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BENDIX BW1726 User's Manual

1. HO VAS 3 IHVNZH NOLDVEL N ONIddS alfidWNOo 79 DAS 3 D Yad DLLSONI9VIQ FIGURE 2 EC 16 CONTROLLER SYSTEM contained in the section entitled Configuring The EC 16 Controller In order to provide full vehicle wheel control antilock the EC 16 controller is used in combination with the following components Four wheel speed sensors Fourair pressure modulator valves One dash mounted antilock condition lamp Oneservice brake relay valve When programmed to provide traction control in addition to antilock the following components are added Onetraction solenoid incorporated into the relay valve Two additional wheel speed sensors optional for tandem drive vehicles with differential braking feature One dash mounted traction condition lamp Serial connection to engine control module for vehicles programmed for torque limiting feature Traction disable wiring and switch PHYSICAL The EC 16 controller electronics are contained in a die cast aluminum housing and are environmentally protected by a self healing silicone compound The metal housing and the design of the digital electronics are intended to provide a high degree of protection from radio and ele
2. 3 W23 ANION JJ zg 3 g er HOSN3S 03395 OZ SM IP 14 2 IH 8 NI 9nd TYNYILX3I 431NdN09 3 150 9 0 19 1ojeinpoy ZZ IA 10 H 1esul Japsejay 998 ON HOLIMS 8208 138 ON 38vN3 NOILOVaL ri HOLIMS 2 ca NOTLOVaL 4 23 M20 IILINV Xt 3e LT 1650 ed 98 998 3 I ra FIGURE 4 EC 16 CONTROLLER SYSTEM WIRING SCHEMATIC WS 20 STRAIGHT SPEED SENSOR WS 20 90 DEGREE SPEED SENSOR FIGURE 5 WS 20 SPEED SENSORS 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 The EC 16 controller is designed to receive wheel speed information from various wheel speed sensor m
3. ISTHISTHESECONDTIMETO THISPOINT STARTHERE WITHIGNITION OFF REMOVE 30 PIN CONNECTOR FROM EC 16 CONTROLLER TURNIGNITION ON AND 1 CHECK FOR VEHICLE VOLTAGE AT ME 2 TERMINAL C2 3 U V UY KJHGF EDCBA 30 PIN CONNECTOR VEHICLE VOLTAGE DETECTED REPLACE EC 16 CONTROLLER REPAIR OR REPLACE WIRE HARNESS AND RETEST SECTION XI TESTING TRACTION CONTROL MODULATOR WITHIGNITIONON INSPECT EC 16 CONTROLLERFORILLUMINATEDLEDs R IS TRC ONLY ON m ARE TRC AND MOD These LED CONTROL MODULE WIRE HARNESS LEDs ON NO GOTOSECTIONXII TESTING ENGINE pese o MAAA m m 2 Pm U W G YES Cl TURN IGNITION OFF AND REMOVE 18 PIN Tu CONNECTORFROM EC 16 CONTROLLER RESET CHECKRESISTANCE BETWEEN PINS D2 amp D3 RESISTANCE SHOULD BE 10 12 OHMS REMOVE 30 PIN CONNECTOR AND CHECK CONTINUITY BETWEEN GROUND A1 2 3 AND D2 amp D3 NOCONTINUITY PERMITTED RESISTANCE CORRECT amp NO U CONTINUITY TOGROUND FED CBA NO m CHECK CONDITION OF 18PIN CONNECTORCLEAN RECONNECT TURNIGNITION ON amp PASS MAGNET OVEREC 16 CONTROLLER RESET REPEAT INITIALSTART UP PROCEDURE ND YES DISCONNECT 2PIN CONNECTOR AT MODULATOR CHECKRESISTANCE OF CONNECTORHALF ATTACHED TOANTILOCK TRACTION RELAY RESISTANCE SHOULD BE 10 12 OHMS THEN CHECK CONTINUITY BE
4. TESTING THE MODULATOR AND TEST THE APPROPRIATEMODULATOR IS MOD LEDILLUMINATED THE SES LED IS ILLUMINATED USING THE TWO POSITIONING LEDs RIGHT LEFT FRONT REAR GO TO SECTION VIIA TESTING THE WHEEL SPEED SENSOR AND TEST THE APPROPRIATE SPEED SENSOR SECTION V TESTING FOR POWER TO THE EC 16 CONTROLLER STARTHERE TURNIGNITIONOFF DISCONNECT 30 PIN CONNECTOR FROM EC 16 CONTROLLER TURNIGNITION ON AND MEASURE VOLTAGE BETWEEN BATTERY PINS B1 K2 K3 AND GROUND PINS A1 A2 A3 ON WIREHARNESS CONNECTOR RECONNECT CONNECTORTOEC 16 CONTROLLER CHECK THE VEHICLE WIRINGFOR CONTINUITY REFERTO VOLTAGE SAME AS BATTERY VOLTAGE MUSTBE BETWEEN 11 AND 17 VOLTS THE VEHICLE SERVICE MANUAL AND CHECKTHE BATTERY VOLTAGE REPAIROR REPLACE WIRING AS NECESSARY AND RETEST 30 PIN CONNECTOR REPEATTHE REPLACE EC 16 INITIALSTART UP CONTROLLER PROCEDURE 21 SECTION VI A TESTING THE MODULATOR TURNIGNITION OFF REFERTO ILLUSTRATION DISCONNECT WIRE HARNESS CONNECTOR FROM EC 16 CONTROLLER STARTHERE 18PIN CONNECTOR 30 PIN CONNECTOR PROBE CONNECTOR WITH VOLT OHM METERAND NOTE THAT PROPER RESISTANCE VALUES ARE OBTAINED FOR MODULA TOR BEING TESTED RESISTANCE VALUES HERE FOR BENDIX 2 M 21 MODULATOR 3 HOLD TOCOMMON READ 3 5 TO 5 OHMS EXHAUST TOCOMMON READ 3 5 TO 5 OHMS EXHAUST TO HOLD READ 7 TO 10 OHMS COMMONTOGROUND NOCONTINUITY Fi LEFT R
5. TURNIGNITION ON AND PASS MAGNET OVER RESETONEC 16 CONTROLLER NOTE REACTIONOF REDLEDs ARE ANY RED LEDs ILLUMINATED REPEATTHE INITIAL START UPPROCEDURE YES REPAIRORREPLACE MODU LATORWIREHARNESS SAMEREDLEDs ILLUMINATED GOTO SECTIONIV INSPECTION FOR ILLUMINATED LEDs AND RETEST 23 24 STARTHERE SECTION VII A TESTING THE WHEEL SPEED SENSOR NO ANY RED LEDs ON NO TURNIGNITION OFF AND CHECK FOLLOWING IGNITIONON NOTE ILLUMINATED LED s 2nd TIME TO THIS POINT DURING TESTING YES DO MAGNETIC RESET NOTE REACTION OF RED LEDs YES SECTION VII PARTB EGGE AND BEGIN TESTING NO YES GOTO SECTION VII PARTB AND BEGIN TESTING CHECK GAP BETWEEN SPEED SENSOR AND EXCITER OR TONE RING GAP FOR BENDIX WS 20 SPEED SENDER IS BETWEENO 015 INCHES IF SENSOR GAP MUST BE ADJUSTED CHECK FOR LOOSE OR WORN WHEEL BEARINGS BEFORE RE GAPPING SENSOR REFERTO VEHICLE MAINTENANCE MANUAL FOR WORN BEARINGS IF SENSOR GAP IS CORRECT CHECK WHEEL BEARING FOR FREE PLAY TO VERIFY IT COMPLIES TOMANUFACTURER S RECOMMENDATIONS MAKE CERTAIN EXCITER OR TONE RING ISIN PLACE AND INSPECT CONDITION CHECK FORMISSING OR DAMAGED TEETH AND THAT IT RUNS TRUE AND PERPENDICULAR TO SENSOR FACE CHECKWIRING HARNESS AND CONNECTORS THAT RUN TO SENSOR CHECK FOR DRAGGING BRAKES OVER ADJUSTED TRAPPED AIR IN ACTUATOR OUT OF ROUND DRUMS FAULTY RETURN SPRINGS PARKING BRAKE SYSTEM FAULTS
6. 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 If one or more ofthe LEDs DO NOT ILLUMINATE and the dash condition lamps indicate the system is functioning properly the nonilluminated LED s should be noted for future reference Although the diagnostic capabilities will be limited the system will continue to function as designed 3 Road test the vehicle by making an antilock stop from a vehicle speed of 20 miles per hour When an antilock stop is made the modulator solenoids pulsate and an audible burst of air can be heard from outside of the cab The wheels should not enter a prolonged lock condition Also make a traction acceleration by accelerating on a road surface with reduced traction As with antilock audible bursts of air can be heard when the traction System is functioning 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 an
7. ILLUMINATED 16 CONTROLLER ISGREEN VOLT LED ILLUMINATED YES GO TO SECTION V TESTING FOR POWER TOTHEEC 16 CONTROLLER REPLACE THE EC 16 CONTROLLER IS GREENLED FLASHING GOTO SECTION IX TESTING FOR FALSE FAILURE INDICATION CAUSED BY WHEELSPEED COMPONENTS ARE ANY RED LEDs ILLUMINATED NOTEAND RECORD THE CONDITIONOF ALL RED LEDs GOTO SECTION IV INSPECTION FOR ILLUMINATED LEDs 6 3 QHD GEN P RESET EC 16 CONTROLLER DIAGNOSTIC DISPLAY 19 SECTION IV INSPECTION FOR ILLUMINATED LEDs STARTHERE P TAoOA ECU LED ON 888886888608 T EC 16 CONTROLLER DIAGNOSTIC DISPLAY 2 B 1LED FROMTHISGROUP 1180 FROMTHISGROUP 1150 FROMTHISGROUP ED ESET EC 16 CONTROLLER DIAGNOSTIC DISPLAY 20 NOTE RED ECU LED IN EC 16 CONTROLLER DIAGNOSTICS WINDOW GOTOSECTION V TESTING FORPOWERTOTHE EC 16 CONTROLLER YES ISTHISLEDILLUMINATED THERE SHOULD BE A MINIMUM OF THREE RED LEDs ILLUMINATED AND OF THE THREE THERE MUST BE A RHT OR LFT PLUS A MID OR RER PLUS A MOD OR SES REPLACE THE EC 16 CONTROLLER AND REPEAT THE INITIAL START UP PROCEDURE DOTHEABOVE CONDITIONS EXIST YES NOTETHETHREEILLUMINATED LEDs USING THE TWO POSITIONINGLEDs RIGHT LEFT FRONT REAR GO TO SECTION
