Volvo EC160B 180B 210B 240B 290B 360B 460B Service Manual - PDF DOWNLOAD

EC160B/180B/210B/240B/290B/360B/460B

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Machine information system change System layout change Electronic control system overview VECU input & output Control circuit EECU Electric circuit(EC160B/180B/210B/240B/290B) EECU Electric circuit(EC360B/460B) Machine status indication(IECU) IECU Electric circuit Old instrument panel circuit Power ON/OFF procedure Indicator operation MCD(Machine Display Center) operation X1 option flow setting Pop-up indicator Code lock(Anti-theft) Error Message(ECU) Error Message(Comunication & Elec. system) Error Message(Hydraulic system) Error Message(Engine) Error Message(Engine) Old start circuit(EC160B/180B/210B/240B/290B) Start circuit ( Old alternator & New IECU- EC160B/180B/210B) Start circuit ( New alternator & Old Inst. panel-EC240B/290B) Start circuit ( New alternator & New IECU- EC160B/180B/210B/240B/290B) Old start circuit(EC360B/460B) Start circuit ( New alternator & Old Inst. panel-EC360B/460B) Start circuit ( New alternator & New IECU- EC360B/460B) Alternator change Safety relay change(Add time delay function)

UPDATE-EC160B~460B-01 UPDATE-EC160B~460B-02 UPDATE-EC160B~460B-03 UPDATE-EC160B~460B-04 UPDATE-EC160B~460B-05 UPDATE-EC160B~460B-05-1 UPDATE-EC160B~460B-05-2 UPDATE-EC160B~460B-06 UPDATE-EC160B~460B-07 UPDATE-EC160B~460B-07-1 UPDATE-EC160B~460B-08 UPDATE-EC160B~460B-09 UPDATE-EC160B~460B-10 UPDATE-EC160B~460B-11 UPDATE-EC160B~460B-12 UPDATE-EC160B~460B-13 UPDATE-EC160B~460B-14 UPDATE-EC160B~460B-15 UPDATE-EC160B~460B-16 UPDATE-EC160B~460B-17 UPDATE-EC160B~460B-18 UPDATE-EC160B~460B-19 UPDATE-EC160B~460B-20 UPDATE-EC160B~460B-21 UPDATE-EC160B~460B-22 UPDATE-EC160B~460B-23 UPDATE-EC160B~460B-24 UPDATE-EC160B~460B-25 UPDATE-EC160B~460B-26 UPDATE-EC160B~460B-27

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Machine Information System Change

2. Simplifying electirc circuit by using communication line instead of the various direct electric connection

1. Integration of hardware

Old Instrument panel

3. Removing duplicated sensor Engine oil pressure switch for indicator

Sensor & Switch

Coolant temperature sensor for needle gage Instrument panel

EMS

1450RPM G1

V-ECU

E- ECU

MDU

13:24

- Fuel level sender

New

MDU (Machine Display Unit)

- Overload warning select switch & pressure switch

IECU V-ECU

4. Changing Connection to VECU

- Alternator charging signal

EECU EMS

123456

Flow control SW

Hour meter

E-ECU Sensor & Switch

I-ECU

Electric signal ( On, Off, Resistance) Information link (J1587) Control link (J1939)

Buzzer

Volvo Construction Equipment Customer Support

UPDATE - EC160B~460B - 01

- Auto-grease ind. signal - Buzzer stop & Confirm switch for Quick fit

System Layout Change Machine Display Unit

Ins trument panel

C

Old OFF

Flow control SW

AUTO

Emergency control switch

A/C controller

� �

� � �

**Flow setting will be done by IECU 123456

Hour meter 2002 RPM MODE

0%

New IECU

New

C

OFF

Emergency control SW Volvo Construction Equipment Customer Support

Remove Flow control SW UPDATE - EC160B~460B - 02

AUTO

A/C controller

Electronic Control System Overview

IECU MID140 EMS(E-ECU) MID128

VECU MID187

2002 RPM MODE

0%

J1939(CAN) J1587(J1708)

MPC(9993892) PC(9998555)

MATRIS

Interface

VCADS Pro Service Display Unit (SDU)

Volvo Construction Equipment Customer Support

UPDATE - EC160B~460B - 03

VECU Input & Output

Hyd. oil temp. sensor (EC360B/ 460B)

Travel Att Hammer B/Float Fuel Auto.

