BENDIX BW2212 User's Manual
Contents
1. 14 IR CAMERA WINDOW HEATER 15 DISPLAY theese ee et 16 COMBINER 16 FOLD MIRROR a 16 DISPLAY BRACKET 17 DISPLAY REPLACEMENT 18 HARNESSES 22 S x eee Ee Kee oea 18 AIMING THE IRCAMERA 21 HORIZONTALAIMING 21 VERTICALAIMING 22 TROUBLESHOOTING 24 SAFE MAINTENANCE PRACTICES WARNING PLEASE READ AND FOLLOW THESE INSTRUCTIONS TO AVOID PERSONAL INJURY OR DEATH When working on or around a vehicle the following general precautions should be observed at all times 1 Park the vehicle on a level surface apply the parking brakes and always block the wheels Always wear safety glasses 2 Stop the engine and remove ignition key when working under or around the vehicle When working in the engine compartment the engine should be shut off and the ignition key should be removed Where circumstances require that the engine be in operation EXTREME CAUTION should be used to prevent personal injury resulting from contact with moving rotating leaking heated or electrically charged components 3 Do not attempt to install remove disassemble or assemble a component until you have read and thoroughly understand the recommended procedures Use only the proper tools and observe all precautions pertaining to use of those tools 4 If the work is being performed on th2. 3 AMP slow open fuse Set pt a Red Ignition Wire Switch Ignition Headlamp bus i tT b Headlamp 1 AMP fast open fuse Butt Splice FIGURE 18 XVISION SYSTEM ELECTRICAL SCHEMATIC The IR camera and display are compatible with 12V DC battery systems with a chassis ground 10 OPERATING INPUT VOLTAGE The IR camera is operational in the temperature range between 40 C to 60 C Normally the IR camera takes about 45 seconds to warm up However as the external temperature gets closer to the extremes listed the warm up time will begin to approach two minutes Refer to Figure 19 1 V E 0 40 Temperature Celsius FIGURE 19 OPERATIONAL TEMPERATURE RANGE AND WARM UP TIME OF IR CAMERA SERVICING THE XVISIONSYSTEM The following sections provide instructions for maintaining and or replacing components of the XVision system CAMERA MOUNTING BRACKET REPLACEMENT 1 Loosen and remove the four 5 16 in bolts securing the IR camera bracket to the mounting bracket 2 Disconnect the camera harnesses 2 pin and 6 pin Remove the IR camera assembly 3 From inside the cab remove all mounting hardware from the mounting bracket 4 Remove the stud plates mounting bracket and shims if used 5 Clean the area around the drilled holes in the cab 6 Align the new mounting bracket with the holes in the cab Note use new mounting hardware for the installation Parts kits listed are
3. Hardware The IR camera bracket kit includes all of the necessary hardware to assemble the IR camera IR camera bracket and mounting bracket CB STYLE MOUNTING KIT PIECE NO 5010081 The CB style mounting kit contains the necessary mounting hardware for the CB style dashboard option and CB style overhead option When the display is mounted the combiner surface and virtual image must be viewable in the driver s peripheral vision A template is provided to help guide the drilling of holes The CB style mounting kit includes the following items Mounting brackets piece no 5009616 The CB style mounting kit includes two mounting brackets that can be used for either the CB dashboard mount or CB overhead mount Parts kits listed are now obsolete and are no longer serviceable through Bendix Mounting Brackets Mounting Brackets CB Style Dashboard CB Style Overhead FIGURE 5 CB MOUNTING BRACKETS Knob kit service piece no 5010247 The knob kit includes four 1 4 in flat washers and two 1 4 20 threaded knobs which are installed onto both sides of the display when it is mounted in the CB style Knob Kit Compo nents FIGURE 6 KNOB KIT COMPONENTS Plastite screws The CB style mounting kit includes four 10 Plastite screws each 1 2 in long Depending on the chosen CB mount the screws are used to attach the mounting brackets to either the headliner or dashboard of the vehicle FRICTI
4. Q Bendix XVision Night Vision System 5010086 consists of individually ordered through Bendix FIGURE 1 BENDIX XVISION SYSTEM SD 19 5160 temno Description av 1 Rem Sid x 2 jiRCameraBraket 1 x 3 jiRCamraHaess 1 x 4 MountingBracket 1 Display x 6 Combiner 1 _ 7 25 PinConmetor 1 8 Foomin Display Harness Aiming Adjuster Tool The display harness shown is for the friction hinge mount visor Please note that this product is obsolete and parts kits listed in this document are no longer serviceable through Bendix oy TABLE OF CONTENTS SAFE MAINTENANCE PRACTICES 3 INTRODUCTION 3 COMPONENTS sa sa lt eee sr a 3 IRCAMERABRACKETKII 4 CB STYLE MOUNTING KIT 3 FRICTION HINGE MOUNTING KIT 5 HARNESS KIT eee 6 AIMING ADJUSTER TOOL 8 IR CAMERA DISPLAY COMBINATION 8 REPLACEMENT KIIS 9 AIMING ADJUSTER REPLACEMENT 9 WINDOW REPLACEMENT 9 HEATER REPLACEMENT 9 COMBINER MIRROR REPLACEMENT 9 FOLD MIRROR REPLACEMENT 9 ELECTRICALSYSTEM 10 POWER AND GROUND INPUTS 10 OPERATING INPUT VOLTAGE 10 SERVICING THE BENDIX XVISION SYSTEM 11 MOUNTING BRACKET 11 IR CAMERA BRACKET 11 IRCAMERA 2 12 IR CAMERA WINDOW
5. 1 Unlock the IR camera by turning the two IR camera aiming adjusters and the IR camera standoff 1 4 turn counterclockwise Remove the IR camera from the IR camera bracket to gain easier access to the connectors Disconnect the 6 pin IR camera connector and the 2 pin window heater connector of the IR camera harness from the IR camera Lay the IR camera face up for easier access to the bezel retaining plug Refer to Figure 27 Bezel Heater Assembly IR Camera Window Black side IR Camera Window Seal IR Camera iene Bezel Retaining Plug FIGURE 27 BEZEL HEATER ASSEMBLY AND RETAINING PLUG 5 6 10 11 12 13 Remove the bezel retaining plug Turn the bezel heater assembly 1 4 turn counterclockwise until it separates from the IR camera Use care to prevent the window from falling and breaking Turn the new bezel heater assembly 1 4 turn clockwise onto the IR camera Note Ensure the window has not moved or it will be damaged Lock the new heater in position with the bezel retaining plug Plug the 2 pin connector of the IR camera harness into the window heater Refer to Figure 24 Plug the 6 pin connector of the IR camera harness into the IR camera connection Refer to Figure 24 Position the IR camera onto the factory installed aiming assemblies Rotate the pivot locks on the end of the aiming assemblies 1 4 turn clockwise using the aiming adjuster tool This will lock th
