Haldex EB+ Gen 2 Manual

Operator’s
Guide
www.haldex.com
ELECTRONIC BRAKE SYSTEMS EB+ GEN 2

Page
EB+ GEN 2 Operator’s guide 2
General Components Guide 3
System Layout 4
Chassis Components 5
System Diagnostics 6
Warning Device, System Check Procedure and
Power-Up Modes 7
Test Procedure 8
Diagnostic Trouble Codes (DTC) 9
ECU Connector Identification 11
Wiring diagram 12
Piping Diagrams 13
Multimeter Reading 17
Recommended Maintenance Schedule 18
Part Reference 19
General Information 21
Your trailer has been fitted with the latest technology Haldex
Electronic Braking System EB+ Gen 2. This system has been
specifically designed to be effective, reliable and easy to service. The
purpose of this booklet is to describe the components involved and
give you sufficient information to make your use of the system easy.
Concept
EB+ Gen2 = Antilock Brake System (ABS)
+ Electronic Load Sensing (ELS)
+ CAN (Controller area network ISO11992 data link - computer data
from and to the towing vehicle)
The system reacts to electrical or pneumatic signal from the towing
vehicle. It electronically processes those signals plus signals received
from other sensors on the trailer. In response to those signals the
EB+Gen 2 regulates pressure to the brake chambers.
System Description
The position of the various components is shown in Tri-axle layout,
Fig 1. The system is equally compatible with single and tandem axles.
The EB+ Gen 2 system is an integrated construction of an
encapsulated Electronic Control Unit (ECU), Electro pneumatic relay
valves (EPRV’s), over moulded connectors, integrated pressure
transducers and a flash upgradable program memory.
Onset of braking is denoted by presence of a demand on the
ISO11992 data link (CAN) via the ISO7638 connector. Driver demand
pressure is then determined electronically either by the data link or
control line pressure transducer within the EPRV’s assembly.
The demand pressure is then modified using data from the air
suspension (Electronic Load Sensing), and may be further modified
when a wheel speed sensor detects imminent locking of the sensed
wheels (ABS).
The output to the brakes is exercised by the ECU control of the
EPRV’s see Fig 2.
The EB+ Gen2 ECU also provides up to 5 auxilliary functions such as
automatic reset-to-ride height (COLAS®), lift axle control (ILAS®-E),
retarder and Stability control.
EB+ Gen 2 incorporates an odometer facility which measures total
distance of the trailer and its read-out is shown on an optional EB+
Info Centre unit (Only when powered by the ISO7638 cable).
The EB+ Info Centre is a side of trailer mounted unit used also for
read-out of diagnostic codes and other information available from the
EB+ Gen 2 ECU.
The EB+ Gen 2 also incorporates an enhanced information storage
and retrieval facility.
For the fleet operator, a ‘Fleet Log Reader’ allows the compilation of a
full history of each trailer or long term monitoring.
For the trailer manufacturer, an ‘End-of-line’ Testing (EOLT) to confirm
correct performance of the EB+ Gen 2 system.
Contents
2

3
Park/Shunt and REV Options
Option 1 Option 2 Option 3
Driver’s
information
plate
Haldex EB+ Gen 2
Assembly
EB+ Info Centre 2
ISO7638 - 7
Pin Socket
assembly
Sensor and
Exciter
Trailer Control Module
(without check valve)
Relay Emergency
Valve (REV)
Optional position
and
Park & Shunt
valve
Fig. 1
Park & Shunt
valve
General Components Guide

The system fitted to your trailer may have 2 or 4 Sensors and 2
Modulators (EPRV's). The variants available being 2S/2M and 4S/2M.
The powering of the system is via :
ISO7638- 7 Pin - Full EBS function Fig 2.
The EB+ Gen 2 system can also be powered via :
ISO7638- 5 Pin - (No CAN data bus) ABS + ELS function only Fig 3.
4
Fig 2
ISO7638 - 7 Pin
EBS EB+
= Full EBS function
Fig 3
ISO7638 - 5 Pin
ABS EB+
= ABS + ELS function only
No CAN data bus
Fig 4
ISO1185 - (24N)
ABS/EBS EB+
= On foot brake application
ABS function only
As a safety back-up ISO1185 (24N) - Stop Light powering provides
ABS function Fig 4.
The ISO7638 controls a Trailer warning device in the driver’s console .
The warning device has two functions:
• To indicate system integrity via the correct sequence (see Figs 10
and 11 on page 10) every time the EB+ Gen 2 ECU is electrically
powered up.
• To indicate by a permanent display, when the vehicle is moving, if
a fault has been detected.
The layout of the chassis components are shown in Fig 5
System Layout

