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MODULAR ABS SERIES SERVICE MANUAL

1. 150 1185 24N 150 7638 ISO 3731 24 MODULAR 2 System Variation 4 2 System as shown 2 2 Delete 2 sensors 3A 3B MODULAR2 COMPONENT PART No ECU 364 279 201 MODULATOR 3 Port Assembly LH 364263001 3 Port Assembly RH 364263011 Sensor Assembly 364 094 XXX Main Loom assembly 2S 2M 364338 XXX Main Loom assembly 4S 2M 364 307 XXX ABS Label 028 5108 09 Diagnostic Label 028518909 COMPONENT VARIATIONS COMPONENT PART No Power cable ISO 7638 Socket 364 357 XXX Un Fused PUR Power cable ISO 7638 Socket 364 362 XXX Fused PVC ISO 1185 24N Cable assembly 364358 XXX PUR ISO 3731 24S Cable assembly 364 373 XXX PUR Fig 12 9 MODULAR 2 4 2 WIRING VARIATIONS FOR SEMI TRAILER AND CENTRE Modular Section 12 0 Issue 1 0 June 1998 MODULAR ISO 7638 TRAILER MOUNTED ABS LAMP ABSMODULATOR CONNECTOR VIEWED ON WIRING SUSPENSION SIDEOF CONNECTOR Ks EN CONTROLLER COLAS COMMON HOLD BBY SN 8 5CORE CABLE BROWN PURPLE 7 5CORECABLE 2x 4 0mm n A1 Bas BN 3 CORE CABLE U 3 CORE CABLE FRONT JUNCTION 3 CORE CABLE 4CORE 1 7 CABLE 0 75mm 2 W CABLE Ki 0 75mm LOOM po CONNECTOR HOLD DUMP ABS MODULATOR CONNECTOR VIEWEDONWIRING foes SIDEOF CONNECTOR I LEFT SENSORS P C INTERFACE LEGEND
2. INT 48 438 43 4614 4516 Fax INT 48 438 433 689 SOUTH KOREA Haldex Korea Ltd Tel INT 822 749 3650 Fax INT 82 2 749 3652 SPAIN Midland Grau S A Tel INT 34 9 3573 1030 Fax 349 3573 0728 SWEDEN Haldex Brake Products AB Tel INT 46418 57700 Fax INT 46418 24435 USA Haldex Midland Corp Tel INT 18168912470 Fax INT 1816 891 9447 Modular Section 14 0 Issue 1 0 June 1998 MODULAR Brake Systems 15 0 ADDITIONAL INFORMATION 15 1 In the interests of product improvement and development Haldex Brake Products Ltd reserve the right to make product and publication changes without prior notification to the customer 15 2 Changes that are introduced may affect the way in which components are maintained serviced or repaired 15 3 Haldex Brake Products Ltd operate a bulletin service to ensure that operators of Haldex Brake Products equipment are informed of such changes whenever necessary In this respect this section of the manual should be used to file relevant product information 15 4 MODULAR ABS has several associated products which are mentioned in the service manual Each product has its own literature in which upgrades are issued with the improvement of the product This section of the manual should be used to file relevant product information to complement this service manual To receive the services of section 15 3 and 15 4 please fill in the form at the front of this
3. The wheel speed sensors will be fitted to one axle only All wires are 1 5mm unless specified Sensor cables to go to the left and right hand wheels of the sensed axle Left and Right hand is as if sat in the driver s seat facing forward The maximum cable length between ISO 1185 24N connector and the front junction box is 1metre Fig 12 10 MODULAR 2 45 2 WIRING DIAGRAM ISO 7638 FUSED AND ISO 1185 24N POWER SUPPLY Modular Section 12 0 Issue 1 0 June1998 MODULAR ISO 7638 ISO 1185 TRAILER MOUNTED ABS LAMP SUSPENSION CONTROLLER COLAS FRONT i JUNCTION CABLE 1mm INFO CENTRE P C INTERFACE LEGEND ABSMODULATOR CONNECTOR VIEWEDONWIRING SIDEOFCONNECTOR COMMON HOLD 3CORE CABLE ll 3CORE CABLE 4CORE CABLE 0 75mm 2CORE CABLE HD 0 75mm COMMON HOLD DUMP ABS MODULATOR CONNECTOR VIEWED ON WIRING SIDE OF CONNECTOR Brake Systems RIGHT SENSORS SRB BIS9N BN C asss p LEFT SENSORS Fig 12 11 MODULAR 2 45 2M WIRING DIAGRAM ISO 7638 UNFUSED AND ISO 1185 24N POWER SUPPLY The wheel speed sensors will be fitted to one axle only All wires are 1 5mm unless specified Sensor cables to go to the left and right hand wheels of the sensed axle Left and Right hand is as if sat in the driver s seat facing forward The maximum cable length between ISO 1
4. MODULAR SERVICE ABS SERIES MANUAL MODULAR 1 UPGRADE MODULAR 1 PLUS MODULAR 2 Brake Systems 000700080 MODULAR DOCUMENT REGISTRATION Included on this page of the Service Manual is a postcard which enables you to register ownership of the document Please fill in the details requested including your postcode in block capitals using a non eraseable ink and return the card to us This will enable us to ensure that any necessary manual revisions and service bulletins which are issued by Haldex Brake Products Ltd will be forwarded to you automatically If you do not return the information to us we regret that we will be unable to ensure that your manual is kept up to date If you should have any queries regarding this manual or its contents please contact our Technical Service Office on 01527 499 600 or Fax us on 01527 499 576 Modular Document Registration Issue 1 0 June 1998 Please Affix Stamp Here TECHNICAL SERVICES DEPT HALDEX BRAKE PRODUCTS LTD MOONS MOAT DRIVE MOONS MOAT NORTH REDDITCH WORCESTERSHIRE B98 9HA MODULAR PLEASE FILL IN YOUR DETAILS BELOW Modular Manual Ownership Registration YOUR oo0000000000 MODULAR NOTES ON THE USE OF THIS MANUAL Preceding the Modular main index sheet this manual should contain the document registration form and an amendment record sheet Both of these documents are intended to assist your Company
5. SENSOR Ho SENSOR Ho Brake Systems Key Modulator w Blowdown v Modulator 4 OK SC Fig 8 8 MODULAR 2 4S 2M SYSTEM CHECKOUT Modular Section 8 0 Issue 1 0 June 1998 MODULAR 9 0 THE INFO CENTRE The Info Centre is a side of trailer mounted diagnostic unit used for read out of odometer and diagnostic codes plus other information as available from the ABS Electronic Control Unit ECU See Fig 9 1 Fig 9 1 INFO CENTRE Itis connected permanently to the ABS ECU s diagnostic connection While the ECU is powered from the vehicle system stoplight or permanent supply information is transferred to the Info Centre s memory which can be recalled Power is supplied from the vehicle systems via the ECU diagnostics connector see Section 12 0 Wiring diagrams The Info Centre comprises an LCD Liquid Crystal Display see Fig 9 2 and buttons marked up down right The button accesses the next main menu item the button is used for sub menu items For adjustment of settings a watch adjustment style procedure is followed Hold down the button for 2 seconds the first digit flashes and can then be increased by pressing the button The next digit is then selected and so on It also has an internal battery which allows display of information including fault indication when the trailer is uncoupled and unpowered It is housedin a plastic enclosure provided wi
6. Check for wear clean and re adjust Perform system 1 2 check out and air 5 6 5 7 leakage check Fig 8 6 to 8 8 asapplicable Perform system 1 2 check out and 5 6 5 7 air leakage check Fig 8 6 to 8 8 Check wiring and piping as applicable security and integrity Checkfor wear clean and re adjust 3 0 Replace Modular Section 13 0 Issue 1 0 June 1998 MODULAR 14 0 FIELD SERVICE INFORMATION 14 1 SERVICE INFORMATION In the event of requiring further assistance your local area Installation or Service centre will be able to provide valuable help A list of these centres is to be found in Sections 14 7 to 14 9 A more comprehensive guide which includes service agencies throughout Mainland Europeis available from Haldex Brake Products Ltd at the address in section 15 6 14 2 TELEPHONE SUPPORT Haldex Brake Products Ltd provide in depth technical assistance and advice via the Redditch Head office when telephoning please ask for Technical Service Dept Telephone 01527 499 600 Fax 01527 499 576 14 3 ENGINEER S CALLS Should it be necessary arrangements can be made for a Haldex Brake Products Ltd Field Service Engineer to provide on site assistance at a nominal charge Contact details are as 14 2 above 14 4 AGENCY SUPPORT AND DEFINITIONS Haldex Brake Products Ltd employ the services of agencies throughout the UK to act on their behalf in providing localised service to customers using Haldex ABS These age
7. In this event the configuration and wiring diagrams should be checked against your installation to ensure that the actual pipe work and wiring conforms to the allowable configuration details See section 12 0 8 5 AUXILIARY CONFIGURATION CODE Modular 1 Plus and Modular 2 ABS ECUs offer extra features beyond the ABS However these features may or may not be used In order to provide the standard of electrical diagnostic associated with ABS type product the ECU needs to know if a solenoid operated valve e g a Reset to Ride COLAS valve should be present The ECUs are supplied in a un configured condition this means that when it is powered after being installed on a vehicle it will check for the presence ofa solenoid operated valve and configure to use one if it is present If auxiliaries are added later which require the use of features which are already disabled by the first auto configuration a fault code will be displayed For example If a Colas valve has been added since initial configuration the diagnostic code will be DDU display 7 A1 Info Centre display RIDE A1 this will be seen by the ECU as a current fault Using the DDU the procedure to clear this configuration is as follows 1 Apply power allow display to settle to fault code A1 2 Read fault code obtain CA or if no other stored fault codes 00 and accept option by pressing the button on DDU 3 Wait approx 5 sec after display has returned
8. 950 364 607 950 364 503 950 364 506 950 364 507 905 027 001 003 8467 09 003 8433 09 042 5074 09 364 317 001 364 317 011 364 385 001 364 385 011 950 364 812 950 364814 950 364 813 950 364815 Brake Systems Modular Section 14 0 Issue 1 0 June 1998 MODULAR 14 7 SERVICECENTRES Antilock Brake Systems Ltd Sutton Coldfield West Midlands Tel 0121 354 2856 B amp T Services Honeyboume Tel 01386841021 H Bowers Ltd Stoke on Trent Tel 01782599990 Button Repairs amp Tpt Services Ipswich Tel 01473612750 Cahil Motor Engineering Newtownabby Tel 0232 853094 Chassis Developments Ltd Leighton Buzzard Tel 01525374151 Cumbria Auto Electrics Ltd Carlisle Tel 0228 31707 CVBS Ltd Brierley Hill West Midlands Tel 0403 464 765 Dennison Commercial Ltd Ballyclare Tel 019 603 52827 Hi Power Tallagh Tel 0001525899 Husk UK Ltd Dover Tel 0304 831222 Longfield Road Motors Ltd Newcastle upon Tyne Tel 01912687648 Lucas Services UK Ltd Southampton Tel 01703777111 MacKenzies Cambuslang Ltd Glasgow Tel 0141 641 6419504 H amp F Moir Aberdeen Tel 01224 79041 1 Montracon Trailers Ltd Newtownabbey Tel 01232 848274 Noden Truck Centre Rugby Tel 01788 579535 Prolek Auto Electrics Mansfield Tel 01623659311 Ring Road Garage Ltd Buckingham Tel 01280814741 Ripon Auto Electrics Ripon Tel 01765602253 Scotmech Trucks Ltd Aberdeen Tel 0
9. Moduar Section 10 0 Issue 1 0 June 1998 MODULAR CODE DISPLAYED 93 Internal ECU fault 99 Internal ECU fault SYSTEM FUNCTION GROUP A1 Reset to ride height COLAS A2 Retarder CONFIGURATION CODES Figures in brackets indicate sensing is disabled when the axle is lifted Function Axle Lifted Sensors Used Modulators Used Co 2S 1M 1A 1B Red C1 2S 2M 2A 2B Blue Yellow C2 4S 2M 2A 2B 3A 3B Blue Yellow C3 4S 2M 20r3 2A 2B 3A 3B Blue Yellow SUNDRY ADDITIONAL CODES CA Erase stored fault CC Clear Configuration CF Sensors and Solenoid not connected CF may alternate with code 90 meaning low voltage See code 90 for diagnosis LO or HI Communication failure between ECU and DDU open or short circuit wiring Modular Section 10 0 Issue 1 0 June 1998 MODULAR Brake Systems 11 0 DIAGNOSTIC UTILITIES 11 1 PC Interface Kit The PC interface Kit is comprised of the Interface 1 Pod together with its connecting cables and a transit case The kit permits the connection of the diagnostic port of the ABS controller to a serial port on a PC The pod is provided with three LEDs to confirm correct functioning of the units as follows Red To indicate that 24V Power is connected Yellow To indicate data is being transmitted by the PC Green To indicate data is being transmitted by the ABS ECU INTERFACE 1 Pod 4 s 5 3 J y PCO connection to ABS ECU connection to PC via
10. Using a 500 volt insulation tester measure the insulation resistance between each sensor wire and chassis The insulation resistance must be more than 10 megohms Codes 11 and 12 indicate that the output of a wheel speed sensor is insufficient The most likely reason for this is that the sensor to exciter gap is too great Adjust the sensor as detailed in section Codes 21 and 22 indicate that there is an intermittent loss of adequate sensor signal when moving The most likely causes are loose connections loose sensor bracket broken sensor retaining clip a distorted exciter or intermittent insulation failures of sensor cables for which a cable insulation test will be required 10 11 MODULATOR SOLENOIDS Codes 61 and 67 indicate that the solenoid or its cable is open circuited 1 Disconnect the solenoid cable at its connector and measure the resistance 2 The resistance should be between 12 ohms and 20 ohms Codes 71 and 77 indicate that a solenoid or its cable is short circuited Codes 80 to 87 indicate that a solenoid or its cable has a short circuit to battery positive 1 Disconnect the harness connector from the solenoid Measure the resistance of the solenoids with a multimeter at the modulator Solenoid resistance should be 12 to 20 ohms 2 Disconnect the harness at the ECU and test at the solenoid connector between each wire and chassis with a 500 volt insulation tester The insulation resistance must be greater
11. after which the brakes should be readjusted to the manufacturer s recommendations 3 Sensor outputs may be checked by using a Diagnostic Display Unit DDU plugged into the ECU diagnostic which will be mounted on the side of the trailer 4 A suitable Multimeter as recommended in section 14 5 the use of which is described in section 3 5 C 3 5 A USING THE DDU 1 Connect the DDU to its harness then locate the diagnostic outlet socket mounted on the side of the trailer marked ABS TEST and plug in the DDU harness 2 With the Modular system powered up rotate the wheel of the sensor to be checked at a speed of one revolution every two seconds 30 RPM and observe the DDU sensor indicator bar appropriate to the wheel being rotated See Fig 3 2 3 If a solid bar appears in the DDU display window then the sensor output is satisfactory 4 If the displayed bar flashes then the sensor requires resetting EXTENSION CABLE CONNECTS ABS TEST SOCKET NUMERIC DISPLAY CONFIGURATION AND FAULT CODES SENSOR OUTPUT SENSOR DISPLAY OUTPUT DISPLAY BARS BARS HAND HELD DIAGNOSTIC DISPLAY UNIT Fig 3 2 THE DDU DISPLAY 5 If there is no bar displayed then the sensor requires either resetting see section 3 4 or it is damaged in which case it requires replacement However before replacing the unit check the sensor resistance and continuity of its extension cable to determine whether the fault lies in the
