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The position of the variouscomponents is shown in Tri-axlelayout, Fig 1. The system isequally compatible with single andtandem axles.The exciter turnswith the wheel and its teeth breakthe magnetic field of the sensor 80or 100 times per revolution. Thisgenerates a wheel speed signalwhich is sent to the electroniccontrol unit (ECU) via the sensorextension cable. The ECU detectslocking of the wheels and controlsthe air brakes via the modulator.The MODULAR 1 PLUS or 2, ECUpasses an electrical signal toHaldex COLAS (also a manualraise/lower valve) whichautomatically resets the trailer tothe correct ride height after it hasbeen raised/lowered when docking.MODULAR ABS series incorporatean odometer facility (except forMODULAR 2 ADR) whichmeasures total mileage of thetrailer and its read-out is shown ona optional INFO-CENTRE unit.The INFO CENTRE is a side oftrailer mounted unit used also forread-out of diagnostic codes andother information as available fromthe ABS ECU.
The MODULAR ABS series alsoincoporates a enhancedinformation storage and retrievalfacility.For the fleet operator, a VehicleData System (VDS) allowing thecompilation of a full history of eachtrailer or long term monitoring.For the trailer manufacturer, a'End-of-line' Testing (EOLT) toconfirm correct performance of theABS system.
BRAKING WITH ABSIn an emergency apply full forceon the brake pedal. The ABS willbe activated immediately you fullyapply the brakes and will assistyou to retain steering control ofyour vehicle according to the roadsurface conditions. DO NOT applyand release the brakes bypumping the brake. This is knownas 'Cadence braking' and can havea detrimental effect on vehiclebraking.
The MODULAR Series ABS containsthe Valve(s), mounting bracket and aElectronic Control unit (ECU).
For general purpose trailers:-
MODULAR 1 Upgrade features2S/1M2 Sensors and 1 Modulator (ABSvalve)Odometer facility'End-of-Line' Test
MODULAR 1 Plus features2S/1MOdometer facilityReset-to-Ride HeightVehicle Data System'End-of-Line' Test
MODULAR 2 features2S/2M or 4S/2MOdometer facilityReset-to-Ride HeightVehicle Data System'End-of-Line' Test
For dangerous load carrying trailers:-
MODULAR 2 ADR features2S/2M or 4S/2MReset-to-Ride HeightVehicle Data System'End-of-Line' Test
Your trailer has been fitted with thelatest technology Haldex anti-lockbraking system. This system has beenspecifically designed to be effective,reliable and easy to service.
The purpose of this booklet is todescribe the components involved andgive you sufficient information to makeyour use of the system easy.
The use of the diagnostic system isdescribed but when overhaul of thecomponents is required, we advise youto refer to the full SERVICE MANUALwhich describes replacementprocedures fully.
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The system fitted to your trailer mayhave 2 or 4 sensors (S) and 1 or2 modulators (M). The variantsavailable being 2S/1M, 2S/2M and4S/2M.
The layout of the chassis componentsare shown in Fig 2. The ECU andModulator(s) are mounted togetheron a single bracket for ease ofinstallation and maintenance.
The powering of the system can bevia either of these two groups:
ISO 7638-Dedicated ABS powercable.ISO 1185 (24N)-Stop Lightpowering.
or
ISO 3731 (24S)-Supplementarypowercable.ISO 1185 (24N)-Stop Lightpowering.
A green warning lamp will also havebeen fitted to the headboard of thetrailer, in a position visible to thedriver through the driving mirror.This lamp will have been connectedto the ABS via a junction box intowhich the ISO 1185 (24N) cablewould also be connected.
When an ISO 7638 is fitted, orpowering is through the ISO 3731(24S), it will normally control a redwarning lamp in the driver's console(ABS 2).
Both warning lamps have twofunctions:
-To indicate system integrity via thecorrect lamp sequence (see Fig 4,Fig 5 on page 7 and step 1- Fig 7 onpage 8) every time theABS ECU is electrically powered up.
-To indicate by permanentillumination, when the vehicle ismoving, if a fault has been detected.
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An important feature of theMODULAR system is that itprovides external diagnostics. Thesystem displays a range of codes,which allow rapid diagnosis of theproblem should one occur.
