Service Information

Document Title: Function Group: Information Type: Date:

Data links, fault tracing 300 Service Information 2014/7/4 0
with Oscilloscope
Profile:
EXC, EW140C [GB]

Data links, fault tracing with Oscilloscope

Op nbr 300-020

9998699 Adapter
9990014 Break out harness
9993893 Break out harness
88830028 Break out harness
88890040 Oscilloscope
88890180 Interface

1. Connect 88890040 Oscilloscope to the VCADS Pro computer and perform 37173–3; Datalinks, fault tracing with
Oscilloscope.
NOTE!
Instructions for how to connect the equipment are described in the VCADS Pro operation.

NOTE!
When the USB-interface (88890020) is default in VCADS Pro, this Interface must be connected to the computer to
be able to start the Oscilloscope operation. For computers with only one USB-port, the interface configuration
should be changed to 9998555.

It is not necessary to connect the interfaces to the machine.

2.

Figure 1
Screen shot, Oscilloscope software
Use button (1) to start or stop the read off
NOTE!
Use “Save as” to save the read off under your preferred name and location.

Detailed user support is available under the menu “Help” in the Oscilloscope software.

General issues
NOTE!
 For explanations about Data links, see: 3002 Electronic control system, description;
3002 Communication with data buses; 3002 Data buses, function;
3021 SAE J1939/CAN control link, description and measuring;
3021 SAE J1708/1587 information link, description and measuring.

The following illustrations should be understood as an example and do not necessarily show exactly the
measurements standard graph. Signals can vary because of different machine types and models. The severity of
errors and the possibility to read off the signals from different measuring points have also influence to the read off
graph.
NOTE!
Communication errors may only be temporarily and do not necessarily create error codes.

NOTE!
For evaluation, see Service Information in Guided Diagnostic

Reference and error examples for J1939 (H/L)

3. The read off signal should look similar to the illustrated graph, when the J1939 (H/L) is working in a proper way.
NOTE!

 The graph borders (1) are clear (vertical).

 The signal strength (2) for J1939 (H) and J1939 (L) is the same.
 The timing (start and duration) for both signals is identical (3).

Figure 2
Reference J1939 (H/L)

4. The read off signal should look similar to the illustrated graph, when the J1939 (H) is affected by an additional
resistance.
NOTE!
  The J1939 (H) signal is reduced.
 The reduction of J1939 (H) has influence to J1939 (L).
 The timing (start and duration) for both signals is identical (3).

Figure 3
Resistor J1939 (H)

5. The read off signal should look similar to the illustrated graph, when the J1939 (L) is affected by an additional
resistance.
NOTE!

 The J1939 (L) signal is reduced.

 The reduction of J1939 (L) has influence to J1939 (H).
 The timing (start and duration) for both signals is identical (3).
 Figure 4
Resistor J1939 (L)

6. The read off signal should look similar to the illustrated graph, when J1939 (H) has short circuit to J1939 (L).
 Figure 5
Short circuit J1939 (H/L)

Reference and error examples for J1708/1587 (A/B)

7. The read off Signal should look similar to the illustrated graph, when the J1708/1587 (A/B) is working in a proper
way.
NOTE!

 The graph borders (1) are clear (vertical).

 The signal strength (2) for J1708/1587 (A) and J1708/1587 (B) is the same.
 The timing (start and duration) for both signals is identical (3).
 Figure 6
Reference J1708/1587 (A/B)

8. The read off signal should look similar to the illustrated graph, when the J1708/1587 (A) is affected by an additional
resistance.
NOTE!

 The J1708/1587 (A) signal is reduced.

 The reduction of J1708/1587 (A) has no influence to J1708/1587 (B).
 The timing (start and duration) for both signals is identical (3).
 Figure 7
Resistor J1708/1587 (A)

9. The read off signal should look similar to the illustrated graph, when the J1708/1587 (B) is affected by an additional
resistance.
NOTE!

 The J1708/1587 (B) signal is reduced.

 The reduction of J1708/1587 (B) has no influence to J1708/1587 (A).
 The timing (start and duration) for both signals is identical (3).
 Figure 8
Resistor J1708/1587 (B)

10. The read off signal should look similar to the illustrated graph, when J1708/1587 (A) has short circuit to J1708/1587
(B).
Figure 9
Short circuit J1708/1587 (A/B)
 Service Information

Document Title: Function Group: Information Type: Date:

Electrical system, Service Information 2014/7/4 0
description
Profile:
EXC, EW180C, EW160C, EW140C [GB]

Electrical system, description

This section of the service manual describes the design and construction of the electrical system and all included
components. This section also contains functional descriptions, troubleshooting and method instructions for servicing.
The electrical system consists, in part, of electrical and electro-mechanical components such as batteries, switches, solenoid
valves, fuses and relays. The electrical system also consists of a computer-based control system that monitors and controls
machine functions.
In order to access certain settings in the information system, special service instruments are required; VCADS Pro. User
instruction for VCADS Pro is available in a separate user’s manual.

WARNING
For all servicing of the electrical system, the general instructions must be strictly followed.
 Service Information

Document Title: Function Group: Information Type: Date:

Electrical system, special Service Information 2014/7/4 0
instructions for servicing,
general
Profile:
EXC, EW180C, EW160C, EW140C [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 Service Information 2014/7/4 0
instructions for servicing,
electrical components,
batteries
Profile:
EXC, EW180C, EW160C, EW140C [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 plus 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 starter unit and/or batteries connected in series to assist when starting may result in high (excess)
voltage and can seriously damage electronic/electric components.
 Service Information

Document Title: Function Group: Information Type: Date:

Electrical system, special Service Information 2014/7/4 0
instructions for servicing,
electrical components,
alternator and charging
regulator
Profile:
EXC, EW160C, EW180C, EW140C [GB]

Electrical system, special instructions for servicing, electrical

components, alternator and charging regulator
 Before any alternator or regulator tests are performed, the batteries and electrical cabling must be checked for
insulation, loose connections and corrosion. Check the alternator belts. All eventual defects according to the above
must be corrected before starting any electrical testing.
 Check the alternator belt and, if needed, make any necessary adjustment/repairs before troubleshooting.

NOTICE
Always connect cabling in a safe manner and make sure that cables are free from rust/dirt. A disconnected
cable may cause damage to both alternator and charging regulator.

NOTICE
Never disconnect the alternator connections when the engine is running. This may damage both alternator
and charging regulator.

NOTICE
Make sure that the alternator plus connection is not connected to the frame. This will damage the
alternator, and may also damage the regulator.
 Service Information

Document Title: Function Group: Information Type: Date:

Electrical system, special Service Information 2014/7/4 0
instructions for servicing,
electronic components
Profile:
EXC, EW180C, EW160C, EW140C [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 Service Information 2014/7/4 0
instructions for servicing,
action when working on
machine
Profile:
EXC, EW180C, EW160C, EW140C [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 2014/7/4 0
Profile:
EXC, EW180C, EW160C, EW140C [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 plus terminal (1) on the machine to be started.
- Connect the other end of the cable (A) to the battery's plus terminal (2) on the assisting machine.
- Connect the other start cable (B) to the battery's minus terminal (3) on the assisting machine.
- Connect the other end of the 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 the cable (B) from the frame (1) on the machine that has been started with auxiliary start.
- Remove the other end of the start cable (B) from the battery's minus terminal (2) on the assisting machine.
- Remove the cable (A) from the battery's plus terminal (3) on the assisting machine.
- Remove the other end of the start cable (A) from the battery's plus terminal (4) on the machine that has been started with
auxiliary start.
 Service Information

Document Title: Function Group: Information Type: Date:

Electronic control system, Service Information 2014/7/4 0
description
Profile:
EXC, EW160C, EW180C, EW140C [GB]

Electronic control system, description

General vehicle electronics
The new vehicle electronics, based on the data bus principle, lay the foundation for being able to proceed with development
and design of the system.
The improved diagnostic possibility makes for easier, faster and safer troubleshooting.
Further, the operator’s demand for information is fulfilled, through added functionality of the instrument, with the possibility
of obtaining read-outs of important information from the different electronic control units.
Conventional control system

Figure 1
Conventional system with connections

In principle, a conventional control system is designed in such a way that one or several of the vehicle’s components have
their own control unit that receives signals from various sensors (earlier generations of excavators have only been equipped
with a vehicle control system). Each control unit serves its own component and sends signals to the other control units and
operating controls by way of electrical cabling.
For example, an engine control unit that receives signals from various sensors on the engine and eventually from other
control units on the vehicle. Engine speed control switch position, travel speed signal, etc. are sent to the engine control unit
by way of cabling from different sensors and switches.
There must be one or several connections (sockets) in the system, where tools can be plugged in for programming and for
read-out of information and eventual error codes.
In the future, the individual machine components will require several control units per component, and machine electronics
will become increasingly complex. In time, this will limit the possibilities for a conventional control system to handle its task.
Data bus system
Figure 2
All control units (ECU) are connected via data buses

Volvo CE’s new vehicle electronics are based on the principle that all communication between the control units in the system
takes place by way of two data buses.
The main vehicle components are equipped with their own control units, that are connected to the buses for communication
with each other.
Simplified, this can be described as follows; when the operator wants to increase speed, a signal is sent from the engine
speed control switch or pedal (T mode) to the vehicle control unit and, through a data bus, the signal is transmitted to the
engine control unit.
The engine control unit communicates with the other control units by way of the buses, either by asking a question or by
receiving direct communication that all is in order to be able to "execute the command".
If a malfunction should appear in a system, a signal is sent out on the information bus, which makes it possible to read the
information, either on the operator’s instrument, the instrument electronic control unit (I-ECU), or with a VCADS Pro
connected to the service connection.
The data bus system provides a very flexible solution with extensive add-on possibilities.
 Service Information

Document Title: Function Group: Information Type: Date:

Communication with data Service Information 2014/7/4 0
buses
Profile:
EXC, EW160C, EW180C, EW140C [GB]

Communication with data buses

Figure 1
Communication

E-ECU Engine electronic control unit

I-ECU Instrument electronic control unit
ECC Electronic climate control unit
V-ECU Vehicle electronic control unit
PC3601 Service socket for VCADS Pro
W-ECU Caretrack system

General
The vehicle electronics are based on the principle that all communication between control units in the system takes place via
two data buses.
The machine's four control units are connected to the buses to be able to communicate with each other.
Communication between the different control units as well as reporting from control units to service sockets takes place on
data buses CAN/J1939 and J1708/J1587.
The buses adhere to SAE-standard and consist of two pair-twisted cables. The purpose of the twisting is to protect the bus
from electrical interference.
If a malfunction should occur in the system, a signal is sent on the information bus, making it possible to read the
information, either on the operator's instruments (I-ECU) or VCADS Pro.
The figure shows the principle for how the control units and service sockets are connected to the buses.
CAN/J1939 control bus
The system's control signals are sent via this bus. The control bus is very fast, which is a requirement for control of the whole
system to function and quickly adapt to varying conditions.
The main communication alternative is the CAN/J1939 bus. However, for E–ECU, some control data is only sent on the
J1708/J1587 bus.
J1708/J1587 information bus
The information bus is connected to the control units and service socket. Information and diagnostic signals are sent on this
bus. In addition, some control data is sent from the engine control unit via this bus.
The bus also functions as "back-up" for the control bus if it doesn't work for some reason.
Via the information bus, the system's status is updated continuously and is available for reading.
By connecting VCADS Pro to service sockets, it's possible to read error codes, perform tests, empty logged information,
upload parameters and upload software.
 Service Information

Document Title: Function Group: Information Type: Date:

Data buses, function Service Information 2014/7/4 0
Profile:
EXC, EW180C, EW160C, EW140C [GB]

Data buses, function

Figure 1
The oscilloscope display shows voltage level on the data bus

Data buses constitute a way to transmit information between different components.

In conventional systems, primarily analogue signals have been used. Analogue signals mean that different voltage levels
represent different values.
A simplified example of analogue signals:
1 Volt = 10 °C (50 °F), 2 Volt = 20 °C (68 °F), 3 Volt = 30 °C (86 °F), etc.
Data buses use digital communication. This means that voltage only varies between two different values, either "high" or
"low". By combining these high and low signals, it is possible to describe different values.
The illustration shows an oscilloscope display where voltage is measured on the data bus. As is evident in the illustration, the
greatest part of the time is "silent" on the bus, but every so often, a number of fast impulses can be seen. A collection of
impulses is called a message.
The enlarged oscilloscope display shows a message that consists of a combination of high and low voltage levels.
Messages and information content
Figure 2
Information content

The different voltage levels are represented by the different digits in the binary number system. The binary number system
only has two digits, ones and zeros.
The ones normally represent a high voltage, and the zeros represent a low voltage.
Note in the example from the oscilloscope display, in this case, ones are shown as low voltage and zeros are shown as high
voltage, and this depends on which bus and on which cables the measurement is performed.
Every individual binary digit is called a "bit". This message consists of four groups of binary digits.
The start and stop bits are shaded since they do not contain any information.
Each group constitutes 1 Byte = 8 bits. One Byte can represent a value between 0 (0+0+0+0+0+0+0+0) and 255 (128+64
+32+16+8+4+2+1).
Figure shows the information content in the four different parts of the message.
The square in the illustration shows the different binary and decimal values that the information in the message contains.
NOTE!
The information is sent out on the bus with the "lowest" digit first of the binary digits. The normal way of noting binary
numbers is shown in the square in the illustration.

Figure 3
Voltage levels binary data

The purpose of the start and stop bits is only to function as markers for where the group begins and ends. In figure, only the
start and stop bits are marked, the other information is shaded.
Identification number
Figure 4
Identification of control units and components

Abbreviation Explanation

MID Message Identification D escription (identification of control unit). There is a unique number for each
control unit.

PID Parameter Identification D escription (identification of parameter/value). There is a unique number for
each parameter.

PPID Proprietary Parameter I dentification Description (Volvo-uniqueidentification of parameter/value).

There is a Volvo-unique number for each parameter.

SID Subsystem Identification D escription (identification of component). The SID-number depends on which
control unit (MID) that they are sent from. Each control unit has its own number series for SID. The
exceptions are SID-numbers 151 –255 which are general for all systems.

PSID Proprietary Subsystem I dentification Description. (Volvo-uniqueidentification of component).

FMI Failure Mode I dentifier (identification of failure type).

Figure 5
Identification of control units and components

The message consists of four parts, A, B, C and D.

Message on data bus

Part Explanation

A MID. MID 128 shows that the message comes from the engine control unit.

B PID. PID 100 shows component oil pressure sensor.

C Data part. In this example, it is shown what the engine oil pressure is. The value can vary between 000 for
minimum oil pressure and 255 for maximum oil pressure.

D Check sum. In this example, 240. The check sum is a check that the message is reasonable.
 Service Information

Document Title: Function Group: Information Type: Date:

Service connection and Service Information 2014/7/4 0
programming connection
Profile:
EXC, EW160C, EW180C, EW140C [GB]

Service connection and programming connection

Figure 1
Electronic system architecture

E-ECU Engine control unit MATRIS MAchine TRacking Information System

I-ECU Instrument control unit VCADS Volvo Computer Aided Diagnostic System Professional
Pro
V-ECU Vehicle control unit J1587 Information bus serial data 9.6 k bps
ECC Electronic climate control unit J1939 Control bus serial data 256 k bps
W-ECU CareTrack system
Figure 2
A: Service socket

The service connection (socket) and programming socket are located by the radio.
The service socket is connected to the information bus and is used for communication with the following 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
 Calibration

When troubleshooting, this is of very significant importance, since all vital parts in the vehicle electronics can be checked
with VCADS Pro.
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.
I-ECU operator's display unit is used for:

 Reading of error codes

 Showing machine information/status for engine and hydraulics
 Showing software (program) version in control unit
 Showing status of inputs and outputs on control units
 Service Information

Document Title: Function Group: Information Type: Date:

Instrument control unit I- Service Information 2014/7/4 0
ECU, function description
Profile:
EXC, EW160C, EW180C, EW140C [GB]

Instrument control unit I-ECU, function description

Figure 1
I-ECU, position

The Instrument electronic control unit (I-ECU) is mounted on the right-hand side wall in the Cab.
The I-ECU displays the information received from the sensors and switches of the machine to alert the operator of any
abnormality.
The I-ECU contains a coolant temperature gauge, fuel gauge, and alert indicators to show machine conditions.
Figure 2
I-ECU

A: Central warning light

B: Gauge screen

C: Main screen

D: Indicator screen

The I-ECU receives information on the data bus. The information is processed and presented on the information display.
 Service Information

Document Title: Function Group: Information Type: Date:

Keypad, description Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Go back to Index Page

Keypad, description

Figure 1
Keypad for display unit and HVAC ( Heating, Ventilation , Air conditioning) system

Keypad is located on the right instrument panel. It is connected to the Instrument control unit (I-ECU).
Button function

Button Digit Description Button Digit Description

1 Fan speed control + - HVAC system on/off

2 Temperature control + 0 Arrow up, Browse upwards

3 Air flow direction - Rear view camera

4 Fan speed control – - Previous screen or escape

5 Temperature control – - Arrow down, Browse downwards

6 Air flow circulation - Selection, Acknowledge

7 Automatic mode selection - Automatic idling

8 Air conditioner - Overload warning

9 Defrost selection - Buzz stop

HVAC control buttons
HVAC control buttons are used to control the HVAC system. Refer to the 387 HVAC system.
Rear view camera button
Rear view camera button turns on/off “Rear view camera screen”. When the rear view camera screen is turned on , whole I-
ECU screen displays only view from “rear view camera”.

Figure 2
Rear view camera

Buzz stop button

Buzz stop button is used to activates or deactivates “ Travel alarm” function of V-ECU. When this button is pressed so that
the function is activated, partial backlight fro this button is turned on.
Overload warning button
Overload warning button activates or deactivates “Overload warning” function. This function is to display the symbol and to
sound an alarm if the “Overload signal” is detected. When this button is pressed so that the function is activated, partial
backlight for this button is turned on.
Automatic idle button
Automatic idle button activates or deactivates “ Automatic idle” function of V-ECU. When this button is pressed so that the
function is activated, partial backlight for this button is turned on.
The engine speed will be lowered automatically to idle mode to reduce fuel consumption if any of control levers, travel
levers (pedals) or engine speed control switch are not operated for 5 seconds or more. If any of the above is operated, the
engine speed returns to the speed set with the engine speed control switch.
Arrow up button
This button is used to scroll items up and adjust the each segment on the screen.
Arrow down button
This button is used to scroll items down and adjust the each segment on the screen.
ESC button
This button is used to go back to the previous screen or to escape without saving. The ESC button is also used to turn OFF
the warning lamp and sound.
 Service Information

Document Title: Function Group: Information Type: Date:

Keypad, description Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Go back to Index Page

Keypad, description

Figure 1
Keypad for display unit and HVAC ( Heating, Ventilation , Air conditioning) system

Keypad is located on the right instrument panel. It is connected to the Instrument control unit (I-ECU).
Button function

Button Digit Description Button Digit Description

1 Fan speed control + - HVAC system on/off

2 Temperature control + 0 Arrow up, Browse upwards

3 Air flow direction - Rear view camera

4 Fan speed control – - Previous screen or escape

5 Temperature control – - Arrow down, Browse downwards

6 Air flow circulation - Selection, Acknowledge

7 Automatic mode selection - Automatic idling

8 Air conditioner - Overload warning

 9 Defrost selection - Buzz stop

- Hammer/shear selection

HVAC control buttons

HVAC control buttons are used to control the HVAC system. Refer to the 387 HVAC system.
Rear view camera button
Rear view camera button turns on/off “Rear view camera screen”. When the rear view camera screen is turned on , whole I-
ECU screen displays only view from “rear view camera”.

Figure 2
Rear view camera

Buzz stop button

Buzz stop button is used to activates or deactivates “ Travel alarm” function of V-ECU. When this button is pressed so that
the function is activated, partial backlight fro this button is turned on.
Overload warning button
Overload warning button activates or deactivates “Overload warning” function. This function is to display the symbol and to
sound an alarm if the “Overload signal” is detected. When this button is pressed so that the function is activated, partial
backlight for this button is turned on.
Automatic idle button
Automatic idle button activates or deactivates “ Automatic idle” function of V-ECU. When this button is pressed so that the
function is activated, partial backlight for this button is turned on.
The engine speed will be lowered automatically to idle mode to reduce fuel consumption if any of control levers, travel
levers (pedals) or engine speed control switch are not operated for 5 seconds or more. If any of the above is operated, the
engine speed returns to the speed set with the engine speed control switch.
Arrow up button
This button is used to scroll items up and adjust the each segment on the screen.
Arrow down button
This button is used to scroll items down and adjust the each segment on the screen.
ESC button
This button is used to go back to the previous screen or to escape without saving. The ESC button is also used to turn OFF
the warning lamp and sound.
Hammer / shear selection button
Hammer / shear selection button is used to activates or deactivates “X1 function” of V-ECU.
 Service Information

Document Title: Function Group: Information Type: Date:

Engine control unit E-ECU, Service Information 2014/7/4 0
function description
Profile:
EXC, EW140C [GB]

Engine control unit E-ECU, function description

Control unit's sensors
The D6E engine's injection system is controlled completely by electronics with regards to injected amount and injection
timing. The system is called EMS 2 (Engine Management System 2).
This section briefly describes the parts that are mounted on the engine. A number of other parts affect the system, for
example, the sensor for engine speed.
The central part in the system, control unit E-ECU, is located on the right side of the air cleaner. All cable connections for the
engine sensors have connectors with DIN-standard.

Figure 1
E-ECU, position

Control unit
The control unit E-ECU is the central part of the injection system. The unit is mounted in brackets with rubber dampers.
The E-ECU receives continuous information from V-ECU (requested engine speed) and a number of sensors on the engine. It
also calculates the fuel amount and at what time the fuel should be injected into the cylinders.
The E-ECU stores information if a malfunction should occur, or if something in the system is abnormal. Even malfunctions
that occur sporadically are stored in the control unit and can thus be traced at a later time.
Functions

 Fuel amounts, injection pump

 Temperatures
 Preheating coil, preheating
 Operating speed (rpm)
 Service Information

Document Title: Function Group: Information Type: Date:

Vehicle control unit V-ECU, Service Information 2014/7/4 0
function description
Profile:
EXC, EW160C, EW180C, EW140C [GB]

Vehicle control unit V-ECU, function description

Figure 1
V-ECU, position

The V-ECU is mounted on the inside left cab wall.

The technical regulations define the specifications for a V-ECU that is to be used in Volvo excavators equipped with I-ECU, E-
ECU, ECC and W-ECU with data links SAE J1587and J1939. The V-ECU is a main control unit and controls solenoid valves,
relays and proportional solenoid valves for hydraulics according to switches in the cab as well as machine sensors with CAN
communication with I-ECU, E-ECU, ECC and W-ECU in Volvo excavator. It also handles logging of machine data in order to
give service personnel access to machine information.
Functions

 Self-diagnostics
 Indication of machine status
 Electro hydraulic pump control
 Automatic idle
 Automatic Power Boost and one-touch Power Boost
 Safe start and stop
 Emergency operation
 Service Information

Document Title: Function Group: Information Type: Date:

Electronic climate control Service Information 2014/7/4 0
unit ECC, description
Profile:
EXC, EW180C, EW140C, EW160C [GB]

Electronic climate control unit ECC, description

The electronic climate controller, ECC, is located at the air conditioner unit. This is a full automatic controller, and controls
the fan speed, the heater, the air conditioner, the indoor/outdoor air selection and the air distribution. ECC has the serial
interface to I-ECU, and the different functions can be controlled by the keypad.

Figure 1
ECC

The control unit receives continuous information about temperature, pressure, rpm, etc. from a number of sensors. The
control unit is connected to the other control units via data link J1587/1708 for communication.
Functions

 Control of temperature, air distribution, and ventilation in cab

 Control of soft start, AC-compressor
 Monitoring of temperature and pressure
 Service Information

Document Title: Function Group: Information Type: Date:

CareTrack system, Service Information 2014/7/4 0
description
Profile:
EXC, EW160C, EW180C, EW140C [GB]

CareTrack system, description

Figure 1
CareTrack system and components

A. W-ECU
B. Wire harness, GPS
C. Antenna cable, GPS
D. Antenna, GPS
E. Antenna cable, satellite
F. Antenna, satellite

The CareTrack system, the VCE telematics solution contains three main services; Mapping, Tracking, Operational
management and Service management.
The Caretrack collects data on machine position, operating hours, fuel consumption, alarms etc. and without wire transfers
them to the computer in user's office.
The Care track answers the questions “ Where are the machines, when do they need service, are they being operated
correctly?
The CareTtrack systems communicates with other control units by serial communication hereby forming a complete control
system.
Services

 Machine Position
 Instantaneous Machine Data
 Geographical Fence
 Location Report
 Snail Trail
 Machine Utilization Report
 Event Report
 Performance/Productivity Report
 Immobilizer
 Alarms and Warnings
 Error Codes
 Service Report
 Logged Machine Data, Complete Download
 Logged Machine Data, Partial Download
 Sleep Mode
 Work shifts
 Over the Air Programming
 Service Information

Document Title: Function Group: Information Type: Date:

Engine Protection 301 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Engine Protection
The function makes limited movement of the machine possible despite alarm level warnings has been reached for vital
engine systems.
Various protection actions such as driver warning lights, engine torque reduction, engine speed limitations and vehicle
speed limitation can be taken when an engine system reaches dangerous levels.
Engine protection is accomplished by limiting (de-rating) engine torque, engine speed is not affected with most alarm
warnings. Engine torque is de-rated from the maximum engine torque available, to the engine protection torque curve. The
amount engine torque de-rates, is depended on the system affected, and the severity of the condition.
There are two different ways to de-rate the engine:
Direct full de-rate
This method is used for low oil pressure and the common fuel rail. This is required because either the sensor is a switch or
the fault is critical and a direct de-rate is needed.
Gradual de-rate
This method is used for the temperature parameters. By using a gradual de-rate the loads on the cooling systems will be
reduced. This will reduce the stress on the engine and the driver can continue to run the machine with gradually reduced
performance until the “red lamp” will tell the driver to shut off the engine.
This gradual de-rate will give the operator a greater possibility to move the machine to a safe position or finish a critical job
than if “Direct full de-rate” is used.

Input signals Conditions for output Output functions

functions
Engine coolant level, Low coolant level Central warning
SE2603 Engine torque de-rate 100%
Engine is forced to idle rpm after 10 seconds.
Engine is shut down after 5 seconds.
Engine coolant Coolant temp. Engine torque de-rate 0%
temperature, SE2606 (100ºC / 212ºF)
Coolant temp. Engine torque de-rate 60%
(103ºC / 217ºF)
Coolant temp. Central warning
(105ºC / 221ºF) Engine torque de-rate 100%
Engine is forced to idle rpm after 10 seconds.
Engine is shut down after 5 seconds.
Engine oil temperature, Engine oil temp. Engine torque de-rate 0%
SE2202 (127ºC / 260.6ºF)
Engine oil temp. Central warning
(130ºC / 266ºF) Engine torque de-rate 40%
Engine oil temp. Central warning
(135ºC / 275ºF) Engine torque de-rate 100%
Engine is forced to idle rpm after 10 seconds.
Engine is shut down after 5 seconds.
Boost temperature, High boost temp. Central warning
SE2507 (90ºC / 194ºF) Engine torque de-rate 0%
High boost temp. Central warning
(92ºC / 197.6ºF) Engine torque de-rate 20%
High boost temp. Central warning
(100ºC / 212ºF) Engine torque de-rate 100%
 Engine is forced to idle rpm after 10 seconds.
Engine is shut down after 5 seconds.
Boost pressure, SE2508 High boost pressure Central warning
(34.8 psi / 240 kpa)
Engine oil pressure, Low engine oil pressure Central warning
SE2203 Engine torque de-rate 100%
Engine is forced to idle rpm after 10 seconds.
Engine is shut down after 5 seconds.
Internal EGR Solenoid, EGR (exhaust gas recirculation) Central warning
MA2504 valve fault
Crank speed sensor, No signal from crank sensor Central warning
SE2701 Engine max. torque: 90%
Engine torque de-rate: 2% per sec.
Common rail system
Fuel rail pressure, SE2309 Fuel rail pressure sensor error Central warning
FMI 0, 1, 2, 4, or 5 Maximum engine speed 1100 rpm
Fuel injectors, Fuel injector error Engine torque de-rate 100%
MA2301-2306 SID 1-6 Common rail pressure limitation 800 bar / 11603 psi
FMI 7 or 14
Fuel control unit, Proportional valve error
PWM2303 FMI 3, 4, 5, 6, or 13
Common rail pressure Pressure system error
system PSID 96, FMI 0, 1, 4, 7 or 12
Common rail pressure Pressure relief valve error
relief valve PSID 97, FMI 0, 7, 11 or 14
Effective torque Too high torque
PPID 435, FMI 0
 Service Information

Document Title: Function Group: Information Type: Date:

Engine start 301 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Go back to Index Page

Engine start
This function disables the crank function to prevent the engine to start. This function is provided from the E-ECU by blocking
the ground connection of the starter motor. Under following conditions the crank function is disabled:

 The engine is running (SE2701, SE2703).

 The control lock out lever is in upper unlocked position (SE8503).
 The antitheft option is activated and no or the wrong code was entered (Parameter ABP).
 The calculated temperature of the starter motor has reached the overheat temperature.
 The time that is needed a overheated starter motor reaches its normal temperature again is not elapsed.

Input signals

Pin No. ECU Description

A7 V-ECU Start Signal (RE3301)
A15 V-ECU Engine start switch (SW3301)
B68 V-ECU Control lockout lever switch (SE8503)

Output signals

Pin No. ECU Description

C58 V-ECU Start lock relay output (RE3301)
B29 E-ECU Ground

NOTE!
Refer also to:370 Wiring diagram SCH01

NOTE!
In case of engine start problems please refer to the Guided Diagnostic.
 Service Information

Document Title: Function Group: Information Type: Date:

Start lock, description 301 Service Information 2014/7/4 0
Profile:
EXC, EW160C, EW180C, EW140C [GB]

Go back to Index Page

Start lock, description

The starter motor operation should be carefully limited so that the engine system could be protected and the antitheft
function could be performed.

Input
Input signal

Pin No. ECU Description

B68 V-ECU Control lockout lever switch (SE8503)
A15 V-ECU Engine start switch (SW3301)

Output
Output signal

Pin No. ECU Description

C58 V-ECU Start lock relay output (RE3301)
 Service Information

Document Title: Function Group: Information Type: Date:

Power OFF 301 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Power OFF
This function secures that the whole machine is able to shut down in a proper and save way. Also all ECU's are allowed to
shut down in the right way to save any kind of data (e.g. Matris data).
After the ignition key was turned into OFF position, the V-ECU sends out a shut down request to all other ECU's. After
receiving the shut down confirmation, or at least 4,5 sec. after the shut down request, the V-ECU will cut off the power.

Pin No. ECU Description

A15 V-ECU Engine Start Switch (SW3301)
C11 V-ECU Main relay (RE3101, RE3102)

NOTE!
Please refer also to: 370 Wiring diagram SCH01 and 370 Wiring diagram SCH02.
 Service Information

Document Title: Function Group: Information Type: Date:

Quick fit control, 301 Service Information 2014/7/4 0
description
Profile:
EXC, EW140C [GB]

Quick fit control, description

This is for the Quickfit attachment control. V-ECU receives the related switch signals and sends them to the I-ECU, and then
I-ECU activates the solenoid.
Input
Input signal

Pin No. ECU Description

A14 V-ECU Quick fit switch (SW9104)
B20 V-ECU Quick fit confirmation switch (SW9160)
B43 V-ECU Quick fit buzz stop switch (SW9160)

Output
Output signal

Pin No. ECU Description

A11 I-ECU Quick fit solenoid (MA9109)
I-ECU Alarm
I-ECU Quick fit indicator
 Service Information

Document Title: Function Group: Information Type: Date:

Boom float position, 301 Service Information 2014/7/4 0
description
Profile:
EXC, EW160C, EW180C, EW140C [GB]

Boom float position, description

Float position means that both the boom cylinder piston and piston rod are connected to the hydraulic tank. This means
that only the weight of the arm and bucket lowers the boom when right control lever is pushed forward.
This function makes the attachment to behave like a floater on the ground, so that the operator easily works leveling and
reduces the fuel consumption using weight of attachment and the material loaded.
Input signal

Pin No. ECU Description

VA12 V-ECU Float position switch, SW9158

Output signal

Pin No. ECU Description

VC32 V-ECU Boom float solenoid valve, MA9120

Output messages

ECU Description
V-ECU Float position indication
V-ECU Float position solenoid, MID187 PPID1128

Parameter

Code Name
BNJ Float position function

See also, 301 Software parameters, description.

Function description

Figure 1
Indicator, float position

For float position control, boom float solenoid valve will be installed. When the float position parameter BNJ is selected and
the float position switch is On, the float position solenoid valve is activated and the indicator is shown on the I-ECU.
NOTE!
When the boom float function is on, the function will remain even if the ignition key is off and on again. The indicator on the
instrument panel will be also displayed
 Service Information

Document Title: Function Group: Information Type: Date:

Limp Home 301 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Limp Home
When V-ECU is working normally, but V-ECU or E-ECU gets no signal or a faulty signal from one of the two engine speed
sensors (camshaft speed sensor to V-ECU and crankshaft speed sensor to E-ECU), the system changes to “limp home”
function. When there is no valid engine speed input signal neither from V-ECU nor E-ECU, the V-ECU sends out a fixed signal
of 350 mA to the pump control proportional valve. This results in a decrease of flow from the pump by 50%.
 Service Information

Document Title: Function Group: Information Type: Date:

Auto idle device, setting 301 Service Information 2014/7/4 0
instructions
Profile:
EXC, EW140C [GB]

Auto idle device, setting instructions

Auto idle is an energy saving function which makes the engine rpm drops to 1000 rpm when the machine is not used for a
certain time.
The auto idle function is activated at following conditions.

1. The engine speed is over 1000 rpm

2. The rpm switch is not used.
3. The auto idle selection switch on the key pad is activated.
4. The travel pedal sensor gets a pressure of less than 3 bar (0.3 MPa, 43.1 psi).
5. The auto idle pressure sensor gets a pressure less than 15 bar (1.5 MPa, /217,6 psi)
6. The pressure sensors at dipper arm-in position and at boom-down position are inactive. (Pressure less than 5 bar,
0.5 MPa, 72.5 psi)

Then V-ECU sends a request to E-ECU to lower the rpm to 1000 rpm.
E-ECU sends a message to I-ECU to indicate the actual engine speed.
With VCADS Pro, it is possible to change the time delay for auto idle function activating. The time delay varies between 3
and 10 seconds, the default value is 5 seconds.
 Service Information

Document Title: Function Group: Information Type: Date:

Boost control, description 301 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Boost control, description

The power boost function provides increased working pressure for a short adjustable time. To increase the working pressure
the power boost solenoid (MA9107) needs to be activated. Then the power boost solenoid (MA9107) leads the servo
pressure to the LS pressure relief valve and increases the limit for the max. working pressure.
Boost control, traveling

1. The control lockout lever is in upper position (unlocked).

2. The P-T-W-C mode selection switch is set to T or W or C mode.
3. The travel pedal pressure sensor located at the travel pedal gets a pressure higher than 7 bar (0.7 MPa, 101.6 psi).

Then, V-ECU sends an output of 24 V to the power boost solenoid valve (MA9107).
Boost control, using power boost button

1. The control lockout lever is in upper position (unlocked).

2. The P-T-W-C mode selection switch is set to W or C mode.
3. The power boost function button on the right hand control lever is pressed.

Figure 1
Power boost symbol

Then V-ECU sends out a 24 V signal to the power boost solenoid valve for a period of 9 seconds (factory setting). V-ECU also
sends I-ECU a signal to display the power boost function symbol.
This function is a repetitive function. When the power boost button is pressed within the power boost period, the timer
starts to count from zero again. The boost duration time is adjustable with parameter HOQ and VCADS Pro operation
17030–3, Parameter programing.
NOTE!
The power boost lasting time must not be set longer than 30 sec!
 Service Information

Document Title: Function Group: Information Type: Date:

Parking brake, function 301 Service Information 2014/7/4 0
description
Profile:
EXC, EW140C [GB]

Parking brake, function description

At least one of the gear selector solenoid valves, turtle or rabbit, needs to be energized to disengage the parking brake
which is located in the gearbox.
When 1) the control lockout lever is down position (locked), 2) the engine is not running, 3) the P-T-W-C mode selection
switch is set to P-mode, both gear selector solenoid valves are not energized and the parking brake is engaged.
Snail speed:
The Q-max solenoid valve and the low speed solenoid valve to the gearbox are energized.
Turtle speed:
Only the low speed solenoid valve to the gearbox is energized.
Rabbit speed:
Only the high speed solenoid valve to the gearbox is energized.
P-mode:
Both gear selector solenoid valves to the gearbox are not energized.
 Service Information

Document Title: Function Group: Information Type: Date:

Control lockout system 301 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Control lockout system

The control lever's operations should be carefully limited for safety reasons. One way of limiting this is through cutting of
the servo pressure to the control levers. When the P-T-W-C mode selection switch is set to T-mode, and the superstructure
is aligned with the undercarriage, V-ECU sends out 24 V to the control lockout relay.
So the control levers are disabled at T-mode when the superstructure is aligned, however, they are enabled when the
superstructure is not aligned. When the P-T-W-C mode selector switch is set to P- mode, the control levers are disabled.
 Service Information

Document Title: Function Group: Information Type: Date:

Forward / Reverse / 301 Service Information 2014/7/4 0
Neutral
Profile:
EXC, EW140C [GB]

Forward / Reverse / Neutral

Forward
If the travel direction is set to forward, the forward solenoid valve is energized, and the control pressure from the travel
pedal is directed to make the excavator moves forward. V-ECU sends a signal to I-ECU to display ”F” symbol.
Neutral
If the travel direction is set to neutral, none of the travel direction solenoid valves are energized, and both sides of the travel
spool are connected to hydraulic tank. V-ECU sends a signal to I-ECU to display ”N” symbol.
Reverse
If the travel direction is set to reverse, the reverse solenoid valve is energized, and the control pressure from the travel pedal
is directed to make the excavator moves reverse. V-ECU sends a signal to I-ECU to display “R” symbol.
When the control lockout lever is down position (locked) or the P-T-W-C switch is set to P-mode, independent of the
position of the forward-reverse selector switch, the result is the same as if neutral would have been selected: none of the
travel direction solenoid valves are energized and, both sides of the travel spool are connected to hydraulic tank. V-ECU
sends a signal to I-ECU to display ”N” symbol.
 Service Information

Document Title: Function Group: Information Type: Date:

Main pump pressure, 301 Service Information 2014/7/4 0
checking and adjusting
Profile:
EXC, EW140C [GB]

Main pump pressure, checking and adjusting

Conditions for main pump pressure checking and adjusting
To be able to check the main pump control pressure, a fixed signal needs to be send to the pump control proportional valve
which is located on the regulator unit of the main pump. Only when the control lockout lever is positioned down (locked),
and the P-T-W-C mode selector switch is set to T-mode, V-ECU sends a fixed output signal of 300 mA to the pump control
proportional valve. In all other positions, the signal will be varied.
 Service Information

Document Title: Function Group: Information Type: Date:

Axle lock 301 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Axle lock
General
The axle locking is a negative system. Therefore the axle is locked when the axle lock solenoid (MA9152) is not energized.
The axle can be locked automatically and manually. If the axle is locked automatically a yellow colored indicator will be
shown in the I-ECU and a green colored one for manual locking. If during operation, the manual and the automatic function
is activated at the same time, the symbol color will change according to the priority.
NOTE!
The automatic locking of the axle has always priority, no matter of the manual function.

Automatik Axle locking

The axle will be locked automatically if one of the following is applied:

Figure 1

 Engine “OFF” (E-ECU)

 Ignition key “OFF” (1)
 P-Mode (2)
 Control lockout lever in lower position (3)
 Brake pedal sensor (4, SE5201) detects pressure > 60 bar (870 PSI)

The locked axle will be automatically unlocked when all of the above mentioned conditions are not longer applied.
Manual Axle locking

Figure 2

The axle is manually locked when one of the two axle lock push buttons (1, SW9151, SW9152) is activated. It is possible to
activate the manual axle lock function when the axle is automatically locked. Then the axle remains locked when the
automatic axle locking conditions are not longer fulfilled. To unlock the axle manually it is necessary to push once again and
hold one of the two axle lock push buttons (1, SW9151, SW9152) longer than 1 sec.
Functionality

Figure 3

 The V-ECU gets a signal to lock the axle automatically (1) or manually (2). The V-ECU gives signal to I-ECU to show
corresponding indicator and deactivates the axle lock solenoid (3, MA9152). The axle is locked now.
 The V-ECU gets no longer signal to lock the axle automatically (1). The V-ECU checks if the axle was locked
manually (2). If the axle was locked manually the axle remains locked.
 The V-ECU gets signal (longer than 1 sec.) to unlock the axle manually (2). The V-ECU checks if there is a signal to
lock the axle automatically (1). If there is a signal to lock the axle automatically the axle remains locked.
 The V-ECU gets no longer signal to lock the axle automatically (1). The V-ECU checks if the axle was locked
manually (2). If the axle was not locked manually the V-ECU activates the axle lock solenoid (3, MA9152). The axle is
now unlocked.
 The V-ECU gets signal (longer than 1 sec.) to unlock the axle manually (2). The V-ECU checks if there is a signal to
lock the axle automatically (1). If there is no signal to lock the axle automatically, the V-ECU activates the axle lock
solenoid (3, MA9152). The axle is now unlocked.
 Service Information

Document Title: Function Group: Information Type: Date:

Overload warning 301 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Overload warning
This function monitors the overload pressure sensor and warns the driver when the pressure value of boom cylinder reach
the defined warning limit.

NOTICE
The overload warning does not give the actual machine limit, but constitutes an indication of a potential risk of
tipping over in case of deteriorating stability.

Function description
Overload function on / off

Figure 1
Overload select indicator

 Parameter HXY enable this function.

 I-ECU sets function on / off with the signal of pressing overload select button from keypad.
 If the overload select button is ON, overload select indicator (green) is shown on the I-ECU and the backlight for
this button is turned on.
 Enable function status is saved when the key is turned off and on.

Overload warning

Figure 2
Warning screen

Figure 3
Overload warning indicator

When the overload function is ON, if the value of pressure sensor is over the setting value, there are several alarm actions:
  Warning screen (only once since key on)
 Buzzer is sounding
 Warning lamp is blinking
 Overload warning indicator (red) is shown on the I-ECU

If the pressure goes below the setting pressure or the overload function is OFF:

 Buzzer is off
 Warning lamp is off
 Overload warning indicator (red) disappears

If the warning screen pops up, it remains with buzzer and lamp until it is cancelled by ESC button. Buzzer and warning lamp
can be cancelled by pressing ESC button if the sensor pressure is below the setting pressure. The warning screen is cancelled
only by pressing ESC button twice regardless of the pressure.
Input signal

Pin No. ECU Description

VB02 V-ECU Overload pressure monitor, SE9401

Parameters

Code Description Default set Set range

HXY Option overload ON ON/OFF
This paramter must not be changed!
IKN Overload boom cylinder EW140C: 15000 kPa (150 bar) 0 — 6553500 kPa
pressure setting EW160C: 15000 kPa (150 bar)
EW180C: 13000 kPa (130 bar)
EW210C: 13000 kPa (130 bar)
EW230C: 14000 kPa (140 bar)
This value is different for each machine and must not be
changed!
 Service Information

Document Title: Function Group: Information Type: Date:

VCADS Pro, parameter 301 Service Information 2014/7/4 0
programming
Profile:
EXC, EW140C [GB]

VCADS Pro, parameter programming

Op nbr 301-010

88890180 Interface
88890027 Cable

1.

Figure 1
Service socket for VCADS Pro
Connect VCADS Pro tool to the Machine (1), using special tools: 88890020 and 88890027.

2. Perform operation VCADS Pro, 17030 – 3 – Parameter, programming.

NOTE!
For instructions how to program and handle parameters, use the “Help” section of VCADS Pro service tool.

For parameter information, see: 301 Software parameters, description.

 Service Information

Document Title: Function Group: Information Type: Date:

Software parameters, 301 Service Information 2014/7/4 0
description
Profile:
EXC, EW140C [GB]

Software parameters, description

New Incorrectly set parameters may cause malfunction symptoms. Check the parameter values so that these are reasonable
by comparing them to the correct values and limits. Use VCADS Pro to check the parameters.
There are two types of parameters that can be programmed, machine parameters and customer parameters.
Machine parameters are of the accessory type or legal requirements, and requires on-line connection to the Volvo data base
VDA (Vehicle Data Administration) to enable programming.
Customer parameters do not require on-line connection, they can be programmed directly.
NOTE!
Default set parameters in the description can be different according to the options installed on the machine and to the
changes made during machines lifetime.

