ABS MOD I TROUBLESHOOTING GUIDE

Before Getting Started

L20302 Rev. 11/03

No special diagnostic tools needed. For trailers built between 2/28/98 and 2/28/01.
This guide lists the most typical installations/problems only. Consult Haldex Brake Systems for anything not addressed here. Power is required at stop light circuit, pin 4, and air is needed to both the supply and service gladhands. Do NOT use a battery charger to power the ABS. A Volt/Ohm Meter is needed for some of the troubleshooting procedures. Before disconnecting anything, remove electrical power and air pressure from the system. The numbers in parentheses ( ) refer to the wiring diagram shown on the reverse side. Start Here Dont overlook the obvious. Check to make sure that you have power and that everything is connected properly. I. ABS Light Comes On And Goes Off While the trailer is sitting still only, there is also a valve blow down (air exhausts from ABS relay valve). This is normal and indicates that the ABS system is Ok. The ABS light will come on and go off. The valve blow down is an audio check of the solenoids (located on the top of the ABS relay valve). If the ABS is powered up when traveling above 6 mph, the ABS light will stay off unless there is a fault. II. ABS Light Never Comes On Or Is Very Dim This troubleshooting procedure requires that electrical power be connected. Older tractors power ABS through the stop light circuit and the ABS light will come on when the brakes are applied. 1. Verify that there is adequate power at the trailer 7-way, pin 4 (1). There should be 12-14 volts for test purposes. If there is no power then the tractor wiring or coiled power cable needs repair. If there is power at the 7-way, check for 10-14 volts at the power cord connector (2). If no power exists, then the trailer ABS power cord needs repair. (Most trailers have integral ABS power in the main trailer wiring.) 2. Check the bulb to verify that it is functional. If not functional, replace it. 3. Disconnect the ABS wire harness at the power cord. Check for continuity through the light wiring (3). The resistance should be 3-6 Ohms. If this is not the case, then the light wiring needs to be repaired. Check connections for excessive pin spread and/or corrosion. 4. If the problem remains, disconnect the ABS ECU connector (4). Check for bent pins, repair and test. Use a Volt/Ohm Meter to test continuity between ABS light and pins in ECU connector. See wiring diagram on reverse side for pin assignments. Replace harness if bad, and ECU if problem continues to exist (5). III. ABS Light Stays On When There Is Power To The ABS System This troubleshooting procedure requires that power be applied to the trailer for 30 seconds/off to verify. The ABS is powered through the auxiliary circuit whenever the key is in the on position and the stop light circuit with the brakes applied. NOTE: For some sensor faults, the trailer must be driven above 6 mph for the light to go off. 1. If the light stays on, the ABS may be wired incorrectly. One of the ABS light wires should be grounded. (The ABS light ground wire may attached to pin #C on the ABS power harnesses 5-pin connector.) The other ABS light wire is attached to pin #D on the ABS power harness 5-pin connector. See wiring diagram on reverse side. 2. Verify the voltage at the 7-way (pin #4) is 12-14 volts and that a valve blow down occurs when powering the ABS. If there is no blow down, then verify that air pressure was applied to the service brakes. If there is air pressure to the service brakes, then disconnect the solenoid connector (6) and check the resistance at the solenoid pins. Readings across the two bottom pins should be 7-9 Ohms. Readings between either bottom pin and the top in should be 3.5-4.5 Ohms. If resistance is okay, then check the female pins in the connector for excessive pin spread and/or corrosion. Repair and test. 3. If there IS a valve blow down, then a sensor is the most likely issue. Sensor gap could be too large. Try pushing the sensors in until they touch the exciter (7). If the problem remains, disconnect the sensor connectors from the sensors and measure the resistance between the two pins in the sensor connector housing (8). The reading for each sensor should be between ~980 and 2350 Ohms. Check for pin spread and/or corrosion also. The sensor should be replaced, if an issue is found. Measure the AC voltage at each sensor while rotating the wheel at a rate of ~1 revolution every two seconds. The reading should average >.200 Volts. If this is not the case, replace the sensor. If the problem persists, disconnect the ECU connector (4). Check for bent pins. Repair and retest. Use a Volt/Ohm Meter to test continuity between pins in valve connector and ABS ECU connector. See wiring diagram on reverse side for pin assignments. Replace harness if bad, and ECU if problem continues to exist (5).

