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ECS 2 Student Booklet
ECS 2 Student Booklet
suspension - ECS 2
Buses
Student booklet
Foreword Contents
This training package contains a general 1 Introduction ........................................................ 3
description of the ECS 2 system for two 2 System components ......................................... 4
and three-axle bus variants. Articulated
3 Two-axle system, pneumatic ............................. 5
buses are described using special
figures. 4 Two-axle system, electric .................................. 6
A description of ECS for RHD buses is 5 Electronic control unit ........................................ 7
not included in this training package. 6 Communication, J1939 and J1708 .................... 8
7 Level sensor locations ....................................... 9
8 Level sensor .................................................... 10
9 ECS, Startup .................................................... 11
10 System description, normal height .................. 12
11 System description, ferry lift ............................ 13
12 System description, low level .......................... 14
13 System description, kneeling ........................... 15
14 Three-axle system, articulated bus ................. 17
15 Three-axle system, tag axle ............................ 18
16 System description, kneeling tag axle ............. 19
17 System description, drive axle pressure
increase ........................................................... 20
18 System description, level control when
cornering .......................................................... 21
19 Diagnosis and programming ........................... 22
1 Introduction
ECS 2 - Electronically controlled suspension, version 2
The ECS system on this 2-axle bus comprises a control unit (MID 150), two solenoid valve
blocks and four sensors. If the bus is equipped with ESP (Electronic Stability Program), there
will be a further three bellows pressure sensors. The front axle bellows have only one common
sensor, while the drive axle has a sensor for each bellows.
ECS 2 is fully integrated in the BEA system, which means that its control unit can exchange
information with the other control units in the bus. Other advantages are that diagnostics and
fault codes can be read on the BIC (Bus Instrument Cluster) or with the VCADS-pro
diagnostic tool. All programming of the ECS 2 is done with VCADS-pro via the 16-pin
datalink connector in the bus.
The system is controlled from the levelling control and kneeling switch on the dashboard.
Whenever a function is activated, the white information lamp will come on and a symbol will
be shown on the bus display. Warning signals from the system are shown with yellow or red
central warning lamps on the dashboard and with symbols on the display.
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1 2
4 5
21 1 3
22
1 21 22
2 System components
Two front level sensors (1) and two rear level sensors (2) read off the height of the bus
continuously.
Each of the level sensors sends signals in turn to the control unit (3), which receives all the
information.
The task of the control unit is now to compare the level sensor values with the ones
programmed in the control unit.
When a difference is registered between the level values programmed in the control unit and
the level for various changes in load, the control unit will compensate for the difference by
operating the solenoid valve block (4 and 5), which supplies or releases compressed air as
necessary from the suspension bellows in question (2). When the values stored in the control
unit agree with the ones from the level sensor, i.e. when the control unit detects that the bus is
at its normal height, it is up to the system to maintain this height and monitor any changes in
the bellows height.
This means that the bus is always at a constant ride height.
The system checks its own operation and if a fault is registered, the driver is made aware of it
by the control unit (3) sending data to the dashboard display.
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74a
74 73
73a 73a
77a
77a
77b 71 75 75a
5 33 33
77a
73a 73a
74 73
74a
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A B STOP
i
Low Air Pressure 3 Bar
E A 1L 11:45
AM
12345 km
74a
74 73
73a 73a
77a
77a
77b 71 75 75a
5 33 33
3/5
AM
11:45
12345 km
77a
5H
33.0
2
73a 73a
Time/Distance
230.0
74 73
1
CC
E
km
50 74a
+1V
2.5 _
Analogue Sender Voltage +24 V
Inputs from Voltage Supply Supply
Chassis Height
Senders
Pressure Sensor
Kneeling
Up to 6 Microprocessor and J1939
Kneeling Digital Inputs Memories
Levelling from Switches (RAM, EPROM, EEPROM) J1705
Auxiliary
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STOP
i
50
Time/Distance 3/5
1 2
km 230.0 33.0
E A 5H 11:45
AM
CC 12345 km
74a
74 73
73a 73a
77a
77a
77b 71 75 75a
5 33 33
77a
73a 73a
74 73
74a
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7 Level sensor locations
On the rear axle, the level sensors are located just in front of the front air bellows.