Engine control unit (E-ECU, MID 128)

Code Titles in VCADS Pro Default set Set range

Description in VCADS Pro Additional explanation
AIZ Fuel consumption, calibration percent 0% -10% – 10%
A percentage correction value between +10 and -10 is If the real fuel consumption is lower or higher than the
programmed to compensate for any fuel consumption. value shown in Matris or I-ECU, you can adjust the
For example the value 4 means an increase of 4% and displayed value to the real value. The cause of the
-4 a decrease of 4%. differences could be fuel quality, working conditions,
The following formula gives the correction value: driver behavior, machine conditions.
(consumption according to the customer’s fuel records Example: real consumption, 95L
- consumption according to display) / consumption displayed consumption, 100L
according to display x 100 = the correction value. Adjust, -5%
Round off the value to the nearest integer. When the
compensation is complete reset the mileage and fuel
data.
AJJ Crank reference offset – -3° – 3°
Calibration of the crank position during production This parameter must not be changed!
compensates for production tolerances in the sensor
wheel and when installing the engine speed (RPM)
sensor.
AJK E-ECU identification – –
Engine manufactor specific information Not applicable for wheeled excavator
AJL Engine Specific data – –
Engine manufactor specific information Not applicable for wheeled excavator
AU Max engine speed stationary 2800 rpm 600 – 2600 rpm
Maximum engine speed allowed when the vehicle is Not applicable for wheeled excavator
stationary. The maximum engine speed varies between
approximately 1200 - 2600 rpm dependent on engine
type.
DN Cust data, Fleet ID – –
The customer unit number can be entered here. Not applicable for wheeled excavator
(maximum 13 characters). The Fleet ID can be set via
the cluster menu.
FXE Engine Governor Type 0 0
 Engine Governor Type Not applicable for wheeled excavator
FRK Maximum engine speed increase rate for PTO 5000 100 – 1000
Maximum engine speed increase rate for PTO Not applicable for wheeled excavator
FRL Maximum engine speed decrease rate for PTO 5000 100 – 1000
Maximum engine speed decrease rate for PTO Not applicable for wheeled excavator
FSQ Cylinder balancing forced status 2 0–2
Cylinder balancing forced status Not applicable for wheeled excavator
GFF Tot. Inj. fuel quantity – 0 – 6553.5 l/h
Total injected fuel quantity in mg/stroke Not applicable for wheeled excavator
GFG Rail pressure setpoint 10000 kPa 0 – 6553500 kPa
Rail pressure setpoint for RailPressureControl in bar Not applicable for wheeled excavator
GFH PRV total opened time 0 sec 0 – 4294967
PRV total opened time After a specified opening time, the PRV shall be
changed and the parameter should be reset to 0 sec.
YA Idle target engine speed 730 rpm 0 – 2000 rpm
Idle speed, desired value This parameter sets the minimum engine speed and
should not be changed.

Instrument control unit (I-ECU, MID 140)

Code Titles in VCADS Pro Default set Set range

Description in VCADS Pro Additional explanation
ABP Anti-theft protection – OFF/ON
Activates the anti-theft device that prevent starting of This parameter is also valid for V-ECU
the vehicle
ABQ Anti-theft protection PIN code 0123 0 – 9999
Select PIN code for anti-theft device This parameter is also valid for V-ECU
The first ZEROs are not displayed. e.g. '0001' is shown
as '1' while '1000' is shown as '1000'.
BGR Central greasing installed – OFF/ON
Automatic lubrication system installed and activated This parameter enables the diagnostic of the automatic
lubrication system so that the operator gets an error
message on the display when the automatic lubrication
system has an error.
FZA Connect JS pattern option – OFF/ON
Connect joystick pattern option This parameter enables the diagnostic of the control
lever's pattern changer and the symbols on the display
which pattern mode is selected “BHL” or “SAE ISO”.
HXY Option Overload ON OFF/ON
Option Overload This parameter must not be changed!
HXZ Option X1/X3 Pin Code – OFF/ON
Option X1/X3 Pin Code With this option the operator has to type in a pin code
when he want to change the setting for the X1 working
tool or X3 settings in the hydraulic menu of the I-ECU.
IAA X1/X3 Pin Code 0123 0 – 9999
X1/X3 Pin Code Select PIN code for X1 or X3 settings.
The first ZEROs are not displayed. e.g. '0001' is shown
as '1' while '1000' is shown as '1000'.
IKM Proportional switch control lever installed – OFF/ON
Indicates control lever with proportional switch This parameter sets the default setting for X1 or X3 to
proportional. (Only use if proportional control lever is
installed!)
IKN Overload boom cylinder pressure setting – 0 – 6553500 kPa
Activate overload warning if boom cylinder pressure is This value is different for each machine and must
higher than this value. not be changed!
IKO Quick fit installed – OFF/ON
Connect the quick fit option. –
ITQ No. of Cameras installed – 0 – 10
No. of Cameras installed Values higher than 4 are not valid for wheeled
excavator.
ITR Theft Deterrent Time Delay 30 sec 0 – 9000 sec
After shutdown, the vehicle can be restarted within this –
time limit without identification.

Caretrack control unit (W-ECU, MID 142)

Code Titles in VCADS Pro Default set Set range

Description in VCADS Pro Additional explanation
FZP Enable immobilizer – 0 – 10
The parameter activates functionality for Immobilizer in Not applicable for wheeled excavator
Caretrack.
0: Deactivated, 1: Activated
IGU Satellite Modem – OFF/ON
The parameter activates satellite modem function for –
Caretrack. This function also needs hardware to be
installed.
ON: Satellite modem installed.
OFF: Satellite modem not installed.
IHA GSM Modem – OFF/ON
The parameter activates GSM Modem function for –
Caretrack.
ON: GSM Modem is used for Caretrack
communication.
OFF: GSM Modem is not used for Caretrack
communication
JDC CARETRACK Power Supply Options – 0–1
Activates functionality for Care Track to communicate Recommended if satellite communication is installed.
without key-dependent power supply.
0: The Care Track control unit need key-dependent
power supply to communicate.
1: The Care Track control unit communicates without
key-dependent power supply. The battery disconnect
switch must be turned on.
NOTE!
When the parameter is set to 1 the control unit
consume current which should be taken in
consideration when battery disconnect switch is turned
on.

Climate control unit (ECC MID 146)

Code Titles in VCADS Pro Default set Set range

Description in VCADS Pro Additional explanation
GYC Air conditioning installed – 0–1
Air conditioning installed Describes if the machine is equipped with air
conditioning unit
0 : not installed, 1 : installed
GYP Air Condition cycling level 4 0 – 250
Defines the temperature cycling levels of AC The temperature after the evaporator is defined by a
0 : not used reference value. In order to prevent ice formation on
1 : levels are 3 and 7 °C the evaporator the AC will shut off when temperature
2 : levels are 2 and 5 °C falls below the “low” level and AC will turn on again
3 : levels are 4 and 8 °C when temperature rises above the “high” level. The
4 : levels are 1 and 6 °C “low” and “high” levels are defined with this “AC
cycling level” parameter. The reasons for having these
different cycling levels are:

 To prevent ice formation on the evaporator at

geographic places where the climate is warm
and has high humidity (e.g. Florida). In this
case the levels can be high.
 To speed up the cooling performance. In this
case the levels should be low. This can only be
done at geographic places with dry climate.

HGO Enable Fan Lim Door Open – 0–1

Limit fan speed when cab door open This parameter defines that the fan (cab blower) speed
is decreased when the cab door is open.
0 : not enabled, 1 : enabled
HGP Enable Model Based Diagnosis – 0–1
Activate model based diagnosis Not applicable for wheeled excavator.
HSZ Pump for recirculation of water – 0–1
Pump for recirculation of water This parameter is set when water recirculation pump is
installed, needed for the function “Cab heat timer”
0 : not installed
1 : installed
Parameter HSZ and HXD are used together.
HXD Heater Installed – 0 – 250
0: Heater core not installed This parameter is set for machines where heater core is
1: Heater core installed installed
0: Heater core not installed
1: Heater core installed
Parameter HSZ and HXD are used together.

Vehicle control unit (V-ECU, MID 187)

Code Titles in VCADS Pro Default set Set range

Description in VCADS Pro Additional explanation
ABP Anti - theft protection – OFF/ON
Activates the anti - theft device that prevent starting of This parameter is also valid for I-ECU.
the vehicle.
ARO Automatic idle delay 4 sec 3 – 10 sec
The parameter activates/deactivates automatic idling The Automatic idle function is activated after the time
delay. set with ARO, when the automatic idling condition is
full filled.
BDT Actual low idle speed diesel engine 800 rpm 0 – 1500 rpm
Minimum engine speed, set point The Low Idle speed is requested and can be adjusted
by this parameter. The Low Idle speed requested by
BDT can't be below the value set with parameter YA.
Any change of the parameter BDT will also have an
effect on the Auto Idle speed.
BDW Automatic idle speed 17 % 0% – 100%
Automatic idle speed in % of the low idle speed The percentage from BDW multiplied with the range
 between requested High Idle in T-Mode (HI) and Low
Idle in P-Mode (BDT) plus the Low Idle in P-Mode
(BDT), gives the requested Auto Idle Speed.
E.g. :
BDT: 800 rpm
HI: 2000 rpm
BDW % * (HI – BDT) + BDT = Auto Idle Speed
204 rpm + 800 rpm = 1004 rpm
The requested Auto Idle speed is rounded 1000 rpm.
BFJ Connect X1 flow control – OFF/ON
Connect X1 flow control This parameter enables the limitation of the max. X1
flow which was set in the X1 tool settings in the I-ECU.
(The option must be installed.)
BFO Connect cruise control PPV – OFF/ON
Connect cruise control PPV This parameter enables the cruise control function
which means that the speed is hold without pressing
the travel pedal when the operator press the related
switch. The option must be installed and calibrated.
BFQ Connect travel alarm – OFF/ON
Connect travel alarm This parameter enables the travel alarm when
travelling. The travel alarm can be turned off
immediately with the switch on the keypad.
BFR Connect travel alarm with delay – OFF/ON
Connect travel alarm with delay This parameter enables the travel alarm when
travelling. The travel alarm can be turned off 10 sec
after pressing the switch on the keypad.
BNJ Float position, function – OFF/ON
Option equipment Float position function installed YES The option must be installed.
= 1; NO = 0
CVS Connect X1 two way switch – OFF/ON
This option allows you to use the X1 function with two The option must be installed.
pressure lines by choosing which line (or both) you
want to have pressure on.
DLD Auto rpm and flow control at hammer use – OFF/ON
When parameter is set to "On", the engine speed and Not applicable for wheeled excavator
the pump flow will automatically be adjusted while the
hammer is used. If the engine speed is lower than 1700
rpm, it will be set to 1700. The flow is set to 100%. If
parameter is set to "Off", the settings is done manually.
EDD Electric lever control, CDC function installed – OFF/ON
Activates CDC function in combination with electric Not applicable for wheeled excavator
servo lever control.
ON = installed OFF = not installed
FYV Connect X1 proportional control – OFF/ON
Connect X1 proportional valve control The option must be installed.
FYW Connect X1 one-way switch – OFF/ON
Connect X1 single-way switch The option must be installed.
FYX Connect X1 presetting pressure – OFF/ON
Connect X1 presetting pressure The option must be installed.
FYY Connect X3 On/Off control – OFF/ON
Connect X3 On/Off valve control The option must be installed.
FYZ Connect X3 proportional control – OFF/ON
Connect X3 proportional valve control The option must be installed.
FZA Connect JS pattern option – OFF/ON
 Connect joystick pattern option This parameter enables the diagnostic of the control
lever's pattern changer and the symbols on the display
which pattern mode is selected “BHL” or “SAE ISO”.
HOQ Boost remaining time 9 sec 3 – 255 sec
Boost lasting time This parameter defines the time how long the power
boost function will be active when pressing the power
boost switch on the control lever.
This time must not be longer than 30 sec!
HOR Connect change function grab/tilt for rotortilt – OFF/ON
Connect change function grab/tilt for rotortilt This parameter enables an extra function of the Grab
change over when a rotortilt is used. You can switch
then between tilting and grabbing with the rotortilt.
(The option must be installed.)
Do not use this parameter in combination with Tilt-
Rotator control system (NVG).
HXV Connect electrical digging brake – OFF/ON
Connect electrical digging brake This parameter enables a semi automatic digging
brake function while the digging is applied when the
machine is standing still, and the digging brake
disengaged when the operator press the travel pedal
again. (The option must be installed.)
HXW Connect X1 hammer control EL pedal – OFF/ON
Connect X1 hammer control EL pedal This parameter enables the X1 hammer function with
electrical pedal. (The option must be installed.)
HXX Connect 2 pcs offset boom – OFF/ON
Connect 2 pcs offset boom The option must be installed.
IAB X1 Current at Step 1 See 0 – 65535 mA
916 Calibration of X1
hydraulic with flow control
.
X1 Current at Step 1 This parameter is used for the current value to get a
certain X1 flow at the flow calibration step 1 . The value
is changed by X1 flow calibration and should not be
changed manually.
The value must not be higher than 1000 mA!
IAC X1 Current at Step 2 See 0 – 65535 mA
916 Calibration of X1
hydraulic with flow control
.
X1 Current at Step 2 This parameter is used for the current value to get a
certain X1 flow at the flow calibration step 2 . The value
is changed by X1 flow calibration and should not be
changed manually.
The value must not be higher than 1000 mA!
IAD X1 Current at Step 3 See 0 – 65535 mA
916 Calibration of X1
hydraulic with flow control
.
X1 Current at Step 3 This parameter is used for the current value to get a
certain X1 flow at the flow calibration step 3 . The value
is changed by X1 flow calibration and should not be
changed manually.
The value must not be higher than 1000 mA!
IAE X1 Current at Step 4 See 0 – 65535 mA
916 Calibration of X1
hydraulic with flow control
.
 X1 Current at Step 4 This parameter is used for the current value to get a
certain X1 flow at the flow calibration step 4 . The value
is changed by X1 flow calibration and should not be
changed manually.
The value must not be higher than 1000 mA!
IAF X1 Current at Step 5 See 0 – 65535 mA
916 Calibration of X1
hydraulic with flow control
.
X1 Current at Step 5 This parameter is used for the current value to get a
certain X1 flow at the flow calibration step 5. The value
is changed by X1 flow calibration and should not be
changed manually.
The value must not be higher than 1000 mA!
IAG X1 Current at Step 6 See 0 – 65535 mA
916 Calibration of X1
hydraulic with flow control
.
X1 Current at Step 6 This parameter is used for the current value to get a
certain X1 flow at the flow calibration step 6 . The value
is changed by X1 flow calibration and should not be
changed manually.
The value must not be higher than 1000 mA!
IAH X1 Current at Step 7 See 0 – 65535 mA
916 Calibration of X1
hydraulic with flow control
.
X1 Current at Step 7 This parameter is used for the current value to get a
certain X1 flow at the flow calibration step 7 . The value
is changed by X1 flow calibration and should not be
changed manually.
The value must not be higher than 1000 mA!
IAI X1 Current at Step 8 See 0 – 65535 mA
916 Calibration of X1
hydraulic with flow control
.
X1 Current at Step 8 This parameter is used for the current value to get a
certain X1 flow at the flow calibration step 8 . The value
is changed by X1 flow calibration and should not be
changed manually.
The value must not be higher than 1000 mA!
IIC X1 flow, Step 1 calibration See 0 – 65535 lpm
916 Calibration of X1
hydraulic with flow control
.
X1 flow, Step 1 calibration This parameter is used for the X1 flow value
corresponds to the X1 current at step 1 . The value
should not be changed manually.
IID X1 flow, Step 2 calibration See 0 – 65535 lpm
916 Calibration of X1
hydraulic with flow control
.
X1 flow, Step 2 calibration This parameter is used for the X1 flow value
corresponds to the X1 current at step 2 . The value
should not be changed manually
IIE X1 flow, Step 3 calibration See 0 – 65535 lpm
916 Calibration of X1
hydraulic with flow control
 .
X1 flow, Step 3 calibration This parameter is used for the X1 flow value
corresponds to the X1 current at step 3 . The value
should not be changed manually.
IIF X1 flow, Step 4 calibration See 0 – 65535 lpm
916 Calibration of X1
hydraulic with flow control
.
X1 flow, Step 4 calibration This parameter is used for the X1 flow value
corresponds to the X1 current at step 4 . The value
should not be changed manually.
IIG X1 flow, Step 5 calibration See 0 – 65535 lpm
916 Calibration of X1
hydraulic with flow control
.
X1 flow, Step 5 calibration This parameter is used for the X1 flow value
corresponds to the X1 current at step 5 . The value
should not be changed manually.
IIH X1 flow, Step 6 calibration See 0 – 65535 lpm
916 Calibration of X1
hydraulic with flow control
.
X1 flow, Step 6 calibration This parameter is used for the X1 flow value
corresponds to the X1 current at step 6. The value
should not be changed manually.
III X1 flow, Step 7 calibration See 0 – 65535 lpm
916 Calibration of X1
hydraulic with flow control
.
X1 flow, Step 7 calibration This parameter is used for the X1 flow value
corresponds to the X1 current at step 7 .The value
should not be changed manually.
IIJ X1 flow, Step 8 calibration See 0 – 65535 lpm
916 Calibration of X1
hydraulic with flow control
.
X1 flow, Step 8 calibration This parameter is used for the X1 flow value
corresponds to the X1 current at step 8. The value
must not be changed manually.
IPO Increase of engine rpm at power boost mode – 0 – 4000 rpm
Increase of engine rpm at power boost mode This value is different for each machine and must
not be changed!
JGX Reversible fan installed – 0–1
Reversible airflow direction control in hydraulic oil/ The option must be installed.
engine coolant cooling system.
0: This equipment don't have reversible fan.
1: This equipment have reversible fan.
JGY Reversal interval time at auto mode 60 min 20 – 120 min
Reversal rotation interval time at auto 1 mode in the Defines the time between the reversible cycles in auto
reversible fan. mode.
JGZ Reversal time at manual mode 60 sec 20 – 180 sec
Reversal rotation time of reversible fan at manual Defines the time how long the fan runs in reversible
mode. direction.
LFL Cooling system selection – 0/1
Cooling system can be selected: The cooling fan runs with a higher speed.
0: Standard cooling system Standard: 1600→ Tropical: 1750
 1: Tropical cooling system Therefore the minimum current is different.
LYU Connect Axle lock extended – OFF/ON
Connect Axle lock extended option; when this option is This parameter is safety related.
selected there will be a further Axle locking condition. For EW230C the default setting is ON.
For EW210C this parameter is depending on the
installed options.
NVG Tilt-Rotator – OFF/ON
Activation of the Tilt-Rotator function for Tilt-Rotator This parameter is exclusively adapted for Tilt-Rotator
preparation. control system.
Do not use this parameter in combination with
‘Connect change function grab/tilt for rotortilt’ (HOR).
 Service Information

Document Title: Function Group: Information Type: Date:

Troubleshooting, general Service Information 2014/7/4 0
Profile:
EXC, EW160C, EW180C, EW140C [GB]

Troubleshooting, general
WARNING
When troubleshooting in the electrical system, read through and follow the work instructions and safety instructions
in the concerned method sections.

This section of the Service Manual describes how to troubleshoot the electrical system. The section contains flow charts that
describe the various steps, and tables that show the signal routes and terms for the various functions.
Instrument control unit (I-ECU) can be used when troubleshooting, see
3002 Instrument control unit I-ECU, function description.

Other assistive devices for troubleshooting the electrical system:

 Wiring diagram and component lists

 Operator's Manual
 Possible component manuals
 Parts Catalogue

The first step in troubleshooting is to gather as much information as possible about how the malfunction is manifested.
NOTE!
The functions in the electronic system may vary depending on which software versions are installed in the electronic units.
Therefore, always check which software versions are installed before starting to troubleshoot.

See current service bulletins for information on updates and differences between software versions.

Malfunctions/errors may be indicated by:

 central warning flashing

 buzzer sounds
 error messages are shown on information display unit
 an error/malfunction symptom is obtained.

When any malfunction is suspected or confirmed it is important to determine the cause as soon as possible.
The first step in troubleshooting is to gather information from the operator regarding the error/malfunction symptom. Then,
attempt to pinpoint the cause by performing checks in a certain order, see 3020 Troubleshooting strategy.
To facilitate troubleshooting and to make it more effective, there are a number of assistive devices available, for example,
VCADS Pro service tool, see 3020 Troubleshooting tools.

WARNING
Continued operation following a malfunction indication may result in damage to persons and property.
 Service Information

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Troubleshooting strategy Service Information 2014/7/4 0
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Troubleshooting strategy
The basis for all troubleshooting is that a malfunction, symptom or defect is noticed. Troubleshooting strategy and
procedures are illustrated in the following flow chart.

Start

Basic data collection, see 3020 Collection of basic data.

Read-out of error messages. Error messages found?

YES
NO

 Note error messages.

 Troubleshoot using error codes, see 3021 Error codes, build-up.
 Repair the defect/malfunction.
 Activate the concerned component or function.
 Read-out of error messages. Problem solved?

YES NO
OK Perform parameter check, see 3002 Instrument control unit I-ECU, function description and
3020 VCADS Pro service tool Is any parameter set incorrectly?

YES
NO
Re-program parameter. Problem solved?

YES NO

OK Troubleshoot using additional information.[ 1] 

The included steps in the troubleshooting strategy are described below.

1. Basic data collection. The basis for all troubleshooting is a symptom or malfunction. In order to establish a basis
for troubleshooting, data should be collected about the symptom/malfunction.
A data collection model is available as 3020 Collection of basic data.
2. Error messages provide a clear indication about the cause of the symptom or malfunction. Therefore, read out the
error messages from the information display unit before troubleshooting begins.
NOTE!
If new or repeated error messages are generated during troubleshooting, then these must be solved first before
continuing to troubleshoot.

A. Error messages are registered and compared with new or recurring error messages.
B. To verify that the problem has been repaired, the appropriate machine components/functions must be
activated to allow the control unit to perform a self-diagnosis and display new or recurring error
messages. The machine should be started and the component/function should be activated in order to
ensure that a self-diagnosis is conducted.
C. Error messages are read to verify that the symptom/malfunction has been repaired and to ensure that no
 additional malfunctions have been generated as a result of the repair.

3. Parameters are checked to ensure that reasonable values are set. See
3002 Instrument control unit I-ECU, function description and 3020 VCADS Pro service tool.

[ 1]Additional information includes wiring diagrams, function descriptions and component troubleshooting.
 Service Information

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Connecting special tools Service Information 2014/7/4 0
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Connecting special tools

Component testing
NOTE!
The images below are intended for components with a 4-pin DIN connector only. The basic test principle is identical for all
other connector types.

NOTICE
Take great care when attaching test cables to connectors so as not to damage or expand the pins and sleeves.

NOTICE
When measuring directly in connectors, good lighting and access is required to avoid short-circuiting between the
leads. Carefully follow all instructions in Electrical system, work instructions.

See also 3020 Special tools for troubleshooting .

Active testing of component and circuit
Active testing implies testing of a closed circuit.
The adapter cable is connected between the cable harness and the component.

Figure 1
Examples of active component testing with adapter cable

Passive component testing

Passive testing implies testing of an open circuit.
The adapter cable is connected to the component or cable harness.
Figure 2
Examples of passive component testing with a 4-pin DIN adapter cable

Figure 3
Examples of passive testing through the cable harness to the component. ECU not connected.

Active testing of E-ECU

Active testing implies testing of a closed circuit.
The multi-pin breaker box is connected between the cable harness and control unit with the adapter cable. For the cable
harness that is not measured, an alternative to using adapter cable is to use inter-connector cable to maintain closed circuit.

Figure 4
Active measuring of engine control unit E-ECU connection EA.
Active testing of V-ECU
Active testing implies testing of a closed circuit.
The test box is connected between the cable harness and control unit.

Figure 5
Active testing of vehicle control unit V-ECU.
 Service Information

Document Title: Function Group: Information Type: Date:

Collection of basic data Service Information 2014/7/4 0
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Collection of basic data

General
Collection of basic data is the first step in all troubleshooting. This is done to get a quick and improved overall picture of
how the malfunction shows up.
In addition to information about machine and customer, it is important to get as much information as possible about events
in connection with the occurrence of the malfunction.
The operator can often have valuable information on the circumstances when the malfunction occurred. The operator is
almost always the person who notices the problem first.
Since it's seldom possible to recreate the experienced problems, without having exactly the same conditions, information
from the operator is of vital importance for correct assessments in continued troubleshooting.
Interview the operator using the following questions.
The answers should be noted and saved together with the work order.
The operator should be able to answer the following questions:
General information

 Customer information
 Dealer information
 Operator
 Machine specifications:

 Machine
 Serial number
 Machine hours
 Engine type
 Engine number
 Model year
 Delivery date
 Transmission type
 Transmission serial number

 Have you detected any error messages?

 Has any new electrical equipment been installed on the machine?

Description of malfunction or symptom

 Describe the problem.

 When did the problem occur?
 How was the problem discovered and what happened just before?
 Does the problem reappear?
 How often does the problem occur?
 For how long does the problem last when it occurs?
 Does the problem always occur during the same conditions, if so, what are the conditions?
 Does the operator have any idea of what the probable cause of the problem may be?
 Does the problem still exist?

Engine data

 Under what operating conditions does the problem occur?

 External circumstances that affect the problem?
  Is the engine difficult to start?
 Is there abnormal smoke?
 Is there any abnormal engine noise?
 Have you detected/confirmed any changes in fuel consumption, oil consumption or engine power?
 What type of fuel is used?
 Any additives used in the fuel? If yes, which ones?
 What repairs or other work has been performed on the engine?
 Other information?

Power transmission, data

 Under what operating conditions does the problem occur?

 External circumstances that affect the problem?
 What type of oil is used?
 Any additives used in the oil? If yes, which ones?
 When was the last oil change performed?
 Is difference in rolling circumference between tyres more than 1.5%?
 Other information?
 Service Information

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Troubleshooting tools Service Information 2014/7/4 0
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Troubleshooting tools
Service manual
Service information for troubleshooting is available in the service manual. The different types of information are listed below:

 Instructions for checking electrical cables and connectors

A general description of these checks can be found in 3020 Electrical cables and connectors, checking.

 Wiring diagrams
Wiring diagrams are of great help during troubleshooting. Wiring diagrams provide cable designations, cable
colours as well as component and connector designations, etc.

 Component diagram
Supplemental information to the wiring diagrams is available in the form of component lists that illustrate the
location of machine components.

VCADS Pro
VCADS Pro is a PC-based service tool which has been developed in order to facilitate troubleshooting work. Components/
functions can be activated and values can be examined with VCADS Pro through the use of tests. Read-out of error
messages can also be performed using VCADS Pro.
For a description of VCADS Pro, see the separate user's manual and 3020 VCADS Pro service tool.
Instrument control unit (I-ECU)
The instrument control unit is used to read error messages, 3021 Error codes, build-up.
 Service Information

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VCADS Pro service tool Service Information 2014/7/4 0
Profile:
EXC, EW160C, EW180C, EW140C [GB]

VCADS Pro service tool

General

Figure 1
VCADS Pro computer

The following is a brief description of the VCADS Pro service tool.

The name VCADS Pro is an abbreviation of Volvo Computer Aided Diagnostic System Professional.

Design of VCADS Pro

Figure 2
Start display

VCADS Pro contains programs for:

 Testing components and functions

 Downloading software for control units
 Storing performed work operations on job card

Operations
Figure 3
Example, tests and programming possibilities

Under Operations, there are several tests and programming possibilities divided according to function group.
The tests show, for example, sensor values, as well as graphic display of how a signal varies in time.
Programming is used to reprogram control units.
Read-out of error codes

Figure 4
Operations, read-out of error codes

Read-out of error codes from operations, function group 1 - Service and maintenance. To pin-point malfunction causes, it's
advantageous to use the service tool VCADS Pro. From VCADS Pro, it's possible to obtain error codes of the SAE-type, from
which the malfunction cause can be determined, see 3021 SAE-code, conversion to error code (I-ECU application).
Parameters
Figure 5
Example, read-out parameters

Read-out and programming of parameters takes place from operation, function group 1 - Service and maintenance.
Job card

Figure 6
Example, job card

The job card function is used to store work operations that have been performed with VCADS Pro, for example, test results
and results of error code read-outs and programming of parameters. The job card is stored locally in the computer in
question.
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VCADS Pro, Operations Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

VCADS Pro, Operations

Operation number Operation title
17012–3 Error codes
17030–3 Parameter programing
17034–3 Vehicle information, test
17055–3 Central systems, updating, replacing control unit
17056–3 Central systems, updating, changing software
17057–3 Central systems, updating, replacing component
21006–3 Cylinder compression test
23017–3 Feed pressure, inspection
23712–3 Injector shut off, manual
23777–3 Fuel system, check
27502–2 Engine speed control, test
28407–3 Sensor values, monitoring
28420–3 Flywheel and camshaft signal, test
28422–3 MID 128 ECU campaign
28423–3 MID 128 ECU programming
30902–3 Keypad status, test
36003–3 Switches, control lever, test
36401–3 Switches, test
36646–3 MID 187 ECU programming
36648–3 MID 187 ECU campaign
38104–3 MID 140 ECU campaign
38145–3 MID 140 ECU programming
39736–3 MID 142 ECU programming
39738–2 MID 142 ECU campaign
39796–3 MID 142 ECU, reset
39797–3 CareTrack status, check.
52102–3 Brake pressure monitor, test
55102–3 Parking brake system, check
87371–3 MID 146 ECU programming
87372–3 MID 146 ECU campaign
87373–3 ECC input and output signal status, test
87374–3 Air mix door valve actuator, test
87375–3 Heat control valve actuator, test
87376–3 Sensor values, ECC, check
91406–3 Solenoid valve power boost , test
91603-3 Cruise control, calibration
91604-3 X1 hydraulic pressure, calibration
91607-3 X1 hydraulic flow, calibration
 Service Information

Document Title: Function Group: Information Type: Date:

Special tools for trouble Service Information 2014/7/4 0
shooting
Profile:
EXC, EW160C, EW180C, EW140C [GB]

Special tools for trouble shooting

This list is a summary of special tools used in Guided Diagnostics and for Troubleshooting

Op nbr 302-500

88890074 Multimeter
88890091 Clip-on ampmeter
9990008 Measuring equipment
9998699 Adapter
9990014 Break out harness
9990025 Break out harness
9990062 Cable
9993893 Break out harness
88830115 Template
9990025 Break out harness
88830028 Break out harness
9993893 Break out harness
88830115 Template
88890016 Break out harness
88890019 Template
88830055 Pressure checking set
88890080 Pressure checking set
88890040 Oscilloscope
9998699 Adapter
9990062 Cable
9990014 Break out harness
11666051 Pressure gauge
11666052 Pressure gauge
14290266 Hose
80872138 Tachometer
9993720 Nipple
14290262 Adapter
14341364 Adapter
88890180 Interface
88890027 Cable
9812330 Cable
9812331 Cable
 Service Information

Document Title: Function Group: Information Type: Date:

999 8699 Multi-pin breaker Service Information 2014/7/4 0
box
Profile:
EXC, EW160C, EW180C, EW140C [GB]

999 8699 Multi-pin breaker box

Description: Multi-pin breaker box
Part no. 999 8699
Specification: Multi-pin breaker box 62-pin with D-SUB connector.
The multi-pin breaker box is universal and can be used
for measuring a number of different connector types.
 Service Information

Document Title: Function Group: Information Type: Date:

999 0014 Adapter cable Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

999 0014 Adapter cable

Description: Adapter cable
Part no. 999 0014
Specification: The adapter cable is used for measuring engine
control unit (E-ECU) connector EA and EB.
Note! For active measuring of E-ECU, 2 adapter cables
are required.
 Service Information

Document Title: Function Group: Information Type: Date:

999 0025 Adapter cable Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

999 0025 Adapter cable

Description: Adapter cable
Part no. 999 0025
Specification: The adapter cable is used for measuring electric
distribution box (EDB) connectors.
 Service Information

Document Title: Function Group: Information Type: Date:

999 0062 Extension cable Service Information 2014/7/4 0
Profile:
EXC, EW160C, EW180C, EW140C [GB]

999 0062 Extension cable

Description: Extension cable
Part no. 999 0062
Specification: Extension cable 2.5 m for multi-pin breaker box 999
8699.
 Service Information

Document Title: Function Group: Information Type: Date:

8883 0028 Adapter cable Service Information 2014/7/4 0
Profile:
EXC, EW180C, EW160C, EW140C [GB]

8883 0028 Adapter cable

Designation: Adapter cable
Part no. 8883 0028
Specification: The adapter cable is used for measuring I-ECU.
 Service Information

Document Title: Function Group: Information Type: Date:

88890040 Oscilloscope for Service Information 2014/7/4 0
VCADS Pro
Profile:
EXC, EW180C, EW160C, EW140C [GB]

88890040 Oscilloscope for VCADS Pro

Designation: Oscilloscope for VCADS Pro
Part no. 88 890 040
Specification: Measuring tool used together with VCADS Pro.
 Service Information

Document Title: Function Group: Information Type: Date:

999 3893 Adapter cable Service Information 2014/7/4 0
Profile:
EXC, EW180C, EW160C, EW140C [GB]

999 3893 Adapter cable

Designation: Adapter cable
Part no. 999 3893
Specification: The adapter cable is used for measuring V-ECU and
ECC.
 Service Information

Document Title: Function Group: Information Type: Date:

999 3894 Template Service Information 2014/7/4 0
Profile:
EXC, EW160C, EW180C, EW140C [GB]

999 3894 Template

Designation: Template
Part no. 999 3894
Specification: Template for Multi-pin breaker box 999 8699.

NOTE!
The numbers on the template correspond to the pin-numbering on the connector.
 Service Information

Document Title: Function Group: Information Type: Date:

11 666 140 Multimeter Service Information 2014/7/4 0
Profile:
EXC, EW160C, EW180C, EW140C [GB]

11 666 140 Multimeter

Description: Multimeter
Part no. 11 666 140
Specification: Multimeter used for fault diagnosis. (Similar
multimeters can also be used)
 Service Information

Document Title: Function Group: Information Type: Date:

Electrical cables and Service Information 2014/7/4 0
connectors, checking
Profile:
EXC, EW180C, EW160C, EW140C [GB]

Electrical cables and connectors, checking

General
When troubleshooting the electrical system, checking of electrical cabling and connectors is important, since causes of a
malfunction often can be attributed to loose connections or damaged cabling.
NOTE!
Before troubleshooting of cabling and connectors, the affected circuit fuses should be checked.

Checking is performed using multimeter, multi-pin breaker box and cable adapters. See Special tools for troubleshooting.
To find suitable checking points, see wiring diagrams.
NOTE!
The following should be observed when working on electrical systems.

 After dismantling connectors, certain connectors should have, for example, contact grease applied to reduce the
risk of oxidation and loose connections. See installation information for respective component under heading
Components, troubleshooting and specifications.
 Do not perform measurements by penetrating the cable insulation.
 Work carefully when measuring with test cord in the connectors so that connector pins and sockets are not
damaged or expanded.

NOTE!
For troubleshooting of information link and CAN-bus, see Information link, general troubleshooting and Control link (CAN-
bus), general troubleshooting.

Connectors and cable terminals, checking

When measuring and checking where connectors are dismantled, the connectors and cable terminals should be checked
visually according to the following.

1. Look for oxidation on the cable terminals. Oxidation may impair contact.
2. Check that the cable terminals are not damaged, that they are correctly inserted in the insulator, and that the
electrical cabling is securely connected in the cable terminals.

Figure 1
Connector, checking mechanical contact
3. Check that the cable terminals have good mechanical contact. Use a test cable terminal when checking.

Open circuit, checking

Open circuits in electrical cabling and cable harnesses are caused by, for example, chafing, crushing, or pulling forces. Check
for open circuits according to the following.

1. Unplug the connectors in question at both ends of the cable harness.

Figure 2
Checking for open circuit with resistance measurement
2. Measure the resistance between the ends of the electrical cabling. The resistance should be ≈0 Ω for cabling
without an open circuit.

Figure 3
Shaking and pulling to find open circuit
3. Shake the cable harness and pull lightly on the connectors while measuring to find eventual open circuits.

Short-circuited to frame ground, checking

Short-circuited between voltage-conducting cabling and frame ground often leads to a fuse blowing. Checking of short-
circuited to frame ground is performed according to the following.

1. Key position to ON.

Figure 4
Checking short-circuiting to frame ground with resistance measurement
2. Activate all switches and sensors in the circuit and check if any fuses blow.
3. Unplug all connectors in question for the components in the circuit so that these do not affect measurements.
4. Measure resistance between the electrical cabling and frame ground. The resistance should be ∞ Ω for electrical
cabling without short-circuit to frame ground.
 Figure 5
Principle for checking short-circuiting to frame ground by measuring

Short-circuited to voltage, checking

Short-circuited between a cable and voltage conducting cable with resistance often leads to a blown fuse when the cable is
supplied with voltage.

1. Measure voltage with a multimeter at suitable points in the circuit at the same time as the switch and sensor are
activated.
The voltage value depends on several parameters. See wiring diagram, signal description and component
information.

Figure 6
Checking short-circuiting to voltage conducting cable with resistance measurement
2. Unplug the connectors in question at both ends of the cable harness.
Measure resistance between electrical cabling that may be short-circuited to each other. Resistance should be ∞ Ω
for cabling not short-circuited to each other.

Figure 7
Principle for checking short-circuiting to voltage by measuring

Connector resistance and oxidation, checking

Loose connections or temporary, repeated malfunctions can be difficult to troubleshooting and often occur due to
oxidation, vibrations or by poorly connected cables.
Moisture in the connectors may also be a cause of contact problems, such as damaged pins or sockets.
The resistance in the connectors and cabling should be ≈0 Ω. Some resistance may be present due to oxidation on the cable
terminals.
If too much connector resistance is encountered, there will be disruptions of the function. The amplitude of the resistance
may vary, without any disruptions occurring, depending on how great the load is in the circuit.
To check contact resistance and oxidation, see Connectors and cable terminals, checking.
Figure 8
Shaking and pulling on the connectors

NOTE!
Shake the cable harness and pull lightly on the connectors while measuring to find eventual loose connections.

Pins and sockets, cleaning

1. Turn OFF the master switch.

2. Blow clean the connectors with compressed air.

Figure 9
Connector, spraying with contact spray
3. Spray the connectors with contact spray.
4. Again, blow clean the connectors with compressed air.
 Service Information

Document Title: Function Group: Information Type: Date:

Measuring, general Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Measuring, general
WARNING
Always follow the instructions "Electrical system, special instructions for servicing".

NOTE!
Checking of leads and connectors is carried out to detect the presence of short circuits, open circuits and loose contacts as
an initial step before checking the components themselves. Faults in contacts and leads are more common then faults in
components. That is why connectors and leads should always be checked before the component in question is checked.

See 3020 Electrical cables and connectors, checking.

Checking components and cabling should be performed when error code for component has been generated.
Measuring is performed to check component, cabling, output signals from ECUs and frame ground connections.
NOTE!
The resistance values should only be given with an accuracy of at the most two digits, because resistance measuring is an
unreliable method. If possible measure voltage instead.
 Service Information

Document Title: Function Group: Information Type: Date:

Measuring symbols, Service Information 2014/7/4 0
description
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Measuring symbols, description

The symbols used for explaining the measurement methods are described below.

NOTICE
When checking components, i.e. relays and solenoid valves controlled by a control unit, certain conditions must be
fulfilled.

General symbols

Symbol Description Symbol Description

Battery disconnect Ignition switch in
switch in position Off. . position 0, 1 or 2

¹⁵⁰⁰⁰³⁶ ¹⁵⁰⁰⁰⁰¹ ¹⁵⁰⁰⁰⁰²

²¹⁰²⁹⁰⁰
Resistance measuring Frame ground (frame
ground connection)
¹⁵⁰⁰⁰⁰⁶ ¹⁵²¹⁶⁰⁰
Voltage measuring Engine off

¹⁵⁰⁰⁰⁰⁷
¹⁰³⁷⁰⁵²
Component Engine idling

⁶⁸²⁴⁶ ¹⁵⁰⁰⁰²⁵
Component is Engine speed > 1000
activated/deactivated rpm
from service tool ¹⁰³⁷⁰⁵⁸
¹⁵⁰⁰⁰³⁰ VCADS Pro

Symbols, check measuring of control unit and cable harness

Measuring cable harness and input/output ports ECU.
Component disconnected.

Symbol Description Symbol Description

Measuring in connector Measuring with 4-pin
without adapter. adapter

¹⁵⁰⁰⁰¹⁵
¹⁵⁰⁰⁰¹⁸
Measuring with 7-pin Measuring with
adapter transmission adapter

¹⁵⁰⁰⁰²⁰
¹⁰³¹⁸⁷³
Symbols, check-measuring cable harness
Measuring cable harness only.
Component and ECU disconnected

Symbol Description Symbol Description

Measuring with multi- Measuring with multi-
pin breaker box and in pin breaker box and 4-
connector pin adapter

¹⁵⁰⁰⁰⁵⁰ ¹⁵⁰⁰⁰⁵¹
Measuring with multi- Measuring with multi-
pin breaker box and pin breaker box and 7-
transmission adapter pin adapter

¹⁰³¹⁸⁷⁶
¹⁵⁰⁰⁰⁵²

Symbols, check measuring component

Measuring component without connected cable harness.

Symbol Description Symbol Description

Measuring component Measuring component
without adapter. Cable against frame ground.
harness disconnected Cable harness
disconnected
¹⁵⁰⁰⁰¹⁶ ¹⁵⁰⁰⁰⁵³
Measuring component Measuring component
with 4-pin adapter. against frame ground
Cable harness with 4-pin adapter.
disconnected Cable harness
disconnected
¹⁵⁰⁰⁰¹⁹ ¹⁵⁰⁰⁰⁵⁴
Measuring component Measuring component
with 7-pin adapter. against frame ground
Cable harness with 7-pin adapter.
disconnected Cable harness
disconnected
¹⁰³²⁵⁶² ¹⁰³¹⁹⁰⁵
Measuring against
transmission. Cable
harness disconnected

¹⁵⁰⁰⁰²¹

Symbols, check measuring subsystem

Measuring circuit/subsystem with and without ECU connected.

Symbol Description Symbol Description

Multi-pin breaker box Multi-pin breaker box
and adapter connected and adapter connected
between ECU and cable between ECU and
harness cable harness. ECU
connected
¹⁵⁰⁰⁰¹¹ ¹⁰⁰¹⁹⁷⁹
 Adapter connected Adapter connected
between component between component
and cable harness. ECU and cable harness. ECU
connected connected

⁶⁷⁹⁷⁷ ¹⁵⁰⁰⁰¹⁷
Adapter connected Adapter connected
between component between component
and cable harness. ECU and cable harness. ECU
connected connected

¹⁰³²⁴¹⁸ ¹⁰³¹⁸⁶⁹
Adapter connected Measuring voltage
between transmission across component.
and cable harness. ECU Cable harness
connected connected
¹⁵⁰⁰⁰²²
¹⁰³⁷⁰³³
Measuring voltage Measuring component
between component and cable harness with
and ground multi-pin breaker box

¹⁰³⁷⁰⁹⁴ ¹⁵⁰⁰⁰¹⁰
Measuring component
and cable harness with
multi-pin breaker box

¹⁰²⁵⁷⁶⁵
 Service Information

Document Title: Function Group: Information Type: Date:

Component descriptions Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Component descriptions
Types

1. Pressure sensors
2. Sensor as level monitor
3. Monitors
4. Temperature sensors
5. Level sensor
6. Inductive sensors
7. Solenoid valves
8. PWM valves

Pressure sensors
These sensors should preferably be checked by measuring the voltage. The measured resistance through these sensors says
very little about whether the sensor is functional or defective.
The sensor is supplied with stabilized 5 V. Stabilized means that the voltage varies very little. The tolerances are
approximately ±0.25 V.
The voltage measured between signal terminal and ground terminal corresponds to a value of the amplitude that the sensor
measures. The measured voltage is always lower than the 5V, which the component is supplied with. In general, the
measuring range is between 0.5 and 4.5 V.

Figure 1
Pressure sensor

Sensor as level monitor

This sensor is measured as a pressure sensor. Its design corresponds to that of the level sensor, but it has a vertical position,
which means that the sensor only senses fluid or no fluid, thus the output signal is high or low.

Figure 2
Oil level sensor

Monitors
The monitors are closing or opening. In general, they are supplied with battery voltage via a fuse. When the monitor closes,
the input signal (battery voltage) reaches the control unit, or opens and the control unit "loses" voltage on the input.
Figure 3
Pressure monitor

Temperature sensors
In general, temperature sensors are of the NTC or PTC type. This means that the resistance in the sensor varies with the
temperature, and either increases or decreases with increasing temperature. It is advantageous to measure resistance of the
temperature sensor between ground and the signal line.

Figure 4
Temperature sensor

Level sensor
In general, level sensors can be measured as pressure sensors. They are dependent on the correct fluid, for example, diesel
fuel for the fuel level sensor, to give correct voltage values.

Figure 5
Level sensor

Inductive sensors
Inductive sensors are often supplied with voltage (in general 5 V) and open for voltage to the signal line when anything
magnetic is moved within the sensor's sensory range. It is suitable to check these sensors by measuring voltage between
signal and ground cable, while a magnetic object is moved in front of the sensor to see if the sensor opens for voltage.

Figure 6
Position sensor

Inductive sensors, rpm sensors

Inductive sensors without feed have a permanent magnet and a coil in the sensory body, which gives a voltage-peak when a
magnetic object is moved in front of the sensory body. How great the voltage-peak becomes depends on the distance to as
well as the speed past the sensory body. It is advantageous to measure these inductive sensors by measuring resistance of
the coil in the sensory body.
Figure 7
Speed sensor

Solenoid valves
The solenoid valve is an electrically controlled valve. The solenoid valve should preferably be checked by measuring the
resistance in its coil. Check that the solenoid valve mechanically "switches over", if the function has failed.
Certain solenoid valves have a "quench diode" connected in parallel with the coil to reduce current peaks when the valve is
deactivated. These "quench diodes" make it impossible for some measuring instruments to measure the resistance of the
coil.

Figure 8
Solenoid valve

PWM valves
The PWM valve is controlled electrically. The coil in the solenoid valve should preferably be checked by measuring the
resistance.
The PWM valve is used for providing variable pressure for the control of fans, exhaust brake etc.

Figure 9
PWM valve
 Service Information

Document Title: Function Group: Information Type: Date:

Component Service Information 2014/7/4 0
troubleshooting, structure,
description
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Component troubleshooting, structure, description

Figure 1
Overview of component troubleshooting

1. Component designation
2. Component title
3. Simplified wiring diagram with signal description
4. Symbols for conditions when measuring, see 3020 Measuring symbols, description
5. Example of diagram for reading measured values (resistance) at a certain temperature
6. Column with command variables (correct values) for intended measuring
7. Column with measuring points for intended measuring
8. Checking subsystems, see 3020 Component troubleshooting, checking subsystem (circuit)
9. Checking components, see 3020 Component troubleshooting, checking component
10. Checking control unit/wiring harness, see
3020 Component troubleshooting, checking wiring harness and input/output on ECU
11. Information about component and references to other sections
 Service Information

Document Title: Function Group: Information Type: Date:

Component Service Information 2014/7/4 0
troubleshooting, checking
wiring harness and input/
output on ECU
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Component troubleshooting, checking wiring harness and input/

output on ECU
(Description of 3020 Component troubleshooting, structure, description, position 10).
Checking wiring harness and input/output on ECU can be done either with the cable harness connected to or disconnected
from the control unit. Primarily measuring should be done with the control unit connected, as this means that both input/
output and the cable harness are checked.
Measuring is done with the instrument positioned close to the component and connected to the cable harness. To achieve
connection there are various adapter cable harnesses available.
Connectors, for which no adapter cable harnesses are available, should be measured directly in the connector.

