SD-13-4869 Bendix EC-60 ABS / ATC / ESP Controllers .
SD-13-4869 Bendix EC-60 ABS / ATC / ESP Controllers (Advanced Models)See SD-13-4863 for Standard and Premium ControllersFIGURE 1 - EC-60 ADVANCED CONTROLLERINTRODUCTIONThe Bendix EC-60 advanced controller is a memberof a family of electronic Antilock Braking System(ABS) devices designed to help improve the brakingcharacteristics of air braked vehicles - including heavy andmedium duty buses, trucks, and tractors. ABS controllersare also known as Electronic Control Units (ECUs).Bendix ABS uses wheel speed sensors, ABS pressuremodulator valves, and an ECU to control either four orsix wheels of a vehicle. The EC-60 controller monitorsindividual wheel turning motion during braking and adjustsor modulates the brake pressure at the wheel end. Whenexcessive wheel slip, or wheel lock-up is detected, theEC-60 controller will activate the pressure modulatorvalves to automatically reduce the brake pressure at oneor more of the wheel ends. By these actions, the ABSsystem helps to maintain the vehicle's lateral stability andsteerability during heavy brake applications and duringbraking on slippery surfaces.TABLE OF CONTENTSPAGEGeneral System InformationIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2ECU Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3EC-60 Controller Hardware Configurations . . . . . . 3EC-60 Controllers with PLC . . . . . . . . . . . . . . . . . . 3EC-60 Controller Inputs . . . . . . . . . . . . . . . . . . . . . 4ABS Off-Road Switch and Indicator Lamp . . . . . . . . 4EC-60 Controller Outputs . . . . . . . . . . . . . . . . . . . . 5Power-Up Sequence. . . . . . . . . . . . . . . . . . . . . . . . . 6ABS Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7ATC Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Advanced ABS with Stability . . . . . . . . . . . . . . . . . . . 9Yaw Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Dynamometer Test Mode . . . . . . . . . . . . . . . . . . . . . 9Automatic Tire Size Calibration. . . . . . . . . . . . . . . . 10ABS Partial Shutdown . . . . . . . . . . . . . . . . . . . . . . 10System ReconfigurationEC-60 Controller System Reconfiguration . . . . . . 11TroubleshootingGeneral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Steering Angle Sensor Calibration . . . . . . . . . . . . . 13Yaw Rate/Lateral Acceleration Calibration . . . . . . . 14Diagnostic Trouble Codes. . . . . . . . . . . . . . . . . . . . 16Using Hand-Held or PC-based Diagnostics . . . . . . 19Diagnostic Trouble Code Troubleshooting Index . . 21Trouble Code Tests . . . . . . . . . . . . . 22 - 37Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39-41Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . 42Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43J1587 SID and FMI Codes . . . . . . . . . . . . . . . 44-47In addition to the ABS function, advanced models of theEC-60 controller provide an Automatic Traction Control(ATC) feature. Bendix ATC can improve vehicle tractionduring acceleration, and lateral stability while acceleratingthrough curves. ATC utilizes Engine Torque Limiting(ETL) where the ECU communicates with the engine’scontroller and/or Differential Braking (DB) whereindividual wheel brake applications are used to improvevehicle traction.Advanced EC-60 controllers have a drag torque controlfeature which reduces driven-axle wheel slip (due todriveline inertia) by communicating with the engine’scontroller and increasing the engine torque.The EC-60 advanced model provides ABS-based stabilityfeatures referred to as ESP Electronic Stability Program.The Bendix ESP system is an ABS-based stability systemthat enhances vehicle stability by both reducing enginethrottle and by applying vehicle braking based on actualvehicle dynamics. Accordingly, the ESP system is availableonly on specific approved vehicle platforms after vehicleapplication and development efforts and validation testing.Only certain limited variations of an approved vehicleplatform are permitted without further validation of the ESPsystem application.ESP stability system consists of Yaw Control (YC) and RollStability Program (RSP) features.ESP is a registered trademark of DaimlerChrysler and is used by BCVS underlicense from DaimlerChrysler.1CAUTIONEven with ESP-equipped vehicles, the driver remainsresponsible for ensuring vehicle stability duringoperation.
