ECAS-4.pdf

System and component information ECAS-4

XF105

F735 /

B166 /

F736 /

B238 /

F615

B250/ B253

F612 / F613 / F614

D992

VIC D310

D899

D529 M1

M2

STOP

CAN C740/ C741/ C895/ C899

DAVIE

©200532 DAF Trucks N.V., Eindhoven, The Netherlands. In the interest of continuing product development, DAF reserves the right to change specifications or products at any time without prior notice. No part of this publication may be reproduced and/or published by printing, by photocopying, o n microfilm or in any way whatsoever without the prior consent in writing of DAF Trucks N.V.

©

20 200532

DW332086

STRUCTURE XF105 series Structure

TECHNICAL DATA ECAS-4

©

200532

0 1

TECHNICAL DATA XF105 series

Contents

CONTENTS Technicaldata

Page 1.

©

ECAS-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 Power supply and earth of ECAS-4 electronic unit . . . . . . . . . . . . . . . . . . 1.2 CAN connection, ECAS-4 electronic unit . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 ECAS valve, front axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 FT ECAS valve, driven axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 FA ECAS valve, driven axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 ECAS valve, lift/lower axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 ECAS height sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 ECAS pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 ECAS remote control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 ECAS switch, normal driving level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 ECAS switch, second driving level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 ECAS switch, lift/lower axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 Traction control switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 ECAS switch, increased manoeuvring level . . . . . . . . . . . . . . . . . . . . . . .

200532

1-1 . . . . . 1-1 . . . . . 1-2 . . . . . 1-3. . . . . 1-5 . . . . . 1-7 . . . . . 1-9 . . . . . 1-11. . . . 1-13. . . . 1-15 . . . . 1-16 . . . . 1-17 . . . . 1-18 . . . . 1-19 . . . . 1-20 . . . .

Date 200532 200532 200532 200532 200532 200532 200532 200532 200532 200532 200532 200532 200532 200532 200532

1

0

TECHNICAL DATA Contents

XF105 series

0

2

©

200532


ECAS-4

1. ECAS-4

0

1.1 POWER SUPPLY AND EARTH OF ECAS-4 ELECTRONIC UNIT

A

B

C

1 4 7 10 13 16

1 4 7 10 13

1 4 7

2 5 8 11 14 17

2 5 8 11 14

2 5 8

3 6 9 12 15 18

3 6 9 12 15

3 6 9 C900599

A

Electronic unit connection point

B

Description of connection point

C

Reading at connection point (Ubat = battery voltage)

D

Measuring unit

E

Explanatory notes (if applicable)

F

"X" mark indicates that additional information is available in "Technical data"

A

B

C

D

A07

Power supply before ignition

Ubat

V DC

A10

Power supply after ignition

Ubat

V DC

A12

Electronic unit earth

<0.5

V DC

©

200532

E

F

Voltage loss measurement with as may consumers as possible switched on.

1-1


0

XF105 series

1.2 CAN CONNECTION, ECAS-4 ELECTRONIC UNIT

A

B

C

1 4 7 10 13 16

1 4 7 10 13

1 4 7

2 5 8 11 14 17

2 5 8 11 14

2 5 8

3 6 9 12 15 18

3 6 9 12 15

3 6 9 C900599

A


B


C


D

Measuring unit

E


F


A

B

A01 A03

1-2

C

D

E

F

V-CAN2-L

V DC

CAN signal in accordance with ISO 11898

V-CAN2-H

V DC

CAN signal in accordance with ISO 11898

©

200532

TECHNICAL DATA XF105 series 1.3

ECAS-4

ECAS VALVE, FRONT AXLE

0

A

B

C

1 4 7 10 13 16

1 4 7 10 13

1 4 7

2 5 8 11 14 17

2 5 8 11 14

2 5 8

3 6 9 12 15 18

3 6 9 12 15

3 6 9 C900599

A


B


C


D

Measuring unit

E


F


A

B

C

D

B04

Supply voltage for solenoid valve (B166)

Ubat

V DC

B11

Solenoid valve (B166), admit/ exhaust air position

0 Ubat

B15

©

Solenoid valve (B166), connect front axle bellows

200532

E

X Connection point B11 is switched to earth for the admit air position

V DC

F

X

Connection point does not have an earth connection for the admit air position To connect the bellows, connection point B15 is switched to earth inside the ECU

X

1-3


XF105 series

0

3

4

1

1 3 4

C900606

Electrical connections 1. Solenoid valve, admit/exhaust air 3. Solenoid valve, front axle bellows 4. Earth Resistance of solenoid valves

(1)

Temperature ( C)

20

Resistance ( ) Minimum

Maximum

50

130

(1) Check the resistance values by measuring between connection points 1 - 4 and 3 - 4 of the component.

Function table Connection point 1

X

1-4

3

Action

X

Exhaust air from right-and left-hand bellows, front axle

X

Admit air to right- and left-hand bellows, front axle

©

200532


ECAS-4

FT ECAS VALVE, DRIVEN AXLE

0

A


B


C


D

Measuring unit

E


F


A

B

C

D

B04


Ubat

V DC

B11


0 Ubat

B13

©

Solenoid valve (B238), connect rear axle bellows

200532

E

X Connection point B11 is switched to earth for the admit air position

V DC

F

X

Connection point does not have an earth connection for the admit air position To connect the bellows, connection point B13 is switched to earth inside the ECU

X

1-5


XF105 series

0

1

4

3

1 3 4

C900607

Electrical connections 1. Solenoid valve, rear axle bellows 3. Solenoid valve, admit/exhaust air 4. Earth Resistance of solenoid valves

(1)

Temperature ( C)

20


Maximum

50

130

(1) Check the resistance value between connection points 1 - 4 and 3 - 4 of the component.