The diagnostic codes can be readfrom a portable Diagnostic DisplayUnit (DDU) or a fixed DiagnosticUnit (INFO CENTRE).The DDU can be connectedremotely via the loom assemblydiagnostic connector socketmounted in an appropriate positionon the trailer chassis indicated inFig 3.The INFO CENTRE is avehicle mounted displaypermanently connected to the trailerABS ECU. Typical locations of thediagnostic connector are shown inFig 3.
The DDU gives two types ofdisplay:
-Horizontal bars indicate theposition of effective speed sensorswhen the wheels are rotated.
-A two digit display can beinterpreted from the list of codesshown on pages 9, 10 and 11.
The INFO CENTRE provides amulti-digit display of:
-Odometer indicates total, trip,service interval kilometres or milesdefined by the ECU and Tyre scalesetting.
-Fault codes as to the list of codesshown on pages 9, 10 and 11.
-ABS ECU Information - Serialnumber,Product code and Configurationcode.
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INFO CENTRE
ABSINFO
ABSINFO
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RED warning lamp located onthe driver's console of the towingvehicle is operated from theISO 7638 (or ISO 3731 - 24S)power cable only when the ABSis powered by the ignition switch.Fig 4.
GREEN warning lamp mountedon the headboard of the trailerand is operated from theISO 1185 (24N) connector whenthe ABS is powered only fromthe stop lamp power supply i.e.when the brake pedal isdepressed. Fig 5.
The warning lamp(s) functiondepends on which powersupply is used:
1 Note: If a dedicated power source isavailable to the ABS from the ISO 7638connector, or to the ISO 3731 (24S),then system integrity will be indicatedby the RED cab mountedwarning lamp which becomes theprimary ABS status indicator, theGREEN trailer lamp becomes thesecondary indicator and duplicates theRED cab mounted lamp function whenthe stop lamp circuit is operated. Fig 6.
On power up of the system, the warninglamp(s) must illuminate in the followingsequence in order to show a fault-freesystem:
ON for 2.5 seconds = Bulb OK andsystem self-checking.
OFF for 1 second = Systemself-checkedand preparingto checksensors.
ON until moving = Systemwaiting forvehicle tomove above10 km/h inorder to checkthat thesensors areworking.
OFF = Once thevehicle ismoving above10 km/h andthe lamp(s)goes (go) out,the electronicsystem is fullychecked.
2 During the self-check procedure,the system operates themodulator/s solenoid once.On MODULAR 1 this operationwill be audible as one exhaustof air from the modulator(RED channel).On MODULAR 2 one exhaustof air from each modulator insequence will be audible(BLUE channel then YELLOWchannel).
Once these two checks aremade with correct results, nofurther checks are required.
If the results are not satisfactory,the DDU or INFO Centre shouldbe used to establish thediagnosis.
This information is describedvisually in Fig 7 on page 8.(MODULAR 1 system shownonly)
3
REDLamp
Fig 4
GREENLamp
Fig 5
REDLamp
GREENLamp
Fig 6
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STEP
2STEP
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Apply foot brake and Power up :STEP 1 WATCH RED and GREEN WARNING LAMP.STEP 2 Listen for BLOW DOWN.STEP 3 REFER TO DIAGNOSTIC DISPLAY CODE on DDU or INFO CENTRE,
Release foot brake (Ignition switch on required for Info Centre mode)SPIN EACH SENSED WHEEL IN TURN,REFER TO DIAGNOSTIC DISPLAY CODE INDICATION.
INFOCENTRESENSORCHECKMODE
DDU CODEOR
STEP
1
Example :MODULAR 1 Key
ModulatorBlowdown
Modulator
O.K.
NOT O.K.
M
4 MULTIPLE LAMP SEQUENCE(GREEN and/or RED)
The Modular ABS seriesincorporates a modified lamp flashof three flashes.The lamp will flash when the systemis powered up when at rest.This lamp sequence relates to :-
1. Service due - indicates that trailer or system service distance isdue. After servicing the trailer orsystem the next service distancemust be reset by using theInfo Centre or EOLT program.2. NON ABS fault - A fault with adevice connected to the ABS butnot directly effecting the ABS,for example : Reset-to-Ride valve(COLAS ).
3. Odometer scaling factorunits mismatch - Where theodometer units (miles or km) donot match between serviceinterval and current recording.4. Code 37 - A diagnosticcode sent to the ABS ECU toactivate the multiple lightsequence.
