installation guide

installation guide
INSTALLATION GUIDE
Soft Docking
Innovative Vehicle Solutions
EB+ Soft Docking
Installation
guide
Notes on the use of this manual
This manual has been designed to assist personnel in
satisfactory installation of Haldex EB+ Soft Docking
onto trailers. The intention has been to illustrate
various aspects of the installation. It is expected that
this manual will be in possession of the appropriate
person throughout their ‘training’ and ‘experience’ and
that the manual will be used as:
a) A teaching aid following supervision of a Haldex
engineer.
b) A reminder of the correct procedure of Haldex
EB+ Soft Docking 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, translation and reprinting are prohibited
without permission from Haldex Brake Products
For any other deviation consult
Haldex Brake Products Ltd.
MIRA Technology Park
Lindley
Warwickshire
CV13 6DE
Tel: +44 (0) 2476 400 300
Fax: +44 (0) 2476 400 301
E-Mail: [email protected]
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EB+ Soft Docking
Contents
Introduction ............................................................... 4
Chassis components .................................................. 5
Sensor cables ........................................................... 12
Installation of EB+ Soft Docking ECU ....................... 14
Installation of LED outline marker light ..................... 15
Installation of audio beeper...................................... 16
Installation of power supply adapter cable ............... 17
Installation of ultrasonic sensor ................................ 18
Configuring EB+ Soft Docking using DIAG+ ............. 23
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Functional test ......................................................... 42
Operating instructions.............................................. 43
Conditions of no detection ...................................... 44
Error repair .............................................................. 46
Liability exclusion ..................................................... 47
Excess cable ............................................................. 48
Painting ................................................................... 49
Part reference .......................................................... 50
Innovative Vehicle Solutions
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EB+ Soft Docking
Installation
guide
Introduction
EB+ Soft Docking is a system for detecting the presence of a dock (‘ramp’ or ‘loading bay’) within 2.5 m, warning
the driver of the distance via flashing side marker lights and audio beeper at a rate dependent on distance and
automatically applying the brakes to halt the vehicle (or reduce the impact speed) at 1 m from the dock.
The system consists of an ECU and from 2 to 5 ultrasonic sensors, additional software for the EB+ ECU, side
marker lights, audio beeper and cables to link the components together. The EB+ Soft Docking ECU is controlled
from the Haldex CAN B+ / B- and communicates with the EBS via Haldex CAN.
Before using the EB+ Soft Docking system please read the description and the operation instructions carefully. The
system cannot replace the driver’s responsibility to ensure a clear passage when manoeuvring. Haldex cannot be
held responsible for any accidents encountered when using the system.
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EB+ Soft Docking
Chassis components
2 sensors (1 plane, 1 offset
3
4
7-1
7-2
7-2
7-1
6
2
Green sensor
channel
Cable connections for item no.2
Cables colour
Yellow sensor
channel
5
1
Function
Grey
Reverse light
White
Earth / common
Black
Left tail light
Brown
Right tail light
Where indicated, if necessary use the
appropriate length of sensor extension cable
(364 622 xxx, see page 12) to reach the
sensor location.
=
1
Item
Description
EB+ Soft Docking ECU
Part number
364 608 001
2
Outline marker and brake cable (open wires)
364 606 001
3
LED outline marker lamp (left)
364 617 001
4
LED outline marker lamp (right)
364 617 011
5
Sensor and audio beeper cable
364 605 001
6
Audio beeper
364 616 001
7-x
Ultrasonic sensor
364 614 001
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Notes
Green connector on ECU
Brown connector on ECU
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EB+ Soft Docking
3 sensors (1 plane, 1 offset)
3
7-2
4
7-3
7-1
7-2
7-3
7-1
8
6
2
Green sensor
channel
Where indicated, if necessary use the
appropriate length of sensor extension cable
(364 622 xxx, see page 12) to reach the
sensor location.
Yellow sensor
channel
5
1
Item
Description
1
EB+ Soft Docking ECU
Part number
364 608 001
2
Outline marker and brake cable (open wires)
364 606 001
3
LED outline marker lamp (left)
364 617 001
4
LED outline marker lamp (right)
364 617 011
5
Sensor and audio beeper cable
364 605 001
6
Audio beeper
364 616 001
7-x
Ultrasonic sensor
364 614 001
8
Sensor splitter cable
364 607 001
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=
Notes
Green connector on ECU
Brown connector on ECU
0.5 m / 0.5 m / 0.5 m
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Installation
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EB+ Soft Docking
3 sensors (1 plane, 2 offsets)
3
4
7-1
7-3
7-1
7-2
7-2
7-3
8
6
2
Green sensor
channel
Where indicated, if necessary use the
appropriate length of sensor extension cable
(364 622 xxx, see page 12) to reach the
sensor location.
