Installation Guide rev Installation instructions for EB+ Generation 2

Transcription

1 Installation Guide rev Installation instructions for EB+ Generation

2 Table of Contents General component guide 5 Chassis components 6 Assembly - EB + Installation options - Semi and Centre axle trailer - 8 Side by Side Installation options - Semi and Centre axle trailer - 9 Side by side (SxS) S/M + SL valve - Self-steered axle Page Installation options - Semi and Centre axle trailer - 0 Integrated Axle by Axle, ASC Front, SL Rear Installation options - Semi and Centre axle trailer - Integrated Axle by Axle, ASC Rear, SL Front Installation options - Full trailers Chassis installation - Position of EB + assembly 3 Chassis installation - Position of EB + assembly Chassis installation - Electrical wiring 5 POWER/DIAG connection Chassis installation - Electrical wiring - 6 POWER A (ISO 638) Chassis installation - Electrical wiring - POWER B (ISO 85, N) Chassis installation - Electrical wiring - 8 Diagnostic DIAG connection Chassis installation - Connectors/blanking plugs 9 Chassis installation - Sensor/Auxilliary Plugs 0 Chassis installation - SENSOR/AUX/DIAG Connection Chassis installation - Sensor Connection Chassis installation - COLAS / ILAS -E connection 3 Chassis installation - Painting - Masked areas Chassis installation - ISO Pin 5 Socket Assembly - V Page Brake piping layout - Side by Side 3 axle with R.E.V. & 3 Combined Park and Shunt valve Suspension system piping layout - Levelling valve 35 Suspension system piping layout - Levelling valve, 36 Colas (auto reset to ride) Suspension system piping layout - 3 axle 3 Semi-Trailer, Levelling valve, Colas with auto reset to ride & ILAS -E Suspension system piping layout - Option axle Semi-Trailer, Colas with height limitation and auto reset to ride Suspension system piping layout - Option axle Semi-Trailer, Colas with height limitation and auto reset to ride Suspension system piping layout - 3 axle Semi-Trailer, 0 line air brake, spring brake chambers with combined park & shunt valve Suspension system piping layout - axle Full Trailer, line air brake, spring brake chambers Wiring schematic Wiring diagram - Sensor, ISO 638 & ISO 85 with 3 Info Centre (3 AUXs fitted) Auxilliary equipment wiring - Sensor, ISO 638 & ISO 85 with Info Centre and L.W.S. (3 AUXs fitted) Auxilliary equipment wiring - COLAS / ILAS, 5 Steer Axle Lock Auxilliary equipment wiring - Traction assist 6 Wiring Diagram - Full system information Hazardous Goods/ADR Installations 8 Hazardous Goods/ADR Installations 9 Programming 50 Multimeter readings 5 General Chassis installation - Anti-vibration support 6 General Chassis installation - Junction box General Chassis installation - Electrical wiring - 8 DIAG Side of Vehicle connection Pipe recommendations - 3 axle Semi-Trailer - 9 line air brake system - S/D brake chambers Brake and Suspension piping layout - 3 axle 30 Semi-Trailer - line air brake system - with R.E.V - S/D brake chambers Brake piping layout - M - 3 axle Semi-Trailer - line 3 air brake system - without R.E.V. - Spring brake chambers Brake piping layout - M - Side by Side 3 axle with TrCM 3 and Spring Brake chambers Brake piping layout - Axle by Axle - 3 axle Semi-Trailer 33 with R.E.V. & Combined Park and Shunt valve

