trailer - haldex

000 700 022/01.99./Redditch

TRAILER

ABS

MGXMGX 2

MGX 2EMGX 100

OPERATOR'SGUIDE

1

CONTENTS MGX ABSOPERATOR'S GUIDE

SYSTEM DESCRIPTION

System Description Page 1

System Layout Page 3

Piping Diagram Page 6

Wiring Diagrams Page 6

Warning lamp and Page 8System CheckProcedure

Lamp circuit Page 9

Multimeter readings Page 10

Fault finding and Page 11rectification chart

Recommended Page 12MaintenanceSchedules

Service Parts Page 13

Your trailer has been fitted the HaldexMGX anti-lock braking system.This system has been specificallydesigned to be effective, reliable andeasy to service.The purpose of this booklet is todescribe the components involvedand give you sufficient information tomake your use of the system easy.

When overhaul of the components isrequired, we advise you to refer to thefull SERVICE MANUAL whichdescribes replacement proceduresfully.

The MGX anti-lock brake systemincorporates two sensor / exciterassemblies and one modulating valvewith combined relay / emergencyfunction (Memory ControlledEmergency Relay Valve).

The position of the various componentsis shown in Fig 1. This layout showsa tri-axle. The system is equallycompatible with single / tandem axles.In the case of full trailers, two completeMGX systems will be fitted, one tocontrol the front (steering) axle, andone for the rear axle(s).

FUNCTIONThe ABS system constantly monitors(on permenant powering) the speed ofrotation of the wheels via sesningequipment.The exciter urns with thewheel and its teeth break the magneticfield of the sensor 60 (or 100 times in thecase of MGX 100) times per revolution.While under braking the first sensedwheel to decelerate too quickly (theonset of a skid) causes the ABS todecrease air pressure to the brakesextremely rapidly from all controlledaxles. The ABS will continue to operateto prevent skidding until the trailer slowsto about 6 mph at which speed the ABSceases to operate.

BRAKING WITH ABSIn an emergency apply full forceon the brake pedal. The ABS willbe activated immediately you fullyapply the brakes and will assistyou to retain steering control ofyour vehicle according to the roadsurface conditions. DO NOT applyand release the brakes bypumping the brake. This is knownas 'Cadence braking' and can havea detrimental effect on vehiclebraking.

The Drivers information plateThe Warning lamp Control module and MCER Valveassembly

ISO 7638 Connector assembly The Sensor The Exciter

2

Fig 1

GENERAL COMPONENTS GUIDE

SYSTEM LAYOUT

The system fitted to your trailer is a2 Sensor and 1 Modulator (Valve)system (2S/1M) descibed on page 1.

The layout of the chassis componentsare shown in Fig 2. The Module andValve are mounted together on a singlebracket for ease of installation andmaintenance.

The powering of the system can be viaany one of the following cables:

ISO 7638 - Dedicated ABSpower cable

ISO 3731 (24S) - Supplementarypower cable.

ISO 1185 (24N) - Stop Lightpowering.

A green warning lamp will also havebeen fitted to the headboard of the trailer,in a position visible to the driver throughthe driving mirror. This lamp will havebeen connected to the ABS via a junctionbox into which the ISO 1185 (24N) cablewould also be connected.

When an ISO 7638 is fitted, or poweringis through the ISO 3731 (24S), it willnormally control a red warning lamp inthe driver's console.

Either warning lamp has two functions:

- To indicate system integrity viathe correct lamp sequence(page 9) every time the ABSmodule is electrically poweredup.

- To indicate by permanentillumination, when the vehicle ismoving, if a fault has beendetected.

3

4

Fig 2

1

2

3

4

5

6

7

8

9

10

ITEM DESCRIPTION

ABS Information Label

Green Warning lampBulb (24v-5w Double pole)

2 core cable

Junction box

ISO 3731 (24S) Cable assembly

ISO 1185 (24N) Cable assembly

Sensor assembly

Exciter

ABS Identification Label

Module/Bracket/Valve assembly

ISO 7638 Socket Assembly

Haldex Junction box (PCB)

11

12

1211

ISO 3731(24S)

ISO 1185(24N)

ISO 7638

ALTERNATIVE

To Module

1

2

9

ISO 1185(24N)

