BENDIX BW2772 User's Manual
Contents
1. 41 91mm St xoxo NENNEN 3 67 93 18mm u 2 90 0 38 gt 73 7mm L 0 38 9 76mm 367 9 76mm E 93 18m Torque Specification Recommended mounting screws 6x19 Plastite thread forming screw 3 8 9 52mm long Torque mounting screw to 7 Ibs in 0 7 0 79Nem 0 08 maximum 22 Mounting Requirements Installation The DIU should be located where the driver can easily view and adjust the controls This can be located on top of or integrated into the dashboard flush with the front edge of the dashboard Ease of operation and visibility of the DIU front panel are the primary considerations The method chosen for routing the wiring harness to the DIU should also be taken into consideration when determining the optimal location Installation involves mounting the DIU to an in dash or on dash bracket Attach the bottom of the DIU to the bracket with 6 19 Plastite screws The four mounting screw locations on the display are 393 10mm deep maximum The screws should leave about 060 1 5mm minimum of clearance between the tip and the bottom of the hole when installed For example a 375 9 5mm long screw with a 060 1 5mm thick bracket would be acceptable Suggested Mounting Brackets In Dash Installation On Dash Installation Driver Interface ON m Driver Interface p 5 PA Unit DIU Hole Mounting Bracket je Mounting Bracket Screws goi OEM Supplied OEM Supplied2. Forward Looking Radar Engine ECM a hae Ignition Power Switched Power RED en Run to Main Power Lead that feeds the Ignition Bus Ground Terminating Run to Cab Ground Stud Resistor uu Terminating gt r Resistor eS lt ar4 efa o tai Terminating Resistor 43 Appendix Collision Warning System with Side Object Detection Driver Interface Unit Forward Looking Radar RED 2 AN Fuse lgnition Power Switched Power r1 9 Run to Main Power Lead that 4 AMP Fuse RED O gt Ignition Power Switched Power Ru Ground n to Main Power Lead that feeds the Ignition Bus Run to Cab Ground Stud Engine ECM feeds the Ignition Bus Ground Run to Cab Ground Stud Terminating Resistor 5 arhe 44 Terminating Resistor SS Terminating Resistor 1 AMP Fuse RED Ignition Power Switched Power Run to Main Power Lead that feeds the Ignition Bus Ground Run to Cab Ground Stud To Turn gt Signal Connector Pin Descriptions Forward Looking Radar 10 pin TRW Connector Appendix PIN 4 SIGNAL NAME TYPE INTERFACE LEVEL 1 NO CONNECTION 2 NO CONNECTION z 3 J1939 SHIELD TRUCK J1939 LINK 4 CAN HI E TRUCK J1939 LINK 5 CAN LO TRUC
3. 0 15mm Thickness recommendation is based on cover being a flat unpainted surface that extends beyond the No Radar Obstruction Zone see previous page Since paints can impact the losses they need to be evaluated separately As with the cover the paint must not contain metal or carbon e The thickness depends on the angle of incidence of the bumper shield located in the radar field view relative to the radar beam axis it should be updated with the real angle e The angle of incidence is recommended to be between 50 to 80 90 is prohibited so as to avoid any spurious reflection of the radar beam back into the Forward Looking Radar Reflected Beam Radar gt Beam e Painting can induce extra losses that depend heavily on the painting thickness itself and on its painting process These paints need to be tested individually to assess their impact on the recommendations made in this document For more information see the Painting section of this publication Mounting Requirements Options in white boxes are considered good options Options in grey boxes are considered possible options Material Recommended Recommended Material Number Commercial Reference Material Thickness mm Thickness with Cover 80 mm 1 Polyloy B69L62 PA6 2 25 2 22 TUC1228 93 2 CYCOLAC XMA 2 36 2 32 TUC1137 94 3 53 3 48 3 B70GFE30 2 1 2 07 TUC308 92 4 Hostacom PPX67
4. h 2 se N T I S Screws Double sided Tape I Screws KX Dashboard 7 OEM Supplied Soke lt gt Dashboard Bezel 23 Electrical Requirements Electrical Requirements Forward Looking Radar FLR Power Requirements e Operating Voltage 9 16Vdc e Power Current lt 2 amps average 1 amp e Recommended Fuse 5 amp delayed fuse Wiring Schematic All electrical connections can be made in the engine compartment Front Looking Radar J1 Mating Connector FEP Connector Body 42122600 1 Terminals Amp Tyco Cable Seal 0964972 1 Cavity Plug 0963531 1 Terminal 20 AWG 0969005 2 FRONT VIEW Terminal 18 AWG 09642742 FLR 10 pin Connnector Double wall shrink tubing 3 FLR 00 J1939 Data 10 pin Connector Link 3 E 5amp fuse 9 a A TI bd 100 S gt 2 24 Electrical Requirements Wiring Harness Forward Looking Radar CTI JS J1 Quantity Mating Connector FEP Connector Body 42122600 1 Terminals Amp Tyco 4 TI J2 Cable Seal 0964972 1 6 Cavity Plug 0963531 1 4 an Terminal 20 AWG 0969005 2 2 Terminal 18 AWG 0964274 2 2 U J2 Mating Connector Packard Connector Body 12092449 1 Cover 12033731 1 Terminal 12020156
5. 1 Remove cable outer jacket approximately 1 25mm Remove foil from exposed wires to within 1 16 2mm from cable jacket Strip insulation from data wires 25 7mm Boom Attach extended wire barrel socket contact to the drain wire or attach adhesive filler solder sleeve and wire to drain wire per manufacturer s recommendations For the solder sleeve option cut the wire on the solder sleeve to a length of 1 25mm and strip the insulation back 25 7mm 5 Crimp the appropriate terminal on each data wire and solder sleeve wire or the extended socket per the manufacturer s recommendations Slide the adhesive filler shrink tube over the cable end Install the terminals into the connector body per the manufacturer s instructions Install the wedge in the front of the connector body per the manufacturer s instructions e n Apply the shrink tube to the end of the connector body per the manufacturer s instructions Solder Sleeve with Wire Extended Socket Cable Drain Wire Wedge Shrink Tube Terminals Data Wires Final Assembly 39 Appendix SAE J1939 11 Recommended Cable Splice Procedure 1 gt m c Im Remove cable outer jacket approximately 1 1 2 to 4 40 to 100mm Remove foil shield from exposed wires to within 1 16 2mm from cable jacket Strip insulation from data wires 25 7mm Attach X link wire to drain wire with crimp slice p
