Central Electronics For Trailer 8150100303t1 PDF

TCE I / II
Central Electronic in
Trailers
815 000 375 3

2nd Edition
This publication is not subject to any update service.

New versions are available in INFORM at
www.wabco-auto.com
815 000 329 3

8150003293
© 2007 WABCO
Vehicle Control Systems
The right of amendment is reserved

Version 002/11.03(en)
8150100303 815 010 030 3
Table of contents
1 Objective
1.1 Concept and Implementation 4
2 General
2.1 External Communication Possibilities 5
2.2 Standards 6
3 Line connection Description
3.1 Functional overview 7
3.2 Electronics 446 122 00. 0 8
3.2.1 TCE top view with connector coding 9
3.3 System connections 10
4 Cable Overview 22
4.1 TCE connection system with connecting cable and PIN connection 15
4.1.1 Overview of plug-in connectors and corresponding cables 15
5 System Functions (acc. to terminals)
5.1 Brake lining wear indicator 37
5.2 Electrical Supply 39
5.2.1 Standardised motor vehicle plug-in connections 39
5.2.2 Supply 40
5.3 Diagnosis mode and warning light function 41
5.3.1 Gateway ISO 7638 / ISO 12098 Trailer data bus 41
5.3.2 warning light function 42
5.4 Freely programmable I/O (special modules) 42
5.4.1 Monitoring functions 42
5.5 Trailer EBS and RGE connection 42
5.5.1 Trailer EBS 42
5.5.2 RGE connection 43
5.6 Rear underdrive protection terminal 44
5.7 Ramp approach help 44
5.8 Paver brake 46
5.9 Electronically controlled air suspension (ECAS) in TCE 46
5.9.1 Components 47
5.9.2 Distance sensor(s) and trailer battery 51
5.10 Pneumatic components and installation instructions 57
6 Commissioning and Diagnosis 82
6.1 Commissioning and Diagnosis 59
6.1.1 The Calibration Process 59
7 PC - Diagnosis 23
7.1 Start- and diagnostic menu 62
7.2 Vehicle definition 63
7.2.1 Chassis & lighting 64
7.2.2 Special parameters 65
7.2.3 ECAS parameters 66
7.3 Special parameters 67
7.4 Axle load calibration 72
7.5 Switch positions / Outputs 72
7.6 Service management 73
7.7 System plate 73
7.8 End Of Line - Protocol 74
8. Annex 77
8.1 Abbreviations 78
8.2 Overview of Outline Drawings 79
2
Objective TCE 1
In modern motor vehicles the onboard information for Integration of trailers into the motor vehicle
drivers becomes more and more extensive. In future system
drivers will be able to read information about truck and
trailer via a display on their dashboard They will get this • Limitation of number of electrical connections
information via data buses, i.e. via communication • Extension of the motor vehicle system functions
connections between different electronics having a CAN to trailers
interface. As a result the connected electronic systems
will be able to exchange, evaluate and further process
information. In future lighting on vehicles will also be Integration of trailer system functions
controlled via data buses and errors will be displayed in
• Level control and lifting axle control
trucks.
• Ramp approach help
Trailers will be included in this exchange of information
via a 7-pin ABS/EBS plug connection acc. to ISO 7638 • Lighting control
and in parallel via a 15-pin plug connection acc. to
• Telematic connection
ISO 12098. In both cases the data connection
corresponds to ISO 11992 part 1. • Additional functions
By a consequent use of the available data connections

between motor vehicle and trailer WABCO creates the
precondition for new innovative vehicle functions while
TCE II
at the same time the number of the required electrical
connections is limited. Modifications due to the introduction of TCE II are
marked in the following text in expanded type.
In summary the objectives are as follows:
System data bus in trailers
• New trailer system functions via data exchange
• More simple realisation of current system
functions
Telematics
TCE
Customer
CAN
functions
Power 7 Pin ISO 7638 Trailer
ECAS Lighting
Data
Power 15 Pin ISO 12098 Diagnosis BUS Brake lining Ramp
wear approach help
IVTM - Integrated
Vehicle Tire EBS modulator
Monitoring system
3
1 TCE Objective
1.1 Concept and Realisation Brake lining wear sensing system with up to six
sensors.
As trailer central electronic TCE enables the
communication between motor vehicle and trailer res. In future reading and processing of analogue and
motor vehicle and trailer systems. Moreover TCE digital information will be possible.
supports the connection of intelligent individual systems e.g.
in trailers to a powerful system like in the towing vehicle. Programmable inputs and outputs for recording of
TCE itself assumes the following electronic and switch positions and analogue values, as well as for
electrical functions: controlling modulators and additional lighting. Indi-
vidual customer modules will be created by
Electrical supply of trailer systems including battery WABCO. These are adjustable via diagnosis.
supply and battery charging equipment. With a trail-
Integrated electronic level control (ECAS) for semi-
er battery diagnostic and ramp operations are pos-
trailers and trailers with one or two level sensors.
sible without a motor vehicle.
Integrated electronic lift axle control with automatic
Motor vehicle - trailer communication for brake and functions as traction help, load dependent lowering
”running gear“ systems (ISO 7638), as well as for / lifting and manoeuvring aid.
general vehicle systems (ISO 12098). ”Running
gear“ means components concerning the driving Ramp approaching help with automatic braking
safety, e.g. chassis, tires, steering and suspension. when backing and approaching the ramp.
Trailer data bus for EBS, running gear, tire systems Electronically secured lighting control and monitor-
and vehicle systems with separate CAN connec- ing with status reports to the motor vehicle.
tions. As a result an exchange of electrical consum-
tire pressure recording and tire pressure monitoring
ers and transmission of information via data
with connected IVTM system.
connection is possible.
Service support (operating hours counter, mileage
Future central diagnostic connection for TCE and counter, electronic notebook, battery hours coun-
all systems connected via CAN. Future diagnosis ter).
from the motor vehicle is provided (e.g. via an on-
board display).
Brake lining wear sensors

ISO 7638 (5/7-pin.)
ABS wheel sensors Ultra sonic sensors
DSENS2 IVTM
WSENS2
TCE
EBS
LA-Ventil
LF-Ventil WSENS1
DSENSEBS DSENS1
BAT
Green warning light

Ultra sonic
Diagnostic plug EBS ABS wheel sensors sensor
ISO 12098 (15/7-pin.)
Diagnostic
Side marking and limiting lights Brake lining wear sensors
plug TCE
Trailer battery
Remote remote control unit
4
General TCE 2
The following data can be transmitted to the motor • Vehicle hitched/unhitched

vehicle provided the respective system is installed: • Battery status
• Axle loads: • Vehicle door open/closed
• Tire pressure values • Operating hours
• Status of vehicle lighting • Mileage
• Distance to ramp • Brake lining wear
• Brake lining wear
• Status of ramp approach help RAH 2.1 External Communication
• Lift axle status Possibilities
Under same conditions as in the motor vehicle the When a telematic system is connected to the TCE
following data can be transmitted to a telematic system: location of the vehicle resp. recall of vehicle specific data
is possible.
• Error in lighting
The following transmission systems can be used:
• Error in RAH function
The Global Positioning System, shortly called
• Vehicle stopped before ramp GPS, enables identification of the vehicle position.
• Service date achieved
The Global System for Mobile Communication
• Vehicle overloaded (GSM) enables wireless data transmission. Thus
• Red /yellow/green warning light remote diagnosis will also be possible in future.
• Axle load
The 'Short Range Communication' is only possible
• Tire pressure values in the yard near a correspond. transmitting / receiv-
• Error in RAH function ing station.
Satellite Satellite
Satellite
Satellite
GPS GSM Tele- Satellite Antenna
Global Positioning System Global System for communications

Mobile Communication Company
(D1, D2, ...)
Mhz
900 z
0Mh
180
Short wave
Communication
(Blue Tooth, DECT, ..)
hz
3M z
43 Mh
868
ISDN
Local Server
Internet Data
(TCP/IP)
Fleet Park
Carrier Management
Management
Services Provider
Carrier owner
Fleet owners WWW Server)
5
2 TCE General
The different systems may be used from trucks with TCE II

trailer connection or separately on trucks and on trailers
Telematic systems in trucks and trailers can retrieve
(e.g. for cooler and service information).
more special information from the TCE II.
Thus the carrier resp. the controller can check for
instance position of the vehicle, temperature of the – event and profile data
cooling system and state of the vehicle. On short term – Service schedule
he may have the vehicle turned around and pick up – Vehicle master data
another load. In case of vehicle problems the controller
can inform a nearby repair shop in advance about the Telematic systems in trailers will automatically be
vehicle state and can care for spare parts if required. informed on additional events
Telematic problems can only be corrected by the – Vehicle door open/closed

respective telematic manufacturer in his service – Vehicle hitched/unhitched
repair shops. – Tire pressure changes
– Service intervals etc.
2.2 Standards
TCE observes the following standards:
– ISO 11992 defines data interfaces – ISO 12098, 15-pin electrical truck-trailer
between motor vehicles and trailers connection for lighting and superstructure
• Part 1: Exchange of digital data between truck • Lighting, conventional lifting and steering axle
and trailer control
• Part 2: Application for brake and ”running gear“ • Electrical supply and data connection for non
of part 1 braking and ”running gear systems“
• Part 3: Application for all further systems of part

1 which were not considered in part 2 – Brake directive ECE-R13
• Part 4: Diagnosis (in preparation) • Supply of braking and running gear equipment
• Cut-off of running gear systems / Functions at
– ISO 7638, 7-pin electrical truck-trailer
electrical overload
connection for braking and running gear
systems
• Chassis, tires and brake
• Use for lighting, superstructure control or similar
is expressly excluded.
6
Line connection Description TCE 3
3.1 Functional overview

Note:
TCE I/II is already fully operational, when except
connection to the motor vehicle only the EBS system is
connected, i.e. Ramp approaching help, ECAS, lighting,
tire pressure control and GPS/GSM do not need to be
installed resp. connected.
Bremse / Fahrwerk
Brake/running gear
Ramp approaching help
Rampenanfahrhilfe
Trailer
Anhänger-
+ batterie
battery
IVTM (Integrated Vehicle Tire Monitor) Operating

Bedieneinheit(en)
EBS System zur Reifendrucküberwachung interfaces
RGE Ein-
input und Ausgangs-
and output
Wegsensor(en)
Path sensors
expansion (control
erweiterung box)
(Bedienbox)
CAN Expansion
RGE CAN-Erweiterung
Bremsbelagverschleißsensoren (Telematic connection)
(Telematikanschluss)
TCE
X11 X21 X31 X41 X51 X61
ISO 7638
ISO 7638(7-pol.)
(7-pin)
X12 X22 X32 X42 X52 X62
NotNicht
belegt
occupied
ISO 12098
ISO 12098(15-pol.),
(15-pin) alternative 24N/S
alternativ 24N/S
X13 X23 X33 X43 X53 X63
X14 X24 X34 X44 X54 X64
Solenoid
Magnetventile
TCE
TCE- valves
warning light
Warnlampe
U Pressure sensors
Drucksensor(en)
Diagnose
Diagnosis
P
U
P
Magnetventil
Solenoid für
valve
Liftachssteuerung
for Lifting axle
control
Verteiler
Superstructure- system
Aufbausystem -CAN Expansion
CAN-Erweiterung
Superstructure -additional lighting,

Aufbau - Zusatzbeleuchtung, Additional
zusätzl. elektr.
Versorgung und Ein-
electrical supply und Ausgänge
and Inputs and outputs
Lighting/superstructure
Beleuchtung systems
/ Aufbausysteme
7
3 TCE Line connection Description
3.2 Electronic 446 122 000 0 /

446 122 001 0 Do not open the electronic remote control unit!
All terminals have to be closed.
All plug in connections are marked with an X and a

number and fitted with special locking clips. To connect
a cable, it is necessary to fold up the locking clip, push
in the plug and then close the locking clip.
Since the terminals are located very close, cables

should be plugged into the electronic in the order from
X11 to X41, X12 to X42, etc.
The front of the electronic consists of coded plug-in

terminals and thus is protected against interchange of
plugs. Unused terminals have to be closed by means of
cap 894 110 139 2.
Installation position:
Fixation to clip by means of cable binder or similar

In order to reverse the
cable back to the vehicle
frame the 45° solution
could be the better one.
Free cable
length to the
point of
fixation
approx.
300 mm
8
X11-Brake lining wear X21-RGE and I/O X31-Ramp approaching X41-Remote remote
help control unit
4 3 2 1 4 3 2 1 4 3 2 1 3 2 1
8 7 6 5 8 7 6 5 8 7 6 5 6 5
X12-ISO 7638 (7-pin) X22-EBS and RGE CAN X32-IVTM and super- X42-Height sensor
structure CAN Battery
4 3 2 1 4 3 2 1 4 3 2 1 4 3 2
7 6 5 8 7 6 5 8 7 6 5 8 7 6
3.2.1 TCE Top View with connector coding
X13-ISO 12098 (15-pin) X23-Lighting X33-Superstructure X43-Solenoid valve

lighting
2
5 4 3 2 1 2 2
5 4 3 1 5 4 3 1
4 3 2 1
Line connection Description
10 9 8 7 6 10 9 8 7 6 10 9 8 7 6
8 7 6 5
15 14 13 12 11 15 14 13 12 11 15 14 13 12 11
X14-Diagnosis and X24-Side marking X34-Tank vehicle X44-Pressure sensor

Warning lamp lighting
TCE
4 3 2 1 4 3 2 1
8 8 7 6 5 8 7 6 5 8 7 6 5
9
3
3.3 System connections • corresponding TCE error (e.g. failure of EBS

modulator)
TCE terminals in numeric order • Switch on of ignition (Pin)
• Interruption of ground connection
1. Row (Pin 3 and 4).
Connection X11 (optional)
Connection for up to six brake lining wear sensors or up Connection X13
to six wear indicators (side wire). Brake lining wear
Motor vehicle connection acc. to ISO 12098
sensors measure the thickness of the brake lining only
(15-pin)
when braking. If wear indicators are installed, thickness
Connection of power supply and lighting lines with data
of the brake lining is actualised in braked or unbraked
connection acc. to ISO 12098 (15-pin). The data bus
condition. For example, if for all indicators 0 Volt will be
contains information on lighting and superstructure
measured, connector break will be identified.
systems.
The Y cable is colour marked. Below the connector there Plug-in pins 10, 11 and 12 are not controlled via PC
is a red resp. blue stripe. The red marked plug belongs diagnosis. These can be parameterize per PC diagnosis
to the right vehicle side, the blue marked plug to the by means of special modules:
left side. Furthermore the axle assignment can be found
behind the plug (L1 = 1 axle on the left).
Pin 10 Brake lining sensor according to
Pin 11 not used ISO 12098 / 1990
Pin 12 Axle lift
Pin 10 not used / steering according to
axle lock ISO 12098 / 2000
Pin 11 Traction help New standard
Pin 12 Axle lift
Standard, if no trailer
Pin 10,
not controlled or lift axle control from
11, 12
the truck desired
Communication truck-trailer acc. to ISO 11992.

Connection X12 Support of trailer recognition via flashing and/or
Motor vehicle connection acc. to ISO 7638 brake light line
Connection motor vehicle connection 7-pins (or 5-pins, Maximum input impedance ≤ 2 kOhm.
if there is no CAN-connection) acc. to ISO 7638 with
truck-trailer data connection acc. to ISO/ 11992 part 1 Sensing/monitoring of lighting lines
and 2.
Under / over voltage recognition of electrical supply
Communication truck-trailer acc. to ISO 11992.
Support of the ABS module in trucks. Truck-trailer data connection acc. to ISO 11992
part 1 and 3 (only with plug connection acc. to
Monitoring of ground connections for break ISO 12098)
Recognition of supply under or over voltage Freely programmable inputs and outputs (special
modules; only with plug connection acc. to
ISO 12098)
Recognition of overload (current and voltage
measurement) and cut-off of running gear
Emergency supply of EBS via brake light, if
Systems
ISO 7638 interface has failed.
Active control of trailer warning light (Pin 5) at:
10
Connection X14 CAN communication via trailer data bus acc. to

ISO 11898 with 250 kBaud.
Diagnostic connection:
Central connection for a diagnostic tool and optional In case of interferences the external CAN data con-
connection for a trailer warning light (green warning nections can be cut off separately.
light).
Information to connection X23/X24/X33/X34
Diagnostic tool connection Trailer lighting
Vehicle lighting left/right is protected separately in the
The electrical power is supplied from ISO 7638
TCE.
Pin 30 (Pin 1). Without a towing vehicle diagnosis
is enabled with a trailer battery. Raising/lowering Note:
per remote remote control unit is also possible in Errors only appear when the lighting is actuated.
the diagnosis mode.
Connect all lights directly to the corresponding cable.
Connection of a warning light Cables must not be shortened or lengthened!
In order to avoid malfunctions during operation, the
An optional green warning light can be mounted to
maximum number of consumers must be observed.
the vehicle.
Thus installation of an additional flashing light to the
The electrical power is supplied from ISO 7638 underdrive protection is not allowed! At any rate the
Pin 30 (Pin 1). manufacturer specifications must be observed.
Following display info is available: Activation, control signal and electrical supply of trailer
Warning light status lighting and extension for superstructure functions are
– flashing: Display of general TCE errors made via plug connection acc. to ISO 12098 (15-pin).
– on: trailer vehicle not within the Electronic control / protection acc. to control sig-
normal level nals via ISO 12098.
– off: vehicle within normal level Error detection for short circuit and interruption,
and without faults or ignition when activated.
switched off.
Connection X23
Standard lighting rear underdrive protection
2. Row (Performance per vehicle side)
Connection X21(optional) TCE I TCE II

