Volvo ECR305C Excavators Service Repair Manual
Complete repair service manual with electrical wiring diagrams for Volvo ECR305C L Excavators, with all the workshop information to maintain, diagnose, repair, and service like professional mechanics.
Volvo Constructions ECR305CL 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.
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
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
Volvo ECR305C L Excavators Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 2,710
File Format: PDF (Windows & Mac & Linux)
Language: English
TABLE OF CONTENTS
000 - Foreword.....2
000 - GENERAL.....3
00 - DESCRIPTION; COMPLETE MACHINE.....4
Machine view.....5
Product plates.....7
03 - SPECIFICATIONS.....9
Alternator, specifications.....12
Audio remote controller, specifications.....14
Auto_Manual pump control switch, specifications.....17
Battery, specifications.....19
Boom lifting cylinder, specifications.....20
Boom, specifications.....22
Bucket cylinder, specifications .....23
Cab, weight.....25
Control lockout lever switch, specifications.....26
Control pattern selector valve, specifications.....28
Coolant pump, thermostat, specifications.....30
Counterweight, specifications.....32
Counterweight, tightening torques.....33
Current_pressure, specifications.....35
Diesel coolant heater (10kw), specifications.....36
Dipper arm cylinder, specifications.....38
Dipper arm, specifications.....40
Dozer blade cylinder, specifications.....41
Dozer blade, specifications.....42
Electric horn, specifications.....43
Electrical system, specifications.....45
Electronic climate control unit ECC, description.....47
Emergency engine speed control switch, specifications.....48
Engine - Pump control, specification.....50
Engine control unit E-ECU, specifications.....52
Engine speed control switch, specifications.....54
Engine, specifications.....56
Engine, weights.....57
Frame and track unit, specifications.....58
Fuel feed pump, specifications.....59
Fuel pressure, specifications.....62
Fuel system, tightening torques.....66
Fuel tank, specifications.....70
Fuse, specifications_{10-52-24}.....71
Fuse, specifications_{10-52-48}.....73
Hour counter, specifications.....75
Hydraulic oil cooling system, specifications.....77
Hydraulic pump, specifications.....79
Hydraulic tank, specifications.....80
Injectors, specifications.....81
Keypad, specification.....82
Line rupture valve (arm), specifications.....85
Line rupture valve (boom), specifications.....87
Logic valve, specifications.....89
Lubrication system, specifications.....90
Main control valve, specifications.....93
Measurement conversion tables.....95
Overload warning pressure switch, specifications.....104
Preheating, specifications.....106
Pressure accumulator, specifications.....108
Proportional solenoid valve, specifications-[3910].....110
Proportional solenoid valve, specifications.....113
Recommended hydraulic oil, specifications.....115
Relay, specifications.....118
Remote control valve (Lever), specifications.....120
Remote control valve (dozer blade), specifications.....122
Remote control valve (pedal), specifications.....123
Rotating beacon, specifications.....125
Rotator pump, specifications.....127
Servo pump, specifications.....128
Slew ring gear, specifications_{10-46-02}.....129
Solenoid valve, specifications-[3647].....130
Solenoid valve, specifications.....132
Start switch, specifications.....134
Starter motor, specifications.....136
Swing gearbox, specifications_{10-48-36}.....137
Swing gearbox, specifications_{10-49-00}.....138
Swing motor, specifications_{10-47-04}.....139
Swing motor, specifications_{10-47-28}.....140
Swing ring gear, specifications_{10-46-26}.....141
Tightening torque, specifications.....142
Tightening torques.....144
Track gearbox, specifications.....153
Track motor, specifications.....154
Travel alarm, specifications.....155
Undercarriage, tightening torque_{10-44-14}.....157
Undercarriage, tightening torque_{10-44-37}.....159
Undercarriage, tightening torque_{10-45-01}.....160
Valve system specifications.....161
Vehicle control unit V-ECU, specifications.....162
Wireless control unit W-ECU, specification.....168
Work lights and extra lights, specifications.....170
07 - STANDARD TIME.....172
Operation numbers for additional work.....173
09 - MISCELLANEOUS.....175
Service positions.....176
001 - STANDARD PARTS, SERVICE.....179
16 - LUBRICANT; FUEL; OTHER FLUID.....180
Alternative fuels.....181
Coolant with freezing and corrosion protection.....184
Recommended lubricants.....188
17 - SERVICE.....191
Air cleaner primary filter, change.....194
Air cleaner primary filter, clean.....195
Air cleaner secondary filter, change.....196
Air conditioner main filter, change.....198
Air conditioner main filter, clean.....201
Arrival Inspection, according to Inspection Programme.....204
Battery condition, check.....209
Cab, prefilter, clean.....212
Cab, prefilter, replace.....216
Cab; door, covers, hinges, joints and locks, lubricate.....220
Coasting left and right swing.....222
Condition test and maintenance program.....224
Coolant anti-freeze resistance, checking .....226
