VOLVO CONSTRUCTION EQUIPMENT
Service manual
BL70B
CONTENT 3 Electrical and Information Systems 3:1 Description and troubleshooting
Foreword This booklet is part of a complete service manual. Read the foreword in the service manual.
WARNING Always read the booklet Safety before proceeding.
PUB 20026874-A 2011.09
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Table of contents 30 GENERAL 300 Comprehensive info, electrical system Electrical system, work instructions ............................................................ 7 Electrical system, description ..................................................................... 8 Electronic control system, description ...................................................... 10 Vehicle control unit V-ECU, description .................................................... 12 Instrument control unit I-ECU, description ................................................ 13 Transmission control unit T-ECU, description .......................................... 14 CareTrack W-ECU, description ................................................................ 15 V-ECU, software functions ........................................................................ 16 Starter motor engagement ........................................................................ 16 Fuel shut-off .............................................................................................. 17 Air filter clogged ........................................................................................ 18 Engine coolant temperature ...................................................................... 19 Engine speed ............................................................................................ 21 Working lights ........................................................................................... 22 Direction indicators ................................................................................... 23 Hazard lights ............................................................................................. 24 Hour meter ................................................................................................ 25 Service light .............................................................................................. 26 Code lock (option) ..................................................................................... 27 Forward / Reverse / Neutral ...................................................................... 28 Forward activation .................................................................................. 28 Forward deactivation .............................................................................. 29 Reverse activation .................................................................................. 30 Reverse deactivation .............................................................................. 31 Neutral activation .................................................................................... 32 Differential lock ......................................................................................... 33 Limp-home operation ................................................................................ 34 Four–wheel drive ...................................................................................... 35 Loader lever lock ...................................................................................... 36 Transmission oil temperature ................................................................... 37 Parking brake ............................................................................................ 38 Seat belt .................................................................................................... 39 Hydraulic oil temperature .......................................................................... 40 Hydraulic pump flow regulation ................................................................. 41 Boom suspension system ......................................................................... 43 Stabilisers ................................................................................................. 44 Hydraulic attachment bracket, backhoe (option) ...................................... 45 Hydraulic attachment bracket, loader (option) .......................................... 46 V-ECU inputs and outputs ........................................................................ 47 I-ECU inputs and Outputs ......................................................................... 49 T-ECU, Inputs and outputs ....................................................................... 51 301 Software documents, complete vehicle Service mode, description ........................................................................ 54 Information display, general ...................................................................... 55 Anti-theft system (optional equipment) ................................................... 55 Entering service mode ............................................................................ 56 Exit service mode ................................................................................... 57 Service mode main display ..................................................................... 58 Diagram, information display .................................................................. 59 Information display, vehicle information (Vehicle information) .................. 60 Submenu Time to service (Time to service) ........................................... 61 Submenu Reset time (Reset time) .......................................................... 62 Submenu Product model (Product model) .............................................. 63 Submenu Set options (Set options) ........................................................ 64 Submenu Select options ......................................................................... 65 3
Submenu Tire size (Tire size) ................................................................. 67 Submenu Set tire size ............................................................................. 68 Submenu IECU part number (IECU part number) .................................. 69 Submenu VECU part number (VECU part number) ............................... 70 Information display, engine (Engine) ........................................................ 72 Submenu Engine speed (Engine speed) ................................................ 73 Submenu Fuel level (Fuel level) ............................................................. 74 Submenu Engine coolant temp ( Engine coolant temp) ......................... 75 Information display, hydraulics (Hydraulic) ............................................... 76 Submenu Hydraulic oil temp (Hydraulic oil temp) ................................... 77 Submenu 4in1 option (4in1) .................................................................... 78 Submenu Ext. dipper option (Ext. dipper) ............................................... 79 Submenu Auxiliary X3 option (Auxiliary X3) ........................................... 80 Information display, electrical system (Electrical system) ......................... 82 Submenu System voltage (System voltage) ........................................... 83 Submenu Fault codes (Fault codes) ....................................................... 84 Submenu fault codes list ......................................................................... 85 Submenu Clear fault codes (Clear fault codes) ...................................... 86 Clear fault codes (Clear fault codes) confirmation .................................. 87 Submenu Digital in/out VECU (Digital in/out VECU) .............................. 88 Digital input/output list VECU ................................................................. 89 Submenu Digital in/out IECU1 (Digital in/out IECU–1) ........................... 90 Digital input/output list IECU1 ................................................................ 91 Submenu Digital in/out IECU2 (Digital in/out IECU–2) ........................... 92 Digital input/output list IECU2 ................................................................ 93 Fault code list ............................................................................................ 94 V-ECU inputs and outputs ...................................................................... 100 I-ECU inputs and Outputs ....................................................................... 102 T-ECU, Inputs and outputs ..................................................................... 104 302 Faulttracing Troubleshooting, general ........................................................................ 106 Collection of basic data ........................................................................... 107 General ................................................................................................. 107 General information .............................................................................. 107 Description of malfunction or symptom ................................................. 107 Engine data ........................................................................................... 108 Power transmission, data ..................................................................... 108 Lead and connector checks .................................................................... 109 General ................................................................................................. 109 Connector and cable terminal checks ................................................... 109 Open circuit, check ............................................................................... 109 Short circuit to ground, check ............................................................... 110 Short circuit to voltage, check ............................................................... 110 Contact resistance and oxidation, check .............................................. 111 Pins and sleeves, cleaning ................................................................... 111 Electrical troubleshooting, Powershift transmission ................................ 113 Solenoids, checking resistance .............................................................. 114 Powershuttle transmission (standard) .................................................. 114 Solenoids, checking resistance .............................................................. 115 Powershift transmission (option) ........................................................... 115 Solenoids, checking resistance .............................................................. 117 Powershift transmission (option) ........................................................... 117 Wires, testing .......................................................................................... 119 Powershift transmission (option), checking gear shift modulation and forward/reverse solenoids .............................................................. 119 Gear selector switch, testing ................................................................... 121 Powershift transmission (option) ........................................................... 121 Loader lever, electrical measuring .......................................................... 122
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31 BATTERY 311 Battery Battery, description ................................................................................. 126 Battery, charging ..................................................................................... 127 Battery, storage ...................................................................................... 128 Batteries, replacing ................................................................................. 129 Battery, checking electrolyte ................................................................... 130
32 ALTERNATOR; CHARGE REGULATOR 320 General, common info about 321 - 322 Alternator, description ............................................................................. 131
33 STARTING SYSTEM 330 General, common info about 331 - 334 Starter motor, description ....................................................................... 133 333 Electric air pre-heater, excluding element Preheating, description ........................................................................... 134
35 LIGHTING 350 General, common info about 351 - 356 Lighting, description ................................................................................ 135
36 OTHER ELECTRICAL EQUIPMENT 367 Electronic standard components V-ECU, replacing .................................................................................... 137 Disassembly ......................................................................................... 137 Assembly .............................................................................................. 138 I-ECU, replacing ..................................................................................... 140 Disassembly I-ECU 1 (side panel) ........................................................ 140 Assembly I-ECU 1 (side panel) ............................................................. 141 I-ECU, replacing ..................................................................................... 142 Disassembly I-ECU 2 (front instrument panel) ..................................... 142 Assembly I-ECU 2 (front instrument panel) .......................................... 143 T-ECU, replacing .................................................................................... 144
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ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS 30 GENERAL 300 Comprehensive info, electrical system Electrical system, work instructions 1 Fully charged and otherwise satisfactory batteries must always be used when testing the electrical system. 2 Test the batteries with an acid tester and a cell tester. The battery disconnect switch should be turned off. 3 When fitting a battery, make sure that the battery is connected with the correct polarity. 4 When changing batteries connected in series, make sure they are of equal capacity, for example, 2 batteries of 105 Ah. The batteries should have the same age (same quality) as the charging current required to reach a certain voltage varies with battery age. 5 If a booster battery is required to start the engine, the instructions 191, Starting with booster batteries must be strictly followed. 6 Before any tests are performed on the alternator or regulator, check the batteries and electrical leads for faulty insulation, loose contacts and corrosion. Check the alternator belts. All possible faults described above must be corrected before starting electrical checks. 7 During all testing of alternating current equipment, "secure" connections must be used. One loose cable can destroy both the alternator and regulator. 8 Never disconnect the alternator leads while the engine is running. This could damage both the alternator and regulator. 9 If the current alternator output socket should be connected to the chassis, damage may occur to the alternator and regulator. 10 When removing or fitting components in the electrical system, the chassis connection should be interrupted or the battery disconnect switch should be turned off. 11 Before performing any electric welding on the machine or attachments connected to the machine, the chassis connection should be interrupted using the battery disconnect switch or by disconnecting the battery earth cable (chassis connection). Connect the welding unit as close as possible to the welding point.
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Electrical system, description 1
2
The machine has a 12 V electrical system and is as standard equipped with a single 12 V battery. As an option, two 12 V batteries can be used in parallel for increased capacity. The battery disconnect switch is located on the battery compartment hatch.
V1096584
Fig.1 battery compartment 1 battery 2 battery disconnect switch
All fuses and relays are located either in the battery compartment or on a printed circuit board in the cabin. The printed circuit board is located in the right hand console behind a cover.
V1094958
Fig.2 Right hand console with printed circuit board
The machine is equipped with an electronic control system that monitors and controls the machine’s functions. The electronic control system consists of several electronic control units (ECU): • V-ECU (vehicle electronic control unit) • I-ECU1 and I-ECU2 (instrument electronic control unit) • T-ECU (transmission electronic control unit) (Powershift option) • W-ECU (wireless electronic control unit) (Caretrack option) V-ECU, T-ECU and W-ECU are located behind the right hand console. I-ECU1 is integrated in the side instrument panel and IECU2 is integrated in the front instrument panel. The side instrument panel includes an additional information display, where machine and diagnostic informations can be viewed. Electrical components and wire harnesses are marked in accordance with the wiring diagram.
NOTICE For working on the electrical system, follow the instructions in section Electrical system, work instructions page 7.
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1
2
3
6 5 4
V1103658
Fig.3 electrical components 1 printed circuit board 2 starter motor 3 front instrument panel (I-ECU2) 4 alternator 5 side instrument panel with information display (I-ECU1) 6 V-ECU/T-ECU
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Electronic control system, description The machine electronics consist of control units which communicate via a CAN-BUS data line. Each control unit processes the values from the sensors and controls, and commands the components so that the required function is achieved. The machine electronics facilitate fault searching via a diagnosis system. On electrical faults, the driver receives a message in the information display. The electronic control system consists of the following ECUs: • V-ECU (vehicle electronic control unit) • I-ECU1 and I-ECU2 (instrument electronic control unit) • T-ECU (transmission electronic control unit) (Powershift option) • W-ECU (wireless electronic control unit) (Caretrack option) The vehicle control unit V-ECU is located under the right hand console and is the main control unit of the machine. It contains software for controlling components and handling information from sensors, operating controls and the other ECUs. The V-ECU is connected to the other control units via the databus. Instrument control units I-ECU1 and I-ECU2 are located in the front instrument panel (I-ECU2) and the side instrument panel (IECU1). They are containing software for presenting current operating information and displays, warning lamps and check lights. The control units are connected to the other control units via the databus. The transmission control unit T-ECU is located under the right hand console and contains software to control the Powershift transmission. The T-ECU is connected to the V-ECU via databus. CareTrack W-ECU (optional equipment) is located under the right hand console and contains software for information exchange via GSM/GPRS and satellite. The W-ECU is not connected to the other control units.
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1
Fuses
2
Lights
3
Sensors and Actuators
T-ECU
V-ECU
I-ECU1
I-ECU2
V1103661
Fig.4 electronic system, overview 1 fuses 2 lights 3 sensors and actuators
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Vehicle control unit V-ECU, description The vehicle control unit has superior machine-related functionality and contains the following functions. The vehicle control unit is located under the right hand console and is connected to the other control units via data bus for communication with the other control units. Functions • Monitoring fuel level V1047231
Fig.5 Vehicle control unit V-ECU
• Monitoring of starter motor engagement • Monitoring of system voltage • Monitoring of pressure, temperature, level and filter for transmission oil • Monitoring of level and temperature for hydraulic oil • Calculation of vehicle travel speed • Parking brake • Request for engine rpm and/or torque limitation • Transmission disengagement • Engagement of differential lock • Boom Suspension System • Attachment locking The connectors and input/output signals of the V-ECU can be checked with a special tool: 9990014 Break out harness 9998699 Adapter See also section V-ECU inputs and outputs page 47 for input/ output pin assignment of the V-ECU.
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Instrument control unit I-ECU, description The machine is equipped with two instrument control units. The instrument control units are integrated in the front instrument panel (I-ECU2) and in the side instrument panel (I-ECU1). Both I-ECUs are receiving informations from the data bus. This informations are processed and shown on gauges, control lights, warning lights and the information display. V1103672
Functions
Fig.6 front instrument panel
• Values for gear position, operating hours as well as status values for parking brake and warning messages are processed and result in a number of figures on the information panel • Special warnings, e.g., central warnings, low engine oil pressure are detected and the corresponding warning lights are activated V1103663
Fig.7 side instrument panel with information display
• Values for transmission oil temperature, coolant temperature engine and fuel level are shown on gauges • Setting of display alternatives and parameter alternatives for information panel • Storage and display of operating hours • PIN-code for theft protection via keypad The connectors and input/output signals of the I-ECU can be checked with a special tool: 88830170 Break out harness 9998699 Adapter See also section I-ECU inputs and Outputs page 49 for input/ output pin assignment of the I-ECUs.
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Transmission control unit T-ECU, description All functions of the Powershift transmission are controlled by the transmission control unit (T–ECU). The T–ECU is located under the right hand console and is connected to the other control units via data bus for communication. If the gear selector (SW4206) is switched to the 4th gear position, the automatic gear shifting mode is activated and the T–ECU starts to control the gear shifting. The fully automatic gear shifting mode is starting in the 2nd gear.
V1103686
1
2
3
4
Fig.8 T-ECU/pin assignment (from right to left) 1 2 3 4
pins 43 – 56 pins 15 – 28 pins 29 – 42 pins 1 – 14
The connectors and input/output signals of the T-ECU can be checked with a special tool: 88830171 Break out harness 88830182 Cable 9998699 Adapter See also sections T-ECU, Inputs and outputs page 51 for input/ output pin assignment and 432, T-ECU, replacing for changing the T-ECU.
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CareTrack W-ECU, description CareTrack is a telematic system making it possible for machine owners to remote-monitor machines from their offices. The CareTrack control unit is located under the right hand console.
2
1
CareTrack combines two systems, independent of each other; GPS and cell phone network, or via satellite. The GPS-receiver receives signals from satellites and calculates the position for the machine using triangulation. Data from the machine is transferred via the cell phone network or via satellite in areas where there is no coverage from cell phone networks.
V1053631
Fig.9 1 W-ECU 2 Satellite modem
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V-ECU, software functions The following describes the control functions that the software performs in the V-ECU. For every output function, one or more conditions must be fulfilled. These are described in the following tables, along with wire/circuit numbers and the expected signal types and signal levels for the related inputs. See also V-ECU inputs and outputs page 47.
