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A60H Service Manual 3 Electrical 3.3 Repair Instructions 20053643-A 2017 09

The Volvo Construction Equipment Service Manual for the A60H provides detailed repair instructions for various electrical and information systems, including battery replacement, alternator servicing, and starter motor replacement. It emphasizes safety precautions and includes specific operational procedures for each component, along with necessary tools and torque specifications. The manual also encourages user feedback to improve future editions.

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© © All Rights Reserved
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0% found this document useful (0 votes)
47 views56 pages

A60H Service Manual 3 Electrical 3.3 Repair Instructions 20053643-A 2017 09

The Volvo Construction Equipment Service Manual for the A60H provides detailed repair instructions for various electrical and information systems, including battery replacement, alternator servicing, and starter motor replacement. It emphasizes safety precautions and includes specific operational procedures for each component, along with necessary tools and torque specifications. The manual also encourages user feedback to improve future editions.

Uploaded by

Sunarto Sunarto
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 56

VOLVO CONSTRUCTION EQUIPMENT

Service Manual
A60H

CONTENT
3 Electrical and Information Systems
3.3 Repair instructions
Foreword
Read the foreword in the Service Manual binder for a complete
overview.

WARNING
Always read the booklet Safety before proceeding.

Feedback
Please send feedback regarding the Service Manual to
[email protected]. Include the following information to
ensure an accurate response:
- Machine model
- Machine serial number
- Function group number
- Title or six digit operation number (Op. No.)
- Publication number located at the bottom of this page

Specifications
For references to specifications (example: 311, Battery
Specifications), see Section 0, General.

20053643-A 2017.09

1
Table of contents
30 GENERAL
300 Comprehensive info, electrical system
Tech Tool, operations ................................................................................. 5
Tests ......................................................................................................... 5
Programming ............................................................................................ 5
Calibration ................................................................................................. 5
HMIM, MID 140, changing pre-programmed ECU ...................................... 6
HMIM, MID 140, changing non-programmed ECU ..................................... 7

31 BATTERY
311 Battery
Batteries, replacing ..................................................................................... 9
Removing .................................................................................................. 9
Installing .................................................................................................. 10

32 ALTERNATOR; CHARGE REGULATOR


321 Alternator inclusive drive
Alternator, replacing incl function checking .............................................. 11
Removing ................................................................................................ 11
Installing .................................................................................................. 13

33 STARTING SYSTEM
331 Starter motor inclusive solenoid
Starter motor, replacing ............................................................................ 14

35 LIGHTING
352 Lighting, front, including parking light and day running light
Headlights, adjusting ................................................................................ 20
Light bulb, replacing .................................................................................. 22
Headlight (high beam 1 pc.), replacing incl. adjusting .............................. 23
Removing ................................................................................................ 24
Installing .................................................................................................. 24
Headlight (low beam 1 pc.), replacing incl. adjusting ................................ 24
Halogen headlight ................................................................................... 24
LED headlight ......................................................................................... 25
Common to halogen insert and LED insert ............................................. 26
353 Lighting, rear
Tail lamp, replacing ................................................................................... 27

36 OTHER ELECTRICAL EQUIPMENT


361 Direction indicator
Flasher lamp front glass or bulb, replacing ............................................... 30
Flasher lamp sidelight glass or bulb, replacing ......................................... 30
363 Cleaner
Windscreen wiper front motor, replacing .................................................. 32
Removing ................................................................................................ 32
366 Automatic control/blocking function, lacking a function group of its own
Control units, changing ............................................................................. 35
T-ECU, MID 130, changing pre-programmed ECU .................................. 35
V-ECU MID 187 pre-programmed, replacing ............................................ 37
V-ECU MID 187 non-programmed, replacing ........................................... 38

38 INSTRUMENT; SENSOR; WARNING AND INFORMATION


SYSTEM
386 Sender, monitoring system
Inclination sensor, replacing ..................................................................... 40
Removing ................................................................................................ 40

3
Installing .................................................................................................. 41

39 MISCELLANEOUS
398 Telematics systems
CareTrack antenna, replacing .................................................................. 42
Radio antenna, changing ........................................................................ 42
GSM/GPS-antenna, changing ................................................................ 44
W-ECU, MID142, changing non-programmed ECU ................................. 48
W-ECU, MID142, changing pre-programmed ECU .................................. 49

4
ELEC. SYSTEM; WARNING
SYSTEM; INFORMATION
SYSTEM; INSTRUMENTS

30 GENERAL

300 Comprehensive info, electrical


system
Tech Tool, operations
The following Tech Tool operations are available for function
group 3.
NOTE!
New operations are developed regularly. For a current list of all
tests, see Tech Tool software.

