellow brake line is exhausted via the exhaust on the trailer control valve in the tractor unit. The EBS vents the service brake cylinder of the braked axles via its ventilation outlets for the left and right side. Connection lines between the towing vehicle and the trailer uncoupled or broken away If the supply line is uncoupled or breaks away, the trailer brake control valve initiates emergency braking (automatic braking with the BBA) by exhausting this line. If the yellow brake line breaks away, nothing happens unless the service brake is actuated. When the service brake in the tractor unit is actuated, the supply line is exhausted via the defect in the brake line, whereupon the TrCM initiates emergency braking (automatic braking with the service brake system). For manoeuvred the unhitched trailer, the service brake can be disengaged by actuating the shunt valve of the TrCM (black button). The red button must also be pressed in this case to disengage the parking brake. The disengagement procedure of the parking brake can only be carried out, if the pressure in the reservoir is greater than approx. 3 bar. When the service brake in the tractor unit is actuated, the trailer control valve admits compressed air to the yellow service line. The braking pressure is then passed on to control port 4 of the TrCM. The TrCM now steers compressed air through the energy outflow to the downstream EBS. The ALB system integrated in the EBS regulates the pressure according to the load status so that pressure appropriate to the load can be guided to the brake cylinders of the braked axles. Compressed air brake system Coupling head (yellow) 4 Additional connections e.g. air suspension Coupling head (red) ISO EBS cable black red - Trailer Control Module TrCM ABS cable connection SB SA SB SB AUX AUX AUX3 AUX4 AUX5 SA SA DIAG PWR-B PWR-A 4S/M Modulator ISO 85 or ISO 098 Junction box Trailer lighting EBS cable -core cable: 4V from brake light (red) Earth (white) PWR-B PWR-A Fig. 9 54

55 5. Brake system 5.. Coupling heads Applications The coupling heads of the two line brake system, red for supply and yellow for brake, are installed to connect the supply and brake lines between the vehicle or the tractor unit and trailer vehicles. They are constructed in such a way that they cannot be wrongly connected. Coupling head emergency Automatic coupling heads are installed on the towing vehicle (commercial vehicle or trailer rear connection) to establish connections to towed vehicles. The coupling head with integrated filter simultaneously protects the compressed air braking system from soiling. The coupling heads meet the requirements of ECE/EC and DIN-ISO 78. Fig. 9 Coupling head service Mode of Operation The coupling heads are connected to each other up to the stop dog. This prevents a supply line coupling head being connected to a brake coupling head. This means they cannot be wrongly connected. Installation Guidelines The supply coupling head (red) is installed in the driving direction to the right and the brake coupling head (yellow) to the left. The coupling sealing surfaces must point towards the right. Tightening torque of the nut: 60 Nm. Fig. 93 Installation dimensions Maintenance free space for coupling The sealing surfaces must be clean and must be replaced if they become damaged. In the case of coupling heads with integrated filter, the filter inserts are to be cleaned regularly (at least once a year) min Inspection - Test of functioning and leak proofness - Stop dog, wear - Cap, present - Correctly inserted Fig. 94 Technical Data Operating medium: Operating temperature: Working pressure: Air -40 C to +80 C 0.0 bar Connection: M 6 x.5 with filter and plastic cover 55

56 5 Installation and Operating Instructions 5. Brake system 5.. Trailer Control Module TrCM Applications Trailer Control Module TrCM The Trailer Controle Module TrCM is a trailer brake valve with emergency brake, combined actuation valves (release and parking valve) and a charging valve without backfl ow. The release valve deactivates the emergency brake (black control button). By activating the parking brake valve, the parking brake is released or activated (red control button). The integrated charging valve without backfl ow guarantees the supply of compressed air to the brake system. The flow of air to secondary systems is only allowed once the brake system has reached the rated pressure. The valve meets the requirements of EC/ECE directives for braking systems. Mode of Operation (modified 0.0.0) Supply line coupled: With the supply line coupled, the supply pressure provided by the towing vehicle is available without limitation. After exceeding the overflow pressure, the supply pressure is also available to the secondary loads. Brake line coupled: With the application of pressure via the brake coupling head, the pressure is transmitted without reduction via control terminal 4 to connection (no relay effect). Parking brake activation: By pulling the release valve (red button), the spring brake system connection is coupled to the venting connection 3. This reduces pressure in the spring brake system and activates the parking brake system. Pushing the red control button couples the spring brake system connection to the air supply tank connection -. This builds up pressure in the spring brake system and releases the parking brake system again. Fig. 95 (modified 0.0.0) Release device service brake system (BBA): The release valve deactivates the automatic braking ( emergency braking ) triggered by the decoupling of the emergency line (cf. EG-RL, Appendix I, Section... and ECE-R3, Section 5...). Pushing the black control button (with decoupled emergency line / brake line deactivates the automatic braking. This is implemented by decoupling connection from connection - and coupling (vented) connection 4 to connection. Recoupling the feed and supply line and supply to the compressed air (towing vehicle) automatically switches the release valve back to the normal operating position. Brake Installation Coupling head (yellow) 4 Additional connections e.g. air suspension Coupling head (red) ISO ISO 85 or ISO 098 EBS Cable black Trailer Control Module TrCM Junction box Trailer lighting red EBS Cable - -core cable: 4V from brake light (red) Earth (white) ABS Cable connection SB SA SB SB AUX AUX AUX3 AUX4 AUX5 SA SA DIAG PWR-B PWR-A PWR-B PWR-A 4S/M Basic Modulator Fig

57 5. Brake system 5.. Trailer Control Module TrCM Pressure loss in the supply line. Effect on the service brake system (BBA): When pressure in the emergency line decreases by at least bar per second, the automatic braking of the towing vehicle is activated before the pressure in the supply line drops to bar. During this process, the reserve tank (connection -) and connection are directly coupled. This ensures automatic braking by the service brake system and regulation of the ABS. Connection Designations 4 Effect on service brake system reserve tanks and secondary equipment: In the event of a supply line rupture (red coupling head) integrated check valves prevent the air supply from escaping from the brake supply air tank of the trailer and the secondary loads. Pressure loss in a secondary load, effect on the service brake system supply air tank: In the event of a pressure loss in a secondary load, the integrated charging valve ensures a safety pressure in the supply tank of the service brake system. Pressure application via coupling head brake, emergency line not coupled: In the event of pressure applied via the coupling head brake (e.g. with activated parking brake system of the towing vehicle), the brake supply tank and therefore the secondary loads as well are filled to a pressure reduced by the overflow loss. The filling of the secondary loads depends upon reaching the opening pressure of the integrated charging valve. An empty / partially filled brake system is therefore filled before coupling the coupling head supply. Caution Danger! Be careful during disassembly, strong spring in the inner part. After installation the brake system must be checked. 3-3 Connection designation Thread = Energy flow (coupling head supply) M x.5 - = Energy release/flow (tank) M 6 x.5 3 = Venting (spring brake) 4 = Gate terminal (coupling head brake) M 6 x.5 = Energy release (EBS/ABS) M 6 x.5 = Energy release (spring brake) M 6 x.5 3 = Energy release (pressure limit valve) M 6 x.5 4 = Energy release (pressure limit valve) M 6 x.5 5 = Energy release (pressure limit valve) M x.5 Fig. 97 Technical Data Operating pressure: p e = 0 bar Operating temperature: - 40 C to + 70 C Weight: approx..8 kg Pressure limit valve: DIN 7479-C 6- Opening pressure: p e = approx. 6. bar Closing pressure: p e = approx. 5.6 bar 4 5 When working with high pressure cleaners, keep a safe distance of at least 50 cm. Coupling processes Decoupling: disconnect the supply line (red) first, and then the brake line (yellow). Coupling: connect the brake line (yellow) and then the supply line (red) 57

