Werkstattinformation Informations d´atelier Informazioni di officina Workshop-information Información de taller

Marke MB/TRAVEGO Gruppe 54.286 Verteiler D Datum 19.08.04 WI-Nr. 04/009 Marque Groupe Distribution Date WI-N°. Marchio SETRA/ Gruppo Distribuzione Data WI-N. Brand Group Distribution Date WI-No. Marca TopClass 400 Grupo Distribución Fecha WI-N°. ComfortClass 400

Replaces WI 02/002/3 – supplement to “Automated programming” item added, extended to include ComfortClass 400 bus model EvoBus-specific cables for Star diagnosis (SD) and their usage

1. Use of connection cable for Star diagnosis (SD) (diagnosis interfaces on vehicle) and use of replacement adapter (FPS self-sealing connector)

2. Job instructions for FPS download

3. Job instructions for DMUX download

4. Job instructions for "Automated parameter setting"

5. Job instructions for self-sealing

1.) Use of connection cable for Star diagnosis (SD) (diagnosis interfaces on vehicle) and use of replacement adapter (FPS self- sealing connector)

Various connection cables are available as accessories for Star diagnosis. Their usage in the field is not always clear.

1.1 Download cable for the FPS download W 628 589 02 63 00 (refer to W number on download cable)

This cable is intended for connecting to the 9-pin download socket (05X02) in the E box, driver's cab. The cable is used to download FPC electronics.

1.2 Combi download cable for the DMUX download W 000 589 838 63 00 (refer to W number on download cable)

N DMUX (Display Multiplexer) combination instrument (driver's cab)

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This cable is required for the DMUX download and is also connected to the 9-pin download socket (05X02) in the E box, driver's cab. This cable can be recognised by its blue band.

N After the DMUX download, it is essential that automated parameter setting of the combination instrument is undertaken. The automated parameter setting process is explained here taking the example of a combination instrument but can also be applied to other systems.

1.3 Diagnosis cable for Star diagnosis (W 6511 1220 99H)

This cable is required for all other applications of Star diagnosis such as diagnosis, teach-in functions, automated parameter setting, etc. The cable is connected by means of the 14-pin diagnosis socket (05X01) in the E box, driver’s cab.

This cable is included in the scope of supply of Star diagnosis and cannot be purchased by means of the normal method used for spare parts.

1.4 Replacement adapter (self-sealing connector) (W 628 589 01 63 00)

This replacement adapter is required when replacing one set of FPS electronics. Again here, the cable is connected by means of the 9-pin download socket (05X02) in the E box, driver’s cab.

N The cables W 628 589 02 63 00 and W 000 589 838 63 00, as well as the replacement adapter W 628 589 01 63 00 are not included in the scope of supply of Star diagnosis, but can be ordered quite normally as tools by specifying the material numbers. The material number is identical to the number on the relevant cable. The 05X01 and 05X02 designations can also be found in the electric circuit diagrams.

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2.) Job instructions for FPS download

A FPS download is only required when retrofitting a system or modifying a program. An FPS download cannot be used to repair a defective system because the system cannot be repaired by means of a download.

N Preconditions for the FPS download

All FPS electronics required for the FPS system are installed in the vehicle and the devices and cables required are connected up. The vehicle-specific program files are available (new vehicle CD with modified files).

The following are required: Rollboy, Compact or Basic Star diagnosis + service license code CAESAR Part D (can be recognised by CAESAR type plate) Part D connection cable (automatically in conjunction with CAESAR Part D) Cable for the FPS download (W 628 589 02 63 00). The cable is connected by means of the 9-pin download socket (05X02) in the E box, driver's cab.

N Warning! The batteries must be charged, the battery voltage must not fall below 24 volts during the download.

N Warning! If FPS electronics are retrofitted, TI no. 54.00M024 MUST be noted (FPS repairs).

2.1 Establish connection between Star diagnosis, CAESAR and vehicle. Switch off workshop switch 01S01 (red) and switch back on. Activate range selector setting, level II.

N During the download, battery charging devices must not be connected to the vehicle and activities must not be undertaken on the vehicle. (no switches pressed, no flaps opened, etc.)