12. cable or the sensor See sections 3 7 and 3 8 3 5 B USING THE INFO CENTRE Refer to relevant information in section 15 0 1 Unclip cover from Info Centre and apply vehicle power 2 The display will switch on showing all segments followed by the total distance reading 3 Press button Diagnostic code will be displayed 4 Press button Wheel speed sensor check command will be displayed WHL 5 Rotate one wheel only at 1 rev 2sec 30 RPM for a minimum of 4 seconds 6 Stop the wheel from rotating 7 Observe the display wheel 1A gives S1A 7 8 Repeat procedure by rotating second sensed wheel wheel 1B gives S1B 9 If the display appears as above then the sensor output is satisfactory If there is no display the sensor requires resetting or is damaged Check as in section 3 5 A point 5 3 5 C USING A MULTIMETER NOTE The meter should be set to AC Volts on a scale range suitable for measuring low values i e 300 millivolt scale 1 Disconnect the sensor at its extension lead terminals 2 Connect a suitable multimeter to the sensor leads see section 14 5 Service Information for recommended types 3 Rotate the sensed wheel at a rate 1 rev 2sec 30 RPM and note the output on the meter 4 Output should be not less than 0 3 Volts A C with not more than 0 15 Volts A C variation during one complete wheel revolution 5 Excessive variation of the sensor output indicates an exciter that
13. i e In section 9 5 reference is made to figures 3 2 and 4 1 which will be found in sections 3 0 and 4 0 respectively annotated by the appropriate figure number Modular Document Registration Issue 1 0 June 1998 Brake Systems MODULAR AMENDMENT RECORD SHEET From time to time it may be necessary for Haldex Brake NUMBER Products Ltd to issue updates to this manual DATE gt m 2 m 2 gt m 2 m z DATE NUMBER JUNE 1998 If you have registered your ownership of this manual using the enclosed documentation you will automatically receive section updates and service bulletins the receipt of which may be recorded on this page as they are entered into this manual amp amp Q ID I A SECTIONS ENTERED AFFECTED 22 l 4 z m m C Modular Section Amendments Issue 1 0 June 1998 MODULAR Brake Systems 1 0 INTRODUCTION 1 4 GLOSSARY OF TERMS BU Refers to BLUE the required channel colour coding for modulators and sensors See also RD and YE CHANNEL The electrical connection between the ECU and modulator The number of ABS control channels is equal to the number of modulators fitted CONFIGURATION The arrangement of ABS components for any given installation EOLT Computer software package for End of line testing of ABS system functions during trailer manufacture
14. 1 0 June 1998 MODULAR Brake Systems DESCRIPTION PART NUMBER VIEW ISO 7638 Socket and cable Assy Fused L 12m PVC Unfused L 12m PUR ISO 7638 Socket cable seprate connector Fused L 12m PVC Unfused L 12m PUR ISO 7638 Plug and cable Assy L 12m PVC ISO 1185 24N Cable Assemsbly ForMODULAR 1 UpgradeandPlus L 12m PVC ForMODULAR2 12 PUR ISO 3731 24S Cable Assemsbly All systems L 12m PVC 12m PUR Green Warning Lamp Bulb 24v 5w Double pole Diagnostic Connector Label 950 364 421 950 364 422 950 364 423 950 364 424 950 364 429 950 364 425 950 364 426 950 364 427 950 364 428 950 364 710 ABS Label 950 364 702 Om aar 079 C 1O km n jer ABS _ 028 5189 09 Modular Section 14 0 Issue 1 0 June 1998 MODULAR Exciter RORTM 100 Tooth 80 Tooth RORTE 100 Tooth BPW 9T 100 Tooth BPW 10T 100 Tooth Sensor Kit Angled inc retaining clip Sensor Kit Straight inc retaining clip Sensor extension cable repair kit 6 0m cable Diagnostic Display Unit DDU c w case and guide 2m Cable only 24m Cable only Case only INFO Centre 1 2m Cable 0 4m Cable 1 2m Cable ADR Version 0 4m Cable ADR Version Vehicle Data System Kit c w Instruction Manual w o Instruction Manual End of Line Test Kit c w Instruction Manual w o Instruction Manual 018 5003 09 018 5004 09 018 5005 09 950 364 606
15. 2 Port No 1 M16 x 1 5 M22 x 1 5 BOTH SIDES BOTH SIDES Modular Section 1 0 Issue 1 0 June 1998 MODULAR Brake Systems THE DRIVER INFORMATION PLATE ECU AND MODULATOR ASSEMBLY O SGRAU ABS Translation With Grau ABS on the tractor or trailer at 10km h or more if ABS lamp is lit then ABS is shut down and will not work POSITIONS REFER TORH DRIVE VEHICLES 1301185 1503731 POSITION MAY VARY ISO 7638 THE WARNING LAMP THE SENSOR ASSEMBLY Fig 1 9 COMPONENT LOCATION 251 SYSTEM SHOWN THE EXCITER Modular Section 1 0 Issue 1 0 June 1998 MODULAR 2 0 THE EXCITERS The exciters will have 100 teeth or 80 teeth dependant on the wheel and hub size see Fig 2 1 They are shrunk onto the nose of the hub such that they are carried by the hub as it rotates with the wheel See Fig 2 2 In certain applications such as SAF axles the exciter may be internally toothed and interference fitted into the hub outboard of the outer bearing However the principles involved and instructions in this manual still apply NOTE THESE EXCITERS SHOULD ONLY BE USED ON SYSTEMS WHICH ARE KNOWN TO REQUIRE THE 100 OR 80 TOOTH TYPE INCORRECT APPLICATION WILL CAUSE SYSTEM PERFORMANCE DEGRADATION 2 1 EXCITER MAINTENANCE 1 Generally the exciter requires no routine maintenance However it should be cleaned and inspected for damage and checked for security on the hub spigot whenever the drum or hub is removed Refer
16. At all other times the trailer lamp function remains dormant Lamp Sequence Vehicle Stationary With the trailer ABS powered solely from the ISO 1185 connector when the brake pedal is pressed the lamp will flash and then come on and stay on until the brake pedal is released at which point the lamp will go off NOTE IF THE LAMP FAILS TO ILLUMINATE THEN THE LAMP LAMP CIRCUIT OR ABS SYSTEM IS FAULTY Lamp Sequence When the vehicle is moving at a speed greater than 6mph 10km h The lamp remains off until the brakes are applied at which point the lamp will flash and remain off IF THE LAMP FAILS TO FLASH OR IF THE LAMP IS ON AT SPEEDS ABOVE 6mph 10km h WHEN BRAKING THE ABS SYSTEM ORLAMP CIRCUIT IS FAULTY Brake Systems 6 2 DASHBOARD WARNING LAMP RED This lamp configuration will be fitted to towing vehicles which are equipped to provide a permanent power supply to the trailer ABS system via either the ISO 3731 24S or ISO 7638 electrical susies In this event semi trailer lamp function which is powered from the stoplight circuit will be secondary and the dash mounted lamp becomes the primary indicator for the ABS operationalstatus Lamp Sequence At ignition switch on the lamp red will illuminate for approximately 2 5 seconds then go out for 1 second and then come on and stay on until the vehicle is driven at a speed above 6mph 10km h when the lamp should go off and stay off IF THE LAMP FAILS TO FLASH OR
17. CONNECTIONS AS IN THE ORIGINAL INSTALLATION WILL RESULT IN POOR BRAKE AND ABS PERFORMANCE WHICH MAY CAUSE THE ABS SYSTEM TO SWITCH OFF Fault codes group 41 42 or 43 see section 8 4 Should it be necessary to change a pipe in the braking system it is essential that the replacement is the same type and has the same bore size as originally fitted Ensure that the replacement piping conforms to the specified standard for Air Brake Systems Nylon air tubing conforming to SAE J844d or DIN 73378 Metric Sizes is the only recommended tubing When replacing brake pipes or modulators ensure that the correct pipe to valve port connections are made as found before removal Brake Systems 13 7 WHEEL BEARINGS Incorrect adjustment may reduce sensor output sufficiently to put the ABS warning lamp on above 6 mph 10 km h When refitting hubs pull the hub onto the stub axle using the bearing centre nut this will avoid rocking the hub and so eliminate any possibility of accidentally knocking the sensor out of adjustment 13 8 WELDING It is essential that the battery is disconnected or the master switch turned off during electric welding Disconnect the wiring between the tractor and the trailer 13 9 ROLLER BRAKE TESTING Roller brake testing is not affected by Haldex ABS and may be undertaken in the normal manner 13 10 ROAD SPRING REPLACEMENT Do not cutthe sensor cable when changing a road spring Always cut the cable ties around the
18. Centre relative to the position of that sensor on the vehicle as shown in the configuration diagrams in section 8 0 SPLIT FRICTION A road surface condition where the tyres of wheels across the same axle experience different amounts of grip from one side of the vehicle to the other PC INTERFACE Computer hardware providing a facility for linking a PC to the ABS ECU YE Refers to YELLOW the required channel colour coding for modulators and sensors See also RD and BU VDS Computer software package for collecting data from the ABS ECU and storing to the PC 281M Two sensors and one modulator see configurations section 8 0 282M Two sensors and two modulators see configuration section 8 0 4S2M Four sensors and two modulators see configuration section 8 0 1 2 DRIVER INFORMATION MODULAR ABS is provided with a warning lamp to indicate the ABS status The GREEN lamp if fitted will be mounted on the headboard of the trailer in the rear view mirror line of vision When the ABS is electrically powered from the stop lamp circuit and no other source the lamp operates only when the brake pedal is pressed Under these circumstances when the vehicle is moving at 6 m p h 10km h or more and the brakes are applied the green lamp should flash briefly and then stay off If the vehicle is stationary and the brake pedal is applied the green lamp should flash briefly then come on and stay on NOTE At speeds above 6 m
19. DDU The hand held Diagnostic Display Unit ECU The Electronic Control Unit of the anti lock brake system EXCITER slotted or castellated steel ring fitted in the hub or brake assembly used in conjunction with the sensor to generate electrical information proportional to wheel speed INFO CENTRE A device with a LCD display trailer mounted which may be used to recall information from the memory of the ECU INTEGRATED SYSTEM A Modular ABS installation where the modulators and ECU are mounted in one unit on a common bracket located over the centre of a bogie See Fig 1 6 1 7 and 1 8 Generally applicable to semi trailers and centre axle trailers ISO 1185 24N electrical connection to the trailer from which power for the ABS may be drawn from pin 4 using the stoplamp circuit ISO 3731 The 24 electrical connection to the trailer from which power for the ABS may be drawn from pin 6 to provide a permanent power supply ISO 7638 The electrical connection to the trailer which provides a dedicated ABS power supply LCD Liquid Crystal Display relevant to the DDU display and Info Centre M Refers to a modulator i e the ABS air control valve MANIFOLD The central device on which modulators of a two channel system may be commonly mounted and pneumatically linked MODULAR ABS The product name for one of a range of trailer Anti lock Brake Systems produced by Haldex Brake Products Ltd MODULATOR S The p
20. Fused Power cable ISO 7638 Socket 364 362 XXX Fused ISO 1185 24N Cable assembly 364 370 XXX PVC ISO 3731 24S Cable assembly 364373XXX PVC Fig 12 5 MODULAR 1 PLUS WIRING VARIATIONS FOR SEMI TRAILER AND CENTRE AXLE Modular Section 12 0 Issue 1 0 June 1998 MODULAR ABSMODULATOR CONNECTOR VIEWED ONWIRING RIGHT SIDEOF CONNECTOR SENSOR COMMON 1m ZI HOLD SUSPENSION CONTROLLER ISO 7638 5CORE BLACK CABLE BROWN 5CORE CABLE 2 x 4 0mm PURPLE 7 3CORECABLE 2 1 fe FRONT 3CORE CABLE JUNCTION BOX TRAILER MOUNTED ABS LAMP CENTRE CABLE MAIN 0 75mm LOOM CONNECTOR LJ LEFT SENSOR P C INTERFACE LEGEND The wheel speed sensors will be fitted to one axle only All wires are 1 5mm unless specified Sensor cables to go to the left and right hand wheels of the sensed axle Left and Right hand is as if sat in the driver s seat facing forward The maximum cable length between ISO 1185 24N connector and the front junction box is 1metre Fig 12 6 MODULAR 1 PLUS WIRING DIAGRAM ISO 7638 FUSED AND ISO 1185 24N POWER SUPPLY Modular Section 12 0 Issue 1 0 June 1998 MODULAR ABSMODULATOR CONNECTOR SUSPENSION VIEWED ON WIRING CONTROLLER SIDEOF CONNECTOR COLAS COMMON aa HOLD DUMP RE ISO 7638 BLACK BROWN E GORE CABLE 2 4 0mm 3 CORE CABLE Bio BN 2 oo o E FRONT 3CORECABLE JUNCT
21. Tel 01246 261666 Ashbourn Tel 01335 346236 D B Wilson Ltd Glasgow Tel 0141 6470161 Digraph Trans Supplies Ltd Awkworth Tel 01602 322195 Doncaster Tel 01302 726636 Derby Tel 01332 380300 Leicester Tel 01530 245756 Dingbro Ltd Aberdeen Tel 01224 682000 Elgin Tel 01343 552888 Fraserbourgh Tel 01346 51234 Inverness Tel 01463 713133 Peterhead Tel 01779476551 Kirkalby Tel 01592 650495 Montrose Tel 01674 675311 Perth Tel 01738 443388 Arbroath Tel 01241 876414 D M H Warrington Ltd Warrington Tel 01925 650601 Crewe Tel 01270 582288 Manchester Tel 0161 832 4427 E M S Ltd Northampton Tel 01604 702552 East Kent Components Ltd Dover Tel 01304 204697 Ashford Tel 01233 631951 FavershamTel 01795 537228 Edmunds Walker Ltd Forlist of branches telephone Straford on Avon Tel 01789414545 Fleet Factors Middlesbrough Tel 01642465141 Stockton Tel 01642 616333 Carlisle Tel 01288 810050 Hexham Tel 01434 600789 Sunderland Tel 0191 567 1587 Gateshead Tel 0191 490 0909 Leeds Tel 0113 277 7400 Stallingborough Tel 01482 227423 Hull Tel 01482 227423 Birtley Tel 0191 410 4437 Manchester Tel 0161 223 0367 Enfield Tel 0181 804 3995 Brake Systems Fleetweel plc Cardiff Tel 0122 378191 Newport Tel 01633 841645 Swansea Tel 01792 775111 Tiverton Tel 01884 258797 Bristol Tel 0117 982 6667 Frenco Service Replacements Ltd Kidderminster Tel 01562 754931 Banbury Tel 01295 270711 Oxford Tel 01
22. Tel 0151 495 1751 Stoke om Trent Tel 01782 586667 Deeside Tel 01244 541214 Winsford Tel 01606 552550 Preston Tel 01772 696668 Southern Comp Grp Ltd Dartford Tel 01322553330 Sittingbourne Tel 01795 420087 Southern Trailer Parts Ltd Reading Tel 01118 932 3577 Transport Supplies NI Ltd Belfast Tel 01232 781230 Craigaven Tel 01762 362 555 Truck and Trailer Specialists Ltd Eastleigh Tel 01703 644746 Brake Systems Truckline Bristol Tel 0117 982 1321 Eastleigh 01703617666 Manchester Tel 0161 8725 457 Grays Tel 01375 394949 Stockton Tel 01642 607811 Doncaster Tel 01977 671206 Woodheads Partco Ltd Forlist of branches telephone Birmingham Tel 0121 717 0071 Modular Section 14 0 Issue 1 0 June 1998 MODULAR 14 9 HALDEX INTERNATIONAL OFFICES AUSTRIA Graubremse Wien GesmbH Tel INT 43 1865 16 40 Fax INT 43 1865 16 4027 BELGIUM Haldex NV Tel INT 32 2725 3707 Fax INT 3227524099 BRAZIL Haldex do Brasil Ind e Com Ltda INT 55 11531 4159 Fax INT 55 11 531 9515 Haldex International Trading Shanghai Co Ltd Tel INT 86 21 6289 4469 Fax INT 8621 6279 0554 FRANCE Haldex Europe S A Tel INT 333 88 68 22 00 Fax INT 333 88 68 22 09 GERMANY Haldex Brake Products GmbH INT 49 177 934 91 70 Fax INT 49 711 934 91 740 GREAT BRITAIN Haldex Ltd Tel INT 44 1 325 310 110 INT 44 7 325 311 834 POLAND Haldex Sp Zo o
