User guide

ManualsBrandsBendix Commercial Vehicle Systems ManualsEquipmentEC-16 ANTILOCK CONTROLLER 4/08

MOUNTING

HOLES

(4)

SD-13-4787

Bendix

EC-16

™

AntiLock - Traction Controller

18 PIN

CONNECTOR

30 PIN

CONNECTOR

DIAGNOSTIC

DISPLAY

FIGURE 1 - EC-16

™

CONTROLLER

DESCRIPTION

GENERAL

The EC-16

™

is an electronic antilock controller. It is the base

component in a family of full vehicle wheel control antilock

systems for buses, trucks and truck tractors. In addition to

the antilock function, the EC-16

™

controller can be

assembled and programmed to provide an optional traction

control feature. Figure 1 shows the basic EC-16

™

controller

configuration.

Designed to minimize the potential of brake lock up on all

wheels during aggressive braking, the EC-16

™

controller

based antilock system provides the vehicle with a high

degree of stability and steerability during braking. In most

cases, vehicle stopping distance is also reduced. The

antilock portion of the EC-16

™

controller based system

minimizes wheel skid during hard or aggressive braking. By

controlling wheel skid at all wheels on the vehicle, optimum

steering control and stopping distance is obtained.

Traction control, an optional feature in the full vehicle wheel

control antilock system, helps improve vehicle traction during

acceleration in adverse road conditions. Integrated with

antilock logic, traction control monitors wheel speed

information from the sensors during acceleration, as well as

braking. The system helps maintain vehicle stability on

hazardous road surfaces and improves driveability and safety.

There are two versions of the EC-16

™

controller. The older

version, was factory pre-programmed with vehicle particulars,

such as the number of speed sensors, if the traction control

feature was enabled and the type of traction control (torque

limiting, differential braking or both). A part number was

assigned to the EC-16

™

controller which was specific for

the programmed features contained in the unit. The newer

version contains a self configuring or learning feature that

allows the EC-16

™

controller to be configured by the user

when installed on the vehicle. Because of this feature, all of

the new version EC-16

™

controllers contain all the features

and options available and will activate the specific features

required for the vehicle it is installed on. The new version

EC-16

™

controller can be installed on vehicles with only

antilock or vehicles using the traction control feature. The

procedure for activating the self configuring feature and

identifying old and new version EC-16

™

controllers is

Summary of content (32 pages)

