Installation Guide - Well Interparts · Brake and Suspension piping layout - 3 axle 30 Semi-Trailer - 2 line air brake system - with R.E.V - S/D brake chambers ... of the this Installation

InstallationGuide

Installation instructions for EB+ Generation 2

000 700 340 rev.09 ‘08

38891 338891 3 3/10/08 15:40:263/10/08 15:40:26

Table of Contents

Page

General component guide 5

Chassis components 6

Assembly - EB+ 7

Installation options - Semi and Centre axle trailer - 8Side by Side

Installation options - Semi and Centre axle trailer - 9Side by side (SxS) 2S/2M + SL valve - Self-steered axle

Installation options - Semi and Centre axle trailer - 10Integrated Axle by Axle, ASC Front, SL Rear

Installation options - Semi and Centre axle trailer - 11Integrated Axle by Axle, ASC Rear, SL Front

Installation options - Full trailers 12

Chassis installation - Position of EB+ assembly 13

Chassis installation - Position of EB+ assembly 14

Chassis installation - Electrical wiring 15POWER/DIAG connection

Chassis installation - Electrical wiring - 16POWER ‘A’ (ISO 7638)

Chassis installation - Electrical wiring - 17POWER ‘B’ (ISO 1185, 24N)

Chassis installation - Electrical wiring - 18Diagnostic ‘DIAG’ connection

Chassis installation - Connectors/blanking plugs 19

Chassis installation - Sensor/Auxilliary Plugs 20

Chassis installation - SENSOR/AUX/DIAG Connection 21

Chassis installation - Sensor Connection 22

Chassis installation - COLAS® / ILAS®-E connection 23

Chassis installation - Painting - Masked areas 24

Chassis installation - ISO 7638 - 7 Pin 25Socket Assembly - 24V

General Chassis installation - Anti-vibration support 26

General Chassis installation - Junction box 27

General Chassis installation - Electrical wiring - 28DIAG Side of Vehicle connection

Pipe recommendations - 3 axle Semi-Trailer - 292 line air brake system - S/D brake chambers

Brake and Suspension piping layout - 3 axle 30Semi-Trailer - 2 line air brake system - with R.E.V -S/D brake chambers

Brake piping layout - 2M - 3 axle Semi-Trailer - 2 line 31air brake system - without R.E.V. - Spring brake chambers

Brake piping layout - 2M - Side by Side 3 axle with TrCM 32and Spring Brake chambers

Brake piping layout - Axle by Axle - 3 axle Semi-Trailer 33with R.E.V. & Combined Park and Shunt valve

Page

Brake piping layout - Side by Side 3 axle with R.E.V. & 34Combined Park and Shunt valve

Suspension system piping layout - Levelling valve 35

Suspension system piping layout - Levelling valve, 36Colas® (auto reset to ride)

Suspension system piping layout - 3 axle 37Semi-Trailer, Levelling valve, Colas® with auto reset to ride & ILAS®-E

Suspension system piping layout - Option 1 - 383 axle Semi-Trailer, Colas® with height limitation and auto reset to ride

Suspension system piping layout - Option 2 - 393 axle Semi-Trailer, Colas® with height limitation and auto reset to ride

Suspension system piping layout - 3 axle Semi-Trailer, 402 line air brake, spring brake chambers with combined park & shunt valve

Suspension system piping layout - 2 axle Full Trailer, 412 line air brake, spring brake chambers

Wiring schematic 42

Wiring diagram - 2 Sensor, ISO 7638 & ISO 1185 with 43Info Centre (3 AUXs fi tted)

Auxilliary equipment wiring - 2 Sensor, ISO 7638 & 44ISO 1185 with Info Centre and L.W.S. (3 AUXs fi tted)

Auxilliary equipment wiring - COLAS®/ ILAS®, 45Steer Axle Lock

Auxilliary equipment wiring - Traction assist 46

Wiring Diagram - Full system information 47

Hazardous Goods/ADR Installations 48

Hazardous Goods/ADR Installations 49

Programming 50

Multimeter readings 51

38891 H:238891 H:2 3/10/08 15:40:333/10/08 15:40:33

Notes on the use of this manualDocument 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:

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: +44 1527 499 499 Fax: +44 1527 499 500.

• 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 specifi cation 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.

Document Registration

Included below is a postcard which enables you to register ownership of the this Installation Guide document.

Please fi ll 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 Offi ce.

EB+ Installation Instructions Registration - Please fi ll in your details below.

YOUR NAME

COMPANY

DELIVERY ADDRESS

POST CODE

EMAIL

38891 H:338891 H:3 3/10/08 15:40:343/10/08 15:40:34

EB+ Installation Instructions Registration

PleaseAffi x

StampHere

Document Registration

MARKETING DEPT.

HALDEX BRAKE PRODUCTS LTD

MOONS MOAT DRIVE

REDDITCH

B98 9HA

UNITED KINGDOM

38891 H:438891 H:4 3/10/08 15:40:343/10/08 15:40:34

5

General Components Guide

Driver’s information

plate

Haldex EB+ Assembly

EB+ Info Centre

ISO7638 - 7 Pin Socket assembly

Sensor and Exciter

TrCM

Fig. 1

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6

Chassis components

Item Description Notes1 EB+ Label2 ISO 7638 - 7 Pin Socket assembly3 Safety backup cable - ISO 1185 (24N)4 EB+ INFO CENTRE (side of vehicle connection) 5 EB+ ECU and EPRV’s assembly6 Sensor assembly7 Exciter8 COLAS® Aux 1, 2 or 39 ILAS®-E Aux 1, 2 or 310 Lining Wear Sensing (LWS) Aux 4 ONLY11 EB+ Stability External Sensor Assembly - Aux 5 ONLY

