Volvo ECS Training Tips And Tactics
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Volvo ECS Training Tips And Tactics

Electronically controlled suspension
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TRAINING TIPS
AND TACTICS
Electronically Controlled
Suspension - ECS
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Summary of Contents for Volvo ECS

  • Page 1 TRAINING TIPS Electronically Controlled Suspension - ECS AND TACTICS...

  • Page 3: Table Of Contents

    Contents General information Solenoid valve block: - front axle ECS general description - drive axle (Not 4x2 tractor) ECS evolution - drive axle (4x2 tractor) Suspension configurations - bogie Air suspension air supply Overflow valves & distribution Overflow valves manifolds...
  • Page 4 ECS Generation 2 Solenoid valve blocks: - pusher axle Main components Pressure sensors Main differences Overflow valves - Gen. 1/Gen. 2 Bogie switch ECU - data link Main instrument panel ECU power supply Additional functions Solenoid valve blocks Height sensor calibration...
  • Page 5 Introduction About this This guide is intended as a memory jogger for the Pocket guide knowledge you have gained during your training course. The guide includes a summary of the material covered in: Electronically Controlled Suspension - ECS...
  • Page 6 Danger, In this guide, risk of injury or damage is indicated by the Warning, following headings: Caution & Note DANGER - indicates a risk of serious personal injury or death. WARNING - indicates a risk of personal injury, or severe product damage.
  • Page 7 Replacement When replacement parts are required, it is essential that parts 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.
  • Page 8 Whilst every effort has been made to ensure the accuracy of this guide, it should not be regarded 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.

  • Page 9: General Information

    General information...
  • Page 10 General information General The information in this section applies to all Generations of information ECS. Information specific to each Generation is found in the sections - Gen. 1, Gen. 2 or Gen. 3.
  • Page 11 General information ECS - general The main advantage of a basic air suspension system description 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 General information Air pipe AS. Air supply 1. Air bellows Electronic control ECU. Electronic Control Unit 2. Height sensor signal 3. Solenoid valve...
  • Page 13 General information Introducing electronic control adds the following main Electronic control benefits: - faster height change response times. - easy addition of other features. With electronic control, the height control valves are replaced by electronic height sensors, and air admission and release is controlled by solenoid valves.
  • Page 14 - ECU (2 connectors vs. 1 connector) - ECU - Solenoid valves - Solenoid valves - Bogie switch functions - Remote control - Overflow valves 52a and 52b - Height sensor calibration Additional: - Pressure sensors - ECS functions - VCADS tests...

  • Page 15: Ecs Evolution

    ʻGenerationsʼ. Generation 1 was introduced on FM trucks in 1998. Gen. 1 All ʻElectronic ʻ98ʼ trucks are fitted with ECS Gen. 1 . Gen. 2 Generation 2 was introduced on ʻVersion 2ʼ FM/FH trucks All ʻVersion 2ʼ trucks are fitted with ECS Gen. 2 .
  • Page 16 General information RAD-A4 - FSS-AIR RAD-A4, tractor - FSS-LEAF RAPD-A6 - FSS-LEAF Suspension configurations...
  • Page 17 General information Rear suspension Front suspension Type Air springs Type Air springs Chassis heights RAD-A4 FSS-LEAF CHH-STD Single drive axle CHH-810* CHH-850** CHH-900*** RAD-A4 FSS-AIR 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.)

  • Page 18: Suspension Configurations

    General information RADT-A8 FSS-AIR RADD-A8 FSS-AIR Suspension configurations...
  • Page 19 General information Rear suspension Front suspension Type Air springs Type Air springs Chassis heights RADT-A8 4 + 4 FSS-AIR CHH850** Single drive axle, trailing axle bogie RADD-A8 4 + 4 FSS-AIR CHHSTD Double drive axle Chassis heights - later designations * CHH-XLOW CHH-STD = 1025mm (min.) ** CHH-LOW...
  • Page 20 General information...

  • Page 21: Air Suspension Air Supply

    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 To ECS solenoid valve blocks...
  • Page 22 General information...

