Haldex EB+ Gen3 Installation Manual Download Page 110

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EB+ Gen3

Installation guide

110

Innovative Vehicle Solutions

2013

Info Centre 2 / DIAG+ displayed DTC

Possible causes

Wheel sensor 1A or 1B continuity

1A or 1B wheel sensor / wiring open or short circuit

Wheel sensor 2A or 2B continuity

2A or 2B wheel sensor / wiring open or short circuit

Wheel sensor 1A or 1B signal integrity

1A or 1B wheel sensor signal fault

Wheel sensor 2A or 2B signal integrity

2A or 2B wheel sensor signal fault

Wheel sensor 1A or 1B output level

1A or 1B wheel sensor system fault

Wheel sensor 2A or 2B output level

2A or 2B wheel sensor system fault

Brake apply solenoid short circuit

Brake apply solenoid open circuit

Brake apply solenoid short circuit drive

Brake apply solenoid short circuit energised

Brake apply solenoid unspeciﬁed fault

Brake apply solenoid control circuit fault

EPRV 21 or 22 hold solenoid short circuit

Modulator 21 or 22 hold solenoid short circuit

EPRV 21 or 22 dump solenoid short circuit

Modulator 21 or 22 dump solenoid short circuit

EPRV 21 or 22 hold solenoid open circuit

Modulator 21 or 22 hold solenoid open circuit

EPRV 21 or 22 dump solenoid open circuit

Modulator 21 or 22 dump solenoid open circuit

EPRV 21 or 22 hold solenoid short to B+

Modulator 21 or 22 hold solenoid short circuit energised

EPRV 21 or 22 dump solenoid short to B+

Modulator 21 or 22 dump solenoid short circuit
energised

EPRV 21 or 22 hold solenoid unspeciﬁed fault

Modulator 21 or 22 hold solenoid control circuit fault

EPRV 21 or 22 dump solenoid unspeciﬁed fault

Modulator 21 or 22 dump solenoid control circuit fault

EPRV 21 or 22 delivery sensor short circuit

Modulator 21 or 22 delivery transducer short circuit

EPRV 21 or 22 delivery open circuit

Modulator 21 or 22 delivery transducer open circuit

EPRV 21 or 22 slow wheel recovery

Modulator 21 or 22 slow recovery of one wheel

Reservoir sensor short circuit

Reservoir pressure transducer short circuit

Reservoir sensor open circuit

Reservoir pressure transducer open circuit

Excessive reservoir pressure

Reservoir pressure greater than 9.75 bar

Pneumatic demand loss

No corresponding pneumatic demand pressure

Suspension sensor short circuit

Suspension pressure transducer short circuit

Suspension sensor open circuit

Suspension pressure transducer open circuit

Suspension pressure low

Suspension pressure values outside operating range

Slave suspension pressure low

Suspension pressure values outside operating range

REV pressure switch short circuit

Relay emergency valve pressure switch short circuit

REV pressure switch open circuit

Relay emergency valve pressure switch open circuit

REV pressure switch pneumatic fault

Relay emergency valve pressure switch pneumatic fault

REV pressure switch signal fault

Relay emergency valve pressure switch no activation

Slave valve sensor

Pressure transducers open or short circuit

Slave valve modulator

Hold, dump or brake apply solenoid open or short circuit

Slave valve cable

Link cable open or short circuit

Slave valve slow recovery

Slow recovery of one wheel of slave valve

Summary of Contents for EB+ Gen3

Page 1: ...Innovative Vehicle Solutions INSTALLATION GUIDE Electronic Braking System ...

Page 2: ...g aid following supervision of a Haldex engineer b A reminder of the correct procedure of Haldex EB Gen3 installation 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 speciﬁcation without notice No legal rights can be derived from the contents of the manual Duplication tran...

Page 3: ... brake 58 System layout 61 ISO 7638 socket assembly 63 ECU connections 2M 65 ECU connections 3M 68 ECU connectors slide lock 70 ECU connectors Sensor AUX DIAG 78 Auxiliary operation 81 Wiring diagram Gen3 2M 86 Wiring diagram Gen3 3M 87 System drawing layout COLAS 88 System drawing layout ILAS E front 89 System drawing layout steer axle lock 93 Painting 95 ADR installations 96 Programming 98 Syste...

Page 4: ...sists of an electronic control unit ECU modulator assembly containing a brake apply solenoid twin solenoid operated relay valve s and pressure sensors for monitoring the pneumatic control line brake delivery reservoir and air suspension pressure Externally the system comprises two or four wheel speed sensors and optionally a pressure sensor sensing the pneumatic control transmission When used the ...

Page 5: ...utput capability Refer to the auxiliary operations section for the function of the EB Gen3 auxiliaries Feature Standard Premium Wheel speed sensors 2 or 4 2 or 4 Modulators 2 2 or 3 Auxiliary inputs 2 analogue 3 digital 2 analogue 5 digital Auxiliary outputs 3 outputs 1 tacho 5 outputs 1 tacho Super AUX Yes Yes Roll over control Yes Yes Auxiliary power extension No Yes Haldex CAN bus Yes Yes Power...

Page 6: ...onger operational life Connect multiple CAN devices e g TPMS Info Centre or telematics EB Gen3 Standard is a 12 24 V EBS with integrated roll over control intended for ﬁtment to semi and centre axle trailers using full air braking systems with air mechanical suspension Speciﬁcations Integrated quick release valve Integrated anti compound valve Service brake test ports ECU operates 8 32V EMC RFI ap...

Page 7: ...ics EB Gen3 Premium is a 12 24V EBS with integrated roll over control intended for ﬁtment to full semi and centre axle trailers using full air braking systems with air mechanical suspension A top of the range conﬁguration delivers EBS braking with integrated ABS electronic load sensing multiple CAN 3 modulator conﬁguration a range of other inputs outputs to control other functions and now with sto...

Page 8: ... Emergency Valve REV TrCM General components 2M artists impression of layout Driver s information plate customers preference Example only customers preference ISO 7638 7 pin socket assembly Sensor and exciter ﬁtted as required EB Gen3 2M assembly Info Centre 2 customers preference ISO 12098 ISO 1185 24N connector Options ...

Page 9: ...ption Notes 1 EB Gen3 assembly Standard version shown 2 EB label 3 ISO 7638 7 pin socket assembly 4 ISO 12098 ISO 1185 24N Optional safety back up cable 5 Info Centre 2 6 Sensor assembly 7 Exciter 8 COLAS Programmable via DIAG 9 ILAS E Programmable via DIAG 10 Lining Wear System LWS Programmable via DIAG 11 EB external stability sensor Programmable via DIAG ...

Page 10: ...Park and shunt valve Relay Emergency Valve REV TrCM Sensor and exciter ﬁtted as required EB Gen3 3M assembly Driver s information plate customers preference Info Centre 2 customers preference ISO 7638 7 pin socket assembly ISO12098 ISO1185 24N connector General components 3M artists impression of layout ...

