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BENDIX SD-13-4986 User's Manual

1. U G suo i U U D E wanna saria J1XV 1VNOILIQQV 31XV 4441S 31XV JAG Au Vid NOISNIASNS AYYANODIS uis L HOSN3S HOSN3S Z YOSNAS Md AWd AWd Md AWd AWd m gunssaud 3unss3ud 3unissaud JATVA 1431 HOW un 1HDl8 um IHO JOULNOD q31Xv JIXY ECO IXY ECO EN NOILD VUL aav aav 1331 1H5lH 1431 1H5IH uis BEE NO INYA SN p EA EA u3als Q Le L OSOS Q 0 ccc c ccc ccc ccc ccc ccc cc ccc LOOP t ol t s F O PF Pjr TT 9 9 ve tt PPL L GNI 21V 4S3 6 c 9 4 E vil s tL OL 8 L E OS L 9 v L 6 OL vl LL SL ZL c 8 L 8 s vl Ll DE UE L 9 y 4 z OL EL 6 OL SL SL L OL 6 ZL SL 81 z L Ll 9 8 1 vl El v Ss 9 o gt lt o P op 9 t e DN n 4 4 vo vu v Uc v o v Lo gt z z ss To ML P D IY X 2 9 a g d e D gt p gt 5 O hes AS be wc p 2 2 2 A AA a E 2929989 aad l 222 222 zz zz 2 A E l zzz zzz l zzz zzz zz e Z gt 3 a m E S S Lon a0 1 1 Ka Uu un Uu um D m E i is 2 222 a E Z E i iS G z amp SEE P P P 5 S o EP P P lt e E Ss Es lt amp SES P Al 2 PR E 3 9 x 3 8 2 3 S S S un E n un t t un un nnn B9B 2 ao 2 o Sg SS BR zee ZS SS E 23 2 a v S BB E aa S 55 lu UE 2333 H S 28 e642 2 9 e E on gt 9 gt gt Ag 6235 o Bez BLE 5 ESE REPE lisos BOE al WEE 3 o SS ES ZS D E Eb GERS l e 265 T ES E ZS E 9 2 Ei A L J 2 L 5
2. The Bendix ESP EC 80 Controller INTRODUCTION The Bendix ESP EC 80 Electronic Control Unit ECU is a member of a family of three Bendix brand electronic Antilock Braking System ABS devices used to help improve the braking characteristics of air braked heavy and medium duty trucks tractors and buses 1 The Bendix ABS ESP ECU uses wheel speed sensors to monitor four wheel ends to detect wheel slip or wheel lock up during braking The system intervenes when needed using Pressure Modulator Valves PMVs to adjust and or pulse the brake pressure in order to optimize the contact between the tires and the road surface The Bendix Automatic Traction Control ATC EC 80 ECU provides standard ABS improves vehicle traction during acceleration and aid lateral stability while driving through curves The Bendix ATC ECU communicates with the engine s Controller to provide Engine Torque Limiting ETL and or use Differential Braking DB to make brake applications at individual wheels The Bendix ESP EC 80 Controller provides in addition to the ABS and ATC functions described above advanced braking features referred to as the Bendix ESP Electronic Stability Program The Bendix ESP EC 80 Controller analyzes the vehicle s motion compared to the driver s intended path and provides Yaw Control YO and Roll Stability Program RSP capabilities When necessary the system will intervene to re
3. gt the vehicle or load has a high or off set center of gravity CG when loaded or gt the vehicle tows doubles or triples Truck Chassis Modifications If the vehicle s chassis components are altered for example a wheel base extension or reduction tag axle addition or removal a major body change such as conversion of a tractor into a truck or an axle suspension or steering system component modification the Bendix ESP system must be disabled Have a qualified mechanic replace the Bendix ESP EC 80 Controller with a Bendix ESP ATC EC 80 Controller and secure the X4 connector which will no longer be used The ATC ESP indicator lamp would continue to function as an ATC indicator lamp and should be designated as ATC only If a modified vehicle does not have the Bendix ESP system disabled serious vehicle braking and performance issues could result including unnecessary ESP system interventions This can lead to a loss of control of the vehicle In addition remove all cab signage e g visor labels etc that were used to show that the Bendix ESP system was installed Make any necessary notations in the vehicle manual s so that drivers do not misunderstand which ABS options are installed on the vehicle Sensor Location Modifications The location and orientation of the Steering Angle Sensor and Yaw Rate Sensor must not be altered When servicing an identical component must be used in the same orientation usi
4. 2nd Blink Code 10 11 38 Location Steering Angle Sensor Diagnostic Trouble Code Description SAS Not Calibrated SAS Calibration in Progress SAS Static Signal SAS Signal Out of Range SAS Signal Reversed SAS Invalid Signal SAS Gradient Error SAS CAN Time out SAS Long Term Calibration Error SAS Plausibility Check SAS detected but not configured Repair Information Steering Angle Sensor SAS has not been calibrated Perform SAS calibration procedure SAS calibration procedure is underway SAS signal incorrect Verify the proper installation of the SAS Verify proper wiring between the Electronic Control Unit ECU and the SAS Check SAS output SAS signal incorrect Verify the proper installation of the SAS Verify proper wiring between the ECU and the SAS Check SAS output Perform SAS calibration procedure SAS signal is reversed Verify the proper installation of the SAS Verify proper wiring between the ECU and the SAS Check SAS output SAS signal is invalid Verify the proper installation of the SAS Verify proper wiring between the ECU and the SAS Check SAS output Verify that correct SAS is being used SAS signal is invalid Verify the proper installation of the SAS Verify proper wiring between the ECU and the SAS Check SAS output Verify that correct SAS is being used Loss of CAN communications between the ECU and the SAS Verify proper wiring between the ECU and the SA
5. Time out or invalid data for Configuration of Engine Retarder ESP Message Time out or invalid data for Configuration of Exhaust Retarder ESP Message Time out or invalid data for Configuration of Transmission Retarder ESP Message Invalid Data Transfer Time out of Driveline Line Retarder ESP Message Invalid Data Transfer Time out of Engine Retarder ESP Message Invalid Data Transfer Time out of Exhaust Retarder ESP Message Repair Information Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Verify the presence of engine on J1939 link Verify that the message is being transmitted Verify that the data for reference torque is correct Verify the Electronic Control Unit ECU configuration Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Verify the presence of engine on J1939 link Verify that the message is being transmitted Verify that the data for reference torque is correct Verify the ECU configuration Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Verify the presence of a retarder on J1939 link Verify that the message is being transmitted Verify that the data for reference torque is correct Verify the ECU configuration Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Verify the presence of engine ECU on J1939 link Verify the presence of engine ECU on J1939 link Verify
6. Verify no continuity between the Hill Start Hill Start Assist lamp and ground Verify continuity between the lamp and the ECU Check the wiring between the lamp and the ECU Check the lamp and the condition of its wiring The Hill Start Hill Start Assist solenoid is shorted to ground or has a broken wire Verify no continuity between the solenoid and ground Check for corroded damaged wiring or connectors between the ECU and the solenoid Verify no continuity between the Hill Start Hill Start Assist Solenoid and voltage Check for corroded damaged wiring or connectors between the ECU and Solenoid There is a brake lamp input mismatch with the brake lamp output Verify brakes are operating correctly Verify that there is not over braking at one or more wheel end s Check the pneumatic plumbing and the exhaust port of the PCVs TCVs and relay valves and confirm that the air is being exhausted from all brake chambers Verify tire sizes on the vehicle match the ABS ECU configuration Verify wheel speed sensors and tone ring are properly adjusted and in good condition Verify that the tires are in good condition Verify that no pneumatic hoses are twisted or kinked Verify that the brakes are operating correctly Verify that the wheel speed sensor and tone ring are properly adjusted Verify tire size Electronic Stability has been disabled due to the vehicle being in the ABS or ATC off road mode Cycle ABS Off Road or ATC Mud snow switch
7. lf there are multiple DTCs on the ABS system the RDU tool will display one DTC first then once that DTC has been repaired and cleared the next code will be displayed Typical Combination Diagnostic Trouble Codes DTCs are Right steer sensor Right drive modulator Left drive modulator e Right additional modulator eft steer sensor Right drive sensor eft drive sensor Right additional sensor Left additional modulator e Rear Axle Traction modulator e ECU Engine serial communication e MOD red LED illuminated shows the Common connection of one or more modulators is shorted to battery or ground e Left additional sensor Right steer modulator eft steer modulator e VLT Flashing indicates either over or under voltage condition To pinpoint the root cause and to ensure the system Diagnostic Trouble Code is properly corrected the first time additional troubleshooting may be necessary Note The Bendix RDU tool is not capable of diagnosing certain Bendix ESP EC 80 system specific DTCs including additional sensors steering angle sensors yaw sensors pressure sensors or modulator valves trailer pressure modulating valves or front axle traction control valves LED DIAGNOSTIC TROUBLE CODES LFT Left SEN Wheel Speed RHT Right Sensor DRV Drive Axle Pressure Modulator ADD X Additional Valve STR Steer Axle Traction Control VLT Power ECU ABS Contro
8. 280 Series 12040977 12077411 x TE Connectivity AMP Terminal Removal Tool Newark Part No 8H0240 Manufacturer Part Number 1 1579007 6 Bendix WS 24 Wheel Speed Sensor Connectors r S Packard GT Packard Deutsch Packard Packard Deutsch DTO4 Standard round 150 series Metripack 150 2 DTMO6 series Metripack 280 Metripack 280 series two pin series series female series male Yaw Rate Sensor Wire Harness Connectors 4 contact Yaw Rate Sensor Wire Harness Straight Connector Schlemmer 9800 351 shown Contact Pin Terminals AMP Connector 2 967325 1 Schlemmer 7814 125 ITT Cannon Connector 121583 001 e AMP 0 962981 1 90 degree Connector Schlemmer 9800 331 ITT Cannon 031 8717 120 Brake Demand Sensor Load Sensor Bendix SAS 60 Sensor Connectors Wire Harness Connectors Robert Bosch 1 928 404 025 Metri Packe Packard 1206 5287 Robert Bosch 1 928 498 001 Contact Pins One Meter Adapter to Connector Packard 1210 3881 Bendix 5015242 shown Packard 12092162 pins 12064971 FIGURE 21 BENDIX ESP EC 80 CONTROLLER COMPONENT CONNECTORS 50 Troubleshooting Wiring Continued Speed Sensor Mounting Block 100 Tooth typical Speed Sensor Exciter Ring WS 24 Speed Sensor Air Disc Brake Note Ensure that the sensor wiring is routed to avoid chafing from moving parts including rotors and steering components Brake Drum Max Gap Sensor to Exciter Mounting 015 Inches T
9. Configuration Error Repair Information Adjust the sensor to contact the exciter ring Rotate the wheel and verify a minimum of 0 25 VAC sensor output at 0 5 RPS Verify the condition of the sensor head Verify the mounting of the exciter ring and condition of the teeth Verify the proper bearing end play Verify the condition and retention of the clamping sleeve Verify the sensor lead routing and clamping Verify 1500 2500 ohms is found across the sensor leads Verify no continuity between the sensor leads and ground or voltage Verify no continuity between the sensor leads and the other sensors Check for corroded damaged wiring or connectors between the Electronic Control Unit ECU and the wheel speed sensor Adjust the sensor to contact the exciter ring Rotate the wheel and verify a minimum of 0 25 VAC sensor output at 0 5 RPS Verify the condition of sensor head Verify the mounting of the exciter ring and condition of the teeth Verify the proper bearing end play Verify the condition and retention of the clamping sleeve Verify the sensor lead routing and clamping Check for corroded damaged wiring or connectors between the ECU and the wheel speed sensor Verify the mounting of exciter ring and the condition of teeth Verify the proper bearing end play Verify the condition and retention of the clamping sleeve Verify the sensor lead routing and clamping Check the mechanical function of
10. Power Supply page 29 Pressure Modulator Valves pages 30 31 Pressure Modulator Valves pages 30 31 Pressure Modulator Valves pages 30 31 Pressure Modulator Valves pages 30 31 J1939 pages 32 33 Miscellaneous pages 34 35 ECU page 36 Wheel Speed Sensors pages 27 28 Wheel Speed Sensors pages 27 28 Pressure Modulator Valves pages 30 31 Pressure Modulator Valves pages 30 31 Drive Axle Traction Control Valve page 37 Steer Axle Traction Control Valve page 37 20 Trailer Pressure Modulator Valve pages 30 31 Steering Angle Sensor pages 38 39 Yaw Rate Sensor pages 40 41 Lateral Acceleration Sensor page 42 Brake Demand Load Sensors page 43 Valves Miscellaneous page 44 J1939 ESP Related page 45 47 Example For a message sequence of 3 2 12 4 For the first sequence go to page 27 and for the second sequence go to page 34 See Page 56 62 for APPENDIX B J1939 SPN and FMI Codes and their Bendix Blink Code Equivalents Troubleshooting Diagnostic Trouble Codes DTCs Wheel Speed Sensors ist Blink Code 2nd Blink Code y 10 Location Left Steer Axle Sensor Right Steer Axle Sensor Left Drive Axle Sensor Right Drive Axle Sensor Left Additional Axle Sensor Right Additional Axle Sensor Diagnostic Trouble Code Description Excessive Air Gap Output Low at Drive off Open or Shorted Loss of Sensor Signal Wheel End Erratic Sensor Signal Tire Size Calibration
11. Reconnectthe connector Ensure that there will be no force applied to the sensor because the connector is pulling on the sensor body 6 If the wire harness leading to the sensor is being replaced ensure that it is adequately tie wrapped so that the full motion of the steering column can be achieved without pulling apart the connectors 7 Reinstall the column sheathing The sensor is not protected against dirt or water intrusion so care must be taken not to introduce these elements during installation STEERING ANGLE SENSOR CALIBRATION The steering angle sensor calibration can only be achieved when the sensor is powered by the Bendix ESP EC 80 Controller No stand alone sensor calibration can be carried out The calibration procedure is performed using Bendix ACom Diagnostic software V6 7 2 5 or higher See Troubleshooting Diagnostic Trouble Codes Steering Angle Sensor Bendix SAS 60 for the calibration procedure using this tool The sensor must be recalibrated using ACom Diagnostic Software after any of these situations e Replacement of the steering angle sensor e Any opening of the connector hub from the steering angle sensor to the column e Any maintenance or repair work on the steering linkage steering gear or other related mechanism e Adjustment of the wheel alignment or wheel track or e After an accident that may have led to damage of the steering angle sensor or assembly If the steering angle sensor
12. The Bendix brand steering angle sensor is only operational in conjunction with a Bendix ESP EC 80 Controller No independent diagnostics can be performed on the sensor See pages 38 39 for Diagnostic Trouble Codes DTCs associated with this device Removal 1 Remove steering column sheathing 2 Depending upon manufacturer the steering angle sensor could be located either near the steering wheel necessitating the removal of the steering wheel or near the joint to the vehicle steering mechanism necessitating the disconnection of this linkage 3 Unplug sensor cable assembly from body of sensor Squeeze the mounting tabs and pull gently on the connector until it disengages 4 Unscrew all three of the mounting screws that hold the body of the sensor to the steering column body 5 Slide the sensor over the column to remove Take note if the sensor label is facing upward or downward Installation 1 Obtain a new sensor The sensor is not repairable in the field 2 Slide the sensor over the column The center hub of the sensor must be aligned with the corresponding notch in the column Different column manufacturers may implement this hub alignment in different ways The sensor label should be facing in the same direction as the removed sensor 18 3 Assemble to column non moving plate with three self locking screws 4 Tighten screws to steering column manufacturer s recommended torque specification 5
13. VT EDILON 335 1ndNI dier dOLS SIYINOJW KINO S312IH3A IAYO 133HM TIV EI MV ZT GNNOUD ANY AH3LIV8 SNOLLdO NOLLONN4 1VI23dS S3NI1 A3LLOO O d3YINO3Y ulvd GALSIML OM St SNOLIVIINANINOD TVIHIS A2 3NIVA TOULNOD NOLLOVUL 6 aauinoaw YIVA GALSIML DMV ST NIYIM SSM 8 PZ SM XION38 SSM YOSNAS 03345 133HM 7 VNId T Nid 34 3sv313u 9 Nid Nid 41H Q10H 8 Nid Nid NWD NOWWOOD CAYVAIVA MNOOTLSIML HOLO3NNOO AWd XOt I4 HOZEN ZE W XIIN38 Ad AATVA HOLVINGOW 3unssad G 6 61 AVS u3d TOYINOD ANION 21v v HOLIMS AYVININOWN E 6 61 AVS VIA SILLSONDVIA Z 6 61 AVS VIA TOYLNOD uaquviau T SALON Y39WNAN Lu Vd YOLIANNOD dv SLOVLNOD JO YJJWNN SHOLO3NNOO SS3NHVH 3HIM VV VNOILIQQV vd ANY JIXV IVNOILIGGV AWd 1H5lH EA Ty Hrs AWd 1331 IXY u3als AWd 1H5lH EA vi LL SL ZL bl Ll a o lo Ux THU V AWd NW V AWd GH V AWd Ty uv AWd NWD YY AWd iH uv AWd V SSM 1V SSM uv SSM uV SSM GION31OS VSH HAM SWAL IS SSM YS SSM 206 SSM 134 15 AWd NW TS AWd GH IS ANd NW2 1d AWd GH 1d AWd Tad ud AWd tl 6 NW HO AWd 31XV JAYA AWd 1H5lH EA nH YA AWd Q LO Lo 7 000000 8l SL LL OL 200 SSM L 6 vs d33lS V X9312IH3A AH IN AZL NOLLINDI AZ L dWV1l VSH HOLIMS 318Vsla VSH MONS 3 SE pui ADL IMYA TO0YLNOD Val Eboooggoc Y Le O OOOQOX DILSONDVIG YO 318VS
14. Verify that there is no resistance measured between the battery and HSA lamp output of the ECU Check the wiring between the ECU and the Hill Start Hill Start Assist lamp Check the lamp and condition of its wiring Check for a short circuit condition between voltage and the I O 2 and I O 3 circuits Verify resistance across the Hill Start Hill Start Assist solenoid Check the ECU and HSA solenoid for corroded or damaged wiring and or connectors Verify the resistance between voltage and the Bendix eTrac solenoid is open Check for corroded or damaged wiring or connectors between the ECU and the eTrac solenoid Verify the resistance between ground and the Bendix eTrac solenoid is open Check for corroded or damaged wiring or connectors between the ECU and the eTrac solenoid Reserved Check X1 12 if pin wire installed X2 12 should have no terminal or connection ABS Warning Lamp is controlled via J1939 35 1st Blink 36 Troubleshooting Diagnostic Trouble Codes DTCs ECU Code 13 Blink Code bh oO O FF C N 10 11 12 13 14 15 16 17 18 19 20 21 22 25 26 28 29 Location ECU Diagnostic Trouble Code Description With HEX designation ECU DTC 5FC ECU DTC 5CD ECU DTC 10 ECU DTC 2678C ECU DTC 1C ECU DTC 6CD Configuration mismatch ECU DTC 56 ECU DTC CAC3 ECU DTC 5F3 ECU DTC F1A ECU DTC F14 Configuration mismatch ECU DTC C6 EC
15. 24 25 Bendix ACom Diagnostic e EE 24 Bendix RDU Remote Diagnostic Unit E 24 Active or Inactive Diagnostic Trouble Codes Index and Troubleshooting Tests 26 47 Troubleshooting Wee el 48 ote o A 49 53 o AA 54 APPENDIX A Troubleshooting a 12 7 Blink Code DTC SID 93 FMI 4 SPN 0802 FMI 04 55 APPENDIX B J1939 SPN and FMI Codes and their Bendix Blink Code Equivalents 56 62 63 64 Log on and Learn from the Best On line training that s available when you are 24 7 365 Visit www brake school com Any references in this document to AMP DEUTSCH ITT METRI PACK NEWARK PACKARD ROBERT BOSCH SCHLEMMER TE and any other company or trademark are solely for identification and cross reference purposes The trademarks are the property of their respective companies SD 13 4986 2015 Bendix Commercial Vehicle Systems LLC All Rights Reserved 1 15
16. 3 FIGURE 23 STANDARD WIRING SCHEMATIC FOR ECUs LISTED ABOVE 52 B Alternate IC Wiring Schemati Troubleshooting Use the wiring schematic on this page for the following Electronic D O 2 c pel Q O E gt O bs C O O O O O ps Co E op LO O NM YOSNAS 3lVd MVA Ad3ArT3G AuvWiHd L HOSN3S uiv 3unss3ud HH uL AWd TIH YL AWd NW HL AWd See the previous page for a NOISNAdSNS HOSN3S 3unss3ud second list of ECU part numbers 3unss3ud Au3Artaa AuUVONOO3S dS NaS NYD If your ECU part number does NW NJS NV IH Nas NYD not appear on either list please OT NJS NYD call 1 800 AIR BRAKE option 2 and speak with the Tech Team NWD VS ADL 3AIVA TOXLNOD NOILIVYL VS ADL OEA IN MONS ANY CNW DLV HLIM Q3 1VALLOV QVO 440 Sav HILIMS QVO 4340 SEV ON C GEGT VIA dV uaTivul dS3 Sav TZ IN9 S9 INb S9 NOLIVH1913NOO 08 23 Yad GATIVLSNI AWd ANY SSM 31XV IVNOILIGAV 92 aauin 3u 3ulM GALSIML YOLONGNOD unod OM 8T SNIUIM HOSN3S NYD NOLLYOINNWWOD 6E6T VIA HOLI E diNV1 dOLS VIA Q3CIAO ud Ce S319IH3A 3AIda 19220 T1V CNV 24V YOW d3YIMO3Y LAdNI HOLIMS diNY 1 dOLS YOLVOIGNI SAV 31VNIIA TTII OL ST33N YATIOULNOD ADOS NDF WOW Q31293NNOOSIG SI TX N3HM LT S3uIM 5NIWIM SWdL 6 SG 1A ANY 6 961L A NOLLVOIJIO3dS LONGOUd St ALON 3SIMY3HLO SSIINN DMV 9T HO NOILOAS SSOYD YOLONGNOD SI SHIM TIY
17. AA Right HLD Sensor CAN Common WSS DA Right WSS SA Right WSS AA Left Sensor CAN Supply NN Indicator Laud mw OEA CU Re e vec AA Bell 5 ABS Dee llenas A SE Diagnostic Switch AWD vehicles only AWD Transfer Case Troubleshooting Wiring ABS ATC WIRING Electronic Control Unit ECU Wiring Harness Connectors The Bendix ESP EC 80 Controller is designed to interface with AMP MCP 2 8 connectors as referenced in Figure 21 Follow all AMP requirements for the repair of wire harnesses All wire harness connectors must be properly seated The use of secondary locks is strongly advised All unused ECU connectors must be covered and receive proper environmental protection ABS Wiring Requirements As a matter of good practice and to ensure maximum system robustness always use the maximum size wire supported by the wire harness connectors for battery ignition ground Pressure Modulator Valve PMV Traction Control Valve TCV Interaxle Differential Lock and indicator lamp circuits All sensor and serial communications circuits J1939 must use twisted pair wiring one to two twists per inch See the appropriate Society of Automotive Engineers SAE document for additional details All wires must be carefully routed to avoid contact with rotating elements Wiring must be properly secured approximately every 6 to 12 inches using UV stabilized non metallic hose clamps or bow tie cable ties to prev
