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BENDIX BW2261 User's Manual

1. Ser sds A NO camane pal ARR ns mn a 41939 J1922 31838 J1822 Gend 1839 ShieldiGen 5 TIL Light Brake Light Input is for indicator Lamp Pressure Modulator Valve FIGURE 47 Gen 4 and Gen 5 Standard Frame Mount ABS Electrical Schematic 46 Glossary ABS Antilock Brake System ABS Event Impending wheel lock situation that causes the ABS controller to activate the modulator valve s Air Gap Distance between the Sensor and tone ring Anti Compounding Valve Prevents the application of the service and spring brakes at the same time Depending on vehicle design the anti compounding valve may be installed in combination with a relay valve or quick release valve Apply Timing The time from the movement of the service brake control for each brake chamber to reach 60 psi with an initial service reservoir pressure of 100 PSI 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 Light A light that indicates when traction control is operating Channel A controlled wheel site CAN Controller Area Network J1939 is an SAE version of the CAN link Clear Codes System to erase histo
2. Flashes Location 10 or 11 PMV Commons Flashes Condition Action 9 Stray voltage has been found on the Unplug ECU and check for voltage on the PMV common pins If voltage is found common line of one or more repair harness If no problem is found in harness replace ECU Note Before of the valves replacing ECU clear trouble codes and verify that trouble code is still present Refer to Schematic short to supply voltage has been Unplug ECU and check for short to 12 volts on PMV common pins If any are found on the common line of one or shorted to supply repair harness If no short is found in harness replace ECU more of the valves Note Before replacing ECU clear trouble codes and verify that trouble code is still present Refer to Schematic A short to ground has been found on Unplug ECU and check for short to ground on PMV common pins If any are the common line of one or more of shorted to ground repair harness If no short is found in harness replace ECU the valves Note Before replacing ECU clear trouble codes and verify that trouble code is Still present Refer to Schematic FIGURE 32 PMV Diagnostic Trouble Code Troubleshooting Guide 32 ABS Modulator Valve Installation 1 Install the valve Torque fasteners to manufacturers specification 2 Connect air lines Supply to port 1 on valve e Service brake chamber to delivery port 2 Removal 1 Turn ignition switch to th
3. 7 ABS Valves 9 Modulator Valve Operation Modes 10 Optional Front Axle Modules 11 Diagnostics 13 Troubleshooting Procedures 13 System Configurations 15 ServiceRanger PC Software 16 Test Equipment 16 Reading Configuration Codes 18 Retrieving Diagnostic Trouble Codes 18 Clearing Diagnostic Trouble Codes and or System Configuration 20 Disabling ATC for Dyno Testing 20 Speed Sensor Troubleshooting 25 The 17 12 Sensor Memory Diagnostic Trouble Code 26 Wheel End Speed Sensor Repair Pressure Modulator Valve PMV Troubleshooting 30 ABS Modulator Valve 33 Automatic Traction Control ATC Valve Troubleshooting 34 Performance Test of the Relay Valve 34 ATC Valve Removal 36 Cab Mount ECU Pin Identification 39 Frame Mount ECU Pin Identification 43 Eaton RoadRanger and ServiceRanger are registered trademarks of Eaton Corporation 1 ANTILOCK BRAKING SYSTEM ABS ABS controlled braking ensures optimum vehicle stability while minimizing the stopping distance During vehicle operation the ABS Electronic Control Unit EC
4. Brake light switch not pushed at this power cycle ATC system is disabled for dynamometer test Warning light short low or open Sensor memory bit is set Use multimeter to verify proper voltage at the retarder control relay Use multimeter to verify proper voltage at the retarder control relay Unplug connector at ECU There should be a voltage between 0 and 2 5 volts on 1939 1922 and a voltage between 2 5 and 5 0 volts on J 1939 1922 Refer to schematic and correct wiring harness as required Unplug connector at ECU There should be a voltage between 0 and 2 5 volts on 1939 1922 and a voltage between 2 5 and 5 0 volts on J 1939 1922 Refer to schematic and correct wiring harness as required There is too great a difference in the rolling radius of the front and rear tires Steer axle tire radius cannot be more than 20 above rears or 10 below If the static loaded radius of the rear tires is outside the range 15 9 to 21 5 inches the ECU must be recalibrated using a diagnostic tool There is too great a difference in the rolling radius of the front and rear tires Steer axle tire radius cannot be more than 20 above rears or 10 below If the static loaded radius of the rear tires is outside the range 15 9 to 21 5 inches the ECU must be recalibrated using a diagnostic tool Press brake pedal If error does not clear check for missing connection at brake light switch If the brake is not applied you sh
5. b Speed Sensor Speed Sensor Speed Sensor Speed Sensor Speed Sensor Speed Sensor Speed Sensor Speed Sensor Left Rear Left Rear Right Rear Right Rear Left Rear R ear Left Rear Rear Right Rear Rear Right Rear Rear Not Used On Basic System Speed Sensor Resistance Test The correct resistance for the speed sensor circuit is between 950 ohms and 1900 ohms Measure resistance at the wheel location to check the speed sensor Measure resistance at the appropriate ECU harness connector pins to check the cable and speed sensor Note Refer to the chart for pin identification X3 Green Speed Sensor Speed Sensor Speed Sensor Speed Sensor t t Left Rear Left Rear Right Rear Right Rear X4 Brown 6 channel Only a W e w ejo Cc Not Used On Basic System Speed Sensor Speed Sensor Speed Sensor Speed Sensor FIGURE 24 Wheel Speed Sensor Harness Circuit Descriptions and Resistance Test Left Rear Rear Left Rear Rear Right Rear Rear Right Rear Rear The 17 12 Sensor Memory Diagnostic Trouble Code The ABS indicator lamp indication and 17 12 diagnostic trouble code are provided to remind the service technician of the need to verify the performance of the ABS wheel speed sensors by driving the vehicle after servicing the sensors ABS wheel speed se
6. System INFO Trouble codes Monitor Data Component Test System Set up ATC Disable English Metric Exit 5 System Setup 6 ATC Disable 7 English Metric 8 Exit For Dyno Test System Config 17 Diagnostic Switch Blink Codes System Configuration and System Faults By properly actuating the ABS diagnostic button configuration codes and diagnostic trouble codes can be retrieved as blinked sequences on the ABS indicator lamp Configuration codes are sequences of four blinked digits while diagnostic trouble codes appear as two blinked numbers Refer to the charts beginning on page 19 for a description of these codes To perform any ofthe activities listed below simply follow the steps as given If you make a mistake during one of the steps stop and start over at the beginning of the procedure All blink codes are displayed by the ABS indicator lamp only The ATC lamp does not display blink codes Note Before attempting any repairs 1 Retrieve the configuration codes and diagnostic trouble codes write them down 2 Reconfigure the ECU if the configuration does not agree with the installed hardware The ECU cannot be configured downward components removed with the diagnostic button For example a 6S 4M cannot be configured to 4S 4M Downward configurations require the use of a ProLink tool or ServiceRanger software 3 Ifthe configuration is correct clear the diagnostic trouble codes The process for clearing the
7. Follow all standard safety procedures outlined by but not limited to the General Precautions listed on page 13 of this document 1 Park vehicle on level surface and block wheels 2 Release parking brake and fully charge the air system governor cut out point 3 Turn the engine OFF Apply the service brake several times then hold and check for prompt brake air chamber application and release at all wheels 4 Apply brake then hold Coat outside of relay valve where cover joins body and connection between modulator valve and relay valve with a soap solution No leakage is permitted 5 Ifa sluggish response is noted at all wheels inspect for kinked or obstructed air line leading to or from valve 6 Increase system air pressure to governor cutoff With the brakes released coat exhaust port of relay valve with a soap solution Leakage of a 1 bubble in 5 seconds is permissible 7 Depress foot valve and keep depressed Coat exhaust port with a soap solution Leakage of a 1 bubble in 3 seconds is permissible 34 Automatic Traction Control ATC Valve Troubleshooting The following ATC troubleshooting pages provide the basic information necessary to identify the diagnostic trouble code locate the problem review the possible cause s select the correct solution and utilize proper repair procedures Follow the steps listed below to locate and correct ATC problems 1 Access active diagnostic trouble code s
