NHTSA ID Number: 11018271
Manufacturer Communication Number: SD-27-5031
TSB/Document Date: 2025-05-14
Summary
Service Data Instructions - Bendix® GSBC® EPM-90™ (Global Scalable Brake Control Electro-Pneumatic Modulator)
11
TROUBLESHOOTING (CONT.)
LEAKAGE TESTS
NOTE: This test typically requires two people to efficiently
conduct the test.
NOTE: If the EPM needs replaced, refer to the Replacement
Instructions section on page 15.
SUPPLY SIDE LEAKAGE TEST
To perform the leakage test for the EPM, complete the
following steps:
1. Ensure that the test preparation procedure has
been completed.
2. Turn the vehicle on, and build the air system
pressure to governor cut-out.
3. Apply a soapy water solution to the body of the
EPM.
a. If bubbles accumulate near the supply fitting,
check to see that the fitting is torqued to the
correct value. Refer to Table 1 for 1C EPM or
Table 2 for 2C EPM torque information. Bubble
diameter(s) should not exceed a one-inch
bubble in less than 3 seconds.
»
If the fitting is torqued to the correct value
and the port continues to leak, replace
the fitting.
»
If the EPM continues to leak after a
replacement fitting has been installed and
correctly torqued, the EPM is damaged
and must be replaced.
b. If bubbles accumulate anywhere on the body
of the EPM, bubble diameter(s) should not
exceed a one-inch bubble in less than 3
seconds.
»
c.
If bubbles exceed this size/rate, the EPM
is damaged and must be replaced.
If bubbles accumulate on or near the silencer
on the exhaust (port 3), bubble diameter(s)
should not exceed a one-inch bubble in less
than 3 seconds.
»
If bubbles exceed this size/rate, the EPM
is damaged and must be replaced.
NOTE: If the EPM does not function as described above,
or if the leakage is excessive, it is recommended that the
EPM be replaced with new genuine Bendix parts, available
at any authorized Bendix parts outlet.
12
SD-27-5031 Rev 001 Bendix
® GSBC® EPM-90™ (Global Scalable Brake Control Electro-Pneumatic Modulator)
TROUBLESHOOTING (CONT.)
DELIVERY SIDE LEAKAGE TEST
To perform the leakage test for the EPM, complete the
following steps:
(ELECTRONIC MODE)
1. Ensure that the test preparation procedure has
been completed.
2. Turn the vehicle on, and build the air system
pressure to governor cut-out.
3. Make sure that the vehicle wheels are properly
chocked to prevent unexpected movement.
4. Release the parking brakes.
5. Apply a soapy water solution to the body of the
EPM, the pneumatic ports, exhaust port(s), and
the silencer.
6. Make and hold a full service brake application
using the foot brake pedal.
a. If bubbles accumulate near any of the
pneumatic fittings, check to see that the
fitting is torqued to the correct value. Refer
to Table 1 for 1C EPM or Table 2 for 2C EPM
torque information. Bubble diameter(s) should
not exceed a one-inch bubble in less than
3 seconds.
»
If the fitting is torqued to the correct value
and the port continues to leak, replace
the fitting.
»
If the EPM continues to leak after a
replacement fitting has been installed and
correctly torqued, the EPM is damaged
and must be replaced.
b. If bubbles accumulate anywhere on the
body of the EPM, bubble diameter(s) should
not exceed a one-inch bubble in less than
3 seconds.
»
c.
If bubbles exceed this size/rate, the EPM
is damaged and must be replaced.
If bubbles accumulate on or near the silencer
on the exhaust (port 3), bubble diameter(s)
should not exceed a one-inch bubble in less
than 3 seconds.
»
If bubbles exceed this size/rate, the EPM
is damaged and must be replaced.
(PNEUMATIC BACKUP MODE)
7. Unplug the electrical connector from the FBM to
put the system into pneumatic backup mode. For
more information on the FBM and how to unplug
the electrical connector, refer to SD-27-5028 on
B2Bendix.com.
8. Apply a soapy water solution to the body of the
EPM on and around the pneumatic backup control
port (port 4).
9. Make and hold a full service brake application
using the foot brake pedal.
a. If bubbles accumulate near any of the
pneumatic fittings, check to see that the
fitting is torqued to the correct value. Refer
to Table 1 for 1C EPM or Table 2 for 2C EPM
torque information. Bubble diameter(s) should
not exceed a one-inch bubble in less than
three (3) seconds.
b. If the fitting is torqued to the correct value and
the port continues to leak, replace the fitting.
»
c.
If the EPM continues to leak after a
replacement fitting has been installed and
correctly torqued, the EPM is damaged
and must be replaced.