Starter motor engagement This function controls the starter motor. Several conditions have to be fullfilled to crank the engine. Input signals Input
Wire
Signal
Condition/ Description
From ignition key switch SW3301 (position IV) to VECU pin 11
528
12 V
Ignition on + crank signal
From Alternator D+ to IECU1 pin 8
607
0V
Engine is not running
Internal conditions from VECU
-
-
Code lock OK At least 1 second has pasted since the last cranking deactivation Engine speed has been below 50 rpm for at least 2 seconds
From F/R lever SW4208 to VECU pin 32 (neutral position) (Powershuttle transmission)
504
0V
Forward or reverse gear not selected
503
0V
From F/R lever SW4205 (on left combi switch 504 FX1016) to VECU pin 32 (neutral position) 503 (Powershift option)
0V
From forward switch SW4229 (on loader joystick) to VECU pin 20
525
0V
From reverse switch SW4230 (on loader joystick) to VECU pin 27
537
0V
Output
Wire
Signal
Description
From VECU pin 31 to starter relay RE3301
601
12 V
Starter relay engages starter motor
From starter relay RE3301 to starter motor MO3301
600
12 V
0V
Output signals
The VECU will stop the starting impulse when: - the engine has started to run - the starting impulse has exceeded 30 seconds See sections 370, Wiring diagram SCH02 and 370, Wiring diagram SCH03 for wiring diagram of this function. See section Forward / Reverse / Neutral page 28 for additional informations about the forward/reverse levers and switches.
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Fuel shut-off This function controls the fuel supply to the engine. The fuel line is opened when the engine stop valve is energized by the ignition key. The fuel line is closed by the valve when the ignition key is switched off, or when the V-ECU deactivates the engine for safety reasons. Input signals Input
Wire
From ignition key switch SW3301 (position 528 IV) to V-ECU pin 11 If the code lock option is installed the entered pin code must be correct
Signal
Condition/ Description
12 V
Activation: When the ignition key is switched to position IV (Ignition on + crank signal) Deactivation: When ignition key is switched to position OFF or when V-ECU deactivates the valve for safety reasons
Output signals Output
Wire
Signal
Description
From V-ECU pin 45 to engine stop valve MA2307
605
12 V
Engine stop valve opens the fuel line to the engine
See sections 370, Wiring diagram SCH02 and 370, Wiring diagram SCH03 for wiring diagram of this function.
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Air filter clogged This function controls the engine air filter. If the air filter is clogged, a warning symbol is shown in the information display which has to be confirmed by pressing ESC. Input signals Input
Wire
Signal
Condition/ Description
From engine air filter clogging sensor SE2502 to I-ECU1 pin 2
612
12 V
Activation: When engine is running and the air filter clogged signal is active for more than 5 seconds Deactivation: When the warning message on the information display is confirmed by pressing ESC
Output
Wire
Signal
Description
Internal signal
-
-
Information symbol is shown in the information display
Output signals
V1093156
See section 370, Wiring diagram SCH03 for wiring diagram of this function.
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Engine coolant temperature The engine coolant temperature is controlled by the V-ECU. The current temperature information is given by the coolant temperature sensor. Input signals Input
Wire
Signal
Condition/ Description
From engine coolant temperature sensor SE2706 to I-ECU1 pin 22
608
V
Voltage is depending on measured coolant temperature
Output
Wire
Signal
Description
Internal signal
-
Output signals Engine coolant temperature is monitored on the side panel (see table below)
V1092568
Internal signal
-
Engine coolant temperature warning
V1096363
Activation: When the engine coolant temperature is above 101°C (213.8 °F) for more than 30 seconds Deactivation: When engine coolant temperature is going below 98°C (208.4 °F)
V1092568
Fig.10
Arrow position (%)
Engine coolant temperature (°C)
0.0
0
50.0
75
50.0
92
55.0
94
60.0
96
95.0
98
98.0
100
99.0
101
100.0
130
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Engine coolant temperature (°C)
Output voltage to I-ECU1
Engine coolant temperature (°C)
Output Voltage to I-ECU1
-40
4.96
65
1.90
-35
4.94
70
1.70
-30
4.92
75
1.52
-25
4.90
80
1.36
-20
4.86
85
1.21
-15
4.81
90
1.07
-10
4.75
95
0.95
-5
4.67
100
0.84
0
4.57
105
0.76
5
4.46
110
0.68
10
4.32
115
0.60
15
4.16
120
0.53
20
3.98
125
0.48
25
3.77
130
0.43
30
3.55
135
0.38
35
3.32
140
0.35
40
3.08
145
0.31
45
2.83
150
0.28
50
2.58
155
0.25
55
2.35
160
0.24
60
2.12 See section 370, Wiring diagram SCH03 for wiring diagram of this function.
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Engine speed The engine speed is calculated by the alternator speed and the ratio between the alternator and the crankshaft pulley. s=60f/r s=engine speed f=rounds per second (rps) r=ratio alternator/crankshaft pulley Input signals Input
Wire
Signal
Condition/ Description
From alternator W to I-ECU1 pin 16
606
12 V
Alternator W=0 V (engine is not running) Alternator W=AC signal (engine is running)
Output
Wire
Signal
Description
I-ECU1 (internal)
-
-
Engine speed information in the information display
From I-ECU1 to V-ECU
CAN J1939
Output signals
Lamp on front panel is alight when the differential lock is engaged
See section 370, Wiring diagram SCH02 (alternator) and 370, Wiring diagram SCH03 (cable 606 to I-ECU1) for wiring diagram of this function.
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Working lights This function controls the front and rear working lights. The standard machine is equipped with two front and two rear working lights. As an option the machine can be equipped with two additional front and rear working lights. When the optional working lights are installed, the switches for front and rear working lights are three-position switches. Switch in upper position = Off Switch in middle position = two lights On Switch in lower position = four lights On The switch for lights must be in upper or middle position to enable the working lights switches. Input signals Input
Wire
Signal
Condition/ Description
Front working lights switch SW3504
Activation: When front working lights switch is pressed in position ON Deactivation: When front working lights switch is pressed in position OFF
Rear working lights switch SW3505
Activation: When rear working lights switch is pressed in position ON Deactivation: When rear working lights switch is pressed in position OFF
Lights switch SW3501/RE3507
Condition: The lights switch must be in upper or middle position to enable the working lights switches.
Output signals Output
Wire
Signal
Description
Front working lights switch SW3504, position: two lights ON
708
12 V
Left and right front working lights (LA3521 and LA3522)
Front working lights switch SW3504, position: four lights ON (option)
708
12 V
Left and right front working lights (LA3521 and LA3522)
707
12 V
Left and right front working lights (LA3523 and LA3524) (option)
Rear working lights switch SW3505, position: two lights ON
712
12 V
Left and right rear working lights (LA3525 and LA3526)
Rear working lights switch SW3505, position: four lights ON
712
12 V
Left and right rear working lights (LA3525 and LA3526)
711
12 V
Left and right rear working lights (LA3527 and LA3528) (option)
See section 370, Wiring diagram SCH13 for wiring diagram of this function.
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Direction indicators This function controls the direction indicators. Input signals Input
Wire
Signal
Direction indicator switch SW3605 (on right combi switch FX1003) Flasher Relay RF3601
Condition/ Description Activation: Direction indicator switch LEFT ON Deactivation: Direction indicator switch OFF Activation: Direction indicator switch RIGHT ON Deactivation: Direction indicator switch OFF
Output signals Output
Wire
Signal
Description
Direction indicator switch SW3605 (on right combi switch FX1003)
718
12 V
Direction indicators front left LA3602 and rear left LA3606 I-ECU2 pin 8 (direction indicator left, front panel)
719
12 V
Direction indicators front right LA3603 and rear right LA3607 I-ECU2 pin 15 (direction indicator right, front panel)
See section 370, Wiring diagram SCH14 for wiring diagram of this function.
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Hazard lights This function controls the hazard lights. On machines with code lock (option), the hazard lights will flash if the start key is turned without first entering the correct code. Input signals Input
Wire
Signal
Hazard lights switch SW3606 Flasher Relay RF3601
Condition/ Description Activation: Hazard lights switch pressed in position ON Deactivation: Hazard lights switch pressed in position OFF
Output signals Output
Wire
Signal
Description
Hazard lights switch SW3606
718
12 V
Direction indicators front left LA3602 and rear left LA3606 I-ECU2 pin 8 (direction indicator left, front panel)
719
12 V
Direction indicators front right LA3603 and rear right LA3607 I-ECU2 pin 15 (direction indicator right, front panel)
See section 370, Wiring diagram SCH14 for wiring diagram of this function.
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Hour meter This is an internal counter that is incremented when the engine is running. The store value is used to trigger the service light and for diagnostic functions. Input signals Input
Wire
Signal
Condition/ Description
From Alternator D+ to I-ECU1 pin 8
607
12 V
Alternator D+ = 0 V (engine not running) D+ up to 14 V (engine is running)
Output
Wire
Signal
Description
Internal signal
CAN J1939
Output signals The working hours of the machine are displayed in the information display (total and daily)
00455,0h 455,0h V1077635
The machine hours left to next service are also shown in the information display
250 h V1077636
See section 370, Wiring diagram SCH02 (alternator) and 370, Wiring diagram SCH03 (cable 607 to I-ECU1) for wiring diagram of this function.
25
Service light This function controls the service warning on the information display, which alerts the operator after every 500 working hours. The service warning has to be confirmed with the ESC-key. The time left to next service can be reset in the service mode of the information display. See section Information display, vehicle information (Vehicle information) page 60. Input signals Input
Wire
Signal
Internal signal from hour meter, see section CAN J1939
300, Hour meter
Condition/ Description The service warning appears every 500 hours Starting at 50 hours left to next service the service warning appears every 10 hours After 0 hours left to next service the service warning appears every time the machine is started
Output signals Output
Wire
Signal
Internal signal
CAN J1939
Description The service warning is displayed in the information display
30 h V1093159
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Code lock (option) The code lock is an optional function that disables the starter relay function unless a correct code is entered. The machine can´t be started without entering the correct code. The code has not to be entered each time the machine is started, the pin code will remain active for a configurable time after stopping the engine. After too many incorrect pin code entries, the machine will be locked. There are three different pin code levels: 1 Secondary pin code level (customer pin code) 2 Primary pin code level (supervisor pin code) 3 Recovery pin code (needs to be generated when the machine is locked due incorrect pin code entries) Input signals Input
Wire
Keypad on information display
-
Signal
Condition/ Description When entered pin code is correct, machine can be started
Output signals Output
Wire
Internal signal V-ECU
-
Signal
Description Code lock OK
27
Forward / Reverse / Neutral This function controls the forward/reverse drive mode of the transmission. The rotation direction of the transmission output shaft is controlled by the forward and reverse valves. The Forward/Reverse/Neutral functions can be activated with the F/R lever on the steering column, or by the push buttons on the loader joystick. The push buttons on the loader joystick can only be used, if the F/R lever is in neutral position and the forward/ reverse joystick authorisation switch is activated. If the parking brake is engaged the activation of forward/reverse mode is not possible. For further details see section Parking brake page 38. The transmission disconnect switch is used to increase the loader bucket power, temporarily. When depressing the transmission disconnect switch, the transmission is reconnected with the gear/ direction that has been selected before.