6. Requirements Mounting Requirements The Forward Looking Radar can be mounted on the front of the vehicle or integrated behind a non metallic body panel as long as the mounting alignment and material requirements are met in the following sections Field of View Definition The Forward Looking Radar FLR field of view in elevation and azimuth is illustrated below The grey area represents a cross cut view of the three dimensional No Radar Obstruction Zone Using the illustration below the diameter of the hole in front of the Forward Looking Radar can de determined For materials within 30mm of the FLR the hole diameter must be greater than 70mm For materials 40mm from the front of the FLR the hole diameter must be Any hole diameter less than the required size will effect a clear line of sight for the FLR unit greater than 90mm Forward Looking Radar No Radar Obstruction Zone Top View and Side View are Identical 77 2 76 3 54 70mm 90mm B PE vi 118 N 30mm N 45 NX 1 57 N 40mm x x 4 72 rm 120mm Mounting Requirements Cover Material Requirements Any material that may be located in the Forward Looking Radar s field of view including bumpers spoilers etc can not be made out of any metallic material or have any carbon content It is recommended that any material that will be located in the FLR field of view be approved b
7. gt lt 51 8mm gt 3 53 89 7mm Space Claim Side Sensor Display FOUR 4 METAL 1 20 30 5mm Pa SCREWS 1 60 40 6mm P 10 BRACKET L CAN BE BENT d x 15 DEGREES 4 X 125 3 2mm THRU MTG HOLES ADHESIVE BACKING 39 00 3 00 2 80 I 990 6mm 76 2mm bg i Space Claim Driver Interface Unit Dimensions 197 50mm 3 67 m 93 18mm 4X R 207 5 25 20 5 2 3 16 80 2 158 40 1 Panel Cut Out 2X 156 39 5 197 50 0 Without bezel Bu 40 9 4 3 22 81 8 3 67 93 18mm uu 2X 63 15 9 2X 2 5 22 5 7 Mounting Requirements Mounting Requirements Overview The installation of the Bendix VORAD VS 400 System is intended to cover a wide range of commercial vehicle applications This publication is intended to be a reference for commercial vehicle installations using the vehicle s SAE J1939 data link interface For vehicles without a SAE J1939 data link some installation procedures may vary for a proper system installation and operation Typical Component Locations Note Not all components are required for every application Side Sensor Display SSD Side Sensor 55 Forward Looking Radar FLR
8. 25 Ignition and Ground aoi tte v done ston and x RR ae dle de nat ec bd a ke ped Rn PORE ja 26 1930 0 5 27 Side Object Detection SOD i o deri nat ea dohod od R El RR E Cr 28 Power Requirements ect rete ae ee b i di a badek i R di d l deh dok Rae e d dd Rade eae a i 28 Wining Seh mall 555e ayi da yi aaa hisa da h gay dan lan nda aye on dab y min dah as ala ded nin 28 ignition and Ground sond 5jy davidd pe w W ilana ERI EE d aya RIP nee va Meere does 29 Driver Interface UND sse caro d an new eo 0 07050 te 30 Power ROGUIrEMENIS seen En eda k RONG b n We d l DEEPA ee be d k W k AA Ped Rede REE eS 30 Wiring ScheMatics gt 4 gt ppi 14o nal G AA E De u we Zan V ya Kde din 30 Wiring gt cesses ine yeu dex Bilek k AR l K r ER ee SR RA RR PAR PAR dee PK aa P ov 31 ignition and Ground gt 00 UIDI 32 1030 OO E 33 Sunc 34 Final Test een nn a aed t cal re Rn Pe e 35 0 0000 Appendix Retrofit Informations rire hr ee eg ee Be ee ee emam obed bed 36 J1939 11 Datalink Detaili gt as Hr sa aaa meer ende 38 SAE J1939 11 Recommended Cable Termination Procedure 39 SAE J1939 11 Recommended Cable Splice Procedure 40 Jil 999 15 lite Datali
9. 9 Horizontal af Alignment Screw Straight gt Edge Locking Screw Mounting Requirements Mounting Requirements Side Object Detection SOD Side Sensor The Side Sensor should be mounted on the side of the vehicle between 22 558 8mm and 36 914 4mm from the ground and at least 18 457 2mm rear of the side view mirror see diagram below Typically the Side Sensor is located on the passenger side of the vehicle however it can also be installed on the driver side of the vehicle Note To reduce the possibility of the sensor detecting objects mounted to the vehicle like the steps or fuel tanks make sure the face of the sensor extends out a minimum of 5 16 7 9mm further than any other object within 6 152 4mm of the sensor s body Failure to mount Side Sensor properly will result in a solid red light indicating a constant detect mode This is critical to the correct operation of the VS 400 system 558 8mm 48 18 i 1219 2mm 457 2mm 20 Mounting Requirements Sensor Orientation The Side Sensor should be orientated so the embossed logo is parallel to the ground Orientation is crucial for proper operation due to the radar s polarized beam profile Mounting the Sensor The sensor should be mounted to the vehicle using 10 24 6mm stainless steel hardware Bolts should be installed from the sensor side with flat washers and nylock nuts on the backside Torque har
