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Technical Manual / Systembook

HPVS/EVS v20 e31

Figuur 2.3
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HPVS/EVS system book v20 e31

© January 2008, Version 00

GINAF Trucks bv
Wageningselaan 243903 LA
Veenendaal
Telephone: 0318-557444
Telefax:0318-510983
E-mail:info@ginaf.nl

Reproduction, copying and all other means of duplication of the content or portions thereof are
only permitted with prior written permission of GINAF Trucks bv

In the interest of continual product development, GINAF reserves the right to change
speci!cations and products without prior noti!cation.

OG0000070109
HPVS/EVS system book v20 e31
HPVS/EVS system book v20 e31

Inhoudsopgave

1. Safety instructions 1

2. HPVS/EVS operation 1
2.1 General 1
2.2 HPVS operation 2
2.3 EVS operation 5

3. HPVS/EVS power supply 1


3.1 General 1
3.2 Oil supply system with pump 3
3.2.1 Pump with regulation block 3
3.2.1.1 Pump regulation 4
3.2.2 HPVS/EVS reservoir with "oat and !lters 6
3.2.4 Proportional pump "ow unit 8
3.2.4.1 Proportional pump "ow valve 9
3.2.4.2 Pressure sensor for pump pressure (DP) 9
3.2.4.3 Measurement point for pump pressure/control pressure (MP) 10
3.2.4.4 Pressure !lter 10

4.1 General 1
4.1.1 HPVS/EVS valve block 1
4.1.2 2/2 Steering valve 2
4.1.3 Restrictor 2
4.2 HPVS cylinder 3
4.3 Suspension accumulator 4
4.4 LSP valve 5
4.5 Hydraulic system operation 6
4.5.1 Filling and draining 6
4.5.1.1 Filling right-rear 8
4.5.1.2 Draining right-rear 9
4.5.1.3 Filling left-rear 10
4.5.1.4 Draining left-rear 11
4.5.2 Stabilisation 12
4.5.2.1 Lateral stabilisation (option) 12
4.5.2.2 Super stabilisation (option) 13
4.5.3 Stabilisation 14
4.5.4 Container lifting system (option) 15
4.5.5 Pump lowering system 15
4.5.6 Flushing 17
4.5.7 Lift axle unit 18
4.5.7.1 Lower/block valve (v20/43 and v20/44) 20
4.5.7.2 Raise valve (all versions) or lower valve (v20/3x) 20
HPVS/EVS system book v20 e31

4.5.7.3 Pressure switch 20


4.5.7.4 Pressure-operated non-return valve 20
4.5.7.5 Lift axle v20/43 and v20/44, not operated 21
4.5.7.6 Lift axle v20/43 and v20/44, raise 21
4.5.7.7 Lift axle v20/43 and v20/44, lower 23
4.5.7.8 Lift axle v20/3x, not operated 24
4.5.7.9 Lift axle v20/3x, raise 26
4.5.7.10 Lift axle v20/3x, lower, phase 1 27
4.5.7.11 Lift axle v20/3x, lower, phase 2 28
4.5.7.12 Lift axle v20/3x, lower, phase 3 29
4.6 Electronic operation 30
4.6.1 Angle sensor 30
4.6.2 Level sensor 31
4.6.3 ECU input 32
4.6.3.1 HPVS/EVS power supply (diagram 1, appendix 1) 32
4.6.3.2 Angle sensors (diagram 4, appendix 1) 32
4.6.3.3 Level sensor (diagram 4, appendix 1) 32
4.6.3.4 Weight indication (diagram 5, appendix 1) 32
4.6.3.5 Indicator lamps (diagram 6, appendix 1) 32
4.6.3.6 Indicator lamps, diff-locks (diagram 9, appendix 1) 33
4.6.3.7 2nd gear protection (diagram 10, appendix 1) 33
4.6.3.8 Lift axle (diagram 3, appendix 1) 33
4.6.3.9 PTO protection (diagram 10, appendix 1) 34
4.6.4 E31 unit operation 35
4.6.4.1 Highest position (diagram 25093, appendix 1) 35
4.6.4.2 Lowest position (diagram 25093, appendix 1) 35
4.6.4.3 Continuous height control (manual) (diagram 25093, appendix 1) 35
4.6.4.4 Continuous height control (automatic) (diagram 25093, appendix 1) 35
4.6.4.5 Lateral levelling system 35
4.6.4.6 Raise/lower axle (lift axle unit v20/43 and v20/44) 36
4.6.4.7 Raise/lower axle (lift axle unit v20/3x) 36
4.6.4.8 Container lifting system 36
4.6.4.9 Lateral stabilisation (manual operation) 36
4.6.4.10 Lateral stabilisation (automatic) 37
4.6.4.11 Hydraulic roll stabiliser (‘superstab’) 37

5. EVS system description 1

5.1 General 1
5.1.1 HPVS/EVS valve block 1
5.1.2 Axle tilting valve block 2
5.2 2/2 steering valve 3
5.3 Proportional steering valve 4
5.3.1 Emergency steering safety valve 4
5.4 Non-return valve 5
5.4.1 Restrictor 5
HPVS/EVS system book v20 e31

5.5 Pressure sensor for emergency steering pressure (DY) 6


5.6 Measure/blow-off/bleed point for emergency steering system (M1) 7
5.7 EVS cylinder 8
5.7.1 EVS cylinder – steering section 8
5.7.2 EVS cylinder – centre position 9
5.7.2 EVS cylinder – emergency steering section 8
5.7.4 EVS cylinder – vehicle steered left 9
5.7.5 EVS cylinder – vehicle steered right 10
5.8 Emergency steering accumulator 11
5.9 Hydraulic system operation 12
5.9.1 Emergency steering system 12
5.9.2 EVS – steering 13
5.9.3 EVS – vehicle steered left 14
5.9.4 EVS – vehicle steered right 15
5.9.5 EVS – coils 16
5.10 Electronic operation 17
5.10.1 Angle sensor 17
5.10.2 ECU power supply E31 v20 17
5.10.3 Operation 17
5.10.4 Pressure sensors 18
5.10.5 Summary of possible circuit states 19
5.10.5.1 Situation 1 19
5.10.5.2 Situation 2 20
5.10.5.3 Situation 3 20
5.10.5.4 Situation 4 21
5.10.5.5 Situation 5 21
5.10.5.6 Situation 6 22
5.10.5.7 Situation 7 23
5.10.5.8 Situation 8 23
5.10.6 Control panel 24
5.10.7 Electronic straight ahead position protection unit (limit sender, speed
switch) 24

6 HPVS/EVS diagnosis box (DCS) 1


6.1 General 1
6.1.1 DCS operation 1
6.2 Connection, login and disconnection 3
6.2.1 DCS1 connection 3
6.2.2 Login 4
6.2.3 Disconnection 4
6.2.4 Screen 1 E31 5
6.2.5 Screen 1-1: ‘real-time’ display of HPVS data 6
6.2.6 Screen 1-2: ‘real-time’ display of EVS data 8
6.2.7 Screen 1-3: fault message readout part 1, system operate normally 9
6.2.8 Screen 1-4: fault message readout part 2, system operate normally 10
6.3 Screen 2 E31 11
HPVS/EVS system book v20 e31

6.3.1 Screen 2-0: settings selection screen for pump and EVS 12
6.3.2 Screen 2-1 14
6.3.3 Screen 2-2: reading in the correction factors 15
6.3.4 Screen 2-3: code calculation 19
6.3.5 Screen 2-4: automatic "ushing HPVS/EVS 20
6.3.6 Screen 2-7: reading out faults 21
6.3.7 Reading out "ash code 22
6.3.7.1 Reading out fault messages 22
6.3.7.2 Erasing fault codes 22
6.3.8 Summary of "ash codes 23
6.3.9 Screen 2-8: reading out data 25

Appendix 1: Electrical installation 1


1.1 Overview of components in schematic diagrams 1
1.2 Overview of connectors 5
1.3 Schematic diagrams 7

Bijlage 2: Schema’s hydrauliek 1


HPVS/EVS system book v20 e31

Preface
This system book for the GINAF Hydro Pneumatic
Suspension System (HPVS)/ Electronic Vehicle
Steering system (EVS), version 20 (v20) contains
the following sections:

• HPVS/EVS operation
• HPVS/EVS power supply
• HPVS system description
• EVS system description
• HPVS/EVS diagnosis box

The descriptions of the operation of the system can


be used to train technical personnel and as a refer-
ence.

Always follow the safety precautions present-


ed in Chapter 1.

GINAF Trucks bv is not liable for the consequences


of work on the HPVS/EVS system that is performed
by unquali!ed personnel, with incorrect tools and/
or without following the speci!ed safety precau-
tions.
HPVS/EVS system book v20 e31
HPVS/EVS system book v20 e31
Safety instructions

1. Safety instructions
Warning symbols
When text is accompanied by the warning symbol
shown here, this indicates that the information
provided is essential for the health and personal
safety of the mechanic.
The warning symbol with the overturned truck
is shown if there are circumstances that could
jeopardize the safety of the vehicle or that could
damage the vehicle.
If the safety instructions and warnings
contained in this chapter are not complied with,
the health or safety of the mechanic may be
jeopardized. In addition, serious damage could
be caused to the vehicle or even a hazardous
situation may arise.
Figure 1.1

• Comply with all warning and safety


instructions referred to in this workshop
manual. Always read the warnings and
instructions on the labels and stickers
which are attached to the components !rst,
then make sure you comply with them. They
have been placed there for your safety and
health, so do not ignore them#

• Wear clean, well-!tting clothes and apply


protective cream to unprotected parts of your
body, if necessary.

• Always disconnect the earth connection of


the battery before carrying out work to the
vehicle.
• Do not run the engine in an enclosed or
unventilated area. Make sure exhaust gases
are properly extracted.
• Remain at a safe distance from rotating and/
or moving components.

• Never remove the !ller cap of the cooling


system with the engine running.

• Be careful when changing the oil. Hot oil may


cause serious injuries.
• Avoid unnecessary contact with drained oil.
Frequent contact causes damage to the skin.

1-1
HPVS/EVS system book v20 e31
Safety instructions

• Various types of oils and lubricants that


are used may constitute a health
hazard. This also applies to engine coolant,
clutch "uid, windscreen washer "uid,
refrigerant in air-conditioning systems,
battery acid and diesel oil. Therefore, avoid
internal and external physical contact.
• Tilt the cab completely if work must be
carried out underneath the cab.
• Always use support stands when carrying out
work underneath the vehicle.

• Be careful when working on springs under


tension, such as those in spring brake
cylinders, valve springs, and the like.
Inadvertently released springs may cause
serious injuries. Even small springs
and circlips may cause injuries when
inadvertently released (wear eye protection).

• Always use the appropriate lifting gear


(gearbox jack) or approved hoists for
the removal and installation of heavy
components. Attach the component properly
to the lifting or hoisting gear.

• Be careful when working on systems


that may be under pressure such as a trailing
axle lift system, cab tilting mechanism, brake
system, steering system, fuel system and the
like.
• After a !re it is possible that hazardous
combustion residues
may remain from certain synthetic materials
possibly used in oil seals and sealing rings.
Wear protective, acid-resistant clothing
and PVC gloves when removing such
combustion residues.

• Submerge these combustion residues in


water, or spray them amply with a calcium
hydroxide solution (slaked lime and water).
Thoroughly clean the protective clothing after
use. Handle the gloves as chemical waste.

• The general safety precautions applicable to


a chassis suspension system also apply to the
HPVS system.

• The general safety precautions applicable to a


steering system also apply to the EVS
system.

During several of the test programs that are


executed via the HPVS/EVS diagnosis box (DCS),
the chassis or the rear axle of the vehicle move
automatically. Before these programs are activated,
make sure there are no people in the vicinity of the
vehicle, otherwise there is a possibility that someone
may become trapped.

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HPVS/EVS system book v20 e31
Safety instructions

The suspension accumulators and HPVS (Hydro


Pneumatic Spring System) cylinders are under
pressure, even if the engine is not running.
First depressurise the HPVS system before removing
any of the parts mentioned below.
• HPVS cylinders
• suspension accumulator
• LSP (load-sensing proportioning) valve
• HPVS/EVS valve block
• cartridge valves: SP6, SP8, SP9, SP10,
SP11, SP14, SP15, SP31
• pressure switch for axle load v20/43 and
v20/44
• lines for components listed above.

The emergency steering circuit is always under


pressure, even if the engine is not running!

Before removal of any of the parts listed below,


depressurise the emergency steering system by
loosening the test nipple on the HPVS/EVS valve
block.
• EVS cylinders
• HPVS/EVS valve block
• emergency steering accumulator
• accumulator valve with SP7
• pressure sensor for emergency steering
pressure
• emergency steering safety valve
• non-return valve 7 (emergency steering
system)
• lines for components listed above.
When a speed signal is absent, as the result of a
defective tachograph for instance, the rear axle will
continue to co-steer completely to a speed of ±88
km/h. This can have a negative effect on the stability
of the vehicle.
A second, independent speed signal has been added
to the X-series.

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HPVS/EVS system book v20 e31
Safety instructions

1-4
HPVS/EVS system book v20 e31
HPVS/EVS operation

2. HPVS/EVS operation
2.1 General

HPVS and the EVS are two systems that can be !tted
on a vehicle. If both systems are !tted, several com-
ponents are shared between them. The HPVS/EVS
consists of a hydraulic section and an electric (con-
trol) section.

The hydraulic section consists of:


• the drive part, consisting of a pump and a
reservoir
• the regulating part, consisting of various
valves
• the work part, consisting of (among other
things) HPVS cylinders, suspension accumula
tors and emergency steering accumulators.

The hydraulic section consists of:


• various sensors and relays
• an Electronic Control Unit (ECU).

The ECU is a microprocessor-controlled calculation


and control unit for controlling and safeguarding the
suspension and steering systems. A control panel is
installed in the cab, which is used for manual con-
trol of the system. This can also be used to read and
erase faults.

A technician can also connect a diagnostic box to


the ECU (GINAF no. OG0000087067-PA (old model Figure 2.1
OG0000008631—PA), see Figure 2.1), which makes
it possible to:
• read faults
• read ‘real time’ parameters
• read correction factors
• adjust angle sensors
• read system data
• "ush the HPVS/EVS system
• test valve connections

For control unit E31, an adapter (programmer, see


Figure 2.2) is required for connection to the DCS.
The switch at the side is an on/off switch. In order to
perform programming, the switch must be in the on
position. If it is in the off position, you can program
but it will not be accepted.

Figure 2.2

2-1
HPVS/EVS system book v20 e31
HPVS/EVS operation

2.2 HPVS operation

For the HPVS, the air bellows and/or leaf springs on


the rear axles are replaced by double-acting HPVS
cylinders.
An HPVS cylinder is a double-acting cylinder contain-
ing a piston. The piston rod is attached to the chassis
and the cylinder is attached to the axle. The top (rod
side) of the piston is connected to the HPVS/EVS
reservoir and is at atmospheric pressure. The bottom
(piston side) of the piston is connected to the bottom
side of the suspension accumulator and the pump.

The suspension accumulators consist of a cylinder


containing a "oating piston. The bottom side of this
piston is exposed to oil pressure from the piston side
of the HPVS cylinders. The top side of this piston is
exposed to nitrogen at a certain set pre-pressure.
One suspension accumulator is required for each side
of the vehicle.

When the vehicle suspension is compressed, the


cylinder moves upwards and displaces the oil on the
piston side of the cylinder. The displaced oil "ows
through a line to the suspension accumulator and
forces the piston of the suspension accumulator up-
wards, which causes the nitrogen above the accumu-
lator piston to be compressed. The resistance caused
by the compression of the nitrogen increases, which
dampens the motion of the suspension.

The hydraulic suspension on the rear axles is com-


pletely separated between the two sides of the ve-
hicle. That is to say, there is no connection between
the cylinders on the left and right sides of the vehi-
cle. On each side of the vehicle, the return connec-
tions to the cylinders are all interconnected, as are
the pressure connections. This results in complete
compensation on each side of the vehicle.

Compensation means that when two or three cylin-


ders are interconnected, the oil that exits one cylin-
der is divided among the other cylinders. Consider
the ‘law of communicating vessels’. HPVS works in
a similar manner. If one cylinder is compressed, the
cylinder connected to it will expand an equal distance
(when the two cylinders have the same dimensions).

The advantage of this is that the vehicle can ride


over bumps and depressions while the chassis re-
mains level and the pressure (i.e. the load) remains
equally distributed over the remaining rear axles
under all conditions.

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HPVS/EVS system book v20 e31
HPVS/EVS operation

The application of hydraulics and electronics instead


of mechanical components also makes it possible to
create all sorts of circuits that improve the function-
ality, safety and ef!ciency of the vehicle. Some of
these features are included as standard equipment
on the vehicles, such as:

• automatic level regulation load maintained at


the same driving height at any vehicle speed
above 1-3 km/h
• manual level regulation makes it possible for
the user to manually adjust the drive height
of the chassis at a vehicle speed under 1 kmh
• manual height control(highest/lowest posi
tion) allows the user to temporarily adjust the
height at a vehicle speed under 1 km/h
• rapid-lowering system(standard since Aug.
1999)
allows the chassis to be rapidly lowered using
oil pressure instead of just under the weight
of the chassis (e.g. for vehicles with a super
structure for swap bodies).

Other features are available as an option, such as:

• lift axle, variable load axle or upcoupling lift


axle
for lifting an axle in the unloaded or loaded
condition, or for the ability to temporarily un
load an axle.
• levelling system for levelling the chassis,
which allows safer tipping.
• hydraulic roll stabiliser (‘superstab’)
for improvement of the lateral stability of the
vehicle in a turn, for superstructures with a
high centre of gravity or dynamic load (liq
uids)
• automatic hydraulic lateral stabiliser
ensures that the HPVS cylinders on a station
ary vehicle can be compressed but cannot
rebound (additional tipping stability)
• manual hydraulic lateral stabiliser
ensures that the HPVS cylinders can be com
pressed but cannot rebound when the switch
is operated (additional tipping stability). This
can be done at any speed and is standard on
the 3-side tipper.
• container pull-up system allows the chassis to
sink to 3 cm above the axle buffers to enable
easier pulling-up or demounting of containers.

2-3
HPVS/EVS system book v20 e31
HPVS/EVS operation

• weight indication system provides an indica


tion of the axle loads of the axles with HPVS
suspension on a display in the cab.

Due to the automatic level regulation, it is not possi-


ble to !t a mechanically-controlled load sensing pro-
portioning (LSP) valve in the brake system. There-
fore, Ginaf !ts an LSP valve with hydraulic pressure
control to convert the axle load to the necessary
brake pressure.

2-4
HPVS/EVS system book v20 e31
HPVS/EVS operation

2.3 EVS operation

For the EVS, the torque rods of the rear axle are
replaced by EVS cylinders (see Figure 2.3). An EVS
cylinder consists of a cylinder with a double-acting
piston. The double-acting piston is for control of the
retraction and extension of the EVS cylinder. During
turning, the cylinder on one side is retracted and the
cylinder on the other side is extended. Because the
axle is attached to the chassis via a V-rod, the axle
can be turned around this point, resulting in a steer-
ing movement.

Inside the EVS cylinder, there is a "oating piston !t-


ted around the piston rod. The purpose of this "oat-
ing piston is to move the EVS cylinder to the centre
position.

The hydraulic energy for the HPVS and EVS systems


is supplied by a hydraulic pump. This pump is driven
by the engine. The HPVS and EVS cylinders can be
operated via the hydraulic valves. Various informa-
tion is registered via the sensors, and this is used for
control of the HPVS and EVS systems.
Figure 2.3

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HPVS/EVS system book v20 e31
HPVS/EVS operation

2-6
HPVS/EVS system book v20 e31
HPVS/EVS power supply

3. HPVS/EVS power supply


3.1 General

The HPVS/EVS system is an independent system. A


motor-driven pump is !tted to supply the hydraulic
power required by both systems. The pump draws oil
from a separate reservoir.
The pump is equipped with a regulation block with
which the maximum "ow and maximum pressure can
be adjusted.

The pump supplies oil to the proportional pump "ow


unit. The proportional pump "ow unit contains the
pressure !lter, the pressure sensor for the pump
pressure and the proportional pump "ow valve SP12
(see
Figure 3.1). This pump "ow valve ensures that oil is
supplied to the HPVS/EVS valve block as required.
A measuring point is also provided on the pressure
!lter cover on the pump "ow unit. The pump pres-
sure and control pressure can be measured at this
measurement point.

FILLER CONNECTION

RETURNFILTER DP
MP MPEH

MP DP MPEH T
AXIAL PISTON PUMP
M

PP
P
PRESS. FILTER
FILLING FILTER SP12

S
FLOAT SWITCH

PROPORTIONEL PUMPFLOW-UNIT

Figure 3.1

3-1
HPVS/EVS system book v20 e31
HPVS/EVS power supply

The oil supply system of the HPVS/EVS system


consists of a number of components (see Figure FILLER CONNECTION

3.2):
• Pump with regulation block
• Reservoir with "oat and !lters
• Filling system

RETURNFILTER

AXIAL PISTON PUMP

M
FILLING FILTER

FLOAT SWITCH

Figure 3.2

3-2
HPVS/EVS system book v20 e31
HPVS/EVS power supply

3.2 Oil supply system with pump

3.2.1 Pump with regulation block


The hydraulic power supply of the HPVS/EVS is sup-
plied by a separate pump (see Figure 3.3 and Figure
3.4).

The pump is an axial plunger pump.


A regulation block is mounted on the pump; this is
used to set the maximum pump pressure and maxi-
mum volume "ow.

Figure 3.3

Figure 3.4

M A

A: Axial pistonpump; B: Regulator

Figure 3.5

3-3
HPVS/EVS system book v20 e31
HPVS/EVS power supply

3.2.1.1 Pump regulation

Inside the pump, there is a branch (1) from the pres-


sure connection to the regulator, so that the pump
pressure is applied to the regulator on the left of the A
two regulator pistons A (max. volume "ow setting)
and B (max. pressure regulation), see !gure 3.6. B
Outside the pump, a choke (3), a pressure !lter (4)
and a 2/2 valve (SP12) are placed in the main "ow.

