INSTALLATION/SERVICE MANUAL€¦ · with Intelligent Control Module (ITCM) Installation/Service Guide (L31290W) Item Quantity Description A 1 Alarm with auxiliary cable B 1 Bracket

INSTALLATION/SERVICEMANUAL

Brake Monitoring System (BMS) Auxiliary used L31290Wwith Intelligent Trailer Control Module (ITCM)

Patent Numbers8,108,118 B2 - US2,680,569 - Canada2009217438 - Australia

Safety FirstThis manual describes the correct installation process for the Haldex Brake Monitoring System (BMS) used with Intelligent Control Module (ITCM) ECU. Care must be taken during each phase of the installation in order to ensure the system is installed and working properly.

Please follow your company’s safety procedures at all times when installing this equipment. Be sure that you understand all instructions before you begin.

Remove all air pressure and electrical power from the brake system before beginning work.

Handling RequirementsThe Haldex Modular Trailer System (HMTS) with Brake Monitoring System (BMS) requires proper handling prior to and during installation. The HMTS should NEVER be lifted by way of tubing, electrical cables or any components. Lifting MUST only be done by way of the panel itself or the two attached I-beam brackets. Failure to do so may result in loose components and subsequent leakage, leading to panel function degradation or failure.

Questions?If you have any questions on this product or any of the innovative products offered by Haldex, contact your local distributor for complete details. Technical Service or Troubleshooting help can be obtained by calling Haldex Technical Services Department at 800-643-2374, Press 2.

Important Notices

Brake Monitoring System (BMS) Auxiliary used with Intelligent Control Module (ITCM)

Installation/Service Guide (L31290W)

Table of Contents

General Information ................................................................................................2

Kit Contents ..............................................................................................................3

System Overview ......................................................................................................4

Hardware Installation ..............................................................................................5

Software Setup .........................................................................................................6

End of Line Test .......................................................................................................10

Troubleshooting ......................................................................................................11

©2017 All Rights ReservedMaterial may only be reproduced with the written permission of Haldex.

Section Page



The products described within this literature, including without limitation, product features, specifications, designs, availability and pricing are subject to change by Haldex and its subsidiaries at any time without notice. This document and other information from Haldex, its subsidiaries and authorized distributors provide product and/or system options for further investigation by users having technical expertise. It is important that you analyze all aspects of your application and review the information concerning the product or system, in the current literature or catalog. Due to the variety of operating conditions and applications for these products or systems, the user, through their own analysis and testing, is solely responsible for making the final selection of the products and systems and assuring that all performance, safety and warning requirements are met.

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Additional InformationInstallation and Troubleshooting Guides available on the Haldex website.

Intelligent Trailer Control Module (ITCM)Installation/Service Manual (L31286W)https://www.haldex.com/globalassets/north-america/documents/l31286W.pdf

DIAG+ Diagnostic Software Users Guide (L31287W)https://www.haldex.com/globalassets/north-america/documents/l31287W.pdf

Overview

General Information

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Haldex BMS Features:

Haldex BMS Benefits:



The Brake Monitoring System (BMS) is the newest platform in safety products offered by Haldex. The BMS notifies the driver of a Supply Brake Pressure and/or a Service Brake Pressure loss.

The Haldex Brake Monitoring System (BMS) uses a Warning Alarm and a flashing Trailer In-Cab Warning Lamp. BMS is also capable of supplying a 12VDC signal to a GPS (programmable option).

The Haldex Brake Monitoring System (BMS) can be used on Single, Tandem or Multi-Axle Trailers and Single or Tandem Axle Dollies with Service Chambers only or Spring Brake Chambers.

