Trailer Roll Stability (TRS) Installation Manual [L30040]
Contents
1. 4S 2M Application 51A 82A S1B and S2B 2S 2M Application STA and S1B Sensors shall be placed on rear most axle Page 16 Rev 5 Wheel End Speed Sensor and Cable This manual depicts speed sensor cable routing along the vehicle axles This was shown for clarity Although it is possible to route cables this way the preferred approach is to route the speed sensor cables along the air hoses between the TRS valve and the brake actuators Tie straps may be used to secure sensor cable to the axle Although tie straps may be used a more reliable installation results if single clips are used to secure speed sensor cables to air hoses Leave some slack in cables to accommodate movement between chassis components Excess cable must not be allowed to hang free it must be bundled and attached to the chassis or air lines to prevent damage due to vibration and abrasion A sensor clip is placed on the hose and sensor wire Single Sensor Hose Clip Excess cable length may be taken up in either a short bone or a long bone arrangement and secured with tie straps Do not coil the cable into a loop smaller then 4 inches in diameter Do not over tighten the tie straps when the cable is coiled as this could cause a cable failure O Push up and attach tie straps Short Cable short bone Long Cable long bone Page 17 Rev 5 HALDEX Wheel End Speed Sensor and Cable 4 Disc brakes may have their excite2. Sensor S1A T Sensor S2A T Roadside Roadside o ee ME HE HE m umm m m UU a Note Legend Haldex TRS with ECU facing RoadSide O AIR BRAKE COMPONENTS AND SYSTEM SCHEMATIC ARE DESIGNED TO ALLOW COMPLIANCE Service Control Line WITH FMVSS121 O HZ 0 u f Emergency Supply Line MANUFACTURERS ULTIMATE RESPONSIBILITY TO CERTIFY THEIR SYSTEM MEETS ALL APPLICABLE REGULATIONS Air Bag Line mm PIPE NIPPLES USED TO MOUNT BRAKE VALVES MUST BE HEAVY WALL TYPE PER SAE J514 Page 9 Rev 5 HALDEX Plumbing the Modulator Air Valve viewed from bottom Reservoir Tank Curbside 1 Reservoir port plumbing shown in red plumb 3 4 O D tubing between the reservoir tank and the modulator reservoir port 1 2 Delivery ports plumbing shown in blue attach delivery hoses from modulator 21 ports to roadside chambers Attach delivery hoses from modulator 22 ports to curbside Front chambers Plug unused delivery ports Use of thread sealant sparingly on all fittings Trailer Loctite ST565 or similar DO NOT use teflon tape on fittings it can break and contaminate the air system Roadside 3 Control port plumbing shown in blue From the gladhand connect the modulator control Port 4 to the Trailer Brake Control Valve port as shown by installing a tee fitting into the TRS modulator a 1 Gladhand Haldex TRS Control P
3. Delivery Ports 1 2 NPT Reservoir Port 1 HALDEX Page 6 Rev 5 Mounting the ECU Modulator Assembly 3 Axle Trailer 2 Axle Trailer 1 Axle Trailer It ECU Modulator Assembly 1 Locate unit inside frame rails it can be offset to the side if necessary 2 Tandems locate unit within 3 ft of the center of the axle spread 3 Tridems locate unit close to center axle for brake balance 4 Locate unit as high up to the trailer floor as possible Haldex ECU Modulator Assembly Back of Trailer should be mounted vertically This angle shown must not exceed up QA 3 ECU must face roadside Roadside Bottom View Looking up The angle shown must not exceed 5 Page Rev 5 Mounting the ECU Modulator Assembly Bottom View Shown The ECU Modulator assembly must be frame mounted on a rigid structural member as high in the chassis as possible to protect the unit from direct spray and other road debris The exhaust ports should be down and ECU facing the roadside of the vehicle This unit should NOT be in the direct spray of high pressure washing b Exhaust Ports ECU Modulator Assembly Ground Lug Located on this Side e ECU faces RoadSide TRS Power Cord w Stop Light Activation xX 1 Determine the center of the axle s spread where the ECU Valve Assembly will be installed as shown on page 7 2 Look for a rigid cross member within 3 feet of
