Diagnostic Display Unit OPERATOR'S GUIDE / / Redditch

Transcription

1 Diagnostic Display Unit OPERATOR'S GUIDE / / Redditch

2 CONTENTS Introduction Page The Diagnostic Display Unit Page ABS for Trucks DGX & DGX-I Page Using the DDU Page Diagnostic codes Interpretation Page DGX diagnostic code list Page DGX wiring 60 tooth system Page 6 DGX wiring 00 tooth system Page 7 DGX-I diagnostic code list Page 8 Introduction This handbook assists you in diagnosis of a range of Haldex ABS products, including DGX and DGX-I for Trucks, MODAL and MODULAR systems for Trailers, using a Diagnostic Display Unit (DDU). The Diagnostic Display Unit The DDU is a hand held instrument comprising, a liquid crystal display and micro computer housed in a shock resistant case, which when connected to a powered ABS diagnostic port, displays diagnostic codes, interpretation of which assists in rapid fault location. The DDU is provided with a push button for use with MODAL and MODULAR trailer systems, it is not used when diagnosing DGX systems or its derivatives. DGX-I wiring 60 tooth system Page 0 DGX-I wiring 00 tooth system Page ABS for Trailers Page MODAL and MODULAR MODAL Diagnostic memory Page MODULAR Diagnostic memory Page Supply switch box Page circuit diagram Initial diagnosis of ABS faults Page Using the DDU Page Reading stored codes Page Erasing fault codes from Page Memory Interpretation diagnostic codes Page Page Modulator Solenoids Page Configuration Codes Page 5 MODAL and MODULAR Diagnostic outlet socket location MODAL Page 6 MODULAR Page 7 Diagnostic code list Page 8 MODAL and MODULAR MODAL wiring diagram Page 0 6S/M system Diagnostic lead and positions output bars Fig. The Diagnostic Display Unit Push button for switching and recalling MODAL/MODULAR diagnostic codes positions Diagnostic code display MODAL + COLAS Page wiring diagram MODAL + Retarder Page wiring diagram MODAL wiring diagram Page S/M (V system) MODULAR Upgrade Page -6 wiring diagram MODULAR Plus Page 7-9 wiring diagram MODULAR wiring diagram Page 0- Additional codes applicable Page to all systems The DDU is supplied as standard with meter extension cable although there is an 8 meter option which is useful for mobile diagnostics on trailers. Spare or replacement cables are available for the following systems as follows:- DGX, DGX-I and MODAL m m MODULAR m m

3 Diagnosing DGX ABS ARNING: It is essential to observe normal safety procedure during diagnostic work. IMPORTANT It should be noted that there are specific differences between DGX and DGX-I systems especially with reference to diagnostic codes. Before attempting repair of either system the following action should be taken.. Determine the system fitted by reference to the electronic control unit identification label, which will refer to DGX or DGX-I.. hen repairing/servicing DGX-I systems familiarise yourself with the information applicable contained in the DGX-I section. Note: DGX and DGX-I use different code lists as shown in this guide. Using the DDU. Plug the DDU, into the diagnostic port (Fig.). This may be done with ignition switched on or off, BUT codes registered in the, disappear if the ignition is switched off, intermittent defects are best investigated by leaving the ignition on after detection (cab lamp lit), plug in the DDU to display the diagnostic code.. Switch ignition on if not already, and drive the vehicle above 6mph (0km/h).. Read the DDU display and consult the diagnostic code list for prescribed repair. Diagnostic Code Interpretation u ith vehicle stationary, no fault present, switch on ignition, the DDU displays '0.7' u Drive above 6mph (0km/h), the display changes to '0.0' u Bars appear for sensors with output, above the necessary minimum. u Stop the vehicle, the display reverts to '0.7'. If sensor bars flash, the sensor is incorrectly adjusted, or has an intermittent defect. ith the vehicle jacked up, spinning a wheel will cause sensor bar to appear if output is above the necessary minimum. Reference DDU codes in the diagnostic code list for prescribed repair. Diagnostic output port is normally panel mounted within m of position Fig. DGX Diagnostic outlet socket location

4 DGX Diagnostic Code List CODE DISPLAD BLANK DISPLA SENSOR BAR No supply on ignition switched line. Possible causes: Fuse blown. DDU or cable fault. Open circuit B - Bar displayed = output O.K. Bar not displayed = output too low 00 System is O.K. vehicle is moving 07 System is O.K. vehicle is stationary 08 Retarder relay coil or wiring open circuit 09 Retarder relay coil or wiring short circuit EE/EF Possible short circuit to B- on sensor S or S. LO SENSOR OUTPUT GROUP sensor system defect - axle sensor system defect - axle sensor system defect - axle sensor system defect - axle 5 sensor system defect - axle 6 sensor system defect - axle Possible causes: worn, maladjusted sensor, coil or wiring open or short circuit. INTERMITTENT LO SENSOR OUTPUT GROUP sensor system defect - axle sensor system defect - axle sensor system defect - axle sensor system defect - axle 5 sensor system defect - axle 6 sensor system defect - axle Possible causes: Loose sensor, connection, bracket or exciter. Damaged exciter. Maladjusted sensor or worn sensor cable insulation. ONE HEEL ITH SLO RECOVER GROUP sensor wheel defect - axle sensor wheel defect - axle sensor wheel defect - axle sensor wheel defect - axle 5 sensor wheel defect - axle 6 sensor wheel defect - axle Possible causes: Slow brake release, restricted piping, SPS valve defect. 60 High resistance in any SPS valve solenoid/wiring defect.