Brake light 21 WA 2 x 21 W
Extension running gear / brake
Connection of 24 V-users and/or 24 V-Sensor analysis. Flashing light 21 WA 2 x 21 W
Power is supplied by means of motor vehicle plug Rear light 30 W 30 W
connection acc. to ISO 7638. Functional assignment is (2 x10 W Rear light +
programmable via special modules. 2 x 5 W Identification
light)
Note: Since the supply is made via ISO 7638, only such
systems/components may be connected, which either Reverse
belong to the vehicle brake or belong to ”running gear“ light 21 W 2 x 21 W + 2 x 70 W each
system! Side with freely
The same concerns systems/components referring to adjustable parameters
driving security, e.g. chassis, tires, steering, suspension Rear fog
light 21W 2 x 21 W per side
with parameters
Connection X22 adjustable
Trailer EBS & Running Gear-Systems Position
Connection of Trailer EBS and of an external Running lamps 2 x 10 W 2 x 10 W or LED’s
Gear Systems.
TCE I:
The electrical power is supplied from ISO 7638 Pin 2 x 70 W reverse lights can be connected either to the
(pin 1) with electronic overload protection. 24 V outputs of X23 pin3 or to X33 pin 3. However, the
11
load must only be connected to one of the plugs. A relay Electrical supply via separate 8 V power genera-
is required between reverse light and the respective pin. tion in the TCE, supplied via motor vehicle connec-
tion acc. to ISO 7638
Sending / receiving signal lines separately for each
X23 X33 or X23 X33
sensor
Reverse light
The Y cable is colour marked. Below the connector there
is a red resp. blue stripe. The red marked plug belongs
to the right vehicle side, the blue marked plug to the
left side.
70 W 70 W 70 W 70 W
TCE II
Now also the connection of LED lamps to TCE II is
possible! Moreover the light failure recognition was
improved.
Via PC diagnosis the sensibility of the parameters for
cable break recognition can be set.
Standard setting: In the case of a failure of one of two
connected lights (e.g. brake light), this will not be Connection X32 (optional)
detected as an error.
Tire pressure monitoring IVTM & general vehicle
Extended parameters: At this setting the failure of the systems
light with same or higher electrical power is detected. Connection tire pressure monitoring and general vehicle
systems (no braking and running gear systems) with
No break recognition with light emitting diodes. CAN data connection.
Connection X24
General vehicle systems
Side marker lamp Electrical supply for IVTM via ISO 7638; electrical
The Y cable is colour marked. Below the connector there supply of general vehicle systems via ISO 12098
to the right vehicle side, the blue marked plug to the In the case of an error in the CAN communication,
left side. it will be cut off separately (CAN connection)
Remark: Due to the electrical supply separated from
ISO 7638, the connected systems are not subject to the
overload cut-off for non braking systems.
Connection X33 (optional)

Additional lighting for superstructure like position
side marking lamps (25 W)
lamps and extensions for the superstructure
Connection of 24 V-users and/or 24 V-Sensor
analysis.
3. Row Functional assignment for freely programmable in-

puts and outputs is done via special modules of the
Connection X31 (optional) PC diagnosis.
Ramp approaching help (RAH)

Connection of two ultrasonic sensors for measuring the
reverse distance between vehicle and ramp at backing.
12
TCE II X42: 1 or 2 level sensors (without temperature

Following functions may be activated via special compensation) and trailer battery
modules. X43: Valves for 1 or 2 point control as well as lift
(Line) axle control
normal level switch I / II PIN 7 white - green
Spring brake actuator X44: 1 or 2 pressure sensors for axle load calcula-
(ISO 11992) Pin 8 grey tion
Door open / closed Pin 9 white - blue
Hitched / unhitched Pin 10 white - black
normal level III / Unloading- Pin 13 red
Connection X41
level switch
Control elements
Outputs are short circuit resp. overload protected As maximum two control elements can be connected.
electrically, or by self reversion. Short circuit against By pushing button IRCU the TCE is activated (Pin 30 or
earth/power or a break is detected as error. 2 x 70 W battery mode!).
reverse lights can be connected either to X23 Pin 3 or
X33 Pin 3. However, the load must only be connected to For connecting two control elements a Y cable has to be
one of the plugs. used. The Y cable is colour marked. Below the
(See pict. connection X23, page 12). connector there is a red resp. blue stripe. The red
Back lights (21 W) marked plug leads to the second control element,
the blue marked plug to the first control element.
By means of a further plug connection between trailer
and tractor installation of a control element in the motor
Connection X34 (optional) vehicle is possible.
Additional lighting for tank vehicles TCE I : A cable length of 25 m must not be exceeded.
For high level lighting carriers with TCE II : Cable lengths up to 60 m are permissible.
Brake lights (21 W)

Flashing lights (21 W)
Back lights (21 W)
The Y cable is colour marked. Below the connector there
to the right vehicle side, the blue marked plug to the
left side.
Connection X42
Height sensor(s), trailer battery
A maximum of 2 height sensors can be connected to the
TCE. Here different configurations of the height sensor
arrangement are possible. This configuration is set by
means of parameters.
4. Row
If only one height sensor is connected to the TCE, height
Electronic level control sensor 2 is active via the prefabricated cable In case of
Electronic level control with following equipment : two height sensors the plug marked with a blue
stripe is to be connected to the rear axle resp. to the
X41: 1 or 2 remote control units (IRCU; Intelligent left height sensor (1st HS). The plug marked with a
Remote remote control unit) red stripe is to be connected to the front axle resp.
13
to the right height sensor (2nd HS). Otherwise Connection X44

incorrect error display !!!
Pressure sensor
TCE I:
A maximum of two pressure sensors can be connected
to the TCE. The 1st pressure sensor (1st PS) always
has to be connected. Among others is is used for axle
load calculation for the trailer EBS system.
TCE II
If a battery with battery box 446 156 090 0 (without For the TCE II system it is not compulsory under certain
batteries), 446 156 094 0 (incl. batteries) is installed onto circumstances (dependent on the connected EBS
the trailer, connect the prefabricated cable only. modulator) to connect one or two pressure sensors.
Only lead gel accumulators may be used in the battery
box. WABCO recommend use of Panasonic LC - The required pressure sensor signal is directly sent from
R127R2PG lead gel accumulators, 12 V, 7,2 A. the EBS modulator (D version) to the TCE II. If the ECAS
is to actuate a lateral or a drawbar trailer control, a
If another box is used for the batteries, the plug of the pressure sensor can be connected to the TCE.
prefabricated cable has to be cut-off. The blue lead must
be connected to a 10 A fuse and the brown lead with the If two pressure sensors are to be installed, the red
earth pole of the battery. marked cable end is to be connected to the pressure
sensor (2nd PS) to the right resp. to the front axle.
The blue marked cable end is to be connected to the
pressure sensor (1st PS) to the left resp. to the rear
axle.
Connection X43
Valves 1-/2-point-control, lift axle valve
Levelling valves for semitrailers with 1- or 2- point
control (right/left), for drawbar trailers 2 point control
(front/rear). Lift axle valve(s) for one or two separately
controlled lift axle(s).
The plug marked blue leads to the lift/lower valve. The
plug marked red to the 1st lift axle valve.
14
Cable overview TCE 4
4.1 The TCE plug in system with
connection cable and the
Pin assignment
Cables are supplied in different lengths. In the
following the different cable types and lengths are listed
and in column ”remark“ among others the components
to be connected. (Outline drawing see appendix).
4.1.1 Overview on terminals and the

respective cables:
Terminal X11:
Brake lining wear indicator
TCE-Electronic
TCE-Elektronik
X 11 X 21 X 31 X 41 X 51 X 61
X12 X 22 X 32 X 42 X 52 X 62
X 13 X 23 X 33 X 43 X 53 X 63
X 14 X 24 X 34 X 44 X 54 X 64
449 874 ...0

Used see: Remark
Cable Drawing
449 874 010 0 449 874 000 0 Limit value indicator,
L=1m one axle 2x1
for PAN 17: 12480038
for PAN 19-1:
12480036 **)
Plug Assignment Plug Assign-

R1-2 / L1-2 A ment
R-1 „A“ +5 V 1 Brake lining
wear R
R-1 „C“ Ground 2 +5V
L-1 „A“ +5V 3 Ground
L-1 „C“ Ground 4 Brake Lining
wear L
Distributor not measurable, since with W network
**) Knorr brake to BPW axle 32480057
15
4 TCE Cable overview
449 884 ... 0

Used see: Remark
Cable Drawing
L1 = 1 m two axles 2x2
L2 = 0.4 m for PAN 17: 12480038
for PAN 19-1:
12480036 **)
Plug Assignment Plug Assignment

R1-2 / L1-2 A
R-2 „A“ +5V 1 Brake lin. w. R1
R-2 „C“ Ground 5 Brake lin. w. R2
R-1 „A“ +5V 2 +5V
R-1 „C“ Ground 3 Ground
L-1 „C“ Ground 3 Ground
L-1 „A“ +5V 2 +5V
L-2 „C“ Ground 4 Brake lin. w. L1
L-2 „A“ +5V 8 Brake lin. w. L2
Used see: Remark

449 894 ... 0 Cable Drawing
L1 = 1 m three axles 2x3
L2 = 0.4 m for PAN 17: 12480038
449 894 043 0 for PAN 19-1:
L =1m 12480036 **)
1
L2 = 1 m

R1-3 / L1-3 A
R-3 „C“ Ground 5 Brake lin. w. R2
R-2 „C“ Ground 2 +5V
R-1 „A“ +5V 3 Ground
R-1 „C“ Ground
L-1 „A“ +5V
L-1 „C“ Ground 3 Ground
L-2 „A“ +5V 2 +5V
L-3 „A“ +5V 8 Brake lin. w. L2
16
Terminal X12: Supply cable
TCE-Electronic
TCE-Elektronik
X 11 X 21 X 31 X 41 X 51 X 61
X12 X 22 X 32 X 42 X 52 X 62 Used see: Remark

Cable Drawing
X 13 X 23 X 33 X 43 X 53 X 63
449 172 090 0 449 172 000 0 ABS/EBS
X 14 X 24 X 34 X 44 X 54 X 64
L=9m Power supply
449 172 100 0 cable
L = 10 m ISO 7638 (7-pin)
from
449 172 ... 0 449 172 120 0
semi trailer
L = 12 m
to motor vehicle
449 172 130 0
L = 13 m
449 172 150 0
L = 15 m
Plug A Plug B Plug Plug Colour Assignment

A B
1 7 red Pin 30
2 6 black Pin 15
3 4 yellow Ground 15
4 5 brown Ground 30
5 3 white Warning light
6 2 white/green CAN H
7 1 white/brown CAN L
449 272 ... 0
Used see: Remark

Cable Drawing
449 272 090 0 449 272 000 0 ABS/EBS
L=9m Supply cable to
ISO 7638
(7-pin) from
449 133 ... 0 drawbar trailer
to motor vehicle
Used see: Remark

Cable Drawing
449 133 120 0 449 133 000 0 ABS/EBS
Plug A Plug B
L = 12 m Power supply
cable with
bayonet connection
17
449 135 ... 0

Used see: Remark
Cable Drawing
449 135 005 0 449 135 000 0 Power supply cable
L = 0,5 m for semitrailer with
bayonet terminal
Plug A Plug B
Plug Plug Colour Assignment
A B
1 7 red Pin 30
2 6 black Pin 15
4 5 brown Ground 30
6 2 white/green CAN H
449 333 ... 0
Used see: Remark

Cable Drawing
Plug A Plug B
L = 0,3 m for semitrailer /
drawbar trailer
with bayonet
counterpart to
449 133 ... 0

A B
449 335 ... 0 2 2 white/green CAN H
5 5 brown Ground 30
6 6 black Pin 15
7 7 red Pin 30
Plug A Plug B
Used see: Remark
Cable Drawing
L = 11 m for semitrailer
with bayonet
449 335 140 0
counterpart to
L = 14 m
449 135 ... 0
18
Terminal X13: Supply
TCE-Electronic
TCE-Elektronik
X 11 X 21 X 31 X 41 X 51 X 61
X12 X 22 X 32 X 42 X 52 X 62
X 13 X 23 X 33 X 43 X 53 X 63
X 14 X 24 X 34 X 44 X 54 X 64 Used see: Remark

Cable Drawing
L = 10 m Adapter from 15 pin
449 113 120 0 to 2 x 7 pin (24 N/S)
L = 12 m may be used
449 113 ... 0
449 113 140 0
L = 14 m

A B
1 8 pink Backing light
2 3 blue Rear fog light
3 9 orange Supply Ub
Plug B Plug A (pin 30-2)
4 4 white/red Ground (GND 3)
5 white Ground (GND 2)
6 15 white/brown CAN_Low
7 14 white/green CAN_High
8 10 grey Brake lining wear
9 12 white/blue Lifting Axle
10 11 white/black Pressure sensor
11 5 black Back light left
12 6 brown Back light right
13 7 red Brake light
14 2 green Turn signal right
15 1 yellow Turn signal left
449 121 ... 0 Used see: Remark

Cable Drawing
449 121 120 0 449 121 000 0 Power supply
L = 12 m cable
for Aspöck
2 x 7 pin to 15 pin
Terminal
19
449 123 ... 0

Used see: Remark
Cable Drawing
449 123 120 0 449 123 000 0 Power supply
L = 12 m cable
for
drawbar trailer
449 311 ... 0
Used see: Remark

Cable Drawing
449 311 120 0 449 311 000 0 Power supply
L = 12 m cable
for Hella
Plug adapter
Plug B Plug A
Plug assignment see page 19
20 2
Terminal X14: Diagnosis
TCE-Electronic
TCE-Elektronik
X 11 X 21 X 31 X 41 X 51 X 61
X12 X 22 X 32 X 42 X 52 X 62
X 13 X 23 X 33 X 43 X 53 X 63
Used see: Remark
X 14 X 24 X 34 X 44 X 54 X 64
Cable Drawing
449 672 030 0 449 672 000 0 Diagnostic cable
L=3m with terminal
449 672 ... 0 for connection cable
449 672 040 0
L=4m 446 300 329 2
( 6 m long ) to
449 672 060 0
Diagnostic Interface
L=6m
Set 446 301 021 0
449 672 080 0
L=8m
449 672 090 0
Plug B Plug A L=9m
Plug Plug Assignment

A B
1 4 K wire
2 1 Supply
3 7 Ground
Used see: Remark

449 644 196 0 449 644 000 0 Y diagnostic cable
L1 = 10 m with terminal
L2 = 4 m for connection cable
446 300 329 2
( 6 m long ) to
Diagnostic Interface
Set 446 301 021 0
and warning light
cable with green
warning light:
446 105 521 2 (cable
with plug
441 032 312 2)
Plug A

A B
4 Ground
8 warning light
1 4 K wire
2 1 Supply
3 7 Ground
Plug B
2 21
Terminal X21: I/O Typ, Erweiterung
TCE-Electronic
TCE-Elektronik
X 11 X 21 X 31 X 41 X 51 X 61
X12 X 22 X 32 X 42 X 52 X 62
X 13 X 23 X 33 X 43 X 53 X 63
X 14 X 24 X 34 X 44 X 54 X 64
Used see: Remark

449 902 050 0 449 902 000 0 RGE
L=5m special functions
449 902 070 0
L=7m
Plug A
Plug Colour Assignment
A
1 white/green Supply 2
2 purple Digital inlet 2
3 yellow Digital inlet 1
4 green Supply 1
5 brown Ground
6 black Digital inlet 4
7 white Digital inlet 3
8 white/brown Ground
449 903 ... 0

Used see: Remark
Cable Drawing
449 903 050 0 449 903 000 0 for ECAS control box
L=5m 446 156 000 0
449 903 090 0
L=9m
Plug B Plug A

A B
2 4 Inlet 2
3 3 Inlet 1
4 1 Supply
5 2 Ground
7 5 Inlet 3
22
Terminal X22: Cable to Trailer EBS
TCE-Electronic
TCE-Elektronik
X 11 X 21 X 31 X 41 X 51 X 61
X12 X 22 X 32 X 42 X 52 X 62
X 13 X 23 X 33 X 43 X 53 X 63
X 14 X 24 X 34 X 44 X 54 X 64
Used see: Remark

Cable Drawing
449 399 020 0 449 399 000 0 to EBS trailer
449 399 ... 0 L=2m modulator
480 102 002 0

A B
Plug B Plug A 1 5 Ground
2 7 Supply
5 1 CAN L
8 2 CAN H
Used see: Remark

Cable Drawing
449 394 346 0 449 394 000 0 to EBS trailer
449 394 ... 0 L1 = 2 m modulator
L2 = 15 m 480 102 002 0
449 394 366 0 and RGE with CAN
L1 = 2 m (telematic)
L2 = 18 m
449 394 386 0
L1 = 2 m
L2 = 20 m
Plug B Plug A

A B
1 5 Ground
2 7 Supply
5 1 CAN L
6 2 CAN H
3 brown Ground
4 red Supply
open
7 blue CAN L
8 yellow CAN H
23
Terminal X23: Standard lighting
TCE-Electronic
TCE-Elektronik
X 11 X 21 X 31 X 41 X 51 X 61
X12 X 22 X 32 X 42 X 52 X 62
X 13 X 23 X 33 X 43 X 53 X 63
X 14 X 24 X 34 X 44 X 54 X 64
Used see: Remark

Cable Drawing
449 392 075 0 449 392 000 0 at the underdrive
L = 7.5 m protection
449 392 ... 0 (lighting carriers of
Hella, Aspöck, etc.)