18. ABS with Stability Control on page 12 for further details During an RSP system intervention the vehicle automatically decelerates RSP can slow the vehicle with or without the operator applying the brake pedal and even when the operator is applying the throttle COMPONENTS The Bendix ESP EC 80 Controller s ABS function utilizes the following components e Bendix WS 24 Wheel Speed Sensors four or six depending on the configuration each with a clamping sleeve Refer to SD 13 4860 e Bendix M 40QR or M 40 HF Pressure Modulator Valves four five or six may be present refer to SD 13 4958 For legacy systems where a Bendix M 32 or M 32QR Pressure Modulator Valve is used refer to SD 13 4870 e Adash mounted tractor ABS Indicator Lamp e Aservice brake Relay Valve e Adash mounted trailer ABS Indicator Lamp e An optional blink code Activation Switch e An optional ABS Off road Switch The Bendix ESP EC 80 Controller s ESP RSP function utilizes the following additional components e ASteer Axle Traction Control Valve may be integral to the service brake Relay Valve or a stand alone device Sensor Clamping Sleeve Straight Speed Sensors 90 Speed Sensors FIGURE 2 BENDIX WS 24 WHEEL SPEED SENSORS Delivery Port 2 Supply Port 1 Electrical M 40X Connector Modulator N Exhaust Port 3 FIGURE 3 EXAMPLE OF A BENDIX M 40X MODULATOR e Adash mounted ESP Status I
19. Circuit AA Right PMV Configuration Error Miscellaneous DTCs J no OD zl A NOOA D CON CO N CO N CO N O N COO N Retarder Relay Open Circuit or Shorted to Ground ON Retarder Relay Open Circuit or Shorted to Voltage Pressure Modulator Valve PMV DTCs 802 3 12 8 PMV Common Shorted to Voltage ON ON 802 4 12 7 PMV Commons Shorted to Ground ON Miscellaneous DTCs ECU DTC F1A ON ON ECU DTC F14 ON ATC Disabled to Prevent Brake Fade 5 Traction Control Valve TCV DTCs TCV DA Solenoid Shorted to Voltage TCV DA Solenoid Shorted to Ground TCV DA Solenoid Open Circuit TCV DA Valve Configuration Error TCV SA Solenoid Shorted to Voltage TCV SA Solenoid Shorted to Ground TCV SA Solenoid Open Circuit TCV SA Valve Configuration Error Miscellaneous DTCs wo HI FW oa C AO NY FW N i OO Wheel Speed Sensors Reversed on an Axle ON ON ABS Dash Indicator Circuit DTC ON Warning Lamp Ground Pin Connected to GND in Conflict with Configuration ON f Settings Additional Axle WSS Configuration Error ON ON 59 APPENDIX B J1939 SPN AND FMI CODES AND THEIR BENDIX BLINK CODE EQUIVALENTS IT SPN FMI BEEN TI e es 31939 J1939 1st 2nd Diagnostic Trouble Code DTC Description Digit Digit Pressure Modulator Valve PMV DTCs 932 3 7 5 Steer Axle Left PMV Hold Solenoid Shorted to Voltage 932 4 i 4 Stee
20. Release Solenoid Open 940 3 9 2 Drive Axle Left PMV Release Solenoid Shorted to Voltage 940 4 9 1 Drive Axle Left PMV Release Solenoid Shorted to Ground 940 5 9 3 Drive Axle Left PMV Release Solenoid Open Circuit 941 3 10 2 Drive Axle Right PMV Release Solenoid Shorted to Voltage 941 4 10 1 Drive Axle Right PMV Release Solenoid Shorted to Ground 941 5 10 d Drive Axle Right PMV Release Solenoid Open Circuit 942 3 16 2 AA Left PMV Release Solenoid Shorted to Voltage 942 4 16 1 AA Left PMV Release Solenoid Shorted to Ground 942 5 16 3 AA Left PMV Release Solenoid Open Circuit 942 13 16 10 Output Configuration Error Additional Axle Left Release 943 3 Iy 2 AA Right PMV Release Solenoid Shorted to Voltage 943 4 17 1 AA Right PMV Release Solenoid Shorted to Ground 943 5 iG 3 AA Right PMV Release Solenoid Open Circuit 943 13 17 10 Output Configuration Error Additional Axle Right Release Miscellaneous DTCs ESP sensor supply too high or too Low ON U Bat too high or too Low for ESP sensor ON Stop Light Switch Defective ON ON Brake Lamp Input Mismatch With Brake Lamp Output ON ON Stop Lamp Switch Not Detected ON 60 APPENDIX B J1939 SPN AND FMI CODES AND THEIR BENDIX BLINK CODE EQUIVALENTS Bendix Blink Code SPN FMI Equivalent s Lamp Status J1939 J1939 1st 2nd Diagnostic Trouble Code DTC Description Digit Digit Pressure Modulator Valve PMV DTCs Trailer PMV Release Solenoid Shorted to Voltage
21. Stability CONTO lts alas 12 13 Important Safety Information About The Bendix ESP System sse 13 14 Dynamometer Test MOS eii 14 Automatic Tire Size Calibration RET 14 System Impact During Active Trouble Codes 15 ABS Parua o GOW METTE m Tm 15 System Reconfiguration einer oido ici 16 Electronic Control Unit ECU Ieconlidul alio Mariana a 16 Buceo fio ETT cmm 16 lo eo Ann A 17 53 Removal Of The Bendix ESP EC 80 Controller Assembly ooooccccccccconcccooccnnnocanoncnonononncnnanennnnnnnons 17 Obtaining A New Bendix ESP EC 80 Controller ooonccccccccccnccnnccccnonccnnncnonanncnnnonononnnnnnnnononncnnnnnss 17 Installing A New Bendix ESP EC 80 Controller oooccccnccccccnccnnnccncnonnnnnnononnnnnnnncnnnnnnennnnononnnnnnnnnnnnns 17 Steering Angle Sensor MGINIENANG E 18 Steering Angle Sensor Calibration 000nnnn0nannnnnosannnnnnoennnnrnsrnnrnnnnsnnrnrrernnnrrrossnnnrrreosnnrrrrnsnnnrnnrrennn nne 18 Removal Of The Yaw Rate Lateral Acceleration Sensor oocccccccncncncccnoconcoconnnnnnnnancnnnonanonnnnnannnnnnnnnens 19 Brake Demand Sensor ee EE 20 Pressure Sensor Installation Requirements en nnnnnannnenennneoennneornrnnnnnrrrrnnrrnrnnrrrrnnrrrrnnrrrrnnrrrrnnrreeenne 20 Troubleshooting Blink Codes and Diagnostic Modes nnn 21 23 A TU 21 St A OCS NER O AP nn E ROO 21 Wiztelns eae c TC eee 22 Troubleshooting Using PC Based or Hand Held Diagnostic Tools
22. Trailer PMV hold Solenoid Shorted to Voltage Trailer PMV Release Solenoid Shorted to Ground Trailer PMV hold Solenoid Shorted to Ground Trailer PMV Release Solenoid Open Circuit Trailer PMV hold Solenoid Open Circuit Trailer PMV Common Open Circuit andar A2 C CO CO NO CO A 0 DP c Co Trailer PMV Configuration Error Brake Demand Load Sensor DTCs PS3 Open or Shorted PS1 Open or Shorted PS Supply Voltage High Error PS Supply Voltage Low Error PS Supply Voltage Error PS Not Calibrated PS1 PS2 Plausibility Error Brake Demand Primary and Secondary Circuit Pressure Sensor Plausibility Error Pressure Sensor not configured PS2 Open or Shorted Miscellaneous DTCs ATC disable by switch Steering Angle Sensor DTCs SAS Static Signal SAS Signal Out of Range SAS Signal Reversed SAS Gradient Error SAS Long Term Calibration Error SAS Plausibility Check Ref YAW Rate SAS CAN Time out SAS Signal Invalid SAS Not Calibrated SAS Calibration in Progress SAS Detected But Not Configured Yaw Rate Sensor DTCs YRS Signal Out of Range YRS Reversed Signal YRS Invalid Signal YRS Gradient Error YRS Static BITE Error YRS Dynamic BITE Error YRS Fast Calibration Error YHRS Static Calibration Error YRS Normal Calibration Error YRS Plausibility Check Ref Yaw Rate YRS Plausibility Error Inside Model Based Limits YRS Plausibility Error Outside Model Based Limits YRS Vibration Detected YRS CAN Time out YRS Detected But N
23. Verify that there is an EEC2 broadcast from the address configured in the ABS ECU Check for other devices inhibiting J1939 communications Invalid pressure signals received from a vehicle Controller Verify the proper operation of brake demand sensors Check wiring between brake demand sensors and the vehicle Controller Verify the proper programming of vehicle Controller Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Check for other device inhibiting J1939 communications Invalid ESP messages on the J1939 link Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Verify the presence of engine and or retarder on J1939 Verify the proper programming of engine and or retarder Check for other devices inhibiting J1939 communications There is loss of communications between the EC 80 ECU and the transmission ECU over the J1939 link Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Verify the presence of transmission ECU on J1939 link Check for other devices inhibiting J1939 communications Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Check for other devices inhibiting J1939 communications Verify the ECU configuration Verify XBR message being broadcast from address 42 There is loss of communications between the Bendix EC 80 Controller and the transmission ECU over the J1939 link Check for damaged
24. YRS output Verify that correct YRS is being used Verify proper ECU programming Perform the YRS calibration procedure There is a YRS calibration error Verify the proper installation of the YRS Verify proper wiring between the ECU and the YRS Check the YRS output Verify that correct YRS is being used Verify proper ECU programming Perform the YRS calibration procedure There is a YRS calibration error Verify the proper installation of the YRS Verify proper wiring between the ECU and the YRS Check the YRS output Verify that correct YRS is being used Verify proper ECU programming Perform the YRS calibration procedure The ECU has detected an incorrect YRS signal Verify the proper installation of the YRS Verify proper wiring between the ECU and the YRS Check the YRS output Verify that correct YRS is being used Verify proper ECU programming Perform the YRS calibration procedure The ECU if configured must confirm that YRS and SAS signals match The vehicle must be exposed to an S shaped driving maneuver for this DTC to automatically clear If the DTC does not clear even after the S shaped driving maneuver check and correct the orientation of the YRS and then repeat the maneuver Inspect the YRS mounting and verify it is securely mounted Note that the YRS may not be relocated from the OEM installed position on vehicle without written Bendix Engineering approval Verify that the ECU is configured for ESP Troubles
25. access stored ECU data or share it with others except with the consent of the vehicle owner in response to an official request by law enforcement or other governmental agency as part of Bendix s defense of litigation or as otherwise required by law Data that Bendix receives may also be used for research purposes or made available to others for research purposes where a need is shown and the data is not linked to a specific vehicle or owner Bendix brand antilock ECUs are not designed to store data for purposes of accident reconstruction and Bendix ACom Diagnostic Software is not intended to retrieve data for purposes of accident reconstruction Bendix makes no representations as to the accuracy of data retrieved and interpreted from Bendix ECUs for purposes of accident reconstruction Troubleshooting General GENERAL SAFETY GUIDELINES Read and follow the General Safety Guidelines shown on page two 2 of this document REMOVAL OF THE BENDIX ESP EC 80 CONTROLLER ASSEMBLY 1 Turn vehicle ignition off 2 Remove as much contamination as possible prior to disconnecting electrical connections 3 Note the Bendix ESP EC 80 Controller assembly mounting position on the vehicle 4 Disconnectthe electrical connectors from the Controller 5 Remove and retain the mounting bolts that secure the Controller The VIN of the vehicle is stored in the Bendix ESP EC 80 Controller s internal memory and is cross checked by the Elect
26. applies the outside front brake while in an under steer condition the inside rear brake is applied See Figure 13 IMPORTANT SAFETY INFORMATION ABOUT THE BENDIX ESP SYSTEM The Bendix ESP EC 80 Controller may reduce the vehicle speed automatically The Bendix ESP system can make the vehicle decelerate automatically and can slow the vehicle with or without the operator applying the brake and even when the throttle is being applied To minimize unexpected deceleration and reduce the risk of a collision the operator must e Avoid aggressive driving maneuvers such as sharp turns or abrupt lane changes at high speeds which might trigger the stability system and e Always operate the vehicle safely drive defensively anticipate obstacles and pay attention to road weather and traffic conditions Bendix ABS ATC and ESP systems are no substitute for prudent careful driving Towing Doubles Or Triples May Reduce The Effectiveness Of Stability Systems The Bendix ESP system with the EC 80 Controller is designed and optimized for trucks and for tractors that tow single trailers If a tractor equipped with Bendix ESP is used to power multiple trailer combinations known as doubles or triples the effectiveness of the Bendix ESP system may be greatly reduced Extremely careful driving is always required when towing doubles or triples Excessive speed and aggressive maneuvers such as sharp turns sudden ste
27. are detected Traction Control with Engine Torque Limiting The Bendix ESP EC 80 Controller uses Engine Torque Limiting to control drive axle wheel slip This is commu nicated to the engine control module using J1939 and is available at all vehicle speeds Bendix SMART ATC System The Bendix ESP EC 80 Controller has an additional feature known as the Bendix SMART ATC system This system monitors the accelerator pedal position using J1939 to help provide optimum traction and vehicle stability By determining the driver s throttle input and adapting the target slip of the drive wheels to the driving situation the Bendix SMART ATC system allows higher wheel slip when the accelerator pedal is applied above a preset level The wheel slip allowed by the Bendix SMART ATC system is decreased when driving through a curve for improved stability Disabling ATC Engine Control and the Bendix SMART ATC System ATC Engine Control and the Bendix SMART ATC system will be disabled under the following conditions 1 In response to a serial communications request from an off board tool 2 At power up until the ECU detects a service brake application 3 If the ECU receives a J1939 message indicating that the vehicle is parked 4 f the dynamometer test mode is active This may be accomplished via an off board tool or the diagnostic Blink Code Switch or 5 When certain DTC conditions are detected 11 Optional ATC Mud Snow O
28. corroded or damaged connectors Check for damaged or reversed J1939 wiring Check for corroded or damaged connectors on J1939 link Verify the presence of engine ECU on the J1939 link Verify the ECU configuration Apply and release service brake Check for brake switch input into ECU see system wiring schematic With service brake released check for presence of the stop lamp bulb With service brake applied verify system voltage is now present at the stop lamp switch input to the ECU Check for damaged wiring between ECU stop lamp switch and bulb Check for corroded or damaged connectors Check for damaged or reversed J1939 wiring Check for corroded or damaged connectors on J1939 link Verify the presence of engine ECU on the J1939 link Verify the ECU configuration ATC or ESP is disabled ECU has been placed in the Dynamometer Test Mode by either the diagnostic Blink Code Switch or a hand held or PC based diagnostic tool Clear DTCs to exit Dynamometer Test Mode Verify vehicle contains a retarder relay Verify the ECU configuration Check wiring between ECU and retarder relay Verify no continuity between retarder disable output of Bendix ESP EC 80 Controller and ground Verify condition and wiring of the retarder relay Check wiring between ECU and retarder relay Verify no continuity between retarder disable output of Bendix ESP EC 80 Controller and voltage Verify condition and wiring of the retarder relay Check operation of diagnos
29. for damaged or reversed J1939 wiring Check for damaged or corroded connectors Verify that the message is being transmitted Verify that the data for differential lock s is correct Verify the ECU configuration Verify 60 ohms of resistance between X1 pin 7 and X1 pin 8 Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Verify that the message is being transmitted Verify that the data for Air Suspension Control 1 is correct Verify the ECU configuration Verify 60 ohms of resistance between X1 pin 7 and X1 pin 8 Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Verify message is being transmitted Verify the ECU configuration Verify 60 ohms of resistance between X1 pin 7 and X1 pin 8 Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Verify message is being transmitted Verify the ECU configuration Verify only one ABS ECU is connected on J1939 bus broadcasting OBh equals 13 decimal Verify only one TPMS ECU is connected on J1939 bus broadcasting 33h Verify 60 ohms of resistance between X1 pin 7 and X1 pin 8 Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Check for messages being transmitted received Verify 60 ohms of resistance between X1 pin 7 and X1 pin 8 Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Check for messages being transmitted receiv
30. for damaged or reversed J1939 wiring Check for damaged or corroded connectors Verify the presence of a retarder on J1939 Link Verify that the message is being transmitted Verify that the data in torque speed control Verify the ECU configuration Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Verify the presence of transmission ECU on J1939 link Verify that the message is being transmitted Verify that the data for shift in process torque configuration lock driveline engaged is correct Verify the ECU configuration Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Verify that the message is being transmitted Verify that the data for reference torque is correct Verify the ECU configuration 45 Troubleshooting Diagnostic Trouble Codes DTCs J1939 Bendix ESP system related continued 1st Blink 46 Code 26 Location J1939 Bendix ESP 2nd Blink Code 12 16 20 21 22 system related Diagnostic Trouble Code Description Time out or invalid data for Configuration of Electronic Engine Controller 1 ESP Message Invalid Data Transfer Time out of EC1 ESP Message Time out or invalid data for Configuration of Driveline Line Retarder ESP Message Time out or invalid CAN data Electronic Engine Controller ESP Message Time out or invalid CAN data Electrionic Transmission Controller 2 message required for ESP
31. if the serial link shows that the vehicle has a retarder device present the ECU will configure itself to communicate with the retarder device for improved ABS performance For example if the ECU detects the presence of a retarder disable relay during a reconfiguration it will configure itself to control the relay to disable the retarding device as needed Reconfiguration Using the Blink Code Switch With ignition power removed from the Bendix ESP EC 80 Controller depress the Blink Code Switch After the ignition power is activated depress and release the switch seven 7 times to initiate a reconfiguration event Diagnostic Tool A reconfiguration event may be initiated using a hand held or PC based diagnostic tool to communicate with the ECU over the SAE J1939 diagnostic link 6S 5M Configuration A Bendix ESP EC 80 Controller will configure for 6S 5M operation when a reconfiguration event is initiated and the ECU detects that an additional axle Pressure Modulating Valve PMV is wired as follows PMV Connector ECU Connector Hold Right Additional Axle Hold Release Left Additional Axle Release Common Right Additional Axle Common 16 DATA STORAGE Depending on the product type and version Bendix brand ECUs may store data related to troubleshooting diagnostics service needs vehicle system operating status and vehicle operator inputs No personally identifying data e g name gender or age is recorded Bendix will not
32. is applied or remain illuminated indicate the need for maintenance HS A If any of the described lamp behaviors do not occur or if the lamp remains on during operation have the vehicle serviced by a qualified mechanic as soon as possible to restore full system functionality Trailer ABS Lamp ON for three 3 seconds ON for three 3 seconds Some vehicle manufacturers may illuminate the trailer ABS indicator lamp at power up regardless of whether a PLC signal is detected from the trailer or not Consult the vehicle manufacturer s documentation for more details Uses dash switch Not for firm road surfaces Allows more wheel lock up less ABS intervention Mode only applies under 25 mph Over 25 mph the system reverts to full ABS including ATC ESP and upon exiting off road mode the ATC lamp extinguishes OR depending on vehicle options a vehicle can have either ABS off road or HSA During HSA Event Lamp OFF HSA Manually Disabled Flashes slowly The HSA lamp is illuminated only at power up or if an HSA DTC is present Uses dash switch Increases allowable wheel slip during ATC interventions Not for firm road surfaces During an Automatic Traction Control ATC Event Flashes quickly Reduces wheel slip during acceleration at low speeds Lamp ON During Dynamometer Mode ATC Disables ATC monitoring functions e When not in Dynamometer Mod
33. is performed only when the vehicle is stationary if the vehicle moves the Chuff Test will not be performed The Bendix ESP EC 80 Controller will perform a PMV Chuff Test on all installed modulators in the following order e Steer Axle Right PMV e Steer Axle Left PMV e Drive Axle Right PMV e Drive Axle Left PMV e Additional Axle Right PMV e Additional Axle Left PMV then Drive Axle TCV The pattern will then repeat itself See Figure 11 Vehicles with a Bendix ESP EC 80 Controller following the completion of the second round of PMV amp TCV Chuff Tests the Controller if configured to do so will perform a test to cross check the trailer PMV operation with the vehicle stop lamps If the trailer PMV circuit is mis wired including the steer axle TC V the PMV will exhaust a large amount of air or none at all NOTICE If there are any active DTCs the stop lamp cross check portion of the Chuff Test will not be carried out until all DTCs are fully diagnosed and the corresponding repairs are successfully conducted The ESP ATC dash indicator will also illuminate when there are active ABS ATC or ESP DTCs The ECU will not perform the PMV Chuff Test when wheel speed sensors show that the vehicle is in motion ABS OPERATION Bendix ABS uses wheel speed sensors ABS pressure modulator valves and an ECU to control either four or six wheels of a vehicle The Bendix ESP EC 80 Controller monitors individual wheel t