8. Rear Rear Speed Sensor 7 Right Rear Rear PMV6 Right Rear Rear Rel Solenoid PMV6 Right Rear Rear Hold Solenoid PMV6 Right Rear Rear Common igniton Looking into D uw mwootetuN Right Rear Dag rios bc Swatch momenmary Contact 2 3 4 5 7 a DAD B e indicator Lamp intertock NC Pressure Modulator Valve FIGURE 42 Gen 4 and Gen 5 Basic Cab Mount ABS Electrical Schematic 41 Looking into Harness channe 4 2 3 5 T 8 9 Left Front PMY m Front Left Front Sensor 41939 1002 Gan 4 J1939 ShieidiGen 5 TIL 11922 couch U hah Troller indicator Lamp Pressure Modulator Valve FIGURE 43 Gen 4 and Gen 5 Standard Cab Mount ABS Electrical Schematic 42 Frame Mount ECU Pin Identification This section shows how to identify Frame Mount ECU harness connectors and pin locations The charts provide a brief description of the signal carried by each pin X2 Black X3 Green X4 Brown FIGURE 44 Cab Mount ECU Pin Identification Chart 43 X1 Grey X3 Green Signal Description IGN Ignition 1 IGN Ignition 2 ATCL ATC Light ATC Switch 1587 J1587 RET Retarder Control ENG J1922 1939 Engine Control Link ENG J1922 1939 Engine Control link SHLD TIL Gen 4 ABS J1939 Shiel
9. RightSteer 13 PMV6 Right Rear Rear PMV3 LeftRear 9 Condition Action There is a short between the se multimeter to check that valve resistances are correct 1 5 Sec release solenoid and supply voltage f valve is OK check harness for short in wiring Pause The is a short between the release Use multimeter to check that valve resistances are correct solenoid and ground f valve is OK check harness for short in wiring There is an open circuit at the Use multimeter to check that valve resistances are correct release solenoid f valve is OK check harness for open in wiring 2nd MEE There is an open circuit in the Use multimeter to check that valve resistances are correct common line to the valve f valve is OK check harness for open in wiring There is a short between the hold solenoid and supply voltage Use multimeter to check that valve resistances are correct f valve is OK check harness for short in wiring The is a short between the hold solenoid and ground Use multimeter to check that valve resistances are correct f valve is OK check harness for short in wiring There is an open circuit at the hold solenoid Use multimeter to check that valve resistances are correct f valve is OK check harness for open in wiring A valve has been found wired in the wrong location Check the control unit configuration and verify that valves are wired in the proper location for the configuration Refer to Schematic
10. Sensor shorted low or high or sensor open 001 012 Internal error at the sensor port of the ECU 001 002 Sensor in the wrong location for the system configuration 002 000 Sensor air gap too large Right Steer Sensor 002 008 Air gap too large or sensor shorted 002 010 Speed Sensor signal is noisy 002 008 Wheel locked too long during an ABS cycle 002 008 High deceleration rate at wheel site or sensor shorted 002 012 Sensor shorted low or high or sensor open 002 012 Internal error at the sensor port of the ECU 002 002 Sensor in the wrong location for the system configuration 003 000 Sensor air gap too large Left Rear Sensor 003 008 Air gap too large or sensor shorted 003 010 Speed Sensor signal is noisy 003 008 Wheel locked too long during an ABS cycle 003 008 High deceleration rate at wheel site or sensor shorted 003 012 Sensor shorted low or high or sensor open 003 012 Internal error at the sensor port of the ECU 003 002 Sensor in the wrong location for the system configuration 004 000 Sensor air gap too large Right Rear Sensor 004 008 Air gap too large or sensor shorted 004 010 Speed Sensor signal is noisy 004 008 Wheel locked for too long during an ABS cycle 004 008 High deceleration rate at a wheel site or sensor shorted 004 012
11. Sequence Flashes Location 14 ATC Valve Flashes Condition Response 1 5 Second Solenoid in ATC valve shorted high Use multimeter to check that valve resistances are correct fig 34 Pause valve is OK check harness for open in wiring Solenoid in ATC valve shorted to se multimeter to check that valve resistances are correct fig 34 2nd ground valve is OK check harness for open in wiring ATC valve open circuit Use multimeter to check that valve resistances are correct fig 34 valve is OK check harness for open in wiring ATC valve found when it should not Verify proper system configuration and components Clear faults be present error cannot be cleared or recurs replace ECU FIGURE 36 ATC Diagnostic Trouble Code Troubleshooting Guide 35 ATC Valve Removal CAUTION Block wheels before beginning this procedure Follow all standard safety procedures outlined by but not limited to the General Precautions listed on page 13 of this document 1 Disconnect the wiring connector from the ATC valve 2 Disconnect the air lines from the supply port 1 and delivery port port 2 and treadle port 3 of the ATC valve 3 Disconnect the valve mounting fasteners and remove the valve Installation 1 Install the ATC valve Torque fasteners to manufacturers Specification 2 Connect Air lines supply port 1 delivery port port 2 and treadle port 3 of the ATC valve Blink Cod
12. Smart The difference in pressure between the left and right brake chamber does not exceed a certain amount This leads to the wheel which is running at the high friction coefficient being braked less strongly Sensor Bushing A bushing which is pressed into steer axles to hold a wheel speed sensor and friction sleeve Stored Faults A Fault 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 47 48 BW2261 2006 Bendix Commercial Vehicle Systems LLC All rights reserved 5 2006 Printed in U S A
13. V 2 Common Right Steer V 2 Release Right Steer V 2 Hold Right Steer V 2 Common Right Steer 1 2 3 7 8 9 1 2 3 V 3 Release Left Rear V 3 Hold Left Rear V 3 Common Left Rear X3 Green 10 12 11 V 3 Release Left Rear V 3 Hold Left Rear V 3Common LeftRear e me e V 4 Release Right Rear V 4 Hold Right Rear V 4 Common Right Rear X3 Green 7 9 8 V 4 Release Right Rear V 4 Hold RightRear V 4 Common Right Rear E 12 Way 6 channel Only 3 V 5 Release Left Rear Rear V 5 Hold Left Rear Rear V 5 Common Left Rear Rear X4 Brown 6 channel Only 10 12 11 V 5 Release Left Rear Rear V 5 Hold Left Rear Rear V 5 Common Left Rear Rear E 12 Way 6 channel Only 10 ll 12 lt o o o o V 6 Release Right Rear Rear V 6 Hold Right Rear Rear V 6 Common Right Rear Rear X4 Brown 6 channel Only 7 9 8 o T o u co V 6 Release Right Rear Rear V 6 Hold RightRear Rear V 6 Common Right Rear Rear Not Used On Basic System Not Used On Basic System FIGURE 31 PMV Harness Circuit Descriptions and Resistance Test 31 Blink Code Sequence Location Flashes Location 11 PMV4 Right Rear PMV 1 LeftSteer ist gt 12 PMVS LeftRearRear PMV2
14. supply tank air to the Modulator Valves on the drive axle s The Electronic Control Unit then activates the appropriate solenoids in order to apply a brake force to the spinning wheel The Automatic Traction Control System cannot increase traction to a particular wheel it can only utilize the available traction Thermal Brake Heat Protection To prevent excessive brake and drum temperature resulting from brake activity ATC incorporates a brake temperature estimation algorithm to determine when differential braking mode should be suspended The differential braking function is re enabled after a cool down period ATC Indicator Lamp The ATC indicator lamp operates when a vehicle is equipped with the optional Automatic Traction System e Gen 4 ABS Lights at key ON and remains lit with inactive until the driver presses the brake pedal e 5 ABS Lights at key ON and turns off after a 2 second lamp check ATC is active after the lamp check Flashes rapidly to indicate that is active Flashes slowly when the mud and snow mode is selected and then flashes more rapidly when the automatic traction control system operates Remains ON if an engine data link failure occurs NOTE Some non ATC equipped vehicles have an ATC lamp that is labeled as a spin light It indicates when a low traction condition has been encountered No control action is taken ETARDER ATC BS FIFTH WAL AIR SUSP A
15. the vehicle has been driven and held above 20 mph for 3 5 minutes For more detailed troubleshooting monitor the wheel speeds and cut out speeds with ServiceRanger or a ProLink hand held diagnostic tool Troubleshoot and repair any speed sensor not reporting a wheel speed or showing a high cut out speed Cut out speeds are an indication of the strength of the sensor signal to the ECU and are proportional to air gap Cut out speeds should be in the range of 3 8 mph Lower numbers indicate a stronger and better signal than higher numbers High values indicate a sensor with an unreliable or non existent signal Blink Code Sequence Flashes Location LeftSteer Right Steer Left Rear Right Rear Left Rear Rear Right Rear Rear o 0 5 Condition Action Sensor air gap too large Air gap too large or sensor shorted Speed sensor signal is noisy Wheel locked for excessive Excessive rate of deceleration found ata wheel site Sensor connection shorted low or high or sensor is open There is an internal error atthe sensor port ofthe ECU A sensor has been found in the wrong location period of time during an ABS cycle If necessary clean and lubricate sensor Press into mounting hole until it bottoms against tone wheel Cleartrouble code and verify that code is corrected by test driving the vehicle The indicator lamp will remain on until proper sensor output is detected even though the co
