Chassis variant No.

of document
C Risk / C fault
1853619

Yellow case for stage update

! Safety risk

Time per stage

Division/Group Issued by, date
SANTRO
24/04/2012 ECO no.:

Q
Stage no.

Position Issue no. Quality point

ECO 385333
11
Designation
Name of stage Importance / notice Symbols
Trailer electric brake
Photos / comments
1.0 Passage of cable through prep. zone If the tightening torque is not specified, apply the
2.0 Make instrument panel harness.
standard class 8.8 or 10.9 (see std sheet 3674/3874)
3.0 Electrical layout.
4.0 Electrical connections inside cab.
5.0 Programming the BWS control unit. If supplier documentation is available, refer to it
6.0 Programming the BWS control unit. and follow the instructions during installation
7.0 Saving the modified SOPS file.
8.0 Preparation and fitting the solenoid valve.
9.0 Pneumatic connection.
10.0 Test of operation.

00:00
Manager Pilot Names Names Names NamesNames Names Names Names Names Names Names Names Names Names
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ECO 385333 1853619 11

Stage no. Chassis variant Issued by / date Safety risk Risk / C fault Quality point Actual time
SANTRO
1.0 24.04.2012
! C Q
Symbol No. Operations Comments Risks
Passage of cable through prep. zone
1 Identify the cable with violet adhesive Violet adhesive
tape at each end. tape for connection
2 Tie plug socket V81 close to the gearbox in the workshop
connectors (C93; C108; C112 etc.)

3 Route the cable through the harness up Adjust the cable

black wire pos 21 to the front plug socket. length by making a
orange wire pos 20 4 Connect the terminals on the green plug loop near the
socket C103. gearbox
connectors.

Names Names Names Names NamesNoms Names Names Names Names Names Names Names Names Names
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ECO 385333 1853619 11

Stage no. Chassis variant Issued by / date Safety risk Risk / C fault Quality point Actual time
SANTRO
2.0 24.04.2012
! C Q
Make instrument panel harness.

grey wire 0.75 mm²

Make this part of the harness
without placing terminals on
the end of the 4 wires. RP21

red wire 0.75 mm² / P2 fuse 17 86 87a(5) 85

(4) (6)
yellow wire 0.75 mm² / C276 30
(2)
black wire 0.75 mm² / G2

orange wire 0.75 mm²/ RP 20 pos 30 black wire 0.75 mm² /G4

wire 1,5mm² C103/21

RP20

86 87a(5) 85
red wire G4
(4) (6)
1.5 mm² black wire 0.75 mm² /G4
C103/20 30
(2)

C234 pos 7
blue wire 0.75 mm² /C493 pos 1

C493 pos 14
green wire 0.75 mm²/C493 pos 13

C260 pos 4
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ECO 385333 1853619 11

Stage no. Chassis variant Issued by / date Safety risk Risk / C fault Quality point Actual time
SANTRO
3.0 24.04.2012
! C Q
Electrical layout.
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ECO 385333 1853619 11

Stage no. Chassis variant Issued by / date Safety risk Risk / C fault Quality point Actual time
SANTRO
4.0 24.04.2012
! C Q
Symbol No. Operations Comments Risks
Electrical connections inside cab.
1 Put switch S102 in place, route the
harness to board P2 and make the
connections.

2 Put relays 20 & 21 in place and make

the electrical connections see electr.
layout (stage 3)
fuse 17
3 Affix the relay and fuse labels

20 21 4 Affix the symbol on the ICL plate.

S 102 C276 &G2

C103

Names Names Names Names Names Names Names Names

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ECO 385333 1853619 11

Stage no. Chassis variant Issued by / date Safety risk Risk / C fault Quality point Actual time
SANTRO
5.0 24.04.2012
! C Q
Symbol No. Operations Comments Risks
Programming the BWS control unit.
1 Connect VCI SDP3 to the vehicle.

1 2 Turn on the ignition

3 Open SDP3, then click on Control and

Settings

4 Open the tab BWS with the +, then

click on Settings. Then click on
Change.

Names Names Names Names Names Names Names Names Names Names Names Names Names Names Names
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ECO 385333 1853619 11

Stage no. Chassis variant Issued by / date Safety risk Risk / C fault Quality point Actual time
SANTRO
6.0 24.04.2012
! C Q
Symbol No. Operations Comments Risks
Programming the BWS control unit.
1 Make the following settings:

Power take-off 1
Power take-off 1: Other.
Selection of signal input: Active high.

Type of activation: Automatic.

Deactivation limit, engine speed:
7 km/h.
Power take-off 3
Type of activation: Automatic.
Lower activation limit, engine speed:
4 km/h.
Lower deactivation limit, engine speed:
4 km/h.
Upper deactivation limit, engine speed:
7 km/h.
2 Click on Execute then on Yes

3 After making the settings, save the

SOPS file (see next stage).

Names Names Names Names Names Names Names Names Names

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ECO 385333 1853619 11

Stage no. Chassis variant Issued by / date Safety risk Risk / C fault Quality point Actual time
SANTRO
7.0 24.04.2012
! C Q
Symbol No. Operations Comments Risks
Saving the modified SOPS file.

Save the SOPS file thus modified:

1 Click on File.
2 Go down to the tab Save SOPS file
and click on it.
3 Click on the arrow Save in and then on SOPS folder exists
Changed SOPS. on the desktop of
Click on Save. the PC.
1 4
5 Close the SDP3 application.
6 Check in the Changed SOPS folder
that there is a SOPS file corresponding
2 to the chassis number.