34. lt 12 VDC 10 VDC 8VDC 6 VDC 4 VDC 2 VDC 0 VDC FIGURE 8 POWER LINE WITHOUT PLC SIGNAL 12 VDC 10 VDC 8 VDC 6 VDC 4 VDC 2 VDC 0 VDC FIGURE 9 POWER LINE WITH PLC SIGNAL The application of PLC technology for the heavy vehicle industry in North America is known as PLC4Trucks The Bendix ESP EC 80 Controller supports PLC communications in accordance with SAE J2497 PLC SIGNAL An oscilloscope can be used to measure or identify the presence of a PLC signal on the power line The PLC signal is an amplitude and frequency modulated signal Depending on the filtering and load on the power line the PLC signal amplitude can range from 5 0 mVp p to 7 05 Vp p Suggested oscilloscope settings are AC coupling with one volt div 100 usec div The signal should be measured at the ignition power input of the Bendix EC 80 Controller Note An ABS trailer equipped with PLC or a PLC diagnostic tool must be connected to the vehicle in order to generate a PLC signal on the power line BENDIX ESP EC 80 CONTROLLER INPUTS Battery and Ignition Inputs The Bendix ESP EC 80 Controller operates at a nominal supply voltage of 12 or 24 volts depending on the ECU The battery input is connected through a 30 amp fuse directly to the battery The ignition input is applied by the ignition switch circuit through a 5 amp fuse Ground Input The Bendix ESP EC 80 Controller supports one ground input See pag
35. pause of three and a half 3 5 seconds the ECU will begin responding with output information blinks See Figure 15 for an example Time in Seconds 2 5 second pause between messages 3 5 second initial pause x N 1 Switch Activation FIGURE 15 EXAMPLE OF A BLINK CODE MESSAGE 1 5 second pause between digits N Lamp stays illuminated for 5 seconds showing end of messages 21 Blink Code Timing The Bendix ESP EC 80 Controller responds with a sequence of blink codes The overall blink code response from the Electronic Control Unit ECU is called a message Each message includes depending on the mode selected by the technician a sequence of one or more groups of blinks Simply record the number of blinks for each sequence and then use the troubleshooting index on page 26 for active or inactive Diagnostic Trouble Codes DTCs and you will be directed to the page that provides troubleshooting information NOTE 1 Sequences of blinks illuminate the ABS indicator lamp for half a second with half second pauses between them 2 Pauses between blink code digits are one and a half 1 5 seconds 3 Pauses between blink code messages are two and a half 2 5 seconds 4 The lamp remains on for five 5 seconds at the end of messages Once the ABS indicator lamp begins displaying a sequence of codes it continues until all blink code messages have been displayed and then returns to the normal op
36. removal Use no more torque than is necessary to firmly secure the ECU into position Over tightening the mounting hardware can cause damage to the Bendix ESP EC 80 Controller 2 Reconnect the electrical connectors to the Bendix EC 80 Controller 3 Apply power and monitor the Bendix ESP EC 80 Controller power up sequence to Verify the proper system operation See Troubleshooting Wiring section beginning on page 45 for more information on wire harnesses The Bendix ESP system with the EC 80 Controller is validated with specific Bendix brand components Always use Bendix brand replacement parts to prevent compromising system performance Bendix is not able to validate the safe and reliable use of substitute or alternate components that may be available from other manufacturers since suppliers of a non Bendix brand ABS component may implement design changes in their component without the knowledge or approval of Bendix which could negatively affect antilock system reliability and braking performance issues 17 STEERING ANGLE SENSOR MAINTENANCE Service Checks 1 Check all wiring and connectors Some installations also include an intermediate connector from the steering angle sensor to the main vehicle wire harness Make sure all connections are free from visible damage 2 Examine the sensor Make sure the sensor its mounting screws and the interface between the hub and the steering column are not damaged Diagnostics
37. spin about its vertical axis During operation if the friction between the road surface and the tires is not sufficient to oppose lateral side forces one or more of the tires can slide causing the truck tractor to spin These events are referred to as either an under steer situation where there is a lack of vehicle response to steering input due to tire slide on the steer axle or an over steer where the tractor s rear end slides out due to tire slide on the rear axle situation Generally shorter wheelbase vehicles tractors for instance have less natural yaw stability while longer wheelbase vehicles straight trucks for instance have greater natural yaw stability Factors that influence yaw stability are wheelbase suspension steering geometry weight distribution front to rear and vehicle track width Yaw Control Yaw control responds to a wide range of low to high friction surface scenarios including rollover jackknife and loss of control It is the recommended system for all power vehicles and especially critical for tractors pulling trailers In the case of vehicle slide over steer or under steer situations the system will reduce the throttle and then brake one or more of the four corners of the vehicle in addition to potentially applying the trailer brakes thus applying a counter force to better align the vehicle with an appropriate path of travel For example in an over steer situation the system
38. the YRS LAS Check YRS LAS output Verify that correct YRS LAS is being used Verify proper ECU programming Perform LAS calibration procedure LAS calibration error Verify the proper installation of the YRS LAS Verify proper wiring between the ECU and the YRS LAS Check YRS LAS output Verify that correct YRS LAS is being used Verify proper ECU programming Perform LAS calibration procedure ECU has detected an incorrect LAS signal Verify the proper installation of the YRS LAS Verify proper wiring between the ECU and the YRS LAS Check YRS LAS output Verify that correct YRS LAS is being used Verify proper ECU programming Perform LAS calibration procedure ECU has detected an incorrect LAS signal Verify the proper installation of the YRS LAS Verify proper wiring between the ECU and the YRS LAS Check YRS LAS output Verify that correct YRS LAS is being used Verify proper ECU programming Perform LAS calibration procedure ECU has detected an erratic signal Verify the proper installation of the YRS LAS Verify proper wiring between the ECU and the YRS LAS Check YRS LAS output Verify that correct YRS LAS is being used Verify proper ECU programming Perform LAS calibration procedure Note When checking for voltage at YRS LAS amp SAS the voltage will only be present momentarily at key ON 1 Follow the steps shown in the Yaw Rate Sensor troubleshooting section for calibration and troubleshooting of the Lateral Accelera
39. tool 1st Number System Power hom ad Wheel Speed Sensors a esos OOO o esensors ard Number Pressure Modulator Vaives a Lr eises OOOO 5 5Momos SSS 6 5Moiios ath Number ABS Configuration 1 4SMMorSEM OOOO 2 SAM 3 jem Sth Number Traction Control Configuration 2z omo S 3 ATC Engine ContiolOny 4 ATC Brake ContiolOny 5 FulATC EngineConto amp BrakeConro a Number Retarder Configuration 1 jNoReade O 2 mme 3 RetarderRelay OOOO 4 1909 Retarder Retarder Relay 1 NoStabilty Progam 2 tectonic Stability Program ESP FIGURE 17 SYSTEM CONFIGURATION CHECK Reconfigure ECU Mode Controller reconfiguration is carried out by using the Reconfigure ECU Mode See page 16 Note To enter the Reconfiguration Mode the Blink Code Switch must be held in before the application of ignition power Once the power is supplied the switch is released and then pressed seven times Other Methods Troubleshooting and DTC clearing as well as reconfigura tion may also be carried out using hand held or PC based diagnostic tools such as the Bendix Remote Diagnostic Unit RDU Bendix ACom Diagnostic Software or similar tools 23 Troubleshooting Using PC Based or Hand Held Diagnostic Tools BENDIX ACOM DIAGNOSTIC SOFTWARE ACom Diagnostics Diagnostic Software forABS Bendix veut 1996 2014 Bendix Commercial Vehicle System
40. 3 Time out at J1939 Time out of message or Invalid Data Received from Transmission Transfer information on J1939 Message Required for ESP Time out or Invalid CAN Data Electronic Axle Controller 1ESP Message J1939 CAN Messages Are Not Being Transmitted Received J1939 Serial Link O PO MPO h M bb bb rnm N N N N nm i N Steer Axle Left WSS Excessive Air Gap Steer Axle Left WSS Open or Shorted Steer Axle Left WSS Wheel End Steer Axle Left Erratic Sensor Signal Steer Axle Left WSS Signal Low at Drive Off Steer Axle Left WSS Loss of Sensor Signal Steer Axle Left WSS Tire Size Calibration Steer Axle Right WSS Excessive Air Gap Steer Axle Right WSS Open or Shorted Steer Axle Right WSS Wheel End Steer Axle Right Erratic Sensor Signal Steer Axle Right WSS Signal Low at Drive Off Steer Axle Right WSS Loss of Sensor Signal Steer Axle Right WSS Tire Size Calibration Drive Axle Left WSS Excessive Air Gap Drive Axle Left WSS Open or Shorted Drive Axle Left WSS Wheel End Drive Axle Left Erratic Sensor Signal Drive Axle Left WSS Signal Low at Drive Off Drive Axle Left WSS Loss of Sensor Signal Drive Axle Left Tire Size Calibration Drive Axle Right WSS Excessive Air Gap Drive Axle Right WSS Open or Shorted Drive Axle Right WSS Wheel End Drive Axle Right Erratic Sensor Signal Drive Axle Right WSS Signal Low at Drive Off Drive Axle Right WSS Loss of Sensor Signal Drive Axle Right Tire Size Calibration Additional
41. 39 CAN Messages Are Not Being Transmitted Received J1939 Troubleshooting Tests 1 Take all measurements at ECU harness connector Check for damaged or reversed J1939 wiring Check for corroded or damaged wiring connector problems such as opens or shorts to voltage or ground Check for other J1939 devices which may be loading down inhibiting J1939 X1 communication Repair Information There is loss of communications between the Bendix ESP EC 80 Controller and the engine Electronic Control Unit ECU over the J1939 link Check for damaged or reversed J1939 wiring Check for corroded or damaged connectors Verify the presence of engine ECU on the J1939 link Verify the ECU configuration Check for other devices inhibiting J1939 communications There is loss of communications between the Bendix EC 80 Controller and the transmission ECU over the J1939 link Check for damaged or reversed J1939 wiring Check for corroded or damaged connectors Verify the presence of engine ECU on the J1939 link Verify the ECU configuration Check for other devices inhibiting J1939 communications Verify 60 ohms of resistance between X1 pin 7 and X1 pin 8 Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Verify that the message is being transmitted Verify data for Electronic Axle Controller1 is correct Verify the ECU configuration Verify 60 ohms of resistance between X1 pin 7 and X1 pin 8 Check
42. AMOMETER are conducted on a Bendix Wingman Advanced equipped vehicle A You should consult the vehicle manufacturer s operating and service manuals and any related literature in conjunction with the Guidelines above Even with the Bendix ESP system with the EC 80 Controller the driver remains responsible for ensuring vehicle stability during operation The braking system can only function within the limits of physics The system helps mitigate potential vehicle stability incidents but cannot prevent them in all cases Other factors such as driving too fast for road traffic or weather conditions oversteering an excessively high vehicle Center of Gravity CG or poor road conditions can cause vehicle instability that is beyond the capability of any stability system to mitigate In addition the effectiveness of Bendix ESP system with the EC 80 Controller can be greatly reduced on vehicles towing multiple trailer combinations The Bendix ESP system with the EC 80 Controller see page 12 may only be used on vehicles tested and approved by Bendix engineering The tests produce a validated parameter data set for use by the vehicle s Bendix ESP EC 80 Electronic Control Unit ECU When replacing an ECU only specific Controllers with the correct parameter set may be used See Obtaining a New Bendix ESP EC 80 Controller on page 17 for further details Bendix ESP system with the EC 80 Controller equipped vehicles should
43. Acceleration Sensor DTC The Bendix ESP system is disabled Bendix ABS and ATC systems remain active Brake Demand Pressure Sensor DTC The Bendix ESP system is disabled Bendix ABS and ATC systems remain active Load Sensor DTC The Bendix ESP system is disabled Bendix ABS and ATC systems remain active Steer Axle Traction Control Valve TCV DTC The Bendix ESP system is disabled Bendix ABS and ATC systems remain active Trailer Pressure Modulator Valve PMV DTC The Bendix ESP system is disabled Bendix ABS and ATC systems remain active 15 SYSTEM RECONFIGURATION The Bendix ESP EC 80 Controller is designed to allow the technician to change the default system settings chosen by the vehicle OEM to provide additional or customized features Depending on the model the customizable features include ABS control settings engine module communication etc Many of these settings can be reconfigured using a hand held or PC based software such as the Bendix ACom Diagnostic software ECU RECONFIGURATION Reconfiguring a Bendix ESP EC 80 Controller may be carried out by using the Blink Code Switch or by using a hand held or PC based diagnostic tool Note During the reconfiguration process and independently from any reconfiguration being carried out by the technician the Electronic Control Unit ECU will automatically check the J1939 serial link and communicate with other vehicle modules In particular
44. Axle Left WSS Excessive Air Gap 2 2 2 2 2 2 2 9 3 3 3 3 3 3 4 4 4 4 4 4 4 5 5 5 5 5 5 5 sch N A A M OO OD zl SM oO GO N AN OO GO N SM OO WO ech D APPENDIX B J1939 SPN AND FMI CODES AND THEIR BENDIX BLINK CODE EQUIVALENTS Lamp Status Bendix Blink Code SPN FMI Equivalent s em J1939 J1939 1st 2nd Diagnostic Trouble Code DTC Description Digit Digit oo Additional Axle Left WSS Open or Shorted Additional Axle Left WSS Wheel End Additional Axle Left Erratic Sensor Signal Additional Axle Left WSS Signal Low at Drive Off Additional Axle Left WSS Loss of Sensor Signal Additional Axle Left Tire Size Calibration Additional Axle Right WSS Excessive Air Gap Additional Axle Right WSS Open or Shorted Additional Axle Right WSS Wheel End Additional Axle Right Erratic Sensor Signal Additional Axle Right WSS Signal Low at Drive Off Additional Axle Right WSS Loss of Sensor Signal Additional Axle Right Tire Size Calibration Pressure Modulator Valve PMV DTCs Steer Axle Left PMV Common Open Circuit Steer Axle Left PMV Configuration Error Steer Axle Right PMV Common Open Steer Axle Right PMV Configuration Error Drive Axle Left PMV Common Open Circuit Drive Axle Left PMV Configuration Error Drive Axle Right PMV Common Open Circuit Drive Axle Right PMV Configuration Error AA Left PMV Common Open Circuit AA Left PMV Configuration Error Additional Axle Right PMV Common Open
45. BS systems and Bendix makes no claims for its operation and or usability with other brands of ABS systems 24 LED lights illuminate Diagnostic Trouble Codes 10 locations in total Pe E S P e z Bendix AABS DIAGNOSTR wu FIGURE 19 THE BENDIX REMOTE DIAGNOSTIC UNIT Features of the Bendix RDU Tool The Bendix RDU tool attaches to the 9 pin diagnostic connector in the cab of the vehicle The Bendix RDU tool allows the technician to Troubleshoot ABS system component problems using DTC reporting via LEDs Reset DTCs on Bendix ESP EC 80 Controllers by holding a magnet over the reset in the center of the RDU tool for less than six 6 seconds and Enter the Self Configuration Mode used by Bendix ESP EC 80 Controllers by holding a magnet over the reset area for greater than six 6 seconds but less than 30 seconds How the Bendix RDU Operates See Figure 14 for typical vehicle connector locations When the Bendix RDU tool is plugged into the diagnostic connector all the LEDs will illuminate and the green LED will flash four 4 times to indicate communications have been established If the Bendix ESP EC 80 Controller has no active DTCs only the green LED will remain illuminated If the Bendix ESP EC 80 Controller has at least one active DTC the RDU tool displays the first DTC by illuminating the red LEDs indicating the malfunctioning ABS component and its location on the vehicle See Figure 20
46. Bendix ESP EC 80 Controllers have a feature referred to as drag torque control which reduces wheel slip on a driven axle due to driveline inertia This condition is addressed by increasing the engine torque to overcome the inertia Drag torque control increases vehicle stability on low traction road surfaces during down shifting or retarder braking actual movement using wheel speed sensors a lateral acceleration sensor a yaw rate sensor and a steering angle sensor If the vehicle shows a tendency to leave an appropriate travel path or if critical threshold values are approached the system will intervene to assist the driver A Real World Example Of How Yaw Control Operates Excessive speed exceeds the threshold creating a situation where a vehicle is likely to spin and jackknife The Bendix Yaw Control system reduces engine throttle and selectively applies brakes to reduce the tendency to jackknife FIGURE 13 YAW CONTROL EXAMPLE Bendix Roll Stability Program RSP9 Bendix RSP an element of the overall Bendix ESP system with the EC 80 Controller addresses rollover conditions In the case of a potential roll event the ECU will override the throttle and quickly apply brake pressure at all wheel ends to slow the vehicle combination The level of braking application during an RSP event will be proportional to roll risk See Figure 12 Yaw Stability Yaw stability counteracts the tendency of a vehicle to
47. Common 4 9 to 5 5 Ohms Hold to Common 4 9 to 5 5 Ohms Helease to Hold 9 8 to 11 0 Ohms Release Hold Common to Voltage or Ground When troubleshooting modulator Diagnostic Trouble Codes DTCs check inactive DTCs and the event history for over voltage or excessive noise DTCs If one of these is found troubleshoot these DTCs first before the PMV Open Circuit no continuity Cab mount ECU Looking into the wire harness connector Left Steer Axle Hold Left Steer Axle Release Left Steer Axle Common Right Steer Axle Hold Right Steer Axle Common Right Steer Axle Release Right Drive Axle Common Right Drive Axle Hold Right Drive Axle Release Left Drive Axle Common Left Drive Axle Hold Left Drive Axle Release x3 Left Additional Axle Hold 15 Way if Left Additional Axle Common the ECU is Left Additional Axle Release Right Additional Axle Common configured for Right Additional Axle Hold 6 modulators Right Additional Axle Release Trailer PMV Hold Trailer PMV Release Trailer PMV Common 31 Troubleshooting Diagnostic Trouble Codes DTCs J1939 Serial Communications 1st Blink Code 32 11 2nd Blink Code 10 Location J1939 Diagnostic Trouble Code Description J1939 Serial Link J1939 Electronic Retarder Time out or Invalid Signal J1939 Electronic Engine Controller 1 Time out or Invalid Signal J1939 Electronic Engine Controller 2 T
48. Controller uses a serial communications message to operate the lamp e mail ABSObendix com be sure to specify the ECU part number or call 1 800 AIR BRAKE 1 800 245 2725 and speak to the Bendix Tech Team Interaxle Differential Lock Control AWD Transfer Case Bendix ESP EC 80 Controllers can control the interaxle differential lock AWD transfer case This is recommended on AWD vehicles but the ECU must be specially configured to provide this feature E mail ABS bendix com for more details 7 INDICATOR LAMPS AND POWER UP SEQUENCE NOTICE The vehicle operator should Verify the proper operation of all installed indicator lamps ABS ATC ESP and trailer ABS when applying ignition power and during vehicle operation See Figure 10 Dash Lamp Behavior for the Bendix ESP EC 80 Controller Lamp ON for three 3 seconds Ignition on start up trailer with Power Line Carrier PLC ON for 2 5 seconds 3 seconds after ignition with no Diagnostic Trouble Codes DTCs At Vehicle Startup Normal During an ATC Lamp flashes slowly every 2 5 seconds Flashes quickly Event Vehicles with Hill Start Aid HSA During HSA Mode Hill Start Hill Start Assist Flashes slowly every 2 5 seconds Special Mode Operation During an ATC ESP OFF Flashes quickly Event Lamp OFF Lamp OFF Lamp OFF SCH Lamp OFF Lamps that do not illuminate as expected when ignition power
49. ECU MOUNTING The Bendix ESP EC 80 Controller is not protected against moisture and must be mounted in an environmentally protected area All wire harness connectors must be properly seated The use of secondary locks is strongly recommended The Bendix ESP EC 80 Controller utilizes connectors from the AMP MCP 2 8 product family HARDWARE CONFIGURATIONS Bendix ESP EC 80 Controllers support applications up to six sensor six modulator 6S 6M installations with ATC and drag torque control They can also support Hill Start functions All 12 volt models support Power Line Carrier PLC 24 volt models do not support PLC See Figure 7 for more details HSA Bendix ABS Ofi ATC SCH Le ES Hill Start eTrac Road EN E Aid Feature system Input Voltage PLC lators Serial Retarder Communication Rela y 31939 For information about the Bendix eTrac automated air suspension transfer system see SD 13 21021 FIGURE 7 BENDIX ESP EC 80 CONTROLLER FEATURES BENDIX ESP EC 80 CONTROLLERS USE POWER LINE CARRIER PLC All new towing vehicles built since March 1 2001 have had an in cab trailer ABS Indicator Lamp installed Trailers built since March 1 2001 transmit the status of the trailer ABS over the power line the blue wire of the J560 connector to the tractor using a Power Line Carrier PLC signal See Figures 8 and 9 Typically the signal is broadcast by the trailer ABS Electronic Control Unit ECU