5
Item Description Notes
1EB+ Gen 2 Label
2ISO7638 - 7 Pin Socket assembly
3Safety backup cable - ISO1185 (24N)
4EB+ Gen 2 Info Centre 1 & 2 (side of vehicle
connection)
5EB+ Gen 2 ECU and EPRV’s assembly
6Sensor assembly
7Exciter
8COLAS® Aux 1, 2 or 3
9ILAS®-E Aux 1, 2 or 3
10 Lining Wear Sensing (LWS) Aux 4 ONLY
11 EB+ Gen 2 Stability External Sensor Assembly - Aux 5 ONLY
Fig. 5
2A
1A
5
4
3
2
1
1B
2B
6
7
6
7
6
7
6
7
11
10
9
8
4
3
2
1
5
ISO 7638
ISO 1185
(24N)
Note: Aux to be set in line with DIAG+
Chassis Components
Electrical connections

An important feature of the EB+ Gen 2 system is that it provides an
extensive on board diagnostic capability. The system displays a range
of codes, which allow rapid diagnosis of the problem should one
occur.
Diagnostic communication is in accordance to ISO11898 using
Keyword (KWP2000) protocol and is accessed by either the ISO7638
- 7 pin connector which uses pin 6 and 7 as a CAN data bus using
ISO Interface Assembly (815 018 001) or optional side-of-vehicle
connector or directly to ECU (Fig 7). Any suitable device connected to
this CAN data bus may read diagnostic information.
An EB+ Gen 2 Info Centre 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 vehicle system via the ECU
diagnostics connector.
For further information on EB+ Gen 2 Info Centre see user guide
(000 700 270).
The EB+ Gen 2 Info Centre provides a multi-digit display of:
Information:
• Read Diagnostic Trouble Code (DTC)
• Clear DTC
• Conguration
• ECU software version number
• ECU serial number
• Vehicle Ident Number (VIN)
• Manufacturer OEM
• Info Centre software version number
Distance:
• Odometer - Total distance
• Trip distance (1st and 2nd)
• Service distance
• Wheel scale factor
• Clock (time and date)
• Clear Trip 1 and 2
Changes:
• Service distance
• Service interval
• Wheel scale factor
• Clock (time and date)
• Options-on/off (parameter updating / backlight)
• Password (PIN number)
• Unlock Info Centre (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.
6
Fig 6
Alternative positions
Diagnostic
connection
'DIAG' on ECU
PC INTERFACE
Connect to ECU
directly or via
side-of-vehicle
connector
Fig 7
Fig 8
Alternative - directly connected to
ECU or side-of-vehicle connection
PC Interface
PC Interface
ISO Interface assembly
System Diagnostics