Fig. 2

2A1A

54

32

11B

2B

6

7

6

7

6

7

6

7

11

10

9

8

4

3

2

1

5

ISO 7638

ISO 1185(24N)

N.B. Aux to be set in line with DIAG+

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7

STUDS x3M10 x 1.5mm

6G

Weight: 7.5Kg

Fig. 3

Delivery port (21) M16 x 1.5

Delivery port (22)M16 x 1.5

280mm

180mm

23.6mm

67.7mm

135.2mm

74.2mm

183.8mm

Assembly - EB+Port identifi cation

Port No. Description Notes

1 Reservoir Port3 Exhaust Port4 Control Port 11 Anti-Compounding Port

21/22 Delivery Ports23 Spring Brake Port41 Air Suspension Port

4

1 23 2323 1

41

33

11M16 x

Delivery test port (22)M12 x 1.5

Delivery port (21)M12 x 1.5

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8

S1B

S1A

S1B

S1A

S1B

S1A

S1B

S1A

S1B

S1A

S1B

S1A

S1B

S1A

S1B

S1A

S1B

S1A

2221

S2B

S2A

2122

2221

2221

S1B

S1A

2221

2122

2122

2122

S1B

S1A

2221

S1B

S1A

S2B

S2A

2122

2122

S2B

S2A

S2B

S2A

2221

Installation options Semi & Centre Axle Trailer - Side by Side

Fig. 4 - 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

MODULATOR

ECU POWER CONNECTORS

Key

R.H

. Pow

er C

able

Con

nect

orL.

H. P

ower

Cab

le C

onne

ctor

R.H

. Pow

er C

able

Con

nect

or

L.H

. Pow

er C

able

C

onne

ctor

4S/2

M

2

S/2M

2221

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9

2S/

2M

Fig. 5 - Side by side (SxS) 2S/2M + Select low valve

• Any axle without directly controlled wheels may be a lift axle.MODULATOR EPRVs


Key

2221

Installation optionsSemi & Centre Axle Trailers - Side by side (SxS) 2S/2M + SL valve - Self-steered axle

S1B

S1A

S1B

S1A

2221

2122

S1B

S1A

2122

A A A

S1B

S1A

2221 A

S1B

S1A

2221 A A

S1B

S1A

2122

A SELECT LOW VALVE

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10

S1B

S1A

S2B

S2A

S1B

S1A

S2B

S2A

S1B

S1A

2221

2221

2122

S2B

S2A

N1

N2

S1B

S1A

S2B

S2A

2122

N1

N4

N1

N4

N3

N2

S1B

S1A

S2B

S2A

2221

N3

N2

S1B

S1A

2122

S2B

S2A

N1

N4

4S/2

M

Sensed axles cannot be lifted

Any axle without directly controlled wheels (un-sensed) may be liftedAny axle may be a steered axle

N1 - N4 Selectable options set by Haldex or Vehicle ManufacturerN1 Adaptive surface control (ASC)2.1N2 Select Low (SL)2.1N3 Adaptive surface control (ASC)2.2N4 Select Low (SL)2.2

Fig. 6 - Axle by Axle

MODULATOR EPRVS


Key

2221

Installation optionsSemi & Centre Axle Trailers - Integrated Axle by Axle, ASC Front, SL Rear

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11

S1B

S1A

S2B

S2A

S1B

S1A

S2B

S2A

S1B

S1A

2221

2221

2122

S2B

S2A

N4

N1

S1B

S1A

S2B

S2A

2122

N2

N3

N1

N4

N1

N4

S1B

S1A

S2B

S2A

2221

N1

N4

S1B

S1A

2122

S2B

S2A

N2

N3

Installation optionsSemi & Centre Axle Trailers - Integrated Axle by Axle, ASC Rear, SL Front

4S/2

M


Any axle without directly controlled wheels (un-sensed) may be a lift axleAny axle may be a steered axle

N1 - N4 Selectable options set by Haldex or Vehicle ManufacturerN1 Adaptive surface control 2.1N2 Select Low 2.1N3 Adaptive surface control 2.2N4 Select Low 2.2

Fig. 7 - Axle by Axle

MODULATOR EPRVS


Key

2221

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12

Installation optionsFull Trailers

4S/3

M


Any axle without directly controlled wheels (un-sensed) may be a lift axle

N1 Master ECU is mounted to EPRV’s 21/22. All Sensors must be connected to this Master ECU.

N2 Slave ECU is mounted to EPRV 2 and is controlled by Master ECU.Slave ECU/EPRV 2 is shown facing rear but can also be installed facing forward, left or right, as EPRV 2 is always select low control.

Fig. 8 - Side by Side

MODULATOR EPRVS

SLAVE ECU


MODULATOR EPRVS

Key

2221

2

2

S1B

S1A

S2B

S2A

2

S1B

S1A

S2B

S2A

2

S1B

S1A

S2B

S2A

S1B

S1A

S2B

S2A

S2B

S2A

2

S1B

S1A

S2B

S2A

2

S1B

S1A

2122

2122

2122

2221

2221

2221

2

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Chassis installationPosition of EB+ assembly

13

Position of EB+ assembly

The following installation paramerters are required for correct STABILITY operation.

Roll angle : ± 3° (1:20).

Yaw angle : ± 5°.

The EB+ Assembly to be mounted within ±1 m of the centre of the axle(s), (Includes any lift axles).

The EB+ Assembly to be within the main Left Hand (LH) and Right Hand (RH) chassis members of the vehicle.

