BENDIX BW2429 User Manual

Bendix® EC-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

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.

SD-13-4869

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 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

specic 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.

TABLE OF CONTENTS PAGE General System Information

Introduction. . . . . . . . . . . . . . . . . . . . . . . 1

Components . . . . . . . . . . . . . . . . . . . . . 3-4

 HardwareCongurations . . . . . . . . . . . . . . . 4

Bendix EC-60 Controller Inputs & Outputs . . . . . 5-7

Indicator Lamps and Power-Up Sequence . . . . . 8-9

ABS Operation . . . . . . . . . . . . . . . . . . . . . 9

ATC Operation . . . . . . . . . . . . . . . . . . 11-12

Advanced ABS With Stability . . . . . . . . . . 12-13

Important Safety Information About

The ESP Stability System . . . . . . . . . . . . 13-14

Dynamometer Test Mode . . . . . . . . . . . . . . 14

System Impact During Active Trouble Codes . . . 15

 SystemReconguration . . . . . . . . . . . . . . . 16

Troubleshooting . . . . . . . . . . . . . . . . . 17-48

Sensor Calibration . . . . . . . . . . . . . . . . 17-19

Blink Codes and Diagnostic Trouble Codes . . 21-23

Wiring Schematic . . . . . . . . . . . . . . . . . . 48

Glossary. . . . . . . . . . . . . . . . . . . . . . . . 49

J1587 SID and FMI Codes . . . . . . . . . . . . 51-55

UDS Codes . . . . . . . . . . . . . . . . . . . . 56-60

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 rolling downhill when moving up a steep incline from a stationary position.

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, trafc or

weather conditions, oversteering, an excessively high vehicle Center of Gravity (CG), or poor road conditions can cause vehicle instability that is beyond the capability of any stability system to mitigate. In addition, the effectiveness of ESP can be greatly reduced on vehicles towing multiple trailer combinations.

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® 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 specic vehicle platform. Therefore, specic steps are

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 highbanked roads – such as those found on high-speed test or 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.

Delivery

(Port 2)

Supply (Port 1)

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 friction surfaces. See "Advanced ABS with Stability Control" on page 12 for further details.

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:

• Bendix® WS-24™ wheel speed sensors (4 or 6, depending on configuration). Each sensor is installed with a Bendix Sensor Clamping Sleeve

• Bendix® M-32™ or M-32QR™ Pressure Modulator

Valves (4, 5, or 6 depending on conguration)

• Dash-mounted tractor ABS Indicator Lamp

• Service brake relay valve

• Dash-mounted trailer ABS Indicator Lamp

• Optional blink code activation switch

• Optional ABS off-road switch

Sensor

90° Speed

Sensors

Clamping

Sleeve

Electrical

M-32QR

Modulator

FIGURE 3 - M-32™ AND M-32QR™ MODULATORS

™

Connector

Exhaust (Port 3)

™

M-32

Modulator

The Bendix EC-60 controller ESP/RSP function utilizes the following additional components:

• Steer Axle Traction Control Valve (may be integral to the service brake relay valve or a stand-alone device)

• Dash-mounted ESP status/indicator lamp (also serves as the ATC status/indicator lamp)

• Bendix SAS-60™ Steering Angle Sensor (mounted to the steering column - See Figure 4)

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)

• Bendix® YAS-60™ or YAS-70X™ Yaw Rate/Lateral Acceleration Sensors (typically mounted to a crossmember near the back of the vehicle cab)

• 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 Speed

Sensors

FIGURE 2 - BENDIX® WS-24™ WHEEL SPEED SENSORS

Straight

Connector

FIGURE 4 - STEERING ANGLE SENSORS

90°

Connector

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)

• Dash-mounted ATC status/indicator lamp

• J1939 serial communication to engine control module

• Stop lamp switch input (may be provided using the ECU hardware input or J1939)

• Optional ATC mud/snow switch (sometimes referred to as an ATC off-road switch)

