MODULAR SERVICE

SERVICE
ABS SERIES MANU AL
MANUAL
MODULAR 1 UPGRADE
MODULAR 1 PLUS
MODULAR 2

000 700 080

MODULAR
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NOTES ON THE USE OF THIS MANUAL

Preceding the Modular main Where cross references are

index sheet, this manual should used, the first number refers to
contain the document registration the appropriate section number,
form and an amendment record whilst the second number refers
sheet. Both of these documents to the sub-section concerned.
are intended to assist your Example: In section 9.2
Company and Haldex Brake reference is made to section 7.4
Products Ltd in maintaining this which may be found in section
manual in an up to date 7.0 item 7.4.
condition. Please follow the
instructions included on each In the case of figure numbers,
sheet to ensure that we are able once again each of the section
to give both yourself and your figures is numbered in sequence
company the best product within its own section. Hence, in
information support whenever the order to avoid repetition, a
need may arise. particular figure which appears in
For ease of reference each one section may have relevance
section of this manual deals with to another section to which it is
an individual aspect or cross referenced. i.e. In section
component part of the 9.5 reference is made to figures
MODULAR trailer ABS system. 3.2 and 4.1 which will be found in
sections 3.0 and 4.0 respectively
To access the particular annotated by the appropriate
information which you require, figure number.
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.

Modular Document Registration Issue 1.0 June 1998

MODULAR
AMENDMENT RECORD
SHEET

From time to time it may be DATE

AMENDMENT SECTIONS AMENDMENT SECTIONS DATE
necessary for Haldex Brake NUMBER AFFECTED ENTERED NUMBER AFFECTED ENTERED
Products Ltd to issue updates to
this manual. 1 JUNE 1998 26
If you have registered your 2 27
ownership of this manual using
the enclosed documentation you 3 28
will automatically receive section
updates and service bulletins the 4 29
receipt of which may be recorded
on this page as they are entered
5 30
into this manual.
6 31
7 32
8 33
9 34
10 35
11 36
12 37
13 38
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16 41
17 42
18 43
19 44
20 45
21 46
22 47
23 48
24 49
25 50

Modular Section Amendments Issue 1.0 June 1998

MODULAR
1.0 INTRODUCTION ISO 7638 The electrical connection to the
trailer which provides a dedicated
1.1 GLOSSARY OF TERMS ABS power supply.
BU Refers to BLUE, the required
channel colour coding for modulators, LCD Liquid Crystal Display relevant to
and sensors.See also RD and YE. the DDU display and Info Centre.

CHANNEL The electrical connection between M Refers to a modulator. i.e. the ABS
the ECU and modulator. The air control valve.
number of ABS control channels is
equal to the number of MANIFOLD The central device on which
modulators fitted. modulators of a two channel
system may be commonly
CONFIGURATION mounted, and pneumatically linked.
The arrangement of ABS
components for any given installation. MODULAR ABS
The product name for one of
EOLT Computer software package for a range of trailer Anti-lock
'End-of-line' testing of ABS system Brake Systems produced by
functions during trailer manufacture. Haldex Brake Products Ltd.

DDU The hand held Diagnostic Display MODULATOR(S)

Unit. The pneumatic control
valve(s) of the anti-lock brake
ECU The Electronic Control Unit of the system.
anti-lock brake system.
NON-INTEGRATED
EXCITER A slotted or castellated steel ring An ABS system in which
fitted in the hub or brake assembly the modulators are mounted
used in conjunction with the sensor remotely from the ECU assembly.
to generate electrical information Generally applicable to Full trailers.
proportional to wheel speed.

INFO CENTRE RD Refers to RED, the required channel

A device with a LCD display, colour coding for modulators, and
trailer mounted, which may sensors.
be used to recall information See also BU and YE
from the memory of the ECU.
S Refers to a sensor.
INTEGRATED SYSTEM
A Modular ABS installation where SENSOR A magnetic device mounted in the
the modulators and ECU are brake or hub assembly used in
mounted in one unit on a common conjunction with the exciter to
bracket, located over the centre of a generate electrical information
bogie. (See Fig 1.6,1.7 and 1.8). proportional to wheel speed.
Generally applicable to semi-trailers
and centre axle trailers. S1A A sensor position displayed on the
DDU or Info Centre relative to the
ISO 1185 The 24N electrical connection to the position of that sensor on the
trailer from which power for the ABS vehicle as shown in the
may be drawn from pin 4 using the configuration diagrams in section
stoplamp circuit. 8.0.

ISO 3731 The 24S electrical connection to the

trailer from which power for the ABS
may be drawn from pin 6 to provide
a permanent power supply.
Modular Section 1.0 Issue 1.0 June 1998
MODULAR
S2A A sensor position displayed on the 2S2M Two sensors and two modulators
DDU or Info Centre relative to the (see configuration section 8.0).
position of that sensor on the
vehicle as shown in the 4S2M Four sensors and two modulators
configuration diagrams in section (see configuration section 8.0).
8.0.
1.2 DRIVER INFORMATION
S3A A sensor position displayed on the MODULAR ABS is provided with a warning lamp
DDU or Info Centre relative to the to indicate the ABS status.
position of that sensor on the The GREEN lamp if fitted, will be mounted on
vehicle as shown in the the headboard of the trailer in the rear view
configuration diagrams in section mirror line of vision. When the ABS is electrically
8.0. powered from the stop lamp circuit and no other
source the lamp operates only when the brake
S1B A sensor position displayed on the pedal is pressed.
DDU or Info Centre relative to the Under these circumstances when the vehicle is
position of that sensor on the moving at 6 m.p.h. (10km/h) or more and the
vehicle as shown in the brakes are applied the green lamp should flash
configuration diagrams in section briefly and then stay off.
8.0. If the vehicle is stationary and the brake pedal is
applied the green lamp should flash briefly, then
S2B A sensor position displayed on the come on and stay on.
DDU or Info Centre relative to the NOTE: At speeds above 6 m.p.h. (10km/h) when
position of that sensor on the the brakes are applied no lamp flash or a
vehicle as shown in the permanently lit lamp indicates a system fault
configuration diagrams in section which should be investigated.
8.0.
A RED lamp will be fitted in the cab dashboard
S3B A sensor position displayed on the when the ABS is powered by a dedicated
DDU or Info Centre relative to the (ISO7638) or a supplementary (24S) power
position of that sensor on the supply from the ignition switch.
vehicle as shown in the When the ignition is turned on the red lamp
configuration diagrams in section should flash briefly and then come on until the
8.0. vehicle speed exceeds 6 m.p.h. (10km/h) then
the lamp should go out.
SPLIT FRICTION NOTE: For any single driving cycle, (ignition on
A road surface condition to ignition off). If there is no lamp flash when the
where the tyres of wheels across the ignition is turned on, or if a permanently
same axle experience different illuminated lamp occurs after the vehicle has
amounts of grip from one side of the exceeded 6 m.p.h. (10 km/h) at initial move off,
vehicle to the other. a system fault is indicated which should be
investigated.
PC INTERFACE If a red lamp (ABS2) is fitted in the cab this
Computer hardware providing becomes the primary indicator and the trailer
a facility for linking a PC to the ABS will be permanently powered. In this case,
ABS ECU. the green trailer lamp will only function if :
(a) on initial power up, if the brake pedal is
YE Refers to YELLOW, the required pressed before the ignition is switched on.
channel colour coding for (b) during a fault event when the red lamp is
modulators, and sensors. illuminated and the brake pedal is pressed.
See also RD and BU. Further information on lamp sequences may be
found in section 6.0.
VDS Computer software package for
collecting data from the
ABS ECU and storing to the PC.

2S1M Two sensors and one modulator

(see configurations section 8.0). Modular Section 1.0 Issue 1.0 June 1998
MODULAR
1.3 BRAKING WITH ABS The dump solenoid releases air pressure from
In an emergency apply full force on the brake above the relay piston and thus from the brake
pedal. The ABS will be activated immediately chamber.
you fully apply the brakes and will assist you to Rapid operation of the hold and dump solenoids
retain steering control of your vehicle according adjusts the brake chamber pressure to the best
to the road surface conditions. DO NOT apply possible condition to maximise tyre to road grip.
and release the brakes by pumping the brake. Tyre to road grip will cause the wheel to recover
This is known as 'cadence braking' and can have from the developing lock condition. During
a detrimental effect on vehicle braking recovery the wheel speed signal increases in
frequency causing the ECU to de-energise the
dump solenoid and switch the hold solenoid
1.4 ABOUT MODULAR ABS rapidly in a series of pulses which progressively
The Haldex MODULAR ABS system employs re-applies the brakes. If the wheel then tends to
microcomputer technology to meet the high lock the ABS action will be repeated.
standards demanded by manufacturers and In the event of a fault occurring the ABS will be
operators for modern trailer ABS. switched off and a fault code stored in the ECU
MODULAR ABS conforms to all the memory for repair reference.
requirements of current and future planned Fault codes will be retained in memory even if
legislation for systems fitted to commercial power to the system is removed.
trailers. The design embodies ease of installation When the power supply to the ECU is restored
and maintenance, with high performance the fault code can be displayed on an "Info
specifications. MODULAR ABS prevents wheel Centre" (see Fig 9.1) or DDU (see Fig 3.2).
lock during braking to maximise tyre grip and Reference to the diagnosis guide in section 10.0,
provide optimum deceleration and stability. and the diagnostic code list in section 10.12 will
enable rapid location and repair of the fault.

1.5 SYSTEM CONFIGURATION

MODULAR ABS may be fitted to trailers in 1.8 SYSTEM PNEUMATICS
different configurations as required by the ABS operation is provided by solenoid controlled
manufacturer or operator. pneumatic Stepping Relay Valves called
The configurations conform to recognised modulators which may have 2, 3 or 6 delivery
standards for wheel sensing and control as ports. The ABS configuration determines the
explained in section 8.0. type of modulator fitted. (See section 5.0
Modulators and section 8.0 Configurations).

1.6 WHEEL SPEED SENSING 1.9 SYSTEM WARNING LAMPS

MODULAR ABS employs exciters and sensors The system may be provided with a warning
mounted in the brake assembly (see Figs 1.5) lamp mounted on the trailer headboard visible to
which provide an electrical output frequency the driver in the rear view mirror.
proportional to the wheel speed. This signal is The headboard lamp is green and may be
relayed to a microcomputer based Electronic duplicated by a red dashboard mounted warning
Control Unit (ECU). lamp in the cab of the towing vehicle. In the case
Section 2.0 details exciter information and of cab mounted lamps reference should be made
section 3.0 sensor information. to the vehicle manufacturer's handbook. Further
details may be found in section 6.0.

1.7 CONTROL ELECTRONICS

The Electronic Control Unit (ECU) incorporates 1.10 SYSTEM POWER SUPPLY
two microcomputers which process information MODULAR ABS fitted to trailers may be
from wheel speed sensors thereby calculating powered from different sources depending on the
wheel acceleration and deceleration. When a supply which is available from the towing unit.
wheel deceleration which would normally result See section 7.0, and wiring diagrams section
in a locked wheel is detected the ECU energises 12.0
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.
Modular Section 1.0 Issue 1.0 June 1998
MODULAR
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 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. 1.1
Wheel rotated at 1 rev/2 sec.

Sensor resistance A B >1.0 <2.4 kohm Sensor 1A, 1B, 2A, 2B or 3A,3B
1.1
Sensor disconnected from ECU.

Modulator Solenoid B- DS >12 <20 ohm Modulator cable disconnected . 1.2

resistance from solenoid.

Modulator Solenoid B- HS >12 <20 ohm Modulator cable disconnected . 1.2

resistance from solenoid.

Supply from 1 4 >18 <32V Ignition on. 1.3

ISO 7638 Approx battery voltage

Supply from 1 4 >18 <32V Brake applied, Ignition on 1.3

ISO 1185 (24N) Approx battery voltage

Earth continuity ECU/Modulator <5 ohms

Bracket and
Vehicle chassis

COLAS Solenoid + - >79 <96 ohms Cable disconnected 1.4

resistance

A B B-
1 2

HS DS

4 3

Sensor Connector - Fig 1.1 Solenoid Connector - Fig 1.2 Diagnostic Connector - Fig 1.3

+ -
COLAS Connector - Fig 1.4

Modular Section 1.0 Issue 1.0 June 1998

MODULAR
SENSOR AND ADJUSTER
ASSEMBLY

SENSOR BRACKET CABLE GROMMET

SENSOR CABLE
TO E.C.U.

AXLE SPINDLE

TORQUE PLATE
HUB ASSEMBLY

BRAKE SHOE

BRAKE DRUM EXCITER

Fig 1.5 TYPICAL SENSOR AND EXCITER INSTALLATION

ELECTRONIC
CONTROL
HOLD / DUMP UNIT
SOLENOIDS

MODULATOR
CONNECTION
THREAD SIZE
M27 x 1.0

ECU
MODULATOR CONNECTION
(VALVE) (19 PINS)

CONTROL PORT
Port No. 4
MOUNTING
M16 x 1.5
BRACKET

RESERVOIR PORT DELIVERY PORT

Port No. 1 Port No. 2
M22 x 1.5 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 ELECTRONIC
BRACKET CONTROL
UNIT
HOLD / DUMP
SOLENOIDS

MODULATOR
CONNECTION
ECU
THREAD SIZE
CONNECTION
M27 x 1.0
(28 PINS)

MODULATOR
(VALVE)

CONTROL PORT
Port No. 4 MOUNTING
M16 x 1.5 BRACKET CLIP

DELIVER PORT
RESERVOIR Port No. 2
PORT M16 x 1.5
Port No. 1
M22 x 1.5

Fig 1.7 ECU AND MODULATOR ASSEMBLY - MODULAR 1 PLUS

HOLD / DUMP MOUNTING ELECTRONIC

SOLENOIDS BRACKET CONTROL
UNIT

ECU
MODULATOR
CONNECTION
CONNECTION
(28 PINS)
THREAD SIZE
M27 x 1.0

MODULATOR
(VALVE)
(BLUE CHANNEL) MOUNTING
BRACKET CLIP

MODULATOR
VALVE
(YELLOW CHANNEL)
RESERVOIR DELIVER PORT
CONTROL PORT PORT Port No. 2
MANIFOLD Port No. 4 Port No. 1 M16 x 1.5
M16 x 1.5 M22 x 1.5 (BOTH SIDES)
(BOTH SIDES) (BOTH SIDES)

Fig 1.8 ECU AND MODULATOR ASSEMBLY - MODULAR 2

Modular Section 1.0 Issue 1.0 June 1998
MODULAR
THE DRIVER INFORMATION PLATE ECU AND MODULATOR ASSEMBLY

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 MODULAR 1 Upgrade shown for example

POSITIONS REFER
TO RH DRIVE
VEHICLES

ISO1185

ISO3731 POSITION MAY

VARY

ISO 7638

THE WARNING LAMP THE SENSOR ASSEMBLY THE EXCITER

Fig 1.9 COMPONENT LOCATION (2S1M SYSTEM SHOWN)

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 Fig 2.1. THE EXCITER (80 or 100 TEETH)
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 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 Fig 2.2. THE HUB AND EXCITER ASSEMBLY
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. EXCITER RING
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). THERMOSTATICALLY
CONTROLLED HOTPLATE

Fig 2.3. HEATING THE EXCITER RING

Modular Section 2.0 Issue 1.0 June 1998
MODULAR
4. During the re-assembly process avoid rocking
ZERO TO EQUAL GAP THROUGH the hub, and as soon as the hub centre nut can
360 DEGREES OF ROTATION 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
HUB ASSEMBLY exciter and sensor, PROVIDED THAT THE
SENSOR WAS CORRECTLY RESET BEFORE
FITTING THE HUB.
5. If the sensor was not reset before assembling
CORRECTLY
LOCATED the hub to the stub axle, set the hub centre nut to
EXCITER the axle manufacturer's recommendations, then
push the sensor through its housing until it
MAXIMUM
RUNOUT contacts the exciter teeth.
= 0.005" (0.125mm) 6. Ensure that exciter teeth have not been
damaged during refitment of the hub to the stub
axle.
Fig 2.4. FITTING THE EXCITER TO THE HUB
7. Rotate the hub several times to automatically
set the ideal running condition.
2.3 FITTING THE HUB 8. The sensor output should now be checked as
1. Check the condition of the existing sensor described in section 3.5.
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.