X

1-6

3

Action

X

Exhaust air from right- and left-hand bellows of driven axle

X

Admit air to right- and left-hand bellows of driven axle

©

200532


ECAS-4

FA ECAS VALVE, DRIVEN AXLE

0

A

B

C

1 4 7 10 13 16

1 4 7 10 13

1 4 7

2 5 8 11 14 17

2 5 8 11 14

2 5 8

3 6 9 12 15 18

3 6 9 12 15

3 6 9 C900599

A


B


C


D

Measuring unit

E


F


A

B

C

D

B04

Solenoid valve earth (B250)

0

V DC

B10

Solenoid valve, rear axle bellows, left (B250)

Ubat

V DC

Bleeding

X

B11

Solenoid valve, admit air, left and right (B250)

Ubat

V DC

Admit air

X

B13

Solenoid valve, rear axle bellows, right (B250)

Ubat

V DC

Bleeding

X

©

200532

E

F X

1-7


XF105 series

0

1

4

1

2

3

3

2

4

C900608

Electrical connections 1. Solenoid valve, admit/exhaust air 2. Solenoid valve, rear axle bellows, left 3. Solenoid valve, rear axle bellows, right 4. Earth Resistance of solenoid valves

(1)

Temperature ( C)


Maximum

50

130

20

(1) Check the resistance value between connection points 1 - 4, 2 - 4 and 3 - 4 of the component.


2

X

X

1-8

3

Action

X

Exhaust air from right-hand bellows of driven axle

X

Admit air to right-hand bellows of driven axle

X

Exhaust air from left-hand bellows of driven axle

X

Admit air to left-hand bellows of driven axle

©

200532


ECAS-4

ECAS VALVE, LIFT/LOWER AXLE

0

A

B

C

1 4 7 10 13 16

1 4 7 10 13

1 4 7

2 5 8 11 14 17

2 5 8 11 14

2 5 8

3 6 9 12 15 18

3 6 9 12 15

3 6 9 C900599

A


B


C


D

Measuring unit

E


F


A

B

C

D

B04


Ubat

V DC

X

B12

Solenoid valve (B254), lifting bellows connection

Ubat

V DC

X

B14


0 Ubat

©

200532

E

Connection point B14 is switched to earth for the admit air position V DC

F

X

Connection point B14 does not have an earth connection for the exhaust air position

1-9


XF105 series

0

3

4

1

1 3 4

C900606

Electrical connections 1. Solenoid valve, lower axle 3. Solenoid valve, lift axle 4. Earth Resistance of solenoid valves

(1)

Temperature ( C)


Maximum

50

130

20

(1) Check the resistance values by measuring between connection points 1 - 4 and 3 - 4 of the component.


X

1-10

3

Action

X

Exhaust air from lifting bellows

X

Admit air to lifting bellows

©

200532


ECAS-4

ECAS HEIGHT SENSOR

0

A

B

C

1 4 7 10 13 16

1 4 7 10 13

1 4 7

2 5 8 11 14 17

2 5 8 11 14

2 5 8

3 6 9 12 15 18

3 6 9 12 15

3 6 9 C900599

A


B


C


D

Measuring unit

E


F


A

B

C

D

B05

Signal voltage from front axle height sensor

0.7-0.8

V DC

X

B08

Signal voltage from rear axle height sensor, left

0.7-0.8

V DC

X

B09

Signal voltage from rear axle height sensor, right

0.7-0.8

V DC

X

B07

Earth

0

V DC

X

©

200532

E

F

1-11


0

XF105 series

Electrical connection points 1. Signal voltage from height sensor 2. Earth

2

1

C900602

Coil resistance Temperature ( C)

1-12

Resistance ( ) Nominal

Minimum

Maximum

-20

73.7

72.1

75.4

-10

77.2

75.4

78.9

0

80.6

78.8

82.5

10

84.1

82.1

86

20

87.5

85.5

89.5

30

90.9

88.9

93.0

40

94.4

92.2

96.5

©

200532


ECAS-4

ECAS PRESSURE SENSOR

0

A

B

C

1 4 7 10 13 16

1 4 7 10 13

1 4 7

2 5 8 11 14 17

2 5 8 11 14

2 5 8

3 6 9 12 15 18

3 6 9 12 15

3 6 9 C900599

A


B


C


D

Measuring unit

E


F


A

B

C

D

B01

Pressure sensor supply voltage

Ubat

V DC

B02

Rear axle pressure sensor output voltage, right

0.5-4.5

V DC

Output signal depending on bellows pressure

X

B03

Pressure sensor output voltage, front axle

0.5-4.5

V DC


X

B06

Rear axle pressure sensor output signal, left

0.5-4.5

V DC


X

B07

Earth

0

V DC

©

200532

E

F X

X

1-13


0

XF105 series

Pressure sensor output signal

Electrical connections 1. Supply voltage 2. Earth 3. Output signal

U V 4.5 3.7 2.9 2.1 1.3 0.5 0

2

4

6

8

4

1

2

3

10

P

C900600

1-14

©

200532


ECAS-4

ECAS REMOTE CONTROL

0

A

B

C

1 4 7 10 13 16

1 4 7 10 13

1 4 7

2 5 8 11 14 17

2 5 8 11 14

2 5 8

3 6 9 12 15 18

3 6 9 12 15

3 6 9 C900599

A


B


C


D

Measuring unit

E


F


A

B

C

D

A13

Power supply after ignition

Ubat

V DC

A15

Earth

0

V DC

A08

Timer signal

20

V DC

A11

Data signal

0.3-0.5

V DC

©

200532

E

F

1-15


0

XF105 series XF105 series

1.10 ECAS SWITCH, SWITCH, NORMAL NORMAL DRIVING DRIVING LEVEL LEVEL

A

B

C

1 4 7 10 13 16

1 4 7 10 13

1 4 7

2 5 8 11 14 17

2 5 8 11 14

2 5 8

3 6 9 12 15 18

3 6 9 12 15

3 6 9 C900599

A


B

Description of co connection point

C

Read Readin ing g at at con conne nect ctio ion n poi point nt (Uba (Ubatt = batt batter ery y vol volta tage ge))