23. U bolts and then refit new cable ties after the re placement spring has been installed Take care not to damage the sensor cable and ensure that when it is refitted it is not routed in such a manner as to place it under undue tensile loading When refitting cable ties place them at approximately 150mm apart and do not excessively overtighten them especially along brake hose runs as this may cause damage to the cable conductors Remember that when the brakes are applied the brake hose will expand and thus tighten the cable tie causing excessive shearing forces to be imparted to the cable 13 11 MAINTENANCE OF AIR SYSTEMS Piping should be checked at regular intervals for damage or restrictions e g pinched or kinked Ensure that the air reservoirs are regularly drained as recommended by the vehicle manufacturer No liquids should be introduced into the air system except for anti freeze compounds approved by the vehicle manufacturer Modular Section 13 0 Issue 1 0 June 1998 MODULAR 13 12 ROUTINE MAINTENANCE SCHEDULE Time or mileage Component whichever occurs first When hubs are Exciter removed Sensor Every 3 months Complete or 25 000 miles system 40 000 km Annually or every Complete 100 000 miles system 160 000 km Sensor Every five years Modulator 500 000 miles and Solenoid 800 000 km Fig 13 1 RECOMMENDED MAINTENANCE SCHEDULE Brake Systems Operation Section Number Check for damage
24. body and slide it away from the connector 6 Withdraw the spider and pin housing assembly from the socket body and disconnect the fused pin blade connector 7 Slide the cable gasket along the cables away from the spider to clear the fused pin blade 8 Separate the spider and pin housings by prising them apart to disengage the retaining barbs 9 Pull pin 1 sideways out of the spider and insert the new fused pin into its housing in the same orientation 10 Re assemble the connector in the reverse procedure ensuring correct location of all gaskets and security of all gland nuts and fittings Modular Section 7 0 Issue 1 0 June 1998 MODULAR 8 0 SYSTEM CONFIGURATIONS 8 1 TERMINOLOGY see also section 1 1 S Refers to a sensor M Refers to a modulator S1A S1B S2A S2B and S3A S3B identify the left and right hand of sensor pairs and the order in which they are installed on the trailer Consider sitting on axle 1 with axle 2 behind you then sensor group A will always be to your left and sensor group B will always be to your right You will note that for this to be true you will be facing forwards for full trailers and backwards for semi or centre axle trailers The configuration reference indicates component quantities in the system Hence a 251M system will have 2 Sensors and 1 Modulator The sensor identity is relevant to the position in which its output is displayed on the DDU or Info Centre when checkin
25. data from the ABS system The first type is test data recorded by the ABS system example wheel speeds as measured on a rolling road and system configuration data The second type is data entered by the user Full details of the EOLT package are available in a seperate publication 11 4 Minimum system specifications The minimum PC or Laptop specification to run either of the diagnostic packages is as follows MS DOS PC AT or compatible RAM 640K Hard Drive 1Mb Free Monitor EGA VGA MS Windows 3 11 or 3 1 Processor 286 or above RAM 4 Megabytes 8 recommended Hard Drive 20 Megabytes Monitor EGA VGA MS Windows 95 Processor 486 or above RAM 8 Megabytes 16 recommended Hard Drive 20 Megabytes Monitor EGA VGA In addition to the above a 3 5 diskette drive is required for software installation and a vacant serial port will be required to connect to the interface 1 pod MODULAR 12 0 SYSTEM WIRING DIAGRAMS 12 1 WIRING REPAIRS 1 Before undertaking maintenance or repairs the MODULAR ABS system it is necessary to understand the system configuration of the vehicle being worked upon see section 8 0 2 First read section 8 0 configurations and determine the wiring diagram to suit your vehicle 3 Proceed with maintenance and repairs accordingly using the appropriate wiring diagram Brake Systems 4 To maintain system reliability wiring repairs must be of a high standard The ECU
26. fasteners securing the ISO 7638 connector to the trailer headboard 3 Pull the socket away from the headboard to expose the cable gland 4 Release the cable gland 5 Unscrew the rear cover from the ISO 7638 connector and slide it away from the connector 6 Pull back the gasket and gasket retainer covering the pin compartment to gain access to the blade terminal of pin 1 7 Disconnect the blade terminal from the fuse assembly 8 Push the relief tool in the service kit fully home over the retaining barbs of pin 1 9 Insert the ejector in the service kit into the relief tool and push it fully home to eject the pin from its housing 10 Fitthe replacement fused pin 1 and reassemble the connector in reverse procedure ensuring correct location of all gaskets and security of all gland nuts and fittings Modular Section 7 0 Issue 1 0 June 1998 MODULAR CABLE GLAND NUT BODY REARCOVER Brake Systems SOCKETBODY PINHOUSING CABLE SPIDER GASKET FUSEDPIN No 1 BLADE CONNECTOR Fig 7 3 ISO 7638 FUSE REPLACEMENT HALDEX CONNECTOR Type B Haldex Connector Green Cover See Fig 7 3 1 Disconnect the trailer from all power sources 2 Remove the fasteners securing the ISO 7638 connector to the trailer headboard 3 Pull the socket away from the headboard to expose the conduit and cable gland 4 Unscrew the cable gland nut from the socket bodyrear cover 5 Unscrew the rear cover from the connector
27. for audible air leakage If audible leakage is noted investigation and remedial action is necessary NOTE It is important that before a leaking modu lator is replaced it is confirmed that the leak is within the unit itself and is not a leak from a pipe fitting or a back feed from a ruptured spring brake diaphragm To check a pipe fitting a water and soap solution or suitable leak detector spray may be applied and the area of suspected leakage inspected for bubbles Brake Applied Check 1 Fully charge the air system 2 Apply the footbrake and listen at the modulator exhaust port for audible leakage If audible leakage is noted investigation and remedial action is necessary 5 5 SOLENOID OPERATION CHECK 1 Fully charge the air brake system 2 Apply the footbrake and switch on the ignition listening for the exhaust of air from each modulator There should be as many single brief pulses of air as there are modulators See section 8 0 configurations NOTE If there is no pulse then a fault exists which may be an open circuit solenoid open circuit wiring or a fault at the ECU connector In the case of a double pulse there is a wiring fault involving incorrect connection between the dump and hold solenoids 3 If a single pulse does not occur repeat 1 and 2 with an assistant observing each of the modulators Establishing which valve s are not producing pulses will provide a start to fault finding see section 10 0 T
28. incorporates a permanent magnet and coil which are environmentally sealed in a stainless steel housing The coil is connected to a moulded flying lead which is terminated with a connector The sensors are secured in their housings on the axle by a retaining clip which must always be fitted to ensure system integrity see Fig 3 1 The sensor is bracket mounted in the axle assembly with its magnetic pole in close proximity to the exciter teeth maximum 0 5mm 0 020 The teeth pass through the magnetic field causing a change in magnetic flux density which in turn generates an alternating voltage in the sensor coil The frequency of the voltage generated is directly proportional to wheel speed It is this signal which is monitored by the ECU to determine changes in wheel speed RETAINING SENSOR SENSOR CLIP HOUSING Fig 3 1 THE SENSOR ASSEMBLY 3 1 SENSOR MAINTENANCE 1 The sensor requires no routine maintenance but should be cleaned and inspected for damage wear and security prior to resetting whenever the brake drums are removed Note If sensor is removed from its housing lightly grease the sensor with a lithium based grease before installing back into the housing 3 2 SENSOR WEAR CHECK 1 Remove the vehicle hub or the sensor from its mounting and clean the end face of the sensor 2 If the sensor casing is holed or damaged it should be replaced See section 3 3 for instructions on replacement 3 If the sensor is servic
29. is damaged or that has been incorrectly fitted 6 If the output is less than 0 3 Volts A C the sensor may require resetting see section 3 4 or if damaged replacement with a new component See section 3 3 Before replacing a sensor check its resistance and the continuity of its extension cable to Modular Section 3 0 Issue 1 0 June1998 MODULAR Brake Systems determine whether the fault lies in the sensor or its cable See section 3 7 and 3 8 3 6 ADDITIONAL SENSOR CHECKS If sensor outputs are found to be unsatisfactory proceed as follows FLASHING DISPLAY on DDU or LOW METER READING 1 Reset the sensor as detailed in section 3 4 and check that the exciter is not damaged and is running true see section 2 1 2 2 and Fig 2 4 2 Check the running clearance between exciter and sensor which should not exceed 0 5 mm 0 020 at any point during one complete revolution 3 Check the exciter face for dents or other damage NO BAR DISPLAY on DDU INFO CENTRE or NO METER READING The sensor is so far out of adjustment or damaged as to not give an output reset as detailed in section 3 4 The sensor or its exten sion cable is open circuit or extension cable connections have an excessively high resistance Proceed as follows section 3 7 and 3 8 3 7 CABLE CONTINUITY 1 Unplug the sensor extension cable from the sensor flying lead at the back of the brake dust cover 2 Bridge the pins of the extension
30. manual if you have not already done so and forward it to the address indicated 15 5 Additional copies ofthis or other SERVICE MANUALS are available at a nominal cost direct from Haldex Brake Products Ltd at the address given below 15 6 Questions concerning product or product information should be directed to Haldex Brake Products Ltd Technical Service Department who will be pleased to assist you with your enquiries and who may be contacted by writing to Haldex Brake Products Ltd Technical Service Dept Moons Moat Drive Moon Moat North Redditch Worcestershire B98 9HA or by Telephone INT 44 1527 499 600 Fax INT 44 1527 499 576 Modular Section 15 0 Issue 1 0 June 1998
31. p h 10km h when the brakes are applied no lamp flash or a permanently lit lamp indicates a system fault which should be investigated A RED lamp will be fitted in the cab dashboard when the ABS is powered by a dedicated 1507638 or a supplementary 24 power supply from the ignition switch When the ignition is turned on the red lamp should flash briefly and then come on until the vehicle speed exceeds 6 m p h 10km h then the lamp should go out NOTE For any single driving cycle ignition on to ignition off If there is no lamp flash when the ignition is turned on or if a permanently illuminated lamp occurs after the vehicle has exceeded 6 m p h 10 km h at initial move off a system fault is indicated which should be investigated If a red lamp ABS2 is fitted in the cab this becomes the primary indicator and the trailer ABS will be permanently powered In this case the green trailer lamp will only function if a on initial power up if the brake pedal is pressed before the ignition is switched on b during a fault event when the red lamp is illuminated and the brake pedal is pressed Further information on lamp sequences may be found in section 6 0 Modular Section 1 0 Issue 1 0 June 1998 MODULAR Brake Systems 1 3 BRAKING WITH ABS In an emergency apply full force on the brake pedal The ABS will be activated immediately you fully apply the brakes and will assist you to retain steering control o
32. preferred 6 Delivery port ABS valve assembly 3 Delivery port ABS valve assembly Axle which may be a lift axle For actuation recommendations consult Haldex Brake Products Ltd Technical Service NOTE The above diagrams illustrate the most common installations For alternative configurations consult Haldex Brake Products Ltd Technical Service Fig 8 4 MODULAR SYSTEM SEMI TRAILER CONFIGURATION LAYOUTS Modular Section 8 0 Issue 1 0 June 1998 Centre Axle Trailer Details viewedfrom above 2 Delivery port ABS valve assembly preferred 6 Delivery port ABS valve assembly 3 Delivery port ABS valve assembly Axle which may be a lift axle For actuation recommendations consult Haldex Brake Products Ltd Technical Service NOTE The above diagrams illustrate the most common installations For alternative configurations consult Haldex Brake Products Ltd Technical Service Fig8 5 MODULAR SYSTEM CENTRE AXLE TRAILER CONFIGURATIONLAYOUTS Modular Section 8 0 Issue 1 0 June 1998 MODULAR SENSOR No SENSOR Fig8 6 MODULAR 1 2 1 SYSTEM CHECKOUT Brake Systems Key Modulator 43 Blowdown M Modulator Z O K SC Modular Section 8 0 Issue 1 0 June 1998 Haldex Key Modulator AXLE Ho Blowdown SENSOR SENSOR dene mm Fig 8 7 MODULAR 2 2S 2M SYSTEM CHECKOUT Modular Section 8 0 Issue 1 0 June 1998 MODULAR AXLE
33. relies upon receiving low voltage signals from the sensors via cables and connectors which should offer minimal electrical resistance It is particularly important therefore that the recommended cable connectors and tools are used to ensure as low a resistance as possible All electrical connections must be made as shown in the relevant wiring diagrams IMPORTANT FAILURE TO OBSERVE THESE RECOMMENDATIONS MAY LEAD TO A SYSTEM MALFUNCTION Modular Section 12 0 Issue 1 0 June 1998 MODULAR Brake Systems MODULAR 1 UPGRADE ISO 1185 24N 150 7638 ISO 3731 24S MODULAR 1 UPGRADE ABS COMPONENT PART No ECU 364 279 002 MODULATOR 6 Port Assembly 364 115 XXX Sensor Assembly 364 094 XXX Main Loom assembly Full function 364 359 XXX ABS Label 028 5108 09 Diagnostic Label 028 5189 09 COMPONENT VARIATIONS COMPONENT PART No Power cable ISO 7638 Socket Un Fused 364357 XXX Power cable ISO 7638 Socket Fused 364362 XXX ISO 1185 24N Cable assembly PVC 364370 XXX ISO 3731 24S Cable assembly PVC 364373 XXX Fig 12 1 MODULAR 1 UPGRADE WIRING VARIATIONS FOR SEMI TRAILER AND CENTRE AXLE Modular Section 12 0 Issue 1 0 June 1998 MODULAR ABSMODULATOR CONNECTOR VIEWED ONWIRING RIGHT SIDEOF CONNECTOR SENSOR COMMON r1 1 HOLD 2CORE Kil CABLE ISO 7638 5CORE CA
34. to A1 4 Repeat reading and clearing of fault code as above upto three times 5 Onthe third time the CA will have been replaced by a CC Accept this option by pressing and holding the button 6 Remove power Modular Section 8 0 Issue 1 0 June 1998 MODULAR Brake Systems 7 Apply power the diagnostic display should show the main C configuration followed by the configuration A1 then 07 The ECU is now re configured 8 Erase diagnostic code A1 from memory Using the Info Centre the procedure to clear the configuration is detailed in the Additional Information section 15 0 8 6 CONFIGURATION AND FUNCTION CHECK In the event of needing to identify the configuration match your trailer details to those shown in Fig 8 4 or Fig 8 5 i e Type of trailer Number of axles modulators and sensors fitted see also Figs 8 1 and 8 2 Having determined this information Fig 8 4 or Fig 8 5 can be used to determine the configuration layout applicable to your trailer Having determined your trailer layout referto the corresponding section diagram from Fig 8 6 which shows the correct checkout procedure inthe order 1 Lamp sequence 2 Modulator blowdown check see section 5 7 3 Sensor output indication on DDU or Info Centre when wheel or wheels are rotated Modular Section 8 0 Issue 1 0 June 1998 0 25 1 2 2S 2M N 2 Details viewed from above 2 Delivery port ABS valve assembly