Coolant level, check.....230
Coolant, change.....231
Creeping of hydraulic cylinder.....233
Cylinder speed.....235
Delivery Inspection, according to Inspection Programme.....238
Engine oil and filter, changing.....242
Engine, oil level, check.....245
Fuel filter extra (water separator element), check_drain.....246
Fuel filter, change.....247
Fuel tank air ventilation filter, change.....248
Fuel tank sediment, drain.....250
Hydraulic oil drain filter, change.....251
Hydraulic oil level, check.....252
Hydraulic oil servo filter, change.....253
Hydraulic oil suction strainer, clean.....254
Hydraulic oil tank breather filter, replacing.....256
Hydraulic oil, changing.....258
Hydraulic pressure, checking.....261
Loose and loss of bolts, check.....263
Lubrication, see lubrication chart.....266
MATRIS, reading, export reading.....268
Maintenance of Stored Machines, according to Inspection Programme.....269
Maintenance service, daily.....273
Maintenance service, every 1000 hours.....274
Maintenance service, every 2000 hours.....276
Maintenance service, every 250 hours.....278
Maintenance service, every 4000 hours.....279
Maintenance service, every 50 hours.....281
Maintenance service, every 500 hours.....282
Maintenance service, every 6000 hours.....284
Measuring condition.....286
Measuring of swing bearing clearance.....287
Radiator outside_hydraulic oil cooler outside, cleaning.....290
Starting engine with booster cables .....293
Straight traveling performance.....297
Swing bath grease, check.....299
Swing gearbox oil level, check.....300
Swing motor gearbox, changing oil.....301
Swing ring gear bearing, lubricate.....304
Swing speed.....305
Test-run and check.....306
The machine, check for external damages, cracks and wear damages.....309
Track gearbox oil level, check.....312
Track motor gearbox, changing oil.....313
Track running speed.....315
Track shoe bolts, check.....317
Track tension_condition, check.....319
Travel Speed.....321
VCADS Pro, logged errors, read off.....323
Valve clearance, check_adjust.....324
Warranty inspection 100 hours.....332
Warranty inspection 1000 hours.....334
Warranty inspection.....336
Washer fluid level, check.....338
Water separator filter element, change.....340
19 - GENERAL.....342
CE-marking, EMC-directive.....343
Checklist after a fire or heat exposure.....346
Decontamination.....350
Environmental handling for the future.....354
Environmentally hazardous fluids.....358
Environmentally safe handling.....362
Fire prevention measures.....365
Health hazards with paint, plastics and rubber.....371
Safety concerns everybody!.....376
Safety rules when servicing.....380
Safety when handling oils and fuel.....383
Safety when handling the machine.....387
Safety when using lifting equipment.....392
Safety when working with air conditioning refrigerant.....396
Safety when working with batteries.....401
Safety when working with hydraulic systems.....406
Starting with booster batteries.....410
Waste handling.....414
Working in environmentally contaminated areas.....418
002 - ENGINE WITH MOUNTING AND EQUIPMENT.....422
20 - GENERAL.....423
Component locations.....424
E-ECU MID 128 non-programmed, replacing.....427
E-ECU MID 128 pre-programmed, replacing.....429
Engine, description.....431
Engine, identification.....433
Engine, tightening torques.....434
Engine, weights .....438
Engine, weights.....439
Fuel system, tightening torques .....440
Fuel system, tightening torques .....444
21 - ENGINE.....448
Basic check, Engine.....449
Camshaft and flywheel signals, checking with VCADS Pro and oscilloscope.....451
Camshaft, description.....457
Connecting rod, description.....460
Crankshaft, description.....463
Cylinder block, description-[3105].....466
Cylinder block, description.....467
Cylinder head gasket, description.....469
Cylinder head, description-[3234].....471
Cylinder head, description.....472
Cylinder liner, description-[3024].....474
Cylinder liner, description.....476
Engine characteristic curve.....478
Engine mounting.....480
Engine timing gear, description.....482
Engine, specifications.....485
Engine, weights.....486
Flywheel, weight.....487
Internal Exhaust Gas Recirculation (IEGR), description.....489
Oil sump, description.....495
Piston cooling.....497
Piston rings, description.....499
Pistons, description.....501
Troubleshooting.....503
Valve system specifications-[2803].....506
Valve system specifications.....507
Valves, adjusting.....508
Valves, description.....516
Vibration damper, description.....518
22 - LUBRICATING SYSTEM.....521
Lubrication system, description.....522
Lubrication system, principle of operation.....525
Lubrication system, specifications.....529
23 - FUEL SYSTEM.....532
Carbon dioxide in fuel system, checking.....533
Feed pump pressure, checking.....536
Feed pump, replacing.....539
Fuel control valve (FCV), description.....542
Fuel control valve (FCV), replacing.....544
Fuel feed pump, description.....550
Fuel feed pump, specifications.....553
Fuel filler pump, description.....556
Fuel filling pump, installing.....558
Fuel filling pump, removing.....560
Fuel filter extra, replacing.....563