Yellow sensor
channel
5
1
Item
Description
1
EB+ Soft Docking ECU
Part number
364 608 001
2
Outline marker and brake cable (open wires)
364 606 001
3
LED outline marker lamp (left)
364 617 001
4
LED outline marker lamp (right)
364 617 011
5
Sensor and audio beeper cable
364 605 001
6
Audio beeper
364 616 001
7-x
Ultrasonic sensor
364 614 001
8
Sensor splitter cable
364 607 001
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=
Notes
Green connector on ECU
Brown connector on ECU
0.5 m / 0.5 m / 0.5 m
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EB+ Soft Docking
4 sensors (2 planes, 2 offsets)
3
4
7-4
7-4
7-3
7-2
7-3
7-1
7-1
8
7-2
8
6
2
Green sensor
channel
Where indicated, if necessary use the
appropriate length of sensor extension cable
(364 622 xxx, see page 12) to reach the
sensor location.
Yellow sensor
channel
5
1
Item
Description
1
EB+ Soft Docking ECU
Part number
364 608 001
2
Outline marker and brake cable (open wires)
364 606 001
3
LED outline marker lamp (left)
364 617 001
4
LED outline marker lamp (right)
364 617 011
5
Sensor and audio beeper cable
364 605 001
6
Audio beeper
364 616 001
7-x
Ultrasonic sensor
364 614 001
8
Sensor splitter cable
364 607 001
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Notes
Green connector on ECU
Brown connector on ECU
0.5 m / 0.5 m / 0.5 m
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EB+ Soft Docking
4 sensors (2 planes, 1 offset)
3
7-3
4
7-2
7-4
8
7-4
7-3
7-1
7-2
7-1
8
6
2
Green sensor
channel
Where indicated, if necessary use the
appropriate length of sensor extension cable
(364 622 xxx, see page 12) to reach the
sensor location.
Yellow sensor
channel
5
1
Item
Description
1
EB+ Soft Docking ECU
Part number
364 608 001
2
Outline marker and brake cable (open wires)
364 606 001
3
LED outline marker lamp (left)
364 617 001
4
LED outline marker lamp (right)
364 617 011
5
Sensor and audio beeper cable
364 605 001
6
Audio beeper
364 616 001
7-x
Ultrasonic sensor
364 614 001
8
Sensor splitter cable
364 607 001
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Notes
Green connector on ECU
Brown connector on ECU
0.5 m / 0.5 m / 0.5 m
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EB+ Soft Docking
5 sensors (2 planes, 2 offsets)
3
7-1
4
7-2
7-5
8
7-3
7-4
7-5
7-1
8
7-4
7-2
7-3
8
6
2
Green sensor
channel
Where indicated, if necessary use the
appropriate length of sensor extension cable
(364 622 xxx, see page 12) to reach the
sensor location.
Yellow sensor
channel
5
1
Item
Description
1
EB+ Soft Docking ECU
Part number
364 608 001
2
Outline marker and brake cable (open wires)
364 606 001
3
LED outline marker lamp (left)
364 617 001
4
LED outline marker lamp (right)
364 617 011
5
Sensor and audio beeper cable
364 605 001
6
Audio beeper
364 616 001
7-x
Ultrasonic sensor
364 614 001
8
Sensor splitter cable
364 607 001
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=
Notes
Green connector on ECU
Brown connector on ECU
0.5 m / 0.5 m / 0.5 m
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Installation
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EB+ Soft Docking
5 sensors (2 planes, 1 offset)
3
7-4
4
7-3
7-5
8
7-2
7-5
7-1
7-1
8
7-4
7-2
7-3
8
6
2
Green sensor
channel
Where indicated, if necessary use the
appropriate length of sensor extension cable
(364 622 xxx, see page 12) to reach the
sensor location.
Yellow sensor
channel
5
1
Item
Description
1
EB+ Soft Docking ECU
Part number
364 608 001
2
Outline marker and brake cable (open wires)
364 606 001
3
LED outline marker lamp (left)
364 617 001
4
LED outline marker lamp (right)
364 617 011
5
Sensor and audio beeper cable
364 605 001
6
Audio beeper
364 616 001
7-x
Ultrasonic sensor
364 614 001
8
Sensor splitter cable
364 607 001
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=
Notes
Green connector on ECU
Brown connector on ECU
0.5 m / 0.5 m / 0.5 m
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EB+ Soft Docking
Sensor cables
The EB+ Soft Docking ultrasonic sensor cables can be extended by using a combination of extension and splitter
cables.
Sensor extension cable
Cable to increase the sensor distance from the ECU
Sensor splitter cable
A
364 622 001
1.0 m
364 622 011
3.0 m
364 622 021
6.0 m
A
Sensor splitter cable
Y cable to add additional sensors
Sensor splitter cable
A
B
C
364 607 001
0.5 m
0.5 m
0.5 m
B
C
A
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Extension cable location
The sensor extension cable is used to increase the length of the cable from the EB+ Soft Docking ECU to the
ultrasonic sensor.
The sensor extension cable can be used anywhere and in any combination within the sensor loom to ensure the
cable is long enough to reach the mounted sensor on the trailer.
Sensor extension cable
position
Where indicated, if necessary use the appropriate length of sensor extension cable (364 622 xxx) to reach the
sensor location.
=
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EB+ Soft Docking
Installation of EB+ Soft Docking ECU
Preparation
Mounting dimensions
75.5 mm
Ensure that you have all the components necessary to
complete the installation.
