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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

1
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

4
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

5
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.

7
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.

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)
V1094958
• W-ECU (wireless electronic control unit) (Caretrack option)
Fig.2 Right hand console with printed circuit board V-ECU, T-ECU and W-ECU are located behind the right hand
console. I-ECU1 is integrated in the side instrument panel and I-
ECU2 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.

8
1 2

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

9
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 (I-
ECU1). 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.

10
1 Fuses T-ECU

2 Lights V-ECU I-ECU1

3 Sensors and
I-ECU2
Actuators

V1103661

Fig.4 electronic system, overview


1 fuses
2 lights
3 sensors and actuators

11
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
• Monitoring of starter motor engagement
Fig.5 Vehicle control unit V-ECU
• 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.

12
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

Fig.6 front instrument panel Functions


• 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
• Values for transmission oil temperature, coolant temperature
V1103663 engine and fuel level are shown on gauges
Fig.7 side instrument panel with information • Setting of display alternatives and parameter alternatives for
display
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.

13
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 pins 43 – 56
2 pins 15 – 28
3 pins 29 – 42
4 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.

14
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.

CareTrack combines two systems, independent of each other;


2 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.
1
V1053631

Fig.9
1 W-ECU
2 Satellite modem

15
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 528 12 V Ignition on + crank signal
IV) to VECU pin 11
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 32 504 0V Forward or reverse gear not selected
(neutral position) (Powershuttle 503 0V
transmission)
From F/R lever SW4205 (on left combi switch 504 0V
FX1016) to VECU pin 32 (neutral position) 503 0V
(Powershift option)
From forward switch SW4229 (on loader 525 0V
joystick) to VECU pin 20
From reverse switch SW4230 (on loader 537 0V
joystick) to VECU pin 27

Output signals
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 600 12 V
MO3301
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.

16
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 Signal Condition/ Description
From ignition key switch SW3301 (position 528 12 V Activation:
IV) to V-ECU pin 11 When the ignition key is switched to position
If the code lock option is installed the entered IV (Ignition on + crank signal)
pin code must be correct 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 605 12 V Engine stop valve opens the fuel line to the
MA2307 engine

See sections 370, Wiring diagram SCH02 and 370, Wiring


diagram SCH03 for wiring diagram of this function.

17
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 612 12 V Activation:
SE2502 to I-ECU1 pin 2 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 signals
Output Wire Signal Description
Internal signal - - Information symbol is shown in the
information display

V1093156

See section 370, Wiring diagram SCH03 for wiring diagram of this
function.

18
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 608 V Voltage is depending on measured coolant
SE2706 to I-ECU1 pin 22 temperature

Output signals
Output Wire Signal Description
Internal signal - 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)

Arrow position (%) Engine coolant temperature


(°C)
0.0 0
50.0 75
V1092568 50.0 92
Fig.10
55.0 94
60.0 96
95.0 98
98.0 100
99.0 101
100.0 130

19
Engine coolant Output voltage to I-ECU1 Engine coolant Output Voltage to I-ECU1
temperature (°C) temperature (°C)
-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.

20
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 signals
Output Wire Signal Description
I-ECU1 (internal) - - Engine speed information in the information
display
From I-ECU1 to V-ECU CAN J1939 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.

21
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, 708 12 V Left and right front working lights (LA3521
position: two lights ON and LA3522)
Front working lights switch SW3504, 708 12 V Left and right front working lights (LA3521
position: four lights ON (option) and LA3522)
707 12 V Left and right front working lights (LA3523
and LA3524) (option)
Rear working lights switch SW3505, 712 12 V Left and right rear working lights (LA3525
position: two lights ON and LA3526)
Rear working lights switch SW3505, 712 12 V Left and right rear working lights (LA3525
position: four lights ON 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.

22
Direction indicators

This function controls the direction indicators.

Input signals
Input Wire Signal Condition/ Description
Direction indicator switch SW3605 (on right Activation:
combi switch FX1003) Direction indicator switch LEFT ON
Flasher Relay RF3601 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 718 12 V Direction indicators front left LA3602 and
combi switch FX1003) 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.