6. Jumper Harness 1 2 Remove any fasteners securing the jumper harness Disconnect the jumper harness from the IR camera harness and the display harness Connect the replacement jumper harness to the IR camera harness and the display harness 4 Turn the system on to verify that it is operating correctly 5 Secure the new jumper harness every 6 12 in with cable ties Parts kits listed are now obsolete and are no longer serviceable through Bendix AIMING THE IR CAMERA The aiming adjusters on the IR camera bracket allow the Dir forward field of view FOV of the IR camera to be adjusted j horizontally and vertically The adjustment screw head s will accommodate an E8 external Torx or a T15 internal Ton When the IR camera is mounted adjust the horizontal and vertical aiming adjusters to align the IR camera FOV with the display The position of the virtual image on the display and how the virtual image correlates to objects in the road depends directly on IR camera aiming NOTE Use two people to aim and adjust the IR camera One technician should view the virtual image on the display while the other technician aims the IR camera NOTE Verify that the vehicle is level and that the tires are properly inflated before beginning the IR camera aiming procedure HORIZONTAL AIMING AND ADJUSTING When the IR camera is not mounted directly above the driver the angle of the IR camera will nee
7. M EST Alternatively you may e mail the Bendix Tech Team at techteam bendix com 25 26 NOTES NOTES 28 BW2212 2011 Bendix Commercial Vehicle Systems LLC AllRights Reserved 8 11 Printed in U S A
8. N PUeyoeY pajeasun uld 8 JO O uuoS YOR S Pueyoed p le sun uld 9 JOJOBUUOD YOed HIS Puleyoe p le sun Uld JuW D 1 YMd HLH MOPUIM 9JlUW 19E8 q GND HLH AODUI AA Ul UIEIG parys u B y UBIH Indu o p A NOJ MO ndu o p A pes 49e q GND eJSWeD al yoe q pe1 YMd P sng lt m O Q ul QO lt m O DQ ul O Zx Jl uwW D 1 YMd HLH MOpUIM pymyelq GND HLH AODUIAA Ul UIEJQ O DpIA uaeJ6 1 H O pIA NO 1 1 O p A Ppes 49e q GND SJSWeD al 198 Q D91 YMd BJOWED H qmaoaqauwd0z SHYM P81 YMd HLH MOPUIM pymyelq GND HLH MOpuIM A ul UleJG APIA uaeJ6 1 H O PIA Wie 417 O p A Pas oe q GND EJ WED al LyvOLOG ss uieH J dwnf esawey HI OLZOLOS GNH BABAR Bf 398l q p 1 YMd PJSWED Ul 97ZOLOS SSOUJEH CIOWELD YI lt m O nD trLZ9800S BJOWED H WIA GND l95u A yoelq p 1 JOmMOod pesn4 SC x O paupjorig ANS eieweg wy VE x Ses molaky mor ndu oopa useJ6 3 UBIH Indu o p A r un uteq plus 9b u SIUM GND HLH Mopuyy x NUWD I Ud HLH MODUIA C PO SERT l x e
9. The kit includes the items below Standoff pivot assembly QTY 1 fastens to the IR camera standoff base with a maximum torque of 16 in lbs Standoff base QTY 1 fastens to the IR camera bracket with 10 Plastite Hex flange head screw and lockwasher with a maximum torque of 18 20 in lbs Aiming adjusters QTY 2 latch the IR camera into position on the IR camera bracket and allow the IR camera forward Field of Vision FOV to be adjusted horizontally and or vertically The adjustment screw head s accommodate an E8 external Torx or a T15 internal Torx tool The aiming adjusters are fastened to the IR camera bracket and torqued to 18 in lbs with four 8 32 Hex Torx screws Aiming Adjusters d 8 32 Hex Torx 18 in lbs 10 Plastite Hex flange with lock washer 18 20 in lbs Standoff Pivot Assembly 16 in Ibs FIGURE 15 AIMING ADJUSTER REPLACEMENT KIT WINDOW REPLACEMENT KIT PIECE NO 5010192 The window replacement kit includes one replacement IR camera window o ring and locking pin See Figure 16 HEATER REPLACEMENT KIT PIECE NO 5010193 The heater replacement kit includes one replacement IR camera heater and locking pin See Figure 16 Camera Heater Camera Window IR Camera FIGURE 16 IR CAMERA AND CAMERA HEATER COMBINER MIRROR REPLACEMENT KIT PIECE NO 5010190 The combiner mirror replacement kit includes one replacement combiner See Figure
10. be ON prior to performing any vehicle maintenance where one or more wheels on a drive axle are lifted off the ground and moving INTRODUCTION The Bendix XVision Night Vision system is an infrared IR vision system for heavy vehicles The system increases a driver s night visibility three to five times beyond the normal range of vehicle headlights allowing earlier detection of hazards The system features an IR camera that detects electromagnetic energy in the 7 14 micron wavelength region and outputs a real time monochrome video signal on a display Objects emit radiation in this wavelength region known as LWIR which is proportional to temperature The resulting video output is a thermal map of the forward road scene where hotter objects appear brighter than cooler objects COMPONENTS The XVision System Piece No 5010086 consists of the following six components described on pages 3 7 e IR Camera Bracket Kit Piece No 5010078 e CB Style Mounting Kit Piece No 5010081 e Friction Hinge Mounting Kit Piece No 5010082 e Harness Kit Piece No 5010083 e Aiming Adjuster Tool e IR Camera Display Combination Parts kits listed are now obsolete and are no longer serviceable through Bendix Parts kits listed are now obsolete and are no longer serviceable through Bendix IR CAMERA BRACKET KIT PIECE NO 5010078 INCLUDES Mounting Bracket Kit piece no 5010187 The mounting bracket is designed to mount to the
11. performance To clean the window use a soft damp cloth moistened with window cleaning solution Shop rags and paper towels will scratch optical surfaces NOTE The IR camera heater cannot melt large amounts of packed snow in the window area It is recommended that the snow be removed manually prior to system operation When cleaning ice or snow from the IR camera use a commercially available spray deicer do not use scrapers or sharp instruments that may scratch or break the window Replacing If the window cracks or breaks it must be replaced 1 14 Unlock the IR camera assembly by turning the two IR camera aiming adjusters and the standoff pivot assembly 1 4 turn counterclockwise Remove the IR camera from the IR camera bracket to gain easier access to the connectors Disconnect the 6 pin IR camera connector and the 2 pin window heater connection of the IR camera harness from the IR camera Lay the IR camera face up for easy access to the bezel retaining plug Refer to Figure 26 Remove the bezel retaining plug Turn the bezel heater assembly 1 4 turn counterclockwise until it separates from the IR camera Replace the damaged window and seal NOTE The replacement window is treated with a black scratch resistant coating on one side only The side that appears black must face the environment NOTE If the area between the IR camera window and IR camera lens is contaminated because of a damaged seal o
