BENDIX SD-13-4863 User Manual

Bendix® EC-60™ ABS / ATC Controllers (Standard & Premium)

Frame Mount Cab Mount

SD-13-4863

Standard Frame

Standard Cab

Premium Frame Premium Cab

See SD-13-4869 for Advanced Controllers

INTRODUCTION Bendix

EC-60™ controllers are members 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 modulator valves, and an ECU to control either four or six wheels of a vehicle. By monitoring individual wheel turning motion during braking, and adjusting or pulsing the brake pressure at each wheel, the EC-60™ controller is able to optimize slip between the tire and the road surface. When excessive wheel slip, or wheel lock-up, is detected, the EC-60™ controller will activate the Pressure Modulator Valves to simulate a driver pumping the brakes. However, the EC-60™ controller is able to pump the brakes on individual wheels (or pairs of wheels), independently, and with greater speed and accuracy than a driver.

In addition to the ABS function, premium models of the EC-60™ controller provide an Automatic Traction Control (ATC) feature. Bendix ATC can improve vehicle traction during acceleration, and lateral stability while driving 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.

Premium 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.

Two Connectors Are Used

Three Connectors Are Used.

(If all four connectors are in use - see the

Advanced SD sheet SD-13-4869)

FIGURE 1 - EC-60™ CONTROLLERS

TABLE OF CONTENTS PAGE General System Information

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

Components...........................2

ECU Mounting ......................... 2

EC-60™ Controller Hardware Congurations ..3

EC-60™ Controllers with PLC ..............3

EC-60™ Controller Inputs .................3

ABS Off-Road Switch and Indicator Lamp ....4

EC-60™ Controller Outputs................4

Power-Up Sequence .................... 5

ABS Operation . . . . . . . . . . . . . . . . . . . . . . . . . 6

ATC Operation ......................... 7

Dynamometer Test Mode .................8

Automatic Tire Size Calibration ............9

ABS Partial Shutdown ................... 9

System Reconguration

EC-60™ Controller System Reconguration ..10

Troubleshooting

General.............................. 11

Blink Codes and Diagnostic Trouble Codes..12 Using Hand-Held or PC-based Diagnostics ..15 Diagnostic Trouble Codes:

Troubleshooting Index................17

Trouble Code Tests ...............18 - 27

Connectors and Harnesses ...........28 - 31

Wiring ............................32 - 34

Wiring Schematics ..................35 - 40

Glossary .............................41

Appendix: J1587 SID and FMI Codes ....42-44

90° Speed

Sensors

Sensor

Clamping

Sleeve

Straight Speed

Sensors

WS-24™ WHEEL SPEED SENSORS

Delivery

(Port 2)

Supply (Port 1)

FIGURE 4 - POWER LINE WITHOUT PLC SIGNALFIGURE 2 - BENDIX

M-32QR

Modulator

FIGURE 3 - M-32

™

Electrical

Connector

Exhaust (Port 3)

™

AND M-32QR™ MODULATORS FIGURE 5 - POWER LINE WITH PLC SIGNAL

™

M-32

Modulator

COMPONENTS

The EC-60™ controller’s ABS function utilizes the following components:

• Bendix depending on ECU and conguration). Each sensor is

installed with a Bendix Sensor Clamping Sleeve

• Bendix (4, 5, or 6 depending on ECU and conguration)

• Dash-mounted tractor ABS Indicator Lamp

• Service brake relay valve

• Dash-mounted trailer ABS Indicator Lamp (used on all

towing vehicles manufactured after March 1, 2001)

• Optional blink code activation switch

• Optional ABS off-road switch. (Off-road feature is not

available on all ECUs - See Chart 1.)

The EC-60™ controller ATC function utilizes the following additional components:

• 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 off-road switch

WS-24™ wheel speed sensors (4 or 6,

M-32™ or M-32QR™ Pressure Modulator V alves

ECU MOUNTING

Cab ECUs

Cab-mounted EC-60™ controllers are 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.