Pilot Position level Pilot Pilot Alternator grease Pressure Pressure Pressure Pressure sensor controller Switch Switch Switch Switch

Rotator Switch

Hammer/ Boost/Shear Select B/Float Switch Switch

B1+

B2+

RH Switch

P/Max Engine Select Speed Control SW Switch

Auto Idle Start Select Switch Switch

NEW

NEW

NEW

Safety Lever Switch

A

Overload warning select switch

Buzzer Stop Confirm Switch

A

A

A

Emergency SW

A

Flow Control Valve Power Shift Valve

SDU Volvo Construction Equipment Customer Support

VECU Status

A/M SW position

Battery Relay

UPDATE - EC160B~460B - 04

2002 RPM

P MODE

Resistor Box

0%

IECU

EECU

Data Memory Relay

Quick Fit Switch

Auto/ Manual Switch

B/Float Sol.

Travel Speed Select Switch

Power Boost

Overload warning pressure SW

NEW NEW

Boom & Arm conflux cutoff

Relay

NEW

Hyd. oil cooling fan(EC360B/460B)

V-ECU

Control Circuit(EC160B~EC460B)

JA21 Auto grease "IND"

Volvo Construction Equipment Customer Support

3

5

EMS DATA RECORD

EB9 EB10

30

1

R/H J/S Center button

EB2(L) EB1(H)

EB26(B) EB25(A)

1

3

7

2

4

8

3

87a

5

1

3

7

2

4

8

Neutral

SS to Safety Relay

2

JA20

30

1

1 1

3 7

5 OFF

1

5

OFF

Engin RPM Ctrl.SW

30

1

5

Safety lever A / M to IECU

P/Shift Ground

VECU operating power

1

2

3

4

5

AUTO MANU

Power Shift P/V

P/V

Resistor Box

UPDATE - EC160B~460B - 05

87a

Rotator

P/V

Flow Control P/V

3

86

Quick fit

Safety sol.

JA56 JA30 JB11 (+24V) JA39 (0.5~4.5) JA14 (GND) Power shift Signal JA32

5

87

2

4

85

Boom float

JB15 JB16

R5

86

6

R6

4

85

87

3

87a

5

L/H J/S RH button

3

L/H J/S LH button

UP

DOWN

2

Quick fit sol.

JA70

Float press.(7k) JA17

1 OFF

Power Max. select JA44

JA46

JA12 Hyd. oil cooling fan

JA37

JA59

JA36 Power Boost

Overload warning select

OFF

##

87

Quick Fit SW L/H

1

JB7 JB8 JA33

JA5

***

4

85

Quick Fit SW R/H

Safety lever

Key on "ACC" JB9 JB9

Hyd. oil temp. sensor

Key start "R2" JB2 JB2

JA15 (GND)JA63

JA47

JA22

JA40

##

Fuel level

J1587

J1939

VECU status

8(A) 9(B)

87a

87

EECU

Flow control Ground

JA61 to Battery relay

1

JB1

Conflux cutoff

Travel Speed

JA7 to alternator

30

5

R12

86

JA68

Floating

T/speed select SW Hammer

Hammer select sol.

Shear select sol.

OFF

87a

2

4

85

VECU

Shear position JA45 Auto grease JA21 Battery Relay JA61 Altenator”L” JA7

5

86

JA23

Boom

1

F28 10A

Power P/V

Arm

Boost position

85

JA69

Travel speed control JA38 T/Speed SW position JA18 Hammer position

3

R4

2

4

87

1

Flow control Signal

5

F12 15A

ON 20K OFF 14K

EB11 EB12

(L)JB6 (H)JB14 JB13 JB5

87a

(B)JB4 (A)JB12

3

Overload Press.(adj.)

JA41 Travel Press.(20k) JA43 Att. Press.(20k) JA19 Hammer Press.(7k) JA66

87

1

5

JA42

30

87a

JA24 JA48 JA1 JA25 JA49 JA26 JA2 JA60 JA35

Q/fit Confirm

3

key "#" key "*" key "V" key ">" "enalber" "data" "clock" Power for solenoid Power for solenoid

4

85

Buzzer stop JA16

87

86

F13 10A

Neutral

A/M ILL. SW from Auto / Work lamp SW Manual

JA13

2

4

85

30

EB4

Auto. Idle JA67

30

1

R1

7

R3

2 86

EMS POWER

JA34

R/H J/S RH button

2

8

9 13 Service Socket 14 1 2 3 4 5 6 7 10 11

F25 10A

1 2 3 4 5 6

POWER FROM BATTERY

IECU(NEW)

