NM249 – NM248

INTERNAL SYSTEMS FOR TRAILERS

INSTALLATION MANUAL VERSION 1-2013

ORDER ON-LINE

www.vigia.ca / 1-888 438-8444

IMPORTANT

Installation requires an experienced mechanic with knowledge of tools and equipment identified in

this manual. Installation, disassembly, repairs and maintenance must be performed by an

Authorized Installer. Authorized Installer must use proper protective equipment such as safety

glasses and gloves when installing the system.

Axles must be prepared for the Vigia system according to axle’s manufacturer approved procedures.

Improper installation or use of unauthorized parts can cause malfunctions, loss of tire pressure or

other consequences, which may result in serious injury or death.

Manufacturer or Distributor will be not responsible for injuries resulting from misuse of equipment,

use contrary to operating instructions of this manual or installation by any person other than an

Authorized Installer.

Information contained in this manual is subject to change. Col-Ven S.A. reserves the right, without notice, to make

changes in equipment design or components as progress in engineering, manufacturing or technology may warrant.

World-wide Patents

VIGIA is a trademark of Col-Ven S.A.

TABLE OF CONTENTS 1 - VIGIA Automatic Tire Pressure System

Features - Operation 1 2 – Axle Components

2.1 – Axle Rod – Hollow Axles 2 2.2 – Axle Rod – Solid Axles 4 2.3 – Axle Rod – Hollow Axles with Reinforcing Wall 7 2.4 – Spindle Assembly 10 2.5 – Back Axle Connection 13

3 – Hub Cap, Rotor and Tire Valves

3.1 – Stemco Star – Oil Filled 15 3.2 – Blind Cap – Grease Filled 15 3.3 – Rotor 16 3.4 – Tire Valves 19

4 – HOSE 23

4.1 – Model NM248 -- Coupling between Tractor and Trailer 24 5 – AIR FILTER - MODEL 249 26 6 – CONTROL MODULE – MODEL 249 27

6.1 – Shredded Valve 27 6.2 – Electrical Installation 28

7 – SYSTEM REGULATION – MODEL 249 29 8 – SYSTEM OPERATION – MODEL 249 31 9 – FINAL SYSTEM TESTING 32 10 – RECOMMENDATIONS TO THE INSTALLER 33 11 – FAILURE LOCATION GUIDE 34 APPENDIX – BLIND HUB CAP PERFORATION 38

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Page 23

Page 29

Page 15

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1 - VIGIA AUTOMATIC TIRE PRESSURE SYSTEM Features: It allows for constant and automatic monitoring and adjustment of tire pressure. The system maintains a predetermined cold pressure, even in a moving vehicle or a vehicle with punctured tires. Operation: In the event of even a minimum decrease in the pre-established pressure in one or more tires due to punctures or other causes, the system automatically generates visual signals that inform the driver of the problem. At the same time the system begins pumping air, keeping tire pressures calibrated at the pre-set levels. If the loss of air is substantial, as in the case of a blow-out, and the equipment is not able to compensate for this loss, a visual signal advises the driver. At the same time, an electronic security mechanism blocks the system stopping the supply of air, thus ensuring the normal operation of the other air-driven systems: brakes, suspension, etc. Model NM249 is a stand-alone system for trailers. Model NM248 is a dedicated system for trailers and requires a tractor equipped with VIGIA System. System components, operation and installation procedure are described in the following sections.

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2 – AXLE COMPONENTS IMPORTANT: Axle must be prepared for the Vigia system according to approved procedures. 2.1. Axle Rod - Hollow Axles

a) Insert Lasso Tool into back-axle perforation and extend lasso. Insert brake pipe from spindle’s end. Make sure that brake pipe goes beyond the Lasso Tool.

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b) Pull lasso to grab the brake pipe. c) Insert the Hose 4 mm inside the brake pipe in all its length (approximately 2 m). d) Remove brake pipe and at the same time gently pull the Lasso Tool from the axle grabbing the

Hose 4 mm.

e) Connect Axle Rod (already with pre-assembled Spindle Assembly -see instructions on Section 2.4) to Hose 4 mm. Use Union 4mm – 1/4”.

f) Pull Hose 4 mm from back axle and at the same time guide the Axle Rod with Spindle Assembly to its position in the axle end.