Tests

Operation Application
30101-3 Sensor values Vehicle control unit The test is used to check that sensors show reasonable values.
(VECU, MID187), check
30901-3 Power supply, control unit (ECU), The test is used to check the voltage feed to the control units.
check
38108-3 Sensor values Instrument control unit The test is used to check that sensors show reasonable values.
(HMIM MID140), check
39796-3 MID 142 Control unit, reset The test is used to reset the Telematics Control Unit.
39797-3 Telematics system status, check The test is used to check the status of the various
communication systems of the Telematics Control Unit.

Programming

Operation Application
17026-3 Program control unit When changing control unit or when reprogramming complete
or part of the software.

Calibration

Operation Application
38335-3 Displayed machine hours, correction Used for correcting machine hours when they do not correspond
to the actual operating time due to technical failure in the control
unit.
38396-3 Displayed total travelled distance, Used for correcting operating distance when it does not
correction correspond to the actual operating distance due to technical
failure in the control unit.
38664-3 Inclination sensor Used to calibrate the sensor for the rear frame's lateral
inclination.

5
HMIM, MID 140, changing pre-programmed ECU
Op. no. 300-075

This operation also includes required tools and times for


applicable parts of the following operations:
- 191, Service positions
- HMIM, MID 140, changing non-programmed ECU page 7
1 Place the machine in service position, see 191, Service
positions.
2 Connect a Tech Tool-computer and run 17030-3, Parameter
programming.
3 Run HMIM, MID 140, changing non-programmed
ECU page 7 from and including step 3 and on.
4 Connect a Tech Tool-computer and run 17030-3, Parameter
programming.
5 Restore the machine to operating condition.

6
HMIM, MID 140, changing non-programmed ECU
Op. no. 300-076

This operation also includes required tools and times for


applicable parts of the following operations:
- 191, Service positions
1 Place the machine in service position, see 191, Service
positions.
2 Connect Tech Tool-computer and run17092-3 Replace
hardware.
- When instructed to connect the new control unit,
perform steps 3-15.

CAUTION
Always follow instructions according to Electrical system, work
instructions, electronic components
300, Electrical system, special instructions for servicing,
electronic components

Removing
3 Make sure that the machine is without electric power supply
(voltage) by turning the ignition to position 0, the information
display unit should also be off.
4 Remove the cover panel in front of the electrical distribution
box.
5 Remove the cover panel above the electrical distribution
box.
6 Remove the bracket (3).
7 Disconnect the control unit (2) from the cab wall by loosening
the two rear bolts (1) and removing the two front bolts.
8 Unplug the connector from the control unit.

Installing
9 Plug in the connector for the control unit.
10 Connect the control unit (2) to the cab wall.

Fig.1
1 Rear bolts
2 HMIM
3 Bracket

7
11 Fit the bracket (3).
12 Install the cover panel over the electrical distribution box.
13 Install the cover panel above the electrical distribution box.

Fig.2
1 Rear bolts
2 HMIM
3 Bracket

NOTE!
When changing pre-programmed ECU, return to HMIM, MID 140,
changing pre-programmed ECU page 6 step 4.
14 Finish Tech Tool-operation 17092-3 Replace hardware.
15 Restore the machine to operating condition.

8
31 BATTERY

311 Battery
Batteries, replacing
Op. no. 311-002

This operation also includes required tools and times for


applicable parts of the following operations:
- 191, Service positions

WARNING
Batteries contain corrosive acid. Handle batteries according to
instructions in Section 3 and Section Safety.
300, Electrical system, special instructions for servicing, electrical
components, batteries

Removing
1 Place the machine in service position, see 191, Service
positions.
2 Open the engine hood.
3 Make sure that the machine is without electric power supply
(voltage) by turning the ignition to position 0, the information
display unit should also be off.
4 Remove fuse FU74.
5 Open the battery cover.
6 Expose the batteries by folding aside the rubber mat.

V1175826
FU74
Fig.3 Fuse
FU74 located on electrical distribution box in cab.