CAUTION: All unused ECU connectors must be covered and receive any necessary protection from moisture, etc.

Cab ECUs utilize connectors from the AMP MCP 2.8 product family.

Frame ECUs

Frame-mounted EC-60™ controllers may be mounted on the vehicle frame, but only in locations where they will not be subjected to direct tire spray . ECU mounting bolts must be torqued to 7.5 to 9 Nm.

CAUTION: The frame wire harness connectors must be properly seated with the seals intact (undamaged). All unused connector terminals must be plugged with the appropriate sealing plugs. Failure to properly seat or seal the connectors could result in moisture or corrosion damage to the connector terminals. ECUs damaged by moisture and/or corrosion are not covered under the Bendix warranty.

Frame ECUs utilize Deutsch connectors.

ECU

Model

Standard Standard

PLC

Premium

Mounting

Cab

Frame

Cab

Frame

Cab

Frame

Input

Voltage

Sensors PMVs ATC

12 4 4

12 4/6 4/5/6

Premium Cab 24 4/6 4/5/6

HARDWARE CONFIGURATIONS

Standard Models

Standard EC-60™ controllers support four sensor/four modulator (4S/4M) applications. Certain models support Power Line Carrier (PLC) communications, with all models supporting 12 volt installations. See Chart 1 for more

details.

Premium Models

Premium EC-60™ controllers support applications up to six sensor/six modulator (6S/6M) installations with ATC and drag torque control. All 12 volt models support PLC. 24 volt models do not support PLC. See Chart 1 for more details.

Blink

Codes

Serial Communication

PLC

J1587 J1939

CHART 1 - EC-60™ CONTROLLERS AV AILABLE

ABS

Off-

Road

ATC

Off-

Road

Retarder

Relay

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 through a 5 amp fuse.

Ground Input

The EC-60™ controller supports one ground input. See pages 35 to 40 for system schematics.

EC-60™ CONTROLLERS WITH PLC

Since March 1, 2001, all towing vehicles must have an in-cab trailer ABS Indicator Lamp. Trailers 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 4 and 5. Typically the signal is broadcast by the trailer ABS ECU. The application of PLC technology for the heavy vehicle industry is known as “PLC4Trucks.” The Standard PLC EC-60™ controller and the Premium EC-60™ controller (12 volt versions) support PLC communications in accordance with SAE J2497.

Identifying an EC-60™ Controller with PLC

Refer to the information panel on the ECU label to see if the controller provides PLC.

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 5.0 mVp-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 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.

Alternatively, the part number shown on the ECU label

can be identied as a PLC or non-PLC ECU by calling the

Bendix T echTeam at 1-800-AIR-BRAKE (1-800-247-2725).

ABS Indicator Lamp Ground Input (Cab ECUs Only)

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 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 EC-60™ controller receives the AC signal, which varies in voltage and frequency as the wheel speed changes.

Vehicle axle congurations and ATC features 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 ABS and ATC 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.

ABS OFF-ROAD SWITCH AND INDICATOR LAMP OPERATION

WARNING: The ABS off-road mode should not be

used on normal, paved road surfaces because vehicle stability and steerability may be affected. When the ECU is placed in the ABS of f-road mode, the ABS Indicator Lamp

will ash constantly to notify the vehicle operator that the

off-road mode is active. Premium EC-60™ controllers use a dash-mounted switch

to place the ECU into the ABS off-road mode. In some cases, ECUs may also be put into the ABS of f-road mode by one of the other vehicle control modules, using a J1939 message to the EC-60™ controller.

(If you need to know if your 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.)

Stop Lamp Switch (SLS)

The Premium 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 know the driver’s intention. This can be provided to the ECU via J1939 communications, or hardware input.

EC-60™ CONTROLLER OUTPUTS

1. During power up (e.g. when the vehicle is started) and turns off after the self test is completed, providing no Diagnostic Trouble Codes (DTCs) are present on the tractor.

