07 ENGINE CONTROL SYSTEM

Engine control system (Overview) EC210/160B-ENG7-01

Engine control system (Sensors #1) EC210/160B-ENG7-02
Engine control system (Sensors #2) EC210/160B-ENG7-03
Engine control system (Emergency control) EC210/160B-ENG7-04
Engine control system (Control circuit) EC210/160B-ENG7-05
Engine control system (E-ECU circuit) EC210/160B-ENG7-06
Engine control system (Sensor specification) EC210/160B-ENG7-07
Engine control system (ECU communication) EC210/160B-ENG7-08
Engine control system (Low coolant level) EC210/160B-ENG7-09
Engine control system (High coolant temperature) EC210/160B-ENG7-10
Engine control system (Low oil pressure) EC210/160B-ENG7-11
Engine control system (High boost temperature) EC210/160B-ENG7-12
Engine control system (Heater unit & relay location) EC210/160B-ENG7-13
Engine control system (preheat function,with preheat) EC210/160B-ENG7-14
Engine control system (preheat function,without preheat) EC210/160B-ENG7-15
Engine control system (preheat function,interrupt & cranking) EC210/160B-ENG7-16
Engine control system (Contronic service display unit #1) EC210/160B-ENG7-17
Engine control system (Contronic service display unit #2) EC210/160B-ENG7-18
Engine control system (Contronic service display unit #3) EC210/160B-ENG7-19
Engine control system (Injection control principle) EC210/160B-ENG7-20
Engine control system (Cylinder balance) EC210/160B-ENG7-21

CLICK THE VOLVO-LOGO IN

MAIN THE LOWER RIGHT CORNER
MENU TO RETURN TO THIS MENU
Control system (Overview)

Engine speed
(crank)
Engine speed
(cam)

Boost pressure Injector

Boost temp.

Coolant temp.
Injection pump
Fuel temp.

Oil pressure
-Begin of delivery
Inlet -Fuel quantity
Press. & temp. Engine oil press. Coolant temp.
switch sensor
Coolant level

Volvo Construction Equipment EC210/160B-ENG7-01

Korea Ltd.
 Engine control system (Sensors #1)

Boost Pressure Coolant temp. Oil Pressure Fuel temp.

for E-ECU for E-ECU
Oil Pressure
Coolant temp. Injection pump for inst. panel
for gauge

Engine speed
(cam)

Volvo Construction Equipment EC210/160B-ENG7-02

Korea Ltd.
Engine control system (Sensors #2)

Boost temp.

Engine speed
(crank)

Volvo Construction Equipment EC210/160B-ENG7-03

Korea Ltd.
Emergency Control
(1) (2)

Neutral Up
800 rpm 1900 rpm

VECU

VECU
Emergency Emergency
Switch Engine ECU Switch Engine ECU
210B : 555mA 340mA
160B : 580mA
Power Shift Power Shift
Valve Valve
(3)
(4)

Neutral
/ Up 800 / Down 2sec.
1900 rpm (Off Engine)
VECU

Emergency
Emergency
Switch Engine ECU Switch Engine ECU
Manual 340mA (engine does not
(Off VECU) stop with key)
Power Shift
Auto/Manual Valve
Switch
Resistor Box

Volvo Construction Equipment EC210/160B-ENG7-04

Korea Ltd.
Control Circuit
F24 F15 MDU Key ACC F25
5A 20A 10A

F14
5A R3 R4
EMS EMS DATA
POWER RECORD

21C11
21C5
21C4 MDU

21C12(H)
SDU / MATRIS

21C1(H)
21C7(L)

21C6(L)
/ VCADS PRO

21C2

21C3
21C9

21C8
21C10
B4 B11 B12
B9
EMS

B26(B)
B25(A)

B1(H)
B2(L)
B10
MDU

23C13
Service Socket
23C8(A)
23C9(B)
23C10
23C11
23C1
23C2
23C3
23C4
23C5
23C6
23C7