A B
1 10 pink Turn signal right
2 13 blue Turn signal left
3 15 orange Supply
Plug A 4 12 white/red Ground
Plug B
5 9 white Back light left
6 1 white/brown Brake light right
7 5 white/green Brake light left
8 11 grey Rear fog light right
9 3 white/blue Rear fog light left
10 6 white/black Back light right
11 14 black Special modules
12 2 brown Back light right
13 7 red Position light
(Britax) right
14 8 green Position light
(Britax) left
15 4 yellow Back light left
449 391 ... 0

Used see: Remark
Cable Drawing
449 391 120 0 449 391 000 0 at the underdrive
L = 12 m protection
(for Aspöck lighting)
24
Terminal X24:
Side marking lights
TCE-Electronic
TCE-Elektronik
X 11 X 21 X 31 X 41 X 51 X 61
X12 X 22 X 32 X 42 X 52 X 62
X 13 X 23 X 33 X 43 X 53 X 63
X 14 X 24 X 34 X 44 X 54 X 64
449 904 ... 0
Used see: Remark

Cable Drawing
449 904 190 0 449 904 000 0 with terminal (Pritax)
L1 = 4 m e.g. side marker flat
L2 = 4 m band of Hella, etc.
449 904 253 0

L1 = 6 m
L2 = 6 m
Plug B
Plug A
Plug Plug Plug Colour Assignment
A B D
5 1 brown Side marking
lights right
6 2 black Ground
7 1 black Ground
Plug D 8 2 brown Side marking
lights left
25
Terminal X31: Ultrasonic sensors
TCE-Electronic
TCE-Elektronik
X 11 X 21 X 31 X 41 X 51 X 61
X12 X 22 X 32 X 42 X 52 X 62
X 13 X 23 X 33 X 43 X 53 X 63
X 14 X 24 X 34 X 44 X 54 X 64
449 704 ... 0

Used see: Remark
Cable Drawing
449 704 253 0 449 704 000 0 two
L1 = 6 m ultra sonic sensors
L2 = 6 m 446 122 400 0
Ram buffer
449 704 295 0 897 534 510 2
L1 = 8 m
L2 = 8 m
Plug D
Plug A
Plug Plug Plug Assignment

A B D
1 4 Signal inlet 2
2 1 Supply 8 V
3 2 Ground
5 3 Signal outlet 2
Plug B 2 1 Supply 8 V
3 2 Ground
4 3 Signal inlet 1
8 4 Signal outlet 1
26
Terminal X32:
Tire pressure monitoring IVTM and
superstructure system connection
TCE-Electronic
TCE-Elektronik
X 11 X 21 X 31 X 41 X 51 X 61
X12 X 22 X 32 X 42 X 52 X 62
X 13 X 23 X 33 X 43 X 53 X 63
X 14 X 24 X 34 X 44 X 54 X 64
449 302 ... 0

Used see: Remark
Cable Drawing
449 302 015 0 449 302 000 0 IVTM
L1 = 1.5 m (Integrated Vehicle
Tire Monitor)
Plug B Plug A

A B
3 3 Ground
4 7 Supply
7 1 CAN L
8 6 CAN H
449 301 ... 0

Used see: Remark
Cable Drawing
449 301 150 0 449 301 000 0 superstructure
L1 = 15 m systems
CAN extension
(General vehicle
systems, e.g. chillers,
global positioning
system GPS, no
braking or running
gear systems)

A
1 brown Ground
2 red Supply
5 blue CAN L
6 yellow CAN H
27
449 304 ... 0

Used see: Remark
Cable Drawing
449 304 098 0 449 304 000 0 Tire pressure
L1 = 15 m monitoring and
L2 = 1.5 m superstructure
system CAN
extension
Plug A Plug Plug Colour Assignment

A B
1 brown Ground
2 red Supply
open
5 blue CAN L
6 yellow CAN H
3 3 Ground
4 7 Supply
Plug B 7 1 CAN L
8 6 CAN H
28
Terminal X 33: Extended lighting
TCE-Electronic
TCE-Elektronik
X 11 X 21 X 31 X 41 X 51 X 61
X12 X 22 X 32 X 42 X 52 X 62
X 13 X 23 X 33 X 43 X 53 X 63
X 14 X 24 X 34 X 44 X 54 X 64
449 393 ... 0

Used see: Remark
Cable Drawing
449 393 075 0 449 393 000 0 additional lighting
L = 7.5 m e.g. for luggage
449 393 085 0 superstructure
L = 8.5 m
449 393 100 0
L = 10 m
Plug A

A
1 pink Analogue inlet 2
2 blue Analogue inlet 1
3 orange Supply
4 white/red Ground
5 white 24 V outlet
6 white/brown Analogue inlet 3
7 white/green normal level switch I/II
8 grey Spring-type brake actuator
9 white/blue Vehicle door open/closed
10 white/black Hitched / unhitched
11 black C3 Outlet
12 brown Digital inlet 6
normal level III/
13 red
Unloading Level
14 green Back light right
15 yellow Back light left
29
Terminal X 34: Additional lighting
TCE-Electronic
TCE-Elektronik
X 11 X 21 X 31 X 41 X 51 X 61
X12 X 22 X 32 X 42 X 52 X 62
X 13 X 23 X 33 X 43 X 53 X 63
X 14 X 24 X 34 X 44 X 54 X 64
449 604 ... 0

Used see: Remark
Cable Drawing
449 604 316 0 449 604 000 0 Additional lighting
L1 = 10 m e.g. for tank vehicles
L2 = 10 m
Plug Cable Colour Assignment

A marking
Plug A 1 yellow Back light right
5 green Turn signal right
RED
2 brown Ground
6 red Brake light right
4 yellow Back light left
8 green Turn signal left
BLUE
3 brown Ground
7 red Brake light left
30
Terminal X 41: ECAS Remote remote
control unit IRCU
TCE-Electronic
TCE-Elektronik
X 11 X 21 X 31 X 41 X 51 X 61
X12 X 22 X 32 X 42 X 52 X 62
Used see: Remark
X 13 X 23 X 33 X 43 X 53 X 63 Cable Drawing
X 14 X 24 X 34 X 44 X 54 X 64 449 635 050 0 449 635 000 0 one ECAS remote
L=5m remote control unit
449 635 070 0 IRCU
L=7m (Intelligent Remote
449 635 ... 0 remote control unit)
446 056 202 0

A B
Plug B Plug A 1 3 yellow Clock
2 1 red Supply
3 2 brown Ground
5 4 green Data 2
Used see: Remark

Cable Drawing
449 634 232 0 449 634 000 0 two ECAS remote
449 634 ... 0 L1 = 5 m remote control
L2 = 5 m units IRCU
449 634 239 0 (Intelligent Remote
L1 = 18 m remote control unit)
L2 = 5 m 446 056 202 0
449 634 278 0
L1 = 15 m
L2 = 7 m
449 634 316 0
Plug D
L1 = 10 m
L2 = 10 m
Plug A
A B D
1 3 yellow Clock
2 1 red Supply
3 2 brown Ground
5 4 green Data 2
1 3 yellow Clock
Plug B 2 1 red Supply
3 2 brown Ground
6 4 green Data 1
31
449 654 ... 0

Used see: Remark
Cable Drawing
449 654 232 0 449 654 000 0 one ECAS remote
L1 = 5 m remote control unit
L2 = 5 m IRCU
449 654 252 0 and
L1 = 5 m one ECAS control
L2 = 6 m box
Plug D

Plug A A B D
1 3 yellow Clock
2 1 red Supply
3 2 brown Ground
5 4 green Data 2
1 3 yellow Clock
2 1 red Supply
Plug B 3 2 brown Ground
6 4 green Data 1
2 6 Pin 15
449 655 ... 0
Used see: Remark

Cable Drawing
449 655 050 0 449 655 000 0 one ECAS control
L=5m box
Plug B Plug A Plug Plug Colour Assignment

A B
1 3 yellow Clock
2 1 red Supply
3 2 brown Ground
5 4 green Data 2
2 6 Pin 15
32
Terminal X42:
Height sensor and battery box
TCE-Electronic
TCE-Elektronik
X 11 X 21 X 31 X 41 X 51 X 61
X12 X 22 X 32 X 42 X 52 X 62
X 13 X 23 X 33 X 43 X 53 X 63
X 14 X 24 X 34 X 44 X 54 X 64
Used see: Remark
Cable Drawing
449 814 ... 0 449 814 228 0 449 814 000 0 one height sensor
L1 = 3 m 441 050 012 0 and
L2 = 5 m battery box:
449 814 272 0 446 156 090 0
L1 = 5 m without 7.2 AH lead
L2 = 7 m gel battery.
446 156 094 0 with
449 814 292 0
batteries
L1 = 5 m
Plug A L2 = 9 m
Plug B

A B D
2 1 height sensor
3 2 Ground
6 1 blue battery switch
7 2 brown Ground
Plug D

Cable Drawing
449 804 228 0 449 804 000 0 two height sensors
L1 = 3 m 441 050 012 0 and
L2 = 5 m one battery box
446 156 090 0 without
7,2 AH lead gel
battery.
446 156 094 0 with
Plug D batteries
Plug A Plug Assignment Plug Colou Assignme

B, D, E A r nt
D1 Height 2 Height
Sensor 2 Sensor 2
Plug B D2 Ground 3 Ground
B1 Height 4 Height
Sensor 1 Sensor 1
B2 Ground 3 Ground
E1 Battery 6 blue Battery
Plug E
E2 Ground 7 brown Ground
33
Terminal X 43:
Solenoid valve, 1-/2 point control
TCE-Electronic
TCE-Elektronik
X 11 X 21 X 31 X 41 X 51 X 61
X12 X 22 X 32 X 42 X 52 X 62
X 13 X 23 X 33 X 43 X 53 X 63
X 14 X 24 X 34 X 44 X 54 X 64
Used see: Remark
Cable Drawing
449 483 015 0 449 483 000 0 Solenoid valve,
L = 1.5 m 472 900 053 0
449 483 025 0 472 900 055 0
449 483 ... 0 L = 2.5 m 472 880 030 0

A B
Plug B Plug A 8 1 Pressurizing
4 4 Supply
7 2 Rear axle right
3 3 Rear axle left

Cable Drawing
449 484 085 0 449 484 000 0 Solenoid valve,
L1 = 1.5 m with
L2 = 1.5 m lifting axle control
449 484 127 0 472 905 114 0 with
L1 = 2.5 m transverse throttle
L2 = 2.5 m or
472 905 111 0
Plug D without transverse
throttle
Plug A

A B, D
3 D1 Rear axle left
4 D4 Supply
7 D2 Rear axle right
Plug B 8 D3 Pressurizing
4 B4 Supply
5 B3 lifting axle raise
6 B1 Lifting axle lower
34
449 485 ... 0

Used see: Remark
Cable Drawing
449 485 106 0 449 485 000 0 Solenoid valve,
L1 = 1.5 m Raising/Lowering
L2 = 1.5 m Valve
472 900 055 0
Spring returned
lifting axle valve
Plug B 463 084 030 0
Plug A

A B, C
3 B3 Rear axle left
B4 Supply
4
C2 Supply
5 C1 lifting axle raise
Plug C
7 B2 Rear axle right
8 B1 Pressurizing
449 494 ... 0

Used see: Remark
Cable Drawing
449 494 025 0 449 494 000 0 Solenoid valve,
L1 = 1.5 m with 2 separate
L2 = 0.4 m lifting axles
472 905 114/111 0
and second lifting
axle solenoid valve
463 084 010 0
Plug D
Plug A

Plug E B, D, E A
D2 Lifting Axle 2 H 1 Lifting axle 2 raise
D1 Supply Supply
E1 Rear axle left 4 Supply
E4 Supply Supply
E2 Rear axle right 5 Lifting axle 1 raise
Plug B
E3 Pressurizing 6 Lifting axle 1 lower
B4 Supply 3 Rear axle left
B3 Lifting axle 1 7 Rear axle right
raise
B1 Lifting axle 1 8 Pressurizing
lower
35
Terminal X 44: Pressure sensor
TCE-Electronic
TCE-Elektronik
X 11 X 21 X 31 X 41 X 51 X 61
X12 X 22 X 32 X 42 X 52 X 62
X 13 X 23 X 33 X 43 X 53 X 63
X 14 X 24 X 34 X 44 X 54 X 64
Used see: Remark

Cable Drawing
449 823 ... 0 449 823 020 0 449 823 000 0 one pressure
L1 = 2 m sensor
441 040 007 0 (old)
441 040 015 0 (new)*
441 040 013 0 (new)
Plug B Plug A * with seal

A B
5 3 Pressure sensor
6 1 Supply
7 2 Ground
449 824 ... 0
Used see: Remark

Cable Drawing
449 824 108 0 449 824 000 0 two
L1 = 3 m Pressure sensors
L2 = 2 m 441 040 007 0 (old)
441 040 015 0 (new)*
441 040 013 0 (new)
Plug D
Plug A * with seal

A B, D
5 B3 Pressure sensor 2
6 B1 Supply
7 B2 Ground
6 D1 Supply
Plug B
7 D2 Ground
8 D3 Pressure sensor 1
36
System functions TCE 5
5.1 Brake lining wear indicator

-> Limit value indicator
Terminal X11
Advantages:
Retrofittable and not expensive
High degree of lining utilisation due to:
1. Skew wear compensation
Brake lining wear sensor
2. Separate sensoring of both lining sides (no safety
allowance required for differential and disc wear)
3. On signal the residual thickness of lining is 2 mm.
Installed brake lining wear sensor
Schematic Z section through the brake

(PAN 19-1)
Slide wire
Brake disc
Residual lining 2 mm
Report point
19 mm Cable abraded
Wear dimension Residual lining 2 mm
37
5 TCE System functions
A maximum of up to six final value indicators (a wire cycles (total of 16 flashes), when the ignition is switched
integrated in the brake lining) can be connected to TCE on.
for monitoring the state of wear of the disc brakes. The
WARNING SIGNAL SEQUENCE WARNING LEVEL 2
driver is warned via the ABS warning light shortly before
and when the wear limit value is achieved.
ON
When at a limit value indicator the wire is abraded in

braked mode, there will occur a short circuit to the OFF
ground (ground connection between brake and frame
Ignition TIME
required) and warning level 1 is activated. At the first ON
warning level the ABS warning light flashes 4 times
(1 cycle) when the ignition is switched on.
The warning is interrupted when the vehicle's speed

WARNING SIGNAL SEQUENCE WARNING LEVEL 1 exceeds 7 km/h. In case of system faults the ABS
warning light is activated continuously!
ON
At the same time, the corresponding information is
OFF
transmitted via the motor vehicle/trailer interface and
can be shown on the display there.
Ignition TIME
ON The system automatically detects when new limit value
indicators are fitted after replacement of the brake lining.
All warning levels are deactivated after a time of 2
When at a limit value indicator the wire is abraded for a minutes (switch on the ignition for at least 2 minutes).
certain time, warning level 2 is activated. At the second The warning light extinguishes not earlier than the next
warning level the ABS warning light flashes 4 times 4 ignition ON.
Wear indicators are available for following axles
Axle manufacturer SAF BPW
Brake type WABCO WABCO Knorr Knorr

PAN 19-1 PAN 22-1 SB 6-7 SB 6-7
PAN 19-1 plus
TDB-/ TDB 0678 361-094-02 TDB 0605 TDB 0568

Test protocol No. TDB 0749 361-106-02 TDB 0606 TDB 0568
361-107-02 TDB 0590 TDB 0632
The TDB Test protocol No. can TDB 0591
be found on the reference plate
of the axle
Per axle
one set is required
12 999 755 VT 12 999 797 12 999 792 12 999 792
Wear indicators are always packed
axlewise
38
5.2 Electrical supply The table delivers an overview of the plug connections
acc. to their application, the second shows the contact
5.2.1 Standardized motor vehicle plug in assignment.
connections
Terminals X12 and X13
Designation Standard Remark

ABS/EBS ISO 7638 Supply and data communication 1)
Plug connection Trailer EBS, Running Gear Systems
15 pin connection ISO 12098 Lighting, trailer supply, special functions
and data connection 1)
24 N ISO 1185 Alternatively to ISO 12098, lighting and
trailer supply
24 S ISO 3731 Alternatively to ISO 12098, lighting, special functions
and trailer supply
1) Data connection acc. to ISO 11992
Figure: Standard motor vehicle-trailer - plug in connections

Terminal X12 Terminal X13
ISO
ISO7638
7836(ABS
(ABS7-pin)
7-polig) I S O /D IS 1 2 0 9 8 (15-pin)
(1 5 -p o lig ) (1994) (2001)
Solenoid control valve
Magnetregelventile ++ 1 F a hsignal
Turn rtric h tuleft n g s a n z e ig e r lin k s 1
Electronic supply +
Elektronikversorgung + 2 F a h rtric
Turn signal right h tu n g s a n z e ig e r re c h ts 2
Electronic supply -
Elektronikversorgung - 3 N e b e ls
Fog rear light c h lu ß le u c h te 3
Solenoid control valve
Magnetregelventile -- 4 M
Ground a s s e 4
Warning device
Warneinrichtung 5 S c hlight
Rear lu ß licleft
h t lin k s 5
CAN High
CAN High 1) 1) 6 S c hlight
Rear lu ß licright
h t re c h ts 6
CAN Low 1) B re m
Brake light s le u c h te 7
CAN Low 1) 7
R ü c k
Backing lightfa h r le u c h te 8
1)1)
Data connection acc.
Datenverbindung to ISO/DIS
nach 11992
ISO/DIS11992 S tro m v e rs
Power supply (pin 30) o r g u n g ( K l. 3 0 ) 9
B re m s b e la
Brake lining wear sensorg v e rs c h le iß s e n s o r 1 0 Steering axle lock
Pressure sensor spring b. actuator 1
D r u c k s e n s o r F e d e rs p e ic h e r 1 traction help
L iftaaxle
Lifting c h s p position
o s itio n 12
Axle lift
M a s s e
Ground data line D a te n le itu n g e n 13
D a te
Data line #1n le itu n g # 1 14 CAN High
D a te
Data line #2n le itu n g # 2 1 5 CAN Low
Terminal X13 can be connected via an adapter 15 pin to 2 x 7 pin. However, then no
then CAN connection between motor vehicle and trailer as well as axle lifting and
traction help function.
ISO1185 (24N) ISO3731 (24S)