58 5 Installation and Operating Instructions 5. Brake system 5.. Trailer Control Module TrCM x M6x.5 - deep 97 5x M8 - deep point fixing Ø 35 (~ Ø 38) ~ Fig max. permissible 0 connecting piece 6 Charging valve 3 point fixing 60 0 Installation Guidelines Install the valve with its attachment flange to the vehicle frame using two/three M 8 screws (5 Nm). Ensure good accessibility to the actuating device. Unnecessary connections are to be closed. For painting tasks, protect the valve openings from penetration by paint. For line fittings / plug connections, comply with the manufacturer s specifications. Maintenance Control according to the legal requirements of 9 StVZO. If defects are found during vehicle inspections or travel, the valve must be replaced. In case of soiling or damage, replace the basket filter in connection. Inspection: Carry out a sealing and function check as described below.. Depressurised system Press the release valves (black and red buttons) (secure vehicle trailer).. Initial filling Supply pressure to connection. The release valve (black button) must switch to the operating position (jump out). 3. Automatic emergency brake Lower the pressure at connection to 0 bar. The emergency brake connection must be automatically activated. 4. Pressure limit Opening and securing pressure (closing pressure) to be checked with a test gauge at the connections 3, 4 and 5 corresponding trailer manufacturing information. Review leakage, for example with a leak detection spray. 5. Parking brake valve (red button) Supply pressure to connection. Pull up the release valve (red button). Connection (FBA) must bleed to 0 bar. Functional diagrams Fig. 99 Pe [bar] 8 Output pressure connection Pe [bar] 8 Energy discharge connection Automatic braking Full function Pe [bar] Input pressure connection Pe - [bar] Energy discharge connection - Release 58

59 5..3 Trailer Control Module TrCM + Applications TrCM + is a parking and shunting valve with with an integrated emergency brake valve for the service brake system and an overflow valve for auxiliary equipment (e.g. air suspension) which is used in two-line air brake systems in trailers The TrCM + has a flange-fitted shunt valve and a parking valve for the service brake and the spring brake. Parking Hold is a new, additional function, whose effect is that, when coupling, although the service brake releases, the spring brake cylinders enter/stay in the braking position. Before starting the journey, the spring brake cylinder must be released manually using the parking valve. In particular, the Trailer Control Module + satisfies the requirements of EEC Braking Systems Directive 7/30 and ECE Regulation R Brake system Trailer Control Module TrCM + Fig. 00 Technical Data Operating pressure: p e = 0 bar Operating temperature: - 40 C to + 70 C Weight: approx..7 kg Pressure limit valve: DIN 7479-C 6- Opening pressure: p e = approx. 6. bar Closing pressure: p e = approx. 5. bar 4 4 Connection designations Thread = Energy flow (coupling head supply) M x.5 - = Energy release/flow (tank) M 6 x.5 = Energy release (spring brake) M 6 x.5 3 = Venting (spring brake) 4 = Gate terminal (coupling head brake) M 6 x.5 = Energy release (-way valve) M x.5 = Energy release (EBS/ABS) M 6 x.5 3 = Energy release (pressure limit valve) M 6 x.5 4 = Energy release (pressure limit valve) M 6 x.5 5 = Energy release (pressure limit valve) M x.5 Fig Brake Installation Trailer Control Module TrCM+ Coupling head (yellow) 4 Coupling head (red) ISO ISO 85 or ISO 098 EBS Cable - black Junction box Trailer lighting red Additional connections e.g. air suspension EBS Cable -core cable: 4V from brake light (red) Earth (white) ABS Cable connection SB SA SB SB AUX AUX AUX3 AUX4 AUX5 SA SA DIAG PWR-B PWR-A PWR-B PWR-A 4S/M Basic Modulator Fig. 0 59

60 5 Installation and Operating Instructions 5. Brake system 5..3 Trailer Control Module TrCM + Mode of Operation Supply line coupled (Fig ): When the supply line is connected, the supply pressure provided by the tractor is available to the braking system in full, the service brake is released and the spring brakes are operating. When the overflow pressure is exceeded, supply pressure is also available to the auxiliary devices. When pressing the parking valve (red button), the spring brakes will be ventilated and thus the parking brake (Fig. 04) will be released. Brake line coupled (Fig ): When pressure is introduced through the service coupling, the pressure is passed on to port through control port 4 without reduction (no relay effect). Initial charging Parking brake activation (Fig. 04, ): When the parking valve (red button) is pulled, the spring brake unit at port is connected to the exhaust port 3. The pressure in the spring brake unit therefore falls, and the parking brake is applied. When the parking valve is pushed, the spring brake system at port is connected to the air supply reservoir, ports -. The pressure in the spring brake system therefore rises, and the parking brake is released again. The parking brake system must always be released manually after uncoupling. The release can, however, only be effected when a pressure of at least 5.0 bar is available in the supply reservoir (Fig. 04). Release device for service braking system (Fig ): The shunt valve (black button) makes it possible to release the automatic braking ( emergency braking ) that is triggered when the supply line is disconnected (cf. EWG-RL, Annex I, Paragraph... or ECE-R3, Paragraph 5...). The automatic braking of the service braking system is cancelled when the shunt valve is pressed (with the supply line / brake line uncoupled). This is caused by the disconnection of combination of port to port - and production of a connection from port to port 4 (exhaust from the yellow hose coupling). When the supply line is reconnected and compressed air is applied, the shunt valve automatically switches back into the normal operating position. Manoeuvring operation (Fig. 06): In order to manoeuvre the uncoupled vehicle, both the operating knobs, black service braking system and red spring braking system, must be pressed. Only this ensures that the service braking system / spring braking system are released and that the vehicle is not braked. The parking valve must be pulled again when the manoeuvring process is complete. Fig. 03 Pressure rise approx. 6. bar Fig. 04 Emergency braking Caution Danger! There must not be anybody in the hazardous area when coupling or uncoupling. Fig

61 5..3 Trailer Control Module TrCM + Pressure loss in the supply line. Effect on the service braking system (Fig. 05): If the pressure in the supply line falls by at least bar per second, the automatic brakes of the trailer vehicle will come on before the pressure in the supply line falls to bar. This establishes a direct connection between the supply reservoir (port -) and port. An automatic braking is carried out by the service brake unit, and ABS remains in operable condition. 5. Brake system Manoeuvring when uncoupled Effect on the service braking system supply reservoir and the auxiliary devices: If the supply line (red coupling head) is pulled off, loss of supply air from the trailer vehicle s supply reservoir and the auxiliary devices is prevented by the integrated low pressure check valve. Fig. 06 Effect on the spring braking system (Fig. 05): The parking valve is pushed out automatically when the spring braking system is released (red button pressed); the parking brake actuator is kept released through the integrated double check valve. As a result, the pressure at ports, and - is the same. If the pressure in the supply reservoir falls further, ports and are vented at the same time; this automatically activates the spring braking system and in that way prevents the trailer vehicle from rolling away. Pressure lost in the auxiliary devices, effect on the service braking system supply reservoir: If pressure is lost through an auxiliary device, a safety pressure is maintained in the supply reservoir of the service brake equipment by the integrated pressure protection valve. Activating the parking brake when coupled Applying pressure through the service coupling, supply reservoir not coupled: If pressure is introduced through the service coupling (e.g. when the tractor vehicle s parking brake is active) the braking supply reservoir (and therefore the auxiliary devices as well) are filled with a pressure that is reduced by the overflow loss. Filling the auxiliary devices depends on reaching the pressure at which the integrated pressure protection valve will open. As a result of this, a braking system that is empty or only partially pressurised is charged even before the palm coupling supply is connected. Fig. 07 Releasing the parking brake when uncoupled Caution Danger! Before starting the journey, the spring brake cylinder must be released manually using the parking valve. Fig. 08 6