3 Notes on the use of this manual Document Registration Preceding the Haldex EB+ main index sheet, this manual should contain the document registration form and an amendment record sheet. Both of these documents are intended to assist your Company and Haldex Brake Products Ltd in maintaining this manual in an up to date condition. Please follow the instructions included on each sheet to ensure that we are able to give both yourself and your company the best product information support whenever the need may arise. This manual has been designed to assist personnel in satisfactorily installing Haldex EB+on Semi and Centre axle trailers. The intention has been to illustrate the various areas of installation. It is expected that this manual will be in possession of the appropriate person throughout their training and experience and that the manual will be used as: Document Registration Included below is a postcard which enables you to register ownership of the this Installation Guide document. Please fill in the details requested, including your postcode, in block capitals using a non eraseable ink and return the card to us. This will enable us to ensure that any necessary installation instructions revisions which are issued by Haldex Brake Products Ltd will be forwarded to you automatically. If you do not return the information to us we regret that we will be unable to ensure that your installation instruction is kept up to date. If you should have any queries regarding this document or its contents please contact your local Technical Services Office. a) A teaching aid following supervision of a HALDEX ENGINEER. b) A reminder of the correct procedure of Haldex EB+ installation. For any other deviation consult Haldex Brake Products Ltd. Moons Moat Drive, Moons Moat North, Redditch, Worcestershire B98 9HA Tel: Fax: Use appropriate spare-parts documentation when obtaining spare parts. Use only genuine Haldex parts in repairs. Due to continuous development the right is reserved to alter the specification without notice No legal rights can be derived from the contents of the manual. Duplication, translation and reprinting are prohibited without permission from Haldex Brake Systems. EB+ Installation Instructions Registration - Please fill in your details below. YOUR NAME COMPANY DELIVERY ADDRESS POST CODE

4 Document Registration EB+ Installation Instructions Registration Please Affix Stamp Here MARKETING DEPT. HALDEX BRAKE PRODUCTS LTD MOONS MOAT DRIVE REDDITCH B98 9HA UNITED KINGDOM

5 General Components Guide Haldex EB+ Assembly Sensor and Exciter Driver s information plate TrCM EB+ Info Centre ISO638 - Pin Socket assembly Fig. 5

6 Chassis components 6 6 ISO 638 ISO 85 (N) 3 B B 3 A 5 A Fig. Item Description Notes EB+ Label ISO Pin Socket assembly 3 Safety backup cable - ISO 85 (N) EB + INFO CENTRE (side of vehicle connection) 5 EB + ECU and EPRV s assembly 6 Sensor assembly Exciter 8 COLAS Aux, or 3 9 ILAS -E Aux, or 3 0 Lining Wear Sensing (LWS) Aux ONLY EB+ Stability External Sensor Assembly - Aux 5 ONLY N.B. Aux to be set in line with DIAG+ 6

7 Assembly - EB+ Port identification STUDS x3 M0 x.5mm 6G 80mm 3.6mm Delivery test port () M x.5 80mm M6 x Delivery port () M x.5 3 Delivery port () M6 x Delivery port () M6 x mm.mm 6.mm Weight:.5Kg Fig mm Port No. Description Reservoir Port 3 Exhaust Port Control Port Anti-Compounding Port / Delivery Ports 3 Spring Brake Port Air Suspension Port Notes

8 L.H. Power Cable Connector R.H. Power Cable Connector L.H. Power Cable Connector R.H. Power Cable Connector Installation options Semi & Centre Axle Trailer - Side by Side SB SB SB SA SA SA SB S/M S/M SA SB SB SB SA SA SA SB SA SB SB SB SB SA SA SA SA SB SB SB SB SA SA SA SA Fig. - Side by side Either (but only one) directly controlled axle may be lifted Any axle without directly controlled wheels may be a lift axle Any axle may be a steered axle Key MODULATOR ECU POWER CONNECTORS 8

9 S/M Installation options Semi & Centre Axle Trailers - Side by side (SxS) S/M + SL valve - Self-steered axle SB SB SB A A A SA SA SA SB SB SB A A A SA SA SA Fig. 5 - Side by side (SxS) S/M + Select low valve Any axle without directly controlled wheels may be a lift axle. Key MODULATOR EPRVs ECU POWER CONNECTORS A SELECT LOW VALVE 9

10 S/M Installation options Semi & Centre Axle Trailers - Integrated Axle by Axle, ASC Front, SL Rear SB SB SB SB N N3 N SA SA N SA SA SB SB N3 N SA SA SB SB SB SB N N N SA SA N SA SA SB SB N N SA SA Fig. 6 - Axle by Axle Sensed axles cannot be lifted Any axle without directly controlled wheels (un-sensed) may be lifted Any axle may be a steered axle N - N Selectable options set by Haldex or Vehicle Manufacturer N Adaptive surface control (ASC). N Select Low (SL). N3 Adaptive surface control (ASC). N Select Low (SL). Key MODULATOR EPRVS ECU POWER CONNECTORS 0

