Teachers Guidel 330 e

8/18/2019 Teachers Guidel 330 e

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Dokumentnamn/Name of document Notes

Utgåva/Edition

1Sida/Page Page 1 of 18

Företagsnamn/Company Name

Volvo CE Customer Support AB Reg nr/Reg. No. Infoklass/Info class Ersätter/Replaces

Utfärdare (enhet, namn, tel, sign)/Issuer (dept., name, phone, sign.) Datum/Date Bilaga/Appendix Flik/Insert

Ärende/Subject Wheel Loaders L330E

Fastställd/Approved

Mottagare/Receiver TRAINERS

Introduction

Introduction and information regarding the course.

Introduction by the course leader. Go through the training program, explain the goal of thecourse. Hand out the course inquiry to the trainees.

Training ProgramCourse Goal

Presentation of Volvo CE.

Explain VCE’s position within the Volvo Group, Net Sales and Result, Number of Employees,Product Lines, The World Market, Operating- and Industrial Structure, Market Position. Binder:Corporate Material

Introduction of L330E

Explain briefly the major features for the new machine.

?? Euro Step 2 emission levels (g/kWh) NOx (Nitrogen Oxides), HC (Hydro Carbonates),PM (Particles) and CO (Carbon Monoxides) are causing engine changes.

?? E i M t S t (EMS) El t i ll t ll d l i i i

PPT L330E: 1-21


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?? E i M t S t (EMS) El t i ll t ll d l i i i


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Mottagare/Receiver centigrade.

Electrical System ?? Computer network including E-ECU, V-ECU and I-ECU.?? VCADS Pro Tool capability.?? Improved capacity on batteries from 240 Ah to 250 Ah.?? Main fuse and "Big" relays located in protected area in engine compartment?? Bosch alternator (previously Valeo) with air tube and filter (option) for increased lifetime?? Improved monitoring functions:?? Fluid levels.?? Intercooler temp/pressure.?? Engine oil degradation.?? Fuel consumption (displayed on Information Panel).

Transmission

.

?? Separate pressure build up for each gear.?? Oil cooler, cooled by engine coolant.?? Oil l l i di t ( i l l)


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Mottagare/Receiver

Electrical System

Describe the principle of a network system.

The vehicle electronics contain three control units that communicate with each other through

two data buses. Engine ECU (E-ECU), Vehicle ECU (V-ECU) and Instrument ECU (I-ECU).Each control unit processes values from sensors, operating controls and controlscomponents so that the desired function is achieved.Communication between the different control units and reporting from control units to theservice sockets takes place on data buses CAN/J1939 (CONTROL BUS) and J1708/J1587(INFORMATION BUS).The buses correspond to SAE standards and consist of two pair-twisted cables. The purposeof the twisted cabling is to protect the bus from electrical interference.

“Contronic III”

L64434FSM 3:1:6

Animation:“Computer NetworkEngine shutdown"

More information:SM 3:1:6 - 9.

Digital Signals

Illustration of an oscilloscope display where voltage is measured on a data bus. Digitalsignals means that the voltage only varies between two voltage levels, either HIGH or LOW.

B bi i th hi h d l i l th t t hi h ill bt f d t th d t b f th ECU’ t i

“Signal transfer“90876


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Mottagare/Receiver

Settings V-ECU

Describe the correct setting for the V-ECU (BB) to be able to program the ECU correctly. Settings V-ECU90845

Distribution box

Show position of circuit board, V-ECU, I-ECU, E-ECU, display unit, switches and differentcontrol lamps.Show components and explain codes on the circuit board. Codes on connectors; R = RearFrame, CDC = Comfort drive Control, D/DA and DB = Dashboard and I-ECU, E = V-ECU, FA= Front Frame, GA = Gear Selector, SA/SB = Right Side Panel, OA = Secondary Steering,

TA/TB = Transmission etc.

L220E LoaderElectrical simulator“Inside cab”L67132BSM 3:1:76

“Distribution box”L66362DSM 3:2:5

Explain wiring diagram and the most common symbols.

Sh h t fi d i f ti b t th l t i l t i th E i “E l ti f i i di ”


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Mottagare/Receiver EB28). If FU17 fails the parking brake will not be released and the system will detect lowvoltage (measured at EB28)!

