Volvo ECR235E L Excavators Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo ECR235E L Excavators, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Volvo Construction ECR235E L 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: 3,462 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
Volvo ECR235E L Excavators Service Repair Manual.pdf
MAIN SECTIONS
000 - Foreword.......2
000 - GENERAL.......3
00 - DESCRIPTION; COMPLETE MACHINE.......4
Machine view.......5
Product plates.......7
03 - SPECIFICATIONS.......9
Main dimensions.......10
Measurement conversion tables.......12
Specifications.......21
Tightening torque, specifications.......23
Tightening torques.......26
07 - STANDARD TIME.......35
Operation numbers for additional work.......36
08 - TOOL.......38
E-tools, NET 8940-00270 Replace tool for the swing ring gear.......39
Infrared Thermometer.......41
NET 8940-00190 Travel motor guide pin.......45
09 - MISCELLANEOUS.......46
Hydraulic cylinders, dieseling.......47
Service positions.......51
Welding on the machine.......54
001 - STANDARD PARTS, SERVICE.......57
16 - LUBRICANT; FUEL; OTHER FLUID.......58
AdBlue_DEF .......59
Alternative fuels.......65
Change capacities.......68
Coolant with freezing and corrosion protection.......69
Coolant.......73
Engine oil.......77
Fuel.......79
Grease.......82
Hydraulic oil.......86
Lubricants, service capacities and intervals.......90
Recommended lubricants.......92
17 - SERVICE.......95
AdBlue_DEF pump unit filter, replacing.......98
AdBlue_DEF tank breather filter, replacing.......101
Air conditioner compressor belt, checking.......102
Air conditioner main filter, cleaning.......104
Air conditioner main filter, replacing.......106
Arrival Inspection, according to Inspection Programme.......108
Battery, checking.......113
Bearings.......115
Cab door, covers, hinges, joints and locks, lubricating.......119
Cab prefilter, cleaning.......121
Cab prefilter, replacing.......123
CareTrack backup battery, replacing.......125
Cleaning prior to repair.......128
Coasting left and right swing.......132
Coolant freezing point, checking.......134
Coolant, changing.......137
Creeping of hydraulic cylinder.......139
Cylinder speed.......141
Delivery Inspection, according to Inspection Programme.......144
Diesel particulate filter, checking and cleaning.......148
Diesel particulate filter, regenerating.......152
Engine air cleaner primary filter, replacing.......154
Engine air cleaner secondary filter, replacing.......156
Engine oil and filter, changing.......158
Fan_alternator belt, checking.......161
Fuel filter, replacing.......163
Fuel tank breather filter, replacing.......165
Hoses and tubes.......168
Hydraulic oil drain filter, replacing.......172
Hydraulic oil level, checking.......173
Hydraulic oil return filter, replacing.......174
Hydraulic oil servo filter, replacing.......176
Hydraulic oil suction strainer, cleaning.......177
Hydraulic oil tank breather filter, replacing.......179
Hydraulic oil, changing.......181
Lubrication, every 50 hours.......183
MATRIS and Tech Tool, reading.......185
Maintenance of Stored Machines, according to Inspection Programme.......186
Maintenance service, every 10 hours.......190
Maintenance service, every 1000 hours.......191
Maintenance service, every 2000 hours.......193
Maintenance service, every 250 hours.......195
Maintenance service, every 4000 hours.......196
Maintenance service, every 4500 hours.......198
Maintenance service, every 50 hours.......199
Maintenance service, every 500 hours_{09-51-11}.......200
Maintenance service, every 500 hours_{09-51-22}.......202
Maintenance service, every 6000 hours_{09-49-29}.......204
Maintenance service, every 6000 hours_{09-49-41}.......206
Maintenance service, every 8000 hours_{09-49-01}.......207
Maintenance service, every 8000 hours_{09-49-12}.......208
Maintenance service, first 500 hours.......209
Measuring condition.......210
Measuring of swing bearing clearance.......213
Pressure testing.......216
Radiator and hydraulic oil cooler, cleaning.......220
Replacement parts.......222
Safety when servicing.......226
Service methods.......230
Service position.......234
Service.......237
Software update, checking.......240
Straight traveling performance.......244
Swing bath grease, checking.......246
Swing gearbox oil level, checking.......247
Swing gearbox oil, changing.......249
Swing ring gear bearing, lubricating.......251
Swing speed.......253
Tech Tool, operations.......254
Test running and checking.......256
Track gearbox oil, changing.......258
Track running speed.......260
Track shoe bolts, checking.......261
Track tension and condition, checking.......263
Travel Speed.......265
Valves, adjusting-[4718].......267
Water separator filter, replacing.......271
19 - GENERAL.......273
CE-marking, EMC-directive.......274
Cautions during operation.......278
Checklist after a fire or heat exposure.......285
Decontamination.......289
Environmental handling for the future.......293
Environmentally hazardous fluids.......297
Environmentally safe handling.......301
Fire prevention measures.......305
Health hazards with paint, plastics and rubber.......311
Move and operate machine safely.......316
Safety concerns everybody!.......319
Safety rules when servicing.......323
Safety when handling oils and fuel.......328
Safety when handling the machine.......332
Safety when using lifting equipment.......338
Safety when working with air conditioning refrigerant.......342
Safety when working with batteries.......347
Safety when working with hydraulic systems.......352
Starting with booster batteries.......356
Waste handling.......360
Working in environmentally contaminated areas.......364
