Volvo L60F, Service Manual

Page 1: ...MORE CARE BUILT IN CONTENT 3 Electrical and Information System Description VOLVO CONSTRUCTION EQUIPMENT SERVICE MANUAL l60F L70F L90F ...

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Page 3: ...Foreword This booklet is part of a complete service manual Read the fore word in the service manual WARNING Always read the booklet Safety before proceeding 1 VOE 21 A 1002889 ...

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Page 5: ...ption 23 33 STARTING SYSTEM 331 Starter motor inclusive solenoid Booting sequence 24 35 LIGHTING 350 General common info about 351 356 Lighting description 25 36 OTHER ELECTRICAL EQUIPMENT 360 General common info about 361 367 Reduced computer communication 28 Interruption in computer communication 29 Limp Home 29 Intermittent wiper and washer 30 Theft protection 32 38 INSTRUMENT SENSOR WARNING AN...

Page 6: ...tion display electrical system 48 Information display vehicle info 49 Information display vehicle messages 51 Information display service 52 Information display service mode 53 Information display settings 55 Information display check 56 Alarm description 57 Central warning 58 4 ...

Page 7: ...e 5 If booster battery is required when starting the following instructions must be followed at all times 191 Safety when working with batteries and 191 Starting with booster batter ies Charging 1 Before performing any tests of the alternator or regulator the batteries must be checked regarding insulation loose fit and corrosion Check the alternator belts 2 For all testing of alternating current e...

Page 8: ...ing on the machine or on attachments on machine voltage feed turned off with battery disconnector connectors for all control units ECUs must be unplugged NOTE Ground the welding unit as close as possible to the weld ing point 6 ...

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Page 10: ... mainly located in the electrical distribution box behind the operator s seat and are accessed by removing the cover for the electrical distribution box The cover s inside is pro vided with a decal that informs which power consuming compo nent is connected to each relay and fuse There is a built in terminal for fuse test in the electrical distribution box The relays in the electrical distribution ...

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Page 12: ...unit ECC Machine electronics facilitate troubleshooting with a well designed and expansive diagnostic system In case of electrical malfunctions errors the operator receives a message on the information panel For service personnel the service tool VCADS Pro can be plugged into sockets located by the electrical distribution box behind the operator s seat Instrument control unit I ECU is located in t...

Page 13: ...ntilation The climate control unit is connected to the other con trol units via data bus Communicationfor programming changing parameters and reading out error codes testing and checking components etc is done with VCADS Pro In VCADS Pro MID designations Mes sage Identification Description are used for the control units Reading of input and output signals setting certain functions reading off mach...

Page 14: ...s to enable communication with each other Communication between the different control units as well as reporting from control units to service sockets takes place on data buses CAN1 J1939 and J1587 1708 The buses follow SAE standards and consist of two pair twisted cables The purpose of the twisted cabling is to protect the bus from electrical interference If an error or malfunction should occur i...

Page 15: ...s as a back up for the control bus if it does not work for some reason The system s status is continuously updated and available for reading via the information bus By connecting VCADS Pro to service socket VP it is possible to read error codes perform test delete logged information down load parameters and download software Software description Regarding L60F L70F L90F Software is stored in the c...

Page 16: ... display Functions Values for gear position operating hours as well as status val ues for parking brake and warning messages are processed and result in a number of figures on the information panel Special warnings e g central warnings low engine oil pres sure are detected and the corresponding warning lights are activated Values for transmission oil temperature coolant temperature engine and fuel...

Page 17: ...engagement Monitoring of system voltage Monitoring of pressure temperature level and filter for trans mission oil Monitoring brake pressure Monitoring of level and temperature for hydraulic oil Monitoring of lubrication oil level for central lubrication Calculation of vehicle travel speed Parking brake Gear shifting strategy Request for engine rpm and or torque limitation Transmission disengagemen...

Page 18: ...r mounts The control unit continuously receives information from the accel erator pedal and sensors on the engine as well as calculating the fuel quantity and at which point in time the fuel shall be injected into the cylinders via the injectors The control unit stores information if a malfunction should occur or if any part of the system reacts abnormally Sporadic malfunc tions are stored in the ...

Page 19: ...rol unit handles all other control The control unit receives continuous information about tempera tures pressure rpm etc from a number of sensors The control unit is connected to the other control units via data link J1587 1708 for communication The control unit is located inside of the right side panel in the cab Functions Control of temperature air distribution and ventilation in cab Control of ...

Page 20: ...ity of 220 Ah The bat teries are located behind the rear wheels on either side of the rear frame The battery disconnect switch is located under the radiator casing at the rear of the machine on the right side The batteries should be in good condition when troubleshooting the system If needed charge the batteries with a battery charger If the batteries do not take the charge replace the batteries 1...

