Teachers Guidel 220 e

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Dokumentnamn/Name of document Trainers Guide 558

Utgåva/Edition

1Sida/Page Page 1 of 29

Företagsnamn/Company Name

Volvo CE Customer Support AB Reg nr/Reg. No.

558-1Infoklass/Info class Ersätter/Replaces

Utfärdare (enhet, namn, tel, sign)/Issuer (dept., name, phone, sign.)

CSA -32, Frank Staffas, 1438/Datum/Date

02-08-23Bilaga/Appendix Flik/Insert

Ärende/Subject

Course No. 558 L220E, 5 days course.Fastställd/Approved

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TeachersGuide.doc

CSP, CSA, CSA-11, CSA-31, CSA-32, CSA-33, CSA-34, CSA-35, CSA-41, CSA-42, CSA-43

Introduction

Introduction and information about 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 L220E.

Walk round the machine, give technical information and explain briefly the major features.

* = Compared with L220D.Engine:?? D12CLBE2 with Engine Management System (EMS) with unit injectors. *?? Air-to-air cooled intercooler. *?? Electrical accelerator pedal and hand throttle. *?? Added Cooling System parameters: inlet air and intercooler temperature. *?? Cooling Fan Motor with integrated non-return valve. *

Electrical System (Contronic III)?? Computer network including E-ECU*, V-ECU and I-ECU.?? VCADS Pro Tool capability. *?? 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 HTE305?? Pulse Width Modulated (PWM) gearshifting.?? Relocated oil f ilter. *?? Separate pressure build up for each gear. *?? Oil cooler integrated with hydraulic oil cooler, cooled by engine coolant. *

Axles AWB50/41 (front/rear)

?? Axle Wet Brake (AWB) with cellulose wear material in the brake discs.?? Lubrizol additive in axle oil for maximum brake and cooling of discs.?? Increased strength of differentials due to central position of crown wheel.

L220E Loader

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?? Single locking nut on reduction hubs.?? AWB50 with two discs and new double acting return springs.?? AWB41 with front bridge permanently lubricated by grease and rear bridge by axle oil.

Brake System?? Sensors for brake light SE301 and output brake pressure SE501 switched position. *

Makes it possible to check front and rear output brake pressure simultaneously.

Steering System?? Increased displacement for Pump 2. 100 cm³ to 130 cm³. *

?? Increased displacement for Steering Valve. Decreases maximum steering turns by ½turn. *?? Steering accumulators for smoother steering.?? Restriction in Priority Valve, located in the Central Valve. Improves priority for steering. *

Frame *?? 150-mm increase of wheelbase increases stability.?? Counterweight with integrated battery boxes.

Hydraulic System?? Butt-welded hydraulic pipes. *?? P1 and P2 pumps. *?? Increased torque on front bolts for the regulators.?? Improved non-return valve for housing pressure.

Product numbers

Product numbers for Engines, HTE305 and Axles. Machine weight, bucket size.Let the trainees become acquainted with the machine and the documentation.

L68253AService Manual(SM)Operators Manual (OM)

Electrical System

Describe the principle of a network system.

The vehicle electronics contain three control units that communicate with each other throughtwo 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 3:1:7

Animation:“Computer NetworkEngine shutdown"

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

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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.

By combining these high and low signals the system can create messages which will betransferred out on the data bus for other ECU’s to receive.

On the CONTROL BUS, CAN2/J1939, (left) the voltage in cable A (CAN High) variesbetween 2,5 and 3,5 V and in cable B (CAN Low) between 1,5 and 2,5 V.

On the INFORMATION BUS, J1708/J1587, (right) the voltage in cable A and B variesbetween +5 and -5 V.

The voltage difference between cable A and B will determine if the signal is considered as1 (HIGH) or 0 (LOW) on the bus, according to the picture.

“Signal transfer“90876

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INFORMATION BUS

A message on the INFORMATION BUS J1708/J1587 consists of four parts in accordancewith SAE standard.A. MID (Message Identification Description) of the transmitting ECU. A unique number for

every type of ECU.B. PID (Parameter Identification Description). A unique number for every parameter or

PPID (Proprietary Parameter Identification Description). A Volvo-unique number orSID (Subsystem Identification Description). Identification of component or

PSID (Proprietary Subsystem Identification Description). A Volvo unique component.