If bubbles accumulate anywhere on the
body of the EPM, bubble diameter(s) should
not exceed a one-inch bubble in less than
3 seconds.
»
If bubbles exceed this size/rate, the EPM
is damaged and must be replaced.
d. If bubbles accumulate on or near the silencer
on the exhaust (port 3), bubble diameter(s)
should not exceed a one-inch bubble in less
than 3 seconds.
»
If bubbles exceed this size/rate, the EPM
is damaged and must be replaced.
10. When diagnostic tests have been completed,
turn off the vehicle, reconnect the FBM electrical
connector, and remove any diagnostic pressure
gauges from the air system.
11. Reapply the parking brakes and go to Installation
Test section on page 17 to validate any repairs
that have been performed.
NOTE: If the EPM does not function as described above,
or if the leakage is excessive, it is recommended that the
EPM be replaced with new genuine Bendix parts, available
at any authorized Bendix parts outlet.
SD-27-5031 Rev 001 Bendix® GSBC® EPM-90™ (Global Scalable Brake Control Electro-Pneumatic Modulator)
13
TROUBLESHOOTING (CONT.)
ELECTRICAL FUNCTION TESTS
The EPM functionality is electronically monitored by both
the EPM and the central ECU. Electrical function testing
is conducted automatically and any faults will be reported
as DTCs. For more information regarding DTCs impacting
EPMs, refer to the Diagnostic Trouble Code (DTC) and
Service Information section on page 21.
5. If the resistance falls outside these thresholds
and/or there is damage to the EPM electrical
connector, confirm there are faults using Bendix
ACom Diagnostic Software or the appropriate
OEM service tool. If so, replace the EPM.
6. If not, reconnect the X1 connector to the
EPM, restore electrical power, and continue
troubleshooting.
HARNESS COMMUNICATION TEST
EPM COMMUNICATION RESISTANCE TEST
Perform this test to troubleshoot the CAN connection on the
vehicle harness between the EPM and the Central ECU.
Perform this test to troubleshoot the physical CAN pins on
the EPM that provide communication between the EPM
and the Central ECU.
1. Turn off the vehicle.
2. Remove electrical power from the vehicle.
3. Disconnect the vehicle harness X1 connector from
the EPM.
4. Measure the resistance between the exposed
pin 3 and pin 4 on the vehicle harness X1 connector.
The nominal resistance is 120 ohm. Resistance
can vary depending on harness length. If the
measured resistance is significantly different, for
example, an open circuit or short to ground:
»
Inspect the vehicle wiring harness for open or
shorted wiring per OEM instructions.
»
Check the electrical connections on the vehicle
harness for damaged connectors or problems.
»
Inspect the electrical connector at the Central
ECU for damage or other problems.
4. If the vehicle harness passes these checks,
reconnect the harness to the EPM and restore
vehicle power. Continue troubleshooting the
problem using Bendix ACom Diagnostic Software
or the appropriate OEM service tool.
EPM INTERNAL POWER CIRCUITRY TEST
1. Prior to troubleshooting the EPM communication
resistance, first confirm that the EPM harness
is fully functional by running the Harness
Communication test.
2. Turn off the vehicle.
3. Remove electrical power from the vehicle.
4. Disconnect the vehicle harness X1 connector from
the EPM.
5. Measure the resistance between the exposed
pin 3 and pin 4 on the X1 connector on the EPM.
Refer to Figure 9 - X1 and X2 Electrical Pinout.
The nominal resistance is 300 ohm. If the measured
resistance is significantly different, for example, an
open circuit or short to ground, it may be indicative
of a faulty EPM.
6. If the resistance falls outside these thresholds
and/or there is damage to the EPM electrical
connector, confirm there are faults using Bendix
ACom Diagnostic Software or the appropriate
OEM service tool. If so, replace the EPM.
7. If not, reconnect the X1 connector to the
EPM, restore electrical power, and continue
troubleshooting.
Perform this test to check for physical damage to the EPM
internal power circuitry.
1. Turn off the vehicle.
2. Remove electrical power from the vehicle.
3. Disconnect the vehicle harness X1 connector from
the EPM.
4. Measure the resistance between the exposed pin 1
and pin 2 of the X1 connector on the EPM. Refer to
Figure 9 - X1 and X2 Electrical Pinout.
The nominal resistance measured should be
between approximately 30 kohm and 36 kohm. If
the measured resistance is significantly different,
for example, an open circuit or short to ground, it
may be indicative of a faulty EPM.
14
SD-27-5031 Rev 001 Bendix® GSBC® EPM-90™ (Global Scalable Brake Control Electro-Pneumatic Modulator)
REPLACEMENT INSTRUCTIONS
If replacing the EPM, use the same mounting location and,
if necessary, the same bracketry as installed by the Original
Equipment Manufacturer (OEM).