2. If the ECU is unplugged or has no power.

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

(the lamp ashes rapidly).

4. T o display blink codes for diagnostic purposes after the external diagnostic switch is activated.

Certain models of the EC-60 other vehicle control modules to operate the ABS Indicator Lamp using serial communications. (If you need to know if your EC-60™ controller uses serial communications to operate the lamp, e-mail ABS@bendix.c om, specifying the ECU part number, or call 1-800-AIR-BRAKE and speak to the Bendix TechTeam.)

™

controller communicate with

Indicator Lamp Control Using Serial Communications Links

As mentioned above, depending on the vehicle manufacturer, the dash indicator lamps (ABS, ATC, 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).

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 EC-60™ controller to modify driver applied air pressure to the service brakes during ABS or ATC activation (See pages 6-8). The PMV is an electro-pneumatic 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 precisely modify the brake pressure during an antilock braking event. The hold solenoid is normally open and the release solenoid is normally closed.

Traction Control Valve (TCV)

Premium EC-60™ controllers will activate the TCV during differential braking ATC events. The TCV may be a separate valve or integrated into the rear axle relay valve.

ABS Indicator Lamp Control with Optional Diagnostic Blink Code Switch (Cab and Frame ECUs)

Cab and frame-mount EC-60™ controllers have internal circuitry to control the ABS Indicator Lamp on the dash panel.

The ABS Lamp Illuminates:

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.

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

Premium EC-60™ controllers utilize the J1939 data link for ATC and drag torque control functions.

Trailer ABS Indicator Lamp Control

Certain models of the EC-60™ controller 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. Typically, the EC-60™ controller directly controls the trailer ABS Indicator Lamp based on the information it receives from the trailer ABS.

ABS System

Status Indicators

Powered Vehicle ABS

Indicator Lamp

Trailer ABS

Indicator Lamp

(PLC Detected)*

ON OFF

0.5

Power

Application

2.5

2.0

ATC System

Power

Application

Status Indicator

3.0 (sec.)1.5

Engine torque limiting

and differential braking

enabled

No ATC

0.5

ON OFF

2.0

2.5

3.0 (sec.)1.5

Trailer ABS Indicator

(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.

FIGURE 6 - ABS DASH LAMP START UP SEQUENCE

Lamp

ON OFF

Alternatively , some vehicles require the 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 your 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.

ATC Lamp Output/ATC Off-Road Switch Input

Premium ECUs control the ATC dash lamp. The ATC Lamp Illuminates:

1. During power up (e.g. when the vehicle is started) and turns off after the self test is completed, providing no diagnostic trouble codes are present.

2. When ATC is disabled for any reason.

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

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

lamp will ash slowly at a rate of 1.0 seconds on, 1.5 seconds off). This noties the vehicle operator that the

off-road mode is active.

Interaxle Differential Lock Control (AWD Transfer Case) Premium ECUs can control the interaxle dif ferential

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.

FIGURE 7 - ATC INDICATOR LAMP START UP SEQUENCE

POWER-UP SEQUENCE

WARNING: The vehicle operator should verify proper

operation of all installed indicator lamps (ABS, ATC, and trailer ABS) when applying ignition power and during vehicle operation. See Figures 6 and 7.

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

ABS Indicator Lamp Operation

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 Status/Indicator Lamp Operation

The ECU will illuminate the ATC 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 illuminate the ATC Indicator Lamp whenever ATC is disabled due to a diagnostic trouble code.

Trailer ABS Indicator Lamp Operation

Certain models of the ECU will control the Trailer ABS Indicator Lamp when a PLC signal (SAE J2497) from a trailer ABS ECU is detected.

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 Chuff Test

After the performance of the conguration test, the EC-60

controller will perform a Bendix-patented PMV Chuff Test.

™

Right Steer

Driver

Left Steer

Right Drive

Left Drive

Additional

Left

Additional

Right

FIGURE 8 - VEHICLE ORIENTATION (TYPICAL)

The Chuff Test is an electrical and pneumatic PMV test that can assist maintenance personnel in verifying proper PMV wiring and installation.