C. Data value regarding the parameter above.

D. Check sum. Tells the receiver if the complete message has been received, The value ofthe check sum is compared with the other parts (A, B and C) of the message.

“Signal content” A1353800

Settings V-ECU

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

90845

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.

Show where to find information about the electrical system in the L220E Service Manual. “Explanations ofwiring diagram”L64903FMore information:SM 3:2:28

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Key dependent feeding, ground connections diagram SCH01.

?? Relays with resistors instead of quenching diodes. Note! Except RE11!?? Location of frame ground connections.?? A table for voltage connections depending of the position of the Starting Key, SW101.?? RE12 with C1, R11 and DI28 that are used for preventing RE12 to fall during sudden

voltage drops. 15EA initially supplies the V-ECU and I-ECU with current.?? RE2 (15A) and RE4 (15B) unloading relays divides the rest of the electrical system into

two “main circuits”.?? R1 ~200 ? , requires 4 W which is equal to LC3 in case LC3 fails.

“SCH01”L66641ESM 3:2:33

More information:SM 3:2:6

ECU feeding diagram SCH02.

?? Note! RE11with quenching diode on the circuit board!1. At starting key position 1-3 current is sent to the I-ECU (pin P1.14) and the V-ECU (pin

EB14).2. I-ECU (pin P3.21) will create ground connection for RE11. I-ECU can then keep RE11

pulled long enough to download all data when the starting key is turned off again.3. Power supply via RE11 for E-ECU (pins EB11/12), I-ECU (pin P1.30) and V-ECU (pin

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

“SCH02”L66641ESM 3:2:34

“SCH31”L67871BSM 3:2:62

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.

L220E LoaderService Display.More information:SM 3:1:98

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Trouble-shooting special tools.

Go through the different tools i.e. harnesses, breakout boxes etc. Show how and where toconnect.

L220E LoaderMore information:SM 3:3:12

Summary Electrical System.

Repeat and discuss the main features of the electrical system. What is the approach whentrouble-shooting this type of network system?Where and how can we read how the software work for different functions?Let the students work two and two explaining to each other one software function.

“Software functiondescription”SM 3:2:20

Engine

D12CLBE2 engine, description.

?? Explain engine code.?? Engine power and torque output. Point out that the increases of torque in the lower

engine speed range may cause problems for inexperienced operators. Easy to get“stuck” in the pile when using too high rpm and thereby receiving too high rimpull.Maximum torque at 1200 rpm!

L220E LoaderD12C engine

“Power/Torque”L68251A

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Inlet filter and intercooler

D12C is 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

Turbo

The exhausts that pass the turbine housing on the way out to the exhaust system drive theturbocharger.

The exhaust flow turns the turbine in the turbine housing. On the same shaft as the turbine,there is a compressor rotor. The compressor rotor is located in a housing that is connectedbetween the air cleaner and the engine induction pipe.

When the compressor rotor turns the air pressure before the turbo decreases. This togetherwith the atmospheric pressure will create airflow through the air cleaner. The air is

compressed and pressed into the engine cylinders, after having been cooled down duringpassage through the intercooler.

TurboL67672A

Cylinder head

Cylinder head

?? One piece cast iron ?? Separate inlet and exhaust channels (Cross-flow)

Valves

?? 2 exhaust valve springs, 1 inlet valve spring ??

Replaceable steel valve seats ?? Oil sealing on every valve ?? Inspection every 5 000 h.

Camshaft

?? 7 replaceable camshaft bearings, rear (WLO) = axial/radial bearing ?? 3 oversize bearings?? self-aligning end bearings

Injector sealing

?? Copper sleeve with rubber ring

Assembly ?? No guide pins only guides for steel sealing?? 3 Special tools for aligning

Note! Very important!