11 S/M Installation options Semi & Centre Axle Trailers - Integrated Axle by Axle, ASC Rear, SL Front SB SB N N SA SA SB SB SB SB N N N SA SA N SA SA SB SB N N SA SA SB SB SB SB N N N3 SA SA N3 SA SA Fig. - Axle by Axle Sensed axles cannot be lifted Any axle without directly controlled wheels (un-sensed) may be a lift axle Any axle may be a steered axle N - N Selectable options set by Haldex or Vehicle Manufacturer N Adaptive surface control. N Select Low. N3 Adaptive surface control. N Select Low. Key MODULATOR EPRVS ECU POWER CONNECTORS

12 S/3M Installation options Full Trailers SB SB SA SA SB SB SB SB SA SA SA SA SB SB SA SA SB SB SB SB SA SA SA SA Fig. 8 - Side by Side Sensed axles cannot be lifted Any axle without directly controlled wheels (un-sensed) may be a lift axle N Master ECU is mounted to EPRV s /. All Sensors must be connected to this Master ECU. N 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 MODULATOR EPRVS ECU POWER CONNECTORS SLAVE ECU MODULATOR EPRVS

13 Chassis installation Position of EB+ assembly Position of EB + assembly The following installation paramerters are required for correct STABILITY operation. Rear End view Roll angle : ± 3 (:0). 3º 3º 3º 3º Fig 9 Plan view 5º 5º Yaw angle : ± 5. Plan view Fig 0 5º 5º Single or Tri-axle The EB + Assembly to be mounted within ± m of the centre of the axle(s), (Includes any lift axles). Within LH and RH chassis members m m Tandem axle The EB + Assembly to be within the main Left Hand (LH) and Right Hand (RH) chassis members of the vehicle. Within LH and RH chassis members For any other applications please refer to Haldex Technical Services. Fig m m Pitch Angle: 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 3

14 Chassis installation Position of EB+ assembly N.B. The Following are applicable to ALL OTHER Installations and Configurations. The preferred assembly orientation should be positioned so that the Power Cable connections face towards the required configuration installation option (configuration) of the trailer. Ref. Figs to. The distance between port () and the air reservoir to be as short as possible. 360º () Fig 3 Mount Modulator Valves centrally to the brake chambers (refer to Installation Options Figs to ). A : Single axle B : Tandem axle C : Tri-axle If mounting to stainless steel, then a suitable membrane must be used. A B C Fig 0.5mm Additional bracket design to be as rigid as possible. The mounting fixing must provide an electrical connection between ECU/Modulator bracket an vehicle chassis. 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. Mounting Bracket Fixing Holes Fig 5.0mm Min. Use NON-CORROSIVE 0mm nuts, torque to 35-5Nm. Fixing Fig 6 Care should be taken to provide reasonable access to the ECU/valve for replacement of cables. D= 50mm minimum E=. Assembly to be above axle centre line.. To be as high in frame as possible. E D Fig

15 Chassis installation Electrical wiring - Power/DIAG connections Check earth continuity between ECU/EPRV/Bracket and vehicle chassis 0 5 Fig 8 Position assembly as high as possible in the chassis to provide as much protection to the assembly from direct spray and other road debris. Also to achieve an acceptable hose routing. DECK OF TRAILER TO BRAKE CHAMBERS TO BRAKE CHAMBERS GROUND LEVEL Fig 9 Electric wiring power connection From the slide lock housing F (top horizontal connector housing) Remove transit cover from POWER A position. Unlock the housing by sliding down lever G. F G Fig 0 Make sure slider is in the unlock position H Ensure contact pins and seal are kept clean and free of any contamination prior to installation. N H Fig 5

16 Chassis installation Electrical wiring - Power A (ISO 638) connection Connections Make sure that all connections (socket and plug) are clean and dry before assembly. Fig POWER A, POWER B and DIAG CONNECTION Feed all connectors through the chassis with the protective cap in place to avoid connector sockets being contaminated. Remove protective cap from end of connector before connecting into the ECU. TRAILER CHASSIS Ø0.0 MIN. Fig 3 POWER A (ISO 638) Identify orientation L of the ISO 638 Blue coloured connector. Ensure contact pins and seal are clean and free of any contamination prior to installation. L In position POWER A, on the slide lock housing, insert connector fully home. Fig BLUE CONNECTOR 6

