EC230 Åkerman, EC230B Akerman, EC230B Volvo Excavators Service Repair Manual
Complete repair service manual for EC230 Åkerman, EC230B Akerman, EC230B Volvo Excavators, with workshop information to maintain, diagnose, repair, and rebuild like professional mechanics.
EC230 Åkerman, EC230B Akerman, EC230B Volvo Excavators workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
99535 - EC230B Volvo (5252-9999) Excavators Parts Manual.pdf
EC230 Åkerman Excavators Service Repair Manual.pdf
EC230B Volvo Excavators Service Repair Manual.pdf
Pages: 1,568 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English
MAIN SECTIONS
0 - GENERAL
1 - STANDARD PARTS, SERVICE
2 - ENGINE WITH MOUNTING AND EQUIPMENT
3 - ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
4 - POWER TRANSMISSION
5 - BRAKE
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPM.; MISC EQUIPM
TABLE OF CONTENTS
99535 - EC230B Volvo (5252-9999) Excavators Parts Manual....2
0 - Foreword....3
0 - GENERAL....4
03 - SPECIFICATIONS....5
Product identification plate....6
2 - ENGINE WITH MOUNTING AND EQUIPMENT....7
21 - ENGINE....8
Camshaft....9
Crankshaft and related parts....11
Cylinder block....13
Cylinder head....15
Cylinder liner and piston....17
Engine Td 063 Kie....19
Engine mounting....21
Flywheel housing....23
Oil sump....25
Repair kits for engine....26
Timing gear casing....30
22 - LUBRICATING SYSTEM....32
Lubricating oil system....33
Oil cooler....35
Oil filter....37
Oil pump....39
23 - FUEL SYSTEM....41
Extra fuel filter 14257924....42
Feed pump....44
Fuel filter....46
Fuel pipes, injectors....48
Fuel pump....50
Fuel system-[3732]....52
Fuel system....54
Fuel tank....56
Injection pump with drive....58
Injection pump....59
Injector....62
25 - INLET & EXHAUST SYSTEM....64
Air filter....65
Exhaust manifold and installation components....66
Exhaust system....67
Induction manifold with fitting parts....69
Inlet system....70
Intercooler....72
Turbo charger....74
Turbocharger with fitting parts....76
26 - COOLING SYSTEM....78
Cooling system....79
Expansion tank with fitting parts....81
Expansion tank, Cab elevation 1220mm. 14260597....83
Fan and installation components....85
Radiator with fitting parts-[3414]....87
Radiator....89
Water pump and thermostat....91
27 - ENGINE CONTROL....94
Fuel miser....95
Hydraulic cylinder-[3234]....97
Potentiometer....99
Stop control....100
Throttle control....102
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS....104
31 - BATTERY....105
Battery, assembly SER NO -4733....106
Battery, assembly SER NO 4734-....108
32 - ALTERNATOR; CHARGE REGULATOR....110
Alternator with assembling details 080 A 14259280....111
Alternator, 080a 14259280....112
Alternator, assembly....114
Alternator....116
33 - STARTING SYSTEM....118
Starter element, assembly....119
Starter motor, mounting....121
Starter motor....122
35 - LIGHTING....125
Lighting, front....126
Lighting, rear....128
Working lamp on boom....129
36 - OTHER ELECTRICAL EQUIPMENT....131
Cirkulation pump 14256586....132
Compressor horn....134
El.engine heater 14255254....135
Electric insatallation onbackhoe equipment....137
Electric insatallation onfront shovel equipm....139
Electric inst. of hammer_shears for adj. boom in base machine....141
Electric installation for Compressor 14256846....143
Electric installation for hydraulic hammer 14261292....144
Electric installation for materials handling equipment. 14258081, 14258084....145
Electric installation forslope bucket_grab equipm.in base machine....147
Electric installation of hammer_shears for mono- bloc boom 14257946....149
Electric installation on boom, matreials handl. equipm. 14258081....151
Electric intallation of hammer_shears on monoboomin base machine 14258074....153
Lunch box heater 14254176....155
Magnet equipment Ohio, Eletric installation 015 kw alternator 14263368....157
Magnet equipment Ohio, alternator 015 kw 14263368....160
Magnet equipment Ohio, alternator anchorage 14263368....162
Magnet equipment Ohio, electric installation on handling boom and arm 14263368....164
