Volvo ECR88 Compact Excavator Service Repair Shop Manual

Service Information Document Title: Function Group: Information Type: Date: Electrical system, description Service Information 2014/4/2 0 Profile: CEX, ECR88 [GB] Electrical system, description The electrical system consists of three major circuits: main power, monitor and control circuits.      The main power circuit functions include: engine starting, battery charging, and lighting operations. The main power circuit operates at 12 volts. The monitor circuit inputs information from various sensors and switches to controller (V-ECU) concerning the machine operating status. The control circuit transfers electrical signals from controller (V-ECU) to main components actuators that control functions such as proportional solenoid valves, proportional control potentiometers, and auto idle solenoid valves. Wiring harness connectors are numbered to facilitate troubleshooting. Slow blow fuses protect electrical components of the main power circuit.

Service Information Document Title: Function Group: Information Type: Date: Electrical system, special instructions for servicing, general Service Information 2014/4/2 0 Profile: CEX, ECR88 [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 2014/4/2 0 Profile: CEX, ECR88 [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. The battery's negative 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. 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 booster 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 2014/4/2 0 Profile: CEX, ECR88 [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 defects must be corrected before starting any electrical testing. Check the alternator belt and, if needed, make any necessary adjustment/repairs before troubleshooting. At correct belt tension, the belt should "give" when pressure is applied to it, measurement according to figure. Figure 1 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 2014/4/2 0 Profile: CEX, ECR88 [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.

Service Information Document Title: Function Group: Information Type: Date: Electrical system, special instructions for servicing, action when working on machine Service Information 2014/4/2 0 Profile: CEX, ECR88 [GB] Electrical system, special instructions for servicing, action when working on machine     For electric welding on the machine, the battery cables must be disconnected and the connectors must be unplugged from the control units. During blasting work on the machine, work very carefully to prevent damage to electrical cabling and components. Never aim the water jet directly at electrical components when using a high-pressure washer. This is especially important when using a combination of warm water and degreasing agents. Before drilling or making any other holes in the machine, all electrical components in the area must be located with great accuracy. NOTICE Drilling and other modifications to the cab structure are forbidden! The reason is that the ROPS protection may not function as intended if the cab structure is modified.

Service Information Document Title: Function Group: Information Type: Date: Auxiliary start Service Information 2014/4/2 0 Profile: CEX, ECR88 [GB] Auxiliary start 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. Auxiliary start with start cables Check the following before connecting; - That the ignition is OFF in both machines. - That the machine cannot start to move when started. - That the machines have the same system voltage. - That the start cables are dimensioned for the Max. current rating that the battery can generate. - Start cables, with regards to cracks, oxidation and other defects. - That battery cables are intact and connections are connected securely. - That the machines do not touch each other. WARNING When using start cables, the positive and negative connection must not come into contact. Risk of personal injury. Connect start cables as follows: Figure 1 Connecting start cables - Connect the first start cable (A) to the battery's positive terminal (1) on the machine to be started. - Connect the other end of cable (A) to the battery's positive terminal (2) on the assisting machine. - Connect the other start cable (B) to the battery's negative terminal (3) on the assisting machine. - Connect the other end of cable (B) to the frame (4) on the machine to be started. Check that good electric contact is obtained. Auxiliary start: - Check that the start cables are connected securely and correctly (figure). - Start the engine in the assisting machine. - Start the engine in the machine to be started. If the engine does not started within 30 seconds, wait for at least two minutes before the next start attempt.

Remove the start cables follows: Figure 2 Removing start cables - Remove cable (B) from the frame (1) on the machine that has been started with auxiliary start. - Remove the other end of start cable (B) from the battery's negative terminal (2) on the assisting machine. - Remove cable (A) from the battery's positive terminal (3) on the assisting machine. - Remove the other end of start cable (A) from the battery's positive terminal (4) on the machine that has been started with auxiliary start.

Service Information Document Title: Function Group: Information Type: Date: Vehicle control unit V-ECU, functional description Service Information 2014/4/2 0 Profile: CEX, ECR88 [GB] Vehicle control unit V-ECU, functional description Figure 1 Vehicle control unit, position The vehicle control unit is mounted on the inside right hand cab wall. The vehicle control unit is the controlling node in the system. It contains overall functionality that is vehicle related. Overall strategic decisions are made in the vehicle control unit. It controls, regulates and monitors the hydraulics. Information is sent out/read in on the data bus for coordination with the other control units. Main functions       Air preheating timer Boom offset selector Quickfit system driver Automatic return to idling Fuel cutoff solenoid (pull coil) drive Proportional control for double acting

Figure 2 Connector A from wire harness (gray) Connector A from wire harness Pin No. Explanation Pin No. Explanation 1 Main ground 7 Quickfit mode coding 2 Key "19" preheat triggering 8 Quickfit triggering 3 Timer coding for preheat (ground : 15 sec, No ground : 4 sec 9 Quickfit relay drive 4 Preheat drive 10 Key '50a" (preheating, auto idle) 5 Boom offset triggering 11 Fuel cutoff relay drive 6 Boom offset relay drive 12 Main power supply Figure 3 Connector B from wire harness (black) Connector B from wire harness Pin No. Explanation Pin No. Explanation 1 Output for PWM valve (feed) 7 Potentiometer signal 2 Output for PWM valve (return) 8 Proportional validation switch 3 Proportional validation, Lamp drive 9 High-flow button 4 Resistor high-flow set 10 Pressure switch for auto idle 5 Safety lever down 11 Drive for auto idle solenoid (pull) 6 Potentiometer power 12 Drive for auto idle solenoid (hold)

Volvo ECR88 Compact Excavator Service Repair Shop Manual

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