  • Page 23: Overflow Valves

    Overflow valve 52a is fed from the wet tank. When air Overflow valves 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).
  • Page 24 General information...
  • Page 25 General information The height sensors are mechanically actuated Height sensors potentiometers. The 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).
  • Page 26 General information 9073 Voltage 42 26 28 output 1 4 2 1 4 2 Ride height 7072LF 7072LR 7072RR...
  • Page 27 General information Height sensors One end of each semicircular contact is fed with 5V from ECU pin 42, and the other end is fed with 0 V from ECU pin Depending on the angle of the lever and, therefore, on the position of the sliding contact, each semicircular contact can supply between 5V and 0V to the sliding contact.
  • Page 28 General information Sensor Component No. Wiring diag. No. location (Version 2 truck) (Electronics ʻ98 truck) Front axle 7072LF Rear axle RH 7072RR Rear axle LH 7072LR...

  • Page 29: Height Sensors

    General information The number of sensors varies according to truck model and Height sensors axle configuration. - number All air suspended trucks have two rear sensors - except - 4x2 tractor with front leaf springs (RAD-A4), which has only one sensor at the O/S. Note: The use of only one sensor is possible because a 4x2 tractor has a short wheelbase.
  • Page 30 General information...

  • Page 31: Air Bellows

    General information Air bellows 1. Air supply from the solenoid valve block 2. Attachment screw 3. Bellows plate 4. Hollow rubber damper 5. Air bellows 6. Plunger 7. Guide pin Bellows plate (3) is attached to the frame, and plunger (6) is attached to the axle.
  • Page 32 General information...
  • Page 33 General information Air bellows CAUTION If the load is being carried on the damper, because of loss of air pressure, the vehicle may be driven at up to 10km/h. Renewing air DANGER bellows When renewing the air bellows, ensure that the following safety precautions are implemented at all times: - Block up the truck frame.
  • Page 34 General information FH12 Air suspension drive level positions 7 Frame, springs, damping and wheels Air suspension specifications (7281) 70 General Air suspension (7281) 71 Frame Compressed air components 72 Suspension ECS signal description 720 General 7200 General 721 Front spring leaf...

  • Page 35: Use Impact

    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 37: Ecs Generation 1

    ECS Generation 1...
  • Page 38 ECS Gen. 1 3019B 3019A...

  • Page 39: In-Cab Components

    - 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 ECS Gen. 1...

  • Page 41: Status Display Icons

    ECS Gen. 1 Suspension Icon (A) is displayed when the switch on the remote control status display has been left in ʻmanualʼ position. icons 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...
  • Page 42 ECS Gen. 1...

  • Page 43: Component Locations

    ECS Gen. 1 1. ECS ECU - 9073 ECS Gen. 1 2. Remote control - 9009, 9010 component 3. Height sensor - 7072 locations 4. Test nipple 5. Air bellows - front axle 6. Distribution manifold - extra equipment (axle lift bellows) 7.
  • Page 44 ECS Gen. 1 Diag. Slow data link - J1587/J1708 MID 136 MID 232 MID 144 MID 128 MID 150 MID 223 MID 130 MID 171 Veh. ECU Engine Air susp. Gear lever Gearbox Inst. MID 163 OPTIONS Immob. Fast data link - J1939...
  • Page 45 ECS Gen. 1 The Gen. 1 ECU has only one connector, and is connected ECS Gen. 1 ECU only to the slow data link. - data link...
  • Page 46 ECS Gen. 1 3019B 3019B 9073 9073 Ignition OFF Ignition ON...

  • Page 47: Ecu Power Supply Relay

    ECS Gen. 1 When the ignition is switched on, a wake-up signal is sent ECU power to ECU pin (22). supply relay The ECU switches a negative to relay pin (85) via ECU pin - 3019B (12). Because fuse F12 is supplying voltage to relay pin (30) and - by link - to pin (86), the relay is energised.
  • Page 48 ECS Gen. 1...

  • Page 49: Solenoid Valve Blocks - Design And Function

    - 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 ECS Gen. 1 +24V +24V + 24V +24V +24V +24V...
  • Page 51 ECS Gen. 1 A. Basic bellows air flow solenoid. ECS Gen. 1 B. Control solenoid - found only in valve block for drive solenoid valve axles. operation DE. Solenoid ʻDe-energisedʼ. +24V supplied to both pins. A - solenoid de- No air can pass through the valve.
  • Page 52 ECS Gen. 1...