Forward activation Input signals Input
Wire
From F/R lever SW4208 to V-ECU pin 32 (if 504 forward is selected) (Powershuttle transmission)
Signal
Condition/ Description
12 V
Enable forward drive The F/R lever has priority to the forward switch on the loader lever
From F/R lever SW4205 (on left combi switch FX1016) to V-ECU pin 32 (if forward is selected) (Powershift option) From forward switch SW4229 (on loader joystick) to V-ECU pin 20
525
12 V
Enable forward drive
From forward/reverse joystick authorisation switch SW4232 to I-ECU1 pin 6
500
12 V
loader joystick button can be used if: - F/R lever is in neutral position - joystick authorisation switch is activated
-
Forward gear can only be enabled, if the parking brake is not activated
Signal
Description
12 V
Forward drive enabled in transmission
Internal condition from V-ECU: parking brake not activated Output signals Output
Wire
From V-ECU pin 21 to forward gear solenoid 509 MA4221 (Powershuttle transmission) From V-ECU pin 21 to T-ECU pin 18 (Powershift option) From T-ECU pin 3 to PWM4213 forward gear 520 proportional valve (Powershift option) Internal signal to I-ECU2
28
12 V
CAN J1939
Lamp on front panel is alight when forward drive is engaged
Forward deactivation Input signals Input
Wire
From F/R lever SW4208 to V-ECU pin 32 (if 504 forward is not selected) (Powershuttle transmission)
Signal
Condition/ Description
0V
Disable forward drive
From F/R lever SW4205 (on left combi switch FX1016) to V-ECU pin 32 (if forward is not selected) (Powershift option) From F/R lever SW4208 to V-ECU pin 22 (if 503 reverse is selected) (Powershuttle transmission)
12 V
From F/R lever SW4205 (on left combi switch FX1016) to V-ECU pin 22 (if reverse is selected) (Powershift option) From transmission disconnect switch SW4226 on gear shift lever (Powershuttle transmission) to I-ECU2 pin 14
501
12 V
From transmission disconnect switch 541 SW4231 on loader joystick to V-ECU pin 19
12 V
Disable forward drive
From reverse switch SW4230 (on loader joystick) to V-ECU pin 27
527
12 V
From neutral switch SW4228 (on loader joystick) to V-ECU pin 23
526
12 V
loader joystick buttons can be used if: - F/R lever is in neutral position - joystick authorisation switch is activated
From forward/reverse joystick authorisation switch SW4232 to I-ECU1 pin 6
500
12 V
Wire
Signal
Description
0V
Forward drive disabled in transmission
Output signals Output
From V-ECU pin 21 to forward gear solenoid 509 MA4221 (Powershuttle transmission) From V-ECU pin 21 to T-ECU pin 18 (Powershift option) From T-ECU pin 3 to PWM4213 forward gear 520 proportional valve (Powershift option)
0V
29
Reverse activation Input signals Input
Wire
From F/R lever SW4208 to V-ECU pin 22 (if 503 reverse is selected) (Powershuttle transmission)
Signal
Condition/ Description
12 V
Enable reverse drive The F/R lever has priority to the reverse switch on the loader lever
From F/R lever SW4205 (on left combi switch FX1016) to V-ECU pin 22 (if reverse is selected) (Powershift option) From reverse switch SW4230 (on loader joystick) to V-ECU pin 27
527
12 V
Enable reverse drive
From forward/reverse joystick authorisation switch SW4232 to I-ECU1 pin 6
500
12 V
loader joystick button can be used if: - F/R lever is in neutral position - joystick authorisation switch is activated
-
Reverse gear can only be enabled, if the parking brake is not activated
Signal
Description
12 V
Reverse drive enabled in transmission
Internal condition from V-ECU: parking brake not activated Output signals Output
Wire
From V-ECU pin 25 to reverse gear solenoid 510 MA4220 (Powershuttle transmission) From V-ECU pin 25 to T-ECU pin 46 (Powershift option) From T-ECU pin 4 to PWM4214 reverse gear 522 proportional valve (Powershift option)
12 V
From V-ECU pin 25 to reversing alarm SA3604
510
12 V
Internal signal to I-ECU2
CAN J1939
30
Activate reversing alarm Lamp on front panel is alight when reverse drive is engaged
Reverse deactivation Input signals Input
Wire
From F/R lever SW4208 to V-ECU pin 32 (if 504 forward is selected) (Powershuttle transmission)
Signal
Condition/ Description
12 V
Disable reverse drive
From F/R lever SW4205 (on left combi switch FX1016) to V-ECU pin 32 (if forward is selected) (Powershift option) From F/R lever SW4208 to V-ECU pin 22 (if 503 reverse is not selected) (Powershuttle transmission)
0V
From F/R lever SW4205 (on left combi switch FX1016) to V-ECU pin 22 (if reverse is not selected) (Powershift option) From transmission disconnect switch SW4226 on gear shift lever (Powershuttle transmission) to I-ECU2 pin 14
501
12 V
From transmission disconnect switch 541 SW4231 on loader joystick to V-ECU pin 19
12 V
Disable reverse drive
From forward switch SW4229 (on loader joystick) to V-ECU pin 20
525
12 V
From neutral switch SW4228 (on loader joystick) to V-ECU pin 23
526
12 V
loader joystick buttons can be used if: - F/R lever is in neutral position - joystick authorisation switch is activated
From forward/reverse joystick authorisation switch SW4232 to I-ECU1 pin 6
500
12 V
Wire
Signal
Description
0V
Reverse drive disabled in transmission
Output signals Output
From V-ECU pin 25 to reverse gear solenoid 510 MA4220 (Powershuttle transmission) From V-ECU pin 25 to T-ECU pin 46 (Powershift option) From T-ECU pin 4 to PWM4214 reverse gear 522 proportional valve (Powershift option)
0V
From V-ECU pin 25 to reversing alarm SA3604
0V
510
Deactivate reversing alarm
31
Neutral activation Input signals Input
Wire
From F/R lever SW4208 to V-ECU pin 32 (if 504 forward is not selected) (Powershuttle transmission)
Signal
Condition/ Description
0V
Disable forward/reverse drive
From F/R lever SW4205 (on left combi switch FX1016) to V-ECU pin 32 (if forward is not selected) (Powershift option) From F/R lever SW4208 to V-ECU pin 22 (if 503 reverse is not selected) (Powershuttle transmission)
0V
From F/R lever SW4205 (on left combi switch FX1016) to V-ECU pin 22 (if reverse is not selected) (Powershift option) From neutral switch SW4228 (on loader joystick) to V-ECU pin 23
526
12 V
Disable forward/reverse drive
From forward/reverse joystick authorisation switch SW4232 to I-ECU1 pin 6
500
12 V
Neutral switch on loader joystick can be used if: - F/R lever is in neutral position - joystick authorisation switch is activated
Wire
Signal
Description
0V
Forward drive disabled in transmission
Output signals Output
From V-ECU pin 21 to forward gear solenoid 509 MA4221 (Powershuttle transmission) From V-ECU pin 21 to T-ECU pin 18 (Powershift option) From T-ECU pin 3 to PWM4213 forward gear 520 proportional valve (Powershift option)
0V
From V-ECU pin 25 to reverse gear solenoid 510 MA4220 (Powershuttle transmission)
0V
Reverse drive disabled in transmission
From V-ECU pin 25 to T-ECU pin 46 (Powershift option) From T-ECU pin 4 to PWM4214 reverse gear 522 proportional valve (Powershift option)
0V
From V-ECU pin 25 to reversing alarm SA3604
0V
510
Deactivate reversing alarm
See section 370, Wiring diagram SCH10 for wiring diagram of the switches on the loader joystick and the forward/reverse joystick authorisation switch. See section 370, Wiring diagram SCH11 for wiring diagram of the F/R lever and the forward/reverse valves (Powershift option). See section 370, Wiring diagram SCH12 for wiring diagram of the F/R lever, the forward/reverse valves and the transmission disconnect switch (Powershuttle transmission) .
32
Differential lock This function controls the differential lock on the rear axle and the indicator for the differential lock. Input signals Input
Wire
Signal
Condition/ Description
From differential lock switch SW4601 to VECU pin 28
513
12 V
Activation: When differential lock switch is pressed and vehicle speed is below 6 km/h (3.72 mph) Deactivation: When differential lock switch is depressed or machine speed is above 12 km/h (7.45 mph)
Wire
Signal
Description
12 V
Differential lock valve engages the differential lock in the rear axle
Output signals Output
From V-ECU pin 09 to differential lock valve 512 MA4601 Internal signal to I-ECU1
CAN J1939
Lamp on front panel is alight when the differential lock is engaged
See section 370, Wiring diagram SCH09 for wiring diagram of this function.
33
Limp-home operation In the event of a Powershift transmission fault, the Limp-home mode will be activated by the T-ECU. Depending on the transmission fault the Limp-home mode will allow driving in the first or second gear. In case of a transmission failure a warning signal illuminates in the information display.
V 1093 573
NOTICE Operation with activated Limp-home mode is only allowed to move the machine to the nearest service location and it is not allowed to drive the machine on public roads. Defective component
Activated gear
Gear selector 1/3 gear (MA4232)
1st gear
Proportional valve, gear shifting 1/3 (PWM4221) Gear selector 2/4 gear (MA4233) Proportional valve, gear shifting 2/4 (PWM4222)
34
2nd gear
Four–wheel drive This function controls the 4WD valve on the transmission and the indicator for the 4WD. Input signals Input
Wire
Signal
Condition/ Description
4WD switch SW4401 to I-ECU1 pin 10
515
0V
Activation: When 4WD switch is switched to position ON and vehicle speed is below 10 km/h (6.2 mph) Deactivation: When 4WD switch is switched to position OFF or when 4WD switch is in position ON and vehicle speed goes above 20 km/h (12.4 mph)
Brake switches SW5503 and SW5504 to IECU1 pin 15
720
12 V
Activation: Powershuttle: When the brake pedals are pressed and the vehicle speed is above 20 km/h (12.4 mph) Powershift (option): When the brake pedals are pressed and the vehicle speed is above 10 km/h (6.2 mph) Deactivation: When the brake pedals are depressed
Powershuttle: Transmission speed sensor SE4307 to V-ECU pin 3
531
up to 1kHz
See above
Powershift (option): Transmission speed sensor SE4307 to T-ECU pin 53
511
Output signals Output
Wire
Signal
Description
From V-ECU pin 33 to 4WD valve MA4409
541
0V
4WD valve activates the 4WD shaft in transmission
I-ECU1
Internal
Lamp on front panel is alight when 4WD is engaged
See section 370, Wiring diagram SCH09 for wiring diagram of this function. See section 370, Wiring diagram SCH15 for wiring diagram of the brake pedals. See sections 370, Wiring diagram SCH12 (Powershuttle) and 370, Wiring diagram SCH11 (Powershift) for wiring diagram of the transmission speed sensor.
35
Loader lever lock This function enables/disables all switches and loader controls on the loader lever. For safety reasons the loader lever controls have to be disabled when travelling on public roads. Input signals Input
Wire
Signal
Condition/ Description
From forward/reverse joystick authorisation switch SW4232 to I-ECU1 pin 6
500
12 V
Activation:When authorisation switch is pressed Deactivation: When authorisation switch is depressed
Output
Wire
Signal
Description
Internal signal to V-ECU
CAN J1939
Output signals V-ECU enables/disables all switches and loader controls on the loader lever
See section 370, Wiring diagram SCH10 for wiring diagram of this function.
36
Transmission oil temperature The transmission oil temperature information is given by the transmission oil temperature switch. When the transmission temperature is to high, a warning symbol is shown to the driver. Input signals Input
Wire
Signal
Condition/ Description
From transmission oil temperature switch SE4202 to I-ECU2 pin 10 (Powershuttle standard)
505
12 V
From transmission oil temperature switch 533 SE4202 to T-ECU pin 43 (Powershift option)
12 V
Activation: When the transmission oil temperature is above 115 °C (239 °F) Deactivation: When transmission oil temperature is going below 115 °C (239 °F)
Output signals Output Internal signal I-ECU2 (Powershuttle standard) Internal signal from T-ECU to I-ECU2 (Powershift option)
Wire
Signal
Description High transmission oil temperature: - internal buzzer sounds - transmission oil temperature warning is shown in the information display
V1104616
See section 370, Wiring diagram SCH12 for wiring diagram of this function if your machine is equipped with Powershuttle transmission (standard). See section 370, Wiring diagram SCH11 for wiring diagram of this function if your machine is equipped with Powershift transmission (option).
37
Parking brake The parking brake is operated mechanically. A switch included in the parking brake lever, sends information about the parking brake status to the ECU. If the parking brake is activated a symbol is shown in the front instrument panel and the forward/reverse drive can´t be enabled. Input signals Input
Wire
Signal
Condition/ Description
From parking brake switch SW5501 to IECU1 pin 9
502
12V
Activation: If parking brake is engaged Deactivation: If parking brake is disengaged
Output
Wire
Signal
Description
I-ECU1
Internal
Output signals Lamp on front panel is alight when the parking brake is activated
V1085792
Internal signal to V-ECU
CAN J1939
Internal condition V-ECU: parking brake activated Forward/reverse drive can´t be enabled Internal condition V-ECU: parking brake not activated Forward/reverse drive can be enabled
See section 370, Wiring diagram SCH15 for wiring diagram of this function.
38
Seat belt This function controls the seat belt lock. A warning symbol is shown in the front display when the engine is running and the seat belt is not fastenend. No hydraulic functions are limited if the seat belt is not fastenend. Input signals Input
Wire
From seat belt sensor SE8501 to I-ECU1 pin 433 4
Signal
Condition/ Description
12 V
When seat belt is fastened
Signal
Description
Output signals Output
Wire
Internal signal to I-ECU2
CAN J1939
A warning symbol is shown in the front display when the engine is running and the seat belt is not fastenend
See section 370, Wiring diagram SCH03 for wiring diagram of this function.
39
Hydraulic oil temperature The hydraulic oil temperature information is given by the hydraulic oil temperature sensor. The current temperature information is controlled and monitored by the V-ECU. Input signals Input
Wire
Signal
Condition/ Description
From hydraulic oil temperature sensor SE9105 to V-ECU pin 4
424
V
Voltage is depending on measured coolant temperature
Output
Wire
Signal
Description
Internal signal from V-ECU to I-ECU1
CAN J1939
Output signals High hydraulic oil temperature: - internal buzzer sounds - hydraulic oil temperature warning is shown in the information display
V1093 195
Activation: When the hydraulic oil temperature is above 97°C (206.6 °F) Deactivation: When hydraulic oil temperature is going below 94°C (201.2 °F) Internal signal from V-ECU to I-ECU1
CAN J1939
Low hydraulic oil temperature: - internal buzzer sounds 4 times - hydraulic oil temperature check symbol is shown in the information display
V1093166
Activation: When the hydraulic oil temperature is below 10°C (50 °F) Deactivation: When hydraulic oil temperature is going above 10°C (50 °F)
Hydraulic oil temperature (°C)
Output voltage to V-ECU
Hydraulic oil temperature (°C)
Output voltage to V-ECU
97
0.78
> 10
4.14
94
0.82
10
4.15
See section 370, Wiring diagram SCH07 for wiring diagram of this function.
40
Hydraulic pump flow regulation This function decreases the oil flow of the hydraulic pump when roading and/or if the hydraulic oil is overheated. Input signals Input
Wire
From forward/reverse lever SW4208, 503 steering column (Powershuttle transmission) or from forward/reverse lever SW4205, steering column (Powershift option) to VECU pin 22 (if reverse is selected)
Signal
Condition/ Description
12 V
Activation: When forward or reverse gear is selected Deactivation: When the transmission is in neutral position
From forward/reverse lever SW4208, 504 steering column (Powershuttle transmission) or from forward/reverse lever SW4205, steering column (Powershift option) to VECU pin 32 (if forward is selected) From forward switch SW4229 (on loader joystick) to V-ECU pin 20 (if forward is selected)
525
From reverse switch SW4230 (on loader joystick) to V-ECU pin 27 (if reverse is selected)
527
From hydraulic oil temperature sensor SE9105 to V-ECU pin 4
424
V
Voltage is depending on measured oil temperature Activation: When hydraulic oil temperature is above 95 °C (203 °F) Deactivation: When hydraulic oil temperature is below 85 °C (185 °F)
From engine coolant temperature sensor SE2706 to I-ECU1 pin 22
608
V
Voltage is depending on measured coolant temperature Activation: When engine coolant temperature is above 98 °C (208.4 °F) Deactivation: When engine coolant temperature is below 95 °C (203 °F)
Engine speed information from V-ECU Internal information Activation: See section Engine speed page 21 for further When engine speed is below 1200 rpm informations Deactivation: When engine speed is above 1050 rpm Output signals Output
Wire
From V-ECU pin 29 to power mode solenoid 434 MA9116
Signal
Description
12 V
Close power mode solenoid, loader mode (30 kW) activated
0V
Open power mode solenoid, excavator mode (46 kW) activated
See section 370, Wiring diagram SCH11 for wiring diagram of the forward/reverse lever.
41
See section 370, Wiring diagram SCH10 for wiring diagram of the forward/reverse switches on the loader joystick. See section 370, Wiring diagram SCH07 for wiring diagram of the hydraulic oil temperature sensor. See section 370, Wiring diagram SCH03 for wiring diagram of the engine coolant temperature sensor. See section 370, Wiring diagram SCH06 for wiring diagram of the power mode solenoid.
42
Boom suspension system This function controls the boom suspension system (BSS). Boom suspension can only be activated if the vehicle speed is above 7km/h and the craning mode is disabled. The boom suspension can only be activated when the engine is running. Boom suspension will be deactived when stopping the engine. Input signals Input
Wire
Signal
Condition/ Description
From BSS switch SW9148 to V-ECU pin 15 406
12 V
Powershuttle: Transmission speed sensor SE4307 to V-ECU pin 3
531
up to 1kHz
Powershift (option): Transmission speed sensor SE4307 to T-ECU pin 53
511
Activation: When BSS switch is switched to position ON and vehicle speed is above 7 km/h (4.3 mph) and craning switch is in position OFF Deactivation: When BSS switch is switched to position OFF or when machine speed is below 5 km/ h (3.1 mph) or when the craning switch is switches to position ON
From craning switch SW9128 to V-ECU pin 468 24
0V
Output signals Output
Wire
Signal
Description
From V-ECU pin 46 to boom suspension relay RE9102
403
12 V
open boom suspension vales
From boom suspension relay RE9102 to boom suspension solenoids MA9103 and MA9114
404
12 V
Internal signal to I-ECU1
CAN J1939
Lamp on front panel is alight when the boom suspension is activated
V10 93016
See section 370, Wiring diagram SCH06 for wiring diagram of this function.
