Operating Instructionsfor the WABCO Diagnostic Controller with Program Card ECAS BUS - SAE446 300 633 0

WABCO

Operating Instructions

for the WABCODiagnostic Controller446 300 320 0 with Program Card ECAS BUS-SAE 446 300 633 0

August 1998 Edition

© Copyright WABCO 1998

WABCOFahrzeugbremsen

A Division ofWABCO Standard GmbH

The right of amendment is reserved

TABLE OF CONTENS:Page

1 Brief description of the “ECAS” system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 Diagnostic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4 Operating the Diagnostic Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

5 Explanation of the program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5.1 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

5.1.1 Error memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

5.1.2 Component actuate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

5.1.3 Testing and measurement values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

5.1.4 Control equipment data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

5.1.5 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5.2 Multimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

5.3 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

5.4 Special functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

6 Example of Fault finding “Movement sensor - Cable break ”. . . . . . . . . . . . . . . 14

7 Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

8 Circuit diagram ECAS BUS 24V, SAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Abbreviations used:AA drive axlecounts unit of measurement for movement or pressure sensor valuesECAS Electronically Controlled Air SuspensionECU Electronic Control UnitHA rear axlek(Ω) kilo(ohm)KW calendar weekLA lift axleSA trailing axleVA front axleV1 version 14x2 description code: 4 wheels, two of them driven6x2 description code: 6 wheels, two of them driven

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1. BRIEF DESCRIPTION OFTHE “ECAS” SYSTEM

ECAS electronics 446 055 ... 0, combinedwith movement sensor 441 050 ... 0,solenoid valve 472 900 / 905 ... 0 andoperating unit 446 056 ... 0, operates theautomatic level regulation of commercialvehicles with air suspension. Distinctionsare drawn between 4x2, 6x2 and bussystems with an appropriate range ofequipment (eg., partial air, full air, trailingaxle, lift axle).

The ECAS system regulates the specifiedlevel by continuous comparison between theactual heights measured (on an inductivebasis) by the movement sensors, and thespecified heights stored in the electronics. Inthe event of deviations between thesevalues, solenoid valves are activated andthe airbags pressurized or depressurizeduntil the specified level is again achieved.The specified level can be the standard level(running level), but it can also be any otherstored level.

All height adjustments take place within pre-selectable tolerance limits.

Adjustments to the level are introduced in amatter of seconds when the vehicle is at astandstill. In motion (recognized by atachometer signal), they only take placeafter a delay of approximately 60 seconds.

The level can be deliberately altered uingthe ECAS operating unit (truck) or theoperating switch (bus). After the change hasbeen completed, it, is then stored as the newspecified level. Re-adjustment takes placeautomatically if there is a change in load.

The ECAS can fulfil other functions:

• automatic upper and lower heightlimitation

• correction of transverse stability

• level and pressure checks

• fault recognition and display

• raise/lower lift-axle

• load/unload trailing axle

• start-up assistance

• zero-point adjustment with raised lift-axle

• LSV control

• maintenance of residual pressure toavoid crushing the airbags

• kneeling (for buses), lowering over onewheel, or the whole side, to assistboarding at bus stops

• start-up lock (for buses)

• door release (for buses)

• storage and retrieval of freely selectablelevels by means of the operating unit

When faults are recognized, the indicatorlamp lights up, and the faults arepermanently stored for diagnostic purposesin the control electronics.

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2. DIAGNOSTIC COMPONENTS

1. Diagnostic controller 446 300 320 02. Program card 446 300 633 03. 35-pin measuring adaptor 446 300 314 04. Multimeter cable, black 894 604 354 25. Multimeter cable, red 894 604 355 26. Connecting cable (SAE, deutsch) 894 604 350 0

Connecting cable (SAE, AMP) 894 604 351 0

The Diagnostic Controller Set 446 300 331 0consists of Diagnostic Controller 446 300 320 0and carrying case 446 300 022 2

AccessoriesKeyboard 446 300 328 0

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2

6

45

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3 CONNECTION OF THE DIAGNOSTIC CONTROLLER

The allocation of PINs in the diagnosticsocket must correspond to the SAE J 1587standard as shown below. ConnectDiagnosstic Cable to diagnostic socket onvehicle.