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Continue to 2.4. Spindle Assembly 2.2. Axle Rod – Solid Axles

AXLE’S CENTRE

300 mm

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a) Insert Lasso Tool into back-axle perforation and extend lasso. Insert brake pipe from spindle’s

end. Make sure that brake pipe goes beyond the Lasso Tool.

b) Pull lasso to grab the brake pipe. c) Insert the Hose 4 mm inside the brake pipe in all its length (approximately 2 m). d) Remove brake pipe and at the same time gently pull the Lasso Tool from the axle grabbing the

Hose 4 mm.

e) Connect Axle Rod to Hose 4 mm. Use Union 4mm – 1/4”. f) Pull Hose 4 mm from back axle and at the same time guide the Axle Rod to its position in the axle

end.

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g) Using a pneumatic hammer insert the Axle Rod to the spindle`s end.

Put liquid Teflon on the bottom side of the ringed area of the rod. Flat side of rod must be upwards.

h) Clean excess Teflon over visible areas and install end spindle ``O`` ring.

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Continue to 2.5. Back Axle Connection 2.3. Axle Rod – Hollow Axles with Reinforcing Wall

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a) Insert Lasso Tool into back-axle perforation and extend lasso. Insert brake pipe from spindle’s end. Make sure that brake pipe goes beyond the Lasso Tool.

b) Pull lasso to grab the brake pipe. c) Insert the Hose 4 mm inside the brake pipe in all its length (approximately 2 m).

d) Remove brake pipe and at the same time gently pull the Lasso Tool from the axle grabbing the

Hose 4 mm. e) Insert protective hose into Axle Rod.

PROTECTIVE HOSE

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f) Connect Axle Rod (already with pre-assembled Spindle Assembly -see instructions on Section 2.4) to Hose 4 mm. Use Union 4mm – 1/4”.

g) Pull Hose 4 mm from back axle and at the same time guide the Axle Rod with Spindle Assembly to its position in the axle end.

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2.4. Spindle Assembly Spindle assembly components Measure the axle’s spindle internal diameter to determine the proper Vigia Spindle Assembly to use. Refer to Parts Catalogue.

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To firmly secure Spindle Assembly use End spindle assembly tool and Hexagonal wrench 1"

If necessary use the Shield for Connection-rodNipple - Part X2442.A217-5

When there is a pin, move the End SpindleAssembly to the inside

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Tighten with torque of approximately 50 lbs./ft. All Spindle Assemblies in the trailer must be positioned at the same distance from the spindle`s end.

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2.5. Back Axle Connection

USE TEFLON

LEAVE VENT UPWARD

INSERT FERRET INTRODUCE MOUNTING NUT WITHOUT TIGHTENING

COMPLETELY PULL OUT HOSE WITHOUT STRANGLING

PUSH BACK HOSE 10 TO 15 MM (3/8” TO 9/16”)

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Remove mounting nut, finish back-axle connection and install Venting Tube “J”

TIGHTEN NUT UNTIL HOSE IS FIRMLY SET

CUT FLUSH HOSE

IINSTALL “O” RING AND ELBOW CONNECTOR

IINSTALL VENTING TUBE “J” 5/16”

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3 – HUB CAP, ROTOR AND TIRE VALVES

3.1 Stemco Star - Oil filled

a) Replace original hub cap face with Rotor housing for Stemco hub cap - Star M24 b) Lubricate “O” ring at Axle Rod nipple with grease.

3.2 Blind hub cap - Grease filled

a) Drill original blind hub cap at center with 29mm hole saw. Please see Appendix – Blind Hub Cap Perforation at the end of this Manual. Clean hub cap of any fillings.

b) Install Rotor housing for blind hub cap M 29 L.20 mm using the appropriate tool. Apply Loctite 277.

LOCTITE 277

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3.3 Rotor

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IMOPORTANT: Distance must be between 1 19/64” and 2 ¾” (33 mm and 70mm). For shorter or longer separations use Adjustable Axle Connection Rod. Transport the measurement to the rotor’s blue hose and cut flush.

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Screw rotor completely into its housing without forcing. Make sure the rotor’s blue hose inserts into the Axle Connection Rod nipple. Unscrew rotor until rotor output terminals are oriented towards the inflation valves.

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3.4 Tire Valves VIGIA offers different tire valve versions: a) Hose and Tire valve 50 cm (Fig. 25): for inside tires in dual-tire configurations. b) Hose and Tire valve 30 cm: for outside tires in dual-tire configurations or for single tires.

Outside tires require the Outside tire connector “U” (Fig. 26) Single tires require the Outside tire connector “L” (Fig. 27)

Installation Procedure (Fig.28) 1- Thoroughly clean the external thread of the

original tire valve, preferably with a threading tool.

2- Remove the valve core. If original valve has

extension, remove it. 3- Screw on the Outside tire connector if required,

lightly tightening it with a wrench. 4- Screw on the VIGIA valve, lightly tightening it

with a wrench. 5- Ensure that the tire pressure is lower than the

desired calibrated tire pressure. VIGIA hose and tire valves must not rub against the wheel rims and/or hubs.