4. Ports on Valve 22 used for CurbSide Plumbing is similar to an ABS relay valve except Port 41 is added which connects to the air bag circuit Plug unused pneumatic delivery ports on the modulator Plug unused electrical ports on the ECU Make sure sensor and connectors lock into the side holes of the ECU Make sure ECU Slidelock Lever is closed and in the locked position Leave some slack in sensor cables to accommodate movement between components and trailer suspension Page 5 Rev 5 HALDEX Haldex TRS Unit Overview All dimensions in inches Overall Height 6 5 5 16 Dia Holes 4 Ground lug 5 9 washer 36 6 7 25 10 5 5 Drill the ECU Modulator 4 hole mounting pattern into the crossmember Use 3 8 drill bit oee page 29 for a mounting pattern template 6 Mount the unit to the crossmember with rust resistant 5 16 x 2 1 4 long bolts SAE Grade 5 or better with washers and locking nuts Torque the mounting bolts to 15 ft Ibs maximum Washers to be used on the modulator and crossmember 3 8 NPT Control Port 4 Weight 11 5 Ibs with serviceable metal 2 modulators 21 22 screen filter Detachable ECU 3 8 NPT Suspension Port 41 air bag symbol near port 3 8 NPT Delivery Ports 22 for Curbside service chambers V NPT Delivery Par for 3 8 NPT Delivery Ports Poadside serice 21 for Roadside service chambers chambers Note Plug all un used
5. Trailer Fault F B Ignition G Not Used Key Location Stop Light Activation Power Cord Diagnostic Cord Roadside Curbside Sensor Sensor S1A S1B Sensor Sensor S2A S2B X Not used for 2S 2M applications Page 13 Rev 5 HALDEX Electrical Connections to the ECU Modulator Assembly u B E u Power and Diagnostic Connections Move lever on the ECU to the unlocked position Insert grey stop light activation power cord and diagnostic cord into ECU ports with molded labels facing upward Press connectors into the ports until they bottom out Ensure the red seal remains seated on the locking lever Move lever to the lock position If the unit remains unlocked vibration will loosen the cords causing them to fall out Disabling the Haldex TRS and ABS functions of the system 1 Pull out locking lever 2 Position Connectors Insert Connectors 4 Push Locking Lever in Molded Label Red Sea iim im Ensure that the moded label faces upward before inserting into the Haldex TRS ECU Locking Tab Lock holes for Sensors and Position Sensors and Plugs Push firmly into correct into correct locations holes and listen for click Page 14 Rev 5 Electrical Connections to the ECU Modulator Assembly Sensor extensions connect sensor extensions to speed sensors and ECU as shown Connectors must be pushed fully into the sensor cable sockets and ECU ports until they cl
6. Center will also read and clear diagnostic trouble codes DIAG This PC based software tool provides the most features and functionality of the diagnostic tools The vehicle parameter data is stored inside the Haldex TRS ECU The DIAG software can be loaded on a PC with the following requirements 486 Processor or above 8 Megabyte RAM 16 recommended 20 Megabyte Hard Drive CD ROM Drive 640 x 480 VGA Monitor 9 pin RS232 serial Com Port if unavailable a USB to RS232 converter is required but not included in the kit Compatible with MS Windows 98 ME XP NT or 2000 HALDEX Page 20 Rev 5 Diagnostic Tools Info Center The TRS Info Center can be used to provide the functions listed here Connect as shown below and apply 12 volt DC power through the 7 way The Haldex ABS PLC Info Center may be used with the TRS system to read and clear DTC s Haldex TRS Info Center INFO CENTER HALDEX Diagnostic cable typically located on the side of the vehicle AVAILABLE FUNCTIONS View Odometer readout View Loaded readout Read amp Delete Diagnostic Trouble Codes View Number of Sensors and Modulators View Orientation of Sensors and Modulators View Sensed Wheel Output View Auxiliary Configuration View ECU Software Version Serial Number View Info Center Software Version 10 View Trailer Manufacturer VIN 11 Monitor trip distance 12 View and change wheel scale factor o o oo0 i amp