NOTE: The EPM does not need to be removed from
the vehicle for maintenance of serviceable parts. Proper
installation allows for sufficient clearance around the part.
However, the part may be removed if necessary for service
or replacement.
7. Remove the Electrical Covering Cap(s) from the
side of the unit. NOTE: The 2C EPM will have
two covers.
8. Disconnect the electrical connections from the
EPM. See Figure 16.
EPM REMOVAL
To remove the EPM from the vehicle, complete the following
steps:
1. Chock the vehicle’s wheels to prevent unintended
movement.
2. Prior to disassembly, remove as much
contamination as possible from the exterior of the
device, taking care to keep all contamination from
entering the open ports.
3. Drain air from primary and secondary reservoirs.
Refer to OEM service manuals for detailed
instructions.
4. Prior to removing the EPM from the vehicle,
take a photo of the current EPM location and
orientation, including air line connections and
routing, for reference during the replacement
steps. Additionally, mark or otherwise identify
air hoses and electrical connectors to aid in the
installation of the new EPM.
Figure 16 – Electrical Harness Connector Removal
9. Remove pneumatic fittings from the EPM and
inspect them for damage or debris. Replace any
damaged fittings as necessary.
10. Remove and retain mounting bolts for use in the
installation. See Figure 17.
5. Clean and inspect all air hoses for damage and
replace as necessary.
6. Disconnect the air hoses from the EPM. NOTE:
Depending on the type of pneumatic fittings used,
special tools may be required. Refer to the OEM
service manual.
Figure 17 – 1C EPM Mounting Bolts Example
Figure 15 – Electrical Covering Cap Removal
SD-27-5031 Rev 001 Bendix® GSBC® EPM-90™ (Global Scalable Brake Control Electro-Pneumatic Modulator)
15
REPLACEMENT INSTRUCTIONS (CONT.)
COMPONENT MOUNTING
The 1C and 2C EPMs are mounted rigidly to the vehicle.
Depending on the vehicle, the EPM may be mounted
directly to the frame or to a bracket.
For fitting torque and replacement information for the
mounting hardware, contact the vehicle OEM.
To prevent potential loss of functionality including
loss of vehicle stability and loss of braking, all unused
electrical and pneumatic connections must be sealed
to protect the EPM from contamination.
Ensure that unused pneumatic ports are plugged
with the appropriate plug fitting and that electrical
connections are sealed using either the mating
connector on the electrical harness or with a blank
“dummy plug.”
Contact the vehicle OEM for replacement parts if these
plugs are missing or damaged.
1C EPM
Mounting
Bolt
Locations
2C EPM
Mounting
Bolt
Locations
Figure 18A – 1C EPM Mounting Bolt Locations
Figure 19A – 2C EPM Mounting Bolt Locations
1
2
3
1C EPM
Three (3)
Points of
Conact
3
2
4
2C EPM
Four (4)
Points of
Contact
Figure 18B – 1C EPM Mounting Points of Contact
16
1
Figure 19B – 2C EPM Mounting Points of Contact
SD-27-5031 Rev 001 Bendix® GSBC® EPM-90™ (Global Scalable Brake Control Electro-Pneumatic Modulator)
REPLACEMENT INSTRUCTIONS (CONT.)
EPM INSTALLATION
To install the EPM on the vehicle, complete the following
steps:
1. Reference the EPM location and orientation image
that was taken in Step 4 of EPM Removal prior to
installing the EPM to the vehicle.
2. Clean and inspect all air hoses for damage and
replace as necessary.
3. Install pneumatic fittings on new EPM and plug any
unused ports. Do not exceed maximum torque on
pneumatic fittings. Refer to Table 1 for 1C EPM or
Table 2 for 2C EPM torque information.
NOTE: All pneumatic fitting ports on both the 1C
and 2C EPM are metric. Be sure to use only metric
straight thread o-ring fittings on this component.
Failure to use the correct fittings may result in air
leakage and permanent damage to the component.
Do not use thread sealant for EPM fittings. EPM threads
do not use sealant. The seal is provided by an o-ring
on the outside of the fitting.
4. Install the EPM and tighten mounting bolts.
NOTE: Verify that mounting points make contact
with the vehicle. For 1C EPM, refer to Figure 18B.
For 2C EPM, refer to Figure 19B.
To prevent potential loss of EPM functionality, all
unused EPM electrical connections must be sealed to
receive the necessary protection from moisture and
prevent corrosion. The sealing element is part of the
connector plug and not the socket. Be careful when
handling and installing the connector plugs so as to
not damage the seal.