7
Warning Device
The warning device function depends on the ISO7638 power supply
used:
A warning device located on the driver's console of the towing
vehicle is operated from the ISO7638 power cable only when the
EB+ Gen 2 is powered by the ignition switch. (Fig 9)
Note: If a dedicated power source is unavailable to the EB+ Gen
2 from the ISO7638 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 ISO7638
power is connected.
Note: The signal produced may be different to that produced by the
cab device due to possible modification of the cab device by the
towing vehicle.
System Check Procedure
1. On power up of the system, the warning device must indicate one
of the following sequences in order to show a fault-free system:
OPTION 'A' - (Fig 10)
OPTION 'B' - (Fig 11)
2. During the self-check procedure, the system cycles the EPRV's.
With foot brake applied one exhaust of air from each EPRV will be
audible.
Once these two checks are made with correct results, no further
checks are required.
If the results are not satisfactory, Haldex DIAG+ or EB+ Info Centre
should be used to establish the diagnosis.
This information is described visually in Fig 14 on page 11.
Power Up Modes
The EB+ Gen 2 system has two power up modes. With switching the
Ignition on (B+ applied) the following occurs:
With no yellow line pneumatic pressure (i.e. Brakes OFF)
The system adopts load sensing mode when the brakes are applied.
This load sensing mode is limited to 2 minutes for any single brake
application, after which it returns to 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 brakes are released for longer than 2 minutes,
after which it returns to load sensing operation.
This condition is cancelled on vehicle movement above 10 km/h
returning the system to load sensing operation.
ON
OFF
2 sec.
ON
OFF
2 sec. 2 sec. @ 10 km/h
Option A
ON for 2 seconds Warning device OK and system self-checking.
OFF System self-checked (not sensors)
Option B
ON for 2 seconds Warning device OK and system self-checking.
OFF for 2
seconds
System self-checked and preparing to check
sensors.
ON until moving System waiting for vehicle to move above 10
km/h in order to check that the sensors are
working.
OFF Once the vehicle is moving above 10 km/h
and the warning device clears, the electronic
system is fully checked.
Fig 10
Fig 11
Fig 9
Warning Device, System Check Procedure and Power-Up Modes

8
Example sequence
STEP 1 Power up,:
WATCH WARNING DEVICE IN TOWING VEHICLE
STEP 2 Apply foot brake, Power up, Listen for EPRV CYCLE.
STEP 3 Reading Diagnostic Codes using EB+ Info Centre 1
Remove foot brake
SPIN EACH SENSED WHEEL IN TURN,
Refer to diagnostic code listing.
STEP 4 MULTIPLE LAMP SEQUENCE
The Haldex EB+ incorporates a modified lamp flash of three flashes.
The red lamp will flash when the system is powered up when at rest.
This lamp sequence relates to:
1. Service due - indicates that trailer or system service distance is
due. After servicing the trailer or system the next service distance
must be reset by using the Info Centre or EOLT program.
2. NON EB+ fault - A fault with a device connected to the EB+ but
not directly effecting the EB+, for example: Reset-to-Ride valve
(COLAS®).
EBS
ON
OFF
EBS
ON
OFF
2 sec.
EBS
EBS
ON
OFF
2 sec.
2 sec.
ON
OFF
Option A
Option B
Fig 12
EB+
Info Display
All segment
display test
Odometer &
load display
Information
menu
display
Diagnostic
menu
display
Diagnostic
code
Fig 14
Refer to
Diagnostic
Trouble Code
listing on
pages 12-13
Fig 13
22 21
2 X
0 X
1 X
2 X
0 X
1 X
22 21
22 21
22 21
Test Procedure
Summary