  • Page 53: Solenoid Valve Operation

    ECS Gen. 1 A. Solenoid valve - front axle, 6035LF (SID 2) ECS Gen. 1 solenoid valve 1/3. Supply air from - and drain to - drive axle valve, 6035C blocks 4. Air supply from wet tank 21. Air to and from LH front air bellows 22.
  • Page 54 ECS Gen. 1 +24V +24V 3019A 6035LF +24V 9073...

  • Page 55: Solenoid Valve Block - Front Axle

    ECS Gen. 1 Solenoid valve A. Solenoid valve - front axle, 6035LF (SID 2) block - 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.
  • Page 56 ECS Gen. 1 3019A 6035C 9073...
  • Page 57 ECS Gen. 1 B. Solenoid valve - drive axle, 6035C Solenoid valve block - drive axle 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.
  • Page 58 ECS Gen. 1 6035C...

  • Page 59: Drive Axle (Not 4X2 Tractor)

    ECS Gen. 1 1. Air supply from wet tank Solenoid valve 3. Air drain via silencer block - drive axle 21. Air to and from LH drive axle air bellows, and trailing (or (not 4x2 tractor) pusher) LH air bellows 21.
  • Page 60 ECS Gen. 1 6035C (4x2)
  • Page 61 ECS Gen. 1 Solenoid valve 1/3. Supply air from - and drain to - drive axle valve, 6035C block - drive axle 4. Air supply from wet tank (4x2 tractor) 21. Air to and from LH front air bellows 22. Air to and from RH front air bellows...
  • Page 62 ECS Gen. 1 3019A 6045 9073 6045...
  • Page 63 ECS Gen. 1 Solenoid valve B. Solenoid valve - bogie, 6045 block - bogie 3. Air drain via silencer 11. Air supply from drive axle valve block, port 21 12. Air supply from drive axle valve block, port 22 13. Air supply to bogie lift 14.
  • Page 64 ECS Gen. 1 6045 SID 8 SID 9 SID 10...
  • Page 65 ECS Gen. 1 Solenoid valve 3. Air drain via silencer block - bogie 11. Air supply from drive axle valve block, port 21 12. Air supply from drive axle valve block, port 22 13. Air supply to bogie lift 14. Air supply to drive axle load sensor 21.
  • Page 66 ECS Gen. 1 6045 SID 8 SID 9 SID 10...

  • Page 67: Bogie

    ECS Gen. 1 There are two variants of the bogie valve block: Solenoid valve - one for trucks with a non-drive axle behind the drive axle, block - bogie ʻtrailingʼ (or ʻTagʼ) axle bogie. - one for trucks with a non-drive axle in front of the drive axle, ʻpusherʼ...
  • Page 68 ECS Gen. 1...

  • Page 69: Manifolds

    ECS Gen. 1 A. Overflow valve without return flow - 52a Overflow valves B. Overflow valve with return flow - 52b and distribution C. Distributor manifold manifolds D. Safety valve E. Test nipple 1. From wet tank 2. To drive axle solenoid valve - 6035C, port 1 3.
  • Page 70 ECS Gen. 1...
  • Page 71 ECS Gen. 1 Valve 52a ensures that air is fed to the brake system before Overflow valve the air suspension system. 52a - no return The valve opens at 6.7 to 7.0 bar, to allow air into the flow suspension system.
  • Page 72 ECS Gen. 1 6035C 6045...

  • Page 73: Pressure Control Valve

    ECS Gen. 1 1. Supply from 2-way valve Pressure control 2. Supply to bogie valve block valve 41. Signal from drive axle air bellows RH 42. Signal from drive axle air bellows LH 56. Drive axle air bellows 57. Non-drive axle air bellows 6035C.
  • Page 74 ECS Gen. 1 DRIVE AXLE - x 100 kPa NON-DRIVE AXLE - x 100kPa...
  • Page 75 ECS Gen. 1 WARNING Pressure control Correct adjustment is important. The non-drive axle load valve - testing sensing valves - which control brake pressure to the non- drive axle brakes - obtain the pressure signal from the non- drive axle air bellows.
  • Page 76 ECS Gen. 1 9073 DOWN MEM 9010 When closed, the internal switches connect the common earth to the appropriate pins 9010...