10. Description Yes No Corrected Validate SmartCruise Adaptive Cruise Control Operation and CWS Operation dyno environment preferred 1 Start truck and verify VS 400 system powers up goes through bulb check with no faults indicated 2 Bring truck up to road speed 50 60 MPH suggested 3 Activate cruise control using vehicle controls set speed switch lever button etc Visually inspect DIU for SmartCruise activation notification Let truck speed stabilize 4 Stepon brake Truck should deactivate cruise function and coast Reactivate cruise function Truck should accelerate to set speed 5 Stepon clutch Truck should defuel coast Reactivate cruise function 6 Stepon accelerator Truck should accelerate Dyno Environment 7 Resume speed Lower the door to the dyno or move a reflective target in front of Forward Looking Radar 15 30 feet away from and directly in front of Forward Looking Radar While the target is moving in front of radar the VS 400 should see the target indicated by the DIU displaying lights CWS alerts LCD screen and audibles and the vehicle should defuel and apply the Jake brakes to slow vehicle speed 8 Assuming the above functions performed properly the vehicle defueled the target stopped moving indicated by no target detection in the DIU the vehicle engine did not drop below 1000 rpm and the road speed did not drop below minimum requirements the vehicle should n
11. Driver Interface Unit DIU Mounting Requirements Mounting Requirements Forward Looking Radar FLR The Forward Looking Radar FLR determines the distance lane position azimuth relative speed velocity and direction of vehicles in front of the host vehicle The FLR is a Doppler radar that transmits at a 77 GHz frequency A built in yaw rate sensor gyro provides relative azimuth for lane positioning in turns The SAE J1939 interface allows the FLR to be installed as a Bendix SmartCruise adaptive cruise control only stand alone unit or as a component of the complete Bendix VORAD VS 400 System The FLR can track multiple objects simultaneously in relative motion within the radar s effective range of view Relative motion is defined as an object s movement towards or away from the radar transceiver Note The Forward Looking Radar is only activated while the vehicle is in motion Mounting Orientation Front View Mounting Hole Locations Mirror Must s Be Visible o ZN n 3 3 84mm O Q L N gt N HOLE DIAMETER 25 6 5mm Connector Must Point Down I o 84mm Mounting Requirements Installation Bu Mounting mper Optional Bracket Adjustment Screw Note The design of the Mounting Bracket may vary This is a typical representation Located on the forward most position of the vehicle the FLR transmits and receives low power high frequency el
12. to Peak Displacement 3 7 3 Spectral Density of the Peak to Peak Displacement LZ d w 0 2 pip STE DE EN 1 N oo 01 i i SN 005 Zeb 0 03 4 I E 4 4 ZB See ju x tore 0 01 j DL 5 10 20 30 40 Vibration Frequency Hz Mechanical movement along the X axis shall be less than Note All values are peak to peak e 5Hz 3mm e 10Hz lt 1mm e 20Hz lt 0 2 mm 30Hz 0 05 mm e Above 40 Hz lt 0 03 mm The spectral density of the peak to peak displacement shown above should be measured over 50ms Also the spectral density of the peak to peak displacement shall be less than the above mentioned values divided by 3 Mounting Requirements Painting A wide variety of colors and textures can be applied to the Forward Looking Radar housing using commercially available organic paints and conventional application processes Painting the component may assist with color degradation over time The following guidelines apply e Paints must not contain metal or carbon particles e Carbon content of paint could be a factor as high concentrations could reduce transparency e Paint thickness may impact the radar s ability to pass through the surface tis not recommended to paint the lens area Do not paint the FLR mirror e Do not paint the mounting points as it could cause incorrect bracket engagement e Protect the connector breather element during any painting operation Front View Do Not Pai
13. 01 Yellow Green JA BICC Brand Rex Shield Termination J 1939 N N 11939 J 1939 Shield T 14945 Yellow Green If an additional wire is added to the drain for insertion into the connector no shield terminal is used and the signal terminal Ifthe drain wire is to be directly inserted into the connector then a shield terminal is used and the signal terminal quantity is 2 quantity is 3 JA E Signal Terminals QTY Shield Terminal QTY Wedge Function 0462 201 1631 3 0462 221 1631 1 W3S 1939 P 2 Through Connector 0462 201 1631 3 0462 221 1631 1 W3S P012 Stub Connector N A N A N A T Receptacle N A N A N A 120 Ohm Termination 0460 202 1631 3 0460 247 1631 1 W3P ECU Receptacle 0460 202 1631 3 0460 247 1631 1 W3P 1939 Flang Receptacle JA N A N A 120 Ohm Termination ECM 1 VS 400 VS 400 FLR DIU I H F T El 1 00 Meter BU B j Max Length 1 00 Meter Max Length B c B B co SHE ud 8er as p mej Za A C A A F A C A A T E 4 I mj 3l Shield C A D Termination 16 Gage GXL 40 00 Meter Max Length 38 Appendix SAE J1939 11 Recommended Cable Termination Procedure
14. 2 5 Amp Fuse 12004005 1 J3 Mating Connector Deutsch Connector Body DTM06 2S 1 Wedge WM 2S 1 Socket 0462 201 20141 2 Notes All wires to be cross link TXL or equivalent unless otherwise specified Use approved J1939 cable Interconnection Table From To Code Gauge From To Code Gauge J1 1 Plug J1 7 Plug J1 2 Plug J1 8 Plug u J1 3 Plug J1 9 71 Ground 18 AWG J1 4 J3 A Yellow 20 AWG J1 10 J2 A IGN1 18 AWG J1 5 J3 B Green 20 AWG J2 B T2 Ignition 18 AWG J1 6 Plug 25 Electrical Requirements Ignition and Ground Forward Looking Radar FLR 10 pin Connector 5 am 9 OI Chassis Ae 777 Ground Ignition power switched power 10 run to main power lead that feeds the ignition bus FRONT VIEW FLR 10 pin Connnector J1 Pin Description J1 9 Chassis Ground J1 10 9 16VDC Switched 26 Electrical Requirements J1939 Note The J1939 data bus uses two 2 120 ohm resistors to terminate each end of the data bus on the vehicle These resistors must remain in place for proper data bus communication Due to the mounting location of the Forward Looking Radar the closest of the vehicle s J1939 terminators may have to be relocated nearer the radar as shown in the diagram below Check the resistance of the data bus using an ohmmeter before and after adding any device to the bus With the ignition key in
