Electrical System

Handout A3540D_03.
doc Last printed 08/04/2005 14:53:00
3 ELECTRICAL SYSTEM
Batteries 90824 Explanation of wiring diagrams 90961 B
ECU's 90846 Grounding points 90980
Electrical central in cab, photo 90881 Electrical schematic A01 91085 A
Electrical central in cab 90882 Electrical schematic A02 91086
Signal transfer 90876 Electrical schematic A03 91087
Information content 90877 Electrical schematic A04 90962 A04B
Data link wiring 90874 Electrical schematic A04 90962 A04C
Machine network 90873 A Electrical schematic A05 90962 A05A
Service connections 90979 Electrical schematic A05 1009717
Service display 91138 Electrical schematic A06 91090
Hardware ECU´s 90875 Electrical schematic A07 90962 A07B
Voltage supply of the ECU´s 90872 B Electrical schematic A08 90962 A08B
Connecting Helpstart 91126 Electrical schematic A09 90962 A09A
Disconnecting Helpstart 91127 Electrical schematic A10 91094
Description Warning and Error 91066 Electrical schematic A11 91095 A
Warning levels 91005 Electrical schematic A12 90962 A12B
Engine sensors 90885 Electrical schematic A13 91097
Air temp and pressure sensor 90971 Electrical schematic A14 91098 A
Oil and fuel sensor 90972 Electrical schematic A15 91099 A
Coolant temp and level 90973 Electrical schematic A16 90962 A16A
Engine speed sensors 90974 Electrical schematic A17 90962 A17A
Turbo pressure and temp sensor 90975 Electrical schematic A18 91102 A
Functions controled by EECU 90976 Electrical schematic A19 90962 A19B
Unit injectors 90977 Electrical schematic A20 90962 A20A
System description Load and Dump 91006 Electrical schematic A21 90962 A21A
System description Parking brake 91009 Electrical schematic A21 1009709
Error code temperature sensor 91152 Electrical schematic A22 91106 A
Error code frequence sensor 91154 Electrical schematic A23 91107 A
Error code analogue sensor 91153 Electrical schematic A24 90962 A24B
Error code digital sensor 91155 Electrical schematic A25 90962 A25A
Right side of cab 90811 Electrical schematic A26 90962 A26A
Right side of cab later versions 1009650 Electrical schematic A27 91111
Electrical schematic A28 91112 CLICK THE VOLVO-LOGO IN
MAIN THE LOWER RIGHT CORNER
MENU TO RETURN TO THIS MENU
1
Handout A3540D_03.doc Last printed 08/04/2005 14:53:00
90824. Batteries
2
90846. ECU´s
E-ECU Engine - ECU

I-ECU Instrument - ECU (Called D-ECU in older material)
C-ECU Cab – ECU
V-ECU Vehicle – ECU
T-ECU Transmission - ECU
3
90881. Electrical central in cab, photo
4
90882. Electrical distribution box, description

The electrical distribution box is located in the cab on the left cab wall.
5
90876. Signal transfer

The control units communicate with one another in computer language by means of electronic pulses
created by two voltage levels, each level representing either a 1 or a 0. 1 or 0 is the smallest
information-carrying unit and is known as a bit. As shown in the diagram, the levels and what they
represent distinguish between the two standards’ A and B cables.
Voltage levels Represents

J1939 A 4 V and B 1 V “0”
A 2.5 V and B 2.5 V “1”
J1708 A 5 V and B 0 V “1”
A 0 V and B 5 V “0”
When the voltage at one level in J1939 is the same (2.5 V) in both the A and the B
cables, the magnetic field around the cables, and therefore the risk of interference, is
minimised.
The transfer capacity is calculated in bits per second, bps, which is a measure of
information quantity per unit of time. J1939 can transfer 250 000 bps, while J1587
can transfer
9 600 BPS
6
90877. Information content

Here is an example of the information content in the four different blocks. There are
start and stop bits between the blocks to indicate when a block starts and ends. These
bits contain no information and are therefore shadowed in the picture. The start bit is
identified by a “0” and the stop bit by a “1”. The binary and decimal values of the
information in the message are shown in the insert. This is the most common way of
writing binary figures. Note that this message is placed on the network in reverse
sequence.
The information section in each block contains 8 bits, which is equivalent to 1 byte.
MID 187 the message sender is the vehicle control unit.
PID 091 accelerator pedal position.
DATA 000 accelerator pedal released completely.
CKSM 022 checksum the checksum is a check that the message is reasonable.
7
90874. Data link wiring