Fig. 26 Fig. 27

Fig. 25

Fig. 28

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Connecting Tire Valves to Rotor 1- Insert the Nipples for Rotor (Fig. 29) to the

VIGIA rotor and torque to approximately 2 Lb./Ft.

Fig. 29

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2- Insert the End Hose Connectors (Fig. 31) to the

Nipples for Rotor and torque to approximately 1 Lb./Ft.

3- Extend tire valve hose to the rotor, making sure that it is not touching the rotor mounting, hub or

wheel rim.

Cut tire valve hose and push free end into End Hose Connector nipple.

Fig. 31

Fig. 32

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4- Install the rotor cover. For positions with hub odometers Rotor for Hub Odometer must be used.

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4. - HOSE Given the vast variety of vehicles in the market, the hose installation will be subjected to the installer's criteria. Nevertheless, the following recommendations will facilitate and optimize the installation: 1- Use only the hose provided with the system. 2- Secure the hose approximately every 40 cm (16"). If the fastening is near brake air pipes or

electrical connections, use the straps provided. If the fastening is on the chassis or body, use the special clips and clamps also provided.

3- Drill the required holes with care. Be sure not to damage pipes, tanks, electrical components, etc. 4- Do not install hoses near heat sources (mufflers, heating pipes, etc.) or moving parts (steering,

suspension, cross-arms, etc.). General Diagram (Model NM249)

AIR FILTER

PROTECTION VALVE

CONTROL MODULESHREDDED VALVE

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Connection Procedure The VIGIA system comes with a full range of joints (Fig. 63) to satisfy multiple needs. Connect the Back Axle Connection Sets on both sides of the axle to the supply hose from the Control Module. Use a” T”, Cross Joint or Four Output Joint. The coupling between hose and joints is similar in each case, and a fastening nut is always provided to prevent the hose from being disconnected. 4.1 Model NM248 - Coupling between tractor and trailer (Fig. 64). For this coupling, a connection set is provided (Fig. 65).

Fig. 65

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Installation procedure: a) Affix the fixed connection valve (C) to the trailer, in a

location near the brake hose. d) Insert the hose end with connection valve (D) from the

tractor system to the fixed connection valve (C) (Fig. 66). e) When detaching the tractor from the trailer, disconnect the hose end with

connection valve (D), and connect it to the hose mounting (B) located on the tractor. Place the cap on the fixed connection valve (C) on the trailer.

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5. - AIR FILTER – MODEL NM249 Purpose: To filter the air entering the VIGIA system, retaining solid impurities and water condensation. Location: 1) If available, select a secondary air tank in the trailer. Otherwise, use the only air tank. 2) Locate a plug, connector, hose or coupling on the output line of the tank or distribution line, where a protection valve (provided) will be placed. 3) Determine a location for the air filter on the chassis as close as possible to the tank. Important: Foresee possible movements between the filter and the air tank. Installation procedure Very Important: Use the manual draining of the air tank to depressurize completely. Never unscrew completely an air tank plug. This could produce serious injuries. 1) Install the Vigia Protection Valve with corresponding adapter to air tank. 2) Air Filter: Secure in the selected position with the bolts, washers and nuts provided. 3) 5/16" Hose: Connect protection valve to air filter. Note:

1) The air filter will prevent problems ONLY in the VIGIA system; therefore the air tanks should be drained periodically.

2) The air filter must be purged at least twice a year to ensure proper operation.

3) Maximum allowed pressure: 160 PSI(11.03 BAR).

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6. – CONTROL MODULE – MODEL 249 Mount Control Module underneath the trailer, preferably on reinforcing members between axles. Use the template provided. Important: do not install where Control Module may be exposed to road debris. 6.1. Shredded Valve Install the provided shredded valve close to the Control Module in the “air to tires” 5’16” hose. The shredded valve is used to calibrate the system and check pressure of tires. Shredded valve can be installed on the Control Module support, on the trailer’s frame or using the provided bracket.

Shredded valve Nm145 5/16"X1411.A037-1

Bracket Stainless Steel 21 x 10 mmX1417.A038-6

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6.2. Electrical Installation

LED Housing

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7. – SYSTEM REGULATION – MODEL 249 The following procedure must be done with “cold” tires, that is, at room temperature (22°C) with the unit parked for at least four hours. Tire pressures before regulation must be lower than desired pressure. Make sure that air tank pressure is higher than desired tire pressure.