PAGE 1
SD-13-4787 ® Bendix® EC-16™ AntiLock - Traction Controller MOUNTING HOLES (4) 18 PIN CONNECTOR 30 PIN CONNECTOR DIAGNOSTIC DISPLAY FIGURE 1 - EC-16™ CONTROLLER DESCRIPTION GENERAL The EC-16™ is an electronic antilock controller. It is the base component in a family of full vehicle wheel control antilock systems for buses, trucks and truck tractors. In addition to the antilock function, the EC-16 ™ controller can be assembled and programmed to provide an optional traction control feature.
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FIGURE 2 - EC-16™ CONTROLLER SYSTEM SCHEMATIC 2 ™ M-21 OR M-22 MODULATORS ™ TRACTION ENABLE SWITCH ANTILOCK LAMP EXCITER WHEEL SPEED SENSOR QUICK RELEASE VALVE RETARDER DISABLE SWITCH TRACTION LAMP SERVICE BRAKE VALVE EC-16™ CONTROLLER AT-1™ OR AT-2™ ANTILOCK TRACTION ASSEMBLY EXCITER WHEEL SPEED SENSOR ENGINE ELECTRONIC CONTROL MODULE BATTERY DIAGNOSTIC COMPUTER TANDEM REAR AXLE M-21™ OR M-22™ MODULATORS REAR AXLE SERVICE & SPRING BRAKES
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contained in the section entitled "Configuring The EC-16™ Controller".
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FIGURE 4 - EC-16™ CONTROLLER SYSTEM WIRING SCHEMATIC 4 M-22 Relay Lamp Relay Battery AntiLock Controller M-22 Modulator Dash Lamp Retarder Switch To To Retarder Retarder Relay Retarder Relay Battery AntiLock Controller See Retarder Relay inset below See Lamp Relay inset below CONNECTOR ON M-22 MODULATOR M-22 AT-1, 2 ANTILOCK TRACTION MODULATOR AND CONTROLLER M-22 A1 A2 A3 B1 B2 B3 C1 C2 C3 D1 D2 D3 E1 E2 E3 F1 F2 F3 A1 A2 A3 B1 B2 B3 C1 C2 C3 D1 D2 D3 E1 E2 E3 F1 F2 F3 G1 G2 G3 H1 H2 H
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ELECTRICAL CONNECTOR SUPPLY PORT M-21™ MODULATOR DELIVERY PORT WS-20™ STRAIGHT SPEED SENSOR EXHAUST PORT DELIVERY PORT SUPPLY PORT M-22™ MODULATOR WS-20™ 90 DEGREE SPEED SENSOR ELECTRICAL CONNECTOR EXHAUST PORT FIGURE 5 - WS-20™ SPEED SENSORS FIGURE 6 - MODULATORS EC-16™ controller in the form of an AC signal which varies in voltage and frequency as the speed of the wheel increases or decreases.
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If the EC-16™ controller is programmed for traction control, it contains the following outputs: - A connection to the engine's electronic control module allows the EC-16™ controller to reduce engine torque under certain circumstances. - A traction dash light is connected to and controlled by the EC-16™ controller and serves as a means of advising the driver of the condition of the traction control system.
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Torque Limiting - In order for the torque limiting control feature to be used, the vehicle must be equipped with an electronically controlled engine throttle. The torque limiting feature allows the EC-16™ controller to reduce engine torque to a suitable level for the available traction. Torque limiting helps to minimize the amount (or speed) of wheel spin. It is especially useful in helping to minimizing a power jackknife and when all drive wheels are on an equally slippery surface.
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Mid or rear sensor - Antilock on that wheel is disabled, but antilock on all other wheels remains active. Traction control is disabled. SYSTEM STILL OPERATING (YES/NO) Traction solenoid - Traction control is disabled. Antilock remains active. Engine Control Module* - If the engine control module (ECM) or the wiring from the EC-16™ controller to the ECM fails, traction control is disabled. Antilock remains active. Voltage* - If system voltage is out of range, antilock and traction are disabled.