Each part of the network has two 0.75 mm 2 electrical cables, which are of twisted-
pair type so that they are resistant to interference. These cables can be recognised by
their colours: green or yellow for J1939, and pink or grey for J1587/J1708. All
information is transmitted via these cables, and this takes place extremely quickly and
in both directions, but in one direction at a time.
The only task of these cables is to carry information. At either “end” of J1939, which
transmits the important control signals between the vehicle control unit, the engine
and the gearbox, there is a terminal resistor, which has the task of ensuring that the
signals are not distorted during transmission. The terminal resistors, 120 ohm each,
are connected in parallel (one is built into the engine control unit). No terminal
resistors are required for signal transfer in J1587/J1708.
The splices have to be reliable in order for the system to work, and therefore all fixed
cable points are spliced together. The network cabling is not laid separately, but is
part of the same cable covering as the other cables. In the event of a loss of power in
J1939, J1587/J1708 acts as a backup, which makes it possible to drive the vehicle to
the workshop. If both links fail, there is another backup system between VECU and
EECU.
8
90873B. Electric control system

E–ECU Engine control unit
D–ECU Instrument control units B
CM Instrument control unit 1 "Center Module"
LM Instrument control unit 2 "Left Module"
C–ECU Cab control unit
V–ECU Vehicle control unit
T–ECU Transmission control unit
CAN1/J1939 Control link serial data 256 kbit
CAN2/J1939 Control link serial data 256 kbit
J1708/J1587 Information link serial data 9.6 kbit
IA Service connection, Contronic
PC Service connection, PC (VCADS and Matris)
9
90979. Service connection and programming connection

The service connection (socket) and programming socket are located by the steering
wheel. The Contronic service socket and PC service socket are connected to the
information bus and is used for communication with external equipment.
VCADS Pro is the PC tool used for:

– Programming of control units
– Downloading of vehicle parameters
– Reading of error codes
– Testing and checking of functions/components.
– When troubleshooting, this is of very significant importance, since all vital parts
in the vehicle electronics can be checked with VCADS Pro.
Contronic service display unit is used for:

– Reading of error codes
– Setting of certain customer parameters
– Showing machine information/status for engine, transmission, dropbox and
hydraulics
– Showing software (program) version in control unit
– Showing status of inputs and outputs on control units
Matris is Volvo CE’s PC software for reading vehicle history. Logged vehicle
parameters are compiled, processed and presented in the form of different diagrams.
10
91138. Service display

Possible views on service display for Articulated Haulers A25D-A40D
11
90875. Hardware
Changes introduced to the hardware of every control unit are such that the control
units can be said to be of a new type, and this applies to all control units and not just
“newly produced” ones such as the vehicle control unit and the instrument module.
Thus other hardware has been modernised at the same time as the circuits for network
connections have been developed.
In each control unit, a controller is used for communications which is integrated with
a micro-processor, an interface for J1939 and J1708 transfer, or simply for J1708
transfer depending on the connection, an E2 PROM as a parameter and fault code
memory, and an EPROM/
Flash as software memory. In the engine control unit, the J1708 interface is located
separately as shown in this picture, while in other control units this is part of the
controller.
As before, there are generally input and output units, such as A/D converters and
amplifiers, for input and output signals in order to receive both digital and analogue
input signals with either varying voltage or varying frequency, and to send high and
low digital output signals with either varying frequency or current strength.
12
90872B. Voltage supply of control units

Code Designation
V–ECU Vehicle control unit
T–ECU Transmission control unit
C–ECU Cab control unit
E–ECU Engine control unit
D–ECU Instrument control units
EBxx, Ecxx Connection for cable. Connector and pin number (xx)
CXxx, LXxx
LYxx
GND Ground connection/Frame grounding point
FUxx Fuses, see Wiring diagrams and Electrical distribution box
FHxx Fuses, see Wiring diagrams and electrical distribution box BA3201/
BA3202 Battery 1 and 2
BAT+ Battery voltage, plus supply

BAT-C Battery control. V-ECU output EC14 (connector EC pin 14)
controls voltage supply to T-, C-, and E-ECUs.
SW3701 Battery disconnect switch battery ground
SW3301 Ignition
Rexxxx Relays for voltage supply, see Wiring diagrams and Electrical
distribution box
13
91066. Description Warning and Error
14
91005. Warning levels
15
90885. Sensors - an overview

The D12C has a total of eight sensors. Three of these have dual functions. This gives
a total of 11 functions.
The dual function sensors are:

