120304 En

12:03-04 Issue 3

ELC generation 2

106 335

Work description

1 586 903

ã Scania CV AB 2002, Sweden

en

Contents

Contents

2

Electrical system

Control unit............................................................... 4 Extra control box ...................................................... 5 Temporary drive level switch ................................... 6

Valves and sensors

Solenoid valve block ................................................ 7 Solenoid valve cassette ............................................. 8 Level sensor .............................................................. 9 Pressure sensor ....................................................... 10

Calibration

Calibration tool....................................................... 11 Calibrating the pressure sensor............................... 12 Calibrating the level sensor .................................... 14

Compressed air system

Components............................................................ 16 Outline diagram for: 4x2A ..................................... 17 Outline diagram for: 4x2 b ..................................... 18 Outline diagram for: 6x2A, 8x2 A, 6x2*4A and 8x2*6A ................................................................... 19 Outline diagram for: 6x2B and 6x2*4B ................. 20 Outline diagram for: 6x4A and 8x4A Without load transfer ............................................................ 21 Outline diagram for: 6x4A and 8x4A With load transfer.................................................................... 22 Outline diagram for: 6x4B Without load transfer.................................................................... 23 Outline diagram for: 6x4B With load transfer........ 24 Outline diagram for: 6x2/4A .................................. 25 Outline diagram for: 6x2/4B .................................. 26 Outline diagram for: 8x2B and 8x2*6B ................. 27 Outline diagram for: 8x2/4A .................................. 28 Outline diagram for: 8x2/4B .................................. 29 Outline diagram for: 8x4B Without load transfer.................................................................... 30 Outline diagram for: 8x4B With load transfer........ 31 Outline diagram for 8x4*4A Without load transfer.................................................................... 32 Outline diagram for 8x4*4A With load transfer .... 33 Outline diagram for 8x4*4B Without load transfer.................................................................... 34 Outline diagram for 8x4*4B With load transfer..... 35

Wiring diagram

Component parts..................................................... 36 Current path diagram.........................................38-44


12:03-04

Contents

12:03-04


3

Electrical system

Electrical system Control unit

Renewal

!

WARNING!

Always use axle stands to support the vehicle when working under vehicles with air suspension. When a faulty component is renewed, the vehicle may suddenly change drive level.

6 Disconnect the computer and switch off the ignition voltage. 7 Calibrate the control unit to the pressure and level sensors. For further information see Calibration. 8 Clear any fault codes. For further information, see Troubleshooting Clearing flashing codes.

The control unit is located in the cab, below the central electric unit.

12_0757

Experience shows that control unit faults seldom occur. Consequently, fault codes and fuses should be checked before the control unit is renewed. 1 Switch off the ignition voltage. 2 Push up the latch clamp and release the control unit.

Push up the clamp to release the control unit

3 Remove the connection of the control unit. 4 Fit the new control unit. When it is a spare part, the control unit is preprogrammed with standard settings but not calibrated for the level and pressure sensors. To enable the control unit to work correctly, it must be programmed to the correct configuration. 5 Program the new control unit using Scania Programmer 2.

4


12:03-04

Electrical system

Extra control box Engaging

Connector C 78 is located in the lead-in union below the central electric unit in position 5. Connector C 163 is located on the left cab wall near the control box.

Load transfer can sometimes be easier with an extra control box at the rear. The vehicle can be fitted with such a control box and it should then also be fitted with a toggle switch in the cab. This is to ensure that both boxes cannot be used at the same time. Use a cable with four wires, cable area 0.75 mm2. It may be as well to place the rear joint in the junction box on the last crossmember to protect it against moisture.

rd

1

bn

2 3 4

ye gn

C78 1

2

M1

M2

STOP

C163 15L rd

1

2

31 bk

2

3

ELC 20 ye

3

rd

bn

1

ye M1

M2

STOP

ELC

4

21gn

A

gn 105 893

4

1 Control box 2 Extra control box A Toggle switch

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5

Electrical system

Temporary drive level switch Engaging button is activated. However, the rear drive level will be raised to 65 mm.