8. ISPOWERDETECTED TROUBLE SHOOTING INFORMATION REPAIR ORREPLACE AS NECESSARY AND REPEAT Ground this THE INITIALSTART UP terminal or wire YES PROCEDURE on relay Coil EC 16 Controller xs Relay CONNECTTHEOPPOSITEENDOF RELAY COILTO VEHICLE GROUND AND NOTE REACTION OF DASH LAMP Vehicle Power Here REPEAT INITIAL START UP PROCEDURE IS DASH LAMP ON NN SECONDTIME TOTHISPOINT AntiLock Dash Lamp YES AntiLock Dash Lamp Relay REPLACE THE RELAY AND Wiring REPLACE THE EC 16 CONTROLLER ANDRETEST REPEAT INITIALSTART UP PROCEDURE 26 SECTION IX TESTING FOR FALSE INDICATION CAUSED BY WHEEL SPEED COMPONENTS WITHIGNITIONON HOLD MAGNET ON RESET OF EC 16 CONTROLLER AND NOTE LEDs STARTHERE REPLACE EC 16 CONTROLLER ARE ALL LEDs ILLUMINATED m 9886806008608 All LEDs Illuminated REMOVEMAGNET TURNTHE IGNITIONOFF AND INSPECT RESET 4 Magnet APPROPRIATE AXLE AND WHEEL FOR hate PRESENCE OF AN EXCITER ORTONE RING AND SPEED SENSOR CHECK SENSOR EC 16 CONTROLLER GAP DISTANCE BETWEEN SPEED DIAGNOSTIC DISPLAY SENSOR AND EXCITER RING AND BEARING END PLAY RE ADJUST AS NECESSARY RUN VEHICLE AT 7 MPH ORMORE FOR 5 SECONDS OR MORE TURN OFF IGNITION REPEAT INITIAL START UP PROCEDURE 27 28 SECTION X TESTING TRACTION CONTROL DASH LAMP REPLACETRACTION DASHLAMP WITH KNOWN GOOD UNIT REPEAT INITIAL START UP PROCEDURE
9. Right LED This Red LED illuminates and latches ON in order to indicate the location of a problem component or its wiring It will light in conjunction with either the FRONT or REAR LED and the MOD or SENS LED LFT Left LED This Red LED illuminates and latches ON in order to indicate the location of a problem component or its wiring It will light in conjunction with either the FRONT or REAR LED and the MOD or SENS LED TRC Traction LED This Red LED illuminates and latches ON to indicate a permanent problem in the traction control system It may be illuminated with the MOD LED or may illuminate by itself NOTE If an intermittent problem exists with the wiring to the engine control module ECM this LED will go on However it will not latch it will go out when the problem corrects itself MOD Modulator LED This Red LED illuminates and latches ON to indicate a permanent or intermittent open or short circuit in the solenoids of one of the four M 21 modulators or the wiring connecting them to the system When indicating a problem with an M 21 modulator this LED will be illuminated with two positioning LEDs RHT LFT FRT RER NOTE The MID positioning LED should not be illuminated with this LED This LED is also used to indicate a problem with an ATR 1 or ATR 2 antilock traction relay solenoid When illuminated for a traction system problem the TRC LED will also be on SEN Speed Sensor LED This Red
10. ANTILOCK AND TRACTION SYSTEM OPERATION DURING COMPONENT FAILURE The Bendix EC 16 controller handles equipment failure using a conservative fail safe philosophy Any single electrical failure of a component devoted to antilock or traction control results in simultaneous illumination of the appropriate condition lamp on the dash a disabling of part or all of the antilock or traction system and reversion to standard braking on wheels no longer under EC 16 controller control Depending upon the type of failure and its position of occurrence the EC 16 controller disables all or only a portion of the antilock and traction system A power or controller failure however will result in complete disabling of both systems and reversion to standard braking on all wheels SINGLE FAILURE The following list and chart describe how the antilock and traction systems respond to a specific component failure Note right and left front mid and rear are determined from the driver s seat Left front is therefore the corner closest to the driver For example if the right mid sensor RM Sensor on the chart fails front and rear antilock will still be operative Traction will be disabled and as always the system has standard air braking Front modulator If a front modulator fails antilock on that wheel is disabled Antilock and traction on all other wheels remains active Rear modulator A rear modulator failure disables the traction
11. ETC AND CORRECT AND RETEST RECONNECT CONNECTORSAT EC 16 CONTROLLER AND SPEED SENSOR DO MAGNETIC RESET NOTE REDLEDs ARE ANY REDLEDs ILLUMINATED GOTO INITIAL START UP PROCEDURE GOTOSECTIONIII INSPECTION FOR ILLUMINATED LEDs SECTION VII B TESTING THE WHEEL SPEED SENSOR GOTOSECTIONIII INSPECTION FORILLUMINATED LEDs SAME LEDs ILLUMINATED START HERE FROM SECTION VIIA IGNITION OFF REMOVE CONNECTORFROMEC 16 CONTROLLER MEASURE RESISTANCE BETWEEN THE 30 PINCONNECTOR APPROPRIATE SPEED SIGNAL AND SIGNAL RETURN RESISTANCE FOR BENDIX WS 20 SENSOR IS BETWEEN 1500 2500 OHMS REFER TO VEHICLE MANUAL FOR THE RESISTANCE VALUES IF OTHER THAN WS 20 SENSOR IS IN USE CHECK CONTINUITY BETWEEN POWER B1 K2 3 SPEED SIGNAL THEN BETWEEN GROUND A1 2 3 AND KJHGF EDCBA SPEEDSIGNAL NOCONTINUITY PERMITTED J2 LEFT FRONT W S RTN J1 LEFT FRONT W S SIGNAL H3 RIGHT FRONT W S RTN H2 RIGHTFRONT W S SIGNAL CORRECT RESISTANCE REPLACE THE EC 16 CONTROLLER A123 GROUND B1K23 POWER 18 PINCONNECTOR DISCONNECT CONNECTORAT SPEED SENSOR INSPECT THE CONNECTOR THENCHECKTHE RESISTANCE REPLACE THE SENSOR BETWEEN TWO PINS ON SENSOR RESISTANCE BETWEEN 1500 2500 OHMS FOR THE BENDIX WS 20 SENSOR CHECK CONTINUITY BETWEEN POWER B1 K2 3 SPEED SIGNAL THEN BETWEEN GROUND A1 2 3 AND SPEED cx SIGNAL NOCONTINUITY PERMITTED C2 LEFTMID W S SIGNAL
12. IGNITION OFF THEN ONANDOBSERVEONLY YES THE TRACTIONSYSTEM IS DASHTRACTIONCONTROL FUNCTIONINGNORMALLY CONDITION LAMP DID IMPORTANT NOTICE AntiLock systems manufactured after January TRACTION CONTROLLAMP 20 1997 are designed so that the antilock dash BLINKTHENGOOUT lamp extinguishes after a successfulselftestof the electronics and system wiring Previous systems required vehicle speed input to extinguish the dash lamp MAKE CERTAIN TRACTION L ISENABLED USE THE UNDER DASH SWITCH RETEST If the EC 16 controller has been recently replaced deter mine if it is a self configuring model refer to service data section entitled 16 CONTROLLER CONFIGURATION and make certain it is configured properly for the vehicle If traction control is part of the configuration the enable DID TRACTION CONTROL disable switch must be placed in the enabled position LAMPBLINKTHEN GO traction control operable OUT NO GOTOSECTIONX TESTING NO YES GOTOSECTIONXI THETRACTIONDASH ea TESTINGTRACTION LAMP CONTROLMODULATOR 16 SECTION I ANTILOCK DASH LAMP TESTING DISCONNECT 30PIN CONNECTOR FROM STARTHERE EC 16 CONTROLLER AND OBSERVE THE ANTILOCK DASHLAMP REPLACE THE EC 16 CONTROLLER ANTILOCK DASH LAMP ILLUMINATED WITHIGNITION ON MEASURE VOLTAGE BETWEEN PINS E3 amp A1 A2 A3 VOLTAGE SHOULD BE SAME AS BATTERY VOLTAGE Al GROUND A2 GROUND A3 R