Modular Section 1.0 Issue 1.0 June 1998

MODULAR
3.0 THE SENSORS 3.3 SENSOR ASSEMBLY REPLACEMENT
1. The design of Modular sensors enable them to
The Modular sensor design incorporates a be easily replaced if damaged. But before any
permanent magnet and coil which are work is commenced ensure that all electrical
environmentally sealed in a stainless steel power is removed from the ECU.
housing. The coil is connected to a moulded 2. When replacing a sensor always replace the
flying lead which is terminated with a connector. retaining clip, and ensure that the electrical
The sensors are secured in their housings on the connections are clean, dry and correctly
axle by a retaining clip which must always be assembled, the sensor should be disconnected
fitted to ensure system integrity (see Fig 3.1) at the plug on its flying extension lead.
The sensor is bracket mounted in the axle 3. Remove the sensor from its housing together
assembly with its magnetic pole in close with the retaining clip. The housing is not usually
proximity to the exciter teeth, maximum 0.5mm replaced, unless it is damaged, however, a new
(0.020"). The teeth pass through the magnetic retaining clip should always be fitted with a new
field causing a change in magnetic flux density sensor.
which in turn generates an alternating voltage in 4. Clean the housing, removing any swarf or dirt.
the sensor coil. The 5. Lightly grease the retaining clip with a lithium
frequency of the voltage generated is directly based grease, and press it fully home into the
proportional to wheel speed. It is this signal housing.
which is monitored by the ECU to determine 6. The sensor may be greased prior to assembly
changes in wheel speed. 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
RETAINING SENSOR in the original installation and secure it with cable
SENSOR CLIP ties every 150mm.
HOUSING 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 sensor correctly follow the steps in
AXLE sensor assembly replacement, then refit the hub
assembly using the hub retaining nut to pull it
Fig 3.1 THE SENSOR ASSEMBLY into place on the stub axle.
DO NOT ROCK THE HUB ASSEMBLY ONCE
3.1 SENSOR MAINTENANCE THE EXCITER HAS CONTACTED THE NOSE
1. The sensor requires no routine maintenance OF THE SENSOR AS THIS WILL CAUSE THE
but should be cleaned and inspected for SENSOR TO BE PUSHED TOO FAR BACK IN
damage, wear and security prior to resetting ITS HOUSING.
whenever the brake drums are removed. 2. Provided that the hub is drawn smoothly onto
Note: If sensor is removed from its housing the stub axle the sensor to exciter air gap will be
lightly grease the sensor with a lithium based automatically set to the correct running
grease before installing back into the housing. clearance as the components come into contact.
3. Setting the hub centre nut correctly to the axle
3.2 SENSOR WEAR CHECK manufacturer's data will ensure sufficient output.
1. Remove the vehicle hub or the sensor from its However it should be noted that the running
mounting and clean the end face of the sensor. clearance between the sensor and exciter must
2. If the sensor casing is holed or damaged it never exceed 0.5mm (0.020") at any point during
should be replaced. (See section 3.3 for one complete revolution.
instructions on replacement). 4. Carry out a sensor output check as detailed in
3. If the sensor is serviceable refer to section section 3.5.
3.4. for adjustment. 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 5. If there is no bar displayed then the sensor
1.2. to ensure that the correct lamp sequence is requires either resetting (see section 3.4) or it is
obtained but bear in mind the Important Note damaged in which case it requires replacement.
referred to in section 6.5 However before replacing the unit check the
sensor resistance and continuity of its extension
cable to determine whether the fault lies in the
3.5 CHECKING THE SENSOR OUTPUT cable or the sensor. (See sections 3.7 and 3.8).
1. Before commencing sensor checks ensure
that the appropriate sensed wheels are jacked
clear of the ground and suitably propped 3.5.B USING THE INFO CENTRE
(observing all normal safety precautions) so that (Refer to relevant information in section 15.0).
the wheels are free to be rotated by hand with no 1. Unclip cover from Info Centre and apply
brake drag evident. vehicle power.
2. If necessary back off the brake adjustment 2. The display will switch on showing all
temporarily for this test, after which the brakes segments followed by the total distance reading.
should be readjusted to the manufacturer's 3. Press button: Diagnostic code will be
recommendations. displayed
3. Sensor outputs may be checked by using a 4. Press button: Wheel speed sensor check
Diagnostic Display Unit (DDU) plugged into the command will be displayed - WHL
ECU diagnostic which will be mounted on the 5. Rotate one wheel only at 1 rev/2sec (30 RPM)
side of the trailer. . for a minimum of 4 seconds
4. A suitable Multimeter as recommended in 6. Stop the wheel from rotating.
section 14.5, the use of which is described in 7. Observe the display -
section 3.5.C. wheel 1A gives S1A
8. Repeat procedure by rotating second sensed
wheel.
3.5.A USING THE DDU wheel 1B gives S1B
1. Connect the DDU to its harness then locate 9. If the display appears as above then the
the diagnostic outlet socket mounted on the side sensor output is satisfactory. If there is no display
of the trailer marked "ABS TEST" and plug in the the sensor requires resetting or is damaged.
DDU harness. Check as in section 3.5.A. point 5.
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) 3.5.C USING A MULTIMETER
and observe the DDU sensor indicator bar NOTE: The meter should be set to AC Volts on a
appropriate to the wheel being rotated. (See Fig scale range suitable for measuring low values.
3.2) i.e. 300 millivolt scale.
3. If a solid bar appears in the DDU display 1. Disconnect the sensor at its extension lead
window then the sensor output is satisfactory. terminals.
4. If the displayed bar flashes then the sensor 2. Connect a suitable multimeter to the sensor
requires resetting. leads (see section 14.5 Service Information for
recommended types) .
3. Rotate the sensed wheel at a rate 1 rev/2sec
EXTENSION CABLE
CONNECTS ABS (30 RPM) and note the output on the meter.
TEST 4. Output should be not less than 0.3 Volts A.C.
NUMERIC DISPLAY
SOCKET
CONFIGURATION with not more than 0.15 Volts A.C. variation
AND FAULT CODES during one complete wheel revolution.
5. Excessive variation of the sensor output
SENSOR
OUTPUT
SENSOR indicates an exciter that is damaged, or that has
OUTPUT been incorrectly fitted.
DISPLAY
DISPLAY
BARS
BARS 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,
HAND HELD
and the continuity of its extension cable to
DIAGNOSTIC DISPLAY UNIT
Fig 3.2 THE DDU DISPLAY
Modular Section 3.0 Issue 1.0 June1998
MODULAR
determine whether the fault lies in the sensor or
its cable. (See section 3.7 and 3.8).
4. If however the resistance is satisfactory then
3.6 ADDITIONAL SENSOR CHECKS the sensor extension cable is at fault and should
If sensor outputs are found to be unsatisfactory be replaced as detailed in section 3.9.
proceed as follows:

FLASHING DISPLAY on DDU or LOW METER 3.9 SENSOR EXTENSION CABLE

READING. REPLACEMENT
1. Reset the sensor as detailed in section 3.4 IMPORTANT NOTE: Cable replacement will
and check that the exciter is not damaged and is involve cutting out and replacement of part of
running true (see section 2.1, 2.2 and Fig 2.4). the ABS harness which is a one piece moulded
2. Check the running clearance between exciter unit. The connection is made by a window type
and sensor, which should not exceed 0.5 mm in-line butt connector. The connectors are
(0.020") at any point during one complete protected by heat shrink tubing containing a
revolution. sealant. When heated the tubing shrinks and the
3. Check the exciter face for dents or other sealant melts. A watertight joint is formed when
damage the sealant solidifies on cooling. Heat should
only be applied with a suitable hot air gun, such
NO BAR DISPLAY on DDU / INFO CENTRE or as Hellerman No. GHL 1550.
NO METER READING.
The sensor is so far out of adjustment or 1. Disconnect sensor extension lead to be
damaged as to not give an output, reset as replaced, from the sensor and remove any
detailed in section 3.4. The sensor or its exten- retaining cable ties.
sion cable is open circuit, or extension cable 2. Cut the extension cable 200mm minimum
connections have an from the ECU moulded connection or where the
excessively high resistance. Proceed as follows: joint can be secured on a rigid area of the cable
(section 3.7 and 3.8) installation. Do not secure the joint on the hose
or pipe going to the brake chamber.
3.7 CABLE CONTINUITY 3. Using wire strippers remove insulation on the
1. Unplug the sensor extension cable from the ABS harness sensor ext.cable.(see Fig 3.3)
sensor flying lead at the back of the brake dust
cover. 24.00
2. Bridge the pins of the extension lead plug at 20.00
the end of the cable using a suitable jump wire. 7.50
3. Disconnect the harness at the ECU and carry 6.50
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. If no continuity reading is obtained replace the
extension cable as detailed in section 3.9. If Fig 3.3 DETAILS OF INSULATION REMOVAL
however continuity is satisfactory then check the
sensor resistance. 4. Using a crimp tool (recommended is Thomas
and Betts (Crimpex) ratchet No. WT2124Y)
3.8 SENSOR RESISTANCE place terminal in the jaws and insert the wire
Carry out a sensor resistance check as follows: until the insulation butts against the terminal
1. Unplug the sensor extension cable from the barrel. Make the crimp, ensuring the
sensor flying lead at the back of the brake dust connector has firmly gripped both the wire and
cover. insulation. Check by pulling the connector.
2. Insert the multimeter probes into the sensor 5. Feed the heatshrink tubing over the new
connector socket and note the resistance, which sensor extension cable.
should fall in the range 980 ohms to 2.35 6. Join the extension cable onto the ABS
kohms. harness via the two in-line crimps using tool as in
3. If the result is outside the specified limits then point 4.
replace the sensor as detailed in section 3.3.
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

Hose

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 overtighten) 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
4.2 DIAGNOSTICS
4.0 THE ELECTRONIC CONTROL The ECU incorporates a diagnostic information
UNIT (ECU) output centre which provides information
relevant to system configuration and diagnostic
The ECU of the MODULAR ABS system is status. It is used for system diagnosis when a
located on a mounting bracket in common with DDU or Info Centre is connected to the unit, at
the modulator valve. (See Fig 1.2, 1.3 and 1.4). the ABS TEST diagnostic connector, enabling
It has microcomputer controlled diagnostics recovery of diagnostic codes.When connected
detection circuits which log diagnostics to a the DDU or the Info Centre may also be used to
memory that may be interrogated with a hand test outputs from associated wheel sensors. (See
held diagnostic display unit (the DDU see Figs section 3.5) Therefore it is possible to view the
3.2 and 4.10) or the Info Centre (see Fig 4.10). diagnostic code display from a remote position,
such as alongside the vehicle or from the tractor
MODULAR 1 Plus or MODULAR 2 unit cab when the vehicle is being driven.
NOTE: A DDU long extension lead (24m) is
available which facilitates dynamic testing. For
further 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
28 Pin Interface power supplies, sensors, modulators and the
connector diagnostic output. These connections are
MODULAR 1 Upgrade 19 Pin Interface incorporated in a single ABS vehicle harness
connector which has an integrally moulded connector,
Fig 4.1 MODULAR SERIES ECU facilitating a single connection point for simplicity
and system integrity.For further information refer
The ABS ECU contains an AA size to section 12.0 System Wiring.
Lithium / Thionyl Chloride Battery
that carries the following warning: 4.3 ECU MAINTENANCE
"Fire, Explosion and Severe Burn Hazard". The ECU requires no routine maintenance.
Under no circumstances should the battery be
re-charged, crushed or tampered with in any 4.4 ECU REPLACEMENT
way. The ECU should not be incinerated or 1. Locate the position on the trailer of the ECU
stored above 100°C. The ABS ECU may be and modulator valve assembly on their common
disposed of by landfill or re-cycled through a mounting bracket.
specialist operator, if in doubt consult your local 2. Remove the ISO 7638, ISO 1185 (24N) and ISO
authority for details or contact Haldex. 3731 (24S) connectors at the trailer coupling head
so that there is no electrical power connected to
4.1 ECU FOR ADR REGULATIONS the trailer.
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 1
Bail latch
INFO CENTRE (see section 9.0) is available
WITHOUT the powered odometer function. ECU

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.
ECU
All other functions are as standard MODULAR 2 Loom
ECU. For reference of the component part connector 1
number refer to service parts in section 14.0.
This ECU must only be replaced by Fig 4.2 ECU BAIL LATCH REMOVAL
its exact equivalent on ADR
vehicles. Modular Section 4.0 Issue 1.0 June 1998
MODULAR
3. Press together the connector clips on the loom c: Ensure bail latch and loom clamp are fixed in
connector, see Fig. 4.3 and pull the ECU away position see Fig. 4.6.
from the connector housing.
ECU Loom
ECU 2 Connector Clips
Loom ECU
connector

Fig 4.3 DISCONNECTION OF ECU

4. Remove the three retaining bolts securing the Fig 4.6 BAIL LATCH AND LOOM CLAMP
ECU using a 8mm ring spanner and remove it from POSITIONING
the mounting bracket.
5. Fit New bail latch provided to new ECU by d: Check earth continuty - ECU/Modulator Bracket
hooking bail latch ends into locating holes on ECU and Vehicle chassis to be <5 ohms.
ensuring that the bail latch is the right way round 7. On completion carry out the driver's checks
to clip over the socket see Fig. 4.4. described in section 1.2. (Driver's information)
and in section 6.0.

