Volvo EC300DL Excavator Full Service & Repair Manual

Service Information Document Title: Function Group: Information Type: Date: VCADS Pro, Operations 300 Service Information 2014/11/28 Profile: EXC, EC300D L [GB] VCADS Pro, Operations The following VCADS Pro operations are available for function group 3. Operations used when changing or working on components are mandatory. Tests Operation Application 30101-3 Sensor values Vehicle control unit (VECU, MID187), check Used when there is a suspicion of fault and/or at abnormal values/readings. 30902-3 Keypad status, test Used when there is a suspicion of fault and/or at abnormal values/readings. 36003-3 Switches, control levers, test Used when there is a suspicion of fault and/or at abnormal values/readings. 36401-3 Switches, test Used when there is a suspicion of fault and/or at abnormal values/readings. 37173-3 Data links, fault tracing with oscilloscope Used when there is a suspicion of fault and/or at abnormal values/readings. 38674-3 Pressure switches, test Used when there is a suspicion of fault and/or at abnormal values/readings. 39796-3 MID 142 Control unit, reset Used when it is transferred to another machine. 39797-3 Care Track status, check Used when there is a suspicion of fault and/or at abnormal values/readings. Calibrations Operation Application – – Programming Operation Application 36646-3 MID 187 ECU, programming When changing V-ECU or only reprogramming. See 366 V-ECU, MID 187, changing non-programmed ECU 36648-3 MID 187 ECU, campaign 38145-3 MID 140 ECU, programming When changing I-ECU or only reprogramming. See 300 I-ECU, MID 140, changing non-programmed ECU 38104-3 MID 140 ECU, campaign 39736-3 MID 142 Control unit, programming When changing W-ECU or only reprogramming. See 398 W-ECU, MID142, changing non-programmed ECU 39738-3 MID 142 Control unit, campaign

Service Information Document Title: Function Group: Information Type: Date: I-ECU, MID 140, changing non-programmed ECU 300 Service Information 2014/11/28 Profile: EXC, EC300D L [GB] I-ECU, MID 140, changing non-programmed ECU Op nbr 300-072 1. Park the machine in the service position A, see . 091 Service positions 2. Download the program for target machine. 3. Connect VCADS Pro computer to the machine, and perform operation '38145-3 MID 140 control unit, programming'. 4. When VCADS pro 'MID 140 ECU, programming' window appears, follow the instructions for replacing I-ECU. 5. Turn OFF battery disconnect switch. 6. Open the windscreen. 7. Remove the screws of plastic cover and disconnect the wire harness from the cab wire harness. 8. Remove the screws fixing I-ECU to the cab. Figure 1 I-ECU, changing 1. 2. Screw Wire harness 9. Install a new I-ECU to the cab with screws and connect wire harness. 10. Install the plastic cover with screws and close the windscreen. 11. After replacing the I-ECU, press OK button of VCADS Pro operation '38145–3 MID 140 control unit, programming'. Now VCADs Pro starts the programming of software and parameters to the new I-ECU.

12. Start the machine and check that no error messages appear.

Service Information Document Title: Function Group: Information Type: Date: I-ECU, MID 140, changing pre-programmed ECU 300 Service Information 2014/11/28 Profile: EXC, EC300D L [GB] I-ECU, MID 140, changing pre-programmed ECU Op nbr 300-074 1. Park the machine in the service position A, see . 091 Service positions 2. Connect VCADS Pro computer to the machine, and perform operation '17030-3 Parameter, programming'. 3. Use the function 'save all parameters to job card'. 4. Turn OFF battery disconnect switch. 5. Open the windscreen. 6. Remove the screws of plastic cover and disconnect the wire harness from the cab wire harness. 7. Remove the screws of fixing I-ECU to the cab. Figure 1 I-ECU, changing 1. 2. Screw Wire harness 8. Install a new I-ECU to the cab with screws and connect wire harness. 9. Install the plastic cover with screws and close the windscreen. 10. Connect VCADS Pro computer to the machine, and perform operation 17030-3 Parameter, programming'. Now the customer parameters are changed according to the job card saved at step 3. 11. Start the machine and check that no error messages appear.

Service Information Document Title: Function Group: Information Type: Date: Electrical system, description Service Information 2014/11/28 Profile: EXC, EC300D L [GB] Electrical system, description This section of the service manual describes the design and construction of the electrical system and all included components. This section also contains functional descriptions, troubleshooting and method instructions for servicing. The electrical system consists, in part, of electrical and electro-mechanical components such as batteries, switches, solenoid valves, fuses and relays. The electrical system also consists of a computer-based control system that monitors and controls machine functions. In order to access certain settings in the information system, special service instruments are required; VCADS Pro. User instruction for VCADS Pro is available in a separate user’s manual. WARNING For all servicing of the electrical system, the general instructions must be strictly followed.