The vehicle can be fitted with a temporary drive level switch. The toggle-type switch is connected according to the diagram below. Control unit pin 19 is earthed via the switch pin 2. Note: After the connection, the temporary drive level must be programmed in the control unit using Scania Programmer 2.

C

10A

No10

If the programming is not carried out, the front drive level will remain unchanged when the

15L 1

S75

20

1

19

21

22

G5−2 23

24

25

105 914

19

31.BK

ELC19.BN

15L.OG

E18

3

4

15L.OG

2

6

The switch is connected to control unit pin 19.

6


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Valves and sensors

Valves and sensors Solenoid valve block

!

WARNING!

Always use axle stands to support the vehicle when working under vehicles with air suspension. Empty the compressed air system before detaching the hoses from the solenoid valve blocks. Always switch off the ignition voltage before any work on the ELC system is undertaken.

Renewal The generation 2 ELC uses a single or double solenoid valve block for suspension control, V54 or V54+V55. The operation of the valve blocks differs depending on the vehicle configuration. In production, Scania uses four different solenoid valve blocks. Only two types of block are available as spare parts: One double and one single. Certain blocks used in production have limited functionality, whereas the spare blocks contain all functions. If a spare block is used for a vehicle with limited functionality, e.g. A-suspension, those outputs that are not used should be sealed off. When tightening the electrical connection (the DIN connector) it should be tightened until a click is heard.

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7

Valves and sensors

Solenoid valve cassette Renewal

!

WARNING!

Always use axle stands to support the vehicle when working under vehicles with air suspension. Disconnect all hose connections to the valve block before the cassette is removed. Any remaining pressure in the block can cause parts to be pushed out during dismantling. Always switch off the ignition voltage before any work on the ELC system is undertaken.

When renewing the solenoid valve cassette on the valve block, the O-rings should also be renewed.

105 917

IMPORTANT! It is extremely important for the workplace to be clean when the valve package is dismantled. Even small amounts of dirt can affect functioning.

Solenoid valve cassette components

These bolts are secured in position using locking compound. When tightening the electrical connection (the DIN connector), it should be tightened until a click is heard.

8


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Valves and sensors

Level sensor Specifications Tightening torque

!

Level sensor bolts

12 Nm

Arm bolt

3.5 Nm

Renewal When renewing a level sensor, the rotating bracket for the arm should be turned so that the protruding lugs face upwards. The front level sensor is located on the crossmember beneath the gearbox.

WARNING!

Make sure the ignition voltage is off before commencing renewal of the level sensors. When a faulty component is renewed, the vehicle may suddenly change drive level if the voltage is on. Always use axle stands to support the vehicle when working under vehicles with air suspension.

The rear level sensor is located on the righthand side of the frame above the rear axle. When tightening the electrical connection (the DIN connector), it should be tightened until a click is heard. Note: After renewing the level sensors, a level calibration must be carried out. For further information, refer to section Calibration.

12_0760

1

The protruding lugs (1) on the rotating bracket should face upwards before the arm is fitted.

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9

Valves and sensors

Pressure sensor Specifications Tightening torque Pressure sensor

27 +/- 2 Nm

Renewal

!

WARNING!

Always use axle stands to support the vehicle when working under vehicles with air suspension. Make sure the ignition voltage is off before commencing renewal of the level sensors. Empty the air system before commencing renewal of the solenoid valve block.

Check that the air hole in the pressure sensor connection is not blocked.

105 942

When tightening the electrical connection (the DIN connector), it should be tightened until a click is heard.

Note: After renewing the pressure sensors, a calibration must be carried out. For further information, refer to section Calibration.

10

The hole in the pressure sensor connection should not be blocked.


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Calibration

Calibration As there are individual component differences the control unit must be informed about these. This takes place during calibration. Calibration should always be carried out when renewing: •

Control unit

•

Level sensor

•

Pressure sensor

Tip Calibration tool A tool can be manufactured to facilitate calibration. Use a spring-loaded switch, flat pin and flat socket.

1

2

3

104 518

Connect the tool between the calibration lead (G9) and the earth ring.

1 Spring-loaded switch 2 Flat pin 3 Flat socket

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11

Calibration

Pressure sensor Calibrating the pressure sensor G

9

Note: Applies only to vehicles with load transfer.