Bail latch

locating hole ECU

Fig 4.4 BAIL LATCH POSITIONING

6. Fit the 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
ECU Loom
connector

Fig 4.5 ENGAMENT OF ECU AND LOOM

CONNECTOR Modular Section 4.0 Issue 1.0 June 1998
MODULAR

7
14
1
15 8
2
9
16 3
10
17 4
11
18 5
12
19 6
13

Contact Pin area Loom Connector (19 Way) Plug Connector

(Headboard)

CONNECTION CONNECTOR (19 Way) PLUG CONNECTOR TERMINAL

CONTACT PIN No. PIN No. PIN No. REFERENCE

ISO 7638 1 7 / RD 1 Battery positive permanent supply (B+P)

2 6 / BK 2 Battery positive ignition switched (B+IGN)
8 4 / YE 3 Battery negative (B-IGN)
16 3/W 4 Cab Lamp Return (B-)
9 5 / BN 5 Battery negative permanent supply (B-P)

ISO 3731 (24S) 1 - Battery positive permanent supply (B+P)

2 6 Battery positive ignition switched (B+IGN)
8 1 Battery negative (B-IGN)
16 2 Cab Lamp Return (B-)
9 - Battery negative permanent supply (B-P)

ISO 1185 (24N) 17 2 1 Battery negative (B-)

3 1 4 Battery positive (stoplamp) (B+)
10 3 - Trailer Lamp Return (B-)

MODULATOR 14 RD Dump Solenoid

SOLENOID 15 BK Battery negative (common) (B-)
7 YE Hold Solenoid

SENSOR 1A 6 Sensor Hi
13 Sensor Lo

SENSOR 1B 12 Sensor Hi
19 Sensor Lo

DIAGNOSTIC 4 1 Battery positive (B+)

SOCKET 11 2 ECU Output
5 3 ECU Input
18 4 Battery negative (B-)
Fig 4.7 MODULAR 1 UPGRADE MAIN LOOM CONNECTOR CONTACT PIN DETAIL

Modular Section 4.0 Issue 1.0 June 1998

MODULAR
20 Identification Key
21
12
22
4
14
5
24
15
6
25
16 7
26 17
8
27 18 Loom Connector (28 Way) Plug Connector
9
19 (Headboard)
28
Contact Pin area

CONNECTION CONNECTOR (28 Way) PLUG CONNECTOR TERMINAL

CONTACT PIN No. PIN No. PIN No. REFERENCE

ISO 7638 7 7 / RD 1 Battery positive permanent supply (B+P)

6 6 / BK 2 Battery positive ignition switched (B+IGN)
16 4 / YE 3 Battery negative (B-IGN)
26 3 / BN 4 Battery negative permanent supply (B-P)
17 5/W 5 Cab Lamp Return

ISO 3731 (24S) 7 7 / RD -

6 6 / BK 6 Battery positive ignition switched (B+IGN)
16 4 / YE 1 Battery negative (B-IGN)
26 3 / BN -
17 5/W 2 Cab Lamp Return

ISO 1185 (24N) 5 1 4 Battery positive (stoplamp) (B+)

15 3 - Trailer Lamp Return
25 2 1 Battery negative (B-)

MODULATOR 4 RD Dump Solenoid

SOLENOID 24 BK Battery negative (common) (B-)
14 YE Hold Solenoid

SENSOR 1A 12 Sensor Hi
22 Sensor Lo

SENSOR 1B 21 Sensor Hi
20 Sensor Lo

DIAGNOSTIC 9 1 Battery positive (B+)

SOCKET 19 2 ECU Output
8 3 ECU Input
18 4 Battery negative (B-)

SUSPENSION 27 Negative
CONTROLLER 28 Positive

Fig 4.8 MODULAR 1 PLUS MAIN LOOM CONNECTOR CONTACT PIN DETAIL
Modular Section 4.0 Issue 1.0 June 1998
MODULAR
10
20 Identification Key
1
11
21
12 2
22
13 3
23
14 4
24
15 5
25
16 6
26 17
7
27 18 8
19 9
28 Loom Connector (28 Way) Plug Connector
(Headboard)
Contact Pin area

CONNECTION PLUG
CONNECTOR (28 Way)CONNECTOR TERMINAL
CONTACT PIN No. PIN No. PIN No. REFERENCE
ISO 7638 7 7 / RD 1 Battery positive permanent supply (B+P)
6 6 / BK 2 Battery positive ignition switched (B+IGN)
16 4 / YE 3 Battery negative (B-IGN)
26 3 / BN 4 Battery negative permanent supply (B-P)
17 5/W 5 Cab Lamp Return
ISO 3731 (24S) 7 7 / RD -
6 6 / BK 6 Battery positive ignition switched (B+IGN)
16 4 / YE 1 Battery negative (B-IGN)
26 3 / BN -
17 5/W 2 Cab Lamp Return
ISO 1185 (24N) 5 1 4 Battery positive (stoplamp) (B+)
15 3 - Trailer Lamp Return
25 2 1 Battery negative (B-)
MODULATOR 4 RD Dump Solenoid
SOLENOID 24 BK Battery negative (common) (B-)
(Yellow Channel) 14 YE Hold Solenoid
MODULATOR 3 RD Dump Solenoid
SOLENOID 23 BK Battery negative (common) (B-)
(Blue Channel) 13 YE Hold Solenoid
SENSOR 2A 1 Sensor Hi
10 Sensor Lo
SENSOR 3A 12 Sensor Hi
22 Sensor Lo
SENSOR 2B 2 Sensor Hi
11 Sensor Lo
SENSOR 3B 20 Sensor Hi
21 Sensor Lo
DDU SOCKET 9 1 Battery positive (B+)
19 2 ECU Output
8 3 ECU Input
18 4 Battery negative (B-)
SUSPENSION 27 Negative
CONTROLLER 28 Positive

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
MODULAR

Preferred position
of Diagnostic
connector

Main Loom
assembly
Diagnostic
connector
Chassis ABS
mounted INFO

DDU

DDU Plug locates in

loom assembly
Diagnostic connector

ALTERNATIVE

ABS
INFO

Diagnostic
connector

INFO CENTRE

Fig 4.10 DIAGNOSTIC OUTLET SOCKET LOCATION

Modular Section 4.0 Issue 1.0 June 1998
MODULAR
5.0 THE MODULATOR VALVE
Procedure :
The modulator comprises a relay type valve with a 1. Ensure that all electrical power sources are
solenoid block containing hold and dump control removed from the ABS.
solenoids mounted on the upper housing. 2. Release all air pressure from the
appropriate air reservoir.
Modular 1 is designed as a 2S1M ABS system 3. Remove any cable ties securing the solenoid
and therefore will have only a single channel, i.e. cable between the solenoid and the ECU.
only one modulator valve electrically connected 4. Unscrew the gland nut which secures the
to the ECU. solenoid electrical cable to its housing and
disconnect it from the solenoid.
Single channel systems on multi-axle trailers 5. Disconnect the signal line from port 4 of the
employ a single modulator which has six delivery modulator valve.
ports, one for each brake chamber. 6. Disconnect the reservoir supply from port 1 of
the modulator valve.
Exceptions do occur though , e.g. single axle 7. Disconnect the brake pipes from the
trailers may have a single 2 port modulator in modulator delivery ports (numbered 2). It is
some cases. important that pipe positions are noted and
replaced in the same ports from which they were
Modular 2 is designed as a 2S2M or a 4S2M ABS removed.
system and therefore will have a two channel 8. Remove the three nuts securing the modulator
system, i.e. two modulator valves electrically to the bracket and lower the modulator from its
connected to the ECU. mountings.
NOTE: When releasing the modulator mounting
nuts, avoid rotating the associated bolts which
5.1 MODULATOR MAINTENANCE also serve to hold the valve body sections
The modulator valve requires no routine mainte- together.
nance but should be periodically checked for 9. Proceed to section 5.3 - If replacing solenoid
security, function and air leaks. only.

It is not possible to service the modulator or

Threaded connector
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 Fig 5.1 MODULATOR VALVE WITH M27

The modulator is mounted on a bracket in com- THREADED CABLE CONNECTOR
mon with the ECU, which is located beneath the
trailer over or near the bogie centre line. 10. Reverse this procedure to refit the new unit.
The electrical connection to the solenoid is (See section 5.5).
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 removed from the solenoid
block, whenever it is necessary to access the
harness or ECU assembly.
Modular Section 5.0 Issue 1.0 June 1998
MODULAR
5.3 FITTING THE MODULATOR ASSEMBLY To check a pipe fitting a water and soap solution
Refitting is the reversal of procedure 5.2 but noting or suitable leak detector spray may be applied
the following points: and the area of suspected leakage inspected for
bubbles.
1. Mount the modulator in the same orientation as
the original installation. Brake Applied Check
2. Always use new self locking nuts to secure the 1. Fully charge the air system.
modulator to its bracket. 2. Apply the footbrake and listen at the
3. Always connect the brake pipes to the same modulator exhaust port for audible leakage.
ports (port 2) of the modulator as in the original If audible leakage is noted investigation and
installation. remedial action is necessary.
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 5.5 SOLENOID OPERATION CHECK
leakage. 1. Fully charge the air brake system.
2. Apply the footbrake and switch on the ignition
listening for the exhaust of air from each
5. Ensure correct location of the solenoid cable modulator. There should be as many single brief
connector and hand tighten the gland nut taking pulses of air as there are modulators. (See
care not to cross thread it. section 8.0 configurations).
6. Replace any cable ties as originally fitted, but
do not over tighten them as this may damage the
cable. NOTE:
7. Reconnect the signal (port 4) and the reservoir If there is no pulse then a fault exists which
(port 1) lines, and charge the air system. may be an open circuit solenoid, open
8. Carry out an air leakage check as detailed circuit wiring or a fault at the ECU
below. connector.
9. Carry out the Lamp sequence check as
described in section 1.2 (driver information). In the case of a double pulse, there is a
wiring fault involving incorrect connection
SPECIAL NOTE: When undertaking any between the dump and hold solenoids.
pipework repairs where it is necessary to seal
fittings, always use a high quality liquid sealant. 3. If a single pulse does not occur repeat 1 and 2
Do not under any circumstances use PTFE tape with an assistant observing each of the
or similar sealants as shreds of this sealant type modulators. Establishing which valve(s) are not
may cause modulator malfunctions if they become producing pulses will provide a start to fault finding
embedded in the ball valve or solenoid areas. see section 10.0.
There should be no continuous audible leaks.
4. Finally carry out the Lamp sequence checks as
5.4 AIR LEAKAGE CHECKS detailed in section 1.2. (driver information).
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) 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.

Modular Section 5.0 Issue 1.0 June 1998

MODULAR
6.0 MODULAR SYSTEM WARNING 6.2 DASHBOARD WARNING LAMP (RED)
LAMPS This lamp configuration will be fitted to towing
vehicles which are equipped to provide a
The various powering options referred to in section permanent power supply to the trailer ABS
7.0 will have a corresponding combination of system via either the ISO 3731 (24S) or ISO 7638
warning lamps fitted to the vehicle. The towing electrical susies. In this event semi-trailer lamp
vehicle dash mounted lamp, operates when the function which is powered from the stoplight circuit
ABS is powered by the ISO 3731 (24S) or ISO will be secondary and the dash mounted lamp
7638 wiring systems. If the ABS is powered becomes the primary indicator for the ABS
through only the ISO 1185 (24N) stop lamp operational status.
supply, then only the green trailer mounted lamp
will indicate the ABS operational status. Lamp Sequence:
At ignition switch on the lamp (red) will illuminate
6.1 TRAILER MOUNTED LAMP (GREEN) for approximately 2.5 seconds, then go out for
This lamp is mounted on the trailer head board 1 second, and then come on and stay on until the
(see Fig 1.9) and is operated from the ISO 1185 vehicle is driven at a speed above 6mph (10km/h)
connector when the ABS is powered only from when the lamp should go off and stay off.
the stop lamp power supply. i.e. when the brake IF THE LAMP FAILS TO FLASH OR IF THE
pedal is pressed. LAMP IS ON AT SPEEDS ABOVE 6mph
(10km/h), THEN THE ABS SYSTEM OR LAMP
NOTE: If a permanent power source is available CIRCUIT IS FAULTY.
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 6.3 CAB DASHBOARD LAMPS (RED and
becomes the primary ABS status indicator, the AMBER)
GREEN trailer lamp becomes the secondary This lamp configuration may be fitted to some
indicator and will only operate: vehicles of European manufacture to suit
(a) If the brake pedal is pressed before the particular types of ABS. The function of the red
ignition is switched on during initial power up. lamp is to indicate the operational status of the
(b) During a fault event when the red lamp is ABS. The function of the amber lamp is to indicate
illuminated and the brake pedal is then pressed. if ABS is fitted to the trailer. It is not however a
In either of these cases the trailer lamp will mandatory requirement and if you have a vehicle
duplicate the red cab mounted lamp function. with this lamp configuration you should refer to the
At all other times the trailer lamp function remains vehicle manufacturer's handbook for further
dormant. information.

Lamp Sequence: Vehicle Stationary. 6.4 MULTIPLE LAMP SEQUENCE

With the trailer ABS powered solely from the ISO ( GREEN and/or RED)
1185 connector, when the brake pedal is pressed The Modular ABS series incorporates an auxiliary
the lamp will flash and then come on and stay on lamp flash of three flashes.
until the brake pedal is released at which point the The lamp will flash when the system is
lamp will go off. powered up when at rest.
NOTE: IF THE LAMP FAILS TO ILLUMINATE This lamp sequence relates to :-
THEN THE LAMP, LAMP CIRCUIT OR ABS
SYSTEM IS FAULTY. 1. Service due - indicates that trailer or
system service distance has been reached. After
Lamp Sequence: When the vehicle is moving servicing the trailer or system the next service
at a speed greater than 6mph (10km/h): distance must be reset by using :
The lamp remains off until the brakes are applied Info Centre (see Section 9.0 additional product
at which point the lamp will flash and remain off. information) or EOLT program (see Section 11.0)
IF THE LAMP FAILS TO FLASH OR IF THE
LAMP IS ON AT SPEEDS ABOVE 6mph
(10km/h) WHEN BRAKING, THE ABS SYSTEM
OR LAMP CIRCUIT IS FAULTY.