Page 21: ...dequately 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 IMPORTANT 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 Elec trolyte spilled on bare skin must...

Page 22: ...ng 1 Place the machine in service position 1 see 191 Service positions 2 Open the battery covers 3 Remove the terminal caps 4 Loosen and remove the cable terminals from the battery ter minals NOTE Start by removing the cable terminal from the minus terminal 5 Loosen the clamp and remove the battery Weight approx 20 kg 44 lbs V1048901 FU74 1 Fig 10 1 Battery disconnector Fig 11 20 ...

Page 23: ...y into place and fit the clamp 7 Clean the battery terminals and cable terminals 8 Install the cable terminals and lube with acid free vaseline 9 Restore the machine 10 Start the machine and check that no error messages appear 21 ...

Page 24: ... voltage Voltage level 31 V Amber central warning Check High system voltage Engine On Voltage level 19 V Amber central warning Check Low system voltage Key feed Regarding L60F L70F L90F Key feed is used as a condition in software functions to define when voltage feed considered to be On and Off respectively Input signals Conditions for output functions Output functions System voltage Voltage 8 V K...

Page 25: ...ne is turned off the batteries normally give a volt age of approx 24 26 V depending on their charging status When the engine is running the batteries are normally charged by the alternator since the alternator s normal charging voltage is higher than the battery voltage If the batteries do not seem to take a charge this may be due to incorrect charge voltage from the alternator Also check the acid...

Page 26: ...d 370 Wiring diagram 303 Input signals Conditions for output functions Output functions Ignition switch On Off Starter motor acti vated anti theft device a Directional gear steering column Engine On Off Key feed Requested gear Ignition switch On running position Engine Off Requested gear N Starter motor activated On Starter motor activated message On Ignition switch On running position Engine Off ...

Page 27: ...m steering wheel High beams Neutral position Low beams Towards steering wheel Headlight flash Control light on the front instrument panel indicates that high beams are on See 370 Wiring diagram 304 Work lights front Work lights front are operated with switch SW3504 located on the pillar panel Switch upper part pressed in Work lights front cab and attachment on Switch in middle position Work lights...

Page 28: ...engagement of work lights rear Selection of function with switch SW3505 located on the pillar panel Switch upper part pressed in Work lights cab and radiator casing on when reverse gear is engaged Switch in middle position Continuous work lights cab and radiator casing on Switch lower part pressed in Continuous work lights cab and radiator casing on Control light on the front instrument panel indi...

Page 29: ...e is connected to the elec trically controlled battery disconnector RE3101 of the ordinary battery disconnector SW3101 is on Hold function for RE3101 is obtained via relay RE3102 Stop of the machine is performed with the ignition or emergency stop SW3102 See 370 Wiring diagram 308 Strobe light optional equipment Strobe light LA3625 is on continuously as long as the battery dis connector is on Cont...

Page 30: ...unication VCADS Pro parameter HKQ 1 No communication via J1587 and CAN1 on V2 ECU or No communication via J1587 and CAN2 on V2 ECU or No communication via CAN1 and CAN2 on V2 ECU Interruption in communica tion between the ECUs On Check ECU Network Communica tion Interrupt No communication via J1587 on E ECU or No communication via CAN1 on E ECU Fail safe mode On Check ECU Network Reduced Communica...

Page 31: ... between the ECUs Interrupted communications Check ECU Network Communica tion Interrupt Gear is moved to Neutral Limp Home Regarding L60F L70F L90F Limp Home means that the machine can only be operated in 2nd gear Input signals Conditions for output functions Output functions Requested gear Engine On Off Accelerator pedal Computer communi cation Engine On Requested gear falure or Accelerator pedal...

Page 32: ...wiper and front washer Input signals Conditions for output functions Output functions Intermittent wiper front SW3602 Washer front SW3608 Intermittent wiper front On Intermittent wiper front active On for 0 5 second and then Off for X seconds a The sequence will be repeated until Intermittent wiper front is Off Intermittent wiper front Off Washer front Off Intermittent wiper front active Off Washe...

Page 33: ...sequence is repeated until Wiper rear is Off or until Wiper front and Intermittent wiper front is Off Wiper rear On and Intermittent wiper front On or Wiper front On and Requested gear R Wiper rear active On Washer rear On Wiper rear active On after 1 second Washer rear Washer front Off Wiper rear active Off after 5 seconds The following applies in case of faulty input signals Input signal Assumed...

