BENDIX EC-60 ABS User Manual

1
ESP
®
is a registered trademark of DaimlerChrysler and is used by BCVS under license from DaimlerChrysler.
®
SD-13-4869
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
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.
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.
All Four Connectors Are Used.
(If only two or three connectors are in
use - see SD-13-4863)
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.

BENDIX EC-60 ABS Specifications

General

Type	ABS Controller
Function	Anti-lock Braking System control
Model	EC-60
Manufacturer	Bendix
Operating Temperature	-40°C to +85°C
Compatibility	Heavy-duty Vehicles

Summary

General Safety Guidelines

Preventing Personal Injury or Death

Instructions to prevent personal injury or death during operation.

ESP System Operation Cautions

Cautions regarding the use and limitations of the ESP stability system.

ESP System Functions

Yaw Control (YC)

Counteracts trailer push and loss-of-control incidents.

EC-60 Controller Components

Steering Angle Sensor

Reports steering wheel position to the controller.

Yaw Rate/Lateral Acceleration Sensors

Indicate vehicle lateral acceleration and rotation.

ABS Operation and System Tests

ABS Operation Overview

How the ABS system controls wheel braking.

ATC Operation Details

ATC Functional Overview

Uses wheel speed and modulator control for traction enhancement.

Advanced ABS With Stability Control

Overview of ESP System

ESP reduces risk of rollovers, jackknifing, and loss-of-control events.

Roll Stability Program (RSP)

Addresses rollover conditions by applying brakes and reducing speed.

Yaw Stability

Counteracts tendency of vehicle to spin about its vertical axis.

Yaw Control

Reduces throttle and applies brakes to prevent slide and jackknife.

Important Safety Information for ESP System

Automatic Vehicle Speed Reduction

ESP can automatically decelerate the vehicle.

Towing Doubles or Triples

ESP effectiveness may be reduced when towing multiple trailers.

Limitations of Stability Systems

Factors that can reduce ESP system effectiveness.

Maximizing ESP Effectiveness

Recommendations for maximizing ESP system effectiveness.

System Configuration and Maintenance

Steering Angle Sensor Re-Calibration

Procedure and importance of recalibrating the steering angle sensor.

Automatic Tire Size Calibration

How the ECU calibrates tire sizes for optimal performance.

General Troubleshooting Procedures

General Safety Guidelines

Essential safety instructions to prevent injury or death.

Sensor Calibration and Removal

Steering Angle Sensor Calibration

Procedure for calibrating the steering angle sensor.

Yaw Rate Sensor Calibration

Procedure for calibrating the Yaw Rate sensor.

Brake Demand Sensor Calibration and Installation

Brake Demand Sensor Calibration

Conditions and procedure for calibrating brake demand sensors.

Troubleshooting: Blink Codes and Diagnostic Modes

ECU Diagnostics

ECU's self-testing diagnostic circuitry and trouble code communication.

Active Diagnostic Trouble Codes

How the ECU handles and indicates active trouble codes.

Blink Codes

Using blink codes to troubleshoot ABS problems.

Diagnostic Modes Overview

Active Diagnostic Trouble Code Mode

Retrieving active diagnostic trouble codes via blink codes.

Inactive Diagnostic Trouble Code Mode

Reviewing stored inactive trouble codes and event history.

Clearing Active Diagnostic Trouble Codes

Procedures for clearing active diagnostic trouble codes.

ECU Reconfiguration

Reconfigure ECU Mode

How to reconfigure the ECU using specific modes.

Troubleshooting with Diagnostic Tools

Bendix RDU (Remote Diagnostic Unit)

Using the RDU tool for ABS diagnostics and DTC reporting.

LED Diagnostic Trouble Codes

Interpreting diagnostic trouble codes displayed by LEDs.

Diagnostic Tool Functions and Software

Bendix RDU Reset Function

How to reset the RDU tool and clear codes.

Bendix ACom Diagnostics Software

Using ACom software for diagnostics and calibration.

Troubleshooting Wheel Speed Sensors

Troubleshooting Power Supply Codes

Power Supply Tests

Tests to perform for power supply issues.

Troubleshooting Pressure Modulator Valves

Troubleshooting J1939 Serial Communications

Troubleshooting Miscellaneous DTCs

Troubleshooting Miscellaneous DTCs (Continued)

Troubleshooting ECU DTCs

Bendix ACom Software for ECU DTCs

Using ACom software for ECU DTC interpretation.

Troubleshooting Traction Control Valves

Traction Control Valve Repair Tests

Tests for troubleshooting TCV trouble codes.

Troubleshooting Steering Angle Sensor (SAS)

Steering Angle Sensor Tests and Calibration

Steering Angle Sensor Tests

Tests and calibration procedures for the Steering Angle Sensor.

Troubleshooting Yaw Rate Sensor (YRS)

Yaw Rate Sensor Tests and Calibration

Yaw Rate Sensor Tests

Tests and calibration procedures for the Yaw Rate Sensor.

Troubleshooting Lateral Acceleration Sensor (LAS)

Troubleshooting Brake Demand/Load Sensors

Brake Demand/Load Sensor Tests

Tests for Brake Demand/Load Sensors.

Controller Connector Pin Assignments

Wiring Troubleshooting and Requirements

ABS/ATC Wiring Requirements

ECU wiring harness connector requirements and seating.

ABS Wiring Best Practices

Best practices for ABS wiring, including wire size and twisting.

Wiring Schematic

Appendix A: Troubleshooting Blink Codes

Advanced In-Cab ECU Troubleshooting

Troubleshooting steps for advanced in-cab ECU faults.

Appendix B: J1587/FMI and Blink Code Equivalents

Wheel Speed Sensor DTCs

J1587/FMI codes for wheel speed sensor DTCs.

Pressure Modulator Valve DTCs

J1587/FMI codes for PMV DTCs.

Miscellaneous DTCs

J1587/FMI codes for miscellaneous DTCs.

TCV DTCs

Steering Angle Sensor DTCs

HSA DTCs

Lateral Acceleration Sensor DTCs

Appendix C: UDS Code Equivalents

ECU Faults