Figures 3.6, 3.7 and 3.8 show the situation in which


there is no oil consumption. The ECU ensures that
SP12 is closed. 5 2
To consumers

Figure 3.6: with branch 1, the pressure will increase, 3 4


just as on the left of regulator pistons A and B. Regu-
lator piston A moves to the right with a pressure of
28 bar, regulator piston B moves to the right with a Figure 3.6
pressure of 190 bar.
Piston A is therefore the !rst to move to the right.
As a result, the channel to the regulator piston for
the stop plate adjustment is released, so that the
stop plate moves to the right and the volume "ow is A
reduced (!gure 3.7).
B
Figure 3.7: the stop plate is now completely vertical,
so that the volume "ow is zero.
The pressure on the left of regulator pistons A and
B falls away, so that they move to the left. This
position is purely theoretical; in reality, the system 52
searches for a balance (!gure 3.8).
To consumers
3 4

Figure 3.7

Figure 3.8: balanced state; the top regulator piston


is on ‘cut’, the stop plate is at a slight angle. The A
pressure at 1 is now 28 bar.
B

52
To consumers
3 4

Figure 3.8

3-4
HPVS/EVS system book v20 e31
HPVS/EVS power supply

From this balanced state at 28 bar, the highest posi-


tion of the chassis is operated, for example. The ECU
now energises SP12 (!gure 3.9). The HPVS cylinders
are extended, which means oil consumption.
A
Figure 3.9: with an oil "ow to the consumers, the
pressure at branch 1 drops. This makes regulator
pistons A and B move to the left. Through branch B
2, pressure is also applied on the right of regulator
piston A. Because both regulator pistons move to the
left, the oil can "ow from the regulator piston for the
stop plate adjustment to the reservoir, so that the
stop plate moves to the left, and the pump delivery
5 2
is increased.
To consumers
3 4
Figure 3.10: in the situation shown here, we con-
tinue to operate the highest position, while the HPVS
cylinders are already extended to a maximum. The
ECU now continues to energise SP12. There is now Figure 3.9
no more oil "ow through choke 3, pressure !lter 4
and SP12. The pressure at branch 1 now increases.
Regulator piston A cannot move to the right, because
the same pressure is also present (on a larger sur-
face) on the right through branch 2. The pressure
increases until regulator piston B opens, i.e. at 190 A
bar. As a result, the oil "ows to the regulator piston
for the stop plate adjustment, which moves to the
right, and the volume "ow is reduced. Here also, a
B
balanced state is searched for (!gure 3.11).

Figure 3.11: balanced state; the bottom regulator


piston is on ‘cut’, the stop plate is at a slight angle.
The pressure at 1 is now 190 bar. 5 2
To consume
As appears from the above, the pump regulation 3 4
continually looks for a balance between 28 and 190
bar, depending on the situation. Here, choke 3, pres-
sure !lter 4 and SP12 play a large role. When there
Figure 3.10
is an oil "ow to the consumers, these three com-
ponents together ensure a pressure drop between
branch 1 and branch 2. The greater the oil "ow (i.e.
the consumption), the greater the pressure drop,
and the earlier that regulator piston A moves to the
right. The regulation then goes towards 28 bar (large A
oil "ow, low pressure). The lower the oil "ow (i.e.
the consumption), the lower the pressure drop, and B
the earlier that regulator piston B moves to the right.
The regulation then goes towards 190 bar (low oil
"ow, high pressure).

The ‘bypass’ (choke and non-return valve) in branch


2 protects regulator piston A. When the pressure on 5 2
the right of this piston falls away quickly and there To consumers

is pressure on the left of the piston, the piston can 3 4


move to the right so quickly that it hits hard against
the stop and is damaged. By placing a choke in the
pipe, this impact is damped. Figure 3.11

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HPVS/EVS system book v20 e31
HPVS/EVS power supply

When SP12 is de-energised, there can still be a cer-


tain residual pressure in the pipe to the consumers,
so that SP12 does not fully close. Branch 5 (to the
reservoir), with a choke of 0.5 mm, is intended to
fully depressurise the pipe to the consumers in this
situation.

3.2.2 HPVS/EVS reservoir with "oat and


!lters

The hydraulic "uid is stored in plastic or stainless


steel reservoirs.
Figure 3.12
There are two types of reservoirs, depending on the
type of vehicle, see !gure 3.12:
• upright reservoir
• vertical reservoir B

This reservoir is !tted with a "oat switch for moni-


toring the "uid level. To prevent contamination, two C
!lters are !tted, see !gures 3.13 and 3.14:
A
- aerating !lter on the reservoir (not !tted in !gure
3.16)
- !lling !lter in the reservoir A: Reservoir; B:Filling filter;
C: Float switch;
The aerating !lter !lters the air that is sucked in. The Figure 3.13
!lling !lter !lters the oil that is poured in through the
!ller opening.
A pipe is !tted to the reservoir, with a quick-!ll con-
nection on the end. Oil should preferably be !lled
(topped up) through this connection. A return !lter
(and a ball valve) is !tted between this quick-!ll
connection and the reservoir. This return !lter !lters
both the oil that is topped up and the oil that "ows
back to the reservoir.
The ball valve is used to shut off the pipe during the
replacement of the return !lter, for example.
The ball valve is not !tted with the X series, because
the return !lter is above the "uid level.

Figure 3.14

3-6
HPVS/EVS system book v20 e31
HPVS/EVS power supply

3.2.3 Filling system


The !lling system (see !gure 3.15) consists of a
quick-!ll connection (1), a return !lter (2) (and pos-
sibly a ball valve (3)).
The quick-!ll connection is a connection with a non- 1
return valve. When a hose is connected, the non-re-
turn valve, and thus the connection are opened. Oil
can be topped up through the quick-!ll connection
with the special !lling pump.
The return !lter !lters the topped-up oil and the
returned oil.
2
The ball valve is !tted to be able to close off the pipe
between the reservoir and the return !lter, to pre-
vent the reservoir from emptying when the return
!lter is removed. Figure 3.15

FILLERCONNECTION

RETURNFILTER

Figure 3.16

3-7
HPVS/EVS system book v20 e31
HPVS/EVS power supply

3.2.4 Proportional pump "ow unit


The proportional pump "ow unit (see Figure 3.17
and Figure 3.18) contains a number of components,
such as:
• proportional pump "ow valve (SP12)
• pressure sensor for pump pressure (DP)
• measurement point for pump pressure/control
pressure (MP)
• pressure !lter

Figure 3.17

MP DP
MPEH
0.5 mm
MP DP MPEH
T

PP
3.5 mm
PRESS. FILTER P

SP12
PUMPFLOWVALVE

PROPORTIONAL PUMPFLOW-UNIT

Figure 3.18

3-8
HPVS/EVS system book v20 e31
HPVS/EVS power supply

3.2.4.1 Proportional pump "ow valve

This is a proportional 2/2 valve (see Figure 3.19),


electrically operated and with a spring return. When
coil SP12 is not energised, the valve is closed and no
oil is supplied to the HPVS/EVS system. When coil
SP12 is energised, an opening is created. This open-
ing becomes larger as the demand for oil increases.

Figure 3.19

SP12

3.2.4.2 Pressure sensor for pump pressure


(DP) Figure 3.20

The pressure sensor (see Figure 3.21) is a sensor


that measures the oil pressure in the system. This
sensor is mounted on connection DP of the pump
"ow unit. When this oil pressure becomes too high or
too low, a fault will be stored in the ECU.

This sensor also monitors contamination of the pres-


sure !lter. An increased pressure drop across the
pressure !lter indicates increased contamination of
the !lter.

Figure 3.21

Figure 3.22

3-9
HPVS/EVS system book v20 e31
HPVS/EVS power supply

3.2.4.3 Measurement point for pump pres-


sure/control pressure (MP)

This measurement point (see Figure 3.23) is a con-


nection with a non-return valve, also referred to as
a test nipple. This test nipple is located on the pres-
sure !lter cover.
When the non-return valve in the test nipple is de-
pressed, the connection is opened. This test nipple
can be used to perform measurements of the pump
pressure and the control pressure.

Figure 3.23

Figure 3.24

3.2.4.4 Pressure #lter

The pressure !lter (see Figure 3.25) !lters the oil


delivered by the pump. A magnet is !tted in the
pressure !lter cover. This magnet collects all the
metal particles. Each time this cover is removed, the
magnet must be cleaned.

Figure 3.25

3-10
HPVS/EVS system book v20 e31
HPVS system description

4.1 General
The pump "ow unit described in the previous chapter
supplies oil to the HPVS/EVS valve block (see Figure
4.1) in which all the valves for the HPVS and EVS
are located except the valves for the lift axle. If a
lift axle, varialble load axle or an uncoupling lift axle
is present, a separate valve block is !tted for that
system.

4.1.1 HPVS/EVS valve block

The diagram below shows the HPVS/EVS valve block.


This valve block can be roughly divided into an upper
and lower half. The lower half (containing valves SP8
through SP11, SP6.1, SP6.2, SP31.1 and SP31.2)
forms the HPVS section.

Figure 4.1

DY
M1

X1L X2R X2L X1R D4 Y M1 ACC


PROP. STEERINGVALVE (NG6)

T P
SP1 SP2

B A
SP7

MPE ACCUMULATORVALVE

SP30 SP5.2 SP5.1


6 2.0 mm
8 NON-RETURN VALVE
(STEERINGSYSTEM)
RELEASE VALVE RELEASE VALVE
PP 7 5
1.0 mm
NON-RETURN VALVE 9
(emercengy steering system)
PUMPBLOCK VALVE EMERGENCYSTEERING VALVE
(regulate 330 +10 bar)

TT TT

PP

SP10 SP11 SP8 SP9 SP31.1 SP6.1 SP31.2 SP6.2


FILLING DRAINING FILLING DRAINING PUMPLOWERING SUPERSTABVALVE PUMPLOWERING SUPERSTABVALVE
LEFT LEFT RIGHT RIGHT LEFT LEFT RIGHT RIGHT

Tandem: 1.00 mm
Tandem: 1.00 mm Tridem: 1.50 mm
1 Tridem: 1.50 mm 2

MBL BL MBR BR T1 T2

Figure 4.2

4-1
HPVS/EVS system book v20 e31
HPVS system description

4.1.2 2/2 Steering valve


(12x)
This is a 2/2 steeringvalve, electrically operated and
with a spring return, twelve of which are !tted in the
HPVS/EVS valve block and which can be classi!ed
into three types (see Figure 4.3).
For HPVS only types B and C are used.

A:
When the coil is not energised, the circuit is opened
so oil can "ow in both directions.
When the coil is energised, the circuit is routed
through the non-return valve so the oil can only "ow
in one direction. (SP5.1/SP5.2)

B:
When the coil is energised, the circuit is opened so
oil can "ow in both directions.
When the coil is not energised, the circuit is routed
Figure 4.3
through the non-return valve so the oil can only "ow
in one direction. (SP6.1/SP6.2/SP7/SP9/SP11/SP30)

C:
This is the same valve as type B. However, this valve A
has an integrated non-return valve. The non-return
valve is placed so the oil can only "ow through the
steering valve in one direction.
When the coil is not energised, both "ow directions
B
are blocked.
When the coil is energised, the oil can only "ow in
one direction. (SP8/SP10/SP31.1/SP31.2)

The type A steering valves are !tted with 26-Volt C


coils.
The type B steering valves are !tted with either 13-
Volt (SP6.1 and SP6.2) or 26-Volt (all others) coils.
Most of the type C steering valves are !tted with 26- Figure 4.4
Volt coils. SP31.1 and SP31.2 are exceptions: these
are !tted with 13-Volt coils.

4.1.3 Restrictor

A restrictor (see Figure 4.5 and Figure 4.6) is a


constriction in a circuit. When "uid passes through Figure 4.5
the restrictor, the pressure before the restictor will
be higher than the pressure after it. We refer to this
as a pressure drop. At a lower "ow rate the pressure
drop will be less than at a higher "ow rate.

Figure 4.6

4-2
HPVS/EVS system book v20 e31
HPVS system description

4.2 HPVS cylinder

The HPVS cylinder consists of a cylinder with a dou-


ble-acting piston (see Figure 4.7 and Figure 4.8).
The piston divides the cylinder into two sections.
The upper section, the rod side, is connected to the
reservoir and is at atmospheric pressure. The lower
section, the piston side, is connected to the suspen-
sion accumulator.

To raise the vehicle, oil is routed from the pump to


connection P so oil is added. The oil enters the piston
side and the piston is pushed upwards.

To lower the vehicle, oil is routed from connection P


to the reservoir so oil is removed. The oil is pushed
out by the weight of the vehicle on the piston side
and the piston moves downwards.

Figure 4.7

Figure 4.8

4-3
HPVS/EVS system book v20 e31
HPVS system description

4.3 Suspension accumulator

The suspension accumulator is a pressure vessel


that consists of two sections (see Figure 4.9). The
two sections are separated from each other by a
"oating piston. The lower section of the accumulator
is !lled with oil. The upper section of the accumula-
tor is !lled with pressurised nitrogen gas.
When the oil pressure in the suspension circuit is
higher than the nitrogen gas pressure in the accumu-
lator (because oil is forced out of the HPVS cylinders
during compression), oil "ows to the accumulator.
When this occurs, the "oating piston compresses the
nitrogen gas, increasing the gas pressure.

When the oil pressure in the suspension circuit is


lower than the nitrogen gas pressure (because the
suspension rebounds), the nitrogen gas pushes
against the piston, forcing the oil in the accumulator
back into the suspension circuit and the cylinders to
extend.

Thus an empty vehicle has a low nitrogen gas pres-


sure, making a relatively large compression possible.
In a loaded vehicle the nitrogen pressure in the ac-
cumulator is much higher, since the vehicle stands at
the same height. Therefore, relatively little compres-
sion will be possible. The result is a relatively supple
Figure 4.9
suspension in the unloaded condition and a stiff sus-
pension when the vehicle is carrying a heavy load.

Figure 4.10

Figure 4.11

4-4
HPVS/EVS system book v20 e31
HPVS system description

4.4 LSP valve

The load-sensing proportioning (LSP) valve is a


standard LSP valve that has been modi!ed (see Fig-
ure 4.12). The valve was originally intended for ve-
hicles with air suspension and is therefore equipped
with an air cylinder.

In this application, the air cylinder has been replaced


by a hydraulic cylinder (see Figure 4.13), which is
connected to the piston side of the HPVS cylinders.
When the pressure in the system increases (due to
an increased vehicle load), the cylinder will be forced
inwards and the brake pressure will be adjusted to
the new load. Figure 4.12

A restrictor is built into the connection nipple to


dampen pressure surges.

This valve is not !tted on vehicles equipped with


EBS.

Figure 4.13

4-5
HPVS/EVS system book v20 e31
HPVS system description

4.5 Hydraulic system operation

4.5.1 Filling and draining


On the basis of user commands and operating condi-
tions, the electronics (ECU) operate certain valves so
the HPVS cylinders are !lled with oil or oil is drained
from them. As explained earlier, the cylinders at the
left and right sides of the vehicle operate independ-
ently and thus the !lling and draining are also per-
formed independently. The height of the chassis is
monitored via angle sensors that are !tted to one of
the rear axles, on the left and right sides.

Example:
The vehicle is stationary. The driver wishes to tem-
porarily lower the chassis and operates the ‘lower
chassis’ button on the control panel. When this but-
ton is operated, oil is drained from the left and right
HPVS cylinders, lowering the chassis.
The driver leaves the chassis height in this position
and begins to drive. The chassis height is reported
to the ECU via the height sensors, as is the vehi-
cle speed. If the vehicle speed exceeds 2 km/h for
longer than 3 to 5 seconds, the ECU will cause the
HPVS cylinders to be !lled until the chassis height
returns to the normal driving position (automatic
level regulation).

As is apparent from this example, the automatic


level regulation only works at vehicle speeds above
2 km/h. The reason for this is that if a vehicle is
stationary and an axle with HPVS suspension is on
a bump or in a depression, the axle with activated
level regulation will attempt to raise or lower the ve-
hicle, which could result in excessive pressure levels
in the system.

The time delay of 3 to 5 seconds upon reaching 2


km/h before activating the valves for the level regu-
lation is intended to prevent the system from mak-
ing continual adjustments when driving slowly over
uneven terrain.

The automatic level regulation may also activate


when the vehicle has been stationary for a long time
and internal leakage has resulted in lowering of the
chassis. After all, a hydraulic steering valve always
has a small amount of internal leakage. It is not
necessary for the driver to take any action, because
just as in the example above, once the vehicle speed
exceeds 2 km/h the chassis will return to the driving
height. Incidentally, it is possible to manually bring
the vehicle to driving height via the control panel.

4-6
HPVS/EVS system book v20 e31
HPVS system description

The switches for !lling and draining the HPVS cyl-


inders on each side, discussed below, not only play
a role in the automatic and manual level regulation
but also in the optional lateral levelling system and
container lifting system.

4-7
HPVS/EVS system book v20 e31
HPVS system description

4.5.1.1 Filling right-rear

In the non-energised state, coil SP8 of the right-


rear supply valve closes the connection between the
pump "ow unit and the HPVS cylinders on the right
side of the vehicle. Now no oil can be pumped to the
HPVS cylinders. In this state the HPVS cylinders can-
not extend.
By energizing coil SP8 of the right-rear supply valve,
a connection is established between the pump "ow
unit and the right-side HPVS cylinders.
Stabiliser valves SP6.1 and SP6.2 are energised so
oil from the rod side of the cylinder can "ow to the
reservoir.
Valve SP6.2 must also be energised to allow all the
oil to drain. This also energises SP6.1 because it is
wired in series with SP6.2. This causes the pump
pressure to be routed to the piston side of the right-
side HPVS cylinders and the supplied oil causes the
HPVS cylinders to extend. The right side of the vehi-
cle is raised.
When coil SP8 is de-energised, the spring will cause
the valve to return to the rest position. In this posi-
tion, a non-return valve is placed in the circuit that
blocks the "ow of oil from the cylinders to the pump.
Now the oil cannot "ow out of the HPVS cylinders
and the vehicle remains in this position.

PP
MPE

TT TT

PP

SP10 SP11 SP8 SP9 SP6.1 SP6.2

1 2

MBL BL MBR BR T1 T2

LOAD SENSING VALVE (ALR)


HPVS-CIL AXLE 2
HPVS-CIL. AXLE 2

LIEFT RIGHT
HPVS-CIL. AXLE 3
HPVS-CIL AXLE 3

HPVS-CIL. AXLE 4
HPVS-CIL. AXLE 4

Figure 4.14

4-8
HPVS/EVS system book v20 e31
HPVS system description

4.5.1.2 Draining right-rear

In the non-energised state, coil SP9 of the right-rear


drain valve closes the connection between the HPVS
cylinders on the right side of the vehicle and the
reservoir. Now the vehicle weight cannot force the
oil to "ow from the right-side HPVS cylinders to the
reservoir.
By energizing coil SP9 of the right-rear drain valve,
a connection is established between the reservoir
and the right-side HPVS cylinders. The vehicle weight
compresses the right-side HPVS cylinders and the oil
"ows via the open right-rear drain valve and the re-
strictor to the reservoir. The right side of the vehicle
lowers.

PP
MPE

TT TT

PP

SP10 SP11 SP8 SP9 SP6.1 SP6.2

1 2

MBL BL MBR BR T1 T2

LOAD SENSING VALVE (ALR)


HPVS-CIL AXLE 2
HPVS-CIL. AXLE 2

RIGHT
LEFT
HPVS-CIL. AXLE 3 HPVS-CIL AXLE 3

HPVS-CIL. AXLE 4
HPVS-CIL. AXLE 4

Figure 4.15

4-9
HPVS/EVS system book v20 e31
HPVS system description

4.5.1.3 Filling left-rear

In the non-energised state, coil SP10 of the left-


rear supply valve closes the connection between the
pump "ow unit and the HPVS cylinders on the left
side of the vehicle. Now no oil can be pumped to the
HPVS cylinders. In this state the HPVS cylinders can-
not extend.
By energizing coil SP10 of the left-rear supply valve,
a connection is established between the pump "ow
unit and the left-side HPVS cylinders.
This causes the pump pressure to be routed to the
piston side of the left-side HPVS cylinders and the
supplied oil causes the HPVS cylinders to extend. The
left side of the vehicle is raised.
Stabiliser valves SP6.1 and SP6.2 are energised so
oil from the rod side of the cylinder can "ow to the
reservoir.
When coil SP10 is de-energised, the spring will cause
the valve to return to the rest position. In this posi-
tion, a non-return valve is placed in the circuit that
blocks the "ow of oil from the cylinders to the pump.
Now the oil cannot "ow out of the HPVS cylinders
and the vehicle remains in this position.

PP
MPE

TT TT

PP

SP10 SP11 SP8 SP9 SP6.1 SP6.2

1 2

MBL BL MBR BR T1 T2

LOAD SENSING VALVE (ALR)


HPVS-CIL AXLE 2
HPVS-CIL. AXLE 2

LEFT RIGHT
HPVS-CIL. AXLE 3
HPVS-CIL AXLE 3

HPVS-CIL. AXLE 4
HPVS-CIL. AXLE 4

Figure 4.16

4-10
HPVS/EVS system book v20 e31
HPVS system description

4.5.1.4 Draining left-rear

In the non-energised state, coil SP11 of the left-rear


drain valve closes the connection between the HPVS
cylinders on the left side of the vehicle and the res-
ervoir. Now the vehicle weight cannot force the oil to
"ow from the left-side HPVS cylinders to the reser-
voir.
By energizing the coil of the left-rear drain valve, a
connection is established between the reservoir and
the left-side HPVS cylinders. The vehicle weight com-
presses the left-side HPVS cylinders and the oil "ows
via the open left-rear drain valve and the restrictor
to the reservoir. The left side of the vehicle lowers.

PP
MPE

TT TT

PP

SP10 SP11 SP8 SP9 SP6.1 SP6.2

1 2

MBL BL MBR BR T1 T2

LOAD SENSING VALVE (ALR)


HPVS-CIL AXLE 2
HPVS-CIL. AXLE 2

RIGHT
LEFT
HPVS-CIL. AXLE 3 HPVS-CIL AXLE 3

HPVS-CIL. AXLE 4
HPVS-CIL. AXLE 4

Figure 4.17

4-11
HPVS/EVS system book v20 e31
HPVS system description

4.5.2 Stabilisation

4.5.2.1 Lateral stabilisation (option)

Lateral stabilisation is automatically activated as


soon as the vehicle speed drops below 2 km/h and
can be manually activated via a control panel button
(if present).
Lateral stabilisation can be activated manually at any
speed.
This system is intended to increase the lateral sta-
bility (at low speeds and during tipping). To achieve
this, the rod ends of the HPVS cylinders are blocked
by 2/2 valves. The piston end is exposed to the nor-
mal pressure of the load while the oil at the rod end
cannot escape. This results in a situation in which
the HPVS cylinders can be compressed but cannot
rebound.
When lateral stabilisation is deactivated, the 2/2
valves (nc) are energised and vice versa (safety).

These 2/2 valves (SP6.1 and SP6.2) are connected in


series, which means that the coils are always en-
ergised together. This series connection is a safety
measure that ensures both valves are deactivated if
one fails.
When coils SP6.1 and SP6.2 of the left- and right-
side stabilisation valves are energised, there is a
connection between the rod side of the left and right
HPVS cylinders and the reservoir. This allows the oil
to "ow to and from the left and right HPVS cylinders
(no stabilisation).
When coils SP6.1 and SP6.2 are not energised, a
non-return valve is placed in the circuits between the
left and right HPVS cylinders and the reservoir so the
oil can only "ow from the reservoir to the left and
right HPVS cylinders and not in the other direction
(stabilisation).

4-12
HPVS/EVS system book v20 e31
HPVS system description

4.5.2.2 Super stabilisation (option)

Hydraulically, super stabilisation works identically to


lateral stabilisation. The big difference in comparison
with lateral stabilisation is that it is activated by the
ECU when demanded by the driving conditions.
It is intended for vehicles with a high centre of grav-
ity or with a ‘live’ load, such as liquids, concrete, etc.
The ECU receives a signal from the tachograph, so
the vehicle speed is known. In addition, there is a
signal from an angle sensor, which measures the
angle of the steered wheels on the front axle. The
ECU combines this data and makes sure the lateral
stabilisation is activated when this is desirable or
when the steering angle of the front axle is too large
in relation to the vehicle speed.