15. 3 Wedge WAP Turn Signal T1 Terminal 1060 16 0144 Side Sensor Display Xx Ignition T2 Ground T3 Notes All wires to be cross link GXL or equivalent unless otherwise specified Use approved J1939 cable Interconnection Table From To Code Gauge From To Code Gauge J2 1 T2 Ignition 18 AWG J2 5 J1 2 Signal Ground 18 AWG J2 2 T3 Chassis Ground 18 AWG J2 6 No Connection 18 AWG J2 3 J1 3 Communication 18AWG J1 4 Ti Right Turn Signal 18 AWG J2 4 J1 1 Power 18 AWG For this example the right turn signal is used however the left turn signal could also be used for a Side Sensor installed on the driver side of the vehicle 28 Electrical Requirements Ignition and Ground oe Sensor A j J2 T rp 1 amp f Side Sensor 6 way Connector 7 Ignition power switched power run to main power lead that Soc feeds the ignition bus T 1 amp UU fuse Ignition power To Side Sensor switched power e r n to main power lead that feeds the ignition bus Connector Rear Side Sensor 6 way Connector TS 5 6 2 29 Electrical Requirements Electrical Requirements Driver Interface Unit DIU Power Requirements e Operating Voltage 9 32Vdc e Power Current Not to exceed 2 amps Recommended Fuse 4 amp Wiring Schematics Driver Interface Unit J1 Mat
16. 8 2 2 38 2 34 TUC1617 89 5 NORYL PX1112 2 35 2 31 TUC648 86 3 53 3 48 6 Hostaform C9021 2 33 2 29 TUC2559 83 65 3 45 7 Hostalen GDPE7255 2 56 2 52 TUC310 92 3 84 3 78 8 Hostacom PPR1042 2 51 2 47 TUC2641 86 3 77 3 71 9 PP Kienb 2 39 2 35 3 58 3 53 10 ABS Kienb 2 32 2 28 11 PPN 1080 2 58 2 54 3 88 3 82 12 XENOY 2 35 2 31 POCAN KU PBT PC 13 ASA 2 26 14 PC 0 196 soot 2 33 2 29 15 TICONA Celanex 2003 2 15 2 12 GV1 20 PBT 20 GF 16 TICONA Celanex 2003 2 05 2 02 GV1 30 PBT 30 GF 17 GE Plastics NORYL 24 2 36 PPX630 PPE PP 30 GF 18 GE Plastics NORYL 2 1 2 07 GTX830 PPE PA 30 GF 19 Ryton PPS R4 240 Nat 2 1 2 07 PPS 40 GF Commercial references are from European suppliers for the automotive market Mounting Requirements Vibration Specifications Mounting mechanisms shall be designed to be compliant with the radar vibration spectrum illustrated below These vibration constraints are based on radio frequency considerations in order to be compliant with the radar functional specification There are no specific mechanical requirements along the Y and Z axis from a radio frequency point of view The mechanical movements measured at the FLR center along the X axis shall be less than the peak to peak displacement shown below Peak to Peak Displacement mm Spectral Density mm No Requirement in this Zone 10 Maximum Peak
17. Bendix testi Bendix VORAD VS 400 Installation Guide Bendix VORAD VS 400 System BW2772 Formerly VOIGO100 September 2010 Table of Contents Introduction VEC a E E E Br eh ek o_oa_gg_z mm 2 Federal Communications Commission iisis hh e 3 Application Inforimatiori sa i x s n ya w n dla an A E ERU Niet S Sa a E gx K D 4 X da EROS dla ben 4 Installation ToolS 3 i esta st bd dada re bie dro k oe bak Aa 6 dad Ee ae db add ho sekat roh Ka 5 Space Claim Forward Looking Radar Dimensions ccs 2 4 sa kay akla kk all ad uk a ab kk rra Zb 7 j 6 Side Object Detection Dimensions 000 9 00 7 8 Driver Interface Unit Dimensions nennen II mamans 9 Mounting Requirements Forward Looking Radar FER i si si njave v hr eR pes een arena en hr 11 19 Side Object Detection SOD 5 tee tr nx al heb s Rawk eee GEE a Re dib Re DER Za 20 21 Driver Interface Unit DIU perine i sanen xa dih E Gf TG dee AY WR Bir HR dee eon eee ed NX A AI AE PV Pra eus 22 23 Electrical Requirements Forward Looking Radar FEAR 5 3540 aan Rape dak spp asco dan Aa E ERU da ph AM ad aya dan nA 24 Power Requirements ss Ss x ac reste PR ena erf 4 ERR 44 XT PRA naka Rene d Rae ake de 24 Wining SEO MANO TP m o u ode od o G oz o n 24 Wiring Harriess scere Tr OS RES RE RET RUN ku ecb G kv koho kv be G oko kk Le ERE Pee ee k
18. ELEKTRIK PIRNA GmbH 8 CO KG Hugo K ttner StraBe 8 01796 Pirna Tel 49 3501 514 0 http www fepz de en e index html Littelfuse World Headguarters 800 E Northwest Highway Des Plains IL 60016 Tel 847 824 1188 Fax 847 391 0894 http www littelfuse com Molex 2222 Wellington Court Lisle IL 60532 1682 Tel 800 78MOLEX http www molex com Packard Delphi Connection Systems 5725 Delphi Drive Mail Station 483 400 301 Troy MI 48098 Tel 800 610 4835 http www delphisecure2 com site home homemain asp Packard Distributor Power 8 Signal Group World Headguarters 4670 Richmond Road Suite 120 Cleveland OH 44128 Tel 800 722 5273 or 216 378 6600 http www powerandsignal com 47 Roadranger The Roadranger System features Bendix brand foundation brakes 901 Cleveland Street Elyria OH 44035 e 1 800 AIR BRAKE gt www bendix com BW2772 2010 Bendix Commercial Vehicle Systems LLC a member of the Knorr Bremse Group All Rights Reserved 0
19. K J1939 LINK 6 NO CONNECTION 7 NO CONNECTION 8 NO CONNECTION 2 9 GROUND POWER CHASSIS GROUND 10 IGNITION POWER 12V SWITCHED Driver Interface Unit 8 Pin Molex Connector PIN 4 SIGNAL NAME TYPE INTERFACE LEVEL 1 RIGHT SPEAKER 0 SPEAKER DRIVER 4 OHM 1 WATT 2 LEFT SPEAKER 0 SPEAKER DRIVER 4 OHM 1 WATT 3 BLACKOUT INPUT SPARE TRI STATE INPUT 4 BATTERY POWER 9 32VDC SWITCHED 5 GROUND POWER CHASSIS GROUND 6 CAN LO TRUCK J1939 LINK 7 CAN HI TRUCK J1939 LINK 8 SPARE ANALOG TRI STATE INPUT 45 Appendix Side Sensor Display Unit 4 pin Deutsch Connector PIN SIGNAL NAME TYPE INTERFACE LEVEL POWER 12V FROM SENSOR GROUND POWER CHASSIS GROUND COMMUNICATION T pp TURN_SIGNAL 12V Side Sensor 6 pin Deutsch Connector PIN SIGNAL NAME TYPE INTERFACE LEVEL 1 IGNITION POWER 12V SWITCHED 2 GROUND POWER CHASSIS GROUND 3 COMMUNICATION O 4 POWER O 12V 5 SODDU GROUND POWER GROUND 6 NO CONNECTION 46 Appendix Vendor Contact Information AMP Tyco Harrisburg PA Tel 800 522 6752 http www tycoelectronics com Champlain Cable Corporation 175 Hercules Drive Colchester Vermont 05446 Tel 800 451 5162 http www champcable com Deutsch LADD Industries 4849 Hempstead Station Dr Kettering OH 45429 Tel 800 223 1236 http www laddinc com FEP FAHRZEUG