9
7 Loosen the nuts (8 pcs.) for all caps.
8 Remove the nuts and lift off each cap.
9 Remove the terminal caps.
10 Disconnect the cable terminals from the battery terminals.
11
WARNING
Batteries contain corrosive acid. Handle batteries according
to instructions in Section 3 and Section Safety.
Lift the batteries with a lifting device. See lifting handles on
the batteries.
Weight: 59 kg (130 lb) per pc.
V1144067

1 2
Fig.4 Battery box
1 Cable terminals
2 Caps

Installing
12
WARNING
Batteries contain corrosive acid. Handle batteries according
to instructions in Section 3 and Section Safety.
Lift the new batteries into place with a lifting device. See
lifting handles on the batteries.
13 Clean the battery terminals and cable terminals.
14 Connect the cable terminals to the battery terminals.
15 Lubricate with vaseline.
16 Install the terminal caps.
17 Align the caps on the clamps.
18 Tighten the nuts (8 pcs.) for all caps.
19 Secure the battery cables to the respective caps with cable
ties.
20 Close the battery cover.
21 Install fuse FU74.
22 Close the engine hood.

V1175826
FU74
Fig.5 Fuse
FU74 located on electrical distribution box in cab.

10
32 ALTERNATOR; CHARGE
REGULATOR

321 Alternator inclusive drive


Alternator, replacing incl function checking
Op. no. 321-002

Tools:
9809753 Sleeve
1159080 Sleeve

Loctite 243 Thread locker


This operation also includes required tools and times for
applicable parts of the following operations:
- 191, Service positions

CAUTION
Always follow instructions according to Electrical system, work
instructions, electronic components
300, Electrical system, special instructions for servicing,
electronic components

Removing
1 Place the machine in service position, see 191, Service
positions.
2 Open the engine hood.
1 3 Make sure that the machine is without electric power
(voltage) by turning the ignition to position 0.
Wait until the machine has shut down all systems in a
controlled way and check that the information display unit
(information panel) is off.
Turn off the main electric power by turning the service switch
handle to the left, position OFF.

V1167722

Fig.6 Service switch


1 Position OFF

11
4 Remove the belt guard.
5 Mark up and disconnect the cables from the alternator.

Fig.7
1 Belt cover
2 Alternator

6 Use a ratchet handle to loosen the drive belt's pre-load.


Remove the drive belt from the alternator.
7 Expose the alternator by removing the belt pulley with
adjusting arm.
8 Remove the alternator.

Fig.8 Alternator

9 Remove the belt pulley. Use 9809753 Sleeve and


1159080 Sleeve.

Fig.9 Removing belt pulley


1 1159080 Sleeve
2 9809753 Sleeve
3 Belt pulley

12
Installing
10 Install the belt pulley on the new alternator. Use
9809753 Sleeve and 1159080 Sleeve as well as apply
Loctite 243 on the thread.
Tightening torque, see 321, Alternator, tightening torques.
NOTE!
Risk of machine damage. A re-used belt pulley nut may
cause machine damage. Always use a new nut when
installing the belt pulley on the alternator.
11 Install the alternator.

Fig.10 Installing belt pulley


1 1159080 Sleeve
2 9809753 Sleeve
3 Belt pulley

12 Connect the cables to the alternator according to earlier


markings.
Tightening torque, see 321, Alternator, tightening torques.
13 Install the belt pulley with adjusting arm.
14 Install the drive belt on the alternator.
NOTE!
Make sure that the drive belt is positioned correctly on all
belt pulleys.
15 Install the belt guard.
16 Close the engine hood.
Fig.11 Alternator
1 Connection B2+
2 Multi-pin connector
3 Connection ground

1 17 Turn on the main electric power by turning the service switch


handle to the right, position ON.
18 Check the function by starting the engine and checking the
charging light.

V1167723

Fig.12 Service switch


1 Position ON

13
33 STARTING SYSTEM

331 Starter motor inclusive solenoid


Starter motor, replacing
Op. no. 331-018

This operation also includes required tools and times for


applicable parts of the following operations:
- 191, Service positions
1 Place the machine in service position, see 191, Service
positions.
2 Lower the front and the footstep. Open and raise the engine
hood.

Fig.13

1 3
NOTICE
Risk of machine damage.
Incorrect handling of the electrical system can lead to
machine damage.
Make sure that the machine is without electric power supply
(voltage) by turning the ignition to position 0, the information
display unit should also be off.
Make sure that the machine is without electric power (zero
voltage). Turn off the main electric power by turning the
handle to the left, position OFF.
V1167722

Fig.14
1 Position OFF

14
4 Disconnect the connections for the inlet and outlet hoses
from the charge-air cooler.

NOTICE
Always cover open air connections with a plastic bag and
rubber bands. Gravel, dust and other particles in these
connections may result in engine failure!

Fig.15
1 Connection, outlet air hose, charge-air cooler
2 Connection, inlet air hose, charge-air cooler

5 Remove the air intake from the carrier. Only applies to


machines with engine alternative F.

Fig.16
1 Air intake

15
6 Remove the cable ties holding the cable harness to SE2512,
charge-air cooler temperature. Only applies to machines
with engine alternative J. Release the contact for MA2606,
charge-air cooler shutdown.