10

## EC360B/460B Only (Hyd. oil temp. sensor & Hyd. oil cooling fan speed control sol.)

86

5

F16 15A

1(H) 2(L) 3(A) 4(B)

*** EC290B Only ( 1 Conflux cutoff sol.)

Hammer Boost Shear select SW 1 2 3 4 5 6 7 8

6

SDU / MATRIS / VCADS PRO

F15 20A

Key ES "ACC"

Clock

POWER FROM BATTERY RELAY

R2

F24 5A

F01 10A

IECU operating power

F27 10A

EECU Electric Circuit( EC160B/180B/210B/240B/290B)

1

n

1

3

2

3 4

(+)

(-)

18

(+)

31

Cyl 5

2 1

7

Cyl 1

New Boost Press. & temp.

Connector A BLACK

2

Coolant Oil temp. press.

Cyl 6

12

n

Fuel temp.

Cyl 3

24

1

Engine speed sensor ,crank

Cyl 4

36

Engine speed sensor ,cam

Cyl 2

E-ECU

Solenoid valve on unit injection pump

2

(+)

(-)

30

13

25

14

3

2

(-)

4

(-)

5

12

(-)

11 23 22

24

35 36 34

Connector A 13

25

26

9 10 11 12

7

17

8

3 13

31

Preheat relay 4

24V(+)

GND

J1708_B

J1708_A

J1939_L

J1939_H

3

Coolant level

Inlet press.

Inlet temp.

Power from fuse 13

Preheat coil

UPDATE - EC160B~460B - 05-1

1

Volvo Construction Equipment Customer Support

2

AH to Fuse 140A

25

Emergency speed control

1

5

(-)

12

(-)

36

(-)

Connector B

RED

2

1

1

Ambient air press.

24

4

25

Connector B

EECU Electric Circuit( EC360B/460B)

1

2

2

2

1 3 (+)

7

(+)

(-)

18

31

Boost Boost temp. press.

4

4

2

2

1

3

4 2

Cyl 6

Cyl 1

Cyl 5

Connector B

1

1 (+)

(-)

30

Cyl 3 Fuel press.

RED

n

Oil Oil temp. press.

25

1

14

2

12

n

Coolant temp.

24

1

Engine speed ,crank

36

Engine speed ,cam

E-ECU

Solenoids on injection pump Cyl 2 Cyl 4

(-)

4

3

(-)

27 5

(-)

12

11 23 22

24

35 36 34

Connector A 13

1

2

25

26

9 10

11 12

7

17

8

3 13

31

(-)

Ground

4

BLACK

J1708 J1708 A B

3

12

Emergency J1939 J1939 Speed H (A) L (B)

2

AH to Fuse 140A

36

Preheat relay 1

5

(-)

24

(-)

1

4

25

Barometer

Connector B

Power supply Power from fuse Coolant level

13

Inlet (air) Inlet (air) press. temp. (filter clogging)

Volvo Construction Equipment Customer Support

UPDATE - EC160B~460B - 05-2

1

25

Preheat coil

Connector A

Machine Status Indication (IECU) Group

Name

Color

Remark

Central warning lamp Fuel level gauge Engine coolant temperature gauge Indicator Parking brake lamp Brake oil pressure warning lamp Steering pressure low Oscillation lock Alignem ent Working l ights lamp (* High beam lamp) Left/right turn signal lamp Engine oil pressure warning lamp Engine coolant temperature warning lamp Coolant level lamp Air cleaner clogging warnin g lamp Air preheating lamp Hy draulic oil tem perature warning Hy draulic oil filter clogging Battery charge warning lamp Quickfit lamp Overload warning lamp Power booster Float operation indicator Hammer selecting indicator Shear selecting indicator MCD Electronic Display Unit (Message Center Display)

Red Red Red Red Yellow Green Blue Green Red Red Red Yellow Yellow Red Yellow Red Red Red Green Green Green Green

Flashes when a fault occurs 8 Step, TN-LCD, Transflective Back light by white color LED

Key

-

Lamp Gauge

1450RPM G1

13:24

Buzzer

Up Down Scroll Confirm Buzzer

Real time Real time clock Clock

Volvo Construction Equipment Customer Support

UPDATE - EC160B~460b - 06

used at wheel excavator used at wheel excavator N/A used at wheel excavator N/A High beam at wheel excavator used at wheel excavator