The EC-60 controller Hill Start Feature utilizes the following additional components:

• Bendix® AT-3™ Traction control valve

• Dash-mounted HSA Status/indicator lamp

• Dash-mounted enable/disable Switch

• Bendix® RV-3™ Pressure reducing valve

• Bendix® DC-4® Double check valve

Brake Demand/

Load Sensor

Bendix® RV-3

Pressure

Reducing Valve

FIGURE 6 - ADDITIONAL VALVES NECESSARY FOR THE

HILL START FEATURE

™

Bendix® AT-3

Traction Control

Valve

™

Bendix Double Check

Valve

DC-4

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® premium and advanced Antilock Brake Systems (ABS). 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 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 predetermined maximum. This action helps the drive axle to gain more traction.

See SD-13-21021 for more information.

Yaw/Lateral

Accelerator Sensors

(Two examples

shown.)

FIGURE 5 - YAW AND BRAKE DEMAND/LOAD SENSORS

ABS

Off-

Road

ATC

Mud/Snow

Blink

Codes

ESP/

RSP

HSA

Bendix

eTrac

system*

Optional Optional Optional 12/24 4/5/6 4/6

ECU MOUNTING

The Bendix® EC-60™ advanced cab-mounted controller is not protected against moisture, and must be mounted in an environmentally protected area.

All wire harness connectors must be properly seated. The use of secondary locks is strongly recommended.

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.

™

Voltage

Input

PLC PMVs

Retarder

Relay

Sensors

Serial

Communication

J1587 J1939

For information about the Bendix® eTrac™ automated air suspension transfer system, see SD-13-21021

CHART 1 - BENDIX

EC-60™ ADVANCED CONTROLLER FEATURES

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 is broadcast by the trailer ABS ECU.

FIGURE 7 - POWER LINE WITHOUT PLC SIGNAL

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 Advanced 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 ltering 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 µsec/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. See 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 Speed 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 dashmounted 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 ABS@ bendix.com, specifying the ECU part number, or call 1-800-AIR-BRAKE and speak to the Bendix TechTeam.)

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 is placed in the ABS off-road mode, the ABS

Indicator Lamp will ash constantly (at a rate of once per

2.5 seconds) to notify the vehicle operator that the off-road mode is active.

Optional ATC Mud/Snow (Off-Road) Switch and Indicator Lamp Operation (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.

WARNING: With HSA option you lose the ABS off-

road function and the retarder relay output.

When the ECU is placed in the HSA off-road mode, the

HSA Indicator Lamp will ash 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 releases. This function is 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 is installed in the primary air brake circuit, and another is installed in the secondary air brake circuit.

Load Sensor

The load sensor provides the controller with an indication of the vehicle load. 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. The 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 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 ow 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 TCV during differential 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. If the ECU is unplugged or has no power.

4. When the ECU is placed into the ABS off-road mode

(the lamp ashes steadily at a rate of once per 2.5 sec.).

5. To display blink codes for diagnostic purposes after the external diagnostic switch is 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 the Bendix Tech Team.)

Indicator Lamp Control Using Serial Communications Links

As mentioned above, depending on the vehicle manufacturer, the dash indicator lamps (ABS, ATC, ESP and trailer ABS) may be controlled using serial communications links. In these cases, the EC-60™ controller will send a serial communications message over the J1939 or J1587 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 congured 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 congured 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:

• To 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

status with other vehicle control modules.

Advanced Bendix EC-60 controllers utilize the J1939 data link for:

• 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 J1587 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 congured to

provide this feature. E-mail ABS@bendix.com for more details.

INDICATOR LAMPS AND POWER-UP

ATC

SEQUENCE

NOTICE: The vehicle operator should verify proper

operation of all installed indicator lamps (ABS, ATC/ESP, and trailer ABS) when applying ignition power and during vehicle operation. See Chart 2.

Lamps that do not illuminate as expected when ignition power is applied, or remain illuminated, indicate the need for maintenance.