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
cleared 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:

SENSOR RELATED 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, or the vehicle must be driven at a
speed greater than 6mph (10km/h) to confirm
sensor signal integrity. The ECU will 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)

Modular Section 6.0 Issue 1.0 June 1998

MODULAR
7.0 SYSTEM POWER SUPPLY AND available power source in the following order of
FUSES. priority:

7.1 POWER SUPPLY (1st) ISO 7638 (Dedicated supply).

1. MODULAR ABS will accept any source of (2nd) ISO 1185 (24 N Stop lamp power supply).
electrical power available from the tractor unit as
listed below. OR

(a) ISO 1185 (24 N Stop lamp power supply). (1st) ISO 3731 (24 S Supplementary supply).
(2nd) ISO 1185 (24 N Stop lamp power supply).
(b) ISO 3731 (24 S Permanent ignition sourced
power supply). 7.2 System Fuses.
A 12 Amp in line ceramic fuse is fitted into pin 1 of
(c )ISO 7638 (Dedicated ignition sourced the ISO 7638 Connector. In the event of a wiring
permanent power supply). short or other overload the fuse will blow resulting
in a permanent lamp indication.
Any of these supplies will power the system on a There are two designs of connector, varying
stand alone basis but trailers will be wired to according to manufacturer. (Type A = AMP,
provide a combination of either: Type B = Haldex).
Both replacement fuse types are provided in
ISO1185 (24N) plus ISO 7638 Haldex service kit number 950 364 401.

OR Fuse Replacement kit

SERVICE KIT PART No. 950 364 401
ISO1185 (24N) plus ISO 3731 (24S) CONTENTS:
FUSED PIN FOR Haldex ISO 7638 connector
This provides operational choices to suit the
majority of new and existing tractor units. FUSED PIN FOR A.M.P ISO 7638 connector
It should be noted that 24S with ISO 7638 is not EJECTOR
available as an option. RELIEF TUBE
2. The power source provided by the tractor unit INSTRUCTIONS
will depend on its age, type of manufacture and
modifications carried out by the operator. NOTE: The fused pin for A.M.P ISO 7638 cannot be
The MODULAR system will only draw current from used to replace the fused pin of the Haldex ISO 7638.
Both fuses are supplied in the kit and are not
one power source at a time and will self select the interchangeable.

Fig 7.1 FUSE SERVICE KIT CONTENT

Modular Section 7.0 Issue 1.0 June 1998

MODULAR MODAL
FUSE
IDENTIFICATION
LABEL
12 AMP

003
7554
09

YELLOW or 3
RED or 2
PURPLE or 1 RELIEF
TUBE EJECTOR
2 1 (FUSED)
3 7
4 5 6
BLACK or Y/GN
FEMALE CRIMP
WHITE or 4 TERMINAL RETAINING
BARBS

FUSED PIN No.1

Fig 7.2. ISO 7638 FUSE REPLACEMENT A.M.P CONNECTOR

Replacement of ISO 7638 Fuse

covering the pin compartment to gain access to
PROCEDURE: the blade terminal of pin 1.
Type A: 7. Disconnect the blade terminal from the fuse
A.M.P. Connector (Black Cover) See Fig.7.2. assembly.
1. Disconnect the trailer from all power sources. 8. Push the relief tool (in the service kit) fully
2. Remove the fasteners securing the ISO 7638 home over the retaining barbs of pin 1.
connector to the trailer headboard. 9. Insert the ejector (in the service kit) into the
3. Pull the socket away from the headboard to relief tool and push it fully home to eject the pin
expose the cable gland. from its housing.
4. Release the cable gland. 10. Fit the replacement (fused pin 1) and
5. Unscrew the rear cover from the ISO 7638 reassemble the connector (in reverse
connector and slide it away from the connector. procedure) ensuring correct location of all gaskets
6. Pull back the gasket and gasket retainer, and security of all gland nuts, and fittings.

Modular Section 7.0 Issue 1.0 June 1998

MODULAR

SOCKET BODY

PIN HOUSING

CABLE GLAND NUT CABLE SPIDER

BODY REAR COVER
GASKET

FUSED PIN No.1

BLADE CONNECTOR

Fig 7.3. ISO 7638 FUSE REPLACEMENT HALDEX CONNECTOR

Type B: 7. Slide the cable gasket along the cables, away

Haldex Connector (Green Cover) See Fig.7.3. from the spider to clear the fused pin blade.
1. Disconnect the trailer from all power sources. 8. Separate the spider and pin housings by prising
2. Remove the fasteners securing the ISO 7638 them apart to disengage the retaining barbs.
connector to the trailer headboard. 9. Pull pin 1 sideways out of the spider, and insert
3. Pull the socket away from the headboard to the new fused pin into its housing in the same
expose the conduit and cable gland. orientation.
4. Unscrew the cable gland nut from the socket 10. Re-assemble the connector in the reverse
body rear cover. procedure ensuring correct location of all gaskets
5. Unscrew the rear cover from the connector body and security of all gland nuts, and fittings.
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.

Modular Section 7.0 Issue 1.0 June 1998

MODULAR
8.2 CONFIGURATION
8.0 SYSTEM CONFIGURATIONS Sensor and modulator channels are colour coded
as follows.
8.1 TERMINOLOGY (see also section 1.1) RD = RED, BU = BLUE, YE = YELLOW
S Refers to a sensor.
M Refers to a modulator. The RED channel sensing is always from
S1A/S1B, S2A/S2B and S3A/S3B identify the left sensors identified as S1A and S1B.
and right hand of sensor pairs and the order in This channel provides select low operation as
which they are installed on the trailer. independant wheel control ABS cannot be applied
Consider sitting on axle 1 with axle 2 behind you, to self steer axles.
then sensor group "A" will always be to your left
and sensor group "B" will always be to your right. The BLUE channel sensing is always from
You will note that for this to be true you will be sensor(s) identified as S2A or S2A and S3A
facing forwards for full trailers and backwards for together:
semi or centre axle trailers.
The configuration reference indicates component The YELLOW channel sensing is always from
quantities in the system. Hence a 2S1M system sensor(s) identified as S2B or S2B and S3B.
will have 2 Sensors and 1 Modulator.
The sensor identity is relevant to the position in MODULAR ABS is capable of controlling 1 or 2
which its output is displayed on the DDU or Info channels of braking effort sensed by 2 or 4
Centre, when checking sensor function (see sensors and may therefore be installed in a range
section 3.5 and 6.0). The sensor identity varies of different configurations:
between different configurations dependant on the
number of axles and sensor pairs fitted. Modular 1 Upgrade = 2S1M
NOTE: These identities should not be confused Modular 1 Plus = 2S1M
with axle numbers, which differ between full Modular 2 = 2S2M or 4S2M
trailers and semi or centre axle trailers. (See
Figs 8.4 to 8.5). System equipment will depend on the type of
trailer, and the degree of ABS control specified
ECU Refers to the electronic control unit of the by the operator or trailer manufacturer. The
MODULAR ABS system. maximum number of control channels will be two,
determined by the number of modulator(s).
Axle numbering:
Semi-Trailer and centre axle trailer axles are Modulator cable Number of ABS
numbered from the rear axle forwards hence connected to ECU: control channels:
axle 1 is the rear axle.
Full trailers (Drawbars) have their axles Red (RD) only 1
numbered from the front of the trailer rearwards so Yellow (YE) & Blue (BU) only 2
that the front axle is number 1.
This numbering system caters for self steering Fig 8.1 NUMBER OF CHANNELS
axles which will always be number 1. Wiring diagrams are shown in section 12. The
If axle 1 is a self steer axle it must always be number of wheel speed sensors connected to the
controlled by the RED modulator channel ECU may be 2 or 4 but the combination of
operating on a “select low” principal, i.e. the ABS modulator solenoid cables and wheel speed
channel controlling that axle reacts to the first sensor cables will always be as shown in Fig 8.2
locking wheel and controls both wheels of the below.
axle to that level of tyre to road grip.
It is not possible to provide individual wheel Modulator cable Sensors
control on self steer axles as split friction is connected to: connected
conditions would result in vehicle instability due to For 2S1M
the differing tyre to road grip across the axle, RD S1A+S1B
which would cause it to self steer. For 2S2M
BU+YE S2A+S2B
For 4S2M
BU+YE 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 disabled when the axle is lifted,
these are indicated in brackets in Fig 8.3 below.

DDU Info Centre Function Axle No. Sensors Modulators

Code Code Lifted Used Used

CO 2S1C CO 2S/1M S1A S1B Red

C1 2S1C C1 2S/2M S2A S2B Blue,Yellow
C2 2S2C C2 4S/2M S3A S2A S2B S3B Blue,Yellow
C3 4S2C C3 4S/2M 2 or 3 (S3A) S2A S2B (S3B) Blue,Yellow

Fig 8.3 CONFIGURATION CODES

8.5 AUXILIARY CONFIGURATION CODE
8.4 CONFIGURATION FAULTS
Modular 1 Plus and Modular 2 ABS ECUs offer
When the ECU is initially powered up, a system
extra features beyond the ABS, However these
configuration code is briefly displayed on the
features may or may not be used. In order to
DDU or Info Centre if attached, which should be
provide the standard of electrical diagnostic
confirmed as correct for the particular installation,
associated with ABS type product, the ECU
by referring to the configuration codes listed in
needs to know if a solenoid operated valve,
Fig 8.3 above.
e.g. a Reset-to-Ride (COLAS) valve, should be
If a vehicle has its modulator piped incorrectly,
present.
solenoid wiring interchanged between solenoids,
The ECUs are supplied in a un-configured
or sensor wiring interchanged between sensors
condition, this means that when it is powered
then it is possible that a correct configuration
after being installed on a vehicle it will check for
code may be displayed but that poor ABS
the presence of a solenoid operated valve and
performance is evident. This will occur due to
configure to use one if it is present. If auxiliaries
incorrect cross connection of sensors and
are added later which require the use of features
modulators at the ECU.
which are already disabled by the first auto
When the ECU receives a locking wheel signal it
configuration a fault code will be displayed.
attempts control of that wheel, but if sensors or
For example: If a Colas valve has been added
modulators are incorrectly connected either
since initial configuration the diagnostic code will
electrically or in the case of the modulator
be :-
pneumatically, the wrong wheel will be controlled,
DDU display = A1
resulting in poor ABS and brake performance.
Info Centre display = RIDE A1
In such circumstances the MODULAR system
this will be seen by the ECU as a current fault.
may generate a fault code indicating slow wheel
recovery group i.e. A fault code number such as,
Using the DDU the procedure to clear this
41, 42, or 43. (see section 10.0)
configuration is as follows:-
In this event the configuration and wiring
1. Apply power, allow display to settle to fault
diagrams should be checked against your
code 'A1'
installation to ensure that the actual pipe work and
2. Read fault code, obtain 'CA' (or if no other
wiring conforms to the allowable configuration
stored fault codes '00') and accept option by
details, (See section 12.0).
pressing the button on DDU.
3. Wait approx 5 sec. after display has returned
to 'A1'.
4. Repeat reading and clearing of fault code as
above up to three times.
5. On the 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
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, refer to the
corresponding section diagram from
Fig 8.6 which shows the correct checkout
procedure in the order:
1. Lamp sequence.
2. Modulator blowdown check (see section 5.7)
3. Sensor output indication on DDU or Info Centre
when a wheel or wheels are rotated.

Modular Section 8.0 Issue 1.0 June 1998

MODULAR

Semi-Trailer

2S/1M

N2 N3 N3

2S/2M

N2 N4 N4

4S/2M L
L L

N4 N4

NOTES:

N1 Details viewed from above.

N2 2 Delivery port ABS valve assembly (preferred).
N3 6 Delivery port ABS valve assembly.
N4 3 Delivery port ABS valve assembly.
N5 L = Axle which may be a lift axle.
N6 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
MODULAR

Centre Axle
Trailer

2S/1M

N2 N3 N3

2S/2M

N2 N4 N4

4S/2M
L L

N4 N4

NOTES:

N1 Details viewed from above.

N2 2 Delivery port ABS valve assembly (preferred).
N3 6 Delivery port ABS valve assembly.
N4 3 Delivery port ABS valve assembly.
N5 L = Axle which may be a lift axle.
N6 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 8.5 MODULAR SYSTEM CENTRE AXLE TRAILER CONFIGURATION LAYOUTS

Modular Section 8.0 Issue 1.0 June 1998
MODULAR

Key
Modulator
Blowdown

M Modulator

O.K.

NOT O.K.

Fig 8.6 MODULAR 1 (2S/1M) SYSTEM CHECKOUT

Modular Section 8.0 Issue 1.0 June 1998
MODULAR

Key
Modulator
Blowdown

M Modulator

O.K.

NOT O.K.

Fig 8.7 MODULAR 2 (2S/2M) SYSTEM CHECKOUT

Modular Section 8.0 Issue 1.0 June 1998
MODULAR

Key
Modulator
Blowdown

M Modulator

O.K.

NOT O.K.

Fig 8.8 MODULAR 2 (4S/2M) SYSTEM CHECKOUT

Modular Section 8.0 Issue 1.0 June 1998
MODULAR
Functions:
9.0 THE INFO CENTRE
Odometer: Total distance
Trip distance
The Info Centre is a side of trailer mounted
Service interval
diagnostic unit used for read-out of odometer and
Distance to next service
diagnostic codes, plus other information as
Tyre scale setting
available from the ABS Electronic Control Unit
(ECU). (See Fig 9.1)
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)

Fig 9.1 INFO CENTRE

It is connected permanently to the ABS ECU's

diagnostic connection. While the ECU is powered
Fig 9.2 THE DISPLAY
from the vehicle system. (stoplight or permanent
supply) information is transferred to the Info
The Legends are as follows:-
Centre's memory, which can be recalled. Power is
supplied from the vehicle systems via the ECU BATTERY:
diagnostics connector. (see Section 12.0 - Wiring - OFF = OK
diagrams) - ON = Internal ABS ECU battery failure.
Diagnostic functions and ECU information
The Info Centre comprises an LCD (Liquid Crystal available only.
Display) (see Fig 9.2) and buttons marked up/down LOCK:
( ) and right ( ). The button accesses - Incorrect ABS ECU connected to Info
the next main menu item, the button is used Centre.
for sub menu items. For adjustment of settings a Odometer functions not available.
watch adjustment style procedure is followed; Hold POWER: Vehicle Power
down the button for 2 seconds, the first digit -ON = Vehicle Supply ON
flashes and can then be increased by pressing the -OFF = NO Vehicle supply
button. The next digit is then selected, and -FLASHING = Communications established
so on. It also has an internal battery which allows between Info Centre and ABS ECU.
display of information (including fault indication) BELLOWS: Air Suspension -
when the trailer is uncoupled and unpowered. It is - Bogie load, Load apportioning, Height
housed in a plastic enclosure provided with a cover control, Manual raise/lower
boot for environmental protection. ODOMETER DISPLAY
- Total distance
The Info Centre contains an AA size - Trip distance
Lithium / Thionyl Chloride Battery ADJUSTMENT ARROWS: Editing Mode
that carries the following warning: -ON = Indicates that information may be
"Fire, Explosion and Severe Burn Hazard". changed by user.
Under no circumstances should the battery be SERVICE FUNCTION / SERVICE DUE:
recharged, crushed or tampered with in any way. -ON = Whilst displaying the odometer
The Info Centre should not be Incinerated or stored value indicating service is due.
above 100°C. The ABS ECU may be disposed of by -FLASHING = Current ABS fault
landfill or recycled through a specialist
operator, if in doubt consult your local authority for
details or contact Haldex. Modular Section 9.0 Issue 1.0 June 1998
MODULAR
9.1 INFO CENTRE FOR ADR REGULATIONS c: Secure cable along the chassis or
To satisfy the ADR regulations for flammable loads appropriate support with cable ties at not more than
(i.e. Petrol tanker trailers) a variant of Info Centre 200mm intervals.
and its associated ECU (see section 4.0) is d: Mate cover to Info Centre and click into position
available WITHOUT odometer making sure both clips are fully engaged at top and
function.This is because hazardous load bottom. (see Fig 9.4)
regulations do not permit the fitting of battery
Info Centre
powered equipment (spark generators) to the rear
cover
of the firewall and so only this variant of Info Centre
must be used.