35. to axle manufacturer s instructions 2 2 EXCITER REPLACEMENT In the event of an exciter being damaged it should be replaced with an identical unit observing the following procedure 1 Remove the relevant hub from the stub axle 2 Prise or drift the old unit off the hub assembly or alternatively drill and split it CAUTION During this operation observe personal safety precautions and take care not to damage the hub assembly 3 Clean the spigot and abutment face of the hub ensuring that they are free from burrs 4 Replace the exciter by heating it evenly to a minimum temperature of 120 degrees Celsius This may be achieved by using a hotplate or oven which is thermostatically controlled see Fig 2 3 5 Whilst the exciter ring is hot place it over the hub nose ensuring that it seats correctly onto the location spigot machined on the hub 6 When the exciter is correctly fitted there should be either a zero or equal gap between the shoulder of the machined hub and the back of the exciter throughout 360 degrees of rotation see Fig 2 4 Brake Systems Fig 2 2 THE HUB AND EXCITER ASSEMBLY EXCITER RING THERMOSTATICALLY CONTROLLED HOTPLATE Fig 2 3 HEATING THE EXCITER RING ModularSection2 0 Issue 1 0 June 1998 MODULAR Brake Systems ZERO TO EQUAL GAP THROUGH 360 DEGREES OF ROTATION HUB ASSEMBLY CORRECTLY LOCATED EXCITER MAXIMUM RUNOUT 0 005 0 125mm Fig 2 4 FITTING TH
36. which goes to ISO 7638 pin 4 See wiring Section 12 Code 92 indicates that the power supply to the ECU is above 32 volts and action must be taken to reduce this over voltage 1 Check the towing vehicle voltage regulator and alternator system or the voltage output from the test power supply in use 2 The correct power supply connections to the ECU supply pins are shown in the pin maps in Fig 4 7 Fig 4 8 and Fig 4 9 10 9 WARNING LAMP FLASH INCORRECT Permanently Illuminated Lamp 1 This may be caused by wiring shorts or by faults which cause the ECU to permanently illuminate the lamp The latter may be due to a system fault if the code displayed is not 07 or a stored sensing system fault if the code displayed is 07 2 Read the diagnostic code If the code is 07 read the fault memory Sensing system faults will be stored if any were present the last time the trailer was moved at a speed greater than 6mph 10km h 3 Make any necessary repairs and clear the memory The lamp flash should now revert to normal after vehicle speed has exceeded 6mph 10km h IMPORTANT See section 6 5 If not there is a lamp wiring short circuit to battery negative or chassis 4 If the code is not 07 make the necessary repairs as indicated by the diagnostic code until the code becomes 07 at which time the lamp sequence should revert to normal within the provisions of section 6 5 NOW ERASE THE MEMORY 5 If after completing the above proce
37. 1224 898844 Dundee Tel 01382451416 G Stout Lube Services Midlothian Tel 01968673247 Tachograph Chester Ltd Ellesmere Port Tel 0151 3552101 Tanner Tachograph Ltd Cardiff Tel 01222 225580 Tramec Bristol Tel 01179822799 Brake Systems Truck Services of Grimsby Grimsby Tel 01472 362929 Frank Tucker Commercial Ltd Exeter Tel 01392 833030 Woodwards SV S St Hellens Tel 01744 20266 Modular Section 14 0 Issue 1 0 June 1998 MODULAR 14 8PARTS DISTRIBUTORS ABS Burton Ltd Burton on Trent Tel 01283 568037 Aldridge Tel 01922455751 Spares Ltd Bridgend Tel 01656 663163 Bristol Tel 0117 9381 144 Llanelli Tel 01269 831177 Cullompton Tel 01884 33810 Hereford Tel 01432 263438 Artic Trailer Ltd Stirling Tel 01786 816 005 Falkirk Tel 01324 613533 Artec Yorks Ltd Sheffield Tel 01246415777 Liversedge Tel 01924 401689 Hull Tel 01482 581141 Malton Tel 01653 698009 Aghabridge Ltd Kent Tel 01634 2949 Crane Fruehauf Ltd Forlist of branches telephone Dereham Tel 01362 69535 Commercial Clutch Services Ltd Birmingham Tel 0121 328 4060 Commercial Equipment Ltd Brierley Hill Tel 01384 78151 CV Components Inverness Tel 01463 220232 CV Spares Ltd Slough Tel 01753 680404 Swindon 01793 5133519 Congleton Motor Factors Ltd Congleton Tel 01260 280400 Wirksworth Tel 01629 823948 Derby Tel 01332 385901 Stafford Tel 01785 254634 Buxton Tel 01298 26588 Chesterfield
38. 185 24N connector and the front junction box is 1 metre Modular Section 12 0 Issue 1 0 June 1998 MODULAR 5CORE CABLE WHITE TRAILER MOUNTED ABS LAMP Brake Systems ABSMODULATOR CONNECTOR VIEWED ON WIRING SIDEOF CONNECTOR RIGHT SUSPENSION COMMON DUMP SENSORS CONTROLLER COLAS HOLD 2CORECABLE BLACK BROWN 5CORECABLE 2x 4 0mm 3 CORE CABLE 2 ad i mm V 4CORECABLE0 75mm 3 CORE CABLE A P COMMON L4 Ll Balb m TP MAINLOOM CONNECTOR DUMP kel 2CORE vi CABLE 0 75mm i LEFT ABS MODULATOR CONNECTOR VIEWED ON WIRING SIDEOF CONNECTOR LEGEND The wheel speed sensors will be fitted to one axle only All wires are 1 5mm unless specified Sensor cables to go to the left and right hand wheels of the sensed axle Left and Right hand is as if sat in the driver s seat facing forward The maximum cable length between ISO 1185 24N connector and the front junction box is 1 metre Fig 12 12 MODULAR 2 4S 2M WIRING DIAGRAM ISO 3731 24 AND ISO 1185 24N POWER Modular Section 12 0 Issue 1 0 June1998 MODULAR EXISTING 3CORE 7CORE CABLE os 1503731 245 EXISTING 7CORE ISO 1185 24N TRAILER MOUNTED ABS LAMP GREEN BK Black BN Brown RD Red YE Yellow W White ISO 1185 1503731 Brake Systems TOECU JUNCTION BOX 24V RELAY TOECU EXISTING 7CORE CABLE TRAILER
39. 1metre Fig 12 3 MODULAR 1 UPGRADE WIRING DIAGRAM ISO 7638 UNFUSED AND ISO 1185 24N POWER SUPPLY Modular Section 12 0 Issue 1 0 June 1998 Haldex MODULAR ABS MODULATOR CONNECTOR VIEWED ONWIRING SIDEOFCONNECTOR RIGHT SRO SENSOR r 2 CORE gt CABLE 5 CABLE WHITE ISO 3731 PLACIC BN JE 24S BLACK w ISO 1185 FRONT 3CORE JUNCTION CABLE BOX CABLE j 0 75mm 2CORE MOUNTED T ii TT CABLE MAIN ABS LAMP 0 75mm LOOM CONNECTOR LEFT SENSOR P C INTERFACE LEGEND The wheel speed sensors will be fitted to one axle only All wires are 1 5mm unless specified Sensor cables to go to the left and right hand wheels of the sensed axle Left and Right hand is as if sat in the driver s seat facing forward The maximum cable length between ISO 1185 24N connector and the front junction box is 1metre Fig 12 4 MODULAR 1 UPGRADE WIRING DIAGRAM ISO 3731 24S AND ISO 1185 24N POWER Modular Section 12 0 Issue 1 0 June 1998 MODULAR 1 PLUS ISO 1185 24N 150 7638 150 3731 24 MODULAR 1 PLUS ABS COMPONENT PART No ECU 364 279 101 MODULATOR 6 Port Assembly 364115 XXX Sensor Assembly 364094 XXX Main Loom assembly Full Function 364329 XXX ABS Label 028 5108 09 Diagnostic Label 028518909 COMPONENT VARIATIONS COMPONENT PART No Power cable ISO 7638 Socket 364 357 XXX Un
40. 865 772161 G E Middleton amp Co Ltd Manchester Tel 0161 872 0923 HGV Truck amp Trailer Parts Boston Tel 01205 365258 HB Commercials Ltd Felixstowe Tel 01394 675675 H amp S Commercials Ltd Wakefield Tel 01924 279294 Bradford Tel 01274 721630 Castleford Tel 01977 603606 Hi Way Components Oldham Tel 0161 652 0315 Hydrair Blackburn Tel 01254 889333 L C Davis amp Sons Ltd London Tel 0181648 7717 LCP Engineering Co Ltd Gillingham Tel 01634 575501 Canterbury Tel 01227 766001 Ashford Tel 01233 623113 Maidstone Tel 0101622672222 Purfleet Tel 01708 891189 Tunbridge Wells Tel 01892 535455 Brighton Tel 01273 430730 Dartford Tel 01322557825 Gravesend Tel 01474 320300 Merlin Components London Ltd Barking Tel 0181591 6908 Modular Section 14 0 Issue 1 0 June 1998 MODULAR 14 8PARTS DISTRIBUTORS Multitruck Components Ltd Milton Keynes Tel 01908 274400 Welwyn Garden City Tel 01707 393000 N E T S Ltd Netton le Hole Tel 0191526 3753 Stockton on Tees Tel 01642 613514 Carlise Tel 01228 511312 Morecombe Tel 01524 841057 A J Parsons amp Sons Ltd Shepton Mallett Tel 01749 346161 Redruth Tel 01209 219764 Launceston Tel 01566 774341 Partic Motors Spares Ltd Newark Tel 01636 702479 Lincoln Tel 01522 689 409 Nottingham Tel 01155 976 0977 Peter Bassett Buckingham Tel 01280817174 Port Brake Services Ltd Ellesmere Port Tel 0151 355 0226 Liverpool Tel 0151 525 1558 Widnes
41. Apply 24 volts to the anti lock system 4 At power up 88 is displayed briefly to confirm LCD function followed by a configuration code and a diagnostic code which is displayed constantly Check that the configuration code agrees with the system wiring by confirming that the number of connected sensors and solenoids are as shown in the configuration codes given in section 8 3 5 Refer to diagnostic codes in section 10 12 to determine the cause of the fault Note that some codes generated confirm correct system function 6 Remove all electrical power and then repair faults as necessary 7 Clear the diagnostic memory as described in 10 5 NOTE Faults which occur whilst the ECU is powered up are logged in two memories Any attempt to erase the permanent memory unless power has been removed since the fault occurred will be unsuccessful as the temporary memory will continuously re write the fault to permanent memory at each erasure attempt 8 Remove electrical power from the ABS system the diagnostic display will be completely blank 9 Disconnect the DDU cable from its connector 10 Restore electrical power and carry out the driver s checks for correct lamp sequence as described in section 1 2 but with regard to the Important Note at section 6 5 10 5 READING STORED CODES ON THE DDU 1 Remove electrical power from the ECU 2 Connect the Diagnostic Display Unit to its connector on the trailer 3 Apply power to the ECU 4
42. BLE JX 4 0mm 3 CORE CABLE FRONT 3CORE CABLE JUNCTION 2CORE i TRAILER CI MOUNTED LAMPS RAN CABLE KFP MAIN ABS LAMP 0 75 LOOM CONNECTOR LEFT SENSOR P C INTERFACE LEGEND The wheel speed sensors will be fitted to one axle only All wires are 1 5mm unless specified Sensor cables to go to the left and right hand wheels of the sensed axle Left and Right hand is as if sat in the driver s seat facing forward The maximum cable length between ISO 1185 24N connector and the front junction box is 1metre Fig 12 2 MODULAR 1 UPGRADE WIRING DIAGRAM ISO 7638 FUSED AND ISO 1185 24N POWER SUPPLY Modular Section 12 0 Issue 1 0 June 1998 MODULAR ABSMODULATOR CONNECTOR VIEWED ON WIRING SIDEOF CONNECTOR COMMON ele HOLD ISO 7638 5CORE CABLE RED RD BLACK BK WHITE W B P BROWN U SCORECABLE FRONT 3CORE CABLE JUNCTION TZ BOX aaa 4CORE CABLE 2CORE TRAILER S 0 75mm CABLE KIP MOUNTED MAIN ABS LAMP Tr THU AT uius LOOM CONNECTOR LEFT SENSOR P C INTERFACE LEGEND The wheel speed sensors will be fitted to one axle only All wires are 1 5mm unless specified Sensor cables to go to the left and right hand wheels of the sensed axle Left and Right hand is as if sat in the driver s seat facing forward The maximum cable length between ISO 1185 24N connector and the front junction box is
43. E EXCITER TO THE HUB 2 3 FITTING THE HUB 1 Check the condition of the existing sensor before re fitting the hub and exciter assembly to the stub axle 2 The sensor should be wiped clean and then reset as detailed in sections 3 1 and 3 4 3 The hub assembly with its new exciter may now be fitted together with its bearings to the stub axle 4 During the re assembly process avoid rocking the hub and as soon as the hub centre nut can be engaged on its thread use it to pull the assembly evenly onto the stub axle This will ensure that as the exciter teeth make contact with the sensor they will push the sensor back in its housing without damage to the exciter teeth or the sensor It also guarantees that an ideal running condition will be set up between the exciter and sensor PROVIDED THAT THE SENSOR WAS CORRECTLY RESET BEFORE FITTING THE HUB 5 f the sensor was not reset before assembling the hub to the stub axle set the hub centre nut to the axle manufacturer s recommendations then push the sensor through its housing until it contacts the exciter teeth 6 Ensure that exciter teeth have not been damaged during refitment of the hub to the stub axle 7 Rotate the hub several times to automatically set the ideal running condition 8 The sensor output should now be checked as described in section 3 5 Modular Section 1 0 Issue 1 0 June 1998 MODULAR Brake Systems 3 0 THE SENSORS The Modular sensor design
44. IF THE LAMP IS ON AT SPEEDS ABOVE 6mph 10km h THEN THE ABS SYSTEM OR LAMP CIRCUIT IS FAULTY 6 3 CAB DASHBOARD LAMPS RED and AMBER This lamp configuration may be fitted to some vehicles of European manufacture to suit particular types of ABS The function of the red lamp is to indicate the operational status of the ABS The function of the amber lamp is to indicate if ABS is fitted to the trailer It is not however a mandatory requirement and if you have a vehicle with this lamp configuration you should refer to the vehicle manufacturer s handbook for further information 6 4 MULTIPLE LAMP SEQUENCE GREEN and or RED The Modular ABS series incorporates an auxiliary lamp flash ofthree flashes The lamp will flash when the system is powered up when at rest This lamp sequence relates to 1 Service due indicates that trailer system service distance has been reached After servicing the trailer or system the next service distance must be reset by using Info Centre see Section 9 0 additional product information or EOLT program see Section 11 0 Modular Section 6 0 Issue 1 0 June 1998 MODULAR 2 NON ABS fault A fault with a device connected to the ABS but not directly effecting the ABS A function group A code will be generated For example a Reset to Ride height valve COLAS has been connected to the ABS an A1 or RIDE A1 diagnostic code will be generated This type of diagnostic code can be cle
45. ION TR CABLE TRAILER 0 75mm MOUNTED ABS LAMP CABLE BB MAIN 0 75mm LOOM CONNECTOR LEFT SENSOR P C INTERFACE LEGEND The wheel speed sensors will be fitted to one axle only All wires are 1 5 unless specified Sensor cables to go to the left and right hand wheels of the sensed axle Left and Right hand is as if sat in the driver s seat facing forward The maximum cable length between ISO 1185 24N connector and the front junction box is 1 metre Fig 12 7 MODULAR 1 PLUS WIRING DIAGRAM ISO 7638 UNFUSED AND ISO 1185 24N POWER SUPPLY Modular Section 12 0 Issue 1 0 June 1998 Haldex MODULAR ABSMODULATOR CONNECTOR VIEWED ONWIRING SIDEOFCONNECTOR RIGHT SUSPENSION COMMON SENSOR CONTROLLER COLAS HOLD Duve m 2CORE CABLE 0 75mm 5CORE CABLE ISO 3731 24S ISO 1185 FRONT 3CORE JUNCTION CABLE BOX TRAILER MOUNTED ABS LAMP LOOM CONNECTOR P C INTERFACE LEGEND The wheel speed sensors will be fitted to one axle only All wires are 1 5mm unless specified Sensor cables to go to the left and right hand wheels of the sensed axle Left and Right hand is as if sat in the driver s seat facing forward The maximum cable length between ISO 1185 24N connector and the front junction box is 1 metre Fig 12 8 MODULAR 1 PLUS WIRING DIAGRAM ISO 3731 24S AND ISO 1185 24N POWER Modular Section 12 0 Issue 1 0 June 1998 MODULAR 2 4S 2M