For any other applications please refer to Haldex Technical Services.

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 9

Fig 12

1m 1m

Within LH and

RH chassis members

Single or Tri-axle

5º5º

5º5º

Plan view

Plan view

Fig 10

3º

3º

3º

3º

Rear End view

1m 1m

Within LH and

RH chassis members

Fig 11

Tandem axle

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Chassis installationPosition of EB+ assembly

14

N.B. The Following are applicable to ALL OTHER Installations and Confi gurations.

The preferred assembly orientation should be positioned so that the Power Cable connections face towards the required confi guration installation option (confi guration) of the trailer. Ref. Figs 4 to 7.The distance between port (1) and the air reservoir to be as short as possible.

Mount Modulator Valves centrally to the brake chambers (refer to Installation Options Figs 4 to 7).

A : Single axleB : Tandem axleC : Tri-axle

If mounting to stainless steel, then a suitable membrane must be used.

Additional bracket design to be as rigid as possible. The mounting fi xing must provide an electrical connection between ECU/Modulator bracket an vehicle chassis.Mounting bracket fl atness 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.

Use NON-CORROSIVE 10mm nuts, torque to 35-45Nm.

Care should be taken to provide reasonable access to the ECU/valve for replacement of cables.

D= 150mm minimumE= 1. Assembly to be above axle centre line. 2. To be as high in frame as possible.

A B C

Fig 14

Fig 17

Fig 15

Fig 16

Fig 13

Fixing

2221

2221

2221

(1)

360º

0.5mm

4.0mm Min.

Mounting Bracket

Fixing Holes

ED

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Chassis installation

Check earth continuity between ECU/EPRV/Bracket and vehicle chassis

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.

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’.

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.

Fig 19

Fig 21

Fig 18

0 5

GROUND LEVEL

TO BRAKECHAMBERS

DECK OF TRAILER

TO BRAKECHAMBERS

Fig 20

F

G

N

Chassis installationElectrical wiring - Power/DIAG connections

15

H

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Connections

Make sure that all connections (socket and plug) are clean and dry before assembly.

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.

POWER ‘A’ (ISO 7638)

Identify orientation ‘L’ of the ISO 7638 Blue coloured connector.

Ensure contact pins and seal are clean and free of any contamination prior to installation.

In position ‘POWER A’, on the slide lock housing, insert connector fully home.

Chassis installation

Fig 23

TRAILER CHASSIS

Ø20.0MIN.

L

✘

BLUECONNECTOR

Chassis installationElectrical wiring - Power ‘A’ (ISO 7638) connection

16

Fig 22

Fig 24

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ORANGECONNECTOR

Chassis installationElectrical wiring - Power ‘B’ (ISO 1185, 24N) connection

17

POWER ‘B’ (ISO 1185, 24N)

Remove blanking plug from position POWER ‘B’.

Identify orientation ‘L’ of the ISO 1185 Orange coloured connector.


In position ‘POWER B’, on the slide lock housing, insert connector fully home.

Fig 26

Fig 25

L

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Chassis installationElectrical wiring - ‘DIAG’ connection

18

Diagnostic ‘DIAG’ connection - Option 1

If NO diagnostic units are to be installed retain blanking plug in position marked ‘DIAG’.

Diagnostic ‘DIAG’ connection - Option 2

If a remote mounted EB+ Info Centre is installed remove blanking plug ‘K’

Identify orientation ‘L’ of the DIAGNOSTIC Green coloured connector.


In position ‘DIAG’, on the slide lock housing, insert connector fully home.

K

Fig 27

Fig 28

L

GREEN CONNECTOR

Fig 29

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Auxiliary equipment wiringsecond title here

19

Chassis installationElectrical wiring - Connectors/blanking plugs

Make sure that all connectors/blanking plugs are all fully inserted into the ECU slide lock housing.

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’

WARNING

If diffi culty is encountered in locking the slider, check plug or connector for correct fi tment.

If the white o-ring is visible, the plug is not installed correctly and slider will not lock into position.

Fig 32

Fig 31

Fig 30

M

N

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20

Chassis installationElectrical wiring - SENSOR/AUX plugs

Sensor Plug

Identifi cation 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.

ECUIdentifi cation

Tags Removed1 2 3 4 A B P 5

Component

S1A Sensor 1A

S1B Sensor 1B

S2A Sensor 2A

S2B Sensor 2B

Auxilliary Plug

Identifi cation tags are incorporated on either side of the Auxilliary connector.These MUST be removed to identify the appropriate usage before connecting into the ECU.

ECUIdentifi cation

Tags Removed1 2 3 4 A B P 5

ComponentExample only

AUX 1 COLAS®

AUX 2 ILAS®-E

AUX 3 Warning lamp

AUX 4 LWS

AUX 5 Stability

PSW Pressure switch

Fig 33

Fig 34

BLACKFront Case}

} BLUEFront Case

EXAMPLE:Sensor 1B

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21

SENSOR/AUX Connection

The ECU is supplied with blanking plugs in positions indicated.These require to be removed to allow fi tment of additional sensors or permitted ancillary equipment.

Transit plugs (T) are used in ports S1A and S1B.

Example - AUX 1 connectionIdentify the AUX 1 position on the top or front face of the ECU.Note the locking tag ‘O’ position.

With a tool ‘P’ having a fl at end of Ø3-2mm insert and press in locking tab of plug. While depressed pull out plug from housing.

Identify orientation of the:• Sensor Black body connector• Auxiliary Blue body connectorEnsure 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 35

Fig 36

Fig 37

Fig 38

P

Ø 3.02.0

ECU ECU

ECU

O

Chassis installationElectrical wiring - SENSOR/AUX/DIAG connections

TT

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22

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.