All other functions are as standard Info Centre .

For reference of the component part number refer
to service parts in section 14.0.

This Info Centre must only be

replaced by its exact equivalent on
ADR vehicles.

9.2 INFO CENTRE MAINTENANCE L

The Info Centre requires no routine maintenance.

9.3 INFO CENTRE REPLACEMENT Fig 9.4 COVER CLIPS LOCATION

1. Locate the position of the unit which should be
in an accessible area either in front, rearward of 9.3 FUNCTION INSTRUCTION
the wheel gear. Refer to Section 15.0 for the relevant product
2. Disconnect the Info Centre connections. information on various functions of the Info Centre
3. Cut away the cable ties securing the cable to with and without vehicle power.
any appropriate supports.
4. Unclip the front cover to expose the two M6
mounting bolts and remove.
5. Fit the 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
mount)

Locking Tab

Fig 9.3 CHASSIS CONNECTION

Modular Section 9.0 Issue 1.0 June 1998

MODULAR
10.0 FAULT FINDING WITH MODULAR 2. If the lamp fails to illuminate check the lamp bulb
and electrical power supply.
10.1 EQUIPMENT REQUIRED 3. If the lamp fails to flash but stays permanently
The following tools are required to carry out the illuminated check the diagnostic display codes
complete schedule of diagnostic tests. including stored diagnostic codes using the
procedure in 10.3. (Also NOTE section 6.5)
Trolley jack 4. If (1) above is satisfactory drive the vehicle at
Multimeter (see recommended units in Sec.14.0) above 6 m.p.h. (10 km/h). The anti-lock warning
500 volt insulation tester lamp should extinguish. If it does not there is a
Switch test box (optional see Fig 10.1). wheel speed sensing fault. Check the diagnostic
Diagnostic Display Unit (DDU) or Info Centre. display code using the procedure in 10.4.
5. To test for correct valve blow down, fully charge
NOTE: A tractor unit may be used as an the air brake system, and turn off all electrical
alternative to a switch test box. power to the trailer. Apply the foot brake and set
the ignition switch to on.
CAUTION : It is essential that normal safety There should be as many brief pulses of air as
procedures are observed when working on vehicles there are ABS modulators. (See section 5.7and
to ensure that they are correctly jacked and sup- Fig 8.6 to 8.8).
ported. Dangerous load carrying vehicles should 7. If the air pulse is incorrect check the diagnostic
always be made safe before commencing remedial display code using the procedure in 10.4. Note that
work. erroneous wiring of the modulator solenoid wiring
will produce two air pulses on the affected
modulator as the dump and hold solenoids are
10.2 INITIAL DIAGNOSIS OF ABS FAULTS electrically identical but have different pneumatic
Perform the following tests. functions.
1. Apply electrical power to the trailer via the"24N" 8. When a wheel is rotated, and electrical power
connector while observing the anti-lock warning is applied, all modulator blowdowns are inhibited
lamp which should flash and then come on and while the wheel is turning.
stay on. (See section 6.0 lamps).

Note: It is recommended
that this circuit breaker
is of the type,
KLOCKNER MOELLER
FAZL6-1, R
or
RS COMPONENTS 335-924

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
5. Press the switch on top of the DDU for
codes automatically. These stored codes are
approximately 5 seconds until the DDU display
retained in memory even when power is
changes.
disconnected from the ABS, and can be recalled
6. Release the switch.
on a hand-held Diagnostic Display Unit (DDU) when
7. The DDU displays the code last entered.
the power supply is restored.
8. Press the switch again for approximately 5
Follow the appropriate procedure described in
seconds until the DDU display changes.
section 10.4 for use with the DDU and section 15.0
This is the highest numerical fault code in
(Additional information) using the Info Centre.
memory.
For wheel sensor output tests the DDU may be
9. Release the switch, and press again to display
used on a trailer which is static in the workshop or
the next highest numerically recorded fault code.
dynamically on the road. The Info Centre can be
Continue this sequence to step through the fault
used on a trailer which is static in the workshop
code memory.
only.
10. After five codes “CA” will be displayed. See 12.
below.
10.4 USING THE DIAGNOSTIC DISPLAY UNIT
11. Release the switch.
(DDU)
1. Remove all electrical power from the trailer.
ERASING FAULT CODES FROM MEMORY
2. Connect the DDU cable to the trailer diagnostic
USING THE DDU
output connector. (See Fig 9.3).
3. Apply 24 volts to the anti-lock system.
12. The ”CA” display is an invitation to erase the
4. At power up 88 is displayed briefly to confirm
memory, pressing and holding the switch while it
LCD function, followed by a configuration code
is displayed will cause the memory to be erased.
and a diagnostic code which is displayed
The LCD will scan the codes as they are cleared.
constantly. Check that the configuration code
13. If the switch is not pressed the next fault code
agrees with the system wiring by confirming that
in the stored list will be displayed.
the number of connected sensors and solenoids
14. At the end of the fault code list "CA" will be
are as shown in the configuration codes given in
displayed again as a further invitation to erase all
section 8.3.
stored faults. Successful erasure of the fault
5. Refer to diagnostic codes in section 10.12 to
codes will only be possible, if the fault causing the
determine the cause of the fault.
code to be logged in memory has been repaired.
Note that some codes generated confirm correct
15. When all codes are cleared, release the button
system function.
briefly, then press and hold. After 5 seconds the
6. Remove all electrical power and then repair
display will read "00" indicating that the memory is
faults as necessary.
empty.
7. Clear the diagnostic memory as described in
10.5 PRESS BUTTON TO
NOTE: Faults which occur whilst the ECU is ACCESS DIAGNOSTIC
powered up are logged in two memories. Any CODES
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 CONNECTOR PLUGS
described in section 1.2 but with regard to the INTO ABS TEST
Important Note at section 6.5. POINT

10.5 READING STORED CODES ON THE DDU Fig 10.2 ACCESSING FAULT CODES USING
1. Remove electrical power from the ECU. THE DDU
2. Connect the Diagnostic Display Unit to its
Using the INFO CENTRE see Section 15.0 for
connector on the trailer.
relevant product information.
3. Apply power to the ECU.
4. Read the display on the DDU. This is the current Moduar Section 10.0 Issue 1.0 June 1998
code which may or may not refer to a fault
MODULAR
10.6 INTERPRETATION OF FAULT CODES Code 91 indicates that when using the ISO 7638
1. When the vehicle is stationary and no fault is power source there is sufficient voltage coming
present the diagnostic display will be 07. from pin 2 of the ISO 7638 connector but the
2. This display will change when the vehicle is voltage coming from pin 1 is low or absent.
driven at above 6 mph (10 km/h) and bars will 1. Check for broken wiring or blown fuses on both
appear in the display window for left and right the trailer and the towing vehicle or with the
sensors representing a sensor output which is workshop power supply if used. The voltage
above the necessary minimum. measured on the ECU connector which goes to
3. The number of bars which appear should be the ISO 7638 pin 1 should be between 18 Volts and 32
same as the number of wheels which have speed Volts when the voltmeter negative lead is on the
sensors fitted. ECU connector which goes to ISO 7638 pin 4.
4. The (DDU) displays “00” as a code which (See wiring Section 12)
indicates correct operation of the system, when
vehicle speeds exceed 6mph (10km/h). Code 92 indicates that the power supply to the
5. When the vehicle stops the code returns to 07. ECU is above 32 volts and action must be taken to
6. Flashing bars indicate that there are poorly reduce this over voltage.
adjusted sensors or loose sensor connections. 1. Check the towing vehicle voltage regulator and
7. Spinning individual wheels with the trailer jacked alternator system or the voltage output from the
up will cause the relevant bar to appear if the test power supply in use.
sensor output is above the minimum. 2. The correct power supply connections to the
8. Codes other than those described above can be ECU supply pins are shown in the pin maps in
interpreted by using the diagnostic code table in Fig.4.7, Fig.4.8 and Fig.4.9 .
section 10.12.
10.9 WARNING LAMP FLASH INCORRECT
10.7 ELECTRICAL TESTS OF SENSOR AND Permanently Illuminated Lamp
SOLENOID WIRING 1. This may be caused by wiring shorts or by
1. When the diagnostic code indicates that there is faults which cause the ECU to permanently
a faulty power supply, wheel speed sensor or illuminate the lamp. The latter may be due to a
modulator solenoid fault, the location of the fault system fault if the code displayed is not 07, or a
can be determined by continuity and resistance stored sensing system fault, if the code displayed
tests and by reference to the appropriate wiring is 07.
diagram. 2. Read the diagnostic code. If the code is 07
2. Test equipment may be connected to the main read the fault memory. Sensing system faults will
ABS harness at the moulded ECU connector for be stored if any were present the last time the
which a pin map is shown in Fig.4.7, Fig.4.8 and trailer was moved at a speed greater than 6mph
Fig.4.9 . (10km/h).
3. Make any necessary repairs and clear the
10.8 POWER SUPPLY FAULTS memory. The lamp flash should now revert to
The correct power supply connections to the ECU normal after vehicle speed has exceeded 6mph
pins are shown in the pin map in Fig.4.6, Fig.4.7 (10km/h). IMPORTANT: See section 6.5.
and Fig.4.8 . If not there is a lamp wiring short circuit to battery
Supply voltages must be in the range 18 to 32 volts negative or chassis.
maximum. 4. If the code is not 07 make the necessary
repairs as indicated by the diagnostic code until
Code 90 indicates a voltage loss when a solenoid the code becomes 07 at which time the lamp
is energised and the voltage at the ECU falls below sequence should revert to normal within the
18 Volts. provisions of section 6.5
1. Ensure that the electrical supply is satisfactory
under full electrical load conditions, i.e. there are NOW ERASE THE MEMORY.
no high resistance connections present.
2. Establish if the voltage drop occurs when using 5. If after completing the above process the lamp
each of the power sources on their own, ISO7638, is still permanently illuminated there is a short
ISO3731 (24S), ISO1185 (24N). circuit between the lamp negative side and battery
3. Check for loose connections in the wiring from negative. The lamp negative goes directly to the
the source which produces the fault code. ECU. The ECU then switches this side to battery
NOTE: An inadequate power supply e.g. negative to illuminate the lamp.
discharged test batteries will cause code 90 to be 6. Measure the resistance of the relevant lamp wire
displayed.
Modular Section 10.0 Issue 1.0 June 1998
MODULAR
to battery negative and vehicle chassis to confirm 10.11 MODULATOR SOLENOIDS
the short.
Codes 61 and 67 indicate that the solenoid or its
No Lamp Illumination cable is open circuited.
1. Check the lamp bulb and holder first. 1. Disconnect the solenoid cable at its connector
2. Connect a test lamp temporarily across the and measure the resistance.
lamp terminals in the junction box, and cycle the 2. The resistance should be between 12 ohms and
system. 20 ohms.
3. The test lamp will operate correctly if the fault
lies downstream of the junction box. i.e. between Codes 71 and 77 indicate that a solenoid or its
the trailer lamp and junction box. cable is short circuited.
If the lamp sequence is incorrect the fault lies
upstream of the junction box towards the ECU. 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
10.10 WHEEL SPEED SENSING solenoid. Measure the resistance of the solenoids
with a multimeter at the modulator. Solenoid
Codes 01 and 02 indicate that a wheel speed resistance should be 12 to 20 ohms.
sensor or its wiring is short or open circuit. 2. Disconnect the harness at the ECU and test at
1. Disconnect the relevant sensor connector at the solenoid connector between each wire and
the extension lead plug and measure the chassis with a 500 volt insulation tester. The
resistance between the 2 sockets in the connector insulation resistance must be greater than
housing. 10 megohms.
2. The ohmmeter reading should be between
980 ohms and 2.35 kohms. Note:If an unlisted diagnostic code is displayed on
3. The extension cable between the controller and the DDU, then the ABS ECU is faulty and must be
wheel has an in line connector. If an open circuit changed.
is measured check that the connector is correctly
assembled. NOTE: Wherever possible alternative
4. Disconnect the harness from the ECU and components may be substituted for existing ones
locate the appropriate pins for the cable to be during fault finding, if the substituted component
tested see Fig.4.7, Fig.4.8 and Fig.4.9 . eliminates the current diagnostic code then it may
5. Using a 500 volt insulation tester measure the be assumed that the component that was causing
insulation resistance between each sensor wire the code to be displayed is at fault.
and chassis. The insulation resistance must be If the code cannot be eliminated then the ABS ECU
more than 10 megohms. is at fault.

Codes 11 and 12 indicate that the output of a DIAGNOSTIC CODES.

wheel speed sensor is insufficient. The most likely Diagnostic codes are listed on the following pages
reason for this is that the sensor to exciter gap is and are separated into groups covering numeric
too great. Adjust the sensor as detailed in section codes, and alpha numeric codes, these are
3.4. followed by the configuration codes which will be
seen at power up of the ABS ECU.
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).

Moduar Section 10.0 Issue 1.0 June 1998

MODULAR
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 No supply on ignition switched line.

Possible causes:
Fuse blown.
DDU / INFO CENTRE or cable fault.Open circuit B -

SENSOR BAR Bar displayed = Sensor output O.K.