Remove existing outline markers.
›
134 mm
Determine a suitable mounting point for:
› EB+ Soft Docking ECU box
Audio beeper
Minimum space required is approximately 200 mm
(width) x 300 mm (height).
All cables must be installed where suitably protected by
the trailer chassis. Fix all cables every 10-15 cm with a
cable tie. Do not fit the cables onto surfaces that can
become hot. Hydraulic fluid pipe lines are not allowed.
Unnecessary cables should be fixed coiled up. Ensure
that any junction box gland nuts are closed correctly.
During all the installation, protect connectors from dirt
and humidity.
102.21 mm
120 mm
Use M6 screw
Screwing torque = 8 Nm max for M6
screws
Fit the box onto a flat surface
Top
Temperature range :
Don’t expose the product below -40 °C and above
80 °C. For example, do not place the product in a paint
oven (temperature > 80 °C). Fit the EB+ Soft Docking
after painting.
The position of the ECU box should be in a suitably
protected position in the rear part of the trailer. The
box should be fixed onto the chassis. Position in a rigid
location which is not susceptible to large vibration
and ensure cables run upwards to the ECU box and
are safely installed. Respect the "Top" indicated on
the box. The cables must be plugged without any
constraints (which could cause a loss of tightness or
product deterioration). Any product opening or any
product change cancels the product warranty.
Note: Ensure that the ECU connectors are plugged
into the correct colour coded cable connectors, and
the polarity of these connectors is also correct. Any
deviations from correct connection will void any
warranty claims.
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Bottom
Green connector
Brown connector
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EB+ Soft Docking
Installation of LED outline marker light
The LED outline marker lights should be mounted to
the trialer so that the lights can be clearly seen from
the truck mirrors. The outline marker connectors
should be plugged into the EB+ Soft Docking cable
(part number 364 606 001).
Mounting dimensions
It is essential that you only use LED outline markers,
not incandescent bulbs.
Note: The EB+ Soft Docking system will go in a failure
mode if incandescent bulbs are used.
The breakage of one or more optical part may cause a
short circuit which causes the temporary extinction of
both of the end outline marker lamps.
78 mm
Ø 6 mm
Any product opening or any product change cancels
the product warranty.
Do not leave any cable connection or any cable end in
an open situation. Each cable connection or cable end
must be tightly closed.
The EB+ Soft Docking is designed for two 1,5 W end
outline marker lamps.
Use 2 x M5 screws
Screwing torque = 3 Nm max.
Fit on a flat surface
If the EB+ Soft Docking is plugged into a 12 V supply,
choose two 12 V end outline marker lamps.
If the EB+ Soft Docking is plugged into a 24 V supply,
choose two 24 V end outline marker lamps.
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EB+ Soft Docking
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Installation of audio beeper
Fit the audio beeper in a protected position which
is not susceptible to vibration. Normally on the rear
light panel or near the rear axle. Put the sound exit
downward with sufficient area around it not to block
the sound downward and backward. The use of a
sound screen near the sound exit is not allowed. When
assembling, pay attention to the location of the alarm,
the cable entry must be at the top and the drain hole
at the bottom (to let water flow).
The audio beeper connector should be plugged into
the EB+ Soft Docking cable part number 364 605 001.
In case of accidental liquid projection inside the beeper,
the beeper sound could be reduced momentarily. It
will return to normal after liquid removal, without any
beeper degradation.
Ø 5 mm Fixing hole
Top
Bottom
Any product opening or any product change cancels
the product warranty.
Use M3.5 screw.
Screwing torque = 1.3 Nm max.
Fit the alarm on a flat surface.
Do not cover or block
Sound level (24 V): 108 +/- 5 dB (A) at 30 cm
Sound level (12V): 93 +/- 5 dB (A) at 30cm
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EB+ Soft Docking
Installation of power supply adapter cable
Connection to Haldex EB+ Gen3 unit
EB+ CAN cable connection
The EB+ Soft Docking system only works with
EB+ Gen3 systems.
Plug the auxiliary CAN cable into one of the CAN
auxiliary ports on the EB+ Gen3 unit, ensure correct
polarity is maintained.
The EB+ Gen3 ECU needs to be updated to the latest
E-level of software if manufactured prior to January
2014.
Installation of power supply into an existing junction box:
Insert cable through spare entry of existing junction
box. Connect wires as appropriate. Ensure waterproof
installation.
Cable connections
Cable colour
Function
Grey
Reverse light
White
Earth / common
Black
Left tail light
Brown
Right tail light
Note: only four out of the eight cable cores are used.
Cut unused wires.
Close the junction box.
Ensure that the junction box gasket is seated correctly.
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EB+ Soft Docking
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Installation of ultrasonic sensor
The sensors must be correctly fitted for the device to
work properly.
If the sensors point to the ground, irregularities and
bumps on the surface may be interpreted as obstacles.
If they point too far up, obstacles will not be detected
at all.
For the sensors to function optimally, the angle
between sensor surface and the road should be 90°
Ultrasonic
concentrator
Ultrasonic
sensor
Minimum height
65 cm without use of settings. If a lower value is used,
the sensor angular settings must be adjusted.
