MODULAR SERVICE - Well Interparts

1 MODULARMODULARMODULARMODULARMODULARABS SERIESMODULAR 1 UPGRADEMODULAR 1 PLUSMODULAR 2 SERSERSERSERSERVICEVICEVICEVICEVICEMANUM ANUMANUMANUMANUALALALALAL000 700 080 MODULARMODULARMODULARMODULARMODULARTECHN ICAL services BRAKE PRODUCTS LTDMOONS MOAT DRIVEMOONS MOAT NORTHREDDITCHWORCESTERSHIREB98 9 HAPleaseAffixStampHereDOCUMENTREGISTRATI ONI ncluded on this page of theService manual is a postcardwhich enables you to registerownership of the fill in the detailsrequested, including yourpostcode , in block capitals usinga non eraseable ink and returnthe card to us. This will enable usto ensure that any necessarymanual revisions and servicebulletins which are issued byHaldex Brake Products Ltd willbe forwarded to you do not return theinformation to us we regret thatwe will be unable to ensure thatyour manual is kept up to you should have any queriesregarding this manual or itscontents please contact ourTechnical SERVICE Office on01527 499 600 or Fax us on01527 499 Document Registration Issue June 1998 MODULARMODULARMODULARMODULARMODULARPLEAS E FILL IN YOUR DETAILS BELOWYOUR NAMECOMPANYDELIVERY ADDRESSPOST CODE MODULAR manual Ownership RegistrationMODULARMODULARMODULARMODULAR MODULARNOTES ON THE USE OF THIS MANUALP receding the MODULAR mainindex sheet.

2 This manual shouldcontain the document registrationform and an amendment recordsheet. Both of these documentsare intended to assist yourCompany and Haldex BrakeProducts Ltd in maintaining thismanual in an up to datecondition. Please follow theinstructions included on eachsheet to ensure that we are ableto give both yourself and yourcompany the best productinformation support whenever theneed may ease of reference eachsection of this manual deals withan individual aspect orcomponent part of theMODULAR trailer ABS access the particularinformation which you require,initially refer to the Main SectionIndex at the front of the manualand select the appropriate item(s) section has its own indexcard at the front of the section,listing sub-sections, which dealwith particular features of thecomponent or necessary crossreferences are made within eachsub-section which guide you torelated are numbered insequence, as are cross references areused, the first number refers tothe appropriate section number,whilst the second number refersto the sub-section : In section is made to section may be found in item Document Registration Issue June 1998In the case of figure numbers,once again each of the sectionfigures is numbered in sequencewithin its own section.

3 Hence, inorder to avoid repetition, aparticular figure which appears inone section may have relevanceto another section to which it iscross referenced. In reference is made to and which will be found insections and respectivelyannotated by the appropriatefigure Section Amendments Issue June 1998 AMENDMENT RECORDSHEETFrom time to time it may benecessary for Haldex BrakeProducts Ltd to issue updates tothis you have registered yourownership of this manual usingthe enclosed documentation youwill automatically receive sectionupdates and SERVICE bulletins thereceipt of which may be recordedon this page as they are enteredinto this 1998 MODULARMODULARMODULARMODULARMODULARM odular Section Issue June GLOSSARY OF TERMSBUR efers to BLUE, the requiredchannel colour coding for modulators,and also RD and The electrical connection betweenthe ECU and modulator.

4 Thenumber of ABS control channels isequal to the number ofmodulators arrangement of ABScomponents for any given software package for'End-of-line' testing of ABS systemfunctions during trailer hand held Diagnostic Electronic Control Unit of theanti-lock brake A slotted or castellated steel ringfitted in the hub or brake assemblyused in conjunction with the sensorto generate electrical informationproportional to wheel CENTREA device with a LCD display,trailer mounted, which maybe used to recall informationfrom the memory of the SYSTEMA MODULAR ABS installation wherethe modulators and ECU aremounted in one unit on a commonbracket, located over the centre of abogie. (See Fig , and ).Generally applicable to semi-trailersand centre axle 1185 The 24N electrical connection to thetrailer from which power for the ABSmay be drawn from pin 4 using thestoplamp 3731 The 24S electrical connection to thetrailer from which power for the ABSmay be drawn from pin 6 to providea permanent power 7638 The electrical connection to thetrailer which provides a dedicatedABS power Crystal Display relevant tothe DDU display and Info to a modulator.