62 5 Installation and Operating Instructions 5. Brake system 5..3 Trailer Control Module TrCM + Mx.5 - deep x M6x.5 - deep 97 5x M8 - deep point fixing (~Ø 38) Ø ~ max. permissible connecting piece Installation Guidelines The TrCM + should be attached to the vehicle chassis through its mounting flange, using two or three M 8 (5 Nm) screws and spacing washers. The maximum tightening torque for the threaded bushings is 34 Nm. The function plate must be attached to a visible area near the palm coupling. Ensure that the operating equipment is easily accessible. Ports that are not needed must be closed off. When painting, the valve openings must be protected to prevent paint penetration. Refer to the respective manufacturer s instructions for the screwed/push-in fittings. Maintenance Control according to the legal requirements of 9 StVZO. If defects are found during vehicle inspections or travel, the valve must be replaced. In case of soiling or damage, replace the basket filter in connection. Inspection: Carry out a sealing and function check as described below.. System without pressure Release valve (black button) must be pushed in (securing the trailer vehicle previous to this test), parking valve (red button) automatically pushed out.. Initial filling Supply pressure to connection. The release valve (black button) must switch to the operating position (jump out). The parking valve (red button) remains pushed out. 3. Automatic emergency brake Lower the pressure at connection to 0 bar. The emergency brake connection must be automatically activated and the red button jump out. 4. Pressure limit Opening and securing pressure (closing pressure) to be checked with a test gauge at the connections 3, 4 and 5 corresponding trailer manufacturing information. Review leakage, for example with a leak detection spray. 5. Parking brake valve (red button) Apply pressure to port. Parking valve (red button) automatically pushed out, push the parking valve (red button) in, at least 5.0 bar in the supply reservoir, pull the parking valve (red button), port (spring brake system) must vent down to 0 bar, vehicle braked. Charging valve 3 point fixing Fig Functional diagrams Pe [bar] 8 Output pressure connection Pe [bar] 8 Energy discharge connection Automatic braking 0 Parking brake valve diagram Fig. 09 Full function Pe [bar] Input pressure connection Pe - [bar] Energy input connection Release

63 5. Brake system 5..4 Brake lining wear sensoring Cable tie 8 AUX cable / cable length m Sensor 6 / cable length.5 m Sensor 5 / cable length 3.5 m Fig. Sensor / cable length.5 m Sensor / cable length 3.5 m Sensor 3 / cable length 4.5 m Sensor 4 / cable length 4.5 m Brake lining wear sensoring The brake lining wear sensoring allows several wear sensors to be connected to just one auxilliary (AUX 4) of the ECU. These can be connected to all types of trailer vehicles which have the option of brake linings. Selection is effected without the wheels having to be taken off by using the Trailer Monitor or Trailer Manager diagnostic tools. The system is connected to special indicators of the brake linings. If corresponding wear of the linings occurs, a signal is transmitted to the ECU of the ECO Tronic EBS, which then results in the warning lights coming on. The brake lining wear sensoring helps to provide early recognition of worn brake linings. It meets the requirements of IP67 (BS EN 6059) when using the ECO Tronic EBS and meets the ADR provisions for Classes to 9. Operating note: Unused sensor connections (e.g. with two-axle vehicles) should be provided with a BPW blind plug. Brake lining wear sensoring attachment 75 Fig. Technical Data 5 9 Cable tie fixing centres Cable material: Operating temperature: ECU Connector: PUR - 40 C to +70 C blue Recommended fixing screws M 6 x or cable ties. 63

64 5 Installation and Operating Instructions 5. Air suspension Fig. 3 BPW Air Suspension A running gear system is only ever good as its suspension. BPW air suspension systems are individually designed to cope with where and for what they re going to be used, and what load they re going to carry. Only in this way it is possible to ensure the optimum driving safety at the same time as reducing the stress on the driver, the cargo and the body. This reduces wear on the tyres and cuts down the stress on the vehicle body and the cargo - as well as reducing your expenses. The modular construction means that it s easy to exchange individual components in the event of a repair. The vehicle suspension has the task of ensuring that jolts occurring during a journey due to uneven driving surfaces are not transferred with full force to the body of the vehicle, but to a reduced degree. Air suspension can easily fulfill this task. All types of construction of air suspensions are deployed as supporting springs for the load of the body. Fig. Abb. 4???? Dual-circuit air suspension installation BPW air suspension systems possess high roll stability characteristics providing minimum body roll when cornering, leading to optimum road safety. This high roll stability characteristic is achieved because the body is supported when cornering not only by the air bags but also by the stabilising effect of the axle beam to trailing arm connection. The specification of the air suspension installation also has a significant influence on the roll stability characteristics: Dual-circuit version with transverse flow restrictor: The air bags on the left and right sides of the vehicle are pneumatically separated and only connected together by a transverse flow restrictor in the air suspension levelling valve (see illustration). During cornering, the air can only equalise itself slowly between the two sides of the vehicle. As a result, the air bags additionally assist in supporting the rolling motion of the vehicle body. The use of single-circuit air suspension installations can lead to damage to the vehicle as a result of the higher loads. For this reason, BPW cannot offer any warranty for chassis and suspension damage resulting from this effect. To achieve optimum function and the greatest possible road safety, in particular in critical situations, we expressly recommend using dual-circuit air suspension installations with a flow restrictor. Lifting axles are the only exception to this recommendation. In this case, it is permitted for at most one lifting axle in a three or four-axle unit to be installed single circuited. 64

65 5.. Standard air spring valve dimensions and connections 5. Air suspension Identification mark for the lever mounting position, lever swivel angle ,5 Washer DIN 5-B Tightening torque: - 4 Nm Charging 4 39 X+00 min. 60 Ø X Discharging max. 30 min Linkage assembled without tension (valve axle) Fig. 5 0 M8 Application The levelling valve is installed as a level control valve for load depended control using the air bellows of vehicles with air suspension. Depending on the version, additional functions, such as. drive height, through a lap position control are possible. Air suspension valve Principle of operation Air spring valves are secured on the vehicle frame and are connected to the axle with the round or flat lever via leverage. The pneumatic connections are made via a reserve connector (), two energy outflows ( and ), as well as via the vent (3). When in the resting state, the valve is said to be in the so-called finishing position, i.e. both inflow and also outflow are closed. Fig. 6 65