  • Page 77: Remote Control - 9010

    ECS Gen. 1 Control 9010 is used for trucks with rear air suspension Remote control only. - 9010 Switch 1. Control switch 3. Regulator position switch Move up Manual control MAN1 Drive Stop position CENTRE Control of Move down drive posʼn...
  • Page 78 ECS Gen. 1 9073 18 32 17 31 16 FRT PAR UP DOW MEM 9009 9009...

  • Page 79: Remote Control - 9009

    ECS Gen. 1 Control 9009 is used for trucks with full air suspension. Remote control - 9009 Switch 2. Axle switch 1. Control switch 3. Regulator position switch Front Raise Manual axle mem. control MAN1 Front & rear Stop Drive axle mem.
  • Page 80 ECS Gen. 1 Chassis 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...
  • Page 81 ECS Gen. 1 CAUTION Changing the To avoid possible vibration and excessive prop-shaft drive height angles, which may cause instability or component damage, the drive height must not be changed by more than the values in the chart above. The system will allow the drive height to be changed up to +/- 40 mm.
  • Page 82 ECS Gen. 1 Location to be 1. Control switch 2. Axle switch raised or lowered position position Front Rear Front & rear Front LH Front RH Rear LH Rear RH...

  • Page 83: Interlock Mode

    ECS Gen. 1 If an ECS fault occurs, the ECU will put the system into Interlock mode ʻinterlockʼ or ʻblockedʼ mode. In this mode, the voltage supplies to the solenoid valve blocks are removed, so automatic height adjustment does not work.
  • Page 84 ECS Gen. 1 Location to be 1. Control switch 2. Axle switch raised or lowered position position Front Rear Front & rear Front LH Front RH Rear LH Rear RH...

  • Page 85: Interlock Mode

    ECS Gen. 1 If it is necessary to change the chassis height before the Changing fault is corrected, select the location to be changed, and set chassis height in the control and axle switches as shown in the chart above.
  • Page 86 ECS Gen. 1 1 0 2 Press Lift 9073...

  • Page 87: Bogie Switch

    The bogie switch is used to fully raise/lower the lifting axle Bogie switch of a 2 axle bogie, or to alter the weight distribution between the two axles. The switch used with ECS Gen. 1 has 3 fixed positions: Switch position Result 1 - upper section...
  • Page 88 ECS Gen. 1...
  • Page 89 ECS Gen. 1 Bogie switch Axle press Axle press allows the drive axle to exert more pressure on (extra traction) the road surface. It is achieved by exhausting 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.
  • Page 90 ECS Gen. 1 6035LF 3019A 6035C 6045 9073...

  • Page 91: Solenoid Valve Relay 3019A

    ECS Gen. 1 When the ignition is switched on, a ʻsensingʼ signal of 2 Solenoid valve milli-volts is sent from ECU pin (29) through each individual solenoid and back to the ECU. relay 3019A This signal checks to ensure that the solenoid circuits are If the return signal to pins 3, 4, 5, 6, 7, 8 and 9 is not correct, relay 3019A will not be energised.
  • Page 92 ECS Gen. 1 6035LF 3019A 6035C 6045 9073...
  • Page 93 ECS Gen. 1 If a fault occurs in a solenoid or sensor, the ECU Solenoid valve automatically puts the system into ʻblockedʼ mode. This relay 3019A means that the normal automatic levelling function no longer works. Blocked mode is activated by removing battery voltage from the solenoids.
  • Page 95 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 Air and electrical circuits - full air suspension...
  • Page 96 ECS Gen. 1 Parameter 9073 ʻLTʼ to ON KL15 FA11...

  • Page 97: Level Control - Switch Off

    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.
  • Page 98 ECS Gen. 1 RST-AIR FRONT AXLE RST-AIR2 6x2 RADT - A6S 6X2 RADT-A6 RAPD -A6...

  • Page 99: Height Sensor Calibration

    ECS Gen. 1 Height sensor The diagrams above show the position of the measuring calibration tools for various bogie configurations. - measuring positions...
  • Page 100 ECS Gen. 1 9998626 9998326...
  • Page 101 - a sensor has been removed 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.
  • Page 102 ECS Gen. 1 9998534 9998551...