• Monitors Service Brake Pressure• Monitors Supply (Spring) Brake Pressure• Monitors Stop Light Power• Monitors Wheel Speeds on Power Line Communication (PLC)• Monitors Air Systems for incorrect air connections on Trailers/Dollies• Mounted Alarm• Supplies a 12VDC Signal to the GPS (programmable option)

• Warns Driver of Potential Brake Drag (Service and/or Spring Brake)• Warns Driver of Air System Leaks on Service or Emergency Line• Warns Driver of incorrect Gladhand Connections• Warns Driver of False Charging of Trailer and Dolly• Warns Driver of Closed Shut-Off Valve• Warns Driver of False Service Brake Applications from the Tractor

TrailerDolly

Trailer

Haldex BMS Features:

Haldex BMS Benefits:

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Kit Contents



Item Quantity Description

A 1 Alarm with auxiliary cable

B 1 Bracket with hardware to mount alarm to the ECU bracket or frame

C 2 3/8” to 1/4” adapters

D 1 Pressure Switch with auxiliary cable to monitor the Supply Air

E 1 Pressure Switch with auxiliary cable to monitor the Delivery Air

Rear View Front View

Notes:

Attach hoses to appropriate brake chambers. Do Not Use teflon tape on fittings. Use liquid thread sealant sparingly on all fittings. (Loctite PST565 or equivalent.)

For plastic ports, hand tighten fittings then rotate 1 to 1 1/2 additional turns. The maximum torque allowed is 210 in. lb.

If all valve ports are in use, a run tee may be plumbed in line to install pressure switches.

The Haldex Brake Monitoring System (BMS) prevents the driver from initially driving away with the alarm (ON) due to inadequate air pressure to the Trailer or Dolly air system. The driver is required to check the air system for proper glad hand locations and shut-off valve positions on each vehicle.

If an air system problem is present and the alarm remains (ON) while the vehicle is static, power up the towed vehicle(s) and verify there is sufficient emergency (Supply) air to the system.

Verify the towed vehicles have gladhand shut-off valves open with the exception of the rear trailer. The rear of the last trailer requires these gladhand shut-off valves to be closed. Verify there is no delivery air to the system without stoplight power from the tractor.

If an air system problem is present and the alarm remains (ON) while the vehicle is in motion, the In-Cab warning Lamp will flash to warn the driver there is an air system problem.

The driver should find a safe place to pull off the road and verify sufficient emergency (Supply) air to each towed vehicle as well as no delivery air is present to the system without stoplight power from the tractor.

Alarm and Pressure Switch Connections

• The BMS Alarm connects to Auxiliary 3 (A3 on the ITCM ECU).• The Service Pressure Switch (A4/DEL) connects to Auxiliary 4 (A4 on the ECU).• The (Spring Brake Release) Emergency Supply Pressure Switch (A5/SBR) connects to

Auxiliary 5 (A5 on the ITCM ECU).• The Optional GPS signal (if programmed) connects to Auxiliary 2 (A2 on the ITCM ECU).

If the problem is ignored for 10 minutes while the vehicle is in constant motion, a 12VDC signal will notify the GPS system to warn the fleet the problem is being ignored.

System Overview



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PAGE 5

Hardware Installation



Reservoir Mount

Use the hardware provided to fasten the Alarm to the bracket and to fasten the bracket/alarm assembly to the existing ITCM ECU bracket. The Alarm should be facing the reservoir tank.

Frame Mount

The Alarm must be remotely mounted where it can still plug into the ECU.

After the ECU/Valve Assembly is mounted to the frame or reservoir, Refer to Figures 1 and 2 below: 1. Use the 3/8” to 1/4” adapter and screw the Pressure Switch labeled “DEL” to the closest Delivery Port on the Valve. Torque to 10-12 lb. ft. Do Not Use teflon tape on adapter, use liquid thread sealant sparingly. (Loctite PST565 or equivalent). 2. Use the other 3/8” to 1/4” adapter to screw the Pressure Switch labeled “SBR” to the closest Spring Brake Port on the Valve. Torque to 10-12 lb. ft. Do Not Use teflon tape on adapter, use liquid thread sealant sparingly. (Loctite PST565 or equivalent). 3. Remove the green plugs from the ECU Connectors labeled A3, A4 and A5. (Push in on keyed locking tabs.) 4. Connect the Pressure Switch labeled “A5” to the ECU Connector labeled A5. (Verify locking tab location.) 5. Connect the Pressure Switch labeled “A4” to the ECU Connector labeled A4. (Verify locking tab location.) 6. Connect the BMS Alarm Cable labeled “A3/Alarm” to the ECU Connector labeled A3. (Verify locking tab location.)Make certain all three connectors are inserted correctly as there is a locking tab to hold each one in place. Use wire ties to keep the cables tied up away from the ground and sharp metal edges.