Allocation of diagnostic socket:

PIN A diagnostic line APIN B diagnostic line BPIN C battery positivePIN E battery negative

Using the connecting adaptor, the pinallocation of the DB-9 “Diagnostic Input”plug on the front of the diagnostic controlleris as follows:

1 Battery positive (terminal 30)2 Battery negative (terminal 31)6 Diagnostic cable (A)7 Diagnostic cable (B)

Connect the 9-pin plug of the connectingcable or connecting adaptor to thediagnostic controller. This provides both the

diagnostic connection and the power supply.Black bars appear on the display screen.

Push the program card into the special slot.

Plug in Card:The contact side must face upwards

Removing Card:Please do not pullhard. If a resistanceis felt, push its endupwards lightly withyour thumb whilstpressing downwardslightly with yourindex and middlefingers. This willmake it very easy toremove.

Depending on the program card used, thefollowing (or similar) will appear in thedisplay. If not, refer to Section 7,Malfunctions .

E C A S B U S - S A EVersion 1.00 (English)

START

G

The first screen displays the System andversion (1.00 in the example). Press theright-hand key.

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4 OPERATING THE DIAGNOSTIC CONTROLLER

The diagnostic controller is operated bymeans of 3 operating keys on the front, orvia the external keypad. The assignment ofkeys depends on the instructions whichappear on the display directly above thekeys.

1 Diagnosis 3 Options2 Multimeter 4 Special functions3 Select function ! EXIT Ò CONT

Display instructions(Function) Operating keys

Here are some examples for different keyfunctions:

Key Function

START start the program.

EXIT the display will return to theprevious menu or programmeitem.

Ò selection of an item from the

main menu. Every time the key is pressed, anew menu item will besuggested. The menu itemselected will flash.

CONT The menu item selectedpreviously is activated oractuated.

ABORT You have the option to abort thefunction in the event of an error

END Ending the function you havebeen working on, i. e. settingparameters.

CHANGE Changing the parametersappearing in the display.

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Operating the External Keyboard446 300 328 0

The external keyboard permits you to enternumerical values. For the program carddescribed in these operating instructions, anexternal keyboard is not required.

Functions are only assigned to the markedkeys.

The keys can be usedinstead oft he three push-buttons on thediagnostic controller

Exception: if it is necessary to enter figuresduring the program, this function does notapply.

Using the ten-key block it is possible either to enter numerical data(for example ISO addresses) or to selectnumbered items from the main menu.

Using the key, the menu itemindicated is executed. The key has the samefunction as the controller key CONTINUE.

Using you can revert to the previousmain menu displayed.

Using , when there is a series of datadisplayed (eg., parameter, function test,calibration data), you can revert to theprevious display.

0

ENTER.

0 1 9to

ENTER

C

*

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5. PROGRAM STRUCTURE

Menu Selection ECAS BUS - SAE 446 300 633 0

1 Diagnosis

1 Error memory

2 Component actuate

1 Raise/Lower2 Central 3/2 valve3 Lamp Test4 External controls

3 Measured values

1 Height sensor2 Tacho signal3 Switch test4 Voltages

4 ECU data

1 Parameters show / edit *2 WABCO data3 Read Fingerprint4 Print data

1 Print erros2 Print parameters

5 Transfer parameter *

1 From ECAS-ECU to Controller2 From Controller to ECAS-ECU

6 Compare parameter *

5 Calibration

1 Calibrate height sensor2 Show height sensor3 Key in data

2 Multimeter

1 DC voltage2 AC voltage3 Resistance

3 Options

1 Online help2 Version3 Supported ECU’s

4 Special functions* only available after entering the PIN

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5.1 DIAGNOSIS

When the diagnostic function is called upfrom Menu Item 1, the connection is made tothe ECAS control unit.

1 Diagnosis 4 Options2 Multimeter 5 Special functions Select function! EXIT Ò CONT

G

Let the cursor flash on ”1“, and press the”CONT“ key.

ECU type : ECAS BUSPart No. : 446 055 057 0Prod. Date : KW35,1996Software-No. : 7.3.0.1 /0 CONT

G

When this has been achieved, the data ofthe ECAS-ECU are shown in the display.

1 Error memory 4 ECU data2 Component actuate 5 Calibration3 Measured values Select function! EXIT Ò CONT

The following functions can be selected indiagnostic mode, and the indicator lampflashes or lights up, depending on thesystem.

5.1.1 Error memoryIf the ECAS control unit has detected anerror in the system (indicator lamp lights upor flashes), this function will help to find thefault. Depending on the ECAS system inuse, and the type of error, the followinginformation will be displayed:

• Cause and location of fault displayed inclear, e.g. ”Height sensor failure, rearright“, ”Broken cable or impedance toohigh“.