002 - ENGINE WITH MOUNTING AND EQUIPMENT.......368
20 - GENERAL.......369
Component locations.......370
Engine belts, replacing.......372
Engine control module (ECM), replacing non-programmed.......375
Engine control module (ECM), replacing pre-programmed.......379
Engine, description.......381
Engine, reference values.......388
Tech Tool, operations_{09-26-36}.......391
Tech Tool, operations_{09-26-47}.......393
21 - ENGINE.......395
Crankcase ventilation, description.......396
Cylinder compression, testing.......400
Engine rotation speed sensor (camshaft), replacing.......404
Engine rotation speed sensor (crank shaft), replacing.......406
Engine, installing.......408
Engine, removing.......418
Engine, replacing_{09-23-30}.......429
Engine, replacing_{09-23-41}.......431
Engine, specifications.......434
Engine, tightening torques.......435
Valve cover, installing.......443
Valve cover, removing.......446
Valve mechanism, specifications.......449
Valves, adjusting.......450
22 - LUBRICATING SYSTEM.......454
Lubrication oil pressure, checking with pressure gauge.......455
Lubrication system, component locations.......458
Lubrication system, description.......460
Lubrication system, specifications.......465
Lubrication system, tightening torques.......467
23 - FUEL SYSTEM.......470
Carbon dioxide in fuel system, checking.......471
Feed pump pressure, checking.......477
Fuel control valve (FCV), replacing.......479
Fuel rail pressure sensor, replacing.......484
Fuel rail, replacing.......486
Fuel system, bleeding.......489
Fuel system, component location.......491
Fuel system, description.......493
Fuel system, specifications.......500
Fuel system, tightening torques.......502
High pressure fuel pipes, replacing.......508
High pressure fuel pump, replacing.......510
Injector sleeves, replacing.......513
Injectors, replacing.......523
Pressure relief valve (PRV), replacing.......528
Water separator, specifications.......531
25 - INLET & EXHAUST SYSTEM.......533
ACM (Aftertreatment control module) non-programmed, replacing.......535
ACM (Aftertreatment control module) pre-programmed, replacing-[0810].......538
ACM (Aftertreatment control module) pre-programmed, replacing.......540
AdBlue_DEF dosing injector, replacing.......542
AdBlue_DEF hoses, replacing.......545
AdBlue_DEF mixing tube, replacing.......549
AdBlue_DEF pump unit diagnostics, description.......553
AdBlue_DEF pump unit, filter, replacing.......557
AdBlue_DEF pump unit, flushing.......560
AdBlue_DEF pump unit, inlet nipple, replacing.......562
AdBlue_DEF pump unit, replacing.......565
AdBlue_DEF quality, checking.......568
AdBlue_DEF tank armature suction filter, replacing.......571
AdBlue_DEF tank armature, cleaning.......573
AdBlue_DEF tank armature, replacing.......576
AdBlue_DEF tank, cleaning.......581
AdBlue_DEF tank, replacing.......584
AdBlue_DEF, draining.......586
AdBlue_DEF.......589
Charge air cooler, replacing.......594
Coolant valve, replacing.......603
Crystallization of AdBlue_DEF, checking.......606
DOC (Diesel oxidation catalyst), replacing.......611
DPF (Diesel particulate filter), checking and cleaning.......615
Exhaust Aftertreatment System, component location.......619
Exhaust Aftertreatment System, description.......621
Exhaust pipe flexible tube, replacing.......635
Inlet and exhaust system, component location.......638
Inlet and exhaust system, description.......640
Inlet and exhaust system, specification.......646
Inlet and exhaust system, tightening torques.......648
Inlet throttle, replacing-[0747].......653
Inlet throttle, replacing.......655
Regeneration log, checking.......657
Regeneration process, description.......668
SCR (Selective catalytic reduction) dosing system, checking.......675
SCR (Selective catalytic reduction) muffler, replacing.......678
Turbocharger, replacing.......684
Wastegate, checking.......687
26 - COOLING SYSTEM.......689
Carbon dioxide in coolant system, checking.......690
Coolant pump, replacing.......696
Coolant with anti-freeze and corrosion protection, recommendation.......699
Cooling fan control.......702
Cooling fan rpm, specifications.......706
Cooling system pressure, checking.......707
Cooling system, description.......709
Cooling system, specifications.......713
Expansion tank, replacing.......715
Radiator, replacing.......718
Reversible cooling fan, description.......720
Thermostat, replacing.......723
27 - ENGINE CONTROL.......725
Engine - Pump control, specification.......726
29 - MISCELLANEOUS.......728
EGR actuator, replacing.......729
EGR cooler, replacing.......731
EGR reed valve, replacing.......735
EGR system, tightening torques.......738
EGR venturi tube, cleaning.......740
EGR venturi tube, replacing.......742
Exhaust Gas Recirculation (EGR), description.......745
Exhaust gas recirculation (EGR), component location.......751
003 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS.......753
30 - GENERAL.......754
AL3201, description and measuring.......760
Attachment quick coupler.......763
Auto Idle.......765
Automatic engine shut-down.......768
Auxiliary start.......771
BA3101, description and measuring.......775
BB1 Communication bus, description and measuring.......777
BB2 Communication bus, description and measuring.......780
Boom float position, description.......783
CU9901, description and measuring.......784
CareTrack with anti-theft.......786
Collection of basic data.......797
Conditions when checking.......801
ECO mode, description.......806
Electrical system, description.......808
Electrical system, special instructions for servicing, action when working on machine.......810
Electrical system, special instructions for servicing, electrical components, alternator and charging regulator.......813