5 DGX Diagnostic Code List CODE DISPLAD OPEN CIRCUIT SPS VALVE SOLENOID OR SOLENOID IRING GROUP 6 dump solenoid circuit defect - axle 6 dump solenoid circuit defect - axle 6 dump solenoid circuit defect - axle 6 dump solenoid circuit defect - axle 65 dump solenoid circuit defect - axle 66 dump solenoid circuit defect - axle 67 Latch solenoid circuit defect - axle 68 Latch solenoid circuit defect - axle 69 Latch solenoid circuit defect - axle SHORT CIRCUIT ACROSS SPS VALVE SOLENOID OR SOLENOID IRING GROUP 7 dump solenoid circuit defect - axle 7 dump solenoid circuit defect - axle 7 dump solenoid circuit defect - axle 7 dump solenoid circuit defect - axle 75 dump solenoid circuit defect - axle 76 dump solenoid circuit defect - axle SPS VALVE SOLENOID IRING OR SOLENOID SHORT TO B+ GROUP 80 Poor insulation in any SPS valve solenoid or wiring fault 8 dump solenoid circuit defect - axle 8 dump solenoid circuit defect - axle 8 dump solenoid circuit defect - axle 8 dump solenoid circuit defect - axle 85 dump solenoid circuit defect - axle 86 dump solenoid circuit defect - axle 87 Latch solenoid circuit defect - axle 88 Latch solenoid circuit defect - axle 89 Latch solenoid circuit defect - axle SUPPL VOLTAGE GROUP 8E No supply on non-ignition switch circuit or fuse blown AN OTHER DISPLA - or DDU defect Note: If a DDU code is displayed and after following the recommended procedure no defect is found, the antilock control module () should be replaced 5

6 Front Front axle cab/ chassis interface Connector Rear axle cab/ chassis interface Rear hite Orange ellow common (B+) Black Orange hite ellow heel Latch Front Front axle valve Black Vehicle Interface 5A Continous rating a 85 0/5 86 Antilock warning lamp v 5w A Continous rating Diagnostic Output Connector Rear axle valve heel Rear Retarder Control Circuit To Direction Indicators Fuse Ignition Switch V Fig. DGX iring diagram - 60 Tooth Exciter Installation 6

7 Front Front axle cab/ chassis interface Connector Rear axle cab/ chassis interface Rear hite Orange ellow common (B+) Black Orange hite ellow heel Latch Front Front axle valve Black Vehicle Interface 5A Continous rating a 85 0/5 86 Antilock warning lamp v 5w A Continous rating Diagnostic Output Connector Rear axle valve heel Rear Retarder Control Circuit To Direction Indicators Fuse Ignition Switch V Fig. DGX iring diagram - 00 Tooth Exciter Installation 7

8 DGX-I Diagnostic Code List CODE DISPLAD BLANK DISPLA SENSOR BAR No supply on ignition switched line. Possible causes: Fuse blown. DDU or cable fault. Open circuit B - Bar displayed = output O.K. Bar not displayed = output too low 00 System is O.K. vehicle is moving 07 System is O.K. vehicle is stationary 08 Retarder relay coil or wiring open circuit 09 Retarder relay coil or wiring short circuit OE arning lamp relay coil/wiring open circuit OF arning lamp relay coil/wiring short circuit EE/EF Possible short circuit to B- on sensor S or S. LO SENSOR OUTPUT GROUP sensor system defect - axle sensor system defect - axle sensor system defect - axle sensor system defect - axle 5 sensor system defect - axle 6 sensor system defect - axle Possible causes: worn, maladjusted sensor, coil or wiring open or short circuit. INTERMITTENT LO SENSOR OUTPUT GROUP sensor system defect - axle sensor system defect - axle sensor system defect - axle sensor system defect - axle 5 sensor system defect - axle 6 sensor system defect - axle Possible causes: Loose sensor, connection, bracket or exciter. Damaged exciter. Maladjusted sensor or worn sensor cable insulation. ONE HEEL ITH SLO RECOVER GROUP sensor wheel defect - axle sensor wheel defect - axle sensor wheel defect - axle sensor wheel defect - axle 5 sensor wheel defect - axle 6 sensor wheel defect - axle Possible causes: Slow brake release, restricted piping, SPS valve defect. 60 High resistance in any SPS valve solenoid/wiring defect. 8

