BENDIX BW1663 User's Manual
Contents
1. Bendix 6 15 AntiLock Controller Assembly FIGURE 1 EC 15 ELECTRONIC CONTROLLER DESCRIPTION GENERAL Bendix antilock systems utilizing the EC 15 electronic controller assembly provide full vehicle wheel control braking for buses trucks and truck tractors By minimizing the potential of brake lock up on all wheels during aggressive braking the vehicle retains a high degree of stability and steerability and in most cases vehicle stopping distance is reduced In order to provide full vehicle wheel control braking the EC 15 controller assembly is used in combination with the following components Four individual wheel speed sensors Four air pressure modulator valves Antilock condition lamp dash mounted MOUNTING HOLES 4 DIAGNOSTICS WINDOW DISPLAY PHYSICAL The EC 15 controller electronics that regulate the function of the antilock system are contained in a die cast aluminum housing and are environmentally protected The metal housing coupled with the design of the digital electronics is intended to provide a high degree of protection from radio and electromagnetic interference A diagnostics display window with 9 light emitting diodes LEDs and a magnetically actuated reset switch is incorporated in the housing for troubleshooting and diagnostic purposes Two types of electrical connectors are currently used to connect the EC 15 controller assembly to the antilock system com2. CONTROLLER NO NOTE REACTION OF RED LEDS REPEAT INITIAL START UP PROCEDURE IF THIS ARE ANY RED LED S GO TO SECTION VI B AND ILLUMINATED TEST STEP HAS REPEATED CONTINUE TESTING TWICE REPLACE THE EC 15 CONTROLLER SAME RED LED S FRONT OR REAR ILLUMINATED MODULATOR REPLACE EC 15 CONTROLLER TEST REAR MODULATOR ON OPPOSITE SIDE OF VEHICLE GO GO TO SECTION IV INSPECTION FOR ILLUMINATED RED LEDS AND RETEST TO BEGINNING THIS SECTION VI AND RETEST IF FAILURE PERSISTS REPLACE THE EC 15 CONTROLLER 19 TROUBLESHOOTING SECTION VI B TESTING THE MODULATOR GO TO MODULATOR INSPECT WIRING CONNECTOR DISCONNECT CONNECTORAND TEST RESISTANCE BETWEEN PINS ON MODULATOR RESISTANCE VALUES FOR BENDIX M 21 MODULATOR FIGURE 5 S HOLD TO SOURCE READ 3 5 TO 5 OHMS EXHAUST TO SOURCE READ 3 5 TO 5 OHMS EXHAUST TO HOLD READ 7 TO 10 OHMS TEST EACH PIN TO VEHICLE GROUND AND NOTE NO CONTINUITY NO REPLACE THE MODULATOR RESISTANCE READINGS CORRECT YES RECONNECT CONNECTOR TO MODULATOR TURN IGNITION ON AND PASS MAGNET OVER RESET ON EC 15 CONTROLLER NOTE REACTION OF RED LEDS ARE ANY RED LED S ILLUMINATED YES SAME RED LED S ILLUMINATED REPEAT THE INITIAL START UP PROCEDURE REPAIR OR REPLACE MODULATOR WIRE HARNESS GO TO SECTION IV INSPECTION FOR ILLUMINATED LEDS AND RETEST 20 TROUBLESHOO
3. EC 15 CONTROLLER YES YES GO TO SECTION REPLACE THE EC 15 V TESTINGFOR veg CONTROLLER POWER THE IS GREEN LED FLASHING EC 15 CONTROLLER NO GO TO SECTION IX TESTING FOR ARE ANY RED LEDS ILLUMINATED FALSE FAILURE INDICATION CAUSED BY WHEEL SPEED COMPONENTS YES NOTE AND RECORD THE CONDITION OF ALL RED LEDS GO TO SECTION IV INSPECTION FOR ILLUMINATED LEDS 16 TROUBLESHOOTING SECTION IV INSPECTION FOR ILLUMINATED LEDS NOTE RED ECU LED IN START HERE EC 15 CONTROLLER DIAGNOSTICS WINDOW GO TO SECTION V TESTING YES IS THIS LED ILLUMINATED FOR POWER TO THE EC 15 CONTROLLER NO THERE MUST BE A MINIMUM OF THREE RED LEDS ILLUMINATED AND OF THE THREE THERE MUST BE A RIGHT OR LEFT PLUS A FRONT OR REAR PLUS A MOD OR SENS DO THE ABOVE CONDITIONS p REPLACE THE EC 15 CONTROLLER EXIST AND REPEAT THE INITIAL START UP PROCEDURE YES NOTE THE THREE ILLUMINATED LEDS USING THE TWO POSITIONING LED S RIGHT LEFT FRONT REAR GOTO SECTION VIA TESTING THE MODULATOR AND TEST THE NO APPROPRIATE MODULATOR THE SENS 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 17 TROUBLESHOOTING SECTION V TESTING FOR POWER TO THE EC 15 CONTROLLER TURN I