16. 5 Excessive voltage on PMV Power Low voltage on PMV Power Vo voltage found on PMV Power Open circuit on PMV Ground Excessive voltage found on ECU Power Low voltage found on ECU Power Voltage difference between PMV Power inputs is too high Verify that vehicle system voltage is OK i e 9 to 16 volts If voltage is out of range correct system problem Unplug connector at ECU and turn on ignition switch If the voltage on PMV Power is different than system voltage repair wiring Clear trouble codes and verify that the indicator lamp turns out after bulb check Verify that vehicle system voltage is OK i e 9 to 16 volts If voltage is out of range correct system problem Unplug connector at ECU and turn on ignition Switch If the voltage on PMV Power is different than system voltage repair wiring Clear trouble codes and verify that the indicator lamp turns out after bulb check Verify that vehicle system voltage is OK i e 9 to 16 volts If voltage is out of range correct system problem Unplug connector at ECU and turn on ignition Switch If the voltage on PMV Power is different than system voltage repair wiring Clear trouble codes and verify that the indicator lamp turns out after bulb check Unplug connector at ECU and check for continuity to ground on PMV Ground If continuity to ground is not present repair harness Verify that vehicle system voltage is OK i e 9 to 16 volts If voltage is ou
17. BS UNLOCKED DEFLATED TRAILER FIGURE 4 ATC Indicator Lamp Component Overview Bendix ABS components include Electronic Control Unit ECU The ECU monitors and controls the ABS It also diagnoses ABS malfunctions and stores specific diagnostic trouble codes Pressure Modulator Valve PMV This component regulates brake chamber air pressure It houses the hold and release solenoids A modulator valve is located near each brake chamber or pair of brake chambers that make up an ABS controlled wheel site Rear Axle Valve Assembly An assembly made up of two pressure modulator valves and a relay valve Wheel End Speed Sensor Single point variable reluctance magnetic sensor that generates an alternating voltage signal in response to the movement of teeth on a tone wheel ABS Lamp Yellow This indicator lamp located on the driver instrument panel warns the driver of ABS malfunctions It is also capable of blinking diagnostic fault codes when the ECU is in the self diagnostic mode In Cab ABS Trailer Lamp This indicator lamp located on the driver instrument panel warns the driver of trailer ABS malfunctions lt is not capable of blinking diagnostic trouble codes ATC Valve The traction control valve applies full system pressure to the relay valve during traction control operation to provide differential side to side braking at controlled drive axles ATC Lamp This indicator lamp located on the driver instr
18. CU must read wheel speeds on all wheels to clear this trouble code Speed Sensor Troubleshooting Follow the steps listed below to locate and correct sensor related ABS trouble codes Wheel Speed Sensor 1 Access active trouble code s using either the Blink Harness Code procedure with ServiceRanger or the Hand held Connector Tester procedure 2 Lookup the code description the possible causes and the repair procedures provided in this section Wheel 3 Perform the recommended repair procedures Speed Sensor 4 After the repairs are completed clear all codes and 1 of 4 or 6 check for any additional codes 5 sensor related trouble code has occurred a code 17 12 will remain in the system until the vehicle has been driven TOP Looking into harness connector 10 7 4 rrr 17 14 11 8 18 12 9 ex 5 E FIGURE 23 Typical Wheel Speed Sensor Circuit Eoooooo X3 Green X4 Brown Harness Connector PIN Circuit Description Harness Connector Circuit Description B 6 Way Speed Sensor Speed Sensor t Left Steer Left Steer C 9 Way Speed Sensor Speed Sensor Right Steer Right Steer X2 Black Speed Sensor Speed Sensor Speed Sensor Speed Sensor t t Right Steer Right Steer Left Steer Left Steer D 15 Way E 12 Way 6 channel Only c clc
19. Cab Mounted Models GEN 4 AND GEN 5 ABS INTRODUCTION This manual describes both the cab mount and the frame mount versions of the Bendix Gen 4 and Gen 5 Antilock Brake System Automatic Traction Control ABS ATC systems Both cab and frame mount versions are designed for Tractors Trucks Buses and Motor Coaches and RVs This manual covers ABS ATC Operation e System Components e Service Procedures Diagnosis and Troubleshooting Procedures For information on disassembly installation and service of related axle and brake components refer to their individual Bendix Service Manuals For assistance in your area call Bendix at 1 800 247 2725 or RoadRanger at 1 800 826 4357 These ABS controllers and systems were originally marketed by Eaton Corporation under the Eaton brand name For more information contact Bendix your local authorized Bendix dealer or RoadRanger Document Revision Level This document is subject to revision For updates please visit www bendix com Frame Mounted Model FIGURE 1 Bendix ABS Controller Assemblies Table of Contents ABS Operation 2 ABS Component Function 3 ABS Indicator Lamp 3 ABS Trailer Indicator Lamp 3 Automatic Traction Control ATC System 4 Component Overview 5 Electronic Control Units ECUs
20. Sensor shorted low or high or sensor open 004 012 Internal error at the sensor port of the ECU 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 4 4 4 4 4 4 4 4 5 5 5 5 5 5 5 5 004 002 Sensor in the wrong location for the system configuration 21 Blink Codes 1st 2nd MID 136 SID FMI 005 000 Description Sensor air gap too large Location Left Rear Sensor 005 008 Air gap too large or sensor shorted 005 010 Speed Sensor signal is noisy 005 008 Wheel locked for too long during an ABS cycle 005 008 High deceleration rate at wheel site or sensor shorted Left Rear Sensor 005 012 Sensor shorted low or high or sensor open continued 005 012 Internal error at the sensor port of the ECU 005 002 Sensor in the wrong location for the system configuration 006 000 Sensor air gap too large Right Rear Sensor 006 008 Air gap too large or sensor shorted 006 010 Speed Sensor signal is noisy 006 008 Wheel locked too long during an ABS cycle 006 008 High deceleration rate at wheel site or sensor shorted 006 012 Sensor shorted low or high or sensor open 006 012 Internal error at the sensor port of the ECU 006 002 Sensor in the wrong location for the system configuration 007 003 Short circuit from the release solenoid to voltage Left Ste
21. U continuously monitors all wheel speed sensors Data input from the wheel speed sensors allows the ECU to Detect impending wheel lock Maintain optimum wheel slip during braking Maximize vehicle stability while maintaining braking effectiveness ABS Operation The ABS controls braking by operating the Pressure Modulator Valves The ECU makes a new assessment of conditions and updates the control signal to the pressure modulator valves at the rate of 100 times per second Speed sensors monitor wheel rotation Braking force remains at optimum level N Hold and release solenoids control air pressure in the brake chambers When inactive the pressure modulator valves provide straight through passages for supply air to the brake chambers During ABS operation ABS event the control unit operates the valves to override the supply of air to the chambers During an ABS release supply air is held off while the chambers are vented to the atmosphere In hold mode supply air is held off and chamber air is held constant When required air is applied to the chamber at a controlled rate by modulating the hold side of the modulator valve The ABS system itself does not apply additional braking power Rather the purpose of ABS is to limit brake torque to prevent locking that results in loss of lateral stability and increased stopping distances Cautious driving practices such as maintaining adequat
22. arder Control FIGURE 19 ServiceRanger Menus amp Hardware Setup 16 4 Product Downloads Read ECU Configuration Configure ECU Disable ATC Hand Held Tester An MPSI ProLink hand held tester with Bendix proprietary cartridge can be used to read and clear error codes and obtain a short description of failures The tester can initiate test sequences for controller outputs and can also read system data such as voltage at the ECU wheels speeds and cutout speeds A standard heavy duty truck cartridge may also be used but cannot initiate test sequences Deutsch HD 10 Connector MPSI Pro Linke Bendix Applications Card 3 Monitor Data Wheel Speeds Cut out Speeds System Volts Input S witches 1 System INFO Part No Date Serial No Software No System Configuration ABS ATC Steer Wheel Size Rear Wheel Size Rear Rear Wheel Size MIC Parameter 2 Trouble Codes Actual Trouble Codes Extended Trouble Codes Clear Memory FIGURE 20 Hand Held Tester Menus and Sei Up 4 Component Test Valve Routines Interface 1 2 3 4 5 6 7 8 CAUTION The ProLink hand held tester can activate output tests for all output devices Since these tests can affect operation of the vehicle braking system the ECU incorporates special safety protection One axle must show zero speed or the test will be halted 10 Diagnostic Connector Diagnostic and Power Cable Eaton ABS Press Enter