9 DGX-I Diagnostic Code List CODE DISPLAD OPEN CIRCUIT SPS VALVE SOLENOID OR SOLENOID IRING GROUP 6 dump solenoid circuit defect - axle 6 dump solenoid circuit defect - axle 6 dump solenoid circuit defect - axle 6 dump solenoid circuit defect - axle 65 dump solenoid circuit defect - axle 66 dump solenoid circuit defect - axle 67 Latch solenoid circuit defect - axle 68 Latch solenoid circuit defect - axle 69 Latch solenoid circuit defect - axle SHORT CIRCUIT ACROSS SPS VALVE SOLENOID OR SOLENOID IRING GROUP 7 dump solenoid circuit defect - axle 7 dump solenoid circuit defect - axle 7 dump solenoid circuit defect - axle 7 dump solenoid circuit defect - axle 75 dump solenoid circuit defect - axle 76 dump solenoid circuit defect - axle 77 Latch solenoid circuit defect - axle 78 Latch solenoid circuit defect - axle 79 Latch solenoid circuit defect - axle SPS VALVE SOLENOID IRING OR SOLENOID SHORT TO B+ GROUP 80 Poor insulation in any SPS valve solenoid or wiring fault 8 dump solenoid circuit defect - axle 8 dump solenoid circuit defect - axle 8 dump solenoid circuit defect - axle 8 dump solenoid circuit defect - axle 85 dump solenoid circuit defect - axle 86 dump solenoid circuit defect - axle 87 Latch solenoid circuit defect - axle 88 Latch solenoid circuit defect - axle 89 Latch solenoid circuit defect - axle SUPPL VOLTAGE GROUP 8E 8F No supply on non-ignition switch circuit or fuse blown B+ wiring shorted to valve solenoids. AN OTHER DISPLA - or DDU defect Note: If a DDU code is displayed and after following the recommended procedure no defect is found, the antilock control module () should be replaced 9

10 Front Front axle cab/ chassis interface Connector Rear axle cab/ chassis interface Rear Black Orange Front hite Orange ellow Front axle valve Black Vehicle Interface 5A Continous rating a 85 0/5 86 Antilock warning lamp v 5w A Continous rating Fuse hite ellow common (B+) heel Latch Diagnostic Output Connector Rear axle valve heel 87 87a 85 0/5 86 Rear Retarder Control Circuit To Direction Indicators Ignition Switch V Fig. 5 DGX-I iring diagram - 60 Tooth Exciter Installation 0

11 Front Front axle cab/ chassis interface Connector Rear axle cab/ chassis interface Rear Black Orange hite Orange ellow common (B+) hite ellow heel Latch Front Front axle valve Black Vehicle Interface 5A Continous rating a 85 0/5 86 Antilock warning lamp v 5w A Continous rating Diagnostic Output Connector /5 Rear axle valve heel 87a 86 Rear Retarder Control Circuit To Direction Indicators Fuse Ignition Switch V Fig. 6 DGX-I iring diagram - 00 Tooth Exciter Installation

12 Diagnosis of MODAL and MODULAR ABS MODAL Diagnostic Memory The (Electronic Control Unit) contains an erasable, permanent memory which records diagnostic codes automatically and displays them on an LED, known as the TODD (Total Onboard Diagnostic Display) housed in the. Information relating to the TODD is included in the full service manual, obtainable from Haldex Ltd. The codes may be recalled, displayed and erased using the DDU. The diagnosis of defects of an electrical electronic nature or those which cause poor anti-lock performance is achieved by reference to the diagnostic code displayed by the TODD or the DDU. MODULAR Diagnostic Memory The incorporates a diagnostic information output centre which provides information relevant to system configuration and diagnostic status. It is used for system diagnosis when a DDU is connected to the unit, at the ABS TEST diagnostic, enabling recovery of diagnostic codes. hen connected the DDU may also be used to test outputs from associated wheel sensors. Therefore it is possible to view the diagnostic code display from a remote position, such as alongside the vehicle or from the tractor unit cab when the vehicle is being driven. Equipment Required If the Truck is not available, a supply switch box (see Fig. 7) may be required for switching the various power supplies, when using the DDU. Note: A Truck may be used as an alternative to a supply switch box, but you should ensure that the electrical supplies and connections are in satisfactory condition. For V Installations referred to information in brackets B+ CIRCUIT BREAKER KLOCKNER MOELLER FAZL6- or R.S. 5-9 ARNING LAMP SITCH ISO 7 SITCH (B+P) ARNING LAMP V.8 (V 5) PIN PIN 6 PIN ISO 7 (S) CONNECTOR + 0- (9-6) VOLTS - ISO 768 (ISO 7570) SITCH (B+P) NOTE: AMMETER OR LIN MUST BE CONNECTED AT ALL TIMES LINK PIN 5 PIN PIN PIN ISO 768 (ISO 7570) ABS CONNECTOR ISO 85 (ISO 7) SITCH (B+I) AMMETER PIN B- PIN PIN ISO 85 -N (ISO 7 -N) CONNECTOR Fig. 7 Supply Switch Box Circuit

