Volvo ECS Training Tips And Tactics Download

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113

ECS Gen. 2

ECS Gen. 2 main

components

1. Pressure sensor

4. Solenoid valve - drive axle

2. ECS ECU

5. Height sensor

3. Solenoid valve -

6. Solenoid valve - trailing axle

front axle

Summary of Contents for ECS

Page 1: ...1 TRAINING TIPS AND TACTICS Electronically Controlled Suspension ECS ...

Page 2: ...2 ...

Page 3: ...ks design and function 49 Solenoid valve operation 51 Solenoid valve block front axle 55 drive axle Not 4x2 tractor 57 drive axle 4x2 tractor 61 bogie 63 Overﬂow valves distribution manifolds 69 Pressure control valve 73 Remote control 9010 77 Remote control 9009 79 Changing the ride height 81 Interlock mode 83 Changing the ride height in interlock mode 85 Memory store recall 85 Bogie switch 87 So...

Page 4: ... drive axle hold 133 drive axle lower 135 Electrical connections 4x2 137 Solenoid valve blocks 6x2 or 8x2 ignition off 141 6x2 or 8x2 raise 143 6x2 or 8x2 lower 145 6x2 or 8x2 axle lift 147 6x2 or 8x2 axle lower 149 Solenoid valve blocks pusher axle 151 Pressure sensors 153 Overﬂow valves 155 Bogie switch 157 Main instrument panel 163 Additional functions 165 Height sensor calibration 181 ECS Gene...

Page 5: ...t this Pocket guide This guide is intended as a memory jogger for the knowledge you have gained during your training course The guide includes a summary of the material covered in Electronically Controlled Suspension ECS ...

Page 6: ...adings DANGER indicates a risk of serious personal injury or death WARNING indicates a risk of personal injury or severe product damage CAUTION indicates risk of product damage Note draws attention to special methods or particular features Read and implement all DANGER WARNING and CAUTION instructions ...

Page 7: ...l that only Volvo genuine parts are ﬁtted If Volvo genuine parts are not used safety features embodied in the vehicle or components may be impaired performance and or operation of the vehicle or components may be adversely affected Volvo warranty terms may be invalidated ...

Page 8: ...garded as an infallible guide to current speciﬁcations of any product Neither Volvo nor the supplier of this guide shall in any circumstances be held liable for inaccuracy or the consequences thereof All rights reserved No part of this publication may be reproduced stored in a retrieval system transmitted or copied without written permission from Volvo Truck Bus Ltd Volvo Truck Bus Ltd 2005 Copyri...

Page 9: ...9 General information ...

Page 10: ...10 General information General information The information in this section applies to all Generations of ECS Information speciﬁc to each Generation is found in the sections Gen 1 Gen 2 or Gen 3 ...

Page 11: ...f a basic air suspension system is the ability to maintain a constant level ride height regardless of changing load This is possible by the use of height control valves which respond to any change of frame to ground clearance and release or admit air to the air springs ...

Page 12: ...12 General information ECU 1 1 1 1 2 2 2 2 3 3 AS 1 Air bellows 2 Height sensor 3 Solenoid valve AS Air supply ECU Electronic Control Unit Air pipe Electronic control signal ...

Page 13: ...laced by electronic height sensors and air admission and release is controlled by solenoid valves The sensors send a voltage signal to an Electronic Control Unit ECU The voltage varies according to ride height The ECU compares the height signals with pre programmed parameters and sends signals to the solenoid valves to admit or release air The concept is shown in the simpliﬁed diagram above Electr...

Page 14: ...ns of ECU 2 connectors vs 1 connector Solenoid valves Bogie switch functions Overﬂow valves 52a and 52b Height sensor calibration Additional Pressure sensors ECS functions VCADS tests Gen 3 vs Gen 2 New versions of ECU Solenoid valves Remote control ...

Page 15: ...on FM trucks in 1998 All ʻElectronic ʻ98ʼ trucks are ﬁtted with ECS Gen 1 Generation 2 was introduced on ʻVersion 2ʼ FM FH trucks All ʻVersion 2ʼ trucks are ﬁtted with ECS Gen 2 Generation 3 was introduced on ʻVersion 2ʼ trucks in week 51 2004 All ʻVersion 2ʼ trucks built after this date are ﬁtted with ECS Gen 3 Gen 1 Gen 2 Gen 3 ...

Page 16: ...16 General information RAD A4 tractor FSS LEAF RAD A4 FSS AIR RAPD A6 FSS LEAF Suspension conﬁgurations ...

Page 17: ...4 FSS LEAF CHH STD Single drive axle CHH 810 CHH 850 CHH 900 RAD A4 4 FSS AIR 2 Single drive axle RAPD A6 4 2 FSS LEAF CHH STD Single drive axle CHH 900 pusher axle bogie Chassis heights later designations CHH XLOW CHH STD 1025mm min CHH LOW CHH MED Front suspension Rear suspension ...

Page 18: ...18 General information RADT A8 FSS AIR RADD A8 FSS AIR Suspension conﬁgurations ...

Page 19: ... springs Chassis heights RADT A8 4 4 FSS AIR 2 CHH850 Single drive axle trailing axle bogie RADD A8 4 4 FSS AIR 2 CHHSTD Double drive axle Chassis heights later designations CHH XLOW CHH STD 1025mm min CHH LOW CHH MED Front suspension Rear suspension ...

Page 20: ...20 1 1a 2a 14 23 24 2b 52a 52b ECS 1a 51 General information 50 ...

Page 21: ...or 1a Safety valve 2a Air dryer 2b Regeneration tank not with AIRDRY E version 2 trucks 14 Wet tank 23 Test point 24 Multi circuit protection valve MCPV 50 Air suspension air tank 51 Pressure limiting valve 52a Overﬂow valve 6 7 7 0 bar 52b Overﬂow valve 10 0 10 4 bar ECS To ECS solenoid valve blocks ...

Page 22: ...22 1 1a 2a 14 23 24 2b 52a 52b ECS 1a 51 General information 50 ...

Page 23: ...r pressure opens the valve air is supplied to the ECS solenoid valve blocks Overﬂow valve 52b is ﬁtted only on trucks with ʻfullʼ air suspension i e at front and rear which have a separate air suspension tank 50 More information on overﬂow valves is included in sections Gen 1 and Gen 2 Overﬂow valves ...

