User's Manual

ManualsBrandsBENDIX ManualsABS SystemBENDIX BW2160

SD-13-4815

TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . PAGE

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

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

Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

EC-30

™

Controller Hardware Conﬁ gurations . . . . . . . . . . 3

EC-30

™

Controller With PLC. . . . . . . . . . . . . . . . . . . . . . . 3

EC-30

™

Controller Inputs . . . . . . . . . . . . . . . . . . . . . . . . . 4

EC-30

™

Controller Outputs . . . . . . . . . . . . . . . . . . . . . . . . 4

Power-Up Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

ABS Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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

Auto-Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

EC-30

™

Controller Conﬁ gurable Parameters . . . . . . . . . . 8

EC-30

™

Controller Self-Conﬁ guration . . . . . . . . . . . . . . . . 8

Fault Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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

EC-30

™

Controller Diagnostic Display . . . . . . . . . . . . . . . 9

Blink Code Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . 10

Bendix DCI Diagnostic Tool . . . . . . . . . . . . . . . . . . . . . . 14

Bendix ABS Diagnostic Software . . . . . . . . . . . . . . . . . . 15

NEXIQ (MPSI) Bendix Cartridge. . . . . . . . . . . . . . . . . . . 15

Contacting Bendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Safe Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . 15

Removing the EC-30

™

Controller Assembly . . . . . . . . . 16

Installing a New EC-30

™

Controller. . . . . . . . . . . . . . . . . 16

ABS and ATC Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

INTRODUCTION

The Bendix

EC-30

™

is an electronic ABS (antilock braking

system) controller. It is the base component in a family of

ABS assemblies for heavy and medium duty buses, trucks

and tractors utilizing pneumatic braking systems.

The ABS function of the EC-30

™

controller is designed to

optimize slip on all vehicle wheels. The EC-30

™

controller

provides the vehicle with improved stability and steerability

during braking. The EC-30

™

controller will also reduce

vehicle stopping distance on most surfaces.

In addition to the ABS function, the EC-30

™

controller can

be conﬁ gured to provide an ATC (automatic traction control)

feature. Bendix ATC can improve vehicle traction during

acceleration on adverse road conditions. ATC can utilize

engine torque limiting and/or differential braking to improve

vehicle traction.

Bendix

EC-30

™

ABS / ATC Controller

FIGURE 1 - EC-30

™

CONTROLLER

18-pin

Connector

Mounting

Inserts

LED Diagnostic

Display

30-pin

Connector

Part Number

Label

Summary of content (32 pages)