66 5 Installation and Operating Instructions 5. Air suspension 5.. Standard air suspension valve When the vehicle is being loaded, the body (frame) approaches the axle, causing the leverage and the control lever to rise and allowing access via the carrier shaft, cam and pistons. Reserve air from connection now flows past the check valve, over the opened inflow, through the space between pistons and inlet bodies via connection and to the air bags. This means the body (frame) is raised until the point where the control lever is horizontal once again, that is to say in the finishing position. When the vehicle is being unloaded, the body is raised upwards due to the higher airbag pressure. The control lever is moved downwards through the leverage. The movement of the control lever is transferred via the carrier shaft as well as the cam to the piston, which opens the outlet during its downwards movement. Compressed air now flows through the open outlet from the air bags into the atmosphere, which causes the body (frame) to lower once again into the driving position, (air suspension valve control lever horizontal). Vehicles are usually only equipped with one air suspension valve. Exceptions can be found, for example in the case of fifth wheel trailers or semi trailers with independent suspension. The airbags on the right as well as the left side of the vehicle are supplied via this one air suspension valve with cross-throttling. Technical Data Operating pressure, dyn.: Permitted dyn. bellow pressure: pe max. 3 bar pe max. 0 bar Operating temperature: - 45 C to + 85 C Operating range (charging - and exhausting): 45 Side of control: on the left and on the right Dead angle at 7-8 bar: Connection designation: = Energy flow / =./. Energy release 3 = Venting Turning the operating handle 80 achieves the same function within a tolerance range of 3.5, as in the adjustment shown. Piping diagram Supplementary functions Air suspension valve with cross-throttling Air suspension valve with cross-throttling and height limitation Air suspension valve with zero point adjustment for nd driving height 3 Air suspension valves with cross-throttling Air suspension valves with cross-throttling prevent the vehicle becoming unstable when cornering, as would occur if the pressure of the air bag on the outside of the curve were to even out to match that of the air bag on the inside of the curve (danger of an accident; tendency already apparent in the body while taking the corner would thus be reinforced even further). A special formation of the inlet valve allows for increased pressure compensation to be achieved between connection and and therewith between the right and left air suspension valve (vehicle side). Fig. 7 Adjustment of mechanical part Assembly instructions - Mechanical The levelling valve has to be installed vertically with exhaust port at bottom. For fixing use at least two M8 screws. The valve should be secured via the middle of the axle. Tightening torque: 5 Nm ( Nm). The freedom of movements of the eccentric shaft must be tested. The leverage must be installed free of tension. The marking on the eccentric shaft must point in the direction of the steering device in order to ensure the operation of the air suspension valve on the correct side (see Fig. 8). Fig. 8 Arrow marking must indicate direction of linkage 66

67 5. Air suspension 5.. Standard air suspension valve Assembly instructions - Pneumatic In the case of the valves with push-on connections, 8 x plastic tubes according with DIN are to be used as pneumatic lines. Care must be taken during assembly that the tubes are cut off at right angles and burr-free for the required length. Before the tubes are inserted into the push-on connections, support sleeves must be pressed into the ends of the tubes. Insert the tube at least mm into the push-on connectors. By pressing down on the over-hanging lock ring (e.g. with an open end spanner), the plastic tube can be removed again (e.g. in case of replacement). When painting is being undertaken, all open connections and the breather must be protected against paint penetrating inside by using suitable means. The protective measures must be removed again once the painting work has been completed. A tubing filter is to be inserted into the line coming from the air tank (prevents soiling occurring). Setting the valve After installation of the valve and connecting the pipe fittings the length of the connecting rod must be determined between axle and valve, after the vehicle chassis has been set at the desired height (vehicle manufacturer- specification). The raising of the frame or chassis to this desired height is reached by lifting the control lever in position charging. At this process the air bellows are inflated with air. At reaching the desired height the control lever must be positioned immediately in the lap position, which can be the horizontal position (depend to version), and fix it with a locking pin (d=4h8) on housing and on bore of the spindle. Statutorily prescribed max. heights must be adhered to. Please see the BPW documentation for air suspension systems for further information. The actual length of the connecting rod between the linkage to axle and the linkage at the control lever can now be determined, and the connecting rod can be fastened. The connecting rod is to be connected using the rubber linkages and fastened with the hose clamps supplied. Last of all remove the locking pin. If a problem-free finishing position still cannot be achieved with the control level in this position, then it is possible to effect a corresponding correction: To lock the lap position, use pin d = 4h8 x 0 DIN 7 fix spindle as well as linkage (d = 6 mm) in horizontal position. Remove the rubber boot and filter pad. With a screwdriver turn the valve tappet so far, that neither a rise nor drop in pressure occurs. As an alternative an adjustment at the linkage to axle is possible: loosen counter nut and shift angles at the axle bracket accordingly. Tighten counter nut again. Pipe connection Assembly plastic pipe Dismantling plastic pipe Fig. 9 Fig. 0. Press in clamp ring Zero point adjustment 4 x Ø 9. Remove plastic pipe Zero point adjustment of the valve by means of the dowel pin 4 x 0 Inspection Check function and leak. In the lap position at the delivery ports, neither rise of pressure nor drop of pressure may result. Free movement and condition of the linkage is to be checked, bent or welded linkages are to be exchanged. Brittle or hardened rubber pieces are to be renewed. 67

68 5 Installation and Operating Instructions 5. Air suspension 5.. Air suspension valve with height limitation dimensions and connections max. 30 min SW Identification mark for the lever mounting position Charging Discharging SW 3 M = 5-0 Nm Fig. Ø Ø SW 3 Exhaust valve Adjusting screw Application The air suspension valve with height limitation controls the pressure in the bellows for vehicles with air suspension and limits the raising procedure in connection with a raising and lowering mechanism (COLAS +) when a maximum permitted body height has been reached, in order to protect other components from being damaged. Operation of the height limitation function The raise/lower valve is fed via the levelling valve from port to port 3. If maximum body height is reached during the lifting action, the twisting of the shaft and the associated downward motion of the pipe cause the valve plate to sit on the valve seat, which interrupts the supply from port to port 3 and so ends the lifting action. Technical Data Operating pressure, dyn.: pe max. 3 bar Permitted dyn. bellow pressure: pe max. 0 bar Operating temperature: - 40 C to + 80 C Operating range (charging - and exhausting): 45 Nominal diameter/type:.3 Side of control: on the left and on the right Dead angle at 7-8 bars: Connection:,, = M x.5, 3 = M 6 x.5 Tightening torques of the connection,, to 5 Nm, 3 0 to 5 Nm Connection designation: /./. Energy flow //3././3. Energy release 3 Venting 68

69 5. Air suspension 5.. Air suspension valve with height limitation Adjustment of Height Limitation The height limitation can be set over a range of α = 5 to 40. If the factory-set height limitation of α = 45 ± needs to be changed, the dump valve must be removed (using SW 3) and the adjuster screw turned with a suitable tool. Clockwise rotation: α < 45 Anticlockwise rotation: α > 45 The angle here refers to the downwards excursion α of the control lever from the horizontal, in degrees. Then refit the dump valve. Piping diagram 3 3 Inspection Check function and leak. The pressure should neither rise nor fall at the delivery ports in the neutral position. Check the linkage moves freely and is good condition, replace if bent. Fig. Changing the body height depending on the lever length Changing the body height depending on the lever length while limiting height Fig. 3 Linkage distance Deflection height changing