Sensor offset
If there is a gap between the rear of the trailer and the
sensor mounting position, independent yellow and
green channel offset settings can be included in the
system using the DIAG+ software.
Maximum offset is 60 cm.
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EB+ Soft Docking
Mounting of sensor
Mounting dimensions
Maximum torque : 8.4 N.m
Hole diameter : 6.3 mm
Obstacle: No obstacle shall be found in a 45° cone.
44 mm
›
No connector without any sensor (due to risk of
water ingress)
›
Maximum 3 sensors per channel
›
Balance the number of sensors between all the
channels : maximum difference of 1 sensor between
each channel
›
51 mm
Minimum 1 sensor per line (yellow channel and
green channel)
63 mm +/- 0.1 mm
›
80 mm
Mounting Rules :
Ø 6.3 mm
Maximum of 5 sensors per system
40 mm
Mounting in front of the trailer plate
Contact between chassis and sensor must be flat.
Ultrasonic concentrator is not required.
Behind trailer plate mounted
In front trailer plate mounted
Mounting behind the trailer plate
Contact between the chassis and sensor must be flat.
Ultrasonic concentrator is required, if there is a gap
between the sensor and the end of the trailer. A
software offset can be set for these sensors using
DIAG+
Refer to customer drawings for sensor mounting dimensions
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EB+ Soft Docking
Orientation of sensor
Vertical mounted sensor
Vertical mounted
Horizontal mounted sensor
The sensor shall be mounted at minimum 35 cm from
the edge of the trailer. This is to avoid detection of
other vehicles / obstacles on the side of the trailer.
If 35 cm is not possible, angular adjustment maybe
required by using the sensor notches.
Horizontal mounted
The sensor shall be mounted at 65 cm from the edge
of the trailer. This is to avoid detection of other vehicles
/ obstacles on the side of the trailer.
Vertical mounted sensor
min 35 cm
If 65 cm is not possible, angular adjustment maybe
required by using the sensor notches.
This orientation is mostly intended for the centre
sensor position on the trailer.
Drill a 25 mm diameter hole, pass the sensor lead
through with connector from the sensor. Fix the sensor
with two fixing screws onto the rear bumper. Plug the
cable into the connector from the EB+ Soft Docking
cable loom.
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Horizontal mounted sensor
min 65 cm
Trailer floor
min
65 cm
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Installation
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EB+ Soft Docking
Sensor adjustment
If you cannot position the sensor assembly on the
outermost area of the rear panel, you can adjust the
angular detection of the sensors by using the sensor
notches.
1 x 6°
To adjust sensor, press firmly on the centre of the
sensor and click onto the next notch, hence changing
the angle of the sensor
1 x 6°
Available settings :
› Vertical : ± 12°
›
Horizontal : ± 36°
Drain hole
The sensor angle can be adjusted by 6° increments by
pressing in directions as shown until the sensor clicks
into position.
3 x 6°
3 x 6°
Refer to customer drawing for sensor adjustment and bandwidth
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EB+ Soft Docking
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Sensor offsets
For sensors which are mounted under the floor of the trailer, the system allows for a sensor channel offset from
0-60 cm to be used on the yellow and / or green channel. These offsets are programmed using DIAG+ version
6.13 or later.
Standard installation
Standard installation,
No offset required
Alternative installation
Alternative installation,
Offset required
Up to 60 cm offset can
be applied using DIAG+
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EB+ Soft Docking
Configuring EB+ Soft Docking using DIAG+
The EB+ Soft Docking is configured using DIAG+ V6
software. The software and operators guide can be
downloaded from the Findex section of the Haldex
website.
To download the software
›
Click here: Haldex Findex
›
Click on DIAG+
›
Click on multi-language version
›
Follow installation procedure
DIAG+ V6 document reference 006300019
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How to check if EB+ Soft Docking is installed
Step 1:
Turn 'on' the power to the EB+ Gen3.
Open DIAG+, select configuration.
Step 4:
Select CAN BUS tab.
Step 2:
Select ECU parameters / configuration.
Step 5:
Observe the EB+ Soft Docking tick box.
Step 3:
Select setup auxiliary configuration.
No tick = EB+ Soft Docking not installed
Tick = EB+ Soft Docking installed
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EB+ Soft Docking
How to remove EB+ Soft Docking from EB+ Gen3
Step 1:
Turn 'on' the power to the EB+ Gen3.
Open DIAG+, select configuration.
Step 4:
Select CAN BUS tab.
Step 2:
Select ECU parameters / configuration.
Step 5:
Select "Modify" button.
Step 3:
Select setup auxiliary configuration.
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EB+ Soft Docking
Step 6:
Select 'Reset Soft Docking to Plug and Play' box.
Installation
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Step 10:
Select 'Yes' to send data to ECU.
Step 11:
Sending data screen.
Step 7:
Click on 'green' ticks until you reach 'Online
Configuration and ECU Programming' window.
Step 8:
Select 'Send data to ECU'.
Step 12:
Select 'green' tick to complete the operation.
Step 9:
Remove EB+ Soft Docking CAN BUS cable from EB+
Gen3 ECU.