PP
MPE

TT TT

PP

SP10 SP11 SP8 SP9 SP6.1 SP6.2

2
1

MBL BL MBR BR T1 T2

ALR-CILINDER
HPVS-CIL AXLE 2
HPVS-CIL. AXLE 2

LEFT RIGHT
HPVS-CIL. AXLE 3 HPVS-CIL AXLE 3

HPVS-CIL. AXLE 4
HPVS-CIL. AXLE 4

Figure 4.18

4-13
HPVS/EVS system book v20 e31
HPVS system description

4.5.3 Stabilisation
This system makes it possible to level the vehicle
in the lateral direction so tipping can be done more
safely (see Figure 4.19 and Figure 4.20). An impor-
tant part of the lateral levelling system is the level
sensor.
The level sensor is an electronic sensor that meas-
ures the horizontal position of the vehicle in the
transverse direction (see also the section ‘Electronic
operation’).
For the HPVS there is a level sensor !tted to the
rearmost cross member of the chassis. This value is
sent to the ECU.

If the driver has placed the vehicle on a slanted


surface for tipping, he presses and holds the lateral
Figure 4.19
levelling system button. At this moment, the auto-
matic level regulation and the lateral stabilisation are
deactivated. The level sensor detects that the vehicle
is tilted and in which direction. The driver is informed
of this via a pulsing buzzer signal. The driver contin-
ues to hold the button. Through the !lling and drain-
ing of oil to and from the HPVS cylinders, the vehicle
reaches a nearly level position. From that moment,
oil is only drained.
By adding oil to the HPVS cylinders on one side of
the vehicle, !nal levelling of the chassis is achieved.
If the cylinders have reached their maximum exten-
sion and the chassis is not yet level, oil will be al-
lowed to "ow out of the cylinders on the other side.
The closer the chassis approaches the level position,
the more rapid the pulsing signal will become. As
soon as the vehicle is level, the buzzer will stop. If
the vehicle is tilted so far that the HPVS cylinders
cannot fully compensate, the buzzer will produce
a continuous signal. This warns the driver that the
vehicle could not be completely levelled.
As soon as the driver releases the lateral levelling Figure 4.20
system button, the lateral stabilisation is activated (if
installed).
The X-series is !tted with PTO protection to ensure
that once levelling has been performed, when the
PTO is activated the driver cannot operate the HPVS
system.

4-14
HPVS/EVS system book v20 e31
HPVS system description

4.5.4 Container lifting system (option)

The container lifting system is available as an op-


tion for vehicles with HPVS. It is intended to make it
easier to pull on and unload containers. To achieve
this, the HPVS system lowers the chassis to create
a more favourable angle of approach. The chassis is
lowered to several centimetres above the rearmost
axle so the weight also remains optimally distributed
among the rear axles in this state (compensation).
When the switch of the container lifting system is
operated, oil "ows out of the left and right HPVS cyl-
inders to achieve the correct position.

4.5.5 Pump lowering system


When a vehicle without the pump lowering system is
lowered by releasing oil from the HPVS cylinders, this
is achieved as a result of the weight of the chassis.
This can be a problem for vehicles with little weight
above the rear axles, because it occurs too slowly as
a result of the friction of the HPVS cylinders.
With the pump lowering system, as the oil drains
from the piston side of the HPVS cylinders, pump
pressure is applied to the rod side of the cylinders
causing the chassis to lower rapidly regardless of the
weight of the chassis. Two extra 2/2 steering valves
(SP31.1 and SP 31.2) are !tted in the HPVS/EVS
valve block for this purpose.
When the ‘lower chassis’ or ‘container lifting system’
switch is operated, the ECU will !rst check whether
valves SP6.1 and SP6.2 (stabilisation) are energised
and, if so, it will de-energise them. Then valves SP9
and SP11 (drain left and right respectively) are en-
ergised so the piston sides of the HPVS cylinders are
connected to the tank. Next, valves SP31.1, SP31.2
and SP12 are engaged so the rod sides of the HPVS
cylinders are connected to the pump.

As shown in the diagram (Figure 4.21), during low-


ering of the chassis, stabilisation valves SP6.1 and
SP6.2 must be de-energised; in other words, the
stabilisation system must be on. That means that the
pump lowering system can only be !tted if stabilisa-
tion valves are also !tted on the vehicle.
Stabiliser valves SP6.1 and SP6.2 are energised so
oil from the rod side of the cylinder can "ow to the
reservoir.
The pump lowering system is standard equipment on
the X-series.

4-15
HPVS/EVS system book v20 e31
HPVS system description

MPE

PP

TT TT

PP

SP10 SP11 SP8 SP9 SP31.1 SP6.1 SP31.2 SP6.2

1 2

MBL BL MBR BR T1 T2

LOAD SENSING VALVE (ALR)


HPVS-CIL. AXLE 2 HPVS-CIL AXLE 2

LEFT
RIGHT
HPVS-CIL. AXLE 3 HPVS-CIL AXLE 3

HPVS-CIL. AXLE 4
HPVS-CIL. AXLE 4

Figure 4.21

4-16
HPVS/EVS system book v20 e31
HPVS system description

4.5.6 Flushing
There is hardly any oil "ow in the HPVS section dur-
ing normal compression and rebound of the cylin-
ders. As a result, the oil is only !ltered to a very
limited degree. In order to !lter this oil it is possible
to run the HPVS system through a ‘"ush procedure’
via the DCS1.
During this procedure the vehicle is !rst put in the
highest position and then in the lowest position in
order to "ush the oil in the HPVS cylinders. Then the
oil in the HPVS section is circulated by the pump so
the oil is !ltered.
To achieve "ushing, the supply (SP8 and SP10) and
drain valves (SP9 and SP11) for the left and right
sides are alternatingly energised. All the valves are
open during this procedure so the oil can be circu-
lated without raising or lowering the vehicle.
The "ush procedure ends when the vehicle is once
again at driving height.

PP
MPE

TT TT

PP

SP10 SP11 SP8 SP9 SP6.1 SP6.2

1 2

MBL BL MBR BR T1 T2

LOAD SENSING VALVE (ALR)


HPVS-CIL AXLE 2
HPVS-CIL. AXLE 2

LEFT RIGHT
HPVS-CIL. AXLE 3 HPVS-CIL AXLE 3

HPVS-CIL. AXLE 4
HPVS-CIL. AXLE 4

Figure 4.22

4-17
HPVS/EVS system book v20 e31
HPVS system description

4.5.7 Lift axle unit


The lift axle unit is a separate valve block for the
lift axle that is mounted near the lift axle. There are
three different versions of the lift axle:

- v20/43 non-uncoupling lift axle (non-driven


axle)
- v20/44 unloadable axle (driven axle)
- v20/3x uncoupling lift axle (non-driven axle)

Version 20/43 is intended for a non-driven lift axle.


This version is used when it must be possible to drive
with the axle lifted, when the vehicle is unloaded.
The axle must be lowered automatically at speeds
above 15 km/h when the load has increased to such
a degree than the other axles exceed the legally
permitted axle load. When stationary and with a full
load, the operation is identical to that of an unload-
able axle.

Version 20/44 is intended for a driven lift axle. Due


to the operation of the differential, driving a vehi-
cle with a lifted driven axle is obviously impossible.
The lift axle is therefore used as an unloading axle,
during tipping for example. By lifting the axle, the
centre of gravity of the load is essentially moved
further towards the forward axle(s), which increases
the tipping stability.

Version 20/3x is intended for a non-driven lift axle.


This version is used when it must be possible to drive
with the axle lifted, even when the vehicle is loaded.
To achieve this, the HPVS cylinders of the lift axle
must be hydraulically isolated from the other HPVS
cylinders.

4-18
HPVS/EVS system book v20 e31
HPVS system description

As shown in Figure 4.23, versions 20/43 and 20/44


are identical except for the pressure switch !tted in
the valve block for version 20/43.

HPVS-CIL. AXLE2 LEFT


HPVS-CIL. AXLE 2 LEFT HPVS-CIL. AXLE 2 RIGHT HPVS-CIL. AXLE2 RIG

MH MH

H1 H2 H2
SP15 SP14 SP15 SP14 H1
PRV CV S2
CV S2 DS
DS PLUG
P P
DRUKSCHAKELAAR

T S1 T S1

HEFAS-UNIT v20/44
HEFAS-UNIT v20/43

Figure 4.2

Figure 4.24 shows version 20/3x. This makes clear


that this is a completely different type of lift axle
unit.

NHZ1 drain drain NHZ2


pilot pilot

HZ1 HZ2
pilot pilot
HPVS-CIL. AXLE 2 LEFT HPVS-CIL AXLE2 RIGHT

HS1 HS2
SP14 SP15 MH2

ACC

HEFAS-UNIT v20/34
T

Figure 4.24

4-19
HPVS/EVS system book v20 e31
HPVS system description

4.5.7.1 Lower/block valve (v20/43 and


v20/44)

This is a 4/2 steering valve, electrically operated A B


and with a spring return. In the energised state of
SP15
electromagnet SP15, all the connections are shut
off and no oil can "ow. In the rest position (parallel
position) connection A and P are connected, as P T
are B and T.
Figure 4.25

4.5.7.2 Raise valve (all versions) or lower


valve (v20/3x)
A
This is a 3/2 steering valve, electrically operated SP14
and with a spring return.
When the coil is not energised, connections A and T
are connected. When the coil is energised, connec-
P T
tions A and P are connected.
Figure 4.26

4.5.7.3 Pressure switch

The pressure switch is an adjustable pressure


switch. On the left side is the pressure that is to be
measured/monitored, and on the right side is an ad-
justable spring. In the normal situation, the valve is
in the position shown in the adjacent drawing.
When the pressure that is to be measured/monitored
exceeds the set pressure, the switch will be forced to
the right and the switch contacts will open. Figure 4.27

4.5.7.4 Pressure-operated non-return


valve

The pressure-controlled non-return valve opens, like


a normal non-return valve, when the pressure at B is
higher than the pressure at A, and it remains closed
when the pressure at A is higher than the pressure
at B. A B
With this valve, however, it is also possible to pilot
achieve a "ow from A to B by applying pressure to drain
the pilot connection, which forces the valve open.
Furthermore, this valve is equipped with a drain con- Figure 4.28
nection to ensure that only a relatively low pressure
is required to open the non-return valve. There is
also a version without a drain connection.

4-20
HPVS/EVS system book v20 e31
HPVS system description

4.5.7.5 Lift axle v20/43 and v20/44, not


operated

In both versions of the lift axle unit there is a lower/


block valve with coil SP15, a non-return valve, a
raise valve with coil SP14 and two restrictors.
When the lift axle is not raised, coil SP14 of the raise
valve is not energised and the rod sides of the HPVS
cylinders of the lift axle are connected to the reser-
voir, as are the other HPVS cylinders (via SP6.1 and
SP6.2). The raise/block valve SP15 is also de-ener-
gised so the accumulator for the lift axle is !lled /
kept under pressure via the pump and the non-re-
turn valve.
P
PP
TT TT
T

PP
SP6.1 SP6.2
SP10 SP8
SP11 SP9

2
1

MBL BL MBR BR T1 T2

HPVS-CIL. AXLE 4 LEFT LOAD SENSING VALVE (ALR)


HPVS-CIL AXLE 4 RIGH

HPVS-CIL. AXLE 3 LEFT


HPVS-CIL AXLE 3 RIGH

HPVS-CIL. AXLE 2 LEFT HPVS-CIL. AXLE2 RIGHT

SP15 SP14

P PRESSURE SWITCH

T
HEFAS-UNIT v20/43

Figure 4.29

4.5.7.6 Lift axle v20/43 and v20/44, raise

To raise the lift axle, coil SP14 of the raise valve


must be energised. The rod sides of the lift cylinders
are connected to the pump and the oil can now be
pumped to the rod sides of the lift cylinders, via the
non-energised lower/block valve, the non-return
valve, the restrictor and the raise valve, so the cylin-
ders retract and the axle is raised.

4-21
HPVS/EVS system book v20 e31
HPVS system description

The oil on the piston sides is displaced to the piston


sides of the other HPVS cylinders.

P PP
TT TT
T

PP
SP6.1 SP6.2
SP10 SP8
SP11 SP9

1 2

MBL BL MBR BR T1 T2

HPVS-CIL. AXLE 4 LEFT LOAD SENSING VALVE (ALR)


HPVS-CIL AXLE4 RIGHT

HPVS-CIL. AXLE 3 LEFT


HPVS-CIL AXLE3 RIGHT

HPVS-CIL. AXLE 2 LEFT HPVS-CIL. AXLE2 RIGHT

SP15
SP14

P
PRESSURE SWITCH

HEFAS-UNIT v20/43

Figure 4.30

The following applies to both versions: the axle will


not raise when the pressure on the piston side of
the lift cylinder (=load) is higher than the pressure
on the rod side. The pressure switch ensures that
the ECU receives a signal when the load becomes
so heavy that the axle must be lowered. This is only
!tted on version 20/43, because the vehicle may not
be driven with a raised axle when the load on the
remaining axles exceeds the legal maximum. The
axle is lowered automatically at speeds higher than
15 km/h. With version 20/44 it is impossible to drive
with a raised axle under any conditions (due to the
operation of the differential), so there is no reason to
!t a pressure switch. For this version there is an ex-
tra protection measure !tted to ensure that the vehi-
cle is not driven in the loaded condition with a raised
axle by making use of the diff-lock. In this case, the
ECU automatically lowers the axle when the vehicle
speed exceeds 2 km/h.

4-22
HPVS/EVS system book v20 e31
HPVS system description

4.5.7.7 Lift axle v20/43 and v20/44,


lower

The lift axle can be lowered manually (via the control


panel) or automatically (as a result of the pressure
switch (v20/43) or the vehicle speed (v20/44)).
In the lifted position, SP14 is energised. If the axle
was to be lowered by de-energising SP14, the oil on
the rod side of the cylinders would be routed directly
to the tank via SP15, causing the axle to fall abruptly
to the lowest position. To do this in a controlled man-
ner, the ECU will !rst energise SP15 and then imme-
diately de-energise SP14 so the oil "ows to the tank
via restrictor S1. Approximately 30 seconds later, the
ECU will de-energise SP15 so the rod side is once
again routed to the tank without the restrictor.

Note:
If the ignition switch is turned off while the axle is
raised, a buzzer signal will sound. The system is
constructed in such a way that the axle must !rst
be lowered before the ignition switch can be turned
off. The reasons for this are that the axle can only
remain in the raised position by keeping SP14 en-
ergised, which could drain the battery, and lowering
the axle automatically when the ignition switch is
turned off could result in hazardous situations.

P
PP
TT TT
T

PP
SP6.1 SP6.2
SP10 SP8
SP11 SP9

1 2

MBL BL MBR BR T1 T2

HPVS-CIL. AXLE4 LEFT LOAD SENSING VALVE (ALR)


HPVS-CIL AXLE4 RIGHT

HPVS-CIL. AXLE3 LEFT


HPVS-CIL AXLE3 RIGH

HPVS-CIL. AXLE2 LEFT


HPVS-CIL. AXLE2 RIGH

Figure
SP14

SP15

P
PRESSURE SWITCH

HEFAS-UNIT v20/43

Figure 4.31

4-23
HPVS/EVS system book v20 e31
HPVS system description

4.5.7.8 Lift axle v20/3x, not operated

In the lift axle unit there is a lower valve with coil


SP15, a non-return valve, a raise valve with coil
SP14, three restrictors and four pressure-controlled
non-return valves.
In this situation (see !gure 32) coil SP14 of the
raise valve is not energised and the rod sides of the
HPVS cylinders for the lift axle are connected to the
reservoir, as are the other HPVS cylinders (via the
energised valves SP6.1 and SP6.2 in the HPVS valve
block). This also causes there to be no pressure at
the pilot connections of valves T3 and T4.
The lower/block valve SP15 is also de-energised so
the circuit between non-return valves T3 and T4 is
connected to the tank. There is no pressure above or
below the piston of the pilot connection in T3 and T4,
so these are closed.
T1 and T2 include a drain connection, so the pres-
sure from the HPVS cylinders of axle 2 cannot be
applied to the top of the piston of the pilot connec-
tion. Therefore, when the valve is opened via the
pilot connection, the only counterpressure is that of
the spring. Now the pressure of the HPVS cylinders
for axle 2 is applied to the pilot connection of T1 and
T2 so these valves are open, and the piston sides of
the HPVS cylinders are interconnected on each side
of the vehicle.
The lift axle is now ‘coupled’. This means that com-
plete compensation is possible because the HPVS
cylinders can send and receive oil to and from one
another. The lift axle, however, can only send oil to
another HPVS cylinder via the valve block. If this
must happen very quickly (e.g. when driving over
a speed bump, if axle 2 must quickly rebound), it
may be that the system responds too slowly. In this
case, the HPVS cylinders of axle 2 require oil quickly,
which could result in a vacuum. To prevent this, an
extra accumulator is placed at every cylinder of the
lift axle.

4-24
HPVS/EVS system book v20 e31
HPVS system description

MBL T1 T2
BL MBR BR

ALR-CILINDER

HPVS-CIL. AXLE3 LEFT HPVS-CIL AXLE3 RIGHT

HPVS-CIL. AXLE 4 LEFT


HPVS-CIL. AXLE4 RIGHT

T P
NHZ1 drain drain NHZ2
T1 pilot pilot T2
T3 T4
HZ1 HZ2

pilot pilot
HPVS-CIL. AXLE 2 LEFT HPVS-CIL AXLE 2 RIGHT

HS1 HS2
SP14 SP15 MH2

ACC
T

HEFAS-UNIT v20/34

Figure 4.32

4-25
HPVS/EVS system book v20 e31
HPVS system description

4.5.7.9 Lift axle v20/3x, raise

To raise the lift axle, coil SP14 of the raise valve


must be energised. The rod sides of the lift cylinders
are connected to the pump and valves T3 and T4 are
opened as a result of the pressure applied to the pi-
lot connections. This removes the pressure from the
lines under T1 and T2, causing them to close, and
disconnects the HPVS cylinders for the lift axle from
the other HPVS cylinders. The HPVS cylinders of the
lift axle will retract, lifting the axle.

MBL T1 T2
BL MBR BR

ALR-CILINDER

HPVS-CIL. AXLE3 LEFT HPVS-CIL AXLE 3 RIGHT

HPVS-CIL. AXLE 4 LEFT HPVS-CIL. AXLE 4 RIGHT

NHZ2
T P drain drain
NHZ1 T1 T2
pilot pilot
T3 T4
HZ1 HZ2

HPVS-CIL. AXLE 2 LEFT pilot pilot HPVS-CIL AXLE 2 RIGHT

HS1 HS2
SP14 SP15 MH2

ACC
T

HEFAS-UNIT v20/34

Figure 4.33

4-26
HPVS/EVS system book v20 e31
HPVS system description

4.5.7.10 Lift axle v20/3x, lower, phase 1

In the lifted position, SP14 is energised and SP15


is de-energised. If the switch for the lift axle is now
operated to lower the axle, in phase 1 the ECU will
energise SP14 and SP15. The pump will supply oil
via SP15 and T3 and T4 (which then begin to func-
tion as normal non-return valves) to the top of the
pistons of the HPVS cylinders for the lift axle as well
as to the rod sides via SP14. Then the pump (SP12)
is brie"y deactivated. The spaces above and below
the pistons of the HPVS cylinders are now !lled with
oil. Due to the difference in rod and piston surface
area, the lift axle will lower under the weight of the
axle. While this occurs, oil "ows from the rod side
to the piston side via SP14, SP15, T3/T4. Then the
pump (SP12) is activated again to bring the axle up
to pressure.

MBL T1 T2
BL MBR BR

ALR-CILINDER

HPVS-CIL. AXLE 3 LEFT


HPVS-CIL AXLE3 RIGHT

HPVS-CIL. AXLE 4 LEFT HPVS-CIL. AXLE 4 RIGHT

T P NHZ1 NHZ2
drain drain
pilot pilot

HZ1 HZ2

HPVS-CIL. AXLE2 LEFT pilot pilot HPVS-CIL AXLE2 RIGHT

HS2
HS1 SP14 MH2
SP15

P
ACC

T
HEFAS-UNIT v20/34

Figure 4.34

4-27
HPVS/EVS system book v20 e31
HPVS system description

4.5.7.11 Lift axle v20/3x, lower, phase 2

In phase 2, SP14 is deactivated and the pump


(SP12) is activated. This results in the rod side of
the HPVS cylinders for the lift axle being connected
to the reservoir. Pressure build-up also occurs on the
piston side via SP15. Valves T3 and T4 now func-
tion as normal non-return valves. Initially the pres-
sure under T1 and T2 will be lower than the pressure
above, causing these valves to remain closed and
the lift axle to remain hydraulically isolated. The load
on the lift axle will continually increase, causing an
increase in the pressure under T1 and T2. Eventually
the pressure under T1 and T2 will exceed the pres-
sure above them, causing them to open and result-
ing in the re-establishment of the hydraulic connec-
tions to the lift axle.

MBL T1 T2
BL MBR BR

ALR-CILINDER

HPVS-CIL. AXLE 3 LEFT HPVS-CIL AXLE 3 RIGHT

HPVS-CIL. AXLE 4 LEFT


HPVS-CIL. AXLE 4 RIGHT

T P NHZ1 NHZ2
drain drain
T1 pilot pilot T2
T3 T4
HZ1 HZ2

HPVS-CIL. AXLE2 LEFT pilot pilot HPVS-CIL AXLE 2 RIGHT

HS2
HS1
SP14 MH2
SP15

P
ACC
T

HEFAS-UNIT v20/34

Figure 4.35

4-28
HPVS/EVS system book v20 e31
HPVS system description

4.5.7.12 Lift axle v20/3x, lower, phase 3

In phase 3, SP15 is de-energised. T1 and T2 were


already opened during phase 2, so the lift axle is
already hydraulically connected. Now that SP15 is
also de-energised, the pressure is removed from the
connection between T3 and T4 causing T3 and T4 to
close, and the separation between the HPVS cylin-
ders is re-established. The system is now once again
in the begin situation described under the heading
‘not operated’; see Figure 4.35.

MBL T1 T2
BL MBR BR

ALR-CILINDER

HPVS-CIL. AXLE3 LEFT HPVS-CIL AXLE3 RIGHT

HPVS-CIL. AXLE4 LEFT HPVS-CIL. AXLE 4 RIGHT

T P NHZ1 NHZ2
drain drain
pilot pilot

HZ1 HZ2
pilot
pilot
HPVS-CIL. AXLE 2 LEFT HPVS-CIL AXLE2 RIGHT

HS2
HS1
MH2
SP14 SP15

P
ACC
T

HEFAS-UNIT v20/34

Figure 4.36

Note:

The following applies to all versions of the lift axle:


If the ignition switch is turned off while the axle is
raised, a buzzer signal will sound. The system is
constructed in such a way that the axle must !rst
be lowered before the ignition switch can be turned
off. The reasons for this are that the axle can only
remain in the raised position by keeping SP14 en-
ergised, which could drain the battery, and lowering
the axle automatically when the ignition switch is
turned off could result in hazardous situations.
Lift axle v20/3x can only be lowered when the en-

4-29
HPVS/EVS system book v20 e31
HPVS system description

4.6 Electronic operation

The electrical diagrams referred to in this description


can be found in the appendices.

4.6.1 Angle sensor

The angle sensor (see Figure 4.37) is a non-contact


sensor.
For the HPVS there are two angle sensors !tted on
the chassis, at the left and right on the rear axle. Via
a lever attached to the lowest torque rods, these an-
gle sensors register the chassis height and send this Figure 4.37
information to the ECU.