23
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 Condition/ Description
Hazard lights switch SW3606 Activation:
Flasher Relay RF3601 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.

24
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 signals
Output Wire Signal Description
Internal signal CAN J1939 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 Condition/ Description
Internal signal from hour meter, see section CAN J1939 The service warning appears every 500
300, Hour meter 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 Description
Internal signal CAN J1939 The service warning is displayed in the
information display

30 h
V1093159

26
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 Signal Condition/ Description
Keypad on information display - When entered pin code is correct, machine
can be started

Output signals
Output Wire Signal Description
Internal signal V-ECU - 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 Signal Condition/ Description
From F/R lever SW4208 to V-ECU pin 32 (if 504 12 V Enable forward drive
forward is selected) (Powershuttle
transmission) The F/R lever has priority to the forward
From F/R lever SW4205 (on left combi switch switch on the loader lever
FX1016) to V-ECU pin 32 (if forward is
selected) (Powershift option)
From forward switch SW4229 (on loader 525 12 V Enable forward drive
joystick) to V-ECU pin 20
From forward/reverse joystick authorisation 500 12 V loader joystick button can be used if:
switch SW4232 to I-ECU1 pin 6 - F/R lever is in neutral position
- joystick authorisation switch is activated
Internal condition from V-ECU: parking brake - - Forward gear can only be enabled, if the
not activated parking brake is not activated

Output signals
Output Wire Signal Description
From V-ECU pin 21 to forward gear solenoid 509 12 V Forward drive enabled in transmission
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 12 V
proportional valve (Powershift option)
Internal signal to I-ECU2 CAN J1939 Lamp on front panel is alight when forward
drive is engaged

28
Forward deactivation

Input signals
Input Wire Signal Condition/ Description
From F/R lever SW4208 to V-ECU pin 32 (if 504 0V Disable forward drive
forward is not selected) (Powershuttle
transmission)
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 12 V
reverse is selected) (Powershuttle
transmission)
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 501 12 V
SW4226 on gear shift lever (Powershuttle
transmission) to I-ECU2 pin 14
From transmission disconnect switch 541 12 V Disable forward drive
SW4231 on loader joystick to V-ECU pin 19
From reverse switch SW4230 (on loader 527 12 V loader joystick buttons can be used if:
joystick) to V-ECU pin 27 - F/R lever is in neutral position
- joystick authorisation switch is activated
From neutral switch SW4228 (on loader 526 12 V
joystick) to V-ECU pin 23
From forward/reverse joystick authorisation 500 12 V
switch SW4232 to I-ECU1 pin 6

Output signals
Output Wire Signal Description
From V-ECU pin 21 to forward gear solenoid 509 0V Forward drive disabled in transmission
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 0V
proportional valve (Powershift option)

29
Reverse activation

Input signals
Input Wire Signal Condition/ Description
From F/R lever SW4208 to V-ECU pin 22 (if 503 12 V Enable reverse drive
reverse is selected) (Powershuttle
transmission) The F/R lever has priority to the reverse
From F/R lever SW4205 (on left combi switch switch on the loader lever
FX1016) to V-ECU pin 22 (if reverse is
selected) (Powershift option)
From reverse switch SW4230 (on loader 527 12 V Enable reverse drive
joystick) to V-ECU pin 27
From forward/reverse joystick authorisation 500 12 V loader joystick button can be used if:
switch SW4232 to I-ECU1 pin 6 - F/R lever is in neutral position
- joystick authorisation switch is activated
Internal condition from V-ECU: parking brake - - Reverse gear can only be enabled, if the
not activated parking brake is not activated

Output signals
Output Wire Signal Description
From V-ECU pin 25 to reverse gear solenoid 510 12 V Reverse drive enabled in transmission
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 12 V
proportional valve (Powershift option)
From V-ECU pin 25 to reversing alarm 510 12 V Activate reversing alarm
SA3604
Internal signal to I-ECU2 CAN J1939 Lamp on front panel is alight when reverse
drive is engaged