7. and BRK APPLY OC replace modulator BRK APPLY SC DRIVE BRK APPLY UNSPEC HOLD SC Internal fault with the hold or dump solenoids of modulator 21 DUMP SC Detach ECU and replace modulator HOLD OC DUMP OC HOLD SC DRIVE DUMP SC DRIVE HOLD UNSPEC DUMP UNSPEC EPRV 22 HOLD SC Internal fault with the hold or dump solenoids of modulator 22 EPRV 22 DUMP SC Detach ECU and replace modulator EPRV 22 HOLD OC EPRV 22 DUMP OC EPRV 22 HOLD SC DRIVE EPRV 22 DUMP SC DRIVE EPRV 22 HOLD UNSPEC EPRV 22 DUMP UNSPEC Internal fault with the service control line pressure transducer Detach ECU and replace modulator Internal fault with the delivery pressure transducer Detach ECU and replace modulator EPRV 21 SLOW REC Wheels are slow to recover after brakes are released Make EPRV 22 SLOW REC sure foundation brakes are operating properly delivery hoses not pinched speed sensors not crossed with modulator correct side by side plumbing Internal fault with the reservoir pressure transducer Detach ECU and replace modulator 1 Check for air leaks on suspension lines 2 Make sure leveling valve is plumbed correctly 3 Internal fault with the SUSP OUT OF RANGE suspension pressure transducer Detach ECU and replace modulator Page 26 Rev 5 Diagnostic Trouble Code List Group 4 ECU Fault Code List 1 ECU configured incorrectly contact Haldex Engineering REV SWITCH OC 2 Internal fault with relay emergency valve press
8. oN2A See TRS Info Center User Guide for more information Page 21 Rev 5 HALDEX Diagnostic Tools PC DIAG Diagnostic port typically located on the side of the vehicle PC interface hardware included in kit Available Functions End of Line Test EOLT Read Delete Diagnostic Trouble Codes Odometer readout oet tire scale factor gt am See DIAG User Guide for more information HALDEX Page 22 Rev 5 Testing After Installation After installing the TRS system and completing pneumatic brake system checks the TRS system should be tested for additional functionality using the following equipment Info Center or DIAG 12 volt DC power supply 3 5 amp minimum not a battery charger 100 to 120 psi air pressure on the emergency gladhand 20 to 40 psi air pressure on the service gladhand Connect the power supply to the 7 way J560 at the nose of the trailer or 5 way ABS drop out connector at the chassis of the trailer Brakes need to be manually adjusted 1 Secure the vehicle against movement 2 Connect the Info Center or DIAG to the ECU diagnostic port 3 Charge the service 20 40 psi and emergency 100 120 psi air system 4 Connect the power source to the Trailer 7 way or ABS 5 way connectors 5 Switch the stop light power source ON A Each valve should blow down a brief shot of exhaust air B ABS light should flash ON for about 2 seconds then go OFF 6 Remove stop light
9. power Switch the permanent power source ON A Each valve should blow down a brief shot of exhaust air B ABS light should flash ON for about 2 seconds then go OFF 7 Read Odometer display for a mileage value 8 Read Diagnostic Trouble Codes DTC It should display Clear 9 If a problem exists a DTC will be displayed Power down the system remove service and emergency air source park the vehicle and correct the problem Clear the DTC 10 Remove the service air pressure and rotate each wheel at 1 rev 2 sec Front roadside wheel should display S1A on the diagnostic tool Front curbside wheel should display S1B on the diagnostic tool Rear roadside wheel should display S2A on the diagnostic tool Rear curbside wheel should display S2B on the diagnostic tool com 11 To perform a road test with a tractor turn on the ignition key and charge air system Again make sure ABS warning light comes on briefly then goes out Pull the trailer at a speed above 6 mph and make a brake application until the tractor trailer has come to a complete stop Verify that the ABS light has remained OFF f the light remains OFF the system is functioning properly f the TRS system detects an error during the stop the warning light will be ON Page 23 Rev 5 HALDEX RN ABS light doesn t flash ON when ignition power supplied to the trailer TRS doesn t power up ABS Power Cord Pin Out A B Stop Light B Not Used Q C