1 23 4

90

Figure 4.38

4-30
HPVS/EVS system book v20 e31
HPVS system description

4.6.2 Level sensor


The level sensor (see Figure 4.39) is a sensor that
measures the horizontal position of the chassis in the
transverse direction.
For the HPVS there is a level sensor !tted to the
rearmost cross member of the chassis (the tow bar).
This location was chosen because it places the sensor
as close as possible to the tipper hinge (if present).
The registered values are sent to the ECU.
Figure 4.39

1 2 3

Figure 4.38

4-31
HPVS/EVS system book v20 e31
HPVS system description

4.6.3 ECU input

4.6.3.1 HPVS/EVS power supply (diagram


1, appendix 1)

The constant power supply is provided via wire 1000,


fuse GE003 and wire R001. Wire R001 is divided
among pins 22-1, 22-2 and 26-26 of the EVS unit.
The power supply controlled by the ignition switch
is provided via wire 1010, fuse GE002, wire 1011e,
diode GD003, fuse GE001 and wire R002. Wire 1011
on pin 22-21 of the EVS unit is the sensor line for ig-
nition on/off. Pin 26-4 is an power supply output that
takes over the function of the ignition switch power
when the lift axle is raised and the ignition switch is
turned off. This output maintains power to the EVS
unit for approximately 5 seconds after the ignition
switch is turned off.

4.6.3.2 Angle sensors (diagram 4, appen-


dix 1)

Angle sensors GD007 and GD008 monitor the chas-


sis height on the left and right sides respectively. The
ECU receives the signal from GD007 on pin 22-4 and
from GD008 on pin 22-16. Both angle sensors re-
ceive power via pin 26-2 and are connected to earth
via pin 22-22.

4.6.3.3 Level sensor (diagram 4, appendix


1)

Level sensor GD004 monitors the horizontal position


of the chassis when desired. The ECU receives the
signal from GD004 on pin 22-9. The level sensor re-
ceives power via pin 26-11 and is connected to earth
via pin 26-14.

4.6.3.4 Weight indication (diagram 5, ap-


pendix 1)

When switch GC006 is operated, display unit GD019


receives power on pin 7 via DAF fuse E163, wire
1258 and "oating fuse GE010. Pressure sensors
GF006 and GF007 are wired in parallel and deter-
mine the current level to the display unit based on
the pressure on the suspension at the left and right
sides of the vehicle.

4.6.3.5 Indicator lamps (diagram 6, ap-


pendix 1)

If raise valve SP14 or lower valve SP15 is energised,


power is supplied to pin 1 of lift axle indicator lamp
GD010 via diode block GD003 and wire SP115.
Power is supplied to fault lamp GD009 via pin 16-13
of the ECU and GG001. If there are no faults, there
is voltage on pin 16-13. In this state, GG001 is en-

4-32
HPVS/EVS system book v20 e31
HPVS system description

ergised, interrupting the connection between GE002


and GD009, causing the lamp to go out. When there
are faults or no ECU is present or the engine is not
running, there will be no voltage on pin 16-13, which
will de-energise GG001 and cause the lamp to light.
Indicator lamp GD011 and relay GG000 are only
present on vehicles with manual lateral stabilisation.
If lateral stabilisation valves SP6.1 and SP6.2 are
energised (no hydraulic stabilisation), the coil of re-
lay GG000 is energised, interrupting contacts 3 and
5 of the relay. The indicator lamp no longer receives
power via wire SP61.
If the oil level of the HPVS/EVS system is too low, oil
level switch GF000 closes. This results in voltage on
wire ES114 and wire ES114a, which causes indica-
tor lamp GD012 to light and the EVS unit to receive
power on pin 12-7.

4.6.3.6 Indicator lamps, diff-locks (dia-


gram 9, appendix 1)

If one or more of the diff-locks is engaged, wire


G2408 of the diode block and the associated control
switch(es) are connected to earth, which causes the
diff-lock indicator lamp in the DIP to light as well.

4.6.3.7 2nd gear protection (diagram 10,


appendix 1)

Sender GF002 is mounted on the transmission or on


the driveshaft of the transfer gearbox. This sender
produces a square wave voltage, the frequency of
which is proportional to the vehicle speed, which is
sent via wire ES351 to speed switch GD001. This
speed switch interrupts the earth connection on wire
ES350 at a variable frequency, which causes the EVS
unit to interrupt wire SP30 by means of a relay.

4.6.3.8 Lift axle (diagram 3, appendix 1)

If a lift axle is present, GE003 ensures that the ECU


continues to receive power if the ignition switch is
turned off while the axle is raised. This allows the
ECU to activate a buzzer signal to warn the driver
that the axle must !rst be lowered before the igni-
tion switch is turned off.
From pin 16-1 of the ECU a signal is sent to raise
valve SP14 and via GD003 to lift axle indicator lamp
GD010. From pin 16-8 of the ECU a signal is sent to
lower/block valve SP15 and via GD003 to lift axle
indicator lamp GD010. When SP14 or SP15 is en-
ergised, lift axle indicator lamp GD010 will be lit. If
the ignition switch is turned off and the axle is in the
raised position, the ECU will continue to receive volt-
age on pin 36 via the continuous power supply wire
(wire no. 1000 rd), GE003.
If the lift axle is in the raised position and the load
exceeds the allowable weight, pressure switch GF001

4-33
HPVS/EVS system book v20 e31
HPVS system description

activates and power is supplied to pin 22-20 of the


EVS unit via wire ES006. Depending on the speed,
the lift axle will be lowered automatically.

4.6.3.9 PTO protection (diagram 10, ap-


pendix 1)

If the PTO is engaged, power is fed to pin 22-20 of


the EVS unit via wire ES022. If the speed is 0 (can
be changed via a parameter), all functions of the
HPVS are ‘frozen’ and valves may be deactivated so
that during use of the PTO the HPVS system cannot
operate. Once the PTO has been deactivated, de-
pending on the parameter setting (speed/time), the
functions are reactivated.
There is also a possibility to !t a proximity switch.
If the bed is raised this will have the same effect as
when the PTO is engaged: the HPVS system will be
‘frozen’.

4-34
HPVS/EVS system book v20 e31
HPVS system description

4.6.4 E31 unit operation

4.6.4.1 Highest position (diagram 25093,


appendix 1)

When switch GC002 on the control panel is oper-


ated, the ECU receives a signal on pin 12-9. The
ECU will energise coils SP8 (add oil to the right side)
and SP10 (add oil to the left side) until the switch is
released.

4.6.4.2 Lowest position (diagram 25093,


appendix 1)

When switch GC002 on the control panel is operated,


the ECU receives a signal on pin 12-3. The ECU will
energise coils SP9 (drain oil from the right side) and
SP11 (drain oil from the left side) until the switch is
released.
If a pump lowering system is !tted, the ECU will also
energise valves SP31, SP31.2 and SP12.

4.6.4.3 Continuous height control (manual


operation) (diagram 25093, appendix 1)

When switch S3 on the control panel is operated, the


ECU receives a signal on pin 12-6. If the angle sen-
sors register that the chassis is not at the set driving
height, the ECU will energise coils SP8 (add oil to the
right side) or SP9 (drain oil from the right side) and
SP10 (add oil to the left side) or SP11 (drain oil from
the left side) until the angle sensors register that the
set driving height has been reached.

4.6.4.4 Continuous height control (auto-


matic) (diagram 25093, appendix 1)

The ECU receives the D3 speed signal from the tach-


ograph on pin 26-22. If a vehicle speed higher than
approx. 3 km/h is registered for at least 5 seconds
and the angle sensors register that the chassis is not
at the set driving height, the ECU will energise coils
SP8 (add oil to the right side) or SP9 (drain oil from
the right side) and SP10 (add oil to the left side)
or SP11 (drain oil from the left side) until the angle
sensors register that the set driving height has been
reached.

4.6.4.5 Lateral levelling system

When switch GC001 on the control panel is operated,


the ECU receives a signal on pin 16-9. If the vehicle
speed is zero and the level sensor registers that the
chassis is not level, the ECU will energise coils SP8
(add oil to the right side) or SP10 (add oil to the left
side), and if the level position cannot yet be reached
with completely extended cylinders, SP9 (drain oil
from the right side) or SP11 (drain oil from the left

4-35
HPVS/EVS system book v20 e31
HPVS system description

side) until the level sensor registers that the chassis


is level or until the HPVS cylinders cannot be extend-
ed or retracted further.

4.6.4.6 Raise/lower axle (lift axle unit


v20/43 and v20/44)

When switch GC003 on the control panel is operated,


the ECU receives a signal on pin 16-10. If the ECU
registers that raise valve SP14 is not energised (the
axle is not lifted), the ECU will energise coil SP14
so the axle is raised. If the ECU registers that raise
valve SP14 is energised (the axle is lifted), the ECU
will energise coil SP15 (raise/block valve) and then
de-energise coil SP14 so the axle is lowered in a con-
trolled manner. Approximately 30 seconds later, the
ECU will de-energise SP15.

4.6.4.7 Raise/lower axle (lift axle unit


v20/3x)

When switch GC003 on the control panel is operated,


the ECU receives a signal on pin 16-10. If the ECU
registers that raise valve SP14 is not energised (the
axle is not lifted), the ECU will energise coil SP14
so the axle is raised. If the ECU registers that raise
valve SP14 is energised (the axle is lifted), the ECU
will energise coils SP12, SP14 and SP15 in the proper
sequence to lower the axle.

4.6.4.8 Container lifting system

When switch GC004 on the control panel is operated,


the ECU receives a signal on pin 12-2. If the angle
sensors register that the chassis is not in the set
position for pulling-up or demounting of a container,
the ECU will energise coils SP9 (drain oil on the right
side) and SP11 (drain oil on the left side) until the
angle sensors register that the correct position has
been reached.
If a pump lowering system is !tted, the ECU will also
energise valves SP31.1 and SP31.2.

4.6.4.9 Lateral stabilisation (manual op-


eration)

When switch GC005 on the control panel is oper-


ated, the ECU receives a signal on pin 12-1. If the
ECU registers that the stabilisation valves SP6.1 and
SP6.2 are energised (in other words, the stabilisation
is switched off), the ECU will de-energise coils SP6.1
and SP6.2 to activate the lateral stabilisation.

4-36
HPVS/EVS system book v20 e31
HPVS system description

4.6.4.10 Lateral stabilisation (automatic)

The ECU receives the D3 speed signal from the


tachograph on pin 26-22. If a vehicle speed below 3
km/h is registered, the ECU will de-energise valves
SP6.1 and SP6.2 so the lateral stabilisation is acti-
vated.

4.6.4.11 Hydraulic roll stabiliser (‘super-


stab’)

The ECU receives the D3 speed signal from the tach-


ograph on pin 26-22 and a signal from angle sensor
PM1, which allows it to compute the cornering speed.
If this cornering speed exceeds a certain value, the
ECU will de-energise coils SP6.1 and SP6.2 to acti-
vate the lateral stabilisation.

4-37
HPVS/EVS system book v20 e31
HPVS system description

4-38
HPVS/EVS system book v20 e31
EVS system description

5. EVS system description


5.1 General

The pump "ow unit, as described in Chapter 3, sup-


plies oil to the HPVS/EVS) valve block (see Figure
5.2) which contains all the valves for the HPVS, the
EVS and axle tilting.

5.1.1 HPVS/EVS valve block

Figure 5.2 shows the HPVS/EVS valve block. This


valve block can be roughly divided into an upper and
lower half. The upper half (containing the proportion-
al steering valve, the release valves, the accumulator
valve, the pump blocking valve and the emergency
steering safety valve) form the EVS section. This up-
per section can also be subdivided into the steering
section (left of non-return valve 7) and the emergen- Figure 5.2
cy steering section (right of non-return valve 7).

DY M1

X1L X2R PROP. STEERING VALVE


X2L X1R D4 Y M1 ACC D3

T P

SP1 SP2
B A

SP7

MPE ACCUMULATORVALVE

SP30 SP5.2 SP5.1


D1 6 2.0 mm
8 NON-RETURN VALVE
(steeringsystem)
RELEASEVALVE RELEASEVALVE
PP 7 5
NON-RETURN VALVE 1.0 mm
(emergency steering system)
MP PUMPLOCK VALVE 9
EMERGENCY STEERING VALVE

TT TT

PP
SP6.1 SP6.2
SP10 SP8
SP11 SP9
DRAINING LEFT DRAINING RIGHT SUPERSTABVALVE RIGHT
FILLING RIGHT SUPERSTABVALVE LEFT
FILLING LEFT

1 1.5 mm 2 1.5 mm

MBL BL MBR BR T1 T2

Figure 5.1

5-1
HPVS/EVS system book v20 e31
EVS system description

5.1.2 Axle tilting valve block

The axle tilting valve block is shown in Figure 5.3.


This valve block prevents the axle from tilting. SP26
and SP27 are 4/2 valves.

EVS-CYLINDER V20 LEFT EVS-CYLINDER V20 RIGHT


Y Y
X1 X1

X2 X2

X1L X2R X2L X1R

SP26 SP27

XA XB

Figure 5.3

5-2
HPVS/EVS system book v20 e31
EVS system description

5.2 2/2 steering valve

This is a 2/2 steering valve, electrically operated and


with a spring return, twelve of which are !tted in the
HPVS/EVS valve block and which can be classi!ed
into three types (see Figure 5.5).
For EPS only types A and B are used.

A:
When the coil is not energised, the circuit is opened
so oil can "ow in both directions.
When the coil is energised, the circuit is routed
through the non-return valve so the oil can only "ow
in one direction. (SP5.1/SP5.2)

B:
When the coil is energised, the circuit is opened so
oil can "ow in both directions.
When the coil is not energised, the circuit is routed
through the non-return valve so the oil can only "ow Figure 5.4
in one direction. (SP6.1/SP6.2/SP7/SP9/SP11/SP30)

C:
This is the same valve as type B. However, this valve
has an integrated non-return valve. This non-return
valve is placed so the oil can only "ow through the
steering valve in one direction. A
When the coil is not energised, both "ow directions
are blocked.
When the coil is energised, the oil can only "ow in
one direction. (SP8/SP10)
B
The type A steering valves are !tted with both 13-
Volt and 26-Volt coils (in series).
The type B steering valves are !tted with either 13-
Volt (SP6.1 and SP6.2) or 26-Volt (all others) coils. C
Most of the type C steering valves are !tted with 26-
Volt coils. SP31.1 and SP31.2 are exceptions: these
are !tted with 13-Volt coils.

Figure 5.5

5-3
HPVS/EVS system book v20 e31
EVS system description

5.3 Proportional steering valve

This is a 4/3 proportional steering valve, double


electrically operated and with a spring return to the
centre position (see Figure 5.6).
When coils SP1 and SP2 are not energised, the
steering valve is in the centre position. Ports A, B, T
and P are then closed.
When coil SP1 is energised, port P (pressure line
connection) is connected to port A and port T (return
line connection) is connected to port B.
When coil SP2 is energised, port P (pressure line
connection) is connected to port B and port T (return
line connection) is connected to port A.

Figure 5.6

T P

SP1 SP2
B A
5.3.1 Emergency steering safety valve
Figure 5.7

The emergency steering safety valve is located in


the HPVS/EVS valve block (see Figure 5.8). This
valve is pre-set to 310 + 60 bar. When the pressure
in the emergency steering system > 310 bar, this
valve opens and the pressure line (PP) is connected
to the return line (TT). This is to protect the emer-
gency steering accumulator and the EVS cylinders.

Figure 5.8

Figure 5.9

5-4
HPVS/EVS system book v20 e31
EVS system description

5.4 Non-return valve

The non-return valve consists of a ball in a line with


a seat at one end and sometimes a spring at the
other (see Figure 5.10 and Figure 5.11).
When the oil "ow comes from the seat side, the ball
is pressed off of the seat, against the spring pres-
sure, and the oil can "ow through.
If the oil "ow comes from the other side, the ball
will be pressed against the seat and the line will be
blocked. Now no more oil can "ow in this direction.

Two non-return valves are !tted in the EVS system:

• Non-return valve 7 (see diagrams in Appen-


dix 2) in the pressure line of the emergency steering
system: this prevents the emergency steering accu-
mulator from draining when there is no pressure in
the pressure line (SP12 closed).
Figure 5.10
• Non-return valve 8 (see diagrams in Appendix
2) in the pressure line of the steering system (!tted
under the proportional steering valve): this prevents
the oil from being forced out of the EVS cylinder
when external force is applied to the cylinder.

5.4.1 Restrictor

Figure 5.11
A restrictor (see Figure 5.13) is a constriction in a
circuit. When "uid passes through the restrictor, the
pressure before the restictor will be higher than the
pressure after it. We refer to this as a pressure drop.
At a lower "ow rate the pressure drop will be less
than at a higher "ow rate.
Figure 5.12

Figure 5.13

Figure 5.14

5-5
HPVS/EVS system book v20 e31
EVS system description

5.5 Pressure sensor for emergency


steering pressure (DY)

The pressure sensor is a sensor that measures the


oil pressure in the emergency steering system (see
Figure 5.15). This sensor can measure pressures
from 0 to 750 bar. When this oil pressure becomes
too high (higher than 240 bar) or too low, a fault will
be stored in the computer.

Figure 5.15

Figure 5.16

5-6
HPVS/EVS system book v20 e31
EVS system description

5.6 Measurement/blow-off/bleed
point for emergency steering system
(M1)

This measurement point is a ‘Minimess’ connection,


also refered to as a test nipple (see Figure 5.17).
This point can be used to measure the pressure in
the emergency steering system. This connection can
also be used to bleed the system or to release the
pressure from the emergency steering system so
repairs can be made safely.

Figure 5.17

Figure 5.18

5-7
HPVS/EVS system book v20 e31
EVS system description

5.7 EVS cylinder

The EVS cylinder (see Figure 5.19) consists of two


sections: the steering section and the emergency
steering/centring section. The two sections have
separate oil circuits.

Figure 5.19

5.7.1 EVS cylinder – steering section Y

The steering section consists of the piston that is X2 X1


operated via line connections X1 and X2. Via the
steering valve, the connections between X1 and X2 Figure 5.20
and the pressure and return lines are exchanged to
achieve the desired steering direction. This causes
the EVS cylinder to extend or retract.

5.7.2 EVS cylinder – emergency steering


section
The emergency steering/centring section is connect-
ed to the emergency steering circuit via line connec-
tion Y on the emergency steering circuit.
The function of the emergency steering/centring sec-
tion is the (return and) blocking of the EVS cylinder
in the centre position.

The emergency steering section consists of two


chambers, with a rod surface on one side and a
"oating piston on the other.

5-8
HPVS/EVS system book v20 e31
EVS system description

RIGHT

5.7.2 EVS cylinder – centre position


Connections X1 and X2 of both cylinders are con-
nected to the reservoir (see Figure 5.21). Connec-
tions Y1 and Y2 of both cylinders are kept under
pressure by the emergency steering accumulator.
This pressure is applied to the piston rod via connec- LEFT
tion Y1 and to the "oating piston (shown in yellow)
via Y2. Because the surface area of the "oating
piston is approx. two times as large as the surface of
the piston rod, the "oating piston will force the main
piston to the left until the "oating piston reaches the Figure 5.21
stop. At the same time, the main piston is forced
to the right, with half the pressure, by Y1. The EVS
cylinder is now !xed in position. This situation oc-
curs when driving straight ahead at the transition
speed or when the EVS switch on the control panel
is off. Once the transition speed is exceeded, thus at
speeds above 45 km/h, the system will close con-
nections X1 and X2 so the oil cannot escape from
the steering compartments. The cylinders are now
doubly hydraulically blocked.

5.7.4 EVS cylinder – vehicle steered left


When the vehicle is steered left, oil is fed to connec- RIGHT
tions X1 (right cylinder) and X2 (left cylinder) (see
Figure 5.22). These connections are linked together.
The oil enters the right EVS cylinder via connection
X1 and will cause the piston to move outward. This
causes the oil at connection X2 to be pushed toward
the reservoir. If the vehicle is steered to the left from
LEFT
the centre position, the main piston will carry the
"oating piston to the right. The oil will be pressed
out of emergency steering compartment Y2 and will
partially !ll emergency steering compartment Y1.
The remaining oil volume returns to the emergency
steering accumulator. At the left EVS cylinder, the oil
Figure 5.22
enters connection X2 and will push the piston inward.
This causes the oil at connection X2 to be pushed
toward the reservoir.
The oil is pressed out of emergency steering com-
partment Y1. Because the volume of emergency
steering compartment Y2 does not change (the "oat-
ing piston remains stationary), this entire volume will
return to the emergency steering accumulator. The
difference in surface area of the main piston on the
X1 and X2 sides is compensated by the difference in
the surface area of the main piston on the Y1 and Y2
sides (ring surface area of "oating piston).

5-9
HPVS/EVS system book v20 e31
EVS system description

5.7.5 EVS cylinder – vehicle steered right


When the vehicle is steered right, oil is fed to con- RIGHT
nections X1 (left cylinder) and X2 (right cylinder)
(see Figure 5.23). These connections are linked
together. The oil enters the left EVS cylinder via
connection X1 and will cause the piston to move
outward. This causes the oil at connection X2 to be
pushed toward the reservoir. If the vehicle is steered
to the right from the centre position, the main piston LEFT
will carry the "oating piston to the right. The oil will
be pressed out of emergency steering compartment
Y2 and will partially !ll emergency steering compart-
ment Y1. The remaining oil volume returns to the
emergency steering accumulator. At the right EVS
cylinder, the oil enters connection X2 and will push Figure 5.23
the piston inward. This causes the oil at connection
X2 to be pushed toward the reservoir.
The oil is pressed out of emergency steering com-
partment Y1. Because the volume of emergency
steering compartment Y2 does not change (the "oat-
ing piston remains stationary), this entire volume will
return to the emergency steering accumulator. The
difference in surface area of the main piston on the
X1 and X2 sides is compensated by the difference in
the surface area of the main piston on the Y1 and Y2
sides (ring surface area of "oating piston).

5-10
HPVS/EVS system book v20 e31
EVS system description

5.8 Emergency steering accumulator

The emergency steering accumulator is a pres-


sure vessel that consists of two sections (see Figure
5.24). The two sections are separated from each
other by a membrane. The upper section of the ac-
cumulator is !lled with oil. The lower section of the
accumulator is !lled with pressurised nitrogen gas.