6

4

3

7 8

510

87

ISO 3731(24S)

ABS CHASSIS COMPONENTS

Fig 4

5

21

2

1

12

2

2

21

1211 11 1112 12

11 12 11 1112

2

12

2

4

12

21

2

12

2

2 2

2

4

11

22-11

21Service

2

4

2

ITEM DESCRIPTION

1 Emergency Coupling2 Service Coupling3 Pipe Filter4 Trailer Release valve5 Relay Valve6 Air Reservoir (40L/Axle - Spring Brake Chamber)7 Drain valve8 Load Sensing valve - pneumatic9 Test point10 MCER Valve. (ABS)11 Spring Brake Chamber12 Park Valve13 Double Check Valve14 Quick Release Valve

Emergency

1

3

4 12

3

2

5

97

6

1

9 8 910

9

14

9

13

11 11 11

111111

PIPING DIAGRAM- 2 Line Air Brake system, 3 Axle Semi-Trailer, Spring Brakes, Air Suspension

Fig 5

6

WIRING DIAGRAM- ISO 3731 (24S) and ISO 1185 (24N) Power Supply

ISO 1185(24N)

ISO 3731(24S)

TRAILERWARNINGLAMP

2 CORECABLE14/0.3

2 CORECABLE14/0.3

5 CORECABLE14/0.3

2 CORECABLE14/0.3

MCERVALVE

LEFTSENSOR

RIGHTSENSOR

MGXMODULE

WHITE

BLACKYELLOWREDBROWN/BLACK

YELLOW

BLACK

WHITE

RED

BLACK

BROWN/BLACK

ANTI LOCKJ U N C T I O NBOX

1

4

26

YE

LLO

W

REDBLAC

K

BR

OW

N/

BLA

CK

WH

ITE

Fig 6

7

WIRING DIAGRAM- ISO 7638 (Fused), ISO 3731 (24S) and ISO 1185 (24N) Power Supply

FUSE

ISO 1185(24N)

ISO 3731(24S)

BROWN/BLACK

BLACK

2 CORECABLE14/0.3

62

4

1WHITE

RED

ISO 7638ABS

5 CORECABLE14/0.3

BLACK

TRAILERWARNINGLAMP

5 CORECABLE14/0.32 CORE

CABLE14/0.3

2 CORECABLE14/0.3

BLACKYELLOWREDBROWN/BLACK

WHITE

LOOP WIREPRE-WIRED RIGHT

SENSOR

LEFTSENSOR

MGXMODULE

RED

BR

OW

N/

BLA

CK

BLACK

YE

LLO

W

WH

ITE

2

5

13

4

PU

RP

LER

ED

YE

LLO

WW

HIT

EB

LAC

K

6

7

12

34

5

8 9 A

B

CD

EFGHJE

MCERVALVE

INTERNAL CONNECTION DETAILS

ANTI LOCK PCBJUNCTION BOX

YELLOW

8

VISUAL

Cab lamp ON for 1second then OFF.NOTE: Trailer lampinhibited.

Any further lampdisplay =SYSTEM FAULT.

MGX

with Mk 1 Fuse BoardBlue caseModule No. 75061172

MGX 2

or MGX with Mk 2 FuseBoardBlack caseModule No. 75061356

Cab and Trailer lampON for 1 second thenOFF.


MGX 2E

Grey caseModule No. 75061413

Cab and Trailer lampON until vehicleexceeds 10 kph thenOFF.


Trailer lamp ON for1 second then OFF.


Trailer lamp ON for1 second then OFF.


Trailer lamp ON for1 second then OFF(if speed is above10 kph) OR lampON until speedexceeds 10 kphthen OFF.


MGX 100

Green caseModule No. 364 080 001

Cab and Trailer lampON for 2.5 second thenOFF 1 second then ONuntil vehicle exceeds10 kph.


Trailer lamp ON for2.5 second then OFF1 second then ON un-til vehicle exceeds 10kph.then OFF.


SYSTEM

WARNINGLAMP

ON

OFF

ON

OFF

ON

OFF

2.5 SEC.

1 SEC.

>10 kph.