43
Stabilisers This function controls the position of the stabilisers. If both stabilisers are not retracted completely, an information symbol is shown in the information display, when activating forward/reverse gear. Input signals Input
Wire
Signal
Condition/ Description
From left stabiliser switch SW9155 and right 411 and stabiliser switch SW9156 to I-ECU1 pin 14 412
0V
From F/R lever SW4208 to V-ECU pin 32 (neutral position) (Powershuttle transmission)
504
12 V
503
12 V
From F/R lever SW4205 (on left combi switch 504 FX1016) to V-ECU pin 32 (neutral position) 503 (Powershift option)
12 V
Activation: When one or both stabiliser(s) is/are not retracted completely and forward or reverse gear is selected Deactivation: When both stabilisers are retracted completely or the transmission is put in neutral position
From forward switch SW4229 (on loader joystick) to V-ECU pin 20
525
12 V
From reverse switch SW4230 (on loader joystick) to V-ECU pin 27
537
12 V
Output
Wire
Signal
Description
Internal signal
-
-
Information symbol is shown in the information display
12 V
Output signals
V 10931 97
See section 370, Wiring diagram SCH09 for wiring diagram of this function.
44
Hydraulic attachment bracket, backhoe (option) This function controls the hydraulic attachment bracket of the backhoe arm. A warning symbol on the information display, a buzzer signal and a red illuminated quick attach switch are informing the operator that the attachment bracket is opened. When the attachment bracket is closed again, the operator has to confirm a message in the information display by pressing the ESC key. Input signals Input
Wire
From quick attach switch SW9104 to V-ECU 410 pin 30
Signal
Condition/ Description
12 V
Activation: When the red safety catch is lifted up and the switch is depressed Deactivation: When the switch is released
Output signals Output
Wire
Signal
Description
From V-ECU pin 5 to quick attach switch SW9104
436
12 V
The solenoid opens the quick attach bracket
From quick attach switch SW9104 to quick attach solenoid MA9109
409
12 V
Internal signal to I-ECU1
CAN J1939
- quick attach switch is illuminated red - internal buzzer sounds - a warning signal is shown in the information display
V1077640
When the attachment bracket is closed again, the operator has to confirm the following message in the information display by pressing the ESC key.
V1093157
See section 370, Wiring diagram SCH08 for wiring diagram of this function.
45
Hydraulic attachment bracket, loader (option) This function controls the hydraulic attachment bracket of the loader unit. A warning symbol on the information display, a buzzer signal and a red illuminated quick attach switch are informing the operator that the attachment bracket is opened. When the attachment bracket is closed again, the operator has to confirm a message in the information display by pressing the ESC key. Input signals Input
Wire
From quick attach switch SW9105 to V-ECU 408 pin 31
Signal
Condition/ Description
12 V
Activation: When the red safety catch is lifted up and the switch is depressed Deactivation: When the switch is released
Output signals Output
Wire
Signal
Description
From V-ECU pin 41 to quick attach switch SW9105
435
12 V
The solenoid opens the quick attach bracket
From quick attach switch SW9105 to quick attach solenoid MA9191
407
12 V
Internal signal to I-ECU1
CAN J1939
- quick attach switch is illuminated red - internal buzzer sounds - a warning signal is shown in the information display
V10931 98
When the attachment bracket is closed again, the operator has to confirm the following message in the information display by pressing the ESC key.
V1093160
See section 370, Wiring diagram SCH08 for wiring diagram of this function.
46
V-ECU inputs and outputs Pin number
On condition
Description
Component
1
12V = on
preheat relay
RE2501
2
N/A
3
see component
gearbox speed sensor
SE4307
4
see component
hydraulic oil temperature sensor
SE9105
5
0V = on
excavator quick attachment, unlocking valve
MA9183
6
see component
X3 roller switch
SW9161
7
see component
X1 primary roller switch (4in1 bucket)
SW9113
8
see component
X1 primary roller switch (extendable dipper)
SW9114
9
12V = on
differential lock valve
MA4601
10
12V = on
wiper intermittent switch
SW3602
11
12V = on
Ignition key switch, position IV (50)
SW3301
12
N/A
13
12V = on
wiper intermittent relay
RE3601
14
12V = on
Button hold function
SW9129
15
12V = on
BSS (boom suspension) switch
SW9148
16
12V = on
air conditioning switch
SW8701
17
12V = on
air conditioning compressor
MO8701
18
12V = on
washer
MA3601
19
12V = on
transmission disconnect switch (joystick)
SW4231
20
12V = on
forward gear switch, loader joystick
SW4229
21
12V = on
forward gear valve (Powershuttle transmission)
MA4221
forward gear proportional valve (Powershift option) PWM4213 22
12V = on
reverse gear combi switch, steering column (Powershuttle transmission)
SW4208
reverse gear combi switch, steering column (Powershift option)
SW4205
23
12V = on
neutral switch, loader joystick
SW4228
24
12V = on
craning switch
SW9128
25
12V = on
reverse gear valve (Powershuttle transmission)
MA4220
reverse gear proportional valve (Powershift option) PWM4214 26
12V = on
preheater check
HE2501
27
12V = on
reverse gear switch, loader joystick
SW4230
28
12V = on
differential lock switch
SW4601
29
0V = on
powermode solenoid
MA9116
30
12V = on
quick attach switch, excavator
SW9104
31
12V = on
quick attach switch, loader
SW9105
32
12V = on
forward gear combi switch, steering column (Powershuttle transmission)
SW4208
forward gear combi switch, steering column (Powershift option)
SW4205
33
0V = on
4WD valve
MA4409
34
-
CAN1 H
-
35
-
VCADS EOL
-
36
0V = on
hammer foot switch
SW9159 47
37
12V = on
starter relay
RE3301
38
-
CAN1 L
-
39
-
CAN2 H
-
40
-
CAN2 L
-
41
0V = on
quick attach switch, loader
MA9191
42
0V = 4in1
4in1/extendable dipper (X1 primary/secondary), selector valve
MA9136
43
-
SAE J1708 SAE J1587
-
44
-
SAE J1708 SAE J1587
-
45
12V = on
injection solenoid
MA2307
46
12V = on
BSS (boom suspension)
RE9102
47
-
5V sensors supply
-
48
-
5V sensors supply
-
49
-
X3 proportional valve (right), GND
-
50
-
4in1/extendable dipper (X1 primary/secondary) proportional valve (right), GND
-
51
-
4in1/extendable dipper (X1 primary/secondary) proportional valve (left), GND
-
52
-
X3 proportional valve (left), GND
-
53
see component
X3 proportional valve (right)
PWM9145
54
see component
4in1/extendable dipper (X1 primary/secondary) proportional valve (right)
PWM9124
55
see component
4in1/extendable dipper (X1 primary/secondary) proportional valve (left)
PWM9123
56
see component
X3 proportional valve (left)
PWM9146
57
see component
Ignition key switch, position I (DR)
-
58
12V = on
main relay
RE3101
59
-
LIN
-
60
-
BATT
-
61
-
AGND
-
62
-
GND
-
48
I-ECU inputs and Outputs IECU1, side instrument panel Pin number
On condition
Description
Component
1
-
analog sensors, GND
-
2
0V = on
air filter clogging sensor
SE2502
3
0V = on
engine oil pressure
SE2203
4
12V = seatbelt fastened
seat belt
SE8501
5
0V = on
hydraulic oil filter clogging sensor
SE9106
6
12V = switch pressed
forward/reverse joystick authorisation switch
SW4232
7
0V = on
X3 authorisation switch
SW9131
8
12V = charging
alternator D+ (L) battery charge
SE3201
9
12V = parking brake activated
parking brake switch
SW5501
10
0V = on
4WD switch
SW4401
11
0V = on
hammer authorisation switch
SW9101
12
0V = on
overload pressure sensor (craning)
SE9401
13
0V = on
X1 primary authorisation switch
-
14
12V = up
stabiliser switch
SW9155
15
12V = on
brake light switch (4WD)
RE5201
16
see component
Alternator W (P)
AL3201
17
-
12V from main relay
-
18
-
GND
-
19
N/A
20
-
CAN A / LIN
-
21
-
CAN B
-
22
see component
Engine coolant circuit, temperature sensor
SE2706
23
see component
fuel level sensor
SE2303
24
N/A
25
N/A
26
N/A
49
IECU2, side instrument panel Pin number
On condition
Description
Component
1
-
analog sensors, GND
-
2
0V = on
X1 secondary authorisation switch
SW9402
3
N/A
4
N/A
5
N/A
6
12V = on
high beam
SW3502
7
N/A
8
12V = on
direction indicator switch, left
SW3605
9
N/A
10
0V = on
11
N/A
12
N/A
13
N/A
14
0V = on
transmission disconnect switch
SW4226
15
12V = on
direction indicator switch, right
SW3605
16
N/A
17
-
12V from main relay
-
18
-
GND
-
19
N/A
20
-
CAN A / LIN
-
21
-
CAN B
-
22
N/A
23
N/A
24
N/A
25
N/A
26
N/A
50
transmission oil temperature sensor (Powershuttle) SE4202
T-ECU, Inputs and outputs Pin number
Input/output
Description
1
Logic Supply 12 V
12 V battery
2
Power Supply 12 V
12 V battery
3
PWM output
Forward valve command (PWM4213)
4
PWM output
Reverse valve command (PWM4214)
5
Power Supply 12 V
12 V battery
6
PWM output
Proportional valve, gear shifting 1st/3rd gear (PWM4221)
7
PWM output
Proportional valve, gear shifting 2nd/4th gear (PWM4222)
8
Power Supply 12 V
12 V from main relay RE3101 (ignition key in Pos I)
9
Digital output
Gear selector 1st/3rd gear (MA4232)
12
PWM current input
Forward valve current feedback (PWM4213)
13
PWM current input
Proportional valve, gear shifting 1st/3rd gear, current feedback (PWM4221)
17
Logic GND
Sensors ground
18
Digital input
Forward input command (V-ECU pin 21)
23
Digital input
2nd gear input command (gear selector SW4206)
27
CAN HIGH
CAN interface
28
RS232 COMM
Transmission service connector
29
GND
Battery ground
34
Power Supply 12 V
12 V from main relay RE3101 (ignition key in Pos I)
38
Digital output
Gear selector 2nd/4th gear (MA4233)
40
PWM current input
Reverse valve current feedback (PWM4214)
41
PWM current input
Proportional valve, gear shifting 2nd/4th gear, current feedback (PWM4222)
43
Temperature input
Transmission oil temperature sensor (SE4202)
44
Analog input
Transmission oil pressure sensor (SE4214)
46
Digital input
Reverse input command (V-ECU pin 25)
48
Digital input
Kickdown input command (SW4220)
50
Digital input
1st gear input command (gear selector SW4206)
51
Digital input
3rd gear input command (gear selector SW4206)
53
Frequency input
Transmission speed sensor (SE4307)
55
CAN LOW
CAN interface
56
RS232 COMM
Transmission service connector
51
301 Software documents, complete vehicle
52
Service mode, description The service mode of the information display provides the technician with diagnostic information about the electrical and hydraulic system, the engine and general vehicle features. There is also the possibility to view and set/change specific parameters. The language of the information display is English.
A
B V 109 3080
Fig.11 information display unit
The display unit consists of two parts: - A = information display - B = keypad The information display shows all menus, submenus and parameters of the service mode. The keypad consists of four keys for user interaction.
V1101076
Fig.12 keypad
Key
Function ESC: Escape the current menu or submenu
V1101095
ARROW-UP: Navigate upwards in the current menu or submenu Increase selected value V1101096
ARROW-DOWN: Navigate downwards in the current menu or submenu Decrease selected value V1101097
V1101098
SELECT: Enter selected menu or submenu Activate/deactivate functions Activate changes For general operation of the service mode, see section Information display, general page 55.
54
Information display, general When starting the machine the drive mode will be active in the information display, automatically. When the ignition switch is turned to starting position, the instrument panel lamps and the buzzer will be tested during a few seconds. After this check, the main display of the drive mode will show up. If the anti-theft system is active, the pin code display will be shown to enter the pin code, see description below.
Anti-theft system (optional equipment) The pin code display is shown. Enter the correct pin code to activate the drive mode.
V1102184
Fig.13
Key
Function No function
V1101095
Increase highlighted pin code character
V1101096
Decrease highlighted pin code character
V1101097
Store the selected pin code character (the next character will be selected) If the last pin code character is already selected, the main display of the drive mode is shown V1101098
NOTICE See the Operator´s manual for further informations about the drive mode and entering the anti-theft system pin code.
55
Entering service mode Use the ARROW-UP and ARROW-DOWN keys until the engine speed display is shown. Press the SELECT key for at least 5 seconds to activate the pin code display. V1102183
Fig.14
The pin code display is shown. Enter the correct pin code to activate the service mode.
V1102184
Fig.15
Key
Function No function
V1101095
Increase highlighted pin code character
V1101096
Decrease highlighted pin code character
V1101097
Store the selected pin code character (the next character will be selected) If the last pin code character is already selected, the service mode will be activated If pressed longer than 5 seconds, the information display will return to the drive mode V1101098
56
Exit service mode The exit function is available in all menus and submenus of the service mode. Press the SELECT key longer than 5 seconds to exit the service mode. Key
Function If pressed longer than 5 seconds, the information display will return to the drive mode
V1101098
The EXIT screen will be shown for 2 seconds.
57
Service mode main display 4 menus are available in the main display of the service mode: 1 Vehicle information (Vehicle information ) 2 Engine (Engine) 3 Hydraulic (Hydraulic) 4 Electrical system (Electrical system) V1101100
Fig.16
Each menu displays parameters about the machine status and machine configurations. The keys of the keypad are used to navigate between the menus and submenus and to change parameters in this menus. The arrows in the upper right and lower right corner of the display indicates, that the ARROW-UP and ARROW-DOWN keys can be used to access a further entry in the current menu.
V1102365
Fig.17
Key
Function No function
V1101095
Select the menu above (the selected menu will be highlighted)
V1101096
Select the menu below (the selected menu will be highlighted)
V1101097
Enter the highlighted display If pressed longer than 5 seconds, the information display will return to the drive mode V1101098
For detailed informations about the several menus, see sections:
Information display, vehicle information (Vehicle information) page 60 Information display, engine (Engine) page 72 Information display, hydraulics (Hydraulic) page 76 Information display, electrical system (Electrical system) page 82
58
Diagram, information display
V1102192
Fig.18 Diagram, information display
59
Information display, vehicle information (Vehicle information)
V1102238
Fig.19 Diagram, submenu Vehicle information
60
V1101100
Fig.20
Following submenus are available in the menu Vehicle information (Vehicle information): 1 Time to service (Time to service) 2 Product model (Product model) 3 Set options (Set options) 4 Tire size (Tire size) 5 IECU part number (IECU part number) 6 VECU part number (VECU part number)
Submenu Time to service (Time to service) This submenu indicates how many hours are left until the next service inspection. The information can be reset to the default value.