17 Chassis installation Electrical wiring - Power B (ISO 85, N) connection POWER B (ISO 85, N) Remove blanking plug from position POWER B. Fig 5 ORANGE CONNECTOR Identify orientation L of the ISO 85 Orange coloured connector. Ensure contact pins and seal are clean and free of any contamination prior to installation. L In position POWER B, on the slide lock housing, insert connector fully home. Fig 6

18 Chassis installation Electrical wiring - DIAG connection Diagnostic DIAG connection - Option If NO diagnostic units are to be installed retain blanking plug in position marked DIAG. Fig Diagnostic DIAG connection - Option K If a remote mounted EB+ Info Centre is installed remove blanking plug K Fig 8 Identify orientation L of the DIAGNOSTIC Green coloured connector. L 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. GREEN CONNECTOR Fig 9 8

19 Auxiliary Chassis installation equipment wiring second Electrical title wiring here- Connectors/blanking plugs Make sure that all connectors/blanking plugs are all fully inserted into the ECU slide lock housing. Fig 30 Push in lock slider M 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 N M N Fig 3 WARNING If difficulty is encountered in locking the slider, check plug or connector for correct fitment. If the white o-ring is visible, the plug is not installed correctly and slider will not lock into position. Fig 3 9

20 Auxiliary Chassis installation equipment wiring second Electrical title wiring here- SENSOR/AUX plugs Sensor Plug Identification tags are incorporated on either side of the sensor/ecu connector. These MUST be removed to identify the appropriate sensor before connecting into the ECU. ECU Identification Tags Removed 3 A B P 5 Component BLACK } Front Case EXAMPLE: Sensor B SA Sensor A SB Sensor B SA Sensor A SB Sensor B Fig 33 Auxilliary Plug Identification tags are incorporated on either side of the Auxilliary connector. These MUST be removed to identify the appropriate usage before connecting into the ECU. ECU Identification Tags Removed 3 A B P 5 Component Example only AUX COLAS } BLUE Front Case AUX ILAS -E AUX 3 Warning lamp AUX LWS AUX 5 Stability PSW Pressure switch Fig 3 0

21 Auxiliary Chassis installation equipment wiring second Electrical title wiring here- SENSOR/AUX/DIAG connections SENSOR/AUX Connection The ECU is supplied with blanking plugs in positions indicated. These require to be removed to allow fitment of additional sensors or permitted ancillary equipment. Transit plugs (T) are used in ports SA and SB. Fig 35 T T Example - AUX connection Identify the AUX position on the top or front face of the ECU. Note the locking tag O position. O Fig 36 With a tool P having a flat end of Ø3-mm insert and press in locking tab of plug. While depressed pull out plug from housing. ECU ECU Ø P Fig 3 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. ECU Fig 38

22 Auxiliary Chassis installation equipment wiring second Electrical title wiring here- SENSOR connection Sensor Connection Sensor extension cable socket must be pushed fully into sensor cable plug till they clip into place to prevent falling out with axle vibration. Extension cable plug Sensor cable socket Clip to click Fig 39 Where possible use a clip and bracket to secure sensor cable connection. Sensor cable Extension cable Dirt shield Connection assembled into clip and bracket Axle Dirt shield fixing bolts Fig 0 U bolts Alternatively: Sensor cable connection to be positioned on axle or between axle U bolts and supported with cable ties within 50mm of each end. Cable tie Cable tie Hub and drum/ disc assembly Axle Fig Connection

23 Auxiliary Chassis installation equipment wiring second Electrical title wiring here- COLAS / ILAS -E connection Sensor cable route should follow the centre line or outer radius of pipe or hose. v Tie wraps not to be overtightened because on brake application rubber hose expands, i.e. tie could damage the hose and sensor cable. Deck of trailer Do NOT run sensors leads in spiral wrapping on hoses. Power leads should be secured down the chassis rail in trunking or to piping and should be sedcured not less than 00mm intervals. NOTE: All cables should run UP TO ECU connections. 00max Cable tie 50max Axle Fig 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. 0min 0mm 0mm ISO638 00min bend radius 0mm 0mm Fig 3 COLAS / ILAS -E connection Cable should be secured down the chassis rail on piping and should be secured not less than 00mm intervals Nm ( lbft) - 6 Nm (3 -. lbft) DIN Connector NOTE: All cables should run UP TO connector Position rubber gasket R in position shown. R Fig 3