Page 11: ...iliary options as per semi trailers 1 6 7 7 6 2B 1B 6 7 6 7 2A 1A 2 4 5 8 Item Description Notes 1 EB Gen3 assembly Premium version shown 2 Slave assembly 3 EB label 4 ISO 7638 7 pin socket assembly 5 ISO 12098 ISO 1185 24N Optional safety back up cable 6 Sensor assembly 7 Exciter 8 3M link cable ...

Page 12: ...3 21 21 1 41 155 mm 135 mm 74 mm 285 mm 30 mm Studs x 3 M10 x 1 5 mm 182 mm Port 3 Delivery test port 21 This way up Port Description Notes 1 Reservoir port M22 x 1 5 mm 3 Exhaust port 4 Control port M16 x 1 5 mm 11 Anti compounding port M16 x 1 5 mm 21 22 Delivery ports M16 x 1 5 mm 21 22 Test point port M12 x 1 5 mm 23 Spring brake port M16 x 1 5 mm 41 Air suspension port M16 x 1 5 mm Standard a...

Page 13: ... up 1 4 22 22 22 22 21 21 23 23 23 23 11 23 23 21 21 1 41 74 mm 182 mm 30 mm Studs x 3 M10 x 1 5 mm Premium assembly Port Description Notes 1 Reservoir port M22 x 1 5 mm 3 Exhaust port 4 Control port M16 x 1 5 mm 11 Anti compounding port M16 x 1 5 mm 21 22 Delivery ports M16 x 1 5 mm 21 22 Test point port M12 x 1 5 mm 23 Spring brake port M16 x 1 5 mm 41 Air suspension port M16 x 1 5 mm ...

Page 14: ...5 mm 3 Exhaust port 4 Control port M16 x 1 5 mm 41 Air suspension port M16 x 1 5 mm Slave assembly 185 mm 185 mm 178 mm Port 3 Port 3 Port 3 Port 3 162 mm 58 mm This way up 4 2 2 2 1 41 2 2 2 Approximate mass of assembly 3 2 Kg Note The EB Gen3 Slave assembly ECU valve is only supplied as one complete unit that cannot should not be separated ...

Page 15: ...le Solutions 2 1 2 2 EPRV S ISO connector end Key Notes applicable to all above diagrams Any axle without directly controlled wheels may be a lift axle Any axle may be a steered axle Semi centre axle trailers side by side SxS System configurations 2S 2M ...

Page 16: ...4S 2M Preferred option Preferred option 2 1 2 2 EPRV S ISO connector end Key Notes applicable to all above diagrams Any axle but only one at a time directly controlled axle may be a lift axle Any axle may be a steered axle Semi centre axle trailers side by side SxS ...

Page 17: ... 1 S1B S1A S1B S1A 2 2 2 1 A 2 2 2 1 A 2 2 2 1 A 2 2 2 1 A S1A S1B A 2 2 2 1 2S 2M A Select Low Valve 2 1 2 2 EPRV S ISO connector end Key Note applicable to all above diagrams Any valve without directly controlled wheels may be a lift axle Semi centre axle trailers side by side SxS select low valve SL ...

Page 18: ...2 2 2 1 A 2 2 2 1 A 2 2 2 1 A 2 2 2 1 S1A S1B A 2 2 2 1 B B A B B B B 2S 2M A Select Low Valve B Relay Valve 2 1 2 2 EPRV S ISO connector end Key Note applicable to all above diagrams Any valve without directly controlled wheels may be a lift axle Semi centre axle trailers side by side SxS select low valve SL relay valve ...

Page 19: ...annot be lifted Any axle without directly controlled wheels not sensed may be a lift axle Any axle may be a steered axle N1 N4 are selectable options set by Haldex or the vehicle manufacturer N1 Adaptive surface control 2 1 ASC N2 Select low 2 1 SL N3 Adaptive surface control 2 2 ASC N4 Select low 2 2 SL Semi centre axle trailers axle by axle ASC front SL rear ...

Page 20: ...t directly controlled wheels not sensed may be a lift axle Any axle may be a steered axle N1 N4 are selectable options set by Haldex or vehicle manufacturer N1 Adaptive surface control 2 1 ASC N2 Select low 2 1 SL N3 Adaptive surface control 2 2 ASC N4 Select low 2 2 SL 2 1 EPRV S 2 2 ISO connector end Semi centre axle trailers axle by axle ASC front SL rear ...

Page 21: ... steered axle N1 N4 are selectable options set by Haldex or vehicle manufacturer N1 Master ECU is mounted to EPRV s 21 22 All sensors must be connected to this Master ECU N2 Directly controlled wheels connected pneumatically to EPRV s 21 22 cannot be lifted N3 Slave ECU is mounted to EPRV 2 and is controlled by Master ECU N4 Slave ECU EPRV 2 is shown facing rear but can also be installed facing fo...

Page 22: ... steered axle N1 N4 are selectable options set by Haldex or vehicle manufacturer N1 Master ECU is mounted to EPRV s 21 22 All sensors must be connected to this Master ECU N2 Directly controlled wheels connected pneumatically to EPRV s 21 22 cannot be lifted N3 Slave ECU is mounted to EPRV 2 and is controlled by Master ECU N4 Slave ECU EPRV 2 is shown facing rear but can also be installed facing fo...

Page 23: ...icable to all above diagrams Sensed axles cannot be lifted Any axle without directly controlled wheels may be a lifted 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 c...

Page 24: ...licable to all above diagrams Sensed axles cannot be lifted Any axle without directly controlled wheels may be lifted 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 co...

Page 25: ...ected pneumatically to EPRV s 21 22 cannot be lifted N3 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 N4 Sensed wheels connected pneumatically to EPRV 2 can be lifted but corresponding indirectly controlled wheels must be lifted in parallel N5 Any axl...

Page 26: ...this Master ECU N2 Directly controlled wheels connected pneumatically to EPRV s 21 22 cannot be lifted N3 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 N4 Sensed wheels connected pneumatically to EPRV 2 can be lifted but corresponding indirectly contr...

Page 27: ...wheels connected pneumatically to EPRV s 21 22 cannot be lifted N3 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 N4 Sensed wheels connected pneumatically to EPRV 2 can be lifted but corresponding indirectly controlled wheels must be lifted in parallel...

Page 28: ...wheels connected pneumatically to EPRV s 21 22 cannot be lifted N3 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 N4 Sensed wheels connected pneumatically to EPRV 2 can be lifted but corresponding indirectly controlled wheels must be lifted in parallel...

Page 29: ...wheels connected pneumatically to EPRV s 21 22 cannot be lifted N3 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 N4 Sensed wheels connected pneumatically to EPRV 2 can be lifted but corresponding indirectly controlled wheels must be lifted in parallel...

Page 30: ...wheels connected pneumatically to EPRV s 21 22 cannot be lifted N3 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 N4 Sensed wheels connected pneumatically to EPRV 2 can be lifted but corresponding indirectly controlled wheels must be lifted in parallel...