23. cations depending on OEM preferences They are combinations of two modulator valves and a relay valve The assemblies are available in 4 0 and 5 5 PSIG versions with or without an integral ATC solenoid Standard Version 1 2 NPT Inlet Port 1 2 Delivery Port Twist Lock Exhaust Port Threaded Connector Exhaust Port FIGURE 8 Modulator Valve FIGURE 9 Rear Axle Valve Assemblies 4 Port ABS and ABS ATC Versions Shown Solenoid Hold Diaphragm Tt Release Diaphragm Exhaust FIGURE 10 Normal Apply and ABS ATC Apply Exhaust FIGURE 12 ABS ATC Hold Modulator Valve Operation Modes 1 10 Apply Air flows straight through valve Hold diaphragm is vented to allow air flow Inlet pressure feeds behind release diaphragm to block the exhaust port No solenoids are activated Normal Release With quick release function hold diaphragm is vented and there is no pressure at the inlet port Air is allowed to flow from outletto inlet Since release diaphragm is not pressurized air also flows out the exhaust port No solenoids are activated Inlet Zero 4 Pressure Outlet i Exhaust FIGURE 13 ABS ATC Release 3 ABS ATC Hold The hold solenoid is activated Both diaphragms are pressurized No air flows through the valve ABS ATC Release Both solenoids are activated The hold diaphragm is pressurized blocking the inlet air The release diaphragm is v
24. control as the cycle progresses PLC Power Line Carrier The serial communication protocol used to communicate with the trailer over the blue full time power wire PMV Pressure Modulator Valve An air valve which is used to vent or block air to the brake chambers to limit or reduce brake torque QR Quick Release Quick release Valves allow faster release of air from the brake chamber after a brake application To balance the system quick release valves have hold off springs that produce higher crack pressures when the valves open Relay Valve Increases the application speed of the service brake Installed near brakes with larger air chambers type 24 or 30 The treadle valve activates the relay valve with an air signal The relay valve then connect its supply port to its delivery ports Equal length air hose must connect the delivery ports of the relay valve to the brake chambers Release Timing The measurement in time from initial brake movement to reach 5 psi with 95 psi initial pressure at the brake chambers Retarder Relay A relay which is used to disable a retarder when ABS is triggered Select High A method of ABS control in which the brake torque is released at several wheels when the last wheel begins to lock Select Low The brake pressures level is the same on both wheels of a given axle The pressure level is based on the wheel which is running at the lower friction coefficient Select
25. cted by test driving the vehicle The indicator lamp will remain on until proper sensor output is detected even though the trouble code has been cleared Clear trouble code and test drive the vehicle The indicator lamp will remain on until proper sensor output is detected even though the code has been cleared If trouble code recurs or cannot be cleared replace ECU Check the control unit configuration and verify that sensors are wired in the proper location for the configuration Refer to Schematic FIGURE 25 Speed Sensor Diagnostic Trouble Code Troubleshooting Guide 27 Wheel End Speed Sensor Repair Front Axle Speed Sensor The front axle speed sensor is located on the inboard side of the steering knuckle CAUTION Block wheels before beginning this procedure Follow all standard safety procedures outlined by but not limited to the General Precautions listed on page 13 of this document CAUTION Do not work under a vehicle supported by a jack Removal T 2 Disconnect sensor cable from harness Remove the sensor from the sensor bushing Do not pull on cable Remove the speed sensor friction sleeve from the steer knuckle Friction Sleeve ABS Sensor a Bushing FIGURE 26 Front Speed Sensor Components 28 Installation 1 Install the sensor bushing with the flange stops towards the inboard side of the vehicle Apply high temperature silicon based grease to the body of the speed s
26. cuit at the release solenoid 12 011 005 Open circuit on the common line to the valve 12 011 003 Short circuit from the hold solenoid to voltage 12 011 004 Short circuit from the hold solenoid to ground 12 011 005 Open circuit at the hold solenoid 12 011 002 System configuration is incorrect 13 012 003 Short circuit from the release solenoid to voltage Right Rear Axle PMV 13 012 004 Short circuit from the release solenoid to ground 13 012 005 Open circuit at the release solenoid 13 012 005 Open circuit on the common line to the valve 13 012 003 Short circuit from the hold solenoid to voltage 13 012 004 Short circuit from the hold solenoid to ground 13 012 005 Open circuit at the hold solenoid 13 012 002 System configuration is incorrect 23 Blink Codes 1st 2nd MID 136 SID FMI 018 003 Description Solenoid in ATC valve shorted high Location ATC Valve 018 004 Solenoid in ATC valve shorted to ground 018 005 ATC valve open circuit 018 002 valve found when it should not be present N 249 002 or 231 002 Time out or no connection to engine link J1922 1939 Data Link 254 012 ECU internal trouble code ECU 253 012 ECU internal trouble code 253 013 ECU internal troubl
27. d Gen 5 ABS TIL 1587 J1587 WL ABS WL Diagnostic Switch GND Ground GND Ground Description Speed Sensor Left Rear Speed Sensor Left Rear Speed Sensor Right Rear Speed Sensor Right Rear Traction Control Valve Traction Control Valve Release Sol Right Rear Common Right Rear Hold Sol Right Rear Release Sol Left Rear Common Left Rear Hold Sol Left Rear X2 Black X4 Brown Description Brake Light Switch Hold Sol Left Steer Release Sol Right Steer Hold Sol Right Steer Speed Sensor Right Steer Speed Sensor Right Steer Speed Sensor Left Steer Speed Sensor Left Steer Common Right Steer Valve Release Left Steer Valve Common Left Steer Valve Off Road Switch Description Diff Lock Control Diff Lock Control Speed Sensor Left Rear Rear Speed Sensor Left Rear Rear Speed Sensor Right Rear Rear Speed Sensor Right Rear Rear Release Sol Right Rear Rear Common Right Rear Rear Hold Sol Right Rear Rear Release Sol Left Rear Rear Common Left Rear Rear Hold Sol Left Rear Rear FIGURE 45 Frame Mount ECU Pin Identification Chart 44 Looking into Torque Converter PMY Pressure Modulator Valve FIGURE 46 Gen 5 Basic Frame Mount ABS Electrical Schematic 45 Om o 0u mur OO b wn Lights On Road Switch LR Sensor o ATC Switch Serer
28. de has been cleared Check sensor resistance If sensor resistance is out of range replace sensor Clean and lubricate sensor Press into mounting hole until it bottoms against tone wheel Clear trouble code and verify that code is corrected by test driving the vehicle The indicator lamp will remain on until proper sensor output 5 detected even though the code has been cleared Use approved lubricant Examine tone ring for damage Replace tone ring and or hub if necessary Check wheel bearing adjustment Adjust wheel bearings if necessary Clear trouble code and verify that code is corrected by test driving the vehicle The indicator lamp will remain on until proper sensor output is detected even though the code has been cleared Check mechanical function of brake Check for kinked or restricted hoses Clear trouble code and verify that code is corrected by test driving the vehicle The indicator lamp will remain on until proper sensor output is detected even though the code has been cleared Check for damaged tone ring or excessive run out Repair tone ring and or adjust wheel bearings Clear trouble code and test drive the vehicle The indicator lamp will remain on until proper sensor output is detected even though the trouble code has been cleared Use an ohm meter to verify proper sensor resistance Fig 24 Check harness for shorts or opens Repair harness and or replace sensor as necessary Clear trouble code and verify that code is corre
29. e Sequence Flashes Location 3 Install the wiring connector to the ATC valve 4 Testthe installation Traction Control Valve Leak Test Make and hold brake application No audible air leaks are permitted Traction Control Valve Component Test with Hand Held Diagnostic Tool Select Traction Control Valve Verify Traction control light operation Drive the vehicle and verify ABS indicator lamp operates properly CAUTION Do not start and engage the transmission with one wheel raised from the floor With ATC power will go to the wheel on the floor and cause the vehicle to move See page 20 to disable ATC for dyno testing ECU Engine Interface Flashes Condition Action link J 1922 1939 Flashes Location No connection found to engine data Refer to electrical schematic Check for proper connection of data link to ECU Verify that polarity is correct Unplug connector at ECU There should be a voltage between 0 and 2 5 volts on J 1922 1939 and a voltage between 2 5 and 5 volts on J 1922 1939 If vehicle is not equipped with J 1922 1939 engine link use diagnostic tool to reconfigure ECU ECU Flashes Condition Action ECU Internal Fault If fault cannot be cleared replace ECU FIGURE 37 System and ECU Diagnostic Trouble Codes Troubleshooting Guide 36 Blink Code Sequence Flashes Location A Power Circui Flashes Condition Action lor