24 Auxiliary Chassis installation equipment wiring second Painting title - masked here areas Painting Mounting face In the event of paint/coating work all non used connections, pneumatic ports and exhausts MUST be protected. These are indicated by the shaded areas in the figure to the right. Adequate protection should be used to avoid penetration of the paint/coating. All electrical ports to have connectors/blanking plugs installed. All pneumatic ports to have pipe fittings/blanking plugs installed. Exhaust ports and connector/s locking areas to be masked during painting. Painting recommendations: Water based, baking for 00 c. Underside Indicates masked areas Front face Left side Right side Fig 5

25 Auxiliary Chassis installation equipment wiring second Electrical title wiring here- ISO Pin Socket Assembly - V Pin detail and identification key location. Pin No. Designation Red (RD) mm B+ BATT Black (BK).5mm B+ IGN 3 Yellow (YE).5mm B+ EARTH Brown (BN) mm B EARTH 5 White (W).5mm LAMP 6 White/Green (W/GN).5mm CAN HI White/Brown (W/BN).5mm CAN LO Key Fig 6 Clearance dimensions. 5º 0 Max 0 Min 60 Max 55 Min 60 Min 60 Min 80 Min Fig Socket mounting dimensions. 5.0 ø ø Fig

26 Auxiliary General chassis equipment installation wiring second Electrical title wiring here- Anti-vibration support Anti-vibration support Excess cable must not be allowed to hang free, but must be attached to the chassis to prevent damage due to vibration and abrasion. Excess cable Cable lengths LESS than m to be coiled into loops of 00mm minimum and 50mm maximum diameter. Excess length which will not form a complete loop may be left to hang in partial loops having a cable bend radius of 50mm minimum. Fig 9 B Ø 50max 00min Cable lengths GREATER than m to be coiled and then flattened in the centre B to produce a dog bone shape. 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. More than one looped cable must not be looped together. Fig 50 Ø00min Fig 5 ISO 638 Connector Should be positioned/grouped with other electrical connections. Fig 5 ISO 85 (N) ISO 638 When installing ISO 638 it is important that sufficient extra length of cable is allowed to expose the socket assembly for replacement in service. It will be necessary to pull the ISO 638 socket clear from the trailer headboard to undo the gland nut. Trailer headboard Approx 350mm Fig 53 Gland nut 6

27 Auxiliary General chassis equipment installation wiring second Electrical title wiring here- Junction box Junction box Junction box Should be mounted on a flat surface. Mounting holes to be drilled 6.5mm diameter to avoid stress at the box from incorrect location. Ensure cables runs are UP TO the junction box. Cable Drain hole to be shielded by chassis as shown to provide as much protection from direct spray and other road debris. Junction box drain hole 5mm min. Ensure outer insulation of the cable is inside junction box by 5mm Minimum. Fig 5 Junction box Piping Avoid elbows as much as possible. If essential, use swept type elbow. Inside diameter of fitting should be the same as the pipe diameter it is serving. Position of additional valves Prefered position of RELAY EMERGENCY VALVE. Fig 55 Outer insulation cable Fig 56 Optional Suppression Emergency Braking - refer to /3 of trailer length Fig 5

28 Auxiliary General Chassis equipment installation wiring second Electrical title wiring here- DIAG Side of vehicle connection Diagnostic DIAG - side of vehicle connection - Option 3 Alt Clearance and mounting dimensions. Shaded area around hole to be flat and free from raised markings or surface imperfections which may prevent flush fitting of the connector. 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. Ø50 MAX 0.0 MIN 0.0 MIN The connector must be mounted horizontally. Ø MAX 0.0 MIN 65.0 MIN Tighten nut R to a torque of 3-Nm (-3 Ibft). ECU connection is as Fig 8. Cable to run UP TO connector and secured to the chassis, or appropriate cable or pipe runs, with cable ties at 00mm intervals. R Note: For Installation of INFO CENTRE refer to Instructions Leaflet. 00 MIN 00 MAX Fig 58 Ensure that the cover is fitted and correctly locked in place. Fig 59 8