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ON

OFF

WHEN ABS POWERED BY

IGNITION STOP LAMPS

WARNING LAMP AND SYSTEM CHECK PROCEDURE

On power up of the system, the warninglamp(s) must illuminate in the followingsequence in order to show a fault-freesystem: (on some installations it will benecessary to depress the brake pedal inorder to power up the ABS).

As mentioned on page 3, therewill be a green warning lampmounted on the headboard ofthe trailer. Their may also be awarning lamp on the driver'sconsole of the towing vehicle.

Fig 7

9

GND

+

B+L

F O/L FI

BLACK YELLOW

GREEN lamp on Trailer

WHITE

B+I

+

D3

BLACKABS II

PIN 6

PIN 2

ISO3731(24S)

RED lamp in Truck

D1 D2FUSE

FR/TPRED

+BROWN

MODULE

PIN 4

PIN 1

ISO1185(24N)

B+P

D4

Terminal Reference Guide

B+P Battery positive permanent supply ISO3731 (24S)B+I Battery positive intermittent (Stoplamp) ISO1185 (24N)B+F Battery positive fusedF O/L Failure output / LampB+L Battery positive lamp supplyFI Failure inputFR/TP Fault reset - MGX2 / Test pulse - MGXGND Ground terminal

B+F

BLACK

LAMP CIRCUITMk II Polar Fuse Board - 24S /24N Power Supplies

Mk II Polar Fuse Board

10

Fig 8

MULTIMETER READINGS

CHECKING MEASURE CORRECT REMARKS POSITION BETWEEN VALUE

Sensor output A & B 0.9V AC Min. (+0.5V) Sensor disconnected from ECU. Measure MGX2 / 2E C & D cable end. Wheel rotated at 1 rev / 2 sec. Sensor resistance A & B >4.0 <6.0 kOhm Sensor disconnected from ECU. MGX2 / 2E C & D Measure cable end. Sensor output A & B 0.2V AC Min. (+0.15V) Sensor disconnected from ECU.Measure MGX100 C & D cable end. Wheel rotated at 1 rev / 2 sec. Sensor resistance A & B >1.0 <2.4 kOhm Sensor disconnected from ECU. MGX 100 C & D Measure cable end. MCER Valve Solenoid V+ V- >6.0 <16 Ohm MCER Valve cable disconnected resistance from Module. Measure cable end. Supply from ISO 3731 B- B+F 24V Ignition switched on or Foot brake applied, (24S)or ISO 1185(24N) ignition switched on. Supply from B- B+I 24V Foot brake applied,ignition switched on ISO 1185 (24N) Supply from ISO 3731 B- B+L 24V Ignition switched on or Foot brake applied, (24S)or ISO 1185(24N) ignition switched on. Supply from ISO 3731 B- FI 24V Ignition swithched on or Foot brake (24S)or ISO 1185(24N) applied,ignition switched on - Warning

lamp ON. Supply from ISO 3731 B- F O/L 1 - 6V Ignition switched on or Foot brake applied, (24S)or ISO 1185(24N) ignition switched on - Warning lamp ON. Supply from ISO 3731 B- FI 24V Ignition switched on or Foot brake applied, (24S)or ISO 1185(24N) ignition switched on - Warning lamp OFF. Supply from ISO 3731 B- F O/L 24V Ignition switched on or Foot brake applied, (24S)or ISO 1185(24N) ignition switched on - Warning lamp OFF. Supply from ISO 3731 B- V+ 0 - 0.1V Ignition switched on or Foot brake applied, (24S)or ISO 1185(24N) ignition switched on. Supply from ISO 3731 B- V- 0 - 0.02V Ignition switched on or Foot brake applied, (24S)or ISO 1185(24N) ignition switched on. Supply from ISO 3731 B- B+P 24V Ignition switched on. (24S)

Note: Alternative Supply toISO 3731 (24S) can beISO 7638

11

LAMP FAULT INDICATION FAULT RECTIFICATION

FAULT FINDING AND RECTIFICATION CHART

No lamp flash at power up.MGX / MGX 2 / MGX 2E / MGX 100

1 - Blown bulb.2 - No power to module

(B+I / B+P).3 - Yellow or black lamp

wire open circuit(F/OL / B+L)

4 - Yellow wire short circuit(D3 Diode blown).

5 - White wire open circuit.6 - Module faulty.