30. e OFF position and apply parking brake CAUTION Block wheels before beginning this procedure Follow all standard safety procedures outlined by but not u limited to the General Precautions listed on page 13 of Connect the wiring connector to the ABS valve this document 4 Testthe installation 2 Disconnect the wiring connector from the ABS valve e Modulator Valve Leak Test Make and hold brake 3 Disconnect the air lines from the supply and delivery application No audible air leaks are permitted ports of the ABS valve Modulator Valve Component Test with Hand Held 4 Disconnect the valve mounting fasteners Diagnostic Tool Select valve routines Verify 5 Remove the ABS valve proper valve location and operation with tool Drive NOTE To service either modular valve or the relay valve Hio vehicle dnd veny ABS indicator lainpepelaies remove the entire assembly and then replace the individual components valve 5 Make several brake applications and check for prompt brake chamber applications and release at all wheels Check the cable connections 6 Clear codes 7 Drivethe vehicle and verify that the ABS indicator lamp operates properly Rear Axle Valve Assembly Standard Rear Axle Valve Assembly FIGURE 33 Rear Axle Valve Assemblies Standard and ATC Version Shown 33 Performance Test of the Relay Valve CAUTION Block wheels before beginning this procedure
31. e code 253 012 ECU internal trouble code ECU cont 254 002 ECU internal trouble code 254 002 ECU internal trouble code 254 002 ECU internal trouble code 253 013 ECU internal trouble code 231 012 internal trouble code 254 012 ECU internal trouble code 254 012 ECU internal trouble code o 251 004 Excessive voltage on PMV Power Power Circuits 251 003 Low voltage found on PMV Power 251 005 No voltage found on PMV Power 251 005 Open circuit found on PMV Ground 251 004 Excessive voltage found on ECU Power 251 003 Low voltage found on ECU Power 251 002 Voltage difference between PMV Power inputs is too high 013 003 Retarder control relay shorted high or open circuit 013 004 Retarder control relay shorted to ground 249 002 or 231 002 J1922 1939 date link not functioning 249 002 or 231 002 J1922 1939 date link time out 253 013 Tire size front to rear out of range 253 013 Tire size out of range or parameter fault Brake light switch not pushed at this power cycle oe 1 0o0 0 Oo N ATC system is disabled for dynamometer test 023 014 Indicator lamp circuit is faulty 24 151 014 Sensor memory bit set sensor trouble code has occurred the E
32. e distances from the vehicle ahead are still essential to safe vehicle operation Speed signal to ECU Electronic Control Unit ECU interprets speed signals and activates valves FIGURE 2 Overview of ABS Operation Sensors on all configured wheels signal status to ECU ABS Component Function The ABS system operates as follows see Figure 2 1 Speed sensors on each wheel monitor wheel rotation 2 Each speed sensor communicates wheel rotation pulses to the central Electronic Control Unit ECU 3 The ECU receives speed sensor input interprets the signal pulses and calculates speed and acceleration rates for the wheels and the vehicle 4 Based on speed sensor input with the brakes applied the ECU detects impending wheel lock and operates the ABS modulator valves as required for proper control The modulator valves can be operated in either a release or a hold mode to regulate air pressure in the brake chambers 5 Braking force is applied at a level which minimizes stopping distance while maintaining as much lateral stability as possible DIFF FIRTH WHET SUSP ABS UNLOCKED DEFLATED TRAILER FIGURE 3 ABS Indicator Lamps ABS Indicator Lamp This lamp is the primary indicator of the ABS status The ABS lamp illuminates steadily for a two second bulb check whenever the switched ignition is ON The ABS lamp turns OFF after the bulb check if there are no ABS malfunc
33. ensor Push the speed sensor completely into sensor bushing by hand until it stops against the tone ring The speed sensor is properly installed and adjusted when it is touching the tone ring NOTE The speed sensor must slide freely in and out of the mounting sleeve bore Operating the vehicle with Seized components will damage the speed sensor and the tone ring 4 Test the installation Check the cable routing and connections Clear the trouble codes A 17 12 trouble code will remain in the system until the vehicle has been driven Test drive the vehicle and verify that the ABS warning lamp operates properly Sensor FIGURE 27 Wheel Speed Sensor Installation Rear Axle Speed Sensor The rear axle speed sensor located inside the brake drum and is only accessible by removing the wheel and drum assembly NOTE For diagnostic and service information on in axle Speed sensors please contact Dana Corporation CAUTION Block wheels before beginning this procedure Follow all standard safety procedures outlined by but not limited to the General Precautions listed on page 13 of this document CAUTION Do not work under a vehicle supported by a jack Removal 1 Back off the slack adjuster to release the brake shoes 2 Remove the wheel and tire assembly from the axle 3 Remove the brake drum 4 Remove the speed sensor with bushing from the mounting block on the axle housing Use twisting motion and avoid pulling on
34. ented allowing air to flow from the outlet port back through the exhaust port Optional Front Axle Modules An optional front axle module is available It is an assembly of two modulator valves and a quick release valve Three crack pressure settings are available e 0 1 PSIG 3 4 PSIG 6 8 PSIG FIGURE 14 Front Axle Module Wheel End Sensor Standard Wheel End Speed Sensor Drive and Steer Axles Right angle version shown Straight version also available FIGURE 15 Sensor Assembly Speed Sensors Each wheel of an axle under direct ABS control is monitored by a speed sensor Speed sensors for drive axles and steer axles may be different styles and installed in different locations Wheel End Sensors For most applications Bendix ABS uses standard wheel end sensors see figure 15 The front sensor is accessible on the inboard side of the steering knuckle The rear drive axle sensor is accessible by removing the wheel and drum assembly Wheel end sensors are conventional single point variable reluctance sensors These are often referred to as magnetic sensors or magnetic pickups These sensors consist of a rod or pole piece surrounded by a coil of wire A magnet 1 closely coupled to the pole piece and circulates a magnetic field through the coil As the teeth of the tone ring rotate past the pole piece the resistance reluctance to the magnetic field varies The variable reluctance causes variations in
35. er Axle PMV 007 004 Short circuit from the release solenoid to ground 007 005 Open circuit at the release solenoid 007 005 Open circuit on the common line to the valve 007 003 Short circuit from the hold solenoid to voltage 007 004 Short circuit from the hold solenoid to ground 007 005 Open circuit at the hold solenoid OINI DOJA 007 002 System configuration is incorrect 151 014 Inter axle differential control circuit shorted high IAD Circuit 151 014 Inter axle differential control circuit shorted low or open 008 003 Short circuit from the release solenoid to voltage Right Steer Axle PMV 008 004 Short circuit from the release solenoid to ground 008 005 Open circuit at the release solenoid 008 005 Open circuit on the common line to the valve 008 003 Short circuit from the hold solenoid to voltage 008 004 Short circuit from the hold solenoid to ground 008 005 Open circuit at the hold solenoid 22 6 6 6 6 6 6 6 6 7 7 7 7 7 7 7 7 8 8 8 8 8 8 8 8 8 8 9 9 9 9 9 9 9 9 008 002 System configuration is incorrect Blink Codes 1st 10 2nd MID 136 SID FMI 009 003 Description Short circuit from the release solenoid to voltage Location Left Rear Axle PMV 10 009 004 Short circuit
36. from the release solenoid to ground 10 009 005 Open circuit at the release solenoid 10 009 005 Open circuit on the common line to the valve 10 009 003 Short circuit from the hold solenoid to voltage 10 009 004 Short circuit from the hold solenoid to ground 10 009 005 Open circuit at the hold solenoid Left Rear Axle PMV cont 10 009 002 System configuration is incorrect 10 or 11 014 003 Common side of valves stray voltage detected PMV Commons 10 or 11 014 003 Common side of valves shorted high 10 or 11 014 004 Common side of the valves shorted to ground 11 010 003 Short circuit from the release solenoid to voltage Right Rear Axle PMV 11 010 004 Short circuit from the release solenoid to ground 11 010 005 Open circuit at the release solenoid 11 010 005 Open circuit on the common line to the valve 11 010 003 Short circuit from the hold solenoid to voltage 11 010 004 Short circuit from the hold solenoid to ground 11 010 005 Open circuit at the hold solenoid 11 010 002 System configuration is incorrect 12 011 003 Short circuit from the release solenoid to voltage Left Rear Axle PMV 12 011 004 Short circuit from the release solenoid to ground 12 011 005 Open cir