13 Initial diagnosis of ABS faults Perform the following tests.. Apply electrical power to the trailer via the "N" while observing the anti-lock warning lamp which should flash and then come on and stay on.. If the lamp fails to illuminate check the lamp bulb and electrical power supply.. If the lamp fails to flash but stays permanently illuminated check the diagnostic display codes including stored diagnostic codes using the procedure in described.. If () above is satisfactory drive the vehicle at above 6 m.p.h. (0 km/h). The anti-lock warning lamp should extinguish. If it does not there is a wheel speed sensing fault. Check the diagnostic display code. 5. To test for correct valve blow down, fully charge the air brake system, and turn off all electrical power to the trailer. Do not apply the foot brake, set the ignition the ignition off in the Truck, if a switch box power supply is being used switch the B+I and B+P switches off. 6. hen using a towing vehicle depress the foot brake then turn the ignition switch on. Alternatively when using a test power supply switch B+I on. There should be as many brief pulses of air as there are ABS modulators (ABS valves). 7. If the number of air pulses is incorrect check the diagnostic display code. Note that erroneous wiring of the modulator solenoid wiring will produce two air pulses on the affected modulator as the dump and hold solenoids are electrically identical but have different pneumatic functions. 8. hen a wheel is rotated, and electrical power is applied, all modulator blowdowns are inhibited while the wheel is turning. Using the DDU. Remove all electrical power from the trailer.. Connect the DDU cable to the trailer diagnostic output. See MODAL - Fig 8, MODULAR - Fig 9. Apply volts to the anti-lock system and observe the DDU display.. At power up 8.8 is displayed briefly to confirm LCD function, followed by a configuration code (see configuration codes), and then either 0.7 or a diagnostic code will be displayed constantly. Check that the configuration code agrees with the system wiring by confirming that the number of connected sensors and modulator solenoids i.e. C6 = 6s + Modulators (6S/M system). Note: Some codes confirm correct system function. i.e. 0.7 is a move off code requiring sensor outputs to be generated, 0.6 down to 0. inclusive are reserved for short or open circuit sensor defects. 5. Refer to diagnostic codes list to diagnose system malfunctions. 6. Remove all electrical power and then repair faults as necessary. 7. Clear the diagnostic memory as described below. Note: Codes which occur whilst the is powered up are logged in two memories. Any attempt to erase the permanent memory unless power has been removed since the fault occurred will be unsuccessful as the temporary memory will continuously rewrite 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 and refit the cover. 0. Restore electrical power and carry out the driver's checks for correct lamp sequence as described in ( and ) of initial ABS diagnosis above. Reading Stored Codes. Remove electrical power from the.. Connect the Diagnostic Display Unit to its on the trailer. See MODAL - Fig 8, MODULAR - Fig 9. Apply power to the.. Read the display on the DDU. This is the current code which may or may not refer to a fault 5. Press the switch on top of the DDU for approximately 5 seconds until the DDU display changes. 6. Release the switch. 7. The DDU displays the code last entered. 8. Press the switch again for approximately 5 seconds until the DDU display changes. This is the highest numerical fault code in memory. 9. Release the switch, and press again to display the next highest numerically recorded fault code. Continue this sequence to step through the fault code memory. 0. After five codes CA will be displayed. See point. (page ). Release the switch.