4. TO EC 15 CONTROLLER CHECK DASH WIRINGAND CHECK 6 CONNECTORS AND CONSULT THE FOR VEHICLE MANUAL FOR TROUBLE NO POWER Ba 1 IS POWER DETECTED SHOOTING INFORMATION REPAIR HERE 1 OR REPLACE AS NECESSARY AND a gt REPEAT THE INITIAL START UP F LAMP YES PROCEDURE LAMP REPLACE THE RELAY AND REPEAT BAD RELAY THE INITIAL START UP PROCEDURE 23 TROUBLESHOOTING SECTION IX TESTING FOR FALSE INDICATION CAUSED BY WHEEL SPEED COMPONENTS HOLD AMAGNET ON RESET START HERE OF EC 15 CONTROLLER AND NOTE LEDS NO REPLACE 0 15 ARE ALL LEDS ILLUMINATED CONTROLLER YES REMOVE MAGNET TURN IGNITION OFF AND INSPECT APPROPRIATE AXLE AND WHEEL FOR PRESENCE OF AN EXCITER OR TONE RING AND SPEED SENSOR CHECK THE SENSOR GAP DISTANCE BETWEEN SPEED SENSOR AND EXCITER RING AND BEARING END PLAY RE ADJUST AS NECESSARY RUN VEHICLE AT 10 MPH OR MORE FOR 30 SECONDS OR MORE TURN OFF IGNITION REPEAT INITIAL START UP PROCEDURE 24 BW1663 2004 Bendix Commercial Vehicle Systems LLC All rights reserved 5 2004 Printed in U S A
5. failure condition is truly stored and is not cleared by loss of power to the EC 15 controller The LEDs will re light 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 15 controller diagnostics by passing a small magnet over the RESET point in the diagnostics window DIAGNOSTIC LEDs There are nine LEDs plus a magnetically actuated reset switch in the EC 15 controller diagnostic window The first five LEDs locate a problem to a specific area of the vehicle while the last four 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 Left front is therefore the corner closest to the driver LEDo FRONT RedLED LED o MID Red LED SEE NOTE BELOW LED 0 REAR RedLED LED o RIGHT Red LED LED o LEFT Red LED LED o MOD Red LED LED o SENS Red LED LED o ECU Red LED LED o VOLT Green LED III RESET No LED NOTE The MID LED shown in the chart above is not used in the diagnostic process for the EC 15 controller however it will light when a magnet is placed on the RESET switch in the diagnostic window EC 15 CONTROLLER DIAGNOSTIC WINDOW FRONT LED This Red LED illuminates and latches ON in order to indicate the location of a problem component or
6. its wiring It will light in conjunction with either the RIGHT or LEFT LED and the MOD or SENS LED MID LED This Red LED is not used in troubleshooting the EC 15 controller and should light only when a magnet is held on the RESET switch 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 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 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 MOD 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 modulators or the wiring connecting it to the system SENS LED This Red LED illuminates and latches ON to indicate permanent or intermittent failure The failures indicated are open or shorted wheel speed sensor open or shorted wheel speed sensor wiring wheel speed signal not present or does not conform to design criteria ECU LED This Red LED when illuminated indicates th
7. 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 Prior to returning the vehicle to service make certain all components and systems are restored to their proper operating condition REMOVING THE EC 15 CONTROLLER ASSEMBLY 56 15 CONTROLLER MOUNTED ON ANTILOCK RELAY VALVE 1 2 3 Identify and remove all air lines connected to the unit Disconnect the electrical connector s from the EC 15 controller Note and mark the mounting position of the controller relay valve 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 15 controller assembly from the vehicle Remove as much contamination as possible from the exterior of the assembly making sure to keep the contamination away from the open ports Note and mark the position of the EC 15 controller relative to the antilock relay valve Remove and retain the four cap screws that secure the EC 15 controller to the antilock relay valve Carefully separate the EC 15 controller from the antilock relay valve making certain not to damage the gasket between the two components Peel the gasket from the EC 15 controller or antilock relay valve and retain for reuse Note Use a new gasket if dam