Electrical system, special instructions for servicing, electrical components, batteries.......816
Electrical system, special instructions for servicing, electronic components.......820
Electrical system, special instructions for servicing, general.......823
Electrical system, specifications.......827
Electro hydraulic pump control, description.......830
Electronic control system, description.......835
Engine stops.......841
Error code information, general.......843
Error codes, build-up.......854
FX1005, description and measuring.......856
FX1006, description and measuring.......859
FX1007, description and measuring.......862
FX1008, description and measuring.......866
FX1054, description and measuring.......870
FX1074, description and measuring.......873
FX1079, description and measuring.......876
FX1116, description and measuring.......879
FX1117, description and measuring.......882
General fault diagnosis information.......885
Grading and lifting control, description.......887
HE2501, description and measuring.......891
HE2511, description and measuring_{07-25-59}.......893
HE2511, description and measuring_{07-26-34}.......895
HE2512, description and measuring_{07-24-38}.......897
HE2512, description and measuring_{07-25-14}.......899
HE2513, description and measuring_{07-23-12}.......901
HE2513, description and measuring_{07-23-52}.......903
Information display, check.......905
Instrument Cluster (IC), description and measuring.......908
Intermittent wiper and washer.......910
Lead and connector checks.......914
Limp home.......920
MA2301-MA2306, description and measuring.......923
MA2517, description and measuring.......926
MA2519, description and measuring.......928
MA2523, description and measuring.......931
MA2524, description and measuring.......933
MA2602, description and measuring.......935
MA9109, description and measuring.......937
MA9116, description and measuring.......940
MA9117, description and measuring.......943
MA9120, description and measuring.......946
MA9125, description and measuring.......949
MO2505, description and measuring.......952
MO2510, description and measuring.......955
MO3301, description and measuring.......957
Mode selection, description.......959
Overload warning.......963
PWM2303, description and measuring.......966
PWM9109, description and measuring.......969
PWM9123, description and measuring.......971
PWM9124, description and measuring.......974
PWM9129, description and measuring.......977
PWM9141, description and measuring_{06-52-53}.......979
PWM9141, description and measuring_{06-53-29}.......982
PWM9142, description and measuring_{06-51-20}.......985
PWM9142, description and measuring_{06-52-03}.......988
PWM9143, description and measuring.......991
PWM9145, description and measuring.......993
PWM9146, description and measuring.......996
PWM9156, description and measuring.......999
PWM9157, description and measuring.......1001
Power Boost control, description.......1004
Power supply CCM, description and measuring.......1007
Power supply ECM, description and measuring.......1009
Power supply GPMECU 1, description and measuring.......1011
Power supply HMICU, description and measuring.......1013
Power supply W-ECU, description and measuring.......1015
Power supply, ACM (Aftertreatment Control Module), description and measuring.......1017
Power supply, description.......1019
RE2501, description and measuring.......1024
RE3101, description and measuring.......1027
RE3102, description and measuring.......1030
RE3502, description and measuring.......1033
RE3507, description and measuring.......1035
RE3508, description and measuring.......1037
RE3511, description and measuring.......1040
RE3607, description and measuring.......1042
RE3611, description and measuring.......1044
RE4206, description and measuring_{06-28-46}.......1047
RE4206, description and measuring_{06-29-30}.......1050
SAE J1939-1 SubNet 1, description and measuring.......1052
SE2203, description and measuring.......1055
SE2301, description and measuring.......1058
SE2303, description and measuring.......1061
SE2309, description and measuring.......1064
SE2511, description and measuring.......1067
SE2512, description and measuring.......1070
SE2513, description and measuring.......1073
SE2515, description and measuring.......1076
SE2516, description and measuring.......1079
SE2519, description and measuring.......1082
SE2521, description and measuring.......1085
SE2522, description and measuring.......1088
SE2533, description and measuring.......1091
SE2543, description and measuring.......1094
SE2544, description and measuring.......1097
SE2603, description and measuring.......1099
SE2606, description and measuring.......1101
SE2701, description and measuring.......1104
SE2703, description and measuring.......1106
SE8701, description and measuring.......1108
SE8702, description and measuring.......1111
SE8705, description and measuring.......1114
SE8706, description and measuring.......1117
SE8708, description and measuring.......1120
SE9105, description and measuring.......1123
SE9121, description and measuring.......1126
SE9122, description and measuring.......1128
SE9123, description and measuring.......1130
SE9124, description and measuring.......1133
SE9125, description and measuring.......1136
SE9126, description and measuring.......1139
SE9127, description and measuring.......1142
SE9128, description and measuring.......1145
SE9130, description and measuring.......1148
SE9131, description and measuring.......1151
SE9132, description and measuring.......1154
SE9136, description and measuring.......1157
SE9138, description and measuring.......1160