Page 31: ...this Master ECU N2 Directly controlled wheels connected pneumatically to EPRV s 21 22 cannot be lifted N3 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 N4 Sensed wheels connected pneumatically to EPRV 2 can be lifted but corresponding indirectly contr...

Page 32: ...this Master ECU N2 Directly controlled wheels connected pneumatically to EPRV s 21 22 cannot be lifted N3 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 N4 Sensed wheels connected pneumatically to EPRV 2 can be lifted but corresponding indirectly contr...

Page 33: ...this Master ECU N2 Directly controlled wheels connected pneumatically to EPRV s 21 22 cannot be lifted N3 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 N4 Sensed wheels connected pneumatically to EPRV 2 can be lifted but corresponding indirectly contr...

Page 34: ... Master ECU N2 Directly controlled wheels connected pneumatically to EPRV s 21 22 cannot be lifted N3 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 N4 Sensed wheels connected pneumatically to EPRV 2 can be lifted but corresponding indirectly controlle...

Page 35: ...RV s 21 22 All sensors must be connected to this Master ECU N2 Directly controlled wheels connected pneumatically to EPRV s 21 22 cannot be lifted N3 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 N4 Any axle without directly controlled wheels may be l...

Page 36: ...ntrolled wheels connected pneumatically to EPRV s 21 22 cannot be lifted N3 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 N4 Sensed wheels connected pneumatically to EPRV 2 can be lifted but corresponding indirectly controlled wheels must be lifted in...

Page 37: ...r ECU is mounted to EPRV s 21 22 All sensors must be connected to this Master ECU N2 Directly controlled wheels connected pneumatically to EPRV s 21 22 cannot be lifted N3 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 N4 Any axle without directly cont...

Page 38: ...r ECU is mounted to EPRV s 21 22 All sensors must be connected to this Master ECU N2 Directly controlled wheels connected pneumatically to EPRV s 21 22 cannot be lifted N3 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 N4 Any axle without directly cont...

Page 39: ...stem is to be mounted within distance X Y from the centre line of the rear axle group bogie includes lift axles The EB Gen3 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 an...

Page 40: ...e shortest delivery pipe lengths The pipe length between the air reservoir and the valve ports 1 x2 should be as short as possible Mount modulator valves centrally to the brake chambers If mounting to stainless steel then a suitable membrane must be used Additional bracket design to be as rigid as possible The mounting ﬁxing must provide an electrical connection between ECU modulator bracket and v...

Page 41: ... as much protection to the assembly from direct spray and other road debris and to achieve an acceptable hose routing Pitch angle assembly must be mounted vertically Deck of trailer To brake chambers To brake chambers Trailer axle Road surface Care should be taken to provide reasonable access to the ECU valve for replacement cables D 150 mm minimum E 1 Assembly to be above axle centre line 2 To be...

Page 42: ...a clip and bracket to secure sensor cable connection The female connector of the sensor cable should always be horizontal or pointing downward to reduce the possibility of water ingress Alternatively sensor cable connection to be positioned on axle or between axle U bolts and supported with cable ties with 50 mm of each end Extension cable plug Sensor cable socket Clip to click Sensor cable Extens...

Page 43: ...cured down the chassis rail in trunking or to piping and should be secured with 300 mm maximum intervals All cables should run up to ECU connections The route of all of the cables from the connector should not start to bend so that the connectors are strained Allow distance of 120 mm minimum before bending of cable Cable should be secured down the chassis rail to existing piping and should be secu...

Page 44: ... than 1 m to be coiled into loops of 100 mm minimum and 150 mm 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 50 mm minimum Cable lengths greater than 1 m to be coiled and then ﬂattened in the centre B to produce a dog bone shape The resulting loops at the end must have a minimum bend radius of 50 mm Cable ties ...

Page 45: ...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 4 Nm 2 3 Ibft ECU connection is as right Cable to run up to connector and secured to the chassis or appropriate cable or pipe runs with cable ties at 300 mm maximum intervals Ensure that the cover is ﬁtted an...

Page 46: ...pipe Nylon 8 x 1 10 x 1 10 x 1 25 12 x 1 5 2 Service pipe Nylon 8 x 1 10 x 1 10 x 1 25 12 x 1 5 3a Reservoir pipe Nylon 8 x 1 10 x 1 10 x 1 25 12 x 1 5 3b Reservoir pipe Nylon 15 x 1 5 15 x 1 5 x 2 off preferred 18 x 2 Short as possible 1 0m max Short as possible 4 0m max 3c Reservoir pipe Nylon 12 x 1 5 4a 4b 4c Brake delivery pipe Nylon or Rubber hose 12 x 1 5 or I D 11 0 I D 13 0 4a 4b and 4c t...

Page 47: ...uide lines only For optimum performance all pipe lengths should be as short as possible Pipe fittings Avoid elbows as much as possible If essential use swept type elbow Inside diameter of ﬁtting should be the same as the inside pipe diameter it is serving On metric parallel thread pipe ﬁtting a backing washer and O ring should be used The use of tape PTFE must not be used Note No pipe sealant or t...

Page 48: ...e 6 Drain valve 7 Test point 8 EB Gen3 assembly 9 Spring brake chamber 10 Single diaphragm brake chamber 11 Test point simulator 12 Suspension bellows Piping layout 2M brake 2M side by side with TrCM Key 1 Port number 1 Components Note EB Gen3 should be supplied with clean dry air 7 1 1 1 3 2 23 24 25 4 4 21 1 2 3 2 2 1 2 10 7 7 9 9 11 12 11 12 11 10 9 9 11 12 11 12 4 22 21 21 41 23 23 22 11 23 22...

Page 49: ... 12 11 7 11 Item Description Notes 1 Emergency coupling Combined coupling ﬁlter available 2 Service coupling Combined coupling ﬁlter available 3 Pipe ﬁlter 4 TEM 5 Air reservoir brake 6 Drain valve 7 Test point 8 EB Gen3 assembly 9 Spring brake chamber 10 Single diaphragm brake chamber 11 Test point simulator 12 Suspension bellows Note EB Gen3 should be supplied with clean dry air Key 1 Port numbe...

Page 50: ...046 001 5 Air reservoir brake 6 Drain valve 7 Test point 8 EB Gen3 assembly 9 Spring brake chamber 10 Single diaphragm brake chamber 11 Test point simulator 12 Suspension bellows 7 2M side by side with combined park shunt valve 1 1 3 2 4 1 2 3 2 22 10 7 7 9 9 11 12 11 12 10 9 9 11 12 11 12 4 22 21 21 23 23 22 11 23 22 1 6 5 6 5 21 23 1 11 1 11 8 41 12 11 11 Key 1 Port number 1 Components Note EB G...

Page 51: ...ir reservoir brake 6 Drain valve 7 Test point 8 EB Gen3 assembly 9 Spring brake chamber 10 Single diaphragm brake chamber 11 Test point simulator 12 Suspension bellows 7 4 2M side by side REV with combined park shunt valve 1 1 3 2 1 2 3 2 22 10 7 7 9 9 11 12 11 12 10 9 9 11 12 11 12 4 22 21 21 23 23 22 11 23 22 1 6 5 6 5 21 23 1 11 2 1 13 4 21 1 2 1 11 8 11 11 41 12 11 Key 1 Port number 1 Componen...