5. Replace the electrical plugs and connectors
removed in Step 7 of the EPM removal process.
6. Replace the Electrical Covering Cap(s).
7. Connect airlines to the EPM by referencing the
photo taken in Step 4 of the EPM Removal process.
Failure to correctly plumb airlines can lead to
limited functionality or loss of ABS, ESP, and other
safety-critical functions. These failures may lead to
serious vehicle braking, instability, and performance
issues, and/or collisions causing property damage,
serious injuries, and/or death.
A change in vehicle braking characteristics or a
dashboard warning lamp may indicate a malfunction
in the braking system. Although the vehicle air brake
system may continue to function, the vehicle should
not be operated until the necessary repairs have been
made by a qualified technician.
Always check the vehicle braking system for proper
operation after performing service or maintenance and
before returning the vehicle to service.
After removal and replacement of the EPM, special
considerations need to be taken to ensure the EPM has
been properly installed on the vehicle. These include:
•
Location and orientation of the EPM
•
Correct plumbing of the EPM
•
Installation Test to verify proper installation.
INSTALLATION TEST
1. Chock the wheels on the vehicle to prevent
unintended movement.
2. Turn the vehicle on and build the air system
pressure to governor cut-out.
3. Check for and clear any system-generated faults
using Bendix ACom Diagnostic Software or the
appropriate OEM service tool. If there are any
remaining active faults, following the relevant
troubleshooting steps associated with the fault.
4. Confirm there are no active warning lamps
associated with the GSBC system on the dash
or display. Refer to the GSBC Operator’s Manual
BW8207 on B2Bendix.com for more information
or contact your vehicle OEM.
5. With the engine off, and ignition power on, make
a series of light brake application. The EPMs
will activate and the internal solenoids will make
audible ‘clicking’ noises as pressure is delivered.
6. If no new warning lamps are illuminated, go to
Step 7 of the Installation Test. If new warning lamps
become illuminated, return to Step 3.
7. Remove the wheel chocks. The EPM installation
procedure is complete.
8. Perform the Installation Test.
SD-27-5031 Rev 001 Bendix® GSBC® EPM-90™ (Global Scalable Brake Control Electro-Pneumatic Modulator)
17
REPLACEMENT INSTRUCTIONS (CONT.)
SILENCER REMOVAL
REPLACEMENT PARTS
NOTE: The EPM does not need to be removed from
the vehicle for maintenance of serviceable parts. Proper
installation allows for sufficient clearance around the part.
However, the part may be removed if necessary for service
or replacement.
DESCRIPTION
PART NUMBER
Silencer
23144853
Electrical Covering Cap
24048059
Table 7 – EPM Replacement Parts Information
To remove a silencer from the EPM, follow these steps:
SILENCER REMOVAL AND REPLACEMENT
1. Chock the wheels and drain the reservoirs to
ambient pressure.
Silencers require regular inspection to ensure they do not
become blocked by external contamination. Contamination
slows down service brake release times, possibly leading to
reduced braking performance and potential noncompliance
to regulations.
2. Lift the retention tab with a small screw driver using
caution to not break the tab. Looking at exhaust
port, rotate counter clockwise using gentle force
to lift the retention tab so that it clears the locking
point on the body casting. See Figure 20.
Accumulation of road debris on the EPM may cause
blockage of the silencer. If the silencer is blocked, the
EPM may be unable to reduce or release service brake
pressure. This could lead to poor brake response,
slow release of the brakes, and poor ABS or ESP
performance.
NOTE: If the retention tab is broken, the silencer
must be replaced.
Failure to perform inspection of the EPM could lead to
serious vehicle braking, instability, and performance
issues, and/or collisions causing property damage,
serious injuries, and/or death. The EPM must be
mounted to minimize the possibility of accumulated
debris on the silencer which can potentially affect
compliance. Refer to the Cleaning and Inspection
section on page 20.
The silencer must not be covered or painted over.
IMPORTANT
If the silencer is found to be contaminated, it must be
replaced. Refer to Table 7 for silencer replacement
information.
- Mixes well with conventional fluids
- Low-moisture formula provides excellent vapor lock...
- Ideal for hydraulic and disc brakes
- Provides an extra margin of safety in extreme braking...
- Mix of polyglycol ethers ensures hot brake-system operation...
- Excellent for ABS, disc and drum brake systems
- Delivers braking power when needed by avoiding a spongy...
- Both wet and dry boiling points exceed the minimum...
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TSB/Document ID: SD-27-5031
Replacement Service Bulletin Number:
MFR Communication Date: 2025-05-14
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM
MFR Component System: Air Brake Control System
MFR Component Subsystem: Electro-Pneumatic Modulator
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