Use calibration lead G9 during calibration (white lead with green insulator marked G9). It is located below the central electric unit and the lead is marked K-dia/C56.

16_0987

For adjustment of air spring heights, refer to Air spring heights under main group 12.

Calibration lead G9

Note: There may be several insulators marked G9 below the central electric unit. These are intended for calibrating other systems. IMPORTANT! During calibration, the tag axle should be lowered. Ensure that there is working pressure in the system. 1 Switch off the ignition power for at least ten seconds. 2 Switch on the ignition power.

4 When the lamps have gone out: Remove the earth connection within five seconds.

12 0752

3 Calibration lead G9 must be earthed within two seconds of switching on the ignition power. The warning lamps will come on two seconds after the earthing cable has been connected. Level fault warning lamp

5 If the control unit detects the request for calibration, the level fault warning lamp will come on.

12


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Calibration

IMPORTANT! All suspension bellows must be entirely pressure-free. 6 Lower the vehicle with the control box to the bump stop. 7 Earth calibration lead G9. 8

Remove calibration lead G9. The pressure sensors are now registering a pressure value of 0 bar.

10 Switch off the ignition power and switch it on again. If the calibration has not been successful, the system fault warning lamp will now flash and the level fault warning lamp will go out. If this is the case, repeat steps 1 to 9.

17 0088

9 If the calibration has been successful, the system fault warning lamp will come on and the level fault warning lamp will go out.

System fault warning lamp

11 After completing the calibration, the tag axle lift/load transfer button must be switched on and off again so that the system will work normally. 12 Press the normal drive level button on the control box. Wait until the chassis has stopped. Press the button again to obtain normal drive level. The level fault warning lamp will come on until the vehicle is at the calibrated drive level. Note: If the control unit is new and has not previously undergone level calibration, then normal drive level will not be obtained. The ELC is now ready for use again.

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13

Calibration

Level sensor Calibrating the level sensor For adjustment of air spring heights, refer to Air spring heights. Use calibration lead G9 during calibration (white lead). It is located below the central electric unit. IMPORTANT! During calibration, the tag axle should be lowered. Ensure that there is working pressure in the system. 1 Place blocks behind and in front of the wheels and release the parking brake. 2 Switch off the power with the starter key and leave the ignition power switched off for at least 10 seconds. 3 Earth calibration lead G9. 4 Switch on the ignition power using the starter key. 5 The ELC will now check its lamps on the instrument panel. This takes approximately 2 seconds. The earth connection to the calibration lead must be interrupted within 5 seconds of the lamps going out. 6 The level fault warning lamp will remain on during the entire calibration procedure, if the control unit has received a request for calibration. If the lamp does not come on: repeat steps 2-4. 7 First the drive level is calibrated. The vehicle drive level is adjusted using the control box. For further information see Air spring heights. 8 Earth calibration lead G9. 9 Break the earth connection from calibration lead G9. 10 The other level which is calibrated is the maximum level. Set maximum level, front and rear, with the control box. Note: The vehicle may stop before reaching maximum level when the control box is first activated. Press the button again to make sure that maximum level is set. 11 Earth calibration lead G9. 12 Break the earth connection with calibration lead G9.

14


12:03-04

Calibration

13 Finally, calibrate the lower mechanical stop. Lower the vehicle until the frame is resting on the bump stop. Check that the movement is not limited by the bellows crumpling. 14 Earth calibration lead G9. 15 Break the earth connection from calibration lead G9. 16 If the calibration has been successful, the level fault warning lamp will go out. The system fault warning lamp will come on to confirm that the calibration has been successful. 17 If the calibration has not been successful, the system fault warning lamp will flash. Repeat steps 1-14. 18 If the calibration has been successful: Switch off the ignition power and switch it on again with the starter key. 19 After completing the calibration, the tag axle lift/load transfer button must be switched on and off again so that the system will work normally. 20 Press the normal drive level button on the control box. Wait until the chassis has stopped. Press the button again to obtain normal drive level. The level fault warning lamp will come on until the vehicle is at the calibrated drive level. The ELC is now ready for use again.