Page 52: ...Test point 8 EB Gen3 assembly 9 Spring brake chamber 10 Single diaphragm brake chamber 11 Test point simulator 12 Suspension bellows 13 Relay Emergency Valve REV 14 Park valve 352 019 xxx 2M axle by axle REV and individual park shunt valves 7 1 1 3 2 1 2 3 2 10 7 7 9 9 11 12 11 12 10 9 9 11 12 11 12 4 22 41 23 23 22 23 1 1 6 5 6 5 11 21 23 22 21 2 1 13 4 2 1 11 8 11 12 4 14 12 2 2 12 1 11 Key 1 Po...

Page 53: ...suspension reservoir 3 Drain valve 4 Pipe ﬁlter 5 Levelling valve 6 Suspension bellows 7 Test point 8 EB Gen3 assembly 9 Test point simulator Piping layout 2M suspension 1 Air supplied from TrCM or TEM or separate pressure protection valve 7 9 3 2 6 6 6 6 6 6 21 22 2 1 1 41 8 7 4 5 2M levelling valve Key 1 Port number 1 Components Note EB Gen3 should be supplied with clean dry air ...

Page 54: ...ension reservoir 3 Drain valve 4 Pipe ﬁlter 5 Levelling valve 6 Suspension bellows 7 Test point 8 EB Gen3 assembly 9 Test point simulator 10 COLAS 2M levelling valve and COLAS Key 1 Port number 1 Components Note EB Gen3 should be supplied with clean dry air 7 10 9 3 2 6 6 6 6 6 6 21 22 2 1 1 41 8 11 21 22 12 1 4 5 7 1 Air supplied from TrCM or TEM or separate pressure protection valve ...

Page 55: ...oir 3 Drain valve 4 Pipe ﬁlter 5 Levelling valve 6 Suspension bellows 7 Test point 8 EB Gen3 assembly 9 Test point simulator 10 COLAS 11 ILAS E 2M COLAS and ILAS E Key 1 Port number 1 Components Note EB Gen3 should be supplied with clean dry air 7 9 3 2 6 6 6 6 6 6 21 22 2 1 1 41 8 11 21 22 12 1 22 11 21 11 10 1 6 5 AUX1 AUX2 4 7 1 Air supplied from TrCM or TEM or separate pressure protection valv...

Page 56: ...spension bellows 7 Test point 8 EB Gen3 assembly 9 Test point simulator 10 COLAS 11 Throttle restrictor Optional upon installation speciﬁcation 12 Double check valve DCV Optional ﬁtment 2M COLAS height limitation option 1 preferred with DCV Key 1 Port number 1 Components Note EB Gen3 should be supplied with clean dry air 4 7 11 9 3 2 6 6 6 6 6 6 2 1 41 8 11 21 1 10 12 AUX1 12 12 2 11 21 22 23 12 1...

Page 57: ...ve With height limitation 6 Suspension bellows 7 Test point 8 EB Gen3 assembly 9 Test point simulator 10 COLAS 11 Throttle restrictor Optional upon installation speciﬁcation 2M COLAS height limitation option 2 without DCV Key 1 Port number 1 Components Note EB Gen3 should be supplied with clean dry air 4 7 11 9 3 2 6 6 6 6 6 6 2 1 41 8 11 21 1 10 12 AUX1 21 22 23 12 1 5 7 22 1 Air supplied from Tr...

Page 58: ...brake 6 Drain valve 7 Test point 8 EB Gen3 assembly Use Premium version 9 Spring brake chamber 10 Single diaphragm brake chamber 11 Test point simulator 12 Suspension bellows 13 EB Gen3 Slave assembly Key 1 Port number 1 Components Piping layout 3M brake 3M with TrCM Note EB Gen3 should be supplied with clean dry air 2 11 11 21 41 1 12 23 21 11 12 23 11 23 23 4 1 41 2 12 11 12 11 1 22 22 1 1 2 21 ...

Page 59: ... Drain valve 7 Test point 8 EB Gen3 assembly Use Premium version 9 Spring brake chamber 10 Single diaphragm brake chamber 11 Test point simulator 12 Suspension bellows 13 EB Gen3 Slave assembly Key 1 Port number 1 Components 3M with TEM 10 13 2 10 8 11 11 11 21 41 1 12 23 21 11 12 7 23 11 23 23 4 7 1 41 2 12 9 9 9 9 11 12 11 12 1 22 22 1 1 3 2 4 1 2 3 2 1 12 1 2 5 6 5 6 7 7 12 4 11 11 Note EB Gen3...

Page 60: ...ter assembly Use Premium version 9 Spring brake chamber 10 Single diaphragm brake chamber 11 Test point simulator 12 Suspension bellows 13 EB Gen3 Slave assembly 14 Relay Emergency Valve REV 15 Park valve Key 1 Port number 1 Components 3M full trailer with REV and individual park shunt valves 7 8 10 11 12 1 1 2 2 1 2 2 1 4 5 4 9 9 10 12 2 11 12 12 13 12 1 14 4 23 11 22 23 1 21 41 1 2 6 5 6 15 7 12...

Page 61: ...ull EBS function EB ABS ELS function only no CAN data bus EB on foot brake application ABS function only System layout The system ﬁtted to your trailer may have 2 or 4 sensors and 2 or 3 modulators EPRV s The variants available being 2S 2M 4S 2M and 4S 3M The system can be powered by the following methods ISO 7638 7 pin Full EBS function ﬁg 1 ISO 7638 5 pin no CAN data bus ABS ELS function only ﬁg...

Page 62: ...tic ISO 7638 7 core PVC 5 x 1 5 mm2 2 x 4 0 mm2 ISO 12098 ISO 1185 24N 2 core PVC 2 x 1 5 mm2 Sensor 2 core PUR 2 x 0 75 mm2 ISO 7638 ISO 12098 ISO 1185 24N Diagnostic 4 core PVC 4 x 0 75 mm2 Info Centre or side of vehicle connector Auxiliary 3 core PVC 3 x 0 75 mm2 2 cores used ...

Page 63: ...batt 2 Black BK 1 5 mm2 B ign 3 Yellow YE 1 5 mm2 B earth 4 Brown BN 4 mm2 B earth 5 White W 1 5 mm2 Lamp 6 White green W GN 1 5 mm2 CAN hi 7 White brown W BN 1 5 mm2 CAN lo ISO 7638 socket assembly ISO 7638 7 pin 10 Max 120 Min 45 º 60 Max 55 Min 60 Min 60 Min 80 Min 50 30 48 70 25 15 24 25 74 90 74 30 37 45 37 15 9 0 8 5 57 0 55 0 ø ø max min max min min min min Clearance dimensions Socket mount...