“Cylinder head”90850

More info:SM 2:1:4

“Cylinder head,assembly”90851

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Cylinder block

?? Rounded shape at each cylinder (cast iron) – Stiffness and low noise?? Stiffening frame bolted to lower part of block?? Solid aluminium oil sump insulated from block by rubber sealing.

“Cylinder block”90849More Info:SM 2:1:5

Piston and liner

?? Solid aluminium pistons?? 2 compression rings, upper keystone?? 1 oil scraper ring?? New installation tool (not conical) for piston into liner

Wet replaceable liners ?? Sealing kit = TD122.?? 3 EPDM rubber (black) 1 fluorine rubber (violet)?? Silicon rubber between liner collar and block?? Convex surface, liner contact with solid steel sealing

“Piston and liner”90989

More Info:SM 2:1:6

Camshaft and valves

?? WLO has the same marking on camshaft as EPG-engines: TDC (0° at flywheel) and 1 –6 for each cylinder.

?? 3 cam lobes: inlet, exhaust and injector.?? Hydraulic damper with wheel for camshaft position sensor.

Rocker arm bushings

?? Pre-lubricate oil channel if cleaned.

“Camshaft withValves”L68277A

More Info:

SM 2:1:7, 2:1:10

Removal of Valve Cover

?? Remove valve cover.?? Describe and show briefly the differences between engines with and engines without

Volvo Engine Brake (VEB).

D12C engine

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Timing gear

?? Assembled on 10 mm steel plate?? Sealed by silicon rubberNote! Type of silicon!

Intermediate gears (no. 2, 5, 10 and 11)?? Pressure lubricated bushing bearings?? Lubrication by oil nozzle?? Idler gear (no. 5) adjustable

“Timing gear”90852

More Info:SM 2:1:8

Crankshaft

?? Inductance hardened bearing surfaces?? 7 journal bearings, the middle = axial/radial bearing?? 5 oversize bearings?? Gear and hub for hydraulic damper pressed on the shaft?? Lip sealing between crankshaft and flywheel casing

Hydraulic damper ?? High viscosity silicon oil?? Steel ring rotating freely

Flywheel ?? Bolted to crankshaft with guiding pin?? Teeth milled for crankshaft position sensor

“Crankshaft”90855

More Info:SM 2:1:11

Engine sensors

Show the location of each sensor on the engine.

?? SE2603 – Coolant Level, Negative Temperature Coefficient (NTC)?? SE2701 – Camshaft position (inductive)?? 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 – Flywheel position (inductive)?? SE2301 – Fuel Charge Pressure (Piezo resistive)?? SE213 – Oil Level (capasitive resistive) NOTE! Input to V-ECU!

“Engine sensors”

L68079A

????

L220E Loader

More Info:SM 2:1:30

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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 3:2:60

Engine speed sensors

Camshaft sensor?? 7 teeth wheel, one per compression + one for TDC 1st cylinder

Flywheel sensor?? 3 groups of teeth

“Engine speedsensors”90974

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V-ECU to Engine sensors

?? SE201 – Engine Speed. Manual reading of frequency at MR1.?? SE207 – Fuel Level. Signal at EB9. Ground EB24

“SCH04”L66246GSM 3:2:36

Fuel System, principle

?? Relief valve (8) provides constant pressure for injectors (3,5 - 4,5 bar)?? Non-return valve (13) may cause low fuel feed pressure if it gets stuck in open position.?? Bleed valves (15) and (17) - after filter replacement?? Drain valve (16) – for draining the fuel system before repair

Fuel System, components

?? Relief valve (8) may be deformed by too high torqueNote! Torque important!

?? Feed pumps drive axleNote! Graphite grease when reinstalling prevents seizure!

?? Two sealing rings between oil and fuel with channel in between for detection of leakage

“Fuel System”L68081A90871L68080A

More Information:SM 2:1:18 andforward.

Unit injector

?? Manufactured by Lucas (for ART it may be Bosch = “Engine Type II“ on E-ECU sticker).?? All six injectors are classified to fit together, from factory.?? Spare part injectors can be installed in any cylinder (nominal classified)

“Unit Injector” Animation

More Information:SM 2:1:25

Unit injector, diagram SCH30

?? 90V from E-ECU pins EA11, EA22, EA23, EA34, EA35 and EA36.?? Ground at EA12 for cylinder 1-3 (SID 001-003) and EA24 for 4-6 (SID 004-006).