Page 34: ...tions VCADS Pro parame ter ABP VCADS Pro parame ter ABQ VCADS Pro parame ter FXZ Keyboard Key feed Time since latest ignition switch Off General conditions for the function VCADS Pro parameter ABP On activation of function VCADS Pro parameter ABQ anti theft code VCADS Pro parameter FXZ delay Deactivation of anti theft device Ignition switch On running position Display unit shows Start lockout Ente...

Page 35: ... Fig 12 Instrument panels 1 Front instrument panel central instrument switches keypad for information display unit 2 Roof panel climate control system 3 Pillar panel mode selector switches ignition hand throttle control and electric power socket 12 V 4 Rear cab wall with electric power socket 24 V hour meter electrical distribution box with fuses and relays Socket for service tool 33 ...

Page 36: ...12 Boom Suspension System activated green 3 Information symbol green 13 Differential lock engaged green 4 High beams blue 14 Lever steering activated green 5 Rotating beacon amber 15 Fuel level 6 Working lights amber 16 Transmission oil temperature 7 Parking brake applied red 17 Coolant temperature 8 Charging battery red 9 Direction indicator left green 10 Direction indicator right green 34 ...

Page 37: ...iggers an alarm when the level is low Input signals Conditions for output functions Output functions Window washer fluid level SE3601 Low level 20 seconds Information Low washer fluid level The following applies in case of faulty input signals Input signal Assumed value in case of a fault Window washer fluid level Normal 35 ...

Page 38: ...eter GZC ON Vehicle info Operational Data Total a Reset Yes or Total fuel consumption 99999 Total fuel consumption 0 a Shows total fuel consumption since last reset The following applies in case of incorrect input signals Input Assumed value in case of error VCADS Pro parameter GZC OFF Reset No Fuel consumption average Input signals Conditions for output functions Output functions VCADS Pro parame...

Page 39: ...l becomes incorrect Travelling speed Regarding L60F L70F L90F The function calculates and informs the operator about the speed The speed is used as input signal to several functions Input signals Conditions for output functions Output functions VCADS Pro parame ter QM Output speed trans mission SE4307 Output speed transmission axle ratio x VCADS Pro parameter QM Distance per second Distance per se...

Page 40: ...n be adapted to the operator by selecting language and display format for units time and date Information organization The information in the information panel is built up in a number of groups functions Initial display Operating information Engine Transmission Hydraulics Axles Brakes Electrical system Vehicle information Vehicle messages Service Setup For detailed information see description of e...

Page 41: ...ower right corner The number values are used e g when setting date and entering PIN code for theft protection The key SELECT is used to e g make selections acknowledge and to get detailed information about any malfunc tions The key ESC is used to return or cancel ESC Return Engine 1 Transmission 2 Hydraulic system 3 Scroll up Axles 4 Electrical system 5 Vehicle information 6 SETUP Scroll down Vehi...

Page 42: ...functions for Service mode are described further under each group Warnings and alarms Warnings and alarms from the machine are obtained through a combination of central warning buzzer and messages in the information panel For further information about central warning see Central warning page 58 Messages about alarms in the information panel are either instructional or informative In case of seriou...

Page 43: ...ine is equipped with theft protection the following fig ure is shown when the ignition is turned to position 2 When correct four digit PIN code is entered the instrument changes automatically to operating display and the machine can be started Start lockout Enter code 41 ...

Page 44: ...for fuel h The lower field may display symbols for various information according to the following example Service mode Vehicle messages found Preheating active Electric lever lock out 4th function At speeds above 20 km h 12 mph an operating display is shown regardless if another display figure is selected If another display than the operating display is selected the system will return to the figur...

Page 45: ... low value bar with marking Low is shown In case of high value bar with marking High is shown By selecting Service mode number values can be shown instead of bars Conditions for activation of Service mode see Information display general page 38 To return to previous figure press ESC Air filter xxxx Normal Clogged In case of clogged air filter alarm CheckClogged air filter engine is also generated ...

Page 46: ... press SELECT to reverse the fan During on going reversal the text in the field changes from 15 min 30 min Off to Reversing NOTE The hydraulic oil temperature must be above 0 C 32 F to enable reversal of the cooling fan Shows any of the following figures for selected fan mode Rev cooling fan Short Interval 15 min Rev cooling fan Long Interval 30 min Rev cooling fan Manual Off Rev cooling fan OFF R...

Page 47: ...e of low value bar with marking Low is shown In case of high value bar with marking High is shown By selecting Service mode number values can be obtained for temperature pressure and level Conditions for activation of Ser vice mode see Information display general page 38 To return to previous figure press ESC Transmission disengagement Make selection for desired function with arrow keys and press ...