N If the FPS system is in download mode, "IT CAN Timeout" appears on the display and the red and yellow warning lights in the combination instrument light up permanently.

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2.2 Start the Star diagnosis and the DAS (Diagnosis Assistance System) with subsequent selection of vehicle type and the "Download FPS flexibly programmed control" menu item.

Enter chassis number in "VIN" box Continue by pressing "F2" key

2.3 Insert vehicle-specific CD in CD-ROM drive.

Once the telltale on the CD-ROM drive has gone out, in the next screen again select the “Download FPS flexibly programmed control" menu item and confirm by pressing the “F3” key.

2.4 Enter password (evobus) in lowercase and as one word.

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2.5 Start the download program.

The following screen is now opened:

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2.6 Confirm by pressing the “F1” function key or move on to the next display via "Open file". The program file intended for the vehicle (can be recognised by vehicle identification number or VIN) must be available. This file now has to be selected. The appropriate file is now displayed in the file name box. Move to the next display by pressing the "OK" key.

N In each case, only one (1) program file is displayed per vehicle CD.

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2.7 Once the FPS file has been successfully downloaded, the vehicle identification number (VIN) must be entered for monitoring purposes. To do this, press the “F2” function key.

N This number MUST be entered in capital letters and without any spaces (e.g. WEB62901213520026).

The safety concept compares the chassis numbers (VINs).

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FPS download safety concept

FIN: WEB62901213520026

1. VIN no. comparison, programe entry with vin no. of FPS pack (on vehicle CD).

FPS-BIN files 2. VIN no. of FPS pack with vin no. from vehicle (in the FPS electronics)

Comparison

Vehicle chassis number

This prevents an incorrect program from being downloaded onto the vehicle.

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2.8 Start the FPS download

Once the vehicle identification number check is complete, the download can be started by pressing the “F3” function key.

At the start of the download, a FPS system comparison is undertaken. The program checks whether all the FPS modules provided are fully functional. During this test, it is possible that a FPS module will not register. This results in the download function being ended. The device structure and voltage supply on the vehicle must be checked. For safety reasons, deactivate voltage on the vehicle then reactivate (red workshop switch 01S01). Restart download.

Firstly, all data from the FPS electronics is deleted. Data is loaded first to the program memory and then duplicate data is loaded into the duplicate memory unit on each FPS electronics are then downloaded. The characteristics memory data of all FPS electronics are only written one after another at the end.

The following data can be found in the characteristics memory data of the FPS electronics:

Time of download Vehicle identification number (VIN) Name of configuration (FPS socket) Version of compilation tool Date of compilation CAESAR ID number CAESAR ID Nummer

A new set of characteristics is downloaded into the characteristics memory after each download.

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2.9 End the download

Once the data has been successfully downloaded, the following message appears:

Press “OK” to confirm and quit the download menu by pressing the “F5” function key. The cable can now be disconnected from the download socket (05X02):

The FPS system is now again fully functional.

2.10 Errors during the FPS download (special download)

If the download has to be aborted for whatever reason once the FPS electronics have been deleted, the download process has to be repeated. Since however, the characteristics memory data of the FPS electronics are empty, the vehicle identification numbers cannot be compared.

The following message appears:

N This message must be confirmed by pressing "Yes" otherwise the vehicle will not function.

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This window then appears:

The following information must be noted down:

FPS file name VIN Code

Now call the after-sales service hotline. Once you have contacted the employee responsible, give them the information noted down from the special downloading process..

After-sales service hotline, Ulm: tel. (+49)-731-181-8873 After-sales service hotline, Mannheim: tel. (+49)-621-740-3280 Hotline can be reached: Monday to Thursday 8.00 a.m.– 5.00 p.m. Friday 8.00 a.m.– 4.00 p.m. Outwith of these hours, the authorisation code can be requested from the plant fire services in Mannheim: tel. (+49)-621-740-0

The after-sales service authorisation code must now be entered into the appropriate box. Once confirmed by pressing the “OK” key, the special downloading process is conducted and the download ended in the normal manner.

N Warning! This window must not be closed before the authorisation code has been entered and confirmed by pressing the “OK” key. Otherwise, another authorisation code must be applied for because the code changes each time you attempt to open this window.

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N The 01S01 and 05X02 designations can also be found in the electric circuit diagrams.