With brake pressure applied, a properly installed PMV will perform one sharp audible exhaust of air by activating the hold solenoid twice and the release solenoid once. If the PMV is wired incorrectly, it will produce two exhausts of air or none at all.

The 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

The pattern will then repeat itself. The ECU will not perform the PMV Chuff Test when wheel

speed sensors show that the vehicle is in motion.

ABS OPERATION

Bendix ABS uses wheel speed sensors, ABS modulator valves, and an ECU to control either four or six wheels of a vehicle. By monitoring individual wheel turning motion during braking, and adjusting or pulsing the brake pressure at each wheel, the EC-60™ controller is able to optimize slip between the tire and the road surface. When excessive wheel slip, or wheel lock-up, is detected, the EC-60 controller will activate the Pressure Modulator Valves to simulate a driver pumping the brakes. However, the EC-60™ controller is able to pump the brakes on individual wheels (or pairs of wheels), independently , and with greater speed and accuracy than a driver.

Steer Axle Control

Although both wheels of the steer axle have their own wheel speed sensor and pressure modulator valve, the 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 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 the vehicle stops with normal braking.

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.

T o avoid this, the 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, 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 ABS may be longer than without ABS. This can occur when a locked wheel on soft ground plows up the road surface in front of the tire, changing the rolling friction value. Although vehicle stopping distance with a locked wheel may be shorter than corresponding stopping distance with ABS control, vehicle steerability and stability is reduced.

Premium EC-60™ controllers have an optional control mode that more effectively accommodates these soft road conditions to shorten stopping distance while maintaining optimal vehicle steerability and stability.

WARNING: The ABS off-road mode should not be

used on normal, paved road surfaces because vehicle

stability and steerability may be reduced. The ashing

ABS Indicator Lamp communicates the status of this mode to the driver.

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.

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.

Premium EC-60

for this conguration to control the differential lock/unlock

solenoid in the A WD 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.

™

controllers can be programmed specically

ATC OPERATION

ATC Functional Overview

Just as ABS improves vehicle stability during braking, ATC improves vehicle stability and traction during vehicle acceleration. The EC-60™ controller A TC function uses the same wheel speed information and modulator control as the ABS function. The EC-60™ controller detects excessive drive wheel speed, compares the speed of the front, nondriven wheels, and reacts to help bring the wheel spin under control. The EC-60 engine torque limiting and/or differential braking to control wheel spin. For optimal ATC performance, both methods are recommended.

ATC Lamp Operation

The ATC Lamp Illuminates:

1. During power up (e.g. when the vehicle is started) and turns off after the self test is completed, providing no diagnostic trouble codes are present.

2. When ATC is disabled for any reason.

3. During an ATC event (the lamp will ash rapidly). When

A TC is no longer active, the A TC active/indicator lamp turns off.

4. When the ECU is placed in the A TC of f-road mode (the

lamp will ash at a rate of 1.0 seconds on, 1.5 seconds off). This noties the vehicle operator that the off-road

mode is active.

Differential Braking

Differential braking is automatically activated when drive wheel(s) on one side of the vehicle are spinning, which typically occur on asphalt road surfaces with patches of ice. The traction system will then lightly apply the brake to the drive wheel(s) that are spinning. The vehicle differential will then drive the wheels on the other side of the vehicle.

Differential braking is available at vehicle speeds up to 25 MPH.

™

controller can be congured to use

Disabling ATC Differential Braking

ATC differential braking is disabled under the following conditions:

1. During power up (e.g. when the vehicle is started), until the ECU detects a service brake application.

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

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

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

5. During brake torque limiting to avoid overheating of the brakes.

6. When certain diagnostic trouble code conditions are detected.

Engine Torque Limiting (ETL) with Smart ATC™ Traction Control

The 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 A TC™ Traction Control

The EC-60™ controller has an additional feature known as Smart A TC™ traction control. Smart ATC™ traction control monitors the accelerator pedal position (using J1939) to help provide optimum traction and vehicle stability. By knowing the driver’s intention 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 target wheel slip is decreased when driving through a

curve for improved stability.