Page 24: ...24 General information 1 2 3 4 5 ...

Page 25: ... sensors 1 are attached to the inside of the chassis frame The bottom end of rod 2 is attached to a point on the axle so any change of height between the frame and axle moves lever 3 Movement of the lever rotates a sliding contact 4 which is in contact with two concentric semi circlular ﬁxed contacts 5 ...

Page 26: ...26 General information 7072LF 7072LR 7072RR 1 4 2 1 4 2 40 42 26 28 41 1 4 2 1 4 2 1 4 2 4 5 2 5 0 5 Ride height Voltage output 9073 ...

Page 27: ...lar contact can supply between 5V and 0V to the sliding contact This voltage which varies in direct proportion to the ride height is fed to ECU pin 26 The ECU compares the sensor signal with pre programmed desired height parameters and sends signals to the air control solenoid valves The valves admit or release air from the air springs to maintain the programmed level chassis ride height Note At n...

Page 28: ...28 General information Sensor SID Component No Wiring diag No location Version 2 truck Electronics ʻ98 truck Front axle 17 B28 7072LF Rear axle RH 18 B30 7072RR Rear axle LH 19 B29 7072LR ...

Page 29: ...he O S Note The use of only one sensor is possible because a 4x2 tractor has a short wheelbase This means that the chassis frame is rigid with very little twist Consequently there is little side to side height deviation Trucks with front air suspension FSS AIR have one front sensor The chart above shows the unique reference numbers for each sensor Note If a sensor is removed and reﬁtted or renewed...

Page 30: ...30 General information 1 4 2 3 5 7 6 ...

Page 31: ...Plunger 7 Guide pin Bellows plate 3 is attached to the frame and plunger 6 is attached to the axle During normal suspension movement and during frame height change rubber air bellows 5 rolls up and down plunger 6 If the bellows is fully compressed due to e g loss of air pressure high speed cornering very uneven surfaces the load is carried on damper 4 ...

Page 32: ...32 General information 1 4 2 3 5 7 6 ...

Page 33: ...damper because of loss of air pressure the vehicle may be driven at up to 10km h DANGER When renewing the air bellows ensure that the following safety precautions are implemented at all times Block up the truck frame Empty all air tanks Chock the truck wheels Renewing air bellows ...

Page 34: ...ping and wheels 70 General 71 Frame 72 Suspension 720 General 7200 General 721 Front spring leaf 72 FH12 Air suspension drive level positions Air suspension speciﬁcations 7281 Air suspension 7281 Compressed air components ECS signal description ...

Page 35: ...35 General information Use IMPACT To ensure that you are using the latest information especially ʻSpeciﬁcationsʼ always get your information via IMPACT Suspension group 72 ...

Page 36: ...36 ...

Page 37: ...37 ECS Generation 1 ...

Page 38: ...38 ECS Gen 1 3 4 5 6 7 9 1 2 8 3019B 3019A ...

Page 39: ...ostic socket 3 Indicator lamps 4 Pressure gauge 5 Pressure sensors for wet tank 754 connected directly to VECU for rear axle load 6x2 6x4 8x2 8x4 7064 connected to ECS ECU 6 Bogie switch 133 7 Relay panel for solenoid valve 3019A for ECU power supply 3019B 8 ʻINFOʼ ʻSTOPʼ lamps information display 9 ECS ECU MID 150 ...

Page 40: ...40 ECS Gen 1 X A B ...

Page 41: ...n This icon is also displayed when suspension air pressure is too low If the truck is driven at above 10 km h the warning buzzer sounds Icon B is displayed when the ʻvehicle is not in a drivable positionʼ i e when the suspension system is still adjusting to the correct ride height When the correct height is reached the icon is cancelled ...

Page 42: ...42 ECS Gen 1 1 2 3 5 12 14 3 4 5 10 11 14 14 16 17 6 7 8 9 15 16 14 3 13 ...

Page 43: ...e 6 Distribution manifold extra equipment axle lift bellows 7 Safety valve 8 Wet tank 9 Test nipple 10 Solenoid valve block front axle 6035LF 11 Solenoid valve block drive axle 6035C 12 Solenoid valve block bogie 6045 13 Overﬂow valve 52a and 52b 14 Air bellows drive axle 15 ECS air tank 16 Air bellows trailing axle 17 Lift bellows taring axle ...

Page 44: ...S Gen 1 MID 171 Inst MID 144 Veh ECU MID 128 Engine MID 150 Air susp MID 136 ABS MID 223 Gear lever MID 130 Gearbox MID 232 SRS MID 163 Immob OPTIONS Diag Slow data link J1587 J1708 Fast data link J1939 9073 ...

Page 45: ...45 ECS Gen 1 ECS Gen 1 ECU data link The Gen 1 ECU has only one connector and is connected only to the slow data link ...

Page 46: ...46 ECS Gen 1 12 9073 1 U 14 22 86 85 30 87a 87 F12 U U 3019B 12 9073 1 U 14 22 86 85 30 87a 87 DR F12 U U 3019B Ignition OFF Ignition ON ...

Page 47: ... signal is sent to ECU pin 22 The ECU switches a negative to relay pin 85 via ECU pin 12 Because fuse F12 is supplying voltage to relay pin 30 and by link to pin 86 the relay is energised Pins 30 and 87 are now connected Voltage from fuse F12 can now pass through the relay to ECU pin 1 ...

Page 48: ...48 ECS Gen 1 C ...

Page 49: ...ock B Drive axle valve block variant 1 for 4x2 tractor variant 2 for other than 4x2 tractor C Bogie axle valve block variant 1 for trailing axle variant 2 for pusher axle All valve blocks contain solenoid operated air valves which control air ﬂow to and from the air bellows The solenoids are energised or de energised by signals from the ECS ECU ...

Page 50: ...50 ECS Gen 1 24V 24V 24V E DE 24V 24V DE 24V E A B 1 3 2 1 3 2 ...