12. tightened to 90 100 in lbs 1 Using Figures 39 42 and a T15 Torx wrench adjust the angle of the IR camera as needed NOTE Two turns of the vertical adjuster is equal to one degree of IR camera movement NOTE It is recommended that the IR camera adjusters be aimed to view approximately 200 ft 61m in front of the vehicle Any thermal objects closer than 200 feet will already be illuminated by the low beam headlamps Vertical Aiming Adjuster 5 16 Bolts Tighten to 90 100 in lbs FIGURE 39 VERTICAL AIMING ADJUSTER NOTE Do not tamper with or adjust any factory installed screws while aiming the camera Only turn the vertical aiming adjuster 22 Combiner Image Center of Combiner Line 200 ft from Vehicle Driver s View FIGURE 40 IR CAMERA AIMED TOO HIGH Combiner Image Horizon Center of ane a TA z Line 200 ft from Vehicle 200 ft line Driver s View A FIGURE 41 IR CAMERA AIMED TOO LOW a EEE Combiner Image Center of Horizon Combiner ail gt 200 ft line AA Line 200 ft from Vehicle Driver s View FIGURE 42 IR CAMERA AIMED CORRECTLY si ploH SN4 o ds yng p le sun J1o jo uuoo q n elu uqns p le sun Uld GZ JO JOBUUOD YJEd HJ N Pseyoed p le S uld Z JolO uuoo YOed WIEeW pseyoed p le S uld 9 JOJOBUUOD YJ2Ed
13. vehicle roof horizontal mounting or faring area vertical mounting and needs to be mounted parallel to the lateral axis of the vehicle side to side Atemplate is provided to help guide the drilling of holes Two stud plates with 1 4 20 studs mount the bracket to the vehicle The final torque on the studs should be 90 100 in lbs Horizontal Mounted Bracket Vertical Mounted Bracket Faring Roof Mount Mount FIGURE 2 MOUNTING BRACKET ORIENTATIONS The mounting bracket kit also includes shims that should be used to level the mounting bracket A sealant is to be used between the vehicle mounting bracket and stud plate Verify that the sealant has been applied appropriately according to the Installation Instructions Additional mounting hardware is also included in the kit Stud Plate L Apply sealant between these surfaces Add shims if the surface is not level Roof FIGURE 3 MOUNTING BRACKET KIT CONTENTS IR Camera Bracket with Aiming Adjusters piece no 5010673 One IR camera bracket is provided in the IR camera bracket kit The bracket includes a standoff base standoff pivot assembly and aiming adjusters all of which are pre installed Holes for Harness Cable Tie Standoff and Pivot Assembly FIGURE 4 IR CAMERA BRACKET WITH AIMING ADJUSTERS Cable Tie A cable tie to fasten the IR camera harness to the IR camera bracket is also included in the IR camera bracket kit
14. wire which needs to be fused to the vehicle ignition and connects directly to the IR camera harness and the other headlamps The harness has one 3 pin connector that to the display harness The jumper harness is not designed connects to the display harness to be mounted externally See Figure 11 and Table 4 The vehicle harness is not designed to be mounted externally After the harness is routed and secured with cable ties the excess wire should be removed and the fuse holders installed See Figure 10 and Table 3 FIGURE 11 JUMPER HARNESS TABLE 4 JUMPER HARNESS PIN OUTS FIGURE 10 VEHICLE HARNESS Delphi Packard Connector lph Fackatd Connector 8 contacts Connector P N 12045688 oe ek TABLE 3 VEHICLE HARNESS PIN OUTS a aa 12047767 Delphi Packard Connector 3 Contacts Connector P N 12047782 Terminal P N 12059894 Vehicle ignition 3 A slow open 12 Volts fuse max RED Not Used Window Heater Window Heater Not Used Window Heater Window Heater 1 A fast open Headlamp active fuse max A bB Vehicle ground pe BLACK C Harness Hardware Two fuse holders three butt splices a 1 Afast open fuse and a 3 A slow open fuse are all included in the harness kit Labels are also included and must be applied to the fuse holders after installation Parts kits listed are now obsolete and are no longer serviceable through Bendix AIMING ADJUSTER TOOL The aiming adjuster tool is included w
15. 17 Parts kits listed are now obsolete and are no longer serviceable through Bendix Display Replacement IMPORTANT The display is not waterproof and should not be exposed to rain snow or moisture Under extreme conditions water may enter the circuitry through the panel buttons In general treat the display as you would a pocket calculator or other small non waterproof electronic instrument IMPORTANT The Bendix XVision Night Vision System display technology is designed to meet severe temperature extremes However when installing the display for head down operation or for use in extremely warm climates take necessary precautions to shield the unit from direct sunlight Prolonged exposure to direct sunlight in enclosed truck cabs can damage the system CB Style Mount Dashboard and or Overhead 1 Unscrew and disconnect the 25 pin connector of the display harness 2 Unscrew the threaded knobs from the display and brackets Refer to Figure 30 Set the knobs and washers aside 3 Remove the old display 4 Setthe DIP switches on the new display according to Table 5 on Page 7 5 Slide one of the washers onto one of the threaded knobs 6 Hold one washer between the new display and a bracket while threading the washer knob from the outside of the bracket Refer to Figure 30 on Page 15 7 Repeat steps 5 and 6 for the other side of the display 8 Plug the 25 pin connector of the display harness into the new dis
16. 7 seconds after the headlamps are turned off the display will turn off Check to see if the IR camera is aimed correctly Display image is upside down Check that DIP switch 4 is set correctly Reference figure 14 on page 8 Display image is reversed right to left Check that DIP switch 3 is set correctly Reference figure 14 on page 8 The display image is difficult to view Check to see if the display intensity is set correctly Check that the combiner is open to an angle that allows you to see the image Check to see if the combiner fold mirror and LCD are clean Check to see if the IR camera window is cracked Moisture between the window and lens will limit image quality Snow build up on the IR camera window with the Bendix XVision Night Vision System powered Check the 2 pin IR camera harness connector is plugged into the IR camera heater Reference figure 21 on page 11 Check that the terminals are seated and the wiring is secure Check the 2 pin IR camera harness connections Reference the XVision system schematic figure 43 on page 23 pin voltage A IR camera heater 12 Volts power IR camera heater ground power Please note that this product is obsolete and parts kits listed in this document are no longer serviceable through Bendix For any inquiries regarding this system call the Bendix technical assistance team at 1 800 AIR BRAKE 1 800 247 2725 Monday through Friday 8 00 A M to 6 00 P