46. MOUNTED ABS LAMP GREEN j Jd tte TOECU B STOPLAMP B a CIRCUIT DIAGRAM FOR REFERENCE ONLY Fig 12 13 MODULAR 1M and 2M SYSTEMS WIRING DIAGRAM ISO 3731 24S ISO 1185 24N AND ISO 7638 POWER SUPPLY Modular Section 12 0 Issue 1 0 June 1998 MODULAR 13 0 ROUTINE MAINTENANCE RECOMMENDATIONS 13 1 THE EXCITER Refer to section 2 0 13 2 THE SENSOR Refer to section 3 0 13 3 THE ELECTRONIC CONTROL UNIT The ECU requires no routine maintenance 13 4 THE MODULATOR Refer to section 5 0 13 5 BRAKE SERVICING Poor brake maintenance will affect the ABS system performance Pay particular attention to seized cam shafts expander assemblies shoe return springs oval drums and correct brake adjustment When removing shoe assemblies avoid damaging the exciter the sensor and its housing or cable Always ensure that the sensor is correctly reset after brake shoe replacement and prior to re fitting the brake drum and wheel assemblies See section 3 4 13 6 BRAKE PIPING Before undertaking maintenance or repairs of a MODULAR ABS it is necessary to understand the configuration because pipework will vary from one configuration to another See section 8 0 Ensure that before stripping out pipework from modulator s and brake chambers that they are clearly marked for replacement into the same ports from which they were removed FAILURE TO OBSERVE THE CORRECT PIPING
47. Read the display on the DDU This is the current code which may or may not refer to a fault 5 Press the switch on top of the DDU for approximately 5 seconds until the DDU display changes 6 Release the switch 7 The DDU displays the code last entered 8 Press the switch again for approximately 5 seconds until the DDU display changes This is the highest numerical fault code in memory 9 Release the switch and press again to display the next highest numerically recorded fault code Continue this sequence to step through the fault code memory 10 After five codes CA will be displayed See 12 below 11 Release the switch ERASINGFAULT CODES FROM MEMORY USING THEDDU 12 The CA display is an invitation to erase the memory pressing and holding the switch while it is displayed will cause the memory to be erased The LCD will scan the codes as they are cleared 13 If the switch is not pressed the next fault code in the stored list will be displayed 14 At the end of the fault code list CA will be displayed again as a further invitation to erase all stored faults Successful erasure of the fault codes will only be possible if the fault causing the code to be logged in memory has been repaired 15 When all codes are cleared release the button briefly then press and hold After 5 seconds the display will read 00 indicating that the memory is empty PRESSBUTTONTO ACCESS DIAGNOSTIC CONNECTOR PLUGS INTO ABS TES
48. T POINT Fig 10 2 ACCESSING FAULT CODES USING THEDDU Using the INFO CENTRE see Section 15 0 for relevant productinformation Moduar Section 10 0 Issue 1 0 June 1998 MODULAR Brake Systems 10 6 INTERPRETATION OF FAULT CODES 1 When the vehicle is stationary and no fault is present the diagnostic display will be 07 2 This display will change when the vehicle is driven at above 6 mph 10 km h and bars will appear the display window for left and right sensors representing a sensor output which is above the necessary minimum 3 The number of bars which appear should be the same as the number of wheels which have speed sensors fitted 4 The DDU displays 00 as a code which indicates correct operation of the system when vehicle speeds exceed 6mph 10km h 5 When the vehicle stops the code returns to 07 6 Flashing bars indicate that there are poorly adjusted sensors or loose sensor connections 7 Spinning individual wheels with the trailer jacked up will cause the relevant bar to appear if the sensor output is above the minimum 8 Codes other than those described above can be interpreted by using the diagnostic code table in section 10 12 10 7 ELECTRICAL TESTS OF SENSOR AND SOLENOID WIRING 1 When the diagnostic code indicates that there is afaulty power supply wheel speed sensor or modulator solenoid fault the location of the fault can be determined by continuity and resistance tests and by r
49. ULATOR Dump Solenoid SOLENOID Battery negative common B Hold Solenoid Sensor Hi Sensor Lo Sensor Hi Sensor Lo Battery positive ECU Output ECU Input Battery negative B Fig 4 7 MODULAR 1 UPGRADE MAIN LOOM CONNECTOR CONTACT PIN DETAIL SENSOR 1A SENSOR 1B DIAGNOSTIC SOCKET Modular Section 4 0 Issue 1 0 June 1998 MODULAR ISO 7638 ISO 3731 24 ISO 1185 24N SENSOR 1A SENSOR 1B SUSPENSION CONTROLLER Identification Key Brake Systems Connector Headboard Battery positive permanent supply B P Battery positive ignition switched B IGN Battery negative B IGN Battery negative permanent supply B P Cab Lamp Return Battery positive ignition switched B IGN Battery negative B IGN Cab Lamp Return Battery positive stoplamp Trailer Lamp Return Battery negative B Dump Solenoid Battery negative common B Hold Solenoid Sensor Hi Sensor Lo Sensor Hi Sensor Lo Battery positive ECU Output ECU Input Battery negative B Negative Positive Fig 4 8 MODULAR 1 PLUS MAIN LOOM CONNECTOR CONTACT PIN DETAIL Modular Section 4 0 Issue 1 0 June 1998 MODULAR Connector Headboard CONTACT PIN PIN No PIN No REFERENCE Battery positive permanent supply B P Battery positive ignition switched B IGN Battery negative B IGN Battery negative permanent supply B P Cab Lamp Return ISO 3731 24S Battery positive ignit
50. and Haldex Brake Products Ltd in maintaining this manual in an up to date condition Please follow the instructions included on each sheet to ensure that we are able to give both yourself and your company the best product information support whenever the need may arise For ease of reference each section of this manual deals with an individual aspect or component part of the MODULAR trailer ABS system To access the particular information which you require initially refer to the Main Section Index at the front of the manual and select the appropriate item s section Each section has its own index card at the front of the section listing sub sections which deal with particular features of the component or procedure concerned Wherever necessary cross references are made within each sub section which guide you to related information Sections are numbered in sequence as are the sub sections Where cross references are used the first number refers to the appropriate section number whilst the second number refers to the sub section concerned Example In section 9 2 reference is made to section 7 4 which may be found in section 7 0 item 7 4 In the case of figure numbers once again each of the section figures is numbered in sequence within its own section Hence in order to avoid repetition a particular figure which appears in one section may have relevance to another section to which it is cross referenced
51. ared by using DDU see procedure in section 8 5 Info Centre see Section 15 0 additional product information EOLT program see Section 11 0 3 Odometer tyre scaling factor units mismatch Where the odometer units miles or km do not match the service interval and current recording This can be checked and corrected as necessary by using the Info Centre see Section 15 0 additional product information or EOLT program see Section 11 0 4 Code 37 An external device writing a 37 user display code to the ABS ECU to activate the multiple light sequence Can be cleared by using DDU refer to Section 10 4 10 5 or Info Centre see Section 15 0 additional product information 6 5 IMPORTANT NOTE SENSORRELATED FAULTS If a system fault occurs the warning lamp s will be illuminated The ECU stores coded diagnostic information in a memory If the diagnostic code stored is in the group 11 to 16 or 21 to 26 i e Sensor related faults see Diagnostic Codes in section 10 12 then after repair on initial power up the lamp s will remain permanently illuminated without the initial flash This is due to the fact that the ECU requires confirmation of satisfactory sensor outputs before it will restore the correct lamp sequence The wheel s which had the sensor fault s must now be rotated with the ECU powered up orthe vehicle must be driven at a speed greater than 6mph 10km h to confirm sensor signal integrity The ECU wi
52. case of Full trailers it is not possible to mount all the modulators in a single group at the rear of the trailer as this would adversely affect the ABS performance of the front axle due to the required long pipe runs Consequently this system is not suitable for this type of trailer 1 11 ROUTINE MAINTENANCE Information regarding routine maintenance of the MODULAR system and of associated braking systems is listed in section 13 0 Modular Section 1 0 Issue 1 0 June 1998 MODULAR 1 12 MULTIMETER READINGS CHECKING MEASURE CORRECT REMARKS Fig POSITION BETWEEN VALUE Sensor output A B 0 2V AC Min Sensor 1A 1B 2A 2B or 3A 3B Sensor disconnected from ECU Wheel rotated at 1 rev 2 sec Sensor resistance A B 21 0 2 4 kohm Sensor 1A 1B 2A 2B 14 Sensor disconnected from ECU Modulator Solenoid gt 12 lt 20 ohm Modulator cable disconnected 42 resistance from solenoid Modulator Solenoid B H gt 12 lt 20 ohm Modulator cable disconnected 12 resistance from solenoid Supply from 1 4 gt 18 lt 32V Ignition on 13 ISO 7638 Approx battery voltage Supply from 1 4 gt 18 lt 32V Brake applied Ignition on 1 3 ISO 1185 24N Approx battery voltage Earth continuity ECU Modulator lt 5 ohms Bracket and Vehicle chassis COLAS Solenoid gt 79 lt 96 ohms Cable disconnected 14 resistance Solenoid Connector Fig 1 2 Diagnostic Connector Fig 1 3 COLAS Connector Fig 1 4 Modular Sect
53. channel provides select low operation as independant wheel control ABS cannot be applied to self steer axles The BLUE channel sensing is always from sensor s identified as S2A or S2A and S3A together The YELLOW channel sensing is always from sensor s identified as S2B or S2B and S3B MODULAR ABS is capable of controlling 1 or 2 channels of braking effort sensed by 2 or 4 sensors and may therefore be installed in a range of different configurations Modular 1 Upgrade 251M Modular 1 Plus 2S1M Modular 2 2S2M or 4S2M System equipment will depend on the type of trailer and the degree of ABS control specified by the operator or trailer manufacturer The maximum number of control channels will be two determined by the number of modulator s Number of ABS control channels Modulator cable connected to ECU Red RD only 1 Yellow YE amp Blue BU only 2 Fig 8 1 NUMBER OF CHANNELS Wiring diagrams are shown in section 12 The number of wheel speed sensors connected to the ECU may be 2 or 4 but the combination of modulator solenoid cables and wheel speed sensor cables will always be as shown in Fig 8 2 below Modulator cable Sensors is connected to connected For 281M 1 1 S2A S2B S2A S2B S3A S3B Fig 8 2 SENSOR AND SOLENOID CABLE COMBINATIONS Modular Section 8 0 Issue 1 0 June 1998 MODULAR 8 3 CONFIGURATION CODES NOTE Where sensed axles are also lift axles the sensors will be disabl
54. e new Info Centre in the reverse procedure to the above noting the following a Tighten the retaining bolts to 12 15Nm b Tighten nut on Info Centre socket and ensure locking tab is located when mated with chassis diagnostic connector see Fig 9 3 Diagnostic Info Centre connector socket chassis Fig 9 3 CHASSIS CONNECTION c Secure cable along the chassis or appropriate support with cable ties at not more than 200mm intervals d Mate cover to Info Centre and click into position making sure both clips are fully engaged at top and bottom see Fig 9 4 Info Centre Fig 9 4 COVER CLIPS LOCATION 9 3 FUNCTIONINSTRUCTION Refer to Section 15 0 for the relevant product information on various functions ofthe Info Centre with and without vehicle power Modular Section 9 0 Issue 1 0 June 1998 MODULAR 10 0 FAULT FINDING WITH MODULAR 10 1 EQUIPMENT REQUIRED The following tools are required to carry out the complete schedule of diagnostic tests Trolley jack Multimeter see recommended units in Sec 14 0 500 volt insulation tester Switch test box optional see Fig 10 1 Diagnostic Display Unit DDU or Info Centre NOTE A tractor unit may be used as an alternative to a switch test box CAUTION It is essential that normal safety procedures are observed when working on vehicles to ensure that they are correctly jacked and sup ported Dangerous load carrying vehicles should alwa
55. eable refer to section 3 4 for adjustment 3 3 SENSOR ASSEMBLY REPLACEMENT 1 The design of Modular sensors enable them to be easily replaced if damaged But before any work is commenced ensure that all electrical power is removed from the ECU 2 When replacing a sensor always replace the retaining clip and ensure that the electrical connections are clean dry and correctly assembled the sensor should be disconnected at the plug on its flying extension lead 3 Remove the sensor from its housing together with the retaining clip The housing is not usually replaced unless it is damaged however a new retaining clip should always be fitted with a new sensor 4 Clean the housing removing any swarf or dirt 5 Lightly grease the retaining clip with a lithium based grease and press it fully home into the housing 6 The sensor may be greased prior to assembly and then pressed firmly into the retaining clip until the sensor cable exit shoulder abuts against the inboard face of the housing ensure the cable is not under tension or fouling the brake shoes or return springs see Fig 3 1 7 Ensure that the sensor cable run is routed as in the original installation and secure it with cable ties every 150mm Note Do not overtighten the cable ties as the brake hose will expand when the brakes are applied and the cable ties may shear the inner conductor of the sensor cable 3 4 SENSOR ADJUSTMENT Resetting 1 To set the senso
56. ed when the axle is lifted these are indicated in brackets in Fig 8 3 below Info Centre Code Lifted 281C CO 2S 1M 2 1 C1 2S 2M 2 2 C2 4S 2M 4 2 4S 2M Function Axle No Brake Systems Sensors Modulators Used Used S1A S1B Red S2A S2B Blue Yellow S3A S2A S2B S3B Blue Yellow S3A S2A S2B S3B Blue Yellow Fig 8 3 CONFIGURATION CODES 8 4 CONFIGURATION FAULTS When the ECU is initially powered up a system configuration code is briefly displayed on the DDU or Info Centre if attached which should be confirmed as correct for the particular installation by referring to the configuration codes listed in Fig8 3above If a vehicle has its modulator piped incorrectly solenoid wiring interchanged between solenoids or sensor wiring interchanged between sensors then it is possible that a correct configuration code may be displayed but that poor ABS performance is evident This will occur due to incorrect cross connection of sensors and modulators at the ECU When the ECU receives a locking wheel signal it attempts control of that wheel but if sensors or modulators are incorrectly connected either electrically or in the case of the modulator pneumatically the wrong wheel will be controlled resulting in poor ABS and brake performance In such circumstances the MODULAR system may generate a fault code indicating slow wheel recovery group i e A fault code number such as 41 42 or 43 see section 10 0
