Volvo ECS Assembly instructions

1
TRAINING TIPS
AND TACTICS
Electronically Controlled
Suspension - ECS

2

3
Contents
General information
ECS general description 11
ECS evolution 15
Suspension configurations 17
Air suspension air supply 21
Overflow valves 23
Height sensors 25
Air bellows 31
Use IMPACT 35
ECS Generation 1
In-cab components 39
Status display icons 41
Component locations 43
ECU - data link 45
ECU power supply relay
- 3019B 47
Solenoid valve blocks
- 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
Solenoid valve relay - 3019A 91
Air & electrical circuits - full air 95
Level control - switch off 97
Height sensor calibration 99
Test equipment 103
VCADSPro 107

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ECS Generation 2
Main components 111
Main differences
- Gen. 1/Gen. 2 111
ECU - data link 115
ECU power supply 117
Solenoid valve blocks
- design and function 119
Solenoid valve operation 121
Solenoid valve blocks:
- front axle 125
- drive axle (Not 4x2 tractor) 127
- drive axle (4x2 tractor) 129
- drive axle - raise 131
- 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 Generation 3
Introduction 184
Component locations 184
Remote control 186
ECU 188
Solenoid valve blocks 190

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Introduction
About 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

6
Danger,
Warning,
Caution &
Note
In this guide, risk of injury or damage is indicated by the
following headings:
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.

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Replacement
parts
When replacement parts are required, it is essential 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.

8
Specification Volvo are constantly seeking ways to improve their
products, and alterations take place accordingly.
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.
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
Copyright
C

9
General information

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.

11
General information
ECS - general
description
The main advantage of 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.

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

13
General information
Introducing electronic control adds the following main
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.
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.
Electronic control

14
General information
Gen. 2 vs. Gen. 1
New versions 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

15
General information
ECS evolution ECS has gradually evolved, and there are now three
ʻGenerationsʼ.
Generation 1 was introduced 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

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General information
RAD-A4, tractor - FSS-LEAF RAD-A4 - FSS-AIR
RAPD-A6 - FSS-LEAF
Suspension configurations

17
General information
Type Air springs Type Air springs Chassis
heights
RAD-A4 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 suspensionRear suspension

18
General information
RADT-A8 FSS-AIR RADD-A8 FSS-AIR
Suspension configurations

19
General information
Type Air springs Type Air 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 suspensionRear suspension

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1
1a
2a
14
23 24
2b
52a
52b
ECS
1a
51
General information
50