Where possible use a clip and bracket to secure sensor cable connection.

Alternatively: Sensor cable connection to be positioned on axle or between axle ‘U’ bolts and supported with cable ties within 50mm of each end.

Chassis installationElectrical wiring - SENSOR connection

Fig 39

Fig 41

Sensor cable socketExtension cable plug

Clip to ‘click’

Dirt shield

Sensor cable Extension cable

Dirt shield fi xing bolts

Axle

Connection assembled into clip and bracket

‘U’ bolts

Connection

Axle

Hub and drum/disc assembly

Cable tieCable tie

Fig 40

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23

Sensor 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.

Power leads should be secured down the chassis rail in trunking or to piping and should be sedcured not less than 400mm intervals.

NOTE: All cables should run ‘UP TO’ ECU connections.

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 42.

COLAS® / ILAS®-E connection

Cable should be secured down the chassis rail on piping and should be secured not less than 400mm intervals.

NOTE: All cables should run ‘UP TO’ connector

Position rubber gasket ‘R’ in position shown.

Chassis installationElectrical wiring - COLAS® / ILAS®-E connection

0.5 - 0.6 Nm (0.4 - 0.5 lbft)

4 - 6 Nm(3 - 4.4 lbft)

Fig 44

Fig 43

120min

ISO7638

0mm

0mm

0mm

0mm

R

24v

Cable tie

Axle

400max

Deck of trailer

Fig 42

150max

100min bend radius

DIN Connector

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24

Chassis installationPainting - masked areas

Painting

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 fi gure 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 fi ttings/blanking plugs installed.

Exhaust ports and connector/s locking areas to be masked during painting.

Painting recommendations: Water based, baking for 1 hour @ 100°c.

Indicates masked areas

Left side Right side

Fig 45

Underside

Mounting face

Front face

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25

Chassis installationElectrical wiring - ISO 7638 - 7 Pin Socket Assembly - 24V

Pin detail and identifi cation key location.

Clearance dimensions.

Socket mounting dimensions.

Fig 46

Fig 47

Fig 48

Key

10 Max 120 Min

45º

60 M

ax

55 M

in 60 Min 60 Min

80 M

in

50.3

048

.70

25.1

524

.25

74.9074.30

37.4537.15

9.08.5

57.055.0ø

ø

Pin No. Designation1 Red (RD) 4mm2 B+ BATT2 Black (BK) 1.5mm2 B+ IGN3 Yellow (YE) 1.5mm2 B+ EARTH4 Brown (BN) 4mm2 B– EARTH5 White (W) 1.5mm2 LAMP6 White/Green (W/GN) 1.5mm2 CAN HI7 White/Brown (W/BN) 1.5mm2 CAN LO

213

45

67

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26

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 1m to be coiled into loops of 100mm minimum and 150mm 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.

Cable lengths GREATER than 1m to be coiled and then fl attened 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 fi x the cable in the fl attened loop shape.

More than one looped cable must not be looped together.

ISO 7638 Connector

Should be positioned/grouped with other electrical connections.

When installing ISO 7638 it is important that suffi cient extra length of cable is allowed to expose the socket assembly for replacement in service.

It will be necessary to pull the ISO 7638 socket clear from the trailer headboard to undo the gland nut.

General chassis installationElectrical wiring - Anti-vibration support

Fig 53

Fig 49

Fig 52ISO 7638ISO 1185

(24N)

Gland nut

Ø 150max100min

Fig 50

B

Fig 51

Ø100min

Trailer headboard

Approx350mm

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27

General chassis installationElectrical wiring - Junction box

Junction box

Should be mounted on a fl at surface.Mounting holes to be drilled 6.25mm diameter to avoid stress at the box from incorrect location.Ensure cables runs are UP TO the junction box.

Drain hole to be shielded by chassis as shown to provide as much protection from direct spray and other road debris.

Ensure outer insulation of the cable is inside junction box by 5mm Minimum.

Piping

Avoid elbows as much as possible. If essential, use swept type elbow.

Inside diameter of fi tting should be the same as the pipe diameter it is serving.

Position of additional valves

Prefered position of RELAY EMERGENCY VALVE.

Optional

Suppression Emergency Braking - refer to 000 700 240.

Fig 55

Fig 56

Fig 57

Fig 54

Cable

Junction box

15mm min.

Outer insulation cable

Junction box

1/3 of trailer length

Junction box drain hole

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28

General Chassis installationElectrical wiring - ‘DIAG’ Side of vehicle connection

Diagnostic ‘DIAG’ - side of vehicle connection - Option 3

Clearance and mounting dimensions.Shaded area around hole to be fl at and free from raised markings or surface imperfections which may prevent fl ush fi tting 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.

The connector must be mounted horizontally.

Tighten nut ‘R’ to a torque of 3-4Nm (2-3 Ibft).

ECU connection is as Fig 28.

Cable to run UP TO connector and secured to the chassis, or appropriate cable or pipe runs, with cable ties at 400mm intervals.

Note: For Installation of INFO CENTRE refer to Instructions 000 700 271 Leafl et.

Ensure that the cover is fi tted and correctly ‘locked’ in place.