Fig.17
1 MA2606, shut-off charge-air cooler
2 Cable tie for SE2512, temperature charge-air
cooler

7 Cut the cable ties and loosen the tensioning straps so that
the fan motor's hydraulic hoses can follow the movement of
the charge-air cooler. Loosen the charge-air cooler from its
bracket. Turn the charge-air cooler outwards and forwards.

Fig.18
Cut off cable ties and loosen tensioning straps

16
8 Mark up and disconnect the cables from the starter motor.
2 1 Disconnect the cables (3) and (4) from the starter motor.
2 Disconnect the cables (1) and (2) from the starter motor.
3 9 Remove the nuts that hold the starter motor.
1 10 Remove the starter motor from the engine compartment.
4 Weight: 15 kg (33 lb)

V1184216

Fig.19
1 Operation voltage.
2 Operation voltage.
3 Voltage feed.
4 Ground.

Installing
11 Install the starter motor.
12 Connect the cables to the starter motor according to earlier
markings. Tightening torque, see331, Starter motor,
tightening torques.
13 Grease the connections to prevent corrosion
14 Angle the charge-air cooler back to its original position and
screw it into place. Fit the air intake. Applies to machines
with engine alternative F.

Fig.20
1 Air intake

17
15 Connect the switch for MA2606, shut-off charge-air cooler.
16 Secure cables and hoses according to the earlier clamping
and cable ties, to prevent damage occurring.

Fig.21
1 MA2606, shut-off charge-air cooler
2 Cable tie for SE2512, temperature charge-air
cooler

17 Connect in and outlet air hoses for the charge-air cooler.


Tightening torque se: 250, Inlet and exhaust system,
tightening torques
18 Close the engine hood and raise the front.

Fig.22
1 Connection, outlet air hose, charge-air cooler
2 Connection, inlet air hose, charge-air cooler

18
1 19 Restore the service switch by turning the handle to position
ON
20 Restore the machine from service position, see: 191,
Service positions.

V1168630

Fig.23
1 Position ON

19
35 LIGHTING

352 Lighting, front, including parking light


and day running light
Headlights, adjusting
Op. no. 352-002

Tools:

Torx TR20, length >150 mm

1 Stand the machine on level ground, at right angles to a wall


or similar.
NOTE!
The machine shall be without load.
NOTE!
The HS-system must be in normal position.

Headlights, high beams


2 Turn on the high beams.
3 Measure the height H1 from the ground up to the centre of
the headlight.

20
4 Adjust the light pattern with the three adjusting screws
through the holes in the hood on each side.
5 Turn off the high beams.

1 2 V1167687

Fig.24 Headlights, left front


1 Adjusting screw, high beams
2 Adjusting screw, low beams

Fig.25 Light pattern, high beams

Measure High beams


ment
B 1900 mm (74.8 in)
H1 Measured value
H2 H1
L 5000 mm (196.8 in)

21
Asymmetric low beams
6 Open the engine hood.
7 Check the setting of asymmetric low beams, the headlight is
3 1 delivered set for right-hand traffic. See figure.
NOTE!
The figure shows headlights set for right-hand traffic.
Headlights of the LED-type do not have this setting, instead
they are ordered for right or left-hand traffic.
When setting for left-hand traffic:
2 1 Remove the bolt (1).
2 Loosen the bolts (2).
3 Turn the back-piece so that the hole (3) ends up in front
2 of the bolt hole for the bolt (1).
4 Install the bolt (1). Tighten the bolts (2).
V1085060 8 Close the engine hood.
Fig.26 Headlights, low beams
1 Screw (used for right-hand traffic)
2 Bolts Headlights, low beams
3 Screw hole (used for left-hand traffic)
9 Turn on the low beams.
10 Adjust the light patterns with the three adjusting screws
through the holes in the hood on each side.
11 Turn off the low beams.

1 2 V1167687

Fig.27 Headlights, left front


1 Adjusting screw, high beams
2 Adjusting screw, low beams

Fig.28 Light pattern, low beams

Measure Low beam


ment
B 2196 mm (86.5 in)
H1 Measured value
H2 H1 minus 250 mm (9,8 in)
L 5000 mm (196.8 in)

Light bulb, replacing


Op. no. 352-001

NOTE!
Do not touch the new bulb's glass with your hands.

22
1 Place machine in the service position. Refer to 191, Service
positions.
2 Open the engine hood approx. 500 mm (19.7 in).
3 Disconnect the cable harness.