57. eference to the appropriate wiring diagram 2 Test equipment may be connected to the main ABS harness at the moulded ECU connector for which a pin map is shown in Fig 4 7 Fig 4 8 and Fig 4 9 10 8 POWER SUPPLY FAULTS The correct power supply connections to the ECU pins are shown in the pin map in Fig 4 6 Fig 4 7 and Fig 4 8 Supply voltages must be in the range 18 to 32 volts maximum Code 90 indicates a voltage loss when a solenoid is energised and the voltage at the ECU falls below 18 Volts 1 Ensure that the electrical supply is satisfactory under full electrical load conditions i e there are no high resistance connections present 2 Establish if the voltage drop occurs when using each of the power sources on their own 1507638 1503731 245 1501185 24N 3 Check for loose connections in the wiring from the source which produces the fault code NOTE An inadequate power supply e g discharged test batteries will cause code 90 to be displayed Code 91 indicates that when using the ISO 7638 power source there is sufficient voltage coming from pin 2 ofthe ISO 7638 connector but the voltage coming from pin 1 is low or absent 1 Check for broken wiring or blown fuses on both the trailer and the towing vehicle or with the workshop power supply if used The voltage measured on the ECU connector which goes to ISO 7638 pin 1 should be between 18 Volts and 32 Volts when the voltmeter negative lead is on the ECU connector
58. f your vehicle according to the road surface conditions DO NOT apply and release the brakes by pumping the brake This is known as cadence braking and can have a detrimental effect on vehicle braking 1 4 ABOUT MODULAR ABS The Haldex MODULAR ABS system employs microcomputer technology to meet the high standards demanded by manufacturers and operators for modern trailer ABS MODULAR ABS conforms to all the requirements of current and future planned legislation for systems fitted to commercial trailers The design embodies ease of installation and maintenance with high performance specifications MODULAR ABS prevents wheel lock during braking to maximise tyre grip and provide optimum deceleration and stability 1 5 SYSTEM CONFIGURATION MODULAR ABS may be fitted to trailers in different configurations as required by the manufacturer or operator The configurations conform to recognised standards for wheel sensing and control as explained in section 8 0 1 6 WHEEL SPEED SENSING MODULAR ABS employs exciters and sensors mounted in the brake assembly see Figs 1 5 which provide an electrical output frequency proportional to the wheel speed This signal is relayed to a microcomputer based Electronic Control Unit ECU Section 2 0 details exciter information and section 3 0 sensor information 1 7 CONTROL ELECTRONICS The Electronic Control Unit ECU incorporates two microcomputers which process information from wheel speed senso
59. g sensor function see section 3 5 and 6 0 The sensor identity varies between different configurations dependant on the number of axles and sensor pairs fitted NOTE These identities should not be confused with axle numbers which differ between full trailers and semi or centre axle trailers See Figs 8 4 to 8 5 ECU Refers to the electronic control unit of the MODULAR ABS system Axle numbering Semi Trailer and centre axle trailer axles are numbered from the rear axle forwards hence axle 1 is the rear axle Fulltrailers Drawbars have their axles numbered from the front of the trailer rearwards so that the front axle is number 1 This numbering system caters for self steering axles which will always be number 1 If axle 1 is a self steer axle it must always be controlled by the RED modulator channel operating on a select low principal i e the ABS channel controlling that axle reacts to the first locking wheel and controls both wheels of the axle to that level of tyre to road grip It is not possible to provide individual wheel control on self steer axles as split friction conditions would result in vehicle instability due to the differing tyre to road grip across the axle which would cause it to self steer Brake Systems 8 2 CONFIGURATION Sensor and modulator channels are colour coded as follows RD RED BU BLUE YE YELLOW The RED channel sensing is always from sensors identified as S1A and S1B This
60. he same orientation as the original installation 2 Always use new self locking nuts to secure the modulator to its bracket 3 Always connect the brake pipes to the same ports port 2 of the modulator as in the original installation 4 DO NOT USE PTFE TAPE as this tends to fragment and work its way into the modulator resulting in malfunctions due to blockage or leakage 5 Ensure correct location of the solenoid cable connector and hand tighten the gland nut taking care not to cross thread it 6 Replace any cable ties as originally fitted but do not over tighten them as this may damage the cable 7 Reconnect the signal port 4 and the reservoir port 1 lines and charge the air system 8 Carry out an air leakage check as detailed below 9 Carry out the Lamp sequence check as described in section 1 2 driverinformation SPECIAL NOTE When undertaking any pipework repairs where it is necessary to seal fittings always use a high quality liquid sealant Do not under any circumstances use PTFE tape or similar sealants as shreds of this sealant type may cause modulator malfunctions if they become embedded in the ball valve or solenoid areas 5 4 AIRLEAKAGE CHECKS After modulator or solenoid remedial work carry out a check for air leaks as follows Brake Unapplied Check 1 Fully charge the air system 2 Without applying the footbrake listen at the modulator exhaust port and manifold interfaces where appropriate
61. here should be no continuous audible leaks 4 Finally carry out the Lamp sequence checks as detailed in section 1 2 driver information Modular Section 5 0 Issue 1 0 June 1998 MODULAR 6 0 MODULAR SYSTEM WARNING LAMPS The various powering options referred to in section 7 0 will have a corresponding combination of warning lamps fitted to the vehicle The towing vehicle dash mounted lamp operates when the ABS is powered by the ISO 3731 24S or ISO 7638 wiring systems If the ABS is powered through only the ISO 1185 24N stop lamp supply then only the green trailer mounted lamp will indicate the ABS operational status 6 1 TRAILER MOUNTED LAMP GREEN This lamp is mounted on the trailer head board see Fig 1 9 and is operated from the ISO 1185 connector when the ABS is powered only from the stop lamp power supply i e when the brake pedal is pressed NOTE If a permanent power source is available to the ABS from the ISO 3731 or ISO 7638 connectors then system integrity will be indicated by a RED cab mounted warning lamp which becomes the primary ABS status indicator the GREEN trailer lamp becomes the secondary indicator and will only operate a If the brake pedal is pressed before the ignition is switched on during initial power up b During a fault event when the red lamp is illuminated and the brake pedal is then pressed In either of these cases the trailer lamp will duplicate the red cab mounted lamp function
62. ion 1 0 Issue 1 0 June 1998 MODULAR SENSORAND ADJUSTER ASSEMBLY SENSORBRACKET HUB ASSEMBLY BRAKEDRUM Fig 1 5 TYPICAL SENSOR AND EXCITER INSTALLATION HOLD DUMP SOLENOIDS MODULATOR CONNECTION THREAD SIZE M27 x 1 0 MODULATOR VALVE CONTROL PORT Port No 4 M16 x 1 5 RESERVOIR PORT Port No 1 M22 x 1 5 EXCITER Brake Systems CABLE GROMMET SENSOR CABLE TO E C U TORQUEPLATE BRAKE SHOE ELECTRONIC CONTROL UNIT ECU CONNECTION 19 PINS MOUNTING BRACKET DELIVERY PORT Port No 2 M16 x 1 5 Fig 1 6 ECU AND MODULATOR ASSEMBLY MODULAR 1 UPGRADE Modular Section 1 0 Issue 1 0 June 1998 MODULAR MOUNTING BRACKET HOLD DUMP SOLENOIDS MODULATOR CONNECTION THREAD SIZE M27 x 1 0 MODULATOR VALVE CONTROL PORT Port No 4 M16 x 1 5 RESERVOIR PORT Port No 1 M22 x 1 5 Brake Systems ELECTRONIC CONTROL UNIT ECU CONNECTION 28 PINS MOUNTING BRACKET CLIP DELIVER PORT Port No 2 M16 x 1 5 Fig 1 7 ECU AND MODULATOR ASSEMBLY MODULAR 1 PLUS HOLD DUMP SOLENOIDS MODULATOR CONNECTION THREAD SIZE M27 x 1 0 MODULATOR VALVE BLUE CHANNEL MODULATOR VALVE YELLOW CHANNEL CONTROL PORT MANIFOLD Port No 4 M16 x 1 5 BOTH SIDES Fig 1 8 ECU AND MODULATOR ASSEMBLY MODULAR 2 MOUNTING ELECTRONIC BRACKET CONTROL UNIT ECU CONNECTION 28 PINS MOUNTING BRACKET CLIP RESERVOIR DELIVER PORT PORT Port No
63. ion switched B IGN Battery negative B IGN Cab Lamp Return Battery positive stoplamp Trailer Lamp Return 1 Battery negative B Dump Solenoid Battery negative common B YE Hold Solenoid RD Dump Solenoid BK YE ISO 1185 24N MODULATOR SOLENOID Yellow Channel ww 1 AIN o RON AD Battery negative common B Hold Solenoid 2 ensor Hi ensor HI 2 e O Sensor Lo RES 2 Iser 21 Sensor Lo DDU SOCKET 9 Battery positive 19 ECU Output 8 ECU Input 18 Battery negative B SUSPENSION 27 Negative Fig 4 9 MODULAR 2 2S 2M and 4S 2M MAIN LOOM CONNECTOR CONTACT PIN DETAIL Modular Section 4 0 Issue 1 0 June 1998 SENSOR 2A 5 W 1 3 2 SENSOR 3A MODULATOR SOLENOID Blue Channel 26 17 5 15 25 4 4 14 3 23 13 1 10 12 2 11 MODULAR Main Loom assembly Diagnostic connector Chassis mounted DDU Plug locates in loom assembly Diagnostic connector ALTERNATIVE r Diagnostic connector INFO CENTRE Brake Systems Preferred position of Diagnostic connector Modular Section 4 0 Issue 1 0 June 1998 MODULAR Brake Systems 5 0 THE MODULATOR VALVE The modulator comprises a relay type valve with a solenoid block containing hold and dump control solenoids mounted on the upper housing Modular 1 is designed as a 281M ABS system and therefore will have only a single channel i e only one modulator valve electrically co
64. l Manual raise lower ODOMETER DISPLAY e Total distance ee Trip distance A ADJUSTMENT ARROWS Editing Mode v ON Indicates that information may be changed by user 3m SERVICE FUNCTION SERVICE DUE ON Whilst displaying the odometer value indicating service is due FLASHING Current ABS fault Modular Section 9 0 Issue 1 0 June 1998 MODULAR Brake Systems 9 1 INFO CENTREFOR ADR REGULATIONS To satisfy the ADR regulations for flammable loads i e Petrol tanker trailers a variant of Info Centre and its associated ECU see section 4 0 is available WITHOUT odometer function This is because hazardous load regulations do not permit the fitting of battery powered equipment spark generators to the rear of the firewall and so only this variant of Info Centre must be used All other functions are as standard Info Centre Forreference ofthe component part number refer to service parts in section 14 0 This Info Centre must only be A replaced by its exact equivalent on ADR vehicles 9 2 INFO CENTRE MAINTENANCE The Info Centre requires no routine maintenance 9 3 INFO CENTRE REPLACEMENT 1 Locate the position of the unit which should be in an accessible area either in front rearward of the wheel gear 2 Disconnect the Info Centre connections 3 Cut away the cable ties securing the cable to any appropriate supports 4 Unclip the front cover to expose the two M6 mounting bolts and remove 5 Fit th
65. lead plug at the end of the cable using a suitable jump wire 3 Disconnect the harness at the ECU and carry out a continuity check of the cable as follows 4 To test sensors connect the multimeter across contact pins in the main loom connector as detailed in section 4 0 Fig 4 6 4 7 and 4 8 The meter should show a full scale deflection 5 f no continuity reading is obtained replace the extension cable as detailed in section 3 9 If however continuity is satisfactory then check the sensor resistance 3 8 SENSOR RESISTANCE Carry out a sensor resistance check as follows 1 Unplug the sensor extension cable from the sensor flying lead at the back of the brake dust cover 2 Insert the multimeter probes into the sensor connector socket and note the resistance which should fall in the range 980 ohms to 2 35 kohms 3 If the result is outside the specified limits then replace the sensor as detailed in section 3 3 4 If however the resistance is satisfactory then the sensor extension cable is at fault and should be replaced as detailed in section 3 9 3 9 SENSOR EXTENSION CABLE REPLACEMENT IMPORTANT NOTE Cable replacement will involve cutting out and replacement of part of the ABS harness which is a one piece moulded unit The connection is made by a window type in line butt connector The connectors are protected by heat shrink tubing containing a sealant When heated the tubing shrinks and the sealant melts A watertight join
66. ll restore the correct lamp sequence However the fault code will remain in the memory and may subsequently be misleading if other faults occur at a later date Therefore the memory should have its stored faults erased immediately after undertaking any repairs See section 10 4 and 10 5 for DDU or section 15 0 additional product information for Info Centre Brake Systems Modular Section 6 0 Issue 1 0 June 1998 MODULAR 7 0 SYSTEM POWER SUPPLY AND FUSES 7 1 POWER SUPPLY 1 MODULAR ABS will accept any source of electrical power available from the tractor unit as listed below ISO 1185 24 Stop lamp power supply b ISO 3731 24 S Permanent ignition sourced power supply c ISO 7638 Dedicated ignition sourced permanent power supply Any of these supplies will power the system on a stand alone basis but trailers will be wired to provide a combination of either 1301185 24N plus ISO 7638 OR ISO1185 24N plus ISO 3731 24S This provides operational choices to suit the majority of new and existing tractor units It should be noted that 24 with ISO 7638 is not available as an option 2 The power source provided by the tractor unit will depend on its age type of manufacture and modifications carried out by the operator The MODULAR system will only draw current from one power source at a time and will self select the Brake Systems available power source in the following order of priorit
67. n and refit any clips originally used b When securing cables along rubber brake hoses do not overtighten cable ties as this will damage the cable hose when pressure is applied during brake application It is always preferable to attach one cable tie to the hose and one to the cable and then loop the two together 10 Carry out the driver s checks as described in section 1 2 Driver information but with regard to the Important Note in section 6 5 Modular Section 3 0 Issue 1 0 June1998 MODULAR 4 0 THE ELECTRONIC CONTROL UNIT ECU The ECU of the MODULAR ABS system is located on a mounting bracket in common with the modulator valve See Fig 1 2 1 3 and 1 4 It has microcomputer controlled diagnostics detection circuits which log diagnostics to a memory that may be interrogated with a hand held diagnostic display unit the DDU see Figs 3 2 and 4 10 or the Info Centre see Fig 4 10 MODULAR 1 Plus or MODULAR 2 Ne d 28 Pin Interface s connector MODULAR 1 Upgrade 19 Pin Interface connector Fig 4 1 MODULAR SERIES ECU The ABS ECU contains an AA size A Lithium Thionyl Chloride Battery that carries the following warning Fire Explosion and Severe Burn Hazard Under no circumstances should the battery be re charged crushed or tampered with in any way The ECU should not be incinerated or stored above 100 The ABS ECU may be disposed of by landfill or re cycled through a specialist operator if in doubt c