SE9141, description and measuring.......1163
SE9142, description and measuring.......1165
SE9401, description and measuring.......1167
SW2506, description and measuring.......1169
SW3301, description and measuring.......1172
SW3802, description and measuring.......1175
SW3803, description and measuring.......1178
SW9161, description and measuring.......1180
SW9162, description and measuring.......1182
Seat belt.......1184
Shockless boom control, description.......1186
Software parameters, description.......1188
Special tools for troubleshooting.......1199
Start lock, description.......1202
System voltage.......1204
Tech Tool, operations-[0952].......1207
Tech Tool, operations.......1209
Tiltrotator detection, description and measuring.......1211
Travel speed, description.......1214
Troubleshooting strategy.......1216
VSV controller, description and measuring.......1218
X1 control, description.......1221
X3 control, description.......1225
31 - BATTERY.......1227
Batteries, replacing.......1228
Battery condition, checking.......1231
Battery, charging.......1234
Battery, description.......1237
Battery, specifications_{05-28-32}.......1240
Battery, specifications_{05-28-55}.......1242
Battery, storage.......1243
Earth lead to battery, replacing.......1246
32 - ALTERNATOR; CHARGE REGULATOR.......1248
Alternator, description.......1249
Alternator, replacing incl function checking.......1252
Alternator, specifications.......1256
Alternator, testing.......1258
Charging, description.......1262
33 - STARTING SYSTEM.......1264
Ignition switch, description and operation.......1265
Ignition switch, specifications.......1268
Preheating, description.......1270
Starter motor, description.......1272
Starter motor, replacing.......1274
Starter motor, specifications.......1276
Starter motor, testing.......1278
Starter switch, testing.......1282
Starting operation.......1285
35 - LIGHTING.......1286
Work lighting headlamp assembly, replacing.......1287
Work lights and extra lights, description.......1289
Work lights and extra lights, specifications.......1292
36 - OTHER ELECTRICAL EQUIPMENT.......1295
Connectors, overview.......1297
Connectors, position.......1302
Control lockout lever switch, replacing.......1310
Electric horn, specifications.......1313
Electric pedal control on X1 (on_off), replacing.......1316
Electric pedal control on X1 (proportional), replacing.......1320
Engine limp home switch, description.......1324
Engine limp home switch, specifications.......1326
GPMECU1 non-programmed, replacing.......1328
GPMECU1 pre-programmed, replacing.......1331
General purpose machine electronic control unit GPMECU, function description.......1334
HMICU non-programmed, replacing.......1337
HMICU pre-programmed, replacing.......1341
Horn, replacing.......1345
Human machine interface control unit HMICU, function description.......1347
Ignition switch, replacing.......1349
Lower wiper motor, description.......1352
Lower wiper motor, specifications.......1354
Pre-heating relay, replacing.......1356
Rotating beacon, replacing.......1358
Rotating beacon, specifications_{05-14-22}.......1361
Rotating beacon, specifications_{05-14-46}.......1363
Travel alarm, description.......1365
Travel alarm, replacing.......1368
Travel alarm, specifications.......1370
Upper wiper motor, description.......1371
Upper wiper motor, specifications.......1373
Window limit switch, description.......1375
Windscreen flusher pump, specifications.......1378
Windscreen wiper front motor, replacing.......1380
Windscreen wiper switch, replacing.......1385
Windscreen wiper, description.......1388
37 - CABLE; FUSE; RELAY.......1390
ACM, I_O list.......1393
CCM, I_O list.......1396
Component designations.......1399
Component list Alternator, batteries, capacitors, electronic units, voltage outlet.......1400
Component list, Heating coils.......1402
Component list, Miscellaneous_{03-10-22}.......1403
Component list, Miscellaneous_{03-10-47}.......1404
Component list, Solenoid valves.......1405
Component list, Switches.......1407
Component list, fuses.......1409
Component list, lights.......1411
Component list, motors.......1412
Component list, relays.......1413
Component list, sensors.......1414
ECM (Engine Control Module), I_O list.......1416
Electrical battery disconnect switch, replacing.......1421
Electrical distribution box, circuit board replacing.......1424
Electrical distribution box.......1428
Electrical symbols and designations.......1431
Engine wire harness, replacing.......1435
Explanation of wiring diagrams.......1441
Fuse, description.......1444
GPMECU1, I_O list.......1447
HMICU, I_O list_{03-02-03}.......1450
HMICU, I_O list_{03-02-39}.......1453
IC (Instrument Cluster), I_O list.......1456
Relay, description_{12-46-51}.......1458
Relay, description_{12-47-36}.......1461
Relay, specifications.......1464
W-ECU, I_O list.......1466
Wiring diagram SCH01_{02-56-49}.......1468
Wiring diagram SCH01_{02-57-52}.......1472
Wiring diagram SCH02.......1476
Wiring diagram SCH03_{02-53-24}.......1480
Wiring diagram SCH03_{02-54-09}.......1484
Wiring diagram SCH04.......1488
Wiring diagram SCH05.......1493
Wiring diagram SCH07_{02-48-54}.......1498
Wiring diagram SCH07_{02-49-45}.......1502
Wiring diagram SCH08_{02-46-48}.......1506
Wiring diagram SCH08_{02-47-41}.......1511
Wiring diagram SCH10.......1516
Wiring diagram SCH11.......1519
Wiring diagram SCH12_{02-27-16}.......1523
Wiring diagram SCH12_{02-28-08}.......1527
Wiring diagram SCH12_{02-29-02}.......1531
Wiring diagram SCH13.......1535
Wiring diagram SCH14_{02-23-57}.......1538
Wiring diagram SCH14_{02-24-48}.......1543
Wiring diagram SCH15_{02-21-09}.......1548
Wiring diagram SCH15_{02-22-01}.......1552