V1092346

Fig.29
1 Cable harness

4 Turn the light bulb holder counter-clockwise and remove it.


5 Change light bulb.
6 Install the light bulb holder by turning it clockwise.
1
7 Fit the cable harness.
8 Close the engine hood.
9 Check that the light bulb works.
10 Restore the machine from service position.

V1092344

Fig.30
1 Light bulb
2 Light bulb holder

Headlight (high beam 1 pc.), replacing incl.


adjusting
Op. no. 352-024

1 Place machine in the service position. Refer to 191, Service


positions.

23
2 Open the engine hood approx. 500 mm (19.7 in).

Removing
3 Unplug the connector for the high beam bulb.
4 Turn the light bulb holder counter-clockwise and remove it.
5 Unplug the connector for the running light bulb.
6 Remove the retaining nuts for the high beam insert.
7 Replace the high beam insert.

1 2 3 4 1 5 V1182827

Fig.31
1 Fastener nut
2 Bulb holder, high beams
3 Connector, high beams
4 Connector, running lights
5 Direction indicators

Installing
8 Fit the retaining nuts on the new insert.
9 Install the light bulb holder by turning it clockwise.
10 Install the connectors.
11 Close the engine hood.
12 Check that the light bulb works.
13 Adjust the headlights, see Headlights, adjusting page 20 .
14 Restore the machine from service position.

Headlight (low beam 1 pc.), replacing incl.


adjusting
Op. no. 352-060

1 Place machine in the service position. Refer to 191, Service


positions.
2 Open the engine hood approx. 500 mm (19.7 in).

Halogen headlight
3 Disconnect the connector.

24
1 2 3 4 2 5 V1182795

Fig.32
1 Low beam
2 Fastener nut
3 Connector
4 Holder, halogen bulb
5 High beams

4 Turn the light bulb holder counter-clockwise and remove it.


5 Remove the retaining nuts for the low beam insert.
6 Replace the low beam insert.
7 Fit the retaining nuts on the low beam insert.
8 Install the light bulb holder by turning it clockwise.
9 Plug in the connector.

LED headlight

V1182796

Fig.33
1 Low beam
2 Bracket
3 High beams

10 Disconnect the connector.

Fig.34
1 Connector
2 LED low beam insert

25
11 Remove the LED low beam insert by pressing in the locking
for the brackets.

Fig.35
1 Locking
2 Bracket

12 Replace the LED low beam insert.


13 Fit the brackets, make sure that their locking clicks into the
plate.
14 Plug in the connector.

Common to halogen insert and LED insert


15 Close the engine hood.
16 Check that the light bulb works.
17 Adjust the headlights, see Headlights, adjusting page 20 .
18 Restore the machine from service position.

26
353 Lighting, rear
Tail lamp, replacing
Op. no. 353-051

1 Place machine in the service position. Refer to 191, Service


positions.
2 Remove the protective grill (three bolts).

V1085884

Fig.36

V1085885

Fig.37

3 Remove the plate with the light bulb inserts (two bolts).

V1085886

Fig.38

27
4 Remove the light bulb insert from the plate. Press out the
rubber strip through the hole.

V1085887

Fig.39

5 Unplug the connector for the light bulb insert.

V1085888

Fig.40

V1085889

Fig.41

28
6 Remove the rubber strip from the light bulb insert.
7 Clean around the light bulb.
8 Replace light bulb insert and reinstall the rubber strip.
9 Plug in the connector.
10 Install the light bulb insert in the plate.
11 Install the plate with the light bulb inserts.
12 Install the protective grill.
13 Check that the light works.

V1085890
14 Restore the machine from service position.
Fig.42

29
36 OTHER ELECTRICAL
EQUIPMENT

361 Direction indicator


Flasher lamp front glass or bulb, replacing
Op. no. 361-005

1 Place machine in the service position. Refer to 191, Service


positions.
2 Open the engine hood approx. 500 mm (19.7 in).
3 Turn the bulb holder for the direction indicator counter-
clockwise and replace the bulb.
4 Remove the bolts and change the insert.
5 Install the bolts for the new insert.
6 Install the light bulb holder by turning it clockwise.
7 Check that the light bulb works.
8 Close the engine hood.
1 2 3 2 9 Restore the machine from service position.
V1182828

Fig.43
1 High beams
2 Screw for insert for direction indicator
3 Bulb holder, direction indicator

Flasher lamp sidelight glass or bulb, replacing


Op. no. 361-006

1 Place machine in the service position. Refer to 191, Service


positions.
2 Open the engine hood.