ECU network diagram SCH24 and SCH31.

CONTROL BUS?? CAN High (A): V-ECU (pin EC16), I-ECU (pin P1.1) and E-ECU (pin EB1) ?? CAN Low (B): V-ECU (pin EC17), I-ECU (pin P1.15) and E-ECU (pin EB2).?? R702 = 120?

INFORMATION BUS?? Cable A: V-ECU (pin EB38), I-ECU (pin P1.7) and E-ECU (pin EB25)

?? Cable B: V-ECU (pin EB11), I-ECU (pin P1.21) and E-ECU (pin EB26)

“SCH24”L66655ESM 3:2:55

“SCH31”L67871BSM 3:2:62

Contronic Service Display.

Go through the different menus in the Service Display. Explain the codes used: o = opencircuit, s = short circuit, m = malfunction since the machine was started,M = malfunction at an earlier occasion.

L330E LoaderService Display.More information:

SM 3 1 98 118


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Mottagare/Receiver

Engine D16BLAE2

The engine originates from the TD164,the engine has been modified with regards to fuel inletand cooling systems.No changes have been made inside the engine.Give a short explanation

PPT 1-5 and 1-6

Inlet filter and intercooler

The engine are equipped with charge-air cooling of the air-to-air type (intercooler).The intercooler lowers the temperature of the induction air by approx. 100 °C (212 °F). Theinduction air is thus made denser, which means that more fuel can be injected. This giveshigher engine power, but the colder air also results in less stress on valves and pistons andless NOx-emissions.

“Inlet filter andintercooler”L68261A


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Mottagare/Receiver

Engine sensors

Show the location of each sensor on the engine.?? SE2603 – Coolant Level, Negative Temperature Coefficient (NTC)?? SE2701 – Fly wheel positioning sensor.?? SE2507 – Turbo Charge Temp (NTC)?? SE2508 – Turbo Charge Pressure (Piezo resistive)?? SE2202 – Oil Temp (NTC)

?? SE2203 – Oil Pressure (Piezo resistive)?? SE2501 – Inlet Air Temp (NTC)?? SE2502 – Inlet Air Pressure (Filter indicator, Piezo resistive)?? SE2606 – Coolant Temp (NTC)?? SE2703 – Rpm injection pump.)?? SE2301 – Fuel Charge Pressure (Piezo resistive)?? SE213 – Oil Level (capasitive resistive) NOTE! Input to V-ECU!

“Engine sensors”L68079A


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Mottagare/Receiver

E-ECU to Engine sensors 1

?? SE2603 – Coolant Level, System voltage from EB7 and ground EB8.?? SE2501 – Inlet Air Temp. 5 V feeding from E-ECU. Signal at EB3 depending on the

resistance of the sensor. Ground EB13.

?? SE2502 – Inlet Air Pressure (Filter indicator). 80% of system voltage from EB17 andground EB8.

“SCH28”L67868BSM 3:2:59

E-ECU to Engine sensors 2

?? SE2606 – Coolant Temp. Signal at EA25. Ground EA5.?? SE2507 – Turbo Charge Temp. Signal at EA2. Ground EA5.?? SE2508 – Turbo Charge Pressure. 5 V from EA4, signal to EA3 and ground EA5.?? SE2202 – Oil Temp. Signal at EA1. Ground EA5.?? SE2203 – Oil Pressure. 5 V from EA4, signal to EA14 and ground EA5.?? SE2301 – Fuel Charge Pressure. 5 V from EA4, signal to EA27 and ground EA5.

“SCH29”L67868BSM 3:2:67


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Mottagare/Receiver

Electric Accelerator Pedal, wiring diagram SCH27

Accelerator Pedal Sensor (APS)?? I-ECU, pin P3.10 = 5 V feeding?? P3.9 = Signal APS 0 ? 100%, 0.65 – 0.8 (IVS closes) – 3.85 V??