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PREVENTIVE MAINTENANCE Every 3 months; 25,000 miles; or 900 operating hours; 1. Check all wiring and connectors to ensure they are secure and free from visible damage. 2. Although the EC-16™ controller incorporates self check diagnostics, the LED display should be inspected to ensure that it is functional. With the vehicle ignition on, a magnet (800 gauss; capable of picking up 3 ounces) held to the LED reset switch should cause all of the LEDs to illuminate.
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4. Remove as much contamination as possible from the assembly's exterior. Keep the contamination away from the open ports. 5. Note and mark the position of the EC-16™ controller relative to the valve it is mounted on. Remove and retain the four cap screws that secure the EC-16™ controller to the valve. Then separate the EC-16™ controller from the valve. BRACKET MOUNTED EC-16™ CONTROLLER 1. Disconnect the electrical connector(s) from the EC-16™ controller. 2.
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Note: FRT Red LED MID Red LED (See Note) RER Red LED RHT Red LED LFT Red LED TRC Red LED MOD Red LED SEN Red LED ECU Red LED VLT Green LED RESET + No LED The MID LED is used with some but not all vehicles. When six speed sensors are not installed this LED is not used in the diagnostic process. However, it will light when a magnet is placed on the RESET switch in the diagnostic display.
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ANTILOCK LAMP Traction Lamp (EC-16™ controller w/torque limiting & differential braking) Traction Lamp (EC-16™ controller w/torque limiting only) Traction Lamp (EC-16™ controller w/differential braking only) LAMP ON 1ST TIME LAMP OFF 1ST TIME LAMP ON 2ND TIME LAMP OFF 2ND TIME LAMP ON STAYS ON On Off On Off Stays Off Off Off On Off Stays Off On Off Off Off Stays Off IDENTIFYING THE SELF CONFIGURING EC-16™ CONTROLLER EC-16™ CONTROLLER SELF CONFIGURING PROCESS The self configuring EC-16
PAGE 13
6. All or part of traction control can be lost during self configuration by; A. Not connecting one of the wire harnesses (engine control module for torque limiting and ATR valve solenoid for differential braking) B. A missing or inoperative traction dash lamp (bulb missing or burned out). C. A missing or inoperative traction control enable disable switch. D. Not placing the traction control enable / disable switch in the disabled position.
PAGE 14
TROUBLESHOOTING IMPORTANT BEFORE TROUBLESHOOTING: 1. Determine if the vehicle is equipped with traction control. The presence of a traction condition lamp on the dash can be used. 2. Some vehicles are equipped with a traction control "disabling switch." If so equipped, ENABLE THE TRACTION SYSTEM BEFORE BEGINNING THE TROUBLESHOOTING. 3. If the vehicle is equipped with traction control and is a tandem axle unit, note the number of drive axles. The "MID" diagnostic LED is used only on 6x4 vehicles.
PAGE 15
DIAGNOSTIC DISPLAY QUICK REFERENCE This index is presented for the benefit of personnel experienced in troubleshooting Bendix full-vehicle wheel control AntiLock with traction control. It provides a quick reference to specific sections that provide testing procedures and values.