23C14 F13
Air Clean. Q/Fit Key Key 10A

J1587

J1939
Ind. Confirm R2 ACC
AC CF R2 ACC

F27
JA2
JA26
JA49
JA25
JA1
JA48
JA24

JA34

JA13

JA22

JA47

(B)JB4
(A)JB12

(L)JB6
(H)JB14
JB13
JB5
JA51

JA42

JB2

JB9

JB7
JB8
20A JA33
JA7
JA60 JA5
JA35 VECU JB15
JB16 MDU
JA38

JA37

JA36

JA12

JA61

JA50

JA40

JA63
JA19
JA43

JA68

JA44
JA28
JA27
JA67
JA18
JA23
JA11
JA62
JA14
JA56
JA30
JA66

JA70

JA39

JA32
JA3

JB1
R2 R1 Hyd.
BT C HY HM PH WT WL
Oil
Power Battery Hyd. Temp Hammer Pre Cool. Cool.
Boost Ind. Relay Temp. Select Heat Temp. Level
Ind. Ind. Ind. Ind.
Engin RPM Power
Flow Ctrl.SW
Travel Travel Power Max Auto Idle Ctrl.SW Flow Ctrl. Shift Valve
Speed Speed Valve Boost SW/
Att. Shear Operation
Press. Q/F SW Hammer
Boom Arm Power Hyd. Press. Rotator LH Resistor
Conflux Conflux Boost Oil Travel Box
Press. Rotator RH
Cutoff Cutoff Cooler

Volvo Construction Equipment EC210/160B-ENG7-05

Korea Ltd.
 Solenoid valve
on unit injection pump
Engine control system (E-ECU circuit) Cyl 2 Cyl 4

Cyl 3 Cyl 6
Engine Engine
speed speed Fuel Boost Coolant Oil Boost
sensor sensor temp. temp. temp. press. press.
,cam ,crank

n n Cyl 1 Cyl 5

(+) (-) (+) (-) (+) (-) (-) (-)

7 18 31 30 13 2 25 14 3 4 5 12 11 23 22 24 35 36 34

Connector A

Connector B Ambient air press.

4 1 2 25 26 9 10 11 12 7 17 8 3 13 31 5
(-) (-) (-)
Preheat
relay

Emergency J1939 J1939 J1708 J1708 Ground Power

speed H (A) L (B) A B supply
control

Power
from
fuse
Coolant Inlet Inlet
level press. temp.

Preheat coil

Volvo Construction Equipment EC210/160B-ENG7-06

Korea Ltd.
Control System (Sensor specification)

Volvo Construction Equipment EC210/160B-ENG7-07

Korea Ltd.
Control System (ECU communication)

Key switch Engine speed

R2 terminal Control Switch

1. Key START signal Preheat

2. Engine speed(Request value) Function
MDU
Fuel Qty.
V-ECU E-ECU & Timing Injector
Solenoid
Instru.
Panel
1. Engine speed (Return value)
2. Error signal Sensors

Volvo Construction Equipment EC210/160B-ENG7-08

Korea Ltd.
Engine control system (Low coolant level)

On service tool
(ER46)

Low coolant level

E-ECU V-ECU

Volvo Construction Equipment EC210/160B-ENG7-09

Korea Ltd.
 On service tool
(ER47)

EC210/160B-ENG7-10
Engine control system (Low oil pressure)

On service tool
(ER45)

Oil press.(kPa)
350

300

250

200

150

100

50

-50
Low oil pressure
-100
0 250 500 750 1000 1300 1500 1750

Engine speed (r/min)

2
Below 0.5~0.9kgf/cm
,Lamp ON

Volvo Construction Equipment EC210/160B-ENG7-11

Korea Ltd.
 On MDU
(ER42)

On MDU
(ER42)

EC210/160B-ENG7-12
Air heater (heater unit & relay location)

Air Heater Unit

Air Heater Relay

Volvo Construction Equipment EC210/160B-ENG7-13

Korea Ltd.
Engine control system (Preheat function,with preheating)
75

Preheat time(sec.)
50

Coolant Coolant
Temp.( C) 25 Temp.( C)
20 0 20
-20 -15 -10 -5 0 12 20 30 40
Coolant temp. ( `C)

Start Key Start Key

START START

ON ON
OFF OFF

Engine Engine
Speed 500 Speed 500
(rpm) (rpm)
35 35

Preheat Preheat
afterheat time preheat time afterheat time
Element Element
ON ON

OFF OFF
Preheat Preheat
Lamp Lamp
ON ON

OFF OFF

Volvo Construction Equipment EC210/160B-ENG7-14

Korea Ltd.
Engine control system (Preheat function,without preheating)

Coolant Coolant
Temp.( C) Temp.( C)
20 20

Start Key Start Key

START START

ON ON
OFF OFF

Engine Engine
Speed 500 Speed 500
(rpm) (rpm)
35 35

Preheat Preheat
afterheat time
Element Element
ON ON

OFF OFF
Preheat Preheat
Lamp Lamp
ON ON

OFF OFF

Volvo Construction Equipment EC210/160B-ENG7-15

Korea Ltd.
Engine control system (Preheat function,interrupt & cranking)
75

Preheat time(sec.)
50

Coolant Coolant
Temp.( C) 25 Temp.( C)
20 0 20
-20 -15 -10 -5 0 12 20 30 40
Coolant temp. ( `C)

