DGX INSTALLATION INSTRUCTIONS

Transcription

1 INSTALLA ALLATION INSTRUCTIONS

2 Components Anti-Lock Braking System for Trucks - 24V Full Air Brakes 00 TOOTH SYSTEM ITEM DESCRIPTION PART No. QTY ABS Instruction Label Body Ident. Label Window Ident. Label Red Warning lamp Bezel Fuse Assy. 3amp Fuse Assy. 5amp Relay Connector Connector Way Housing DDU Bracket Self tap Screws Grommet Female Connector Male Connector Stud (Short) Stud (Long) Lock Nut Flat Washer Blanking Plug M Sealing Washer M O Ring M Sealing Washer M O Ring M CHASSIS KIT No DGX-I Module (Truck) DGX-I Module (Bus) Module Loom (m DDU) Module Loom (3m DDU) SPS Valve (Front) SPS Valve (Rear) x2 Truck ONLY SPS Valve (Front) SPS Valve (Rear) x2 6x4, Bus - Long Wheel Base Vehicles ONLY Sensor Total 4 Retaining Clip Total 4 Sensor Extension Cable 2/22 2-Right Hand FRONT 22- Left Hand FRONT m m m m m m m m m m 23/24 23-Right Hand REAR 24-Left Hand REAR m m m m m m m m m m FRONT SPS Valve m Cable Assembly m m m 26 REAR SPS Valve m Cable Assembly m m m 27 Exciter Manu.f Ref. Total 4 Additional Parts Mounting Brackets Cab Cabeling Cable Ties

3 Electronic Control ol Unit (ECU) Connector Retaining Clip Identification label 30.0 Date Code Way Connector 40.0

4 SPS Valv alve - 4 Por ort 24V PORT DETAILS Elecrtical connections Control Ports (4) M6 x.5 42 Delivery Ports (2-2) x 2 M22 x.5 MOUNTING POSITIONS The valve is to be chassis mounted from either face 'A' or face 'B' by use of a mounting bracket with the studs provoded. Using face 'A' any two diagonally opposite mounting holes can be used as a minimum fixing. 200 Face A Delivery Ports (2-) x 2 M22 x.5 Reservoir Ports () M22 x Face B 9.5 IMPORTANT SIX MOUNTING HOLES M0 USE ONLY STUDS PROVIDED SECURE WITH STUDLOCK 270 TORQUE TO 2-4Nm ( lb ft) NUT TORQUE 33-40Nm (24-30lb ft) 3.5 Max

5 ISO 7638 Wiring Diagram am Existing vehicle wiring ABS Wiring (Additional to standard vehicle wiring) 24V IGNITION SWITCH 25A 3A BK/BN RD YE DIRECTION INDICATORS FUSE TRAILER ABS WARNING LAMP W BK ISO 7638 CONNECTOR N N2 N3 N4 This wire is to be connected to the unfused ignition switched battery positive supply. This wire is to be connected to the fused ignition switched battery positive supply (same point as the direction indicators). This wire is to be connected using seperate ring tongue connectors to the main battery negative pick up point. This wire is to be connected to an unfused battery positive supply which has a continous current rating of at least 5A. The supply will be switched by a relay internal to the control ISO 7638 Description Colour Cable size Pin No. 25A Unfused BAT+ BK/BN 6.0mm² 2 3A Ignition switched B+ RD.5mm² 3 BAT - YE.5mm² Key BK = Black BN = Brown RD = Red YE = Yellow W = White 4 BAT - W 6.0mm² 5 Lamp (Direction indicators) BK.5mm²

6 FRONT Sensor leads Sensor leads are made up as separate assemblies, and are identified as follows:- SENSOR RH FRONT SENSOR LH FRONT The front RH and LH sensors are to be connected to the FRONT SPS Valve cable assembly identified as such:- FRONT 9-Way Housing The RH SENSOR is marked with YELLOW and 2 markers close to the female connectors. These connectors are inserted in the SPS Valve 9 -way housing into positions marked and 2. These positions are adjacent to the YELLOW SPS valve cable. YELLOW valve cable ORANGE YELLOW WHITE BLACK WHITE valve cable 9-Way Housing SENSOR RH FRONT YELLOW cable makers WHITE cable makers The LH SENSOR is marked with WHITE 6 and 7 markers close to the female connectors are insrted in the SPS Valve 9 - way housing two temaining positions marked 6 and 7.

7 REAR Sensor leads Sensor leads are made up as separate assemblies, and are identified as follows:- SENSOR RH REAR SENSOR LH REAR The front RH and LH sensors are to be connected to the REAR SPS Valve cable assembly identified as such:- REAR 9-Way Housing The LH SENSOR is marked with YELLOW and 2 markers close to the female connectors. These connectors are inserted in the SPS Valve 9 -way housing into positions marked and 2. These positions are adjacent to the YELLOW SPS valve cable. WHITE valve cable 9-Way Housing WHITE BLACK ORANGE YELLOW YELLOW valve cable SENSOR RH REAR WHITE cable makers YELLOW cable makers The RH SENSOR is marked with WHITE 6 and 7 markers close to the female connectors are insrted in the SPS Valve 9 - way housing two temaining positions marked 6 and 7.