Step 13:
Check using DIAG+ that the EB+ Soft Docking has
now been removed.
EB+ CAN BUS cable
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EB+ Soft Docking
How to install a 3 sensor (1 x yellow & 2 x green) EB+ Soft Docking system
using DIAG+
Step 1:
Turn 'off' the power to EB+ Gen3.
Step 7:
Read data from ECU.
Step 2:
Connect EB+ Soft Docking to the EB+ CAN BUS
connector.
Step 3:
Turn 'on' the power to EB+ Gen3.
Step 4:
Check installation using DIAG+
Step 5:
Open DIAG+, check that no DTC's are shown.
Step 8:
Select ECU parameters / configuration.
Step 9:
Select set up auxiliary configuration.
Step 6:
If no DTC's are present select configuration.
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Step 10:
Select CAN BUS tab.
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EB+ Soft Docking
Step 11:
Observe the EB+ Soft Docking tick box.
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Step 14:
Ensure that the 'CAN Bus Termination' box is selected.
Note: the 'CAN Bus termination' shall always be
selected unless otherwise advised by Haldex.
Step 12:
Select 'Modify' button.
Step 15:
Select 'i' button for additional information.
Step 13:
Check that the number of sensors is correct.
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EB+ Soft Docking
Step 16:
If no sensor channel offsets are required, go to step 17.
If sensor channel offsets are required, go to step 18.
Offset example:
Both channels the same value.
Step 17:
Proceed to EOLT.
Click on 'green' ticks until you reach 'DIAG+ home
page'
Step 18:
Adjust channel values to sensor installation offset.
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Offset example:
Both channels are different values.
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EB+ Soft Docking
Installation
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Step 19:
Click on 'green' ticks until you reach 'Online
Configuration and ECU Programming' window.
Step 20:
Select 'Send data to ECU'.
Step 21:
Select 'Yes' to send data to ECU.
Step 22:
Click green tick to return to DIAG+ home page.
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EB+ Soft Docking
How to configure a sensor channel offset
Step 1:
Turn 'on' the power to the EB+ Gen3.
Open DIAG+, select configuration.
Step 4:
Select CAN BUS tab.
Step 2:
Select ECU parameters / configuration.
Step 5:
Select "Modify" button.
Step 3:
Select setup auxiliary configuration.
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EB+ Soft Docking
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Step 6:
Adjust channel values to sensor installation offset.
Offset example:
Both channels are different values.
Offset example:
Both channels the same value.
Step 7:
Click on 'green' ticks until you reach 'Online
Configuration and ECU Programming' window.
Step 8:
Select 'Send data to ECU'.
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EB+ Soft Docking
Step 9:
Select 'Yes' to send data to ECU.
Step 10:
Click green tick to return to DIAG+ home page.
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EB+ Soft Docking
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How to check for a faulty installation using DIAG+
Step 1:
Turn 'on' the power to EB+ Gen3.
DTC error:
Incorrect number of sensors - either the yellow or
green channel has no working sensors connected.
Step 2:
Open DIAG+, select service.
DTC error:
EE data mismatch - sensor mismatch between EB+
Gen3 stored data and EB+ Soft Docking stored data.
Reset EB+ Gen3 to remove this error.
Step 3:
Select DTC's.
Step 4:
Check 'Diagnostic Trouble Code' window for any active
DTC's.
DTC error:
Sensor error - damaged or faulty sensor detected.
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EB+ Soft Docking
Step 5:
Click on 'green' ticks until you reach the DIAG+ home
window.
Step 9:
Select CAN BUS tab.
Step 6:
Select configuration.
Step 10:
Select "Modify" button.
Step 7:
Select ECU parameters / configuration.
Step 11:
Check displayed sensors for errors.
Step 8:
Select setup auxiliary configuration.
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EB+ Soft Docking
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Step 12:
Rectification of faulty sensors
a
b
c
d
e
36
Turn 'off' power to the EB+ Gen3.
Based on the information obtained, replace a sensor with a new sensor.
Turn 'on' the power to the EB+ Gen3.
Use DIAG+ to check for any active DTC's.
Repeat steps (a) to (d) until no active EB+ Soft Docking sensor DTC's are shown.
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Installation
guide
EB+ Soft Docking
How to complete EB+ Soft Docking EOLT using DIAG+ for a 3 sensor
(1 x yellow & 2 x green) system
Step 1:
Turn 'on' the power to the EB+ Gen3.
Check that there are no active DTC's.
Step 5:
No active DTC's present, start EOLT.
Note: Do not start the EOLT if there are any active
DTC's.
Step 6:
Select 'End of line test procedure'
Step 2:
Open DIAG+, select service.
Step 3:
Select DTC's.
Step 7:
Select 'End of line test'
Step 4:
Check 'Diagnostic Trouble Code' window for any active
DTC's.
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Step 8:
Tick the EB+ Soft Docking box.
Step 9:
Select 'arrow' to start the EOLT.
EOLT option:
If required, tick the 'Pause Between Tests' box.
Step 10:
Check 'Actual Sensors' displayed value is correct.
When ticked the EOLT waits for a prompt from the
operator before proceeding to the next test.