30
Reverse deactivation

Input signals
Input Wire Signal Condition/ Description
From F/R lever SW4208 to V-ECU pin 32 (if 504 12 V Disable reverse drive
forward is selected) (Powershuttle
transmission)
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 0V
reverse is not selected) (Powershuttle
transmission)
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 501 12 V
SW4226 on gear shift lever (Powershuttle
transmission) to I-ECU2 pin 14
From transmission disconnect switch 541 12 V Disable reverse drive
SW4231 on loader joystick to V-ECU pin 19
From forward switch SW4229 (on loader 525 12 V loader joystick buttons can be used if:
joystick) to V-ECU pin 20 - F/R lever is in neutral position
- joystick authorisation switch is activated
From neutral switch SW4228 (on loader 526 12 V
joystick) to V-ECU pin 23
From forward/reverse joystick authorisation 500 12 V
switch SW4232 to I-ECU1 pin 6

Output signals
Output Wire Signal Description
From V-ECU pin 25 to reverse gear solenoid 510 0V Reverse drive disabled in transmission
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 0V
proportional valve (Powershift option)
From V-ECU pin 25 to reversing alarm 510 0V Deactivate reversing alarm
SA3604

31
Neutral activation

Input signals
Input Wire Signal Condition/ Description
From F/R lever SW4208 to V-ECU pin 32 (if 504 0V Disable forward/reverse drive
forward is not selected) (Powershuttle
transmission)
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 0V
reverse is not selected) (Powershuttle
transmission)
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 526 12 V Disable forward/reverse drive
joystick) to V-ECU pin 23
From forward/reverse joystick authorisation 500 12 V Neutral switch on loader joystick can be used
switch SW4232 to I-ECU1 pin 6 if:
- F/R lever is in neutral position
- joystick authorisation switch is activated

Output signals
Output Wire Signal Description
From V-ECU pin 21 to forward gear solenoid 509 0V Forward drive disabled in transmission
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 0V
proportional valve (Powershift option)
From V-ECU pin 25 to reverse gear solenoid 510 0V Reverse drive disabled in transmission
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 0V
proportional valve (Powershift option)
From V-ECU pin 25 to reversing alarm 510 0V Deactivate reversing alarm
SA3604

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 V- 513 12 V Activation: When differential lock switch is
ECU pin 28 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)

Output signals
Output Wire Signal Description
From V-ECU pin 09 to differential lock valve 512 12 V Differential lock valve engages the
MA4601 differential lock in the rear axle
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) 2nd gear
Proportional valve, gear shifting 2/4 (PWM4222)

34
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 I- 720 12 V Activation:
ECU1 pin 15 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 531 up to See above
SE4307 to V-ECU pin 3 1kHz
Powershift (option): Transmission speed 511
sensor SE4307 to T-ECU pin 53

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 500 12 V Activation:When authorisation switch is
switch SW4232 to I-ECU1 pin 6 pressed
Deactivation: When authorisation switch is
depressed

Output signals
Output Wire Signal Description
Internal signal to V-ECU CAN J1939 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 505 12 V Activation:
SE4202 to I-ECU2 pin 10 (Powershuttle When the transmission oil temperature is
standard) above 115 °C (239 °F)
From transmission oil temperature switch 533 12 V Deactivation:
SE4202 to T-ECU pin 43 (Powershift option) When transmission oil temperature is going
below 115 °C (239 °F)

Output signals
Output Wire Signal Description
Internal signal I-ECU2 (Powershuttle High transmission oil temperature:
standard) - internal buzzer sounds
Internal signal from T-ECU to I-ECU2 - transmission oil temperature warning is
(Powershift option) 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 I- 502 12V Activation: If parking brake is engaged
ECU1 pin 9 Deactivation: If parking brake is disengaged

Output signals
Output Wire Signal Description
I-ECU1 Internal 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 Signal Condition/ Description
From seat belt sensor SE8501 to I-ECU1 pin 433 12 V When seat belt is fastened
4

Output signals
Output Wire Signal Description
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 424 V Voltage is depending on measured coolant
SE9105 to V-ECU pin 4 temperature

