_____________

Are the foundation brakes applied?

Yes

No

_____________

Does your truck proceed toward the forward vehicle without
a Following Distance Alert (FDA) or braking intervention?

Yes

No

_____________

Does it give a following distance alert?
With cruise engaged, if a faster vehicle passes your vehicle on the left or right
on a straight road:
Does it give a Following Distance Alert (FDA)?
With cruise control engaged, if the vehicle ahead slows moderately or cuts in
front of your truck and slows down:
Does your vehicle slow and the Bendix® Fusion™
System maintain the following distance?
Is the engine throttle reduced?

7

1.2 NARROWING DOWN THE PROBLEM
Use this table to help assess if the Bendix® Fusion™ FLR-25™ Radar Sensor is not performing correctly. Be sure to have
a thorough understanding of the system’s normal behavior; this will reduce the troubleshooting time. This table provides
a guide to basic troubleshooting questions and possible corrective actions. Items in italics cross-reference to the service
procedures in this manual to repair the condition described.

Narrowing Down the Problem (1.2)
Questions

Next Steps

Blocked Radar Sensor Issues
Is mud, ice, or snow covering the
radar sensor?

Clean the radar sensor front surface immediately. Remove anything blocking the radar
sensor then power cycle and read any remaining Diagnostic Trouble Codes (DTCs).

Is anything blocking the view of the
radar sensor?

Refer to Section 2.5: Diagnostic Trouble Codes.
Refer to Appendix A3: Bendix™ FLR-25™ Radar Sensor Mounting Clearance.
If the radar sensor is blocked by ice, snow, mud, tampering, etc. so that it cannot "see" a
forward vehicle, the Fusion system will notify the driver by an audible and/or visual alert.
After the blockage is removed, the audible and/or visual alert will be removed. Drivers
should visually check the radar sensor for blockage during the pre-trip inspection.

Potential False Warnings
Do false warnings seem to happen
in construction zones?

Several road scenarios have a tendency to cause false warnings, including construction
zones and bridges. Unless these false warnings are frequent, the system is likely reacting
normally. The driver should not set the cruise control in construction zones. If driver
complaints persist, continue asking questions to more narrowly define the driving condition
presenting the problems. Review proper operating conditions in the operator's manual.

Mounting Problems
Is the radar sensor mounting
location (bumper or cross-member)
damaged?

Inspect the radar mounting. A solid mounting surface is necessary in order to hold the
alignment. If the bumper or mounting cross-member is damaged, replace it.

Does the system seem to not "see"
as far as it “used to," or warn on
many more overhead bridges/signs
than previously?
Does the mounting bracket look
damaged or tampered with?

Other than expected surface scratches or some discoloration over time, there should be no
visible damage to the radar sensor bracket assembly or the bumper.
The radar sensor needs a solid mounting surface in order to hold the alignment. If the
radar sensor alignment cannot be held in place, the bracket assembly must be replaced,
and/or if the bumper or mounting cross-member is damaged, replace it as needed.

Table 2 – Narrowing Down the Problem

8

Narrowing Down the Problem (1.2)
Questions

Next Steps

Has the system worked without
problems in the past but is not
working as expected now?

This is a good indication that something has changed. Review the following questions with
the driver to further diagnose the problem.

Has the radar sensor been
changed recently?

If so, the new radar sensor may be incompatible with the vehicle. In addition, check any
system Diagnostic Trouble Codes (DTCs) with Bendix® ACom® PRO™ Diagnostic Software.
Refer to Section 2.5: Diagnostic Trouble Codes.
Check the radar sensor baud rate. Confirm the part number (located on the front face of
the radar sensor) is the correct part number per the vehicle's VIN. Confirm the radar sensor
is not installed backwards (the connector tab on the radar sensor is a good reference).

Did the radar sensor currently on
the vehicle come from another
vehicle?

The radar sensor may be incompatible with the new vehicle. Check system DTCs with
Bendix ACom PRO Diagnostic Software. Refer to Section 2.5: Diagnostic Trouble Codes.