Fuel filter, checking.....565
Fuel filters, replacing.....566
Fuel pressure, specifications.....567
Fuel pump, inspecting.....572
Fuel rail pressure sensor, replacing.....575
Fuel rail pressure, checking.....578
Fuel return pressure, checking.....582
Fuel system, bleeding.....584
Fuel system, description.....585
Fuel system, tightening torques.....590
Fuel tank, description.....594
Fuel tank, specifications.....595
High pressure fuel pump, checking.....596
Injector, replacing one.....600
Injectors, description.....603
Injectors, specifications.....607
Instructions for working with electronic fuel injection.....608
Pressure relief valve (PRV), inspecting.....611
25 - INLET & EXHAUST SYSTEM.....613
Exhaust system, description.....614
Inlet system, description.....615
Turbocharger, description.....616
26 - COOLING SYSTEM.....619
Coolant anti-freeze resistance, checking.....620
Coolant pump, thermostat, specifications.....625
Coolant, changing.....627
Expansion tank, replacing.....629
Fan belt and_or alternator-, compressor belt, replacing all belts.....632
Reversible cooling fan, description.....634
Thermostat, checking.....637
27 - ENGINE CONTROL.....641
Engine - Pump control, specification.....642
Engine speed control switch, description.....644
Engine speed control switch, inspection.....647
Engine speed control switch, specifications.....649
003 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS.....651
30 - GENERAL.....652
11 666 140 Multimeter.....658
8883 0028 Adapter cable.....660
999 0014 Adapter cable.....662
999 0062 Extension cable.....665
999 3893 Adapter cable.....667
999 3894 Template.....669
999 8699 Multi-pin breaker box.....671
AL3201, description and measuring.....673
Auto Idle.....677
Auxiliary start.....679
BA3101, description and measuring.....682
Boom float position, description .....685
CU9901, description and measuring.....687
Collection of basic data.....689
Communication with data buses.....692
Component descriptions.....695
Component troubleshooting, checking component.....699
Component troubleshooting, checking subsystem (circuit).....702
Component troubleshooting, checking wiring harness and input_output on ECU.....705
Component troubleshooting, structure, description.....708
Connecting special tools.....710
Data buses, function.....714
ECC (MID146) Electronic climate control unit, active measuring conditions.....720
ECC (MID146) Electronic climate control unit, passive measuring conditions.....723
Electrical cables and connectors, checking.....726
Electrical system, description.....732
Electrical system, special instructions for servicing, action when working on machine.....734
Electrical system, special instructions for servicing, electrical components, alternator and charging regulator.....736
Electrical system, special instructions for servicing, electrical components, batteries.....738
Electrical system, special instructions for servicing, electronic components.....741
Electrical system, special instructions for servicing, general.....743
Electro hydraulic pump control, description.....746
Electronic control system, description.....748
Emergency operation, description.....751
Engine Protection.....754
Error code information, description.....757
Error code information, general.....759
Error codes, build-up.....762
FU18, description and measuring.....767
FU26, description and measuring.....769
FU6, description and measuring.....771
HE2501, description and measuring.....773
I-ECU (MID140) Instrument control unit, active measuring conditions.....775
I-ECU (MID140) Instrument control unit, passive measuring conditions.....777
MA2301MA2306, description and measuring.....779
MA2504, description and measuring.....782
MA2602, description and measuring.....784
MA4216, description and measuring.....786
MA9103, description and measuring.....788
MA9104, description and measuring.....790
MA9105, description and measuring.....792
MA9106, description and measuring.....794
MA9107, description and measuring-.....796
MA9107, description and measuring.....798
MA9109, description and measuring.....800
MA9116, description and measuring.....803
MA9117, description and measuring.....805
MA9118, description and measuring.....807
MA9120, description and measuring.....809
MA9166, description and measuring.....811
MID 128 SID 230, description and measuring.....813
MID 140 PID 251, description and measuring.....816
MID 140 PPID 1144, description and measuring.....819
MO3301, description and measuring.....821
Measuring symbols, description.....823
Measuring, general.....827
Mode selection, description.....829
PPID1336, description and measuring.....832
PWM2303, description and measuring.....835
PWM9101, description and measuring.....837
PWM9102, description and measuring.....839
PWM9103, description and measuring.....841
PWM9105, description and measuring.....843
PWM9106, description and measuring.....845
PWM9109, description and measuring.....847
PWM9123, description and measuring.....849
PWM9124, description and measuring.....851
PWM9129, description and measuring.....853
Power Boost control, description.....855
Quick fit control, description.....857
