Volvo EW210D Excavators Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo EW210D Excavators, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Volvo Construction EW210D 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.
PRODUCT DETAILS:
Total Pages: 3,143 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
Volvo EW210D Excavators Service Repair Manual.pdf
MAIN SECTIONS
000 - Foreword.......2
000 - GENERAL.......3
00 - DESCRIPTION; COMPLETE MACHINE.......4
Component locations-[4723].......5
Description, complete machine.......9
Product plates.......10
03 - SPECIFICATIONS.......11
Capacities.......12
Conversion tables.......13
Machine weights_{02-45-42}.......21
Machine weights_{02-45-53}.......23
Specifications, weight.......24
Tightening torques.......25
05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION.......31
Lifting instructions.......32
07 - STANDARD TIME.......35
Operation numbers for additional work.......36
08 - TOOL.......38
E-3508.......39
E-3509.......41
E-tool, 3500 Support plate for travel gearbox and motor.......43
E-tool, 3502 Plate for turning crankshaft.......45
Infrared Thermometer.......47
09 - MISCELLANEOUS.......49
Control units, changing.......50
Hydraulic cylinders, dieseling.......51
Service positions_{02-42-23}.......53
Service positions_{02-42-36}.......56
Welding on the machine.......59
001 - STANDARD PARTS, SERVICE.......60
16 - LUBRICANT; FUEL; OTHER FLUID.......61
Alternative fuels.......62
Coolant with freezing and corrosion protection.......65
Recommended lubricants_{02-40-43}.......67
Recommended lubricants_{02-41-02}.......70
17 - SERVICE.......74
Air conditioning unit, maintenance-[2133].......78
Arrival Inspection, according to Inspection Programme.......79
Axles, changing oil.......84
Axles, checking oil level.......88
Battery condition, check.......91
Bearings.......94
Boom suspension accumulator, checking and adjusting-[3331].......95
Brake discs, checking wear.......99
Brake system, checking function.......102
Cab main filter, replacing.......103
Cab, main filter, clean.......106
Cab, prefilter, clean.......109
Cab, prefilter, replace.......111
Check engine oil level.......113
Checking for cracks and leaks.......114
Cleaning prior to repair.......115
Coasting left and right swing.......116
Coolant level, check.......118
Coolant's freezing point, check.......120
Coolant, change.......122
Creeping of hydraulic cylinder.......126
Cylinder speed.......130
DPF (Diesel particulate filter), checking and cleaning-[1420].......133
Delivery Inspection, according to Inspection Programme.......139
Door hinges, lubricate with grease.......141
Elimination of trapped hydraulic pressure.......143
Emergency operation, description-[1039].......145
Fuel filters, primary and secondary filter, replace.......148
Fuel tank breather filter, replacing.......150
Fuel tank water and sediment, drain.......152
Grease points on booms, lubrication_{02-31-02}.......154
Grease points on booms, lubrication_{02-31-15}.......156
Grease points on dipper arm, lubrication_{02-31-33}.......158
Grease points on dipper arm, lubrication_{02-31-46}.......161
Grease points on superstructure, lubrication.......163
Grease points on undercarriage, lubrication.......165
Hoses and tubes.......169
Hydraulic oil drain filter, change.......170
Hydraulic oil return filter, changing_{02-18-16}.......172
Hydraulic oil return filter, changing_{02-18-29}.......174
Hydraulic oil servo filter, change_{02-17-19}.......176
Hydraulic oil servo filter, change_{02-17-35}.......179
Hydraulic oil suction strainer, cleaning.......183
Hydraulic system, changing oil.......186
Hydraulic system, checking oil level_{02-29-51}.......190
Hydraulic system, checking oil level_{02-30-03}.......192
Hydraulic tank breather filter, changing.......194
Lubrication.......196
MATRIS, reading, export reading.......197
Maintenance of Stored Machines, according to Inspection Programme.......199
Maintenance service, daily.......201
Maintenance service, every 1000 hours.......202
Maintenance service, every 2000 hours.......204
Maintenance service, every 250 hours.......206
Maintenance service, every 3000 hours_{02-34-41}.......207
Maintenance service, every 3000 hours_{02-34-52}.......209
Maintenance service, every 4000 hours.......211
Maintenance service, every 4500 hours.......213
Maintenance service, every 50 hours.......214
Maintenance service, every 500 hours.......215
Maintenance service, every 6000 hours_{02-33-47}.......217
Maintenance service, every 6000 hours_{02-33-58}.......218
Maintenance service, first 500 hours.......219
Measuring condition.......220
Measuring of swing bearing clearance.......221
Periodic maintenance.......222
Pressure testing.......223
Radiator, cleaning.......224
Replacement parts.......227
Secondary lowering of digging equipment.......228
Service journal (included in Operator's manual), fill in.......230
Service methods.......231
Service positions_{02-37-03}.......232
Service positions_{02-37-16}.......235
Service.......238
Spark plug, replacing-[1351].......239
Starting engine with booster cables.......241
Swing gearbox oil level, checking.......243
Swing gearbox oil, changing.......245
Swing ring gear, grease check.......247
Swing speed.......249
Tech Tool, operations-[3821].......250
Test-run and check.......251
Towing.......252
Trailer hitch, checking.......255
Travel Speed.......259
Travel gearbox oil level, checking.......260
Travel gearbox, changing oil.......262
Turbocharger inclusive inlet and exhaust systems, leakage, check.......264
Tyres, wear and air pressure, checking.......268
VCADS Pro, logged errors, read off.......270
Valves, adjusting-[1618].......272
Water separator, drain.......280
Wheel nuts, check torque.......281
19 - GENERAL.......282
CE marking and declaration of conformity.......283
Checklist after a fire or heat exposure.......285
Decontamination.......286
Environmental handling for the future.......287
Environmentally hazardous fluids.......288
Environmentally safe handling.......289
Fire prevention measures.......291