13. It must be remembered however that unlike the driver the EC 16 controller is able to pump each brake on the vehicle independently and with far greater speed and accuracy OPERATION TRACTION CONTROL PHILOSOPHY Traction control is a natural extension of antilock Just as antilock helps vehicle control and stability during braking traction control helps during vehicle acceleration The wheel speed sensors not only detect rapid decreases in wheel speed for antilock but also detect unreasonably high increases for traction control With traction control a spinning wheel is instantly detected and compared with the other wheels on the vehicle both front and rear Two different methods are used to control wheel spin torque limiting and differential braking Depending upon vehicle type speed and road surface condition each method provides a unique and desirable type of wheel spin control Ideally both methods are used to control vehicle traction While all new version EC 16 controllers are capable of providing wheel control antilock and traction control utilizing both methods of control not all systems will be configured for both methods Depending upon the vehicle either or both traction control methods will be activated during the self configuration procedure 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 li
14. position of the EC 16 controller diagnostic display until the LEDs begin to randomly flash then remove the magnet If the magnet is not removed during the random LED flashing a second self configuration may be initiated The magnet may have to be held on the RESET for as long as 20 seconds When the self configuration process is complete the EC 16 controller will automatically go through a self test During the self test the diagnostic display will indicate the new configuration as described under the section entitled EC 16 Controller Configuration Display Note If the EC 16 controller is being configured with traction control either torque limiting differential braking or both the traction control condition dash lamp will be illuminated as well as the appropriate LEDs on the EC 16 controller diagnostic display The traction control dash lamp will be illuminated until the traction control enable disable switch is placed in the traction control enabled position traction control operative Place the traction control enable disable switch in the traction control enabled position traction control operative the traction control dash lamp should be off Before placing the vehicle in service verify the configuration and the system condition by turning the ignition OFF then ON while observing the EC 16 controller diagnostic display The diagnostic display should indicate the desired configuration as described under the section en
15. system Antilock on that wheel will also be disabled but antilock on all other wheels remains active Front sensor The wheelis still modulated using input from the opposite sensor The traction system is disabled Mid or rear sensor Antilock on that wheel is disabled but antilock on all other wheels remains active Traction control is disabled Controller Antilock and traction are disabled The system reverts to standard air braking 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 The system reverts to standard air braking Note Avoltage problem and an intermittent ECM wiring problem can correct themselves For example a power surge can take the system out of voltage range for a moment which will flash the voltage LED and an intermittent wiring problem between the EC 16 controller and the ECM can cause the traction LED to go on During the time that the problem is occurring the dash lamp will also be on When the problem corrects itself the system is restored The dash lamp and the appropriate LED go out For all other problems the system will not be restored in the problem area until the error is corrected and the EC 16 c
16. 18 PIN 30 PIN CONNECTOR 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 Y T m MOUNTING HOLES 4 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 driveabi
17. EAR MOD COMMON Hi LEFT FRONT MOD COMMON D1 LEFT REAR MOD EXHAUST FA LEFT FRONT MOD EXHAUST HOLD TO BATTERY POWER NOCONTINUITY E1 LEFT REAR MOD HOLD Gi LEFT FRONT MOD HOLD A RIGHT REAR MOD COMMON C1 RIGHT FRONT MOD COMMON HOLD TO GROUND NOCONTINUITY RIGHT REAR MOD EXHAUST Ei RIGHT FRONT MOD EXHAUST EXHAUST TO GROUND NOCONTINUITY Bi RIGHT REAR MOD HOLD Di RIGHT FRONT MOD HOLD INSPECT CONNECTOR AND RECONNECT TO EC 16 CONTROLLER TURN IGNITION ON AND PASS MAGNET OVER RESET ON EG 16 CONTROLLER NOTE REACTION OF REDLEDs ARERESISTANCE VALUES CORRECT REPEAT INITIALSTART UP PROCEDURE IFTHIS TEST STEP HAS REPEATED TWICE REPLACE THE EC 16 CONTROLLER SAMEREDLEDs YES REPLACETHEEC 16 ILLUMINATED CONTROLLER GO TO SECTION VI BAND CONTINUETESTING ARE ANY RED LEDs ILLUMINATED GO TO SECTION IV INSPECTIONFOR ILLUMINATEDLEDs ANDRETEST 22 SECTION VI B TESTING THE MODULATOR CONNECTOR ON M 22 MODULATOR GOTOMODULATOR INSPECT WIRING CONNECTOR DISCONNECT CONNECTORAND TEST RESISTANCE BETWEENPINS ON MODULATOR RESISTANCE VALUES FOR BENDIX M 22 MODULATOR HOLD TOCOMMON READ 3 5 TO 5 OHMS EXHAUSTTO COMMON READ 3 5 TO 5 OHMS EXHAUST TOHOLD READ 7 TO 10 OHMS TEST EACH PIN TO VEHICLE GROUND AND NOTE NO CONTINUITY STARTHEREFROM SECTION VIA EXHAUST COMMON HOLD RESISTANCEREADINGS CORRECT REPLACETHEMODULATOR RECONNECT CONNECTORTOMODULATOR
18. EPLACE RELAY amp RETESTFORBATTERY VOLTAGE TO DASH LAMP RELAY CHECKWIRING HARNESS AND RELAY FOR REPAIRORREPLACEWIRE SHORTS TO GROUND RECONNECT AND HARNESS CHECK REPLACE THE FOLLOWING 1 DASH LIGHT BULB 2 FUSE 3 RELAY POWER WIRE 4 RELAY AFTERREPLACINGEACHCOMPONENT TEST THE DASH LAMP DASH LAMP TO DASH LAMP 1 2 RELAY GRQUND es REPEAT THE INITIAL START UP PROCEDURE VEHICLE POWER IGNITION DASH LAMP 17 SECTION II INSPECTION FOR ILLUMINATED LEDs INSPECTEC 16 CONTROLLERFOR PRESENCE OF ILLUMINATED LEDs AND RECORD STARTHERE CHECK CLOSELY AND NO OFF NOTE IF GREEN VLT LEDIS ILLUMINATED REPLACETHE EC 16 u CONTROLLER ISGREENLED FLASHING GO TO SECTION V TESTINGFORPOWER TOTHEEC 16 CONTROLLER ARE ANY RED LEDs ILLUMINATED NOTEAND RECORD THE GO TO SECTION V TESTING CONDITION OF ALL RED FORPOWERTOTHE EC 16 LEDs CONTROLLER GOTO SECTIONIV INSPECTIONFOR ILLUMINATED LEDs RED LEDs GOTOSECTIONVIII TESTINGFOR FALSEFAILURE INDICATION CAUSED BY DASH LAMP RELAY CD D GEN cU lt L GREEN VLT LED RESET EC 16 CONTROLLER DIAGNOSTIC DISPLAY SECTION III INSPECTION FOR ILLUMINATED LEDs INSPECT THE EC 16 CONTROLLER FOR PRESENCE OF ILLUMINATEDLEDS AND RECORD START HERE GOTO SECTION V ARE ANY RED TESTINGFORPOWER LEDs
19. F3 LEFT REAR W S RTN F2 LEFT REARW S SIGNAL B3 RIGHT MID W S RTN RIGHT MID W S SIGNAL RECONNECTCONNECTORATSPEED MENTON SIGNAL SENSOR AND 16 CONTROLLER AND DO MAGNETIC RESET NOTE IF ANY RED LEDs ARE ILLUMINATED REPEAT THE INITIAL START UP PROCEDURE AREANYLEDs ILLUMINATED GOTOSECTIONIII INSPECTION FORILLUMINATED LEDs ARE SAME REDLEDSILLUMINATED REPAIRORREPLACESPEED SENSORWIRING HARNESS 25 SECTION VIII TESTING FOR FALSE INDICATION CAUSED BY DASH LIGHT RELAY WITHIGNITION ON HOLDMAGNET STARTHERE ONEC 16 CONTROLLERRESET AND NOTE ALL LEDs ILLUMINATED E3 TO DASH LAMP RELAY ARE ALL LEDs ILLUMINATED NO REPLACE THE EC 16 CONTROLLER YES REMOVE MAGNET FROM EC 16 CONTROLLER TURN IGNITION OFF AND DISCONNECT THE 30 PIN KJHGF EDCBA CONNECTORFROM EC 16 CONTROLLER CHECK 30 PINCONNECTOR CONTINUITY OF WARNINGLAMP WIRE BETWEEN ON THE 30 PIN CONNECTOR AND THE TERMINALON THELAMP RELAY E3 from 30 pin EC 16 connector Controller Relay NO REPAIRORREPLACE WIRE HARNESS ISCONTINUITY DETECTED RECONNECT EC 16 CONTROLLER WIREHARNESS AND REPEAT THE INITIALSTART UP PROCEDURE YES RECONNECT THE 30 PIN CONNECTORTOTHEEC 16 CONTROLLER TURNIGNITIONON AntiLock AND CHECK FOR VEHICLE POWER Dash Lamp AT THE LAMP RELAY COLL AntiLock Dash Lamp Relay Wiring CHECK DASH WIRING AND CONNECTORS NO AND CONSULT THE VEHICLE MANUAL FOR