37. g ATC for Dyno Testing System Configuration Turn the ignition key to ON With the ignition OFF press and hold the diagnostic Press and hold the diagnostic button for at least 3 button seconds and release Turn the ignition key to ON while pressing the ATC light turns ON and ABS light blinks 17 8 indicating diagnostic button ATC is disabled Wait two seconds and release the diagnostic button Atthe next ignition cycle will be reactivated Pressandrelease the brake pedal ECU is reconfigured to match connected components and diagnostic trouble codes are cleared Repeat the Retrieving Diagnostic Trouble Codes procedure to verify that the trouble codes are cleared 3 Sec 2 Sec First Trouble Code Additional Trouble Codes first half of code first half of code 4 5 1 5 second pause second 1 5 second pause 4 5 second pause jaus Sequence continues second half of code second half of code until all trouble codes are reported FIGURE 22 Typical Blink Code Report 20 Blink Codes 1st 2nd MID 136 SID FMI Description No Trouble Found Location 001 000 Sensor air gap too large Left Steer Sensor 001 008 Air gap too large or sensor shorted 001 010 Speed Sensor signal is noisy 001 008 Wheel locked too long during an ABS cycle 001 008 High deceleration rate at wheel site or sensor shorted 001 012
38. ically 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 an AD IS air dryer system or a dryer reservoir module be sure to drain the purge reservoir 5 Following the vehicle manufacturer s recommended procedures deactivate the electrical system in a manner that safely removes all electrical power from the vehicle 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 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 comp
39. ink Code procedure or the hand held tester procedure 2 Lookup the code description the possible causes and the repair procedures provided in this section 3 Perform the recommended repair procedures 4 After the repairs are completed clear all codes and check for any additional codes FIGURE 29 Typical PMV Circuit No Connection Release Measur Resistan Measure sure esistance From To Range Q Common Hold 3 8 Ohms Q 3 Release 3 8 Ohms P un HoldRelease 6 16 Ohms Common Hold Twist Lock Connector Twist Lock C t i onnector PMV Resistance Test Common Measure resistance at the PMV location to check the valve Measure resistance at the appropriate 5 ECU harness connector pins to check the cable and valve Hold Release Note Refer to the chart for pin identification Threaded Threaded Connector Connector Looking Into Valve FIGURE 30 PMV Harness Circuit Descriptions and Resistance Test 30 E Cab Mount TOP Looking into harness connector Frame Mount X2 Black X3 Green Harness Connector PIN ircuit Description Harness Connector ircuit Description B 6 Way V 1 Release Left Steer V 1 Hold Left Steer V 1 Common Left Steer X2 Black V 1 Hold Left Steer V 1 Release Left Steer V 1 Common Left Steer V 2 Release Right Steer V 2 Hold Right Steer
40. n describes how to retrieve configuration information and error codes to troubleshoot ABS system diagnostic trouble codes There are three ways to retrieve and display ABS configuration information and trouble codes ServiceRanger PC software Displays configuration information and diagnostic trouble codes on the PC monitor Refer to the ServiceRanger PC software information later in this section ProLink hand held tester Displays configuration information and diagnostic trouble codes on the hand held tester display Refer to the hand held tester information later in this section Diagnostic switch Flashes configuration code and diagnostic trouble codes on the ABS indicator lamp Refer to page 18 for operation of the diagnostic switch WARNING PLEASE READ AND FOLLOW THESE INSTRUCTIONS 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 removed Where circumstances require that the engine be in operation EXTREME CAUTION should be used to prevent personal injury resulting from contact with moving rotating leaking heated or electr
41. ne data link For applications other than these factory configurations for example use of a retarder control relay 4s 3m operation 6s 6m operation or traction control it is necessary to perform a configuration or setup process This process sets up the ECU for the components that are installed so that proper control and fault tolerance will be Tone Ring Wheel Speed Sensor s WSS 4 Pressure Modulator Valve PMV 4S AM 65 6M w ATC 65 4M w ATC FIGURE 18 Typical ABS Configurations implemented The diagnostic switch MPSI Pro Link tool or ServiceRanger PC software may be used to configure to a higher level add components or functionality If it is desired to move the configuration downward fewer components than standard the ProLink tool or ServiceRanger PC software must be used How to Configure Use the SYSTEM SETUP menu with the MPSI ProLink tool the diagnostic switch refer to page 25 for procedure or ServiceRanger PC software Use of the SETUP function will also clear inactive trouble codes from the system However it is recommended that the CLEAR TROUBLE CODES function be used for clearing inactive codes Verification It is important to verify that the intended configuration has been obtained Refer to Figure 20 page 17 for proper interpretation of configuration blink codes Rear Axle Valve Assembly 15 Test Equipment Bendix recommends the use of the following product
42. nsors do not generate signals unless the wheels are turning Because of this certain sensor codes can only be detected when the vehicle is in motion The trouble code 17 12 is generated after the initial sensor codes are cleared The ABS indicator lamp remains lit The trouble codes must be rechecked after clearing the sensor codes in order to see 17 12 reported A 17 12 trouble code and ABS indicator lamp signal for sensor code cannot be cleared using a ProLink ServiceRanger software or the diagnostic button They can only be cleared by driving the vehicle The ABS ECU will clear the 17 12 blink code and turn off the ABS indicator lamp when all active sensor code issues are resolved and the vehicle is driven above 5 mph The ABS ECU must detect speeds at all monitored wheels for the condition to clear Procedure 1 Check trouble codes 2 Troubleshoot and eliminate causes for all trouble codes 3 Clear trouble codes 4 Check trouble codes again 17 12 will be reported if sensor codes are cleared 5 f 17 12 error code is reported drive vehicle above 5 mph ABS indicator lamp will go out and 17 12 trouble code will be cleared after a short period if all sensor signals are acceptable 26 Note If sensor codes still exist the ABS indicator lamp will remain lit The trouble codes will be logged once again after driving the vehicle If more than one sensor site is affected the codes may not be re logged by the ECU until
43. onent 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 Antilock Traction Control ATC the ATC function must be disabled ATC indicator lamp should be ON priorto performing any vehicle maintenance where one or more wheels on a drive axle are lifted off the ground and moving Troubleshooting Procedures Figure 17 shows an organized approach to troubleshooting ABS trouble codes Follow the steps listed below to locate and correct ABS component and wiring problems 1 Check that the ABS ECU configuration corresponds to the ABS components installed on the vehicle Reconfigure the ECU if the configuration does not match the installed ABS components 2 Access active diagnostic trouble code s Inactive historical diagnostic trouble codes are also reported and may provide additional information to aid in troubleshooting 3 Lookup the code description the possible causes and the repair procedures provided in this section 4 Perform the recommended repair procedures 5 After the repairs are completed clear all codes and check for any additional codes 13 Cycle ignition key OFF to ON Observe ABS indicator lamp operation Lamp turns OFF after Lamp stays ON Lamp never ON 2 second lamp check ABS system not reporting Select Eaton ABS diagnostic tool ed poweri AB TOD Codes perform traditional indicato
44. ould measure the resistance of the brake light bulb bulb broken If the brake is applied you should measure vehicle system voltage i e 9 16v Cycle ignition switch and ATC will be re enabled Diagnostic switch may have been pressed for an excessive period of time 230 seconds If not check wiring associated with indicator lamp This trouble code should clear when the vehicle is driven and the ECU is able to read sensor output voltage If this does not happen verify that the sensors are properly adjusted pressed full in to tone wheels Note For codes 17 and 174 the problem may be within the engine controller another controller on the data link or within the wiring or connectors FIGURE 39 Miscellaneous Diagnostic Trouble Codes Troubleshooting Guide 38 Cab Mount ECU Pin Identification This section shows how to identify Cab Mount ECU harness connectors and pin locations The charts provide a brief description of the signal carried by each pin Looking Into Harness Connector FIGURE 40 Cab Mount ECU Connector Layout Connector A 18 Way Connector B 6 Way Connector C 9 Way Connector D 15 Way 12 Way 39 ECU CONNECTOR PIN DESCRIPTION ECU CONNECTOR PIN DESCRIPTION J1922 J1939 Gen 4 ABS J1939 Shld Gen 5 ABS TIL J1922 J1939 NC Off Road ABS Switch ORS Mud amp Snow Switch A 18 Way Ignition Switched V Bat2 V Ba