With cruise control set, does the
system consistently apply the
foundation brakes when a forward
vehicle slows?

This is normal operation. If the radar system interventions are not typical, the radar sensor
may be misaligned.
Inspect the radar mounting. A solid mounting surface is necessary in order to hold the
alignment. If the bumper or mounting cross-member is damaged, replace it.
The service technician will need to check trouble codes as well. Read Section 2.5:
Diagnostic Trouble Codes.

Does a DTC seem to occur when
driving through the desert or in
barren areas (no road signs, trees,
or vehicles)?

In normal operation, the active cruise control with braking feature of the Bendix Fusion
system may indicate a DTC if it hasn’t detected a metallic object after a pre-determined
period. This is rare, but most likely to occur when driving in deserts or barren areas. If
the system does set a DTC, the Bendix Fusion system provides a visible warning to the
driver, but cruise control will still be active. Full and proper radar sensor functionality will be
restored after a power cycle.

Does the system seem to
disengage after an automatic
braking event?

This is normal operation. Contact the vehicle OEM for details on cruise control operation.

Does cruise control disengage
sometimes when the brakes come
on and not at other times?

This is normal operation. When traveling with lightly loaded trailers, or “bobtail”, the active
cruise control with braking feature of the Bendix Fusion system may continue to function
even after an automatic brake application. No driver input is needed. Contact the vehicle
OEM for details on cruise control operation.

Does the connector or wiring
appear damaged?

Wires can become corroded if the radar sensor is not plugged in properly. Clean the
connectors on the wire harness, as well as the radar sensor, and reattach. If wires are
chafed, replace the wire harness. Also, check for trouble codes.
Refer to Section 2.5: Diagnostic Trouble Codes and
Section 2.12: Troubleshooting Wiring Harnesses.

Does the system generate a DTC
going down a grade when using
ACB (Active Cruise‑control with
Braking) to slow the vehicle, but the
code goes away later?

This is normal operation. The active cruise control with braking feature of the Bendix
Fusion system is not intended to be used on grades. Verify there are no DTCs. Proper
downgrade driving techniques should be used.

Does the radar sensor have
noticeable damage beyond normal
discoloration or surface scratches?

The radar sensor and bracket are very durable. However, if the radar sensor housing
or cover is cracked or broken, immediately look for trouble codes via Bendix ACom
PRO diagnostic software and replace the damaged radar sensor. Refer to Section 2.5:
Diagnostic Trouble Codes and Appendix A3: Radar Sensor Mounting Clearance.

Refer to Section 2.5: Diagnostic Trouble Codes.

Table 2 – Narrowing Down the Problem

9

1.3 OVERVIEW OF POSSIBLE ISSUES
Some customer issues are actually misunderstandings of how the Bendix® Fusion™ system performs normally. Use Table
3 below to learn the causes of potential issues if the Fusion system is not performing correctly. Some issues can be
investigated by a visual inspection. Others may cause a Diagnostic Trouble Code (DTC) to be logged: Refer to Section
2.5: Diagnostic Trouble Codes.

Overview of Possible Issues (1.3)
Issue

Description

Vehicle Diagnostic
Trouble Codes
(DTCs)

The Bendix Fusion system will not operate and will set a DTC if any of the following
vehicle systems also show a DTC: engine, engine cruise, instrument cluster, Bendix®
ABS, Bendix® ATC, Bendix® ESP®, or transmission. These components must be
repaired and cleared of DTCs before troubleshooting the Fusion system. (NOTE:
Clearing the vehicle DTCs may be the only step needed to reestablish full Fusion
system functionality. Refer to Section 2.6: Clearing Diagnostic Trouble Codes (DTCs).

System familiarity

Verify the system functionality. Is it operating normally or not? Drivers who are unfamiliar with
the system may report dissatisfaction over the way it beeps or how it activates the brakes.
Refer to Section 1.0: Introduction to Troubleshooting, Section 1.1: Troubleshooting Basics,
and Section 2.5: Diagnostic Trouble Codes to verify if the system is functioning normally;
then continue.