NOTICE
When measuring directly in connectors, good lighting and access is required to avoid short-circuiting between the
leads. Carefully follow all instructions in Electrical system, work instructions.

NOTE!
Adapter cable and multi-pin breaker box should be used for all measuring which entails connecting to the connectors on the
control units (ECU). See also 3020 Special tools for troubleshooting.

Measuring with cable harness connected to control unit (ECU)

When measuring, check that voltage alternatively resistance values correspond to specified correct values.
Example:

 Measuring connector using adapter cable harness.

Figure 1

Measuring with cable harness disconnected from control unit (ECU)

When measuring, the resistance is checked in order to detect possible open circuit, see also
3020 Electrical cables and connectors, checking
Example:

 Measuring connector using adapter cable harness and multi-pin breaker box.

Figure 2
For complete list of measuring symbols, see 3020 Measuring symbols, description.
Lead types, measuring methods
Frame ground cable
During this check the conductivity of the frame ground cable to ground is measured. The instrument is set for measuring
resistance (ohm). Alternatively only the lead is measured according to "Measuring with cable harness disconnected from
control unit (ECU)".
Feed cable or control cable
During the measuring the voltage in the feed or control cable is checked in relation to frame ground. The instrument is set
for measuring voltage (VDC). Alternatively only the lead is measured according to "Measuring with cable harness
disconnected from control unit (ECU)".
Signal line
During this check the conductivity of the signal cable to the control unit is measured. The instrument is set for measuring
resistance (ohm). Alternatively only the lead is measured according to "Measuring with cable harness disconnected from
control unit (ECU)".
 Service Information

Document Title: Function Group: Information Type: Date:

Component Service Information 2014/7/4 0
troubleshooting, checking
component
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Component troubleshooting, checking component

(Description of 3020 Component troubleshooting, structure, description, position 9).
Checking of component is done in two ways, usually in combination:

 Measuring component internal resistance.

 Measuring component resistance against frame ground. Checking to determine that there is no short-circuit to the
component housing.

Measuring is done with the instrument positioned close to the component and with disconnected cable harness. To achieve
connection to the component there are various adapter cable harnesses available.
Connectors, for which no adapter cable harnesses are available, should be measured directly in the component.

NOTICE
When measuring directly in connectors, good lighting and access is required to avoid short-circuiting between the
leads. Carefully follow all instructions in Electrical system, work instructions.

When measuring, check that the resistance agrees with specified correct values.
Example:

 Measuring component using adapter cable harness.

Figure 1

 Measuring component against frame ground by measuring directly in connector.

Figure 2

For complete list of measuring symbols, see 3020 Measuring symbols, description.
 Service Information

Document Title: Function Group: Information Type: Date:

Component Service Information 2014/7/4 0
troubleshooting, checking
subsystem (circuit)
Profile:
EXC, EW160C, EW140C, EW180C [GB]

Component troubleshooting, checking subsystem (circuit)

(Description of 3020 Component troubleshooting, structure, description, position 8).
When measuring subsystem (circuit), a check is carried out of the entire circuit including cable harness, component and, if
applicable, also the input/output ports of the control unit.
Measuring is done with the instrument positioned close to the component, transmission or control unit (ECU). To achieve
connection there are various adapter cable harnesses available.
Connectors, for which no adapter cable harnesses are available, should be measured directly in the connector.

NOTICE
When measuring directly in connectors, good lighting and access is required to avoid short-circuiting between the
leads. Carefully follow all instructions in Electrical system, work instructions.

NOTE!
Adapter cable and multi-pin breaker box should be used for all measuring which entails connecting to the connectors on the
control units (ECU). See also 3020 Special tools for troubleshooting.

When measuring, check that voltage alternatively resistance values correspond to specified correct values.
Example:

 Measuring in adapter cable harness connected between component and cable harness. ECU connected.

Figure 1

 Measuring in multi-pin breaker box and adapter cable harness connected to cable harness by ECU. ECU
disconnected.

Figure 2

For complete list of measuring symbols, see 3020 Measuring symbols, description
 Service Information

Document Title: Function Group: Information Type: Date:

Error codes, build-up Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Error codes, build-up

Display unit
The error codes shown on the display unit, I-ECU are built up from a character combination with the following appearance
and meaning.

Figure 1
Example of error code "Temperature sensor engine oil, too high voltage"

Position 1
Indicates which type of component or function that has generated the error code. Abbreviations are found in the first 2–3
letters of the error codes.

HE Heating element
MA Solenoid valve
PWM Pulse width modulated valve
RE Relay
SE Sensor or monitor
SW Switches

Positions 2a and 2b
States component number where 2a signifies function group and 2b is a consecutive number within the function group.
Position 3
States FMI-code and based on SAE standard J1587. FMI means Failure Mode Identifier and states which type of error that
has caused the error code.

00 Data valid but above normal operating range

01 Data valid but below normal operating range
02 Intermittent or incorrect data
03 Abnormally high voltage or short-circuit to higher voltage
Abbreviated in error code texts "high voltage"
04 Abnormally low voltage or short-circuit to lower voltage
Abbreviated in error code texts "too low voltage"
05 Abnormally low current or open circuit
Abbreviated in error code texts "too low current"
06 Abnormally high current or short-circuit to frame ground
Abbreviated in error code texts "high current"
07 Incorrect reply from mechanical system
Abbreviated in error code texts "mechanical error"
08 Abnormal frequency
09 Abnormal updating rate
10 Abnormally wide variations
11 Unidentifiable malfunction
Abbreviated in error code texts "other error"
12 Defective unit or component
13 Calibration value outside limits
14 Special instructions
15 Reserved for future use

NOTE!
FMI 0 and 1 indicate to values outside normal operating range. These generate an error code with a warning. Warning is
shown on the display unit and through red central warning lamp.

Figure 2
Red central warning

Service tool VCADS Pro

The error codes in VCADS Pro are built up as follows.

Position in Abbreviation Explanation

figure
1 MID Message Identification Description (identification of control unit).
There is a unique number for each control unit.
2 PID Parameter Identification Description (identification of parameter/value).
There is a unique number for each parameter.
PPID Proprietary Parameter Identification Description (Volvo-unique identification of
parameter/value). There is a Volvo-unique number for each parameter.
SID Subsystem Identification Description (identification of component). The SID-number
depends on which control unit (MID) that they are sent from. Each control unit has its
own number series for SID. The exceptions are SID-numbers 151–255 which are
general for all systems.
PSID Proprietary Subsystem Identification Description (Volvo-unique identification of
component).
3 FMI Failure Mode Identifier (identification of failure type).
Figure 3
Error code screen in service tool VCADS Pro

Position 1, MID
Indicates the control unit that generated the error code. Based on SAE standard J1587.

128 Engine electronic control unit

140 Instrument electronic control unit
146 Electronic climate control unit
187 Vehicle electronic control unit

Position 2, PID, PPID, SID, PSID

Indicates the component/parameter that generated the error code. Based on SAE standard J1587.
Position 3, FMI
Indicates the FMI code. FMI means Failure Mode Identifier and the code indicates which type of malfunction has generated
the error code. FMI is based on SAE standard J1587.
Components with Volvo-specific FMI number
For a few components FMI has a Volvo-specific meaning (not according to SAE standard J1587), see for example, error code,
MID187 PPID1319 (MA9103).
 Service Information

Document Title: Function Group: Information Type: Date:

Error code information, Service Information 2014/7/4 0
description
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Error code information, description

In the following example the design of the error code information is explained.

Figure 1
Error code information, general layout

1. Error code screen on display unit

2. Component name and type of error (the error type is connected to the FMI code, e.g. 3 = too high voltage)
3. SAE code
4. Reaction from control unit
5. Reference to troubleshooting information

NOTICE
Checking of electrical cabling and connectors is used to check short-circuiting, open circuits and loose
connections as a first action before components are checked.

Contact / cable defects are more common than component malfunction. Therefore, always check the
connector and cabling before checking the component in question.

6. Symptom / functional disorder

7. Possible error cause. Used with the aim of facilitating troubleshooting
8. Condition. States the criteria/conditions that apply to generate the error code. The aim of this information is to
make it possible to make a correct verification after repair.
 Service Information

Document Title: Function Group: Information Type: Date:

Error code information, Service Information 2014/7/4 0
general
Profile:
EXC, EW180C, EW160C, EW140C [GB]

Error code information, general

An error code is generated when the system detects an error on input to / output from a control unit (ECU). This occurs
when the signal to / from a component is outside the range that has been defined as the signal’s limit values.
The machine’s control units have integrated diagnostic programs which monitor input and output signals for components.
All control units can generate error codes.
NOTE!
An error code indicates that there is an error somewhere in the circuit that is connected to the input / output. That is,
component, cable or connector.

The following describes which error codes can be generated, brief information about the error codes and references to
troubleshooting information.

General
The SAE-codes are generated automatically by the electronic controllers. The SAE-code is generated according to SAE-
standards and are given a designation depending on which control unit (MID) that generates the SAE-code, which
component (PID) it applies to, as well as what type of error / malfunction (FMI) that the control unit has detected. Thus, that
is the appearance of the SAE-code which is read by the service tool VCADS Pro.
The SAE-code which is generated by the electronic controllers and can be read with VCADS Pro, is converted in the software
to VOLVO EXCAVATOR error codes. Thus, the SAE-code generated by the electronics , for example, MID128 PID102 FMI3.
Control units
The control units generate SAE-codes according to how they perceive the signals from / to components. This means that an
open circuit in a signal line (from “5 V sensor”) does not always has to be given an SAE-code with FMI 04 (low voltage).
The reason for this is the design of the control units, which sometimes have inputs connected to voltage, and sometimes
ground.
For this reason, an open circuit in a signal line, connected to voltage in the control unit, can give an SAE-code which ends
with FMI 03 (high voltage).
The above example applies to inputs that read off voltage. For inputs / outputs that read off current, open circuits give low
current, short-circuiting to ground gives high current, etc.
Each component can have maximum three error codes. For this reason, FMI 11 (other error) is given for the errors that are
not included in the interpretation of the first two FMI’s for each component.
Example of error code interpretation

Figure 1
Input connected to voltage (+DC)
FMI 03 = High voltage
Open circuit in a signal line, input connected to voltage. Gives FMI 03 (high voltage). This FMI can be generated even when
the signal line is intact, but 5 V supply to the component exceeds 5 V (for example, short-circuiting to higher voltage). An
open circuit in the input (when connected to voltage) on the control unit also gives this FMI.

Figure 2
Input connected to ground (GND)

FMI 04 = Low voltage

Open circuit in a signal line, input connected to ground. Gives FMI 04 (low voltage). This FMI can be generated even when
the signal line is intact, but 5 V supply to the component is below 5 V (for example, voltage drop due to loose connection or
open circuit in supply cable). An open circuit in the input (when connected to ground) on the control unit also gives this FMI.
 Service Information

Document Title: Function Group: Information Type: Date:

RExxxx, Relays general, Service Information 2014/7/4 0
description and measuring
Profile:
EXC, EW140C, EW160C, EW180C [GB]

RExxxx, Relays general, description and measuring

RE XXXX Relay, general troubleshooting
Function A relay is controlled electrically and is mostly use for activating a
function.
Wiring See 370 Component list, Relays
diagram X, control signal to the relay
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tools:
Adjusting: 3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
EDB:3020 999 0025 Adapter cable
E-ECU:3020 999 0014 Adapter cable
ECC-ECU:3020 999 3893 Adapter cable
I-ECU:3020 8883 0028 Adapter cable
V-ECU:3020 999 3893 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Frame ground cable ≈0Ω
cable harness:
85–

Feed cable ≈ Uᵇᵃᵗ

30–

Control cable ≈ Uᵇᵃᵗ

(relay activated)
86–
≈0V
(relay not activated)
Component: 85–86 ≈ 220 Ω
30–87A ≈0Ω
Other measuring ≈ ∞ Ω
combinations
Subsystem: ≈ Uᵇᵃᵗ
X– (31) (relay activated)

≈0V
(relay not activated)
 Service Information

Document Title: Function Group: Information Type: Date:

SAE J1939/CAN control Service Information 2014/7/4 0
link, description and
measuring
Profile:
EXC, EW140C, EW160C, EW180C [GB]

SAE J1939/CAN control link, description and measuring

Description

SAE J1939/CAN Control link, general troubleshooting

Function The system control signals are sent on the control link.
NOTE!
The voltage on the information link varies, depending on the intensity of signals on the link. The
measured values should therefore be regarded as guiding values only.

References 370 Wiring diagram SCH02

Miscellaneous VCADS Pro:

 37173-3 Data links, fault tracing with oscilloscope

 300 Data links, fault tracing with Oscilloscope

Measuring

Measuring point Correct value Condition Test method

≈ 2–5 V
CAN H –
≈ 0–3 V
CAN L–

CAN H–CAN L ≈ 0–5 V

CAN H–CAN L ≈ 25–70 Ω

 ≈ > 1 KΩ
CAN H–

≈ > 1 KΩ
CAN L–

CAN H–CAN L ≈ 100–140 Ω

(E-ECU, I-ECU)
≈ 1 KΩ – 10 MΩ
(All others)

≈ > 1 KΩ
CAN H–

≈ > 1 KΩ
CAN L–

Verifying

SAE J1939 (CAN ) Tools

H L
E–ECU B51 B55 3020 999 8699 Multi-pin breaker box
3020 999 0014 Adapter cable
3020 999 0062 Extension cable
3020 11 666 140 Multimeter
I–ECU A6 A16 3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 8883 0028 Adapter cable
3020 11 666 140 Multimeter
V–ECU C15 C16 3020 999 8699 Multi-pin breaker box
3020 999 3893 Adapter cable
3020 999 0062 Extension cable
3020 11 666 140 Multimeter
ECC 34 58 3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter
K-PAD 3 4 3020 11 666 140 Multimeter

Information

Text Explanation
DATA BITS Data bits zeros or ones
Voltage, Volts Voltage, Volts
time, seconds time, seconds
high, low high, low
 Measuring points Theoretical value V
Data bit→ 0 1
J1939H–Ground 2.5 – 4.0
J1939L–Ground 2.5 – 1.0
J1939H–J1939L 0.0 – 3.0

Voltage levels J1939 CAN-bus

 Service Information

Document Title: Function Group: Information Type: Date:

SAE J1708/1587 Service Information 2014/7/4 0
information link,
description and measuring
Profile:
EXC, EW140C, EW160C, EW180C [GB]

SAE J1708/1587 information link, description and measuring

Description

SAE J1708/ Information link, general troubleshooting

J1587
Function The information link is connected to all control units and the service/programming socket. Information and
diagnostic signals are sent on the link.
NOTE!
The voltage on the information link varies, depending on the intensity of signals on the link. The measured
values should therefore be regarded as guiding values only.

References 370 Wiring diagram SCH02

Miscellaneo VCADS Pro:
us VCADS Pro detects which ECUs that respond when connected to machine

 37173-3 Data links, fault tracing with oscilloscope

 300 Data links, fault tracing with Oscilloscope

Measuring

Measuring point Correct value Condition Test method

U ≈ <4.0 V
J1708A–
U ≈ >1.0 V
J1708B–
[T1][T2]
J1708A–J1708B U ≈ 0–5 V DC

[T3][T4]
J1708A–J1708B ≈ 500 Ω –100 KΩ

≈ 250 Ω — 20 KΩ
J1708A —

≈ 250 Ω — 5 KΩ
J1708B —

J1708A–J1708B ≈ 3 KΩ— 20 KΩ

≈ 3 KΩ— 20 KΩ

≈ 3 KΩ — 5 KΩ

[T1]Voltage U should vary within the stated range.

[T2]The measured value Umax./Umin. relate to measuring with MIN and MAX function in multimeter.

[T3]Voltage U should vary within the stated range.

[T4]The measured value Umax./Umin. relate to measuring with MIN and MAX function in multimeter.

Verifying

SAE J1708 A SAE J1708 B Tools

E–ECU A34 A33 3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 0014 Adapter cable
3020 11 666 140 Multimeter
I–ECU A7 A17 3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 8883 0028 Adapter cable
3020 11 666 140 Multimeter
V–ECU C38 C39 3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter
ECC 10 11 3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
 3020 999 3893 Adapter cable
3020 11 666 140 Multimeter
K-PAD 5 6 3020 11 666 140 Multimeter

Information

Text Explanation
DATA BITS Data bits zeros or ones
Voltage, Volts Voltage, Volts
time, seconds time, seconds
high, low high, low

Measuring points Theoretical value V

Data bit→ 0 1
J1708A–Ground 0.0 – 5.0
Voltage levels J1708 bus J1708B–Ground 5.0 – 0.0
J1708A–J1708B 5.0 5.0
 Service Information

Document Title: Function Group: Information Type: Date:

AL3201, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

AL3201, description and measuring

AL3201 Alternator
Function Supplies the power to the electrical system, and charges the
battery.
Wiring 370 Wiring diagram SCH01
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque:
Adjusting: VCADS Pro:
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 8883 0028 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Signal cable ≈0Ω
cable harness: L–A10

Subsystem: ≈ 28 V
A10–

Battery Battery charging ≈ 28 V

Voltage
B+ to B-
 Service Information

Document Title: Function Group: Information Type: Date:

BA3101, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

BA3101, description and measuring

BA3101 Battery
Function Supplies the power to the electric system.
Wiring 370 Wiring diagram SCH02
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque:
Adjusting: VCADS Pro:
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
I-ECU: 3020 8883 0028 Adapter cable
V-ECU: 3020 999 3893 Adapter cable
E-ECU: 3020 999 0014 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Frame ground cable ≈0Ω
cable harness: I-ECU A8, A18, B14–

V-ECU B70, C48, C61,

C70 –
E-ECU A57, B58, B59,

B61–
Feed cable ≈ 24 V

I-ECU A1, A9–

V-ECU A8, A16 –

E-ECU B57, B60–

 Service Information

Document Title: Function Group: Information Type: Date:

CU9901, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

CU9901, description and measuring

CU9901 CU9901, Auto lubrication system
Function Supplies the grease to the bearings.
Wiring 370 Wiring diagram SCH20
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque:
Adjusting: VCADS Pro:
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 8883 0028 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Frame ground cable ≈0Ω
cable harness:
2–

Feed cable ≈ 24V

1–

Signal cable ≈0Ω

4–A3

Subsystem: ≈ 24 V
A3– (low level or
malfunction)
≈0V
(normal level)
 Service Information

Document Title: Function Group: Information Type: Date:

FU6, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

FU6, description and measuring

FU6 Fuse, V-ECU power supply to solenoid valves
Function Check the power supply to solenoid valves.
Wiring 370 Wiring diagram SCH08
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
C23, Feed cable
Installing/ Tightening torque:
Adjusting: VCADS Pro:
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Feed cable ≈ 24 V
cable harness:
C23–
 Service Information

Document Title: Function Group: Information Type: Date:

FU18, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

FU18, description and measuring

FU18 Fuse, V-ECU power supply to PWM valves
Function Power supply to PWM valves.
Wiring 370 Wiring diagram SCH08
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
C24, Feed cable
Installing/ Tightening torque: C47, Feed cable
Adjusting: VCADS Pro:
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Feed cable ≈ 24 V
cable harness:
C24–

C47–
 Service Information

Document Title: Function Group: Information Type: Date:

FU26, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

FU26, description and measuring

FU26 Fuse, V-ECU power supply to relays
Function Check the power supply to relays.
Wiring 370 Wiring diagram SCH15
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
C1, Feed cable
Installing/ Tightening torque:
Adjusting: VCADS Pro:
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Feed cable ≈ 24 V
cable harness:
C1–
 Service Information

Document Title: Function Group: Information Type: Date:

HE2501, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

HE2501, description and measuring

Description

HE2501 Heater, inlet air

Function Heating the engine inlet air
Reference 370 Wiring diagram SCH03
Miscellaneous Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 0014 Adapter cable
3020 11 666 140 Multimeter

B7, Signal line

B25, Control line

Measuring

Measuring point Correct value Condition Test method

Signal line ≈0Ω
HE2501(+) –EB7

≈0Ω
HE2501(+)–

Verifying

Measuring point Correct value Condition Test method

≈0V
HE2501(+) –

≈ 24 V
(Active< 0°C / 32°F)
 Service Information

Document Title: Function Group: Information Type: Date:

MA2301–MA2306, Service Information 2014/7/4 0
description and measuring
Profile:
EXC, EW140C [GB]

MA2301–MA2306, description and measuring

Description

MA2301 — Fuel injectors 1 – 4

MA2304
Function High pressure fuel injectors
Reference 370 Wiring diagram SCH03
Miscellaneous VCADS Pro:
VCADS Pro, 23712-3 - Injectors shut off, manual
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 0014 Adapter cable
3020 11 666 140 Multimeter

A36, A40, A48, and A56, Control line High

side
A59 and A60, Ground Low side

Measuring

Measuring point Correct value Conditions Test method

[T1] Low side — ≈ 1.0–1.8 Ω
[T2] High side

Low side / ≈∞Ω

High side –

[T1]It is assumed that both leads are disconnected from the respective injectors.

[T2]Small resistance values are difficult to measure. The values should be considered as guide values and as an aid in
detecting open circuits in the injector circuits.

Verifying

Measuring point Correct value Condition Test method

[T1] A48–A59 ≈ 1.0–1.8 Ω
A56–A59
A36–A60
A40–A60
 A36 / A40 / ≈ ∞ Ω
A48 /A56–

[T1]Small resistance values are difficult to measure. The values should be considered as guide values and as an aid in
detecting open circuits in the injector circuits.
 Service Information

Document Title: Function Group: Information Type: Date:

MA2504, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

MA2504, description and measuring

MA2504 IEGR valve
(Internal Exhaust Gas Recirculation)
Function Return of exhausts for maximal combustion
Wiring 370 Wiring diagram SCH03
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque: B30, Signal
Adjusting: VCADS Pro: B60 Feed Uᵇᵃᵗ
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 0014 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Feed cable ≈ Uᵇᵃᵗ
cable harness:
1–

Signal cable ≈0Ω

2–B30

Component: B30–B60 ≈ 35 Ω

Subsystem: B30 – B56 ≈ Uᵇᵃᵗ

(inactive)
≈0V
(active)
 Service Information

Document Title: Function Group: Information Type: Date:

MA9107, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

MA9107, description and measuring

MA9107 Solenoid valve, power boost
Function Controls the power boost mode
Wiring 370 Wiring diagram SCH08
diagram
Error code 3021 MA9107, error codes
info: C55, Signal power boost

Installing/ Tightening torque:

Adjusting: VCADS Pro:
Control unit/ Frame ground cable ≈0Ω
cable harness:
2–

Control cable ≈0Ω

1–C55

Component: 1–2 ≈ 20 Ω

Subsystem: 1–2 Uᵇᵃᵗ V

(active)
0V
(inactive)
 Service Information

Document Title: Function Group: Information Type: Date:

MA4214, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

MA4214, description and measuring

MA4214 Solenoid valve, Q-max
Function Control the travel motor with creep speed.
Wiring 370 Wiring diagram SCH09
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info: C51, Signal Q-max

Installing/ Tightening torque:

Adjusting: VCADS Pro:
55102-3 Parking brake system test
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Frame ground cable ≈0Ω
cable harness:
2–

Control cable ≈0Ω

1–C51

Component: 1–2 ≈ 30 Ω

Subsystem: 1–2 ≈ UᵇᵃᵗV

(active)

≈ 0V
(inactive)
 Service Information

Document Title: Function Group: Information Type: Date:

MA4218, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

MA4218, description and measuring

Description

MA4218 Solenoid valve, travelling forward

Function Control the travelling direction, forward
SW4602 Travel Manual, is coneccted to this function,
see wiring diagram.
Reference 370 Wiring diagram SCH09
Miscellaneous Tools: C30, Signal travel forward
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter

Measuring

Measuring point Correct value Condition Test method

Frame ground cable ≈0Ω

2–

Control cable ≈0Ω

1–C30

1–2 ≈ 30 Ω

Verifying

Measuring point Correct value Condition Test method

≈ Uᵇᵃᵗ V
C30– (active)

≈0V
(inactive)
 Service Information

Document Title: Function Group: Information Type: Date:

MA4219, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

MA4219, description and measuring

Description

MA4219 Solenoid valve, travelling reverse

Function Control the travelling direction, reverse
SW4206, Trvel Manual is connected to this function, see
wiring diagram.
Reference 370 Wiring diagram SCH09
Miscellaneous Tools: C7, Signal travel reverse
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter

Measuring

Measuring point Correct value Condition Test method

Frame ground cable ≈0Ω

2–

Control cable ≈0Ω

1–C7

1–2 ≈ 30 Ω

Verifying

Measuring point Correct value Condition Test method

Uᵇᵃᵗ V
C7– (active)
0V
(inactive)
 Service Information

Document Title: Function Group: Information Type: Date:

MA4302, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

MA4302, description and measuring

MA4302 Solenoid valve, travel gearbox, low speed
Function Controls the travel gearbox, low speed
Wiring 370 Wiring diagram SCH09
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info: C29, Signal low speed

Installing/ Tightening torque:

Adjusting: VCADS Pro:
55102-3 Parking brake system test
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Frame ground cable ≈0Ω
cable harness:
2–

Control cable ≈0Ω

1–C29

Component: 1–2 ≈ 35 Ω

Subsystem: 1–2 Uᵇᵃᵗ V

(active)
0V
(inactive)
 Service Information

Document Title: Function Group: Information Type: Date:

MA4303, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

MA4303, description and measuring

MA4303 Solenoid valve, travel gearbox, high speed
Function Controls the travel gearbox, high speed
SW9103, Pump Manual, is connected to this function see
wiring diagram
Wiring 370 Wiring diagram SCH09
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS. C52, Signal high speed
info:
Installing/ Tightening torque:
Adjusting: VCADS Pro:
55102-3 Parking brake system test
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Frame ground cable ≈0Ω
cable harness:
2–

Control cable ≈0Ω

1–C52

Component: 1–2 ≈ 35 Ω

Subsystem: 1–2 Uᵇᵃᵗ V

(active)
0V
(inactive)
 Service Information

Document Title: Function Group: Information Type: Date:

MA5205, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

MA5205, description and measuring

MA5205 Solenoid valve, electrical digging brake
Function Controls the electrical digging brake
Wiring 370 Wiring diagram SCH09
diagram 370 Wiring diagram SCH25
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info: C37, Signal digging brake

Installing/ Tightening torque:

Adjusting: VCADS Pro:
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Frame ground cable ≈0Ω
cable harness:
2–

Control cable ≈0Ω

1–C37

Component: 1–2 ≈ 30 Ω

Subsystem: 1–2 Uᵇᵃᵗ V

(active)
0V
(inative)
 Service Information

Document Title: Function Group: Information Type: Date:

MA9103, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

MA9103, description and measuring

Description

MA9103 Solenoid valve, X1, left

Function Controls X1, left
Reference 370 Wiring diagram SCH15
Miscellaneous Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable C28, X1 left
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter

Measuring

Measuring point Correct value Condition Test method

Frame ground cable ≈0Ω

2–

Control cable ≈0Ω

1–C28

1–2 ≈ 30 Ω

Verifying

Measuring point Correct value Condition Test method

Uᵇᵃᵗ V
C28– (active)
0V
(inactive)
 Service Information

Document Title: Function Group: Information Type: Date:

MA9104, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

MA9104, description and measuring

Description

MA9104 Solenoid valve, X1, right

Function Controls X1, right
Reference 370 Wiring diagram SCH15
Miscellaneous Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable C5, Signal X1 right
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter

Measuring

Measuring point Correct value Condition Test method

Frame ground cable ≈0Ω

2–

Control cable ≈0Ω

1–C5

1–2 ≈ 30 Ω

Verifying

Measuring point Correct value Condition Test method

Uᵇᵃᵗ V
C5– (active)
0V
(inactive)
 Service Information

Document Title: Function Group: Information Type: Date:

MA9107, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

MA9107, description and measuring

Description

MA9107 Solenoid valve, power boost

Function Controls the power boost mode
Reference 370 Wiring diagram SCH08
Miscellaneous VCADS Pro:
91406-3 Solenoid valve power boost, test
Tools: C55, Signal power boost
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter

Measuring

Measuring point Correct value Condition Test method

Frame ground cable ≈0Ω

2–

Control cable ≈0Ω

1–C55

1–2 ≈ 20 Ω

Verifying

Measuring point Correct value Condition Test method

Uᵇᵃᵗ V
C55 — (active)
0V
(inactive)
 Service Information

Document Title: Function Group: Information Type: Date:

MA9120, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

MA9120, description and measuring

MA9120 Solenoid valve, boom float
Function Controls the boom float
Wiring 370 Wiring diagram SCH17
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
C32, Signal boom float
info:
Installing/ Tightening torque:
Adjusting: VCADS Pro:
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Frame ground cable ≈0Ω
cable harness:
2–

Control cable ≈0Ω

1–C32

Component: 1–2 ≈ 30 Ω

Subsystem: 1–2 Uᵇᵃᵗ

(active)
0V
(inactive)
 Service Information

Document Title: Function Group: Information Type: Date:

MA9152, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

MA9152, description and measuring

MA9152 Solenoid valve, pivot axle lock
Function Controls the pivot axle lock
SW9103, Pump manual, is connected to this function see
wiring diagram
Wiring 370 Wiring diagram SCH09
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS. C6, Signal axle lock
info:
Installing/ Tightening torque:
Adjusting: VCADS Pro:
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Frame ground cable ≈0Ω
cable harness:
2–

Control cable ≈0Ω

1–C6

Component: 1–2 ≈ 30 Ω

Subsystem: 1–2 Uᵇᵃᵗ V

(active)
0V
(inactive)
 Service Information

Document Title: Function Group: Information Type: Date:

MA9164, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

MA9164, description and measuring

MA9164 Solenoid valve, adjustable boom, offset
Function Controls the adjustable boom for offset
Wiring 370 Wiring diagram SCH15
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
C54, Signal adjustable boom, offset
info:
Installing/ Tightening torque:
Adjusting: VCADS Pro:
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Frame ground cable ≈0Ω
cable harness:
2–

Control cable ≈0Ω

1–C54

Component: 1–2 ≈ 30 Ω

Subsystem: 1–2 Uᵇᵃᵗ V

(active)
0V
(inactive)
 Service Information

Document Title: Function Group: Information Type: Date:

MA9165, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

MA9165, description and measuring

MA9165 Solenoid valve, grab change over
Function Controls the grab change over
Wiring 370 Wiring diagram SCH21
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
C8, Signal grab change over
info:
Installing/ Tightening torque:
Adjusting: VCADS Pro:
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Frame ground cable ≈0Ω
cable harness:
2–

Control cable ≈0Ω

1–C8

Component: 1–2 ≈ 30 Ω

Subsystem: 1–2 Uᵇᵃᵗ V

(active)
0V
(inactive)
 Service Information

Document Title: Function Group: Information Type: Date:

MO3301, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

MO3301, description and measuring

Description

MO3301 Starter motor

Function Starts the engine
Reference 370 Wiring diagram SCH03
Miscellaneous Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
E-ECU 3020 999 0014 Adapter cable
V-ECU 3020 999 3893 Adapter cable
3020 11 666 140 Multimeter

Measuring

Measuring point Correct value Conditions Test method

Frame ground cable ≈0Ω

31–

Feed cable ≈ Uᵇᵃᵗ V

30 –

Verifying

Measuring point Correct value Conditions Test method

RE3301/87–B29 ≈ 10–15 Ω
 Service Information

Document Title: Function Group: Information Type: Date:

PPID1336, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

PPID1336, description and measuring

PPID1336 Pattern changer signal
Function Check the pattern changer signal
Wiring 370 Wiring diagram SCH04
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque:
Adjusting: VCADS Pro:
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 8883 0028 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Frame ground cable ≈0Ω
cable harness:
2–

Feed cable ≈ 24 V

1–

Signal cable ≈0Ω

3– I-ECU/B10
3– V-ECU/B22
Signal cable
3– I-ECU/B11
3– V-ECU/B60
Subsystem: X ≈ 24 V According to table.
 Service Information

Document Title: Function Group: Information Type: Date:

MA9109, description and Service Information 2014/7/4 0
measurement
Profile:
EXC, EW180C, EW160C, EW140C [GB]

MA9109, description and measurement

MA9109 Solenoid valve, quickfit
Function Controls the quickfit cylinder
Wiring 370 Wiring diagram SCH17
diagram 370 Wiring diagram SCH21
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque:
Adjusting: VCADS Pro:
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter
A11, Signal quickfit
Control unit/ Frame ground cable ≈0Ω
cable harness:
2–

Control cable ≈0Ω

1–A11 (SW9104 in position
on)
≈∞Ω
(SW9104 in position
off)
Component: 1–2 ≈ 30 Ω

Subsystem: 1–2 Uᵇᵃᵗ V

(active)
0V
(inactive)
 Service Information

Document Title: Function Group: Information Type: Date:

PWM2303, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

PWM2303, description and measuring

PWM2303 Proportional solenoid valve, common rail fuel control
unit
Function Controls the common rail fuel control unit
Wiring 370 Wiring diagram SCH03
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS. A12, High
info: A16, Low
Installing/ Tightening torque:
Adjusting: VCADS Pro:
23777-3 Fuel system, check
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 0014 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Control cable (+) ≈0Ω
cable harness: A12–1

Return cable (-)

A16–2
Component: 1–2 ≈ 4.0 Ω
 Service Information

Document Title: Function Group: Information Type: Date:

PWM9103, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW140C, EW160C, EW180C [GB]

PWM9103, description and measuring

Description

PWM9103 Proportional solenoid valve, cooling fan

Function Controls the cooling fan speed.
Reference 370 Wiring diagram SCH16
Miscellaneous Tightening torque:
Adjusting screw jam nut 10 Nm (7.4 lbf ft).
VCADS Pro:
91003-3 Cooling fan control, test
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter

Measuring

Measuring point Correct value Condition Test method

Control cable (+) ≈0Ω
C21–1
Return cable (-)
C22–2

1–2 ≈ 21– 32 Ω (20 °C)

≈∞Ω
1–

2–
C21–C22 ≈ 21– 32 Ω (20 °C)

Verifying

Measuring point Correct value Condition Test method

C21–C22 5V-20V
200Hz
 Service Information

Document Title: Function Group: Information Type: Date:

PWM4211, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

PWM4211, description and measuring

Description

PWM4211 Proportional solenoid valve for cruise control

Function Activates the cruise control.
Reference 370 Wiring diagram SCH09
Miscellaneous Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter

Measuring

Measuring point Correct value Condition Test method

Control cable (-) ≈0Ω
C20–2
Return Cable (+)
C19–1

1–2 ≈ 10 Ω

Verifying

Measuring point Correct value Condition Test method

C19–C20 5V-20V
200Hz
Activated function
 Service Information

Document Title: Function Group: Information Type: Date:

PWM6603, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

PWM6603, description and measuring

PWM6603 Proportional solenoid valve for comfort driving control
Function Controls the steering with the comfort driving control on the
control lever.
Wiring 370 Wiring diagram SCH09
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque:
Adjusting: VCADS Pro:
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Control cable(+) ≈0Ω
cable harness: C17–1[T1]
Return cable(-)
C18–2

Component: 1–2 ≈9Ω

[T1]When SW4207 is in on position

 Service Information

Document Title: Function Group: Information Type: Date:

PWM9101, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

PWM9101, description and measuring

Description

PWM9101 Proportional solenoid valve for pump flow control

Function Controls the pump flow.
Reference 370 Wiring diagram SCH08
Miscellaneous Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter

Measuring

Measuring point Correct value Condition Test method

Control cable(-) ≈0Ω
C66–2
Return cable(+)
C67–1

1–2 ≈ 30 Ω

Verifying

Measuring point Correct value Condition Test method

C66–C67 5V-20V
200Hz
 Service Information

Document Title: Function Group: Information Type: Date:

PWM9103, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW140C, EW160C, EW180C [GB]

PWM9103, description and measuring

Description

PWM9103 Proportional solenoid valve, cooling fan

Function Controls the cooling fan speed.
Reference 370 Wiring diagram SCH16
Miscellaneous Tightening torque:
Adjusting screw jam nut 10 Nm (7.4 lbf ft).
VCADS Pro:
91003-3 Cooling fan control, test
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter

Measuring

Measuring point Correct value Condition Test method

Control cable (+) ≈0Ω
C21–1
Return cable (-)
C22–2

1–2 ≈ 21– 32 Ω (20 °C)

≈∞Ω
1–

2–
C21–C22 ≈ 21– 32 Ω (20 °C)

Verifying

Measuring point Correct value Condition Test method

C21–C22 5V-20V
200Hz
 Service Information

Document Title: Function Group: Information Type: Date:

PWM9104, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

PWM9104, description and measuring

Description

PWM9104 Proportional solenoid valve for thermostatic

function
Function Controls the thermostatic function for X1.
Reference 370 Wiring diagram SCH15
Miscellaneous Tools:
3020 999 8699 Multi-pin breaker box C44, Control cable
3020 999 0062 Extension cable C44, Return cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter

Measuring

Measuring point Correct value Condition Test method

Control cable(+) ≈0Ω
C44–1
Return cable(-)
C45–2

1–2 ≈ 20 Ω
 Service Information

Document Title: Function Group: Information Type: Date:

PWM9105, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

PWM9105, description and measuring

Description

PWM9105 Proportional solenoid valve for X3 left

Function Controls X3 left function.
Reference 370 Wiring diagram SCH16
Miscellaneous Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable C41, Control cable
3020 999 3893 Adapter cable C46, Return cable
3020 11 666 140 Multimeter

Measuring

Measuring point Correct value Condition Test method

Control cable(-) ≈0Ω
C41–1
Return Cable(+)
C46–2

1–2 ≈ 20 Ω

Verifying

Measuring point Correct value Condition Test method

C41–C46 5V-20V
200Hz
Activated function
 Service Information

Document Title: Function Group: Information Type: Date:

PWM9106, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

PWM9106, description and measuring

Description

PWM9106 Proportional solenoid valve for X3 right

Function Controls X3 right function.
Reference 370 Wiring diagram SCH16
Miscellaneous Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable C43, Control cable
3020 999 3893 Adapter cable C42, Return cable
3020 11 666 140 Multimeter

Measuring

Measuring point Correct value Condition Test method

Control cable(-) ≈0Ω
C43–1
Return cable(+)
C42–2

1–2 5Ω

Verifying

Measuring point Correct value Condition Test method

C42–C431 5V–20V
200Hz
Activated function
 Service Information

Document Title: Function Group: Information Type: Date:

PWM9109, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

PWM9109, description and measuring

PWM9109 Proportional solenoid valve for X1 flow control
Function Controls X1 flow.
Wiring 370 Wiring diagram SCH15
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info: C69, Control cable
C68, Return cable
Installing/ Tightening torque:
Adjusting: VCADS Pro:
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Control cable(+) ≈0Ω
cable harness: C69–1
Return cable(-)
C68–2

Component: 1–2 ≈ 10 Ω
 Service Information

Document Title: Function Group: Information Type: Date:

PWM9129, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

PWM9129, description and measuring

PWM9129 Proportional solenoid valve for X1 pressure control
Function Controls X1 pressure.
Wiring 370 Wiring diagram SCH15
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque:
Adjusting: VCADS Pro:
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter
Control cable(+) ≈0Ω
C62–1
Return cable(-)
C63–2

Component: 1–2 ≈ 10 Ω
 Service Information

Document Title: Function Group: Information Type: Date:

RE2501, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

RE2501, description and measuring

RE2501 Relay, inlet air preheating
Function Activates the preheating coil.
Wiring 370 Wiring diagram SCH03
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque: M5, 3.5 Nm (2.6 lbf ft)
Adjusting: Tightening torque: M8, 9.5 Nm (7.0 lbf ft)
VCADS Pro:
1 , Control cable
Tools:
2 , Feed cable control
3020 999 8699 Multi-pin breaker box
3 , Feed cable preheating
3020 999 0062 Extension cable
4 , Preheating power
3020 999 0014 Adapter cable
B7 , Signal cable
3020 11 666 140 Multimeter
B25, Control cable
Control unit/ Feed cable ≈ Uᵇᵃᵗ V
cable harness:
3–

2–
Control cable ≈0Ω
1–B25
Signal cable
4–B7

Component: 1–2 ≈ 20 Ω
 Service Information

Document Title: Function Group: Information Type: Date:

SE2202, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SE2202, description and measuring

SE2202 Sensor, engine oil temperature
Function Measures the engine oil temperature.
Wiring 370 Wiring diagram SCH04
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque:
Adjusting: VCADS Pro:
28407-3 Sensor values, monitoring
91003-3 Cooling fan control, test
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 0014 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Frame ground cable ≈0Ω
cable harness:
4–

Signal cable ≈0Ω

A31–2

Component: ≈∞Ω
2–

4–
2–4 ≈resistance value according to table

Subsystem: A31–A11 ≈3V

(20°C / 68°F)
 Service Information

Document Title: Function Group: Information Type: Date:

SE2203, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SE2203, description and measuring

SE2203 Sensor, engine oil pressure
Function Measures the engine oil pressure.
Wiring 370 Wiring diagram SCH04
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque:
Adjusting: VCADS Pro:
28407-3 Sensor values, monitoring B11, Signal
Tools: B17, Feed 5V
3020 999 8699 Multi-pin breaker box B18, Ground
3020 999 0062 Extension cable
3020 999 0014 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Frame ground cable ≈0Ω
cable harness:
3–

Feed cable ≈5V

1–

Signal cable ≈0Ω

2–B11

Component: ≈∞Ω
1–

2–
Subsystem: 2–3 0.5 V
(engine off)

2–3 ≈ Voltage according to diagram

 Service Information

Document Title: Function Group: Information Type: Date:

SE2205, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SE2205, description and measuring

SE2205 Sensor, engine oil level
Function Measures the engine oil level.
Wiring 370 Wiring diagram SCH04
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque:
Adjusting: VCADS Pro:
28407-3 Sensor values, monitoring
Tools: B3, Low
3020 999 8699 Multi-pin breaker box B4, High
3020 999 0062 Extension cable
3020 999 0014 Adapter cable
3020 11 666 140 Multimeter
Control unit/ 1–B4 ≈0Ω
cable harness: 3–B3

Component: ≈∞0Ω
1–

3–
1–3 ≈ 11.5–13 Ω

Subsystem: B3–B4 ≈ pulse 3–4 V every

30 seconds[T1]

[T1]Measuring is easiet done with aid of a multimeter using the MAX function.
 Service Information

Document Title: Function Group: Information Type: Date:

SE2301, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SE2301, description and measuring

SE2301 Sensor, fuel pressure
Function Measures the fuel pressure.
Wiring 370 Wiring diagram SCH04
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque:
Adjusting: VCADS Pro:
28407-3 Sensor values, monitoring B16, Signal
23777-3 Fuel system, check B17, Feed 5V
Tools: B18, Ground
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 0014 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Frame ground cable ≈0Ω
cable harness:
4–

Feed cable ≈5V

1–

Signal cable ≈0Ω

2–B16

Component: ≈∞Ω
1–

2–
Subsystem: 2–4 ≈ voltage according to table
 Service Information

Document Title: Function Group: Information Type: Date:

SE2302, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SE2302, description and measuring

SE2302 Sensor, water in fuel
Function Checks if there is water in fuel.
Wiring 370 Wiring diagram SCH04
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque: B8 Signal
Adjusting: VCADS Pro: B10 Ground
28407-3 Sensor values, monitoring
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 0014 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Frame ground cable ≈0Ω
cable harness:
2–

Signal line ≈0Ω

3–B8

Component: ≈∞Ω
2–

3–
Subsystem: 2–3 ≈ 20 V
No water in fuel
≈ 0.5 V
Water in fuel
 Service Information

Document Title: Function Group: Information Type: Date:

SE2303, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SE2303, description and measuring

SE2303 Sensor, fuel level
Function Measures the fuel level.
Wiring 370 Wiring diagram SCH04
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque: A4, High
Adjusting: VCADS Pro: A12 Low
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 8883 0028 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Signal cabel ≈0Ω
cable harness: 1–A4 (high)
2–A12 (low)

Component: ≈∞Ω
1–

2–
Subsystem: 1–2 ≈ 82 Ω
Full
≈ 218 Ω
Half
≈ 358 Ω
Empty
 Service Information

Document Title: Function Group: Information Type: Date:

SE2309, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SE2309, description and measuring

SE2309 Sensor, common rail pressure
Function Measures the fuel pressure in the common rail.
Wiring 370 Wiring diagram SCH03
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque:
Adjusting: VCADS Pro:
28407-3 Sensor values, monitoring A7, Feed 5V
23777-3 Fuel system, check A11, Ground
Tools: A19 Signal
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 0014 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Frame ground cable ≈0Ω
cable harness:
1–

Feed cable ≈5V

3–

Signal cable ≈0Ω

2–A19

Component: ≈∞Ω
2–

3–
Subsystem: 2–1 ≈ 0.5 V
(engine off)
≈ 1.5–2.2 V[ 1] 
(engine on)

[ 1]Depending on rpm.
 Service Information

Document Title: Function Group: Information Type: Date:

SE2501, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SE2501, description and measuring

SE2501 Inlet air temperature sensor
Function Measures induction air temperature after air cleaner.
Combined sensor with SE2502
Wiring 370 Wiring diagram SCH03
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque:
Adjusting: VCADS Pro:
B18, frame ground
28407-3 Sensor values, monitoring
B31, signal ambiente temperature
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 0014 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Frame ground cable ≈0Ω
cable harness:
4–