“SCH30”L67870BSM 3:2:61

Lubrication System

Note! Colour disappears by time (water based)?? Pressure relief valve (1), 3 - 5,5 bar – Blue marking?? By-pass filter valve (2)?? Piston cooling valve (3), ~2 bar – Orange marking

Note! Replace nozzle screws when removed!

“Lubrication”L68010B

L68264ASM 3:2:61

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?? Full flow filter valve (4)?? Safety valve (5) – Yellow marking?? Cooler by-pass valve (6), opens 2,4 bar and close 105 – 116 ?C.

Oil pump and cooler

Pump?? All in aluminium, except for gears.?? No bushings used as bearings for the gears.?? No repair kits for pump available!?? Housing and rear wall machined together – Can not be replaced separately.

“Oil pump and

cooler”90854

More info:SM 2:1:16

Starter motor and induction air heating, diagram SCH03 + SCH31

?? RE9 starter inhibitor relay when F or R gear is selected.?? RE202 extra unloading relay.?? No automatic heating only operator initiated.?? Pressing SW201 means requesting heating. Input to I-ECU, pin P2.18. I-ECU

communicates with E-ECU, which will connect RE2501 to ground and heat up heatingelement HE2501 with current via FU14.

?? Feedback from activated heating element to I-ECU, pin P1.4, and E-ECU, pin EB5.

“SCH03”L66815E“SCH31”L67871B

More info:SM 3:1:26

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% per

sec 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

“SCH27”L67865B

More info:SM 3:1:32,3:3:51-52

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?? P1.29 = Ground?? Deactivation: IVS = Closed or SE501 = 10 bar?? Incorrect R205 < 0.15 V or > 4.85 V

Integrated Cooling System

?? Integrates the engine, transmission, drive axles (when oil cooling is installed) andhydraulic systems.

?? Strives to heat up low temperature systems and cool down high temperature systems.I.e. engine heats up first and will warm up transmission, drive axles (if cooled) andhydraulic oil.

?? Pump 3 supplies the hydraulic cooling fan motor with hydraulic oil. ?? Return oil from fan motor drives axle cooling motors, which makes the pumps able to

circulate the oil. ?? Separate oil filters for each Drive Axle circuit. ?? Radiator coolant goes into the combined transmission- and hydraulic oil cooler. ?? The coolant flows from the combined cooler to the coolant pump and into the engine. ?? Temperature sensors supply the V-ECU with information. ?? V-ECU controls the flow from pump 3 with proportional valve MA202.

“Cooling System”L63131E

More info:SM 2:2:40-50

Coolant Circulation in Cylinder Block and Head

Main flow through oil cooler:?? Into upper part of liner via calibrated nozzles.?? Into cylinder head, via brass coolant nozzles.

Note! Brass coolant nozzle for No 4 turned 30? towards No 5, due to design of nozzle!?? Into cylinder head

Minor flow:?? Into lower part liner

Coolant Pump

?? Repair = replace everything except rear housing?? Sealing in one piece, made of carbon and ceramic material.

“Coolant Circulation,filter and pump”90867


Pulse Width Modulation (PWM)

?? Describe the way PWM is used at Volvo CE. “PWM” Animation

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Hydraulic System

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

symbols and location.

“Cooling Fan System, overview” Animation

“Cooling Fan System, details” Animation

“Hydraulic diagram, Cooling Fan incl. Drive axle cooling”

L67992A

Cooling Fan System, diagram SCH05

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

“SCH05”L66247H

More info:SM 3:1:30

Hydraulic Pumps

?? A = Pump 1 for Brakes, Servo and Working Hydraulics,Pressure Compensator = 6, Flow Compensator = 7.

?? C = Pump 2 for Brakes, Servo, Steering and Working Hydraulics,Pressure Compensator = 8, Flow Compensator = 9.