20. X X CWS Only X X S C amp CWS X X S C CWS amp SOD X X X SOD Only X S C Bendix SmartCruise adaptive cruise control CWS Collision Warning System Introduction Installation Tools Recommended Tools e Forward Looking Radar Alignment Tools Digital Level and 4 6 Straight Edge PC Based Service Tool ServiceRanger TCMT 0070B e Basic Hand Tools Reference Literature e Installation Guide BW2772 Troubleshooting Guide BW2771 e Driver Instructions BW2769 Reference Drawings e Side Object Detection System Display 15670 001 Installation Drawing e Side Object Detection System Sensor 15671 001 Installation Drawing e Side Object Detection System Harness 15672 001 Installation Drawing e Forward Looking Radar VSFR 001 Installation Drawing e Driver Interface Unit VSDI 001 Installation Drawing For more information within the U S Canada and Mexico call 1 800 AIR BRAKE 1 800 247 2725 or contact a local OEM dealer Space Claim Space Claim Forward Looking Radar Dimensions 3 85 98 0mm 2 49 63 4mm 3 87 98 5mm 3 30 84 0mm 1 60 40 6mm 3 30 84 0mm Space Claim Side Object Detection Dimensions Side Sensor 0 82 we 5 60 142 2mm 1 38 gt 35 1mm 0 9 22 9mm 2 04 2 04 151 8mm
21. al Terminals QTY Function DTMO06 28 0462 201 20141 2 Through Connector DTMO06 28 0462 201 20141 2 Stub Connector DTMO4 2P P007 N A T Receptacle DTMO04 2P EP10 N A 120 Ohm Termination DTMO4 2P 0460 202 20141 2 ECU Receptacle DTM04 2P 0460 202 20141 2 Through Receptacle DTM06 2S EP10 N A 120 Ohm Termination ECM A ENGINE VS 400 ECM MODULES x i h E 1 00 Meter E m Max Length B 3 00 Meter Max Length B L G c B B J ae cow aA y C A A F A c T n E GT C A D 40 00 Mete Max Length r 41 Appendix Wiring Schematics Bendix SmartCruise Adaptive Cruise Control and or Collision Warning System Using the OEM Integrated Dash as Display Forward Looking Radar Engine ECM 5 AMP Fuse a Ignition Power Switched Power gt Run to Main Power Lead that feeds the Ignition Bus r Ground Terminating Run to Cab Ground Stud Resistor E D nimi Terminating Resistor 42 Appendix Bendix SmartCruise Adaptive Cruise Control and or Collision Warning System Using the Driver Interface Unit as Display Driver Interface Unit 4 AMP Fuse RED Ignition Power Switched Power 5 Run to Main Power Lead that feeds the Ignition Bus Ground Run to Cab Ground Stud
22. arate hang on switch or relay of the correct capacity using added wiring of the correct gauge Failure to adopt this precaution will lead to switch contacts burning The following wire table suggests wire gauges for various maximum current draws and will aid in the selection of the correct wire size The current capacity of a given wire varies with temperature and type of insulation but the following values are generally acceptable If the total electrical load on the circuit after the addition of electrical equipment is less than the fuse protection in that circuit or less than the capacity of some limiting component switch relay etc the items to be added can be connected directly to that circuit The connection points and allowable loads are normally found in the owner s manual Contact the OEM with any questions Appendix Maximum Current Capacity Wire Gauge Crosslink Polythlene Copper Wire 20 14 Amps 18 18 Amps 16 24 Amps 14 34 Amps 12 42 Amps 10 58 Amps 8 80 Amps 6 110 Amps 37 Appendix J1939 11 Data Link Detail Recommended Cable Manufacturer Cable Part Number J1939 PIN A Color Color J1939 PIN B J1939 PIN C Shield Champlain 23 00013 001 Yellow Green IA Champlain 23 00028 001 Yellow Green JA Raychem 2021D0311 Yellow Green JA Raychem 2021D0001 Yellow Green JA Raychem 2021D03
23. ay vary Locking A a Screw Alignment Digital Level Screws see 1 ZNS Locking Screw Mounting Requirements Horizontal Alignment The Forward Looking Radar must be facing straight ahead azimuth of the vehicle in order to optimally detect objects in the vehicle path 1 Select two truck reference points that are identical and symmetrical about the truck centerline Ensure the reference points are equally aligned Items such as fenders and headlights should not be damaged or distorted otherwise the alignment will be inaccurate Center a 4 6 1 2m straight edge across a flat surface of the Forward Looking Radar bracket Measure the distance between the reference points and the face of the straight edge Use a 5 32 Allen wrench to loosen the locking screws Note Failure to loosen both locking screws will result in damage to the alignment bracket Adjust the alignment screw until the two measurement points are equal within 1 2 54mm Once the measurements are equal for both of the reference points tighten the locking screws Check both the vertical and horizontal alignment a Re measure the reference points to ensure they are equal b Use the digital level to verify the vertical alignment is still face down 0 from vertical 2 Note The illustration below shows a typical mounting and mounting bracket The design may vary id gt
24. d by the assembly plant are designed to accommodate only the OEM installed wires Additional wiring or tubing must be retained by additional clips When added wires to tubes are routed through sheet metal panels new holes must be used with adequate wire protection and sealing All wiring connections to components of the factory installed system must be accomplished by using the correct mating wire termination Connections on studs and ground connections must use ring type terminations When it is necessary to splice wires the splice must be adequately crimped to provide a good mechanical and electrical connection Double wall heat shrink tubing should be used where the outer wall will provide adequate electrical insulation and the inner wall melts and seals the splice from the envionrment Never add another circuit or splice into the ignition or battery power supplies The fuses and curcuit breakers installed at the assembly plant are designed to protect the wiring and electrical components from overloads Never remove a factory installed fuse or circuit breaker and replace with a high value device If the added electrical device causes fuse blow or circuit breaker cycling it indicates the total load is too high for the factory installed circuit protection and requires revisions in the added circuit not an increase in fuse or circuit breaker size In this case the device cannot be added directly to the circuit but must be connected through a sep