The ESP system can only function within the limits ofphysics. ESP functionality mitigates potential vehiclestability incidents, but cannot prevent them in all cases.Other factors such as driving too fast for road, traffic orweather conditions, oversteering, an excessively highvehicle Center of Gravity (CG), or poor road conditions cancause vehicle instability that is beyond the capability of anystability system to mitigate. In addition, the effectivenessof ESP can be greatly reduced on vehicles towing multipletrailer combinations.CAUTIONThe ESP stability system may only be used on vehiclestested and approved by Bendix engineering. ESPinstallations require on-vehicle testing and EC-60 parameter tuning. See "Advanced ABS with StabilityControl" on page 9 for further details.Accordingly, the EC-60 controller is provided with acorresponding parameter data set that is validated for aspecific vehicle platform. Therefore, specific steps arenecessary should a replacement ECU be required. See“Obtaining a New EC-60 Controller” on page 13 for furtherdetails.ESP-equipped vehicles should not be driven on high-bankedroads – such as those found on high-speed test or racetracks. Test personnel must have ESP functionality disabledprior 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 wheelends, as well as applying the trailer brakes, to counteracttrailer “push” that, during certain maneuvers, could lead toa loss of control or a jackknife incident. See "Yaw Stability"on page 9 for further details.ROLL STABILITY PROGRAM (RSP)The Bendix Roll Stability Program (RSP), is an all-axleABS solution that helps reduce vehicle speed by reducingthe engine's throttle and applying all vehicle brakes asneeded, reducing the vehicle's tendency to roll over. RSPfocuses on reducing the vehicle’s speed below the criticalroll threshold during direction-changing maneuvers such asdriving on curved highway exit ramps or obstacle avoidancemaneuvers on dry, high friction surfaces. See "AdvancedABS with Stability Control" on page 9 for further details.90 SpeedSensorsStraight SpeedSensorsFIGURE 2 - BENDIX WS-24 WHEEL SPEED SENSORSDelivery(Port 2)Supply(Port 1)M-32QR Modulator2ElectricalConnectorExhaust (Port 3)M-32 ModulatorFIGURE 3 - M-32 AND M-32QR MODULATORSCOMPONENTSThe EC-60 controller’s ABS function utilizes the followingcomponents: Bendix WS-24 wheel speed sensors (4 or 6,depending on configuration). Each sensor isinstalled with a Bendix Sensor Clamping Sleeve Bendix M-32 or M-32QR Pressure ModulatorValves (4, 5, or 6 depending on configuration) 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 switchThe EC-60 controller ATC function utilizes the followingadditional components: Drive axle traction control valve (may be integralto the service brake relay valve or a stand-alonedevice) Dash-mounted ATC status/indicator lamp J1939 serial communication to engine controlmodule Stop lamp switch input (may be provided using theECU hardware input or J1939) Optional ATC mud/snow switch (sometimes referredto as an ATC off-road switch)WARNINGDuring an RSP system intervention, the vehicleautomatically decelerates. RSP can slow the vehiclewith or without the operator applying the brake pedal,and even when the operator is applying the throttle.SensorClampingSleeve
InputVoltageSensorsPMVs12 VDC4/64/5/6ATCESP/RSPBlinkCodesSerial CommunicationJ1587 J1939PLCABSATCOff-Road Mud/SnowRetarderRelayCHART 1 - EC-60 ADVANCED CONTROLLER FEATURESECU MOUNTINGThe Bendix EC-60 advanced cab-mounted controller isnot protected against moisture, and must be mounted inan environmentally protected area.All wire harness connectors must be properly seated. Theuse of secondary locks is strongly recommended.StraightConnector90 ConnectorFIGURE 4 - STEERING ANGLE SENSORSYaw/Lateral AccelSensor PackageBrake Demand/Load SensorFIGURE 5 - YAW AND BRAKE DEMAND/LOAD SENSORSThe EC-60 controller ESP/RSP function utilizes thefollowing additional components: Steer Axle Traction Control Valve (may be integralto the service brake relay valve or a stand-alonedevice) Dash-mounted ESP status/indicator lamp (alsoserves as the ATC status/indicator lamp) Bendix SAS-60 Steering Angle Sensor (mountedto the steering column) Bendix YAS-60 Yaw Rate/Lateral AccelerationSensor (typically mounted to a cross-member nearthe back of the vehicle cab) Brake Demand Sensors (installed in the primaryand secondary delivery circuits) Load Sensor (typically installed in the suspensionair bag) An additional Modulator Valve (Bendix M-32 orM-32QR Pressure Modulator Valve) that controlspressure apply to trailer brakes during systeminterventionCab ECUs utilize connectors from the AMP MCP 2.8product family.HARDWARE CONFIGURATIONAdvanced model EC-60 controllers support applicationsup to six sensor/six modulator (6S/6M) installations withATC and drag torque control. Available in 12 volt models,all advanced model EC-60 controllers support PLC (SeeChart 1).ADVANCED EC-60 CONTROLLERS USEPOWER LINE CARRIER (PLC)All new towing vehicles built since March 1, 2001 have hadan in-cab trailer ABS Indicator Lamp installed.Trailers built since March 1, 2001 transmit the status ofthe trailer ABS over the power line (the blue wire of theJ560 connector) to the tractor using a Power Line Carrier(PLC) signal. See Figures 6 and 7. Typically the signal isbroadcast by the trailer ABS ECU.The application of PLC technology for the heavy vehicleindustry in North America is known as “PLC4Trucks.”The Advanced EC-60 controller supports PLCcommunications in accordance with SAE J2497.FIGURE 6 - POWER LINE WITHOUT PLC SIGNAL3
Diagnostic Blink Code SwitchA momentary switch that grounds the ABS Indicator Lampoutput is used to place the ECU into the diagnostic blinkcode mode and is typically located on the vehicle’s dashpanel.Optional ABS Off-Road Switch and IndicatorLamp OperationFIGURE 7 - POWER LINE WITH PLC SIGNALPLC SIGNALAn oscilloscope can be used to measure or identify thepresence of a PLC signal on the power line. The PLCsignal is an amplitude and frequency modulated signal.Depending on the filtering and load on the power line, thePLC signal amplitude can range from 5.0mVp-p to 7.0Vp-p. Suggested oscilloscope settings are AC coupling, 1volt/div, 100 µsec/div. The signal should be measured atthe ignition power input of the EC-60 controller.Note: An ABS trailer equipped with PLC, or a PLC diagnostictool, must be connected to the vehicle in order to generatea PLC signal on the power line.EC-60 CONTROLLER INPUTSBattery and Ignition InputsAdvanced EC-60 controllers use an optional dashmounted switch for the operator to place the ECU into theABS off-road mode. See "Optional ABS Off-Road Mode"on page 7 for further details. In some cases, ECUs mayalso be put into the ABS off-road mode by one of the othervehicle control modules, using a J1939 message to theEC-60 controller.(If you need to know if this EC-60 controller uses a J1939message to operate the lamp, e-mail ABS@bendix.com,specifying the ECU part number, or call 1-800-AIR-BRAKEand speak to the Bendix TechTeam.)WARNING: The ABS off-road mode should not be used onnormal, paved road surfaces because vehicle stability andsteerability may be adversely affected. When the ECU isplaced in the ABS off-road mode, the ABS Indicator Lamp willflash constantly (at a rate of once per 2.5 seconds) to notifythe vehicle operator that the off-road mode is active.Optional ATC Mud/Snow (Off-Road) Switch andIndicator Lamp Operation (see also page 8.)The ECU operates at a nominal supply voltage of 12 volts.The battery input is connected through a 30 amp fusedirectly to the battery.Advanced controllers use a dash-mounted switch forthe operator to place the ECU into the ATC Mud/Snowmode.The ignition input is applied by the ignition switch circuitthrough a 5 amp fuse.Stop Lamp Switch (SLS)Ground InputThe EC-60 controller supports one ground input. See page42 for a system schematic.ABS Indicator Lamp Ground InputAdvanced EC-60 cab