Volvo L60F User manual

MORE CARE. BUILT IN.
CONTENT
3 Electrical and Information System
Description
VOLVO CONSTRUCTION EQUIPMENT
SERVICE MANUAL
l60F/L70F/L90F

Foreword
This booklet is part of a complete service manual. Read the fore‐
word in the service manual.
WARNING!
Always read the booklet Safety before proceeding.
1
VOE 21 A 1002889

Content
30 GENERAL
300 Comprehensive info, electrical system
Electrical system, work instructions ............................................................ 5
Electrical system, description ..................................................................... 8
Electronic control system, description ...................................................... 10
Communication with data buses ............................................................... 12
Software, description ................................................................................ 13
Instrument control unit I-ECU, description ................................................ 14
Vehicle control unit V-ECU, description .................................................... 15
Vehicle control unit V2-ECU, description .................................................. 16
Engine control unit E-ECU, description .................................................... 16
Climate control unit ECC, description ....................................................... 17
31 BATTERY
310 General, common info about 311 - 313
Battery, description ................................................................................... 18
Battery, charging ....................................................................................... 19
Batteries, replacing ................................................................................... 20
System voltage ......................................................................................... 22
Key feed .................................................................................................... 22
32 ALTERNATOR; CHARGE REGULATOR
320 General, common info about 321 - 322
Alternator 80 A, description ...................................................................... 23
33 STARTING SYSTEM
331 Starter motor inclusive solenoid
Booting sequence ..................................................................................... 24
35 LIGHTING
350 General, common info about 351 - 356
Lighting, description .................................................................................. 25
36 OTHER ELECTRICAL EQUIPMENT
360 General, common info about 361 - 367
Reduced computer communication .......................................................... 28
Interruption in computer communication ................................................... 29
Limp Home ............................................................................................... 29
Intermittent wiper and washer ................................................................... 30
Theft protection ......................................................................................... 32
38 INSTRUMENT; SENSOR; WARNING AND INFORMATION
SYSTEM
380 General, common info about 383 - 387
Instruments ............................................................................................... 33
Instrument panels, position .................................................................... 33
Middle instrument panel with warning lights ............................................. 34
386 Sender, monitoring system
Washer fluid level ..................................................................................... 35
Fuel consumption ..................................................................................... 36
Travelling speed ....................................................................................... 37
Machine hours .......................................................................................... 37
387 Warning/information unit, display unit
Information display, general ...................................................................... 38
Information display, start lockout .............................................................. 41
Information display, operating display ...................................................... 42
Information display, engine ....................................................................... 43
Information display, transmission ............................................................. 45
3

Information display, hydraulics ................................................................. 46
Information display, axles / brakes ........................................................... 47
Information display, electrical system ....................................................... 48
Information display, vehicle info ................................................................ 49
Information display, vehicle messages ..................................................... 51
Information display, service ...................................................................... 52
Information display, service mode ............................................................ 53
Information display, settings ..................................................................... 55
Information display, check ........................................................................ 56
Alarm, description ..................................................................................... 57
Central warning ......................................................................................... 58
4

ELEC. SYSTEM; WARNING
SYSTEM; INFORMATION
SYSTEM; INSTRUMENTS
30 GENERAL
300 Comprehensive info, electrical
system
Electrical system, work instructions
Regarding: L60F, L70F, L90F
Batteries
1 Fully charged and otherwise satisfactory batteries must
always be used when working on the electrical system.
2 Test the batteries with an acid tester. The battery disconnect
switch should be turned off.
3 When installing a battery, make sure that the battery is con‐
nected 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), since the
charging current required to reach a certain voltage varies with
the battery's age.
5 If booster battery is required when starting, the following
instructions must be followed at all times;
191, Safety when
working with batteries
and 191, Starting with booster batter‐
ies
.
Charging
1 Before performing any tests of the alternator or regulator, the
batteries must be checked regarding insulation, loose fit, and
corrosion. Check the alternator belts.
2 For all testing of alternating current equipment, use “secure”
connections in order to prevent sparks and voltage transients.
A loose cable may result in destruction of both the alternator
and regulator.
3 Never disconnect the alternator leads while the engine is run‐
ning. This could damage both the alternator and regulator.
4 If the current alternator output socket should be connected to
the chassis, damage may occur to the alternator and regulator.
Components
When removing or installing components in the electrical system,
turn off the voltage supply with the battery disconnector.
5

Welding
For electric welding on the machine or on attachments on
machine:
- voltage feed turned off with battery disconnector
- connectors for all control units (ECUs) must be unplugged
NOTE! Ground the welding unit as close as possible to the weld‐
ing point.
6