Page 51: ... to one pin negative supplied to other pin Air can pass through the valve DE Control solenoid ʻDe energisedʼ 24V supplied to both pins Outlet 2 is connected to exhaust 3 No air can pass from inlet 1 to outlet 2 E control solenoid ʻEnergisedʼ 24V supplied to one pin negative supplied to other pin Inlet 1 is connected to outlet 2 Air can pass through the valve A solenoid de energised A solenoid ener...

Page 52: ...52 ECS Gen 1 ...

Page 53: ... front air bellows 22 Air to and from RH front air bellows B Solenoid valve drive axle 6035C 1 Air supply from wet tank 3 Air drain via silencer 21 Air to and from LH drive axle air bellows and trailing or pusher LH air bellows 22 Air to and from RH drive axle air bellows and trailing or pusher LH air bellows 23 Air to and from front axle solenoid valve plugged if rear air suspension only ...

Page 54: ...54 ECS Gen 1 87a 87 30 86 85 X U U 3 29 15 10 4 1 9073 3019A 6035LF 22 21 4 4 1 3 1 22 21 4 4 1 3 1 24V 24V 24V DE E ...

Page 55: ...xle 6035LF SID 2 1 3 Supply air from and drain to drive axle valve 6035C 4 Air supply from wet tank 21 Air to and from LH front air bellows 22 Air to and from RH front air bellows 3019A Power supply relay ECU to solenoid valve 6035F Solenoid valve front axle 9073 ECS ECU ...

Page 56: ...56 ECS Gen 1 87a 87 30 86 85 X U U 5 29 15 10 3 4 9073 3019A 6035C U 4 2 U 6 1 ...

Page 57: ...ng or pusher LH air bellows 22 Air to and from RH drive axle air bellows and trailing or pusher RH air bellows 23 Air to and from front axle solenoid valve plugged if rear air suspension only 3019A Power supply relay ECU to solenoid valve 6035C Solenoid valve drive axle 9073 ECS ECU Solenoid valve block drive axle SID Noʼs SID 3 RH SID 4 LH SID 7 central ...

Page 58: ...58 ECS Gen 1 23 1 22 21 3 6035C ...

Page 59: ... and from front axle solenoid valve plugged if rear air suspension only The solenoid block for all variants except 4x2 tractor contains 3 solenoid valves SID 3 the RH valve air to and from RH air bellows for drive axle and trailing or pusher axle SID 4 the LH valve air to and from LH air bellows for drive axle and trailing or pusher axle SID 7 the ʻcentralʼ valve operating as a control valve Solen...

Page 60: ...60 ECS Gen 1 1 3 22 21 6035C 4x2 ...

Page 61: ...axle valve 6035C 4 Air supply from wet tank 21 Air to and from LH front air bellows 22 Air to and from RH front air bellows The solenoid block for 4x2 tractors contains 2 solenoid valves SID 3 the RH valve air to and from RH and LH air bellows SID 7 the ʻcentralʼ valve operating as a control valve ...

Page 62: ...62 ECS Gen 1 87a 87 30 86 85 X U U 9 29 15 10 1 4 9073 3019A 6045 U 8 2 U 7 3 6045 ...

Page 63: ...pply from drive axle valve block port 22 13 Air supply to bogie lift 14 Air supply to drive axle load sensor 21 Air to and from trailing or pusher LH air bellows 21 Air to and from trailing or pusher RH air bellows 23 Air to and from trailing or pusher lifting bellows 3019A Power supply relay ECU to solenoid valve 6045 Solenoid valve bogie 9073 ECS ECU ...

Page 64: ...64 ECS Gen 1 23 13 3 21 22 6045 1 4 2 4 4 3 LV RV 11 12 SID 10 SID 9 SID 8 ...

Page 65: ...bogie lift 14 Air supply to drive axle load sensor 21 Air to and from trailing or pusher LH air bellows 21 Air to and from trailing or pusher RH air bellows 23 Air to and from trailing or pusher lifting bellows LV Limiting valve RV Retention valve SID 8 Blocking valve SID 9 Draining valve SID 10 Lifting valve ECS Gen 1 Solenoid valve block bogie ...

Page 66: ...66 ECS Gen 1 23 13 3 21 22 6045 1 4 2 4 4 3 LV RV 11 12 SID 10 SID 9 SID 8 ...

Page 67: ...n the set pressures of the limiting valve LV and the retention valve RV which control the residual pressure in the lifting bellows Residual pressure is set between 0 5 and 0 9 bar Residual pressure is set between 1 2 and 1 6 bar When residual pressure falls to the lower limit the limiting valve cuts in and supplies air to the lifting bellows When residual pressure reaches the higher limit the rete...

Page 68: ...68 ECS Gen 1 ...

Page 69: ...Distributor manifold D Safety valve E Test nipple 1 From wet tank 2 To drive axle solenoid valve 6035C port 1 3 From drive axle solenoid valve 6035C port 21 4 From drive axle solenoid valve 6035C port 22 5 To drive axle LH air bellows 6 To drive axle RH air bellows 7 To load sensing valve ports 41 and 42 8 To air suspension air tank ...

Page 70: ...70 ECS Gen 1 52a 52b 1 2 1 2 3 ...

Page 71: ... e at front and rear which have a separate air suspension tank 50 To ensure that the vehicle reaches correct ride height as soon as possible valve 52b feeds air to ﬁll the air bellows before allowing air to suspension air tank 50 The valve opens at 10 0 to 10 4 bar to allow air into the suspension air tank If the pressure is lower at inlet 1 than at outlet 2 the valve allows return ﬂow from outlet...

Page 72: ...72 ECS Gen 1 41 42 2 1 6045 56 56 56 56 57 57 6035C ...

Page 73: ...7 Non drive axle air bellows 6035C Drive axle valve block 6045 Bogie valve block A pressure control valve is ﬁtted only to early trucks with a pusher axle bogie up to and including ʻElectronics ʻ98 The valve controls the pressure in the non drive axle air bellows in proportion to the pressure in the drive axle air bellows In this way the weight distribution between the axles ensures optimum tracti...

Page 74: ...74 ECS Gen 1 41 42 2 1 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 10 DRIVE AXLE x 100 kPa NON DRIVE AXLE x 100kPa ...