DTCs caused by
temporary operating
conditions

Some DTCs indicate a temporary condition and will clear when that condition is no longer
present. If these persist, further investigation is warranted.

Radar sensor
blocked

If the system doesn’t seem to work at all, the radar sensor may possibly be blocked. If the
radar is blocked, an alert should be issued to the driver to indicate this condition. Visually
inspect the area around the radar, clear the blockage, turn the ignition on and run through
a power cycle. Refer to Appendix A3 for more information about radar mounting and
clearances.

Damaged radar
sensor or bracket

If the vehicle has been in an accident, it is likely the radar sensor will need to be re-inspected
or replaced. Inspect the radar sensor and housing for damage. Radar sensor discoloration
or small scratches may be acceptable. Significant damage (such as cracks or broken pieces)
will require radar sensor replacement. Regardless of the exterior condition, check for DTCs
outlined in the Section 2.5: Diagnostic Trouble Codes (DTCs) to determine if radar sensor
replacement is necessary.

Damaged connector
or wiring

Visually inspect the connector and wire harness for corrosion or chafing. Refer to Sections
2.7: Troubleshooting Diagnostic Trouble Codes: Power Supply and 2.8 Serial Data (J1939)
Communications Link of this document for additional troubleshooting.

Radar sensor
misalignment

Inspect the front of the vehicle. If a) it has been damaged; or b) the vehicle does not track
straight, either of these conditions must be repaired before troubleshooting the Bendix Fusion
system.

Refer to Section 1.1: Troubleshooting Basics.

If there is a DTC set or if the system does not function, the radar sensor may be severely
misaligned and the Fusion system will not operate until this is corrected.
J1939 network
problems

If the entire system is non-functional, it may be a J1939 network problem. Follow the
instructions in Section 2.8: Serial Data (J1939) Communications Link.

Power to radar
sensor problems

If the entire system is non-functional, another likely cause may be a lack of power to the radar sensor.
Follow the instructions in Section 2.7: Troubleshooting Diagnostic Trouble Codes: Power Supply.

Table 3 – Overview of Possible Issues

10

1.4 IMPORTANT NOTE ON
TELEMATICS WIRING
Where a vehicle does not have an On Board Computer/
Telematics (OBC/T) system – in order to prevent
interference to the SafetyDirect® by Bendix CVS Web
Portal Processor – disconnect the OBC/T harness (any
wiring harness provisionally installed in the vehicle for
potential use for Telematics) from the main vehicle harness.
Re-connect the harness only when an OBC/T system is
installed.

2.0 TROUBLESHOOTING/
DIAGNOSTICS SECTION

STARTING BENDIX ACOM PRO
DIAGNOSTIC SOFTWARE
The ACom PRO Diagnostic Software can be started from
the desktop shortcut. To begin, the technician should
select “Connect” from the main toolbar, then “Heavy Duty”
connection type. The “Heavy Duty” button connects to the
vehicle BUS using all vehicle protocols. This process could
take approximately two (2) minutes. After the connection is
complete, the roll call will show the ECU and its active and
inactive DTCs. The connection depends on a compatible
RP1210C adapter. For assistance with the ACom PRO
Diagnostic Software, contact the Bendix Tech Team at
1-800-AIR-BRAKE (1-800-247-2725, option 2, option 2).

IMPORTANT
All vehicle Diagnostic Trouble Codes (DTCs)
related to the engine, transmission, instrument
cluster, engine cruise control, and Bendix®
ABS, ATC, or ESP® systems must first be
resolved – with no trouble codes present
during the vehicle operation while in cruise
control – before attempting to diagnose
Bendix® Fusion™ system DTCs.
Important examples are VDC2 and EBC
DTCs which are typically related to the brake
controller. The hierarchy of Electronic Control
Units (ECUs) determines that any DTCs on
the brake controller must be resolved before
attempting to troubleshoot the Fusion system.