Masse
Ground 1 31/1 Masse
Ground 1 31/1
Schlu
Rear ßlicht
light leftlinks 2 58L/2 nicht
not belegt
connected 2 58L/2
Fahrtrich
Turn signaltung
leftsanzeiger links 3 L/3 R ü ckfahrleuchte 3 L/3
Backing light
B rem sleu chte 4 Stromversorgung 4
Brake light 54/4 Power supply (pin (K
30)l. 30) 54/4
Fahrtrichtungsanzeiger rechts 5 R/5 S teuerung über M
Control via ground asse 5 R/5
Turn signal right
Schlußlicht rechts 6 58R/6 Stromversorgung
Power supply (pin (K
15)l. 15) 6 58R/6
Rear light right
Steuerung Anh ängerbrem 7
Control trailer brake valve sung 7 54g/7 N ebelschlußleu
Fog rear light ch te 54g/7
39
5.2.2 Supply Control of TCE battery supply as well as of con-

nected trailer systems (incl. diagnostic tool) for di-
Three types of supply are supported: agnostic and ramp operations (electronic levelling).
Moreover a connected tire pressure monitoring
• Standard supply ISO 7638 (X12) with Pin 30
(terminal X32) is permanently supplied via the trail-
(Pin 1), Pin 15 (Pin 2) for Braking and Running
er battery if a motor vehicle supply is missing.
Gear Systems, ISO 12098 (X13) with Pin 30
(Pin 9) for all other systems. Charging equipment with electronic protection for
trailer batteries up to 10Ah approx.
• Battery supply – Ramp operation:
only TCE level control function Sensoring of electrical motor vehicle supply lines.
• Battery supply - diagnostic mode: Emergency supply of EBS via ISO 12098 brake
only braking and RG systems light and ground.
Central load dump protection for all TCE compo- Dependent on the supply voltage the functional
nents and connected external systems. conditions are complied acc. to the following table.
Table: TCE functional conditions 1)
No. Designation Supply voltage Functional condition

Below range of service UB < 16 V Restricted functionality, if necessary, cut off
1
voltage of certain switching parts
Below 16 V ≤ UB < 18 V No control of levelling and lift axle valves, no
2
under voltage threshold electrical supply of RGE systems
3 Service voltage range 18 V ≤ UB ≤ 32 V All system functions active
Over voltage threshold UB > 32V Restricted functionality, if necessary, cut off
4
exceeded of certain switching parts.
1. Remark: The functional conditions of systems connected may be different.
5.2.2.1 Standard supply • Connection of a diagnostic tool to connection X14.

The TCE is supplied via the plug connections acc. to Here activation of the TCE can follow via one or
ISO 7638 (X12) Pin 30 (Pin 1) and Pin 15 (Pin 2). The several points at the same time.
respective ground connections GND15 (Pin 3) and
GND30 (Pin 4) are monitored for breaks. The service voltage is measured and monitored for
falling below resp. exceeding the under resp.
In case of a failure of ground lines GND15 or GND30 the overvoltage threshold. In case ISO 7638 (X12) Pin 15
trailer warning light is activated. (Pin 2) is cut in without ISO 7638 Pin 30 (Pin 1), this is
detected as failure and the trailer warning light
(ISO 7638, Pin 5) in the motor vehicle is activated.
TCE is switched on via
• cut in ISO 7638 Pin 15 (Pin 2) 5.2.2.2 Emergency supply of EBS
• Data transfer from motor vehicle via ISO 7638 or In case of a failure of supply ISO 7638, the TEBS is
ISO 12098 additionally controlled via the brake light supply
• Operation of remote control unit (IRCU) for level ISO 12098. The TEBS is supplied only as long as the
control brake is operated. This function is designed for
emergency cases only. At any rate the ISO 7638
• Signal at special plug pins connection has to be plugged.
40
5.3 Diagnostic mode and warning responses, the TCE is responsible.

light function; connection X14 5.3.1.2 TCE Diagnosis
If a communication is initialised from a connected test For parameter settings and system start-up incl.
device via the K line, EBS and all other modules with calibrating a WABCO training is obligatory! For
connected consumers are switched on. To prevent an registration and training schedule please phone to
overload, the supply mode ”battery supply - diagnostic + 49 511 922 2971.
mode“ is communicated via the trailer data bus to the
modules and systems supplied. Functions which are not Diagnosis of TCE and systems connected is effected via
actually to be checked shall be cut off from the systems the diagnostic tool connection X14. The TCE diagnostic
during this type of supply. This kind of operation is functions correspond to the VDA recommendation and
automatically terminated if there is no communication the WABCO directive for KWP2000. They include the
between test device and TCE or if the diagnostic mode following tasks:
is explicitly closed by the test device.
– Parameter settings, system start-up
– Fault storage and access to fault storage
5.3.1 Gateway ISO 7638 / ISO 12098 – System check / Service

Trailer data bus Diagnosis is possible only by means of a PC. This
applies to end line tests at the vehicle manufacturer as
The TCE represents a bidirectional gateway between
well as for troubleshooting in the workshop.
data connection of ISO 7638 resp. ISO 12098 and the
CAN trailer data bus. Messages received will be filtered
complying with a programmed table and be transmitted A diagnosis can be performed, when the TCE is
to the connected trailer systems / components. The supplied via the 7 pin + 15 pin plug connection to the
messages will be processed in dependence of event trailer. Performance of the diagnosis is also possible
and time. Messages from the motor vehicle which are to during the battery mode. However, in this battery mode
be transmitted to the trailer data bus and messages from the connection to the diagnostic tool will be interrupted
the trailer bus which are to be transmitted to the motor 5 minutes after the last query in order to save battery
vehicle, will be processed event controlled. Messages to power. A renewed diagnosis is enabled by connecting/
be sent from TCE to the motor vehicle or on the trailer disconnecting the diagnostic plug to the vehicle.
data bus are processed simultaneously. During the diagnostic mode the vehicle can be raised
resp. lowered by means of the service unit. Only in the
When messages on both data interfaces are received at calibrating mode this is impossible.
the same time the interface to the motor vehicle has
priority. Messages to send are respectively queued up System requirement
on both data connections according to their priorities.
– Remarkbook/Laptop or PC
– Pentium processor
– 32 MB main memory, colour display 800x600
5.3.1.1 Gateway diagnostic tool Trailer data
bus – approx. 10 MB free hard disc memory
The TCE represents a bidirectional gateway between 3 ½" floppy disc drive
data connection of ISO 14230 resp. ISO 12098 and the – COM interface (9-pin connection) for the
CAN trailer data bus. Messages received will be filtered WABCO Diagnostic Interface
complying with a programmed table and be transmitted
to the connected trailer systems / components. The – Windows 95/98, Windows NT
messages are processed in dependence of events.
When messages on both data interfaces are received at Software order No.
the same time, the interface to the motor vehicle has 446 301 680 0 German
priority. Messages to send are respectively queued up
on both data connections according to their priorities. In addition a diagnostic interface and a diagnostic
For maintaining the communication with the test device connector cable are required for the connection between
resp. for keeping the timing especially in case of delayed electronic and computer.
41
446 301 021 0 Diagnostic Interface Set (incl. a Operating voltage monitoring
diagnostic interface + diagnostic cable The operating voltage is measured and in case of being
to the PC) above or below the operating voltage range, the change
to the respective mode will be effected.
446 300 329 2 trailer diagnostic cable, length 6 m
(Connecting cable between diagnostic Overload monitoring / cutting-off
interface + external round diagnostic In accordance with the directives to ECE-R 13 power
plug terminal). and operating voltage are monitored via plug connection
ISO 7638 and in case of an overload, electrical non
5.3.2 Warning Light Functions braking systems / consumers are cut off.
A green system warning light can be connected to the
TCE. It indicates the following states:
Warning light status

– flashing: Display of general TCE errors 5.5 Trailer EBS and RGE
– on: trailer vehicle not within the
normal level
Connection Terminal X22
– off: vehicle within normal level 5.5.1 Trailer EBS
and without faults or ignition
The Trailer EBS works independently from the TCE and
switched off.
disposes of an own PC diagnostic tool which is operated
via the diagnostic connection. For more information
please see our brochure ”Trailer EBS - electronically
5.4 Freely programmable I/O controlled brake system in trailer vehicles“,
(Special modules) terminal X21 Wabco print 815 010 019 3 and 815 010 020 3.
and X33
Important
Implementation of vehicle and equipment specific TCE I:
functions. In this connection the trailer modules 480 102 002/005 0
TCE II have to be used.
At terminal X33 various ”special modules“, whose
parameters are to be set via the PC diagnosis, can be TCE II
released. Using TCE II the EBS axle modulator 480 102 015 0 (D)
should be connected. However, TCE II also works in
• Reading of analogue and digital information connection with previous modulators 480 102 002/005
• Control of electrical equipment 0. In this case special requirements of the pressure
sensor connection have to be observed.
• Transfer and transmission of information via CAN
data connections Air bellows pressure
connection 5
P U P U
• Receiving and processing of CAN control data
EBS modulator EBS modulator
After a reset all inputs / outputs are highly resistive. All 480 102 002/005 0 480 102 015 0
inputs / outputs are resistant to short circuits due to
supply voltage and ground.
Air bellows pressure
P U P U connection 5
5.4.1 Monitoring functions EBS modulator

480 102 002/005 0
EBS modulator
480 102 015 0
Watchdog (program running time monitoring )

Function of the micro controller resp. software
processing is monitored by an external watchdog.
If another EBS trailer modulator is used, this will be
Memory test reported as error on the TCE when the system is started.
Parameter memory and ROM memory are cyclically
tested during operation.
42
Reason: The values of the pressure or axle load sensors EBS

and of the brake lining wear sensors are already • The sequence for system start up must be first EBS
supplied from the TCE electronic. and then TCE.
Remarks for the system start up 5.5.2 RGE Connection

EBS modulator When in the diagnostic mode the connection ”additional
function“ is activated, the trailer data bus and the voltage
• Modifications resp. differences between TCE I and supply are released.
TCE II:
EBS-Modulator to be used for TCE I The connection may be used for activation of a telematic
480 102 002 0 (C) system or of a brake or chassis related system. The
480 102 005 0 (C+RSS) electrical power is supplied via the TCE.
EBS-Modulator to be used for TCE II
480 102 015 0 (D0).
• Voltage supply cable to be connected to TCE ECU.
• Create new set of parameters for modulator. Here

”electr. switch output 1+2“ has to be clicked as ”not
available“. The brake lining wear indicator as ”not
existing“.
43
5.6 Rear underdrive protection terminals.

To terminals X23 and X24 the standard lighting is connected
Connecting plan 15 pin connector

7 Chamber light left 1 Brake light right red
7 Chamber light right
2 Rear and identification light right brown
Pin No.: Function Colour 3 Rear fog light left blue Colour
4 Rear and identification light right black Pin No.: Function
31 Ground white white
5 Brake light left red 31 Ground
54 Brake light red red
6 Backing light right purple 54 Brake light
Rfl Backing light purple purple
7 Position lamp right white/black Rfl Backing light
58L Rear light black black
8 Position lamp left white/blue 58L Rear light
Bli Flashing light yellow yellow
9 Backing light left purple Bli Flashing light
Nsl Rear fog light blue blue
10 Turn signal right green Nsl Rear fog light
11 Rear fog light right blue
12 Ground white
13 Turn signal left yellow
14 Special Functions grey
15 Permanent plus orange
Main supply
Rear light left Rear light right
Position lamp left Special Functions Permanent plus Position lamp right
e.g. from HELLA, status 03.2000 chassis (backed position for sensor installation).
Only the standard lighting may be connected.
Connection of higher loads may cause cutting off the
TCE! For certain purposes the ramp approach help can be cut
off for a short time. Cut off is done by operating the brake
after having shifted into the reverse gear. The positions
5.7 Ramp approach help lamps are switched off after 30 sec. brake operation.
Terminal X31 The ramp operation help remains in cut off mode during
the complete backing. By shifting into a forward gear
TCE I: and renewed shifting into the reverse gear the system is
The stopping distance is firmly adjusted to 40 cm. activated anew.
on
TCE II Reverse gear
off
Here adjustability by means of setting a respective
parameter between 20 cm and 100 cm is enabled on
(preadjusted reference value): 40 cm ). Brake
30 sec.
The installation position of the ramp approach help
sensor can be adjusted between 0 and 100 cm. Position
on
light
This requires a functional test in order to prevent
”reflections“ of the supersonic sensor from the vehicle
44
The ramp approach help supports the driver at backing light on), provided the vehicle stands still with a
to loading ramps. Here in interaction with the WABCO minimum distance (set parameter) from an obstacle.
trailer EBS the trailer vehicle is automatically braked When the vehicle has stopped in front of the ramp, the
before contacting the loading ramp in order to prevent brake is vented after ca. 3 seconds. By this the driver is
damages to vehicle and ramp. The braking pressure of permitted to contact the ramp with the buffers, if
the WABCO trailer EBS is defined by the TCE necessary. Provided the ramp is equipped with a
dependent on vehicle speed and the ultrasonic-wise shelter, the semitrailer is first braked shelter oriented.
measured distance to the ramp. After 3 seconds the brake is released and the position
Provided the speed is below 7 km/h the brake is lamps are switched off. The ramp approach help
activated only for final stopping of the vehicle in front of continues to be active, however, no automatic braking
the ramp. In case the vehicle is > approaching the ramp will occur. The help function is activated for the second
with 7 km/h, the ramp approach help induces short time after having passed the shelter and a distance of
brake impulses to remind the driver of the excess speed. > 40 cm is measured. The position lamps will again
To avoid damages at loading and unloading due to begin to flash. Monitoring of the speed limitations and of
relative movements of the vehicle towards the ramp, a all brake relevant parameters is done by the trailer EBS.
distance between trailer and ramp is adhered. Reading of the backing light signal and specifying of the
brake pressure set point is done by the TCE.
Remark: This function is restricted to distance
recognition towards a loading ramp and does not Activation of the ramp approach help is communicated
release the driver from his care to be directed during to the driver via a flashing of the position lamps. In
backing. relation to the distance towards the ramp the flashing
frequency is increased and changes to a permanent
Precondition for the function is a voltage supply of the light when the vehicle stands still.
trailer via the 5 or 7 pin electrical plug connection to
ISO 7638 and a backing light signal (corresponding to a Flashing frequencies:
shifted reverse gear) from the motor vehicle via the slow flashing (1 Hz) > 3 m distant
15 pin plug connection to ISO 12098. Beyond that there
are no further requirements regarding the equipment of slow flashing (2 Hz) 3 m - 1 m distant
the towing vehicle.
rapid flashing (4 Hz) < 1 m distant
The ramp approach help is activated only at a vehicle In parallel to this an information will be transmitted to the
halt (v <= 2.5 km/h) by shifting the reverse gear (backing plug connection acc. to ISO 7638 via the CAN data
Detail ”rubber buffer“
Ram approach help sensor

Measure ”X“ until here!
Outer edge
Rubber buffer
from approx. 5 m distance

recognition of ramp
Underdrive protection
45
interference and can be displayed to the driver in the Installation position of the ramp approach help
motor vehicle. In case of position lamps being off, the sensors
system is not active.
In the PC diagnosis is indicated under ”Structure and
Via CAN line of ISO 12098 the distance to the obstacle
lighting“, whether a ramp approach help is installed. For
can be evaluated.
this distance ”X“ between outer edge of ramp approach
help sensor (until WABCO logo) and farest vehicle edge
has to be indicated in cm.
Radiation angle of ultrasonic sensors
5.8 Paver brake the known ECAS systems by means of the PC diagnosis
resp. the PC start-up.
TCE II is able to perform the function of a paver brake
without additional pneumatic valves. The corresponding
TCE II
special module will be installed and the input brake Due to new parameter settings the ECAS function
pressure can be adjusted between 0 and 2 bar. can be set out of service. A lift axle control is
nevertheless possible!
At X13-8 resp. ISO 12098 PIN 10 +24 V are necessary
and at X33-13 the trigger contact of the modules is
connected (to ground). For activation the driver will Function
operate the activation switch in the cabin via ISO 12098 The vehicle level is continuously recorded from the TCE
and start the dump action. As soon as the dump will lift, via max. 2 height sensors. In case of the occurrence of
the contact at X33-13 will be connected to ground and deviations from the set reference level, TCE will activate
TCE starts pressurising the brake pressure as set by the respective solenoid valves. At this - each according
parameters. to the level - the airbellows will be pressurized or vented
until the nominal level will be achieved. Dynamic spring
This function can be activated only at standstill. movements will not be respected and do not cause a
At v > 12.5 km/h the paver brake is deactivated and will response of the control.
be reactivated only after stand still of the vehicle.
Differences to the known ECAS
5.9 Electronic Levelling (ECAS) in 1. As a maximum 2 height sensors of TCE are
connectable. The TCE height sensor has the part
the TCE, Terminals X41, 42, 43 number 441 050 012 0.
and X44 Other height sensors are not permitted!
In TCE the electronic level control (ECAS) with one or Note:

two height sensors as well as the electronic lift axle All ECAS functions of our well known ECAS systems are
control with automatic functions as traction help and described in detail in our brochure ”Electronic levelling
load dependant lowering are integrated. Setting of control for air suspended trailer vehicles (ECAS),
parameters was significantly simplified in comparison to functional and installation instructions“
46
This brochure can be ordered For loading and unloading the vehicle level can be
under part No. 815 010 025 3 from WABCO. adapted to the loading ramp. The new reference level is
automatically kept constant during the following loading
5.9.1 Components and unloading phase.
In the TCE the 4 terminals X41 to X44 are reserved for Manual discharge of the lifting axle is always possible by
ECAS components. pressing the lifting axle button at empty or part loaded
vehicles, provided the admissible axle load is not
5.9.1.1 Control elements exceeded.
at terminal X41 / X21 By using a switch or IRCU 2 further normal levels can be
Part numbers adjusted.
446 056 202 0 IRCU - Intelligent remote remote
The control element enables the user to change the
control unit
nominal level and the lifting axle position, to activate the
446 156 000 0 Control box only for
traction help and to preselect the desired vehicle level
TCE terminal X21
(not with 446 156 xxx 0). The vehicle level can be
446 156 010 0 IRCU control box raising/lowering
adjusted with the remote remote control unit only while
the vehicle is either stationary or moving at a speed
lifting axle function
which is slower than a selected speed limit. This limit
speed is communicated to the ECU as part of the
Drawbar vehicles
procedure for setting the parameters.
As maximum 2 control elements can be connected to
X41 and one control box to X21. TCE is activated by IRCU Mode
pressing a button as far as terminal 30 is active or in in Even with cut off ignition (IRCU mode) changes of the
the battery mode. By means of a further plug connection nominal values and control operations can be
between trailer and tractor the installation of a control performed. For this the electronic being supplied from
element in the motor vehicle is possible. pin 30/battery can be ”waked up“ (not possible with ...)
116 0 / ... 117 0).
TCE I : A cable length of 25 m must not be exceeded. The ”wake up“ is possible either by means of a remote
TCE II : Cable lengths up to 60 m are permissible. control unit or by means of a control box.
Control element 446 056 116 0 and 446 056 117 0 must For the time being the endurance of the IRCU mode was
not be applied. They both do not cut off automatically, set to 15 seconds. This complies with the active time of
thus a trailer battery - as far as terminal 30 (motor the TCE, waiting for user commands per remote control
vehicle) is active - resp. the motor vehicle battery will be unit or control box. Every time a button is pressed, the
discharged. ”Stand-by“ mode is not possible interval is started anew.
Remote control unit / box Wake up of the TCE