Output signals
Output Wire Signal Description
Internal signal from V-ECU to I-ECU1 CAN J1939 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 Output voltage to V-ECU Hydraulic oil temperature Output voltage to V-ECU
(°C) (°C)
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 Signal Condition/ Description
From forward/reverse lever SW4208, 503 12 V Activation:
steering column (Powershuttle transmission) When forward or reverse gear is selected
or Deactivation:
from forward/reverse lever SW4205, When the transmission is in neutral position
steering column (Powershift option) to V-
ECU pin 22 (if reverse is selected)
From forward/reverse lever SW4208, 504
steering column (Powershuttle transmission)
or
from forward/reverse lever SW4205,
steering column (Powershift option) to V-
ECU pin 32 (if forward is selected)
From forward switch SW4229 (on loader 525
joystick) to V-ECU pin 20 (if forward is
selected)
From reverse switch SW4230 (on loader 527
joystick) to V-ECU pin 27 (if reverse is
selected)
From hydraulic oil temperature sensor 424 V Voltage is depending on measured oil
SE9105 to V-ECU pin 4 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 608 V Voltage is depending on measured coolant
SE2706 to I-ECU1 pin 22 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 Signal Description
From V-ECU pin 29 to power mode solenoid 434 12 V Close power mode solenoid, loader mode
MA9116 (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 Activation:
Powershuttle: Transmission speed sensor 531 up to When BSS switch is switched to position ON
SE4307 to V-ECU pin 3 1kHz and vehicle speed is above 7 km/h (4.3 mph)
and craning switch is in position OFF
Powershift (option): Transmission speed 511 Deactivation:
sensor SE4307 to T-ECU pin 53 When BSS switch is switched to position
From craning switch SW9128 to V-ECU pin 468 0V OFF or when machine speed is below 5 km/
24 h (3.1 mph) or when the craning switch is
switches to position ON

Output signals
Output Wire Signal Description
From V-ECU pin 46 to boom suspension 403 12 V open boom suspension vales
relay RE9102
From boom suspension relay RE9102 to 404 12 V
boom suspension solenoids MA9103 and
MA9114
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 0V Activation:
stabiliser switch SW9156 to I-ECU1 pin 14 412 When one or both stabiliser(s) is/are not
From F/R lever SW4208 to V-ECU pin 32 504 12 V retracted completely and forward or reverse
(neutral position) (Powershuttle gear is selected
503 12 V Deactivation:
transmission)
When both stabilisers are retracted
From F/R lever SW4205 (on left combi switch 504 12 V completely or the transmission is put in
FX1016) to V-ECU pin 32 (neutral position) 503 12 V neutral position
(Powershift option)
From forward switch SW4229 (on loader 525 12 V
joystick) to V-ECU pin 20
From reverse switch SW4230 (on loader 537 12 V
joystick) to V-ECU pin 27

Output signals
Output Wire Signal Description
Internal signal - - Information symbol is shown in the
information display

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 Signal Condition/ Description
From quick attach switch SW9104 to V-ECU 410 12 V Activation:
pin 30 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 436 12 V The solenoid opens the quick attach bracket
SW9104
From quick attach switch SW9104 to quick 409 12 V
attach solenoid MA9109
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 Signal Condition/ Description
From quick attach switch SW9105 to V-ECU 408 12 V Activation:
pin 31 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 435 12 V The solenoid opens the quick attach bracket
SW9105
From quick attach switch SW9105 to quick 407 12 V
attach solenoid MA9191
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 SW4208
(Powershuttle transmission)
reverse gear combi switch, steering column SW4205
(Powershift option)
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 SW4208
(Powershuttle transmission)
forward gear combi switch, steering column SW4205
(Powershift option)
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), MA9136
selector valve
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) PWM9124
proportional valve (right)
55 see component 4in1/extendable dipper (X1 primary/secondary) PWM9123
proportional valve (left)
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 parking brake switch SW5501
activated
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 transmission oil temperature sensor (Powershuttle) SE4202
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
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.