50. IO DLV ET up N st m wn o 6 ZL SL 8L c WWOO SWd L CQ3123NNOO LON 320 TH31NI GNI MS DVIO YO SIG 21V 318VSIO VSH NOLLINDI aNnou QNI 21V AdiLIV8 IH eer OT erer COINVO TIH NYD NWD VG ADL va ADL ONG SWdL FIGURE 24 CAB WIRING SCHEMATIC FOR ECU LISTED ABOVE 53 GLOSSARY ABS Antilock Brake System ABS Event Impending wheel lock situation that causes the ABS Controller to activate the modulator valve s ABS Indicator Lamp An amber lamp which indicates the operating status of an antilock system When the indicator lamp is on ABS is disabled and the vehicle reverts to normal brake operation Air Gap Distance between the Sensor and tone ring ASR Automatic Slip Regulation Another name for traction control ATC Automatic Traction Control An additional ABS function in which engine torque is controlled and brakes are applied differentially to enhance vehicle traction ATC ESP Lamp A lamp that indicates when stability functions including traction control roll stability program or yaw control are operating Channel A controlled wheel site CAN Controller Area Network J1939 is an SAE version of the CAN link Clear Codes System to erase historical Diagnostic Trouble Codes DTOs from the ECU from either the Diagnostic Switch or from a hand held diagnostic tool only repaired DTCs may be cleared Configuration The primary objective is to identif
51. IT X4 3 Load Sensor Verify Continuity 6 Follow the prompts to test the Brake Demand Sensor s and or the Load Sensor 43 Troubleshooting Diagnostic Trouble Codes DTCs 1st Blink 44 Code 25 2nd Blink Code 1 Location Valves Diagnostic Trouble Code Description Differential Lock Solenoid Open Differential Lock Solenoid Shorted to Ground Differential Lock Solenoid Shorted to Voltage I O 3 Open Circuit I O 3 shorted to Ground I O 3 Shorted to Battery Output Configuration Error Diff Output Configuration Error 1 0 3 Valves Miscellaneous Repair Information Verify resistance between Diff solenoid and Diff common Check for corroded damaged wriing or connectors between the Electronic Control Unit ECU and the Diff solenoid Verify no continuity between the Diff Lock Solenoid and ground Check for corroded damaged wiring or connectors between the ECU and Diff Lock Solenoid Verify no continuity between the Diff Lock Solenoid and voltage Check for corroded damaged wiring or connectors between the ECU and Diff Lock Solenoid Verify resistance for 1 03 circuit Check for corroded damaged wiring or connector between ECU and I O Check for a short circuit condition between ground and the l O 3 circuit Verify resistance between Input Output and ground is open Check for a short circuit condition between voltage and the UO 3 circuit Verify resistance between Input Output and v
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53. S Check SAS output SAS calibration error Verify the proper installation of the SAS Verify proper wiring between the ECU and the SAS Check SAS output Verify that correct SAS is being used Verify proper ECU programming Perform SAS calibration procedure ECU has detected incorrect SAS signal as compared to the Yaw Rate sensor signal Verify the proper installation of the SAS Verify proper wiring between the ECU and the SAS Check SAS output Verify that correct SAS is being used Verify proper ECU programming Perform SAS calibration procedure Verify the ECU is configured for ESP Troubleshooting Diagnostic Trouble Codes DTCs Steering Angle Sensor SAS Bendix SAS 60 Sensor continued bad 0000 Steering Angle Sensor SAS Connector Looking into wire harness connector Note When checking for voltage at YAW LAS amp SAS the voltage will only be present momentarily at key ON Steering Angle Sensor Tests 1 Measure resistance between input voltage and ground at the sensor wiring harness connector Verify continuity between the Electronic Control Unit ECU and SAS 60 and Yaw Rate Sensor typically YAS 70 or YAS 60 Ground Input the ECU ECU Wire Harness Measurement Terminal Terminal 3 Verify wiring between the Steering Angle Sensor and 4 to Voltage amp Verify open circuit no Ground continuity Connector Pin Function ME 12 Way SAS Wire Verify Continuity power ground 3 to V
54. S off road mode on vehicles equipped with this optional feature it will switch off the retarder only when ABS is active on a steer axle wheel and a drive axle wheel Optional ABS Off Road Mode On some road conditions particularly when the driving surface is soft the stopping distance with conventional ABS may be longer than without ABS This can occur when a locked wheel on soft ground or loose gravel plows up the road surface in front of the tire changing the rolling friction value Although vehicle stopping distance with a locked wheel in the absence of ABS may be shorter than 10 corresponding stopping distance with conventional ABS control vehicle steerability and stability would be reduced Bendix ESP EC 80 Controllers have an optional dash switch that initiates a modified ABS control mode known as off road ABS that more effectively accommodates these soft road conditions to shorten stopping distance while maintaining optimal vehicle steerability and stability Note Off road mode is not available if the vehicle is equipped with Hill Start Hill Start Assist HS or HSA The ABS off road mode should not be used on normal paved road surfaces because vehicle stability and steerability may be reduced The ABS Indicator Lamp will flash slowly to indicate to the driver that the ABS off road mode is engaged When ABS off road mode is engaged stability functions are disabled at speeds below approximately 25mph 40k
55. Static Calibration Error YRS Normal Calibration Error YRS Plausibility Check Ref Yaw Rate YRS Plausibility Error Inside Model Based Limits YRS Plausibility Error Outside Model Based Limits YRS SAS Signal Cross check Incomplete YRS Vibration Detected YRS Detected But Not Configured Yaw Rate Sensor YRS Repair Information The YRS signal is incorrect Verify the proper installation of the YRS Verify proper wiring between the Electronic Control Unit ECU and the YRS Check the YRS output Perform the YRS calibration procedure The YRS signalis reversed Verify the proper installation of the YRS Verify the wiring between the ECU and the YRS Check the YRS output The YRS signal is invalid Verify the proper installation of the YRS Verify proper wiring between the ECU and the YRS Check the YRS output Verify that correct YRS is being used Loss of CAN communications between the ECU and the YRS Verify proper wiring between the ECU and the YRS Check the YRS output The YRS signal fails static self test Verify the proper installation of the YRS Verify proper wiring between the ECU and the YRS Check the YRS output Verify that correct YRS is being used Verify proper ECU programming Perform the YRS calibration procedure The YRS signal fails self test conducted while vehicle is in motion Verify the proper installation of the YRS Verify proper wiring between the ECU and the YRS Check the
56. U DTC CF ECU DTC CO ECU DTC C8C ECU DTC CC ECU DTC 63 ECU DTC 6E ECU DTC 6C ECU DTC 63C ECU Internal VIN Mismatch Valve Configuration Mismatch ECU DTC 7CD ECU DTC 5D Repair Information Check for damaged or corroded connectors Check for damaged wiring Clear Diagnostic Trouble Codes DTCs If DTCs return contact the Bendix Tech Team at 1 800 AIR BRAKE 1 800 247 2725 option 2 then 1 for further troubleshooting assistance Verify components installed match the Electronic Control Unit ECU configuration Check for damaged or corroded connectors Check for damaged wiring Clear DTCs If DTCs return contact the Bendix Tech Team at 1 800 AIR BRAKE 1 800 247 2725 option 2 then 1 for further troubleshooting assistance Verify components installed match ECU configuration Check for damaged or corroded connectors Check for damaged wiring Clear DTCs If DTCs return contact the Bendix Tech Team at 1 800 AIR BRAKE 1 800 247 2725 option 2 then 1 for further troubleshooting assistance Parameter file was not downloaded To verify that the vehicle specific parameters have been loaded contact Bendix for more information at 1 800 AIR BRAKE 1 800 247 2725 Check for damaged or corroded connectors Check for damaged wiring Clear DTCs If DTCs return contact the Bendix Tech Team at 1 800 AIR BRAKE 1 800 247 2725 option 2 then 1 for further troubleshoo
57. V Verify no continuity between the PMV leads and ground Verify 4 9 to 5 5 ohms from REL to CMN amp HLD to CMN and 9 8 to 11 ohms from REL to HLD Check for corroded damaged wiring or connectors between the ECU and PMV Verify no continuity between the PMV leads and voltage Verify 4 9 to 5 5 ohms from REL to CMN amp HLD CMN and 9 8 to 11 ohms from REL to HLD Check for corroded damaged wiring or connectors between the ECU and PMV Verify 4 9 to 5 5 ohms from REL to CMN amp HLD to CMN and 9 8 to 11 ohms from REL to HLD Check for corroded damaged wiring or connectors between the ECU and PMV Verify 4 9 to 5 5 ohms from REL to CMN amp HLD to CMN and 9 8 to 11 ohms from REL to HLD Check for corroded damaged wiring or connectors between the ECU and PMV This is potentially a miswired or internal mechanical problem A mis match exists between the ECU configuration and the modulator installation and wiring Verify the PMV wiring and installation Verify the ECU configuration Special Note regarding Trailer PMV Pneumatic issues can result in this DTC being set Verify all lines are free from debris or other obstructions kinks etc Pressure Modulator Valve PMV Repair Tests 1 Take all measurements at the Electronic Control Unit ECU harness connector pins in order to check wire harness and PMV Probe the connector carefully so that the terminals are not damaged 2 The pressure modulator resistance should read Release to
58. Verify wiring between ECU and the sensors Verify the proper output voltage from ECU Check for presence of pressure sensors Make sure ESP is enabled 3 Verify wiring between the Load Sensor and power ground Load Sensor Measurement Harness Terminal C to Voltage amp Ground Verify open circuit no continuity 4 Toperform a calibration procedure of the Brake Demand Sensor s ensure that the air system is fully charged Brake Demand Load Sensor Tests Apply ignition power and wait 30 seconds Perform a full application of the service brake and hold for 5 seconds Release the service brake 5 To test the Brake Demand Sensor and or the Load Power and Ground Input Test Measurement z Sensor Bendix ACom Diagnostic Software V6 7 2 5 B Power Input or higher is required Using the program select the A Ground Input X4 1 Common Component Test option followed by the ESP Test 2 Verify wiring between the Load Sensor and the ECU option The following screen should be displayed Load Sensor ECU Wire Harness Wire Harness Terminal Terminal Lames Sonras Sensors ESP ect a Meng Aegis Measurement n fuste he cosy Sew iid an v Ow ao rep The mos Powel teed TI domm Si t eom X4 2 Brake Demand Verity Continui pu Geer 4 Sensor primary brake circuit y i DEM C X4 5 Brake Demand Sensor VeifvConinutv M 3 3 3M secondary brake circuit y d E M
59. ability during braking Automatic Traction Control ATC improves vehicle stability and traction during vehicle acceleration The Bendix ESP EC 80 Controller s ATC function uses the same wheel speed information and modulator control as the ABS function The Bendix ESP EC 80 Controller detects excessive drive wheel speed compares the speed to the front non driven wheels and reacts to help bring the wheel spin under control The Controller can be configured to use engine torque limiting and or differential braking to control wheel spin For optimal ATC performance both methods are recommended ATC ESP Lamp Output ATC Mud Snow Switch Input Bendix ESP EC 80 Controllers operate the ATC ESP dash lamp as follows The ATC ESP dash lamp illuminates 1 During power up e g when the vehicle is started for approximately 2 5 seconds and turns off after the self test is completed providing no Diagnostic Trouble Codes DTCs are present 2 When ESP or ATC is disabled for any reason 3 During an ESP or ATC event the lamp will flash rapidly at a rate of 2 5 times per second 4 When the ECU is placed in the ATC off road mode the lamp will flash steadily at a rate of once every 2 5 seconds This notifies the vehicle operator that the ATC Mud Snow mode is active 5 When the ECU is placed in the ABS off road mode When in this mode ESP will be disabled below 25 mph and its inactive status will be indicated by a steadily illuminat
60. ake chambers in the event of electrical trouble The Bendix ESP EC 80 Controller also utilizes an additional Pressure Modulator Valve PMV for control of the trailer service brakes during stability interventions Traction Control Valve TCV Bendix ESP EC 80 Controllers use two TCVs one on the steer axle and one on the drive axle The TCV may bea separate valve or integrated into the rear axle relay valve The Controller will activate the drive axle TCV during differential braking ATC events During stability interventions the Controller will activate both the steer axle and drive axle TCVs as required Stop Lamp Output The Controller provides an output to control a relay that illuminates the vehicle stop lamps during stability interventions This information is also available using the J1939 serial communications link ABS Indicator Lamp Control with Optional Diagnostic Blink Code Switch The Bendix ESP EC 80 Controller has internal circuitry to control the ABS Indicator Lamp on the dash panel The ABS Lamp Illuminates 1 During power up e g when the vehicle is started for approximately three 3 seconds and turns off after the self test is completed providing no Diagnostic Trouble Codes DTCs are present on the ECU 2 When full ABS operation is not available due to the presence of a DTC on the ECU 3 Ifthe ECU is unplugged or has no power 4 When the ECU is placed into the ABS off road mode the lamp flas
61. brake Check for kinked or restricted air hoses Adjust the sensor to contact the exciter ring Rotate the wheel and verify a minimum of 0 25 VAC sensor output at 0 5 RPS Verify the condition of sensor head Verify the mounting of the exciter ring and condition of the teeth Verify the proper bearing end play Verify the condition and retention of the clamping sleeve Verify the sensor lead routing and clamping Check for corroded damaged wiring or connectors between the ECU and the wheel speed sensor Verify the correct tire size as desired Verify the proper tire inflation Verify the correct number of exciter ring teeth The ECU is configured for four sensors but it has detected the presence of additional sensors Verify the sensor wiring and the ECU configuration 27 28 Speed Sensor Repair Tests 1 Take all measurements at the Electronic Control Unit ECU harness connector pins in order to the check wire harness and sensor Probe the connector carefully so that the terminals are not damaged 2 The wheel speed sensor measurements should read Sensor to voltage or ground Open Circuit no continuity Sensor output voltage gt 0 25 of VAC sensor output at 0 5 revs sec 3 Clearthe DTC after the issue is corrected The sensor DTC will remain until the power is cycled to the ABS ECU and vehicle is driven above 15 MPH or the DTC was cleared using either the diagnostic Blink Code Switch or a diagnostic tool Cab mo
62. d Using Bendix ACom V6 7 2 5 or higher select the Component Test option followed by the ESP Test option The following screen should be displayed Follow the prompts to perform a test of the Yaw Rate Sensor Lanes Seres Sensory ESP Meomanee Diseno hese tes stu Feed t pr dta um ed MAILLOT II Liege RES amp e peros ved wet D deren a 4 Tee DA MM wow fare ao el The amos Ad rend T emm tO Sow 4 Come fue summ aem M St y Oe wt The orar iiad m tO erer rw Pera p e o e en Te m mc Dal tm A mepi cnm Y im x l 41 Troubleshooting Diagnostic Trouble Codes DTCs Lateral Acceleration Sensor LAS 1st Blink Location Code Lateral Acceleration 23 Sensor Diagnostic Trouble Code Description LAS Signal Out of Range LAS Calibration in Progress LAS Static Calibration Error LAS Long Term Calibration Error LAS Plausibility Error Inside ECU specific Limits LAS Plausibility Error Outside ECU specific Limits Erratic ESP Sensor Signal Repair Information LAS signal incorrect Verify the proper installation of the YRS LAS Verify proper wiring between the Electronic Control Unit ECU and the YRS LAS Check YRS LAS output Perform LAS calibration procedure LAS calibration procedure is underway LAS calibration error Verify the proper installation of the YRS LAS Verify proper wiring between the ECU and
63. duce the engine throttle and or apply the brakes at one or more of the wheel ends to help the vehicle return to the intended direction Previous Bendix EC 60 ECU Bendix EC 80 Key Components System Name Designations ECU Pressure Modulator Valves PMVs NOS tiae Four Wheel Speed Sensors Items above plus Automatic Traction Control ATC Valve Option of two more Premium Wheel Speed Sensors and PMVs All items above plus Yaw Rate Sensor Steering Angle Sensor Load Sensor Steer axle ATC valve Brake Demand Advanced Sensor and an Additional PMV FIGURE 1 THE BENDIX ESP EC 80 CONTROLLER The driver is always responsible for the control and safe operation of the vehicle at all times The Bendix ABS system does not replace the need for a skilled alert professional driver reacting appropriately and in a timely manner and using safe driving practices TABLE OF CONTENTS Components Indicator Lamps and Power Up Sequence ABS Operation ATC Operation ESP ABS With Stability Control Important Safety Information About The ESP Stability System Troubleshooting See page 63 for the full Table of Contents Key System Features ECU Designation Shown on the ECU Label SEMIS EE Service Data Locations Sheet Provided F ABS Antilock Braking SD 13 4983 EC 80 ABS ABS plus ATC Traction Control SD 13 4983 EC 80 ATC ABS plus ATC plus ESP Yaw Control YC and Roll S
64. e an illuminated lamp indicates an Disabled ATC DTC is present During an ESP Event Flashes quickly System intervenes to reduce the risk of rollovers loss of control etc ABS System icm Status Indicators at Start Up 0 5 1 5 2 0 2 5 3 0 sec ON OFF Powered Vehicle ABS Indicator Lamp Trailer ABS Indicator Lamp PLC Detected ON OFF Trailer ABS Indicator Lamp PLC Not Detected ON OFF ATC ESP System Status Indicator at Start Up Power Application 0 5 1 5 2 0 2 5 3 0 sec ATC ESP enabled i OFF ON No ESP or ATG OFF FIGURE 10 BENDIX ESP EC 80 CONTROLLER INDICATOR LAMP BEHAVIOR 8 ABS Indicator Lamp Operation Bulb Check The Bendix ESP EC 80 Controller will illuminate the ABS Indicator Lamp for approximately three seconds when ignition power is applied after which the lamp will extinguish if no Diagnostic Trouble Codes DTCs are detected The Controller will illuminate the ABS Indicator Lamp whenever full ABS operation is not available due to a DTC In most cases partial ABS is still available ATC ESP Status Indicator Lamp Operation The Bendix ESP EC 80 Controller will illuminate the ATC ESP lamp for approximately 2 5 seconds when ignition power is applied after which the lamp will extinguish if no DTCs are detected The Controller will continuously illuminate the ATC ESP Indicator Lamp whenever ESP or ATC is disabled due to a DTC During an ESP or ATC
65. e ABS off road mode See Optional ABS Off Hoad Mode on page 10 for further details In some cases ECUs may also be put into the ABS off road mode by one of the other vehicle control modules using a J1939 message to the Bendix ESP EC 80 Controller If you need to know if a specific Bendix ESP EC 80 Controller uses a J1939 message to operate the lamp contact the Bendix Tech Team E mail the Tech Team at ABS bendix com be sure to specify the ECU part number or call 1 800 AIR BRAKE 1 800 245 2725 The ABS off road mode should not be used on normal paved road surfaces because vehicle stability and steerability may be adversely affected When the ECU is placed in the ABS off road mode the ABS Indicator Lamp will flash constantly at a rate of once per 2 5 seconds to notify the vehicle operator that the off road mode is active Optional ATC Mud Snow Off Road Switch and Indicator Lamp Operation also see page 8 The Bendix ESP system uses a dash mounted switch for the operator to place the ECU into the ATC Mud Snow mode Optional Hill Start Hill Start Assist Feature Switch and Lamp Operation see also page 8 ESP Controllers use a dash mounted switch for the operator to place the ECU into the hill start mode This feature interfaces between the transmission and the braking system to help the driver prevent the vehicle from roling downhill when moving up a steep incline from a stationary position With Hill Start Aid F
66. e test mode press and release the Blink Code Switch three times or use a hand held or PC based diagnostic tool AUTOMATIC TIRE SIZE CALIBRATION The ECU requires a precise rolling circumference ratio between steer axle and drive axle tires in order for the Bendix ABS ATC and ESP systems to perform in an optimal manner For this reason a continuously monitoring process takes place in which the precise ratio is calculated This calculated value is stored in the ECU memory provided the following conditions are met 1 Rolling circumference ratio is within the permissible range 2 Vehicle speed is greater than approximately 12mph 19 kph 3 No acceleration or deceleration is taking place and 4 There are no active speed sensor Diagnostic Trouble Codes DTCs The ECU is provided with a ratio value of 1 00 as a default setting If the automatic tire size alignment calculates a different value this is used to overwrite the original figure in the memory This process adapts the ABS and ATC function to the vehicle Acceptable Tire Sizes The speed calculation for an exciter ring with 100 teeth is based on a default tire size of 510 revolutions per mile This figure is based on the actual rolling circumference of the tires which varies with tire size tire wear tire pressure vehicle loading etc The ABS response sensitivity is reduced when the actual rolling circumference is excessive on all wheels For a 100 tooth exciter rin