IV. ABS Light Only Comes On Some Times

If the tractor has stoplight power only, and there is a fault, the light will only stay on with the brakes applied. 1. Intermittent problems are the most difficult to diagnose. The best place to start is at the speed sensors. Sensor gap could be too large. Try pushing in the sensors until they touch the exciter (7). Refer to Section III, Paragraph 3, on the reverse side, for further sensor related testing. Next check for a loose sensor and excess wheel end play. The sensor should fit tight in its mounting. If the sensor feels loose, replace the sensor clip. If wheel bearing end play is excessive, or if the wheel bearing is worn, the sensor can produce an intermittent signal and cause a fault. Repair as needed and retest. Other possible causes include tires that are significantly different in size or a damaged exciter. Inspect the exciter teeth (7) closely. If any damage is found, replace the exciter. 2. If no problem is found, then the rest of the electrical system needs to be inspected. The most common cause of ABS faults involve wires and connectors. This can include connectors not latched properly, bad splices, abrasion, spread or bent pins, pin corrosion, and wire strand breaks. Check for these issues at each connection (1,2,3,4,6 & 8). Look closely at all splices. Repair or replace as required.

V.

ABS Light Comes On When Powered Up, Goes Off Above 6 mph, But Wheels Lock-Up

This indicates that the ABS is functioning properly electrically. ABS requires properly operating brakes to do its job. Some things to consider. 1. MOD I is a 2 sensor, 1 modulator system. On a tandem or tri-axle trailer the ABS cant see what the non-sensed axles are doing (axles with no speed sensors). The ABS only knows what the sensed axle is doing. Because of this, the non-sensed axle may lock during braking. 2. A dragging service or parking brake, a pinched or kinked delivery hose, or excess use of 90 fittings, can all cause wheel lock. A perfectly functioning ABS system may not be able to overcome these issues. Examine the air installation and look for these types of problems. Replace any defective hardware and retest. 3. If both sensors have excessive gap or if both exciters are missing, the ABS system will ALWAYS assume that the vehicle is sitting still. There will be no indication of a fault. In this case, the ABS system can not respond to a locked wheel condition. Try pushing in the sensors until they touch the exciter (7). Inspect for missing exciters. 4. If the problem is still present, contact Haldex Technical Service at (800) 643-2374, Prompt #2.

3
B A D E C

Power Connector
Front View A: +12V Stop light B: +12V Ign perm C: Cab lamp D: Trailer Lamp E: -12V Ground Hand tighten collar

Make sure connector is locked into place (listen for two clicks when connecting wire harness)

5 6
Curb side 1A

FFABS Valve With ECU

6 1

Solenoid Connector
1 2 3

ECU Connector
Hold solenoid Trailer lamp
14 15 16 17 18 19

-12V Ground Cab lamp

7 8 9 10 1 2 3 4 5 6

1: Solenoid ground 2: Dump solenoid 3: Hold solenoid

Standard (SAE J560)

white blue red yel/wht
cab mount malfunction lamp

Dump solenoid Solenoid ground Open Open Diagnostic BSensor 1B Lo Wire harness Exciter ring Sensor Road side 1B Diagnostic connection

11 12

+12V Ign perm Diagnostic B+ +12V Stop light Open Diagnostic input Sensor 1A Hi

8
Power cord (see pin out below)

Diagnostic out Sensor 1B Hi Sensor 1A Lo

7-Way Connector

8 7

Sensor 1A Connector

1 Hi 2 Lo

1 Hi 2 Lo

ABS Light (Note: Light is mounted on side of trailer.)

Sensor 1B Connector

Haldex Commercial Vehicle Systems

North American Sales Division Haldex Brake Products Corporation 10707 N.W. Airworld Drive Kansas City, MO 64153-1215 Phone: (816) 891-2470 Fax: (816) 880-9766 North American Sales Division Haldex Limited 525 Southgate Drive, Unit 1 Guelph, Ontario CANADA N1G 3W6 Phone: (519) 826-7723 Fax: (519) 826-9497

L20302W US 11/03 WEB ONLY

www.haldex.com - www.hbsna.com