17. IR camera onto the factory installed aiming adjusters Rotate the pivot locks on the ends of the aiming adjusters 1 4 turn clockwise using the included aiming adjuster tool This will lock the IR camera in position Parts kits listed are now obsolete and are no longer serviceable through Bendix Replacing the Aiming Adjusters 1 Unlock the IR camera by turning the two IR camera aiming adjusters and the IR camera standoff 1 4 turn counterclockwise 2 Remove the IR camera from the IR camera bracket to get easier access to the connectors 3 Disconnect the 6 pin IR camera connector and the 2 pin window heater connector of the IR camera harness from the IR camera Cut the cable tie to allow access Refer to Figure 24 Cable Tie 6 pin connector 2 pin connector FIGURE 24 CONNECTING THE CAMERA HARNESSES 4 Remove the 8 32 Hex Torx screws from the damaged aiming adjuster s Refer to Figure 25 5 Remove the Plastite Hex flange head screw and 10 lock washer from the damaged standoff pivot assembly 8 32 Hex Torx 18 in Ibs 10 Plastite Hex o flange with lock washer 18 20 in lbs Standoff Base Standoff Pivot Assembly 16 in lbs FIGURE 25 AIMING ADJUSTER REPLACEMENT KIT COMPONENTS 6 Replace the damaged parts with the new aiming adjusters and standoff pivot assembly that were received with the service kit piece no 5010079 NOTE The IR camera bra
18. ON HINGE MOUNTING KIT PIECE NO 9010082 Friction hinge mounting allows the driver to use the sun visor during the day and the Bendix XVision Night Vision system at night The display pivots on a pair of friction hinges similar to a vehicle sun visor The hinges allow the display to be flipped out of the way of the visor and latched into either position by use of a magnet and striker plates The friction hinge mounting kit includes the following items Hinge Supports Two hinge supports secure the display to the vehicle headliner when the friction hinge mount is used The hinge supports are fastened to the headliner with four 10 Plastite pan head screws and to the display with two M2 5 threadroll pan head screws Magnet Kit piece no 5010524 The magnet kit includes a magnet striker plates spring and hardware The magnet and spring are attached to the display and one 1 striker plate is fastened to the vehicle headliner The other striker plates 2 sandwich the sun visor 10 Plastite Pan Head Screws Qty 4 Hinge Supports M2 5 Threadroll Pan Head Screw i Magnet Kit M2 5 Threadroll 4 Components Pan Head Screw FIGURE 7 FRICTION HINGE MOUNTING KIT COMPONENTS Screw and Shim Kit piece no 5010249 The screw and shim kit includes twelve 10 Plastite pan head screws and twelve spacer blocks The screws are used to fasten the friction hinge supports to the vehicle headliner and are supplie
19. UNT DASHBOARD POSITION WITH DISPLAY HARNESS The orientation of the virtual image on the display will depend on the display mounting style that you have chosen On the bottom of the display under a switch cover there are four dual inline position DIP switches which allow you to rotate or invert the image To access the DIP switches slide the cover away from the 25 pin connector Displays arrive from the factory with the DIP switches configured for the CB style dashboard mount Refer to Table 5 for the DIP switch settings appropriate for your mount FIGURE 14 DISPLAY DIP SWITCHES FOR DASHBOARD MOUNT TABLE 5 DIP SWITCH POSITIONS DIP Switch Positions Video ramets Tz o 4 Mounting Position Dash Mounted NTSC Overhead Mounted NTSC Parts kits listed are now obsolete and are no longer serviceable through Bendix REPLACEMENT KITS The following five kits contain replacement parts for the Bendix XVision Night Vision System Each of the replacement kits can be ordered through Bendix For instructions on installing replacement parts see the appropriate section of Servicing the XVision System beginning on Page 10 AIMING ADJUSTER REPLACEMENT KIT PIECE NO 5010079 The IR camera bracket can only be ordered as a component of the IR camera bracket kit However the components that attach to the IR camera bracket to aim and adjust the IR camera can each be ordered in the aiming adjuster replacement kit
20. ay harness Heat Shrinkable Shroud O Ring Externally Threaded Nut FIGURE 31 HEAT SHRINKABLE SHROUD ASSEMBLY 18 Pull the IR camera harness through the opening between the IR camera bracket and mounting bracket 19 Plug the 2 pin connector of the IR camera harness into the window heater Refer to Figure 32 20 Plug the 6 pin connector of the IR camera harness into the IR camera connection Refer to Figure 32 Cable Tie 6 pin connector 2 pin connector FIGURE 32 CONNECTING THE CAMERA HARNESSES 21 Loosely install the harness tie wrap around the harness 22 Position the IR camera onto the factory installed aiming assemblies Refer to Figure 33 23 Rotate the pivot locks on the ends of the aiming assemblies 1 4 turn clockwise using the included aiming adjuster tool This will lock the IR camera in position FIGURE 33 FULLY ASSEMBLED CAMERA 24 Securely tighten the harness cable tie 25 Ensure that the harness reaches the A pillar without trouble Once the shroud assembly is heat shrunk the harness cannot be moved or adjusted 26 After the IR camera harness is properly secured and routed heat shrink the shroud assembly from the outside of the vehicle using a heat gun WARNING Do not touch the shroud assembly after it has been heat shrunk It will be hot and may cause burns IMPORTANT Be careful not to melt the wiring or o ring during the heat shrinking process 19 Pa
21. cket can only be ordered as a component of the IR camera bracket kit However the components that attach to the IR camera bracket to aim and adjust the IR camera can each be ordered in the aiming adjuster replacement kit The kit includes the items below Standoff pivot assembly QTY 1 fastens to the IR camera standoff base with a maximum torque of 16 in lbs Standoff base QTY 1 fastens to the IR camera bracket with 10 Plastite Hex flange head screw and lockwasher with a maximum torque of 18 20 in Ibs Aiming adjusters QTY 2 latch the IR camera into position on the IR camera bracket and allow the IR camera forward FOV to be adjusted horizontally and or vertically The adjustment screw head s accommodate an E8 external Torx or a T15 internal Torx tool The aiming adjusters are fastened to the IR camera bracket and torqued to 18 in lbs with four 8 32 Hex Torx screws Install the new aiming adjuster s using the 8 32 Hex Torx screws Torque the screws to 18 in lbs Install the new standoff pivot assembly using the 10 lock washer and Plastite Hex flange head screw Torque the screw to 16 in lbs 13 Parts kits listed are now obsolete and are no longer serviceable through Bendix IR CAMERA WINDOW Maintaining The IR camera window a 1 3 mm thick silicon disk is an optical element and should be cleaned when it becomes dirty or filled with debris Dirt and debris can affect the IR camera