By pressing one of the buttons „STOP“, „ “ „ “ or
TCE II
normal level on the control box resp. by pressing any
If a control box is connected to X21, special parameter button of the remote control unit the system can be
settings are required for this. If a control box is ”waked“.
parameterized but not connected, TCE changes to
failure mode. When one of the above mentioned buttons is operated
for at least 100 ms, the system is ”waked“ and the ECAS
The control boxes 446 156 000 0 warning lamp is switched on - as far as installed. First
010 0 the self test is running (present duration 5 seconds).
011 0 Only after termination of that test the buttons are
012 0 accepted and the ECAS solenoid valves are operated.
dispose of a warning light. In case of a failure of TCE the
warning light flashes resp. lights permanently when the A raised lifting axle resp. a released trailing axle will be
vehicle is outside the normal level. When this control box lowered or loaded automatically.
is retrofitted in TCE I, the warning light comes on at
button operation. This is no indication for a failure.
Deceleration time in IRCU mode
Using a control element the nominal level of the vehicle During the IRCU mode the level is adjusted after
can be changed below a preset speed rate. Assembly of expiration of the ”Control delay during standstill“.
several control elements to the chassis is possible. Changes of nominal level are started without delay.
47
Tolerances in IRCU mode operation, respectively reducing or increasing the

The ”normal“ tolerances as existing at switched on load on the trailing axle.
ignition are effective.
– Activating the traction help function
Termination of IRCU mode – Preselection of a normal level from up to 3 possible
All adjustments will be breaked and the stand-by normal levels and adjustment of the actual - means
operation will be terminated, if one of the following preselected - normal level
conditions is fulfilled:
– Storing of up to 2 preference (i.e. memory) levels
– Start of stand-by mode by pressing the STOP
and setting these levels when the appropriate
button of IRCU for at least 2 seconds
button is pressed briefly.
– Switch on of ignition
– Adjustment of the vehicle to STAND-BY operation
– Duration (15 seconds) expired.
– Instantaneous interruption of any raising or
5.9.1.2 Remote remote control unit lowering processes by pressing the STOP button.
Remote control unit 446 056 202 0 is installed on the The remote control unit can perform only functions,
vehicle preferably inside a box. Contact with the ECU is which are available on this unit and whose parameters
established via a spiral cable and a terminal on the are set in the TCE. That means for instance that on a
vehicle frame. vehicle without lifting axle the button for lifting axle
Various remote control units are available depending on function is not applicable.
the type of system used. The following picture shows the
remote control unit 446 056 202 0. The functions of this The layout of the remote remote control unit shows three
RCU are: lamps (referred to as check lamps) in its upper row
which inform the user which axle has been preselected
– Lowering and lifting of the superstructure via all for the adjustment to be made.
axles simultaneously, via front or rear axle resp.
axle assembly separately and with the
Below these are the 3 preselect buttons in a row. Each
corresponding system design separated to right
of these buttons is located below the corresponding
and left side.
check lamp. If one of these buttons is pressed, the
– Raising and lowering of the lifting axle and thereby corresponding check lamp will come on, indicating to the
switching off or on any fully automatic lifting axle user that the preselected axle can be actuated.
Indication lamp front axle
Indication lamp rear axle

Preselection button front axle
or left vehicle side at
existing right/left control Indication lamp lifting axle
Memory level 2 – button

M2 Preselect button rear axle
or right vehicle side
Memory level 1 – button at existing
M1 existing right/left control
RAISE button Preselect button lifting axle
normal level button

LOWER button
Stop button
48
A renewed operation of the preselection button causes Traction help

also the belonging check lamp to go out. It now makes By means of button ”M1“ and preselected lifting axle the
evident to the user that the input mode of the remote traction help is activated ( only when parameters are set
remote control unit is interrupted. Any activation by for lifting and trailing axle automatic!). Traction help is
using the remote control unit is not possible. For any terminated by pressing the STOP button or by exceed-
changes of the reference level for the whole of the ing the parameterized speed. Observe specifications
vehicle, the preselect buttons for front and rear axles of axle manufacturers.
must be pressed. There upon both corresponding check A traction help cannot be started with the remote control
lamps must be on to indicate that the system is ready for unit.
actuation.
Manoeuvring aid
IMPORTANT! Usually any input using the remote
By pressing button ”M1“ and preselected lifting axle the
control unit begins by preselecting the desired
traction help is activated ( only when parameters are set
axle(s) and ends by cancelling the input mode.
for lifting and trailing axle automatic!). The manoeuvring
aid is interrupted by pressing the STOP button or when
raising and lowering of the chassis v > 10 km/h. A manoeuvring aid cannot be started with
By pressing the ”RAISE“ or ”LOWER“ buttons, the ECU the remote control unit.
is given a changed reference level for the superstructure
above the preselected axles. Now without any delay the Normal level
superstructure changes its distance to the axle as long If respective parameters are set the normal levels I, II
as the respective button is pressed. Releasing the and III can be adjusted via the remote control unit (only
button terminates the change of the nominal value, the with RCU 446 056 202 0). When a remote control unit
latest nominal value at releasing the button is regarded is connected, no 3rd normal level must be
as new nominal value. parameterized per remote control unit. In order to
adjust another normal level the remote control unit must
Raising and lowering the lifting axle be activated. For that press the button for axle selection.
Briefly pressing the ”RAISE“ or ”LOWER“ buttons after Subsequently another normal level can be selected via
preselecting the lifting axle causes the lifting axle to be a button combination. This level is active as long as a
raised or lowered and the weight resting on the trailing new normal level will be selected per remote control unit.
axle increased or decreased. Raising, i.e. increasing the By pressing the FN button the new selected normal level
weight, is only possible provided the defined permitted will be set in future again and again. With the following
maximum pressure in the main axle's supporting button combinations you may select the active normal
bellows is not exceeded. Lowering the lifting axle resp. level:
increasing the weight on the trailing axle causes cut off Press the green normal level button and at the same
of a lifting / trailing axle automatic with possibly set time
parameters.
– button ”M1“ for normal level I
Switching automatic lifting axle operation on – button ”M2“ for normal level II
and off
As described above, automatic operation of the lifting/ – the button ” “ for normal level III
trailing axle can be switched off by pressing the To avoid undesired normal level activations,
”LOWER“ button provided at least one lifting/trailing axle parameters should not be set for various normal
had been automatically raised/relieved due to a light levels.
load. Switching off automatic lifting axle operation
means that the lifting axle which before was raised Memory Levels
automatically now is lowered, or the load on any relieved (only with remote control unit 446 056 202 0)
trailing axle will be increased. If a certain vehicle level is to be set frequently when the
vehicle is being loaded or unloaded, that level can be
Automatic operation is switched on again by means of:
stored and set again as often as required at the press of
- Remote control unit a button.
(Preselection lifting axle, button ”lifting“).
In case of a semi automatic lifting axle with set By pressing the ”STOP“ button and then also pressing
parameters the lifting axle is lowering in either the ”M1“ or ”M2“ memory button, an existing
dependence on the pressure. Raising of the reference level can be stored as the preferential (or
lifting axle is enabled by remote control unit or memory) level.
switch. The stored values aren't lost when the ignition is
- Switch on and off ignition switched off. They apply to the whole of the vehicle, i.e.
49
when retrieving it, it is sufficient to simply preselect one Pressing several buttons simultaneously
axle. By then briefly pressing the corresponding memory If several buttons are pressed simultaneously and these
button, i.e. ”M1“ or ”M2“, the vehicle's superstructure is do not represent a plausible combination, no command
immediately brought to the stored level. will be accepted when a specific level change is started,
and the STOP function is performed instead.
The remote control unit does not have any memory
levels. Simultaneous operation of both control units
If both control units are operated simultaneously, the
Stop stop function will be activated. Further targeted height
By pressing the ”STOP“ button, all level control changes are possible after that only when meanwhile no
processes are stopped immediately, the present level further buttons are operated.
being recognised as the reference level. This function
primarily permits the operator to cancel any automatic Disconnecting the remote control unit
changes in the vehicle's level (memory, normal level) if If during the raising / lowering action the control unit will
he considers that the continuation of that control process be disconnected, the stop function is performed.
would be hazardous.
Priority
If the STOP button is held down and the ignition
If an unloading level function has been activated and a
switched off, the vehicle is put into STAND-BY mode.
raise/lower command is given via the remote control
unit, the command from the remote control unit will be
executed.
Speed dependency
Functions ”Raising and lowering of superstructure“ and The remote control unit has a high priority within the
”Memory level“ are available only at standstill as well as system. So, if the control function has failed, the
below a selectable speed rate. Control functions started vehicle's superstructure can be taken to a reasonable
below this speed are brought to completion even if the level by using the ”Raise“ and ”Lower“ functions to allow
speed is exceeded whilst they are in progress. the vehicle to be driven to the workshop.
Manual lifting / trailing axle control via RCU is accepted
by the electronic only below a further speed rate to be
preselected. 5.9.1.3 ECAS - Control unit for semitrailers
with lifting axle: 446 156 000 0 for X21
Stand-By Mode
The stand-by mode is a service mode which keeps the
normal level constant with switched off ignition for a
preselected period (max. 63 hours).
Stand-by can be activated the following way:

When the ignition is switched off with operated stop
button, a stand-by mode is activated for a preselected
time.
When TCE is supplied only via pin 30 or via a battery,
the stand-by mode can be activated by operating the
stop button for more than 2 seconds.
A raised lifting axle resp. a released trailing axle will be

lowered or loaded automatically.
The deceleration time in the stand-by mode is set by
means of a parameter in the PC diagnosis. As well the
tolerances during the stand-by mode. Thus the air The control box 446 156 0xx 0 can be assembled
consumption with frequent significant load changes (due directly on the vehicle frame. Assembly position
to driving with a fork lift) is minimized must be in such a distance from the lifting axle that
Stand-by mode is terminated by switching on the the user must not be injured at a lifting axle
ignition, two times operation of a RCU button, if the operation.
stand-by time is over, or at the occurrence of a failure.
50
In addition to the known control box also IRCU boxes sensors are connectable, at which only height sensor
are available whose functions are equal to that of the 012 0 is allowed to be connected.
control box.
446 156 010 0 IRCU control box Raise / Lower

Lifting axle function
446 156 012 0 IRCU control box raising/lowering Sensor lever
Drawbar vehicle
Functions of control unit and control box: Sensor shaft
Lever guide
Height sensor with a lever

fastened to the height sensor shaft
Raising/Lowering X X The height sensor 441 050 012 0 continuously picks up

Raising/lowering of X (X) any changes in the height of the superstructure. It is
lifting axle designed for installation on the vehicle frame.
Traction help X –
Manoeuvring aid X – The measuring principle of the height sensor is inductive
which means the position (distance) of an anchor inside
normal level II, III X –
a coil is measured. An externally initiated rotary motion
Memory Level X – via a lever is transformed inside the sensor into a linear
Stop X X movement of the anchor into the coil without clearance,
Stand-by X X following the crankshaft drive principle. The 'dipping
movement' of the ferro-magnetic armature into the
Wake up at X X
stationary coil causes a phase displacement between
Ignition off
current and voltage. The ECU measures the
Normal level X X displacement of the current and converts it into counts.
TCE II: The height sensor cannot be functionally tested by using

The warning lamp of control box 446 156 000 0 is a voltage meter. If a check of the height sensor is
activated: Failures detected by the TCE are necessary, the coil resistance of the height sensor can
indicated by flashing of the warning lamp. In case be checked. The resistance must be approx. 120 ohm.
the present vehicle level is outside the normal level The coil's induction is evaluated more than 50 times a
(FN), this is indicated by a permanent light of the second by a special evaluation circuit within the ECU.
WL. In case a control box is assembled, it should be The ECU monitors the proper function.
abandoned from the 3rd drinving level per control
element in order to avoid maloperations. The height sensor is located on the vehicle's frame near
the axle whose air suspension bellows are to be
5.9.2 Height sensor(s) and trailer controlled. The master gauge for the holes used for
battery at terminal X42 fastening the sensor is identical to that of a conventional
air suspension valve.
5.9.2.1 Height sensor
Steered (front) axles usually have one height sensor
Part numbers:
(1-point control) above the centre of the axle. (Leading)
441 050 012 0 Height Sensor
axles with a steady contact to the ground, can have one
446 156 090 0 Battery box without battery
or even two height sensors fitted; if the latter is the case,
446 156 094 0 Battery box with batteries
they should be as far apart as possible in order to
In ECAS systems always at least one height sensor achieve the best possible control performance for the
has to be installed. For TCE a maximum of two height individual height sensors (2-point control on one axle).
51
The height sensor is firmly attached to the axle to be torque acting on the sensor shaft. For this reason, all
controlled via a threaded rod which has rubber end swiveling axes must be in parallel to each other.
pieces acting as dampers and compensating devices.
Only one type of height sensor is available. The sensor
Installation possibilities: level can, however, be mounted in steps of 90 degrees
on the sensor shaft which can be smoothly turned in the
sensor housing. For accurate operation and measure-
ment of values, the sensor shaft has to be properly
aligned. To facilitate this, two projections have been pro-
vided on the sensor shaft which are used as lever
guides. It is important that the height sensor moves free-
ly across the whole of its operating range, and that the
lever can only move in the way intended.
When mounting the height sensor onto the vehicle's

superstructure, the sensor's raising and lowering
reactions must be taken into account. Dipping of the
cylinder in direction RAISE increases the induction,
extending in direction LOWER reduces it. The values
measured can be displayed on suitable diagnostic
equipment (e.g. Diagnostic Controller, PC).
Raising the superstructure increases and lowering

the superstructure reduces the displayed measured
values.
In the normal level the height sensor lever must have a