14 Erasing Fault Codes from Memory. The CA display is an invitation to erase the memory, pressing and holding the switch while it is displayed will cause the memory to be erased. The LCD will scan the codes as they are cleared.. If the switch is not pressed the next fault code in the stored list will be displayed.. At the end of the fault code list "CA" will be displayed again as a further invitation to erase all stored faults. Successful erasure of the fault codes will only be possible, if the fault causing the code to be logged in memory has been repaired. 5. hen all codes are cleared, release the button briefly, then press and hold. After 5 seconds the display will read "00" indicating that the memory is empty. Interpretation of Diagnostic Codes.. hen the vehicle is stationary and no fault is present the diagnostic display will be 07.. This display will change when the vehicle is driven at above 6 mph (0 km/h) and bars will appear in the display window for left and right sensors representing a sensor output which is above the necessary minimum.. The number of bars which appear should be the same as the number of wheels which have speed sensors fitted.. The (DDU) displays 00 as a code which indicates correct operation of the system, when vehicle speeds exceed 6mph (0km/h). 5. hen the vehicle stops the code returns to Flashing bars indicate that there are poorly adjusted sensors or loose sensor connections. 7. Spinning individual wheels with the trailer jacked up will cause the relevant bar to appear if the sensor output is above the minimum. 8. Codes other than those described above can be interpreted by using the diagnostic code table. s Codes 0 to 06 indicate that a wheel speed sensor or its wiring is short or open circuit.. Disconnect the relevant sensor at the extension lead plug and measure the resistance between the sockets in the housing.. The ohmmeter reading should be between 980 ohms and.5 kohms.. The extension cable between the controller and wheel has an in line. If an open circuit is measured check that the is correctly assembled.. Disconnect the harness from the and locate the appropriate pins for the cable to be tested, see the appropriate system wiring diagrams. 5. Using a 500 volt insulation tester measure the insulation resistance between each sensor wire and chassis. The insulation resistance must be more than 0 megohms. Codes to 6 indicate that the output of a wheel speed sensor is insufficient. The most likely reason for this is that the sensor to exciter gap is too great. Adjust the sensor. Codes to 6 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). Modulator Solenoids Codes 6 to 69 indicate that the solenoid or its cable is open circuit.. Disconnect the solenoid cable at its and measure the resistance.. The resistance should be between V systems - ohms and 0 ohms. V systems -.75 ohms and 6.5 ohms. Codes 7 to 79 indicate that a solenoid or its cable is short circuit. Codes 80 to 89 indicate that a solenoid or its cable has a short circuit to battery positive.. Disconnect the harness from the solenoid. Measure the resistance of the solenoids with a multimeter at the modulator. Solenoid resistance should be v systems - ohms and 0 ohms. v systems -.75 ohms and 6.5 ohms.. Disconnect the harness at the and test at the solenoid between each wire and chassis with a 500 volt insulation tester. The insulation resistance must be greater than 0 megohms. Code 90 indicates a voltage loss when a solenoid is energised and the voltage at the falls below 8 or 9 Volts.. Ensure that the electrical supply is satisfactory under full electrical load conditions, i.e. there are no high resistance connections present.. Establish if the voltage drop occurs when using each of the power sources on their own, ISO768, ISO7 (S), ISO85 (N).. Check for loose connections in the wiring from the source which produces the fault code. NOTE: An inadequate power supply e.g. discharged test batteries will cause code 90 to be displayed.

15 Code 9 indicates that when using the ISO 768 power source there is sufficient voltage coming from pin of the ISO 768 but the voltage coming from pin is low or absent.. Check for broken wiring or blown fuses on both the trailer and the towing vehicle or with the workshop power supply if used. The voltage measured on the which goes to ISO 768 pin should be between 8 Volts and Volts when the voltmeter negative lead is on the which goes to ISO 768 pin. Code 9 indicates that the power supply to the is above volts and action must be taken to reduce this over voltage.. Check the towing vehicle voltage regulator and alternator system or the voltage output from the test power supply in use.. The correct power supply connections to the supply pins as shown in the appropriate system wiring diagrams. MODAL Configuration Codes Figures in brackets indicate sensing is disabled when the axle is lifted. Code Function Axle s Modulators Lifted Used Used C0 S/M SA SB Red C S/M SA SB Blue,ellow C S/M SA SA SB SB Blue,ellow C S/M or (SA) SA SB (SB) Blue,ellow C S/M SA SA SB SB Blue,Red,ellow C5 S/M or SA (SA)(SB) SB Blue,(Red),ellow C6 6S/M SA SA SA SB SB SB Blue,Red,ellow C7 6S/M SA SA(SA)(SB)SB SB Blue,(Red),ellow C8 6S/M or (SA) SA SA SB SB (SB) Blue,Red,ellow C9 6S/M + or (SA)SA(SIA)(SIB)SB(SB) Blue,(Red),ellow s used by various MODAL configurations System S/M S/M S/M S/M 6S/M Used Red SA,SB Blue SA, ellow SB Blue SA,SA ellow SB,SB Red SA,SB+Blue SA, ellow SB Red SA,SB+Blue SA,SA ellow SB,SB Modulator Valves Used Red Blue, ellow Blue, ellow Red, Blue, ellow Red, Blue, ellow MODULAR Configuration Codes Figures in brackets indicate sensing is disabled when the axle is lifted. Code Function Axle s Modulators Lifted Used Used C0 S/M SA SB Red C S/M SA SB Blue,ellow C S/M SA SB SA SB Blue,ellow C S/M or SA SB (SA) (SB) Blue,ellow s used by various MODULAR configurations S/M S/M S/M System Used Red SA,SB Blue SA, ellow SB Blue SA,SA ellow SB,SB Modulator Valves Used Red Blue, ellow Blue, ellow 5

16 Note: faults in code groups to 6 will electronically 'trip' the lamp drive such that, after repair of an associated sensor, on powering the ABS system, the lamp will come on and stay on. To effect reset of the lamp drive and restore normal lamp function, you must now drive the vehicle >6mph (0km/hr) or spin the wheel with the ABS powered up. This generates a signal, confirming sensor function, and allows the microprocessor controlled lamp drive to reset. Gland box incorporating DDU socket located in underside of gland box DDU Plug locates in gland box outlet socket in base of gland box Fig. 8 MODAL Diagnostic outlet socket location 6