4 Sec min.
STOP TOTAL DISTANCE DIAGNOSTIC CODE CHECK SENSEDWHEELS COMMAND
RECORDEDDISPLAY
S1Betc.
Fig 7
1rev / 2sec
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CODE DISPLAYED
DDU INFO CENTRE
BLANK DISPLAY BLANK DISPLAY No supply on ignition switched line.Possible causes:Fuse blown.DDU / INFO CENTRE or cable fault.Open circuit B -
SENSOR BAR SENSOR BAR Bar displayed = Sensor output O.K.Bar not displayed = Sensor output too low
00 OK 00 System is O.K. vehicle is moving01 S1A 01 1A Sensor/wiring open or short circuit02 S1B 02 1B Sensor/wiring open or short circuit03 S2A 03 2A Sensor/wiring open or short circuit04 S2B 04 2B Sensor/wiring open or short circuit05 S3A 05 3A Sensor/wiring open or short circuit06 S3B 06 3B Sensor/wiring open or short circuit07 OK 07 System is O.K. vehicle is stationary08 RET 08 Retarder / Wiring open circuit09 RET 09 Retarder / Wiring short circuitOA RIDE OA Reset to ride / Wiring open circuitOC RIDE OC Reset to ride / Wiring short circuitOE LAMP OE Warning lamp circuit fault
LOW SENSOR OUTPUT GROUP
11 S1A 11 1A Sensor system fault12 S1B 12 1B Sensor system fault13 S2A 13 2A Sensor system fault14 S2B 14 2B Sensor system fault15 S3A 15 3A Sensor system fault16 S3B 16 3B Sensor system fault
Possible causes:Sensor worn, maladjusted sensor, wiring open or short circuit.
20 EXC 20 Incorrect exciter type.Possible causes:Exciter tooth count different each side of axle.
INTERMITTENT LOW SENSOR OUTPUT GROUP
21 S1A 21 1A Sensor system fault22 S1B 22 1B Sensor system fault23 S2A 23 2A Sensor system fault24 S2B 24 2B Sensor system fault25 S3A 25 3A Sensor system fault26 S3B 26 3B Sensor system fault
Possible causes:Loose sensor, connection, bracket or exciter.Damaged exciter.Maladjusted sensor or worn sensor cable insulation.
If a diagnostic code not listed below is displayed check for intermittent sensor and wiring faults.Refer to Service Manual for detailed diagnostic testing procedures.
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Dia Dia Dia Dia Diagnostic Codesgnostic Codesgnostic Codesgnostic Codesgnostic Codes
CODE DISPLAYED
DDU INFO CENTRE
37 EXT 37 An diagnostic code sent to the ABS ECU to activate themultiple light sequence.
ONE WHEEL WITH SLOW RECOVERY GROUP
40 XSEn 40 Sensor wiring crossed across an axle41 SLW 41 Slow recovery of one wheel of red channel42 SLW 42 Slow recovery of one wheel of blue channel43 SLW 43 Slow recovery of one wheel of yellow channel
Possible causes:Slow brake release, foundation brake mechanical faults, drybearings, broken spring, restricted pipingCheck for kinks and blockages etc.Incorrect piping, WiringModulator fault
OPEN CIRCUIT MODULATOR SOLENOID ORSOLENOID WIRING GROUP
61 RDHd61 Hold solenoid circuit fault, red channel62 BUHd62 Hold solenoid circuit fault, blue channel63 YEHd 63 Hold solenoid circuit fault, yellow channel67 RDDu67 Dump solenoid circuit fault, red channel68 BUDu68 Dump solenoid circuit fault, blue channel69 YEDu 69 Dump solenoid circuit fault, yellow channel
SHORT CIRCUIT ACROSS MODULATOR SOLENOID ORSOLENOID WIRING GROUP
71 RDHd71 Hold solenoid circuit fault, red channel72 BUHd72 Hold solenoid circuit fault, blue channel73 YEHd 73 Hold solenoid circuit fault, yellow channel77 RDDu77 Dump solenoid circuit fault, red channel78 BUDu78 Dump solenoid circuit fault, blue channel79 YEDu 79 Dump solenoid circuit fault, yellow channel
MODULATOR SOLENOID WIRING ORSOLENOID SHORT TO B+ GROUP
80 SOL 80 Poor insulation in the modulator solenoid or wiring fault81 RDHd81 Hold solenoid circuit fault, red channel.82 BUHd82 Hold solenoid circuit fault, blue channel83 YEHd 83 Hold solenoid circuit fault, yellow channel87 RDDu87 Dump solenoid circuit fault, red channel88 BUDu88 Dump solenoid circuit fault, blue channel89 YEDu 89 Dump solenoid circuit fault, yellow channel
SUPPLY VOLTAGE GROUP
90 B+LO 90 Supply voltage at ECU less than 18v when a solenoid is energised91 ISOI 91 Faulty supply from ISO 7638 Pin 1 or fuse blown92 B+HI 92 Supply voltage at the ECU greater than 32v93 ECU 93 Internal ECU fault
10
Dia Dia Dia Dia Diagnostic Codesgnostic Codesgnostic Codesgnostic Codesgnostic Codes
CODE DISPLAYED
DDU INFO CENTRE99 ECU 99 Internal ECU fault
SYSTEM FUNCTION GROUP
A1 AUX A1 Reset to ride heightA2 AUX A2 Retarder
CONFIGURATION CODES
Figures in brackets indicate sensing is disabled when the axleis lifted.