Page 75: ...e signal from the non drive axle air bellows Connect an air supply via an adjustable pressure regulator to ports 1 41 and 42 Connect a pressure gauge to port 2 Gradually increase the supply pressure and note the valve output pressure on the gauge Supply pressure Output pressure 1 0 5 2 0 5 3 0 5 4 0 5 5 4 6 6 CAUTION The valve adjuster screw is sealed Adjustment has legal implications re axle load...

Page 76: ...76 ECS Gen 1 33 17 31 16 9073 19 14 U U U U U U U U U U U U U 9010 MAN 1 MAN 2 UP DOWN MEM 1 3 9010 When closed the internal switches connect the common earth to the appropriate pins ...

Page 77: ...ol 9010 Control 9010 is used for trucks with rear air suspension only Switch 1 Control switch position UP CENTRE DOWN Manual control MAN1 Drive position AUT Control of drive posʼn MAN2 3 Regulator switch Move up Stop Move down ...

Page 78: ...78 ECS Gen 1 33 17 31 16 9073 19 14 U U U U U U U U U U U U U 9009 MAN 1 MAN 2 18 32 U U U U FRT PAR UP DOW MEM 1 2 3 9009 ...

Page 79: ...h full air suspension ECS Gen 1 Switch position UP CENTRE DOWN Manual control MAN1 Drive position AUT Control of drive posʼn MAN2 3 Regulator switch Raise Stop Lower Front axle mem M1 Front rear axle mem PARA M2 Rear axle mem M3 1 Control switch 2 Axle switch ...

Page 80: ...ssis height Bogie Maximum change of arrangement position mm CHH STD RAD A4 RAPD A6 40 RADT A6 40 RADD A8 0 0 CHH MED RAD A4 WB 3 7 7 0 RAD A4 WB 3 7 7 0 RAPD A6 0 0 CHH LOW RAD A4 RADT A6 0 0 CHH XLOW RADT A8 RADT A6S ...

Page 81: ...height to be changed up to 40 mm However as shown in the chart the maximum permissible height increase is 10 mm and this is only with bogie arrangement RADT A6 with chassis height CHH STD DANGER Do not leave the control switch in the MAN 1 position when working on the truck with the ignition off Because the system is in stand by mode automatic height adjustment may still occur This may cause a dan...

Page 82: ...82 ECS Gen 1 Location to be raised or lowered Front Rear Front rear Front LH Front RH Rear LH Rear RH 1 Control switch position 2 2 2 3 1 3 1 2 Axle switch position 1 3 2 1 1 3 3 1 2 3 1 2 3 1 2 3 ...

Page 83: ...e blocks are removed so automatic height adjustment does not work A quick method to ﬁnd out if the system is in interlock mode on trucks with a lifting rear axle put the control switch 1 in normal driving position AUT move the regulator switch 3 to raise or lower position if the axle is raised or lowered the system is in interlock mode Is the system in interlock mode ...

Page 84: ...84 ECS Gen 1 Location to be raised or lowered Front Rear Front rear Front LH Front RH Rear LH Rear RH 1 Control switch position 2 2 2 3 1 3 1 2 Axle switch position 1 3 2 1 1 3 3 1 2 3 1 2 3 1 2 3 4 ...

Page 85: ...ve Note Because of the design of the solenoid block used on 4x2 tractors i e ports 21 and 22 are controlled by a common solenoid valve individual control of LH and RH is not possible The settings arrived at using switch 2 in M1 or M2 position can be stored in memory and recalled using button 4 To store a setting press the button for more than 5 sec To recall a setting press the button for less tha...

Page 86: ...86 ECS Gen 1 35 9073 20 2 4 10 1 7 9 1 0 2 Press Lift 133 133 1 3 2 ...

Page 87: ...tion between the two axles The switch used with ECS Gen 1 has 3 ﬁxed positions Switch position Result 1 upper section Axle lift or axle press with offset pressed raising Max axle load 11 5 13 0 or 15 0 tonne depending on variant 2 centre position Normal drive position axle lowered 3 lower section Axle press without offset pressed raising ...

Page 88: ...88 133 1 3 2 ECS Gen 1 ...

Page 89: ...sting all the air from the non drive axle air bellows This can give extra traction and can be useful on certain poor road surfaces e g slippery rutted quarry roads etc Offset raising raises the chassis height slightly to maintain ground clearance of raised axle tyres It is achieved by supplying more air to the drive axle air bellows when the non drive axle is raised ...

Page 90: ...90 ECS Gen 1 87a 87 30 86 85 X U U 9 29 15 10 1 4 9073 3019A 6045 U 8 2 U 7 3 X U 5 1 4 6035C U 4 2 U 6 3 X U 3 1 4 6035LF ...

Page 91: ... correct relay 3019A will not be energised If the return signal is correct ECU pin 10 will supply a negative to relay pin 85 Because ECU pin 15 supplies battery voltage to relay pin 30 and by link to pin 86 the relay is now energised and supplies battery voltage to the solenoids via pin 87 ECU pins 3 4 5 6 7 8 and 9 also supply battery voltage to the solenoids so the solenoids are not energised To...

Page 92: ...92 ECS Gen 1 87a 87 30 86 85 X U U 9 29 15 10 1 4 9073 3019A 6045 U 8 2 U 7 3 X U 5 1 4 6035C U 4 2 U 6 3 X U 3 1 4 6035LF ...

Page 93: ...ply from pin 10 from negative to positive Relay 3019A is no longer energised so battery voltage from ECU pin 15 can not pass through the relay to the solenoids At the same time ECU pins 3 4 5 6 7 8 and 9 become negative and ECU pin 29 is positive All solenoids are now energised and the chassis is raised In this condition the only way to alter the ride height is to use the remote control The ECU wi...

Page 94: ...94 ...

Page 95: ...ir bellows bogie 58 air bellows axle lift 68 Air bellows front axle 3019A Relay solenoid valves 3019B Relay ECU power supply 6035C Sol valve drive axle 6035LF Sol valve front axle 6045 Sol valve bogie 7072LF LR RR Height sensors 7064 Pressure sensor 9073 ECS ECU 9009 Remote control ...

Page 96: ...96 ECS Gen 1 9073 39 U FA11 KL15 A Parameter ʻLTʼ to ON ...