10. this center to mount the ECU Modulator Assembly It may be necessary to straddle two cross members with a metal mounting bracket 3 16 minimum thickness If bracket is to be painted mask off the area on the bracket where the modulator ground lug washer is located 3 The side to side roadside to curbside position should be within the frame rails as shown on page 7 lt is permissible to offset the unit to one side as long as sufficient clearances exist for airline and electrical cabling connections 4 The ECU must face the roadside of the vehicle and be level as shown on page 7 5 If the Power Cord with Stop Light Activation is selected secure the electronic module by fastening it to the trailer frame with P clamps tie straps etc HALDEX Page 8 Rev 5 TRS Plumbing Schematic Note Delivery Hose shown in Blue shall be attached to Modulator 21 ports to Roadside chambers and Modulator 22 ports to Curbside chambers ECU Modulator Trailer Brake Port 1 from valve A ssembl to air tank should y Control Valve be 3 4 tubing Plumbing Schematic 4S 2M puu na Sensor S1B Sensor S2B Curbside Curbside 13 a Front of Trailer Service Control Port 22 Port 41 Port 21 C JS Emergency Supply E Trailer Brake Control Valve l pou z O PON Haldex TRS Electronic Control Unit ECU
11. 1 703400 E Mail info DE Haldex com Hungary Haldex Hungary Kft Szentl rinck ta Tel 36 29 631 300 Fax 56 29 551 501 E Mail Info HU Haldex com India Haldex India Limited Nasik Tel 91 253 2580094 Fax 91 254 2580729 E Mail info IN Haldex com L30040 US Rev 5 08 5M CM Italy Haldex Italia SRL Biassono Milan Tel 39 039 471 702 Fax 4 59 059 27 54 409 E Mail info T haldex com Poland Haldex Sp z 0 0 Praszka Tel 48 34 350 11 00 Fax 48 34 550 11 11 E Mail info PL haldex com Russia OOO Haldex RUS Moscow Tel 7 495 747 59 56 Fax 7 495 786 49 70 E Mail info RU haldex com South Korea Haldex Korea Ltd Seoul Tel 82 2 2636 7545 Fax 82 2 2646 7548 E Mail info KR haldex com Spain Haldex Espafia S A Parets del Valles Barcelona Tel 34 93 573 10 30 Fax 34 94 573 O7 28 E Mail info ES haldex com Sweden Haldex Brake Products AB Landskrona Tel 46 418 47 60 OO Fax 46 418 47 60 01 E Mail info SE haldex com United Kingdom Haldex Ltd Newton Aycliffe Tel 44 1225 310 110 Fax 44 1325 311 834 E Mail info GBAy haldex com Haldex Brake Products Ltd Redditch Tel 44 1527 499 499 Fax 44 1527 499 500 E Mail info GBRe haldex com USA Haldex Brake Products Corp Kansas City MO Tel 1 816 891 2470 Fax 1 816 891 9447 E Mail info US haldex com www haldex com www hbsna com
12. Installation Guide L30040 5 08 Rev 5 HALDEX TRS Trailer Roll Stability Installation Service Manual for 4S 2M and 2S 2M Systems 7 00 Technical Service and Engineering Support In the U S please call 1 800 643 2374 press 2 In Canada please call 1 800 267 9247 www hbsna com IMPORTANT NOTICE The data listed herein is correct to the best of Haldex s knowledge and belief having been compiled from reliable and official sources of information However HALDEX CAN NOT ASSUME ANY RESPONSIBILITY for possible error or misapplication of the product Final determination of the suitability of the products for the use contemplated by the Buyer is the sole responsibility of the Buyer Haldex shall have no responsibility in connection with this Suitability IMPORTANT NOTICE The description and specifications contained in this Installation Manual are current at the time of printing Haldex Brake Products Corp reserves the right to discontinue or modify its models and or procedure and to change specifications at any time without notice Page 1 Rev 5 HALDEX Table of Contents Section Page General ODEIaUON eee ee ene eee I OU NIRE IR RUDI 9 System O59 1 1 818 8 lll sooo cesse prctio nn 4 System O VETVIEN ee 5 IUS AGA CHOITIBIE i een 6 Mounting of ECU Modulator and PLC Power Adapter 7 9 Plumbing of Modulator Air Valve 9 11 Electrical