Disabling A TC Engine Control and Smart A TC™ 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 Off-Road Mode

In some road conditions, the vehicle operator may desire additional drive wheel slip when ATC is active. The Premium EC-60™ controller has an optional control mode to permit this desired performance.

The vehicle operator can activate the off-road function with a switch on the dash panel. Alternately, a J1939 message may be used to place the vehicle in this mode. The ATC

Indicator Lamp will ash continually to conrm that the

off-road ATC function is engaged. To exit the ATC off-road mode, depress and release the

ATC off-road switch.

Drag Torque Control Functional Overview

Premium 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.

DYNAMOMETER TEST MODE

WARNING: A TC must be disabled prior to conducting

any dynamometer testing. When the Dynamometer Test Mode is enabled, ATC brake control and engine control along with drag torque control 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 purpose.

The Dynamometer T est 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. The Dynamometer Test Mode will remain active even if

power to the ECU is removed and re-applied. Press and release the blink code switch three times, or use a handheld or PC-based diagnostic tool to exit the test mode.

AUTOMATIC TIRE SIZE CALIBRATION

The ECU requires a precise rolling circumference ratio between steer axle and drive axle tires in order for ABS and A TC to perform in an opt imal manner. For this reason, a learning process continuously 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 are 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.

ABS PARTIAL SHUTDOWN

Depending which component the trouble code is detected on, the ABS and ATC functions may be fully or partially disabled. Even with the ABS indicator lamp on, the E C-60 controller may still provide ABS function on wheels that are not affected. The EC-60™ 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.

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.

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 front axle. ABS remains active on the rear wheels. ATC is disabled.

Drive Axle/Additional Axle Wheel Speed Sensor Diagnostic Trouble Code

ATC is disabled. In a four sensor system, ABS on the affected wheel is disabled, but ABS on all other wheels remains active.

In a six sensor system, ABS remains active by using input from the remaining rear wheel speed sensor on the same side.

ATC Modulator Diagnostic Trouble Code

ATC is disabled. ABS remains active.

J1939 Communication Diagnostic Trouble Code

ATC is disabled. ABS remains active.

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ECU Diagnostic Trouble Code

ABS and ATC are disabled. The system reverts to normal braking.

Voltage Diagnostic Trouble Code

While voltage is out of range, ABS and ATC are disabled. The system reverts to normal braking. When the correct voltage level is restored, full ABS and ATC function is available. Operating voltage range is 9.0 to 17.0 VDC.

Reconguring EC-60

™

Controllers

SYSTEM RECONFIGURATION

The EC-60™ controller is designed to allow the technician to change the default system settings (chosen by the vehicle OEM) to provide additional or customized features. When replacing an ECU, be sure to use an equivalent Bendix replacement part number so that the standard default settings are provided.

Depending on the model, the customizable features include ABS control settings, engine module communication etc.

Many of these settings can be recongured using a hand-

held or PC-based software, such as the Bendix Diagnostics program.

ACom

ECU RECONFIGURATION

Reconguring Standard ECUs

Reconguring an EC-60

using the Blink Code Switch or by using a hand-held or PC-based diagnostic tool.

Note: During the reconguration process, and independently from any reconguration being carried out by the technician,

standard ECUs automatically check the J1939 serial link and communicate with other vehicle modules. In particular, if the serial link shows that the vehicle has a retarder device

present, the ECU will congure itself to communicate with

the retarder device for improved ABS performance. For example, if the ECU detects the presence of a retarder

disable relay during a reconguration, it will congure

itself to control the relay to disable the retarding device as needed.