Note: Manually edit the sensor boxes for the correct
values before proceeding with the EOLT.
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Step 11:
Select 'OK' button.
Step 14:
Activate the sensor on the yellow channel.
Step 12:
Select vehicle reverse gear.
Sensor activation sequence:
The sensor is activated / detected using a solid object
(see example) placed at 150 mm in front of the sensor.
Note: Do not place the solid object onto the sensor
face, a 150 mm gap must be maintained for correct
activation.
Solid object examples:
Rigid cardboard (200 mm x 100 mm)
Rigid metal sheet (200 mm x 100 mm)
Step 13:
Check all installed sensors are displayed.
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EB+ Soft Docking
Test sequence:
›
Marker lights flashing.
›
Place a solid object 150 mm away from the sensor
face.
›
Marker lights stop flashing (remain 'on') and bleeper
sounds, when the sensor has been detected.
›
DIAG+ screen shows that the sensor has been
detected using a green box (S1, S2 or S3)
Installation
guide
Step 15:
Sensor on the yellow channel has been detected (S1
box green).
Activate any sensor on the green channel.
Solid object
200 mm x 100 mm cardboard
Sensor
Step 16:
Sensor on green channel has been detected (S1 box
green).
Activate the next sensor on the green channel.
150 mm
So object
Solid
200 mm x 100 mm cardboard
Sensor
150 mm
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Step 17:
Sensor on green channel has been detected (S2 box
green).
Step 18:
Select / click the correct button.
Step 19:
Select / click correct button.
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Step 20:
Disable vehicle reverse gear.
Step 21:
EOLT completed.
Step 22:
EOLT passed, select 'green' tick to continue.
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Functional test
After the successful completion of the DIAG+ EOLT, you should test the system thoroughly. For this test you
require a test sample (preferred material is a cardboard box approx. 500 x 500 mm, if there is no box available,
you can use a similar object material with a smooth surface). Please ensure that there are no obstacles situated
within the range of 4 m x 4 m behind the vehicle. The test procedure must be carried out in the following steps:
Step
Activity
Results
LED outline marker has to shine.
Note: to work corrctly ensure that the EB+ is also
powered
1
Ignition on / tail light on
2
Engage reverse gear
3
Place the test sample perpendicular to a LED outline marker: slow flashing frequency
sensor within a range of 3 m behind the Reverse alarm: slow beep
vehicle
4
Remove the test sample from the vehicle Completed phase 1 (see picture below) (area greater
until the beeping and LED outline are
than 3 m)
extinguished.
5
Move the test sample slowly inwards
towards the trailer sensor
Run through the complete range of phases as shown
within diagram below.
6
Repeat step 4 with other sensor
See step 4
7
Repeat step 5 with other sensor
See step 5
LED outline marker is deactivated when the radar is
at 3 m from the obstacle
Testing of the silent mode (night silent switch off)
Step
8
Activity
Place the test sample in the distance as
in step 3.
9
Engage the reverse gear twice
(within 2 seconds)
10
Let the system work for minimum 10
seconds. After this, disengage the
reverse gear.
11
42
Engage reverse gear once only.
Results
LED outline marker: slow flashing frequency
Reverse alarm: no signal
LED outline marker: slow flashing frequency
Reverse alarm: returns to slow beep frequency
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EB+ Soft Docking
Note: during the function test, the test sample will always be moved perpendicular to the respective sensor axis.
The maximum detectable distance is 2.5 metre from the sensor.
EB+ Soft Docking indication modes
No beep / flashes
> 2.5 metre
3 Beeps per sec (3 Hz) / flashes
2.0 - 2.5 metre
5 Beeps per sec (5 Hz) / flashes
1.0 - 2.0 metre
EBS applies brakes for 2 seconds
1.0 metre
8 Beeps per sec (8 Hz) / flashes
0.5 - 1.0 metre
Permanent tone / lamp
< 0.5 metre
Operating instructions
The complete system is installed into the last third of the trailer. Thus the EB+ Soft Docking is independent of
the truck and also very well suited for changes of the truck and trailer combination. Engage the reverse gear to
activate the system.
Sensors indicate the minimum distance to an obstacle to the system electronics. Depending on the distance to an
object, the system electronics will give out a warning signal (from the reversing alarm and LED outline marker),
which varies dependent to the object distance.
At a 2.5 metre distance, the driver receives optical and audio warnings. If the rear of the vehicle comes within
1 metre, the system applies the brakes with a force automatically adjusted for the speed of the vehicle and the
weight of the load.
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Day time mode activation
After engaging the reverse gear the LED outline markers are turned on.
At a distance to the obstacle greater than 2.5 m, the LED outline markers are on, and the buzzer is silent.
At a distance to the obstacle less than 2.5 m, the system switches to the indication modes (see page 26).
Night silent mode activation
If the reverse gear is engaged twice (within 2 seconds) the audio beeper will be set to ‘’night silent’’ mode. The
‘’night silent’’ mode is to prevent audible nuisance at night in residential areas.
The LED outline markers are still active as usual.