N/A

128x64 pixels LCD Back light by amber colored LED Screen Up Screen Down Scroll Confirm sounds when fault occurs and buttons are pressed Capacitor supply power to clock for 500 hrs without external power

JA34 H

TO VECU

Volvo Construction Equipment Customer Support

L A B Auto/Manual SW position

VECU STATUS

VECU JB16

21C7 (ILLU.LAMP)

21C10

21C8

21C4 (J1587 B)

21C3 (J1587 A)

21C2 (J1939 L)

21C1 (J1939 H)

21C9

UPDATE - EC160B~460B - 07

SHEAR

HAMMER

BOOM FLOAT

POWER BOOST

OVER LOAD

QUICK FIT

CHARGE

HYD FILTER

HYD TEMP

PRE HEAT

AIR CLEANER

COOLANT LEVEL

COOL TEMP

E/OIL PRESS

LH/RH TURN

HIGH BEAM

ALIGNE

AXLE LOCK

STEER PRESS.

BRAKE FAIL

PARK BRAKE

CENTRAL WARNING

F1 10A

21C5 (CLOCK)

21C6 KEY ON

From battery

From battery relay

IECU Electric Cirucit

F16 15A

W/TEMP FUEL

LCD DISPLAY (MCD)

IECU

From work lamp switch 5 1

10 6

Volvo Construction Equipment Customer Support

Buzzer C11

C16

10 1

20 11

Connector C UPDATE - EC160B~460B - 07-1

VECU

VECU

Connector D

1 10

11 20

Alternator "D+"

VECU

Grease Cont.

B+

VECU

VECU

C4

C5

C7

C10

C8

C12

D2

C14

C17

C13

C15

C20

D6

D14

D3

D11 D1

Buzzer stop C9 Confirm C19

B+

Alternator "W"

C18

D20

D4 C1

Coolant temp.

Hour meter

Centeral warning

Centeral warning

Charge

Engine oil

Coolant temp.

Air cleaner

Brake failure

Auto grease

Overload

Preheating

Fuel warmer

Quick fit

Water seperator

Hyd. oil temp.

Coolant level

Boom float

Spare

D12 Em'cy ready D5 Parking

D13

D10

D17

D19

D18

D7

C2

C3 D9

Fuel level

High beam Em'cy operation

LH turn

RH turn

Hammer

Shear

Powr boost

Axle lock

ILL

ILL

ACC ACC

B+

B+

B+

B+

B+

B+

B+

B+

B+

B+ B+

Old Instrument Panel Circuit

Power On/Off procedure Power

Key on -> 3 sec.

Key Off -> 3 sec.

(After receiving “off” signal from VECU

Centeral warning lamp

On for 3 sec.

off

Gauge all segment “On” immediatly Indicator all lamp “On” for 3 sec.

MCD (Message Center Display)

all segment “Off” immediatly Off

0 RPM I2

EC210B

Gauge back light MCD back light Button back light Buzzer Button

Volvo Construction Equipment Customer Support

800RPM I2

13:24

13:24

On

Off

Warning sound 2 times Locked(no response)

Silent Locked(no response)

UPDATE - EC160B~460B - 08

EC210B

Indicator operation

Overload warn Brake oil pressure low Quickfit open Steering pressure low Battery no-charge Air cleaner clogging

On On On On On On

Blink Blink Blink Blink Blink Blink

A larm A larm A larm A larm Caution Caution

Coolant level low Hy draulic oil temperature high

On On

Blink Blink

Caution Caution

Hy draulic oil filter cloggi ng

On

Blink

Caution

Air preheating Alignment Parking brake High Beam (Working lamp) Left/right turn signal Hammer selecting Shear selecting Power boost operating Oscillation lock Float operation

On On On On On On On On On On

X X X X X X X X X X

X X X X Alarm X X X X X

500ms

500ms

(2) Quick fit buzzer stop & Confirm a) Open Q/fit open

b) Buzzer stop Q/fit open

Buzzer stop

c) Q/fit engage & Confirm Q/fit engage

Confirm

Buzzer Alarm sound will last until operator pushes confirm button of IECU Volvo Construction Equipment Customer Support

UPDATE - EC160B~460B - 09

IECU

A larm

IECU

Blink

Alarm : Two sounds pulses every seconds

IECU

Telltale

On

1000ms

VECU

Caution

Engine oil pressure low

Caution : One sound pulse

VECU

Alarm

Operation Indicator Central Buzzer warning Sound Engine coolant temperature high On Blink A larm Sym ptom

VECU

Category

(1) Buzzer Sound spec.