Electrical system, description
Regarding: L60F, L70F, L90F
The machine has a 24 V electrical system with two 12 volt bat‐
teries connected in series, located on each side of the rear frame
in the counterweight.
The battery disconnector is located under the radiator casing.
Fuse FU74 is next to the battery disconnector and supplies volt‐
age to certain components (e.g., voltage converter for radio),
even when the battery disconnector is turned off.
Voltage feed takes place via a fuse box located in the engine
compartment. The fuse box contains main fuse as well as fuses
for preheating coil and secondary steering pump.
Relays and fuses are mainly located in the electrical distribution
box behind the operator's seat and are accessed by removing the
cover for the electrical distribution box. The cover's inside is pro‐
vided with a decal that informs which power-consuming compo‐
nent is connected to each relay and fuse. There is a built-in
terminal for fuse test in the electrical distribution box. The relays
in the electrical distribution box are interchangeable.
Components are marked according to which function group they
belong. The first two digits indicate function group and the other
digits are running numbers, e.g., SE2203.
NOTE! For working on the electrical system, follow the instruc‐
tions in section
Electrical system, work instructions page 5 .
1
2
3
4
V1048614
Fig.1 Position
1 Fuse box
2 Batteries
3 Battery disconnector, fuse FU74
4 Electrical distribution box
8

Electronic control system, description
Regarding: L60F, L70F, L90F
Vehicle electronics, general
52, 3 4
1
V1048627
Fig.2 Position of control units
1 Engine control unit E-ECU (MID128)
2 Vehicle control unit V-ECU (MID187)
3 Vehicle control unit V2-ECU (MID249)
4 Climate control unit ECC (MID146)
5 Instrument control unit I-ECU (MID140)
The machine electronics contain five control units that communi‐
cate with each other via two data buses. Each control unit pro‐
cesses values from sensors and operating controls, and controls
components so that desired function is obtained.
Control units included in the system are the instrument control
unit I-ECU, vehicle control unit V-ECU, vehicle control unit V2-
ECU, engine control unit E-ECU, and climate control unit ECC.
Machine electronics facilitate troubleshooting with a well-
designed and expansive diagnostic system. In case of electrical
malfunctions/errors, the operator receives a message on the
information panel.
For service personnel, the service tool VCADS Pro can be
plugged into sockets located by the electrical distribution box
behind the operator's seat.
Instrument control unit I-ECU is located in the instrument panel
and contains software for presenting operator information on the
information panel, including warning and control lights. The con‐
trol unit receives information from the other control units via data
bus.
Engine control unit E-ECU is located on intermediate wall in the
engine compartment and contains software for controlling engine
functions. The control unit receives information from the engine's
own sensors as well as from a data bus. The control unit also
sends information to the other control units via data bus.
10

Vehicle control units V-ECU and V2-ECU are located by the elec‐
trical distribution box behind the operator's seat and contains
software for controlling components and handling information
from sensors located outside the cab. The vehicle control unit is
connected to the other control units via data bus.
Climate control unit ECC are located inside the right side panel in
the cab and contain software for controlling heating, cooling, and
ventilation. The climate control unit is connected to the other con‐
trol units via data bus.
Communicationfor programming, changing parameters, and
reading out error codes, testing and checking components, etc.
is done with VCADS Pro. In VCADS Pro, MID-designations (Mes‐
sage Identification Description) are used for the control units.
Reading of input and output signals, setting certain functions,
reading off machine information, etc. can be performed with the
information panel.
If a malfunction occurs in any system, information is sent via the
data bus, which makes it possible to read off the information on
the information panel or by using VCADS Pro.
11

Communication with data buses
Regarding: L60F, L70F, L90F
VP
E-ECU
CAN1/J1939
J1587 708/1
V1047172
V-ECU
CAN2/J1939
I-ECU V2-ECU ECC
MID 187MID 140 MID 249 MID 128MID 146
Fig.3 Communication
ECC Electronic climate control unit
E-ECU Engine control unit
I-ECU Instrument control unit
V-ECU Vehicle control unit
V2-ECU Vehicle control unit
VP Service socket for VCADS Pro
General
In principle, the machine electronics are based on all communi‐
cation between control units in the system taking place via two
data buses. The machine's control units are connected to the
buses to enable communication with each other.
Communication between the different control units as well as
reporting from control units to service sockets takes place on data
buses CAN1/J1939 and J1587/1708.
The buses follow SAE standards and consist of two pair-twisted
cables. The purpose of the twisted cabling is to protect the bus
from electrical interference.
If an error or malfunction should occur in any system, a signal is
sent out on the information bus which makes it possible to read
off the information either in the information display or with VCADS
Pro. In VCADS Pro, MID-designations (Message Identification
Description) are used for the control units.
The figure above shows the principle for how the control units and
service sockets are connected to the buses.
12