17 Preferred position of Diagnostic Main Loom assembly Diagnostic Chassis mounted DDU DDU Plug locates in loom assembly Diagnostic Fig. 9 MODULAR Diagnostic outlet socket location 7

18 MODAL and MODULAR Diagnostic Code List Note: If an unlisted diagnostic code is displayed, clear the memory and repeat the test procedure. should the code persist, consult HALDEX Technical Service on Tel: Refer to this section for diagnostic test procedures. A and B define left and right hand side of the vehicle. A comprehensive fault code list is shown in this section. CODE DISPLAD POSSIBLE CAUSE 00 Normal running i.e. no fault found 0 A or wiring open or short circuit 0 B or wiring open or short circuit 0 A or wiring open or short circuit 0 B or wiring open or short circuit 05 A or wiring open or short circuit 06 B or wiring open or short circuit Possible causes: loose, cable damaged, sensor faulty. 07 System is OK but all sensors have no output. Drive above 6 mph (0 km/h), sensor bars will appear if sensors are OK. 08 Retarder relay or wiring open circuit. 09 Retarder relay or wiring short circuit. LO SENSOR OUTPUT GROUP A, low output B, low output A, low output B, low output 5 A, low output 6 B, low output Possible causes: worn, sensor loose, maladjusted sensor, wiring open or short circuit, short across conductors in cable. EXCITER GROUP 0 Incorrect exciter type fitted. i.e. 80 tooth instead of 00 tooth or vice versa. INTERMITTENT LO SENSOR OUTPUT GROUP A, intermittent low output B, intermittent low output A, intermittent low output B, intermittent low output 5 A, intermittent low output 6 B, intermittent low output Possible causes: Loose or maladjusted sensor, sensor loose, bracket or exciter loose damaged exciter, worn sensor cable insulation. 7 Lamp signalled by external device SENSED HEEL SLO RECOVER GROUP 0 wiring crossed across an axle Slow recovery of sensed wheel(s) of red channel. Slow recovery of sensed wheel(s) of blue channel. Slow recovery of sensed wheel(s) of yellow channel. Possible causes: Slow brake release, check foundation brake for mechanical faults, dry bearings, broken springs, restricted piping, check for kinks and blockages etc. Check for incorrectly wired sensors and modulator solenoids, incorrect piping or modulator fault. OPEN CIRCUIT SOLENOID OR IRING 6 Red channel, hold solenoid or wiring 6 Blue channel, hold solenoid or wiring 6 ellow channel, hold solenoid or wiring 67 Red channel, dump solenoid or wiring 68 Blue channel, dump solenoid or wiring 69 ellow channel, dump solenoid or wiring 8

19 CODE DISPLAD POSSIBLE CAUSE SHORT CIRCUIT MODULATOR SOLENOID OR IRING 7 Red channel, hold solenoid or wiring 7 Blue channel, hold solenoid or wiring 7 ellow channel, hold solenoid or wiring 77 Red channel, dump solenoid or wiring 78 Blue channel, dump solenoid or wiring 79 ellow channel, dump solenoid or wiring SOLENOID IRING SHORT TO B+ OR LO SOL. RESISTANCE 80 Poor insulation in solenoid or wiring 8 Hold solenoid, red channel 8 Hold solenoid, blue channel 8 Hold solenoid, yellow channel 87 Dump solenoid red channel 88 Dump solenoid blue channel, Also shown briefly as a display segment check at power up. 89 Dump solenoid yellow channel SUPPL VOLTAGE GROUP 90 supply voltage <8V (<9v on V system) when solenoid energised. 9 Faulty supply from IS0 768 Pin or fuse blown 9 supply voltage >V. (<6v on V system) 9 Internal fault 99 Internal fault ALPHA/NUMERIC DIAGNOSTIC CODES CA hen reading codes this appears as an invitation to Clear All. CC hen revising configuration this appears as an invitation to Clear Configuration. CF Unacceptable combination of sensors and solenoids. OA COLAS solenoid wiring open circuit. OC COLAS solenoid wiring short circuit. OE arning lamp circuit fault. Open or short circuit. Bulb may be faulty. E# hen using the DDU to read fault codes, where the TODD and DDU displays disagree and an "E#" is displayed on the DDU where # is a number between 0 and 9. Then the is faulty. AUXILIAR CODES A Automatic Reset-to-ride (COLAS ) and wiring fitted ABS function available. A Retarder relay and wiring fitted ABS function available. A Steerable axle locking device signal available. db SUNDR CODES Indicates that electrical contact has been made when using the diagnostic s to switch through fault codes, the symbol is displayed between stored codes. The symbol when using the DDU, is not displayed on the DDU. Blank Display No supply on ignition switched line, fuse blown, DDU or cable fault, open circuit B-. Bar Bar displayed = OK. Bar not displayed = output too low. Unlisted Display. or DDU fault. Replace faulty component as necessary. Note: If a code is displayed and after following the recommended procedure fault is found, the should be replaced. 9