2. Turbo boost pressure/air temperature in inlet manifold.
5. Air temperature before intercooler and pressure drop indicator. Located in the
union pipe between the air filter housing and the turbocharger inlet.
8. Oil pressure/temperature.
The other sensors are:

1. Fuel pressure sensor. Senses the pressure after the fuel filter.
3. Camshaft position sensor. Located in the upper timing mechanism cover.
4. Engine coolant level. Located in the expansion tank.
6. Engine coolant temperature. Located in the rear end of the cylinder head.
7. Engine speed sensor. Located in the flywheel cover.
Apart from the sensors above, the system includes a sensor for Atmospheric Pressure,
located inside the EECU. The D12C has a total of eight sensors. Three of these have
dual functions. This gives a total f 11 functions.
16
90971. Air temperature sensor/ pressure drop indicator

The air temperature sensor and pressure drop indicator is a combined sensor.
Measuring the air temperature before the turbocharger is a new function.
The temperature measuring part of the sensor is of NTC-type, Negative Temperature

Coefficient. This means that as the temperature increases the resistance value of the
sensor decreases.
The sensor is located in the union pipe between the air filter housing and the
turbocharger inlet. The pressure drop indicator will alert the driver if the pressure drop
after the filter increases, due to a blocked air filter.
17
90972. Oil pressure/ temperature Fuel pressure sensors

This combined sensor is situated on This sensor is of the combined type for
the side of the cylinder block. both temperature and pressure but the
temperature measuring part is not in
The temperature measuring part is a NTC- function on the D 12 C.
device, Negative Temperature Coefficient.
18
90973. Engine coolant temperature Engine coolant level

This sensor is of a NTC-type, Negative This sensor is situated in the
Temperature Coefficient. expansion tank
It is located in the rear of the cylinder head The sensor is of On-Off-type and
sends a signal if the coolant level
is too low.
19
90974. Engine speed sensors

The Engine Speed Sensor, or Crank Sensor, is mounted on the side of the flywheel
housing.
The flywheel has three groups of teeth machined into the outside edge. The inductive
type sensor generates a signal each time a gap between two teeth in the flywheel
passes it. The sensors™ signal is received by the EECU for engine speed information
and crankshaft position.
The Camshaft Sensor is located in the upper timing mechanism cover. Like the
Engine Speed Sensor it is an inductive type. Signals are generated as the teeth of a
seven teeth wheel mounted to the camshaft drive gear pass by.
Six of the teeth are aligned to signal the compression stroke of each cylinder. The
seventh tooth identifies cylinder number one.
This information, together with the information from the Engine Speed Sensor,
enables the EECU to precisely locate the position of each cylinder.
If one of these Sensors fails, the system is able to run the engine in lower capacity,
with information from the other sensor.
20
90975. Turbo boost pressure / air temperature sensor

The turbo boost pressure / air temperature sensor is mounted into the inlet manifold.
The EECU provides a common feed voltage for both devices within this sensor. A
NTC device, Negative Temperature Coefficient, carries out the temperature function.
The operating ranges for both functions remain similar to those in the individual
sensors used in the past.
21
90976. Functions controlled by the EECU

The EECU sends signals to different components on the engine and thus controls a
series of functions and components:
1. Unit Injectors
2. Exhaust Pressure Governor
3. Starting Heater
4. Compression Brake
22
90977. Unit injectors

The fuel system for D12 C has electronically controlled Unit Injectors, one for each
cylinder.
The injection pressure is achieved mechanically from an over head camshaft via
rocker arms.
The injection angle and the amount of fuel to be injected into the cylinder is decided
by the EECU which sends signals to the Electro-magnetically controlled fuel valve in
the unit injector housing.
23
91006. System description Load and Dump brake
24
91009. System description Parking brake
25
Error code from Temperature sender

Ex. SE2606 (Engine coolant temp)
FMI 3 High Voltage

24V FMI 4 Low Voltage
FMI 11 Other fault
E-ECU 5V
1 (1)
MID128 C° Resistance SE 2606-03
PID110 relative
FMI3
temp. INFO STOP
<0,08V or >4,95V
GND
GR D-ECU
1708A
OR
1708B
MID128 PID110 FMI3(or4) MID128

PID110 SE 2606-03
FMI3
Volvo Construction Equipment 91152

Customer Support AB
91152 Error code from temperature sensor
26
Error code from Frequence sensor

