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BENDIX BW2429 User's Manual

1. EN O 1st Digit Miscellaneous DTCs 22 810 T 12 23 811 2 12 42 795 3 7 42 795 4 7 42 795 5 7 43 796 3 8 43 796 4 8 43 796 5 8 44 797 3 9 44 797 4 9 44 797 5 9 45 798 3 10 45 798 4 10 45 798 5 10 46 799 3 16 46 799 4 16 46 799 5 16 47 800 3 17 47 800 4 17 47 800 5 17 48 800 3 7 48 795 4 7 48 795 5 T 49 795 3 8 49 796 4 8 49 796 5 8 50 796 3 9 50 797 4 9 50 797 5 9 51 797 3 10 51 798 4 10 51 798 5 10 52 798 3 16 52 799 4 16 52 799 5 16 53 799 3 17 53 800 4 17 53 800 5 17 For more Pressure Modulator Valve DTCs see 5105 66 and 93 below 2nd Digit 11 6 5 MM WAN D zb MM D Do OS Om OS Om OS Om OS Om OS 3 Retarder Relay Circuit or HSA Lamp Shorted to Voltage DTCs Retarder Relay or HSA Lamp Open Circuit or Shorted to Ground Dynamometer Test Mode ATC Disabled to Prevent Brake Fade TCV DA Solenoid Shorted to Voltage TCV DA Solenoid Shorted to Ground TCV DA Solenoid Open Circuit TCV DA Configuration Error TCV SA Solenoid Shorted to Voltage TCV SA Solenoid Shorted to Ground TCV SA Solenoid Open Circuit TCV SA Configuration Error Wheel Speed Sensors Reversed on an Axle ABS Dash Indicator Circuit DTC SA Left PMV HLD Solenoid Shorted to Voltage SA Left PMV HLD Solenoid Shorted to Ground SA Left PMV HLD Solenoid Open Circuit SA Right PMV HLD Solenoid Shorted to Voltage SA Right PMV HLD Solenoid Shorted to Ground SA Right
2. The ECU will illuminate the ABS Indicator Lamp whenever full ABS operation is not available due to a diagnostic trouble code In most cases partial ABS is still available ATC ESP Status Indicator Lamp Operation The ECU will illuminate the ATC ESP lamp for approximately 2 5 seconds when ignition power is applied after which the lamp will extinguish if no diagnostic trouble codes are detected The ECU will continuously illuminate the ATC ESP Indicator Lamp whenever ESP or ATC is disabled due to a diagnostic trouble code During an ESP or ATC intervention the lamp will flash rapidly 2 5 times per second When the ECU 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 ECU 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 after which the lamp will extinguish if there are no issues with the HSA system ECU Configuration Test Within two seconds of the application of ignition power the ECU will perform a test to detect system configuration with regards to the number of wheel speed sensors and PMVs This can be audibly detected by a rapid cycling of the PMVs Note The ECU will not perform the configuration test when whee
3. 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 49 1 2 3 4 5 6 7 8 9 APPENDIX Troubleshooting 12 7 Blink Code fault SID 93 FMI 4 SPN 0802 FMI 04 Advanced In Cab ECU Remove X1 X2 X3 and X4 connector from the ECU Using X1 1 as the ground connection check for resistance for the entire X2 connector There should be no resistance to ground found Please fill out attached worksheet Using X1 1 as the ground connection check for resistance for X1 4 and X1 5 There should be no resistance to ground Using X1 1 as the ground connection check for resistance for 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 is not configured for 6S 6M Using X1 1 as the ground connection check for resistance for X4 6 X4 9 and 4 12 There should be no resistance to ground Troubleshoot any pin that has resistance to ground If no issues are found continue to step 7 Reconnect X1 connector only and apply IGN power to the ECU and using the DTC screen of Bendix ACom Diagnostics clear all DTCs Re check for any DTCs Ifthe 12 7 DTC is still present the problem is the Traction Solenoid Wiring or Solenoid I
4. Wiring Schematic Glossary 41587 SID and Codes UDS Codes Additional features include Automatic Traction Control ATC Bendix ATC can improve vehicle traction during acceleration and lateral stability while accelerating through curves ATC utilizes Engine Torque Limiting ETL where the ECU communicates with the engine s controller and or Differential Braking DB where individual wheel brake applications are used to improve vehicle traction Advanced Bendix EC 60 controllers have a drag torque control feature which reduces driven axle wheel slip due to driveline inertia by communicating with the engine s controller and increasing the engine torque For vehicles with the Hill Start Feature optional feature this system interfaces between the transmission and braking system to help the driver prevent the vehicle from roling downhill when moving up a steep incline from a stationary position 1 GENERAL SAFETY GUIDELINES A WARNING PLEASE READ AND FOLLOW THESE INSTRUCTIONS TO AVOID PERSONAL INJURY OR DEATH When working on or around a vehicle the following general precautions should be observed at all times 1 Park the vehicle on a level surface apply the parking brakes and always block the wheels Always wear safety glasses 2 Stop the engine and remove 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 rem
5. 335 1nd dvi 8015 S3YINOIY ANO S3121H3A JAIXO 133HM 11 HOLIMS AYVLN3NON HOLIMS 3002 178 91 LSONDVIG 961 3VS Y3d SOILSONDVIG 661 JYS YO VIA Y430YV133Y FIGURE 20 STANDARD CAB WIRING D 5 5310 C NOILINDI Alz NEN dg 8015 gt 515 HOLIMS 8015 310d ZI r EE 3109 1 wem dNv1 3015 r AE d nn Bes MOSN3S YOSN3S 310d 81 l H C 31v3 3 TONY MVA 9NI3331S 3108 41 i I Y YN N38NnN 1NVd lt 15 1 09 3019 3NNOO I I 40 1 Be SYOLO3NNOD SSINYVH 3NIM l L PEE PONE i SBv 4311V8L I MO1V210NI B Emm 1 1 HSVO S8v i I u 69 540 i HILIMS 1 QVOY 330 i i a SN fran i INNO 180 U wm wm wm wm mm mm mm vm vm vm vm vm mm mm mm vm vm mmm vm mm mm mm mm wm mmm mm mm mm 1 4 An A unm Mj Cui I A jut Jis AAA Ecg Geet ey EE A fer quam uf M SL 130 AY3A 1130 31xv 31XV 1 ady i 31XV 43315 31XV SAI 21 NOISN3dSNS ANVONOO3S 43315 esed YOSN3S NOSN3S 2 MOSN3S JAVA ANd And we ANd ANd 081N02 u31ivu 38155339 J8NSSIYA 3unSS3ud E 1331 1H913 1331 1H913 1231 And DIN 31xv 31xv NS 31xv 31xv 31xv NO Lea 00 1331 1H918 1331 gg 83315 83315 3 130 3 130 2219
6. 4 mm 15 Way AMP E pe MCP 2 8 X3 8 968973 1 Controller Harness 12 Way AMP 10 25 mm 2 8 X4 8 968972 1 539723 2 ABS Modulator Harness AMP Twist Lock Bayonet 067 e m ATC Modulator 929975 1 Harness AMP Twist Lock Bayonet 539635 1 ABS Modulator Harness 3 pin Packard Metri Pack 280 Series 12040977 Packard GT Packard Deutsch DTMO6 Packard Packard Deutsch DT04 Standard round 150 series Metripack 150 2 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 T Schlemmer 7814 125 ITT Cannon Connector 121583 001 a US AMP 0 962981 1 90 degree Connector Schlemmer 9800 331 Cannon 031 8717 120 Brake Demand Sensor Load Sensor SAS 60 Sensor Connectors Wire Harness Connectors Robert Bosch 1 928 404 025 Metri Pack Packard 1206 5287 2 Robert Bosch 1 928 498 001 Contact Pins Mn One Meter Adapter to Connector Packard 1210 3881 Bendix 5015242 shown Packard 12092162 pins 12064971 CHART 4 EC 60 CONTROLLER COMPONENT CONNECTORS 46 Troubleshooting Wiring Continuea Speed Sensor Mounting Block 100 Tooth typical Speed Sensor Exciter Ring WS 24 Speed Sensor i dr CM Je 1 kan EN Air Disc Brake Note Ensure that the sensor wiring is route
7. Bendix 60 ABS ATC ESP Controllers Advanced See SD 13 4863 for Standard and Premium Controllers See SD 13 21021 for the Bendix eTrac Automated Air Suspension Transfer System All Four Connectors Are Used If only two or three connectors are in use see SD 13 4863 FIGURE 1 EC 60 ADVANCED CONTROLLER INTRODUCTION The Bendix EC 60 advanced controller is a member of a family of electronic Antilock Braking System ABS devices designed to help improve the braking characteristics of air braked vehicles including heavy and medium duty buses trucks and tractors ABS controllers are also known as Electronic Control Units ECUs 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 EC 60 controller monitors individual wheel turning 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 EC 60 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 In addition to the ABS function advanced models of the EC 60 controller provide ABS based stability features referred to as ESP Electronic
8. TCV DA Configuration Error TCV SA Configuration Error Timeout or invalid CAN data AUX Open or Shorted Load Sensor SA Left WSS Open or Shorted Shorted Brake Demand Sensor Primary CKT Open Shorted Brake Demand Sensor Secondary CKT Open Plausibility Error Brake Demand Sensor SA Left WSS Wheel End PS Supply Voltage Error SA Left WSS Excessive Air Gap SA Left WSS Output Low Drive Off SA Left WSS Erratic Sensor Signal SA Left WSS Loss of Sensor Signal LAS Calibration in Progress Erratic ESP Sensor Signal SAS Calibration in Progress SAS Not Calibrated SA Left PMV HLD Solenoid Open Circuit SA Left PMV HLD Solenoid Shorted to Ground SA Left PMV HLD Solenoid Shorted to Voltage SA Left PMV CMN Open Circuit SA Left PMV REL Solenoid Open Circuit SA Left PMV REL Solenoid Shorted to Ground SA Left PMV REL Solenoid Shorted to Voltage SAS CAN Timeout SAS Signal Out of Range SAS Invalid Signal 97 58 APPENDIX UDS Codes and their Bendix Blink Code Equivalents 1939 73 DM1 2 SPN FMI Lamp P Status DTC Description SAS Gradient Error SAS Long Term Calibration Error SA Left PMV Configuration Error SAS Static Signal SAS Signal Reversed SAS Plausibility Check Ref Yaw Rate DA Right WSS Open or Shorted YRS CAN Timeout YRS Signal Out of Range YRS Invalid Signal DA Right WSS Wheel End YRS Static BITE Error DA Right WSS Excessive Air Gap DA Right WSS Output Low Drive Of
9. 1 789 14 2 2 SA Left WSS Output Low Drive Off 2 790 1 3 1 SA Right WSS Excessive Air Gap 2 790 2 3 3 SA Right WSS Open or Shorted 2 790 7 3 5 SA Right WSS Wheel End 2 790 8 3 6 SA Right WSS Erratic Sensor Signal 2 790 10 3 4 SA Right WSS Loss of Sensor Signal 2 790 13 3 7 SA Right WSS Tire Size Calibration 2 790 14 3 2 SA Right WSS Output Low Drive Off 3 791 1 4 1 DA Left WSS Excessive Air Gap 3 791 2 4 3 DA Left WSS Open or Shorted 3 791 T 4 5 DA Left WSS Wheel End 3 791 8 4 6 DA Left WSS Erratic Sensor Signal 3 791 10 4 4 DA Left WSS Loss of Sensor Signal 3 791 13 4 7 DA Left WSS Tire Size Calibration 3 791 14 4 2 DA Left WSS Output Low Drive Off 4 792 1 5 1 DA Right WSS Excessive Air Gap 4 792 2 5 3 DA Right WSS Open or Shorted 4 792 7 5 5 DA Right WSS Wheel End 4 792 8 5 6 DA Right WSS Erratic Sensor Signal 4 792 10 5 4 DA Right WSS Loss of Sensor Signal 4 792 13 5 7 DA Right WSS Tire Size Calibration 4 792 14 5 2 DA Right WSS Output Low Drive Off 5 793 1 14 1 AA Left WSS Excessive Air Gap 5 793 2 14 3 AA Left WSS Open or Shorted 5 793 7 14 5 AA Left WSS Wheel End 5 793 8 14 6 AA Left WSS Erratic Sensor Signal 5 793 10 14 4 AA Left WSS Loss of Sensor Signal 5 793 13 14 T AA Left WSS Tire Size Calibration 5 793 13 14 10 AA Left WSS Configuration Error 5 793 14 14 2 AA Left WSS Output Low Drive Off 6 794 1 15 1 AA Right WSS Excessive Air Gap 6 794 2 15 3 AA Right WSS Open or Shorted 6 794 7 15 5 AA Right WSS Wheel End 6 794 8 15
10. ABS Indicator Ground 13 J1587 B PMV DA Right REL PMV AA Right REL 14 J1587 A WSS SA Right WSS AA Left WSS AA Right 15 ABS Indicator Interlock WSS DA Left Battery PMV DA Left HLD ABS Dash Indicator WSS DA Left AWD vehicles only AWD Transfer Case Designation Designation PMV Left HLD Ground 2 Trailer ABS Indicator PMV SA Left REL 5 7 PMV SA Right REL WSS SA Left PMV DA Right CMN PMV DA Right HLD WSS SA Right PMV DA Left CMN 10 11 12 A 4 Troubleshooting Wiring ABS ATC WIRING ECU Wiring Harness Connectors The Advanced Bendix EC 60 controller is designed to interface with AMP MCP 2 8 connectors as referenced in Chart 4 Follow all AMP requirements for the repair of wire harnesses All wire harness connectors must be properly seated The use of secondary locks 15 strongly advised A CAUTION 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 PMV TCV Interaxle Differential Lock and indicator lamp circuits All sensor and serial communications circuits J1587 and 1939 must use twisted pair wiring one to two twists per inch See the appropriate SAE document for additional details A CAUTION Al