13. Stability Lamp D B Permanent E Trailer Fault Q o F B Ignition G Not Used Key Location ABS Light Faults Ensure all power cables are connected properly 7 way 5 way ECU permanent power Check for burned out bulb Check for open or short circuit in lamp Check power at 5 way and ECU If power is available at the 5 way but not at the TRS unit replace power adapter cable Reference page 13 of this manual for pin identifications Perform the following checks Make sure the power adapter cable is plugged into the ECU properly Make sure 12 volts at the 5 way plug Disconnect Grey Permanent Power cable at the ECU and check for 12 volts between sockets B and B ignition Apply stop light power and check for 12 volts between socket B and socket B stoplight Note Most ABS or TRS problems are related to A Cut Corroded or Abraded Wires B Corroded Connectors and Terminals C Connector Terminal not latched or seated correctly to mating assemblies D Excessive sensor air gap Sensor clip retention or E Wheel bearing end play Page 24 Rev 5 Diagnostic Trouble Code List There are 6 failure modes with this system The fault codes are grouped in this manner 1 Power Supply 2 Sensors 3 Modulators 4 ECU 5 Lateral Accelerometer 6 Auxiliaries Group 1 Power Supply Fault Code List ECU TIME OUT or NO LINK No supply on ignition switched line Check truck fu
14. The Haldex TRS product can help reduce the potential risk of rollover in conjunction with good driving practices Driving too fast for conditions may still result in a rollover even with a Haldex TRS equipped trailer Safe driving remains the most important element in accident prevention Failure to drive safely can result in serious personal injury and or damage to property Page 3 Rev 5 HALDEX System Components see Haldex Trailer ABS Service Components Catalog L20243 for additional information on Haldex ABS Products Haldex Supplied Items Required Optional Supplier Section Trailer Brake Control Valve 90 Sensor TRS Power ECU Modulator Cord w Stop Assembly Light Activation LED Stop Light j e opeed Sensor Diagnostic Cable P AX Cable Extensions Sensor Clip ABS Lamp Diagnostic Tools Optional Installation Aids f 3 Way Clip Hose Clip Software T PC Cable PC Diagnostics Kit PC not included 7 Way Diagnostic Connector Basic TRS Power Cord fJ Tie Strap Sensor Clip TRS Info Center Page 4 Rev 5 System Overview Front of Vehicle N Key Installation Points for the Haldex TRS unit 1 E dE SA TRS Valve and ECU preferred location is centered between axles centered between frame rails and as close to the trailer floor as possible ECU must face toward the roadside of the vehicle Side by Side plumbing Delivery Ports on Valve 21 used for RoadSide Delivery
15. U back from the modulator which disconnects the electrical connector 3 To reinstall the ECU securely fasten the ECU to the modulator with 4 bolts 4 Control port metal screen filter The filter should be serviced as deemed necessary based on the application and environment The filter should also be checked when service brakes are slow to apply Disconnect air line fitting and back the filter out of the port using needle nose pliers or a straight blade screwdriver Page 19 Rev 5 HALDEX RN Diagnostic Tools There are two tools available to troubleshoot the TRS system faults the Info Center and a PC based software tool DIAG Both tools need to be connected to the diagnostic port of the ECU and the vehicle powered with 12 volts DC Do Not use a battery charger AC voltages or unregulated shop air when servicing the vehicle INFO CENTER HALDEX Info Center This hand held dedicated tool is used for display of odometer and diagnostic fault codes plus other information stored in the ECU It consists of a LCD Liquid Crystal Display and two buttons marked with an up down and right pointing arrows The left hand button showing a right pointing arrow means select The right hand button showing an up down arrow means change or next to allow movement between the different menus and options An internal battery allows the tool to remember the settings and faults of the last powered up ECU it was connected to ABS PLC Info