RE2501, description and measuring-[1801].....859
RE2501, description and measuring.....862
RE3101, description and measuring.....865
RE3301, description and measuring-[0128].....867
RE3301, description and measuring.....869
RE4206, description and measuring.....871
RExxxx, Relays general, description and measuring.....873
SAE J1708_1587 information link, description and measuring.....875
SAE J1939_CAN control link, description and measuring.....879
SAE code, conversion for component designation, E-ECU.....882
SAE code, conversion to component designation, ECC.....884
SAE code, conversion to component designation, IECU.....885
SAE code, conversion to component designation, V-ECU.....886
SE2202, description and measuring.....888
SE2203, description and measuring .....891
SE2203, description and measuring.....894
SE2205, description and measuring.....896
SE2301, description and measuring.....898
SE2302, description and measuring.....901
SE2303, description and measuring.....904
SE2309, description and measuring.....907
SE2501, description and measuring.....909
SE2502, description and measuring.....912
SE2507, description and measuring.....915
SE2508, description and measuring.....918
SE2603, description and measuring.....921
SE2606, description and measuring.....924
SE2701, description and measuring.....927
SE2703, description and measuring.....930
SE8701, description and measuring.....933
SE8702, description and measuring.....936
SE8705, description and measuring.....939
SE8706, description and measuring.....942
SE8708, description and measuring.....945
SE9105, description and measuring.....947
SE9122, description and measuring.....950
SE9123, description and measuring.....952
SE9124, description and measuring.....954
SE9125, description and measuring.....956
SE9126, description and measuring.....958
SE9127, description and measuring.....960
SE9128, description and measuring.....962
SE9129, description and measuring.....964
SE9131, description and measuring.....966
SE9132, description and measuring.....968
SE9138, description and measuring.....970
SE9401, description and measuring.....972
SID211, description and measuring.....974
SID232, description and measuring.....977
SID240, description and measuring.....980
SID253, description and measuring.....982
SW2701, description and measuring.....984
SW3301, description and measuring.....986
SW9160, description and measuring.....988
SW9161, description and measuring.....991
SW9162, description and measuring.....994
SWxxxx, description and measuring.....997
Service connection and programming connection.....999
Software parameters, description.....1001
Special tools for troubleshooting.....1009
Start lock, description.....1011
Troubleshooting strategy.....1013
Troubleshooting tools.....1016
Troubleshooting, general.....1018
V-ECU (MID187) Vehicle control unit, active measuring conditions.....1021
V-ECU (MID187) Vehicle control unit, passive measuring conditions.....1027
VCADS Pro service tool.....1033
VCADS Pro, 17030-3 - Parameter, programming.....1038
W-ECU (MID142) Wireless control unit, active measuring conditions.....1041
W-ECU (MID142) Wireless control unit, passive measuring conditions.....1043
X1 control, description.....1045
X1 pressure control, description.....1050
X3 control, description.....1052
31 - BATTERY.....1055
Batteries, replacing.....1056
Battery charging capacity, checking.....1060
Battery, charging.....1063
Battery, description.....1065
Battery, storage.....1067
Starting engine with booster cables.....1069
32 - ALTERNATOR; CHARGE REGULATOR.....1073
Alternator, description.....1074
Alternator, replacing incl function checking.....1076
Alternator, testing.....1080
Charging, description.....1083
33 - STARTING SYSTEM.....1085
Starter motor, description.....1086
Starter motor, replacing.....1088
Starter motor, testing.....1092
Starter relay, replacing.....1095
Starter switch (engine start switch), replacing.....1096
Starter switch, testing_{09-45-04}.....1098
Starter switch, testing_{09-45-38}.....1101
Starting operation.....1104
35 - LIGHTING.....1107
Work lights and extra lights, description.....1108
36 - OTHER ELECTRICAL EQUIPMENT.....1109
Auto_Manual pump control switch, description.....1110
Connectors, overview.....1112
Control lockout lever switch, replacing.....1126
Control units changing, precaution.....1129
Electric horn, description.....1131
Electronic climate control unit ECC, description .....1133
Electronic climate control unit ECC, specification .....1134
Emergency engine speed control switch, description.....1136
Engine control unit E-ECU, function description.....1138
Horn, replacing_{09-41-07}.....1139
Horn, replacing_{09-41-46}.....1141
I-ECU MID 140 non-programmed, replacing.....1143
I-ECU MID 140 pre-programmed, replacing.....1147
Instrument control unit I-ECU, functional description.....1151
Instrument control unit I-ECU, specifications.....1153
Rotating beacon, description.....1156
Rotating beacon, replacing.....1157
Start switch, description.....1159
Travel alarm, description.....1162
Travel alarm, replacing.....1163
V-ECU MID 187 non-programmed, replacing.....1165