20 HALDEX BU SA SA SA SB SB SB GN G BU M M M Fig. 0 MODAL iring diagram - 6S/M 0

21 COLAS - + FRONT JUNCTION BOX mm² mm² CORE CABLE HALDEX OMITTED FOR CLARIT. BU SA SA SA SB SB SB GN G BU M M M Fig. MODAL iring diagram - 6S/M with Automatic Reset-to-ride (COLAS )

22 (REQUIRED IF LOCKING DEVICE FITTED ON STEER AXLE) HALDEX HALDEX BU SA SA SA SB SB SB GN G BU M M M Fig. MODAL iring diagram - 6S/M with Retarder

23 ISO 7 DIN 7570 FRONT JUNCTION BRON /BLACK 6mm² 6mm² B HALDEX BU SA SA SA SB SB SB GN G BU M M M Fig. MODAL iring diagram - S/M (V System)

24 Key PU BU X - hite - Black - Purple - Red - ellow - Blue - Fuse position (Pin Assy.) - m MAX. COMMON HOLD ABS Modulator iring side View DUMP Loom Connector X ISO 768 ABS PU B+P B+IGN B- CAB LAMP B-P ISO 85 (N) B- B+ TRAILER LAMP INFO CENTRE D.D.U. PC. INTERFACE Fig. MODULAR Upgrade iring diagram - S/M with ISO 768 (Fused) and ISO 85 (N)

25 Key PU BU - hite - Black - Purple - Red - ellow - Blue - Brown - m MAX. COMMON HOLD ABS Modulator iring side View DUMP Loom Connector ISO 768 ABS B+P B+IGN B- CAB LAMP B-P ISO 85 (N) B- B+ TRAILER LAMP INFO CENTRE D.D.U. PC. INTERFACE Fig. 5 MODULAR Upgrade iring diagram - S/M with ISO 768 (UnFused) and ISO 85 (N) 5

26 Key PU BU - hite - Black - Brown - Red - ellow - Purple - Blue - m MAX. HOLD ABS Modulator iring side View COMMON DUMP Loom Connector ISO 7 (S) ISO 85 (N) / / Front Junction Box B-P B- CAB LAMP B- B+ B+ IGN B+P TRAILER LAMP 8 9 INFO CENTRE D.D.U. PC. INTERFACE Fig. 6 MODULAR Upgrade iring diagram - S/M with ISO 7 (S) and ISO 85 (N) 6

27 Key PU BU X - hite - Black - Purple - Red - ellow - Blue - Brown - Fuse position (Pin Assy.) - m MAX. SUSPENSION CONTROLLER (COLAS ) COMMON HOLD ABS Modulator iring side View DUMP Loom Connector - + X ISO 768 ABS PU B+P B+IGN B- CAB LAMP B-P ISO 85 (N) Front Junction Box B- B+ TRAILER LAMP INFO CENTRE D.D.U. PC. INTERFACE Fig. 7 MODULAR Plus iring diagram - S/M with ISO 768 (Fused) and ISO 85 (N) 7

28 Key BU - hite - Black - Purple - Red - ellow - Blue - m MAX. SUSPENSION CONTROLLER (COLAS ) COMMON HOLD ABS Modulator iring side View DUMP Loom Connector - + ISO 768 ABS ISO 85 (N) B+P B+IGN B- CAB LAMP B-P B- B+ TRAILER LAMP Front Junction Box INFO CENTRE D.D.U. PC. INTERFACE Fig. 8 MODULAR Plus iring diagram - S/M with ISO 768 (UnFused) and ISO 85 (N) 8

29 Key PU BU - hite - Black - Purple - Red - ellow - Blue - Brown - m MAX. SUSPENSION CONTROLLER (COLAS ) COMMON HOLD ABS Modulator iring side View DUMP Loom Connector - + ISO 7 (S) ISO 85 (N) / / B-P B-IGN B- B+ CAB LAMP TRAILER LAMP B+IGN B+P Front Junction Box INFO CENTRE D.D.U. PC. INTERFACE Fig. 9 MODULAR Plus iring diagram - S/M with ISO 7 (S) and ISO 85 (N) 9

30 Key PU BU X - hite - Black - Purple - Red - ellow - Blue - Fuse position (Pin Assy.) - m MAX. SUSPENSION CONTROLLER (COLAS ) - + COMMON ABS Modulator iring side View HOLD DUMP s Loom Connector 0 ISO 768 ABS X PU B+P B+IGN B- CAB LAMP B-P ISO 85 (N) Front Junction Box B- B+ TRAILER LAMP INFO CENTRE COMMON HOLD DUMP ABS Modulator iring side View PC. INTERFACE D.D.U. s Fig. 0 MODULAR iring diagram - S/M with ISO 768 (Fused) and ISO 85 (N) 0