* = 2 Coding projections of height sensor lever guide rectangular (90°) position to the height sensor. This can
be aligned by means of a 4 mm pin.
Important for installation
The height sensor has a measuring range from + 43° to
- 40° starting from a horizontal sensor lever position. The 5.9.2.2 Battery supply
sectional view of the height sensor, looking onto the TCE enables the connection of a trailer battery. With
sensor lever attachment, displays the arrangement of connected termial 15 this is charged via the TCE
the positive and negative areas. Ideally the whole of the (charging current via ISO 7638 terminal 30 (Pin 1)).
excursion range is used, with the lever being close to
horizontal at the normal level. The maximum excursion The TCE integrated charging control fulfills the following
of the lever (+/-50°) may not be exceeded. For the lever boundary conditions:
linkage, a threaded rod is preferable to a smooth rod,
because this way slipping within the rubber is virtually • Direct battery charging via operating voltage with up
impossible. to 6A.
• 100% charging via voltage increase with 1 A max.
The length of the sensor lever is selectable but must be
• Control of charging voltage (voltage increase)
identical for the height sensors on one axle. A short
dependent on charging state.
sensor lever ensures a high resolution of the measured
values even when the change in height is slight; • Battery capacity 2 Ah ... 10 Ah.
however, it can only cover a short range of adjustment.
• Protection against total discharge
A long sensor lever achieves the opposite: a long
suspension travel can be covered at the expense of the Battery supply via connected systems is activated only
resolution of measured values. It should always be when there is no supply via pin connection acc. to
targeted to make use of an angular range as large as ISO 7638 terminal 30 (Pin 1). When for instance a trailer
possible. is disconnected, TCE remains to be active. The positive
line of the battery has to be fused at the battery (10 A).
Bending the lever at right angles must be avoided Charging characteristic for the assembled battery must
because this might result in an impermissible tilting be preset in the PC diagnosis.
52
Per control unit / box the height levelling can be set to For the purposes of controlling the system, the ECAS
stand-by mode so that in case of height changes the solenoid valve is the interface between the electronic
system automatically will adjust. However, the control output signals from the electronic control unit and the
characteristic depends on the parameters set. pneumatic actuating signals for the air suspension
Additionally the superstructure can be raised resp. bellows. Each one ECAS solenoid valve is installed per
lowered by means of the control unit / box. axle resp. axle assembly.
Battery charge In the ECAS solenoid valve several individual solenoid

valves are combined in a block. Each of these solenoid
The trailer battery is charged by TCE only with switched
valves is a combination of an individual solenoid with
on ignition (terminal 15, ISO 7638). Moreover the
one or two pneumatic valves with one or two control
charging connection is activated only when a connected
slides.
battery was detected. Criterion for this is the idle running
voltage at the time of switching in of 14V at the battery
connection at present. The electrical control signal for activation of the
individual solenoids is sent from the electronic control
unit by means of the electrical plugs on the individual
For monitoring of the battery charging the battery
solenoids or individual solenoid valve blocks. This
voltage, the voltage at pin 30 (ISO 7638), the charging
individual solenoid effects opening/closing of the
current and the charging capacity are calculated.
respective valves resp. moving of the respective slides.
Besides charging current and capacity there is defined
for lead gel accumulators a voltage of 29 V at pin 30 as
This control represents an indirect control since the
interrupting criterion for the charging procedure. In
valve solenoids are opening a valve seat. Via this
addition the charging is cyclically interrupted to prevent
opened valve seat the supply pressure or air supply
the battery from damages. Charging time and and
flows to the control pistons resp. control slide and
interrupting cycle depend on the battery type.
pressurizes it so that it moves into the position desired.
Starting from the solenoid control of the pneumatic

valves, 2 types of valves are distinguished:
5.9.2.3 Solenoid valves at terminal X43
The spring returned valve acts as a 3/2 or 2/2
Part number Description directional control valve in the ECAS solenoid valve.
472 905 114 0 ECAS valve for 1 point, It is mainly used to control the supporting bellows at
R/L, Lifting Axle with traction the front axle or the rear axle with permanent ground
help contact. The valve can be designed as slide or seat
472 905 111 0 ECAS valve for 2 point, valve.
R/L, Lifting Axle with traction The spring returned valve acts as a 3/3 ode 2/2
help directional control valve in the ECAS solenoid valve.
old: 472 900 055 0 ECAS valve for It is mainly used for controlling the lifting axle bellow
new: 472 880 030 0 R/L at rear axle in combination with the supporting bellows of the
old: 472 900 053 0 ECAS valve for 2 point, lifting axle.
new: 472 880 001 0 R/L at front or rear axle By means of impulse controlled valves a lifting axle
old: 472 900 058 0 ECAS valve for 1 point, automatic can be realised. Usually the solenoid valve
new: 472 880 021 0 R/L at front axle block for control of the lifting bellow is flanged to the
solenoid valve block for control of the main axle.
463 084 010 0 ECAS valve for Lifting Axle
2 circuit) without traction help Due to the individual solenoid valves no partial load
463 084 030 0 ECAS valve for Lifting Axle pressures at the valve seats are possible. The three
(1 circuit) without traction help functions:
Trailers with 1 point, 2 point or lateral control (right/left). • Pressure build-up

Drawbar trailers (front/rear). • Pressure maintenance
Lift axle valve(s) for one or two separately controlled lift
axle(s). • Pressure reduction
53
are obtained by combining the individual solenoid valve with one 2/2-way valve – on a 1-point controlled axle –
functions. Changed balance conditions of the air or two 2/2-way valves – on a 2-point controlled axle.
suspension system are only monitored by the height There are three
sensor, interpreted by the electronic and the required 3/3-way valves in the block of lifting axle valves. These
commands be transmitted to the ECAS solenoid valve. are actuated by two valve solenoids and are responsible
for controlling the lifting bellows and the supporting
The ECAS solenoid valve is located on the frame – bellows of the first lifting axle.
preferably on a frame cross-member – above the axle to
be controlled, or above the axle assembly to be Due to that the pinning of the electrical pins is not
controlled. The pipes and cables leading off to the uniform, clear assignments can be done only by means
bellows should be symmetrical, i.e. identical in length of a circuit diagram (see annex), the following directive
and diameter. Take care that the proper allocation of is applicable for the pneumatic pinning:
electrical and air connections follows the numbering
system. Connection 1 Supply from the reservoir for
There are three main different groups of ECAS solenoid downstream consumers (only with Rear
valves, depending on their location: Axle/Lifting Axle valves).
• Front axle valve (also: Front Axle valve) Connection 11 Supply from the reservoir for
downstream consumers (only with
• Rear axle valve (also: Rear Axle valve) Front Axle valves and Rear Axle
• Rear axle/lifting axle valve (also: Rear Axle/ valves).
Lifting Axle valve) Connection 12 Control pressure from the reservoir for
The Front Axle valve is located near the front axle and controlling the control elements in the
controls the supporting bellows for the front axle. Usually ECAS solenoid valve (only with Front
the Front Axle valve is only equipped with a 2/2 way Axle valves and Rear Axle valves).
valve for the front axle (steering axle) - 1 point controlled Connection 13 Not relevant.
axle. The process of increasing and decreasing the
pressure is taken over by the 3/2-way valve of the rear Connection 14 Supply connection coming from Rear
axle valve. Axle valve (only with Front Axle valves).
The Rear Axle valve is the core of an ECAS system with Connection 21 with dedicated Rear Axle valves: Output
no automatic lifting axle facilities. It is located near the for connection 14 of Front Axle valve.
rear axle and controls the supporting bellows of the rear Only on Rear Axle/Lifting Axle valves:
axle. An additional air exit can be used to pressurize or Output for (left-hand) supporting
vent any downstream consumers, e.g. a Front Axle bellows of the axle(s) which is (are) on
valve on drawbar trailers. the ground.
The Rear Axle valve is usually equipped with a 3/2-way Connection 22 Output for (right-hand) supporting
valve for the pressurising/venting function and, bellows of the axles(s) which is (are) on
depending on the control version of the ECAS system, the ground.
with one 2/2-way valve – on a 1-point controlled axle –
connection 23 On dedicated Front Axle or Rear Axle
or two 2/2-way valves – on a 2-point controlled axle.
valves: Output for (left-hand) supporting
bellows of the axle(s) which is (are) on
The Rear Axle/Lifting Axle valve is the core valve of a the ground.
system with automatic lifting axle control. This valve Only on Rear Axle/Lifting Axle valves:
consists of a rear axle block whose function corresponds Output for (left-hand) supporting
to that of the rear axle valve, and a lift axle block. bellows of the lifting axle for fully
automatic lifting axle operation.
It is located near the rear axle and controls not only the
supporting bellows of the rear axle but also the lifting Connection 24 Output for (right-hand) supporting
bellows and the supporting bellows of the first lifting bellows of the lifting axle for fully
axle. An additional air exit can be used to pressurize or automatic lifting axle operation.
vent any downstream consumers, e.g. a Front Axle
Connection 25 Output to the lifting bellows of the lifting
valve on drawbar trailers.
axle.
The Rear Axle valve is usually equipped with a 3/2-way Connection 26 Only on Rear Axle/Lifting Axle valves:
valve for the pressurising/venting function and, Possible output for connection 14 of
depending on the control version of the ECAS system, Front Axle valve.
54
On buses also output for supporting Rear Axle valve with DIN bayonet
bellows on the front axle for the 472 900 055 0 or
'kneeling' function. 472 880 030 0 (new)
Connection 27 no relevant in trailers, in buses also
outlet to supporting bellows of front axle
at kneeling.
Connection 3 Exhaust to downstream consumers
(only with Rear Axle valves).
Connection 31 Exhaust to downstream consumers in
the rear axle block (only with Rear Axle/
Lifting Axle valves).
Connection 32 Exhaust to downstream consumers in
the lifting axle block (only with Rear
Axle/Lifting Axle valves).
At present, ECAS solenoid valves with DIN bayonet

connectors are used. The solenoids are no longer
visible, they are located inside a block of solenoid
valves.
ECAS solenoid valve for implementing a

2-point control on the driven axle
472 900 053 0 or
472 880 001 0 (new)
ECAS solenoid valve for front axle
472 900 058 0 or
472 880 021 0 (new)
55
Pulse-controlled sliding valve Pressure sensor

(Rear axle and lifting axle control) For utilising pressure-controlled ECAS functions, a
472 905 114 0 pressure sensor must be used. This pressure sensor
picks up the pressure in the supporting bellows on the
axle which is always in contact with the ground (on the
Connection Connection
for Rear Axle for Lifting Axle trailer this is usually a rear axle) for controlling the lifting
axle, the traction help or for compensating the tire
deflection.
The pressure is recorded by means of extension

measuring strips. As the pressure is increased, the
resistance at a Wheatstone bridge changes, thus
effecting a voltage in proportion to the pressure.
Depending on the type of pressure sensor used, it is
energised with 8 ... 32 V. Via a signaling line (sensor
cable) the voltage generated by the pressure is
transmitted to the ECU.
In a pressureless condition (pressure sensor offset), the
output is 0.5 volts. The transmissible voltage at the
upper limit of the measuring valve at a pressure of 10 bar
is 4.5 V. The max. admissible pressure of 16 bar for
pressure sensors must not be exceeded.
The output of measuring values is done in digital form,
i.e. in steps. The values measured can be displayed on
a suitable PC diagnostic equipment.
The pressure sensor is connected to a separate terminal
on the supporting bellows or on a T-piece on the bellows'
inlet port. At any rate the pressure sensor must not be
installed in the air line between supporting bellow and
ECAS solenoid valve and also not directly onto the
bellow plate, because errors due to the high dynamic at
actual pressurizing and venting operations may occur.
5.9.2.4 Pressure sensor(s) at

terminal X44 Pressure Sensor 441 040 007 0 ... 013 0 /... ... 015 0
Part numbers: with DIN bayonet connection for the sensor cable.
441 040 007 0 Pressure sensor expires 2001
441 040 013 0 Pressure sensor new Connection:
441 040 015 0 Pressure sensor new (Design with DIN bayonet)
(with sealing ring)
Positive line
+
In case no EBS D modulator is installed, it is possible to
connect one or two pressure sensors for axle load
calculation, at which one pressure sensor is required for
the load sensing EBS control. The EBS D modulator has
an integrated pressure sensor and is evaluated by the
TCE II. In this case the parameter ”pressure sensor in
Ground line - Signaling line
the EBS“ has to be selected.
56
5.9.2.5 Axle load calculation the use of pressure limiting valves and charging valves
In TCE II the axle load calculation can be separately set in the diagram as option. The instructions of the lifting
for each axle (by parameters). This requires a calibration bellows' manufacturers are binding.
of the respective axle load characteristic via the TCE
diagnostic program. By means of the recorded data the Most of the vehicle manufacturers apply plug-in
TCE II software calculates the effective characteristic for connections, available from WABCO under the brand
the respective axle and calculates the axle loads by Anoflex. ECAS also achieves savings regarding screw-
means of the connected sensor(s). in connections. No such screw-in work is required at the
rotary slide valve or the air-suspension valve for the
remote control unit or the height sensor. Even the
Service schedule expenditures for vehicle owners are reduced
The TCE II disposes of a socalled service schedule: By significantly when they use ECAS. Surveys among
means of date, covered distance and/or service hours a vehicle manufacturers fitting ECAS in series production
service interval can be defined. Via the PC diagnosis or have shown that installation times were reduced in
the telematic function this information can be displayed. comparison to conventional systems.
In case of service test connections are essential for

quickly locating any defects. In the extreme case of a
total system failure nevertheless the vehicle should
5.10 Pneumatic Components and remain to be able to be raised or lowered in laden or
unladen state. Therefore at least 2 test connections for
Installation Instructions service brake and supporting bellow should lead to the
atmosphere at a 1-point control. This allows the driver to
Like conventional air suspension systems, electronic air
externally lower the vehicle (pressing the test
suspension systems include pneumatic components
connection), or to raise it. (Connecting the two ports by
such as: air reservoirs, charging valves, plastic pipes
means of the test hose and pressurizing via the service
and couplings. As in any air suspension system, the
brake system.) After deconnection the pressure is
circuit for ancillary consumers is secured against the
included in the air suspensions, since an ECAS system
service brake circuit with a charging valve without return
without power supply interrupts all connections. Only a
flow of 6.0 bar (e.g. 434 100 125 0). The size of the air
normal leakage will then cause the superstructure to be
reservoirs for the air suspension system depends on the
lowered again over time. While checking the normal
number of axles and the system requirements: For
level, usually the vehicle can be driven across a short
vehicles without lifting axles a volume of 60-80 l is
distance to the nearest workshop for repair.
sufficient, only for systems with lifting axles reservoir
sizes of 80-120 l should be preferred. This provides
When selecting suitable sites for the individual
sufficient reserves for the control process in loading
components, there are no definite rules other than those
ramp operation and for frequent lifting axle operation
defined for the fitting position (see Annex - outline
without requesting any additional compressed air from
drawings). However, accessibility for servicing is
the motor vehicle. In this respect, ECAS is not different
important. In detail:
from other air suspension systems.
Regarding plastic pipes, ECAS achieves considerable
savings compared to other systems which offer the Remote Control Unit:
same scope of function. On a vehicle with lifting axle Its location varies with the type of system used, and the
control and an air-suspension valve with height limiting, type of vehicle. In any case an externally well accessible
this will be more than 30 meters. Because of the valve's connection with cap should be installed at a water
large nominal width, the nominal width of the plastic protected location. For tank and chemical vehicles often
pipes between the solenoid valve and the bellows is the lateral cases are used for that purpose.
between 10 and 12 mm. 12 mm is recommended unless
the axle manufacturer or WABCO's diagrams require Solenoid valve:
otherwise. The supply line's nominal width should never For sure the easy accessibility in case of necessary
be less than 12 mm. In order to prevent tire damages service is the most important criterion, because in case
due to a too fast raising and lowering, the pipe nominal of service the incoming pneumatic lines have to be
width of 8 mm towards the lifting bellow should be disassembled here. The lifting axle block consists of two
accepted as recommendation. valve units screwed together. The part containing the
To protect the lifting bellows against excessive pneumatic ports is the 'front'. Thus the 'rear' would be
pressures, and against crinkling, WABCO has provided the valve portion facing the frame. The plastic pipes
57
leading to the supporting bellows should be of equal does not make contact in the upper or lower area. It
length. should be taken into consideration that during the driving
operation additional jounce travels often will occur and
therefore sufficient distance to the limit stops is required.
If possible chose a site which is protected against falling
rocks and splash water. For systems with two height
sensors at the rear axle install these as far from each
other as possible. In order to prevent transverse forces
all swiveling axles must have the same direction. The
lever also should not be bent at right angles. As linking
of the lever to the axle a threaded rod should be
preferred. Unintentional slipping thus is nearly excluded.
The lever has three holes for length adjustment. The
longer the lever, the greater the possible control range.
At the calibrated or main normal level, a lever position of
90° to the sensor is recommended to achieve the best
possible solution. This can be simply realised by moving
the lever on the threaded rod during the normal level and
subsequent tightening.
The pressure sensor
It is located near the supporting bellow and is
recommended for connection to a test valve
(463 710 998 0) for pressure simulation. This allows all
of the vehicle's control processes to be simulated and
checked, regardless of the load it carries, e.g. to check
the behaviour of its lifting axle. For that it should be
mounted within reach and accessible without too great
efforts. Any pressure peaks are suppressed by the ECU.
Pressure sensor with test connection
The height sensor

Instead of the conventional levelling valve the height
sensor is installed. The master gauge for installation is
fully identical and the installation site as well. It is
important that for the whole of the control range the lever
58
System start-up and Diagnosis TCE 6
The electrical supply lines:

Excess lengths of sensor and solenoid lines should be
arranged in Z form as already known from ABS. Cables
which have to be routed along permanently vibrating
objects should be attached using double cable binders
894 326 012 4. Such rocking or vibration will eventually
result in strain-hardening and consequently premature
breaks. All cable binders should only be tightened to that
extent that the cables are sufficiently held in place. This
prevents premature breaks of the cable cords and thus
of the electrical conductor.
Height sensor at the Rear Axle
6.1 System start-up and Diagnosis 6.1.1.1 Height sensor calibration

The process of calibrating the height sensor means that
6.1.1 Calibrating the height sensor is adjusted to the electronic control
unit. As a rule, the vehicle's superstructure is moved to
As part of the start-up procedure for a new vehicle, the normal level I, to the upper and lower levels (stops
sensors have to be calibrated after the parameters have beyond which no movement is possible when raising
been set. The height sensors integrated in the system and lowering) and the respective level is informed to the
have to be ”introduced“ to the electronic. This means electronic control unit.
that a reference value for the electronic control unit has Correct calibration requires the following preparatory
to be defined. The calibration process has to be work to be carried out diligently:
repeated every time the electronic control unit is to work
with a new sensor. This also applies for: – Place the vehicle on a surface which is horizontal
and even.
• Exchange of a sensor
– Make sure that the height sensor has been
• Exchange of the electronic control unit properly installed and that its lever can move freely
across the whole of the raising/lowering range.
By means of the PIN (i.e. Personal Identification
Number) the calibration can be performed as often as – If the vehicle has two height sensors on one axle,
required. This enables the driver to change the normal the bellows on both sides are connected to each
level(s). Calibration of a drawbar trailer with two height other by means of a test hose (balancing the
sensors means simultaneous calibration of Front Axle pressure to spread the load evenly across the
and Rear Axle height sensors. axle).
59
6 TCE System start-up and Diagnosis
– Don't brake the vehicle (protect it against rolling – measuring as close as possible to the air bellow
movements) (seen in axle direction).
– Make sure sufficient air supply The calculated calibration heights should be recorded,
to have the values available in case of a service
– Driving height in mm as distance between required.
superstructure and vehicle axle respectively
according to one of the present reference Apply only one measuring procedure for a vehicle with
dimensions. several axles. Indication of the heights is made in the
following sequence driving height, maximum level,
minimum level.
Upper edge Example for a complete designation:

OKR
Chassis Reference type A, V 250/390/202, RL 273/420/210,
Lower edge
RR 275/422/213 (R= Rear Left, dimensions in mm).
UKR
Chassis
CDE If the electronic control unit is to be replaced and the
ABF calibration data for the vehicle are not known, the
calibration data for the height sensors of the former
electronic control unit may be displayed in the menu
”system, calibration data, height sensors“. If this is no
longer possible, the following assumptions may be used:
Survey on the various reference dimensions for
At normal normal level I the height sensor lever will
height sensor calibration
be aligned horizontally.
A Lower edge (frame) longitudinal beam until middle
Movement to the upper and lower levels takes
of the axle
place until the superstructure can no longer be
B Lower edge longitudinal beam until upper side of raised or lowered.
the axle
C Upper side longitudinal beam until middle of the
axle
6.1.1.2 Height sensor calibration with the PC
C Upper side longitudinal beam until upper side of
the axle To calibrate 3 calibration levels, move to each level to be
calibrated in the following sequence: normal level I,
E Upperside longitudinal beam until road surface
upper level and lower level. Do this using the DC/PC.
E Upperside longitudinal beam until road surface
For a uniform documentation standard measuring points
Note: When calibrating, an increase of the normal
are defined according to the shown survey of reference
level with raised lifting axle and tire deflection
dimensions. If possible indicate the calibrating heights in
compensation has to be taken into account.
accordance with the specifications of the axle
manufacturer. As a rule this means the distance
between the axle centre and the lower edge of the a) First the vehicle is taken to the established normal
longitudinal beam. Dimension A in the drawing. The level I (for the front axle and the rear axle
indication of the measured heights always must respectively). Then the calibration process is
also show the respective letter in order to identify initiated (actual levels are now stored as normal
them correctly. levels).
b) Move the vehicle to the level of the upper stop. Re-

Avoid to make use of reference dimensions E and F, initiate the calibration process. (Actual levels are
since with this measurement also the tire deflection is stored as upper stop levels.) To protect the stops,
respected and thus results may be wrong depending on the electronic control unit will automatically reduce
the vehicle load. For calculation of the calibration height the value for the upper stop level by 3 counts.
the following principles are to be kept:
c) Move the vehicle to the level of the lower stop. Re-
– measuring directly at the axle, not in front of or after initiate the calibration process. (Actual levels are
the wheel (seen in travelling direction), stored as lower stop levels.)
60
System start-up and Diagnosis TCE 6
Note: When using the Diagnostic Controller for calibration value to be entered for the ”upper stop
calibration, the vehicle's levels cannot be changed using level rear“.
the remote control unit.
3. Calculate the differences between the ”normal level
After the individual calibration phases are completed, rear left“ – ”lower stop level rear left“ and ”normal
the Diagnostic Controller will check the fault memory level rear right“ – ”lower stop level rear right“.
and display whether calibration has been achieved
successfully or not. 4. Subtract the smaller difference from the expected
calibration value ”normal level rear left“ to obtain the
For a successful completion of the calibration the calibration value to be entered for the ”lower stop
following principles for the height sensor values HSV level rear“.
have to be considered:
During the calibration procedure the calculated values
– The entered height sensor values must be greater will be entered into the PC.
than 4 counts and less than 255 counts.
4 counts < HSV < 255 counts After the individual calibration phases are completed,
the Diagnostic Controller will check the fault memory
– The upper stop level UL must be larger than the and display whether calibration has been achieved
total of normal level NL increased by 3 counts and successfully or not.
three times the reference value tolerance.
– The lower stop level LL must be smaller than the The third possibility to communicate calibration values to
normal level NL reduced by the double reference the electronic is direct input of the height sensor values.
value tolerance DHSL. This can be accomplished only with a PIN. To do this,
the height sensor values have to be known. The direct
A second possibility is the calibration of a driving level input is done with the PC diagnostic program under
and manual entry of the upper and lower stop level. This system/calibration data height sensors.
kind of calibration can be reasonable when the
superstructure is intended to move to the stops. Thus
If values are entered for these parameters, it may be that
stop release in the upper level can be avoided.
calibration will not lead to the desired result. When
calibrating a partially laden vehicle, the lifting axle must
Also for this procedure the calibration guidelines have to
be lowered. If at a partially laden vehicle the lifting axle
be observed. Starting from the normal level rear left and
is raised during calibrating, an undesired increase of the
rear right, the calibration values for the ”upper/lower stop
normal level will result. The vehicle then perhaps might
level rear“ can be defined as follows:
be in unladen condition with raised lifting axle above the
admissible vehicle height.
1. Calculate the differences between the ”upper stop
level rear left“ – ”normal level rear left“ and ”upper
stop level rear right“ – ”normal level rear right“. As well for a partially laden resp. fully laden vehicle the
compensation of the tire deflection must be considered.
2. Add the smaller difference to the expected That means the vehicle must be calibrated partially or
calibration value ”normal level rear left“ to obtain the fully laden deducting the tire deflection compensation!
61
7 TCE PC Diagnosis
When starting the diagnosis the following

interfaces will appear. The individual
parameters are explained as follows:
7.1 Start and diagnostic menu scope < 2 V. In case of a respective failure entry
this value has to be considered.
After start of the diagnostic program the data as stored
Information to part number, production date, serial
in the TCE will appear. On the right side the basic
number, software version, diagnostic recognition,
configuration of the trailer vehicles is shown.
mileage counter, operating hours counter and battery
In the TCE diagnosis version 2.01 (de) the start screen hours counter is shown. Vehicle manufacturer and
was extended by the following information: chassis number will be shown only after system start-up,
as far as they were entered.
– Date / time (GMT). This will appear after
adjustment. GMT stands for ”Greenwich time“.
(Germany is located 1 hour before this time zone) Mileage counter, this displays the covered miles of the
– Display of voltage Pin 15 trailer vehicle with connected TCE. May be different
from EBS mileage counter!
– Display of voltage Pin 30 of the 7 pin trailer plug
– Display of voltage Pin 30 of the 15 pin trailer plug Operating hours counter, displays the period, over
– Display of voltage of trailer battery, as far as which TCE was supplied via Pin 30.
installed
Battery hours counter, displays the period, over which
– Display of a possibly existing voltage potential TCE was supplied only via the battery.
between ground connections of supply plug
ISO 12098 (15 pin) and ISO 7638 (7 pin). As a rule Actual or stored information will be displayed red
(standard design) the display should be within the resp. blue.
62
PC Diagnosis TCE 7
7.2 Vehicle definition This is effected by means of ”pressure keep“. This is

active only in combination with the first lifting axle valve.
Input must be from top to bottom resp. on the next
screens from top left to bottom right. If this procedure is Wear indicators
not kept, errors of the system may occur. When wear sensors are installed, identification of the
On the vehicle definition screen and the following sensor type is required.
screens the basic configuration is adjusted.
Levelling control:
So first of all the vehicle type has to be selected.
As a maximum two height sensors can be installed on
Axles & sensors: the vehicle.
Here the number of front and rear axles is to be set. For semitrailers must be decided whether two height
sensors for lateral control are to be installed or if one or
Axle assignment: two height sensors on the rear axle are to be assembled.
In the first line indicate on which axle(s) the first lifting
axle valve is acting and under the designation For drawbar trailers always one height sensor is
F = spring return and I = impulse control the mechanical obligatory at front and rear axle.
structure of the valve.
In the second line select a second lifting axle valve. This TCE II
valve is always designed as spring returned. For vehicles without ECAS function select ”no level
In the third line must indicate whether brake lining wear control“. Connection of height sensors and ECAS valve
sensors are installed and if yes on which axle. If one axle block can be omitted then. A lift axle control is
is selected, the field 'wear sensor' becomes active. nevertheless possible!
With a for the traction help the first axle can be
released in accordance with legal directives. Pressure sensors:
With a for the manoeuvring aid the last axle can be Two pressure sensors can be mounted as maximum.
released. The pressure sensor always has to record the bellow
The additional valve should be selected in order to pressure of that axle controlled by the trailer modulator.
ensure a comfortable control of the traction resp.
manoeuvring aid at spring returned lifting axle valves.
2 63
7 TCE PC Diagnosis
TCE II Standard monitoring:

In vehicles with TEBS-D the modulator has an In the case of a failure of one of two connected lights
integrated pressure sensor. In this case no pressure (e.g. brake light), this will not be detected as an error.
sensor has to be connected to the TCE II. Select option
”... there of one pressure sensor in the EBS“. Extended monitoring:
At this adjustment the failure of the light with same or
higher electrical power is detected.
7.2.1 Superstructure & lighting
Lighting: LED monitoring:
In case of activating 'standard', will be displayed for With light emitting diodes nobreak recognition.
the lamps to be connected. Connect terminal X23 at
Ramp approach help / paver brake:
standard. If luggage superstructure is selected, connect
terminal X23 and X33. For tank superstructure connect In case of installing a ramp approach help, the
X23, X33 and X34. installation position (see page 44) has to be indicated.
If a lamp is not connected, select ”freely defined“ and The stopping distance can be varied from 100 cm to
of the respective lamp has to be removed. 20 cm. For paver brake mode the brake pressure can be
A new option is that the backing light right and/or left is adjusted from 0 to 2 bar.
additionally selectable as well as also the rear fog light
right/left. Trailer battery:
In this case selection of the correct accumulator is
Now also the connection of LED lamps to TCE II is important. Acid accumulators resp. lead gel
possible! Moreover the light failure recognition was accumulators have different charging characteristics.
improved. Via parameter settings by PC the ”sensibility“
for ”cable break recognition“ can be set. Green system warning light:
The green system warning light shows messages from
the system with flashing light. In case the vehicle is
outside the normal level, the system warning light is
permanently flashing.
64
PC Diagnosis TCE 7
Connection of a CAN electronic The special modules shown on the left side can be
As a maximum three further CAN electronics can be selected. The selected modules will then be shown on
installed on the vehicle. the right side. Some special modules as for instance the
ISS (integrated speed switch) have parameters, which
If 'additional functions' is selected, it is necessary to
activate a CAN electronic at terminal X22 via a second can be shown on the right side, too. With respect to fully
CAN line. functionable special modules further parameters have to
be set in the diagnostic software, e.g. the level switch
Tire pressure monitoring must be selected in case an will be functionable only then when also the ECAS
IVTM electronic is connected at X32.
parameter ”Normal level via switch“ was adjusted.
In order to enable control of CAN superstructure
systems, a CAN electronic may be connected at
terminal X32. Manoeuvring aid:
The manoeuvring aid supports improved and tire saving
Additional lines of the 15 pin trailer socket: back driving in the manoeuvring mode. This can be
Not available: Selection via special module interface activated by means of a control unit or a press button to
possible. Ubat from the motor vehicle. A special module must be
parameterized for that. It is deactivated when exceeding
7.2.2 Special modules a rate of 10km/h or ignition ”OFF“ resp. pressing the
STOP button or pressing the button for more than
The menu item special modules was added in the new 5 seconds. An excess pressure of the admitted bellow
TCE diagnostic program 2.01. pressure by the 1,5-fold value will cause deactivation.
This does not affect the level and is not adapted. An
Here the modules are listed which are integrated in the offset is not possible! For vehicles without lifting axle at
respective TCE and available as parameters. the respective axle, the bellow pressure for raising must
be set lower in the special parameter than the empty
A description of the module is under menu item: Info bellow pressure. Only then the axle is running
module X to be seen. permanently pressurized.
65
7 TCE PC Diagnosis
7.2.3 ECAS Parameter level. In both cases the difference in height to the
calibrated normal level has to be indicated in +/- counts.
Here now the last standard parameter page for TCE. If
Speed threshold between standstill and drive is that
no special parameters are required, the parameter
driving speed at which the normal level is automatically
settings can be terminated after this surface pate.
adjusted. In case a control box is used, it should be
Normal level selection: abandoned from the 3rd driving level via control unit to
Preselect whether the 2nd or 3rd normal level are to be avoid maloperations.
activated via control units or a switch.
New:
TCE I: Normal level not to be activated via switch Selection of the control box is not relevant in this
TCE II: Entire functional range parameter display because a respective choice has to
be made in the new diagnostic program under ”special
Normal level 2 modules“.
When the second normal level is chosen via switch/
control unit, indicate the difference in height to the Vehicle selection:
normal level in +/- counts, after the function was The difference between fast unloading and standard
selected. Whether the second normal level is activated vehicle is the shorter subsequent control time at
by means of a switch or a control unit depends on the unloading of the vehicle. Selection of fast unloading
choice under 'level selection'. means reaction of the vehicle to changes in load within
When the 2nd normal level shall be speed controlled, one second. As a rule the vehicle reacts within six
indicate additionally to the difference in height in+/- seconds.
counts also the speed rates for the first and second
normal level. Air bellows pressure:
The pressure at maximum admitted axle load is required
3. level: to calculate the values for lifting axle raise and lower, the
Selection is possible whether the third level shall be an traction help pressure and the tire deflection
unloading level, thus active only at standstill, or a driving compensation. This value is a must.
66
PC Diagnosis TCE 7
Lifting Axle Control Vehicle data:

Choosing the full automatic function of the lifting axle, Here indication of manufacturer and chassis number is
the lifting axle will automatically be lowered or loaden necessary, When these data are missing they also will
after having exceeded the set pressure value for the not appear in the various protocols resp. on the first
supporting bellow. Raising of the lifting axle/loading of diagnostic interface.
the trailing axle follows automatically as well after falling
below the set pressure value for the supporting bellow. The following pages have to be respected
only if special parameter settings are
Choosing the semi automatic function of the lifting axle
required.
results only in an automatic lowering of the lifting axle.
Raising of the lifting axle is done manually via a control
element or switch, e.g. in the cabin.
7.3 Special parameters
Traction help:
The traction help has to be adjusted in accordance Tire Deflection Compensation:
to legal directives resp. specification of the axle This is permanently active. At the maximum value of the
manufacturer. air bellow pressure 10 counts will be compensated. In
the case of vehicles with larger transport volumes there
Possible preadjustments are as follows: are selected besides small wheels also short spring
travels in order to maintain the legally specified vehicle
The maximum axle load for the axles remaining on the heights. Due to this the superstructure might easily hit
ground is increased by 30 % for all 3 types of traction the rubber buffers when the vehicle is laden.
help. With increasing loads the distance axle/superstructure
As already described the traction help can be started via is extended and thus with constant vehicle height a
control unit or by means of a press button against Ubat+ longer spring travel is realised.
from the motor vehicle. Therefore a special module has
to be parameterized. The traction help effects more Control delay:
traction onto the driven axle in the starting gears and can Control delay while stationary delivers a period, in
be effectively used in narrow bends. The traction help is which the reference value control is made while
cut off when exceeding a rate of 30km/h, pressing the stationary.
STOP button, ignition OFF or pressing the button for
more than 5 seconds! In the traction help mode the Control delay while driving delivers the period, in
normal level is kept - an offset is not possible! For which the reference value control is made while driving.
vehicles without lifting axle at the respective axle, the Vehicles with swing axles (Inloaders) require an
bellow pressure for raising must be set lower in the adjustment different from the standard parameter set!
special parameter than the empty bellow pressure. Only
then the axle is running permanently pressurized. Control delay in Stand-By delivers the period, in which
the height sensor signals at stationary vehicles in Stand-
Traction help to EG by mode have to be continuously beyond the admissible
nominal value tolerance range to effect a subsequent
The traction help to ”EG“ is active up to 30 km/h with
adjustment.
30 % overload. It is possible to activate this until a speed
rate of 25 km/h. Both values are able to be reduced by
means of the diagnosis. Increase is not possible. Admissible level deviations:
Admissible right/left deviation of the levels at the
rear axle, required only for systems with 2 height
Traction help to 'time limit'
sensors at the rear axle. It defines the permissible slant
Traction help to ”time limit“ is active for 90 seconds with of the superstructure if the load is not evenly distributed.
max. 30 % overload. After a compulsory break of In the case of independent wheel suspensions this value
50 seconds the traction help can be started a fresh, should be cut off.
provided 20 km/h are not exceeded. In case 30 km/h is
exceeded, the traction help will cut off automatically. Max. right/left deviation during raising/lowering in
the levels at the rear axle refers only to axles with 2
Traction help to 'Northland' height sensors. This value indicates the admissible
Traction help to ”Northland“ can be cut in until a speed range during larger level changes (raising/lowering). At
rate of 25 km/h and remains active until cut off unilaterally loaded vehicles, the less loaded side will
irrespective of the speed. quicker be raised resp. lowered than the other. This may
67
7 TCE PC Diagnosis
possibly cause a dangerous slant as the level is being as long as the vehicle has not exceeded a speed of
changed. By pulsing the bellows supporting the lighter k.p.h. since start off. At vehicle speeds of more than
load, a more even raising/lowering process is achieved. 10 km/h this control is not effective and will be
At vehicles with swing axles (inloaders) the adjusted reactivated only at the start of driving after a renewed
value must not exceed 5! stand still.
Max. front/rear deviation at raising/lowering into the Speeds:
levels refers to full-air cushioned vehicles. In the case of Speed rate up to which targeted level changes by
level changes the front and the rear of superstructure means of the control unit/box can be effected
should reach the new reference level simultaneously. describes the limit speed at which the control unit/box
The axle with the shorter distance will be raised/lowered keeps the buttons active during driving. This function is
respectively slower. A minor permissible deviations designed for installation of a control unit in the motor
causes constant pulsing of the solenoid valves during vehicle. This allows memory levels, raising, lowering,
the control process and should, therefore, be avoided. etc. to be carried out. After exceeding of the adjusted
speed the control unit will be cut off. A level deviation
Admissible level increase 7 sec. after start off resp. from the normal level is controlled as long as achieving
at activated mode 'unloading level' refers to the driving speed at which the normal level is
unloading actions. This option permits an exceeding of automatically adjusted.
the reference level of the superstructure distance above
Driving speed at which the normal level is
the axle. When 7 seconds after start off or with activated
automatically adjusted. When exceeding the set
unloading level an exceeding of the reference level plus
speed rate the actual level will be automatically
the count values of this option is measured at all
adjusted. The actual normal level is depending on the
distance sensors, the ECU detects an unloading action.
position of the driving level switch resp. the normal level
An immediate adjustment to the level nominal level plus
preselection via control unit or on the adjustment of the
the selected count value is the consequence.
speed dependent normal level control.
If the function unloading level is active, an immediate This parameter is of major importance for the attaching
control even at brake actuations will occur, when the or detaching of semitrailers. Here a speed should be
level change exceeds the value nominal level plus selected being high enough to prevent an automatic
selected count value. The control process will continue activation of the driving level at slow speeds.
68
PC Diagnosis TCE 7
Tolerances: Shall the lower height limit be above the rubber buffer?
Then enter a ”+“ value. The exhausting process is
The values describe the admitted values above or below terminated, when the sum of the lower level + this
the nominal level. Tolerance range is two times the parameter has fallen below the specified value and no
indicated value. further change in height will occur during the indicated
period of the plausibility check. Since usually plausibility
Plausibility: messages are only possible in tilting positions of the
vehicle or on an uneven ground, an adjustment between
The values for the limit of the plausibility check at 5 and 20 is recommended.
lowering of the respective axles define the limit value of
the distance sensor. Below this the electronic does not The parameter plausibility check defines a period in
detect a plausibility message during lowering of the which the electronic control unit expects a command to
superstructure. Depending on the definition of the lowest be executed or continued. If a given command is not
permissible level, the function of the parameter varies: followed by any reaction, the ECU detects implausible
behaviour. A useful adjustment is a period of
30 seconds.
In case the rubber buffer shall be the lower height limit?
Then enter a ”-“ value. The value to be entered is defined Calibration levels:
by the elasticity of the rubber buffers, because an empty
vehicle does not compress the buffer as much as a As a standard here ”three calibration levels“ are to be
laden vehicle. If the calibration was done on the laden selected. ECU is expecting during the calibration
vehicle, the unladen vehicle will not reach this lowest process the moving towards three levels, normal level,
level even when the bellows are completely exhausted. upper and lower level.
This results in a plausibility message. When ”calibrate only normal level“ is selected, the upper
and lower level must be known as count values and be
Recommendation: if calibration is done in an unladen entered as number values during the calibration
state, enter a value between -10 and -25. In order to process. The nominal level is moved to during the
avoid a plausibility message, when only one side is calibration process.
resting on the buffer due to the vehicle being in a tilting
position.
69
7 TCE PC Diagnosis
Lifting Axle Control: Lower lift axle, here the pressure of the air bellows can
be manually changed. As a standard the value is ajusted
Here different lift axle functions can be selected. from the max. permitted value of the axle load minus
10 %.
Lower lift axle is adjusted as a standard to ”Lift axle to
be lowered at ignition off“. The lifting axle(s) will be Raise lift axle, here the pressure of the air bellows can
lowered only if contact at Terminal 30 is maintained for be manually changed. As a standard this value will be
a short time after the ignition has been switched off. Not calculated dependent on the max. permitted axle load
after detaching the ABS coiled cable. value and the number of axles and lift axles.
Raise lift axle is adjusted as standard to ”Lift axle to be Same is true for the next two parameters.
raised only at speed“. With ignition on the lift axle
remains at the ground and will be raised only after the Increase of normal level with raised lift axle will
preset driving speed is achieved beyond which the lift deliver the value for the increase. Thus an improved
axle is raised in case of a fully automatic function. This clearance for the wheels of the lifting axle is resulting.
adjustment has a positive effect on construction vehicles The value set for this parameter is important for the
and on motor vehicles with a poor cold start ability. The calibration process. This is exclusively active to increase
decision on whether the lifting axle(s) can be raised is the driving level depending on the option increase of
made while the vehicle is stationary. driving level with an unladen or partially laden vehicle.
The increase of the driving level is not active during the
When the lift axle shall be raised at ignition on, the first
traction help mode.
line has to be chosen. Raising of the lift axle will then
follow in dependence on the load. Driving speed until which a manual lift axle control
is possible, delivers the value until which a control is
Driving speed above which the lift axle is raised at a possible. Lowering the lifting axle at higher speeds could
fully automatic function delivers the speed at which possibly cause tire damages due to higher forces
the lift axle is raised after ignition on. This parameter is becoming effective while the tires make contact with the
only active at corresponding selection of lift axle to be road surface.
raised. Recommended here is an adjustment of 10 ...
20 km/h. Around 20 km/h the tire circumference speed Special parameter 3:
is sufficient to remove adherent impurities.
Changed structure, identical content!
In case of vehicles with two separately controlled lift Old designation: Overload protection
axles, this value should be smaller than the driving New: Static overload protection, i.e.., dynamic peaks
speed up to which a manual lift axle control is possible. are ”admissible“ resp. will be filtered out.
This would also effect raising of the 2nd lifting axle,
when driving after an effective traction, and not only after
standstill of the vehicle. Also after unloading, the lifting
Traction help:
axle will not be raised earlier then when set value has The traction help will be adjusted in accordance with the
been exceeded. selected type of traction help and the respective
admitted legislation.
The traction help has to be adjusted in accordance
Increases of normal levels (with raised lift axle), can to legal directives resp. specification of the axle
refer to the first and second normal level or to the lowest manufacturer.
level only. As a standard it is referred to the lowest
normal level. In case the first line is selected, the third Differences in air bellow pressures:
level should be the highest of the three possible levels. At vehicles with a height sensor the level will be directly
moved to.
The level will be raised only if the vehicle is actually at its At vehicles with two height sensors ”minimizing of bellow
driving level. pressure differences“ is activated. Prior to addressing
the driving level, the vehicle's superstructure is lowered
Automatic lowering is effective to all lift axles as a slightly and then raised to its driving level by
standard. When the input automatic lowering shall be simultaneously pressurizing the bellows. This ensures a
exclusively effective to the 2nd lift axle, select the balance in pressures on the left-hand side and the right-
second line. hand side of the bellows.
70
PC Diagnosis TCE 7
Buffer recognition: and very quickly unloaded. Since ECAS needs a certain
time for readjusting to the selected unloading level, the
The buffer recognition time defines the period, in which
bellows pressurized with value ”laden“ press the
the ECU is to recognize the lower stop (”rubber buffer“).
superstructure against the belts. In the case of the
When at sending the command 'lower superstructure' no
absence of belts, the vibration dampers may be
more height change takes place during this period and
extended to their maximum. An extraordinary tensile
the distance of the superstructure above the axle is on
load is the result. Consequence would be that ECAS
one level, the pulsing of the ECAS solenoid valve will be
would have to vent the supporting bellows such as to
interrupted.
readjust the unlading level. If the ignition is switched off
Axle load calculation: at that point, ECAS would interrupt the control process.
Due to the lack of any power supply, the superstructure
TCE I: would remain in its upper position for some time, and the
Cannot be activated. strain on the buffers, or stops, could be excessive.
TCE II: The same exessive strain could occur if the ignition of a
Function to calculate the axle load can be activated. It tanker truck using ECAS is switched off while it is being
requires to perform the ”axle load calibration“ at the unloaded by means of an external pump. Also in this
system start-up of the TCE II. case with an adjusted unloading level avoidance of an
Period: overstress of the stops by means of this parameter is
possible.
Stand-by time may be entered here in steps of
15 minutes. Overload protection:
Follow-up time with unloading level switched on Admissible overload pressure, reports the admissible
delivers a follow-up time after ignition off. If the pressure of the supporting bellow which must not be
superstructure is at the upper stop while switching off exceeded. If this value is exceeded, further pressurizing
the ignition, ECAS will lower the superstructure to the is impossible and the superstructure is lowered to the
upper stop level with voltage from terminal 30. This buffers.
means venting the bellows so that the shock absorber
When this happens, return to normal operating
stop will no longer be stressed.
conditions is possible after having reduced the axle load
This function is valuable when a vehicle is just suddenly and switching on/off the ignition.
71
7 TCE PC Diagnosis
7.4 Axle load calibration:

If under ”special parameter 3“ determination
of the axle load was selected a calibration of
the axles is required. For calibrating the axle
load the vehicle has to be set to the normal
level.
Only thus relevant pressures and
consequently the weight of the load can be
determined.
For each axle the empty and partial weight

has to be indicated in kg and bar, as well as
the admissible axle load. By means of the
pressure sensor TCE calculates the
individual axle loads as well as the total load.
This is transferred to the motor vehicle via
the CAN data connection of the 7 pin plug
connection to ISO 7638.
The axle load determination is only as exact

as was calibrated. An unexact entry of the
empty resp. partial load may result in
immense deviations. The most precise
method to calibrate a vehicle type is to load
the vehicle respectively and to enter
pressure and weight in tons.
7.5 Switch Positions /

Outputs
In menu ”Measured values / switch posi-
tions“ the set parameters for the switches
can be tested. If for instance in the parame-
ters the special module 2 is selected, the
TCE port at X13 Pin 9 is indicated and a
functional test detects whether the signal is
recognized from the correct switch input.
TCE outlets can be likewise tested under

menu ”Measured values / outlets“.
72
PC Diagnosis TCE 7
7.6 Service management

It is possible to adjust service intervals in the
TCE for the most different activities. These
can depend on a date, mileage or service
hours. If 90% of a service interval are
achieved, a message on the first page of the
diagnostic software will appear. Under
”service management“ the required acitivity
can be read out and be confirmed after
successful service completion.
Dependence on the date can be shown only

when date and time are prior adjusted in the
TCE. This is shown on the first page of the
diagnostic software.
7.7 System label
TCE
HERSTELLER Parameter : Wert
MANUFACTURER
CONSTRUCTEUR WABCO Parameter : Value
Paramètre : Valeur
WABCO TEILENUMMER
1 2 3 4 5 6 7
WABCO PART NUMBER
RÉFERENCE WABCO 446 122 001 0
SERIENNUMMER
1 14 100 10 0 0 4 20
SERIAL NUMBER
NUMERO DE SÉRIE
002610000035 2 48 0 30 4 10 100 0
FAHRZEUG-IDENT.NR. 3 133 0 60 10 20 8 0
CHASSIS NUMBER WDE20030901234567
NUMERO DE CHASSIS
4 193 0 30 0 255 10 0
PARAMETERSATZ-NUMMER
PARAMETER SETTING NO.
NO. DE LA LISTE PARAMÈTRES
5 56 0 0 10 25 240
6 198 0 0 30 30 11
FPIO PARAMETER
2; 1,00; 240 7 31 0 0 90 0 128
FPIO PARAMETER
FPIO PARAMÈTRES 8 97 0 10 60 255 7
Version
9 0 20 15 0 0 0
10 65 0 20 0 130 0
FAHRHÖHEN [mm] VORN HINTEN
DRIVING LEVEL [mm] FRONT REAR
NIVEAU DE ROULAGE [mm] AVANT ARRÉRÉ
TYP
TYPE
TYPE
A
NORMALNIVEAU I 250 mm
NORMAL LEVEL I
NIVEAU NORMAL I 89 cts
SERVICE http://www.wabco-auto.com
73
7. TCE PC Diagnosis
7.8 End Of Line - Protocol
EOL - PROTOKOLL Seite 1/1
System TCE
WABCO Teilenummer 446 122 001 0
Fertigungsdatum 2003-07-29
Seriennummer 002610000035
ECU Software Version = TCE00R0326A01-0206 ECAS Kalibrierdaten

Diagnostic ID = 71000300
Kalibrierniveaus = 1
Diagnostic Software SN = 1130000010201-776368
FN vorn/rechts = 0
TCE Parameter / FPIO Sondermodule ON vorn/rechts = 0
UN vorn/rechts = 0
1 2 3 4 5 6 7
FN hinten/links = 89
1 14 100 10 0 0 4 20
ON hinten/links = 140
2 48 0 30 4 10 100 0
UN hinten/links = 50
3 133 0 60 10 20 8 0
Kalibriertyp vorn/rechts =
4 193 0 30 0 255 10 0
Fahrniveau vorn/rechts [mm]
5 56 0 0 10 25 240
Kalibriertyp hinten/links = A
6 198 0 0 30 30 11
Fahrniveau hinten/links [mm] = 250
7 31 0 0 90 0 128
8 97 0 10 60 255 7
9 0 20 15 0 0 0
10 65 0 20 0 130 0
2; 1,00; 240
Achslast Achse 1 Achse 2 Achse 3 Achse 4 Achse 5

bar / kg bar / kg bar / kg bar / kg bar / kg
Leergewicht 1,20 / 800,00 1,20 / 800,00 1,20 / 800,00 --- / --- --- / ---
Teillast 2,50 / 4000,00 2,50 / 4000,00 2,50 / 4000,00 --- / --- --- / ---
zul. Achslast 5,00 / 8000,00 5,00 / 8000,00 5,00 / 8000,00 --- / --- --- / ---
Fingerprint
Typ ID - Code Firmencode Testgeräte Nr. Datum
CAN Kommunikation 240 25 190 1403/00/00
TCE Parameter 240 189 776368 2003/11/20
ECAS Parameter 240 189 776368 2003/11/20
ECAS Kalibrierdaten 240 189 776368 2003/11/20
Achslastdaten 240 189 776368 2003/11/20
VIN 240 189 776368 2003/11/20
FPIO 240 189 776368 2003/11/20
Notizen 1 240 25 190 1403/00/00
Notizen 2 240 25 190 1403/00/00
Serviceremainder 240 25 190 1403/00/00
Testergebnis = FEHLER Anzahl Tests 1

Parametrierung = durchgeführt Beleuchtung = FEHLER
Warnlampe = inaktiv Fehlerspeicher = o.k.
Wegsensorkalibrierung = durchgeführt Rampenanfahrhilfe = nicht getestet
Achslastkalibrierung = durchgeführt Liftachse = o.k.
Bedieneinheit = nicht getestet Verschleißsensor = nicht getestet
Hersteller WABCO Fahrzeug-Ident.Nr. WDE20030901234567

Fahrzeugtyp WDE2003 Kilometerstand 1,41
Prüfername Musterfrau
Datum 2003-11-20 Unterschrift
74 2
PC Diagnosis TCE 7
Explanations: Fingerprint
The fingerprint detects when which area of the electronic
FPIO Modules / special modules was modified by whom via PC diagnosis.
These are adjustable partial functions of the TCE.
Selection in interface ”special modules“. The special
modules allow a linkage between inlets and outlets of Tester result = o.k.
the TCE, thus enabling to use the same inlet for
activating different functions. o.k. – parameterized and tested
inactive – not parameterized
ECAS calibration data:
Other possible indications:
FN – Nominal level not tested - parameterized but not tested
ON – Upper level
ON – Lower level
For the protocol a 1-point-control (rear leftside) was

chosen.
75
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TCE I / II

815 000 375 3

This publication is not subject to any update service.

815 000 329 3

Vehicle Control Systems

The right of amendment is reserved

By a consequent use of the available data connections

Brake lining wear sensors

Green warning light

The following data can be transmitted to the motor • Vehicle hitched/unhitched

GPS GSM Tele- Satellite Antenna

Global Positioning System Global System for communications

The different systems may be used from trucks with TCE II

Telematic problems can only be corrected by the – Vehicle door open/closed

• Part 3: Application for all further systems of part

3.1 Functional overview

IVTM (Integrated Vehicle Tire Monitor) Operating

X14 X24 X34 X44 X54 X64

Superstructure -additional lighting,

3.2 Electronic 446 122 000 0 /

All plug in connections are marked with an X and a

Since the terminals are located very close, cables

The front of the electronic consists of coded plug-in

Fixation to clip by means of cable binder or similar

X13-ISO 12098 (15-pin) X23-Lighting X33-Superstructure X43-Solenoid valve

X14-Diagnosis and X24-Side marking X34-Tank vehicle X44-Pressure sensor

3.3 System connections • corresponding TCE error (e.g. failure of EBS

Communication truck-trailer acc. to ISO 11992.

Connection X14 CAN communication via trailer data bus acc. to

Connection X21(optional) TCE I TCE II

Connection X33 (optional)

3. Row Functional assignment for freely programmable in-

Ramp approaching help (RAH)

TCE II X42: 1 or 2 level sensors (without temperature

Brake lights (21 W)

to the right height sensor (2nd HS). Otherwise Connection X44

4.1.1 Overview on terminals and the

449 874 ...0

Plug Assignment Plug Assign-

Distributor not measurable, since with W network

**) Knorr brake to BPW axle 32480057

449 884 ... 0

Plug Assignment Plug Assignment

Distributor not measurable, since with W network

Used see: Remark

Plug Assignment Plug Assignment

Distributor not measurable, since with W network

X12 X 22 X 32 X 42 X 52 X 62 Used see: Remark

Plug A Plug B Plug Plug Colour Assignment

Used see: Remark

Used see: Remark

449 135 ... 0

Used see: Remark

Plug Plug Colour Assignment

X 14 X 24 X 34 X 44 X 54 X 64 Used see: Remark

Plug Plug Colour Assignment

449 121 ... 0 Used see: Remark

449 123 ... 0