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controller may be carried out by

Reconguring Premium ECUs

As with standard ECUs, the Premium EC-60™ controller

also carries out, independently from any reconguration

being carried out by the technician, an automatic check of the J1939 serial link and communicates with other vehicle modules. This includes checking for ATC and retarder disable relay operation. In addition, premium EC-60™ controllers will determine the number of wheel

speed sensors and PMVs installed and congure itself

accordingly.

6S/5M Conguration

Premium EC-60™ controllers will configure for 6S/5M

operation when a reconguration event is initiated and the

ECU detects that an additional axle PMV is wired as follows:

PMV Connector ECU Connector Hold Right Additional Axle Hold Release Left Additional Axle Release Common Right Additional Axle Common

See 6S/5M System Schematics (pages 37 & 40) for details.

Reconguration Using the Blink Code Switch

The reconguration event is the same for both Standard

and Premium ECUs. With ignition power removed from the EC-60™ controller, depress the blink code switch. After the ignition power is activated, depress and release the switch

seven times to initiate a reconguration event.

Diagnostic Tool

A reconguration event may be initiated using a hand-held

or PC-based diagnostic tool to communicate with the ECU over the SAE J1587 diagnostic link.

Troubleshooting: General

GENERAL SAFETY GUIDELINES

WARNING! PLEASE READ AND FOLLOW

THESE INSTRUCTIONS TO A VOID 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 electrically charged components.

3. Do not attempt to install, remove, disassemble

or assemble a component until you have read and thoroughly understand the recommended procedures. Use only the proper tools and observe all precautions pertaining to use of those tools.

4. If the work is being performed on the vehicle’s

air brake system, or any auxiliary pressurized air systems, make certain to drain the air pressure from all reservoirs before beginning ANY work on the vehicle. If the vehicle is equipped with a Bendix 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® brand eplacement parts,

components and kits. Replacement hardware,

tubing, hose, ttings, etc. must be of equivalent

size, type and strength as original equipment and

be designed specically 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 specically stated and approved by the

vehicle and component manufacturer.

AD-IS® air dryer system or a dryer reservoir

10. Prior to returning the vehicle to service, make certain all components and systems are restored to their proper operating condition.

11. For vehicles with Automatic T raction Control (ATC), the ATC function must be disabled (ATC indicator lamp should be ON) prior to performing any vehicle maintenance where one or more wheels on a drive axle are lifted off the ground and moving.

REMOVING THE EC-60™ CONTROLLER ASSEMBLY

1. Turn vehicle ignition off.

2. Remove as much contamination as possible prior to

disconnecting air lines and electrical connections.

3. Note the EC-60™ controller assembly mounting position

on the vehicle.

4. Disconnect the electrical connectors from the EC-60

controller.

5. Remove and retain the mounting bolts that secure the

EC-60™ controller.

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INSTALLING A NEW EC-60™ CONTROLLER

CAUTION! When replacing the EC-60™ controller, verify

that the unit you are installing has the correct default settings. Failure to do so could result in a loss of features, such as ATC and PLC, or noncompliance with U.S. regulations such as FMVSS 121. It is recommended to use only the correct replacement part number. However,

most conguration settings can be altered using the Bendix

ACom® ABS Diagnostic Software program. Verify correct operation of the EC-60™ controller system

and indicator lamps prior to putting the vehicle back into service. Towing vehicles manufactured after March 1, 2001 must support the trailer ABS indicator lamp located on the dash.

For further information, contact either the vehicle manufacturer, Bendix or your local authorized Bendix dealer.

1. Position and secure the EC-60™ controller in the original

mounting orientation using the mounting bolts retained during removal. On frame-mount ECUs, torque the mounting bolts to 7.5 to 9 NM (66-80 in. Ibs). For cabmount units use no more torque than is necessary to

rmly secure the ECU into position. Over-tightening the

mounting hardware can cause damage to the EC-60 controller.

2. Reconnect the electrical connectors to the EC-60

controller.

3. Apply power and monitor the EC-60™ controller power-

up sequence to verify proper system operation.

See Troubleshooting: Wiring section beginning on page 32 for more information on wiring harnesses.