When the oil pressure in the emergency steering


circuit is higher than the nitrogen gas pressure in
the accumulator (because oil is forced out of the EVS
cylinders during compression), oil "ows to the accu-
mulator and is stored there.
When this occurs, the membrane compresses the
nitrogen gas, increasing the gas pressure.
Figure 5.24
When the oil pressure in the emergency steering
circuit is decreased (because the EVS cylinder re-
turns to the centre position), the nitrogen gas press-
ing against the membrane forces the oil out of the
accumulator and back into the emergency steering
circuit.
In this manner pressure is maintained in the emer-
gency steering circuit.
Figure 5.25

5-11
HPVS/EVS system book v20 e31
EVS system description

5.9 Hydraulic system operation

5.9.1 Emergency steering system


For oil to enter the EVS section, coil SP30 of the
pump blocking valve must be energised. The oil then
"ows via the non-return valve (7) and the restric-
tor (5) to the emergency steering accumulator. Due
to the non-return valve, the oil cannot "ow from the
emergency steering accumulator back to the pump.
The pressure in the emergency steering system is
protected by the emergency steering safety valve.
For the operation of the emergency steering system,
it is not necessary that coil SP30 of the pump block-
ing valve be energised. Coil SP7 (accumulator valve)
is not energised, so the oil can "ow from the accu-
mulator to the cylinders, but not vice versa.
The pressure from the emergency steering accumu-
lator is applied to the connection (Y) of each EVS
cylinder. This pressure is now applied to the "oating
piston in each EVS cylinder. These "oating pistons
hold the main pistons in the centre position. How-
ever, due to the non-return valve for the accumula-
tor valve, the oil cannot escape from the emergency
steering system and the cylinders remain !xed in the
centre position. For safety reasons, coil SP7 of the
accumulator valve is connected so it is closed in the
non-energised state. At vehicle speeds above 45 km/
h, release valves SP5.1 and SP5.2 will be connected
so the connection between the X connections and
the reservoir are closed and the rear axle is doubly
hydraulically blocked.
EVS-CYLINDER V20 LEFT EVS-CYLINDER V20 RIGHT
EMERGENCY STEERING ACCUMULATOR
Y Y ACC
X1 X1
X2 X2

DY
M1

X1L X2R X2L X1R M1 ACC


PROP. STEERING VALVE (NG6)
Y
T P

SP1 SP2
B A
SP7

ACCUMULATORVALVE
MPE

SP5.2 SP5.1 6
SP30 8
RELEASEVALVE RELEASEVALVE
PP 7 5

9
EMERGENCY STEERING VALVE
TT TT
PUMPLOCK VALVE

Figure 5.26

5-12
HPVS/EVS system book v20 e31
EVS system description

5.9.2 EVS – steering


During steering, coil SP30 of the pump blocking valve
must be energised so the oil can "ow to the EVS sec-
tion. In addition, coil SP7 of the accumulator valve
must be energised so the oil can "ow freely from
and to the emergency steering system. Finally, coils
SP5.1 and SP5.2 of the left and right release valves
must be energised to close the connection between
the proportional control valve and the reservoir so
pressure can be built up to the X connections. Coils
SP5.1 and SP5.2 of the left and right release valves
are connected in series and are therefore opened
and closed simultaneously.
Beginning with the X series, in the standard con!gu-
ration, valves SP5.1 and SP5.2 are not connected in
series.

EVS-CYLINDER V20 LEFT EVS-CYLINDER V20 RIGHT


EMERGENCYSTEERING ACCUMULATOR
Y Y ACC
X1 X1
X2 X2

DY
M1

X1L X2R PROP. STEERINGVALVE (NG6)


X2L X1R Y M1 ACC

T P
SP1 SP2

B A
SP7

ACCUMULATORVALVE
MPE

SP5.2 SP5.1
6
SP30 8
VRIJZETKLEP VRIJZETKLEP
PP 7 5

9
EMERGENCYSTEERING VALVE
TT TT
PUMPLOCKVALVE

Figure 5.27

5-13
HPVS/EVS system book v20 e31
EVS system description

5.9.3 EVS – vehicle steered left


In order to steer the vehicle to the left, the left-side
EVS cylinder must be retracted and the right-side
EVS cylinder must be extended. That means that oil
must be supplied to connection X2 of the left EVS
cylinder and connection X1 of the right EVS cylinder.
The connections of the two cylinders are cross-con-
nected: X1L to X2R and X1R to X2L. In order to steer
the vehicle to the left, coil SP1 of the proportional
steering valve will be energised so it can supply oil to
the connections of the EVS cylinders as required.

EVS-CYLINDER V20 LEFT EVS-CYLINDER V20 RIGHT


EMERGENCYSTEERINGACCUMULATOR
Y Y ACC
X1 X1
X2 X2

DY
M1

X1L X2R X2L X1R Y M1 ACC


PROP. STEERINGVALVE(NG6)

T P

SP1 SP2
B A
SP7

ACCUMULATORVALVE
MPE

SP5.2 SP5.1
6
SP30 8
RELEASEVALVE RELEASEVALVE
PP 7 5

9
NOODSTUURVEILIGHEIDSKLEP
TT TT
PUMPLOCK VALVE

Figure 5.28

5-14
HPVS/EVS system book v20 e31
EVS system description

5.9.4 EVS – vehicle steered right


In order to steer the vehicle to the right, the right-
side EVS cylinder must be retracted and the left-side
EVS cylinder must be extended. That means that oil
must be supplied to connection X2 of the right EVS
cylinder and connection X1 of the left EVS cylinder.
The connections of the two cylinders are cross-con-
nected: X1L to X2R and X1R to X2L. In order to steer
the vehicle to the right, coil SP2 of the proportional
steering valve will be energised so it can supply oil to
the connections of the EVS cylinders as required.

One of the functions of the left and right release


valves is the protection of the centre position. When
the controller fails, the left and right release valves
open. The oil that is supposed to "ow to the EVS cyl-
inders via the proportional steering valve now goes
directly to the reservoir via the open release valves.
Therefore no steering movement occurs.

EVS-CYLINDER V20 LEFT EVS-CYLINDER V20 RIGHT

EMERGENCYSTEERING ACCUMULATOR
Y Y ACC
X1 X1
X2 X2

DY
M1

X1L PROP. STEERING VALVE (NG6)


X2L X1R Y M1 ACC
X2R
T P

SP1 B A SP2
SP7

ACCUMULATORVALVE
MPE

SP5.2 SP5.1
6
SP30 8
VRIJZETKLEP VRIJZETKLEP
PP 7 5

9
EMERGENCYSTEERING SYSTEM
TT TT
PUMP LOCKVALVE

Figure 5.29

5-15
HPVS/EVS system book v20 e31
EVS system description

5.9.5 EVS – coils


In the EVS section, just as in the HPVS section, the
oil is hardly circulated during steering. As a result,
the oil is only !ltered to a very limited degree. In or-
der to !lter this oil it is possible to run the EVS sys-
tem through a ‘"ush procedure’ via the DCS1. During
this procedure the oil in the EVS section is circulated
by the pump so the oil is !ltered. Then the rear axle
is steered to the left and right several times in order
to "ush the oil in the EVA cylinders.
In order to allow "ushing, release valves SP5.1 and
SP5.2 remain non-energised. Pump blocking valve
SP30 and (alternately) coil SP1 and SP2 are ener-
gised. All the valves are open during this procedure
so the oil can be circulated without steering the rear
axle to the left or right.

EVS-CYLINDER V20 LEFT EVS-CYLINDER V20 RIGHT


EMERGENCY STEERINGACCUMULATOR
Y Y ACC
X1 X1
X2 X2

DY
M1

X1L X2R X2L X1R Y M1 ACC


PROP.STEERINGVALVE (NG6)

T P

SP1 SP2
B A
SP7

ACCUMULATORVALVE
MPE

SP5.2 SP5.1
6
SP30 8
RELEASEVALVE RELEASEVALVE
PP 7 5

9
EMERGENCY STEERING VALVE
TT TT
PUMPLOCK VALVE

Figure 5.30

5-16
HPVS/EVS system book v20 e31
EVS system description

5.10 Electronic operation

5.10.1 Angle sensor


The angle sensor is a contact-free sensor.
For the EVS, an angle sensor is !tted to the sector
shaft on the steering house (see Figure 5.31). This
angle sensor registers the rotation of the sector shaft
and supplies this information to the ECU.
An angle sensor is also !tted to the V-rod of the
rearmost axle. This angle sensor registers the rota-
tion of the rearmost axle and supplies this value to
the ECU.
Figure 5.31

5.10.2 ECU power supply E31 v20


The constant power supply is provided via wire 1000,
fuse GE003 and wire R001. Wire R001 is divided 1 2 3 4
among pins 22-1, 22-2 and 26-26 of the EVS unit.
The power supply controlled by the ignition switch 90
is provided via wire 1010, fuse GE002, wire 1011e,
diode GD002, fuse GE001 and wire R002. Wire 1011 Figure 5.32
on pin 22-21 of the EVS unit is the sensor line for
ignition on/off. Pin 26-4 is a power supply output for
take-over of ignition switch power when the lift axle
is raised and the ignition switch is turned off. This
output maintains power to the EVS unit for approxi-
mately 5 seconds after the ignition switch is turned
off.

In addition to the vehicle speed and earth connec-


tion, the ECU receives the speed signal from the
tachograph and a signal from the tachometer to reg-
ister whether or not the engine is running.

5.10.3 Operation
For the measurement of the wheel de"ection on the
front axle, angle sensor GD005 is !tted to the sector
shaft on the steering house. For the measurement
of the steering angle of the rear axle, angle sensor
GD006 is !tted to the V-rod on the tandem. These
angle sensors are supplied with approx. 5 V from the
ECU and respond to angular rotation.
A changing signal from angle sensor GD005 (front
axle) tells the ECU that the vehicle is being steered.
Depending on the vehicle speed, during a left turn
the ECU energises electromagnetic valve SP1 and
during a right turn the ECU energises electromagnet-
ic valve SP2. Electromagnetic valves SP5.1, SP5.2,
SP7 and SP30 are also energised.

5-17
HPVS/EVS system book v20 e31
EVS system description

The electromagnetic valves are controlled with the


vehicle system voltage.
The control of electromagnetic valves SP1 and SP2
is done proportionally. The valves are actuated as
required. This is determined by the software and is
dependent on factors such as the wheel de"ection
angle and the vehicle speed.
In response to the control of electromagnetic valve
SP1 or SP2, the ECU receives a different signal from
angle sensor GD006 (angle sensor on the rear axle).
As soon as angle sensor GD006 has reached the de-
sired angle, the ECU switches electromagnetic valve
SP1 or SP2 off.
The ECU checks whether the signals from angle sen-
sors GD005 and GD006 agree.
Up to a speed of approx. 25 km/h, the rear axle can
reach full wheel de"ection.
At a speed of approx. 25 - 45 km/h, the wheel de-
"ection of the rear axle is limited.
At speeds above approx. 50 km/h, the steering sys-
tem for the rear axle is deactivated and the rear axle
remains in the centre position during steering.
As the vehicle speed increases or decreases, the
steering system is gradually deactivated or activated.
Via electromagnetic valve SP1 or SP2, the ECU steers
the rear axle back to the centre position.
Once the ECU receives a signal from angle sensor
GD006 (angle sensor for the rear axle) indicating
that the rear axle is in the centre position, the ECU
!rst de-energises electromagnetic valve SP30, then
electromagnetic valve SP1 or SP2, then electromag-
netic valves SP5.1 and SP5.2, and several seconds
later electromagnetic valve SP7. Then electromag-
netic valves SP5.1 and SP5.2 are re-energised to
block the rear axle in the centre position.

5.10.4 Pressure sensors


To monitor the pressure in the system, a pressure
sensor is !tted in the proportional pump "ow unit.
When the pressure is above or below the set pres-
sure, a fault will be stored in the ECU.
There is also a pressure sensor in the emergency
steering system. This monitors the pressure in the
emergency steering system. When the pressure in
the emergency steering system is too high or too
low, a fault will be stored in the ECU.

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EVS system description

5.10.5 Summary of possible circuit


states
This section provides an overview of the various
EVS circuit states that can occur during driving.
This overview is not complete, however, because an
extremely large number of combinations can occur,
especially when faults or combinations of faults are
present: virtually every fault is responded to in a dif-
ferent way#
Furthermore, steering to a certain position is not
truly a static event, because the steering wheel is
continuously adjusted. If you want to test the follow-
ing situations it is recommended that you switch off
the engine and begin in the centre position, perhaps
with a DELSI installed to simulate certain vehicle
speeds (DELSI is a tool that simulates the signal
from the speed sensor on the transmission or trans-
fer gearbox for test purposes).

5.10.5.1 Situation 1

Steering to the left from the centre position,


speed below transition speed, no faults

Energised valves:

SP12 Proportional pump "ow valve


- so the pump can supply oil to the
HPVS/EVS valve block

SP30 Pump blocking valve


- so the pump can supply oil to the EVS
section

SP7 Accumulator valve


- so the oil can "ow freely to the emergency
steering accumulator

SP5.1/5.2 Release valves


- so pressure can be built up to the
EVS cylinders

SP1 Proportional steering valve


- so this valve is moved to the parallel position
causing the left cylinder to retract and the
right cylinder to extend

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EVS system description

5.10.5.2 Situation 2

Steering to the right from the centre position,


speed below transition speed, no faults

Energised valves:

SP12 Proportional pump "ow valve


- so the pump can supply oil to the
HPVS/EVS valve block

SP30 Pump blocking valve


- so the pump can supply oil to the EVS
section

SP7 Accumulator valve


- so the oil can "ow freely to the emergency
steering system

SP5.1/5.2 Release valves


- so pressure can be built up to the
EVS cylinders

SP2 Proportional steering valve


- so this valve is moved to the cross position
causing the right cylinder to retract and the
left cylinder to extend

5.10.5.3 Situation 3

Front axle in the centre position (approx.


straight ahead, small corrections permitted),
speed lower than transition speed but higher
than 15 km/h, no alarms

While driving approximately straight ahead, steer-


ing of the rear axle is undesirable: it must be in the
100% straight ahead position. This is achieved by
deactivating the main steering system and centring
the rear axle with the emergency steering system.
During this process, oil must be prevented from "ow-
ing to the accumulator as a result of external forces.
The same applies when the EVS switch is off. After
all, you do not want the rear axle to steer.

Energised valves: none

The main steering system is deactivated by de-en-


ergising release valves SP5.1 and SP5.2. After all,
when these are de-energised, no pressure can be
built up to the EVS cylinders, regardless of which
other valve may be energised.

SP7 is de-energised to prevent oil from the emergen-


cy steering system from "owing to the accumulator.
Now it is only possible for oil from the accumulator

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EVS system description

to "ow to emergency steering connections Y1 and Y2


and not vice versa.
Because the oil in the accumulator is held under
pressure, the axle will remain in the centre position.

SP12 does not have to be energised because it is not


necessary to build up pressure. However, the HPVS
can still energise SP12, if, for example, the height
control is activated.

Note: When the vehicle is driven at less than 15 km/


h in this situation, the main steering system and SP7
are non de-activated by de-energising the release
valves, except when the vehicle is driven straight
ahead for a minimum time (2.5 s).

5.10.5.4 Situation 4

Front axle in any position, speed higher than


transition speed, no faults

When the vehicle is driven at a speed above the


transition speed, the rear axle may not steer; this
ensures good vehicle stability.

In fact, this amounts to the same as the situation


described above, however the speed is higher, so de-
viations from the straight ahead position of the rear
axle are even more dangerous. For this reason, the
rear axle is now doubly hydraulically blocked. This is
done by activating the main steering system while
not energising the proportional steering valve. As a
result, this remains in the centre position, in which
the ports are blocked. A speed switch serves as a
safeguard to ensure that SP30 cannot be energised.
This speed switch is also the second speed protection
measure. Beginning with the X series, the V-gearbox
or intermediate gearbox is !tted with an extra ta-
chometer, which sends a signal in the same manner
for the purpose of deactivating the EVS.

5.10.5.5 Situation 5

Transition from desired rear axle angle other


than centre position to desired rear axle angle
= centre position, speed lower than transition
speed, no faults

Essentially this is a transition from situation 1 or 2


to situation 3, in which the reason for steering back
to the centre is either that the front axle has moved
back to the approximate centre position or the vehi-
cle speed has become so high that, despite steering
of the front axle, the rear axle angle should be the
centre position.

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EVS system description

What happens is that SP1 or SP2 is energised to


return the axle to the centre position. Once both cyl-
inders have reached the centre position, the system
waits approx. 3 seconds, then SP7 is de-energised,
followed by SP5.1 and SP5.2 0.2 seconds later; situ-
ation 3 has now been reached.

Energised valves:
SP5.1/5.2 Release valves
- First, so pressure can be built up to
the EVS cylinders

SP30 Pump blocking valve for EVS


- Pump can now supply oil to the EVS
section

SP7 Accumulator valve


- at the same time as SP5.1 and SP5.2 so the
oil can "ow freely to the accumulator.

SP1 or SP2 Proportional steering valve


- at the same time as SP5.1, SP5.2 and SP7 so
the rear axle steers to the right or left

Once the centre position of both EVS cylinders has


been reached, the valves are de-energised as de-
scribed above.

5.10.5.6 Situation 6

Front axle in any position, transition from a


speed lower than the transition speed to a
speed higher than the transition speed, no
faults

In fact, this is nothing more than a transition from


situation 3 to situation 4, because at a speed under
the transition speed, the rear axle will already be
steered electronically to the centre position. That is
because the maximum rear axle steering angle at
this speed is, at a maximum, 0% of the maximum
rear axle steering angle, thus the straight ahead
position of the rear axle is desired. If this is not the
case, situation 5 takes place !rst.
If situation 3 is reached and the transition speed has
been passed (both conditions must be met), a wait-
ing time of approx. 3 seconds begins, after which
SP5.1 and SP5.2 are energised.

Energised valves:
Initially none (see situation 3), so the rear axle is
straight ahead and blocked by the emergency steer-
ing system.
Once the transition speed has been exceeded and a
waiting time of 3 sec. has elapsed: SP5.1 and SP5.2

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EVS system description

so the rear axle is doubly hydraulically blocked (see


situation 4).

5.10.5.7 Situation 7

Front axle in any position, transition from a


speed higher than the transition speed to a
speed lower than the transition speed, no faults

No response from the system, situation 4 is main-


tained until the front axle has been steered to a
point at which the desired rear axle position is not
the centre position; then situation 1 or 2 goes into
effect. If necessary, SP12 can be energised again to
adjust the HPVS.

The fact that SP5.1 and SP5.2 are not de-energised


again is done to prevent unnecessary wear; this con-
siderably decreases the number of switching cycles
for these valves.

Note:
The vehicle speeds at which the rear axle transitions
from steering to not steering and vice versa are not
identical. There is a difference of approx. 3 km/h be-
tween these speeds to prevent rapid switching when
driving at speeds around the switch point.

5.10.5.8 Situation 8

Change in position of EVS on/off switch

When the switch is off, the rear axle ‘steers’ as if


the front axle is exactly in the straight ahead posi-
tion, in which case the rear axle should also be in
the straight ahead position. As the speed changes,
situation 3 or 4 will occur or, immediately following
deactivation of the rear axle steering, situation 5.
The switch can be operated at any time. An off-to-on
transition, however, will only be accepted once the
angle of the front axle has passed through the centre
position since activation; this prevents unsafe situa-
tions (sudden ‘oversteering’). An on-to-off transition
will always be accepted, because sudden ‘unders-
teering’ is not dangerous.

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EVS system description

5.10.6 Control panel

In the cab of the X series, the switches for control of


the HPVS/EVS system are integrated into the dash-
board (see Figure 5.33). This makes it possible, for
instance, for the driver to manually deactivate the
EVS system or level the vehicle.
This control panel also includes a warning lamp for
reading out the faults from the ECU. When a fault
occurs in the system, the warning lamp will light.

5.10.7 Electronic straight ahead


position protection unit (limit Figure 5.33
sender, speed switch)

As an extra safety measure, an electronic straight


ahead position protection unit (also called a limit
sender or speed switch) is !tted. The protection unit
receives the D3 speed signal from the tachograph.
In the E31 box, the speed switch (see Figure 5.34) is
mounted outside the box. At a speed of approx. 57
km/h the protection unit interrupts the connection to
electromagnet SP30 by means of a relay. Above this
speed it is no longer possible for the pump to build
up pressure in the EVS section of the valve block, not
even when SP12 is energised for the height control
of the HPVS.
Beginning with the X-series, the second speed signal
has been !tted as standard equipment.
Figure 5.34

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6 HPVS/EVS diagnosis box


(DCS)
6.1 General

6.1.1 DCS operation


The DCS (see Figure 6.1), special tool (GINAF no.
OG0000087067--PA) (old model OG0000008631)
makes it possible to:
• read faults
• read ‘real time’ parameters
• read correction factors
• adjust angle sensors
• read system data
• "ush the HPVS/EVS system
• test valve connections

The values displayed on the DCS are in hexadecimal


numbers instead of decimal numbers.
Figure 6.1
For control unit E31, an adapter (programmer, see
Figure 2.2) is required for connection to the DCS.
The switch at the side is an on/off switch. In order to
perform programming, the switch must be in the on
position. If this is in the off position, you can pro-
gram but it will not be accepted.

6.1.2 Hexadecimal numbers


The hexadecimal, or base-16 number system, con-
sists of a maximum of 2 positions; letters are used in
addition to numbers. The hexadecimal system runs
from 00 to FF.
The numbers 0 to 9 are the same in both the hexa-
decimal and decimal system.
Differences occur from number 10 onwards. After
number 9, the hexadecimal system continues with
the letters A to F. In the hexadecimal system, the Figure 6.2
number 10 comes after the letter F (expressed as
one - zero). In the hexadecimal system, the value
of number 10 therefore differs from its value in the
decimal system.

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6.1.2 Overview of the decimal system

00 10 20 30 40 50 60 70 80 90 A0 B0 C0 D0 E0 F0
01 11 21 31 41 51 61 71 81 91 A1 B1 C1 D1 E1 F1
02 12 22 32 42 52 62 72 82 92 A2 B2 C2 D2 E2 F2
03 13 23 33 43 53 63 73 83 93 A3 B3 C3 D3 E3 F3
04 14 24 34 44 54 64 74 84 94 A4 B4 C4 D4 E4 F4
05 15 25 35 45 55 65 75 85 95 A5 B5 C5 D5 E5 F5
06 16 26 36 46 56 66 76 86 96 A6 B6 C6 D6 E6 F6
07 17 27 37 47 57 67 77 87 97 A7 B7 C7 D7 E7 F7
08 18 28 38 48 58 68 78 88 98 A8 B8 C8 D8 E8 F8
09 19 29 39 49 59 69 79 89 99 A9 B9 C9 D9 E9 F9
0A 1A 2A 3A 4A 5A 6A 7A 8A 9A AA BA CA DA EA FA
0B 1B 2B 3B 4B 5B 6B 7B 8B 9B AB BB CB DB EB FB
0C 1C 2C 3C 4C 5C 6C 7C 8C 9C AC BC CC DC EC FC
0D 1D 2D 3D 4D 5D 6D 7D 8D 9D AD BD CD DD ED FD
E
0E 1E 2E 3E 4E 5 6E 7E 8E 9E AE BE CE DE EE FE
0F 1F 2F 3F 4F 5F 6F 7F 8F 9F AF BF CF DF EF FF
Table 6.1

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6.2 Connection, login and disconnec-


tion

6.2.1 DCS1 connection

Turn off the vehicle ignition switch.


1. Tip the armrest of the passenger seat for Figure
ward.
2. Attach the connector of the DCS to the ECU.
3. Turn on the vehicle ignition switch. The login
screen appears on the display.
4. If the login screen does not appear, there is
a problem with the cable or the ECU is defec
tive.
Figure 6.3

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6.2.2 Login
1. Enter the login code (four characters): screen
1 appears.
Note
L OG I N - CO D E :
If the DCS is connected but is not logged in, the
HPVS/EVS system does not function.