Dash Lamps

Mode

Ignition on - start up

(trailer with PLC)

3 seconds after ignition

Start Up

At Vehicle

During an Automatic Traction Control (ATC) Event

(with no Diagnostic

Trouble Codes)

ABS

Off-

Road

Mode

Vehicles with the Hill Start Feature

Deep

Special Mode Operation

Mud/

Snow/

Mode

During Dynamometer Mode

Normal

During an ATC

Event

(“Hill Start Assist”)

Normal Off

During an ATC/

ESP Event

During an ESP Event

seconds*

Lamp Off* Lamp Off* Lamp Off* Lamp Off*

Lamp ashes

slowly (every

2.5 seconds)

ABS

Lamp

On for 3

Off

TRLR

ATC/ESP

Lamp

On for 2.5

seconds*

Lamp OFF

Flashes

quickly

During HSA Event Lamp OFF

HSA Manually Disabled

Flashes

slowly (every

2.5 seconds)

Flashes

quickly

Flashes

quickly

Lamp ON

(ATC

Disabled)

Flashes

quickly

On for 3

seconds**

•

HSA

Trailer

ABS

Lamp

• Uses dash switch

• Not for rm road surfaces

• Allows more wheel lock-up (less ABS intervention)

• Mode only applies under 25 mph (Over 25 mph, the system reverts to full ABS — including ATC/ESP — and lamp goes off.)

• Uses dash switch

• Increases allowable wheel slip during ATC interventions

• Not for rm road surfaces

• Reduces wheel slip during acceleration at low speeds

• Disables ATC monitoring functions

• When not in Dynamometer Mode, an illuminated lamp indicates an ATC trouble code is present

System intervenes to reduce the risk of rollovers, loss-of-control, etc.

HSA

Lamp

On for 3 seconds

Flashes

slowly

Comments

*If any of the described lamp behaviors do

not occur — or if the lamp remains on during operation — have the vehicle serviced by a

qualied mechanic as soon as possible to

restore full system functionality.

Lamp remains ON if HSA DTC is present

Power

ABS System

Application

Status Indicators

at Start-Up

Powered Vehicle ABS

Indicator Lamp

Trailer ABS

Indicator Lamp

(PLC Detected)**

Trailer ABS Indicator

Lamp**

(PLC Not Detected)

*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

0.5 2.0 2.5 3.0 (sec.)1.5

OFF

ATC/ESP System

Status Indicator

at Start-Up

ATC/ESP

enabled

No ESP

or ATC

0.5 2.0 2.5 3.0 (sec.)1.5

OFF

Power

Application

ABS Indicator Lamp Operation (Bulb Check)

The ECU will illuminate the ABS Indicator Lamp for approximately three seconds when ignition power is applied, after which the lamp will extinguish if no diagnostic trouble codes are detected.

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 ash

rapidly (2.5 times per second). When the ECU is placed

in the ATC Mud/Snow (off-road) mode, the lamp will ash

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CongurationTest

Within two seconds of the application of ignition power, the

ECU will perform a test to detect system conguration 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 conguration test when

wheel speed sensors show that the vehicle is in motion.)

Pressure Modulator Valve and Traction Control Valve Chuff Test

Right Steer

Driver

Left Steer

FIGURE 9 - VEHICLE ORIENTATION (TYPICAL)

After the performance of the conguration test, the Bendix®

EC-60™ controller will perform a Bendix-patented PMV and TCV Chuff Test. The Chuff Test is an electrical and

Right Drive

Left Drive

Right

Additional

Left

Additional

pneumatic PMV test that can assist maintenance personnel in verifying proper PMV wiring and installation.