PAGE 1
SD-13-4815 Bendix® EC-30™ ABS / ATC Controller Mounting Inserts 18-pin Connector Part Number Label 30-pin Connector FIGURE 1 - EC-30™ CONTROLLER INTRODUCTION The Bendix® EC-30™ is an electronic ABS (antilock braking system) controller. It is the base component in a family of ABS assemblies for heavy and medium duty buses, trucks and tractors utilizing pneumatic braking systems. The ABS function of the EC-30™ controller is designed to optimize slip on all vehicle wheels.
PAGE 2
EC-30™ Controller ABS / ATC Assembly ATC Modulator (integral) ATC Modulator Connector ATR VALVE FIGURE 2 - EC-30™ CONTROLLER WITH ATR VALVE COMPONENTS The EC-30™ controller ABS function utilizes the following components: - Wheel speed sensors (4 or 6, depending on configuration) - Electro-pneumatic ABS modulator valves (4) - Dash mounted tractor ABS warning lamp (relay controlled) - Service brake relay valve - Dash mounted trailer ABS warning lamp (towing vehicles manufactured after March 1, 20
PAGE 3
EC-30™ CONTROLLER HARDWARE CONFIGURATIONS Measuring / Identifying the PLC Signal An oscilloscope can be used to verify the presence of a PLC signal on the power line. The PLC signal is an amplitude and frequency modulated signal. Depending on the filtering 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 power leads of the EC-30™ controller.
PAGE 4
EC-30™ CONTROLLER INPUTS Blink Code Switch Power and Ground The EC-30™ controller can be configured to support an optional diagnostic blink code switch to ground, which can be used to activate several functions available through blink code diagnostics. Pin F3, of the 30-pin connector, is the blink code switch input. Power is supplied to the EC-30™ controller from the ignition circuit through a 30 Amp fuse. The EC-30™ controller is grounded to the vehicle chassis.
PAGE 5
Trailer ABS Warning Lamp ATC Modulator Premium EC-30 controller models configured for differential braking ATC will activate the ATC modulator during ATC situations. The ATC modulator is an electrically controlled air valve integral to the ATR valve. Pins D2 and D3, of the 18-pin connector, control the ATC modulator. A connection to the ATC modulator is provided via a two-pin Deutsch connector from the ATR valve. See figure 2.
PAGE 6
POWER-UP SEQUENCE ABS Warning Lamp at Power-Up At power-up without detected faults, the ABS warning lamp turns on for 2.5 seconds and then turns off. See figure 7. Diagnostic LEDs at Power-Up At power-up, the diagnostic LEDs all turn on, then display the configuration for sensors and the ATC. After showing the configuration, only the green VLT LED will stay on. However, if a fault is detected, the faulted component will be identified by the red LEDs. See chart 4.
PAGE 7
ABS OPERATION Bendix ABS uses wheel speed sensors, ABS modulators and an ECU to control either four or six wheels. By monitoring the wheel slip during braking, and adjusting the brake pressure at each wheel, the EC-30™ controller is able to optimize slip between the tire and the road surface. When excessive wheel slip is detected, the EC-30™ controller will activate ABS. The EC-30™ controller controls the ABS modulators to simulate a driver pumping the brakes.
PAGE 8
AUTO-CALIBRATION Auto-calibration is a feature that allows the EC-30 ™ controller to compensate for tire size changes throughout the life of the vehicle. Auto-calibration is needed for proper ATC performance. The EC-30™ controller will perform an auto-calibration when the tire size difference exceeds approximately 4 percent. Tire size (rolling radius) setting information can be retrieved or adjusted by using Bendix ABS Diagnostics Software or MPSI.
PAGE 9
ABS PARTIAL SHUTDOWN Reading a Fault Depending which component the fault is detected on, the ABS and ATC functions may be fully or partially disabled. Even with the ABS warning lamp on, the EC-30™ controller may still provide ABS function on wheels that are not affected by the fault. The EC-30™ controller should be serviced as soon as possible. When a fault is detected, the EC-30™ controller identifies the faulted component with the diagnostic LEDs.
PAGE 10