Bar not displayed = Sensor output too low

00 System is O.K. vehicle is moving

01 1A Sensor/wiring open or short circuit
02 1B Sensor/wiring open or short circuit
03 2A Sensor/wiring open or short circuit
04 2B Sensor/wiring open or short circuit
05 3A Sensor/wiring open or short circuit
06 3B Sensor/wiring open or short circuit
07 System is O.K. vehicle is stationary
08 Retarder / Wiring open circuit
09 Retarder / Wiring short circuit
OA Reset to ride / Wiring open circuit
OC Reset to ride / Wiring short circuit
OE Warning lamp circuit fault

LOW SENSOR OUTPUT GROUP

11 1A Sensor system fault

12 1B Sensor system fault
13 2A Sensor system fault
14 2B Sensor system fault
15 3A Sensor system fault
16 3B Sensor system fault
Possible causes:
Sensor worn, maladjusted sensor, wiring open or short
circuit.

20 Incorrect exciter type.

Possible causes:
Exciter tooth count difrent each side of axle.

INTERMITTENT LOW SENSOR OUTPUT GROUP

21 1A Sensor system fault

22 1B Sensor system fault
23 2A Sensor system fault
24 2B Sensor system fault
25 3A Sensor system fault
26 3B Sensor system fault
Possible causes:
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

ONE WHEEL WITH SLOW RECOVERY GROUP

40 Sensor wiring crossed across an axle

41 Slow recovery of one wheel of red channel
42 Slow recovery of one wheel of blue channel
43 Slow recovery of one wheel of yellow channel
Possible causes:
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
77 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 B+ 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

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

C0 2S/1M 1A, 1B Red

C1 2S/2M 2A, 2B Blue, Yellow
C2 4S/2M 2A, 2B, 3A, 3B Blue, Yellow
C3 4S/2M 2 or 3 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
11.0 DIAGNOSTIC UTILITIES Supplied with the VDS software package, are
sample spreadsheet templates that show
11.1 PC Interface Kit examples of information that can be collected and
stored in your VDS system.
The PC interface Kit is comprised of the Interface You can also create your own templates and
1 Pod, together with its connecting cables and a macros that will enable you to store information
transit case. The kit permits the connection of the specific to your business.
diagnostic port of the ABS controller to a serial
port on a PC. Full details of the VDS package are available in a
The pod is provided with three LEDs to confirm separate publication.
correct functioning of the units as follows:
11.3 End-of-Line Test (EOLT)
Red: To indicate that 24V Power is connected. EOLT offers the ability to execute tests on all of the
Modular and Modal ABS products. This is achieved
Yellow: To indicate data is being transmitted by by collection and storing two types of data from the
the PC. ABS system. The first type is test data recorded
by the ABS system, example wheel speeds as
Green: To indicate data is being transmitted by measured on a rolling road and system
the ABS ECU. configuration data. The second type is data entered
by the user.
INTERFACE 1 Pod
Full details of the EOLT package are available in a
seperate publication.
POWER

PC
ECU 11.4 Minimum system specifications:
The minimum PC or Laptop specification to run
either of the diagnostic packages is as follows:
connection to
ABS ECU connection to PC MS-DOS :
via the PC-AT or compatible.
diagnostic connector RAM - 640K
Fig 11.1 INTERFACE 1 POD Hard Drive - 1Mb Free
Monitor - EGA / VGA
This kit provides the interface required by the two
communication packages: Vehicle Data System MS Windows 3.11 or 3.1:
(VDS) and End-of-Line Test (EOLT). Processor - 286 or above
RAM - 4 Megabytes (8 recommended)
11.2 Vehicle Data System (VDS) Hard Drive - 20 Megabytes
VDS offers the ability to capture operational data Monitor - EGA / VGA
from the ABS ECU and to store it on a PC. It is
then possible to manipulate the data using MS Windows 95:
common PC spreadsheets. Processor - 486 or above
The data stored in the ECU is divided into two RAM - 8 Megabytes
sections. The first section is data recorded by the (16 recommended)
ABS ECU during trailer highway operation and Hard Drive - 20 Megabytes
includes ABS system status and vehicle mileage. Monitor - EGA / VGA
The second is information created by the user for
example service and maintenance records, such In addition to the above, a 3.5" diskette drive is
as information related to the treatment of specific required for software installation and a vacant serial
loads, tyre wear statistics or other details that port will be required to connect to the interface 1
would be useful to your business. pod.
This data is stored inside the ABS ECU and will
remain intact even after electrical power is
removed from the trailer.
MODULAR
12.0 SYSTEM WIRING DIAGRAMS 4.To maintain system reliability wiring repairs
must be of a high standard. The ECU relies upon
12.1 WIRING REPAIRS receiving low voltage signals from the sensors via
1.Before undertaking maintenance or repairs on a cables and connectors which should offer minimal
the MODULAR ABS system it is necessary to electrical resistance. It is particularly important
understand the system configuration of the vehicle therefore that the recommended cable, connectors
being worked upon. (see section 8.0) and tools are used to ensure as low a resistance
as possible. All electrical connections must be
2.First read section 8.0 configurations and made as shown in the relevant wiring diagrams.
determine the wiring diagram to suit your vehicle.
IMPORTANT: FAILURE TO OBSERVE THESE
3.Proceed with maintenance and repairs RECOMMENDATIONS MAY LEAD TO A
accordingly using the appropriate wiring diagram. SYSTEM MALFUNCTION.

Modular Section 12.0 Issue 1.0 June 1998

MODULAR
MODULAR 1 UPGRADE
5 1A

3
8 2

1
ISO 1185
(24N)

7 7-1
6
4
ISO 7638
3

ISO 3731 1B
(24S)
9

MODULAR 1 UPGRADE ABS

IDENT COMPONENT PART No. QTY
No.
1 ECU 364 279 002 1
2 MODULATOR - 6 Port Assembly 364 115 XXX 1
3 Sensor Assembly 364 094 XXX 2
4 Main Loom assembly - Full function 364 359 XXX 1
5 ABS Label 028 5108 09 1
6 Diagnostic Label 028 5189 09 1

COMPONENT VARIATIONS
IDENT COMPONENT PART No. QTY
No.
7 Power cable - ISO 7638 Socket 364 357 XXX 1
Un-Fused
7-1 Power cable - ISO 7638 Socket 364 362 XXX 1
Fused
8 ISO 1185 (24N) Cable assembly 364 370 XXX 1
PVC
9 ISO 3731 (24S) Cable assembly 364 373 XXX 1
PVC

Fig 12.1 MODULAR 1 UPGRADE WIRING VARIATIONS FOR SEMI TRAILER AND CENTRE AXLE.
Modular Section 12.0 Issue 1.0 June 1998
MODULAR

ABS MODULATOR
CONNECTOR
VIEWED ON WIRING RIGHT
SIDE OF CONNECTOR SENSOR
COMMON

HOLD
DUMP

RD 1A
2 CORE
3 CORE CABLE
CABLE 0.75mm²

6
13
ISO 7638 14
FUSE 5 CORE 5 CORE
ABS 15
CABLE CABLE 7
2x 4.0mm²
1 B+P PURPLE 7 1
2 B+IGN RED 6 2
3 5 B-P YELLOW 4 8
4 CAB LAMP BLACK 5 9
B-P WHITE 3 16
7 CORE 3 CORE CABLE
CABLE ECU
ISO 1185
B- WHITE WHITE 2 17
(24N) 1 B+ RED RED 1 3
BLACK 3 10
4

FRONT 3 CORE CABLE

4
JUNCTION 11
5
BOX 18
YELLOW 123 4
BLACK
4 CORE 12
2 CORE CABLE 2 CORE
19
TRAILER CABLE 0.75mm² CABLE
MOUNTED MAIN
1mm² 0.75mm²
ABS LAMP LOOM
INFO 1B
CONNECTOR
CENTRE

LEFT
SENSOR
DDU

P.C. INTERFACE

LEGEND
N1 The wheel speed sensors will be fitted to one axle only.
N2 All wires are 1.5mm² unless specified.
N3 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.
N4 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

ABS MODULATOR
CONNECTOR
VIEWED ON WIRING RIGHT
SIDE OF CONNECTOR SENSOR
COMMON

HOLD
DUMP

RD 1A
2 CORE
3 CORE CABLE
CABLE 0.75mm²

6
13
ISO 7638 14
5 CORE 5 CORE
ABS 15
CABLE CABLE 7
2x 4.0mm²
1 B+P RED RD 1
2 B+IGN BLACK BK 2
3 5 B-P YELLOW YE 8
4 CAB LAMP WHITE W 9
B-P BROWN BN 16
7 CORE 3 CORE CABLE
CABLE ECU
ISO 1185
B- WHITE WHITE 2 17
(24N) 1 B+ RED RED 1 3
BLACK 3 10
4

FRONT 3 CORE CABLE

4
JUNCTION 11
5
BOX 18
YELLOW 123 4
BLACK
4 CORE 12
2 CORE CABLE 2 CORE
19
TRAILER CABLE 0.75mm² CABLE
MOUNTED MAIN
1mm² 0.75mm²
ABS LAMP LOOM
INFO 1B
CONNECTOR
CENTRE

LEFT
SENSOR
DDU

P.C. INTERFACE

LEGEND
N1 The wheel speed sensors will be fitted to one axle only.
N2 All wires are 1.5mm² unless specified.
N3 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.
N4 The maximum cable length between ISO 1185 (24N) connector and the
front junction box is 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
MODULAR
ABS MODULATOR
CONNECTOR
VIEWED ON WIRING
SIDE OF CONNECTOR RIGHT
SENSOR
COMMON

HOLD
DUMP

RD 1A 2 CORE
CABLE
0.75mm²
3 CORE
CABLE
6
13
14
5 CORE 15
5 CORE 7
CABLE
CABLE 2x 4.0mm²
WHITE
1 B-P BLACK BN 16
ISO 3731 2
YE 8
6 CAB LAMP BLACK
(24S) W 9
BK 2
B+P BROWN RD 1
BLACK
3 CORE CABLE ECU
B- WHITE WHITE 2 17
1 B+ RED RED 1 3
ISO 1185
(24N) BLACK 3 10
4
FRONT 3 CORE
7 CORE 4
JUNCTION CABLE 11
CABLE 5
BOX 18
123 4
YELLOW
BLACK
4 CORE
12
CABLE 19
2 CORE 0.75mm² 2 CORE
TRAILER
MOUNTED CABLE CABLE MAIN
INFO 0.75mm² LOOM
ABS LAMP 1mm²
CENTRE 1B
CONNECTOR

LEFT
SENSOR
DDU

P.C. INTERFACE

LEGEND
N1 The wheel speed sensors will be fitted to one axle only.
N2 All wires are 1.5mm² unless specified.
N3 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.
N4 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
MODULAR 1 PLUS
5
1A

3
8 2

1
ISO 1185
(24N)

7 7-1 4
6

ISO 7638
3

ISO 3731 1B
(24S)
9

MODULAR 1 PLUS ABS

IDENT COMPONENT PART No. QTY
No.
1 ECU 364 279 101 1
2 MODULATOR - 6 Port Assembly 364 115 XXX 1
3 Sensor Assembly 364 094 XXX 2
4 Main Loom assembly - Full Function 364 329 XXX 1
5 ABS Label 028 5108 09 1
6 Diagnostic Label 028 5189 09 1

COMPONENT VARIATIONS
IDENT COMPONENT PART No. QTY
No.
7 Power cable - ISO 7638 Socket 364 357 XXX 1
Un-Fused
7-1 Power cable - ISO 7638 Socket 364 362 XXX 1
Fused
8 ISO 1185 (24N) Cable assembly 364 370 XXX 1
PVC
9 ISO 3731 (24S) Cable assembly 364 373 XXX 1
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
ABS MODULATOR
CONNECTOR
VIEWED ON WIRING RIGHT
SUSPENSION SENSOR
CONTROLLER SIDE OF CONNECTOR
COMMON
HOLD DUMP

RD 1A
2 CORE
CABLE
0.75mm²
22
+ - 12
3 CORE
10
CABLE 1
4
24
14
ISO 7638
FUSE 5 CORE BLACK
ABS 27
CABLE BROWN
5 CORE CABLE
28
2 x 4.0mm²
21 B+P PURPLE 7 7
B+IGN RED 6 6
B-P YELLOW 4 16
3 5 CAB LAMP BLACK 5 17
4
B-P WHITE 3 26
7 CORE 3 CORE CABLE ECU
ISO 1185 CABLE
B- WHITE WHITE 2 25
(24N) 1 B+ RED RED 1 5
BLACK 3 15
4

FRONT 3 CORE CABLE

9
JUNCTION 19
8
BOX 18
YELLOW 123 4
BLACK
4 CORE 3
CABLE 23
2 CORE 13
TRAILER CABLE 0.75mm² 2
MOUNTED 1mm²
11
ABS LAMP 20
INFO 21
CENTRE 2 CORE
CABLE MAIN
0.75mm² LOOM
1B
CONNECTOR

DDU LEFT
SENSOR

P.C. INTERFACE

LEGEND
N1 The wheel speed sensors will be fitted to one axle only.
N2 All wires are 1.5mm² unless specified.
N3 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.
N4 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

ABS MODULATOR
CONNECTOR RIGHT
SUSPENSION VIEWED ON WIRING SENSOR
CONTROLLER SIDE OF CONNECTOR
(COLAS) COMMON
HOLD DUMP

RD 1A
2 CORE
CABLE
0.75mm²
22
+ - 12
3 CORE
10
CABLE 1
4
24
14
ISO 7638
5 CORE BLACK
ABS 27
CABLE BROWN
5 CORE CABLE
28
2x 4.0mm²
21 B+P RED RD 7
B+IGN BLACK BK 6
B-P YELLOW YE 16
3 5 CAB LAMP WHITE W 17
4
B-P BLACK BN 26
7 CORE 3 CORE CABLE ECU
ISO 1185 CABLE
B- WHITE WHITE 2 25
(24N) 1 B+ RED RED 1 5
BLACK 3 15
4

FRONT 3 CORE CABLE

9
JUNCTION 19
8
BOX 18
YELLOW 123 4
BLACK
4 CORE 3
CABLE 23
2 CORE 13
TRAILER CABLE 0.75mm² 2
MOUNTED 1mm²
11
ABS LAMP 20
INFO 21
CENTRE 2 CORE
CABLE MAIN
0.75mm² LOOM
1B
CONNECTOR

DDU LEFT
SENSOR

P.C. INTERFACE

LEGEND
N1 The wheel speed sensors will be fitted to one axle only.
N2 All wires are 1.5mm² unless specified.
N3 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.
N4 The maximum cable length between ISO 1185 (24N) connector and the
front junction box is 1metre.