Figure 1 ITCM ECU Pin Out

Figure 2 Connecting the Pressure Switches to the Valve and ECU

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Run DIAG+ for Auxiliary Programming (Refer to DIAG+ Diagnostic Software Users Guide - L31287W).

Software Setup



Program BMS by Opening DIAG+ and click on:“Confi gure, Read, Setup and Program the ECU”

Click on “Read Confi guration Information From ECU”

Click on “Edit ECU Parameters and Confi gure”

Click on “Setup Aux Con� guration Data”

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Run DIAG+ for Auxiliary Programming (Refer to DIAG+ Diagnostic Software Users Guide - L31287W).

Software Setup (cont’d)



Use the pull down on AUX 3 OUT and choose BMS Alarm.The BMS Alarm is displayone AUX 3 OUT (marked as A3 On the ECU).The BMS Service Pressure Switch is displayed on AUX 4.The BMS Emergency Pressure Switch is displayed on AUX 5.The BMS Signal to GPS INPUT is displayed on AUX 2 OUT. (You can click on the AUX 2 OUT drop down menu and click on “Unused” if not needed.)

When complete, click on the green check at the bottom.

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Run DIAG+ for Auxiliary Programming Reference L31287W GuideSoftware Setup (cont’d)

Click the Green Check.

Click the to Program the BMS Confi guration into the ECU.

Click Confi rm Send Data to ECU.

Wait for the New Auxiliary Confi guration Parameters to download. The ECU will Reset (Re-Power)when this is complete.

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Run DIAG+ for Auxiliary Programming Reference L31287W GuideSoftware Setup (cont’d)

After the ECU will Resets (Re-Powers), click the Green Check then click to close.

Haldex Modular Trailer System (HMTS)with Brake Monitoring System (BMS)


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Stationary Testing of the Brake Monitoring System (BMS) for proper functionality

End of Line Test

Step 1 Apply 12 Volts DC to the Blue ABS Pin #7 on the 7-Way Connector and verify the external mounted trailer ABS Warning Lamp goes (ON/OFF). The ABS System is OK (No Active ABS Faults). If the ABS Warning Lamp stays ON solid, an ABS Fault is present. Refer to L31286W ITCM Installation/Service Manual.

Step 2 Wait 15 Seconds After ABS Permanent Power is Applied.

Step 3 The BMS Alarm will turn ON with No Emergency Supply Air Applied. If > 85 PSI is present, the BMS Alarm should turn ON for 2.5 seconds and turn OFF. This means the system is functioning properly.

Step 4 Charge the Emergency (Supply) Gladhand to > 85 PSI and verify the BMS Alarm turns OFF. If the BMS Alarm does NOT turn OFF, refer to the troubleshooting section.

Step 5. While the ABS permanent power is still applied, apply 12 Volts to the Stoplight power Pin # 4 on the 7-Way Connector, with NO Service air applied to the Blue Service (IN) glad hand, wait 60 seconds to verify the Alarm turns ON. If the alarm does NOT turn ON, refer to the troubleshooting section.

Step 6. Charge the Service (IN) glad hand to > 6 psi and verify the alarm turns OFF. If the alarm does NOT turn OFF, refer to the troubleshooting section.

NOTE: If the alarm continues to sound after validation of everything listed in the troubleshooting section, go to the troubleshooting section which tests the pressure switches and pressure switch cables as well as the ECU connections.

7-Way Connector

Ground Pin

Blue ABS Pin #7

Red Stoplight Pin #4

Haldex Modular Trailer System (HMTS)with Brake Monitoring System (BMS)


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TroubleshootingIf the BMS Alarm turns ON and the Trailer In-Cab Warning Lamp starts Flashing while the vehicle is moving, first verify the Hand Brake Control Valve or Foot Brake are not slightly on as this can cause the In-Cab Lamp to flash and the BMS Alarm to come ON. If this is not the cause, then find a safe place to pull off the road and STOP. The BMS Alarm and In-Cab Warning Lamp will turn OFF. If this occurs, re-apply power to the Trailer/Dolly with the Tractor parked and release the Trailer/Dolly Parking Brakes, wait 15 seconds and the BMS Alarm should turn ON/OFF.