25. dware to a maximum of 22 Ibs in 2 5 Nm Do not over torque A CAUTION Failure to observe torque setting will result in a damaged or cracked sensor and result in a void of warranty Mounting Wrench Side Sensor Side Sensor Display The Side Sensor Display SSD should be mounted on the inside of the cab to the windshield pillar The display unit should be positioned in line with the side view mirror on the same side of the vehicle as the sensor without obstructing the driver s view The Side Sensor Display is not weather proof and must be mounted on the inside of the cab Failure to observe this warning will result in a void of warranty Side Sensor Display To Side Sensor Vehicles with dual left and right side sensors will have a display mounted on both the left and right windshield pillars 21 Mounting Requirements Mounting Requirements Driver Interface Unit DIU The Driver Interface Unit DIU serves as the Bendix VORAD Collision Warning System s central information center The DIU provides the driver with visual and audible alerts as well as system configuration status and diagnostic information The DIU uses the vehicle s SAE J1939 data link to communicate with the FLR and other vehicle system devices Mounting Orientation Mouting Screw Locations Dash Cutout Bottom View Fm oby 23 23mm un endu 50mm 1 65 P N VSD 001
26. ectromagnetic energy Transmitted energy that is reflected off objects in front of the vehicle is received and processed by the radar s internal microprocessor to determine the object s relative distance position azimuth speed velocity and direction of travel For proper operation the 77GHz forward looking radar unit shall be installed on the vehicle with the following constraints The radar unit must be rigidly attached to the forward most position of the vehicle chassis perpendicular with the vehicle s forward thrust axis The lateral position of the radar should be located as close to the vehicle s center as possible 50mm The vertical position of the radar must be at a minimum of 12 304 8mm and a maximum of 28 711 2mm from the ground The radar must be installed in a manner that protects it from minor frontal impacts as well as protecting the radar s harness connector from road debris The mounting hardware must allow for a minimum of 3 mechanical adjustment of the radar s horizontal and vertical axis The radar must be orientated so the harness connector is pointing in the downward position The mounting location must provide a clear view in front of the radar Ideally the radar will be recessed behind the profile of the vehicle s front bumper or grill but not to interfere with the radar s sight profile See No Radar Obstruction Zone on next page 16 406 4mm On Vehicle Centerline
27. er manufacturer s recommendation Slide adhesive filled shrink tube over crimp splice Slide adhesive filled shrink tube over cable end Crimp Shrink Tube Drain Wire Cross Link Shrink Tube Cable zl Data Wires me Shrink Tube Cable Drain Wire Data Wires Final Assembly Existing Drain Wire Splice Sealing Method 40 1 a mL X 0 s qe Remove cable outer jacket approximately 1 1 2 to 4 40 to 100mm Remove foil shield from exposed wires to within 1 16 2mm from cable jacket Strip insulation from data wires 25 7mm Crimp stub branch lines and drain wire to main backbone data lines and drain wire Cover each splice with insulation shrink tubing Wrap unshielded area with shielding material Apply adhesive filled shrink tube to splice junction For shield termination crimp maximum 16 gauge GXL wire to drain wire Appendix J1939 15 lite Data Link Detail Maximum 131 feet 40 meters length Maximum 10 feet 3 meters stub length Maximum 10 modules on segment Twisted pair 18 or 20 AWG with 1 twist per inch 120 Ohm terminating resistors must be used Connector at ECU is not defined The third pin for sheild is not used in in line the T connectors Recommended Cable Manufacturer Cable Part Number J1939 PIN A Color J1939 PIN B Color Champlain J 1939 15 Yellow Green Twisted Pair Body Sign
28. ing Connector Molex Connector Body 30700 1081 Terminal Amp Tyco FRONT VIEW Terminal 18 20 AWG 1393366 1 DIU 8 pin Connnector Optional I O 1 Right Speaker ee Left Speaker 3 Spare Input 1 Blackout DIU 8 pin Connector J 1939 Data Link 30 Electrical Requirements Wiring Harness T3 Z4 n T5 a 5 Ed Ih erm fo Quantity J1 9 Tl Mating Connector Molex ON Connector Body 30700 1081 1 T2 Terminal Amp Tyco 4 Terminal 18 20 AWG 1393366 1 4 J2 Mating Connector Packard Connector Body 12092449 1 Cover 12033731 1 Terminal 12020156 2 4 Amp Fuse 12004004 1 J2 on J3 Mating Connector Deutsch o Connector Body DTM06 2S 1 U Wedge WM 2S 1 Socket 0462 201 20141 2 Notes All wires to be cross link GXL or equivalent unless otherwise specified Use approved J1939 cable Interconnection Table From To Code Gauge From To Code Gauge J1 7 J3 A Yellow 20 AWG J2 B T2 Ignition 18 AWG J1 6 J3 B Green 20 AWG J1 1 T3 R SPK 20 AWG J1 5 T Ground 18 AWG J1 2 T4 L SPK 20 AWG J1 4 J2 A IGN1 18AWG J1 3 T5 Blackout 20 AWG 31 Electrical Requirements Ignition and Ground Driver Interface Unit o 5 l_J Bandit U J1 DIU 8 pin Connector 4 5 7 Chassis a 77 Ground Ig