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Troubleshooting: Blink Codes and Diagnostic Modes

ECU DIAGNOSTICS

The EC-60™ controller contains self-testing diagnostic circuitry that continuously checks for the normal operation of internal components and circuitry, as well as external ABS components and wiring.

Active Diagnostic Trouble Codes

When an erroneous system condition is detected, the EC-60™ controller:

1. Illuminates the appropriate indicator lamp(s) and disengages part or all of the ABS and ATC functions. (See page 9.)

2. Places the appropriate trouble code information in the ECU memory.

3. Communicates the appropriate trouble code information over the serial communications diagnostic link as required. Hand-held or PC-based diagnostic tools attach to the vehicle diagnostic connector, typically located on or under the dash (see Figure 9).

Located on Dash Panel

FIGURE 9 - TYPICAL VEHICLE DIAGNOSTIC CONNECTOR

LOCATIONS (J1708/J1587, J1939)

Located Under

Dash Panel

BLINK CODES

Blink codes allow a technician to troubleshoot ABS problems without using a hand-held or PC-based diagnostic tool. Instead, information about the ABS system is communicated by the ECU using the ABS indicator lamp to display sequences of blinks.

Note: The ECU will not enter the diagnostic blink code mode if the wheel speed sensors show that the vehicle is in motion. If the ECU is in the diagnostic blink code mode and then detects vehicle motion, it will exit the blink code mode.

In addition, by operating the blink code switch as described below, one of several diagnostic modes can be entered. See Diagnostic Modes below.

Blink Code Switch Activation

When activating the blink code switch:

1. Wait at least two seconds after “ignition on.” (Except when

entering Reconguration Mode - see Reconguration

section on page 10)

2. For the ECU to recognize that the switch is activated “on,” the technician must press for at least 0.1 seconds, but less than 5 seconds. (If the switch is held for more than 5 seconds, the ECU will register a malfunctioning switch.)

3. Pauses between pressing the switch when a sequence is required, (e.g. when changing mode) must not be longer than 2 seconds.

4. After a pause of 3.5 seconds, the ECU will begin responding with output information blinks. See Figure 10 for an example.

FIGURE 10 - EXAMPLE OF BLINK CODE MESSAGE

Blink Code Timing

The ECU responds with a sequence of blink codes. The overall blink code response from the ECU is called a “message.” Each message includes, depending on the mode selected by the technician, a sequence of one or more groups of blinks. Simply record the number of blinks for each sequence and then use the troubleshooting index on page 17 for active or inactive trouble codes and you will be directed to the page that provides troubleshooting information.

NOTE:

1. Sequences of blinks illuminate the ABS indicator lamp for half a second, with half-second pauses between them.

2. Pauses between blink code digits are 1.5 seconds.

3. Pauses between blink code messages are 2.5 seconds.

4. The lamp remains on for 5 seconds at the end of messages.

See Figure 10 for an example showing the message:

2,1 followed by 2,2.

Once the ABS indicator lamp begins displaying a sequence of codes, it continues until all blink code messages have been displayed and then returns to the normal operating mode. During this time, the ECU will ignore any additional blink code switch activation.

All trouble codes, with the exception of voltage and J1939 trouble codes, will remain in an active state for the remainder of the power cycle.

Voltage trouble codes will clear automatically when the voltage returns within the required limits. All ABS functions will be re-engaged.

J1939 trouble codes will clear automatically when communications are re-established.

DIAGNOSTIC MODES

In order to communicate with the ECU, the controller has several modes that the technician can select, allowing information to be retrieved, or other ECU functions to be accessed.

Diagnostic Modes

To enter the various diagnostic modes:

No. of

Times to

Press the

Blink Code

Switch

1 Active diagnostic trouble code retrieval 2 Inactive diagnostic trouble code retrieval 3 Clear active diagnostic trouble codes 4 System conguration check 5 Dynamometer Test Mode

7* Recongure ECU

* To enter the Reconguration Mode, the switch must be held

in before the application of ignition power. Once the power is supplied, the switch is released and then pressed seven times.