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

SELECT:
Enter selected menu or submenu
Activate/deactivate functions
V1101098 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 Each menu displays parameters about the machine status and
Fig.16 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
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)
V1101100
5 IECU part number (IECU part number)
Fig.20 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 Enable/disable the anti theft device
theft)
Air condition (Air Enable/disable the air condition
condition)
V1101109

Quick attach Enable/disable the quick attachment


(Quick attach)
Boom Enable/disable the boom suspension system
suspension
(Boom
V1102267
suspension)
Four in one (Four Enable/disable the 4in1 multipurpose bucket
in one) (Parameter only available for BL70B/BL71B)
Extendable Enable/disable the extendable dipper
dipper (Parameter only available for BL70B/BL71B)
(Extendable
dipper)
Powershift Enable/disable the Powershift transmission
V1102268
transm. If the machine is equipped with a Powershift
(Powershift transmission, this parameter must be enabled
transm.)
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
V1102269
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 Enable/disable the washers and wipers
(Washer and
wiper)

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
If pressed longer than 5 seconds, the information display will return to the drive mode

68
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
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)
V1102146

Fig.36 The values shown in this submenus cannot be modified.

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
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)
V1102147
5 Digital in/out IECU–1 (Digital in/out IECU–1)
Fig.42 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.

The fault code entry consists of two lines.


In the first line the component id and the FMI (=fault mode
V1102318 identifier) code are shown (separated by a hyphen -).
Fig.45 In the second line the time-stamp of the fault code is shown.
Fault code entry:
Component FU20 with FMI code 4 See Fault code list page 94 for possible fault codes.
appeared after 3.8 machine hours

Key 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.

The first two digits of each row are defining, if the row consists of
input or output signals.
V1102323 DI = Digital Input
Fig.49 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.

The first two digits of each row are defining, if the row consists of
input or output signals.
V1102324 DI = Digital Input
Fig.51 V1102324 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.
The first two digits of each row are defining, if the row consists of
V1102325 input or output signals.
Fig.53 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 FMI codes Description
name
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 FMI codes Description
name
AL3201 0 Alternator W (P)
See section 370, Component list, Alternator, batteries, code lock, radio for component locations and wiring
diagrams.

Compressor
Component FMI codes Description
name
MO8701 5 Compressor
See section 370, Component list, Motors for component locations and wiring diagrams.

Relays
Component FMI codes Description
name
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 FMI codes Description
name
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 FMI codes Description
name
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 FMI codes Description
name
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 FMI codes Description
name
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 FMI codes Description
name
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 FMI codes Description
name
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 FMI codes Description
name
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 FMI codes Description
name
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 FMI codes Description
name
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 SW4208
(Powershuttle transmission)
reverse gear combi switch, steering column SW4205
(Powershift option)
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 SW4208
(Powershuttle transmission)
forward gear combi switch, steering column SW4205
(Powershift option)
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), MA9136
selector valve
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) PWM9124
proportional valve (right)
55 see component 4in1/extendable dipper (X1 primary/secondary) PWM9123
proportional valve (left)
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 parking brake switch SW5501
activated
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 transmission oil temperature sensor (Powershuttle) SE4202
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

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:
Fuses FU12, FU13
Relays RE02
Switches SW3607, SW3301 (Ignition key
switch)
Other SE2203, D2, BA3101 (Battery)

106
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 Place the machine in service position 2, see section 191,


Service position 2.
2 Turn off the battery disconnect switch.
1 3 Remove the floor mat in the cab.
4 Remove the cab floor plate in front of the seat.

V1094146

Fig.61 battery disconnect switch


1 position 0: battery disconnect switch off
2 position 1: battery disconnect switch on

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.

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 Place the machine in service position 2, see section 191,
Service position 2.
2 Turn off the battery disconnect switch.
1 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.
V1104013

Fig.65 Solenoid
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.

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 Place the machine in service position 2, see section 191,
Service position 2.
2 Turn off the battery disconnect switch.
1 3 Remove the knob of the hand throttle lever.

