BPW ECO Tronic EBS Operating And Installation Instructions Download Page 88

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Fig. 157

Fig. 158

DIN connector

Junction box

Any wiring required to a junction box (for brake lamp power
supply)

must be

fully approved for use on an ADR vehicle

(Fig. 157).

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 (Fig. 158).

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

Summary of Contents for ECO Tronic EBS

Page 1: ...ECO Tronic EBS Operating and Installation Instructions Version 1 4 BPW THE QUALITY FACTOR Operating and Instal lation Instructions Version 1 4...

Page 2: ...2 BPW Operating and Installation Instructions...

Page 3: ...38 connections 35 3 2 9 POWER ISO 1185 36 Super AUX connections 3 2 10 DIAG connections 37 3 2 11 DIAG Side of vehicle connection 38 Page 3 2 12 Connectors Blanking plugs 39 3 2 13 Sensor AUX plugs 40...

Page 4: ...ement Basic functions of an EBS Companies which want to transport goods from A to B as safely and ef ciently as possible nd that an EBS is practically essential nowadays This is because EBS offers a w...

Page 5: ...f skidding and tipping over e g when cornering or due to a shifting load is reduced to a minimum thanks to Trailer Roll Stability Lifting axle control Another practical performance feature of EBS is t...

Page 6: ...ed by BPW for the vehicle history ECO Tronic EBS means that you are always precisely informed about the status of your trailers which gives you the perfect tool for optimum eet management For example...

Page 7: ...oad Sensing Load Sensing Valve Function for automatically adapting the braking force to the load of the vehicle EOLT End Of Line Test End of line system check to ensure correct system installation EPR...

Page 8: ...ing protective clothing gloves safety boots safety goggles etc and using the recommended tools The vehicle must be secured against rolling away during repair work Please observe the relevant safety re...

Page 9: ...d with electrical power via the ISO 1185 24N plug if the power supply via the ISO 7638 plug fails In this case only the ABS function and optionally the ALB function are in effect see Fig 3 ECO Tronic...

Page 10: ...the main components and their location in the trailer 1 5 1 Location of components in the trailer Driver s information plate Trailer Monitor Trailer Control Module TrCM modi ed 01 01 2011 optional opt...

Page 11: ...service brake connections which can allow direct connections to the exterior test points Integrated double check valve with distributor An integrated anti compounding spring brake distribution manifo...

Page 12: ...f cient cost effective overall installation package Individual electrical connections The EBS Modulator utilises well recognised sliding connectors and the slide lock mechanism has been improved to al...

Page 13: ...Output TA AUX 4 Lining Wear Sensor General Purpose Input Control Line Sensor Soft Docking Mechanical Height Sensor AUX 5 Lateral Accelerometer General Purpose Input Control Line Sensor Soft Docking Me...

Page 14: ...Notes 1 ECO Tronic EBS label 2 ISO 7638 7 pin connector 3 Safety back up cable ISO 1185 24N or SAUX optional 4 Trailer Monitor side of vehicle connection 5 Modulator 6 ABS sensor 7 Exciter ring 8 COL...

Page 15: ...AILER LIFT AXLE LIFT CLOSE TO LIFT ISO 7638 EBS ABS N 1 Auxiliary cabling termination is given in the table below Wire colour AUX 1 AUX 2 AUX 3 AUX 4 AUX 5 Red 0 V 24 V 0 V 24 V 0 V 24 V 5 V 5 V Black...

Page 16: ...Modulator must be diode suppressed N 7 If the solenoid is not approved by BPW t a 1 A 100 V minimum diode as shown N 8 Pressure sensor can be tted to AUX 4 or 5 2 SLAVE ECU ASSEMBLY Brake Systems AUX...

Page 17: ...9 COLAS 10 Suspension air bags bellows 11 Single diaphragm brake chamber 12 Spring brake chamber 13 Test point 14 Test point if not integrated in COLAS 1 Item 1 Port 1 12 21 1 2 1 1 1 21 21 11 12 11 1...

Page 18: ...1B S1A S2B S2A 21 22 21 22 S2B S2A S2B S2A 22 21 Fig 20 Either but only one directly controlled axle may be lifted 4S 2M Any axle without directly controlled wheels may be a lift axle 2S 2M Any axle m...