Signal cable ≈5V

3–

Component: ≈∞Ω
4–

3–
Subsystem: 3–4 ≈ 2.6 V
(20 °C / 68 °F)

≈ 1.2 V
(50 °C / 122 °F)
 Service Information

Document Title: Function Group: Information Type: Date:

SE4217, description and Service Information 2014/7/4 0
measurement
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SE4217, description and measurement

SE4217 Sensor, travel pedal pressure
Function Measures the travel pedal pressure for travelling.
Wiring 370 Wiring diagram SCH08
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque:
Adjusting: VCADS Pro:
Tools: B6: Signal
3020 999 8699 Multi-pin breaker box B7: Feed 5V
3020 999 0062 Extension cable B54: Ground
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Frame ground cable ≈0Ω
cable harness:
2–

Feed cable ≈5V

1–

Signal cable ≈0Ω

3–B6

Component: ≈∞Ω
1–

3–
Subsystem: 2–3 0.5–4.5 V
 Service Information

Document Title: Function Group: Information Type: Date:

SE2502, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SE2502, description and measuring

SE2502 Sensor, air filter pressure
Function Detect clogged air filter.
Wiring 370 Wiring diagram SCH04
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque:
Adjusting: VCADS Pro:
28407-3 Sensor values, monitoring
A15 Ground
Tools:
A29 Signal
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 0014 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Frame ground cable ≈0Ω
cable harness:
2–

Signal cable ≈ 0.8 x Uᵇᵃᵗ

1–

Signal cable ≈0Ω

1–A29

Component: 1–2 ≈ 330 Ω

(not clogged)

≈ 2.2 kΩ
(clogged)
Subsystem: 1–2 ≈3V
(not clogged)

≈ 11 V
(clogged)
 Service Information

Document Title: Function Group: Information Type: Date:

SE2507, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SE2507, description and measuring

SE2507 Sensor, charge air temperature
Function Measures the charge air temperature.
Wiring 370 Wiring diagram SCH04
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque:
Adjusting: VCADS Pro:
28407-3 Sensor values, monitoring
Tools: A7, Feed 5V
3020 999 8699 Multi-pin breaker box A11, Ground
3020 999 0062 Extension cable A47, Signal
3020 999 0014 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Frame ground cable ≈0Ω
cable harness:
2–

Signal cable ≈0Ω

2–A47

Component: ≈∞Ω
1–

2–
1–2 ≈ resistance according to table
Subsystem: 1–2 ≈ 1.5 V
(20 °C / 68 °F)
 Service Information

Document Title: Function Group: Information Type: Date:

SE2508, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SE2508, description and measuring

SE2508 Sensor, charge air pressure
Function Measures the charge air pressure.
Wiring 370 Wiring diagram SCH04
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque:
Adjusting: VCADS Pro:
28407-3 Sensor values, monitoring
Tools: A7, Feed 5V
3020 999 8699 Multi-pin breaker box A11, Ground
3020 999 0062 Extension cable A22, Signal
3020 999 0014 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Frame ground cable ≈0Ω
cable harness:
1–

Feed cable ≈5V

3–

Signal cable ≈0Ω

4–A22

Component: ≈∞Ω
1–

3–
Subsystem: 4–1 ≈ voltage according to table
(≈ 1.1 V 0 metres above sea level)
 Service Information

Document Title: Function Group: Information Type: Date:

SE2510, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SE2510, description and measuring

SE2606 Sensor, Exhaust gas temperature
Function Measures the Exhaust gas temperature.
Wiring 370 Wiring diagram SCH27
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque: B18, Ground
Adjusting: VCADS Pro: B44, Signal

Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 0014 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Signal cablee ≈0Ω
cable harness: 2– B44

Feed cable ≈ 0V

1–

Component: ≈∞Ω
1–

2–
Subsystem: 18–44 ≈ 0.24 V
(20 °C / 68 °F)

≈ 0.34 V
( 150°C / 302 °F)
 Service Information

Document Title: Function Group: Information Type: Date:

SE2511, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SE2511, description and measuring

SE2511 Sensor, Particulate trap inlet pressure
Function Measures the diesel particulate trap inlet pressure.
Wiring 370 Wiring diagram SCH27
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque: 5 Nm (3.68ft)
Adjusting: VCADS Pro:
B12, Signal
Tools: B17, Feed 5V
3020 999 8699 Multi-pin breaker box B18, Ground
3020 999 0062 Extension cable
3020 999 0014 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Frame ground cable ≈0Ω
cable harness:
3–

Feed cable ≈5V

1–

Signal cable ≈0Ω

2–B12

Component: ≈∞Ω
1–

2–
Subsystem: 18–12 ≈ 0.5 V
(engine off)

18–12 ≈ Voltage according to diagram

 Service Information

Document Title: Function Group: Information Type: Date:

RE2501, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

RE2501, description and measuring

RE2501 Relay, inlet air preheating
Function Activates the preheating coil.
Wiring 370 Wiring diagram SCH03
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque: M5, 3.5 Nm (2.6 lbf ft)
Adjusting: Tightening torque: M8, 9.5 Nm (7.0 lbf ft)
VCADS Pro:
1 , Control cable
Tools:
2 , Feed cable control
3020 999 8699 Multi-pin breaker box
3 , Feed cable preheating
3020 999 0062 Extension cable
4 , Preheating power
3020 999 0014 Adapter cable
B7 , Signal cable
3020 11 666 140 Multimeter
B25, Control cable
Control unit/ Feed cable ≈ Uᵇᵃᵗ V
cable harness:
3–

2–
Control cable ≈0Ω
1–B25
Signal cable
4–B7

Component: 1–2 ≈ 20 Ω
 Service Information

Document Title: Function Group: Information Type: Date:

SE2603, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SE2603, description and measuring

SE2603 Sensor, engine coolant level
Function Measures the engine coolant level.
Wiring 370 Wiring diagram SCH04
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque: B10, Ground
Adjusting: VCADS Pro: B23, Signal
28407-3 Sensor values, monitoring
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 0014 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Frame ground cable ≈0Ω
cable harness:
2–

Signal cable ≈ 0.8 x Uᵇᵃᵗ

1–

Component: ≈∞Ω
1–

2–
1–2 ≈∞
(normal level)

≈0Ω
(low level)
Subsystem: 1–2 ≈ 0.8 x Uᵇᵃᵗ
(normal level)

< 6.5 V
(low level)
 Service Information

Document Title: Function Group: Information Type: Date:

SE2606, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SE2606, description and measuring

SE2606 Sensor, engine coolant temperature
Function Measures the engine coolant temperature.
Wiring 370 Wiring diagram SCH04
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque: B18, Ground
Adjusting: VCADS Pro: B27, Signal
28407-3 Sensor values, monitoring
91003-3 Cooling fan control, test
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 0014 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Frame ground cable ≈0Ω
cable harness: 2–B27

Feed cable ≈0V

1–

Component: ≈∞Ω
1–

2–
Subsystem: 1–2 ≈ 3.0 V
(20 °C / 68 °F)

≈ 0.6 V
( 85 °C / 185 °F)
 Service Information

Document Title: Function Group: Information Type: Date:

SE2701, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SE2701, description and measuring

Description

SE2701 Sensor, engine crankshaft speed

Function Measures the engine crankshaft speed
Reference 370 Wiring diagram SCH03
Miscellaneous VCADS Pro:
28407-3 Sensor values, monitoring
28420-3 Flywheel and camshaft signal, test
Tools: A37, A38 Signal line
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 0014 Adapter cable
3020 11 666 140 Multimeter

Measuring

Measuring point Correct value Conditions Test method

2 – A37 ≈0Ω
1 – A38 ≈0Ω

≈∞Ω
1–

2–
1–2 ≈ 775–945 Ω

Verifying

Measuring point Correct value Conditions Test method

A37 – A38 ≈ 775–945 Ω
 Service Information

Document Title: Function Group: Information Type: Date:

SE2703, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SE2703, description and measuring

Description

SE2703 Sensor, engine camshaft speed

Function Measures the engine camshaft speed
Reference 370 Wiring diagram SCH03
Miscellaneous VCADS Pro:
28407-3 Sensor values, monitoring
28420-3 Flywheel and camshaft signal, test
Tools: A45, A46 Signal line
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 0014 Adapter cable
3020 11 666 140 Multimeter

Measuring

Measuring point Correct value Conditions Test method

2 – A46 ≈0Ω
1 – A45 ≈0Ω

≈∞Ω
1–

2–
1–2 ≈ 3.5 KΩ

Verifying

Measuring point Correct value Conditions Test method

A45 – A46 ≈ 3.5 KΩ
 Service Information

Document Title: Function Group: Information Type: Date:

SE2707, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SE2707, description and measuring

Description

SE2707 Sensor, engine flywheel speed

Function Measures the engine flywheel speed.
Reference 370 Wiring diagram SCH08
Miscellaneous Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 3893 Adapter cable B48, Low
3020 11 666 140 Multimeter B51, High

Measuring

Measuring point Correct value Condition Test method

Signal cable (–) ≈0Ω
2–B48
Signal cable (+) ≈0Ω
1–B51

≈∞Ω
1–

2–

Verifying

Measuring point Correct value Condition Test method

1–2 ≈ 314 Ω
 Service Information

Document Title: Function Group: Information Type: Date:

SE4213, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SE4213, description and measuring

SE4213 Sensor, travel motor speed
Function Measures the travel motor speed.
Wiring 370 Wiring diagram SCH25
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS. B1, feed 24 V
info: B36, signal
Installing/ Tightening torque:
Adjusting: VCADS Pro:
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Frame ground cable ≈0Ω
cable harness:
1–

Feed cable ≈ 24 V

3–

Signal line ≈0Ω

2 – B36

Component: ≈∞Ω
1–

2–
2–3 ≈ 1.5KΩ
 Service Information

Document Title: Function Group: Information Type: Date:

SE4217, description and Service Information 2014/7/4 0
measurement
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SE4217, description and measurement

SE4217 Sensor, travel pedal pressure
Function Measures the travel pedal pressure for travelling.
Wiring 370 Wiring diagram SCH08
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque:
Adjusting: VCADS Pro:
Tools: B6: Signal
3020 999 8699 Multi-pin breaker box B7: Feed 5V
3020 999 0062 Extension cable B54: Ground
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Frame ground cable ≈0Ω
cable harness:
2–

Feed cable ≈5V

1–

Signal cable ≈0Ω

3–B6

Component: ≈∞Ω
1–

3–
Subsystem: 2–3 0.5–4.5 V
 Service Information

Document Title: Function Group: Information Type: Date:

SE4218, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SE4218, description and measuring

Description

SE4218 Switch, steering servo pressure

Function Measures the servo pressure for steering.
Reference 370 Wiring diagram SCH04
Miscellaneous Tools:
3020 999 8699 Multi-pin breaker box B67, Signal, steering pressure
3020 999 3893 Adapter cable
3020 999 0062 Extension cable
3020 11 666 140 Multimeter

Measuring

Measuring point Correct value Condition Test method

Frame ground cable ≈0Ω

2–

Feed cable ≈24 V

1–

≈∞Ω
1–

3–

Verifying

Measuring point Correct value Condition Test method

≈ 24V
B67– (Low or no pressure)
≈ 0V
(Pressure)
 Service Information

Document Title: Function Group: Information Type: Date:

SE5201, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SE5201, description and measuring

SE5201 Sensor, brake pressure
Function Measures the brake pressure.
Wiring 370 Wiring diagram SCH06
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque:
Adjusting: VCADS Pro:
52102-3 Brake pressure monitor, test B1, Feed 5V
Tools: B25, Signal
3020 999 8699 Multi-pin breaker box B49, Ground
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Frame ground cable ≈0Ω
cable harness:
2–

Feed cable ≈5V

1–

Signal cable ≈0Ω

3–B25

Component: ≈∞Ω
1–

3–
Subsystem: 3–2 ≈ 0.3–4.7V
 Service Information

Document Title: Function Group: Information Type: Date:

SE5205, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SE5205, description and measuring

Description

SE5205 Switch, brake failure pressure

Function Measures the brake pressure at the accumulator.
Reference 370 Wiring diagram SCH04
Miscellaneous VCADS Pro:
52102-3 Brake pressure monitor, test B21, Control cable
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter

Measuring

Measuring point Correct value Condition Test method

Frame ground cable ≈0Ω

2–

Control cable ≈ 24 V

1–

≈∞Ω
1–

3–

Verifying

Measuring point Correct value Condition Test method

≈ 24V
B21– (Low or no pressure)
≈ 0V
(Pressure)
 Service Information

Document Title: Function Group: Information Type: Date:

SE8701, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SE8701, description and measuring

SE8701 Sensor, air conditioner refrigerant high side pressure
Function Measures the air conditioner refrigerant pressure at the high
side.
Wiring 370 Wiring diagram SCH10
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info: ECC/8, Signal
Installing/ Tightening torque:
Adjusting: VCADS Pro:
87376-3 Sensor values, ECC, check
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Feed cable ≈ 24 V
cable harness:
1–

Signal line ≈0Ω

2–ECC/8

Subsystem: ECC/8–ECC/22 ≈ 24 V
(normal pressure)
≈0V
(high pressure)
 Service Information

Document Title: Function Group: Information Type: Date:

SE8702, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SE8702, description and measuring

SE8702 Sensor, evaporator temperature
Function Measures the evaporator temperature.
Wiring 370 Wiring diagram SCH10
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque: 48, Ground
Adjusting: VCADS Pro: 50, Signal
87376-3 Sensor values, ECC, check
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Frame ground cable ≈0Ω
cable harness:
2–

Signal ≈5V

1–

Signal line ≈0Ω

1–ECC/50

Component: 1–2 ≈ 3.2 KΩ (20°C)

Subsystem: ECC/50–ECC/48 ≈ 2.5 V (20°C)

 Service Information

Document Title: Function Group: Information Type: Date:

SE8705, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SE8705, description and measuring

SE8705 Sensor, ambient air temperature
Function Measures the ambient air temperature.
Wiring 370 Wiring diagram SCH10
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque: 48, Ground
Adjusting: VCADS Pro: 51, Signal
87376-3 Sensor values, ECC, check
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Frame ground cable ≈0Ω
cable harness:
2–

Signal cable ≈5V

1–

Signal line ≈0Ω

: 1–ECC/51

Component: 1–2 ≈ 3.2 kΩ (20°C)

Subsystem: ECC/51–ECC/48 ≈ 2.5 V (20°C)

 Service Information

Document Title: Function Group: Information Type: Date:

SE8706, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SE8706, description and measuring

SE8706 Sensor, cab interior air temperature
Function Measures the air temperature in the cab.
Wiring 370 Wiring diagram SCH10
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque: 26, Signal
Adjusting: VCADS Pro: 48, Ground
87376-3 Sensor values, ECC, check
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Frame ground cable ≈0Ω
cable harness:
2–

Signal cable ≈5V

1–

Signal cable ≈0Ω

1–ECC/26

Component: 1–2 ≈ 3.2 KΩ (20°C)

Subsystem: ECC/26–ECC/48 ≈ 2.5 V (20°C)

 Service Information

Document Title: Function Group: Information Type: Date:

SE9101, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SE9101, description and measuring

Description

SE9101 Sensor, auto idle pressure

Function Measures the hydraulic pressure for auto idling
function.
Reference 370 Wiring diagram SCH08
Miscellaneous Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter
B11: Feed line 5V
B26: Signal line
B49: Ground

Measuring

Measuring point Correct value Condition Test method

Frame ground cable ≈0Ω

2–

Feed cable ≈5V

1–

Signal cable ≈0Ω

3–B26

≈∞Ω
1–

3–

Verifying

Measuring point Correct value Condition Test method

B26–B49 ≈ 0.3–4.7V
 Service Information

Document Title: Function Group: Information Type: Date:

SE9105, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SE9105, description and measuring

SE9105 Sensor, hydraulic oil temperature
Function Measures the hydraulic oil temperature.
Wiring 370 Wiring diagram SCH16
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque: B13, Control cable
Adjusting: VCADS Pro:
91003-3 Cooling fan control, test
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Frame ground cable ≈0Ω
cable harness:
2–

Control cable ≈5V

1–

Control cable ≈0Ω

1–B13

Component: ≈∞Ω
1–

2–
1–2 ≈ 1.6 KΩ (20°C)

Subsystem: 1–2 ≈ 0.8–4.6 V

(≈ 4.2 V, 20°C)
 Service Information

Document Title: Function Group: Information Type: Date:

SE9106, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SE9106, description and measuring

Description

SE9106 Sensor, hydraulic oil filter pressure

Function Measures the hydraulic oil pressure to detect the filter
clogging.
Reference 370 Wiring diagram SCH04
Miscellaneous Tools: B65, Signal line
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter

Measuring

Measuring point Correct value Condition Test method

Frame ground cable ≈0Ω

2–

Control cable ≈ 24 V

1–

≈∞Ω
1–

2–

Verifying

Measuring point Correct value Condition Test method

≈ 24 V
B65– (open)
≈0V
(closed/clogged)
 Service Information

Document Title: Function Group: Information Type: Date:

SE9401, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SE9401, description and measuring

SE9401 Sensor, overload warning
Function Measures the pressure applied to the digging unit for
warning the overload.
Wiring 370 Wiring diagram SCH04
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque:
Adjusting: VCADS Pro: A5, Feed 5V
Tools: A13, Signal
3020 999 8699 Multi-pin breaker box A14, Ground
3020 999 0062 Extension cable
3020 8883 0028 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Frame ground cable ≈0Ω
cable harness:
2–

Feed cable ≈5V

1–

Signal cable ≈0Ω

3–A13

Component: ≈∞Ω
1–

3–
Subsystem: 3–2 0.5–4.5 V
 Service Information

Document Title: Function Group: Information Type: Date:

SID211, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SID211, description and measuring

E-ECU Power supply to sensors

Function Supplies 5V to the sensors
Reference 370 Wiring diagram SCH03
Miscellaneous Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 0014 Adapter cable
3020 11 666 140 Multimeter

B17: Feed line (+5V)

B18: Ground
Description and Carry out “Description and measuring” of connected sensors as follows.
measuring
 3021 SE2203, description and measuring
 3021 SE2301, description and measuring
 3021 SE2606, description and measuring
 3021 SE2501, description and measuring
 Service Information

Document Title: Function Group: Information Type: Date:

SID232, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SID232, description and measuring

Description

E-ECU Power supply to sensors

Function Supplies 5V to the sensors
Reference 370 Wiring diagram SCH03
370 Wiring diagram SCH04
Miscellaneous Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 0014 Adapter cable
3020 11 666 140 Multimeter A7: Feed line (+5V)
A11: Ground
Description and Carry out “Description and measuring” of connected sensors as follows.
measuring
 3021 SE2202, description and measuring
 3021 SE2309, description and measuring
 3021 SE2508, description and measuring
 3021 SE2507, description and measuring
 Service Information

Document Title: Function Group: Information Type: Date:

SW2701, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SW2701, description and measuring

SW2701 Switch, engine rpm control
Function Controls the engine rpm according to the work condition.
Wiring 370 Wiring diagram SCH03
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque:
Adjusting: VCADS Pro:
27502-2 Engine speed control, test B1, Feed 24V
Tools: B35, Signal
3020 999 8699 Multi-pin breaker box B58, Ground
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Frame ground cable ≈0Ω
cable harness:
3–

Feed cable ≈ 24 V

1–

Signal cable ≈0Ω

2–B35

Component: ≈∞Ω
1–

3–
Subsystem: B35–B58 Step 1
≈ 0.48V
Step 5
≈ 2:26 V
Step 9
≈ 4.05V
 Service Information

Document Title: Function Group: Information Type: Date:

SW3301, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW140C, EW160C, EW180C [GB]

SW3301, description and measuring

SW3301 Switch, engine start key
Function Activates the engine starter motor.
Wiring 370 Wiring diagram SCH01
diagram 370 Wiring diagram SCH03
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque:
Adjusting: VCADS Pro:
36401-3 Switches, test
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
V-ECU:3020 999 3893 Adapter cable
EDB:3020 999 0025 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Feed cable ≈ Uᵇᵃᵗ
cable harness:
30–

Signal line ≈0Ω

54–A15

Component: B+(30) – BR(15) / ACC(54) / C(50) R2 ≈

Resistance according to the below.
X=0Ω
–=∞Ω

Subsystem: ≈ Uᵇᵃᵗ (switch ON)

A15–
 Service Information

Document Title: Function Group: Information Type: Date:

SW3611, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SW3611, description and measuring

Description

SW3611 Switch, mode selection

Function Selects the machine's operation mode P, T, W or C.
Reference 370 Wiring diagram SCH09
Miscellaneous VCADS Pro:
55102-3 Parking brake system test
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
A1, Signal T-mode
3020 999 3893 Adapter cable
A9, Signal W-mode
3020 11 666 140 Multimeter
B47, Signal C-mode

Measuring

Measuring point Correct value Condition Test method

Feed cable ≈ 24 V

5–

6–
Signal cable ≈0Ω
2–A1
3–A9
4–B47

≈∞Ω
1–

3–

Verifying

Measuring point Correct value Condition Test method

A1 / A9 / B47– ≈ Voltage according

to table
1 ≈ 24 V
0≈0V
 Service Information

Document Title: Function Group: Information Type: Date:

SW4202, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SW4202, description and measuring

SW4202 Switch, travel speed selection
Function Selects the travel speed 1st, 2nd or 3rd.
Wiring 370 Wiring diagram SCH09
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque:
B17, Signal low speed
Adjusting: VCADS Pro:
B64, Signal high speed
36401-3 Switches, test
55102-3 Parking brake system test
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Feed cable ≈ 24 V
cable harness:
1–
|
7–
Signal cable ≈0Ω
3–B64
4–B17

Subsystem:
3/4– Voltage according to table
1 ≈ 24 V
0≈0V
Creep, Low, High speed
 Service Information

Document Title: Function Group: Information Type: Date:

SW4205, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SW4205, description and measuring

SW4205 Switch, travel direction selection
Function Selects the travel direction between forward and reverse.
Wiring 370 Wiring diagram SCH09
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info: B42, Signal reverse
B66, Signal forward
Installing/ Tightening torque:
Adjusting: VCADS Pro:
36003-3 Switches, control levers, test
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Feed cable ≈ 24 V
cable harness:
3–

Signal cable ≈0Ω

1–B66
2–B42

Subsystem:
1/2– Voltage according to table
1 ≈ 24 V
0≈0V
Neutral, Forward, Reverse
 Service Information

Document Title: Function Group: Information Type: Date:

SW9160, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SW9160, description and measuring

SW9160 Switch, quickfit confirm/buzzer stop
Function Confirm the selection of the quickfit function, and stop the
buzzer.
Wiring 370 Wiring diagram SCH17
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque:
Adjusting: VCADS Pro:
36401-3 Switches, test
Tools: B20, Signal comfirm
3020 999 8699 Multi-pin breaker box B43, Signal buzzer
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Frame ground cable ≈0Ω
cable harness:
2–

5–
Signal cable ≈0Ω
3–B43
(buzzer stop)
4–B20
(comfirm)
Subsystem:
3/4– Voltage according to table
1 ≈ 24 V
0≈0V
Quick fit switch positions:
Neutral[T1]
Buzzer stop
Comfirm

[T1]When switch is not in use

 Service Information

Document Title: Function Group: Information Type: Date:

SW9161, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SW9161, description and measuring

SW9161 Switch, X3 proportional input
Function Controls the X3 proportionally with the left hand control
lever.
Wiring 370 Wiring diagram SCH16
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque:
Adjusting: VCADS Pro:
36003-3 Switches, control levers, test
B10, Feed 12V
Tools:
B14, Ground
3020 999 8699 Multi-pin breaker box
B38, Signal
3020 999 0062 Extension cable
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Frame ground cable ≈0Ω
cable harness:
2–

Feed cable ≈ 12 V

1–

Signal cable ≈0Ω

3–B38

Component: ≈∞Ω
1–

3–
 Service Information

Document Title: Function Group: Information Type: Date:

SW9162, description and Service Information 2014/7/4 0
measuring
Profile:
EXC, EW180C, EW160C, EW140C [GB]

SW9162, description and measuring

SW9162 Switch, X1 proportional input
Function Controls X1 proportionally with the right hand control lever.
Wiring 370 Wiring diagram SCH15
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque:
Adjusting: VCADS Pro:
36003-3 Switches, control levers, test
Tools: B10, Feed 12V
3020 999 8699 Multi-pin breaker box B14, Ground
3020 999 0062 Extension cable
B39, Signal
3020 999 3893 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Frame ground cable ≈0Ω
cable harness:
2–

Feed cable ≈ 12 V

1–

Signal cable ≈0Ω

3–B39

Component: ≈∞Ω
1–

3–
 Service Information

Document Title: Function Group: Information Type: Date:

MID 128 SID 230, Service Information 2014/7/4 0
description and measuring
Profile:
EXC, EW140C, EW160C, EW180C [GB]

MID 128 SID 230, description and measuring

SW2704 Buffered IVS
Function Send a signal to E-ECU for limp home mode.
Wiring 370 Wiring diagram SCH02
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque:
Adjusting: VCADS Pro:
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
3020 999 0014 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Signal cable ≈0Ω
cable harness: SW2704/3–B15

Component: ≈∞Ω
1–

3–
Subsystem: B15 – B61 ≈ Uᵇᵃᵗ V
Activated
≈0V
Not activated
 Service Information

Document Title: Function Group: Information Type: Date:

MID 140 PPID 1144, Service Information 2014/7/4 0
description and measuring
Profile:
EXC, EW140C, EW160C, EW180C [GB]

MID 140 PPID 1144, description and measuring

PPID1144 V-ECU operating check clock
Function Checks the function of the operating check clock.
Wiring 370 Wiring diagram SCH02
diagram
Error code See section 3:4 Error codes or Diagnostics in PROSIS.
info:
Installing/ Tightening torque:
Adjusting: VCADS Pro:
Tools:
3020 999 8699 Multi-pin breaker box
3020 999 0062 Extension cable
I-ECU:3020 8883 0028 Adapter cable
V-ECU:3020 999 3893 Adapter cable
3020 11 666 140 Multimeter
Control unit/ Signal line ≈0Ω
cable harness: C60–A15
 Service Information

Document Title: Function Group: Information Type: Date:

E-ECU (MID128) Engine Service Information 2014/7/4 0
control unit, active
measuring conditions
Profile:
EXC, EW140C [GB]

E-ECU (MID128) Engine control unit, active measuring conditions

Figure 1
voltage measurement with multi-pin breaker box and adapter cable connected between cable harness and engine
control unit (E-ECU)

Conditions
1) Control unit connected

2) Multi-pin breaker box connected between control unit and cable harness
3) Inter-connecting cable connected to the other connector.
NOTE! NOTE!
For measuring voltage, the following applies: For measuring resistance, the following applies:

4a) Turn master switch to the ON position, 4b)Turn start switch to the OFF position,

turn start switch to the ON position and turn master switch to the OFF position and
measure the voltage with the multimeter. measure the resistance with the multimeter.

NOTE!
During all resistance measurements, the master switch must
be turned OFF.

5) Engine off

Abbreviation Explanation
U Direct voltage in volts (V)
Uᵇᵃᵗ Battery voltage
Uᵒ Voltage near to 0 volt or 0 volt
R Resistance in ohm (Ω)

E-ECU Active measuring

Pin Signal/component Measuring Correct value

points
EA1 – EA6 Not connected
EA7 Feed to sensor (5V) EA7 - EA57 U≈5V
EA8 – EA10 Not connected
EA11 Signal ground to sensor
EA12 PWM2303, actuator MPROP common rail, high
EA13 – EA14 Not connected
EA15 SE2502, ambient filter ground See EA29
EA16 PWM2303, actuator MPROP common rail, low
EA17 – EA18 Not connected
EA19 SE2309, rail pressure EA19 - EA11 U ≈ 0.5 V
EA20 – EA21 Not connected
EA22 SE2508, boost pressure signal EA22 - EA11 U ≈ 1.1 V (at 0 meter above see level)
EA23 – EA28 Not connected
EA29 SE2502, air cleaner indicator EA29 - EA15 U≈3V
EA30 Not connected
EA31 SE2202, oil temperature, signal EA31 - EA11 U ≈ 2.4 V (20°C / 68°F)
EA32 Not connected
EA33 J1708B EA33 - EA57 U ≈ < 4.0 V
EA34 J1708A EA34 - EA57 U ≈ > 1.0 V
EA35 – EA36 Not connected
EA37 SE2701, engine crank speed, high
EA38 SE2701, engine crank speed, low
EA39 Not connected
EA40 MA2302, injector cylinder 2, high
EA41 – EA43 Not connected
EA44 MA2303, injector cylinder 3, high
EA45 SE2703, engine camshaft speed, high
EA46 SE2703, engine camshaft speed, low
EA47 SE2507, boost temperature, signal EA47 - EA11 U ≈ 01.5 V (20°C / 68°F)
EA48 – EA51 Not connected
EA52 MA2304, injector cylinder 4, high
EA53 – EA55 Not connected
EA56 MA2301, injector cylinder 1, high
EA57 ECU ground
EA58 Not connected
EA59 MA2301 and MA2304, injector cylinder 1 and
4, low
EA60 MA2302 nad MA2303, injector cylinder 2 and
3, low
EA61 – EA62 Not connected
----- ---------------------------------------- --------------- -----------------------------------------
EB1 – EB2 Not connected
EB3 SE2205, engine oil level, low
EB4 SE2205, engine oil level, high
EB5 – EB6 Not connected
EB7 RE2501, preheating diagnostics coil EB7 - EB58 U ≈ 20 V (open)
U ≈ 0 V (closed)
EB8 SE2302, water in fuel, signal EB8 - EB10 U ≈ 20 V (open)
EB9 Not connected
EB10 Switch Ground
EB11 SE2203, engine oil pressure, signal EB11 - EB18 U ≈ 0.5 V (when engine is off)
EB12 – EB14 Not connected
EB15 SW2704, emergency switch (IVS)
EB16 SE2301, fuel pressure, signal EB16 - EB18 U ≈ 0.5 V (for stationary engine)
EB17 Feed to sensor EB17 - EB18 U≈5V
EB18 Signal ground to sensor
EB19 – EB22 Not connected
EB23 SE2603, coolant level, signal EB23 - EB10 U ≈ 20 V (open, normal)
U < 6.5 (closed, low level)
EB24 Not connected
EB25 RE2501, preheating relay (coil) EB25 - EB58 U ≈Uᵇᵃᵗ (inactive)
U ≈ 0 V (active)
EB26 Not connected
EB27 SE2606, coolant temperature, engine, signal EB27 - EB18 U ≈ 3.0 – 0.6 V (+20 °C to +85 °C / +68 °F
to +185 °F)
EB28 – EB29 Not connected
EB30 MA2504, solenoid valve for on/off EB30 – EB58 U ≈ Uᵇᵃᵗ (inactive)
U ≈ 0.5 (active)
EB31 SE2501, ambient air temperature EB31 - EB18 U ≈ 2.6 – 1.2 V (+20 °C to +50 °C / +68 °F
to +122 °F)
EB32 – EB50 Not connected
EB51 J1939_H EB51 - EB58 U≈2–5V
EB52 – EB54 Not connected
EB55 J1939_L EB55 - EB58 U≈0–3V
EB56 Not connected
EB57 Voltage feed (ECU supply) EB57 - EB58 U ≈ Uᵇᵃᵗ
EB58 ECU ground
EB59 ECU ground
EB60 Voltage feed (ECU supply) EB60 - EB58 U ≈ Uᵇᵃᵗ
EB61 ECU ground
EB62 Not connected
 Service Information

Document Title: Function Group: Information Type: Date:

E-ECU (MID128) Engine Service Information 2014/7/4 0
control unit, passive
measuring conditions
Profile:
EXC, EW140C [GB]

E-ECU (MID128) Engine control unit, passive measuring conditions

Figure 1
resistance measurement against cable harness, engine control unit (E-ECU) disconnected

Conditions
1) Control unit disconnected

2) Multi-pin breaker box connected against cable harness

NOTE! NOTE!
For measuring voltage, the following applies: For measuring resistance, the following applies:

3a) Turn master switch to the ON position, 3b)Turn start switch to the OFF position,

turn start switch to the ON position and turn master switch to the OFF position and

measure the voltage with the multimeter. measure the resistance with the multimeter.

NOTE!
 During all resistance measurements, the master switch must
be turned OFF.

4) Engine off

Abbreviation Explanation
U Direct voltage in volts (V)
Uᵇᵃᵗ Battery voltage
Uᵒ Voltage near to 0 volt or 0 volt
R Resistance in ohm (Ω)

E-ECU passive measuring

Pin Signal/component Measuring Correct value

points
EA1 – EA6 Not connected
EA7 Feed to sensor (5V)
EA8 – EA10 Not connected
EA11 Signal ground to sensor
EA12 PWM2303, actuator MPROP common rail, high EA12 - EA16 R ≈ 4.0 Ω
EA13 – EA14 Not connected
EA15 SE2502, ambient filter ground
EA16 PWM2303, actuator MPROP common rail; low See EA12
EA17 ~EA18 Not connected
EA19 SE2309, rail pressure
EA20 – EA21 Not connected
EA22 SE2508, boost pressure signal
EA23 – EA28 Not connected
EA29 SE2502, air cleaner indicator EA29 - EA15 R ≈ 330 Ω
EA30 Not connected
EA31 SE2202, oil temperature, signal EA31 - EA11 R ≈ 1.1 KΩ (20 °C / 68 °F)
EA32 Not connected
EA33 J1708B
EA34 J1708A
EA35 – EA36 Not connected
EA37 SE2701, engine crank speed, high EA37 - EA38 R ≈ 775 – 945 KΩ
EA38 SE2701, engine crank speed, low) See EA37
EA39 Not connected
EA40 MA2302, injector cylinder 2, high EA40 - EA60 R ≈ 1.0 – 1.8 Ω
EA41 – EA43 Not connected
EA44 MA2303, injector cylinder 3, high EA44 - EA60 R ≈ 1.0 – 1.8 Ω
EA45 SE2703, engine camshaft speed, high EA45 - EA46 R ≈ 3.5 KΩ
EA46 SE2703, engine camshaft speed, minus (-) See EA45
EA47 SE2507, boost temperature, signal EA47 - EA11 R ≈ 2.5 KΩ (20°C / 68°F)
EA48 – EA51 Not connected
EA52 MA2304, injector cylinder 4, high EA52 - EA59 R ≈ 1.0 – 1.8 Ω
EA53 – EA55 Not connected
EA56 MA2301, injector cylinder 1, high EA56 - EA59 R ≈ 1.0 – 1.8 Ω
EA57 ECU ground
EA58 Not connected
EA59 MA2301 and MA2304, injector cylinder 1 and See MA2301,
4, low MA2304
EA60 MA2302 and MA2303, injector cylinder 2 nad See MA2302,
3, low MA2303
EA61 – EA62 Not connected
----- ---------------------------------------- --------------- -----------------------------------------
EB1 Not connected
EB2
EB3 SE2205, engine oil level, low EB3 - EB4 R ≈ 11.5 – 13.0 Ω
EB4 SE2205, engine oil level, high See EB3
EB5 – EB6 Not connected
EB7 RE2501, preheating diagnostics coil
EB8 SE2302, water in fuel, signal
EB9 Not connected
EB10 Switch Ground
EB11 SE2203, engine oil pressure, signal
EB12 – EB14 Not connected
EB15 SW2704, emergency switch (IVS)
EB16 SE2301, fuel pressure, signal
EB17 Feed to sensor
EB18 Signal ground to sensor
EB19 – EB22 Not connected
EB23 SE2603, coolant level, signal EB23 - EB10 R ≈ ∞Ω (open) normal level
R ≈ 0 Ω (closed) low level
EB24 Not connected
EB25 RE2501, preheating relay (coil) EB25 - EB60 R ≈ 20 Ω
EB26 Not connected
EB27 SE2606, coolant temperature, engine, signal EB27 - EB18 R ≈ 1. 7 KΩ
EB28 – EB29 Not connected
EB30 MA2504, solenoid valve for on/off EB30 - EB57 R ≈ 35 Ω
EB31 SE2501, ambient air temperature EB31 - EB18 R ≈ 6.2 - 1.7 KΩ (+20 °C to +50 °C / +68 °F
to +122 °F)
EB32 – EB50 Not connected
EB51 J1939–H
EB52 – EB54 Not connected
EB55 J1939–L
EB56 Not connected
EB57 Voltage feed (ECU supply)
EB58 ECU ground EB58 – EB61 U≈0Ω
EB59 ECU ground EB59 – EB61 U≈0Ω
EB60 Voltage feed (ECU supply)
EB61 ECU ground EB61 – U≈0Ω

EB62 Not connected

 Service Information

Document Title: Function Group: Information Type: Date:

I-ECU (MID140) Instrument Service Information 2014/7/4 0
control unit, active
measuring conditions
Profile:
EXC, EW160C, EW180C, EW140C [GB]

I-ECU (MID140) Instrument control unit, active measuring conditions

Conditions
1) Control unit connected
2) Multi-pin breaker box connected between control unit and cable harness.
3) Inter-connecting cable connected to the other connector.
NOTE! NOTE!
For measuring voltage, the following applies: For measuring resistance, the following applies:

4a) Turn master switch to the ON position, 4b)Turn start switch to the OFF position,

turn start switch to the ON position and turn master switch to the OFF position and

measure the voltage with the multimeter. measure the resistance with the multimeter.

NOTE!
During all resistance measurements, the master switch must
be turned OFF.

5) Engine off

Abbreviation Explanation
U Direct voltage in volts (V)
Uᵇᵃᵗ Battery voltage
Uᵒ Voltage near to 0 volt or 0 volt
R Resistance in ohm (Ω)

I-ECU Active measuring

Pin Signal/component Measuring Correct value

points
JA1 SW3301 (15) power supply JA1 — JA18 U ≈ Uᵇᵃᵗ switch activated
JA2 SW3501 llumination JA2 — JA18 U ≈ Uᵇᵃᵗ switch activated
JA3 CU9901 Automatic greasing JA3 — JA18 0V normal level
24V low level or malfunction
JA4 SE2303 Fuel level sensor (+) JA4 - JA12 Signal voltage related to the fuel level.
see passive measuring
JA5 5 V (Sensor power) JA5 - JA18 U ≈ 5V
JA6 J1939_H (CAN1) JA6 - JA18 U≈2–5V
JA7 J1587_A JA7 - JA18 U ≈ >1.0 V
JA8 Battery ground JA8 — JA9 U ≈ Uᵇᵃᵗ
JA9 +24 V (Battery) JA9 - JA8 U ≈ Uᵇᵃᵗ
JA10 AL3201 Alternator JA10 - JA18 U ≈ 1.25V if the engine are not running
 (U ≈ Uᵇᵃᵗif the engin is runing)
JA11 MA9109 Quickfit solenoid JA11 - JA18 U ≈ 9.1 V function not activated
U ≈ U ᵒ function activated
JA12 SE2303 Fuel level sensor (−) JA12 - JA4 Signal voltage related to the fuel level.
see passive measuring
JA13 SE9401 Overload pressure sensor, input JA13 - JA14 Signal voltage related to the pressure level.
see passive measuring
JA14 Sensor ground JA14 - JA9 U ≈ Uᵇᵃᵗ
JA15 V-ECU status A15 - JA18 U ≈ 15 V
JA16 J1939_L (CAN1) JA16 - JA18 U ≈ 0 – 3V
JA17 J1587_B JA17 - JA18 U ≈ <4 V
JA18 Battery ground JA18 - JA9 U ≈ Uᵇᵃᵗ
----- ---------------------------------------- --------------- -----------------------------------------
JB1 Rear view video signal 1 JB1 - JA18 depend on the installed equipment
JB2 SW3502 High beam JB2 - JA18 U ≈ U ᵒ Switch off
U ≈ UᵇᵃᵗSwitch on
JB3 SW3605 Turn signal, Left-hand JB3 - JA18 U ≈ U ᵒ Switch off
U ≈ alternated signalUᵇᵃᵗSwitch on
JB4 SW3605 Turn signal, right-hand JB4 - JA18 U ≈ U ᵒ Switch off
U ≈ alternated signalUᵇᵃᵗSwitch on
JB5 SW9103 Pump manual switch JB5 - JA18 U ≈ U ᵒ Switch off
U ≈ UᵇᵃᵗSwitch on
JB6 Rear view video power JB6 - JA18 depend on the installed equipment
JB7 Rear view video signal 1 ground JB7 - JA18 depend on the installed equipment
JB8 Rear view video signal 2 JB8 - JA18 depend on the installed equipment
JB9 Rear view video signal 2 ground JB9 - JA18 depend on the installed equipment
JB10 SE9141 Pattern change ISO type joystick JB10 - JA18 U ≈ UᵇᵃᵗSwitch in ISO standard
JB11 SE9142 Pattern change SAE type joystick JB10 - JA18 U ≈ UᵇᵃᵗSwitch in SAE standard
JB12 Not connected
JB13 Signal ground JB13 - JA9 U ≈ Uᵇᵃᵗ
JB14 Sensor ground JB14 - JA9 U ≈ Uᵇᵃᵗ
 Service Information

Document Title: Function Group: Information Type: Date:

I-ECU (MID140) Instrument Service Information 2014/7/4 0
control unit, passive
measuring conditions
Profile:
EXC, EW160C, EW180C, EW140C [GB]

I-ECU (MID140) Instrument control unit, passive measuring

conditions
Conditions
1) Control unit disconnected
2) Multi-pin breaker box connected against cable harness.
NOTE! NOTE!
For measuring voltage, the following applies: For measuring resistance, the following applies:

3a) Turn master switch to the ON position, 3b)Turn start switch to the OFF position,

turn start switch to the ON position and turn master switch to the OFF position and

measure the voltage with the multimeter. measure the resistance with the multimeter.

NOTE!
During all resistance measurements, the master switch must
be turned OFF.

4) Engine off

Abbreviation Explanation
U Direct voltage in volts (V)
Uᵇᵃᵗ Battery voltage
Uᵒ Voltage near to 0 volt or 0 volt
R Resistance in ohm (Ω)

I-ECU Active measuring

Pin Signal/component Measuring Correct value

points
JA1 SW3301 power supply +24 (15)
JA2 SW3501 llumination
JA3 CU9901 Automatic greasing
JA4 SE2303 Fuel level sensor (+) JA4 - JA12 R ≈ 82Ω full
R ≈ 218Ω half
R ≈ 358Ω empty
JA5 5 V (Sensor power)
JA6 J1939_H (CAN1)
JA7 J1587_A
JA8 Battery ground
JA9 +24 V (Battery)
JA10 AL3201 Alternator
JA11 MA9109 Quickfit solenoid
JA12 SE2303 Fuel level sensor (−) JA12 - JA4 see JA4
JA13 SE9401 Overload pressure sensor, input JA13 - JA14 R ≈ 14.1kΩ
JA14 Sensor ground JA13 - JA14 see JA13
JA15 V-ECU status
JA16 J1939_L (CAN1)
JA17 J1587_B
JA18 Battery ground
----- ---------------------------------------- --------------- -----------------------------------------
JB1 Rear view video signal 1
JB2 High beam
JB3 Turn signal, Left-hand
JB4 Turn signal, right-hand
JB5 Pump manual switch
JB6 Rear view video power
JB7 Rear view video signal 1 ground
JB8 Rear view video signal 2
JB9 Rear view video signal 2 ground
JB10 Pattern change switch 1
JB11 Pattern change switch 2
JB12 Not connected
JB13 Signal ground JB13 - JB14 R≈0Ω
JB14 Sensor ground JB14 - JB13 R≈0Ω
 Service Information

Document Title: Function Group: Information Type: Date:

W-ECU (MID142) Wireless Service Information 2014/7/4 0
control unit, active
measuring conditions
Profile:
EXC, EW140C, EW160C, EW180C [GB]

W-ECU (MID142) Wireless control unit, active measuring conditions

Conditions
1) Control unit connected
NOTE! NOTE!
For measuring voltage, the following applies: For measuring resistance, the following applies:

2a) Turn the battery disconnect switch to the ON position, 2b)Turn start switch to the OFF position, turn the battery
turn start switch to the ON position and measure the disconnect switch to the OFF position and measure the
voltage with the multimeter. resistance with the multimeter.
NOTE!
During all resistance measurements, the battery disconnect
switch must be turned OFF.

3) Engine off

Abbreviation Explanation
U Direct voltage in volts (V)
Uᵇᵃᵗ Battery voltage
Uᵒ Voltage near to 0 volt or 0 volt
R Resistance in ohm (Ω)

W–ECU Active measuring

Pin Signal/component Measuring Correct value

points
1–6 Not connected
7 Battery plus (+) 7 – 12 U ≈ Uᵇᵃᵗ
8 – 10 Not connected
11 J1587A 11 – 12 U > 1.0 V
12 Ground
13 Not connected
14 Switch key plus (+) 14 – 12 U ≈ Uᵇᵃᵗ when the key position is on.
15 – 16 Not connected
17 J1587B 17 – 12 U < 4.0 V
18 Not connected
 Service Information

Document Title: Function Group: Information Type: Date:

W-ECU (MID142) Wireless Service Information 2014/7/4 0
control unit, passive
measuring conditions
Profile:
EXC, EW160C, EW180C, EW140C [GB]

W-ECU (MID142) Wireless control unit, passive measuring conditions

Conditions
1) Control unit disconnected
NOTE! NOTE!
For measuring voltage, the following applies: For measuring resistance, the following applies:

2a) Turn the battery disconnect switch to the ON position, 2b)Turn start switch to the OFF position, turn the battery
turn start switch to the ON position and measure the disconnect switch to the OFF position and measure the
voltage with the multimeter. resistance with the multimeter.
NOTE!
During all resistance measurements, the battery disconnect
switch must be turned OFF.