?? B = Pump 3 for Fan and Brake Systems, Pressure Compensator = 2.?? 3 = Pump 1 Checkpoint, 4 = LS-pressure Checkpoint, 5 = Pump 2 Checkpoint

in Non Return Valve Block on top of Pump 1.

“Hydraulic Pumps”L67567D

More info:SM 9:1:25

Pump Hoses

?? Leak-Off Hoses for Pump 1 (item 15), Pump 2 (item 5) and Pump 3(item 10).

?? Tank Hoses for Pump 1 (item 10), Pump 2 (item 5) and Pump 3 (item6).

?? Pressure Hoses for Pump 1 (item 26), Pump 2 (item 5) and Pump 3(item 13).

“Hydraulic pumps leak-off hoses”EK139

“Hydraulic pumps tank hoses”EK154

“Hydraulic pumps pressure hoses”

EK156

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Disassemble and reassemble Pump 3

?? Regulator OBS! Omposning av L66465E!?? Show design of Flow Compensator.?? Spring for Flow Compensator Spool (5) can protrude over the small edge of the Spool

and cause malfunction.?? Show design of Pressure Compensator.?? Show design of Regulating Piston (7) and Restriction inside.

?? Pump?? Keep the Pistons in the original position in the Rotor when reinstalling.?? Show design of Swash Plate bearing.?? Show position of Anti-rotation Pin in Rotor Bearing Ring when reinstalling! Incorrect

installation will cause malfunction of Swash Plate movement!?? Show the design of Sealing and Rotor Shaft Bearing.

“Cooling FanSystem, details” Animation

“Pump 3”L66465E

More info:SM 2:2:44

Checking Cooling Fan System

Check?? Maximum Fan Speed: Mode A, B and C.?? Low Fan Speed and Pressure.?? Max Pressure Test.

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


Axle Oil Cooling Components

Check out the location of the components on the machine.

Front?? Item 4 Hose to Combined Hydraulic Motor and Pump.?? Item 11 Hose to Oil Filter.?? Item 20 Hose to Axle Oil Cooler.?? Item 22 Hose back to Drive Axle.?? Item 47 = Combined Hydraulic Motor and Pump and Hoses.

Rear?? Item 4 Hose for Return Oil from Hydraulic Fan Motor to Combined Hydraulic Motor and

Pump.?? Item 41 (upper) Hose from Pump to Oil Filter.?? Item 14 Hose to Axle Oil Cooler.?? Item 24 Hose to Combined Hydraulic and Transmission Oil Cooler.

“Parts Axle Oil

Cooling Front”EK302

“Parts Axle OilCooling Rear”EK311

L220E Loader

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Brake System

?? Explain the Brake System andhow it is integrated with theCooling Fan System.

?? Go through the hydraulic diagramand explain symbols and location.

“Brake System, overview” Animation

“Brake System, details” Animation

“Hydraulic diagram, Cooling fan and brake system” L67994A

Brake System Components

Show the location of the Brake System Components on the machine.?? Item 23 Foot Brake Valve.?? Item 5 Hose to Accumulator Block.?? Item 17 Hose to Front Axle Brakes.?? Item 18 Hose to Rear Axle Brakes.?? Item 31 Hose to Tank.

“Parts BrakeSystem, overview”EK183L220E Loader

Disassemble Central Valve (Cooling Fan and Brake System components)

Show design of:?? MA502 Cut-Off Valve.?? 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. Over view and diagram”L67883A

“Central valve. Cut view”L63260HMore info:SM 9:1:6

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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Parking Brake Components

Show the location of the Parking Brake Components on the machine.?? Item 7 Parking Brake Solenoid Valve, MA501.

?? Item 15 Hose from Accumulator Block.?? Item 16 Hose to Parking Brake in Transmission.?? Item 13 Hose to Tank.