Fig 58

Fig 59

Ø24 MAX

Ø50 MAX

40.0MIN

40.0MIN

400 MAX

100 MIN

R

Alt

120.0MIN

65.0MIN

38891 H:2838891 H:28 3/10/08 15:42:333/10/08 15:42:33


29

Pipe recommendations2M system, Side by Side, 3 axle Semi-Trailer - 2 line air brake - S/D brake chambers

2222

22

2121

21

413c

5a

5a

5a

5b

5b

4a 4b 4c

4a 4b 4c

1

2a

Emergency

Service

3b 1

1

2122

2b

4

3a

4

1

2

2-1

Pref = Preferred Alt = Alternative All pipe and rubber hose to comply with recognised international standards. Nylon pipe to DIN 73378 or DIN 74324-1, Rubber hose to SAE 1402. The above pipie sizes are defi ned 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.

Item Description Material Size Remark

1 Emergency pipe Nylon 8 X 1 10 X 1 / 1.25 12 X 1.5

2a Service pipe Nylon 8 X 1 Pref10 X 1 Alt10 X 1.25 Alt

2a to be 1/3 total trailer length

2b Service pipe Nylon 8 X 110 X 1 10 X 1.25

3a Reservoir pipe Nylon 12 X 1.5 Pref15 X 1.5 Alt

3b Reservoir pipe Nylon 15 X 1.516 x 218 X 2

Short as possible 1.0m MaxShort as possible 3.0m Max.

3c Reservoir pipe Nylon 8 x 110 X 1.25

4a Brake pipe Nylon 12 X 1.5 or 4a and 4c to be similar in length,4c Brake pipe Rubber hose I.D. 11.0

I.D. 13.04b to be as short as possible

5a Suspension pipe Nylon * *As per Suspension Manufacturers recommendations5b Suspension bellows Nylon * *As per Suspension Manufacturers recommendations

Fig. 60

2M system, Side by Side confi guration, 3 axle Semi-Trailer - 2 line air brake system - S/D brake chambers

12

2

38891 H:2938891 H:29 3/10/08 15:42:353/10/08 15:42:35


30

Brake and Suspension piping layout2M, Side-by-Side, with R.E.V., and Single Diaphragm Brake Chambers

4

2222

2121

211

41

Emergency

Service

22

121

4 10

7

7

7

9 9 9

9 9 9

7

7

8

13

3

3

3

11

1

2

7

5

12 12 12

12 12 12

4

2-1

2

1

22

Item Description Notes

1 Emergency coupling

2 Service coupling

3 Pipe fi lter

4 Relay Emergency Valve

5 Air reservoir

6 Drain valve

7 Test point

8 EB+ Assembly

9 Single Diaphragm Brake chamber

10 Levelling valve

11 Pressure protection valve

12 Suspension bellows

13 Test point simulator

Fig. 61

2M system, Side by Side confi guration, 3 axle Semi-Trailer - 2 line air brake system - S/D brake chambers

6

6

5

38891 H:3038891 H:30 3/10/08 15:42:463/10/08 15:42:46

Brake piping layout2M, Side-by-Side, with Combined Park and Shunt valve (352-046-001)

31

Fig. 62

Side by Side confi guration, 3 axle Semi-Trailer - 2 line air brake system - Spring brake chambers

Emergency

Service

3

3

1

2

4

7

7

8

7

10

10 9 9

9

9

5

6

22

11

1

4

1

1

2

2

41

21

21

11 12 11 12

11 12 11 121

1

22

22

4

11

23

23

23

22



2 Service coupling

3 Pipe fi lter

4 Combined Park and Shunt valve 352-046-001

5 Air reservoir

6 Drain valve

7 Test point

8 EB+ Assembly

9 Spring Brake Chamber

10 Single Diapragm Brake Chamber

11 Suspension Bellows

23

11

7

21

38891 H:3138891 H:31 3/10/08 15:42:553/10/08 15:42:55

Brake piping layout2M, Side-by-Side with TrCM and Spring brake chambers

32

Fig. 63

Side by Side confi guration, 3 axle Semi-Trailer - 2 line air brake system with Trailer Control Module - Spring brake chambers

Emergency

Service

3

3

1

2

4

7

7

8

7

10

10 9 9

5

6

21

1-2

1

1

1

2

2

41

2121 21

11 12 11 12

11 12 11 121

1

22

22

22

4

11

23

23

23

AUXs

9

9

22

11

12

4



2 Service coupling

3 Pipe fi lter

4 Trailer Control Module (TrCM)

5 Air reservoir - service

6 Drain valve

7 Test point

8 EB+ Assembly



11 Test Point Simulator


7

23

23/24/25

38891 H:3238891 H:32 3/10/08 15:43:023/10/08 15:43:02

Brake piping layoutAxle by Axle with R.E.V. and Combined Park and Shunt valve (352-044-001)

33

Fig. 64

Axle by axle confi guration, 3 axle Semi-Trailer - 2 line air brake system - Spring Brake chambers - Combined Park and Shunt valve



2 Service coupling

3 Pipe fi lter

4 Park & Shunt Valve 352-044-001

5 Air Reservoir

6 Drain valve

7 Test Point

8 EB+ Assembly



11 Relay Emergency Valve (REV)



5

6

Emergency

Service

3

3

1

2

4

7

7

7

8

10

10 9 9

9

9

22

111

4

1

1

2

2

41

23

11 11 12

11 12 111

1

22

4

2-1

2

11

13

12

12

13

21 12

23

22

11

23 23

1

21

22

21

7

38891 H:3338891 H:33 3/10/08 15:43:103/10/08 15:43:10

Brake piping layoutSide by Side with R.E.V. and Combined Park and Shunt valve

34

5

6

Emergency

Service

3

3

1

2

4

7 7 7

8

7

10

10 9 9

9

9

22

11

1

4

1

1

2

2

41

2121 21

11 12 11 12

11 12 11 121

1

22

22

22

4

11

23

23

23

21

12-1

2

11

1223

Fig. 65

Side by Side confi guration, 3 axle Semi-Trailer - 2 line air brake system - Spring Brake chambers - Combined Park and Shunt valve