Loginscreen Figure 6.4

2. Press A: screen 2 appears. G I N A F E V S / H P V S - e 3 V 2 0


E V S / H P V S P ROG . : 0 - 4
< G E E N E V S : G E E N ' 2 ' >
= > A
Screen 1 Figure 6.5

3. Enter the desired choice. Attention: If you


enter 2 (settings program – EVS correction PMP / E V S : 0 H P V S : 1
factors) or 3 (settings program E V S - CO R : 2 H P V S - CO R : 3
– HPVS correction factors), the entire
con!guration must be performed. It is S P O E L E N : 4 F O U T U I T L : 7
not possible to interrupt the program. GE G E V E N S : 8 E C U : C = > A
Screen 2 Figure 6.6

6.2.3 Disconnection
1. Press E.
2. Turn off the vehicle ignition switch.
3. Disconnect the DCS from the ECU.
4. Reattach the fuse panel.

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6.2.4 Screen 1 E31


In the screen shown here, a selection can be made
from the following options: E V S / H P V S - e 3 1 V 2 0 - T R I
E V S / H P V S P ROG . : 0 - 4
Note:
Every screen shown in this book is labelled to in- ( G E E N E V S : G E E N ' 2 ' )
dicate which screen it is. This also indicates which = > A
buttons are used to access the screen. Screen 2-0-1
means: screen 2, button 0, button 1. Screen 1 Figure 6.7

Choice Description
0 blanco screen, HPVS/EVS is working normally
1 'real-time' screen HPVS specifications, HPVS/EVS is working normally
2 'real-time' screen EVS specifications, HPVS/EVS is working normally
3 Actual alarms, HPVS/EVS is working normally
4 Actual alarms, HPVS/EVS is working normally
A Go to screen 2
E exit,
Table 6.2

Selection:
Enter the desired number an the requested screen
appears.

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6.2.5 Screen 1-1: ‘real-time’ display of


HPVS data
Screen 1-1 shows the ‘real-time’ display of a number
of HPVS data items. The HPVS/EVS continues to op-
erate while this screen is displayed. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A X X X X X X X X X X X X X X X X X X
B X X X X X X X X X X X X X X
C X X X X X X X X X X X

Postion Value Description


A1, 2 00 Only level regulation by speed
02 Lateral stabilizer on
08 Automatic level regulation: on
10 Heighest position:
n on
20 lowest position: on
40 Container- lifting system
A3,4 00 Manual lateral stabilizer: stabilizer not active
40 Manual lateral stabilizer: stabilizer active
A6-7 IRQ-counter
A9 -12 Speed (Example. 001E = ± 42 km/h)
A17,18 Frontangle
A20 0 Stabilizer valve SP6.1 / SP6.2 off
1 Stabilizer valve SP6.1 / SP6.2 on
B1,2 soll-value height
B4,5 ist-value height left
B7 0 height -left: okay
1 height -left: too high
2 height -left too low
B9,10 ist-value height right
B12 0 height -right: okay
1 height -right: too high
2 height -right: too low
B14 0 synchronisation: not active
1 synchronisation: active
B16,17 00 HPVS bock: not active
01 HPVS block: active
B19.20 ist-waarde levelling sensor
C1 0 filling left SP10: not active

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1 Filling left SP10: active


C3 0 Draining left SP11: not active
1 Draining left SP11: active
C5 0 Filling right SP8: not active
1 Filling right SP8: active
C7 0 Draining right SP9: not active
1 draining right SP9: active
C9 0 status levelling left: too low
1 status levelling left: okay
C11 0 status levelling rigth: too low
1 status levelling right: okay
C13 0 soll/ist-control sensors : not active
1 soll/ist-control sensors : active
C15,16 regulation value SP12
C18,19 sensorvalue pumppressure
D1,2 00 SP12 for lifting/lowering: not active
01 SP12 for lifting/lowering: active
D4 0 Lifting/lowering: not active
1 Lifting
2 Lowering
D6,7 Timecounter lowering
D9 0 ignition control: not active
1 ignition control: ignition off, axle lifted
D11 0 Pressure switch automatic lowering: pressure < max.
1 Pressure switch automatic lowering: pressure > max.
D13 0 Automatic lowering: not active
1 Automatic lowering: active
D15 0 Later stabilizer (superstab): not active
1 Later stabilizer (superstab): active
D17,18 Later stabilizer (superstab) value
D20 0 approach switch container lifting system:
- not active
1 approach switch container lifting system:
- active
Table 6.3

Press E to return to screen 1.

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6.2.6 Screen 1-2: ‘real-time’ display of EVS


data 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A X X X X X X X X X X X X X X
Screen 1-2 shows the ‘real-time’ display of a number B
X X X X X X X X X X X X
of EVS data items. The HPVS/EVS continues to oper-
ate while this screen is displayed. C X X X X X X X X X
D X X X X X X X X X X
Screen1-2 Figure 6.9

Postion Value Description


A1,2 00 Middle register: middle
01 Middle register: steering left
80 Middle register: steering right
A4,5 ist-value front-angle
A7,8 reductionfactor 00– 80
A10-13 Speed (Example. 001E = ± 42 km/h)
A15 0 SP5.1: not active
1 SP5.1: active
A16 0 SP5.2: not active
1 SP5.2: active
A17 0 SP7: not active
1 SP7: active
A20 0 SP30: not active
1 SP30: active
B1,2 minimum soll-value
B4,5 ist-value rearangle
B7,8 masimum soll-value
B10 soll-flag
B12,13 max. permitted soll/ist -difference
B15,16 actual soll/ist -difference
B18
C1,2 Pumppressure
C4,5 Emergency steering pressure
C7,8 Feeding voltage
C10 0 Engine control: engine off
1 Engine control: engine on
C12 0 Regulation off, because parking
- brake not engaged
1 Regulation off, because parking
- brake engaged
C14 0 Filling emergencysystem: not active
1 Filling emergencysystem: active
D1,2 Regulation value SP1
D4,5 Regulation value SP2
D7,8 Regulation value SP12
D10,11
D13.14
Table 6.4

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6.2.7 Screen 1-3: fault message readout


part 1, HPVS/EVS operates normally
Screen 1-3 shows part 1 of the correct fault mes-
sages. The fault must occur !ve times or be continu-
ously present before a fault message is shown.
The HPVS/EVS continues to operate while this screen
is displayed.
A fault message is indicated by a 1. The nature of
the fault message is determined based on the posi-
tion on the screen. If zeros change to ones in row A,
you must look on screen 1-4 (part 2) because a fault
message will be shown there as well.

Note
See the workshop instruction manual for an overview
of the fault messages.

Example
In this screen, a 1 is shown in position B11. The po-
sition represents the fault message EVS front angle 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
> allowed.
A X X X X X X X X X X X X ∗ 3
• Press C to clear the error message(s). B 0 0 0 0 0 1 0 0
• Press E to return to screen 1.
C 0 0 0 0 0 0 0 0
D 0 0 0 0 0 0 0 0
Screen 1-3 Figure 6.10

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6.2.8 Screen 1-4: HPVS fault message rea-


dout part 2, HPVS/EVS operates nor-
mally
Screen 1-4 shows part 2 of the correct fault mes-
sages. The fault must occur !ve times or be continu-
ously present before a fault message is shown.
The HPVS system continues to operate while this
screen is displayed.
A fault message is indicated by a 1. The nature of
the fault message is determined based on the posi-
tion on the screen. If zeros change to ones in row A,
you must look on screen 1-3 (part 1) because a fault
message will be shown there as well.

Note
See the workshop instruction manual for an overview
of the fault messages.

Example
In this screen, a 1 is shown in position C7. The posi-
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
tion represents the fault message HPVS left-rear
target-actual value > allowed. A X X X X X X X X X X X X ∗ 4
B 0 0 0 0 0 0 0 0
• Press C to clear the error message(s).
C 0 0 0 1 0 0 0 0
• Press E to return to screen 1.
D 0 0 0 0 0 0 0 0
Screen 1-4 Figure 6.11

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6.3 Screen 2 E31

In the screen shown here, a selection can be made P M P / E V S : 0 H P V S : 1


from the following options: C O R R E C . : 2 CO D E B E R . : 3
S P O E L E N : 4 F O U T U I T L : 7
G E G E V E N S : 8 E C U : C = > A
Screen 2 Figure 6.12

Choice Description
0 Settingsselection-screen pump and EVS
1 Settingselection-sreen HPVS
2 Adjust correctionfactors HPVS/EVS and
others
3 Code-calculation
4 Automatic flushing HPVS/EVS
7 Reading out faults
8 Reading out specifications
C Control the ECU
A go to screen 1
Table 6.5

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6.3.1 Screen 2-0: settings selection screen


for pump and EVS

I N S T E L K E U Z E S C H E RM
Control screen for pump and emergency steering POMP / NOO D S T U U R S Y S : 1
pressure E V S S E N S OR S E . V . : 2
E = E X I T
Screen 2-0 Figure 6.13

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A V H : X X A H : X X P Y : X X
B P O MP = 1 ∗ P P : X X I : X X / X X
C S P 3 0 = 4 ∗ L I = 2 ∗ R E = 3 ∗
D F L OW = F ∗ E X I T = E
Screen 2-0-1 Figure 6.14

Position Description
A4,5 value front-angle sensor
A10,11 value rear-anglesensor
A16,17 value emergencypressure sensor
B11,12 value pump-pressure sensor
B16,17 controlvalue pumpflow
B19,20 maximum value pumpflow
Table 6.6

Choice Description
1 By-passvalve SP12 on/off
2 Steering Left SP1
3 Steering right SP2
4 pump-lock valveSP30 on/off
F flowcontrol
E exit, go to previous screen
Table 6.7

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A M V H : X X M A H : X X B - D -/ E
B V 2 4 = X X L / R : 0 / 1 - 4 / 5 *
C V H : X X S P 1 = X X S P 2 = X X
D A H = X X S P 1 2 = X X / X X 6 - A
Screen 2-0-2 Figure 6.15

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A M V H : X X M A H : X X E = E X I T
B V 2 4 = X X L / R : 0 / 1 - 4 / 5 *
C V H : X X S P 1 = X X S P 2 = X X
D A H = X X S P 1 2 = X X / X X 6 - A
Screen 2-0-2 Figure 6.16

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Position Description
A5,6 Middle frontangle
A12,13 Middle rearangle
B5,6 Value feeding voltage
C4,5 Actual value front angle
C11,12 Regulation-value SP1
C18,19 Regulation-value SP2
D4,5 Actual value rear-angle
Control screen for EVS sensors and the steering D12,13 Active regulation-value SP12
valve D15,16 Right regulation value SP12
For a vehicle without lift axle Table 6.8

Choice Description
0 Regulation SP1 <-> SP2
1 Lower regulationvalue SP1
Control screen for EVS sensors and the steering 2 Higher regulationvalue SP1
valve for a vehicle with lift axle 3 Lower regulation value SP2
4 Higher regulation value SP2
5 SP5.1 and SP5.2 on/off
6 Min. regulation value SP12
7 Lower regulation value SP12
8 Higher regulation value SP12
9 Max. regulationvalue SP12
B19 without *, SP5.1/SP5.2 de-energised
B19 with *, SP5.1/SP5.2 energised A Make the right SP12 value active
B Lift the axle
C Lower the axle
D By-coupling
E exit,go to the previous screen
Table 6.9

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HPVS/EVS diagnosis box

6.3.2 Screen 2-1


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A 0 =WP L A / R A B Y / A F = 1 - 4
HPVS settings selection screen B 5 - 8 = 1 + 4 / 2 + 3 / 1 + 3 / 2 + 4
C A = HG T B - D = H E F F = S T AB
D L A : X X R A : X X WP : X X
Screen 2-1 Figure 6.17

Position Description
D4,5 Actual value, heightsensor left
D10,11 Actuel value, heightsensor right
D16,17 Actual value levelsensor
Table 6.10

Choice Description
0 Lateral levelling reg. active
1 Filling Left SP10
2 Draining Left SP1 1
3 Filling Right SP8
4 Draining right SP9
5 Filling left and draining right
6 Draining left and filling right
7 Filling left and right
8 Draining left and right
A Height regulation active
B Liftvalve active (SP14)
C Drainval ve active (SP15) Attention:
SP14 and SP15 still engaged)
D Bycoupling active
E exit, go to previous screen
F Testing stabilsation
Table 6.11

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6.3.3 Screen 2-2: reading in the correction COR R . F A C T . E V S : 1


factors COR R . F A C T . H P V S : 2
COR R . F A C T . O V E R I G : 3
E = E X I T
Screen 2-2 Figure 6.18

Choice Description
1 Adjust correctionfactors EVS
2 Adjust correctionfactors HPVS
3 Adjust correctionfactors others
Table 6.12
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A E V S - CO R R . F A C T O R E N
B S t u u r d e v o o r a s n a a r
Reading in the EVS correction factors C r e c h t u i t : d r u k A
D S T U U R HO E K V OO R A S : X X
Screen 2-2-1 Figure 6.19

Position Description
D19,20 Actual valua front-angle sensor
Table 6.13
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A E V S - CO R R . F A C T O R E N
B D r a a i s t u u r v o l l e d i g
C n a a r l i n k s : d r u k A
D S T U U R H O E K V O O R A S : X X
Screen 2-2-1-... Figure 6.20

Position Description
D19,20 Actual value front-angle sensor
Table 6.14
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A E V S - CO R R . F A C T O R E N
B D r a a i s t u u r v o l l e d i g
C n a a r r e c h t s : d r u k A
D S T U U R H O E K V O O R A S : X X
Screen 2-2-1-... Figure 6.21

Position Description
D19,20 Actual value front-angle sensor
Table 6.15

D e o p n a m e v a n d e E V S
s t u u r h o e k e n g e b e u r t
a u t om a t i s c h ! P A S OP
V OO R D E W I E L E N - E -
Screen 2-2-1-... Figure 6.22

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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A *
A C H T E R A S M I D D E N *
B 0 = S T O P 1 = S T A R T
C E V S - S T U U R HO E K : X X
D A = A C C E P T . D E W A A R D E
Screen 2-2-1-... Figure 6.23
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A *
R E C H T S OM S T U R E N *
B 0 = S T O P 1 = S T A R T
C E V S - S T U U R HO E K : X X
D A = A C C E P T . D E W A A R D E
Screen 2-2-1-... Figure 6.24

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A *
L I N K S OM S T U R E N *
B 0 = S T O P 1 = S T A R T
C E V S - S T U U R HO E K : X X
D A = A C C E P T . D E WA A R D E
Screen 2-2-1-... Figure 6.25

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A D E CO R R E C T I E F A C T O R E N
B A FW : X X M I N : X X MA X : X X
C V HM : X X V H L : X X V H R : X X
D A HM : X X AH L : X X A H R : X X
Screen 2-2-1-... Figure 6.26
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A S T D . R I J HOOG T E I N S T .
B L I / R E O P / N E E R = 1 - 4
C S E N S O R L A : X X R A : X X
D A = A C C E P T . D E WA A R D E
Screen 2-2-2 Figure 6.27

Position Description
C11,12 Actual value sensor left
C17,18 Actual value sensor right
Table 6.16
D e o p n a m e v a n H P V S
s e n s o r w a a r d e n g a a t
a u t om a t i s c h ! P A S O P ,
V O E R T U I G B EWE E G T - E -
Screen 2-2-2-... Figure 6.28
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A *
HOOG S T E S T A N D *
B 0 = S T O P 1 = S T A R T
C S E N S O R L A : X X R A : X X
D A = A C C E P T D E WA A R D E
Screen 2-2-2-... Figure 6.29

Position Description
C11,12 Actual value sensor left
C17,18 Actual value sensor right
Table 6.17

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HPVS/EVS diagnosis box

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A *
L A AG S T E S T A N D *
B 0 = S T O P 1 = S T A R T
C S E N S O R L A : X X R A : X X
D A = A C C E P T D E WA A R D E
Screen 2-2-2-... Figure 6.30
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A D E C O R R E C T I E F A C T O R E N
B A FW : X X M I N : X X MA X : X X
C L AM : X X L A H : X X L A L : X X
D R AM : X X R A H : X X R A L : X X
Screen 2-2-2-... Figure 6.31

COR R . F A C T . WA T E R P . : 1
COR R . F A C T . P - S E N S . : 2

E = E X I T
Screen 2-2-3 Figure 6.32

Choice Description
1 Correctionfactors levelling control
2 Correctionfactors PX en PY
Table 6.18
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A W A T E R P A S M I D . I N S T .
B L I N K S O P / N E E R = 1 / 2
C S E N S O R WA T E R P A S : X X
D A = A C C E P T D E WA A R D E
Screen 2-2-3-1 Figure 6.33

Choice Description
1 Filling left (SP10)
2 Draining left (SP8)
Table 6.19

Position Description
C17,18 Actual valua levelsensor
Table 6.20

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A D E C OR R E C T I E F A C T OR E N
B A F W: X X
C WP M : X X
D E = E X I T
Screen 2-2-3-1-... Figure 6.34

Position Description
B5,6 Maximum differende (08)
C5,6 Real difference (less thanAFW)
Table 6.21

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HPVS/EVS diagnosis box

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A P OMP D R U K P X = X X
B NO OD S T U U R D R U K P Y = X X
C S E N S . W . ME T S P 1 2 U I T
D A = A C C E P T . D E WA A R D E
Figure 6.35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A P OMP D R U K P X = X X
B NO OD S T U U R D R U K P Y = X X
C S E N S . W . ME T S P 1 2 A AN
D A = A C C E P T . D E WA A R D E
Figure 6.36

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A D E CO R R E C T I E F A C T O R E N
B P X : X X / 7 0 - 9 0 P Y : X X
C P X A : X X P X C : X X P Y A : 0 2
D E = E X I T
Figure 6.37
Position Description
B5, 6 Maximum permitted correction factor
B19, 20 Maximum permitted correction factor
C5, 6 Actual correction value
C12, 13 Actual correction value
C19, 20 Actual correction value
Table 6.22

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HPVS/EVS diagnosis box

6.3.4 Screen 2-3: code calculation


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A K A S T : X X X X C O D 1 : X X X X
B C O D 2 : X X X X C O D 3 : X X X X
C K - W A A R D E : X X X X X X
D V E R D E R : J A = 1 /E = E X I T

D * B E L N U G I N A F ! *
Screen 2-3 Figure 6.38

Position Description
A6-9 ECU serienumber
A16-19 Value code 1
B6-9 Value code 2
B16-19 Value code 3
C10-14 k-value (tacho)
Table 6.23
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A K A S T : X X X X C O D 1 : X X X X
After the code is entered, press 1 (=yes). B C O D 2 : X X X X C O D 3 : X X X X
If you did not enter the code correctly, press 2 C G I N A F / V S E C O D E : - - - -
(=no). D O K : J A = 1 / N E E = 2 / E = E X I T
Screen 2-2-2-1 Figure 6.39

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HPVS/EVS diagnosis box

6.3.5 Screen 2-4: automatic "ushing HPVS/


S P O E L P ROG . H P V S / E V S
EVS DOO R S P O E L E N H P V S = 1
DOO R S P O E L E N E V S = 2
E = E X I T
Screen 2-4 Figure 6.40

Choice Description
1 Flushing HPVS system
2 Flushing EVS system
Table 6.24

P A S O P B I J S P O E L E N
B EWE E G T H E T V O E R T U I G
T I J D S D U U R : C A . 3 M I N
E = E X I T
Screen 2-4-1 Figure 6.41

P A S O P B I J S P O E L E N
B EWE E G T D E E V S - A S
T I J D S D U U R : C A . 3 M I N
E = E X I T
Screen 2-4-2 Figure 6.42

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HPVS/EVS diagnosis box

6.3.6 Screen 2-7: reading out faults


Button 1 F O U T U I T L E Z I NG
The fault messages are displayed. Press any button OP G E S L AG E N A L ARME N : 1
to display the following fault message. F OU T E N T E L L E R S : 2
E = E X I T
Screen 2-7 Figure 6.43

Press C or E C = W I S S E N E N E X I T ,
You now return to screen 7-2. ( N I E T : C O R R . F A C T. )
E = A L L E E N E X I T

Screen 2-7-1 Figure 6.44

A L . T E L L E R : 1 / 2 / C / E
Press 1 or 2

Screen 2-7-2 Figure 6.45

Choice Description
1 Errorcounter screen 1
2 Errorcounter screen 2
C Delete errors
E Exit
Table 6.25

A L . T E L L E R : 1 * / 2 / C / E
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
Screen 2-7-2-1 Figure 6.46

A L . T E L L E R : 1 / 2 * / C / E
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
Screen 2-7-2-2 Figure 6.47

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HPVS/EVS diagnosis box

6.3.7 Reading out "ash code

The warning lamp on the instrument panel can be


used to read out the fault memory of the ECU. This
method of read-out provides less information than
when the DCS1 is used.
The warning lamp indicates the fault message by
"ashing a fault code.
The "ash code represents the fault code. If the warn-
ing lamp "ashes 3 times, fault code 3 is indicated.
If the warning lamp "ashes 5 times, this indicates
either fault code 5.1 or fault code 5.2.

Reading out fault codes with the "ash code is only


possible when the vehicle engine is not running. Dur-
ing activation of the "ash code, the HPVS/EVS sys-
tem is de-activated.

6.3.7.1 Reading out fault messages

1. Hold the button for the lateral levelling sys


tem and the button for either the lowest posi
tion or the highest position simultaneously
until a pulsing tone is heard.
Release both buttons. If there is no fault code
in the memory, a short pulsing tone is heard.
2. If there are fault messages in the memory,
a long pulsing tone is heard.
The tone is followed by a "ash code.
3. If there are multiple fault messages in the
memory, the fault message with the lowest
number is displayed !rst. Each fault message
is followed by a tone. After the tone the fol
lowing fault message is displayed via a "ash
code.
4. After the last fault message a long tone is
produced.
5. The fault messages remain in the memory af
ter they have been read out and can be read
multiple times with the "ash code.

6.3.7.2 Erasing fault codes

1. Hold the button for the lateral levelling sytem


and the button for either the lowest position
or the highest position simultaneously un
til a pulsing tone is heard. First the faults are
read out; now continue to hold the buttons
until a short pulsing tone is heard – this
means the fault messages have been erased.