V1101101
Fig.21
Key
Function Return to the main display
V1101095
No function
V1101096
Select the menu item Product model (Product model)
V1101097
Enter the Reset time submenu (Reset time) (see description below) If pressed longer than 5 seconds, the information display will return to the drive mode V1101098
61
Submenu Reset time (Reset time) In this submenu the hours left to next service can be reset to the default value.
V1101108
Fig.22
Key
Function Return to submenu Time to service (Time to service) without resetting to default value
V1101095
No function
V1101096
No function
V1101097
Reset the hours left to next service to the default value and return to submenu Time to service (Time to service) If pressed longer than 5 seconds, the information display will return to the drive mode V1101098
62
Submenu Product model (Product model) In this menu the product model is shown. The selected model should not be changed.
V1101102
Fig.23
Key
Function Return to the main display
V1101095
Select the menu item Time to service (Time to service)
V1101096
Select the menu item Set options (Set options)
V1101097
No changes should be done in this submenu If pressed longer than 5 seconds, the information display will return to the drive mode V1101098
63
Submenu Set options (Set options) This submenu shows the number of activated options. Options installed on the machine can be enabled/disabled in this submenu, e.g. when the VECU has to be changed.
V1101103
Fig.24
Key
Function Return to the main display
V1101095
Select the menu item Product model (Product model)
V1101096
Select the menu item Tire size (Tire size)
V1101097
Enter the Select options menu (see description below) If pressed longer than 5 seconds, the information display will return to the drive mode V1101098
64
Submenu Select options This submenu shows a list of options that can be enabled/ disabled. Only enable options that are installed on your machine.
V1101109
Fig.25
Key
Function Return to submenu Set options (Set options) without saving changes
V1101095
Select the option list entry above (the selected entry will be highlighted)
V1101096
Select the option list entry below (the selected entry will be highlighted)
V1101097
Enable or disable the highlighted option and return to the submenu Set options (Set options) If pressed longer than 5 seconds, the information display will return to the drive mode V1101098
65
Following options are available in the list: Option
Description X3
Enable/disable the auxiliary hydraulic function
Anti theft (Anti theft)
Enable/disable the anti theft device
Air condition (Air condition)
Enable/disable the air condition
Quick attach (Quick attach)
Enable/disable the quick attachment
Boom suspension (Boom suspension)
Enable/disable the boom suspension system
V1101109
V1102267
Four in one (Four Enable/disable the 4in1 multipurpose bucket in one) (Parameter only available for BL70B/BL71B)
V1102268
Extendable dipper (Extendable dipper)
Enable/disable the extendable dipper (Parameter only available for BL70B/BL71B)
Powershift transm. (Powershift transm.)
Enable/disable the Powershift transmission If the machine is equipped with a Powershift transmission, this parameter must be enabled
Disable 4th gear. Enable/disable the 4th gear (Disable 4th If the machine is not allowed to run faster than 20 km/ gear.) h, this option must be activated If this option is not selected, the 4th gear is active (This paramater is only valid for machines equipped with Powershift transmissions On machines equipped with Powershuttle transmissions, the 4th gear has to be enabled/disabled mechanically) 4WD (4WD)
Enable/disable the 4WD option (Parameter only available for BL60B/BL61B) If the machine is equipped with a 4WD front axle, this parameter must be enabled
MPH (MPH)
Enable/disable machine speed in mph If this option is enabled, the machine speed is shown in mph, otherwise it is shown in km/h The machine speed is shown in the front instrument panel
Washer & wiper (Washer and wiper)
Enable/disable the washers and wipers
V1102269
66
Submenu Tire size (Tire size) This submenu shows the rear tire size. It is mandatory to enter the correct tire size, because the travel speed of the machine is calculated on the tire size entered here and the transmission output rotation. See the Operators Manual for tire specifications.
V1101104
Fig.26
Key
Function Return to the main display
V1101095
Select the menu item Set options (Set options)
V1101096
Select the menu item IECU part number (IECU part number)
V1101097
Enter the Set tire size display (see description below) If pressed longer than 5 seconds, the information display will return to the drive mode V1101098
67
Submenu Set tire size In this menu the rear tire size can be changed. It is mandatory to enter the correct tire size, because the travel speed of the machine is calculated on the tire size and the transmission output rotation. V1101236
Fig.27
Key
Function Enter service mode submenu Tire size without saving changes
V1101095
Increase highlighted character
V1101096
Decrease highlighted character
V1101097
Store the selected character (the next character will be selected) If the last character is already selected, the tire size will be stored and the submenu Tire size (Tire size) will be shown V1101098
68
If pressed longer than 5 seconds, the information display will return to the drive mode
Submenu IECU part number (IECU part number) This submenu shows the part number of the IECU.
V1101105
Fig.28
Key
Function Return to the main display
V1101095
Select the menu item Tire size (Tire size)
V1101096
Select the menu item VECU part number (VECU part number)
V1101097
No function If pressed longer than 5 seconds, the information display will return to the drive mode V1101098
69
Submenu VECU part number (VECU part number) This submenu shows the part number of the VECU. The lower number is the part number of the VECU, the upper number is the part number of the installed software.
V1101106
Fig.29
Key
Function Return to the main display
V1101095
Select the menu item IECU part number (IECU part number)
V1101096
No function
V1101097
No function If pressed longer than 5 seconds, the information display will return to the drive mode V1101098
70
Information display, engine (Engine)
V1102293
Fig.30 Diagram, submenu Engine
72
Following submenus are available in the menu Engine (Engine): 1 Engine speed (Engine speed) 2 Fuel level (Fuel level) 3 Engine coolant temp ( Engine coolant temp) The values shown in this submenus cannot be modified. V1102145
Fig.31
Submenu Engine speed (Engine speed) This submenu shows the current engine speed (rpm).
V1101111
Fig.32
Key
Function Return to the main display
V1101095
No function
V1101096
Select the menu item Fuel level (Fuel level)
V1101097
No function If pressed longer than 5 seconds, the information display will return to the drive mode V1101098
73
Submenu Fuel level (Fuel level) This submenu shows the fuel tank level in percent and also the corresponding voltage information from the fuel level sensor SE2303.
V1101110
Fig.33
Key
Function Return to the main display
V1101095
Select the menu item Engine speed (Engine speed)
V1101096
Select the menu item Engine coolant temp ( Engine coolant temp)
V1101097
No function If pressed longer than 5 seconds, the information display will return to the drive mode V1101098
74
Submenu Engine coolant temp ( Engine coolant temp) This submenu shows the engine coolant temperature in degrees (Celsius/Fahrenheit) and also the corresponding voltage information from the coolant temperature sensor SE2702.
V1101107
Fig.34
Key
Function Return to the main display
V1101095
Select the menu item Fuel level (Fuel level)
V1101096
No function
V1101097
No function If pressed longer than 5 seconds, the information display will return to the drive mode V1101098
75
Information display, hydraulics (Hydraulic)
V1102307
Fig.35 Diagram, submenu Hydraulic
76
V1102146
Following submenus are available in the menu Hydraulic (Hydraulic): 1 Hydraulic oil temperature (Hydraulic oil temp) 2 4in1 option (4in1) 3 Ext. dipper option (Ext. dipper) 4 Auxiliary X3 option (Auxiliary X3) The values shown in this submenus cannot be modified.
Fig.36
Submenu Hydraulic oil temp (Hydraulic oil temp) This submenu shows the hydraulic oil temperature in degrees (Celsius/Fahrenheit) and also the corresponding voltage information from the hydraulic oil temperature sensor SE9105.
V1102308
Fig.37
Key
Function Return to the main display
V1101095
No function
V1101096
Select the menu item 4in1 (4in1)
V1101097
No function If pressed longer than 5 seconds, the information display will return to the drive mode V1101098
77
Submenu 4in1 option (4in1) This submenu shows the electrical input and output values of the 4in1 function. SW: 4in1 switch, loader joystick (SW9113) PWM 1: PWM9123 PWM 2: PWM9124
V1101112
Fig.38
Key
Function Return to the main display
V1101095
Select the menu item Hydraulic oil temp (Hydraulic oil temp)
V1101096
Select the menu item Ext. dipper (Ext. dipper)
V1101097
No function If pressed longer than 5 seconds, the information display will return to the drive mode V1101098
78
Submenu Ext. dipper option (Ext. dipper) This submenu shows the electrical input and output values of the extendable dipper function. SW: extendable dipper switch, backhoe joystick (SW9114) PWM 1: PWM9123 PWM 2: PWM9124
V1102305
Fig.39
Key
Function Return to the main display
V1101095
Select the menu item 4in1 (4in1)
V1101096
Select the menu item Auxiliary X3 (Auxiliary X3)
V1101097
No function If pressed longer than 5 seconds, the information display will return to the drive mode V1101098
79
Submenu Auxiliary X3 option (Auxiliary X3) This submenu shows the electrical input and output values of the bidirectional auxiliary function. SW: auxiliary switch, backhoe joystick (SW9161) PWM 1: PWM9145 PWM 2: PWM9146
V1102306
Fig.40
Key
Function Return to the main display
V1101095
Select the menu item Ext. dipper (Ext. dipper)
V1101096
No function
V1101097
No function If pressed longer than 5 seconds, the information display will return to the drive mode V1101098
80
Information display, electrical system (Electrical system)
V1102337
Fig.41 Diagram, submenu Electrical system
82
V1102147
Fig.42
Following submenus are available in the menu Electrical system (Electrical system): 1 System voltage (System voltage) 2 Fault codes (Fault codes) 3 Clear fault codes (Clear fault codes) 4 Digital in/out VECU (Digital in/out VECU) 5 Digital in/out IECU–1 (Digital in/out IECU–1) 6 Digital in/out IECU–2 (Digital in/out IECU–2) The values shown in this menu cannot be modified.
Submenu System voltage (System voltage) This submenu shows the current battery voltage.
V1102144
Fig.43
Key
Function Return to the main display
V1101095
No function
V1101096
Select the menu item Fault codes (Fault codes)
V1101097
No function If pressed longer than 5 seconds, the information display will return to the drive mode V1101098
83
Submenu Fault codes (Fault codes) This submenu shows a list with fault codes, that have appeared during machine operation.
V1102316
Fig.44
Key
Function Return to the main display
V1101095
Select the menu item System voltage (System voltage)
V1101096
Select the menu item Clear fault codes (Clear fault codes)
V1101097
Enter the fault code list (see description below) If pressed longer than 5 seconds, the information display will return to the drive mode V1101098
84
Submenu fault codes list This submenu shows a list with the last 10 fault codes, that have appeared during machine operation. The fault codes are shown in chronological order with the most recent fault code on top.
V1102318
Fig.45 Fault code entry: Component FU20 with FMI code 4 appeared after 3.8 machine hours
Key
The fault code entry consists of two lines. In the first line the component id and the FMI (=fault mode identifier) code are shown (separated by a hyphen -). In the second line the time-stamp of the fault code is shown. See Fault code list page 94 for possible fault codes.
Function Return to the submenu Fault codes (Fault codes)
V1101095
Select the error code list entry above
V1101096
Select the error code list entry below
V1101097
No function If pressed longer than 5 seconds, the information display will return to the drive mode V1101098
85
Submenu Clear fault codes (Clear fault codes) In this submenu the fault codes list can be cleared.
V1102317
Fig.46
Key
Function Return to the main display
V1101095
Select the menu item Fault codes (Fault codes)
V1101096
Select the menu item Digital in/out VECU (Digital in/out VECU)
V1101097
Enter the Clear fault codes (Clear fault codes) confirmation (see description below) If pressed longer than 5 seconds, the information display will return to the drive mode V1101098
86
Clear fault codes (Clear fault codes) confirmation
V1102319
Fig.47
Key
Function Return to the submenu Clear fault codes (Clear fault codes) without clearing the fault codes list
V1101095
No function
V1101096
No function
V1101097
Clear the fault code list and return to the submenu Clear fault codes (Clear fault codes) If pressed longer than 5 seconds, the information display will return to the drive mode V1101098
87
Submenu Digital in/out VECU (Digital in/out VECU) In this submenu all input and output signals of the VECU are shown.
V1102320
Fig.48
Key
Function Return to the main display
V1101095
Select the menu item Clear fault codes (Clear fault codes)
V1101096
Select the menu item Digital in/out IECU–1 (Digital in/out IECU–1)
V1101097
Enter the digital input/output list of the VECU If pressed longer than 5 seconds, the information display will return to the drive mode V1101098
88
Digital input/output list VECU In this list all digital input and output numbers of the VECU are listed. Each input/output number consists of 2 digits and has a corresponding pin on the VECU.
V1102323
Fig.49
The first two digits of each row are defining, if the row consists of input or output signals. DI = Digital Input DO = Digital Output When there is a signal on an input/output port, the corresponding number is highlighted. See also section V-ECU inputs and outputs page 100.
Key
Function Return to the submenu Digital in/out VECU (Digital in/out VECU)
V1101095
Navigate upwards through the input/output list
V1101096
Navigate downwards through the input/output list
V1101097
No function If pressed longer than 5 seconds, the information display will return to the drive mode V1101098
89
Submenu Digital in/out IECU1 (Digital in/out IECU–1) In this submenu all input and output signals of the IECU1 are shown.
V1102321
Fig.50
Key
Function Return to the main display
V1101095
Select the menu item Digital in/out VECU (Digital in/out VECU)
V1101096
Select the menu item Digital in/out IECU–2 (Digital in/out IECU–2)
V1101097
Enter the digital input/output list of the IECU1 If pressed longer than 5 seconds, the information display will return to the drive mode V1101098
90
Digital input/output list IECU1 In this list all digital input and output numbers of the IECU1 are listed. Each input/output number consists of 2 digits and has a corresponding pin on the IECU1.
V1102324
Fig.51 V1102324
The first two digits of each row are defining, if the row consists of input or output signals. DI = Digital Input DO = Digital Output When there is a signal on an input/output port, the corresponding number is highlighted. See also section I-ECU inputs and Outputs page 102.
Key
Function Return to the submenu Digital in/out IECU1 (Digital in/out IECU–1)
V1101095
Navigate upwards through the input/output list
V1101096
Navigate downwards through the input/output list
V1101097
No function If pressed longer than 5 seconds, the information display will return to the drive mode V1101098
91
Submenu Digital in/out IECU2 (Digital in/out IECU–2) In this submenu all input and output signals of the IECU2 are shown.
V1102322
Fig.52
Key
Function Return to the main display
V1101095
Select the menu item Digital in/out IECU–1 (Digital in/out IECU–1)
V1101096
No function
V1101097
Enter the digital input/output list of the IECU2 If pressed longer than 5 seconds, the information display will return to the drive mode V1101098
92
Digital input/output list IECU2 In this list all digital input and output numbers of the IECU2 are listed. Each input/output number consists of 2 digits and has a corresponding pin on the IECU2. See also section I-ECU inputs and Outputs page 102.
V1102325
Fig.53
The first two digits of each row are defining, if the row consists of input or output signals. DI = Digital Input DO = Digital Output When there is a signal on an input/output port, the corresponding number is highlighted.