MCD operation *** 800RPM I2

0123 EC210B

Input password 0123

13:24

13:24 24.04.2004

1 24

x1: 120L

1111 hour

X1

X1 100 L

100 L 120 L 140 L

30 min

110 L

X1 100 L

*

0123

**

0123

***

***Time setting

111.1 H

13:24 24.04.2004

1 24

28.2 V

0123

****

EC210B S.No:12345

Press for more than 2 sec.

No Error

ECU

or

187 SID 254 12 Volvo Construction Equipment Customer Support

UPDATE - EC160B~460B - 10

DD-MM-YYYY

24.04.2004

X1 Option flow setting (3) Max. & Min. flow at rated engine rpm (1) Parameter programming : X1 option(ON)

VCADS Pro

1) X1 option "ON"

Model

800RPM I2

VECU MID187

13:24

x1: 100L

Present setting flow at rated engine rpm

(2) Flow setting

Changing unit(LPM/GPM) by pressing this button

EC180B EC210B EC240B

1111 hour X1 100 L

EC160B

X1

100 L 120 L 140 L

Display : Min.(20L), Max(480L)

110 L

X1

100 L

EC290B

Fine setting : Resolution(5L)

EC360B EC460B

Volvo Construction Equipment Customer Support

UPDATE - EC160B~460B - 11

Pump flow PV current (Lpm / Gpm) (mA)

Max.

143/38

270

Min.

30/8

610

Max.

143/38

270

Min.

30/8

610

Max.

200/53

260

Min.

40/11

600

Max.

230/61

280

Min.

40/11

610

Max.

250/66

280

Min.

40/11

610

Max.

280/74

300

Min.

40/11

600

Max.

345/91

300

Min.

40/11

630

Pop-up indicator

Overload selection (not warning)

Auto grease

800RPM I2

13:24 800RPM I2

13:24

** If two pop-up indicators are activated at the same time, The indicator of highest priority is shown on MCD. Priority ( 1 : Overload selection, 2 : Auto grease)

Volvo Construction Equipment Customer Support

UPDATE - EC160B~460B - 12

Code Lock(Anti-theft) (2) After Code Lock enabled, Key "ON" 0123

1) Code Lock option "ON" VCADS Pro 0123

3) Input Note) Wrong code 4 times, 10 min. system locking. password No 5) Send confirmed result

*

2) Save Password code 0

RPM

Saved code Yes = Entered code

0123

I2

**

13:24

0123 0123

****

(4) IECU abnormal

IECU

1) Request "SHUTDOWN"

4) Send confirmed result

*

**

Saved code Yes = Entered code

0123

Save the latest confirmed time at IECU

***

0123

****

EC210B

0

3) Press for more than 2 sec.

Volvo Construction Equipment Customer Support

RPM

T 13:24

VECU

0123

VECU

No

5) Request EECU to release "SHUTDOWN"

Saved option status for code lock from previous operation

EECU

0123

0123

4) Press for more than 2 sec.

UPDATE - EC160B~460B - 13

I2

1) Request "SHUTDOWN"

EECU

(3) VECU abnormal

EC210B

6) Request EECU to release "SHUTDOWN"

Save the latest confirmed time at IECU

***

2) Input password

2) Request "SHUTDOWN"

1) Save option status for code lock at VECU

EECU

IECU

VECU

(1) Parameter programming

Error Message (ECU) (1) VECU

ECU 187 SID 254 12 ***

Error From Signal FMI Code MID Code 11 187 SID 240 2 187 SID 253 2 187 SID 254 12 ***Auto/manual switch is Auto position and there is no VECU status signal.