Page 19: ...ly controlled wheels may be lifted Any axle can be a steered axle Master ECU is mounted to EPRV s All sensors must be connected to this Master ECU Directly controlled wheels connected pneumatically to...

Page 20: ...mmended for self steered axle 2S 2M Modulators ECU power connectors Key 22 21 S1B S1A S1B S1A 22 21 21 22 S1B S1A 21 22 A A A S1B S1A 22 21 A S1B S1A 22 21 A A S1B S1A 21 22 A Select low valve SL Fig...

Page 21: ...s 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 23 Modulator...

Page 22: ...required installation option con guration of the trailer See Figs 20 to 23 The distance between port 1 and the air reservoir should be as short as possible Fig 24 Mount the Modulator centrally to the...

Page 23: ...bar trailer 3 0 m 1 5 m The Modulator has to be mounted inside the main left hand LH and right hand RH chassis members of the vehicle Fig 29 For any other applications please refer to BPW Bergische Ac...

Page 24: ...22 x 1 5 3 Exhaust port 4 Control port M 16 x 1 5 11 Double Check Valve DCV M 16 x 1 5 21 22 Delivery ports M 16 x 1 5 21 22 Delivery test ports M 12 x 1 5 23 Spring brake port M 16 x 1 5 41 Air suspe...

Page 25: ...Modulator Weight approx 3 5 kg 185 mm 58 mm 161 5 mm 26 6 mm 41 6 mm 107 35 mm 27 25 mm 27 65 mm 55 3 mm 41 6 mm 107 35 mm 27 25 mm 27 65 mm 55 3 mm 132 6 mm 185 5 mm 178 mm Fixing bolts x 4 M 8 x 1...

Page 26: ...ig 32 Adequate protection should be used to avoid penetration of the paint coating All electrical ports have to be closed by connectors blanking plugs All pneumatic ports have to be closed by pipe tti...

Page 27: ...ine 2 The position should be as high as possible in the frame Position the Modulator as high as possible in the chassis to provide optimum protection from direct spray and other road dirt and also to...

Page 28: ...d not exceed 4 m Failure to comply with the above recommendation may result in insuf cient voltage at the ECU Sensor 2 Core 2 x 0 75 mm ISO 7638 7 Core 5 x 1 5 mm 2 x 4 0 mm Safety back up 2 Core 2 x...

Page 29: ...ensor S1A Sensor S1B Red Black Red Black Red Black B Sensors A Sensors Fig 38 2 Sensors ISO7638 ISO1185 with Trailer Monitor 3 AUX s tted ISO7638 ISO1185 DIAG S1A S1B S2A S2B AUX 1 AUX 2 AUX 3 AUX 4 A...

Page 30: ...kit A Sensors B Sensors NB1 Lining Wear System to be tted in AUX 4 only NB2 External acceleration sensor to be tted in AUX 5 only NB1 ISO7638 ISO1185 DIAG S1A S1B S2A S2B AUX 1 AUX 2 AUX 3 AUX 4 AUX 5...

Page 31: ...ete loop may be left to hang in partial loops having a cable bend radius of 50 mm minimum Cable lengths greater than 1 m to be coiled and then attened in the centre Fig 41 2 to produce a dog bone shap...

Page 32: ...7638 socket clear from the trailer headboard to undo the gland nut Fig 44 Clearance dimensions Fig 45 Socket mounting dimensions Fig 46 Pin No Designation 1 Red RD 4 mm2 Plus electro valve 2 Black BK...

Page 33: ...the box from incorrect location On mounting ensure cable runs are up to the junction box Fig 47 Drain hole to be shielded by chassis as shown to provide as much protection from direct spray and other...

Page 34: ...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 50 PWR A PWR...

Page 35: ...nd free of any contamination prior to installation PWR A ISO 7638 connection Make sure that all connections socket and plug are clean and dry before assembly Fig 53 Identify orientation of the ISO 763...

Page 36: ...loured connector or the black SAUX connector Fig 56 Ensure contact pins and seal are clean and free of any contamination prior to installation In position PWR B on the slide lock housing insert connec...

Page 37: ...on Option 2 If a remote mounted Trailer Monitor is installed remove blanking plug Fig 58 Identify orientation of the diagnostic green coloured connector Fig 59 Ensure contact pins and seal are clean a...