3.) Job instructions for “DMUX download”

A download is required when fitting the new combination instrument or if the combination instrument malfunctions (emergency operations) (exterior lighting and hazard warning flasher system are operating, combination instrument is not functioning). The “Automated parameter setting” must be undertaken after a DMUX download or after an additional switch has been fitted to the combination instrument but has not yet been approved in the combination instrument (in order to do this, a new vehicle CD, with modified parameters, should be applied for via the after-sales service responsible).

N Preconditions for the “DMUX download” (combination instrument) New combination instrument (DMUX) is fitted and connected up. The vehicle-specific files (vehicle CD) are available.

The following are required: Rollboy, Compact or Basic Star diagnosis + service license code CAESAR Part D (can be detected from type plate of CAESAR) CAESAR Part D connection cable (automatically in conjunction with CAESAR Part D) Cable for DMUX download (W 000 589 838 63 00). The cable is connected by means of the 9-pin download socket (05X02) in the E box, driver’s cab.

N Warning! The batteries must be charged, the battery voltage must not fall below 24 volts during the download.

3.1 Establish connection between Star diagnosis, CAESAR and vehicle. Switch off workshop switch 01S01 (rot/red) and then switch back on. Activate range selector level II.

N During the download, battery charging devices must not be connected to the vehicle.

N When the combination instrument is in download mode, “IT CAN Timeout” appears on the display.

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3.2 Start the Star diagnosis and the DAS (Diagnose Assistance System) with subsequent selection of vehicle type and “Download DM Display- Multiplexer” menu item.

Enter the chassis number in the “VIN” box Continue by pressing the “F2” key

3.3 Insert vehicle-specific CD in CD-Rom drive.

Once the telltale on the CD-Rom drive has gone out, again select the “Download DM Display-Multiplexer” menu item in the next screen and confirm by pressing the “F3” key.

3.4 The download is now started.

Since only the program parts required are downloaded, displays including the following may now appear on screen (see photo):

- Initialise program - Initialise DMUX - Download operating system - Download basic program - Download resource - Check DMUX

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During the download, the display in the combination instrument is dark and the red warning display light flashes.

During a download, the following information is saved in a special memory area which can be read via the “Control device identification” menu item:

- Download date - Chassis number - Version of Flashware data record (program version) - CAESAR-ID - Name of download application - Version of download application - Status

3.5 Once the data has been successfully downloaded, the following message appears:

Once confirmed by pressing the “OK” and the download menu has been exited using the “F5” function key, the cable can now be disconnected from the download socket (05X02).

N Warning! After a DMUX download, it is essential that “Automated parameter setting” is undertaken.

4.) Job instructions for “Automated parameter setting”

N Preconditions for undertaking “Automated parameter setting” (combination instrument)

DMUX download has been undertaken or additional switch has been fitted (which has not yet been approved in the combination instrument / in conjunction with a new vehicle CD with modified parameter record).

The following are required: Rollboy, Compact or Basic Star diagnosis + service license code CAESAR Part D CAESAR Part D connection cable 14-pin diagnosis cable (Star diagnosis scope of supply). The cable is connected by means of the 14-pin diagnosis socket (05X01) in the E box, driver’s cab.

N Warning! The batteries must be charged, and battery voltage must not drop below 24 volts during the “Automated parameter setting”.

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4.1 Establish connection between Star diagnosis, CAESAR and vehicle. Activate range selector position II.

N During parameter setting, battery charging devices must not be connected to the vehicle.

4.2 Start the Star diagnosis and the DAS with subsequent selection of vehicle type and the “Short test” or “System identification” menu item.

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4.3 Once the repair order number has been entered (press “F2” key), select the “DM Display Multiplexer” system and confirm by pressing the “F3” key.

This example shows the display screen after system identification.

4.4 Insert vehicle CD in CD-Rom drive. Once the drive telltale has stopped flashing, select the “Automated parameter setting” item from the “Control devices adaptation”

sub-menu and start parameter setting using the “F3” key.

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4.5 Start parameter setting by again pressing the “F3” key.

The following messages now appear in the display: Initialisation MB item number Data is written Download successfully completed

N Warning! After parameter setting, the control unit must be re-initialised.