1- Let the system build pressure until only the green light is on. 2- Check that yellow light does not light up for at least three minutes. Should yellow light blink,

check for leaks in the system before continuing. 3- Check system pressure with a gauge on the provided shredded valve. 4- Locate the adjustment control labeled “OUTLET” at the back of the Control Module. Remove its

cap and use an Allan key to regulate. 5- Turn the adjustment control to the plus sign to increase pressure until the yellow light is on. Wait

until pressure is increased and only green light is on. Check new pressure. If pressure is still below desired, repeat this procedure.

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Intake Sensor The adjustment control labelled “INTAKE” regulates the cut-off air pressure at which the Control Module disconnects itself. This is a safety device and factory-set. DO NOT TOUCH THIS CONTROL. The recommended cut-off pressure is approximately 15 PSI (1.03 BAR) below the minimum compressor operating pressure. The following procedure explains how to set this value if factory set pressure is not appropriate. 1. Set the compressor's air pressure at the desired intake sensor pressure. 2. With the VIGIA system connected:

a) If the red indicator light remains on, adjust (towards the right) the intake sensor adjustment control until the light goes off. b) If the red indicator light is off, loosen (towards the left) the adjustment control until the indicator is on, and then adjust back until the light goes off.

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8. - SYSTEM OPERATION – MODEL 249

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9 - FINAL SYSTEM TESTING (in operation) 1- Verify that there are no air leaks in the system. To detect air leaks, use soapy water and monitor all connections and joints. Note: To facilitate detection of small air leaks, isolate the system network by sections through the use of

plugs. 2 - Verify the operation of the safety mechanism (intake sensor) by producing a very large air leak (For example take a plug out, press the brakes repeatedly, etc.) - The green and red LEDs will be on. 3- Confirm that air is reaching each tire. 4- Verify, after a few minutes, the correct gauge reading with respect to the set calibration. 5- Clean all the working surfaces. 6- Control the adjustment and aesthetics of all the elements. 7- Verify that there are no air leaks in the air filter.

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10 - RECOMMENDATIONS TO THE INSTALLER 1- Explain to the user how the system works. Provide the user with the following elements: User's Manual, Warranty Card, N/F 3/8" plugs, straight joint 5/16", fastening nuts and hose provided with the system. 2- Inform the user that each time a tire is replaced it should have a pressure lower than the calibration pressure. The system only provides air to tires, it does not deflate tires. 3- Remind the user that the excess pressure generated by rolling must not be higher than 12% of the cold calibrated pressure. If the gauges indicate a pressure higher than that percentage, the user must verify whether the pressure is generated due to system failure or by rolling, proceeding as follows:

- Disconnect one or more tires from the system. - Drive until gauge readings for connected tires exceed the specified tolerance. Compare pressures of connected and disconnected tires with a tire gauge. - If the pressures are similar, rolling causes the increase. If pressures differ, there may be damage to the control module. See "Failure location guide".

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11 - FAILURE LOCATION GUIDE – MODEL NM249 To quickly trace an air leak (green and yellow indicators on) disconnect the system: a) If the gauge reading falls quickly, the leak is located in the system network between the VIGIA tire valve and the control module. b) If the gauge reading falls very slowly, the leak is located in the tire or in the VIGIA tire valve. PROBLEM PROBABLE CAUSES SOLUTIONS

Green indicator always on and yellow on during short intervals. With the system disconnected, the gauge reading falls very slowly.

1-Small pressure loss in one or more tires. 2-Small loss between the original tire valve's thread and the VIGIA tire valve.

1 - Repair the affected tire. 2 -a) Adjust the VIGIA tire valves lightly with a wrench. b) Replace the VIGIA tire valve. c) Check the original and VIGIA valves' thread (clean with a threading tool). Replace if necessary.

Green and yellow indicators always on. With the system disconnected, the gauge reading falls slowly.

1-Substantial loss of pressure in one or more tires. 2-Substantial loss of pressure between the original tire valve and the VIGIA tire valve. 3- Air compressor regulator too low.

1-Repair the affected tire(s). 2- a) Adjust the VIGIA tire valve lightly with a wrench. b) Replace the VIGIA tire valve. c) Check the original and VIGIA valves' thread (clean with a threading tool). Replace if necessary. 3- Check the compressor's inflation capacity. Adjust if necessary.

Green indicator always on and yellow indicator on during short intervals. With the system disconnected, the gauge reading falls quickly.

1. Loss of pressure in the system network, between the tire valve and the control module, caused by: a) Worn out or defective rotor. b) Deteriorated hose. c) Couplings, connectors, joints, etc. d) Connection valves between the tractor and the trailer.