5 The ABSair control The central device on whichmodulators of a two channelsystem may be commonlymounted, and pneumatically ABSThe product name for one ofa range of trailer Anti-lockBrake Systems produced byHaldex Brake Products (S)The pneumatic controlvalve(s) of the anti-lock ABS system in whichthe modulators are mountedremotely from the ECU applicable to Full to RED, the required channelcolour coding for modulators, also BU and YESR efers to a magnetic device mounted in thebrake or hub assembly used inconjunction with the exciter togenerate electrical informationproportional to wheel sensor position displayed on theDDU or Info Centre relative to theposition of that sensor on thevehicle as shown in theconfiguration diagrams in Section Issue June 1998S2AA sensor position displayed on theDDU or Info Centre relative to theposition of that sensor on thevehicle as shown in theconfiguration diagrams in sensor position displayed on theDDU or Info Centre relative to theposition of that sensor on thevehicle as shown in theconfiguration diagrams in sensor position displayed on theDDU or Info Centre relative to theposition of that sensor on thevehicle as shown

6 In theconfiguration diagrams in sensor position displayed on theDDU or Info Centre relative to theposition of that sensor on thevehicle as shown in theconfiguration diagrams in sensor position displayed on theDDU or Info Centre relative to theposition of that sensor on thevehicle as shown in theconfiguration diagrams in FRICTIONA road surface conditionwherethe tyres of wheels across thesame axle experience differentamounts of grip from one side of thevehicle to the INTERFACEC omputer hardware providinga facility for linking a PC to theABS to YELLOW, the requiredchannel colour coding formodulators, and also RD and software package forcollecting data from theABS ECU and storing to the sensors and one modulator(see configurations section ).

7 2S2 MTwo sensors and two modulators(see configuration section ).4S2 MFour sensors and two modulators(see configuration section ). DRIVER INFORMATIONMODULAR ABS is provided with a warning lampto indicate the ABS GREEN lamp if fitted, will be mounted onthe headboard of the trailer in the rear viewmirror line of vision. When the ABS is electricallypowered from the stop lamp circuit and no othersource the lamp operates only when the brakepedal is these circumstances when the vehicle ismoving at 6 (10km/h) or more and thebrakes are applied the green lamp should flashbriefly and then stay the vehicle is stationary and the brake pedal isapplied the green lamp should flash briefly, thencome on and stay : At speeds above 6 (10km/h) whenthe brakes are applied no lamp flash or apermanently lit lamp indicates a system faultwhich should be RED lamp will be fitted in the cab dashboardwhen the ABS is powered by a dedicated(ISO7638) or a supplementary (24S) powersupply from the ignition the ignition is turned on the red lampshould flash briefly and then come on until thevehicle speed exceeds 6 (10km/h) thenthe lamp should go : For any single driving cycle, (ignition onto ignition off).

8 If there is no lamp flash when theignition is turned on, or if a permanentlyilluminated lamp occurs after the vehicle hasexceeded 6 (10 km/h) at initial move off,a system fault is indicated which should a red lamp (ABS2) is fitted in the cab thisbecomes the primary indicator and the trailerABS will be permanently powered. In this case,the green trailer lamp will only function if :(a) on initial power up, if the brake pedal ispressed before the ignition is switched on.(b) during a fault event when the red lamp isilluminated and the brake pedal is information on lamp sequences may befound in section Section Issue June BRAKING WITH ABSIn an emergency apply full force on the brakepedal. The ABS will be activated immediatelyyou fully apply the brakes and will assist you toretain steering control of your vehicle accordingto the road surface conditions.

9 DO NOT applyand release the brakes by pumping the is known as 'cadence braking' and can havea detrimental effect on vehicle ABOUT MODULAR ABSThe Haldex MODULAR ABS system employsmicrocomputer technology to meet the highstandards demanded by manufacturers andoperators for modern trailer ABS conforms to all therequirements of current and future plannedlegislation for systems fitted to commercialtrailers. The design embodies ease of installationand maintenance, with high performancespecifications. MODULAR ABS prevents wheellock during braking to maximise tyre grip andprovide optimum deceleration and SYSTEM CONFIGURATIONMODULAR ABS may be fitted to trailers indifferent configurations as required by themanufacturer or configurations conform to recognisedstandards for wheel sensing and control asexplained in section WHEEL SPEED SENSINGMODULAR ABS employs exciters and sensorsmounted in the brake assembly (see Figs )which provide an electrical output frequencyproportional to the wheel speed.

10 This signal isrelayed to a microcomputer based ElectronicControl Unit (ECU).Section details exciter information andsection sensor CONTROL ELECTRONICSThe Electronic Control Unit (ECU) incorporatestwo microcomputers which process informationfrom wheel speed sensors thereby calculatingwheel acceleration and deceleration. When awheel deceleration which would normally resultin a locked wheel is detected the ECU energisesthe hold and dump solenoids in the modulator(s).The hold solenoid isolates the signal line to themodulator and prevents further pressure build upabove the relay dump solenoid releases air pressure fromabove the relay piston and thus from the operation of the hold and dump solenoidsadjusts the brake chamber pressure to the bestpossible condition to maximise tyre to road to road grip will cause the wheel to recoverfrom the developing lock condition.