11. LAS Calibration in Progress Erratic ESP Sensor Signal SAS Calibration in Progress SAS Not Calibrated SA Left PMV HLD Solenoid Open Circuit SA Left PMV HLD Solenoid Shorted to Ground SA Left PMV HLD Solenoid Shorted to Voltage SA Left PMV CMN Open Circuit SA Left PMV REL Solenoid Open Circuit SA Left PMV REL Solenoid Shorted to Ground SA Left PMV REL Solenoid Shorted to Voltage SAS CAN Timeout SAS Signal Out of Range SAS Invalid Signal 97 58 APPENDIX UDS Codes and their Bendix Blink Code Equivalents 1939 73 DM1 2 SPN FMI Lamp P Status DTC Description SAS Gradient Error SAS Long Term Calibration Error SA Left PMV Configuration Error SAS Static Signal SAS Signal Reversed SAS Plausibility Check Ref Yaw Rate DA Right WSS Open or Shorted YRS CAN Timeout YRS Signal Out of Range YRS Invalid Signal DA Right WSS Wheel End YRS Static BITE Error DA Right WSS Excessive Air Gap DA Right WSS Output Low Drive Off DA Right WSS Erratic Sensor Signal DA Right WSS Loss of Sensor Signal YRS Dynamic BITE Error YRS Gradient Error YRS Fast Calibration Error YRS Static Calibration Error DA Right PMV HLD Solenoid Open Circuit DA Right PMV HLD Solenoid Shorted to Ground DA Right PMV HLD Solenoid Shorted to Voltage DA Right PMV CMN Open Circuit DA Right PMV REL Solenoid Open Circuit DA Right PMV REL Solenoid Shorted to Ground DA Right PMV REL Solenoid Shorted to Voltage YRS Norma
12. Troubleshooting Connectors Bendix EC 60 Controller Wire Harness Connector Part Numbers and Pin Assignments ADVANCED CAB CONNECTOR CONNECTOR CONNECTOR CONNECTOR Advanced Cab Bendix EC 60 Controller Advanced cab models utilize four AMP connectors for wire harness connections X1 Connector Pin X2 Connector Pin X3 Connector Pin X4 Connector Pin Assignments Assignments Assignments Assignments Designation Designation ABS ORS Pressure Sensor CMN Brake Demand Primary Diff Lock SOL CKT Signal Ignition PMV SA Left CMN CMN SA Load Sensor Signal TCV CMN DA PMV SA Right HLD PMV AA Left HLD Pressure Sensor Supply Brake Demand Secondary TCV DA WSS SA Left TCV SA GE ATG ESF Indicator and ATC piv SA Right CMN PMV AA Left CMN PMV Trailer HLD OR 31939 Low PMV AA Left REL 1939 High Stop Lamp Output SLS Input PMV AA Right CMN WSS DA Right PMV AA Right HLD WSS DA Right WSS AA Left WSS AA Right ABS Indicator Ground 13 J1587 B PMV DA Right REL PMV AA Right REL 14 J1587 A WSS SA Right WSS AA Left WSS AA Right 15 ABS Indicator Interlock WSS DA Left Battery PMV DA Left HLD ABS Dash Indicator WSS DA Left AWD vehicles only AWD Transfer Case Designation Designation PMV Left HLD Ground 2 Trailer ABS Indicator PMV SA Left REL 5 7 PMV SA Right REL WSS SA Left PMV DA Right CMN PMV DA Right HLD
13. disabled The system reverts to normal braking When the correct voltage level is restored full ABS and ATC function 15 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 Diagnostic Trouble Code ESP 15 disabled ABS and ATC remain active Yaw Rate Lateral Acceleration Sensor Diagnostic Trouble Code ESP is disabled ABS and ATC remain active Brake Demand Pressure Sensor Diagnostic Trouble Code ESP 15 disabled ABS and ATC remain active Load Sensor Diagnostic Trouble Code ESP 15 disabled ABS and ATC remain active Steer Axle TCV Diagnostic Trouble Code ESP 15 disabled ABS and ATC remain active Trailer PMV Diagnostic Trouble Code ESP 15 disabled ABS and ATC remain active 15 SYSTEM RECONFIGURATION The Bendix EC 60 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 Diagnostics program ECU RECONFIGURATION Reconfiguring a Bendix EC 60 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
14. Bes MOSN3S YOSN3S 310d 81 l H C 31v3 3 TONY MVA 9NI3331S 3108 41 i I Y YN N38NnN 1NVd lt 15 1 09 3019 3NNOO I I 40 1 Be SYOLO3NNOD SSINYVH 3NIM l L PEE PONE i SBv 4311V8L I MO1V210NI B Emm 1 1 HSVO S8v i I u 69 540 i HILIMS 1 QVOY 330 i i a SN fran i INNO 180 U wm wm wm wm mm mm mm vm vm vm vm vm mm mm mm vm vm mmm vm mm mm mm mm wm mmm mm mm mm 1 4 An A unm Mj Cui I A jut Jis AAA Ecg Geet ey EE A fer quam uf M SL 130 AY3A 1130 31xv 31XV 1 ady i 31XV 43315 31XV SAI 21 NOISN3dSNS ANVONOO3S 43315 esed YOSN3S NOSN3S 2 MOSN3S JAVA ANd And we ANd ANd 081N02 u31ivu 38155339 J8NSSIYA 3unSS3ud E 1331 1H913 1331 1H913 1231 And DIN 31xv 31xv NS 31xv 31xv 31xv NO Lea 00 1331 1H918 1331 gg 83315 83315 3 130 3 130 2219 x E Nn x A e x iie Per O Og S o i ali 622 OOOOOCX OOOOOCX E Mic EE EE 9 e oooO TEE IX 6 Zl 11018 4 6 OI vl 2 SL L 9 US ZL OL 1 6 OL 81 GI LL OL 6 21518 91 vi cl S D 0 D D v v OO OO 0 V D D D D KA gt v P 9 v D D D 0 v D D D n 533 a aA a a Sess 222 222 aa 55 2 AA SS 555 555 555 55 8 55 roz 3 9 8 9 o
15. 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 from the ECU from either the Diagnostic Switch or from a hand held diagnostic tool only repaired diagnostic trouble codes may be cleared Configuration The primary objective is to identify 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 J1587 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 HSA Hill Start Assist HSA interfaces between the transmission a
16. DTCs O oO P e LAS Signal Out of Range LAS Static Calibration Error LAS Long Term Calibration Error LAS Plausibility Error Inside ECU Specific Limits LAS Plausibility Error Outside ECU Specific Limits LAS Calibration in Progress Erratic ESP Sensor Signal 93 APPENDIX B J1587 SID and Codes and their Bendix Blink Code Equivalents Bendix Blink Code SID SPN FMI J1587 Equivalent s Diagnostic Trouble Code Description J1587 41939 14939 4st Digit 2nd Digit Miscellaneous DTCs HSA Solenoid Shorted to Voltage high HSA Solenoid Shorted to Ground Low or Open circuit Sensor CAN Supply Voltage Error ESP Sensor Voltage Out of Range YRS Signal Out of Range YRS Sensor Reversed Signal YRS Invalid Signal YRS Gradient Error YRS Static BITE Error YRS Dynamic BITE Error YRS Fast Calibration Error YRS Static Calibration Error YRS Normal Calibration Error YRS Sensitivity Calibration Error YRS Plausibility Check Ref Yaw Rate YRS Plausibility Error Inside ECU Specific Limits YRS Plausibility Error Outside ECU Specific Limits Yaw Rate Sensor Vibration Detected YRS CAN Timeout 151 611 wheel speed sensor failure in previous power on cycle 154 614 i o 2 3 Shorted to Voltage J1939 Engine Communications J1939 Invalid Data Engine Retarder J1939 Supply Pressure J1939 ESP Messages Invalid Data Tim
17. REL Solenoid Shorted to Voltage timeout or invalid data on J1939 AWD params for ESP AWD operation AA Left PMV Configuration Error Maximum number of PCV cycles reached Maximum number of TCV cycles reached LAS Signal Out of Range AA Right PMV HLD Solenoid Open Circuit AA Right PMV HLD Solenoid Shorted to Ground AA Right PMV HLD Solenoid Shorted to Voltage AA Right PMV CMN Open Circuit AA Right PMV REL Solenoid Open Circuit AA Right PMV REL Solenoid Shorted to Ground AA Right PMV REL Solenoid Shorted to Voltage LAS Long Term Calibration Error LAS Static Calibration Error LAS Plausibility Error Inside Model Based Limits LAS Plausibility Error Outside Model Based Limits AA Right PMV Configuration Error Log on and Learn from the Best On line training that s available when you are 24 7 365 Visit www brake school com SD 13 4869 US 003 02013 Bendix Commercial Vehicle Systems LLC All Rights Reserved 6 13 60
18. Shorted to Ground AA Right PMV HLD Solenoid Open Circuit SA Left PMV REL Solenoid Shorted to Voltage SA Left PMV REL Solenoid Shorted to Ground SA Left PMV REL Solenoid Open Circuit SA Right PMV REL Solenoid Shorted to Voltage SA Right PMV REL Solenoid Shorted to Ground SA Right PMV REL Solenoid Open Circuit DA Left PMV REL Solenoid Shorted to Voltage DA Left PMV REL Solenoid Shorted to Ground DA Left PMV REL Solenoid Open Circuit DA Right PMV REL Solenoid Shorted to Voltage DA Right PMV REL Solenoid Shorted to Ground DA Right PMV REL Solenoid Open Circuit AA Left PMV REL Solenoid Shorted to Voltage AA Left PMV REL Solenoid Shorted to Ground AA Left PMV REL Solenoid Open Circuit AA Right PMV REL Solenoid Shorted to Voltage AA Right PMV REL Solenoid Shorted to Ground AA Right PMV REL Solenoid Open Circuit APPENDIX B J1587 SID and Codes and their Bendix Blink Code Equivalents FMI Bendix Blink Code J1587 Equivalent s Diagnostic Trouble Code Description J1939 1st Digit 2nd Digit 2 Stop Lamp Switch Defective Brake Lamp Input Mismatch with Brake Lamp Output 1 Stop Lamp Switch Not Detected 20 Trailer PMV REL Solenoid Shorted to Voltage 20 Trailer PMV HLD Solenoid Shorted to Voltage 20 Trailer PMV REL Solenoid Shorted to Ground 20 Trailer PMV HLD Solenoid Shorted to Ground 20 Trailer PMV REL Solenoid Open Circuit 20 Trailer PMV HLD Solenoid Open Circuit 20 Trailer PMV CMN Open Circuit 20 PMV Configuratio
19. Stability Program The Bendix ESP system is an ABS based stability system that enhances vehicle stability by both reducing engine throttle and by applying vehicle braking based on actual vehicle dynamics Accordingly the ESP system is available only on specific approved vehicle platforms after vehicle application and development efforts and validation testing Only certain limited variations of an approved vehicle platform are permitted without further validation of the ESP system application ESP stability system consists of Yaw Control YC and Roll Stability Program RSP features ESP is a registered trademark of DaimlerChrysler and is used by BCVS under license from DaimlerChrysler The driver is always responsible for the control and safe operation of the vehicle at all times The Bendix ESP stability 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 General System Information Introduction Components Hardware Configurations Bendix EC 60 Controller Inputs amp Outputs Indicator Lamps and Power Up Sequence ABS Operation ATC Operation Advanced ABS With Stability Important Safety Information About The ESP Stability System Dynamometer Test Mode System Impact During Active Trouble Codes System Reconfiguration Troubleshooting Sensor Calibration Blink Codes and Diagnostic Trouble Codes
20. anticipate obstacles and pay attention to road weather and traffic conditions ABS ATC and ESP stability systems are no substitute for prudent careful driving Towing Doubles Or Triples May Reduce The Effectiveness Of Stability Systems ESP 15 designed and optimized for trucks and for tractors that tow single trailers If a tractor equipped with ESP 15 used to power multiple trailer combinations known as doubles or triples the effectiveness of the 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 steering inputs or abrupt lane changes should be avoided Limitations Of Stability Systems The ESP stability system s effectiveness may be greatly reduced if 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 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 rapidly winding steering inputs are inputted at high speeds There are mechanical problems with suspension leveling of the tractor or trailer resulting in uneven loads The vehicle is mane
21. 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 Advanced Bendix EC 60 Contollers will remain engaged in the Dynamometer Test Mode even if power to the ECU is removed and re applied To exit the 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 ABS ATC and ESP 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 15 stored in ECU memory provided the following conditions are met 1 Rolling circumference ratio is within the permissible range Vehicle speed 15 greater than approximately 12 No acceleration or deceleration 15 taking place 4 There are no active speed sensor diagnostic trouble codes The ECU 15 provided with ratio value of 1 00 as a default setting If the automatic tire size alignment calculates a different value this 15 used to overwrite the original figure in the memory This process adapts the ABS and ATC function to the