Service Information Document Title: Function Group: Information Type: Date: Electrical system, special instructions for servicing, general Service Information 2014/11/28 Profile: EXC, EC300D L [GB] Electrical system, special instructions for servicing, general WARNING No changes may be made to the electrical system without prior approval from Volvo. Changes may affect machine functions and can result in risks for personal injury or machine damage. WARNING Carelessness when working with the electrical system may result in risks of serious personal injuries as well as machine damage. When working on the electrical system, the following instructions as well as instructions in respective section must be followed carefully. Also read instructions in Section Safety and in the Operator's Manual. WARNING Always remove watches, rings, bracelets and other metallic objects from the body before starting to work on the electrical system. Figure 1 WARNING Never boost-start the machine by connecting directly to the starter motor. This may result in uncontrolled machine movements. When using another machine to boost-start, it must not touch the machine that is being started. Never test if a cable/connection is supplied with electric power by producing "spark". This may permanently damaged electrical/electronic components.

Service Information Document Title: Function Group: Information Type: Date: Electrical system, special instructions for servicing, electrical components, batteries Service Information 2014/11/28 Profile: EXC, EC300D L [GB] Electrical system, special instructions for servicing, electrical components, batteries WARNING During rapid charging of batteries, always remove the cell caps. During charging, an explosive mixture of oxygen and hydrogen is formed. A short-circuit, open flame or spark near the battery can cause a powerful explosion. Always turn off the charging current before disconnecting the charging clamps. Ventilate well, especially if the battery is being charged in a confined area. The battery electrolyte contains corrosive sulphuric acid. Remove spilled electrolyte from the skin immediately. Wash with soap and plenty of water. If electrolyte has splashed into the eyes or on any other sensitive body part, rinse immediately with plenty of water and contact a physician immediately. WARNING The batteries could explode due to the current surge if a fully charged battery is connected to a completely discharged battery. Since the batteries contain sulphuric acid, this could result in personal injuries. WARNING Never charge a frozen battery. Explosion hazard!      Never disconnect the main electric current or disconnect battery cables when the engine is running. Figure 1 The battery's minus connection must always be disconnected before removing or installing components and connections in the electrical system. NOTE! Incorrect handling may cause damage to, for example, control unit/ECU which results in downtime. Figure 2 Fully charged batteries must be used when checking the electrical system. If the batteries are not fully charged, charge them or replace with new batteries. During battery charging, the battery terminal cables must always be disconnected from the battery. When changing batteries connected in series, the batteries should have the same capacity (for example, 150 Ah). The batteries should be of the same age (equally good). The reason for this is that the charging current required to give the battery a certain charge varies with the age of the battery.

 Only batteries may be used as assistant starting devices. An auxiliary starter unit and/or batteries connected in series to assist when starting may result in high (excess) voltage and can seriously damage electronic/electric components.

Service Information Document Title: Function Group: Information Type: Date: Electrical system, special instructions for servicing, electrical components, alternator and charging regulator Service Information 2014/11/28 Profile: EXC, EC300D L [GB] Electrical system, special instructions for servicing, electrical components, alternator and charging regulator   Before any alternator or regulator tests are performed, the batteries and electrical cabling must be checked for insulation, loose connections and corrosion. Check the alternator belts. All eventual defects according to the above must be corrected before starting any electrical testing. Check the alternator belt and, if needed, make any necessary adjustment/repairs before troubleshooting. NOTICE Always connect cabling in a safe manner and make sure that cables are free from rust/dirt. A disconnected cable may cause damage to both alternator and charging regulator. NOTICE Never disconnect the alternator connections when the engine is running. This may damage both alternator and charging regulator. NOTICE Make sure that the alternator plus connection is not connected to the frame. This will damage the alternator, and may also damage the regulator.

Service Information Document Title: Function Group: Information Type: Date: Electrical system, special instructions for servicing, electronic components Service Information 2014/11/28 Profile: EXC, EC300D L [GB] Electrical system, special instructions for servicing, electronic components  If a connector on any of the data buses has been damaged, the bus must be replaced. Note that the two cables included in each data bus are paired and twisted in order to protect them from electrical interference. Cabling must only be repaired by trained personnel. As an alternative, the entire cable harness can be completely replaced. NOTE! Electronic equipment is sensitive and may easily be damaged by electro-magnetic fields and/or by static electricity from tools or the human body. Therefore, always follow the instructions below when performing work involving electronic components. The following instructions must be followed in order to meet the requirements for electro-magnetic compatibility (EMC).        Connections to an electronic component must never be disconnected when the unit is supplied with electric power, this may damage the electronics. Discharge any static electricity in tools before servicing the electrical system by touching the tool to a metallic machine part that is connected to the frame. Never touch the connector pins on electronic units. Avoid touching circuit boards when servicing the electrical system. If this is necessary – only hold the circuit board by the edges. Never touch individual electronic components. Make sure that ground cables are securely connected when replacing units. Never replace paired, twisted cabling with paired, non-twisted cabling.

Volvo EC300DL Excavator Full Service & Repair Manual

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