  • Page 103: Test Equipment

    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 ECS Gen. 1...
  • Page 105 ECS Gen. 1 Test equipment System check using break-out box and test harness. - Connecting to the ECU Pull out purple locking slide (1) to remove the multi-way plug. Connect cables as shown above.
  • Page 106 ECS Gen. 1 9998555...

  • Page 107: Vcadspro

    ECS Gen. 1 VCADSPro After connecting the VCADSPro PC to the diagnostic socket, 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...

  • Page 109: Ecs Generation 2

    ECS Generation 2...
  • Page 110 ECS Gen. 2...
  • Page 111 ECS Gen. 2 1. ECU 5. Overflow valve ECS Gen. 2 main 2. Solenoid valve 6. Relay panel components 3. Height sensor 7. Remote control 4. Pressure sensor The main differences between Gen. 1 and Gen. 2 systems Gen. 1/Gen.2 -...
  • Page 112 ECS Gen. 2 6x2 - full air suspension - trailing axle bogie...

  • Page 113: Main Components

    ECS Gen. 2 ECS Gen. 2 main 1. Pressure sensor 4. Solenoid valve - drive axle components 2. ECS ECU 5. Height sensor 3. Solenoid valve - 6. Solenoid valve - trailing axle front axle...
  • Page 114 ECS Gen. 2 J1708/J1587 CAN-4 ABS-F SAE J1939 ABS-B Body-builder J1939-1 Alarm EECU VECU TECU RECU Cluster IMMO Audio Tacho GECU J1939-5 J1939-2 Buttons Phone in wheel Dyna J1939-3 VCADS 9073...
  • Page 115 ECS Gen. 2 The Gen. 2 ECU has two connectors - X1 (30 pins) and X2 ECS Gen. 2 ECU (22 pins), and is connected to both the slow data link and - data link the fast data link.
  • Page 116 ECS Gen. 2 X2:5 X2:2 X2:12 X2:4 A16 - MID 150 X2:15 X1:12 X1:2 X1:16 X1:1 X1:15 X1:13 X2:22 X2:3 DOWN MEM...
  • Page 117 ECS Gen. 2 The ECU is located in a compartment within the offside ECS Gen. 2 ECU storage locker, behind the drivers seat. - power supply 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.
  • Page 118 ECS Gen. 2...

  • Page 119: Solenoid Valve Blocks - Design And Function

    - 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 ECS Gen. 2 + 24V +24V...
  • Page 121 ECS Gen. 2 ECS Gen. 1 A. Basic bellows air flow solenoid. solenoid valve B. Control solenoid - found only in valve block for drive operation axles. DE. Solenoid ʻDe-energisedʼ. Negative to one pin. A - solenoid de- No air can pass through the valve.
  • Page 122 ECS Gen. 2...
  • Page 123 ECS Gen. 2 A. Solenoid valve - front axle, Y40 ECS Gen. 2 solenoid valve 1/3. Supply air from - and drain to - drive axle valve, Y25 blocks 4. Air supply from wet tank 21. Air to and from LH front air bellows 22.
  • Page 124 ECS Gen. 2 X1:8 1, 3 +24V...

  • Page 125: Solenoid Valve Blocks: - Front Axle

    ECS Gen. 2 Solenoid valve A16. ECS ECU block - front axle 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...
  • Page 126 ECS Gen. 2...
  • Page 127 ECS Gen. 2 Solenoid valve Y25. Solenoid valve - drive axle block - drive axle 1. Air supply from wet tank - not 4x2 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 ECS Gen. 2 21 22...
  • Page 129 ECS Gen. 2 Y25. Solenoid valve - drive axle Solenoid valve block - drive axle 1. Air supply from wet tank - 4x2 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.
  • Page 130 ECS Gen. 2 +24V...
  • Page 131 ECS Gen. 2 Solenoid valve If the driver switches the bogie switch to ʻraiseʼ position, block - drive and/or the ECU receives a ʻraiseʼ signal from a height axle - 4x2 - sensor, the ECU sends +24 V to energise the control suspension raise solenoid and drive axle solenoid.
  • Page 132 ECS Gen. 2...
  • Page 133 ECS Gen. 2 Solenoid valve When the bogie switch is moved to off position, and/or the block - drive ECU receives a signal from a height sensor confirming axle - 4x2 - that the correct ride height has been reached, the ECU...
  • Page 134 ECS Gen. 2 +24 V...