1 Emergency Coupling

2 Service Coupling

3 Pipe Filter

4 Combined Park and Shunt Valve 352-044-... / 352-045-...

5 Air Reservoir

6 Drain Valve

7 Test Point

8 EB+ Assembly





38891 H:3438891 H:34 3/10/08 15:43:183/10/08 15:43:18

Suspension system piping layoutwith Levelling valve

35

2

3

4

1

2

1

2

5

6 6

7

941

1

22

1

6 6 6

6

8

21

7

Fig. 66

Levelling valve



2 Air reservoir

3 Drain valve

4 Pipe fi lter

5 Levelling valve

6 Air bellows

7 Test point

8 EB+ Assembly


38891 H:3538891 H:35 3/10/08 15:43:263/10/08 15:43:26

Suspension system piping layoutwith Levelling valve and COLAS®

36

2

3

4

1

2

1

2

5

6 6

7

9

41

1

1

6 6 6

6

8

102122

12 22 211

11

Fig. 67

Levelling valve, Colas® (auto reset to ride)



2 Air reservoir

3 Drain valve

4 Pipe fi lter

5 Levelling valve

6 Air bellows

7 Test point

8 EB+ Assembly


10 Colas®

38891 H:3638891 H:36 3/10/08 15:43:313/10/08 15:43:31

Suspension system piping layoutwith COLAS® and Ilas®-E

37

Fig. 68

3 axle Semi-Trailer, Colas® with auto reset to ride, ILAS®-E, Levelling valve

2

3

1

1

5

9 9

7

11

419 9 9

9

8

10

12 22

1

11

21

21

Aux1

Aux2

2

4

1

21

22

116

1

22



2 Air reservoir

3 Drain valve

4 ILAS®-E

5 Levelling valve

6 Air bellows

7 Test point

8 EB+ Assembly

9 Suspension bellows

10 Colas®


38891 H:3738891 H:37 3/10/08 15:43:383/10/08 15:43:38

Suspension system piping layoutwith COLAS®, Height Limitation and D.C.V. - Option 1 (Preferred)

38

Fig. 69

3 axle Semi-Trailer, Colas® with height limitation and auto reset to ride

2

3

1

5

10 10

11

12

41 10 10 10

10

7

8

11

21

Aux1

2

4

11

2

21

12 11

2

6

1

1

9

22



2 Air reservoir

3 Drain valve

4 Pipe fi lter

5 Levelling valve with height limitation

6 Double check valve (Piston type preferred)

7 EB+ Assembly

8 Colas®

9 Throttle

10 Air bellows

11 Test point


12

23

1222

38891 H:3838891 H:38 3/10/08 15:43:443/10/08 15:43:44

Suspension system piping layoutwith COLAS® and Height Limitation - Option 2

39

Fig. 70

3 axle Semi-Trailer, Colas® with height limitation and auto reset to ride

2

3

1

5

10 10

11

12

41 10 10 10

10

7

8

1

11

21

Aux1

2

4

11

2

21

23

1

22

9



2 Air reservoir

3 Drain valve

4 Pipe fi lter

5 Levelling valve with height limitation

6 -

7 EB+ Assembly

8 Colas®

9 Throttle

10 Air bellows

11 Test point


12

12 22

38891 H:3938891 H:39 3/10/08 15:43:533/10/08 15:43:53



2 Service Coupling

3 Pipe Filter

4 Combined Park and Shunt Valve 352-044-... / 352-045-...


6 Air Reservoir

7 Drain Valve

8 Test Point

9 EB+ Assembly Master ECU

10 EB+ Assembly Slave ECU


12 Single Diaphragm Brake Chamber


40

Brake piping layout3M, 3 axle Semi-Trailer - 2 line air brake, Spring brake chambers with Combined Park and Shunt valve

Fig. 71

Side by Side confi guration, 3 axle Semi-Trailer - 2 line air brake system - Spring Brake chambers - Combined Park and Shunt valve

6

7

Emergency

Service

3

3

1

2

4

8

11 11 12

11 11 12

109

22

11

1

4

1

1

2

2

11 12

11

12 11 12

1123

23

21

21

12-1

2

5

13

12

8

8

11

2

2

4

4

41

21

11

38891 H:4038891 H:40 3/10/08 15:44:003/10/08 15:44:00

Brake piping layout3M, 2 axle Full Trailer - 2 line air brake, Spring brake chambers

41



2 Service Coupling

3 Pipe Filter

4 Shunt Valve


6 Air Reservoir

7 Drain Valve

8 Test Point

9 EB+ Assembly 2 M (Master ECU)

10 EB+ Assembly 1 M (Slave ECU)


12 Single Diaphragm Brake Chamber


14 Park Valve

Fig. 72

Side by Side confi guration, 3 axle Full Trailer - 2 line air brake system - Spring Brake chambers

Emergency

Service

3

4

14

3

5

1

2

12 11

1112

1

1

2

1

1

2

98

8

8

13

13

10

6

7

8

41

41

12

11

11

12

12

21

22

23

23

111

4

4

4

2

2

2

1

2-1

2

12

38891 H:4138891 H:41 3/10/08 15:44:093/10/08 15:44:09


42

Fig. 73

Semi-Trailer and Centre Axle Trailer Installation Option

N1 MAXIMUM length of cable between ISO 1185(24N) connector and front junction box to be 1m.Failure to comply with the above recommendation may result in insuffi cient voltage at the ECU.