12:03-04


15

Air and electricity

Air and electricity Compressed air system Components

1 2 5 3

6

4 7

105 892

3

1 2 3 4

16

Solenoid valve block Double check valve Pressure sensor Manifold fitting

5 Level sensor, rear 6 Manifold fitting 7 Pressure limiting valve


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Air and electricity

Outline diagrams, air

Outline diagram for 4x2A

2

4

3

10 T 73

LZJ

6

LZA

6

7

1

LC

8

LE

8

V54 3

21 23

22

11

6

12

LBX

12

LU

8

LBY

12

LBW

12

LBW

12

5

2

1 2 3 4 5

Solenoid valve block Suspension bellows Pressure gauge in cab To load-sensing valve Manifold fitting, supply

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6 7 8 9 10

102 759

9

Test connection Manifold fitting Load handling tanks Double check valve Level sensor


17

Air and electricity

Outline diagram for 4x2B 2

2

4

3

10 T 73

8

LZJ

6

6

LZA

LAL

7

1

V54

LC

8

LE

8

3

21 23

8

8

1 2 3 4 5

18

LBY

12

LBW

12

LBW

12

5

9

T 72

2

12

2

10


6 7 8 9 10


102 750

LAJ

LU

12

8

11

6

LBX

LAK

22


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Air and electricity

Outline diagram for 6x2A, 8x2A, 6x2*4A and 8x2*A 4 9 2 LV

3

LZJ

6

LBZ

8

LCA

8

LZA

2

8

LG

8

10

6

T 73

7 23

22

LC

V55

LE

1

LG LJ

8 8

8 8

V54

12

3

LBZ

8

2

23

22

13

11

6

12

1

12

LU

8

LBY

12

LBW

12

5 T 70

9 2

1 2 3 4 5 6 7

Solenoid valve block Suspension bellows Pressure gauge in cab To load-sensing valve Manifold fitting, supply Test connection Manifold fitting

12:03-04

8 9 10 11 12 13

11

11 T 71 2

102 749

12

LBX

LBW

Load handling tanks Double check valve Level sensor Pressure sensor Tag axle lift bellows Pressure limiting valve 8.0 bar


19

Air and electricity

Outline diagram for 6x2B and 6x2*4B 4 9 2

2 LV

3

6

8

LG

10

6

LZA

8

T 73

8

LZJ

2

LAL

7 23

22

LC

V55

LE

1

LG LJ

8 8

8 8

V54

12

3

LBZ

13 LAK LAJ

8 8

23

22

8

2

11

6

LU

12

1

6 8

12

LZA LBZ 12

LBW

12

LBX

LBW

10

LBY

12

5 T 70

9

2

1 2 3 4 5 6 7

20


11 T 71

2

8 9 10 11 12 13

11

2

102 748

8

T 72



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Air and electricity

Outline diagram for 6x4A and 8x4A Without load transfer 2 LC

3

8

2

4

10 T 73

LZJ

6

LZA

6

7 LG LJ

8 8

V54

1

3

21 23

11

6

LU

12

8

LBY

12

LBW

12

LBW

12

LE

9

5

8

2

1 2 3 4 5


12:03-04

6 7 8 9 10

2

102 745

LBX

12

22



21

Air and electricity

Outline diagram for 6x4A and 8x4A With load transfer 4 LG

2

8

2

9 10 T 73 LZJ

6

LZA

6

7 3

LE

8

LC

8

8

LV

V54 1

3

21 23

22

11

6

LU

12

8 LJ

8

8

LBY

12

LBW

12

LBW

12

5

11

9 2

2

1 2 3 4 5 6

22

Solenoid valve block Suspension bellows Pressure gauge in cab To load-sensing valve Manifold fitting, supply Test connection

7 8 9 10 11


102 752

LBX

12

LG

Manifold fitting Load handling tanks Double check valve Level sensor Pressure sensor