Key
Function Return to the submenu Digital in/out IECU2 (Digital in/out IECU–2)
V1101095
Navigate upwards through the input/output list
V1101096
Navigate downwards through the input/output list
V1101097
No function If pressed longer than 5 seconds, the information display will return to the drive mode V1101098
93
Fault code list The following FMI codes are used to describe machine failures: FMI codes
Description
0
Data valid but above normal operational range
1
Data valid but below normal operational range
2
Data erratic, intermittent, or incorrect
3
Voltage above normal or shorted high
4
Voltage below normal or shorted low
5
Current below normal or open circuit
6
Current above normal or grounded circuit
7
Mechanical system not responding properly
8
Abnormal frequency, pulse width, or period
9
Abnormal update rate
10
Abnormal rate of change
11
Failure mode not identifiable
12
Bad intelligent device or component
13
Out of Calibration
14
Special Instructions
15
Reserved for future assignment by the SAE Data Format Subcommittee
94
NOTICE The following diagnostic informations are supported by the VECU: Electronical control units (ECUs) Component name
FMI codes
Description
IECU
2
IECU memory not read/writeable
IECU
10
IECU hour recorder value out of range
VECU
10
VECU hour recorder value out of range
See section 370, Component list, Distribution boxes and control units for component locations and wiring diagrams. Alternator Component name
FMI codes
Description
AL3201
0
Alternator W (P)
See section 370, Component list, Alternator, batteries, code lock, radio for component locations and wiring diagrams. Compressor Component name
FMI codes
Description
MO8701
5
Compressor
See section 370, Component list, Motors for component locations and wiring diagrams. Relays Component name
FMI codes
Description
RE2501
2, 5
Preheat relay
RE3101
0, 1
Battery potential
RE3101
5, 6
Main relay
RE3301
5
Starter relay
RE3601
5
Wiper intermittent relay
RE9112
5, 6
Boom Suspension System
See section 370, Component list, Relays for component locations and wiring diagrams.
95
Sensors Component name
FMI codes
Description
SE2303
3, 4
Fuel level sensor
SE2502
0
Air filter clogging sensor
SE2706
0, 3, 4
Engine coolant circuit, temperature sensor
SE3201
1
Alternator D+ (L) Battery charge
SE4307
3, 4
Transmission, speed sensor (output rotation) (Powershuttle)
SE9105
3, 4
Hydraulic oil temperature sensor
SE9106
3
Hydraulic oil filter clogging sensor
See section 370, Component list, Sensors for component locations and wiring diagrams. Switches Component name
FMI codes
Description
SW9113
3, 4
4in1 roller switch (X1 primary)
SW9114
3, 4
Extendable dipper roller switch (X1 secondary)
SW9161
3, 4
Auxiliary roller switch (X3)
See section 370, Component list, Switches for component locations and wiring diagrams. Solenoid valves Component name
FMI codes
Description
MA2307
6
Engine stop solenoid
MA4220
5
Gear shifting, reverse (Powershuttle standard)
MA4221
5
Gear shifting, forward (Powershuttle standard)
MA4409
5
4WD disconnect
MA4601
5
Differential lock
MA9116
5
Pump, power regulation
MA9136
5, 6
X1 selector
PWM9145
3, 4, 5, 6
X3 left (hammer/aux option)
PWM9146
3, 4, 5, 6
X3 right (hammer/aux option)
PWM9123
3, 4, 5, 6
X1 left (4in1/Extendable dipper)
PWM9124
3, 4, 5, 6
X1 right (4in1/Extendable dipper)
See section 370, Component list, Solenoid valves for component locations and wiring diagrams.
96
NOTICE The following diagnostic informations are supported by the VECU if the machine is equipped with a Powershift transmission (option): Electronical control units (ECUs) Component name
FMI codes
Description
VECU
9
Missing CAN cyclic messages from VECU
TECU
0
Internal TECU failure, sensor supply high, replace TECU controller if reoccurring
TECU
1
Internal TECU failure, sensor supply low, replace TECU controller if reoccurring
TECU
12
Internal TECU failure, replace TECU controller if reoccurring
See section 370, Component list, Distribution boxes and control units for component locations and wiring diagrams. Battery Component name
FMI codes
Description
BA3201
0
TECU, pin 34: Battery voltage above 16 volts for 2.5 seconds
BA3201
1
TECU, pin 34: Battery voltage below 10 volts for 2.5 seconds
See sections 370, Component list, Distribution boxes and control units and 370, Component list, Alternator, batteries, code lock, radio for component locations and wiring diagrams. Fuses Component name
FMI codes
Description
FU20
4
Main Power supplies (pin 1,2,5) not powered
FU43
2
No electric signal from gearshift lever
FU43
4
Power supply for digital outputs (Pin 8) not powered
See section 370, Component list, Fuses for component locations and wiring diagrams. Sensors Component name
FMI codes
Description
SE4202
2
Temperature signal erratic or incorrect
SE4202
4
TECU, pin 43: Temperature sensor input is shorted to a ground
SE4202
6
TECU, pin 43: Temperature sensor input is open circuited or shorted to a voltage above 5 volts
SE4214
2
Charge pressure is not detected when engine speed is above 700 rpm for 10 seconds
SE4214
2
Charge pressure switch is closed with no engine speed detected by the VECU controller
SE4214
7
Charge pressure is not detected and vehicle speed is over 10 km/h
SE4307
8
Transmission output shaft frequency above 3000 Hz detected
See section 370, Component list, Sensors for component locations and wiring diagrams.
97
Switches Component name
FMI codes
Description
SW4208
2
Erratic signals from gearshift lever
SW4208
2
Erratic signals from gearshift lever: transmission in neutral receives forward and neutral together
SW4208
2
Erratic signals from gearshift lever: transmission in forward receives forward and reverse together.
SW4208
2
Erratic signals from gearshift lever: transmission in reverse receives forward and reverse together.
SW4208
10
Erratic signals from gearshift lever: transmission in neutral receives reverse and neutral together
SW4208
10
Erratic signals from gearshift lever: transmission in forward receives neutral and forward together
SW4208
10
Erratic signals from gearshift lever: transmission in reverse receives neutral and reverse together
See sections 370, Component list, Switches and 370, Component list, Distribution boxes and control units for component locations and wiring diagrams.
98
Solenoid valves Component name
FMI codes
Description
MA4232
6
1st/3rd gear solenoid shorted to ground
MA4233
6
2nd/4th gear solenoid shorted to ground
PWM4213
0
Forward solenoid valve is drawing more current then commanded
PWM4213
1
Forward solenoid valve is drawing less current then commanded
PWM4213
3
TECU, pin 12: forward input feedback circuit is reading current without command
PWM4213
5
TECU, pin 12: forward input current is too low with command present
PWM4213
6
TECU, pin 3 or 4: forward drive shorted to ground
PWM4214
0
Reverse solenoid valve is drawing more current then commanded
PWM4214
1
Reverse solenoid valve is drawing less current then commanded
PWM4214
3
TECU, pin 40: Reverse input feedback circuit is reading current without command
PWM4214
5
TECU, pin 40: Reverse input current is too low with command present
PWM4221
0
1st/3rd gear modulation solenoid is drawing more current then commanded
PWM4221
1
1st/3rd gear modulation solenoid is drawing less current then commanded
PWM4221
3
TECU, pin 13: 1st/3rd gear modulation solenoid input feedback circuit is reading current without command.
PWM4221
5
TECU, pin 13: 1st/3rd gear modulation solenoid input current is too low with command present.
PWM4221
6
TECU, pin 5 or 6: PWM 1 drive shorted to ground
PWM4222
0
2nd/4th gear modulation solenoid is drawing more current then commanded
PWM4222
1
2nd/4th gear modulation solenoid is drawing less current then commanded
PWM4222
3
TECU, pin 41: 2nd/4th gear modulation solenoid input feedback circuit is reading current without command.
PWM4222
5
TECU, pin 41: 2nd/4th gear modulation solenoid input current is too low with command present.
See section 370, Component list, Solenoid valves and 370, Component list, Distribution boxes and control units for component locations and wiring diagrams.
99
V-ECU inputs and outputs Pin number
On condition
Description
Component
1
12V = on
preheat relay
RE2501
2
N/A
3
see component
gearbox speed sensor
SE4307
4
see component
hydraulic oil temperature sensor
SE9105
5
0V = on
excavator quick attachment, unlocking valve
MA9183
6
see component
X3 roller switch
SW9161
7
see component
X1 primary roller switch (4in1 bucket)
SW9113
8
see component
X1 primary roller switch (extendable dipper)
SW9114
9
12V = on
differential lock valve
MA4601
10
12V = on
wiper intermittent switch
SW3602
11
12V = on
Ignition key switch, position IV (50)
SW3301
12
N/A
13
12V = on
wiper intermittent relay
RE3601
14
12V = on
Button hold function
SW9129
15
12V = on
BSS (boom suspension) switch
SW9148
16
12V = on
air conditioning switch
SW8701
17
12V = on
air conditioning compressor
MO8701
18
12V = on
washer
MA3601
19
12V = on
transmission disconnect switch (joystick)
SW4231
20
12V = on
forward gear switch, loader joystick
SW4229
21
12V = on
forward gear valve (Powershuttle transmission)
MA4221
forward gear proportional valve (Powershift option) PWM4213 22
12V = on
reverse gear combi switch, steering column (Powershuttle transmission)
SW4208
reverse gear combi switch, steering column (Powershift option)
SW4205
23
12V = on
neutral switch, loader joystick
SW4228
24
12V = on
craning switch
SW9128
25
12V = on
reverse gear valve (Powershuttle transmission)
MA4220
reverse gear proportional valve (Powershift option) PWM4214 26
12V = on
preheater check
HE2501
27
12V = on
reverse gear switch, loader joystick
SW4230
28
12V = on
differential lock switch
SW4601
29
0V = on
powermode solenoid
MA9116
30
12V = on
quick attach switch, excavator
SW9104
31
12V = on
quick attach switch, loader
SW9105
32
12V = on
forward gear combi switch, steering column (Powershuttle transmission)
SW4208
forward gear combi switch, steering column (Powershift option)
SW4205
33
0V = on
4WD valve
MA4409
34
-
CAN1 H
-
35
-
VCADS EOL
-
36
0V = on
hammer foot switch
SW9159
100
37
12V = on
starter relay
RE3301
38
-
CAN1 L
-
39
-
CAN2 H
-
40
-
CAN2 L
-
41
0V = on
quick attach switch, loader
MA9191
42
0V = 4in1
4in1/extendable dipper (X1 primary/secondary), selector valve
MA9136
43
-
SAE J1708 SAE J1587
-
44
-
SAE J1708 SAE J1587
-
45
12V = on
injection solenoid
MA2307
46
12V = on
BSS (boom suspension)
RE9102
47
-
5V sensors supply
-
48
-
5V sensors supply
-
49
-
X3 proportional valve (right), GND
-
50
-
4in1/extendable dipper (X1 primary/secondary) proportional valve (right), GND
-
51
-
4in1/extendable dipper (X1 primary/secondary) proportional valve (left), GND
-
52
-
X3 proportional valve (left), GND
-
53
see component
X3 proportional valve (right)
PWM9145
54
see component
4in1/extendable dipper (X1 primary/secondary) proportional valve (right)
PWM9124
55
see component
4in1/extendable dipper (X1 primary/secondary) proportional valve (left)
PWM9123
56
see component
X3 proportional valve (left)
PWM9146
57
see component
Ignition key switch, position I (DR)
-
58
12V = on
main relay
RE3101
59
-
LIN
-
60
-
BATT
-
61
-
AGND
-
62
-
GND
-
101
I-ECU inputs and Outputs IECU1, side instrument panel Pin number
On condition
Description
Component
1
-
analog sensors, GND
-
2
0V = on
air filter clogging sensor
SE2502
3
0V = on
engine oil pressure
SE2203
4
12V = seatbelt fastened
seat belt
SE8501
5
0V = on
hydraulic oil filter clogging sensor
SE9106
6
12V = switch pressed
forward/reverse joystick authorisation switch
SW4232
7
0V = on
X3 authorisation switch
SW9131
8
12V = charging
alternator D+ (L) battery charge
SE3201
9
12V = parking brake activated
parking brake switch
SW5501
10
0V = on
4WD switch
SW4401
11
0V = on
hammer authorisation switch
SW9101
12
0V = on
overload pressure sensor (craning)
SE9401
13
0V = on
X1 primary authorisation switch
-
14
12V = up
stabiliser switch
SW9155
15
12V = on
brake light switch (4WD)
RE5201
16
see component
Alternator W (P)
AL3201
17
-
12V from main relay
-
18
-
GND
-
19
N/A
20
-
CAN A / LIN
-
21
-
CAN B
-
22
see component
Engine coolant circuit, temperature sensor
SE2706
23
see component
fuel level sensor
SE2303
24
N/A
25
N/A
26
N/A
102
IECU2, side instrument panel Pin number
On condition
Description
Component
1
-
analog sensors, GND
-
2
0V = on
X1 secondary authorisation switch
SW9402
3
N/A
4
N/A
5
N/A
6
12V = on
high beam
SW3502
7
N/A
8
12V = on
direction indicator switch, left
SW3605
9
N/A
10
0V = on
11
N/A
12
N/A
13
N/A
14
0V = on
transmission disconnect switch
SW4226
15
12V = on
direction indicator switch, right
SW3605
16
N/A
17
-
12V from main relay
-
18
-
GND
-
19
N/A
20
-
CAN A / LIN
-
21
-
CAN B
-
22
N/A
23
N/A
24
N/A
25
N/A
26
N/A
transmission oil temperature sensor (Powershuttle) SE4202
103
T-ECU, Inputs and outputs Pin number
Input/output
Description
1
Logic Supply 12 V
12 V battery
2
Power Supply 12 V
12 V battery
3
PWM output
Forward valve command (PWM4213)
4
PWM output
Reverse valve command (PWM4214)
5
Power Supply 12 V
12 V battery
6
PWM output
Proportional valve, gear shifting 1st/3rd gear (PWM4221)
7
PWM output
Proportional valve, gear shifting 2nd/4th gear (PWM4222)
8
Power Supply 12 V
12 V from main relay RE3101 (ignition key in Pos I)
9
Digital output
Gear selector 1st/3rd gear (MA4232)
12
PWM current input
Forward valve current feedback (PWM4213)
13
PWM current input
Proportional valve, gear shifting 1st/3rd gear, current feedback (PWM4221)
17
Logic GND
Sensors ground
18
Digital input
Forward input command (V-ECU pin 21)
23
Digital input
2nd gear input command (gear selector SW4206)
27
CAN HIGH
CAN interface
28
RS232 COMM
Transmission service connector
29
GND
Battery ground
34
Power Supply 12 V
12 V from main relay RE3101 (ignition key in Pos I)
38
Digital output
Gear selector 2nd/4th gear (MA4233)
40
PWM current input
Reverse valve current feedback (PWM4214)
41
PWM current input
Proportional valve, gear shifting 2nd/4th gear, current feedback (PWM4222)
43
Temperature input
Transmission oil temperature sensor (SE4202)
44
Analog input
Transmission oil pressure sensor (SE4214)
46
Digital input
Reverse input command (V-ECU pin 25)
48
Digital input
Kickdown input command (SW4220)
50
Digital input
1st gear input command (gear selector SW4206)
51
Digital input
3rd gear input command (gear selector SW4206)
53
Frequency input
Transmission speed sensor (SE4307)
55
CAN LOW
CAN interface
56
RS232 COMM
Transmission service connector
104
302 Faulttracing
105
Troubleshooting, general
WARNING During troubleshooting and all work with the electrical system, carefully follow all instructions in Electrical system, work instructions. See section Electrical system, work instructions page 7. When trouble–shooting in the electrical system, have the following available: • Service Manual • Operators Manual • Component manuals • Parts Catalogue For each component or system described in this manuals there is a list of related components that also should be checked if a malfunction occurs. Example Related components:
106
Fuses
FU12, FU13
Relays
RE02
Switches
SW3607, SW3301 (Ignition key switch)
Other
SE2203, D2, BA3101 (Battery)
Collection of basic data General Collection of basic data is the first step in all troubleshooting. This is done to get a quick and improved overall picture of how the malfunction shows up. In addition to information about machine and customer, it is important to get as much information as possible about events in connection with the occurrence of the malfunction. The operator can often have valuable information on the circumstances when the malfunction occurred. The operator is almost always the person who notices the problem first. Since it's seldom possible to recreate the experienced problems, without having exactly the same conditions, information from the operator is of vital importance for correct assessments in continued troubleshooting. Interview the operator using the following questions. The answers should be noted and saved together with the work order. The operator should be able to answer the following questions:
General information • Customer information • Dealer information • Operator • Machine specifications: - Machine - Serial number - Machine hours - Engine type - Engine number - Model year - Delivery date - Transmission type - Transmission serial number • Have you detected any error messages? • Has any new electrical equipment been installed on the machine?