If the BMS Alarm remains ON, follow the steps below:

Step 1 Verify (Emergency Spring Brake) Supply Pressure - Check Gladhand for proper connections and system air leaks. - Verify Gladhand Shuf-Off Valves are open, except rear most trailer. - Allow sufficient time for the system to fully charge. - Apply Supply Air and verify the Pressure Switch A5/SBR has > 85 PSI. - Check the A5/SBR Pressure Switch is connected to the correct Supply Port and connected to the ITCM ECU Auxiliary Port A5. - Check the system for air leaks.

Step 2 Verify Service (Delivery) Brake Pressure - Apply Service Brakes and check for air at the rear most trailer Service Gladhand. - Check if Trailer Brake Lamps are ON. - With no Service Brakes applied, remove lead trailer Service Gladhand and check for leakage from the tractor Service Gladhand (if using a tractor to test). - Apply Service Brakes and verify the A4/DEL Pressure Switch has > 6 PSI. - Check the A4/DEL Pressure Switch is connected to the correct Service Port and connected to the ITCM ECU Auxiliary Port A4. - Check the system for air leaks.

Step 3 Verify StopLight Power - Apply Service Brakes and check Brake Lamps turn ON at the rear most trailer. - Remove Service Brakes and check Brake Lamps Turn OFF.

Stationary Testing of the Brake Monitoring System (BMS) for proper functionality

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Troubleshooting (cont’d)If all the previous steps have been verified and the BMS Alarm is still ON, testing of the Pressure Switch Cable Assemblies is required.

Step 1 Test the Supply A5/SBR Pressure Switch/Cable Assembly - Park the tractor and shut off the ignition power. - Remove the Cable Connector labeled A5 from the ITCM ECU A5 Auxiliary Port. - Apply > 85 PSI to the Supply Gladhand to test the A5/SBR Pressure Switch/Cable Assembly. - Using an Ohm Meter or Test Light, verify the Connector Terminals on the end of the A5/SBR Cable have an Open Circuit and there is No Continuity. - If the Connector Terminals have a Closed Circuit and Full Continuity, replace the A5/SBR Pressure Switch/Cable Assembly. - Verify at 0 PSI the Connector Terminals on the end of the A5/SBR Cable have a Closed Circuit. - If it’s an Open Circuit with 0 PSI, replace the A5/SBR Pressure Switch/Cable Assembly.

Step 2 Test the Delivery A4/DEL Pressure Switch/Cable Assembly - Park the tractor and shut off the ignition power. - Remove the Cable Connector labeled A4 from the ITCM ECU A4 Auxiliary Port. - Apply > 6 PSI to the Service Gladhand to test the A4/DEL Pressure Switch/Cable Assembly. - Using an Ohm Meter or Test Light, verify the Connector Terminals on the end of the A4/DEL Cable have a Closed Circuit and there is Full Continuity. - If the Connector Terminals have an Open Circuit and No Continuity, replace the A4/DEL Pressure Switch/Cable Assembly. - Verify at 0 PSI the Connector Terminals on the end of the A4/DEL Cable have an Open Circuit. - If it’s a Closed Circuit with 0 PSI, replace the A4/DEL Pressure Switch/Cable Assembly.

Haldex develops and provides reliable and innovative solutions with focus on brake and air suspension

products to the global commercial vehicle industry.

Listed on the Stockholm Stock Exchange, Haldex has annual sales of approximately 3.9 billion SEK and

employs about 2,200 people.

haldex.com

Haldex Brake Products Corporation 10930 N. Pomona Avenue

Kansas City, MO 64153 PH: 816-891-2470 FX: 816-891-9447

Haldex Limited/Haldex Limitée 500 Pinebush Road, Unit 1

Cambridge, ON N1T 0A5 Canada PH: 519-621-6722 FX: 519-621-3924

L31290W US 6/17 WEB ONLY

Documents

INSTALLATION/SERVICE MANUAL€¦ · with Intelligent Control Module (ITCM) Installation/Service Guide (L31290W) Item Quantity Description A 1 Alarm with auxiliary cable B 1 Bracket