• Indication of how frequently the fault hasoccurred.

• The display ”The failure exists atpresent !“ means that the fault was stillpresent when the diagnostic mode wasselected. There then arises a moredetailed fault finding path with concreteinstructions for fault correction. Anexample is given on page 14.

Upon instruction, the integrated multimeter,together with a measuring adapter, can beused to take electrical readings (e.g.resistance). Actual and preset values willboth be displayed.

Once repair of the fault has been confirmed,it is deleted from the ECU. The fault tracingpath can now be left once all faults havebeen repaired or the ignition switched off.

5.1.2 Component Actuate

1 Raise/Lower 3 Lamp Test2 Central 3/2 valve 4 External controls

Select function! EXIT Ò CONT

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”Component actuate“ permits certaincomponents of the ECAS system to beactivated to check that they are workingproperly.

If a fault is detected when the valves areactivated, an error message will be returnedand the activation remains ineffective (e. g.front axle valve interrupt).

Raising/Lowering

Depending on the type of system/parameters installed, this function can beused to activate the solenoid valves on thefront and rear axles, or the individualbellows. The height sensor readings willappear on the display.

When pressing the ”IN“ key, the respectiveheight sensor value will increase.

When pressing the ”OUT“ key, therespective height sensor value willdecrease.

If no height sensor is connected, a value of”255“ will appear instead. In the event of ashort circuit, ”---“ will appear on the display.

The following maximum of combinations ispossible (full configuration):

• front axle and driving axle right and left• front axle only• driving axle only• driving axle left only• driving axle right only

Pressurizing Valve

The ”pressurizing valve“ (also called thecentral 3/2-way valve) is arranged in linewith the 2/2-way valves and determines

whether ”raising“ or ”lowering“ is inoperation. By pressing ”ON“ it is actuatedindependently from the 2/2-way valves. Theheight sensor readings must not changewhen that key is pushed; if they do thisimplies that a 2/2-way valve is leaking.

Lamp Testing

Depending on the system/parameters inuse, different lamps can be switched on atthe push of a button:

• Signal Lamp• Kneeling Lamp• Low Ride Lamp• High Ride Lamp

When exiting from the routine, all lamps areswitched off.

Actuate Exits

At the push of a key, different exits can beactuated. If any exits have not beenconnected due to the parameters set, therespective location will show ”---“ (actuationis then not possible).

• Exterior Sounder• Dash Sounder• Aux. Tank Control• Wheel Chair Lift Inhibit

5.1.3 Testing and Measuring Values

1 Height sensor 3 Switch test2 Tacho signal 5 Voltages

Select function! EXIT Ò CONT

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Height sensor Readings

The current readings of the height sensorswill be displayed. If no height sensor hasbeen connected, a value of ”255“ will bedisplaced, and if there is a short-circuit, ”0“will appear in the display. If no height sensorhas been fitted due to the parameters set,”---“ will be displayed.

Tacho signal

This function can be used to verify theconnection to the signal output of thespeedometer. For this purpose the vehiclemust be brought to a speed supplying thespeedometer with a signal (faster than1 k.p.h.), e. g. on a roller dynamometer.

Switch Positions

This function can be used to display thestatus of various switches. For this purpose,please actuate the respective switches onthe vehicle.

• Park Brake Active• Service Brake Active• Input Door Position• Shipping Level• Transmission in Neutral• Automatik Kneeling• Manual Kneeling• Recover to Normal• High Ride• Low Ride• Stop

Voltage

The current operating voltage and the valverelay voltages are displayed.

5.1.4 Control Equipmemt Data

1 Parameters 4 Print data2 WABCO data 5 Transfer parameter3 Read Fingerprint 6 Compare parameterSelect function! EXIT Ò CONT

Parameter

Parameters are values set on the ECU for aspecific system and can be displayed usingthe Diagnostic Controller. After entering thePIN under menu item ”special functions“, theparameters can be changed and stored inthe control unit.

WABCO Data

Display of the data stored in the ECAScontrol unit: Type of ECU, type ofequipment, part number, manufacturingdate and ECU software number.

Read Fingerprint

Here you can see who last entered orchanged the parameters. Information isprovided on:

• ID-Code• Company code• Serial number of the program card

Print Data

This is where the contents of the errormemory and/or the parameters can beprinted in a table.

Connection with the printer is established viathe 25-pin socket on the rear and a serialprinter cable. The cable must have a DB 25-

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plug (not socket !) at both ends.