Magnet equipment Älmhult Electric intallation 009 Kw Alternator 14265072 SER NO 4549-....166
Magnet equipment Älmhult,electric installation on scrap handling equipment 14265072 SER NO 4549-....168
Magnet equipment, Älmhultalternator installation 14265072....170
Rotating beacon....172
Windscreen wiper, lower....174
Windscreen wiper, upper....176
Windshield washer 14253371 SER NO - 4482, STD SER NO 4483 -....178
37 - CABLE; FUSE; RELAY....180
Cable harness, Side panel, Lh....181
Cable harness, Side panel, Rh....183
Cable harness, upper section....185
Cable harnesses, cab....187
Electric installation on driver's seat....189
Electrical distribution box....193
Electrical distribution unit, relay....195
Magnet equipment Ohio, Electrical distribution unit 14263368....197
Magnet equipment Ohio, controller unit 14263368....199
Magnet equipment Ohio, disconnector unit 14263368....200
Magnet equipment Ohio, instrument box 14263368....202
Magnet equipment Älmhult,electric distr. unit 14265072....204
Main fuse box....206
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM....208
Electric installation for load limiting device 14248197....209
Engine control panel....211
Magnet equipment Ohio_älmhult Instrument box, cab 14263368 14265072....213
Switch panel. SER NO -4709....215
Switch panel. SER NO 4710-....217
39 - MISCELLANEOUS....219
Radio installation Converter....220
4 - POWER TRANSMISSION....222
42 - TRANSMISSION; HYDRAULIC CONTROL....223
Pedal valve with foot rest....224
Pedal valve-[2219]....226
Pedal valve....227
43 - GEARBOX....229
Assembly pump gear box....230
Planetary drive....231
Pump gear box....233
Swing gearbox....235
44 - HYDROSTATIC DRIVE....237
Hydraulic motor, slew gear box....238
Hydraulic system crawler....240
Hydraulics in long undercarriage. C-C 003,73....242
Hydraulics in short undercarriage. C-C 003,35....245
Travel motor hydraulics, servo hydraulics....248
Turning joint....251
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT....253
71 - FRAME....254
Counterweights 14261186, 14261187....255
Undercarriage....256
77 - WHEELS; TRACKS; TYRE; HUB; DRUM....258
Bottom roller....259
Crawler track 14266172....260
Crawler unit....261
Front wheel, spring package and tension cylinder....263
Top roller 14261274....265
Track assembly. Short undercarriage....267
Track assembly....269
Track chain....271
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE....273
81 - CAB, NAKED; CANOPY....274
Cab body and operators area....275
Cab elevation on superstructure, 1220 mm 14260597....277
Cab elevation on superstructure, 600 mm_ 1220 mm 14260534....279
Door....281
Operator's cab....283
Side panel, Lh....284
Side panel, Rh....286
82 - ENGINE HOOD; MUDGUARD; FOOT STEP....288
Casing over battery....289
Door Lh, rear-[1559]....291
Door Lh, rear....293
Door Rh, rear....295
Door, LH....297
Door, RH....299
Engine cover, Centre....301
Engine cover, Rear....303
Hatch Front....305
Hatch-[1628]....307
Hatch....309
Hutch over engine....311
83 - DOORS; HATCH; COVER PLATE, (all)....313
Door SER NO - 4417....314
Door SER NO 4418 -....316
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING....318
Entire unbreak.windscr. 14262514....319
Front window Lifting device....321
Front window....323
Rear view mirror....326
Sliding window SER NO 4418 -....328
Window lifts....330
Windows....332
85 - CAB INTERIOR; UPHOLSTERY....335
Cabin coating....336
Drivers seat with fitting part....338
Operator seat Be-ge....340
Operator seat Viking....342
Operator's seat Be-ge....344
Operator's seat with fitting parts....346
87 - AIR CONDITIONING UNIT....348
Air duct Cab....349
Air inlet....351
Cab heater....353
Compressor with fitting parts. Cooling agent, R012 14256846....355
Condenser with fitting parts. Cooling agent R012 14256846....357
Diode....359
Evaporator with fitting parts Cooling agent, R012 14256846....361
Heater control....363
Heater, diesel, installation 14263505....365
Heater, diesel....367
Radiator with fitting parts....369
Timer....371
88 - INTERIOR EQUIPMENT....373
Interior components....374
Sun visor 14247059....377
89 - MISCELLANEOUS....378
Cat-walk 14241012....379