CA CLR CA Erase stored faultCC CLR CC Clear ConfigurationCF CF Sensors and Solenoid not connected
Alternating with code 90 (incomplete solenoid function)LO or HI COM FAIL Communication failure between ECU, INFO CENTRE or DDU
open or short circuit wiring
Note: If a code is displayed and after following recommended procedure, as detailed in the ServiceManual, no fault is found, the ABS ECU should be replaced.
11
Dia Dia Dia Dia Diagnostic Codesgnostic Codesgnostic Codesgnostic Codesgnostic Codes
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TIME OR MILEAGE COMPONENT OPERATION(whichever occurs first)
When hubs are removed Exciter Check for damage
Sensor Check for wear clean and readjust.
Every 3 months Complete System Perform system check out and airor 25,000 miles leakage check.(40,000 km)
Annually or every Complete System Perform system check out and airor 100,000 miles leakage check. Check wiring and(160,000 km) piping security and integrity.
Sensor Check for wear clean and readjust.
Every five years Modulator Replace.500,000 miles and Solenoid(800,000 km) Assembly
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The list of available serviceparts is indicated on page16 to 18. Theses can beobtained from Haldex servicecentres or distributors.
A European Service Guide isavailable free of charge onapplication.
The different components areshown in view form in order to alloweasy recognition.
R R R R Recommended Maintenance Scecommended Maintenance Scecommended Maintenance Scecommended Maintenance Scecommended Maintenance Schedulehedulehedulehedulehedule
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The Haldex Group is a global supplier of proprietaryproducts for trucks, cars and industrial vehicles, withspecial emphasis on performance and safety.TheGroup is organized in Divisions which focus ontheir respective product niche:
Haldex Brake Systems supplies ABSand brake components for heavy vehicle air brakes.
Haldex Barnes Hydraulics supplies gear pumpsandhydraulic systems for power steering and liftingfunctions on industrial vehicles and trucks.
Haldex Traction Systems supplies 4WD systems forcars and trucks.
Sales companies are established in Europe, North andSouthAmerica and Asia. Production takes place in 9factories in USA, 9 factories in Europe and 1 jointventure in India.
The Haldex Group is listed on the Stockholm StockExchange.
Company VisionWe use our demonstratedcompetence to provide innovativecomponents, systems and service fortrucks, trailers and buses, that lowerlife cycle costs and improve vehiclesafety. Haldex wants to become thefirst choice business partner ofcommercial vehicle manufacturesworld wide in the areas of braking andsuspension control systems with specialemphasis on heavy commercial vehicles.
Total SupportA uniquely wide range of services isavailable from Haldex. These includeexpert consultancy for braking andsuspension development, brakecalculations, type approvals andapplication engineering.The aim is accurate specification formanufactures and low cost of ownership for the operator.Full aftermarket support includes aWorldwide parts distribution andservice network, on-line technicaladvice, field visits and installation/maintenance training held on-site orat Haldex facilities.
Research andDevelopmentContinual, heavy investment inResearch and Development is carriedout in response to ever increasingcommercial, legislative,environmental, performance andtechnological demands.
Quality andProductionStandardsThe very latest production technologyensures the very highest qualitystandards. All production sites areISO 9001 approved.