1. a) Replace the rotor. b) Replace the affected hose

length. c) Tighten or replace the affected element. d) Replace the seal in the fixed joint valve.

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Green and yellow indicators always on. With the system disconnected, the gauge reading falls quickly.

1.Substantial loss of pressure in the system network, between the tire valve and the control module, caused by: a) Worn out or defective rotor. b) Deteriorated hose. c) Couplings, connectors, joints, etc. d) Connection valves between the tractor and the trailer.

1. a) Replace the rotor. b) Replace the affected element. c) Tighten or replace the affected element. d) Replace the seal in the fixed joint valve.

Gauge indicates more than 12% from the set calibration - with yellow indicator off- after having rolled the unit.

1-Overheating caused by lower calibration than the one set by tire manufacturer. 2-Tire(s) with pressure higher than the one calibrated for the system. 3-Uneven load distribution. 4-Mechanical defects (mallets with worn or broken spring, misaligned axles, etc.). 5-Speeding. 6-Inadequate tires for the type of load. 7-Control module damage.

1-With “cold” tires reset the VIGIA system to the pressure indicated by tire manufacturer. 2-Deflate the tire(s) to a pressure lower than the calibrated one. The system will reset the tire(s) again. 3-Distribute the load correctly. 4-Repair the mechanical defects. 5-Slow down. 6-Replace tires with adequate specifications. 7-Replace control module.

Gauge indicates higher than calibrated pressure, with the yellow indicator on.

1-Calibration altered. 2-Control module damage.

1-Deflate the tire(s) to a pressure lower than the calibrated one and adjust the VIGIA Control module again. 2-Replace Control module.

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With green and yellow indicators on, the system is not inflating.

1- a) Insufficient voltage in the electrical installation. b) The control module voltage does not correspond to the unit's voltage. 2- Control module damage.

1- a) Verify the control module power source, (red positive cable (+)). Modify if necessary. b) Replace control module. 2-Replace control module.

With green and yellow indicators on, the system is not inflating to the set pressure.

1-Insufficient pressure in the air tank (which must be 15 PSI higher than the set pressure) caused by: a) Incorrect tank selection for air supply to the control module. b) Defective compressor operation. c) Compressor cut-off valve with low calibration. 2-Obstructed Air Filter. 3-Strangled connecting hose between air tank and control module. 4-Control module damage.

1- a) Correctly select air tank according to installation instructions for the air filter b) Repair compressor. c) Adjust the compressor cut-off valve. Repair if necessary. 2-Purge the air filter. 3-Replace hose. 4-Replace control module.

Green and Red indicators on.

1-Insufficient pressure in the air tank caused by: a) Incorrect tank selection for air supply to the control module. b) Defective compressor operation. c) Compressor cut-off valve with low calibration. 2-Obstructed air filter.

1- a) Correctly select air tank according to installation instructions for the air filter.

b) Repair compressor. c) Adjust the compressor cut-off valve. Repair if necessary. 2-Purge the air filter.

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3-Strangled connecting hose between air tank and control module. 4-Incorrect intake sensor adjustment. 5-Control module damage.

3-Replace hose. 4-Adjust the intake sensor. 5-Replace control module.

Red indicator on.

1-VIGIA system disconnected. 2-Control module damage.

1-Connect system - press On/Off switch. 2-Replace control module.

Pressure falls and system does not recover - yellow indicator off.

1-Calibration altered. 2-Control module damage.

1-Adjust the VIGIA control module again. 2-Replace control module.

Air from tires leak back to the system.

1-Leak in tire valves.

1-a) Activate the valve's internal piston with a blunt element.

b) Replace tire valve if necessary.

With the system disconnected, the air continues to leak from the control module while disconnecting a hose from the network.

1-Control module damage.

1-Replace control module.

Deflated tire and green light on (indication of correct operation.)

Obstructed rotor, hose, tire valve, connectors or joints.

Replace affected element.

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Appendix - Blind Hub Cap Perforation Drilling must be performed using the Hilti carriage and drill.

Insert the Ø 29 mm hole saw into the drill clutch. Attach to the front of the carriage the mounting disk appropriate to the blind hub cap. Different mounting disk are available for different blind caps Attach the original hub cap to the mounting disk with 3 bolts. Drill at slow speed.

Take the hub cap out and clean.

INSTALLATION MAUNUAL – VIGIA NM249 – NM248

REVISION 1-2013

P.O.Box 1352 – 1500 Avenue Road Toronto, Ontario M5M 0A1 CANADA

Ruta 11 Km.814 - Guadalupe Norte Prov. de Santa Fe (S3574XAB) ARGENTINA

ORDER ON-LINE

www.vigia.ca / 1-888 438-8444