V-ECU MID 187 pre-programmed, replacing.....1168
Vehicle control unit V-ECU, functional description.....1171
Windscreen flusher pump, replacing.....1173
Windscreen wiper controller, replacing.....1175
Windscreen wiper front motor, replacing.....1177
37 - CABLE; FUSE; RELAY.....1181
Circuit breaker, description.....1183
Circuit breaker, specification.....1184
Component designations.....1186
Component list Alternator, batteries, capacitors, electronic units, voltage outlet.....1188
Component list Control lights_warning lights.....1189
Component list, Heating coils.....1190
Component list, Miscellaneous.....1191
Component list, Solenoid valves.....1192
Component list, Switches.....1194
Component list, lights.....1196
Component list, motors.....1197
Component list, relays.....1198
Component list, sensors.....1199
Control system diagram.....1201
Electrical distribution box_{09-55-28}.....1204
Electrical distribution box_{09-55-57}.....1206
Electrical symbols and designations.....1208
Explanation of wiring diagrams.....1212
Fuse, description.....1215
Fuse, specifications.....1217
Grounding points, frame connections.....1219
Main switch, replacing.....1221
Relay, description.....1223
Wiring diagram .....1225
Wiring diagram SCH01_{08-14-15}.....1227
Wiring diagram SCH01_{08-14-49}.....1230
Wiring diagram SCH02.....1233
Wiring diagram SCH03.....1236
Wiring diagram SCH04.....1240
Wiring diagram SCH07.....1244
Wiring diagram SCH08.....1247
Wiring diagram SCH10.....1251
Wiring diagram SCH11_{08-08-46}.....1255
Wiring diagram SCH11_{08-09-14}.....1257
Wiring diagram SCH12.....1260
Wiring diagram SCH13.....1263
Wiring diagram SCH14.....1266
Wiring diagram SCH15.....1269
Wiring diagram SCH16.....1273
Wiring diagram SCH17.....1275
Wiring diagram SCH18_{08-03-21}.....1278
Wiring diagram SCH18_{08-03-50}.....1280
Wiring diagram SCH22.....1283
Wiring diagram SCH24_{08-01-30}.....1285
Wiring diagram SCH24_{08-01-58}.....1287
Wiring diagram, electrical distribution box.....1289
Wiring harnesses.....1293
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM.....1298
Booting sequence.....1299
Control levers, description.....1302
Control lockout lever switch, description.....1304
Control types for X1 and X3 operation.....1306
Display unit, content.....1309
Electrical system.....1316
Engine system.....1319
HVAC system .....1321
Hour counter, description.....1324
Hydraulic system.....1325
Instruments and controls, front instrument panel.....1328
Instruments and controls, left instrument panel.....1330
Instruments and controls, overview.....1332
Instruments and controls, rear instrument panel.....1334
Instruments and controls, right instrument panel.....1335
Keypad, description-[3852].....1337
Keypad, description.....1340
MAIN MENU.....1343
Menu tree.....1346
Pop-up screen.....1348
SETUP.....1351
Service mode.....1360
Terminology.....1363
Theft protection.....1390
39 - MISCELLANEOUS.....1393
Audio remote controller, description.....1394
CareTrack system, description.....1397
DCDC converter, description.....1398
DCDC converter, specifications.....1400
Radio with CD and MP3 player, description.....1406
Radio with CD and MP3 player, specifications.....1410
Radio with tape player, description.....1413
Radio, description.....1416
Radio, replacing.....1419
Voltage converter, replacing.....1421
W-ECU, MID142, changing non-programmed ECU.....1423
W-ECU, MID142, changing pre-programmed ECU.....1426
Wireless control unit W-ECU, specification_{09-21-20}.....1429
Wireless control unit W-ECU, specification_{09-21-49}.....1431
004 - POWER TRANSMISSION.....1433
40 - GENERAL.....1434
Power transmission, description.....1435
Tightening torque, specifications.....1437
43 - GEARBOX.....1439
Swing gearbox, assembly.....1440
Swing gearbox, description.....1448
Swing gearbox, disassembly.....1451
Swing gearbox, maintenance.....1457
Swing gearbox, replacing.....1460
Swing gearbox, specifications_{09-10-39}.....1466
Swing gearbox, specifications_{09-11-04}.....1467
Swing unit, replacing.....1468
Track gearbox cover, replacing.....1470
Track gearbox, assembly.....1473
Track gearbox, description_{09-17-16}.....1483
Track gearbox, description_{09-17-49}.....1487
Track gearbox, disassembly.....1491
Track gearbox, maintenance.....1500
Track gearbox, precautions for operation.....1504
Track gearbox, tools.....1507
Track gearbox, troubleshooting.....1508
Track unit, replacing.....1510
44 - HYDROSTATIC DRIVE.....1513
Center passage hose (center passage motor), replacing.....1514
Center passage hose (valve center passage), replacing.....1517
Center passage, assembling.....1520
Center passage, description-[4412].....1526
Center passage, description.....1528
Center passage, disassembling.....1532
Center passage, inspection and troubleshooting.....1537
Center passage, maintenance.....1542
Center passage, tightening torques_{08-44-51}.....1546
Center passage, tightening torques_{08-45-18}.....1548
Hydraulic pump coupling, description.....1550
Pump gearbox coupling assembly, replacing.....1554
Slew motor, troubleshooting.....1555
Swing motor relief valve, replacing.....1559
Swing motor, description-[5345].....1561