22. 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 Advanced Bendix EC 60 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 stability during braking ATC improves vehicle stability and traction during vehicle acceleration The Bendix EC 60 controller ATC function uses the same wheel speed information and modulator control as the ABS function The Bendix EC 60 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 M
23. g when the vehicle is started until the ECU detects a service brake application 2 f 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 In response to a serial communications request from a diagnostic tool 5 IfATC Differential Braking function is activated for a long time period to avoid overheating of the brakes It would take approximately 3 continuous minutes of activation for the timeout to occur Once timed out approixmately 2 minutes of cool off time would be required before ATC Differential Braking can be used again 6 When certain diagnostic trouble code conditions are detected Engine Torque Limiting with Smart ATC Traction Control The Bendix EC 60 controller uses Engine Torque Limiting to control drive axle wheel slip This is communicated to the engine control module using J1939 and is available at all vehicle speeds Bendix Smart ATC Traction Control The Bendix EC 60 controller has an additional feature known as Smart ATC traction control Smart ATC traction control 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 situa
24. independently from any reconfiguration being carried out by the technician the ECU will automatically check the J1939 serial link and communicate with other vehicle modules In particular 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 16 Reconfiguration Using the Blink Code Switch With ignition power removed from the Bendix EC 60 controller depress the blink code switch After the ignition power is activated depress and release the switch seven times to initiate a reconfiguration event Diagnostic Tool Areconfiguration event may be initiated using a hand held or PC based diagnostic tool to communicate with the ECU over the SAE J1587 diagnostic link 6S 5M Configuration Advanced Bendix EC 60 controllers will configure for 6S 5M operation when a reconfiguration event 15 initiated and the ECU detects that an additional axle PMV is wired as follows PMV Connector ECU Connector Hold Right Additional Axle Hold Release Left Additional Axle Release Common Right Additional Axle Common Troubleshooting General GENERAL SAFETY GUIDELINES WARNING PLEASE READ AND FOLLOW THESE INSTRUCTIONS TO AVOID PERSONAL INJURY OR D
25. its 1 0 must match the size of the wire bundle as closely as possible A CAUTION 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 SAS 60 Sensors YAS 60 or YAS 70X Sensor Wiring If it is necessary to replace the wiring that connects the 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 45 ABS Component Connector Wire Terminal ire Seal ermina Terminal Crimp Tool Plug Lock In Cab Controller SP Harness DN ni 17 Way AMP bh MCP 2 8 X1 i KEE 967634 X1 12 4 18 In Cab Controller Harness au tt 18 Way AMP eiii 2 8 2 T In Cab Controller A 968874 Harness Es 2 5 4 mm 15 Way AMP E pe MCP 2 8 X3 8 968973 1 Controller Harness 12 Way AMP 10 25 mm 2 8 X4 8 968972 1 539723 2 ABS Modulator Harness AMP Twist Lock Bayonet 067 e m ATC Modulator 929975 1 Harness AMP Twist Lock Bayonet 539635 1 ABS Modulator Harness 3 pin Packard Metri Pack 280 Series 12040977 Packard GT Packard Deutsch DTMO6 Packard Packard Deutsch DT04 Standard round 150 series Metripack 150 2 series Metripack 280
26. two sensors but only one Pressure Modulator Valve 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 EC 60 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 ABS 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 10 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 AB
27. x E Nn x A e x iie Per O Og S o i ali 622 OOOOOCX OOOOOCX E Mic EE EE 9 e oooO TEE IX 6 Zl 11018 4 6 OI vl 2 SL L 9 US ZL OL 1 6 OL 81 GI LL OL 6 21518 91 vi cl S D 0 D D v v OO OO 0 V D D D D KA gt v P 9 v D D D 0 v D D D n 533 a aA a a Sess 222 222 aa 55 2 AA SS 555 555 555 55 8 55 roz 3 9 8 9 oS oo D FI d ln ke d CC CC res pe pp Pp Pp CC CC ree rei pp pow pa gt e 3 3 DD ore rr S 4144 2 um t t n n EN gt gt gt gt gt b b nn nu 1 nnn bb 5 E AS ke us 00 700 vo 53 ppp o 2 o D mm gt Ep T ppp ne aa um a D e 22 ITT pp ties er ppp ror 02 32 z m m Log PUT 20r m CC 29 z 292 E 292 lao agr Ct 56 S a Io xk 9 mer Ww Itc m F m E m E m E mer m P m gt Se rzo 970 z r zo 20 rzo r zo 25 r zo o2 D z z 2 Ml T Eme a A E A coc A en 2 o o 48 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 reve
28. 0799 13 0615 14 0615 14 1809 02 0800 05 0800 04 0800 03 0800 05 0800 05 0800 04 0800 03 1809 02 1809 02 1809 02 1809 02 0800 13 APPENDIX C UDS Codes and their Bendix Blink Code Equivalents DTC Description AA Right WSS Erratic Sensor Signal AA Right WSS Loss of Sensor Signal Trailer PMV REL Solenoid Open Circuit Trailer PMV REL Solenoid Shorted to Ground Trailer PMV REL Solenoid Shorted to Voltage ABS Indicator Lamp Circuit Tire Size Out of Range Front to Rear Wheel Speed Sensors Reversed on an Axle Stop Lamp Switch Not Detected ATC Disabled or Dynamometer Test Mode Active Stop Lamp Switch Defective Diff Lock Solenoid Shorted to Voltage total shutdown Diff Lock Shorted to Ground or Open Circuit AA Left PMV HLD Solenoid Open Circuit AA Left PMV HLD Solenoid Shorted to Ground AA Left PMV HLD Solenoid Shorted to Voltage AA Left PMV CMN Open Circuit AA Left PMV REL Solenoid Open Circuit AA Left PMV REL Solenoid Shorted to Ground AA Left PMV REL Solenoid Shorted to Voltage timeout or invalid data on J1939 AWD params for ESP AWD operation AA Left PMV Configuration Error Maximum number of PCV cycles reached Maximum number of TCV cycles reached LAS Signal Out of Range AA Right PMV HLD Solenoid Open Circuit AA Right PMV HLD Solenoid Shorted to Ground AA Right PMV HLD Solenoid Shorted to Voltage AA Right PMV CMN Open Circuit AA Right PMV REL Solenoid Open Circuit AA Right PMV REL Solenoid Shorted to Grou
29. 1 02 231 02 231 02 231 02 1939 73 DM1 2 SPN FMI 0793 02 0793 13 0629 12 0793 07 0629 12 0793 01 0793 14 0793 08 0793 10 0629 02 0629 12 1808 02 0629 12 0629 12 0629 02 0629 02 0629 12 0629 02 0630 13 0630 13 0630 12 0629 02 0802 12 0802 12 0630 12 0630 13 0630 13 0627 03 0627 04 0627 04 0627 03 0627 04 0627 04 0627 05 0630 12 0630 13 0802 03 0802 04 0639 02 0639 02 0639 02 0639 02 DTC Description no DTC AA Left WSS Open or Shorted AA Left WSS Configuration Error ECU 04 AA Left WSS Wheel ECU 06 AA Left WSS Excessive Air Gap AA Left WSS Output Low Drive Off AA Left WSS Erratic Sensor Signal AA Left WSS Loss of Sensor Signal ECU 0D ECU 0E Sensor CAN Supply Voltage Error ECU 10 ECU 11 ECU 12 ECU 13 ECU 14 ECU 15 ECU 16 ECU 17 ECU 18 ECU 19 ECU ECU 18 ECU 1C ECU 1D ECU 1E Ignition Voltage Too High 18 19 Ignition Voltage Too Low Ignition Voltage Too Low During ABS Battery Voltage Too High Battery Voltage Too Low Battery Voltage Too Low During ABS Battery Voltage Input Open Circuit ECU 27 ECU 28 PMV Common Shorted to Voltage PMV Common Shorted to Ground Timeout or invalid CAN data for ETC7 VP15 1939 Invalid Data Engine Retarder 1939 Supply Pressure Timeout or invalid CAN data XBR 1939 73 DM1 2 SPN FMI 0801 03 2622 03 0801 02 2622 02 0807 05 0639 12 0
30. 13 08 13 09 13 10 13 18 13 11 13 12 13 19 13 21 13 22 06 06 06 05 06 07 06 02 06 01 06 03 06 04 13 20 13 23 12 08 12 07 11 07 11 04 11 05 11 08 000 00 005 02 005 13 254 12 005 07 254 12 005 01 005 14 005 08 005 10 254 02 254 12 103 02 254 12 254 12 254 02 254 02 254 12 254 02 254 13 254 13 254 12 254 02 254 12 254 12 253 12 253 13 253 13 251 03 251 04 251 04 251 03 251 04 251 04 251 05 253 12 253 13 093 03 093 04 231 02 231 02 231 02 231 02 1939 73 DM1 2 SPN FMI 0793 02 0793 13 0629 12 0793 07 0629 12 0793 01 0793 14 0793 08 0793 10 0629 02 0629 12 1808 02 0629 12 0629 12 0629 02 0629 02 0629 12 0629 02 0630 13 0630 13 0630 12 0629 02 0802 12 0802 12 0630 12 0630 13 0630 13 0627 03 0627 04 0627 04 0627 03 0627 04 0627 04 0627 05 0630 12 0630 13 0802 03 0802 04 0639 02 0639 02 0639 02 0639 02 DTC Description no DTC AA Left WSS Open or Shorted AA Left WSS Configuration Error ECU 04 AA Left WSS Wheel ECU 06 AA Left WSS Excessive Air Gap AA Left WSS Output Low Drive Off AA Left WSS Erratic Sensor Signal AA Left WSS Loss of Sensor Signal ECU 0D ECU 0E Sensor CAN Supply Voltage Error ECU 10 ECU 11 ECU 12 ECU 13 ECU 14 ECU 15 ECU 16 ECU 17 ECU 18 ECU 19 ECU ECU 18 ECU 1C ECU 1D ECU 1E Ignition Voltage Too High 18 19 Ignition Voltage Too Low Ign
31. 6 AA Right WSS Erratic Sensor Signal 6 794 10 15 4 AA Right WSS Loss of Sensor Signal 6 794 13 15 7 AA Right WSS Tire Size Calibration 6 794 13 15 10 AA Right WSS Configuration Error 6 794 14 15 2 AA Right WSS Output Low Drive Off Pressure Modulator Valve DTCs SA Left PMV CMN Open Circuit SA Left PMV Configuration Error SA Right PMV CMN Open Circuit SA Right PMV Configuration Error DA Left PMV CMN Open Circuit DA Left PMV Configuration Error DA Right PMV CMN Open Circuit DA Right PMV Configuration Error AA Left PMV CMN Open Circuit AA Left PMV Configuration Error AA Right PMV CMN Open Circuit AA Right PMV Configuration Error N 8 7 8 7 8 7 8 7 8 7 8 51 52 APPENDIX B 1587 SID and Codes and their Bendix Blink Code Equivalents SPN 71939 Bendix Blink Code Equivalent s Diagnostic Trouble Code Description Miscellaneous DTCs Pressure Modulator Valve DTCs P ON P EN O 1st Digit Miscellaneous DTCs 22 810 T 12 23 811 2 12 42 795 3 7 42 795 4 7 42 795 5 7 43 796 3 8 43 796 4 8 43 796 5 8 44 797 3 9 44 797 4 9 44 797 5 9 45 798 3 10 45 798 4 10 45 798 5 10 46 799 3 16 46 799 4 16 46 799 5 16 47 800 3 17 47 800 4 17 47 800 5 17 48 800 3 7 48 795 4 7 48 795 5 T 49 795 3 8 49 796 4 8 49 796 5 8 50 796 3 9 50 797 4 9 50 797 5 9 51 797 3 10 51 798 4 10 51 798 5 10 52 798 3 16 52 799 4 16 52 7
32. 639 14 0639 02 0639 02 0629 12 0807 04 0807 03 0806 05 0806 04 0806 03 0806 13 0807 13 0639 02 1059 02 0789 02 1067 02 1068 02 1067 11 0789 07 1067 02 0789 01 0789 14 0789 08 0789 10 1809 13 1808 14 1807 13 1807 13 0795 05 0795 04 0795 03 0795 05 0795 05 0795 04 0795 03 1807 09 1807 02 1807 12 APPENDIX C UDS Codes and their Bendix Blink Code Equivalents Lamp S Status DTC Description Retarder Relay Circuit Shorted to Voltage Retarder Relay Circuit or Hill Start Assist Lamp Shorted to Voltage Retarder Relay Open Circuit or Shorted to Ground Retarder Relay Circuit or Hill Start Assist Lamp open or Shorted to Ground TCV SA Solenoid Open Circuit J1939 Serial Link 1939 Retarder 1939 Engine Communications Invalid Data from Transmission ECU 37 TCV SA Solenoid Shorted to Ground TCV SA Solenoid Shorted to Voltage TCV DA Solenoid Open Circuit TCV DA Solenoid Shorted to Ground TCV DA Solenoid Shorted to Voltage TCV DA Configuration Error TCV SA Configuration Error Timeout or invalid CAN data AUX Open or Shorted Load Sensor SA Left WSS Open or Shorted Shorted Brake Demand Sensor Primary CKT Open Shorted Brake Demand Sensor Secondary CKT Open Plausibility Error Brake Demand Sensor SA Left WSS Wheel End PS Supply Voltage Error SA Left WSS Excessive Air Gap SA Left WSS Output Low Drive Off SA Left WSS Erratic Sensor Signal SA Left WSS Loss of Sensor Signal
33. 9 1st Digit 2nd Digit 2 Stop Lamp Switch Defective Brake Lamp Input Mismatch with Brake Lamp Output 1 Stop Lamp Switch Not Detected 20 Trailer PMV REL Solenoid Shorted to Voltage 20 Trailer PMV HLD Solenoid Shorted to Voltage 20 Trailer PMV REL Solenoid Shorted to Ground 20 Trailer PMV HLD Solenoid Shorted to Ground 20 Trailer PMV REL Solenoid Open Circuit 20 Trailer PMV HLD Solenoid Open Circuit 20 Trailer PMV CMN Open Circuit 20 PMV Configuration Error For more Pressure Modulator Valve DTCs see SID 93 below 24 Open or Shorted Load Sensor 24 Shorted Brake Demand Sensor Primary CKT Open 24 PS Supply Voltage Error 24 PS Not Calibrated 24 Plausibility Error Brake Demand Sensor 24 Shorted Brake Demand Sensor Secondary CKT Open C2 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 Timeout SAS Invalid Signal SAS Not Calibrated Steering Angle Sensor Calibration Not Finished YRS Sign Check Not Finished 93 802 3 12 8 PMV Common Shorted to Voltage 93 802 4 12 7 PMV Common Shorted to Ground HSA lamp shorted to ground or broken wire HSA lamp shorted to Voltage HSA solenoid shorted to Voltage total shutdown HSA solenoid shorted to Voltage ATC 4 ESP shutdown HSA solenoid shorted to ground or broken wire HSA solenoid shorted to Voltage Lateral Acceleration Sensor