Wiring diagram SCH15_{02-22-51}.......1556
Wiring diagram SCH16_{02-19-15}.......1560
Wiring diagram SCH16_{02-20-04}.......1564
Wiring diagram SCH17_{02-17-21}.......1568
Wiring diagram SCH17_{02-18-12}.......1572
Wiring diagram SCH18.......1576
Wiring diagram SCH20_{02-14-06}.......1579
Wiring diagram SCH20_{02-14-56}.......1582
Wiring diagram SCH21_{01-08-23}.......1585
Wiring diagram SCH21_{02-12-46}.......1588
Wiring diagram SCH24.......1592
Wiring diagram SCH25.......1595
Wiring diagram SCH27.......1598
Wiring diagram SCH30_{01-00-18}.......1604
Wiring diagram SCH30_{01-01-07}.......1607
Wiring diagram SCH30_{01-01-58}.......1610
Wiring diagram, electrical distribution box.......1613
Wiring diagram.......1616
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM.......1618
Control lockout lever switch, description.......1619
Control lockout lever switch, specifications.......1622
Electrical system.......1625
Engine oil pressure sensor, replacing.......1629
Engine system.......1631
Engine temperature sensor, replacing.......1634
Fuel level sender, replacing.......1636
Hour meter, replacing.......1639
Hydraulic oil temperature sensor, replacing.......1642
Hydraulic system.......1644
Instruments and controls, front instrument panel.......1648
Instruments and controls, left instrument panel.......1650
Instruments and controls, overview.......1652
Instruments and controls, rear instrument panel.......1654
Instruments and controls, right instrument panel.......1655
Keypad, description.......1657
Keypad, specification.......1659
Service mode.......1661
Volvo Smart View accuracy, checking.......1664
Volvo Smart View camera, replacing.......1670
Volvo Smart View, calibrating.......1674
Volvo Smart View, specification.......1679
Volvo Smart View.......1682
39 - MISCELLANEOUS.......1686
Antenna, replacing.......1687
CareTrack W-ECU, description.......1690
CareTrack antenna, replacing.......1695
CareTrack battery, replacing.......1700
DCDC converter, description.......1703
DCDC converter, specifications.......1706
Radio with MP3, description.......1709
Radio with MP3, specifications.......1712
Speaker, replacing.......1713
Voltage converter, replacing.......1715
W-ECU, replacing, non-programmed.......1718
W-ECU, replacing, pre-programmed.......1722
004 - POWER TRANSMISSION.......1726
40 - GENERAL.......1727
Power transmission, description.......1728
Tightening torque, specifications .......1731
43 - GEARBOX.......1732
Swing gearbox removed, replacing shaft.......1733
Swing gearbox removed, seal replacing.......1746
Swing gearbox, assembly.......1749
Swing gearbox, description.......1756
Swing gearbox, description_{10-13-08}.......1760
Swing gearbox, description_{10-13-41}.......1762
Swing gearbox, disassembly.......1764
Swing gearbox, maintenance standard.......1770
Swing gearbox, replacing.......1774
Swing gearbox, specifications.......1779
Swing unit, replacing.......1780
Track gearbox (removed), replacing floating seal_{11-42-47}.......1785
Track gearbox (removed), replacing floating seal_{11-42-49}.......1790
Track gearbox cover, replacing.......1795
Track gearbox, assembly.......1798
Track gearbox, description.......1807
Track gearbox, description_{09-57-41}.......1808
Track gearbox, description_{09-58-53}.......1812
Track gearbox, disassembly.......1818
Track gearbox, maintenance standard.......1826
Track gearbox, specifications.......1832
Track.......1833
44 - HYDROSTATIC DRIVE.......1840
Center passage, assembly_{03-03-27}.......1842
Center passage, assembly_{03-05-16}.......1849
Center passage, description_{07-43-03}.......1856
Center passage, description_{07-43-33}.......1859
Center passage, description_{07-44-05}.......1862
Center passage, description_{07-44-35}.......1865
Center passage, disassembling_{03-08-15}.......1868
Center passage, disassembly_{03-09-28}.......1873
Center passage, maintenance standard.......1878
Center passage, replacing seal kit.......1883
Center passage, replacing_{04-25-41}.......1887
Center passage, replacing_{04-25-42}.......1892
Center passage, specifications_{07-45-14}.......1898
Center passage, specifications_{07-45-39}.......1900
Center passage, specifications_{07-51-10}.......1902
Center passage, specifications_{07-51-35}.......1903
Hydraulic pump coupling, description.......1904
Pump gearbox coupling assembly, replacing.......1906
Slew motor, adjustment.......1908
Swing motor relief valve, replacing.......1910
Swing motor removed, seal replacing.......1912
Swing motor, assembly.......1915
Swing motor, description.......1922
Swing motor, disassembly.......1926
Swing motor, maintenance standard_{07-46-44}.......1931
Swing motor, maintenance standard_{07-47-13}.......1935
Swing motor, replacing brake piston seal.......1937
Swing motor, replacing plate (brake).......1941
Swing motor, replacing.......1946
Swing motor, specifications.......1950
Tightening torque, specifications_{07-46-27}.......1951
Tightening torque, specifications_{07-47-01}.......1954
Tightening torque, specifications_{07-48-07}.......1956
Track motor relief valve, replacing.......1960
Track motor, assembly.......1962
Track motor, description_{08-49-01}.......1977
Track motor, description_{08-50-04}.......1984
Track motor, disassembly.......1991
Track motor, maintenance standard.......2006
Track motor, specifications.......2012
Travel speed, description.......2013
49 - MISCELLANEOUS.......2016
Swing ring gear grease pipe, replacing.......2017
Swing ring gear inner seal, replacing.......2020
Swing ring gear outer seal, replacing.......2023
Swing ring gear, description.......2030
Swing ring gear, replacing.......2034
Swing ring gear, specifications.......2036
007 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT.......2037