20. IN OH GOW HV3H LHOIH Andino AYVITIXNY qu9 1 NOWINOO GOW LHOIH 4 3 23 13 ea 29 o d ca V IV AHILLVE 634 AHILLVE 2M J318VSId H3QHVl13H 134 aunoH9SISSVHO NlH S MINOHJ1331 ef WNODIS S MINOHH 1437 IP NIH S MINOHJIHOIH WNODIS S A LNOHH LHOIH NONINOO GOW LNOHd 1337 IH TVIHIS V 1VIH3S DILSONDVIA 29 qIOH QOWINOH431331 19 Q3Snl1ON 4 HOLIMS 318VN3 NOILOVEL 53 1SNVHX3 GOW 1 1437 13 dAVTONINHYM 35 10 53 1SNVHX3 dOW INOHdIHOIH 13 G3SNION a 35 10 GOW LNOYS LHOIH 10 AYVIIXNY NOILOVHL 29 NOWINOO GOW LNOYS LHOIH 19 TYIHIS 3NIDN3 68 V TYIHIS lOHINOO 3NIDN3 28 AHILLVE 18 ONNOYD EV cv IV JOH NO YOLDANNOD HOLLY INGOW 1SnvHX3 496 89 oL uos 0 Rjay due qz lt Er NES c 19 i YOLVINGON NOLLOVHL Z 1 17 ce N
21. LED illuminates and latches ON to indicate permanent or intermittent failure The failures indicated are open or shorted wheel does not conform to design criteria The SEN LED will be illuminated with two positioning LEDs RHT LFT FRT MID RER ECU Electronic Control Unit LED This Red LED when illuminated indicates that the controller itself has failed It is latched ON for all EC 16 controller failures except low voltage Before controller replacement is considered always check vehicle voltage to the controller VLT LED This Green LED illuminates and remains ON during vehicle operation to indicate that vehicle power is reaching the controller If vehicle power is out of range below 11 VDC or above 17 VDO this LED will flash until power is brought into range RESET Beneath the RESET area of the display is a magnetically sensitive switch that is used to reset the diagnostic system The device will respond to a magnet which has strength sufficient to lift a three 3 ounce weight Momentarily holding a magnet against the RESET will cause ALL LEDs to light during the time the magnet is against it Holding a magnet against the RESET longer than 20 seconds will cause the newer version EC 16 controller to initiate the self configuration feature EC 16 CONTROLLER CONFIGURATION GENERAL All EC 16 controllers manufactured on or after August 1 1995 incorporate the self configuring feature New replacement EC 16 controll
22. LEDs will illuminate then go out 3 The number of active sensors will be displayed by the momentary illumination of the red SEN sensor LED and two or more of the red locating LEDs No other LEDs will be on A SEN FRT front RER rear A four sensor configuration all systems must have at least a 4 sensor configuration B SEN FRT MID middle RER A six sensor configuration 4 Thered TRC LED will momentarily illuminate by itself if traction control torque limiting is active if not then the display will go to the condition described in 5 5 Thered TRC and MOD LEDs will momentarily illuminate if traction control differential braking is active if not then the display will go to the condition described in 46 No other LEDs will be on 6 The diagnostic display will return to its normal operational status Assuming no problems exist in the antilock or traction system all red LEDs will be off and the single green VLT LED is illuminated 12 On On Off On On Off EC 16 CONTROLLER SELF CONFIGURING PROCESS Important General Information 1 Three aspects of the antilock and traction system are influenced by the self configuring feature of the EC 16 controller Stays Off Stays Off Stays Off A Speed Sensors The number of speed sensors connected to the EC 16 controller will be detected during the self configuration process The EC 16 controller will check the MID SEN mid axle speed sensor loca
23. 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 itis 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 Note and mark the mounting position of the EC 16 controller on the vehicle Loosen remove and save the nuts on the mounting hardware that attaches the EC 16 controller bracket to the vehicle Remove the EC 16 controller and bracket from the vehicle 3 Remove and retain the four cap screws that secure the EC 16 controller to the bracket Separate the EC 16 controller from the bracket 4 Perform the Initial Start up Procedure in the TROUBLESHOOTING section to assure proper system operation INSTALLING THE EC 16 CONTROLLER EC 16 CONTROLLER MOUNTED ON ANTILOCK RELAY VALVE OR ANTILOCK TRACTION RELAY VALVE 1 After noting the relationship of the positioning marks made prior to disassembly position and secure the EC 16 controller to the valve using the four cap screws Torque the cap screws to 50 80 165 in 2 Mount the assembled EC 16 controller and antilock relay valve on the vehicle and orient it in the position marked before removal 3 Reconnect all
24. TWEEN GROUND ON30PIN CONNECTOR A1 2 3 AND BOTH PINS ON THE 2PINCONNECTORLEADING TO THE MODULATOR NOCONTINUITY PERMITTED 2 pin Modulator Connector EC 16 Controller and NO Bes 2 RESISTANCE CORRECT amp NO AntiLock Traction Relay MODULATOR CONTINUITY TOGROUND Modulator 30PIN CONNECTOR YES REPAIRORREPLACEWIRE HARNESS FROM 18PIN KJHGF EDCBA CONNECTORTO2 PINCONNECTOR sr GROUND 29 SECTION XII TESTING ENGINE CONTROL MODULE WIRE HARNESS PASS MAGNET OVER EC 16 CONTROLLERRESET amp REPEAT INITIALSTART UP PROCEDURE STARTHERE TRCONLY REDLED ON YES R TURNIGNITION OFF DISCONNECT 30PIN CONNECTOR FROM EC 16 CONTROLLER amp 2PINCONNECTORAT ENGINE ELECTRONIC CONTROLMODULE CONNECTOR AT ENGINE ELECTRONIC CONTROL MODULE m a 7 A 92 Z A Illuminated CHECK WIRE CONTINUITY BETWEENSOPIN CONNECTORAT EC 16 CONTROLLERAND2 PINCONNECTORAT ENGINECONTROL MODULE PINS B2 amp B8 ON 30 PIN CONNECTORCORRESPONDTO THEWIRES LEADINGTO2PIN CONNECTORAT ENGINE CONTROLMODULE 30 PIN CONNECTOR TEST ENGINE CONTROL MODULE USING ENGINE MANUFACTURER S PROCEDURE WIRE CONTINUITY OK REPAIRORREPLAGE VEHICLE WIRE HARNESS 30 31 32 BW1726 O 2004 Bendix Commercial Vehicle Systems LLC All rights reserved 6 2004 Printed in U S A
25. air lines to the assembly 4 Reconnect the electrical connector s to the EC 16 controller 5 Testthe valve for operation and leakage prior to placing the vehicle in service 6 Perform the Initial Start Up Procedure in the TROUBLESHOOTING section to assure proper system operation BRACKET MOUNTED EC 16 CONTROLLER 1 Secure the EC 16 controller to its bracket using the four cap screws Torque to 50 80 Ibs in 2 After noting the positioning marks mount the EC 16 controller on the vehicle using the mounting hardware retained during removal 3 Connect the electrical connector s to the EC 16 controller 10 4 Perform the initial Start up Procedure in the TROUBLESHOOTING section to assure proper system operation DIAGNOSING AND LOCATING A SYSTEM PROBLEM GENERAL The EC 16 controller contains self test and diagnostic circuitry that continuously checks for proper operation of the entire antilock traction system including wiring continuity The EC 16 controller is programmed at the factory to accommodate the needs of the vehicle and the customer s desires All EC 16 controllers are not factory programmed with the traction control feature in which case antilock only will be active The newer self configuring EC 16 controller can be reconfigured by the end user to include traction control A vehicle equipped with traction control can generally be identified by noting the presence of a dashmounted conditi