29 Auxiliary Pipe recommendations equipment wiring second M system, title Side hereby Side, 3 axle Semi-Trailer - line air brake - S/D brake chambers 5b Emergency 5a a 5a a b c Service - 3a b 3c 5a 3b a b c 5b Fig. 60 M system, Side by Side configuration, 3 axle Semi-Trailer - line air brake system - S/D brake chambers Item Description Material Size Remark Emergency pipe Nylon 8 X 0 X /.5 X.5 a Service pipe Nylon 8 X Pref 0 X Alt 0 X.5 Alt b Service pipe Nylon 8 X 0 X 0 X.5 3a Reservoir pipe Nylon X.5 Pref 5 X.5 Alt 3b Reservoir pipe Nylon 5 X.5 6 x 8 X 3c Reservoir pipe Nylon 8 x 0 X.5 a to be /3 total trailer length Short as possible.0m Max Short as possible 3.0m Max. a Brake pipe Nylon X.5 or a and c to be similar in length, c Brake pipe Rubber hose I.D..0 b to be as short as possible I.D a Suspension pipe Nylon * *As per Suspension Manufacturers recommendations 5b Suspension bellows Nylon * *As per Suspension Manufacturers recommendations Pref = Preferred Alt = Alternative All pipe and rubber hose to comply with recognised international standards. Nylon pipe to DIN 338 or DIN 3-, Rubber hose to SAE 0. The above pipie sizes are defined as guide lines 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. 9

30 Auxiliary Brake and equipment Suspension wiring piping layout second M, Side-by-Side, title here with R.E.V., and Single Diaphragm Brake Chambers Emergency Service Fig. 6 M system, Side by Side configuration, 3 axle Semi-Trailer - line air brake system - S/D brake chambers Item Description Notes Emergency coupling Service coupling 3 Pipe filter Relay Emergency Valve 5 Air reservoir 6 Drain valve Test point 8 EB + Assembly 9 Single Diaphragm Brake chamber 0 Levelling valve Pressure protection valve Suspension bellows 3 Test point simulator 30

31 Brake piping layout M, Side-by-Side, with Combined Park and Shunt valve ( ) Emergency Service Fig. 6 Side by Side configuration, 3 axle Semi-Trailer - line air brake system - Spring brake chambers Item Description Notes Emergency coupling Service coupling 3 Pipe filter Combined Park and Shunt valve Air reservoir 6 Drain valve Test point 8 EB + Assembly 9 Spring Brake Chamber 0 Single Diapragm Brake Chamber Suspension Bellows 3

32 Brake piping layout M, Side-by-Side with TrCM and Spring brake chambers Emergency - 3//5 AUXs Service Fig. 63 Side by Side configuration, 3 axle Semi-Trailer - line air brake system with Trailer Control Module - Spring brake chambers Item Description Notes Emergency coupling Service coupling 3 Pipe filter Trailer Control Module (TrCM) 5 Air reservoir - service 6 Drain valve Test point 8 EB + Assembly 9 Spring Brake Chamber 0 Single Diapragm Brake Chamber Test Point Simulator Suspension Bellows 3

33 Brake piping layout Axle by Axle with R.E.V. and Combined Park and Shunt valve ( ) Emergency 3 3 Service Fig. 6 Axle by axle configuration, 3 axle Semi-Trailer - line air brake system - Spring Brake chambers - Combined Park and Shunt valve Item Description Notes Emergency coupling Service coupling 3 Pipe filter Park & Shunt Valve Air Reservoir 6 Drain valve Test Point 8 EB + Assembly 9 Spring Brake Chamber 0 Single Diapragm Brake Chamber Relay Emergency Valve (REV) Test Point Simulator 3 Suspension Bellows 33

34 Brake piping layout Side by Side with R.E.V. and Combined Park and Shunt valve Emergency Service Fig. 65 Side by Side configuration, 3 axle Semi-Trailer - line air brake system - Spring Brake chambers - Combined Park and Shunt valve Item Description Notes Emergency Coupling Service Coupling 3 Pipe Filter Combined Park and Shunt Valve / Air Reservoir 6 Drain Valve Test Point 8 EB+ Assembly 9 Spring Brake Chamber 0 Single Diapragm Brake Chamber Relay Emergency Valve Suspension Bellows 3