Fig.44
1 Direction indicator
2 Running lights

30
Fig.45
1 Connector
2 Bracket for running light and direction
indicator

3 Turn the light bulb holder for the direction indicator counter-
clockwise and replace the bulb.
4 Disconnect the connector.
5 Remove the screws from the bracket.

Fig.46
1 Light bulb holder
2 Connector
3 Bracket for running light and direction
indicator

6 Remove the bolts and change the insert.


7 Install the bolts for the new insert and the bracket.
8 Install the light bulb holder for the direction indicator by
turning it clockwise.
9 Plug in the connector.
10 Check that the light bulb works.
11 Close the engine hood.
12 Restore the machine from service position.

Fig.47
1 Light bulb holder
2 Bolts for insert

31
363 Cleaner
Windscreen wiper front motor, replacing
Op. no. 363-002

This operation also includes required tools and times for


applicable parts of the following operations:
- 191, Service positions

Removing
1 Place the machine in service position, see 191, Service
positions.
2 Open the engine hood.
3 Make sure that the machine is without voltage by turning the
ignition to position 0 and waiting until the information display
unit is off.

Engine compartment, front cab wall


4 Release the footstep and release the windscreen wiper
motor bracket by angling the footstep down with the coolant
reservoir.
5 Cut applicable cable ties so that the hoses can follow the
movement of the coolant reservoir.
6 Split the washer fluid hose at the joint.

Fig.48
1 Coolant reservoir
2 Foot step

32
Wiper arms
7 Remove the nuts and washers that hold the wiper arms.
8 Remove the windshield wiper arms.
For each windshield wiper arm:
1 Place a pry bar against the holder and the attachment for
the wiper arm, pry carefully with the pry bar to loosen the
wiper arm, balance with the wiper arm's spring load.
2 Remove the windshield wiper arm.

Fig.49
1 Bracket windscreen wiper motor
2 Hose for washer fluid
3 Holder for windscreen wiper arm
4 Windscreen wiper arm

9 Remove the bracket with the windscreen wiper motor (4 x


screws).

Fig.50
1 Bracket Windscreen wiper motor
2 Holders for windscreen wiper arms
3 Upper attachment for bolt to cab
4 Lower attachment for bolt to cab

10 Unplug the connector for the windshield wiper motor from


the cab wall.
11 Disconnect the windshield wiper motor from the bracket.

Fig.51
1 Windshield wiper motor
2 Connector

33
Installing
1 2 12 Install the windshield wiper motor on the bracket. Adjust the
distance as shown in the figure.
Tightening torque, see 363, Windscreen wiper motor,
tightening torques.
NOTE!
Check the distance on both shafts.
13 Plug in the windshield wiper motor's connector.
A 14 Install the windscreen wiper motor's bracket loosely with the
V1103252
two upper screws.
Fig.52
A = 50 mm 15 Install the two lower screws loosely.
(2 in) 16 Tighten the bolts.
A = 50 mm (2 in) NOTE!
1 Windshield wiper motor
Check that the bracket has solid contact with both the inner
2 Bracket windscreen wiper motor
and upper cab wall.
17 Install the windshield wiper arm, washer, and nut on each
holder.
18 Adjust the arms so that the wiping movement starts in
position as shown in the figure.
Tightening torque, see 363, Windscreen wiper motor,
tightening torques.
19 Turn the ignition to position 1.
20 Check the windshield wiper blade's movement.
21 Assemble the hose for washer fluid at the joint and check
that the windshield washer works.
A

V1103253

Fig.53
Distance (A) is measured at the windshield wiper
blade's lower edge.
A = 78 ±10 mm (3 ±0.4 in)

22 Install the footstep with the coolant reservoir.


23 Install the cable tie to secure the hoses.
24 Close the engine hood.

Fig.54
1 Coolant reservoir
2 Foot step

34
366 Automatic control/blocking function,
lacking a function group of its own
Control units, changing
Control Unit MID Links
Identification numbers
ACM MID233 254, ACM (Aftertreatment control module) pre-programmed, replacing
254, ACM (Aftertreatment control module) non-programmed,
replacing
E-ECU MID128 200, E-ECU MID 128 pre-programmed, replacing
200, E-ECU MID 128 non-programmed, replacing
ECC MID146 870, ECC MID 146 pre-programmed ECU, replacing
870, ECC MID 146 non-programmed ECU, replacing
HMIM MID140 HMIM, MID 140, changing pre-programmed ECU page 6
HMIM, MID 140, changing non-programmed ECU page 7
V-ECU MID187 V-ECU MID 187 pre-programmed, replacing page 37
V-ECU MID 187 non-programmed, replacing page 38
Gateway MID 165 366, Engine Gateway MID 165 pre-programmed, replacing
366, Engine Gateway MID 165 non-programmed, replacing
V2-ECU MID249 900, V2-ECU, MID 249, changing pre-programmed ECU
900, V2-ECU, MID 249, changing non-programmed ECU
W-ECU MID142 W-ECU, MID142, changing pre-programmed ECU page 49
W-ECU, MID142, changing non-programmed ECU page 48
T-ECU MID130 T-ECU, MID 130, changing pre-programmed ECU page 35

T-ECU, MID 130, changing pre-programmed ECU


Op. no. 432-078

Tools:

This operation also includes required tools and times for


applicable parts of the following operations:
- 191, Service positions
1 Place the machine in service position. See 191, Service
positions.