8. BLY WS 20 SPEED SENSOR FIGURE 5 WS 20 WHEEL SPEED SENSORS 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 lose traction 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 the speed sensors and modulators both brakes on one side of the tandem are treated as one since they will most likely be on the same type of road surface Refer to figure 2 NON ANTILOCK BRAKE APPLICATION During normal braking air pressure from the brake valve enters the control port of the service relay valve either an antilock or standard relay 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 15 controller does not initiate any corrective action and the vehicle comes to a stop in anormal fashion PACKARD CONNECTOR DEUTSCH CONNECTOR ANTILOCK CONTROLLED BRAKE APPLICATION SYSTEM FULLY OPERATIONAL If a service brake application is made and the wheel speed sensors detect an impending wheel lockup the EC 15 controller will immediately begin modification of the brake application using the antilock modulator s at the affected
9. ER AND DO MAGNETIC RESET NOTE IF ANY RED LEDS ARE ILLUMINATED REPEAT THE INITIAL START UP PROCEDURE ARE ANY LED S ILLUMINATED GO TO SECTION III INSPECTION FOR ILLUMINATED LEDS ARE SAME RED LED S ILLUMINATED REPAIR OR REPLACE SPEED SENSOR WIRING HARNESS 22 TROUBLESHOOTING SECTION VIII TESTING FOR FALSE INDICATION CAUSED BY DASH LIGHT RELAY START HERE HOLD A MAGNET ON EC 15 CONTROLLER RESET AND NOTE ALL LEDS ILLUMINATED ARE ALLLEDS ILLUMINATED NO REPLACE 50 15 CONTROLLER YES TESTING THE LAMP RELAY REMOVE MAGNET FROM EC 15 CONTROLLER TURN IGNITION OFF AND DISCONNECT THE WIRING HARNESS GROUND THIS WIRE AT CONNECTOR S FROM EC 15 CONTROLLER TURN EC 15 CONTROLLER IGNITION ON GROUND LAMP RELAY WIRE PIN 1K FIG 7 CONNECTOR PIN 3F FIG 8 AND NOTE DASH LAMP REACTION TO EC 15 RELAY CONTROLLER CONNECTOR e DASH LAMP OFF blk REPLACE EC 15 CONTROLLER e aus NO 1 i TURN IGNITION OFF AND CHECK CONTINUITY OF LAMP ON WIRING LAMP WIRE BETWEEN EC 15 CONTROLLER CONTINUE WIRING HARNESS CONNECTOR SEE FIG 7 amp 8 AND TESTING TERMINAL ON LAMP RELAY REPAIR OR REPLACE WIRE HARNESS RECONNECT EC 15 CONTROLLER WIRE HARNESS AND REPEAT THE INITIAL START UP YES PROCEDURE RECONNECT THE EC 15 CONTROLLER WIRE HARNESS CONNECTOR S AND CHECK FOR TESTING THE LAMP RELAY VEHICLE POWER AT THE LAMP RELAY COIL
10. GNITION OFF REFER TO FIGURES 7 AND 8 DISCONNECT WIRE HARNESS START HERE CONNECTOR FROM EC 15 CONTROLLER FRONT CONNECTOR ONLY IN FIGURE 7 TURN IGNITION ON AND MEASURE VOLTAGE BETWEEN BATTERY AND GROUND PINS ON WIRE HARNESS CONNECTOR SEE FIGURES 7 AND 8 RECONNECT CONNECTOR TO EC 15 CONTROLLER CHECK THE VEHICLE WIRING FOR CONTINUITY REFER TO THE VEHICLE SERVICE MANUALAND CHECK THE BATTERY VOLTAGE REPAIR OR REPLACE AS NECESSARY AND REPEAT THE INITIAL START UP PROCEDURE VOLTAGE SAME AS BATTERY VOLTAGE MUST BE BETWEEN 11 AND 17 VOLTS REPEAT THE INITIAL START UP PROCEDURE REPLACE EC 15 CONTROLLER 18 TROUBLESHOOTING SECTION VI A TESTING THE MODULATOR TURN IGNITION OFF REFER TO FIGURES 7 AND 8 DISCONNECT WIRE HARNESS CONNECTOR START HERE FROM EC 15 CONTROLLER PROBE CONNECTOR WITH VOLT OHM METERAND NOTE THAT PROPER RESISTANCE VALUES ARE OBTAINED FOR MODULATOR BEING TESTED FIGS 7 AND 8 RESISTANCE VALUES HERE FOR BENDIX M 21 MODULATOR FIG 5 HOLD TO SOURCE READ 3 5 TO 5 OHMS EXHAUST TO SOURCE READ 3 5 TO 5 OHMS EXHAUST TO HOLD READ 7 TO 10 OHMS SOURCE TO BATTERY POWER NO CONTINUITY SOURCE TO GROUND NO CONTINUITY NOTE SOURCE TO BATTERY TEST NOT REQUIRED FOR CONNECTOR 2 REAR DEUTSCH CONNECTOR FIGURE 7 INSPECT CONNECTOR AND YES RECONNECT TO EC 15 VALUES CORRECT CONTROLLER TURN IGNITION ON AND PASS MAGNET OVER RESET ON EC 15
11. H ASNYHX3 HOLVINGOW YYY LHOIY LHOIY 3 TYNDIS q33dS JYNDIS 3348 YVAIY LHOIY 1437 HOLVINGOW GT1OH HOLVINGOW YUVIH 1331 ASNVHXA3 HOLVINGOW tiV3ti 1437 NYNLAY TYNDIS q33dS YVIY 1431 3348 uvat 1437 NYNL3Y TYNDIS q33dS LNOtid LHOIY q33dS 1 LHOIY HOLVTNAON LNOHH LHDIY 0 HOLVINGOW LNOHH LHOIH ASNYHX3 HOLVTNAON LNOYS LHOIY YIGYVLIY NYNLAY TYNDIS Q33dS LNOtid 1437 JYNDIS q33dS LNOYS 1437 HOLVTNGON LNOYS 1437 GT1OH HOLVINGOW INOHH 1437 ASNYHX3 HOLVINGOW LNOYS 1437 ANNOHD 0 NOILOANNOO TVNIINH3 L de EIS ve ER 6 de ODE GE dl ol ER OG EIS ME ER HL OE HE fe DL OG de Ve 8 Vi JE Me ML TYNINYIL 0 4 YOLV TNGON LZA NO HOLOANNOO CTIOH ADYNOS 1SNVHXA JOYLNOD vil AV lsd YOSNAS CO FIGURE 9 WIRING SCHEMATIC FOR EC 15 CONTROLLER WITH PACKARD CONNECTOR BRACKET MOUNTED 6 15 CONTROLLER 1 Disconnect the electrical connector s from the EC 15 controller 2 Note and mark the mounting position of the EC 15 controller on the vehicle Loosen remove and save the nuts on the mounting hardware that attaches the EC 15 controller bracket to the vehicle Remove the EC 15 cont