34. 99 5 16 53 799 3 17 53 800 4 17 53 800 5 17 For more Pressure Modulator Valve DTCs see 5105 66 and 93 below 2nd Digit 11 6 5 MM WAN D zb MM D Do OS Om OS Om OS Om OS Om OS 3 Retarder Relay Circuit or HSA Lamp Shorted to Voltage DTCs Retarder Relay or HSA Lamp Open Circuit or Shorted to Ground Dynamometer Test Mode ATC Disabled to Prevent Brake Fade TCV DA Solenoid Shorted to Voltage TCV DA Solenoid Shorted to Ground TCV DA Solenoid Open Circuit TCV DA Configuration Error TCV SA Solenoid Shorted to Voltage TCV SA Solenoid Shorted to Ground TCV SA Solenoid Open Circuit TCV SA Configuration Error Wheel Speed Sensors Reversed on an Axle ABS Dash Indicator Circuit DTC SA Left PMV HLD Solenoid Shorted to Voltage SA Left PMV HLD Solenoid Shorted to Ground SA Left PMV HLD Solenoid Open Circuit SA Right PMV HLD Solenoid Shorted to Voltage SA Right PMV HLD Solenoid Shorted to Ground SA Right PMV HLD Solenoid Open Circuit DA Left PMV HLD Solenoid Shorted to Voltage DA Left PMV HLD Solenoid Shorted to Ground DA Left PMV HLD Solenoid Open Circuit DA Right PMV HLD Solenoid Shorted to Voltage DA Right PMV HLD Solenoid Shorted to Ground DA Right PMV HLD Solenoid Open Circuit AA Left PMV HLD Solenoid Shorted to Voltage AA Left PMV HLD Solenoid Shorted to Ground AA Left PMV HLD Solenoid Open Circuit AA Right PMV HLD Solenoid Shorted to Voltage AA Right PMV HLD Solenoid
35. A Right PMV CMN Open Circuit SA Right PMV REL Solenoid Open Circuit SA Right PMV REL Solenoid Shorted to Ground SA Right PMV REL Solenoid Shorted to Voltage J1939 HSA switch error or unavailable Hill Start Assist solenoid shorted to voltage SA Right PMV Configuration Error Hill Start Assist solenoid shorted to ground or open circuit DA Left WSS Open or Shorted DA Left WSS Wheel End DA Left WSS Excessive Air Gap DA Left WSS Output Low Drive Off DA Left WSS Erratic Sensor Signal DA Left WSS Loss of Sensor Signal Yaw Rate Sensor Vibration Detected ATC Disabled to Prevent Brake Fade DA Left PMV HLD Solenoid Open Circuit DA Left PMV HLD Solenoid Shorted to Ground DA Left PMV HLD Solenoid Shorted to Voltage DA Left PMV CMN Open Circuit DA Left PMV REL Solenoid Open Circuit DA Left PMV REL Solenoid Shorted to Ground DA Left PMV REL Solenoid Shorted to Voltage DA Left PMV Configuration Error Trailer PMV HLD Solenoid Open Circuit AA Right WSS Open or Shorted Trailer PMV HLD Solenoid Shorted to Ground AA Right WSS Configuration Error Trailer PMV HLD Solenoid Shorted to Voltage AA Right WSS Wheel End Trailer PMV CMN Open Circuit AA Right WSS Excessive Air Gap AA Right WSS Output Low Drive Off 59 J1939 73 DM1 2 SPN FMI 0794 08 0794 10 1056 05 1056 04 1056 03 0811 02 1069 13 0810 07 1045 07 0576 14 1045 02 0564 03 0564 05 0799 05 0799 04 0799 03 0799 05 0799 05 0799 04 0799 03 0639 02
36. AA Left WSS Excessive Air Gap 5 793 2 14 3 AA Left WSS Open or Shorted 5 793 7 14 5 AA Left WSS Wheel End 5 793 8 14 6 AA Left WSS Erratic Sensor Signal 5 793 10 14 4 AA Left WSS Loss of Sensor Signal 5 793 13 14 T AA Left WSS Tire Size Calibration 5 793 13 14 10 AA Left WSS Configuration Error 5 793 14 14 2 AA Left WSS Output Low Drive Off 6 794 1 15 1 AA Right WSS Excessive Air Gap 6 794 2 15 3 AA Right WSS Open or Shorted 6 794 7 15 5 AA Right WSS Wheel End 6 794 8 15 6 AA Right WSS Erratic Sensor Signal 6 794 10 15 4 AA Right WSS Loss of Sensor Signal 6 794 13 15 7 AA Right WSS Tire Size Calibration 6 794 13 15 10 AA Right WSS Configuration Error 6 794 14 15 2 AA Right WSS Output Low Drive Off Pressure Modulator Valve DTCs SA Left PMV CMN Open Circuit SA Left PMV Configuration Error SA Right PMV CMN Open Circuit SA Right PMV Configuration Error DA Left PMV CMN Open Circuit DA Left PMV Configuration Error DA Right PMV CMN Open Circuit DA Right PMV Configuration Error AA Left PMV CMN Open Circuit AA Left PMV Configuration Error AA Right PMV CMN Open Circuit AA Right PMV Configuration Error N 8 7 8 7 8 7 8 7 8 7 8 51 52 APPENDIX B 1587 SID and Codes and their Bendix Blink Code Equivalents SPN 71939 Bendix Blink Code Equivalent s Diagnostic Trouble Code Description Miscellaneous DTCs Pressure Modulator Valve DTCs P ON P
37. ABS Battery Voltage Input Open Circuit Input Voltage Excessive Noise Latched N NN NNNNNDN bb BR BR WWD o o oO o o oO o OD _ I APPENDIX B J1587 SID and Codes and their Bendix Blink Code Equivalents Bendix Blink Code SID SPN Equivalent s Diagnostic Trouble Code Description SATA AE 1st Digit 2nd Digit ECU ECU 0D Invalid ESP Configuration ECU 02 ECU 10 ECU 11 ECU 14 ECU 18 ECU 1A ECU 18 ECU 80 ECU 04 ECU 0 6 ECU 0E ECU 37 ECU Internal VIN Mismatch Invalid ABS Configuration ECU 17 56 APPENDIX UDS Codes and their Bendix Blink Code Equivalents Lamp Status d Oo O 13 14 15 16 li 18 19 20 21 22 23 24 25 26 2 28 29 30 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 01 01 14 03 14 10 13 14 14 05 13 15 14 01 14 02 14 06 14 04 13 17 13 16 12 14 13 02 13 03 13 04 13 05 13 06 13 07 13 08 13 09 13 10 13 18 13 11 13 12 13 19 13 21 13 22 06 06 06 05 06 07 06 02 06 01 06 03 06 04 13 20 13 23 12 08 12 07 11 07 11 04 11 05 11 08 000 00 005 02 005 13 254 12 005 07 254 12 005 01 005 14 005 08 005 10 254 02 254 12 103 02 254 12 254 12 254 02 254 02 254 12 254 02 254 13 254 13 254 12 254 02 254 12 254 12 253 12 253 13 253 13 251 03 251 04 251 04 251 03 251 04 251 04 251 05 253 12 253 13 093 03 093 04 23
38. Blink Code Equivalents Lamp Status DTC Description SA Right WSS Output Low Drive Off SA Right WSS Erratic Sensor Signal SA Right WSS Loss of Sensor Signal ECU Internal VIN Mismatch Trailer PMV potentially miswired or internal mechanical problem YRS Sign Check Not Finished i o 2 or i o shorted high or Stop Lamp Output Error SA Right PMV HLD Solenoid Open Circuit SA Right PMV HLD Solenoid Shorted to Ground SA Right PMV HLD Solenoid Shorted to Voltage SA Right PMV CMN Open Circuit SA Right PMV REL Solenoid Open Circuit SA Right PMV REL Solenoid Shorted to Ground SA Right PMV REL Solenoid Shorted to Voltage J1939 HSA switch error or unavailable Hill Start Assist solenoid shorted to voltage SA Right PMV Configuration Error Hill Start Assist solenoid shorted to ground or open circuit DA Left WSS Open or Shorted DA Left WSS Wheel End DA Left WSS Excessive Air Gap DA Left WSS Output Low Drive Off DA Left WSS Erratic Sensor Signal DA Left WSS Loss of Sensor Signal Yaw Rate Sensor Vibration Detected ATC Disabled to Prevent Brake Fade DA Left PMV HLD Solenoid Open Circuit DA Left PMV HLD Solenoid Shorted to Ground DA Left PMV HLD Solenoid Shorted to Voltage DA Left PMV CMN Open Circuit DA Left PMV REL Solenoid Open Circuit DA Left PMV REL Solenoid Shorted to Ground DA Left PMV REL Solenoid Shorted to Voltage DA Left PMV Configuration Error Trailer PMV HLD Solenoid Open Circuit AA Right WSS Open or Shorted
39. D BRAKE DEMAND LOAD SENSORS Cab ECUs utilize connectors from the AMP MCP 2 8 product family HARDWARE CONFIGURATIONS Advanced Bendix EC 60 controllers support applications up to six sensor six modulator 6S 6M installations with ATC and drag torque control They can support HSA functions All 12 volt models support PLC 24 volt models do not support PLC See Chart 1 for more details ABS ATC Blink ESP Ber Input Retarder Sue EE 5 Codes RSP 2085 Voltage PEE Pawe Relay Road EEN system 31587 31939 For information about the Bendix eTrac automated air suspension transfer system see SD 13 21021 CHART 1 BENDIX EC 60 ADVANCED CONTROLLER FEATURES 4 ADVANCED BENDIX EC 60 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 7 and 8 Typically the signal 15 broadcast by the trailer ABS ECU lt 12 VDC lt 10 VDC 8 VDC 6 VDC 4VDC 2 VDC 0 VDC FIGURE 7 POWER LINE WITHOUT PLC SIGNAL 12 VDC 10 VDC 8 VDC 6 VDC 4 VDC 2 VDC 0 VDC FIGURE 8 POWER LINE WITH PLC SIGNAL The application of PLC technology for the heavy vehicle industry in North America is known as PLC4Trucks The A
40. EATH When working on or around a vehicle the following general precautions should be observed at all times REMOVING THE BENDIX EC 60 CONTROLLER ASSEMBLY 1 2 Turn vehicle ignition off Remove as much contamination as possible prior to disconnecting electrical connections Note the Bendix EC 60 controller assembly mounting position on the vehicle Disconnect the electrical connectors from the Bendix EC 60 controller Remove and retain the mounting bolts that secure the Bendix EC 60 controller 10 11 Do not attempt repairs requiring machining or welding unless specifically stated and approved by the vehicle and component manufacturer Prior to returning the vehicle to service make certain all components and systems are restored to their proper operating condition 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 CAUTION The VIN of the vehicle is stored in the ECU internal memory and is cross checked by the ECU using information obtained from other vehicle controllers If the VIN stored in the ECU does not match the VIN obtained from the other vehicle controller the ECU will generate an ECU Internal VIN Mismatch DTC Accordingly do not switch Advanced controllers from one vehicle to another 17
41. EC 60 parameter tuning See Advanced ABS with Stability Control on page 12 for further details Accordingly the Bendix EC 60 controller is provided with a corresponding parameter data set that is validated for a specific vehicle platform Therefore specific steps necessary should a replacement ECU be required See Obtaining a New Bendix EC 60 Advanced Controller on page 18 for further details ESP equipped vehicles should not be driven on high banked roads such as those found on high speed test race tracks Test personnel must have ESP functionality disabled prior to operating an ESP vehicle on such tracks YAW CONTROL YC Advanced ECU can include Yaw Control YC functionality which 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 9 for further details ROLL STABILITY PROGRAM RSP The Bendix Roll Stability Program RSP is an all axle ABS solution that helps reduce vehicle speed by reducing the engine s throttle and applying all vehicle brakes as needed reducing 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 frictio
42. 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 T Schlemmer 7814 125 ITT Cannon Connector 121583 001 a US AMP 0 962981 1 90 degree Connector Schlemmer 9800 331 Cannon 031 8717 120 Brake Demand Sensor Load Sensor SAS 60 Sensor Connectors Wire Harness Connectors Robert Bosch 1 928 404 025 Metri Pack Packard 1206 5287 2 Robert Bosch 1 928 498 001 Contact Pins Mn One Meter Adapter to Connector Packard 1210 3881 Bendix 5015242 shown Packard 12092162 pins 12064971 CHART 4 EC 60 CONTROLLER COMPONENT CONNECTORS 46 Troubleshooting Wiring Continuea Speed Sensor Mounting Block 100 Tooth typical Speed Sensor Exciter Ring WS 24 Speed Sensor i dr CM Je 1 kan EN Air Disc Brake Note Ensure that the sensor wiring is routed to avoid chafing from moving parts including rotors and steering components Max Gap Sensor to Exciter 015 Inches WS 24 Speed Sensor Lo Mounting Brake Drum 90 Speed Sensors Sensor Clamping Straight Speed Sleeve Sensors FIGURE 19 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 ne
