Volvo EC160B, EC180B, EC210B, EC240B, EC290B Service Manual

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

Machine information system change UPDATE-EC160B~460B-01 System layout change UPDATE-EC160B~460B-02 Electronic control system overview UPDATE-EC160B~460B-03 VECU input & output UPDATE-EC160B~460B-04 Control circuit UPDATE-EC160B~460B-05 EECU Electric circuit(EC160B/180B/210B/240B/290B) UPDATE-EC160B~460B-05-1 EECU Electric circuit(EC360B/460B) UPDATE-EC160B~460B-05-2 Machine status indication(IECU) UPDATE-EC160B~460B-06 IECU Electric circuit UPDATE-EC160B~460B-07 Old instrument panel circuit UPDATE-EC160B~460B-07-1 Power ON/OFF procedure UPDATE-EC160B~460B-08 Indicator operation UPDATE-EC160B~460B-09 MCD(Machine Display Center) operation UPDATE-EC160B~460B-10 X1 option flow setting UPDATE-EC160B~460B-11 Pop-up indicator UPDATE-EC160B~460B-12 Code lock(Anti-theft) UPDATE-EC160B~460B-13

MAIN MENU

Error Message(ECU) UPDATE-EC160B~460B-14 Error Message(Comunication & Elec. system) UPDATE-EC160B~460B-15 Error Message(Hydraulic system) UPDATE-EC160B~460B-16 Error Message(Engine) UPDATE-EC160B~460B-17 Error Message(Engine) UPDATE-EC160B~460B-18 Old start circuit(EC160B/180B/210B/240B/290B) UPDATE-EC160B~460B-19 Start circuit Start circuit Start circuit Old start circuit( Start circuit Start circuit Alternator change UPDATE-EC160B~460B-26 Safety relay change(Add time delay function) UPDATE-EC160B~460B-27

( Old alternator & New IECU- EC160B/180B/210B ( New alternator & Old Inst. panel-EC240B/290B) ( New alternator & New IECU- EC160B/180B/210B/240B/290B)

EC360B/460B)

( New alternator & Old Inst. panel-EC360B/460B) ( New alternator & New IECU- EC360B/460B)

UPDATE-EC160B~460B-23

) UPDATE-EC160B~460B-20

UPDATE-EC160B~460B-21

UPDATE-EC160B~460B-22

UPDATE-EC160B~460B-24

UPDATE-EC160B~460B-25

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Machine Information System Change

1. Integration of hardware

instead of the various direct electric connection

Instrument panel

2. Simplifying electirc circuit

by using communication line

Old

Instrument panel

Sensor & Switch

EMS

3. Removing

duplicated sensor

Engine oil

pressure switch for

indicator

Coolant

temperature

sensor for

needle gage

4. Changing

MDU

(Machine Display Unit)

Flow control SW

Buzzer

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1450RPM

G1

13:24

IECU

123456

Hour meter

V-ECU

New

V-ECU

Sensor & Switch

UPDATE - EC160B~460B - 01

E-ECU MDU

E-ECU

EMS

ECU

E-

Electric signal ( On, Off, Resistance)

Information link (J1587)

Control link (J1939)

MDU

I-ECU

Connection to VECU

- Fuel level sender

- Overload warning select switch & pressure switch

- Alternator charging signal

- Auto-grease ind. signal

- Buzzer stop & Confirm switch for Quick fit

System Layout Change

Instrument panel

C

Machine Display Unit

A/C controller

Emergency control SW

AUTOOFF

123456

Hour meter

Old

New

Remove Flow control SW

Flow control SW

Emergency

�

control switch

**Flow setting will be done by IECU

2002 RPM

MODE 0%

New IECU

C

AUTOOFF

A/C controller

�

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UPDATE - EC160B~460B - 02

Electronic Control System Overview

IECU

MID140

EMS(E-ECU)

MPC(9993892) PC(9998555)

MID128

J1939(CAN)

J1587(J1708)

Interface

VECU

MID187

2002 RPM

MODE 0%

MATRIS

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VCADS Pro

Service Display Unit (SDU)

UPDATE - EC160B~460B - 03

VECU Input & Output

NEW

RH Switch

Travel

Pilot

Pressure

Switch

Att

Pilot

Pressure

Switch

Hammer

Pilot

Pressure

Switch

B/Float

Position

Pressure

Switch

Fuel level sensor

Alternator

B2+

Auto.

grease

controller

Hyd. oil

temp.

sensor

(EC360B/

460B)

Rotator Switch

Overload warning

pressure SW

Hammer/

Boost/Shear

B/Float Switch

Quick

Fit

Switch

Select

Switch

Engine Speed Control SW

Relay

Travel Speed Select Switch

P/Max Select Switch

Power Boost

Boom & Arm conflux cutoff

Auto Idle Select Switch

B/Float Sol.