Cooler protection SER NO 4913-, 14268198....381
Jalusi Rear window 14250379 SER NO -3228, 14302328 SER NO 3229-....383
Ladder with cage 14022280....385
Protection over drivers cab 14261347....386
Sign plates and decals....388
Sign plates and transfer,inner location....392
Sign plates and transfer,outer location....394
Sun visor Outer 14250635....396
Tools 14249656....398
Tropic roof 14244816....400
Windscreen protection 14246974, 14247182, 14253611....402
Windscreen protection 14259352 14262775....404
Windscreen protection incl. roof guard 14260384 14262776....406
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS....408
91 - WORKING HYDRAULIC; SERVO HYDRAULICS....409
Air filter retainer....414
Anticavitation valve....416
Backhoe hydraulics, boom 5.20m....417
Base machine hydraulics for hammer_shears on adjustable boom 14261296....420
Base machine hydraulics for hammer_shears on adjustable boom. 14261296....422
Base machine hydraulics for hammer_shears on monobloc boom. 14261294....424
Button operated slope bucket_grab hydraulics onadj. boom. 14261297....427
Connection block with hoses....429
Connection board....430
Control block for end position damp-[5734]....432
Control block for end position damp....433
Control block, hammer and shears....435
Control block, travel_servo....437
Control block....438
Control pressure valve-[5904]....440
Control pressure valve....442
Control valve block....444
Electric valve block, extra....446
Extra valve block....447
Face shovel equipment, boom....448
Face shovel equipment, dipper arm....451
Filter box....453
Four-way valve Primary....455
Four-way valve for hammer_shears-[5255]....457
Four-way valve for hammer_shears....458
Four-way valve....460
Four-way valves Primary....462
Four-way valves, Secondary....464
Fuel miser valve....466
Guide block for hydraulic hammer....467
Hammer hydraulics for dipper arm incl. shut-offcocks. 14254988, 14254990, 14254992....469
Hammer hydraulics in base machine, 2 pumps. 14261292....471
Hammer hydraulics on dipper arm, 2.25 m, 2.80 m, 3.30 m. 14254986, 14254989, 14254991....473
Hammer hydraulics on monoboom, 5.20 m and 5.70 m 14254205, 14260975....475
Hammer_shears hydraulics on adjustable boom. 14261703....477
Hand pump....479
High speed valve-[0258]....481
High speed valve....482
Hose rupture valve 14260953, 14260954, 14261001....483
Hose rupture valve, dipper arm cylinder....485
Hose rupture valve,dipperarm cylind.mtrl.handl.eq 14247490,14266898....487
Hydr. quick fit equipm. on long dipper arm 14255215, 14255217....489
Hydr. quick fit equipm. on mono boom 14249783....491
Hydr. quick fit equipm. on short dipper arm, 2.25m 14263409....493
Hydr. quick fit equipm. on super structure 14246054....495
Hydraulic equipment, adjustable boom 14261001....496
Hydraulic line, servo pump....499
Hydraulic oil cooler....501
Hydraulic oil tank....503
Hydraulic pump P4....505
Hydraulic pumps P1_p2_p3....507
Hydraulic system Bucket....509
Hydraulic system Dipper arm....511
Hydraulic system for materials handling equipm....513
Hydraulic system suction lines....516
Hydraulic system, boom 5.70m....518
Hydraulic system, boom....521
Hydraulic system, feeding lines....523
Hydraulic system, line brk valve,dipper armcylinder 14247490,14266898....525
Hydraulic system, line brk valve,dipper armcylinder....527
Hydraulic system, oil cooler....529
Hydraulic system, pump installation P4....531
Hydraulic system, pump installation....533
Hydraulic system, return lines....535
Hydraulic system, slewing....537
Hydraulik oiltank with tank pumps....539
Joy sticks, left and right....540
Leak oil filter incl. connections....543
Leak oil filter....545
Magnet equipment Ohio, hydraulic installation, 15 kw alternator 14263368....547
Magnet equipment Ohio_älmhult Pressure limiting valve 14263368 14265072....549
Magnet equipment Älmhult Hydraulic installation 9 Kw alternator 14265072 SER NO 4549-....551
Magnet equipment, Älmhult, valve assembly 14265072 SER NO 4549-....553
Magnetic equipment Ohio, Valve body 14263368....555
Main valve block, tubes and fittings....558
Main valve block, valves....560