43. PENDIX B J1587 SID and Codes and their Bendix Blink Code Equivalents FMI Bendix Blink Code J1587 Equivalent s Diagnostic Trouble Code Description J1939 1st Digit 2nd Digit 1 1 No DTCs 1 789 1 2 1 SA Left WSS Excessive Air Gap 1 789 2 2 3 SA Left WSS Open or Shorted 1 789 7 2 5 SA Left WSS Wheel End 1 789 8 2 6 SA Left WSS Erratic Sensor Signal 1 789 10 2 4 SA Left WSS Loss of Sensor Signal 1 789 13 2 7 SA Left WSS Tire Size Calibration 1 789 14 2 2 SA Left WSS Output Low Drive Off 2 790 1 3 1 SA Right WSS Excessive Air Gap 2 790 2 3 3 SA Right WSS Open or Shorted 2 790 7 3 5 SA Right WSS Wheel End 2 790 8 3 6 SA Right WSS Erratic Sensor Signal 2 790 10 3 4 SA Right WSS Loss of Sensor Signal 2 790 13 3 7 SA Right WSS Tire Size Calibration 2 790 14 3 2 SA Right WSS Output Low Drive Off 3 791 1 4 1 DA Left WSS Excessive Air Gap 3 791 2 4 3 DA Left WSS Open or Shorted 3 791 T 4 5 DA Left WSS Wheel End 3 791 8 4 6 DA Left WSS Erratic Sensor Signal 3 791 10 4 4 DA Left WSS Loss of Sensor Signal 3 791 13 4 7 DA Left WSS Tire Size Calibration 3 791 14 4 2 DA Left WSS Output Low Drive Off 4 792 1 5 1 DA Right WSS Excessive Air Gap 4 792 2 5 3 DA Right WSS Open or Shorted 4 792 7 5 5 DA Right WSS Wheel End 4 792 8 5 6 DA Right WSS Erratic Sensor Signal 4 792 10 5 4 DA Right WSS Loss of Sensor Signal 4 792 13 5 7 DA Right WSS Tire Size Calibration 4 792 14 5 2 DA Right WSS Output Low Drive Off 5 793 1 14 1
44. PMV HLD Solenoid Open Circuit DA Left PMV HLD Solenoid Shorted to Voltage DA Left PMV HLD Solenoid Shorted to Ground DA Left PMV HLD Solenoid Open Circuit DA Right PMV HLD Solenoid Shorted to Voltage DA Right PMV HLD Solenoid Shorted to Ground DA Right PMV HLD Solenoid Open Circuit AA Left PMV HLD Solenoid Shorted to Voltage AA Left PMV HLD Solenoid Shorted to Ground AA Left PMV HLD Solenoid Open Circuit AA Right PMV HLD Solenoid Shorted to Voltage AA Right PMV HLD Solenoid Shorted to Ground AA Right PMV HLD Solenoid Open Circuit SA Left PMV REL Solenoid Shorted to Voltage SA Left PMV REL Solenoid Shorted to Ground SA Left PMV REL Solenoid Open Circuit SA Right PMV REL Solenoid Shorted to Voltage SA Right PMV REL Solenoid Shorted to Ground SA Right PMV REL Solenoid Open Circuit DA Left PMV REL Solenoid Shorted to Voltage DA Left PMV REL Solenoid Shorted to Ground DA Left PMV REL Solenoid Open Circuit DA Right PMV REL Solenoid Shorted to Voltage DA Right PMV REL Solenoid Shorted to Ground DA Right PMV REL Solenoid Open Circuit AA Left PMV REL Solenoid Shorted to Voltage AA Left PMV REL Solenoid Shorted to Ground AA Left PMV REL Solenoid Open Circuit AA Right PMV REL Solenoid Shorted to Voltage AA Right PMV REL Solenoid Shorted to Ground AA Right PMV REL Solenoid Open Circuit APPENDIX B J1587 SID and Codes and their Bendix Blink Code Equivalents FMI Bendix Blink Code J1587 Equivalent s Diagnostic Trouble Code Description J193
45. Q31S M1 WW DS SNOILVOINAQNNOO VI N9 S9 Wv S9 NOI1V309 JNOO 09 23 Hd OJTIVISNI ANd SSM 31XV TVNOILIOOV HOLIMS ABVIN3JWON A91 JAVA 1OMINOO 1 03IYINO3Y 3YIM OILSIML YOLONGNOD YNOF WW OS DNIYIM YOSNIS NVI NOI LVOINOWAOO 6 61f YO INANI JYVMGYVH VIA 38 AVN S3191H3A 34190 133HM llv ONV 21 INANI HOLIMS dAV 3015 039I1N03Y MIVd Q3LSIML WN OS I 9NISIM 2 SM XIQN38 SSM 405 35 03385 1 0000 MOLVOIGNI 59 3HL INILVNIWAT111 ONNOSI Ol LINDYID NOIVOIQNI JHL V 139 3573 SISOHS MOOTYSINI JHL N93 WOYS OJLIINNOISIO SI LX N3HM 2 Nid 0 8 Z NND NOWWOO Q3AON3N 91 OYVAIVd M9O1 LSIML SOLO3NNOO Ald 8311V8 AC Md G4Z M8 NOI1V213I23dS 19nQONd SL YOZEN ZE N XIQN38 ANd JAVA JYNSSIYA Q310N 3SIMY3HLO SSIINN WW OS el 30 NOII123S SSONO YOLONGNOD SI 3YIM 1Y pl 6 61 3VS YId IOYINOD 3NI9N3 21 EN 335 1nd dvi 8015 S3YINOIY ANO S3121H3A JAIXO 133HM 11 HOLIMS AYVLN3NON HOLIMS 3002 178 91 LSONDVIG 961 3VS Y3d SOILSONDVIG 661 JYS YO VIA Y430YV133Y FIGURE 20 STANDARD CAB WIRING D 5 5310 C NOILINDI Alz NEN dg 8015 gt 515 HOLIMS 8015 310d ZI r EE 3109 1 wem dNv1 3015 r AE d nn
46. S oo D FI d ln ke d CC CC res pe pp Pp Pp CC CC ree rei pp pow pa gt e 3 3 DD ore rr S 4144 2 um t t n n EN gt gt gt gt gt b b nn nu 1 nnn bb 5 E AS ke us 00 700 vo 53 ppp o 2 o D mm gt Ep T ppp ne aa um a D e 22 ITT pp ties er ppp ror 02 32 z m m Log PUT 20r m CC 29 z 292 E 292 lao agr Ct 56 S a Io xk 9 mer Ww Itc m F m E m E m E mer m P m gt Se rzo 970 z r zo 20 rzo r zo 25 r zo o2 D z z 2 Ml T Eme a A E A coc A en 2 o o 48 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
47. S may be shorter than corresponding stopping distance with conventional ABS control vehicle steerability and stability would be reduced Advanced Bendix EC 60 controllers have an optional dash switch that initiates a modified ABS control mode know 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 Assist HSA A WARNING 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 A CAUTION When ABS off road mode is engaged stability functions are disabled at speeds below approximately 25 mph 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 15 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
48. TABILITY CONTROL Overview ESP stability system reduces the risk of rollovers jackknifing and other loss of control events ESP features include Roll Stability Program RSP and Yaw Control During operation the ECU of the Bendix Advanced ABS system constantly compares performance models to the 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 15 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 11 RSP EXAMPLE 12 Drag Torque Control Functional Overview Advanced Bendix EC 60 controllers have a feature referred to as drag torque control which reduces wheel slip on driven axle due to driveline inertia This condition is addressed by increasing the engine torque to the inertia Drag torque control increases vehicle stability on low traction road surfaces during down shifting or retarder braking vehicle s actual movement using the wheel speed sensors of the ABS system as well as lateral yaw and steering angle sensors 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 Exam
49. Trailer PMV HLD Solenoid Shorted to Ground AA Right WSS Configuration Error Trailer PMV HLD Solenoid Shorted to Voltage AA Right WSS Wheel End Trailer PMV CMN Open Circuit AA Right WSS Excessive Air Gap AA Right WSS Output Low Drive Off 59 J1939 73 DM1 2 SPN FMI 0794 08 0794 10 1056 05 1056 04 1056 03 0811 02 1069 13 0810 07 1045 07 0576 14 1045 02 0564 03 0564 05 0799 05 0799 04 0799 03 0799 05 0799 05 0799 04 0799 03 0639 02 0799 13 0615 14 0615 14 1809 02 0800 05 0800 04 0800 03 0800 05 0800 05 0800 04 0800 03 1809 02 1809 02 1809 02 1809 02 0800 13 APPENDIX C UDS Codes and their Bendix Blink Code Equivalents DTC Description AA Right WSS Erratic Sensor Signal AA Right WSS Loss of Sensor Signal Trailer PMV REL Solenoid Open Circuit Trailer PMV REL Solenoid Shorted to Ground Trailer PMV REL Solenoid Shorted to Voltage ABS Indicator Lamp Circuit Tire Size Out of Range Front to Rear Wheel Speed Sensors Reversed on an Axle Stop Lamp Switch Not Detected ATC Disabled or Dynamometer Test Mode Active Stop Lamp Switch Defective Diff Lock Solenoid Shorted to Voltage total shutdown Diff Lock Shorted to Ground or Open Circuit AA Left PMV HLD Solenoid Open Circuit AA Left PMV HLD Solenoid Shorted to Ground AA Left PMV HLD Solenoid Shorted to Voltage AA Left PMV CMN Open Circuit AA Left PMV REL Solenoid Open Circuit AA Left PMV REL Solenoid Shorted to Ground AA Left PMV
50. WSS SA Right PMV DA Left CMN 10 11 12 A 4 Troubleshooting Wiring ABS ATC WIRING ECU Wiring Harness Connectors The Advanced Bendix EC 60 controller is designed to interface with AMP MCP 2 8 connectors as referenced in Chart 4 Follow all AMP requirements for the repair of wire harnesses All wire harness connectors must be properly seated The use of secondary locks 15 strongly advised A CAUTION 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 PMV TCV Interaxle Differential Lock and indicator lamp circuits All sensor and serial communications circuits J1587 and 1939 must use twisted pair wiring one to two twists per inch See the appropriate SAE document for additional details A CAUTION 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 prevent 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
51. 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 EC 60 CONTROLLER OUTPUTS Bendix M 32 and M 32QR Pressure Modulator Valves PMV The Bendix M 32 and M 32QR pressure modulator valves PMV are operated by the Bendix EC 60 controller to modify driver applied air pressure to the service brakes during ABS ATC RSP or YC activation See page 3 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 brake chambers in the event of electrical trouble The Advanced Bendix EC 60 controller also utilizes an additional PMV for control of the trailer service brakes during stability interventions Traction Control Valve TCV Advanced Bendix EC 60 controllers use two TCVs one on the steer axle and one on the drive axle The TCV may be a separate valve or integrated into the rear axle relay valve The controller will activate the drive axle during di
52. are preferred The use of grommets or other suitable protection is required whenever the cable must pass through metallic 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 47 WW DS GNNOYD 5 01 180 NOILONNS 1vI23dS SINIA 031 03310033 Q31S M1 WW DS SNOILVOINAQNNOO VI N9 S9 Wv S9 NOI1V309 JNOO 09 23 Hd OJTIVISNI ANd SSM 31XV TVNOILIOOV HOLIMS ABVIN3JWON A91 JAVA 1OMINOO 1 03IYINO3Y 3YIM OILSIML YOLONGNOD YNOF WW OS DNIYIM YOSNIS NVI NOI LVOINOWAOO 6 61f YO INANI JYVMGYVH VIA 38 AVN S3191H3A 34190 133HM llv ONV 21 INANI HOLIMS dAV 3015 039I1N03Y MIVd Q3LSIML WN OS I 9NISIM 2 SM XIQN38 SSM 405 35 03385 1 0000 MOLVOIGNI 59 3HL INILVNIWAT111 ONNOSI Ol LINDYID NOIVOIQNI JHL V 139 3573 SISOHS MOOTYSINI JHL N93 WOYS OJLIINNOISIO SI LX N3HM 2 Nid 0 8 Z NND NOWWOO Q3AON3N 91 OYVAIVd M9O1 LSIML SOLO3NNOO Ald 8311V8 AC Md G4Z M8 NOI1V213I23dS 19nQONd SL YOZEN ZE N XIQN38 ANd JAVA JYNSSIYA Q310N 3SIMY3HLO SSIINN WW OS el 30 NOII123S SSONO YOLONGNOD SI 3YIM 1Y pl 6 61 3VS YId IOYINOD 3NI9N3 21 EN
53. atus with other vehicle control modules Advanced Bendix EC 60 controllers utilize the J1939 data link for e ATC and drag torque control functions Vehicle stability functions Trailer ABS Indicator Lamp Control The Advanced Bendix EC 60 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 EC 60 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 EC 60 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 EC 60 controller uses a serial communications message to operate the lamp e mail ABS bendix com specifying the ECU part number or call 1 800 AIR BRAKE and speak to the Bendix TechTeam SAE J1708 J1587 Serial Communications An SAE J1708 data link implemented according to SAE 41587 recommended practice is available for diagnostic purposes as well as ECU status messages Interaxle Differential Lock Control AWD Transfer Case Advanced ECUs 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 mai
54. d to avoid chafing from moving parts including rotors and steering components Max Gap Sensor to Exciter 015 Inches WS 24 Speed Sensor Lo Mounting Brake Drum 90 Speed Sensors Sensor Clamping Straight Speed Sleeve Sensors FIGURE 19 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
55. dvanced Bendix EC 60 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 0mVp p to 7 0 Vp p Suggested oscilloscope settings are AC coupling 1 volt div 100 usec div The signal should be measured at the ignition power input of the Bendix EC 60 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 EC 60 CONTROLLER INPUTS Battery and Ignition Inputs The ECU 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 EC 60 controller supports one ground input page 48 for a system schematic ABS Indicator Lamp Ground Input Advanced Bendix EC 60 cab ECUs require 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 S
56. eds 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 metallic 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 47 WW DS GNNOYD 5 01 180 NOILONNS 1vI23dS SINIA 031 03310033