Health hazards with paint, plastics and rubber.......294
Safety concerns everybody!.......296
Safety rules when servicing.......298
Safety when handling oils and fuel.......300
Safety when handling the machine.......301
Safety when using lifting equipment.......305
Safety when working with air conditioning refrigerant.......306
Safety when working with batteries.......308
Safety when working with hydraulic systems.......310
Service positions_{02-08-31}.......312
Service positions_{02-08-43}.......315
Some simple rules regarding tyre handling.......318
Starting with booster batteries.......320
Waste handling.......321
Working in environmentally contaminated areas.......322
002 - ENGINE WITH MOUNTING AND EQUIPMENT.......323
20 - GENERAL.......324
Component locations.......325
E-ECU MID 128 non-programmed, replacing.......328
E-ECU MID 128 pre-programmed, replacing.......331
Electric components location_{02-00-56}.......334
Electric components location_{02-01-12}.......341
Engine, description.......348
Engine, identification.......352
Engine, volume.......353
Engine, weights-[0128].......354
Tech Tool, operations-[0227].......355
21 - ENGINE.......357
Basic check, Engine.......358
Camshaft and flywheel signals, checking with VCADS Pro and oscilloscope.......359
Connecting rod, description.......365
Crankcase ventilation, description.......367
Crankshaft, description.......368
Cylinder compression, PC test.......369
Engine characteristic curve.......370
Engine mount front, replacing.......372
Engine mounting rear, changing.......377
Engine mounting, tightening torque.......380
Engine, installing.......383
Engine, removing.......394
Engine, specifications.......404
Engine, tightening torques.......405
Engine, weights.......407
Oil level sensor, replacing-[5347].......408
Oil sump, replacing.......412
Troubleshooting-[5907].......419
Valve cover, installing.......421
Valve cover, removing.......426
Valve system specifications.......431
Valves, adjusting.......432
Vibration damper, description.......440
22 - LUBRICATING SYSTEM.......442
Lubricating system, description.......443
Lubrication oil pressure, checking with pressure gauge.......447
Lubrication system, component locations.......451
Lubrication system, specifications.......453
Lubrication system, tightening torques.......455
Oil cooler, description.......457
Oil cooler, replacing.......458
23 - FUEL SYSTEM.......462
Air cleaner, specification-[4453].......464
Feed pump pressure, checking.......465
Feed pump, replacing.......470
Fuel control valve (FCV), checking.......476
Fuel control valve (FCV), replacing.......481
Fuel feed pump, description.......484
Fuel filler pump, description.......485
Fuel filler pump, specifications.......487
Fuel filling pump, installing.......488
Fuel filling pump, removing.......490
Fuel filter extra, replacing.......493
Fuel filter, checking.......495
Fuel filter, description.......496
Fuel filters, replacing.......497
Fuel pressure, checking.......499
Fuel pressure, specifications.......502
Fuel rail pressure sensor, replacing-[4140].......504
Fuel rail pressure, checking.......506
Fuel rail, replacing.......511
Fuel return pressure, checking.......519
Fuel system, bleeding.......521
Fuel system, component location.......523
Fuel system, description.......525
Fuel system, specifications.......531
Fuel system, tightening torques.......533
Fuel tank, description.......539
Fuel tank, replacing.......541
Fuel tank, specification.......548
High pressure fuel pump, checking.......549
High pressure fuel pump, replacing.......554
Injector sleeves, replacing.......559
Injectors, replacing.......569
Injectors, specifications.......578
Instructions for working with electronic fuel injection.......579
Pressure relief valve (PRV), inspecting.......580
Pressure relief valve (PRV), replacing.......585
25 - INLET & EXHAUST SYSTEM.......588
ACM (Aftertreatment control module) non-programmed, replacing.......590
ACM (Aftertreatment control module) pre-programmed, replacing.......592
Air cleaner, description.......594
Air cleaner, specification.......595
Air pump safety valve, replacing.......596
Air pump, replacing.......598
Burner function, checking.......601
Burner, replacing.......606
Charge air cooler, replacing.......613
DOC (Diesel oxidation catalyst), replacing.......616
DPF (Diesel particulate filter) inlet temperature sensor, replacing-[1404].......619
DPF (Diesel particulate filter) outlet temperature sensor, replacing-[1228].......622
DPF (Diesel particulate filter), checking and cleaning.......625
DPF regeneration control.......631
Exhaust Aftertreatment System, component location.......632
Exhaust Aftertreatment System, description_{01-37-06}.......634
Exhaust Aftertreatment System, description_{01-38-14}.......641
Exhaust aftertreatment system, specifications.......652
Exhaust aftertreatment system, tightening torques.......655
Exhaust pipe flexible tube, replacing.......657
Fuel metering unit A, replacing.......660
Fuel metering unit B, replacing.......664
Glow plug, replacing.......670
Inlet and exhaust system, component location.......672
Inlet and exhaust system, description.......674
Inlet and exhaust system, tightening torques.......678
NOx sensor, replacing-[0949].......680
Perform a service regeneration.......684
Preheating coil, replacing.......686
Regeneration process, description.......688
Semi-auto DPF regeneration-[1511].......693
Spark plug cable, replacing.......694
Spark plug control unit, replacing.......696
Spark plug, inspecting.......698
Spark plug, replacing.......700
Turbocharger, description.......702
Turbocharger, replacing.......704
26 - COOLING SYSTEM.......709
Carbon dioxide in coolant system, checking.......710
Coolant anti-freeze resistance, checking.......716
Coolant pump, replacing.......718
Coolant pump, thermostat, specifications.......725
Cooling fan clutch, description.......726
Cooling fan clutch, replacing.......729
Cooling fan clutch, specifications.......735
Cooling fan speed control, description.......736
Cooling system pressure, checking.......738