Main valve block....562
Mounting plate....564
Overcenter valve 14261001....566
Parallel connected grab hydraulics incl. shut-offcocks on dipper arms. 14258210, 14258212, 14258214....568
Parallel connected grab hydraulics on dipper arm. 14258209, 14258211, 14258213....570
Pedal operated slope bucket_grab hydaulics on monoboom. 14246350....572
Pedal operated slope bucket_grab hydaulics on monoboom. 14302170....574
Pressure lim. valve....576
Pressure limiting valve-[0100]....578
Pressure limiting valve-[0111]....580
Pressure limiting valve-[0214]....582
Pressure limiting valve-[0226]....584
Pressure limiting valve-[0246]....586
Pressure limiting valve....588
Pump installation....589
Relay valve....591
Relay valves....593
Relief valve....595
Servo hydraulic system, dipper on materials handling equipment. 14258081, 14258084....596
Servo hydraulics, boom....597
Servo hydraulics, bucket....599
Servo hydraulics, dipper arm....601
Servo hydraulics, slewing....603
Servo pump....605
Shunt valve....606
Slew valve assembly Valves....608
Slew valve block, tubings....610
Slew valve block....612
Slope bucket and grab equipment on adjustable boom, 5.90 m 14261702....614
Slope bucket and grab equipment on boom, 5.20 mresp. 5.70 m 14255034 14260974....616
Slope bucket equipment ondipper 2.25 m, 2.80 m, 3.30 m. On left side. 14255228, 14255231, 14255234....618
Speed control block....620
Thermostat kit 14341442....622
Thermostatic valve....623
Tubing....624
Valve for hammer_shears on adjustable boom....626
Valve, travel brake....627
92 - MECHANICAL EQUIPMENT_ATTACHMENT....628
Articulated slope buckets....629
Cable bucket....632
Clamshell rest 14259252....634
Fixed slope buckets....636
Grab link 14255320....637
Hammer plate 14255386....639
Hydraulic cylinder-[5018]....641
Hydraulic cylinder....643
Jib 14253079....645
Quickfit, hydraulic 14255322....647
Quickfit, mechanical 14255321....649
Ripper 14253092....651
97 - UNIT, DIGGING....652
Adjustable boom 14261001....653
Backhoe boom 5.20m 14260953....655
Backhoe boom 5.70m 14260954....658
Backhoe dipper arm 2.25m 14257609....661
Backhoe dipper arm 2.80m 14257195....663
Backhoe dipper arm 3.30m 14257269....665
Backhoe dipper arm 3.35m 14262328....667
Boom cylinder....669
Bucket cylinder....671
Dipper arm cylinder Material handle equipm. 14258081, 14258084....673
Dipper arm cylinder....675
Excavator 5.20m....677
Front shovel dipper arm 14264385....679
Front shovel equipm....681
Front shovel equipment Boom 14264385....682
Knuckle cyl. Front shovel cyl....684
Knuckle cylinder....686
Materials handl. equipm. Material handling arm. 4.4m, 5.15m....688
Materials handling equipmboom 6.0m, 6.75m....690
Slewing brake....692
Slewing ring attachment....694
Superstructure with slew transmission....696
Unit for digging 5.70m....698
99 - MISCELLANEOUS....700
Backhoe lubricating 5.20m-[4502]....701
Backhoe lubricating 5.20m....702
Backhoe lubricating. Adjustable boom.-[4430]....703
Backhoe lubricating. Adjustable boom.-[4442]....705
Backhoe lubricating. Adjustable boom....707
Extra boom cylinder attachment 14019518....709
Fire extinguisher 14248861....710
Overfilling guard 14259798....711
Overload protection SER NO 4683-....713
Spark shield 14262810....715
EC230 Åkerman Excavators Service Repair Manual....716
0 - Foreword....717
0 - GENERAL....718
00 - DESCRIPTION; COMPLETE MACHINE....719
Description....720
Product Identification Signs....721
03 - SPECIFICATIONS....724
Specification, general....725
Specifications, dimensions....727
Tightening torques....728
Weight specifications....730
1 - STANDARD PARTS, SERVICE....731
16 - LUBRICANT; FUEL; OTHER FLUID....732
Recommendations for hydraulic oil....733
17 - SERVICE....734
Dieseling in hydraulic cylinders....735
Filtering hydraulic oil....736
Instructions for shrinking....738
Instructions for vacuum pump....740
Recommendations for cleanliness when working on hydraulic systems....742
2 - ENGINE WITH MOUNTING AND EQUIPMENT....745
21 - ENGINE....746
Description....747
Exchange of rubber cushion on the front engine mounting....748