29. liable connection and to prevent terminal fatigue Terminals and splices that are connected outside the body should be moisture resistant design Molded insulator for ring terminals should be used Molded connector insulators are recommended for use with blade or pin type terminals Wires must be routed to provide at least 3 75mm clearance to moving parts unless positively fastened or protected by conduit Wire routing should avoid areas where temperatures exceed 80 C 180 F and a minimum clearance of 6 150mm should be maintained from exhaust system components Where compliance with this requirement is not possible heat insulation and heat shields are required Wire routing and component mounting switches relays etc should be located to be easily removed for service Do not surround the components with body structure that will prevent removal for service Wiring to all circuit components switches relays etc in exposed locations shall provide a drip loop to prevent moisture from being conducted into the device via the wire connection Routing wiring into wheel splash areas should be avoided When such routing cannot be avoided adequate clipping or protective shielding is required to protect wiring from stone and ice damage Routing wires under the frame side members or at points lower than the bottom frame flange should be avoided to prevent damage to the wires in off road operations The wire retainers and grommets installe
30. nition power switched power d mn gt run to main power lead that feeds the ignition bus FRONT VIEW DIU 8 pin Connnector Pin Description J1 4 9 32VDC Switched J1 5 Chassis Ground 32 J1939 Terminating resistor Electrical Requirements Driver Interface Unit DIU 8 pin Connector Bulkhead connector located at firewall Engine ECM 1939 15 data link OEM supplied Terminating resistor FRONT VIEW DIU 8 pin Connnector Note The illustration above shows J1939 11 however J1939 15 2 wire can be used Pin Description J1 6 J1939 J1 7 J1939 33 Electrical Requirements Optional I O Driver Interface Unit J1 DIU 8 pin Connector 14 18 2 4 3 15 FRONT VIEW DIU 8 pin Connnector Hi WIRE SOFTWARE PIN DESCRIPTION FUNCTION INPUT OUTPUT REQUIRED 1 R SPK Right Speaker Output 4 ohm 1 watt Yes 2 L SPK Left Speaker Output 4 ohm 1 watt Yes 3 Blackout Blackout Input Input Tri state Yes 34 Final Test Final Test Bendix VORAD VS 400 SmartCruise Adaptive Cruise OEM Control and Collision Warning Chassis S N Trans Model Trans S N Functionality Testing Clutch Size Type Shift Control S N
31. nk Det ll gt x 2 2 ya y n wenay kuk kal hay Weda b wa Q ea are Wa v he 41 Wining SCHEMAS aus ss tes ur 0000 42 SmartCruise and or Collision Warning System 43 Collision Warning System with Side Object Detection 44 Connector Pin Descriptions 2 444444 ere Rp E REERRORCRPRRRGqR te d bod 4 h ee RIPE ER RR 45 Vendor Contact Information 2222 2040 24200000 47 General Information Warnings and Cautions Improper use of this system could lead to a serious accident Read this entire Installation Guide before operating the Bendix VORAD VS 400 system Pay particular attention to the safety messages below This manual should be used in conjunction with proper training Limitations of Collision Warning Systems The Bendix VORAD VS 400 collision warning system is intended solely as an aid for an alert and conscientious professional driver It is not to be used or relied upon to operate a vehicle The system should be used in conjunction with rear view mirrors and other instrumentation to maintain safe operation of the vehicle ground personnel and adjacent property A vehicle equipped with the Bendix VORAD VS 400 system should be operated in the same safe manner as if the system were not installed The system is not a substitute for normal safe driving procedures It will not compe
32. nsate for any driver impairment such as drugs alcohol or fatigue Should the system become inoperative it could jeopardize the safety or lives of those who depend on the system for safety The system will not sense objects if the sensor view is obstructed Therefore do not place objects in front of the system sensor Remove heavy buildups of mud dirt ice and other materials Proper alignment is critical to correct operation of the system Testing and inspection of the system in accordance with these instructions and record of the results should be listed on the daily maintenance report The units on operating vehicles must be tested each day see the Testing and Maintenance section prior to the vehicle s operation Results of this test must be recorded in the maintenance log People operating this equipment MUST check for proper operation at the beginning of every shift or safety inspection period People s lives depend on the proper installation of this product in conformance with these instructions It is necessary to read understand and follow all instructions shipped with the product Failure to follow all safety precautions and instructions may result in property damage serious injury or death The Bendix VORAD VS 400 system is intended for commercial use Proper installation of a backup aid requires a good understanding of truck electrical systems and procedures along with proficiency in the installation Store these instr
33. nt Mirror Do Not Paint Connector Breather Location Mounting Requirements Alignment The alignment of the Forward Looking Radar is critical to the correct operation of the Bendix VORAD VS 400 system Improper alignment can cause the system to improperly detect objects in the vehicle s path Every precaution should be taken to ensure the VS 400 alignment both horizontal and vertical is correct Alignment of the Forward Looking Radar is a repetitive process of adjusting the vertical and horizontal axis using the bracket screws Note The vehicle must be parked on a level surface If the vehicle is on an angled surface then level compensations must be made to ensure proper alignment Below are steps for a typical alignment procedure Other companies such as Hunter Engineering Company 11250 Hunter Drive Bridgeton MO 63044 314 731 3020 can also be contacted to establish alignment using professional alignment equipment Vertical Alignment The steps for vertical alignment are as follows 1 Hold a digital level against the flat surface of the mounting bracket 2 Use a 5 32 Allen wrench to loosen the locking screws Note Failure to loosen both locking screws will result in damage to the alignment bracket 3 Adjust the alignment screws until the digital level reads down 0 2 4 Once aligned tighten the locking screws Note The illustration below shows a typical mounting and mounting bracket The design m