3) Engine off

Abbreviation Explanation
U Direct voltage in volts (V)
Uᵇᵃᵗ Battery voltage
Uᵒ Voltage near to 0 volt or 0 volt
R Resistance in ohm (Ω)

W–ECU Passive measuring

Pin Signal/component Measuring Correct value

points
1–6 Not connected
7 Battery plus (+)
8 – 10 Not connected
11 J1587A
12 Ground R≈0Ω
12 –
13 Not connected
14 Switch key plus (+)
15 – 16 Not connected
17 J1587B
18 Not connected
 Service Information

Document Title: Function Group: Information Type: Date:

Care Track can not Service Information 2014/7/4 0
communicate with the
machine
Profile:
EXC, EW180C, EW160C, EW140C [GB]

Care Track can not communicate with the machine

Care Track problems
Tools:
3020 11 666 140 Multimeter
VCADS Pro, Tools
Information:
3002 Electronic control system, description
3002 Communication with data buses
3002 CareTrack system, description
3002 Wireless control unit W-ECU, specification

Fault tracing order Problem Check measuring

Step 1. Error code Have a look in the error code descriptions for the MID142
error code
Step 2. Physical connection Follow the active and passive measuring
3021 W-ECU (MID142) Wireless control unit, active
measuring conditions
3021 W-ECU (MID142) Wireless control unit, passive
measuring conditions
370 Wiring diagram SCH24
3021 SAE J1708/1587 information link, description and
measuring
Step 3. Component check (W-ECU) VCADS Pro test
39797-3 Care Track status, check

General information
3020 Troubleshooting, general
302 Troubleshooting strategy
3020 Troubleshooting tools
3020 VCADS Pro service tool
3020 Electrical cables and connectors, checking
3020 Measuring, general
 Service Information

Document Title: Function Group: Information Type: Date:

ECC (MID146) Electronic Service Information 2014/7/4 0
climate control unit, active
measuring conditions
Profile:
EXC, EW140C, EW160C, EW180C [GB]

ECC (MID146) Electronic climate control unit, active measuring

conditions

Figure 1
voltage meassurment with multi-pin breaker box and adapter cable connected between cable harness and electrical
climate control unit (ECC)

Conditions
1) Control unit connected
2) Multi-pin breaker box connected between control unit and cable harness.
3) Inter-connecting cable connected to the other connector.
NOTE! NOTE!
For measuring voltage, the following applies: For measuring resistance, the following applies:

4a) Turn the battery disconnect switch to the ON position, 4b)Turn start switch to the OFF position,

turn start switch to the ON position and turn the battery disconnect switch to the OFF position and

measure the voltage with the multimeter. measure the resistance with the multimeter.

NOTE!
During all resistance measurements, the battery disconnect
switch must be turned OFF.

5) Engine off

Abbreviation Explanation
U Direct voltage in volts (V)
Uᵇᵃᵗ Battery voltage
Uᵒ Voltage near to 0 volt or 0 volt
R Resistance in ohm (Ω)
ECC Active measuring

Pin Signal/component Measuring Correct value

points
1~7 Not connected
8 SE8701, refrigerant pressure switch, normally 8 – 70 U ≈ Uᵇᵃᵗ
closed
9 Not connected
10 J1708A 10 – 70 U ≈ > 1.0 V
11 J1708B 11 – 70 U ≈ < 4.0 V
12 Foot actuator open, left-hand 12 – 70 U ≈ 20 V (active)
13 Foot actuator close, left-hand 13 - 70 U ≈ 20 V (active)
14 Face actuator close 14 – 70 U ≈ 20 V (active)
15 Face actuator open 15 - 70 U ≈ 20 V (active)
16 Foot actuator close, right-hand 15 - 70 U ≈ 20 V (active)
17 Foot actuator open, right-hand 17 – 70 U ≈ 20 V (active)
18 Not connected
19 SW3301, 54(ACC) Ignition switch 19 - 70 U ≈ Uᵇᵃᵗ
20 Not connected
21 HVAC relay 21 - 70 U ≈ 24 V
22 Ground to actuator
23 Compressor clutch 23 - 70 U ≈ Uᵇᵃᵗ (not active)
24 ~ 25 Not connected
26 SE8706 Cab temperature sensor
27 Air mix actuator feedback (3) 27 - 48 U ≈ 0.2 – 2.5 V
28 ~ 33 Not connected
34 CAN_L 34 - 70 U≈0–3V
35 ~ 41 Not connected
42 Power from RE8701 42 - 70 U ≈ Uᵇᵃᵗ
43 ~ 44 Not connected
45 Air mix actuator (1) 45 – 70 Max cool ≈ 0 V
Max heat ≈ 24 V
U ≈ Uᵇᵃᵗ (max varm)
U ≈ 0 V (max cool)
46 Blower 46 - 70 U ≈ Uᵇᵃᵗ (off)
(Max speed ≈ 0.2 V)
(Min speed ≈ 10.2 V)
47 Not connected
48 Ground_analogue
49 Not connected
50 SE8702, evaporator temperature sensor
51 SE8705, ambient / outdoor temperature
sensor
52 ~ 53 Not connected
54 Diesel heater signal 54 – 70 U ≈ Uᵇᵃᵗ (active)
55 ~ 57 Not connected
58 CAN_H 58 - 70 U≈2–5V
59 Not connected
60 Air recirculation actuator 60 — 70 U ≈ Uᵇᵃᵗ (active)
61 ~ 62 Not connected
63 Fresh air actuator 63 - 70 U ≈ 20 V (active)
64 ~ 65 Not connected
66 Power from RE8701 66 - 70 U ≈ Uᵇᵃᵗ
67 24 V to actuator 67 - 70 U ≈ 24 V
68 Air mix actuator (2) 68 - 70 U ≈ Uᵇᵃᵗ (max cool)
U ≈ 0 V (max varm)
69 Ground
70 Ground
 Service Information

Document Title: Function Group: Information Type: Date:

ECC (MID146) Electronic Service Information 2014/7/4 0
climate control unit,
passive measuring
conditions
Profile:
EXC, EW160C, EW180C, EW140C [GB]

ECC (MID146) Electronic climate control unit, passive measuring

conditions

Figure 1
resistance measurement against cable harness, electronic climate control unit (ECC) disconnected

Conditions
1) Control unit disconnected
2) Multi-pin breaker box connected against cable harness
NOTE! NOTE!
For measuring voltage, the following applies: For measuring resistance, the following applies:

3a) Turn the battery disconnect switch to the ON position, 3b)Turn start switch to the OFF position,

turn start switch to the ON position and turn the battery disconnect switch to the OFF position and

measure the voltage with the multimeter. measure the resistance with the multimeter.

NOTE!
During all resistance measurements, the battery disconnect
switch must be turned OFF.

4) Engine off

Abbreviation Explanation
U Direct voltage in volts (V)
Uᵇᵃᵗ Battery voltage
Uᵒ Voltage near to 0 volt or 0 volt
R Resista 357.8 nce in ohm (Ω)

ECC Passive measuring

Pin Signal/component Measuring Correct value
points
1~7 Not connected
8 SE8701, pressure switch, normally closed
9 Not connected
10 J1708A
11 J1708B
12 Foot actuator open, left-hand
13 Foot actuator close, left-hand
14 Face actuator open
15 Face actuator close
16 Foot actuator open, right-hand
17 Foot actuator close, right-hand
18 Not connected
19 SW3301, 54(ACC) Ignition key
20 Not connected
21 HVAC relay 21 - 70 R ≈ 220 Ω
22 Ground to actuator
23 Compressor clutch
24 ~ 25 Not connected
26 SE8706, Cab temperature sensor 26 - 48 R ≈ 0.6 ~ 44 KΩ (3 KΩ 20°C/68°F)
27 Mix actuator feedback (3)
28 ~ 33 Not connected
34 CAN_L
35 ~ 41 Not connected
42 Battery
43 ~ 44 Not connected
45 Mix actuator (1)
46 Blower 46 - 42 R ≈ 1.7 Ω
47 Not connected
48 Ground_analogue
49 Not connected
50 SE8702, evaporator temperature sensor 50 - 48 R ≈ 1.3 ~ 8 KΩ (3 KΩ 20°C/68°F)
51 SE8705, Ambient / outdoor temperature 51 - 48 R ≈ 0.3 ~ 44 KΩ (3 KΩ 20°C/68°F)
sensor
52 ~ 53 Not connected
54 Diesel heater signal 54 - 70 R ≈ 12 KΩ (not active)
55 ~ 57 Not connected
58 CAN_H
59 Not connected
60 Recirculation actuator
61 ~ 62 Not connected
63 Fresh actuator
64 ~ 65 Not connected
66 Battery
67 24 V to actuator
68 Mix actuator (2)
69 Ground 69 – 70 R≈0Ω
70 Ground R≈0Ω
70 –
 Service Information

Document Title: Function Group: Information Type: Date:

V-ECU (MID187) Vehicle Service Information 2014/7/4 0
control unit, active
measuring conditions
Profile:
EXC, EW160C, EW180C, EW140C [GB]

V-ECU (MID187) Vehicle control unit, active measuring conditions

Figure 1
voltage measurement with multi-pin breaker box and adapter cable connected between cable harness and vehicle
control unit (V-ECU)

Conditions
1) Control unit connected

2) Multi-pin breaker box connected between control unit and cable harness
3) Inter-connecting cable connected to the other connector.
NOTE! NOTE!
For measuring voltage, the following applies: For measuring resistance, the following applies:

4a) Turn master switch to the ON position, 4b)Turn start switch to the OFF position,

turn start switch to the ON position and turn master switch to the OFF position and

measure the voltage with the multimeter. measure the resistance with the multimeter.

NOTE!
During all resistance measurements, the master switch must
be turned OFF.

5) Engine off

Abbreviation Explanation
U Direct voltage in volts (V)
Uᵇᵃᵗ Battery voltage
Uᵒ Voltage near to 0 volt or 0 volt
R Resistance in ohm (Ω)
Depending on which options that are installed on the machine, some of the functions are not available. See machine
card for valid configuration.
V-ECU active measuring, connector (JA)

Pin No. Signal/component Measuring points Correct value

A1 SW3611, Mode selection switch, (T-mode) A1 – B70 U ≈ Uᵇᵃᵗ (switch on)
A2 SW9405, X3 left-hand switch A2 – B70 U ≈ Uᵇᵃᵗ (switch on)
A3 SW9163, X1 left-hand switch A3 – B70 U ≈ Uᵇᵃᵗ (switch on)
A4 SW9108, Boost/hammer switch A4 – B70 U ≈ Uᵇᵃᵗ (switch on)
A5 SW9165, Grab changeover switch A5 – B70 U ≈ Uᵇᵃᵗ (switch on)
A6 SW4204, Cruise control switch A6 – JB70 U ≈ Uᵇᵃᵗ (switch on)
A7 RE3301 Engine start signal A7 – B70 U ≈ 24 V (when cranking
engine)
A8 VECU power +24 V (thru SW9103) A8 – B70 U ≈ Uᵇᵃᵗ (switch on)
A9 SW3611 Mode selection switch, (W-mode) A9 – B70 U ≈ Uᵇᵃᵗ (switch on)
A10 SW9406, X3 right-hand switch A10 – B70 U ≈ Uᵇᵃᵗ (switch on)
A11 SW9164 X1 right-hand switch A11 – B70 U ≈ Uᵇᵃᵗ (switch on)
A12 SW9158, Float position switch A12 – B70 U ≈ Uᵇᵃᵗ (switch on)
A13 SE4902 ; SE9116 Position sensor extended axel log A13 – B70 U ≈ Uᵇᵃᵗ (if boom out and upper
frame ≈ straight)
A14 SW9104, Quickfit switch A14 – B70 U ≈ Uᵇᵃᵗ (switch on)
A15 SW3301, Engine start key 54(ACC) A15 – B70 U ≈Uᵇᵃᵗ
A16 VECU power +24 V (thru SW9103) A16 – B70 U ≈ Uᵇᵃᵗ (switch on)

V-ECU active measuring, connector (JB)

Pin No. Signal/component Measuring points Correct value

B1 SW2701; SE4213 Power +24 V B1 – B58 U ≈ 24 V
B2 – B5 Notconnected
B6 SE4217, Travel pedal sensor B6 – B54 U ≈ 0.5–4.5 V (0.5 V no
pressure)
B7 SE 4217; SE9126 Power +5 V B7 – B54 U≈5V
B8 – B9 Notconnected
B10 SW9161; SW9162 Power +12 V B10 – B14 U ≈ 12 V
B11 SE5201; SE9101 Power + 5 V B11–B49 U≈5V
B12 Notconnected
B13 SE9105, Hydraulic oil tank temperature. B13 – B40 U ≈ 0.8–4.6 V (4.2 V 20°C (68°
F))
B14 SW9161; SW9162 Ground B10 – B14 U ≈ 12 V
B15 – B16 Not connected
B17 SW4202, Travel speed selection, 3rd speed B17–B70 U ≈ 24V (switch on 3rd speed)
B18 SW9403, Rototilt selection switch B18 – B70 U ≈ Uᵇᵃᵗ (switch on)
B19 Not connected
B20 SW9160, Quickfit buzzer stop/confirmation switch B20 – B70 U ≈ 24 V (confirm off)
B21 SE5205, Brake pressure monitor B21 – B70 U ≈ 24 V (low pressure)
U ≈ 0 V (normal pressure)
B22 SE9141, Pattern change switch 1 B22 – B70 U ≈ 24 V (switch on)
B23 SW9107, Hammer/shear selection selection switch B23 – B70 U ≈ Uᵇᵃᵗ (switch on)
(Only for console switch.)
B24 Not connected
B25 SE5201, Brake pressure sensor B25 – B49 U ≈ 0.5–4.5 V (0.5 V no
pressure)
B26 SE9101, Automatic idle pressure sensor B26 – B49 U ≈ 0.5–4.5 V (0.5 V no
pressure)
B27 SE6401, Swing angle sensor (EW230C) B27 – B70 U ≈ 0.5–4.5 V (2.5 V in neutral
=180°)
B28 Not connected
B29 SE9126, Swing brake pressure sensor (EW230C) B29 – B54 U ≈ 0.5–4.5 V (0.5 V no
pressure)
B30 – B34 Not connected
B35 SW2701, Engine speed switch signal B35 – B58 U ≈ 0.48 — 4.05 V
Step1 ≈ 0.48V
Step5 ≈ 2.26V
Step9 ≈ 4.05V
B36 SE4213 T/M speed sensor B36 – B70 U ≈ 10 V
0 RPM
B37 SW9166, 2 piece boom offset switch B37 – B70 U ≈ Uᵇᵃᵗ (switch on)
B38 SW9161, Proportional switch signal (X3) B38 – B14 U ≈ 2.4 – 9.6 V
(≈ 4.5V neutral)
B39 SW9162, Proportional switch signal (X1) B39 – B14 U ≈ 2.4 – 9.6 V
(≈ 4.5V neutral)
B40 SE9105, Hydraulic oil temperature sensor ground
B41 SW9159, Hammer foot switch B41 – B70 U ≈ 24 V (switch off)
B42 SW4205, Travel direction selection, reverse signal B42 – B70 U ≈ Uᵇᵃᵗ (reverse on)
B43 SW9160, Quickfit buzzer stop/confirmation switch B43 – B70 U ≈ 24 V (buzzer stop off)
B44 SE9114 / SE9115, Pressure monitor boom down and B44 – B70 U ≈ 24 V
dipper in, (auto idle)
B45 SE4901, Turret alignment sensor B45 – B70 U ≈ Uᵇᵃᵗ (aligned)
B46 Not connected
B47 SW3611, Mode selection switch, C-mode B47 — B70 U ≈ Uᵇᵃᵗ (C-mode)
B48 SE2707 Ground
B49 SE5201; SE9101 ground
B50 Not connected
B51 SE2707, Engine speed sensor signal (flywheel)
B52 – B53 Not connected
B54 SE4217; SE9126 Ground
B55 – B57 Not connected
JB58 SW2701 Ground
B59 Not connected
B60 SE9142, Pattern change switch 2 B60 – B70 U ≈ 24 V (switch on)
B61 SW4207, CDC or X3 selection switch B61 – B70 U ≈ Uᵇᵃᵗ (switch on)
B62 SW5205, Electrical digging brake switch B62 – B70 U ≈ Uᵇᵃᵗ (switch on)
B63 Not connected
B64 SW4202, Travel speed selection, 2nd speed B64 – B70 U ≈ 24V (switch on 2nd speed)
B65 SE9106, Return hydraulic oil filter B65 – B70 U ≈ Uᵇᵃᵗ
B66 SW4205, Travel direction selection, forward signal B66 – B70 U ≈ Uᵇᵃᵗ (forward on)
B67 SE4218, Steering servo pressure monitor B67 – B70 U ≈ Uᵇᵃᵗ
B68 SE8503, RE9108 Control lock out B68 – B70 U ≈ Uᵇᵃᵗ (switch on)
B69 SW9151 / SW9152, Axle lock switch B69 – B70 U ≈ Uᵇᵃᵗ (switch on)
B70 Ground

V-ECU active measuring, connector (JC)

Pin No. Signal/component Measuring points Correct value

C1 FU26, Fuse for Relay and Solenoid C1 – C70 U ≈ Uᵇᵃᵗ
C2 – C4 Not connected
C5 MA9104, X1 right solenoid C5 – C70 U ≈ 24 V (active)
C6 MA9152, Pivot axle lock solenoid C6 – C70 U ≈ 24 V (active)
C7 MA4219, Travel REV (reverse) solenoid JC7 – C70 U ≈ 24 V (active)
C8 MA9165, Grab changeover solenoid C8 – C70 U ≈ 24 V (active)
C9 MA5503, Swing brake solenoid C9 – C70 U ≈ 24 V (active)
C10 Not connected
C11 RE3101; RE3102 Main relays C11 – C70 U ≈ 24 V
C12 MA2602 Reversible fan solenoid C12– C70 U ≈ 24 V
C13 RE5201, Stop light relay JC13 – JC70 U ≈ 24 V (active)
C14 Shield J1939
C15 J1939_H C15 – C70 U ≈ 2 – 5 V (alternate signal)
C16 J1939_L C16 – C70 U ≈ 0 – 3 V (alternate signal)
C17 Not connected
C18 Not connected
C19 PWM4211, Cruise control proportional valve +
C20 PWM4211, Cruise control proportional valve –
C21 PWM9103, Fan motor coolant proportional valve + C21 — C22 at ≈ 550 mA
≈9V
C22 PWM9103, Fan motor coolant proportional valve – C21 — C22 at ≈ 550 mA
≈9V
C23 FU06, Fuse for solenoid C23 – C70 U ≈ Uᵇᵃᵗ
C24 FU18 Fuse for Proportional valve C24 – C70 U ≈ Uᵇᵃᵗ
C25 – C26 Not connected
C27 MA9157, Rototilt solenoid C27 – C70 U ≈ 24 V (active)
C28 MA9103, X1 left solenoid C28 – C70 U ≈ 24 V (active)
C29 MA4302, Travel gearbox solenoid, low speed JC29 – JC70 U ≈ 24 V (active)
C30 MA4218, Travel FWD solenoid C30 – C70 U ≈ 24 V (active)
C31 Not connected
C32 MA9120, Boom float solenoid C32 – C70 U ≈ 24 V (active)
C33 – C34 Not connected
C35 RE9108, Control lockout relay C35 – C70 U ≈ 24 V (active)
C36 RE4206, Travel alarm relay C36 – C70 U ≈ 24 V (active)
C37 MA5205, Electrical digging brake solenoid C37 – C70 U ≈ 24 V (active)
C38 J1587_A C38 – C70 U ≈ < 4.0 V (alternate signal)
C39 J1587_B C39 – C70 U ≈ > 1.0 V (alternate signal)
C40 Shield_J1587
C41 PWM9105, X3 left proportional valve –
C42 PWM9106, X3 right proportional valve +
C43 PWM9106, X3 right proportional valve –
C44 PWM9104, Anti cavitation proportional valve +
C45 PWM9104, Anti cavitation proportional valve –
C46 PWM9105, X3 left proportional valve +
C47 FU18, Fuse for PWM C47 – C70 U ≈ Uᵇᵃᵗ
C48 Ground
C49 – C50 Not connected
C51 MA4214, Travel motor/Q-maximum solenoid C51 – C70 U ≈ 24 V (active)
C52 MA4303, Travel gearbox solenoid, high speed C52 – C70 U ≈ 24 V (active)
C53 Not connected
C54 MA9164, 2 piece boom offset solenoid 1 C54 – C70 U ≈ 24 V (active)
C55 MA9107, Power boost solenoid C55 – C70 U ≈ 24 V (active)
C56 Not connected
C57 MA9174 2 piece boom offset solenoid 2 C57 – C70 U ≈ 24 V (active)
C58 RE3301, Start lock relay C58 – JC70 U ≈ 24 V (active)
C59 RE4201. Travel reverse light relay C59 – C70 U ≈ 24 V (active)
C60 V-ECU status to I-ECU C60 – C70 U ≈ 2–24V (alternate signal)
C61 Ground
C62 PWM9129, X1 PPRV +
C63 PWM9129, X1 PPRV –
C64 – C65 Not connected
C66 PWM9101, Main pump regulation, proportional valve –
C67 PWM9101, Main pump regulation, proportional valve +
C68 PWM9109, X1 Main flow control, proportional valve –
SW9103 Pump manual switch not activated
C69 PWM9109, X1 Main flow control, proportional valve +
SW9103 Pump manual switch not activated
C70 Ground
 Service Information

Document Title: Function Group: Information Type: Date:

V-ECU (MID 187) Vehicle Service Information 2014/7/4 0
control unit, passive
measuring, conditions
Profile:
EXC, EW160C, EW180C, EW140C [GB]

V-ECU (MID 187) Vehicle control unit, passive measuring, conditions

Figure 1
resistance measurement against cable harness, vehicle control unit (V–ECU) disconected

Conditions
1) Control unit disconnected

2) Multi-pin breaker box connected against cable harness

NOTE! NOTE!
For measuring voltage, the following applies: For measuring resistance, the following applies:

3a) Turn master switch to the ON position, 3b)Turn start switch to the OFF position,

turn start switch to the ON position and turn master switch to the OFF position and

measure the voltage with the multimeter. measure the resistance with the multimeter.

NOTE!
During all resistance measurements, the master switch must
be turned OFF.

4) Engine off

Abbreviation Explanation
U Direct voltage in volts (V)
Uᵇᵃᵗ Battery voltage
Uᵒ Voltage near to 0 volt or 0 volt
R Resistance in ohm (Ω)

V-ECU active measuring, connector (JA)

Pin No. Signal/component Measuring points Correct value
A1 SW3611, Mode selection switch, (T-mode)
A2 SW9405, X3 left-hand switch
A3 SW9163, X1 left-hand switch
A4 SW9108, Boost/hammer switch
A5 SW9165, Grab changeover switch
A6 SW4204, Cruise control switch
A7 Engine start signal
A8 VECU power +24 V (thru SW9103)
A9 SW3611 Mode selection switch, (W-mode)
A10 SW9406, X3 right-hand switch
A11 SW9164 X1 right-hand switch
A12 SW9158, Float position switch
A13 SE4902 ; SE9116 Position sensor extended axel log
(EW210C; EW230C
A14 SW9104, Quickfit switch
A15 SW3301, Engine start key 54(ACC)
A16 VECU power +24 V (thru SW9103)

V-ECU active measuring, connector (JB)

Pin No. Signal/component Measuring points Correct value

B1 SW2701; SE4213 Power +24 V
B2 – B5 Notconnected
B6 SE4217, Travel pedal sensor
B7 SE 4217; SE9126 Power +5 V
B8 – B9 Notconnected
B10 SW9161; SW9162 Power +12 V
B11 SE5201; SE9101 Power + 5 V
B12 Notconnected
B13 SE9105, Hydraulic oil tank temperature. B13 – B40 R ≈ 1.7 KΩ (20°C/68°F)
B14 SW9161; SW9162 Ground
B15 – B16 Not connected
B17 SW4202, Travel speed selection, 3rd speed
B18 SW9403, Rototilt selection switch
B19 Not connected
B20 SW9160, Quickfit buzzer stop/confirmation switch
B21 SE5205, Brake pressure monitor
B22 SE9141, Pattern change switch 1
B23 SW9107, Hammer/shear selection selection switch
B24 Not connected
B25 SE5201, Brake pressure sensor
B26 SE9101, Automatic idle pressure sensor
B27 SE6401,Swing angle sensor (EW230C)
B28 Not connected
B29 SE9126, Swing brake pressure sensor (EW230C)
B30– B34 Not connected
B35 SW2701, Engine speed switch signal
B36 SE4213 T/M speed sensor B36–B1 R ≈ 1.5 kΩ
B37 SW9166, 2 piece boom offset switch
B38 SW9161, Proportional switch signal (X3) B38 – B14 R ≈ 3.5 kΩ
B39 SW9162, Proportional switch signal (X1) B39 – B14 R ≈ 3.5 kΩ
B40 SE9105, Hydraulic oil temperature sensor ground
B41 SW9159, Hammer foot switch
B42 SW4205, Travel direction selection, reverse signal
B43 SW9160, Quickfit buzzer stop/confirmation switch
B44 SE9114/9115, Pressure monitor boom down and dipper
in, (auto idle)
B45 SE4901, Turret alignment sensor
B46 Not connected
B47 SW3611, Mode selection switch, C-mode
B48 SE2707 Ground
B49 SE5201; SE9101 Pressure switch sensor ground
B50 Not connected
B51 SE2707, Engine speed sensor signal (flywheel) B51–B48 R ≈ 775–945 Ω
B52 – B53 Not connected
B54 SE4217; SE9126 Ground
B55 – B57 Not connected
B58 SW2701 Ground
B59 Not connected
B60 SE9142, Pattern change switch 2
B61 SW4207, CDC or X3 selection switch
B62 SW5205, Electrical digging brake switch
B63 Not connected
B64 SW4202, Travel speed selection, 2nd speed
B65 SE9106, Return hydraulic oil filter
B66 SW4205, Travel direction selection, forward signal
B67 SE4218, Steering servo pressure monitor
B68 SE8503, RE9108 Control lock out
B69 SW9151/9152, Axle lock switch
B70 Ground R≈0Ω
B70 –

V-ECU active measuring, connector (JC)

Pin No. Signal/component Measuring points Correct value

C1 FU26, Fuse for Relay and Solenoid
C2 – C4 Not connected
C5 MA9104, X1 right solenoid C5 – C70 R ≈ 30 Ω
C6 MA9152, Pivot axle lock solenoid C6 – C70 R ≈ 30 Ω
C7 MA4219, Travel REV (reverse) solenoid C7 – C70 R ≈ 30 Ω
C8 MA9165, Grab changeover solenoid C8 – C70 R ≈ 30 Ω
C9 MA5503, Swing brake solenoid C8 – C70 R ≈ 35 Ω
C10 Not connected
C11 RE3101, RE3102 Main relas C11 – C70 R ≈ 1.8 MΩ
C12 MA2602 Reversible fan solenoid C12 – C70 R ≈ 20 Ω
C13 RE5201, Stop light relay C13 – C70 R ≈ 220 Ω
C14 Shield J1939
C15 J1939_H
C16 J1939_L
C17 Not connected
C18 Not connected
C19 PWM4211, Cruise control proportional valve + C19 – C20 R ≈ 10 Ω
C20 PWM4211, Cruise control proportional valve –
C21 PWM9103, Fan motor coolant proportional valve + C21 – C22 R ≈ 25 Ω
C22 PWM9102, Fan motor coolant proportional valve –
C23 FU06, Fuse for solenoid
C24 FU18, Fuse for Proportional valve
C25 – C26 Not connected
C27 MA9157, Rototilt solenoid C27 – C70 R ≈ 30 Ω
C28 MA9103, X1 left solenoid C28 – C70 R ≈ 30 Ω
C29 MA4302, Travel gearbox solenoid, low speed C29 – C70 R ≈ 35 Ω
C30 MA4218, Travel FWD solenoid C30 – C70 R ≈ 30 Ω
C31 Not connected
JC32 MA9120, Boom float solenoid C32 – C70 R ≈ 35 Ω
C33 – C34 Not connected
C35 RE9108, Control lockout relay C35 – C70 R ≈ 220 Ω
C36 RE4206, Travel alarm relay C36 – C70 R ≈ 220 Ω
C37 MA5205, Electrical digging brake solenoid C37 – C70 R ≈ 30 Ω
C38 J1587_A
C39 J1587_B
C40 Shield_J1587
C41 PWM9105, X3 left proportional valve –
C42 PWM9106, X3 right proportional valve + C42 – C43 R ≈ 20 Ω
C43 PWM9106, X3 right proportional valve –
C44 PWM9104, Anti cavitation proportional valve + C44 – C45 R ≈ 20 Ω
C45 PWM9104, Anti cavitation proportional valve –
C46 PWM9105, X3 left proportional valve + C46 – C41 R ≈ 20 Ω
C47 FU18, Fuse for PWM
C48 Ground C48 – C70 R≈0Ω
C49 – C50 Not connected
JC51 MA4214, Travel motor/Q-maximum solenoid C51 – C70 R ≈ 30 Ω
C52 MA4303, Travel gearbox solenoid, high speed C52 – C70 R ≈ 35 Ω
C53 Not connected
C54 MA9164, 2 piece boom offset solenoid 1 C54 – C70 R ≈ 30 Ω
C55 MA9107, Power boost solenoid C55 – C70 R ≈ 20 Ω
C56 Not connected
C57 MA9174, 2 piece boom offset solenoid 2 C54 – C70 R ≈ 30 Ω
C58 RE3301, Start lock relay C58 – C70 R ≈ 220 Ω
C59 RE4201. Travel reverse light relay C59 – C70 R ≈ 220 Ω
C60 VECU status to I-ECU
C61 Ground C61 – C70 R≈0Ω
C62 PWM9129, X1 PPRV + C62 – C63 R ≈ 10 Ω
C63 PWM9129, X1 PPRV –
C64 – C65 Not connected
C66 PWM9103, Main pump regulation, proportional valve –
C67 PWM9101, Main pump regulation, proportional valve + C67 – C66 R ≈ 30 Ω
C68 PWM9109, X1 Main flow control, proportional valve –
C69 PWM9109, X1 Main flow control, proportional valve + C69 – C68 R ≈ 10 Ω
C70 Ground
C70 –
 Service Information

Document Title: Function Group: Information Type: Date:

Battery, description 311 Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Battery, description
 The two batteries (12V each) connected in series supply 24 volts of electrical power.
 Batteries are used to start the engine, supply the current to the electrical components, and store the current from
the alternator.

WARNING
If a tool touches a cable connected between the positive terminal and the chassis, there is danger that it will cause
sparks. Battery post clamps must be tightly connected. If loosely connected, the terminal may burn or be eroded by
sparks caused by defective contact. Battery acid can burn or blind you. If acid gets on your skin or in your eyes,
immediately wash with plenty of clean water and consult a doctor immediately.

NOTICE
When removing the battery, first disconnect the cable with the black tube from the ground (normally, from the
negative (–) terminal).

NOTICE
Battery power may be lowered under severe cold weather. In this case, warm up the batteries and start the engine.
 Service Information

Document Title: Function Group: Information Type: Date:

Battery, storage 311 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Battery, storage
Batteries lose their charge gradually through either self-discharge, which is dependent on storage temperature and charge
level or dark current, when connected in the machine.
Self discharge (Discharge without any connection to any electrical device)
Self discharge is a phenomenon in batteries in which internal chemical reactions reduce the stored charge of the battery
without any connection between the electrodes.
Lead-acid type batteries are used in our machines and have a 4∼6% self discharge rate per month in general.
This phenomenon tends to occur more quickly at higher temperatures.
Dark current
Dark current is the relatively small electrical current that will leak when the battery is connected to electrical devices.
The capacity of the battery will be reduced depending on dark current amount. In our machines dark current amount is
estimated to about 55 mA and consumed by I-ECU and diodes, etc.

Figure 1
Example of capacity reduction in % by dark current (at 25°C, 100 Ah)

A: 30 mA B: 10 mA C: 0 mA
D area: charging required E area: cranking not possible
x axle: Month y axle: Capacity reduction by dark
current %

Engine cranking ability versus capacity of battery: when the battery capacity drops below 30% engine cranking becomes
not possible.

Once the battery is discharged 100%, recharging efficiency drops dramatically and this will result in short life of battery.

NOTE!
The graph is not made with real data, it is just to help general understanding of battery characteristics.

Recommendations on battery usage

A fully charged battery stored in a cool place loses insignificant capacity in a three-month period.
Separate storage from the machine (battery disassembled)

 Store a battery in dry and cool place and avoid heat, direct sun light and rain.
  Do not lean battery more than 45 degrees.
 When storing battery for a long period, check the voltage at every 6 month. If the voltage is lower than 12.5V,
recharge it.

Long term parking of the machine (battery assembled)

 Disconnect the battery from the machine by turning off the battery main switch.
 Preferably always remove the battery from the machine and store as described above.
NOTE!
After approximately one month engine cranking will not be possible because of low battery capacity. In this case
battery life time will be reduced dramatically even after it is recharged.

Examples of misuse:
Extra electrical devices
When an extra electrical 12V device is connected to one of the series connected batteries, this causes a difference in voltage
between the two batteries and can lead to short life of the battery.
For extra electrical devices, use either a separate battery or a voltage converter.

Figure 2
Example of wrong connection of extra electrical device

(x) consumer 1A

Loose and bad contact

When a clamp or connector of a battery terminal is loose, energy is wasted, caused by contact resistance.
Clamps or connectors of batteries should be checked regularly.
Connection between two different batteries
Connecting two different batteries in series can cause charging difference, due to different aging state and charging
efficiency between two batteries. This can cause insufficient and unstable battery performance.
Always use Volvo genuine batteries and it is recommended to replace both batteries at the same time.
 Service Information

Document Title: Function Group: Information Type: Date:

Battery, charging 311 Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Battery, charging
WARNING
Battery charging generates hydrogen gas, which may be explosive. Short-circuiting, an open flame or a spark near
the battery may cause a powerful explosion.

Make sure ventilation is adequate when charging batteries. Never smoke near batteries.

The batteries must be in good condition when troubleshooting the electrical system. Check the battery voltage with a
voltmeter. Also check the electrolyte fluid in the battery cells with a densitometer.
If needed, charge the batteries with a battery charger according to the instructions in the Operator's Manual.

NOTICE
Always turn off the current to the battery charger before disconnecting the charging clamps.

 Batteries may only be charged with a battery charger.

 Check that the battery connections are attached securely and free from rust and dirt.
 Check the voltage when the batteries are at rest, that is, before attempting to start. Each battery must be at least
half-charged.

If the batteries do not charge:

 Check the density in the battery cells.

 Measure the charging voltage between the alternator's B+ connection and the chassis with a voltmeter. Correct
charging voltage is 28.5 ±0.5V .

Charge level Voltage Acid weight g/cm3

-20 °C 0 °C +20 °C +40 °C
Fully charged battery 13.5 V 1.30 1.29 1.28 1.27
Half-charged battery 12.4 V 1.23 1.22 1.21 1.20
Discharged battery 11.6 V and lower 1.14 1.13 1.12 1.11
NOTE!
Difference in density between the cells may not exceed 0.04 g/cm3 .
 Service Information

Document Title: Function Group: Information Type: Date:

Batteries, replacing 311 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Batteries, replacing
Op nbr 311-002

WARNING
Batteries contain corrosive acid. Handle batteries according to instructions in Section 3 and Section Safety.

1. Park the machine in the service position A, see 091 Service positions.

2. Open tool box cover (1).

Figure 1
Tool box cover

3. Turn OFF battery disconnect switch (1).

Figure 2
Battery disconnect switch off position

4. Remove tool box (2).

5. Disconnect ground cable (1), extension cable (2) and positive cable (3) from the battery.
NOTE!
Disconnect the ground cable first.
 Figure 3
Battery cables
1. Ground cable
2. Extension cable
3. Positive Cables

6. Remove bracket (1) fixing the batteries.

Figure 4
Battery bracket
1. Battery fixing bracket

WARNING
The parts are heavy. Take appropriate safety cautions when handling them.

7. Replace the batteries with new ones.

8. Reinstall battery bracket (1).

Figure 5
Battery bracket
 9. Connect positive cable (3), extension cable (2) and ground cable (1) to the batteries.
NOTE!
Connect the positive cable first.

NOTE!
Make sure that the battery terminals are clean and firmly fixed.

Figure 6
Battery cables
1. Ground cable
2. Extension cable
3. Positive Cables

10. Install tool box (2).

Figure 7
Tool box

11. Turn ON battery switch (1).

12. Close tool box cover (1) and lock it.

Figure 8
Tool box cover
 Service Information

Document Title: Function Group: Information Type: Date:

Alternator, description 320 Service Information 2014/7/4 0
Profile:
EXC, EW180C, EW160C, EW140C [GB]

Alternator, description

Figure 1
Alternator

1. B-
2. B2+
3. B1+, M8, tightening torque;15 Nm (11 lbf ft)
4. Terminal W
5. Terminal L
6. Terminal 15
7. Terminal BS
8. Terminal DFM
9. Regulator
 Service Information

Document Title: Function Group: Information Type: Date:

Charging, description 320 Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Charging, description
When the starter motor is activated and the engine starts:

 The alternator generates current to activate all the electrical systems, and the extra current charges the battery.
 After the engine starting, the battery charge warning lamp is turned off because the signal from "L" goes to the I-
ECU. I-ECU recognize charging status.
 The current flows to the hour meter, which operates during engine running condition.
 Service Information

Document Title: Function Group: Information Type: Date:

Alternator, test 321 Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Alternator, test
Op nbr 321-075

Wire harness test

The following test must be performed with alternator installed, all wiring harness leads connected and the ignition switch
“ON.” Connect a voltmeter from:

1. Alternator “B–” TERMINAL and frame ground.

2. Alternator “B+” TERMINAL and ground (B–).

Figure 1
Alternator

1. B–
2. B2+
3. B1+, M8, tightening torque;15 Nm (11 lbf ft)
4. Terminal W
5. Terminal L
6. Terminal 15
7. Terminal BS
8. Terminal DFM
9. Regulator

3. Alternator five pin connector TERMINAL (5, 6, 7) and ground (B–).

NOTE!
A zero volt reading on either of these tests indicates an open circuit between the voltmeter connection point and
the battery.

4. Repair/replace wiring harness as required.

 The following test must be performed with all accessories turned “OFF.” Connect a voltmeter from:

Output voltage test

5. Alternator “B+” TERMINAL (2) and ground.

6. Operate the engine at a low idle.

7. If the voltage is 28 V or more, the voltage regulator is defective.

8. If the voltage is lower than battery voltage, the alternator inner coil is defective.
Remove the alternator and replace it with a new one.
 Service Information

Document Title: Function Group: Information Type: Date:

Alternator, replacing incl 321 Service Information 2014/7/4 0
function check
Profile:
EXC, EW140C [GB]

Alternator, replacing incl function check

Op nbr 321-002

1. Place the machine in the service position B, see 091 Service positions.

2. Turn off the electric power using the battery disconnect switch.

3. Open the engine hood.

4. Disconnect five pin connector (1), positive battery cable (2) and ground cable (3).

Figure 1
Cables, disconnection

5. Turn belt tensioner (2) clockwise, and remove belt (4).

NOTE!
The belt adjuster tension is very strong. Pay attention to prevent injury after removing the belt.

NOTE!
Tools: 1/2” socket handle
 Figure 2
Belt tensioner

1. Alternator
2. Belt tensioner
3. Fuel feed pump
4. Belt

6. Remove the nut on upper guard (1), and remove screw (2).

Figure 3
Alternator, removal

7. Swing the alternator.

8. While holding the alternator, remove screw (1) from the upper guard.

9. Remove the alternator from the engine.

10. Install the new alternator and tighten screws (1) and (2).

11. Turn the belt tensioner (2) clockwise, and install belt (4).
NOTE!
The belt adjuster tension is very strong. Pay attention to prevent injury after removing the belt.
 NOTE!
Tools: 1/2” socket handle

Figure 4
belt, installation

12. Connect five pin connector (1), positive battery cable (2) and ground cable (3).

Figure 5
Cables, connection

13. Close the engine hood.

14. Turn on the battery disconnect switch.

15. Test the alternator function.

 Service Information

Document Title: Function Group: Information Type: Date:

Starting operation 330 Service Information 2014/7/4 0
Profile:
EXC, EW180C, EW160C, EW140C [GB]

Starting operation
Power supply

 The negative terminal (–) of battery is grounded to the machine. When the battery disconnect switch is in the OFF
position, the power supply is disconnected.

If the battery disconnect switch is turned to the ON position and the start switch to the OFF position, the current flows in the
following circuits.

 Battery (+) → Starter motor terminal (B+) → Battery relay→ Alternator

 Battery (+) → Circuit breaker (FC02, 80 A) → Battery relay (RE3101)

 Fuse (FU11, 10A) → I-ECU

 Fuse (FU07, 10A) → V-ECU
 Fuse (FU22, 15A) → E-ECU
 Fuse (FU06, 10A) → V-ECU
 Fuse (FU18, 10A) → V-ECU
 Fuse (FU20, 10A) → Diesel heater control unit
 Fuse (FU34, 10A) → Wiper motor
 Fuse (FU27, 15A) → Seat heater
 Fuse (FU16, 10A) → Cigarette lighter

 Battery (+) → Circuit breaker (FC02, 80A) → Battery relay (RE3102)

 Fuse (FU02, 10A) → Socket for option

 Fuse (FU09, 15A) → Water separator heater (option), Automatic grease
 Fuse (FU04, 20A) → Work light, boom and superstructure
 Fuse (FU14, 10A) → Work light, Cab and counterweight
 Fuse (FU21, 10A) → Travel alarm
 Fuse (FU19, 10A) → Beacon light

 Battery (+) → Circuit breaker (FC02, 80A) → Fuse (FU29, 15A) →Socket for option

 Battery (+) → Circuit breaker (FC02, 80A) → Fuse (FU24, 15A) →Start switch

When the start switch is turned to the ON position, current flows in the following circuits.

 Start switch terminal (B+) → ACC terminal →

 V-ECU (A15)
 Air conditioner controller (CU8701)
 Alternator (15)

 Start switch terminal (B+) → BR terminal → Battery relay coil (RE3101, RE3102)→ Ground

 Start switch terminal (B+) → BR terminal → Alternator resistance (R3201)→ Alternator (L), I-ECU warning lamp signal

Engine starting
If the start switch is turned to the START position, the current flows in the following circuits.

 Start switch terminal (B+)

  V-ECU (C58) → Start relay (RE3301)

When the start relay is operated:

 Fuse (FU24, 15A) → Start relay (RE3301) → Start motor relay coil → E-ECU (B29) → E-ECU ground

Starter safety lockout

If the start switch is in the START position continuously:

 V-ECU cut off the start relay (RE3301) coil, therefore the start motor run continuously.
 While the engine is running, the starter motor can not engage even if the start switch is turned to the START
position.

Stop

 If the start switch is released, it automatically returns to the ON position. When the start switch is turned to the OFF
position. Request engine stop from V-ECU is sent to E-ECU until engine is stopped.

V-ECU avoids the PEAK load by keeping the electrical system active when the engine stops.

 V-ECU (C11) → Diode (D11) → so, the electric current flows to the battery relay coil (RE3101, RE3102) to temporarily
activate the battery relay. At this time, the V-ECU sets the engine speed into the low idling condition to reduce the
load, and then cuts off the battery relay.
 Service Information

Document Title: Function Group: Information Type: Date:

Starter switch (engine start 330 Service Information 2014/7/4 0
switch), replacing
Profile:
EXC, EW180C, EW160C, EW140C [GB]

Starter switch (engine start switch), replacing

Op nbr 334-011

1. Park the machine in the service position A, see 091 Service positions

2. Turn OFF the battery disconnect switch.

3. Open the upper cover on the right-hand control box.

4. Disconnect the wire harness connectors from control box wire harness.

Figure 1

1. Key assembly
2. Wire harness connectors

5. Remove the nut securing the starter switch.

6. Replace the switch with a new one.

7. Tighten the nut and connect the wire harnesses.

8. Close the upper cover.

9. Check engine starting.

 Service Information

Document Title: Function Group: Information Type: Date:

Starter motor, description 331 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Starter motor, description

The starter motor MO3301 is supplied directly from the battery disconnection switch and has a built-in start relay. The relay
is controlled by the plus signal from the relay RE3301 and RE3302 in a row. The start relay is also controlled by the ground
signal from the E-ECU.
RE3302 is controlled by the ignition key SW3301, and supplies the current to RE3301 which is controlled by the V-ECU.
 Service Information

Document Title: Function Group: Information Type: Date:

Starter motor, replacing 331 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Starter motor, replacing

Op nbr 331-018

1. Place the machine in the service position B, see 091 Service positions.

2. Disconnect the electric power with battery disconnecting switch.

3. Open the engine hood.

4. Remove the counterweight, see 716 Counterweight, removing.

5. Remove the starter motor protection cover.

6. Disconnect the main cable and from starter motor.

Figure 1

1. Starter motor
2. Main cable
3. Screw

7. Remove the mounting screws and take the starter motor out.

8. Install a new starter motor.

9. Reconnect main cable and tighten screws.

10. Install the counterweight, see 716 Counterweight, removing.

11. Turn battery disconnection switch on and check the engine starting.
 Service Information

Document Title: Function Group: Information Type: Date:

Starter motor, tests 331 Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Starter motor, tests

Op nbr 331-021

1. Place the machine in service position B, see 091 Service positions.

2. Disconnect the electric power with battery disconnecting switch.

3. Tag and disconnect all wires and cables at the starter solenoid.

4. Remove the starter motor from the vehicle for bench testing

5. Remove the wire from terminal on the starter housing (1).

Figure 1
Starter terminals

6. Ground the starter housing to a bench power supply, and apply positive (+) 24 V power to the lead (2) on the
starter motor (3).