SENSOR2 Core - PUR2 x 0.75mm²

ISO 7638 7 Core - PUR5 x 1.5mm²2 x 4.0mm²

Safety back-up2 Core - PUR2 x 1.5mm²

AUXILIARY3 Core - PUR3 x 0.75mm²

(2 cores used)

DIAGNOSTIC4 Core - PUR4 x 0.75mm²

ISO 7638

ISO 1185(24N)

INFO CENTRE or SIDE OF VEHICLE

CONNECTOR

Wiring schematic

38891 H:4238891 H:42 3/10/08 15:44:173/10/08 15:44:17


43

Wiring diagram2 Sensors + ISO7638 & ISO1185 with Info Centre (3 Aux’s fi tted)

Pin1Pin4

ISO 1185 ISO 7638

Interface (DIAG+)

Info Centre

Sensor S1ASensor S1B

Red

+

Bla

ck –

Red

+

Bla

ck –

Red

+

Bla

ck –

A Sensors

B Sensors

Fig. 74

ISO7638 ISO1185 DIAG S1A S1B S2A S2B AUX 1 AUX 2 AUX 3 AUX 4 AUX 5

✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓

38891 H:4338891 H:43 3/10/08 15:44:183/10/08 15:44:18


44

Auxiliary equipment wiring2 Sensors + ISO7638 & ISO1185 with Info Centre & LWS (3 Aux’s fi tted)

Pin1Pin4

ISO 1185 ISO 7638

Interface (DIAG+)

Info Centre

LWS

Sensor S1A

Sensor S2A

Sensor S1B

Sensor S2B

Red

+

Bla

ck –

Red

+

Bla

ck –

Red

+

Bla

ck –

NB2

EB+ External Stability

Accelerometer

A Sensors

B Sensors

ISO7638 ISO1185 DIAG S1A S1B S2A S2B AUX 1 AUX 2 AUX 3 AUX 4 AUX 5

✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓

NB1 - Lining Wear Sensor to be fi tted in AUXs 4 only

NB2 - External Stability Accelerometer to be fi tted in AUXs 5 only

NB1

Fig. 75

38891 H:4438891 H:44 3/10/08 15:44:213/10/08 15:44:21


45

Fig 76 - COLAS®

Fig 78 - Warning lamp

Fig 79 - STEER AXLE LOCK (inc. Reversing axle lock)

Fig 77 - ILAS®-E

BLACK (-)

RED (+)

WARNING LAMP

RED (+)

(+)

BLACK (-)BLA

CK

(-)

RED

(+

)

BLA

CK

(-)

RED

(+

)

AUX AUX

Reverse lamp

Relay 2Relay 1

DIODE (1Amp, 100V Min.)

85 30

8687

85 30

8687

Lock Sol.

Lock Sol.

BLA

CK

(-)

RED

(+

)

BLA

CK

(-)

RED

(+

)

Auxiliary equipment wiring

38891 H:4538891 H:45 3/10/08 15:44:253/10/08 15:44:25

46

Auxiliary equipment wiring

Traction assist is made operative by a 24v (constant or intermittent) supply to the yellow wire in the 3 core auxiliary cable connected to AUX 2 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 130% of the laden

bag pressure

Fig 80 - Traction Assist using ILAS®-E

RED + -

2 Core cable1.5mm²

BLACK

ISO 12098(15 PIN)

12

24v PINK 1.5mm²

Junction Box

YELLOW

BLACK

24v from TruckTraction Assist

switch From AUX 2 or 3

DIN Connector

RED + –

2 Core cable

1.5mm²

BLACK

YELLOW

BLACK

From AUX 2/3

From AUX 2/3Side-of-Vehicle

switch

YELLOW 1.5mm² RED

Junction Box

ILAS®-E

ILAS®-E

Fig 81 - ILAS®-E (Traction Assist - option)

DIN Connector

38891 H:4638891 H:46 3/10/08 15:44:263/10/08 15:44:26

47

Wiring diagramFull System information (911-440-001)

DIAGRAM to be supplied

Fig 82 - Wiring Diagram (911-440-001)

38891 H:4738891 H:47 3/10/08 15:44:263/10/08 15:44:26

48

Hazardous Goods/ADR Installations

Introduction

Vehicles equipped to transport hazardous goods or explosive substances are required to have electrical systems with specifi ed levels of safety and protection. These requirements are defi ned in the European Agreement on International Transport of Dangerous Goods by Road (ADR 2007)’.

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 certifi cate 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 400mm intervals.

NOTE: All cables should run ‘UP TO’ ECU connections.

Brake lamp back-up power supply

The brake lamp power supply can be either ISO 12098 or ISO 1185 (24N) connector. These Connectors MUST BE fully approved for use on an ADR vehicle.

Warning lamps

It is the installers responsibility to ensure that the Green Trailer Warning Lamp if fi tted is fully approved for use on an ADR vehicle.

The warning lamp bulb MUST BE twin pole bayonet type.

Fig 84

Fig 85

Fig 83

ADR/GGVS: ---/----/--

38891 H:4838891 H:48 3/10/08 15:44:363/10/08 15:44:36

49

Junction box

Any wiring required to a junction box (for brake lamp power supply) MUST BE fully approved for use on an ADR vehicle.

Auxilliary connections

It is the installers responsibility to ensure that the Auxiliary component fi tted, the connector and cable MUST BE sealed in accordance with ADR requirements.

Towing vehicles

Towing vehicles in categories EXIII and FL must have a battery master switch fi tted so that all electrical loads including the trailer are connected to the non-battery side of the master switch.