26. controller diagnostic display The first six LEDs locate a problem to a specific area of the vehicle and the next three indicate the problem component or its wiring The LEDs are software driven and are either ON or OFF depending upon their monitor function Note right and left front and rear are determined from the driver s seat FRT RedLED MID RedLED See Note RER RedLED RHT RedLED LFT RedLED TRC RedLED MOD RedLED SEN RedLED ECU RedLED VLT Green LED RESET NoLED 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 Note FRT Front LED This Red LED illuminates and latches ON in order to indicate the location of a problem component or its wiring It will light in conjunction with either the RIGHT or LEFT LED and the MOD or SENS LED MID Mid Axle LED This Red LED is not used in all installations On those vehicles that have six speed sensors installed this Red LED illuminates and latches ON to indicate the location of a problem speed sensor or its wiring The MID LED should not illuminate with the MOD LED RER Rear LED This Red LED illuminates and latches ON in order to indicate the location of a problem component or its wiring It will light in conjunction with either the RIGHT or LEFT LED and the MOD or SENS LED RHT
27. ctromagnetic interference The patented light emitting diode LED display and a magnetically actuated reset switch is incorporated in the housing for troubleshooting and diagnostic purposes Two electrical connectors located in the controller housing opposite the diagnostic display connect the EC 16 controller to antilock and traction system components one 30 pin and one 18 pin Packard Electric 150 series Metri pack connector In addition to these two housing mounted connectors the EC 16 controller also uses a 2 pin Deutsch connector when programmed with the optional traction control feature The 2 pin connector is linked to a traction solenoid which is located in the upper portion of the antilock traction relay valve assembly See Figure 3 MOUNTING The EC 16 controller is available in two different mounting styles One model shown in Figure 1 is a stand alone It is intended for bracket mounting to a frame member and is not attached to an antilock relay valve EC 16 CONTROLLER ANTILOCK TRACTION ASSEMBLY 2 PIN CONNECTOR TO TRACTION SOLENOID TRACTION SOLENOID TRACTION RELAY FIGURE 3 EC 16 CONTROLLER W ANTILOCK TRACTION RELAY VALVE The other EC 16 controller is designed to be mounted on one of four different valves All of the valves provide the relay function and replace the standard service relay on antilock equipped vehicles In some instances the valves also provide specialized f
28. d 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 Useonly the propertools and observe all precautions pertaining to use of those tools 4 Ifthe 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 an AD IS air dryer system ora dryer reservoir 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 genui
29. e EC 16 controller is able to improve braking between the vehicle tire and the road surface it is on while maintaining vehicle stability The rear axle brakes are controlled independently therefore brake application pressure at an individual wheel is adjusted solely on the basis of its behavior on the road surface on which it is traveling While each steering axle brake is under the control of an individual modulator the EC 16 controller does not treat these brakes totally independently The EC 16 controller uses a modified individual control philosophy for the steering axle brakes This is done in order to minimize steering wheel pull in the event each wheel is traveling on a different road surface for example ice close to the curb and a dry crown Essentially the EC 16 controller controls the braking force differences between the two brakes The wheel on dry pavement is initially given less braking force and is brought up to optimum during the stop while the wheel on ice attempts to maintain optimum braking during the entire stop In the case of vehicles equipped with tandem rear axles 6x2 6x4 the wheel speed sensors are installed at the wheels on the axle that is most likely to lock first A single modulator controls both curb side brakes on the tandem and another modulator controls both brakes on the driver s side of the tandem With this arrangement of speed sensors and modulators both brakes on one side of the tand
30. elf or the wiring The following troubleshooting procedure is devoted to narrowing the problem to either the wiring or a specific AntiLock or traction component It should be noted that ALL TROUBLESHOOTING BEGINS BY OBSERVING THE ANTILOCK AND TRACTION CONDITION LAMPS ON THE DASH All troubleshooting should begin by first performing the Initial Start Up Procedure and following the directions contained in it TROUBLESHOOTING TIPS 1 Begin by observing the dash condition lamp s and performing the Initial Start Up Procedure 2 The troubleshooting technician should record all findings and the action taken during the troubleshooting process 3 No voltage or resistance tests are performed into the EC 16 controller All voltage and resistance tests are performed by beginning at the wire harness half of the connector and moving AWAY from the EC 16 controller toward an antilock traction system component modulator wheel speed sensor etc 4 f a problem mysteriously reoccurs and no apparent cause can be detected during troubleshooting closely inspect the quality of the power supply to the antilock system Check the vehicle wiring wiring connectors AND the alternator Defects in these components can cause false failure indications 14 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 provid
31. em are treated as one since they will most likely be on the same type of road surface 6 NON ANTILOCK BRAKE APPLICATION During normal braking air pressure from the brake valve enters the control port of the service relay valve The service relay delivers air to and through the antilock modulator located near the braked wheel and into the brake actuator The service brakes are thus applied If the wheel sensors do not detect an impending wheel lock up the EC 16 controller does not initiate any corrective action and the vehicle comes to a stop in a normal fashion ANTILOCK BRAKE APPLICATION If a service brake application is made and the wheel speed sensors detect an impending wheel lockup the EC 16 controller will immediately begin modification of the brake application using the antilock modulator s at the affected wheel s Solenoid valves contained in the modulator are energized and de energized by the EC 16 controller in order to modify the brake application When a solenoid coil is energized its shuttle moves Depending upon the function of the specific solenoid it either opens or closes thereby causing the exhaust or re application of air pressure to the brake actuator The solenoids in each modulator are controlled independently by the EC 16 controller By opening and closing the solenoid valves in the appropriate modulator the EC 16 controller is actually simulating what drivers do when they pump the brakes