Cooling system, component location.......740
Cooling system, description.......743
Cooling system, specifications.......746
Cooling system, tightening torques.......747
Expansion tank, replacing.......748
Fan belt and_or alternator-, compressor belt, replacing all belts.......751
Radiator hoses all, replacing.......756
Radiator, description.......759
Radiator, installing.......761
Radiator, removing.......768
Radiator, replacing.......775
Thermostat, inspecting.......779
Thermostat, replacing.......782
27 - ENGINE CONTROL.......786
Engine control, specifications.......787
Engine speed control switch, description-[0022].......789
Engine speed control switch, specifications.......790
Engine speed control, function checking.......791
29 - MISCELLANEOUS.......792
EGR actuator, replacing.......793
EGR cooler, replacing.......802
EGR pressure sensor, replacing-[5821].......815
EGR reed valve, replacing.......818
EGR system function, checking.......825
EGR system, tightening torques.......829
EGR temperature sensor, replacing-[5837].......832
EGR valve, replacing.......834
EGR venturi tube, replacing.......835
Exhaust Gas Recirculation (EGR), description.......838
Exhaust gas recirculation (EGR), component location.......843
003 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS.......845
30 - GENERAL.......846
11 666 140 Multimeter.......852
8883 0028 Adapter cable.......853
88890040 Oscilloscope for VCADS Pro.......854
999 0014 Adapter cable.......855
999 0025 Adapter cable.......856
999 0062 Extension cable.......857
999 3893 Adapter cable.......858
999 3894 Template.......859
999 8699 Multi-pin breaker box.......860
AL3201, description and measuring.......861
Auto idle device, setting instructions.......863
Automatic engine shut-down.......865
Axle lock.......868
BA3101, description and measuring.......872
Boom Suspension System, description.......874
Boom float position, description-[5114].......877
CU2501, description and measuring.......879
CU2503, description and measuring.......881
CU9901, description and measuring.......883
Care Track can not communicate with the machine.......885
Collection of basic data.......887
Communication with data buses.......889
Component descriptions.......891
Component troubleshooting, checking component.......894
Component troubleshooting, checking subsystem (circuit).......896
Component troubleshooting, checking wiring harness and input_output on ECU.......898
Component troubleshooting, structure, description.......900
Connecting special tools.......902
Control lockout system, description.......905
DPF regeneration control_{12-46-51}.......906
DPF regeneration control_{12-47-08}.......914
DPF regeneration control_{12-47-27}.......922
Data buses, function.......931
Data links, fault tracing with Oscilloscope.......936
ECO mode, description.......946
Electrical cables and connectors, checking.......948
Electrical digging brake, description-[5225].......953
Electrical system, description.......955
Electrical system, special instructions for servicing, action when working on machine.......956
Electrical system, special instructions for servicing, electrical components, alternator and charging regulator.......957
Electrical system, special instructions for servicing, electrical components, batteries.......958
Electrical system, special instructions for servicing, electronic components.......960
Electrical system, special instructions for servicing, general.......961
Electrical system, specifications.......963
Electronic control system, description.......964
Emergency operation, description.......966
Error code information, description.......969
Error code information, general.......971
Error codes, build-up.......973
FU18, description and measuring.......977
FU26, description and measuring.......978
FU6, description and measuring.......979
FX1005, description and measuring.......980
FX1006, description and measuring.......983
FX1007, description and measuring.......986
FX1008, description and measuring.......989
FX1031, description and measuring.......992
Forward _ Reverse _ Neutral.......995
HE2501, description and measuring.......996
Limp Home.......998
MA2301MA2306, description and measuring.......1000
MA2508, description and measuring.......1002
MA2509, description and measuring.......1004
MA2510, description and measuring.......1006
MA2512, description and measuring.......1008
MA2602, description and measuring.......1010
MA4214, description and measuring.......1012
MA4226, description and measuring.......1014
MA4227, description and measuring.......1016
MA4302, description and measuring.......1018
MA4303, description and measuring.......1020
MA5205, description and measuring.......1022
MA9109, description and measuring.......1024
MA9120, description and measuring.......1026
MA9121, description and measuring.......1028
MA9122, description and measuring.......1030
MA9125, description and measuring.......1032
MA9152, description and measuring.......1034
MA9164, description and measuring.......1036
MA9165, description and measuring.......1038
MA9615, description and measuring.......1040
MA9618, description and measuring.......1042
MA9619, description and measuring.......1044
MA9620, description and measuring.......1046
MID 140 PPID 1144, description and measuring.......1048
MO3301, description and measuring.......1049
Measuring symbols, description.......1051
Measuring, general.......1054
Overload warning.......1055
PPID 437 explanation.......1057
PPID1336, description and measuring.......1058
PWM2303, description and measuring.......1060
PWM2602, description and measuring-[2052].......1062
PWM2602, description and measuring.......1064
PWM4219, description and measuring.......1066
PWM4220, description and measuring.......1068
PWM9109, description and measuring.......1070
PWM9129, description and measuring.......1072
PWM9141, description and measuring.......1074
PWM9143, description and measuring.......1076
PWM9145, description and measuring.......1078
PWM9146, description and measuring.......1080