Hazardous Goods/ADR Installations

Fig 87

Fig 86

Screw +‘O’ ring seal

Cable seal

Connector seal

Fig 88

DIN Connector

38891 H:4938891 H:49 3/10/08 15:44:373/10/08 15:44:37

50

Programming

To complete the EB+ installation the ECU must be programmed

using DIAG+ software.

Refer to DIAG+ User Guide 000 700 255 for further information.

38891 H:5038891 H:50 3/10/08 15:44:383/10/08 15:44:38

51

Multimeter readings

Fig. 89 - Sensor connector

Checking position Measure between Correct value Remarks Fig

Sensor output A B 0.2V AC Min Sensor 1A, 1B or 2A, 2B Sensor diconnected from ECU Wheel rotated at 1 rev/2 sec.

86

Sensor resistance A B >1.0 <2.4 kohm Sensor 1A, 1B or 2A, 2B Sensor diconnected from ECU

86

Earth continuity ECU/EPRVBracket and chassis

0 ohms<5 ohms

87

COLAS® Solenoidresistance

+ - >79 <96 ohms Cable disconnected 88 & 90

ILAS®-E Solenoidresistance

+ - >79 <96 ohms Cable disconnected 89 & 91

Fig. 91 - COLAS® connector

Fig. 90 - Earth continuity

Fig. 92 - ILAS®-E connector

BA

0 5

BLA

CK

(-)

RED

(+

)

BLA

CK

(-)

RED

(+

)

Fig. 93 - COLAS® DIN connector Fig. 94 - ILAS®-E DIN connector

A (-)Common

B (+)Output

A (-)Common

B (+)Output

38891 H:5138891 H:51 3/10/08 15:44:383/10/08 15:44:38

www.haldex.comwww.brake-eu.haldex.com

Commercial Vehicle Systems

000 700 340_GB/09.2008/Redditch/10.2008

AustriaHaldex Wien Ges.m.b.H.ViennaTel.: +43 1 8 69 27 97Fax: +43 1 8 69 27 97 27E-Mail: [email protected]

BelgiumHaldex N.V./S.A.Balegem Tel.: +32 9 363 90 00Fax: +32 9 363 90 09E-Mail: [email protected]

BrazilHaldex do BrasilSão PauloTel.: +55 11 213 55 000Fax: +55 11 503 49 515E-Mail: [email protected]

CanadaHaldex LtdGuelph, OntarioTél.: +1 519 826 7723Fax :+1 519 826 9497E-Mail: [email protected]

ChinaHaldex International Trading Co. Ltd.ShanghaiTel.: +86 21 5240 0338Fax: +86 21 5240 0177E-Mail: [email protected]

FranceHaldex Europe SASWeyersheim (Strasbourg)Tel.: +33 3 88 68 22 00Fax: +33 3 88 68 22 09E-Mail: [email protected]

Germany Haldex Brake Products GmbHHeidelbergTel.: +49 6221 7030Fax: +49 6221 703400E-Mail: [email protected]

HungaryHaldex Hungary Kft.SzentlörinckátaTel.: +36 29 631 300Fax: +36 29 631 301E-Mail : [email protected]

IndiaHaldex India LimitedNasikTel.: +91 253 2380094Fax +91 253 2380729E-Mail : [email protected]

ItalyHaldex Italia Srl.Biassono (Milan)Tel.: +39 039 47 17 02Fax: +39 039 27 54 309E-Mail: [email protected]

PolandHaldex Sp. z.o.o.PraszkaTel.: +48 34 350 11 00Fax: +48 34 350 11 11E-Mail: [email protected]

RussiaOOO Haldex RUSMoscowTel..: + 7 495 747 59 56Fax: +7 495 786 39 70E-Mail: [email protected] South KoreaHaldex Korea Ltd.SeoulTel.: +82 2 2636 7545Fax: +82 2 2636 7548E-Mail: [email protected]

SpainHaldex España S.A.Parets del Valles (Barcelona)Tel.: +34 93 573 10 30Fax: +34 93 573 07 28E-Mail: [email protected]

SwedenHaldex Brake Products ABLandskronaTel.: +46 418 47 60 00Fax: +46 418 47 60 01E-Mail: [email protected]

United KingdomHaldex Ltd.Newton AycliffeTel.: +44 1325 310 110Fax: +44 1325 311 834E-Mail: [email protected]

Haldex Brake Products Ltd.RedditchTel.: +44 1527 499 499Fax: +44 1527 499 500E-Mail: [email protected]

USAHaldex Brake Products Corp.Kansas City MOTel.: +1 816 891 2470Fax: +1 816 891 9447E-Mail : [email protected]

Haldex offers proprietary vehicle technology solutions to the global vehicle industry within specifi c niches. We focus on products to improve safety, the environment and vehicle dynamics.

We are enhancing our competitive capabilities and building long-term customer relationships through high performance, low total costs to the customer throughout the product’s service life, ethical business practices and commitment to long-term partnerships. Haldex operations are divided into four business areas: Commercial Vehicle Systems, Hydraulic Systems, Garphyttan Wire and Traction Systems.

©2007, Haldex AB. This material may contain Haldex trademarks and third party trademarks, trade names, corporate logos, graphics and emblems which are the property of their respective companies. The contents of this document may not be copied, distributed, adapted or displayed for commercial purposes or otherwise without prior written consent from Haldex.

38891 238891 2 3/10/08 15:40:253/10/08 15:40:25

Documents

Installation Guide - Well Interparts · Brake and Suspension piping layout - 3 axle 30 Semi-Trailer - 2 line air brake system - with R.E.V - S/D brake chambers ... of the this Installation