A60H Service Manual 3 Electrical 3.3 Repair Instructions 20053643-A 2017 09
A60H Service Manual 3 Electrical 3.3 Repair Instructions 20053643-A 2017 09
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
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
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
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
6
HMIM, MID 140, changing non-programmed ECU
Op. no. 300-076
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
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
Tools:
9809753 Sleeve
1159080 Sleeve
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
11
4 Remove the belt guard.
5 Mark up and disconnect the cables from the alternator.
Fig.7
1 Belt cover
2 Alternator
Fig.8 Alternator
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.
V1167723
13
33 STARTING SYSTEM
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
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
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
Tools:
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
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
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
V1092344
Fig.30
1 Light bulb
2 Light bulb holder
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.
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
LED headlight
V1182796
Fig.33
1 Low beam
2 Bracket
3 High beams
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
26
353 Lighting, rear
Tail lamp, replacing
Op. no. 353-051
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
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
Fig.43
1 High beams
2 Screw for insert for direction indicator
3 Bulb holder, direction indicator
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
Fig.47
1 Light bulb holder
2 Bolts for insert
31
363 Cleaner
Windscreen wiper front motor, replacing
Op. no. 363-002
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.
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
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
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)
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
Tools:
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
37
V-ECU MID 187 non-programmed, replacing
Op. no. 366-064
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.
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
Removing
2 Remove the screws (3x) and cover plate, see figure, position
1 and 2.
Fig.59
1 Screw
2 Cover plate
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.
V1182296
Fig.61
1 Lateral angle in percent
2 Longitudinal angle in percent
Fig.62
1 Screws for bracket
Fig.63
12 Check that the angle is 0 percent in the display.
13 Restore from service position.
41
39 MISCELLANEOUS
Fig.64
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
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
Fig.73
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
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.
49
Ref. no. PUB 20053643-A English
2017.09
Volvo, Braås