Start Key Start Key

START START

ON ON
OFF OFF

Engine Engine
Speed 500 Speed 500
(rpm) (rpm)
35 35

Preheat Preheat
preheat time preheat time afterheat time
Element Element
ON ON

OFF OFF
Preheat Preheat
Lamp Lamp
ON ON

OFF OFF

Volvo Construction Equipment EC210/160B-ENG7-16

Korea Ltd.
 Control System (Contronic service display unit #1)

INITIALSCREEN ENGINE1 VOLTAGE HYDRAULIC1 ENTRANCE DIAGNOSTIC0

How to start -SERVICE CONTRONIC-
Excavator
Serial No
xxxxxx
yyyyyy
------ENGINE
Speed
1------
xxxx
-ELECTRICAL SYSTEM-
B a t t e r y Vo l t x x . x V
- - - H Y D R AU L I C 1 - - -
O i l Te m p .
Powe r S h i f t
xxx
yyy mA
----- PROGRAM -----#
xxxx
--- DIAGNOSTIC
T O TA L : x x
---

Request Speed yyyy E E C U Vo l t y y. y V

1. Connect contronic to service socket! Key No zz Engine % Load zzz% Flow Control zzz mA

INFORMATION ENGINE2 ON/OFFINPUTSIGNAL1 HYDRAULIC2 KEYNO DIAGNOSTIC1

- - - - I N F O R M AT I O N - - - - ------ENGINE 2------ --ON/OFF INPUT 1-- - - - H Y D R AU L I C 2 - - - ------ KEY NO ----- --- DIAGNOSTIC 1 --#
Prod.Date 3 1 / M AY / 0 1 Oil Press. xxx kPa Star t SW ACC x Attach Por t Press. x xx * 11 w xxxxx yyyyy zz*
To t a l H o u r s x x x x x x h O i l Te m p . y y y Start SW R2 x Tr a v e l P o r t P r e s s . x ^ # 12 w xxxxx yyyyy zz
R a t e d Po w e r y y y / z z z z Air Filter zzzzzz Po w e r M a x S W x H a m m e r Po r t P r e s s. x 13 w xxxxx yyyyy zz

SETTINGS ENGINE3 ON/OFFINPUTSIGNAL2 HYDRAULIC3 PRODUCTDATE DIAGNOSTIC2

---- SETTINGS ---- # ------ENGINE 3------ --ON/OFF INPUT 2-- - - - H Y D R AU L I C 3 - - - - - - P R O D U C T D AT E - - - --- DIAGNOSTIC 2 --#
Language xxxxxxx * C o o l a n t Te m p . x x x Auto Decel SW x Boost Relay x x x / M AY / y y * 14 w xxxxx yyyyy zz*
Units C kPa lit Coolant Level yyyyyy Rotator SW x Cut Off Relay x ^ # 21 w xxxxx yyyyy zz
^ Fuel Used zzzzzzzz l Boost/Hammer SW x T. M o t o r R e l a y x 31 w xxxxx yyyyy zz

ECU VERSION ENGINE4 ANALOGINPUTSIGNALS HYDRAULIC4 DIAGNOSTIC3

--- ECU VERSION --- ------ENGINE 4------ --ANALOG INPUTS-- - - - H Y D R AU L I C 4 - - - --- DIAGNOSTIC 3 --#
VECU xxxxxxxx F u e l P r e s s. xx x k Pa Speed Control SW x Oil Cooler Relay x 32 w xxxxx yyyyy zz*
EECU xxxxxxxx F u e l Te m p . y y y Flow Control SW x Hammer Hours yyyyyyh 41 w xxxxx yyyyy zz
MDU xxxxxxxx Fuel Rate zzz l/h 42 w xxxxx yyyyy zz

1 2 3
4 5 6

MSW VERSION ENGINE5 ON/OFFOUTPUTSIGNAL1 DIAGNOSTIC4

--- MSW VERSION --- ------ENGINE 5------ - ON/OFF OUTPUT 1 - --- DIAGNOSTIC 4 --#
VECU xxxxxxxx Boost Press. xxx kPa EECU CutOff Relay x 43 w xxxxx yyyyy zz*
EECU xxxxxxxx Inlet Press. yyy kPa VECU CutOff Relay x 44 w xxxxx yyyyy zz
Barometer zzz kPa Preheater Ind. x 45 w xxxxx yyyyy zz