7. If the starter motor turns, but the starter drive gear does not extend, the magnetic switch (4) is defective.

8. If the starter motor is defective, install a replacement starter in the machine.

9. Connect wires and cable removed in Step 3 to the starter.

10. Turn battery disconnection switch on and check the engine starting.
 Service Information

Document Title: Function Group: Information Type: Date:

Starter relay, replacing 331 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Starter relay, replacing

Op nbr 331-081

1. Park the machine in the service position A, see 091 Service positions

2. Open the side door of the cab rear.

3. Open the cover of the Electrical distribution box.

4. Pull out the starter relay, RE3301.

Figure 1

1. Starter relay, RE3301

5. Replace it with a new one.

6. Close the cover of the Electrical distribution box and side door.
 Service Information

Document Title: Function Group: Information Type: Date:

Preheating, description 333 Service Information 2014/7/4 0
Profile:
EXC, EW180C, EW160C, EW140C [GB]

Preheating, description
The purpose of the preheating coil is to heat the air in the induction pipe before and after (but not during) engine cranking
when the engine is being started. This warm air assists starting at very low temperatures and reduces the amount of smoke
produced at cold starts.
 Service Information

Document Title: Function Group: Information Type: Date:

Preheating coil, replacing 333 Service Information 2014/7/4 0
Profile:
EXC, EW160C, EW180C, EW140C [GB]

Preheating coil, replacing

Op nbr 256-006

WARNING
Risk of burns - stop the diesel engine and allow it to cool down before starting any work.

1. Park the machine in service position B, see 091 Service positions.

2. Disconnect the electric power with battery disconnecting switch.

3. Open the engine hood.

4. Disconnect the preheating power supply cable (1).

5. Remove screws (4) and remove the preheater housing with the charge air cooler outlet pipe (3).

Figure 1
Preheating unit

1. Preheater power supply connector

2. Preheater unit
3. Charge air cooler outlet hose
4. Screws

6. Replace the preheater (2) with new one.

NOTE!
Replace the preheating coil gaskets each side.

7. Install the preheating housing with the charge air cooler outlet hose (3).

8. Connect the wire harness (1).

9. Close the engine hood.

10. Check the function of preheating unit. See 3021 HE2501, description and measuring.
 Service Information

Document Title: Function Group: Information Type: Date:

Headlights, adjusting 352 Service Information 2014/7/4 0
Profile:
EXC, EW160C, EW140C [GB]

Headlights, adjusting
Op nbr 352-002

Low beams, adjusting

1. Park the machine in the service position B, see 091 Service positions.
NOTE!
The battery disconnect switch should be on.

2. Turn on the low beams.

3. Adjust the upper boundary of the low beams at the height (B) and the distance (C) with the 2 adjusting screws on
respective side.
Check the distance (D) between the centers of the low beams.

Figure 1
Adjusting screws
NOTE!
Adjusting measurements are shown in figure below.

Figure 2
Headlight adjustment
 Measurement Value
A 1342 mm (52.84 in)
B 1118 mm (44.02 in)
C 5000 mm (196.6 in)

4. Turn off the low beams.

 Service Information

Document Title: Function Group: Information Type: Date:

Rotating beacon, replacing 356 Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Rotating beacon, replacing

Op nbr 362-041

1. Park the machine in the service position A, see 091 Service positions.

2. Remove the screw from the bracket.

Figure 1

1. Rotating beacon light

2. Screw

3. Install a new beacon.

4. Check the rotating beacon operation.

 Service Information

Document Title: Function Group: Information Type: Date:

Electric horn, description Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Electric horn, description

Horn operation

 Pressing one of the horn switches (1,2,3) operates the electric horn, see: 370 Wiring diagram SCH12
1 Horn switch, control lever with four buttons
2 Horn switch, control lever with two buttons and proportional switch
3 Horn switch, multi-function lever

Figure 1
Horn switches

Horn location

 The electrical horn (1) is located in the superstructure on the right side in drive direction.
Figure 2
Horn location
 Service Information

Document Title: Function Group: Information Type: Date:

Horn, replacing Service Information 2014/7/4 0
Profile:
EXC, EW160C, EW140C [GB]

Horn, replacing
Op nbr 362-002

1. Park the machine in the service position A, see 091 Service positions.

2. Disconnect the wire-harness from the horn.

3. Remove the screws of the horn from the bracket.

Figure 1

1. Horn
2. Horn
3. Bracket
4. Screw
5. Screw

4. Install the horn with a new one.

5. Reconnect the wire-harness to the horn.

6. Check the horn operation.

 Service Information

Document Title: Function Group: Information Type: Date:

Rotating beacon, Service Information 2014/7/4 0
description
Profile:
EXC, EW180C, EW160C, EW140C [GB]

Rotating beacon, description

Figure 1
Rotating beacon

A. Rotating beacon lamp

B. Screw
C. Bracket
D. Rubber cover
 Service Information

Document Title: Function Group: Information Type: Date:

Rotating beacon, replacing Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Rotating beacon, replacing

Op nbr 362-041

1. Park the machine in the service position A, see 091 Service positions.

2. Remove the screw from the bracket.

Figure 1

1. Rotating beacon light

2. Screw

3. Install a new beacon.

4. Check the rotating beacon operation.

 Service Information

Document Title: Function Group: Information Type: Date:

Travel alarm, description Service Information 2014/7/4 0
Profile:
EXC, EW180C, EW160C, EW140C [GB]

Travel alarm, description

 Travel alarm is a safety device that sounds when the machine travels forward or reverse to warn workers of
impending danger.
 V-ECU activates function according to the travel pilot pressure sensor signal.

NOTE!
The specifications of each pressure switch are different, so do not change the position.

Figure 1
Travel alarm

1. Alarm unit
2. Bracket
3. Screw
4. Wire harness
5. Clip
6. Screw
7. Connector
 Service Information

Document Title: Function Group: Information Type: Date:

Travel alarm, replacing Service Information 2014/7/4 0
Profile:
EXC, EW180C, EW160C, EW140C [GB]

Travel alarm, replacing

Op nbr 362-051

1. Park the machine in the service position A, see 091 Service positions.

2. Remove the under cover of lower engine.

3. Disconnect the wire-harness of the travel alarm.

4. Remove the alarm.

Figure 1

1. Alarm unit
2. Bracket
3. Screw
4. Wire harness
5. Clip
6. Screw
7. Connector

5. install a new travel alarm.

6. Connect the wire-harness of the alarm

7. Reinstall the under cover.

8. Check the travel alarm operation after starting the machine.

 Service Information

Document Title: Function Group: Information Type: Date:

Windscreen wiper, Service Information 2014/7/4 0
description
Profile:
EXC, EW180C, EW160C, EW140C [GB]

Windscreen wiper, description

 By the use of the wiper controller, the upper and lower (option) wiper motor provides various functions.

NOTE!
If the upper window is lifted up or the lower window is pulled up, the limit switch is activated, so upper and lower (option)
wiper motor do not work.

Figure 1
Windscreen wiper

1. Upper windscreen wiper

2. Lower windscreen wiper

 If the upper wiper switch is at the ON position, the upper wiper motor moves the arm/blade from the PARK
position (on the left side of the upper window) onto the upper window, and sweeps the blade through 65°. When
the upper wiper is switched to the OFF position, the arm / blade stops sweeping on the left side of the upper
window.
 Pushing the washer switch sprays the washer solution onto the window, and after about 0.5 second, the upper and
lower (option) wiper motor engage. When the washer switch operation is stopped, the wiper blades wipe the
windows 3 more times, and then return to the park position.
 Lifting the front window while the upper and lower (option) wiper motor are running immediately stops the
operation. However, lowering the window will not automatically restart the wiper motors. The wiper switch must be
turned OFF and then ON again to activate the wiper function.
 Service Information

Document Title: Function Group: Information Type: Date:

Wiper controller, Service Information 2014/7/4 0
description
Profile:
EXC, EW180C, EW160C, EW140C [GB]

Wiper controller, description

 The wiper controller is located in the electrical box attached to the fuel tank.
 The wiper controller receives information from the upper wiper switch, lower wiper switch (option), washer switch,
upper window limit switch and lower window limit switch, to control the wiper motor and washer pump operation.
 While the wiper motor and washer pump are operating, the wiper controller receives the operating information
from the wiper motor.

Figure 1
Wiper controller

1 AVS 1.25 GN/W 9 AVS 0.85 BL/W

2 AVS 0.85 W/BL 10 AVS 0.85 BN/GR
3 AVS 0.85 BL/Y 11 AVS 0.85 GN/Y
4 AVS 0.85 BN/W 12 AVS 0.85 R/GN
5 AVS 0.85 BL/Y 13 AVS 0.85 W
6 AVS 0.85 SB 14 AVS 0.85 GN/SB
7 AVS 0.85 GN 15 AVS 0.85 Y
8 AVS 0.85 GN/R 16 AVS 0.85 W/BL
 Service Information

Document Title: Function Group: Information Type: Date:

Upper wiper motor, Service Information 2014/7/4 0
description
Profile:
EXC, EW210C, EW230C, EW180C, EW160C, EW140C [GB]

Upper wiper motor, description

 The upper wiper motor system is composed of a motor, arm, blade, controller and limit switch.
 When the motor rotates once, the wiper blade operates reciprocally right and left by the linkage.

Figure 1
Upper wiper motor

1 Positive, auxiliary park feed (Y)

2 Park feed (GN)
3 Negative, GND (SB)
4 Positive, n2 speed (BL)
5 Positive, n1 speed (R)
 Service Information

Document Title: Function Group: Information Type: Date:

Lower wiper motor, Service Information 2014/7/4 0
description
Profile:
EXC, EW180C, EW160C, EW140C [GB]

Lower wiper motor, description

 The lower wiper motor rotates alternately to both directions according to the output direction of wiper controller.
 The cam plate in the motor outputs the signals to the controller in accordance with the motor position.

Figure 1
Lower wiper motor

1 Park feed (GN)

2 Negative, GND (SB)
3 Positive, auxiliary park feed (Y)
4 Positive, n1 speed (R)
 Service Information

Document Title: Function Group: Information Type: Date:

Windscreen wiper, Service Information 2014/7/4 0
components location
Profile:
EXC, EW230C, EW180C, EW160C, EW140C [GB]

Windscreen wiper, components location

The windscreen wiper components location are pointed out in Fig.1.

Figure 1
Component locations

1. Window limit switch (upper)

2. Upper windscreen wiper and motor
3. Window limit switch (lower)
4. Lower windscreen wiper and motor
5. Multi function lever (several functions for windscreen wiper)
6. Washer fluid reservoir
7. Lower windscreen washer switch (optional equipment)
8. Lower windscreen wiper switch (optional equipment)
9. Wiper motor controller
 Service Information

Document Title: Function Group: Information Type: Date:

Window limit switch, Service Information 2014/7/4 0
description
Profile:
EXC, EW230C, EW180C, EW160C, EW140C [GB]

Window limit switch, description

The Cabin is equipped with window limit switches for windscreen (1) and for lower window (2, optional equipment) to
protect windscreen wipers and motors from damage, caused by operation without window. If the upper window is lifted up
or the lower window is pulled up, the upper or lower window limit switch deactivates the wiper motor function. So according
to activated window limit switch the wiper motor do not work. Lifting a window while the wiper motor is running
immediately stops the operation of these wiper motor. However, lowering the window will not automatically restart the
wiper motor. The wiper switch must be turned OFF and then ON again to activate the wiper function. For electrical
information, see: 370 Wiring diagram SCH13.

Figure 1
Window limit switch locations

1. Window limit switch (upper) inside cabin behind covering

2. Window limit switch (lower) with snap function in top and lower position

NOTE!
Take care that the limit switch is not in snap position after pulling up or pulling down lower window
 Service Information

Document Title: Function Group: Information Type: Date:

Windscreen wiper, Service Information 2014/7/4 0
replacing controller
Profile:
EXC, EW140C [GB]

Windscreen wiper, replacing controller

Op nbr 363-091

1. Place the machine in the service position B, see 091 Service positions.

2. Turn off the electric power using the battery disconnect switch.

3. Open the battery box cover (1).

Figure 1
Battery box cover

4. Open the electrical distribution box cover.

5. Disconnect the wire harness from wiper controller (1).

Figure 2
Wiper controller
 1. Wiper controller
2. Circuit breaker, 150 A
3. Circuit breaker, 80 A
4. DC-DC converter
5. Pre-heater relay

6. Replace the wiper controller with new one.

7. Connect the wire harness to the wiper controller.

8. Install the electrical distribution box cover.

9. Check the wiper controller operation.

 Service Information

Document Title: Function Group: Information Type: Date:

Windscreen wiper front, Service Information 2014/7/4 0
replacing motor
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Windscreen wiper front, replacing motor

Op nbr 363-002

1. Place the machine in the service position B, see 091 Service positions.

2. Turn off the electric power using the battery disconnect switch.

3. Remove washer fluid nozzle (5) from the cab.

Figure 1
Wiper motor assembly

1. Nut
2. Rubber boot
3. Packing
4. Wiper motor swing shaft
5. Washer fluid nozzle
6. Wiper arm

4. Remove wiper arm (6) and blade.

NOTE!
Be careful when removing the wiper and blade not to damage the washer fluid nozzle.

5. Remove nut (1), rubber boot (2) and packing (3) from wiper motor swing shaft (4).

6. Remove the screw fixing the wiper motor cover on the roof and take out the cover.

7. Disconnect the motor wire harness connector from cab wire harness connector.
 Figure 2
Wiper motor

1. Wire harness
2. Wiper motor

8. Remove the screws fixing the wiper motor bracket on the cab and take out the motor.

9. Remove the screws fixing motor on the bracket and replace the motor with new one.

10. Install the wiper motor to the cab, and connect the wire harness.

11. Install the wiper motor cover to the cab.

12. Install nut (1), rubber boot (2) and packing (3) to wiper motor swing shaft (4).

Figure 3
Wiper motor assembly

1. Nut
2. Rubber boot
3. Packing
4. Wiper motor swing shaft
5. Washer fluid nozzle
6. Wiper arm

13. Install wiper arm (6) and blade.

NOTE!
Be careful when removing the wiper and blade not to damage the washer fluid nozzle.

14. Install washer fluid nozzle (5) to the cab.

15. Check the wiper motor operation.

 Service Information

Document Title: Function Group: Information Type: Date:

Windscreen wiper, Service Information 2014/7/4 0
replacing switch
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Windscreen wiper, replacing switch

Op nbr 363-003

1. Place the machine in the service position B, see 091 Service positions.

2. Turn off the electric power using the battery disconnect switch.

3. Open upper cover (1) on the right-hand console box, see 881 Instrument panel, replacing (right).

Figure 1
Lower windscreen switches

1. Upper cover of right-hand console

2. Lower windscreen flusher switch
3. Lower windscreen wiper switch

4. Disconnect the wire harness connector and lift off lower windscreen flusher switch (2) and lower windscreen wiper
switch (3).

5. Install new switches (2) and (3), and connect the wire harness connectors.

6. Install upper cover (1) on the right-hand console box, see 881 Instrument panel, replacing (right).

7. Check the switch operation.

 Service Information

Document Title: Function Group: Information Type: Date:

Windscreen flusher pump, Service Information 2014/7/4 0
replacing
Profile:
EXC, EW140C [GB]

Windscreen flusher pump, replacing

Op nbr 363-004

1. Place the machine in the service position B, see 091 Service positions.

2. Turn off the electric power using the battery disconnect switch.

3. Open the left side door of the machine, and disconnect wire harness connector (1).

Figure 1
Windscreen flusher pump

1. Wire harness connector

2. Washer fluid hoses
3. Washer fluid tank
4. Screws

4. Disconnect washer fluid hoses (2), and drain the washer fluid.
NOTE!
Prepare a container to collect the washer fluid.

5. Remove screws (4), and take out washer fluid tank (3).

6. Install washer fluid tank with new flusher pump.

7. Connect the hoses and wire harness.

8. Check the windscreen flusher pump operation.

 Service Information

Document Title: Function Group: Information Type: Date:

Battery disconnect switch, Service Information 2014/7/4 0
description
Profile:
EXC, EW180C, EW140C, EW160C [GB]

Battery disconnect switch, description

Figure 1
Main switch

1. Off position
2. On position
3. Tightening torque: 1,4 ±0,1 N m (1,1 ±0,1 lbf ft)
 Service Information

Document Title: Function Group: Information Type: Date:

Start switch, description Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Start switch, description

 The switch selectively routes power supply to various electrical components of the engine start / stop and accessory
circuits.

Figure 1
Start switch

Figure 2
Start switch, circuit

1 START
2 ON
3 OFF
Figure 3
Connection of terminals
 Service Information

Document Title: Function Group: Information Type: Date:

Engine speed control Service Information 2014/7/4 0
switch, description
Profile:
EXC, EW180C, EW160C, EW140C [GB]

Engine speed control switch, description

 The operator can easily control the work mode, engine speed, and maximum working horsepower by turning the
engine speed control switch if the V-ECU is in the automatic operating position.
 The switch also controls the engine speed and maximum working horsepower according to the built-in program of
V-ECU for each mode.
 The engine speed control switch changes the PWM input to V-ECU according to the position (step) selected.

Engine speed control switch

No. Wire specification Signal

1 0.85 R Power (B+)
2 0.85 W Output (SIG)
3 0.85 SB Ground (GND)
4 0.85 RW 24 V (Illumination)
5 0.85 SB GND (Illumination)
6 Shield GND
 Service Information

Document Title: Function Group: Information Type: Date:

Emergency engine speed Service Information 2014/7/4 0
control switch, description
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Emergency engine speed control switch, description

Figure 1
Emergency engine speed control switch

ES Emergency switch
U Upper position, emergency mode
N Neutral position, normal operation mode
D Down position, emergency engine stop
 Service Information

Document Title: Function Group: Information Type: Date:

Multi-function lever switch, Service Information 2014/7/4 0
description
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Multi-function lever switch, description

Housing B

Terminal number Terminal designation Color

1 H Brown-yellow
2 15/1 Black-violet
3 56b Yellow
4 53c Black-yellow
5 56 White-yellow
6 56a White

Housing C

Terminal number Terminal designation Color

1 15 Black-blue
2 J Black-blue-brown
3 53 Black-blue-yellow
4 31b Brown-blue
5 49a Violet-white
6 L Violet-green
7 R Violet-red
8 53b Black-blue-white
Figure 1
Multi-function switch, connectors

B Connector housing B
C Connector housing C
J Windshield wiper
K Washer
X Left turn signal OFF
Y Left turn signal ON
Z Right turn signal ON
W Right turn signal OFF
 Service Information

Document Title: Function Group: Information Type: Date:

Manual travel control Service Information 2014/7/4 0
switch, description
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Manual travel control switch, description

Figure 1
Manual travel control switch

R: Travel manual control, reverse

N: Neutral, automatic travel control

F: Travel manual control, forward

 Service Information

Document Title: Function Group: Information Type: Date:

Auto/Manual pump control Service Information 2014/7/4 0
switch, description
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Auto/Manual pump control switch, description

Figure 1
Manual pump control switch

A. Pump manual control position

B. Pump automatic control position
C. Terminal array and schematic diagram
 Service Information

Document Title: Function Group: Information Type: Date:

Connectors, overview Service Information 2014/7/4 0
Profile:
EXC, EW180C, EW160C, EW140C [GB]

Connectors, overview
Connectors configuration 1

Figure 1
AMP-1
Connectors configuration 2

Figure 2
AMP-2

Connectors configuration 3
Figure 3
AMP-3

Connectors configuration 4
Figure 4
AMP-4

Connectors configuration 5
Figure 5
AMP-5

Connectors configuration 6
Figure 6
DEUTSCH-1

Connectors configuration 7
Figure 7
DEUTSCH-2

Connectors configuration 8
Figure 8
FCI

Connectors configuration 9
Figure 9
YAZAKI/KET-1

Connectors configuration 10
Figure 10
YAZAKI/KEY-1

Connectors configuration 11
Figure 11
OTHERS-1

Connectors configuration 12
Figure 12
OTHERS-2
 Service Information

Document Title: Function Group: Information Type: Date:

Electric center passage, Service Information 2014/7/4 0
description
Profile:
EXC, EW140C [GB]

Go back to Index Page

Electric center passage, description

Electric center passage, 6 channels

Figure 1
Electric center passage, 6 channels

1. Connected to male pin connector

2. Hydraulic center passage
3. Electric center passage
4. Male pin connector, DEUTSCH DT04–6P-C015

Electric center passage, 11 channels

Figure 2
Electric center passage, 11 channels

1. Connected to male pin connector

2. Connected to female pin connector
3. Hydraulic center passage
4. Electric center passage
5. Male pin connector, DEUTSCH DT04–6P-C015
6. Female pin connector, DEUTSCH DT04–6S-C015
 Service Information

Document Title: Function Group: Information Type: Date:

Electric center passage, Service Information 2014/7/4 0
description
Profile:
EXC, EW140C [GB]

Go back to Index Page

Electric center passage, description

The Electric Center Passage is installed on top of the hydraulic center passage. The electric center passage is turnable about
360°. It leads electrical signals and power to the undercarriage. Depending on the options the machine is equipped with 6 or
14 channels center passage.
Electric center passage, 6 channels

Figure 1
Electric center passage, 6 channels

This is the electric center passage with 6 channels and a Deutsch Connector, DT04–6P–C015 for cable (1, 2).
Electric center passage, 14 channels
This is the electric center passage with 14channels. Three connectors (3, 4, 5) are installed at the cables (1, 2).
Deutsch Connector, DT04–6P–CO15 (3, 5)
Deutsch Connector, DT04–3P–CE05 (4)
Figure 2
Electric center passage, 14 channels

Figure 3
Back view of connectors, with numbering

Connector configuration for cable (2), 14 channel center passage

Connector / type Connector numbering Cable numbering

Deutsch Connector, DT04–6P–CO15 / 1 1
male 2 2
3 3
4 4
5 5
6 Empty
Deutsch Connector, DT04–3P–CE05 / A 6
male B 7
C 8
Deutsch Connector, DT04–6P–CO15 / 1 11
female 2 10
3 9
4 14
5 13
6 12
 Service Information

Document Title: Function Group: Information Type: Date:

Electric center passage, Service Information 2014/7/4 0
replacing
Profile:
EXC, EW140C [GB]

Electric center passage, replacing

Op nbr 364-001

1. Place the machine in service position A, see: 091 Service positions.

2. Eleminate trapped hydraulik pressure, see: 170 Elimination of trapped hydraulic pressure.

3. Turn OFF electrical power, using the battery disconnect switch.

Removal

4.

Figure 1

Disconnect all connectors (1) of electrical center passage wire harness for under carriage.

5. Remove the connectors from wire harness.

NOTE!
Write down the connectors configurations

6.
 Figure 2

Disconnect the connectors of electrical center passage wire harness (1).

7. Remove retainer (2) and hydraulic hose bracket (3).

8.

Figure 3

Loosen lock nut (2, wrench size 46mm) and screw out electrical center passage (1, wrench size 36mm).

9. Remove electrical center passage

Installation

10. Screw in electric center passage.

NOTE!
Lock center passage with locknut carefully

11.

Figure 4

Fix center passage retainer (2) and hydraulic hose bracket (3).

12. Reconnect the connectors of wire harness (1) and fix them with cable ties.
13.

Figure 5

Connect the connectors (1) to wire harness.

NOTE!
For connectors configuration see your notes or 3642 Electric center passage, description.

14. Reconnect all connectors of center passage for under carriage and fix them with cable ties.
 Service Information

Document Title: Function Group: Information Type: Date:

Control units changing, 367 Service Information 2014/7/4 0
precaution
Profile:
EXC, EW180C, EW160C, EW140C [GB]

Control units changing, precaution

Before changing electronic control unit Volvo CE product specialist should be consulted.
NOTE!
Before changing a control unit, customer parameters must be read out so that they can be programmed again.

WARNING
The control unit connectors must be unplugged during all electric welding.

See also, 091 Welding on the machine.

 Service Information

Document Title: Function Group: Information Type: Date:

W-ECU, MID 142, replacing 367 Service Information 2014/7/4 0
Profile:
EXC, EW230C, EW210C, EW180C, EW160C, EW140C [GB]

W-ECU, MID 142, replacing

Op nbr 367-058

88890180 Interface
88890027 Cable

1. Download the W-ECU software for the target machine to the VCADS Pro computer.

2. Park the machine in a suitable service position, see: 091 Service positions.

3. Connect the VCADS Pro computer to the machine and perform the operation 39736–3, MID 142 ECU
programming.

4. When in VCADS Pro the MID 142 ECU programming window appears, follow the instructions for replacing W-ECU.

5. Turn OFF electrical power using the battery disconnect switch.

6. Move the operator's seat to the front position, and fold the backrest forward.

7. Remove the plastic casing over the cab fan.

Figure 1
Plastic casing, removal

8. Remove the Satellite system from the W-ECU if this system is installed.
 Figure 2
Satellite system
NOTE!
The satellite system is optional equipment.

9. Disconnect all connectors of the W-ECU and remove it.

Figure 3
W-ECU connectors

10. Install the new W-ECU and connect all connectors.

11. Connect the satellite system and attach it to the new W-ECU if this system is installed.

Figure 4
Satellite system
NOTE!
Remove the rubber plug from W-ECU.

12. Reinstall the plastic casing over the cab fan.

 Figure 5
Plastic casing, installing

13. Return the operator's seat back to the original position.

14. Turn ON electrical power using the battery disconnect switch.

15. Confirm in the dialog box in VCADS Pro, that the new control module is connected and the power is ON.
NOTE!
The programming of software and parameters starts not until confirmation.
 Service Information

Document Title: Function Group: Information Type: Date:

E-ECU, MID 128, changing 367 Service Information 2014/7/4 0
pre-programmed ECU
Profile:
EXC, EW140C [GB]

E-ECU, MID 128, changing pre-programmed ECU

Op nbr 200-070

1. Park the machine in the service position A, see 091 Service positions.

2. Connect VCADS Pro computer to the machine, and perform the operation '17030-3 Parameter, programming'.

3. Use the function 'save all parameters to job card'.

NOTE!
Before the removal of E-ECU, make sure the battery disconnect switch is off.

4. Disconnect the wiring harness connector from E-ECU.

Figure 1
Connector, removal
NOTE!
Pull up the locking device to disconnect the connector.

5. Remove four screws fixing E-ECU.

Install new E-ECU, and tighten four screws.
 Figure 2
E-ECU, changing

6. Connect the wiring harness connector to the E-ECU.

Figure 3
Connector, installation

7. Connect VCADS Pro computer to the machine, and perform the operation 17030-3 Parameter, programming'. Now
the customer parameters are changed according to the job card saved at step 2.
 Service Information

Document Title: Function Group: Information Type: Date:

E-ECU, MID 128, changing 367 Service Information 2014/7/4 0
non-programmed ECU
Profile:
EXC, EW140C [GB]

E-ECU, MID 128, changing non-programmed ECU

Op nbr 200-068

1. Park the machine in the service position A, see 091 Service positions.

2. Download software to VCADS Pro computer for target machine.

3. Connect the VCADS Pro computer to the machine, and perform the operation '28423-7 MID 128 control unit,
programming'.

4. When VCADS Pro 'MID 128 ECU, programming' window appears, follow the instructions for replacing E-ECU.
NOTE!
Before the removal of E-ECU, make sure the battery disconnect switch is off.

5. Disconnect the wiring harness connector from E-ECU.

Figure 1
Connector, removal
NOTE!
Pull up the locking device to disconnect the connector.

6. Remove four screws fixing E-ECU.

Install new E-ECU, and tighten four screws.
 Figure 2
E-ECU, changing

7. Connect the wiring harness connector to the E-ECU.

Figure 3
Connector, installation

8. After replacing E-ECU, press OK button of VCADS Pro operation '28423-7 MID 128 control unit, programming'.
Now VCADS Pro starts the programming of software and parameters to the new E-ECU.
 Service Information

Document Title: Function Group: Information Type: Date:

I-ECU, MID 140, changing 367 Service Information 2014/7/4 0
pre-programmed ECU
Profile:
EXC, EW160C, EW180C, EW140C [GB]

I-ECU, MID 140, changing pre-programmed ECU

Op nbr 300-074

1. Park the machine in the service position A, see 091 Service positions.

2. Connect VCADS Pro computer to the machine, and perform operation '17030-3 Parameter, programming'.

3. Use the function 'save all parameters to job card'.

4. Turn OFF battery disconnect switch.

5. Open the windscreen.

6. Remove the screws of plastic cover and disconnect the wire harness from the cab wire harness.

7. Remove the screws of fixing I-ECU to the cab.

Figure 1
I-ECU, changing

1. Screw
2. Wire harness

8. Install a new I-ECU to the cab with screws and connect wire harness.

9. Install the plastic cover with screws and close the windscreen.

10. Connect VCADS Pro computer to the machine, and perform operation 17030-3 Parameter, programming'. Now the
customer parameters are changed according to the job card saved at step 3.
 Service Information

Document Title: Function Group: Information Type: Date:

I-ECU, MID 140, changing 367 Service Information 2014/7/4 0
non-programmed ECU
Profile:
EXC, EW160C, EW180C, EW140C [GB]

I-ECU, MID 140, changing non-programmed ECU

Op nbr 300-072

1. Park the machine in the service position A, see 091 Service positions.

2. Download the program for target machine.

3. Connect VCADS Pro computer to the machine, and perform operation '38145-3 MID 140 control unit,
programming'.

4. When VCADS pro 'MID 140 ECU, programming' window appears, follow the instructions for replacing I-ECU.

5. Turn OFF battery disconnect switch.

6. Open the windscreen.

7. Remove the screws of plastic cover and disconnect the wire harness from the cab wire harness.

8. Remove the screws fixing I-ECU to the cab.

Figure 1
I-ECU, changing

1. Screw
2. Wire harness

9. Install a new I-ECU to the cab with screws and connect wire harness.

10. Install the plastic cover with screws and close the windscreen.

11. After replacing the I-ECU, press OK button of VCADS Pro operation '38145–3 MID 140 control unit, programming'.
Now VCADs Pro starts the programming of software and parameters to the new I-ECU.
 Service Information

Document Title: Function Group: Information Type: Date:

V-ECU, MID 187, changing 367 Service Information 2014/7/4 0
pre-programmed ECU
Profile:
EXC, EW160C, EW180C, EW140C [GB]

V-ECU, MID 187, changing pre-programmed ECU

Op nbr 366-066

1. Park the machine in the service position A, see 091 Service positions.

2. Connect VCADS Pro computer to the machine, and perform operation '17030-3 Parameter, programming'.

3. Use the function 'save all parameters to job card'.

4. Turn OFF battery disconnect switch.

5. Move the operator's seat to the front position, and fold the backrest forward.

6. Remove the plastic casing over the cab fan.

Figure 1
Cab fan casing

7. Disconnect the wire harness connectors of the outlet and diesel heater switch, and remove screws of the cassette
cover and screws of the plastic plate between fan and seat.

8. Disconnect two wiring harness connectors from the V-ECU.

Figure 2
V-ECU connectors
 NOTE!
Concerning JB and JC connector, 70 pins, pull up the locking device to disconnect it.

Figure 3
Connector locking device
NOTE!
Concerning JA connector, 16 pins, pull out the red locking device to disconnect it.

9. Remove two screws at the upper side of V-ECU, and loosen two screws at the bottom side of V-ECU.

Figure 4
V-ECU, replacement

10. Lift off the V-ECU, and replace it with a new one.

11. Install four screws fixing V-ECU to the cab.

12. Connect two wiring harness connectors to the V-ECU.

Figure 5
V-ECU connectors

13. Reinstall the screws of the plastic plate between fan and seat and screws of the cassette cover, and connect the wire
 harness connector of outlet and diesel heater switch.

14. Fit the plastic casing over the cab fan.

Figure 6
Cab fan casing

15. Return the operator's seat to the original position.

16. Connect VCADS Pro computer to the machine, and perform operation 17030-3 Parameter, programming'. Now the
customer parameters are changed according to the job card saved at step 2.
 Service Information

Document Title: Function Group: Information Type: Date:

V-ECU, MID 187, changing 367 Service Information 2014/7/4 0
non-programmed ECU
Profile:
EXC, EW160C, EW180C, EW140C [GB]

V-ECU, MID 187, changing non-programmed ECU

Op nbr 366-064

1. Park the machine in the service position A, see 091 Service positions.

2. Down load software to VCADS Pro computer for target machine.

3. Connect the VCADS Pro computer to the machine, and perform the operation '36646-3 MID 187 control unit,
programming'.

4. When VCADS Pro 'MID 187 ECU, programming' window appears, follow the instructions for replacing V-ECU.

5. Turn OFF battery disconnect switch.

6. Move the operator's seat to the front position, and fold the backrest forward.

7. Remove the plastic casing over the cab fan.

Figure 1
Cab fan casing

8. Disconnect the wire harness connectors of the outlet and diesel heater switch, and remove screws of the cassette
cover and screws of the plastic plate between fan and seat.

9. Disconnect two wiring harness connectors from the V-ECU.

 Figure 2
Connector locking device
NOTE!
Concerning JB and JC connector, 70 pins, pull up the locking device to disconnect it.

NOTE!
Concerning JA connector, 16 pins, pull out the red locking device to disconnect it.

Figure 3
V-ECU connectors

10. Remove two screws at the upper side of V-ECU, and loosen two screws at the bottom side of V-ECU.

Figure 4
V-ECU, replacement

11. Lift off the V-ECU, and replace it with a new one.

12. Install four screws for fixing V-ECU to the cab.

13. Connect two wiring harness connectors to the V-ECU.

 Figure 5
V-ECU connectors

14. Reinstall the screws of the plastic plate between fan and seat and screws of the cassette cover, and connect the wire
harness connector of outlet and diesel heater switch.

15. Fit the plastic casing over the cab fan.

Figure 6
Cab fan casing

16. Return the operator's seat to the original position.

17. After replacing V-ECU, press OK button of VCADS Pro operation '36646-3 MID 187 control unit, programming'.
Now VCADS Pro starts the programming of software and parameters to the new V-ECU.
 Service Information

Document Title: Function Group: Information Type: Date:

ECC control unit, replacing 367 Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

ECC control unit, replacing

Op nbr 873-019

1. Park the machine in the service position A, see 091 Service positions.

2. Turn OFF battery disconnect switch.

3. Move the operator's seat to the front position, and fold the backrest forward.

4. Remove the plastic casing over the cab fan.

Figure 1
Cab fan casing

5. Disconnect the wire harness connectors of the outlet and diesel heater switch, and remove screws of the cassette
cover and screws of the plastic plate between fan and seat.

6. Disconnect wire harness connector from the ECC.

Figure 2
Connector locking device
 Figure 3
ECC connector

7. Remove two screws at the upper side of ECC, and loosen a screw at the bottom side of ECC.

Figure 4
ECC, replacement

8. Lift off the ECC and replace it with a new one.

9. Install three screws for fixing ECC to the air conditioner unit.

10. Connect the wire harness to the ECC.

11. Reinstall the screws of the plastic plate between fan and seat and screws of the cassette cover, and connect the wire
harness connector of outlet and diesel heater switch.

12. Fit the plastic casing over the cab fan.

Figure 5
Cab fan casing
13. Return the operator's seat to the original position.

14. Check the air conditioner working after turning on the battery disconnect switch.
 Service Information

Document Title: Function Group: Information Type: Date:

Component list: Alternator, 370 Service Information 2014/7/4 0
batteries, capacitors,
electronic units, voltage
outlet
Profile:
EXC, EW160C, EW180C, EW140C [GB]

Component list: Alternator, batteries, capacitors, electronic units,

voltage outlet
Marking Description Wiring diagram
AL3201 Alternator 370 Wiring diagram SCH01
3021 AL3201, description and measuring
BA3101 Battery 1 370 Wiring diagram SCH01
3021 BA3101, description and measuring
BA3102 Battery 2 370 Wiring diagram SCH01
3021 BA3101, description and measuring
E-ECU Engine ECU 370 Wiring diagram SCH02
I-ECU Instrument ECU 370 Wiring diagram SCH02
V-ECU Vehicle ECU 370 Wiring diagram SCH02
W-ECU Caretrack ECU 370 Wiring diagram SCH24
ECC Electronic climate control unit 370 Wiring diagram SCH10
CU3601 Wiper controller 370 Wiring diagram SCH13
CU8702 Time control unit for Diesel heater 370 Wiring diagram SCH11
CU9901 Auto grease control unit 370 Wiring diagram SCH20
 Service Information

Document Title: Function Group: Information Type: Date:

Component list, Heating 370 Service Information 2014/7/4 0
coils
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Component list, Heating coils

Marking Description Wiring diagram
HE2301 Fuel warmer 370 Wiring diagram SCH03
HE2501 Element, preheating induction air 370 Wiring diagram SCH03
370 Wiring diagram SCH04
3021 HE2501, description and measuring
HE3801 Cigar lighter, 28VDC 370 Wiring diagram SCH14
HE8501 Element, heated seat 370 Wiring diagram SCH14
HE8701 Diesel Cabin heater 370 Wiring diagram SCH11
 Service Information

Document Title: Function Group: Information Type: Date:

Component list, Lights 370 Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Component list, Lights

Marking Description Wiring diagram
LA3501 Cab interior light 370 Wiring diagram SCH14
LA3502 Low beam, left head light 370 Wiring diagram SCH06
LA3503 Low beam, right head light 370 Wiring diagram SCH06
LA3504 High beam, left head light 370 Wiring diagram SCH06
LA3505 High beam, right head light 370 Wiring diagram SCH06
LA3506 Position light, front left 370 Wiring diagram SCH05
LA3507 Position light, front right 370 Wiring diagram SCH05
LA3510 Tail light, rear left 370 Wiring diagram SCH05
LA3511 Tail light, rear right 370 Wiring diagram SCH05
LA3514 Work light , cab rear 370 Wiring diagram SCH07
LA3515 Work light , counterweight 370 Wiring diagram SCH07
LA3521 Work light on the left of cab front 370 Wiring diagram SCH07
LA3522 Work light on the right of cab front 370 Wiring diagram SCH07
LA3527 Work light 1 on the left of boom 370 Wiring diagram SCH07
LA3528 Work light 1 on the right of boom 370 Wiring diagram SCH07
LA3531 Number plate light, left 370 Wiring diagram SCH05
LA3532 Number plate light, right 370 Wiring diagram SCH05
LA3533 Fog light 370 Wiring diagram SCH06
LA3534 Lateral light 370 Wiring diagram SCH05
LA3601 Rotating beacon 370 Wiring diagram SCH14
LA3602 Direction indicator, front left 370 Wiring diagram SCH05
LA3603 Direction indicator, front right 370 Wiring diagram SCH05
LA3608 Direction indicator, rear left 370 Wiring diagram SCH05
LA3609 Direction indicator, rear right 370 Wiring diagram SCH05
LA4201 Reverse travelling light 370 Wiring diagram SCH06
LA5201 Stop light, right 370 Wiring diagram SCH06
LA5202 Stop light, left 370 Wiring diagram SCH06
 Service Information

Document Title: Function Group: Information Type: Date:

Component list: Control 370 Service Information 2014/7/4 0
lights/warning lights
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Component list: Control lights/warning lights

Marking Description Wiring diagram
IM3803 Fuel level gauge 370 Wiring diagram SCH04
IM3811 Coolant gauge 370 Wiring diagram SCH04
IM3812 Hour meter 370 Wiring diagram SCH04
LC2201 Low oil pressure, engine oil 370 Wiring diagram SCH04
LC2205 Low level, engine oil 370 Wiring diagram SCH04
LC2302 Water in fuel 370 Wiring diagram SCH04
LC2501 Clogged Air filter 370 Wiring diagram SCH04
LC2502 Preheating 370 Wiring diagram SCH04
LC2601 Engine temperature high 370 Wiring diagram SCH04
LC2602 Coolant level low 370 Wiring diagram SCH04
LC3201 Battery, charging 370 Wiring diagram SCH04
LC3501 High beams 370 Wiring diagram SCH06
LC3602 LH direction indicator 370 Wiring diagram SCH05
LC3603 TH direction indicator 370 Wiring diagram SCH05
LC3801 Amber central warning 370 Wiring diagram SCH17
370 Wiring diagram SCH21
LC3803 Red central warning 1 370 Wiring diagram SCH04
LC5201 Brake error, servo pressure 370 Wiring diagram SCH04
LC6401 Steering pressure low indicator 370 Wiring diagram SCH04
LC9154 Hydraulic oil filter indicatorr 370 Wiring diagram SCH04
LC9155 Hydraulic oil temperature indicator 370 Wiring diagram SCH04
LC9156 Hammer selection indicator 370 Wiring diagram SCH15
LC9157 Shear selection indicator 370 Wiring diagram SCH15
LC9201 Quick fit open indicator 370 Wiring diagram SCH17
370 Wiring diagram SCH21
LC9401 Over load indicator 370 Wiring diagram SCH04
LC9911 Automatic lubricating pilot indicator 370 Wiring diagram SCH04
 Service Information

Document Title: Function Group: Information Type: Date:

Component list, Solenoid 370 Service Information 2014/7/4 0
valves
Profile:
EXC, EW140C [GB]

Component list, Solenoid valves

Connectors list, solenoid valve

Marking Description Wiring diagram

MA2301 Injector 1 370 Wiring diagram SCH03
MA2302 Injector 2 370 Wiring diagram SCH03
MA2303 Injector 3 370 Wiring diagram SCH03
MA2304 Injector 4 370 Wiring diagram SCH03
MA2504 Internal exhausted gas recirculation 370 Wiring diagram SCH03
MA4214 Q-max 370 Wiring diagram SCH09
MA4218 Travel forward 370 Wiring diagram SCH09
MA4219 Travel reverse 370 Wiring diagram SCH09
MA4302 Travel gearbox, low speed 370 Wiring diagram SCH09
MA4303 Travel gearbox, high speed 370 Wiring diagram SCH09
MA5205 Electrical digging brake 370 Wiring diagram SCH09
370 Wiring diagram SCH25
MA8701 Compressor clutch 370 Wiring diagram SCH10
MA9103 X1 Left-hand 370 Wiring diagram SCH15
MA9104 X1 Right-hand 370 Wiring diagram SCH15
MA9107 Power boost 370 Wiring diagram SCH08
MA9108 Hydraulic safety 370 Wiring diagram SCH08
MA9109 Quickfit 370 Wiring diagram SCH17
370 Wiring diagram SCH21
MA9120 Boom float 370 Wiring diagram SCH17
MA9152 Pivot axle lock 370 Wiring diagram SCH09
MA9153 Stabilizer, front left 370 Wiring diagram SCH19
MA9154 Stabilizer, front right 370 Wiring diagram SCH19
MA9155 Stabilizer, rear left 370 Wiring diagram SCH19
MA9156 Stabilizer, rear right 370 Wiring diagram SCH19
MA9157 Rototilt quickfit 370 Wiring diagram SCH21
MA9162 Rototilt solenoid 370 Wiring diagram SCH21
MA9164 Adjustable offset boom 370 Wiring diagram SCH15
MA9165 Grab changeover 370 Wiring diagram SCH21

Connectors list, proportional solenoid valve

Marking Description Wiring diagram

PWM2303 Actuator-MPROP common rail 370 Wiring diagram SCH03
PWM2602 Coolant fan motor 370 Wiring diagram SCH16
PWM4211 Cruise speed 370 Wiring diagram SCH09
PWM6603 CDC steering 370 Wiring diagram SCH09
PWM9101 Pump power shift 370 Wiring diagram SCH08
PWM9103 Oil cooler fan motor 370 Wiring diagram SCH16
PWM9104 Anti-cavitation 370 Wiring diagram SCH15
PWM9105 X3 left 370 Wiring diagram SCH16
PWM9106 X3 right 370 Wiring diagram SCH16
PWM9109 X1 main flow control 370 Wiring diagram SCH15
PWM9129 X1 PPRV1 370 Wiring diagram SCH15
 Service Information

Document Title: Function Group: Information Type: Date:

Component list, Motors 370 Service Information 2014/7/4 0
Profile:
EXC, EW180C, EW160C, EW140C [GB]

Component list, Motors

Marking Description Wiring diagram
MO2302 Fuel filler pump 370 Wiring diagram SCH18
MO3301 Starter motor 370 Wiring diagram SCH01
370 Wiring diagram SCH03
3021 MO3301, description and measuring
MO3601 Windscreen washer 370 Wiring diagram SCH13
MO3602 Windscreen wiper 370 Wiring diagram SCH13
MO3603 Windscreen wiper, lower 370 Wiring diagram SCH13
MO3604 Windscreen washer, lower 370 Wiring diagram SCH13
MO8501 Air suspension motor (option) 370 Wiring diagram SCH14
MO8701 A/C cooling fan 370 Wiring diagram SCH10
MO8703 Air conditioner - Intake actuator 370 Wiring diagram SCH10
MO8704 Air conditioner - Face actuator 370 Wiring diagram SCH10
MO8705 Air conditioner - Foot RH actuator 370 Wiring diagram SCH10
MO8706 Air conditioner - Foot LH actuator 370 Wiring diagram SCH10
MO8707 Air conditioner - Mix actuator 370 Wiring diagram SCH10
MO8708 Diesel heater water pump motor (option) 370 Wiring diagram SCH11
MO8709 Diesel heater fuel pump motor (option) 370 Wiring diagram SCH11
 Service Information

Document Title: Function Group: Information Type: Date:

Component list, Relays 370 Service Information 2014/7/4 0
Profile:
EXC, EW180C, EW160C, EW140C [GB]

Component list, Relays

For description and measuring, see: 3021 RExxxx, Relays general, description and measuring

Marking Description Wiring diagram

RE2501 Pre heating, induction air 370 Wiring diagram SCH03
3021 RE2501, description and measuring
RE3101 Main relay 1 370 Wiring diagram SCH01
RE3102 Main relay 2 370 Wiring diagram SCH01
RE3301 Starter motor on the motor 370 Wiring diagram SCH01
370 Wiring diagram SCH03
RE3302 Starter power relay 370 Wiring diagram SCH01
RE3501 Working lights, front 370 Wiring diagram SCH06
RE3503 Working lights 370 Wiring diagram SCH07
RE3504 Timer relay (interior light) — deleted 370 Wiring diagram SCH14
RE3611 Horn 370 Wiring diagram SCH12
RE3701 Spare relay 1 370 Wiring diagram SCH01
RE3702 Spare relay 2 370 Wiring diagram SCH01
RE4201 Reversing light, reversing alarm 370 Wiring diagram SCH06
RE4206 Travel alarm 370 Wiring diagram SCH12
RE5201 Stop lights 370 Wiring diagram SCH06
RE8701 Diesel heater (option) 370 Wiring diagram SCH11
RE9108 Control lockout relay/safety relay (=pilot cut-off) 370 Wiring diagram SCH03
370 Wiring diagram SCH08
RE9403 Rototilt relais 370 Wiring diagram SCH21
RF3601 Flasher relay 370 Wiring diagram SCH05
RT3501 Timer (interior light) — deleted 370 Wiring diagram SCH14
 Service Information