68. ncies fall into four categories as follows INSTALLATION CENTRES These agencies provide a complete service to the customer including primary installation of Haldex Brake Products Ltd ABS service and repair of existing systems and component part retail sales to the end user SERVICE CENTRES Provide aservice and repair function for existing Haldex Brake Products Ltd ABS systems and also component part retail sales See section 14 7 PARTS DISTRIBUTORS Provide retail sales of all component parts relating to Haldex Brake Products Ltd ABS systems See Section 14 8 TRAILERPARTS DISTRIBUTORS ONLY Stockist and retail sales of component parts specifically relating to trailers equipped with the MODULAR series of equipment See Section 14 8 e g Crane Fruehauf Crane Fruehauf also provide a repair service from a majority of depots which are also listed in the Brake Systems Crane Fruehaufservice guide 14 5 SERVICE EQUIPMENT 1 Available from all Haldex Brake Products Ltd installation service and parts centres listed on the previous pages 2 MULTIMETER METRIXMX570 3 TEST SWITCH BOX May be used as an alternative to a towing vehicle as power switching facility The switch box is not supplied by Haldex but can be constructed easily using the circuit diagram Fig 10 1 4 SUNDRY ITEMS Trolley Jack Axle stands 8mm Hexagonal key spanner 5mm Hexagonal key spanner 3mm Hexagonal key spanner 2 X Male blade te
69. nel Possiblecauses Slow brake release foundation brake mechanical faults dry bearings broken spring restricted piping Check for kinks and blockages etc Incorrect piping wiring modulator fault OPEN CIRCUIT MODULATOR SOLENOID OR SOLENOID WIRING GROUP 61 Hold solenoid circuit fault red channel 62 Hold solenoid circuit fault blue channel 63 Hold solenoid circuit fault yellow channel 67 Dump solenoid circuit fault red channel 68 Dump solenoid circuit fault blue channel 69 Dump solenoid circuit fault yellow channel SHORT CIRCUIT ACROSS MODULATOR SOLENOID OR SOLENOID WIRING GROUP 71 Hold solenoid circuit fault red channel 72 Hold solenoid circuit fault blue channel 73 Hold solenoid circuit fault yellow channel Dump solenoid circuit fault red channel 78 Dump solenoid circuit fault blue channel 79 Dump solenoid circuit fault yellow channel MODULATOR SOLENOID WIRING OR SOLENOID SHORT TO GROUP 80 Poor insulation in the modulator solenoid or wiring fault 81 Hold solenoid circuit fault red channel 82 Hold solenoid circuit fault blue channel 83 Hold solenoid circuit fault yellow channel 87 Dump solenoid circuit fault red channel 88 Dump solenoid circuit fault blue channel 89 Dump solenoid circuit fault yellow channel SUPPLY VOLTAGE GROUP 90 Supply voltage at ECU less than 18v when a solenoid is energised 91 Faulty supply from ISO 7638 Pin 1 or fuse blown 92 Supply voltage at the ECU greater than 32v
70. neumatic control valve s of the anti lock brake system NON INTEGRATED An ABS system in which the modulators are mounted remotely from the ECU assembly Generally applicable to Full trailers RD Refers to RED the required channel colour coding for modulators and sensors See also BU and YE 5 Refers to a sensor SENSOR A magnetic device mounted in the brake or hub assembly used in conjunction with the exciter to generate electrical information proportional to wheel speed S1A sensor position displayed on the DDU or Info Centre relative to the position of that sensor on the vehicle as shown in the configuration diagrams in section 8 0 Modular Section 1 0 Issue 1 0 June 1998 MODULAR S2A A sensor position displayed on the DDU or Info Centre relative to the position of that sensor on the vehicle as shown in the configuration diagrams in section 8 0 S3A A sensor position displayed on the DDU or Info Centre relative to the position of that sensor on the vehicle as shown in the configuration diagrams in section 8 0 S1B A sensor position displayed on the DDU or Info Centre relative to the position of that sensor on the vehicle as shown in the configuration diagrams in section 8 0 S2B A sensor position displayed on the DDU or Info Centre relative to the position of that sensor on the vehicle as shown in the configuration diagrams in section 8 0 S3B A sensor position displayed on the DDU or Info
71. nnected to the ECU Single channel systems on multi axle trailers employ a single modulator which has six delivery ports one for each brake chamber Exceptions do occur though e g single axle trailers may have a single 2 port modulator in Some cases Modular 2 is designed as a 252M or a 482M ABS system and therefore will have a two channel system i e two modulator valves electrically connected to the ECU 5 1 MODULATORMAINTENANCE The modulator valve requires no routine mainte nance but should be periodically checked for security function and air leaks It is not possible to service the modulator or solenoid block but each of these items may be replaced independently of the other with a new guaranteed component Should either the hold or dump solenoids be suspected as faulty they may be tested for the correct values of resistance which should lie in the range 12 to 20 ohms IMPORTANT It is vital that only genuine Haldex replacement parts are used as any other make may result in defective braking and or ABS malfunction 5 2 MODULATOR REPLACEMENT The modulator is mounted on a bracket in com mon with the ECU which is located beneath the trailer over or near the bogie centre line The electrical connection to the solenoid is achieved via a connector moulded to the cable and is retained in the solenoid block by an M27 threaded knurled gland nut which secures the cable connector to the valve This type may be remo
72. onsult your local authority for details or contact Haldex 4 1 ECU FOR ADR REGULATIONS To satisfy the ADR regulations for flammable loads i e trailers built to FL EX III specification a variant of a MODULAR 2 and its associated INFO CENTRE see section 9 0 is available WITHOUT the powered odometer function Note Hazardous load regulations do not permit the fitting of battery powered equipment spark generators to the rear of the firewall and so only this variant of MODULAR must be used All other functions are as standard MODULAR 2 ECU For reference of the component part number refer to service parts in section 14 0 This ECU must only be replaced by A its exact equivalent on ADR vehicles Haldex Brake Systems 4 2 DIAGNOSTICS The ECU incorporates a diagnostic information output centre which provides information relevant to system configuration and diagnostic status It is used for system diagnosis when a DDU or Info Centre is connected to the unit at the ABS TEST diagnostic connector enabling recovery of diagnostic codes When connected the DDU or the Info Centre may also be used to test outputs from associated wheel sensors See section 3 5 Therefore it is possible to view the diagnostic code display from a remote position such as alongside the vehicle or from the tractor unit cab when the vehicle is being driven NOTE A DDU long extension lead 24m is available which facilitates dynamic testing For furthe
73. ow System is O K vehicle is moving 1A Sensor wiring open or short circuit 1B Sensor wiring open or short circuit 2A Sensor wiring open or short circuit 2B Sensor wiring open or short circuit 3A Sensor wiring open or short circuit 3B Sensor wiring open or short circuit System is O K vehicle is stationary Retarder Wiring open circuit Retarder Wiring short circuit Reset to ride Wiring open circuit Reset to ride Wiring short circuit Warning lamp circuit fault LOW SENSOR OUTPUT GROUP 1A Sensor system fault 1B Sensor system fault 2A Sensor system fault 2B Sensor system fault 3A Sensor system fault 3B Sensor system fault Possiblecauses Sensor worn maladjusted sensor wiring open or short circuit Incorrect exciter type Possiblecauses Exciter tooth count difrent each side of axle INTERMITTENT LOW SENSOR OUTPUT GROUP 1A Sensor system fault 1B Sensor system fault 2A Sensor system fault 2B Sensor system fault 3A Sensor system fault 3B Sensor system fault Possiblecauses Loose sensor connection bracket or exciter Damaged exciter Maladjusted sensor or worn sensor cable insulation Modular Section 10 0 Issue 1 0 June 1998 MODULAR CODE DISPLAYED 37 Lamp signalled by external device ONEWHEEL WITH SLOW RECOVERY GROUP 40 Sensor wiring crossed across an axle 41 Slow recovery of one wheel ofred channel 42 Slow recovery of one wheel of blue channel 43 Slow recovery of one wheel of yellow chan
74. peration is provided by solenoid controlled pneumatic Stepping Relay Valves called modulators which may have 2 3 or 6 delivery ports The ABS configuration determines the type of modulator fitted See section 5 0 Modulators and section 8 0 Configurations 1 9 SYSTEM WARNING LAMPS The system may be provided with a warning lamp mounted on the trailer headboard visible to the driver in the rear view mirror The headboard lamp is green and may be duplicated by a red dashboard mounted warning lamp in the cab of the towing vehicle In the case of cab mounted lamps reference should be made to the vehicle manufacturer s handbook Further details may be found in section 6 0 1 10 SYSTEM POWER SUPPLY MODULAR ABS fitted to trailers may be powered from different sources depending on the supply which is available from the towing unit See section 7 0 and wiring diagrams section 12 0 Modular Section 1 0 Issue 1 0 June 1998 MODULAR Brake Systems 1 10 COMPONENT LOCATION The location of MODULAR components will vary from one trailer type to another Generally semi trailers are equipped with units in which the ECU and modulator s are mounted on a common bracket This is referred to as an integrated system and is convenient where such an assembly is mounted over the centre of an axle or axle group as in the case of semi trailers and Centre Axle Trailers This type of installation on a semi trailer is shown in Fig 1 9 In the
75. r correctly follow the steps in sensor assembly replacement then refit the hub assembly using the hub retaining nut to pull it into place on the stub axle DO NOT ROCK THE HUB ASSEMBLY ONCE THE EXCITER HAS CONTACTED THE NOSE OF THE SENSOR AS THIS WILL CAUSE THE SENSOR TO BE PUSHED TOO FAR BACK IN ITS HOUSING 2 Provided that the hub is drawn smoothly onto the stub axle the sensor to exciter air gap will be automatically set to the correct running clearance as the components come into contact 3 Setting the hub centre nut correctly to the axle manufacturer s data will ensure sufficient output However it should be noted that the running clearance between the sensor and exciter must never exceed 0 5mm 0 020 at any point during one complete revolution 4 Carry out a sensor output check as detailed in section 3 5 5 Refit the brake drum and road wheels and Modular Section 3 0 Issue 1 0 June 1998 MODULAR carry out the driver s checks described in section 1 2 to ensure that the correct lamp sequence is obtained but bear in mind the Important Note referred to in section 6 5 3 5 CHECKING THE SENSOR OUTPUT 1 Before commencing sensor checks ensure that the appropriate sensed wheels are jacked clear of the ground and suitably propped observing all normal safety precautions so that the wheels are free to be rotated by hand with no brake drag evident 2 If necessary back off the brake adjustment temporarily for this test
76. r information refer to section 10 4 For further information on the Info centre refer to section 9 0 and relevant product information in section 15 0 4 3 ELECTRICAL CONNECTIONS The electrical connections to the ECU include power supplies sensors modulators and the diagnostic output These connections are incorporated in a single ABS vehicle harness which has an integrally moulded connector facilitating a single connection point for simplicity and system integrity For further information refer to section 12 0 System Wiring 4 3 ECU MAINTENANCE The ECU requires no routine maintenance 4 4 ECU REPLACEMENT 1 Locate the position on the trailer of the ECU and modulator valve assembly on their common mounting bracket 2 Remove the ISO 7638 ISO 1185 24N and ISO 3731 24S connectors at the trailer coupling head so that there is no electrical power connected to the trailer Loom connector Fig 4 2 ECU BAIL LATCH REMOVAL Modular Section 4 0 Issue 1 0 June 1998 MODULAR 3 Press together the connector clips on the loom connector see Fig 4 3 and pull the ECU away fromthe connector housing connector Fig4 3 DISCONNECTION OF ECU 4 Remove the three retaining bolts securing the ECU using a 8mm ring spanner and remove it from the mounting bracket 5 Fit New bail latch provided to new ECU by hooking bail latch ends into locating holes on ECU ensuring that the bail latch is the right way round to clip over the socke
77. rminals 6 35mm 500 Volt insulation tester 14 6 SERVICE REPLACEMENT PARTS Service replacement parts are available from all agents listed from section 14 7 through to section 14 8 or in the case of International Operations from the offices listed in section 14 9 In order to assist you in determining the appropriate replacement component required selection of common spares is shown in the following listing Modular Section 14 0 Issue 1 0 June 1998 MODULAR SERVICEPARTS Brake Systems DESCRIPTION PART NUMBER VIEW Electronic Control Unit MODULAR 1 Upgrade ECU 364 279 002 MODULAR 1 Plus ECU 364 279 101 MODULAR 2 ECU 364 279 201 MODULAR 2 ADR ECU 364 279 202 Modulator valve Assembly 6 Port 364 115 021 3 Port 364 263 001 RH 3 Port 364 263 011 LH Manifold for 2S 4S 2M systems ECU Loom Assembly MODULAR 1 Upgrade 2S 1M c w 4m Sensor ext cables MODULAR 1 Plus 2S 1M c w 4m Sensor ext cables and Reset to Ride MODULAR 2 2S 2M or 4S 2M c w 4m Sensor ext cables and Reset to Ride ISO 7638 Socket Kit Green cover c w Fuse Black cover w o Fuse crimp pins Red cover w o Fuse screw pins Replacement fuse kit for fused ISO 7638 950 364 801 950 364 802 950 364 803 950 364 804 950 364 047 950 364 806 950 364 807 950 364075 950 364 417 950 364 418 950 364 419 950 364 072 950 364 402 950 364 420 950 364 401 Wu Com Modular Section 14 0 Issue