Parking brake, description-[4958].......1082
Power Boost control, description.......1084
Power OFF.......1086
Power supply E-ECU, description and measuring.......1087
Power supply, ACM (Aftertreatment Control Module), description and measuring.......1089
Quick fit control, description.......1090
RE2501, description and measuring.......1092
RExxxx, Relays general, description and measuring.......1094
SAE J1708_1587 Information link, description and measuring.......1096
SAE J1939_CAN control link, description and measuring.......1099
SAEJ1939_CAN7 Control link, description and measuring.......1102
SE2203, description and measuring.......1105
SE2301, description and measuring.......1107
SE2303, description and measuring.......1109
SE2309, description and measuring.......1111
SE2512, description and measuring.......1113
SE2515, description and measuring.......1115
SE2516, description and measuring.......1117
SE2519, description and measuring.......1119
SE2520, description and measuring.......1121
SE2521, description and measuring.......1123
SE2522, description and measuring.......1125
SE2523, description and measuring.......1127
SE2524, description and measuring.......1129
SE2525, description and measuring.......1131
SE2526, description and measuring.......1133
SE2603, description and measuring.......1135
SE2604, description and measuring-[4720].......1137
SE2604, description and measuring.......1139
SE2606, description and measuring.......1141
SE2701, description and measuring.......1143
SE2703, description and measuring.......1145
SE2704, description and measuring.......1147
SE4216, description and measuring.......1149
SE4217, description and measuring.......1151
SE4234, description and measuring.......1153
SE4307, description and measuring.......1155
SE5201, description and measuring.......1157
SE5221, description and measuring.......1159
SE8701, description and measuring.......1161
SE8702, description and measuring.......1163
SE8705, description and measuring.......1165
SE8706, description and measuring.......1167
SE9105, description and measuring.......1169
SE9109, description and measuring.......1171
SE9188, description and measuring.......1173
SE9401, description and measuring.......1175
SID211, description and measuring.......1177
SID232, description and measuring.......1178
SW2701, description and measuring.......1179
SW3301, description and measuring.......1181
SW3619, description and measuring.......1183
SW4202, description and measuring.......1185
SW4205, description and measuring.......1187
SW9160, description and measuring.......1189
SW9161, description and measuring.......1191
SW9162, description and measuring.......1193
Semi-auto DPF regeneration.......1195
Service connection and programming connection.......1198
Software parameters, description_{12-48-03}.......1200
Software parameters, description_{12-48-15}.......1213
Special tools for troubleshooting.......1226
Start lock, description.......1228
Tech Tool, operations-.......1229
Tech Tool, operations-[5310].......1231
Tiltrotator control system, software updating.......1232
Travel speed control, description.......1239
Troubleshooting strategy.......1242
Troubleshooting tools.......1244
Troubleshooting, general.......1245
VCADS Pro service tool.......1247
VCADS Pro, parameter programming.......1251
31 - BATTERY.......1253
Batteries, replacing.......1254
Battery, charging.......1258
Battery, description.......1260
Battery, specifications.......1262
Battery, storage.......1263
32 - ALTERNATOR; CHARGE REGULATOR.......1266
Alternator, description.......1267
Alternator, replacing incl function checking.......1269
Alternator, specifications.......1273
Alternator, testing.......1274
Charging, description.......1276
33 - STARTING SYSTEM.......1277
Preheating, description.......1278
Preheating, specifications.......1279
Starter motor, description.......1280
Starter motor, replacing.......1281
Starter motor, specifications.......1286
Starter motor, testing.......1287
Starter motor, tightening torques.......1291
Starter relay, replacing.......1294
Starter switch (engine start switch), replacing.......1296
35 - LIGHTING.......1298
Headlights, adjusting.......1299
Lights, specifications.......1301
Rotating beacon, description.......1302
Rotating beacon, replacing.......1303
Rotating beacon, specifications.......1305
36 - OTHER ELECTRICAL EQUIPMENT.......1306
Auto_Manual pump control switch, description.......1308
Auto_Manual pump control switch, specifications.......1309
Battery disconnect switch, description.......1310
Battery disconnect switch, specifications.......1311
Connectors, overview.......1312
Control levers, specifications.......1325
Control units changing, precaution.......1333
Dozer blade solenoid valve, specifications.......1334
Electric center passage, description.......1335
Electric center passage, replacing.......1338
Electric center passage, specification.......1342
Electric horn, description.......1343
Electric horn, specifications.......1345
Electronic climate control unit ECC, description-[5637].......1346
Electronic climate control unit ECC, specification-[5530].......1347
Emergency engine speed control switch, description.......1348
Emergency engine speed control switch, specifications.......1349
Engine control unit E-ECU, function description.......1350
Engine speed control switch, description.......1352
Horn, replacing.......1353
I-ECU MID 140 non-programmed, replacing.......1355
I-ECU MID 140 pre-programmed, replacing.......1357
Instrument control unit I-ECU, functional description.......1359
Instrument control unit I-ECU, specifications.......1361
Lower wiper motor, description.......1362
Lower wiper motor, specifications.......1364
Manual travel control switch, description.......1365
Manual travel control switch, specifications.......1366
Multi-function lever switch, description.......1367
Multi-function lever switch, specifications.......1369
Power outlet, specifications.......1370
Servo valve block solenoids, specifications.......1371
Stabiliser solenoid valve, specifications.......1372