1 - Check/replace bulb.2 - Check for 224 Volts to

B+I / B+P terminals.3 - Check yellow and black

lamp wire for open circuit(F/OL / B+L).

4 - Check D3 Diode (if burnt orblown rectify short circuit onyellow wire and replace polarfuse board).

5 - Check white wire for open circuitand rectify.

6 - Replace Module.

Lamp comes ON and stays ON whenstationary.MGX / MGX 2 / MGX 100

1 - Module latched(exept MGX)

2 - Black wire short circuitto B- or Ground.

3 - Broken or missing barjumper.

4 - Fuse blown.5 - Module faulty.

1 - De-Latch module (Apply B+,Short between FR / TP and B+F,remove B+, wait, then re-applyB+).

2 - Apply B+, disconnect black wireat module.

3 - Check bar jumper security(Inspect for cracks).

4 - Repalce polar fuse board.5 - Replace Module.

Lamp comes ON at speed0 -20 kph.MGX / MGX 2 / MGX 2E / MGX 100

1 - Sensor fault. 1 - Adjust/replace faulty sensor.

Lamp comes ON at speed80+ kph.MGX / MGX 2 / MGX 2E / MGX 100

1 - Damaged exciter.2 - Excessive exciter run out.3 - Loose sensor.4 - Loose exciter.

1 - Check exciter and sensors forsecurity condition and run out.

Lamp stays ON above 10 kph.MGX 2E / MGX 100

1 - Sensor fault.2 - Module latched

(MGX 2E only)

1 - Adjust/replace faulty sensor.2 - De-Latch module.

Module will not De-Latch.MGX 2 / MGX 2E / MGX 100

1 - Solenoid open or shortcircuit.

2 - Supply wiring fault.3 - Supply voltage <18 Volts

or >32 Volts.

1 - Check solenoid for open or shortcircuit. Check solenoid foroperation

2 - Check junction boxes forcorrosion/water ingress.

3 - Rectify supply voltage (batterycondition, alternator andelectrical circuit for volts leak toground).

1 - Solenoid open or shortcircuit.

2 - Module faulty.

1 - Check solenoid for open or shortcircuit. Check solenoid foroperation

2 - Replace module.

Delayed lamp (lamp flashes ON/OFFthen comes back on afterapproximately 3 seconds).MGX only

12

TIME OR MILAGE COMPONENT OPERATION(whichever occurs first)

When hubs are removed Exciter Check for damage

Sensor Check for wear clean and re-adjust.

Every 3 months Complete System Perform system check out and airor 25,000 miles leakage check.(40,000 km)

Annually or every Complete System Perform system check out and airor 100,000 miles leakage check. Check wiring and(160,000 km) piping security and integrity.

Sensor Check for wear clean and re-adjust.

Every two years MCER Valve Repalce or service as necessary.200,000 miles(320,000 km)

SERVICING PARTS

RECOMMENDED MAINTENANCE SCHEDULE

A European Service Guide is avaliablefree of charge on application.

The diffrent components are shown inview form in order to allow easyrecognition.

The list of available service parts isindicated on page 13 to 18. These canbe obtained from Haldex servicecentres or distributors.

13

SERVICE PARTS

DESCRIPTION PART NUMBER VIEW

MGX / MGX 2 / MGX 2E / MGX 100Polar fuse board

Module Lid

MGXBar Jumper

MCER Valve - 75611959MCER Valve - Conduit

MGX 2 / MGX 2E / MGX 100Bar Jumper

Solenoid 24v (PVC)Solenoid 24v (Conduit)

950 364 10475612002

950 364 106950 364 009

75612653

75611835

75610347

950 364 108

MGX 2 Module(Black) - 75061356MGX 2E Module(Grey) - 75061413MGX 100 Module(Green) - 364 080 001

950 364 101

950 364 102

950 364 103

14

SERVICE PARTS


Flow ValveFlow Valve Kit(inc. 'O' ring, b/washer)

For 24S and 24N power supplyJunction Box

For ISO 7638, 24S and 24Npower supplyPCB Junction Box (w/o fuse)PCB Junction Box (fused)PCB Junction Box (fused)