16. Wiring OVOTVvIQW a cciconoa ctt tota aaepe eet 12 Electrical Connections of ECU Modulator Assembly 13 15 Wheel End Speed Sensors and Cables 16 18 Paint tepel AO i rn dE en 19 vcrc 19 DIANO UC TOO c 20 22 Test after NASTALA NOE RETE 23 ABS Light talis anne ee een 24 Diagnostic Trouble Code LISL uses 25 27 OdOMELIT SEN RN een 27 Wheel Scale Chat 28 Mounting Pattern Iembplidl amp sedan iru en 29 This installation manual describes the correct installation procedures for the Haldex TRS Trailer Roll Stability for trailers Safety First Please follow your company s safety procedures when you install this equipment Be sure that you understand all instructions before you begin Note Remove all air pressure and electrical power from the brake system before beginning work HALDEX Page 2 Rev 5 General Operation Haldex TRS is the latest offering in a full line of Haldex trailer ABS systems Haldex TRS provides a further enhancement in safety by detecting the potential of trailer rollover Haldex TRS continually monitors the trailers vehicle speed air suspension pressure and lateral acceleration along the vehicle s roll axis If the Haldex TRS determines that a rollover threshold is reached a series of light brake applications are applied to the side of the vehicle lifting off the ground If the wheel slip on the unloading side exceed
17. eel Scale Factor Chart Use DIAG to set wheel scale factor using Rolling Radius mm found in columns below Rolling Radius Rolling Radius Rdyn mm Rdyn mm Rev Mile Rev Mile 100T 100T 80T Trailer Tire 80T Smallest Tire 215 75R17 5 100T Smallest Tire 305 70R19 5 11R17 5HC 10 00R15TR 100T Largest Tire Factory Tire Scale Set At 508 mm rolling radius or 502 Rev Mile Wheel Scale Factor for other tire sizes SF 1000 Rc x T 100 or SF N x T 100 Rdyn rolling radius mm Rc Rolling Circumference m 2 3 14 x Rdyn 1000 N Revolution Mile T Exciter Ring Teeth HALDEX Page 28 Rev 5 Mounting Pattern Template V Valve Mounting Pattern When using valve template holes these holes are on the ECU Side or Roadside l When using valve template holes these holes face REARWARD on the vehicle Page 29 Rev 5 THIS PAGE INTENTIONALLY LEFT BLANK Notes Page 31 Rev 5 HALDEX NN Notes HALDEX Page 32 Rev 5 Haldex offers proprietary vehicle technology so lutions to the global vehicle industry within spe cific niches We focus on products to improve safety the environment and vehicle dynamics We are enhancing our competitive capabilities and building long term customer relationships through high performance low total costs to the customer thr
18. ick into place to prevent falling out due to vibration Ensure contact pins are clean Ensure o rings are present and clean on both sides of the sensor extensions Front Front Axle Axle Roadside Curbside Sensor Sensor S1A S1B Sensor Sensor S2A S2B Rear Rear Axle Axle Plugs 2 sensor extension identification is used for traceability from Example S1B the wheel end to the ECU This is easily accomplished by Front Axle Curbside removing identification tabs for each sensor extension as shown below Tab Removed Component a a LY a ba ai DO NOT cut items in the grey boxes Not used for 2S 2M applications Cul bwin Sessor Page 15 Rev 5 HALDEX Wheel End Speed Sensor and Cable Correct location and mounting of speed sensors at the wheel ends is critical for proper TRS system operation The Haldex TRS system will adjust the braking air pressure in response to input from the speed sensors Incorrect installation or location of speed sensors and exciter rings will result in poor or no Haldex TRS system performance In the figure below the speed sensors are cabled to specific socket locations on the ECU Sensor S1B Curbside Sensor S2B Curbside lt 5 5 55 5 Front of Trailer Haldex TRS ECU 11 Electronic Control Unit il Must face Roadside r 1 i i i 1 1 i i i 1 i 1 l T Sensor S1A Roadside Sensor S2A Roadside Legend Sensor Requirement