12:03-04

Air and electricity

Outline diagram for 6x4B Without load transfer 2

2

2

4

10 T 73

LZJ

6

LZA

6

LAL

8

3

LE

8

LC

8

7 LG LJ

1

8 8

V54

3

21

8 8

23

22

11

6

LU

12

LBX

12

LAK LAJ

10

LBY

12


12:03-04

LBW

12

5

9

2

1 2 3 4 5

12

2

6 7 8 9 10

2

102 744

8

T 72

LBW



23

Air and electricity

Outline diagram for 6x4B With load transfer 4 9 2

2

2 LV

LZJ

6

LZA

8

LG

10 T 73

8

LAL

LC

LAK LAJ

8

7

23

22

8

8

6

8

3

V55 1

LG LJ

V54

8 8

3

23

22

11

6

LU

12 8

12

LE

12

LBW

12

LBX

LBW

8

T 72

LBY

5

12

T 71

11

10

9

2

1 2 3 4 5 6

24


2

7 8 9 10 11


11

2

102 751

T 70


12:03-04

Air and electricity

Outline diagram for 6x2/4A 4

LY

8

9 2 LV

LG LY

3

13

8

6

LZJ

LZA

LCA LBZ

1

2 8

8

10

6

T 73

7

8 8 22

V55

23

LC LE

8 8

12

1

LBZ

8

2

3

V54 11

6

LU

12

12

22

LBX

LZH

8

LBY

12

LBW

12

LBW

12

8

2


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11

5

T 70

LJ

9

1 2 3 4 5 6 7

T 71

8

8 9 10 11 12 13

2

11

102 747

23



25

Air and electricity

Outline diagram for 6x2/4B 4

LY

8

9 2

2 LV

8

LG LY

3

6

LZA

LAL

13

LCA LBZ

1

8

8

10

6

T 73

8

LZJ

2

7

8 8 22

V55

23

LC LE

8 8

1

LBZ

8

2

12

3

V54 22

11

6

LU

12

12

8 8

LBX

LZH

8

T 72

10

LBY

12

26


12

LBW

12

11

5

T 70

9

LJ

8

2

2

1 2 3 4 5 6 7

LBW

T 71

8

8 9 10 11 12 13


2

11

102 746

23

LAK LAJ


12:03-04

Air and electricity

Outline diagram for 8x2B and 8x2*6B 4 9 2

2

2 LV LZJ

6

LG

LBZ

8

LCA

8

8

10

6

LZA

T 73

LAL

8

3

2

8

7 23

22

LC

V55

LE

1

LG LJ

8 8

8 8

V54

12

3

LBZ

8

2

8

LCD

8

22

13

11

6

LU

12

8

T 72

1

LBW

12

LBY

LBW

12

5

12

T 70

9 2

1 2 3 4 5 6 7


12:03-04

2

2

8 9 10 11 12 13

11

11 T 71 2

105 948

LAJ

23

12

8 8

LBX

10

LCE LAK



27

Air and electricity

Outline diagram for 8x2/4A LCF

4

8

9

2 LCG

LV LZJ

LY

6

LBZ

8

LCA

8

LZA

2

V72

LG

LC

V55

LE

LG LJ

LCH 8

10

7 23

14 2

8

T 73

1

1

8

6

22

1

2

8 LCF

3

8

8

LH

2

8

8 8

8 8

V54

12

3

LBZ

V71

8

2

23

22

13

11

6

LU

12

1

12

15

8

LBY

12

12

5 T 70

9 2

2 LN

1 2 3 4 5 6 7 8

28

Solenoid valve block Suspension bellows Pressure gauge in cab To load-sensing valve Manifold fitting, supply Test connection Manifold fitting Load handling tanks

9 10 11 12 13 14 15


11

11 T 71 2

105 945

12

LBW

LBX

LBW

8

Double check valve Level sensor Pressure sensor Tag axle lift bellows Pressure limiting valve 8.0 bar Front tag axle lift bellows Front tag axle solenoid valves

12:03-04

Air and electricity

Outline diagram for 8x2/4B LCF

2

4

8

9

2 LCG

LV

3

LG

LBZ

8

LCA

8

LZA

8 T 73

LAL

7 23

22 1

2

V72

LC

V55

LE

1

15

LG LJ

14 1

2

LCH 8

8

10

6

8

LZJ

2

8 LCF

6

8

8

LY

LH

2

8

8 8

8 8

V54

12

3

LBZ

V71

8

2

8

LAJ

8

23

22

13

11

6

LU

12

1

12

LAK

8

T 72

LBY

12

12

LBW

12

5 T 70

9 2

2

2 LN

1 2 3 4 5 6 7 8

Solenoid valve block Suspension bellows Pressure gauge in cab To load-sensing valve Manifold fitting, supply Test connection Manifold fitting Load handling tanks