34. ow accelerate back to the set speed on its own 9 Ifall tests performed and operated as outlined the Adaptive Cruise Control and CWS functionality test has completed properly and the Adaptive Cruise Control validation process is complete Note Because of the high horsepower engines in use today and the ability of the Jake brakes to apply twice the braking horsepower to the rear wheels the truck may defuel to the point the vehicle drops out of Cruise before the target has stopped moving This moving target indicated by the DIU displaying lights LCD screen and audibles would indicate a viable reason to defuel thereby causing the vehicle to Jake to the point the engine will disengage the cruise function This is normal and not a deficiency with the system Note To test each specific CWS alert requires accurate road speed and target closing distance calculations Therefore additional procedures are necessary to facilitate this functionality 35 Appendix Retrofit Information Retrofit Recommended Practices Body builder electrical systems that are to be interconnected with the VS 400 electrical system should adhere to the latest recommendations of SAE J1292 In addition to SAE J1292 the following recommendations should be followed 1 10 11 12 36 All wiring terminals should be properly insulated to prevent short circuits All terminals should be of insulation grip design to provide a re
35. the OFF position the resistance of the data bus should read approximately 60 ohms 120 2 Forward Looking Radar FLR 10 pin Connector Bulkhead connector located at firewall Terminating resistor 1939 11 data link OEM supplied Terminating Shield resistor zh termination FRONT VIEW FLR 10 pin Connnector Note The illustration above shows J1939 11 however J1939 15 2 wire can be used Pin Description J1 3 J1939_SHIELD J1 4 CAN_HI J1 5 CAN_LO 27 Electrical Requirements Electrical Requirements Side Object Detection SOD The Side Object Detection SOD system consists of two components a Side Sensor SS and a Side Sensor Display SSD Power Requirements e Operating Voltage 9 32Vdc e Power Current Not to exceed 0 25 amps Recommended Fuse 1 amp Wiring Schematics Side Sensor J2 9 NG ML Connector Rear V HARNESS A A Connector Rear l i INTERCONNECT I pem gt Ji 00U Fear ia Mating Connector Deutsch Connector Body DT04 6P CE03 Wedge Terminal W6P 1060 16 0144 Mating Connector Deutsch Connector Body DT04 4P CE0
36. uctions in a safe place and refer to them when maintaining and or reinstalling the product FCC Compliance Statement Federal Communications Commission This device complies with Part 15 of the FCC Federal Communications Commission rules Operation is subject to the following two conditions 1 This device may not cause harmful interference and 2 this device must be able to accept any interference received including interference that may cause undesired operation Any interference that may be caused should be reported to the local FCC field office or to the Federal Communications Commission Enforcement Bureau 445 12th Street S W Room 7 C485 Washington DC 20054 Any changes or modifications made by the user to this equipment that are not expressly approved by Bendix Commercial Vehicle Systems LLC could void the user s authority to operate the equipment Every effort has been made to ensure the accuracy of all information in this brochure However Bendix Commercial Vehicle Systems LLC makes no expressed or implied warranty or representation based on the enclosed information Errors or omissions should be reported to Bendix Commercial Vehicle Systems LLC 901 Cleveland Street Elyria OH 44035 or 1 800 AIR BRAKE 1 800 247 2725 Application Information Application Information Driver Interface Unit DIU and Side Object Forward Looking Radar FLR Detection System Function FLR DIU SOD S C Only
37. y Bendix Commercial Vehicle Systems prior to use If the radar has a cover perpendicular to the radar beam even a very slight vibration of the cover can cause the reflected radar signal to be Seen as a very strong false target at close range If the radar cover is not perpendicular by more than 5 then the returned reflection does not enter the receiver channel and hence is not detected The recommended angle of the beam to the cover is 50 to 80 There have been applications that have the cover perpendicular but the forward radar and the cover were directly mounted to each other to minimize the cover s movement to the radar module This may be a difficult condition to maintain The cover must not contain any metal or high carbon concentrations as this reduces the radar range The electrical characteristics of the cover material on microwave RF and its thickness can effect the range as well Polymeric or ceramic material is recommended Recommended thickness are based on the cover s angle The table on the following page lists material thicknesses for a perpendicular or 80 angle cover The ideal thickness also depends on the angle of incidence of the cover relative to the radar beam axis The materials in this table do not represent the only possible make up for a cover The recommendation scoring system has been applied as follows Losses shall be less than 0 7dB Thickness for rigidity reasons shall be greater than 2mm Thickness accuracy
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