12. N PLACE AND INSPECT CONDITION CHECK FOR MISSING OR DAMAGED TEETHAND THAT IT RUNS TRUE AND PERPENDICULAR TO SENSOR FACE CHECK WIRING HARNESS AND CONNECTORS THAT RUN TO SENSOR CHECK FOR DRAGGING BRAKES OVER ADJUSTED TRAPPED AIR INACTUATOR OUT OF ROUND DRUMS FAULTY RETURN SPRINGS PARKING BRAKE SYSTEM FAULTS ETC AND CORRECT AND RETEST RECONNECT CONNECTORS AT EC 15 CONTROLLER AND SPEED SENSOR DO MAGNETIC RESET NOTE RED LED S GO TO SECTION III ARE ANY RED LED S ILLUMINATED IES INSPECTION FOR ILLUMINATED LED S NO GOTO INITIAL START UP PROCEDURE 21 TROUBLESHOOTING SECTION VI PART B TESTING THE WHEEL SPEED SENSOR START HERE FROM NO GO TO SECTION III INSPECTION SAME LED S ILLUMINATED SECTION VII PART A FOR ILLUMINATED LEDS YES IGNITION OFF REMOVE CONNECTOR S FROM EC 15 CONTROLLER MEASURE RESISTANCE BETWEEN THE 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 INUSE REFER TO FIGURE 7 amp 8 A YES REPLACE EC 15 CORRECT RESISTANCE CONTROLLER NO DISCONNECT CONNECTOR AT SPEED SENSOR INSPECT THE CONNECTOR THEN CHECK THE NO RESISTANCE BETWEEN TWO PINS ON SENSOR RESISTANCE BETWEEN 1500 2500 OHMS FOR THE BENDIX WS 20 SPEED SENSOR YES RECONNECT CONNECTORAT SPEED SENSOR AND EC 15 CONTROLL
13. RATION GENERAL The Bendix EC 15 antilock controller system provides individual wheel control by using a wheel speed sensor and modulator at each wheel By monitoring the rate of deceleration during braking and subsequently adjusting the brake application pressure at each wheel the EC 15 controller is able to provide improved braking between the vehicle tire and the road surface it is on while maintaining vehicle stability The rear axle brakes are controlled completely independent of each other and 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 15 controller does not treat these brakes totally independent of each other The EC 15 controller utilizes 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 e g ice close to the curb and a dry crown Essentially the EC 15 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 EXCITER RING 100 TOOTH WS 20 ANGLED SENSOR HUB ASSEM
14. TING SECTION VII PART A TESTING THE WHEEL SPEED SENSOR START HERE IGNITION ON NOTE ILLUMINATED LED S ON LOG SHEET DO MAGNETIC RESET NOTE REACTION OF RED LED S 2ND TIME TO THIS POINT YES GO TO SECTION VII PART DURING TESTING BAND BEGIN TESTING NO son DE SON GOTO SECTION AND RED LED S ON LED S ON GO TO SECTION IV YES NO GO TO SECTION VII PART B AND BEGIN TESTING TURN IGNITION OFF AND CHECK FOLLOWING A REMOVE CONNECTOR S FROM EC 15 CONTROLLER AND MEASURE RESISTANCE BETWEEN APPROPRIATE SPEED SENSOR SIGNAL AND SIGNAL RETURN RESISTANCE FOR BENDIX WS 20 SPEED SENSOR IS BETWEEN 1500 2500 CHMS REFER TO VEHICLE MAINTENANCE MANUAL IF OTHER THAN THE WS 20 SPEED SENSOR IS IN USE REFER FIG8 IF RESISTANCE NOT CORRECT DISCONNECT CONNECTOR AT SPEED SENSOR INSPECT CONNECTOR THEN CHECK RESISTANCE BETWEEN PINS ON SENSOR IF RESISTANCE IS NOT CORRECT BETWEEN 1500 2500 OHMS FOR THE BENDIX WS 20 SPEED SENSOR REPLACE SENSOR OTHERWISE PROCEED TO STEP B CHECK GAP BETWEEN SPEED SENSOR AND EXCITER OR TONE RING GAP FOR BENDIX WS 20 SPEED SENSOR SPEED SENDER IS BETWEEN 0 015 INCHES IF SENSOR GAP MUST BE ADJUSTED CHECK FOR LOOSE OR WORN WHEEL BEARINGS BEFORE RE GAPPING SENSOR REFER TO VEHICLE MAINTENANCE MANUAL FOR WORN BEARINGS IF SENSOR GAP IS CORRECT CHECK WHEEL BEARING FOR FREE PLAY TO VERIFY IT COMPLIES TO MANUFACTURER S RECOMMENDATIONS MAKE CERTAIN EXCITER OR TONE RING IS I