Conditions of no detection
The system will not detect the loading dock when:
›
The system is not properly connected to EB+ Gen3
›
The vehicle is not in reverse gear
›
The vehicle speed exceeds 15 Km/h
›
EB+ Gen3 is not operating
If the trailer is driven at an angle to the dock, it is possible for the sensor not to detect the dock. Some materials
like textiles weaken the ultrasonic signals, significantly reducing the sensing distance.
The system cannot replace the driver’s responsibility to ensure a clear passage when manoeuvring. The operation
needs to be tested on a vehicle after installation.
The vehicle requires Haldex EB+ Gen3 2M or 3M systems to function.
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Except for a complete failure of the system the
following situations can lead to an erroneous signal.
The reason for this is that in these cases, the physical
limits of the ultrasonic sound are exceeded.
If the trailer is driven at an angle to the dock, it is
possible for the sensor not to detect the dock.
Caution with ramps with floors that point out from the
main body.
Attention: It is the driver’s responsibility to manoeuvre
safely.
Ramps with curtains require special attention:
a) The material of the curtains can absorb the
ultrasonic, this means that the reflected sound is too
weak for the sensor to detect.
b) If the curtain is deformed, so that the ultrasonic
signal could be absorbed.
Some materials like textiles weaken the ultrasonic
signals, significantly reducing the sensing distance.
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Error repair
Error repair / sensor diagnosis
There is no fuse to change.
Fuses are resettable.
Diagnosis is done by DIAG+ Software.
If ECU box is opened warranty is void.
When adding or moving sensors, DIAG+ software may be used to make a complete check of the system.
If lights stay frozen when reverse is engaged, the system has detected an error.
Attention:
EB+ Soft Docking is protected against an AC voltage supply, but will not function. It will function again correctly
when reconnected with a DC supply.
If the EBS is not powered (or EB+ Soft Docking is unplugged), the lights will be switched off when position
function is activated. The system will not operate.
If one sensor is removed or moved the system will detect an error. To clear the error, a reset and EOL test must be
performed with the DIAG+ software.
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Liability exclusion
The system is not 100% accurate under all circumstances. When using the EB+ Soft Docking system the driver
must manoeuvre with care and attention up to the dock / ramp. Haldex cannot be held responsible for any
damage that may occur when using the system. It is the always the drivers responsibility to reverse / manoeuvre
safely.
Cable connections
Ensure that the EB+ Soft Docking ECU connectors are plugged into the correct colour coded cable connectors,
and with the correct polarity.
Ensure that the EB+ CAN cable is only plugged into the EB+ Gen3 CAN connectors, and with the correct polarity.
Any deviations will void any warranty claims.
Green connector
Brown
own connector
EB+ CAN cable connection
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Installation
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Excess cable
Excess cable must not be allowed to hang free, but
must be attached to the chassis to prevent damage
due to vibration and abrasion.
Ø150 max
100 min
B
Cable lengths less 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.
Ø100 min
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 are to be used to fix
the cable in the flattened loop shape.
More than one looped cable must not be looped
together.
Sensor 1A
Sensor 1B
Solenoid
Sensor 1A
Sensor 1B
Solenoid
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Painting
Masked areas
In the event of paint or coating work all none used
connections, bleeper and sensors must be protected.
These are indicated by the yellow shaded areas as
shown. Adequate protection should be used to avoid
penetration of the paint or coating. All electrical ports
to have connectors or blanking plugs installed during
painting.
Bleeper
Painting recommendations: water based, baking for
1 hour @ 100oC
Electro static painting: Haldex recommends that the
EB+ Soft Docking assembly is fitted to the trailer after
electro static painting.
Sensor
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Part reference
These available service parts can be obtained from Haldex service centres or distributors.
EB+ Soft Docking ECU
The ECU receives sensor information, determines the system status, and
sends it to the EBS via the trailer CAN.
EB+ Soft Docking ECU
Part number
ECU
364 608 001
Green connector
Brown connector
Led outline marker lamp (visual warning signals)
Used to warn the driver of the distance to the obstacle via flashes
dependent on distance .
LED outline marker lamp
Part number
Left side
364 617 001
Right side
364 617 011
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Outline marker lamp and brake cable
Used to connect the EB+ Soft Docking ECU (green connector) to the
EB+ Gen3 and trailer wiring loom.
Outline marker lamp and brake cable
Part number
Outline marker with molded marker connectors
364 606 001
Outline marker with molded marker connectors
364 606 011
Cable colour
Function
Grey
Reverse light
White
Earth / common
Black
Left tail light
Brown
Right tail light
Refer to customer drawings for cable dimensions
Outline marker lamp and brake loom
Part number
Outline marker and brake loom
364 610 001
Cable colour
Function
Grey
Reverse light
White
Earth / common
Black
Left tail light
Brown
Right tail light
Blue
B- (common return)
Brown
Right tail light
Refer to customer drawings for cable dimensions
Outline marker lamp / brake cable with DIN
Part number
Outline marker with molded marker connectors
364 623 001
Outline marker with molded marker connectors
364 623 011
Pin
Wire colour
Function
1
Red
Reverse light
2
Blue
Earth / common
3
Green
Left tail light
4
Yellow
Right tail light
DIN connector
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Refer to customer drawings for cable dimensions
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EB+ Soft Docking
Sensor and audio beeper cable
Beeper connection
Used to connect the EB+ Soft Docking ECU (brown
connector) to the sensors and audio beeper.