Page 64: ...rth 5 White W 1 5 mm2 Lamp 6 White green W GN 1 5 mm2 CAN hi 7 White brown W BN 1 5 mm2 CAN lo Towing vehicle EBS ABS ISO 7638 wiring ISO 7638 7 pin 1 2 3 4 5 6 CAN High 7 CAN Low Truck EBS Amber Red Red Fuse 25 30 A 16 A 2A ISO7638 1996 Not fitted on ISO7638 1985 ISO 7638 1996 Not fitted on ISO 7638 1995 Lamp indicator 25 30 A 16 A 2A 6 CAN high 5 4 3 2 1 7 CAN low Fuse Red Amber red ...

Page 65: ...self check procedure the system displays the following functions the trailer EBS warning light comes On and stays On One audible cycle is produced by the EPRV s EBS valves At the same time the led on the USB dongle will illuminate red green to show that is receiving a power supply from the ECU Note It is possible to use the DIAG software to set the ECU parameters with only the power supply ISO 763...

Page 66: ...Sensor S1B Sensor S1A DIAG interface Info Centre 2 B sensors A sensors ISO 7638 ISO 12098 ISO 1185 24N COLAS AUX 1 ILASE E AUX 2 Pressure sensor AUX 5 ISO 7638 ISO 12098 DIAG S1A S1B S2A S2B AUX 1 AUX 2 AUX 3 AUX 4 AUX 5 D D D D D D D D 2 sensors 2 modulators 3 AUX with Info Centre 2 ...

Page 67: ...ing wear sensor to be ﬁtted in AUX 4 only NB2 External stability accelerometer to be ﬁtted in AUX 5 only EB external stability accelerometer NB2 DIAG Interface Info Centre 2 B sensors A sensors ISO7638 AUX 4 AUX 5 TPMS ISO 7638 ISO 12098 DIAG S1A S1B S2A S2B AUX 1 AUX 2 AUX 3 AUX 4 AUX 5 D D D D D D D D D 4 sensors 2 modulators 3 AUX with Info Centre 2 and TPMS ...

Page 68: ...1 2 3 9 10 11 12 13 14 4 5 6 7 8 Make connection to the Slave ECU using the interconnecting cable It is possible to use the DIAG software to set the ECU parameters with only the power supply ISO 7638 and interconnection cable Master to Slave ECU connected But diagnostic codes will be logged and will require to be deleted on the ﬁnal vehicle installation Note The EB Gen3 Slave assembly ECU valve is...

Page 69: ...ons shown Sensor S2B Sensor S1A Sensor S2A COLAS DIAG Interface Info Centre 2 B sensors A sensors ISO7638 ISO12098 ISO1185 24N AUX 1 ILASE E AUX 2 ISO 7638 ISO 12098 DIAG S1A S1B S2A S2B AUX 1 AUX 2 AUX 3 AUX 4 AUX 5 3M D D D D D D D D D 4 sensors 3 modulators 2 AUX with Info Centre 2 ...

Page 70: ... lever G Make sure slider is in the unlocked position H Ensure contact pins and seal are kept clean and free of any contamination prior to installation Push in lock slider M to secure in place all plugs and connectors Do not use extreme force to push in slider Make sure slider is in the lock position N G Slide lock power connectors ...

Page 71: ...onnectors and blanking plugs are fully inserted into the ECU slide lock housing Warning If difﬁculty is encountered in locking the slider check plug or connector for correct ﬁtment If the white o ring is visible the plug is not installed correctly and slider will not lock into position ...

Page 72: ...onnections make sure that all connections socket and plug are clean and dry before assembly Feed all connectors through the chassis with protective cap in place to avoid connector sockets being contaminated ø20 0 min 1 2 3 Remove protective cap from end of connector before connecting into the ECU ...

Page 73: ...ntify orientation of the ISO 7638 blue coloured connector Ensure contact pins and seal are clean and free of any contamination prior to installation In position PWR A on the slide lock housing insert connector fully home Remove the blanking plug from the PWR A position PWR B PWR A 3M ...

Page 74: ...PWR B Connections make sure that all connections socket and plug are clean and dry before assembly Feed all connectors through the chassis with protective cap in place to avoid connector sockets being contaminated ø20 0 min 1 2 3 Remove protective cap from end of connector before connecting into the ECU ...

Page 75: ...rientation of the ISO 12098 ISO 1185 24N black coloured connector 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 connector fully home Remove the blanking plug from the PWR B position PWR B PWR A 3M ...

Page 76: ...onnections make sure that all connections socket and plug are clean and dry before assembly Feed all connectors through the chassis with protective cap in place to avoid connector sockets being contaminated ø20 0 min 1 2 3 Remove protective cap from end of connector before connecting into the ECU ...

Page 77: ...ntify orientation of the 3M link cable yellow coloured connector Ensure contact pins and seal are clean and free of any contamination prior to installation In position 3M on the slide lock housing insert connector fully home Remove the blanking plug from the 3M position PWR B PWR A 3M ...

Page 78: ...e AUX 1 connection Identify the AUX 1 position on the front face of the ECU Locate the locking tag O position With a tool P having a ﬂat end of Ø3 2 mm insert and press in locking tab of plug While depressed pull out plug from housing Identify orientation Sensor black body connector Auxiliary blue body connector Diagnostic black body connector Ensure contact pins and seal are kept clean and free o...

Page 79: ...ning lamp AUX 4 LWS AUX 5 Stability Example sensor 1B Black front case Blue front case Example COLAS Sensor connector Identiﬁcation 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 Auxiliary connector Identiﬁcation tags are incorporated on either side of the auxiliary connector These must be rem...

Page 80: ... Mechanical height sensor remote External pressure sensor AUX 5 Lateral accelerometer General purpose input Control line sensor Soft Docking Mechanical height sensor Mechanical height sensor remote External pressure sensor AUX 2 3 COLAS Retarder Trailer lamp ILAS E front ILAS E rear AUX power Steer axle lock Service lamp Overload lamp Remote overload lamp Stability lamp ILAS E front manual ILAS E ...

Page 81: ...ry Error message an error message will be displayed if an auxiliary conﬁguration is created and sent to an ECU that does not support that function Auxiliary operation Standard AUX STD Connections 3 outputs 2 inputs EB includes by default 5 auxiliary ports for various surrounding functions 3 of these auxiliaries are digital 2 are analogue inputs These amount of inputs and outputs are sufﬁcient for ...

Page 82: ...ystem has been extended by the introduction of the Super AUX The connector includes an additional three digital inputs and 24 V signal supply only use the 24 V signal supply for the Super AUX control switches The control inputs can be linked to any auxiliary feature and this allows very sophisticated applications to be realised in a very simple manner Some examples for controllable auxiliary featu...

Page 83: ...p down box options Always No speed signal referenced Less than and equal to selected km h Greater than selected km h Click on the button to cancel with no modiﬁcations Click on the button to exit and keep the modiﬁcations Inputs A B and C can also be renamed to there intended activation input e g door The required input combination can be achieved by using the drop down boxes for The input signal ...