19. ort 4 Trailer Brake Control Valve Tee __ Control Port Service Control Line HALDEX Page 10 Rev 5 Plumbing the Modulator Air Valve Suspension Air Bags Suspension port plumbing connect the modulator suspension port 41 to the delivery side of the leveling valve This connection can be made by adding a tee to the delivery port of the leveling valve or the connection can be made by cutting the synflex tubing of the air bag circuit and adding a tee Air Bag Symbol Port 41 Page 11 Rev 5 Electrical Wiring Overview Basic Power Cord Note All electrical plugs are keyed and have a locking tab to Trailer remove ABS Power Connector Always install dummy plugs in ECU sockets not used Diagnostic Connector Mounted to the side of Trailer Diagnostic Connector Basic TRS Power Cord r Roadside CEE Push in Slidelock to Lock Connectors Curbside Sensor Sensor ein Plug Loe u Plug S1B AM 11 lag Yen fla Sensor Sensor S2A S2B X Not used for 2S 2M applications Plugs 2 TNC gt om Page 12 Rev 5 Electrical Wiring Overview Stop Light Activation Power Cord The Stop Light Activation Power Cord illuminates trailer brake lights during roll event Trailer Diagnostic Connector ABS Power Mounted to the side of Trailer Connector ABS Power Cord Pin Out A B Stop Light B Not Used C Stability Lamp D B Permanent E
20. ough the product s service life ethi cal business practices and commitment to long term partnerships Haldex operations are divided into four business areas Commercial Vehicle Systems Hydraulic Systems Garphyttan Wire and Traction Systems 2007 This material may contain Haldex trademarks and third party trademarks trade names corporate logos graphics and emblems which are the property of their respective com panies The contents of this document may not be copied distributed adapted or displayed for commercial purposes or otherwise without prior written consent from Haldex Commercial Vehicle Systems Austria Haldex Wien Ges m b H Vienna Tel 43 1 865 16 40 Fax 43 1865 16 40 27 E Mail info AT Haldex com Belgium Haldex N V S A Balegem Ghent Tel 32 9 363 90 00 Fax 32 9 363 90 09 E Mail info BE Haldex com Brazil Haldex do Brasil Ind e Com Ltda Sao Paulo Tel 55 11 213 55 000 Fax 55 11 503 49 515 E Mail info BR Haldex com Canada Haldex Ltd Guelph Ontario Tel 1 519 826 7723 Fax 1 519 826 9497 E Mail info CA Haldex com China Haldex International Trading Co Ltd Shanghai Tel 86 21 5240 0338 Fax 86 21 5240 0177 E Mail info CN Haldex com France Haldex Europe SAS Weyersheim Strasbourg Tel 33 3 88 68 22 00 Fax 35 5 00 68 22 09 E Mail info EUR Haldex com Germany Haldex Brake Products GmbH Heidelberg Tel 49 6221 7030 Fax 49 622
21. r rings machined into the disc or hub Speed sensor mounting holes may be found on the torque plate or the caliper assembly First determine the location of the exciter ring in the disc brake Next locate the speed sensor mounting holes Insert the speed sensor clip into the sensor mounting hole Lightly grease the speed sensor with a lithium based grease use Dow Corning Molycoat CU7439 or equivalent and insert into the sensor clip Ensure the sensor cable is not under any tension is not touching the disc brake and is clear from moving parts Drum Brake Installation Disc Brake Installation oensor Sensor Clip Sensor Clip Sensor Sensor Block Torque Plate Exciter Ring Page 18 Rev 5 Paint Preparation 1 Prior to Painting or Undercoating the ECU Modulator Assembly r re MUST BE PROTECTED All unused electrical connections are to have sealed plugs installed All unused pneumatic ports are to have pipe plugs installed Mask off bottom side exhaust ports as shown Painting recommendations Water based baking for 1 hour 212 F Service of ECU Modulator ECU Shoulder Bolt Modulators 1 The ECU and Modulator can be separated if required There are 4 bolts that hold the ECU to the modulator and a 26 pin electrical connector When removing and reinstalling the ECU be careful not to damage the electrical pins 2 Begin by removing the 4 bolts on the face of the ECU using a T20 torx tool Pull the EC