22. d in three different lengths The spacer blocks can be used to level the friction hinge supports if necessary Based on the number of spacers needed to level out the mount use either the 1 2 in 3 4 in or 1 in long screws 5 Parts kits listed are now obsolete and are no longer serviceable through Bendix HARNESS KIT PIECE NO 5010083 The harness kit includes IR Camera Harness piece no 5010246 service piece no 801156 The IR camera harness is approximately three feet long and has three connectors The 8 pin connector connects to the display harness the 2 pin connector connects to the IR camera window heater and the 6 pin connector connects to the IR camera power and video See Figure 8 and Table 1 below FIGURE 8 IR CAMERA HARNESS TABLE 1 IR CAMERA HARNESS PIN OUTS Delphi Packard Connector Delphi Packard Connector 6 contacts Connector P N 12162856 Terminal P N 12124075 Ramee 8 contacts Connector P N 12047886 Terminal P N 12047767 Delphi Packard Connector 2 contacts Connector P N 12162852 Terminal P N 12124075 IR Camera Video High Window Heater po Video High Heater E Video Drain Window Window Heater Display Harnesses CB style piece no 5010259 service piece no 801151 Friction Hinge piece no 5010263 service piece no 801155 The harness kit includes two display harnesses one for CB style mounts and one for the friction hinge mounts The
23. d to be adjusted Align the display image horizontally with the objects in the road to give the driver a sense of object location 1 Using Figures 35 38 and a T15 Torx wrench adjust the angle of the IR camera as needed NOTE Two and one quarter turns of the horizontal adjuster is equal to one degree of IR camera movement Driver s View FIGURE 37 IR CAMERA AIMED TOO FAR RIGHT Horizontal Aiming Ad juster Combiner image i y q A 1 w gt ae 5 Pu aD t FIGURE 35 HORIZONTAL AIMING ADJUSTER NOTE Do not tamper with or adjust any z Driver s View factory installed screws while aiming the camera Only turn the horizontal aiming adjuster FIGURE 38 R CAMERA AIMED CORRECTLY 21 Parts kits listed are now obsolete and are no longer serviceable through Bendix VERTICAL AIMING AND ADJUSTING The virtual image should be aligned vertically so that the horizon appears in the lower one half to one third of the combiner Keeping the image at this adjustment should provide a view of the road when the vehicle is driven up and down hills The vertical aiming adjusters can accommodate approximately 4 degrees of movement If the IR camera needs more than 4 degrees of vertical movement the IR camera bracket will need to be adjusted Before changing the vertical aiming adjuster make sure the 5 16 bolts of the IR camera bracket are
24. dsiq yooq oN anq Azi onov IH P yoerq GND piyan D yoelq AN9 epiuen G foed AN9 OPA nlq AZL onjoy TH O O ana AZI ony TH dwy snd pel JOMOd NO V x V pol JOMOd NO 9ZOLOS 40 6SZOLOS 1 depv sseusey dwy snd S9l eLu uoSsSs Aejdsiq yxooq oN pue esowey yy UBIY SALOD yopms duo POSH pal JOMOd NII SLZLLOS Wy SS UJEH ISAOd 22143A FIGURE 43 ELECTRICAL WIRING DIAGRAM FOR BENDIX XVISION NIGHT VISION SYSTEM 23 TROUBLESHOOTING Troubleshooting Your Bendix XVision Night Vision System Situation Possible Solutions Check that the combiner is open to an angle that allows you to see the image No image on the display Bendix logo does not appear during power up combiner and fold io qc Deh Make sure the vehicle accessory power headlights and the XVision system are all on Check that the display intensity is set at an appropriate level to view the image Check that the 25 pin connector of the display harness is com pletely plugged into the display and fastened Check the 25 pin display harness connections reference XVision system schematic figure 43 on page 23 Voltags round 72 Volis 12 Vols Incorrect voltage value ignition headlamp Check that the 3 A slow open fuse connecting the red wire of ground at 25 pin connector the vehicle harness to the 12V battery is intact Check that there
25. e IR camera in position Aim and adjust the IR camera Refer to Aiming the IR Camera on pages 21 and 22 15 Parts kits listed are now obsolete and are no longer serviceable through Bendix DISPLAY Maintaining the Combiner Mirror The combiner is a sensitive optical element and should be cleaned when it becomes dirty or filled with debris Dirt and debris can affect the display performance 1 Remove heavy dirt or grit with air 2 Clean the combiner with a soft damp cloth moistened with window cleaning solution Shop rags and paper towels will scratch this optical surface NOTE Do not use ammonia to clean any of the display components It will remove scratch resistant and anti glare coatings Replacing the Combiner Mirror 1 Locate the depression in the center of the combiner door Refer to Figure 28 Combiner Mirror Depression in Combiner Door FIGURE 28 REPLACEMENT COMBINER 2 Pry the old combiner out by inserting a small screwdriver or pocket knife into the depressions and pushing upward 3 Snap the new combiner gently in place 16 Maintaining the Fold Mirror Remove heavy dirt or grit from the fold mirror with air Clean the fold mirror with a soft damp cloth moistened with window cleaning solution Shop rags and paper towels will scratch this optical surface NOTE Do not use ammonia to clean any of the display components It will remove scratch resistant and anti glare coatings Replac
26. e vehicle s air brake system or any auxiliary pressurized air systems make certain to drain the air pressure from all reservoirs before beginning ANY work on the vehicle If the vehicle is equipped with a Bendix AD IS air dryer system or a dryer reservoir module be sure to drain the purge reservoir 5 Following the vehicle manufacturer s recommended procedures deactivate the electrical system in a manner that safely removes all electrical power from the vehicle 6 Never exceed manufacturer s recommended pressures 7 Never connect or disconnect a hose or line containing pressure it may whip Never remove a component or plug unless you are certain all system pressure has been depleted 8 Use only genuine Bendix brand replacement parts components and kits Replacement hardware tubing hose fittings etc must be of equivalent size type and strength as original equipment and be designed specifically for such applications and systems 9 Components with stripped threads or damaged parts should be replaced rather than repaired Do not attempt repairs requiring machining or welding unless specifically stated and approved by the vehicle and component manufacturer 10 Prior to returning the vehicle to service make certain all components and systems are restored to their proper operating condition 11 For vehicles with Automatic Traction Control ATC the ATC function must be disabled ATC indicator lamp should