V1094146

Fig.66 battery disconnect switch


1 position 0: battery disconnect switch off
2 position 1: battery disconnect switch on

4 Loosen and remove the retaining screws of the side panel.


5 Carefully lift away the side panel.

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.
14 Assemble and fasten the retaining screws of the side panel.
15 Assemble the knob of the hand throttle.

Fig.69 T-ECU with connector


1 T-ECU
2 T-ECU connector

118
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 Place the machine in service position 2, see section 191,


Service position 2.
2 Turn off the battery disconnect switch.
1 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.

V1094146

Fig.70 battery disconnect switch


1 position 0: battery disconnect switch off
2 position 1: battery disconnect switch on

6 Loosen and remove the retaining screws of the side panel.


7 Carefully lift away the side panel.

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.
19 Assemble and fasten the retaining screws of the side panel.
20 Assemble the knob of the hand throttle.

Fig.74 T-ECU with connector


1 T-ECU
2 T-ECU connector

120
Gear selector switch, testing

Powershift transmission (option)

Op. no.

1 Place the machine in service position 2, see section 191,


Service position 2.
2 Turn off the battery disconnect switch.
1 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.
V1094146
5 Check the electrical resistance in the connector FX1016
according to illustration below. X indicates approximately 0
Fig.75 battery disconnect switch
Ω between pins. Change the position of the switch as
1 position 0: battery disconnect switch off
2 position 1: battery disconnect switch on
necessary.

1 2 3 4 5 6 7 8
F1 X X X X
F2 X X X
F3 X X X
F4 X X X X
N1 X X X
N2 X X
N3 X X
N4 X X X
R1 X X X X
R2 X X X
R3 X X X
R4 X X X X
H 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.

V1101112 Preparation
Fig.77 submenu 4in1 option 1 Place the machine in service position 2, see section 191,
Service position 2.
2 Turn off the battery disconnect switch.
1

V1094146

Fig.78 battery disconnect switch


1 position 0: battery disconnect switch off
2 position 1: battery disconnect switch on

122
3 Remove the switch cover (1) from the joystick housing.
4 Loosen and remove the retaining screw (2).
5 Carefully remove the joystick housing.

Fig.79 joystick housing, disassembly


1 switch cover
2 retaining screw
3 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.80

Checking connector SW9113 (4in1 function)


1 10 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
V1070722 neutral position ca 2.5 V
Fig.81 forwards position ca. 4.3 V
1 roller for 4in1 bucket backwards position ca.0.7 V
3 Ground
4 Not used

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 Function
1 + after key

V1070730
2 Neutral SW4228
Fig.82 3 Not used
1 transmission kick-down 4 Transmission disconnect SW4231
2 transmission disconnect
3 forward 5 Kick-down SW4220
4 reverse 6 Not used
5 neutral
7 Not used
8 Not used
9 Reverse SW4230
10 Not used
11 Forward SW4229
12 Not used

Reassembly
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.

Fig.83 joystick housing, disassembly


1 switch cover
2 retaining screw
3 joystick housing

124
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 WARNING
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
NOTICE
The electrolyte level should stand approx. 10 mm (0.4 in)
5 V1092347 above the cell plates. Check the level indicator.
Fig.86 current capacity, check 7 Reassemble the cell caps.
1 cell cap
2 level indicator
3 maximum level
4 minimum level
5 level indicator

130
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 Alternator
5 Regulator
6 Bracket

132
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.

This causes the preheating indicator on the display unit to light up


and energizes the preheating relay, which closes the circuit
V1095047 between battery plus and the glow plugs.

Fig.90 Preheating indicator on display unit, right


instrument panel
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
Fuses FC1, FU02
Relays RE2501
Switches SW3301 (ingnition
key)
Glow plugs HE2501

134
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.

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.
Fig.91 switch head lights, SW3501 - 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.
V1095050 - Lever in neutral position: low or high beams on.
Fig.92 multifunctional lever on the steering column - 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).