  • Page 135: Drive Axle (Not 4X2 Tractor)

    ECS Gen. 2 Solenoid valve If the driver presses the bogie switch to ʻlowerʼ position, block - drive and/or the ECU receives a ʻlowerʼ signal from a height axle - 4x2 - sensor, the ECU sends +24 V to energise the drive axle suspension lower solenoid.
  • Page 136 ECS Gen. 2 X2:5 X1:17 X1:28 X1:11 X2:2 X2:12 X2:4 A16 - MID 150 X2:15 X1:12 X1:2 X1:16 X1:1 X1:15 X1:13 X2:22 X2:3 X2:10 X1:5 X1:30 X1:7X1:23 DOWN MEM...
  • Page 137 ECS Gen. 2 A16. ECS ECU Electrical B30. Height sensor connections - 4x2 B58. Pressure sensor F49. Fuse - ignition supply K11. Relay - battery supply to ECU S66. Remote control Y25. Solenoid valve - drive axle ECU (A16) sends a low (earth) signal to:...
  • Page 138 ECS Gen. 2 X2:5 X1:17 X1:28 X1:11 X2:2 X2:12 X2:4 A16 - MID 150 X2:15 X1:12 X1:2 X1:16 X1:1 X1:15 X1:13 X2:22 X2:3 X2:10 X1:5 X1:30 X1:7X1:23 DOWN MEM...
  • Page 139 ECS Gen. 2 A16. ECS ECU Electrical B30. Height sensor connections - 4x2 B58. Pressure sensor F49. Fuse - ignition supply K11. Relay - battery supply to ECU S66. Remote control Y25. Solenoid valve - drive axle ECU (A16) receives a varying voltage signal from height sensor (B30) at pin (X1:28), representing chassis height.
  • Page 140 ECS Gen. 2 PIN NUMBERS 1. Control 2. Air bellows - trailing/ pusher 3. Air bellows - axle lift 4. Earth PORT NUMBERS Y25. solenoid valve - drive axle 1. Air supply from wet tank Y29. Solenoid valve - trailing/pusher 3.

  • Page 141: Solenoid Valve Blocks

    PORT NUMBERS 1. Air supply from wet tank 3. Exhaust 21. To LH/RH trailing/pusher bellows 22. To lift axle bellows 23. Plugged Solenoid valve Note that, with ignition off, air cannot pass through any blocks - 6x2 or valve. 8x2 - ignition off So, on Gen.
  • Page 142 ECS Gen. 2 PIN NUMBERS 1. Control 2. Air bellows - trailing/ pusher 3. Air bellows - axle lift 4. Earth PORT NUMBERS Y25. Solenoid valve - drive axle 1. Air supply from wet tank Y29. Solenoid valve - trailing/pusher 3.
  • Page 143 PORT NUMBERS 1. Air supply from wet tank 3. Exhaust 21. To LH/RH trailing/pusher bellows 22. To lift axle bellows 23. Plugged Solenoid valve blocks - 6x2 or If the driver presses the bogie switch to ʻraiseʼ position, 8x2 - suspension and/or the ECU receives a ʻraiseʼ...
  • Page 144 ECS Gen. 2 PIN NUMBERS 1. Control 2. Air bellows - trailing/ pusher 3. Air bellows - axle lift 4. Earth Y25. Solenoid valve - drive axle PORT NUMBERS Y29. Solenoid valve - trailing/ 1. Air supply from wet tank pusher axle/axle lift 3.
  • Page 145 PORT NUMBERS 1. Air supply from wet tank 3. Exhaust 21. To LH/RH trailing/pusher bellows 22. To lift axle bellows 23. Plugged Solenoid valve blocks - 6x2 or If the driver presses the bogie switch to ʻlowerʼ position, 8x2 - suspension and/or the ECU receives a ʻlowerʼ...
  • Page 146 ECS Gen. 2 PIN NUMBERS 1. Control 2. Air bellows - trailing/ pusher 3. Air bellows - axle lift 4. Earth Y25. Solenoid valve - drive axle PORT NUMBERS Y29. Solenoid valve - trailing/ 1. Air supply from wet tank pusher axle/axle lift 3.
  • Page 147 PORT NUMBERS 1. Air supply from wet tank 3. Exhaust 21. To LH/RH trailing/pusher bellows 22. To lift axle bellows 23. Plugged Solenoid valve blocks - 6x2 or If the driver presses the bogie switch to ʻlift axleʼ position, the ECU 8x2 - axle lift energises the control solenoid in (Y25), and control and lift axle solenoids in (Y29).
  • Page 148 ECS Gen. 2 PIN NUMBERS 1. Control 2. Air bellows - trailing/ pusher 3. Air bellows - axle lift 4. Earth Y25. Solenoid valve - drive axle PORT NUMBERS Y29. Solenoid valve - trailing/ 1. Air supply from wet tank pusher axle/axle lift 3.
  • Page 149 PORT NUMBERS 1. Air supply from wet tank 3. Exhaust 21. To LH/RH trailing/pusher bellows 22. To lift axle bellows 23. Plugged Solenoid valve blocks - 6x2 or If the driver presses the bogie switch to ʻlower axleʼ position, the ECU removes the voltage from the control solenoid in (Y29).
  • Page 150 ECS Gen. 2...