27. harness for the CB style mounts exits toward the back of the display and the harness for the friction hinge mount exits toward the front of the display Both harnesses are three feet long When installed the display harness should be secured with a cable tie every three inches Both display harnesses have three connectors The 25 pin connector connects to the display the 3 pin connector connects to the vehicle harness and the 8 pin connector connects to the IR camera harness See Figure 9 and Table 2 A Display Harness Friction Hinge Mount Display Harness CB Mounts FIGURE 9 DISPLAY HARNESSES TABLE 2 DISPLAY HARNESS PIN OUTS Delphi Packard Connector 8 contacts Connector P N 12045688 Delphi Packard Connector 3 contacts Connector P N 12047782 Vehicle Ground Terminal Terminal P N 12059894 P N 12059894 IR Camera D Subminiature 25 Contacts D Video High Not Used Window Window Heater Parts kits listed are now obsolete and are no longer serviceable through Bendix Vehicle Harness piece no 5010260 service piece no Jumper Harness piece no 5010441 service piece no 801157 The vehicle harness is approximately 12 feet 801152 Thejumper harness acts as an extension cord long and provides power to the Bendix XVision Night when the display and IR camera are mounted more than Vision System The harness is made of a twisted tri six feet apart The harness has two 8 pin connectors one
28. ing the Fold Mirror 1 Locate one of the four depressions along the perimeter of the fold mirror Refer to Figure 29 Depressions in Fold Mirror FIGURE 29 REPLACEMENT FOLD MIRROR 2 Pry the old fold mirror out by inserting a small screwdriver or pocket knife into one of the depressions and pushing upward 3 Snap the new fold mirror gently into place Parts kits listed are now obsolete and are no longer serviceable through Bendix Display Bracket Replacement CB Style Mount Dashboard 1 Unscrew and disconnect the 25 pin connector of the display harness 2 Unscrew the threaded knobs from the display and brackets Set the display knobs and washers aside Exercise care to prevent dropping the washers into the venting on the dash 3 Remove the four 10 Plastite pan head screws from the brackets and dashboard Set the four screws aside 4 Secure the replacement brackets with the four screws from Step 3 5 Torque the screws to approximately 20 in lbs 6 Slide one of the washers onto one of the threaded knobs 7 Hold one washer between the display and a bracket while threading the washer knob from the outside of the bracket See Figure 30 i S SSES Ses Sz Sy ya aah a ios Went Tht aw w Pauling RE FIGURE 30 WASHERS AND THREADED KNOBS SHOWN IN CB STYLE MOUNT OVERHEAD POSITION 8 Repeat steps 6 and 7 for the other side of the display 9 Reconnect the 25 pin connector
29. is 12 Volts at this location using a multimeter Check that the 1 A fast open fuse connecting the blue wire of the vehicle harness to the head lamp circuit is intact With headlamps on check that there is 12 Volts at this location us ing a multimeter Check the ground connection of the vehicle harness Check the 3 pin vehicle harness connections reference XVision system schematic figure 43 on page 23 a 3 Pin Voltage A 72 Vols ground e TZ Volt Bendix logo remains on the display after 2 Check that the video in out switch is set to out Reference minutes figure 13 on page 7 Check that the 6 pin camera harness connector is plugged completely into the IR camera reference figure 21 on page 10 Check that the terminals are seated and the wiring secure Check the 6 pin IR camera harness connections 2 pins not used reference XVision system schematic figure 43 on page 23 Voltage 72 Vols C B IR camera ground Check to see if the IR camera harness 8 pin connector is plugged into the display harness 8 pin connector Reference figures 8 amp 9 on page 5 24 IR camera image is not displayed after the Wait two minutes after the Bendix XVision Night Vision Sys Bendix logo fades away on the display tem has been powered to view the IR camera image Check to see if the IR camera window is blocked Headlamps were turned off and the XVision system timed out approximately
30. isconnect the IR camera connector 6 pin and the window heater connector 2 pin of the IR camera harness Remove the IR camera and IR camera harness from the IR camera bracket The IR camera harness should be tied to the bracket with a cable tie Cut the tie to remove the harness Loosen and remove the four 5 16 in bolts from the IR camera bracket 5 Remove the old IR camera bracket 8 Place the new IR camera bracket in the same location as the old Insert the four 5 16 in bolts through the mounting bracket and new IR camera bracket into the threaded inserts and hand tighten Replace the camera shroud Attach the IR camera harness 9 10 11 12 Pull the IR camera harness through the opening between the IR camera bracket and mounting bracket Plug the 2 pin connector of the IR camera harness into the window heater Refer to Figure 21 Plug the 6 pin connector of the IR camera harness into the IR camera connection Refer to Figure 21 Loosely install the harness cable tie around the harness Cable Tie 6 pin connector FIGURE 21 CONNECTING THE CAMERA HARNESSES 11 Parts kits listed are now obsolete and are no longer serviceable through Bendix Attach the IR camera to the IR camera bracket 13 14 15 16 Position the IR camera onto the factory installed aiming assemblies Refer to Figure 22 Rotate the pivot locks on the ends of the aiming assemblies 1 4 tu