Page 38: ...om raised markings or surface imperfections which may prevent ush tting of the connector The connector must be mounted horizontally Tighten nut Fig 61 1 to a torque of 3 4 Nm ECU connection is as Fig...

Page 39: ...rs Note Do not use extreme force to push in slider Make sure slider is in the lock position Fig 64 2 WARNING If dif culty is encountered in locking the slider check plug or connector for correct tment...

Page 40: ...nent S1A Sensor 1A S1B Sensor 1B S2A Sensor 2A S2B Sensor 2B Auxilliary Plug Identi cation tags are incorporated on either side of the Auxilliary connector Fig 67 These must be removed to identify the...

Page 41: ...tag position Fig 69 arrow With a tool having a at end of 2 3 mm insert and press in locking tab of plug While depressed pull out plug from housing Fig 70 Identify orientation of the Sensor black body...

Page 42: ...falling out with axle vibration Fig 72 Where possible use a clip and bracket to secure sensor cable connection Fig 73 Alternatively Sensor cable connection to be positioned on axle or between axle U b...

Page 43: ...e chassis rail on piping and should be secured at not more than 400 mm intervals NOTE All cables should run up to connector Position rubber seal Fig 75 1 in position shown 3 2 16 COLAS ILAS E connecti...

Page 44: ...76 Fig 78 Fig 79 Black Red Red Black Black Red Black Red AUX AUX Reverse lamp Relay 2 Relay 1 Diode 1 A 100 V min 85 30 86 87 85 30 86 87 Lock Sol Lock Sol Warning lamp Steer axle lock incl reversing...

Page 45: ...lifts The front axle drops when either The vehicle speed exceeds 30 km h or The suspension pressure reaches more than 130 of the laden bag pressure Fig 80 2 Core cable 1 5 mm ISO 12098 15 Pin 12 24 V...

Page 46: ...tance A B 1 0 k R 2 4 k Sensor 1A 1B or 2A 2B Sensor disconnected 83 Earth continuity ECO Tronic EBS bracket and chassis 0 R 5 84 COLAS Solenoid resistance 79 R 96 Cable disconnected 85 ILAS E Solenoi...

Page 47: ...47...

Page 48: ...ailer Control Module spring brake chambers and suspension air bags bellows 1 Item 1 Port 21 1 2 1 1 1 21 21 11 12 11 12 11 12 11 12 1 22 22 4 11 23 23 23 22 4 23 23 1 1 22 1 21 41 24 25 22 1 22 12 21...

Page 49: ...stic or Rubber hose 12 x 1 5 Pref I D 11 0 Alt I D 13 0 Alt 4a and 4c to be similar in length 4b to be as short as possible 5a 5b Brake pipe FBA Plastic or Rubber hose 8 x 1 Pref I D 11 0 Alt 6a 6b Su...

Page 50: ...chamber 9 Single diaphragm brake chamber 10 Test point 11 Suspension air bags bellows 4 2 1 2M 3 axle semi trailer side by side Emergency Service 1 2 3 6 7 9 8 8 4 5 21 1 2 1 1 1 21 21 11 12 11 12 11...

Page 51: ...Additional Modulator 1 M 9 Spring brake chamber 10 Single diaphragm brake chamber 11 Test point 12 Suspension air bags bellows 4 2 2 3M 3 axle semi trailer Emergency Service 1 2 3 6 7 9 9 4 5 21 1 2...

Page 52: ...lator 1 M 9 Spring brake chamber 10 Single diaphragm brake chamber 11 Test point 12 Suspension air bags bellows 4 2 3 3M 2 axle drawbar trailer full trailer Emergency Service 4 2 Brake piping layout F...

Page 53: ...alve 5 Lift cylinder 6 Test point if not integrated in COLAS 7 Modulator 8 Suspension air bags bellows 9 COLAS Air suspension leveling valve COLAS and ILAS E Fig 90 3 axle semi trailer COLAS with auto...

Page 54: ...to the brake cylinders of the braked axles Connection lines between the towing vehicle and the trailer uncoupled or broken away If the supply line is uncoupled or breaks away the trailer brake contro...

Page 55: ...nnected to a brake coupling head This means they cannot be wrongly connected Installation Guidelines The supply coupling head red is installed in the driving direction to the right and the brake coupl...

Page 56: ...ng connection 3 This reduces pressure in the spring brake system and activates the parking brake system Pushing the red control button couples the spring brake system connection 22 to the air supply t...