78. rs thereby calculating wheel acceleration and deceleration When a wheel deceleration which would normally result in a locked wheel is detected the ECU energises the hold and dump solenoids in the modulator s The hold solenoid isolates the signal line to the modulator and prevents further pressure build up above the relay piston The dump solenoid releases air pressure from above the relay piston and thus from the brake chamber Rapid operation of the hold and dump solenoids adjusts the brake chamber pressure to the best possible condition to maximise tyre to road grip Tyre to road grip will cause the wheel to recover from the developing lock condition During recovery the wheel speed signal increases in frequency causing the ECU to de energise the dump solenoid and switch the hold solenoid rapidly in a series of pulses which progressively re applies the brakes If the wheel then tends to lock the ABS action will be repeated In the event of a fault occurring the ABS will be Switched off and a fault code stored in the ECU memory for repair reference Fault codes will be retained in memory even if power to the system is removed When the power supply to the ECU is restored the fault code can be displayed on an Info Centre see Fig 9 1 or DDU see Fig 3 2 Reference to the diagnosis guide in section 10 0 and the diagnostic code list in section 10 12 will enable rapid location and repair of the fault 1 8 SYSTEM PNEUMATICS ABS o
79. ss the lamp is still permanently illuminated there is a short circuit between the lamp negative side and battery negative The lamp negative goes directly to the ECU The ECU then switches this side to battery negative to illuminate the lamp 6 Measure the resistance of the relevant lamp wire Modular Section 10 0 Issue 1 0 June 1998 MODULAR to battery negative and vehicle chassis to confirm the short No Lamp Illumination 1 Check the lamp bulb and holder first 2 Connect a test lamp temporarily across the lamp terminals in the junction box and cycle the system 3 The test lamp will operate correctly if the fault lies downstream of the junction box i e between the trailer lamp and junction box If the lamp sequence is incorrect the fault lies upstream of the junction box towards the ECU 10 10 WHEEL SPEED SENSING Codes 01 and 02 indicate that a wheel speed sensor or its wiring is short or open circuit 1 Disconnect the relevant sensor connector at the extension lead plug and measure the resistance between the 2 sockets in the connector housing 2 The ohmmeter reading should be between 980 ohms and 2 35 kohms 3 The extension cable between the controller and wheel has an in line connector If an open circuit is measured check that the connector is correctly assembled 4 Disconnect the harness from the ECU and locate the appropriate pins for the cable to be tested see Fig 4 7 Fig 4 8 and Fig 4 9 5
80. t is formed when the sealant solidifies on cooling Heat should only be applied with a suitable hot air gun such as Hellerman No GHL 1550 1 Disconnect sensor extension lead to be replaced from the sensor and remove any retaining cable ties 2 Cut the extension cable 200mm minimum from the ECU moulded connection or where the joint can be secured on a rigid area of the cable installation Do not secure the joint on the hose or pipe going to the brake chamber 3 Using wire strippers remove insulation on the ABS harness sensor ext cable see Fig 3 3 Fig 3 3 DETAILS OF INSULATION REMOVAL 4 Using a crimp tool recommended is Thomas and Betts Crimpex ratchet No WT2124Y place terminal in the jaws and insert the wire until the insulation butts against the terminal barrel Make the crimp ensuring the connector has firmly gripped both the wire and insulation Check by pulling the connector 5 Feed the heatshrink tubing over the new sensor extension cable 6 Join the extension cable onto the ABS harness via the two in line crimps using tool as in point 4 Modular Section 3 0 Issue 1 0 June 1998 MODULAR 8 Secure the joint to a rigid area see Fig 3 4 Sensor extension cable joint Power cables Fig 3 4 POSITION OF SENSOR JOINT 9 Route the wiring as in the original installation and connect as appropriate but note the following a Fit cable ties to support the cables at 150mm intervals do not overtighte
81. t see Fig 4 4 Bail latch locating hole Fig 4 4 BAIL LATCH POSITIONING 6 Fitthe new ECU in the reverse procedure to the above noting the following a Clip the loom connector onto the ECU connector block ensuring that the both connector clips engage fully see Fig 4 5 b Tighten the retaining bolts to 1 7 2 8Nm ECU Loom connector Fig 4 5 ENGAMENT OF ECU AND LOOM CONNECTOR c Ensure bail latch and loom clamp are fixed in position see Fig 4 6 ECU Loom Connector Clips Fig 4 6 BAIL LATCH AND LOOM CLAMP POSITIONING d Check earth continuty ECU Modulator Bracket and Vehicle chassis to be 5 ohms 7 On completion carry out the driver s checks described in section 1 2 Driver s information and in section 6 0 Modular Section 4 0 Issue 1 0 June 1998 MODULAR Contact Pin area Loom Connector 19 Way Connector Headboard CONNECTOR 19 Way PLUG CONNECTOR TERMINAL CONTACT PIN No PIN No PIN No REFERENCE Battery positive permanent supply B P Battery positive ignition switched B IGN Battery negative B IGN Cab Lamp Return B Battery negative permanent supply B P Battery positive permanent supply B P Battery positive ignition switched B IGN Battery negative B IGN Cab Lamp Return B Battery negative permanent supply B P ISO 1185 24N Battery negative B Battery positive stoplamp Trailer Lamp Return B 1 2 3 4 5 6 1 2 1 4 MOD
82. th a cover boot for environmental protection The Info Centre contains an AA size A Lithium Thionyl Chloride Battery that carries the following warning Fire Explosion and Severe Burn Hazard Under no circumstances should the battery be recharged crushed or tampered with in any way The Info Centre should not be Incinerated or stored above 100 C The ABS ECU may be disposed of by landfill or recycled through a specialist operator if in doubt consult your local authority for details or contact Haldex Brake Systems Functions Odometer Total distance Trip distance Service interval Distance to next service Tyre scale setting Diagnostic Display current diagnostic code Display stored diagnostic codes Sensor cabling check ECU Serial number Information Product type code Configuration code Auxiliary code Re Configure ABS ECU adding or removing COLAS 3255 IC DENN ZN UN 5 C Ib kg mile km bar psi Fig 9 2 THE DISPLAY The Legends are as follows BATTERY E OFF OK Internal ABS ECU battery failure Diagnostic functions and ECU information available only LOCK Incorrect ABS ECU connected to Info Centre Odometer functions not available 4 POWER Vehicle Power ON Vehicle Supply ON OFF NO Vehicle supply FLASHING Communications established between Info Centre and ABS ECU 3 BELLOWS Air Suspension Bogie load Load apportioning Height contro
83. than 10 megohms Note lf an unlisted diagnostic code is displayed on the DDU then the ABS ECU is faulty and must be changed NOTE Wherever possible alternative components may be substituted for existing ones during fault finding if the substituted component eliminates the current diagnostic code then it may be assumed that the component that was causing the code to be displayed is at fault If the code cannot be eliminated then the ABS ECU is at fault DIAGNOSTIC CODES Diagnostic codes are listed on the following pages andare separated into groups covering numeric codes and alpha numeric codes these are followed by the configuration codes which will be seen at power up of the ABS ECU Moduar Section 10 0 Issue 1 0 June 1998 MODULAR Brake Systems 10 12 DIAGNOSTIC CODES FOR MODULAR ABS SERIES Note If a diagnostic code not listed below is displayed the ECU is suspect and should be changed Refer to 10 5 for detailed diagnostic procedures A diagnostic code list as displayed on the DDU is shown in this section For the Info Centre diagnostic code listing refer to relevant information in section 15 0 CODE DISPLAYED BLANK DISPLAY SENSORBAR 00 01 02 03 04 05 06 07 08 mage 20 21 23 24 25 26 No supply on ignition switched line Possiblecauses Fuse blown DDU INFO CENTRE or cable fault Open circuit Bar displayed Sensor output Bar not displayed Sensor output too l
84. the diagnostic connector Fig 11 1 INTERFACE 1 POD This kit provides the interface required by the two communication packages Vehicle Data System VDS and End of Line Test EOLT 11 2 Vehicle Data System VDS VDS offers the ability to capture operational data from the ABS ECU and to store it on a PC It is then possible to manipulate the data using common PC spreadsheets The data stored in the ECU is divided into two sections The first section is data recorded by the ABS ECU during trailer highway operation and includes ABS system status and vehicle mileage The second is information created by the user for example service and maintenance records such as information related to the treatment of specific loads tyre wear statistics or other details that would be useful to your business This data is stored inside the ABS ECU and will remain intact even after electrical power is removed from the trailer Supplied with the VDS software package are sample spreadsheet templates that show examples of information that can be collected and stored in your VDS system You can also create your own templates and macros that will enable you to store information specific to your business Full details of the VDS package are available in a separate publication 11 3 End of Line Test EOLT EOLT offers the ability to execute tests on all of the Modular and Modal ABS products This is achieved by collection and storing two types of
85. the modulator solenoid wiring will produce two air pulses on the affected modulator as the dump and hold solenoids are electrically identical but have different pneumatic functions 8 When a wheel is rotated and electrical power is applied all modulator blowdowns are inhibited while the wheel is turning WARNING LAMP 24V 28 PIN Z 180 3731 PIN amp 245 CONNECTOR PIN 1 PIN 5 PIM 1 150 7638 PIN 2 ABS CONNECTOR LINK or PIN3 AMMETER PIN 4 PIN 4 ISO 1185 24 e Pina CONNECTOR Fig 10 1 CIRCUIT DIAGRAM FOR OPTIONAL SWITCH TEST BOX Modular Section 10 0 Issue 1 0 June 1998 MODULAR 10 3 DIAGNOSTIC DISPLAY The ECU has a memory which stores diagnostic codes automatically These stored codes are retained in memory even when power is disconnected from the ABS and can be recalled on a hand held Diagnostic Display Unit DDU when the power supply is restored Follow the appropriate procedure described in section 10 4 for use with the DDU and section 15 0 Additional information using the Info Centre For wheel sensor output tests the DDU may be used on a trailer which is static in the workshop or dynamically on the road The Info Centre can be used on a trailer which is static in the workshop only 10 4 USING THE DIAGNOSTIC DISPLAY UNIT DDU 1 Remove all electrical power from the trailer 2 Connect the DDU cable to the trailer diagnostic output connector See Fig 9 3 3
86. ved from the solenoid block whenever it is necessary to access the harness or ECU assembly Procedure 1 Ensure that all electrical power sources are removed from the ABS 2 Release all air pressure from the appropriate air reservoir 3 Remove any cable ties securing the solenoid cable between the solenoid and the ECU 4 Unscrew the gland nut which secures the solenoid electrical cable to its housing and disconnect it from the solenoid 5 Disconnect the signal line from port 4 of the modulator valve 6 Disconnect the reservoir supply from port 1 of the modulator valve 7 Disconnect the brake pipes from the modulator delivery ports numbered 2 It is important that pipe positions are noted and replaced in the same ports from which they were removed 8 Remove the three nuts securing the modulator to the bracket and lower the modulator from its mountings NOTE Whenreleasing the modulator mounting nuts avoid rotating the associated bolts which also serve to hold the valve body sections together 9 Proceed to section 5 3 If replacing solenoid only Threaded connector Fig 5 1 MODULATOR VALVE WITH M27 THREADED CABLE CONNECTOR 10 Reverse this procedure to refit the new unit See section 5 5 Modular Section 5 0 Issue 1 0 June 1998 MODULAR Brake Systems 5 3 FITTING THEMODULATOR ASSEMBLY Refitting is the reversal of procedure 5 2 but noting the following points 1 Mount the modulator in t
87. y 1st 180 7638 Dedicated supply 2nd ISO 1185 24 Stop lamp power supply OR 1st ISO 3731 24 S Supplementary supply 2nd ISO 1185 24 Stop lamp power supply 7 2 System Fuses A 12 Amp in line ceramic fuse is fitted into pin 1 of the ISO 7638 Connector In the event of a wiring short or other overload the fuse will blow resulting in a permanent lamp indication There are two designs of connector varying according to manufacturer Type A AMP Type B Haldex Both replacement fuse types are provided in Haldex service kit number 950 364 401 Fuse Replacement kit SERVICE KIT PART No 950 364 401 CONTENTS FUSED PIN FOR Haldex ISO 7638 connector FUSED PIN FOR A M P ISO 7638 connector EJECTOR RELIEF TUBE INSTRUCTIONS NOTE The fused pin for A M P ISO 7638 cannot be used to replace the fused pin of the Haldex ISO 7638 Both fuses are supplied in the kit and are not interchangeable Fig 7 1 FUSESERVICE KIT CONTENT Modular Section 7 0 Issue 1 0 June 1998 MODULAR YELLOW or 3 RED or2 Brake Systems FUSE IDENTIFICATION PURPLE or 1 RELIEF FUSED TUBE C e m4 5 6 BLACK or Y GN FEMALE CRIMP WHITE or 4 TERMINAL RETAINING B5 FUSEDPIN No 1 Fig 7 2 ISO 7638 FUSE REPLACEMENT A M P CONNECTOR Replacement of ISO 7638 Fuse PROCEDURE Type A A M P Connector Black Cover See Fig 7 2 1 Disconnect the trailer from all power sources 2 Remove the
88. ys be made safe before commencing remedial work 10 2 INITIAL DIAGNOSIS OF ABS FAULTS Perform the following tests 1 Apply electrical power to the trailer via the 24N connector while observing the anti lock warning lamp which should flash and then come on and stay on See section 6 0 lamps WARMING LAMP SWITCH CIRCUIT d BREAKER Note It is recommended that this circuit breaker is of the type 150 3731 KLOCKNER MOELLER B P FAZL6 1 or RS COMPONENTS 335 924 20 32 VOLTS 150 1185 BI 2 If the lamp fails to illuminate check the lamp bulb and electrical power supply 3 If the lamp fails to flash but stays permanently illuminated check the diagnostic display codes including stored diagnostic codes using the procedure in 10 3 Also NOTE section 6 5 4 If 1 above is satisfactory drive the vehicle at above 6 m p h 10 km h The anti lock warning lamp should extinguish If it does not there is a wheel speed sensing fault Check the diagnostic display code using the procedure in 10 4 5 To test for correct valve blow down fully charge the air brake system and turn off all electrical power to the trailer Apply the foot brake and set the ignition switch to on There should be as many brief pulses of air as there are ABS modulators See section 5 7and Fig 8 6 to 8 8 7 If the air pulse is incorrect check the diagnostic display code using the procedure in 10 4 Note that erroneous wiring of

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