31. ith the Bendix XVision Night Vision System kit but cannot be ordered individually It is the only tool that should be used to install the IR camera onto the aiming adjusters IR CAMERA DISPLAY COMBINATION The IR camera and display are serviceable and can be ordered individually The IR camera display combination can be purchased as an entire XVision system IR Camera piece no 5008214 service piece no 801150 The IR camera must always be mounted externally to the vehicle and attaches to the standoff pivot assembly and aiming adjusters on the IR camera bracket The IR camera is operational within the range of 40 C to 60 C The IR camera has two electrical connections a 6 pin IR camera connector and a 2 pin window heater connector Aiming Adjuster Mounting IR Camera Window Heater Connection Connection FIGURE 12 IR CAMERA Video Display piece no 5010210 service piece no 801154 The display is operational within the range of 40 C to 60 C During power up the Bendix icon will be displayed in the combiner for approximately 45 seconds The intensity control will need to be adjusted according to light conditions and driver preference After the initial warm up the IR camera s field of view FOV will be displayed in the combiner Combiner F Intensity Control On Off Switch Fold Mirror Video In Out Switch 25 pin Connector FIGURE 13 DISPLAY SHOWN IN CB STYLE MO
32. now obsolete and are no longer serviceable through Bendix Center line of Sight Lateral Axis of Mounting bracket can be any where along driver s center line of sight and must be parallel to lateral axis of vehicle Driver s IG L sll Vehicle FIGURE 20 MOUNTING BRACKET AND LATERAL AXIS OF VEHICLE T 10 11 12 13 Verify that the mounting bracket is level If it is not use the shims included in the mounting bracket kit Apply sealant between all contact areas between the roof and the shims between each shim between the shims and the bracket and between the bracket and stud plates Install the stud plates on both sides of the replacement mounting bracket From inside the cab tighten all mounting hardware to 90 100 in lbs Insert the four 5 16 in bolts through the mounting bracket into the new IR camera bracket and hand tighten Allow enough mobility for adjustments to be made during the aiming procedure Reconnect the 2 pin and 6 pin harnesses Aim and adjust the IR camera Refer to Aiming the IR Camera on Pages 21 22 IR CAMERA BRACKET REPLACEMENT The new IR camera bracket will have factory installed aiming adjusters and standoff base pivot assembly 1 Remove the camera shroud if equipped Unlock the IR camera by turning the two IR camera aiming adjusters and the IR camera standoff 1 4 turn counterclockwise using the adjuster tool 2 D
33. of the display harness Display Bracket Replacement CB Style Mount Overhead Refer to CB Style Mount Dashboard procedure Display Bracket Replacement Friction Hinge Mount Visor 1 Unscrew and disconnect the 25 pin connector of the display harness 2 Flip the display down to allow access to the friction hinge supports 3 Remove the four 10 Plastite pan head screws that secure the display to the headliner 4 Remove the two M2 5 threadroll pan head screws that secure the friction hinge supports to the display 5 Secure the new friction hinge supports to the display with the M2 5 threadroll pan head screws IMPORTANT Do not exceed 15 in lbs when fastening If 15 in lbs are exceeded the screw head will shear off or the standoffs will strip The threadroll screws will form threads in the standoffs as they are tightened If it feels as though the screw is binding back out the screw slightly and continue to tighten to prevent breakage 6 Secure the new friction hinge supports to the headliner with the four 10 Plastite pan head screws Torque the screws to approximately 15 in Ibs 7 Reconnect the 25 pin connector of the display harness Base Plate 8 32 Mounting Four 8 32 inserts are provided in the display base A template is provided to help guide the drilling of holes Use a 13 64 in bit for drilling the four clearance holes Typically this installation is used when the display is being recessed
34. onnector of the IR camera harness from the display harness 3 Turn the two IR camera aiming adjusters and the IR camera standoff pivot assembly 1 4 turn 4 Remove the IR camera from the IR camera bracket to gain easier access to the connectors 5 Disconnect the IR camera connector 6 pin and the window heater connector 2 pin of the IR camera harness 6 Cut the cable tie that secures the IR camera harness to the IR camera mounting bracket 7 From inside the cab remove the externally threaded nut from the harness 8 Remove the IR camera harness from the cab 9 Remove the externally threaded nut from the heat shrinkable shroud assembly on the replacement harness 10 From inside the cab push the threaded nut through the hole in the roof NOTE The threaded section of the nut should protrude past the vehicle surface Refer to Figure 31 11 Place the o ring over the externally threaded end 12 Thread the harness through the externally threaded nut 13 Fasten the heat shrinkable shroud onto the nut 14 Hand tighten the shroud from the outside of the roof 15 Torque the heat shrinkable shroud with a spanner Parts kits listed are now obsolete and are no longer serviceable through Bendix wrench to approximately 15 to 20 in lbs or until the o ring is slightly flattened 16 Route the IR camera harness to the A pillar of the cab 17 Connectthe 8 pin connector of the IR camera harness to the displ
35. play Friction Hinge Mount Visor 1 Disconnect the 25 pin connector of the display harness 2 Flip the display down to allow access to the friction hinge supports 3 Remove the four 10 Plastite pan head screws that secure the display to the headliner Remove the old display 5 Remove the two M2 5 threadroll pan head screws that secure the friction hinge supports to the display 6 Secure the friction hinge supports to the new display with the two M2 5 threadroll pan head screws IMPORTANT Do not exceed 15 in lbs when fastening If 15 in lbs are exceeded the screw head will shear off or the standoffs will strip The threadroll screws will form the threads on the standoffs as 18 they are tightened If it feels as though the screw is binding back out the screw slightly and continue to tighten to prevent breakage 7 Secure the friction hinge supports to the headliner with the four 10 Plastite pan head screws 8 Torque the screws to approximately 15 in lbs 9 Connect the 25 pin connector of the display harness to the new display HARNESS REPLACEMENT Each of the XVision System harnesses is replaceable and can be ordered through Bendix Refer to Figure 43 on page 22 for more detailed information regarding the electrical wiring of the system IR camera Harness 1 Remove the trim pieces covering the harness and the cab headliner in areas covering the IR camera harness 2 Disconnect the 8 pin c