Page 48: ...igh is shown By selecting Service mode number values can be obtained for temperature and level Conditions for activation of Service mode see Information display general page 38 To return to previous figure press ESC Boom Susp System The figure shows if the boom suspension system is engaged or disengaged Activation and selection of speed dependent or gear dependent boom suspension system takes plac...

Page 49: ...ay of normal low or normal high Half bar is shown for normal value In case of low value bar with marking Low is shown In case of high value bar with marking High is shown By selecting Service mode number values can be obtained for temperature and pressure Conditions for activation of Service mode see Information display general page 38 To return to previous figure press ESC Axles Brakes Brake pres...

Page 50: ...e following menu figure Voltage level is shown as a bar Half bar is shown for normal value In case of low value bar with marking Low is shown By selecting Service mode number values can be obtained for battery voltage Conditions for activation of Service mode see Information display general page 38 To return to previous figure press ESC Electrical system Voltage Low 48 ...

Page 51: ...alt US gal Resid time fuel Residual operating time left for remaining fuel Instantaneous Current consumption in litres h alt US gal h Avg Average consumption in litres h alt US gal h Total Total consumption in litres alt US gal Service mode HW SW E ECU Engine control unit ECC ECU Electronic climate control unit I ECU Instrument control unit V ECU Vehicle control unit V2 ECU Vehicle control unit 2 ...

Page 52: ...CU Shows selected control unit HW No Hardware MSW No Software DST1 No Data set 1 DST2 No Data set 2 Vehicle info HW SW X ECU HW No xxxxxxxxPxx MSW No xxxxxxxxPxx DST1 No xxxxxxxxPxx DST2 No xxxxxxxxPxx 50 ...

Page 53: ...lower field in the operating figure The 20 latest active messages are saved Press the key to show messages To return press ESC Service mode In Service mode all messages are shown both inactive and active The 30 latest active messages are saved Conditions for activation of Service Mode see Information dis play general page 38 Press the key to show messages To return press ESC For error messages mor...

Page 54: ...service Central lubrication Interval Shows selected interval Light Normal Heavy To change setting press SELECT Make selection with the arrow keys and press SELECT to confirm the selection Level Shows lubricant level in the reservoir Normal Low Test Make test selection with the arrow keys Bulb test Press SELECT and all control lights on the instrument panel should be lit Brake test Press SELECT 1 A...

Page 55: ...and all control lights on the instrument panel should be lit Brake test Press SELECT 1 Accelerate over 20 km h 2 Brake to standstill 3 Read off the test result Retardation and Pressure To return to previous figure press ESC Brake test log Press SELECT Memory of retardation for the last 3 brake applications Memory of output brake pressure for the last 3 brake applications To return to previous figu...

Page 56: ...l in the form of a matrix according to example for V ECU The connector s pin number corresponds to the same number in the figure e g VA1 is shown in the figure as 01 High signal on digital input DI and digital output DO is shown with yellow filled rectangle and pin number Low signal on digital input DI and digital output DO is shown only with pin number Analogue frequency and PWM signals are not s...

Page 57: ...ting of display s light intensity 40 60 80 100 To change settings for Date Time Select function with the arrow keys and press SELECT Make selection with the arrow keys and press SELECT for each field To change settings for Language Intensity Select function with the arrow keys and press SELECT Make selection with the arrow keys and press SELECT To change settings for Units Clock options Date forma...

Page 58: ...ode shows any error code in the form of component desig nation followed by FMI failure error cause If the problem cannot be associated to a component designation the error code is shown instead according to SAE standard e g MID128 PID123 FMI12 Source shows which control unit detected the error failure First event logged date for first time that the failure error occurred Number of events number of...

Page 59: ...me of the follow ing Instruction figure is shown e g Gear sel failureCheck at next stop Warning figure e g Reduce speed Buzzer sounds in varying equal intervals on off in case of gear position F R Buzzer sounds with four short signals for gear position N Amber or red central warning Warning figure and buzzer remain until corrective action has been taken then return to previous figure Alarm prio 2 ...

Page 60: ...g is shown in the information panel Red central warning Light for red central warning flashes to informer the operator about serious failure error The reason for the central warning is shown in the information panel Reinforced central warning buzzer If red central warning is active at the same time as directional gear is active Forward or Reverse the buzzer sounds to reinforce the operator s atten...

Page 61: ... make a photo copy of this page and write down your points of view and post it to us To From Volvo Construction Equipment AB Customer Support Division Dept CEE S 631 85 Eskilstuna Sweden e mail servicemanuals volvo com Concerns publication Ref no Page no Suggestion Reason why Date Name ...

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Page 64: ...Ref no VOE 21 A 1002889 English Printed in Sweden 2007 01 CST Volvo Eskilstuna ...