Start switch, description.......1373
Start switch, specifications.......1375
Switch, replacing.......1376
Travel alarm, description.......1379
Travel alarm, replacing.......1382
Travel alarm, specifications.......1384
Upper wiper motor, description.......1385
Upper wiper motor, specifications.......1387
V-ECU MID 187 non-programmed, replacing.......1388
V-ECU MID 187 pre-programmed, replacing.......1393
Vehicle control unit V-ECU, functional description.......1398
Window limit switch, description.......1399
Windscreen flusher pump, replacing.......1401
Windscreen flusher pump, specifications.......1403
Windscreen wiper controller, replacing.......1404
Windscreen wiper front motor, replacing.......1406
Windscreen wiper switch, replacing.......1409
Windscreen wiper, components location.......1411
Windscreen wiper, description.......1413
Wiper controller, description.......1415
Wiper controller, specifications.......1417
37 - CABLE; FUSE; RELAY.......1418
ACM, I_O list.......1422
Component designations.......1425
Component list Alternator, batteries, capacitors, electronic units, voltage outlet_{04-51-20}.......1426
Component list Alternator, batteries, capacitors, electronic units, voltage outlet_{04-51-31}.......1427
Component list, Heating coils.......1429
Component list, Miscellaneous_{04-48-56}.......1430
Component list, Miscellaneous_{04-49-07}.......1431
Component list, Solenoid valves_{04-46-08}.......1432
Component list, Solenoid valves_{04-46-19}.......1434
Component list, Switches_{04-45-24}.......1436
Component list, Switches_{04-45-35}.......1438
Component list, fuses_{04-50-36}.......1440
Component list, fuses_{04-50-47}.......1442
Component list, lights_{04-49-27}.......1444
Component list, lights_{04-49-38}.......1446
Component list, motors.......1448
Component list, relays_{04-47-53}.......1449
Component list, relays_{04-48-04}.......1450
Component list, sensors_{04-47-04}.......1451
Component list, sensors_{04-47-14}.......1453
Component list, sensors_{04-47-25}.......1455
Control system diagram_{04-41-51}.......1457
Control system diagram_{04-42-04}.......1460
E-ECU, I_O list.......1463
ECC, I_O list.......1467
Electrical diagram, single acting trailer hydraulic.......1469
Electrical distribution box, circuit board replacing.......1474
Electrical distribution box, description_{04-22-07}.......1477
Electrical distribution box, description_{04-22-19}.......1480
Electrical symbols and designations.......1483
Explanation of wiring diagrams.......1487
Flasher relay, specifications.......1490
Fuse, description.......1491
Grounding points, frame connections.......1493
I-ECU, I_O list.......1496
Power distribution box, description.......1498
Relay, description.......1500
Relay, specifications.......1502
Tiltrotator control system, diagram.......1503
V-ECU, I_O list.......1516
W-ECU, I_O list.......1522
Wiring diagram SCH01_{04-41-05}.......1524
Wiring diagram SCH01_{04-41-20}.......1530
Wiring diagram SCH02_{04-40-28}.......1536
Wiring diagram SCH02_{04-40-43}.......1541
Wiring diagram SCH03_{04-39-52}.......1546
Wiring diagram SCH03_{04-40-07}.......1552
Wiring diagram SCH04_{04-39-06}.......1558
Wiring diagram SCH04_{04-39-19}.......1564
Wiring diagram SCH05_{04-38-31}.......1571
Wiring diagram SCH05_{04-38-45}.......1576
Wiring diagram SCH06_{04-37-55}.......1583
Wiring diagram SCH06_{04-38-10}.......1588
Wiring diagram SCH07_{04-37-19}.......1593
Wiring diagram SCH07_{04-37-34}.......1598
Wiring diagram SCH08_{04-36-45}.......1603
Wiring diagram SCH08_{04-36-58}.......1610
Wiring diagram SCH09_{04-35-55}.......1617
Wiring diagram SCH09_{04-36-11}.......1623
Wiring diagram SCH10_{04-35-20}.......1629
Wiring diagram SCH10_{04-35-33}.......1636
Wiring diagram SCH11_{04-34-46}.......1643
Wiring diagram SCH11_{04-34-59}.......1649
Wiring diagram SCH12_{04-34-10}.......1655
Wiring diagram SCH12_{04-34-25}.......1660
Wiring diagram SCH13_{04-33-34}.......1665
Wiring diagram SCH13_{04-33-49}.......1671
Wiring diagram SCH14_{04-33-01}.......1677
Wiring diagram SCH14_{04-33-14}.......1681
Wiring diagram SCH15_{04-32-27}.......1687
Wiring diagram SCH15_{04-32-42}.......1692
Wiring diagram SCH16_{04-31-50}.......1697
Wiring diagram SCH16_{04-32-05}.......1704
Wiring diagram SCH17_{04-31-15}.......1711
Wiring diagram SCH17_{04-31-29}.......1717
Wiring diagram SCH18_{04-30-38}.......1723
Wiring diagram SCH18_{04-30-54}.......1729
Wiring diagram SCH19_{04-29-59}.......1735
Wiring diagram SCH19_{04-30-14}.......1741
Wiring diagram SCH20_{04-29-25}.......1747
Wiring diagram SCH20_{04-29-38}.......1752
Wiring diagram SCH21_{04-28-49}.......1757
Wiring diagram SCH21_{04-29-04}.......1763
Wiring diagram SCH22_{04-28-14}.......1769
Wiring diagram SCH22_{04-28-27}.......1774
Wiring diagram SCH23.......1779
Wiring diagram SCH24_{04-27-21}.......1785
Wiring diagram SCH24_{04-27-33}.......1788
Wiring diagram SCH25_{04-26-45}.......1791
Wiring diagram SCH25_{04-26-58}.......1796
Wiring diagram SCH27.......1801
Wiring diagram SCH28_{04-25-51}.......1807
Wiring diagram SCH28_{04-26-04}.......1812
Wiring diagram SCH29_{04-25-04}.......1817
Wiring diagram SCH29_{04-25-17}.......1821
Wiring diagram SCH29_{04-25-30}.......1825
Wiring diagram SCH30_{04-24-27}.......1829
Wiring diagram SCH30_{04-24-39}.......1834
Wiring diagram, electrical distribution box.......1839
Wiring diagram, general_{04-43-01}.......1842
Wiring diagram, general_{04-43-12}.......1844
Wiring harnesses_{04-23-00}.......1846
Wiring harnesses_{04-23-12}.......1850
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM.......1854
Auto idle pressure switch, specifications.......1856
Boost pressure _ charge-air temperature sensor, replacing.......1857
Booting sequence.......1862
Control levers, description.......1864
Control lockout lever switch, description.......1866
Control lockout lever switch, specifications.......1868
Control types for X1 and X3 operation.......1869
DPF (Diesel particulate filter) inlet temperature sensor, replacing.......1871