Page 97: ...r of which is ﬁtted by the body builder The body builder also ﬁts some type of signal to indicate when level control is switched off The switch connection to the ECS ECU is as shown in the above diagram When switch A is closed if the parking brake is applied level control is switched off on both front and rear axles if the parking brake is released level control is switched off on the front axle o...

Page 98: ...98 ECS Gen 1 H1 H2 6x2 RADT A6S RAPD A6 4X2 H2 6X2 RADT A6 6X4 8X2 8X4 RST AIR RST AIR2 H2 4x2 FRONT AXLE ...

Page 99: ...99 ECS Gen 1 The diagrams above show the position of the measuring tools for various bogie conﬁgurations Height sensor calibration measuring positions ...

Page 100: ...100 ECS Gen 1 9998626 9998326 ...

Page 101: ...emoved and reﬁtted a new sensor is ﬁtted a new ECS ECU is ﬁtted Refer to IMPACT for correct ride height speciﬁcations Follow the calibration instructions in IMPACT and VCADSPro User Manual Note During calibration there must be no load on the truck On trucks with a lifting axle the axle must be down ...

Page 102: ...102 ECS Gen 1 9998551 9998534 ...

Page 103: ...103 ECS Gen 1 Test equipment 9511355 is used to connect to the ECS ECU 9998534 is used to check height sensors and solenoid valves ...

Page 104: ...104 ECS Gen 1 1 ...

Page 105: ...105 ECS Gen 1 Test equipment Connecting to the ECU System check using break out box and test harness Pull out purple locking slide 1 to remove the multi way plug Connect cables as shown above ...

Page 106: ...106 ECS Gen 1 9998555 ...

Page 107: ...et using communications unit 9998555 several tests and settings can be carried out The checks and settings are listed on a testing calibration menu Instructions on how to reach and use the menu are contained within the VCADSPro programme and in Group 0 of the VCADSPro User Manual ...

Page 108: ...108 ...

Page 109: ...109 ECS Generation 2 ...

Page 110: ...110 ECS Gen 2 1 2 3 7 6 5 4 ...

Page 111: ...Remote control 4 Pressure sensor The main differences between Gen 1 and Gen 2 systems are ECU now has 2 connectors Solenoid valves Additional pressure sensors Bogie switch operation Overﬂow valves Height sensor calibration Additional functions Additional VCADSPro tests Only one relay Gen 1 Gen 2 main differences ...

Page 112: ...112 ECS Gen 2 1 2 3 4 1 5 1 1 5 1 6 5 6x2 full air suspension trailing axle bogie ...

Page 113: ...113 ECS Gen 2 ECS Gen 2 main components 1 Pressure sensor 4 Solenoid valve drive axle 2 ECS ECU 5 Height sensor 3 Solenoid valve 6 Solenoid valve trailing axle front axle ...

Page 114: ...S B EBS ABS F EECU VECU LCM TECU Tacho GECU RECU ECS BBM Audio Cluster Alarm IMMO SWM Buttons in wheel Phone SRS STD MCC ECC Dyna VCADS ESP J1939 2 J1939 5 J1939 3 J1708 J1587 J1939 1 CAN 4 SAE J1939 Body builder PWM 9073 ...

Page 115: ...115 ECS Gen 2 ECU data link ECS Gen 2 The Gen 2 ECU has two connectors X1 30 pins and X2 22 pins and is connected to both the slow data link and the fast data link ...

Page 116: ...116 ECS Gen 2 S66 MAN 1 MAN 2 UP DOWN MEM A16 MID 150 X2 15 4 5 3 1 2 K11 X1 12 X1 2 X1 16 X1 1 X1 15 X1 13 X2 22 X2 3 X2 5 X2 2 X2 12 F23 30 F49 DR X2 4 ...

Page 117: ...ithin the offside storage locker behind the drivers seat When the ignition key is turned on a voltage is fed from the DR line to the ECU via fuse F49 The ECU now energises relay K11 via pin X2 5 Via fuse F23 K11 now supplies a voltage from the 30 line to ECU pin X2 2 and pin 2 12 ...

Page 118: ...118 ECS Gen 2 C ...

Page 119: ...Gen 2 A Front axle valve block B Drive axle valve block variant 1 for 4x2 tractor variant 2 for other than 4x2 tractor C Bogie axle valve block All valve blocks contain solenoid operated air valves which control air ﬂow to and from the air bellows The solenoids are energised or de energised by signals from the ECS ECU ...

Page 120: ...120 ECS Gen 2 24V E DE DE 24V DE A B 1 3 2 1 3 2 ...

Page 121: ...edʼ 24V supplied to one pin negative supplied to other pin Air can pass through the valve DE Solenoid ʻDe energisedʼ Negative to one pin Outlet 2 is connected to exhaust 3 No air can pass from inlet 1 to outlet 2 E Solenoid ʻEnergisedʼ 24V supplied to one pin negative supplied to other pin Inlet 1 is connected to outlet 2 Air can pass through the valve A solenoid de energised A solenoid energised ...

Page 122: ...122 ECS Gen 2 23 21 1 3 22 21 1 3 4 22 A B ...

Page 123: ...rom wet tank 21 Air to and from LH front air bellows 22 Air to and from RH front air bellows B Solenoid valve drive axle Y25 1 Air supply from wet tank 3 Air drain via silencer 21 Air to and from LH drive axle air bellows 22 Air to and from RH drive axle air bellows 23 Air to and from front axle solenoid valve plugged if rear air suspension only ...

Page 124: ...124 ECS Gen 2 X X1 8 4 1 A16 Y40 22 21 4 4 1 3 1 22 21 4 4 1 3 1 24V DE E Y40 22 1 3 21 4 ...

Page 125: ...alve block front axle A16 ECS ECU Y40 Solenoid valve front axle 1 3 Supply air from and drain to drive axle valve 6035C 4 Air supply from wet tank 21 Air to and from LH front air bellows 22 Air to and from RH front air bellows ...

Page 126: ...126 ECS Gen 2 21 22 23 3 1 2 3 4 1 Y25 Y25 ...