8 Pipe Recommenda ecommendations 4a 4b FV F.RES 2a a 3a a ABS ABS 2b 2-2- R.RES 2-3b 4a b 2-2 3b 2-2 4b FV= F.RES= R.RES= ABS= Foot Valave Front Reservoir Rear Reservoir ABS Valve - (SPS) Nylon Pipe ab= 0x (3/8") 2ab= 2x.5 ( /2") 3ab= 2x.5 (/2") 4ab 2x.5 (/2") I.D Hose Nylon pipe to specification: DIN / DIN Metric pipe SAE J844 - Imperial pipe

9 Vehic ehicle Interface Wiring BK 28/0.3 (2.0mm ) 2 PL 28/0.3 (2.0mm ) 5 amp FUSE Continuous 2 2 BN 28/0.3 (2.0mm ) 8-WAY HOUSING VEHICLE INTERFACE CONNECTOR 30/ A RETARDER RELAY Retarder control circuit BK/W GN/RD GN/PL GN 3 amp FUSE Continuous W Ignition switch VIEW OF WIRING END OF 8-WAY HOUSING GN/YE 87A /5 WARNING LAMP RELAY Existing vehicle fuse W = White BK =Black BN =Brown PL = Purple RD =Red YE = Yellow GN = Green GN/YE BK ABS 24V 2.8W GN Use separate connectors To Direction Indicators or Warning lights or Gauges 24V All wires are 4/0.3 (.0mm ) unless otherwise indicated. RETARDER RELAY Is fitted in order to switch OFF the retarder during Anti-lock operation. WARNING LAMP RELAY Is fitted so that if the 35 way connector has not been correctly installed onto the ECU the ABS warning lamp remains ON.

10 Wiring Diagram am

11 Cab Wiring Vehicle Model : WAY HOUSING COLOUR CABLE CONNECTOR CABLE LENGTH 2 SIZE (mm ) TYPE PART No. (mm) 5 3A Purple 2 Make connection 5 during vehicle installation 4 B - Black Black / White Full insulated Red Lucar A RETARDER RELAY Green Green/ Red Green/ Purple Make connection 6 during vehicle installation Make connection 6 during vehicle installation. Connection 86 = Full insulated Blue Lucar Full insulated Red Lucar A B - WARNING LAMP RELAY Green/ Yellow Black Full insulated Red Lucar Full insulated Red Lucar Green/ Yellow Full insulated Red Lucar position RED WARNING LAMP 2 IGNITION SWITCH FUSED B+ Green Position = Full insulated Red Lucar Position 2 =

12 Test Procedur ocedure B 2B ABS A A Power ON, Watch ABS lamp. 2.5 SEC. ABS ABS ABS SEC. 2 Power ON, Depress foot brake, Power ON, Listen for order of blow down. nd st th rd X 2 X 0 X 3 Plug in Diagnostic Display Unit and refer to code. Spin each wheel in turn and refer to DDU indication. A 2A 3A Diagnostic Display Unit B 2B 3B A A 2A 3A Diagnostic Display Unit B 2B 3B

13 Installation tion Specification - GS 0025

14 Installation tion Specification - GS 0025

15 Installation tion Specification - GS 0025

16 Installation tion Specification - GS 0025

17 Installation tion Specification - GS 0025

18 Installation tion Responce Requir equirements ements - GS 0025

19 Air / Hydr draulic Installations tions

20 Air / Hydr draulic Installations tions

21 Air / Hydr draulic Installations tions

22 Air / Hydr draulic Installations tions

23 Air / Hydr draulic Installations tions Piping Layout FRONT Axle Foot Valve REAR Axle SPS Valves (DGX ABS Valves) Air-Hydraulic Booster Air-Hydraulic Boosters Reservoir Reservoir Air / Hyd Braking System Checks Following the installation of the Anti - Lock Brake System, before removal of the axle stands, the following checks should be carried out in order to check the integrity of the brake system. Fully charge the air system before each of the following checks:- Apply the foot brake and check that the brake has been applied on each wheel. Release the foot brake. 2 3 Fully drain the front brake circuit reservoir. Apply the foot brake and check that the brake has applied on both REAR wheels and that both FRONT wheels rotate. Remove the delivery pipe and fitting from port 2- of the rear SPS Valve and blank off port. Apply the foot brake. The RIGHT REAR wheel brake should be ON. The LEFT REAR wheel should ROTATE. Remove blanking plug and reconnect delivery pipe.

24 For further information: Austria Haldex Wien Ges.m.b.H Vienna Tel: Fax: office@baeder-haldex.at Belgium Haldex N.V./S.A. Zaventem (Brussels) 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.et.cn France Haldex Europe S.A. 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: info@huk.haldex.com Haldex Brake Products Ltd. Redditch Tel: Fax: info@hbpuk.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. TheGroup 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 pumpsand hydraulic systems for power steering and lifting functions on industrial vehicles and trucks. Haldex Garphyttan Wire supplies specially steelalloyed 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 SouthAmerica and Asia. Production takes place in 9 factories in USA, 9 factories in Europe and joint venture in India. The Haldex Group is listed on the Stockholm Stock Exchange. Innovative Vehicle Technology Quality and Production Standards The very latest production technology ensures the very highest quality standards. All production sites are ISO 900 approved.