Page 84: ... 3 are capable to operate two separate functions An example for an extended application could be ILAS E front including TA on AUX 2 steer axle lock on AUX 3 and COLAS RtR on AUX 1 The twin outputs of AUX 2 and AUX 3 are colour coded red and yellow within the DIAG software These colours then match the twin identiﬁers of the cables below Auxiliary connection cables To use the full auxiliary twin fun...

Page 85: ...r later The AUX conﬁguration screen shows the various auxiliary connections that can be used AUX 1 AUX 2 Red AUX 2 Yellow AUX 3 Red AUX 3 Yellow AUX 4 AUX 5 Super AUX Clicking on the drop down arrow displays a list of options that can be selected on that auxiliary Premium AUX example AUX 2 red AUX COLAS AUX 2 yellow AUX ILAS E front AUX 3 red AUX Service lamp AUX 3 yellow AUX Stability lamp ...

Page 86: ...EB Gen3 Installation guide 86 Innovative Vehicle Solutions 2013 Wiring diagram Gen3 2M ...

Page 87: ...EB Gen3 Installation guide 87 2013 Innovative Vehicle Solutions Wiring diagram Gen3 3M ...

Page 88: ...t No Backup Power Option 3 4 AUX3001 00 5 4 7 8 9 10 11 12 14 15 2 Sensor Cable 3m 814 004 401 1 EB Modulator 823 008 001 1 ISO 7638 Cable 12m 814 003 102 1 24N Cable 6m 814 002 222 1 AUX Cable 7m DIN 814 012 201 Example Only Date Colas RtR Air suspension Return to ride height RD BK WH RD Light System ISO 12098 4 Ground B 7 Stop Light 8 Reverse Light 9 Supply B 10 Wear Control free 11 Trailer Brak...

Page 89: ... 4 AUX3002 00 5 4 7 8 9 10 11 12 14 15 2 Sensor Cable 3m 814 004 401 1 EB Modulator 823 008 001 1 ISO 7638 Cable 12m 814 003 102 1 24N Cable 6m 814 002 222 1 AUX Cable 7m DIN 814 012 201 Example Only Date 6 ILAS E Front 1 AUX Cable 1m DIN 814 012 221 Colas RtR Air suspension Return to ride height RD BK RD BK WH RD Light System ISO 12098 4 Ground B 7 Stop Light 8 Reverse Light 9 Supply B 10 Wear Co...

Page 90: ...1 1 EB Modulator 823 008 001 1 ISO 7638 Cable 12m 814 003 102 1 24N Cable 6m 814 002 222 1 AUX Cable 7m DIN 814 012 201 Example Only Date 6 ILAS E Front 1 AUX Cable 1m DIN 814 012 221 ILAS E using side of vehicle switch via GPI 7 Signal 5 s Traction Assist Signal 5 s Lift axle OFF Colas RtR Air suspension Return to ride height RD BK RD BK 1 Switch Cable 7m 815 040 001 WH RD Light System ISO 12098 ...

Page 91: ...7638 Cable 12m 814 003 102 1 SAUX Cable 6m 814 002 301 1 AUX Cable 7m DIN 814 012 201 Example Only Date 6 ILAS E Front 1 AUX Cable 1m DIN 814 012 221 ILAS E using switch in cab via Super Aux Colas RtR Air suspension Return to ride height RD BK RD BK 4 7 8 9 10 11 12 14 15 Super Aux WH Ground B RD Stop Light YE Input A BN Input B GN Input C BK Output 24V Light System ISO 12098 4 Ground B 7 Stop Lig...

Page 92: ...102 1 SAUX Cable 6m 814 002 301 1 AUX Cable 7m DIN 814 012 201 Example Only Date 6 ILAS E Front 1 AUX Cable 1m DIN 814 012 221 ILAS E using side of vehicle and cab switch Colas RtR Air suspension Return to ride height RD BK RD BK 7 Signal 5 s Traction Assist Signal 5 s Lift axle OFF 1 Switch Cable 7m 815 040 001 RD YE Super Aux WH Ground B RD Stop Light YE Input A BN Input B GN Input C BK Output 2...

Page 93: ...012 201 Example Only Date 6 ILAS E Front 2 AUX Cable 1m DIN 814 012 221 ILAS E using side of vehicle and cab switch Steer axle lock using reverse light Colas RtR Air suspension Return to ride height RD BK RD BK 7 Signal 5 s Traction Assist Signal 5 s Lift axle OFF 1 Switch Cable 7m 815 040 001 Lock 1 2 3 6 YE BN GN BK RD WH RD BK Steer axle locking device 4S 3M recommended by Haldex RD YE Super Au...

Page 94: ...ront 2 AUX Cable 1m DIN 814 012 221 ILAS E using side of vehicle and cab switch Steer axle lock using reverse light Colas RtR Air suspension Return to ride height RD BK RD BK 7 Signal 5 s Traction Assist Signal 5 s Lift axle OFF 1 Switch Cable 7m 815 040 001 Lock 1 2 3 6 RD BK Steer axle lock device 9 10 8 8 2 Sensor Cable 6m 814 004 411 1 Gen3 Link Cable 5m 814 041 021 1 Gen3 Slave Valve 810 023 ...

Page 95: ...dequate protection should be used to avoid penetration of the paint or coating All electrical ports to have connectors blanking plugs installed Exhaust ports and connectors locking areas to be masked during painting Painting recommendations water based baking for 1 hour 100o C Mounting face Electro static painting Haldex recommends that the EB Gen3 assembly is ﬁtted to the trailer after electro st...

Page 96: ...key points should be observed on hazardous goods ADR trailer installations Trailer plate The print out of the load plate from the DIAG program must have the ADR GGVS certiﬁcate number as indicated Stop lamp back up power supply The back up power supply is connected using the ISO 12098 connector Cable routes Sensor cable route should not be installed to brake air pipes Do not run sensor leads in sp...

Page 97: ...ngth from the junction box to the ISO 12098 connector must not exceed 4 metres Auxiliary connections It is the installers responsibility to ensure that with any auxiliary component ﬁtted the connector and cable must be sealed in accordance with ADR requirements Towing vehicles Towing vehicles in categories EX III and FL must have a battery master switch ﬁtted so that all electrical loads including...

Page 98: ...tion guide 98 Innovative Vehicle Solutions 2013 Programming To complete the EB installation the ECU must be programmed using DIAG software version 6 or later Refer to DIAG User Guide 000 300 019 for further information ...

Page 99: ... bus using ISO interface assembly 815 018 001 or optional side of vehicle connector or directly to ECU Any suitable device connected to this CAN data bus may read diagnostic information An Info Centre 2 can be connected permanently to the ECU s diagnostic DIAG connection While the ECU is powered information is transferred to the Info Centre s memory which can be recalled Power is supplied from the...

Page 100: ...dating backlight Password pin number Unlock Info Centre 2 pin number unknown Testing Load Wheels sensor cabling check Pressure Plate load plate data Auxiliaries Brake test Lining wear indication A Haldex pc based program DIAG may be used for more advanced diagnosis This also allows conﬁguration with system parameters to be entered and an end of line test to be carried out ...