Page 57: ...ary loads as well are lled to a pressure reduced by the over ow loss The lling of the secondary loads depends upon reaching the opening pressure of the integrated charging valve An empty partially lle...

Page 58: ...n must switch to the operating position jump out 3 Automatic emergency brake Lower the pressure at connection 1 to 0 bar The emergency brake connection 21 must be automatically activated 4 Pressure li...

Page 59: ...e limit valve DIN 74279 C 6 22 Opening pressure pe approx 6 2 bar Closing pressure pe approx 5 2 bar Connection designations Thread 1 Energy ow coupling head supply M 22 x 1 5 1 2 Energy release ow ta...

Page 60: ...re of at least 5 0 bar is available in the supply reservoir Fig 104 Release device for service braking system Fig 105 106 The shunt valve black button makes it possible to release the automatic brakin...

Page 61: ...rough the integrated double check valve As a result the pressure at ports 21 2 and 1 2 is the same If the pressure in the supply reservoir falls further ports 21 and 2 are vented at the same time this...

Page 62: ...e black button must switch to the operating position jump out The parking valve red button remains pushed out 3 Automatic emergency brake Lower the pressure at connection 1 to 0 bar The emergency brak...

Page 63: ...Selection is effected without the wheels having to be taken off by using the Trailer Monitor or Trailer Manager diagnostic tools The system is connected to special indicators of the brake linings If...

Page 64: ...safety This high roll stability characteristic is achieved because the body is supported when cornering not only by the air bags but also by the stabilising effect of the axle beam to trailing arm co...

Page 65: ...The pneumatic connections are made via a reserve connector 1 two energy out ows 21 and 22 as well as via the vent 3 When in the resting state the valve is said to be in the so called nishing position...

Page 66: ...3 bar Permitted dyn bellow pressure pe max 20 bar Operating temperature 45 C to 85 C Operating range charging and exhausting 45 Side of control on the left and on the right Dead angle at 7 8 bar 2 Con...

Page 67: ...ontal position depend to version and x it with a locking pin d 4h8 on housing and on bore of the spindle Statutorily prescribed max heights must be adhered to Please see the BPW documentation for air...

Page 68: ...12 to port 23 and so ends the lifting action Operating pressure dyn pe max 13 bar Permitted dyn bellow pressure pe max 20 bar Operating temperature 40 C to 80 C Operating range charging and exhaustin...

Page 69: ...s excursion of the control lever from the horizontal in degrees Then re t the dump valve Inspection Check function and leak The pressure should neither rise nor fall at the delivery ports in the neutr...

Page 70: ...3 Air suspension valve with zero point adjustment dimensions and connections Discharging Charging M8 10 48 66 G2 G2 24 57 5 92 G2 104 50 40 G2 max 320 min 80 Identification mark for the lever mounting...

Page 71: ...oint setting 320 300 260 2 5 3 5 4 5 220 180 140 100 60 20 280 240 200 160 120 80 40 0 Fig 126 Change of the body height depending on the level length at zero point setting Piping diagram Fig 125 5 2...

Page 72: ...ction and the lever remains xed in the rotated position after it is released Connections 21 22 and 3 remain coupled to each other The air bags are continuously vented This venting is for example requi...

Page 73: ...nut clockwise to make certain that it is correctly attached and locks in to ensure optimum sealing An electrical connection to the solenoid valve is permissible only via the ECO Tronic EBS ECU which p...

Page 74: ...e ections can lead to individual components being damaged For painting tasks protect all open plug connections and the venting with suitable covers against penetration by paint After painting remove t...

Page 75: ...with push in ttings When assembling the air pipes care should be taken to ensure that the pipes are cut square to the required length and are free from burrs Inspection Check function of unit and sec...

Page 76: ...ir bag respect lifting cylinder of axle lift device 5 2 5 ILAS E Identi cation of ports and xings 65 mm 41 mm 18 4 mm 9 2 mm 14 mm 17 mm 67 mm 34 mm 137 mm 204 mm 40 5 mm 49 5 mm 1 11 22 2 21 2 22 1 2...

Page 77: ...ion with exhaust is installed for this Principle of operation In the shut position the handle is at right angles to the ow direction transverse to the line and the passage is blocked If the handle is...