Fuse - 10 amp

Warning Lamp - Green

Warning Lamp Controller

Bulb (24v - 5w) Double pole

950 364 710

950 364 711

950 364 111

042 5332 09

003 7682 09 - Semi Trailer003 7861 09 - Semi Trailer003 7683 09 - Full Trailer

75611675

950 364 110393 027 001

15

SERVICE PARTS


45 / 60 Tooth Sensor - Straightinc. Inline crimp and heat shrinksleeve

45 / 60 Tooth Sensor - Angledinc. Inline crimp and heat shrinksleeve

45 / 60 Tooth Sensor assy - StraightCable length = 2.4minc. grommet

45 / 60 Tooth Sensor assy - AngledCable length = 2.6m

80 / 100 Tooth Sensor - AngledCable = 0.5m + Retaining clipCable = 1.0m, w/o Retaining clip

80 / 100 Tooth Sensor - StraightCable = 0.5m, w/o Retaining clipCable = 2.0m, w/o Retaining clip

Retaining Clip(for 80 / 100 Tooth Sensors)

950 364 503 - Standard364 094 031

059 5123 09

950 364 506364 208 011

950 364 502

950 364 501

393 046 001

393 045 001

16

SERVICE PARTS


80 / 100 Tooth SensorExtension Cable (PUR)2m3m

5 Core CableB l a c k / R e d / W h i t e / Y e l l o w /Brown+Black2m100m

2 Core Cable - For ISO 1185 (24N)White/Red12.5m100m

2 Core Cable - For ISO 3731 (24S)Black/Brown+Black12.5m100m

Connector - Module, Warning lamp

2 Core Cable - For warning lampBlack/Yellow12.5m100m

Connector - Module, Sensor

75611708

75612019

75612126059 5077 09

75612128059 5076 09

75612127059 5078 09

75612944059 5076 09

059 5098 09059 5104 09

17

SERVICE PARTS


In-line Crimp

Heat Shrink Sleeve

Spiral sleeve1m100m

Exciter45 T. - ROR 15"45 T. - YORK 15"60 T. - ROR, YORK, 22.5"60 T. - BPW 8-9 Tonne60 T. - BPW 10-12 Tonne

Label - ABS

Exciter80 T. - ROR 15"100 T. - ROR 22.5" - TM100 T. - ROR 22.5" - TE

Flex Coil - Suzie ISO 7638

950 364 702

950 364 720

018 5004 09018 5003 09018 5005 09

75613235069 5000 09

75610245

75610251

756118217561190175611817016 7119 0975611384

18

SERVICE PARTS


ISO 7638 Socket / Cable Assembly12m - (fused)12m - (w/o fuse)

ISO 7638 Socket and pin kit(w/o fuse)

Replacement fuse kit for fusedISO 7638

ISO 7638 Plug and socket kit

Warning Lamp Bracket

Earth cable kit(Front and Rear Full-TrailersInstallations only)

Reset Tool

75611973

75061374

393 052 001

950 364 403

950 364 401

950 364 402

950 364 404364 221 111

MGX Test Set (inc. loom)Test set loom (only)

903 030 001905 030 001

AustriaAustriaAustriaAustriaAustriaHaldex Wien Ges.m.b.HViennaTel: + 43 1865 16 40Fax: + 43 1865 16 4027e-mail: [email protected]

BelgiumBelgiumBelgiumBelgiumBelgiumHaldex N.V./S.A.Zaventem (Brussels)Tel: + 32 2725 3707Fax: + 32 2752 4099e-mail: [email protected]

BrazilBrazilBrazilBrazilBrazilHaldex do BrazilSão PauloTel: + 5511 531 4999Fax: + 55 11 531 9515e-mail: [email protected]

ChinaChinaChinaChinaChinaHaldex International Trading Co. Ltd.ShanghaiTel: + 86 21 6289 4469Fax: + 86 21 6279 0554e-mail: [email protected]

FranceFranceFranceFranceFranceHaldex Europe S.A.Weyersheim (Strasbourg)Tel: + 333 88 68 22 00Fax: + 333 88 68 22 09e-mail: [email protected]

GermanyGermanyGermanyGermanyGermanyHaldex Brake Products G.m.b.HDenkendorf (Stuttgart)Tel: + 49 711 93 49 17 0Fax: + 49 711 93 49 17 40e-mail: [email protected]