Ex. SE2701 (Engine rpm sender)
FMI 2 Incorrect signal

24V FMI 3 Bad OHM at 0 rpm
FMI 8 Abnormal frequency
E-ECU -
1 (1)
MID128 ~ SE 2701-03
SID22 Speed Hz
FMI3
INFO STOP
+
GND
GR D-ECU
1708A
OR
1708B
MID128 SID22 FMI3 MID128

PID110 SE 2701-03
FMI3

Customer Support AB
91154. Error code from Frequence sensor
27
Error code from Analogue sensor

Ex. SE2301 (Engine fuel feed pressure)
FMI 3 High Voltage

24V FMI 4 Low Voltage
FMI 11 Other fault
E-ECU 5V
1 (1)
SE 2301-03
MID128
PID94
<0,08V or >4,95V Pa
FMI3
STO
GND
GND
GR D-ECU
1708A
OR
1708B
MID128 PID94 FMI3(or4) MID128

PID94 SE 2301-03
FMI3

Customer Support AB
91153 Error code from Analogue sensor
28
Error code from Digital sensor

Ex. SE2308 (Needle lift sensor)
Only possible with

24V logic diagnostic.
FMI 2 Engine rpm but no signal
E-ECU 5V
1 (1)
SE 2308-02
MID128
PID21
FMI2
INFO STOP
0V or 5V
GND
GR D-ECU
1708A
OR
1708B
MID128 SID21 FMI2 MID128

SID21 SE 2308-02
FMI2

Customer Support AB
91155 Error code from Digital sensor
29
90811. Right side, cab
30
1009650 Right side of cab with new version P-brake
31
90961B. Explanation of wiring diagrams

Pos. Explanation
A Reference, cable (lead) has a permanent
connection to wiring diagram A11
B Connector with pin marking
C Component marking
D Permanent connection
E Cable/lead colour, see table below
F Cable/lead marking
G Key dependent voltage supply
H Connection marking
J Frame grounding point (frame connection)
K Connector with pin number
L Removable connection
Cable (lead) colours on wiring diagrams are outlined in the following table.
Code Colour Code Colour

BL Blue R Red
BN Brown SB Black
GN Green VO Violet
GR Grey W White
OR Orange Y Yellow
P Pink
32
90980. Grounding points, (Frame ground connections)

Marking Designation
GC1 Cab
GE1 Engine
GF1 Front frame left
GF2 Front frame (under cab instep)
GF3 Front frame right
GFSM Starter motor
GR1 Rear
TUTUP FILE INI

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Handout A3540D_03.

doc Last printed 08/04/2005 14:53:00

E-ECU Engine - ECU

90881. Electrical central in cab, photo

90882. Electrical distribution box, description

90876. Signal transfer

Voltage levels Represents

90877. Information content

90874. Data link wiring

90873B. Electric control system

90979. Service connection and programming connection

VCADS Pro is the PC tool used for:

Contronic service display unit is used for:

91138. Service display

90872B. Voltage supply of control units

BAT+ Battery voltage, plus supply

91066. Description Warning and Error

91005. Warning levels

90885. Sensors - an overview

The dual function sensors are:

The other sensors are:

90971. Air temperature sensor/ pressure drop indicator

The temperature measuring part of the sensor is of NTC-type, Negative Temperature

90972. Oil pressure/ temperature Fuel pressure sensors

90973. Engine coolant temperature Engine coolant level

90974. Engine speed sensors

90975. Turbo boost pressure / air temperature sensor

90976. Functions controlled by the EECU

90977. Unit injectors

91006. System description Load and Dump brake

91009. System description Parking brake

Error code from Temperature sender

FMI 3 High Voltage

MID128 PID110 FMI3(or4) MID128

Volvo Construction Equipment 91152

91152 Error code from temperature sensor

Error code from Frequence sensor

FMI 2 Incorrect signal

MID128 SID22 FMI3 MID128

Volvo Construction Equipment 91154

91154. Error code from Frequence sensor

Error code from Analogue sensor

FMI 3 High Voltage

MID128 PID94 FMI3(or4) MID128

Volvo Construction Equipment 91153

91153 Error code from Analogue sensor

Error code from Digital sensor

Only possible with

MID128 SID21 FMI2 MID128

Volvo Construction Equipment 91155

91155 Error code from Digital sensor

90811. Right side, cab

1009650 Right side of cab with new version P-brake

90961B. Explanation of wiring diagrams

Code Colour Code Colour

90980. Grounding points, (Frame ground connections)

TUTUP FILE INI

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