Page 127: ...4x2 Y25 Solenoid valve drive axle 1 Air supply from wet tank 3 Exhaust via silencer 21 Air to and from LH drive axle air bellows 22 Air to and from RH drive axle air bellows The solenoid valve block for other than 4x2 trucks contains 3 solenoid valves ...

Page 128: ...128 ECS Gen 2 21 22 3 1 2 4 1 Y25 Y25 ...

Page 129: ... 3 Exhaust via silencer 21 Air to and from LH drive axle air bellows 22 Air to and from RH drive axle air bellows The solenoid valve block for 4x2 trucks contains 2 solenoid valves Because both LH and RH air bellows are fed from a common solenoid valve the bellows cannot be inﬂated or deﬂated independently ...

Page 130: ...130 ECS Gen 2 24V 22 21 3 1 4 4 2 1 ...

Page 131: ...ʻraiseʼ position and or the ECU receives a ʻraiseʼ signal from a height sensor the ECU sends 24 V to energise the control solenoid and drive axle solenoid Air can now pass from valve block inlet 1 supply from wet tank to outlets 21 and 22 to the LH and RH air bellows The chassis is raised to the required height ...

Page 132: ...132 ECS Gen 2 22 21 3 1 4 4 2 1 ...

Page 133: ...f position and or the ECU receives a signal from a height sensor conﬁrming that the correct ride height has been reached the ECU removes 24 V from the control solenoid and drive axle solenoid The solenoid valves close so no air can escape from the air bellows The chassis is stays at the required height ...

Page 134: ...134 ECS Gen 2 22 21 3 1 4 4 2 1 24 V ...

Page 135: ...o ʻlowerʼ position and or the ECU receives a ʻlowerʼ signal from a height sensor the ECU sends 24 V to energise the drive axle solenoid The control solenoid is not energised so a path from the drive axle solenoid valve to exhaust via the control valve is created The chassis is lowered to the required height ...

Page 136: ...n 2 S66 MAN 1 MAN 2 UP DOWN MEM A16 MID 150 X2 15 4 5 3 1 2 K11 X1 12 X1 2 X1 16 X1 1 X1 15 X1 13 X2 22 X2 3 X2 5 X2 2 X2 12 F23 30 F49 DR X2 4 X2 10 X1 5 X1 30 X1 7X1 23 X1 17 X1 28 X1 11 1 4 2 1 4 2 B30 B58 Y25 ...

Page 137: ...y K11 Relay battery supply to ECU S66 Remote control Y25 Solenoid valve drive axle ECU A16 sends a low earth signal to height sensor B30 from pin X1 11 pressure sensor B58 from pin X1 7 ECU A16 sends a reference voltage to height sensor B30 from pin X1 17 0 5V to 4 5V pressure sensor B58 from pin X1 30 0 2V to 4 8V ...

Page 138: ...n 2 S66 MAN 1 MAN 2 UP DOWN MEM A16 MID 150 X2 15 4 5 3 1 2 K11 X1 12 X1 2 X1 16 X1 1 X1 15 X1 13 X2 22 X2 3 X2 5 X2 2 X2 12 F23 30 F49 DR X2 4 X2 10 X1 5 X1 30 X1 7X1 23 X1 17 X1 28 X1 11 1 4 2 1 4 2 B30 B58 Y25 ...

Page 139: ...5 Solenoid valve drive axle ECU A16 receives a varying voltage signal from height sensor B30 at pin X1 28 representing chassis height ECU A16 receives a varying voltage signal from pressure sensor B58 at pin X1 23 representing chassis weight Pin X2 22 provides the main earth connection for ECU A16 The common earth point also provides an earth path for height sensor B30 ...

Page 140: ...axle bellows 22 To RH drive axle bellows 23 To front axle Y25 solenoid valve drive axle Y29 Solenoid valve trailing pusher axle axle lift 56 Air bellows drive axle 57 Air bellows trailing pusher axle 58 Air bellows axle lift PIN NUMBERS 1 Control 2 Air bellows trailing pusher 3 Air bellows axle lift 4 Earth Y25 ...

Page 141: ...on spread across 2 pages Note that with ignition off air cannot pass through any valve So on Gen 2 system when the ignition is switched off the lifting axle does not drop down PORT NUMBERS 1 Air supply from wet tank 3 Exhaust 21 To LH RH trailing pusher bellows 22 To lift axle bellows 23 Plugged Y29 ...

Page 142: ...drive axle bellows 22 To RH drive axle bellows 23 Y25 Solenoid valve drive axle Y29 Solenoid valve trailing pusher axle axle lift 56 Air bellows drive axle 57 Air bellows trailing pusher axle 58 Air bellows axle lift PIN NUMBERS 1 Control 2 Air bellows trailing pusher 3 Air bellows axle lift 4 Earth 24 24 24 ...

Page 143: ...ceives a ʻraiseʼ signal from a height sensor the ECU sends 24 V to energise the control solenoid and drive axle solenoids in Y25 The control solenoid and drive axle solenoid in Y29 are also energised Air is supplied to both the drive axle and trailing pusher axle air bellows 24 24 PORT NUMBERS 1 Air supply from wet tank 3 Exhaust 21 To LH RH trailing pusher bellows 22 To lift axle bellows 23 Plugg...

Page 144: ...e bellows 22 To RH drive axle bellows 23 To front axle Y25 Solenoid valve drive axle Y29 Solenoid valve trailing pusher axle axle lift 56 Air bellows drive axle 57 Air bellows trailing pusher axle 58 Air bellows axle lift PIN NUMBERS 1 Control 2 Air bellows trailing pusher 3 Air bellows axle lift 4 Earth 24 24 Y25 ...

Page 145: ... switch to ʻlowerʼ position and or the ECU receives a ʻlowerʼ signal from a height sensor the ECU removes 24V from the control solenoids in Y25 and Y29 the air bellows solenoids remain energised Air escapes to atmosphere via ports 3 24 PORT NUMBERS 1 Air supply from wet tank 3 Exhaust 21 To LH RH trailing pusher bellows 22 To lift axle bellows 23 Plugged Y29 ...