Exchange of rubber cushion on the rear engine mounting....750
Specification, general....753
22 - LUBRICATING SYSTEM....754
Specification, Capacities....755
23 - FUEL SYSTEM....756
Repairing fuel filling pump....757
Specification, Capacities....759
26 - COOLING SYSTEM....760
Specification, capacities....761
27 - ENGINE CONTROL....762
Adjusting fuelmiser....763
Description of fuelmiser....764
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS....765
30 - GENERAL....766
Description of fuelmiser....767
Instructions for work with the electrical system....768
Main electrical components....769
Solenoid Valves....771
31 - BATTERY....772
Batteries, overhaul....773
Specification, General....775
32 - ALTERNATOR; CHARGE REGULATOR....778
Overhaul of charging system....779
Specification, general ....780
37 - CABLE; FUSE; RELAY....781
Component lists and index for wiring diagrams....782
Diagram 1. Current supply equipment....806
Diagram 11. Climate control equipment....809
Diagram 2. Monitoring equipment....812
Diagram 3. Monitoring equipment....815
Diagram 4. Travel light equipment....818
Diagram 5. Various equipment....821
Diagram 6. Optional equipment....824
Diagram 7. Cab equipment....827
Diagram 8. Working light equipment....830
Diagram 9. Control equipment....833
Electrical distribution box, A2....836
Exchange of electric central A2....837
Explanations to wiring diagrams and component lists....841
Fuse box, A1....844
Lead marking....847
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM....848
Central unit, A3....849
Connector for central unit (A3)....850
Displayenhet A9....854
Exchange of central unit A3....856
Exchange of display unit A9....858
Monitors and sensors....860
Parameter codes A3....862
Parameter codes A9....865
Parameter programming....867
Pins in connector for display unit (A9)....869
Speed sensing control, SSC....870
The use of special test unit for SSC....875
Voltage divider, U4....889
4 - POWER TRANSMISSION....890
43 - GEARBOX....891
Removal and mounting of planetary gear box with fixed hydraulic motor....892
Removal and mounting of planetary gear box with variable hydraulic motor....896
Specification, capacities....901
44 - HYDROSTATIC DRIVE....902
Description....903
49 - MISCELLANEOUS....905
Axial movement in the slewing ring joint....906
Exchange of slew brake....909
Measuring backlash in slewing system....915
Slew drift checking....916
Specification Capacities....918
Specification, General ....919
5 - BRAKE....922
53 TRACK BRAKE....923
Description of track brake....924
Reconditioning of brake in planetary gearbox with fixed hydraulic motor....925
Reconditioning of brake in planetary gearbox with variable hydraulic motor....933
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT....943
77 - WHEELS; TRACKS; TYRE; HUB; DRUM....944
Exchange of sprocket wheel....945
Measuring track tension....946
Measuring wear of crawler unit....947
Measuring wear of track chain....949
Tightening torque....951
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE....952
83 - DOORS; HATCH; COVER PLATE, (all)....953
Exchange of door hook door latch....954
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING....956
Exchange of upper windshield....957
Exchange of window pane with wedge strip....959
87 - AIR CONDITIONING UNIT....962
Exchange of cabin ventilator....963
Exchange of control valve for cab heater....966
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS....969
90 - GENERAL....970
Description of the hydraulic system and its components....971
91 - WORKING HYDRAULIC; SERVO HYDRAULICS....973
Adjusting of hydraulic pressure....975
Control-pressure valve for track steering (12q)....1005
Control-pressure valves 12a_b and 12c_d)....1007
Description of hydraulic systems....1011
Exchange of gear on hydraulic pump....1012
Exchange of pumps on the pump gearbox....1019
Exchange of shaft seal in the working pumps (P1, P2 and P3), the slewing motor and the track motors....1035
Exchange of spring in four-way valve....1039
Four-way valves (5a-h)....1043
Four-way_float-position valve (5e_7a)....1048
Hose Rupture Valve for boom cylinder–EXCHANGE....1050