The program works with EPSON FX-compatible printers with a serial interface(RS 232). The transmission parameters ofthe printer must be set to the configurationshown below:

Speed: 1200 BaudData bits: 8

Stop bit: 1Parity bit: X ON / X OFF

Transfer Parameters

Parameters can be transferred from theECU and the Diagnostic Controller, andvice-versa. Thus it is possible to copy theparameters from one ECU into another. Thisfunction requires entry of the PIN under themenu item ”special functions“.

Compare Parameters

This allows the parameters stored in theDiagnostic Controller to be compared withthose in the ECU.

5.1.5 Calibration1 Cal. height sen. 3 Key in data2 Show height sen.

Select function! EXIT Ò CONT

The purpose of system calibration is toeliminate to the largest possible extent anyinstallation and equipment tolerancesresulting from ECAS installation. Calibrationalso has to be repeated when sensors orECU have been replaced.

How is the calibration made?

Using the ”ACTUATE“ key, the vehicle isbrought to the desired normal level (runninglevel). By operating the keys, the actual levelis stored as the normal level. Depending onthe system, further levels (upper and lowerlevel) are calibrated in the same way.

Note: at least the normal level must beknown, for instance as a distancebetween the frame and the axle, inaccordance with the vehiclemanufacturer’s data. It shouldalso be known whether the upperand lower level are the bufferstops, for instance, or whetherother levels must be calibrated.

Error Recognition During System Cali-bration

If faulty calibration is suspected, thecalibration data can be read via menu item”Show height sensor“. The calibration levelsmust show a clear allocation.

Calibration must meet the followingrequirements:

1. The height sensor values must be > 4 counts, and

2. < 255 counts.

3. The upper stop level must be largerthan the normal level (in counts) plustriple tolerance of the index level plus 3counts.

Printer

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4. The lower stop level must be smallerthan the normal level minus double to-lerance of the index level.

Please note: The index level tolerances front/rear are determined byParameters 8/9.

Display Calibration Values

The calibration data stored in the ECAScontrol unit for all three levels are displayed.

Enter Calibration Values

After entering the PIN under ”specialfunctions“, it is possible to manually enterthe calibration data for all three levels.

5.2 MULTIMETER

1 DC voltage 3 Resistance2 AC voltage

Select function! EXIT Ò CONT

The integrated multimeter function permitselectric measurements on the vehicle. Onlythe desired measuring function (directvoltage, alternating voltage or resistance)needs to be selected. The measuring rangeis automatically set by the unit.

Application:Direct voltage: supply voltage on vehicleAlternating voltage:sensor voltageResistance: valves, relays, sensors,

wiring

NOTE: The measuring instrument is designed onlyfor measurings within the vehicle-specific-range (low voltage). It must not be usedbeyond the above-mentioned measuringrange.

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Range Display resolution Accuracy of measuring range. Final value at 20°C

DC-voltage 2.0 volt20.0 volt50.0 volt

0.1 volt0.1 volt0.1volt

± 0.2 %± 0.2 %± 0.2 %

± 0.0 volt± 0.1 volt± 0.1 volt

AV-Voltage 2.0 volt35.0 volt

0.01 volt0.1 volt

± 0.6 %± 0.6 %

± 0.02 volt± 0.4 volt

Resistance 20.0 Ω200.0 Ω

2.0 kΩ 20.0 kΩ 95.0 kΩ

0.1 Ω 0.1 Ω 1.0 Ω 10.0 Ω 100.0 Ω

± 0.3 %± 0.2 %± 0.2 %± 0.1 %± 0.2 %

± 0.1 Ω± 0.1 Ω± 1.0 Ω± 10.0 Ω± 100.0 Ω

5.3 OPTIONS

1 Online help 3 Support ECU´s2 Version

Select function! EXIT Ò CONT

Help Texts

This function permits the operator to obtainadditional operating information. If thisfunction has been activated, more detailedinformation on the programme will appear atsuitable times between the programme'ssteps.

Versions

Thus function shows the data on theController and the Programme Cardsupplied: e. g.:

Hardware : V1 Multimeter: V1Operating system: V3.1 (07.03.1991)Program : V1.00 (09.09.1997)Serial number : 22435 CONT

ECUs for TestingIndicates the WABCO numbers of thecontrol units supported by the program.

5.4 SPECIAL FUNCTIONS

When a code (PIN) is entered in this menu,the ECU’s specific parameters applying tothat vehicle which normally cannot bealtered may be adjusted and transmittedfrom one control unit to another.