35 Suspension system piping layout with Levelling valve Fig. 66 Levelling valve Item Description Notes Pressure protection valve Air reservoir 3 Drain valve Pipe filter 5 Levelling valve 6 Air bellows Test point 8 EB+ Assembly 9 Test point simulator 35

36 Suspension system piping layout with Levelling valve and COLAS Fig. 6 Levelling valve, Colas (auto reset to ride) Item Description Notes Pressure protection valve Air reservoir 3 Drain valve Pipe filter 5 Levelling valve 6 Air bellows Test point 8 EB + Assembly 9 Test point simulator 0 Colas 36

37 Suspension system piping layout with COLAS and Ilas -E Aux 8 Aux Fig axle Semi-Trailer, Colas with auto reset to ride, ILAS -E, Levelling valve Item Description Notes Pressure protection valve Air reservoir 3 Drain valve ILAS -E 5 Levelling valve 6 Air bellows Test point 8 EB+ Assembly 9 Suspension bellows 0 Colas Test Point Simulator 3

38 Suspension system piping layout with COLAS, Height Limitation and D.C.V. - Option (Preferred) Aux Fig axle Semi-Trailer, Colas with height limitation and auto reset to ride Item Description Notes Pressure protection valve Air reservoir 3 Drain valve Pipe filter 5 Levelling valve with height limitation 6 Double check valve (Piston type preferred) EB + Assembly 8 Colas 9 Throttle 0 Air bellows Test point Test point simulator 38

39 Suspension system piping layout with COLAS and Height Limitation - Option Aux Fig. 0 3 axle Semi-Trailer, Colas with height limitation and auto reset to ride Item Description Notes Pressure protection valve Air reservoir 3 Drain valve Pipe filter 5 Levelling valve with height limitation 6 - EB + Assembly 8 Colas 9 Throttle 0 Air bellows Test point Test point simulator 39

40 Brake piping layout 3M, 3 axle Semi-Trailer - line air brake, Spring brake chambers with Combined Park and Shunt valve Emergency Service Fig. Side by Side configuration, 3 axle Semi-Trailer - line air brake system - Spring Brake chambers - Combined Park and Shunt valve Item Description Notes Emergency Coupling Service Coupling 3 Pipe Filter Combined Park and Shunt Valve / Relay Emergency Valve 6 Air Reservoir Drain Valve 8 Test Point 9 EB+ Assembly Master ECU 0 EB+ Assembly Slave ECU Spring Brake Chamber Single Diaphragm Brake Chamber 3 Test Point Simulator 0

41 Brake piping layout 3M, axle Full Trailer - line air brake, Spring brake chambers Emergency Service Fig. Side by Side configuration, 3 axle Full Trailer - line air brake system - Spring Brake chambers Item Description Notes Emergency Coupling Service Coupling 3 Pipe Filter Shunt Valve 5 Relay Emergency Valve 6 Air Reservoir Drain Valve 8 Test Point 9 EB+ Assembly M (Master ECU) 0 EB+ Assembly M (Slave ECU) Spring Brake Chamber Single Diaphragm Brake Chamber 3 Test Point Simulator Park Valve

42 Auxiliary Wiring schematic equipment wiring second title here ISO 638 Core - PUR 5 x.5mm² x.0mm² Safety back-up Core - PUR x.5mm² SENSOR Core - PUR x 0.5mm² ISO 638 ISO 85 (N) DIAGNOSTIC Core - PUR x 0.5mm² INFO CENTRE or SIDE OF VEHICLE CONNECTOR AUXILIARY 3 Core - PUR 3 x 0.5mm² ( cores used) Fig. 3 Semi-Trailer and Centre Axle Trailer Installation Option N MAXIMUM length of cable between ISO 85(N) connector and front junction box to be m. Failure to comply with the above recommendation may result in insufficient voltage at the ECU.