Page 146: ...le bellows 22 To RH drive axle bellows 23 To front axle Y25 Solenoid valve drive axle Y29 Solenoid valve trailing pusher axle axle lift 56 Air bellows drive axle 57 Air bellows trailing pusher axle 58 Air bellows axle lift PIN NUMBERS 1 Control 2 Air bellows trailing pusher 3 Air bellows axle lift 4 Earth 24 Y25 ...

Page 147: ...nergises the control solenoid in Y25 and control and lift axle solenoids in Y29 Air is fed to the lift axle air bellows 58 Max air pressure in the lift axle air bellows is 12 bar for a pusher axle and 8 bar for a trailing axle The ride height is raised by 5 to 8mm 24 24 PORT NUMBERS 1 Air supply from wet tank 3 Exhaust 21 To LH RH trailing pusher bellows 22 To lift axle bellows 23 Plugged Y29 ...

Page 148: ...le bellows 22 To RH drive axle bellows 23 To front axle Y25 Solenoid valve drive axle Y29 Solenoid valve trailing pusher axle axle lift 56 Air bellows drive axle 57 Air bellows trailing pusher axle 58 Air bellows axle lift PIN NUMBERS 1 Control 2 Air bellows trailing pusher 3 Air bellows axle lift 4 Earth 24 Y25 ...

Page 149: ...esses the bogie switch to ʻlower axleʼ position the ECU removes the voltage from the control solenoid in Y29 Air escapes to atmosphere via port 3 of Y29 Note that the ʻlift axleʼ solenoid in Y29 remains energised 24 PORT NUMBERS 1 Air supply from wet tank 3 Exhaust 21 To LH RH trailing pusher bellows 22 To lift axle bellows 23 Plugged Y29 ...

Page 150: ...150 ECS Gen 2 22 21 1 3 ...

Page 151: ... axle solenoid valve block 3 Exhaust via silencer 21 Air to and from LH and RH bogie axle air bellows 22 Air to and from lifting axle air bellows The solenoid valve block for 4x2 trucks contains 2 solenoid valves The valves control the pusher axle suspension air bellows and the lifting axle air bellows ...

Page 152: ...152 A16 MID 150 X1 30 X1 7 X1 20 X1 21 X1 22 X1 23 ECS Gen 2 B57 B55 B24 B58 1 4 2 1 4 2 1 4 2 1 4 2 B56 1 4 2 X1 19 ...

Page 153: ...lows B55 lift axle suspension bellows B56 front axle bellows B57 drive axle bellows RH B58 drive axle bellows LH This allows the pressure in each individual circuit to be separately monitored This means that the pressure control valve is not needed Pressure vs voltage Sensed pressure bar Voltage to ECU 1 0 8 3 1 5 5 2 2 7 2 8 9 3 5 11 4 2 ...

Page 154: ...154 ECS Gen 2 ...

Page 155: ...2 Overﬂow valves Gen 2 overﬂow valves are still referred to as 52a and 52b As for the Gen 1 design the two valves are identical externally but different internally 52a 6 7 7 0 bar 52b 10 0 10 3 bar Opening pressure ...

Page 156: ...156 ECS Gen 2 0 1 2 ...

Page 157: ...according to the suspension variant Position 3 is normally spring return Switch position Result 0 upper section Axle lifted unladen condition pressed only 1 centre position Normal drive position axle lowered 60 load on drive axle 40 load on pusher trailing axle 2 lower section 1st press optimised traction pressed 2nd press extra traction 3rd press back to 60 40 split Light ON OFF ON FLASH OFF See ...

Page 158: ...158 ECS Gen 2 0 1 2 ...

Page 159: ...bution between the two axles The switch may have 2 or 3 positions according to the suspension variant Position 3 is normally spring return Switch position Result 0 upper section Axle lifted laden max 14950kg pressed Drive axle load increased by 30 1 centre position Axle lowered optimised traction 2 lower section 1st press extra traction pressed 30 kph 2nd press back to optimised traction See follo...

Page 160: ...ve the best weight distribution and traction for the prevailing conditions The pressure is controlled by the ECU in response to air pressure signals from the air bellows pressure sensors When driving in certain conditions of poor road surface composition e g slippery rutted quarry roads etc it may be possible to increase traction if more weight is carried by the drive axle This is done by releasin...

Page 161: ...161 ...

Page 162: ...162 ECS Gen 2 1 2 3 4 5 ...

Page 163: ...s designed to get the attention of the driver 1 STOP 2 CHECK 3 Information The information display panel 4 can be used to access a variety of additional information including diagnostic information e g fault codes If the truck has a lifting axle indicator lamps 5 show the status of the axle ...

Page 164: ... 6 7 8 1 Inhibit ride height 1x2P 2x2P 2x2P 2x2P 2x2P 2x2P 2x2P 2x2P 2 Kneeling Park brake applied 1x2P 1x3P 2x2P 1x3P 1x3P 2x2P 3 Kneeling One axle 1x2p 2x2P 2x2P 4 Alternative drive height 1x2P 2x2P 2x2P 2x2P 2x2P 5 Load height M1 1x2P 1x3P 1x3P 2x2P 6 Load height M2 1x2P 2x2P 7 Ferry mode 1x2P 1x3P 8 Alternative axle load distribution 1x2P ...

Page 165: ... functions the customer can choose one or two of functions 1 8 function 11 The table above shows permitted combinations and the required switches 1x2P One x 2 position switch 2x2P Two x 2 position switch 1x3P One by 3 position switch Combination not permitted Function not requested if other function is requested or active ...

Page 166: ... 6 7 8 1 Inhibit ride height 1x2P 2x2P 2x2P 2x2P 2x2P 2x2P 2x2P 2x2P 2 Kneeling Park brake applied 1x2P 1x3P 2x2P 1x3P 1x3P 2x2P 3 Kneeling One axle 1x2P 2x2P 2x2P 4 Alternative drive height 1x2P 2x2P 2x2P 2x2P 2x2P 5 Load height M1 1x2P 1x3P 1x3P 2x2P 6 Load height M2 1x2P 2x2P 7 Ferry mode 1x2P 1x3P 8 Alternative axle load distribution 1x2P ...

Page 167: ...wn would need One x 2 position switch Function 1 with function 2 would need Two x 2 position switches etc Note Only one of functions 2 3 5 and 6 can be activated at the same time Functions 3 and 5 6 7 are not available together Example ...