D

Measuring unit

E

Exp Explanatory ory notes (if applicable)

F

"X" "X" mark mark indi indica cates tes that that add addit itio iona nall infor informa mati tion on is is avai availa labl ble e in "Tec "Techn hnic ical al dat data" a"

A

B

C

D

E

F

A05

Voltage signal from normal driving level switch

earth

V DC

Switch operated

X

Electrical connections (C740) 1. Earth 7. Not connected 5. Connected to ECAS un unit

-

Switch not operated

7

1

5

C900615

1-16

©

200532

TECHNICAL DATA XF105 series XF105 series

ECAS-4

1.11 ECAS SWITCH, SWITCH, SECOND SECOND DRIVING DRIVING LEVEL LEVEL

0

A

B

C

1 4 7 10 13 16

1 4 7 10 13

1 4 7

2 5 8 11 14 17

2 5 8 11 14

2 5 8

3 6 9 12 15 18

3 6 9 12 15

3 6 9 C900599

A


B


C


D

Measuring unit

E


F


A

B

C

D

E

F

A05

Voltage signal from second driving level switch

earth

V DC

Switch operated

X

Electrical connections (C899) 1. Earth 7. Not connected 5. Connected to ECAS un unit

0

Switch not operated

7

1

5

C900615

©

20 200532

1-17


0

XF105 series XF105 series

1.12 ECAS SWITCH, SWITCH, LIFT/LOW LIFT/LOWER ER AXLE AXLE

A

B

C

1 4 7 10 13 16

1 4 7 10 13

1 4 7

2 5 8 11 14 17

2 5 8 11 14

2 5 8

3 6 9 12 15 18

3 6 9 12 15

3 6 9 C900599

A


B


C


D

Measuring unit

E


F


A

B

C

D

E

F

A04

Voltage signal from lift/lower axle switch

Ubat

V DC

Switch in axle lifting position

X

Electrical connections (C741) 1. Powe ower supply after ignition 7 Earth 3. Connected to ECAS un unit

earth

Switch in axle lowering position

1

7

3

C900616

1-18

©

200532


ECAS-4

1.13 TRACTION CONTROL SWITCH

0

A

B

C

1 4 7 10 13 16

1 4 7 10 13

1 4 7

2 5 8 11 14 17

2 5 8 11 14

2 5 8

3 6 9 12 15 18

3 6 9 12 15

3 6 9 C900599

A


B


C


D

Measuring unit

E


F


A

B

C

D

E

F

A06

Voltage signal from traction control switch

earth

V DC

Switch operated

X

Electrical connections (C742) 1. Earth 7. Not connected 5. Connected to ECAS unit

-

Switch not operated

7

1

5

C900618

©

200532

1-19


0

XF105 series

1.14 ECAS SWITCH, INCREASED MANOEUVRING LEVEL

A

B

C

1 4 7 10 13 16

1 4 7 10 13

1 4 7

2 5 8 11 14 17

2 5 8 11 14

2 5 8

3 6 9 12 15 18

3 6 9 12 15

3 6 9 C900599

A


B


C


D

Measuring unit

E


F


A

B

C

D

E

F

A06

Voltage signal from increased manoeuvring level switch

Ubat

V DC

Switch operated

"X"

Electrical connections (C895) 1. Power supply after ignition 7. Not connected 5. Connected to ECAS unit

0

Switch not operated

7

1

5

C900619

1-20

©

200532

ECAS-4 XF105 series

Contents

CONTENTS ECAS-4

Page 1.

Date

SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ECAS system operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 Axle load monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 Axle load calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. . . . 1-1 . . . . 1-2 . . . . 1-5 . . . . 1-6 . . . .

. . . . .

200532 200532 200532 200532 200532

2.

DESCRIPTION OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 Height sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 Remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 Normal driving level switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 Pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 Solenoid valve block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 ECAS electronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 Pressure-relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. . . . . 2-1 . . . . . 2-3 . . . . . 2-7. . . . . 2-7 . . . . . 2-8. . . . . 2-11 . . . . 2-12 . . . .

200532 200532 200532 200532 200532 200532 200532 200532

3.

CONTROL FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 Chassis height control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 Highest/lowest chassis level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 Control via the remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 Delay setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 Automatic lowering of lifting axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 Traction control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 Axle load monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. . . . . 3-1 . . . . . 3-2 . . . . . 3-4 . . . . . 3-5 . . . . . 3-6 . . . . . 3-7 . . . . . 3-8 . . . . .

200532 200532 200532 200532 200532 200532 200532 200532

4.

DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200532 4.1 Key to block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200532 4.2 Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 . . . . . 200532

©

1

200532

1

ECAS-4 Contents

XF105 series

1

2

©

200532

ECAS-4 XF105 series

System description

1. SYSTEM DESCRIPTION 1.1

INTRODUCTION

1

ECAS in ECAS-4 is an abbreviation for Electronically Controlled Air Suspension. The "4" indicates that this is the fourth version of the ECAS system. The functions of the ECAS-4 system are: 1.

2. 3.

©

Adjustment of the chassis height when loading and unloading. This control maintains a constant vehicle height independent of the load. Adjustment of the air suspension while driving. The chassis height is automatically controlled while the vehicle is being driven. Calculation of the axle loads on the basis of the bellows pressures.

