LINING WEAR SENSING INSTALLATION INSTRUCTIONS

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1 LINING WEAR SENSING INSTALLATION INSTRUCTIONS / / Redditch

2 Assembly INTRODUCTION EB+ Lining wear is a device that allows multiple lining wear indicatiors (LWI) to be connected to a single analogue input AUX 4 on the EB+ ECU. EB+ Lining wear device can be installed on all types of towed vehicles were provisions are made in the brake pads. The product provides lining wear indication, without the need to remove wheels as required on disc brakes, via the EB+ diagnostic tools INFO CENTRE or DIAG+. The device connects to specified sensors from the brake pads and when a brake lining has reached its wear limit the sensor signals the EB+ Lining wear device which activates the EBS warning lamp indicating a fault Ø EB+ AUX 4 Sensor 6 Sensor 5 Sensor 1 Sensor 2 Sensor 3 Sensor 4 Fig 1 Assembly Part No Cable Lengths (mm) EB+ AUX Sensor 1 Sensor 2 Sensor 3 Sensor 4 Sensor 5 Sensor

3 Chassis Installation POSITION OF EB+ LINING WEAR ASSEMBLY Assembly must be mounted vertically. The assembly should not be in direct spray or splash water area and should be protected against high pressure cleaning. Fig Min EB+ LINING WEAR assembly TO BE mounted directly to a rigid part of the vehicle structure. Fixing option A Use M6 Bolt and self lock nut with flate washer T Nm. Fixing Option B Use cabel tie and wrap around the body of the assy refer to Cable tie mounting centres. A Any additional bracket design to be as rigid as possible. The mounting foot of the EB+ LINING WEAR assembly bracket to be in full contact with the total body. Mounting bracket flatness to be not more than 0.5mm deviation from its true plane. i.e. the surface must lie between two parallel planes 0.5mm apart Min B Ø10 Cable tie mounting centres Fig 3 Position EB+ LINING WEAR assembly as high as possible in the chassis to provide as much protection to the assembly from direct spray and other road debris. C Care should be taken to provide reasonable access to the EB+ LINING WEAR assembly for replacement. C= Allow distance of 40mm befor bending of cables D D= 1. Assembly to be above axle centre line. 2. To be as high in frame as possible. Fig 4 3

4 Chassis Installation CONNECTION TO SENSORS Any cable lenght can be used to any sensor as appropriate to the Installation. Fig 5 EB+ LINING WEAR assy cable plug must be pushed fully into sensor cable socket till they clip into place to prevent falling out with axle vibration. Where possible use a clip and bracket to secure connection, alternatively support with cable tie within 50mm of each end. Fig 6 LINING WEAR ASSY PLUG SENSOR SOCKET CLIP TO CLICK Fig 7 UN-USED CONNECTIONS Terminate the cable from the EB+ LINING WEAR assembly by using the recmmended termination socket ( Haldex Part No ) If the termination socket is not available the unused cable must have the wire conductors joined together in order to complete the circuit and the resulting connection must be sealed appropriatley. LINING WEAR ASSY PLUG TERMINATION SOCKET (Haldex ) Fig 8 4

5 Chassis Installation AUXILIARY PLUG Identification tags are incorporated on either side of the Auxiliary connector. These MUST be removed to identify the appropriate useage before connecting into the EB+ ECU. Indent tag marked 4 to remain remove all other tags. Fig 9 ELECTRIC CONNECTION Remove blanking plug from position marked AUX 4 on EB+ ECU. EB+ ECU LINING WEAR ASSY AUX 4 Fig 10 Identify orientation of the 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 EB+ ECU s housing into positions. EB+ ECU Fig 11 5