  • Page 151: Solenoid Valve Blocks: - Pusher Axle

    ECS Gen. 2 Y29. Solenoid valve - pusher axle Solenoid valve block - pusher 1. Air supply from drive axle solenoid valve block axle 3. Exhaust via silencer 21. Air to and from LH and RH bogie axle air bellows 22.
  • Page 152 ECS Gen. 2 A16 - MID 150 X1:30 X1:7 X1:20 X1:21 X1:23 X1:19 X1:22 1 4 2 1 4 2 1 4 2 1 4 2 1 4 2...

  • Page 153: Pressure Sensors

    ECS Gen. 2 ECS Gen. 2 systems have four pressure sensors (five if front air suspension is fitted): Pressure sensors B24 - lift axle lifting bellows B55 - lift axle suspension bellows B56 - front axle bellows B57 - drive axle bellows RH...
  • Page 154 ECS Gen. 2...

  • Page 155: Overflow Valves

    ECS Gen. 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 Opening pressure 52b - 10.0 - 10.3 bar...
  • Page 156 ECS Gen. 2...

  • Page 157: Bogie Switch

    ECS Gen. 2 The bogie switch is used to fully raise/lower the lifting axle Bogie switch - of a 2 axle bogie, or to alter the weight distribution between early type the two axles. The switch may have 2 or 3 positions according to the suspension variant.
  • Page 158 ECS Gen. 2...
  • Page 159 ECS Gen. 2 The bogie switch is used to fully raise/lower the lifting axle of a Bogie switch - 2 axle bogie, or to alter the weight distribution between the two axles. later type The switch may have 2 or 3 positions according to the suspension variant.
  • Page 160 ECS Gen. 2 Bogie switch When the bogie switch is pressed to lower the lifting axle *Optimised - or to select ʻoptimised tractionʼ , the air pressure, in the traction drive axle and lift axle air bellows, is adjusted to give the best weight distribution and traction for the prevailing conditions.
  • Page 162 ECS Gen. 2...

  • Page 163: Main Instrument Panel

    ECS Gen. 2 The main instrument panel has three main warning lamps Main instrument designed to get the attention of the driver; panel 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.
  • Page 164 ECS Gen. 2 Function Inhibit ride height 1x2P 2x2P 2x2P 2x2P 2x2P 2x2P 2x2P 2x2P Kneeling Park brake applied 1x2P 1x3P 2x2P 1x3P 1x3P 2x2P Kneeling One axle 1x2p 2x2P 2x2P Alternative drive height 1x2P 2x2P 2x2P 2x2P 2x2P Load height M1...