Page 168: ...utomatic adjustment is not wanted e g using a snow plough DIH on pin X2 06 BHA 1 to inhibit ride height adjustment One x 2 position switch BHC DIH Digital High Input In simple terms a ʻpositiveʼ Parameters in the ECU which are switched on The ECU will then accept DIH input as a programming request Function 1 Programming ...

Page 169: ... the chassis is lowered at the front and or rear by the amount programmed Can be applied when the road speed is 30 km h and functions 1 3 5 or 6 are not active or requested DIH on pin X2 06 BHA 2 to kneel when park brake applied One x 2 position switch BHC Function 2 Programming ...

Page 170: ...sed the chassis is lowered at front or rear by the amount programmed Can be applied when the road speed is 30 kmh and functions 1 2 5 or 6 are not active or requested DIH on pin X2 06 BHA 3 to kneel at front or rear One x 2 position switch BHC Function 3 Programming ...

Page 171: ...ts to the normal setting Note The alternative height must be within the permitted range for the particular truck suspension variant If the function switch is not pressed the ride height will be either the normal ride height or the height last set using the remote control DIH on pin X2 06 BHA 4 to activated alternative ride height One x 2 position switch BHC Function 4 Programming ...

Page 172: ...0 kmh and functions 1 2 3 or 6 are not active or requested Note The truck must have a remote control which allows load height M1 to be set for a full air suspension system Function 5 on its own DIH on pin X2 06 BHA 5 Function 5 another function DIH on pin X2 66 BHB One x 2 position switch BHB Two x 2 position switch BHA 5 Function 5 Programming ...

Page 173: ...red as M2 Can be applied when the road speed is 30 kmh and functions 1 2 3 or 6 are not active or requested Note The truck must have a remote control which allows load height M2 to be set for a full air suspension system DIH on pin X2 06 BHA 6 to set load height at M2 One x 2 position switch BHC Programming ...

Page 174: ...de on the remote control All air is released from all air bellows allowing the vehicle to be chained to the ferry deck Can be applied when the road speed is 30 km h DIH on pin X2 06 BHA 7 to lower chassis fully One x 2 position switch BHC Function 7 Programming ...

Page 175: ...tribution ﬁgure is programmed and activated by pressing the function switch The function is de activated at road speeds 30 km h and must be re activated by pressing the function switch or by switching the ignition off and on This function is not available when function 1 is active or requested DIH on pin X2 06 BHA 8 to activate alternative axle load distribution One x 2 position switch BHC Functio...

Page 176: ...variant When the bogie switch is set to position 1 trailing axle lifted and road speed 30 km h the drive axle load may increase by up to 30 Note This applies only to suspension variants RALIM 115 105 and 95 DIH on pin X2 06 CMR to ʻYES to activate bogie lift 30 Fit Bogie Lift switch One x 3 position switch Function 11 ...

Page 177: ...177 ECS Gen 2 A16 X2 6 U CLH5 KI 15 X2 16 U CLH3 KI 15 A U FA 2 U FA 3 GR Y ...

Page 178: ... 06 plug X2 from an additional switch a DIH signal to pin 16 plug X2 from an additional switch Depending upon the requirements of the customer activation be arranged as follows 1 or 2 functions activated by one x 2 position switch or one x 3 position switch 2 functions activated by two x 2 position switches For more information refer to IMPACT section 72 Switch permutations ...

Page 179: ...179 ECS Gen 2 2 4 10 1 7 9 1 0 2 2 10 1 7 9 1 0 2 10 1 7 9 1 0 2 10 1 7 9 1 0 One x 2 position Two x 2 position One x 3 position ...

Page 180: ...itches BHC 1 One x 2 position switch on X216 active high 2 One x 2 position switch on X206 active high 3 One x 3 position switch on X206 and X216 active high 4 Two x 2 position switch on X206 and X216 active high 5 No added function switch ...

Page 181: ... Compared to Gen 1 there is an important difference to remember when calibrating Gen 2 height sensors irrespective of ride height a ﬁxed calibration height of 307 mm is always used For more information refer to IMPACT Diagnostics 722881 8 step 5 ...

Page 182: ...182 ECS Generation 3 ...

Page 183: ...183 ECS Gen 3 1 5 2 4 3 3 5 5 5 5 5 5 5 4 2 2 3 ...

Page 184: ...principle of operation is the same as previous generations but new components are used ECS ECU height sensors pressure sensors solenoid valves New Service Information is included in IMPACT Group 72 1 ECS ECU 2 Height sensor 3 Pressure sensor 4 Solenoid valve 5 Air bellows ECS Gen 3 introduction ...

Page 185: ...185 ECS Gen 3 S66 9 S66 9 ...

Page 186: ...esʼ through the functions and the LED indicates which function has been selected A new feature is the ʻSTOPʼ button If a function is started and then a dangerous situation develops pressing the ʻSTOPʼ button immediately cancels the selected function The Gen 3 control can be used with Gen 1 and Gen 2 but needs connection of an additional wire to power the LEDʼs via the 5V supply to the sensors ...

Page 187: ...187 ECS Gen 3 ...

Page 188: ...re is new hardware and software Provided that the correct adapted software and data sets are loaded the Gen 3 unit will work with Gen 1 and Gen 2 systems So using the correct software and data sets a Gen 3 ECU can be used to replace a faulty Gen 1 or Gen 2 ECU Note The new software does not work with earlier ECUʼs ...

Page 189: ...189 ECS Gen 3 23 21 22 11 3 21 23 22 11 3 ...

Page 190: ...characteristics features a slightly higher air ﬂow rate and a slightly slower response time port numbering electrical pin conﬁguration on single channel valves for drive axles is different on Volvo valves and Renault valves Note Volvo valves can be identiﬁed by the fact that they are painted valve location ...

Page 191: ...191 ECS Gen 3 23 21 22 11 3 21 23 22 11 3 ...

Page 192: ...ust be installed on separate brackets To prevent excessive heat build up they must not be stacked on top of each other Some materials in the valve blocks can soften at high temperatures This can lead to vibration causing the valve blocks to come loose on the brackets ...

Page 193: ...193 ...

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