200532

1-1

ECAS-4 System description 1.2

1

XF105 series

ECAS SYSTEM OPERATION

F735 /

B166 /

F736 /

B238 /

F615

B250/ B253

F612 / F613 / F614

D992

VIC D310

D899

D529 M1

M2

STOP

CAN C740/ C741/ C895/

DAVIE

C899

C900603

The electronic unit (D992) processes the signals of the ECAS-4 system. The chassis height at the driving level is stored in the memory of the electronic unit. The height sensor (F612/F613/F614) registers the chassis height and sends this value to the electronic unit. Inside the unit this value is compared with the desired chassis height in the memory.

1-2

©

200532

ECAS-4 XF105 series

System description

If there is a difference between the chassis height in the memory and the measured chassis height, the electronic unit actuates the solenoid valve block (B166/B238/B254/B253), which in turn admits air to or exhausts air from the air b ellows. When the vehicle is stationary this is done immediately. When the vehicle is being driven, the difference should be present for longer than 60 seconds in connection with driving around roundabouts and to limit air consumption. The unit recognises this situation as it receives a speed signal via the CAN.

1

If the chassis height measured by the unit does not correspond to the chassis height for the normal driving level that is stored in the unit memory, the warning lamp on the instrument panel (D899) is activated by the VIC (D310). The chassis can be brought back to the normal driving height by activating the normal driving level switch (C740). I there is a fault present in the ECAS system this will be shown on the master display of the instrument panel (D899).

©

200532

1-3

ECAS-4 System description

XF105 series

The height of the chassis can be adjusted as desired with the remote control (D529). It can be used to:

1

Adjust the height to line up with a loading bay.

C900040

Pick up and remove a swap body for vehicles which also have an air-sprung front axle.

C900041

Couple and uncouple a semi-trailer rapidly.

C900042

1-4

©

200532

ECAS-4 XF105 series 1.3

System description

AXLE LOAD MONITORING

The axle load monitoring system calculates the axle loads on the basis of the air suspension bellows pressure. The driver can activate the individual axle loads and the load's weight via the Menu Control Switch and have them shown on the DIP master display.

N

6.5

1

N

9.0

(x 1000 Kg)

6.0

6.0

6.0

(x 1000 Kg) C900604

With axle load monitoring it is possible to display the "overload" and "load's weight" indications. The driver can use "Overload" to obtain an automatic warning when the permitted axle load is exceeded. This value can be programmed using DAVIE XD; a warning is generated when the programmed value is exceeded. Axle loads can also be shown on FT vehicles equipped with a leaf-sprung front axle. The axle load value for the front axle is a calculated value which is obtained on the basis of the axle load value of the rear axle, the wheel base and the KA factor.

Note: When an FT vehicle is equipped with an adjustable fifth wheel and the position of the fifth wheel changes, calibration is called for, using DAVIE XD.

KA WB C900601

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200532

1-5

ECAS-4 System description 1.4

1

XF105 series

AXLE LOAD CALIBRATION

If the vehicle is equipped with axle load monitoring, it is recommended to regularly perform an axle load calibration (at least once per year and when the vehicle is first taken into service). The axle load values are set to a higher value ex-factory. Correct calibration of the axle loads requires a weighbridge on which the individual axle loads are measured. If the actual value measured deviates from the display reading, it can be corrected using the remote control. Weigh the vehicle when it is (fully) loaded.

Calibration using the remote control Press the key (1) to lift/lower the prime mover trailing axle. The prime mover indicator lights (2) will come on. Press key "STOP" (3) and hold it down for at least 5 seconds. The indicator lights (4) will come on one after another.

2

4

1 M1

M2

3

STOP

D001143

-

Select the axle (5) that is to be calibrated. Use the arrow keys (6) to increase or decrease value (A).

5 M1

M2

6 STOP

D001144

4.0

A

2.0

B

(x 1000Kg) D001150

1-6

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200532

ECAS-4 XF105 series

-

System description

To store the values, press keys "STOP" (3) and "M1" (7) simultaneously. Then select the next axle (5) that needs calibrating. To stop calibrating, hold key "STOP" (3) down for at least 5 seconds.

-

Note: During calibration, the remote control is automatically switched off if it is not operated for 20 seconds. Any values that had been programmed until that moment are not stored.

1 7

M1

M2

STOP

3

D001145

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200532

1-7

ECAS-4 System description

XF105 series

1

1-8

©

200532

ECAS-4 XF105 series

Description of components

2. DESCRIPTION OF COMPONENTS 2.1

HEIGHT SENSOR

1

The chassis height is measured using the height sensor which is attached to the chassis and linked mechanically with the axle. The height sensor consists of a fixed coil (2) with a metal bridge (1). In the coil there is a core (3) on which a moon-shaped metal plate is attached. This core follows the movement of the horizontal control rod using an axle (4). The ECAS unit continuously sends an electrical signal to the height sensors. Depending on the chassis height, the position of the moon-shaped metal plate on the core changes relative to the metal bridge on the coil. The position of the moon-shaped plate relative to the metal bridge determines the bundling of lines of force and, therefore, the strength of the magnetic field. This alters the self-induction of the coil, distorting the signal. The degree of distortion is a measure of the chassis height.

1 2 3 4

C900254

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200532

2-1

ECAS-4 Description of components A. B.

1

C.

Mean bundling of lines of force. Mean magnetic field. Smaller bundling of lines of force. Weaker magnetic field. Larger bundling of lines of force. Stronger magnetic field.

XF105 series 1 2 A 3

FA vehicles are equipped with two height sensors on the driven axle. FT vehicles are equipped with one height sensor on the driven axle. One height sensor is also used on the air-sprung front axle.

3 1 2

B 3 1 2

4

C 3 1 2

C900253

2-2

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200532



REMOTE CONTROL

When keys on the remote control are pressed, the control transmits a signal (the "data signal"). At the same time, the ECAS unit sends a timer signal to the remote control. Each key transmits a different data signal, so that the ECAS unit recognises which key has been pressed. These signals are received by the ECAS unit and turned into commands.