“Foot Brake Valve”L67880A

“Foot Brake Valve,cut-away view”L67879A

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Brake System pressure charging, wiring diagram SCH15B

SE501, Out-put Brake Pressure?? V-ECU, pin EB40 = 5 V feeding?? EB5 = Signal. ~0,5 V (0 bar) – ~2 V (full brake pressure)?? EB24 = Ground connection

SE502, Low Brake Pressure (Accumulator Block)?? V-ECU, pin EB36, 24 V = Normal Brake Pressure

SW501, Parking Brake?? I-ECU, pin P2.16, 24 V = Request for Releasing Parking Brake?? V-ECU, pin EC4, 24 V = Actuating MA501 (Releasing Parking Brake)?? V-ECU, pin EA9, 24 V = Hydraulic Pressure to Parking Brake (Parking Brake Released).

Required within 3 sec from Actuation of MA501, else “ERROR, Parking Brake Circuit”!

SE504, Brake Charging?? V-ECU, pin EA10, 24 V = Request for Brake Charging?? Actuating MA502 (Cutting-Off Hydraulic Fan System)

“SCH15B”L66758D


Brake System Electrical Components

OBS! Omposning av bild!!!!Show the location of the components on the machine.?? Item 1 SE504, Brake Charging Sensor

?? Item 2 SE502, Low Brake Pressure Sensor?? Item 3 SE501, Out-put Brake Pressure Sensor?? Item 4 SE301, Brake Light Sensor?? Item 5 MA502, Cut-Off Solenoid Valve?? Item 6 MA202, Proportional Valve?? Item 7 SE503, Parking Brake Pressure Sensor

?? Item 8 MA501, Parking Brake Solenoid Valve?? Item 9 Connector UA used for several Brake System functions.

“Parts Wire HarnessBrake System”EK309???

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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

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

More info:SM 5:??

Transmission HTE305

Hydraulic transmission consisting of Torque Converter transferring the torque from theDiesel Engine, via three Clutch Shafts (Forward-1st, 2nd-Reverse and 4th-3rd) and adropbox to the Output Shaft with spring loaded Parking Brake.

“Drive Train”L68247A

Hydraulic Diagram

?? Pump delivers 170 dm³/min at 17 bar (1 900 r/min)?? By-pass Valve opens at ~3,5 bar?? SE401, Filter Indicator, opens at ~2,8 bar and closes ~2,1 bar?? V-ECU alarms for clogged filter if oil temp. > 50?C.?? SE405, Pressure Sensor. Different alarm levels depending on engine speed.?? Pressure-limiting Valve limits Main Pressure to the PWM-valves.?? Separate plugs make it possible to measure each Clutch Pressure.?? Converter Safety Valve delivers 50-70 dm³/min by a rubber hose back to the sump.

NOTE! Main cause for oil transfer from Transmission to Hydraulics was before the

rubber hose installation!?? Oil Cooler can take ~100-120 dm³/min?? Lubrication Pressure Limiting Valve and SE406, Temp. Sensor, on return line from Oil

Cooler.?? Quick couplings for checking Main, Converter and Lubrication Pressure.

“Hydraulic diagramtransmission”L63066D


Transmission. Break down

Describe the location of the components?? Item 5, Clutch Shaft F – 1st

?? Item 6, Clutch Shaft 2nd

– R?? Item 7, Clutch Shaft 4th – 3rd ?? Item 19 SE413, Transmission Oil Level

“Transmission.Break down”

EK339

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Converter housing 1

Describe the location of the components?? Item 4, Oil Pump?? Item 6, Converter Base??? Item 17, Turbine Shaft?? Item 30 SE201, Engine Speed Sensor?? Item 32 SE402, Turbine Shaft Speed Sensor

“Converter housing1”EK297

Converter housing 2

Describe the location of the components. OBS! Omposning!?? Item A, Converter Safety Valve?? Item 3, Pressure Pipe?? Item 10, Distributor for 4th/3rd Clutch?? Item 12A, Hose for 4th Gear Clutch?? Item 12B, Hose for 3rd Gear Clutch?? Item 12C, Hose for Lubrication of 4th/3rd Gear Clutch?? Item 20, Distributor for 2nd/ Reverse Clutch?? Item 31, Distributor for Forward/1st Clutch?? Item 37, Spray Nozzle for PTO Gear Lubrication

“Converter housing

2”EK327

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Clutch Shaft (Forward / 1st)