DPF (Diesel particulate filter) outlet temperature sensor, replacing.......1872
Display unit, content.......1873
Display unit.......1880
EGR pressure sensor, replacing.......1881
EGR temperature sensor, replacing.......1882
Electrical system.......1883
Engine oil pressure sensor, replacing.......1887
Engine rotation speed sensor (camshaft), replacing.......1890
Engine rotation speed sensor, replacing_{04-15-56}.......1892
Engine rotation speed sensor, replacing_{04-16-07}.......1895
Engine system.......1897
Fuel level sensor, specifications.......1899
Fuel rail pressure sensor, replacing.......1901
HVAC system-[1023].......1902
Hour counter, description.......1904
Hour counter, specifications.......1905
Hydraulic oil temperature sensor, replacing.......1906
Hydraulic system.......1909
Instruments and controls, left instrument panel_{04-19-19}.......1911
Instruments and controls, left instrument panel_{04-19-30}.......1913
Instruments and controls, overview.......1916
Instruments and controls, rear instrument panel.......1917
Instruments and controls, right instrument panel_{04-18-49}.......1918
Instruments and controls, right instrument panel_{04-19-01}.......1921
Keypad, description-[1116].......1924
Keypad, description.......1927
Keypad, specification.......1928
Language.......1930
Main menu.......1932
NOx sensor, replacing.......1934
Oil level sensor, replacing.......1935
Pop-up screen.......1936
Service mode.......1938
Setup.......1940
Swing position sensor, specifications.......1948
Temperature sensor cooling system, replacing.......1949
Theft protection.......1951
Vehicle information.......1953
39 - MISCELLANEOUS.......1955
Antenna, replacing.......1956
Audio remote controller, description.......1958
Audio remote controller, specifications.......1959
CareTrack antenna, replacing.......1960
CareTrack system, description.......1963
DCDC converter, description.......1965
DCDC converter, specifications.......1967
Radio with CD and MP3 player, description_{04-05-47}.......1968
Radio with CD and MP3 player, description_{04-05-59}.......1970
Radio with CD and MP3 player, specifications_{04-06-17}.......1972
Radio with CD and MP3 player, specifications_{04-06-28}.......1974
Radio with MP3, description.......1975
Radio with MP3, specifications.......1977
Speaker, replacing.......1978
W-ECU, MID142, changing non-programmed ECU.......1980
W-ECU, MID142, changing pre-programmed ECU.......1984
Wireless control unit W-ECU, specification.......1988
004 - POWER TRANSMISSION.......1989
40 - GENERAL.......1990
Power transmission, description.......1991
Tech Tool, operations-[0333].......1992
43 - GEARBOX.......1993
Travel gearbox multi-disc, replacing_{01-17-32}.......1994
Travel gearbox multi-disc, replacing_{01-18-31}.......2004
Travel gearbox, bleeding.......2006
Travel gearbox, description.......2009
Travel gearbox, installing.......2019
Travel gearbox, removing.......2025
Travel gearbox, specifications.......2029
44 - HYDROSTATIC DRIVE.......2030
Center passage, description.......2031
Center passage, disassembling and assembling.......2033
Center passage, specifications.......2038
Centre passage, installing.......2040
Centre passage, removing.......2045
Pump coupling, installing.......2049
Pump coupling, removing.......2050
Retardation valve, replacing.......2051
Swing motor pressure, checking and adjusting.......2056
Swing motor, description.......2060
Swing motor, installing.......2064
Swing motor, principle of operation.......2069
Swing motor, removing.......2076
Swing motor, specifications.......2080
Travel motor (electric proportional control) pressure, checking and adjusting.......2081
Travel motor (electric proportional control), description.......2085
Travel motor pressure, checking and adjusting.......2093
Travel motor regulation start, checking and adjusting.......2097
Travel motor removed, seal replacing.......2102
Travel motor, calibrating.......2105
Travel motor, description.......2108
Travel motor, installing.......2113
Travel motor, removing.......2117
Travel motor, specifications.......2121
45 - PROPELLER SHAFT.......2122
Propeller shaft front, replacing.......2123
Propeller shaft rear, replacing.......2126
Propeller shaft, specifications.......2129
46 - FRONT AXLE; REAR AXLE.......2131
Axle, installing.......2132
Axle, removing.......2135
Front axle knuckle.......2138
Front axle, description.......2141
Front axle, installing.......2143
Front axle, removing.......2146
Front axle, specification.......2150
Input shaft seal, replacing.......2151
King pin and bushing, replacing.......2153
Rear axle, specifications.......2154
49 - MISCELLANEOUS.......2155
Measuring rotational clearance.......2156
Swing ring gear inner seal, replacing.......2160
Swing ring gear outer seal, replacing_{11-38-11}.......2162
Swing ring gear outer seal, replacing_{11-38-27}.......2165
Swing ring gear, description.......2167
Swing ring gear, specifications.......2171
Swing ring, installing.......2172
Swing ring, measuring axial clearance.......2174
Swing ring, removing.......2178
Tightening torque, specifications.......2180
005 - BRAKE.......2181
52 - HYDRAULIC BRAKE SYSTEM.......2182
Accumulator, installing.......2183
Accumulator, removing.......2185
Brake accumulator charging pressure, adjusting.......2187
Brake accumulator, description.......2190
Brake accumulator, specifications.......2192
Brake system circuit pressure, checking and adjusting.......2194
Brake system, bleeding.......2200
Discarded accumulators-[3023].......2202
Electrical digging brake, description.......2204
Foot brake valve, replacing.......2207
Hydraulic brake system, description.......2212
Hydraulic oil filter, replacing-[2823].......2217
Service brakes function, checking.......2219
55 - PARKING BRAKE.......2221
Parking brake function, checking.......2222
Parking brake, description.......2224
Parking brake, manually releasing.......2230
006 - STEERING.......2233
60 - GENERAL.......2234
Steering system function, checking.......2235
64 - STEERING.......2237
Control valve (steering unit), description.......2238