15. VOLTAGE BETWEEN LAMP RELAY AND GROUND VOLTAGE SHOULD BE SAME AS BATTERY VOLTAGE SEE FIGURES 7 AND 8 REPLACE FUSE NO IS VOLTAGE CORRECT AND OR REPAIR OR REPLACE WIRE HARNESS YES CHECK WIRING HARNESS AND RELAY FOR SHORTS TO GROUND RECONNECT AND CHECK REPLACE THE FOLLOWING 1 DASH LIGHT BULB 2 RELAY POWER WIRE 3 RELAY AFTER REPLACING EACH COMPONENT TEST THE DASH LAMP REPEAT THE INITIAL START UP PROCEDURE 14 TROUBLESHOOTING SECTION INSPECTION FOR ILLUMINATED LEDS INSPECT EC 15 CONTROLLER FOR PRESENCE OF ILLUMINATED LEDS AND RECORD CHECK CLOSELY AND NOTE IF GREEN LED IS ILLUMINATED NO OFF ARE ANY RED YES ON LED S ILLUMINATED GO TO SECTION V NO ARE ANY RED LEDS NO ILLUMINATED IS GREEN LED FLASHING NO TESTING FOR POWER YES YES TO THE EC 15 CONTROLLER REPLAGE THE EG 15 CONTROLLER NOTE AND RECORD THE CONDITION OF GO TO SECTION V TESTING ALL RED LEDS FOR POWER TO THE EC 15 CONTROLLER GO TO SECTION IV INSPECTION FOR ILLUMINATED LEDS GO TO SECTION VIII TESTING FOR FALSE FAILURE INDICATION CAUSED BY DASH LAMP RELAY 15 TROUBLESHOOTING SECTION III INSPECTION FOR ILLUMINATED LED S INSPECT THE EC 15 CONTROLLER START HERE FOR PRESENCE OF ILLUMINATED LEDS AND RECORD GO TO SECTION 15 GREEN VOLT LED NO 0 Re V TESTING FOR ILLUMINATED POWER TO THE ILLUMINATED
16. aged during removal or if a new gasket is immediately available YOLV TNGON IZAN YOLOSANNOO C1OH ADYNOS 1SNWHXA g WIdyas Hz v 436 82 HZH 1497 TOHIA HOLVTNGON LHOIY 32 Aq U CTIOH HOLVINGOW tiV3ati LHOIY NZ 0 ar ASNYHX3 HOLVINGOW YYY LHOIH 32 NYNL3H TYNDIS q33dS YVAIH LHOIY q33dS YVIH LHOIY We HOLVINGOW tiV3ti 1437 qz q1OH HOLVINGOW 1437 Oz K ASNYHX3 HOLVINGOW YUVAH 1437 K NYN LAY TYNDIS q33dS YVAIY 1437 52 q33dS YVIH 1431 MZ NYNLAY TYNDIS q33dS LNOYS LH q33dS 1NOtid LHDIY HL HOLVINGOW LNOYS LHOIH qt CTIOH HOLVINGOW LNOH4 LHOIH VL 15 HOLVINGOW LNOHH 1 8308 13 al NYNLIH TYNDIS qQ33dS LNOYS 1437 3348 LNOYS 1437 31 HOLVTINAON LNOYS 1d31 AL GT1OH HOLVINGOW LNOYS 1437 15 HOLWINGOW LNOYS 1437 dl 8 H3AAOd NOLLOANNOO TVNINWYSL TVNINYIL 1 1NOY4 d Z HOLDINNOD HOLDAINNOD EE SHOLOANNOO 35 1 INS LHOY FIGURE 7 WIRING SCHEMATIC FOR EC 15 CONTROLLER WITH DEUTSCH CONNECTORS LON LON g v 1VIH3S HOLVTNAON HU LHOIY OOH HOLVINGOW tiV3ati 1H I
17. agonally For example if the modulator at the right front wheel has a broken wire lead the EC 15 controller disables the antilock function for BOTH the right front and left rear wheels The antilock will continue to function on the left front and right rear wheels and will remain under the control of the EC 15 controller Note Right and left front and rear are determined from the driver s seat Left front is therefore the corner closest to the driver Depending upon the type of failure and its position of occurrence the EC 15 controller either disables all or only aportion of the antilock system A power or controller failure for instance will result in complete disabling of the antilock system and reversion to standard braking on all wheels Two or more failures regardless of their position of occurrence will also result in the disabling of the entire system With the failed component approach described the 6 SOLENOID CONNECTOR SUPPLY DELIVERY vehicle will retain improved braking stability after a single failure It should be remembered that the driver will be advised of the degraded antilock operation via the dash lamp and that standard air braking will still be available on those brakes where the antilock has been disabled by the EC 15 controller ANTILOCK WIRING The wires that carry information and power into and out of the EC 15 controller are generally grouped and terminate at a connector The
18. at the controller itself has failed It is latched ON for all EC 15 controller failures except low voltage For voltages less than 9VDC the LED illuminates to indicate the controller is inoperative however when the voltage again exceeds 9VDC the LED will go OUT by itself VOLT 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 for proper operation below 11 vdc or above 17 vdc this LED will flash until power is brought into range RESET Beneath the RESET area of the window 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 Holding a magnet against the RESET will cause all LEDs to light during the time the magnet is against it 11 TROUBLESHOOTING GENERAL While the EC 15 controller diagnostic display locates a specific problem area it is still necessary to confirm whether the problem resides in the component itself or the wiring Basically the troubleshooting procedure that follows is devoted to narrowing the problem to either the wiring ora specific antilock component TROUBLESHOOTING TIPS 1 All troubleshooting begins by observing the antilock condition lamp on the dash Troubleshooting should begin by first performing the Initial Start up Procedure and f