Swing motor, description.....1565
Swing motor, maintenance.....1569
Swing motor, principle of operation.....1572
Swing motor, replacing.....1581
Swing motor, specifications.....1587
Swing motor, specifications_{08-54-20}.....1588
Swing motor, specifications_{08-54-44}.....1589
Track motor relief valve, replacing.....1590
Track motor, adjusting.....1592
Track motor, assembling.....1596
Track motor, description.....1607
Track motor, disassembling.....1618
Track motor, maintenance.....1627
Track motor, troubleshooting.....1630
49 - MISCELLANEOUS.....1634
Slew ring gear, description.....1635
Swing ring gear grease pipe, replacing_{08-34-41}.....1637
Swing ring gear grease pipe, replacing_{08-35-13}.....1638
Swing ring gear inner seal, replacing_{08-33-31}.....1643
Swing ring gear inner seal, replacing_{08-33-59}.....1646
Swing ring gear outer seal, replacing_{08-32-20}.....1650
Swing ring gear outer seal, replacing_{08-32-49}.....1654
Swing ring gear, replacing.....1661
Swing ring gear, specifications.....1663
007 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT.....1664
70 - GENERAL.....1665
Machine weight, specifications.....1666
Undercarriage, tightening torque_{08-30-35}.....1668
Undercarriage, tightening torque_{08-30-59}.....1670
Undercarriage, tightening torque_{08-31-23}.....1671
71 - FRAME.....1672
Counterweight, installing.....1673
Counterweight, removing.....1676
Machine weight, specifications.....1679
Superstructure, installing_{08-27-19}.....1681
Superstructure, installing_{08-27-55}.....1683
Superstructure, removing.....1689
Undercarriage, description_{08-23-22}.....1694
Undercarriage, description_{08-23-51}.....1695
Undercarriage, description_{08-24-20}.....1696
77 - WHEELS; TRACKS; TYRE; HUB; DRUM.....1697
Bottom roller, assembly.....1699
Bottom roller, description.....1703
Bottom roller, disassembly.....1705
Bottom roller, measurement of wear.....1708
Bottom roller, replacing one.....1711
Bottom roller, replacing seal.....1715
Front idler, replacing one.....1721
Idler, assembly.....1724
Idler, description.....1727
Idler, disassembly.....1729
Idler, measurement of wear.....1732
Selection of track shoes.....1735
Spring package, assembly.....1737
Spring package, disassembling_{07-56-56}.....1740
Spring package, disassembly_{07-56-28}.....1743
Sprocket, measurement of wear.....1746
Sprocket, replacing one.....1749
Tools & equipment.....1751
Top roller wear, measuring.....1756
Top roller, assembly.....1759
Top roller, description_{08-06-55}.....1763
Top roller, description_{08-07-23}.....1765
Top roller, disassembly.....1767
Top roller, measurement of wear.....1769
Top roller, replacing one.....1772
Track chain assembly, installing.....1776
Track chain assembly, removing.....1780
Track chain wear, measuring_{08-11-18}.....1783
Track chain, description_{08-14-20}.....1789
Track chain, description_{08-14-48}.....1791
Track chain, measurement of wear_{08-10-44}.....1793
Track guard, replacing one.....1798
Track guards_{07-58-47}.....1801
Track guards_{07-59-15}.....1803
Track link, dimension_{08-13-10}.....1805
Track link, dimension_{08-13-38}.....1806
Track links, replacing.....1808
Track recoil spring (tensioner) assembly, replacing.....1813
Track shoe, replacing one.....1816
Track, adjusting track sag_{08-11-59}.....1818
Track, adjusting track sag_{08-12-28}.....1820
008 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE.....1825
81 - CAB, NAKED; CANOPY.....1826
Cab suspension, description.....1827
Cab, installing.....1828
Cab, removing.....1833
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING.....1837
Windows, general.....1838
Windscreen, replacing.....1840
87 - AIR CONDITIONING UNIT.....1847
Air conditioning unit, description.....1849
Air conditioning unit, maintenance.....1853
Air conditioning unit, specifications_{07-48-57}.....1855
Air conditioning unit, specifications_{07-49-21}.....1857
Air distribution, description.....1859
Cab filter, replacing.....1860
Compressor, replacing incl draining and filling.....1863
Condenser, replacing incl draining and filling.....1867
Cooler and Heater assembly, installing.....1870
Cooler and Heater assembly, removing.....1876
Defroster actuator, replacing.....1883
Diesel coolant heater (10kw), description.....1885
ECC (Electronic Climate Control), replacing-[4614].....1888
ECC (Electronic Climate Control), replacing.....1891
Electronic climate control unit ECC, specification.....1894
Evaporator, replacing incl draining and filling.....1896
Expansion valve, replacing incl draining and filling.....1898
Fan motor, replacing.....1902
HVAC system.....1904
Heater core, replacing.....1907
Heating system, description.....1909
Intake actuator, replacing.....1911
Mode (foot) actuator, replacing.....1914
Performance test, AC unit.....1917
Receiver, replacing incl draining and filling.....1923
Troubleshooting (10kw).....1925
Troubleshooting_{07-33-31}.....1930
Troubleshooting_{07-34-26}.....1938
Vent actuator, replacing.....1948
Water valve, replacing.....1950
Wiring diagram.....1953
88 - INTERIOR EQUIPMENT.....1955
Instrument panel (left), replacing.....1956
Instrument panel (right), replacing.....1959