2.1 BENDIX® ACOM® PRO™
DIAGNOSTIC SOFTWARE
Bendix® ACom® PRO™ Diagnostic Software is a PC-based
software program available to purchase from bendix.com.
This software provides the technician with access to all
the available Electronic Control Unit (ECU) diagnostic
information and configuration capability. For controllerspecific system diagnostics, use a current version of the
ACom PRO Diagnostic Software.

Figure 5 - Starting Bendix ACom PRO Diagnostic Software

Figure 4 – Bendix ACom PRO Diagnostic Software

11

2.2 READING DIAGNOSTIC
TROUBLE CODES (DTCS)
1. Connect a current version of the Bendix® ACom®
PRO™ Diagnostic Software to the vehicle.
2. Once the roll call is complete, you can view active
and inactive DTCs and clear DTCs from all vehicle
components or solely from a selected Bendix
controller.

2.3 READING THE SYSTEM
SOFTWARE VERSION

Connect a current version of Bendix® ACom® PRO™
Diagnostic Software to the vehicle. View the software
version by selecting the appropriate vehicle.

3. To read and clear DTCs from all vehicle components
at the same time, select the vehicle on the roll call and
clear the DTCs by selecting “Clear Faults.”
4. To read and clear DTCs from a specific Bendix
Electronic Control Unit (ECU), select the Bendix ECU
on the roll call select “Clear Faults.”
For assistance with ACom PRO Diagnostic Software,
contact the Bendix Tech Team at 1-800-AIR-BRAKE
(1-800-247-2725, option 2, option 2).

Figure 6 – Bendix® ACom® PRO™ Diagnostic Software
Starter Screen Showing Software Version

12

2.4 HOW TO GENERATE A BENDIX® FUSION™ FLR-25™ RADAR
SENSOR DIAGNOSTIC TROUBLE CODE (DTC) REPORT
1. Connect a current version of the Bendix® ACom® PRO™
Diagnostic Software with the vehicle.

2. O
nce the roll call is complete, you can select the DTC Report
icon on the top menu.

3. The DTC report drop-down gives you the following options:

4. S
elect “Print Preview” to generate and save the report.

•

Print DTC Report

•

Print Preview of the DTC Report

•

Submit DTC Report

13

2.5 TABLE OF BENDIX® FUSION™ FLR-25™ RADAR SENSOR DIAGNOSTIC
TROUBLE CODES (DTCs) AND SERVICE ACTION CODES
IMPORTANT
Review the preliminary steps prior to referencing the Table 4A (DTCs) and Table 4B (Service Action Codes).
1. Check Bendix® ACom® PRO™ Diagnostic Software for the Diagnostic Trouble Codes (DTCs) that indicate an inoperable
radar. If one of these DTCs is active and displayed on ACom PRO and the Bendix® Fusion™ System is still under
warranty, you can submit for a warranty evaluation.
2. Faults referencing J1939 Signal Missing are faults indicating that the Bendix® FLR-25™ Radar Sensor did not receive
a required message from the component listed in the fault description (refer to the acronym table below). Refer to
the associated Service Action Code list in Table 4B.
Acronym
ABS

Antilock Braking System

ACC

Adaptive Cruise Control

AEBS

Autonomous Emergency Brake System

ASR
CC

Anti-slip Reduction
Cruise Control

CCVS

Cruise Control Vehicle Speed

CMT

Collision Mitigation Technology

CVW

Combined Vehicle Weight

DTC

Diagnostic Trouble Code

DM

Diagnostic Message

EBC

Electronic Brake Control

EC

Electronic Control

ECM

Electronic Control Module

EEC

Electronic Engine Control

ERC

Electronic Retarder Control

FLC

Forward-looking Camera

GCVW

Gross Combined Vehicle Weight

HDB

Highway Departure Braking

OEL

Operator's External Light

RC

Retarder Control

ROP
TC

14

Description

Rollover Prevention
Torque Control

TSC

Torque/Speed Control

VDC

Vehicle Dynamic Controller

XBR

External Brake Request

Description

Go to the Service
Action Code List in
Table 4B

DTC

SPN

FMI

8192

57376

2