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HPVS/EVS diagnosis box

6.3.8 Summary of "ash codes

Faultcode Number of Description


flashes
AL011 1 Oil pressure of the emergency steering system incorrect
AL02 2 Oil level HPVS/EVS too low
AL03 3 EVS target-actual fault; rear axle does not steer to the correct position
AL04 4 The measured speed is very irregular
AL051 5 The angle sensor at the front axle is not working correctly (value < 07)
AL052 5 The angle sensor at the front axle is not working correctly (value > F8)
AL061 6 The angle sensor at the rear axle is not working correctly (value <07)
AL062 6 The angle sensor at the rear axle is not working correctly (value > F8)
AL071 7 Wire break / short circuit in the pump lock valve (SP30)
AL072 7 The pump lock valve (SP30) relay remains correctly
AL081 8 Wire break / short circuit in the steering valve SP1 (cross position)
AL082 8 Wire break / short circuit in the steering valve SP2 (parallel position)
AL09 9 Wire break / short circuit in the release valves (SP5.1/SP5.2)
AL101 10 Wire break / short circuit in the accumulatorvalve (SP7)
AL102 10 Accumulatorvalve (SP7) does not switch on correctly
AL111 11 Wire break / short circuit in the pump flow valve (SP12)
AL112 11 Pumpflowvalve (SP12) does not switch off correctly
AL113 11 Pumpflowvalve (SP12) does not switch on correctly
AL121 12 Wire break / short circuit in the filling height control valve (SP8) RIGHT
AL122 12 Wire break / short circuit in the draining height control valve (SP9) RIGHT
AL123 12 Wire break / short circuit in the filling height control valve (SP10) LEFT
AL124 12 Wire break / short circuit in the draining height control valve (SP11) LEFT
AL13 13 Wire break / short circuit in the pump lowering valves (SP31.1/SP31.2)
AL14 14 Wire break / short circuit in the transverse stabilizer valves (SP6.1/SP6.2)
AL151 15 The emergency steering pressure sensor is not working correctly (value < 04)
AL152 15 The emergency steering pressure sensor is not working correctly (value > DF)
AL161 16 The pump pressure sensor is not working correctly (value <04)
AL162 16 The pump pressure sensor is not working correctly (value >DF)
AL171 17 The levelling sensor is not working correctly (value < 04)
AL172 17 The levelling sensor is not working correctly (value >DF)
AL18 18 Wire break / short circuit in the lifting axle valve / axle load reducing valve SP14
AL19 19 Wire break / short circuit in the lowering valve (SP15)
AL231 23 HPVS target-actuel (soll-ist) left side does not reach the correct height
AL232 23 HPVS target-actuel (soll-ist) right side does not reach the correct height
AL261 26 Height sensor at the rear left is not working correctly (value <06)
AL262 26 Height sensor at the rear left is not working correctly (value >F8)
AL271 27 Height sensor at the rear right is not working correctly (value <06)
AL272 27 Height sensor at the rear right is not working correctly (value >F8)
AL28 28 Pump pressure too high with SP12 switched on
AL29 29 VCC/VDD fault
Table 6.26

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HPVS/EVS diagnosis box

Silent alerts

Faultcode Number of Description


flashes
AL012 -- Refill time of the emergency steering system too long
AL20 -- EVS correction factors out of range
AL21 -- HPVS correction factors out of range
AL301 -- Pump pressure too low with SP12 switched off
AL302 -- Pump pressure too low with SP12 switched on
AL31 -- System started at speed
AL32 -- -
AL33 -- -
Table 6.27

6-24
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HPVS/EVS diagnosis box

6.3.9 Screen 2-8: reading out data OV E R Z . V T G . I N F O : 1


L AD E N S T D . P AR AM . : 2
OV E R Z . / W I J Z . P AR AM . : 3
E = E X I T
Screen 2-8 Figure 6.48

Choice Description
1 Setting vehicle parameters
2 Load standard parameters
3 Change parameters
Table 6.28

K E U Z E S C H E R M G E G E V E N S
E P R O M : 1 T Y P E / D R U K : 2
A C C U M : 3 S MO R I NG E N : 4
P A R A M : 5 D I V : 6 E X I T = E
Screen 2-8-1 Figure 6.49

Choice Description
1 Eprom version
2 Survey pressures
3 Survey accumulator pressures
4 Restrictor diameters EVS+HPVS
5 Parameters
6 Divers
Table 6.29
P AG 1 / 1 0 : - E P ROMS -

P ROG R AMMA : X X X X X X X X

Screen 2-8-1-1 Figure 6.50

H P V S v a r i a n t : V 2 0 / 3 4
P A G 2 / 1 0 : - D R U K K E N -
P O MP D R U K : X X X b a r
R E G E L D R U K : X X b a r
Screen 2-8-1-2 Figure 6.51

P A G 4 / 1 0 : - A C C U ‘ S -
V E R I NG : P O = X X b - X / + X
E V S : P O = X X X b - X X / + X
H E F A S : P O = X X b - X / + X
Screen 2-8-1-3 Figure 6.52

6-25
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HPVS/EVS diagnosis box

P A G 5 / 1 0 : - SMOR I NG -
H O OG T E R E G . : X X X mm
H E F K L E P : X X X mm
Z A K K L E P : 2 x X X X mm
Screen 2-8-1-4 Figure 6.53

P A G 6 / 1 0 : - SMOR I NG -
S P 1 - 2 : G E E N
S M O R I NG 5 : X X X mm
S M O R I NG 6 : X X X mm
Screen 2-8-1-4-... Figure 6.54

P A G 7 / 1 0 : - P A R A M . -
H P V S S T D . R I J H . : $ X X
H P V S MA X . R I J H . : $ X X
S T D . WA T E R P A SW . : $ X X
Screen 2-8-1-5 Figure 6.55

P A G 8 / 1 0 : - P A R AM . -
M I N . E V S HO E K : $ X X
M A X . E V S HO E K : $ X X
V O O R : MA X . G E S T U U R D
Screen 2-8-1-5-... Figure 6.56

P A G 9 / 1 0 : - P A R AM . -
A C H T E R : B I J B E N U T T E N
V A N D E V O L L E D I G S L AG
V A N D E E V S - C I L I N D E RS
Screen 2-8-1-5-... Figure 6.57

P A G 1 0 / 1 0 : - D I V . -
Z I E OO K WP L . H AN D BO E K
V O O R A L G EME N E U I T L EG
O V E R H P V S / E V S !
Screen 2-8-1-6 Figure 6.58

B A S I S G E G E V E N S L A D E N
S T D . P A R AME T E R S : 3
S T D . T E K S T E N : 4
E = E X I T
Screen 2-8-2 Figure 6.59

U O V E R S C H R I J F T UW
OU D E P A R AME T E R S I N C L
COR R E C T I E F A C T OR E N !
J A = 1 N E E = E
Scherm 2-8-2-3 figuur 6.60

U O V E R S C H R I J F T UW
OU D E P A R AME T E R S I N C L
COR R E C T I E F A C T OR E N !
J A = 1 N E E = E
Screen 2-8-2-4 Figure 6.61

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Electrical installation

Appendix 1: Electrical installation


1.1 Overview of components in schematic diagrams

Overview of basic code numbers in the schematic diagram


25093/00 (diagram is included in the appendix)
Number on
E.C.N. Description reference
bar
GB000 Coil, pump "ow unit, SP12 0018
GB001 Coil, steering valve, SP1 0011
GB002 Coil, steering valve, SP2 0013
GB003 Coil, release valve, SP51 0003
GB004 Coil, release valve, SP52 0006
GB005 Coil, accumulator valve, SP7 0008
GB006 Coil, EVS protection valve, SP30 0015
GB007 Coil, lateral stabilisation, left, SP6.1 0024
GB008 Coil, lateral stabilisation, right, SP6.2 0024
GB009 Coil, !ll left HPVS, SP10 0028
GB010 Coil, drain left HPVS, SP11 0030
GB011 Coil, !ll right HPVS, SP8 0033
GB012 Coil, drain right HPVS, SP9 0035
GB013 Coil, lift axle, SP14 0037
GB014 Coil, lift axle, SP15 0041
GB015 Coil, rapid-lowering HPVS left, SP31.1 0044
GB016 Coil, rapid-lowering HPVS right, SP31.2 0044
GB017 Coil, battery blocking HPVS left, SP28.1 0046
GB018 Coil, battery blocking HPVS right, SP28.2 0046
GB019 Coil, axle tilting protection, SP26 0020
GB020 Coil, axle tilting protection, SP27 0022
GB021 Buzzer, EVS 0051
GB022 Buzzer, 4th brake circuit 0159
GB023 Valve, front wheel drive 0125
GB024 Valve, diff-lock, front 0130
GB025 Valve, cross-axle lock, rear 0135
GB026 Valve, diff-lock, rear 0140
GB027 Valve, cross-axle lock, steered axles 0145
GB028 Valve, intermediate gearbox, low 0153
GB029 Valve, intermediate gearbox, high 0150
GB030 Valve, 3rd PTO
GB031 Valve, intermediate gearbox, neutral
GB032 Buzzer, reverse signal
GB033 Valve, "ow-control, SP201 0220
GB034 Coil, steering valve, SP011 0224
GB035 Coil, release valve, SP051 0227
GB036 Buzzer, EMAS 0194
GB037 Valve, asphalt brake
GB038 Buzzer, pneumatic lift axle (ignition switch off/ lift axle raised)
GB039 Valve, lift bellows
GB040 Valve for bleeding of lift bellows (disconnection)
GB041 Electric motor, lift axle unit

B1-1
HPVS/EVS system book v20 e31
Electrical installation

GC000 Switch, EVS on/off 0007


GC001 Switch, levelling/height control 0010
GC002 Switch, highest/lowest position 0013
GC003 Switch, lift axle 0016
GC004 Switch, lowering system 0019
GC005 Switch, manual lateral stabilisation 0022
GC006 Switch, weigh system 0240
GC007 Switch, front wheel drive 0125
GC008 Switch, diff-lock, front 0130
GC009 Switch, cross-axle lock, rear 0135
GC010 Switch, diff-lock, rear 0140
GC011 Switch, cross-axle lock, steered axles 0145
GC012 Switch, intermediate gearbox, high/low 0150
GC013 Switch, 3rd PTO
GC014 Reverse lamp, left
GC015 Reverse lamp, right
GC016 Switch, alphalt brake
GC017 Switch, emergency, lift axle unit motor
GC018 Switch, highest/lowest position, left
GC019 Switch, disconnect, rearmost axle (silo demounting system)
GD000 Electronic unit, HPVS, EVS
GD001 Electronic unit, protection, EVS (speed switch) 0102
GD002 Diode unit (3 diodes)
GD003 Diode unit (9 diodes) 0035, 0116,
0175
GD004 Diode unit (1 diode)
GD004 Levelling unit 0055
GD005 Front angle sensor 0058
GD006 Rear angle sensor 0061
GD007 Height sensor, left rear 0064
GD008 Height sensor, right rear 0067
GD009 Warning lamp, EVS 0114
GD010 Indicator lamp, lift axle 0117
GD011 Indicator lamp, lateral stabilisation 0112
GD012 Indicator lamp, oil level 0121
GD013 Indicator lamp 4th steering circuit 0156
GD014 Indicator lamp, front wheel drive 0161
GD015 Indicator lamp, diff-lock, front 0164
GD016 Indicator lamp, cross-axle lock, rear 0166
GD017 Indicator lamp, diff-lock, rear 0171
GD018 Indicator lamp, cross-axle lock, steered axles 0169
GD019 Electronic unit, weigh system 0242
GD020 Indicator lamp, 3rd PTO
GD021 Angle sensor, axle 1, left (EMAS) 0207
GD022 Angle sensor, axle 1, right (EMAS) 0210
GD023 Angle sensor, axle 2, left (EMAS) 0214
GD024 Angle sensor, axle 2, right (EMAS) 0217
GD025 Indicator lamp, EMAS 0198
GD026 Electronic unit, protection, EMAS (speed switch) 0191
GD027 Electronic unit, EMAS 0216
GD028 Indicator lamp, probe installation (tracks raised)
GD029 Electronic unit, protection, asphalt brake (speed switch)
GD030 Indicator lamp, asphalt brake
GD031 Indicator lamp, EMAS oil level 0201
GD032 Indicator lamp, PTO protection active 0053

B1-2
HPVS/EVS system book v20 e31
Electrical installation

GD033 Diode unit (1 diode)


GD034 Electronic unit, protection, lift axle unit
GD035 Electronic unit, protection, uncoupling lift axle (speed switch)
GE001 Fuse, HPVS and EVS, power from ignition switch 0031
GE002 Fuse, power monitoring/speed switch/switches/various chassis 0037
GE003 Fuse, HPVS and EVS, continuous power 0047
GE004 Proximity switch, lift axle 0086
GE005 Proximity switch, lowering system, axle 2, right 0088
GE006 Proximity switch, lowering system, axle 4, left 0091
GE007 Fuse, diff-lock valves 0125
GE008 Fuse, indicator lamps, diff-locks 0156
GE009 Fuse, accessories
GE010 Fuse, weigh system ("oating fuse) 0241
GE011 Fuse, asphalt brake
GE012 Proximity switch, PTO protection 0082
GE013 Proximity switch, lowered reverse switch
GE014 Fuse, pneumatic lift axle, power from ignition switch
GE015 Fuse, pneumatic lift axle, continuous power
GF000 Switch, HPVS/EVS oil level 0025
GF001 Pressure switch, automatic lowering, lift axle 0028
GF002 Speed sensor (2nd speed) 0098
GF003 Pressure sensor, monitor SP30 0073
GF004 Pressure sensor, emergency steering pressure 0070
GF005 Pressure sensor, pump pressure 0075
GF006 Pressure sensor, suspension system, left 0242
GF007 Pressure sensor, suspension system, right 0245
GF008 Control switch, front wheel drive 0161
GF009 Control switch, diff-lock, front 0164
GF010 Control switch, cross-axle lock, rear (rear axle 2-3) 0166
GF011 Control switch, diff-lock, rear 0171
GF012 Control switch, cross-axle lock, steered axles (rearmost axle) 0169
GF013 Control switch, 4th steering circuit 0156
GF014 Control switch, 3rd PTO (intermediate gearbox)
GF015 Control switch, clutch
GF016 Control switch, cross-axle lock, steered axles (axle 1) 0170
GF017 Control switch, cross-axle lock, steered axles (axle 2) 0172
GF018 Control switch, diff-lock, rear (rear axle 1-2) 0176
GF020 Pressure sensor, X-system 0230
GF021 Pressure sensor, 0-system 0233
GF022 Switch, engine coolant temperature
GF023 Switch, EMAS oil level
GF024 Pressure switch, pneumatic lift axle 4.3b
GF025 Pressure switch, pneumatic lift axle 5.3b
GF026 Pressure switch, lift axle unit
GG000 Relay, lateral stab. lamp 0027, 0111
GG001 Relay, alarm lamp 0049,0114
GG002 Relay, lowered reverse switch
GG003 Relay, ign. take-over 3rd PTO
GG004 Relay, engagement delay 3rd PTO
GG005 Relay, EMAS indicator lamp 0199
GG006 Relay, 2nd speed, EMAS 0194
GG007 Relay, neutral switch, probe inst.
GG008 Relay, starter interrupter, probe inst.
GG009 Relay, charging current lamp, probe inst.

B1-3
HPVS/EVS system book v20 e31
Electrical installation

GG010 Relay, asphalt brake


GG011 Relay, PTO protection 0080
GG012 Relay, EMAS oil level 0203
GG013 Relay, protection, manual lowering of lift axle (V>30km/h)
GG014 Relay, ign. take-over, lift axle switch
GG015 Relay, automatic lowering (V>30km/h and P>4.3b)
GG016 Relay, buzzer (lift axle raised and ign. off)
GG017 Relay, raise/bleed pneumatic lift axle
GG018 Relay, engagement delay, automatic lowering
GG019 Relay, lowering delay, lift axle unit
GG020 Relay, lift axle unit motor
GG021 Relay, interruption of axle raising
GG022 Relay 2nd speed (EVS) only for VG2000 intermediate gearbox
GG023 Relay, clutch, intermediate gearbox PTO
GG024 Relay, raise condition, uncoupling lift axle

B1-4
HPVS/EVS system book v20 e31
Electrical installation

1.2 Overview of connectors

Connector overview

Column 1 = Connector coding


Column 2 = No. of connection points on the connector
Column 3 = Colour of the connector
Column 4 = Description of the connector
Column 5 = Location of the connector in the vehicle

1 2 3 4 5
K000 18 Black Conn. to diode block Central PCB
K001 21 Blue Chassis wiring for EVS and Bulkhead feed-through location
HPVS valves D7/8
K002 21 Yellow Chassis wiring for EVS and Bulkhead feed-through location
HPVS sensors A7/8
K003 9 Grey Chassis conn. for diff-lock Bulkhead feed-through location
valves B7
K004 6 Grey Chassis conn. for diff-lock Bulkhead feed-through location
indicator lamps B8
K005 6 Green Conn. for 2nd speed signal Bulkhead feed-through location
C9
K006 6 Green Chassis conn. for proximity Bulkhead feed-through location
switches / oil level C4
K007 6 Yellow Conn. for various DAF signals Bulkhead feed-through location
A4
K008 12 Yellow Conn. for diff.lock control Behind cover for radio panel
switches
K009 21 Green Conn. for switches and indic. Behind cover for radio panel
lamps EVS and HPVS.
K010 6 Blue Conn. for accessories and weigh Behind cover for radio panel
system
K011 12 Yellow Conn. for diff-lock indic. lamps Right-side heater panel
K012 10 Green Conn. for control lamp relay Central PCB
K013 6 Black Conn. for HPVS/EVS fuses Central PCB
K014 6 Black Conn. for accessory fuses Central PCB
K015 4 White Conn. for speed switch, 2nd Under central PCB
speed EVS
K016 18 Black Conn. for 9-position relay block Under central PCB
K017 9 Grey Conn. for E-MAS Under central PCB
K018 4 Black Conn. for axle tilting protection At rear of chassis
K019 4 Black Conn. for proximity switch, For T-beam chassis
lowering system, left
K020 4 Black Conn. for oil level Near HPVS tank
K021 4 Black Conn. for pressure sensor, Right side FUP
pump
K022 4 Black Conn. for front angle sensor Left side FUP
K023 4 Black Conn. for pressure sensors In T-beam chassis
emer. steering system/control
SP30
K024 35 Black Conn. for HPVS/EVS valve block In T-beam chassis
K025 4 Black Conn. for "ow valve SP12 Right side FUP

B1-5
HPVS/EVS system book v20 e31
Electrical installation

1 2 3 4 5
K026 4 Black Conn. for battery blocking At rear of chassis
valves
K027 8 Black Conn. for lift axle valve block For T-beam chassis
K028 4 Black Conn. for levelling unit Right rear, in chassis
K029 4 Black Conn. for pressure sensors, In T-beam chassis
weigh sys.
K030 4 Black Conn. for height sensor, left Left side, under T-beam chassis
K031 4 Black Conn. for height sensor, right Right side, under T-beam
chassis
K032 4 Black Conn. for rear angle sensor On V-rod, rearmost axle
K033 2 White Conn. for press. sensors, weigh Ceiling compartment, driver's
sys. side
K034 21 Green Chassis wiring, lighting Bulkhead feed-through location
C5/6
K035 4 Black Conn. for lowered reverse On transmission
switch
K036 35 Black Conn. for tail lights At rear of chassis
K037 21 Yellow Chassis wiring for EMAS Bulkhead feed-through location
A1/2
K038 4 White Conn. for speed switch, 2nd Under central PCB
speed EMAS
K039 10 Green Conn. for relay indicator lamp/ Central PCB
2nd speed EMAS
K040 16 Black Diagnostic connector, EMAS Central PCB
K041 12 Yellow Conn. for diff-lock indic. lamps Left-side heater panel
K042 3 Black Conn. for pressure sensor, PSF E-MAS "ow-valve block
K043 2 Black Connection SP201 E-MAS "ow-valve block
K044 4 Black Conn. for right-front sensor (E- Right-front chassis, near front
MAS) axle 1
K045 4 Black Conn. for right-rear sensor (E- Right-front chassis, near front
MAS) axle 2
K046 3 Black Conn. for pressure sensor, PSX E-MAS steering valve block
K047 2 Black Connection SP051 E-MAS steering valve block
K048 4 Black Connection SP011 E-MAS steering valve block
K049 4 Black Conn. for left-rear sensor (E- Left side of chassis, near front
MAS) axle 2
K050 4 Black Conn. for left-front sensor (E- Left side of chassis, near front
MAS) axle 1
K051 6 Yellow Conn. for relay, transfer Under central PCB
gearbox
K052 4 Black Conn. for prox. sw., PTO Behind cab
protection
K053 6 Blue Chassis wiring, pneum. lift axle Bulkhead feed-through location
D3
K054 4 Black Conn. for press. sw., pneum. lift At lift axle, in chassis
axle
K055 2 Black Conn. for reverse buzzer In tow bar
K056 6 Blue Conn. for lowered reserve Bulkhead feed-through location
switch D9
K057 4 Black Conn. for reverse switch On transmission
K058 4 Black Conn. for 2nd speed sensor On transmission
K059 4 Black Conn. for 2nd speed sensor for On transmission
AS Tronic
K060 4 Black Conn. for 2nd speed sensor for On transmission
AS Tronic
B1-6
HPVS/EVS system book v20 e31
Electrical installation

1.3 Schematic diagrams

Partial diagrams from schematic diagram 25093/00

1 HPVS/EVS power supply

2 EVS valves / SP12

3 HPVS valves

4 Angle sensors / Level sensor

5 Pressure sensors / Weight indication

6 HPVS/EVS indicator lamps

7 HPVS/EVS control switches

8 Diff-lock control switches

9 Diff-lock indicator lamps

10 Tachograph and tachometer / 2nd gear pro


tection / Pressure switch for lift axle / PTO
protection

11 Power for E-MAS / Indicator lamp / Buzzer /


2nd gear protection

12 Valves for E-mas / Pressure sensors for E-


MAS

13 Angle sensors for E-MAS

B1-7
HPVS/EVS system book v20 e31
Electrical installation

1 HPVS/EVS power supply

The constant power supply is provided via wire 1000,


fuse GE003 and wire R001.
Wire R001 is divided among pins 22-1, 22-2 and 26-
26 of the EVS unit.
The power supply controlled by the ignition switch is
provided via wire 1010, fuse GE002, wire R1011, di-
ode GD002, fuse GE001 and wire R002. Wire R1011
on pin 22-21 of the EVS unit is the sensor line for
ignition on/off. Pin 26-4 is a power supply output for
take-over of ignition switch power when the lift axle
is raised and the ignition switch is turned off. This
output maintains power to the EVS unit for approxi-
mately 5 seconds after the ignition switch is turned
off.