ECUs require a second ground input(X1-12) for the ABS indicator lamp. The X1 wire harnessconnector contains an ABS indicator lamp interlock (X1-15),which shorts the ABS indicator lamp circuit (X1-18) toground if the connector is removed from the ECU.Bendix WS-24 Wheel Speed SensorsWheel speed data is provided to the EC-60 controller fromthe WS-24 wheel speed sensor (see Figure 2). Vehicleshave an exciter ring (or “tone ring”) as part of the wheelassembly, and as the wheel turns, the teeth of the exciterring pass the wheel speed sensor, generating an AC signal.The EC-60 controller receives the AC signal, which variesin voltage and frequency as the wheel speed changes.Vehicle axle configurations determine the number ofWS-24 wheel speed sensors that must be used. A vehiclewith a single rear axle requires four wheel speed sensors.Vehicles with two rear axles can utilize six wheel speedsensors for optimal performance.4The Advanced EC-60 controller monitors the vehicle stoplamp status. Certain vehicle functions, such as ATC andAll-Wheel Drive (AWD), use the status of the stop lamp todetermine when the driver makes a brake application. Thiscan be provided to the ECU via J1939 communications,or hardware input.Brake Demand SensorsThe brake demand sensors provide the controller with anindication of driver-applied brake pressure. One is installedin the primary air brake circuit, and another is installed inthe secondary air brake circuit.Load SensorThe load sensor provides the controller with an indicationof the vehicle load. It is typically installed in one of thesuspension air bags.Bendix SAS-60 Steering Angle SensorThe Steering Angle Sensor (SAS) is used to provide driversteering input to the controller. It reports the steeringwheel position to the controller utilizing a dedicated serialcommunications link that is shared with the YAS-60 sensor. The controller supplies the power and ground inputsto the SAS-60 sensor.The SAS-60 sensor is available with two different stylesof wire harness connectors. (See Figure 4)
Bendix YAS-60 Yaw Rate/Lateral AccelerationSensorThe Yaw Rate/Lateral Acceleration Sensor is used toprovide the controller an indication of vehicle lateralacceleration and rotation around the vertical axis. Thisinformation is provided to the controller utilizing a dedicatedserial communications link that is shared with the SAS-60 sensor. The controller supplies the power and ground inputsto the YAS-60 sensor.EC-60 CONTROLLER OUTPUTSBendix M-32 and M-32QR PressureModulator Valves (PMV)The Bendix M-32 and M-32QR pressure modulatorvalves (PMV) are operated by the EC-60 controller tomodify driver applied air pressure to the service brakesduring ABS, ATC, RSP or YC activation (See pages 7-8).The PMV is an electropneumatic control valve and is thelast valve that air passes through on its way to the brakechamber. The modulator hold and release solenoids areactivated to "modulate" or "control" the brake pressureduring an antilock braking event. The hold solenoid isnormally open and the release solenoid is normally closed,such that the PMV nominally allows air to flow through.This design allows for air delivery to brake chambers inthe event of electrical trouble.The Advanced EC-60 controller also utilizes an additionalPMV for control of the trailer service brakes during stabilityinterventions.Traction Control Valve (TCV)Advanced EC-60 controllers use two TCVs, one on thesteer axle and one on the drive axle. The TCV may bea separate valve or integrated into the rear axle relayvalve.The controller will activate the drive axle TCV duringdifferential braking ATC events.During stability interventions, the ECU will activate boththe steer axle and drive axle TCVs as required.Stop Lamp OutputThe controller provides an output to control a relaythat illuminates the vehicle stop lamps during stabilityinterventions. This information is also available using theJ1939 serial communications link.ABS Indicator Lamp Control with