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
MODULAR

ABS MODULATOR
CONNECTOR
VIEWED ON WIRING
SIDE OF CONNECTOR RIGHT
SUSPENSION COMMON SENSOR
CONTROLLER
(COLAS)
HOLD DUMP

RD 1A
2 CORE
CABLE
0.75mm² 22
12
+ - 3 CORE 10
CABLE 1
4
24
14

5 CORE BLACK 27
BROWN 28
CABLE
WHITE
5 CORE CABLE 2x 4.0mm²
B-P BLACK BN 26
ISO 3731 2 1 YE 16
(24S) 6 CAB LAMP BLACK W 17
BK 6
B+P BROWN RD 7
BLACK
3 CORE CABLE ECU
B- WHITE WHITE 2 25
1 B+ RED RED 1 5
ISO 1185
BLACK 3 15
(24N)
4
FRONT 3 CORE 9
7 CORE 19
JUNCTION CABLE 8
CABLE 18
BOX 1 2 34
YELLOW
BLACK 4 CORE 3
23
CABLE 13
TRAILER 2 CORE 0.75mm² 2
MOUNTED CABLE
INFO 11

ABS LAMP 1mm² CENTRE 20

21
2 CORE
CABLE
0.75mm² MAIN
1B
LOOM
CONNECTOR

DDU
LEFT
SENSOR
P.C. INTERFACE

LEGEND
N1 The wheel speed sensors will be fitted to one axle only.
N2 All wires are 1.5mm² unless specified.
N3 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.
N4 The maximum cable length between ISO 1185 (24N) connector and the
front junction box is 1metre.

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
MODULAR 2 - 4S/2M 3
5 3A
2A
2

8
1
ISO 1185
(24N)

4
7 7-1
6
ISO 7638

ISO 3731 2B
(24S) 3B

3
9

MODULAR 2 System Variation

4S/2M - System as shown
2S/2M - Delete 2 sensors (3A/3B)

MODULAR 2
IDENT COMPONENT PART No. QTY
No.
1 ECU 364 279 201 1
2 MODULATOR - 3 Port Assembly-LH 364 263 001 1
3 Port Assembly-RH 364 263 011 1
3 Sensor Assembly 364 094 XXX 2
4 Main Loom assembly - 2S/2M 364 338 XXX 1
Main Loom assembly - 4S/2M 364 307 XXX 1
5 ABS Label 028 5108 09 1
6 Diagnostic Label 028 5189 09 1

COMPONENT VARIATIONS
IDENT COMPONENT PART No. QTY
No.
7 Power cable - ISO 7638 Socket 364 357 XXX 1
Un-Fused - PUR
7-1 Power cable - ISO 7638 Socket 364 362 XXX 1
Fused - PVC
8 ISO 1185 (24N) Cable assembly 364 358 XXX 1
PUR
9 ISO 3731 (24S) Cable assembly 364 373 XXX 1
PUR

Fig 12.9 MODULAR 2 - 4S/2M WIRING VARIATIONS FOR SEMI TRAILER AND CENTRE
Modular Section 12.0 Issue 1.0 June 1998
MODULAR
ABS MODULATOR
CONNECTOR
VIEWED ON WIRING
SUSPENSION RIGHT
SIDE OF CONNECTOR
CONTROLLER SENSORS
(COLAS) COMMON

HOLD DUMP

2 CORE
BU 3A 2A
CABLE
0.75mm²

10
+ - 3 CORE 1
22
CABLE 12
3
23
13
ISO 7638
FUSE 5 CORE BLACK
ABS 27
CABLE BROWN 28
5 CORE CABLE 2x 4.0mm²
2 1 B+P PURPLE 7 7
B+IGN RED 6 6
3 B-P YELLOW 4 16
45 CAB LAMP BLACK 5 17
B-P WHITE 3 26
3 CORE CABLE ECU
7 CORE CABLE
ISO 1185 25
B- WHITE WHITE 2
(24N) 1 B+ RED RED 1 5
BLACK 3 15
4
3 CORE CABLE
FRONT 9
19
JUNCTION 8
YELLOW BOX 123 4
18
BLACK 3 CORE CABLE
4 CORE 14
CABLE 24
2 CORE 4
TRAILER CABLE 0.75mm² 20
MOUNTED 1mm² YE 21
2 CORE
ABS LAMP 2
INFO COMMON CABLE 11
CENTRE 0.75mm²
HOLD MAIN
DUMP LOOM
3B 2B
CONNECTOR
ABS MODULATOR
CONNECTOR
VIEWED ON WIRING
SIDE OF CONNECTOR
DDU LEFT
SENSORS

P.C. INTERFACE

LEGEND
N1 The wheel speed sensors will be fitted to one axle only.
N2 All wires are 1.5mm² unless specified.
N3 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.
N4 The maximum cable length between ISO 1185 (24N) connector and the
front junction box is 1metre.

Fig 12.10 MODULAR 2 - 4S/2M WIRING DIAGRAM ISO 7638 (FUSED) AND ISO 1185 (24N) POWER
SUPPLY
Modular Section 12.0 Issue 1.0 June1998
MODULAR

ABS MODULATOR
CONNECTOR
VIEWED ON WIRING
RIGHT
SUSPENSION SIDE OF CONNECTOR
SENSORS
CONTROLLER
(COLAS) COMMON

HOLD DUMP

2 CORE
BU 3A 2A
CABLE
0.75mm²

10
+ - 3 CORE 1
22
CABLE 12
3
23
13
ISO 7638
5 CORE BLACK
ABS 27
CABLE BROWN 28
5 CORE CABLE 2x 4.0mm²
2 1 B+P RED RD 7
B+IGN BLACK BK 6
3 B-P YELLOW YE 16
45 CAB LAMP WHITE W 17
B-P BROWN BN 26
3 CORE CABLE ECU
7 CORE CABLE
ISO 1185 25
B- WHITE WHITE 2
(24N) 1 B+ RED RED 1 5
BLACK 3 15
4
3 CORE CABLE
FRONT 9
19
JUNCTION 8
YELLOW BOX 123 4
18
BLACK 3 CORE CABLE
4 CORE 14
CABLE 24
2 CORE 4
TRAILER CABLE 0.75mm² 20
MOUNTED 1mm² YE 21
2 CORE
ABS LAMP 2
INFO COMMON CABLE 11
CENTRE 0.75mm²
HOLD MAIN
DUMP LOOM
3B 2B
CONNECTOR
ABS MODULATOR
CONNECTOR
VIEWED ON WIRING
SIDE OF CONNECTOR
DDU LEFT
SENSORS

P.C. INTERFACE

LEGEND
N1 The wheel speed sensors will be fitted to one axle only.
N2 All wires are 1.5mm² unless specified.
N3 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.
N4 The maximum cable length between ISO 1185 (24N) connector and the
front junction box is 1metre.

Fig 12.11 MODULAR 2 - 4S/2M WIRING DIAGRAM ISO 7638 (UNFUSED) AND ISO 1185 (24N) POWER
SUPPLY
Modular Section 12.0 Issue 1.0 June 1998
MODULAR
ABS MODULATOR
CONNECTOR
VIEWED ON WIRING
SIDE OF CONNECTOR
RIGHT
SUSPENSION COMMON DUMP SENSORS
CONTROLLER
(COLAS)
HOLD

BU 3A 2A
2 CORE CABLE
0.75mm²

10
1
+ -
22
3 CORE 12
CABLE 3
23
13

5 CORE BLACK 27
BROWN 28
CABLE
WHITE
5 CORE CABLE 2x 4.0mm²
ISO 3731 2 1 B-P BLACK BN 26
YE 16
(24S) 6 CAB LAMP BLACK W 17
BK 6
B+P BROWN RD 7
BLACK
3 CORE CABLE ECU
B- WHITE WHITE 2 25
ISO 1185 1 B+ RED RED 1 5
(24N) BLACK 3 15
4
4 CORE CABLE 0.75mm²
FRONT 3 CORE 9
7 CORE 19
JUNCTION CABLE
CABLE 8
18
BOX 1 234
YELLOW 3 CORE CABLE
BLACK 14
24
4
TRAILER 2 CORE 20
MOUNTED CABLE INFO COMMON
YE 21

ABS LAMP 1mm² 2

CENTRE 11

MAIN LOOM
HOLD
DUMP CONNECTOR
3B 2B 2 CORE
CABLE
0.75mm²

DDU
LEFT
SENSORS
P.C. INTERFACE ABS MODULATOR
CONNECTOR
VIEWED ON WIRING
SIDE OF CONNECTOR

LEGEND
N1 The wheel speed sensors will be fitted to one axle only.
N2 All wires are 1.5mm² unless specified.
N3 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.
N4 The maximum cable length between ISO 1185 (24N) connector and the
front junction box is 1metre.

Fig 12.12 MODULAR 2 - 4S/2M WIRING DIAGRAM ISO 3731 (24S) AND ISO 1185 (24N) POWER
Modular Section 12.0 Issue 1.0 June1998
MODULAR

ISO 7638
TO ECU

EXISTING JUNCTION BOX

3 CORE 7 CORE 24V RELAY
CABLE CABLE
1.5mm² YE 30
85 86
1 2.0mm² W 87A
ISO 3731 2
1.0mm² BK
6 1.0mm² BN W 87
(24S)
RD BN BN
EXISTING
7 CORE
CABLE
1 W
ISO 1185 DIODE
(24N) RD 50V/3A
4
W
RD
YE BK TO ECU
BK
TRAILER 2 CORE
CABLE EXISTING
MOUNTED 1.0mm²
RD 7 CORE
ABS CABLE
LAMP
(GREEN)

Key

BK = Black
BN = Brown
RD = Red
YE = Yellow
W = White

87A
30

87
4
ISO 1185 86
(24N) 1
85 TRAILER
MOUNTED
6 ABS LAMP
(GREEN)
ISO 3731 2 B+ STOPLAMP
(24S)
1 LAMP
TO ECU
B-

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 13.7 WHEEL BEARINGS
Incorrect adjustment may reduce sensor output
13.1 THE EXCITER sufficiently to put the ABS warning lamp on above
6 mph (10 km/h). When refitting hubs, pull the hub
Refer to section 2.0
onto the stub axle using the bearing centre nut,
this will avoid rocking the hub and so eliminate
13.2 THE SENSOR
any possibility of accidentally knocking the sensor
Refer to section 3.0.
out of adjustment.
13.3 THE ELECTRONIC CONTROL UNIT
13.8 WELDING
The ECU requires no routine maintenance.
It is essential that the battery is disconnected or
the master switch turned off during electric
13.4 THE MODULATOR
welding. Disconnect the wiring between the
Refer to section 5.0.
tractor and the trailer.
13.5 BRAKE SERVICING
13.9 ROLLER BRAKE TESTING
Poor brake maintenance will affect the ABS
Roller brake testing is not affected by Haldex ABS
system performance. Pay particular attention to
and may be undertaken in the normal manner.
seized cam shafts, expander assemblies, shoe
return springs, oval drums and correct brake
13.10 ROAD SPRING REPLACEMENT
adjustment. When removing shoe assemblies
Do not cut the sensor cable when changing a road
avoid damaging the exciter, the sensor and its
spring. Always cut the cable ties around the ‘U’
housing or cable. Always ensure that the sensor
bolts and then refit new cable ties after the re-
is correctly reset, after brake shoe replacement
placement spring has been installed. Take care
and prior to re-fitting the brake drum and wheel
not to damage the sensor cable and ensure that
assemblies. (See section 3.4).
when it is refitted it is not routed in such a manner
as to place it under undue tensile loading.
13.6 BRAKE PIPING
When refitting cable ties place them at
Before undertaking maintenance or repairs of a
approximately 150mm apart and do not
MODULAR ABS, it is necessary to understand
excessively overtighten them, especially along
the configuration because pipework will vary from
brake hose runs, as this may cause damage to
one configuration to another (See section 8.0).
the cable conductors. Remember that when the
Ensure that before stripping out pipework from
brakes are applied, the brake hose will expand
modulator(s) and brake chambers that they are
and thus tighten the cable tie, causing excessive
clearly marked for replacement into the same
shearing forces to be imparted to the cable.
ports from which they were removed.
13.11 MAINTENANCE OF AIR SYSTEMS
FAILURE TO OBSERVE THE CORRECT
Piping should be checked at regular intervals for
PIPING CONNECTIONS AS IN THE ORIGINAL
damage or restrictions e.g. pinched or kinked.
INSTALLATION WILL RESULT IN POOR
Ensure that the air reservoirs are regularly
BRAKE AND ABS PERFORMANCE, WHICH
drained as recommended by the vehicle
MAY CAUSE THE ABS SYSTEM TO SWITCH
manufacturer.
OFF (Fault codes group 41, 42 or 43 see section
No liquids should be introduced into the air
8.4).
system except for anti-freeze compounds
approved by the vehicle manufacturer.
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.

Modular Section 13.0 Issue 1.0 June 1998

MODULAR
13.12 ROUTINE MAINTENANCE SCHEDULE

Time or mileage Component Operation Section

(whichever occurs first) Number

When hubs are Exciter Check for damage 2.0

removed
Sensor Check for wear
clean and re-adjust 3.0

Every 3 months Complete Perform system 1.2

or 25,000 miles system check out and air 5.6 + 5.7
(40,000 km) leakage check Fig.8.6 to 8.8
as applicable

Annually or every Complete Perform system 1.2

(100,000 miles system check out and 5.6 + 5.7
(160,000 km) air leakage check. Fig. 8.6 to 8.8
Check wiring and piping as applicable
security and integrity

Sensor Check for wear

clean and re-adjust 3.0

Every five years Modulator Replace 5.0

500,000 miles and Solenoid
(800,000 km)

Fig 13.1 RECOMMENDED MAINTENANCE SCHEDULE

Modular Section 13.0 Issue 1.0 June 1998

MODULAR
14.0 FIELD SERVICE INFORMATION Crane Fruehauf service guide.

14.1 SERVICE INFORMATION 14.5 SERVICE EQUIPMENT

ln the event of requiring further assistance your 1. Available from all Haldex Brake Products Ltd
local area Installation or Service centre will be installation, service, and parts centres listed on
able to provide valuable help. the previous pages.
A list of these centres is to be found in Sections
14.7 to 14.9. A more comprehensive guide, which 2. MULTIMETER
includes service agencies throughout Mainland METRIX MX570
Europe is available from
Haldex Brake Products Ltd at the address in 3. TEST SWITCH BOX
section 15.6. May be used as an alternative to a towing vehicle
as a power switching facility. The switch box is
14.2 TELEPHONE SUPPORT not supplied by Haldex but can be constructed
Haldex Brake Products Ltd provide in depth easily using the circuit diagram Fig 10.1.
technical assistance and advice via the Redditch
Head office, when telephoning please ask for 4. SUNDRY ITEMS
Technical Service Dept. Trolley Jack
Telephone: 01527 499 600 Axle stands
Fax: 01527 499 576 8mm Hexagonal key spanner
5mm Hexagonal key spanner
14.3 ENGINEER'S CALLS 3mm Hexagonal key spanner
Should it be necessary arrangements can be 2 X Male blade terminals (6.35mm)
made for a Haldex Brake Products Ltd Field 500 Volt insulation tester
Service Engineer to provide on site assistance at
a nominal charge. Contact details are as 14.2 14.6 SERVICE REPLACEMENT PARTS
above. Service replacement parts are available from all
agents listed from section 14.7 through to
14.4 AGENCY SUPPORT AND DEFINITIONS section 14.8 or in the case of International
Haldex Brake Products Ltd employ the services of Operations from the offices listed in section 14.9.
agencies throughout the UK to act on their behalf
in providing localised service to customers using In order to assist you in determining the
Haldex ABS. These agencies fall into four appropriate replacement component required, a
categories as follows: selection of common spares is shown in the
following listing.
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 a service 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).