Removing
2 Make sure that the machine is without electric power supply
(voltage) by turning the ignition to position 0, the information
display unit should also be off.

35
3 Loosen the screw and release the connector from the control
unit.
4 Remove the control unit from the front cab wall by loosening
the bolts (3 pcs.).

Installing
5 Install the control unit on the cab wall and fasten the bolts.
6 Plug in the connector for the control unit.
7 Restore the machine.

Fig.55
1 T-ECU, MID 130
2 Connector
3 Screw, connector

36
V-ECU MID 187 pre-programmed, replacing
Op. no. 366-066

This operation also includes required tools and times for


applicable parts of the following operations:
- 191, Service positions
- V-ECU MID 187 non-programmed, replacing page 38
1 Place the machine in service position, see 191, Service
positions.
2 Connect a Tech Tool-computer and run 17030-3, Parameter
programming.
3 Run V-ECU MID 187 non-programmed, replacing page 38
from and including step 3 and on.
4 Connect a Tech Tool-computer and run 17030-3, Parameter
programming.
5 Restore the machine to operating condition.

37
V-ECU MID 187 non-programmed, replacing
Op. no. 366-064

This operation also includes required tools and times for


applicable parts of the following operations:
- 191, Service positions
1 Place the machine in service position, see 191, Service
positions.
2 Connect a Tech Tool-computer and run 17092-3 Replace
hardware.
- When instructed to connect the new control unit,
perform steps 3-15.

CAUTION
Always follow instructions according to Electrical system, work
instructions, electronic components
300, Electrical system, special instructions for servicing,
electronic components

Removing
3 Make sure that the machine is without electric power supply
(voltage) by turning the ignition to position 0, the information
display unit should also be off.
4 Remove the cover panels in front of and to the right of the
electrical distribution box.
5 Remove the insert in the air direction shutter with a small
screwdriver.
6 Remove the air direction shutter.

Fig.56 Air direction shutter

7 Expose the control unit by moving aside the air channel (2).
8 Unplug the connectors (3) from the control unit.
9 Remove the control unit (1).

Fig.57
1 V-ECU
2 Air duct
3 Connectors

38
Installing
10 Install the control unit (1).
11 Plug in the connectors for the control unit (3).
12 Install the insert in the air direction shutter. Install the air
direction shutter and connect the air channel (2) to the air
direction shutter.
13 Install the cover panels in front of and to the right of the
electrical distribution box.

Fig.58
1 V-ECU
2 Air duct
3 Connectors

NOTE!
When changing pre-programmed control unit, go back to V-ECU
MID 187 pre-programmed, replacing page 37 step 4.
14 Finish Tech Tool-operation 17092-3 Replace hardware.
15 Restore the machine to operating condition.

39
38 INSTRUMENT; SENSOR;
WARNING AND INFORMATION
SYSTEM

386 Sender, monitoring system


Inclination sensor, replacing
Op. no. 386-089

1 Place the machine in service position, see 191, Service


positions
NOTE!
It is important that the machine is level both longitudinally and
laterally as the method includes calibration of the sensor.

Removing
2 Remove the screws (3x) and cover plate, see figure, position
1 and 2.

Fig.59
1 Screw
2 Cover plate

3 Disconnect the cable, see figure, position 1, and remove the


sensor.
4 Remove the terminator connector, see figure, position 2.

Fig.60
1 connector
2 Terminator connector

40
Installing
5 Install the terminator connector on the new sensor.
6 Connect the cable.
7 Fit the screws.

1 2 8 Check the machine's angle in the display or service tool. The


angle must be less than 8 percent (longitudinally and
laterally) in order to perform calibration

V1182296

Fig.61
1 Lateral angle in percent
2 Longitudinal angle in percent

9 If necessary, adjust the sensor so that the angle is less 8


percent. Adjust longitudinal angle by loosening the screws
for the sensor or the screws in the bracket. See figure,
position 1.
10 Check that the angle is less than 8 percent and connect the
Techtool service tool.