CAN1/J1939 control bus
System control signals are sent via this bus. The control bus is
very quick, which is necessary for control of the entire system to
work and quickly adapt to changing conditions.
The main communication alternative is the CAN1/J1939-bus.
However, for E-ECU, some control data is only sent on the J1587/
J1708-bus.
CAN2/J1939 control bus
CAN2/J1939 is used to obtain redundancy for CAN-communica‐
tion.
J1587/1708 information bus
The information bus is connected to the control units and service
socket. Information and diagnostic signals are sent on this bus.
In addition, some control data is sent from the engine control unit
via this bus.
The bus also acts as a “back-up” for the control bus if it does not
work for some reason. The system's status is continuously
updated and available for reading via the information bus.
By connecting VCADS Pro to service socket VP, it is possible to
read error codes, perform test, delete logged information, down‐
load parameters, and download software.
Software, description
Regarding: L60F, L70F, L90F
Software is stored in the control units. To determine which soft‐
ware is in the control units, the part number of the software (Main
software) is read in the information panel or with the service tool
VCADS Pro.
Updating of the machine's software is handled through release of
a new edition. The releases are designated with Year:edition, for
example, R2006:5 and gets a new part number.
Updating of software for control units takes place through down‐
loading of new software from VOLVO with VCADS Pro.
13

Instrument control unit I-ECU, description
Regarding: L60F, L70F, L90F
0
rpm
V1048600
Fig.4 Instrument control unit with information dis‐
play
V1047258
Fig.5 Keypad for information display
The instrument control unit is integrated with the main instrument
and receives information from the data bus. The information is
processed and shown on gauges, control lights, warning lights
and information display.
Functions
• Values for gear position, operating hours as well as status val‐
ues 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 pres‐
sure are detected and the corresponding warning lights are
activated.
• 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
14

Vehicle control unit V-ECU, description
Regarding: L60F, L70F, L90F
The vehicle control unit has superior machine-related functional‐
ity and contains the following functions.
The vehicle control unit is located by the electrical distribution box
behind the operator's seat, and is connected to the other control
units via data link for communication with the other control units.
Functions
• Monitoring fuel level
• Monitoring of starter motor engagement
• Monitoring of system voltage
• Monitoring of pressure, temperature, level and filter for trans‐
mission oil
• Monitoring brake pressure
• Monitoring of level and temperature for hydraulic oil
• Monitoring of lubrication oil level for central lubrication
• Calculation of vehicle travel speed
• Parking brake
• Gear shifting strategy
• Request for engine rpm and/or torque limitation
• Transmission disengagement
• Engagement of differential lock
• Warming of hydraulic oil
• Boom Suspension System
• Secondary steering
• Cooling fan adjustment
• Reversal of cooling fan
• Attachment locking
• Brake pressure charging
V1047231
Fig.6 Vehicle control unit V-ECU
15

Vehicle control unit V2-ECU, description
Regarding: L60F, L70F, L90F
The vehicle control unit is the controlling unit in the system for the
following functions.
The vehicle control unit is located by the electrical distribution box
behind the operator's seat, and is connected to the other control
units via data link for communication with the other control units.
Functions
• Lever steering (CDC)
Engine control unit E-ECU, description
Regarding: L60F, L70F, L90F
The engine control unit is the central part of the injection system.
It is located on the partition wall in the engine compartment
installed in rubber-damper mounts.
The control unit continuously receives information from the accel‐
erator pedal and sensors on the engine as well as calculating the
fuel quantity and at which point in time the fuel shall be injected
into the cylinders via the injectors.
The control unit stores information if a malfunction should occur
or if any part of the system reacts abnormally. Sporadic malfunc‐
tions are stored in the control unit and can then be traced at a
later time.
Functions
• Control of fuel injection (Common Rail)
• Temperature monitoring
• Engagement of preheating
• Detecting engaged preheating
• Monitoring of water in fuel
• Monitoring of EGR-valve
• Automatic fuel shut-off at risk of high fuel temperature in the
return line when PRV-valve is open.
V1047231
Fig.7 Vehicle control unit V2-ECU
V1040516
Fig.8 Engine control unit
16

Climate control unit ECC, description
Regarding: L60F, L70F, L90F
ECC, Electronic Climate Control, is a fully automatic climate con‐
trol system that controls fan speed, heat, cooling, fresh air inlet,
and air distribution. Desired temperature is set on the climate
control system's control panel , and the control unit handles all
other control.
The control unit receives continuous information about tempera‐
tures, pressure, rpm, etc. from a number of sensors. The control
unit is connected to the other control units via data link
J1587/1708 for communication. The control unit is located inside
of the right side panel in the cab.
Functions
• Control of temperature, air distribution, and ventilation in cab
• Control of soft start, AC-compressor
• Monitoring of temperatures and pressure
V1048568
Fig.9 Control unit ECC
17

31 BATTERY
310 General, common info about 311 -
313
Battery, description
Regarding: L60F, L70F, L90F
The battery consists of two 12 V batteries connected in a series,
which together provide 24 V with a capacity of 220 Ah. The bat‐
teries are located behind the rear wheels on either side of the rear
frame. The battery disconnect switch is located under the radiator
casing at the rear of the machine on the right side.
The batteries should be in good condition when troubleshooting
the system. If needed, charge the batteries with a battery charger.
If the batteries do not take the charge, replace the batteries.
18