009 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS.....1963
90 - GENERAL.....1964
Description, general.....1965
Hydraulic components, storing and transporting.....1966
Hydraulic oil, description.....1970
Hydraulic oil, storage and handling.....1974
Hydraulic system, cleanliness when handling hydraulic components.....1978
Hydraulic system, description.....1982
Hydraulic system, repair of hydraulic components in workshop.....1986
91 - WORKING HYDRAULIC; SERVO HYDRAULICS.....1991
2 stage port relief valve, adjustment.....1997
2 stage port relief valve, description.....2000
2 stage port relief valve, disassembly and assembly.....2006
Accumulator, replacing.....2010
Arm holding valve, description.....2012
Arm holding valve, disassembly and assembly.....2015
Arm parallel conflux check valve, disassembly and assembly.....2017
Arm parallel conflux valve, disassembly and assembly.....2019
Arm regenerating valve, description.....2021
Arm regenerating valve, disassembly.....2024
Boom 2 conflux shut-off valve, description.....2026
Boom 2 conflux shut-off valve, disassembly.....2028
Boom and arm holding valve (Boom-1, Arm-1), disassembly.....2030
Boom back pressure check valve, disassembly.....2033
Boom cylinder, rupture valve, replacing.....2035
Boom float position, description.....2040
Boom holding valve, description.....2041
Boom regenerating valve, description.....2046
Breather, replacing.....2048
Bucket flow control valve, description.....2049
Bucket flow control valve, disassembly.....2052
Bucket regenerating valve, description.....2056
Bucket regenerating valve, disassembly.....2059
Center bypass valve, description.....2061
Center bypass valve, disassembly and assembly.....2064
Check valve, description.....2066
Checking and Adjusting procedure.....2068
Conflux check valve, description.....2071
Control pattern selector valve, description.....2073
Dipper arm cylinder, rupture valve, replacing.....2076
Fan motor, assembly.....2078
Fan motor, description.....2085
Fan motor, disassembly.....2091
Fan motor, tools.....2099
Fan motor, troubleshooting.....2102
Fan pump, assembly.....2105
Fan pump, description.....2108
Fan pump, disassembly.....2110
Fan pump, parts inspection.....2112
Flow control valve, description.....2115
Flow control valve, disassembly and assembly.....2118
General, precautions.....2121
General, tools.....2126
Hammer and Shears (X1 Line option), description.....2129
Hammer and shear pedal valve (RCV), replacing.....2131
Hammer return filter, description.....2135
Hydraulic components, description.....2137
Hydraulic diagram, schematic.....2140
Hydraulic oil cooler, description.....2143
Hydraulic oil cooling system, description.....2144
Hydraulic oil tank, description.....2147
Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump.....2150
Hydraulic pump (removed), changing shaft seal.....2153
Hydraulic pump regulator, replacing.....2156
Hydraulic pump, description.....2160
Hydraulic pump, maintenance standard, Specifications.....2165
Hydraulic pump, replacing.....2169
Hydraulic system, position of main components.....2183
Hydraulic system, work instructions.....2186
Line rupture valve (arm), description.....2191
Line rupture valve (arm), disassembly.....2196
Line rupture valve (arm), troubleshooting.....2198
Line rupture valve (boom), description.....2200
Line rupture valve (boom), disassembly.....2206
Line rupture valve (boom), troubleshooting.....2208
Line rupture valve relief pressure, adjustment.....2210
Line rupture valve relief pressure, measurement.....2212
Line rupture valve, adjustment.....2213
Load check valve - double, description.....2215
Load check valve - single, description.....2216
Load check valve single, disassembly and assembly.....2219
Logic valve, description.....2222
Main control valve troubleshooting.....2225
Main control valve, description.....2230
Main pressure relief valve, replacing.....2243
Main relief valve, adjustment.....2245
Main relief valve, description.....2248
Main relief valve, disassembly and assembly.....2251
Main spool, disassembly and assembly.....2254
Make up valve, description.....2257
Make up valve, disassembly.....2259
Oil cooler line bypass valve (check valve), replacing.....2261
Oil level gauge, replacing.....2263
Overload warning device, description.....2265
Overload warning device, operation.....2267
Pipe and hose (pump - valve), replacing.....2269
Port relief valve pressure, adjustment (when installing or dismantling the line rupture valve).....2272
Port relief valve pressure, checking and adjusting.....2275
Port relief valve, description.....2278
Port relief valve, disassembly and assembly.....2281
Pressure accumulator, description.....2284
Pressure relief valve, troubleshooting.....2287
Proportional relief valve, description.....2291
Proportional solenoid valve (power shift), replacing.....2295
Proportional solenoid valve, description .....2298
Proportional solenoid valve, description.....2301
Proportional solenoid valve, measuring and adjustment.....2302
Proportional solenoid valve, specifications .....2305
Proportional solenoid valve, troubleshooting.....2308
Pump, assembly.....2311