Hydraulic oil filter, replacing.......2242
Steering system working pressure, checking.......2244
Steering system, description_{11-25-26}.......2247
Steering system, description_{11-25-54}.......2252
Steering valve, installing.......2257
Steering valve, removing.......2262
007 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT.......2266
71 - FRAME.......2267
Counterweight, installing.......2268
Counterweight, removing.......2271
Counterweight, specifications.......2274
Step, installing.......2275
Step, removing.......2277
Superstructure, installing.......2279
Superstructure, removing.......2283
Undercarriage, description.......2288
Undercarriage, tightening torque.......2290
76 - SHOCK ABSORBER; AXLE LOCKING; ANTI ROLL BAR; LEVEL_SIDE CONTROL.......2292
Pivot axle lock cylinder seals, changing.......2293
Pivot axle lock cylinder, description.......2298
Pivot axle lock cylinder, installing.......2305
Pivot axle lock cylinder, releasing for towing.......2307
Pivot axle lock cylinder, removing.......2310
Pivot axle lock, function check.......2312
77 - WHEELS; TRACKS; TYRE; HUB; DRUM.......2314
Wheel, installing.......2315
Wheel, removing.......2317
Wheels, specifications.......2319
008 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE.......2320
80 - GENERAL.......2321
Tech Tool, operations-[1353].......2322
81 - CAB, NAKED; CANOPY.......2323
Cab suspension, description.......2324
Cab, installing.......2325
Cab, removing.......2332
Cab, weight.......2339
83 - DOORS; HATCH; COVER PLATE, (all).......2340
Cab door, installing door catch.......2341
Cab door, removing door catch.......2344
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING.......2347
Cab roof window, replacing.......2348
Door window, replacing.......2351
Rear window, replacing.......2353
Side window, replacing.......2358
Windows, general.......2364
Windscreen, replacing.......2365
85 - CAB INTERIOR; UPHOLSTERY.......2378
Backrest, replacing.......2379
Driver's seat, description_{11-03-00}.......2383
Driver's seat, description_{11-03-18}.......2386
Driver's seat, specifications_{11-02-21}.......2389
Driver's seat, specifications_{11-02-32}.......2390
Longitudinal adjustment cable, replacing.......2391
Longitudinal suspension cable, replacing.......2397
Seat belt, replacing.......2401
Seat cushion, replacing.......2404
Seat heater pad, replacing.......2409
Seat heater, checking.......2416
Seat support, replacing.......2419
Seat, replacing.......2425
87 - AIR CONDITIONING UNIT.......2434
Air conditioning unit, description.......2436
Air conditioning unit, maintenance.......2442
Air conditioning unit, refrigerant check and recharging.......2444
Air conditioning unit, specifications.......2452
Air distribution, description.......2453
Air mix door actuator, replacing.......2455
Air-conditioning, component location.......2458
Auxiliary heater, description_{10-48-47}.......2460
Auxiliary heater, description_{10-49-04}.......2465
Auxiliary heater, principles_{10-48-11}.......2469
Auxiliary heater, principles_{10-48-25}.......2473
Cab filter, replacing.......2476
Compressor, replacing incl draining and filling.......2477
Condenser, replacing incl draining and filling.......2481
Diesel coolant heater (5kw), specifications.......2484
ECC MID 146 non-programmed ECU, replacing.......2485
ECC MID 146 pre-programmed ECU, replacing.......2489
Electronic climate control unit ECC, description.......2492
Electronic climate control unit ECC, specification.......2493
Evaporator, replacing incl draining and filling.......2494
Expansion valve, replacing incl draining and filling.......2499
Fan motor, replacing.......2504
HVAC system.......2510
Heater core, replacing.......2512
Heating system, description.......2518
Intake actuator, replacing.......2520
Mode (foot) actuator, replacing.......2523
Personal competence and accreditation.......2526
Receiver, replacing incl draining and filling.......2527
Troubleshooting (5kw)_{10-46-37}.......2530
Troubleshooting (5kw)_{10-47-23}.......2534
Vent actuator, replacing.......2543
Wiring diagram.......2546
88 - INTERIOR EQUIPMENT.......2547
Instrument panel (left), replacing.......2548
Instrument panel (right), replacing.......2553
009 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS.......2557
90 - GENERAL.......2558
Description, general.......2559
Hydraulic components, storing and transporting.......2560
Hydraulic oil, description.......2561
Hydraulic oil, storage and handling.......2565
Hydraulic system, cleanliness when handling hydraulic components.......2566
Hydraulic system, flushing.......2568
Hydraulic system, repair of hydraulic components in workshop.......2569
Hydraulic system, warming up.......2574
Measuring tools and techniques.......2578
Tech Tool, operations.......2583
Vacuum pump, connection.......2584
Vacuum pump, disconnection.......2587
91 - WORKING HYDRAULIC; SERVO HYDRAULICS.......2589
Accumulator, description.......2593
Back-up pressure increase_{10-28-01}.......2595
Back-up pressure increase_{10-28-14}.......2597
Back-up valve, checking and adjusting.......2599
Back-up valves.......2604
Boom Suspension System, description_{10-04-00}.......2607
Boom Suspension System, description_{10-04-25}.......2616
Boom Suspension System, specifications_{10-03-16}.......2625
Boom Suspension System, specifications_{10-03-31}.......2627
Boom cylinder, rupture valve, replacing.......2630
Boom float position, description.......2633
Boom suspension accumulator, checking and adjusting.......2636
Boom suspension system, changing accumulator.......2640
Boom suspension system, component location.......2644
Boom suspension system, solenoid valve test.......2646
Calibration of X1 hydraulic with flow control.......2648
Calibration of X1 hydraulic with pressure control.......2651
Changing the hydraulic oil.......2653
Control lockout lever, function check.......2656
Control pattern selector valve, description.......2658
Cooling fan speed, checking and adjusting with VCADS Pro.......2663
Cruise control, description.......2668
Cruise control, specifications.......2673