70 - GENERAL.......2038
Frame and track unit, description.......2039
Frame and track unit, specifications.......2041
Undercarriage, tightening torque.......2042
71 - FRAME.......2044
Counterweight, description.......2045
Counterweight, installing.......2047
Counterweight, removing.......2051
Counterweight, specifications.......2055
Counterweight, tightening torques.......2056
Machine weight, specifications.......2058
Superstructure, installing.......2060
Superstructure, removing.......2066
Tightening torque, specifications.......2071
Undercarriage, description_{12-36-28}.......2072
Undercarriage, description_{12-36-43}.......2073
Undercarriage, description_{12-36-59}.......2076
77 - WHEELS; TRACKS; TYRE; HUB; DRUM.......2079
Bottom roller, assembly.......2081
Bottom roller, description.......2084
Bottom roller, disassembly.......2086
Bottom roller, measurement of wear.......2090
Bottom roller, replacing one.......2094
Bottom roller, replacing seal.......2099
Front idler, replacing one.......2104
Full track guard, replacing.......2108
Idler, assembly.......2112
Idler, description.......2117
Idler, disassembly.......2120
Idler, measurement of wear.......2125
Recoil spring cylinder seal kit, replacing.......2129
Rubber pads.......2133
Rubber shoe_pad usage.......2134
Selection of track shoes.......2136
Spring package, assembly dimension.......2138
Spring package, assembly.......2140
Spring package, disassembly.......2144
Sprocket, measurement of wear.......2149
Sprocket, replacing one.......2153
Top roller wear, measuring.......2155
Top roller, assembly.......2158
Top roller, description.......2162
Top roller, disassembly.......2164
Top roller, measurement of wear.......2167
Top roller, replacing one.......2170
Track chain assembly, installing.......2175
Track chain assembly, removing.......2180
Track chain, description.......2185
Track chain, measurement of wear.......2187
Track guard, replacing one.......2192
Track guards_{12-16-07}.......2196
Track guards_{12-16-21}.......2198
Track link, dimension.......2200
Track links, replacing.......2202
Track recoil spring (tensioner) assembly, replacing.......2207
Track shoe, replacing one.......2211
Track, adjusting track sag_{12-30-56}.......2215
Track, adjusting track sag_{12-31-09}.......2220
008 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE.......2225
80 - GENERAL.......2226
Tech Tool, operations.......2227
81 - CAB, NAKED; CANOPY.......2229
Cab suspension, description.......2230
Cab, installing.......2231
Cab, removing.......2232
83 - DOORS; HATCH; COVER PLATE, (all).......2236
Door, replacing.......2237
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING.......2241
Door window, replacing.......2242
Rear window, replacing.......2245
Side window, replacing.......2253
Windows, general.......2260
Windscreen, replacing.......2263
85 - CAB INTERIOR; UPHOLSTERY.......2277
Driver's seat, description.......2278
Driver's seat, specifications.......2283
Seat heater, checking.......2287
87 - AIR CONDITIONING UNIT.......2291
Air conditioning unit, description.......2292
Air conditioning unit, maintenance.......2299
Air conditioning unit, refrigerant check and recharging.......2302
Air conditioning unit, specifications.......2310
Air distribution, description_{11-55-38}.......2312
Air distribution, description_{11-55-51}.......2313
Auxiliary heater, description.......2316
Auxiliary heater, principles.......2319
CCM non-programmed ECU, replacing.......2322
CCM pre-programmed ECU, replacing.......2324
Compressor, replacing incl draining and filling.......2326
Condenser, replacing incl draining and filling.......2330
Cooler and Heater assembly, replacing_{11-53-09}.......2333
Cooler and Heater assembly, replacing_{11-53-38}.......2341
Fan motor, replacing.......2348
HVAC system.......2350
Heater core, replacing.......2354
Heating system, description.......2362
Performance test, AC unit.......2364
Water valve, replacing.......2370
88 - INTERIOR EQUIPMENT.......2373
Instrument panel (left), replacing.......2374
Instrument panel (right), replacing.......2378
009 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS.......2382
90 - GENERAL.......2383
Description, general.......2384
Hydraulic components, storing and transporting.......2385
Hydraulic oil, storage and handling.......2389
Hydraulic pressure, specifications.......2393
Hydraulic system, cleanliness when handling hydraulic components.......2395
Hydraulic system, description.......2399
Hydraulic system, repair of hydraulic components in workshop.......2403
Recommended hydraulic oil, specifications.......2408
Tech Tool, operations.......2412
91 - WORKING HYDRAULIC; SERVO HYDRAULICS.......2414
2 stage port relief valve, adjustment.......2421
2 stage port relief valve, description.......2424
2 stage port relief valve, disassembly and assembly.......2430
3 way selector valve, description.......2432
3 way selector valve, specifications.......2435
91618-3 Tiltrotator calibration.......2437
Accumulator, replacing.......2439
Adjustable boom (1st boom), description.......2441
Adjustable boom (2nd boom), description.......2444
Adjustable boom cylinder, description.......2447
Adjustable boom cylinder, specifications.......2450
Adjustable boom valve, description.......2452
Adjustable boom valve, disassembly.......2458
Adjustable boom, specifications.......2467
Arm holding valve, description.......2469
Arm holding valve, disassembly and assembly.......2472
Arm parallel conflux check valve, disassembly and assembly.......2474
Arm parallel conflux valve, disassembly and assembly.......2476
Arm regenerating valve, description.......2478
Arm regenerating valve, disassembly.......2481