70 5 Installation and Operating Instructions 5. Air suspension 5..3 Air suspension valve with zero point adjustment dimensions and connections Identification mark for the lever mounting position, lever-swivel angle 360 Charging max. 30 min. 80 G G 9 Washer DIN 5-B Tightening torque: - 4 Nm Ride height 4 G Ø9 Discharging 45. Ride height G 4 Ø Linkage assembled without tension (valve axle) Fig. 4 0 M8 Application The levelling valve is fitted as a level control valve for loaddependent control of the air spring bellows volume in vehicles with air suspension. This version provides a second ride height by means of a zero point adjustment. Operation of the zero point adjustment In the case of admission flow of connection 4, the zero point in the valve is adjusted by 0 via a tappet. This opens the inflow and the body is raised in order to reach the finishing position. The integrated construction of the zero point adjustment has the following advantages: - a nd ride height on vehicles with lift axles, so that when the axle is lifted, the wheel does not contact the road surface when passing over unevenness in the ground, thus preventing increased tyre wear. - can be matched to various trailer heights, thereby facilitating operations for the fleet operator. Technical Data Operating pressure, dyn.: pe max. 3 bar Permitted dyn. bellow pressure: pe max. 0 bar Operating temperature: - 40 C to + 80 C Operating range (charging - and exhausting): 45 Nominal diameter/type:.3 Side of control: on the left and on the right st ride height dead angle at 7-8 bar: nd ride height dead angle at 7-8 bar: 3.5 Necessary switching pressure: 6.5 bar Connection designation: = Energy flow / =./. Energy release 3 = Venting 4 = Gate terminal If the actuator lever is twisted through 80, the same function is obtained with a tolerance range of 3.5 for the first ride height and 4,5 for the second ride height, as for the setting shown in the drawing. 70

71 5. Air suspension 5..3 Air suspension valve with zero point adjustment Inspection Check function and leak. The pressure should neither rise nor fall at the delivery ports, in the neutral position. Check the linkage moves freely and is in good condition, replace if bent or welded. Replace hardened or brittle rubber parts. Piping diagram 4 3 Fig. 5 Adjustment of the body height in a zero point setting Change of the body height depending on the level length at zero point setting Fig. 6 Linkage distance Deflection height changing

72 5 Installation and Operating Instructions 5. Air suspension 5..4 COLAS + COLAS + Applications The COLAS + raising/lowering valve has a broad range of functions. The following features are integrated: deadman function, RoRo position and Reset to Ride (RtR) function. Mode of Operation Drive position The lever is in the central position when pulled out and is secured by an anti-rotational lock. In this position connection is coupled to connection and connection to, enabling a direct air connection between the air suspension valve and the air bags. Stop position The lever is in the central position when pressed in. Connection is not coupled to connection and connection is not coupled to connection Lower position The lever is rotated clockwise from the Stop position approx. 35 degrees, so that connections and is connected to connection 3, enabling venting of the air bags. After releasing the lever, it automatically rotates back to the central Stop position and de-couples connection and from connection 3 (so called dead man switch ). The air bags are then no longer vented. RoRo ( Lowered locked ) position The lever is rotated clockwise from the Stop position, approx. 35 degrees and pressed into this position. This de-activates the dead man function and the lever remains fixed in the rotated position after it is released. Connections, and 3 remain coupled to each other. The air bags are continuously vented. This venting is, for example, required with ferry or rail loading of the vehicle. Raise position The lever is rotated counter clockwise from the Stop position approx. 35 degrees so that connection and are coupled to connection, enabling the charging of the air bags. After releasing the lever, it automatically rotates back to the central Stop position and de-couples connections and from connection (so called dead man switch ). Resetting of Stop or Lower Locked position to Travel position Resetting from the central position is performed manually by pulling out the lever, so that the anti-rotational lock is again activated. For vehicle speeds in excess of 5 km/h (adjustable) the solenoid valve is pulsed from the ABS/EBS, automatically pressing the lever to the Travel position. This function prevents driving with vented air bags and thus damage being done to the running gear. Fig. 7 Piping diagram Drive Raise Stop Lower Lower-Locked 3 Caution Danger! Fig. 8 During the raising and/or lowering process, no persons may be present in the hazardous zone. A lowered body can automatically lift during start-up, Reset to Ride. 7

73 5. Air suspension 5..4 COLAS Test point Ø 44 4x Ø 9.5 4x M 8 Ø Rest Position - Lower 94 Stop Position 0 Travel Position 56.6 Fig. 9 Installation Guidelines Mechanical Part: 50 Technical Data Operating pressure: p e max. 8.5 bar Operating temperature: - 40 C to +80 C Weight: approx..5 kg Solenoid Valve: perm. duty cycle 0 s Voltage U B = 4 VDC +7/-8 Current / Output lo= 50 ma / Po = 6 W Protection class DIN IP 6K 9K Attachment is by at least holes provided on the housing with M 8 bolts and a tightening torque of 5 Nm ( Nm). The installation site must be chosen so that the COLAS + valve is protected from spray or high pressure wash water. Good accessibility to the operating lever must be provided. Ensure that the unit does not protrude outside the overall vehicle width. The vehicle manufacturer must provide suitable protection against unauthorised activation. Electrical Connection Electrical Part: Bayonet connection according to DIN For the bayonet connection, turn the union nut clockwise to make certain that it is correctly attached and locks in to ensure optimum sealing. An electrical connection to the solenoid valve is permissible only via the ECO Tronic EBS-ECU, which provides a signal Reset to ride height. BPW Bergische Achsen is not liable for other types of actuation. Fig

74 5 Installation and Operating Instructions 5. Air suspension 5..4 COLAS + Pneumatic Part: Connection Designations The pneumatic connection can be implemented according to the installation diagrams. COLAS + is equipped as standard with PTC (Push To Connect) push-on connectors. Protect the ventilation connection 3 from penetration of dirt and water. During installation of the pneumatic pipelines, make sure that they are cut to the required length, at right angles and free of burrs, with suitable tools. To ensure the permitted spring deflections are not exceeded during the raising process, it is advisable to use a height limitation device (e.g.: BPW air suspension valve with height limitation). Any exceeding of permitted spring deflections can lead to individual components being damaged. For painting tasks, protect all open plug connections and the venting with suitable covers against penetration by paint. After painting, remove the protective covers again. Attach the BPW sign (Fig. 3) near COLAS +. 3 Maintenance If defects are found during vehicle inspections, travel or during commissioning, the device must be replaced. When working with high-pressure cleaners, keep a safe distance of at least 50 cm from the COLAS +. = Supply, DIN x = from air suspension valve, DIN x = to air suspension valve, DIN x = to air bags, DIN x = to air bags, DIN x 3 = Venting (at least DN 9) Fig. 3 BPW Sign COLAS + Fig. 3 74

75 5. Air suspension 5..5 ILAS -E Application ILAS -E is used for electrically controlled lifting and lowering of one or several lift - axles with conventional air suspension systems. With electronically controlled air brake systems, e.g. EBS, ILAS- E are controlled by the load depended output signal. ILAS -E Principle of operation Electrically actuated lift axle control device for lifting and lowering of lift axle(s). With electric power on: Axle is up With electric power off: Axle is down Traction control: By using a traction control device you have to follow the regulations for lift devices (97/9/EG). Installation Guidelines Mechanical Part: The ILAS-E should be mounted using the holes which are provided. It should not be located in an area where there is excessive water spray / splash and should be protected from high pressure washing equipment. Additional protection should be provided by the vehicle manufacturer against unintentional activation. Fig. 33 Pneumatical Part: A nylon pipe in accordance with DIN x should be used for the versions with push-in fittings. When assembling the air pipes, care should be taken to ensure that the pipes are cut square, to the required length and are free from burrs. Inspection Check function of unit and security. Function: With electric power on: Axle is up With electric power off: Axle is down To lower the lifting axle, e.g. for servicing work (HU, SP), the power supply must be interrupted. Alternatively, the lifting device can also likewise be switched off during operating through pre-fixing of a stop cock with venting before connection (axle lowers itself). Porous rubber parts must be replaced. When painting is being undertaken, all open connections, the atmospheres connection and the breather must be protected against paint penetrating inside by using suitable means. The protective measures must be removed again once the painting work has been completed. A safety distance of at least 50 cm should be kept when working with high pressure cleaners. Technical Data Medium: Air Operating pressure: p e max. 8.5 bar Operating temperature: - 40 C to +80 C Required switch pressure: pe >.5 bar Voltage: 4 VDC Current Power consumption at 0 C: IO = 50 ma/p0 = 6W Permissible duty: 00% Type of protection: DIN IP 67 A 75