Describe the function of the one step clutch.?? Sealing Rings of Steel, due to the higher clutch pressure (compared to HT200)?? Channel A = Clutch Pressure Forward gear?? Channel B = Clutch Pressure 1st gear?? Channel C = Lubrication Pressure?? Roller Bearings for Forward/1st Clutch Gear Wheels makes them rotate freely until clutch

pressure fixates the Gears to the Shaft.?? Each Friction Plate is connected with splines to the Drum?? Each Steel Plate is connected with splines to the Hub?? Clutch Pressure enters behind the Piston and compresses the Spring.?? The increased friction between Friction Plates and Steel Plates locks the Hub and Drum

together and thereby fixates the Shaft to the Gear Wheel.

“Clutch shaftForward / Gear 1.One step clutches”L63067B

Clutch shaft F/R, lubrication

?? A lubrication channel into the Clutch opens when the Piston for Forward or Reverse gear

is moved for engagement.?? This provides cooling for the Directional Gears during engagement. “Clutch shaft F/R,lubrication” Animation

Pressure build-up in Disc Clutch

?? Pressure build-up controlled by PWM technology in the Gear Selector Valve. (Ref. ToPWM animation.)

?? Different pressure build-up/pressure release depending on selected Gear. CompareReverse with 2nd Gear and Forward with 1st Gear!

General description of output pressure to the clutches (Speed Gears) from Gear SelectorValve:?? Pressure to “Previous Gear” is immediately decreased to the minimum required pressure

to prevent slippage.?? Then the pressure is dropped down to a level where it may start to slip.?? During modulation (PWM) the pressure smoothly decreases before modulation stops

and the pressure drops down to “zero”.?? Pressure to “Next Gear” is increased to quickly fill up the clutch.?? After that, the clutch is normally considered to be filled-up and a Start Pressure is

applied. The Start Pressure is applied during a short time before the modulation starts.?? The pressure is smoothly increased during modulation and both gears are slipping, until

“Next Gear” reaches the required pressure to prevent slippage.

?? The pressure quickly increases up to normal clutch pressure and the Gearshift iscompleted.

?? If slippage is detected in the clutch (after the Gearshift), the pressure can be increased

“Pressure build-upin disc clutch”L68047B

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up to Main Pressure.

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Gear Selector Valve

Disassemble and reassemble the Gear Selector Valve.?? SE405 is located opposite the Pressure-limiting Valve inside the Gear Selector Valve.

Note! Easy to break SE405 during removal or installation!?? Necessity of clean oil, due to the need for exacts modulation with PWM-valves.?? SA = Forward Gear, SB = 1st Gear?? SC = 2nd Gear, SD = Reverse Gear?? SE = 4th Gear, SF = 3rd Gear

HTE305,Gear Selector Valve

“Gear selectorvalve, Cut view”L63065C

“PWM solenoidvalve, Cut away“L67231A

Gear Shifting Solenoids and Transmission disengagement, wiring diagram SCH11

?? Resistance ~22 ? ?? When a failed solenoid is detected another suitable gear is selected instead according to

a specific program. ?? SW411 = Request for Transmission disengagement

“SCH11”L66756D

More info:SM 3:1:55, 3:3:813:1:52

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?? P1.2 = Heavy?? P1.25 = Manual

Differential Lock?? SW414 ? I-ECU, pin P2.16 = request for Differential Lock?? V-ECU, pin EC2 = Current for Differential Lock Solenoid Valve MA407?? SE408 ? V-ECU, pin EA35 = Feedback of Differential Lock Piston movement

“SCH12”L66255D

More info:

SM 3:1:44-48, 57

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Transmission Oil Filter

?? New location of Oil Filter (compared to L220D) for improved accessibility. “Parts Oil filter”EK332

Transmission Check

?? Check the main pressure, torque converter pressure, clutch pressure, and lubricationpressure.

?? Check the stalling speed with 3rd gear engaged (1810-1880 r/min).