Page 101: ...able to the EB Gen3 from the ISO 7638 connector then system integrity will not be indicated by the cab mounted warning device As an option to the cab warning device a trailer mounted warning lamp may be provided as an auxiliary function This lamp mimics the signal to the cab warning device but will only function if the ISO 7638 power is connected The signal produced by the trailer warning lamp may...

Page 102: ... a push through condition approx 1 1 The push through condition is cancelled on vehicle movement above 10 km h returning the system to load sensing operation With yellow line pneumatic pressure i e Brakes On park on air Apply foot brake switch Ignition On The system adopts a push through approx 1 1 condition When the brakes are released and re applied the system remains in push through unless the ...

Page 103: ... 24N switch B I Circuit breaker 8 32 volts B Pin 5 Pin 1 Pin 2 Pin 3 Pin 4 B ISO 12098 ISO 1185 24N connector Pin 4 Pin 1 To ensure correct operation of the supply switch test box the B connection must be connected to the trailer chassis 24V 0V 25A Bridge rectifier 3A fuse 110V or 240V AC 200VA 20 sec 4 capacitors 10 000 uF each 40V DC at 2A ripple current A B C D Connect A to C and B to D for 110...

Page 104: ... Sensor disconnected from ECU Wheel rotated at 1 rev 2 sec Sensor resistance A B 1 0 AB 2 4 K Sensor 1A 1B or 2A 2B Sensor disconnected from ECU Earth continuity resistance ECU EPRV Bracket and chassis 0 0 R 5 COLAS 180 R 215 Cable disconnected ILAS E solenoid resistance 180 R 215 Cable disconnected Multimeter readings Sensor connector Earth continuity COLAS connector ILAS E connector COLAS DIN co...

Page 105: ...nt low sensor output group S1A SIGNAL 1A sensor signal fault S1B SIGNAL 1B sensor signal fault S2A SIGNAL 2A sensor signal fault S2B SIGNAL 2B sensor signal fault Loose sensor connection bracket or exciter Damaged exciter Maladjusted sensor or worn sensor cable insulation Low sensor output group S1A OUTPUT 1A sensor signal fault S1B OUTPUT 1B sensor signal fault S2A OUTPUT 2A sensor signal fault S...

Page 106: ...y group EPRV 21 SLOW REC Slow recovery of one wheel of modulator 21 EPRV 22 SLOW REC Slow recovery of one wheel of modulator 22 Slow brake release foundation brake mechanical faults dry bearings broken spring restricted piping Check for kinks and blockages etc Incorrect piping wiring Modulator fault Sensor wiring crossed across an axle EPRV 22 hold and dump solenoid group EPRV 22 HOLD SC Modulator...

Page 107: ...OUT OF RANGE Suspension pressure values outside operating range Pressure switch group REV SWITCH SC Relay emergency valve pressure switch short circuit REV SWITCH OC Relay emergency valve pressure switch open circuit REV SWITCH PNEUMATIC Relay emergency valve pressure switch pneumatic fault REV SWITCH SIGNAL Relay emergency valve pressure switch failed to activate Supply voltage group PWR ISO 7638...

Page 108: ...ircuit Slave valve group SLAVE VALVE SENSOR Pressure transducers open or short circuit SLAVE VALVE MODULATOR Hold dump or brake apply solenoid open or short circuit SLAVE VALVE CABLE Link cable open or short circuit SLAVE VALVE SLOW REC Slow recovery of one wheel slave valve SLAVE SUSP LOW Suspension pressure values outside operating range ISO 11992 CAN electrical signal group PNEUMATIC DEMAND LOS...

Page 109: ... the Info Centre is battery powered Tilt Angle Used to set the tilt angle before the Service LED ﬂashes The Start Screen menu allows the user to choose Info Centre functions to be displayed at start up before the main menu The user can choose 1 from 10 options available s None if selected there will be no start screen s Distance s DTC s AUX s Axle Load Sum s Language s Unlock s Tilt Angle s Tyre P...

Page 110: ...solenoid unspeciﬁed fault Modulator 21 or 22 hold solenoid control circuit fault EPRV 21 or 22 dump solenoid unspeciﬁed fault Modulator 21 or 22 dump solenoid control circuit fault EPRV 21 or 22 delivery sensor short circuit Modulator 21 or 22 delivery transducer short circuit EPRV 21 or 22 delivery open circuit Modulator 21 or 22 delivery transducer open circuit EPRV 21 or 22 slow wheel recovery ...

Page 111: ...l ECU fault ECU EEprom error Internal ECU fault ECU conﬁguration error ECU not programmed ECU EEprom unspeciﬁed error Internal ECU fault ECU shutdown FET Internal ECU fault Lateral accelerometer short circuit Lateral accelerometer wiring short circuit Lateral accelerometer open circuit Lateral accelerometer wiring open circuit Lateral accelerometer signal Lateral accelerometer signal fault AUX 1 A...

Page 112: ...or Check for damage Check for wear clean and readjust Every 3 months or 25 000 miles 40 000 Km Complete system Perform system check out and air leakage test Annually or every 100 000 miles 160 000 km Complete system Sensor Perform system check out and air leakage check Check wiring and piping security and integrity Check for wear clean and readjust Recommend maintenance schedule ...

Page 113: ... B Exciter solid type Available in two sizes to suit differing diameters of wheel Establish correct exciter teeth in relation to tyre size refer to GS0006 100 tooth exciter dynamic effective rolling radius rdyn 442 to 645 mm 80 tooth exciter dynamic effective rolling radius rdyn 357 to 522 mm Heat exciter uniformly to required temperature Fit to hub and ensure that it is fully seated on the locati...

Page 114: ...ousing and insert sensor through the retaining clip pushing it ﬁrmly into place until the sensor abuts against the back face of the bracket housing J With a grease based corrosion inhibitor recommended type Molykote Cu 7439 Plus Dow Corning or from the 4g sachet Haldex part number 042 5857 09 liberally coat sensor l steel casing retaining clip H and bore of bracket housing G Push the retaining cli...

Page 115: ...e Avoid any sharp edges and moving parts The cable exit from the brake torque plate or dirt shield should be via a grommet K Reassemble hub assembly Sensor must be central over the exciter teeth The gap between exciter M and sensor l must not exceed N 0 5 mm Maximum run out of 0 2 mm true indicator reading Before ﬁtment of hub cap cover check sensor output N I M ...

Page 116: ...ould be used as an aid to normal good driving practice The stability function is a safety back up system like the anti lock braking function It uses a lateral accelerometer to determine the level of cornering and as part of its operation it applies brief pulses of brake pressure during normal cornering below a level at which a rollover may occur These pulses may be noticeable to a driver but will ...

Page 117: ...the measurements by radio frequency RF to the receiver control unit RCU The RCU then determines the system status and sends it to the electronic braking system EBS on the trailer CAN bus The EBS then transmits this information to the dashboard which can display the required information of pressure warning alerts and system status for the vehicle driver The system is conﬁgured and diagnosed through...