Fig.62
1 Screws for bracket

11 Calibrate the sensor by running operation 38664-3


Inclination sensor.

Fig.63
12 Check that the angle is 0 percent in the display.
13 Restore from service position.

41
39 MISCELLANEOUS

398 Telematics systems


CareTrack antenna, replacing
Op. no. 398-001

Radio antenna, changing


1 Place the machine in service position.
2 Make sure that the machine is not supplied with voltage.
There are two ways to disconnect the electric power supply,
depending on machine model.
– Turn off the electric power using the battery disconnector.
– Turn the ignition to position 0, the information display unit
should also be Off.
NOTE!
Risk of machine damage.
Incorrect handling of electrical and electronic systems can
lead to machine damage.
3 Disconnect the radio antenna.

Fig.64

4 Remove the antenna.

Fig.65
1 Antenna

42
5 Disconnect the antenna bracket and pull out the antenna
cable harness from the cab.

Fig.66
1 Bolt

Fig.67
1 Antenna bracket

Fig.68
1 Antenna cable

43
6 Install the bracket and the new antenna.

Fig.69
1 Antenna bracket

7 Connect the antenna to the radio.


8 Check that the antenna works.

Fig.70
1 Radio aerial

GSM/GPS-antenna, changing
1 9 Position of antenna
NOTE!
On older machines the antenna has a different position.

V1149643

Fig.71
1 Antenna

44
10 Loosen and remove the air channel.

Fig.72

11 Disconnect the headlining (inner roof) and remove the


satellite antenna.
NOTE!
The headlining's plugs should be replaced when reinstalling.

Fig.73

12 Remove the nut.

Fig.74
1 Nut

45
13 Remove and change the cable harness from the W-ECU.
Connect the new antenna's cable harness according to the
colour markings.
NOTE!
The W-ECU is in different position depending on model.

Fig.75
1 Cable
2 Cable

Fig.76
1 Cable

46
14 Clamp the cable harness against the cab wall up to the cab
roof.
15 Install the antenna on the cab roof.
Tightening torque 5 Nm.
NOTE!
When installing, make sure to clamp the antenna cable
harness against the cab roof.
16 Check that the antenna works.
When registering the machine on CareTrack website, make
sure that the machine is outdoors and the ignition key is in
running position for approx. 30 minutes, to ensure correct
transfer of setup data between the machine and the
CareTrack system.
17 Restore the machine.

Fig.77
1 Cable

47
W-ECU, MID142, changing non-programmed
ECU
Op. no. 398-003

This operation also includes required tools and times for


applicable parts of the following operations:
- 191, Service positions
1 Place the machine in service position, see 191, Service
positions.
2 Connect Tech Tool-computer and start operation17092-3
Replace hardware.

CAUTION
Always follow instructions according to Electrical system, work
instructions, electronic components
300, Electrical system, special instructions for servicing,
electronic components

Removing
3 Make sure that the machine is without electric power supply
(voltage) by turning the ignition to position 0, the information
display unit should also be off.
4 Remove the cover panel in front of the electrical distribution
box.
5 Remove the cover panel above the electrical distribution
box.
6 Expose the control unit by removing the upper bolt on the
bracket(1). Fold down the bracket.
7 Disconnect the control unit (2) from the cab wall.
8 Unplug the connectors from the control unit.

Installing
9 Plug in the connectors for the control unit.
10 Connect the control unit to the cab wall.

Fig.78
1 Bracket
2 W-ECU

48
11 Raise up the bracket (1) and install the upper bolt.
12 Install the cover panel over the electrical distribution box.
13 Install the cover panel above the electrical distribution box.

Fig.79
1 Bracket
2 W-ECU

NOTE!
When changing pre-programmed control unit, go back to W-ECU,
MID142, changing pre-programmed ECU page 49 step 4.
14 Finish Tech Tool-operation 17092-3 Replace hardware.
15 Restore the machine to operating condition.

W-ECU, MID142, changing pre-programmed ECU


Op. no. 398-002

This operation also includes required tools and times for


applicable parts of the following operations:
- 191, Service positions
- W-ECU, MID142, changing non-programmed ECU page 48
1 Place the machine in service position, see 191, Service
positions.
2 Connect Tech Tool-computer and start 17030-3, Parameter
programming.
3 Run W-ECU, MID142, changing non-programmed
ECU page 48 from and including step 3 and on.
4 Connect Tech Tool-computer and finish 17030-3,
Parameter programming.
5 Restore the machine to operating condition.

49
Ref. no. PUB 20053643-A English
2017.09
Volvo, Braås

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