P3.3 = Ground?? Incorrect sensor < 0.25 V or > 4.75 V ? Limp Home

Idle Validation Switch (IVS)?? I-ECU, pin P2.13 = Possible to activate Limp Home if APS fails.?? P3.15 = 24 V feeding (not system voltage).?? Incorrect switch APS > 2.75 V and IVS open

Limp Home

?? IVS closed (I-ECU, pin P2.13) ? Increase engine speed to 1000 rpm then + 20% persec as long as IVS is closed.

Electric Hand Throttle R205, wiring diagram SCH27

?? I-ECU, pin P3.22 = 5 V feeding?? P3.14 = Signal, Activation 0.5 – 2 V, 0 – 100% ? 2 – 4.25 V?? P1.29 = Ground?? Deactivation: IVS = Closed or SE501 = 10 bar?? Incorrect R205 < 0.15 V or > 4.85 V

Sevice manual3:2:65


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Mottagare/Receiver

Hydraulic System

?? Describe the Cooling Fan System.?? Go through the hydraulic diagram and explain symbols

and location.Central Valve:?? MA 502 lets a small flow through in closed position, to

reduce stress on fan motor with frequent starts andstops.

“Cooling Fan System, overview” V1000744

“Cooling Fan System, details”

Cooling Fan System, diagram SCH05

?? Possible to use pins UA7 and UA13 for measuring the level of PWM-signal, i.e. mean

voltage at high idle.?? ~ 5 V = Low Fan Speed (No Cooling Demand)?? ~ 12 V = A Mode ( Noise Reduction Kit)?? ~ 14 V = B Mode (EU Execution)?? ~ 18 V = C Mode (High Cooling Performance)?? 18-20 V = Max Pressure Test?? MA204 and MA205 = Reversible fan

Service manual3:2:43


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Ärende/Subject Wheel Loaders L330EFastställd/Approved

Mottagare/Receiver

Disassemble Central Valve (Cooling Fan and Brake System components)

Show design of:?? MA502 Cut-Off Valve. 1mm restriction allows a small f low to the fan motor even during

brake charging.?? MA202 Proportional Valve, with restriction.?? Ports PF, LSF and PFF used for the Cooling Fan System.?? Pressure Reducing Valve, Maximum Brake Pressure.?? Shuttle Valve for Brake System

“Central valve. Overview and diagram”L67883A

“Central valve. Cutview”

Foot Brake Valve

Disassemble and reassemble the Foot Brake ValveM1 = Port for SE501, M2 = Port for SE301Front Circuit

?? SP1 = From Accumulator Block, BR1 = Brake Circuit.Rear Circuit

?? SP2 = From Accumulator Block, BR2 = Brake Circuit.

“Foot Brake Valve”L67880A

“Foot Brake Valve,cut-away view”L67879A


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Mottagare/Receiver

Checking Brake System

Check

?? Maximum Brake Pressure.?? Cut-in and Cut-off Pressure (brake charging).?? Brake System performance (Accumulators).?? Low Brake Pressure Sensor and Control Lamp.?? Accumulator Precharging Pressure.?? Out-put Brake Pressure?? Brake disc wear indicator

Discuss what happens in each test and how they might be useful during trouble-shooting.

Service manual5:2.20-28

Transmission Principle 8421H-21

Transmission description: Walk round machine and locate components.Point out major components and their locations on the actual transmission.The transmission has a completely new gear selector valve,NO PWM technology has been

d! I d hif i h b hi d h h d l i l f

4:10-13


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Mottagare/Receiver

Wiring diagrams transmission

Go through the wiring diagrams and explain all funtions pertaining to the transmissionIe. Gear selector ,kick down ,APS,.electrical fuction descriptions .

Service manual

3:1:44 and onwards.

Transmission System, wiring diagram SCH12

SE405, Transmission Oil Pressure (V-ECU, pin):?? EB40 = 5 V feeding?? EB4= Signal. ~0,5 V (0 bar) – ~3,8 V (16 bar)?? EB24 = Ground connection

SW412, APS II Mode Selector I-ECU, pin):?? No input = Light I?? P1.24 = Light II?? P1.11 = Normal

?? 1 2

“SCH12”L66255D

More info:SM 3:1:44-48, 57


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Ärende/Subject Wheel Loaders L330E Fastställd/Approved

Mottagare/Receiver

?? P2.22 = Request for Forward gear?? R2 = Resistor to prevent oxidation of Selector?? Reference flag 2 to SCH03 = Starter Lockout with F or R selected.