76 5 Installation and Operating Instructions 5. Air suspension 5..5 ILAS -E - Identification of ports and fixings Bayonet connection according to DIN 7585 All ports Push-in fittings for tube DIN 744-8x - 3 mm deep 04. mm 65 mm. 67 mm 49.5 mm. 4 mm.. 4 mm 40.5 mm Ø 9 mm 37 mm 9. mm 8.4 mm 3 34 mm 7 mm 40 mm 50 mm Note: The installation of a maximum of one single-circuit lifting axle is permitted within a three or four axle suspension. Weight: approx. 0.8 kg Fig. 34 Port No. Description Notes Reservoir port 3 Exhaust port Air bags, no lifted axles. Air bag of lifted axle. Air bag of lifted axle. Air bag respect. lifting cylinder of axle lift device. Air bag respect. lifting cylinder of axle lift device 76

77 5. Air suspension 5..6 Shut-off cock M x M x Fig. 35 Application The shut-off cock is used for filling and exhausting compressed air lines, e.g. lift axle valves, combined chambers or steering axles. The shut-off cock is used, for example, for manually activating the steering axle lock when reversing (see example of application p. 79). The version with exhaust is installed for this. Principle of operation In the shut position, the handle is at right-angles to the flow direction (transverse to the line) and the passage is blocked. If the handle is turn /4 of a turn (parallel to the line), the passage is clear and compressed air can flow through it. Installation instructions There must be enough room to operate the handle manually. Maintenance Grease the shut-off cock with a mineral oil grease if it becomes stiff. Fig. 36 Technical Data Medium: Air Operating pressure: max. 8 bar Operating temperature: - 40 C to + 80 C Handle: Aluminium 77

78 5 Installation and Operating Instructions 5. Air suspension /-Ways magnetic valves 70 7 M x Bayonet connection according to DIN 7585 Ø 8.4 Fig. 37 M x Application 3/-ways magnetic valves are used to control ventilation and breathing procedures in pneumatic installations. These valves are operated electrically and used in connection with the ECO Tronic EBS, for example for controlling steering axle blocks or for zero point adjustment in the case of air suspension valves with a nd driving height in air suspension systems. Installation instructions Install vertically with the solenoid at the top. Installation site must be protected against splash water. Mount using bolts and nuts in holes in the body. They can be mounted as a block, in which case replace the bolt and seal ring with gasket (ordered separately). Inspection Check for operation and leaks. Fig. 38 Technical Data Voltage: 4V Input power consump.: W Emergization time: 00 % Nominal size:.5 Pressure range: 0-0 bar Type of protection: DIN IP67 Fitting position: Solenoid above Operating temperature: - 40 C to + 85 C 78

79 5. Air suspension 5..8 Example of an application of a steering axle block (with 3/-ways magnetic valve and manual shut-off cock) AUX 8 6 AUX 4 7 = Item = Prot Fig. 39: 3-axle semi trailer, COLAS + with auto reset to ride (RtR), air suspension levelling valve, 3/-ways magnetic valve for installation with a steering axle lock as well as manual shut-off cock Item Description Notes Air reservoir suspension Drain valve 3 Air suspension levelling valve 4 3/-ways magnetic valve 5 Manual stop-cock, exhausting the air 6 Lock cylinder for steering axle 7 Test point (if not integrated in COLAS +) 8 Modulator 9 Suspension air bags 0 COLAS + 79

80 5 Installation and Operating Instructions 5.3 Soft Docking Increased control into reversing through innovation and engineering Reversing into docking bays has always been an area where damage is likely to occur to the vehicle or the dock if the vehicle is allowed to hit the dock at speed. Soft Docking BPW offers added security with Soft Docking, when linked to the ECO Tronic EBS which can apply the brakes automatically when reversing into a loading bay. Benefits: Independent from truck braking system Measures braking power to match load and speed Audible and visual reversing aids Silent mode for night deliveries The system cannot replace the driver s responsibility to ensure a clear passage when manoeuvring. BPW cannot be held responsible for any accidents encountered when using the system. Dimensions Width: 34.5 mm Height: 55.5 mm Fig. 40 Components. Soft Docking junction box including the electronics.. Power Supply Cable 3. Adjustable sensor in protective housing 4. Reversing Alarm (Audible warning system) 5. Warning lights (visual warning signals) 6. Auxiliary cable to EBS. 00 mm x + 3 x.5 mm 500 mm 4 x 0.75 mm mm 7 x mm mm 4 x 0.75 mm 8 pol.sw 8 pol.ge 000 mm 000 mm 8 pol. GN 8 pol. SW 4 x 0.75 mm 4 x 0.75 mm 00 mm 00 mm x mm x mm 4000 mm x mm 7000 mm 3 x 0.75 mm Fig

81 Preparation - Determine a suitable mounting point for: - Soft Docking junction box - Reversing alarm 6 mm - Ø 6 mm 5.3 Soft Docking Soft Docking Junction Box Installation All cables must be installed where suitably protected by the trailer chassis. Fix all cables every 0-5 cm with a cable tie. Do not fit the cables onto surfaces that can become hot. Fixing of cables along with hydraulic fluid pipes is not allowed. Unnecessary cables should be fixed coiled up. Ensure that the junction box gland nuts are closed correctly. Fig mm Ø 6 mm Installation of Soft Docking Junction Box The position of the junction box has to be in a suitably protected position in the rear part of the trailer. The box has to be fixed on to the chassis. Position in a rigid location unsusceptible to large vibration and ensure cables run upwards to the junction box and are safely installed. LED Outline Marker Lights Installation of LED Outline Marker Light The new LED outline marker lights has to be assembled in the same locations as the old lamp (ensure that the lights can be seen from the truck mirrors clearly). The connectors has to be plugged into the Soft Docking junction box. Please ensure the existing connections for the old outline marker lamps are sealed. It is essential that you only use LED outline markers not incandescent bulbs, they are clearer in daylight and require less power. 79 mm Ø 6 mm Fig. 43 Installation of Reversing Alarm Fit the reversing alarm in a protected position unsusceptible to vibration. Normally on the rear light panel or near the rear axle. When assembling pay attention to the location of the alarm, the cable entry must be at the top (observe TOP on the alarm). Plug the cable into the Soft Docking junction box. Reversing alarm Entry cable at the top 8.4 mm Fig. 44 8