Central Warning lamp Blink Blink Blink Blink

Error From Code MID 12 128 128 128 128 128

Central Warning lamp Blink Blink Blink Blink Blink

Buzzer A larm A larm A larm A larm

Source Program memory failure(Flash) Data set memory failure(EEPROM) Controller failure Controller failure

ECU 187 no signal

(2) EECU

ECU 128 SID 254 12

Volvo Construction Equipment Customer Support

Signal SID 240 SID 253 SID 253 SID 253 SID 254

FMI Code 2 2 12 13 12

UPDATE - EC160B~460B - 14

Buzzer A larm A larm A larm A larm A larm

Source Program memory failure(Flash) Data set memory failure(EEPROM) Bad component out of calibration Controller failure

Error Message (Communication & Electric system) (1) J1939 - CAN Bus ECU ECU

187 SID 231 12

Error From Code MID 13 128 128 128 187 187

Signal

FMI Code

SID 231 SID 231 SID 231

9 11 12

Central Warning lamp Blink Blink Blink

SID 231 SID 231

9 12

Blink Blink

Buzzer caution caution caution caution caution

Source Communication J1939 error J1939 Other malfunction J1939 defective unit or component Communication J1939 error J1939 defective unit or component

(2) J1587 - Information Bus ECU ECU

187 SID 250 12

Error From Code MID 14 128 187 187

Signal SID 250 SID 250 SID 250

FMI Code 12 9 12

Central Warning lamp Blink Blink Blink

Buzzer caution caution caution

Source Communication J1587 error J1587 Communication error J1587 defective unit or component

(3) Battery

187 SID 251 0 Volvo Construction Equipment Customer Support

Error From Code MID 21 187 187

Signal SID 251 SID 251

FMI Code 0 1

UPDATE - EC160B~460B - 15

Central Warning lamp Blink Blink

Buzzer caution caution

Source Battery voltage, to o high Battery voltage, too low

Error Message (Hydraulic system) (1) Power shift proportional valve

187 PPID 1190 3

Error From MID Code 31 187 187 187

Signal

FMI Code

PPID 1190 3 PPID 1190 4 PPID 1190 5

Central Warning lamp Blink Blink Blink

Buzzer caution caution caution

Source Power shift PV, High voltage Power shift PV, low voltage Power shift PV, open circuit

(2) Pedal pressure sensor

187 PID 91 3

Volvo Construction Equipment Customer Support

Error From Code MID 33 187 187 187

Signal PID 91 PID 91 PID 91

FMI Code 3 4 5

UPDATE - EC160B~460B - 16

Central Warning lamp Blink Blink Blink

Buzzer caution caution caution

Source Pressure sensor, High voltage Pressure sensor, low voltage Pressure sensor, open circuit

Error Message (Engine) (1) Boost temperature sensor

128 PID 105 3

Error From Code MID 42 128 128 128

Signal PID 105 PID 105 PID 105

FMI Code 3 4 11

Central Warning lamp Blink Blink Blink

Buzzer caution caution caution

Source too high voltage, shorted high too low voltage, shorted low Not identified, Other malfunction

(2) Speed sensor ( flywheel )

128 SID 22 2

Error From MID Code 43 128 128 128 128 128

Signal SID 22 SID 22 SID 22 SID 22 SID 22

FMI Code 2 3 8 0 14

Central Warning lamp Blink Blink Blink Blink Blink

Buzzer caution caution caution caution caution

Source Intermitternt or incorrect data too high voltage, shorted high A bnormal frequency valid, but too high above normal Special instruction

(3) Boost pressure sensor

128 PID 102 3 Volvo Construction Equipment Customer Support

Error From Code MID 44 128 128 128 128

Signal PID 102 PID 102 PID 102 PID 102

FMI Code 3 4 11 2

UPDATE - EC160B~460B - 17

Central Warning lamp Blink Blink Blink Blink

Buzzer A larm A larm A larm A larm

Source too high voltage, shorted high too low voltage, shorted low Not identified, Other malfunction Intermitternt or incorrect data

Error Message (Engine) (4) Preheater Error Code

128 PID 45 4

From MID 128 128

PID 45 PID 45

3 4

Central Buzzer Warning lamp Blink Caution Blink A larm

128 128 128 128

PID 45 SID 70 SID 70 SID 70

5 3 4 5

Blink Blink Blink Blink

Signal

FMI Code

Caution A larm Caution Caution

Source High voltage Low voltage (problem because preheat relay always ON) open circuit, disconnected High voltage(Coil On) L ow voltage too low current

(5) Coolant temperature sensor Error Code

128 PID 110 3

From MID 128 128 128

Signal PID 110 PID 110 PID 110

FMI Code 2 3 4

Central Warning lamp Blink Blink Blink

Buzzer Alarm Alarm Alarm

Source Intermittent or incorrect data too high voltage, shorted high too low voltage, shorted low