19. d in the modulator provide the electrical interface between the EC 15 controller electronics and the air brake system The EC 15 controller is able to simultaneous and independently control four individual modulator assemblies A dash light and its electrical relay is connected to and controlled by the EC 15 controller and serves as a means of advising the driver of the condition of the antilock system A connection to the engine or transmission retarder is provided on the EC 15 controller which allows the EC 15 controller to temporarily disable the retarder during certain modes of operation While the EC 15 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 data link function enables the EC 15 controller to report its operating condition to a specialized external computer in response to certain commands it receives The EC 15 controller data link configuration conforms to S A E standard J1708 and the protocol or coded language used conforms to S A E standard J1587 There are two connections to the EC 15 controller devoted to the data link While the EC 15 controller is capable of this function and connections are provided it is not always used Use of the data link is not essential for the EC 15 controller to be functional 4 OPE
20. ed information is provided to the EC 15 controller via a wiring harness from individual wheel speed sensors located at or in the vehicle wheels Working in conjunction with an exciter or tone ring wheel speed sensors provide information to the EC 15 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 15 controller is designed to receive wheel speed information from various wheel speed sensor models at the rate of 100 pulses per wheel revolution The EC 15 controller is able to simultaneously receive and individually interpret soeed signals from four wheel speed sensors Vehicle power is supplied to the EC 15 controller from the ignition switch through a fuse or circuit breaker The electrical ground for the EC 15 controller is the vehicle chassis OUTPUTS Modulators like the Bendix M 21 are the means by which the EC 15 antilock controller is able to modify driver applied air pressure to the service brakes The modulator is an electrically controlled air valve that is located near the service 3 EC 15 ELECTRONIC CONTROLLER AR 1 ANTILOCK RELAY VALVE FIGURE 4 EC 15 CONTROLLER MOUNTED AN AR 1 VALVE actuator s it controls and is the last air valve through which air passes on its way to the brake actuator Awiring harness connects the modulator to the EC 15 antilock controller Solenoid valves containe
21. here 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 Do not attempt to install remove disassemble or assemble a component until you have read and thoroughly understand the recommended procedures Use only the proper tools and observe all precautions pertaining to use of those tools 10 If the 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 or a dryer reservoir module be sure to drain the purge reservoir Following the vehicle manufacturer s recommended procedures deactivate the electrical system in a manner that safely removes all electrical power from the vehicle Never exceed manufacturer s recommended pressures 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 Use only genuine 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 Components with stripped