82 5 Installation and Operating Instructions 5.3 Soft Docking Installation of Sensor onto Rear Bumper Drill a hole of 35 mm, pass the sensor lead through with the 7 pin ASS connector from the sensor. Fix the sensor with four fixing screws onto the rear bumper (Fig. 45). Plug the cable into the connector from the Soft Docking junction box. Sensor on rear bumper Note: The sensor is ineffective when the load is longer than the trailer, or the trailer/container overhangs the sensor, as it can only measure the distance between the sensor and the loading bay. (Example: skeleton trailer for long containers ie. 45 ft) Installation of Power Supply into an existing Junction Box: (None Aspöck) Cut the connector off the end of the power cable. Insert cable through spare entry of existing junction box. Connect wires as appropriate. Ensure waterproof installation. Contact allocation: black tail light left grey reverse light brown tail light right white earth connection Close the junction box. Important! Ensure the junction box gasket is seated correctly mm - Ø 0 mm 60 mm Ø 0 mm Fig. 45 Installation of Power Supply with an Adapter Cable Disconnect the connector between main cable and the rear junction box cable. Installation with an adapter cable Main cable Rear junction box cable Plug the adapter for the power supply between these two connectors (main cable and rear junction cable) (Fig. 46). Fig. 46 Connection to ECO Tronic EBS Plug the Auxiliary Cable into the AUX ports 4 or 5 in the EBS Modulator (Fig. 47). Connection to the Modulator Soft Docking has to be enabled using the Trailer Manager software. Fig. 47 8

83 5.3 Soft Docking Functional Test After the installation is completed you should test the system thoroughly. For this test you require a test sample (preferred material is a cardboard box approx. 500 x 500 mm, if there is no box available, you can use a similar object material with a smooth surface). Please ensure that there are no obstacles situated within the range of 4 m x 4 m behind the vehicle. The test procedure must be carried out in the following steps: Step Activity Result Ignition on / Tail light on LED outline marker has to shine Engage reverse gear 3 Place the test sample in perpendicular to a sensor within a range of 3 m behind the vehicle 4 Remove the test sample from the vehicle until the beeping and LED outline are extinguished. 5 Move the test sample slowly inwards towards the trailer sensor 6 Repeat step 4 with the second sensor See step 3/4 7 Repeat step 5 with the second sensor See step 5 LED outline marker is deactivated when the radar is at 3 m from the obstacle. LED outline marker: slow flashing frequency Reverse alarm: slow beep Completed phase (see picture below) (area greater than 3 m) Run through the complete range of phases as shown within diagram below. Testing of the silent mode (night silent switch off) 8 Place the test sample in the distance as in step 3. 9 Engage the reverse gear twice (within seconds) LED outline marker: slow flashing frequency Reverse alarm: no signal 0 Let the system work for min. 0 seconds. After this, disengage the reverse gear. Engage reverse gear once only. LED outline marker: slow flashing frequency Reverse alarm: returns to slow beep frequency Principle of operation The controlled automatic braking commences at meter distance from the dock. The system is equipped with distance sensors and distance from the dock is first detected when the trailer is in reverse and less than 3 meters away from the dock. The braking command is delivered from the ECO Tronic EBS via an auxiliary port. The braking at meter distance lasts for seconds before the system releases the brakes giving control back to the driver. Working range Please note during the function test that the test sample will be moved always perpendicular to the respective sensor axis. The maximum detectable distance is 3 m from the sensor and detection is shown below in five phases. Please study the sketch below. No Beep / Flashes 3 Beeps per sec (3 Hz) / Flashes 5 Beeps per sec (8 Hz) / Flashes 8 Beeps per sec (8 Hz) / Flashes > 3 meters meters meters meters Fig. 48 Permanent Tone / Lamp < 0.5 meters 83

84 5 Installation and Operating Instructions 5.3 Soft Docking Adjusting the sensors: If you cannot position the sensor assembly on the outermost area of the rear panel, you can adjust the detection of the sensors with a special tool (DIN 546). The available adjustable area of the sensor is 0 horizontal and vertical. Adjusting the sensors By rotating the screw clockwise, the housing will be inclined in the direction of the rotated screw. Fig. 49 You adjust the sensor by rotating 3 fixing screws (DIN 546) Due to the order of the screws (3 x 0 ) you have the possibility to incline the sensor in any direction (maximum adjusting area is 0 ). The adjustment should only be made with an obstacle in place. Adjusting with an obstacle Obstacle Fig. 50 ATTENTION: Soft Docking is protected against an AC voltage supply, but will not function. It will function again correctly when reconnected with DC supply. Operating instructions: The complete system is installed into the last third of the trailer. Thus the Soft Docking is independent of the truck and also very well suited for changes of the truck and trailer combination. Engage the reverse gear and you activate the system. Both sensors indicate the distance to an obstacle to the system electronics. Depending on the distance to an object, the system electronics will give out a warning signal (from the reversing alarm and LED outline marker), which varies depending on the object distance. System check. (De-activation of the system by switching on the tail lights): If the tail light is on while engaging the reverse gear, the tail light function in the outline marker is deactivated for about seconds. As soon as the obstacle is more than 3 m away, the lamp is switched to normal permanent operation. The buzzer is not activated. If you get nearer than 3 m to the obstacle, the system switches to the 5 test phases. System check. (Activation of the system during the day with tail lights switched on): After engaging the reverse gear the outline marker is turned on. Distance to the obstacle > 3 m: Outline marker is on, buzzer is silent! Distance to the obstacle < 3 m: System switches to the five test phases. 84

85 Night Silent Mode If the reverse gear is engaged twice (within seconds) the acoustic warning installation (buzzer) will be night silent. The outline marker is however active. The night silent option is to prevent audible nuisance at night in residential areas. Technical Data Nominal voltage Operating voltage Operating temperature Current consumption 5.3 Soft Docking 4 V 9 bis 3 V -30 bis +65 C < 300 ma (total system) Ultrasonic sensors: Max. range 500 mm Min. range 350 mm Detection angle 5 Operating voltage - 30 V Max. current consumption < 35 ma Frequency 80 khz Reversing alarm: Operating voltage - 30 V Max. current consumption < 35 ma Sensor diagnosis Sensor faults are indicated by six LED s inside the Soft Docking junction box (Fig. 5). ) One green LED: shows, that the voltage supply is in order. ) Two red LED s: indicates in which of the sensors a fault has occurred. Superpoint LED Operating voltage 4 V Max. current consumption < 35 ma The sensor has an area (< 350 mm), within which the measurement result might not be 00% accurate. Fault indicator junction box 3) Three yellow LED s: indicates an error code, which describes the type of default. Error code 0 Possible reasons Sensor cable break Defect on head of sensor Sensor cable break Repair Change sensor Change sensor Change sensor In the case of an error the LED outline marker will permanently illuminate and the reverse alarm will permanently sound for about 5-7 seconds. Afterwards the alarm switches off automatically and the LED outline marker continues to operate. Fig. 5 Error repair / Sensor diagnosis Error Possible reason Repair Display an obstacle, A sensor is obscured Adjust Sensor when none present Soft Docking doesn t work LED outline marker light does not shine Reverse alarm doesn t work - Reversing light, tail light L/R and earth connection is defective - One of the fuses (tail light L/R or reversing light) defective - Supply voltage is too small (< 9 V) - LED defective - When activating the system an error occurs - Defective alarm - Silent mode is active - Establish or check all the connections - Change one of the fuses - Check the light control unit of the truck - Change LED - Activate the system once again - Change the alarm - Engage the reverse gear 85