Dipper arm cylinder, rupture valve, replacing.......2674
Dipper arm in speed, checking and adjusting.......2677
Discarded accumulators.......2679
Grab bucket, description.......2680
Hydraulic diagram, Boom Suspension System.......2686
Hydraulic diagram, X1 with flow control.......2689
Hydraulic diagram, X1 with pressure control.......2692
Hydraulic diagram, X3.......2695
Hydraulic diagram, boom float valve.......2698
Hydraulic diagram, complete.......2701
Hydraulic diagram, component list.......2704
Hydraulic diagram, cruise control.......2707
Hydraulic diagram, dozer blade and outrigger.......2710
Hydraulic diagram, elevating cab-[3626].......2713
Hydraulic diagram, grab piping.......2716
Hydraulic diagram, quick fit.......2719
Hydraulic diagram, single acting trailer hydraulic.......2724
Hydraulic diagram, travel (low speed).......2729
Hydraulic diagram, with reversible cooling fan.......2732
Hydraulic oil cooler, installing.......2735
Hydraulic oil cooler, removing.......2736
Hydraulic oil cooling system, description.......2737
Hydraulic oil cooling system, specifications.......2738
Hydraulic oil tank, description_{10-33-12}.......2740
Hydraulic oil tank, description_{10-33-25}.......2743
Hydraulic oil tank, installing.......2746
Hydraulic oil tank, releasing pressure.......2749
Hydraulic oil tank, removing.......2750
Hydraulic oil, cleaning.......2753
Hydraulic pressure, specifications.......2755
Hydraulic pump, specifications.......2760
Hydraulic system, description.......2762
Hydraulic system, position of main components.......2763
Hydraulic system, work instructions.......2766
Hydraulic tank, specifications.......2767
Hydraulically driven cooling fan, description.......2768
LS-pressure relief valve, replacing.......2772
Line rupture valve (boom), description.......2775
Line rupture valve (boom), troubleshooting.......2778
Line rupture valve for 2-piece boom cylinder X2, description.......2780
Line rupture valve for dipper arm cylinder, description.......2785
Line rupture valve pressure, checking and adjusting.......2790
Main control valve block, description.......2796
Main control valve, installing.......2802
Main control valve, removing.......2805
Option X1 pressure control.......2809
Pressure relief valves, description.......2817
Pump, installing.......2821
Pump, removing.......2825
Remote control valve (pedal), specifications.......2829
Reversible cooling fan, description.......2831
Rupture valve, replacing (2pcs boom tilt cylinder).......2835
Secondary pressure limiting valve, checking.......2839
Servo Accumulator.......2842
Servo accumulator, installing.......2843
Servo accumulator, removing.......2845
Servo pressure, checking and adjusting.......2847
Servo pump, installing.......2850
Servo pump, removing.......2852
Servo system, description.......2854
Servo valve, installing.......2858
Servo valve, removing.......2861
Shock and anti-cavitation valve, description.......2864
Single acting trailer hydraulic.......2867
Tiltrotator control system, description.......2871
Trailer towing solution (TTS).......2886
Unload valve, checking and adjusting.......2894
Unload valve, replacing.......2898
VCADS Pro, 91610-3 X1 hydraulic pressure control system, test.......2902
Working pressure, checking and adjusting.......2905
Working pump, description.......2914
X1 Pre-set relief valve, description.......2917
X1 pressure relief valve, adjusting-[0956].......2921
X1 pressure relief valve, adjusting.......2924
X1, Specifications.......2928
X1, description.......2933
X1, function check.......2944
X3 pressure and flow, adjusting.......2946
X3 shock and refilling valves, adjusting.......2951
X3, description.......2955
X3, function check.......2964
X3, specifications.......2966
92 - MECHANICAL EQUIPMENT_ATTACHMENT.......2968
Cylinder for hydraulic quickfit S1, installing.......2969
Cylinder for hydraulic quickfit S1, removing.......2971
Cylinder for hydraulic quickfit S6, installing.......2973
Cylinder for hydraulic quickfit S6, removing.......2976
Cylinder for hydraulic quickfit Universal, installing.......2983
Cylinder for hydraulic quickfit Universal, removing.......2987
Dozer blade, description.......2991
Hydraulic quickfit cylinder, installing.......2992
Hydraulic quickfit cylinder, removing.......2995
Quickfit, function check_{09-53-59}.......2999
Quickfit, function check_{09-54-11}.......3001
Quickfit, installing.......3003
Quickfit, removing.......3006
Quickfit, replacing.......3008
Standard quick coupler.......3012
Steelwrist quick coupler_{09-58-52}.......3017
Steelwrist quick coupler_{09-59-12}.......3018
Universal quick coupler_{09-59-34}.......3025
Universal quick coupler_{09-59-54}.......3029
97 - UNIT, DIGGING.......3035
2-piece boom, installing.......3036
2-piece boom, removing.......3040
Boom lifting cylinder, description.......3044
Bucket cylinder, description.......3046
Bucket cylinder, installing.......3048
Bucket cylinder, removing.......3052
Cylinder, description.......3056
Cylinder, specifications.......3059
Digging equipment bearings, measuring radial clearance.......3060
Digging equipment bearings, shimming.......3063
Digging equipment bearings, specifications.......3065
Dipper arm cylinder, description.......3067
Dipper arm, installing.......3069
Dipper arm, removing.......3072
Stabilisers and stabiliser blade, description.......3075
Stabilisers, hydraulic cylinder, installing.......3077
Stabilisers, hydraulic cylinder, removing.......3082
99 - MISCELLANEOUS.......3086
Automatic lubrication pump, installing.......3087
Automatic lubrication pump, removing.......3093
Automatic lubrication system, description.......3095
Automatic lubrication system, specifications.......3102
Bleeding air.......3103
Cab elevating cylinder, replacing.......3104
Control unit, description.......3109
Control units, software functions.......3111
E-tool Sleeve.......3117
Explanations to hydraulic diagram.......3119
Hydraulic diagram, elevating cab.......3130
Hydraulic elevating cab, description.......3133
Maintenance service, general.......3139
Troubleshooting.......3142