22. ollowing the directions contains in it 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 15 controller All voltage and resistance tests are performed by beginning at the wire harness half of the connector and moving AWAY from the EC 15 controller toward an antilock system component modulator wheel speed sensor etc 12 TROUBLESHOOTING INITIAL START UP PROCEDURE TURN VEHICLE IGNITION ON OBSERVE DASH ANTILOCK CONDITION LAMP START HERE IS DASHLAMP ILLUMINATED GOTOSECTIONI DASH LAMP TESTING YES DASH LAMP DOES NOT BLINK IT COMES ON AND REMAINS ON GO TO SECTION II INSPECTION FOR ILLUMINATED LED S DASH LAMP FLASHES AND COMES ON AND STAYS ON INCREASE VEHICLE SPEED TO ABOVE 10 MPH FOR AT LEAST 30 SECONDS AND OBSERVE THE DASH LAMP GO TO SECTION III INSPECTION FOR ILLUMINATED LED S DASH LAMP REMAINS ON THE SYSTEM IS FUNCTIONING NORMALLY MAKE NOTES OF THE PARTS REPLACED OR REPAIRED AND STEPS TAKEN ON THE TROUBLE SHOOTING SHEET 13 TROUBLESHOOTING SECTION I DASH LAMP TESTING DISCONNECT WIRE HARNESS CONNECTOR START HERE FROM EC 15 CONTROLLER FRONT CONNECTOR ONLY IN FIGURE 7 AND OBSERVE THE DASH LAMP YES REPLACE THE EC 15 DASH LAMP ILLUMINATED CONTROLLER NO WITH IGNITION ON MEASURE
23. ponents a single 30 pin Packard Electric 150 series Metri pack or a pair of 14 pin Deutsch HID 30 series connectors t HOSNSS 0 13345 DA rr IIIA TEAL 2 peer x 22 OLE LEE LLL IEEE ELLIO EE ETE km 4 DIN WHIS ei FIGURE 2 EC 15 CR 15 ANTILOCK SYSTEM PACKARD 30PIN CONNECTOR FIGURE 3 EC 15 CONTROLLER AND CONNECTOR STYLES MOUNTING The EC 15 controller is available in two different mounting styles One model is designed to be mounted on an antilock relay valve such as the AR 1 valve see Service Data Sheet SD 13 4795 The AR 1 valve is a modified version of the R 12 relay valve When the EC 15 controller is mounted on an antilock relay valve the resulting assembly receives a different designation For example when the EC 15 antilock controller is mounted on the AR 1 valve the resulting assembly is known as a CR 15 antilock controller relay The other EC 15 controller model is intended for bracket mounting to a frame member and is not attached to an antilock relay valve CONTROLLER INPUTS OUTPUTS The EC 15 controller receives information from several components in the antilock system and based on these inputs issues commands or delivers information Some portions of the EC 15 controller both receive and deliver commands and information DEUTSCH 14 PIN CONNECTORS INPUTS Wheel spe
24. roller and bracket from the vehicle 3 Remove and retain the four cap screws that secure the EC 15 controller to the bracket Separate the EC 15 controller from the bracket INSTALLING THE EC 15 CONTROLLER ASSEMBLY 56 15 CONTROLLER MOUNTED ANTILOCK RELAY VALVE 1 After noting the relationship of the positioning marks made prior to disassembly position the gasket on the EC 15 controller then secure the EC 15 controller to the antilock relay valve using the four cap screws Torque the cap screws to 50 80 Ibs in 2 Mount the assembled EC 15 controller and antilock relay valve on the vehicle and orient it in the position marked prior to removal 3 Reconnect all air lines to the assembly Reconnect the electrical connector s to the EC 15 controller 5 Test the antilock relay 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 antilock system operation BRACKET MOUNTED EC 15 CONTROLLER 1 Secure the EC 15 controller to its bracket using the four cap screws Torque the cap screws to 50 80 Ibs in 2 After noting the positioning marks mount the EC 15 controller on the vehicle using the mounting hardware retained during removal 3 Connect the electrical connector s to the EC 15 controller 4 Perform the Initial Start up Procedure in the TROUBLESHOOTING section
25. sure they are secure and free from visible damage Although the EC 15 controller incorporates a self check diagnostics the LED display should be inspected to ensure that they are 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 LED s to illuminate If one or more of the LED s DO NOT ILLUMINATE and the antilock condition lamp on the dash indicates the system is functioning properly the non illuminated LED s should be noted for future reference Although the diagnostic capabilities will be limited the system will continue to function as designed Road test the vehicle by making 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 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 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 W