PAGE 16
INITIAL START-UP PROCEDURE 0 TURN IGNITION ON AND OBSERVE DASH ANTILOCK LAMP. START HERE 0 ANTILOCK DASH LAMP DOES NOT BLINK, COMES ON AND REMAINS ILLUMINATED GO TO SECTION II “INSPECTION FOR ILLUMINATED LEDS ” NO DID ANTILOCK DASH LAMP BLINK? YES NO - See Notice IS ANTILOCK DASH LAMP STILL ILLUMINATED? YES - See Notice INCREASE VEHICLE SPEED TO ABOVE 7 MPH FOR AT LEAST 5 SECONDS AND OBSERVE THE DASH LAMP.
PAGE 17
SECTION I - ANTILOCK DASH LAMP TESTING START HERE DISCONNECT 30 PIN CONNECTOR FROM EC-16™ CONTROLLER AND OBSERVE THE ANTILOCK DASH LAMP. YES ANTILOCK DASH LAMP ILLUMINATED? REPLACE THE EC-16™ CONTROLLER NO WITH IGNITION ON, MEASURE VOLTAGE BETWEEN PINS E3 & A1, A2, A3. VOLTAGE SHOULD BE SAME AS BATTERY VOLTAGE A1 GROUND A2 GROUND A3 GROUND E3 TO DASH LAMP RELAY NO IS VOLTAGE CORRECT? YES CHECK WIRING HARNESS AND RELAY FOR SHORTS TO GROUND. RECONNECT AND CHECK/REPLACE THE FOLLOWING: 1.
PAGE 18
SECTION II - INSPECTION FOR ILLUMINATED LEDs INSPECT EC-16™ CONTROLLER FOR PRESENCE OF ILLUMINATED LEDs AND RECORD START HERE CHECK CLOSELY AND NOTE IF GREEN, VLT LED IS ILLUMINATED YES (ON) NO ARE ANY RED LEDs ILLUMINATED? NOTE AND RECORD THE CONDITION OF ALL RED LEDs ARE ANY RED LEDs ILLUMINATED? YES REPLACE THE EC-16™ CONTROLLER NO NO YES NO (OFF) IS GREEN LED FLASHING? GO TO SECTION V “TESTING FOR POWER TO THE EC-16™ CONTROLLER” YES GO TO SECTION V “TESTING FOR POWER TO THE EC-16™ CONT
PAGE 19
SECTION III - INSPECTION FOR ILLUMINATED LEDs START HERE INSPECT THE EC-16™ CONTROLLER FOR PRESENCE OF ILLUMINATED LEDS AND RECORD NO IS GREEN VOLT LED ILLUMINATED? YES GO TO SECTION V “TESTING FOR POWER TO THE EC-16™ CONTROLLER” ARE ANY RED LEDs ILLUMINATED? NO GO TO SECTION V “TESTING FOR POWER TO THE EC-16™ CONTROLLER” YES REPLACE THE EC-16™ CONTROLLER YES IS GREEN LED FLASHING? NO NO ARE ANY RED LEDs ILLUMINATED? GO TO SECTION IX “TESTING FOR FALSE FAILURE INDICATION - CAUSED BY WHEEL SPEED C
PAGE 20
SECTION IV - INSPECTION FOR ILLUMINATED LEDs START HERE NOTE RED “ECU” LED IN EC-16™ CONTROLLER DIAGNOSTICS WINDOW. YES IS THIS LED ILLUMINATED? GO TO SECTION V “TESTING FOR POWER TO THE EC-16™ CONTROLLER” NO "ECU" LED ON? THERE SHOULD BE A MINIMUM OF THREE RED LEDs ILLUMINATED AND OF THE THREE THERE MUST BE A “RHT” OR “LFT”, PLUS A “FRT”, "MID" OR “RER”, PLUS A “MOD” OR “SES”.
PAGE 21
SECTION V - TESTING FOR POWER TO THE EC-16™ CONTROLLER TURN IGNITION OFF, DISCONNECT 30 PIN CONNECTOR FROM EC-16™ CONTROLLER START HERE TURN IGNITION ON AND MEASURE VOLTAGE BETWEEN BATTERY PINS B1, K2, K3 AND GROUND PINS A1, A2, A3 ON WIRE HARNESS CONNECTOR VOLTAGE SAME AS BATTERY VOLTAGE. MUST BE BETWEEN 11 AND 17 VOLTS. B1 A1 A2 A3 K2 K3 NO RECONNECT CONNECTOR TO EC-16™ CONTROLLER. CHECK THE VEHICLE WIRING FOR CONTINUITY. REFER TO THE VEHICLE SERVICE MANUAL AND CHECK THE BATTERY VOLTAGE.
PAGE 22
SECTION VI A - TESTING THE MODULATOR TURN IGNITION OFF. REFER TO ILLUSTRATION, DISCONNECT WIRE HARNESS CONNECTOR FROM EC-16™ CONTROLLER. START HERE 18 PIN CONNECTOR PROBE CONNECTOR WITH VOLT/OHM METER AND NOTE THAT PROPER RESISTANCE VALUES ARE OBTAINED FOR MODULATOR BEING TESTED. RESISTANCE VALUES HERE FOR BENDIX® M-21™ MODULATOR. HOLD TO COMMON: READ 3.5 TO 5 OHMS EXHAUST TO COMMON: READ 3.
PAGE 23