12:03-04

9 10 11 12 13 14 15

11

11 T 71 2

105 944

LBW LBX

10

8

Double check valve Level sensor Pressure sensor Tag axle lift bellows Pressure limiting valve 8.0 bar Front tag axle lift bellows Front tag axle solenoid valves


29

Air and electricity

Outline diagram for 8x4B Without load transfer

2

2

2

4

3

6

LZA

2

6

8

LZJ

LAL

10 T 73

7 LG

LC

1

LE

8 8

LJ

V54

8

8

3

21

LCE

8 8

LAJ

8

LCD

8

23

22

11

6

LU

12

12

LAK

LBW

12

LBW

12

LBX

8

T 72

LBY

5

12

9 2

1 2 3 4 5

30

2

2


6 7 8 9 10


2

105 947

10


12:03-04

Air and electricity

Outline diagram for 8x4B With load transfer 4 9 2

2

2 3

6

LZA

6

LV

LAL

8

LZJ

LCE

8

LG

8

LAJ

8

LCD

8

8

10

8

LAK

2

T 73

7 23

22

LC

V55

LE

1

LG LJ

8 8

8 8

V54 3

23

11

6

LU

12

12

22

12

8

T 72

LBY

LBW

12

5

12

T 70

9 2

1 2 3 4 5 6


12:03-04

2

2

7 8 9 10 11

11

11 T 71 2

105 946

LBW LBX

10



31

Air and electricity

Outline diagram for 8x4*4A Without load transfer

1 2 3 4 5 6

32


7 8 9 10 11 12

Manifold fitting Load handling tanks Double check valve Level sensor Tag axle lift bellows Tag axle lowering/raising solenoid valve


12:03-04

Air and electricity

Outline diagram for 8x4*4A With load transfer

1 2 3 4 5 6 7


12:03-04

8 9 10 11 12 13

Load handling tanks Double check valve Level sensor Pressure sensor Tag axle lift bellows Tag axle lowering/raising solenoid valve


33

Air and electricity

Outline diagram for 8x4*4B Without load transfer

1 2 3 4 5 6

34


7 8 9 10 11 12

Manifold fitting Load handling tanks Double check valve Level sensor Tag axle lift bellows Tag axle lowering/raising solenoid valve


12:03-04

Air and electricity

Outline diagram for 8x4*4B With load transfer

1 2 3 4 5 6 7


12:03-04

8 9 10 11 12 13

Load handling tanks Double check valve Level sensor Pressure sensor Tag axle lift bellows Tag axle lowering/raising solenoid valve


35

Air and electricity

Wiring diagram Components

36


12:03-04

Air and electricity

Components Component C56 C58 C67 C78, C163 C268 E18 G5, G9, G10, G13, G18 O4 P2 R8 S48 S75 S105 S106 S107 S108 T70, T71 T72, T73 V32 V54, V55 W51 W52 W53

12:03-04

Function Distribution terminal, 18-pin Connector, 2-pin Union point for solenoid valve earth cables Connector, 9-pin Connector, 17-pin Control unit Earthing points Tachograph Central electrical unit Brake light relay Diagnosis switch Temporary drive level switch Load transfer/tag axle lift switch Load transfer switch (with time limiter) Control box Load transfer switch (without time limiter) Pressure sensor for rear axle and tag axle/rear rear axle Level sensor, front and rear Parking brake release solenoid valve Solenoid valve block Warning lamp for level fault Warning lamp for system fault Warning lamp for load transfer


37

Air and electricity

Current path diagram Current path 1 - 25

Current path 26 - 50

38


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Air and electricity



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Air and electricity



40


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Air and electricity



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41

Air and electricity



42


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Air and electricity



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43

Air and electricity



44


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120304 En

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