43 Auxiliary Wiring diagram equipment wiring second Sensors title + here ISO638 & ISO85 with Info Centre (3 Aux s fitted) B Sensors Black Red + A Sensors Black Red + ISO 85 ISO 638 Pin Pin Sensor SB Black Red + Sensor SA Interface (DIAG+) Info Centre Fig. ISO638 ISO85 DIAG SA SB SA SB AUX AUX AUX 3 AUX AUX 5 3

44 Auxiliary equipment wiring second Sensors title + here ISO638 & ISO85 with Info Centre & LWS (3 Aux s fitted) LWS NB B Sensors A Sensors Black Red + Black Red + EB+ External Stability Accelerometer NB ISO 85 ISO 638 Pin Pin Sensor SB Black Red + Sensor SA Interface (DIAG+) Sensor SB Sensor SA Info Centre Fig. 5 ISO638 ISO85 DIAG SA SB SA SB AUX AUX AUX 3 AUX AUX 5 NB - Lining Wear Sensor to be fitted in AUXs only NB - External Stability Accelerometer to be fitted in AUXs 5 only

45 Auxiliary equipment wiring second title here Fig 6 - COLAS Fig - ILAS -E RED (+) BLACK (-) RED (+) BLACK (-) WARNING LAMP RED (+) BLACK (-) Fig 8 - Warning lamp AUX AUX RED (+) BLACK (-) RED (+) BLACK (-) Lock Sol. Lock Sol. Relay Relay (+) RED (+) BLACK (-) Reverse lamp DIODE (Amp, 00V Min.) Fig 9 - STEER AXLE LOCK (inc. Reversing axle lock) 5

46 Auxiliary equipment wiring v from Truck Traction Assist switch ISO 098 (5 PIN) v PINK.5mm² Core cable.5mm² BLACK Junction Box YELLOW From AUX or 3 RED + - BLACK DIN Connector ILAS -E Fig 80 - Traction Assist using ILAS -E Traction assist is made operative by a 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. Function: On request for traction assist, front axle lifts. The front axle drops when either :- The vehicle speed exceeds 30kph or The supension pressure reaches more than 30% of the laden bag pressure YELLOW.5mm² RED Side-of-Vehicle switch From AUX /3 BLACK Core cable.5mm² YELLOW Junction Box From AUX /3 RED BLACK + DIN Connector ILAS -E Fig 8 - ILAS -E (Traction Assist - option) 6

47 Wiring diagram Full System information (9-0-00) DIAGRAM to be supplied Fig 8 - Wiring Diagram (9-0-00)

48 Hazardous Goods/ADR Installations Introduction 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 00). 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. Trailer load pressure data The print out of the Load Plate Pressure Data from the DIAG+ programme MUST HAVE the ADR/GGVS certificate number as indicated. Cable routes Sensor cable route should not be installed to brake air pipes. Do NOT run sensors leads in spiral wrapping on hoses. Cables should be securly 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 than 00mm intervals. Fig 83 NOTE: All cables should run UP TO ECU connections. Brake lamp back-up power supply The brake lamp power supply can be either ISO 098 or ISO 85 (N) connector. These Connectors MUST BE fully approved for use on an ADR vehicle. Fig 8 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. The warning lamp bulb MUST BE twin pole bayonet type. Fig 85 8

49 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 86 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. Screw + O ring seal Cable seal Connector seal Fig 8 DIN Connector Fig 88 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. 9

50 Programming To complete the EB + installation the ECU must be programmed using DIAG + software. Refer to DIAG + User Guide for further information. 50

51 Multimeter readings A B 0 5 Fig Sensor connector Fig Earth continuity RED (+) BLACK (-) RED (+) BLACK (-) Fig. 9 - COLAS connector Fig. 9 - ILAS -E connector B (+) Output B (+) Output A (-) Common A (-) Common Fig COLAS DIN connector Fig. 9 - ILAS -E DIN connector Checking position Measure between Correct value Remarks Fig Sensor output A B 0.V AC Min Sensor A, B or A, B Sensor diconnected from ECU Wheel rotated at rev/ sec. Sensor resistance A B >.0 <. kohm Sensor A, B or A, B Sensor diconnected from ECU Earth continuity COLAS Solenoid resistance ILAS -E Solenoid resistance ECU/EPRV Bracket and chassis 0 ohms <5 ohms + - >9 <96 ohms Cable disconnected 88 & >9 <96 ohms Cable disconnected 89 &

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