BENDIX EC-60 ABS-ATC STD-PREM CONTROLLERS Troubleshooting General, Safe Maintenance Practices

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Troubleshooting: General

SAFE MAINTENANCE PRACTICES

WARNING! PLEASE READ AND FOLLOW THESE INSTRUCTIONS TO AVOID PERSONAL INJURY OR DEATH:

When working on or around a vehicle, the following general precautions should be observed at all times:

1.Park the vehicle on a level surface, apply the parking brakes, and always block the wheels. Always wear safety glasses.

2.Stop the engine and remove ignition key when working under or around the vehicle. 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. Use only the proper tools and observe all precautions pertaining to use of those tools.

4.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.

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 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.

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 indicator lamp should be ON) prior to performing any vehicle maintenance where one or more wheels on a drive axle are lifted off the ground and moving.

REMOVING THE EC-60CONTROLLER ASSEMBLY

1.Turn vehicle ignition off.

2.Remove as much contamination as possible prior to disconnecting air lines and electrical connections.

3.Note the EC-60controller assembly mounting position on the vehicle.

4.Disconnect the electrical connectors from the EC-60controller.

5.Remove and retain the mounting bolts that secure the EC-60controller.

INSTALLING A NEW EC-60CONTROLLER

CAUTION! When replacing the EC-60controller, verify that the unit you are installing has the correct default settings. Failure to do so could result in a loss of features, such as ATC and PLC, or noncompliance with U.S. regulations such as FMVSS 121. It is recommended to use only the correct replacement part number. However, most configuration settings can be altered using the Bendix AComABS Diagnostic Software program.

Verify correct operation of the EC-60controller system and indicator lamps prior to putting the vehicle back into service. Towing vehicles manufactured after March 1, 2001 must support the trailer ABS indicator lamp located on the dash.

For further information, contact either the vehicle manufacturer, Bendix or your local authorized Bendix dealer.

1.Position and secure the EC-60controller in the original mounting orientation using the mounting bolts retained during removal. On frame-mount ECUs, torque the mounting bolts to 7.5 to 9 NM (66-80 in. Ibs). For cab- mount units use no more torque than is necessary to firmly secure the ECU into position. Over-tightening the mounting hardware can cause damage to the EC-60controller.

2.Reconnect the electrical connectors to the EC-60controller.

3.Apply power and monitor the EC-60controller power- up sequence to verify proper system operation.

See Troubleshooting: Wiring section beginning on page 32 for more information on wire harnesses.

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Contents Standard Frame Standard Cab Premium Frame Premium Cab IntroductionFrame ECUs ComponentsECU Mounting Cab ECUsEC-60CONTROLLER Inputs Hardware ConfigurationsEC-60CONTROLLERS with PLC EC-60CONTROLLER Outputs POWER-UP Sequence ABS Operation ATC Operation Bendix Smart ATC Traction Control Optional ATC Off-Road ModeDynamometer Test Mode Engine Torque Limiting ETL with Smart ATC Traction ControlABS Partial Shutdown ECU Reconfiguration Reconfiguring EC-60ControllersSystem Configuration Installing a NEW EC-60CONTROLLER Troubleshooting GeneralSafe Maintenance Practices Removing the EC-60CONTROLLER AssemblyBlink Codes Troubleshooting Blink Codes and Diagnostic ModesECU Diagnostics Inactive Diagnostic Trouble Code Mode Diagnostic ModesDiagnostic Modes Active Diagnostic Trouble Code ModeReconfigure ECU Mode Clearing Active Diagnostic Trouble CodesSystem Configuration Check Mode Bendix RDU Reset Function Using HAND-HELD or PC-BASED DiagnosticsBendix RDU Remote Diagnostic Unit Features of the Bendix RDU ToolBendix Technical Assistance Team Bendix ACom Diagnostics 3.0 SoftwareBendix RDU Communication Problems Nexiq Bendix Application Card1st Blink Code Go Here for Troubleshooting Tests Number Active or Inactive Diagnostic Trouble CodesCode Description Troubleshooting Diagnostic Trouble Codes2nd Diagnostic Blink Trouble Code Wheel Speed SensorsSpeed Sensor Repair Tests Cab-mount ECU Looking into wire harness connectorFrame-mount ECU Looking into wire harness connector Connector PinPressure Modulator Valves Pressure Modulator Valve Repair Tests Connector Pin PMV LocationTraction Control Valve Repair Tests Traction Control ValvesConnector Pin Power Supply Test Troubleshooting Diagnostic Trouble Codes Power SupplyPower Supply Tests J1939 High J1939 Troubleshooting TestsConnector Pin J1939 Connector Pin J1939 J1939 LowECU Repair Information Troubleshooting Diagnostic Trouble Codes Miscellaneous2nd. Diagnostic Blink Trouble Code Code Description PMV Commons Miscellaneous TroubleshootingABS Indicator Lamp Retarder RelayNot Used Standard Cab X1 Connector Pin AssignmentsStandard Cab X2 Connector Pin Assignments Standard Frame X2 Connector Pin Assignments Standard Frame X1 Connector Pin AssignmentsPremium Cab Model EC-60Controller Premium Cab X1 Connector Pin AssignmentsPremium Cab X2 Connector Pin Assignments Premium Cab X3 Connector Pin AssignmentsPremium Frame X3 Connector Pin Assignments Premium Frame X1 Connector Pin AssignmentsPremium Frame X2 Connector Pin Assignments ABS/ATC Wiring Troubleshooting WiringTerminal ABS Component Connector Wire Wire Seal TerminalPlug Lock Crimp Tool Wheel Speed Sensor Wiring Troubleshooting WiringDrive Axle Steer Axle Troubleshooting Standard Cab Wiring Schematic 4S/4MPackard BPin CPin APin Troubleshooting Premium Cab Wiring Schematic 6S/6MPackard Pin B Pin C Pin a Troubleshooting Premium Cab Wiring Schematic 6S/5MSteer Axle Drive Axle Troubleshooting Standard Frame Wiring Schematic 4S/4MPremium Frame Wiring Schematic 6S/6M Troubleshooting Premium Frame Wiring Schematic 6S/6MPremium Frame Wiring Schematic 6S/5M Troubleshooting Premium Frame Wiring Schematic 6S/5MGlossary SID FMI J1587 J1587 Equivalents General