Boom back pressure check valve, disassembly.......2483
Boom cylinder, rupture valve, replacing.......2485
Boom float position, description.......2492
Boom holding valve, description.......2496
Boom holding valve, disassembly.......2501
Boom regenerating valve, description.......2503
Breather, replacing.......2505
Bucket flow control valve, description.......2507
Bucket flow control valve, disassembly.......2510
Bucket regenerating valve, description.......2514
Bucket regenerating valve, disassembly.......2516
Center bypass valve, description.......2518
Center bypass valve, disassembly and assembly.......2521
Check valve, description.......2523
Conflux check valve, description.......2525
Control valve, replacing.......2527
Current_pressure, specifications.......2537
Dipper arm cylinder, rupture valve, replacing.......2538
Disassembly and assembly, general.......2545
Fan motor, assembly.......2548
Fan motor, description.......2555
Fan motor, disassembly.......2561
Fan motor, tools.......2569
Fan motor, troubleshooting.......2572
Fan pump, assembly_{11-38-56}.......2575
Fan pump, assembly_{11-39-17}.......2578
Fan pump, assembly_{11-39-28}.......2582
Fan pump, description.......2584
Fan pump, disassembly_{11-39-52}.......2589
Fan pump, disassembly_{11-40-09}.......2592
Fan pump, disassembly_{11-40-21}.......2595
Fan pump, parts inspection.......2597
Flow control valve, description.......2600
Flow control valve, disassembly and assembly.......2603
General, precautions.......2606
General, tools.......2611
Hammer and shear pedal valve (RCV), replacing.......2613
Hydraulic components, description.......2616
Hydraulic cooling fan control, specifications.......2619
Hydraulic oil cooler, description.......2621
Hydraulic oil cooler, replacing.......2623
Hydraulic oil cooling system, description.......2624
Hydraulic oil cooling system, specifications.......2626
Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump.......2628
Hydraulic pump, description.......2632
Hydraulic pump, maintenance standard, Specifications.......2640
Hydraulic pump, specifications.......2645
Hydraulic system, position of main components.......2646
Hydraulic system, work instructions.......2649
Hydraulic tank, description.......2654
Hydraulic tank, specifications.......2657
Line rupture valve (arm), air breathing.......2658
Line rupture valve (arm), assembly.......2661
Line rupture valve (arm), description.......2664
Line rupture valve (arm), disassembly.......2670
Line rupture valve (arm), specifications.......2673
Line rupture valve (arm), troubleshooting.......2675
Line rupture valve (boom), air breathing.......2677
Line rupture valve (boom), assembly.......2680
Line rupture valve (boom), description.......2683
Line rupture valve (boom), disassembly.......2689
Line rupture valve (boom), specifications.......2692
Line rupture valve (boom), troubleshooting.......2694
Line rupture valve pressure, checking and adjusting.......2697
Line rupture valve relief pressure, measurement.......2700
Load check valve - single, description.......2702
Load check valve single, disassembly and assembly.......2705
Main control valve adjustor, adjusting.......2708
Main control valve troubleshooting.......2711
Main control valve, description.......2716
Main control valve, port size and tightening torque.......2727
Main control valve, specifications.......2730
Main pressure relief valve, replacing.......2732
Main relief valve, adjustment.......2734
Main relief valve, description.......2737
Main relief valve, disassembly and assembly.......2740
Main spool, disassembly and assembly.......2743
Oil cooler fan motor, replacing.......2745
Oil cooler fan pump, replacing.......2749
Oil cooler line bypass valve (check valve), replacing.......2750
Oil level gauge, replacing.......2753
Port relief valve pressure, adjustment (when installing or dismantling the line rupture valve).......2755
Port relief valve pressure, checking and adjusting.......2758
Port relief valve, description.......2761
Port relief valve, disassembly and assembly.......2764
Pressure accumulator, description.......2767
Pressure accumulator, specifications.......2769
Pressure relief valve, troubleshooting.......2770
Proportional relief valve, description.......2774
Proportional relief valve, specifications.......2775
Proportional solenoid valve, description-[1047].......2776
Proportional solenoid valve, description.......2780
Proportional solenoid valve, measuring and adjustment.......2783
Proportional solenoid valve, specifications-[1115].......2788
Proportional solenoid valve, specifications.......2791
Proportional solenoid valve, troubleshooting.......2794
Pump, assembly.......2797
Pump, disassembly.......2803
Pump, installation.......2808
Pump, tools.......2810
Pump, troubleshooting.......2812
Regulator, description.......2817
Regulator, disassembly and assembly.......2823
Remote control valve (Lever), assembly_{11-01-53}.......2830
Remote control valve (Lever), assembly_{11-02-17}.......2843
Remote control valve (Lever), description_{11-05-33}.......2855
Remote control valve (Lever), description_{11-06-03}.......2865
Remote control valve (Lever), disassembly_{11-03-12}.......2878
Remote control valve (Lever), disassembly_{11-03-35}.......2891
Remote control valve (Lever), maintenance standard, Specifications_{11-04-38}.......2903
Remote control valve (Lever), maintenance standard, Specifications_{11-04-49}.......2906
Remote control valve (Lever), specifications_{11-06-24}.......2910
Remote control valve (Lever), specifications_{11-06-36}.......2912
Remote control valve (Lever), troubleshooting_{11-00-51}.......2916
Remote control valve (Lever), troubleshooting_{11-01-02}.......2919
Remote control valve (lever), replacing.......2922