Haldex Brake Products G.m.b.HHeidelbergTel: + 49 6221 70 30Fax: + 49 6221 70 34 00e-mail: [email protected]

Innovative Vehicle Technology

For further information:Great BritainGreat BritainGreat BritainGreat BritainGreat BritainHaldex Ltd.Newton AycliffeTel: + 44 1 325 310 110Fax: + 44 1 325 311 834e-mail: [email protected]

Haldex Brake Products Ltd.RedditchTel: + 44 1527 499 499Fax: + 44 1527 499 500e-mail: [email protected]

PolandPolandPolandPolandPolandHaldex Sp z o.o.PraszkaTel: + 48 34 350 11 00Fax: + 48 34 350 11 11e-mail: [email protected]

South KoreaSouth KoreaSouth KoreaSouth KoreaSouth KoreaHaldex Korea Ltd.SeoulTel: + 82 2 2636 7545Fax: + 82 2 2636 7548e-mail: [email protected]

SpainSpainSpainSpainSpainHaldex España S.A.Parets del Valles (Barcelona)Tel: + 34 93 573 1030Fax: + 34 93 573 0728e-mail: [email protected]

SwedenSwedenSwedenSwedenSwedenHaldex Brake Products ABLandskronaTel: + 46 418 47 6000Fax: + 46 418 47 6001e-mail: [email protected]

USAUSAUSAUSAUSAHaldex Brake Products Corp.Kansas CityTel: + 1 816 891 2470Fax: + 1 816 891 9447e-mail: [email protected]

The Haldex GroupThe Haldex GroupThe Haldex GroupThe Haldex GroupThe Haldex Group is a global supplier of proprietaryproducts for trucks, cars and industrial vehicles, withspecial emphasis on performance and safety.TheGroup is organized in Divisions which focus ontheir respective product niche:

Haldex Brake SystemsHaldex Brake SystemsHaldex Brake SystemsHaldex Brake SystemsHaldex Brake Systems supplies ABSand brake components for heavy vehicle air brakes.

Haldex Barnes HydraulicsHaldex Barnes HydraulicsHaldex Barnes HydraulicsHaldex Barnes HydraulicsHaldex Barnes Hydraulics supplies gear pumpsandhydraulic systems for power steering and liftingfunctions on industrial vehicles and trucks.

Haldex Garphyttan WireHaldex Garphyttan WireHaldex Garphyttan WireHaldex Garphyttan WireHaldex Garphyttan Wire supplies specially steel-alloyed wire products mainly for applications incombustion engines.

Haldex Traction SystemsHaldex Traction SystemsHaldex Traction SystemsHaldex Traction SystemsHaldex Traction Systems supplies 4WD systems forcars and trucks.

Sales companies are established in Europe, North andSouthAmerica and Asia. Production takes place in 9factories in USA, 9 factories in Europe and 1 jointventure in India.

The Haldex Group is listed on the Stockholm StockExchange.

Company VisionCompany VisionCompany VisionCompany VisionCompany VisionWe use our demonstratedcompetence to provide innovativecomponents, systems and service fortrucks, trailers and buses, that lowerlife cycle costs and improve vehiclesafety. Haldex wants to become thefirst choice business partner ofcommercial vehicle manufacturesworld wide in the areas of brakingand suspension control systemswith special emphasis on heavycommercial vehicles.

Total SupportTotal SupportTotal SupportTotal SupportTotal SupportA uniquely wide range of services isavailable from Haldex. These includeexpert consultancy for braking andsuspension development, brakecalculations, type approvals andapplication engineering.The aim is accurate specification formanufactures and low cost of ownership for the operator.Full aftermarket support includes aWorldwide parts distribution andservice network, on-line technicaladvice, field visits and installation/maintenance training held on-site orat Haldex facilities.

Research andResearch andResearch andResearch andResearch andDevelopmentDevelopmentDevelopmentDevelopmentDevelopmentContinual, heavy investment inResearch and Development is carriedout in response to ever increasingcommercial, legislative,environmental, performance andtechnological demands.

Quality andQuality andQuality andQuality andQuality andProductionProductionProductionProductionProductionStandardsStandardsStandardsStandardsStandardsThe very latest production technologyensures the very highest qualitystandards. All production sites are ISO9001 approved.

trailer - haldex

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