Each of the four level sensors (six on articulated buses) contain a potentiometer.
A lever acts on the potentiometer via a control rod linked to the respective axle.
The air suspension system is used to ensure that the bus maintains its normal height.
When the distance between the chassis and the axle changes, the level sensor will detect this
and send information to the control unit.
The illustration also shows the holes were the sensor is fixed in normal height position. The
level sensors should indicate 2.5 volts in this position
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3.3 V
Max. + 80 mm
0 mm 2.5 V
Min. - 80 mm
1.7 V
8 Level sensor
The part of the housing where the rotating slip contact is mounted can be seen on the right.
The control rod is mounted on the pivot shaft.
On the left is the white plate with two circular contacts.
The level sensor is supplied with 5.0 volts at a point on the outer contact.
Half a turn from there, the voltage is zero.
The slip contact acts as a bridge between the contact surfaces and its position corresponds
to a certain voltage.
The output voltage from the level sensor will be about 2.5 volts in normal position.
An output signal is then sent to the control unit from the inner contact.
The level sensor function can be explained with this principle diagram.
The position of the level sensor during normal driving is shown in the middle.
In principle, the bellows height differs 0 mm from the normal height, which corresponds to
about 2.5 volts in the output signal from the sensor.
The maximum bellows high when “Raising” at the top. The bellows height is approximately 80
millimetres higher than normal height. The output signal changes here to approximately 3.3
volts.
The lower sensor shows the position for minimum bellows height when “Lowering” or
“Kneeling”.
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+30
+15
1
A16 A17
A25
2
3
B914
A11
F26 F1 1
2
A24
3
B915
K3 1
A26 2
3
B29
1
B12 A28 2
3
B30
B2
B5
A8 1
2 4
Y40
B4 A3
3
A6
B10 1
2 4 Y25
A4
3
A5
B3 S915
1
B22 A1 2
3
A15
B1
B11
STOP
B14
i B13
E N N1 11:45
AM A03
A17
12345 km A18
9 ECS, Startup
A16 ECS control unit B914/15 Level sensor, front axle S915 Kneeling switch
A17 Vehicle control unit B29/30 Level sensor, drive axle Y25 Solenoid valve block, drive axle
A03 Display K3 Relay Y40 Solenoid valve block, front axle
When the starter key energises the +15 line, fuse F26 in the fuse box will be activated to apply
a voltage on pin B4 on the ECS control unit (A16), which makes the control unit go into
standby mode. When the engine is started, the pressure in the ECS system is sufficiently high
and the handbrake has been released (or the ECS control is pressed), pin B5 on the control
unit will be activated, which activates relay K3 and thereby energises the control unit via pins
B2 and B12 via fuse F1.
The system now performs a self test and the white information lamp will come on. As long as
the system is working correctly, the lamp will go out after about two seconds.
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42 43
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1 1
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1 1
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21
35
4
3
34
22
21 21
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3 22
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1 1
43 42a 42 41 41 42 43
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19 Diagnosis and programming
As mentioned earlier, it is now possible to read fault codes on the bus display or with
VCADS-pro.
The following operations are currently in VCADS-pro:
Tests,
72885-2 Air suspension control unit input/output signals, test
72880-8 Bogie switch, test
72873-8 External signals to ECS, test
72875-8 Pressure sensor, test
72876-8 Level sensor, test
72877-8 Solenoid valves, test
Calibration:
72881-7 Level sensor, calibration
Programming:
72886-2 MID150 Control unit, campaign
72888-2 MID 150 Control unit, programming
Bellows height adjustment is carried out with VCADS-pro in a similar manner as on earlier
variants but it is now easier to grasp and more logical.
Bellows height adjustment is now performed in two stages:
72876-8 Level sensor, test
72881-7 Level sensor, calibration
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