6 Chassis Installation EB+ LINING WEAR cable should be secured down the chassis rail in trunking or to piping and should be sedcured not less than 150mm intervals. NOTE: All cables should run UP TO EB+ ECU connections. DECK OF TRAILER LINING WEAR ASSY 150 MAX Fig 12 Cable route should follow the centre line or outer radius of pipe or hose. Tie wraps not to be overtightened because on brake application rubber hose expands, i.e. tie could damage the hose and sensor cable. Do NOT run sensors leads in spiral wrapping on hoses. CABLE TIE 150 MAX Cable lengths GREATER than 0.5m to be coiled and then flattened in the centre B to produce a dog bone shape. B Fig 13 The resulting loops at the end must have a minimum bend radius of 50mm. Cable ties are to be used to fix the cable in the flattened loop shape. Ø100 MIN Excess coiled up cable of ABS wheel sensor to be seperated from EB+ LINING WEAR coiled cable by 200 min. Where appropriate seperate straight runs by 100 min. Fig Min. 200 Min. Fig 15 6

7 EB+ ECU Configuration Refer to DIAG+ User guide AUX 4 Option and End-of -line Test for AUX 4. 7

8 For further information: Austria Haldex Wien Ges.m.b.H Vienna Tel: Fax: office@baeder-haldex.at Belgium Haldex N.V. Balegem (Oosterzele) Tel: Fax: info@hbe.haldex.com Brazil Haldex do Brazil São Paulo Tel: Fax: info@hbr.haldex.com China Haldex International Trading Co. Ltd. Shanghai Tel: Fax: haldex@public.sta.net.cn France Haldex Europe S.A.S Weyersheim (Strasbourg) Tel: Fax: info@hfr.haldex.com Germany Haldex Brake Products G.m.b.H Denkendorf (Stuttgart) Tel: Fax: info@hde.haldex.com Haldex Brake Products G.m.b.H Heidelberg Tel: Fax: info@hbpde.haldex.com Great Britain Haldex Ltd. Newton Aycliffe Tel: Fax: aycliffe.info@haldex.com Haldex Brake Products Ltd. Redditch Tel: Fax: redditch.info@haldex.com Italy Haldex Italia Srl. Muggiò Tel: Fax: info@hit.haldex.com Poland Haldex Sp z o.o. Praszka Tel: Fax: info@haldex.net.pl South Korea Haldex Korea Ltd. Seoul Tel: Fax: haldexk@mail.hkr.haldex.com Spain Haldex España S.A. Parets del Valles (Barcelona) Tel: Fax: haldexsa_esp@passwordsta.es Sweden Haldex Brake Products AB Landskrona Tel: Fax: info@hbpse.haldex.com USA Haldex Brake Products Corp. Kansas City Tel: Fax: info@hbpus.haldex.com Company Vision We use our demonstrated competence to provide innovative components, systems and service for trucks, trailers and buses, that lower life cycle costs and improve vehicle safety. Haldex wants to become the first choice business partner of commercial vehicle manufactures world wide in the areas of braking and suspension control systems with special emphasis on heavy commercial vehicles. Total Support A uniquely wide range of services is available from Haldex. These include expert consultancy for braking and suspension development, brake calculations, type approvals and application engineering. The aim is accurate specification for manufactures and low cost of owner ship for the operator. Full aftermarket support includes a Worldwide parts distribution and service network, on-line technical advice, field visits and installation/ maintenance training held on-site or at Haldex facilities. Research and Development Continual, heavy investment in Research and Development is carried out in response to ever increasing commercial, legislative, environmental, performance and technological demands. The Haldex Group is a global supplier of proprietary products for trucks, cars and industrial vehicles, with special emphasis on performance and safety. The Group is organized in Divisions which focus on their respective product niche: Haldex Brake Systems supplies ABS and brake components for heavy vehicle air brakes. Haldex Barnes Hydraulics supplies gear pumps and hydraulic systems for power steering and lifting functions on industrial vehicles and trucks. Haldex Garphyttan Wire supplies specially steel-alloyed wire products mainly for applications in combustion engines. Haldex Traction Systems supplies 4WD systems for cars and trucks. Sales companies are established in Europe, North and South America and Asia. Production takes place in 9 factories in USA, 9 factories in Europe and 1 joint venture in India. The Haldex Group is listed on the Stockholm Stock Exchange. Quality and Production Standards The very latest production technology ensures the very highest quality standards. All production sites are ISO 9001 approved.

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