(6) Oil pressure sensor Error Code

128 PID 100 3 Volvo Construction Equipment Customer Support

From MID 128 128 128

Signal PID 100 PID 100 PID 100

FMI Code 2 3 4

UPDATE - EC160B~460B - 18

Central Warning lamp Blink Blink Blink

Buzzer Alarm Alarm Alarm

Source Intermittent or incorrect data too high voltage, shorted high too low voltage, shorted low

Old Start Circuit( EC160B/180B/210B/240B/290B ) To Auto Grease Controller

To Room Lamp, Diesel Heater, Fuel Filler Pump, DC-DC Converter

Slow Blow Fuse 40A

40A To Auto Grease Controller

F30 10A

F16 15A

F1 10A

Main Power Supply to Fuse Box

To DC-DC Converter INSTRUMENT PANEL B+

Cluster Control

B+ BR R1 R2 C ACC OFF ON START

80A 80A

140A AH To Air Heater Relay

Slow Blow Fuse B+

B-

Volvo Construction Equipment Customer Support

UPDATE - EC160B~460B - 19

EMS Power Relay

SS From Safety Limit SW

ACC AS4 ES Air Con. SW

IC Regulator

C From VECU (Safety Stop)

R2

To VECU

W

To VECU

D+

Start Circuit( Old Alternator & New IECU- EC160B/180B/210B) POWER FROM BATTERY

40A

40A

POWER FROM BATTERY RELAY

F16 15A

F30 15A

80A

to VECU JA21 PT150 1

2

RE3101

PT150

POWER TO IECU CLOCK

B+ B+ BR R1 R2

3

C ACC

OFF ON INDI

START

M

AMP

2

to Air Heater

0.75Y

0.75B

5

B+

JA61

6 0.5W

4

0.5L

3

WB

AUTO GREASE CONTROLLER 2

AH

9

to VECU

D+ W

+

M

JA7

-

IC Regulator

to VECU

4

B-

Volvo Construction Equipment Customer Support

UPDATE - EC160B~460B - 20

SL

JB2 JB9 A/C

ES

from safety lever

to Relay EMS power

12

to Air Contioner

8

1

to VECU

7

4

to VECU

1

3

L

T/E

A/S

140A

Start Circuit( New Alternator & Old Inst. panel- EC240B/290B) POWER FROM BATTERY

40A

40A

POWER FROM BATTERY RELAY

F16 15A

F30 15A

80A

to IND.

AG PT150 1

2

PT150

B+ B+ BR R1 R2

3

F1 10A

C ACC

OFF ON INDI

START

M

To DC-DC Converter

AMP

2

to Air Heater 1

7

8

3

L

T/E

A/S

140A

12

4

INSTRUMENT PANEL

1

AH

Cluster Control

9

AUTO GREASE CONTROLLER 6

+

M

to VECU

15 L W

-

4

Volvo Construction Equipment Customer Support

B-

UPDATE - EC160B~460B - 21

JB2 JB9 A/C

ES to Relay EMS power

I.C REG.

BS

from safety lever

to VECU

DFM

JA61

to Air Contioner

SL

B+

to VECU

0.5W

0.75B

5 0.5L

4

3 0.75Y

WB

2

Start Circuit( New Alternator & New IECU- EC160B/180B/210B/240B/290B) POWER FROM BATTERY

40A

40A

POWER FROM BATTERY RELAY

F16 15A

F30 15A

80A

to VECU JA21 PT150 1

2

RE3101

PT150

POWER TO IECU CLOCK

B+ B+ BR R1 R2

3

C ACC

OFF ON INDI

START

M

AMP

2

to Air Heater 1

7

8

3

L

T/E

A/S

140A

12

4

1

AH

9

AUTO GREASE CONTROLLER 6

+

M

JA61

SL

JB2 JB9 A/C

ES

to VECU

from safety lever

to Relay EMS power

I.C REG.

BS 15 L W

-

4

B-

JA7 to VECU

Volvo Construction Equipment Customer Support

UPDATE - EC160B~460B - 22

to VECU

DFM

to Air Contioner

B+

to VECU

0.5W

0.75B

5 0.5L

4

3 0.75Y

WB

2

Old Start Circuit( EC360B/460B) To Auto Grease Controller

To Room Lamp, Diesel Heater, Fuel Filler Pump, DC-DC Converter

Slow Blow Fuse 40A

40A To Auto Grease Controller

F30 10A

F16 15A

F1 10A

Main Power Supply to Fuse Box

To DC-DC Converter INSTRUMENT PANEL B+

Cluster Control

B+ BR R1 R2 C ACC OFF ON START

80A 80A

140A

Slow Blow Fuse

To Air Heater Relay

AH

B+

B-

Volvo Construction Equipment Customer Support

UPDATE - EC160B~460B - 23

EMS Power Relay

SS From Safety Limit SW

ACC AS4 ES Air Con. SW

IC Regulator

C From VECU (Safety Stop)

R2

To VECU

W

To VECU

D+

Start Circuit( New Alternator & Old Instrument panel - EC360B/460B) POWER FROM BATTERY

40A

40A

POWER FROM BATTERY RELAY

F16 15A

F30 15A

80A

to IND.