67. eature option you lose the ABS off road function and the retarder relay output When the ECU is placed in the Hill Start Aid HSA feature mode the HSA Indicator Lamp will flash constantly at a rate of once per 2 5 seconds to notify the vehicle operator that the HSA mode is active The ECU receives J1939 messages from the transmission to engage the HS HSA components When engaged the system applies 44 psi to the rear brakes for three 3 seconds then releases This function is totally controlled by the automatic transmission 6 Stop Lamp Switch SLS The Bendix ESP EC 80 Controller monitors the vehicle stop lamp status Certain vehicle functions such as ATC and All Wheel Drive AWD use the status of the stop lamp to determine when the driver makes a brake application This can be provided to the ECU via J1939 communications or hardware input Brake Demand Sensors The brake demand sensors provide the Controller with an indication of driver applied brake pressure One is installed in the primary air brake circuit and another is installed in the secondary air brake circuit Load Sensor The load sensor provides the Controller with an indication of the vehicle load lt is typically installed in one of the suspension air bags Bendix SAS 70X Steering Angle Sensor Bendix brand Steering Angle Sensors SAS are used to report the steering wheel position to the Controller utilizing a dedicated serial communications link
68. eceive equal brake pressure during an ABS stop The rear wheel speed sensors must be installed on the axle with the lightest load Dual Rear Axle Control 6S 6M Configuration For vehicles with dual rear axles 6x4 6x2 using a6S 6M configuration the rear wheels are controlled independently Therefore brake application pressure at each wheel is adjusted according to the individual wheel behavior on the road surface 6x2 Vehicles with 6S 5M Configuration 6x2 vehicles can utilize a 6S 5M configuration with the additional axle a non driven rear axle having two sensors but only one Pressure Modulator Valve PMV In this case the PMV controls both wheels on the additional axle The additional axle wheels would receive equal brake pressure based on the wheel that is currently experiencing the most wheel slip Normal Braking During normal braking brake pressure is delivered through the ABS PMV and into the brake chamber If the ECU does not detect excessive wheel slip it will not activate ABS control and normal vehicle service braking is applied Retarder Brake System Control On surfaces with low traction application of the retarder can lead to high levels of wheel slip at the drive axle wheels which can adversely affect vehicle stability To prevent this the Bendix ESP EC 80 Controller switches off the retarder as soon as a lock up is detected at one or more of the drive axle wheels When the ECU is placed in the AB
69. ed Cab mount ECU Looking into wire harness connector Connector Pin o J1939 Low 18Way 8 J1939 High 33 Troubleshooting Diagnostic Trouble Codes DTCs Miscellaneous 1st Blink Location Miscellaneous Code 12 34 2nd Blink Code 11 14 17 19 Diagnostic Trouble Code Description Stop Lamp Switch Not Detected Stop Lamp Switch Defective ATC or ESP Disabled or Dynamometer Test Mode Active Retarder Relay Open Circuit or Shorted to Ground Retarder Relay Circuit Shorted to Voltage ABS Indicator Lamp Circuit DTC PMV Common Shorted to Ground PMV Common Shorted to Voltage ATC Disabled to Prevent Brake Fade Wheel Speed Sensors Reversed on an Axle Sensor CAN Supply Voltage Error ABS disabled due to off road mode Maximum number of PMV cycles exceeded Repair Information The Electronic Control Unit ECU has not detected the presence of the stop lamp switch since ignition power was applied note that stop lamp switch input may be applied to the Bendix ESP EC 80 Controller using either hard wire input or J1939 Apply and release service brake Check for brake switch input into ECU see system wiring schematic With service brake released check for presence of the stop lamp bulb With service brake applied verify system voltage is now present at the stop lamp switch input to the ECU Check for damaged wiring between ECU stop lamp switch and bulb Check for
70. ed ATC ESP lamp Differential Braking Differential braking within ATC is automatically activated when drive wheel s on one side of the vehicle are spinning excessively This typically occurs on road surfaces with patches of ice The traction system will then lightly apply the brake to the drive wheel s that are spinning excessively The vehicle differential will then drive the wheels on the other side of the vehicle Differential braking as part of ATC functionality is available at vehicle speeds up to 25 mph 40 kph Disabling ATC Differential Braking ATC differential braking is disabled under the following conditions 1 During power up e g when the vehicle is started until the ECU detects a service brake application 2 If the ECU receives a J1939 message indicating that the vehicle is parked 3 When the dynamometer test mode is active The Dynamometer test mode is entered using the diagnostic Blink Code Switch or by using a diagnostic tool such as Bendix ACom Diagnostics 4 n response to a serial communications request from a diagnostic tool 5 If ATC Differential Braking function is activated for a long time period to avoid overheating of the brakes It would take approximately three 3 continuous minutes of activation for the time out to occur Once timed out approximately two 2 minutes of cool off time would be required before ATC Differential Braking can be used again 6 When certain DTC conditions
71. ensor Yaw Lateral Accelerator Sensors Two examples shown FIGURE 5 YAW AND BRAKE DEMAND LOAD SENSORS The Bendix ESP EC 80 Controller s Hill Start Aid function utilizes the following additional components e A Bendix AT 3 Traction Control Valve e Adash mounted Hill Start Status Indicator Lamp e Adash mounted Enable Disable Switch e ABendix RV 3 Pressure Reducing Valve e ABendix DC 4 Double Check Valve Bendix DC 49 Double Check Valve Bendix AT 3 Traction Control Reducing Valve Valve Bendix RV 3 Pressure FIGURE 6 ADDITIONAL VALVES NECESSARY FOR THE HILL START AID FEATURE BENDIX ETRAC AUTOMATED AIR SUSPENSION TRANSFER SYSTEM The Bendix eTrac automated air pressure transfer system is used on 6 x 2 semi tractors that feature Bendix ATC and ESP Antilock Brake Systems ABS This system complements the Bendix SMART ATC traction control feature of our ABS system to provide improved traction at low speeds e g pulling away on an inclined ramp or in slippery conditions such as mud or snow covered surfaces etc When active the Bendix eTrac system vents or dumps the air pressure of the tag axle suspension air bags and increases the air pressure in the drive axle suspension air bags to a pre determined maximum This action helps the drive axle to gain more traction See SD 13 21021 for more information about the Bendix eTrac Automated Air Suspension Transfer System
72. ent pinching binding or fraying It is recommended that wires be routed straight out of a connector for a minimum of three inches before the wire is allowed to bend Battery and ground wires should be kept to a minimum length If convoluted tubing is used its I D must match the size of the wire bundle as closely as possible Wire harness lengths must be carefully selected for the vehicle Excess lengths of wire are not to be wound to form coils instead re route repair or replace wire harness to avoid the possibility of electrical interference and wire damage Do not attempt to stretch harnesses that are too short since mechanical strain can result in wire breakage Bendix SAS 60 Sensors and YAS 60 or YAS 70X Sensor Wiring If it is necessary to replace the wiring that connects the Bendix SAS 60 or the Yaw Rate sensor to the ECU it is important to use the same wiring as that used by the vehicle OEM 49 In Cab Controller Harness 17 Way AMP N A MCP 2 8 X1 Kong 1718091 1 EE 7 In Cab Controller Harness lt S A e 18 Way AMP eii PT A MCP 2 8 X2 e i d 8 968974 1 v In Cab Controller Harness 968874 15 Way AMP 2 5 4 mm MCP 2 8 X3 8 968973 1 0e Controller Harness we 12 Way AMP 539723 2 MCP 2 8 X4 968873 1 0 2 5 mm ABS Modulator Harness AMP Twist Lock Bayonet ATC Modulator Harness 929975 1 AMP Twist Lock Bayonet 539635 1 ABS Modulator Harness 3 pin Packard Metri Pack
73. erating mode During this time the Bendix ESP EC 80 Controller will ignore any additional Blink Code Switch activation All DTCs with the exception of voltage and J1939 DTCs will remain in an active state for the remainder of the power cycle Voltage DTCs will clear automatically when the voltage returns within the required limits All Bendix ABS functions will be re engaged J1939 DTCs will clear automatically when communications are re established 22 DIAGNOSTIC MODES In order to communicate with the Bendix ESP EC 80 Controller there are several modes that the technician can select to allow information to be retrieved or other ECU functions to be accessed Diagnostic Modes To enter the various diagnostic modes No of Times to Press the Blink Code Switch ot Active Diagnostic Trouble Code DTC Retrieval 9 Inactive DTC Retrieval 08 Clear Active DTCs System Mode Entered 004 System Configuration Check 5 3 Dynamometer Test Reconfigure ECU To enter the Reconfiguration Mode the switch must be held in before the application of ignition power Once the power is supplied the switch is released and then pressed seven times FIGURE 16 DIAGNOSTIC MODES Active Diagnostic Trouble Code Mode For troubleshooting typically the Active and Inactive DTC Retrieval Modes are used The technician presses the Blink Code Switch once and the ABS indicator lamp flashes a first group of two codes and if th
74. ere are more DTCs recorded this is followed by a second set of codes etc See page 26 for a directory of these codes All active DTCs may also be retrieved using a hand held or PC based diagnostic tool such as the Bendix ACom Diagnostic Software To clear active DTCs as problems are fixed simply clear or self heal by removing and re applying ignition power The only exception is for wheel speed sensor DTCs which clear when power is removed re applied and the ECU detects valid wheel speed from all wheel speed sensors Alternately codes may be cleared by pressing the diagnostic Blink Code Switch three 3 times to enter the Clear Active Diagnostic Trouble Code Mode or by using a hand held or PC based diagnostic tool Hand held or PC based diagnostic tools are able to clear wheel speed sensor DTCs without the vehicle being driven Inactive Diagnostic Trouble Code Mode The Bendix ESP EC 80 Controller stores past Diagnostic Trouble Codes DTCs and comments such as configuration changes in its memory This record is commonly referred to as event history When an active DTC is cleared the Electronic Control Unit ECU stores it in the event history memory as an inactive DTC Using blink codes the technician may review all inactive DTCs stored on the ECU The ABS indicator lamp will display inactive diagnostic blink codes when the diagnostic Blink Code Switch is depressed and released two times See page 26 for t
75. ering inputs or abrupt lane changes should be avoided Limitations Of Stability Systems The effectiveness of the Bendix ESP system with the EC 80 Controller may be greatly reduced if e The load shifts due to improper retention accident damage or the inherently mobile nature of some loads for example hanging meat live animals or partially laden tankers e The vehicle has an unusually high or off set center of gravity CG e One side of the vehicle drops off the pavement at an angle that is too large to be counteracted by a reduction in speed e The vehicle is used to haul double or triple trailer combinations f very rapid steering changes are attempted at high speeds e There are mechanical problems with suspension leveling of the tractor or trailer resulting in uneven loads e The vehicle is maneuvering on a high banked road creating either additional side forces due to the weight mass of the vehicle or a deviation between expected amp actual yaw rates e Gusty winds are strong enough to cause significant side forces on the vehicle and any towed vehicles 13 To Maximize The Effectiveness Of The Bendix ESP System with the EC 80 Controller Loads must be properly secured at all times Drivers need to exercise extreme caution at all times plus avoid sharp turns sudden steering adjustments or abrupt lane changes at high speeds particularly if gt the vehicle hauls loads that could shift
76. es Figure 8 Power Line Without PLC Signal Figure 9 Power Line With PLC Signal Figure 10 Bendix ESP EC 80 Controller Indicator Lamp Behavior Figure 11 Vehicle Orientation Typical Figure 12 RSP Example Figure 13 Yaw Control Example Figure 14 Typical Vehicle Diagnostic Connector Locations J1939 Figure 15 Example Of Blink Code Message Figure 16 Diagnostic Modes Figure 17 System Configuration Check Figure 18 Bendix ACom Diagnostics Figure 19 The Bendix Remote Diagnostic Unit Figure 20 Diagnostic Trouble Codes Figure 21 Bendix EC 80 Controller Component Connectors Figure 22 WS 24 Wheel Speed Sensor Installation S Cam And Air Disc Brake Figures 23 amp 24 Troubleshooting Wiring Schematics 62 Full Table of Contents O AA E a 1 co o A nn o oO o A E ET 3 FROWN re ii andres AIM miel E 3 Bo e Pe o A 3 4 Bendix eTrac Automated Air Suspension Transfer System ccccccoonccnnccccconnccnncnnnnonenonnnonnnncnnnnnnnnnanonns 4 ze NIOUNUNO mu 4 Hardware Configurations srta iaa Red eS PS UE Ea 4 Bendix ESP EC 80 Controllers USE Power Line Carrier DC 5 Bendix ESP EC 80 Controller Inputs essseetett pests iesus nio atat ubntcti amate tirones B Bendix ESP EC 80 Controller Outputs cccccccoccccnncccoconcnnnoconnnaconononnononnnnnnonnnnnnnnnnnnnnnnnnnnnnnnannnennnnnnnnns 6 7 Indicator Lamps And Power Up EIERE edel Seege 8 9 A nn a M uec sRDPI DIUTIUS O EINEN ER 9 10 e 11 12 Bend ESP ABS With
77. es 52 and 53 for wiring system schematics ABS Indicator Lamp Ground Input The Bendix ESP EC 80 Controller requires a second ground input X1 12 for the ABS indicator lamp The X1 wire harness connector contains an ABS indicator lamp interlock X1 15 which shorts the ABS indicator lamp circuit X1 18 to ground if the connector is removed from the ECU Bendix WS 24 Wheel Speed Sensors Wheel speed data is provided to the Bendix ESP EC 80 Controller from the Bendix WS 24 wheel speed sensor see Figure 2 Vehicles have an exciter ring or tone ring as part of the wheel assembly As the wheel turns the teeth of the exciter ring pass the wheel speed sensor generating an AC signal The Bendix ESP EC 80 Controller receives the AC signal which varies in voltage and frequency as the wheel speed changes Vehicle axle configurations determine the number of Bendix WS 24 wheel speed sensors that must be used A vehicle with a single rear axle requires four wheel speed sensors Vehicles with two rear axles can utilize six wheel speed sensors for optimal performance Diagnostic Blink Code Switch A momentary switch that grounds the ABS Indicator Lamp output is used to place the ECU into the diagnostic blink code mode and is typically located on the vehicle s dash panel Optional ABS Off Road Switch and Indicator Lamp Operation Vehicle operators use an optional dash mounted switch to place the Bendix ESP EC 80 Controller into th
78. ff Road Mode In some road conditions the vehicle operator may desire additional drive wheel slip when ATC is active The Bendix ESP EC 80 Controller has an optional control mode to permit this desired performance The vehicle operator can activate the Mud Snow function with a switch on the dash panel Alternately a J1939 message may be used to place the vehicle in this mode The ATC ESP Indicator Lamp will flash steadily at a rate of once every 2 5 seconds to confirm that the ATC mud snow mode is engaged To exitthe ATC Mud Snow mode depress and release the ATC Mud Snow switch BENDIX ESP EC 80 ABS WITH STABILITY CONTROL Overview The Bendix ESP system with the EC 80 Controller reduces the risk of rollovers jackknifing and other loss of control events Bendix ESP EC 80 Controllers include Roll Stability Program RSP9 and Yaw Control YC functions During operation the Bendix ESP EC 80 Controller constantly compares performance models to the vehicle s A Real World Example Of How The RSP System Operates Excessive speed for road conditions creates forces that exceed the threshold at which a vehicle is likely to rollover on a higher friction surface The system automatically reduces engine torque and applies the service brakes based on the projected rollover risk to reduce the vehicle speed thereby reducing the tendency to roll over FIGURE 12 RSP EXAMPLE 12 Drag Torque Control Functional Overview
79. g Check for damaged or corroded connectors Verify message is being transmitted Verify the ECU configuration Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Verify message is being transmitted Verify the ECU configuration 47 Troubleshooting Connectors Bendix ESP EC 80 Controller Wire Harness Connector Part Numbers and Pin Assignments CONNECTOR CONNECTOR CONNECTOR CONNECTOR Bendix ESP EC 80 Controller Controllers utilize four 4 AMP connectors for wire harness connections X1 Connector Pin Assignments Vary by Part Number K098920R000 K105303R000 K098921R000 X2 Connector X3 Connector XAC tor Pi K103428R000 Pin Pin Pain ida e GE Assignments Assignments g K105095R000 K105096R000 K105097R000 PMV SA LeftHLD ABS ORS Pressure Sensor CMN Brake D P Tece taea ets eel vt TS eo AA Circuit Signal PMV SA Left CMN TCV CMN S Load Sensor Signal Pressure Sensor mvowes CMN DA TCV DA PMV SA Right HLD PMV AA Left HLD ST Brake Demand TCV DA TCV CMN DA WSS SA Left TOV S Secondary Circuit Signal ATC ESP Indicator and ATC ORS TPMS Ground PMV SA Right CMN PMV AA Left CMN PMV Trailer HLD J1939 High PMV SA iE REL PMV AA Left REL Sensor CAN Low J1939 Low WSS SA Left Stop Lamp Output Sensor CAN High TPMS n SLS Input Zeen PMV DA Right CMN PMV AA Right CMN PMV Trailer REL Communications WSS DA Right PMV DA Right HLD PMV
80. g the minimum number of tire revolutions per mile is 376 and the maximum is 665 The ECU will set a Diagnostic Trouble Code DTC if the number of revolutions is out of this range In addition the size of the steer axle tires compared to the drive axle tires also has to be within the ABS system design To avoid DICs the ratio of the effective rolling circumference of the steer axle divided by the effective rolling circumference of the drive axle must be between 0 85 to 1 15 A CAUTION The Bendix ESP system with the EC 80 Controller effectiveness relies on the accuracy of vehicle speed If a major change on the tire sizes is made such that the odometer setting needs to be changed to correct for the new tires the Bendix ESP EC 80 Controller s setting of tire sizes must also be reprogrammed to revised values SYSTEM IMPACT DURING ACTIVE DIAGNOSTIC TROUBLE CODES DTCs ABS PARTIAL SHUTDOWN Depending on which component the DTC is detected the Bendix ABS ATC and ESP system functions may be fully or partially disabled Even with the ABS indicator lamp illuminated the Bendix ESP EC 80 Controller may still provide ABS function on wheels that are not affected The ABS system Controller should be serviced as soon as possible Steer Axle ABS Modulator DTC ABS on the affected wheel is disabled ABS and ATC on all other wheels remains active The Bendix ESP system with the EC 80 Controller is disabled Drive Axle Additio
81. g all vehicle brakes as needed reducing the tendency to roll over SAS Steering Angle Sensor Sensor Clamping Sleeve A beryllium copper sleeve which has fingers cut into it Itis pressed between an ABS sensor and mounting hole to hold the sensor in place Stored Diagnostic Trouble Codes A DTC that occurred in the past TCS Traction Control System another name for ATC or ASR TCV Traction Control Valve Tone Ring A ring that is usually pressed into a wheel hub that has a series of teeth usually 100 and provides actuation for the speed sensor Note maximum run out is 008 YC Yaw Control Helps stabilize rotational dynamics of vehicle YRS Yaw Rate Sensor APPENDIX A TROUBLESHOOTING A 12 7 BLINK CODE EQUIVALENT TO A SID 93 FMI 4 SPN 0802 FMI 04 DIAGNOSTIC TROUBLE CODE DTC Bendix EC 80 ESP Electronic Control Unit ECU 1 Remove the X1 X2 X3 and X4 connectors from the ECU 2 Using X1 1 as the ground connection check for resistance Below for the entire X2 connector There should be no resistance x We doin to ground found Please fill out worksheet on this page AE dl OE 3 Using X1 1 as the ground connection check for resistance for X1 4 and X1 5 There should be no resistance to ground X 4 4 Using X1 1 asthe ground connection check for resistance for Xt5 X3 4 X3 6 X3 7 X3 9 X3 10 X3 13 X3 3 and X3 5 There should be no resistance to ground Even if the vehicle
82. he index showing DTCs and the troubleshooting guide page to read Inactive DTCs and event history may be retrieved and cleared by using a hand held or PC based diagnostic tool such as the Bendix ACom Diagnostic Software Clearing Active DTCs The ECU will clear active DTCs when the diagnostic Blink Code Switch is depressed and released three 3 times System Configuration Check Mode The ABS indicator lamp will display system configuration information when the diagnostic Blink Code Switch is depressed and released four times The lamp will blink out configuration information codes using the following patterns See Figure 17 In this mode the ECU tells the technician by means of a series of seven 7 blink codes the type of ABS system that the ECU has been set up to expect For example if the fourth blink code is the number two 2 the technician knows that a 6S AM sensor modulator configuration has been set Dynamometer Test Mode The Dynamometer Test Mode is used to disable Bendix ESP amp ATC system functions when needed e g when performing any vehicle maintenance where the wheels are lifted off the ground and moving including dynamometer testing Note For Bendix ESP and ABS EC 80 Controllers this mode will remain engaged even if power to the ECU is removed and re applied To exit the Dynamometer Test Mode press and release the Blink Code Switch three 3 times or use a hand held or PC based diagnostic