L220E Loader

More info:SM 4:17

Gear Selector and Control Lever carrier, wiring diagram SCH09

SW401, Speed Gear Selector (I-ECU, pin):?? P2.21 + P2.8 = Request for 1st gear?? P2.8 = Request for 2nd gear?? No input = Request for 3rd gear?? P2.20 = Request for 4th gear?? P2.7 = Request for Kick-down

SW402, Directional Gear Selector (I-ECU, pin):?? P2.9 = Request for Reverse gear?? 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

“SCH09”L66659F

More info:

SM 3:1:53-55,3:3:77-80

Drive Axles AWB50/41 (Front/Rear)

?? Describe the design of the axles and the wet disc working principle.?? Explain how to check the wear on the brake disc, including converting from former to

later design.?? Show the oil flow inside the axles for cooling and lubrication.?? Show design of differential lock.?? Explain the rear axle self-lubricating suspension.?? Explain how the limited slip differential works.

AWB50/41“AWB50 Front axle”L68269AMore info:SM 4:31

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Steering System

Steering System Components

Show location on machine for the components in the Steering System and the relationshipbetween them.

?? Pump 2.?? Central Valve.?? Steering Valve.?? Shift Valve?? Steering Cylinders with Accumulators.

“Steering SystemComponents, x-ray”L68270A

More info:SM 6:3

Steering System

?? Explain the Steering System.?? Go through the hydraulic diagram and explain

symbols and location in the machine.

“Steering System, overview” Animation

“Steering System, details” Animation

“Hydraulic diagram, Steering system” L67882A

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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 Steering valve”EK275More information:SM 6:4-5

Valve Block

Disassemble and reassemble the Steering Valve.

?? Item 3, Anti-cavitation Valves.?? Item 4, Shock Valves.

“Parts Valve block”EK273

Checking Steering System

Check

?? Stand-by and maximum pressure.?? Shift pressure.?? Time for one full turn. (maximum steering angle)?? Check if you can turn the steering wheel >1 turn/min at maximum steering angle (internal

leakage).

SM 6:17-18

Working Hydraulics, General Description

General description

?? Pump 1 connected directly to Control Valve.?? Pump 2 connected via Central Valve.?? Central Valve controls Servo Pressure and supply from P2.?? Servo Valve with two sections (lift and tilt) as standard. Sections for 3-4th hydraulic

function as option.?? Control Valve with lift and tilt section.

“Workinghydraulics,principle”L68276A


ORFS hose connection

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O-Ring Face Seal

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

“ORFS hoseconnection.L64423B

More info:SM 9:1:6

Servo Valve

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

Servo Valve“Servo Valve” AnimationMore info:SM 9:1:37-39

Control Valve

?? Point out the location of the different components inside the ControlValve.

?? The Load Holding Valves and NOT the Spools are designed to seal theconnection to tank in neutral position. The clearance between the Spoolsand housing are too large to seal properly.

?? Pilot Valves are used to be able to lift the Load Holding Valves and drainthe side of the Cylinder, which is not pressurised.

“Control Valve”L67307BL67308BL67309AL67310B


Tilt Section, Tilt - In

?? Explain Tilt - In function. “Tilt In” Animation

“Lift section neutral” L67240A

More info: SM 9:1:16-17

Tilt Section, Shock

?? Explain Shock function. “Shock” Animation

“Shock/anticavitation valves”

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Animation

More info: SM 9:1:18

Lift Section, Lowering

?? Explain Lowering function. “Lowering” Animation

“Lift section Lowering” L67238A


Lift Section, Lowering and Tilt - In

?? Explain Lowering and Tilt - In. “Lowering and tilt-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

?? The return flow must open the Back-up Valvebefore it may be drained to tank.

?? Depending on the flow the pressure may varybetween 2-10 bar.

“Back-up valve, cut away.” L67236A

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LS-signal

?? One common LS-signal to the Central Valve fromthe different functions in the Control Valve.

?? Constant LS-draining (bleed-off) independently ofthe pressure.

?? Non-return Valves for each function. Sealing whenthe function is not in use.

“LS-signal, cut away.” L67244A

Control Valve, Hydraulic





Checking Working Hydraulics





Documents

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