BLINK CODE DIAGNOSTICS ™ The EC-30 controller provides diagnostic and configuration functions using blink code diagnostics. When the blink code mode is activated, the EC-30™ controller flashes the ABS warning lamp to communicate active fault codes, fault code history or, ABS and ATC configurations. The blink code diagnostics mode can also be used to reset active fault codes. See chart 5. The ABS warning lamp illuminates while the blink code switch is pressed.
PAGE 11
CHART 7 - EC-30™ CONTROLLER BLINK CODE DEFINITIONS (1 of 3) 11
PAGE 12
Sensor output low or missing during vehicle operation above 10 mph. Verify condition of tone ring mounting. Adjust speed sensor to contact tone ring. Rotate wheel and verify: (a) for WS-20 speed sensor that output is minimally 0.8 VAC @ 1 RPS or (b) for WS-24 speed sensor that output is minimally 0.250 VAC @ 0.5 RPS. Verify condition and retention force of sensor clips. Verify proper sensor lead routing and clamping. Sensor output intermittent or excessive wobble in exciter ring.
PAGE 13
Check for corroded or damaged modulator wiring and connections. Verify for M-21, M-22, or M-30 that resistance between pins: Hold to Common is 3.5 to 5.0 Ohms, Exhaust to Common is 3.5 to 5.0 Ohms, Exhaust to Hold is 7.0 to 10 Ohms. For M-32 and M-32QR, Verify that resistance between pins: Hold to Common is 4.9 to 5.5 Ohms, Exhaust to Common is 4.9 to 5.5 Ohms, Exhaust to Hold is 9.8 to 11 Ohms. Verify no continuity from modulator leads to ground.
PAGE 14
BENDIX DCI DIAGNOSTIC TOOL Reading a Fault with DCI The Bendix Diagnostic Communication Interface (DCI) is a hand held diagnostic tool that was designed for use with the Bendix® EC-17™ controller system and can also be used as a stand alone diagnostic tool for the EC-30™ controller. See figure 10 for illustration. The Bendix DCI has the same 10 diagnostic LEDs as the EC-30™ controller. A reset button on the DCI duplicates the function of the magnetic reset on the EC-30™ controller.
PAGE 15
BENDIX ABS DIAGNOSTIC SOFTWARE Bendix ABS Diagnostic Software is a RP-1210 compliant PC-based program that provides technicians with the highest level of diagnostic information and control of the EC-30™ controller. See figure 12. It can also be used to diagnose the EC-15™, EC-16™, EC-17™ and MC-30™ controllers (Trailer) ABS units. With Bendix ABS Diagnostic Software, the technician can perform the following: the field.
PAGE 16
SAFE MAINTENANCE PRACTICES WARNING! PLEASE READ AND FOLLOW THESE INSTRUCTIONS TO AVOID 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.
PAGE 17
ABS Component Connector Wire Terminal Wire Seal/ Plug Terminal Lock Terminal Crimp Tool EC-30™ Controller Harness 12034398 12103881 (18-16 GA) Plug 12065266 N/A 12094429 30-pin Packard Metri-Pack 150 Series EC-30™ Controller Harness 12040921 N/A 12155975 18-pin Packard Metri-Pack 150 Series ABS Modulator Harness 12040977 12077411 (18-16 GA) 12015323 (18-16 GA) 12034145 3-Pin Packard Metri-Pack 280 Series Wheel Speed Sensor 15300014 15300027 2-Pin Packard Metri-Pack 280 Series Whee
PAGE 18
FIGURE 13 - EC-30™ CONTROLLER SYSTEM SCHEMATIC 18
PAGE 19
1. Position and secure the EC-30™ controller in the original mounting orientation using the four hex head bolts. Torque the hex head EC-30™ controller mounting bolts to 98 in. Ibs. Over-tightening the ECU bolts can cause damage to the EC-30™ controller. 2. For a valve-mounted EC-30™ controller, position and secure the EC-30™ controller assembly to the vehicle, in the original mounting orientation. Reconnect all air lines to the EC-30™ controller assembly.
PAGE 20
SECTION A - EC-30™ CONTROLLER POWER-UP SEQUENCE ABS WARNING LAMP AND ATC ACTIVE/WARNING LAMP Turn ignition on and observe the ABS warning lamp. ABS Warning Lamp at Power-Up ABS warning lamp does not come on. Go to Section C. NO The ABS warning lamp should immediately illuminate when ignition power is applied to the vehicle. YES The ABS warning lamp stays on. Go to Section F. Verify that the ABS warning lamp stays on for 2.5 seconds and then turns off. NO YES The ABS unit is functioning normally.
PAGE 21
SECTION B - EC-30™ CONTROLLER POWER-UP SEQUENCE TRAILER ABS WARNING LAMP Verify that a PLC trailer is connected to the tractor via the seven pin connector. Turn ignition on and observe the trailer ABS warning lamp. Trailer ABS Warning Lamp at Power-Up Trailer ABS warning lamp does not come on. Note: Only towing vehicles built after March 1, 2001 will be required to have a trailer ABS warning lamp.