OptionalDiagnostic Blink Code SwitchThe Advanced EC-60 controller has internal circuitry tocontrol the ABS Indicator Lamp on the dash panel.The ABS Lamp Illuminates:1. During power up (e.g. when the vehicle is started) forapproximately 3 seconds and turns off after the self testis completed, providing no Diagnostic Trouble Codes(DTCs) are present on the ECU.2. When full ABS operation is not available due topresence 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 flashes steadily at a rate of once per 2.5sec.).5. To display blink codes for diagnostic purposes after theexternal diagnostic switch is activated.The EC-60 controller may communicate with othervehicle control modules to operate the ABS Indicator Lampusing serial communications. (If you need to know if thisEC-60 controller uses serial communications to operatethe lamp, e-mail ABS@bendix.com, specifying the ECUpart number, or call 1-800-AIR-BRAKE and speak to theBendix Tech Team.)Indicator Lamp Control Using SerialCommunications LinksAs 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 serialcommunications message over the J1939 or J1587 linksindicating the required status of the lamp(s). Anothervehicle control module receives the message and controlsthe indicator lamp(s).Retarder Relay Disable OutputThe retarder relay disable output may be used to control aretarder disable relay. When configured to use this output,the ECU will energize the retarder disable relay and inhibitthe use of the retarder as needed.SAE J1939 Serial CommunicationsA Controller Area Network (CAN) data link (SAE J1939) isprovided for communication. This link is used for variousfunctions, such as: To disable retarding devices during ABS operation.To request torque converter lock-up during ABSoperation. To share information such as wheel speed and ECUstatus with other vehicle control modules.Advanced EC-60 controllers utilize the J1939 data link for: ATC and drag torque control functions. Vehicle stability functions.Trailer ABS Indicator Lamp ControlThe Advanced EC-60 controller will activate a trailer ABSIndicator Lamp (located on the dash panel) that indicatesthe status of the trailer ABS unit on one, or more trailers, ordollies that are equipped with PLC functionality. Typically,the EC-60 controller directly controls the trailer ABSIndicator Lamp based on the information it receives fromthe trailer ABS, via PLC.Alternatively, some vehicles require the EC-60 controller toactivate the trailer ABS Indicator Lamp by communicating withother vehicle controllers using serial communications.5
(If you need to know if this EC-60 controller uses a serialcommunications message to operate the lamp, e-mailABS@bendix.com, specifying the ECU part number, or call1-800-AIR-BRAKE and speak to the Bendix TechTeam.)SAE J1708/J1587 Serial CommunicationsAn SAE J1708 data link, im
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)
1 Bendix TABS‑6 Advanced Multi‑Channel Trailer ABS Module FIGURE 1 - bendix tAbS-6 AdvAnced multi-ch Annel module (bendix tAbS-6 AdvAnced mc) 1. InTRodUCTIon The Bendix TABS‑6 Advanced MC module is an integrated multi‑channel (4S/2M) trailer service brake module controller for
ACom diagnostic software 5.12, open the Bendix ACom diagnostic software 5.12 User Guide PDF available on the Bendix web site (www.bendix.com). Bendix ACom Diagnostic Windows 6.9 ECU Status Screen Refer to the Service Data sheet for the system being diagnosed for all cautions and warnings; certainFile Size: 2MB
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6 Brake Size Unlined Application Shoe Number BW7248 BRAKE SHOE QUICK REFERENCE LISTED BY DRUM DIAMETER NOTE: Unlined shoes are listed numerically by FMSI number in the Brake Shoe Application section of this catalog. 161/2 X 7 4701HA BENDIX (SPICER ) HEAVY AXLE 161/2 X 7 4707R ROCKWELL / MERITOR Q PLUS 161/2 X 7 4708H BENDIX (SPICER ) CAST 161/2 X 7 4708M BENDIX (SPICER ) SEVERE DUTY
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