83. hes steadily at a rate of once per 2 5 Sec or 5 Todisplay blink codes for diagnostic purposes after the external diagnostic switch is activated The Bendix ESP EC 80 Controller may communicate with other vehicle control modules to operate the ABS Indicator Lamp using serial communications lf you need to know if this Bendix ESP EC 80 Controller uses serial communications to operate the lamp e mail ABSO bendix com be sure to specify the ECU part number or call 1 800 AIR BRAKE 1 800 247 2725 and speak to the Bendix Tech Team Indicator Lamp Control Using Serial Communications Links As mentioned above depending on the vehicle manufacturer the dash indicator lamps ABS ATC ESP and trailer ABS may be controlled using serial communications links In these cases the Bendix ESP EC 80 Controller will send a serial communications message over the J1939 link indicating the required status of the lamp s Another vehicle control module receives the message and controls the indicator lamp s Dynamometer Mode Indicator Lamp Operation When the Bendix ESP EC 80 Controller is put into the Dynamometer mode for testing purposes the ATC Indicator Lamp will be illuminated Retarder Relay Disable Output The retarder relay disable output may be used to control a retarder disable relay When configured to use this output the ECU will energize the retarder disable relay and inhibit the use of the retarder as needed If the ECU is c
84. hooting Diagnostic Trouble Codes DTCs Yaw Rate Sensor YRS continued O O O Yaw Connector Looking into wire harness connector Note When checking for voltage at YAW LAS SAS the voltage will only be present momentarily at key ON Yaw Rate Sensor Tests 1 Verify continuity between the Electronic Control Unit ECU and the Yaw Rate Sensor typically YAS 70 or YAS 60 Comedor Pim 2 Voltage Input ves 2 Voltage Inp Ground Input EGU 11 Power a LU 12 Way Common 2 Verify wiring between the Yaw Rate Sensor and the ECU YRS Wire ECU Wire Harness Harness Measurement Terminal Terminal Verify Continuity Verify Continuity 3 Verify wiring between the Yaw Rate Sensor and power ground YRS Wire Harness Measurement Terminal 4 to Voltage amp Verify open circuit no Ground continuity 3 to Voltage amp Verify open circuit no Ground continuity 4 To perform a calibration procedure of the Yaw Rate Sensor ACom Diagnostic Software V6 7 2 5 or higher is required Using the program select the Configuration option followed by the Calibrate option The following screen should be displayed Samot Caisson Moe n Saeeeng angle Stadur a Di sue H Core Lateral Acker att SACO s Oner Seg EN a Zell Lg Proges Follow the prompts to perform a calibration of the Yaw Rate Sensor To test the Yaw Rate Sensor ACom V6 7 2 5 or higher is require
85. ide and remove Pins 1 2 11 amp 12 Reconnect the connector and apply IGN power to the X6 ECU Using Bendix ACom Diagnostics clear all DTCs X37 Record Resistances If the 12 7 DTC returns the problem is either the wiring harness inside the cab or the ECU 55 APPENDIX B J1939 SPN AND FMI CODES AND THEIR BENDIX BLINK CODE EQUIVALENTS STE SPN FMI E es Amp otas J1939 J1939 1st 2nd Diagnostic Trouble Code DTC Description Digit Digit SSES LL LL Power Supply DTCs 168 3 6 2 Battery Voltage Too High ON ON 168 4 6 1 Battery Voltage Too Low Miscellaneous DTCs 564 25 3 Differential Lock Solenoid Shorted To Voltage ON ON 564 4 25 2 Differential Lock Solenoid Shorted To Ground ON 564 5 25 1 Differential Lock Solenoid Open ON 564 13 25 7 Output Configuration Error Differential ON E ABS Disabled Due To Special Mode Or Off Road ABS Active 575 14 12 17 Note The ABS warning lamp will be flashing indicating the is in ABS off ON road mode 576 14 12 3 ATC or ESP Disabled or Dynamometer Test Mode Active ON I O 2 or 3 Shorted High EC 80 ATC OR Dus le ga I O 2 or 3 Shorted High e Stop pes Output Error ESP EC 80 j SH 614 3 25 6 I O 3 Shorted to Voltage ON 614 4 25 5 UO 3 Shorted to Ground ON 614 5 25 4 I O 3 Open Circuit ON 614 13 25 8 Output Configuration Error I O 3 ON 615 14 12 19 Maximu
86. ime out or Invalid Signal J1939 AIR Message Time out or Invalid Signal ESP J1939 CAN Message Time out J1939 Transmission Communication for HSA Time out or invalid data on XBR J1939 Electronic Transmission Controller 1 Time out or Invalid Signal AUXIO CAN message Time out J1939 Hill Start Feature Switch Signal Not Available J1939 CAN Message related to ESP is incomplete Repair Information There is loss of communications between the Bendix ESP EC 80 Controller and other devices connected to the J1939 link Check for damaged or reversed J1939 wiring Check for corroded or damaged connectors Verify the Electronic Control Unit ECU configuration Check for other devices inhibiting J1939 communications Check for damaged or reversed J1939 wiring Check for corroded or damaged connectors Verify the presence of a retarder on the J1939 link Verify the ECU configuration Verify that the retarder is configured to broadcast ERC1 Check for other devices inhibiting J1939 communications Check for damaged or reversed J1939 wiring Check for corroded or damaged connectors Verify the presence of ECU on the J1939 link Verify the ECU configuration Verify the ECU is configured to broadcast EEC1 Check for other devices inhibiting J1939 communications Check for damaged or reversed J1939 wiring Check for corroded or damaged connectors Verify the presence of Engine ECU on the J1939 link Verify the ECU configuration
87. ime out or Invalid Signal J1939 Electronic Engine Controller 1 Time out or Invalid Signal J1939 Electronic Engine Controller 2 Time out or Invalid Signal J1939 AIR Message Time out or Invalid Signal ESP J1939 CAN Message Time out Time out or Invalid CAN Data for ETC7 VP15 Time out or Invalid Data on XBR J1939 Electronic Transmission Controller 1 Time out or Invalid Signal AUXIO CAN Message Time out J1939 Hill Start Aid Switch Signal Not Available HSA LAMP ON J1939 CAN Message Related to ESP is Incomplete J1939 Electronic Engine Controller 3 Time out or Invalid Signal J1939 Electronic Transmission Controller 2 Time out J1939 EAC1 Time out or Invalid Signal CAN Message CGW C1 Time out or Invalid Signal CAN Message ASC1_CLCS Time out or Invalid Signal J1939 CCVS Time out or Invalid Signal J1939 TCO Tachograph Time out J1939 Proprietary XBR Message Out of Range J1939 CAN Time out of ESP Message Time out or Invalid CAN Data CCVS 2 ESP Message Time out or Invalid CAN Data Electronic Engine Controller 1 ESP Message Time out or Invalid CAN Data EEC2 ESP Message Time out or Invalid CAN Data Driveline Line Retarder ESP Message Time out or Invalid CAN Data Engine Retarder ESP Message Time out or Invalid CAN Data Exhaust Retarder ESP Message Time out or Invalid CAN Data PROP XBR ESP Message Time out or Invalid CAN Data Transmission Retarder ESP Message Time out or Invalid CAN Data Electronic Transmi
88. intervention the lamp will flash rapidly 2 5 times per second When the Controller is placed in the ATC Mud Snow off road mode the lamp will flash slowly at a rate of once every 2 5 seconds Trailer ABS Indicator Lamp Operation The Controller will control the Trailer ABS Indicator Lamp when a PLC signal SAE J2497 from a trailer ABS ECU is detected Hill Start Assist HSA Indicator Lamp Operation Vehicles with HSA enabled will illuminate the HSA Indicator Lamp when ignition power is applied The lamp will extinguish if there are no issues with the HSA system Pressure Modulator Valve PMV and Traction Control Valve TCV Chuff Test Right Right Drive Additional Eo Right Steer EE Q Driver C Left Steer CEC CC Left Drive Left Additional FIGURE 11 VEHICLE ORIENTATION TYPICAL After the performance of the configuration test the Bendix ESP EC 80 Controller will perform a Bendix patented PMV and TCV Chuff Test The Chuff Test is an electrical and pneumatic PMV test that can assist maintenance personnel in verifying proper PMV wiring and installation When ignition power is applied each modulator solenoid is briefly energized If the air system is fully charged and the service brake pedal is depressed during ignition the modulator creates a single sharp audible chuff of air pressure The modulators are energized in a certain pattern right front left front right rear then left rear This test
89. is not configured for 6S 6M 5 Using X1 1 as the ground connection check for resistance ES for X4 6 X4 9 and X4 12 There should be no resistance to x22 ground x23 o 6 Troubleshoot any pin that has resistance to ground If no x24 issues are found continue to step 7 x25 7 Reconnect the X1 connector only and apply IGN power to the ECU and using the DTC screen of Bendix ACom Diagnostic gl Software clear all DTCs Re check for any DTCs If the x27 12 7 DTC is still present the problem is the Traction Solenoid X28 Wiring or Solenoid x29 8 Ifthe 12 7 DTC does not reappear remove power and connect the X2 connector reapply power then clear all DTCs If the X2 10 SEEN 12 7 DTC is no longer present connect the X3 connector X2 11 Ed and clear all DTCs X212 MEE 9 If at this point the 12 7 DTC is not present the problem is X2 13 ZEEEN with the X4 connector TET For Peterbilt amp Kenworth Trucks Only X245 MIO asp Clear all DTCs If the 12 7 DTC reappears the issue is x16 on the X4 connector Otherwise proceed to the next step xaz Disconnect all modulators and the traction solenoid Clear all DTCs If the DTC does not reappear connect x218 one modulator and Traction Solenoid at a time until the DTC reappears Otherwise continue to the next step Make sure all modulators and the traction solenoid are X4 connected Disconnect the ABS bulkhead connector at xl the engine top left s
90. is not properly recalibrated as needed the yaw control system may not function properly which can result in a loss of vehicle control YAW RATE LATERAL ACCELERATION SENSOR MAINTENANCE Different generations of yaw rate lateral acceleration sensors are not compatible Only replace these sensors with exactly the same device Service Checks 1 Check all wiring and connectors Make sure all connections are free from visible damage 2 Examine the sensor Make sure the sensor its mounting bolts and the mounting bracket are not damaged 3 Check the vent hole in underbody of sensor housing The vent hole should remain free from paint and debris at all times Diagnostics The yaw rate sensor is only operational in conjunction with a Bendix ABS ATC or ESP system with the EC 80 Controller No independent diagnostics can be performed on the sensor See pages 40 41 for Diagnostic Trouble Codes associated with this device Removal 1 Unplug the sensor cable assembly from body of sensor The connector must be twisted and pulled gently to release 2 In some mounting configurations the sensor can be removed independently from its mounting bracket Otherwise remove entire assembly then remove sensor from bracket 3 Take note of the direction in which the connector is pointed Installation 1 Obtain a new sensor The sensor is not repairable in the field A WARNING The location of the Yaw Rate Sensor
91. ith the Bendix ESP system with EC 80 Controllers However replacement of brake demand sensors or clearing of demand pressure sensor related DTCs require the following 1 Use Bendix ACom Diagnostic Software V6 7 2 5 or higher to clear the active pressure sensor DTC 2 Carrying out the demand pressure sensor initialization procedure which involves applying service brakes of 90 psi or greater for three 3 seconds while stationary Once this procedure is carried out successfully if there are no other active DTCs the ATC ESP indicator lamp will no longer be illuminated Troubleshooting Blink Codes and Diagnostic Modes ELECTRONIC CONTROL UNIT ECU DIAGNOSTICS The Bendix ESP EC 80 Controller contains self testing diagnostic circuitry that continuously checks for the normal operation of internal components and circuitry as well as external ABS components and wiring Active Diagnostic Trouble Codes DTCs When an erroneous system condition is detected the Bendix ESP EC 80 Controller 1 llluminates the appropriate indicator lamp s and disengages part or all of the Bendix ABS ATC and ESP system functions See ABS Partial Shutdown on page 15 2 Places the appropriate DTC information in the Electronic Control Unit ECU memory and 3 Communicates the appropriate DTC information over the serial communications diagnostic link as required Hand held or PC based diagnostic tools attach to the vehicle diagnostic connec
92. ling on the sensor body When removing or installing the sensor care must be used to prevent damage Do not strike or pry the sensor Do not use an impact tool to install the mounting hardware Sensor Location Modifications The location and orientation of the Yaw Rate Sensor must not be altered When servicing an identical component must be used in the same orientation using OEM brackets amp torque requirements During installation follow the OEM leveling guidelines Yaw Rate Sensor Calibration The yaw rate sensor calibration can only be achieved via the Bendix ESP system with the EC 80 Controller The sensor must be recalibrated after any of these situations e Replacement of the sensor e After an accident that may have led to damage of the yaw rate sensor The calibration procedure is performed using Bendix ACom Diagnostic Software V6 7 2 5 or higher See Troubleshooting Diagnostic Trouble Codes Yaw Rate Sensor for the calibration procedure 19 BRAKE DEMAND SENSOR CALIBRATION Calibration must be performed under the following conditions e After servicing any pressure sensor related Diagnostic Trouble Codes DTCs e Replacement of any sensor The calibration procedure is performed using Bendix ACom Diagnostic Software V6 7 2 5 or higher See Troubleshooting Diagnostic Trouble Codes Brake Demand Sensor Load Sensor for the calibration procedure 20 PRESSURE SENSOR INSTALLATION REQUIREMENTS Ser
93. ller MOD TRC Example If the Diagnostic Trouble Code is Right Steer Axle Sensor the Bendix RDU tool will display one green and three red LEDs FIGURE 20 DIAGNOSTIC TROUBLE CODES AS DISPLAYED ON THE BENDIX RDU TOOL Bendix RDU Reset Function The magnetic reset switch is located in the center top of the Bendix RDU tool Activation requires a magnet with 30 gauss minimum The reset operations are 1 If the magnet is held over the switch for less than 6 seconds the clear current DTCs command is sent 2 If the magnet is held over the switch for more than 6 seconds but less than 30 seconds the Bendix ABS self configuration command is sent Additionally it is recommended at the end of any inspection that the user switches off and restores the power to the Bendix ESP EC 80 Controller then check the ABS Indicator Lamp operation and Bendix RDU tool to see if they indicate any remaining DTCs Bendix RDU Communication Problems If the Bendix ESP EC 80 Controller does not respond to the RDU tool s request for DTCs the RDU tool will illuminate each red LED in a clockwise pattern This pattern indicates the loss of communication and will continue until the Bendix ESP EC 80 Controller responds and communication has been established Possible sources of communication problems are 1 A problem with the J1939 link at the in cab off board diagnostic connector 9 or 6 Pin 2 The Bendix ESP EC 80 Controlle
94. lso measure between 9 to 17 VDC Cab mount ECU Looking into wire harness connector Connector Power Supply Test RN 29 Troubleshooting Diagnostic Trouble Codes DTCs Pressure Modulator Valves PMVs ist Blink Code Location Left Steer Axle Right Steer Axle Left Drive Axle Right Drive Axle Left Additional Axle Right Additional Axle Trailer PMV Bee Diagnostic Trouble Code Code Description 1 Release Solenoid Shorted to Ground 2 Release Solenoid Shorted to Voltage 3 Release Solenoid Open Circuit 4 Hold Solenoid Shorted to Ground 5 Hold Solenoid Shorted to Voltage 6 Hold Solenoid Shorted to Open Circuit 7 CMN Open Circuit 8 Configuration Error 30 O sl U 1 Y E 4 at PU LA LI Gi D og 16 Repair Information Verify no continuity between the PMV leads and ground Verify 4 9 to 5 5 ohms from REL to CMN amp HLD to CMN and 9 8 to 11 ohms from REL to HLD Check for corroded damaged wiring or connectors between the Electronic Control Unit ECU and PMV Verify no continuity between the PMV leads and voltage Verify 4 9 to 5 5 ohms from REL to CMN amp HLD to CMN and 9 8 to 11 ohms from REL to HLD Check for corroded damaged wiring or connectors between the ECU and PMV Verify 4 9 to 5 5 ohms from REL to CMN amp HLD to CMN and 9 8 to 11 ohms from REL to HLD Check for corroded damaged wiring or connectors between the ECU and PM
95. m Number of Pressure Modulator Valve PMV Cycles Exceeded 615 14 12 20 Maximum Number of Traction Control Valve TCV Cycles Exceeded I O 2 or 3 Shorted High EC 80 ATC OR sum is Sp I O 2 or 3 Shorted High Se Stop E Output Error ESP EC 80 i SIR 614 3 25 6 I O 3 Shorted to Voltage ON 614 4 25 5 UO 3 Shorted to Ground ON 614 5 25 4 I O 3 Open Circuit ON 614 ds 25 8 Output Configuration Error I O 3 ON 615 14 12 19 Maximum Number of PMV Cycles Exceeded 615 14 12 20 Maximum Number of TCV Cycles Exceeded ECU DTOs Also see other 629 codes ECU DTC 2678C ON ON ECU DTC 1C ON ON Configuration Mismatch ON ON ECU DTC C8C ON ON Miscellaneous DTCs ECU DTOs Also see other 629 codes ECU DTC 10 ON ON ECU DTC C6 ON ON ECU DTC CF ON ON ECU DTC C0 ON ON Miscellaneous DTCs Air System Mechanical Component ON ON ESP Disabled Due to Off Road Mode 56 APPENDIX B J1939 SPN AND FMI CODES AND THEIR BENDIX BLINK CODE EQUIVALENTS Bendix Blink Code SPN FMI Equivalent s Lamp Status 41939 J1939 1st 2nd Digit Digit Diagnostic Trouble Code DTC Description ECU DTOs Also see other 629 codes ECU DTC 5FC ECU DTC 6CD ECU DTC 5F3 ECU DTC 63 ECU DTC 6E ECU DTC 7CD ECU DTC 5CD ECU DTC 56 ECU DTC CA3C ECU DTC CC ECU DTC 6C ECU DTC 636 VIN Mismatch Valve Configuration Mismatch ECU DTC 5D Configuration Mismatch J1939 Electronic Retarder T
96. mitted Verify the ECU configuration Troubleshooting Diagnostic Trouble Codes DTCs J1939 Bendix ESP system related continued 1st Blink Location J1939 ESP related Diagnostic Trouble Code Description Time out or invalid CAN data CCVS ESP Message Time out or invalid CAN data TCO ESP Message Invalid Data Transfer Time out of Driveline Line Retarder ESP Message ESP related CM3 Time out at J1939 Time out of message or invalid data received from transmission transfer information on J1939 message required for ESP Time out or invalid CAN data Electronic Axle Controller 1ESP Message Repair Information Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Verify message is being transmitted on J1939 link Verify data for park brake brake lamp switch clutch and tachograph Verify the Electronic Control Unit ECU configuration Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Verify message is being transmitted Verify the ECU configuration Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Verify the presence of a retarder on J1939 link Verify message is being transmitted Verify the ECU configuration Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Verify message is being transmitted Verify the ECU configuration Check for damaged or reversed J1939 wirin
97. nal Axle ABS Modulator DTC ATC is disabled ABS on the affected wheel is disabled ABS on all other wheels remains active The Bendix ESP EC 80 system is disabled Steer Axle Wheel Speed Sensor DTC The wheel with the DTC is still controlled by using input from the remaining wheel speed sensor on the steer axle ABS remains active on the rear wheels The Bendix ATC and ESP systems are disabled Drive Axle Additional Axle Wheel Speed Sensor DTC The Bendix ATC and ESP systems are disabled In a four sensor system ABS on the affected wheel is disabled but ABS on all other wheels remains active In a six sensor system ABS remains active by using input from the remaining rear wheel speed sensor on the same side ATC Modulator DTC The Bendix ATC and ESP systems are disabled ABS remains active J1939 Communication DTC The Bendix ATC and ESP systems are disabled ABS remains active ECU DTC The Bendix ABS ATC and ESP systems are disabled The system reverts to normal braking Voltage DTC While voltage is out of range Bendix ABS ATC and ESP systems are disabled The system reverts to normal braking When the correct voltage level is restored full ABS and ATC function is available The operating voltage range is 9 0 to 17 0 VDC for 12 volt systems and 20 to 33 5 volts for 24 volt systems Steering Angle Sensor DTC The Bendix ESP system is disabled Bendix ABS and ATC systems remain active Yaw Rate Lateral
98. ndicator Lamp also serves as the ATC Status Indicator Lamp A Bendix SAS 60 Steering Angle Sensor mounted to the steering column See Figure 4 When replacing a steering wheel take care not to damage the Steering Angle Sensor or interfere with its operation and the Steering Angle Sensor must be recalibrated see Troubleshooting section af kia Rf ee gapa OF 002 IUIUS ippost D am pne e O a plain 90 Connectors Straight Connector FIGURE 4 EXAMPLES OF STEERING ANGLE SENSORS e Bendix YAS 60 or YAS 70X Yaw Rate Lateral Acceleration Sensors typically mounted to a cross member near the back of the vehicle cab See Figure 5 Brake Demand Sensors installed in the primary and secondary delivery circuits e ALoad Sensor typically installed in the suspension air bag e Anadditional Modulator Valve Bendix M 40QR or M 40HF Pressure Modulator Valve that controls the pressure applied to the trailer brakes during a system intervention The Bendix ESP EC 80 Controller s ATC function utilizes the following additional components e Adrive axle Traction Control Valve may be integral to the service brake relay valve or a stand alone device Adash mounted ATC Status Indicator Lamp e AJ1939 serial communication Control Module e A J1939 or ECU hardware provided Stop Lamp Switch Input e An optional ATC Mud Snow Switch sometimes referred to as an ATC off road switch Brake Demand Load S