Remote control valve (pedal), assembling_{10-57-39}.......2934
Remote control valve (pedal), assembly_{10-57-24}.......2943
Remote control valve (pedal), description_{10-59-36}.......2955
Remote control valve (pedal), description_{10-59-52}.......2963
Remote control valve (pedal), disassembling_{10-58-35}.......2969
Remote control valve (pedal), disassembly_{10-58-20}.......2979
Remote control valve (pedal), maintenance standard, Specifications.......2990
Remote control valve (pedal), replacing.......2993
Remote control valve (pedal), specifications.......2998
Remote control valve (pedal), specifications_{11-00-23}.......3000
Remote control valve (pedal), specifications_{11-00-33}.......3002
Remote control valve (pedal), troubleshooting_{10-56-27}.......3003
Remote control valve (pedal), troubleshooting_{10-56-38}.......3006
Rotator (X3 Line option), description.......3008
Rotator pump, assembly.......3012
Rotator pump, description.......3013
Rotator pump, disassembly.......3017
Rotator pump, parts inspection.......3018
Rotator pump, specifications.......3020
Rotator valve, adjustment.......3022
Servo hydraulic block.......3025
Servo hydraulic pressure, adjustment.......3027
Servo pump, description.......3030
Servo pump, parts inspection.......3034
Servo pump, replacing.......3037
Servo pump, specifications.......3040
Shuttle valve block, description.......3042
Single pedal stopper position.......3045
Slew flow control valve, description.......3047
Slew flow control valve, disassembly and assembly.......3050
Solenoid valve for rotator.......3053
Solenoid valve, description-[5555].......3055
Solenoid valve, description.......3058
Solenoid valve, disassembly and assembly.......3062
Solenoid valve, inspection.......3066
Solenoid valve, replacing.......3069
Solenoid valve, specifications-[5608].......3071
Solenoid valve, specifications.......3072
Solenoid valve, troubleshooting.......3074
Stop valve.......3078
Straight travel pedal, description.......3080
Tightening torques-[2048].......3084
Tightening torques-[5059].......3088
Tightening torques-[5345].......3091
Tightening torques_{11-06-58}.......3093
Tightening torques_{11-07-14}.......3098
Tiltrotator control system, description.......3104
Two stage gear pump, replacing.......3112
X1 Line, description.......3116
X1 Pre-set relief valve, adjusting.......3121
X1 Pre-set relief valve, description.......3125
X1 Pre-set relief valve, disassembly and assembly.......3130
92 - MECHANICAL EQUIPMENT_ATTACHMENT.......3133
Attachment quick coupler solenoid valve, description_{10-41-54}.......3134
Attachment quick coupler solenoid valve, description_{10-42-06}.......3136
Attachment quick coupler, adjustment.......3141
Attachment quick coupler, description_{10-43-58}.......3145
Attachment quick coupler, description_{10-44-22}.......3156
Attachment quick coupler, operation.......3169
Attachment quick coupler, replacing_{10-42-49}.......3172
Attachment quick coupler, replacing_{10-43-07}.......3182
Check valve, replacing.......3191
Control lever (dozer blade), replacing.......3195
Dozer blade cylinder, description.......3202
Dozer blade cylinder, replacing.......3204
Dozer blade cylinder, specifications.......3210
Dozer blade, description.......3212
Dozer blade, specifications.......3215
Remote control valve (dozer blade), description.......3216
Remote control valve (dozer blade), specifications.......3219
Tightening torques-[4130].......3220
97 - UNIT, DIGGING.......3222
Boom cylinder, description.......3224
Boom cylinder, replacing.......3226
Boom cylinder, specifications.......3234
Boom, description_{10-35-12}.......3235
Boom, description_{10-35-24}.......3237
Boom, replacing.......3239
Boom, specifications.......3260
Bucket cylinder bushing lever-link, replacing.......3261
Bucket cylinder bushing on dipper arm, replacing.......3265
Bucket cylinder, description.......3270
Bucket cylinder, replacing.......3272
Bucket cylinder, specifications.......3282
Connecting rod yoke, replacing.......3283
Cylinder, description.......3291
Cylinder, disassembly and assembly_{10-36-38}.......3296
Cylinder, disassembly and assembly_{10-36-55}.......3313
Cylinder, disassembly and assembly_{10-37-12}.......3327
Cylinder, troubleshooting.......3341
Digging unit, maintenance.......3345
Dipper arm connecting rod, replacing.......3347
Dipper arm cylinder bushing on boom, replacing.......3354
Dipper arm cylinder bushing on dipper arm, replacing.......3359
Dipper arm cylinder, description.......3363
Dipper arm cylinder, replacing.......3365
Dipper arm cylinder, specifications.......3375
Dipper arm, description.......3376
Dipper arm, replacing.......3378
Dipper arm, specifications.......3391
Function description.......3392
Hydraulic Cylinder, disassembling and assembling.......3394
Link, description.......3402
Lower boom cylinder bushing, replacing.......3404
Tightening torques.......3409
Tiltable ditching bucket cylinder, description.......3417
Tiltable ditching bucket cylinder, specifications.......3420
Tiltable ditching bucket, description.......3422
Upper boom cylinder bushing, replacing.......3427
99 - MISCELLANEOUS.......3431
Explanations to hydraulic diagram.......3432
Hydraulic diagram, standard Image.......3443
Hydraulic diagram, standard.......3444
Hydraulic diagram, with option components_{10-21-14} Image 1.......3447
Hydraulic diagram, with option components_{10-21-14} Image 2.......3448
Hydraulic diagram, with option components_{10-21-14}.......3449
Hydraulic diagram, with option components_{10-21-15} Image 1.......3455
Hydraulic diagram, with option components_{10-21-15} Image 2.......3456
Hydraulic diagram, with option components_{10-21-15}.......3457