9
DTC Displayed Possible Causes
ECU TIME OUT
or
NO LINK
No supply on ignition switched line.
Possible causes:
Truck fuse blown
EB+ GEN2 INFO CENTRE or cable fault.
Open circuit B -. ISO7638 not connected
Sensor Group
S1A CONT 1A Sensor1/wiring open or short circuit
S1B CONT 1B Sensor/wiring open or short circuit
S2A CONT 2A Sensor/wiring open or short circuit
S2B CONT 2B Sensor/wiring open or short circuit
Intermittent 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
Possible causes:
Loose sensor, connection, bracket or
exciter. Damaged exciter.
Maladjusted sensor or worn sensor cable
insulation.
Low Sensor Output Group
S1A OUTPUT 1A Sensor system fault
S1B OUTPUT 1B Sensor system fault
S2A OUTPUT 2A Sensor system fault
S2B OUTPUT 2B Sensor system fault
Possible causes:
Sensor worn, maladjusted sensor, wiring
open or short circuit
Brake Apply Solenoid Group
BRK APPLY SC Brake apply solenoid short circuit
BRK APPLY OC Brake apply solenoid short circuit
BRK APPLY SC DRIVE Brake apply solenoid short circuit
permanently energised
BRK APPLY UNSPEC Brake apply solenoid short circuit
EPRV 21 Hold and Dump Solenoid Group
EPRV 21 HOLD SC Modulator 21 hold solenoid short circuit
EPRV 21 DUMP SC Modulator 21 dump solenoid short circuit
EPRV 21 HOLD OC Modulator 21 hold solenoid open circuit
EPRV 21 DUMP OC Modulator 21 dump solenoid open circuit
EPRV 21 HOLD SC
DRIVE
Modulator 21 hold solenoid short circuit
permanently energised
If a Diagnostic Trouble Code displayed is not listed here, check for intermittent sensor and wiring faults.
DTC Displayed Possible Causes
EPRV 21 DUMP SC
DRIVE
Modulator 21 dump solenoid short circuit
permanently energised
EPRV 21 HOLD
UNSPEC
Modulator 21 hold solenoid control
circuit fault
EPRV 21 DUMP
UNSPEC
Modulator 21 dump solenoid control
circuit fault
EPRV 22 Hold and Dump Solenoid Group
EPRV 22 HOLD SC Modulator 22 hold solenoid short circuit
EPRV 22 DUMP SC Modulator 22 dump solenoid short circuit
EPRV 22 HOLD OC Modulator 22 hold solenoid open circuit
EPRV 22 DUMP OC Modulator 22 dump solenoid open circuit
EPRV 22 HOLD SC
DRIVE
Modulator 22 hold solenoid short circuit
permanently energised
EPRV 22 DUMP SC
DRIVE
Modulator 22 dump solenoid short
circuit permanently energised
EPRV 22 HOLD
UNSPEC
Modulator 22 hold solenoid control
circuit fault
EPRV 22 DUMP
UNSPEC
Modulator 22 dump solenoid control
circuit fault
Demand Pressure Transducer Group
DEMAND SC Service line pressure transducer
short circuit
DEMAND OC Service line pressure transducer
open circuit
Delivery Pressure Transducer Group
EPRV 21 DEL SC Modulator 21 delivery pressure transducer
short circuit
EPRV 21 DEL OC Modulator 21 delivery pressure transducer
open circuit
EPRV 22 DEL SC Modulator 22 delivery pressure transducer
short circuit
EPRV 22 DEL OC Modulator 22 delivery pressure transducer
open circuit
One Wheel with Slow Recovery 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
Possible causes:
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
Diagnostic Trouble Codes (DTC)

10
DTC Displayed Possible Causes
Reservoir Pressure Transducer Group
RESR SC Reservoir pressure transducer short circuit
RESR OC Reservoir pressure transducer open circuit
Suspension Pressure Transducer Group
SUSP SC Suspension pressure transducer
short circuit
SUSP OC Suspension pressure transducer
open circuit
SUSP 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
ISO11992 (CAN) Electrical Signal Group
PNEUMATIC
DEMAND LOSS
No corresponding pneumatic demand
pressure
TOWED CAN
DEMAND LOSS
CAN line (pin 6 and 7 on ISO7638) fault
TOWED CAN
CONTROL LOSS
CAN line (pin 6 and 7 on ISO7638) data
fault
Supply Voltage Group
PWR ISO7638 FAIL Power loss on pin 1 or 2 (ISO7638)
PWR LO VOLT Supply voltage at ECU less than 19v when
brake apply solenoid energised
PWR HI VOLT Supply voltage at the ECU greater than 32v
PWR UNSPEC Internal ECU fault
ECU Group
ECU EE ERR Internal ECU fault or ECU not programmed
ECU PARAM ERR Internal ECU fault or ECU not programmed
ECU EE UNSPEC Internal ECU fault or ECU not programmed
DTC Displayed Possible Causes
Auxiliary Components Group
AUX1 Auxiliary 1 system/wiring open or
short circuit
AUX2 Auxiliary 2 system/wiring open or
short circuit
AUX3 Auxiliary 3 system/wiring open or
short circuit
AUX4 Auxiliary 4 system/wiring open or
short circuit
AUX5 Auxiliary 5 system/wiring open or
short circuit
Lining Wear Group
BRAKE PADS Lining wear wiring open circuit
Lateral Accelerometer
LAT ACC OC Lateral accelerometer wiring open circuit
LAT ACC SC Lateral accelerometer wiring short circuit
LAT ACC SIGNAL Lateral accelerometer signal fault
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
Note: If a DTC is displayed and after following recommended
procedure, as detailed in the Service Manual, no fault is found,
the ECU should be replaced.
Diagnostic Trouble Codes (DTC)