Hyd. oil cooling fan(EC360B/460B)

AA

AAAA

Start Switch

V-ECU

Battery Relay

Auto/ Manual Switch

A/M

SW

position

B1+

VECU Status

Safety Lever Switch

Emergency SW

Data Memory Relay

select

switch

Buzzer

Stop

Confirm

Switch

Overload

warning

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Flow Control Valve

Power Shift Valve

SDU

UPDATE - EC160B~460B - 04

Resistor Box

2002 RPM

PMODE 0%

IECU

EECU

Control Circuit(EC160B~EC460B)

F27 10A

POWER

FROM

BATTERY

RELAY

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

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

R2 R1

Hammer Boost Shear select SW

1 2 3 4 5 6 7 8

Shear

select sol.

Hammer

select sol.

2

86

30

1

R/H J/S RH button

Hammer

4

85

87a

87

3 5

Travel Speed

2

86

30

1

OFF

T/speed select SW

87

3 5

1

F24 5A

1 2 3 4 5 6

SDU / MATRIS / VCADS PRO

F01 10A

IECU operating power 6105

F16 15A

POWER

FROM

BATTERY

Clock

IECU(NEW)

2(L)

1(H)

4(B)

8

A / M

SW

Auto /

Manual

JA34

Power Boost

JA36

7

ILL. from

Work lamp

SW

JA12

Overload

OFF

Hyd. oil cooling fan

warning

select

13

Service Socket

14

123 456

7

10 11

8(A)

9(B)

VECU status

9

4

85

87a

Travel speed control

T/Speed SW position

5

key "#"

key "*" key "V" key ">"

"enalber"

"data"

"clock"

Power for solenoid Power for solenoid

Hammer position

Boost position

Shear position

Auto grease

Battery Relay

Altenator”L”

JA7

to

alternator

JA61

to

Battery

relay

JA24 JA48 JA1 JA25 JA49

JA26 JA2 JA60 JA35

JA38

JA18

JA68

JB1

JA45

JA21

JA61

JA7

JA59

Floating

Boom

JA37

Conflux cutoff

Arm

JA21

Auto

grease

"IND"

***

##

3(A)

JA47

JA22

JA13

VECU

JA16

Buzzer stop

1 3

JA42

Q/fit Confirm

7

JA46

JA44

JA67

Auto. Idle

1

5

Power Max. select

1

5

OFF

1

5

F15 20A

POWER

EB4 EB11 EB12

EB26(B)

EB25(A)

EB2(L)

EB1(H)

J1587

J1939

JB13

(L)JB6

(B)JB4

(A)JB12

(H)JB14

JA43

JA19

JA41

JA66

Att. Press.(20k)

Travel Press.(20k)

Overload Press.(adj.)

Hammer Press.(7k)

Key

ES

"ACC"

R3

2

86

EMS

30

87

1

3 5

EECU

##

Fuel level

JB5

JA15

(GND)JA63

JA17

JA56

Float press.(7k)

Flow control Signal

Flow control Ground

P/V

Flow

Control

P/V

R4

2

4

85

86

30

87a

1

Key start "R2"

JB2

Hyd. oil temp. sensor

JA40

JA30

JB11 (+24V)

JA14 (GND)

JA39 (0.5~4.5)

Engin RPM

Ctrl.SW

4

85

EMS DATA

87a

87

RECORD

3 5

EB9

EB10

Key on "ACC"

JB9

JB2

JB7 JB8

JA33

Power P/V

JA69

Boom float

JA23

Quick fit

JA70

Rotator

JA20

Safety lever

P/Shift Ground

JA5

JB15

JB16

VECU operating

JA32

power

Power shift Signal

AUTO MANU

F25 10A

F13 10A

R/H J/S Center button

1 2 3

Power

Shift

P/V

1

UP

2 3

Safety lever

A / M

P/V

F12 15A

DOWN

SS

to

Safety Relay

to

IECU

4 5 6

Resistor

Quick Fit SW R/H

Neutral

Quick Fit SW L/H

Neutral

Safety sol.

Box

F28 10A

ON 20K OFF 14K

R12

2

4

86

85

30

87a

87

1

3 5

847

23

1

847

23

1

R5

2

86

30

87

1

3 5

R6

2

4

85

87a

4

86

85

30

87a

87

1

3 5

L/H J/S LH button

L/H J/S RH button

Quick fit sol.

Volvo Construction Equipment Customer Support

UPDATE - EC160B~460B - 05

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

Engine speed sensor ,cam

1 2 1 2

n

(+)

(-)

7 18

Engine speed sensor ,crank

n

(+)

31 30 13

Connector A

Connector B

4 1 2 25 26 9 10 11 12 7 17 8 3 13 31 5

Solenoid valve

E-ECU

on unit injection pump

Cyl 2

Cyl 3

New Boost Fuel temp.