Control Lever carrier?? SW403 = Activation F/R

?? SW404 = F/R?? SW405 = Kick-down?? SW406 = Engine Brake

Drive Axles 53R312

The front axle has a reinforced housing (stiffening members)The rear axle has a new cast cradle

Loose fit on half shafts(already introduced on the D series)Limited slip differencial standard.

PPT E series2-6


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Mottagare/Receiver

Steering Valve

Disassemble and reassemble the Steering Valve.

?? Position of inner and outer spools!?? Position of Cross Pin in comparison with the Rotor and Rotor Ring!??

Leaf Springs positions!

Steering Valve“Parts Steeringvalve”EK275

Valve Blocks

Disassemble and reassemble the steering valve block,and flow amplifier..

?? Item 3, Anti-cavitation Valves.?? Item 4, Shock Valves.?? Show and explain components in flow amplifier.

“Parts steeringValve block” EK273Parts flow amplifierEQ159

Checking Steering System L330E

Check:

?? Working pressure checking.

??

Service manual6:2:19


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Mottagare/Receiver

Servo Valve

?? Explain the Servo System.Detent Solenoids?? MA901 – Bucket Positioner?? MA902 – Float Position?? MA904 – Boom Kick-out

Servo Valve“Servo Valve” Animation

Refer to servicemanual 9:1

Control Valve

?? Point out the location of the different components inside the Control Valve.?? The Load Holding Valves and NOT the Spools are designed to seal the connection to

tank in neutral position. The clearance between the Spools and housing are too large to

seal properly.?? Pilot Valves are used to be able to lift the Load Holding Valves and drain the side of the

Cylinder, which is not pressurised.

“Control Valve”L67307BL67308B

L67309AL67310B


Tilt Section, Tilt - In


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Mottagare/Receiver

ORFS hose connection

O-Ring Face Seal

?? Important with lubricated o-ring of correct size.

“ORFS hose connection. L64423B

Servo Valve

?? Explain the Servo System.Detent Solenoids?? MA901 – Bucket Positioner?? MA902 – Float Position?? MA904 – Boom Kick-out

Servo Valve“Servo Valve” Animation


Control Valve

?? Point out the location of the different components inside the Control Valve.?? The Load Holding Valves and NOT the Spools are designed to seal the connection to

tank in neutral position. The clearance between the Spools and housing are too large to

“Control Valve”L67307BL67308B


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Mottagare/Receiver “Lift section Lowering” L67238A

Refer to service manual 9:1

Lift Section, Lowering and Tilt - In

?? Explain Lowering and Tilt - In. “Lowering and ti lt-in” Animation

“Lift section Lowering” L67243A


Lift Section, Float Position

?? Explain Float Position function. “Float Position” Animation

“Lift section, Float Position“ L67239A


Back-up Valve


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PROGRAM Service Training

Course Wheel Loader L330E Course No

Instructor Notes

TIME MONDAY TUESDAY WEDNESDAY THURSDAY FRIDAY

08.00

Engine D16BLAE2

Description.

Central valve description. Axle 53R312 Clark.

Description.

Working hydraulics cont

Presentation Volvo CE

Course information and

goal.

Engine electronics Disassemble central valve. Steering system description. Valve disassembly.

Presentation of the

Machine using PPT.

Checking Injection timing. Brake system description. Steering valve disassembly. Working hydraulics

checking.

Machine walk round. cont Brake system checking. Flow amplifier disassembly. Course evaluation and

dispersal.

LUNCH

Electrical system

description.

Cooling system description. cont Check steering system.

Electrical diagram reading Fan and brake system

description.

Transmission description.

8421H-21 Clark.

Working hydraulics

description.

-

Special tools (electrical)

Diagnostic equipment.

Checking fan system Disassemble gear selector

valve.

Servo system.

16.45

cont cont Transmission checking. Checking servo system.

Volvo Construction Equipment Customer Support ABMAINMENU

Documents

Teachers Guidel 330 e