Remote control used on vehicles with airsprung rear axle

M1

1

M2

STOP

C900268

Remote control used on vehicles with airsprung front and rear axle

M1

M2

STOP

C900269

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200532

2-3

ECAS-4 Description of components

1

Vehicles equipped with an axle load monitoring system have a remote control system with calibration function for the axle loads. In addition to the air-sprung front and rear axle, this remote control also supports the drawn vehicle; however, this drawn vehicle must be able to process RGE22 and EBS22 CAN (in accordance with SAE J1939) messages.

XF105 series Remote control used on vehicles with axle load monitoring

Note: The remote controls are not interchangeable.

M1

M2

STOP

C900592

The following keys are on the remote control: -

Key to select the front axle of the primer mover.

C900030

-

Key to select the rear axle of the primer mover.

C900031

-

Key to adjust the prime mover to the normal driving level.

C900035

-

Key to lift/lower the trailing axle of the prime mover.

-

Key to select the front side of the drawn vehicle.

-

Key to select the rear side of the drawn vehicle.

2-4

©

200532

ECAS-4 XF105 series -

Key to lift/lower the trailing axle of the drawn vehicle.

-

M 1; this is a memory key that can be programmed by the driver.


1

M1 C900033

-

M 2; this is a memory key that can be programmed by the driver.

M2 C900034

-

Key to lower the chassis.

C900036

-

Key to lift the chassis.

C900037

-

Stop key to stop the controls.

STOP C900038

Memory key The chassis can be brought to the desired height with the "Lower chassis" and "Lift chassis" keys. Pressing the stop key and then the memory key (with the stop key held down), programs the required height into the ECAS unit. When the relevant memory key is subsequently pressed, the vehicle will automatically adjust to the programmed chassis height.

©

200532

2-5


XF105 series

Stop key If the stop key on the remote control is pressed, the system will respond as follows, irrespective of the vehicle speed:

1

-

-

2-6

When the chassis height is being changed, the electropneumatic valves are cut out immediately. After 4 seconds the current height becomes the required height. The stop key can be used to make the system function when the ignition is turned off. This so-called delay setting is realised by operating the stop key while turning off the ignition. This height adjustment remains active for 60 minutes (providing that in the meantime the ignition is not switched on and off or the air supply does not run out).

©

200532



NORMAL DRIVING LEVEL SWITCH

This spring-loaded switch (C740) has the same function as the normal driving level button on the remote control.

1

The vehicle can be adjusted to the normal driving level using this spring-loaded switch, irrespective of the vehicle speed.

Note: In some applications 2 normal driving levels are programmed in the unit. In this case, a twoposition switch (C899) is also used. If the vehicle has 2 normal driving levels, a different driving level has been calibrated.

2.4

C900274

PRESSURE SENSOR

The pressure sensor is screwed into the bellows top and checks the bellows pressure. The sensor is a piezo element which converts pressure to a voltage for the electronic unit. This voltage is used to calculate the axle load. This pressure sensor is used on vehicles that have axle load monitoring.

C900621

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200532

2-7

ECAS-4 Description of components 2.5

XF105 series

SOLENOID VALVE BLOCK

Solenoid valve block for FA vehicles

1 1

2

3

11

12

13

11

22

23

3

C900114

This solenoid valve block is used in combination with 2 height sensors. The solenoid valve block is an assembly of electropneumatic valves which open or close the connections to the air bellows. These electropneumatic valves are activated by the ECAS unit. Air is admitted to or exhausted from the air bellows depending on the required actions. The valve block has three electropneumatic valves: two 2/2-way valves (12 and 13) and one 3/2-way valve (11). Depending on whether the solenoid, connection point 1 on the solenoid valve block, is active or not, the central passage is connected to the reservoir connection 11 or the vent 3 via the 3/2-way valve. The left-and right-hand air bellows of the driven axle are connected to connections 22 and 23 respectively. Depending on the position of the 2/2-way valves (12 and 13) and the 3/2-way valve (11), connection points 22 and 23 are shut off from the central passage or are connected to reservoir connection 11 or vent connection 3 via the central passage.

2-8

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200532

ECAS-4 XF105 series



2

X

X

3

Action

X

Exhaust air from right-hand bellows of driven axle

X

Admit air to right-hand bellows of driven axle

X

Exhaust air from left-hand bellows of driven axle

X

Admit air to left-hand bellows of driven axle

1

Solenoid valve block for FT vehicles and vehicles with air-sprung front axle

1

11

3

12

13

22

23

3 11

C900111

This solenoid valve block is used in combination with one height sensor. The solenoid valve block is an assembly of electropneumatic valves which open or close the connections to the air bellows. These electropneumatic valves are activated by the ECAS unit. Air is admitted to or exhausted from the air bellows depending on the required actions. The valve block has three electropneumatic valves: two 2/2-way valves (12 and 13) and one 3/2-way valve (11).

©

200532

2-9


1

XF105 series

Depending on whether the solenoid, connection point 1 on the solenoid valve block, is active or not, the central passage is connected to the reservoir connection 11 or the vent 3 via the 3/2-way valve. The left-and right-hand air bellows of the driven axle are connected to connections 22 and 23 respectively. Depending on the position of the 2/2-way valves (12 and 13) and the 3/2-way valve (11), connection points 22 and 23 are shut off from the central passage or are connected to reservoir connection 11 or vent connection 3 via the central passage. In the solenoid valve block, a small passage has been created between connections 22 and 23, equalising the bellows pressure on the left and right.


X

2-10

3

Action

X

Exhaust air from right-hand and left-hand bellows of driven axle or front axle

X

Admit air to right-hand and left-hand bellows of driven axle or front axle

©

200532



ECAS ELECTRONIC UNIT

The ECAS electronic unit adjusts and controls the entire system. This ECAS unit consists of: -

1

A microprocessor as a central unit that processes the signals of the other ECAS components and exchanges information with other vehicle systems via the CAN. A fixed, non-erasable memory (Read Only Memory) in which a control program for the specific controls is stored, such as the sequence of air admission to bellows, damping control, signal filtering, etc. An electronic erasable memory (EEPROM) that retains the information in its memory when the ECAS unit power supply is off.