36. r window carefully remove the contamination If a window cleaning solvent is used to clean the area be sure to remove all of the moisture from the sealed cavity before assembling the o ring seal and window Moisture remaining in the sealed area will affect the performance of the IR camera NOTE Use care when removing shards of glass 10 11 12 13 14 Turn the bezel heater assembly 1 4 turn clockwise to reattach it to the IR camera Note Ensure the window is positioned correctly or it can be damaged when installing the bezel Lock the bezel heater assembly in place with the bezel retention plug Plug the 2 pin connector of the IR camera harness into the window heater Refer to Figure 24 on page 12 Plug the 6 pin connector of the IR camera harness into the IR camera connection Refer to Figure 24 on page 12 Position the IR camera onto the factory installed aiming assemblies Rotate the pivot locks on the end of the aiming assemblies 1 4 turn clockwise using the aiming adjuster tool This will lock the IR camera in position Aim and adjust the IR camera Refer to Aiming the IR Camera on pages 21 and 22 Bezel Heater As sembly IR Camera Window Black side IR Camera Win dow Seal Bezel Retaining Plug IR Camera FIGURE 26 IK CAMERA WINDOW AND BEZEL RETAINING PLUG Parts kits listed are now obsolete and are no longer serviceable through Bendix IR CAMERA WINDOW HEATER REPLACEMENT
37. rn clockwise using the included aiming adjuster tool This will lock the IR camera in position Adjust the harness ensuring that it is not pulled tight which could cause a water leak into the camera Securely tighten the harness cable tie to prevent wire chaffing from the bracket Aim and adjust the IR camera Refer to Aiming the IR Camera on pages 21 and 22 Aiming Assembly FIGURE 22 FULLY ASSEMBLED IR CAMERA 12 IR CAMERA Maintaining The IR camera weighs approximately 2 lbs Conduct the following maintenance inspections on a regular basis 1 2 3 4 Inspect the harnessing for chafing Inspect mounting for loose bolts Inspect aiming adjusters for cracks or breaks Replace as necessary Inspect and clean the camera window Replacing IR Camera 1 Unlock the IR camera by turning the two IR camera aiming adjusters and the IR camera standoff 1 4 turn counterclockwise Remove the IR camera from the IR camera bracket to get easier access to the connectors Disconnect the 6 pin IR camera connector and the 2 pin window heater connector of the IR camera harness from the IR camera Install new camera Plug the 2 pin connector of the IR camera harness into the window heater Refer to Figure 23 Cable Tie 6 pin connector FIGURE 23 CONNECTING THE IR CAMERA HARNESSES 5 Plug the 6 pin connector of the IR camera harness into the IR camera connection Refer to Figure 23 Position the
38. rts kits listed are now obsolete and are no longer serviceable through Bendix TABLE 6 VEHICLE HARNESS WIRING Vehicle ignition 3 A slow open fuse pep 12 Volts max 27 28 29 Re install the headliner and the A pillar cover Turn on the system to verify that it is operating correctly Aim and adjust the IR camera Refer to Aiming the IR Camera on pages 20 and 21 Display Harness 1 Unscrew and disconnect the 25 pin connector of the display harness Remove the trim pieces covering the harness Disconnect the display harness from the 8 pin IR camera harness connector and the 3 pin vehicle harness connector Remove any fasteners securing the display harness 5 Connect the new display harness as follows the 3 pin connector to the vehicle harness the 8 pin connector to the IR camera harness e the 25 pin connector to the display Turn on the system to verify that it is operating correctly Replace the A pillar cover 8 Secure the new display harness every 3 in with cable ties Vehicle Harness WARNING Improper installation of the vehicle harness can cause damage to your vehicle s wiring and or to the Bendix Vision Night Vision System It is the responsibility of the installer to review wiring and service information for the vehicle and to identify proper locations for connecting the vehicle harness to the power Many modern vehicles have additional built in fused acces
39. s 17 amp 28 FOLD MIRROR REPLACEMENT KIT PIECE NO 5010189 The fold mirror replacement kit contains one replacement fold mirror See Figures 17 amp 29 Combiner Fold Mirror FIGURE 17 COMBINER AND FOLD MIRROR Parts kits listed are now obsolete and are no longer serviceable through Bendix ELECTRICAL SYSTEM POWER AND GROUND POWER INPUTS Electrical power to the Bendix XVision Night Vision System is provided through the vehicle harness The vehicle ignition wire A Red should be fused to a 3 A slow open fuse maximum and connected to the ignition bus of the vehicle The ground wire B black should be connected to the ground bus of the vehicle The headlamp active wire C blue should be fused to a 1 A fast open fuse maximum and connected to the vehicle headlamp circuit When the headlamps are on 12V should be present on the blue wire WARNING Vehicle power and headlight circuits MUST be fused Permanent damage to the display IR camera or vehicle electrical system could occur if power to these units is not fused Eliminating fuses from circuit will void all warranties IMPORTANT When replacing a fuse it is important to use only the specified fuse with the correct amperage as listed above The use of a fuse witha rating other than indicated may result in a dangerous electrical system overload Repeated opening of a properly rated fuse indicates a problem in the circuit that must be corrected
40. sory power breakouts and these breakouts should be used if at all possible 1 Remove the trim pieces covering the harness Disconnect the vehicle harness from the display harness 3 Remove the red wire A contact from the ignition bus T oo Se ol 20 Remove the blue wire C contact that is butt spliced between the headlamp and the headlamp switch Remove the black wire ground from the ground bus Remove any fasteners securing the vehicle harness Remove the old vehicle harness Strip the three ends of the new vehicle harness Connect the red wire A contact of the new vehicle harness to the ignition bus with a 3 Aslow open fuse Connector 3 Contacts Vehicle Harness B Vehicle ground A Wire Headlamp active ATO Op rise BLUE max 3 AMP slow open fuse pasin N Sa Red G gnition Switch Ignition Headlamp Battery T b Headlamp es l Switch 1 AMP fast open fuse Butt Splice FIGURE 34 XVISION SYSTEM ELECTRICAL POWER SCHEMATIC 10 11 12 13 14 15 Butt splice the blue wire C contact of the new vehicle harness between the headlamp and the headlamp switch with a 1 A fast open fuse Connect the black wire to the ground bus Route the new vehicle harness to the display harness and connect them Turn the system on to verify that it is operating correctly Secure the new vehicle harness every 6 12 in with cable ties Replace the A pillar cover
Download Pdf Manuals
Related Search