45. out ATC requires 1 ATC valve Either a stand alone valve or a Rear Axle Valve Assembly with integral ATC solenoid may be used 2 SAE J1922 or J1939 engine interface the ABS ECU serial data interface must match the engine controller interface 3 Brake Light Switch input 4 ATC Indicator Lamp The Electronic Control Unit ECU must be configured for ATC operation either by using the diagnostic switch an MPSI ProLink hand held tester or Eaton s ServiceRanger PC software ATC Operation During periods of wheel slip the Electronic Control Unit enters an Automatic Traction Control mode There are various modes of Automatic Traction Control System operation At speeds above 25 mph the engine is throttled back via the SAE J1922 or SAE J1939 data link to control spin out At speeds below 25 mph both engine control and differential brake control are activated as required to control wheel slip Once triggered differential braking mode remains active regardless of vehicle speed Anoptional mud and snow switch allows greater wheel spin more torque when activated It is intended for adverse conditions usually off highway Except for special cases the switch is programmed for momentary operation ATC reverts to normal operation when the switch is cycled a second time and whenever the system goes through a power up cycle Component Function When brake control is utilized the ATC valve is activated diverting
46. r lamp and wiring foundation brake troubleshooting and repair Activate blink codes Use Service Ranger Use MPSI with diagnostic button diagnostic software ProLink tool Check ECU configuration Does tester communicate with Check J 1587 data link wiring ECU Check ECU configuration Indicator lamp Does configuration blinking when activated information agree Reconfigure ECU with diagnostic with available button hardware Read trouble codes and descriptions Take corrective action Check power circuit Clear active and inactive trouble codes forECU Reconfigure ECU Recheck trouble codes after clearing If indicator lamp remains lit ls this a trailer and no trouble codes are set ECU drive vehicle to turn off indicator lamp Recheck trouble codes after clearing If indicator lamp remains lit and 17 12 trouble code is set drive vehicle to clear and turn off indicator lamp FIGURE 17 Antilock Brake System Troubleshooting Chart 14 SYSTEM CONFIGURATIONS Available Configurations A wide variety of system configurations are available refer to Figure 17 It is important to be able to read system configurations and to be able to properly reconfigure a system when necessary When to Configure ECUs are factory configured for the most common requirements Basic systems are setup for 4s 4m operation with retarder control via retarder relay Standard systems are setup for 6s 4m operation with retarder control via engi
47. rical faults from the ECU from either the Diagnostic Button or from a hand held diagnostic tool only repaired faults may be cleared Coefficient of Friction The horizontal force required to move a body on a relatively smooth level surface divided by the weight of the body 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 Crack Pressure The ascending input pressure or input force to an air valve required to initiate output pressure of flow Diagonal Control ABS is configured with two diagonal circuits Diagonal control allows each control circuit to provide electrical control of modulator valves on opposite sides of the vehicle 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 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 Differential Braking Application of brake force to a spinning wheel so that torque can be applied to wheels which are not slipping ECU Elec
48. s to troubleshoot the ABS system Amultimeter or digital volt ohmmeter DVOM Eaton ServiceRanger PC software or an MPSI ProLink hand held tester Multimeter A multimeter can be used to check Speed sensor circuit resistance e PMV and valve solenoid resistances ABS power circuit voltages Engine data link voltages Retarder control relay Wiring harness diagnostic trouble codes Deutsch HD 10 Serial Communicator ServiceRanger PC Software ServiceRanger PC software can be used to read and clear error codes and obtain a short description of failures The software can initiate test sequences for controller outputs and can also read system data such as voltage at the ECU wheel speeds and cutout speeds CAUTION Eaton ServiceRanger PC software can activate output tests for all output devices Since these tests can affect operation of the vehicle braking system the ECU incorporates special safety protection One axle must show zero speed or the test will be halted To Diagnostic Connector Laptop PC ServiceR anger Software CD w 1 Monitor Data Wheel Speeds Cut Out S peeds Input Voltages Switch States Interface ServiceRanger Main Menu Options 1 Monitor Data 2 Retrieve Diagnostic Trouble Codes 3 Advanced Product Functions 4 Product Downloads 2 Retrieve Trouble Codes 3 Adv Prod Functions Retrieve Trouble Codes Test Valves Clear Trouble Codes Test Lights Test Ret
49. t 1 Ground ECU oO A C _ 0 Ground Diagonal 2 E Ground Diagonal 1 SAE J1587 SAE J1587 NC Interlock ATC Light E A CO Retarder Relay E Indicator Lamp Diagnostic Switch D 15 Way Oo oO FR C z du luo Ius m a fF N gt o PMV3 Left Rear Rel Solenoid PMV3 Left Rear Hold Solenoid Left Rear Common ATC Valve Speed Sensor 4 Left Rear Speed Sensor 4 Left Rear ATC Valve Speed Sensor 5 Right Rear Speed Sensor 5 Right Rear PMVA Right Rear Rel Solenoid PMVA Right Rear Hold Solenoid PMV4 Right Rear Common NC NC NC PMV1 Left Steer Rel Solenoid PMV1 Left Steer Hold Solenoid PMV1 Left Steer Common Speed Sensor 2 Left Steer Speed Sensor 2 Left Steer Brake Light Switch Speed Sensor 3 Right Steer Speed Sensor 3 Right Steer NC PMV2 Right Steer Rel Solenoid PMV2 Right Steer Hold Solenoid PMV2 Right Steer Common A FIGURE 41 Cab Mount ECU Pin Identification Chart 40 oO FPF WO 1286 gt O PMV5 Left Rear Rear Rel Solenoid PMV5 Left Rear Rear Hold Solenoid PMV5 Left Rear Rear Common NC Speed Sensor 6 Left Rear Rear Speed Sensor 6 Left Rear Rear NC Speed Sensor 7 Right
50. t of range correct system problem Unplug connector at ECU and turn on ignition switch If the voltage on pin A 8 is different than system voltage repair wiring Clear trouble codes and verify that the indicator lamp turns out after bulb check Verify that vehicle system voltage is OK i e 9 to 16 volts If voltage is out of range correct system problem Unplug connector at ECU and turn on ignition switch If the voltage on PMV Power is different than system voltage repair wiring Clear trouble codes and verify that the indicator lamp turns out after bulb check Verify that vehicle system voltage is OK i e 9 to 18 volts If voltage is out of range correct system problem Unplug connector at ECU and turn on ignition switch If the voltage on one PMV Power pin differs from the other by greater than 0 5 volts repair wiring Check circuit breakers and or fuses on diagonal supply line Clear trouble codes and verify that the indicator lamp turns out after bulb check FIGURE 38 Power Circuit Diagnostic Trouble Codes Troubleshooting Guide 37 Blink Code Sequence Flashes Location lst x Miscellaneous Flashes Condition Action Retarder control relay shorted high or open circuit Retarder control relay shorted low or open circuit 1922 1939 data link not functioning Retarder 1922 1939 data link time out Tire size front to rear out of range Tire size out of range or parameter fault
51. the cable 5 Disconnect any fasteners that hold sensor cable to other components and disconnect the speed sensor from the harness FIGURE 28 Rear Speed Sensor Components Installation 1 Install the sensor bushing with the flange stops toward the inboard side of the vehicle 2 Apply a non conductive grease lubricant to the body of the speed sensor 3 Pushthe speed sensor completely into sensor bushing by hand until it stops against the tone ring The speed sensor is properly installed and adjusted when it is touching the tone ring NOTE The speed sensor must slide freely in and out of the mounting sleeve bore Operating the vehicle with seized components will damage the speed sensor and the tone ring 4 Route the cable to the frame 5 Connect sensor cable to harness and install fasteners to hold the sensor cable in position 6 Install the brake drum on the wheel hub 7 Adjust the rear axle brakes 8 Install the wheel and tire assembly and tighten the wheel nuts 9 Testthe installation 10 Check the cable connections 11 Clear the trouble codes A 17 12 trouble code will remain in the system until the vehicle has been driven 12 Test drive the vehicle and verify that the ABS indicator lamp operates properly 29 Pressure Modulator Valve PMV Troubleshooting Follow the steps listed below to locate and correct ABS modulator valve problems 1 Access active trouble code s using either the Bl