AG PT150 1

2

PT150

B+ B+ BR R1 R2

3

F1 10A

C ACC

OFF ON INDI

START

M

To DC-DC Converter

AMP

2

to Air Heater 1

7

8

3

L

T/E

A/S

140A

12

4

INSTRUMENT PANEL

1

AH

Cluster Control

9

AUTO GREASE CONTROLLER 6

+

M

to VECU

15 L W

-

4

Volvo Construction Equipment Customer Support

B-

UPDATE - EC160B~460B - 24

JB2 JB9 A/C

ES to Relay EMS power

I.C REG.

BS

from safety lever

to VECU

DFM

JA61

to Air Contioner

SL

B+

to VECU

0.5W

0.75B

5 0.5L

4

3 0.75Y

WB

2

Start Circuit( New Alternator & New IECU- EC360B/460B) POWER FROM BATTERY

40A

40A

POWER FROM BATTERY RELAY

F16 15A

F30 15A

80A

to VECU JA21 PT150 1

2

RE3101

PT150

POWER TO IECU CLOCK

B+ B+ BR R1 R2

3

C ACC

OFF ON INDI

START

M

AMP

2

to Air Heater 1

7

8

3

L

T/E

A/S

140A

12

4

1

AH

9

AUTO GREASE CONTROLLER 6

+

M

JA61

SL

JB2 JB9 A/C

ES

to VECU

from safety lever

to Relay EMS power

I.C REG.

BS 15 L W

-

4

B-

JA7 to VECU

Volvo Construction Equipment Customer Support

UPDATE - EC160B~460B - 25

to VECU

DFM

to Air Contioner

B+

to VECU

0.5W

0.75B

5 0.5L

4

3 0.75Y

WB

2

Alternator change

NEW

B+

DFM BS 15 L W

B-

D+

+ B2

OLD

W

B-

B1

+

EC140B~210B Standard(80A) EC240B~460B Standard(55A) Option(80A)

B+

EC140B~460B Standard(80A) D+

B+ DFM

W I.C REG.

BS

IC Regulator B-

Volvo Construction Equipment Customer Support

B-

UPDATE - EC160B~460B - 26

15 L W

Safety relay change( Add time delay function) Alternator "L"

Key "C"

GND

Safety lever

(1) Old(14526226) Normal operation

KEY SWITCH SAFETY RELAY

v

ST ON

*** During the air bleeding procedure from fuel line, We need more cranking time to start engine.

But at this situation, new alternator produce a little bit higer voltage at the termianl “L”.

So this voltage deenergize safety relay and interrupt start motor. To prevent this, we add the time delay function at safety relay.

(1) New(14531201) Start the engine again after the failure

Tum the key Hold key switch on ST switch to ST and position after ON while engine is running engine started. v ST ST

ST

ON

ON

ON

t

t

v

v

t

t

v

r/min

t

t

STARTER

KEY SWITCH

ON OFF

Normal operation

SAFETY RELAY

2-4 sec.

OFF

v

ST ON

***td = 30 +/- 5sec

ST

ST

ON

ON

ON

t

t

v

***td v

t

t

v

r/min

t

t

r/min

ENG

SAFETY RELAY Volvo Construction Equipment Customer Support

OFF

ENG

OFF

t

t

r/min

r/min

ALT t

B

OFF

ALT

Prevent

overrunning

restart

t

t

A

Prevent

2-4 sec.

OFF

r/min

OFF

t

ON OFF

STARTER

OFF

Start the engine again after the failure

Tum the key Hold key switch on ST switch to ST and position after ON while engine is running engine started. v ST

Prevent overrunning while motor is cranking

SAFETY RELAY

UPDATE - EC160B~460B - 27

B

OFF A

Prevent

Prevent

overrunning

restart

Prevent overrunning while motor is cranking