When ignition power is applied, each modulator solenoid

is briey 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:

• Steer Axle Right PMV

• Steer Axle Left PMV

• Drive Axle Right PMV

• Drive Axle Left PMV

• Additional Axle Right PMV

• 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 second round of PMV &

TCV chuff tests, the controller (if congured to do so) will

perform a test to cross-check the trailer PMV operation with the vehicle stop lamps. If the trailer PMV circuit is mis-wired (including the steer axle 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

Steer Axle Control

Although both wheels of the steer axle have their 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 Modied 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Conguration)

For vehicles with dual drive axles (6x4) using a 4S/4M

conguration, 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(6S/6MConguration)

For vehicles with dual rear axles (6x4, 6x2) using a 6S/6M

conguration, the rear wheels are controlled independently.

Therefore, brake application pressure at each wheel is adjusted according to the individual wheel behavior on the road surface.

6x2Vehicleswith6S/5MConguration

6x2 vehicles can utilize a 6S/5M conguration, with the

additional axle (a non-driven rear axle) having 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.

Optional ABS Off-Road Mode

On some road conditions, particularly when the driving surface is soft, the stopping distance with conventional ABS may be longer than without ABS. This can occur when a locked wheel on soft ground or loose gravel plows up the road surface in front of the tire, changing the rolling friction value. Although vehicle stopping distance with a locked wheel (in the absence of ABS) may be shorter than 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 modied 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).

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ashslowlytoindicatetothe

driver that the ABS off-road mode is engaged.

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 is responsible for ensuring that vehicles equipped with the ABS off-road function meet all FMVSS-121 requirements and have adequate operator indicators and instructions.

The vehicle operator activates the off-road function with a

switch on the dash panel. A ashing ABS Indicator Lamp

indicates to the driver that the ABS off-road function is engaged. To exit the ABS off-road mode, depress and release the switch. A new ignition cycle will also cause the ECU to exit the ABS off-road mode.

All-Wheel Drive (AWD) Vehicles

AWD vehicles with an engaged interaxle differential (steer axle to rear axle)/AWD transfer case may have negative effects on ABS performance. Optimum ABS performance is achieved when the lockable differentials are disengaged, allowing individual wheel control.

Advanced Bendix EC-60 controllers can be programmed

specically for this conguration 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 congured

to use engine torque limiting and/or differential braking to control wheel spin. For optimal ATC performance, both methods are recommended.

ATC/ESP Lamp Output/ATC Mud/Snow Switch Input

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 is started) for approximately 2.5 seconds and turns off after the self test is completed, providing no diagnostic trouble codes are present.

2. When ESP or ATC is disabled for any reason.

3. During an ESP or ATC event (the lamp will ash rapidly

at a rate of 2.5 times per second).

4. When the ECU is placed in the ATC off-road mode

(the lamp will ash steadily at a rate of once per 2.5 seconds). This noties 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.g. when the vehicle is started), until the ECU detects a service brake application.

2. If the ECU receives a J1939 message indicating that the vehicle is parked.

3. When the dynamometer test mode is active. The dynamometer test mode is entered using the diagnostic blink code switch or by using a diagnostic tool (such as Bendix

4. In response to a serial communications request from a diagnostic tool.

5. If ATC Differential Braking function is activated for a long time period to avoid overheating of the brakes. It would take approximately 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.

ACom® Diagnostics).

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 situation, 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. If the dynamometer test mode is active. This may be accomplished via an off-board tool or the diagnostic blink code switch.

5. When certain diagnostic trouble code conditions are detected.

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 ash steadily at a rate of once every 2.5 seconds to conrm 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 STABILITY CONTROL

Overview

ESP stability system reduces the risk of rollovers,

jackkning 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

Drag Torque Control Functional Overview

Advanced Bendix® EC-60™ controllers have a feature referred to as drag torque control which reduces wheel slip on a driven axle due to driveline inertia. This condition is addressed by increasing the engine torque to overcome the inertia.

Drag torque control increases vehicle stability on lowtraction 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 Example Of How The RSP System Operates:

Excessive speed for road conditions creates forces that exceed the threshold at which a vehicle is likely to rollover on a higherfriction 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.