Pump, disassembly.....2317
Pump, tools_{06-37-44}.....2323
Pump, tools_{06-38-11}.....2325
Pump, troubleshooting.....2327
Regulator, description.....2332
Regulator, disassembly and assembly.....2338
Remote control valve (Lever), assembly_{06-17-41}.....2346
Remote control valve (Lever), assembly_{06-18-10}.....2359
Remote control valve (Lever), description_{06-22-07}.....2371
Remote control valve (Lever), description_{06-22-44}.....2380
Remote control valve (Lever), disassembly_{06-19-11}.....2393
Remote control valve (Lever), disassembly_{06-19-40}.....2406
Remote control valve (Lever), maintenance standard, Specifications_{06-20-54}.....2418
Remote control valve (Lever), maintenance standard, Specifications_{06-21-17}.....2420
Remote control valve (Lever), specifications_{06-23-22}.....2424
Remote control valve (Lever), specifications_{06-23-46}.....2426
Remote control valve (Lever), troubleshooting_{06-16-16}.....2430
Remote control valve (Lever), troubleshooting_{06-16-39}.....2432
Remote control valve (lever), replacing.....2435
Remote control valve (pedal), assembling_{06-10-53}.....2439
Remote control valve (pedal), assembly_{06-10-25}.....2448
Remote control valve (pedal), description_{06-14-10}.....2461
Remote control valve (pedal), description_{06-14-38}.....2467
Remote control valve (pedal), disassembling_{06-12-26}.....2473
Remote control valve (pedal), disassembly_{06-11-58}.....2483
Remote control valve (pedal), maintenance standard, Specifications.....2494
Remote control valve (pedal), replacing.....2496
Remote control valve (pedal), specifications_{06-15-15}.....2501
Remote control valve (pedal), specifications_{06-15-38}.....2503
Remote control valve (pedal), troubleshooting_{06-09-01}.....2504
Remote control valve (pedal), troubleshooting_{06-09-25}.....2507
Rotator pump, assembly.....2509
Rotator pump, description.....2510
Rotator pump, disassembly.....2512
Servo hydraulic block.....2513
Servo hydraulic pressure, adjustment.....2515
Servo pump, assembly.....2516
Servo pump, description.....2523
Servo pump, disassembly.....2526
Servo pump, parts inspection.....2532
Servo pump, replacing.....2534
Shuttle valve block, description.....2536
Slew flow control valve, description.....2539
Slew flow control valve, disassembly and assembly.....2542
Solenoid valve (1) for hammer and shear selection.....2545
Solenoid valve, description-[0756].....2548
Solenoid valve, description.....2552
Solenoid valve, disassembly and assembly.....2555
Solenoid valve, inspection.....2559
Solenoid valve, replacing.....2562
Solenoid valve, specifications-[0822].....2564
Solenoid valve, troubleshooting.....2566
Standard of the setting pressure.....2570
Stop valve.....2572
Tightening torques .....2574
92 - MECHANICAL EQUIPMENT_ATTACHMENT.....2580
Attachment quick coupler solenoid valve, description.....2581
Attachment quick coupler, description_{05-53-43}.....2586
Attachment quick coupler, description_{05-54-12}.....2588
Blade lift cylinder, installing.....2601
Blade lift cylinder, removing-[5045].....2604
Blade lift cylinder, removing.....2607
Check valve, replacing.....2610
Dozer blade cylinder, description_{05-48-10}.....2613
Dozer blade cylinder, description_{05-48-38}.....2615
Dozer blade cylinder, replacing.....2617
Dozer blade, description.....2622
Remote control valve (dozer blade), description.....2625
97 - UNIT, DIGGING.....2628
Adapter, installing.....2630
Adapter, removing.....2632
Boom cylinder, installing.....2634
Boom cylinder, removing.....2636
Boom cylinder, replacing.....2638
Boom lifting cylinder, description.....2641
Boom, description.....2643
Boom, installing.....2646
Boom, removing.....2652
Bucket assembly, installing.....2659
Bucket assembly, removing.....2662
Bucket assembly, replacing.....2665
Bucket cylinder, description.....2669
Bucket cylinder, installing.....2671
Bucket cylinder, removing.....2674
Bucket cylinder, replacing.....2677
Bucket cylinder, specifications.....2681
Bucket operation_{05-35-24}.....2683
Bucket operation_{05-35-48}.....2685
Connecting rod yoke, installing.....2687
Connecting rod yoke, removing.....2690
Connecting rod yoke, replacing.....2693
Cylinder, description.....2697
Cylinder, troubleshooting.....2700
Digging unit, maintenance.....2703
Dipper arm connecting rod, installing.....2705
Dipper arm connecting rod, removing.....2708
Dipper arm connecting rod, replacing.....2712
Dipper arm cylinder, description.....2717
Dipper arm cylinder, installing.....2719
Dipper arm cylinder, removing.....2721
Dipper arm cylinder, replacing.....2724
Dipper arm, description.....2727
Dipper arm, installing.....2729
Dipper arm, removing.....2733
Dipper arm, replacing.....2738
Function description.....2741
Link, description.....2743
99 - MISCELLANEOUS.....2745
Explanations to hydraulic diagram.....2746
Hydraulic diagram, standard Image.....2757
Hydraulic diagram, standard.....2758
Hydraulic diagram, with option components_{05-20-05} Image.....2761
Hydraulic diagram, with option components_{05-20-05}.....2762
Hydraulic diagram, with option components_{05-20-28} Image.....2766
Hydraulic diagram, with option components_{05-20-28}.....2767