-

-

This memory contains parameters for: normal driving level maximum chassis height axle load monitoring

C900605

These parameters can differ according to the vehicle type. The right parameters can be programmed using DAVIE XD.

©

200532

2-11

ECAS-4 Description of components 2.7

1

XF105 series

PRESSURE-RELIEF VALVE

The pressure relief valve with full flow-back ensures that the circuit for the air-sprung front axle is pressurised first, followed by the circuit for the air-sprung rear axle. This is because of the greater mechanical resistance of the front axle suspension that is present when lifting the front of the vehicle. The compressed air enters through connection 1. The non-return valve (5) is kept closed by the air pressure of connection 1. As the diaphragm (3) keeps bore (2) closed with the spring (4), the air pressure cannot flow to space (6).

4 3

5 2 1

6 C900285

As soon as the force of the spring is overcome by the force exerted by the pressure under the diaphragm (3), the diaphragm (3) will move upwards and open the bore (2). The com pressed air from connection 1 can now flow to space (6). Following a pressure drop on connection 1 the compressed air can flow back from space (6) via bore (2). If the pressure under the diaphragm (3) drops below the closing pressure, bore (2) is closed by the diaphragm (3) under the influence of the spring (4). The return flow can then only take place along the side of the non-return valve (5).

4 3

5 2 1

6 C900286

2-12

©

200532

ECAS-4 XF105 series

Control functions

3. CONTROL FUNCTIONS 3.1

CHASSIS HEIGHT CONTROL

1000

1

1010

E051

E351

VCAN2 G535

G1

G2

L N A C

H N

A1

A3

B9

B1

A C

B

7

1 5

1 Level

A7

A10

B A

C740

A5

ECAS-4 D992 B4

B15

B11

B13

B11

B13

B10

1

3

1

3

2

B7

B8

F613

3

1

left/ right

infl./ defl.

infl./ defl.

4 Valve block front axle G

B166

infl./ defl.

left/ right

4 Valve block driven axle H

B238

right

left

B5

1

Height 2 sensor rear right

L

F612

1 L

F614

Height 2 sensor rear left

1 L

B3

F735

Height 2 sensor front

1 P

Pressure 2 sensor front

3 U

B6

F736

1 P

Pressure 2 sensor rear left

3 U

B2

F615

1 P

3 U

Pressure 2 sensor rear right

4 Valve block driven axle J

B250

L

M

N

C900612

The chassis height at the driving level is stored in the memory of the electronic unit (D992). The height sensor (F612/F613/F614) registers the chassis height and sends these values to the electronic unit (D992) where they are compared with the desired chassis height in the memory. If there is a difference between the chassis height in the memory and the measured chassis height, the electronic unit (D992) actuates the solenoid valve block (B166/B238/B250), which in turn admits air to or exhausts air from the air b ellows. When the vehicle is stationary this is done immediately. When driving (above 3 km/h) (CAN) the difference has to be present for longer than 60 seconds for driving around roundabouts and to limit the consumption of compressed air.

©

200532

3-1

ECAS-4 Control functions 3.2

1

XF105 series

HIGHEST/LOWEST CHASSIS LEVEL

1000

1010

M1

M 2

STOP

E051

E351

RC-ECAS

VCAN2

D529

1

A7

A10

2

3

G535

4

G1

G2

C D K A C N L T V G C A D

L N A C

H N A C

A13 A15 A8 A11

A1

A3

B9

B1

ECAS-4 D992 B4

B15

B11

B13

B11

B13

B10

1

3

1

3

2

B7

B8

F613

3

1

left/ right

infl./ defl.

infl./ defl.


B166

infl./ defl.

left/ right


B238

right

left

B5

1


1 L

F612

1 L

F614


L

B3

F735


1 P


3 U

B6

F736

1 P

B2

3 F615

U


1 P

3 U



B250

L

M

N

C900613

The chassis height can be altered using the remote control (D529). The remote control (D529) sends the data/timer signals via pins A8 and A11 to the ECAS-4 unit (D992). The highest level is determined by the mechanical limit when the chassis moves upwards. The electronic limit (parameter) is approx. 10 mm below the mechanical limit.

Highest chassis level For the highest chassis level, an earth signal is applied to pins B11 and B13 of the solenoid valve block (B238) or to pins B10, B11 and B13 of the solenoid valve block (B250) to admit air to the driven axle. On an air-sprung front axle, an earth signal is applied to pins B11 and B15 of the solenoid valve block (B166) to admit air to the front axle. Note: On vehicles where it is desirable to limit the highest level or to use the best possible level, a different highest chassis level can be programmed using DAVIE XD.

3-2

©

200532

ECAS-4 XF105 series

Control functions

Lowest chassis level For the lowest chassis level, the earth signal is interrupted on pins B11 and B13 of the solenoid valve block (B238) or on pins B10, B11 and B13 of the solenoid valve block (B250) to exhaust air from the driven axle. On an air-sprung front axle, the earth signal is interrupted on pins B11 and B15 on the solenoid valve block (B166) to exhaust air from the front axle.

1

The lowest level is the mechanical stop (bump level). There is a parameter to suppress a fault message ("Lower chassis" command while the chassis can no longer be lowered). The value of this parameter is such that the fault message function is switched off approx. 5 mm above the rubber stop.

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200532

3-3


1

XF105 series

CONTROL VIA THE REMOTE CONTROL

1000

1010

M1

M 2

STOP

E051

E351

RC-ECAS

VCAN2

D529

1

A7

A10

2

3

G535

4

G1

G2


L N A C

H N A C

A13 A15 A8 A11

A1

A3

B9

B1

ECAS-4 D992 B4

B15

B11

B13

B11

B13

B10

1

3

1

3

2

B7

B8

F613

3

1

left/ right

infl./ defl.

infl./ defl.