Hose Rupture Valve for boom cylinder–RECONDITIONING....1054
Hose Rupture Valve for dipper cylinder on backhoe equipment (extra)–RECONDITIONING....1058
Hose Rupture Valve for dipper cylinder on handling equipment–EXCHANGE....1065
Hose Rupture Valve for dipper cylinder on handling equipment–RECONDITIONING....1069
Hose-rupture valve (7c)....1075
Hydraulic oil cooler (18d)....1077
Non-return valves for refilling (8g), (refilling valves or, anti-cavitation valves)....1081
Pressure-limiting valve (2b, 2c)....1083
Pressure-limiting valve (2d)....1084
Servopump (1d)....1086
Shock valves (3)....1087
Shunt valve (7t)....1088
Shuttle valves....1090
Slewing pressure limiting valve (2f)....1091
Solenoid valves....1092
Specification capacities....1094
Specification, General....1096
Specification, general....1098
Stamping of leaking non-return valves in slewing block....1108
The control-pressure valve for travelling forward (12j) and rearward (12k)....1111
The hydraulic oil tank (19c)....1113
The restricting valves 8j and 8k....1115
92 - MECHANICAL EQUIPMENT_ATTACHMENT....1116
Exchange of hydraulic cylinder in quick-fit device....1117
97 - UNIT, DIGGING....1127
Exchange of boom cylinder....1128
Exchange of bucket cylinder....1138
Exchange of dipper cylinder....1144
Shimming of equipment joints....1151
Unit for digging....1154
99 - MISCELLANEOUS....1155
Hydraulic circuit diagrams....1156
List of components for hydraulic circuit diagrams....1159
EC230B Volvo Excavators Service Repair Manual....1165
000 - Foreword....1166
000 - GENERAL....1167
00 - DESCRIPTION; COMPLETE MACHINE....1168
Description....1169
Product Identification Signs....1170
03 - SPECIFICATIONS....1173
Specification, general....1174
Specifications, dimensions....1176
Tightening torques....1177
Weight specifications....1179
001 - STANDARD PARTS, SERVICE....1180
16 - LUBRICANT; FUEL; OTHER FLUID....1181
Recommendations for hydraulic oil....1182
17 - SERVICE....1183
Dieseling in hydraulic cylinders....1184
Filtering hydraulic oil....1185
Instructions for shrinking....1187
Instructions for vacuum pump....1189
Recommendations for cleanliness when working on hydraulic systems....1191
002 - ENGINE WITH MOUNTING AND EQUIPMENT....1194
21 - ENGINE....1195
Description....1196
Exchange of rubber cushion on the front engine mounting....1197
Exchange of rubber cushion on the rear engine mounting....1199
Specification, general....1202
22 - LUBRICATING SYSTEM....1203
Specification, capacities....1204
23 - FUEL SYSTEM....1205
Repairing fuel filling pump....1206
Specification, capacities....1208
26 - COOLING SYSTEM....1209
Specification, capacities....1210
27 - ENGINE CONTROL....1211
Adjusting fuelmiser....1212
Description of fuelmiser....1213
003 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS....1214
30 - GENERAL....1215
Instructions for work with the electrical system....1216
Main electrical components....1217
Solenoid valves....1219
Specification, general....1220
31 - BATTERY....1221
Batteries, overhaul....1222
Specification, general....1224
32 - ALTERNATOR; CHARGE REGULATOR....1225
Overhaul of charging system....1226
Specification, general....1227
37 - CABLE; FUSE; RELAY....1228
Component lists and index for wiring diagrams....1229
Diagram 001. Current supply equipment....1237
Diagram 002. Monitoring equipment....1240
Diagram 003. Monitoring equipment....1243
Diagram 004. Travel light equipment....1246
Diagram 005. Various equipment....1249
Diagram 006. Optional equipment....1252
Diagram 007. Cab equipment....1255
Diagram 008. Working light equipment....1258
Diagram 009. Control equipment....1261
Diagram 010. Control equipment....1264
Diagram 011. Climate control equipment....1267
Electrical distribution box, A002....1270
Exchange of electric central A002....1271
Explanations to wiring diagrams and component lists....1275
Fuse box, A001....1278
Lead marking....1281
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM....1282
Central unit, A003....1283
Connector for central unit (A003)....1284
Displayenhet A009....1286
Exchange of central unit A003....1288
