Bendix XVISION SYSTEMS User Manual

Bendix® XVision® System

SD-19-5160

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Figure 1 XVision® System

NOTE: The information in this Service Data is correct and complete as of the time of printing. Options or updates to the XVision

System that were developed after publication may not be included.

TABLE OF CONTENTS

SAFE MAINTENANCE PRACTICES 3

INTRODUCTION 3

COMPONENTS 3

IR CAMERA BRACKET KIT 4

CB STYLE MOUNTING KIT 5

FRICTION HINGE MOUNTING KIT 5

HARNESS KIT 6

AIMING ADJUSTER TOOL 8

IR CAMERA/DISPLAY COMBINATION 8

REPLACEMENT KITS 9

AIMING ADJUSTER REPLACEMENT 9

WINDOW REPLACEMENT 9

HEATER REPLACEMENT 9

COMBINER MIRROR REPLACEMENT 9

FOLD MIRROR REPLACEMENT 9

ELECTRICAL SYSTEM 10

POWER AND GROUND (INPUTS) 10

OPERATING INPUT VOLTAGE 10

SERVICING THE XVISION

MOUNTING BRACKET 11

IR CAMERA BRACKET 11

IR CAMERA 12

IR CAMERA WINDOW 14

IR CAMERA WINDOW HEATER 15

DISPLAY 16

COMBINER 16

FOLD MIRROR 16

DISPLAY BRACKET 17

DISPLAY REPLACEMENT 18

HARNESSES 18

AIMING THE IR CAMERA 21

HORIZONTAL AIMING 21

VERTICAL AIMING 22

TROUBLESHOOTING 24

SYSTEM 11

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, 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 the 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 an 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® 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.

EXTREME CAUTION should

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 Antilock Traction Control (ATC), the ATC function must be disabled (ATC indicator lamp should 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® System is an infrared (IR) night 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.

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COMPONENTS

The XVision® System (Piece No. 5010086) consists of the following six components, described on pages 3-7:

• IR Camera Bracket Kit (Piece No. 5010078)

• CB Style Mounting Kit (Piece No. 5010081)

• Friction Hinge Mounting Kit (Piece No. 5010082)

• Harness Kit (Piece No. 5010083)

• Aiming Adjuster Tool

• IR Camera/Display Combination

Parts/Kits listed with piece numbers are serviceable and can be ordered 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 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). A template 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.

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 preinstalled.

Aiming Adjuster Assemblies

Holes for Harness

Cable Tie

FIGURE 4 - IR CAMERA BRACKET WITH AIMING ADJUSTERS

Standoff and

Pivot Assembly

Horizontal Mounted Bracket

(Roof Mount)

FIGURE 2 - MOUNTING BRACKET ORIENTATIONS

Vertical Mounted Bracket

(Faring Mount)

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

Apply sealant

between

these

surfaces

Add shims if the surface is not level

Roof

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.

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.

FIGURE 3 - MOUNTING BRACKET KIT CONTENTS

Mounting Brackets

FRICTION HINGE MOUNTING KIT (PIECE NO.

5010082)

Mounting Brackets

CB Style (Dashboard)

FIGURE 5 - CB MOUNTING BRACKETS

CB Style (Overhead)

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 Components

Friction hinge mounting allows the driver to use the sun

visor during the day and the XVision

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.

Hinge Supports

#10 Plastite Pan Head

Screws (Qty. 4)

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.

Magnet Kit

M2.5

Threadroll

Pan Head

Screw

FIGURE 7 - FRICTION HINGE MOUNTING KIT COMPONENTS

Components

M2.5 Threadroll Pan Head Screw

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 supplied 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.

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

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 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.

TABLE 1 - IR CAMERA HARNESS PIN OUTS

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Display Harness CB Mounts

FIGURE 9 - DISPLAY HARNESSES

Display Harness Friction Hinge Mount

TABLE 2 - DISPLAY HARNESS PIN OUTS

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Vehicle Harness (piece no. 5010260, service piece no.

801157) – The vehicle harness is approximately 12 feet

long and provides power to the XVision

system. The harness is made of a twisted tri-wire, which needs to be fused to the vehicle ignition and headlamps. The harness has one 3-pin connector that connects to the display harness.

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.

Jumper Harness (piece no. 5010441, service piece no.

801152) – The jumper harness acts as an “extension cord”

when the display and IR camera are mounted more than six feet apart. The harness has two 8-pin connectors, one connects directly to the IR camera harness and the other to the display harness. The jumper harness is not designed to be mounted externally. See Figure 11 and Table 4.

FIGURE 10 - VEHICLE HARNESS

TABLE 3 - VEHICLE HARNESS PIN OUTS

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Harness Hardware – Two fuse holders, three butt splices, a 1 A fast 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.

FIGURE 11 - JUMPER HARNESS

TABLE 4 - JUMPER HARNESS PIN OUTS

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AIMING ADJUSTER TOOL

The aiming adjuster tool is included with the XVision® 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

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.

system.

Aiming Adjuster Mounting

Combiner

Intensity

Control

On/Off Switch

FIGURE 13 - DISPLAY (SHOWN IN CB STYLE MOUNT (DASHBOARD) POSITION WITH DISPLAY HARNESS)

Fold Mirror

Video In/Out

25-pin Connector

Switch

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.

Window

Heater

Connection

FIGURE 12 - IR CAMERA

Standoff Pivot Mounting

IR Camera Connection

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.

FIGURE 14 - DISPLAY DIP SWITCHES FOR DASHBOARD MOUNT

TABLE 5 - DIP SWITCH POSITIONS

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REPLACEMENT KITS

The following five kits contain replacement parts for the XVision® 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 . 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.)

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 Window

O-ring

IR Camera

FIGURE 16 - IR CAMERA AND CAMERA HEATER

Camera Heater

Locking Pin

COMBINER MIRROR REPLACEMENT KIT (PIECE NO. 5010190)

The combiner mirror replacement kit includes one replacement combiner. See Figures 17 & 28.

Aiming

Adjusters

Standoff

Base

FIGURE 15 - AIMING ADJUSTER REPLACEMENT KIT

#8-32 Hex®/ Torx (18 in-lbs.)

#10 Plastite® Hex flange with lock washer (18-20 in-lbs.)

Standoff Pivot

Assembly

(16 in-lbs.)

FOLD MIRROR REPLACEMENT KIT (PIECE NO. 5010189)

The fold mirror replacement kit contains one replacement fold mirror. See Figures 17 & 29.

Combiner

Fold Mirror

FIGURE 17 - COMBINER AND FOLD MIRROR

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