32. ers will be provided factory preprogrammed for 6 speed sensor inputs and both the differential braking and torque limiting features for traction control 11 ANTILOCK LAMP LAMP ON LAMP OFF LAMP ON LAMP OFF LAMP ON 1ST TIME 1ST TIME 2ND TIME 2ND TIME STAYS ON Traction Lamp EC 16 controller w torque limiting amp differential braking Traction Lamp EC 16 controller w torque limiting only Traction Lamp EC 16 controller w differential braking only IDENTIFYING THE SELF CONFIGURING EC 16 CONTROLLER The self configuring EC 16 controller can most easily be identified while installed on the vehicle Identification can be made by observing the reaction of the diagnostic display when the ignition is switched ON and power is applied to the EC 16 controller The current configuration of the EC 16 controller is displayed via the troubleshooting LEDs and occurs during the normal self test sequence This configuration review is repeated each time the ignition is turned on The sequence and manner of LED illumination is described in the section entitled EC 16 Controller Configuration Display That section should also be used to confirm that the system is configured as desired TM The diagnostic LEDs on older versions of the EC 16 controller will only react as described in items 2 and 6 under the section entitled EC 16 Controller Configuration Display EC 16 CONTROLLER CONFIGURATION DISPLAY 1 Turnthe ignition ON 2 All
33. es a quick reference to specific sections that provide testing procedures and values D aD GHD NOTHING ON GO TOSECTIONV ED EN EN EN ED ED FLASHING GO TO ON NOT FLASHING GO RESET RESET SE SECTIONV TOSECTIONII D ONEFROMTHIS ONEFROMTHIS e r GROUPON GROUPON pd ONEFROMTHIS ONEFROMTHIS ONEOR GROUPON GROUPON MOREON RO 3 3 ON GO TO SECTION VI A 3 2558 ON GO TO SECTION VII A ED SECTIONIV ON NOT FLASHING E ON GO TO ON GO TO SECTIONXII SECTIONXI D gt 653 2888808868 R INITIAL START UP PROCEDURE TURN IGNITION ON AND OBSERVE DASH ANTILOCK LAMP STARTHERE ANTILOCK DASH LAMP DOES NOT BLINK COMES ON AND REMAINS ILLUMINATED GO TOSECTIONII INSPECTION FORILLUMI NATEDLEDS DID ANTILOCK DASH LAMP BLINK YES NO See Notice ISANTILOCKDASHLAMP __ _ STILLILLUMINATED 71 YES See Notice INCREASE VEHICLE SPEED TO ABOVE 7 MPH FOR AT LEAST 5 SECONDS AND OBSERVE THEDASHLAMP GOTOSECTIONIII INSPECTION YES DASHLAMP ILLUMINATES OR FORILLUMINATED LEDs REMAINSON NO THEANTILOCK SYSTEM IS FUNC TIONING NORMALLY MAKE NOTE OFANY PARTS REPLACED OR REPAIRED NO ISVEHICLEEQUIPPEDWITH 24 TRACTION CONTROL YES TURN
34. he EC 16 controller self test 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 The operator can tell that the traction features are lost by noting the absence ofthe traction lamp flash upon power up The operator should note the flashing of the antilock condition lamp and the traction lamp if traction equipped upon every power up Observing the dash lamps is the only method the operator has to verify the system operation The EC 16 controller can be reprogrammed up to 10 000 times When a replacement EC 16 controller is installed on a vehicle that does not have one or more of the pre programmed features a failure will be registered on the dash lamp s and on the EC 16 controller diagnostic display For this reason it is necessary to perform the self configuring procedure Some configuration information is available by observing the reaction of the dash condition lamps on vehicles configured with traction control and equipped with the self configuring EC 16 controller When the ignition is switched ON the EC 16 controller self
35. ing feature Note The data link enables the EC 16 controller to report its operating condition to a specialized external computer in response to certain commands it receives The EC 16 controller diagnostic data link hardware conforms to S A E standard J1708 The protocol or coded language used conforms to S A E standard J1587 There are two connections to the EC 16 controller devoted to the data link While connections are provided for this function it is not always used The data link is not essential for the EC 16 controller to be functional If the EC 16 controller is programmed for traction control it contains the following outputs Aconnection to the engine s electronic control module allows the EC 16 controller to reduce engine torque under certain circumstances Atraction 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 Aconnection to the traction solenoid located in the upper portion of the antilock traction relay valve see Figure 3 is provided via a 2 pin Deutsch connector OPERATION ANTILOCK PHILOSOPHY The Bendix EC 16 controller antilock system uses individual sensors modulators and an electronic controller to control the four vehicle wheel ends By monitoring the deceleration rate during braking and subsequently adjusting the brake application pressure at each wheel th
36. lity 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 ofthis 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 1 Yoxa YILIDXI 7 HOSN3S 5 1 YOSNAS 5 33 INTIVA Divdd IDNYIS S HOLV T ICIOIAI CC YN TAN ATEINSSSV NOLLOVuL DIO ILLNV Z Y HO T Y 1NAON TOYLNOD ODINOHLOH 143 HOLMS 3 I8VSK1 12
37. miting 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 Differential Braking In order for the differential braking control feature to be used the vehicle must be equipped with an antilock traction relay valve such as the Bendix ATR 1 or ATR 2 relay valve The ATR 1 and ATR 2 relay valve contain a solenoid assembly which provides this feature The differential braking feature allows the EC 16 controller to gently pump the brake on the spinning wheel Since the vehicle s differential tends to drive the wheel that presents the least resistance the wheel on the slipperiest surface a slight brake application to this wheel only forces the differential to drive the stationary or slowly spinning wheel While a vehicle must be equipped with an electronic throttle to utilize the torque limiting feature of traction control differential braking can be used on all vehicles Differential braking can be activated only when vehicle speed is under 25 MPH and one drive wheel is spinning faster than the other s TRACTION CONTROL AT VEHICLE SPEEDS OF 0 TO 25 MPH When wheel spin is detected and the vehicle is stopped or moving at any speed up to 25 mph the EC 16 controller simultane