52. the magnetic field which in turn induce a varying voltage in the coils which are wound around the pole piece Some general characteristics of variable reluctance magnetic sensors are The output the air gap increases The output voltage increases with the speed of the teeth past the pole piece The output voltage waveform is independent of the direction of wheel rotation voltage decreases as Wheel End Sensors are protected with stainless steel metal sheaths They are designed to fit within beryllium copper friction sleeves which give them a self adjustment feature 11 Electrical Layout Rear Axle Speed Sensor Valve Assembly Indicator Lamps ABS Tractor Indicator Lamp IL ABS Trailer IL after 3 1 01 ATC Lamp when ATC equipped Electronic Control Unit ECU Cab Mount or Frame Mount Diagnostic Connector Front Axle Diagnostic S witch Pressure ABS Off Road Switch optional Modulator Valve ATC Mud amp Snow Switch optional Traction Control Valve Stand Alone or Integral with Rear Axle Valve Assembly Pneumatic Layout Chamber Relay Valve Pressure Modulator Valve 7 1 T casino Brake Pi Supply L po Quick Release Valve Steer Axle ATC Valve Anti Compounding Modulator Valve Relay Quick Release Valve FIGURE 16 Typical Electrical and Pneumatic Layouts 12 DIAGNOSTICS An important feature of Bendix ABS is the system diagnostic capability This sectio
53. ther service information is available on www bendix com Bendix Part Number Bendi Bendix Part Number 300 xxx M Bendix 9 M 83 x KS 34 NE E Pe a Yeu TANT um RE Le WL Li H 3 Suede ELACK Resigred Man facdiree by Arense sinned an XRXXXXXXXXXXX Jw SERE E vit i vi vo nn IL LIE E EIE LT Serial Number TON Date Cod Frame Mount Serial Number Cab Mount FIGURE 6 Electronic Control Unit Identification Tags Gen 4 ABS Standard Cab Mount Sliding Lock ECU Cover Connector ECU Connector 1 of 4 Gen 5 ABS PLC Basic Frame Mount Gen4 amp Gen5 ABS Standard Frame Mount FIGURE 7 Available Bendix ABS Electronic Control Units ABS Valves The ABS modulator valve controls air pressure to individual brake assemblies Depending on the particular ABS configuration a system may utilize three four or six modulator valves See Figure 8 Each modulator valve contains two air control solenoids which act as pilots to the hold and release diaphragms The hold solenoid blocks inlet air to brake chambers the release solenoid removes pressure from the brake The 3 pin threaded connector has pins for the hold and release solenoid and a third common terminal Rear Axle Valve Assemblies Rear Axle Valve Assemblies are available for some appli
54. tions present The ABS lamp flashes on and off continuously when the off highway mode is selected Special option for military and off highway vehicles e Indicator Lamp remains ON after the bulb check there is an ABS diagnostic trouble code that requires service NOTE In the case of a speed sensor failure which has been corrected the indicator lamp will remain on until sensor output has been verified by the control unit In this case it is necessary to move the vehicle above 5 mph before the indicator lamp will turn off ABS Trailer Indicator Lamp Tractor Towing vehicles manufactured on or after March 1 2001 are equipped with a cab mounted ABS Trailer indicator lamp When an ABS equipped trailer with Power Line Carrier PLC communications capability is connected to the tractor the ABS Trailer indicator lamp will illuminate for a two second bulb check after the ignition is switched on The ABS lamp turns OFF after the bulb check if there are no ABS malfunctions present on the trailer ABS If the trailer is NOT equipped with ABS or ABS with PLC capability the ABS trailer indicator lamp in the cab will not illuminate Automatic Traction Control ATC System The ATC system is available on all Standard ABS ECU s ATC is not available on Basic ECU s It helps improve traction on slippery or unstable driving surfaces by preventing excessive wheel spin ATC also enhances vehicle stability by prevention of power spin
55. tronic Control Unit FMVSS 121 Federal Motor Vehicle Safety Standard which regulates air brake systems Friction Sleeve Aberyllium copper sleeve which has fingers cut into it It is pressed between an ABS sensor and mounting hole to hold the sensor in place Indicator Lamp An amber light 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 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 J1587 The SAE heavy duty standard diagnostic data link J1708 An SAE standard which defines the hardware and software protocol for implementing 9600 baud heavy vehicle data links Both J1587 and J1922 are versions of J1708 data links J1922 The SAE heavy vehicle data link which operates according to J1708 protocol It is generally used for ATC or automatic transmission interface to an engine 41939 A high speed 250 000 baud data link which is expected to replace J1922 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 Usually control begins at pure select low and moves towards independent
56. trouble codes and reconfiguring the ECU is the same when using the diagnostic button 4 Once again retrieve the diagnostic trouble codes Only active codes will now be displayed Reading Configuration Codes Turnthe ignition key to Press and hold the diagnostic button for two seconds and release Without pause press the diagnostic button a 2nd time for two seconds and release Four digit configuration code is retrieved and displayed 2 Sec 15 2 Sec 18 Retrieving Diagnostic Trouble Codes Turn the ignition key to ON If vehicle is equipped with ATC apply and release brakes once before proceeding Press and hold the diagnostic button for two seconds and release Two number blink codes are retrieved and displayed 2 Sec Blink Code Sequence VOLTAGE CONFIGURATIONS Flashes Description 151 Volt System 2 24 Volt System ABS CONFIGURATIONS Flashes Description 2 4 Sensors 4 Modulator Valves 4 Sensors 3 Modulator Valves 6 Sensors 4 Modulator Valves 6 Sensors 6 Modulator Valves 6 Sensors 5 Modulator Valves Select Low Steer RETARDER CONFIGURATIONS INTERAXLE Flashes Engine Interface Retarder Relay Control Interaxle Lock Control NO NO NO YES YES NO NO YES YES YES ATC CONFIGURATIONS Flashes Engine Control Brake Control 2 NO NO 3 N A N A 4 N A N A 5 FIGURE 21 Reading ABS Configuration Codes 19 Clearing Diagnostic Trouble Codes and or Disablin
57. ument panel lights to indicate loss of traction which is being managed by the Automatic Traction Control System Relay Breaker Panel The OEM provides two circuit breakers and either one or two relays as part of the ABS One relay is used for indicator lamp control A second optional relay may be used to control a retarder and or lockup torque converter Diagnostic Port Connector The diagnostic port connector is an industry standard connector that is used to connect to the J1587 diagnostic link This connector also provides power and ground for diagnostic test equipment Diagnostic Port Connector Rear Axle for Hand held Valve Assembly Speed Sensor and PC Based Diagnostics Diagnostic Switch Dash Mounted Relay Breaker Panel Rocker Switch onfiguration Varies with OEM Please Refer to Figure 9 Traction for ECU Control Valve Configurations Front Axle Pressure Neduitorvave 2 Indicator Lamps Rear Axle Typical Light Bar Valve Assembly ATC Version FIGURE 5 ABS Components Electronic Control Units ECUs Identification Frame mount ECUs are environmentally packaged versions of the related Gen 4 amp Gen 5 ABS cab mounted units Standard Basic The circuitry and software is the same Gen 5 ABS units incorporate power line carrier PLC hardware ECUs are available in 4 and 6 channel versions with either J1922 or J1939 data links There is also a 24 volt version Fur
58. using either the Blink Code procedure or the hand held tester procedure 2 Lookup the code description the possible causes and the repair procedures provided in this section 3 Perform the recommended repair procedures 4 After the repairs are completed clear all codes and check for any additional codes Whether the ATC Valve is used as a stand alone valve as shown in Figure 34 or is integrated into the cover of a relay valve as shown in Figure 33 the troubleshooting procedure is the same 2 Relay valve P d control line 1 Tank Air 3 Treadle FIGURE 34 ATC Valve Cab Mount Frame Mount TOP Looking into harness connector 10 7 4 Lr 17 14 11 85 2 I 2 tends X3 Green X4 Brown Harness Connector Circuit Description Harness Connector Circuit Description A 18 Way ATC Mud and Snow S witch X1 Grey ATCL ATC Light ATC S witch ATCL ATC Light X3 Green ATC Valve ATC Valve 4 ATC valve 4 ATC Valve ATC Valve Resistance Test The correct resistance for the ATC Valve circuit is between 9 ohms and 15 ohms Measure resistance at the ATC Valve to check the valve Measure resistance atthe appropriate ECU harness connector pins to check the cable and valve Note Refer to the chart for pin identification FIGURE 35 ATC Harness Circuit Descriptions and Resistance Test Blink Code

BENDIX BW2261 User's Manual

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