Description of malfunction or symptom • Describe the problem. • When did the problem occur? • How was the problem discovered and what happened just before? • Does the problem reappear? • How often does the problem occur? • For how long does the problem last when it occurs? • Does the problem always occur during the same conditions, if so, what are the conditions? 107
• Does the operator have any idea of what the probable cause of the problem may be? • Does the problem still exist?
Engine data • Under what operating conditions does the problem occur? • External circumstances that affect the problem? • Is the engine difficult to start? • Is there abnormal smoke? • Is there any abnormal engine noise? • Have you detected/confirmed any changes in fuel consumption, oil consumption or engine power? • What type of fuel is used? • Any additives used in the fuel? If yes, which ones? • What repairs or other work has been performed on the engine? • Other information?
Power transmission, data • Under what operating conditions does the problem occur? • External circumstances that affect the problem? • What type of oil is used? • Any additives used in the oil? If yes, which ones? • When was the last oil change performed? • Is difference in rolling circumference between tyres more than 1.5%? • Other information?
108
Lead and connector checks General An important part of electrical system trouble-shooting is lead and connector checks, which can indicate the cause of malfunctions in the form of loose connections or damaged electrical leads.
NOTICE Before troubleshooting leads and connectors is conducted, the appropriate fuses should be checked. These checks are conducted with help of a multimeter. For suitable test points, refer to the wiring diagram.
CAUTION The following should be observed when working on electrical systems. • Testing should not be conducted by sticking objects through electrical lead insulation. • Exercise caution while testing with a test cable in connectors to avoid damage to or widening of connector pins and sleeves.
Connector and cable terminal checks For all tests and checks during which connectors are dismantled, connectors and cable terminals should be visually checked as follows: 1 Look for cable terminal oxidation. Oxidation can impair the contact. 2 Check for cable terminal damage, correct placement in the insulator and that the leads are correctly connected to the terminals. 3 Check for good mechanical contact in the cable terminals. Use a separate cable terminal for checking.
Fig.54 Connector, mechanical contact check
Open circuit, check Open circuits in electrical cables and cable harnesses can be caused by chafing due to friction, pressure due to squeezing and tension load. Checks for open circuits are conducted as follows: 1 Switch off the battery connection switch. 2 Dismantle the appropriate connector in both ends of the cable harness.
109
3 Conduct a resistance test between the lead ends. The resistance should be ∞ Ω for a faultily open circuit.
L67454A
Fig.55 Check for open circuit with resistance testing
4 Shake the cable harness and pull lightly on the connectors simultaneously during testing to find possible open circuits.
L67457A
Fig.56 Troubleshooting open circuit
Short circuit to ground, check A short circuit between the power supply lead and ground often leads to fuse failure. A check for short circuit to ground is conducted as follows: 1 Switch on the battery connection switch. 2 Start key in position 1. 3 Close all switches, activate circuit functions and check if any fuses are tripped. 4 Put start key in position 0. 5 Switch off the battery connection switch. 6 Dismantle the appropriate connector to the circuit components so they do not to affect the test. 7 Resistance test between lead and ground. The resistance should be ≈ 0 Ω for a defective lead with short circuit to ground. L67455A
Fig.57 Check for short circuit to ground (frame ground connection) with resistance testing
Short circuit to voltage, check A short circuit between a lead and voltage often leads to fuse failure. 1 Switch on the battery connection switch. 2 Start key in position 1. 3 Test the voltage with a multimeter on suitable circuit points while the switch is connected and the sensor is activated. The voltage value is dependent on several parameters. See wiring diagram, signal description and component information. 4 Put the start key in position 0. 5 Switch off the battery connection switch.
110
6 Dismantle the appropriate connector in both ends of the cable harness. Resistance test between the leads that can be short-circuited with each other. The resistance should be ≈ 0 Ω for defective leads which are short-circuited. L67458A
Fig.58 Check for short circuit to voltage with resistance testing
Contact resistance and oxidation, check Loose contacts or temporary recurring malfunctions can be difficult to diagnose and are often caused by corrosion, vibrations of poorly connected leads. Dampness in the connectors can also cause contact problems as well as damaged pins or sleeves. Resistance in the connectors and leads should normally be ≈ 0 Ω. Some resistance, however, can occur due to corrosion in the cable terminals. If the contact resistance is too large, function disruption can occur. The amount of resistance that may occur without disruption varies according to the circuit load. To check contact resistance and oxidation, see Connector and cable terminal checks.
CAUTION Shake the cable harness and pull lightly on the connectors while measuring to find eventual loose connections.
L67457A
Fig.59
Pins and sleeves, cleaning 1 Switch off the battery disconnect switch. 2 Clean the connectors using compressed air. 3 Spray the connectors with contact spray. 4 Use compressed air once again on the connectors.
L67460A
Fig.60 Connectors, spraying with contact spray
111
112
Electrical troubleshooting, Powershift transmission When having problems with the Powershift transmission, and the problems are judged to be electrical, perform the following tests:
Solenoids, checking resistance page 117 Wires, testing page 119 Gear selector switch, testing page 121
113
Solenoids, checking resistance Powershuttle transmission (standard) Op. no. Tools: 9990008 Measuring equipment Multimeter
1
1
Place the machine in service position 2, see section 191, Service position 2.
2
Turn off the battery disconnect switch.
3
Remove the floor mat in the cab.
4
Remove the cab floor plate in front of the seat.
5
Remove the electrical connector from the solenoid.
6
Measure the electrical resistance between the two poles of a solenoid. See section 302, Solenoid valves, specification for resistance specification. See also sections 370, Wiring diagram SCH09 and 370, Wiring diagram SCH12 for wiring diagrams.
7
Reconnect the electrical connector to the solenoid.
8
Perform the last three steps for the other solenoids.
9
Fit the cab floor plate in front of the seat.
10
Fit the floor mat in the cab.
V1094146
Fig.61 battery disconnect switch 1 position 0: battery disconnect switch off 2 position 1: battery disconnect switch on
Fig.62 transmission solenoids 1 Reverse gear solenoid (MA4220) 2 Forward gear solenoid (MA4221) 3 Differential lock solenoid (MA4601) 4 4WD solenoid (MA4409)
114
Solenoids, checking resistance Powershift transmission (option) Op. no. Tools: 9990008 Measuring equipment Multimeter The following solenoids of the Powershift transmission can also be measured with special checking equipment via the T-ECU: Forward gear solenoid (PWM4213) Reverse gear solenoid (PWM4214) Proportional valve, gear shifting 1st/3rd gear (PWM4221) Proportional valve, gear shifting 2nd/4th gear (PWM4222) See also section Solenoids, checking resistance page 117.
Fig.63 powershift transmission, checking solenoids 1 gear shift modulation, 2nd/4th gear (PWM4222) 2 reverse gear shift (PWM4214) 3 forward gear shift (PWM4213) 4 gear shift modulation, 1st/3rd gear (PWM4221) 5 gear selector, 1st/3rd gear (PWM4232) 6 differential lock (MA4601) 7 gear selector, 2nd/4th gear (PWM4233) 8 4WD drive (MA4409)
1
1
Place the machine in service position 2, see section 191, Service position 2.
2
Turn off the battery disconnect switch.
3
Remove the floor mat in the cab.
4
Remove the cab floor plate in front of the seat.
V1094146
Fig.64 battery disconnect switch 1 position 0: battery disconnect switch off 2 position 1: battery disconnect switch on
115
5
Remove the electrical connector from the solenoid.
6
Measure the electrical resistance between the two poles of a solenoid. See section 302, Solenoid valves, specification for resistance specification. See also sections 370, Wiring diagram SCH09 and 370, Wiring diagram SCH11 for wiring diagrams.
7
Reconnect the electrical connector to the solenoid.
8
Perform the last three steps for the other solenoids.
9
Fit the cab floor plate in front of the seat.
10
Fit the floor mat in the cab.
V1104013
Fig.65 Solenoid
116
Solenoids, checking resistance Powershift transmission (option) Op. no. Tools: 88830171 Break out harness 88830182 Cable 9998699 Adapter Multimeter The following solenoids of the Powershift transmission can be measured with special checking equipment via the T-ECU: Forward gear solenoid (PWM4213) Reverse gear solenoid (PWM4214) Proportional valve, gear shifting 1st/3rd gear (PWM4221) Proportional valve, gear shifting 2nd/4th gear (PWM4222) For measuring the solenoids without special checking equipment or for checking the solenoids (MA4232 gear selector 1/3 gear), MA4233 (gear selector 2/4 gear), MA4601 (differential lock) and MA4409 (4WD disconnect ), see section Solenoids, checking resistance page 115.
1
1
Place the machine in service position 2, see section 191, Service position 2.
2
Turn off the battery disconnect switch.
3
Remove the knob of the hand throttle lever.
4
Loosen and remove the retaining screws of the side panel.
5
Carefully lift away the side panel.
V1094146
Fig.66 battery disconnect switch 1 position 0: battery disconnect switch off 2 position 1: battery disconnect switch on
NOTICE Take care of the connectors and harnesses on the rear of the panel. V1103768
Fig.67 side panel, removal
117
6
Remove the connector (2) from the T-ECU (1).
7
Connect the break out harness to the connector. 88830171 Break out harness
8
Connect the adapter cable to the break out harness. 88830182 Cable
9
Connect the break out box to the adapter cable. Use the template for further pin identification. 9998699 Adapter 88890019 Template
10
Measure the electrical resistance between the two poles of a solenoid (see table below). See section 302, Solenoid valves, specification for resistance specification.
Fig.68 T-ECU with connector 1 T-ECU 2 T-ECU connector
Solenoid
T-ECU pins
Forward gear solenoid (PWM4213)
3
12
Reverse gear solenoid (PWM4214)
4
40
Proportional valve, gear shifting 1st/3rd gear (PWM4221)
6
13
Proportional valve, gear shifting 2nd/4th gear (PWM4222)
7
41
See also sections T-ECU, Inputs and outputs page 51 and 370, Wiring diagram SCH11 for pin assignment and wiring diagram of the solenoids. 11
Repeat the last step for the other solenoids.
12
Remove the measuring equipment and reassemble the connector (2) to the T-ECU (1).
13
Carefully assemble the side panel.
NOTICE Take care of the connectors and harnesses on the rear of the panel.
Fig.69 T-ECU with connector 1 T-ECU 2 T-ECU connector
118
14
Assemble and fasten the retaining screws of the side panel.
15
Assemble the knob of the hand throttle.
Wires, testing Powershift transmission (option), checking gear shift modulation and forward/reverse solenoids Op. no. Tools: 88830171 Break out harness 88830182 Cable 9998699 Adapter 9990008 Measuring equipment Multimeter
1
1
Place the machine in service position 2, see section 191, Service position 2.
2
Turn off the battery disconnect switch.
3
Remove the floor mat in the cab.
4
Remove the cab floor plate in front of the seat.
5
Remove the knob of the hand throttle lever.
6
Loosen and remove the retaining screws of the side panel.
7
Carefully lift away the side panel.
V1094146
Fig.70 battery disconnect switch 1 position 0: battery disconnect switch off 2 position 1: battery disconnect switch on
NOTICE Take care of the connectors and harnesses on the rear of the panel. V1103768
Fig.71 side panel, removal
8
Remove the connector (2) from the T-ECU (1).
9
Connect the break out harness to the connector. 88830171 Break out harness
10
Connect the adapter cable to the break out harness. 88830182 Cable
11
Connect the break out box to the adapter cable. Use the template for further pin identification. 9998699 Adapter 88890019 Template
Fig.72 T-ECU with connector 1 T-ECU 2 T-ECU connector
119
Fig.73 powershift transmission, checking wires 1 gear shift modulation, 2nd/4th gear (PWM4222) 2 reverse gear shift (PWM4214) 3 forward gear shift (PWM4213) 4 gear shift modulation, 1st/3rd gear (PWM4221)
12
Remove the electrical connector from the solenoid.
13
Measure the resistance of both ends of each connector wire. Measure between the connector and the T-ECU. Each wire should have an electrical resistance of approximately 0 Ω.
14
Measure resistance between wires. There should be no electrical connection between wires.
15
Reconnect the connector to the solenoid.
16
Repeat the last 4 steps for all solenoid connectors and cables.
17
Remove the measuring equipment and reassemble the connector (2) to the T-ECU (1).
18
Carefully assemble the side panel.
NOTICE Take care of the connectors and harnesses on the rear of the panel.
Fig.74 T-ECU with connector 1 T-ECU 2 T-ECU connector
120
19
Assemble and fasten the retaining screws of the side panel.
20
Assemble the knob of the hand throttle.
Gear selector switch, testing Powershift transmission (option) Op. no.
1 V1094146
1
Place the machine in service position 2, see section 191, Service position 2.
2
Turn off the battery disconnect switch.
3
Remove the steering wheel and the front console, see section 851, Front console, removing.
4
Disconnect the connector from the multi functional lever FX1016.
5
Check the electrical resistance in the connector FX1016 according to illustration below. X indicates approximately 0 Ω between pins. Change the position of the switch as necessary.
Fig.75 battery disconnect switch 1 position 0: battery disconnect switch off 2 position 1: battery disconnect switch on
1
2
3
4
5
F1
X
X
X
X
F2
X
X
F3
X
X
F4
X
X
N1
X
N2
X
N3
X
N4
X
X X
R1
X
X
R2
X
X
R3
X
X
R4
X
X
H
6
7
8
X
X
X X X X
X X X X X X X X
X
X
F=Forward, R=Reverse, N=Neutral 1–4=gear that should be engaged for measurement 6
Assemble the front console and the steering wheel, see section 851, Front console, installing.