TRAILER PARTS 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
Modular Section 14.0 Issue 1.0 June 1998
MODULAR
SERVICE PARTS

DESCRIPTION PART NUMBER VIEW

Electronic Control Unit

MODULAR 1 Upgrade ECU - 364 279 002 950 364 801
MODULAR 1 Plus ECU - 364 279 101 950 364 802
MODULAR 2 ECU - 364 279 201 950 364 803
MODULAR 2 ADR ECU - 364 279 202 950 364 804

Modulator valve Assembly

6 Port - 364 115 021 950 364 047
3 Port - 364 263 001 - RH 950 364 806
3 Port - 364 263 011 - LH 950 364 807

Manifold - for 2S-4S/2M systems 950 364 075

ECU Loom Assembly

MODULAR 1 Upgrade - 2S/1M 950 364 417

c/w 4m Sensor ext. cables

MODULAR 1 Plus - 2S/1M 950 364 418

c/w 4m Sensor ext. cables and
Reset to Ride

MODULAR 2 - 2S/2M or 4S/2M 950 364 419

c/w 4m + 6m Sensor ext. cables
and Reset to Ride

ISO 7638 Socket Kit

Green cover - c/w Fuse 950 364 072
Black cover - w/o Fuse, crimp pins 950 364 402
Red cover - w/o Fuse, screw pins 950 364 420

Replacement fuse kit for fused 950 364 401

ISO 7638

Modular Section 14.0 Issue 1.0 June 1998

MODULAR

DESCRIPTION PART NUMBER VIEW

ISO 7638 Socket and cable Assy.

Fused - L = 12m - PVC 950 364 421
Unfused - L = 12m - PUR 950 364 422

ISO 7638 Socket / cable +

seprate connector
Fused - L = 12m - PVC 950 364 423
Unfused - L = 12m - PUR 950 364 424
+

L
ISO 7638 Plug and cable Assy.
L = 12m - PVC 950 364 429

ISO 1185 (24N) Cable Assemsbly

For MODULAR 1 Upgrade and Plus
L = 12m - PVC 950 364 425
For MODULAR 2
L = 12m - PUR 950 364 426

ISO 3731 (24S) Cable Assemsbly

(All systems)
L = 12m - PVC 950 364 427
L = 12m - PUR 950 364 428

Green Warning Lamp 950 364 710

Bulb - (24v - 5w) Double pole 950 364 711

ABS Label 950 364 702

Diagnostic Connector Label 028 5189 09

Modular Section 14.0 Issue 1.0 June 1998

MODULAR

DESCRIPTION PART NUMBER VIEW

Exciter
ROR TM 100 Tooth 018 5003 09
80 Tooth 018 5004 09
ROR TE 100 Tooth 018 5005 09
BPW-9T 100 Tooth 950 364 606
BPW-10T 100 Tooth 950 364 607

Sensor Kit - Angled 950 364 503

(inc. retaining clip)
Sensor Kit - Straight 950 364 506
(inc. retaining clip)

Sensor extension cable repair kit 950 364 507

(6.0m cable)

Diagnostic Display Unit (DDU) 905 027 001

c/w case and guide
2m Cable only 003 8467 09
24m Cable only 003 8433 09

Case only 042 5074 09

INFO Centre
1.2m Cable 364 317 001
0.4m Cable 364 317 011
1.2m Cable - ADR Version 364 385 001
0.4m Cable - ADR Version 364 385 011

Vehicle Data System Kit

c/w Instruction Manual 950 364 812
w/o Instruction Manual 950 364 814
VDS

'End-of-Line' Test Kit

c/w Instruction Manual 950 364 813
w/o Instruction Manual 950 364 815
EOLT

Modular Section 14.0 Issue 1.0 June 1998

MODULAR
14.7 SERVICE CENTRES

Antilock Brake Systems Ltd MacKenzies (Cambuslang) Ltd Truck Services of Grimsby
Sutton Coldfield Glasgow Grimsby
West Midlands Tel: 0141 641 6419504 Tel: 01472 362929
Tel: 0121 354 2856
H & F Moir Frank Tucker (Commercial) Ltd
B & T Services Aberdeen Exeter
Honeybourne Tel: 01224 790411 Tel: 01392 833030
Tel: 01386 841021
Montracon Trailers Ltd Woodwards S V S
H. Bowers Ltd Newtownabbey St Hellens
Stoke-on-Trent Tel: 01232 848274 Tel: 01744 20266
Tel: 01782 599990
Noden Truck Centre
Button Repairs & Tpt. Services Rugby
Ipswich Tel: 01788 579535
Tel: 01473 612750
Prolek P.B. Auto Electrics
Cahil Motor Engineering Mansfield
Newtownabby Tel: 01623 659311
Tel: 0232 853094
Ring Road Garage Ltd
Chassis Developments Ltd Buckingham
Leighton Buzzard Tel: 01280 814741
Tel: 01525 374151
Ripon Auto Electrics
Cumbria Auto Electrics Ltd Ripon
Carlisle Tel: 01765 602253
Tel: 0228 31707
Scotmech Trucks Ltd
CVBS Ltd Aberdeen
Brierley Hill Tel: 01224 898844
West Midlands Dundee
Tel: 0403 464 765 Tel: 01382 451416

Dennison Commercial Ltd G.Stout Lube Services

Ballyclare Midlothian
Tel: 019 603 52827 Tel: 01968 673247

Hi-Power Tachograph (Chester) Ltd

Tallagh Ellesmere Port
Tel: 0001 525899 Tel: 0151 3552101

Husk (UK) Ltd Tanner Tachograph Ltd

Dover Cardiff
Tel: 0304 831222 Tel: 01222 225580

Longfield Road Motors Ltd Tramec

Newcastle-upon-Tyne Bristol
Tel: 0191 2687648 Tel: 01179 822799

Lucas Services UK Ltd

Southampton
Tel: 01703 777111

Modular Section 14.0 Issue 1.0 June 1998

MODULAR
14.8 PARTS DISTRIBUTORS

ABS Burton Ltd D B Wilson Ltd Fleetweel plc

Burton on Trent Tel: 01283 568037 Glasgow Tel: 0141 6470161 Cardiff Tel: 0122 378191
Aldridge Tel: 01922 455751 Newport Tel: 01633 841645
Digraph Trans Supplies Ltd Swansea Tel: 01792 775111
All Spares Ltd Awkworth Tel: 01602 322195 Tiverton Tel: 01884 258797
Bridgend Tel: 01656 663163 Doncaster Tel: 01302 726636 Bristol Tel: 0117 982 6667
Bristol Tel: 0117 9381 144 Derby Tel: 01332 380300
Llanelli Tel: 01269 831177 Leicester Tel: 01530 245756 Frenco Service Replacements Ltd
Cullompton Tel: 01884 33810 Kidderminster Tel: 01562 754931
Hereford Tel: 01432 263438 Dingbro Ltd Banbury Tel: 01295 270711
Aberdeen Tel: 01224 682000 Oxford Tel: 01865 772161
Artic Trailer Ltd Elgin Tel: 01343 552888
Stirling Tel: 01786 816 005 Fraserbourgh Tel: 01346 51234 G.E. Middleton & Co Ltd
Falkirk Tel: 01324 613533 Inverness Tel: 01463 713133 Manchester Tel: 0161 872 0923
Peterhead Tel: 01779 476551
Artec Yorks Ltd Kirkalby Tel: 01592 650495 HGV Truck & Trailer Parts
Sheffield Tel: 01246 415777 Montrose Tel: 01674 675311 Boston Tel: 01205 365258
Liversedge Tel: 01924 401689 Perth Tel: 01738 443388
Hull Tel: 01482 581141 Arbroath Tel: 01241 876414 HB Commercials Ltd
Malton Tel: 01653 698009 Felixstowe Tel: 01394 675675
D.M.H. Warrington Ltd
Aghabridge Ltd Warrington Tel: 01925 650601 H & S Commercials Ltd
Kent Tel: 01634 2949 Crewe Tel: 01270 582288 Wakefield Tel: 01924 279294
Manchester Tel: 0161 832 4427 Bradford Tel: 01274 721630
Crane Fruehauf Ltd Castleford Tel: 01977 603606
For list of branches telephone E.M.S. Ltd
Dereham Tel: 01362 69535 Northampton Tel: 01604 702552 Hi-Way Components
Oldham Tel: 0161 652 0315
Commercial Clutch Services Ltd East Kent Components Ltd
Birmingham Tel: 0121 328 4060 Dover Tel: 01304 204697 Hydrair
Ashford Tel: 01233 631951 Blackburn Tel: 01254 889333
Commercial Equipment Ltd Faversham Tel: 01795 537228
Brierley Hill Tel: 01384 78151 L.C. Davis & Sons Ltd
Edmunds Walker Ltd London Tel: 0181 648 7717
CV Components For list of branches telephone
Inverness Tel: 01463 220232 Straford-on-Avon Tel: 01789 414545 LCP Engineering Co Ltd
Gillingham Tel: 01634 575501
CV Spares Ltd Fleet Factors Canterbury Tel: 01227 766001
Slough Tel: 01753 680404 Middlesbrough Tel: 01642 465141 Ashford Tel: 01233 623113
Swindon Tel: 01793 5133519 Stockton Tel: 01642 616333 Maidstone Tel: 0101622 672222
Carlisle Tel: 01288 810050 Purfleet Tel: 01708 891189
Congleton Motor Factors Ltd Hexham Tel: 01434 600789 Tunbridge Wells Tel: 01892 535455
Congleton Tel: 01260 280400 Sunderland Tel: 0191 567 1587 Brighton Tel: 01273 430730
Wirksworth Tel: 01629 823948 Gateshead Tel: 0191 490 0909 Dartford Tel: 01322 557825
Derby Tel: 01332 385901 Leeds Tel: 0113 277 7400 Gravesend Tel: 01474 320300
Stafford Tel: 01785 254634 Stallingborough Tel: 01482 227423
Buxton Tel: 01298 26588 Hull Tel: 01482 227423 Merlin Components (London) Ltd
Chesterfield Tel: 01246 261666 Birtley Tel: 0191 410 4437 Barking Tel: 0181 591 6908
Ashbourn Tel: 01335 346236 Manchester Tel: 0161 223 0367
Enfield Tel: 0181 804 3995

Modular Section 14.0 Issue 1.0 June 1998

MODULAR
14.8 PARTS DISTRIBUTORS

Multitruck Components Ltd Truckline

Milton Keynes Tel: 01908 274400 Bristol Tel: 0117 982 1321
Welwyn Garden City Eastleigh Tel: 01703 617666
Tel: 01707 393000 Manchester Tel: 0161 8725 457
Grays Tel: 01375 394949
N.E.T.S. Ltd Stockton Tel: 01642 607811
Netton-le-Hole Tel: 0191 526 3753 Doncaster Tel: 01977 671206
Stockton-on-Tees Tel: 01642 613514
Carlise Tel: 01228 511312 Woodheads / Partco Ltd
Morecombe Tel: 01524 841057 For list of branches telephone
Birmingham Tel: 0121 717 0071
A.J. Parsons & 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: 01280 817174

Port Brake Services Ltd

Ellesmere Port Tel: 0151 355 0226
Liverpool Tel: 0151 525 1558
Widnes 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: 01322 553330
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

Modular Section 14.0 Issue 1.0 June 1998

MODULAR
14.9 HALDEX - INTERNATIONAL
OFFICES

AUSTRIA SWEDEN
Graubremse Wien GesmbH Haldex Brake Products AB
Tel: INT + 43 1865 16 40 Tel: INT + 46 418 57700
Fax: INT + 43 1865 16 4027 Fax: INT + 46 418 24435

BELGIUM USA
Haldex NV Haldex Midland Corp.
Tel: INT + 32 2725 3707 Tel: INT + 1 816 891 2470
Fax: INT + 32 2752 4099 Fax: INT + 1 816 891 9447

BRAZIL
Haldex do Brasil Ind. e Com. Ltda
Tel: INT + 55 11 531 4159
Fax: INT + 55 11 531 9515

CHINA
Haldex International Trading
(Shanghai) Co. Ltd.
Tel: INT + 86 21 6289 4469
Fax: INT + 86 21 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
Tel: INT + 49 177 934 91 70
Fax: INT + 49 711 934 91 740

GREAT BRITAIN
Haldex Ltd.
Tel: INT + 44 1 325 310 110
Fax: INT + 44 7 325 311 834

POLAND
Haldex Sp Zo.o.
Tel: INT + 48 438 43 4614/4516
Fax: INT + 48 438 433 689

SOUTH KOREA
Haldex Korea Ltd.
Tel: INT + 82 2 749 3650
Fax: INT + 82 2 749 3652

SPAIN
Midland Grau S/A
Tel: INT + 34 9 3573 1030
Fax: INT + 34 9 3573 0728

Modular Section 14.0 Issue 1.0 June 1998

MODULAR
15.0 ADDITIONAL INFORMATION
15.5 Additional copies of this or other SERVICE
15.1 In the interests of product improvement and MANUALS are available at a nominal cost direct
development Haldex Brake Products Ltd reserve from Haldex Brake Products Ltd at the address
the right to make product and publication given below.
changes without prior notification to the customer.
15.6 Questions concerning product or product
15.2 Changes that are introduced may affect the information should be directed to Haldex Brake
way in which components are maintained, Products Ltd Technical Service Department who
serviced, or repaired. will be pleased to assist you with your enquiries
and who may be contacted by writing to:
15.3 Haldex Brake Products Ltd operate a bulletin
service to ensure that operators of Haldex Brake Haldex Brake Products Ltd,
Products equipment are informed of such Technical Service Dept.,
changes whenever necessary. Moons Moat Drive,
In this respect this section of the manual should Moon Moat North,
be used to file relevant product information. Redditch,
Worcestershire,
15.4 MODULAR ABS has several associated B98 9HA
products which are mentioned in the service
manual. Each product has its own literature in or by
which upgrades are issued with the improvement
of the product. This section of the manual should Telephone INT +44 1527 499 600
be used to file relevant product information to Fax INT +44 1527 499 576
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
manual if you have not already done so and
forward it to the address indicated.

Modular Section 15.0 Issue 1.0 June 1998