31 Key PU BU - hite - Black - Purple - Red - ellow - Blue - Brown - m MAX. SUSPENSION CONTROLLER (COLAS ) ABS Modulator iring side View COMMON HOLD DUMP s - + Loom Connector 0 ISO 768 ABS ISO 85 (N) Front Junction Box B+P B+IGN B- B- CAB LAMP B-P B+ TRAILER LAMP INFO CENTRE COMMON HOLD DUMP ABS Modulator iring side View PC. INTERFACE D.D.U. s Fig. MODULAR iring diagram - S/M with ISO 768 (UnFused) and ISO 85 (N)

32 Key PU BU - hite - Black - Purple - Red - ellow - Blue - Brown - m MAX. N and S SUSPENSION CONTROLLER (COLAS ) COMMON ABS Modulator iring side View HOLD DUMP s Loom Connector ISO 7 (S) / B-P B-IGN / ISO 85 (N) B- Front Junction Box CAB LAMP B+IGN B+ TRAILER LAMP B+P INFO CENTRE COMMON HOLD DUMP ABS Modulator iring side View PC. INTERFACE D.D.U. s Fig. MODULAR iring diagram - S/M with ISO 7 (S) and ISO 85 (N)

33 Specialised Codes Applicable to all systems The following additional diagnostic codes may be displayed by the D.D.U. HI Short circuit wiring to the D.D.U. either between the module and the socket or in the D.D.U. fly lead. The supply voltage to the system is outside the operational tolerance i.e. <8V or >V (<9V or >6V on V systems). The is faulty. The D.D.U. is faulty LO Open circuit wiring to the D.D.U. either between the module and the socket or in the D.D.U. fly lead. The is faulty. The D.D.U. is faulty.

34 For further information: Austria Haldex ien Ges.m.b.H Vienna Tel: Fax: office@baeder-haldex.at Belgium Haldex N.V./S.A. Zaventem (Brussels) Tel: Fax: info@hbe.haldex.com Brazil Haldex do Brazil São Paulo Tel: Fax: info@hbr.haldex.com China Haldex International Trading Co. Ltd. Shanghai Tel: Fax: haldex@public.sta.et.cn France Haldex Europe S.A. eyersheim (Strasbourg) Tel: Fax: info@hfr.haldex.com Germany Haldex Brake Products G.m.b.H Denkendorf (Stuttgart) Tel: Fax: info@hde.haldex.com Haldex Brake Products G.m.b.H Heidelberg Tel: Fax: info@hbpde.haldex.com Great Britain Haldex Ltd. Newton Aycliffe Tel: Fax: info@huk.haldex.com Haldex Brake Products Ltd. Redditch Tel: Fax: info@hbpuk.haldex.com Poland Haldex Sp z o.o. Praszka Tel: Fax: info@haldex.net.pl South Korea Haldex Korea Ltd. Seoul Tel: Fax: haldexk@mail.hkr.haldex.com Spain Haldex España S.A. Parets del Valles (Barcelona) Tel: Fax: haldexsa_esp@passwordsta.es Sweden Haldex Brake Products AB Landskrona Tel: Fax: info@hbpse.haldex.com USA Haldex Brake Products Corp. Kansas City Tel: Fax: info@hbpus.haldex.com Company Vision e use our demonstrated competence to provide innovative components, systems and service for trucks, trailers and buses, that lower life cycle costs and improve vehicle safety. Haldex wants to become the first choice business partner of commercial vehicle manufactures world wide in the areas of braking and suspension control systems with special emphasis on heavy commercial vehicles. Total Support A uniquely wide range of services is available from Haldex. These include expert consultancy for braking and suspension development, brake calculations, type approvals and application engineering. The aim is accurate specification for manufactures and low cost of owner ship for the operator. Full aftermarket support includes a orldwide parts distribution and service network, on-line technical advice, field visits and installation/ maintenance training held on-site or at Haldex facilities. Research and Development Continual, heavy investment in Research and Development is carried out in response to ever increasing commercial, legislative, environmental, performance and technological demands. The Haldex Group is a global supplier of proprietary products for trucks, cars and industrial vehicles, with special emphasis on performance and safety. TheGroup is organized in Divisions which focus on their respective product niche: Haldex Brake Systems supplies ABS and brake components for heavy vehicle air brakes. Haldex Barnes Hydraulics supplies gear pumpsand hydraulic systems for power steering and lifting functions on industrial vehicles and trucks. Haldex Garphyttan ire supplies specially steelalloyed wire products mainly for applications in combustion engines. Haldex Traction Systems supplies D systems for cars and trucks. Sales companies are established in Europe, North and SouthAmerica and Asia. Production takes place in 9 factories in USA, 9 factories in Europe and joint venture in India. The Haldex Group is listed on the Stockholm Stock Exchange. Innovative Vehicle Technology Quality and Production Standards The very latest production technology ensures the very highest quality standards. All production sites are ISO 900 approved.