121
Loader lever, electrical measuring Op. no. 302-130 Tools: 9998699 Adapter 88890019 Template 88890016 Break out harness Multimeter Use the Service mode of the information display to check the functions of the loader lever. If this values are incorrect, measure the loader lever like described below. The transmission control switches can be checked in the submenu digital in/out VECU. See section Information display, electrical system (Electrical system) page 82.
V1102320
Fig.76 submenu digital in/out VECU
The 4in1 switch can be checked in the submenu 4in1 option. See section Information display, hydraulics (Hydraulic) page 76. For general description of the information display see section Information display, general page 55. Preparation
V1101112
Fig.77 submenu 4in1 option
1 V1094146
Fig.78 battery disconnect switch 1 position 0: battery disconnect switch off 2 position 1: battery disconnect switch on
122
1
Place the machine in service position 2, see section 191, Service position 2.
2
Turn off the battery disconnect switch.
3
Remove the switch cover (1) from the joystick housing.
4
Loosen and remove the retaining screw (2).
5
Carefully remove the joystick housing.
6
Disconnect the connectors marked as CN12 and SW9113.
7
Connect the suitable breakout box cables between the connectors CN12 and SW9113. Special tools: 9998699 Adapter 88890019 Template 88890016 Break out harness Multimeter
8
Turn on the battery disconnect switch.
9
Turn the key switch in position I.
Fig.79 joystick housing, disassembly 1 switch cover 2 retaining screw 3 joystick housing
Fig.80
Checking connector SW9113 (4in1 function) 10
1
Open/close the 4in1 bucket with the roller. Check the voltage on pin 2 while opening/closing the bucket and when the roller is in neutral position. See table below for correct values.
Connector SW9113 Pin
Function
1
Supply voltage SW9113 from V-ECU (5V)
2
Output signal SW9113 to V-ECU neutral position ca 2.5 V forwards position ca. 4.3 V backwards position ca.0.7 V
3
Ground
4
Not used
V1070722
Fig.81 1 roller for 4in1 bucket
123
Checking connector CN12
1
2
3
4
5
11
Press the buttons for forward, reverse, neutral, transmission disconnect and transmission kick-down one after another and perform a continuity check for each function. Measure the regarding pin of the function (see table below) against pin 1.
Connector CN12 Pin
V1070730
Fig.82 1 transmission kick-down 2 transmission disconnect 3 forward 4 reverse 5 neutral
Function
1
+ after key
2
Neutral SW4228
3
Not used
4
Transmission disconnect SW4231
5
Kick-down SW4220
6
Not used
7
Not used
8
Not used
9
Reverse SW4230
10
Not used
11
Forward SW4229
12
Not used
Reassembly
Fig.83 joystick housing, disassembly 1 switch cover 2 retaining screw 3 joystick housing
124
12
Turn the key switch in position 0.
13
Turn off the battery disconnect switch.
14
Remove the measuring equipment and reassemble the connectors CN12 and SW9113.
15
Assemble the joystick housing and fasten the retaining screw (2).
16
Assemble the switch cover (1) to the housing.
31 BATTERY 311 Battery
125
Battery, description 1
2
The standard battery is located in the battery compartment on the left side of the machine. An optional second battery can be installed in parallel with the standard battery to increase battery capacity in colder climates. The battery disconnect switch connects the battery to the negative terminal. The battery is supplying a voltage of approximately 12 V to the system, depending on the battery charge level. In the wiring diagram the standard battery is marked as BA3201 and the optional battery is marked as BA3202. See 370, Wiring diagram SCH02.
V1096584
Fig.84 1 Standard battery 2 Battery disconnect switch
126
Battery, charging
WARNING Hydrogen gas is formed during battery charging. Hydrogen gas is flammable and may be explosive. A short circuit, open flame or spark near the battery can cause a powerful explosion. Therefore, ventilate well. Never smoke near batteries. - Batteries must only be charged using a battery charger. - Check the battery terminal connections and make sure that they are adequately tightened and free from corrosion and dirt. - Check the battery voltage when the batteries are at rest (before starting). Each battery must be at least half-charged.
CAUTION Always turn off the current to the battery charger before disconnecting the charging clamps.
WARNING Corrosive sulphuric acid The battery electrolyte includes corrosive sulphuric acid. Electrolyte spilled on bare skin must be removed immediately. Wash with soap and plenty of water. If electrolyte gets into your eyes or any other sensitive body part, rinse immediately with plenty of water and seek immediate medical attention.
127
Battery, storage A battery gradually loses its charge through self–discharge, which depends on the storage temperature and the level of charge. A fully charged battery stored in an cool location loses insignificant capacity during a three month period. A partly charged battery and/or a battery stored in room temperature loses capacity faster. Therefore, always store batteries fully charged and as cool as possible, however, not at freezing temperatures. During extended storage, the battery should be checked periodically and trickle–charged when needed.
128
Batteries, replacing Op. no. 311-002
WARNING Explosion hazard. A fire or explosion can result if the positive terminal of the battery is short–circuited to the negative terminal or the frame. Therefore, always protect the battery terminals. Always disconnect the ground cable from the battery first to reduce the risk of sparks that can cause fire.
1
2
1
Switch off the battery disconnect switch.
2
Remove the cover.
3
Disconnect the negative (–) cable from the terminal. Disconnect the positive (+) cable from the terminal.
4
Remove the nuts and the flat bar and lift out the battery.
5
Lift the new battery into position and fit the flat bar and the nuts.
6
Connect the positive cable to the battery. Connect the ground cable to the battery.
7
Switch on the battery disconnect switch.
V1060041
Fig.85 1 disconnect switch 2 battery
129
Battery, checking electrolyte Op. no. 1
Before performing any work on the battery, read the following document: 191, Safety when working with batteries.
2
Turn off the battery disconnect switch.
3
Check that the cable terminals and pole studs are clean, well tightened and coated with petroleum jelly or similar.
4
1
2
The battery electrolyte contains corrosive sulphuric acid. Electrolyte spilled on bare skin should be removed immediately. Wash the affected area with soap and plenty of water. If electrolyte gets into your eyes or any other sensitive body part, rinse immediately with plenty of water and seek immediate medical attention.
3
Remove the cell caps. 5
Check the charging status for all battery cells with an acid tester.
6
Check the electrolyte level. Top up with distilled water if necessary.
4
5 Fig.86 current capacity, check 1 cell cap 2 level indicator 3 maximum level 4 minimum level 5 level indicator
130
WARNING
NOTICE The electrolyte level should stand approx. 10 mm (0.4 in) above the cell plates. Check the level indicator.
V1092347
7
Reassemble the cell caps.
32 ALTERNATOR; CHARGE REGULATOR 320 General, common info about 321 322 Alternator, description The alternator is a 95 A alternating current alternator with integrated charge regulator. When the engine is not running, the battery normally supplies a voltage of approximately 12 V, depending on the battery charging level. When the engine is running, the battery is charged by the alternator, since the charge voltage (∼14 V) normally is higher than the battery voltage. If the charging voltage is too low or too high, the charging warning indicator on the side instrument panel is lit. In the wiring diagram the alternator is marked as AL3201. See 370, Wiring diagram SCH02.
Fig.87 Charging warning indicator
6 5 4 3 2 1
V1019907
Fig.88 Alternator and fittings 1 Fan belt 2 Pulley 3 Plate
131
4 5 6
132
Alternator Regulator Bracket
33 STARTING SYSTEM 330 General, common info about 331 334 Starter motor, description The starter motor has a built–in solenoid which is energized via the starter relay in the battery box. The V–ECU prevents the starter motor from being engaged if the engine is running or if the transmission is not in neutral.
Fig.89 Starter motor and fittings 1 Solenoid 2 Starter motor
In the wiring diagram the starter motor is marked as MO3301. See 370, Wiring diagram 1. Related components Fuses
FU01 (fuse for starter relay)
Relays
RE3301 (starter relay)
Switches
SW3301 (ignition key)
Other
Battery, V–ECU
133
333 Electric air pre-heater, excluding element Preheating, description The electrical preheating is built into the engine and is activated manually by turning the ignition key to position 2.
V1095047
Fig.90 Preheating indicator on display unit, right instrument panel
This causes the preheating indicator on the display unit to light up and energizes the preheating relay, which closes the circuit between battery plus and the glow plugs.
NOTICE Activating the electrical preheating for more than 30 seconds is not advisable since this might drain the battery, especially when outside temperature is below –10 °C (14 °F). See 370, Wiring diagram SCH02 for preheating function. Related components
134
Fuses
FC1, FU02
Relays
RE2501
Switches
SW3301 (ingnition key)
Glow plugs
HE2501
35 LIGHTING 350 General, common info about 351 356 Lighting, description The machine is standard equipped with four working lights on the cab. The electrical system is pre–wired for additional working lights on the cab superstructure and backhoe boom. The switches to operate the lights, are located on the right instrument panel. Head lights switch SW3501: Ignition key in position 0 - Switch in upper position: Parking lights off. - Switch in middle position: Parking lights on. - Switch in lower position: Parking lights on.
Fig.91 switch head lights, SW3501
V1095050
Fig.92 multifunctional lever on the steering column
Head lights switch SW3501: Ignition key in position 1 - Switch in upper position: Parking lights off. - Switch in middle position: Parking lights on and the switches for front and rear working lights are enabled. - Switch in lower position: High/low beam is on and the switches for front and rear working lights are enabled. High and low beam are controlled with the right multifunctional lever on the steering column. - Lever in neutral position: low or high beams on. - Lever downwards: High beam on and the control light for high beam is lit.
Fig.93 control light high beam
The front working lights are controlled with switch SW3504, located on the side console, if the light switch SW3501 is in it's middle or lower position. - Switch in upper position: lights off. - Switch in middle position: two lights on. - Switch in lower position: four lights on (optional equipment).
Fig.94 switch front working lights
135
The rear working lights are controlled with switch SW3505, located on the side console, if the light switch SW3501 is in it's middle or lower position. - Switch in upper position: lights off. - Switch in middle position: two lights on. - Switch in lower position: four lights on (optional equipment).
V1085622
Fig.95 switch rear working lights
136
See 370, Wiring diagram SCH13 and 370, Wiring diagram SCH14 for lighting.
36 OTHER ELECTRICAL EQUIPMENT 367 Electronic standard components V-ECU, replacing Op. no. 367-052
Disassembly
1
1
Place the machine in service position 2, see section 191, Service position 2.
2
Turn off the battery disconnect switch.
3
Remove the knob of the hand throttle lever.
4
Loosen and remove the retaining screws of the side panel.
5
Carefully lift away the side panel.
V1094146
Fig.96 battery disconnect switch 1 position 0: battery disconnect switch off 2 position 1: battery disconnect switch on
NOTICE Take care of the connectors and harnesses on the rear of the panel. V1103768
Fig.97 side panel, removal
6
Disassemble the plate.
7
Disassemble the T-ECU, if the machine is equipped with a Powershift transmission (option). See section 432, T-ECU, replacing.
Fig.98 V-ECU, disassembly
137
8
Loosen the retaining screws and remove them together with the cable (1).
9
Remove the mounting bracket (1).
10
Remove the connector (2) from the V-ECU (1).
11
Loosen and remove the three retaining screws of the VECU.
12
Remove the V-ECU.
Fig.99 V-ECU, disassembly 1 cable 2 mounting bracket
Fig.100 V-ECU, disassembly 1 V-ECU 2 V-ECU connector
Assembly
Fig.101 V-ECU, assembly 1 V-ECU 2 V-ECU connector
138
13
Assemble the V-ECU and the retaining screws, fasten the retaining screws.
14
Reassemble the connector (2) to the V-ECU.
15
Assemble the mounting bracket (2).
16
Assemble the retaining screws and the cable (1), fasten the retaining screws.
17
Assemble the T-ECU, if the machine is equipped with a Powershift transmission (option). See section 432, T-ECU, replacing.
18
Reassemble the plate.
19
Carefully assemble the side panel.
Fig.102 V-ECU, assembly 1 cable 2 mounting bracket
Fig.103 V-ECU, assembly
NOTICE Take care of the connectors and harnesses on the rear of the panel. V1103768
Fig.104 side panel, removal
20
Assemble and fasten the retaining screws of the side panel.
21
Assemble the knob of the hand throttle.
139
I-ECU, replacing Op. no. 367-056
Disassembly I-ECU 1 (side panel)
1
1
Place the machine in service position 2, see section 191, Service position 2.
2
Turn off the battery disconnect switch.
3
Remove the knob of the hand throttle lever.
4
Loosen and remove the retaining screws of the side panel.
5
Carefully lift away the side panel.
V1094146
Fig.105 battery disconnect switch 1 position 0: battery disconnect switch off 2 position 1: battery disconnect switch on
NOTICE Take care of the connectors and harnesses on the rear of the panel. V1103768
Fig.106 side panel, removal
Fig.107 I-ECU 1, disassembly 1 I-ECU 1 2 I-ECU 1 connector
140
6
Disconnect the connector from the I-ECU 1.
7
Loosen and remove the retaining screws, remove the I-ECU 1.
Assembly I-ECU 1 (side panel) 8
Assemble the I-ECU 1 and the retaining screws, fasten the retaining screws.
9
Connect the connector to the I-ECU 1.
10
Carefully assemble the side panel.
Fig.108 I-ECU 1, assembly 1 I-ECU 1 2 I-ECU 1 connector
NOTICE Take care of the connectors and harnesses on the rear of the panel. V1103768
Fig.109 side panel, removal
11
Assemble and fasten the retaining screws of the side panel.
12
Assemble the knob of the hand throttle.
141
I-ECU, replacing Op. no. 367-056
Disassembly I-ECU 2 (front instrument panel)
1
1
Place the machine in service position 2, see section 191, Service position 2.
2
Turn off the battery disconnect switch.
3
Remove the steering wheel, see section 641, Steering wheel, replacing.
4
Loosen and remove the retaining screws, remove the instrument panel cover.
5
Loosen and remove the retaining screws, remove the IECU 2.
6
Disconnect the connector from the I-ECU 2.
V1094146
Fig.110 battery disconnect switch 1 position 0: battery disconnect switch off 2 position 1: battery disconnect switch on
V1098891
Fig.111 instrument panel cover, removing
Fig.112 I-ECU 2, disassembly 1 I-ECU 2
142
Assembly I-ECU 2 (front instrument panel) 7
Connect the connector to the I-ECU 2.
8
Assemble the I-ECU 2 and the retaining screws, fasten the retaining screws.
9
Assemble the instrument panel cover and the retaining screws, fasten the retaining screws.
10
Assemble the steering wheel, see section 641, Steering wheel, replacing.
Fig.113 I-ECU 2, assembly 1 I-ECU 2
V1098891
Fig.114 instrument panel cover, removing
143
T-ECU, replacing See section 432, T-ECU, replacing.
144
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Ref. no. PUB 20026874-A 2011.09 Volvo, Konz
English CST