99. ng OEM brackets amp torque requirements During installation follow the OEM leveling guidelines Steering Angle Sensor Re Calibration Whenever maintenance or repair work is performed to the steering mechanism linkage steering gear adjustment of the wheel track or if the steering angle sensor is replaced a recalibration of the Steering Angle Sensor must be performed 14 If the Steering Angle Sensor is not recalibrated the yaw control system may not function properly which can result in incidents leading to loss of vehicle control See page 19 of this document for more details on this procedure DYNAMOMETER TEST MODE Bendix ATC and ESP systems must be disabled prior to conducting any dynamometer testing When the Dynamometer Test Mode is engaged the Bendix ATC EC 80 Controller s brake control and engine control along with drag torque control and Bendix ESP system functions are disabled This test mode is used to avoid torque reduction or torque increase and brake control activation when the vehicle is operated on a dynamometer for testing purposes The Dynamometer Test Mode may be activated by pressing and releasing the diagnostic Blink Code Switch five times or by using a hand held or PC based diagnostic tool During Dynamometer Test Mode the ATC lamp remains ON Bendix ESP EC 80 Controllers will remain engaged in the Dynamometer Test Mode even if power to the ECU is removed and re applied To exit th
100. not be driven on high banked roads such as those found on high speed test or race tracks Test personnel must have the Bendix ESP system s stability features disabled prior to operating a vehicle on such tracks For vehicles with the optional Hill Start Aid HSA system sometimes referred to as a Hill Start Assist or simply Hill Start this feature interfaces between the transmission and the braking system HSA helps the driver prevent the vehicle from rolling downhill when moving up a steep incline from a stationary position See page 6 for more information YAW CONTROL YC A Bendix EC 80 ESP Controller includes Yaw Control YC functionality Yaw Control has the ability to apply brakes to individual wheel ends as well as applying the trailer brakes to counteract trailer push that during certain maneuvers could lead to a loss of control or a jackknife incident See Yaw Stability on page 13 for further details ROLL STABILITY PROGRAM RSP The Bendix Roll Stability Program RSP is an all axle ABS solution that helps decrease vehicle speed by reducing the engine s throttle and applying all vehicle brakes as needed mitigating the vehicle s tendency to roll over RSP focuses on reducing the vehicle s speed below the critical roll threshold during direction changing maneuvers such as driving on curved highway exit ramps or obstacle avoidance maneuvers on dry high friction surfaces See ESP
101. nuity to Voltage between TCV leads and voltage Check for corroded damaged wiring or connectors between ECU and TCV TCV Solenoid Open Verify 7 to 19 ohms between TCV and TCV common Check for corroded Circuit damaged wiring or connectors between ECU and TCV TCV Configuration Error The ECU is not configured for ESP or ATC but has detected the presence of a TCV Verify TCV wiring Inspect for the presence of a TCV Verify the ECU configuration ATR valve inspections should include looking for kinked air hoses inside the harness socket on the valve for removed or corroded connector pins and a test to verify that the ATC valve solenoids are functioning correctly Traction Control Valve TCV Repair Tests 1 Take all measurements at ECU harness connector pins in order to check wire harness and traction control valve Probe the connector carefully so that the terminals are not damaged 2 Tractor Control Valve resistance measurements should read 7 to 19 Ohms Open Circuit no continuity Cab mount ECU Looking into wire harness connector X 3 X 1 Traction Control Test Connector Pin Pin Traction Control Test Drive Axle Traction Steer Axle Traction X1 Control Valve Common X3 Control Valve Common 18 Way Drive Axle Traction 15 Way Steer Axle Traction Control Valve Control Valve Troubleshooting Diagnostic Trouble Codes DTCs Steering Angle Sensor SAS Bendix SAS 60 Sensor 1st Blink Code 1 2
102. o WS 24 Speed Sensor Lo SSS 100 Tooth Exciter Ring 90 Speed Sensors Straight Speed amping Sensors Sleeve FIGURE 22 BENDIX WS 24 WHEEL SPEED SENSOR INSTALLATION S CAM AND AIR DISC BRAKE Wheel Speed Sensor Wiring Route sensor wiring coming out of the wheel ends away from moving brake components Sensor wiring needs to be secured to the axle to prevent excess cable length and wiring damage It is required that cable ties be installed to the sensor wire within 3 inches 76 2 mm of the sensor head to provide strain relief Following the axle the sensor wires must be attached along the length of the service brake hoses using cable ties with ultraviolet protection and secured every 6 to 8 inches 152 to 203 mm Sufficient but not excessive cable length must be provided to permit full suspension travel and steering axle movement Install wires so that they cannot touch rotating elements such as wheels brake discs or drive shafts Radiation protection may be necessary in the area of brake discs Bendix does not recommend using standard tie wraps to secure wiring harnesses directly to rubber air lines This may cause premature wiring failure from the pressure exerted on the wiring when air pressure is applied through the air line Non metallic hose clamps or bow tie tie wraps are preferred The use of grommets or other suitable protection is required whenever the cable must pass through me
103. oltage amp 2 Voltage Input 2 Verify wiring between the Steering Angle Sensor and Harness SAS Wire Harness Ground Verify open circuit no continuity 4 To perform a calibration procedure of the Steering Angle Sensor Bendix ACom Diagnostic Software V6 7 2 5 or higher is required Using the program select the Configuration option followed by the Calibrate option The following screen should be displayed 5 Follow the prompts to perform a calibration of the Steering Angle Sensor 6 To test the Steering Angle Sensor ACom V6 7 2 5 or higher is required Using Bendix ACom V6 7 2 5 or higher select the Component Test option followed by the ESP Test option The following screen should be displayed oe Lives Duras Sensors ESP ttecetarec tje one fe cem m uns Pe ne The amos Ponai imd EI nm 5 deges 4 niche fe me mee vers t Wf The ar ics theasd gg EI de emi n E t Tet cou im Peter man es Par Sg e 7 Follow the prompts to perform a test of the Steering Angle Sensor 39 Troubleshooting Diagnostic Trouble Codes DTCs 1st Blink 40 Code 10 12 13 14 15 16 17 Location Yaw Rate Sensor Diagnostic Trouble Code Description YRS Signal Out of Range YRS Sensor Reversed Signal YRS Invalid Signal YRS Gradient Error YRS CAN Time out YRS Static BITE Error YRS Dynamic BITE Error YRS Fast Calibration Error YRS
104. oltage is open Mismatch between ECU configuration and Diff valve Mismatch between ECU configuration and 1 03 Troubleshooting Diagnostic Trouble Codes DTCs Bendix ESP system related 2nd Blink Code 11 Diagnostic Trouble Code Description J1939 CAN Time out of ESP Message Time out or Invalid CAN data CCVS 2 ESP Message Time out or Invalid CAN data Electronic Engine Controller 1 ESP Message Time out or Invalid CAN data EEC2 ESP Message Time out or Invalid CAN data Driveline Line Retarder ESP Message Time out or Invalid CAN data Engine Retarder ESP Message Time out or Invalid CAN data Exhaust Retarder ESP Message Time out or Invalid CAN data PROP XBR ESP Message Time out or Invalid CAN data Transmission Retarder ESP Message Time out or Invalid CAN data Electronic Transmission Controller 1 ESP Message Time out or Invalid AUXI O ESP Message Repair Information Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Verify message is being transmitted on J1939 link Verify the Electronic Control Unit ECU configuration Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Verify message is being transmitted on J1939 link Verify the ECU configuration Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Verify the presence of engine ECU on J1939 link Verif
105. on the vehicle the means of fastening the unit to the vehicle and the sensor s orientation MUST NOT BE ALTERED When servicing an identical component must be used in the same orientation using OEM brackets amp torque requirements During installation follow the OEM leveling guidelines If any of these requirements are not followed the Bendix ESP system may not function properly which can result in incidents leading to loss of vehicle control 2 Assembly yaw rate sensor housing to mounting bracket The bracket must be the same design as used on the original vehicle configuration 3 For Bendix YAS 60 Yaw Rate Sensors the correct fasteners are three M8 size bolts and the fixing torque should be 20 Nm 2 Nm For Bendix YAS 70X Yaw Hate Sensors the correct fasteners are two M10 size bolts 1 5 mm pitch angle or OEM supplied hardware and the fixing torque should be 46 Nm x9 Nm Note that the Bendix YAS 70X sensor has two alternate designs one with an aligning post see the kit instruction sheet for more information In all cases the connector should be facing in the same direction as the removed sensor The unit must not be installed upside down where there is a pressure balancing hole 4 The sensor should be as level as possible and parallel to the road surface when installed on the vehicle 5 Reconnectthe connector Ensure that there will be no force applied to the sensor because the connector is pul
106. onfigured for the Hill Start Hill Start Assist feature HS HSA the retarder relay output pin is used to control the Hill Start status lamp As a result the vehicle loses the retarder relay function when it has the Hill Start feature SAE J1939 Serial Communications A Controller Area Network CAN data link SAE J1939 is provided for communication This link is used for various functions such as Diagnostic purposes To disable retarding devices during ABS operation o request that the torque converter disable lock up during ABS operation To share information such as wheel speed and ECU status with other vehicle control modules Bendix ESP EC 80 Controllers utilize the J1939 data link for ATC and drag torque control functions e Vehicle stability functions Trailer ABS Indicator Lamp Control The Bendix ESP EC 80 Controller will activate a trailer ABS Indicator Lamp located on the dash panel that indicates the status of the trailer ABS unit on one or more trailers or dollies that are equipped with PLC functionality Typically the Bendix ESP EC 80 Controller directly controls the trailer ABS Indicator Lamp based on the information it receives from the trailer ABS via PLC Alternatively some vehicles require the Bendix ESP EC 80 Controller to activate the trailer ABS Indicator Lamp by communicating with other vehicle Controllers using serial communications If you need to know if this Bendix ESP EC 80
107. or reversed J1939 wiring Check for corroded or damaged connectors Verify the presence of engine ECU on the J1939 link Verify the ECU configuration Check for other devices inhibiting J1939 communications Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Check for other devices inhibiting J1939 communications Verify the ECU configuration Verify AUX IO broadcast from address configured in EC 80 ECU Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Verify the ECU configuration Verify EBC1 being broadcast with a valid SPN 577 parameter Check for other devices inhibiting J1939 communications Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Check for other devices inhibiting J1939 communications Verify the ECU configuration Verify ESP messages 2nd Blink Code 15 16 20 21 22 23 24 26 2 28 29 Diagnostic Trouble Code Description J1939 Electronic Engine Controller 3 Time out or Invalid Signal J1939 Electronic Transmission Controller 2 Time out J1939 EAC1 Time out or Invalid Signal CAN Message CGW C1 Time out or invalid signal CAN Message ASC1 CLCS Time out or invalid signal J1939 CCVS Time out or Invalid Signal J1939 TCO Tachograph Time out J1939 Address Conflict ABS Address J1939 Address Conflict TPMS Address J1939 Proprietary XBR Message Out of Range J19
108. ot Configured Erratic ESP Signal ONDNNDNNNNNN NN NN m NS A 0 61 APPENDIX B J1939 SPN AND FMI CODES AND THEIR BENDIX BLINK CODE EQUIVALENTS Bendix Blink Code SPN FMI Equivalent s gc J1939 J1939 1st 2nd Diagnostic Trouble Code DTC Description Lamp Status Digit Digit Lateral Acceleration Sensor DTCs LAS Signal of Range LAS Static Calibration Error LAS Long Term Calibration Error LAS Plausibility Error Inside Model Based Limits LAS Plausibility Error Outside Model Based Limits YRS SAS Signal Cross Check Incomplete LAS Calibration in Progress Miscellaneous ABS ECU CAN Address Conflict ON TPMS ECU CAN Address Conflict TPMS INDICATOR LAMP ON ON HS HSA Hill Start Feature DTCs HSA lamp Open Circuit or Shorted to GND HSA valve Solenoid Shorted to Voltage HSA lamp Shorted to Voltage HSA valve Solenoid Shorted to Ground HSA valve Solenoid Open Circuit Bendix eTrac DTCs Bendix eTrac Solenoid Shorted to Voltage Bendix eTrac Solenoid Shorted to Ground Figures Used Figure 1 Bendix ESP EC 80 Controller Figure 2 Bendix WS 24 Wheel Speed Sensors Figure 3 Example Of A Bendix M 40X Modulator Figure 4 Examples Of Steering Angle Sensors Figure 5 Yaw And Brake Demand Load Sensors Figure 6 Additional Valves Necessary For The Hill Start Feature Figure 7 Bendix ESP EC 80 Controller Featur
109. ph The ATC ESP dash lamp will illuminate to indicate to the driver that the stability system is disabled The vehicle manufacturer should provide the optional ABS off road function only for vehicles that operate on unpaved surfaces or that are used in off road applications and is responsible for ensuring that vehicles equipped with the ABS off road function meet all FMVSS 121 requirements and have adequate operator indicators and instructions The vehicle operator activates the off road function with a switch on the dash panel A flashing ABS Indicator Lamp indicates to the driver that the ABS off road function is engaged To exit the ABS off road mode depress and release the switch A new ignition cycle will also cause the ECU to exit the ABS off road mode All Wheel Drive AWD Vehicles AWD vehicles with an engaged interaxle differential steer axle to rear axle AWD transfer case may have negative effects on ABS performance Optimum ABS performance is achieved when the lockable differentials are disengaged allowing individual wheel control Bendix ESP EC 80 Controllers can be programmed specifically for this configuration to control the differential lock unlock solenoid in the AWD transfer case When programmed to do so the ECU will disengage the locked interaxle AWD transfer case during an ABS event and reengage it once the ABS event has ended ATC OPERATION ATC Functional Overview Just as ABS improves vehicle st
110. question is directed individually into each brake chamber J1939 A high speed data link used for communications between the ABS ECU engine transmission and retarders LAS Lateral Acceleration Sensor MIR Modified Independent Regulation A method of controlling the opposite sides of a steer axle during ABS operation so that torque steer and stopping distance are minimized PLC Power Line Carrier The serial communication protocol used to communicate with the trailer over the blue full time power wire PMV Pressure Modulator Valve An air valve which is used to vent or block air to the brake chambers to limit or reduce brake torque QR Quick Release Quick release valves allow faster release of air from the brake chamber after a brake application To balance the system quick release valves have hold off springs that produce higher crack pressures when the valves open Relay Valve Increases the application speed of the service brake Installed near brakes with larger air chambers type 24 or 30 The treadle valve activates the relay valve with an air signal The relay valve then connects its supply port to its delivery ports Equal length air hose must connect the delivery ports of the relay valve to the brake chambers Retarder Relay A relay which is used to disable a retarder when ABS is triggered RSP Roll Stability Program An all axle ABS solution that helps reduce vehicle speed by applyin
111. r Axle Left PMV Hold Solenoid Shorted to Ground 932 5 Y 6 Steer Axle Left PMV Hold Solenoid Open Circuit 933 3 8 5 Steer Axle Right PMV Hold Solenoid Shorted to Voltage 933 4 8 4 Steer Axle Right PMV Hold Solenoid Shorted to Ground 933 5 8 6 Steer Axle Right PMV Hold Solenoid Open Circuit 934 3 9 5 Drive Axle Left PMV Hold Solenoid Shorted to Voltage 934 4 9 4 Drive Axle Left PMV Hold Solenoid Shorted to Ground 934 5 9 6 Drive Axle Left PMV Hold Solenoid Open Circuit 935 3 10 5 Drive Axle Right PMV Hold Solenoid Shorted to Voltage 935 4 10 4 Drive Axle Right PMV Hold Solenoid Shorted to Ground 935 5 10 6 Drive Axle Right PMV Hold Solenoid Open Circuit 936 3 16 5 AA Left PMV Hold Solenoid Shorted to Voltage 936 4 16 4 AA Left PMV Hold Solenoid Shorted to Ground 936 5 16 6 AA Left PMV Hold Solenoid Open Circuit 936 13 16 11 Output Configuration Error Left Additional Axle Hold 937 3 d 5 AA Right PMV Hold Solenoid Shorted to Voltage 937 4 17 4 AA Right PMV Hold Solenoid Shorted to Ground 937 5 17 6 AA Right PMV Hold Solenoid Open Circuit 937 Fe 17 11 Output Configuration Error Additional Axle Right Hold 938 3 Y 2 Steer Axle Left PMV Release Solenoid Shorted to Voltage 938 4 7 1 Steer Axle Left PMV Release Solenoid Shorted to Ground 938 5 Ti 3 Steer Axle Left PMV Release Solenoid Open Circuit 939 3 8 2 Steer Axle Right PMV Release Solenoid Shorted to Voltage 939 4 8 1 Steer Axle Right PMV Release Solenoid Shorted to Ground 939 5 8 8 Steer Axle Right PMV
112. r does not support PID194 3 No power is being supplied to the Bendix ESP EC 80 Controller and or the diagnostic connector 4 The J1939 bus is overloaded with information and the RDU can not arbitrate access or 5 Amalfunctioning Bendix RDU tool Other Information For more information on Bendix ACom Diagnostics Software or RP 1210 compliant tools go to www bendix com or visit your local authorized Bendix distributor See pages 56 62 for Appendices showing J1939 SID FMI codes and their Bendix blink code equivalents www bendix com For the latest information and for free downloads of the Bendix AComf Diagnostic Software and its User Guide visit the Bendix website at www bendix com Bendix Technical Assistance Team For direct telephone technical support call the Bendix technical assistance team at 1 800 AIR BRAKE 1 800 247 2725 option 2 then 1 Monday through Friday 8 00 a m to 6 00 p m ET and follow the instructions in the recorded message E mail the Bendix Technical Assistance Team at techteamObendix com 25 Active or Inactive Diagnostic Trouble Codes DTCs INDEX How to interpret the first digit of messages received when Active or Inactive Diagnostic Trouble Code Mode is entered 1st Blink Troubleshooting Tests Code Number No DTOs 1 1 Wheel Speed Sensors pages 27 28 Wheel Speed Sensors pages 27 28 Wheel Speed Sensors pages 27 28 Wheel Speed Sensors pages 27 28
113. ronic Control Unit ECU using information obtained from other vehicle Controller s If the VIN stored in the ECU does not match the VIN obtained from the other vehicle Controller s the ECU will generate an ECU Internal VIN Mismatch Diagnostic Trouble Code DTC Accordingly do not attempt to move a Bendix ESP EC 80 Controller from one vehicle to another OBTAINING A NEW BENDIX ESP EC oO CONTROLLER Should the Bendix ESP EC 80 Controller require replacement certain steps must be followed 1 Record the vehicle model VIN year and date of manufacture from the vehicle 2 Record the part number of the Bendix ESP EC 80 Controller 3 Provide this information to your local OEM vehicle service department to obtain a new Bendix ESP EC 80 ECU The OEM service department will install the same parameter set in the new Controller that was loaded into the original ECU at the vehicle OEM assembly facility INSTALLING A NEW BENDIX ESP EC 80 CONTROLLER When replacing the Bendix ESP EC 80 Controller verify with the OEM service department that the unit you are installing has the correct parameter set Failure to do so could result in a loss of features or degraded ESP performance For further information contact either the vehicle manufacturer Bendix or your local authorized Bendix distributor 1 Position and secure the Bendix ESP EC 80 Controller in the original mounting orientation using the mounting bolts retained during
114. ryer reservoir module or a Bendix AD 9si air dryer be sure to drain the purge reservoir A Following the vehicle manufacturer s recommended procedures deactivate the electrical system in a manner that safely removes all electrical power from the vehicle A Never exceed manufacturer s recommended pressures A Never connect or disconnect a hose or line containing pressure it may whip Never remove a component or plug unless you are certain all system pressure has been depleted A Use only genuine Bendix brand replacement parts components and kits Replacement hardware tubing hose fittings etc must be of equivalent size type and strength as original equipment and be designed specifically for such applications and systems A Components with stripped threads or damaged parts should be replaced rather than repaired Do not attempt repairs requiring machining or welding unless specifically stated and approved by the vehicle and component manufacturer A Prior to returning the vehicle to service make certain all components and systems are restored to their proper operating condition A For vehicles with Automatic Traction Control ATC the ATC function must be disabled ATC indicator lamp should be ON prior to performing any vehicle maintenance where one or more wheels on a drive axle are lifted off the ground and moving A The power MUST be temporarily disconnected from the radar sensor whenever any tests USING A DYN