38. ne Bendix replacement parts components and kits Replacement hardware tubing hose fittings etc must be of equivalent size type and strength as original equipment and be designed specifically for such applications and systems DIAGNOSTIC DISPLAY LEDs RESET SWITCH FIGURE 7 EC 16 CONTROLLER DIAGNOSTIC DISPLAY 9 Components with stripped threads or damaged parts should be replaced rather than repaired Do not attempt repairs requiring machining or welding unless specifically stated and approved by the vehicle and component manufacturer 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 Antilock Traction Control ATC the ATC function must be disabled ATC indication lamp should be ON priorto performing any vehicle maintenance where one or more wheels on a drive axle are lifted off the ground and moving REMOVING THE EC 16 CONTROLLER EC 16 CONTROLLER MOUNTED ON ANTILOCK RELAY VALVE OR ANTILOCK TRACTION RELAY VALVE 1 Identify and remove all air lines connected to the unit 2 Disconnect the electrical connector s from the EC 16 controller 3 Note and mark the mounting position of the assembly on the vehicle Loosen remove and save the nuts on the mounting hardware that attaches the controller relay assembly bracket to the vehicle Remove the relay valve and EC 16 controller from the vehicle 4
39. odels at the rate of 100 pulses per wheel revolution The EC 16 controller is able to simultaneously receive and individually interpret speed signals from six wheel speed sensors Vehicle drive configuration and whether the traction control feature is in use determines the number of speed sensors that must be used A vehicle with a single rear axle drive 4 x 2 4x 40r 6 x 2 requires 4 speed sensors for both antilock and traction operation A vehicle with two rear drive axles 6 x 4 requires 4 speed sensors for antilock only operation but have the option to use 6 speed sensors for enhanced performance of both antilock and traction operation Vehicle power is supplied to the EC 16 controller from the ignition switch through a fuse or circuit breaker 30 amp The electrical ground for the EC 16 controller is the vehicle chassis Aconnection for a traction enable switch is provided but not always used The switch allows traction to be turned on or off manually OUTPUTS Modulators like the Bendix M 21 or M 22 modulator are the means by which the EC 16 controller modifies driver applied air pressure to the service brakes The modulator is an electrically controlled air valve located near the service actuator s it controls It is the last valve that air passes through on its way to the brake actuator wiring harness connects the modulator to the EC 16 antilock controller Solenoid valves contained in the modulat
40. on lamp a disable switch for the traction control System and atraction solenoid located above the relay valve Separate dash lamps controlled by the EC 16 controller advise the driver of the condition of the entire antilock traction system The condition of specific components is provided by a series of labeled light emitting diodes LEDs in the EC 16 controller housing No special tools or equipment are needed to read or interpret the EC 16 controller diagnostic display It should be noted that the EC 16 controller diagnostics display is separate from the antilock and traction condition lamps on the dash With this separation the driver is aware of any problems that occur but is not confused by diagnostic information When the controller senses an erroneous condition it stores the condition in memory disables the antilock or traction function and illuminates the dash mounted condition lamp and the appropriate diagnostic LEDs on the EC 16 controller The failure condition is truly stored and is not cleared by loss of power to the EC 16 controller The LEDs will relight when power is restored and remain illuminated until the failure is corrected After the actual problem is corrected maintenance personnel can clear or reset the EC 16 controller diagnostics by holding a small magnet over the RESET point in the diagnostics display DIAGNOSTIC LEDS There are ten LEDs plus a magnetically actuated reset switch inthe EC 16
41. ontroller is cleared with the reset switch It should be remembered that the driver will be advised of the degraded operation via the dash lamps and that standard air braking will still be available on those brakes where the EC 16 controller has disabled the system MULTIPLE FAILURES In the event that multiple failures occur the dash lamp will react as it normally would during a single failure and the LEDs will show one failure at a time When the first problem is fixed and the system is reset the next problem area will appear atthe LEDs This way the driver or mechanic does not lose track of problem areas and the system is not restored until each and every error is corrected and the EC 16 controller is reset SYSTEM STILL OPERATING YES NO Std ABS Front ABS Rear Traction Braking Left Right Left Right RF Sensor YES YES YES YES NO YES LF Sensor 5 YES RM Sensor YES YES YES YES YES LM Sensor YES YES YES YES YES RR Sensor YES YES YES NO YES LR Sensor MESSREYES NO YES YES RF Modulator YES NO YES YES YES LF Modulator NO YES YES YES YES RR Modulator YES YES YES NO YES LR Modulator YES YES NO YES YES Controller NO NO NO NO YES Solenoid YES YES YES YES YES Engine Control YES YES YES YES YES Module Voltage 5 2 NO NO NO NO YES When ECM wiring or voltage corrects itself system is restored ANTILOCK AND TRACTION WIRING GENERAL NOTES The wires that carry information and p
42. or provide the electrical interface between the EC 16 controller electronics ELECTRICAL CONNECTOR SUPPLY PORT M 21 MODULATOR DELIVERY PORT EXHAUST PORT SAA DELIVERY J PORT SUPPLY PORT M 22 MODULATOR 7 4 EXHAUST PORT and the air brake system The EC 16 controller is able to simultaneously and independently control four individual modulator assemblies ELECTRICAL CONNECTOR FIGURE 6 MODULATORS An antilock dash light and its electrical relay are connected to and controlled by the EC 16 controller and serve as a means of advising the driver of the condition of the antilock system Aconnection to the engine or transmission retarder and its relay is provided on the EC 16 controller which allows the EC 16 controller to temporarily disable the retarder during certain modes of operation While the EC 16 controller is capable of this function and connections are provided it is not always used Use of the retarder disable function is not essential but highly recommended for vehicles equipped with a retarder The EC 16 controller can also disable the retarder using the same J1922 protocol it uses to control the traction control engine torque limiting feature For this redundant retarder disable to function the EC 16 controller must be connected to the engine control module as would be the case if the EC 16 controller is programmed for the traction control torque limit
43. ously executes the following operations It instantly blinks the traction dash lamp to advise the driver that a wheel spin is occurring If the torque limiting feature is active the EC 16 controller uses its link to the engine control module and sends a signal to reduce engine torque to a level suitable for the available traction If the differential braking feature is configured into the system the EC 16 controller energizes the solenoid in the ATR valve which then applies air to each of the rear axle modulators Because the modulators are controlled by the EC 16 controller the solenoid valves in the appropriate modulator are opened and closed to gently pump the brake on the spinning wheel only This gentle brake application forces the differential to drive the stationary or slowly spinning wheel Once wheel spin is eliminated the dash lamp goes out and the traction system disengages control TRACTION CONTROL AT VEHICLE SPEEDS ABOVE 25 MPH If wheel spin occurs at any speed above 25 mph the EC 16 controller will instantly blink the traction dash lamp to advise the driver that a wheel spin is occurring If the torque limiting feature is programmed in the EC 16 controller uses its link to the engine control module and sends a signal to reduce engine torque to a level suitable for the available traction THE EC 16 CONTROLLER WILL NOT SIGNAL THE ATR VALVE TO APPLY THE BRAKES EVEN SLIGHTLY AT ANY SPEED ABOVE 25 MPH