B166

infl./ defl.

left/ right


B238

right

left

B5

1


1 L

F612

1 L

F614


L

B3

F735


1 P


3 U

B6

F736

1 P

B2

3 F615

U


1 P

3 U



B250

L

M

N

C900613

The chassis height can be varied with the remote control (D529) by pressing the "Lift" or "Lower" keys. "Lifting" or "lowering" of the chassis stops when the keys are released. If the "Driving level" key is briefly depressed, the chassis automatically assumes the driving level. At a vehicle speed exceeding 25 km/h (CAN), the ECAS unit (D992) no longer responds to the remote control (D529), with the exception of the "Stop" and "Normal level" keys.

3-4

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200532


Control functions

DELAY SETTING

1000

1010

M1

1

M 2

STOP

E051

E351

RC-ECAS D529

1

2

3

4


A7

A10

A13 A15 A8 A11

ECAS-4 D992 B4

B15

B11

B13

B11

B13

B10

1

3

1

3

2

B7

B8

F613

3

1

left/ right

infl./ defl.

infl./ defl.


B166

infl./ defl.

left/ right


B238

right

left

B5

1


B9

1 L

F612

B1

1 L

F614


L

B3

F735


1 P


3 U

B6

F736

1 P


B2

3 F615

U

1 P

3 U



B250

L

M

N

C900614

A delay setting can be selected using the remote control (D529). Pressing the stop key on the remote control (D529) while turning off the ignition activates the delay setting. When this setting is activated, the height adjustment remains active for 60 minutes when the ignition is switched off or until the air supply has become insufficient. When the delay setting is in operation, any faults are suppressed.

©

200532

3-5


AUTOMATIC LOWERING OF LIFTING AXLE

1000

1010

E051

1

XF105 series

E351

VCAN2 G535

A7

A10

G1

G2

L N A C

H N A C

A1

A3

B9

B1

A12

ECAS-4 D992 B4

B15

B11

3

1

B13

B10

2

1

B14

B12

1

3

B7

A1 3

6 0 4 B

F613

infl./ defl.

infl./ defl.


B166

right

1

4 Valve block driven axle K

infl./ defl.

left

B253

I 2

6 6 3 B

right

B5

1


B1 left/ right

B8

L

F612

1 L

F614


1 L

B3

F735


1 P


3 U

B6

F736

1 P

B2

3 F615

U


1 P

3 U


4 Leading-/ trailing axle B254

L

M

N

C900623

The axle load is registered by the pressure sensor (F615). The trailing axle will be automatically lowered when the measured load on the driven axle has attained a specific value and the vehicle speed is less than around 3 km/h. When the non-driven axle is lowered, the pressures in the bellows of the driven axle will adapt to the changed load status.

3-6

©

200532


Control functions

TRACTION CONTROL

Vehicles with air suspension 1000

1010

E051

1

E351

D

7

1

B

5

A7

A10

A C742

Traction aid

A6

A12

ECAS-4 D992 B4

B15

B11

3

1

B13

B10

2

1

B14

B12

1

3

B7

A1 3

6 0 4 B

F613

infl./ defl.

infl./ defl.


B166

right

1

4 Valve block driven axle K

infl./ defl.

left

B253

I 2

6 6 3 B

right

B5

1


B1 left/ right

B8

L

F612

B9

1 L

F614


B1

1 L

B3

F735


1 P


3 U

B6

F736

1 P


3 U

B2

F615

1 P

3 U


4 Leading-/ trailing axle B254

L

M

N

C900624

On vehicles with a trailing axle or a leading rear axle and air suspension, the bellows pressure of this axle can be reduced. As a result, the bellows pressure of the driven axle will be increased, so that load is transferred from the non-driven to the driven axle. This facility is operated via a switch on the control panel. This is useful if increased traction is required, for example to pull out of slippery or muddy terrain. Traction control is switched on using switch (C742). When this switch is operated at a standstill or at a speed of no higher than 3 km/h, pin 17 of the unit (D802) will be connected to earth and the unit will exhaust the air from the bellows of the trailing axle/leading rear axle. After 3 minutes or when the speed is higher than 20 km/h, this function deactivates again and the vehicle will drop to the previously selected level. The function can be repeated by operating the switch again.

©

200532

3-7


1

XF105 series

AXLE LOAD MONITORING

The axle loads are measured by the pressure sensors. The pressure reading is converted to a voltage signal for the ECAS unit; this voltage represents a specific axle load. The axle load information is transmitted to the VIC via the CAN network. Use the Menu Control Switch to have the axle load information shown on the master display.

1000 E051

1010 E351

VCAN2 G535

G1

A7

G2

L N A C

H N A C

A1

A3

A10

A12

ECAS-4 D992 B7

B1

B3

F735

1 P


3 U

B6

F736

1 P

B2

3 F615

U


1 P

3 U


N

C900625

3-8

©

200532

ECAS-4 XF105 series

Diagrams

4. DIAGRAMS 4.1

KEY TO BLOCK DIAGRAM Basic code

©

B166

ECAS valve, front axle

B238

ECAS valve, driven axle, air supply (FT)

B250

ECAS valve, driven axle, air supply (FA)