22. s a threshold the system automatically applies a heavy brake application on the opposite side Vehicle stability is achieved by reducing the vehicle speed to a Safe Harbor range The Haldex TRS product is compatible with all towing vehicles and is compliant with FMVSS121 providing the ABS functionality through either permanent or stoplight power permanent power is required for the roll stability feature In the event of power failure as with other ABS systems Haldex TRS defaults to a standard service brake system A Haldex TRS system may be used on most air suspension equipped semi trailer configurations with 1 to 3 axles and may be used in either 4 sensor 2 modulator 4S 2M or 2 sensor 2 modulator 2S 2M applications plumbed in a side by side configuration only using either disc or drum brakes For other vehicle configurations contact Haldex Engineering Support TRS may be used on B trains full trailers pulled by tractors or straight trucks Not on doubles or triples using A frame dollies The Haldex TRS product MUST NOT be installed on center axle trailers full trailers or semi trailers and dollies equipped with mechanical spring suspension For vehicles with axle spreads greater then 72 inches contact Haldex Engineering Support VEHICLE REQUIREMENTS Constant permanent power 7 Pin Blue wire on J560 connector LED stop lamps because the stop lamps are illuminated during a rollover event Air Suspension Warning
23. ses 7 way connection 5 way ABS connection power cable connections Check diagnostic cable for corrosion PWR 1507638 FAIL Intermittent power loss Check all electrical connections as mentioned above PWR LO VOLT Supply voltage lt 8 volts Check voltage regulator on tractor loose connections and corrosion PWR HI VOLT Supply voltage gt 17 volts Same as above Group 2 Sensor Sensor Extension Fault Code List Note The fault code identified which sensor wheel end needs to be checked Open or Short Circuit 1 Disconnect the sensor extension cable from sensor and measure electrical resistance between the two pins in the sensor housing it should be between 980 2350 ohms 2 Disconnect sensor extension from ECU and measure continuity 91A SIGNAL Intermittent low sensor output occurs when vehicle is moving 91B SIGNAL Check for broken sensor retaining clip damaged or misaligned 924A SIGNAL exciter ring excessive wheel bearing end play loose S2B SIGNAL damaged corroded sensor connections or a break inside the sensor cabling 91A OUTPUT Low sensor output 1 Rotate the wheel at 1 rev 2 sec and S1B OUTPUT measure AC voltage at the sensor plug it should be 200 92A OUTPUT millivolts 2 Make sure sensors are pushed up against exciter S2B OUTPUT rings Page 25 Rev 5 Diagnostic Trouble Code List Group 3 Modulators Fault Code List BRK APPLY SC Internal fault with the brake apply solenoid Detach ECU
24. ure REV SWITCH PNEUMATIC switch Detach ECU and replace REV SWITCH SIGNAL PNEUMATIC DEMAND LOSS No corresponding pneumatic demand pressure Detach ECU and replace TOWED CAN DEMAND LOSS CAN communication fault Detach ECU and replace TOWED CAN CONTROL LOSS CAN communication data fault Detach ECU and replace ECU EE ERR Internal ECU fault Detach ECU and replace ECU PARAM ERR Internal ECU fault Detach ECU and replace ECU EE UNSPEC Internal ECU fault Detach ECU and replace Group 5 Lateral Accelerometer Fault Code List Ensure proper positioning ECU connection and no LAT ACC SC damage to the lateral accelerometer cable Replace LAT ACC SIGNAL external lateral accelerometer Otherwise replace ECU Group 6 Auxiliaries Fault Code List AUX1 Auxiliary Channel 1 Auxiliary Channel 2 stop lamp circuit Auxiliary Channel 3 trailer fault lamp circuit Auxiliary Channel 4 Auxiliary Channel 5 Open or short circuit check auxiliary channel wiring connections misaligned connector Detach and replace Odometer Setting The TRS system requires a wheel scale setting to ensure accuracy of the odometer The default value is 508 millimeter rolling radius or 502 revs mile This value may change depending on the tire size Consult tire manufacturer for rolling or loaded radius and tire scale factor on the next page To change the tire scale factor consult the PC DIAG operating manual Page 27 Rev 5 HALDEX Wh
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