PAGE 22
SECTION C - TROUBLESHOOTING THE ABS WARNING LAMP ABS Warning lamp did not illuminate during the EC-30™ controller powerup sequence. ABS Warning lamp stays on with no red LEDs on. See Note this page Turn the ignition off and disconnect the 30-pin connector from the EC-30™ controller. Turn the ignition off and disconnect the 30-pin connector from the EC-30™ controller. Turn the ignition on and verify that the ABS warning lamp turns on.
PAGE 23
SECTION D - TROUBLESHOOTING THE ATC ACTIVE/WARNING LAMP ATC Active/Warning lamp did not illuminate during the EC-30™ controller power-up sequence. ATC active/warning lamp stays on with no red LEDs on. Verify that the EC-30™ controller is configured for ATC by observing the LEDs at power-up, blink code diagnostics or using a diagnostic tool. Verify that the ATC enable/disable switch is in the enable position. See Note this page With ignition off, remove the 30-pin connector from the EC-30™ controller.
PAGE 24
SECTION E - TROUBLESHOOTING THE TRAILER ABS WARNING LAMP Trailer ABS Warning lamp did not illuminate during the EC-30™ controller power-up sequence. Trailer ABS lamp stays on with no trailer connected to towing vehicle. See Note this page With ignition off, remove the 30-pin connector from the EC-30™ controller. With ignition off, remove the 30-pin connector from EC-30™ controller. See Note this page Turn ignition on and measure voltage between pin E2 and ground (pins A1, A2 or A3).
PAGE 25
SECTION F - DIAGNOSTIC LED QUICK REFERENCE Comparing your EC-30™ controller to the following images, identify the fault indicated by the diagnostic LEDs and follow the instructions in the related troubleshooting section. Power System OK - A solid green VLT LED indicates proper voltage is reaching the EC-30™ controller. If no red LEDs are on, then no faults are detected. If either the ABS warning lamp or ATC active/warning lamp is on with no red LEDs, go to Section C or D.
PAGE 26
SECTION G - TROUBLESHOOTING POWER TO THE EC-30™ CONTROLLER ABS Warning lamp is on and green VLT LED is off or flashing. Due to corrosion, damage or poor termination, the wiring and/ or connectors may be limiting the electrical current flow to the EC-30™ controller. This means that when the EC-30™ controller needs more current, the voltage level may be dropping.
PAGE 27
SECTION H - TROUBLESHOOTING WHEEL SPEED SENSORS Turn ignition off and remove the 30-pin or 18-pin connector from the EC-30 ™ controller. SEN LED and ABS warning lamp are on. Make repairs to wiring or replace wheel speed sensor. Reconnect all connectors to the EC-30™ controller and sensor. Reset fault codes by briefly holding a magnet in place at the RESET location of the diagnostic display. Then rerun the power up sequence. Go to Section A.
PAGE 28
SECTION I - TROUBLESHOOTING ABS MODULATORS MOD LED and ABS warning lamp are on. Turn the ignition off and remove the 30-pin or 18-pin connector from the EC-30™ controller. Static ABS Modulator Faults. For (a) M-30 modulator verify 3.5 to 5.0 OHMS across Hold to Common connector pins, 3.5 to 5.0 OHMS across Exhaust to Common connector pins, and 7.0 to 10.0 OHMS across Exhaust to Hold connector pins, or for (b) M-32 modulator verify 4.9 to 5.5 OHMS across Hold to Source connector pins, 4.9 to 5.
PAGE 29
SECTION J - TROUBLESHOOTING THE ATC MODULATOR TRC and MOD LEDs and ATC active/warning lamp are on. Make repairs to wiring or replace ATC modulator. Reconnect all connectors to the EC-30™ controller and ATC modulator. Reset fault codes by briefly holding a magnet in place at the RESET location of the diagnostic display. Then rerun the power-up sequence. Go to Section A. Turn the ignition off and remove the 18-pin connector from the EC-30™ controller. Verify 10.0 to 12.
PAGE 30
SECTION K - TROUBLESHOOTING EC-30™ CONTROLLER SERIAL COMMUNICATION TRC LED and ATC active/warning lamp are on. Verify proper operation of the electronic engine controller. Turn ignition off and remove the 30-pin connector from the EC-30™ controller. Also remove the 2- or 3-pin connector at engine controller. For vehicles using J1939, verify continuity between the 30-pin connector (pins C3, D2, D3) and the 3-pin engine or dash controller connector.
PAGE 31
NOTES 31