B253

ECAS valve, driven axle, air supply

B254

ECAS valve, steered leading rear axle/trailing axle

B366

Buzzer, lowering trailing axle

B383

ECAS valve, FAK/FTM leading rear axle

B406

Resistance, lowering trailing axle

C740

ECAS switch, normal driving level

C741

ECAS switch, lift axle

C742

Traction control switch

C895

ECAS switch, increased manoeuvring level

C899

ECAS switch, second driving level

D529

ECAS remote control

D992

ECAS-4 electronic unit

E051

Fuse, ECAS

E351

Fuse, ECAS

E589

ECAS switch, FAK driven axle

F612

ECAS height sensor, rear axle, left

F613

ECAS height sensor, rear axle, right

F614

ECAS height sensor, front axle

F615

ECAS pressure sensor, driven axle, right

F735

ECAS pressure sensor, front axle

F736

ECAS pressure sensor, driven axle, left

200532

1

Description

4-1

ECAS-4 Diagrams 4.2

1

XF105 series

BLOCK DIAGRAM

Block diagram C900594 applies to: XF105 model, 4x2 with leaf-sprung front axle Explanation of block diagram A: Used on vehicles with 1 normal driving level B: Used on vehicles with 2 driving levels C: Used on FT vehicles D: Used on FA vehicles E: Used on FA vehicles

4-2

©

200532

ECAS-4 XF105 series

Diagrams 4 9 5 0 0 9 C

1 2 1 A

2 H N A C G 2 5 N 3 A 5 C G 1 L V N A C G

3 A

1 A

t t r f

e h o l 2 g s r 1 i n a 6 e e e F H s r

1 1 A

T A D 4 A

S A L C 9 3 K C 2 E 5 2 D N G C D R 1 C CV

8 A 5 1 A 3 1 A

5 B

L 1

2

E 8 B

2 9 9 D

L 1

2

t r t 3 h o h 1 g s i g i 6 r e n e F H s r a e r

7 B

4 S A C E

l a

9 l h c m t 9 r e i 8 o v w e s N l C

l e v e B L 2 1

A 5

7

B l e v B e L

t f e l

0 1 B

2

5

t h g i r

5 A

3

7 e l x a n e v i r d k c o l b e v l a V

l l

h 0 a e c v i 4 m t e 7 r l w C o s

A

N

3 1 B

1 1 B

/ t h t f g i e l r 3 . / l . f l f e n i d 1

C

0 1 0 1

0 0 0 1

©

200532

1 5 3 E

1 5 0 E

e l x a

A

1 1

4

. / l . f l f e n i d 1

D

n e v i r d k c o l b e v l a V 4 0

5 2 B

8 3 2 B

0 1 A

7 A

4 B

4-3

ECAS-4 Diagrams

XF105 series

Block diagram C900595 applies to: XF105 model, all variants, 4x2 with leafsprung front axle and FAK excepted

1

Explanation of block diagram A: Used on vehicles with lifting axle B: Used on vehicles with 1 normal driving level C: Used on vehicles with 2 driving levels D: Used on vehicles with traction control E: Used on vehicles with increased manoeuvring level F: Used on vehicles with EMAS G: Used on vehicles with air-sprung front axle H: Used on FT vehicles I: Used on vehicles with lifting axle, Australia version only J: Used on FA vehicles K: Used on FAT, FAN, FAX, FAR, FAS, FTP, FTG, FTR, FTS, FTM, FAC vehicles L: Used on FA vehicles M: Used on vehicles with air-sprung front axle N: Used on vehicles with axle load monitoring

4-4

©

200532

ECAS-4 XF105 series

Diagrams 5 9 5 0 0 9 C

3

S 2 5 A 3 1 9 B M E D

U 2 r t e r o h u s g s n i r s e r 5 e s a r 1 e P r

2 B

1 P

6 B

3

9 C

6 F

F

U 2 t e r f r o e u s l s n r s e a 6 e s e r r 3 P 7

1

1 P

F

3 B 2 1 A

3

U 2 r t e r o n u s o r s n f s e e s 5 r 3 P

1 P

7 F

2 G

2 5 N 3 A 5 C G 1 V G

4 S A 9 3 C 2 E 5 2 C D R 1

H N A C

3 A

1 B

L N A C

1 A

9 B

4 1 6 F

1 1 A 8 A 5 1 A

A T A D K L C D N G

5 B

3 1 A

C CV

B 1 7

E

B 1 7

D

B 1 7

C

L 1 2 1 6 F

l e v e l g n i r v u A e o n a 5 M

8 B

2 9 9 D

5 9 8 C

2

A 4

7 C

5 d i a n o i t c a r T

L 1

6 A

4 S A C E

7 B

L 1 3 1 6 F

N

2 t r t h o n g s o i r f e n e H s

M

2 t r t f h o e g s l i r e n e H s a e r

L

1

t h g i r 3 . / . l f l f e n d i

4 1 B

1

4 e 5 l x 2 a B

g n i l i a r t / g n i d a e L 4

8 C

. / . l l f f e n i d 3

t f e l 2 1 0 1 4 B A 1 B 6

2

t h g i r

I 3

e 8 l x 3 a

. / . l l f f e n i d

2

B 1 7

B

0 A 4 7 C

5 l e v e L 1

3 1 B

t / t h f g i e l r 3

5 A 1 1 B

. / . l f l f e n i d 1

k c o l b e v l a V 4

6 6 3 B

5 l e v e L 2

n e v i r d

K

0 1 B

9

A 9

e l x a t h g i r

2

2 1 B

3 5 2 B

t f e l

2 t r r t h o a h e g g s r i n i r e e H s

n B e v i r d k c o l b e v l a V 4

1

0 5 2 B

e l x a n e v i r d

k c o l b e v l a V 4

J

H B 7

1

A 4

7 C

3 1

0 1 0 1

0 0 0 1

©

200532

1 5 3 E

1 5 0 E

A

e l x a t f i L

4 A

. / . l l f f e n i d 1

0 1 A

7 A

5 1 B

/ t t f h g i e l r 3

6 e 6 l x 1 a t B n o r f k c o l b e v l a V 4

G 4 B

4-5

ECAS-4 Diagrams

XF105 series

1

4-6

©

200532

ECAS-4.pdf

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