57. el slip during ATC interventions During an ATC 5 Flashes Not for firm road surfaces ESP Event quickly During an Automatic Traction Control ATC Event puts Reduces wheel slip during acceleration at low speeds At Vehicle Special Mode Operation Lamp ON Disables ATC monitoring functions During Dynamometer Mode ATC When not in Dynamometer Mode an illuminated lamp indicates an Disabled ATC trouble code is present E Flashes During an ESP Event quickly System intervenes to reduce the risk of rollovers loss of control etc Power ABS System Application ATC ESP System Status Indicators Status Indicator at Start Up 0 5 1 5 2 0 2 5 3 0 sec at Start Up Powered Vehicle ABS ON Indicator Lamp OFF Power Application 0 5 1 5 2 0 2 5 3 0 5 Trailer ABS ATC ESP ON Indicator Lamp enabled PLC Detected OFF OFF Trailer ABS Indicator ON ON Lamp No ESP or ATC OFF PLC Not Detected OFF 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 CHART 2 BENDIX EC 60 INDICATOR LAMP BEHAVIOR 8 ABS Indicator Lamp Operation Bulb Check The ECU will illuminate the ABS Indicator Lamp for approximately three seconds when ignition power 15 applied after which the lamp will extinguish if no diagnostic trouble codes are detected
58. eout or invalid data on ETC7 VP15 for HSA function ONMNNMNN NIN NNNDNNNNNN timeout or invalid data on XBR Invalid Data From Transmisson 1939 HSA switch error or unavailable timeout or invalid data for ESP AWD operation 1939 Serial Link 1939 Retarder Input Voltage Excessive Noise Temp Battery Voltage Too High Ignition Voltage Too High Battery Voltage Too Low Battery Voltage Too Low During ABS Ignition Voltage Too Low Ignition Voltage Too Low During ABS Battery Voltage Input Open Circuit Input Voltage Excessive Noise Latched N NN NNNNNDN bb BR BR WWD o o oO o o oO o OD _ I APPENDIX B J1587 SID and Codes and their Bendix Blink Code Equivalents Bendix Blink Code SID SPN Equivalent s Diagnostic Trouble Code Description SATA AE 1st Digit 2nd Digit ECU ECU 0D Invalid ESP Configuration ECU 02 ECU 10 ECU 11 ECU 14 ECU 18 ECU 1A ECU 18 ECU 80 ECU 04 ECU 0 6 ECU 0E ECU 37 ECU Internal VIN Mismatch Invalid ABS Configuration ECU 17 56 APPENDIX UDS Codes and their Bendix Blink Code Equivalents Lamp Status d Oo O 13 14 15 16 li 18 19 20 21 22 23 24 25 26 2 28 29 30 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 01 01 14 03 14 10 13 14 14 05 13 15 14 01 14 02 14 06 14 04 13 17 13 16 12 14 13 02 13 03 13 04 13 05 13 06 13 07
59. es This function 15 totally controlled by the automatic transmission Stop Lamp Switch SLS The Advanced Bendix EC 60 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 15 installed in the primary air brake circuit and another 15 installed in the secondary air brake circuit Load Sensor The load sensor provides the controller with an indication of the vehicle load It is typically installed in one of the suspension air bags Bendix SAS 60 Steering Angle Sensor The Steering Angle Sensor SAS is used to provide driver steering input to the controller It reports the steering wheel position to the controller utilizing a dedicated serial communications link that is shared with the Yaw Rate sensor he controller supplies the power and ground inputs to the Bendix SAS 60 sensor The Bendix SAS 60 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 yaw rate lateral acceleration sensors are used to provide the controller an indication of vehicle lateral acceleration
60. es 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 applying 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 It is pressed between an ABS sensor and mounting hole to hold the sensor in place Stored Diagnostic Trouble Codes A diagnostic trouble code that occurred TCS Traction Control System another name for ATC or ASR 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 49 1 2 3 4 5 6 7 8 9 APPENDIX Troubleshooting 12 7 Blink Code fault SID 93 FMI 4 SPN 0802 FMI 04 Advanced In Cab ECU Remove X1 X2 X3 and X4 connector f
61. f DA Right WSS Erratic Sensor Signal DA Right WSS Loss of Sensor Signal YRS Dynamic BITE Error YRS Gradient Error YRS Fast Calibration Error YRS Static Calibration Error DA Right PMV HLD Solenoid Open Circuit DA Right PMV HLD Solenoid Shorted to Ground DA Right PMV HLD Solenoid Shorted to Voltage DA Right PMV CMN Open Circuit DA Right PMV REL Solenoid Open Circuit DA Right PMV REL Solenoid Shorted to Ground DA Right PMV REL Solenoid Shorted to Voltage YRS Normal Calibration Error YRS Sensitivity Calibration Error YRS Plausibility Check Ref Yaw Rate YRS Sensor Reversed Signal YRS Plausibility Error Inside Model Based Limits DA Right PMV Configuration Error YRS Plausibility Error Outside Model Based Limits J1939 ESP Messages Invalid Data ECU 80 SA Right WSS Open or Shorted Input Voltage Excessive Noise Temp Input Voltage Excessive Noise Latched ESP Sensor Voltage Out of Range SA Right WSS Wheel End PS Not Calibrated SA Right WSS Excessive Air Gap J1939 73 DM1 2 SPN FMI 0790 14 0790 08 0790 10 0629 12 1056 07 1808 13 0614 03 0796 05 0796 04 0796 03 0796 05 0796 05 0796 04 0796 03 0639 02 2622 03 0796 13 2622 05 0791 02 0791 07 0791 01 0791 14 0791 08 0791 10 1808 02 0614 14 0797 05 0797 04 0797 03 0797 05 0797 05 0797 04 0797 03 0797 13 1056 05 0794 02 1056 04 0794 13 1056 03 0794 07 1056 05 0794 01 0794 14 APPENDIX C UDS Codes and their Bendix
62. f the 12 7 DTC does not reappear remove power and connect X2 connector reapply power then clear all DTCs Ifthe 12 7 DTC is no longer present connect the X3 connector and clear all DTCs If at this point the 12 7 DTC is not present the problem 15 with the X4 connector For Peterbilt 8 Kenworth Trucks Only 10 11 50 Clear all DTCs If the 12 7 DTC reappears the issue is on the X4 connector Otherwise proceed to the next step Disconnect all modulators and the traction solenoid Clear all DTCs If the DTC does not reappear connect 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 connected Disconnect the ABS bulkhead connector at the engine top left side and remove Pins 1 2 11 amp 12 Reconnect the connector and apply IGN power to the ECU Using Bendix ACom Diagnostics clear all DTCs If the 12 7 DTC returns the problem is either the wiring harness inside the cab or the ECU Record Resistances Below X1 1 for ground point xs a 02 xs pea es xe er EAT xeu xa I xx peas bear we x hes xer ee rae 5 amp 3 xs I xe xs xa AP
63. ff road switch 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 e Dash mounted HSA Status indicator lamp premium and advanced Antilock Brake Systems ABS e Dash mounted enable disable Switch This system complements the Bendix Smart Automatic Traction Control ATC 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 Brake Demand A Load Sensor 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 The 60 controller Start Feature utilizes the following additional components e Bendix AT 3 Traction control valve e Bendix RV 3 Pressure reducing valve e Bendix DC 4 Double check valve See SD 13 21021 for more information ECU MOUNTING Yaw Lateral Accelerator Sensors The Bendix EC 60 advanced cab mounted controller is o not protected against moisture and must be mounted in SEHR an environmentally protected area All wire harness connectors must be properly seated The use of secondary locks is strongly recommended FIGURE 5 YAW AN
64. fferential braking ATC events During stability interventions the ECU 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 Advanced Bendix EC 60 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 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 presence of a DTC on the ECU 3 Ifthe ECU is unplugged or has no power 4 When the ECU 15 placed into the ABS off road mode the lamp flashes steadily at a rate of once per 2 5 sec 5 To display blink codes for diagnostic purposes after the external diagnostic switch 15 activated The Bendix EC 60 controller may communicate with other vehicle control modules to operate the ABS Indicator Lamp using serial communications If you need to know if this Bendix EC 60 controller uses serial communications to operate the lamp e mail ABS bendix com specifying the ECU part number or call 1 800 AIR BRAKE and speak to t
65. he 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 EC 60 controller will send a serial communications message over the J1939 or 1587 links 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 EC 60 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 configured for Hill Start Assist HSA the retarder relay output pin is used to control the HSA status lamp The vehicle loses the retarder relay function 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 disable retarding devices during ABS operation To request that the torque converter disable lock up during ABS operation To share information such as wheel speed and ECU st
66. heir own wheel speed sensor and pressure modulator valve the Bendix EC 60 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 EC 60 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 right side rear wheels and the other modulator controls both left side rear wheels Both wheels on each side receive 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 65 6 Configuration For vehicles with dual rear axles 6x4 6x2 using a 6S 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 65 5 Configuration 6x2 vehicles can utilize a 6S 5M configuration with the additional axle a non driven rear axle having
67. ition Voltage Too Low During ABS Battery Voltage Too High Battery Voltage Too Low Battery Voltage Too Low During ABS Battery Voltage Input Open Circuit ECU 27 ECU 28 PMV Common Shorted to Voltage PMV Common Shorted to Ground Timeout or invalid CAN data for ETC7 VP15 1939 Invalid Data Engine Retarder 1939 Supply Pressure Timeout or invalid CAN data XBR 1939 73 DM1 2 SPN FMI 0801 03 2622 03 0801 02 2622 02 0807 05 0639 12 0639 14 0639 02 0639 02 0629 12 0807 04 0807 03 0806 05 0806 04 0806 03 0806 13 0807 13 0639 02 1059 02 0789 02 1067 02 1068 02 1067 11 0789 07 1067 02 0789 01 0789 14 0789 08 0789 10 1809 13 1808 14 1807 13 1807 13 0795 05 0795 04 0795 03 0795 05 0795 05 0795 04 0795 03 1807 09 1807 02 1807 12 APPENDIX C UDS Codes and their Bendix Blink Code Equivalents Lamp S Status DTC Description Retarder Relay Circuit Shorted to Voltage Retarder Relay Circuit or Hill Start Assist Lamp Shorted to Voltage Retarder Relay Open Circuit or Shorted to Ground Retarder Relay Circuit or Hill Start Assist Lamp open or Shorted to Ground TCV SA Solenoid Open Circuit J1939 Serial Link 1939 Retarder 1939 Engine Communications Invalid Data from Transmission ECU 37 TCV SA Solenoid Shorted to Ground TCV SA Solenoid Shorted to Voltage TCV DA Solenoid Open Circuit TCV DA Solenoid Shorted to Ground TCV DA Solenoid Shorted to Voltage
68. ix SAS 60 Steering Angle Sensor mounted to the steering column See Figure 4 A CAUTION 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 e YAS 60 or YAS 70X Yaw Rate Lateral Acceleration Sensors typically mounted to a cross member near the back of the vehicle cab e Brake Demand Sensors installed in the primary and secondary delivery circuits Load Sensor typically installed in the suspension air bag An additional Modulator Valve Bendix M 32 or M 32QR Pressure Modulator Valve that controls pressure apply to trailer brakes during system intervention Straight Connector Connector FIGURE 4 STEERING ANGLE SENSORS The Bendix EC 60 controller ATC function utilizes the following additional components Drive axle traction control valve may be integral to the service brake relay valve or a stand alone device e Dash mounted ATC status indicator lamp e J1939 serial communication to engine control Bendix RV 3 Bendix AT 3 Bendix DC 49 module Pressure Traction Control Double Check Reducing Valve Valve Valve Stoplamp switch input may be provided using the ECU hardware input or J1939 FIGURE 6 ADDITIONAL VALVES NECESSARY FOR THE e Optional mud snow switch sometimes referred MIEE SIART FEATURE to as an ATC o