Document Title: Function Group: Information Type: Date:

Component list, Sensors 370 Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Component list, Sensors

Marking Description Wiring diagram
SE2202 Engine oil temperature 370 Wiring diagram SCH03
370 Wiring diagram SCH04
SE2203 Engine oil pressure 370 Wiring diagram SCH04
SE2205 Engine oil level 370 Wiring diagram SCH03
370 Wiring diagram SCH04
SE2301 Fuel pressure 370 Wiring diagram SCH04
SE2302 Water in fuel level 370 Wiring diagram SCH04
SE2303 Fuel level 370 Wiring diagram SCH04
SE2304 Fuel pump level 370 Wiring diagram SCH18
SE2309 Common rail fuel pressure 370 Wiring diagram SCH03
SE2501 Ambient air temperature 370 Wiring diagram SCH03
SE2502 Air filter clogging 370 Wiring diagram SCH04
SE2507 Boost air temperature 370 Wiring diagram SCH04
SE2508 Boost air pressure 370 Wiring diagram SCH04
SE2603 Coolant level 370 Wiring diagram SCH04
SE2606 Coolant temperature 370 Wiring diagram SCH03
370 Wiring diagram SCH04
370 Wiring diagram SCH16
SE2701 Engine speed, flywheel 370 Wiring diagram SCH03
SE2703 Engine speed, camshaft 370 Wiring diagram SCH03
SE2707 Engine speed, flywheel 370 Wiring diagram SCH08
SE3602 Limit switch, upper wiper 370 Wiring diagram SCH13
SE3603 Limit switch, lower wiper 370 Wiring diagram SCH13
SE4213 Transmission speed 370 Wiring diagram SCH09
370 Wiring diagram SCH25
SE4217 Travel pedal pressure 370 Wiring diagram SCH08
SE4218 Steering pressure 370 Wiring diagram SCH04
SE4901 Turret alignment 370 Wiring diagram SCH09
SE5201 Service brake pressure 370 Wiring diagram SCH06
SE5205 Brake pressure 370 Wiring diagram SCH04
SE8301 Left door position 370 Wiring diagram SCH14
SE8503 Control lockout lever position 370 Wiring diagram SCH08
SE8701 Pressure, refrigerant 370 Wiring diagram SCH10
SE8702 Temperature, refrigerant 370 Wiring diagram SCH10
SE8705 Temperature, ambient 370 Wiring diagram SCH10
SE8706 Recirculation air temperature, cab 370 Wiring diagram SCH10
SE8707 Temperature, coolant 370 Wiring diagram SCH10
SE9101 Auto idle pressure 370 Wiring diagram SCH08
SE9105 Hydraulic oil tank temperature 370 Wiring diagram SCH04
 370 Wiring diagram SCH16
SE9106 Hydraulic oil tank return oil pressure 370 Wiring diagram SCH04
SE9114 Auto idle pressure, boom down 370 Wiring diagram SCH08
SE9115 Auto idle pressure, arm in 370 Wiring diagram SCH08
SE9141 Position, ISO type control lever 370 Wiring diagram SCH04
SE9142 Position, Backhoe type control lever 370 Wiring diagram SCH04
SE9401 Overload pressure 370 Wiring diagram SCH04
 Service Information

Document Title: Function Group: Information Type: Date:

Component list, Switches 370 Service Information 2014/7/4 0
Profile:
EXC, EW180C, EW160C, EW140C [GB]

Component list, Switches

Marking Description Wiring diagram
SW2301 Fuel warmer 370 Wiring diagram SCH03
SW2302 Fuel refilling pump start 370 Wiring diagram SCH18
SW2303 Fuel refilling pump stop 370 Wiring diagram SCH18
SW2701 Engine speed control 370 Wiring diagram SCH03
SW2703 Auto idling 370 Wiring diagram SCH03
SW2704 Emergency engine speed control and stop 370 Wiring diagram SCH02
370 Wiring diagram SCH03
SW3101 Battery disconnection 370 Wiring diagram SCH01
SW3301 Engine start 370 Wiring diagram SCH01
370 Wiring diagram SCH03
SW3501 Travel lights, front 370 Wiring diagram SCH05
SW3502 High and low beam 370 Wiring diagram SCH06
SW3503 Cab interior light 370 Wiring diagram SCH14
SW3504 Work light, front 370 Wiring diagram SCH07
SW3505 Work light, rear 370 Wiring diagram SCH07
SW3510 Fog light 370 Wiring diagram SCH06
SW3602 Wiper, upper 370 Wiring diagram SCH13
SW3603 Wiper, lower 370 Wiring diagram SCH13
SW3604 Horn 370 Wiring diagram SCH12
SW3605 Direction indicators 370 Wiring diagram SCH05
SW3606 Hazard flashers 370 Wiring diagram SCH05
SW3607 Rotating beacon 370 Wiring diagram SCH14
SW3608 Washer, upper 370 Wiring diagram SCH13
SW3609 Horn switch on the left control lever 370 Wiring diagram SCH12
SW3611 Mode selection 370 Wiring diagram SCH09
SW3613 Washer, lower 370 Wiring diagram SCH13
SW3902 Cassette remote control 370 Wiring diagram SCH12
SW4202 Travel speed selection 370 Wiring diagram SCH09
SW4204 Cruise control 370 Wiring diagram SCH09
SW4205 Travel direction selection, right control lever 370 Wiring diagram SCH06
370 Wiring diagram SCH09
SW4206 Manual travel direction selection 370 Wiring diagram SCH09
SW4207 CDC or X3 selection 370 Wiring diagram SCH09
370 Wiring diagram SCH16
SW5205 Electrical digging brake, left control lever 370 Wiring diagram SCH09
370 Wiring diagram SCH25
SW8501 Seat heater 370 Wiring diagram SCH14
SW8502 Air suspension 370 Wiring diagram SCH14
SW8701 Climate control system 370 Wiring diagram SCH02
 370 Wiring diagram SCH10
SW9103 Automatic/manual pump control 370 Wiring diagram SCH02
370 Wiring diagram SCH08
SW9104 Quickffit 370 Wiring diagram SCH17
370 Wiring diagram SCH21
SW9107 Shear/hammer selection 370 Wiring diagram SCH15
SW9108 Power boost & hammer 370 Wiring diagram SCH15
SW9151 Pivot axle locking 370 Wiring diagram SCH09
SW9152 Auto axle locking, right control lever 370 Wiring diagram SCH09
SW9153 Stabilizer, front left 370 Wiring diagram SCH19
SW9154 Stabilizer, front right 370 Wiring diagram SCH19
SW9155 Stabilizer, rear left 370 Wiring diagram SCH19
SW9156 Stabilizer, rear right 370 Wiring diagram SCH19
SW9158 Boom float, right control leve 370 Wiring diagram SCH17
SW9159 Hammer foot 370 Wiring diagram SCH15
SW9160 Quickffit buzz stop/confirm 370 Wiring diagram SCH17
SW9161 X3 proportional, left control lever 370 Wiring diagram SCH16
SW9162 X1 proportional, right control lever 370 Wiring diagram SCH15
SW9163 X1 switch, left side, right control lever 370 Wiring diagram SCH15
SW9164 X1 switch, right side, right control lever 370 Wiring diagram SCH15
SW9165 Grab changeover, left control lever 370 Wiring diagram SCH21
SW9166 Adjustable offset boom, left control lever 370 Wiring diagram SCH15
SW9401 Overload warning selection switch 370 Wiring diagram SCH04
SW9403 Rototilt selection 370 Wiring diagram SCH21
SW9405 X3 left, left control lever 370 Wiring diagram SCH16
SW9406 X3 right, left control lever 370 Wiring diagram SCH16
SW9901 Automatic greasing 370 Wiring diagram SCH20
 Service Information

Document Title: Function Group: Information Type: Date:

Component list, Fuses 370 Service Information 2014/7/4 0
Profile:
EXC, EW160C, EW180C, EW140C [GB]

Component list, Fuses

Circuit breaker
Breaker Capacity Designation Wiring diagram
FC01 150 A Air preheater 370 Wiring diagram SCH01
FC02 80 A Main fuse 370 Wiring diagram SCH01
FC03 15 A B+ fuse 370 Wiring diagram SCH01

Fuses in distribution box

Fuse Capacity Designation Wiring diagram
FU01 10 A Horn 370 Wiring diagram SCH12
FU02 10 A Power outlet 370 Wiring diagram SCH01
370 Wiring diagram SCH20
FU03 10 A Stop light 370 Wiring diagram SCH06
FU04 20 A Work light (Boom) 370 Wiring diagram SCH07
FU05 10 A High beams 370 Wiring diagram SCH06
FU06 10 A Spare 2, hydraulic option 370 Wiring diagram SCH08
370 Wiring diagram SCH09
FU07 10 A V-ECU 370 Wiring diagram SCH02
370 Wiring diagram SCH08
FU08 10 A High and low beams 370 Wiring diagram SCH06
FU09 15 A Fuel warmer 370 Wiring diagram SCH03
Auto lubrication 370 Wiring diagram SCH20
FU10 10 A Low beam, right 370 Wiring diagram SCH06
FU11 10 A I-ECU 370 Wiring diagram SCH02
370 Wiring diagram SCH04
370 Wiring diagram SCH12
FU12 15 A Spare 370 Wiring diagram SCH01
FU13 10 A Hazard flasher 370 Wiring diagram SCH05
FU14 15 A Work light (extra) 370 Wiring diagram SCH07
FU15 10 Low beam, left 370 Wiring diagram SCH06
FU16 10 A Cigarette lighter 370 Wiring diagram SCH14
FU17 15 A Fuel refilling pump 370 Wiring diagram SCH18
FU18 10 A Spare 1, hydraulic option 370 Wiring diagram SCH08
FU19 10 A Rotating beacon 370 Wiring diagram SCH14
FU20 15 A Auxiliary heater 370 Wiring diagram SCH11
FU21 10 A Backward travelling warning 370 Wiring diagram SCH12
FU22 20 A E-ECU 370 Wiring diagram SCH02
370 Wiring diagram SCH03
FU23 Travel light 370 Wiring diagram SCH05
Direction indicator 370 Wiring diagram SCH06
FU24 15 A Engine start switch / I-ECU 370 Wiring diagram SCH01
370 Wiring diagram SCH02
 370 Wiring diagram SCH03
FU25 20 A Voltage convertor for CD/radio 370 Wiring diagram SCH12
FU26 10 A Spare 3, hydraulic option 370 Wiring diagram SCH06
370 Wiring diagram SCH15
370 Wiring diagram SCH17
FU27 15 A Seat heating & air suspension 370 Wiring diagram SCH14
FU28 10 A Cab interior light 370 Wiring diagram SCH14
FU29 15 A Automatic greasing 370 Wiring diagram SCH01
FU30 10 A Fog light 370 Wiring diagram SCH05
Position light, right
FU31 10 A Stabilizer 370 Wiring diagram SCH19
Dozer blade
FU32 10 A Quickfit 370 Wiring diagram SCH17
370 Wiring diagram SCH21
FU33 10 A Position light, left 370 Wiring diagram SCH05
FU34 10 A Wiper & washer 370 Wiring diagram SCH12
370 Wiring diagram SCH13
 Service Information

Document Title: Function Group: Information Type: Date:

Component list, 370 Service Information 2014/7/4 0
Miscellaneous
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Component list, Miscellaneous

Marking Description Wiring diagram
ANT3901 Antenna 370 Wiring diagram SCH12
CR3901 Cassette/CD player 370 Wiring diagram SCH12
DI3603 Diode for windscreen washer 370 Wiring diagram SCH13
DI3604 Diode for horn 1 370 Wiring diagram SCH12
DI3605 Diode for horn 2 370 Wiring diagram SCH12
DI3606 Diode for windscreen washer, lower 370 Wiring diagram SCH13
DI8701 Diode for air conditioner cooling fan 370 Wiring diagram SCH10
PC3601 Socket for VCADS pro 370 Wiring diagram SCH02
PO3902 Power socket, 14V 10A 370 Wiring diagram SCH12
PO3903 Power socket, 14V 4A 370 Wiring diagram SCH12
PO3904 Socket for communication 370 Wiring diagram SCH02
R3201 Resister 370 Wiring diagram SCH01
R9101 Manual resister 1 370 Wiring diagram SCH08
RC3903 Rear view camera 370 Wiring diagram SCH22
SA3602 Horn 370 Wiring diagram SCH12
SA3603 Horn 370 Wiring diagram SCH12
SA3901 Speaker, Left-hand 370 Wiring diagram SCH12
SA3902 Speaker, Right-hand 370 Wiring diagram SCH12
SA4206 Travel alarm 370 Wiring diagram SCH12
SO3901 DC-DC converter 370 Wiring diagram SCH12
 Service Information

Document Title: Function Group: Information Type: Date:

Wiring harnesses 370 Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C [GB]

Wiring harnesses
Figure 1
Wiring diagram, general
 Service Information

Document Title: Function Group: Information Type: Date:

Control system diagram 370 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Control system diagram

Figure 1
Control system diagram
 Service Information

Document Title: Function Group: Information Type: Date:

Wiring diagram, electrical 370 Service Information 2014/7/4 0
distribution box
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Wiring diagram, electrical distribution box

Figure 1
EDB circuit diagram
 Service Information

Document Title: Function Group: Information Type: Date:

Grounding points (frame 370 Service Information 2014/7/4 0
connections)
Profile:
EXC, EW140C [GB]

Grounding points (frame connections)

Figure 1
Ground connections

1. Grounding point GC1, in the cab behind the V-ECU

2. Grounding point GF3, under the air filter
3. Grounding point GF1, beside the batteries
4. Grounding point GE1, engine starter motor side,
5. Grounding point GF2, upper frame under the engine
 Service Information

Document Title: Function Group: Information Type: Date:

Wiring diagram, general 370 Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Wiring diagram, general

Schema Description Link
Wire – harness layout 370 Wiring harnesses
Control system diagram 370 Control system diagram
Grounding points 370 Grounding points (frame connections)
SCH01 Power feed 370 Wiring diagram SCH01
SCH02 ECU power & communication 370 Wiring diagram SCH02
SCH03 Starting & rpm control 370 Wiring diagram SCH03
SCH04 Warning & sensor 370 Wiring diagram SCH04
SCH05 Turn signal 370 Wiring diagram SCH05
SCH06 Head & stop light 370 Wiring diagram SCH06
SCH07 Working light 370 Wiring diagram SCH07
SCH08 Machine control 370 Wiring diagram SCH08
SCH09 Travelling 370 Wiring diagram SCH09
SCH10 HVAC 370 Wiring diagram SCH10
SCH11 5KW Diesel heater 370 Wiring diagram SCH11
SCH12 Audio & horn 370 Wiring diagram SCH12
SCH13 Wiper & washer 370 Wiring diagram SCH13
SCH14 Seat heater, beacon, room lamp 370 Wiring diagram SCH14
SCH15 X1 Control 370 Wiring diagram SCH15
SCH16 X3 & cooler control 370 Wiring diagram SCH16
SCH17 Quick fit, float 370 Wiring diagram SCH17
SCH18 Fuel refilling pump 370 Wiring diagram SCH18
SCH19 Stabilizer & dozer blade 370 Wiring diagram SCH19
SCH20 Auto grease 370 Wiring diagram SCH20
SCH21 Rototilt 370 Wiring diagram SCH21
SCH22 Rear view camera 370 Wiring diagram SCH22
SCH23 Swing brake 370 Wiring diagram SCH23
SCH24 Caretrack 370 Wiring diagram SCH24
SCH25 Electrical digging brake 370 Wiring diagram SCH25
SCH26 CDC 370 Wiring diagram SCH26
SCH27 DPF, Diesel particle filter 370 Wiring diagram SCH27
 Service Information

Document Title: Function Group: Information Type: Date:

Component designations 370 Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Component designations
The components in the electrical system are grouped in sixteen component groups according to standard SS-IEC 750 . The
component group is indicated by a letter according to the following table. Each separate component has a running number
after the letter.

Description Designation
Antenna ANT
Diodes DI
Alternator AL
Sensors and monitors SE
Indicator light LC
Cassette radio CRR
Control unit CU
Lights LA
Solenoid valve MA
Motor MO
Proportional valve PWM
Relay RE
Service connection IS
Horn, speakers SA
Voltage converter SO
Power (electric) source BA
Switches SW
Control unit V-ECU, E-ECU, I-ECU, W-ECU, ECC
Fuses FU
Timers and counters IM
Connections and connectors PO
Heaters HE
 Service Information

Document Title: Function Group: Information Type: Date:

Explanation of wiring 370 Service Information 2014/7/4 0
diagrams
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Explanation of wiring diagrams

Figure 1
Example of cable and component markings

Position Explanation Position Explanation

1 Reference, cable (lead) has permanent 6 Key dependent voltage supply
connection to wiring diagram SCH07
The flag's point indicates direction of current
2 Connector with pin marking 7 Connection marking
3 Component marking 8 Frame grounding point (frame connection)
4 Cable/lead color, see table below 9 Diagram number
5 Cable/lead marking 10 Reference, cable has a splicing point which has
connected to other function diagram SCHXX

Cable (lead) colors on wiring diagrams are outlined in the following table.
Code & color

Code Color Code Color

BL Blue R Red
BN Brown SB Black
GN Green VO Violet
GR Grey W White
OR Orange Y Yellow
P Pink LG Light green
 Service Information

Document Title: Function Group: Information Type: Date:

Electrical symbols and 370 Service Information 2014/7/4 0
designations
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Electrical symbols and designations

Designation Symbol Explanation
AL Alternator with charging regulator

BA Battery

CU Electronic control unit

DI Diode
ECC Climate control unit

E-ECU Engine control unit

FU Fuse
HE Heaters

I-ECU Instrument control unit

IM Instrument, i.e. hour meter

LA Light
LC Control light, fixed light
Control light, flashing light
MA Solenoid valve

MO Electric motor

Starter motor

PO Power outlets

PWM Proportional solenoid valve

R Resistor

RE Relay

RFX Relay

SA Audible signal

SE Speed sensor

Level sensor

Temperature sensor

Pressure sensor

Pressure switch

Mechanical switch

Position switch

SW Switch

Switch

V-ECU Vehicle control unit

Ground connection

Ground connection engine block

Shielded cable
 Service Information

Document Title: Function Group: Information Type: Date:

Wiring diagram SCH01 370 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Wiring diagram SCH01

Figure 1
Power feed

Marking Designation
AL3201 Alternator
BA3101 Battery 1
BA3102 Battery 2
FC01 Pre–heater fuse (150 A)
FC02 Main fuse (80 A)
FC03 B+ fuse (15 A)
MO3301 Starter motor
FU02 Spare fuse 2 (10A)
FU24 Start switch (15A) / fuse I-ECU
FU29 Spare fuse 1 (15A)
MO3301 Starter motor
R3201 Alternator resistor 220 Ohm / 5W
RE3101 Main relay 1
RE3102 Main relay 2
RE3301 Starter motor on the motor
RE3302 Starter power relay
RE3701 Spare relay 1
RE3702 Spare relay 2
SW3101 Battery disconnection switch (main)
SW3301 Ignition switch

Figure 2
Component location
 Service Information

Document Title: Function Group: Information Type: Date:

Wiring diagram SCH02 370 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Wiring diagram SCH02

ECU power and communication
Figure 1
Wiring diagram SCH02

Marking Designation Marking Designation

PC3601 Socket for VCADS pro ECC Electronic climate controller
PO3904 Socket for communication E-ECU Engine control unit
SW2704 Emergency engine speed control and stop I-ECU Instrument Control unit
switch
SW8701 Key pad for air conditioner V-ECU Vehicle control unit
SW9103 Automatic/manual pump control switch

Figure 2
Component location
 Service Information

Document Title: Function Group: Information Type: Date:

Wiring diagram SCH03 370 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Wiring diagram SCH03

Engine starting and speed control system
Figure 1
Wiring diagram SCH03

Marking Designation Marking Designation

HE2301 Fuel warmer RE9108 Control lockout relay
HE2501 Air preheater SE2202 Engine oil temperature sensor
MA2301 Injector 1 SE2205 Engine oil level sensor
MA2302 Injector 2 SE2309 Common rail fuel pressure sensor
MA2303 Injector 3 SE2501 Ambient air temperature sensor
MA2304 Injector 4 SE2606 Coolant temperature sensor
MA2305 Injector 5 SE2701 Engine speed sensor, crankshaft
MA2306 Injector 6 SE2703 Engine speed sensor, camshaft
MA2504 Internal exhausted gas recirculation SE8503 Control lockout lever, position sensor
MO3301 Starter motor SW2301 Fuel warmer switch
PWM2303 Actuator-MPROP common rail SW2701 Engine speed control switch
RE2501 Preheater relay SW2703 Auto idle switch
RE3301 Starter motor relay SW2704 Emergency engine speed control and stop
switch
RE3302 Starter motor power relay SW3301 Engine start switch

Figure 2
Component location
 Service Information

Document Title: Function Group: Information Type: Date:

Wiring diagram SCH04 370 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Wiring diagram SCH04

Warning and sensor
Figure 1
Wiring diagram SCH04

Marking Designation Marking Designation

HE2501 Air preheater, element SE2202 Engine oil temperature sensor
IM3803 Fuel level gauge SE2203 Engine oil pressure sensor
IM3811 Coolant temperature gauge SE2205 Engine oil level sensor
IM3812 Hour counter SE2301 Fuel pressure sensor
LC2201 Engine oil pressure indicator SE2302 Water in fuel level switch
LC2201 Engine oil low pressure indicator SE2303 Fuel level sensor
LC2205 Engine oil low level indicator SE2502 Air filter clogging switch
LC2302 Water in fuel indicator SE2507 Boost air temperature sensor
LC2502 Preheating indicator SE2508 Boost air pressure sensor
LC2601 Engine high temperature indicator SE2603 Coolant level switch
LC2602 Coolant low level indicator SE2606 Coolant temperature sensor
LC3201 Battery charging indicator SE4218 Steering pressure sensor
LC3803 Central warning indicator SE5205 Brake pressure sensor
LC5201 Low brake pressure SE9105 Hydraulic oil temperature sensor
LC6401 Low steering pressure SE9106 Hydraulic return oil pressure sensor
LC9154 Hydraulic oil filter clogging indicator SE9141 Position sensor, ISO type control lever
LC9155 Hydraulic oil temperature indicator SE9142 Position sensor, Backhoe type control lever
LC9401 Overload indicator SE9401 Overload pressure sensor
LC9911 Automatic greasing indicator SW9401 Overload warning selection switch

Figure 2
Component location 1
Figure 3
Component location 2

Figure 4
Component location 3
 Service Information

Document Title: Function Group: Information Type: Date:

Wiring diagram SCH05 370 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Wiring diagram SCH05

Turn signal
Figure 1
Wiring diagram SCH05

Marking Designation Marking Designation

LA3506 Position light, front left LA3608 Direction indicator, rear left
LA3507 Position light, front right LA3609 Direction indicator, rear right
LA3510 Tail light, rear left LC3602 Direction indicator, left
LA3511 Tail light, rear right LC3603 Direction indicator, right
LA3531 Number plate light, left RF3601 Flasher relay
LA3532 Number plate light, right SW3501 Travel light, front
LA3534 Lateral light SW3605 Direction indicator
LA3602 Direction indicator, front left SW3606 Hazard flashers
LA3603 Direction indicator, front right

Figure 2
Component location
 Service Information

Document Title: Function Group: Information Type: Date:

Wiring diagram SCH06 370 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Wiring diagram SCH06

Figure 1
Lights

Marking Designation Marking Designation

FU03 Fuse stop light LA4202 Reversing back – up light left
FU05 Fuse high beam light LA5201 Stop light, right
FU08 Fuse RE3501 LA5202 Stop light, left
FU10 Fuse low beam right LC3501 High beams
FU15 Fuse low beam left RE3501 Working lights, front
FU23 Fuse hazard light RE4201 Reversing light, reversing alarm
LA3502 Low beam, left, front head light RE5201 Stop lights
LA3503 Low beam, right, front head light SE5201 Pressure switch, service brake
LA3504 High beam, left, front head light SW3502 High and low beams
LA3505 High beam, right, front head light SW4205 Travel direction selection
LA4201 Reversing back – up light right

Figure 2
Component location
 Service Information

Document Title: Function Group: Information Type: Date:

Wiring diagram SCH07 370 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Wiring diagram SCH07

Work lights
Figure 1
Wiring diagram SCH07

Marking Designation Marking Designation

LA3514 Work light, rear cab LA3528 Work light 1, boom right
LA3515 Work light, rear counterweight RE3503 Working lights
LA3521 Work light, cab front, left SW3504 Work light switch, front
LA3522 Work light, cab front, right SW3505 Work light switch, rear
LA3527 Work light 1, boom left

Figure 2
Component location
 Service Information

Document Title: Function Group: Information Type: Date:

Wiring diagram SCH08 370 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Wiring diagram SCH08

Figure 1
Machine control

Marking Designation Marking Designation

FU06 Fuse V-ECU SE2707 Engine speed (flywheel 2)
FU07 Fuse manual switch SE4217 Pressure monitor travel speed
FU18 Fuse V-ECU SE8503 Control lockout switch
MA9107 Power boost SE9101 LS pressure switch
MA9108 Control lockout solenoid valve SE9114 Pressure monitor, boom down (auto idle)
PWM9101 Pump power shift 1 SE9115 Pressure monitor, dipper in (auto idle)
R9101 Resistor pump 1 manual SE9117 Pressure monitor swing (auto idle), only
EW230C
RE9108 Control lockout relay (= pilot cutoff relay) SW9103 Pump manual switch

Figure 2
Component location
 Service Information

Document Title: Function Group: Information Type: Date:

Wiring diagram SCH09 370 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Wiring diagram SCH09

Figure 1
Travelling

Marking Designation Marking Designation

FU06 Fuse V-ECU SE4901 Inductive sensor, turret alignment
MA4214 Q-max SW3611 Mode switch
MA4218 Travel forward SW4202 Travel speed
MA4219 Travel reverse SW4204 Cruise
MA4302 Low gear drop box SW4205 Travel direction selection (right joystick)
MA4303 High gear drop box SW4206 Travel manual
MA9152 Axle locking SW9151 Axle locking switch
PWM4211 Cruise speed SW9152 Auto axle locking (left joystick)

Figure 2
Component location
 Service Information

Document Title: Function Group: Information Type: Date:

Wiring diagram SCH10 370 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Wiring diagram SCH10

Figure 1
Electronic climate controller

Marking Designation Marking Designation

ECC Climate ECU SE2606 Engine coolant temperature
MA8701 Compressor, air conditioner SE2701 Engine speed flywheel 1
MO8701 A/C cooling fan SE8701 Pressure monitor refrigerant, air
conditioning
MO8703 Air conditioner, intake actuator SE8702 Temperature monitor, refrigerant
MO8704 Air conditioner, face actuator SE8705 Temperature monitor, ambient
MO8705 Air conditioner, foot right actuator SE8706 Temperature monitor, incar
MO8706 Air conditioner, foot left actuator SW8701 Climate control system A/C
MO8707 Air conditioner, air mix actuator

Figure 2
Component location
 Service Information

Document Title: Function Group: Information Type: Date:

Wiring diagram SCH11 370 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Wiring diagram SCH11

Figure 1
Diesel heater

Marking Designation Marking Designation

CU8702 Time control unit Diesel heater MO8708 Diesel heater water – pump motor (option)
FU20 Fuse HVAC/heater MO8709 Diesel heater fuel – pump motor (option)
HE8701 Diesel cabin heater RE8701 Diesel heater (option)
Figure 2
Component location
 Service Information

Document Title: Function Group: Information Type: Date:

Wiring diagram SCH12 370 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Wiring diagram SCH12

Audio and horn
Figure 1
Wiring diagram SCH12

Marking Designation Marking Designation

ANT3901 Antenna SA3901 Speaker, rear left
CR3901 Cassette/CD player SA3902 Speaker, rear right
DI3604 Diode, horn 1 SA4206 Travel alarm
PO3903 Power socket, 14 V 4 A SO3901 DC-DC converter
RE3611 Horn relay SW3604 Horn switch
RE4206 Travel alarm relay SW3609 Horn switch, left control lever
SA3602 Horn 1 SW3902 Remote control switch for CD radio

Figure 2
Component location
 Service Information

Document Title: Function Group: Information Type: Date:

Wiring diagram SCH13 370 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Wiring diagram SCH13

Wiper and washer
Figure 1
Wiring diagram SCH13

Marking Designation Marking Designation

CU3601 Wiper motor controller SE3602 Limit switch, upper wiper
DI3603 Diode, windscreen washer SE3603 Limit switch, lower wiper (option)
DI3606 Diode, windscreen washer, lower SW3602 Wiper switch, upper
MO3601 Washer pump SW3603 Wiper switch, lower (option)
MO3602 Wiper motor, upper SW3608 Washer switch, upper
MO3603 Wiper motor, lower (option) SW3613 Washer switch, lower (option)
MO3604 Washer pump, lower (option)

Figure 2
Component location
 Service Information

Document Title: Function Group: Information Type: Date:

Wiring diagram SCH14 370 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Go back to Index Page

Wiring diagram SCH14

Seat heater, beacon light, and cab interior light
Figure 1
Wiring diagram SCH14
Marking Designation Marking Designation
HE3801 Cigarette lighter RT3501 deleted
HE8501 Seat heater SE8301 Door position sensor
LA3501 Cab interior light SW3503 Cab interior light switch
LA3601 Rotating beacon SW3607 Rotating beacon switch
MO8501 Air suspension motor SW8501 Seat heater switch
RE3504 deleted SW8502 Air suspension switch

Figure 2
Component location
 Service Information

Document Title: Function Group: Information Type: Date:

Wiring diagram SCH14 370 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Go back to Index Page

Wiring diagram SCH14

Seat heater, beacon light, and cab interior light
Figure 1
Wiring diagram SCH14

Marking Designation Marking Designation

HE3801 Cigarette lighter RT3501 Timer (cab interior light)
HE8501 Seat heater SE8301 Door position sensor
LA3501 Cab interior light SW3503 Cab interior light switch
LA3601 Rotating beacon SW3607 Rotating beacon switch
MO8501 Air suspension motor SW8501 Seat heater switch
RE3504 Timer relay (cab interior light) SW8502 Air suspension switch

Figure 2
Component location
 Service Information

Document Title: Function Group: Information Type: Date:

Wiring diagram SCH15 370 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Wiring diagram SCH15

X1 control
Figure 1
Wiring diagram SCH15

Marking Designation Marking Designation

LC9156 Hammer selection indicator SW9107 X1 tool selection switch
LC9157 Shear selection indicator SW9108 Power boost switch
MA9103 X1 solenoid, left SW9159 Hammer foot switch
MA9104 X1 solenoid, right (hammer) SW9162 X1 proportional switch
MA9164 Adjustable offset boom solenoid SW9163 X1 switch, left (right control lever)
PWM9104 Anticavitation valve SW9164 X1 switch, right (right control lever)
PWM9109 X1 main flow control valve SW9166 Adjustable offset boom switch (not
EW230C)
PWM9129 X1 PPRV valve SW9166 Slew brake switch (only EW230C)

Figure 2
Component location
 Service Information

Document Title: Function Group: Information Type: Date:

Wiring diagram SCH16 370 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Wiring diagram SCH16

Figure 1
X3 and cooler control

Marking Designation Marking Designation

MA2602 Reverse solenoid (reversible fan motor, SE2606 Temperature sensor, coolant, engine
coolant)
PWM2602 Fan motor coolant SE9105 Temperature sensor, hydraulic oil tank
PWM9103 Fan motor, hydraulic oil SW9161 X3 proportional switch, left joystick
PWM9105 X3 left PPRV SW9405 X3 left switch, left joystick
PWM9106 X3 right PPRV SW9406 X3 right switch, left joystick
Figure 2
Component location
 Service Information

Document Title: Function Group: Information Type: Date:

Wiring diagram SCH17 370 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Wiring diagram SCH17

Figure 1
Quickfit and boom float

Marking Designation Marking Designation

FU32 Fuse quick fit MA9120 Boom float
LC3801 Amber central warning 1 SW9104 Quickfit switch 1
LC9201 Quick fit open indicator SW9158 Float position
MA9109 Quick fit SW9160 Buzzer stop & confirm switch

Figure 2
Component location
 Service Information

Document Title: Function Group: Information Type: Date:

Wiring diagram SCH18 370 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Wiring diagram SCH18

Figure 1
Fuel refilling pump

Marking Designation Marking Designation

D Anti surge diode SW2302 Fuel pump start switch
MO2302 Fuel filler pump SW2303 Fuel pump stop switch
SE2304 Fuel pump level sensor
Figure 2
Component location
 Service Information

Document Title: Function Group: Information Type: Date:

Wiring diagram SCH19 370 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Wiring diagram SCH19

Figure 1
Stabilizer
Marking Designation Marking Designation
MA9153 Magnet valve stabilizer, front left SW9153 Selection switch rocker stabilizer, front left
MA9154 Magnet valve stabilizer, front right/blade SW9154 Selection switch rockersStabilizer, front
right/blade
MA9155 Magnet valve stabilizer, rear left SW9155 Selection switch rocker stabilizer, rear left
MA9156 Magnet valve stabilizer, rear right/blade SW9156 Selection switch rocker stabilizer, rear right/
blade

Figure 2
Component location
 Service Information

Document Title: Function Group: Information Type: Date:

Wiring diagram SCH20 370 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Wiring diagram SCH20

Figure 1
Automatic greasing

Marking Designation Marking Designation

CU9901 Auto grease control unit SW9901 Automatic lubrication switch
Figure 2
Component location
 Service Information

Document Title: Function Group: Information Type: Date:

Wiring diagram SCH21 370 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Wiring diagram SCH21

Figure 1
Rototilt

Marking Designation Marking Designation

LC3801 Amber central warning MA9165 Grab changeover solenoid
LC9201 Quick fit open indicator RE9403 Rototilt relay
MA9109 Rototilt quick fit (option) SW9104 Quick fit switch
MA9157 Rototilt quick fit (option) SW9165 Grab change over switch (left joystick)
MA9162 Rototilt solenoid SW9403 Rototilt selection

Figure 2
Component location
 Service Information

Document Title: Function Group: Information Type: Date:

Wiring diagram SCH22 370 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Go back to Index Page

Wiring diagram SCH22

Rear view camera

Figure 1
Wiring diagram SCH22

Marking Designation Marking Designation

RC3903 Rear view camera (option) IECU Instrument control unit
Figure 2
Component location
 Service Information

Document Title: Function Group: Information Type: Date:

Wiring diagram SCH22 370 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Go back to Index Page

Wiring diagram SCH22

Rear view camera

Figure 1
Wiring diagram SCH22

Marking Designation Marking Designation

RC3903 Rear view camera (option) IECU Instrument control unit
Figure 2
Component location
 Service Information

Document Title: Function Group: Information Type: Date:

Wiring diagram SCH24 370 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Wiring diagram SCH24

Figure 1
Care track system

Marking Designation Marking Designation

PC3601 Socket for VCADS Pro WECU Caretrack ECU (option)
PO3904 Socket for option
Figure 2
Component location
 Service Information

Document Title: Function Group: Information Type: Date:

Wiring diagram SCH25 370 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Wiring diagram SCH25

Figure 1
Electrical digging brake

Marking Designation Marking Designation

MA5205 Electrical digging brake solenoid SW5205 Electrical digging brake
SE4213 T/M speed sensor
Figure 2
Component location
 Service Information

Document Title: Function Group: Information Type: Date:

Electrical distribution box Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Electrical distribution box

WARNING
Before working on the electrical distribution box, the battery must be completely disconnected. It's not sufficient to
turn off the battery disconnect switch as some connections in the electrical distribution box are supplied directly
from the battery.

Figure 1
Electrical distribution box

A: Relay

B: Fuse

C: Diode
Figure 2
Converter and circuit break

1: Wiper control unit (CU3601)

2: Circuit break fuse (Air pre-heater fuse, FC01,150 A)

3: Circuit break fuse (Main fuse, FC02, 80 A)

4: Voltage converter (SO3901)

5: Pre-heater relay (RE2501)

Figure 3
Electrical distribution box

A: Decal

B: Circuit board
 Service Information

Document Title: Function Group: Information Type: Date:

Fuse, description Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Fuse, description

Figure 1
Fuse unit

NOTICE
Always install a fuse of the same type with the correct amperage rating to prevent electrical system damage from
overload.

Fuse (blade-type) color codes

Amperage rating Color Amperage rating Color

3A Violet 15 A Light blue
4A Pink 20 A Yellow
5A Tan 25 A Natural (White)
7.5 A Brown 30 A Light green
10 A Red

Fuse, continuity test

Fuse failure is often caused by a fine crack in the fuse, and this kind of crack is very hard to detect by visual inspection.
Checking fuse continuity with a tester is far superior to eye inspection.
 Service Information

Document Title: Function Group: Information Type: Date:

Relay, description Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Relay, description

Figure 1
Relay

Figure 2
Timer

Troubleshooting
Concerning the relay troubleshooting information, see 370 Component list, Relays.
 Service Information

Document Title: Function Group: Information Type: Date:

Circuit breaker, description Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Circuit breaker, description

Figure 1
Circuit breaker

1: Circuit breaker (Air pre-heater fuse, DC 30 V, 150 A)

2: Circuit breaker (Main fuse, DC 30 V, 80 A)

A: Circuit breaker unit

Troubleshooting
Concerning the circuit breaker troubleshooting information, see 370 Component list, Fuses.
 Service Information

Document Title: Function Group: Information Type: Date:

Instruments and controls, 380 Service Information 2014/7/4 0
overview
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Instruments and controls, overview

Cab interior

Figure 1
Cab, instruments and controls

1. Main instrument panel (I-ECU)

2. Right instrument panel
3. Left instrument panel
4. Rear instrument panel
 Service Information

Document Title: Function Group: Information Type: Date:

Instruments and controls, 380 Service Information 2014/7/4 0
front instrument panel
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Instruments and controls, front instrument panel

Figure 1
Main instrument (I-ECU) and keypad

Item Description Item Description

1 Central warning lamp 5 Arrow up button
2 Gauge screen 6 Arrow down button
3 Main screen 7 ESC button
4 Indicator screen 8 Selection button

3–A Engine speed screen

3–B Mode screen
3–C Time and HVAC screen
 Service Information

Document Title: Function Group: Information Type: Date:

Instruments and controls, 380 Service Information 2014/7/4 0
left instrument panel
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Instruments and controls, left instrument panel

Figure 1
Left instrument panel

Item Marking Description

1 Control lever for stabilizer leg/blade
2 SW3501 Light control switch
3 Left control lever
4 SW3902 Remote controller for radio and CD
5 SW9104 Attachment bracket (quickfit) switch
6 SW9160 Audible warning and confirm switch for attachment bracket (quickfit)
7 SW9153 Stabilizer switch, front left
8 SW9154 Stabilizer switch, front right/blade
9 SW3503 Interior light switch
10 SW9155 Stabilizer switch, rear left
11 SW9156 Stabilizer switch, rear right
12 SW2704 Emergency engine speed control and stop switch
13 SW9103 Automatic/manual pump control switch
14 SW4206 Travel manual control switch
 Service Information

Document Title: Function Group: Information Type: Date:

Instruments and controls, 380 Service Information 2014/7/4 0
right instrument panel
Profile:
EXC, EW140C, EW180C, EW160C [GB]

Instruments and controls, right instrument panel

Figure 1
Right instrument panel

Item Marking Description

1 HE3801 Cigarette lighter
2 SE8706 Cab temperature sensor
3 SW3607 Rotating beacon switch
4 SW2301 Fuel heater switch
5 SW3504 Working light switch
6 SW3505 Extra work light switch
7 SW4202 Travel speed selection switch
8 SW3611 Mode selection switch
9 Right control lever
10 Cup holder
11 SW3603 Wiper switch, lower
12 SW3613 Washer switch, lower
13 SW4204 Cruise control switch
14 SW9151 Pivot axle locking switch
15 SW2701 Engine speed control switch
16 SW8701 Keypad
17 SW4207 X3/CDC selection switch
18 SW9107 Hammer / Shear selection switch
19 SW3301 Ignition key
20 SW3510 Fog light switch
21 SW9901 Automatic greasing switch
22 PO3902 Power outlet
 Service Information

Document Title: Function Group: Information Type: Date:

Instruments and controls, 380 Service Information 2014/7/4 0
rear instrument panel
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Instruments and controls, rear instrument panel

Figure 1
Rear instrument panel

Item Marking Description

1 CR3901 Radio and Cassette / CD player (optional)
2 HE8701 Cab auxiliary heater (optional)
3 PC3601 Service socket for VCADS Pro and MATRIS
4 PO3903 Power outlet
 Service Information

Document Title: Function Group: Information Type: Date:

Control levers, description 380 Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Control levers, description

Figure 1
Levers and pedals

1 Stabilizer blade lever

2 Left control lever
3 Optional pedal (X1)
4 Optional pedal (adjustable boom)
5 Service brake pedal
6 Travel pedal
7 Right control lever
 Service Information

Document Title: Function Group: Information Type: Date:

Hour counter, description 383 Service Information 2014/7/4 0
Profile:
EXC, EW180C, EW160C, EW140C [GB]

Hour counter, description

Figure 1
Hour counter

A : Hour counter
 Service Information

Document Title: Function Group: Information Type: Date:

Control lockout lever 386 Service Information 2014/7/4 0
switch, description
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Control lockout lever switch, description

When the control lockout lever is in the up position, the hydraulic system, swing and travel unit will work.
When the control lockout lever is in the down position, the servo pressure is cut off to functions, which are operated with
control levers and pedals.

Figure 1
Control lockout lever switch

1. Wire harness assembly

2. Control lockout lever
3. Cover
4. Limit switch assembly
5. Screw
6. Washer
7. Screw
8. Washer
9. Washer
Figure 2
Limit switch

N.O = Normally open

N.C = Normally closed

COM = Common

NOTE!
Switch mounting torque (M3 X 16 mm): 0.3 kg m (0.2 lbf ft)
 Service Information

Document Title: Function Group: Information Type: Date:

Engine oil pressure sensor, 386 Service Information 2014/7/4 0
replacing
Profile:
EXC, EW140C [GB]

Engine oil pressure sensor, replacing

Op nbr 386-007

1. Place the machine in service position B, see 091 Service positions.

2. Turn off the electric power using the battery disconnect switch.

3. Open the engine hood.

4. Disconnect wire harness connector (1).

Figure 1
Pressure sensor, removal

1. Wire harness connector

2. Engine oil pressure sensor (SE2203)
3. Engine oil cooler

5. Remove engine oil pressure sensor (2) from engine oil cooler (3).
NOTE!
Prepare a container to collect the engine oil.

6. Install new engine oil pressure sensor (2) with new copper seal ring.
NOTE!
Tightening torque: 40 Nm (29.6 lb/ft)

7. Connect wire harness connector (1) to the sensor.

8. Check the sensor operation, see: 3021 SE2203, description and measuring.
 Service Information

Document Title: Function Group: Information Type: Date:

Engine rotation speed 386 Service Information 2014/7/4 0
sensor, replacing
Profile:
EXC, EW140C [GB]

Engine rotation speed sensor, replacing

Op nbr 386-038

1. Place the machine position A according 091 Service positions.

2. Open the engine hood.

3. Disconnect wire harness connector.

Figure 1

1. Connector

4. Remove the ties of the sensor cable.

Figure 2

1. Tie

5. Remove the engine rotation speed sensor (flywheel) from engine body and replace it with a new one.
 Figure 3

1. Sensor
NOTE!
When installing a new sensor, be sure to make a distance, 0.8 mm between sensor and tooth.

Figure 4

1. Gauge

6. Lay cable between the front cover and fan console and fix it with cable ties.

7. Reconnect the wire harness connector.

8. Check the sensor operation.

 Service Information

Document Title: Function Group: Information Type: Date:

Engine rotation speed 386 Service Information 2014/7/4 0
sensor (camshaft),
replacing
Profile:
EXC, EW140C [GB]

Engine rotation speed sensor (camshaft), replacing

Op nbr 386-088

1. Park the machine in the service position A, see091 Service positions.

2. Open the engine hood.

3. Disconnect the wire harness connector.

Figure 1

1. Connector

4. Remove the engine rotation speed sensor (camshaft) from engine body and replace it with new one.

Figure 2

1. Screw
NOTE!
While installing the rotation speed sensor, be sure to clean the sealing surface on the sensor and oil O-ring lightly.
5. Reconnect the wire harness.

6. Check the sensor operation.

 Service Information

Document Title: Function Group: Information Type: Date:

Booting sequence 387 Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Booting sequence

Figure 1

A : VOLVO logo

B : Initializing screen

C : Antitheft system (option)

D : Daily maintenance

E : Ordinary screen

Initial booting sequence is done as follows

A : VOLVO logo
If the user turns the ignition key to ON position, the VOLVO log on the I-ECU screen lights up for a few seconds.
B : Initializing
After the VOLVO logo lights up, the user can see the status of initialization process that is required by the operating system.
At this step, I-ECU will initialize all internal devices and its operating system.
NOTE!
It takes a few seconds for the system to turn on the initial status. The machine can be turned on and engine mode can be
changed during this period.