Authorization to modify these parametersrequires attending a WABCO trainingcourse.

6 EXAMPLE OF FAULT FIND-ING “MOVEMENT SENSORCABLE BREAK”

The fault finding is explained in this section,using an example.

The ECAS-ECU has stored3 error(s) in the error memory

CONT

This display only appears if more than onefault has been stored.

2/2 valve rear axle left(Broken wire or impedance too high)

The failure exist at present !( 1 x recorded) CONT REPAIR

Fault location (2/2 valve rear axle left) andtype (Broken wire or impedance too high)are displayed. In addition, there is anindication of whether the fault was actuallypresent when the diagnosis started. If thefault occurs several times (eg., anintermittent contact) the frequency isindicated

The fault search is started with the”REPAIR“ key.

Any further faults present are then revealedby using ”CONT“ key.

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Please note: When using the separatekeyboard 446 300 328 0, this keycan be used to return to theprevious error display.

Press ”REPAIR“ to initiate the fault findingpath.

Check height sensor,connecting cable and connectorfor damage.Fault found? NO YES

Check components visually for damage. Iffault has been found, confirm with ”YES“. Ifnot, answer ”NO“ to go on to the next step.

Check resistance: PIN 25 / 27Should be: 100 - 140 Ω ACTUAL: > 1 kΩCheck actual value

LOW OK HIGH

Connect multimeter cables (red and black)to the multimeter sockets on the DiagnosticController. In this example, the test probesmust be plugged into sockets 25 and 27 ofthe measuring adaptor.

Compare the actual value (the measuredvalue) with the specified value. Using theappropriate key, enter whether the actualvalue is lower, within the tolerance range OKor greater than the specified value (on thedisplay illustrated, the actual value is greaterthen the specified value).

Disconnect sensor from connecting cable.Check resistance: PIN 25 / 27SHOULD BE > 45 kΩ ACTUAL: >100 kΩActual value OK ? NO YES

Disconnect the sensor from the cable andmeasure again. After once again comparingthe specified value with the actual value, usethe respective button to indicate whether thespecified value has been achieved (YES) ornot (NO). In this example it has beenachieved.

Sensor faulty!Exchange Sensor.

CONT

Check the parts indicated (the sensor in thiscase) and replace them as required.If there is more than one fault or error, thedisplay would now show the next fault. If allerrors are displayed according to identical orsimilar repair instructions, the following willappear on the display:

No FURTHER errors stored in the ECAS-ECU

CONT

No further errors are stored.

The error memory in the ECAS-ECUhas now been cleared !

CONT

The fault memory is read again for checkingpurposes. The display indicates that no faultis stored in the ECU. Otherwise the faultsearch would recommence.

To quit the fault search path press ”CONT“.

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7. MALFUNCTIONS

no display

black ”bars“

*** LOW VOLTAGE ***

CONT

Cause Remedy

• no voltage supply• undervoltage (less than about 7 volts)

• check all plugged connections• check supply voltage

Cause Remedy

• program card not inserted • push program card in as far as thestop (Contacts overhead).

Cause Remedy

• Supply voltage too low (only duringdiagnostic operation)

• check battery load capacity, andensure adequate supply.

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*** Initialization error ***Switch ignition on!

Check diagnostic connection!CONT

*** Unknown control unit ***Diagnosis not possiblewith this program card!

CONT

*** Communication Breakdown ***Check diagnostic connection

and diagnostic lines. Restart diagnostic procedure. CONT

Cause Remedy

• Insufficient supply voltage (< 18 volts)

• No supply voltage (ignition off)

• Diagnostic lines switched ordisconnected

• Ensure supply

• Switch on ignition

• Check lines and connections forfunction and proper allocation

Cause Remedy

• Wrong ECU connected• Wrong ”WABCO Data“ in ECU or

defective ECU

• Check ECU part number• If right ECU has been,

fitted, replace

Cause Remedy

• Data transmission discontinued during• Diagnostic Line or voltage disconnection

during diagnosis• critical error in diagnostic operation

• Check all connections

• switch on ignition

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*** Error during self-test ***EEPROM of Diagnostic Controller

faultyCONT

Cause Remedy

• EEPROM (Diagnostic Controller's)non-volatile memory of DC defective

• Repair Diagnostic Controller

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WABCOFahrzeugbremsenA Division ofWABCO Standard GmbH

Am Lindener Hafen 2130453 HannoverTelefon (05 11) 9 22-0Telefax (05 11) 2 10 23 57

WABCO