See 370, Wiring diagram SCH13 and 370, Wiring diagram


V1085622 SCH14 for lighting.
Fig.95 switch rear working lights

136
36 OTHER ELECTRICAL
EQUIPMENT

367 Electronic standard components


V-ECU, replacing

Op. no. 367-052

Disassembly
1 Place the machine in service position 2, see section 191,
Service position 2.
2 Turn off the battery disconnect switch.
1 3 Remove the knob of the hand throttle lever.

V1094146

Fig.96 battery disconnect switch


1 position 0: battery disconnect switch off
2 position 1: battery disconnect switch on

4 Loosen and remove the retaining screws of the side panel.


5 Carefully lift away the side panel.

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).

Fig.99 V-ECU, disassembly


1 cable
2 mounting bracket

10 Remove the connector (2) from the V-ECU (1).


11 Loosen and remove the three retaining screws of the V-
ECU.
12 Remove the V-ECU.

Fig.100 V-ECU, disassembly


1 V-ECU
2 V-ECU connector

Assembly
13 Assemble the V-ECU and the retaining screws, fasten the
retaining screws.
14 Reassemble the connector (2) to the V-ECU.

Fig.101 V-ECU, assembly


1 V-ECU
2 V-ECU connector

138
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.

Fig.102 V-ECU, assembly


1 cable
2 mounting bracket

18 Reassemble the plate.

Fig.103 V-ECU, assembly

19 Carefully assemble the side panel.

NOTICE
Take care of the connectors and harnesses on the rear of
the panel.
20 Assemble and fasten the retaining screws of the side panel.
V1103768
21 Assemble the knob of the hand throttle.
Fig.104 side panel, removal

139
I-ECU, replacing

Op. no. 367-056

Disassembly I-ECU 1 (side panel)


1 Place the machine in service position 2, see section 191,
Service position 2.
2 Turn off the battery disconnect switch.
1 3 Remove the knob of the hand throttle lever.

V1094146

Fig.105 battery disconnect switch


1 position 0: battery disconnect switch off
2 position 1: battery disconnect switch on

4 Loosen and remove the retaining screws of the side panel.


5 Carefully lift away the side panel.

NOTICE
Take care of the connectors and harnesses on the rear of
the panel.
V1103768

Fig.106 side panel, removal

6 Disconnect the connector from the I-ECU 1.


7 Loosen and remove the retaining screws, remove the I-ECU
1.

Fig.107 I-ECU 1, disassembly


1 I-ECU 1
2 I-ECU 1 connector

140
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.

Fig.108 I-ECU 1, assembly


1 I-ECU 1
2 I-ECU 1 connector

10 Carefully assemble the side panel.

NOTICE
Take care of the connectors and harnesses on the rear of
the panel.
11 Assemble and fasten the retaining screws of the side panel.
V1103768
12 Assemble the knob of the hand throttle.
Fig.109 side panel, removal

141
I-ECU, replacing

Op. no. 367-056

Disassembly I-ECU 2 (front instrument panel)


1 Place the machine in service position 2, see section 191,
Service position 2.
2 Turn off the battery disconnect switch.
1 3 Remove the steering wheel, see section 641, Steering
wheel, replacing.

V1094146

Fig.110 battery disconnect switch


1 position 0: battery disconnect switch off
2 position 1: battery disconnect switch on

4 Loosen and remove the retaining screws, remove the


instrument panel cover.

V1098891

Fig.111 instrument panel cover, removing

5 Loosen and remove the retaining screws, remove the IECU


2.
6 Disconnect the connector from the I-ECU 2.

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.

Fig.113 I-ECU 2, assembly


1 I-ECU 2

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.

V1098891

Fig.114 instrument panel cover, removing

143
T-ECU, replacing

See section 432, T-ECU, replacing.

144
USER FEEDBACK

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To From
Volvo Construction Equipment AB ....................................................................................
Customer Support Division
Dept. 45110, RLA 0301 ....................................................................................
SE-631 85 Eskilstuna
Sweden ....................................................................................
e-mail: servicemanuals@volvo.com

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Ref. no. PUB 20026874-A English
2011.09 CST
Volvo, Konz