B1-8
1000
1010

08/06
1010a
1000

R1012
R1012a
R1012b
12 14 B2 C2
Electrical installation

5A
15 A

GD003
GE002
GE003

11 13 B1 C1
R1011b

R1012
R1014
R1011
R001

R1012f
R1012e
R1012d
R1012c
R1012b
R1011c
R1011a
A2

K009 GG000 GG001 GD001 K005 K006 K017 GG011


1 B3 A3 1 1 2 1 30

2A
7 10 10 10 10 6 11 10

GE001
A1

R002
R1014
R1011d
R001b
R001a
R001c

01
26-12 26-4 22-21 22-1 22-2 26-26

GD000
22-12 26-13

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51
HPVS/EVS system book v20 e31

25093/00
B1-9
HPVS/EVS system book v20 e31
Electrical installation

2 EVS valves / SP12

B1-10
B1-11

25093/00 08/06
02

1010
1000
1
2
3
4
5
6
7

16-15
SP51 SP51 SP51
8

K024 K024 K001


9

GB003
10

11
11

26-6
SP52 SP52 SP52
12

K024 K024 K001


13

GB004
14

2
15

26-3
SP7 SP7 SP7
K024 K024 K001
16

GB005
17
18

26-16
19

SP1 SP1 SP1


K024 K024 K001
20

GB001
21
22

16-4

SP2 SP2 SP2


23

GD000

K024 K024 K001


24

GB002
25

10
26

26-8

SP30 SP30 SP30


27

K024 K024 K001


28

GB006
29

12
2

1
30

16-12

SP12 SP12 SP12


K025 K025 K001
31

GB000
32
33

16
2

26-20
34

SP26 SP26 SP26


K018 K018 K001
35

GB019
36
37

17
4

26-19

SP27 SP27 SP27


38

K018 K018 K001


39

GB020
40

22-1 22-2 26-26

R001b
22-12
41

R001a
42

26-13

R001c
43
44
45
46 47

C1

C2

15 A
R001 1000
48

GE003
4

Electrical installation
HPVS/EVS system book v20 e31
HPVS/EVS system book v20 e31
Electrical installation

3 HPVS valves

B1-12
B1-13

25093/00 08/06
03

1010
1000
1
2
3
4
5
6

K061
SP14a
6
2
7

13
2

16-1
SP14 SP14 SP14
8

K027 K027 K001


9

GB013
10

K061

SP15a
6
1

14
11

16-8
SP15 SP15 SP15
12

K027 K027 K001


13

GB014
14
15

16-3
SP10 SP10 SP10
16

K024 K024 K001


17

GB009
18

9
19

16-14

SP11 SP11 SP11


K024 K024 K001
20

GB010
21
22

16-16
23

SP8 SP8 SP8


GD000

K024 K024 K001


24

GB011
25
26

16-2

SP9 SP9 SP9


27

K024 K024 K001


28

GB012
29

K012

SP6a
6
1
30

1
l

k
2

16-5

SP6 SP6 SP6


31

K024 K024 K024 K001


32

GB008 GB007
33

15
G

1
F

E
2

D
34

26-9

SP31 SP31 SP31


K024 K024 K024 K001
35

GB016 GB015
36
37

18
2

26-7
38

SP28 SP28 SP28


K026 K026 K001
39

GB018 GB017 0ptioneel


40

22-1 22-2 26-26

R001b
22-12
41

R001a
42

26-13

R001c
43
44
45
46 47

C1

C2

15 A
R001 1000
48

GE003
49

Electrical installation
HPVS/EVS system book v20 e31
HPVS/EVS system book v20 e31
Electrical installation

4 Angle sensors / lateral levelling system

B1-14
1000
1010

08/06
Electrical installation

GD000
22-13 22-15 26-15 22-14 22-22 22-16 26-2 22-4 26-11 26-14 22-9 22-3

PM1
PM1
PM1
PM4
PM3
PM3
PM3
PM2
PM61
PM61
PM62
PM62

1 2 3 4 5 6 7 8 15 13 20 21
K002

04
PM1
PM1
PM1
PM4
PM4
PM4
PM3
PM3
PM3
PM2
PM2
PM2
PM6
PM6
PM6
PM6

1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4

K022
K032
K031
K030
K028

o o o o
90 90 90 90
U U U U U
GD005 GD006 GD008 GD007 GD004

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49
HPVS/EVS system book v20 e31

25093/00

B1-15
HPVS/EVS system book v20 e31
Electrical installation

5 Pressure sensors / Weight indication

Weight indication

When switch GC006 is operated, display unit GD019


receives power on pin 7 via DAF fuse E163, wire
1258 and "oating fuse GE010.
Pressure sensors GF006 and GF007 are wired in par-
allel and determine the current level to the display
unit based on the pressure on the suspension at the
left and right sides of the vehicle.

B1-16
1000
1010

08/06
1010
25A
10A

E163
(DAF)
E117
(DAF)
Electrical installation

1258
GD000 2630

22-17 22-11 22-6 26-24 22-5 16-6 22-7 26-23 22-10


2 4 8
183C
(DAF)

PM7
PM5
PM5
PM5
PM9
PM8
PM8
PM8
PM8
2 1

14 9 10 11 12 16 17 18 19

K002
0 1
ES603
ES602
GC006

1 2

05
6 10
K033

PM7
PM7
PM7
PM5
PM5
PM5
PM9
ES602
ES603
ES602a
ES603a
1
1 2 3 4 1 2 3 4 1 2 3 4

K021
K023
K029
3A
GE010

PM7
PM7
PM7
PM5
PM5
PM5
PM9
PM9
PM9
5 1 2 6 7 8
+ + +
_ out _ out _ out 1 2 1 2
P P P P P GD019
U U U I I
GF005 GF004 GF003 GF006 GF007

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49

25093/00
HPVS/EVS system book v20 e31

B1-17
HPVS/EVS system book v20 e31
Electrical installation

6 HPVS/EVS indicator lamps

If raise valve SP14 or lower valve SP15 is energised,


power is supplied to pin 1 of lift axle indicator lamp
GD010 via diode block GD003 and wire SP115.

Indicator lamp GD009 is controlled by the EVS unit


via wire ES008, relay GG001 and wire ES009.

Indicator lamp GD011 and relay GG000 are only


present on vehicles with manual lateral stabilisation.
If lateral stabilisation valves SP6.1 and SP6.2 are en-
ergised (no hydraulic stabilisation), the coil of relay
GG000 is energised, interrupting contacts A3 and A5
of the relay. The indicator lamp no longer receives
power via wire SP61.

If the oil level of the HPVS/EVS system is too low, oil


level switch GF000 closes. This results in voltage on
wire ES114 and wire ES114a, which causes indica-
tor lamp GD012 to light and the EVS unit to receive
power on pin 12-7.

B1-18
1000
1010

08/06
1010
B2

R1012b
R1012a
R1012

5A
14 12

GE002
R1012
B1
R1014
K005

GD002
R1011d 1
13 11 10
Electrical installation

22-21 26-4

R1011
R1011a
R1011b
R1011c
GD000
GG011 K017
1 12-7 16-1 16-8 16-7 16-5 16-13
30
10 11
SP6

SP14
SP15

ES114
ES004
R1012f
R1012e
R1012c
R1012b

13 14

K001
K001
5
K001

K017 K027 K027 K017 K009 GE001 K024 GD001


2 1 3 3 1 A2 j 1
11 3 3 11 7 1 3 10
SP6a

SP14a
SP15a
ES008

R1012e
R1012c

R1012d
SP14b SP15b B3 B1 A3 A1

06
15 17

GD003
GG000
GG001

16 18
B4 B5 B2 A4 A5 A2

R1011c
R1011d
ES114
ES114a
ES114a
ES004
ES009

SP61

SP115

K006
GG011
1 3 13 14 16 15

K009
K009
K009
K009
K009

86

K006
10
GB021
SP61

ES114
ES114
SP115
ES009

2
1 1 1 1
GD011

GF000
GD012
GD010
GD009

R1011

R1011a
2 2 2 2
1
K027
6
10

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49

25093/00
HPVS/EVS system book v20 e31

B1-19
HPVS/EVS system book v20 e31
Electrical installation

7 HPVS/EVS control switches

B1-20
1000
1010

08/06
2630a 2630b 2630c 2630d 2630e
R1011a R1011b R1011c R1011d R1011e
9 5 9 3 9 3 9 3 9 3 9 3
Electrical installation

1 0 1 0 2 1 0 2 1 0 1 0 1 0

GD010 GD009 GD011 GD012

GC001
GC002
GC003
GC004
GC005

2 2 2 2

GC000
6 6 6 6
10 1 7 10 7 1 10 7 1 10 7 1 10 1 7 10 1 7

ES013
ES035
ES201
ES203
ES204
ES031
ES030
ES210
ES215

2630

R1011
1 2 3 12 7 6 4 5 9 8 10 11
K009

07
2630

2630a

R1012f
GE001 K008

ES013
ES035
ES201
ES203
ES204
ES031
ES030
ES210
ES215

A2 2 1
1 8 DAF

16-11 16-9 12-6 12-9 12-3 12-5 16-10 12-2 12-1

GD000

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49

25093/00
HPVS/EVS system book v20 e31

B1-21
HPVS/EVS system book v20 e31
Electrical installation

8 Diff-lock control switches

B1-22
1000
1010

08/06
1010
B2

10 A
GE007
B1

2630a 2630b 2630c 2630d 2630e


R007a R007b R007c R007d R007e
Electrical installation

A 5 A 5 A 5 A 5 A 5 A 5

1 0 1 0 1 0 1 0 1 0 1 0

GC012
GC008
GC007
GC010
GC011
GC009

B 1 7 B 1 7 B 1 7 B 1 7 B 1 7 B 1 7

2630

R007
R007
SP082
SP084
SP081
SP080
G4518
SP083
G4517

1 2 3 6 8 5 4 10 7 9
K008

SP082a

R007
2630

08
2630a
K051

SP082
SP084
SP081
SP080
G4518
SP083
G4517

1
10
K009
1 2
3 5 2 1 7 4 6
K003

DAF 7

SP082
SP084
SP081
SP080
G4518
SP083
G4517

1 1 1 1 1 1 1

GB028
GB029
GB024
GB023
GB026
GB027
GB025

2 2 2 2 2 2 2

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51

25093/00
HPVS/EVS system book v20 e31

B1-23
HPVS/EVS system book v20 e31
Electrical installation

9 Diff-lock indicator lamps

If one or more of the diff-locks is engaged, wire


G2408 of the diode block and the associated control
switch(es) are connected to earth, which causes the
diff-lock indicator lamp in the DIP to light as well.

B1-24
1000
1010

08/06
1010

A2

R005
1A

R005f R005e R005d R005c R005b


GE008

+ 1 1 1 1 1 1
A1

GB022
GD013
GD018
GD016
GD017
GD014
GD015
Electrical installation

- 2 2 2 2 2 2

R083
3408
3409
R080
R081
R005a
R005
R005

ES3600
GD003 4 3 6 1 2 12

ES3600a
1
2
K011

3409b
3409a

3
4
R083a
R083

G3408
5
6
3408a
R005

3408

7
8
R081a
7 R081

9
10

K011
R080a

09
R080

11
12
GD000
12-8
3409

10

ES3600
13
14
8 1 2 3 4 6

K003
15
16
K004

17
18
R080
R081
3408

ES3600
R083a
R083b
R083c
3409b
3409a

1 1 1 1 1 1 1 1 1

3408

G3408
D310
P
C34

GF013
GF008
GF009
GF010
GF017
GF016
GF012
GF011
GF018

DAF
5 13

K004
K034
2 2 2 2 2 2 2 2 2
G3408

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 5

25093/00
HPVS/EVS system book v20 e31

B1-25
HPVS/EVS system book v20 e31
Electrical installation

10 Tachograph and tachometer / 2nd gear


protection / Pressure switch for lift axle
/ PTO protection

2nd gear protection

Sensor GF002 is !tted on the transmission or the


transfer gearbox. This sender produces a square
wave voltage, the frequency of which is proportional
to the vehicle speed, which is sent via wire ES351
to speed switch GD001. This speed switch interrupts
the earth connection on wire ES350 at a variable fre-
quency, which causes the EVS unit to interrupt wire
SP30 by means of a relay.
Note: With an AS Tronic transmission the 2nd sensor
is connected to the Ginaf wiring via an extra wiring
harness.

Pressure switch, lift axle

If the lift axle is in the raised position and the load


exceeds the allowable weight, pressure switch GF001
activates and power is supplied to pin 12-10 of the
EVS unit via wire ES006. Depending on the speed,
the lift axle will be automatically lowered.

PTO protection

When the PTO is operated, voltage is provided to


pin 85 of relay GG011 via wire 4594, which inter-
rupts the power to proximity switch GE012. This
removes the voltage on pin 22-20 of the EVS unit. If
the speed is 0 (can be changed via a parameter), all
functions of the HPVS are ‘frozen’ and valves may be
deactivated so that during use of the PTO the HPVS
system cannot operate. After the PTO is disengaged,
the proximity switch receives power again. It reg-
isters the position of the tipping bed. Only once the
tipping bed has been completely lowered does the
proximity switch supply power to the EVS unit again
and, depending on the parameter setting (speed/
time), are the functions once again active.

B1-26
1000
1010
6

08/06
R1011a ES036
2

1010
R1011c R1011 K027 2

4594 B2 K006
P
GF001

5A
R1011
4D

GE002
2

K002
3
DAF B1 K020
1
6
ES006

R1011a

4594
Electrical installation

R1011
5

GE012
K027

85 30

R1011b
R1011c
1 3 2
107C 107C
ES006

K052
12 8
K017 GD003 3
DAF DAF

GG011
1 13

R1013
ES022
K006

11 1 21
86 87a

K001
20
3003
3502
ES006

R1013

ES022
R1012b
K001 R1011d

22-20 22-21 26-21 26-22 12-10

KD017 GG001 24V U2.8


6 A3
GD000

R1012
R1012
ES351

R1012a
11 1
26-10 26-8 26-5

10
GD003 GD003
14 12
1 1 ES351a

ES351
R1012b
R1012c
4 1 3 2
SP30
ES010

ES350a

K005
ES350
K001 8
2 3 1 4
K011

10
2
2
K015

GD001
ES010

K051

4 1 3 2 87 86
SP82

K058
GD032

1
N
GG022
K051

GF002 30 85
SP82

SP82a

9
K011

3 K008 K003
6 3
K051

8 8

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 4

25093/00
HPVS/EVS system book v20 e31

B1-27
HPVS/EVS system book v20 e31
Electrical installation

11 Power for E-MAS / Indicator lamp /


Buzzer / 2nd gear protection

B1-28
B1-29

25093/00 08/06
11

1010
1000
1
2
3

3
4

K008
5

12
9

2
6

2115 2115 2115


K008
7

K017 GD031
8

11
8

2
9

2009 2009 2009


K008
10

K017 GD025
11

B1

B2
5A
12

1
2010 1011 1011 R1011 1010
GE002
13

K017
4

2009
14

1011d

1011a
15

GG005
+

2008
16

GB036
1011e

2101 1011b
17

4
18

3
5

2100
19

GG006
20
21

30

1011c
87a
22

2115
23

86

85

19

2114a 2114
4
24

2101 K037
GG012
25

GD001
6

GF023
10

ES351 ES351a
3
26

K017
1

20

1011e
27

1011f 1011f 1011


2

K037
28

6-B 2114
29

GD026
12-B 2100
30

2-C 2008
31

GD003
32

12-A SP14 SP14 SP14b


15
6

2010 1-C
33

9-A SP15 SP15 SP15b


GD003
34

15-B 2002 2002


17
6
35

3-A 2015 2015


36

101C
DAF

9-B 3157 3157 3157


8
37

GD027

K017
38

107C
DAF

12-D 3502 3502


8
39

10A
2

1
40

1-A 1221 1221 1221


107C E062
41

4-A 1117a
10A
2

5-A 1117b
42

1117 1117
1-B 1117c
107C E051
43

2-B 1117d
(DAF)
44

1117e
1
45

2-A 5-D 2011 2011


8
46 47

18-B 6-D 2012 2012


10

3-B 15-C 2013 2013


16
48

K040
49
50

Electrical installation
HPVS/EVS system book v20 e31
HPVS/EVS system book v20 e31
Electrical installation

12 Valves for E-mas / Pressure sensors

B1-30
B1-31

25093/00 08/06
12

1010
1000
1
2
3
4
5
6
7
8
9
10
11
12

13

2026 2026 2026 13-B


13
14

14
1

2026 2027 2027 2027 14-B


15
16

GB033
17
18

15
19

2020 2020 2020 16-B


20

16
1

2
21

2020 2021 2021 2021 17-B


4

3
22

GB034
23
24
25

17

GD027

2022 2022 2022 10-B


26
27

18
1

2022 2023 2023 2023 11-B


28

GB035
29
30
31

2019a
32

_
P
GF020

10
out
33

2718 2718 2718 9-C


U

+
34

2016a
35
36
37
38

12
39

2019 2019 2019 3-D


_
P
GF021

11
40

out

2018 2018 2018 10-C


U
41

9
+

2016 2016 2016 4-D


42

K037
43
44
45
46 47
48

Electrical installation
HPVS/EVS system book v20 e31
HPVS/EVS system book v20 e31
Electrical installation

13 Angle sensors for E-MAS

B1-32
1000
1010

08/06
Electrical installation

GD027

4-C
14-C
3-C
13-C
1-D
12-C
2-D
11-C

PM1
PM1
PM1
PM2
PM3
PM3
PM3
PM4

1 2 3 4 5 6 7 8
K037

13
PM1
PM1
PM1
PM2
PM2
PM2
PM3
PM3
PM3
PM4
PM4
PM4

1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4

K050
K044
K049
K045

o o o o
90 90 90 90
U U U U
GD021 GD022 GD023 GD024

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

25093/00
HPVS/EVS system book v20 e31

B1-33
HPVS/EVS system book v20 e31
Electrical installation

B1-34
HPVS/EVS systeemboek v20 e31
Electrische installatie

Bijlage 2: Schema’s hydrauliek

B2-1
HPVS/EVS systeemboek v20 e31
Elektrische installatie

B2-2
© January 2007 GINAF Trucks b.v. OG0000070109
1 2 3 4 5 6 7 8 9 10

F
SNELVULAANSLUITING F

16x2.0

16x2.0

16x2.0

HPVS MANIFOLD
RETOURFILTER
MET BYPASS (3.5 BAR), - BLACK ANODIZED ALUMINIUM, 350 bar, 32 l/min.
B75=05 um DP 10x1.5 D1 - NG6-CONNECTION FOR STEERING VALVE
MP - G1/2": PP(2x)-TT(2x)-T1-T2
E MPEH - G3/8": BR-BL E

MEETPUNT EVS+HPVS DRUK

(OP DEKSEL PERSFILTER)


(TESTNIPPEL STD. NIET MONTEREN)

MEETPUNT POMPDRUK + REGELDRUK


DRUKSENSOR POMPDRUK
- G1/4": MP-D1-MBL-MBR
0.5 mm nulleiding
MP DP MPEH -SMORINGEN 1 en 2 MONTEREN NA SPOELEN
16x2.0
T
MP
AXIALE PLUNJERPOMP
A10VO/028-28bar

M
i=1.455xn-motor, max. 30 l/min
Pmax. 190bar
16x2.0 16x2.0 SLANG TBV FLOWMETING + SPOELEN SYSTEEM
16x2.0 PP
28x1.5 3.5 mm
PERSFILTER P
smoring 2x 0,7mm ZONDER BYPASS, 16x2.0 PP
0.3 mm B05=75
Line filter
SP12 without BYPASS
B30=75
16x2.0 POMPFLOWKLEP
10X1.5 S
D 22L/15L D

VUL_BELUCHTINGSFILTER PROPORTIONEEL POMPFLOW-UNIT 16x2.0 TT TT


30 um + 3 um
22L/15L

PP
16x2.0
28x1.5

SP10 SP11 SP8 SP9 SP31.1 SP6.1 SP31.2 SP6.2


Warning: Pipe length (suction, return and vent pipe) to the two reservoirs must be the same. PUMP UP FLOW OFF PUMP UP FLOW OFF QUICK-LOWERING SUPERSTAB.VALVE SUPERSTAB.VALVE
QUICK-LOWERING
left-rear left-rear right-rear right-rear left-rear left-rear right-rear
right-rear

1 Tridem: 1.50 mm 2 Tridem: 1.50 mm

VLOTTERSCHAKELAAR
POMPFLOW MANIFOLD

ART.NR.: XXXXXX MBL BL BR T1 T2


C
MBR C
UITVOERING: Pressure switch connection G1/4"
NO adjustable (setting 77bar)
Line filter Line filter Line filter Line filter
PLUG WITHOUT-BYPASS PLUG WITHOUT-BYPASS WITHOUT-BYPASS WITHOUT-BYPASS
B10=75 B10=75
- ZWART GEANODISEERD ALUMINIUM, 350 bar, 32 l/min. B10=75 B10=75
- SMORING 3.5 mm GEINTEGREERD (ALLEEN BIJ restriction 0,3mm
EERSTE BLOKKEN VERWIJDERBAAR) PRESSURE-SENSOR
10x1.5
- SMORING 0.5 mm IN T VERWIJDERBAAR (M10 INBUS) 10x1.5 16x2
PRESSURE-SENSOR
- G1/2": PP-P
16x2
16x2

- G1/4": T-S-MP-DP-MPEH 16x2


2nd axle right side
HPVS-CYL. 2nd axle left. 10x1.5 75x56x320
25x3

75x56x320

25x3
16x2
16x2
16x2

GINAF HYDR. ALR-CYLINDER


with reducing valve 1mm. in connection. ACCUM.

16x2 16x2
16x2 25x3
25x3

1.0L-PO=10bar
1.0L-PO=10bar 16x2 16x2 16x2
3rd axle right side
HPVS-CIL. 3rd axle left. 80x56x260
16x2
16x2

25x3
80x56x260
25x3

16x2
B B
16x2
25x3

16x2 25x3
16x2
25x3 1.0 L - P0=10 bar
1.0 L - P0=10 bar 16x2
4th axle right side
16x2

HPVS-CIL. 4th axle left. 16x2 80x56x260


16x2
80x56x260
16x2

16x2

WIJZ. OMSCHRIJVING WIJZIGING DATUM GET. GEC.


NR.
GET. B.v.Toorn. BLAD Deze tekening blijft het eigendom
van GINAF en mag zonder haar
GEC. GEZ. 1 schriftelijke toestemming, noch
geheel, noch gedeeltelijk
DATUM 14-03-2007 VAN gekopieerd of aan derden ter hand
gesteld of getoond worden.
1
A SCHAAL A
MAT. MAT. NR. PROJECTIE GINAF
OPM.

WARMTE/OPP. BEH. PASSINGEN RUIMHEID, VORM- MATEN IN


EN PLAATSTOL. VOLGENS ISO
MATERIAAL VLGS. 10027-1/2 MM
TITEL TEKENING NR. FORMAAT

schema,hydr-HPVS/EVS-V22 25703/00 A1
X5376
CAD SCHEMATIC
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6

GB
GB
1000 1000 GET.

1010 1010
05-10-2007
20-09-2007
DATUM

D 5A 3A 5A D
approach switch
GE012 GE011 GE010
GE002
Added for dump body indication light and buzzer
GINAF

GE012
R1014

R1014a

R1015
1 3
1 3 2

R1013
K052
1 3
D7/8:20

ES022b
Check light

ES022
load indication R3 (GG026) Check light
24V 21W 1 2 Dump body indication
ES022a 2 4 Vmax application
D7/8:21 4A
Overrule switch 3039 4
ES705a

R1013
approach switch 2 4
DAF

ES700
2 1
A1/2:2
C ES705 C
ES035c 3
ES706 ES706b
5 ES706a

ES022
1 3 A 7
16
22-20 R1 (GG024) 1 0
Brake deactivation
Pressure P P Air pressure GD000 R2 (GG025) switch
switch HPVS switch adjustable
0-150 bar (77 bar) 0-10 bar 26-18 26-17 16-9 2 5 B 5
15

V = 0 km/h 11 12
SP090b

4594
ES035
A1/2:5

13
1 0

ES708
3 1

B R4 (GG027) Description relays B

14 ES035a
SP090

R1 = Relay v=0
5 2 D993 C750 R2 = Relay Brake
C7 1 A1/2:1
2630

valve
DAF DAF
R3 = Relay vmax
R4 = Relay v=0

4594a
Dashboard light
1 2
ES035b

Overrule switch Brake valve


Updated schematic
Dump body indication added
OMSCHRIJVING

PTO protection
03
02
REV.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53
A A
LOCATIE

Deze tekening blijft het eigendom van GINAF en GET. G. de Bruin


mag
CAD SCHEMATIC zonder haar schriftelijke toestemming, noch geheel, GEC. GEZ.
noch gedeeltelijk gekopieerd of aan derden ter hand
gesteld of getoond worden DATUM 18-04-2007
TITEL: TEKENING NR. Formaat

Scheme, X5376 tipper security 25784/03 A3


KLASS.KODE:
and indication lights

1 2 3 4 5 6