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4.6 Initialise the combination instrument again

The range selector (ignition) must first be switched off for 10 seconds and then switched back on (is displayed on screen). Then the “F2” key must be pressed. The display shown above appears. Once this procedure is complete, the “Start parameter setting” screen appears again. Parameter setting is now complete. The combination instrument (DMUX) is now again fully functional. If the range selector (ignition) cannot be switched back on immediately after this process, this is not an error. The normal function will be re-established after approx. 5- 10 seconds or once the range selector (ignition) has been switched off and on again.

If the download of the combination instrument is aborted for whatever reason, the download process must be repeated. If this occurs during “Automated parameter setting”, both the combination instrument download and the “Automated parameter setting” will have to be repeated.

N After the parameter setting process, the error memory of the combination instrument will have to be deleted.

The 01S01, 05X01 and 05X02 designations can also be found in the electric circuit diagrams.

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Note the following if “automated programming” is not possible following a DMUX download:

On some vehicles there is a possibility that terminal 15 cannot be switched on following a DMUX download. The terminal 15 relief relay (01K01) is not activated. In this event, it is necessary to bridge the relief relay for terminal 15 (01K01). This relay is located on the auxiliary switch panel (installation location 03). On the S 431 DT, relay 01K01 is located on auxiliary switch panel 1 (installation location 06) and second relay 01K09 is located on the auxiliary switch panel (installation location 03). Both relays on this bus model need to be bridged.

U Caution, risk of short circuit. When bridging relays, take care not to earth live parts (electrical wires, etc.). To enable activation for terminal 15 on the FPC 4 electronics circuit:

Activate high-side output 5 of FPC 4 (auxiliary switch panel, installation location 03), connector V/pin 8, using a fused wire (fuse rating max. 10 amps, 2.5 mm2 cross-section) and a positive signal (see the power supply circuit diagram of the bus model concerned).

It is also possible to activate contact (1) directly at relay (2) as an alternative:

To do this, use a fused wire (fuse rating max. 10 amps, 2.5 mm2 cross-section) to connect control device (1) of terminal 15 relief relay (2) to the positive terminal of terminal 30 (3) (see the power supply circuit diagram of the bus model concerned).

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2

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This line bridge must remain connected until the end of the programming procedure. The bridge must be removed as soon as StarDiagnosis displays the “Switch off ignition (driving switch)” message. All the functions of the DMUX will be available again.

5.) Job instructions for self-sealing

The FPS system is now fully functional again.

Replacement adapter application (FPS self-sealing connector)

Should a FPS module fail completely, this will not necessarily 01S01 result in total system failure but in the failure of all consumers and input parameters connected to this module. This module must therefore be replaced with an intact module as quickly as possible and this also at the same time loaded with the vehicle program required. When new, all FPS modules have the same design. In order to also easily shape the downloading of the correct vehicle-specific program in the replacement FPS, the FPS modules have a duplicate memory unit which contains a complete copy of the program of the neighbouring FPS. By initiating the self-sealing process, the programs required can be easily transferred from the duplicate memory unit of an intact FPS module into the replacement module. C N Warning! The batteries must be charged, the battery voltage must not fall below 24 volts during self-sealing. D N Warning! The batteries must be charged, the battery voltage must not fall below 24 volts during self-sealing.

- Switch off electrical system via workshop switch 01S01 (red). - Replace defective FPS module with replacement module. - Connect FPS replacement adapter (1) to 9-pin download socket (05X02). - Switch electrical system back on via workshop switch 01S01 (red). – Activate range selector level II. - Wait approx. 5 minutes until the telltale on the FPS replacement adapter (1) flashes, then remove replacement adapter.

If self-sealing is interrupted for whatever reason, the process can be easily repeated.

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N A Warning! Before replacing FPS electronics, TI no. 54.00M024 (FPS repairs) MUST be noted.

N If the FPS system is in self-sealing mode, “IT CAN Timeout” appears in the display and the red and yellow warning display lights in the combination instrument light up continuously.

N The 01S01 and 05X02 designations can also be found in the electric circuit diagrams.

EvoBus GmbH

H. Suffel S. Wittlinger Leitung AfterSales Leitung AfterSales Training und -Dokumentation

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