SECTION VI B - TESTING THE MODULATOR START HERE FROM SECTION VI A GO TO MODULATOR, INSPECT WIRING CONNECTOR. DISCONNECT CONNECTOR AND TEST RESISTANCE BETWEEN PINS ON MODULATOR. RESISTANCE VALUES FOR BENDIX® M-22™ MODULATOR. HOLD TO COMMON: READ 3.5 TO 5 OHMS EXHAUST TO COMMON: READ 3.5 TO 5 OHMS EXHAUST TO HOLD: READ 7 TO 10 OHMS TEST EACH PIN TO VEHICLE GROUND AND NOTE NO CONTINUITY. CONNECTOR ON M-22™ MODULATOR. EXHAUST COMMON HOLD NO RESISTANCE READINGS CORRECT? REPLACE THE MODULATOR.
PAGE 24
SECTION VII A - TESTING THE WHEEL SPEED SENSOR IGNITION ON, NOTE ILLUMINATED LED's. DO MAGNETIC RESET, NOTE REACTION OF RED LEDs. START HERE GO TO SECTION VII PART B AND BEGIN TESTING YES 2nd TIME TO THIS POINT DURING TESTING? NO NO YES ANY RED LEDs ON? SAME RED LEDs ON? GO TO SECTION IV. YES NO A. B. C. D. E. GO TO SECTION VII PART B AND BEGIN TESTING TURN IGNITION OFF AND CHECK FOLLOWING: CHECK "GAP" BETWEEN SPEED SENSOR AND EXCITER OR TONE RING.
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SECTION VII B - TESTING THE WHEEL SPEED SENSOR NO START HERE FROM SECTION VII A GO TO SECTION III "INSPECTION FOR ILLUMINATED LEDs" SAME LEDs ILLUMINATED? YES 30 PIN CONNECTOR 1 2 3 KJHGF EDCBA J2 J1 LEFT FRONT W. S. RTN LEFT FRONT W. S. SIGNAL H3 H2 RIGHT FRONT W. S. RTN RIGHT FRONT W. S. SIGNAL A1,2,3 B1,K2,3 GROUND POWER IGNITION OFF. REMOVE CONNECTOR FROM EC-16™ CONTROLLER. MEASURE RESISTANCE BETWEEN THE APPROPRIATE SPEED SIGNAL (+) AND SIGNAL RETURN (-).
PAGE 26
SECTION VIII - TESTING FOR FALSE INDICATION CAUSED BY DASH LIGHT RELAY WITH IGNITION ON, HOLD MAGNET ON EC-16™ CONTROLLER RESET AND NOTE ALL LEDs ILLUMINATED. START HERE E3 TO DASH LAMP RELAY NO ARE ALL LEDs ILLUMINATED? REPLACE THE EC-16™ CONTROLLER YES 1 2 3 KJHGF REMOVE MAGNET FROM EC-16™ CONTROLLER, TURN IGNITION OFF AND DISCONNECT THE 30 PIN CONNECTOR FROM EC-16™ CONTROLLER.
PAGE 27
SECTION IX - TESTING FOR FALSE INDICATION CAUSED BY WHEEL SPEED COMPONENTS START HERE WITH IGNITION ON, HOLD A MAGNET ON RESET OF EC-16™ CONTROLLER AND NOTE LEDs NO ARE ALL LEDs ILLUMINATED? REPLACE EC-16™ CONTROLLER YES All LEDs Illuminated? REMOVE MAGNET Magnet here EC-16™ CONTROLLER DIAGNOSTIC DISPLAY TURN THE IGNITION OFF AND INSPECT APPROPRIATE AXLE AND WHEEL FOR PRESENCE OF AN EXCITER OR TONE RING AND SPEED SENSOR.
PAGE 28
SECTION X - TESTING TRACTION CONTROL DASH LAMP NO START HERE REPLACE TRACTION DASH LAMP WITH KNOWN GOOD UNIT. REPEAT "INITIAL START-UP PROCEDURE" IS THIS THE SECOND TIME TO THIS POINT? YES C2 WITH IGNITION OFF, REMOVE 30 PIN CONNECTOR FROM EC-16™ CONTROLLER. TURN IGNITION ON AND CHECK FOR VEHICLE VOLTAGE AT TERMINAL C2.
PAGE 29
SECTION XI - TESTING TRACTION CONTROL MODULATOR WITH IGNITION ON, INSPECT EC-16™ CONTROLLER FOR ILLUMINATED LEDs START HERE YES IS "TRC" ONLY ON? NO GO TO SECTION XII "TESTING ENGINE CONTROL MODULE WIRE HARNESS" ARE "TRC" AND "MOD" LEDs ON? These LEDs Illuminated? YES TURN IGNITION OFF AND REMOVE 18 PIN CONNECTOR FROM EC-16™ CONTROLLER. CHECK RESISTANCE BETWEEN PINS D2 & D3. RESISTANCE SHOULD BE 10 - 12 OHMS. REMOVE 30 PIN CONNECTOR AND CHECK CONTINUITY BETWEEN GROUND (A1,2,3) AND D2 & D3.
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SECTION XII- TESTING ENGINE CONTROL MODULE WIRE HARNESS NO START HERE TRC ONLY RED LED ON? PASS MAGNET OVER EC-16™ CONTROLLER RESET & REPEAT "INITIAL START-UP PROCEDURE" YES TURN IGNITION OFF. DISCONNECT 30 PIN CONNECTOR FROM EC-16™ CONTROLLER & 2 PIN CONNECTOR AT ENGINE ELECTRONIC CONTROL MODULE. CONNECTOR AT ENGINE ELECTRONIC CONTROL MODULE. Illuminated? B2 CHECK WIRE CONTINUITY BETWEEN 30 PIN CONNECTOR AT EC-16™ CONTROLLER AND 2 PIN CONNECTOR AT ENGINE CONTROL MODULE.
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