Page 118: ...on Semi trailer complex installation example Program Gen3 via DIAG without CAN termination Gen3 tab in auxiliary setup if telematics unit has CAN termination Cable description Part number RCU cable rear unterminated 814 040 101 Cable description Part number RCU cable rear unterminated 814 040 001 Splitter cable 814 038 001 DIN telematics cable 814 033 0xx ...

Page 119: ... Gen3 via DIAG without CAN termination Gen3 tab in auxiliary setup Program Gen3 via DIAG without CAN termination Gen3 tab in auxiliary setup Cable description Part number RCU cable unterminated 814 040 001 Splitter cable 814 038 001 Front RCU cable terminated 814 040 2xx Cable description Part number RCU cable unterminated 814 040 001 Splitter cable Qty 2 814 038 001 DIN telematic cable 814 033 0x...

Page 120: ...ervice centres or distributors See page 130 for a complete list of Gen3 assembly part numbers The EB Gen3 Slave assembly ECU valve is only supplied as one complete unit that cannot should not be separated EB Gen3 1M Slave Part number Gen3 1M Slave 810 023 001 EB Gen3 label Part number Label 028 5262 09 Sensor kit Part number Angled inc retaining clip 950 364 503 Straight inc retaining clip 950 364...

Page 121: ... xxx ILAS E Part number Lift axle valve 352 061 xxx Lift axle valve 352 062 xxx Lift axle valve 352 070 xxx TrCM Part number With without safe parking 352 067 xxx TEM Part number With safe parking 352 075 xxx REV Part number With port for control line sensor 351 033 xxx Control line sensor Part number M16 x 1 5 thread for REV port 815 022 001 Main assembly service kits Part number QRV service kit ...

Page 122: ...art number Complete system with acoustic and optical aids 815 024 001 Kit without optical aid 815 025 001 Kit without acoustic aid 815 026 001 Basic kit 815 027 001 Lite kit 815 051 001 Sensor adjusting tool 042 708 309 Lining wear system Part number L 2 m AUX cable standard 815 015 001 Blanking plug std version 027 5260 09 Sensor extension cable 5 m 814 007 111 EB Gen3 stability Part number Exter...

Page 123: ...t contents USB pc interface DIAG 815 023 001 USB cable 042 707 309 Haldex Fleet is the winner of the Trailer Innovation Award 2013 in the Smart Trailer category This pan European awards scheme involving lead ing road transport magazines from ten European countries is held every two years to tie in with IAA Internationale Automobil Austellung com mercial vehicles show in Hannover Germany WINNER CAT...

Page 124: ...8 plug unfused Length 814 004 102 9 m 814 004 112 12 m 814 004 122 15 m 814 004 132 18 m Power A Length 814 009 101 16 m 814 009 111 14 m 814 009 121 12 m 814 009 131 5 m 814 009 141 1 5 m 814 009 151 4 5 m ISO 7638 to 7 pin DIN connector Length 814 003 201 1 m 814 003 211 12 m ISO cable assembly male female Length 814 022 001 30 m ISO power A to 7 pin connector Length 814 026 001 1 5 m 814 026 01...

Page 125: ...nstallation guide 125 2013 Innovative Vehicle Solutions ISO 7638 Diagnostic Length 815 018 001 0 5 m ISO 12098 ISO 1185 24N Length 814 002 301 6 m 814 002 311 12 m 814 002 321 9 m 814 002 331 4 m 814 002 341 1 m ...

Page 126: ...2 10 m Auxiliary cable to DIN connector Length 814 012 201 7 m 814 012 211 18 m 814 012 221 1 m 814 012 231 2 m 814 012 241 5 m 814 012 251 3 m 814 012 261 4 m 814 012 271 10 m Male to female to female 2x2x2 way L1 L2 814 027 001 0 5 m 0 5 m Male to female to female 3x2x2 way L1 L2 814 028 011 4 m 2 m 814 028 001 0 5 m 0 5 m Auxiliary 3 pole to auxiliary 3 pole Length 814 032 001 1 m 814 032 011 4...

Page 127: ...2 m 814 002 321 9 m 814 002 331 4 m 814 002 341 1 m Power B to ISO 15170 Super AUX Length 814 004 301 4 pole 1 m 814 004 311 4 pole 6 m L1 L 2 Power B to ISO 15170 Super AUX L1 L2 814 029 001 4 pole 1 m 1 m 814 029 011 4 pole 6 m 5 m 814 029 021 4 pole 6 m 1 m Sensor cable Length 814 004 401 3 m 814 004 411 6 m 814 004 421 2 m 814 004 431 10 m 814 004 441 14 m 814 004 451 8 m 814 004 461 12 m 814 ...

Page 128: ...Length 814 030 001 6 5 m 814 030 011 2 5 m 814 030 021 5 m 814 030 031 15 m Vehicle to pc interface dongle Length 814 011 001 6 5 m 814 011 011 15 m DIAG to DIN Length 814 033 001 1 m 814 033 011 12 m DIAG to pc interface dongle Length 814 036 001 6 5 m 814 036 011 15 m 814 036 021 20 m DIAG to DIAG Length 814 037 001 6 5 m 814 037 011 0 5 m 814 037 021 8 m 814 037 031 14 m ...

Page 129: ...unterminated 1 2 m 814 040 101 front RCU unterminated 1 2 m 814 040 201 front RCU terminated 1 2 m 814 040 211 front RCU terminated 6 m 814 040 221 front RCU terminated 10 m Y splitter 4x4x4 way Length 814 038 001 0 5 m Sensor cable Length 814 041 001 12 m 814 041 011 2 m 814 041 021 5 m 814 041 031 14 m 814 041 041 10 m 814 041 051 8 m ...

Page 130: ... 5 12x1 5 12x1 5 12x1 5 8x1 8x1 8x1 8x1 8x1 12x1 5 8x1 Plug 8x1 15x1 5 823 034 001 D D D D D M16 M22 M12 M16 M16 M16 M16 M16 M16 M16 M16 M16 M16 M16 M16 M16 M12 M16 M22 823 034 101 D D D D D 8x1 15x1 5 Plug 12x1 5 8x1 12x1 5 12x1 5 12x1 5 12x1 5 8x1 8x1 Plug Plug 8x1 12x1 5 8x1 8x1 8x1 15x1 5 823 034 111 D D D D D 8x1 15x1 5 8x1 12x1 5 Plug 12x1 5 12x1 5 12x1 5 12x1 5 10x1 8x1 8x1 8x1 8x1 12x1 5 P...

Page 131: ...EB Gen3 Installation guide 131 2013 Innovative Vehicle Solutions Notes ...

Page 132: ...l 91 253 6699501 Fax 91 253 2380729 Italy Haldex Italia Srl Biassono Tel 39 039 47 17 02 Fax 39 039 27 54 309 E Mail info it haldex com 2013 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 displ...

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