86 5 Installation and Operating Instructions 5.3 Soft Docking Error repair Except a complete failure of the system the following situations can lead to an erroneous signal on the display. The reason for this is that in these cases, the physical limits of the ultrasonic sound are exceeded. Physical Limit a) If the trailer is driven at an angle to the dock, it is possible for the sensor not to detect the dock (Fig. 5, a). a) b) Caution while reversing towards ramps with floors that point out from the main body (Fig. 5, b). b) Fig. 5 ATTENTION: It is the driver s responsibility to manoeuvre safely. Ramps with curtains require special attention: Ramps with curtains a) The material of the curtains can absorb the ultrasonic, this means that the reflected sound is too weak for the sensor to detect (Fig. 53). b) If the curtain is deformed, so that the ultrasonic signal could deflected not absorbed (Fig. 53). a) b) Some materials like textiles weaken the ultrasonic signals, significantly reducing the sensing distance. Fig. 53 Conditions of no detection The system will not detect the dock when the vehicle is not in reverse. System will not operate if the speed of the vehicle is excessive (more than 5 km per hour). If the trailer is driven at an angle to the dock, it is possible for the sensor not to detect the dock. Some materials like textiles weaken the ultrasonic signals, significantly reducing the sensing distance. The system cannot replace the driver s responsibility to ensure a clear passage when manoeuvring. The operation needs to be tested on a vehicle after installation. The vehicle requires BPW ECO Tronic EBS system to function. Liability Exclusion The system is not totally accurate under all circumstances. The driver must manoeuvre with care up to the dock. BPW cannot be held responsible for any damage that may occur when using the system. It is the driver s responsibility to reverse safely. 86

87 6 Hazardous goods / ADR installations Vehicles equipped to transport hazardous goods or explosive substances are required to have electrical systems with specified levels of safety and protection. These requirements are defined in the European Agreement on International Transport of Dangerous Goods by Road (ADR 007). ADR/GGVS: ---/----/-- The ADR requirements apply to the following classes of dangerous load carrying vehicles: EX/II, EX/III, FL, OX, and AT. The following key points should be observed on Hazardous Goods/ADR trailer installations. Data of the Load Plate The print out of the Load Plate Pressure Data from the Trailer Manager programme must have the ADR/GGVS certificate number as indicated (Fig. 54). Fig. 54 Cable routes Sensor cable route should not be installed to brake air pipes. Do not run sensor leads in spiral wrapping on hoses. Cables should be securely fastened to prevent abrasion and positioned to protect against mechanical and thermal stress. It is recommended that the cables are either run in trunking or secured at no less more than 400 mm intervals. Note: All cables should run up to ECU connections. Brake lamp back-up power supply The brake lamp power supply can be either an ISO 098 or an ISO 85 (4N) connector. These connectors must be fully approved for use on an ADR vehicle (Fig. 55). Fig. 55 Warning lamps It is the installers responsibility to ensure that the green trailer warning lamp, if fitted, is fully approved for use on an ADR vehicle (Fig. 56). The warning lamp bulb must be of twin pole bayonet type. Fig

88 6 Hazardous goods / ADR installations Junction box Any wiring required to a junction box (for brake lamp power supply) must be fully approved for use on an ADR vehicle (Fig. 57). Fig. 57 Auxilliary connections It is the installers responsibility to ensure that the auxiliary component fitted, the connector and cable must be sealed in accordance with ADR requirements (Fig. 58). DIN connector Fig. 58 Towing vehicles Towing vehicles in categories EXIII and FL must have a battery master switch fitted so that all electrical loads including the trailer are connected to the non-battery side of the master switch. 88

89 7 Programming To complete the ECO Tronic EBS installation the ECU must be programmed by using the Trailer Manager software. Refer to Trailer Manager Operator s Guide BPW-BA-TM 37070e for further information. 89

90 90

91 8 System diagnostics An important feature of the ECO Tronic EBS is that it provides an extensive on board diagnostic capability. The system displays a range of codes, which allow rapid diagnosis of the problem should one occur. BPW offers a diagnostic case containing the necessary software and connectors. 8. System diagnostics Alternative positions Diagnostic communication is in accordance to ISO 898 using Keyword Protocol (KWP000). It is accessed by an optional sideof-vehicle connector, or by the ISO pin connector which uses pin 6 and 7 as a CAN data bus using the ISO Interface Assembly (Fig. 59), or directly via the diagnostic connection to the ECU (Fig. 60, 6). Any suitable device connected to this CAN data bus may read diagnostic information. The Trailer Monitor can be connected permanently to the ECU s diagnostic DIAG connection. While the ECU is powered information is transferred to the Trailer Monitor s memory, which can be recalled. Power is supplied from the vehicle system via the ECU diagnostics connector. The Trailer Monitor also contains a replaceable battery. The Trailer Monitor displays the following on a backlit dotmatrix LCD screen: Distance: Total distance in km Trip distance in km Distance and time to next service... PC Interface PC Interface ISO Interface assembly Information: Active DTC s (DTC = Diagnostic Trouble Codes) Stored DTC s Configuration of the trailer Version of the ECU Pressure values of the sensors in the ECO Tronic EBS Brake lining wear information... Settings: Service interval Tyre size Date Time Units... Auxiliaries: Detect the presence of auxiliaries Test auxiliaries... Test: Vehicle load Detected speed of each wheel sensor... Pressure values, wheel sensor values and vehicle load are displayed with bar-graph style visual indicators. Please refer to the Trailer Monitor documentation for additional information. A PC based programme from BPW - Trailer Manager - may be used for more advanced diagnosis. This also allows configuration with system parameters to be entered and an End-of-Line Test to be carried out. Fig. 59 Fig. 60 Connect to side-of-vehicle connector or to ECU directly Diagnostic connection 'DIAG' on ECU PC Interface Please bear in mind our extensive and practical training courses on this topic, since only trained and qualified specialist personnel are allowed to undertake work on the vehicle and the corresponding software. Fig. 6 Connected to side-of-vehicle connection or - as an alternative - directly to ECU 9

92 8 System diagnostics 8. System diagnostics 8.. Warning lamp A warning lamp located on the driver s console of the towing vehicle is operated from the ISO 7638 power cable only when the ECO Tronic EBS is powered by the ignition switch (Fig. 6). As an option in addition to the cab warning lamp a trailer mounted warning lamp may be provided as an auxiliary function. This lamp shows the signal to the cab warning lamp (will only function if the ISO 7638 power is connected). Note: The signal produced may be different to that produced by the cab device due to possible modification of the cab device by the towing vehicle. Fig. 6 Option A ON sec 8.. System check procedure. When the ignition is turned on the warning lamp shows the following flash sequences, according to the configuration in the Trailer Manager software, to indicate an error-free system: OFF ON Option A (Fig. 63) ON for seconds OFF Warning lamp OK and system selfchecking. System self-check (not sensors) completed OFF Fig. 63 Option B sec sec at 0 km/h Option B (Fig. 64) ON for seconds OFF for seconds Warning lamp OK and system selfchecking. System self-checked and preparing to check sensors. ON OFF ON until moving OFF System waiting for vehicle to move above 0 km/h in order to check that the sensors are working Once the vehicle is moving above 0 km/h and the warning lamp clears, the electronic system is fully checked. ON OFF Fig. 64 In the case of an error the warning lamp comes on and stays on if it is set according to option A, while it stays off if it is configured according to option B.. During the self-check procedure, the system cycles the EPRV s. With foot brake applied one exhaust of air from each EPRV will be audible (Fig. 65). Once these two checks are made with correct results, no further checks are required. If the results are not satisfactory, Trailer Monitor or Trailer Manager should be used to establish the diagnosis. X X 0 X X X 0 X Fig. 65 9