(-)

Coolant temp.

Oil press.

3

1

Press. & temp.

1

2

3

4

2

(+)

225 14 3 4 5 12 11 23 22 24 35 36 34

Ambient air press.

(-) (-) (-)

Cyl 1

Preheat

relay

1 2 3 4

Cyl 4

Cyl 6

Cyl 5

AH

to Fuse 140A

Connector A

24

36 36

25

12

13

1

24

12

BLACK RED

Emergency speed control

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J1939_L

J1939_H

J1708_A

J1708_B

GND

24V(+)

Coolant level

Inlet press.

Inlet temp.

UPDATE - EC160B~460B - 05-1

Power from fuse

Preheat coil

13

25

1

Connector B

EECU Electric Circuit( EC360B/460B)

Solenoids on injection pump

Cyl 2

E-ECU

Cyl 4

Engine speed ,cam

1

n

(+)

7 18

1

2

(-)

31 30 1 2 25 14 3

Connector A

Connector B

4 1 2 25 26 9 10 11 12 7

Emergency

Speed

Engine speed ,crank

n

(+)

2

(-)

J1939 H (A)

Coolant temp.

2

1

J1939 L (B)

Oil

temp.

press.

3

J1708

J1708BGround Power

A

Cyl 3

Boost

temp.

press.

4

2

1

3

4

2

1

Barometer

Fuel press.

4

2

1

(+)

4 27 5 12 11 23 22 24 35 3634

1 2 3 4

(-) (-)

8 3 13 31 5

17

(-) (-) (-)

Cyl 1

Preheat

relay

Cyl 6

Cyl 5

(-)

Connector B

24

36 36

25

12

13

1

24

12

RED BLACK

AH to Fuse 140A

supply

Power from fuse

Coolant level

Inlet (air) press. (filter clogging)

Inlet (air) temp.

13

25

1

Volvo Construction Equipment Customer Support

UPDATE - EC160B~460B - 05-2

Preheat coil

Connector A

Machine Status Indication (IECU)

1450RPM

G1

13:24

Group Name Color Remark

Lamp Central warning lamp Red Flashes when a fault occurs

Fuel level gauge -Gauge Engine coolant tem

Indicator

MCD Electronic Display Unit

Key Up - Screen Up

Buzzer Buzzer sounds when fault occurs and

Real time Clock

Parking brake lamp Red used at wheel excavator Brake oil pressure warning lamp Red used at wheel excavator Steering pressure low Red N/A Oscillation lock Yellow used at wheel excavator Alignem ent Green N/A Working l ights lamp (* High beam lamp) Blue High beam at wheel excavator Left/right turn signal lamp Green used at wheel excavator Engine oil pressure warning lamp Red Engine coolant temperature warning lamp Red Coolant level lamp Red Air cleaner clogging warnin g lamp Yellow Air preheating lamp Yellow Hydraulic oil tem perature warning Red Hydraulic oil filter clogging Yellow N/A Battery charge warning lamp Red Quickfit lamp Red Overload warning lamp Red Power booster Green Float operation indicator Green Hammer selecting indicator Green Shear sele

(Message Center Display)

Down - Screen Down Scroll - Scroll Confirm - Confirm

Real time clock

cting indicator Green

perature gauge -

8 Step, TN-LCD, Transflective Back light by white color LED

128x64 pixels LCD Back light by amber colored LED

buttons are

Capacitor supply power to clock for 500 hrs without external power

pressed

Volvo Construction Equipment Customer Support

UPDATE - EC160B~460b - 06

IECU Electric Cirucit

From battery

From battery relay

F1

10A

21C6

KEY ON

F16 15A

21C5

(CLOCK)

W/TEMP

FUEL

CENTRAL

WARNING

21C9

VECU STATUS

JA34

TO

VECU

PARK

BRAKE

21C1

H

BRAKE

FAIL

(J1939 H)

21C2

STEER

PRESS.

21C3

(J1939 L)

L

AXLE

LOCK

(J1587 A)

21C4

A

HIGH

ALIGNE

(J1587 B)

B

BEAM

21C8

VECU JB16

LH/RH

TURN

E/OIL

21C10

PRESS

21C7

COOL

TEMP

(ILLU.LAMP)

AIR

CLEANER

COOLANT

LEVEL

PRE

IECU

From work lamp switch

LCD DISPLAY

(MCD)

HEAT

HYD

TEMP

HYD

FILTER

CHARGE

QUICK

FIT

OVER

LOAD

POWER

BOOST

BOOM

FLOAT

HAMMER

SHEAR

15

610

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Auto/Manual SW position

UPDATE - EC160B~460B - 07