44. ower into and out of the EC 16 controller are generally grouped and terminate at a connector The wire groups or wire harnesses along with the connectors are most often specified and or supplied by the vehicle manufacturer The connectors used on the EC 16 controller are illustrated in Figure 4 The wiring harnesses and connectors are weather resistant and the wires that enter the connector are sealed to the connector The wire gauge used in the wire harnesses is specific to the task performed When diagnosing wiring in the antilock system the following general rules apply and should be followed where applicable 1 Itis generally advisable to replace a wire harness rather than repair individual wires in the harness If a splice repair must be made it is important that the splice be properly soldered with a rosin flux not acid based and made water proof 2 Donotpierce wire insulation when checking for continuity Check for power ground or continuity by disconnecting the connector and testing the individual pins or sockets in the connector 3 Always check the vehicle handbook for wire and connector identification Individual wire identification will differ depending upon the type of connectors in use the vehicle manufacturer and the system features in use 4 While the retarder disable serial link and traction on off connections 4 total are present on all EC 16 controllers they are not always used PREVENTIVE MAINTENANCE
45. test is begun During the self test the dash lamps will flash on and off together as indicated in the chart depending upon the type and amount of traction control configured into the EC 16 controller Note For more information on this subject see the TROUBLESHOOTING section of this document Self Configuration Process In order to successfully complete the self configuring process follow the steps presented 1 Connect all antilock and traction control wire harnesses Refer to the schematic in Figure 4 Make certain that all the speed sensors present on the vehicle are connected H2 H3 J1 J2 on the 30 pin connector and E2 E3 F2 F3 B2 B3 C2 C3onthe 18 pin connector If the vehicle has an electronic engine and traction control torque limiting is desired the engine control module must be connected B2 and B3 on the 30 pin connector If the vehicle is equipped with either an ATR 1 or ATR 2 valve the solenoid connection must be made to the EC 16 controller D2 and D3 on the 18 pin connector in order to obtain traction control differential braking 2 If the vehicle is to be configured with traction control it must have a traction control dash lamp and a traction control enable disable switch Both the lamp and switch must be functional Place the traction control enable disable switch in the traction control disabled position traction control inoperative Turn the ignition ON and hold a magnet on the RESET
46. tions on its connector to determine if a sensor is connected to it and will default to a six sensor configuration if it detects even one sensor connected If no mid axle speed sensor is detected the EC 16 controller will default to a four sensor configuration B Electronic Engine Control If the EC 16 controller is connected to the control module of an electronic engine the torque limiting feature of traction control Will be activated during the self configuring process C Antilock Traction Relay Valve If the solenoid assembly in the ATR valve is connected to the EC 16 controller the differential braking feature of traction control will be activated during the self configuring process 2 methodi is available to disable the self configuration feature 3 Dueto the extended period of time the magnet must be held on the RESET to initiate the self configuration process 20 seconds it is unlikely that a self configuration would occur accidentally 4 Basic four speed sensor antilock operation can not be removed during the self configuration process This is a minimum configuration for all EC 16 controllers 5 speed sensor is connected to either wheel on the mid axle the EC 16 controller will configure for six sensors If no mid axle speed sensor is detected the EC 16 controller will configure for four sensors Any disconnected speed sensor s will register as a failure on the diagnostic display at the end of t
47. titled EC 16 Controller Configuration Display and no red LEDs should be illuminated at the end of the self test If the configuration appears correct but the diagnostic LEDs indicate a failure somewhere in the system refer to the General Configuration Information below and use the Troubleshooting section of this manual to locate and repair the problem If the configuration is incorrect the process can be repeated as required One common error is performing the self configuration with the traction enable disable switch in the wrong position This will prevent any traction features from being activated Note The traction switch must be in the disable position to configure traction but must be placed in the enable position to allow the traction lamp to flash 13 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 GENERAL While the EC 16 controller diagnostic display locates a specific problem area it is still necessary to confirm whether the problem resides in the component its
48. unctions When the EC 16 controller is mounted on any of these valves the result is a final assembly with its own model designation Refer to the chart and figure 3 AntiLock Added Function Vehicle Valve Provided Application AR 1 None All AR2 Bobtail Brake Designation Valve EC 16 CR 17 Controller Relay Tractors Only CR 18 Controller Relay Proportioning Traction All Traction amp Bobtail Tractors Only AT 2 AntiLock Traction Brake Proportioning ATR 1 ATR 2 AT 1 AntiLock Traction EC 16 CONTROLLER INFORMATIONAL INPUTS AND COMMAND OUTPUTS GENERAL The EC 16 controller receives information from several components in system and based on these inputs issues commands or delivers information Some portions of the EC 16 controller both receive and deliver commands and information See Figure 4 INPUTS Wheel speed information is provided to the EC 16 controller via a wiring harness from individual wheel speed sensors at or in the vehicle wheels Working with an exciter or tone ring wheel speed sensors provide information to the 3 S HV3H 1331 IVNSIS S HV3H 1331 NOWINOO GOW HV3H 1331 S HV3H JYNDIS S HV3H OH GOW HV3H 1331 AIONITOS NOILOVHL AOYNOS AIONITOS NOILOVH L 1SNYHX GOW HV3H 1331 S M GIA 1437 TJYNDIS S M IN 1437 LSNYHX3 GOW HV3H S M GIN LHOIH IVNSIS S M A

BENDIX BW1726 User's Manual

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