  • Page 165: Additional Functions

    ECS Gen. 2 Additional Nine additional functions can be programmed into the ECS functions ECU using VCADSPro. Of the nine functions, the customer can choose one or two of functions 1 - 8 + function 11. The table above shows permitted combinations and the...
  • Page 166 ECS Gen. 2 Function Inhibit ride height 1x2P 2x2P 2x2P 2x2P 2x2P 2x2P 2x2P 2x2P Kneeling Park brake applied 1x2P 1x3P 2x2P 1x3P 1x3P 2x2P Kneeling One axle 1x2P 2x2P 2x2P Alternative drive height 1x2P 2x2P 2x2P 2x2P 2x2P Load height M1...
  • Page 167 ECS Gen. 2 Function 1 on its own would need One x 2 position switch. Example 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.
  • Page 168 ECS Gen. 2 Inhibit ride height adjustment Function 1 ECS is active, but automatic ride height adjustment is prevented. Used when automatic adjustment is not wanted - e.g. using a snow plough. Programming DIH* on pin X2-06 (BHA**-1) to inhibit ride height adjustment.
  • Page 169 ECS Gen. 2 Function 2 Kneeling axle - park brake applied. When the park brake is applied 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.
  • Page 170 ECS Gen. 2 Kneeling one axle. Function 3 When the function switch is pressed, 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.
  • Page 171 ECS Gen. 2 Alternative ride height Function 4 An alternative ride height is programmed, and activated using the function switch irrespective of road speed. When not activated, the height reverts to the normal setting. Note: The alternative height must be within the permitted range for the particular truck/suspension variant.
  • Page 172 ECS Gen. 2 Function 5 Load height - M1 Pressing the function switch changes the chassis height to that stored as M1. Can be applied when the road speed is < 30 kmh, and functions 1, 2, 3, or 6 are not active or requested.
  • Page 173 ECS Gen. 2 Function 6 Load height - M2 Pressing the function switch changes the chassis height to that stored as M2. Can be applied when the road speed is < 30 kmh, and functions 1, 2, 3, or 6 are not active or requested.
  • Page 174 ECS Gen. 2 Ferry mode Function 7 This is a ʻshort-cutʼ for ferry mode 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.
  • Page 175 ECS Gen. 2 Alternative axle load distribution Function 8 CAUTION The alternative load distribution must be within the permitted range for the particular truck/suspension/tyre variant. An alternative axle load distribution figure is programmed, and activated by pressing the function switch.
  • Page 176 ECS Gen. 2 Function 11 Bogie lift + 30% CAUTION Ensure that this function is permissible for the particular truck/suspension/tyre 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%.
  • Page 177 ECS Gen. 2 X2:16 X2:6 KI 15 KI 15 CLH3 CLH5 FA 3 FA 2...
  • Page 178 ECS Gen. 2 The additional functions are hard wired into connector (FA), Additional pins (2) and (3), and can be activated by either: functions - wiring connection - a DIH signal to pin (06) plug (X2) from an additional switch.
  • Page 179 ECS Gen. 2 One x 2 position 1 0 2 One x 3 position Two x 2 position...
  • Page 180 ECS Gen. 2 1. One x 2 position switch on X216 - active high. Additional functions - 2. One x 2 position switch on X206 - active high. switches, BHC 3. One x 3 position switch on X206 and X216 - active high.

  • Page 181: Height Sensor Calibration

    ECS Gen. 2 Height sensor Note: Compared to Gen. 1, there is an important difference calibration 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 -...

  • Page 182: Ecs Generation 3

    ECS Generation 3...
  • Page 183 ECS Gen. 3...

  • Page 184: Introduction

    ECS Gen. 3 ECS generation 3 was introduced week 51 2004. ECS Gen. 3 The principle of operation is the same as previous introduction generations, but new components are used: - ECS ECU - height sensors - pressure sensors - solenoid valves New Service Information is included in IMPACT Group 72.
  • Page 185 ECS Gen. 3 S66:9 S66:9...
  • Page 186 ECS Gen. 3 Gen. 3 remote control contains a micro processor, and has Remote control 9 terminals. Operation of this control is similar to that for previous controls, but the selector button ʻtogglesʼ through the functions, and the LED indicates which function has been selected.
  • Page 187 ECS Gen. 3...

  • Page 188: Ecu

    ECS Gen. 3 ECS ECU The external appearance of Gen. 3 ECS ECU is identical to that used with Gen. 2. Internally there 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.
  • Page 189 ECS Gen. 3...

  • Page 190: Solenoid Valve Blocks

    - 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 ECS Gen. 3...
  • Page 192 ECS Gen. 3 Valve block CAUTION The valve blocks must be installed on separate brackets. installation 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.

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