Active Diagnostic Trouble Code Mode

For troubleshooting, typically the Active and Inactive Diagnostic Trouble Retrieval Modes are used. The technician presses the blink code switch once and the ABS

indicator lamp ashes a rst group of two codes, and if

there are more trouble codes recorded, this is followed by a second set of codes, etc. (See page 17 for a directory of these codes.) All active trouble codes may also be retrieved using a hand-held or PC-based diagnostic tool, such as the Bendix® ACom® Diagnostics software.

To clear active diagnostic trouble codes (as problems

are xed), simply clear (or “self-heal”) by removing and

re-applying ignition power. The only exception is for wheel speed sensor trouble codes, which clear when power is removed, re-applied, and the ECU detects valid wheel speed from all wheel speed sensors. Alternately, codes may be cleared by pressing the diagnostic blink code switch 3 times (to enter the Clear Active Diagnostic Trouble Code Mode) or by using a hand-held or PC-based diagnostic tool. Hand-held or PC-based diagnostic tools are able to clear wheel speed sensor trouble codes without the vehicle being driven.

System Mode Entered

CHART 2 - DIAGNOSTIC MODES

Inactive Diagnostic Trouble Code Mode

The ECU stores past trouble codes and comments (such

as conguration changes) in its memory. This record is

commonly referred to as “event history.” When an active trouble code is cleared, the ECU stores it in the event history memory as an inactive trouble code.

Using blink codes, the technician may review all inactive trouble codes stored on the ECU. The ABS indicator

lamp will display inactive diagnostic blink codes when the diagnostic blink code switch is depressed and released two times. See page 17 for the index showing trouble codes

and the troubleshooting guide page to read for help. Inactive trouble codes, and event history , may be retrieved

and cleared by using a hand-held or PC-based diagnostic tool, such as the Bendix® ACom® Diagnostics software.

Clearing Active Diagnostic Trouble Codes

The ECU will clear active trouble codes when the diagnostic blink code switch is depressed and released three times.

System Conguration Check Mode

The ABS indicator lamp will display system conguration

information when the diagnostic blink code switch is depressed and released four times. The lamp will blink

out conguration information codes using the following

patterns. (See Chart 3).

1st Number System Power 1 12 Volts 2 24 Volts 2nd Number Wheel Speed Sensors 4 4 Sensors 6 6 Sensors 3rd Number Pressure Modulator Valves 4 4 Modulators 5 5 Modulators 6 6 Modulators 4th Number ABS Conguration 1 4S/4M or 6S/6M 2 6S/4M 3 6S/5M 5th Number Traction Control Conguration 2 No ATC 3 ATC Engine Control Only 4 ATC Brake Control Only 5 Full ATC (Engine Control & Brake Control) 6th Number Retarder Conguration 1 No Retarder 2 J1939 Retarder 3 Retarder Relay 4 J1939 Retarder, Retarder Relay

CHART 3 - SYSTEM CONFIGURATION CHECK

In this mode the ECU tells the technician, by means of a series of six blink codes, the type of ABS system that the ECU has been set up to expect. For example, if the fourth blink code is a three, the technician knows that a 6S/5M

sensor/modulator conguration has been set.

Dynamometer Test Mode

The Dynamometer T est Mode is used to disable A TC when needed (e.g. when performing any vehicle maintenance where the wheels are lifted off the ground and moving, including dyno testing). This mode is not reset by power off, power on, cycling. Instead a hand-held or PC-based diagnostic tool must be used to change the setting. Alternatively, depressing and releasing the blink code switch three times will cause the ECU to exit the blink code mode.

Recongure ECU Mode

Vehicle reconfiguration is carried out by using the

Recongure ECU Mode. (See page 10.) Note: To enter the Reconguration Mode, the blink code switch must be

held in before the application of ignition power. Once the power is supplied, the switch is released and then pressed seven times.

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