Exchange of display unit A009....1290
Monitors and sensors....1292
Parameter codes A003....1294
Parameter codes A009....1297
Parameter programming....1299
Pins in connector for display unit (A009)....1301
Speed sensing control, SSC....1302
The use of special test unit for SSC....1307
Voltage divider, U004....1321
004 - POWER TRANSMISSION....1322
43 - GEARBOX....1323
Removal and mounting of planetary gear box with fixed hydraulic motor....1324
Removal and mounting of planetary gear box with variable hydraulic motor....1328
Specification, capacities....1333
44 - HYDROSTATIC DRIVE....1334
Description....1335
49 - MISCELLANEOUS....1336
Axial movement in the slewing ring joint....1337
Description....1340
Exchange of slew brake....1341
Measuring backlash in slewing system....1347
Slew drift checking....1348
Specification capacities....1350
Specification, general....1351
005 - BRAKE....1352
53 - TRACK BRAKE....1353
Description of track brake....1354
Reconditioning of brake in planetary gearbox with fixed hydraulic motor....1355
007 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT....1373
77 - WHEELS; TRACKS; TYRE; HUB; DRUM....1374
Exchange of sprocket wheel....1375
Measuring track tension....1376
Measuring wear of crawler unit....1377
Measuring wear of track chain....1379
Specification, general....1381
Tightening torque....1383
008 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE....1384
83 - DOORS; HATCH; COVER PLATE, (all)....1385
Exchange of door hook door latch....1386
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING....1388
Exchange of upper windshield....1389
Exchange of window pane with wedge strip....1391
87 - AIR CONDITIONING UNIT....1394
Exchange of cabin ventilator....1395
Exchange of control valve for cab heater....1398
009 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS....1401
91 - WORKING HYDRAULIC; SERVO HYDRAULICS....1402
Adjusting of hydraulic pressure....1404
Control-pressure valve for track steering (012q)....1414
Control-pressure valves 012a_b and 12c_d)....1416
Description of hydraulic systems....1420
Exchange of gear on hydraulic pump....1421
Exchange of pumps on the pump gearbox....1428
Exchange of shaft seal in the working pumps (P001, P2 and P3), the slewing motor and the track motors....1444
Exchange of spring in four-way valve....1448
Four-way valves (005a-h)....1450
Four-way_float-position valve (005e_7a)....1455
Hose Rupture Valve for boom cylinder–EXCHANGE....1457
Hose Rupture Valve for boom cylinder–RECONDITIONING....1461
Hose Rupture Valve for dipper cylinder on backhoe equipment (extra)–RECONDITIONING....1465
Hose Rupture Valve for dipper cylinder on handling equipment–EXCHANGE....1472
Hose Rupture Valve for dipper cylinder on handling equipment–RECONDITIONING....1476
Hose-rupture valve (007c)....1482
Hydraulic oil cooler (018d)....1484
Non-return valves for refilling (008g), (refilling valves or, anti-cavitation valves)....1486
Pressure-limiting valve (002b, 2c)....1488
Pressure-limiting valve (002d)....1489
Servopump (001d)....1491
Shock valves (003)....1492
Shunt valve (007t)....1493
Shuttle valves....1495
Slewing pressure limiting valve (002f)....1496
Solenoid valves....1497
Specification capacities-[1223]....1499
Specification capacities....1500
Specification, general-[1210]....1501
Specification, general-[429]....1503
Specification, general-[607]....1504
Specification, general-[718]....1505
Stamping of leaking non-return valves in slewing block....1506
The control-pressure valve for travelling forward (012j) and rearward (12k)....1509
The hydraulic oil tank (019c)....1511
The restricting valves 008j and 8k....1513
92 - MECHANICAL EQUIPMENT_ATTACHMENT....1514
Exchange of hydraulic cylinder in quick-fit device....1515
97 - UNIT, DIGGING....1525
Exchange of boom cylinder....1526
Exchange of bucket cylinder....1536
Exchange of dipper cylinder....1542
Shimming of equipment joints....1549
Specification, general....1552
Unit for digging....1559
99 - MISCELLANEOUS....1560
Hydraulic circuit diagrams....1561
List of components for hydraulic circuit diagrams....1564