69. l ABS bendix com for more details INDICATOR LAMPS AND POWER UP SEQUENCE NOTICE The vehicle operator should verify proper Lamps that do not illuminate as expected when ignition operation of all installed indicator lamps ABS ATC ESP power is applied or remain illuminated indicate the need and trailer ABS when applying ignition power and during for maintenance vehicle operation See Chart 2 Dash Lamps Trailer ABS ATC ESP Lamp Ignition on start up On for 2 5 On for 3 trailer with PLC seconds seconds seconds seconds If any of the described lamp behaviors do not occur or if the lamp remains on during aem operation have the vehicle serviced by a decenas der M ti n qualified mechanic as soon as possible to with no Diagnostic Lamp Off Lamp Off Lamp Off Lamp Off restore full system functionality Trouble Codes Uses dash switch Lamp flashes Not for firm road surfaces slowly every Allows more wheel lock up less ABS intervention During an ATC 2 5 seconds Flashes Mode only applies under 25 mph Over 25 mph the system reverts Event quickly to full ABS including ATC ESP and lamp goes off During HSA Event Lamp OFF Vehicles with the Hill Start Feature Hill Start Assist Flashas Lamp remains ON if HSA DTC is present HSA Manually Disabled slowly Uses dash switch Flashes Normal Off slowly every 2 5 seconds Increases allowable whe
70. l Calibration Error YRS Sensitivity Calibration Error YRS Plausibility Check Ref Yaw Rate YRS Sensor Reversed Signal YRS Plausibility Error Inside Model Based Limits DA Right PMV Configuration Error YRS Plausibility Error Outside Model Based Limits J1939 ESP Messages Invalid Data ECU 80 SA Right WSS Open or Shorted Input Voltage Excessive Noise Temp Input Voltage Excessive Noise Latched ESP Sensor Voltage Out of Range SA Right WSS Wheel End PS Not Calibrated SA Right WSS Excessive Air Gap J1939 73 DM1 2 SPN FMI 0790 14 0790 08 0790 10 0629 12 1056 07 1808 13 0614 03 0796 05 0796 04 0796 03 0796 05 0796 05 0796 04 0796 03 0639 02 2622 03 0796 13 2622 05 0791 02 0791 07 0791 01 0791 14 0791 08 0791 10 1808 02 0614 14 0797 05 0797 04 0797 03 0797 05 0797 05 0797 04 0797 03 0797 13 1056 05 0794 02 1056 04 0794 13 1056 03 0794 07 1056 05 0794 01 0794 14 APPENDIX C UDS Codes and their Bendix Blink Code Equivalents Lamp Status DTC Description SA Right WSS Output Low Drive Off SA Right WSS Erratic Sensor Signal SA Right WSS Loss of Sensor Signal ECU Internal VIN Mismatch Trailer PMV potentially miswired or internal mechanical problem YRS Sign Check Not Finished i o 2 or i o shorted high or Stop Lamp Output Error SA Right PMV HLD Solenoid Open Circuit SA Right PMV HLD Solenoid Shorted to Ground SA Right PMV HLD Solenoid Shorted to Voltage S
71. l speed sensors show that the vehicle is in motion Pressure Modulator Valve and Traction Control Valve Chuff Test Right Right Drive Additional Right Steer C Q Driver Left Steer EJ Left Drive Left Additional FIGURE 9 VEHICLE ORIENTATION TYPICAL After the performance of the configuration test the Bendix EC 60 controller will perform a Bendix patented PMV and 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 as follows right front left front right rear left rear This test is performed only when the vehicle is stationary if the vehicle moves the chuff test will not be performed The Bendix EC 60 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 Drive Axle Left PMV e Additional Axle Right PMV e Additional Axle Left PMV Drive Axle TCV The pattern will then repeat itself If equipped with a Bendix EC 60 advanced controller following the completion of the sec
72. l 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 prevent 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 1 0 must match the size of the wire bundle as closely as possible A CAUTION 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 SAS 60 Sensors YAS 60 or YAS 70X Sensor Wiring If it is necessary to replace the wiring that connects the 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 45 ABS Component Connector Wire Terminal ire Seal ermina Terminal Crimp Tool Plug Lock In Cab Controller SP Harness DN ni 17 Way AMP bh MCP 2 8 X1 i KEE 967634 X1 12 4 18 In Cab Controller Harness au tt 18 Way AMP eiii 2 8 2 T In Cab Controller A 968874 Harness Es 2 5
73. mber or call 1 800 AIR BRAKE and speak to the Bendix Tech Team A WARNING 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 15 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 15 active Optional ATC Mud Snow Off Road Switch and Indicator Lamp Operation see also page 8 Advanced controllers use a dash mounted switch for the operator to place the ECU into the ATC Mud Snow mode Optional Hill Start Feature Switch and Indicator Lamp Operation see also page 8 Advanced controllers use a dash mounted switch for the operator to place the ECU into the Hill Start Assist HSA mode HSA 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 A WARNING with HSA option you lose the ABS off road function and the retarder relay output When the ECU 15 placed in the HSA off road 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 HSA components When engaged the HSA system applies 44 psi to the rear brakes for three 3 seconds then releas
74. n Error For more Pressure Modulator Valve DTCs see SID 93 below 24 Open or Shorted Load Sensor 24 Shorted Brake Demand Sensor Primary CKT Open 24 PS Supply Voltage Error 24 PS Not Calibrated 24 Plausibility Error Brake Demand Sensor 24 Shorted Brake Demand Sensor Secondary CKT Open C2 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 Timeout SAS Invalid Signal SAS Not Calibrated Steering Angle Sensor Calibration Not Finished YRS Sign Check Not Finished 93 802 3 12 8 PMV Common Shorted to Voltage 93 802 4 12 7 PMV Common Shorted to Ground HSA lamp shorted to ground or broken wire HSA lamp shorted to Voltage HSA solenoid shorted to Voltage total shutdown HSA solenoid shorted to Voltage ATC 4 ESP shutdown HSA solenoid shorted to ground or broken wire HSA solenoid shorted to Voltage Lateral Acceleration Sensor DTCs O oO P e LAS Signal Out of Range LAS Static Calibration Error LAS Long Term Calibration Error LAS Plausibility Error Inside ECU Specific Limits LAS Plausibility Error Outside ECU Specific Limits LAS Calibration in Progress Erratic ESP Sensor Signal 93 APPENDIX B J1587 SID and Codes and their Bendix Blink Code Equivalents Bendix Blink Code SID SPN FMI J1587 E
75. n surfaces See Advanced ABS with Stability Control on page 12 for further details A WARNING 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 EC 60 controller s ABS function utilizes the following components e WS 24 wheel speed sensors 4 6 depending on configuration Each sensor is installed with a Bendix Sensor Clamping Sleeve e M 32 or M 32QR Pressure Modulator Valves 4 5 or 6 depending on configuration Dash mounted tractor ABS Indicator Lamp e Service brake relay valve e Dash mounted trailer ABS Indicator Lamp e Optional blink code activation switch Optional ABS off road switch Sensor Clamping e 90 Speed Sleeve UT ie Sensors Straight Speed Sensors FIGURE 2 BENDIX WS 24 WHEEL SPEED SENSORS Delivery Port 2 Supply Electrical Connector E d 3208 Modulator Modulator Exhaust Port 3 FIGURE 3 M 32 AND M 32QR MODULATORS The Bendix EC 60 controller ESP RSP function utilizes the following additional components e Steer Axle Traction Control Valve may be integral to the service brake relay valve or a stand alone device e Dash mounted ESP status indicator lamp also serves as the ATC status indicator lamp e Bend
76. nd AA Right PMV REL Solenoid Shorted to Voltage LAS Long Term Calibration Error LAS Static Calibration Error LAS Plausibility Error Inside Model Based Limits LAS Plausibility Error Outside Model Based Limits AA Right PMV Configuration Error Log on and Learn from the Best On line training that s available when you are 24 7 365 Visit www brake school com SD 13 4869 US 003 02013 Bendix Commercial Vehicle Systems LLC All Rights Reserved 6 13 60 Troubleshooting Connectors Bendix EC 60 Controller Wire Harness Connector Part Numbers and Pin Assignments ADVANCED CAB CONNECTOR CONNECTOR CONNECTOR CONNECTOR Advanced Cab Bendix EC 60 Controller Advanced cab models utilize four AMP connectors for wire harness connections X1 Connector Pin X2 Connector Pin X3 Connector Pin X4 Connector Pin Assignments Assignments Assignments Assignments Designation Designation ABS ORS Pressure Sensor CMN Brake Demand Primary Diff Lock SOL CKT Signal Ignition PMV SA Left CMN CMN SA Load Sensor Signal TCV CMN DA PMV SA Right HLD PMV AA Left HLD Pressure Sensor Supply Brake Demand Secondary TCV DA WSS SA Left TCV SA GE ATG ESF Indicator and ATC piv SA Right CMN PMV AA Left CMN PMV Trailer HLD OR 31939 Low PMV AA Left REL 1939 High Stop Lamp Output SLS Input PMV AA Right CMN WSS DA Right PMV AA Right HLD WSS DA Right WSS AA Left WSS AA Right
77. nd braking system to help the driver prevent the vehicle from rolling downhill when moving up a steep incline from a stationary position 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 question is directed individually into each brake chamber 41587 The SAE heavy duty standard diagnostic data link 41708 An SAE standard which defines the hardware and software protocol for implementing 9600 baud heavy vehicle data links J1587 version of a J1708 data link 41939 A high speed 250 000 baud 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 pressur
78. ne 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 applying 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 It is pressed between an ABS sensor and mounting hole to hold the sensor in place Stored Diagnostic Trouble Codes A diagnostic trouble code that occurred TCS Traction Control System another name for ATC or ASR
79. ogram 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 HSA Hill Start Assist HSA 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 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 question is directed individually into each brake chamber 41587 The SAE heavy duty standard diagnostic data link 41708 An SAE standard which defines the hardware and software protocol for implementing 9600 baud heavy vehicle data links J1587 version of a J1708 data link 41939 A high speed 250 000 baud 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 Li
80. ond 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 Ifthe trailer PMV circuit is mis wired including the steer axle TCV the PMV will exhaust a large amount of air or none at all NOTICE If there are any active Diagnostic Trouble Codes the stop lamp cross check portion of the chuff test will not be carried out until all DTCs are fully diagnosed and corresponding repairs are successfully conducted The ESP ATC dash indicator will also be illuminated 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 EC 60 controller monitors individual wheel turning 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 EC 60 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 t
81. oved 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 3 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 4 Ifthe 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 or a dryer reservoir module be sure to drain the purge reservoir 5 Following the vehicle manufacturer s recom mended procedures deactivate the electrical system in a manner that safely removes all electrical power from the vehicle A CAUTION Even with ESP equipped vehicles the driver remains responsible for ensuring vehicle stability during operation The ESP system can only function within the limits of physics ESP functionality mitigates 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 or poor road conditions can cause vehicle ins