A Real World Example Of How Yaw Control Operates:

Excessive speed exceeds the threshold, creating a situation where a vehicle is likely to spin and jackknife.

The Bendix and selectively applies brakes to reduce the tendency to jackknife.

Yaw Control system reduces engine throttle

FIGURE 11 - RSP EXAMPLE

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 sufcient

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 inuence yaw

stability are: wheelbase, suspension, steering geometry, weight distribution front to rear, and vehicle track width.

Yaw Control

Yaw Control responds to a wide range of low- to highfriction 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 understeer 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.

CAUTION

To minimize unexpected deceleration and reduce the risk of a collision the operator must:

• Avoid aggressive driving maneuvers, such as sharp turns or abrupt lane changes at high speeds, which might trigger the stability system.

• Always operate the vehicle safely, drive defensively, anticipate obstacles and pay attention to road, weather

and trafc 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 is designed and optimized for trucks and for tractors that tow single trailers. If a tractor equipped with ESP is 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),

• 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,

• The vehicle is used to haul double or triple trailer combinations,

• If 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 maneuvering on a high banked road creating either additional side forces due to the weight (mass) of the vehicle or a deviation between expected & actual yaw rates,

• Gusty winds are strong enough to cause signicant

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.

TruckChassisModications

If the vehicle’s chassis components are altered (for example, a wheel base extension or reduction, tag axle addition or removal, a major body change such as conversion of a tractor into a truck, or an axle, suspension, or steering

system component modication) the Bendix® ESP® system must be disabled. Have a qualied 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.

WARNING:Ifamodiedvehicledoesnothave

the ESP system disabled, serious vehicle braking and performance issues could result, including unnecessary ESP system interventions. This can lead to a loss-of-control of the vehicle. In addition, remove all cab signage (e.g. visor labels, etc.) 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Modications

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 & 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.

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.

DYNAMOMETER TEST MODE

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 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 ve times or

by using a hand-held or PC-based diagnostic tool.

During Dynamometer Test Mode the ATC lamp remains ON.

Advanced Bendix 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.

EC-60™ Contollers will remain engaged

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 is stored in the ECU memory provided the following conditions are met:

1. Rolling-circumference ratio is within the permissible range.

2. Vehicle speed is greater than approximately 12 MPH.

3. No acceleration or deceleration is taking place.

4. There are no active speed sensor diagnostic trouble codes.

The ECU is provided with a ratio value of 1.00 as a default setting. If the automatic tire size alignment calculates a

different value, this is used to overwrite the original gure

in the memory. This process adapts the ABS and ATC function to the vehicle.

Acceptable Tire Sizes

The speed calculation for an exciter ring with 100 teeth is based on a default tire size of 510 revolutions per mile.

This gure is based on the actual rolling circumference of

the tires, which varies with tire size, tire wear, tire pressure, vehicle loading, etc.

The ABS response sensitivity is reduced when the actual rolling circumference is excessive on all wheels. For a 100 tooth exciter 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.

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.

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certiedmechanic.

SYSTEM IMPACT DURING ACTIVE TROUBLE CODES

ABS PARTIAL SHUTDOWN

Depending on which component the trouble code is detected, the ABS, ATC, and ESP functions may be fully or partially disabled. Even with the ABS indicator lamp 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 is disabled.

Drive Axle/Additional Axle ABS Modulator Diagnostic Trouble Code

ATC is disabled. ABS on the affected wheel is disabled. ABS on all other wheels remains active. ESP is disabled.

Steer Axle Wheel Speed Sensor Diagnostic Trouble Code

The wheel with the diagnostic trouble code is 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.

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 disabled. The system reverts to normal braking. When the correct voltage level is restored, full ABS and ATC function is available. The operating voltage range is 9.0 to 17.0 VDC for 12 volt systems, and 20 to 33.5 volts for 24 volt systems.

Steering Angle Sensor Diagnostic Trouble Code