26. to assure proper antilock system operation 10 DIAGNOSING AND LOCATING A SYSTEM PROBLEM GENERAL The EC 15 controller contains self test and diagnostic circuitry that continuously checks for proper operation of the entire antilock system including wiring continuity A dash lamp controlled by the EC 15 controller advises the driver of the condition of the entire antilock system The condition of specific antilock components is provided to the mechanic by aseries of labeled light emitting diodes LED s displayed through a window in the EC 15 controller housing No special tools or equipment are needed to read or interpret the EC 15 controller diagnostics window It should be noted that the EC 15 controller diagnostics display is separate from the antilock condition lamp on the dash With this separation the driver is aware of any problems that occur but is not confused by the diagnostic information A special feature of the EC 15 controller is the failure latching and diagnostic system Intermittent problems particularly in the wheel speed sensing area can be difficult to diagnose When the controller senses an erroneous condition whether in the controller electronics the modulator or wheel speed sensing areas it stores the condition in non volatile memory disables the antilock function illuminates the dash mounted antilock condition lamp and the appropriate diagnostic LEDs onthe EC 15 controller The
27. wheel s Solenoid valves contained in the modulator are energized and de energized by the EC 15 controller in order to modify the brake application When a solenoid coil is energized its shuttle moves and depending upon the function of the specific solenoid it either opens or closes thereby causing the exhaust or reapplication of air pressure to the brake actuator The solenoids in each modulator are controlled independently by the EC 15 controller By opening and closing the solenoid valves in the appropriate modulator the EC 15 controller is actually simulating what the driver does when he pumps the brakes It must be remembered however that unlike the driver the EC 15 controller is able to pump each brake on the vehicle independently and with far greater speed and accuracy SUPPLY MOUNTING HOLES EXHAUST FIGURE 5 M 21 MODULATOR ANTILOCK SYSTEM OPERATION COMPONENT FAILURE The Bendix EC 15 controller handles equipment failure using aconservative fail safe philosophy Any single electrical failure of a component devoted to antilock braking results in simultaneous illumination of the antilock condition lamp on the dash a disabling of all or part of the antilock system and reversion to standard braking on wheels no longer under the control of antilock When coping with wheel equipment modulator or wheel speed sensor exciter failure the EC 15 controller divides and separates the brakes di
28. wire groups or wire harnesses along with the connectors are most often specified and or supplied by the vehicle manufacturer Two examples of the connectors used on the EC 15 controller are illustrated in figures 7 amp 8 The wiring harnesses and connectors are weather proof 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 flux and made water proof 2 Do not pierce wire insulation when testing Check for power ground or continuity by disconnecting the connector and testing the individual pins or sockets in the connector Always check the vehicle hand book 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 While the retarder disable and serial link connections 3 total are present on all EC 15 controllers they are not always used PREVENTATIVE MAINTENANCE Every 3 months 25 000 miles or 900 operating hours 1 Check all wiring and connectors to en
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