82. p illuminated the Bendix EC 60 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 Diagnostic Trouble Code ABS on the affected wheel is disabled ABS and ATC on all other wheels remains active ESP 15 disabled Drive Axle Additional Axle ABS Modulator Diagnostic Trouble Code ATC 15 disabled ABS on the affected wheel 15 disabled ABS on all other wheels remains active ESP 15 disabled Steer Axle Wheel Speed Sensor Diagnostic Trouble Code The wheel with the diagnostic trouble code 15 still controlled by using input from the remaining wheel speed sensor on the steer axle ABS remains active on the rear wheels ATC and ESP are disabled Drive Axle Additional Axle Wheel Speed Sensor Diagnostic Trouble Code ATC and ESP 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 Diagnostic Trouble Code ATC and ESP are disabled ABS remains active J1939 Communication Diagnostic Trouble Code ATC and ESP are disabled ABS remains active ECU Diagnostic Trouble Code ABS ATC and ESP are disabled The system reverts to normal braking Voltage Diagnostic Trouble Code While voltage is out of range ABS ATC and ESP are
83. peed Sensors Wheel speed data is provided to the Bendix EC 60 controller from the WS 24 wheel speed sensor see Figure 2 Vehicles have an exciter ring or tone ring as part of the wheel assembly and as the wheel turns the teeth of the exciter ring pass the wheel speed sensor generating an AC signal The Bendix EC 60 controller receives the AC signal which varies in voltage and frequency as the wheel speed changes Vehicle axle configurations determine the number of 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 Advanced Bendix EC 60 controllers use an optional dash mounted switch for the operator to place the ECU into the ABS off road mode See Optional ABS Off Road 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 EC 60 controller If you need to know if this Bendix EC 60 controller uses a J1939 message to operate the lamp e mail ABSO bendix com specifying the ECU part nu
84. ple 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 12 YAW CONTROL EXAMPLE Roll Stability Program Bendix RSP an element of the overall ESP system 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 11 Yaw Stability Yaw stability counteracts the tendency of a vehicle to 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 stabili
85. quivalent s Diagnostic Trouble Code Description J1587 41939 14939 4st Digit 2nd Digit Miscellaneous DTCs HSA Solenoid Shorted to Voltage high HSA Solenoid Shorted to Ground Low or Open circuit Sensor CAN Supply Voltage Error ESP Sensor Voltage Out of Range YRS Signal Out of Range YRS Sensor Reversed Signal YRS Invalid Signal YRS Gradient Error YRS Static BITE Error YRS Dynamic BITE Error YRS Fast Calibration Error YRS Static Calibration Error YRS Normal Calibration Error YRS Sensitivity Calibration Error YRS Plausibility Check Ref Yaw Rate YRS Plausibility Error Inside ECU Specific Limits YRS Plausibility Error Outside ECU Specific Limits Yaw Rate Sensor Vibration Detected YRS CAN Timeout 151 611 wheel speed sensor failure in previous power on cycle 154 614 i o 2 3 Shorted to Voltage J1939 Engine Communications J1939 Invalid Data Engine Retarder J1939 Supply Pressure J1939 ESP Messages Invalid Data Timeout or invalid data on ETC7 VP15 for HSA function ONMNNMNN NIN NNNDNNNNNN timeout or invalid data on XBR Invalid Data From Transmisson 1939 HSA switch error or unavailable timeout or invalid data for ESP AWD operation 1939 Serial Link 1939 Retarder Input Voltage Excessive Noise Temp Battery Voltage Too High Ignition Voltage Too High Battery Voltage Too Low Battery Voltage Too Low During ABS Ignition Voltage Too Low Ignition Voltage Too Low During
86. rom the ECU Using X1 1 as the ground connection check for resistance for the entire X2 connector There should be no resistance to ground found Please fill out attached worksheet Using X1 1 as the ground connection check for resistance for X1 4 and X1 5 There should be no resistance to ground Using X1 1 as the ground connection check for resistance for 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 is not configured for 6S 6M Using X1 1 as the ground connection check for resistance for X4 6 X4 9 and 4 12 There should be no resistance to ground Troubleshoot any pin that has resistance to ground If no issues are found continue to step 7 Reconnect X1 connector only and apply IGN power to the ECU and using the DTC screen of Bendix ACom Diagnostics clear all DTCs Re check for any DTCs Ifthe 12 7 DTC is still present the problem is the Traction Solenoid Wiring or Solenoid If the 12 7 DTC does not reappear remove power and connect X2 connector reapply power then clear all DTCs Ifthe 12 7 DTC is no longer present connect the X3 connector and clear all DTCs If at this point the 12 7 DTC is not present the problem 15 with the X4 connector For Peterbilt 8 Kenworth Trucks Only 10 11 50 Clear all DTCs If the 12 7 DTC reappears the issue is on the X4 connector Otherwise proceed to the next step Disconnect all mod
87. rts 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 from the ECU from either the Diagnostic Switch or from a hand held diagnostic tool only repaired diagnostic trouble codes may be cleared Configuration The primary objective is to identify 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 J1587 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 Pr
88. tability that is beyond the capability of any stability system to mitigate In addition the effectiveness of ESP can be greatly reduced on vehicles towing multiple trailer combinations 6 Never exceed manufacturer s recommended pressures 7 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 8 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 9 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 10 Prior to returning the vehicle to service make certain all components and systems are restored to their proper operating condition 11 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 CAUTION The ESP stability system may only be used on vehicles tested and approved by Bendix engineering ESP installations require on vehicle testing and Bendix
89. tion the Smart ATC traction control allows higher wheel slip when the accelerator pedal is applied above a preset level The wheel slip allowed by Smart ATC is decreased when driving through a curve for improved stability Disabling ATC Engine Control and Smart ATC Traction Control ATC Engine Control and Smart ATC traction control 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 Ifthe dynamometer test mode is active This may be accomplished via an off board tool or the diagnostic blink code switch o When certain diagnostic trouble code conditions are detected 11 Optional ATC Mud Snow Off Road Mode In some road conditions the vehicle operator may desire additional drive wheel slip when ATC is active The Advanced Bendix EC 60 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 exit the ATC Mud Snow mode depress and release the ATC Mud Snow switch ADVANCED ABS WITH S
90. tions This can lead to a loss of control of the vehicle In addition remove all cab signage e g visor labels etc used to show that Bendix ESP was installed and 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 using OEM brackets 4 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 A WARNING 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 14 DYNAMOMETER TEST MODE A CAUTION ATC and ESP must be disabled prior to conducting any dynamometer testing When the Dynamometer Test Mode is engaged ATC brake control and engine control along with drag torque control and ESP are turned off This test mode is used to avoid torque reduction or torque increase and brake
91. ty 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 applies the outside front brake while in an under steer condition the inside rear brake is applied See Figure 12 IMPORTANT SAFETY INFORMATION ABOUT THE BENDIX ESP STABILITY SYSTEM ESP May Reduce The Vehicle Speed Automatically ESP can make the vehicle decelerate automatically ESP can slow the vehicle with or without the operator applying the brake and even when the throttle is being applied A CAUTION 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 e Always operate the vehicle safely drive defensively
92. ud Snow Switch Input Advanced ECUs control the ATC ESP dash lamp as follows The ATC ESP dash lamp illuminates 1 During power up e g when the vehicle 15 started for approximately 2 5 seconds and turns off after the self testis completed providing no diagnostic trouble codes are present 2 When ESP or ATC 15 disabled for any reason During an ESP or ATC event the lamp will flash rapidly ata rate of 2 5 times per second 4 When the ECU 15 placed in the ATC off road mode the lamp will flash steadily at a rate of once per 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 illuminated 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 which 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 Disabling ATC Differential Braking ATC differential braking is disabled under the following conditions 1 During power up e
93. ulators and the traction solenoid Clear all DTCs If the DTC does not reappear connect 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 connected Disconnect the ABS bulkhead connector at the engine top left side and remove Pins 1 2 11 amp 12 Reconnect the connector and apply IGN power to the ECU Using Bendix ACom Diagnostics clear all DTCs If the 12 7 DTC returns the problem is either the wiring harness inside the cab or the ECU Record Resistances Below X1 1 for ground point xs a 02 xs pea es xe er EAT xeu xa I xx peas bear we x hes xer ee rae 5 amp 3 xs I xe xs xa APPENDIX B J1587 SID and Codes and their Bendix Blink Code Equivalents FMI Bendix Blink Code J1587 Equivalent s Diagnostic Trouble Code Description J1939 1st Digit 2nd Digit 1 1 No DTCs 1 789 1 2 1 SA Left WSS Excessive Air Gap 1 789 2 2 3 SA Left WSS Open or Shorted 1 789 7 2 5 SA Left WSS Wheel End 1 789 8 2 6 SA Left WSS Erratic Sensor Signal 1 789 10 2 4 SA Left WSS Loss of Sensor Signal 1 789 13 2 7 SA Left WSS Tire Size Calibration
94. uvering 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 Gusty winds are strong enough to cause significant side forces on the vehicle and any towed vehicles To Maximize The Effectiveness Of ESP Loads must be properly secured at all times Drivers need to exercise extreme caution at all times and avoid sharp turns sudden steering inputs or abrupt lane changes at high speeds particularly if the vehicle hauls loads that could shift the vehicle or load has a high or off set center of gravity CG when loaded or the vehicle tows doubles or triples 13 Truck Chassis Modifications Ifthe 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 Advanced EC 60 ECU with a Premium EC 60 ECU 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 A WARNING If a modified vehicle does not have the ESP system disabled serious vehicle braking and performance issues could result including unnecessary ESP system interven
95. vehicle Acceptable Tire Sizes The speed calculation for an exciter ring with 100 teeth 15 based on a default tire size of 510 revolutions per mile This figure 15 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 Fora 100 tooth exciter ring the minimum number of tire revolutions per mile is 426 and the maximum is 567 The ECU will set diagnostic trouble codes 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 diagnostic trouble codes 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 ESP system effectiveness relies on the accuracy of vehicle speed If a major change on the tire sizes occurs such that the odometer setting needs to be changed the Advanced ABS controller s setting of tire sizes must be reprogrammed to new values at the same time by a certified mechanic SYSTEM IMPACT DURING ACTIVE TROUBLE CODES ABS PARTIAL SHUTDOWN Depending on which component the trouble code 15 detected the ABS ATC and ESP functions may be fully or partially disabled Even with the ABS indicator lam

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