115. s LLC a member of the Knorr Bremse Group All Rights Reserved FIGURE 18 BENDIX ACOM DIAGNOSTICS Bendix ACom Diagnostic Software is a PC based program and is designed to meet RP 1210 industry standards developed by the Truck Maintenance Council TMC This software provides the technician with access to all the available Bendix EC 80 ESP Controller s diagnostic information and configuration capability including e ECU information e Diagnostic Trouble Codes DTCs and repair information e Configuration ABS ATC and more e Wheel speed information e Perform component tests and e Save and print information Note Bendix ACom Diagnostic Software V6 7 2 5 or higher is required to calibrate the Steering Angle Sensor the Yaw Rate Lateral Acceleration Sensor the Brake Demand Sensors and the Load Sensor When using ACom Diagnostic Software V6 7 2 5 or higher to diagnose the Bendix ESP EC 80 Controller the computer s serial or parallel port needs to be connected to the vehicle s diagnostic connector BENDIX RDU REMOTE DIAGNOSTIC UNIT The Bendix RDU tool Bendix part number K101596N001 provides the technician with a visual indication of Antilock Braking System ABS component Diagnostic Trouble Code DTC information Note Previous versions of the RDU tool are not compatible with the Bendix ESP EC 80 Controller The Bendix RDU tool is specifically designed for use with Bendix brand A
116. shing indicating the ECU is in the off road ABS mode Remove and re apply ignition power Replace all PMV valves and clear the DTC 2nd Blink Code 20 22 24 25 26 27 28 29 30 31 32 33 34 35 36 38 Diagnostic Trouble Code Description Maximum Number of TCV Cycles Exceeded ESP Sensor Voltage Out of Range HS Feature Lamp Open or Shorted to Ground HS Feature Solenoid Open or Shorted to Ground HS Feature Solenoid Shorted to Voltage Brake Lamp Input Mismatch With Brake Lamp Output Air system Mechanical Component Air system Mechanical Component ESP Disabled due to Off Road Mode HS Feature Lamp Shorted to Voltage I O 2 or 3 Shorted High EC 80 ATC OR I O 2 or 3 shorted High or Stop Lamp Output error ESP EC 80 HS Feature Solenoid Open Circuit eTrac Valve Solenoid Shorted to Voltage eTrac Valve Solenoid Shorted to Ground Reserved Invalid ABS Warning Lamp Configuration Repair Information Replace all Traction Control Valve TCV valves and clear the Diagnostic Trouble Code DTC Incorrect supply voltage is detected for the Bendix SAS 60 and the Yaw Rate sensor Verify the proper voltage at sensor connectors Verify wiring between the Electronic Control Unit ECU and the sensors Verify the proper output voltage from ECU Note When checking for voltage at YAW LAS amp SAS the voltage will only be present momentarily at key ON
117. ssion Controller 1 ESP Message Time out or Invalid AUX I O ESP Message Time out or Invalid Data for Configuration of Electronic Engine Controller 1 ESP Message Oo O JO OS C N meek O 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 E NO APPENDIX B J1939 SPN AND FMI CODES AND THEIR BENDIX BLINK CODE EQUIVALENTS Bendix Blink Code SPN FMI Equivalent s Lamp Status 41939 31939 1st 2nd Digit Digit Diagnostic Trouble Code DTC Description Invalid Data Transfer Time out of EC1 ESP Message Time out or Invalid Data for Configuration of Driveline Line Retarder ESP Message Time out or Invalid CAN Data Electronic Engine Controller ESP Message Time out or Invalid CAN Data Electronic Transmission Controller 2 Message Required for ESP Time out or Invalid Data for Configuration of Engine Retarder ESP Message Time out or Invalid Data for Configuration of Exhaust Retarder ESP Message Time out or Invalid Data for Configuration of Transmission Retarder ESP Message Invalid Data Transfer Time out of Driveline Line Retarder ESP Message Invalid Data Transfer Time out of Engine Retarder ESP Message Invalid Data Transfer Time out of Exhaust Retarder ESP Message Time out or Invalid CAN Data CCVS ESP Message Time out or Invalid CAN Data TCO ESP Message Invalid Data Transfer Time out of Driveline Line Retarder ESP Message ESP Related CM
118. tability Program RSP9 EC 80 ESP SD 13 4986 This Document ESP is a registered trademark of DaimlerChrysler and is used by BCVS under license GENERAL SAFETY GUIDELINES WARNING PLEASE READ AND FOLLOW THESE INSTRUCTIONS A TO AVOID PERSONAL INJURY OR DEATH When working on or around a vehicle the following guidelines should be observed AT ALL TIMES A Park the vehicle on a level surface apply the parking brakes and always block the wheels Always wear personal protection equipment A Stop the engine and remove the ignition key when working under or around the vehicle When working in the engine compartment the engine should be shut off and the ignition key should be removed Where circumstances require that the engine be in operation EXTREME CAUTION should be used to prevent personal injury resulting from contact with moving rotating leaking heated or electrically charged components A Do not attempt to install remove disassemble or assemble a component until you have read and thoroughly understand the recommended procedures Use only the proper tools and observe all precautions pertaining to use of those tools A If the work is being performed on the vehicle s air brake system or any auxiliary pressurized air systems make certain to drain the air pressure from all reservoirs before beginning ANY work on the vehicle If the vehicle is equipped with a Bendix AD IS air dryer system a Bendix DRM d
119. tallic frame members All sensor wiring must utilize twisted pair wire with approximately one to two twists per inch It is recommended that wires be routed straight out of a connector for a minimum of three inches before the wire is allowed to bend 51 ICA Wiring Schemati Troubleshooting D C O c C Ww cC 0 LE VV va VS D T pus W9 S9 W S9 NOLIVENDIANO 08 23 43d GATIVLSNI AWd ANY SSM 3TXV 1VNOLLIQQV WNOLIGGV JAIHG Y3315 o wa s T HOLIMS AYYLNIWOW J c M X G34INOZ8 38IA GALSIML YOLINGNOD YNO DMY 81 SNISIM HOSN3S NYD 1 c o NOLLVDINNWWOD 6 6Lf HO LNdNI 3HVMQSVH VIA GACIAOUd 38 AVIA eme o lt SIMIHIA JAIN 133HM TIV ANY 21V HCH GIYINOIY LOdNI H2LIMS dag dOLS O C O HOIV2IQNI Sav O Sep o 3HLSNLIVNIWATTII INQOHD OL LINDYID HOLWIGNI IHL SLYOHS ADOTHALNI IHL 93 WOYA Q3123NNODSIQ SI LX N3HM 2 ab O c IDNYAQY 09 23 HO LNIWIDY1d3Y IDIAYIS V SV GANDISIG NI 08 23 NV HOH SI DILYWIHIS NOILDINNOD ONIYIM WALSAS SIHL VS Oo C 00000 O OO O 6 961 LA NOLIVOHID3dS LINAOYA o eOocooooooOuus O O e O ILON 3SIMY3HLO SSIINN DMV 91 JO NOIL23S SSOUD HOLINANOD SI 38M TIY CO OO OO OO OO OO 0 H o o IE EE GE EE E EE EE EC du o 6 31ON 335 LNdNI dier dOLS SIBINDIHAINO STOEN AND TIJHM TV d T Y cc o E QI CO Qo ZOE gt lt T DMY ZL ANNOYD ANY AH3LIVS C o O 060 ON NU O O O O Qo v X 9 YDIH3A 4 x o Tu ooo c SNOILAO MOUNT 7V1D34S SINN GaLLOd o O CO CO co co LO LO LO LO D nH D e 2 CO CO CO C
120. that is shared with the Yaw Rate Sensor The Controller supplies the power and ground inputs to the Bendix SAS 70X sensor The Bendix SAS 70X sensor is available with two different styles of wire harness connectors See Figure 4 Bendix YAS 60 or YAS 70X Yaw Rate Lateral Acceleration Sensors Bendix brand yaw rate lateral acceleration sensors are used to provide the Controller an indication of vehicle lateral acceleration and rotation around the vertical axis This information is provided to the Controller utilizing a dedicated serial communications link that is shared with the Bendix SAS 60 sensor The Controller supplies the power and ground inputs to the yaw rate sensor BENDIX ESP EC 80 CONTROLLER OUTPUTS Bendix M A40QR and M 40HF Pressure Modulator Valves PMVs The Bendix ESP EC 80 Controller operates Bendix M 40QR and M 40HF Pressure Modulator Valves PMVs to modify the driver applied air pressure to the service brakes during ABS ATC RSP or YC activation see pages 9 13 The PMV is an electropneumatic control valve and is the last valve that air passes through on its way to the brake chamber The modulator hold and release solenoids are activated to modulate or control the brake pressure during an antilock braking event The hold solenoid is normally open and the release solenoid is normally closed such that the PMV nominally allows air to flow through This design allows for air delivery to br
121. the ECU configuration Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Verify the presence of transmission ECU on J1939 link Verify that the message is being transmitted Verify that the data for current gear is correct Verify the ECU configuration Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Verify the presence of a retarder on J1939 link Verify message is being transmitted Verify the ECU configuration Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Verify the presence of a retarder on J1939 link Verify message is being transmitted Verify the ECU configuration Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Verify the presence of Radar on J1939 link Verify the ECU configuration Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Verify the presence of a retarder on J1939 link Verify message is being transmitted Verify the ECU configuration Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Verify the presence of a retarder on J1939 link Verify message is being transmitted Verify the ECU configuration Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Verify the presence of a retarder on J1939 link Verify the presence of a retarder on J1939 link Verify message is being trans
122. tic Blink Code Switch Check wiring of diagnostic Blink Code Switch verify ABS wire is not grounded where used and ABS Indicator Lamp Verify ABS Indicator Lamp ground input On some vehicles with multi plex dashes the ground wire may not be present see ECU 19 DTC Verify no continuity between the Release Hold and CMN of all Pressure Modulator Valves PMVs Traction Control Valve TCV HSA Diff Lock Solenoid and ground Check for corroded damaged wiring or connectors between the ECU and CMN of all PMVs TCV and Diff Lock Solenoid See the extended troubleshooting for this code in Appendix A Verify no continuity between the Release Hold and CMN of all PMVs TCV HSA Diff Lock Solenoid and voltage Check for corroded damaged wiring or connectors between the ECU and CMN of all PMVs TCV and Diff Lock Solenoid The Bendix ATC Automatic Traction Control system is temporarily disabled to prevent excessive heating of the foundation brakes Sensors are reversed left to right on one of the axles Verify the proper installation connection and wiring of the sensors Incorrect supply voltage for the Steering Angle Sensor SAS and the Yaw Rate sensor Verify the proper voltage at the sensor connectors Verify the wiring between the ECU and the sensors Verify the proper output voltage from ECU Note When checking for voltage at YAW LAS amp SAS the voltage will only be present momentarily at key ON The ABS indicator lamp will be fla
123. ting assistance The ECU internally stored VIN does not match the VIN of the vehicle Ensure that the ECU is installed on the correct vehicle Verify the ECU programming Verify engine programming Check for damaged or corroded connectors Check for damaged wiring Clear DTCs If DTCs return contact the Bendix Tech Team at 1 800 AIR BRAKE 1 800 247 2725 option 2 then 1 for further troubleshooting assistance Check for damaged or corroded connectors Check for damaged wiring including power and ground wiring Clear DTCs If DTCs return contact the Bendix Tech Team at 1 800 AIR BRAKE 1 800 247 2725 option 2 then 1 for further troubleshooting assistance Troubleshooting Diagnostic Trouble Codes DTCs Traction Control Valves TCV 1st Blink Code 18 Drive Axle Traction Control Valve 19 Steer Axle Traction Control Valve Location NOTE When troubleshooting Traction Control Valve DTCs it may be useful to look for a potential connection between them and ECU DTCs in particular DTCs 13 8 and 13 18 shown on page 36 Diagnostic Trouble Repair Information Code Description TCV Solenoid Shorted Verify 7 to 19 ohms between Traction Control Valve TCV and TCV to Ground common Verify no continuity between TCV leads and ground Check for corroded damaged wiring or connectors between the ECU and TCV TCV Solenoid Shorted Verify 7 to 19 ohms between TCV and TCV common Verify no conti
124. tion Sensors previous page 42 Troubleshooting Diagnostic Trouble Codes DTCs Brake Demand Load Sensors 1st Blink Location Code Brake Demand Load Sensor Diagnostic Trouble Code Description PS1 Open or Shorted PS2 Open or Shorted PS3 Open or Shorted P51 2 Plausibility Error PS Supply Voltage Error PS Not Calibrated PS Error PS Supply Voltage Error PS Not Configured a O ek O Looking into wire harness connector 1 Verify continuity between the ECU and the pressure sensor power and ground Repair Information Check wiring between Brake Demand Sensor primary brake circuit and Electronic Control Unit ECU Verify operation of pressure sensor Check wiring between Brake Demand Sensor secondary brake circuit and ECU Verify operation of pressure sensor Check wiring between Load Sensor and ECU Verify operation of pressure sensor ECU has detected an invalid pressure sensor signal from one of the Brake Demand Sensors Incorrect supply voltage to the sensors Verify the proper voltage at sensor connectors Verify wiring between the ECU and the sensors Verify the proper output voltage from the ECU Specifically ensure that X4 4 PS SPL is not shorted to ground Perform static sensor calibration procedure NOTE When replacing an ECU this DTC may occur Verify operation of pressure sensor Incorrect supply voltage to sensors Verify the proper voltage at sensor connectors
125. tor typically located on or under the dash see Figure 14 FIGURE 14 TYPICAL VEHICLE DIAGNOSTIC CONNECTOR LOCATIONS 41939 BLINK CODES Blink codes allow a technician to troubleshoot ABS problems without using a hand held or PC based diagnostic tool Instead information about the ABS system is communicated by the Bendix ESP EC 80 Controller using the ABS indicator lamp to display sequences of blinks Note The Bendix ESP EC 80 Controller will not enter the diagnostic blink code mode if the wheel speed sensors show that the vehicle is in motion If the ECU is in the diagnostic blink code mode and then detects vehicle motion it will exit the blink code mode In addition by operating the Blink Code Switch as described below one of several diagnostic modes can be entered See Diagnostic Modes below Blink Code Switch Activation When activating the Blink Code Switch 1 Wait at least two seconds after ignition on Except when entering Reconfiguration Mode see System Reconfiguration section on page 16 2 Forthe Bendix ESP EC 80 Controller to recognize that the switch is activated on the technician must press for at least 0 1 seconds but less than five 5 seconds If the switch is held for more than five 5 seconds the ECU will register a malfunctioning switch 3 Pauses between pressing the switch when a sequence is required e g when changing mode must not be longer than two 2 seconds 4 After a
126. unt ECU Looking into the wire harness connector Wheel Speed Sensor connector em eon in xi 8 LeftSteerAxe x2 18 Way x3 15 Way if ECU is configured for Right Additional Axle 6 sensors Right Additional Axle Troubleshooting Diagnostic Trouble Codes DTCs Power Supply 1st Blink Code 6 Power Supply Location Diagnostic Trouble Repair Information Code Description Battery Voltage Too Measure the battery voltage under load Check the vehicle battery and associated Low components Check for damaged wiring Check for damaged or corroded connectors and connections Battery Voltage Too Measure the battery voltage under load Ensure that battery voltage is correct High for the Electronic Control Unit ECU Check the vehicle battery and associated components Check for damaged wiring Check for damaged or corroded connectors and connections Power Supply Tests 1 Take all measurements at the ECU harness 3 Check for damaged wiring damaged or corroded connector connectors and connections 2 Place a load e g an 1157 stop lamp across the 4 Check the condition of the vehicle battery and battery or ignition and ground connection measure associated components verify that the ground the ignition and battery voltage with the load Ignition connection is good and tightened to Ground should measure between 9 to 17 VDC 5 Check the alternator output for excessive noise Battery to Ground should a
127. urning motion during braking and adjusts or modulates the brake pressure at the wheel end When excessive wheel slip or wheel lock up is detected the Bendix ESP EC 80 Controller will activate the pressure modulator valves to automatically reduce the brake pressure at one or more of the wheel ends By these actions the ABS system helps to maintain the vehicle s lateral stability and steerability during heavy brake applications and during braking on slippery surfaces Steer Axle Control Although both wheels of the steer axle have their own wheel speed sensor and pressure modulator valve the Bendix ESP EC 80 Controller blends the applied braking force between the two steering axle brakes This Bendix patented brake application control called Modified Individual Regulation MIR is designed to help reduce steering wheel pull during an ABS event on road surfaces with poor traction or areas of poor traction e g asphalt road surfaces with patches of ice Single Drive Axle Control 4x2 Vehicle For vehicles with a single rear drive axle 4x2 the brakes are operated independently by the Bendix ESP EC 80 Controller based on the individual wheel behavior Dual Drive Axle Control 4S 4M Configuration For vehicles with dual drive axles 6x4 using a 4S AM configuration one ABS modulator controls both of the right side rear wheels the other modulator controls both of the left side rear wheels Both wheels on each side r
128. vice Checks 1 Check all wiring and connectors Make sure all connections are free from visible damage 2 Examine the sensor Make sure the sensor and its interface to the pressure location are not damaged Diagnostics See the test diagram supplied by the Bendix ACom Diagnostic Software The pressure sensor can be independently diagnosed when supplied with a five volt voltage supply to the B location and ground to the A location shown in the test diagram Signal output on the C location should read approximately 0 5V if there is no pressure applied The signal output should increase proportionately as pressure is applied up to a maximum of 4 5V at 150 psi Removal 1 Unplug sensor cable assembly from body of sensor Pull gently on the mounting tab and connector until it disengages 2 Remove sensor from its pressure mounting using approved air brake push in fitting tools Installation 1 Obtain a new sensor The sensor is not repairable in the field Insert sensor into pressure fitting using approved tools Reconnect the connector Ensure that there will be no force applied to the sensor because the connector is pulling on the sensor body 4 f the wire harness leading to the sensor is being replaced ensure that it is adequately tie wrapped Pressure Sensor Calibration There is no need for pressure sensor calibration as long as the part replaced is identical to the part removed and a component approved for use w
129. y a normal set of sensors and modulators for the Electronic Control Unit so that it will identify future missing sensors and modulators Diagnostic Connector Diagnostic receptacle in vehicle cab for connection of J1939 hand held or PC based test equipment The tester can initiate test sequences and can also read system parameters Diagnostic Switch A switch used to activate blinks codes Differential Braking Application of brake force to a spinning wheel so that torque can be applied to wheels which are not slipping ECU Electronic Control Unit ESP Electronic Stability Program Full stability function that includes RSP amp YC subfunctions Diagnostic Trouble Code A condition that interferes with the generation or transmission of response or control signals in the vehicle s ABS system that could lead to the functionality of the ABS system becoming inoperable in whole or in part FMVSS 121 Federal Motor Vehicle Safety Standard which regulates air brake systems Hill Start or Hill Start Assist HS HSA This feature interfaces between the transmission and braking system to help the driver prevent the vehicle from rolling downhill when moving up a steep incline from a stationary position 54 IR Independent Regulation A control method in which a wheel is controlled at optimum slip a point where retardation and stability are maximized The brake pressure that is best for the wheel in
130. y message is being transmitted on J1939 link Verify data for driver s demand torque actual engine torque engine speed is correct Verify the ECU configuration Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Verify the presence of engine ECU on J1939 link Verify message is being transmitted on J1939 link Verify acceleration pedal position and acceleration pedal status is correct Verify the ECU configuration Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Verify the presence of a retarder on J1939 Link Verify that the message is being transmitted Verify that the data is correct for torque speed control Verify the ECU configuration Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Verify the presence of a retarder on J1939 Link Verify that the message is being transmitted Verify that the data is correct for torque speed control Verify the ECU configuration Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Verify the presence of a retarder on J1939 Link Verify that the message is being transmitted Verify that the data is correct for torque speed control Verify the ECU configuration Check for damaged or reversed J1939 wiring Check for damaged or corroded connectors Verify the presence of Radar on J1939 link Verify message is being transmitted Verify the ECU configuration Check

BENDIX SD-13-4986 User's Manual

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