DST1 VERSION ENGINE6 ON/OFFOUTPUTSIGNAL2 DIAGNOSTIC5

2. Press two red button at the same time! -- DST1 VERSION -- ------ENGINE 6------ - ON/OFF OUTPUT 2 - --- DIAGNOSTIC 5 --#
VECU xxxxxxxx I n l e t Te m p . x x x H y d O i l Te m p . I n d . x 46 w xxxxx yyyyy zz*
EECU xxxxxxxx B o o s t Te m p . y y y C o o l a n t Te m p . I n d . x 47 w xxxxx yyyyy zz
Coolant Level Ind. x 48 w xxxxx yyyyy zz

--- MSW VERSION --- DST2 VERSION ON/OFFOUTPUTSIGNAL3 DIAGNOSTIC6

VECU xxxxxxxx -- DST2 VERSION --
- ON/OFF OUTPUT 3 -
Air Cleaner Ind. x
---
49
DIAGNOSTIC 6
w xxxxx yyyyy
--#
zz*
VECU xxxxxxxx
EECU xxxxxxxx EECU xxxxxxxx
4A
4B
w xxxxx yyyyy
w xxxxx yyyyy
zz
zz

DIAGNOSTIC7
--- DIAGNOSTIC 7 --#
4C w xxxxx yyyyy zz*
4D w xxxxx yyyyy zz
4E w xxxxx yyyyy zz

Volvo Construction Equipment EC210/160B-ENG7-17

Korea Ltd.
Control System (Contronic service display unit #2)

Set up
---- SETTINGS ---- #
Language xxxxxxx * The display unit shows language and units of measurement.
Units C kPa lit There are five languages and five units that may be selected.
^ Language: English
S08209K German
French
Spanish
Portuguese
Unit °C > F/kPa > bar > psi/lit > gal

Change language or unit by pressing the key .

Select language or unit by pressing the key .

The cursor "*" indicates the selected item between language

and unit.
The cursor "^" indicates the selected item units.

MSW VERSION (Main software part numbers)

DST1 VERSION (Data set 1 part numbers)

DST2 VERSION (Data set 2 part numbers)

Volvo Construction Equipment EC210/160B-ENG7-18

Korea Ltd.
Control System (Contronic service display unit #3)

Diagnostic 0
--- DIAGNOSTIC ---#
T O TA L : x x * xx Shows the total number of active errors.

Press the key to select all error code items.

S08431K

The cursor "*" indicates that all the error code items are
selected.

Press the key to erase all the logged error history.

Diagnostic 1
--- DIAGNOSTIC 1 --#
11 w xxxxx yyyyy zz* 11 Shows error code of V-ECU.
12 w xxxxx yyyyy zz
13 w xxxxx yyyyy zz 12 Shows error code of E-ECU.
13 Shows error code of data bus CAN/SAE
S08239K
J1939 for E-ECU.
w Shows active error status as s (error) or
c (no error).
xxxxx Shows the time in initial occurrence of
the error according to machine hour.
yyyyy Shows the time in the latest occurrence
of the error according to machine hour.
zz Shows the total number of occurrence of
the error.

Press the key to select error code item.

The cursor "*" indicates the selected error code item.

Press the key to erase the logged error history.

If there is no error or the logged error history has been erased,

the value "w xxxxx yyyyy zz" is displayed as "-------------".

Volvo Construction Equipment EC210/160B-ENG7-19

Korea Ltd.
Engine control system (Injection control principle)

Environment Injection Fuel Qty

Condition EMS Control Injection timing

1) Altitude
Fuel Low Early
Qty
Injection
Timing
High

Fuel Low altitude

Late Qty
Speed Altitude

2) Turbo-charger High altitude

Fuel
Qty
With turbo
Speed

No turbo

Speed

3) Temperature
Fuel Cold Early
Qty
Injection
Timing
Warm Cold

Late
Speed Warm Altitude

Volvo Construction Equipment EC210/160B-ENG7-20

Korea Ltd.
Engine control system (Cylinder balance)

Cylinder balance at idle speed - injectors

1 5 3 6 2 4 1 5 3 6 2 4

Cyl No.
Flywheel speed

Fuel qty.
1 5 3 6 2 4 1 5 3 6 2 4

Cyl No.

1 5 3 6 2 4 1 5 3 6 2 4

Cyl No.

Volvo Construction Equipment EC210/160B-ENG7-21

Korea Ltd.