Page 78: ...ple for controlling steering axle blocks or for zero point adjustment in the case of air suspension valves with a 2nd driving height in air suspension systems Fig 137 5 2 7 3 2 Ways magnetic valves 3...

Page 79: ...ck exhausting the air 6 Lock cylinder for steering axle 7 Test point if not integrated in COLAS 8 Modulator 9 Suspension air bags 10 COLAS 5 2 8 Example of an application of a steering axle block with...

Page 80: ...Silent mode for night deliveries The system cannot replace the driver s responsibility to ensure a clear passage when manoeuvring BPW cannot be held responsible for any accidents encountered when usin...

Page 81: ...e junction box and are safely installed Installation of LED Outline Marker Light The new LED outline marker lights has to be assembled in the same locations as the old lamp ensure that the lights can...

Page 82: ...cable Insert cable through spare entry of existing junction box Connect wires as appropriate Ensure waterproof installation Contact allocation black tail light left grey reverse light brown tail light...

Page 83: ...uency 3 meters 2 0 3 0 meters Permanent Tone Lamp 8 Beeps per sec 8 Hz Flashes 5 Beeps per sec 8 Hz Flashes 3 Beeps per sec 3 Hz Flashes No Beep Flashes 0 5 meters 0 5 1 0 meters 1 0 2 0 meters Please...

Page 84: ...the sensor is 10 horizontal and vertical By rotating the screw clockwise the housing will be inclined in the direction of the rotated screw Fig 149 Adjusting the sensors Fig 150 Adjusting with an obs...

Page 85: ...sensors a fault has occurred 3 Three yellow LED s indicates an error code which describes the type of default Error code 2 1 0 Possible reasons Repair Sensor cable break Change sensor Defect on head o...

Page 86: ...ome materials like textiles weaken the ultrasonic signals signi cantly reducing the sensing distance Conditions of no detection The system will not detect the dock when the vehicle is not in reverse S...

Page 87: ...ensor cable route should not be installed to brake air pipes Do not run sensor leads in spiral wrapping on hoses Cables should be securely fastened to prevent abrasion and positioned to protect agains...

Page 88: ...he installers responsibility to ensure that the auxiliary component tted the connector and cable must be sealed in accordance with ADR requirements Fig 158 Towing vehicles Towing vehicles in categorie...

Page 89: ...complete the ECO Tronic EBS installation the ECU must be programmed by using the Trailer Manager software Refer to Trailer Manager Operator s Guide BPW BA TM 37071102e for further information 7 Progra...

Page 90: ...90...

Page 91: ...Trip distance in km Distance and time to next service Information Active DTC s DTC Diagnostic Trouble Codes Stored DTC s Con guration of the trailer Version of the ECU Pressure values of the sensors i...

Page 92: ...sensors completed Option B Fig 164 ON for 2 seconds Warning lamp OK and system self checking OFF for 2 seconds System self checked and preparing to check sensors ON until moving System waiting for veh...

Page 93: ...the following occurs With no yellow line pneumatic pressure i e Brakes OFF The system adopts automatic load sensing mode when the brakes are applied This load sensing mode is limited to 2 minutes for...

Page 94: ...T Brake apply solenoid open circuit BRAKE APPLY SOLENOID SHORT TO B Brake apply solenoid short circuit permanently energised BRAKE APPLY UNSPECIFIED FAULT Brake apply solenoid control circuit fault EP...

Page 95: ...UIT Reservoir pressure transducer open circuit EXCESSIVE RESERVOIR PRESSURE Reservoir pressure above 9 75 bar DTC Displayed Description Air Suspension Pressure Transducer Group SUSPENSION SENSOR SHORT...

Page 96: ...ing open short circuit or unknown AUX3 Auxiliary 3 system wiring open short circuit or unknown AUX4 Auxiliary 4 system wiring open short circuit or unknown AUX5 Auxiliary 5 system wiring open short ci...

Page 97: ...omplete system Perform system check out and air leakage check Annually or every 160 000 km Complete system Perform system check out and air leakage check Check wiring and piping security and integrity...

Page 98: ...98 Notice...

Page 99: ...99...

Page 100: ...BPW Bergische Achsen Kommanditgesellschaft P O Box 12 80 D 51656 Wiehl Phone 49 2262 78 0 info bpw de www bpw de BPW EA EBS 37041103e...

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