C : Antitheft system
The optional antitheft system is only displayed if this optional equipment is selected.
Refer to the 387 Theft protection.
D : Daily maintenance
The user can see the daily maintenance items once a day. This screen is dismissed by pressing the ECS button or the SELECT
button and disappears automatically after 5 seconds if there is no button input.
– Engine oil level
– Coolant level
– Water separator
– Air cleaner
– Hydraulic oil level
– Travel/Working lights
E: Ordinary screen
After the booting is completed, the ordinary screen is displayed. Indicator for seat belt will be displayed for 3 seconds.
Fasten the seat belt before operating the machine.
 Service Information

Document Title: Function Group: Information Type: Date:

MAIN MENU 387 Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

MAIN MENU
The main menu is reached by pressing the SELECT button on the keypad at the ordinary screen. Scroll the list by using the
ARROW buttons on the keypad. When a folder is highlighted, its sub screens are shown when pressing the SELECT button.
Use the ARROW buttons to scroll between the sub screens. Interrupt the action at any time by pressing the ESC button on
the keypad.
I-ECU display unit provides the operator with improved and easy to understand information about functions monitored by
the ECUs.
Screen arrangement of “Main menu”
Main menu is displayed on “Main screen region”. When the user enters “Main menu”, “Main menu screen” replaces all of the
screen on the “Main screen region”, such as “RPM screen”, “Mode screen, and “Time and HVAC screen”. Refer to the
380 Instruments and controls, front instrument panel.

Entering Main menu screen

Press the SELECT button to enter menu screen from ordinary screen. Press the Arrow up button or Arrow down button to
move to each menu item. Press the SELECT button to select the highlighted item. Use the ESC button to cancel the selection
or exit from the menu item.

Figure 1
Menu control

Changing to Service Mode

There are two levels of access control on I-ECU, “User Mode” and “Service Mode”.
For special purpose such as service or diagnosis, “Service Mode” supports special functions and information.
“Service Mode” is activated when the SELECT button on Keypad is pressed for three seconds highlighting the “Service”
menu.
In “Service Mode”, there are 3 items, Engine system, Hydraulic system and Electrical system, which have sub menus to show
the value of various sensor, switches and valves etc.
Figure 2

A: Service mode indicator

 Service Information

Document Title: Function Group: Information Type: Date:

Menu tree 387 Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Menu tree
Menu tree on the I-ECU display unit
Main menu is divided into seven function groups as follows.

1. Engine
2. Hydraulics
3. Electrical system
4. Vehicle information
5. Service
6. Setup
7. Vehicle message

Menu tree (User Mode)

Menu tree on the I-ECU display unit

Main Sub 1 Sub 2 Sub 3

Engine Engine Oil pressure
Engine oil level
Hydraulics Oil temperature
Hammer operation hours
Work tool
Response mode Soft
Normal
Active
Electrical system Voltage
Vehicle information Model
Serial number
Work timer
Current fuel consumption
Average fuel consumption
Ambient temperature
Service Next service
Setup X1 tool New
Change
Delete
X3 operation Toggle
Push
Proportional
Language English
Korean
Chinese
German
 ...
Units Metric
US
Time/Date Clock format 24h
AM/PM
Date format yy/mm/dd
mm/dd/yy
Time/Date set
Display light Contrast
Keypad backlight
Vehicle message Message 1
Message 2
...
 Service Information

Document Title: Function Group: Information Type: Date:

Display unit, content 387 Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Display unit, content

1. Engine

Figure 1

Oil pressure
This shows the measured value of the engine oil pressure. When the bar graph is green, the value is OK, within normal
operation range. When the bar graph is red, the value is abnormal.
Oil level
This shows the measured value of the engine oil level. When the bar graph is green, the value is OK, within normal operation
range. When the bar graph is yellow, the value is abnormal.
2. Hydraulics
Figure 2

Oil temperature
This shows the measured value of hydraulic oil temperature. When the bar graph is green, the value is OK, within normal
operation range. When the bar graph is red, the value is abnormal.
Hammer operation hours
This shows the counted value of hammer operating time in the unit of hour.
X1 work tool

Figure 3

This informs the operator which tool is selected at the moment. It also allows the operator to select a preset tool showing
the name and settings of each tool. When pressing the ARROW button, another preset work tool is displayed. When
pressing the SELECT button to another tool, the screen reverts the screen to the former screen displaying the name of the
newly selected tool.
Response mode

Figure 4

This informs the operator which response mode is selected at the moment. It also allows the operator to select a response
mode from three different modes. The operator can select a response mode from three modes with the ARROW buttons.
When pressing the SELECT button, the marked response mode is set. The screen reverts to the former screen displaying the
name of the newly selected item.
– Active
– Normal
– Soft
Operator can adjust the sensitivity of movement of attachments when operating the levers. “Active” mode is the most
sensitive.
3. Electrical system

Figure 5

Voltage
This shows the measured value of voltage of he battery. When the bar graph is green, the value is OK, within normal
operation range. When the bar graph is red, the value is abnormal.
4. Vehicle information

Figure 6

Model
This shows the model name of the machine.
Serial number
This shows the serial number of the machine.
Work timer
Figure 7

This shows the counted working time. Work time can be reset by pressing the SELECT button when the “Work timer” value is
highlighted. Pressing SELECT button results in a “Yes/No” question on the screen. Press ESC button for “No” and SELECT
button for “Yes”.
Current fuel consumption
This shows the calculated fuel consumption at the time.
Average fuel consumption
This shows the calculated average fuel consumption at the time.
Ambient temperature
This shows the measured ambient temperature.
5. Service

Figure 8

Interval
This shows the value of service interval with the unit of hours. First interval is 250 hours and then the service interval is every
500 hours.
Time remaining
This shows the value of remained time for next service.
When the “ Time remaining” reaches at 40 hours, 20 hours and 0 hour, check screen with “Time remaining” and “Interval “
will pops up on I-ECU. Service the maintenance items which should be serviced in that interval.
Reset time remaining ?

Figure 9

After servicing the maintenance item, the time can be reset. Pressing selecting button results in a “Yes/No” question on the
screen. Press ESC button for “No” or the SELECT button for “Yes”. When the time is reset, the next service interval adn “Time
remaining” will be displayed.
6. Setup

Figure 10

There are 7 sub items in the Setup menu as follows.

1) X1 work tool
2) X3 operation
3) Language
4) Units
5) Time/Date
6) Display light
7) Keypad backlight

Refer to the 387 SETUP.

7. Vehicle message

Figure 11
This shows the headlines of messages. There are no errors or warning messages in normal operation.
If an abnormal condition is sensed, then the message will display the specific error/failure.
When pressing the SELECT button to view detail information about a headline, the displayed information replaces the whole
“main screen”. The contents of information include following items.”, “Source”, “First Event”, “No. of events”, and “Last event”.
– Fault Active
– Error Code
– Source
– First event
– No. of events
– Last event
 Service Information

Document Title: Function Group: Information Type: Date:

SETUP 387 Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

SETUP
1. X1 work tool

Figure 1

This is to preset X1 setting so that operator uses it just by selecting the tools from the list.
There are three sub items which are “New”, “Change”, and “Delete”. Use the ARROW buttons to place the cursor
(highlighting bar) on the required item, and then press the SELECT button.
Enter X1/X3 password : Enter the password to proceed the setting for X1 tools. The password screen is displayed when the
password is ever set by VCADS Pro.

There are 3 sub items which are

– New
– Change
– Delete
Use the ARROW buttons to place the cursor (highlighting bar) on the required item, and then press the SELECT button.
New
Figure 2

The New setting is used to add new X1 tools. Follow the steps from 1 through 7, described below, to set and “Save” the
parameters for the new attachment desired.
NOTE!
If “Save” procedure is not done, all the setting are cancelled automatically.

1). Select “New” after entering “X1 work tool”.

2). Enter : Enter the name of the tool.

 Use the ARROW UP and ARROW DOWN button to select the characters (A, B... Z, 0,1...9).
 Use the SELECT button to enter the selected character.
 Use the ESC button to delete the character entered.
 Press the SELECT button more than 3 seconds to save the name.
 Press the ESC button more than 3 seconds to escape without saving the name.

3). Flow : Set the flow rate when this optional function is selected.
– Select the preferred flow rate value using ARROW buttons.
– Save the selected value using the SELECT button. Use the ESC button to escape without saving.
Figure 3

4). Pressure : Set the pressure when this optional function is selected.
– Select the preferred pressure value using the ARROW buttons.
– Save the selected value using the SELECT button. Use the ESC button to escape without saving.
5). Control : Choose the control type.
– Select the preferred control type using the ARROW buttons.
– Save the selected item using the SELECT button. Use the ESC button to escape without saving.

There are 3 control types which are

– Toggle
– Push-button
– Proportional
6). Attachment : Choose the 1 way or 2 way control.
– Select the preferred setting between 1 or 2 way using the ARROW buttons.
– Save the selected item using the SELECT button. Use the ESC button to escape without saving.
7). Save : Save the setting.
– Select “Save” and press the SELECT button to save all the settings including “ Name”, “Flow”, “Pressure”, “Control, and
“Attachment”.
NOTE!
After entering the new settings, the “Save” procedure should be done to record the new parameters into the system
memory. If “Save” procedure is not done, all the settings will be cancelled automatically.

– If some items are not set up, the error message “Fill out all items” will appear.
8). The added X1 tool is newly listed.

Change

Figure 4

This is modify the setting of preset X1 tools.

1). Select “Change “ after entering “X1 work tool”.
2). Select the tool to be modified using the ARROW buttons and press the SELECT button.
3). Flow the same procedures from 2 to 7 explained in “New” section to change the setting.
4). There are some restrictions to modify the setting.
– The “Name” of two default X1 tools “HAMMER” and “SHEAR” are not modifiable.
– The “HAMMER” can not be “2 way”.
5). The modified X1 tool is listed.

Delete
Figure 5

This is to delete the preset “X1 work tool” proceed as follows.

1). Select the “Delete” button after entering “X1 work tool”.
2). Select the tool to delete using the ARROW buttons and press the SELECT button.
3).Are you sure to delete ? : Confirming message is displayed on the screen, press the SELECT button for “Yes” and the ESC
button for “No”.

2. X3 Operation

Figure 6

Enter X1/X3 password : Enter the password to proceed the setting for X3 tools. The password screen is displayed when the
password is ever set by VCADS Pro.
Place the mark the preferred item from the three listed with the ARROW button.
When the SELECT button is pressed, the marked item is set. The screen reverts to the former screen displaying the newly
selected item.
For more information, refer to the 387 Control types for X1 and X3 operation.
3. Language

Figure 7
Supported languages are listed in the screen in the form of their own languages.
Use the ARROW buttons to scroll up and down to find your specific language. Press the SELECT button to select the chosen.
The screen reverts to the former screen displaying the newly selected language.
When the operator sets a language that is not English, the “Lang” is written in both the selected language and English.

4. Units

Figure 8

Two units systems can be displayed : “Metric” and “US”. Operator can select one of the two using the ARROW buttons and
save it by pressing the SELECT button.
The units in I-ECU are as follows.

Units in I-ECU

Item Metric US
Time h h
Fluid rate l/h USgal/h
Volume L USgal
Voltage V V
Current A A
Temperature °C °F
Revolution rpm rpm
Speed km/h mph
Pressure bar psi
Distance km mile

5. Time/Date

Figure 9
Clock format :
The items “24h” and “AM/PM” decide how the I-ECU describes the time, 24–hour–system or 12–hour–system.
Date format
The items “yy/mm/dd”, “dd/mm/yy”and “mm/dd/yy” decide how the I-ECU describes the date. “yy” means year, “mm”
means month, and “dd” means day.
Time/Date set
This is to adjust the time and date. The preset clock and date format is shown in the first row of the screen Operator can
adjust the time and date with the ARROW, ESC and SELECT buttons. The SELECT and ESC buttons are used to proceed or go
back the cursor. The ARROW buttons are used to adjust each segment of the time and date.

6. Display light

Figure 10

This is to change the contrast of the I-ECU. The adjust bar in the screen is controlled by the ARROW buttons and the value is
set by the SELECT button.
The contrast is adjustable for day and night independently.
Contrast (Day)
Contrast (Night)
NOTE!
When adjusting the “Contrast (Night)”, the working lamp of the machine should be turned on.

7. Keypad backlight

Figure 11

The brightness of the keypad backlight is changed by the adjustment. The adjusting bar in the screen is controlled by the
ARROW buttons and the value is set by the SELECT button.
 Service Information

Document Title: Function Group: Information Type: Date:

Pop-up screen 387 Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Pop-up screen
The pop-up screens are divided in three groups.

Figure 1

A: Information screen

B: Check screen

C: Warning screen

1. Information screen
This screen is to give useful information about the machine.
The main screen is replaced by a green–outlined box with title of “Info”, information. The buzzer alarm sounds only 1 time.
The “Info screen” disappears automatically in 2 seconds.
2. Check screen
This screen is to inform the operator when a partial failure of the machine is detected.
The main screen is replaced by a yellow–outlined box with title of “Check”. The buzzer alarm sounds 4 times..
To get more information about the message on the screen, press the SELECT button. To go back to the user's screen, press
the ECS button.
3. Warning screen
This screen is to warn the operator when the electronic system senses a machine malfunction or a safety related failure. Stop
the machine immediately and investigate the cause.
The whole I-ECU screen is replaced by a red–outlined box with title of “Warning”.
A warning alarm sounds when the “Warning screen” pops up.
When the ESC button is pressed, the warning sound will stop and the central warning lamps will be turned off. To dismiss
the “Warning screen”, the ESC button should be pressed again. The message will not appear again as long as the power is
switched on even though the error signal is still valid.
To get more information about the message, refer to the “ Vehicle message in the main menu.

Error messages related with common rail pressure.

1. E–ECU Common rail pressure sensor : SE2309–0/1/2/4/5

2. E–ECU Effective torque common rail : PPID435–0/1
3. E–ECU Rail pressure system : PSID96–0/1/4/7/12
4. E–ECU Pressure release valve: PSID97–0/7/11/14
5. E–ECU CR fuel control unit (FCU) : PWM2303–3/4/5/6/13
 Service Information

Document Title: Function Group: Information Type: Date:

Keypad, description 387 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Go back to Index Page

Keypad, description

Figure 1
Keypad for display unit and HVAC ( Heating, Ventilation , Air conditioning) system

Keypad is located on the right instrument panel. It is connected to the Instrument control unit (I-ECU).
Button function

Button Digit Description Button Digit Description

1 Fan speed control + - HVAC system on/off

2 Temperature control + 0 Arrow up, Browse upwards

3 Air flow direction - Rear view camera

4 Fan speed control – - Previous screen or escape

5 Temperature control – - Arrow down, Browse downwards

6 Air flow circulation - Selection, Acknowledge

7 Automatic mode selection - Automatic idling

8 Air conditioner - Overload warning

9 Defrost selection - Buzz stop

HVAC control buttons
HVAC control buttons are used to control the HVAC system. Refer to the 387 HVAC system.
Rear view camera button
Rear view camera button turns on/off “Rear view camera screen”. When the rear view camera screen is turned on , whole I-
ECU screen displays only view from “rear view camera”.

Figure 2
Rear view camera

Buzz stop button

Buzz stop button is used to activates or deactivates “ Travel alarm” function of V-ECU. When this button is pressed so that
the function is activated, partial backlight fro this button is turned on.
Overload warning button
Overload warning button activates or deactivates “Overload warning” function. This function is to display the symbol and to
sound an alarm if the “Overload signal” is detected. When this button is pressed so that the function is activated, partial
backlight for this button is turned on.
Automatic idle button
Automatic idle button activates or deactivates “ Automatic idle” function of V-ECU. When this button is pressed so that the
function is activated, partial backlight for this button is turned on.
The engine speed will be lowered automatically to idle mode to reduce fuel consumption if any of control levers, travel
levers (pedals) or engine speed control switch are not operated for 5 seconds or more. If any of the above is operated, the
engine speed returns to the speed set with the engine speed control switch.
Arrow up button
This button is used to scroll items up and adjust the each segment on the screen.
Arrow down button
This button is used to scroll items down and adjust the each segment on the screen.
ESC button
This button is used to go back to the previous screen or to escape without saving. The ESC button is also used to turn OFF
the warning lamp and sound.
 Service Information

Document Title: Function Group: Information Type: Date:

Keypad, description 387 Service Information 2014/7/4 0
Profile:
EXC, EW140C [GB]

Go back to Index Page

Keypad, description

Figure 1
Keypad for display unit and HVAC ( Heating, Ventilation , Air conditioning) system

Keypad is located on the right instrument panel. It is connected to the Instrument control unit (I-ECU).
Button function

Button Digit Description Button Digit Description

1 Fan speed control + - HVAC system on/off

2 Temperature control + 0 Arrow up, Browse upwards

3 Air flow direction - Rear view camera

4 Fan speed control – - Previous screen or escape

5 Temperature control – - Arrow down, Browse downwards

6 Air flow circulation - Selection, Acknowledge

7 Automatic mode selection - Automatic idling

8 Air conditioner - Overload warning

 9 Defrost selection - Buzz stop

- Hammer/shear selection

HVAC control buttons

HVAC control buttons are used to control the HVAC system. Refer to the 387 HVAC system.
Rear view camera button
Rear view camera button turns on/off “Rear view camera screen”. When the rear view camera screen is turned on , whole I-
ECU screen displays only view from “rear view camera”.

Figure 2
Rear view camera

Buzz stop button

Buzz stop button is used to activates or deactivates “ Travel alarm” function of V-ECU. When this button is pressed so that
the function is activated, partial backlight fro this button is turned on.
Overload warning button
Overload warning button activates or deactivates “Overload warning” function. This function is to display the symbol and to
sound an alarm if the “Overload signal” is detected. When this button is pressed so that the function is activated, partial
backlight for this button is turned on.
Automatic idle button
Automatic idle button activates or deactivates “ Automatic idle” function of V-ECU. When this button is pressed so that the
function is activated, partial backlight for this button is turned on.
The engine speed will be lowered automatically to idle mode to reduce fuel consumption if any of control levers, travel
levers (pedals) or engine speed control switch are not operated for 5 seconds or more. If any of the above is operated, the
engine speed returns to the speed set with the engine speed control switch.
Arrow up button
This button is used to scroll items up and adjust the each segment on the screen.
Arrow down button
This button is used to scroll items down and adjust the each segment on the screen.
ESC button
This button is used to go back to the previous screen or to escape without saving. The ESC button is also used to turn OFF
the warning lamp and sound.
Hammer / shear selection button
Hammer / shear selection button is used to activates or deactivates “X1 function” of V-ECU.
 Service Information

Document Title: Function Group: Information Type: Date:

HVAC system 387 Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

HVAC system
HVAC, Heating, Ventilation , air-conditioning
The machine can be equipped with different kind of system, for example, with air conditioning unit or heater with air
conditioning unit.

Figure 1

A Time 1 Fan speed control button +

B Air conditioner mode 2 Temperature control button +
C Temperature 3 Air flow direction button
D Fan speed 4 Fan speed control button –
E Air flow direction 5 Temperature control button –
F Air flow circulation 6 Air flow circulation button
G Air-conditioning status 7 Automatic mode selection button
8 Air conditioner button
9 Defroster selection button
10 HVAC system ON/OFF button

Fan speed control

Press buttons 1 or 4 to increase or decrease the fan speed. When pressing any of them, automatic mode will be switched
automatically to manual mode.
Temperature control
Press buttons 2 or 5 to raise or lower the temperature. Default setting value is 22 °C (71.6 °F) and setting range is 16 °C ~ 32
°C. If the temperature sensor in cabin is malfunction, automatic mode shall be turned OFF.
Air flow direction
Press button 3 to select the direction of the air flow. When pressing the button, automatic mode will be changed to manual
mode automatically.
Air flow circulation
Press button 6 to select the circulation of the air flow ; recycle the air inside the cab or draw fresh air from outside into the
cab. When the defrost mode is activated, the fresh air mode is selected automatically.
Automatic mode
Press button 7 to select the Automatic mode for temperature setting. Required temperature can be changed with buttons 2
or 5.
Air conditioner
Press button 8 to activate the air conditioning.
Defroster
Press button 9 to select to activate the defroster. The fresh air mode is selected automatically. In automatic mode, if this
button is pressed, mode shall be changed to manual mode.
HVAC system ON/OFF
Press button 10 to turn the HVAC system ON or OFF. All settings remain if the system is turned OFF. Even if HVAC system is
turned OFF, when ECC (electronic climate controller) gets auxiliary heater signal, ECC turns ON the cooling fan setting 1st
step in manual mode.
 Service Information

Document Title: Function Group: Information Type: Date:

Theft protection 387 Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Theft protection

Figure 1
Antitheft system in booting sequence

The antitheft system screen arrangement is only displayed if the two following conditions are satisfied. One is that 'Option
Code Lock' is selected. The other is that a certain amount of time has elapsed since turning off the engine. The default time
is 15 seconds and is changeable using VCADS Pro which is a common Volvo diagnostic tool. The time lapse can be set from
0 to 15 minutes.
The antitheft system functions as a deterrent to help prevent theft and unauthorized use of the machine. Unless the correct
password is entered, the user cannot start the engine. A four-digit-number is used as a password. The password is entered
by keypad that has numbers from 0 to 9 printed on the buttons.
If the user inputs the wrong code, the text “wrong code” appears on the display and the input field clears and the user has to
enter the code again.
After entering all 4 digits, the SELECT button must be pressed as confirming.
 Service Information

Document Title: Function Group: Information Type: Date:

Service mode 387 Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Service mode
There are two levels of access control on I-ECU, “User Mode” and “Service Mode”.
For special purpose such as service or diagnosis, “Service Mode” supports special functions and information.
“Service Mode” is activated when the “SELECT button on Keypad is pressed for three seconds highlighting the “Service”
menu.
In “Service Mode”, there are 3 items, Engine system, Hydraulic system and Electrical system, which have sub menus to show
the value of various sensor, switches and valves etc.
Menu tree on Service mode
Menu tree on the I-ECU display unit

Main Sub 1 Sub 2

Engine Engine RPM 1. Engine RPM 1(4)
Engine sensor 2. Engine sensor 2(4)
2. Engine sensor 3(4)
Engine status 3. Engine status 4(4)
Hydraulics Cooling system 1. Cooling system 1(8)
Pressure switch 2. Pressure switch 2(8)
Pressure sensor 3. Pressure sensor 3(8)
Solenoid 4. Solenoid 4(8)
4. Solenoid 5(8)
4. Solenoid 6(8)
Proportional valve 5. Proportional valve 7(8)
5. Proportional valve 8(8)
Electrical system Power supply 1. Power supply 1(18)
On/Off input 2. On/Off input 2(18)
2. On/Off input 3(18)
2. On/Off input 4(18)
2. On/Off input 5(18)
2. On/Off input 6(18)
2. On/Off input 7(18)
2. On/Off input 8(18)
2. On/Off input 9(18)
2. On/Off input 10(18)
2. On/Off input 11(18)
2. On/Off input 12(18)
Analog input 3. Analog input 13(18)
3. Analog input 14(18)
PWM input 4. PWM input 15(18)
On/Off output 5. On/Off output 16(18)
5. On/Off output 17(18)
Climate system 6. Climate system 18(18)
 Service Information

Document Title: Function Group: Information Type: Date:

Engine system 387 Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Engine system
Engine system Screen on Service mode
Engine system

Screen name Item Display Description

Engine Engine initial screen

1.Engine RPM 1
(4)
Engine speed xxxx: Value [rpm]
Requested speed xxxx: Value [rpm]
Engine % load xxx: Value [%]

2. Engine sensor
2(4)
Engine oil pressure xxxx: Value [bar]
Engine oil temperature xxx: Value [°C]
Engine oil level xxx: %
Coolant temperature xxx: Value [°C]
Coolant level xxx: %

2. Engine sensor
3(4)
Boost temperature xxx: Value [°C]
Boost pressure xxxx: Value [bar]
Air inlet temperature xxx: Value [°C]
Air inlet pressure xxxx: Value [bar]
Barometric pressure xxxx: Value [bar]

3. Engine status
4(4)
Engine filter status x: o' (normal) / 'l' (full)
Fuel pressure xxxx: Value [bar]
Fuel rate xxx: Value [liter/h]
Total fuel used xxxxxxxx: Value [liter]
Rail pressure xxxx: Value [bar]
 Service Information

Document Title: Function Group: Information Type: Date:

Hydraulic system 387 Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Hydraulic system
Hydraulic system screen on I-ECU
Hydraulic system

Screen name Item Display Description

Hydraulics Hydraulic sub screen

1. Cooling
system 1(8)
Hydraulic oil temperature xxx: Value [°C]
Hydraulic oil filter x: '0' / '1'
Cooling fan control valve current xxx: Value [mA]

2. Pressure
switch 2(8)
Hydraulic pressure monitor x: '0' / '1'
Low brake pressure switch x: '0' / '1'
Overload pressure switch x: '0' / '1'

3. Pressure
sensor 3(8)
Travel pedal pressure sensor xxxxx: Value [bar]
Brake pressure sensor xxxxx: Value [bar]
Auto idle pressure sensor xxxx: Value [bar]
Overload pressure sensor xxxx: Value [bar]

3. Pressure
sensor 4(8)
Travel forward solenoid x: '0' / '1'
Travel reverse solenoid x: '0' / '1'
Travel gearbox solenoid, low x: '0' / '1'
Travel gearbox solenoid, high x: '0' / '1'
Q-max solenoid x: '0' / '1'

3. Pressure
sensor 5(8)
Pivot axle locking solenoid x: '0' / '1'
Electric digging brake solenoid x: '0' / '1'
 Grab changeover solenoid x: '0' / '1'
Adjustable offset boom solenoid x: '0' / '1'

4. Solenoid 6(8)

Power boost solenoid x: '0' / '1'

Boom float position solenoid x: '0' / '1'
Quikfit solenoid x: '0' / '1'
X1 control valve solenoid, left x: '0' / '1'
X1 control valve solenoid, right x: '0' / '1'

5. Proportional
valve (PPRV) 7(8)
Pump flow control valve current xxxx: Value [mA]
Thermostatic valve current xxxx: Value [mA]
Cruise control valve current xxxx: Value [mA]
CDC control valve current xxxx: Value [mA]

5. Proportional
valve (PPRV) 8(8)
X1 flow control valve current xxxx: Value [mA]
X1 pressure control valve current xxxx: Value [mA]
X3 control valve current, right xxxx: Value [mA]
X3 control valve current, left xxxx: Value [mA]
 Service Information

Document Title: Function Group: Information Type: Date:

Electrical system 387 Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Electrical system
Electrical system screen on I-ECU
Electrical system

Screen name Item Display Description

Electrical system Electrical initial screen

1. Power supply 1
(18)
Battery (I-ECU input) voltage xx.x: Value [V]
Battery (V-ECU input) voltage xx.x: Value [V]
Battery (E-ECU input) voltage xx.x: Value [V]
Alternator voltage x: '0' / '1'

2. On/Off input 2
(18)
Start switch (ACC) x: '0' / '1'
Start switch (R2) x: '0' / '1'
Safety lever switch x: '0' / '1'
Automatic idling selection switch x: '0' / '1'

2. On/Off input 3
(18)
Quickfit switch x: '0' / '1'
Quickfit confirmation switch x: '0' / '1'
Quickfit buzzer stop switch x: '0' / '1'
keypad switch xx: Value

2. On/Off input 4
(18)
X1 selection switch x: '0' / '1'
Power boost switch x: '0' / '1'
Rototilt selection switch x: '0' / '1'

2. On/Off input 5
(18)
 X1 left switch x: '0' / '1'
X1 right switch x: '0' / '1'
X3 left switch x: '0' / '1'
X3 right switch x: '0' / '1'

2. On/Off input 6
(18)
Pattern change switch 1 (I-ECU) x: '0' / '1'
Pattern change switch 2 (I-ECU) x: '0' / '1'
Pattern change switch 1 (V-ECU) x: '0' / '1'
Pattern change switch 2 (V-ECU) x: '0' / '1'
Float position switch x: '0' / '1'

2. On/Off input 7
(18)
Grab changeover switch x: '0' / '1'
Adjustable offset boom switch x: '0' / '1'

2. On/Off input 8
(18)
Travel mode switch x: '0' / '1'
Work mode switch x: '0' / '1'
Customer mode switch x: '0' / '1'
2nd speed switch x: '0' / '1'
3rd speed switch x: '0' / '1'

2. On/Off input 9
(18)
Travel forward switch x: '0' / '1'
Travel reverse switch x: '0' / '1'
Cruise control switch x: '0' / '1'

2. On/Off input
10(18)
CDC/X3 selection switch x: '0' / '1'
Turret alignment switch x: '0' / '1'
Pivot axle lock switch x: '0' / '1'
Electrical digging brake switch x: '0' / '1'

2. On/Off input
11(18)
Overload selection switch x: '0' / '1'
Auto lubrication switch x: '0' / '1'

2. On/Off input
12(18)
Illumination switch x: '0' / '1'
Auto/manual switch x: '0' / '1'
 High beam switch x: '0' / '1'
Turning signal switch, left x: '0' / '1'
Turning signal switch, right x: '0' / '1'

3. Analog input
13(18)
Fuel level sensor xxx: Value [V]
Fuel level sensor xxx: Value [%]

3. Analog input
14(18)
Engine speed sensor (load sensing) xxx: Value [rpm]
Steering position sensor xxx: Value [°]

4. PWM input 15
(18)
Engine speed control (RPM) switch xxx: Value [%]
Engine speed control (RPM) switch step z: Value [1..9]
X1 proportional switch xxx: Value [%]
X3 proportional switch xxx: Value [%]

5. On/Off output
16(18)
V-ECU power cutoff relay x: '0' / '1'
V-ECU status x: '0' / '1'
Start lock relay x: '0' / '1'
Travel alarm relay x: '0' / '1'

5. On/Off output
17(18)
Safety relay x: '0' / '1'
Reverse traveling light relay x: '0' / '1'
Stop light relay x: '0' / '1'

6. Climate system
18(18)
Cabin temperature xxx: Value [°C]
Ambient temperature xxx: Value [°C]
Evaporator temperature xxx: Value [°C]
Compressor On/Off x: '0' / '1'
Blower motor speed xxx: Value [%]
 Service Information

Document Title: Function Group: Information Type: Date:

Language 387 Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Language
I-ECU display unit with updated software supports 29 languages in the form of their own languages. The user can select the
language on the SETUP menu with the ARROW and the SELECT button on the keypad.

Figure 1

Languages on I-ECU display unit

No Language
1 English
2 Spanish
3 Korean
4 German
5 Chinese
6 French
7 Italian
8 Swedish
9 Norwegian
10 Portuguese for Brazil
11 Portuguese for Portugal
12 Turkish
13 Russian
14 Arabic
15 Hindi
16 Dutch
17 Danish
18 Finnish
19 Indonesian
20 Thai
21 Czeck
22 Polish
23 Greek
24 Estonian
25 Latvian
26 Lithuanian
27 Hungarian
28 Slovak
29 Slovenian
 Service Information

Document Title: Function Group: Information Type: Date:

Terminology 387 Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Terminology
The meaning of short words embedded on I-ECU for each language are described as follows.
Description on terminology
Description of the terminology used on I-ECU display unit.

No. Description No. Description

1 Engine RPM 31 Attach port pressure switch
2 Engine sensor 32 Travel port pressure switch
3 Engine status 33 Hammer port pressure switch
4 Requested speed 34 Float port pressure switch
5 Engine % load 35 Pressure sensor
6 Engine oil pressure 36 Travel pedal pressure sensor
7 Engine oil temperature 37 Brake pressure sensor
8 Engine oil level 38 Automatic idle pressure sensor
9 Coolant temperature 39 Overload pressure sensor
10 Coolant level 40 Pump 1 discharge pressure sensor
11 Boost temperature 41 Pump 2 discharge pressure sensor
12 Boost pressure 42 Control lever pressure sensor (Arm in)
13 Air inlet temperature 43 Control lever pressure sensor (Arm out)
14 Air inlet pressure 44 Control lever pressure sensor (Swing)
15 Barometric pressure 45 Control lever pressure sensor (Travel left)
16 Air filter status 46 Control lever pressure sensor (Travel right)
17 Fuel pressure 47 Control lever pressure sensor (Boom up)
18 Fuel rate 48 Control lever pressure sensor (Boom down)
19 Total fuel used 49 Control lever pressure sensor (Bucket)
20 Normal 50 Control lever pressure sensor (Dozer blade up)
21 Water In Fuel 51 Control lever pressure sensor (X1)
22 Cooling system 52 Control lever pressure sensor (X2 up)
23 Hydraulic oil temperature 53 Solenoid
24 Hydraulic oil filter 54 Travel forward solenoid
25 Cooling fan control valve current 55 Travel reverse solenoid
26 Pressure switch 56 High gear solenoid
27 Pressure monitor pressure switches 57 Q-Max solenoid
28 Brake pressure low switch 58 Axle lock solenoid
29 Steering servo pressure switch 59 Cruise control solenoid
30 Overload pressure switch 60 Electrical digging brake solenoid

Description of the terminology used on I-ECU display unit.

No. Description No. Description

61 Grab change-over solenoid 91 On/Off input
62 Boost solenoid 92 Start switch (ACC)
63 Float position solenoid 93 Start switch (R2)
64 Quick fit solenoid 94 Control lockout lever switch
65 X1 control valve left hand solenoid 95 Automatic idle selection switch
66 X1 control valve right hand solenoid 96 Power maximum mode switch
67 Travel motor solenoid 97 Quick fit switch
68 Boom conflux cutoff solenoid 98 Quick fit confirmation switch
69 Arm in conflux cutoff solenoid 99 Quick fit confirmation switch
70 Arm out conflux cutoff solenoid 100 Boost / Hammer switch
71 X1 conflux cutoff solenoid (X1 2 pump selection 101 X1 left switch
solenoid)
72 Conflux cutoff solenoid 102 X1 right switch
73 X1 pressure control solenoid 1 103 X3 left switch
74 X1 pressure control solenoid 2 104 X3 right switch
75 Hammer selection solenoid 105 Hammer foot switch
76 Shear selection solenoid 106 Pattern change switch 1 (I-ECU)
77 Proportional valve 107 Pattern change switch 2 (I-ECU)
78 Pump 1 flow control proportional valve current 108 Pattern change switch 1 (V-ECU)
79 Pump 2 flow control proportional valve current 109 Pattern change switch 2 (V-ECU)
80 Pump flow control proportional valve current 110 Float position switch
81 Cruise control proportional valve current 111 2 piece offset boom selection switch
82 Comfort Drive Control proportional valve current 112 T mode switch
83 X1 flow control valve current 113 W mode switch
84 X1 pressure control proportional current 114 C mode switch
85 X1 control proportional valve right hand current 115 2nd speed switch
86 X1 control proportional valve left hand current 116 3rd speed switch
87 X3 control proportional valve left hand current 117 Travel forward switch
88 X3 control proportional valve right hand current 118 Travel reverse switch
89 Power shift proportional valve current 119 Cruise control switch 1
90 Power supply 120 Comfort Drive Control//X3 selection switch

Description of the terminology used on I-ECU display unit.

No. Description No. Description

121 X1 selection switch 151 Cabin temperature
122 Turret alignment switch 152 Ambient temperature
123 Axle lock switch 153 Evaporator temperature
124 Electrical digging brake switch 154 Compressor ON/OFF
125 Overload selection switch 155 Blower motor speed
126 Automatic lubrication switch 156 Rototilt selection switch
127 Pressure monitor pressure switches 157 Information
128 Illumination switch 158 Check
129 Automatic/Manual switch 159 Warning
130 High beam switch 160 Close
131 Turning signal left hand switch 161 Ambient temperature
132 Turning signal right switch 162 Arm in pressure
133 Analog input 163 Arm out pressure
134 Fuel Level sensor 164 Battery relay failure
135 Engine speed sensor (Load sensing) 165 Boom down pressure
136 Steering hall sensor 166 Boom up pressure
137 PWM input 167 Brake pressure
138 Engine speed control (RPM) switch 168 Brake pressure low
139 Engine speed control (RPM) switch step 169 Bucket pressure
140 X1 Proportional Switch 170 Comfort drive control failure
141 X3 Proportional Switch 171 Climate system error
142 On/Off output 172 Clock failure
143 V-ECU Power Cutoff relay 173 Communication failure
144 V-ECU status 174 Computer failure
145 Start lock relay 175 Cooling fan
146 Travel alarm relay 176 Cruise control
147 Control lockout relay 177 Dozer blade pressure
148 Travel reverse light relay 178 Electrical digging brake
149 Stop light relay 179 Engine air filter clogged
150 Climate system 180 Engine air heater

Description of the terminology used on I-ECU display unit.

No. Description No. Description

181 Engine error 211 Travel alarm
182 Engine speed 212 Travel direction (FNR)
183 Float position 213 Travel forward
184 Fuel filter clogged 214 Travel left pressure
185 Fuel level 215 Travel motor speed
186 Fuel level low 216 Travel pedal pressure
187 Fuse-PWM failure 217 Travel reverse
188 Fuse-Relay failure 218 Travel reverse lamp
189 Fuse-Solenoid failure 219 Travel right pressure
190 Alternator voltage 220 Travel speed selection
191 High gear 221 Turn off battery switch
192 High system voltage 222 Turn off engine
193 Hydraulic oil filter clogging switch 223 Water in fuel
194 Hydraulic oil 224 X1 PWM input failure
195 Hydraulic oil temperature 225 X3 PWM input failure
196 Hydraulic system 226 Boost temperature high
197 Cab Interior temperature 227 Check at next stop
198 Low gear 228 Engine coolant level low
199 Low system voltage 229 Engine coolant temperature high
200 Operating mode 230 Engine air heater
201 Overload pressure 231 Engine error
202 Quick fit failure 232 Engine oil level low
203 Engine speed (RPM) control switch failure 233 Engine oil pressure low
204 Control lockout relay failure 234 Engine oil temperature high
205 Start key failure 235 Failure
206 Start lock relay failure 236 Pattern signal failure
207 Steering servo pressure low 237 Relay failure
208 Stop light failure 238 Sensor failure
209 Stop machine 239 Switch failure
210 Swing pressure 240 Temperature high
Description of the terminology used on I-ECU display unit.

No. Description No. Description

241 Voltage failure 271 Korean
242 Engine 272 Swedish
243 Oil pressure 273 Norwegian
244 Oil level 274 Danish
245 Hydraulics 275 Finnish
246 Oil temperature 276 German
247 Hammer operating hours 277 Dutch
248 Response mode 278 French
249 Active 279 Spanish
250 Normal 280 Italian
251 Soft 281 Portuguese for Portugal
252 Electrical system 282 Chinese
253 Voltage 283 Portuguese for Brazil
254 Minimum 284 Indonesian
255 Vehicle information 285 Thai
256 Key number 286 Hindi
257 Production date 287 Arabic
258 Model 288 Turkish
259 Serial number 289 Russian
260 Work timer 290 Units
261 Reset work timer 291 Time/date
262 Yes 292 Clock format
263 No 293 Date format
264 Current fuel consumption 294 Time/Date set
265 Average fuel consumption 295 Display light
266 Service 296 Keypad backlight
267 Time remaining 297 X1 tools
268 Reset time remaining? 298 New
269 Setup 299 Name
270 Language 300 Duplicated name (Message)

Description of the terminology used on I-ECU display unit.

No. Description No. Description

301 Flow 333 Hydraulic oil level
302 Pressure 334 Travel/working lights
303 Control 335 Antitheft system
304 Attachment 336 Enter driver code
305 Save 337 Wrong code
306 Fill out all items (Message) 338 Preheating
307 Change 339 ECU Version
308 Toggle switch function 340 X1 (Tool name)
309 Push button switch function 341 Error in X1 setting
310 Proportional 342 Error in X3 setting
311 1 way 343 Set X3 operation
312 2 way 344 Time remaining
313 Delete 345 Interval
314 Are you sure 346 Yes
315 to delete ? 347 No
316 X3 operation 348 Keypad
317 Vehicle messages 349 X1 work tool
318 Fault active 350 Invalid name
319 Error code 351 Enter X1/X3 password
320 Source (where the error happens) 352 Contrast (Day)
321 Date for error occurred first 353 Contrast (Night)
322 Times of total error 354 Travel straight solenoid
323 Date for error occurred last 355 Automatic lubrication system
324 Entering into service mode 356 System
325 Service mode 357 Thermostatic solenoid
326 Exiting from service mode 358 Set X1 work tool
327 Service mode 359 X1 pressure
328 Daily maintenance items 360 X2 pressure
329 Engine oil level 361 Grab changeover
330 Coolant level 362 Engine shutoff
331 Water in fuel of water separator 363 Minute
332 Air cleaner 364 Service mode

Terminology used for each language.

The terminologies used on I-ECU for each language are as follows.
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Figure 12
Figure 13
Figure 14
Figure 15
Figure 16
Figure 17
Figure 18
 Service Information

Document Title: Function Group: Information Type: Date:

Control types for X1 and X3 387 Service Information 2014/7/4 0
operation
Profile:
EXC, EW160C, EW180C, EW140C [GB]

Control types for X1 and X3 operation

Figure 1
Control types for X1 and X3

There are three control types for X1 and X3 operation as follows.

– Toggles
– Push
– Proportional
If a machine has a “proportional control option” for X1 or X3, the user can set one of these 3 types. Otherwise the user is
only allowed to set one of 2 types that are “Toggle” or “Push”.
Control using on/off switch on the control lever

Figure 2
Control lever with on/off switch

1. Toggle type in I-ECU

Actuator for X1 or X3 is activated by pressing the on/off switch on the control lever and it will stay active even when the
switch is released. The actuator will be deactivated when the same switch is pressed again or the other switch for opposite
direction is pressed.

2. Push type in I-ECU

Actuator for X1 or X3 is activated while the on/off switch is depressed (ON position). The function will be deactivated when
the on/off switch is released.

Control using proportional switch on the control lever

Figure 3
Control lever with proportional switch

1. Toggle and Push-button type in I-ECU

These controls with proportional switch are similar as the ones with on/off switch but it has a special point to activate the
actuator because the proportional switch also has a proportional value.
In toggle type, the actuator will be activated by moving the proportional switch to one direction and it will be deactivated
when the switch is moved to same direction again or to opposite direction.

2. Proportional type in I-ECU

Actuator for X1 or X3 is activated proportional to the movement of the proportional switch.
 Service Information

Document Title: Function Group: Information Type: Date:

DC–DC converter, 393 Service Information 2014/7/4 0
description
Profile:
EXC, EW140C, EW160C, EW180C [GB]

DC–DC converter, description

 The converter lowers battery voltage of 24V to supply the working voltage for cassette.

Figure 1
DC-DC converter

Inspection method

 Put the tester in the voltage measuring position, and measure the voltage across the output and ground terminals.
 Service Information

Document Title: Function Group: Information Type: Date:

Radio with tape player, Service Information 2014/7/4 0
description
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Radio with tape player, description

Figure 1

Item Description Item Description

1 Audio mode 8 Eject
2 FM / AM 9 Power / Volume
3 Tape 10 Tune seek
4 Preset 1 11 Preset 4
5 Preset 2 12 Preset 5 / REW
6 Preset 3 13 Preset 6 / FF
7 Cassette door 14 LCD
 Service Information

Document Title: Function Group: Information Type: Date:

Radio with tape or CD Service Information 2014/7/4 0
player, descriptions
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Radio with tape or CD player, descriptions

 A high quality AM, FM radio and cassette tape unit / CD player, powered through the start switch.
 If the cassette mute switch (option) is installed and turned to ON, the audio through is cut off even when the
cassette power is ON.
 For the operating method, see the operator’s manual.

Figure 1
Radio with tape player / CD player

1. Mute / Power
2. Sound styles
3. Eject
4. Cassette / CD door
5. Rewind
6. Fast forward
7. Band
8. Search up
 9. AST / RDS
10. Search down
11. TA AF
12. Preset 5
13. Preset 4
14. LCD
15. Preset 1
16. Preset 2
17. Preset 3
18. Volume –
19. Volume +
 Service Information

Document Title: Function Group: Information Type: Date:

Audio remote controller, Service Information 2014/7/4 0
description
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Go back to Index Page

Audio remote controller, description

Figure 1
Audio remote controller

S1 Volume down 1 Switching signal (SW+)

S2 Volume up 2 Switching signal (SW-)
S3 Audio source selection 3 Ground
S4 Search up 4 Illumination
S5 Search down 5 Engine start switch signal
S6 Next channel 6 Power from audio system
S7 Power on/off GND Ground
REM Audio remote controller PWR Power
AUD Audio system ILL Illumination
IGN Ignition (engine start) switch BAT Battery
 Service Information

Document Title: Function Group: Information Type: Date:

Audio remote controller, Service Information 2014/7/4 0
description
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Go back to Index Page

Audio remote controller, description

Figure 1
Audio remote controller

S1 Volume down AUD Audio system

S2 Volume up 1 Switching signal (SW+)
S3 Audio source selection 2 Switching signal (SW-)
S4 Search up 3 Ground
S5 Search down 4 Illumination
S6 Mute 5 N/A
S7 Power on/off 6 Power from audio system
REM Audio remote controller
 Service Information

Document Title: Function Group: Information Type: Date:

Antenna, replacing 395 Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Antenna, replacing
Op nbr 395-021

1. Park the machine in the service position A, see 091 Service positions.

2. Remove the cab rear bracket.

Figure 1

1. Bracket
2. Cab cover

3. Remove the door cushion.

4. Remove the cab cover and put it on the cab.

5. Disconnect the wire harness and antenna cable connector from cab wire harness and antenna cable.

6. Remove the antenna from cab body.

 Figure 2

1. Antenna
2. Screw

7. Install a new antenna.

8. Reconnect the wire harness and antenna cable connector to the cab wire harness and antenna cable.

9. Reinstall the cab cover and bracket and cushion.

10. Check radio operation.

 Service Information

Document Title: Function Group: Information Type: Date:

Speaker, replacing 395 Service Information 2014/7/4 0
Profile:
EXC, EW140C, EW160C, EW180C [GB]

Speaker, replacing
Op nbr 395-031

1. Park the machine in the service position A, see 091 Service positions.

2. Remove the screws fixing speaker.

3. Disconnect the wire harness connector.

Figure 1

1. Speaker

4. Install a new speaker.

5. Connect the wire harness connector.

6. Reinstall the screws.

7. Check the speaker operation.

 Thank you for your purchase.
Have a nice day.

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