Names Names Names Names Names Names Names Names Names Names Names Names Names Names Names
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ECO 385333 1853619 11

Stage no. Chassis variant Issued by / date Safety risk Risk / C fault Quality point Actual time
SANTRO
8.0 24.04.2012
! C Q
Symbol No. Operations Comments Risks
Preparation and fitting the solenoid valve.
1 Prepare the solenoid valve with the
elbow union and the quick release
coupling.

2 Mount the solenoid valve in the central

part.
3 Connect plug socket V81 onto the
solenoid valve.
4 Route the FBC pipe from the solenoid
valve to the check valve

Tightening
torque

8 Nm ± 2

Names Names Names Names Names Names Names Names Names

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ECO 385333 1853619 11

Stage no. Chassis variant Issued by / date Safety risk Risk / C fault Quality point Actual time
SANTRO
9.0 24.04.2012
! C Q
Symbol No. Operations Comments Risks
Pneumatic connection.
1 Modify the bracket for the check valve.

2 Put the valve and its bracket in place in

the wheel housing.
3 Connect the pipes.
(The original pipe FBS1 will be
deviated from the axle valve to the Dotted line on the
check valve.) diagram below

D = 6.5mm 15 mm
= = LEFT FRONT AXLE VALVE SOLENOID VALVE

Tightening
torque

8 Nm ± 2

FBS 2 FBC

CHECK VALVE BAC BANK

Names Names Names Names Names Names

FBS 1
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ECO 385333 1853619 11

Stage no. Chassis variant Issued by / date Safety risk Risk / C fault Quality point Actual time
SANTRO
10.0 24.04.2012
! C Q
No. Operations Comments Risks
Test of operation.
Connect a pneumatic extension with Release the
manometer to the yellow brake palm parking brake to
3 coupling (pipe SX). make the
Test of operation. connection.
Static test:
1 Turn on the ignition.
2 Release the parking brake and press
the switch: trailer braking (indication
Move the vehicle while on manometer) + ICL lamp lit.
pressing on the switch
Dynamic test:

A ok B ok 3 Move the vehicle while pressing on the

switch:
(A) Speed of vehicle between 0 and
7 km/h Trailer braking (indication on
manometer)
Above (B) Speed of vehicle above 7 km/h: no
0/7 km/h 7 km/h trailer braking.
(C) If the speed of the vehicle is above 4
Speed of vehicle between Speed of vehicle above km/h: Activation of trailer braking is
0 and 7 Km/h 7 Km/h not possible (no indication on the
manometer).
C ok
Above
4 km/h

If speed above 4 Km/h, activation of trailer Names Names Names Names Names Names Names Names
brake not possible.
ECO385333
1 1853619 A T 1 ASSEMBLY INSTRUCTION
1 1855481 A T 1 WIRING DIAGRAM
1 1421876 A 1 SWITCH TRAILER BRAKE
1 1443257 A 1 CONTACT HOUSING
1 1436901 A 100 CABLE
1 1436912 A 520 CABLE
1 1436901 A 650 CABLE
1 1436901 A 900 CABLE
1 1436901 A 900 CABLE
1 1436901 A 1000 CABLE
1 1436903 A 1720 CABLE
1 1436904 A 100 CABLE
1 1436904 A 1200 CABLE
1 1436905 A 100 CABLE
1 1436907 A 900 CABLE
1 1436908 A 2200 CABLE
1 1436909 A 1200 CABLE
1 1436919 A 900 CABLE
1 1443343 A 12 CABLE TERMINAL FLAT SOCKET
1 1443344 A 2 CABLE TERMINAL FLAT SOCKET
1 1448955 A 1 CABLE TERMINAL FLAT SOCKET
1 1431781 A 2 RELAY MINI
1 1320851 A 2 RELAY SOCKET 9-POLE
1 814020 A 6 CABLE TERMINAL
1 813907 A 2 CABLE TERMINAL
1 1443333 A 2 CABLE TERMINAL ROUND PIN
1 1482773 A 1 CABLE H BMS ABS TC FRAME
1 1376794 A 1 2038655 A 1 SOLENOID VALVE
1 812503 A 2 FLANGE SCREW M6X20
1 1363808 A 1 INSERT CONNECTION
1 1538087 A 1 CHECK VALVE DOUBLE
1 1371197 A 5 INSERT CONNECTION 8/M14 INV.
1 322286 A 2 ELBOW UNION 8/M16K
1 1735689 A 1 GREASE DISTRIBUTOR BRACKET
1 802193 A 3 HEXAGON SCREW M6X40
1 815613 A 2 HEXAGON FLANGE LOCK NUT M6
1 812957 A 1 ELBOW UNION
1 313700 A 2 O-RING
1 305479 A 2 CONE
1 815122 A 1 HEXAGON NUT M6
1 1443302 A 1 CONTACT HOUSING
1 1539078 A 1 STRAP
1 815149 A 1 HEXAGON LOCK NUT M14
1 2078452 A T 1 TRAILER BRAKE FUSE STICKER
1 1787630 A 1 TRAILER BRAKE SWITCH ICL SYMBO
1 816156 A 5 CABLE TIE 380X8,9
FBC pipe
1 1483544 A 6500 PLASTIC PIPE 8X1
FBS pipe
1 1483544 A 700 PLASTIC PIPE 8X1
1 1855441 A T 1 SAFETY ANALYSIS