Green sensor
channel
Sensor and audio beeper cable
Part number
Sensor and audio beeper cable
364 605 001
Yellow sensor
channel
Brown connector
Refer to customer drawings for cable dimensions
Sensor with no audio beeper
Part number
Sensor with no audio beeper
364 625 001
Green sensor
channel
Yellow sensor
channel
Brown connector
Refer to customer drawings for cable dimensions
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Audio beeper (audible warning system)
The audio beeper is used to warn the driver of the distance to the
obstacle.
EB+ Soft Docking audio beeper
Part number
Audio beeper
364 616 001
Ultrasonic sensor
Used to calculate the distance to the obstacle.
Ultrasonic sensor
Part number
Ultrasonic sensor
364 614 001
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Sensor extension cable
Cable to increase the sensor distance from the ECU
Sensor splitter cable
A
364 622 001
1.0 m
364 622 011
3.0 m
364 622 021
6.0 m
A
Sensor splitter cable
Y cable to add additional sensors
Sensor splitter cable
A
B
C
364 607 001
0.5 m
0.5 m
0.5 m
B
C
A
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Austria
Haldex Wien Ges.m.b.H.
Vienna
Tel.: +43 1 8 69 27 97
Fax: +43 1 8 69 27 97 27
E-Mail: [email protected]
Korea
Haldex Korea Ltd.
Seoul
Tel.: +82 2 2636 7545
Fax: +82 2 2636 7548
E-Mail: [email protected]
Belgium
Haldex N.V.
Balegem
Tel.: +32 9 363 90 00
Fax: +32 9 363 90 09
E-Mail: [email protected]
Mexico
Haldex de Mexico S.A. De C.V.
Monterrey
Tel.: +52 81 8156 9500
Fax: +52 81 8313 7090
Brazil
Haldex do Brasil Ind. E Com.
Ltda
São José dos Campos
Tel.: +55 12 3935 4000
Fax: +55 12 3935 4018
E-Mail: [email protected]
Canada
Haldex Ltd
Cambridge, Ontario
Tel.: +1 519 621 6722
Fax: +1 519 621 3924
E-Mail: [email protected]
China
Haldex Vehicle Products Co. Ltd.
Suzhou
Tel.: +86 512 8885 5301
Fax: +86 512 8765 6066
E-Mail: [email protected]
France
Haldex Europe SAS
Weyersheim
Tel.: +33 3 88 68 22 00
Fax: +33 3 88 68 22 09
E-Mail: [email protected]
Germany
Haldex Brake Products GmbH
Heidelberg
Tel.: +49 6 221 7030
Fax: +49 6 221 703400
E-Mail: [email protected]
Hungary
Haldex Hungary Kft
Szentlörinckáta
Tel.: +36 29 631 400
Fax: +36 29 631 401
E-Mail: [email protected]
India
Haldex India Limited
Nashik
Tel.: +91 253 66 99 501
Fax: +91 253 23 80 729
©2015, Haldex AB. This material may contain Haldex
trademarks and third party trademarks, trade names,
corporate logos, graphics and emblems which are
the property of their respective companies. The
contents of this document may not be copied,
distributed, adapted or displayed for commercial
purposes or otherwise without prior written consent
from Haldex.
Innovative Vehicle Solutions
Poland
Haldex Sp. z.o.o.
Praszka
Tel.: +48 34 350 11 00
Fax: +48 34 350 11 11
E-Mail: [email protected]
Russia
OOO “Haldex RUS”
Moscow
Tel.: +7 495 747 59 56
Fax: +7 495 786 39 70
E-Mail: [email protected]
Spain
Haldex España S.A.
Granollers
Tel.: + 34 93 84 07 239
Fax: + 34 93 84 91 218
E-Mail: [email protected]
Sweden
Haldex Brake Products AB
Landskrona
Tel.: +46 418 47 60 00
Fax: +46 418 47 60 01
E-Mail: [email protected]
United Kingdom
Haldex Ltd.
Newton Aycliffe
Tel.: +44 1325 310 110
Fax: +44 1325 311 834
E-Mail: [email protected]
Haldex Brake Products Ltd.
MIRA Technology Park
Tel.: +44 2476 400 300
Fax: +44 2476 400 301
E-Mail: [email protected]
USA
Haldex Brake Products Corp.
Kansas City
Tel.: +1 816 891 2470
Fax: +1 816 891 9447
E-Mail: [email protected]
Italy
Haldex Italia Srl.
Biassono
Tel.: +39 039 47 17 02
Fax: +39 039 27 54 309
E-Mail: [email protected]
www.haldex.com
006 300 035_EN/08.2015/Haldex UK
Haldex develops and provides reliable and
innovative solutions with focus on brake
and air suspension products to the global
commercial vehicle industry.
Listed on the Stockholm Stock Exchange,
Haldex has annual sales of approximately
4.4 billion SEK and employs about
2,235 people.
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